Manitowoc Grove GMK6300L-1 Maintenance Manual
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Manitowoc Grove GMK6300L-1 Maintenance Manual

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Maintenance manual
3 302 719 en
13.02.2018

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Summary of Contents for Manitowoc Grove GMK6300L-1

  • Page 1 Maintenance manual 3 302 719 en 13.02.2018...
  • Page 2 Manitowoc Crane Group Germany GmbH © Copyright reserved by Manitowoc Crane Group Germany GmbH Industriegelände West D-26389 Wilhelmshaven, Germany Phone: [+49] (0)44 21 294-0 Fax: +[49] (0) 44 21 294-301 The passing on or duplication of this document as well as the utilisation and disclosure of its contents is prohibited unless expressly permitted.
  • Page 3 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 4 Blank page 3 302 809 en Additional pages for maintenance manual GMK truck cranes...
  • Page 5 Protection of the main boom telescopic sections Additional monthly maintenance work (M 1) 1.1.1 Checking the guard strips The figure shows the main boom on a GMK5250L truck crane. Other GMK models have a similar arrangement of guard strips (1) on the upper surface of the telescopic sections.
  • Page 6 When turning three times is no longer sufficient • Have the damaged guard strips replaced by or an Manitowoc Crane Care authorised GROVE dealer or your qualified repair crew. 1.1.2 Conversion from plastic guard strips to steel rollers GMK 6300L-1 The GMK 6300L-1 truck crane is delivered as standard with steel rollers running in ball bearing races.

  • Page 7: Table Of Contents

    Contents General instructions Safety and environmental protection Cleaning Running-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 manual.
  • Page 8 Blank page 3 302 719 en Maintenance manual GMK6300L-1...
  • Page 9 General instructions Instructions for using the maintenance manual......1 - Warnings and symbols ..........1 - Maintenance instructions .
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  • Page 11: 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 12: 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 13 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 14: 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 3 302 719 en Maintenance manual...

  • Page 15: 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 16: Conversion Table For Us Measuring Units

    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 17 Safety and environmental protection Safety rules ............2 - 2.1.1 Securing against unauthorised use .
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  • Page 19: 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 20 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 21: 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 22: 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 to the environment? environment by applicable national and regional regulations.
  • Page 23 Safety and environmental protection 2.2 Handling substances which are harmful to the environment Separate collection Substances which are harmful to the environment should always be and storage collected separately from other waste. • Ask your local environmental protection authority about the different categories of the substances.

  • Page 24: 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 25 Cleaning Overview of assemblies easily damaged when cleaning ....3 - Maintenance manual 3 302 719 en GMK6300L-1...
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  • Page 27: Cleaning

    Cleaning Cleaning During the first The paintwork on the truck crane will continue to harden for the first three 3 months 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 28 Cleaning 3.1 Overview of assemblies easily damaged when cleaning Overview of assemblies easily damaged when cleaning 3 - 2 3 302 719 en Maintenance manual GMK6300L-1...
  • Page 29 Cleaning 3.1 Overview of assemblies easily damaged when cleaning 1 RCL terminal box 2 Telescopic slide faces 3 RCL length data transmitter 4 Angle data transmitter 5 Pressure sensors 6 Lowering limit switch 7 Suspension struts 8 Superstructure switch box 9 Control units for outriggers 10 Slewing angle sensor 11 Lifting limit switch...
  • Page 30 Cleaning 3.1 Overview of assemblies easily damaged when cleaning Blank page 3 - 4 3 302 719 en Maintenance manual GMK6300L-1...
  • Page 31 Running-in regulations Maintenance manual 3 302 719 en GMK6300L-1...
  • Page 32 3 302 719 en Maintenance manual GMK6300L-1...

  • Page 33: Running-In Regulations

    Running-in regulations Running-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 34 Running-in regulations Operating hours Additional maintenance work on the (oper. hrs.) 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 35 Maintenance overview Maintenance intervals..........5 - Maintenance plans .
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  • Page 37: Maintenance Overview

    Maintenance overview 5.1 Maintenance intervals Maintenance overview – Maintenance plans D (= daily), – Maintenance plans W (= weekly) and – Maintenance plans M 1 (= once monthly) 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 38 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 call up the engine and power unit operating hours (oper. hrs.) of the superstructure one by one on the ECOS display in the crane cab.
  • Page 39 Maintenance overview 5.2 Maintenance plans Maintenance plans The descriptions for certain maintenance work for the maintenance plans D, W, M 1 to M 12 and Y 2 to Y 10 are provided for – the carrier in Kapitel 7 and for –...
  • Page 40 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 - 11 à – Checking the air filter p. 7 - 14 à –...
  • Page 41 Maintenance overview 5.2 Maintenance plans Maintenance work on the SUPERSTRUCTURE: Daily/before putting into operation Engine à – Checking the oil level p. 8 - 11 à – Checking the air filter p. 8 - 14 à – Checking the coolant level p.
  • Page 42 Maintenance overview 5.2 Maintenance plans 5.2.2 Maintenance plan W Maintenance work on the CARRIER: Weekly Engine à – General inspection p. 7 - 16 Transmission à – General inspection p. 7 - 41 Transfer case à – General inspection p. 7 - 45 Axle lines à...
  • Page 43 Maintenance overview 5.2 Maintenance plans Maintenance work on the SUPERSTRUCTURE: Weekly Engine à – General inspection p. 8 - 16 Hoists à – Checking the oil level p. 8 - 41 à – General inspection p. 8 - 42 à –...
  • Page 44 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 - 11 Exhaust system with exhaust emission control à...
  • Page 45 Maintenance overview 5.2 Maintenance plans Maintenance work on the SUPERSTRUCTURE: Monthly/after approx. 100 operating hours Engine à à Engine manufacturer’s documentation – Notes; p. 8 - 11 Exhaust system with exhaust emission control à – Check the exhaust system for external damage p.
  • Page 46 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 - 11 Fuel system à...
  • Page 47 Maintenance overview 5.2 Maintenance plans Maintenance work on the SUPERSTRUCTURE: every three months/after 250 oper. hrs. Engine à à Engine manufacturer’s documentation – Notes; p. 8 - 11 Fuel system à – Replacing fuel filter 1 p. 8 - 29 Slewing bearing à...
  • Page 48 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 - 11 Transfer case à...
  • Page 49 Maintenance overview 5.2 Maintenance plans Maintenance work on the SUPERSTRUCTURE: every six months/after 500 oper. hrs. Engine à à Engine manufacturer’s documentation – Notes; p. 8 - 11 Hoists à – Lubricating the auxiliary hoist p. 8 - 43 Slewing gear à...
  • Page 50 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 - 11 à...
  • Page 51 Maintenance overview 5.2 Maintenance plans M 12 Maintenance work on the SUPERSTRUCTURE: every 12 months/after 1,000 operating hours Engine à à Engine manufacturer’s documentation – Notes; p. 8 - 11 à – Have the radiator checked/cleaned p. 8 - 17 Fuel system à...
  • Page 52 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 - 11 à –...
  • Page 53 – Have the Cardan shaft between the transmission on the engine and the transfer case replaced by or an authorised GROVE dealer. Manitowoc Crane Care Maintenance work on the SUPERSTRUCTURE: every 60 months/after 5,000 oper. hrs. Cable drums and slewing angle sensor à...
  • Page 54 120 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 12000 oper. hrs. Steel construction – Check the load-bearing steel construction. For further information, please...
  • Page 55 Maintenance overview 5.3 Periodic inspections Periodic inspections Your GMK6300L-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 56 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, y 1, y 2. The original dimensions y, y 1, y 2 are specified in field (2) on the load hooks.
  • Page 57 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 - 46. 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 58 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 59 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 60 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 61 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 62 5.4 Measures required for winch monitoring 5.4.3 Example A GMK6300L-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 63 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 1920 h 0,125 Remaining theoretical service life: D2 = 3040 h -1920 h = 1120 h. The above values are entered in the table (see table example p.
  • Page 64 Maintenance overview 5.4 Measures required for winch monitoring 5 - 28 3 302 719 en Maintenance manual GMK6300L-1...
  • Page 65 Lubricants and consumables Lubricants............6 - 6.1.1 Lubricants list .
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  • Page 67: 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 68: 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 228.31/.51 TranSynd TE295 6829101690 Gear oil synthetic C4-27403598 MIL-L 2105 B...

  • Page 69: Lubricant Applications List

    Lubricants and consumables 6.1 Lubricants 6.1.2 Lubricant applications list Consec. Lubricant Usage Filling Mainte- type quantity in nance litres (gal) interval à Diesel engine for carrier; p. 7 - 21 42 (11.1) Engine oil à Diesel engine for superstructure; p. 8 - 21 29 (7.6) à...
  • Page 70 Lubricants and consumables 6.1 Lubricants Consec. Lubricant Usage Fill Mainte- type quantity nance in litres interval (gal) à Carrier central lubrication; p. 7 - 99 à Superstructure central lubrication; p. 8 - 107 à Cardan shafts – transverse; p. 7 - 58 à...

  • Page 71: Refrigerant

    Lubricants and consumables 6.2 Refrigerant Refrigerant Refrigerant Usage Quantity Maintenance Designation to be filled interval in kg (lbs) Air conditioning system in the driver's à Tetrafluoroethane (R134a) 1.0 (2.2) M 12 cab; p. 7 - 112 CAS no. 811-97-2 Air-conditioning system in the crane EC no.

  • Page 72: Exhaust Gas Emission Control

    Lubricants and consumables 6.3 Consumables 6.3.3 Exhaust gas emission control Designation Usage Filling quantity in litres (gal) à DEF (Diesel Exhaust Fluid) AdBlue tank on the carrier; p. 7 - 32 40 (10.5) AdBlue: à AdBlue tank on the superstructure; p.
  • Page 73 Maintenance work on the carrier General instructions ..........7 - 7.1.1 Covers .
  • Page 74 7.10 Vehicle brake ............7 - 69 7.10.1 Checking brake lining thickness .
  • Page 75 7.18 Towbar coupling ........... . 7 - 115 7.18.1 Lubricating the towbar coupling .
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  • Page 77: Maintenance Work On The Carrier

    Maintenance work on the carrier 7.1 General instructions Maintenance work on the carrier General instructions 7.1.1 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 78: Overview Of Maintenance Work On The Carrier

    Maintenance work on the carrier 7.1 General instructions 7.1.2 Overview of maintenance work on the carrier 7 - 2 3 302 719 en Maintenance manual GMK6300L-1...
  • Page 79 Maintenance work on the carrier 7.1 General instructions à Symbols for maintenance work p. 7 - 9 à 1 Instrument panel p. 7 - 9 à 2 ECOS display p. 7 - 9 à Engine p. 7 - 11 à 6 Diesel engine p.
  • Page 80 Maintenance work on the carrier 7.1 General instructions 7 - 4 3 302 719 en Maintenance manual GMK6300L-1...
  • Page 81 Maintenance work on the carrier 7.1 General instructions à Wheels p. 7 - 61 à 3 Wheels p. 7 - 61 17 Spare wheel (alternative: storage box) à Vehicle brake p. 7 - 69 à 8 Brake linings p. 7 - 69 à...
  • Page 82 Maintenance work on the carrier 7.1 General instructions 7 - 6 3 302 719 en Maintenance manual GMK6300L-1...
  • Page 83 Maintenance work on the carrier 7.1 General instructions à Electrical system p. 7 - 103 à 10 Carrier lighting p. 7 - 103 à 12 Battery box p. 7 - 104 à 11 External starting socket p. 7 - 109 à...
  • Page 84 Maintenance work on the carrier 7.1 General instructions Blank page 7 - 8 3 302 719 en Maintenance manual GMK6300L-1...

  • Page 85: Symbols For Maintenance Work

    Maintenance work on the carrier 7.2 Symbols for maintenance work Symbols for maintenance work Check the following symbols every day before starting work. On the instrument If one of the symbols is displayed in the driver's cab you must carry out the panel corresponding maintenance work: à...
  • Page 86 Maintenance work on the carrier 7.2 Symbols for maintenance work Blank page 7 - 10 3 302 719 en Maintenance manual GMK6300L-1...

  • Page 87: 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. • Checking the Start the engine. oil level Risk of damage to the engine if the oil pressure is too low.
  • Page 88 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 89: 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 in Designation Specification GROVE part no. litres (gal) according to classification DIN 51502 42 (11.1) HD - CD MIL-L 2104 C SAE 5 W-30...

  • Page 90: Checking The Air Filter

    Maintenance work on the carrier 7.3 Engine 7.3.3 Checking the air filter If the symbol is displayed on the instrument panel in the driver's cab, the air filter must be changed. If the symbol is displayed in the crane cab on the ECOS display (Warning submenu) , the air filter must be changed.

  • Page 91: 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 3 302 719 en...

  • Page 92: 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 an authorised specialist workshop. 7 - 16 3 302 719 en Maintenance manual...

  • Page 93: Have The Radiator Checked/Cleaned

    Maintenance work on the carrier 7.3 Engine M 12 7.3.6 Have the radiator checked/cleaned • Reducing the Under difficult operating conditions – at extremely sandy or dusty interval locations or if there is a heavy density of fallen leaves – you must have the radiator fins cleaned earlier than this.
  • Page 94 Maintenance work on the carrier 7.3 Engine The radiator units are protected by grilles (5) and plates (7). The fan impellers (6) are located under the grilles. When the engine is running, the fan impellers rotate behind the grilles! Risk of injury due to the fan impellers! When the fan impellers are rotating they can trap the fingers of your hand and amputate them.
  • Page 95 Maintenance work on the carrier 7.3 Engine Have them cleaned Risk of injury due to the fan impellers! When the fan impellers are rotating they can trap the fingers of your hand and amputate them. Never reach into the fan impellers when they are rotating.
  • Page 96 Maintenance work on the carrier 7.3 Engine • Have the radiator units (1), (2), (3) and (4) 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 97: Changing The Oil And Oil Filter

    Maintenance work on the carrier 7.3 Engine 7.3.7 Changing the oil and oil filter Oil, spare parts, Engine oil in Designation Specification GROVE part no. tools litres (gal) according to Classification DIN 51502 42 (11.1) HD - CD MIL-L 2104 C SAE 5 W-30 DB 228.31/.51 03329588...
  • Page 98 Maintenance work on the carrier 7.3 Engine Oil filter • Place a receptacle underneath the engine. • Remove the cover (1). • Remove the oil filter (3) from the housing. • Place the old filter (3) in the receptacle. • Insert a new filter (3) and a new gasket (2) into the housing.

  • Page 99: Changing The Coolant

    Maintenance work on the carrier 7.3 Engine 7.3.8 Changing the coolant Tools – Connecting piece and hose (toolbox). à – Receptacle, approx. 40 ltr (10.5 gal); p. 2 - 4. à – Antifreeze; Engine manufacturer’s documentation . Prerequisites – Information on the coolant and admixture ratio has been obtained; à...
  • Page 100 Maintenance work on the carrier 7.3 Engine Topping up when the engine is cold • Slowly top up the expansion tank (1) with coolant until it is filled up to the lower edge in the filler neck. • Wait about 1 minute. Add more coolant if necessary.

  • Page 101: Fuel System

    Maintenance work on the carrier 7.4 Fuel system Fuel system To fill up with fuel you must open the cover (4) à Manual de over the 2-chamber fuel tank (3); instrucciones . 1 Fuel tank for the carrier engine 480 litres (126 gal) 2 Fuel tank for the superstructure engine 200 litres (52 gal)

  • Page 102: 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 and – Receptacle, approx. 5 ltr (1.5 gal); p. 2 - 4. tools Prerequisites – The truck crane must be standing level and on outriggers; à...

  • Page 103: Replacing Fuel Filter 1

    Maintenance work on the carrier 7.4 Fuel system 7.4.2 Replacing fuel filter 1 Spare parts Designation Quantity GROVE part no. and tools Filter (large) 04161567 alternatively: 04180966 Set for both filters 1 + 2 (large + small) à – Receptacle, approx. 5 ltr (1.5 gal); p.
  • Page 104 Maintenance work on the carrier 7.4 Fuel system • Remove the cover (1). • Remove the old filter (3) from the casing. • Place the old filter (3) in the receptacle. • Insert a new filter (3) and a new gasket (2) into the housing.

  • Page 105: Replacing Fuel Filter 2

    Maintenance work on the carrier 7.4 Fuel system M 12 7.4.3 Replacing fuel filter 2 Spare parts and Designation Quantity GROVE part no. tools Filter (small) 04161566 alternatively: 04180966 Set for both filters 1 + 2 (large + small) à –...
  • Page 106 Maintenance work on the carrier 7.4 Fuel system • Remove the cover (1). • Remove the old filter (3) from the casing. • Place the old filter (3) in the receptacle. • Insert a new filter (3) and a new gasket (2) into the housing.

  • Page 107: 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 108: 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 warning lamp for checking the AdBlue system is located on the instrument panel in the driver's cab, a gauge for checking the AdBlue tank level is located on the ECOS display.

  • Page 109: 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 Manual de instrucciones . Danger of scalding due to ammonia vapours. Ammonia vapour can escape if the AdBlue tank is opened when the outside temperature is high.
  • Page 110 • Switch off the engine. If you discover any damage Have any damaged parts of the exhaust system replaced immediately or an authorised GROVE dealer. Manitowoc Crane Care 7 - 34 3 302 719 en Maintenance manual GMK6300L-1...

  • Page 111: Having The Adblue System Checked

    7.5.4 Having the AdBlue system checked This inspection may only be performed by or an Manitowoc Crane Care authorised GROVE dealer or an authorised specialist workshop. • Have the entire AdBlue system checked for leaks and correct operation; Overview , p. 7 - 31.
  • Page 112 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 04156032. à •...

  • Page 113: Transmission

    Maintenance work on the carrier 7.6 Transmission Transmission 7.6.1 Checking the oil level Risk of damage to the transmission. If the oil level is too low or too high, this can lead to malfunctions and damage to the transmission. Carry out the oil level checks in the sequence specified. Prerequisites –...
  • Page 114 Maintenance work on the carrier 7.6 Transmission Prior to starting the engine Risk of damage to the transmission. The engine must not be started without the gear oil level having been checked beforehand. This prevents damage to the transmission being caused by undetected loss of oil.
  • Page 115 Maintenance work on the carrier 7.6 Transmission • When the gear Heat up the gear oil to a temperature range between 75 and 95 °C à Warming up the gear oil , p. 7 - 39. oil is warm (160 to 200 °F); •...
  • Page 116 Maintenance work on the carrier 7.6 Transmission Speeding up the warming up procedure • Allow the engine to run at idling speed in neutral position N. • Fully press the service brake pedal, even if the parking brake is applied. Risk of damage to the transmission when speeding up the warming up procedure When the wheels are locked, the full engine output may only be applied in...

  • Page 117: 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 an authorised specialist workshop. 7.6.3 Changing the oil and oil filter Oil, spare parts...
  • Page 118 Maintenance work on the carrier 7.6 Transmission Changing 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. Risk of environmental damage due to leaking consumables.
  • Page 119 Maintenance work on the carrier 7.6 Transmission Topping up oil • Top up the oil via the dipstick tube (2). • Wait so that the oil is evenly distributed in the transmission. • Use the dipstick (1) to check whether the oil level is clearly above the mark (3), otherwise the engine may not be started.
  • Page 120 Maintenance work on the carrier 7.6 Transmission Blank page 7 - 44 3 302 719 en Maintenance manual GMK6300L-1...

  • Page 121: 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 and...

  • Page 122: Changing The Oil

    Maintenance work on the carrier 7.7 Transfer case Checking the oil level • Place a clean container under the screw (1). • Remove the drain plug (1). About 3 litres (0.8 gal) of oil will then flow from the opening (1) (the oil radiator is mounted above).
  • Page 123 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 124 Maintenance work on the carrier 7.7 Transfer case Blank page 7 - 48 3 302 719 en Maintenance manual GMK6300L-1...

  • Page 125: 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. 7.8.2 Axle centre drives – Checking the oil level...
  • Page 126 Maintenance work on the carrier 7.8 Axle lines 1.+ 5./6. axle lines In case of drive 12 x 6, this axle centre drive is on the 1st and 5th axle line. In case of drive 12 x 8, this axle centre drive is on the 1st and 6th axle line. •...
  • Page 127 Maintenance work on the carrier 7.8 Axle lines 4. 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 128: Axle Centre Drives - Changing The Oil

    Maintenance work on the carrier 7.8 Axle lines M 12 7.8.3 Axle centre drives – Changing the oil Oil, spare parts, Gear oil in litres Designation Specification GROVE part no. tools (gal) according to Classification DIN 51502 Axle line 1+5/6: C - LPF MIL-L 2105 B 00552891...
  • Page 129 Maintenance work on the carrier 7.8 Axle lines 1st + 5th/6th In case of drive 12 x 6, this axle centre drive is on the 1st and 5th axle line. axle line In case of drive 12 x 8, this axle centre drive is on the 1st and 6th axle line. •...
  • Page 130 Maintenance work on the carrier 7.8 Axle lines 4th axle line • Place a receptacle under screws (2) and (3). • Remove screws (1), (2), (3) and (4) and let the oil drain off. • Fit new gaskets and tighten the screws (2) and (3).

  • Page 131: Final Drives - Checking The Oil Level

    Maintenance work on the carrier 7.8 Axle lines 7.8.4 Final drives – Checking the oil level Spare parts and For drive Designation Quantity GROVE part no. tools 12 x 6 x 12 Gasket 24 x 29 Cu DIN 7603 00117145 12 x 8 x 12 Gasket 24 x 29 Cu DIN 7603 00117145...

  • Page 132: Final Drives - Changing The Oil

    Maintenance work on the carrier 7.8 Axle lines M 12 7.8.5 Final drives – Changing the oil Oil, spare parts, Gear oil in Designation Specification GROVE part no. tools litres (gal) according to Classification DIN 51502 for each final C - LPF MIL-L 2105 B 00552891 drive:...
  • Page 133 Maintenance work on the carrier 7.8 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 134: Lubricating The Cardan Shafts In The Axle Lines

    Maintenance work on the carrier 7.8 Axle lines 7.8.6 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 135: Lubricating Longitudinal Cardan Shafts

    Maintenance work on the carrier 7.8 Axle lines 7.8.7 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 136 Maintenance work on the carrier 7.8 Axle lines Blank page 7 - 60 3 302 719 en Maintenance manual GMK6300L-1...

  • Page 137: Wheels

    Maintenance work on the carrier 7.9 Wheels Wheels 7.9.1 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 138: Checking The Tyre Pressure

    Maintenance work on the carrier 7.9 Wheels 7.9.2 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 139: Checking That The Wheel Nuts Are Tight

    Maintenance work on the carrier 7.9 Wheels 7.9.3 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 140: Changing The Wheels

    Maintenance work on the carrier 7.9 Wheels 7.9.4 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 141 Maintenance work on the carrier 7.9 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 142 Maintenance work on the carrier 7.9 Wheels • Mount the wheels on another axle, as shown in the diagram. Replace any à damaged parts. Tighten the wheel nuts; p. 7 - 63. 7 - 66 3 302 719 en Maintenance manual GMK6300L-1...
  • Page 143 Maintenance work on the carrier 7.9 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 144 Maintenance work on the carrier 7.9 Wheels Blank page 7 - 68 3 302 719 en Maintenance manual GMK6300L-1...

  • Page 145: Vehicle Brake

    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...
  • Page 146 7 - 69. • 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 147: 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. Do not fill oil through the inspection glass connections.

  • Page 148: Suspension Struts - Checking The Fastening

    Maintenance work on the carrier 7.11 Suspension 7.11.2 Suspension struts – checking the fastening Spare parts and – Torque wrench for torques up to 900 Nm (664 lbf ft). tools à Manual de instrucciones. Prerequisites – The truck crane must be raised on outriggers; –...

  • Page 149: 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 Manitowoc or an authorised GROVE dealer or your qualified repair crew. Crane Care Maintenance manual...

  • Page 150: Pressure Accumulator - Checking The Gas Pressure

    The filling pressure at 20 °C (68 °F) is 40 bar (580 psi). • Have the filling pressure checked, and if necessary corrected, by Manitowoc Crane or an authorised GROVE dealer or Care an authorised specialist workshop. 7 - 74...

  • Page 151: Steering

    Bleeding the hydraulic system , p. 7 - 94. Bleed the hydraulic system; If damage cannot be rectified immediately or further damage is likely • Notify or an authorised GROVE dealer or your Manitowoc Crane Care repair crew. Maintenance manual 3 302 719 en 7 - 75 GMK6300L-1...

  • Page 152: Pressure Accumulator - Checking The Gas Pressure

    The filling pressure at 20 °C (68 °F) is: 89 bar (1290 psi) 100 bar (1450 psi) • Have the filling pressure checked, and if necessary corrected, by Manitowoc Crane or an authorised GROVE dealer or Care an authorised specialist workshop. 7 - 76 3 302 719 en...

  • Page 153: Compressed Air System

    (2) to (7). If a great deal of water escapes • Have the compressed air drier checked or replaced by Manitowoc Crane Care an authorised GROVE dealer or your qualified repair crew. Maintenance manual 3 302 719 en 7 - 77...

  • Page 154: Checking For Leaks

    If damage cannot be rectified immediately or further damage is likely: • Notify or an authorised GROVE dealer or your Manitowoc Crane Care repair crew. 7 - 78 3 302 719 en Maintenance manual...

  • Page 155: Replacing The Filter Cartridge Of The Compressed Air Drier

    Maintenance work on the carrier 7.13 Compressed air system 7.13.3 Replacing the filter cartridge of the compressed M 12 air drier Spare parts Designation Quantity GROVE part no. and tools Filter cartridge 04156032 – Strap wrench. Prerequisites – The truck crane must be raised on outriggers or parked over an inspection pit.
  • Page 156 Maintenance work on the carrier 7.13 Compressed air system Blank page 7 - 80 3 302 719 en Maintenance manual GMK6300L-1...

  • Page 157: Hydraulic System

    Maintenance work on the carrier 7.14 Hydraulic system 7.14 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 158: Checking The Hydraulic Hoses

    Maintenance work on the carrier 7.14 Hydraulic system 7.14.2 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 159: Cleaning The Magnetic Rods

    Bleed the carrier's hydraulic system; p. 7 - 94. If damage cannot be rectified immediately or further damage is likely • Notify or an authorised GROVE dealer or your repair Manitowoc Crane Care crew. 7.14.4 Cleaning the magnetic rods Spare parts and Designation Quantity GROVE part no.
  • Page 160 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 checked by Manitowoc Crane Care an authorised GROVE dealer or your repair crew. • Assemble the filters and install them.

  • Page 161: Changing The Ventilation Filter

    Maintenance work on the carrier 7.14 Hydraulic system M 12 7.14.5 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 162: Taking Oil Samples

    Maintenance work on the carrier 7.14 Hydraulic system M 12 7.14.6 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 and –...
  • Page 163 Maintenance work on the carrier 7.14 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 then be incorrect.
  • Page 164 Maintenance work on the carrier 7.14 Hydraulic system Taking an oil sample The hose end (1) is connected to the control block (3). The hose end (2) is in receptacle (4). • Allow 2 litres (0.5 gal) of oil to flow into the receptacle.
  • Page 165 Maintenance work on the carrier 7.14 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 166 Maintenance work on the carrier 7.14 Hydraulic system Blank page 7 - 90 3 302 719 en Maintenance manual GMK6300L-1...

  • Page 167: Changing The Hydraulic Oil

    Maintenance work on the carrier 7.14 Hydraulic system 7.14.7 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 - 89. need for it; Oil, spare parts, Hydraulic oil Designation...
  • Page 168 Maintenance work on the carrier 7.14 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 169 Maintenance work on the carrier 7.14 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 170 If the steering system is still not operating properly • Notify or an author- Manitowoc Crane Care ised GROVE dealer or an authorised special- ist workshop. 7 - 94 3 302 719 en Maintenance manual GMK6300L-1...

  • Page 171: Changing The Hydraulic Oil Filter

    Maintenance work on the carrier 7.14 Hydraulic system 7.14.8 Changing the hydraulic oil filter Oil filters must be replaced when changing the oil. In case of a warning message on the ECOS display in the driver's cab – the symbol (1) in the Warning submenu shows that you need to change filters 1 and 2, –...
  • Page 172 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 checked by Manitowoc Crane Care an authorised GROVE dealer or your qualified repair crew. • Assemble the filters and install them.
  • Page 173 Maintenance work on the carrier 7.14 Hydraulic system Changing filters 3 Filter 3 is installed on the left side and filter 4 is on the right side. 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 174 Maintenance work on the carrier 7.14 Hydraulic system Blank page 7 - 98 3 302 719 en Maintenance manual GMK6300L-1...

  • Page 175: Central Lubrication System

    Maintenance work on the carrier 7.15 Central lubrication system 7.15 Central lubrication system The central lubrication system supplies the steering lever and all the axle lines. 7.15.1 Checking the level Grease, spare Lubricating Designation Specification GROVE part no. parts, tools grease according to Classification...
  • Page 176 Maintenance work on the carrier 7.15 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 opening and filling pump until immediately before refilling the grease.

  • Page 177: Bleeding The Central Lubrication System

    Maintenance work on the carrier 7.15 Central lubrication system 7.15.2 Bleeding the central lubrication system If the grease container is empty or contains bubbles, you must bleed the central lubrication system. The grease container (3) must be full. • Undo the connection (4). •...
  • Page 178 Maintenance work on the carrier 7.15 Central lubrication system Blank page 7 - 102 3 302 719 en Maintenance manual GMK6300L-1...

  • Page 179: 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 following functions every day before operating or driving the truck crane, and have faulty parts repaired: –...

  • Page 180: Checking The Batteries

    Maintenance work on the carrier 7.16 Electrical system 7.16.2 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 181 Maintenance work on the carrier 7.16 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 182: Checking The Charge Level Of The Batteries

    Maintenance work on the carrier 7.16 Electrical system 7.16.3 Checking the charge level of the batteries à Spare parts and – Battery testing device; Separate engine operating instructions, provided by the manufacturer , or 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 183 Maintenance work on the carrier 7.16 Electrical system Before checking • Switch the battery master switch (1) off and remove the selector handle. • Open the cover (2) on the battery box. Checking the acid concentration Batteries without covers (1) are maintenance- free.

  • Page 184: Charging The Batteries Using The Battery Charger

    Maintenance work on the carrier 7.16 Electrical system 7.16.4 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 185: Check The External Starting Socket

    Maintenance work on the carrier 7.16 Electrical system 7.16.5 Check the external starting socket The battery box can be equipped with an external starting socket (1) as additional equipment. Accessories A connection cable (1) for the external starting socket is supplied with the truck crane (tool set).
  • Page 186 Maintenance work on the carrier 7.16 Electrical system Blank page 7 - 110 3 302 719 en Maintenance manual GMK6300L-1...

  • Page 187: 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. 7.17.2 Checking hoses Risk of burns due to escaping refrigerant.

  • Page 188: 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 189 Maintenance work on the carrier 7.17 Air conditioning system Refrigerant Fill quantity Designation CAS no. in kg (lbs) EC no. 1.0 (2.2) Tetrafluoroethane (R134a) 811-97-2 212-377-0 Filler connections The filler connections (1) for the refrigerant are behind the front flap (2) in the driver's cab. Maintenance manual 3 302 719 en 7 - 113...

  • Page 190: Changing The Pollen Filter

    Maintenance work on the carrier 7.17 Air conditioning system M 12 7.17.5 Changing the pollen filter • Reducing the Under difficult operating conditions – at extremely sandy or dusty interval locations – you must change the pollen filter earlier than usual. Spare parts Designation Quantity...

  • Page 191: Towbar Coupling

    Maintenance work on the carrier 7.18 Towbar coupling 7.18 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 192 Maintenance work on the carrier 7.18 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 193: Checking The Bearing

    Maintenance work on the carrier 7.18 Towbar coupling 7.18.2 Checking the bearing à Prerequisites – The coupling must be closed; p. 7 - 116. Checking the bearing Risk of injury! Ensure that the towbar coupling is closed for the following work (lever points downwards).

  • Page 194: 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 personnel. • Also check the cotter pin for the correct vertical play.

  • Page 195: 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. 7.18.5 Checking the initial tension of the springs The coupling head should require physical force to twist it when checking the torque.

  • Page 196: Checking The Support Ring

    Maintenance work on the carrier 7.18 Towbar coupling 7.18.6 Checking the support ring à Prerequisites – The coupling must be closed; p. 7 - 116. 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 197 Maintenance work on the carrier 7.18 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 198 Maintenance work on the carrier 7.18 Towbar coupling Blank page 7 - 122 3 302 719 en Maintenance manual GMK6300L-1...

  • Page 199: Other Maintenance Work

    Maintenance work on the carrier 7.19 Other maintenance work 7.19 Other maintenance work 7.19.1 Checking the windscreen washing system Water, spare Designation Quantity GROVE part no. parts, tool Wiper blades 02311858 – Water; add commercially available detergent and antifreeze to it. –...

  • Page 200: Lubricating The Outrigger Beams

    Maintenance work on the carrier 7.19 Other maintenance work 7.19.2 Lubricating the outrigger beams à • Comply also with the Running-in regulations , p. 4 - 1. Grease, spare Lubricating Designation Specification GROVE part no. parts, tools grease according to classification DIN 51502 Grease...

  • Page 201: Checking The Functioning Of 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 Manitowoc Crane Care authorised specialist workshop. M 12 7.19.4 Lubricating the cab door...

  • Page 202: 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 203: Renewing The Corrosion Protection

    Maintenance work on the carrier 7.19 Other maintenance work M 12 7.19.6 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 204 Maintenance work on the carrier 7.19 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 205: Having The Fire Extinguisher Checked

    Maintenance work on the carrier 7.19 Other maintenance work 7.19.7 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 206 Maintenance work on the carrier 7.19 Other maintenance work Blank page 7 - 130 3 302 719 en Maintenance manual GMK6300L-1...
  • Page 207 Maintenance work on the superstructure General instructions ..........8 - 8.1.1 Covers .
  • Page 208 Hydraulic system ........... 8 - 65 8.9.1 Checking the oil level .
  • Page 209 8.17 Other maintenance work ..........8 - 119 8.17.1 Checking the windscreen washing system .
  • Page 210 3 302 719 en Maintenance manual GMK6300L-1...

  • Page 211: 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 For various jobs (e.g. on the slewing gear, storage batteries, engine or for refuelling) you must remove/fold back the covers. Before maintenance work •...

  • Page 212: 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 3 302 719 en Maintenance manual GMK6300L-1...
  • Page 213 Maintenance work on the superstructure 8.1 General instructions à Symbols for maintenance work p. 8 - 9 à 1 ECOS display p. 8 - 9 à Engine p. 8 - 11 à 18 Diesel engine p. 8 - 11 à 10 Covers p.
  • Page 214 Maintenance work on the superstructure 8.1 General instructions 8 - 4 3 302 719 en Maintenance manual GMK6300L-1...
  • Page 215 Maintenance work on the superstructure 8.1 General instructions à Hydraulic system p. 8 - 65 à 19 Oil tank with sight glass p. 8 - 65 à 13 Oil cooler p. 8 - 17 à 22 Oil filler opening p. 8 - 77 à...
  • Page 216 Maintenance work on the superstructure 8.1 General instructions Additional equipment 8 - 6 3 302 719 en Maintenance manual GMK6300L-1...
  • Page 217 Maintenance work on the superstructure 8.1 General instructions à Air conditioning system p. 8 - 115 à 1 Crane cab air conditioning system p. 8 - 115 à 7 Condenser fins p. 8 - 116 à Other maintenance work p. 8 - 119 à...
  • Page 218 Maintenance work on the superstructure 8.1 General instructions Blank page 8 - 8 3 302 719 en Maintenance manual GMK6300L-1...

  • Page 219: 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. On the ECOS display à • Open the Warning submenu in the crane cab; Manual de instrucciones . You must carry out the corresponding maintenance work if a symbol is red: à...
  • Page 220 Maintenance work on the superstructure 8.2 Symbols for maintenance work Blank page 8 - 10 3 302 719 en Maintenance manual GMK6300L-1...

  • Page 221: Engine

    Maintenance work on the superstructure 8.3 Engine Engine • In addition, carry out further maintenance work specified in the Engine manufacturer’s documentation supplied. 8.3.1 Checking the oil level Prerequisites – The truck crane must be level. • Checking the oil Start the engine.
  • Page 222 Maintenance work on the superstructure 8.3 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 223: Topping Up The Oil

    Maintenance work on the superstructure 8.3 Engine 8.3.2 Topping up the oil à Data on the prescribed oil specification; Engine manufacturer’s documentation . Engine oil in Designation Specification GROVE part no. litres (gal) according to Classification DIN 51502 29 (7.6) HD - CD MIL-L 2104 C SAE 5 W-30...

  • Page 224: Checking The Air Filter

    Maintenance work on the superstructure 8.3 Engine 8.3.3 Checking the air filter • Start the engine. On the ECOS display, check whether the lamp (1) next to the button (2) lights up. • Press the button (2) once. This opens the Warning submenu. You must change the air filter if the symbol is red.

  • Page 225: 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 3 302 719 en...

  • Page 226: 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 - 16 3 302 719 en Maintenance manual...

  • Page 227: Have The Radiator Checked/Cleaned

    Maintenance work on the superstructure 8.3 Engine M 12 8.3.6 Have the radiator checked/cleaned • Reducing the Under difficult operating conditions – at extremely sandy or dusty interval locations or if there is a heavy density of fallen leaves – you must have the radiator fins cleaned earlier than this.
  • Page 228 Maintenance work on the superstructure 8.3 Engine The two radiator units (1) and (2) are protected by grilles (3) and plates (4). When the engine is running, the fan impellers rotate (5). Risk of injury at the fan impeller! When the fan impellers are rotating they can trap the fingers of your hand and amputate them.
  • Page 229 Maintenance work on the superstructure 8.3 Engine Have them cleaned Risk of injury at the fan impeller! When the fan impeller is rotating it can trap the fingers of your hand and amputate them. Never reach into the fan impeller when it is rotating. Do not push any tools through the impeller to clean it.
  • Page 230 Maintenance work on the superstructure 8.3 Engine • Have the radiator units (1) and (2) opened up by the repair specialists, so that the radiator fins are accessible. • Have the radiator fins cleaned on both sides, using suitable cleaning agents.

  • Page 231: Changing The Oil And The Oil Filter

    Maintenance work on the superstructure 8.3 Engine 8.3.7 Changing the oil and the oil filter Oil, spare parts, Engine oil in Designation Specification GROVE part no. tools litres (gal) according to Classification DIN 51502 29 (7.6) HD - CD MIL-L 2104 C SAE 5 W-30 DB 228.31/.51 03329588...
  • Page 232 Maintenance work on the superstructure 8.3 Engine Changing 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. Risk of environmental damage due to leaking consumables.

  • Page 233: Changing The Coolant

    Maintenance work on the superstructure 8.3 Engine 8.3.8 Changing the coolant Tools – Connecting piece and hose (toolbox). à – Receptacle, approx. 45 ltr (12 gal); p. 2 - 4. à – Antifreeze; Engine manufacturer’s documentation . Prerequisites – Information on the coolant and admixture ratio has been obtained; à...
  • Page 234 Maintenance work on the superstructure 8.3 Engine Changing Draining when the engine is cold • Open the cap (1) on the expansion tank. • Place a receptacle under the valve (2) in the cooling circuit. • Screw the connecting piece and hose on to the valve (2) and drain the coolant;...

  • Page 235: Change The Silicate Cartridge

    Maintenance work on the superstructure 8.3 Engine 8.3.9 Change the silicate cartridge Spare parts and Designation Quantity GROVE part no. tools Silicate cartridge with O-ring 04165276 – Torque wrench for a torque of 50 Nm (36 lbf ft). Prerequisites – The engine must be switched off and secured against unauthorised use; à...
  • Page 236 Maintenance work on the superstructure 8.3 Engine Blank page 8 - 26 3 302 719 en Maintenance manual GMK6300L-1...

  • Page 237: Fuel System

    Maintenance work on the superstructure 8.4 Fuel system Fuel system To fill up with fuel you must open the cover (4) à Manual de over the 2-chamber fuel tank (3); instrucciones . 1 Fuel tank for the carrier engine 480 litres (126 gal) 2 Fuel tank for the superstructure engine 200 litres (52 gal)

  • Page 238: Draining Off Water From Fuel Filter 1

    Maintenance work on the superstructure 8.4 Fuel system 8.4.1 Draining off water from fuel filter 1 Optional As an option, the truck crane GMK6300L-1 can be fitted with the fuel filter 1. This allows water to be removed from the fuel more easily. à...

  • Page 239: Replacing Fuel Filter 1

    Maintenance work on the superstructure 8.4 Fuel system 8.4.2 Replacing fuel filter 1 à Optional Note the option; p. 8 - 28. Spare parts and Designation Quantity GROVE part no. tools Filter cartridge 04181165 Filter element 04181166 à – Receptacle, approx. 5 ltr (1.5 gal); p.
  • Page 240 Maintenance work on the superstructure 8.4 Fuel system • (A) – Remove the filter element (2) and the filter (1). If necessary, replace any damaged parts. • (B) – Screw on a new filter (1) and the filter element (2). •...

  • Page 241: Changing Fuel Filters 2 And 3

    Maintenance work on the superstructure 8.4 Fuel system M 12 8.4.3 Changing fuel filters 2 and 3 Spare parts and Designation Quantity GROVE part no. tools Filter (small) 04165265 Filter (large) 04165266 à – Receptacle, approx. 5 ltr (1.5 gal); p.
  • Page 242 Maintenance work on the superstructure 8.4 Fuel system Changing filters 2 The filters 2 and 3 are on the inner side of the engine behind the rectangular and 3 opening. Changing filter 2 • Unscrew the cap (1) and remove the filter (3) so that the consumable can drain.
  • Page 243 Maintenance work on the superstructure 8.4 Fuel system à Bleeding the Note the option; p. 8 - 28. fuel line A receptacle is under the end of the hose (2). The lever (1) is parallel with the end of the hose.
  • Page 244 Maintenance work on the superstructure 8.4 Fuel system Blank page 8 - 34 3 302 719 en Maintenance manual GMK6300L-1...

  • Page 245: Exhaust System With Exhaust Emission Control

    Maintenance work on the superstructure 8.5 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 246: Checking The Adblue Tank Level

    Maintenance work on the superstructure 8.5 Exhaust system with exhaust emission control 8.5.1 Checking the AdBlue tank level Checking The warning lamp for checking the AdBlue system and a display for the AdBlue level in the tank is on the ECOS display in the crane cab. The tank has a maximum filling volume of about 40 ltr (10.5 gal).

  • Page 247: Check The Exhaust System For External Damage

    Maintenance work on the superstructure 8.5 Exhaust system with exhaust emission control • Filling up Find out about filling up in the operating manual and note the warnings; à Manual de instrucciones . Danger of scalding due to ammonia vapours. Ammonia vapour can escape if the AdBlue tank is opened when the outside temperature is high.
  • Page 248 • Switch off the engine. If you discover any damage Have any damaged parts of the exhaust system replaced immediately or an authorised GROVE dealer. Manitowoc Crane Care 8 - 38 3 302 719 en Maintenance manual GMK6300L-1...

  • Page 249: Having The Adblue System Checked

    M 12 8.5.4 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. 8 - 35.
  • Page 250 Maintenance work on the superstructure 8.5 Exhaust system with exhaust emission control Blank page 8 - 40 3 302 719 en Maintenance manual GMK6300L-1...

  • Page 251: Hoists

    Maintenance work on the superstructure 8.6 Hoists Hoists 8.6.1 Checking the oil level Spare parts and Designation Quantity GROVE part no. tools Oil inspection glass; complete 04161717 à Manual de Prerequisites – The truck crane must be level and in on-road mode; instrucciones .

  • Page 252: 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. 8.6.3 Checking the hoist brake Check that the hoist brake is working correctly on the main hoist and the auxiliary hoist.

  • Page 253: Lubricating The Auxiliary Hoist

    Maintenance work on the superstructure 8.6 Hoists 8.6.4 Lubricating the auxiliary hoist Grease, spare Lubricating Designation Specification GROVE part no. parts, tools grease according to Classification DIN 51502 Grease KP - 1K - 50 DIN 51825 03233369 – Grease gun from the tool set. Prerequisites –...
  • Page 254 Maintenance work on the superstructure 8.6 Hoists M 12 8.6.5 Changing the oil/checking the oil à • Comply also with the Running-in regulations , p. 4 - 1. Oil, spare parts, Gear oil in Designation Specification GROVE part no. tools litres (gal) according to Classification...

  • Page 255: Changing The Oil/Checking The Oil

    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 Maintenance manual 3 302 719 en...

  • Page 256: Having A Partial Inspection Carried Out

    Maintenance work on the superstructure 8.6 Hoists 8.6.6 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 257: Slewing Gear

    Maintenance work on the superstructure 8.7 Slewing gear Slewing gear 8.7.1 Checking the oil level Spare parts Designation Quantity GROVE part no. and tools Gasket 10 x 14 Cu DIN 7603 00117125 à Manual de Prerequisites – The truck crane must be level and in on-road mode; instrucciones .

  • Page 258: 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. 8.7.3 Checking the slewing gear brake Prerequisites – The truck crane is rigged with an outrigger span of at least 8.70 x 8.50 m à...
  • Page 259 – If the superstructure does slew, the slewing gear brake is defective and must be repaired immediately by Manitowoc Crane Care an authorised GROVE dealer. • Switch the slewing gear off and switch the engine off.

  • Page 260: Changing The Oil/Checking The Oil

    Maintenance work on the superstructure 8.7 Slewing gear M 12 8.7.4 Changing the oil/checking the oil à • Comply also with the Running-in regulations , p. 4 - 1. Oil, spare parts, Gear oil in Designation Specification GROVE part no. tools litres (gal) according to...
  • Page 261 Maintenance work on the superstructure 8.7 Slewing gear Draining oil • Remove the plate (1). • Place a receptacle under the screw (2). • Unscrew the filter (4) and screws (3) and (2). • Drain the oil. • Replace the gasket and screw the screw (2) back in.
  • Page 262 Maintenance work on the superstructure 8.7 Slewing gear Blank page 8 - 52 3 302 719 en Maintenance manual GMK6300L-1...

  • Page 263: Slewing Bearing

    5009 please refer to the applicable additional sheet 3 302 522 for these truck cranes. More far-reaching disassembly is necessary in order to achieve free access. • For information please contact Manitowoc Crane Care Tools – Torque wrench. à – Auxiliary tools for the torque wrench;...
  • Page 264 Do not put the truck crane back into operation and have the slewing bearing repaired by Manitowoc Crane Care Access to the outer ring The outer ring is attached to the carrier by the bolts (1).
  • Page 265 Maintenance work on the superstructure 8.8 Slewing bearing Access to the inner ring The inner ring is attached to the turntable by the bolts (1). • Check all 87 bolts (1) from below. To do this, you must rotate the turntable grad- ually to gain access to a pair of bolts (1) oppo- site one another, through the openings (2) in the carrier.
  • Page 266 Maintenance work on the superstructure 8.8 Slewing bearing Torques Screw type GROVE part number Torque Nm (lbf ft) Roller slewing bearing 03295952 Bearing type: RDV, three rows Model plate: Inside the inner ring. M27 x 150: 88 pieces on the outer ring 03227567 1150 (848) M27 x 180: 87 pieces on the inner ring...
  • Page 267 Maintenance work on the superstructure 8.8 Slewing bearing • Start the engine (from the crane cab) and turn the turntable by 90° – the second pair of screws on the opposite side is now accessible. • Switch off the engine. •...

  • Page 268: Lubricating The Gear Teeth

    Maintenance work on the superstructure 8.8 Slewing bearing 8.8.2 Lubricating the gear teeth Grease Designation Quantity GROVE part no. Adhesive lubricating grease (spray can) 00554205 Observe the instructions and safety instructions on the adhesive lubricating grease packaging. à Manual de Prerequisites –...
  • Page 269 Maintenance work on the superstructure 8.8 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 270: 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 271: Measuring Tilting Play

    Maintenance work on the superstructure 8.8 Slewing bearing 8.8.4 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 272 The base value of the tilting play is determined and documented by play or an authorised GROVE dealer when the ball Manitowoc Crane Care slewing bearing is put into operation or replaced. The maximum permissible wear is 0,7 mm (0,028 in).

  • Page 273: Lubricating The Locking Of Turntable

    Maintenance work on the superstructure 8.8 Slewing bearing M 12 8.8.5 Lubricating the locking of turntable Grease, spare Lubricating Designation Specification GROVE part no. parts, tools grease according to Classification DIN 51502 Grease KP - 1K - 50 DIN 51825 03233369 –...
  • Page 274 Maintenance work on the superstructure 8.8 Slewing bearing Blank page 8 - 64 3 302 719 en Maintenance manual GMK6300L-1...

  • Page 275: Hydraulic System

    Maintenance work on the superstructure 8.9 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. 8.9.1 Checking the oil level à...

  • Page 276: Checking The Hydraulic Hoses

    Maintenance work on the superstructure 8.9 Hydraulic system 8.9.2 Checking the hydraulic hoses The inspection work is described in section Checking the hydraulic hoses , p. 7 - 82. 8.9.3 Checking the ventilation filter • Check the display (1) on the ventilation filter. If the indicator is coloured à...

  • Page 277: Checking For Leaks

    Bleed the hydraulic system; p. 8 - 79. If damage cannot be rectified immediately or further damage is likely • Notify or an authorised GROVE dealer or your Manitowoc Crane Care repair crew. Maintenance manual 3 302 719 en 8 - 67 GMK6300L-1...

  • Page 278: Oil Filter 1 - Cleaning The Magnetic Rod

    Maintenance work on the superstructure 8.9 Hydraulic system 8.9.5 Oil filter 1 – cleaning the magnetic rod Spare parts Designation Quantity GROVE part no. and tools For oil filter 1: Filter 03325700 Packing set 03135853 à – Receptacle, approx. 5 ltr (1.5 gal); p.
  • Page 279 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. • Replace the gaskets (packing set) if necessary.

  • Page 280: Changing The Ventilation Filter

    Maintenance work on the superstructure 8.9 Hydraulic system M 12 8.9.6 Changing the ventilation filter Spare parts Designation Quantity GROVE part no. and tools Filter 03319602 Prerequisites – The engine must be switched off and secured against unauthorised use; à p.

  • Page 281: Pressure Accumulator - Checking The Gas Pressure

    The filling pressure at 20 °C (68 °F) is: 1 Pressure accumulator 20 bar (290 psi) 2 Pressure accumulator 180 bar (2610 psi) • Have the filling pressure checked and if necessary corrected by Manitowoc Crane or an authorised GROVE dealer. Care M 12 8.9.8 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 282 Maintenance work on the superstructure 8.9 Hydraulic system There is a gauge port (1) on the pump (2). When a hydraulic function is run, e.g. tilting the crane cab , oil can then be taken at the gauge port. Taking oil samples •...

  • Page 283: Changing The Hydraulic Oil Filter

    Maintenance work on the superstructure 8.9 Hydraulic system 8.9.9 Changing the hydraulic oil filter All oil filters must be replaced when changing the oil. In the event of a warning message, the red symbols in the Warning submenu indicate which oil filters you have to change. 1 Red –...
  • Page 284 Maintenance work on the superstructure 8.9 Hydraulic system Changing oil filter 1 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 285 Maintenance work on the superstructure 8.9 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). Changing oil filter 3 •...
  • Page 286 Maintenance work on the superstructure 8.9 Hydraulic system After changing the filter Risk of damage to the hydraulic pumps The engine may only be started if the valve in the suction line of the hydraulic pumps is open and there is enough hydraulic oil in the hydraulic oil tank.

  • Page 287: Changing The Hydraulic Oil

    Maintenance work on the superstructure 8.9 Hydraulic system 8.9.10 Changing the hydraulic oil The oil only needs to be changed if the laboratory analysis results indicate à Taking oil samples , p. 8 - 71. this; Oil, spare parts, Hydraulic oil Designation Specification GROVE part no.
  • Page 288 Maintenance work on the superstructure 8.9 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 289 Maintenance work on the superstructure 8.9 Hydraulic system Establishing After having changed the oil filters and topping up the oil, you must the 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 290 Maintenance work on the superstructure 8.9 Hydraulic system Blank page 8 - 80 3 302 719 en Maintenance manual GMK6300L-1...

  • Page 291: Main Boom

    Maintenance work on the superstructure 8.10 Main boom 8.10 Main boom 8.10.1 Greasing the piston rod of the derricking cylinder Grease, spare Designation GROVE part no. parts and tools Lubricant RHUS 2 AF; 1 kg 03325215 (Apply the grease with a brush) Spray on Berulub;...

  • Page 292: Lubricating The Telescopic Sections

    Maintenance work on the superstructure 8.10 Main boom 8.10.2 Lubricating the telescopic sections Reducing the Under difficult operating conditions – at extremely sandy or rainy locations – interval you must change them earlier than normal. Grease, spare Designation GROVE part no. parts, tools Lubricant for the locking pins: 03325215...
  • Page 293 Maintenance work on the superstructure 8.10 Main boom Information Risk of overturning when telescoping if the RCL is overridden. Do not override the rated capacity limiter (RCL) when telescoping is switched off. Select a suitable lifting capacity table which contains the required telescoping.
  • Page 294 Maintenance work on the superstructure 8.10 Main boom • Telescopic Observe the following instructions regarding maintenance work. section I • Extend the telescopic section I to 100%. Lubricate the slide faces • Use a brush or a roller (PAL1) to lubricate the outer, upper and outer, lower slide faces (3).
  • Page 295 Maintenance work on the superstructure 8.10 Main boom • Telescopic Observe the following instructions regarding maintenance work. section VI - II The following diagrams show the lubrication of the telescopic section VI . The telescope sections V, IV, III and II are lubricated in he same way. •...

  • Page 296: Checking The Sheaves

    Have damaged, worn, stiff or extremely soiled sheaves replaced by or an authorised GROVE dealer or your repair crew. Manitowoc Crane Care 8 - 86 3 302 719 en Maintenance manual...

  • Page 297: Checking The Locking System

    Have the maintenance work on the main boom locking system performed regularly by or an authorised GROVE dealer. Manitowoc Crane Care This prevents the complete unlocking of a telescopic section in emergency operation/emergency program mode, which could cause serious accidents and damage to the truck crane.
  • Page 298 Maintenance work on the superstructure 8.10 Main boom Blank page 8 - 88 3 302 719 en Maintenance manual GMK6300L-1...

  • Page 299: Hoist Ropes

    Maintenance work on the superstructure 8.11 Hoist ropes 8.11 Hoist ropes 8.11.1 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 300: Checking The Hoist Ropes

    Maintenance work on the superstructure 8.11 Hoist ropes 8.11.2 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 Manual de instrucciones .

  • Page 301: 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 302: Assessing The Condition Of The Hoist Rope

    Maintenance work on the superstructure 8.11 Hoist ropes 8.11.4 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 303 Maintenance work on the superstructure 8.11 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 304 Maintenance work on the superstructure 8.11 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 305 Maintenance work on the superstructure 8.11 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 306 Maintenance work on the superstructure 8.11 Hoist ropes Damage Description Cause Replacement Loop Outer layer wires in General wear due to Immediately replace rope if the formation (1) the form of hair pins ageing of the rope or rope structure has been are protruding from consequential substantially altered by the...
  • Page 307 Maintenance work on the superstructure 8.11 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 308: Replacing The Hoist Rope

    Maintenance work on the superstructure 8.11 Hoist ropes 8.11.5 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 309 Maintenance work on the superstructure 8.11 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 310 Maintenance work on the superstructure 8.11 Hoist ropes • Guide the rope through the hole (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 311: Setting The Lowering Limit Switch

    Maintenance work on the superstructure 8.11 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 312 Maintenance work on the superstructure 8.11 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 313: Cable Drums And Slewing Angle Sensor

    Maintenance work on the superstructure 8.12 Cable drums and slewing angle sensor 8.12 Cable drums and slewing angle sensor 8.12.1 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 314: Maintenance Of The Slip Ring Assemblies

    Maintenance work on the superstructure 8.12 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 315: Lubricating The Slewing Angle Sensor

    Maintenance work on the superstructure 8.12 Cable drums and slewing angle sensor 8.12.2 Lubricating the slewing angle sensor Grease, spare Lubricating Designation Specification GROVE part no. parts, tools grease according to Classification DIN 51502 Grease KP - 1K - 50 DIN 51825 03233369 Designation...
  • Page 316 Maintenance work on the superstructure 8.12 Cable drums and slewing angle sensor Blank page 8 - 106 3 302 719 en Maintenance manual GMK6300L-1...

  • Page 317: Central Lubrication System

    Maintenance work on the superstructure 8.13 Central lubrication system 8.13 Central lubrication system 8.13.1 Checking the level The maintenance of the pump (1) is the same à Central as the maintenance on the carrier; lubrication system , p. 7 - 99. Connected lubricating points –...
  • Page 318 Maintenance work on the superstructure 8.13 Central lubrication system Blank page 8 - 108 3 302 719 en Maintenance manual GMK6300L-1...

  • Page 319: 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 8.14.2 Lubricating à...
  • Page 320 Some manufacturers recommend dismantling every 4 years or after 500 operating hours. • about the maintenance intervals for the Manitowoc Crane Care hook blocks supplied to you. • Have the hook blocks dismantled by or an Manitowoc Crane Care authorised GROVE dealer or your qualified repair crew.

  • Page 321: 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 lamps and displays on the ECOS and RCL control units;...

  • Page 322: Checking The Batteries

    Maintenance work on the superstructure 8.15 Electrical system 8.15.2 Checking the batteries • Switch the battery master switch (1) off and remove the selector handle. • Remove the cap (3) from the battery box. • Check the batteries (2) in the same way as when checking them on the carrier;...

  • Page 323: Charging The Batteries Using The Battery Charger

    Maintenance work on the superstructure 8.15 Electrical system 8.15.4 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 324: Check The External Starting Socket

    Maintenance work on the superstructure 8.15 Electrical system 8.15.5 Check the external starting socket The battery box can be equipped with an external starting socket (1) as additional equipment. Accessories A connection cable (1) for the external starting socket is supplied with the truck crane (tool set).

  • Page 325: Air Conditioning System

    • 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. Maintenance manual 3 302 719 en 8 - 115...

  • Page 326: Cleaning The Condenser Fins

    8.16.4 Checking the entire air-conditioning system This inspection may only be performed by Manitowoc Crane Care an 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 327 Maintenance work on the superstructure 8.16 Air conditioning system Refrigerant Fill quantity Designation CAS no. in kg (lbs) EC no. 1.1 (2.4) Tetrafluoroethane (R134a) 811-97-2 212-377-0 Filler connections The filler connections (1) for the refrigerant are behind the flap (2). Maintenance manual 3 302 719 en 8 - 117...
  • Page 328 Maintenance work on the superstructure 8.16 Air conditioning system Blank page 8 - 118 3 302 719 en Maintenance manual GMK6300L-1...

  • Page 329: Other Maintenance Work

    Maintenance work on the superstructure 8.17 Other maintenance work 8.17 Other maintenance work 8.17.1 Checking the windscreen washing system Water, spare Designation Quantity GROVE part no. parts, tool Windscreen wiper blade 03326121 Roof wiper blade 03326121 – Water; add commercially available detergent and antifreeze to it. –...

  • Page 330: Checking The Functioning Of The Auxiliary Heater

    Maintenance work on the superstructure 8.17 Other maintenance work Wiping The wiping/washing system operation is described in the accompanying à Manual de instrucciones . operating instructions; • Spray water on the windscreen – press down on the switch. • Spray water on the skylight – press up on the switch. •...

  • Page 331: 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 3 302 719 en 8 - 121...

  • Page 332: 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 - 122 3 302 719 en Maintenance manual GMK6300L-1...

  • Page 333: 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 334: Renewing The Corrosion Protection

    Maintenance work on the superstructure 8.17 Other maintenance work M 12 8.17.6 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 335 Maintenance work on the superstructure 8.17 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 336: Having The Fire Extinguisher Checked

    Maintenance work on the superstructure 8.17 Other maintenance work 8.17.7 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 337 Longer out of service periods Maintenance manual 3 302 719 en GMK6300L-1...
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  • Page 339: 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 Clean the truck crane thoroughly on the inside and outside. truck crane •...
  • Page 340 Longer out of service periods • Ensure that the tyre positioning is different each time the crane is parked (without outriggers). • Seal all air filters again. If the truck crane is going to be out of service for more than 12 months: •...
  • Page 341 Torques 10.1 Torques for the retaining bolts ........10 - 10.2 Special torques .
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  • Page 343: 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- Socket screw...
  • Page 344 Torques 10.2 Special torques 10.2 Special torques Thread size Size across flats Torque (Nm) (mm) (mm) Name Hexagon- Socket head bolt screw Suspension strut: – Bracket for the vehicle chassis, top M 16 — – Bracket for the vehicle chassis, M 24 —...
  • Page 345 Spare parts required for maintenance 11.1 General information ..........11 - 11.2 Lighting .
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  • Page 347: 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 348 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 03328445 P21W 24 V – Low-beam + full-beam headlights 03134828 H7 24 V –...
  • Page 349 Spare parts required for maintenance 11.2 Lighting Installation point GROVE part Designation Power (W) number Red triple light strip for USA: (at the rear of the chassis) – Triple light strip 7581100056 White front marker lights: (at the top on the driver's cab) –...
  • Page 350 Spare parts required for maintenance 11.2 Lighting Installation point GROVE part Designation Power (W) number SUPERSTRUCTURE LIGHTING: Marker lights, yellow: (on the main boom head) – Marker light; complete 03329569 Red rear marker lights: (on the turntable) – Marker light 03329492 FPL 98 CKS Yellow rotating beacon:...

  • Page 351: 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 04163882 1 item when the symbol lights up Air filter –...
  • Page 352 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 Vehicle brake (per axle line) 1. and 2 axle line (duplex brake): Brake shoe with brake lining 03322112 Spring...
  • Page 353 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 gasket 04161614 Transmission Oil filter set with gaskets (contains two filters and one oil drain 03141323 plug gasket)

  • Page 354: 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 Engine Air filter 04183736 1 item when the symbol lights up Fuel system Filter (filter 1) 04181165...
  • Page 355 Spare parts required for maintenance 11.4 Spare parts for the superstructure Quantity, in single parts Assemblies and spare parts GROVE- For maintenance interval Superstructure part number M 12 Hoist ropes Cover gasket for the lowering limit 1 (if damaged) 02315305 switch for every rope change on the hoist Cable drums...
  • Page 356 Spare parts required for maintenance 11.4 Spare parts for the superstructure Blank page 11 - 10 3 302 719 en Maintenance manual GMK6300L-1...
  • Page 357 Appendix Maintenance manual 3 302 719 en GMK6300L-1...
  • Page 358 3 302 719 en Maintenance manual GMK6300L-1...

  • Page 359: Appendix

    Appendix...

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