Page 1 Maintenance manual 3 302 574 en 03.11.2017...
Page 2 Important note Any type of duplication or excerpt from this document, even in electronic form, is not subject to the revision service of Manitowoc Crane Group Germany GmbH © Copyright reserved by Manitowoc Crane Group Germany GmbH Industriegelände West D-26389 Wilhelmshaven, Germany...
Page 3 Slewing angle sensor Version (A) and (B) Depending on the type of truck crane, a slewing angle sensor of type (A) or (B) can be installed on the slewing bearing. Version (A) For this version, the specifications in the supplied maintenance manual apply. Version (B) Deviating from the specifications in the maintenance manual supplied, this version of the slewing angle sensor is maintenance-free.
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Page 5: Table Of Contents
Contents: General instructions Safety and environmental protection Cleaning Run-in regulations Maintenance overview Lubricants and consumables Maintenance work on the carrier Maintenance work on the superstructure Longer out of service periods 10 Torques 11 Spare parts required for maintenance Appendix This maintenance manual does not replace the operating manual. Details of operation and standard safety instructions can be found in the operating manual.
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Page 7 General instructions Using the maintenance manual ........1 - Warnings and symbols .
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Page 9: General Instructions
General instructions 1.1 Using the maintenance manual General instructions 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 10: Maintenance Instructions
– appropriate workshop equipment, – special tools and – Spare parts approved by Manitowoc Crane Group Germany GmbH. 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.
Page 11 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 12: Instructions Regarding The Electronic Controls
Manitowoc Crane Care All welding work (especially on load carrying members) may only be per- formed by qualified professional personnel with the prior written permis- sion from Manitowoc Crane Group Germany GmbH. 1 - 4 3 302 574 en Maintenance manual...
Page 13: Definition Of Direction Information
General instructions 1.6 Definition of direction information Definition of direction information 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 14: 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 meas- urement and vice versa.
Page 15 Safety and environmental protection Safety rules ............2 - 2.1.1 Securing against unauthorised use .
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Page 17: Safety And Environmental Protection
Safety and environmental protection 2.1 Safety rules Safety and environmental protection Safety rules Observe the applicable accident prevention regulations when carrying out maintenance work. 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 18 Safety and environmental protection 2.1 Safety rules If due to exceptional circumstances the truck crane needs be put into oper- ation 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 19: 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 20: Handling Substances That Are Harmful To The Environment
Safety and environmental protection 2.2 Handling substances that are harmful to the environment Handling substances that are harmful to the environment Which substances When you carry out maintenance work on the truck crane you will occasion- are harmful to the ally work with consumables which are classified as harmful to the environ- environment? ment by applicable national and regional regulations.
Page 21 Safety and environmental protection 2.2 Handling substances that are harmful to the environment Separate collec- Substances which are harmful to the environment should always be tion and storage collected separately from other waste. • Ask your local environmental protection authority about the different cat- egories of the substances.
Page 22: 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 23 Cleaning Overview of assemblies easily damaged when cleaning ....3 - Maintenance manual 3 302 574 en GMK3060...
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Page 25: 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 26 Cleaning 3.1 Overview of assemblies easily damaged when cleaning Overview of assemblies easily damaged when cleaning 3 - 2 3 302 574 en Maintenance manual GMK3060...
Page 27 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 Lowering limit switch 6 Suspension struts 7 Slewing angle sensor 8 Control units for outriggers 9 Drag link supporting plate 10 Spotlights, pivoting 11 Lifting limit switch...
Page 28 Cleaning 3.1 Overview of assemblies easily damaged when cleaning Blank page 3 - 4 3 302 574 en Maintenance manual GMK3060...
Page 29 Run-in regulations Maintenance manual 3 302 574 en GMK3060...
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Page 31: Run-In Regulations
Run-in regulations Run-in regulations There are regulations about running in individual parts which must be followed, after: – First commissioning or – Part replacement or – General overhaul. This is why you must carry out additional maintenance work on the carrier and superstructure at specific intervals: Operating Driven km...
Page 32 Run-in regulations Operating hours Additional maintenance work on the (oper. hrs.) SUPERSTRUCTURE during the first 100 Check hydraulic oil filter 3 in the superstructure every week, and change it if necessary; à Changing oil filter 3 , p. 7 - 100. after 100 Tighten the bolts on the slewing bearing;...
Page 33 Maintenance overview Maintenance intervals..........5 - Maintenance plans .
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Page 35: Maintenance Overview
Maintenance overview 5.1 Maintenance intervals Maintenance overview – Maintenance plans D (= daily), – Maintenance plans W (= weekly) and – Maintenance plans M 1 (= once a month) to M 12 (= every 12 months) and – Maintenance plans Y 2 (= every 24 month) to Y 10 (= every 120 months). The maintenance plans are provided as tables, divided into –...
Page 36 Maintenance overview 5.1 Maintenance intervals The maintenance interval that occurs first determines when the next maintenance is due. – The driven km (or mi) can be taken from the speedometer. – The operating hours (oper. hrs.) of the engine an power units of the superstructure can be called up individually on the CCS CCS display in the crane cab.
Page 37 Maintenance overview 5.2 Maintenance plans Maintenance plans The descriptions of 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 Chapter 7 and for –...
Page 38 Maintenance overview 5.2 Maintenance plans 5.2.1 Maintenance plan D Maintenance work on the CARRIER: Daily/before putting into operation Engine à – Check the oil level p. 7 - 15 à – Checking the air filter p. 7 - 18 à –...
Page 39 Maintenance overview 5.2 Maintenance plans Maintenance work on the SUPERSTRUCTURE: Daily/before putting into operation Hoist ropes à – Checking the winding p. 8 - 45 Electrical system à – Checking the lighting and indicators p. 8 - 67 Maintenance manual 3 302 574 en 5 - 5 GMK3060...
Page 40 Maintenance overview 5.2 Maintenance plans 5.2.2 Maintenance plan W Maintenance work on the CARRIER: Weekly Engine à – General inspection p. 7 - 23 Transmission à – General inspection p. 7 - 47 Axle lines à – General inspection p. 7 - 51 Wheels à...
Page 41 Maintenance overview 5.2 Maintenance plans Maintenance work on the SUPERSTRUCTURE: Weekly Hoists à – Checking the oil level p. 8 - 9 à – General inspection p. 8 - 10 à – Checking the hoist brake p. 8 - 10 Slewing gear à...
Page 42 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 - 15 à – Checking the air intake inhibitor p.
Page 43 Maintenance overview 5.2 Maintenance plans Maintenance work on the SUPERSTRUCTURE: Monthly/after 100 oper. hrs. Main boom à – Grease the piston rod of the derricking cylinder p. 8 - 37 Air-conditioning system à – Checking the air-conditioning system p. 8 - 69 Other maintenance work à...
Page 44 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 - 15 Vehicle brake à...
Page 45 Maintenance overview 5.2 Maintenance plans Maintenance work on the SUPERSTRUCTURE: Every three months/after 250 oper. hrs. Slewing bearing à – Checking the bolts p. 8 - 23 Main boom à – Lubricating the telescopic sections p. 8 - 38 à –...
Page 46 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 - 15 à...
Page 47 Maintenance overview 5.2 Maintenance plans Maintenance work on the SUPERSTRUCTURE: Every six months/after 500 oper. hrs. Hoists à – Lubricating the auxiliary hoist p. 8 - 11 Slewing gear à – Checking the slewing gear brake p. 8 - 17 Slewing bearing à...
Page 48 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 - 15 à...
Page 49 Maintenance overview 5.2 Maintenance plans M 12 Maintenance work on the SUPERSTRUCTURE: Every twelve months/after 1 000 oper. hrs. Hoists à – Changing the oil/checking the oil p. 8 - 12 Slewing gear à – Changing the oil/checking the oil – Slewing gear transmission p.
Page 50 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 - 15 à...
Page 51 Maintenance overview 5.2 Maintenance plans 5.2.9 Maintenance plan Y 5 Maintenance work on the CARRIER: every 60 months / 100,000 km (62,000 mi) No maintenance work in this period. The long-term intervals always include the short-term intervals! Maintenance work on the SUPERSTRUCTURE: every 60 months/after 5 000 oper.
Page 52 – Replace the battery on the electronics board p. 7 - 112 Steel construction – Check the load-bearing steel construction. For further information, please contact Manitowoc Crane Care Maintenance work on the SUPERSTRUCTURE: every 120 months/after 12 000 oper. hrs. Electrical system à...
Page 53 Maintenance overview 5.3 Periodic inspections Periodic inspections Your GMK3060 truck crane has been inspected before delivery. – Truck cranes used in Germany are inspected in accordance with the reg- ulations of the professional trade association as defined by BGV D 52 (BGV D 6).
Page 54 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 dimensions y, y1, y2. The original dimensions y, y1, y2 are specified in the field (2) on the load hooks.
Page 55 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 - 14. These measures for monitoring the winches (hoisting gears) were compiled by VDMA and are to be used for all vehicle cranes according to the Accident Prevention Regulations for Winches, Hoisting and Tractor Machines DGUV Regulation 52 (BGV D 6) and DGUV Regulation 54 (BGV D 8) .
Page 56 Maintenance overview 5.4 Measures required for winch monitoring The actual service life of a winch is affected by a number of additional exter- nal 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 57 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 58 Maintenance overview 5.4 Measures required for winch monitoring One of the load spectra listed above should be selected on the basis of the actual operating conditions and entered in the crane logbook for the respec- tive testing interval. Note for truck cranes: The load spectrum L1 and the factor of the load spectrum Km = 0.125 are generally applied to truck cranes in assembly mode.
Page 59 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 theo- retical service life D upon completion of the general overhaul.
Page 60 5.4 Measures required for winch monitoring 5.4.3 Example A GMK3060 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 L 1, Km = 0.125...
Page 61 Maintenance overview 5.4 Measures required for winch monitoring The used proportion S of theoretical service life after the 2nd inspection is therefore:  -------------- - 480 h 1,920 h 0,125 Remaining theoretical service life: D2 = 3,040 h - 1,920 h = 1,120 h. The aforementioned values are entered in the table (see table example p.
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Page 63 Lubricants and consumables Lubricants............6 - 6.1.1 Lubricants list .
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Page 65: 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 66: Lubricants List
Lubricants and consumables 6.1 Lubricants 6.1.1 Lubricants list Con- GROVE- Lubricant Designation Specification Viscosity sec. Part type according to Classification number DIN 51502 CES 20081 04162428 Engine oil HD - CD SAE 15 W-40 Cummins ZF TE-ML02 03325153 Gear oil Ecofluid M ZF (synthetic) MIL-L 2105 B...
Page 67: Lubricant Applications List
Lubricants and consumables 6.1 Lubricants 6.1.2 Lubricant applications list Con- Lubricant Usage Fill quan- Mainte- sec. type tity nance in litres interval (gal) à Engine oil Diesel engine; p. 7 - 24 26.5 (7.0) à Gear oil Manual transmission; p. 7 - 48 12.5 (3.3) à...
Page 68: Refrigerant
Lubricants and consumables 6.2 Refrigerant Con- Lubricant Usage Fill quan- Mainte- sec. type tity nance in litres interval (gal) à Spray Slewing bearing gear teeth; p. 8 - 27 à Slide paste Telescope slide faces; p. 8 - 38 à Derricking cylinder piston rod;...
Page 69: Engine Coolant Admixtures
Lubricants and consumables 6.3 Consumables 6.3.2 Engine coolant admixtures The specifications and admixture ratios can be found in the Engine manufacturer's documentation . The coolant must be renewed every two years (Y 2); à Engine manufacturer’s documentation . 6.3.3 After-treatment of exhaust gases Designation Usage Fill quantity...
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Page 71 Maintenance work on the carrier General instructions ..........7 - 7.1.1 Front flap .
Page 72 7.8.3 Checking that the wheel nuts are tight ....... 7 - 62 7.8.4 Changing the wheels .
Page 73 7.17.2 Checking the bearing ..........7 - 121 7.17.3 Checking the cotter pin .
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Page 75: Maintenance Work On The Carrier
Maintenance work on the carrier 7.1 General instructions Maintenance work on the carrier General instructions The GMK3060 truck crane is fitted as standard with an AdBlue system for exhaust gas emis- sion control – Tier4 final. In this case an AdBlue tank (1) is fitted to the à...
Page 76: Front Flap
Maintenance work on the carrier 7.1 General instructions 7.1.1 Front flap Some maintenance tasks require that the front flap be opened. Opening • Pull the lever (1). • Push the lever (6) to the right and open the flap (5). •...
Page 77: Tilting And Lowering The Driver's Cab
Maintenance work on the carrier 7.1 General instructions 7.1.3 Tilting and lowering the driver's cab Some maintenance tasks on the engine and the transmission require that the driver's cab be tilted forwards using a hydraulic hand pump. Safety instruc- tions The driver's cab is tilted using a hydraulic hand pump (1).
Page 78: Overview Of Maintenance Work On The Carrier
Maintenance work on the carrier 7.1 General instructions 7.1.4 Overview of maintenance work on the carrier 7 - 4 3 302 574 en Maintenance manual GMK3060...
Page 79 Maintenance work on the carrier 7.1 General instructions à Symbols for maintenance work p. 7 - 11 à 9 On the instrument panel and CCS control unit p. 7 - 11 à Engine p. 7 - 15 à 1 Diesel engine p.
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Page 81 Maintenance work on the carrier 7.1 General instructions à Axle lines p. 7 - 51 à 5 Axle centre drives p. 7 - 51 à 3 Final drives p. 7 - 55 à 6 Cardan shafts p. 7 - 58 à...
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Page 83 Maintenance work on the carrier 7.1 General instructions à Wheels p. 7 - 61 à 6 Wheels p. 7 - 61 à 4 Spare wheel p. 7 - 61 à Suspension p. 7 - 71 à 10 Suspension struts p. 7 - 71 à...
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Page 85: Symbols For Maintenance Work
Maintenance work on the carrier 7.2 Symbols for maintenance work Symbols for maintenance work 7.2.1 Instrument panel • Middle Check the symbols on the instrument panel in the driver's cab each day before starting operations. • Carry out a lamp test after switching on the ignition. Check that the lamps light up briefly.
Page 86 Maintenance work on the carrier 7.2 Symbols for maintenance work à Exhaust gas temperature; p. 7 - 44. à Exhaust gas regeneration (passive); p. 7 - 44. à Exhaust gas regeneration (active); p. 7 - 44. à Transmission malfunction; p. 7 - 47. 7 - 12 3 302 574 en Maintenance manual...
Page 87: Ccs Display
Maintenance work on the carrier 7.2 Symbols for maintenance work 7.2.2 CCS display • Check the symbols on the CCS Start menu ( Crane Control System ) in the driver's cab each day before starting operations. • The Start menu shows the most important measurements and the Warning submenu shows all pending warning messages;...
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Page 89: Engine
Maintenance work on the carrier 7.3 Engine Engine • Also carry out the additional maintenance work specified in the Engine manufacturer's documentation supplied. 7.3.1 Check the oil level Prerequisites – The truck crane must be level. Check the oil level •...
Page 90 Maintenance work on the carrier 7.3 Engine • Check that the oil level on the dipstick (1) is between the Min. and Max. marks (arrow markings). • Put the oil dipstick into the dipstick tube after the check and close the front flap. If the oil level is too low à...
Page 91: Topping Up The Oil
Maintenance work on the carrier 7.3 Engine 7.3.2 Topping up the oil à Information on the prescribed oil specification; Engine manufacturer’s documentation . Engine oil Designation Specification GROVE part no. in litres (gal) to DIN 51502 Classification 26.5 (7.0) HD - CD CES 20081 SAE 15 W-40 Cummins...
Page 92: Checking The Air Filter
Maintenance work on the carrier 7.3 Engine 7.3.3 Checking the air filter Change the air filter if the symbol is displayed. Spare parts Designation Quantity GROVE part no. and tools Main filter 04182216 Back-up filter 04182217 Prerequisites – The engine must not be running and must be secured against unauthor- à...
Page 93: Checking The Air Intake Inhibitor
Maintenance work on the carrier 7.3 Engine 7.3.4 Checking the air intake inhibitor Additional The GMK3060 truck crane can be equipped with an air intake inhibitor as à Operating Instructions . equipment additional equipment; Purpose The engine speed of the truck increases if the intake air at the current site of the truck crane is enriched with explosive gases or dust (in extreme cases this can lead to destruction of the engine).
Page 94 Maintenance work on the carrier 7.3 Engine Prerequisites – The truck crane is in on-road mode and the engine is running. Checking The function test is performed via the CCS menu. • Select and confirm the symbol (1). The Air intake inhibitor menu opens. •...
Page 95 Maintenance work on the carrier 7.3 Engine • On the Instrument Also note the additional monitoring elements on the middle instrument panel panel in the driver's cab. The state of the air intake inhibitor is indicated by the symbol (1). Symbol (1) lights up: closed Symbol (1) is not lit:...
Page 96: Checking The Coolant Level
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. 7 - 22 3 302 574 en...
Page 97: 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. Maintenance manual 3 302 574 en 7 - 23...
Page 98: 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 Designation Specification GROVE part no. tools in litres (gal) to DIN 51502 Classification 26.5 (7.0) HD - CD CES 20081 SAE 15 W-40 Cummins 04162428 Designation...
Page 99 Maintenance work on the carrier 7.3 Engine à • Tilt the driver's cab; Tilting and lowering the driver's cab , p. 7 - 3. Draining oil • Place a receptacle underneath the engine. • Remove the cover (2) from the filler neck. •...
Page 100: Have The Radiator Checked/Cleaned
Maintenance work on the carrier 7.3 Engine M 12 7.3.8 Have the radiator checked/cleaned • Reducing the Under difficult operating conditions – at extremely sandy or dusty loca- interval tions or if there is a heavy density of fallen leaves – you must have the radiator fins cleaned earlier than this.
Page 101 Maintenance work on the carrier 7.3 Engine The radiator unit is located in front of the diesel engine. The diesel engine fan impeller (5) is surrounded by a fan hood (4). The fan impeller rotates when the engine is running! Risk of injury at the fan wheel! When the fan impeller is rotating it can trap the fingers of your hand and amputate them.
Page 102 Maintenance work on the carrier 7.3 Engine Have them cleaned Risk of injury at the fan wheel! 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 openings in the fan hood to clean them.
Page 103 Maintenance work on the carrier 7.3 Engine • Have the radiator units (1, 2, 3) 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 104: Changing The Coolant
Maintenance work on the carrier 7.3 Engine 7.3.9 Changing the coolant à Tools – Receptacle, approx. 20 l (5.3 gal); p. 2 - 4. à Engine manufacturer’s documentation . – Antifreeze 20 l (5.3 gal); Prerequisites – Information on the coolant and admixture ratio has been obtained; à...
Page 105 Maintenance work on the carrier 7.3 Engine Topping up when the engine is cold • Slowly top up the expansion tank (2) with coolant until it is filled up to the middle of the inspection glass (1). • Wait about 1 minute. Add more coolant if necessary.
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Page 107: Fuel System
(1). If the truck crane is additionally equipped with a 2-chamber fuel tank, please refer to for information on the Manitowoc Crane Care fuel filters required. The following are installed in the fuel line as standard: 1 Fuel filter 1...
Page 108: Draining Off Water From Fuel Filter 1
Maintenance work on the carrier 7.4 Fuel system 7.4.1 Draining off water from fuel filter 1 à Spare parts – Receptacle, approx. 5 l (1.5 gal); p. 2 - 4. and tools Prerequisites – The truck crane must be level. –...
Page 109: 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 04182148 à – Receptacle, approx. 5 l (1.5 gal); p. 2 - 4. Prerequisites – The truck crane must be level. –...
Page 110 Maintenance work on the carrier 7.4 Fuel system • Remove the electrical connecting cable (3) from the water sensor (WIF = Water in Fuel). • Remove the filter (1). • Screw on a new filter (1) and tighten it. • Close the valve (2) manually.
Page 111: Replacing Fuel Filter 2
Maintenance work on the carrier 7.4 Fuel system 7.4.3 Replacing fuel filter 2 Spare parts Designation Quantity GROVE part no. and tools Filter 04182157 à – Receptacle, approx. 5 l (1.5 gal); p. 2 - 4. à Operating Instructions . Prerequisites –...
Page 112 Maintenance work on the carrier 7.4 Fuel system Bleeding the If necessary, the fuel line can be bled via the bleed screw on the head of fuel line filter 2. At filter 2 • Open the screw (2) on the head of filter 2. At filter 1 •...
Page 113: 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 adhere to the exhaust emission regulations, you are only permitted to drive the crane with the multi-stage exhaust system consisting of a DOC catalytic converter, DPF particle filter and SCR catalytic converter (DOC = Diesel Oxidation Catalyst, DPF = Diesel Particulate Filter, SCR = Selective Catalytic Reduction).
Page 114: 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 • Start the engine. • Check that the symbol on the instrument panel is no longer lit. When the symbol lights up the filling level is already at the reserve level and when the à...
Page 115: Check The Exhaust System For External Damage
Maintenance work on the carrier 7.5 Exhaust system with exhaust emission control • Filling up Find out about filling up in the operating manual and note the warnings; à Operating Instructions . Danger of scalding due to ammonia vapours! Ammonia vapour can escape if the AdBlue tank is opened when the outside temperature is high.
Page 116 • Attach the heat shield (6). If you discover any damage Have any damaged parts of the exhaust system replaced immediately by or an authorised GROVE dealer. Manitowoc Crane Care 7 - 42 3 302 574 en Maintenance manual GMK3060...
Page 117: 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 - 39.
Page 118: Having The Soot Particle Filter System Checked
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 119 • Service partner Have the particulate filter and catalytic converter replaced by service partners. Information can be obtained from Manitowoc Crane Care Prerequisites – The engine must not be running and must be secured against unauthor- à ised use; p. 2 - 3.
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Page 121: Transmission
• Check that pipes and hoses are tightly connected and undamaged. If any damage is found, report it to or an authorised Manitowoc Crane Care GROVE dealer or an authorised specialist workshop. M 12 7.6.2 Check the oil level...
Page 122: Changing The Oil
Maintenance work on the carrier 7.6 Transmission Check 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. Check the oil level at the correct intervals. Wait until the oil cools down (below 40 °C (104 °F)).
Page 123 Maintenance work on the carrier 7.6 Transmission Prerequisites – The gear oil must be at operating temperature (70 to 95 °C (160 to 200 °F)). – The truck crane must be raised on outriggers or parked over an inspection pit. –...
Page 124 Maintenance work on the carrier 7.6 Transmission Topping up the oil • Fill the oil up to the lower edge of the opening. • Replace the gasket and tighten the drain plug (1) – torque 60 Nm (44.2 lbf ft). Checks after the oil change After changing oil, check for leakage:...
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. 7.7.2 Axle centre drives – checking the oil level...
Page 126 Maintenance work on the carrier 7.7 Axle lines 1st and 3rd axle Axle centre drive on the 1st Axle line only present with a 6 x 6 x 6 drive. line • Unscrew the screw (1). • Check that the oil reaches the lower edge of the opening.
Page 127: Axle Centre Drives - Changing The Oil
Maintenance work on the carrier 7.7 Axle lines M 12 7.7.3 Axle centre drives – changing the oil Oil, spare parts, Gear oil Designation Specification GROVE part no. tools in litres (gal) to DIN 51502 Classification Axle lines 1+3: C - LPF MIL-L 2105 B 00552891 13.0 (3.5) each...
Page 128 Maintenance work on the carrier 7.7 Axle lines 1st and 3rd axle Axle centre drive on the 1st Axle line only present with a 6 x 6 x 6 drive. line • Place a receptacle under the drain plug (2). •...
Page 129: Final Drives - Checking The Oil Level
Maintenance work on the carrier 7.7 Axle lines 7.7.4 Final drives - Checking the oil level Spare parts for drive Designation Quantity GROVE part no. and tools 6 x 4 x 6 Gasket 24 x 30 Cu DIN 7603 04181265 6 x 6 x 6 Gasket 24 x 30 Cu DIN 7603 04181265...
Page 130: Final Drives - Changing The Oil
Maintenance work on the carrier 7.7 Axle lines M 12 7.7.5 Final drives - Changing the oil Oil, spare parts, Gear oil Designation Specification GROVE part no. tools in litres (gal) to DIN 51502 Classification for each final C - LPF MIL-L 2105 B 00552891 drive:...
Page 131 Maintenance work on the carrier 7.7 Axle lines Draining oil • Change the oil on all final drives in the same way. • Turn the wheel until the marking (2) is hori- zontal and to the right – the screw (3) points downwards.
Page 132: Lubricating The Drive Shafts In The Axle Lines
Maintenance work on the carrier 7.7 Axle lines 7.7.6 Lubricating the drive shafts in the axle lines Check all drive shafts to see if they have grease nipples. Drive shafts with grease nipples must be serviced, drive shafts without grease nipples are maintenance-free. Grease, spare Lubricating Designation...
Page 133: Lubricating Longitudinal Drive Shafts
Maintenance work on the carrier 7.7 Axle lines 7.7.7 Lubricating longitudinal drive shafts Check all drive shafts to see if they have grease nipples. Drive shafts with grease nipples must be serviced, drive shafts without grease nipples are maintenance-free. Grease, spare Lubricating Designation Specification...
Page 134 Maintenance work on the carrier 7.7 Axle lines Blank page 7 - 60 3 302 574 en Maintenance manual GMK3060...
Page 135: Wheels
Maintenance work on the carrier 7.8 Wheels Wheels 7.8.1 Checking the tyres for damage Prerequisites – The truck crane must be raised on outriggers. – The engine must not be running and must be secured against unauthor- à ised use; p.
Page 136: Checking The Tyre Pressure
Maintenance work on the carrier 7.8 Wheels 7.8.2 Checking the tyre pressure Risk of damage to the tyres! The air pressure increases when the tyres become hot during driving. Never release the increased air pressure of tyres at operating temperature! Always check the air pressure in on-road driving mode with cold tyres.
Page 137 Maintenance work on the carrier 7.8 Wheels In the case of Aluminium rims Risk of accidents through incorrect wheel nuts! Incorrect wheel nuts can come loose while driving and cause accidents. You are only permitted to used wheel nuts from the initial equipment man- ufacturer because the wheel nuts are matched to the diameter of the pres- sure plate and the thread length of the respective aluminium rim.
Page 138: Changing The Wheels
Maintenance work on the carrier 7.8 Wheels 7.8.4 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 reg- ularly.
Page 139 Maintenance work on the carrier 7.8 Wheels Recognising two-piece aluminium rims The round-head bolts (1) are on the outer face of the wheel 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 140 Maintenance work on the carrier 7.8 Wheels • Mount the wheels on another axle, as shown in the diagram. Replace any à damaged parts. Tighten the wheel nuts; p. 7 - 62. 7 - 66 3 302 574 en Maintenance manual GMK3060...
Page 141 Maintenance work on the carrier 7.8 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.
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Page 143: 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 144 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 145: 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 con- nections.
Page 146: Suspension Struts - Checking The Fastening
Maintenance work on the carrier 7.10 Suspension 7.10.2 Suspension struts – checking the fastening Spare parts – Torque wrench for torques up to 900 Nm (664 lbf ft). and tools à Operating Instructions. Prerequisites – The truck crane must be raised on outriggers; –...
Page 147: 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 148: Pressure Accumulator - Checking The Gas Pressure
60 bar (870 psi) 65 bar (943 psi) • Have the filling pressure checked, and if nec- essary corrected, by Manitowoc Crane Care an authorised GROVE dealer or an author- ised specialist workshop. 7 - 74 3 302 574 en...
Page 149: Steering
Bleeding the hydraulic system , p. 7 - 97. Bleed the hydraulic system; If damage cannot be rectified immediately or further damage is likely • Notify or an authorised GROVE dealer or your repair Manitowoc Crane Care crew. Maintenance manual 3 302 574 en 7 - 75 GMK3060...
Page 150: Lubricating The Drag Link Supporting Plate
Maintenance work on the carrier 7.11 Steering 7.11.2 Lubricating the drag link supporting plate The front drag link from the servo steering to the first axle line is brought over a lubricated supporting plate made of synthetic material. Lubricate the supporting plate every time you clean the truck crane with a à...
Page 151: Pressure Accumulator - Checking The Gas Pressure
The filling pressure at 20 °C (68 °F) is: 100 bar (14,504 psi) • Have the filling pressure checked, and if nec- essary corrected, by Manitowoc Crane Care an authorised GROVE dealer or an author- ised specialist workshop. Maintenance manual 3 302 574 en...
Page 152 Maintenance work on the carrier 7.11 Steering Blank page 7 - 78 3 302 574 en Maintenance manual GMK3060...
Page 153: Compressed Air System
(7). If a great deal of moisture escapes • Have the compressed air drier checked or replaced by or an Manitowoc Crane Care authorised GROVE dealer or your qualified repair crew. Maintenance manual 3 302 574 en 7 - 79...
Page 154: Checking For Leaks
If damage cannot be rectified immediately or further damage is likely: • Notify or an authorised GROVE dealer or your repair Manitowoc Crane Care crew. 7 - 80 3 302 574 en Maintenance manual...
Page 155: Replacing The Filter Cartridge Of The Compressed Air Drier
Maintenance work on the carrier 7.12 Compressed air system 7.12.3 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 7.12 Compressed air system Blank page 7 - 82 3 302 574 en Maintenance manual GMK3060...
Page 157: Hydraulic System
Maintenance work on the carrier 7.13 Hydraulic system 7.13 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 7.13 Hydraulic system 7.13.2 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: Checking For Leaks
Bleed the carrier's hydraulic system; p. 7 - 97. If damage cannot be rectified immediately or further damage is likely • Notify or an authorised GROVE dealer or your repair Manitowoc Crane Care crew. Maintenance manual 3 302 574 en 7 - 85 GMK3060...
Page 160: Changing The Ventilation Filter
Maintenance work on the carrier 7.13 Hydraulic system M 12 7.13.4 Changing the ventilation filter • Reducing Under difficult operating conditions – at extremely sandy or dusty loca- the interval tions – you must change the ventilation filters earlier than normal. Spare parts Designation Quantity...
Page 161 Maintenance work on the carrier 7.13 Hydraulic system • Remove the caps (1) and pull out the filters (2). • Place the filters in a receptacle. • Insert the new filters (2). • Fasten the caps. Maintenance manual 3 302 574 en 7 - 87 GMK3060...
Page 162: Taking Oil Samples
Maintenance work on the carrier 7.13 Hydraulic system M 12 7.13.5 Taking oil samples • Reducing Under difficult operating conditions – at tropical or very hot locations – the interval you must halve the oil change interval. Spare parts – A hose with a connecting piece for a gauge port. and tools Hose lengths GROVE part no.
Page 163 Maintenance work on the carrier 7.13 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 labo- ratory analysis would then be incorrect.
Page 164 Maintenance work on the carrier 7.13 Hydraulic system Taking oil samples The hose end (1) is connected to the control block (3). The hose end (2) is in the receptacle (4). • Start the engine. • Move the counterweight lifting cylinders to the stop.
Page 165 Maintenance work on the carrier 7.13 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 7.13 Hydraulic system Blank page 7 - 92 3 302 574 en Maintenance manual GMK3060...
Page 167: Changing The Hydraulic Oil
Maintenance work on the carrier 7.13 Hydraulic system 7.13.6 Changing the hydraulic oil The oil only needs to be changed if the laboratory analysis indicates the à Determining the condition of the oil , p. 7 - 91. need for it; Oil, spare parts, Hydraulic oil Designation...
Page 168 Maintenance work on the carrier 7.13 Hydraulic system Risk of damage to the hydraulic pumps! Be sure to secure the engine against unauthorised use. If the engine is started while the valves in the suction line are closed, the hydraulic pumps will be damaged! Handling The valves can only be opened and closed using the connecting piece and the valves...
Page 169 Maintenance work on the carrier 7.13 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. The superstructure is slewed to the rear. •...
Page 170 Maintenance work on the carrier 7.13 Hydraulic system Establishing After having changed the oil filters and topping up the oil, you must the operating re-establish the operating conditions. conditions Opening the valves • Open the valves (1) – lever parallel with the line.
Page 171 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. Maintenance manual 3 302 574 en 7 - 97 GMK3060...
Page 172: Changing The Hydraulic Oil Filter
Maintenance work on the carrier 7.13 Hydraulic system 7.13.7 Changing the hydraulic oil filter Oil filters must be replaced when changing the oil. In the event of a warning message in the driver's cab the symbols (1), (2), (3) and (4) on the CCS (Crane Control System) control unit indicate the oil filter(s) you need to change.
Page 173 Maintenance work on the carrier 7.13 Hydraulic system Prerequisites – The engine must not be running and must be secured against unauthor- à ised use; p. 2 - 3. – The hydraulic system is depressurised. Changing oil filters 1 and 2 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 7.13 Hydraulic system Changing oil filter 4 • Release the receptacle (1) at the hexagon head. • Change the filter (2). • Replace the gaskets. • Screw the receptacle on. • Start the engine and check for leaks. Changing oil filter 3 •...
Page 175: Central Lubrication System
Maintenance work on the carrier 7.14 Central lubrication system 7.14 Central lubrication system 7.14.1 Checking the filling level Grease, spare Lubricating Designation Specification GROVE part no. parts, tools grease to DIN 51502 Classification Grease KP - 1K - 50 DIN 51825 03233369 Designation Quantity...
Page 176 Maintenance work on the carrier 7.14 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 immedi- ately before refilling the grease.
Page 177: Bleeding The Central Lubrication System
Maintenance work on the carrier 7.14 Central lubrication system 7.14.2 Bleeding the central lubrication system If the grease container is empty or contains bubbles, you must bleed the central lubrication system. The grease container (1) is full. • Release the connection (3). •...
Page 178 Maintenance work on the carrier 7.14 Central lubrication system Blank page 7 - 104 3 302 574 en Maintenance manual GMK3060...
Page 179: Electrical System
Risk of accidents if the safety devices are faulty! Have faulty lights and indicators repaired by or an Manitowoc Crane Care authorised GROVE dealer or an authorised specialist workshop. • Check the following functions every day before starting operations or driving the truck crane, and have faulty parts repaired: –...
Page 180: Checking The Batteries
Maintenance work on the carrier 7.15 Electrical system 7.15.2 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 7.15 Electrical system Checking the connecting terminals • Keep the batteries clean and dry. • Release 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 7.15 Electrical system 7.15.3 Checking the charge level of the batteries à Spare parts – Battery testing device; Separate operating instructions , or and tools – Acid siphon. Charge level table The measurement of the acid concentration with the acid siphon will give you an indication of the charge level of the batteries.
Page 183 Maintenance work on the carrier 7.15 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 mainte- nance-free.
Page 184: Charging The Batteries Using The Battery Charger
Maintenance work on the carrier 7.15 Electrical system 7.15.4 Charging the batteries using the battery charger Prerequisites – The engine must not be running and must be secured against unauthor- à ised use; 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 7.15 Electrical system 7.15.5 Check the external starting socket The battery box can also 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) as additional equipment.
Page 186: Replace The Battery On The Electronics Board
Maintenance work on the carrier 7.15 Electrical system Y 10 7.15.6 Replace the battery on the electronics board Spare parts Designation Quantity GROVE part no. and tools Lithium battery 3.6 V 03143172 Prerequisites – The engine must not be running and must be secured against unauthor- à...
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. 7.16.2 Cleaning the condenser fins Risk of damage to the condenser! Do not use a high pressure cleaner or steam jet cleaner.
Page 188: Checking Hoses
• Check all refrigerant hoses for damage and areas of wear. Have damaged hoses checked by or an authorised Manitowoc Crane Care GROVE dealer or an authorised specialist workshop only. M 12 7.16.4 Checking the entire air-conditioning system...
Page 189 Maintenance work on the carrier 7.16 Air-conditioning system Refrigerant Fill quantity Designation CAS no. in kg (lbs) EC no. 1.4 (3.1) Tetrafluoroethane (R134a) 811-97-2 212-377-0 Compressor oil FUCHS SE 55 Filler connections The filler connections (1) for the refrigerant are behind the front flap (2) in the driver's cab.
Page 190: Check V-Belt/V-Belt Tension
Maintenance work on the carrier 7.16 Air-conditioning system M 12 7.16.5 Check V-belt/V-belt tension Spare parts Designation Quantity GROVE part no. and tools V-belt 01207273 – Frequency measuring instrument; GROVE part no. 04165439; new V-belt: Frequency 68 Hz; run-in V-belt: Frequency 60 Hz. à...
Page 191 Maintenance work on the carrier 7.16 Air-conditioning system • Familiarise yourself with the correct operation of the frequency measur- à Separate operating instructions . ing instrument; • Switch the frequency measuring instru- ment (1) on – it is now ready for acoustic measurement.
Page 192: Changing The Pollen Filter
Maintenance work on the carrier 7.16 Air-conditioning system M 12 7.16.6 Changing the pollen filter • Reducing Under difficult operating conditions – at extremely sandy or dusty loca- the interval tions – you must change the filter earlier than normal. Spare parts Designation Quantity...
Page 193: Towbar Coupling
Maintenance work on the carrier 7.17 Towbar coupling 7.17 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 194 Maintenance work on the carrier 7.17 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 195: Checking The Bearing
Maintenance work on the carrier 7.17 Towbar coupling 7.17.2 Checking the bearing à Prerequisites – The coupling must be closed; p. 7 - 120. Checking the bearing Risk of injury! Ensure that the towbar coupling is closed for the following work (lever points downwards).
Page 196: Checking The Cotter Pin
46.0 mm (1.81 in) If the dimension is smaller than that given above, have the cotter pin replaced by or an authorised GROVE Manitowoc Crane Care dealer or your qualified repair crew. • Also check the cotter pin for the correct ver- tical play.
Page 197: 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. 7.17.5 Checking the initial tension of the springs The coupling head should require physical force to twist it when checking the torque.
Page 198: Checking The Support Ring
Maintenance work on the carrier 7.17 Towbar coupling 7.17.6 Checking the support ring à Prerequisites – The coupling must be closed; p. 7 - 120. 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 199 Maintenance work on the carrier 7.17 Towbar coupling Checking the function 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.
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Page 201: Other Maintenance Work
Maintenance work on the carrier 7.18 Other maintenance work 7.18 Other maintenance work 7.18.1 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 202: Lubricating The Outrigger Beams
Maintenance work on the carrier 7.18 Other maintenance work 7.18.2 Lubricating the outrigger beams à • Comply also with the running-in instructions; p. 4 - 1. Grease, spare Lubricating Designation Specification GROVE part no. parts, tools grease to DIN 51502 Classification Grease KP - 1K - 50...
Page 203: Checking The Functioning Of The Auxiliary Heater
Remove any grease that emerges. • In case the doors are stiff or do not close properly after lubrication, have them adjusted by or by an authorised GROVE Manitowoc Crane Care dealer. Maintenance manual 3 302 574 en 7 - 129...
Page 204: 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 an authorised GROVE dealer or your qualified repair crew. • Use only authentic replacement pins.
Page 205: Renewing The Corrosion Protection
Maintenance work on the carrier 7.18 Other maintenance work M 12 7.18.6 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 206 Maintenance work on the carrier 7.18 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 207: Having The Fire Extinguisher Checked
Maintenance work on the carrier 7.18 Other maintenance work 7.18.7 Having the fire extinguisher checked Depending on your truck crane's equipment, it can be fitted with fire extin- guishers. The maintenance interval may even be shorter, depending on the respective national regulations and the site.
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Page 209 Maintenance work on the superstructure General instructions ..........8 - 8.1.1 Covers .
Page 210 Cable drums and slewing angle sensor....... . . 8 - 59 8.9.1 Maintenance of the slip ring assemblies .
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 Various types of work (e.g. oil filter change) require that the cover be removed. Before maintenance work • Remove the cover (1). After 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 3 302 574 en Maintenance manual GMK3060...
Page 213 Maintenance work on the superstructure 8.1 General instructions à Symbols for maintenance work p. 8 - 7 à 1 CCS (Crane Control System) control unit p. 8 - 7 à Hoists p. 8 - 9 à 21 Hoist ropes p. 8 - 45 à...
Page 214 Maintenance work on the superstructure 8.1 General instructions 8 - 4 3 302 574 en Maintenance manual GMK3060...
Page 215 Maintenance work on the superstructure 8.1 General instructions à Central lubrication system p. 8 - 63 à 10 Distributor head p. 8 - 64 à 11 Centralized lubrication pump p. 8 - 64 à Electrical system p. 8 - 67 à...
Page 216 Maintenance work on the superstructure 8.1 General instructions Blank page 8 - 6 3 302 574 en Maintenance manual GMK3060...
Page 217: Symbols For Maintenance Work
Maintenance work on the superstructure 8.2 Symbols for maintenance work Symbols for maintenance work • Check the symbols on the CCS Start menu ( Crane Control System ) in the driver's cab each day before starting work. • The Start menu shows the most important measurements and the Warning submenu shows all pending warning messages;...
Page 218 Maintenance work on the superstructure 8.2 Symbols for maintenance work Blank page 8 - 8 3 302 574 en Maintenance manual GMK3060...
Page 219: Hoists
Maintenance work on the superstructure 8.3 Hoists Hoists 8.3.1 Checking the oil level Spare parts Designation Quantity GROVE part no. and tools Oil inspection glass with 2 hoses 04193151 For main hoist; complete Oil inspection glass with 2 hoses 04193153 For auxiliary hoist;...
Page 220: General Inspection
• Check that pipes and hoses are tightly connected and undamaged. If any damage is found, report it to or an authorised Manitowoc Crane Care GROVE dealer or your repair crew. 8.3.3 Checking the hoist brake Check that the hoist brake is working correctly on the main hoist and the auxiliary hoist.
Page 221: Lubricating The Auxiliary Hoist
Maintenance work on the superstructure 8.3 Hoists 8.3.4 Lubricating the auxiliary hoist Grease, spare Lubricating Designation Specification GROVE part no. parts, tools grease to DIN 51502 Classification Grease KP - 1K - 50 DIN 51825 03233369 – Grease gun from the tool set. Prerequisites –...
Page 222: Changing The Oil/Checking The Oil
Maintenance work on the superstructure 8.3 Hoists M 12 8.3.5 Changing the oil/checking the oil à • Comply also with the run-in regulations; p. 4 - 1. Oil, spare parts, Gear oil Designation Specification GROVE part no. tools in litres (gal) to DIN 51502 Classification 3 (0.8)
Page 223 Some abrasion particles may appear in the first oil filled. If you notice abrasion particles during the first oil change (after 200 oper. hrs.), first consult before introducing any specific measures. Manitowoc Crane Care Maintenance manual 3 302 574 en 8 - 13...
Page 224: Having A Partial Inspection Carried Out
Maintenance work on the superstructure 8.3 Hoists 8.3.6 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 225: Slewing Gear
Maintenance work on the superstructure 8.4 Slewing gear Slewing gear 8.4.1 Oil level check – Slewing gear transmission Spare parts Designation Quantity GROVE part no. and tools Gasket 10 x 14 Cu DIN 7603 00117125 à Operating Prerequisites – The truck crane is horizontal and is in on-road mode; Instructions .
Page 226: Oil Level Check - Slewing Gear Brake
• 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 3 302 574 en Maintenance manual...
Page 227: Checking The Slewing Gear Brake
Maintenance work on the superstructure 8.4 Slewing gear 8.4.4 Checking the slewing gear brake Prerequisites – The truck crane is on outriggers with an outrigger span of 6.825 x 6.2 m à Operating Instructions . (22.4 x 20.3 ft) and is aligned horizontally; –...
Page 228 – If the superstructure slews, the slewing gear brake is defective and must be repaired immediately by or an Manitowoc Crane Care authorised GROVE dealer. • Switch the slewing gear off and switch the engine off.
Page 229: Changing The Oil/Checking The Oil - Slewing Gear Transmission
Maintenance work on the superstructure 8.4 Slewing gear 8.4.5 Changing the oil/checking the oil – Slewing gear M 12 transmission à • Comply also with the run-in regulations; p. 4 - 1. Oil, spare parts, Gear oil Designation Specification GROVE part no. tools in litres (gal) to DIN 51502...
Page 230 Maintenance work on the superstructure 8.4 Slewing gear Draining oil • Remove the plate (2). • Place a receptacle under the screw (1). • Unscrew the filter (4) and screws (3) and (1). • Drain the oil. • Replace the gasket and screw the screw (1) back in.
Page 231: Changing The Oil/Checking The Oil - Slewing Gear Brake
Maintenance work on the superstructure 8.4 Slewing gear 8.4.6 Changing the oil/checking the oil – Slewing M 12 gear brake à • Comply also with the run-in regulations; p. 4 - 1. Oil, spare parts, Gear oil Designation Specification GROVE part no. tools in litres (gal) to DIN 51502...
Page 232 Maintenance work on the superstructure 8.4 Slewing gear Draining oil • Use a drain channel and place a container under the screw (1). • Unscrew the filter (2). • Unscrew the screw (1). • Drain the oil. • Replace the O-ring and screw the screws (1) back in.
Page 233: Slewing Bearing
Maintenance work on the superstructure 8.5 Slewing bearing Slewing bearing 8.5.1 Checking the bolts à • Comply also with the run-in regulations; p. 4 - 1. Tools – Torque wrench for maximum of 790 Nm (583 lbf ft). à – Auxiliary tools for the torque wrench; p.
Page 234 Do not put the truck crane back into operation and have the slewing bearing repaired by Manitowoc Crane Care Access The outer ring is attached to the carrier by the bolts (1).
Page 235 Maintenance work on the superstructure 8.5 Slewing bearing Selecting the tools Outer ring The bolt heads (1) are easily accessible for fitting a socket wrench. Therefore, you can use manual or powered torque wrenches (electric or hydraulic drivers). Inner ring The bolt head (1) is accessible only via the opening (2).
Page 236 Maintenance work on the superstructure 8.5 Slewing bearing • Checking the Divide the checking of the 52 screws into 13 working steps of 4 screws outer ring each. Between each of the 13 operation steps you need to rotate the turntable to the next group of 4 bolts on the opposite side.
Page 237: Lubricating The Gear Teeth
Maintenance work on the superstructure 8.5 Slewing bearing 8.5.2 Lubricating the gear teeth Grease Designation Quantity GROVE part no. Adhesive lubricating grease 00554205 (spray can) Observe the instructions and safety instructions on the adhesive lubricating grease packaging! à Operating Instructions . Prerequisites –...
Page 238 Maintenance work on the superstructure 8.5 Slewing bearing First lubrication • Remove the plate (2). • Remove the old grease from all the gear teeth (1). • Apply a thin layer of new grease to all the gear teeth and allow it to penetrate for about 10 minutes.
Page 239: 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 240: Measuring Tilting Play
Maintenance work on the superstructure 8.5 Slewing bearing 8.5.4 Measuring tilting play • Reducing When after several years of intensive crane operation, half of the value for the interval the maximum permissible tilting play is reached, then you must reduce the maintenance interval.
Page 241 The base value of the tilting play is determined and documented by tilting play or an authorised GROVE dealer when the slewing Manitowoc Crane Care bearing is put into operation or replaced. The maximum permissible wear is 2.6 mm (0.102 in).
Page 242: Lubricating The Locking Of Turntable
Maintenance work on the superstructure 8.5 Slewing bearing M 12 8.5.5 Lubricating the locking of turntable The GMK3060 truck crane can be fitted with a hydraulic turntable lock as additional equipment. Grease, spare Lubricating Designation Specification GROVE part no. parts, tools grease to DIN 51502 Classification...
Page 243: Hydraulic System
• Bleed the hydraulic system. If damage cannot be rectified immediately or further damage is likely • Notify or an authorised GROVE dealer or your repair Manitowoc Crane Care crew. Maintenance manual 3 302 574 en 8 - 33 GMK3060...
Page 244: Pressure Accumulator - Checking The Gas Pressure
1 Pressure accumulator 20 bar (290 psi) 2 Pressure accumulator 180 bar (2,610 psi) • Have the filling pressure checked and if necessary corrected by Manitowoc Crane or an authorised GROVE dealer. Care 8 - 34 3 302 574 en...
Page 245: Changing Oil Filter 3
Maintenance work on the superstructure 8.6 Hydraulic system 8.6.4 Changing oil filter 3 The changing of the oil filter 3 (1) in the superstructure is described together with the changing of oil filter 1, 2, 4 in the carrier; à Changing the hydraulic oil filter , p.
Page 246 Maintenance work on the superstructure 8.6 Hydraulic system Blank page 8 - 36 3 302 574 en Maintenance manual GMK3060...
Page 247: Main Boom
Maintenance work on the superstructure 8.7 Main boom Main boom 8.7.1 Grease the piston rod of the derricking cylinder Grease, spare Designation GROVE part no. parts and tools Lubricant RHUS SW 2 03325215 Spray on Berulub; 0.5 litres 01929824 (spray-on) –...
Page 248: Lubricating The Telescopic Sections
– A grease gun for the grease nipples on the upper telescopic slide faces. – A brush or roller for the outer, upper and lower telescopic slide faces. Manitowoc Crane Group Germany GmbH recommends pneumatic grease spray guns for more effective lubrication of the telescopic slide faces: Designation GROVE part no.
Page 249 Maintenance work on the superstructure 8.7 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 rigging table which contains the required telescoping.
Page 250 Maintenance work on the superstructure 8.7 Main boom • Extend telescopic section I to 47%. • Use the grease gun (PAL1) to lubricate the upper slide faces at the lubricating nipples (1) on both sides. • Fully retract telescopic section I . •...
Page 251 Maintenance work on the superstructure 8.7 Main boom • Derrick the main boom to 15°. • Extend telescopic section IV to 0% and telescopic section V to 55%. • Lock and unlock telescopic section V several times, so that the grease is distributed over the locking pins.
Page 252: Checking The Sheaves
Check all sheaves (1) and (2) for damage, wear, mobility and heavy soiling. • Have damaged, worn, stiff or extremely soiled sheaves replaced by Manitowoc Crane or an authorised GROVE dealer or your Care repair crew. 8 - 42 3 302 574 en...
Page 253: Checking Locking Units
Manitowoc Crane Care inspection at the same time as lubricating the telescopic sections (M 3), which is required every three months, as you will have established the telescope statuses needed for inspection.
Page 254: 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 255: Hoist Ropes
Maintenance work on the superstructure 8.8 Hoist ropes Hoist ropes 8.8.1 Checking the winding Risk of accidents due to turning rope drum! Keep away from the rope drum while it is turning. This will prevent your limbs from being drawn in and getting crushed. à...
Page 256: Checking The Hoist Ropes
Maintenance work on the superstructure 8.8 Hoist ropes 8.8.2 Checking the hoist ropes Spare parts – Torque wrench for 44 Nm (32 lbf ft). and tools – Establish a rigging mode in accordance with the lifting capacity table her Prerequisites à...
Page 257: Lubricating The Hoist Rope
– by running it through a tray filled with lubricant or – by means of high-pressure lubrication with a pressure pump. 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 258: Assessing The Condition Of The Hoist Rope
Maintenance work on the superstructure 8.8 Hoist ropes 8.8.4 Assessing the condition of the hoist rope If in doubt about damage assessment, always consult an approved inspector. To assess the condition of the rope, you must be familiar with the following: –...
Page 259 Maintenance work on the superstructure 8.8 Hoist ropes The tables show by rope diameter the number of wire breaks in a length 6 times and 30 times the rope diameter which if reached would require replacement of the rope. • Familiarise yourself with DIN ISO 4309:2013-06 (rotation-resistant ropes).
Page 260 Maintenance work on the superstructure 8.8 Hoist ropes Risk of accidents due to reduced load bearing capacity! Remember that other factors may also make it necessary to replace a rope before the number of wire breaks requiring rope replacement has been reached (age of rope, frequency of use or exceptional loading).
Page 261 Maintenance work on the superstructure 8.8 Hoist ropes Damage Description Cause Replacement Reduced The diameter of the Structural changes Replace the rope immediately diameter (1) rope has become if the diameter has decreased smaller along large by 15% or more compared to sections.
Page 262 Maintenance work on the superstructure 8.8 Hoist ropes Damage Description Cause Replacement Loop Outer layer wires in General wear due to Immediately replace the rope if formation (1) the form of hair pins ageing of the rope or the rope structure has been are protruding from consequential substantially altered by the...
Page 263 Maintenance work on the superstructure 8.8 Hoist ropes Damage Description Cause Replacement Flattening (1) Crushed areas, Mechanical damage, Determine number of wire mostly with wire e. g. due to driving breaks; replace rope breaks. over the rope. immediately if serious crushing has occurred.
Page 264: Replacing The Hoist Rope
Maintenance work on the superstructure 8.8 Hoist ropes 8.8.5 Replacing the hoist rope à Spare parts – An original replacement rope; Rope certificate . and tools – A reel stand with braking block. – Torque wrench for 44 Nm (32 lbf ft). Risk of accidents from falling load! Use only a replacement rope that has the same technical specifications as the defective rope, or an authentic replacement rope.
Page 265 Maintenance work on the superstructure 8.8 Hoist ropes • Remove the clamp (4). • Push the rope through the bore (3) until the rope wedge (1) slides out of the pocket (2). • Remove the rope wedge and place the old rope away from the truck crane.
Page 266 Maintenance work on the superstructure 8.8 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 267: Adjusting The Lowering Limit Switch
Maintenance work on the superstructure 8.8 Hoist ropes Observe the hook block when unreeling. The hook block must not rotate! Risk of accidents if the lowering limit switch is set incorrectly! After inserting a new rope, the lowering limit switch must always be reset. In this way you avoid the lowering limit switch switching off too late or not at all, the rope being damaged and the load being dropped.
Page 268 Maintenance work on the superstructure 8.8 Hoist ropes Adjusting the lowering 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 269: Cable Drums And Slewing Angle Sensor
Maintenance work on the superstructure 8.9 Cable drums and slewing angle sensor Cable drums and slewing angle sensor 8.9.1 Maintenance of the slip ring assemblies On the telescopic boom The slip ring assemblies are located in: 1 Cable drum 1 2 Cable drum 2 On the turntable The slip ring assemblies are located in:...
Page 270 Maintenance work on the superstructure 8.9 Cable drums and slewing angle sensor Spare parts Designation Quantity GROVE part no. and tools Cover gasket 03138891 Cable drum 1 Cover gasket 03138894 Cable drum 2 – Clean, lint-free cloth. – Dry, oil-free compressed air. Prerequisites For cable drum 1 à...
Page 271: Maintenance Of The Slip Ring Assemblies
Maintenance work on the superstructure 8.9 Cable drums and slewing angle sensor Maintenance of the slip ring assemblies • Remove the cover (1) or (2). • Clean and dry the cover. • Replace the gasket if necessary. • Check that the cover (3) is undamaged. This slip ring assembly is maintenance-free.
Page 272: Lubricating The Slewing Angle Sensor
Maintenance work on the superstructure 8.9 Cable drums and slewing angle sensor 8.9.2 Lubricating the slewing angle sensor Grease, spare Lubricating Designation Specification GROVE part no. parts, tools grease to DIN 51502 Classification Grease KP - 1K - 50 DIN 51825 03233369 Designation Quantity...
Page 273: Central Lubrication System
Maintenance work on the superstructure 8.10 Central lubrication system 8.10 Central lubrication system Connected lubricating points: – Main hoist drum, – Ball slewing bearing, – Telescopic boom – pivot pins, – Derricking cylinder – pivot pin. Lubricating points not connected: à...
Page 274 Maintenance work on the superstructure 8.10 Central lubrication system On the distributor head Standard equipment The central lubrication system is as standard equipped with a distributor head. Using the filling pump, you manually convey the grease to the lubricating points via the distributor head.
Page 275: Hook Blocks
Check the sheaves in the hook blocks for damage, wear, mobility and extreme soiling. Have damaged, worn, stiff or extremely soiled sheaves replaced by or an authorised GROVE dealer or your repair crew. Manitowoc Crane Care M 12 8.11.2 Greasing à...
Page 276 Some manufacturers recommend dismantling every 4 years or after 500 operating hours. • about the maintenance intervals for the hook Manitowoc Crane Care blocks supplied to you. • Have the hook blocks dismantled by or an Manitowoc Crane Care authorised GROVE dealer or your qualified repair crew.
Page 277: 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 symbols and displays on the CCS (Crane Control System) control à...
Page 278: Replace The Battery On The Electronics Board
Maintenance work on the superstructure 8.12 Electrical system Risk of accidents from exploding glass bodies and high voltage! The glass bodies of gas discharge lamps (xenon lights) are pressurised. If the lamp breaks, the glass splinters explosively and shards scatter. Xenon lights operate at high voltage.
Page 279: Air-Conditioning System
Maintenance work on the superstructure 8.13 Air-conditioning system 8.13 Air-conditioning system 8.13.1 Checking the air-conditioning system • Check the air-conditioning system in the crane cab in the same way as in à Checking the air-conditioning system , p. 7 - 113. the driver's cab;...
Page 280 Maintenance work on the superstructure 8.13 Air-conditioning system Blank page 8 - 70 3 302 574 en Maintenance manual GMK3060...
Page 281: Other Maintenance Work
Maintenance work on the superstructure 8.14 Other maintenance work 8.14 Other maintenance work 8.14.1 Checking the windscreen washing system Water, spare Designation Quantity GROVE part no. parts, tool Windscreen wiper blade 03268512 Roof wiper blade 03326121 – Water; add commercially available detergent and antifreeze to it. –...
Page 282 Maintenance work on the superstructure 8.14 Other maintenance work Wiping The wiping/washing system operation is described in the supplied à Operating Instructions . operating instructions; • Spray water on the windscreen – press the bottom part of the switch. • Spray water on the skylight –...
Page 283: Checking The Functioning Of The Auxiliary Heater
Maintenance work on the superstructure 8.14 Other maintenance work 8.14.2 Checking the functioning of the auxiliary heater • Check the auxiliary heater (1) in the crane cab in the same way as in the driver's cab; à Checking the functioning of the auxiliary heater , p.
Page 284: 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 adjusted by or an authorised GROVE-dealer. Manitowoc Crane Care 8 - 74 3 302 574 en Maintenance manual...
Page 285: Lubricating The Step
Check that the step is locked by the spring latch (3). 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 Maintenance manual 3 302 574 en 8 - 75...
Page 286: 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 an authorised GROVE dealer or your qualified repair crew. • Use only authentic replacement pins.
Page 287: Renewing The Corrosion Protection
Maintenance work on the superstructure 8.14 Other maintenance work M 12 8.14.6 Renewing the corrosion protection Protective agent, Protective agent GROVE part no. tools Corrosion protection 03140192 – Spray gun with spray extension. – Brush. – Protective clothing, protective goggles. Prerequisites –...
Page 288 Maintenance work on the superstructure 8.14 Other maintenance work Spraying Risk of injury to the eyes! While working with the spray extension you could be hit by the spray jet or spray droplets. Wear protective goggles, protective clothing and gloves. •...
Page 289: Having The Fire Extinguisher Checked
Maintenance work on the superstructure 8.14 Other maintenance work 8.14.7 Having the fire extinguisher checked Depending on your truck crane's equipment, it can be fitted with fire extinguishers. The maintenance interval may even be shorter, depending on the respective national regulations and the site. Ask the local fire safety officer about the national and local regulations.
Page 290 Maintenance work on the superstructure 8.14 Other maintenance work Blank page 8 - 80 3 302 574 en Maintenance manual GMK3060...
Page 291 Longer out of service periods Maintenance manual 3 302 574 en GMK3060...
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Page 293: Longer Out Of Service Periods
Longer out of service periods Longer out of service periods Carry out the following jobs if the truck crane is going to be out of service for a long period (months). • Putting the truck Clean the truck crane thoroughly on the inside and outside. crane out of •...
Page 294 Longer out of service periods • Ensure that the tyre positioning is different each time the crane is parked (without outriggers). • Seal the air filter again. If the truck crane is going to be out of service for more than 12 months: •...
Page 295 Torques 10.1 Torques for the retaining bolts ........10 - 10.2 Special torques .
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Page 297: 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) Spanner size (mm) Bolt quality Hexagon- Cylinder...
Page 298 Torques 10.2 Special torques 10.2 Special torques Thread size Spanner size Torque (Nm) (mm) (mm) Designation Hexagon- Cylinder head bolt screw Suspension strut: – Bracket for the vehicle chassis, M 16 — – Bracket for the vehicle chassis, M 24 —...
Page 299 Spare parts required for maintenance 11.1 General information ..........11 - 11.2 Lighting .
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Page 301: 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 302 Spare parts required for maintenance 11.2 Lighting Installation location 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 303 Spare parts required for maintenance 11.2 Lighting Installation location GROVE part Designation Power (W) number Outrigger beam spotlights: (above the front and rear outrigger beams) – Filament lamp 02316460 8GH 002090251 – Spotlight; complete 03143786 Yellow rotating beacon: (on the driver's cab) –...
Page 304 Spare parts required for maintenance 11.2 Lighting Blank page 11 - 4 3 302 574 en Maintenance manual GMK3060...
Page 305: 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 04182216 1 item when the symbol lights up Air filter –...
Page 306 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) 1st axle line (duplex): Brake shoe with brake lining 03322112 Spring 03322110...
Page 307 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 Transmission Gasket 22 x 27 Cu DIN 7603 00117142 O-ring 04155708 Electrical system Lithium battery 3.6 V 03143172 Maintenance manual...
Page 308: Spare Parts For The Superstructure
Spare parts required for maintenance 11.4 Spare parts for the superstructure 11.4 Spare parts for the superstructure Quantity, in single parts Assemblies and spare parts GROVE- For maintenance interval Superstructure part number M 12 Hoists Sight glass with hoses; complete 04193151 For main hoist (if damaged)
Page 309 Spare parts required for maintenance 11.4 Spare parts for the superstructure Assemblies and spare parts GROVE- Quantity, in single parts Superstructure part number For maintenance interval Y 10 Slewing angle sensor Gasket 16 x 20 Cu DIN 7603 00117134 Electrical system Lithium battery 3.6 V 03143172 Maintenance manual...
Page 310 Spare parts required for maintenance 11.4 Spare parts for the superstructure Blank page 11 - 10 3 302 574 en Maintenance manual GMK3060...
Page 311 Appendix Maintenance manual 3 302 574 en GMK3060...
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Page 313: Appendix
Appendix...

Manitowoc GROVE GMK 3060 Maintenance Manual

Table of Contents

2 2 Safety and Environmental Protection

6 6 Lubricants and Consumables

Lubricants

Lubricants and Consumables

Consumables

Refrigerant

7 7 Maintenance Work on the Carrier

General Instructions

Symbols for Maintenance Work

Engine

Fuel System

Exhaust System with Exhaust Emission Control

Transmission

Axle Lines

Wheels

Vehicle Brake

Suspension

Steering

Compressed Air System

Hydraulic System

Central Lubrication System

Electrical System

Air-Conditioning System

Towbar Coupling

Other Maintenance Work

8 8 Maintenance Work on the Superstructure

General Instructions

Maintenance Work on the Superstructure

Symbols for Maintenance Work

Hoists

Slewing Gear

Slewing Bearing

Hydraulic System

Main Boom

Hoist Ropes

Cable Drums and Slewing Angle Sensor

Central Lubrication System

Hook Blocks

Electrical System

Air-Conditioning System

Other Maintenance Work

Appendix

Quick Links

Chapters

Related Manuals for Manitowoc GROVE GMK 3060

Summary of Contents for Manitowoc GROVE GMK 3060