Manitowoc GROVE GMK4090 Maintenance Manual
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Manitowoc GROVE GMK4090 Maintenance Manual

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Maintenance manual
3 302 649 en
07.12.2017

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Summary of Contents for Manitowoc GROVE GMK4090

  • Page 1 Maintenance manual 3 302 649 en 07.12.2017...
  • 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: Table Of Contents

    Contents: General instructions Safety and environmental protection Cleaning Run-in regulations Maintenance overview Lubricants and consumables Maintenance work on the carrier Maintenance work on the superstructure Longer out-of-service periods 10 Torques 11 Spare parts required for maintenance Appendix This maintenance manual does not replace the operating manual. Details of operation and standard safety instructions can be found in the operating instructions.
  • Page 4 Blank page 3 302 649 en Maintenance manual GMK4090...
  • Page 5 General instructions Using the maintenance manual ........1 - Warnings and symbols .
  • Page 6 3 302 649 en Maintenance manual GMK4090...
  • Page 7 Safety and environmental protection Safety rules ............2 - 2.1.1 Securing against unauthorised use .
  • Page 8 3 302 649 en Maintenance manual GMK4090...
  • Page 9 Cleaning Overview of assemblies easily damaged when cleaning ....3 - Maintenance manual 3 302 649 en GMK4090...
  • Page 10 3 302 649 en Maintenance manual GMK4090...
  • Page 11 Run-in regulations Maintenance manual 3 302 649 en GMK4090...
  • Page 12 3 302 649 en Maintenance manual GMK4090...
  • Page 13 Maintenance overview Maintenance intervals..........5 - Maintenance plans .
  • Page 14 3 302 649 en Maintenance manual GMK4090...
  • Page 15 Lubricants and consumables Lubricants............6 - 6.1.1 Lubricants list .
  • Page 16 3 302 649 en Maintenance manual GMK4090...
  • Page 17 Maintenance work on the carrier General instructions ..........7 - 7.1.1 Covers .
  • Page 18 7.10 Wheels ............7 - 67 7.10.1 Checking the tyres for damage .
  • Page 19 7.19 Towbar coupling ........... . 7 - 125 7.19.1 Lubricating the towbar coupling .
  • Page 20 3 302 649 en Maintenance manual GMK4090...
  • Page 21 Maintenance work on the superstructure General instructions ..........8 - 8.1.1 Covers .
  • Page 22 8.8.5 Replacing the hoist rope ......... . . 8 - 60 8.8.6 Setting the lowering limit switch .
  • Page 23 Longer out-of-service periods Maintenance manual 3 302 649 en GMK4090...
  • Page 24 3 302 649 en Maintenance manual GMK4090...
  • Page 25 Torques 10.1 Torques for retaining bolts ......... . . 10 - 10.2 Special torques .
  • Page 26 3 302 649 en Maintenance manual GMK4090...
  • Page 27 Spare parts required for maintenance 11.1 General information ..........11 - 11.2 Lighting .
  • Page 28 3 302 649 en Maintenance manual GMK4090...
  • Page 29 Appendix Maintenance manual 3 302 649 en GMK4090...
  • Page 30 3 302 649 en Maintenance manual GMK4090...

  • Page 31: 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 32: 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 when the following conditions are met: –...
  • Page 33 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 34: Instructions Regarding The Electronic Controls

    Manitowoc Crane Care All welding work (especially on load carrying members) may only be performed by qualified expert personnel with the prior written permission from Manitowoc Crane Group Germany GmbH. 1 - 4 3 302 649 en Maintenance manual...

  • Page 35: Definition Of Direction Information

    General instructions 1.6 Definition of direction information Definition of direction information Basic rule Directions always depend 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 36: 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 and vice versa when the truck crane is being used in countries that use US units of measurement.

  • Page 37: 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 38 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 39: 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 –...

  • Page 40: 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 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 41 Safety and environmental protection 2.2 Handling substances which are harmful to the environment Separate collec- Substances which are harmful to the environment should always be tion and storage collected separately from other waste. • Ask your local environmental protection authority about the different cat- egories of the substances.

  • Page 42: 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 43: 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 only be cleaned with cold water. • Do not use high-pressure or steam jet cleaning equipment during this period.
  • Page 44 Cleaning 3.1 Overview of assemblies easily damaged when cleaning Overview of assemblies easily damaged when cleaning 3 - 2 3 302 649 en Maintenance manual GMK4090...
  • Page 45 Cleaning 3.1 Overview of assemblies easily damaged when cleaning 1 Electrical connections on the boom head 2 Telescopic slide faces 3 RCL length data transmitter 4 Angle data transmitter 5 Pressure sensors on the derricking cylinder 6 Lowering limit switch 7 Steering computer 8 Suspension struts 9 Heating/air conditioning system under the crane cab...
  • Page 46 Cleaning 3.1 Overview of assemblies easily damaged when cleaning Blank page 3 - 4 3 302 649 en Maintenance manual GMK4090...

  • Page 47: Run-In Regulations

    Run-in regulations Run-in regulations There are regulations about running in individual parts which must be followed, after: – First commissioning or – Replacement of a part or – General overhaul. This is why you must carry out additional maintenance work on the carrier and superstructure at specific intervals: Operating Driven km...
  • Page 48 Run-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 49: Maintenance Overview

    Maintenance overview 5.1 Maintenance intervals Maintenance overview – Maintenance plans D (= daily), – Maintenance plans W (= weekly) and – Maintenance plans M 1 (= once a month) to M 12 (= every 12 months) and – Maintenance plans Y 2 (= every 24 months) to Y 10 (= every 120 months). The maintenance plans are provided in tabular form, divided into –...
  • Page 50 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. – You can individually call up the Operating hours (oper. hrs.) of the engine and power units on the CCS display.
  • Page 51 Maintenance overview 5.2 Maintenance plans Maintenance plans The descriptions 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 Chapter 7 and for –...
  • Page 52 Maintenance overview 5.2 Maintenance plans 5.2.1 Maintenance plan D Maintenance work on the CARRIER: Daily/before putting into operation Engine à – Check the oil level p. 7 - 13 à – Checking the air filter p. 7 - 16 à –...
  • Page 53 Maintenance overview 5.2 Maintenance plans Maintenance work on the SUPERSTRUCTURE: Daily/before putting into operation Hydraulic system à – Check the oil level p. 8 - 31 Hoist ropes à – Checking the winding p. 8 - 51 Electrical system à –...
  • Page 54 Maintenance overview 5.2 Maintenance plans 5.2.2 Maintenance plan W Maintenance work on the CARRIER: weekly Engine à – General inspection p. 7 - 18 Transmission à – General inspection p. 7 - 40 Transfer case à – General inspection p. 7 - 45 Angle gear à...
  • Page 55 Maintenance overview 5.2 Maintenance plans Maintenance work on the SUPERSTRUCTURE: weekly Hoists à – Checking the oil level p. 8 - 9 à – General inspection p. 8 - 10 à – Checking the hoist brake p. 8 - 10 Slewing gear à...
  • Page 56 Maintenance overview 5.2 Maintenance plans 5.2.3 Maintenance plan M 1 Maintenance work on the CARRIER: monthly/after about 2,000 km (about 1,240 mi) Engine à à Engine manufacturer’s documentation – Notes; p. 7 - 13 Exhaust system with exhaust emission control à...
  • Page 57 Maintenance overview 5.2 Maintenance plans Maintenance work on the SUPERSTRUCTURE: Monthly/after approx. 100 operating hours Main boom à – Grease the piston rod of the derricking cylinder p. 8 - 45 Air conditioning system à – Checking the air conditioning system p.
  • Page 58 Maintenance overview 5.2 Maintenance plans 5.2.4 Maintenance plan M 3 Maintenance work on the CARRIER: every three months/after 5,000 – 6,000 km (3,100 – 3,730 mi) Engine à à Engine manufacturer’s documentation – Notes; p. 7 - 13 Fuel system à...
  • Page 59 Maintenance overview 5.2 Maintenance plans Maintenance work on the SUPERSTRUCTURE: every three months/after 250 oper. hrs. Slewing bearing à – Checking the screws p. 8 - 21 Hydraulic system à – Cleaning the magnetic rods p. 8 - 34 Main boom à...
  • Page 60 Maintenance overview 5.2 Maintenance plans 5.2.5 Maintenance plan M 6 Maintenance work on the CARRIER: every six months/after 10,000 – 12,500 km (6,210 – 7,770 mi) Engine à à Engine manufacturer’s documentation – Notes; p. 7 - 13 Transfer case à...
  • Page 61 Maintenance overview 5.2 Maintenance plans Maintenance work on the SUPERSTRUCTURE: every six months/after 500 oper. hrs. Slewing gear à – Checking the slewing gear brake p. 8 - 16 Slewing bearing à – Lubricating the gear teeth p. 8 - 25 à...
  • Page 62 Maintenance overview 5.2 Maintenance plans M 12 5.2.6 Maintenance plan M 12 Maintenance work on the CARRIER: every 12 months/after 20,000 – 25,000 km ( 12,430 – 15,530 mi) Engine à à Engine manufacturer’s documentation – Notes; p. 7 - 13 à...
  • Page 63 Maintenance overview 5.2 Maintenance plans M 12 Maintenance work on the SUPERSTRUCTURE: Every twelve months / after 1,000 oper. hrs. Hoists à – Changing the oil/checking the oil p. 8 - 11 Slewing gear à – Changing the oil/checking the oil p.
  • Page 64 Maintenance overview 5.2 Maintenance plans 5.2.7 Maintenance plan Y 2 Maintenance work on the CARRIER: every 24 months/after 40,000 – 50,000 km (25,000 – 31,000 mi) Engine à à Engine manufacturer’s documentation – Notes; p. 7 - 13 à – Replace coolant (with water retarder) p.
  • Page 65 – Have the Cardan shaft between the transmission on the engine and the trans- fer case replaced by or an authorised GROVE dealer. Manitowoc Crane Care Maintenance work on the SUPERSTRUCTURE: every 60 months/after 5,000 oper. hrs. – Have both the Cardan shafts on the angle gear replaced by or an authorised GROVE dealer.
  • Page 66 Maintenance work on the CARRIER: every 120 months/after 200,000 km (124,000 mi) Steel constructions – Check the load-bearing steel fabrication. For more information, please contact Manitowoc Crane Care Maintenance work on the SUPERSTRUCTURE: every 120 months/after 12,000 oper. hrs. Electrical system à...
  • Page 67 Maintenance overview 5.3 Periodic inspections Periodic inspections Your GMK4090 truck crane has been inspected before delivery. – Truck cranes used in Germany are inspected in accordance with the regu- lations of the professional trade association as defined by BGV D 6 (VBG 9). –...
  • Page 68 Maintenance overview 5.3 Periodic inspections 5.3.1 Load hook inspection The hook opening on the load hooks must be checked regularly for deformation. The hook opening may not have expanded by more than 10% of the original dimension y, y1, y2. The original dimensions y, y1, y2 are specified in field (2) on the load hooks.
  • Page 69 Maintenance overview 5.4 Measures required for winch monitoring Measures required for winch monitoring Also observe the information on the general inspection of the hoists; à p. 8 - 13. These measures for monitoring the winches (hoists) were compiled by the German Machine Builders' Association (VDMA) and are to be used for all mobile cranes according to the German Accident Prevention Regulations for Winches, Hoists and Tractor Machines, BGV D 6 (VGB 9 ) and BGV D 8 (VBG 8) .
  • Page 70 Maintenance overview 5.4 Measures required for winch monitoring The actual service life of a winch is affected by a number of additional 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 71 Maintenance overview 5.4 Measures required for winch monitoring Determining the The truck crane's load spectrum is divided into groups (see also ISO 4301/1, operating FEM 1.001): conditions (load spectrum) When determining the load spectrum, the existing rope pull is used as the standard, i.e.
  • Page 72 Maintenance overview 5.4 Measures required for winch monitoring One of the load spectrums listed above should be selected on the basis of the actual operating conditions and entered in the crane logbook for the respective testing interval. Note for truck cranes: The load spectrum L1 and the factor of the load spectrum Km = 0.125 are generally applied to truck cranes in assembly mode.
  • Page 73 Maintenance overview 5.4 Measures required for winch monitoring The general overhaul is to be arranged by the operator and performed by the manufacturer or a representative authorised by the manufacturer. The results are to be entered in the crane logbook. The manufacturer or an authorised representative will specify a new theo- retical service life D upon completion of the general overhaul.
  • Page 74 5.4 Measures required for winch monitoring 5.4.3 Example A GMK4090 is equipped with a separate operating hours counter for the hoist and is classified by Manitowoc Crane Group Germany GmbH as follows: Power unit group: Load spectrum: light L1, Km = 0.125...
  • Page 75 Maintenance overview 5.4 Measures required for winch monitoring The used proportion S of theoretical service life after the second inspection is therefore: × -------------- - 480 h 1920 h 0,125 Remaining theoretical service life: D2 = 3,040 h - 1,920 h = 1,120 h. The above values are entered in the table (see table example p.
  • Page 76 Maintenance overview 5.4 Measures required for winch monitoring 5 - 28 3 302 649 en Maintenance manual GMK4090...

  • Page 77: 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 78: Lubricants List

    Lubricants and consumables 6.1 Lubricants 6.1.1 Lubricants list Con- GROVE Lubricant Designation Specifications Viscosity sec. part type according to Classification number DIN 51502 MIL-L 2104 C 03329588 Engine oil HD - CD SAE 5 W-30 DB 228.5 Fuchs Titan Cytrac MB Synth 04162042 Gear oil SAE 75 W-90...

  • Page 79: Lubricant Applications List

    Lubricants and consumables 6.1 Lubricants 6.1.2 Lubricant applications list Con- Lubricant Usage Fill Mainte- sec. type quantity nance in litres interval (gal) à Engine oil Diesel engine; p. 7 - 25 34 (9,0) à Gear oil Transmission; p. 7 - 42 15,5 (4,1) à...
  • Page 80 Lubricants and consumables 6.1 Lubricants Con- Lubricant Usage Fill Mainte- sec. type quantity nance in litres interval (gal) à Carrier central lubrication; p. 7 - 109 à Superstructure central lubrication; p. 8 - 67 à Cardan shafts – transverse; p. 7 - 64 à...

  • Page 81: Refrigerant

    Lubricants and consumables 6.2 Refrigerant Refrigerant Refrigerant Usage Fill quantity Mainte- Designation in kg (lbs) nance interval Driver's cab air-conditioning system; à p. 7 - 122 1,0 (2,2) M 12 Tetrafluoroethane (R134a) (Compressor oil: FUCHS SE 55) CAS no. 811-97-2 1 x 1.0 (2.2) Crane cab air-conditioning system;...

  • Page 82: After-Treatment Of Exhaust Gases

    Lubricants and consumables 6.3 Consumables 6.3.3 After-treatment of exhaust gases Designation Usage Fill quantity in litres (gal) DEF (Diesel Exhaust Fluid) à AdBlue: AdBlue tank on the carrier; p. 7 - 34 40 (10,5) GROVE part number: 03140555 DEF (Diesel Exhaust Fluid), Consumable for exhaust gas emission control, for example, AdBlue .

  • Page 83: Maintenance Work On The Carrier

    Maintenance work on the carrier 7.1 General instructions Maintenance work on the carrier General instructions The truck crane GMK4090 is fitted as standard with an AdBlue system for exhaust gas emission control. In this case an AdBlue tank (1) fitted to à...

  • Page 84: Tilting/Lowering The Driver's Cabin

    Maintenance work on the carrier 7.1 General instructions 7.1.2 Tilting/lowering the driver's cabin • Check whether the truck crane GMK4090 is fitted with driver's cab that can be tilted (additional equipment). A driver's cab that can be tilted makes it easier to access the front of the motor and maintenance work can be performed more conveniently.
  • Page 85 Maintenance work on the carrier 7.1 General instructions Blank page Maintenance manual 3 302 649 en 7 - 3 GMK4090...

  • Page 86: Overview Of Maintenance Work On The Carrier

    Maintenance work on the carrier 7.1 General instructions 7.1.3 Overview of maintenance work on the carrier 7 - 4 3 302 649 en Maintenance manual GMK4090...
  • Page 87 Maintenance work on the carrier 7.1 General instructions à Symbols for maintenance work p. 7 - 11 à 1 CCS (Crane Control System) control unit p. 7 - 11 à Engine p. 7 - 13 à 5 Diesel engine p. 7 - 13 à...
  • Page 88 Maintenance work on the carrier 7.1 General instructions 7 - 6 3 302 649 en Maintenance manual GMK4090...
  • Page 89 Maintenance work on the carrier 7.1 General instructions à Axle lines p. 7 - 55 à 7 Axle centre drives p. 7 - 55 à 6 Final drives p. 7 - 61 à 8 Cardan shafts p. 7 - 64 à...
  • Page 90 Maintenance work on the carrier 7.1 General instructions 7 - 8 3 302 649 en Maintenance manual GMK4090...
  • Page 91 Maintenance work on the carrier 7.1 General instructions à Wheels p. 7 - 67 à 5 Wheels p. 7 - 67 3 Spare wheel (alternatively storage box) à Suspension p. 7 - 77 à 8 Suspension struts p. 7 - 79 à...
  • Page 92 Maintenance work on the carrier 7.1 General instructions Blank page 7 - 10 3 302 649 en Maintenance manual GMK4090...

  • Page 93: Symbols For Maintenance Work

    Maintenance work on the carrier 7.2 Symbols for maintenance work Symbols for maintenance work • Check the symbols on the CCS start menu (Crane Control System) in the driver's cab each day before starting operations. • The Start menu shows the most important measurements and the Maintenance submenu shows all the outstanding warning messages;...
  • Page 94 Maintenance work on the carrier 7.2 Symbols for maintenance work Blank page 7 - 12 3 302 649 en Maintenance manual GMK4090...

  • Page 95: Engine

    Maintenance work on the carrier 7.3 Engine Engine • In addition, carry out 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. à • Operating manual . Check the oil level Start the engine from the driver's cab;...
  • Page 96 Maintenance work on the carrier 7.3 Engine • On the dipstick (1), check that the oil level is between the Min. and 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 97: Topping Up The Oil

    Maintenance work on the carrier 7.3 Engine 7.3.2 Topping up the oil à Data on the prescribed oil specification; Engine manufacturer’s documentation . Engine oil Designation Specifications GROVE part no. in litres (gal) acc. to Classification DIN 51502 34 (9,0) HD - CD MIL-L 2104 C SAE 5 W-30...

  • Page 98: Checking The Air Filter

    Maintenance work on the carrier 7.3 Engine 7.3.3 Checking the air filter • Start the engine and observe the display. • If the symbol (1) is displayed, you must change the air filter. • Switch the engine off. Spare parts Designation Quantity GROVE part no.

  • Page 99: 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 3 302 649 en...

  • Page 100: General Inspection

    Checking the coolant level , p. 7 - 17. • Check that pipes and hoses are tightly connected and undamaged. If any damage is found, report it to or an authorised Manitowoc Crane Care GROVE dealer or an authorised specialist workshop. M 12 7.3.6 Have the radiator checked/cleaned •...
  • Page 101 Maintenance work on the carrier 7.3 Engine Check the level of dirt The radiator units (1), (2) and (3) are protected by grilles (4) and plates (5). The fan impellers (6) are located under the grilles. When the engine is run- ning, the fan wheel rotates under the grille! Risk of injury at the fan wheel When the fan wheel is rotating, it can trap and cut off amputate your fin-...
  • Page 102 Maintenance work on the carrier 7.3 Engine Radiator unit 1 The radiator unit 1 consists of: – Radiator for water/charge air engine – Radiator for the transmission gear oil – Radiator for the transfer case gear oil – Cooling coil for compressed air –...
  • Page 103 Maintenance work on the carrier 7.3 Engine • • Have the radiator units (1), (2) and (3) opened up by the repair crew so that the radiator fins are accessible. • Have the radiator fins cleaned on both sides, using suitable cleaning agents.
  • Page 104 Maintenance work on the carrier 7.3 Engine • After checking/ Remove all tools and cleaning equipment. cleaning • Check whether all grilles and metal sheets are attached. • Start the engine and wait until the fan wheels are rotating. • Check that the fan wheels are running freely.

  • Page 105: Checking The V-Belt Tension

    Maintenance work on the carrier 7.3 Engine M 12 7.3.7 Checking the V-belt tension à • Comply also with the run-in regulations; p. 4 - 1. • Check whether your truck crane is fitted with a second alternator (2) (additional equipment). Maintenance of the V-belt of the first alternator (1) fitted as standard equip- à...
  • Page 106 Maintenance work on the carrier 7.3 Engine • Familiarise yourself with the correct operation of the frequency measur- à Separate operating manual . ing instrument; • Switch the frequency measuring instru- ment (1) on – it is now ready for acoustic measurement.

  • Page 107: Changing The Oil And Oil Filter

    Maintenance work on the carrier 7.3 Engine 7.3.8 Changing the oil and oil filter Oil, spare parts, Engine oil Designation Specifications GROVE part no. tools in litres (gal) acc. to Classification DIN 51502 34 (9,0) HD - CD MIL-L 2104 C SAE 5 W-30 DB 228.5 03329588...
  • Page 108 Maintenance work on the carrier 7.3 Engine Draining oil • Place a receptacle underneath the engine. • Remove the cap (2) from the filler neck. • Turn the drain plug (1) contrary to the sense of the arrow until it reaches the stop, then take it off.

  • Page 109: Fuel System

    à Operating manual . • Obtain information from on the additional fuel Manitowoc Crane Care filter required for the dual tank system. The following elements are installed as standard in the carrier fuel line: 1 Fuel filter 1 (large) 2 Fuel filter 2 (small)

  • Page 110: 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, about 5 l (1.5 gal); p. 2 - 4. and tools à Operating manual . Prerequisites – The truck crane must be level and on outriggers; à...

  • Page 111: 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) 04161991 alternatively: 04183793 Set for both filters 1 + 2 (large + small) à – Receptacle, about 5 l (1.5 gal); p.
  • Page 112 Maintenance work on the carrier 7.4 Fuel system • Remove the cap (1). • Remove the old filter (2) from the casing. • Place the old filter (2) in the receptacle. • Insert a new filter (2) into the casing. •...

  • Page 113: Replacing Fuel Filter 2

    Maintenance work on the carrier 7.4 Fuel system M 12 7.4.3 Replacing fuel filter 2 Spare parts Designation Quantity GROVE part no. and tools Filter (small) 04161566 alternatively: 04183793 Set for both filters 1 + 2 (large + small) à –...
  • Page 114 Maintenance work on the carrier 7.4 Fuel system • Open the two tank covers on the fuel tank; à p. 7 - 27. • Operate the hand pump (1) until you sense definite resistance. • Close the two tank covers on the fuel tank. •...

  • Page 115: 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 116: 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 Check The display includes a gauge showing the level in the AdBlue tank. The tank has a maximum filling volume of approx. 40 l (10.5 gal). Depending on where the truck crane is used, it may be sensible to carry additional canisters of AdBlue.

  • Page 117: Check The Exhaust System For External Damage

    Maintenance work on the carrier 7.5 Exhaust system with exhaust emission control • Refuelling Find out about refuelling in the operating manual and note the warnings; à Operating manual . Danger of scalding due to ammonia vapours Ammonia vapour can escape if the AdBlue tank is opened when the outside temperature is high.
  • Page 118 • Switch the engine off. If you discover any damage Have any damaged parts of the exhaust system replaced immediately by or an authorised GROVE dealer. Manitowoc Crane Care 7 - 36 3 302 649 en Maintenance manual GMK4090...

  • Page 119: 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 - 33.
  • Page 120 Oil from the compressed air system can damage the pump unit. Therefore, a filter cartridge must be installed in the compressed air drier that removes both water and oil. recommends the Manitowoc Crane Care suitable filter cartridge with the GROVE part number 04157844. à •...

  • Page 121: Transmission

    Maintenance work on the carrier 7.6 Transmission Transmission overview Engine-transmission unit – Diesel engine (1), – Transmission (2), – Water retarder SWR (3); are the rear of the transmission (additional equipment); SWR = Secondary Water Retarder. Transmission The automatic transmission has 16 speeds and the type designation G 280-16.

  • Page 122: General Inspection

    The transmission oil cooler is located within the radiator unit 1; à p. 7 - 20. If any damage is found, report it to or an authorised Manitowoc Crane Care GROVE dealer or an authorised specialist workshop. 7 - 40 3 302 649 en Maintenance manual...

  • Page 123: Check The Oil Level

    Maintenance work on the carrier 7.6 Transmission M 12 7.6.2 Check the oil level Spare parts Designation Quantity GROVE part no. and tools Gasket 24 x 29 Cu DIN 7603 00117145 à – Receptacle, about 5 l (1.5 gal); p. 2 - 4. –...

  • Page 124: Changing The Oil

    Maintenance work on the carrier 7.6 Transmission 7.6.3 Changing the oil Oil, spare parts Gear oil Specifications GROVE part no. and tools in litres (gal) Classification 15,5 (4,1) Fuchs Titan 04162042 Cytrac MB Synth with oil cooler API-GL-4; SAE 75 W-90 Designation Quantity GROVE part no.
  • Page 125 Maintenance work on the carrier 7.6 Transmission • Place a receptacle under the screw (2). • Unscrew bolts (1) and (2) and allow the oil to drain. • Clean the drain plugs. • Replace the gasket and tighten the drain plug (2) –...
  • Page 126 Maintenance work on the carrier 7.6 Transmission Topping up the oil • Fill the oil up to the lower edge of the opening. • Replace the gasket and tighten the drain plug (1) – torque 25 Nm (18.4 lbf ft). Checks after the oil change After changing oil, check for leakage:...

  • Page 127: 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 Check the oil level Spare parts...

  • Page 128: Changing The Oil

    Maintenance work on the carrier 7.7 Transfer case Checking • Remove the drain plug (1). • Check that the oil reaches the lower edge of the opening. • Fit a new gasket and tighten the screw. If the oil level is too low à...
  • Page 129 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 130 Maintenance work on the carrier 7.7 Transfer case Blank page 7 - 48 3 302 649 en Maintenance manual GMK4090...

  • Page 131: Angle Gear

    Maintenance work on the carrier 7.8 Angle gear Angle gear à • Comply also with the run-in regulations; p. 4 - 1. Access The angle gear (1) is located in the travel gear frame at the centre of rotation of the turntable. Within the oil circuit (2) the gear oil for the angle gear (1) is routed via a separate oil cooler (3) and through a separate filter (4).

  • Page 132: General Inspection

    Check the oil level , p. 7 - 50. • Check that pipes and hoses are tightly connected and undamaged. If any damage is found, report it to or an authorised Manitowoc Crane Care GROVE dealer or an authorised specialist workshop. 7.8.2 Check the oil level Spare parts...
  • Page 133 Check the secure fastening and the condi- tion of the resilient dampers (1): If the resilient dampers are damaged, have them replaced by or an authorised GROVE dealer. Manitowoc Crane Care Maintenance manual 3 302 649 en 7 - 51...

  • Page 134: Changing The Oil And The Oil Filter

    Maintenance work on the carrier 7.8 Angle gear 7.8.3 Changing the oil and the oil filter Oil, spare parts, Gear oil Designation Specifications GROVE part no. tools in litres (gal) acc. to Classification DIN 51502 7,2 (1,9) MIL-L 2105 B 01373344 API-GL-5 for type A...
  • Page 135 Maintenance work on the carrier 7.8 Angle gear Changing the oil Risk of scalding from gear oil at operating temperature You could scald yourself by gear oil escaping in an uncontrolled manner at operating temperature. Wear appropriate protective gloves and take care not to come into contact with the gear oil.
  • Page 136 Maintenance work on the carrier 7.8 Angle gear • Remove the screw (1) from the oil cooler (2). • Fill the oil up to the lower edge of the opening (1). • If necessary fit a new gasket and tighten the screw (1).

  • Page 137: Axle Lines

    Check that pipes and hoses are tightly connected and undamaged. If any damage is found, report it to or an authorised Manitowoc Crane Care GROVE dealer or an authorised specialist workshop. 7.9.2 Axle centre drives – checking the oil level...
  • Page 138 Maintenance work on the carrier 7.9 Axle lines 1. and 4th axle lines • Remove the drain plug (1). • Check that the oil reaches the lower edge of the opening. • Fit a new gasket and tighten the screw. If the oil level is too low à...

  • Page 139: Axle Centre Drives - Changing The Oil

    Maintenance work on the carrier 7.9 Axle lines 3. axle line The drive has two oil chambers. • Remove the screw (1). • Check that the oil reaches the lower edge of the openings. • Fit a new gasket and tighten the screw. If the oil level is too low à...
  • Page 140 Maintenance work on the carrier 7.9 Axle lines Prerequisites – The truck crane must be raised on outriggers or parked over an inspec- tion pit. – The engine is not running and is secured against unauthorised use; à p. 2 - 3. Risk of environmental damage due to leaking consumables Always let consumables drain into suitable receptacles.
  • Page 141 Maintenance work on the carrier 7.9 Axle lines 3rd axle line The drive has two oil chambers. Risk of oil overheating When topping up the oil, both openings must be opened so that both oil tanks are filled equally. This prevents the oil tanks from being overfilled and thus the oil from overheating.
  • Page 142 Maintenance work on the carrier 7.9 Axle lines Blank page 7 - 60 3 302 649 en Maintenance manual GMK4090...

  • Page 143: Final Drives - Checking The Oil Level

    Maintenance work on the carrier 7.9 Axle lines 7.9.4 Final drives – Checking the oil level Spare parts for drive Designation Quantity GROVE part no. and tools 8 x 6 x 8 Gasket 24 x 29 Cu DIN 7603 00117145 8 x 8 x 8 Gasket 24 x 29 Cu DIN 7603 00117145...

  • Page 144: Final Drives - Changing The Oil

    Maintenance work on the carrier 7.9 Axle lines M 12 7.9.5 Final drives – changing the oil Oil, spare parts, Gear oil Designation Specifications GROVE part no. tools in litres (gal) acc. to Classification DIN 51502 for each final C - LPF MIL-L 2105 B 00552891 drive:...
  • Page 145 Maintenance work on the carrier 7.9 Axle lines Draining oil • Change the oil on all final drives in the same way. • Turn the wheel until the bolt (1) is at the bottom. • Use a drain channel and place a receptacle under the screw.

  • Page 146: Lubricating The Cardan Shafts In The Axle Lines

    Maintenance work on the carrier 7.9 Axle lines 7.9.6 Lubricating the Cardan shafts in the axle lines Check all Cardan shafts to see if they have grease nipples. Cardan shafts with grease nipples must be serviced, Cardan shafts without grease nipples are maintenance-free. Grease, spare Lubricating Designation...

  • Page 147: Lubricating Longitudinal Cardan Shafts

    Maintenance work on the carrier 7.9 Axle lines 7.9.7 Lubricating longitudinal Cardan shafts Check all Cardan shafts to see if they have grease nipples. Cardan shafts with grease nipples must be serviced, Cardan shafts without grease nipples are maintenance-free. Grease, spare Lubricating Designation Specifications...
  • Page 148 Maintenance work on the carrier 7.9 Axle lines Blank page 7 - 66 3 302 649 en Maintenance manual GMK4090...

  • Page 149: Wheels

    Maintenance work on the carrier 7.10 Wheels 7.10 Wheels 7.10.1 Checking the tyres for damage Prerequisites – The truck crane must be raised on outriggers. – The engine is not running and is secured against unauthorised use; à p. 2 - 3. –...

  • Page 150: Checking The Tyre Pressure

    Maintenance work on the carrier 7.10 Wheels 7.10.2 Checking the tyre pressure Risk of damage to the tyres The air pressure increases when the tyres become hot during driving. 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 151: Checking That The Wheel Nuts Are Tight

    Maintenance work on the carrier 7.10 Wheels 7.10.3 Checking that the wheel nuts are tight Spare parts Designation Quantity GROVE part no. and tools per wheel Wheel nut with pressure plate 01207756 for steel rims Wheel nut with pressure plate 7659100000 for aluminium rims –...

  • Page 152: Changing The Wheels

    Maintenance work on the carrier 7.10 Wheels 7.10.4 Changing the wheels The wear on tyres varies depending on whether the axle – is driven/not driven, – is steered/not steered, – is braked/not braked, – and whether it is subject to more or less load. To achieve even wear, you must swap the wheels to different positions reg- ularly.
  • Page 153 Maintenance work on the carrier 7.10 Wheels Recognising two-piece aluminium rims The round-head bolts (1) are on the outer face of the 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 154 Maintenance work on the carrier 7.10 Wheels • Mount the wheels on another axle, as shown in the diagram. Replace any à damaged parts. Tighten the wheel nuts; p. 7 - 69. 7 - 72 3 302 649 en Maintenance manual GMK4090...
  • Page 155 Maintenance work on the carrier 7.10 Wheels Optimised wheel To ensure even more even wear on all tyres, you can also rotate the tyres change on the wheel rim and mount them on the other side of the vehicle. Risk of accidents if procedure is incorrect This section only shows the sequence to be followed when changing wheels.
  • Page 156 Maintenance work on the carrier 7.10 Wheels Blank page 7 - 74 3 302 649 en Maintenance manual GMK4090...

  • Page 157: 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 158 7 - 75. • 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 159: Suspension

    Notify or an authorised GROVE dealer. Manitowoc Crane Care Risk of damage to the suspension struts due to insufficient lubrication It is difficult to inject the oil. Even so, do not fill oil through the sight glass connections.
  • Page 160 Change the filter (6) if necessary and fasten the cover. • Defective suspension struts should be replaced as soon as possible by or an authorised GROVE dealer. Manitowoc Crane Care 7 - 78 3 302 649 en Maintenance manual GMK4090...

  • Page 161: Suspension Struts - Checking The Fastening

    Maintenance work on the carrier 7.12 Suspension 7.12.2 Suspension struts – checking the fastening Spare parts – Torque wrench for torques up to 900 Nm (664 lbf ft). and tools à Operating manual. Prerequisites – The truck crane must be raised on outriggers; –...

  • Page 162: Forced Lever - Checking Correct Functioning

    If the suspension struts are not extended or only partially extended, the forced lever is faulty. • Faulty forced levers should be replaced as soon as possible by or an authorised GROVE dealer or your qualified Manitowoc Crane Care repair crew. 7 - 80 3 302 649 en Maintenance manual...

  • Page 163: Pressure Accumulator - Checking The Gas Pressure

    The filling pressure at 20 °C (68 °F) is 50 bar (725 psi). • Have the filling pressure checked, and if nec- essary corrected, by Manitowoc Crane Care an authorised GROVE dealer or an author- ised specialist workshop. Maintenance manual 3 302 649 en...
  • Page 164 Maintenance work on the carrier 7.12 Suspension Blank page 7 - 82 3 302 649 en Maintenance manual GMK4090...

  • Page 165: Steering

    Maintenance work on the carrier 7.13 Steering 7.13 Steering 7.13.1 Checking the steering monitoring Checks in the driver's cab • Consult the operating instructions regarding lights and symbols for steer- à Operating manual . ing monitoring in the driver's cab; •...

  • Page 166: Checking The Angle Sensors

    Check the steering computer and the dis- plays for external damage. If you find damage to the angle sensors or steering computers • Immediately notify or an authorised GROVE dealer. Manitowoc Crane Care 7 - 84 3 302 649 en Maintenance manual GMK4090...

  • Page 167: Checking For Leaks

    Bleeding the hydraulic system , p. 7 - 105. 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 3 302 649 en 7 - 85 GMK4090...
  • Page 168 Maintenance work on the carrier 7.13 Steering Blank page 7 - 86 3 302 649 en Maintenance manual GMK4090...

  • Page 169: Compressed Air System

    (1) to (8). If a great deal of water escapes • Have the compressed air drier checked or replaced by or an Manitowoc Crane Care authorised GROVE dealer or your qualified repair crew. Maintenance manual 3 302 649 en 7 - 87...

  • Page 170: 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 - 88 3 302 649 en Maintenance manual...

  • Page 171: Replacing The Filter Cartridge Of The Compressed Air Drier

    Maintenance work on the carrier 7.14 Compressed air system 7.14.3 Replacing the filter cartridge of the compressed M 12 air drier Spare parts Designation Quantity GROVE part no. and tools Filter cartridge 04157844 – Strap wrench. Prerequisites – The truck crane must be raised on outriggers or parked over an inspection pit.
  • Page 172 Maintenance work on the carrier 7.14 Compressed air system Blank page 7 - 90 3 302 649 en Maintenance manual GMK4090...

  • Page 173: Hydraulic System

    Maintenance work on the carrier 7.15 Hydraulic system 7.15 Hydraulic system Risk of environmental damage due to leaking consumables Always let consumables drain into suitable receptacles. Wipe up any consumables that escape. Store/dispose of consumables and any soaked equipment properly. Ask about the applicable regulations.

  • Page 174: Checking The Hydraulic Hoses

    Maintenance work on the carrier 7.15 Hydraulic system 7.15.2 Checking the hydraulic hoses Hydraulic hoses are also subject to ageing as well as internal and external strain. • Check the hydraulic hoses for – external damage (tears, abrasion, heat damage, chemical damage), –...

  • Page 175: Cleaning The Magnetic Rods

    Bleed the carrier's hydraulic system; p. 7 - 105. If damage cannot be rectified immediately or further damage is likely • Notify or an authorised GROVE dealer or your repair Manitowoc Crane Care crew. 7.15.4 Cleaning the magnetic rods Spare parts Designation Quantity GROVE part no.
  • Page 176 Large amounts of metal particles are a sign of damage in the hydraulic sys- tem. Have the hydraulic system checked by or an Manitowoc Crane Care authorised GROVE dealer or your qualified repair crew. • Assemble the filters (2) and insert them.

  • Page 177: Changing The Ventilation Filter

    Maintenance work on the carrier 7.15 Hydraulic system M 12 7.15.5 Changing the ventilation filter • Reducing the Under difficult operating conditions – at extremely sandy or dusty loca- interval tions – you must change the ventilation filter earlier than normal. Spare parts Designation Quantity...

  • Page 178: Taking Oil Samples

    Maintenance work on the carrier 7.15 Hydraulic system M 12 7.15.6 Taking oil samples • Reducing the Under difficult operating conditions – at tropical or very hot locations – interval you must halve the oil change interval. Spare parts – A hose with a connecting piece for a gauge port. and tools Hose lengths GROVE part no.
  • Page 179 Maintenance work on the carrier 7.15 Hydraulic system Protecting the hose from dirt Danger of contamination of the oil sample If the hose with the connecting piece is dirty, the dirt can contaminate the oil sample in the sample container during the sampling process. The laboratory analysis would then be incorrect.
  • Page 180 Maintenance work on the carrier 7.15 Hydraulic system Taking oil samples The hose end (1) is connected to the cylinder (3). The hose end (2) is in receptacle (4). • Start the engine. • Allow 2 litres (0.5 gal) of oil to flow into the receptacle.
  • Page 181 Maintenance work on the carrier 7.15 Hydraulic system Dispatch the oil gives you the opportunity to have the oil sample ana- Manitowoc Crane Care sample to the lab- lysed at our contracted laboratory. A delivery note and a protective mailing bag oratory are available along with the sample containers (GROVE part no.
  • Page 182 Maintenance work on the carrier 7.15 Hydraulic system Blank page 7 - 100 3 302 649 en Maintenance manual GMK4090...

  • Page 183: Changing The Hydraulic Oil

    Maintenance work on the carrier 7.15 Hydraulic system 7.15.7 Changing the hydraulic oil The oil only needs to be changed if the laboratory analysis indicates the à Determining the quality of the oil , p. 7 - 99. need for it; Oil, spare parts, Hydraulic oil Designation...
  • Page 184 Maintenance work on the carrier 7.15 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 185 Maintenance work on the carrier 7.15 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 valves. •...
  • Page 186 Maintenance work on the carrier 7.15 Hydraulic system Establishing an After having changed the oil filters and topping up the oil, you must operational status re-establish the operating condition. Opening the valves • Open the valves – lever (1) parallel with the line.
  • Page 187 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 3 302 649 en 7 - 105 GMK4090...

  • Page 188: Changing The Hydraulic Oil Filter

    Maintenance work on the carrier 7.15 Hydraulic system 7.15.8 Changing the hydraulic oil filter When changing the oil, all the oil filters must be replaced. If a warning message appears the red symbol in the Warning submenu indi- cates that you must change oil filters 1 and 2. If a warning message appears the red symbol in the Warning submenu indi- cates that you must change oil filters 3.
  • Page 189 Large amounts of metal particles are a sign of damage in the hydraulic system. Have the hydraulic system checked by or an author- Manitowoc Crane Care ised GROVE dealer or your qualified repair crew. • Assemble the filters (2) and insert them.
  • Page 190 Maintenance work on the carrier 7.15 Hydraulic system Changing filters 3 and 4 Risk of damage to the environment from filter residues Store used hydraulic oil filter inserts in suitable receptacles and have them disposed of properly by qualified personnel. •...

  • Page 191: Central Lubrication System

    Maintenance work on the carrier 7.16 Central lubrication system 7.16 Central lubrication system 7.16.1 Checking the filling level Grease, spare Lubricating Designation Specifications GROVE part no. parts, tools grease acc. to Classification DIN 51502 Grease KP - 1K - 50 DIN 51825 03233369 –...
  • Page 192 Maintenance work on the carrier 7.16 Central lubrication system Topping up Risk of damage to the central lubrication system Cleanliness is of the utmost importance when handling grease and filling pumps. Do not remove the caps from the connections and the filling pump until immediately before refilling the grease, as the grease could otherwise become contaminated.

  • Page 193: Bleeding The Central Lubrication System

    Maintenance work on the carrier 7.16 Central lubrication system • Attach the filling pump to the respective connections (1), (2) or (3). • Press the button (4) once. Intermediate lubrication will be triggered. • Fill the grease container up to the Max. marking.

  • Page 194: Triggering Intermediate Lubrication

    Maintenance work on the carrier 7.16 Central lubrication system 7.16.3 Triggering intermediate lubrication Intermediate lubrication should be activated: – after high pressure cleaning, – to check the lubrication system at all lubricating points. • Switch on the ignition. • Press the button (1) once. An intermediate lubrication cycle will be trig- gered which lasts about two minutes.

  • Page 195: Electrical System

    Risk of accidents in the event of faulty safety devices! Have faulty lights and indicators repaired by or an Manitowoc Crane Care authorised GROVE dealer or an authorised specialist workshop. • Check the following functions every day before operating or driving the truck crane, and have faulty parts repaired: –...

  • Page 196: Checking The Batteries

    Maintenance work on the carrier 7.17 Electrical system 7.17.2 Checking the batteries Risk of poisoning from storage 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 197 Maintenance work on the carrier 7.17 Electrical system Checking the connecting terminals • Keep the storage 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 198: Checking The Charge Level Of The Batteries

    Maintenance work on the carrier 7.17 Electrical system 7.17.3 Checking the charge level of the batteries à Spare parts – Battery charger (additional equipment); p. 7 - 118; 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 199 Maintenance work on the carrier 7.17 Electrical system Before checking • Switch off the battery master switch (1). • Open the cover on the battery box. Checking the acid concentration Batteries without covers (1) are maintenance- free. • Remove all covers (1). •...

  • Page 200: Charging The Batteries Using The Battery Charger

    Maintenance work on the carrier 7.17 Electrical system 7.17.4 Charging the batteries using the battery charger Prerequisites – The engine is not running and is secured against unauthorised use; à p. 2 - 3. – An external 230 V mains power supply must be available at the location. –...

  • Page 201: Check The External Starting Socket

    Maintenance work on the carrier 7.17 Electrical system 7.17.5 Check the external starting socket The battery box is equipped with an external starting socket (1). Accessories A connection cable (1) for the external starting socket is supplied with the truck crane (tool set). Designation GROVE part no.
  • Page 202 Maintenance work on the carrier 7.17 Electrical system Blank page 7 - 120 3 302 649 en Maintenance manual GMK4090...

  • Page 203: Air Conditioning System

    • Do not start it up again to avoid further damage. Have the air-conditioning system repaired as soon as possible by or an authorised GROVE dealer or an authorised Manitowoc Crane Care specialist workshop. 7.18.2 Checking hoses Risk of burns due to escaping refrigerant Wear suitable safety glasses and gloves when checking the hoses and connections.

  • Page 204: 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 205 Maintenance work on the carrier 7.18 Air conditioning system Refrigerant Fill quantity Designation CAS no. in kg (lbs) EC no. Tetrafluoroethane (R134a) 811-97-2 1,0 (2,2) 212-377-0 Compressor oil: FUCHS SE 55 Filler connections The filler connections (1) for the refrigerant are behind the front flap (2) in the driver's cab.

  • Page 206: Changing The Pollen Filter

    Maintenance work on the carrier 7.18 Air conditioning system M 12 7.18.5 Changing the pollen filter • Reducing the Under difficult operating conditions – at extremely sandy or dusty loca- interval tions – you must change the filter earlier than normal. Spare parts and Designation Quantity...

  • Page 207: Towbar Coupling

    Maintenance work on the carrier 7.19 Towbar coupling 7.19 Towbar coupling Depending on the equipment fitted to your truck crane, it may have towbar couplings (additional equipment) from different manufacturers. The wear values for other manufacturers may vary from those specified; à...
  • Page 208 Maintenance work on the carrier 7.19 Towbar coupling Closing the towbar coupling Risk of injury when closing the towbar coupling by hand 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 209: Checking The Bearing

    Maintenance work on the carrier 7.19 Towbar coupling 7.19.2 Checking the bearing à Prerequisites – The coupling is closed; p. 7 - 126. Checking the bearing Risk of injury Ensure that the towbar coupling is closed for the following work (lever points downwards).

  • Page 210: 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 211: Checking The Lower Bushing

    Model series 700: 34.2 mm (1.35 in) If the dimension is larger than that given above, have the bushing replaced by or an authorised GROVE Manitowoc Crane Care dealer or your specialist repair crew. 7.19.5 Checking the initial tension of the springs The coupling head should require physical force to twist it when checking the torque.

  • Page 212: Checking The Support Ring

    Maintenance work on the carrier 7.19 Towbar coupling 7.19.6 Checking the support ring à Prerequisites – The coupling is closed; p. 7 - 126. 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 213 Maintenance work on the carrier 7.19 Towbar coupling Checking for cor- rect 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 214 Maintenance work on the carrier 7.19 Towbar coupling Blank page 7 - 132 3 302 649 en Maintenance manual GMK4090...

  • Page 215: Other Maintenance Work

    Maintenance work on the carrier 7.20 Other maintenance work 7.20 Other maintenance work 7.20.1 Checking windscreen washing system Water, spare Designation Quantity GROVE part no. parts, tool Wiper blades 04159795 – Water; add commercially available detergent and antifreeze to it. –...

  • Page 216: Lubricating The Outrigger Beams

    Maintenance work on the carrier 7.20 Other maintenance work 7.20.2 Lubricating the outrigger beams à • Comply also with the run-in regulations; p. 4 - 1. Grease, spare Lubricating Designation Specifications GROVE part no. parts, tools grease acc. to Classification DIN 51502 Grease KP - 1K - 50...

  • Page 217: Checking The Auxiliary Heater

    Check that the system is working properly. Also perform a functional check of the controls. • If the heating system is not working correctly, report it to or an authorised GROVE dealer or an authorised Manitowoc Crane Care specialist workshop. M 12 7.20.4 Lubricating the cab door...

  • Page 218: 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 219: Renewing The Corrosion Protection

    Maintenance work on the carrier 7.20 Other maintenance work M 12 7.20.6 Renewing the corrosion protection Protective agent, Protective agent GROVE part no. tools Corrosion protection 03140192 – Spray gun with spray extension. – Brush. – Protective clothing, protective goggles. Prerequisites –...
  • Page 220 Maintenance work on the carrier 7.20 Other maintenance work Spraying Risk of injury to the eyes While working with the spray extension you could be hit by the spray jet or spray droplets. Wear protective goggles, protective clothing and gloves. •...

  • Page 221: Having The Fire Extinguisher Checked

    Maintenance work on the carrier 7.20 Other maintenance work 7.20.7 Having the fire extinguisher checked Depending on your truck crane's equipment, it can be fitted with fire extin- guishers. The maintenance interval may even be shorter, depending on the respective national regulations and the operating location.
  • Page 222 Maintenance work on the carrier 7.20 Other maintenance work Blank page 7 - 140 3 302 649 en Maintenance manual GMK4090...

  • Page 223: Maintenance Work On The Superstructure

    Maintenance work on the superstructure 8.1 General instructions Maintenance work on the superstructure General instructions 8.1.1 Covers Various types of work (e.g. oil change) require that covers be removed. Before maintenance work • Remove the covers (1). After maintenance work •...

  • Page 224: 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 3 302 649 en Maintenance manual GMK4090...
  • Page 225 Maintenance work on the superstructure 8.1 General instructions à Symbols for maintenance work p. 8 - 7 à 1 CCS (Crane Control System) control unit p. 8 - 7 à Hoists p. 8 - 9 à 17 Hoist ropes p. 8 - 51 à...
  • Page 226 Maintenance work on the superstructure 8.1 General instructions 8 - 4 3 302 649 en Maintenance manual GMK4090...
  • Page 227 Maintenance work on the superstructure 8.1 General instructions à Main boom p. 8 - 45 à 1 Telescopic sections 1 to 5 and basic section p. 8 - 46 à 16 Derricking cylinder p. 8 - 45 à 15 Sheaves p.
  • Page 228 Maintenance work on the superstructure 8.1 General instructions Blank page 8 - 6 3 302 649 en Maintenance manual GMK4090...

  • Page 229: Symbols For Maintenance Work

    Maintenance work on the superstructure 8.2 Symbols for maintenance work Symbols for maintenance work Check the following symbols every day before starting work. • Check the symbols on the CCS start menu ( Crane Control System ) in the crane cab each day before starting work. •...
  • Page 230 Maintenance work on the superstructure 8.2 Symbols for maintenance work Blank page 8 - 8 3 302 649 en Maintenance manual GMK4090...

  • Page 231: 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 Gasket 18 x 24 Cu DIN 7603 01377793 à Operating manual . Prerequisites – The truck crane must be level and in on-road mode; –...

  • Page 232: 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 233 Maintenance work on the superstructure 8.3 Hoists M 12 8.3.4 Changing the oil/checking the oil à • Comply also with the run-in regulations; p. 4 - 1. Oil, spare parts, Gear oil Designation Specifications GROVE part no. tools in litres (gal) acc.

  • Page 234: 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 further measures. Manitowoc Crane Care 8 - 12 3 302 649 en...

  • Page 235: Having A Partial Inspection Carried Out

    Maintenance work on the superstructure 8.3 Hoists 8.3.5 Having a partial inspection carried out Only suitably trained specialists should carry out a partial inspection of: – the multiple-disk brake – the plug connections between the hydraulic motor and the multiple-disk brake –...
  • Page 236 Maintenance work on the superstructure 8.3 Hoists Blank page 8 - 14 3 302 649 en Maintenance manual GMK4090...

  • Page 237: Slewing Gear

    Maintenance work on the superstructure 8.4 Slewing gear Slewing gear 8.4.1 Checking the oil level Spare parts Designation Quantity GROVE part no. and tools Gasket 10 x 14 Cu DIN 7603 00117125 à Operating manual . Prerequisites – The truck crane must be level and in on-road mode; –...

  • Page 238: Checking For Leaks

    • Check that pipes and hoses are tightly connected and undamaged. If any damage is found, report it to or an authorised Manitowoc Crane Care GROVE dealer or your repair crew. 8.4.3 Checking the slewing gear brake Prerequisites –...
  • Page 239 – If the superstructure does slew, the slewing gear brake is defective and must be repaired immediately by or an author- Manitowoc Crane Care ised GROVE dealer. Maintenance manual 3 302 649 en 8 - 17...
  • Page 240 Maintenance work on the superstructure 8.4 Slewing gear • Switch the slewing gear off and switch the engine off. • Fasten the coil (1) to the valve Y 2307 using the nut (release the slewing gear brake). • Start the engine and check the slewing gear for correct operation.
  • Page 241 Maintenance work on the superstructure 8.4 Slewing gear M 12 8.4.4 Changing the oil/checking the oil à • Comply also with the run-in regulations; p. 4 - 1. Oil, spare parts, Gear oil Designation Specifications GROVE part no. tools in litres (gal) acc.

  • Page 242: Changing The Oil/Checking The Oil

    Maintenance work on the superstructure 8.4 Slewing gear Draining oil • Remove the plate (1). • Place a container under the screws (2). • Unscrew the filter (4) and screws (3) and (2). • Drain the oil. • Replace the gasket and tighten the screws (2). Topping up the oil •...

  • Page 243: Slewing Bearing

    Maintenance work on the superstructure 8.5 Slewing bearing Slewing bearing 8.5.1 Checking the screws à • Comply also with the run-in regulations; p. 4 - 1. Tools – Torque wrench. à – Auxiliary tools for the torque wrench; p. 8 - 23. Prerequisites –...
  • Page 244 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 245 Maintenance work on the superstructure 8.5 Slewing bearing Selecting the tools Outer ring The screw heads (1) are easily accessible for fitting a socket wrench. Therefore, you can use manual or mechanical torque tools (electric or hydraulic screw drivers). Inner ring The screw head (1) is accessible only via the opening (2).
  • Page 246 Maintenance work on the superstructure 8.5 Slewing bearing • Checking the Divide the checking of the 68 bolts into 17 working steps of 4 bolts each (1). outer ring Between each of the 17 operation steps you need to rotate the turntable to the next group of 4 screws on the opposite side.

  • Page 247: Lubricating The Gear Teeth

    • If need be, remove dirt and foreign bodies from the pinion (2). • If any damage is found, report it to or an authorised Manitowoc Crane Care GROVE-dealer. • Attach the plate. Maintenance manual 3 302 649 en 8 - 25...
  • Page 248 Maintenance work on the superstructure 8.5 Slewing bearing Lubrication 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 249: 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 250: 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 251 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 3.2 mm (0.126 in).

  • Page 252: 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 truck crane GMK4090 can be fitted with a turntable lock as additional equipment. Grease, spare Lubricating Designation Specifications GROVE part no. parts, tools grease acc.

  • Page 253: Hydraulic System

    Maintenance work on the superstructure 8.6 Hydraulic system Hydraulic system Risk of environmental damage due to leaking consumables Always let consumables drain into suitable receptacles. Wipe up any con- sumables that escape. Store/dispose of consumables and any soaked equipment properly. Ask about the applicable regulations.

  • Page 254: Checking The Hydraulic Hoses

    Maintenance work on the superstructure 8.6 Hydraulic system 8.6.2 Checking the hydraulic hoses The inspection work is described in section Checking the hydraulic hoses , p. 7 - 92. 8.6.3 Checking ventilation filters • Check the display (1) on the ventilation filter. If the indicator is coloured à...

  • Page 255: Checking For Leaks

    Bleed the hydraulic system; p. 8 - 44. If damage cannot be rectified immediately or further damage is likely • Notify or an authorised GROVE dealer or your repair Manitowoc Crane Care crew. Maintenance manual 3 302 649 en 8 - 33 GMK4090...

  • Page 256: Cleaning The Magnetic Rods

    Maintenance work on the superstructure 8.6 Hydraulic system 8.6.5 Cleaning the magnetic rods Spare parts Designation Quantity GROVE part no. and tools For oil filter 1: Filter 04156358 Packing set 04165792 à – Receptacle, about 5 l (1.5 gal); p. 2 - 4. Prerequisites –...
  • Page 257 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 your Manitowoc Crane Care qualified repair crew. • Assemble the filter (3) and insert it. •...

  • Page 258: Changing The Ventilation Filter

    Maintenance work on the superstructure 8.6 Hydraulic system M 12 8.6.6 Changing the ventilation filter Spare parts Designation Quantity GROVE part no. and tools Filter 03134932 Prerequisites – The engine is not running and is secured against unauthorised use; à p.

  • Page 259: Pressure Accumulator - Checking The Gas Pressure

    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 Care or an authorised GROVE dealer. M 12 8.6.8 Taking oil samples The oil sample from the superstructure hydraulic system is taken in a way similar to that for the carrier hydraulic system.
  • Page 260 Maintenance work on the superstructure 8.6 Hydraulic system The MLS gauge port (1) is located on the bracket (2). When a hydraulic function is run (tilt the crane cab), oil can be taken at the gauge port. • This maintenance work must be performed by a team of two persons: –...

  • Page 261: Changing The Hydraulic Oil Filter

    Maintenance work on the superstructure 8.6 Hydraulic system 8.6.9 Changing the hydraulic oil filter All oil filters must be replaced when changing the oil. If a warning message appears, the red symbols on the CCS control unit CCS indicate whether oil filter 1 or oil filter 2 is clogged. 1 Red –...
  • Page 262 Large amounts of metal particles are a sign of damage in the hydraulic system. Have the hydraulic system checked by or an Manitowoc Crane Care authorised GROVE dealer or your qualified repair crew. • Assemble the filter (3) and insert it.
  • Page 263 Maintenance work on the superstructure 8.6 Hydraulic system Changing oil filter 2 • Release the receptacle (1) at the hexagon head. • Change the filter (2). • Replace the gaskets. • Fill the receptacle with clean oil and tighten it – torque 25 Nm (18.5 ft lbf). After changing the filter Risk of damage to the hydraulic pumps...

  • Page 264: Changing The Hydraulic Oil

    Maintenance work on the superstructure 8.6 Hydraulic system 8.6.10 Changing the hydraulic oil The oil only needs to be changed if the laboratory analysis results indicate à Taking oil samples , p. 8 - 37. this; Oil, spare parts, Hydraulic oil Designation Specifications GROVE part no.
  • Page 265 Maintenance work on the superstructure 8.6 Hydraulic system Draining oil Risk of environmental damage due to leaking consumables Use the supplied connecting piece and hose and a receptacle with sufficient capacity to drain the hydraulic oil. • Place a receptacle underneath the valve. •...
  • Page 266 Maintenance work on the superstructure 8.6 Hydraulic system Establishing After having changed the oil filters and topping up the oil, you must re- the operating establish the operating condition. condition Opening the valve • Open the flap (1). • Pull the locking bar (3). •...

  • Page 267: 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; 1 kg 03325215 (Apply the grease with a brush) Spray on Berulub;...

  • Page 268: Lubricating The Telescopic Sections

    – A grease gun for the grease nipples on the upper telescopic slide faces. – A brush or roller for the outer, upper and lower telescopic slide faces. The Manitowoc Crane Group Germany GmbH recommends pneumatic grease spray guns for more effective lubrication of the telescopic slide...
  • Page 269 Maintenance work on the superstructure 8.7 Main boom Notes 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 telescope status.
  • Page 270 Maintenance work on the superstructure 8.7 Main boom • Extend the telescopic section I to 50%. • Use the grease gun (PAL1) to lubricate the upper inner slide faces at the lubricating nipples (1) on both sides. • Fully retract telescopic section I . •...
  • Page 271 Maintenance work on the superstructure 8.7 Main boom • Raise the main boom to 15°. • Extend telescopic section IV to 0% and telescopic section V to 50%. • Lower the main boom to 0° – do not lower to below 0°.

  • Page 272: Lubricating The Sheaves

    Have damaged, worn, stiff or extremely soiled sheaves replaced by or an authorised GROVE dealer or your repair crew. Manitowoc Crane Care M 12 8.7.4 Checking the locking system Risk of accidents if maintenance work is not carried out...

  • Page 273: Hoist Ropes

    Maintenance work on the superstructure 8.8 Hoist ropes Hoist ropes 8.8.1 Checking the winding Risk of accidents due to rotating 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 274: 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 79 Nm (58 lbf ft). and tools – Establish a rigging mode in accordance with the Lifting capacity table and Prerequisites à...

  • Page 275: 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 276: 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 inspec- tor. To assess the condition of the rope, you must be familiar with the following: –...
  • Page 277 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 278 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 279 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 280 Maintenance work on the superstructure 8.8 Hoist ropes Damage Description Cause Replacement Loop forma- Outer layer wires in General wear due to Immediately replace the rope if tion (1) the form of hair pins ageing of the rope or the rope structure has been are protruding from consequential dam- substantially altered by the...
  • Page 281 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 immedi- breaks. over the rope. ately if serious crushing has occurred.

  • Page 282: 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 part; Rope certificate . and tools – A reel stand with braking block. – Torque wrench for 79 Nm (58 lbf ft). Risk of accidents due to falling loads Use only a replacement rope that has the same technical specifications as the defective rope, or an authentic replacement rope.
  • Page 283 Maintenance work on the superstructure 8.8 Hoist ropes • Remove the clamp (4). • Push the rope through the hole (3) until the rope wedge (1) slides out of the pouch (2). • Remove the rope wedge and place the old rope away from the truck crane.
  • Page 284 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 pouch. •...

  • Page 285: Setting The Lowering Limit Switch

    Maintenance work on the superstructure 8.8 Hoist ropes Observe the hook block when unreeling. The hook block must not rotate. Risk of accidents from incorrectly set lowering limit switch 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 286 Maintenance work on the superstructure 8.8 Hoist ropes Setting the lower- ing limit switch Risk of accidents due to rope end fitting being 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 287: Cable Drums

    Maintenance work on the superstructure 8.9 Cable drums Cable drums 8.9.1 Maintenance of the slip ring assemblies The slip ring assemblies are located in: 1 Cable drum 1 2 Cable drum 2 Spare parts Designation Quantity GROVE part no. and tools Cover gasket for cable drum 1 03138891 Cover gasket for cable drum 2...
  • Page 288 Maintenance work on the superstructure 8.9 Cable drums 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 289: Central Lubrication System

    Maintenance work on the superstructure 8.10 Central lubrication system 8.10 Central lubrication system 8.10.1 Checking the filling level The maintenance of the pump (1) is similar to à Central the maintenance on the carrier; lubrication system , p. 7 - 109. Connected lubricating points –...
  • Page 290 Maintenance work on the superstructure 8.10 Central lubrication system Blank page 8 - 68 3 302 649 en Maintenance manual GMK4090...

  • Page 291: Hook Blocks

    Check the sheaves in the hook blocks for damage, wear, mobility and extreme soiling. Have damaged, worn, stiff or extremely soiled sheaves replaced by or an authorised GROVE dealer or your repair crew. Manitowoc Crane Care M 12 8.11.2 Lubricating hook blocks à...
  • Page 292 Maintenance work on the superstructure 8.11 Hook blocks The diagram gives an example of the arrange- ment of the grease nipples (1), (2) and (3) on a hook block. There are more grease nipples on the other side. • Clean the grease nipples on all hook blocks and grease them using a grease gun.
  • Page 293 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 author- Manitowoc Crane Care ised GROVE dealer or your qualified repair crew.
  • Page 294 Maintenance work on the superstructure 8.11 Hook blocks Blank page 8 - 72 3 302 649 en Maintenance manual GMK4090...

  • Page 295: Electrical System

    Risk of accidents in the event of faulty safety devices Have faulty lights and indicators repaired by or an Manitowoc Crane Care authorised GROVE dealer or an authorised specialist workshop. • Check the symbols and indicator lamps on the CCS (Crane Control System) à...

  • Page 296: Have The Battery On The Electronics Board Replaced

    Maintenance work on the superstructure 8.12 Electrical system Risk of accidents from exploding glass bodies and high voltage The glass bodies of gas discharge lamps (xenon lights) are pressurised. If the lamp breaks, the glass splinters explosively and shards scatter. Xenon lights operate at high voltage.

  • Page 297: Air Conditioning System

    Maintenance work on the superstructure 8.13 Air conditioning system 8.13 Air conditioning system 8.13.1 Checking the air conditioning system • Check the air-conditioning system in the same way as when checking it on à Checking the air conditioning system , p. 7 - 121. the carrier;...

  • Page 298: Checking Hoses

    • Check all refrigerant hoses for damage and areas of wear. Have damaged hoses checked by or an authorised Manitowoc Crane Care GROVE dealer or an authorised specialist workshop only. M 12 8.13.4 Checking the entire air conditioning system...
  • Page 299 Maintenance work on the superstructure 8.13 Air conditioning system Refrigerant Fill quantity Designation CAS no. in kg (lbs) EC no. 1,0 (2,2) 1-circuit (3 KW) 811-97-2 Tetrafluoroethane (R134a) 212-377-0 2 x 0.95 (2.1) 2-circuit (6 KW) Compressor oil: POE OIL; EMKARATE RL68H Filler connections The filler connections (1) for the refrigerant are on the compressor behind the cover (2).

  • Page 300: Changing The Pollen Filter

    Maintenance work on the superstructure 8.13 Air conditioning system M 12 8.13.5 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 301: Other Maintenance Work

    Maintenance work on the superstructure 8.14 Other maintenance work 8.14 Other maintenance work 8.14.1 Checking 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 302: Checking The Auxiliary Heater

    Maintenance work on the superstructure 8.14 Other maintenance work Wiping The wiping/washing system operation is described in the accompanying à Operating manual . operating instructions; • Spray water on the windscreen – press down on the switch. • Spray water on the skylight – press the top part of the switch. •...

  • Page 303: 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 3 302 649 en 8 - 81...

  • Page 304: Lubricating The Step

    Check whether the spring pin (5) is engaged in the step. If the step is stiff, bent or does not retract completely, have the step aligned and adjusted by or an authorised GROVE dealer. Manitowoc Crane Care 8 - 82 3 302 649 en Maintenance manual...

  • Page 305: 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 306: 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 307 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 308: 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 extin- guishers. The maintenance interval may even be shorter, depending on the respective national regulations and the operating location.

  • Page 309: 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 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 310 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 put out of service for more than 12 months: • Carry out all maintenance work in accordance with the maintenance plan M 12.

  • Page 311: Torques

    Torques 10.1 Torques for retaining bolts Torques 10.1 Torques for retaining bolts Metric screw thread Approximate values Metric fine thread Thread size Torques (maximum permissible (mm) pre-tensioning for bolts) for oiled bolts (Nm) Size across flats (mm) Bolt quality Hexagon Cylinder 10.9 12.9...
  • Page 312 Torques 10.2 Special torques 10.2 Special torques Thread size Spanner size Torque (Nm) (mm) (mm) Description Hexagon Cylinder head screw screw Suspension strut: – Bracket for the vehicle chassis, M 16 — – Bracket for the vehicle chassis, M 24 —...

  • Page 313: 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. Listed here are only the spare parts required for the maintenance work described.
  • Page 314 Spare parts required for maintenance 11.2 Lighting Installation point GROVE part Designation Output (W) number CARRIER LIGHTING: Front spotlights: (integrated in the bumper) – Daytime driving light (left) 04163680 – Daytime driving light (right) 04136679 – Low-beam + full-beam headlights 03134828 H7 24 V –...
  • Page 315 Spare parts required for maintenance 11.2 Lighting Installation point GROVE part Designation Output (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 316 Spare parts required for maintenance 11.2 Lighting Installation point GROVE part Designation Output (W) number SUPERSTRUCTURE LIGHTING: Marker lights, yellow: (left and right on the main boom head) – Marker light; complete 03329569 Red rear marker lights: (on the turntable) –...

  • Page 317: Spare Parts For The Carrier

    Spare parts required for maintenance 11.3 Spare parts for the carrier 11.3 Spare parts for the carrier Quantity, in single parts Assemblies and spare parts GROVE For maintenance interval Carrier Part number M 12 Engine Air filter – main filter 04158601 1 item when the symbol lights up Air filter –...
  • Page 318 Spare parts required for maintenance 11.3 Spare parts for the carrier Quantity, in single parts Assemblies and spare parts GROVE For maintenance interval Carrier Part number M 12 Wheels Wheel nuts for steel rims 01207756 In case of damage; 12 each per wheel Wheel nuts for aluminium rims 7659100000 Vehicle brake (per axle lines)
  • Page 319 Spare parts required for maintenance 11.3 Spare parts for the carrier Quantity, in single parts Assemblies and spare parts GROVE For maintenance interval Carrier Part number Y 10 Engine Oil filter with cover gasket 04163013 Original oil drain plug, complete 04161529 Transmission Filter...

  • Page 320: 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 Gasket 18 x 24 Cu DIN 7603 01377793 (if damaged) Gasket 18 x 24 Cu DIN 7603...
  • Page 321 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 Electrical system Lithium battery 3.6 V 03143172 Maintenance manual 3 302 649 en 11 - 9 GMK4090...
  • Page 322 Spare parts required for maintenance 11.4 Spare parts for the superstructure Blank page 11 - 10 3 302 649 en Maintenance manual GMK4090...

  • Page 323: Appendix

    Appendix...

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