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Manitowoc GROVE GMK7450 Maintenance Manual

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Maintenance manual
3 302 577 en
16.08.2018

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Summary of Contents for Manitowoc GROVE GMK7450

  • Page 1 Maintenance manual 3 302 577 en 16.08.2018...
  • 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 manual.
  • Page 4 Blank page 3 302 577 en Maintenance manual GMK7450...
  • Page 5 General instructions Using the maintenance manual ........1 - Warnings and symbols .
  • Page 6 3 302 577 en Maintenance manual GMK7450...

  • Page 7: 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, special- ist knowledge and that of proper safety procedures! Please read Chapters 1 and 2 carefully before beginning maintenance work.

  • Page 8: 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 9 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 10: Instructions Regarding The Electronic Controls

    Manitowoc Crane Care All welding work (especially on load carrying members) may only be per- formed by qualified expert personnel with the prior written permission from Manitowoc Crane Group Germany GmbH. 1 - 4 3 302 577 en Maintenance manual...

  • Page 11: Definition Of Direction References

    General instructions 1.6 Definition of direction references Definition of direction references 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 12: Conversion Table For Us Measuring Units

    General instructions 1.7 Conversion table for US measuring units Conversion table for US measuring units The following conversion factors will help you convert from metric to US units when the truck crane is used in countries that use US units of measurement and vice versa.
  • Page 13 Safety and environmental protection Safety rules ............2 - 2.1.1 Securing against unauthorised use .
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  • Page 15: 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 16 Safety and environmental protection 2.1 Safety rules • Perform maintenance work only after the truck crane has been shut down. Always ensure that the truck crane is well-protected from unauthorised operation before beginning maintenance work. Remove the key and put up warning signs.

  • Page 17: 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 18: 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 19 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 col- tion and storage lected separately from other waste. • Ask your local environmental protection authority about the different cat- egories of the substances.

  • Page 20: 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 21 Cleaning Overview of assemblies easily damaged when cleaning ....3 - Maintenance manual 3 302 577 en GMK7450...
  • Page 22 3 302 577 en Maintenance manual GMK7450...

  • Page 23: Cleaning

    Cleaning Cleaning During the first The paintwork on the truck crane will continue to harden for the first 3 months three months. • During this period the crane may be cleaned only with cold water. • Do not use high-pressure or steam jet cleaning equipment during this period.
  • Page 24 Cleaning 3.1 Overview of assemblies easily damaged when cleaning Overview of assemblies easily damaged when cleaning 3 - 2 3 302 577 en Maintenance manual GMK7450...
  • Page 25 Cleaning 3.1 Overview of assemblies easily damaged when cleaning 1 Air-conditioning system in the driver's cab 2 Connection for the hand-held control 3 Derricking-cylinder pressure sensor, left 4 Suspension struts 5 Control units for outriggers 6 Spotlights, pivoting 7 Lowering limit switch 8 Control unit at connection 1 9 Derricking-cylinder pressure sensor, right 10 Angle sensor switch box...
  • Page 26 Cleaning 3.1 Overview of assemblies easily damaged when cleaning Blank page 3 - 4 3 302 577 en Maintenance manual GMK7450...
  • Page 27 Run-in regulations Maintenance manual 3 302 577 en GMK7450...
  • Page 28 3 302 577 en Maintenance manual GMK7450...

  • Page 29: Run-In Regulations

    Run-in regulations Run-in regulations There are regulations about running in individual parts which must be fol- lowed, 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 30 Run-in regulations Operating hours (oper. hrs.) Additional maintenance work on the SUPERSTRUCTURE after 50 Tighten the clips on the coolant hoses; à Special torques , P. 10 - 2. during the first 100 Check the hydraulic oil filter every week, and change it if necessary;...
  • Page 31 Maintenance overview Maintenance intervals..........5 - Maintenance plans .
  • Page 32 3 302 577 en Maintenance manual GMK7450...

  • Page 33: 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 34 Maintenance overview 5.1 Maintenance intervals The maintenance interval that occurs first determines when the next main- tenance is due. – The driven km (or mi) can be taken from the speedometer. – You can call up the individual engine and power unit operating hours (oper.
  • Page 35 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 36 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 - 11 à – Checking the air filter P. 7 - 14 à –...
  • Page 37 Maintenance overview 5.2 Maintenance plans Maintenance work on the SUPERSTRUCTURE: Daily/before putting into operation Engine à – Check the oil level P. 8 - 13 à – Checking the air filter P. 8 - 16 à – Checking the coolant level P.
  • Page 38 Maintenance overview 5.2 Maintenance plans 5.2.2 Maintenance plan W Maintenance work on the CARRIER: Weekly Engine à – General inspection P. 7 - 16 Transmission à – General inspection P. 7 - 47 Transfer case à – General inspection P. 7 - 51 Axle lines à...
  • Page 39 Maintenance overview 5.2 Maintenance plans Maintenance work on the SUPERSTRUCTURE: Weekly Engine à – General inspection P. 8 - 18 Hoists à – Checking the oil level P. 8 - 43 à – General inspection P. 8 - 44 à –...
  • Page 40 Maintenance overview 5.2 Maintenance plans 5.2.3 Maintenance plan M 1 Maintenance work on the CARRIER: monthly / after approx. 2,000 km (approx. 1 240 mi) Engine à à Engine manufacturer’s documentation – Notes; P. 7 - 11 Exhaust system with exhaust emission control à...
  • Page 41 Maintenance overview 5.2 Maintenance plans Maintenance work on the SUPERSTRUCTURE: Monthly/after approx. 100 operating hours Engine à à Engine manufacturer’s documentation – Notes; P. 8 - 13 Exhaust system with exhaust emission control à – Check the exhaust system for external damage P.
  • Page 42 Maintenance overview 5.2 Maintenance plans 5.2.4 Maintenance plan M 3 Maintenance work on the CARRIER: every three months/after 5,000 - 6,000 km (3 100 - 3 730 mi) Engine à à Engine manufacturer’s documentation – Notes; P. 7 - 11 Vehicle brake à...
  • Page 43 Maintenance overview 5.2 Maintenance plans Maintenance work on the SUPERSTRUCTURE: every three months/after 250 oper. hrs. Engine à à Engine manufacturer’s documentation – Notes; P. 8 - 13 Slewing bearing à – Checking the screws P. 8 - 55 Hydraulic system à...
  • Page 44 Maintenance overview 5.2 Maintenance plans 5.2.5 Maintenance plan M 6 Maintenance work on the CARRIER: every six months / after 10,000 - 12,500 km (6 210 - 7 770 mi) Engine à à Engine manufacturer’s documentation – Notes; P. 7 - 11 à...
  • Page 45 Maintenance overview 5.2 Maintenance plans Maintenance work on the SUPERSTRUCTURE: every six months/after 500 oper. hrs. Engine à à Engine manufacturer’s documentation – Notes; P. 8 - 13 à – Changing the oil and the oil filter P. 8 - 19 Fuel system à...
  • Page 46 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.
  • Page 47 Maintenance overview 5.2 Maintenance plans M 12 Maintenance work on the SUPERSTRUCTURE: every 12 months/after 1,000 operating hours Engine à à Engine manufacturer’s documentation – Notes; P. 8 - 13 à – Have the radiator checked/cleaned P. 8 - 21 à...
  • Page 48 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.
  • Page 49 P. 7 - 11 – 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. Engine à...
  • Page 50 120 months/after 200, 000 km (124 000 mi) Steel construction – Check the load-bearing steel fabrication. For further information, please contact Manitowoc Crane Care Maintenance work on the SUPERSTRUCTURE: every 120 months/after 12,000 oper. hrs. Steel construction – Check the load-bearing steel fabrication. For further information, please...
  • Page 51 Maintenance overview 5.3 Periodic inspections Periodic inspections Your GMK7450 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 DGUV Regulation 52 (BGV D 6) . –...
  • Page 52 Maintenance overview 5.3 Periodic inspections 5.3.1 Load hook inspection The hook opening on the load hooks must be checked regularly for defor- mation. 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 field (2) on the load hooks.
  • Page 53 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 - 48. These measures for monitoring the winches (hoists) were compiled by the German Machine Builders' Association (VDMA) and are to be used for all truck cranes according to the German Accident Prevention Regulations for Winches, Hoists and Tractor Machines, DGUV Regulation 52 (BGV D 6) and...
  • Page 54 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 55 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 56 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 57 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 58 5.4 Measures required for winch monitoring 5.4.3 Example A GMK7450 is equipped with a separate operating hours counter for the hoist and is classified by Manitowoc Crane Group Germany GmbH as fol- lows: Power unit group: Load spectrum: light L1, Km = 0.125...
  • Page 59 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 1920 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.
  • Page 60 Maintenance overview 5.4 Measures required for winch monitoring 5 - 28 3 302 577 en Maintenance manual GMK7450...
  • Page 61 Lubricants and consumables Lubricants............6 - 6.1.1 Lubricants list .
  • Page 62 3 302 577 en Maintenance manual GMK7450...

  • Page 63: 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 applica- tions list.

  • Page 64: Lubricants List

    Lubricants and consumables 6.1 Lubricants 6.1.1 Lubricants list Consec. GROVE- Lubricant Designation to Specification Viscosity Part number type DIN 51502 classification CES 20081 04162428 Engine oil HD - CD SAE 15 W-40 Cummins TranSynd TE295 6829101690 Gear oil synthetic C4-27403598 MIL-L 2105 B Hyp SAE 90 00552891...

  • Page 65: Lubricant Applications List

    Lubricants and consumables 6.1 Lubricants 6.1.2 Lubricant applications list Consec. Lubricant Usage Fill quan- Mainte- type tity nance in litres interval (gal) à Diesel engine for carrier; P. 7 - 17 53 (14.0) Engine oil à Diesel engine for superstructure; P.
  • Page 66 Lubricants and consumables 6.1 Lubricants Consec. Lubricant Usage Fill quan- Mainte- type tity nance in litres interval (gal) à Carrier central lubrication; P. 7 - 103 à Superstructure central lubrication; P. 8 - 113 à Cardan shafts – transverse; P. 7 - 62 à...

  • Page 67: Refrigerant

    Lubricants and consumables 6.2 Refrigerant Refrigerant Refrigerant Usage Fill quantity Mainte- Designation in kg (lbs) nance interval Air-conditioning system in the driver's cab; à Tetrafluoroethane (R134a) 1.25 (2.75) M 12 P. 7 - 114 CAS no. 811-97-2 Air-conditioning system in the crane cab; EC no.

  • Page 68: 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) AdBlue tank on the carrier; à 56.8 (15) DEF (Diesel Exhaust Fluid) P. 7 - 36 AdBlue: AdBlue tank on the superstructure; GROVE part number: 03140555 à...
  • Page 69 Maintenance work on the carrier General instructions ..........7 - 7.1.1 Covers .
  • Page 70 7.9.2 Checking the tyre pressure ......... 7 - 66 7.9.3 Checking that the wheel nuts are tight .
  • Page 71 7.18.5 Lubricating the connecting and socket pins ......7 - 122 7.18.6 Renewing the corrosion protection ........7 - 123 7.18.7 Having the fire extinguisher checked .
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  • Page 73: Maintenance Work On The Carrier

    Maintenance work on the carrier 7.1 General instructions Maintenance work on the carrier General instructions 7.1.1 Covers Various types of work (e.g. oil change) require that covers be removed. Before maintenance work • Remove the covers (1). After maintenance work •...

  • Page 74: Overview Of Maintenance Work On The Carrier

    Maintenance work on the carrier 7.1 General instructions 7.1.2 Overview of maintenance work on the carrier 7 - 2 3 302 577 en Maintenance manual GMK7450...
  • Page 75 Maintenance work on the carrier 7.1 General instructions à Symbols for maintenance work P. 7 - 9 à 1 Instrument panel P. 7 - 9 à Engine P. 7 - 11 à 6 Diesel engine P. 7 - 11 à 18 Covers P.
  • Page 76 Maintenance work on the carrier 7.1 General instructions 7 - 4 3 302 577 en Maintenance manual GMK7450...
  • Page 77 Maintenance work on the carrier 7.1 General instructions à Wheels P. 7 - 65 à 3 Wheels P. 7 - 65 2 Removable Outrigger Box (ROB) à Vehicle brake P. 7 - 73 à 5 Brake linings P. 7 - 73 à...
  • Page 78 Maintenance work on the carrier 7.1 General instructions 7 - 6 3 302 577 en Maintenance manual GMK7450...
  • Page 79 Maintenance work on the carrier 7.1 General instructions à Electrical system P. 7 - 107 à 8 Carrier lighting P. 7 - 107 à 4 Battery box P. 7 - 108 à Air-conditioning system P. 7 - 113 à 2 Air-conditioning system in the driver's cab P.
  • Page 80 Maintenance work on the carrier 7.1 General instructions Blank page 7 - 8 3 302 577 en Maintenance manual GMK7450...

  • Page 81: Symbols For Maintenance Work

    Maintenance work on the carrier 7.2 Symbols for maintenance work Symbols for maintenance work Check the following lamps daily before starting operations. On the instrument If one of the lamps on the instrument panel in the driver's cab is lit you must panel carry out the corresponding maintenance work: à...
  • Page 82 Maintenance work on the carrier 7.2 Symbols for maintenance work Blank page 7 - 10 3 302 577 en Maintenance manual GMK7450...

  • Page 83: Engine

    Maintenance work on the carrier 7.3 Engine Engine • In addition, carry out further maintenance work specified in the Engine manufacturer’s documentation supplied. 7.3.1 Check the oil level Prerequisites – The truck crane must be level. Check the oil level •...
  • Page 84 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 85: 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 specifications; Engine manufacturer’s documen- tation . Engine oil Designation Specifications GROVE part no. in litres (gal) to DIN 51502 Classification 53 (14.0) HD - CD CES 20081 SAE 15 W-40...

  • Page 86: Checking The Air Filter

    Maintenance work on the carrier 7.3 Engine 7.3.3 Checking the air filter You must change the air filter if the lamp lights up. • Also check the visual pressure indicator (1) directly on the air filter. If the visual pressure indicator is in the red area (2) (CHANGE), then the air filter is clogged (100%).

  • Page 87: 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 3 302 577 en...

  • Page 88: General Inspection

    • Check that pipes and hoses are tightly connected and undamaged. If any damage is found, report it to or an authorised Manitowoc Crane Care GROVE dealer or an authorised specialist workshop. 7 - 16 3 302 577 en Maintenance manual...

  • Page 89: Changing The Oil And Oil Filter

    Maintenance work on the carrier 7.3 Engine 7.3.6 Changing the oil and oil filter Oil, spare parts, Engine oil Designation Specifications GROVE part no. tools in litres (gal) to DIN 51502 Classification 53 (14.0) HD - CD CES 20081 SAE 15 W-40 Cummins 04162428 Designation...
  • Page 90 Maintenance work on the carrier 7.3 Engine Oil filter • Place a receptacle underneath the engine. • Unscrew the filter (1). • Apply a light film of oil to the seal of the new filter (1) and firmly screw it in by hand. •...

  • Page 91: Have The Radiator Checked/Cleaned

    Maintenance work on the carrier 7.3 Engine M 12 7.3.7 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 92 Maintenance work on the carrier 7.3 Engine The radiator units are protected by grilles (3) and plates. The fan wheels (4) are located under the grilles. When the engine is running, the fan impellers rotate behind the grilles! Risk of injury due to the fan impellers! When the fan impellers are rotating they can trap the fingers of your hand and amputate them.
  • Page 93 Maintenance work on the carrier 7.3 Engine Have them cleaned Risk of injury due to the fan impellers! When the fan impellers are rotating they can trap the fingers of your hand and amputate them. Never reach into the fan impellers when they are rotat- ing.
  • Page 94 Maintenance work on the carrier 7.3 Engine • Have the radiator units (1) and (2) opened up by the repair specialists, so that the radiator fins are accessible. • Have the radiator fins cleaned on both sides, using suitable cleaning agents.

  • Page 95: Changing The Coolant

    Maintenance work on the carrier 7.3 Engine M 12 7.3.8 Changing the coolant à Tools – Receptacle, approx. 50 l (13.5 gal); P. 2 - 4. à Engine manufacturer’s documentation . – Antifreeze 50 l (13.5 gal); Prerequisites – Information on the coolant and admixture ratio has been obtained; à...
  • Page 96 Maintenance work on the carrier 7.3 Engine Topping up when the engine is cold • Slowly top up the expansion tank (1) with coolant until it is filled up to the lower edge in the filler neck. • Wait about 1 minute. Add more coolant if necessary.

  • Page 97: Changing The Coolant Cartridge

    Maintenance work on the carrier 7.3 Engine M 12 7.3.9 Changing the coolant cartridge Spare parts and Designation Quantity GROVE part no. tools Coolant cartridge 04241506 Prerequisites – The truck crane must be level. – The engine must not be running and must be secured against unauthor- à...
  • Page 98 Maintenance work on the carrier 7.3 Engine Blank page 7 - 26 3 302 577 en Maintenance manual GMK7450...

  • Page 99: Fuel System

    Maintenance work on the carrier 7.4 Fuel system Fuel system The following elements are installed in the carrier fuel system: 1 Fuel tank 2 Fuel filter 1 3 Valve in the supply line; for shutting off the supply 4 Fuel filter 2 5 3-way valve in the return line;...

  • Page 100: Checking Fuel Filter 1

    Maintenance work on the carrier 7.4 Fuel system 7.4.1 Checking fuel filter 1 à Prerequisites – The truck crane must be level; Operating manual . – The engine must not be running and must be secured against unauthor- à ised use; P.

  • Page 101: Draining Off Water From Fuel Filter 1

    Maintenance work on the carrier 7.4 Fuel system 7.4.2 Draining off water from fuel filter 1 à Spare parts and – Receptacle, approx. 5 l (1.5 gal); P. 2 - 4. tools à Operating manual . Prerequisites – The truck crane must be level; –...

  • Page 102: Replacing Fuel Filter 1

    Maintenance work on the carrier 7.4 Fuel system 7.4.3 Replacing fuel filter 1 Interval The engine manufacturer specifies a interval of 500 oper. hrs. (M 6) for à Engine manufacturer’s documentation . changing the fuel filter; • Change the filter at the very latest when soiling degree (D) is reached; à...
  • Page 103 Maintenance work on the carrier 7.4 Fuel system • Release the pin (1) using the special wrench (2). • Remove the ring (1) upwards and off. • Remove the cap (4). • Remove the old filter (5) and place it in the receptacle.

  • Page 104: Replacing Fuel Filter 2

    Maintenance work on the carrier 7.4 Fuel system 7.4.4 Replacing fuel filter 2 Spare parts and Designation Quantity GROVE part no. tools Filter 04241343 à – Receptacle, approx. 5 l (1.5 gal); P. 2 - 4. – Strap wrench. à Operating manual .
  • Page 105 Maintenance work on the carrier 7.4 Fuel system Changing the filter • Place a receptacle under the filter (1). • Remove the filter (1). • Fill a new filter (1) with clean consumable and screw it up (lightly grease the gasket). •...
  • Page 106 Maintenance work on the carrier 7.4 Fuel system Blank page 7 - 34 3 302 577 en Maintenance manual GMK7450...

  • Page 107: Exhaust System With Exhaust Emission Control

    Maintenance work on the carrier 7.5 Exhaust system with exhaust emission control Exhaust system with exhaust emission control Overview In order to adhere to the exhaust emission regulations, you are only permit- ted to drive the crane with the multi-stage exhaust system consisting of DOC catalytic converter, DPF particle filter, SCR catalytic converter (DOC = Diesel Oxidation Catalyst, DPF = Diesel Particulate Filter, SCR = Selective Catalytic Reduction).

  • Page 108: Checking The Adblue Tank Level

    Maintenance work on the carrier 7.5 Exhaust system with exhaust emission control 7.5.1 Checking the AdBlue tank level Checking The warning lamp for checking the DEF system and a gauge for checking the tank DEF level are located on the instrument panel in the driver's cab. The tank has a maximum filling volume of approx.

  • Page 109: Check The Exhaust System For External Damage

    Maintenance work on the carrier 7.5 Exhaust system with exhaust emission control • Refuelling Find out about filling up 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 110 • 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 - 38 3 302 577 en Maintenance manual GMK7450...

  • Page 111: Having The Adblue System Checked

    7.5.4 Having the AdBlue system checked This inspection may only be performed by or an Manitowoc Crane Care authorised GROVE dealer or an authorised specialist workshop! • Have the entire AdBlue system checked for leaks and correct operation; Overview , p. 7 - 35.

  • Page 112: 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 113 100,000 km (62,000 mi), or 5,000 operating hours (5,000 oper. hrs.). • Service partner Have the particulate filter cleaned 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;...
  • Page 114 Have a back pressure test performed to check if the exhaust system is gas- tight. 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 3 302 577 en Maintenance manual GMK7450...

  • Page 115: Transmission

    Maintenance work on the carrier 7.6 Transmission Transmission 7.6.1 Check the oil level • Check the warning lamp (1) on the instrument panel in the driver's cab on a daily basis. • Switch on the ignition. – The warning lamp (1) lights up briefly and then goes out. –...
  • Page 116 Maintenance work on the carrier 7.6 Transmission Prior to starting the engine Risk of damage to the transmission! The engine must not be started without the gear oil level having been checked beforehand. This prevents damage to the transmission being caused by undetected loss of oil.
  • Page 117 Maintenance work on the carrier 7.6 Transmission • When the gear oil Heat up the gear oil to a temperature range between 75 and 95 °C (160 to à Warming up the gear oil , P. 7 - 45. is warm 200 °F);...
  • Page 118 Maintenance work on the carrier 7.6 Transmission Speeding up the warming up procedure • Allow the engine to run at idling speed in neutral position N. • Fully press the service brake pedal, even if the parking brake is applied. Risk of damage to the transmission when speeding up the warming up procedure! When the wheels are locked, the full engine output may only be applied in...

  • Page 119: General Inspection

    • Check that pipes and hoses are tightly connected and undamaged. If any damage is found, report it to or an authorised Manitowoc Crane Care GROVE dealer or an authorised specialist workshop. 7.6.3 Changing the oil and oil filter Oil, spare parts...
  • Page 120 Maintenance work on the carrier 7.6 Transmission Changing Risk of scalding from gear oil at operating temperature! You could scald yourself by gear oil escaping in an uncontrolled manner at operating temperature. Wear appropriate protective gloves and take care not to come into contact with the gear oil. Risk of environmental damage due to leaking consumables! Always let consumables drain into suitable receptacles.
  • Page 121 Maintenance work on the carrier 7.6 Transmission Topping up the oil • Top up the oil via the dipstick tube (2). • Wait so that the oil is evenly distributed in the transmission. • Use the dipstick (1) to check whether the oil level is clearly above the mark (3), otherwise the engine may not be started.
  • Page 122 Maintenance work on the carrier 7.6 Transmission Blank page 7 - 50 3 302 577 en Maintenance manual GMK7450...

  • Page 123: 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 and...

  • Page 124: Changing The Oil

    Maintenance work on the carrier 7.7 Transfer case Checking the oil level • Remove the drain plug (1). • Check that the oil reaches the lower edge of the opening (1). • Fit a new gasket and tighten the screw (1). If the oil level is too low à...
  • Page 125 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 126 Maintenance work on the carrier 7.7 Transfer case Blank page 7 - 54 3 302 577 en Maintenance manual GMK7450...

  • Page 127: Axle Lines

    Check that pipes and hoses are tightly connected and undamaged. If any damage is found, report it to or an authorised Manitowoc Crane Care GROVE dealer or an authorised specialist workshop. 7.8.2 Axle centre drives – checking the oil level...
  • Page 128 Maintenance work on the carrier 7.8 Axle lines 1st and 5th axle line • Remove the drain plug (1). • Check that the oil reaches the lower edge of the openings. • Fit new gaskets and tighten the screws. If the oil level is too low à...

  • Page 129: Axle Centre Drives - Changing The Oil

    Maintenance work on the carrier 7.8 Axle lines M 12 7.8.3 Axle centre drives – changing the oil Oil, spare parts, Gear oil Designation Specifications GROVE part no. tools in litres (gal) to DIN 51502 Classification Axle line 1+5: C - LPF MIL-L 2105 B 00552891 13.0 (3.5) each...
  • Page 130 Maintenance work on the carrier 7.8 Axle lines 1st and 5th axle line • Place a receptacle under the screw (2). • Unscrew drain plugs (1) and (2) and allow the oil to drain. • Fit a new gasket and tighten the screw (2). •...

  • Page 131: Final Drives - Checking The Oil Level

    Maintenance work on the carrier 7.8 Axle lines 7.8.4 Final drives – Checking the oil level Spare parts and For drive Designation Quan- GROVE part no. tools tity 14 x 6 x 14 Gasket 24 x 29 Cu DIN 7603 00117145 14 x 8 x 14 Gasket 24 x 29 Cu DIN 7603...

  • Page 132: Final Drives - Changing The Oil

    Maintenance work on the carrier 7.8 Axle lines M 12 7.8.5 Final drives – Changing the oil Oil, spare parts, Gear oil Designation Specifications GROVE part no. tools in litres (gal) to DIN 51502 Classification for each final C - LPF MIL-L 2105 B 00552891 drive:...
  • Page 133 Maintenance work on the carrier 7.8 Axle lines Draining oil • Change the oil on all final drives in the same way. • Turn the wheel until the bolt (1) is at the bot- tom. • Use a drain channel and place a receptacle under the screw.

  • Page 134: Lubricating The Drive Shafts In The Axle Lines

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

    Maintenance work on the carrier 7.8 Axle lines 7.8.7 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 Specifications...
  • Page 136 Maintenance work on the carrier 7.8 Axle lines Blank page 7 - 64 3 302 577 en Maintenance manual GMK7450...

  • Page 137: Wheels

    Maintenance work on the carrier 7.9 Wheels Wheels 7.9.1 Checking the tyres for damage Prerequisites – The truck crane is raised on outriggers. – The engine must not be running and must be secured against unauthor- à ised use; P. 2 - 3. –...

  • Page 138: Checking The Tyre Pressure

    Maintenance work on the carrier 7.9 Wheels 7.9.2 Checking the tyre pressure Risk of damage to the tyres! The 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 139: Checking That The Wheel Nuts Are Tight

    Maintenance work on the carrier 7.9 Wheels 7.9.3 Checking that the wheel nuts are tight Spare parts and Designation Quantity GROVE part no. tools per wheel Wheel nut with pressure plate 01207756 for steel rims Wheel nut with pressure plate 7659100000 for aluminium rims –...

  • Page 140: Changing The Wheels

    Maintenance work on the carrier 7.9 Wheels 7.9.4 Changing the wheels The wear on tyres varies depending on whether the axle – is driven/not driven, – is steered/not steered, – is braked/not braked, – and whether it is subject to more or less load. To achieve even wear, you must swap the wheels to different positions reg- ularly.
  • Page 141 Maintenance work on the carrier 7.9 Wheels Recognising two- piece aluminium rims The round-head bolts (1) are on the outer face of the 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 142 Maintenance work on the carrier 7.9 Wheels • Mount the wheels on another axle, as shown in the diagram. Replace any à damaged parts. Tighten the wheel nuts; P. 7 - 67. 7 - 70 3 302 577 en Maintenance manual GMK7450...
  • Page 143 Maintenance work on the carrier 7.9 Wheels Optimised wheel To ensure even more even wear on all tyres, you can also rotate the tyres changes on the wheel rim and mount them on the other side of the vehicle. Risk of accidents if the procedure is not carried out correctly! This section only shows the sequence to be followed when changing wheels.
  • Page 144 Maintenance work on the carrier 7.9 Wheels Blank page 7 - 72 3 302 577 en Maintenance manual GMK7450...

  • Page 145: Vehicle Brake

    Maintenance work on the carrier 7.10 Vehicle brake 7.10 Vehicle brake 7.10.1 Checking brake lining thickness Spare parts and Designation Quantity GROVE part no. tools per axle line 1st and 2nd axle line (duplex brake) Brake shoe with brake lining 03322112 Spring 03322110...
  • Page 146 Incorrect work invalidates the operating approval of the truck crane and no claims of liability for damage can then be accepted. All repair work on the vehicle brakes may only be performed by Manitowoc or an authorised GROVE dealer or an authorised specialist work- Crane Care shop with specially trained repair crew.
  • Page 147 P. 7 - 74. • 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 148 Maintenance work on the carrier 7.10 Vehicle brake Blank page 7 - 76 3 302 577 en Maintenance manual GMK7450...

  • Page 149: 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 150: Suspension Struts - Checking The Fastening

    Maintenance work on the carrier 7.11 Suspension • Check whether oil is visible in the middle of the inspection glass (1) on each suspension strut. If the oil level is too low • Open the connection (2) – oil escapes – and quickly connect the press with the hose.

  • Page 151: 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 152: Pressure Accumulator - Checking The Gas Pressure

    The filling pressure at 20 °C (68 °F) is 40 bar (580 psi). • Have the filling pressure checked, and if nec- essary corrected, by Manitowoc Crane Care an authorised GROVE dealer or an author- ised specialist workshop. 7 - 80 3 302 577 en...

  • Page 153: Steering

    Bleeding the hydraulic system , P. 7 - 100. 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 3 302 577 en 7 - 81 GMK7450...
  • Page 154 Maintenance work on the carrier 7.12 Steering Blank page 7 - 82 3 302 577 en Maintenance manual GMK7450...

  • Page 155: Compressed Air System

    (7). If a great deal of water escapes • Have the compressed air drier checked or replaced by or an Manitowoc Crane Care authorised GROVE dealer or your qualified repair crew. Maintenance manual 3 302 577 en 7 - 83...

  • Page 156: 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 - 84 3 302 577 en Maintenance manual...

  • Page 157: Replacing The Filter Cartridge Of The Compressed Air Drier

    Maintenance work on the carrier 7.13 Compressed air system 7.13.3 Replacing the filter cartridge of the M 12 compressed air drier Spare parts and Designation Quantity GROVE part no. tools Filter cartridge 04156032 – Strap wrench. Prerequisites – The truck crane must be raised on outriggers or parked over an inspection pit.
  • Page 158 Maintenance work on the carrier 7.13 Compressed air system Blank page 7 - 86 3 302 577 en Maintenance manual GMK7450...

  • Page 159: Hydraulic System

    Maintenance work on the carrier 7.14 Hydraulic system 7.14 Hydraulic system Risk of environmental damage due to leaking consumables! Always let consumables drain into suitable receptacles. Wipe up any con- sumables that escape. Store/dispose of consumables and any soaked equipment properly. Ask about the applicable regulations.

  • Page 160: Checking The Hydraulic Hoses

    Maintenance work on the carrier 7.14 Hydraulic system 7.14.2 Checking the hydraulic hoses Hydraulic hoses are also subject to ageing as well as internal and external strain. • Check the hydraulic hoses for – external damage (tears, abrasion, heat damage, chemical damage), –...

  • Page 161: Cleaning The Magnetic Rods

    Bleed the carrier's hydraulic system; P. 7 - 100. If damage cannot be rectified immediately or further damage is likely • Notify or an authorised GROVE dealer or your repair Manitowoc Crane Care crew. 7.14.4 Cleaning the magnetic rods Spare parts and Designation Quantity GROVE part no.
  • Page 162 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 repair crew. • Assemble the filters and install them.

  • Page 163: Changing The Ventilation Filter

    Maintenance work on the carrier 7.14 Hydraulic system M 12 7.14.5 Changing the ventilation filter • Reducing the Under difficult operating conditions – at extremely sandy or dusty loca- interval tions – you must change the ventilation filters earlier than normal. Spare parts and Designation Quantity...

  • Page 164: Taking Oil Samples

    Maintenance work on the carrier 7.14 Hydraulic system M 12 7.14.6 Taking oil samples • Reducing the Under difficult operating conditions – at tropical or very hot locations – interval you must halve the oil change interval. Spare parts and –...
  • Page 165 Maintenance work on the carrier 7.14 Hydraulic system Protecting the hose from dirt Danger of contamination of the oil sample! If the hose with the connecting piece is dirty, the dirt can contaminate the oil sample in the sample container during the sampling process. The labo- ratory analysis would then be incorrect.
  • Page 166 Maintenance work on the carrier 7.14 Hydraulic system Taking oil samples The hose end (1) is connected to the gauge port (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 167 Maintenance work on the carrier 7.14 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 oratory bag are available along with the sample containers (GROVE part no.
  • Page 168 Maintenance work on the carrier 7.14 Hydraulic system Blank page 7 - 96 3 302 577 en Maintenance manual GMK7450...

  • Page 169: Changing The Hydraulic Oil

    Maintenance work on the carrier 7.14 Hydraulic system 7.14.7 Changing the hydraulic oil The oil only needs to be changed if the laboratory analysis indicates the à Determining the quality of the oil , P. 7 - 95. need for it; Oil, spare parts, Hydraulic oil Designation...
  • Page 170 Maintenance work on the carrier 7.14 Hydraulic system Handling the The valves can only be opened and closed using the connecting piece and valves hose. The connecting piece is available in the toolbox. Risk of environmental damage due to leaking consumables! Use the supplied connecting piece and hose and a receptacle with sufficient capacity to drain the hydraulic oil.
  • Page 171 Maintenance work on the carrier 7.14 Hydraulic system Topping up the oil Risk of damage to the hydraulic system! Cleanliness is of the utmost importance when handling hydraulic oil. Even fresh hydraulic oil must be filtered before it is added to the tank. •...
  • Page 172 If the steering system is still not operating properly • Notify or an author- Manitowoc Crane Care ised GROVE dealer or an authorised special- ist workshop. 7 - 100 3 302 577 en Maintenance manual GMK7450...

  • Page 173: Changing The Hydraulic Oil Filter

    Maintenance work on the carrier 7.14 Hydraulic system 7.14.8 Changing the hydraulic oil filter The hydraulic oil filters must be replaced when changing the oil. If the warning lamp (1) lights up, change the hydraulic oil filter. Spare parts and Designation Quantity GROVE part no.
  • Page 174 Large amounts of metal particles are a sign of damage in the hydraulic sys- tem. Have the hydraulic system checked by or an author- Manitowoc Crane Care ised GROVE dealer or your repair crew. • Assemble the filters and install them.

  • Page 175: Central Lubrication System

    Maintenance work on the carrier 7.15 Central lubrication system 7.15 Central lubrication system The central lubrication system supplies the steering lever on the first, sec- ond and third axle lines. 7.15.1 Checking the filling level Grease, spare Lubricating Designation Specifications GROVE part no.
  • Page 176 Maintenance work on the carrier 7.15 Central lubrication system Topping up Risk of damage to the central lubrication system! Cleanliness is of the utmost importance when handling grease and filling pumps. Do not remove the caps from the opening and filling pump until immedi- ately before refilling the grease.

  • Page 177: Bleeding The Central Lubrication System

    Maintenance work on the carrier 7.15 Central lubrication system 7.15.2 Bleeding the central lubrication system If the grease container is empty or contains bubbles, you must bleed the central lubrication system. The grease container (3) must be full. • Undo the connection (4). •...
  • Page 178 Maintenance work on the carrier 7.15 Central lubrication system Blank page 7 - 106 3 302 577 en Maintenance manual GMK7450...

  • 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 operating or driving the truck crane, and have faulty parts repaired: –...

  • Page 180: Checking The Batteries

    Maintenance work on the carrier 7.16 Electrical system 7.16.2 Checking the batteries Risk of poisoning from batteries containing lead! Battery poles, terminals and parts inside the battery contain lead. Residue containing lead can stick to your hands and may not be allowed to enter your body –...
  • Page 181 Maintenance work on the carrier 7.16 Electrical system Checking the connecting terminals • Keep the batteries clean and dry. • 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 7.16 Electrical system 7.16.3 Checking the charge level of the batteries à Spare parts and – Battery testing device; Separate operating manual , or tools – Acid siphon. Charge level table The measurement of the acid concentration with the acid siphon will give you an indication of the charge level of the batteries.
  • Page 183 Maintenance work on the carrier 7.16 Electrical system Before checking • Switch the battery master switch (1) off and remove the selector handle. • Open the cover (2) on the battery box. Checking the acid concentration Batteries without covers (1) are maintenance- free.

  • Page 184: Charging The Batteries Using The Battery Charger

    Maintenance work on the carrier 7.16 Electrical system 7.16.4 Charging the batteries using the battery charger Prerequisites – The engine must 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: Air-Conditioning System

    Do not start it up again to avoid further damage. • Have the air-conditioning system repaired as soon as possible by Manitowoc Crane Care or an authorised GROVE dealer or an authorised specialist workshop. 7.17.2 Checking hoses Risk of burns due to escaping refrigerant! Wear suitable safety glasses and gloves when checking the hoses and con- nections.

  • Page 186: 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 con- nections.
  • Page 187 Maintenance work on the carrier 7.17 Air-conditioning system Refrigerant Fill quantity Designation CAS no. in kg (lbs) EC no. 1.25 (2.75) Tetrafluoroethane (R134a) 811-97-2 212-377-0 Filler connections The filler connections (1) for the refrigerant are located on the roof of the driver's cab. Maintenance manual 3 302 577 en 7 - 115...

  • Page 188: Changing The Pollen Filter

    Maintenance work on the carrier 7.17 Air-conditioning system M 12 7.17.5 Changing the pollen filter • Reducing the Under difficult operating conditions – at extremely sandy or dusty loca- interval tions – you must change the pollen filter earlier than usual. Spare parts and Designation Quantity...
  • Page 189 Maintenance work on the carrier 7.17 Air-conditioning system Heating system • Remove the frame (1). • Remove the filter (2) from the housing and clean the housing with a cloth. • Insert a new filter. • Fasten the frame (1). Maintenance manual 3 302 577 en 7 - 117...
  • Page 190 Maintenance work on the carrier 7.17 Air-conditioning system Blank page 7 - 118 3 302 577 en Maintenance manual GMK7450...

  • Page 191: 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 192: Lubricating The Outrigger Beams

    Maintenance work on the carrier 7.18 Other maintenance work 7.18.2 Lubricating the outrigger beams à • Also adhere to the Run-in regulations , P. 4 - 1. Grease, spare Lubricating Designation Specifications GROVE part no. parts, tools grease to DIN 51502 Classification Grease KP - 1K - 50...

  • Page 193: Checking The Functioning Of The Auxiliary Heater

    Remove any grease that has escaped. • 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 3 302 577 en 7 - 121...
  • Page 194 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 195 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 196 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 197 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 operating location.
  • Page 198 Maintenance work on the carrier 7.18 Other maintenance work Blank page 7 - 126 3 302 577 en Maintenance manual GMK7450...
  • Page 199 Maintenance work on the superstructure General instructions ..........8 - 8.1.1 Covers .
  • Page 200 Pump transfer case ..........8 - 65 8.9.1 General inspection .
  • Page 201 8.18 Other maintenance work ..........8 - 125 8.18.1 Checking the windscreen washing system .
  • Page 202 3 302 577 en Maintenance manual GMK7450...

  • Page 203: 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 Before Various types of work (e.g. oil change) require that covers be removed. maintenance work • Slew the crane cab in the crane operation posi- à...
  • Page 204 Maintenance work on the superstructure 8.1 General instructions After maintenance work • Slew the crane cab the driving position ; à Operating manual . • Fasten the covers (1) with the locks. • Fold in the railings, and secure the ladders and platforms (1) in the holders in the driv- à...
  • Page 205 Maintenance work on the superstructure 8.1 General instructions Blank page Maintenance manual 3 302 577 en 8 - 3 GMK7450...

  • Page 206: 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 - 4 3 302 577 en Maintenance manual GMK7450...
  • Page 207 Maintenance work on the superstructure 8.1 General instructions à Symbols for maintenance work P. 8 - 11 à 4 Side panel P. 8 - 11 à 3 ECOS display P. 8 - 12 à Engine P. 8 - 13 à 7 Diesel engine P.
  • Page 208 Maintenance work on the superstructure 8.1 General instructions 8 - 6 3 302 577 en Maintenance manual GMK7450...
  • Page 209 Maintenance work on the superstructure 8.1 General instructions à Slewing bearing P. 8 - 55 à 5 Gear teeth P. 8 - 59 à 7 Turntable lock P. 8 - 64 à Pump transfer case P. 8 - 65 à 1 Oil level plug P.
  • Page 210 Maintenance work on the superstructure 8.1 General instructions Additional equipment 8 - 8 3 302 577 en Maintenance manual GMK7450...
  • Page 211 Maintenance work on the superstructure 8.1 General instructions à Electrical system P. 8 - 117 à 6 Spotlights on the crane cab P. 8 - 117 à 8 Spotlights on the telescopic boom P. 8 - 117 à 1 Anemometer, air traffic control light P.
  • Page 212 Maintenance work on the superstructure 8.1 General instructions Blank page 8 - 10 3 302 577 en Maintenance manual GMK7450...

  • Page 213: Symbols For Maintenance Work

    Maintenance work on the superstructure 8.2 Symbols for maintenance work Symbols for maintenance work • Check the following lamps and symbols on the side panel and ECOS dis- play on a daily basis before you start work. On the side panel If one of the lamps on the side panel is lit in the driver's cab you must carry out the corresponding maintenance work: à...
  • Page 214 Maintenance work on the superstructure 8.2 Symbols for maintenance work à • On the ECOS Open the Warning submenu in the crane cab; Operating manual . display You must carry out the corresponding maintenance work if a symbol is rot: à...

  • Page 215: Engine

    Maintenance work on the superstructure 8.3 Engine Engine • In addition, carry out further maintenance work specified in the Engine manufacturer’s documentation supplied. 8.3.1 Check the oil level Prerequisites – The truck crane must be level. Check the oil level •...
  • Page 216 Maintenance work on the superstructure 8.3 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 217: Topping Up The Oil

    Maintenance work on the superstructure 8.3 Engine 8.3.2 Topping up the oil à Data on the prescribed oil specifications; Engine manufacturer’s documen- tation . Engine oil Designation Specifications GROVE part no. in litres (gal) to DIN 51502 Classification 17 (4.5) HD - CD CES 20081 SAE 15 W-40...

  • Page 218: Checking The Air Filter

    Maintenance work on the superstructure 8.3 Engine 8.3.3 Checking the air filter When the engine malfunction lamp on the side panel lights up then the air filter might be clogged. à • Also check the symbol on the ECOS display; P.

  • Page 219: 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 3 302 577 en...

  • 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 - 18 3 302 577 en Maintenance manual...

  • Page 221: Changing The Oil And The Oil Filter

    Maintenance work on the superstructure 8.3 Engine 8.3.6 Changing the oil and the oil filter Oil, spare parts, Engine oil Designation Specifications GROVE part no. tools in litres (gal) to DIN 51502 Classification 17 (4.5) HD - CD CES 20081 SAE 15 W-40 Cummins 04162428...
  • Page 222 Maintenance work on the superstructure 8.3 Engine Changing Risk of environmental damage due to leaking consumables! Always let consumables drain into suitable receptacles. Wipe up any con- sumables that escape. Store/dispose of consumables and any soaked equipment properly. Ask about the applicable regulations. Risk of environmental damage due to leaking consumables! Use the supplied connecting piece and hose and a receptacle with sufficient capacity to drain the oil.

  • Page 223: Have The Radiator Checked/Cleaned

    Maintenance work on the superstructure 8.3 Engine M 12 8.3.7 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 224 Maintenance work on the superstructure 8.3 Engine The two radiator units (1) and (2) are protected by grilles (3) and plates (4). When the engine is running, the fan impellers rotate (5). Risk of injury at the fan wheel! When the fan impellers are rotating they can trap the fingers of your hand and amputate them.
  • Page 225 Maintenance work on the superstructure 8.3 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 impeller to clean it.
  • Page 226 Maintenance work on the superstructure 8.3 Engine • Have the radiator units (1) and (2) opened up by the repair specialists, so that the radiator fins are accessible. • Have the radiator fins cleaned on both sides, using suitable cleaning agents.

  • Page 227: Changing The Coolant

    Maintenance work on the superstructure 8.3 Engine M 12 8.3.8 Changing the coolant à Tools – Receptacle, approx. 15 l (4 gal); P. 2 - 4. à Engine manufacturer’s documentation . – Antifreeze; Prerequisites – Information on the coolant and admixture ratio has been obtained; à...
  • Page 228 Maintenance work on the superstructure 8.3 Engine Changing Draining when the engine is cold • Open the cap (1) on the expansion tank. • Place a container under the oil filter (2). • Unscrew the drain plug (3) and let the oil drain off.

  • Page 229: Fuel System

    Maintenance work on the superstructure 8.4 Fuel system Fuel system The following elements are installed in the superstructure fuel line: 1 Fuel tank 2 Fuel filter 1 3 Fuel filter 2 4 3-way valve in the return line; for draining the fuel 5 Valve in the supply line;...

  • Page 230: Draining Off Water From Fuel Filter 1

    Maintenance work on the superstructure 8.4 Fuel system 8.4.1 Draining off water from fuel filter 1 à Spare parts and – Receptacle, approx. 5 l (1.5 gal); P. 2 - 4. tools Prerequisites – The truck crane must be level. –...

  • Page 231: Replacing Fuel Filter 1

    Maintenance work on the superstructure 8.4 Fuel system 8.4.2 Replacing fuel filter 1 Spare parts and Designation Quantity GROVE part no. tools Filter 04182148 à – Receptacle, approx. 5 l (1.5 gal); P. 2 - 4. Prerequisites – The truck crane must be level. –...
  • Page 232 Maintenance work on the superstructure 8.4 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 233: Replacing Fuel Filter 2

    Maintenance work on the superstructure 8.4 Fuel system 8.4.3 Replacing fuel filter 2 Spare parts and Designation Quantity GROVE part no. tools Filter 04182157 à – Receptacle, approx. 5 l (1.5 gal); P. 2 - 4. à Operating manual . Prerequisites –...
  • Page 234 Maintenance work on the superstructure 8.4 Fuel system Changing filter 2 The filter 2 is mounted on the inner side of the engine and is accessible from below. • Place a receptacle under the filter (1). • Remove the filter (1). •...
  • Page 235 Maintenance work on the superstructure 8.4 Fuel system • Turn the valve – lever (2) at right angles to the end of the hose (1). • Start the engine and check that the fuel fil- ters are not leaking. • Remove the receptacle under the end of the hose.
  • Page 236 Maintenance work on the superstructure 8.4 Fuel system Blank page 8 - 34 3 302 577 en Maintenance manual GMK7450...

  • Page 237: Exhaust System With Exhaust Emission Control

    Maintenance work on the superstructure 8.5 Exhaust system with exhaust emission control Exhaust system with exhaust emission control Overview In order to adhere to the exhaust emission regulations, you are only permit- ted to drive the crane with the multi-stage exhaust system consisting of DOC catalytic converter, DPF particle filter, SCR catalytic converter (DOC = Diesel Oxidation Catalyst, DPF = Diesel Particulate Filter, SCR = Selective Catalytic Reduction).

  • Page 238: Checking The Adblue Tank Level

    Maintenance work on the superstructure 8.5 Exhaust system with exhaust emission control 8.5.1 Checking the AdBlue tank level Checking The warning lamp for checking the AdBlue system and a display for the AdBlue level in the tank is located on the side console in the crane cab. The tank has a maximum filling volume of approx.

  • Page 239: Check The Exhaust System For External Damage

    Maintenance work on the superstructure 8.5 Exhaust system with exhaust emission control • Refuelling Find out about filling up 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 240 Switch the engine off and allow it to cool down. If you discover any damage Have any damaged parts of the exhaust system replaced immediately by or an authorised GROVE dealer. Manitowoc Crane Care 8 - 38 3 302 577 en Maintenance manual...

  • Page 241: Having The Adblue System Checked

    8.5.4 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. 8 - 35.

  • Page 242: Having The Soot Particle Filter System Checked

    Maintenance work on the superstructure 8.5 Exhaust system with exhaust emission control M 12 8.5.5 Having the soot particle filter system checked Checking daily The exhaust system contains a soot particle filter (DPF particle filter). • Check the operating status of the exhaust system on a daily basis by checking the lamps (1) to (3) on the side console in the crane cab;...
  • Page 243 (Y 5), or 5,000 operating house (5,000 oper. hrs.). • Service partner Have the particulate filter cleaned 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;...
  • Page 244 Have a back pressure test performed to check if the exhaust system is gas- tight. If you discover any damage Have any damaged parts of the exhaust system replaced immediately by or an authorised GROVE dealer. Manitowoc Crane Care 8 - 42 3 302 577 en Maintenance manual GMK7450...

  • Page 245: Hoists

    Maintenance work on the superstructure 8.6 Hoists Hoists 8.6.1 Checking the oil level Spare parts and Designation Quantity GROVE part no. tools Gasket 14 x 18 Cu DIN 7603 00117131 Gasket 18 x 22 Cu DIN 7603 00117137 à Operating manual . Prerequisites –...

  • Page 246: General Inspection

    • Check that pipes and hoses are tightly connected and undamaged. If any damage is found, report it to or an authorised Manitowoc Crane Care GROVE dealer or your repair crew. 8.6.3 Checking the hoist brake Check that the hoist brake is working correctly on the main hoist and the auxiliary hoist.

  • Page 247: Lubricating The Auxiliary Hoist

    Maintenance work on the superstructure 8.6 Hoists 8.6.4 Lubricating the auxiliary hoist Grease, spare Lubricating Designation Specifications 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 248: Changing The Oil/Checking The Oil

    Maintenance work on the superstructure 8.6 Hoists M 12 8.6.5 Changing the oil/checking the oil à • Also adhere to the Run-in regulations , P. 4 - 1. Oil, spare parts, Gear oil Designation Specifications GROVE part no. tools in litres (gal) to DIN 51502 Classification 11.5 (3.0)
  • Page 249 Some abrasion particles may appear in the first oil filled. If you notice abra- sion particles during the first oil change (after 200 oper. hrs.), first consult before introducing any specific measures. Manitowoc Crane Care Maintenance manual 3 302 577 en...

  • Page 250: Having A Partial Inspection Carried Out

    Maintenance work on the superstructure 8.6 Hoists 8.6.6 Having a partial inspection carried out Only suitably trained specialists should carry out a partial inspection of – the multiple-disc brake, – the plug connections between the hydraulic motor and the multiple-disk brake, –...

  • Page 251: Slewing Gear

    Maintenance work on the superstructure 8.7 Slewing gear Slewing gear 8.7.1 Checking the oil level Spare parts and Designation Quantity GROVE part no. 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 252: Checking For Leaks

    • Check that pipes and hoses are tightly connected and undamaged. If any damage is found, report it to or an authorised Manitowoc Crane Care GROVE dealer or your repair crew. 8.7.3 Checking the slewing gear brake Prerequisites – The crane must be rigged with an outrigger span of at least 8.76 x 8.90 m à...
  • Page 253 – 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. • Switch the slewing gear off and switch the engine off.

  • Page 254: Changing The Oil/Checking The Oil

    Maintenance work on the superstructure 8.7 Slewing gear M 12 8.7.4 Changing the oil/checking the oil à • Also adhere to the Run-in regulations , P. 4 - 1. Oil, spare parts, Gear oil Designation Specifications GROVE part no. tools in litres (gal) to DIN 51502 Classification...
  • Page 255 Maintenance work on the superstructure 8.7 Slewing gear Draining oil • Remove the plate (1). • Place a receptacle under the screw (2). • Unscrew the filter (4) and screws (3) and (2). • Drain the oil. • Replace the gasket and screw the screw (2) back in.
  • Page 256 Maintenance work on the superstructure 8.7 Slewing gear Blank page 8 - 54 3 302 577 en Maintenance manual GMK7450...

  • Page 257: Slewing Bearing

    . • Be sure to first obtain detailed information from Manitowoc Crane Care – The Mega-Wing-Lift, lattice extension and auxiliary hoist are removed. – In addition, the tyres on the 5th and 6th axle lines should be removed to improve the freedom of movement under the slewing bearing.
  • Page 258 Do not put the truck crane back into operation and have the slewing bearing repaired by Manitowoc Crane Care Access to the outer ring The outer ring is attached to the carrier by the bolts (1).
  • Page 259 Maintenance work on the superstructure 8.8 Slewing bearing Selecting the tools Outer ring The screw heads (1) are easily accessible for fitting a socket wrench. There- fore, you can use manual or mechanical torque tools (electric or hydraulic drivers). Inner ring The screw head (1) is accessible only via the opening (2).
  • Page 260 Maintenance work on the superstructure 8.8 Slewing bearing • Checking the Divide the checking of the 96 screws into 24 working steps of 4 screws outer ring each (1). Between each of the 24 operation steps you need to rotate the turntable to the next group of 4 screws on the opposite side.

  • Page 261: Lubricating The Gear Teeth

    Maintenance work on the superstructure 8.8 Slewing bearing 8.8.2 Lubricating the gear teeth Grease Designation Quantity GROVE part no. Adhesive lubricating grease (spray 00554205 can) Observe the instructions and safety instructions on the adhesive lubricating grease packaging! à Operating manual . Prerequisites –...
  • Page 262 Maintenance work on the superstructure 8.8 Slewing bearing First lubrication • Remove the plate (1). • Remove the old grease from all the gear teeth (2). • Apply a thin layer of new grease to all the gear teeth and allow it to penetrate for about 10 minutes.

  • Page 263: General Inspection

    If unusual noises occur, take a sample of the grease that has escaped. Have examine the sample for metal residue. Manitowoc Crane Care • Check the slewing bearing for damage (e.g. gaskets). If any damage is found, report it to...

  • Page 264: Measuring Tilting Play

    . • Be sure to obtain detailed information from before Manitowoc Crane Care measuring tilting play on the GMK7450. – The crane must be rigged with an outrigger span of at least 8.76 x 8.90 m à Operating manual .
  • Page 265 The base value of the tilting play is determined and documented by play or an authorised GROVE dealer when the ball slewing Manitowoc Crane Care bearing is put into operation or replaced. The maximum permissible wear is 1 mm (0.039 in).

  • Page 266: Lubricating The Locking Of Turntable

    Maintenance work on the superstructure 8.8 Slewing bearing M 12 8.8.5 Lubricating the locking of turntable Grease, spare Lubricating Designation Specifications GROVE part no. parts, tools grease to DIN 51502 Classification Grease KP - 1K - 50 DIN 51825 03233369 –...

  • Page 267: Pump Transfer Case

    Check the connections on the transmission for leaks. If consumables are à Check the oil level , P. 8 - 65. leaking; If any damage is found, report it to or an authorised Manitowoc Crane Care GROVE-dealer. 8.9.2 Check the oil level Spare parts and Designation Quantity GROVE part no.

  • Page 268: Changing The Oil

    Maintenance work on the superstructure 8.9 Pump transfer case M 12 8.9.3 Changing the oil Oil, spare parts Gear oil Specifications GROVE part no. and tools in litres (gal) Classification 3.8 (1.0) Aral Degol BG 220 00554217 MIL-L 2105 C SAE 90 Designation Quantity...
  • Page 269 Maintenance work on the superstructure 8.9 Pump transfer case • Place a receptacle under the screw (2). • Unscrew bolts (1) and (2) and allow the oil to drain. • Fit a new gasket and tighten the screw (2). • Fill the oil up to the lower edge of the open- ing (1).
  • Page 270 Maintenance work on the superstructure 8.9 Pump transfer case Blank page 8 - 68 3 302 577 en Maintenance manual GMK7450...

  • Page 271: Hydraulic System

    Maintenance work on the superstructure 8.10 Hydraulic system 8.10 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 272: Checking The Hydraulic Hoses

    Maintenance work on the superstructure 8.10 Hydraulic system 8.10.2 Checking the hydraulic hoses The inspection work is described in section Checking the hydraulic hoses , p. 7 - 88. 8.10.3 Checking the ventilation filter • Check the display (1) on the ventilation filter. If the indicator is coloured à...

  • Page 273: Checking For Leaks

    Establishing an operational status , P. 8 - 84. 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 3 302 577 en 8 - 71 GMK7450...

  • Page 274: Oil Filters 1 And 2 - Cleaning The Magnetic Rod

    Maintenance work on the superstructure 8.10 Hydraulic system 8.10.5 Oil filters 1 and 2 – cleaning the magnetic rod Spare parts and Designation Quantity GROVE part no. tools For oil filter 1: Filter 03325700 Packing set 03135853 For oil filter 2: Filter 03317083 Seal (O-ring)
  • Page 275 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. • Replace the gaskets (packing set) if neces- sary.
  • Page 276 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. • Replace the gaskets. •...

  • Page 277: Changing The Ventilation Filter

    Maintenance work on the superstructure 8.10 Hydraulic system M 12 8.10.6 Changing the ventilation filter Spare parts and Designation Quantity GROVE part no. tools Filter 03319602 Prerequisites – The engine must not be running and must be secured against unauthor- à...

  • Page 278: Pressure Accumulator - Checking The Gas Pressure

    180 bar (2610 psi) accumulator • Have the filling pressure checked and if nec- essary corrected by Manitowoc Crane Care an authorised GROVE dealer. M 12 8.10.8 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 279 Maintenance work on the superstructure 8.10 Hydraulic system The gauge port (1) is mounted on the con- trol block (2). When a hydraulic function is run, e.g. tilting the crane cab , oil can then be taken at the gauge port. •...

  • Page 280: Changing The Hydraulic Oil Filter

    Maintenance work on the superstructure 8.10 Hydraulic system 8.10.9 Changing the hydraulic oil filter All the oil filters must be replaced when changing the oil. In the event of a warning message, the red symbols in the Warning sub- menu indicate which oil filters you have to change. 1 Red –...
  • Page 281 Maintenance work on the superstructure 8.10 Hydraulic system Change oil filter 1 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 282 Maintenance work on the superstructure 8.10 Hydraulic system Change oil filter 2 • Take off the cap (1) and pull out the filter. • Place the filter in a receptacle. • Remove the spring (2). • Remove the nut (5). •...
  • Page 283 Maintenance work on the superstructure 8.10 Hydraulic system Change oil filter 3 • Release the receptacle (1) at the hexagon head. • Change the filter (2). • Replace the gaskets. • Fill the receptacle with clean oil and tighten it up. à...

  • Page 284: Changing The Hydraulic Oil

    Maintenance work on the superstructure 8.10 Hydraulic system 8.10.10 Changing the hydraulic oil The oil only needs to be changed if the laboratory analysis results indicate à Taking oil samples , P. 8 - 76. this; Oil, spare parts, Hydraulic oil Designation Specifications GROVE part no.
  • Page 285 Maintenance work on the superstructure 8.10 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 286 Maintenance work on the superstructure 8.10 Hydraulic system Establishing an After having changed the oil filters and topping up the oil, you must re- operational status establish the operating conditions. Risk of damage to the hydraulic pumps! Open the valves prior to starting the engine. This prevents damage to the hydraulic pumps.

  • Page 287: Main Boom

    Maintenance work on the superstructure 8.11 Main boom 8.11 Main boom 8.11.1 Grease the piston rod of the derricking cylinder Grease, spare Designation GROVE part no. parts and tools Lubricant RHUS 2 AF; 1 kg 03325215 (Apply the grease with a brush) Spray on Berulub;...

  • Page 288: Lubricating The Locking Pins

    Maintenance work on the superstructure 8.11 Main boom 8.11.2 Lubricating the locking pins Reducing the Under difficult operating conditions – at extremely sandy or rainy locations – interval you must lubricate them more frequently. Grease, spare Lubricating Designation Specifications GROVE part no. parts, tools grease to DIN 51502...
  • Page 289 Maintenance work on the superstructure 8.11 Main boom Telescopic section I • Mechanically lock the telescopic section I at a fixed length of 44%. You can now access the locking pins (1) from the outside. Lubricating the locking pins • Spray oil around the gap (1).
  • Page 290 Maintenance work on the superstructure 8.11 Main boom • Telescopic sec- Retract all telescopic sections. tion II -IV • Enter the RCL rigging code for the current rigging mode of the truck crane. Risk of overturning when telescoping if the RCL is overridden! You must override the rated capacity limiter (RCL) in order to telescope a second telescopic section in a horizontal position.

  • Page 291: Lubricating The Telescopic Slide Faces

    – 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. recommends using pneumatic Manitowoc Crane Group Germany GmbH grease spray guns for more effective lubrication of the telescopic slide faces: Designation GROVE part no.
  • Page 292 Maintenance work on the superstructure 8.11 Main boom Safety instructions Risk of accidents from slipping off the main boom! There is grease residue on the telescopic sections. For this reason, you must not walk on the main boom. Use the ladder provided with your crane! Risk of overturning when telescoping if the RCL is overridden! You must override the rated capacity limiter (RCL) in order to telescope a second telescopic section in a horizontal position.
  • Page 293 Maintenance work on the superstructure 8.11 Main boom Location of the lubricating points The diagram shows the telescoping for the lubrication of telescopic section IV . There are four slide faces on the edges of the telescopic sections. – The two outer lower slide faces (4) and the outer upper slide faces (5) are lubricated from the outside in the extended state.
  • Page 294 Maintenance work on the superstructure 8.11 Main boom • Telescopic Retract all telescopic sections. section IV • Enter the RCL rigging code for the current rigging mode of the truck crane. • Telescope telescopic section IV to the first locking position (44%) and lock it.
  • Page 295 Maintenance work on the superstructure 8.11 Main boom • Telescopic Retract all telescopic sections. section II • Enter the RCL rigging code for the current rigging mode of the truck crane. • Telescope telescopic section II to the first locking position (44%) and lock it.

  • Page 296: Checking The Sheaves

    Have damaged, worn, stiff or extremely soiled sheaves replaced by or an authorised GROVE dealer or your repair crew. Manitowoc Crane Care 8 - 94 3 302 577 en Maintenance manual...

  • Page 297: Checking The Locking System

    Have the maintenance work on the main boom locking system performed regularly by or an authorised GROVE dealer. Manitowoc Crane Care This prevents the complete unlocking of a telescopic section in Emergency operation/Emergency program mode, which could cause serious accidents and damage to the truck crane.
  • Page 298 Maintenance work on the superstructure 8.11 Main boom Blank page 8 - 96 3 302 577 en Maintenance manual GMK7450...

  • Page 299: Hoist Ropes

    Maintenance work on the superstructure 8.12 Hoist ropes 8.12 Hoist ropes 8.12.1 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 300: Checking The Hoist Ropes

    Maintenance work on the superstructure 8.12 Hoist ropes 8.12.2 Checking the hoist ropes Spare parts and – Torque wrench for 80 Nm (59 lbf ft). tools – Establish a rigging mode in accordance with the Lifting capacity table and Prerequisites à...

  • Page 301: Lubricating The Hoist Rope

    – by running it through a tray filled with lubricant or – by means of high-pressure lubrication with a pressure pump. Manitowoc Crane Group Germany GmbH recommends high-pressure lubrication with a pressure pump (GROVE part no. 90018525) for reasons of sustainability, efficiency and environmental protection.

  • Page 302: Assessing The Condition Of The Hoist Rope

    Maintenance work on the superstructure 8.12 Hoist ropes 8.12.4 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 303 Maintenance work on the superstructure 8.12 Hoist ropes The tables show by rope diameter the number of wire breaks in a length 6 times and 30 times the rope diameter which if reached would require replacement of the rope. • Familiarise yourself with DIN ISO 4309:2013-06 (rotation-resistant ropes).
  • Page 304 Maintenance work on the superstructure 8.12 Hoist ropes Risk of accidents due to reduced load bearing capacity! Remember that other factors may also make it necessary to replace a rope before the number of wire breaks requiring rope replacement has been reached (age of rope, frequency of use or exceptional loading).
  • Page 305 Maintenance work on the superstructure 8.12 Hoist ropes Damage Description Cause Replacement Reduced The diameter of the Structural changes Replace the rope immediately diameter (1) rope has become if the diameter has decreased smaller along large by 15% or more compared to sections.
  • Page 306 Maintenance work on the superstructure 8.12 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 307 Maintenance work on the superstructure 8.12 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 308: Replacing The Hoist Rope

    Maintenance work on the superstructure 8.12 Hoist ropes 8.12.5 Replacing the hoist rope à Spare parts and – An original replacement part; Rope certificate . tools – A reel stand with braking block. – Torque wrench for 80 Nm (59 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 309 Maintenance work on the superstructure 8.12 Hoist ropes • Remove the clamp (2). • Push the rope (1) through the bore hole (3) until the rope wedge (4) slides out of the pocket. • Remove the rope wedge and place the old rope away from the truck crane.
  • Page 310 Maintenance work on the superstructure 8.12 Hoist ropes • Push the rope (1) through the bore (2), until it protrudes approx. 1.5 m (5.0 ft) out of the pocket (4). • Feed the free end of the rope back through the pouch into the hole (6).

  • Page 311: Setting The Lowering Limit Switch

    Maintenance work on the superstructure 8.12 Hoist ropes Observe the hook block when unreeling. The hook block must not rotate! Risk of accidents if the lowering limit switch is set incorrectly! After inserting a new rope, the lowering limit switch must always be reset. In this way you avoid the lowering limit switch switching off too late or not at all, the rope being damaged and the load being dropped.
  • Page 312 Maintenance work on the superstructure 8.12 Hoist ropes Setting the lower- ing limit switch Risk of accidents if the rope end fitting is overloaded! The lowering limit switch must always be reset after repair work on the hoist and after rope replacement. A faulty lowering limit switch must always be replaced! •...

  • Page 313: Cable Drums And Slewing Angle Sensor

    Maintenance work on the superstructure 8.13 Cable drums and slewing angle sensor 8.13 Cable drums and slewing angle sensor 8.13.1 Maintenance of the slip ring assemblies The slip ring assemblies are located in: 1 Cable drum 1 2 Cable drum 2 Spare parts and Designation Quantity...

  • Page 314: Maintenance Of The Slip Ring Assemblies

    Maintenance work on the superstructure 8.13 Cable drums and slewing angle sensor Risk of damage to the RCL! Before maintenance work on the slip ring assemblies, always switch off the battery master switch so that the cable drum is without power. This prevents short circuits which may lead to damage to the rated capacity limiter (RCL).

  • Page 315: Central Lubrication System

    Maintenance work on the superstructure 8.14 Central lubrication system 8.14 Central lubrication system 8.14.1 Checking the filling level The maintenance of the pump (1) is the same à Central as the maintenance on the carrier; lubrication system , P. 7 - 103. Connected lubricating points –...
  • Page 316 Maintenance work on the superstructure 8.14 Central lubrication system Blank page 8 - 114 3 302 577 en Maintenance manual GMK7450...

  • Page 317: 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 8.15.2 Greasing à...
  • Page 318 Some manufacturers recommend dismantling every 4 years or after 500 operating hours. • about the maintenance intervals for the hook Manitowoc Crane Care blocks supplied with your crane. • Have the hook blocks dismantled by...

  • Page 319: Electrical System

    Risk of accidents if the safety devices are faulty! Have faulty lights and indicators repaired by or an Manitowoc Crane Care authorised GROVE dealer or an authorised specialist workshop. • Check the lamps and displays on the ECOS and RCL control units;...

  • Page 320: Checking The Batteries

    Maintenance work on the superstructure 8.16 Electrical system 8.16.2 Checking the batteries • Switch the battery master switch (1) off and remove the selector handle. • Check the batteries (2) in the same way as when checking them on the carrier; à...

  • Page 321: Charging The Batteries Using The Battery Charger

    Maintenance work on the superstructure 8.16 Electrical system 8.16.4 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 322 Maintenance work on the superstructure 8.16 Electrical system Blank page 8 - 120 3 302 577 en Maintenance manual GMK7450...

  • Page 323: Air-Conditioning System

    Do not start it up again to avoid further damage. • Have the air-conditioning system repaired as soon as possible by Manitowoc Crane Care or an authorised GROVE dealer or an authorised specialist workshop. 8.17.2 Checking hoses Risk of burns due to escaping refrigerant! Wear suitable safety glasses and gloves when checking the hoses and con- nections.

  • Page 324: 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 con- nections.
  • Page 325 Maintenance work on the superstructure 8.17 Air-conditioning system Refrigerant Fill quantity Designation CAS no. in kg (lbs) EC no. 1.45 (3.2) Tetrafluoroethane (R134a) 811-97-2 212-377-0 Filler connections The refrigerant filler connections (1) are located on the lines between the refrigerant compressor (3) and the condenser (2).
  • Page 326 Maintenance work on the superstructure 8.17 Air-conditioning system Blank page 8 - 124 3 302 577 en Maintenance manual GMK7450...

  • Page 327: Other Maintenance Work

    Maintenance work on the superstructure 8.18 Other maintenance work 8.18 Other maintenance work 8.18.1 Checking the windscreen washing system Water, spare Designation Quantity GROVE part no. parts, tool Windscreen wiper blade 03322652 Roof wiper blade 03322631 – Water; add commercially available detergent and antifreeze to it. –...

  • Page 328: Checking The Functioning Of The Auxiliary Heater

    Maintenance work on the superstructure 8.18 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 the bottom part of the switch. • Spray water on the skylight –...

  • Page 329: 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 Maintenance manual 3 302 577 en 8 - 127...

  • Page 330: 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 331: Renewing The Corrosion Protection

    Maintenance work on the superstructure 8.18 Other maintenance work M 12 8.18.5 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 332 Maintenance work on the superstructure 8.18 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 333: Having The Fire Extinguisher Checked

    Maintenance work on the superstructure 8.18 Other maintenance work 8.18.6 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 334 Maintenance work on the superstructure 8.18 Other maintenance work Blank page 8 - 132 3 302 577 en Maintenance manual GMK7450...
  • Page 335 Longer out of service periods Maintenance manual 3 302 577 en GMK7450...
  • Page 336 3 302 577 en Maintenance manual GMK7450...

  • Page 337: 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 338 Longer out of service periods • Ensure that the tyre positioning is different each time the crane is parked (without outriggers). • Seal all air filters again. If the truck crane is going to be out of service for more than 12 months: •...
  • Page 339 Torques 10.1 Torques for the retaining bolts ........10 - 10.2 Special torques .
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  • Page 341: 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-tension- (mm) ing for bolts) for oiled bolts (Nm) Spanner size (mm) Bolt quality Hexagon- Cylinder...
  • Page 342 Torques 10.2 Special torques 10.2 Special torques Thread size Size across flats Torque (Nm) (mm) (mm) Designation Hexagon- Cylinder head bolt screw Suspension strut: – Bracket for the vehicle chassis, M 16 — – Bracket for the vehicle chassis, M 24 —...
  • Page 343 Spare parts required for maintenance 11.1 General information ..........11 - 11.2 Lighting .
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  • Page 345: 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 346 Spare parts required for maintenance 11.2 Lighting Installation point GROVE part Designation Power (W) number CARRIER LIGHTING: Front spotlights: (integrated in the bumper) – Daytime driving light 03328445 P21 W 24 V – Low-beam + full-beam headlights 03134828 H7 24 V –...
  • Page 347 Spare parts required for maintenance 11.2 Lighting Installation point GROVE part Designation Power (W) number White front marker lights: (at the top on the driver's cab) – Marker light 00438514 C5 W 24 V Yellow additional lights for USA: (at the top on the driver's cab) –...
  • Page 348 Spare parts required for maintenance 11.2 Lighting Installation point GROVE part Designation Power (W) number SUPERSTRUCTURE LIGHTING: Marker lights, yellow: (on the main boom head) – Marker light; complete 03329569 Red rear marker lights: (on the turntable) – Marker light 03329492 FPL 98 CKS Yellow rotating beacon:...

  • Page 349: 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 90025830 1 item when the symbol lights up Air filter –...
  • Page 350 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 and 2nd axle line (duplex brake): Brake shoe with brake lining 03322112 Spring...
  • Page 351 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 Oil filter set with gaskets (contains two filters and one oil drain 03141323 plug gasket) Maintenance manual...

  • Page 352: Spare Parts For The Superstructure

    Spare parts required for maintenance 11.4 Spare parts for the superstructure 11.4 Spare parts for the superstructure Quantity, in single parts Assemblies and spare parts GROVE- For maintenance interval Superstructure Part number M 12 Engine Air filter – main filter 04256761 1 item when the symbol lights up Air filter –...
  • Page 353 Spare parts required for maintenance 11.4 Spare parts for the superstructure Quantity, in single parts Assemblies and spare parts GROVE- For maintenance interval Superstructure Part number M 12 Hydraulic system Filter 1 (only clean it) 03325700 Packing set 03135853 Filter 2 (only clean it) 03317083 Gasket 01372280...
  • Page 354 Spare parts required for maintenance 11.4 Spare parts for the superstructure Blank page 11 - 10 3 302 577 en Maintenance manual GMK7450...
  • Page 355 Appendix Maintenance manual 3 302 577 en GMK7450...
  • Page 356 3 302 577 en Maintenance manual GMK7450...

  • Page 357: Appendix

    Appendix...

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