Page 1 Maintenance manual 3 302 756 en 16.11.2018...
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: 1 General instructions 2 Safety and environmental protection 3 Cleaning 4 Run-in regulations 5 Maintenance overview 6 Lubricants and consumables 7 Maintenance work on the carrier 8 Maintenance work on the superstructure 9 Longer out of service periods 10 Torques 11 Spare parts required for maintenance Appendix This maintenance manual does not replace the operating manual.
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Page 5 General instructions Using the maintenance manual ........1 - Warnings and symbols .
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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, specialist 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 performed by qualified expert personnel with the prior written permission from Manitowoc Crane Group Germany GmbH. 1 - 4 3 302 756 en Maintenance manual...
Page 11: Definition Of Direction Information
General instructions 1.6 Definition of direction information Definition of direction information Basic rule Directions always depend on whether the carrier or the superstructure is being operated. On the carrier The driver's cab is always at the front, which means that: 1: front 2: right 3: rear...
Page 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 and vice versa when the truck crane is being used in countries that use US units of measurement.
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, 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 ignition key and put up warning signs. If due to exceptional circumstances the truck crane needs be put into oper- ation for certain types of maintenance work, great care must be taken where there are moving parts (superstructure, outriggers, Cardan shafts, slewing...
Page 17 Safety and environmental protection 2.1 Safety rules 2.1.1 Securing against unauthorised use • Secure the truck crane against unauthorised use by: – Applying the parking brake – Switching the transmission to position N – Turning off the engine – Removing the ignition key –...
Page 18 Safety and environmental protection 2.2 Handling substances which are harmful to the environment Handling substances which are harmful to the environment Which substances When you carry out maintenance work on the truck crane you will occasion- are harmful to the ally work with consumables which are classified as harmful to the environ- environment? ment by applicable national and regional regulations.
Page 19 Safety and environmental protection 2.2 Handling substances which are harmful to the environment Separate collec- Substances which are harmful to the environment should always be collect- tion and storage ed separately from other waste. • Ask your local environmental protection authority about the prescribed disposal options.
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Page 21 Cleaning Overview of assemblies easily damaged when cleaning ....3 - Maintenance manual 3 302 756 en GMK6400...
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Page 23: Cleaning
Cleaning Cleaning During the The paintwork on the truck crane will continue to harden for the first three first 3 months months. • During this period the crane may only be cleaned with cold water. • Do not use high-pressure or steam jet cleaning equipment during this period.
Page 24 Cleaning 3.1 Overview of assemblies easily damaged when cleaning Overview of assemblies easily damaged when cleaning 3 - 2 3 302 756 en Maintenance manual GMK6400...
Page 25 Cleaning 3.1 Overview of assemblies easily damaged when cleaning 1 RCL terminal box 2 Telescopic slide faces 3 Pressure sensors on the derricking cylinder 4 Angle data transmitter 5 Suspension struts 6 Control units for outriggers 7 Lifting limit switch 8 Housing of the input-output circuit boards on the carrier 9 RCL length data transmitter 10 Spotlights, slewable...
Page 26 Cleaning 3.1 Overview of assemblies easily damaged when cleaning Blank page 3 - 4 3 302 756 en Maintenance manual GMK6400...
Page 27 Run-in regulations Maintenance manual 3 302 756 en GMK6400...
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Page 29: Run-In Regulations
Run-in regulations Run-in regulations There are regulations regarding running in individual parts that must be followed, after: – First commissioning or – Replacement of a part or – General inspection. 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 Additional maintenance work on the (oper. hrs.) SUPERSTRUCTURE during the first 100 Check the hydraulic oil filter every week, and change it if necessary; à Cleaning the magnetic rods , p. 8 - 46, à Changing the hydraulic oil filter , p. 8 - 53. after 100 Tighten the screws on the slewing bearing;...
Page 31 Maintenance overview Maintenance intervals..........5 - Maintenance plans .
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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 maintenance is due. – You can read the driven km (or mi) on 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 – Checking the oil level p. 7 - 13 à – Checking the air filter p. 7 - 17 à –...
Page 37 Maintenance overview 5.2 Maintenance plans Maintenance work on the SUPERSTRUCTURE: Daily/before putting into operation Pump transfer case à – Checking the oil filter p. 8 - 35 Hydraulic system à – Checking the oil level p. 8 - 43 Hoist ropes à...
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 - 19 Transmission à – General inspection p. 7 - 42 Transfer case à – General inspection p. 7 - 53 Axle lines à...
Page 39 Maintenance overview 5.2 Maintenance plans Maintenance work on the SUPERSTRUCTURE: Weekly Hoists à – Checking the oil level p. 8 - 11 à – General inspection p. 8 - 12 à – Checking the hoist brake p. 8 - 12 Slewing gear à...
Page 40 Maintenance overview 5.2 Maintenance plans 5.2.3 Maintenance plan M 1 Maintenance work on the CARRIER: Monthly/after 2,000 km (about 1,240 mi) Engine à à Engine manufacturer's documentation – Notes; p. 7 - 13 Exhaust system with exhaust emission control à –...
Page 41 Maintenance overview 5.2 Maintenance plans Maintenance work on the SUPERSTRUCTURE: Monthly / after 100 oper. hrs. Pump transfer case à – Checking the oil level p. 8 - 36 Main boom à – Greasing the piston rod of the derricking cylinder 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 - 13 Fuel system à...
Page 43 Maintenance overview 5.2 Maintenance plans Maintenance work on the SUPERSTRUCTURE: Monthly / after 250 oper. hrs. Hoists à – Support for block – Checking the sheaves p. 8 - 13 Slewing bearing à – Checking the bolts p. 8 - 23 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 - 13 Transfer case à...
Page 45 Maintenance overview 5.2 Maintenance plans Maintenance work on the SUPERSTRUCTURE: Every six months / after 500 oper. hrs. Slewing gear à – Checking the slewing gear brake p. 8 - 18 Slewing bearing à – Lubricating the gear teeth p. 8 - 27 à...
Page 46 Maintenance overview 5.2 Maintenance plans M 12 5.2.6 Maintenance plan M 12 Maintenance work on the CARRIER: Every twelve months/after 20,000 – 25,000 km (12,430 – 15,530 mi) Engine à à Engine manufacturer's documentation – Notes; p. 7 - 13 à...
Page 47 Maintenance overview 5.2 Maintenance plans M 12 Maintenance work on the SUPERSTRUCTURE: Every twelve months/after 1,000 oper. hrs. Hoists à – Changing the oil/checking the oil p. 8 - 14 Slewing gear à – Changing the oil/checking the oil p. 8 - 20 Slewing bearing 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. 7 - 13 à – Changing the oil and oil filter p.
Page 49 – 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 – Have the two drive shafts between the engine and the hydraulic pumps replaced by or an authorised GROVE dealer.
Page 50 Maintenance work on the CARRIER: Every 120 months / after 200,000 km (124,000 mi) Steel structures – Check the load-bearing steel structures. For more information contact Manitowoc Crane Care Maintenance work on the SUPERSTRUCTURE: Every 120 months / after 12,000 oper. hrs. Steel structures –...
Page 51 Maintenance overview 5.3 Periodic inspections Periodic inspections Your GMK6400 truck crane has been inspected before delivery. – Truck cranes used in Germany are inspected in accordance with the regulations of the professional trade association as defined by BGV D 6 (VBG 9).
Page 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 deformation. The hook opening may not have expanded by more than 10% of the original dimension y, y1, y2. The original dimensions y, y1, y2 are specified in field (2) on the load hooks.
Page 53 Maintenance overview 5.4 Measures required for monitoring the winches Measures required for monitoring the winches Also observe the information on the general inspection of the hoists; à p. 8 - 16. These measures for monitoring the winches (hoists) were compiled by the German Machine Builders' Association (VDMA) and are to be used for all mobile cranes according to the German Accident Prevention Regulations for Winches, Hoists and Tractor Machines, BGV D 6 (VGB 9 ) and BGV D 8 (VBG 8) .
Page 54 Maintenance overview 5.4 Measures required for monitoring the winches The real service life of a winch is affected by a number of additional external factors, such as: 1. Overloading caused by improper use of the truck crane. 2. Insufficient maintenance: Oil is not changed at the specified intervals.
Page 55 Maintenance overview 5.4 Measures required for monitoring the winches Determining The truck crane's load spectrum is divided into groups (see also ISO 4301/1, the 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 monitoring the winches 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 re- spective 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 monitoring the winches The general overhaul is to be arranged by the operator and performed by the manufacturer or a representative authorised by the manufacturer. The results are to be entered in the crane logbook. The manufacturer or an authorised representative will specify a new theoretical service life D upon completion of the general overhaul.
Page 58 5.4 Measures required for monitoring the winches 5.4.3 Example A GMK6400 is equipped with a separate operating hours counter for the hoist and is classified by Manitowoc Crane Group Germany GmbH as follows: Power unit group: Load spectrum: light L 1, Km = 0.125...
Page 59 Maintenance overview 5.4 Measures required for monitoring the winches The used proportion S of theoretical service life at the 2nd inspection is therefore: × -------------- - 480 h 1,920 h 0.125 Remaining theoretical service life: D2 = 3,040 h - 1,920 h = 1,120 h. The aforementioned values are entered in the table (see table example p.
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Page 61 Lubricants and consumables Lubricants............6 - 6.1.1 Lubricants list .
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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 applications list.
Page 64: Lubricants List
Lubricants and consumables 6.1 Lubricants 6.1.1 Lubricants list Con- GROVE Lubricant Designation Specifications Viscosity sec. Part type according to Classification number DIN 51502 MIL-L 2104 C 03329588 Engine oil HD - CD SAE 5 W-30 DB 228.5 ZF TE-ML02 03325153 Gear oil Ecofluid M ZF (synthetic)
Page 65: Lubricant Applications List
Lubricants and consumables 6.1 Lubricants 6.1.2 Lubricant applications list Con- Lubricant Usage Fill Mainte- sec. type quantity nance in litres interval (gal) à Engine oil Carrier diesel engine; p. 7 - 24 27 (7.1) à Transmission without Intarder; p. 7 - 45 15 (4.0) à...
Page 66 Lubricants and consumables 6.1 Lubricants Con- Lubricant Usage Fill Mainte- sec. type quantity nance in litres interval (gal) à Carrier central lubrication; p. 7 - 107 Superstructure central lubrication; à p. 8 - 89 à Cardan shafts – transverse; p. 7 - 67 à...
Page 67: Refrigerant
Lubricants and consumables 6.2 Refrigerant Refrigerant Refrigerant Usage Fill quantity Mainte- Designation in kg (lbs) nance inter- à Air-conditioning system; p. 7 - 120 2.60 (5.73) M 12 Tetrafluoroethane (R134a) CAS no. 811-97-2 à Air-conditioning system; p. 7 - 120 EC no.
Page 68: After-Treatment Of Exhaust Gases
Lubricants and consumables 6.3 Consumables 6.3.3 After-treatment of exhaust gases à Only with AdBlue system additional equipment; p. 7 - 1. Designation Usage Fill quantity in litres (gal) DEF (Diesel Exhaust Fluid) à AdBlue: AdBlue tank on the carrier; p. 7 - 36 40 (10.5) GROVE part number: 03140555 DEF (Diesel Exhaust Fluid),...
Page 69 Maintenance work on the carrier General instructions ..........7 - 7.1.1 Covers .
Page 70 Wheels ............7 - 69 7.9.1 Checking the tyres for damage .
Page 71 7.18 Towbar coupling ........... . 7 - 123 7.18.1 Lubricating the towbar coupling.
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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 When the tank (1) is present, then the truck crane is equipped with the AdBlue system additional equipment. The AdBlue-System is only present in truck cranes that comply with the exhaust emissions in TIER4i or Euromot 3B.
Page 74: Covers
Maintenance work on the carrier 7.1 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 • Fasten the covers (1) with the locks. 7 - 2 3 302 756 en Maintenance manual...
Page 75 Maintenance work on the carrier 7.1 General instructions Blank page Maintenance manual 3 302 756 en 7 - 3 GMK6400...
Page 76: 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 - 4 3 302 756 en Maintenance manual GMK6400...
Page 77 Maintenance work on the carrier 7.1 General instructions à Symbols for maintenance work p. 7 - 11 à 1 Instrument panel p. 7 - 11 à 2 ECOS display p. 7 - 12 à Engine p. 7 - 13 à 4 Diesel engine p.
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Page 79 Maintenance work on the carrier 7.1 General instructions à Axle lines p. 7 - 57 à 6 Axle centre drives p. 7 - 58 à 7 Hydraulic drives p. 7 - 60 à 5 Final drives p. 7 - 63 à...
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Page 81 Maintenance work on the carrier 7.1 General instructions à Vehicle brake p. 7 - 77 à 10 Brake linings p. 7 - 77 à Suspension p. 7 - 79 à 7 Suspension struts p. 7 - 79 à 9 Forced lever p.
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Page 83: Symbols For Maintenance Work
Maintenance work on the carrier 7.2 Symbols for maintenance work Symbols for maintenance work Check the following symbols every day before starting work. On the If one of the symbols is displayed in the driver's cab you must carry out the Instrument panel corresponding maintenance work: à...
Page 84 Maintenance work on the carrier 7.2 Symbols for maintenance work On the ECOS display • Open the Warning submenu in the driver's cab; à Operating manual . You must carry out the corresponding maintenance work if a symbol is displayed in red: à...
Page 85: Engine
Maintenance work on the carrier 7.3 Engine Engine • Also carry out additional maintenance work specified in the Engine manu- facturer's documentation supplied. Pay attention to the information relating to use of bio-diesel fuel – the oil change interval must be halved. •...
Page 86 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 87: Topping Up The Oil
Maintenance work on the carrier 7.3 Engine 7.3.2 Topping up the oil Data on the prescribed oil specification; à Engine manufacturer's documentation . Engine oil Designation Specifications GROVE part no. in litres (gal) to DIN 51502 Classification 27 (7.1) HD - CD MIL-L 2104 C SAE 5 W-30 DB 228.5...
Page 88: Installing The Drain Valve
Maintenance work on the carrier 7.3 Engine 7.3.3 Installing the drain valve You can replace the drain plug on the oil pan with a valve. This makes it easier to check the draining oil during subsequent oil changes. Spare parts Designation Quantity GROVE part no.
Page 89: Checking The Air Filter
Maintenance work on the carrier 7.3 Engine 7.3.4 Checking the air filter If the symbol is displayed on the instrument panel in the driver's cab, the air filter must be changed. If the symbol is displayed in the crane cab on the ECOS display ( Warning submenu) the air filter must be changed.
Page 90: Checking The Coolant Level
If the coolant has to be topped up frequently, the cooling system may be leaking. Have the cooling system checked by or an Manitowoc Crane Care authorised GROVE dealer or your repair crew. The cooling circuit also feeds the heat exchanger on the transmission with à...
Page 91: General Inspection
à Checking the coolant level , p. 7 - 18. If any damage is found, report it to or an authorised Manitowoc Crane Care GROVE dealer or an authorised specialist workshop. Maintenance manual 3 302 756 en 7 - 19...
Page 92: 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 93 Maintenance work on the carrier 7.3 Engine The two radiator units (1) and (2) consist of different radiators (4). These are located under the griller (3) or the plate (5). The fan impellers (6) are located under the radiators. The fan impellers rotate when the engine is running! Risk of injury due to the fan impellers! Rotating fan impellers can trap your fingers and amputate them.
Page 94 Maintenance work on the carrier 7.3 Engine Have them cleaned Risk of injury due to the fan impellers! When the fan impellers are rotating they can trap the fingers of your hand and amputate them. Never reach into the fan impellers when they are rotating.
Page 95 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 (4) cleaned on both sides, using suitable cleaning agents.
Page 96: Changing The Oil And Oil Filter
Maintenance work on the carrier 7.3 Engine 7.3.8 Changing the oil and oil filter Oil, spare parts, Engine oil Designation Specifications GROVE part no. tools in litres (gal) to DIN 51502 Classification 27 (7.1) HD - CD MIL-L 2104 C SAE 5 W-30 DB 228.5 03329588...
Page 97 Maintenance work on the carrier 7.3 Engine Oil filter • Place a receptacle underneath the engine. • Remove the cover (1) and pull out the filter (3). • Insert a new filter (3). • Replace the gasket (2). • Screw on the cover (1) using the socket wrench –...
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Page 99: Fuel System
à Operating manual . • about the addi- Manitowoc Crane Care tional fuel filter required for the dual tank system. As standard, the following elements are installed in the fuel line: 1 Fuel filter 1...
Page 100: Draining Water From Fuel Filter 1
Maintenance work on the carrier 7.4 Fuel system 7.4.1 Draining water from fuel filter 1 à Spare parts – Receptacle, about 5 l (1.5 gal); p. 2 - 4. and tools Prerequisites – The truck crane must be level. – The engine must not be running and must be secured against unauthor- à...
Page 101: Changing Fuel Filter 1
Maintenance work on the carrier 7.4 Fuel system 7.4.2 Changing fuel filter 1 Spare parts Designation Quantity GROVE part no. and tools Filter 03322877 Gasket 03322879 Filter element 03328656 à – Receptacle, about 5 l (1.5 gal); p. 2 - 4. Prerequisites –...
Page 102 Maintenance work on the carrier 7.4 Fuel system • (A) – Remove the filter element (2) and the filter (1). If necessary, replace any damaged parts. • (B) – Screw on a new filter (1) and the filter element (2). •...
Page 103: Changing Fuel Filter 2
Maintenance work on the carrier 7.4 Fuel system M 12 7.4.3 Changing fuel filter 2 Spare parts Designation Quantity GROVE part no. and tools Filter with gasket 03319653 à – Receptacle, about 5 l (1.5 gal); p. 2 - 4. –...
Page 104 Maintenance work on the carrier 7.4 Fuel system • Place a receptacle underneath the end of the hose (2). • (A)– Turn the valve – lever (1) horizontal. • Let the consumable drain. • (B)– Turn the valve – lever (1) vertical. Leave the receptacle under the hose.
Page 105 Maintenance work on the carrier 7.4 Fuel system Bleeding the fuel line A receptacle is under the end of the hose (2). • Close the drain plug (3). • Open the valve – lever (1) parallel to the line. • Open the valve –...
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Page 107: Exhaust System With Exhaust Emission Control
Maintenance work on the carrier 7.5 Exhaust system with exhaust emission control Exhaust system with exhaust emission control Overview To comply with the exhaust emission regulations, the truck crane may only be run with the exhaust system with SCR catalytic converter (SCR = Selective Catalytic Reduction).
Page 108: Checking The Adblue Tank Level
Maintenance work on the carrier 7.5 Exhaust system with exhaust emission control 7.5.1 Checking the AdBlue tank level Checks The warning lamp for checking the AdBlue system is located on the instru- ment panel in the driver's cab, a gauge for checking the AdBlue tank level is located on the ECOS display.
Page 109: Checking The Exhaust System For External Damage
Maintenance work on the carrier 7.5 Exhaust system with exhaust emission control • Refuelling Find out about refuelling in the operating manual and note the warnings; à Operating manual . Danger of scalding due to ammonia vapours! Ammonia vapour can escape if the AdBlue tank is opened when the outside temperature is high.
Page 110 • Switch the engine off. If you discover any damage Have any damaged parts of the exhaust system replaced immediately by or an authorised GROVE dealer. Manitowoc Crane Care 7 - 38 3 302 756 en Maintenance manual GMK6400...
Page 111: Having The Adblue System Checked
7.5.4 Having the AdBlue system checked This inspection may only be carried out 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 Therefore, a filter cartridge must be installed in a compressed air drier that removes both water and oil. recommends the suitable filter cartridge with the Manitowoc Crane Care GROVE part number 04156032. • If necessary, change to the suitable filter cartridge;...
Page 113: Transmission
Maintenance work on the carrier 7.6 Transmission Transmission Transmission The truck crane can be equipped with an Intarder (integrated Retarder) as à Operating manual . variants additional equipment; (A) – Transmission with Intarder The Intarder (2) is an additional brake integrat- ed into the transmission (1) and shares the oil chamber with the transmission.
Page 114: 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 - 42 3 302 756 en Maintenance manual...
Page 115: Checking The Transmission Oil Level
Maintenance work on the carrier 7.6 Transmission M 12 7.6.2 Checking the transmission oil level Spare parts Designation Quantity GROVE part no. and tools O-ring 21 x 2 04155708 à – Receptacle, about 5 l (1.5 gal); p. 2 - 4. –...
Page 116: Checking The Oil Level - Power Take-Off
Maintenance work on the carrier 7.6 Transmission M 12 7.6.3 Checking the oil level – power take-off Spare parts Designation Quantity GROVE part no. and tools Gasket 26 x 31 Cu DIN 7603 00117147 à – Receptacle, about 5 l (1.5 gal); p.
Page 117: Changing The Oil And Oil Filter - Transmission
Maintenance work on the carrier 7.6 Transmission 7.6.4 Changing the oil and oil filter – Transmission Oil, spare parts Gear oil Specifications GROVE part no. and tools in litres (gal) Classification without Intarder ZF TE-ML02 03325153 15 (4.0) Ecofluid M ZF synthetic with Intarder 25 (6.6)
Page 118 Maintenance work on the carrier 7.6 Transmission Draining 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 119 Maintenance work on the carrier 7.6 Transmission Changing the The oil filter is only present in transmissions with an Intarder. oil filter Transmissions without an Intarder do not have an oil filter. Risk of damage to the transmission! Clogged oil filters can damage transmissions with an Intarder. You must fit a new oil filter at each oil change.
Page 120 Maintenance work on the carrier 7.6 Transmission Topping up the oil • Fill the oil up to the lower edge of the opening. • Replace the seal and tighten the drain plug (1) to a torque of 60 Nm (44.2 lbf ft). à...
Page 121: Changing The Oil And Oil Filter - Power Take-Off
Maintenance work on the carrier 7.6 Transmission 7.6.5 Changing the oil and oil filter – Power take-off Oil, spare parts Gear oil Specifications GROVE part no. and tools in litres (gal) Classification 4.5 (1.2) ZF TE-ML02 03325153 Ecofluid M ZF synthetic Designation Quantity...
Page 122 Maintenance work on the carrier 7.6 Transmission • Place a receptacle underneath the Screw (2) on the power take-off. • Unscrew bolts (1) and (2) and allow the oil to drain. • Clean the drain plugs. • Replace the seal and tighten the drain plug (2) to a torque of 60 Nm (44.2 lbf ft).
Page 123 Maintenance work on the carrier 7.6 Transmission Topping up the oil • Top up the oil through the opening (2) until oil is visible in the sight glass (1). • Replace the seal and tighten the drain plug (2) to a torque of 60 Nm (44.2 lbf ft). à...
Page 124: Test Drive
Maintenance work on the carrier 7.6 Transmission 7.6.6 Test drive • Drive the truck crane for a distance of about 5 km (3 mi). • Do not actuate the Intarder (lever on the steering column). • Switch the engine off. Checking the oil level again On the transmission...
Page 125: Transfer Case
• Check that pipes and hoses are tightly connected and undamaged. If any damage is found, report it to or an authorised Manitowoc Crane Care GROVE dealer or an authorised specialist workshop. 7.7.2 Checking the oil level Spare parts...
Page 126: Changing The Oil
Maintenance work on the carrier 7.7 Transfer case Checking • Unscrew the screw (1). • Check that the oil reaches the lower edge of the opening. • Fit a new gasket and tighten the screw. If the oil level is too low à...
Page 127 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.
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Page 129: Axle Lines
Maintenance work on the carrier 7.8 Axle lines Axle lines à • Comply also with the running-in regulations; p. 4 - 1. Overview There are different drive systems on the 6 axle lines. Driven axle lines Drive system Yes; permanent Axle centre drive, drive shafts, final drives Yes;...
Page 130: 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. 7.8.2 Axle centre drives – checking the oil level...
Page 131 Maintenance work on the carrier 7.8 Axle lines 1st axle line • Unscrew the screw (1). • Check that the oil reaches the lower edge of the opening. • Fit a new gasket and tighten the screw. If the oil level is too low à...
Page 132: Checking The Hydraulic Drives
Check the guard (6) and the cable cover (4) for damage. If any damage is found, report it to or an authorised Manitowoc Crane Care GROVE dealer or an authorised specialist workshop. 7 - 60 3 302 756 en Maintenance manual...
Page 133: Axle Centre Drives - Changing The Oil
Maintenance work on the carrier 7.8 Axle lines M 12 7.8.4 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: C - LPF MIL-L 2105 B 00552891 14.0 (3.7)
Page 134 Maintenance work on the carrier 7.8 Axle lines 1st axle line • Place a receptacle underneath the screw (2). • Unscrew bolts (1) and (2) and allow the oil to drain. • Fit a new seal and tighten the screw (2). •...
Page 135: Final Drives - Checking The Oil Level
Maintenance work on the carrier 7.8 Axle lines 7.8.5 Final drives – Checking the oil level Spare parts Designation Quanti- GROVE part no. and tools Gasket 24 x 29 Cu DIN 7603 00117145 Prerequisites – The truck crane must be raised on outriggers and must be level. –...
Page 136: Final Drives - Changing The Oil
Maintenance work on the carrier 7.8 Axle lines M 12 7.8.6 Final drives – Changing the oil Oil, spare parts, Gear oil Designation Specifications GROVE part no. tools in litres (gal) to DIN 51502 Classification Axle lines 1 + 2: C - LPF MIL-L 2105 B 00552891...
Page 137 Maintenance work on the carrier 7.8 Axle lines Draining oil On the axle line 1, 2, 4 and 5 • Turn the wheel until the bolt (1) is at the bottom. • Use a drain channel and place a receptacle under the screw.
Page 138 Maintenance work on the carrier 7.8 Axle lines Topping up the oil • Turn the wheel until the marking (2) is hori- zontal and is on the right, next to the centre of the axle. • Find out about the different quantities of oil à...
Page 139: Lubricating The Drive Shafts In The Axle Lines
Maintenance work on the carrier 7.8 Axle lines 7.8.7 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 140: Lubricating The Longitudinal Drive Shafts
Maintenance work on the carrier 7.8 Axle lines 7.8.8 Lubricating the 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...
Page 141: Wheels
Maintenance work on the carrier 7.9 Wheels Wheels 7.9.1 Checking the tyres for damage Prerequisites – The truck crane must be raised on outriggers. – The engine must not be running and must be secured against unauthor- à ised use; p.
Page 142: 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 are warm. Never release the increased air pressure of tyres at operating temperature! Always check the tyre pressure with cold tyres in on-road driving mode. •...
Page 143: Checking The Tightness Of Wheel Nuts
Maintenance work on the carrier 7.9 Wheels 7.9.3 Checking the tightness of wheel nuts 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 144: 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 145 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 that the specialist workshop must adhere to.
Page 146 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 - 71. 7 - 74 3 302 756 en Maintenance manual GMK6400...
Page 147 Maintenance work on the carrier 7.9 Wheels Extended Wheel To ensure even more even wear on all tyres, you can also rotate the tyres change on the wheel rim and mount them on the other side of the vehicle. Risk of accidents if the procedure is not carried out correctly! This section only shows the sequence to be followed when changing wheels.
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Page 149: Vehicle Brake
All repair work on the vehicle brakes may only be performed by or an authorised GROVE dealer or an authorised Manitowoc Crane Care specialist workshop with specially trained repair crew. à...
Page 150 7 - 77. • All repair work on the vehicle brakes may only be performed by or an authorised GROVE dealer or an authorised Manitowoc Crane Care specialist workshop with specially trained repair crew. à • Spare parts and tools , Make sure that only original spare parts are used;...
Page 151: Suspension
Notify or an authorised GROVE dealer. Manitowoc Crane Care Risk of damage to the suspension struts due to insufficient lubrication! It is difficult to inject the oil. Do not fill oil through the inspection glass connections! If you do this, the oil will not reach all the lubricating points.
Page 152: Suspension Struts - Checking The Fastening
Maintenance work on the carrier 7.11 Suspension 7.11.2 Suspension struts – checking the fastening Spare parts – Torque wrench for torques of up to 900 Nm (664 lbf ft). and tools à Operating manual. Prerequisites – The truck crane must be raised on outriggers; –...
Page 153: Forced Lever - Checking Correct Functioning
If the suspension struts are not extended or only partially extended, the forced lever is faulty. • Have faulty forced levers replaced as soon as possible by or an authorised GROVE dealer or your Manitowoc Crane Care qualified repair crew. Maintenance manual 3 302 756 en 7 - 81...
Page 154: Pressure Accumulator - Checking The Gas Pressure
The filling pressure at 20 °C (68 °F) is 40 bar (580 psi). • Have the filling pressure checked, and if necessary corrected, by Manitowoc Crane Care or an authorised GROVE dealer or an authorised specialist workshop. 7 - 82 3 302 756 en...
Page 155: Steering
Bleeding the hydraulic system , p. 7 - 102. 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 3 302 756 en 7 - 83 GMK6400...
Page 156: Pressure Accumulator - Checking The Gas Pressure
89 bar (1,290 psi) 100 bar (1,450 psi) • Have the filling pressure checked, and if necessary corrected, by Manitowoc Crane Care or an authorised GROVE dealer or an authorised specialist workshop. 7 - 84 3 302 756 en Maintenance manual...
Page 157: Compressed Air System
7 - 1. 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 3 302 756 en 7 - 85...
Page 158: 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 - 86 3 302 756 en Maintenance manual...
Page 159: Replacing The Compressed Air Dryer Filter Cartridge
Maintenance work on the carrier 7.13 Compressed air system M 12 7.13.3 Replacing the compressed air dryer filter cartridge Spare parts Designation Quantity GROVE part no. and tools Filter cartridge with gasket 04156032 – Strap wrench. Prerequisites – The truck crane must be raised on outriggers or parked over an inspection pit.
Page 160 Maintenance work on the carrier 7.13 Compressed air system Blank page 7 - 88 3 302 756 en Maintenance manual GMK6400...
Page 161: Hydraulic System
Maintenance work on the carrier 7.14 Hydraulic system 7.14 Hydraulic system Risk of environmental damage due to leaking consumables! Always let consumables drain into suitable receptacles. Wipe up any consumables that escape. Store/dispose of consumables and any soaked equipment properly. Ask about the applicable regulations.
Page 162: 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 (cracks, abrasion, heat damage, chemical damage) –...
Page 163: Cleaning The Magnetic Rods
Bleed the carrier hydraulic system; p. 7 - 102. 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 164 Risk of damage to the hydraulic system! Large amounts of metal particles are a sign of damage in the hydraulic system. Have the hydraulic system checked by or an Manitowoc Crane Care authorised GROVE dealer or your repair crew. • Assemble the filters and install them.
Page 165: Changing The Ventilation Filters
Maintenance work on the carrier 7.14 Hydraulic system M 12 7.14.5 Changing the ventilation filters • Reducing the Under difficult operating conditions – at extremely sandy or dusty loca- interval tions – you must change the ventilation filter earlier than normal. Spare parts Designation Quantity...
Page 166: 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 – A hose with a connecting piece for a gauge port. and tools Hose lengths GROVE part no.
Page 167 Maintenance work on the carrier 7.14 Hydraulic system Protecting the hose from dirt Danger of contamination of the oil sample! If the hose with the connecting piece is dirty, the dirt can contaminate the oil sample in the sample container during the sampling process. The laboratory analysis would then be incorrect.
Page 168 Maintenance work on the carrier 7.14 Hydraulic system Taking oil samples The hose end (1) is connected to the cylinder (3). The hose end (2) is in the receptacle (4). • Start the engine. • Allow 2 litres (0.5 gal) of oil to flow into the receptacle.
Page 169 Maintenance work on the carrier 7.14 Hydraulic system Dispatching the oil gives you the opportunity to have the oil sample Manitowoc Crane Care sample to the analysed at our contracted laboratory. A delivery note and a protective laboratory mailing bag are available along with the sample containers (GROVE part no.
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Page 171: 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 - 97. need for this; Oil, spare parts, Hydraulic oil Designation...
Page 172 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 173 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 174 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 - 102 3 302 756 en Maintenance manual GMK6400...
Page 175: Changing The Hydraulic Oil Filter
Maintenance work on the carrier 7.14 Hydraulic system 7.14.8 Changing the hydraulic oil filter All oil filters must be replaced when changing the oil. In the event of a warning message, the red symbols in the Warning submenu indicate which oil filters you have to change. 1 Red –...
Page 176 Large amounts of metal particles are a sign of damage in the hydraulic system. Have the hydraulic system checked by or an author- Manitowoc Crane Care ised GROVE dealer or your repair crew. • Assemble the filters and install them.
Page 177 Maintenance work on the carrier 7.14 Hydraulic system Changing Filter 3 is installed on the left side and filter 4 is on the right side. filters 3 and 4 • Place a receptacle underneath the filter. • Remove the housing (1). •...
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Page 179: Central Lubrication System
Maintenance work on the carrier 7.15 Central lubrication system 7.15 Central lubrication system The central lubrication system supplies the steering lever and all the axle lines. 7.15.1 Checking the filling level Grease, spare Lubricating Designation Specifications GROVE part no. parts, tools grease to DIN 51502 Classification...
Page 180 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 181: 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). •...
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Page 183: Electrical System
Risk of accidents in the event of faulty safety devices! Have faulty lights and indicators repaired by or an Manitowoc Crane Care authorised GROVE dealer or an authorised specialist workshop. • Check the following functions every day before starting work or driving and have any faulty parts repaired: –...
Page 184: Checking The Batteries
Maintenance work on the carrier 7.16 Electrical system 7.16.2 Checking the batteries Risk of poisoning from storage batteries containing lead! Battery poles, terminals and parts inside the battery contain lead. Residue containing lead can stick to your hands and may not be allowed to enter your body –...
Page 185 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 186: 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 – Battery testing device; Separate operating manual , o and tools – Acid siphon. Charge level table The measurement of the acid concentration with the acid siphon will give you an indication of the charge level of the batteries.
Page 187 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 mainte- nance-free.
Page 188: 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 189: Checking The External Starting Socket
Maintenance work on the carrier 7.16 Electrical system 7.16.5 Checking the external starting socket The GMK6400 truck crane can be equipped with an external starting socket (1) as additional equipment. Accessories A connection cable (1) for the external starting socket can be ordered as an accessory.
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Page 191: 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 connections.
Page 192: Cleaning The Condenser Fins
This inspection may only be carried out by or an Manitowoc Crane Care authorised GROVE dealer or an authorised specialist workshop! Risk of burns due to escaping refrigerant! Wear suitable safety glasses and gloves when checking the hoses and connections.
Page 193 Maintenance work on the carrier 7.17 Air-conditioning system Refrigerant Fill quantity Designation CAS no. in kg (lbs) EC no. 2.60 (5.73) 811-97-2 Tetrafluoroethane (R134a) 2.85 (6.28) 212-377-0 (with Fuel Saver ) Filler connections The filler connections (1) for refrigerants are located behind the front flap (2) on the driver's cab.
Page 194: Changing The Pollen Filter
Maintenance work on the carrier 7.17 Air-conditioning system M 12 7.17.5 Changing the pollen filter • Reducing the Under difficult operating conditions – at extremely sandy or dusty interval locations – you must change the pollen filter earlier. Spare parts Designation Quantity GROVE part no.
Page 195: Towbar Coupling
Maintenance work on the carrier 7.18 Towbar coupling 7.18 Towbar coupling Depending on the equipment fitted to your truck crane, it may have towbar couplings (additional equipment) from different manufacturers. The wear values for other manufacturers may vary from those specified; à...
Page 196 Maintenance work on the carrier 7.18 Towbar coupling Closing the towbar coupling Risk of injury when closing the towbar coupling by hand! When closing, the lever moves down with great force in the direction of the coupling jaw. Start the closing process only by moving the lever briefly in the direction of the coupling jaw with the ball of your hand.
Page 197: Checking The Bearing
Maintenance work on the carrier 7.18 Towbar coupling 7.18.2 Checking the bearing à Prerequisites – The coupling is closed; p. 7 - 124. Checking the bearing Risk of injury! Ensure that the towbar coupling is closed for the following work (lever points downwards).
Page 198: Checking The Cotter Pin
If the dimension is smaller than the above mentioned dimension then have the coupling pin replaced by or an au- Manitowoc Crane Care thorised GROVE dealer or your qualified repair crew. • Also check the cotter pin for the correct vertical play.
Page 199: Checking The Lower Bushing
Model series 700: 34.2 mm (1.35 in) If the dimension is larger than that given above, have the bushing replaced by or an authorised GROVE Manitowoc Crane Care dealer or your repair crew. 7.18.5 Checking the initial tension of the springs The coupling head should require physical force to twist it when checking the torque.
Page 200: Checking The Support Ring
Maintenance work on the carrier 7.18 Towbar coupling 7.18.6 Checking the support ring à Prerequisites – The coupling is closed; p. 7 - 124. Checking the support ring • Check the support ring (1) at the bottom of the coupling jaw. When the trailer is coupled, the draw eyelet of the trailer must not be in contact with the lower bushing (2).
Page 201 Maintenance work on the carrier 7.18 Towbar coupling Checking the functionality The coupling jaw must be able to move easily in both directions. • Hold the coupling jaw (1) pressed slightly to the left or right. • Open the coupling (position A) and let the coupling jaw go.
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Page 203: Other Maintenance Work
Maintenance work on the carrier 7.19 Other maintenance work 7.19 Other maintenance work 7.19.1 Checking the windscreen washing system Water Designation Quantity GROVE part no. Spare parts Tool Wiper blades 02311858 – Water; add commercially available detergent and antifreeze to it. –...
Page 204: Lubricating The Outrigger Beams
Maintenance work on the carrier 7.19 Other maintenance work 7.19.2 Lubricating the outrigger beams à • Comply also with the running-in regulations; p. 4 - 1. Grease, spare Lubricating Designation Specifications GROVE part no. parts, tools grease to DIN 51502 Classification Grease KP - 1K - 50...
Page 205: Checking The Functioning Of The Auxiliary Heater
Check that the system is working properly. Also check the functionality of the controls. • If the heating system is not working correctly, report it to or an authorised GROVE dealer or an Manitowoc Crane Care authorised specialist workshop. M 12 7.19.4 Lubricating the cab door...
Page 206: Lubricating The Connecting Pins 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 207: Renewing The Corrosion Protection
Maintenance work on the carrier 7.19 Other maintenance work M 12 7.19.6 Renewing the corrosion protection Protective agent, Protective agent GROVE part no. tools Corrosion protection 03140192 – Spray gun with spray extension. – Brush. – Protective clothing, protective goggles. Prerequisites –...
Page 208 Maintenance work on the carrier 7.19 Other maintenance work Spraying Risk of injury to the eyes! While working with the spray extension you could be hit by the spray jet or spray droplets. Wear protective goggles, protective clothing and gloves. •...
Page 209: Having The Fire Extinguisher Checked
Maintenance work on the carrier 7.19 Other maintenance work 7.19.7 Having the fire extinguisher checked Depending on your truck crane's equipment, it can be fitted with fire extinguishers. The maintenance interval may even be shorter, depending on the respective national regulations and the operating location. Ask the local fire safety officer about the national and local regulations.
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Page 211 Maintenance work on the superstructure General instructions ..........8 - 8.1.1 Covers .
Page 212 Main boom ............8 - 65 8.8.1 Greasing the piston rod of the derricking cylinder .
Page 213: Maintenance Work On The Superstructure
Maintenance work on the superstructure 8.1 General instructions Maintenance work on the superstructure General instructions 8.1.1 Covers For certain maintenance work, you must remove/fold out the covers. Before maintenance work • Remove the covers (1). After maintenance work • Fasten the covers (1) with the locks. Maintenance manual 3 302 756 en 8 - 1...
Page 214: Overview Of Maintenance Work On The Superstructure
Maintenance work on the superstructure 8.1 General instructions 8.1.2 Overview of maintenance work on the superstructure 8 - 2 3 302 756 en Maintenance manual GMK6400...
Page 215 Maintenance work on the superstructure 8.1 General instructions à Covers p. 8 - 1 à 5 Covers p. 8 - 1 à Symbols for maintenance work p. 8 - 9 à 1 ECOS display p. 8 - 9 à Hoists p.
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Page 217 Maintenance work on the superstructure 8.1 General instructions à Pump transfer case p. 8 - 35 à 5 Oil inspection plug p. 8 - 36 à 14 Oil cooler p. 8 - 37 à 15 Oil filter p. 8 - 41 à...
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Page 219 Maintenance work on the superstructure 8.1 General instructions à Central lubrication system p. 8 - 89 à 10 Centralised lubrication pump p. 8 - 89 à Electrical system p. 8 - 95 à 7 Spotlights on the crane cab p. 8 - 95 à...
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Page 221: Symbols For Maintenance Work
Maintenance work on the superstructure 8.2 Symbols for maintenance work Symbols for maintenance work Check the following symbols every day before starting work. On the ECOS display • Open the Warning submenu in the crane cab; à Operating manual . You must carry out the corresponding maintenance work if a symbol is displayed in red: à...
Page 222 Maintenance work on the superstructure 8.2 Symbols for maintenance work Blank page 8 - 10 3 302 756 en Maintenance manual GMK6400...
Page 223: Hoists
Maintenance work on the superstructure 8.3 Hoists Hoists 8.3.1 Checking the oil level Spare parts Designation Quantity GROVE part no. and tools Gasket 14 x 18 St DIN 7603 03043733 Gasket 18 x 22 St DIN 7603 01927403 Prerequisites – The truck crane must be level. à...
Page 224: General Inspection
• Check that pipes and hoses are tightly connected and undamaged. If any damage is found, report it to or an authorised Manitowoc Crane Care GROVE dealer or your repair crew. 8.3.3 Checking the hoist brake Check that the hoist brake is working correctly on the main hoist and the auxiliary hoist.
Page 225: Support For Block - Checking The Sheaves
(2) for damage, wear, mobility and extreme soiling. Have damaged, worn, sluggish or extremely soiled sheaves replaced by or an authorised GROVE dealer or your repair crew. Manitowoc Crane Care Maintenance manual 3 302 756 en 8 - 13...
Page 226: Changing The Oil/Checking The Oil
Maintenance work on the superstructure 8.3 Hoists M 12 8.3.5 Changing the oil/checking the oil à • Comply also with the running-in regulations; p. 4 - 1. Oil, spare parts, Gear oil Designation Specifications GROVE part no. tools in litres (gal) to DIN 51502 Classification 7 (1.9)
Page 227 Some abrasion particles may appear in the first oil filled. If you notice such particles during the first oil change (after 200 oper. hrs.), first consult , before initiating any further measures. Manitowoc Crane Care Maintenance manual 3 302 756 en...
Page 228: Having A Partial Inspection Carried Out
Maintenance work on the superstructure 8.3 Hoists 8.3.6 Having a partial inspection carried out Only suitably trained specialists should carry out a partial inspection of: – The multiple-disk brake – The plug connections between the hydraulic motor and the multiple-disk brake –...
Page 229: Slewing Gear
Maintenance work on the superstructure 8.4 Slewing gear Slewing gear 8.4.1 Checking the oil level Spare parts Designation Quantity GROVE part no. and tools Gasket 10 x 13.5 Cu DIN 7603 00117125 à Operating manual . Prerequisites – The truck crane must be level and in on-road mode; –...
Page 230: Checking For Leaks
In the event of leaking consumables; • Check that pipe lines and hoses are tightly connected and undamaged. If any damage is found, report it to or an authorised Manitowoc Crane Care GROVE dealer or your repair crew. 8.4.3 Checking the slewing gear brake Prerequisites –...
Page 231 – If the superstructure slews, the slewing gear brake is faulty and must be repaired immediately by or an authorised Manitowoc Crane Care GROVE dealer. • Switch the slewing gear off and switch the engine off.
Page 232: Changing The Oil/Checking The Oil
Maintenance work on the superstructure 8.4 Slewing gear M 12 8.4.4 Changing the oil/checking the oil à • Comply also with the running-in regulations; p. 4 - 1. Oil, spare parts, Gear oil Designation Specifications GROVE part no. tools in litres (gal) to DIN 51502 Classification 0.9 (0.24)
Page 233 Maintenance work on the superstructure 8.4 Slewing gear Draining oil • Remove the plate (1). • Place a container under the screws (2). • Unscrew the filter (4) and bolts (3) and (2). • Drain the oil. • Replace the gasket and tighten the screws (2).
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Page 235: Slewing Bearing
Maintenance work on the superstructure 8.5 Slewing bearing Slewing bearing 8.5.1 Checking the bolts à • Comply also with the running-in regulations; p. 4 - 1. Tools – Torque wrench for maximum of 1,450 Nm (1,070 lbf ft). à – Auxiliary tools for the torque wrench; p.
Page 236 Do not put the truck crane back into operation and have the slewing bearing repaired by Manitowoc Crane Care Access The outer ring is attached to the carrier by the bolts (1).
Page 237 Maintenance work on the superstructure 8.5 Slewing bearing Selecting the tools Outer ring The bolt heads (1) are easily accessible for fitting a socket wrench. There- fore, you can use manual or mechanical torque tools (electric or hydraulic screw drivers). Inner ring The screw head (1) is accessible only via a rectangular, long, narrow opening (2).
Page 238 Maintenance work on the superstructure 8.5 Slewing bearing • Checking the Divide the checking of the 80 screws into 16 working steps of 5 screws outer ring each. Between each of the 16 operation steps you need to rotate the turntable to the next group of 5 screws on the opposite side.
Page 239: Lubricating The Gear Teeth
Maintenance work on the superstructure 8.5 Slewing bearing 8.5.2 Lubricating the gear teeth Grease Designation Quantity GROVE part no. Adhesive lubricating grease (spray 00554205 can) Observe the instructions and safety instructions on the adhesive lubricating grease packaging! à Operating manual . Prerequisites –...
Page 240 Maintenance work on the superstructure 8.5 Slewing bearing First lubrication • Remove the plate (1). • Remove the old grease from all the gear teeth (2). • Apply a thin layer of new grease to all the gear teeth and allow it to penetrate for about 10 minutes.
Page 241: 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 ball slewing bearing for damage (e.g. gaskets). If any damage is found, report it to...
Page 242: Measuring Tilting Play
Maintenance work on the superstructure 8.5 Slewing bearing 8.5.4 Measuring tilting play • Reducing the When after several years of intensive crane operation, half of the value for interval the maximum permissible tilting play is reached, then you must reduce the maintenance interval.
Page 243 The base value of the tilting play is determined and documented by tilting play or an authorised GROVE dealer when the slewing Manitowoc Crane Care bearing is put into operation or replaced. The maximum permissible wear is 0.7 mm (0.028 in).
Page 244: Lubricating The Turntable Lock
Maintenance work on the superstructure 8.5 Slewing bearing M 12 8.5.5 Lubricating the turntable lock Grease, tools Lubricating Designation Specifications GROVE part no. grease to DIN 51502 Classification Grease KP - 1K - 50 DIN 51825 03233369 – Brush. Prerequisites –...
Page 245 Check whether the locking cylinder (1) retracts into the housing (2) straight and without jerks. If any damage is found, report it to or an authorised Manitowoc Crane Care GROVE dealer. Maintenance manual 3 302 756 en 8 - 33...
Page 246 Maintenance work on the superstructure 8.5 Slewing bearing Blank page 8 - 34 3 302 756 en Maintenance manual GMK6400...
Page 247: Pump Transfer Case
• Check that pipe lines and hoses are tightly connected and undamaged. If any damage is found, report it to or an authorised Manitowoc Crane Care GROVE dealer or an authorised specialist workshop. Maintenance manual 3 302 756 en 8 - 35...
Page 248: Checking The Oil Level
Maintenance work on the superstructure 8.6 Pump transfer case 8.6.3 Checking the oil level Spare parts Designation Quantity GROVE part no. and tools Gasket 21 x 26 Cu DIN 7603 00117141 Prerequisites – The truck crane is supported and levelled with an outrigger span of at least 8.70 x 2.71 m (28.5 x 8.9 ft).
Page 249: Changing The Oil
Maintenance work on the superstructure 8.6 Pump transfer case M 12 8.6.4 Changing the oil Oil, spare parts, Gear oil Designation Specifications GROVE part no. tools in litres (gal) to DIN 51502 Classification 4.6 (1.2) Omala S4 GX 150 03143502 Designation Quantity GROVE part no.
Page 250 Maintenance work on the superstructure 8.6 Pump transfer case Draining • Place a receptacle under the filter (5) and à Changing the oil filter , replace the filter; p. 8 - 41. • Remove the end of the hose (2) on the filter (5).
Page 251 Maintenance work on the superstructure 8.6 Pump transfer case Topping up • Connect the end of the hose (2) to the grille (1). • Position a funnel at the end of the hose (2). • Empty all of the oil slowly through the funnel.
Page 252 Maintenance work on the superstructure 8.6 Pump transfer case • Remove the funnel. • Disconnect the end of the hose (2) from the grille (3) and attach it to the filter (1). à • After changing Check the oil level; p.
Page 253: Changing The Oil Filter
Maintenance work on the superstructure 8.6 Pump transfer case M 12 8.6.5 Changing the oil filter If the visual display is no longer green, then you must replace the oil filter; à Checking the oil filter , p. 8 - 35. When changing the oil the oil filter must be replaced.
Page 254 Maintenance work on the superstructure 8.6 Pump transfer case à • After Changing Check the oil level; p. 8 - 36. filters • Check the oil filter for leaks. 8 - 42 3 302 756 en Maintenance manual GMK6400...
Page 255: Hydraulic System
Maintenance work on the superstructure 8.7 Hydraulic system Hydraulic system Risk of environmental damage due to leaking consumables! Always let consumables drain into suitable receptacles. Wipe up any consumables that escape. Store/dispose of consumables and any soaked equipment properly. Ask about the applicable regulations. 8.7.1 Checking the oil level à...
Page 256: Checking The Hydraulic Hoses
Maintenance work on the superstructure 8.7 Hydraulic system 8.7.2 Checking the hydraulic hoses The inspection work is described in section Checking the hydraulic hoses , p. 7 - 90. 8.7.3 Checking the ventilation filters • Check the displays (1) on the ventilation filters.
Page 257: Checking For Leaks
Bleed the hydraulic system; p. 8 - 59. 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 3 302 756 en 8 - 45 GMK6400...
Page 258: Cleaning The Magnetic Rods
Maintenance work on the superstructure 8.7 Hydraulic system 8.7.5 Cleaning the magnetic rods Spare parts Designation Quantity GROVE part no. and tools For oil filter 1: Filter 03325700 Packing set 03135853 For oil filter 2: Filter 03317083 Cover gasket 01372280 à...
Page 259 Risk of damage to the hydraulic system! Large amounts of metal particles are a sign of damage in the hydraulic system. Have the hydraulic system inspected by or by Manitowoc Crane Care your qualified repair personnel. • Replace the gaskets (packing set) if necessary.
Page 260 Risk of damage to the hydraulic system! Large amounts of metal particles are a sign of damage in the hydraulic system. Have the hydraulic system inspected by or by Manitowoc Crane Care your qualified repair personnel. • Replace the cap gasket.
Page 261: Changing The Ventilation Filters
Maintenance work on the superstructure 8.7 Hydraulic system M 12 8.7.6 Changing the ventilation filters Spare parts Designation Quantity GROVE part no. and tools Filter 03134932 Prerequisites – The engine must not be running and must be secured against unauthor- à...
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Page 263: Taking Oil Samples
Maintenance work on the superstructure 8.7 Hydraulic system M 12 8.7.7 Taking oil samples The oil sample from the superstructure hydraulic system is taken in a way similar to that for the carrier hydraulic system. Information on taking samples with the hose and for the laboratory analy- à...
Page 264 Maintenance work on the superstructure 8.7 Hydraulic system Taking oil samples • Clean the gauge port and connect the à Connecting hose (1) to the pump (3); the hose , p. 7 - 95. • Put the hose end (2) into the receptacle (4). •...
Page 265: Changing The Hydraulic Oil Filter
Maintenance work on the superstructure 8.7 Hydraulic system 8.7.8 Changing the hydraulic oil filter All oil filters must be replaced when changing the oil. In the event of a warning message, the red symbols in the Warning sub- menu indicate which oil filters you have to change. 1 Red –...
Page 266 Maintenance work on the superstructure 8.7 Hydraulic system Changing oil filter 1 Risk of environmental damage due to leaking consumables! Always let consumables drain into suitable receptacles. Wipe up any consumables that escape. Store/dispose of consumables and any soaked equipment properly. Ask about the applicable regulations.
Page 267 Maintenance work on the superstructure 8.7 Hydraulic system Changing oil filter 2 Risk of environmental damage due to leaking consumables! Always let consumables drain into suitable receptacles. Wipe up any consumables that escape. Store/dispose of consumables and any soaked equipment properly. Ask about the applicable regulations.
Page 268 Maintenance work on the superstructure 8.7 Hydraulic system Changing oil filter 3 • Release the container (1). • Change the filter (2). • Replace the gaskets. • Fill the receptacle with clean oil and tighten it – torque 25 Nm (18.5 ft lbf). After changing filters Risk of damage to the hydraulic pumps!
Page 269: Changing The Hydraulic Oil
Maintenance work on the superstructure 8.7 Hydraulic system 8.7.9 Changing the hydraulic oil The oil only needs to be changed if the laboratory analysis results indicate à Taking oil samples , p. 8 - 51. this; Oil, spare parts, Hydraulic oil Designation Specifications GROVE part no.
Page 270 Maintenance work on the superstructure 8.7 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 271 Maintenance work on the superstructure 8.7 Hydraulic system Establishing After changing the oil filters and topping up the oil, you must re-establish the operating the operating condition. condition Risk of damage to the hydraulic pumps! Open the valve prior to starting the engine. This prevents damage to the hydraulic pumps.
Page 272: Have The Radiator Checked/Cleaned
Maintenance work on the superstructure 8.7 Hydraulic system M 12 8.7.10 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 273 Maintenance work on the superstructure 8.7 Hydraulic system The two radiator units (1) and (2) consist of different radiators (4). They are located below or behind the grilles (3). The fan impellers (6) are located un- der the radiators (4). The fan impellers rotate when the engine is running! Risk of injury at the fan impeller! When the fan impellers are rotating they can trap the fingers of your hand and amputate them.
Page 274 Maintenance work on the superstructure 8.7 Hydraulic system Have them cleaned Risk of injury at the fan impeller! When the fan impeller is rotating it can trap the fingers of your hand and amputate them. Never reach into the fan impeller when it is rotating. Do not push any tools through the impeller to clean it.
Page 275 Maintenance work on the superstructure 8.7 Hydraulic system • Have the radiator units (1) and (2) opened up by the repair specialists, so that the radiator fins (4) are accessible. • Have the radiator fins (4) cleaned on both sides, using suitable cleaning agents.
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Page 277: Main Boom
Maintenance work on the superstructure 8.8 Main boom Main boom 8.8.1 Greasing the piston rod of the derricking cylinder Grease, spare Designation GROVE part no. parts and tools Lubricant RHUS SW 2; 1 kg 03325215 (Apply the grease with a brush) Spray on Berulub;...
Page 278: Lubricating The Telescopic Sections
– A grease gun for the grease nipples on the upper telescopic slide faces. – A brush or roller for the outer, upper and lower telescopic slide faces. 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 279 Maintenance work on the superstructure 8.8 Main boom Notes Risk of overturning when telescoping if the RCL is overridden! Do not override the rated capacity limiter (RCL) when telescoping is switched off. Select a suitable lifting capacity table which contains the required telescope status.
Page 280 Maintenance work on the superstructure 8.8 Main boom Lubricating the locking pins • Use the grease gun (RHUS 2 AF) to lubricate the locking pins at the grease nipples (1) on both sides. • Lock and unlock the telescopic section I sev- eral times, so that the grease is distributed over the locking pins.
Page 281 Maintenance work on the superstructure 8.8 Main boom Lubricating the locking pins • Use the grease gun (RHUS 2 AF) to lubricate the locking pins at the grease nipples (1) on both sides. • Raise the main boom to 15°. •...
Page 282: Checking The Sheaves
Check all sheaves (1) and (2) for damage, wear, mobility and heavy soiling. Have damaged, worn, stiff or extremely soiled sheaves replaced by or an authorised GROVE dealer or your repair crew. Manitowoc Crane Care M 12 8.8.4 Checking the locking system...
Page 283: Hoist Ropes
Maintenance work on the superstructure 8.9 Hoist ropes Hoist ropes 8.9.1 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. Prerequisites –...
Page 284: Checking The Hoist Ropes
Maintenance work on the superstructure 8.9 Hoist ropes 8.9.2 Checking the hoist ropes Spare parts – Torque wrench for 80 Nm (59 lbf ft). and tools – Establish a rigging mode in accordance with the lifting capacity table and Prerequisites à...
Page 285: 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 286: Assessing The Condition Of The Hoist Rope
Maintenance work on the superstructure 8.9 Hoist ropes 8.9.4 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 287 Maintenance work on the superstructure 8.9 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 288 Maintenance work on the superstructure 8.9 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 289 Maintenance work on the superstructure 8.9 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 290 Maintenance work on the superstructure 8.9 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 291 Maintenance work on the superstructure 8.9 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 292: Replacing The Hoist Rope
Maintenance work on the superstructure 8.9 Hoist ropes 8.9.5 Replacing the hoist rope à Spare parts – An original replacement part; Rope certificate . and tools – A reel stand with braking block. – Torque wrench for 80 Nm (59 lbf ft). Risk of accidents due to falling loads! Use only a replacement rope that has the same technical specifications as the defective rope, or an authentic replacement rope.
Page 293 Maintenance work on the superstructure 8.9 Hoist ropes • Remove the clamp (4). • Push the rope through the hole (3) until the rope wedge (1) slides out of the pouch (2). • Remove the rope wedge and place the old rope away from the truck crane.
Page 294 Maintenance work on the superstructure 8.9 Hoist ropes • Guide the rope through the hole (3) until it protrudes about 1.5 m (5.0 ft) beyond the pocket (2). • Feed the free end of the rope back through the pouch. •...
Page 295: Setting The Lowering Limit Switch
Maintenance work on the superstructure 8.9 Hoist ropes Observe the hook block when unreeling. The hook block must not rotate! Risk of accidents from incorrectly set lowering limit switch! After inserting a new rope, the lowering limit switch must always be reset. In this way you avoid the lowering limit switch switching off too late or not at all, the rope being damaged and the load being dropped.
Page 296 Maintenance work on the superstructure 8.9 Hoist ropes Setting the lower- ing limit switch Risk of accidents due to overloaded rope end fitting! 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 297: Cable Drums And Slewing Angle Sensor
Maintenance work on the superstructure 8.10 Cable drums and slewing angle sensor 8.10 Cable drums and slewing angle sensor 8.10.1 Maintenance of the slip ring assemblies The slip ring assemblies are located in: 1 Cable drum 1 2 Cable drum 2 Spare parts Designation Quantity...
Page 298: Maintenance Of The Slip Ring Assemblies
Maintenance work on the superstructure 8.10 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 299: Lubricating The Slewing Angle Sensor
Maintenance work on the superstructure 8.10 Cable drums and slewing angle sensor 8.10.2 Lubricating the slewing angle sensor Grease, spare Lubricating Designation Specifications GROVE part no. parts, tools grease to DIN 51502 Classification Grease KP - 1K - 50 DIN 51825 03233369 Designation Quantity...
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Page 301: Central Lubrication System
Maintenance work on the superstructure 8.11 Central lubrication system 8.11 Central lubrication system 8.11.1 Checking the filling level The maintenance of the pump (1) is the same as the maintenance on the carrier; à Central lubrication system , p. 7 - 107. Connected lubricating points: –...
Page 302 Maintenance work on the superstructure 8.11 Central lubrication system Blank page 8 - 90 3 302 756 en Maintenance manual GMK6400...
Page 303: 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 8.12.2 Lubricating à...
Page 304 Maintenance work on the superstructure 8.12 Hook blocks The diagram gives an example of the arrange- ment of the grease nipples (1), (2) and (3) on a hook block. There are more grease nipples on the other side. • Clean the grease nipples on all hook blocks and grease them using a grease gun.
Page 305 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 306 Maintenance work on the superstructure 8.12 Hook blocks Blank page 8 - 94 3 302 756 en Maintenance manual GMK6400...
Page 307: Electrical System
Risk of accidents in the event of faulty safety devices! Have faulty lights and indicators repaired by or an Manitowoc Crane Care authorised GROVE dealer or an authorised specialist workshop. • Check the lamps and displays on the ECOS and RCL control units;...
Page 308 Maintenance work on the superstructure 8.13 Electrical system Blank page 8 - 96 3 302 756 en Maintenance manual GMK6400...
Page 309: 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. 8.14.2 Checking hoses • Check the hoses in the same way as when checking them on the carrier;...
Page 310 Maintenance work on the superstructure 8.14 Air-conditioning system Blank page 8 - 98 3 302 756 en Maintenance manual GMK6400...
Page 311: Other Maintenance Work
Maintenance work on the superstructure 8.15 Other maintenance work 8.15 Other maintenance work 8.15.1 Checking the windscreen washing system Water Spare Designation Quantity GROVE part no. parts Tool Windscreen wiper blade 03326121 Roof wiper blade 03326121 – Water; add commercially available detergent and antifreeze to it. –...
Page 312 Maintenance work on the superstructure 8.15 Other maintenance work Wipe up 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. •...
Page 313: Checking The Functioning Of The Auxiliary Heater
Maintenance work on the superstructure 8.15 Other maintenance work 8.15.2 Checking the functioning of the auxiliary heater • Check the auxiliary heater (1) in the crane cab in the same way as in the driver's cab; à Checking the functioning of the auxiliary heater , p.
Page 314: Lubricating The Crane Cab Door
Check if the door moves smoothly on the rails and if it locks easily. If the door is sluggish or does not close properly, have it adjusted by or an authorised GROVE-dealer. Manitowoc Crane Care 8 - 102 3 302 756 en Maintenance manual...
Page 315: Lubricating The Step
Fully retract the step. If the step is stiff, bent or does not retract completely, have the step aligned and adjusted by or an authorised GROVE dealer. Manitowoc Crane Care Maintenance manual 3 302 756 en 8 - 103 GMK6400...
Page 316: Lubricating The Connecting Pins 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 317: Renewing The Corrosion Protection
Maintenance work on the superstructure 8.15 Other maintenance work M 12 8.15.6 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 318 Maintenance work on the superstructure 8.15 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 319: Having The Fire Extinguisher Checked
Maintenance work on the superstructure 8.15 Other maintenance work 8.15.7 Having the fire extinguisher checked Depending on your truck crane's equipment, it can be fitted with fire extinguishers. The maintenance interval may even be shorter, depending on the respective national regulations and the operating location. Ask the local fire safety officer about the national and local regulations.
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Page 321 Longer out of service periods Maintenance manual 3 302 756 en GMK6400...
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Page 323: Longer Out Of Service Periods
Longer out of service periods Longer out of service periods Carry out the following work if the truck crane is to be out of service for a long period (months). • Shut down Clean the truck crane thoroughly on the inside and outside. •...
Page 324 Longer out of service periods • Ensure that the tyre positioning is different each time the crane is parked (without outriggers). • Seal the air filter again. If the truck crane is put out of service for more than 12 months: •...
Page 325 Torques 10.1 Torques for retaining bolts ......... . . 10 - 10.2 Special torques .
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Page 327: Torques
Torques 10.1 Torques for retaining bolts Torques 10.1 Torques for retaining bolts Metric standard screw thread Approximate values Metric fine screw-thread Thread size Torques (mm) (greatest permissible preloading for bolts) Size across flats (mm) for oiled bolts (Nm) Bolt quality Hexagon Cylinder 10.9...
Page 328 Torques 10.2 Special torques 10.2 Special torques Thread size Size across flats Torque (mm) (mm) (Nm) Description Hexagon Cylinder head screw screw Suspension strut: – Bracket for the vehicle chassis, M 16 — – Bracket for the vehicle chassis, M 24 —...
Page 329 Spare parts required for maintenance 11.1 General information ..........11 - 11.2 Lighting .
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Page 331: 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. Only the spare parts required for the maintenance work described are listed here.
Page 332 Spare parts required for maintenance 11.2 Lighting Installation point GROVE part Designation Power (W) number CARRIER LIGHTING: Front spotlights: (integrated in the bumper) – Daytime driving light 03328445 P21W 24 V – Low-beam + full-beam headlights 03134828 H7 24 V –...
Page 333 Spare parts required for maintenance 11.2 Lighting Installation point GROVE part Designation Power (W) number Red triple light strip for USA: (at the rear of the chassis) – Triple light strip 7581100056 White front marker lights: (at the top on the driver's cab) –...
Page 334 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, left and right 03329569 Red rear marker lights: (on the turntable) – Marker light 03329492 FPL 98 CKS Yellow rotating beacon:...
Page 335: 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 Valve M 20 x 1.5 03041579 Once when the oil is changed the first time;...
Page 336 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 337 Spare parts required for maintenance 11.3 Spare parts for the carrier Quantity, in single parts Assemblies and spare parts GROVE For maintenance interval carrier Part number Y 10 Engine Oil filter with gasket 03328365 Gasket for oil drain plug 03329824 for diesel engine with AdBlue system Gasket for oil drain plug for diesel engine without AdBlue...
Page 338: Spare Parts For The Superstructure
Spare parts required for maintenance 11.4 Spare parts for the superstructure 11.4 Spare parts for the superstructure Quantity, in single parts Assemblies and spare parts GROVE For maintenance interval superstructure Part number M 12 Hoists Gasket 14 x 18 St DIN 7603 03043733 (if damaged) Gasket 18 x 22 St DIN 7603...
Page 339 Spare parts required for maintenance 11.4 Spare parts for the superstructure Quantity, in single parts Assemblies and spare parts GROVE For maintenance interval superstructure Part number M 12 Hoist ropes Cover gasket for the lowering limit 1 piece (if damaged) 03137794 switch For every rope change on the hoist...
Page 340 Spare parts required for maintenance 11.4 Spare parts for the superstructure Blank page 11 - 10 3 302 756 en Maintenance manual GMK6400...
Page 341 Appendix Maintenance manual 3 302 756 en GMK6400...
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Page 343: Appendix
Appendix...

Manitowoc GROVE GMK6400 Maintenance Manual

Table of Contents

6 6 Lubricants and Consumables

Lubricants

Lubricants and Consumables

Consumables

Refrigerant

7 7 Maintenance Work on the Carrier

General Instructions

Symbols for Maintenance Work

Engine

Fuel System

Exhaust System with Exhaust Emission Control

Transmission

Transfer Case

Axle Lines

Wheels

Vehicle Brake

Suspension

Steering

Compressed Air System

Hydraulic System

Central Lubrication System

Electrical System

Air-Conditioning System

Towbar Coupling

Other Maintenance Work

8 8 Maintenance Work on the Superstructure

General Instructions

Maintenance Work on the Superstructure

Symbols for Maintenance Work

Hoists

Slewing Gear

Slewing Bearing

Pump Transfer Case

Hydraulic System

Main Boom

Hoist Ropes

Cable Drums and Slewing Angle Sensor

Central Lubrication System

Hook Blocks

Electrical System

Air-Conditioning System

Other Maintenance Work

Appendix

Quick Links

Chapters

Related Manuals for Manitowoc GROVE GMK6400

Summary of Contents for Manitowoc GROVE GMK6400