Manitowoc Grove GMK 5200-1 Maintenance Manual
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Manitowoc Grove GMK 5200-1 Maintenance Manual

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Maintenance manual
3 302 746 en
09.03.2018

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Summary of Contents for Manitowoc Grove GMK 5200-1

  • Page 1 Maintenance manual 3 302 746 en 09.03.2018...
  • 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 Tel.: [+49] (0) 44 21 294-0...

  • 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.
  • Page 4 Blank page 3 302 746 en Maintenance manual GMK5200-1...
  • Page 5 General instructions Instructions for using the maintenance manual......1 - Warnings and symbols ..........1 - Maintenance instructions .
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  • Page 7: General Instructions

    General instructions 1.1 Instructions for using the maintenance manual General instructions Instructions for using the maintenance manual This maintenance manual is not designed to replace proper training and instructions. Maintenance personnel for this truck crane must have the relevant, special- ist knowledge and that of proper safety procedures.

  • 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 if 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 Control

    Manitowoc Crane Care All welding work (especially on load carrying members) may only be per- formed by qualified professional personnel with the prior written permis- sion from Manitowoc Crane Group Germany GmbH. 1 - 4 3 302 746 en Maintenance manual...

  • Page 11: Definition Of Direction References

    General instructions 1.6 Definition of direction references Definition of direction references Basic rule Direction information always depends on whether the carrier or the super- structure 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 meas- urement 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 Which Are Harmful To The Environment

    Safety and environmental protection 2.2 Handling substances which are harmful to the environment Handling substances which are harmful to the environment Which substances When you carry out maintenance work on the truck crane you will occasion- are harmful to the ally work with consumables which are classified as harmful to the environ- environment? ment by applicable national and regional regulations.
  • Page 19 Safety and environmental protection 2.2 Handling substances which are harmful to the environment Collecting and Substances which are harmful to the environment should always be col- storing separately 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 put your truck crane out of service and to scrap • 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 3 302 746 en GMK5200-1...
  • Page 22 3 302 746 en Maintenance manual GMK5200-1...

  • Page 23: Cleaning

    Cleaning Cleaning During the first The paintwork on the truck crane will continue to harden for the first three 3 months months. • During this period the crane may be cleaned only with cold water. • Do not use high-pressure or steam jet cleaning equipment during this period.
  • Page 24 Cleaning 3.1 Overview of assemblies easily damaged when cleaning Overview of assemblies easily damaged when cleaning 3 - 2 3 302 746 en Maintenance manual GMK5200-1...
  • 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 Lowering limit switch 5 Suspension struts 6 Heating/air conditioning system under the crane cab 7 Slewing angle sensor 8 Control units for outriggers 9 Angle data transmitter 10 RCL length data transmitter...
  • Page 26 Cleaning 3.1 Overview of assemblies easily damaged when cleaning Blank page 3 - 4 3 302 746 en Maintenance manual GMK5200-1...
  • Page 27 Run-in regulations Maintenance manual 3 302 746 en GMK5200-1...
  • Page 28 3 302 746 en Maintenance manual GMK5200-1...

  • Page 29: Run-In Regulations

    Run-in regulations Run-in regulations There are rules about running in individual parts which 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 after specific periods of time have expired: Operating Driven km...
  • Page 30 Run-in regulations Operating hours Additional maintenance work on the (oper. hrs.) SUPERSTRUCTURE after 50 Tighten the clips on the coolant hoses; à Special torques , p. 10 - 2. during the first 100 Check the hydraulic oil filter every week, and change it if necessary;...
  • Page 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 given in table form, divided into –...
  • Page 34 Maintenance overview 5.1 Maintenance intervals The maintenance interval which occurs first determines when the next maintenance is due. – The driven km (or mi) can be taken from the speedometer. – You can individually call up the Operating hours (oper. hrs.) of the engine and power units on the CCS display.
  • 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 - 11 à – Checking the air filter p. 7 - 15 à –...
  • Page 37 Maintenance overview 5.2 Maintenance plans Maintenance work on the SUPERSTRUCTURE: daily/before putting into operation Hydraulic system à – Checking the oil level p. 8 - 31 Hoist ropes à – Checking the winding p. 8 - 53 Electrical system 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 - 17 Transmission à – General inspection p. 7 - 40 Transfer case à – General inspection p. 7 - 49 Angle gear à...
  • Page 39 Maintenance overview 5.2 Maintenance plans Maintenance work on the SUPERSTRUCTURE: weekly Hoists à – Checking the oil level p. 8 - 9 à – General inspection p. 8 - 10 à – Checking the hoist brake p. 8 - 10 Slewing gear à...
  • Page 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 oper. hrs. Main boom à – Greasing the piston rod of the derricking cylinder p. 8 - 47 Air conditioning system à – Checking the air conditioning system 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 Fuel system à...
  • Page 43 Maintenance overview 5.2 Maintenance plans Maintenance work on the SUPERSTRUCTURE: every three months/after 250 oper. hrs. Slewing bearing à – Checking the screws p. 8 - 21 Hydraulic system à – Cleaning the magnetic rods p. 8 - 34 Main boom à...
  • Page 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 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 - 16 Slewing bearing à – Lubricating the gear teeth p. 8 - 25 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. 7 - 11 à...
  • Page 47 Maintenance overview 5.2 Maintenance plans M 12 Maintenance work on the SUPERSTRUCTURE: every 12 months/after 1,000 oper. hrs. Hoists à – Changing the oil/checking the oil p. 8 - 11 Slewing gear à – Changing the oil/checking the oil p. 8 - 19 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 - 11 à –...
  • 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 Maintenance work on the SUPERSTRUCTURE: every 60 months/after 5,000 oper. hrs. – Have both the cardan shafts (+ resilient damper) on the angle gear 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 fabrication – 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. Electrical system à...
  • Page 51 Maintenance overview 5.3 Periodic inspections Periodic inspections Your GMK5200-1 truck crane has been inspected before delivery. – Truck cranes that are to be 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 defor- mation. The hook opening must not have increased 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 winch monitoring Measures required for winch monitoring Also observe the information on the general inspection of the hoists; à p. 8 - 13. These measures for monitoring the winches (hoists) were compiled by the German Machine Builders' Association (VDMA) and are to be used for all truck cranes according to the German Accident Prevention Regulations for Winches, Hoists and Tractor Machines, BGV D 6 (VBG 9 ) and BGV D 8 (VBG 8) .
  • 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 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 winch monitoring One of the load spectrums listed above should be selected on the basis of the actual operating conditions and entered in the crane logbook for the respective testing interval. Note for truck cranes: The load spectrum L1 and the load spectrum factor Km = 0.125 are generally applied to truck cranes in assembly mode.
  • Page 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 GMK5200-1 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 L 1, Km = 0.125...
  • Page 59 Maintenance overview 5.4 Measures required for winch monitoring The used proportion S of theoretical service life after the second inspection is therefore: × -------------- - 480 h 1,920 h 0.125 Remaining theoretical service life: D2 = 3,040 h –1,920 h = 1,120 h. The above values are entered in the table (see table example p.
  • Page 60 Maintenance overview 5.4 Measures required for winch monitoring 5 - 28 3 302 746 en Maintenance manual GMK5200-1...
  • 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 applica- tions list.

  • Page 64: Lubricants List

    Lubricants and consumables 6.1 Lubricants 6.1.1 Lubricants list Serial GROVE part Lubricant Designation to Specification Viscosity number type DIN 51502 classification MIL-L 2104 C 03329588 Engine oil HD - CD SAE 5 W-30 DB 228.5 Shell Spirax 04162043 Gear oil S6 ATF VM Fuchs Titan Cytrac MB Synth...

  • Page 65: Lubricant Applications List

    Lubricants and consumables 6.1 Lubricants 6.1.2 Lubricant applications list Serial Lubricant type Usage Filling Mainten- quantity in ance inter- litres (gal) à Engine oil Diesel engine; p. 7 - 24 39 (10.3) à Gear oil VIAB (Voith); p. 7 - 43 11 (2.9) à...
  • Page 66 Lubricants and consumables 6.1 Lubricants Serial Lubricant type Usage Filling Mainten- quantity in ance inter- litres (gal) à Carrier central lubrication; p. 7 - 119 à Superstructure central lubrication; p. 8 - 69 à Cardan shafts – transverse; p. 7 - 70 à...

  • Page 67: Refrigerant

    Lubricants and consumables 6.2 Refrigerant Refrigerant Refrigerant Usage Quantity to Mainten_an Designation be filled in ce interval kg (lbs) Driver's cab air-conditioning system; à p. 7 - 132 1.0 (2.2) M 12 Tetrafluoroethane (R134a) (Compressor oil: FUCHS SE 55) CAS no. 811-97-2 1 x 1.0 (2.2) Crane cab air-conditioning system;...

  • Page 68: After-Treatment Of Exhaust Gases

    Lubricants and consumables 6.3 Consumables 6.3.3 After-treatment of exhaust gases Designation Usage Filling quantity in litres (gal) DEF (Diesel Exhaust Fluid) à AdBlue: AdBlue tank on the carrier; p. 7 - 34 40 (10.5) GROVE part number: 03140555 DEF (Diesel Exhaust Fluid), Consumable for after-treatment of exhaust gases, e.g.
  • Page 69 Maintenance work on the carrier General instructions ..........7 - 7.1.1 Covers .
  • Page 70 7.9.6 Lubricating the cardan shafts in the axle lines ......7 - 70 7.9.7 Lubricating longitudinal cardan shafts ....... 7 - 71 7.10 Wheels .
  • Page 71 7.18.4 Checking the entire air conditioning system ......7 - 132 7.18.5 Changing the pollen filter ......... . . 7 - 134 7.19 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 7.1.1 Covers Various types of work (e.g. oil change) require that the 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 3 302 746 en Maintenance manual GMK5200-1...
  • Page 75 Maintenance work on the carrier 7.1 General instructions à Symbols for maintenance work p. 7 - 9 à 1 CCS (Crane Control System) control unit p. 7 - 9 à Engine p. 7 - 11 à 4 Diesel engine p. 7 - 11 à...
  • Page 76 Maintenance work on the carrier 7.1 General instructions 7 - 4 3 302 746 en Maintenance manual GMK5200-1...
  • Page 77 Maintenance work on the carrier 7.1 General instructions à Axle lines p. 7 - 61 à 7 Axle centre drives p. 7 - 61 à 6 Final drives p. 7 - 67 à 8 Cardan shafts p. 7 - 70 à...
  • Page 78 Maintenance work on the carrier 7.1 General instructions 7 - 6 3 302 746 en Maintenance manual GMK5200-1...
  • Page 79 Maintenance work on the carrier 7.1 General instructions à Wheels p. 7 - 73 à 6 Wheels p. 7 - 73 3 Spare wheel (alternatively storage box) à Suspension p. 7 - 89 à 10 Suspension struts p. 7 - 91 à...
  • Page 80 Maintenance work on the carrier 7.1 General instructions Blank page 7 - 8 3 302 746 en Maintenance manual GMK5200-1...

  • Page 81: Symbols For Maintenance Work

    Maintenance work on the carrier 7.2 Symbols for maintenance work Symbols for maintenance work • Check the symbols on the CCS start menu (Crane Control System) in the driver's cab each day before starting work. • The Start menu shows the most important measurements and the Maintenance submenu shows all the outstanding warning messages;...
  • Page 82 Maintenance work on the carrier 7.2 Symbols for maintenance work à – Disc brakes wear display; p. 7 - 81. 7 - 10 3 302 746 en Maintenance manual GMK5200-1...

  • Page 83: Engine

    Maintenance work on the carrier 7.3 Engine Engine • In addition, carry out the additional maintenance work as specified in the Engine manufacturer's documentation supplied with the vehicle. • At the first oil change, fit a drain valve in place of the drain plug; à...
  • Page 84 Maintenance work on the carrier 7.3 Engine • On the dipstick (1), check that the oil level is between the min. and the max. marks (arrow markings). • Put the dipstick into the dipstick tube after checking the oil level. 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 specification; Engine manufacturer's documenta- tion . Engine oil in Designation to Specification GROVE part no. litres (gal) DIN 51502 Classification 39 (10.3) HD - CD MIL-L 2104 C SAE 5 W-30...

  • Page 86: 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 and Designation Quantity GROVE part no.

  • Page 87: Checking The Air Filter

    Maintenance work on the carrier 7.3 Engine 7.3.4 Checking the air filter • Start the engine and observe the display. • If the symbol (1) is displayed, you must change the air filter. • Switch off the engine. Spare parts and Designation Quantity GROVE part no.

  • Page 88: Checking The Coolant Level

    If the coolant has to be topped up frequently, the cooling system may be leaking. Have the cooling system checked by or an Manitowoc Crane Care authorised GROVE dealer or your repair crew. 7 - 16 3 302 746 en...

  • Page 89: General Inspection

    • Check that pipes and hoses are tightly connected and not damaged. If any damage is found, report it to or an authorised Manitowoc Crane Care GROVE dealer or an authorised specialist workshop. Maintenance manual 3 302 746 en 7 - 17...

  • Page 90: 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 91 Maintenance work on the carrier 7.3 Engine The two radiator units (1) and (2) are protected by grilles (3) and plates (5). The fan wheels (4) are located under the grilles. When the engine is running, the fan wheels rotate under the grilles! Risk of injury due to the fan wheels.
  • Page 92 Maintenance work on the carrier 7.3 Engine Have them cleaned Risk of injury due to the fan wheels. When the fan wheels are rotating they can trap the fingers of your hand and amputate them. Never reach into the fan wheels when they are rotating. Do not push any tools through the grilles to clean them.
  • Page 93 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 94: Check V-Belt Tension

    Maintenance work on the carrier 7.3 Engine M 12 7.3.8 Check V-belt tension à • Note the Run-in regulations , p. 4 - 1. • Check whether your mobile crane is equipped with a second alternator (2). The maintenance on the V-belt of the standard first alternator (1) is à...
  • Page 95 Maintenance work on the carrier 7.3 Engine • Familiarise yourself with the correct operation of the frequency à Separate operating manual . measuring equipment; • Turn on the frequency measuring equipment (1) – it is ready for acoustic measurement. • Hold the measuring head (3) over the V-belt (4).

  • Page 96: Changing The Oil And Oil Filter

    Maintenance work on the carrier 7.3 Engine 7.3.9 Changing the oil and oil filter Oil, spare parts, Engine oil in Designation to Specification GROVE part no. tools litres (gal) DIN 51502 Classification 39 (10.3) 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. • Change the oil filter (1) using a socket wrench – torque 55 Nm (40.5 lbf ft); à Engine manufacturer's documentation . • Leave the receptacle in place for the oil change.
  • Page 98 Maintenance work on the carrier 7.3 Engine Blank page 7 - 26 3 302 746 en Maintenance manual GMK5200-1...

  • Page 99: Fuel System

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

  • Page 100: Draining Off Water From Fuel Filter 1

    Maintenance work on the carrier 7.4 Fuel system 7.4.1 Draining off water from fuel filter 1 à Spare parts and – Receptacle, approx. 5 l (1.5 gal); p. 2 - 4. tools à Operating manual . Prerequisites – The truck crane must be level and on outriggers; à...

  • Page 101: Replacing Fuel Filter 1

    Maintenance work on the carrier 7.4 Fuel system 7.4.2 Replacing fuel filter 1 Spare parts and Designation Quantity GROVE part no. tools Filter (large) 04161567 Alternatively: 04180966 Set of both filters 1 + 2 (large + small) à – Receptacle, approx. 5 l (1.5 gal); p.
  • Page 102 Maintenance work on the carrier 7.4 Fuel system • Remove the cover (1). • Remove the old filter (2) from the casing. • Place the old filter (2) in the receptacle. • Insert a new filter (2) into the casing. •...

  • Page 103: Replacing Fuel Filter 2

    Maintenance work on the carrier 7.4 Fuel system M 12 7.4.3 Replacing fuel filter 2 Spare parts and Designation Quantity GROVE part no. tools Filter (small) 04161566 Alternatively: 04180966 Set of both filters 1 + 2 (large + small) à –...
  • Page 104 Maintenance work on the carrier 7.4 Fuel system • Open the two tank covers on the fuel tank; à p. 7 - 27. • Operate the hand pump (1) until you sense definite resistance. • Close the two tank covers on the fuel tank. •...

  • Page 105: 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 106: Checking The Adblue Tank Level

    Maintenance work on the carrier 7.5 Exhaust system with exhaust emission control 7.5.1 Checking the AdBlue tank level Check the The display includes a gauge showing the level in the AdBlue tank. following The tank has a maximum filling volume of approx. 40 l (10.5 gal). Depending on where the truck crane is used, it may be sensible to carry additional can- isters of AdBlue.

  • Page 107: Check The Exhaust System For External Damage

    Maintenance work on the carrier 7.5 Exhaust system with exhaust emission control • Filling up Find out about filling up in the operating manual and note the warnings; à Operating 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 108 • Switch off the engine. If you discover any damage Have any damaged parts of the exhaust system replaced immediately by or an authorised GROVE dealer. Manitowoc Crane Care 7 - 36 3 302 746 en Maintenance manual GMK5200-1...

  • Page 109: Having The Adblue System Checked

    M 12 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 proper functioning; à...
  • Page 110 Oil from the compressed air system can damage the pump unit. Therefore, a filter cartridge must be installed in the compressed air drier that removes both water and oil. recommends the Manitowoc Crane Care suitable filter cartridge with the GROVE part number 04157844. à •...

  • Page 111: Transmission

    Maintenance work on the carrier 7.6 Transmission Transmission Overview Engine-transmission unit – Diesel engine (1), – VIAB (2), – Transmission (3). VIAB VIAB is the abbreviation for: Verschleißfreies Integriertes Anfahr- und Bremssystem (wear- free integrated starting and braking system). The VIAB is an oil-filled clutch which permits starting and braking and delicate manoeuv- ring.

  • Page 112: General Inspection

    • Check that pipes and hoses are tightly connected and not damaged. If any damage is found, report it to or an authorised Manitowoc Crane Care GROVE dealer or an authorised specialist workshop. 7 - 40 3 302 746 en...

  • Page 113: Checking The Viab Oil Level

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

  • Page 114: Checking The Transmission Oil Level

    Maintenance work on the carrier 7.6 Transmission M 12 7.6.3 Checking the transmission oil level Spare parts and Designation Quantity GROVE part no. tools Gasket 24 x 29 Cu DIN 7603 00117145 à – Receptacle, approx. 5 l (1.5 gal); p.

  • Page 115: Changing The Viab Oil

    Maintenance work on the carrier 7.6 Transmission 7.6.4 Changing the VIAB oil Oil, spare parts Gear oil in Specification GROVE part no. and tools litres (gal) Classification 11.0 (2.9) Shell Spirax 04162043 S6 ATF VM Designation Quantity GROVE part no. Gasket 24 x 29 Cu DIN 7603 00117145 (oil filler neck, top)
  • Page 116 Maintenance work on the carrier 7.6 Transmission Risk of environmental damage due to leaking consumables. Always let consumables drain into suitable receptacles. Wipe up any con- sumables that have leaked. Store/dispose of consumables and any soaked equipment properly. Ask about the applicable regulations. •...
  • Page 117 Maintenance work on the carrier 7.6 Transmission Topping up the oil • Remove the drain plug (1). • Top up oil through the hole (2) until oil comes out of the hole (1). • Replace the gasket and tighten the drain plug (1) –...

  • Page 118: Transmission Oil Change

    Maintenance work on the carrier 7.6 Transmission 7.6.5 Transmission oil change Oil, spare parts Gear oil in Specification GROVE part no. and tools litres (gal) Classification 17.5 (4.6) 04162042 Fuchs Titan Cytrac MB Synth (with oil API-GL-4; SAE 75 W-90 cooler) Designation Quantity...
  • Page 119 Maintenance work on the carrier 7.6 Transmission • Place a receptacle under the valve (1). • Screw the connecting piece and hose onto the valve (1) and drain the oil into the recep- à tacle; Handling the valves , p. 7 - 112. •...
  • Page 120 Maintenance work on the carrier 7.6 Transmission Topping up the oil • Remove the drain plug (1). • Remove the hose (2). • Top up oil through the hole (2) until oil comes out of the hole (1). • Replace the gasket and tighten the drain plug (1) –...

  • Page 121: Transfer Case

    • Check that pipes and hoses are tightly connected and not damaged. If any damage is found, report it to or an authorised Manitowoc Crane Care GROVE dealer or an authorised specialist workshop. 7.7.2 Checking the oil level Spare parts and...

  • Page 122: Changing The Oil

    Maintenance work on the carrier 7.7 Transfer case Checking • Remove the drain plug (1). • Check that the oil reaches the lower edge of the opening. • Fit a new gasket and tighten the drain plug. If the oil level is too low à...
  • Page 123 Maintenance work on the carrier 7.7 Transfer case Changing the oil Risk of scalding from gear oil at operating temperature. You could burn yourself by gear oil escaping in an uncontrolled manner at operating temperature. Wear appropriate protective gloves and take care not to come into contact with the gear oil.
  • Page 124 Maintenance work on the carrier 7.7 Transfer case Blank page 7 - 52 3 302 746 en Maintenance manual GMK5200-1...

  • Page 125: Angle Gear

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

  • Page 126: General Inspection

    Checking the oil level , p. 7 - 54. • Check that pipes and hoses are tightly connected and not damaged. If any damage is found, report it to or an authorised Manitowoc Crane Care GROVE dealer or an authorised specialist workshop. 7.8.2 Checking the oil level Symbols...
  • Page 127 Maintenance work on the carrier 7.8 Angle gear Prerequisites – The crane must be rigged with an outrigger span of at least 8.95 x 7.80 m à Operating manual . (29.4 x 25.6 ft) and be level; à Operating – The main boom must be fully retracted and fully raised; manual .
  • Page 128 • Check the secure fastening and the condi- tion of the resilient dampers (1). If the resilient dampers are damaged, have them replaced by Manitowoc or an authorised GROVE dealer. Crane Care 7 - 56 3 302 746 en...

  • Page 129: Changing The Oil And The Oil Filter

    Maintenance work on the carrier 7.8 Angle gear 7.8.3 Changing the oil and the oil filter Oil, spare parts, Gear oil in Designation to Specification GROVE part no. tools litres (gal) DIN 51502 Classification 7.7 (2.0) MIL-L 2105 B 01373344 API-GL-5 Viscosity: Hyp SHC 75-90...
  • Page 130 Maintenance work on the carrier 7.8 Angle gear Drain tap Risk of damage to the angle gear! If the drain tap remains open after changing the oil, the oil circuit will be interrupted and the upper bearing will not be adequately supplied with oil. This can lead to malfunctions and transmission damage.
  • Page 131 Maintenance work on the carrier 7.8 Angle gear Changing the oil Risk of scalding from gear oil at operating temperature. You could burn 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 132 Maintenance work on the carrier 7.8 Angle gear • Tighten the filter (4). • Remove the connecting piece and hose from the valve (3) – the valve (3) is closed. • Fill the oil up to the lower edge of the open- ing (1).

  • Page 133: Axle Lines

    Check that pipes and hoses are tightly connected and not damaged. If any damage is found, report it to or an authorised Manitowoc Crane Care GROVE dealer or an authorised specialist workshop. 7.9.2 Axle centre drives – checking the oil level...
  • Page 134 Maintenance work on the carrier 7.9 Axle lines and 5 axle line • Remove the drain plug (1). • Check that the oil reaches the lower edge of the opening. • Fit a new gasket and tighten the drain plug. If the oil level is too low à...

  • Page 135: Axle Centre Drives - Changing The Oil

    Maintenance work on the carrier 7.9 Axle lines axle line The drive has two oil chambers. • Remove the drain plug (1). • Check that the oil reaches the lower edge of the opening. • Fit a new gasket and tighten the drain plug. If the oil level is too low à...
  • Page 136 Maintenance work on the carrier 7.9 Axle lines Prerequisites – The truck crane must be raised on outriggers or parked over an inspection pit. – The engine must be switched off and secured against unauthorised use; à p. 2 - 3. Risk of environmental damage due to leaking consumables.
  • Page 137 Maintenance work on the carrier 7.9 Axle lines axle line The drive has two oil chambers. Risk of oil overheating. When topping up the oil, both openings must be opened so that both oil tanks are filled equally. This prevents both oil tanks from being overfilled and thus the oil from overheating.
  • Page 138 Maintenance work on the carrier 7.9 Axle lines Blank page 7 - 66 3 302 746 en Maintenance manual GMK5200-1...

  • Page 139: Final Drives - Checking The Oil Level

    Maintenance work on the carrier 7.9 Axle lines 7.9.4 Final drives – checking the oil level Spare parts and for drive Designation Quantity GROVE part no. tools 10 x 6 x 10 Gasket 24 x 29 Cu DIN 7603 00117145 10 x 8 x 10 Gasket 24 x 29 Cu DIN 7603 00117145...

  • Page 140: Final Drives - Changing The Oil

    Maintenance work on the carrier 7.9 Axle lines M 12 7.9.5 Final drives – changing the oil Oil, spare parts, Gear oil in Designation to Specification GROVE part no. tools litres (gal) DIN 51502 Classification for each final C - LPF MIL-L 2105 B 00552891 drive:...
  • Page 141 Maintenance work on the carrier 7.9 Axle lines Draining oil • Change the oil on all final drives in the same way. • Turn the wheel until the screw (1) is at the bottom. • Use a drain channel and place a receptacle under the screw.

  • Page 142: Lubricating The Cardan Shafts In The Axle Lines

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

  • Page 143: Lubricating Longitudinal Cardan Shafts

    Maintenance work on the carrier 7.9 Axle lines 7.9.7 Lubricating longitudinal cardan shafts Check all cardan shafts to see if they have grease nipples. Cardan shafts with grease nipples must be serviced, cardan shafts without grease nipples are maintenance-free. Grease, spare Lubricating Designation to Specification...
  • Page 144 Maintenance work on the carrier 7.9 Axle lines Blank page 7 - 72 3 302 746 en Maintenance manual GMK5200-1...

  • Page 145: Wheels

    Maintenance work on the carrier 7.10 Wheels 7.10 Wheels 7.10.1 Checking the tyres for damage Prerequisites – The truck crane must be raised on outriggers. – The engine must be switched off and secured against unauthorised use; à p. 2 - 3. –...

  • Page 146: Checking The Tyre Pressure

    Maintenance work on the carrier 7.10 Wheels 7.10.2 Checking the tyre pressure Risk of damage to the tyres. The tyre pressure increases during operation. Never release the increased air pressure of tyres at operating temperature. Always check the tyre pressure in on-road driving mode with cold tyres. •...

  • Page 147: Checking That The Wheel Nuts Are Tight

    Maintenance work on the carrier 7.10 Wheels 7.10.3 Checking that the wheel nuts are tight Spare parts 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 148: Changing The Wheels

    Maintenance work on the carrier 7.10 Wheels 7.10.4 Changing the wheels The wear on tyres varies depending on whether the axle – is driven/not driven, – is steered/not steered, – is braked/not braked – and whether it is subject to more or less load. To achieve even wear, you must swap the wheels to different positions regularly.
  • Page 149 Maintenance work on the carrier 7.10 Wheels Recognising two- piece aluminium rims The round-head bolts (1) are on the outer face of the rim. The round heads must be free of cracks, and the bolts must be seated securely in the holes. Around the edge of the aluminium rim there are impressed marks and safety instructions which must be complied with by the specialist...
  • Page 150 Maintenance work on the carrier 7.10 Wheels • Mount the wheels on another axle, as shown in the diagram. Replace any à damaged parts. Tighten the wheel nuts; p. 7 - 75. 7 - 78 3 302 746 en Maintenance manual GMK5200-1...
  • Page 151 Maintenance work on the carrier 7.10 Wheels Optimised wheel To ensure even more even wear on all tyres, you can also rotate the tyres 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 152 Maintenance work on the carrier 7.10 Wheels Blank page 7 - 80 3 302 746 en Maintenance manual GMK5200-1...

  • Page 153: Vehicle Brake

    Maintenance work on the carrier 7.11 Vehicle brake 7.11 Vehicle brake 7.11.1 Checking the wear display On the brake calliper Each brake calliper (1) carries two brake pads (2), arranged one to the left and one to the right of the brake disc (3). The lining thickness (A) is monitored by an electric wear indicator on the brake calliper (1).

  • Page 154: Checking Disc Brakes

    Maintenance work on the carrier 7.11 Vehicle brake If the symbol (1) is displayed on the on-board computer, one of the disc brakes has exceeded the brake lining wear limit. à • Checking disc brakes , p. 7 - 82. Check all disc brakes on all axle lines;...
  • Page 155 All repair work on the vehicle brakes may only be performed by or an authorised GROVE dealer or an authorised spe- Manitowoc Crane Care cialist workshop with specially trained repair crew. •...
  • Page 156 Maintenance work on the carrier 7.11 Vehicle brake Checking the surface • Check for signs of damage such as cracks and irregularities: (A) – fine network of cracks, (B) – radial cracks, (C) – circular irregularities, (D) – continuous cracks. •...
  • Page 157 Maintenance work on the carrier 7.11 Vehicle brake • Checking the Check the thickness of the brake pads on all axle lines. brake pads Each brake calliper (1) carries two brake pads (2), arranged one to the left and one to the right of the brake disc (3). This first axle line has two brake callipers per brake disc.
  • Page 158 Maintenance work on the carrier 7.11 Vehicle brake Risk of injury due to rotation of the ring spanner. If you are holding the ring spanner when another person in the driver's cab applies the brakes your hand could be crushed. Do not hold the ring spanner when another person in the driver's cab applies the brakes.
  • Page 159 7 - 83. • 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 160 Maintenance work on the carrier 7.11 Vehicle brake Blank page 7 - 88 3 302 746 en Maintenance manual GMK5200-1...

  • Page 161: Suspension

    Notify or an authorised GROVE dealer. Manitowoc Crane Care Risk of damage to the suspension struts due to insufficient lubrication. It is difficult to inject the oil. Even so, do not fill oil through the inspection glass connections.
  • Page 162 Change the filter (6) if necessary and fasten the cover. • Defective suspension struts should be replaced as soon as possible by or an authorised GROVE dealer. Manitowoc Crane Care 7 - 90 3 302 746 en Maintenance manual GMK5200-1...

  • Page 163: Suspension Struts - Checking The Fastening

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

  • Page 164: 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 7 - 92...

  • Page 165: Pressure Accumulator - Checking The Gas Pressure

    The filling pressure at 20 °C (68 °F) is 50 bar (725 psi). • Have the filling pressure checked, and if necessary corrected, by Manitowoc Crane or an authorised GROVE dealer or an Care authorised specialist workshop. Maintenance manual 3 302 746 en...
  • Page 166 Maintenance work on the carrier 7.12 Suspension Blank page 7 - 94 3 302 746 en Maintenance manual GMK5200-1...

  • Page 167: Steering

    Bleeding the hydraulic system , p. 7 - 114. 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 3 302 746 en 7 - 95 GMK5200-1...

  • Page 168: Pressure Accumulator - Checking The Gas Pressure

    The filling pressure at 20 °C (68 °F) is 89 bar (1,290 psi). • Have the filling pressure checked, and if necessary corrected, by Manitowoc Crane or an authorised GROVE dealer or an Care authorised specialist workshop. 7 - 96...

  • Page 169: Compressed Air System

    (2) to (9). If a great deal of moisture escapes • Have the compressed air drier checked or replaced by or an Manitowoc Crane Care authorised GROVE dealer or your qualified repair crew. Maintenance manual 3 302 746 en 7 - 97...

  • Page 170: Checking For Leaks

    If damage cannot be rectified immediately or further damage is likely: • Notify or an authorised GROVE dealer or your repair Manitowoc Crane Care crew. 7 - 98 3 302 746 en Maintenance manual...

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

    Maintenance work on the carrier 7.14 Compressed air system M 12 7.14.3 Replacing the filter cartridge of the compressed air drier Spare parts and Designation Quantity GROVE part no. tools Filter cartridge with gasket 04157844 – Strap wrench. Prerequisites – The truck crane must be raised on outriggers or parked over an inspection pit.
  • Page 172 Maintenance work on the carrier 7.14 Compressed air system Blank page 7 - 100 3 302 746 en Maintenance manual GMK5200-1...

  • Page 173: Hydraulic System

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

  • Page 174: Checking The Hydraulic Hoses

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

  • Page 175: Cleaning The Magnetic Rods

    Bleed the carrier's hydraulic system; p. 7 - 114. If damage cannot be rectified immediately or further damage is likely • Notify or an authorised GROVE dealer or your repair Manitowoc Crane Care crew. 7.15.4 Cleaning the magnetic rods Spare parts and Designation Quantity GROVE part no.
  • Page 176 Large amounts of metal particles are a sign of damage in the hydraulic sys- tem. Have the hydraulic system checked by or an Manitowoc Crane Care authorised GROVE dealer or your qualified repair crew. • Assemble the filters (2) and insert them.

  • Page 177: Changing The Ventilation Filter

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

  • Page 178: Taking Oil Samples

    Maintenance work on the carrier 7.15 Hydraulic system M 12 7.15.6 Taking oil samples • Reducing the Under difficult operating conditions – at tropical or very hot locations – interval you must halve the oil change interval. Spare parts and –...
  • Page 179 Maintenance work on the carrier 7.15 Hydraulic system Protecting the hose from dirt Danger of contamination of the oil sample. If the hose with the connecting piece is dirty, the dirt can contaminate the oil sample in the sample container during the sampling process. The labo- ratory analysis would thus be incorrect.
  • Page 180 Maintenance work on the carrier 7.15 Hydraulic system Taking oil samples The hose end (1) is connected to the cylinder (3). The hose end (2) is in receptacle (4). • Start the engine. • Allow 2 litres (0.5 gal) of oil to flow into the receptacle.
  • Page 181 Maintenance work on the carrier 7.15 Hydraulic system Dispatch the oil gives you the opportunity to have the oil sample ana- Manitowoc Crane Care sample to the lysed at our contracted laboratory. A delivery note and a protective mailing laboratory bag are available along with the sample containers (GROVE part no.
  • Page 182 Maintenance work on the carrier 7.15 Hydraulic system Blank page 7 - 110 3 302 746 en Maintenance manual GMK5200-1...

  • Page 183: Changing The Hydraulic Oil

    Maintenance work on the carrier 7.15 Hydraulic system 7.15.7 Changing the hydraulic oil The oil only needs to be changed if the laboratory analysis indicates the à Determining the quality of the oil , p. 7 - 109. need for it; Oil, spare parts, Hydraulic oil Designation to...
  • Page 184 Maintenance work on the carrier 7.15 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 185 Maintenance work on the carrier 7.15 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 186 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 - 114 3 302 746 en Maintenance manual GMK5200-1...

  • Page 187: Changing The Hydraulic Oil Filter

    Maintenance work on the carrier 7.15 Hydraulic system 7.15.8 Changing the hydraulic oil filter Oil filters must be replaced when changing the oil. If a warning message appears, the symbol (1) in the Warning submenu indi- cates that you must change oil filters 1 and 2. Filters 3 and 4 must be replaced after the first 50 hours in driving mode and then annually (M 12) after this.
  • Page 188 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 qualified repair crew. • Assemble the filters (2) and insert them.
  • Page 189 Maintenance work on the carrier 7.15 Hydraulic system Changing filters 3 and 4 Risk of damage to the environment from filter residues. Store used hydraulic oil filter inserts in suitable receptacles and have them disposed of properly by qualified personnel. •...
  • Page 190 Maintenance work on the carrier 7.15 Hydraulic system Blank page 7 - 118 3 302 746 en Maintenance manual GMK5200-1...

  • Page 191: Central Lubrication System

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

  • Page 193: Bleeding The Central Lubrication System

    Maintenance work on the carrier 7.16 Central lubrication system 7.16.2 Bleeding the central lubrication system If the grease container is empty or contains bubbles, you must bleed the central lubrication system. The grease container (1) is full. • Loosen the lubricating pipe at the connec- tion (2).
  • Page 194 Maintenance work on the carrier 7.16 Central lubrication system Blank page 7 - 122 3 302 746 en Maintenance manual GMK5200-1...

  • Page 195: 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 196: Checking The Batteries

    Maintenance work on the carrier 7.17 Electrical system 7.17.2 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 197 Maintenance work on the carrier 7.17 Electrical system Checking the connecting terminals • Keep the batteries clean and dry. • Remove any dirty connecting terminals (1) and clean them. • Fasten any loose connecting terminals. • Grease the connecting terminals and poles lightly with a special battery terminal grease.

  • Page 198: Checking The Charge Level Of The Batteries

    Maintenance work on the carrier 7.17 Electrical system 7.17.3 Checking the charge level of the batteries à Spare parts and – Battery charger (additional equipment); p. 7 - 128 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 199 Maintenance work on the carrier 7.17 Electrical system Before checking • Switch off the battery master switch; à Operating manual . • Pull the battery box out. Checking the acid concentration Batteries without caps (1) are maintenance- free. • Remove all caps (1). •...

  • Page 200: Charging The Batteries Using The Battery Charger

    Maintenance work on the carrier 7.17 Electrical system 7.17.4 Charging the batteries using the battery charger Prerequisites – The engine must be switched off and secured against unauthorised use; à p. 2 - 3. – An external 230 V mains power supply must be available at the location. –...

  • Page 201: Check The External Starting Socket

    Maintenance work on the carrier 7.17 Electrical system 7.17.5 Check the external starting socket The battery box is equipped with an external starting socket (1). Accessories A connection cable (1) for the external starting socket is supplied with the truck crane (tool set). Designation GROVE part no.
  • Page 202 Maintenance work on the carrier 7.17 Electrical system Blank page 7 - 130 3 302 746 en Maintenance manual GMK5200-1...

  • Page 203: Air Conditioning System

    • Check all refrigerant hoses for damage and areas of wear. Have damaged hoses checked by or an authorised Manitowoc Crane Care GROVE dealer or an authorised specialist workshop only. Maintenance manual 3 302 746 en 7 - 131...

  • Page 204: Cleaning The Condenser Fins

    Checking the entire air conditioning system This inspection may only be performed by or an Manitowoc Crane Care authorised GROVE dealer or an authorised specialist workshop. Risk of burns due to escaping refrigerant. Wear suitable safety glasses and gloves when checking the hoses and con- nections.
  • Page 205 Maintenance work on the carrier 7.18 Air conditioning system Refrigerant Fill quantity Designation CAS no. in kg (lbs) EC no. Tetrafluoroethane (R134a) 811-97-2 1.0 (2.2) 212-377-0 Compressor oil: FUCHS SE 55 Filler connections The filler connections (1) for refrigerants are on the refrigerant compressor hoses.

  • Page 206: Changing The Pollen Filter

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

  • Page 207: Towbar Coupling

    Maintenance work on the carrier 7.19 Towbar coupling 7.19 Towbar coupling Depending on the equipment fitted to your truck crane, it may have towbar couplings (additional equipment) from different manufacturers. The wear values for other manufacturers may vary from those specified; à...
  • Page 208 Maintenance work on the carrier 7.19 Towbar coupling Closing the towbar coupling Risk of injury when manually closing the towbar coupling. When closing, the lever moves down with great force in the direction of the coupling jaw. Start the closing process only by moving the lever briefly in the direction of the coupling jaw with the ball of your hand.

  • Page 209: Checking The Bearing

    Maintenance work on the carrier 7.19 Towbar coupling 7.19.2 Checking the bearing à Prerequisites – The coupling must be closed; p. 7 - 136. Checking the bearing Risk of injury. Ensure that the towbar coupling is closed for the following work (lever points downwards).

  • Page 210: Checking The Cotter Pin

    46.0 mm (1.81 in) If the dimension is smaller than that given above, have the cotter pin replaced by or an authorised GROVE Manitowoc Crane Care dealer or your qualified repair personnel. • Also check the cotter pin for the correct ver- tical play.

  • Page 211: Checking The Lower Bushing

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

  • Page 212: Checking The Support Ring

    Maintenance work on the carrier 7.19 Towbar coupling 7.19.6 Checking the support ring à Prerequisites – The coupling must be closed; p. 7 - 136. Checking the support ring • Check the support ring (1) at the bottom of the coupling jaw. When the trailer is coupled, the draw eyelet of the trailer must not be in contact with the lower bushing (2).
  • Page 213 Maintenance work on the carrier 7.19 Towbar coupling Checking for correct functioning The coupling jaw must be able to move easily in both directions. • Hold the coupling jaw (1) pressed slightly to the left or right. • Open the coupling (position A) and let the coupling jaw go.
  • Page 214 Maintenance work on the carrier 7.19 Towbar coupling Blank page 7 - 142 3 302 746 en Maintenance manual GMK5200-1...

  • Page 215: Other Maintenance Work

    Maintenance work on the carrier 7.20 Other maintenance work 7.20 Other maintenance work 7.20.1 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 216: Lubricating The Outrigger Beams

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

  • Page 217: Checking The Auxiliary Heater

    Remove any grease that emerges. • In case the doors are stiff or do not close properly after lubrication, have them adjusted by or by an authorised GROVE Manitowoc Crane Care dealer. Maintenance manual 3 302 746 en 7 - 145...

  • Page 218: Lubricating The Connecting And Socket Pins

    Check the pins for wear such as rust, deformation, broken clips, chains and pin-type keepers. • If the pins are damaged, have them replaced by Manitowoc Crane Care an authorised GROVE dealer or your qualified repair crew. • Use only authentic replacement pins.

  • Page 219: Renewing The Corrosion Protection

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

  • Page 221: Having The Fire Extinguisher Checked

    Maintenance work on the carrier 7.20 Other maintenance work 7.20.7 Having the fire extinguisher checked Depending on your truck crane's equipment, it has fire extinguishers. The maintenance interval may even be shorter, depending on the respective national regulations and the operating location. Ask the local fire safety officer about the national and local regulations.
  • Page 222 Maintenance work on the carrier 7.20 Other maintenance work Blank page 7 - 150 3 302 746 en Maintenance manual GMK5200-1...
  • Page 223 Maintenance work on the superstructure General instructions ..........8 - 8.1.1 Covers .
  • Page 224 8.8.5 Replacing the hoist rope ......... . . 8 - 62 8.8.6 Setting the lowering limit switch .

  • Page 225: Maintenance Work On The Superstructure

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

  • Page 226: 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 3 302 746 en Maintenance manual GMK5200-1...
  • Page 227 Maintenance work on the superstructure 8.1 General instructions à Symbols for maintenance work p. 8 - 7 à 1 CCS (Crane Control System) control unit p. 8 - 7 à Hoists p. 8 - 9 à 8 Hoist ropes p. 8 - 53 à...
  • Page 228 Maintenance work on the superstructure 8.1 General instructions 8 - 4 3 302 746 en Maintenance manual GMK5200-1...
  • Page 229 Maintenance work on the superstructure 8.1 General instructions à Main boom p. 8 - 47 à 1 Telescopic sections 1 to 5 and basic section p. 8 - 48 à 16 Derricking cylinder p. 8 - 47 à 15 Sheaves p.
  • Page 230 Maintenance work on the superstructure 8.1 General instructions Blank page 8 - 6 3 302 746 en Maintenance manual GMK5200-1...

  • Page 231: Symbols For Maintenance Work

    Maintenance work on the superstructure 8.2 Symbols for maintenance work Symbols for maintenance work Check the following symbols every day before starting work. • Check the symbols on the CCS start menu ( Crane Control System ) in the crane cab each day before starting work. •...
  • Page 232 Maintenance work on the superstructure 8.2 Symbols for maintenance work Blank page 8 - 8 3 302 746 en Maintenance manual GMK5200-1...

  • Page 233: Hoists

    Maintenance work on the superstructure 8.3 Hoists Hoists 8.3.1 Checking the oil level Spare parts and Designation Quantity GROVE part no. tools Oil inspection glass; complete 04161717 à Operating manual . Prerequisites – The truck crane must be level and in on-road mode; –...

  • Page 234: General Inspection

    • Check that pipes and hoses are tightly connected and not damaged. 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 235: Changing The Oil/Checking The Oil

    Maintenance work on the superstructure 8.3 Hoists M 12 8.3.4 Changing the oil/checking the oil à • Comply also with the Run-in regulations , p. 4 - 1. Oil, spare parts, Gear oil in Designation to Specification GROVE part no. tools litres (gal) DIN 51502...
  • Page 236 Some abrasion particles may appear in the first oil filled. If you notice such particles during the first oil change (after 200 oper. hrs.), first consult before introducing any specific measures. Manitowoc Crane Care 8 - 12 3 302 746 en...

  • Page 237: Having A Partial Inspection Carried Out

    Maintenance work on the superstructure 8.3 Hoists 8.3.5 Having a partial inspection carried out Only suitably trained specialists should carry out a partial inspection of – the multiple-disc brake, – the plug connections between the hydraulic motor and the multiple-disk brake, –...
  • Page 238 Maintenance work on the superstructure 8.3 Hoists Blank page 8 - 14 3 302 746 en Maintenance manual GMK5200-1...

  • Page 239: Slewing Gear

    Maintenance work on the superstructure 8.4 Slewing gear Slewing gear 8.4.1 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 240: Checking For Leaks

    • Check that pipes and hoses are tightly connected and not damaged. 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 241 – If the superstructure does slew, the slewing gear brake is defective and must be repaired immediately by or an author- Manitowoc Crane Care ised GROVE dealer. Maintenance manual 3 302 746 en 8 - 17...
  • Page 242 Maintenance work on the superstructure 8.4 Slewing gear • Switch the slewing gear off and switch the engine off. • Fasten the coil (1) to the valve Y 2304 using the nut. • Start the engine and check the slewing gear for correct operation.

  • Page 243: 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 Run-in regulations , p. 4 - 1. Oil, spare parts, Gear oil in Designation to Specification GROVE part no. tools litres (gal) DIN 51502...
  • Page 244 Maintenance work on the superstructure 8.4 Slewing gear Draining oil • Remove the plate (1). • Place a container under the screws (2). • Unscrew the filter (4) and screws (3) and (2). • Drain the oil. • Replace the gasket and tighten the screws (2).

  • Page 245: Slewing Bearing

    Maintenance work on the superstructure 8.5 Slewing bearing Slewing bearing 8.5.1 Checking the screws à • Run-in regulations , p. 4 - 1. Comply also with the Tools – Torque wrench. à – Auxiliary tools for the torque wrench; p. 8 - 23. à...
  • Page 246 Do not put the truck crane back into operation and have the slewing bearing repaired by Manitowoc Crane Care Access The outer ring is connected to the carrier with the screws (1).
  • Page 247 Maintenance work on the superstructure 8.5 Slewing bearing Selecting the tools Outer ring The screw heads (1) are easily accessible for fitting a socket wrench. There- fore, you can use manual or mechanical torque tools (electric or hydraulic drivers). Inner ring The screw head (1) is accessible only via a rectangular, long, narrow open- ing (2).
  • Page 248 Maintenance work on the superstructure 8.5 Slewing bearing • Checking the Divide the checking of the 96 screws into 24 working steps of 4 screws outer ring each. Between each of the 24 working steps you need to rotate the turntable to the next group of 4 screws on the opposite side.

  • Page 249: Lubricating The Gear Teeth

    • If need be, remove dirt and foreign bodies from the pinion (2). • If any damage is found, report it to or an authorised Manitowoc Crane Care GROVE-dealer. • Attach the plate. Maintenance manual 3 302 746 en 8 - 25...
  • Page 250 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 approx.

  • Page 251: 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 252: 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 253 The base value of the tilting play is determined and documented by play or an authorised GROVE dealer when the slewing Manitowoc Crane Care bearing is put into operation or replaced. The maximum permissible wear is 4.0 mm (0.157 in).

  • Page 254: Lubricating The Locking Of Turntable

    Maintenance work on the superstructure 8.5 Slewing bearing M 12 8.5.5 Lubricating the locking of turntable Grease, spare Lubricating Designation to Specification GROVE part no. parts, tools grease DIN 51502 Classification Grease KP - 1K - 50 DIN 51825 03233369 –...

  • Page 255: Hydraulic System

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

  • Page 256: Checking The Hydraulic Hoses

    Maintenance work on the superstructure 8.6 Hydraulic system 8.6.2 Checking the hydraulic hoses The inspection work is described in section Checking the hydraulic hoses , p. 7 - 102. 8.6.3 Checking the ventilation filter • Check the display (1) on the ventilation filter. If the indicator is coloured à...

  • Page 257: Checking For Leaks

    Bleed the hydraulic system; p. 8 - 46. 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 3 302 746 en 8 - 33 GMK5200-1...

  • Page 258: Cleaning The Magnetic Rods

    Maintenance work on the superstructure 8.6 Hydraulic system 8.6.5 Cleaning the magnetic rods Spare parts and Designation Quantity GROVE part no. tools For oil filter 1: Filter 04156358 Packing set 04165792 à – Receptacle, approx. 5 l (1.5 gal); p. 2 - 4. Prerequisites –...
  • Page 259 Risk of damage to the hydraulic system. Large amounts of metal particles are a sign of damage in the hydraulic sys- tem. Have the hydraulic system inspected by or by your Manitowoc Crane Care qualified repair crew. • Assemble the filter (3) and insert it. •...

  • Page 260: Changing The Ventilation Filter

    Maintenance work on the superstructure 8.6 Hydraulic system M 12 8.6.6 Changing the ventilation filter Spare parts and Designation Quantity GROVE part no. tools Filter 03134932 Prerequisites – The engine must be switched off and secured against unauthorised use; à p.

  • Page 261: Pressure Accumulator - Checking The Gas Pressure

    The filling pressure at 20 °C (68°F) is: 1 Pressure accumulator 20 bar (290 psi) 2 Pressure accumulator 180 bar (2,610 psi) • Have the filling pressure checked and if necessary corrected by Manitowoc Crane or an authorised GROVE dealer. Care M 12 8.6.8 Taking oil samples The oil sample from the superstructure hydraulic system is taken in a way similar to that for the carrier hydraulic system.
  • Page 262 Maintenance work on the superstructure 8.6 Hydraulic system The MLS gauge port (1) is located on the bracket (2). When a hydraulic function is run, oil can be taken at the gauge port. Taking oil samples • Clean the gauge port and connect the hose à...

  • Page 263: Changing The Hydraulic Oil Filter

    Maintenance work on the superstructure 8.6 Hydraulic system 8.6.9 Changing the hydraulic oil filter All oil filters must be replaced when changing the oil. If a warning message appears, the red symbols on the CCS control unit indi- cate whether oil filter 1 or oil filter 2 is clogged. There is no indicator for oil filter 3.
  • Page 264 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 qualified repair crew. • Assemble the filter (3) and insert it.
  • Page 265 Maintenance work on the superstructure 8.6 Hydraulic system Changing oil filter 2 • Release the receptacle (1) at the hexagon. • Change the filter (2). • Replace the gaskets. • Fill the receptacle with clean oil and tighten it – torque 25 Nm (18.4 lbf ft). Changing oil The oil filter 3 is located in the centre of rotation under the telescopic boom.
  • Page 266 Maintenance work on the superstructure 8.6 Hydraulic system After changing the filter Risk of damage to the hydraulic pumps. The engine may only be started if the valve in the suction line of the hydrau- lic pumps is open and there is enough hydraulic oil in the hydraulic oil tank. •...
  • Page 267 Maintenance work on the superstructure 8.6 Hydraulic system Blank page Maintenance manual 3 302 746 en 8 - 43 GMK5200-1...

  • Page 268: Changing The Hydraulic Oil

    Maintenance work on the superstructure 8.6 Hydraulic system 8.6.10 Changing the hydraulic oil The oil only needs to be changed if the laboratory analysis results indicate à Taking oil samples , p. 8 - 37. this; Oil, spare parts, Hydraulic oil Designation to Specification GROVE part no.
  • Page 269 Maintenance work on the superstructure 8.6 Hydraulic system Draining oil Risk of environmental damage due to leaking consumables. Use the supplied connecting piece and hose and a receptacle with sufficient capacity to drain the hydraulic oil. • Place a receptacle underneath the valve. •...
  • Page 270 Maintenance work on the superstructure 8.6 Hydraulic system Establishing the After having changed the oil filters and topping up the oil, you must operating re-establish the operating conditions. conditions Risk of damage to the hydraulic pumps. Open the valve prior to starting the engine. This prevents damage to the hydraulic pumps.

  • Page 271: Main Boom

    Maintenance work on the superstructure 8.7 Main boom Main boom 8.7.1 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 272: Lubricating The Telescopic Sections

    – A grease gun for the grease nipples on the upper telescopic slide faces. – A brush or roller for the outer, upper and lower telescopic slide faces. The Manitowoc Crane Group Germany GmbH recommends pneumatic grease spray guns for more effective lubrication of the telescopic slide...
  • Page 273 Maintenance work on the superstructure 8.7 Main boom If the desired telescoping status is not a fixed length, you can first telescope to the next closest fixed length with the semi-automation and then tele- à Operating manual . scope further to the desired length manually; Information Risk of overturning when telescoping if the RCL is overridden.
  • Page 274 Maintenance work on the superstructure 8.7 Main boom • Extend the telescopic section I to 50%. • Use the grease gun (PAL1) to lubricate the upper inner slide faces at the lubricating nip- ples (1) on both sides. • Fully retract telescopic section I . •...
  • Page 275 Maintenance work on the superstructure 8.7 Main boom • Raise the main boom to 15°. • Extend telescopic section IV to 0% and tele- scopic section V to approx. 50%. • Lower the main boom to 0° – do not lower to below 0°.

  • Page 276: Checking The Sheaves

    (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 8.7.4 Checking the locking system Risk of accidents if maintenance work is not carried out.

  • Page 277: Hoist Ropes

    Maintenance work on the superstructure 8.8 Hoist ropes Hoist ropes 8.8.1 Checking the winding Risk of accidents when the rope drum is turning. Keep away from the rope drum while it is turning. This will prevent your limbs from being drawn in and getting crushed. à...

  • Page 278: Checking The Hoist Ropes

    Maintenance work on the superstructure 8.8 Hoist ropes 8.8.2 Checking the hoist ropes Spare parts and – Torque wrench for 78 Nm (57.5 lbf ft). tools – Establish a rigging mode in accordance with the Lifting capacity table and Prerequisites à...

  • Page 279: Lubricating The Hoist Rope

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

  • Page 280: Assessing The Condition Of The Hoist Rope

    Maintenance work on the superstructure 8.8 Hoist ropes 8.8.4 Assessing the condition of the hoist rope If in doubt about damage assessment, always consult an official inspector. To assess the condition of the rope, you must be familiar with the following: –...
  • Page 281 Maintenance work on the superstructure 8.8 Hoist ropes The tables show by rope diameter the number of wire breaks in a length 6 times and 30 times the rope diameter which if reached would require replacement of the rope. • Familiarise yourself with DIN ISO 4309:2013-06 (rotation-resistant ropes).
  • Page 282 Maintenance work on the superstructure 8.8 Hoist ropes Risk of accidents due to reduced load bearing capacity. Remember that other factors may also make it necessary to replace a rope before the number of wire breaks requiring rope replacement has been reached (age of rope, frequency of use or exceptional loading).
  • Page 283 Maintenance work on the superstructure 8.8 Hoist ropes Damage Description Cause Replacement Reduced The diameter of the Structural changes Immediately replace the rope diameter (1) rope has become if the diameter has decreased smaller along large by 15% or more compared to sections.
  • Page 284 Maintenance work on the superstructure 8.8 Hoist ropes Damage Description Cause Replacement Loop forma- Outer layer wires in General wear due to Immediately replace rope if the tion (1) the form of hair pins ageing of the rope or rope structure has been sub- are protruding from consequential dam- stantially altered by the loop...
  • Page 285 Maintenance work on the superstructure 8.8 Hoist ropes Damage Description Cause Replacement Flattening (1) Crushed areas, Mechanical damage, Determine number of wire mostly with wire e.g. due to driving breaks; replace rope immedi- breaks. over the rope. ately if serious crushing has occurred.

  • Page 286: Replacing The Hoist Rope

    Maintenance work on the superstructure 8.8 Hoist ropes 8.8.5 Replacing the hoist rope à Spare parts and – An authentic replacement rope; Rope certificate . tools – A reel stand with braking block. – Torque wrench for 78 Nm (57.5 lbf ft). Risk of accidents from falling load.
  • Page 287 Maintenance work on the superstructure 8.8 Hoist ropes • Remove the clamp (4). • Push the rope through the hole (3) until the rope wedge (1) slides out of the pocket (2). • Remove the rope wedge and place the old rope away from the truck crane.
  • Page 288 Maintenance work on the superstructure 8.8 Hoist ropes • Guide the rope through the hole (3) until it protrudes about 1.5 m (5.0 ft) beyond the pocket (2). • Feed the free end of the rope back through the pocket. •...

  • Page 289: Setting The Lowering Limit Switch

    Maintenance work on the superstructure 8.8 Hoist ropes Observe the hook block when unreeling. The hook block must not rotate. Risk of accidents 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 290 Maintenance work on the superstructure 8.8 Hoist ropes Setting the lowering limit switch Risk of accidents if the rope end fitting is overloaded. The lowering limit switch must always be reset after repair work on the hoist and after rope replacement. A faulty lowering limit switch must always be replaced.

  • Page 291: Cable Drums

    Maintenance work on the superstructure 8.9 Cable drums Cable drums 8.9.1 Maintenance of the slip ring assemblies The slip ring assemblies are located in: 1 Cable drum 1 2 Cable drum 2 Spare parts and Designation Quantity GROVE part no. tools Cover gasket for cable drum 1 03325575...

  • Page 292: Maintenance Of The Slip Ring Assemblies

    Maintenance work on the superstructure 8.9 Cable drums Risk of damage to the RCL. Before maintenance work on the slip ring assemblies, always switch off the battery master switch so that the cable drum is without power. This prevents short circuits which may lead to damage to the rated capacity limiter (RCL).

  • Page 293: Central Lubrication System

    Maintenance work on the superstructure 8.10 Central lubrication system 8.10 Central lubrication system 8.10.1 Checking the level The maintenance of the pump (1) is similar to à Central the maintenance on the carrier; lubrication system , p. 7 - 119. Connected lubricating points –...
  • Page 294 Maintenance work on the superstructure 8.10 Central lubrication system Blank page 8 - 70 3 302 746 en Maintenance manual GMK5200-1...

  • Page 295: Hook Blocks

    Check the sheaves in the hook blocks for damage, wear, mobility and extreme soiling. Have damaged, worn, stiff or extremely soiled sheaves replaced by or an authorised GROVE dealer or your repair crew. Manitowoc Crane Care M 12 8.11.2 Greasing à...
  • Page 296 Maintenance work on the superstructure 8.11 Hook blocks The diagram gives an example of the arrange- ment of the grease nipples (1), (2) and (3) on a hook block. There are more grease nipples on the other side. • Clean the grease nipples on all hook blocks and grease them using a grease gun.
  • Page 297 Some manufacturers recommend dismantling every 4 years or after 500 operating hours. • about the maintenance intervals for the hook Manitowoc Crane Care blocks supplied to you. • Have the hook blocks dismantled by or an author- Manitowoc Crane Care ised GROVE dealer or your qualified repair crew.
  • Page 298 Maintenance work on the superstructure 8.11 Hook blocks Blank page 8 - 74 3 302 746 en Maintenance manual GMK5200-1...

  • Page 299: Electrical System

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

  • Page 300: Have The Battery On The Electronics Board Replaced

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

  • Page 301: Air Conditioning System

    Maintenance work on the superstructure 8.13 Air conditioning system 8.13 Air conditioning system 8.13.1 Checking the air conditioning system • Check the air-conditioning system in the same way as when checking it on à Checking the air conditioning system , p. 7 - 131. the carrier;...

  • Page 302: Checking Hoses

    • Check all refrigerant hoses for damage and areas of wear. Have damaged hoses checked by or an authorised Manitowoc Crane Care GROVE dealer or an authorised specialist workshop only. M 12 8.13.4 Checking the entire air conditioning system...
  • Page 303 Maintenance work on the superstructure 8.13 Air conditioning system Refrigerant Fill quantity Designation CAS no. in kg (lbs) EC no. 1,0 (2,2) 1-circuit (3 KW) 811-97-2 Tetrafluoroethane (R134a) 212-377-0 2 x 0.95 (2.1) 2-circuit (6 KW) Compressor oil: POE OIL; EMKARATE RL68H Filler connections The filler connections (1) for the refrigerant are on the compressor behind the cover (2).

  • Page 304: Changing The Pollen Filter

    Maintenance work on the superstructure 8.13 Air conditioning system M 12 8.13.5 Changing the pollen filter • Reducing the Under difficult operating conditions – at extremely sandy or dusty loca- interval tions – you must change the filter earlier than normal. Spare parts and Designation Quantity...

  • Page 305: Other Maintenance Work

    Maintenance work on the superstructure 8.14 Other maintenance work 8.14 Other maintenance work 8.14.1 Checking the windscreen washing system Water, spare Designation Quantity GROVE part no. parts, tool Windscreen wiper blade 03268512 Roof wiper blade 03326121 – Water; add commercially available detergent and antifreeze to it. –...

  • Page 306: Checking The Auxiliary Heater

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

  • Page 307: Lubricating The Crane Cab Door

    Check if the door moves smoothly on the rails and if it locks easily. If the door is sluggish or does not close properly, have it reset by or an authorised GROVE-dealer. Manitowoc Crane Care Maintenance manual 3 302 746 en 8 - 83...

  • Page 308: Lubricating The Step

    Fully retract the step. If the step is stiff, bent or does not retract completely, have the step aligned and adjusted by or an authorised GROVE dealer. Manitowoc Crane Care 8 - 84 3 302 746 en Maintenance manual GMK5200-1...

  • Page 309: 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 310: Renewing The Corrosion Protection

    Maintenance work on the superstructure 8.14 Other maintenance work M 12 8.14.6 Renewing the corrosion protection Protective agent, Protective agent GROVE part no. tools Corrosion protection 03140192 – Spray gun with spray extension. – Brush. – Protective clothing, protective goggles. Prerequisites –...
  • Page 311 Maintenance work on the superstructure 8.14 Other maintenance work Spraying Risk of injury to the eyes. While working with the spray extension you could be hit by the spray jet or spray droplets. Wear protective goggles, protective clothing and gloves. •...

  • Page 312: Having The Fire Extinguisher Checked

    Maintenance work on the superstructure 8.14 Other maintenance work 8.14.7 Having the fire extinguisher checked Depending on your truck crane's equipment, it has fire extinguishers. The maintenance interval may even be shorter, depending on the respective national regulations and the operating location. Ask the local fire safety officer about the national and local regulations.
  • Page 313 Longer out of service periods Maintenance manual 3 302 746 en GMK5200-1...
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  • Page 315: 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 316 Longer out of service periods • Ensure that the tyre positioning is different each time the crane is parked (without outriggers). • Seal the air filter again. If the truck crane is going to be out of service for more than 12 months: •...
  • Page 317 Torques 10.1 Torques for the retaining bolts ........10 - 10.2 Special torques .
  • Page 318 3 302 746 en Maintenance manual GMK5200-1...

  • Page 319: 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 (mm) pre-tensioning for bolts) for oiled bolts (Nm) Spanner wrench size (mm) Bolt quality Hexagon Cylinder 10.9...
  • Page 320 Torques 10.2 Special torques 10.2 Special torques Thread size Spanner wrench size Torque (Nm) (mm) (mm) Designation Hexagon Cylinder head bolt screw Suspension strut: – Bracket for the vehicle chassis, M 16 — – Bracket for the vehicle chassis, M 24 —...
  • Page 321 Spare parts required for maintenance 11.1 General information ..........11 - 11.2 Lighting .
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  • Page 323: 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 324 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 (left) 04163680 – Daytime driving light (right) 04163679 – Low-beam + full-beam headlights 03134828 H7 24V –...
  • Page 325 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 326 Spare parts required for maintenance 11.2 Lighting Installation point GROVE part Designation Power (W) number SUPERSTRUCTURE LIGHTING: Yellow marker lights: (left and right on the main boom head) – Marker light; complete 03329569 Red rear marker lights: (on the turntable) –...

  • Page 327: 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 part For maintenance interval number Carrier M 12 Engine Valve M 20 x 1.5 03041579 Once when the oil is changed the first time;...
  • Page 328 Spare parts required for maintenance 11.3 Spare parts for the carrier Quantity, in single parts Assemblies and spare parts GROVE part For maintenance interval number Carrier M 12 Wheels Wheel nuts for steel rims 01207756 in case of damage; 12 each per wheel Wheel nuts for aluminium rims 7659100000 Vehicle brake (for all 5 axle lines)
  • Page 329 Spare parts required for maintenance 11.3 Spare parts for the carrier Quantity, in single parts Assemblies and spare parts GROVE part For maintenance interval number Carrier Y 10 Engine Oil filter 04161614 Cover gasket 03328606 Gasket for oil drain plug 04161531 Transmission –...

  • Page 330: 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 part For maintenance interval number Superstructure M 12 Hoists Sight glass with hoses; complete 04161717 (if damaged) Slewing gear...
  • Page 331 Spare parts required for maintenance 11.4 Spare parts for the superstructure Assemblies and spare parts GROVE part Quantity, in single parts Superstructure number For maintenance interval Y 10 Electrical system Lithium battery 3.6 V 03143172 Maintenance manual 3 302 746 en 11 - 9 GMK5200-1...
  • Page 332 Spare parts required for maintenance 11.4 Spare parts for the superstructure Blank page 11 - 10 3 302 746 en Maintenance manual GMK5200-1...
  • Page 333 Appendix Maintenance manual 3 302 746 en GMK5200-1...
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  • Page 335: Appendix

    Appendix...

Table of Contents