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Manitowoc Grove GMK 4100L-1, Maintenance Manual

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Manitowoc Grove GMK 4100L-1 Maintenance Manual Download Page 163

Maintenance work on the carrier

7.11 Vehicle brake

2

5

.1

1.

201

6

Maintenance manual 

3 302 364 en

7 - 75

GMK 4100L-1 

 7.11            

Vehicle brake 

 7.11.1            

Checking the wear display 

On the brake caliper 

Each brake caliper (

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 caliper (

1

). 

If the lining thickness (

A

) falls below the 

permissible minimum value, a warning 
message is displayed on the on-board 
computer in the driver's cab. 

On the on-board computer 

•

Familiarise yourself with the correct 
operation of the on-board computer; 

à

Operating Instructions

. 

The 

Operation and Maintenance

 menu also 

provides information on the condition of 
the disc brakes. 

•

Check the outstanding warning messages 
every day. 

s

D

Summary of Contents for Grove GMK 4100L-1

Page 1: ...Maintenance manual 3 302 364 en 25 11 2016 ...

Page 2: ...ment as well as the utilisation and disclosure of its contents is prohibited unless expressly permitted Infringement will incur liability for compensation All rights pertaining to registration of patent or utility model are reserved The original language of this document is German Important note Any type of duplication or excerpt from this document even in electronic form is not subject to the rev...

Page 3: ...gineers If the local maintenance personnel discover any damage then trained customer service engineers from Manitowoc Crane Care or an authorised GROVE dealer must be requested to perform repairs on the telescoping cylinder and check the entire locking system à Note Having the telescoping cylinder repaired p 1 9 1 1 Maintenance plan 1 1 1 Maintenance plan M 12 M 12 Maintenance work on the SUPERSTR...

Page 4: ...24 04 2017 2 3 302 584 en Additional pages for maintenance manual GMK 4100L 1 Blank page ...

Page 5: ...ease Tools Brush Feeler gauge Prerequisites The truck crane must be level The hook block must be unreeved The main boom must be completely retracted and lowered into horizontal position A rigging mode must be created with a telescope status that satisfies the lifting capacity table necessary for maintenance à Lifting capacity table Section Telescoping sequences for lubricating the main boom The RC...

Page 6: ... the lid 1 the pressure accumula tor 2 and head 3 of the telescoping cylin der 4 are now accessible Checking the pressure accumulator The pressure accumulator 1 is located on the telescoping cylinder Filling pressure at 20 C 68 F 10 bar 145 psi Tolerances Have the filling pressure checked and if necessary corrected by Manitowoc Crane Care or an authorised GROVE dealer G Risk of accidents due to in...

Page 7: ...type B is installed on your truck crane Check lubricate the head Disconnect the locking cylinder Pull out the pin 2 and disconnect the locking cylinder 1 from the connecting link 3 This allows the connecting link 3 to be manually moved to both end positions s Type A The connecting link 1 slides on the head 2 on metal surfaces Type B The connecting link 1 slides on the head 2 over six plastic wear ...

Page 8: ...hs for damage Check the sensor electrical connectors for damage Manually push the connecting link 1 multiple times to both end positions The movement must be soft and free The stroke of the connecting link must be 44 mm 1 7 in Check the tappet Check the tappet 1 for wear Manually press the tappet 1 down against the spring force Release the tappet 1 the spring force must return the tappet to the en...

Page 9: ...9 If the gap dimensions are correct Lubricate the head Lubricate the running surfaces of the head 3 the connecting link 1 and the guides and joints of the lever 2 using a brush PAL 1 lubricant paste Manually push the connecting link 1 multiple times to both end positions to distribute the lubricant paste The movement must be soft and free s Head Measuring point 1 Measuring point 2 Type A 1 3 mm up...

Page 10: ...ct the telescopic section I to 0 and mechanically lock the telescopic section I in the basic section à Operating manual Testing the telescoping cylinder Telescope all telescopic sections into different positions one after another to check for correct operation of the telescoping cylinder à Operating manual You will need to put the truck crane out of service if malfunctions occur in the telescoping...

Page 11: ... system on the main boom inspected annually M12 by Manitowoc Crane Care or an authorised GROVE dealer Especially the head of the telescoping cylinder is checked and adjusted during this annual maintenance work Components can be replaced if necessary The gap dimensions are corrected with shims if necessary Conversion from head type A to type B is possible after consultation with Manitowoc Crane Car...

Page 12: ...24 04 2017 10 3 302 584 en Additional pages for maintenance manual GMK 4100L 1 Blank page ...

Page 13: ... GMK4100L 1 GMK5150 GMK5150L Engine transmission unit Diesel engine type OM 470 1 Transmission 2 Water retarder SWR 3 are the rear of the transmission additional equipment SWR Secondary Water Retarder Transmission The automatic transmission has 16 speeds and the type designation G 280 16 A transmission with Water Retarder SWR B transmission without Water Retarder SWR s ...

Page 14: ... Transmission oil change Change the oil every three years Y 3 1 2 2 Replace coolant In the engine manufacturer s documentation supplied it is recommended to replace the coolant in the radiator circuit of the diesel engine every three years Y3 à Engine manufacturer s documentation If a transmission with Water Retarder SWR is present you must replace the coolant after two years Y 2 Transmission with...

Page 15: ... on the slewing bearing Version A For this version the specifications in the supplied maintenance manual apply Version B Deviating from the specifications in the maintenance manual supplied this version of the slewing angle sensor is maintenance free Only use the telephone number 04160234 if in need of spare parts Slewing angle sensor Version A and B ...

Page 16: ...11 01 2018 2 3 302 704 en Additional page GMK truck cranes Blank page ...

Page 17: ...supplied ladder Prerequisites The main boom must be completely retracted and lowered into horizontal position The hook block must be unreeved The engine must not be running and must be secured against unauthor ised use Lubrication Lubricate the rope attachment point 1 on the grease nipple 2 with the grease gun every three months M3 Check whether the rope attachment point 1 on the axle can be freel...

Page 18: ...03 09 2018 2 3 302 809 en Additional pages for maintenance manual GMK truck cranes Blank page ...

Page 19: ...ance 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 Details of operation and standard safety instructions can be found in the operating instructions ...

Page 20: ...25 11 2016 3 302 364 en Maintenancemanual GMK 4100L 1 Blank page ...

Page 21: ...ions for using the maintenance manual 1 1 1 2 Warnings and symbols 1 1 1 3 Maintenance instructions 1 2 1 4 Instructions regarding the electronic controls 1 4 1 5 Safety instructions for welding work 1 4 1 6 Definition of direction references 1 5 1 7 Conversion table for US measuring units 1 6 ...

Page 22: ...25 11 2016 3 302 364 en Maintenancemanual GMK 4100L 1 ...

Page 23: ...ting manual to highlight particularly important information The vertical line to the left of the text indicates that This text regardless of its length relates to the warning symbol s G This symbol indicates hazards related to the described operation and which may cause personal injury during execution The type of danger e g life threatening personal injury risk of crushing or electric shocks gene...

Page 24: ...epair work may only be carried out by a qualified repair crew e g Manitowoc Crane Care Repair work also requires appropriate workshop equipment special tools and spare parts approved by Manitowoc Crane Group Germany GmbH It is your responsibility to maintain and service the truck crane regularly and carefully in order to extend its service life and keep it in good working order Please note that Ma...

Page 25: ... by trained qualified personnel A few general maintenance instructions Clean the parts of the truck crane that are to be serviced particularly the area around the oil filler opening the oil inspection opening the oil drain opening and the lubricating nipples When changing the oil it should run out at operating temperature Ensure that only oils and lubricants specified in the Lubricants p 6 1 are u...

Page 26: ...lic roads 1 4 Instructions regarding the electronic controls The electronic controls are generally designed for a service life of 10 years In terms of use the control system s service life can be estimated based on the following limiting factors The service life of the EEPROM allows 106 accesses Data is retained for 10 years Some conventional capacitors in the control system have a service life of...

Page 27: ... means that Forwards always means with the driver s cab leading Backwards always means with the rear lights on the carrier leading On the superstructure The main boom head is always at the front which means that Switches and buttons For switches and buttons the terms down and up are used Regardless of the fitting position vertical horizontal diagonal transverse or turned the following always appli...

Page 28: ... of measurement and vice versa Converting from into Multiply by mm in 0 03937 in mm 25 4 m ft 3 28084 ft m 0 30479 m ft 10 76391 cm in 0 155 cm in 0 061 ltr gal US 0 264178 kg lbs 2 204622 lbs kg 0 45359 t lbs 2204 622 lbs t 0 0004536 kN lbf 224 809 daN cm lbf in 14 50378 lbf in daN cm 0 06895 bar psi 14 50378 psi bar 0 06895 m s ft s 3 28084 km h or km mph or mi 0 62137 mph or mi km h or km 1 609...

Page 29: ...al 3 302 364 en GMK 4100L 1 2 Safety and environmental protection 2 1 Safety rules 2 1 2 1 1 Securing against unauthorised use 2 3 2 2 Handling substances which are harmful to the environment 2 4 2 3 Disposal of the truck crane 2 6 ...

Page 30: ...25 11 2016 3 302 364 en Maintenancemanual GMK 4100L 1 ...

Page 31: ...nded into horizontal position Do not carry out maintenance work unless the truck crane is standing on flat stable ground and is secured against rolling away Keep all handles steps railings and ladders free of dirt grease snow and ice Use the provided safe access aids and working platforms when carrying out work above body height Wear a safety harness when carrying out maintenance work at a great h...

Page 32: ...aulic and compressed air systems of the truck crane are pressurised even when the crane is not in operation Tighten loose screw connections only when the systems are depressurised Always depressurise the hydraulic and compressed air systems before opening them Do not allow hot fluids to escape in an uncontrolled manner Risk of scalding Observe the applicable safety regulations when working with fl...

Page 33: ... driver s cab Locking the driver s cab and the crane cab Set up warning signs in the driver s cab and in the crane cab with information about when why and by whom the truck crane was secured to prevent unauthorised use Remove the warning signs from the driver s cab and the crane cab after completion of the maintenance work G Danger due to unauthorised use Always stow away the hand held control in ...

Page 34: ...tructions in this chapter Using suitable equipment Substances harmful to the environment can sometimes be corrosive When doing maintenance work involving these consumables oils coolant fuel always use receptacles hoses pumps funnels etc which have sufficient capacity and which are resistant to the consumables For oil samples always use receptacles that can be closed and have sufficient capacity an...

Page 35: ...es which are harmful to the environment keep solid materials e g filter cartridges separate from fluids Disposal costs will be reduced if you collect fluids separately according to defined categories Store environmentally harmful substances only in approved receptacles and in locations which meet the requirements of applicable national and regional regulations Disposal Ask your local environmental...

Page 36: ...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 On site find out about certified vehicle disposal companies Have the vehicle disposal company issue a disposal certificate for the truck crane Once collected have all the environmentally harmful substances disposed of only by disposal c...

Page 37: ...25 11 2016 3 Maintenance manual 3 302 364 en GMK 4100L 1 3 Cleaning 3 1 Overview of assemblies easily damaged when cleaning 3 2 ...

Page 38: ...25 11 2016 3 302 364 en Maintenancemanual GMK 4100L 1 ...

Page 39: ...and switch boxes suction and ventilation filters or control elements and lubricated surfaces To prevent corrosion relubricate all slide faces after cleaning Keep all electric and hydraulic connections free of dirt Check the connecting points for dust foreign bodies and moisture before installation This also applies to protective caps and bridging plugs The parts specified in the next section are p...

Page 40: ...Cleaning 3 1 Overview of assemblies easily damaged when cleaning 3 2 3 302 364 en Maintenancemanual GMK 4100L 1 25 11 2016 3 1 Overview of assemblies easily damaged when cleaning ...

Page 41: ...ons on the boom head 2 Telescopic slide faces 3 Angle data transmitter 4 Lowering limit switch 5 Steering computer 6 Suspension struts 7 Slewing angle sensor 8 Heating air conditioning system under the crane cab 9 Control units for outriggers 10 Steering angle sensor 11 Carrier electronic control equipment 12 Lifting limit switch 13 Pressure sensors on the derricking cylinder 14 Battery box 15 RCL...

Page 42: ...Cleaning 3 1 Overview of assemblies easily damaged when cleaning 3 4 3 302 364 en Maintenancemanual GMK 4100L 1 25 11 2016 Blank page ...

Page 43: ...25 11 2016 4 Maintenance manual 3 302 364 en GMK 4100L 1 4 Run in regulations ...

Page 44: ...25 11 2016 3 302 364 en Maintenancemanual GMK 4100L 1 ...

Page 45: ...nator additional equipment à Checking the V belt tension p 7 23 after 50 30 Tighten the wheel nuts à Special torques p 10 2 after 150 95 Tighten the wheel nuts à Special torques p 10 2 after 50 Tighten the clips on the coolant hoses à Special torques p 10 2 after 100 Lubricate the outrigger beams à Lubricating the outrigger beams p 7 140 during the first 100 Check the hydraulic oil filters on a we...

Page 46: ... filter p 8 39 after 100 Tighten the bolts on the slewing bearing à Checking the screws p 8 21 à Special torques p 10 2 after 100 Hook blocks à Lubricating p 8 71 after 200 First oil change on the hoists à Changingtheoil checkingtheoil p 8 11 after 1 000 or after 12 months at the latest Second oil change on the hoists à Changingtheoil checkingtheoil p 8 11 after 200 Change the slewing gear oil à C...

Page 47: ... 5 10 5 2 5 Maintenance plan M 6 5 12 5 2 6 Maintenance plan M 12 5 14 5 2 7 Maintenance plan Y 2 5 16 5 2 8 Maintenance plan Y 3 5 16 5 2 9 Maintenance plan Y 5 5 17 5 2 10 Maintenance plan Y 6 5 17 5 2 11 Maintenance plan Y 10 5 18 5 3 Periodic inspections 5 19 5 3 1 Load hook inspection 5 20 5 4 Measures required for winch monitoring 5 21 5 4 1 Theoretical service life 5 21 5 4 2 Proportion of ...

Page 48: ...25 11 2016 3 302 364 en Maintenancemanual GMK 4100L 1 ...

Page 49: ...which the appropriate maintenance work is described The cross references consist of the chapter number and the corresponding page number e g Check hydraulic oil level à p 7 97 Checking the hydraulic oil level is described in Chapter 7 the section starts on page 7 97 5 1 Maintenance intervals The length of the maintenance interval depends on the grade of oil used and operating conditions of the tru...

Page 50: ...ce plans Please note that the long term maintenance plans always include the short term ones Maintenance plans Maintenance interval Driven km mi carrier Engineoperating hours oper hrs D daily before putting into operation W Weekly M 1 monthly approx 2 000 approx 1 240 approx 100 M 3 every three months 5 000 6 000 3 100 3 730 250 M 6 every six months 10 000 12 500 6 210 7 770 500 M 12 every 12 mont...

Page 51: ...plan for better comprehension In addition to the Maintenance work on the carrier and the Maintenance work on the superstructure Chapter 6 also lists the Lubricants and consumables The designations of the oils lubricants in accordance with Lubricants list p 6 2 The amounts as approximate values for oil amounts in litres ltr and US gallons gal the exact oil amounts can always be determined by the oi...

Page 52: ... Checking the coolant level à p 7 17 Fuel system Draining off water from fuel filter 1 à p 7 28 Exhaust system with exhaust emission control Checking the AdBlue tank level à p 7 34 Wheels Checking the tyres for damage à p 7 67 Vehicle brake Checking the wear display à p 7 75 Steering Checking the steering monitoring à p 7 89 Checking for leaks à p 7 91 Hydraulic system Checking the oil level à p 7...

Page 53: ...manual 3 302 364 en 5 5 GMK 4100L 1 D Maintenance work on the SUPERSTRUCTURE Daily before putting into operation Hydraulic system Checking the oil level à p 8 31 Hoist ropes Checking the winding à p 8 51 Electrical system Checking the lighting and indicators à p 8 73 ...

Page 54: ...eral inspection à p 7 45 Angle gear General inspection à p 7 50 Axle lines General inspection à p 7 55 Wheels Checking the tyre pressure à p 7 68 Compressed air system Draining water from the compressed air system à p 7 93 Checking for leaks à p 7 94 Hydraulic system Checking the hydraulic hoses à p 7 98 Checking for leaks à p 7 98 Central lubrication system Checking the level à p 7 115 Other main...

Page 55: ... p 8 10 Checking the hoist brake à p 8 10 Slewing gear Checking the oil level à p 8 15 Checking for leaks à p 8 16 Hydraulic system Checking the hydraulic hoses à p 8 32 Checking the ventilation filter à p 8 32 Checking for leaks à p 8 33 Hoist ropes Checking the hoist ropes à p 8 52 Central lubrication system Checking the level à p 8 69 Other maintenance work Checking the windscreen washing syste...

Page 56: ...the oil level à p 7 50 Axle lines Axle centre drives checking the oil level à p 7 55 Final drives Checking the oil level à p 7 61 Lubricating the Cardan shafts in the axle lines à p 7 64 Wheels Checking that the wheel nuts are tight à p 7 69 Suspension Suspension struts Checking the oil level à p 7 83 Suspension struts checking the fastening à p 7 85 Electrical system Checking the batteries à p 7 ...

Page 57: ...enance work on the SUPERSTRUCTURE Monthly after approx 100 operating hours Main boom Greasing the piston rod of the derricking cylinder à p 8 45 Air conditioning system Checking the air conditioning system à p 8 75 Cleaning the condenser fins à p 8 75 Other maintenance work Checking the auxiliary heater à p 8 80 ...

Page 58: ...ension Forced lever checking correct functioning à p 7 86 Hydraulic system Cleaning the magnetic rods à p 7 99 Electrical system Checking the charge level of the batteries à p 7 122 Charging the batteries using the battery charger à p 7 124 Check the external starting socket à p 7 125 Towbar coupling Checking the bearing à p 7 133 Checking the cotter pin à p 7 134 Checking the lower bushing à p 7 ...

Page 59: ...e SUPERSTRUCTURE every three months after 250 oper hrs Slewing bearing Checking the screws à p 8 21 Hydraulic system Cleaning the magnetic rods à p 8 34 Main boom Lubricating the telescopic sections à p 8 46 Lubricating the sheaves à p 8 50 Hoist ropes Lubricating the hoist rope à p 8 53 Hook blocks Checking the sheaves à p 8 71 ...

Page 60: ...RRIER every six months after 10 000 12 500 km 6 210 7 770 mi Engine Notes à Engine manufacturer s documentation à p 7 13 Transfer case Changing the oil à p 7 46 Angle gear Changing the oil and the oil filter à p 7 52 Axle lines Lubricating longitudinal Cardan shafts à p 7 65 Wheels Changing the wheels à p 7 70 Air conditioning system Checking hoses à p 7 127 ...

Page 61: ...CTURE every six months after 500 oper hrs Slewing gear Checking the slewing gear brake à p 8 16 Slewing bearing Lubricating the gear teeth à p 8 25 General inspection à p 8 27 Measuring tilting play à p 8 28 Cable drums and slewing angle sensor Maintenance of the slip ring assemblies à p 8 65 Air conditioning system Checking hoses à p 8 76 ...

Page 62: ...e centre drives changing the oil à p 7 57 Final drives Changing the oil à p 7 62 Suspension Pressure accumulator checking the gas pressure à p 7 87 Compressed air system Replacing the filter cartridge of the compressed air drier à p 7 95 Hydraulic system Changing the ventilation filter à p 7 101 Taking oil samples depending on the oil sample test results Changing the hydraulic oil à p 7 102 à p 7 ...

Page 63: ...lter à p 8 36 Pressure accumulator checking the gas pressure à p 8 37 Taking oil samples depending on the oil sample test results Changing the hydraulic oil à p 8 37 à p 8 42 Changing the hydraulic oil filter à p 8 39 Main boom Checking the locking system à p 8 50 Hook blocks Lubricating à p 8 71 Air conditioning system Checking the entire air conditioning system à p 8 76 Changing the pollen filte...

Page 64: ...il and oil filter à p 7 25 Other maintenance work Having the fire extinguisher checked à p 7 145 Maintenance work on the SUPERSTRUCTURE every 24 months after 2 000 oper hrs Other maintenance work Having the fire extinguisher checked à p 8 86 Y 3 Maintenance work on the CARRIER every 36 months No maintenance work in this period The long term intervals always include the short term intervals Mainten...

Page 65: ...mission Changing the oil à p 7 42 Maintenance work on the SUPERSTRUCTURE every 60 months after 5 000 oper hrs Have both the Cardan shafts on the angle gear replaced by Manitowoc Crane Care or an authorised GROVE dealer Cable drums and slewing angle sensor Lubricating the slewing angle sensor à p 8 67 Y 6 Maintenance work on the CARRIER every 72 months No maintenance work in this period The long te...

Page 66: ...e load bearing steel construction For further information please contact Manitowoc Crane Care Maintenance work on the SUPERSTRUCTURE every 120 months after 12 000 oper hrs Electrical system Have the battery on the electronics board replaced à p 8 74 Steel construction Check the load bearing steel construction For further information please contact Manitowoc Crane Care Rated capacity limiter RCL Ha...

Page 67: ...s are generally visual examinations intended to assess the condition of the truck crane and its components Their purpose is to detect defects at an early stage and thus prevent accidents Inspections must be carried out on the following if they are not already included in the list of periodic maintenance work the hydraulic and electrical control and safety devices the rated capacity limiter RCL the...

Page 68: ... The original dimensions y y1 y2 are specified in field 2 on the load hooks To check this measure the distance between the marked measuring points on the load hook shaft 1 and the tip of the hook 3 The hook block may no longer be used if the opening has increased by more than 10 of its original dimension G Risk of accidents due to the load falling Hook blocks with deformed load hooks are no longer...

Page 69: ...lations for Winches Hoists and Tractor Machines BGV D 6 VGB 9 and BGV D 8 VBG 8 5 4 1 Theoretical service life The theoretical service life is determined according to certain operating conditions and a theoretical total operating time assumed by the design engineer when calculating and dimensioning the winches of your truck crane The power unit group M 3 and the load spectrum L1 Km 0 125 are gener...

Page 70: ...m and the hoist operating hours must be determined for each inspection interval when determining the proportion of theoretical service life that has been used The operating company is responsible for proper documentation in the crane logbook 1 Overloading caused by improper use of the truck crane 2 Insufficient maintenance Oil is not changed at the specified intervals 3 Operating errors Extreme ac...

Page 71: ... which are generally subject to only low stress 10 of the running time with greatest load dead load 1 1 payload 40 of the running time with dead load 1 3 payload 50 of the timing period with dead load only 0 125 Medium Q2 L2 Power units or parts thereof that are subject to high stress quite frequently but which are generally subject to only low stress 1 6 of the running time with greatest load dea...

Page 72: ... 8 the proportion of theoretical service life used Si is calculated using the formula This used proportion is subtracted from the remaining theoretical service life Di after every inspection interval see example in the appendix to this chapter If the remaining theoretical service life is not sufficient for the next operating period then a general overhaul of the winch must be performed If theoreti...

Page 73: ...haul under the following conditions The crane inspector has confirmed that the used proportion of the service life is correct and proper by signing his her name in the crane logbook after every expert inspection In this case the crane inspector must closely inspect the winch This includes at least a visual examination of the exterior for leaks damage deformation etc an oil inspection especially fo...

Page 74: ...oad spectrum L 1 i e Km1 0 125 The operating hours counter for the main hoist reads 160 h i e T1 160 h The used proportion S1 of theoretical service life after the first inspection therefore is Remaining theoretical service life D1 3 200 h 160 h 3 040 h The above values are entered in the table see table example p 5 28 2 inspection 2nd year The truck crane was used for unloading work on docks Load...

Page 75: ...urs counter for the main hoist reads 940 h i e during this period 940 h 640 h 300 h T3 300 h The used proportion S3 of theoretical service life after the third inspection is therefore Remaining theoretical service life D3 1 120 h 600 h 520 h The values are entered in the table see table example p 5 28 The remaining theoretical service life is to be documented in a separate table for each winch Thi...

Page 76: ...s of the entire crane Operating hours of the superstruc ture Operating hours of the superstruc ture since the last inspection Winch operating hours Operating hours T i of the winch since the last inspection Used proportion S i of theoretical service life D Remaining theoretical service life D i D i 1 S i Name of the expert Signature Comment Name of the approved inspector Signature i Km i h h h h h...

Page 77: ...icants 6 1 6 1 1 Lubricants list 6 2 6 1 2 Lubricant applications list 6 3 6 2 Refrigerant 6 5 6 3 Consumables 6 5 6 3 1 Fuel 6 5 6 3 2 Engine coolant admixtures 6 5 6 3 3 Exhaust gas emission control 6 6 6 3 4 Windscreen washing system admixtures 6 6 6 3 5 Fuel for crane cab heating system 6 6 ...

Page 78: ...25 11 2016 3 302 364 en Maintenancemanual GMK 4100L 1 ...

Page 79: ...cants and consumables 6 1 Lubricants All lubricants that you require for Maintenance work on the carrier p 7 1 and Maintenance work on the superstructure p 8 1 are listed with serial numbers in the lubricants list and the lubricant applications list à Lubricants list p 6 2 à Lubricant applications list p 6 3 ...

Page 80: ...B API GL 5 Hyp SAE 90 ISO VG 220 4 01373344 Gear oil MIL L 2105 C API GL 5 SHC 75 W 90 5 02310863 Gear oil Rivolta S K D 170 6 02313611 Gear oil C LPF MIL L 2105 B API GL 4 5 synthetic SAE 75 W 90 EP ISO VG 220 7 04162158 Hydraulic oil HVLP Castrol Hyspin AWH M 32 DIN 51524 3 ISO VG 32 8 04177395 Hydraulic oil HVLP Shell Tellus S2 VX 15 9 03233369 Lubricating grease KP 1K 50 DIN 51825 Renolit JP 1...

Page 81: ...ine axle centre drive à p 7 57 13 0 3 5 M 12 2 Axle line axle centre drive à p 7 57 15 0 4 0 M 12 3 Axle line axle centre drive à p 7 57 16 5 4 4 M 12 6 or 8 x final drives à p 7 62 2 7 0 7 M 12 4 Gear oil Angle drive type A à p 7 52 7 2 1 9 M 6 Angle drive type B à p 7 52 8 6 2 3 M 6 5 Gear oil 8 x suspension struts à p 7 83 1 5 0 4 each M 1 6 Gear oil 2 x hoists à p 8 11 3 3 0 9 each M 12 2 x sl...

Page 82: ... 7 140 M 1 Turntable lock à p 8 30 M 12 Slewing angle sensor à p 8 67 Y 5 Hook blocks à p 8 71 M 12 Cab door hinges à p 7 141 M 12 Carrier pins à p 7 142 M 12 Superstructure pins à p 8 83 M 12 10 Spray Slewing bearing gear teeth à p 8 25 M 6 11 Slide paste Telescopic slide faces à p 8 46 M 3 12 Lubricating grease Telescopic locking pins à p 8 46 M 3 Derricking cylinder piston rod à p 8 45 M 1 Cab ...

Page 83: ... of additives is not permitted and can damage the engine system 6 3 2 Engine coolant admixtures The specifications and admixture ratios can be found in the Engine manufacturer s documentation Refrigerant designation Usage Fillquantity in kg lbs Maintenance interval Tetrafluoroethane R134a CAS no 811 97 2 EC no 212 377 0 Air conditioning system in the driver s cab à p 7 128 Compressor oil FUCHS SE ...

Page 84: ...the truck crane is fitted with a separate tank for the auxiliary heater do you have the option of selecting whether to use the same fuel as in Section 6 3 1 or to use EL heating oil Designation Usage Fill quantity in litres gal DEF Diesel Exhaust Fluid 1 AdBlue GROVE part number 03140555 AdBlue tank on the carrier à p 7 34 40 10 5 1 DEF Diesel Exhaust Fluid Consumable for exhaust gas emission cont...

Page 85: ...Exhaust system with exhaust emission control 7 33 7 5 1 Checking the AdBlue tank level 7 34 7 5 2 Filling up with AdBlue 7 34 7 5 3 Check the exhaust system for external damage 7 35 7 5 4 Having the AdBlue system checked 7 37 7 6 Transmission 7 39 7 6 1 General inspection 7 40 7 6 2 Checking the oil level 7 41 7 6 3 Changing the oil 7 42 7 7 Transfer case 7 45 7 7 1 General inspection 7 45 7 7 2 C...

Page 86: ...ilter cartridge of the compressed air drier 7 95 7 15 Hydraulic system 7 97 7 15 1 Checking the oil level 7 97 7 15 2 Checking the hydraulic hoses 7 98 7 15 3 Checking for leaks 7 98 7 15 4 Cleaning the magnetic rods 7 99 7 15 5 Changing the ventilation filter 7 101 7 15 6 Taking oil samples 7 102 7 15 7 Changing the hydraulic oil 7 107 7 15 8 Changing the hydraulic oil filter 7 111 7 16 Central l...

Page 87: ...ion of the springs 7 135 7 19 6 Checking the support ring 7 136 7 19 7 Checking the function of the coupling jaw resetting the middle position 7 136 7 20 Other maintenance work 7 139 7 20 1 Checking the windscreen washing system 7 139 7 20 2 Lubricating the outrigger beams 7 140 7 20 3 Checking the auxiliary heater 7 141 7 20 4 Lubricating the cab door 7 141 7 20 5 Lubricating the connecting and s...

Page 88: ...25 11 2016 3 302 364 en Maintenancemanual GMK 4100L 1 ...

Page 89: ...ted at the respective place of use without an AdBlue system is available but only as special equipment In that case there is no AdBlue tank 1 fitted to the truck crane The relevant maintenance work does not arise à Exhaust system with exhaust emission control p 7 33 7 1 1 Covers Various types of work e g oil change require that covers be removed Before maintenance work Remove the covers 1 Remove t...

Page 90: ...can find information on how to operate the hand pump in the operating manual Make sure you observe the safety instructions mentioned there à Operating Instructions Tilting and lowering the driver s cab Oil tools Oil level Lower edge of opening 2 Check every 12 months Refilling When required via opening 2 Lever for hand pump 1 from the toolbox Before maintenance work Tilt the driver s cab à Operati...

Page 91: ...Maintenance work on the carrier 7 1 General instructions 25 11 2016 Maintenance manual 3 302 364 en 7 3 GMK 4100L 1 Blank page ...

Page 92: ...Maintenance work on the carrier 7 1 General instructions 7 4 3 302 364 en Maintenancemanual GMK 4100L 1 25 11 2016 7 1 3 Overview of maintenance work on the carrier ...

Page 93: ... 15 19 Air filter à p 7 16 2 Coolant reservoir à p 7 17 17 Oil filter à p 7 25 Fuel system à p 7 27 12 Left fuel tank à p 7 27 20 Right fuel tank à p 7 27 14 Filter 1 à p 7 28 15 Filter 2 à p 7 31 Exhaust system with exhaust emission control à p 7 33 13 AdBlue tank à p 7 34 16 Exhaust silencer with SCR catalytic converter à p 7 35 Transmission à p 7 39 6 Oil level plug à p 7 41 7 Oil filter on the...

Page 94: ...Maintenance work on the carrier 7 1 General instructions 7 6 3 302 364 en Maintenancemanual GMK 4100L 1 25 11 2016 ...

Page 95: ...r system à p 7 93 10 Receptacle à p 7 93 14 Drier à p 7 95 Hydraulic system à p 7 97 1 Oil tank with sight glass à p 7 97 2 Oil filters 1 and 2 à p 7 111 5 Oil filters 3 and 4 à p 7 111 3 Ventilation filter à p 7 101 4 Oil filler opening à p 7 107 Central lubrication system à p 7 115 15 Centralized lubrication pump à p 7 115 Air conditioning system à p 7 127 12 Air conditioning system in the drive...

Page 96: ...Maintenance work on the carrier 7 1 General instructions 7 8 3 302 364 en Maintenancemanual GMK 4100L 1 25 11 2016 ...

Page 97: ...eering cylinder à p 7 91 Electrical system à p 7 119 13 Carrier lighting à p 7 119 11 Battery box à p 7 120 14 External starting socket à p 7 125 Towbar coupling à p 7 131 15 Towbar coupling 1 à p 7 131 Other maintenance work à p 7 139 6 Windscreen washing system receptacle à p 7 139 4 Outrigger beams à p 7 140 7 Cab door hinges à p 7 141 12 Driver s cab auxiliary heater 1 à p 7 141 Various connec...

Page 98: ...Maintenance work on the carrier 7 1 General instructions 7 10 3 302 364 en Maintenancemanual GMK 4100L 1 25 11 2016 Blank page ...

Page 99: ...k The Start menu shows the most important measurements and the Maintenance submenu shows all the outstanding warning messages à Operating Instructions Maintenance submenu If one of the symbols is displayed you must carry out the appropriate maintenance work Oil pressure à p 7 13 Coolant level à p 7 17 Air filter à p 7 16 Hydraulic oil filter à p 7 111 AdBlue system à p 7 34 Disc brakes wear displa...

Page 100: ...Maintenance work on the carrier 7 2 Symbols for maintenance work 7 12 3 302 364 en Maintenancemanual GMK 4100L 1 25 11 2016 Blank page ...

Page 101: ...ne from the driver s cab à Operating Instructions Start the engine and watch the symbol 1 Stop the engine immediately if the symbol does not disappear after 10 seconds If symbol 1 is displayed the oil pressure is too low Allow the engine to run at idling speed for 2 3 minutes Switch the engine off Check the oil level after about 2 minutes s D S Risk of damage to the engine if the oil pressure is t...

Page 102: ...n Maintenancemanual GMK 4100L 1 25 11 2016 On the dipstick 1 check that the oil level is between the min and the max marks arrow markings After checking the oil level put the dipstick back in the dipstick tube If the oil level is too low Top up the oil à p 7 15 ...

Page 103: ...he cap Put the dipstick 1 into the dipstick tube after checking the oil level Engine oil in litres gal Designation to DIN 51502 Specification classification GROVE part no 34 9 0 HD CD MIL L 2104 C DB 228 5 SAE 5 W 30 03329588 S Risk of damage to the engine if the oil level is too high Do not overfill with oil the oil level must not be higher than the max mark arrow marking Drain off oil if necessa...

Page 104: ...hange the air filter Switch the engine off Spare parts and tools Prerequisites The engine must be switched off and secured against unauthorised use à p 2 3 Replacing the air filter Undo all the clamps 1 and remove the cover 2 Change the main filter 3 and the back up filter 4 Replace the cover and secure it with all the clamps D Designation Quantity GROVE part no Main filter 1 04158601 Back up filt...

Page 105: ...s too low Top up the coolant Composition of the coolant à Engine manufacturer s documentation Close the cap 1 D G There is a risk of scalding when the cooling circuit is hot The hot cooling circuit is under pressure When you open the expansion tank you could be scalded by escaping steam coolant Wear suitable protective gloves and cover the cap on the expansion tank with a rag before opening it Tur...

Page 106: ... authorised specialist workshop 7 3 6 Have the radiator checked cleaned Reducing the interval Under difficult operating conditions at extremely sandy or dusty locations or if there is a heavy density of fallen leaves you must have the radiator fins cleaned earlier than this Prerequisites The truck crane must be supported on outriggers and must be level à Operating Instructions The main boom must b...

Page 107: ...6 are located under the grilles When the engine is running the fan impeller rotates under the grille s G Risk of injury at the fan impeller When the fan impeller is rotating it can trap the fingers of your hand and amputate them Never reach into a fan impeller that is rotating Do not push any tools through the grille to clean it Always stop the engine before attempting to clean the fan impeller an...

Page 108: ...y remove leaves twigs and other debris from the grilles 4 View the fan impellers 6 through the grilles from above to check their condition The impeller blades must be clean and undamaged H If the radiator fins are heavily soiled have them cleaned since further soiling can lead to overheating à Have them cleaned p 7 20 Have them cleaned G Risk of injury at the fan impeller When the fan impeller is ...

Page 109: ...nits 1 2 and 3 opened up by the repair crew so that the radiator fins are accessible Have the radiator fins cleaned on both sides using suitable cleaning agents Have the fan impellers 6 cleaned Have the enclosure plates 5 cleaned Have the hoses and connections checked for damage and leaks Have any damaged parts replaced s ...

Page 110: ...and cleaning equipment Check that the grille 4 and enclosure plates 5 are secure Start the engine and wait until the fan impellers are rotating Check that the fan impellers are running freely Check the respective temperature displays in the driver s cab à Operating Instructions Switch the engine off Check the radiator and connections for leaks ...

Page 111: ...d à Engine manufacturer s documentation Spare parts and tools Frequency measuring instrument GROVE part no 04165439 new V belt Frequency 78 2 Hz run in V belt Frequency 68 6 Hz Prerequisites The engine must not be running and must be secured against unauthorised use Checking Check the V belt 1 for cracks and damage If necessary fit a new V belt 1 Undo the nuts and bolts 2 Tilt the alternator 3 dow...

Page 112: ...perating instructions provided by the manufacturer Switch the frequency measuring instrument 1 on it is now ready for acoustic measurement Hold the measuring head 3 over the V belt 4 Strike the V belt 4 with an object tool so that it vibrates On the display 2 read the measured value new V belt 78 2 Hz run in V belt 68 6 Hz If necessary correct the pre tension until the specified measured value is ...

Page 113: ...o change the oil and the oil filter à Engine manufacturer s documentation The truck crane must be level The engine must be switched off and secured against unauthorised use à p 2 3 Changing s Y 2 Engine oil in litres gal Designation to DIN 51502 Specification classification GROVE part no 34 9 0 HD CD MIL L 2104 C DB 228 5 SAE 5 W 30 03329588 Designation Quantity GROVE part no Oil filter with cover...

Page 114: ...ufacturer s documentation Leave the receptacle in place for the oil change Draining oil Turn the drain plug 1 contrary to the sense of the arrow until it reaches the stop then take it off Let the oil drain into the receptacle Insert the drain plug 1 and turn it in the sense of the arrow until it reaches the stop spring loaded engagement detent Remove the receptacle Topping up oil Top up with fresh...

Page 115: ...may only be filled with a single type of fuel For additional equipment with a dual tank system the fuel tanks 1 and 2 are separate and are filled with different types of fuel à Operating Instructions Obtain information from Manitowoc Crane Care on the additional fuel filter required for the dual tank system The following elements are installed as standard in the carrier fuel line 1 Fuel filter 1 l...

Page 116: ...nstructions The engine must be switched off and secured against unauthorised use à p 2 3 Draining off water Place a receptacle underneath the filter Open the valve 1 If the consumable that emerges is clean close the valve by hand Remove the receptacle and properly dispose of the drained consumable D O Risk of environmental damage due to leaking consumables Always let consumables drain into suitabl...

Page 117: ...d à Operating Instructions The engine must be switched off and secured against unauthorised use à p 2 3 If the fuel is dirty Reduce the maintenance interval Changing Place a receptacle underneath the filter Open the valve 1 and let the consumable drain out s M 3 Designation Quantity GROVE part no Filter large 1 04161991 O Risk of environmental damage due to leaking consumables Always let consumabl...

Page 118: ...ce the old filter 2 in the receptacle Insert a new filter 2 into the casing Attach the cover 1 torque 55 Nm 40 5 lbf ft à Engine manufacturer s documentation Remove the receptacle 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 Start the engine and check for leaks ...

Page 119: ...ned from the fuel filter 1 à p 7 29 If the fuel is dirty Reduce the maintenance interval Changing Place a receptacle underneath the filter 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 Attach the cover 1 torque 15 Nm 11 lbf ft à Engine manufacturer s documentation Remove the receptacle s M 12 Designation Qu...

Page 120: ...7 32 3 302 364 en Maintenancemanual GMK 4100L 1 25 11 2016 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 Start the engine and check for leaks ...

Page 121: ...ly reduced when there is not enough AdBlue solution available Driving with an empty AdBlue tank will invalidate the truck crane s licence for use on public roads à Operating Instructions à Engine manufacturer s documentation AdBlue system 1 AdBlue tank with insulation hood 2 Pump unit for pumping AdBlue to the dosing unit on the diesel engine and for pumping engine coolant for preheating the AdBlu...

Page 122: ...arry additional canisters of AdBlue Start the engine and check the gauge after the engine starts à p 7 35 Refill with AdBlue before the tank becomes empty 7 5 2 Filling up with AdBlue Consumable and tools As required Two canisters of about 20 ltr each 5 gal à p 2 4 Prerequisites A service station with a filling pump for AdBlue can be used or AdBlue can be filled manually from canisters The engine ...

Page 123: ...ternal damage Spare parts and tools Prerequisites The engine must be switched off and secured against unauthorised use à p 2 3 The engine and the exhaust system must be cool s G Danger of scalding due to ammonia vapours Ammonia vapour can escape if the AdBlue tank is opened when the outside temperature is high Ammonia vapours can irritate mucous membranes skin and eyes Ensure that there is adequat...

Page 124: ...k the AdBlue injection nozzle 4 for outer damage After checking Start the engine Check the AdBlue system gauge on the display in the driver s cab à p 7 34 Check whether exhaust gases are leaking from any damaged places in the exhaust system Switch the engine off If you discover any damage Have any damaged parts of the exhaust system replaced immediately by Manitowoc Crane Care or an authorised GRO...

Page 125: ...for engine coolant for preheating the AdBlue tank Maintenance interval for the pump unit The engine manufacturer specifies additional maintenance intervals for the pump unit 1 à Engine manufacturer s documentation AdBlue filter Have the AdBlue filter in the pump unit 1 changed for the first time after one year M 12 after that every two years Y 2 Pressure accumulator Have the pressure accumulator i...

Page 126: ...tridge à Replacing the filter cartridge of the compressed air drier p 7 95 S Risk of damage to the pump unit 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 Manitowoc Crane Care recommends the suitable filter cartridge with the GROVE part number 04157844 ...

Page 127: ...iew Engine transmission unit Diesel engine 1 Transmission 2 Water retarder SWR 3 are the rear of the transmission additional equipment SWR Secondary Water Retarder Transmission The automatic transmission has 16 speeds and the type designation G 280 16 A transmission with Water Retarder SWR B transmission without Water Retarder SWR ...

Page 128: ...sumables à Checking the oil level p 7 41 Check that pipes and hoses are tightly connected and undamaged From the rear transmission area two hoses run to the transmission oil cooler The transmission oil cooler is located within the radiator unit 1 à p 7 20 If any damage is found report it to Manitowoc Crane Care or an authorised GROVE dealer or an authorised specialist workshop W Access Inspection ...

Page 129: ...uck crane must not running and secured against unauthorised use à p 2 3 The inspection opening are now accessible à p 7 40 Check the oil level Remove the drain plug 1 Check the oil level it must reach to the lower edge of the opening Replace the gasket and tighten the drain plug torque 25 Nm 18 4 lbf ft If the oil level is too low Top up the oil à p 7 44 M 12 Designation Quantity GROVE part no Gas...

Page 130: ... in litres gal Specification Classification GROVE part no 15 5 4 1 with oilcooler Fuchs Titan Cytrac MB Synth API GL 4 SAE 75 W 90 04162042 Designation Quantity GROVE part no Filter 1 03328342 Spring 1 03328343 Gasket 42 x 49 Al DIN 7603 1 03328344 Gasket 24 x 29 Cu DIN 7603 2 00117145 G Risk of scalding from gear oil at operating temperature You could scald yourself by gear oil escaping in an unc...

Page 131: ... gasket and tighten the drain plug 2 torque 25 Nm 18 4 lbf ft Cleaning the filter Remove the drain plug 1 Take the filter 2 and the spring 3 out and clean them Replace any damaged parts Insert the spring and filter into the opening Replace the gasket and tighten the drain plug torque 60 Nm 44 25 lbf ft s G Risk of injury due to spring tension The oil filter bolt is spring loaded Release it careful...

Page 132: ...il Fill the oil up to the lower edge of the opening Replace the gasket and tighten the drain plug 1 torque 25 Nm 18 4 lbf ft Checks after the oil change After changing oil check for leakage Start the engine and let it idle in neutral N Check the screw plugs 1 to 3 for leakage Check the hoses and connections on the oil cooler ...

Page 133: ...re leaking à Checking the oil level p 7 45 Check that pipes and hoses are tightly connected and undamaged If any damage is found report it to Manitowoc Crane Care or an authorised GROVE dealer or an authorised specialist workshop 7 7 2 Checking the oil level Spare parts and tools Prerequisites The truck crane must be raised on outriggers or parked over an inspection pit The engine must be switched...

Page 134: ...re parts tools Receptacle approx 15 ltr 4 0 gal à p 2 4 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 M 6 Gear oil in litres gal Designation to DIN 51502 Specification classification GROVE part no 14 3 7 with oil cooler C LPF MIL L 2105 B API GL 5 Viscosity Hyp SAE 90 ISO VG 2...

Page 135: ...witch the engine off and wait for about 5 minutes Check the oil level à p 7 45 Check drain plugs 1 and 2 for leaks G Risk of scalding from gear oil at operating temperature You could scald yourself by gear oil escaping in an uncontrolled manner at operating temperature Wear appropriate protective gloves and take care not to come into contact with the gear oil O Risk of environmental damage due to ...

Page 136: ...Maintenance work on the carrier 7 7 Transfer case 7 48 3 302 364 en Maintenancemanual GMK 4100L 1 25 11 2016 Blank page ...

Page 137: ...rough a separate filter 4 The oil cooler 3 and the filter 4 are also located within the chassis in the area of the centre of rotation Access to the angle gear 1 is possible only from the underside of the chassis Access via the port 3 can be enlarged if necessary by removing the Cardan shaft 4 between the third and fourth axle lines If the additional equipment Driving from the crane cab is fitted t...

Page 138: ...nd report it to Manitowoc Crane Care or an authorised GROVE dealer or an authorised specialist workshop 7 8 2 Checking the oil level Spare parts and tools 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 The angle gear must be adequately cooled The inspection opening and the inte...

Page 139: ...e crane cab Remove the drain plug 1 Check that the oil reaches the lower edge of the opening Fit a new gasket and tighten the screw If the oil level is too low Top up the oil à p 7 52 Checking the resilient dampers The angle gear is mounted on four resilient dampers Check the secure fastening and the condition of the resilient dampers 1 If the resilient dampers are damaged have them replaced by Ma...

Page 140: ... unauthorised use à p 2 3 The angle gear must be adequately cooled The inspection opening and the interior space must be clean and free of oil so that the fitter can work safely in the restricted space where the angle gear is installed M 6 Gear oil in litres gal Designation to DIN 51502 Specification classification GROVE part no 7 2 1 9 for type A 8 6 2 3 for type B MIL L 2105 B API GL 5 Viscosity...

Page 141: ... to the valve 3 on to the oil cooler and drain the oil into the receptacle Take the connecting piece and hose off the valve 3 Remove the filter 4 and allow the oil to drain from it into the receptacle Change the filter 6 Replace the gasket 5 Tighten the filter 4 s G Risk of scalding from gear oil at operating temperature You could scald yourself by gear oil escaping in an uncontrolled manner at op...

Page 142: ...on B angle gear with hydraulic drive additional equipment Driving from the crane cab Fill the oil up to the lower edge of the opening 1 Fit a new gasket and tighten the drain plug 1 Checks after the oil change In order to circulate the oil around the oil circuit you must try out operation of a hydraulic function on the superstructure for instance tilting the crane cab Switch the engine off and wai...

Page 143: ...Checking the oil level p 7 61 Check that pipes and hoses are tightly connected and undamaged If any damage is found report it to Manitowoc Crane Care or an authorised GROVE dealer or an authorised specialist workshop 7 9 2 Axle centre drives checking the oil level Spare parts and tools 1 Additional equipment 2nd driven axle line Prerequisites The truck crane must be raised on outriggers or parked ...

Page 144: ...ches the lower edge of the opening Fit a new gasket and tighten the screw If the oil level is too low Top up the oil à p 7 58 2nd axle line This axle centre drive is present only with the 8 x 8 x 8 drive Remove the drain plug 1 Check that the oil reaches the lower edge of the opening Fit a new gasket and tighten the screw If the oil level is too low Top up the oil à p 7 58 ...

Page 145: ...uipment 2nd driven axle line Receptacle approx 20 ltr 5 0 gal à p 2 4 s M 12 Gear oil in litres gal Designation to DIN 51502 Specification classification GROVE part no Axle line 1 4 each 13 0 3 5 Axle line 2 15 4 0 Axle line 3 16 5 4 4 C LPF MIL L 2105 B API GL 5 Viscosity Hyp SAE 90 ISO VG 220 00552891 for drive Designation Quantity GROVE part no 8 x 6 x 8 Gasket 30 x 36 Cu DIN 7603 3 00117151 Ga...

Page 146: ... oil up to the lower edge of the opening Fit a new gasket and tighten the drain plug 1 2nd axle line This axle centre drive is present only with the 8 x 8 x 8 drive Place a receptacle under the screw 2 Unscrew the screws 1 and 2 and allow the oil to drain off Fit a new gasket and tighten the drain plug 2 Fill the oil up to the lower edge of the opening Fit a new gasket and tighten the drain plug 1...

Page 147: ...the oil drain off Fit new gaskets and tighten the screws 3 and 4 First add 1 5 ltr 0 4 gal oil through the hole 2 Add more oil through the hole 1 up to the lower edge of the hole 1 Fit new gaskets and tighten the screws 1 and 2 S Risk of oil overheating When topping up the oil both openings must be opened so that both oil tanks are filled equally This prevents the oil tanks from being overfilled a...

Page 148: ...Maintenance work on the carrier 7 9 Axle lines 7 60 3 302 364 en Maintenancemanual GMK 4100L 1 25 11 2016 Blank page ...

Page 149: ...nauthorised use à p 2 3 The parking brake must be released Checking the oil level Check the oil level at all other final drives in the same way Turn the wheel until the marking 2 is horizontal and is on the right next to the centre of the axle Remove the drain plug 1 Check that the oil level is at the mark 2 Fit a new gasket and tighten the screw If the oil level is too low Top up the oil à p 7 63...

Page 150: ...g brake must be released M 12 Gear oil in litres gal Designation to DIN 51502 Specification classification GROVE part no for each final drive 2 7 0 7 C LPF MIL L 2105 B API GL 5 Viscosity Hyp SAE 90 ISO VG 220 00552891 for drive Designation Quantity GROVE part no 8 x 6 x 8 Gasket 24 x 29 Cu DIN 7603 6 00117145 8 x 8 x 81 Gasket 24 x 29 Cu DIN 7603 8 00117145 O Risk of environmental damage due to l...

Page 151: ...e same way Turn the wheel until the screw 1 is at the bottom Use a drain channel and place a receptacle under the screw Remove the screw and let the oil drain out Topping up the oil Turn the wheel until the marking 2 is horizontal and is on the right next to the centre of the axle Top up the oil through the opening Fit a new gasket and tighten the drain plug 1 ...

Page 152: ...ngine must be switched off and secured against unauthorised use à p 2 3 The wheels must be turned as far as they will go so that the lubricating nipples on the sides of the final drives are more easily accessible Lubricating Cardan shafts 2 are fitted only to the 8 x 8 x 8 drive Check which Cardan shafts 1 and 2 have lubricating nipples 3 Clean the grease nipples 3 Inject grease into the grease ni...

Page 153: ...ust 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 Lubricating The Cardan shaft 2 is fitted only to the 8 x 8 x 8 drive Check which Cardan shafts 1 and 2 have lubricating nipples 3 Clean the grease nipples 3 Inject grease into the grease nipples until grease escapes from the bearing points Do not inject grease w...

Page 154: ...Maintenance work on the carrier 7 9 Axle lines 7 66 3 302 364 en Maintenancemanual GMK 4100L 1 25 11 2016 Blank page ...

Page 155: ...released Checking Check all tyres for Broken off tread blocks Dents Areas of uneven wear Whether the wear mark 1 has been reached Replace any damaged tyres If the tyres show varying degrees of wear change the wheels à Changing the wheels p 7 70 D S Risk of accidents due to uneven braking When replacing the tyres only use the same quality of tyres as those originally fitted dimensions load bearing ...

Page 156: ... 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 Tyres Air pressure in bar psi with cold tyres 14 00 R 25 10 0 145 14 00 R 25 X Crane 9 0 131 16 00 R 25 9 0 131 17 50 R 25 7 0 102 20 50 R 25 7 0 102 385 95 R25 10 0 145 445 80 R25 7 0 102 445 95 R25 9 0 131 ...

Page 157: ...t be switched off and secured against unauthorised use à p 2 3 Check the wheel nuts Check the wheel nuts and the pressure plates for damage Replace any damaged wheel nuts or pressure plates Check the wheel nuts in sequence 1 12 for a tight fit torque 650 Nm 480 lbf ft M 1 Designation Quantity per wheel GROVE part no Wheel nut with pressure plate for steel rims 12 01207756 Wheel nut with pressure p...

Page 158: ...Only for two piece aluminium rims Have a specialist workshop check the bolts on the two piece aluminium rims using the appropriate special tool Depending on the manufacturer there are 20 or 22 bolts visible on the outer face of the rim On the inner face of the rim there are 20 or 22 nuts It is the torque of these that you must have checked in a specialist workshop à Recognising two piece aluminium...

Page 159: ...ts must be seated securely in the bores Around the edge of the aluminium rim there are impressed marks and safety instructions which must be complied with by the specialist workshop The nuts 1 are on the inner face of the rim The round heads must be free of cracks and securely seated on the bolts The torque must be checked within the specialist workshop s Aluminium rims with 20 nuts 550 Nm 406 lbf...

Page 160: ...nce work on the carrier 7 10 Wheels 7 72 3 302 364 en Maintenancemanual GMK 4100L 1 25 11 2016 Mount the wheels on another axle as shown in the diagram Replace any damaged parts Tighten the wheel nuts à p 7 69 ...

Page 161: ... if the procedure is not carried out correctly This section only shows the sequence to be followed when changing wheels When removing installing the wheels observe all the safety instructions and the procedure stated in the operating manual G Risk of accidents due to errors when mounting aluminium wheel rims Only have tyres fitted to aluminium wheel rims in an authorised workshop with the correct ...

Page 162: ...Maintenance work on the carrier 7 10 Wheels 7 74 3 302 364 en Maintenancemanual GMK 4100L 1 25 11 2016 Blank page ...

Page 163: ...lining thickness A is monitored by an electric wear indicator on the brake caliper 1 If the lining thickness A falls below the permissible minimum value a warning message is displayed on the on board computer in the driver s cab On the on board computer Familiarise yourself with the correct operation of the on board computer à Operating Instructions The Operation and Maintenance menu also provides...

Page 164: ... and tools Measuring tools for brake pad and brake disc thicknesses Dial gauge for the brake disc runout Ring spanner for adjustment Prerequisites The truck crane must be parked over an inspection pit The truck crane must be raised on outriggers The engine must be switched off and secured against unauthorised use à p 2 3 The wheels must be removed from all the axle lines The parking brake must be ...

Page 165: ...ll axle lines Measure the thickness Measure the thickness A of the brake discs 1 New brake discs have a thickness of approx 41 mm 1 61 in You must have the brake disc replaced if the thickness is less than 33 mm 1 30 in à Having the brakes repaired p 7 81 s G Risk of accidents due to incorrect work on the vehicle brakes Incorrect work on the vehicle brakes can lead to failure of the brakes causing...

Page 166: ...t values for damage A permissible B only permissible for a crack length up to three quarters of the length Y B only permissible for a crack width of up to 0 5 mm 0 02 in C only permissible for a crack depth of up to 1 5 mm 0 06 in D not permissible Measure the runout Attach the dial gauge 1 to the brake anchor plate 2 Position the measuring probe 3 perpendicular to the brake disc 4 The distance A ...

Page 167: ... glazed broken or oily à Having the brakes repaired p 7 81 Check that the electrical cable to the wear display is undamaged H Brake pad wear A is taken up by the automatic adjustment mechanism When the pad thickness is small the travel adjustment is large and you must also check the adjustment mechanism à Checking the adjustment mechanism p 7 79 Checking the adjustment mechanism Using a ring spann...

Page 168: ...echanism is OK if the ring spanner turns one step anticlockwise at each brake application rotating a small angle at each step The adjustment mechanism is defective if the ring spanner fails to turn at any of the brake applications or turns only at the first brake application or at the brake application first turns anticlockwise but then turns back clockwise again If the adjustment mechanism is def...

Page 169: ... be run in by periodic braking Perform a test drive to make sure that the new brake pads are sufficiently run in before putting the truck crane into normal operation G Risk of accidents due to uneven braking If the brake pads and brake discs are replaced on only one side of the axle then the wheels will brake unevenly Always have the brake pads and brake discs replaced on both sides of the axle Wh...

Page 170: ...Maintenance work on the carrier 7 11 Vehicle brake 7 82 3 302 364 en Maintenancemanual GMK 4100L 1 25 11 2016 Blank page ...

Page 171: ... too low Open the connection 2 oil escapes and quickly connect the press with the hose Inject oil until it reaches the middle of the sight glass Remove the hose and quickly close the connection 2 s M 1 Oil in litres gal Designation GROVE part no for each suspension strut 1 5 0 4 Gear oil Rivolta S K D 170 02310863 S Risk of damage due to faulty suspension struts If the oil level is above the upper...

Page 172: ...3 by means of a bleed hose 2 Place a receptacle underneath the oil collection tank 3 Open the drain plug 4 and allow the oil to drain normally this is a very small quantity If there is has been a large quantity of oil collected then one or more suspension struts are defective Close the drain plug 4 Defective suspension struts should be replaced as soon as possible by Manitowoc Crane Care or an aut...

Page 173: ... 664 lbf ft Prerequisites The truck crane must be raised on outriggers à Operating Instructions The engine must be switched off and secured against unauthorised use à p 2 3 The wheels must have been removed Check whether the screws on all suspension struts are securely seated à Special torques p 10 2 M 1 1 on the upper bracket 2 on the lower bracket 3 on the lower flange 4 on the half shells for t...

Page 174: ...on the suspension à Operating Instructions Check whether all suspension struts are extended and the forced levers 1 are slackened 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 Crane Care or an authorised GROVE dealer or your qualified repair crew M 3 G Risk of crushing when re...

Page 175: ...he suspension features integrated pressure accumulators that contain nitrogen 1 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 Care or an authorised GROVE dealer or an authorised specialist workshop M 12 G Risk of accidents due to incorrect inspection The gas pressure test must be carried out only by an authorised...

Page 176: ...Maintenance work on the carrier 7 12 Suspension 7 88 3 302 364 en Maintenancemanual GMK 4100L 1 25 11 2016 Blank page ...

Page 177: ...he steering is out of position the steering computers send a malfunction message to the display in the driver s cab à Checks in the driver s cab p 7 89 During the course of an inspection not less than every two years you must have all the event messages in the steering computer read Intensive off road driving can cause damage to the angle sensors Depending on the operating conditions of the truck ...

Page 178: ...he angle sensors 2 and the linkage 3 Check that all bolts on the bracket are securely seated Check the linkage for deformation and damage Steering computer There are two steering computers fitted Do not press the button 2 only the qualified repair crew are authorised to do this Use only a cloth to clean the steering computer 1 Check the steering computer and the displays for external damage If you...

Page 179: ... à Checking the oil level p 7 97 After changing pipes and hose lines Bleed the hydraulic system à Bleeding the hydraulic system p 7 110 If damage cannot be rectified immediately or further damage is likely Notify Manitowoc Crane Care or an authorised GROVE dealer or your repair crew D G Risk of accidents from hydraulic oil spraying out Never tighten leaking connections when the system is under pre...

Page 180: ...Maintenance work on the carrier 7 13 Steering 7 92 3 302 364 en Maintenancemanual GMK 4100L 1 25 11 2016 Blank page ...

Page 181: ...pit The compressed air supply is completely full à Operating Instructions The engine must be switched off and secured against unauthorised use à p 2 3 Draining water from the com pressed air system Actuate the valves 8 on the air reservoirs 1 to 7 If a great deal of water escapes Have the compressed air drier checked or replaced by Manitowoc Crane Care or an authorised GROVE dealer or your qualifi...

Page 182: ...ks in the compressed air system connections pipes hose lines and valves If damage cannot be rectified immediately or further damage is likely Notify Manitowoc Crane Care or an authorised GROVE dealer or your repair crew W G Risk of accidents due to escaping compressed air Never tighten connections when the system is under pressure Only change gaskets pipes and hose lines when the system is depress...

Page 183: ...The engine must be switched off and secured against unauthorised use à p 2 3 Changing the filter cartridge Using the valve 1 release all the air from the reservoir 2 Replace the filter cartridge 3 using the strap wrench lubricate gasket slightly M 12 Designation Quantity GROVE part no Filter cartridge 1 04157844 G Risk of injury from escaping compressed air If the reservoir 2 is not completely ven...

Page 184: ...Maintenance work on the carrier 7 14 Compressed air system 7 96 3 302 364 en Maintenancemanual GMK 4100L 1 25 11 2016 Blank page ...

Page 185: ...ured against unauthorised use à p 2 3 Check that oil is visible in the middle of the sight glass 1 before starting work If the oil level is too low Top up the oil à p 7 109 O Risk of environmental damage due to leaking consumables Always let consumables drain into suitable receptacles Wipe up any consumables that escape Store dispose of consumables and any soaked equipment properly Ask about the a...

Page 186: ... operation pressure are marked on the hose fitting Always ensure that the corresponding parts of the hydraulic system are depressurised Damaged or old hydraulic hoses must be replaced immediately 7 15 3 Checking for leaks When the engine is running carry out a visual inspection for leaks on the hydraulic system pumps drives cylinders control blocks valves pipe and hose lines and connections Check ...

Page 187: ...ne must be standing on a level surface The engine must be switched off and secured against unauthorised use à p 2 3 During the first 100 operating hours Clean the magnetic rods weekly s G Risk of accidents from hydraulic oil spraying out Never tighten any leaking connections when the system is under pressure Change pipes and hose lines only when the system is depressurised O Risk of environmental ...

Page 188: ... magnetic rod 2 out of the filter cage 3 and clean it Replace any damaged parts where necessary Assemble the filters 2 and insert them Replace the gaskets if necessary and fasten the cap 1 Start the engine and check for leaks S Risk of damage to the hydraulic system Large amounts of metal particles are a sign of damage in the hydraulic system Have the hydraulic system checked by Manitowoc Crane Ca...

Page 189: ...y locations you must change the ventilation filters earlier than normal Spare parts and tools Prerequisites The engine must be switched off and secured against unauthorised use à p 2 3 Change the filter 1 M 12 Designation Quantity GROVE part no Filter 1 01576026 O Risk of damage to the environment from filter residues Store used hydraulic oil filter inserts in suitable receptacles and have them di...

Page 190: ...uisites The engine must be switched off and secured against unauthorised use à p 2 3 Select the sampling location To determine the usability of the oil you must take a sample from the hydraulic system To do that you must connect the hose with the connecting piece to a gauge port Remove the cover 3 The gauge port 1 is located on the cylinder 2 of the outrigger Clean the gauge port before connecting...

Page 191: ...nnecting piece is dirty the dirt can contaminate the oil sample in the sample container during the sampling process The laboratory analysis would thus be incorrect For flushing always allow 2 litres 0 5 gal of oil to flow through the hose into a receptacle before filling the sample container O Danger due to escaping hydraulic oil When you screw the connecting piece on to the gauge port the gauge p...

Page 192: ...ine off and put the hose end 2 into the sample container 5 Start the engine Allow 0 3 litres 0 08 gal of oil to flow into the sample container Switch the engine off Put the hose end back into the receptacle Seal the sample container Disconnecting the hose Disconnect the hose 2 the gauge port 1 closes Close the gauge port with the cap Allow the oil to flow out of the hose into the receptacle 3 Clos...

Page 193: ...aboratory the viscosity the viscosity index the contamination the water content Determining the quality of the oil Compare the laboratory analysis with the limit values and carry out the specified measures if necessary Viscosity limit values Viscosity ISO VG 32 as per DIN 51524 Part 2 Viscosity index Vi 150 If one of these limit values has been reached fallen short of Carry out an oil change à p 7...

Page 194: ...Maintenance work on the carrier 7 15 Hydraulic system 7 106 3 302 364 en Maintenancemanual GMK 4100L 1 25 11 2016 Blank page ...

Page 195: ...retracted à Operating Instructions The engine must be switched off and secured against unauthorised use à p 2 3 Close the valves Close the valves lever 1 at right angles to the line s Hydraulic oil in litres gal Designation to DIN 51502 Specification classification GROVE part no 165 44 HVLP DIN 51524 3 Viscosity ISO VG 32 04162158 Castrol Hyspin AWH M 32 Designation Quantity GROVE part no Cover ga...

Page 196: ...neath the valves One after the other screw the connecting piece and hose onto the valves 1 and 2 à Handling the valves p 7 108 Change the filters à p 7 111 O 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 G Danger due to escaping hydraulic oil When the connecting piece is screwe...

Page 197: ...hes the centre of the sight glass 1 Fasten the cover with the filter 4 Establishing the operating conditions After having changed the oil filters and topping up the oil you must re establish the operating conditions Opening the valves Open the valves lever 1 parallel with the line s S Risk of damage to the hydraulic system Cleanliness is of the utmost importance when handling hydraulic oil Even fr...

Page 198: ...nders Preparations The truck crane must be raised on outriggers à Operating Instructions The parking brake must be applied Bleed the steering cylinders individually one after the other Start the engine Bleed each steering cylinder 2 by loosening each of the collar nuts 1 in turn until the oil coming out no longer contains air bubbles If the steering system is still not operating properly Notify Ma...

Page 199: ...ates that you must change oil filter 3 If a warning message appears the symbol 1 in the Warning submenu indicates that you must change oil filter 4 Filters 3 and 4 must be replaced together after the first 50 hours in driving mode and must then be replaced together annually M 12 after this Spare parts and tools Receptacle approx 5 ltr 1 5 gal à p 2 4 Prerequisites The engine must be switched off a...

Page 200: ...ilter cage 4 Replace any damaged parts where necessary Assemble the filters 2 and insert them Replace the gaskets and fasten the caps 1 Start the engine and check for leaks O Risk of environmental damage due to leaking consumables Store used hydraulic oil filter inserts in suitable receptacles and have them disposed of properly by qualified personnel S Risk of damage to the hydraulic system Large ...

Page 201: ...n a receptacle Change the filter 2 Replace any defective parts where necessary Fill the receptacle with clean oil Put the receptacle on and tighten it Change the filter on the opposite side in the same way O 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 202: ...Maintenance work on the carrier 7 15 Hydraulic system 7 114 3 302 364 en Maintenancemanual GMK 4100L 1 25 11 2016 Blank page ...

Page 203: ...The parking brake must be applied Checking the level Check the level in the grease container 1 The grease level must be close to the max mark and the green lamp 2 must light ready for operation If it is below the min mark the grease level is too low and the red lamp 3 will light If the level is too low Add more grease à p 7 116 s W Lubricating grease Designation to DIN 51502 Specification classifi...

Page 204: ... before refilling the grease as the grease could otherwise become contaminated This prevents dirt particles from getting into the grease and damaging the central lubrication system Do not overfill the container above the max mark 1 Grease nipple standard for connection of a manual grease gun GROVE part no 04158709 2 Filling coupling plug optional for connecting a the hose to a grease filling stati...

Page 205: ...e filling pump wipe away any excess grease and close the holes 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 must be full Loosen the lubricating pipe at the connection 2 Switch on the ignition Press the button 3 Repeat the procedure until the grease flowing from the connection...

Page 206: ...ld be activated after high pressure cleaning to check the lubrication system at all lubricating points Switch on the ignition Press the button 1 once An intermediate lubrication cycle will be triggered which lasts approximately 2 minutes Check that grease is escaping at all lubricating points steering arms on the 1st 2nd 3rd and 4th axle lines Switch off the ignition and remove any excess grease ...

Page 207: ...ail light fog light outrigger lights Hazard warning system Brake lights Reversing lights Warning buzzer Reverse camera additional equipment High beam headlight headlight flasher Turn signal indicators Windscreen wipers Windscreen washing system Horn Date Time on CCS display You can correct the time date via the Settings menu in the CCS display à Operating Instructions D G Risk of accidents if the ...

Page 208: ...k of explosion from escaping hydrogen Do not place tools on the battery and keep naked lights away from it G Risk of explosion from static charge Only use antistatic cloth to clean the batteries This prevents static charging which could result in hydrogen mixtures exploding G Risk of burns from battery acids Battery acid is highly caustic Wear safety glasses and protective gloves Do not tilt the b...

Page 209: ...tery terminal grease Checking the acid level Batteries without covers 1 are maintenance free Remove all caps 1 The acid level must be above the plates If the acid level is too low Top it up using only distilled water until the plates are covered Tightly bolt on all covers 1 After checking Close the cover on the battery box Switch the battery master switch 1 on Check the timers on the tachograph an...

Page 210: ...he battery contain lead Residue containing lead can stick to your hands and may not be allowed to enter your body e g by touching food Wash your hands after working on batteries G Risk of explosion from escaping hydrogen Do not place tools on the battery and keep naked lights away from it G Risk of explosion from static charge Only use antistatic cloth to clean the batteries This prevents static c...

Page 211: ...nce free Remove all caps 1 Read off the cell value on the acid siphon 2 and compare the value with that in the table à Charge level table p 7 122 Check all cells in the same way Tightly bolt on all covers 1 After checking Close the cover on the battery box Switch the battery master switch 1 on Check the timers on the tachograph and the auxiliary heater à Operating Instructions Enter the code for t...

Page 212: ...ng instructions provided by the manufacturer Connecting Take the battery charger out of its storage compartment in the driver s cab Insert the plug 1 into the socket 2 on the battery box Place the battery charger 3 in a protected place where you can see the indicator lamp 4 The battery charger can be suspended from the ring eyes 5 Insert the plug 6 into the socket on the mains supply 230 V at the ...

Page 213: ...additional equipment Consult the operating instructions supplied with the battery charger and regularly check that all components are functioning correctly to ensure that the external starting socket connecting cable and battery charger are ready for operation if needed à Operating Instructions Checking Remove the cap 4 from the socket 1 Check that the cap is not damaged and is secured with the ch...

Page 214: ...Maintenance work on the carrier 7 17 Electrical system 7 126 3 302 364 en Maintenancemanual GMK 4100L 1 25 11 2016 Blank page ...

Page 215: ... to avoid further damage Have the air conditioning system repaired as soon as possible by Manitowoc Crane Care or an authorised GROVE dealer or an authorised specialist workshop 7 18 2 Checking hoses Check all refrigerant hoses for damage and areas of wear Have damaged hoses checked by Manitowoc Crane Care or an authorised GROVE dealer or an authorised specialist workshop only M 1 M 6 G Risk of bu...

Page 216: ...roper functioning The inspection of the air conditioning system particularly includes the inspection of the refrigerant collector in accordance with the pressure container regulations test group II and the refrigerant compressor Only allow the system to be topped up with suitable refrigerant M 12 S Risk of damage to the condenser Do not use a high pressure cleaner or steam jet cleaner The powerful...

Page 217: ...anual 3 302 364 en 7 129 GMK 4100L 1 Refrigerant Compressor oil FUCHS SE 65 Filler connections The filler connections 1 for the refrigerant are behind the front flap 2 in the driver s cab Fill quantity in kg lbs Designation CAS no EC no 1 0 2 2 Tetrafluoroethane R134a 811 97 2 212 377 0 ...

Page 218: ...g conditions at extremely sandy or dusty locations you must change the filter earlier than normal Spare parts and tools Prerequisites The engine must be switched off and secured against unauthorised use à p 2 3 Changing Open the cover 1 Remove the filter 2 from the housing and clean the housing with a cloth Insert a new filter Fasten the cover M 12 Designation Quantity GROVE part no Filter 1 03254...

Page 219: ...connected to the central lubrication system Grease spare parts tools Grease gun from the tool set H To avoid over lubrication the towbar coupling may only be lubricated when open Clean the grease nipples 2 and 3 Open the towbar coupling To do this move the lever 1 up Press grease into the grease nipples 2 and 3 Close the towbar coupling s M 1 Lubricating grease Designation to DIN 51502 Specificati...

Page 220: ...ction of the coupling jaw observe the arrow Remove any grease that has escaped G 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 If you hold the lever and move it down it may carry...

Page 221: ...upling by vigorously shaking it up and down and in the longitudinal direction arrows Hold the towbar coupling at the top and bottom of the coupling head and not by the coupling jaw The vertical play at the coupling head must be no more than 3 mm 0 1 in M 3 G Risk of injury Ensure that the towbar coupling is closed for the following work lever points downwards The lever may otherwise come down with...

Page 222: ... of the crowned section arrows must not be less than the following values If the dimension is smaller than that given above have the cotter pin replaced by Manitowoc Crane Care or an authorised GROVE dealer or your qualified repair crew Also check the cotter pin for the correct vertical play Take a screwdriver and press the pin 1 upwards The vertical play 2 of the pin must not exceed 4 mm 0 15 in ...

Page 223: ...ceed the following values If the dimension is larger than that given above have the bushing replaced by Manitowoc Crane Care or an authorised 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 Twist the coupling head clockwise and anticlockwise to check the initial tensi...

Page 224: ...w When the trailer is coupled the draw eyelet of the trailer must not be in contact with the lower bushing 2 Have the support ring changed if The trailer s draw eyelet touches the lower bushing because of wear or The support ring has reached its wear limit of H 14 mm 0 55 in 7 19 7 Checking the function of the coupling jaw resetting the middle position Spare parts and tool Torque wrench for a torq...

Page 225: ...jaw go The lever must automatically lock the coupling jaw in the middle position The coupling jaw is locked when the coupling can no longer move to the side H If the lever does not automatically engage with the coupling jaw the middle position must be re adjusted à p 7 137 Resetting the middle position Open the coupling lever 1 pointing upwards and loosen the screws 2 Push the coupling jaw to the ...

Page 226: ...Maintenance work on the carrier 7 19 Towbar coupling 7 138 3 302 364 en Maintenancemanual GMK 4100L 1 25 11 2016 Blank page ...

Page 227: ...nd antifreeze to it A can for mixing and filling Topping up Open the cap 1 on the filler neck Top up the windscreen washing fluid through the filler neck Close the filler neck with the cap Wiping Press the multipurpose switch of the windscreen wiper washing system à Operating Instructions Check all the wiping stages slow fast intermittent If the windscreen does not wipe clean Change the wiper blad...

Page 228: ...2 of the outrigger cylinder and bearing surfaces on the outrigger pad by removing old grease dirt particles and rust Spray the uncovered end 2 making sure the grease coating is evenly distributed After every high pressure cleaning operation on the truck crane Lubricate the outrigger beams M 1 Lubricating grease Designation to DIN 51502 Specification classification GROVE part no Grease KP 1K 50 DIN...

Page 229: ...orrectly report it to Manitowoc Crane Care or an authorised GROVE dealer or an authorised specialist workshop 7 20 4 Lubricating the cab door Grease tools Brush Lubricating Open the doors on the driver and passenger side Clean the door hinges 1 Lubricate the door hinges 1 lightly with a brush Close and open the doors several times the doors should move easily Remove any grease that has escaped In ...

Page 230: ...ing panels under the bumper Fastenings for the outrigger pads and socket pins on the outrigger Locks on the removable covers Hinges on the doors and covers of the storage box 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 or an authorised GROVE dealer or your qualified repair crew Use only...

Page 231: ...t the factory the underside of the carrier was sprayed with corrosion protection for the first time The corrosion protection is solvent free and is water soluble while being sprayed on A transparent waxy protective film is formed after a drying time of one hour Check the condition of the original protective film If required remove any rust and touch up the paintwork before you spray on a new prote...

Page 232: ...e carrier using a spray extension Clean surfaces sprayed by accident immediately with water Let the corrosion protection dry for one hour Check that a transparent waxy protective film has covered the entire surface G 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 233: ... the respective national regulations and the operating location Ask the local fire safety officer about the national and local regulations Observe the instructions 1 on the fire extinguisher Have the fire extinguisher serviced by trained personnel in good time before the maintenance interval specified on the label 2 expires Y 2 S Danger due to the fire extinguisher not working There is no guarante...

Page 234: ...Maintenance work on the carrier 7 20 Other maintenance work 7 146 3 302 364 en Maintenancemanual GMK 4100L 1 25 11 2016 Blank page ...

Page 235: ...cating the gear teeth 8 25 8 5 3 General inspection 8 27 8 5 4 Measuring tilting play 8 28 8 5 5 Lubricating the locking of turntable 8 30 8 6 Hydraulic system 8 31 8 6 1 Checking the oil level 8 31 8 6 2 Checking the hydraulic hoses 8 32 8 6 3 Checking the ventilation filter 8 32 8 6 4 Checking for leaks 8 33 8 6 5 Cleaning the magnetic rods 8 34 8 6 6 Changing the ventilation filter 8 36 8 6 7 P...

Page 236: ...ng and indicators 8 73 8 12 2 Have the battery on the electronics board replaced 8 74 8 13 Air conditioning system 8 75 8 13 1 Checking the air conditioning system 8 75 8 13 2 Cleaning the condenser fins 8 75 8 13 3 Checking hoses 8 76 8 13 4 Checking the entire air conditioning system 8 76 8 13 5 Changing the pollen filter 8 78 8 14 Other maintenance work 8 79 8 14 1 Checking the windscreen washi...

Page 237: ...e manual 3 302 364 en 8 1 GMK 4100L 1 8 Maintenance work on the superstructure 8 1 General instructions 8 1 1 Covers Various types of work e g oil change require that covers be removed Before maintenance work Remove the covers 1 After maintenance work Fasten the covers 1 with the locks ...

Page 238: ...Maintenance work on the superstructure 8 1 General instructions 8 2 3 302 364 en Maintenancemanual GMK 4100L 1 25 11 2016 8 1 2 Overview of maintenance work on the superstructure ...

Page 239: ...ope drums à p 8 51 16 Oil inspection glasses à p 8 9 10 Hook block à p 8 71 8 Rope end fitting à p 8 52 3 Lowering limit switch à p 8 63 Slewing gear à p 8 15 12 Oil inspection glasses à p 8 15 Slewing bearing à p 8 21 11 Gear teeth à p 8 25 13 Turntable lock à p 8 30 Hydraulic system à p 8 31 7 Oil tank with sight glass à p 8 31 4 Oil filler opening à p 8 42 5 Ventilation filter à p 8 36 14 Press...

Page 240: ...Maintenance work on the superstructure 8 1 General instructions 8 4 3 302 364 en Maintenancemanual GMK 4100L 1 25 11 2016 ...

Page 241: ...ized lubrication pump à p 8 69 Electrical system à p 8 73 2 Spotlights on the crane cab à p 8 73 11 Spotlights on the telescopic boom à p 8 73 12 Anemometer air traffic control light à p 8 73 Air conditioning system à p 8 75 3 Crane cab air conditioning system à p 8 75 7 Condenser fins à p 8 75 5 Pollen filter à p 8 78 Other maintenance work à p 8 79 9 Windscreen washing system receptacle à p 8 79...

Page 242: ...Maintenance work on the superstructure 8 1 General instructions 8 6 3 302 364 en Maintenancemanual GMK 4100L 1 25 11 2016 Blank page ...

Page 243: ...every day before starting work CCS Check the symbols on the CCS start menu Crane Control System in the crane cab each day before starting work The Start menu shows the most important measured values and the Warning submenu shows all pending warning messages à Operating Instructions Warning submenu If a symbol is displayed you must carry out the maintenance work Hydraulic oil filter à p 8 39 ...

Page 244: ...Maintenance work on the superstructure 8 2 Symbols for maintenance work 8 8 3 302 364 en Maintenancemanual GMK 4100L 1 25 11 2016 Blank page ...

Page 245: ...red against unauthorised use à p 2 3 Checking the oil level Check that the oil level is visible between the min and the max marks 1 If the oil level is too low Top up the oil à p 8 11 H The oil level in the hoist gear must be 15 mm below the centre of rotation of the hoist If the sight glass is loose in the clamps or a new sight glass has been fitted you must adjust this difference in height befor...

Page 246: ... to Manitowoc Crane Care or an authorised 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 Attach the hook block to the hoist rope reeved once Lift a load of approx 7 t 15 500 lbs to approx 30 cm 1 0 ft above the ground Measure the distance to the ground when the load is hanging completely stil...

Page 247: ...slightly and then eventually rises again to its true level s M 12 Gear oil in litres gal Designation to DIN 51502 Specification classification GROVE part no 3 3 0 9 for each hoist C LPF MIL L 2105 B API GL 4 5 Viscosity SAE 75 W 90 EP ISO VG 220 02313611 Synthetic oil do not mix this with mineral based oils Designation Quantity GROVE part no Oil inspection glass complete 2 84012690 S Risk of damag...

Page 248: ... the waste oil for abrasion particles or have it tested in a laboratory Pour the waste oil through a clean filter mat Examine the oil i e the residues on the filter mat using a magnifying glass If you find abrasion particles or solid materials on the mat the hoist gear must be dismantled and inspected by the manufacturer H Some abrasion particles may appear in the first oil filled If you notice su...

Page 249: ... the multiple disk brake and transmission unit and be permitted to exchange parts with signs of wear 8 3 6 Having a general inspection carried out H When carrying out the general inspection of the hoists also observe the information contained in Measures required for winch monitoring p 5 21 The general inspection involves removing the transmission and sending it to the manufacturer to be examined ...

Page 250: ...Maintenance work on the superstructure 8 3 Hoists 8 14 3 302 364 en Maintenancemanual GMK 4100L 1 25 11 2016 Blank page ...

Page 251: ...el and in on road mode à Operating Instructions The engine must be switched off and secured against unauthorised use à p 2 3 Checking the oil level Always check the oil level prior to using the crane Check that oil is visible in the sight glass 1 Always check the oil level for all the slewing gears If the oil level is too low Top up the oil à p 8 19 W Designation Quantity GROVE part no Gasket 10 x...

Page 252: ...must be rigged for a slewing range of 360 according to the lifting capacity table The RCL code for the current rigging mode must be entered à Operating Instructions The current load must not exceed 1 t 2 200 lbs if necessary unreeve the hook block The slewing range 360 around the truck crane must be secured The main boom must be raised to 45 and fully retracted W M 6 G Risk of overturning while sl...

Page 253: ... slewing gear is switched on Start the engine and switch on the slewing gear Open the CCS menu Hydraulic pressure Display 1 will show the pressure in the slewing gear s hydraulic circuit Move the control lever slowly to the stop and wait until the pressure in the hydraulic circuit has risen to approx 200 bar approx 2 900 psi If the superstructure still does not slew the braking force of the slewin...

Page 254: ...18 3 302 364 en Maintenancemanual GMK 4100L 1 25 11 2016 Switch the slewing gear off and switch the engine off Fasten the coil 1 to the valve Y 2307 using the nut release the slewing gear brake Start the engine and check the slewing gear for correct operation ...

Page 255: ...s change the oil in all slewing gears s M 12 Gear oil in litres gal Designation to DIN 51502 Specification classification GROVE part no 0 9 0 24 for each slewing gear C LPF MIL L 2105 B API GL 4 5 Viscosity SAE 75 W 90 EP ISO VG 220 02313611 Synthetic oil do not mix this with mineral based oils Designation Quantity GROVE part no Gasket 10 x 14 Cu DIN 7603 2 00117125 Gasket 14 x 20 Cu DIN 7603 2 00...

Page 256: ...er neck 4 until oil is visible in the sight glass 5 Replace the gaskets and tighten the screw 3 and the filter 4 Replace the plate 1 Checking the oil Check the waste oil that was drained from the slewing gears for abrasion particles or have it tested at a laboratory Pour the waste oil through a clean filter mat Examine the oil i e the residues on the filter mat using a magnifying glass If you find...

Page 257: ...oved The main boom must be fully retracted and raised to 75 à Operating Instructions The current load must not exceed 1 t 2 200 lbs if necessary unreeve the hook block The slewing range 360 around the truck crane must be secured The engine must be switched off and secured against unauthorised use à p 2 3 Safety instructions s M 3 S Risk of damage to the screws on the slewing bearing All screws wer...

Page 258: ...screws 1 Check all 71 screws 1 from below To do this you must rotate the turntable gradually with a pair of screws 1 each on the opposite side through the openings 2 in the carrier G Danger of the slewing bearing being ripped off If while checking you notice very loose broken or missing screws then the slewing bearing has been overloaded and is no longer safe to use During crane operation the slew...

Page 259: ...r ring The screw head 1 is accessible only via the opening 2 An extension 4 is required for fitting a socket wrench 3 A manual torque tool 5 is recommended so that it can be tightened gently and slipping from the screw head 1 is avoided Torques s Screw type GROVE part number Torque Nm lbf ft Ball slewing bearing Bearing type KDV single row 03272334 or 03272344 Model plate Inside the inner ring M 2...

Page 260: ... turntable by 180 the second group on the opposite side is now accessible Switch the engine off Check all other groups in the same way Checking the inner ring Divide the inspection of the 71 screws into 35 work steps with 2 screws each and 1 work step with 1 screw Between each of the 35 operation steps you need to rotate the turntable to the next pair of screws on the opposite side Switch the engi...

Page 261: ... Operating Instructions The main boom must be fully raised à Operating Instructions The engine must be switched off and secured against unauthorised use à p 2 3 Lubricating A distinction is made between initial lubrication and subsequent lubrications s M 6 Designation Quantity GROVE part no Adhesive lubricating grease spray can 1 00554205 G Risk of crushing from the gear teeth Fingers may be crush...

Page 262: ...se from all the gear teeth 2 Apply a thin layer of new grease to all the gear teeth and allow it to penetrate for about 10 minutes Apply a second thicker layer of grease and allow it to penetrate for about 30 minutes Attach the plate Subsequent lubrication Remove the plate 1 Apply new grease to all the gear teeth 2 Allow it to penetrate for about 30 minutes Attach the plate ...

Page 263: ...ual noises occur take a sample of the grease that has escaped Have Manitowoc Crane Care examine the sample for metal residue Check the slewing bearing for damage e g gaskets If any damage is found report it to Manitowoc Crane Care or an authorised GROVE dealer or your repair crew H The maintenance interval specified here must be reduced if the slewing bearing was subjected to heavy blows falling l...

Page 264: ...e slewing bearing must have been previously checked for tightness à Checking the screws p 8 21 The crane must be rigged with an outrigger span of at least 8 66 x 5 31 m 28 4 x 17 4 ft and be level à Operating Instructions The auxiliary hoist or alternatively the compensation weight 0 8 t 1 750 lbs must be rigged No further counterweight must be been rigged The lattice extension must be removed The...

Page 265: ...g 3 as close as possible to the gasket 2 Slowly lower the main boom to 50 The hook block may not touch the ground Read off from the dial gauge how far the turntable is inclined and record this value as the current tilting play à Appendix Tilting play measurement report Remove the dial gauge Repeat the measurement with the slewing angles If the current tilting play is greater than the max permissib...

Page 266: ... must be level and in on road mode à Operating Instructions The engine must be switched off and secured against unauthorised use à p 2 3 Lubricating Familiarise yourself with the correct operation of the turntable lock à Operating Instructions Grease the lubricating points 1 and 2 with the brush M 12 Lubricating grease Designation to DIN 51502 Specification classification GROVE part no Grease KP 1...

Page 267: ...be switched off and secured against unauthorised use à p 2 3 Checking the oil level Check whether oil is visible in the middle of the sight glass 1 If the oil level is too low Top up the oil à p 8 43 O Risk of environmental damage due to leaking consumables Always let consumables drain into suitable receptacles Wipe up any consumables that escape Store dispose of consumables and any soaked equipme...

Page 268: ...emanual GMK 4100L 1 25 11 2016 8 6 2 Checking the hydraulic hoses The inspection work is described in section Checking the hydraulic hoses p 7 98 8 6 3 Checking the ventilation filter Check the display 1 on the ventilation filter If the indicator is coloured Replace the filter à p 8 36 W W ...

Page 269: ...hecking the oil level p 8 31 After hydraulic components have been changed Bleed the hydraulic system à Establishing the operating conditions p 8 44 If damage cannot be rectified immediately or further damage is likely Notify Manitowoc Crane Care or an authorised GROVE dealer or your repair crew W G Risk of accidents from hydraulic oil spraying out Never tighten any leaking connections when the sys...

Page 270: ...engine must be switched off and secured against unauthorised use à p 2 3 During the first 100 operating hours Clean the magnetic rods weekly M 3 Designation Quantity GROVE part no For oil filter 1 Filter 1 04156358 Packing set 1 04165792 O Risk of environmental damage due to leaking consumables Always let consumables drain into suitable receptacles Wipe up any consumables that escape Store dispose...

Page 271: ...e Remove the filter 4 from the filter cage 5 Clean the filter cage 5 and the magnetic rod 3 Replace the filter 4 if necessary Assemble the filter 3 and insert it Replace the cover gasket if necessary Bolt the cover 2 on Attach the cover 1 S Risk of damage to the hydraulic system Large amounts of metal particles are a sign of damage in the hydraulic system Have the hydraulic system inspected by Man...

Page 272: ...be switched off and secured against unauthorised use à p 2 3 Remove the cap 2 Change the filter 3 and fasten the cap Reset the display by depressing the pin 1 on the housing M 12 Designation Quantity GROVE part no Filter 1 03134932 O 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...

Page 273: ...ic system Information for taking samples with the hose and for the laboratory analysis à Taking oil samples p 7 102 Prerequisites The engine must be switched off and secured against unauthorised use à p 2 3 Select the sampling location To determine the usability of the oil you must take a sample from the hydraulic system To do that you must connect the hose with the connecting piece to a gauge por...

Page 274: ...lean the gauge port and connect the hose 1 at the port 3 à Connecting the hose p 7 103 Put the hose end 2 into the receptacle 4 Start the engine from the crane cab Tilt the crane cab Allow 2 litres 0 5 gal of oil to flow into the receptacle Switch the engine off and put the hose end 2 into the sample container 5 Start the engine from the crane cab Tilt the crane cab Allow 0 3 litres 0 08 gal of oi...

Page 275: ... ft Receptacle approx 5 ltr 1 5 gal à p 2 4 Prerequisites The truck crane must be level and in on road mode à Operating Instructions The engine must be switched off and secured against unauthorised use à p 2 3 s 1 red Change oil filter 1 2 red Change oil filter 2 Designation Quantity GROVE part no For oil filter 1 Filter 1 04156358 Packing set 1 04165792 For oil filter 2 Filter 1 03142356 Housing ...

Page 276: ...essary Assemble the filter 3 and insert it Replace the cover gasket if necessary Bolt the cover 2 on Attach the cover 1 O Risk of environmental damage due to leaking consumables Always let consumables drain into suitable receptacles Wipe up any consumables that escape Store dispose of consumables and any soaked equipment properly Ask about the applicable regulations S Risk of damage to the hydraul...

Page 277: ...f ft After changing the filter Check the valve on the hydraulic oil tank Open the valve if necessary à p 8 44 Check the oil level Top up the oil if necessary à p 8 43 To bleed the system from the crane cab start the engine and let it idle for 3 minutes Check that none of the oil filters is leaking S Risk of damage to the hydraulic pumps The engine may only be started if the valve in the suction li...

Page 278: ... engine must be switched off and secured against unauthorised use à p 2 3 The oil filters must be removed à Changing the hydraulic oil filter p 8 39 Closing the valve Open the flap 1 Pull the locking bar 3 Close the valve lever 2 at right angles to the line Insert the locking bar 3 Leave the flap 1 open Hydraulic oil in litres gal Designation to DIN 51502 Specification classification GROVE part no...

Page 279: ... Remove the cap 1 and the filter 2 Add new oil via the filler neck 3 through a filter until the level reaches the centre of the sight glass 4 Tighten the cap and filter s O 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 S Risk of damage to the hydraulic system Cleanliness is of ...

Page 280: ...en Pull the locking bar 3 Open the valve lever 2 parallel to the line Insert the locking bar 3 Close the flap 1 Start the engine from the crane cab Carry out all hydraulic functions several times to remove any air in the system Check that none of the oil filters is leaking Check the oil level through the sight glass on the hydraulic oil tank Top up oil if necessary à p 8 43 S Risk of damage to the...

Page 281: ...pressure cleaning operation on the truck crane Grease the piston rod H You can hinder the formation of rust if you turn the main boom to the side between maintenance intervals and completely lower it M 1 Designation GROVE part no Lubricant RHUS SW 2 1 kg Apply the grease with a brush 03325215 or Spray on Berulub 0 5 litres spray on 01929824 S Risk of damage to the derricking cylinder s gasket due ...

Page 282: ...ity table necessary for maintenance à Lifting capacity table Section Telescoping sequences for greasing the boom The RCL code for the current rigging mode must be entered H If initially you set up a rigging mode under which the telescope statuses 50 100 0 0 0 0 are available in the context of the associated lifting capacity table this rigging mode allows you to perform the complete maintenance wor...

Page 283: ...ce work Extend the telescopic section I to 100 Use a brush or a roller PAL1 to lubricate the outer upper and outer lower slide faces 3 Use the grease gun PAL1 to lubricate the upper inner slide faces at the lubricating nipples 1 on both sides Use the grease gun RHUS SW 2 to lubricate the locking pins at the grease nipples 2 on both sides Lock and unlock the telescopic section I several times so th...

Page 284: ...nstructions regarding maintenance work The following diagrams show the lubrication of the telescopic section VI The telescopic sections V IV III II are lubricated in the same way Extend the telescopic section VI 100 and the telescopic section V approx 25 Use a brush or a roller PAL1 to lubricate the outer upper and outer lower slide faces 3 Use the grease gun PAL1 to lubricate the upper inner slid...

Page 285: ... sides Raise the main boom to 15 Retract the telescopic sections V and VI to 0 Fully extend and retract the telescopic section VI again so that the grease is distributed over the telescope slide faces Lower the main boom to 0 Lubricate the telescopic sections V IV III and II in the same way Before driving the truck crane Fully retracting all telescopic sections of the main boom after greasing may ...

Page 286: ...ealer or your repair crew 8 7 4 Checking the locking system Have the main boom locking system checked regularly by Manitowoc Crane Care or an authorised GROVE dealer M 3 M 12 G Risk of accidents if maintenance work is not carried out Have the maintenance work on the main boom locking system performed regularly by Manitowoc Crane Care or an authorised GROVE dealer This prevents the complete unlocki...

Page 287: ...ted Checking Always check the entire length of the winding of the ropes 1 Slowly perform the lowering movement until the rope has moved over the complete width X of the rope drum The rope must be evenly wound The rope turns on the drum must be evenly spaced 0 to 2 mm 0 to 0 08 in apart The cross over points must be offset by approximately 180 H The ropes of the top layer lie over the ropes of the ...

Page 288: ...à Assessing the condition of the hoist rope p 8 54 When 5 turns are left on the rope drum the lowering limit switch must switch off If the lowering limit switch does not switch off or switches off too late it must be reset à Setting the lowering limit switch p 8 63 Check the clamp 1 for damage and firm seating torque to 78 Nm 57 5 lbf ft The free end of the rope must not project above the flanged ...

Page 289: ...ying brushing rolling or by running it through a tray filled with lubricant or by means of high pressure lubrication with a pressure pump H 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 When lubricating the hoist ropes observe the instructions concerning t...

Page 290: ... you must be familiar with the following the type of rope lang lay rope the number of load bearing wires in the outer strands the rope diameter à Operating Instructions In a lang lay rope 1 the wires run at an angle of approximately 45 to the longitudinal direction of the rope The number of load bearing outer wires 1 is found by counting the number of outer strands of the rope and multiplying by 7...

Page 291: ...on a rotation resistant hoist rope The rope section runs over a rope disc or on a drum wound as a single layer Number of load bearing outer wires 13 mm 16 mm 17 mm to 78 mm to 390 mm to 96 mm to 480 mm to 102 mm to 510 mm 101 120 3 5 3 5 3 5 121 140 3 5 3 5 3 5 19 mm 22 mm 24 mm to 114 mm to 570 mm to 132 mm to 660 mm to 144 mm to 720 mm 101 120 3 5 3 5 3 5 121 140 3 5 3 5 3 5 The rope section is ...

Page 292: ...re protruding from the rope General wear caused by ageing of the rope or consequential damage as a result of damage to the rope Replace the rope at the latest when the maximum permissible number of wire breaks according to the table are visible externally Replace the rope immediately if wire wire breakage clusters or strand breakages occur The frequency of wire breaks increases with a rope s age F...

Page 293: ...er Corkscrew type rope deforma tion 2 The rope winds its way along its longitudinal axis in a way that is similar to a corkscrew Deformation is measured with suspended hook block Damage resulting from overloading Even a small amount of deformation leads to increased abrasion wire breaks and rough operation of the rope drive If deformation x at a position on the rope is greater than a third of the ...

Page 294: ... loose Only the inner strands continue to bear the load Corrosion or abrasion Replace the rope immediately Other causes The number of wire breaks determines when the rope must be replaced Knot forma tion 3 If there is repeat edly occurring knot like thicken ing of the rope the insert comes out frequently Strands bear on each other at thin points increased frequency of wire breaks General wear due ...

Page 295: ...iving over the rope Determine number of wire breaks replace rope immediately if serious crushing has occurred Kinks 2 Rope deformation with twists and wire breaks Rope in the eyelets was pulled straight while twisted Replace the rope immediately Buckling 3 Buckled section in the rope Mechanical damage Replace the rope immediately Crinkling 4 Crinkling rope deformation Loaded rope was pulled over a...

Page 296: ...Instructions Replacing the old rope Unreel the hoist rope until it switches off Adjust the lowering limit switch so that you can unreel the rope completely à Setting the lowering limit switch p 8 63 Unreel the remaining layers from the hoist drum Protect the truck crane from unauthorised use à p 2 3 S Risk of accidents from falling load Use only a replacement rope that has the same technical speci...

Page 297: ...ervice life therefore Make sure the rope is not twisted when it is inserted Avoid soiling and damage when fitting Wind the rope up in the same direction in which the rope is reeled on to the reel Tense the rope slightly while winding it up Place the reel stand 1 with the new rope in front of the main boom head The distance X between the reel stand 1 and the head sheave 2 must be at least 30 m so t...

Page 298: ...78 Nm 57 5 lbf ft Place the rope wedge 1 in the loop Push the rope back until the rope wedge 1 is fully in the pocket 2 Ensure that the rope wedge loop and rope end do not protrude beyond the flanged wheel This will prevent damage Start the engine from the crane cab Hold the rope taut and wind up the rope slowly Reeve a hook block reeve it at least 5 times à Operating Instructions Raise the main b...

Page 299: ... on the auxiliary hoist Spare parts and tools Prerequisites A hook block must be reeved 5 fold à Operating Instructions The main boom is fully raised and extended à Operating Instructions The hook block is lowered until only five turns of the rope remain on the hoist drum s G Risk of accidents if the lowering limit switch is set incorrectly After inserting a new rope the lowering limit switch must...

Page 300: ...ing switch off Raise the hook block until there are approx 10 turns on the hoist drum Lower the hook block and check whether the lowering limit switch switches off properly The lowering limit switch must switch off the hoist while five rope turns are still on the hoist drum Correct the setting of the lowering limit switch if necessary G Risk of accidents if the rope end fitting is overloaded The l...

Page 301: ...quisites All counterweight sections must be removed the opening for cable drum 2 at the rear of the turntable must be accessible à Operating Instructions The main boom must be set down on the support à Operating Instructions The engine must be switched off and secured against unauthorised use à p 2 3 The battery master switch must be switched off in the driver s cab à Operating Instructions s 1 Ca...

Page 302: ... the cover to the cable drum S 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 G Risk of crushing from movement of the main boom Only perform maintenance work when the main boom is resting in the su...

Page 303: ...icating Remove the drain plug 1 Clean the grease nipple 2 and inject about 5 cm 0 3 in of grease Remove any excess grease and close the grease nipple Tighten the bolt with a new gasket and sealing agent torque 25 Nm 18 5 lbf ft Y 5 Lubricating grease Designation to DIN 51502 Specification classification GROVE part no Grease KP 1K 50 DIN 51825 03233369 Designation Quantity GROVE part no Gasket 16 x...

Page 304: ...Maintenance work on the superstructure 8 9 Cable drums and slewing angle sensor 8 68 3 302 364 en Maintenancemanual GMK 4100L 1 25 11 2016 Blank page ...

Page 305: ...ate lubrication by pressing button 2 The duration of the intermediate lubrication is about 6 minutes The lights green ready for operation red empty are located on the display 3 Topping up There are various options for filling the grease container 1 W 4 Grease nipple standard for connection of a manual grease gun GROVE part no 04158709 5 Filling coupling plug optional for connecting a the hose to a...

Page 306: ...Maintenance work on the superstructure 8 10 Central lubrication system 8 70 3 302 364 en Maintenancemanual GMK 4100L 1 25 11 2016 Blank page ...

Page 307: ...gulations p 4 1 Grease spare parts tools Grease gun from the tool set Prerequisites The hook block has been reeved at least twice à Operating Instructions Lubricating On the hook blocks supplied the sheaves crossheads and load hooks of the axial bearings are greased H The sheaves on the hook block often have no grease nipple and are maintenance free Check all hook blocks for grease nipples Hook bl...

Page 308: ...se them using a grease gun Having them dismantled Depending on the manufacturer there are different maintenance intervals for the dismantling of the hook blocks The maintenance free sheaves are also greased at this time Some manufacturers recommend dismantling every 4 years or after 500 operating hours Ask Manitowoc Crane Care about the maintenance intervals for the hook blocks supplied to you Hav...

Page 309: ...l light Spotlight on the main boom xenon light Horn anemometer Camera lights on the main and auxiliary hoists Date Time on CCS display You can correct the time date via the Settings menu in the CCS display à Operating Instructions A long life battery with a service life of 10 years for retaining the control system data is located next to the fuses in the crane cab à Have the battery on the electro...

Page 310: ... the electronics board 3 Close the cover Check the correct operation of all controls G 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 While changing the lamp there is still a danger of residual voltage discha...

Page 311: ...ir conditioning system in the same way as when checking it on the carrier à Checking the air conditioning system p 7 127 8 13 2 Cleaning the condenser fins Switch the air conditioning system off Clean the condenser fins 1 with compressed air M 1 M 1 S Risk of damage to the condenser Do not use a high pressure cleaner or steam jet cleaner The powerful jet may damage the fins Use only compressed air...

Page 312: ...ion of the air conditioning system particularly includes the inspection of the refrigerant collector in accordance with the pressure container regulations test group II and the refrigerant compressor Only allow the system to be topped up with suitable refrigerant M 6 G Risk of burns due to escaping refrigerant Wear suitable safety glasses and gloves when checking the hoses and connections This wil...

Page 313: ...connections 1 for the refrigerant are on the compressor behind the cover 2 Depending on the output KW of the air conditioning system there may be two separate refrigerant circuits which must be filled separately There are then four filler connections 1 instead of two Fill quantity in kg lbs Designation CAS no EC no 1 0 2 2 1 circuit 3 KW Tetrafluoroethane R134a 811 97 2 212 377 0 2 x 0 95 2 1 2 ci...

Page 314: ...ing conditions at extremely sandy or dusty locations you must change the filter earlier than normal Spare parts and tools Prerequisites The engine must be switched off and secured against unauthorised use à p 2 3 Changing Open the cover 1 Remove the filter 2 from the housing and clean the housing with a cloth Insert a new filter Fasten the cover 1 M 12 Designation Quantity GROVE part no Filter 1 0...

Page 315: ...ommercially available detergent and antifreeze to it A can for mixing and filling Prerequisites The crane cab door is pushed back the filler neck with the cap 1 is accessible Topping up If the tank is empty Open the cap 1 on the filler neck Top up the windscreen washing fluid through the filler neck Close the filler neck with the cap s W Designation Quantity GROVE part no Windscreen wiper blade 1 ...

Page 316: ...ittent operation push the switch in the middle position Switch off the windscreen wiper press the switch up Switch on the roof window wiper press the switch down for continuous operation Also check intermittent operation push the switch in the middle position Switch off the roof window wiper press the switch up In case the windscreen skylight is not wiped clean Change the wiper blade 8 14 2 Checki...

Page 317: ...p 2 3 Lubricating With the door closed clean the rails 1 outside Lubricate the rails 1 lightly with a brush Open the door completely using the handle the door locks in place Clean the rails 2 Lubricate the rails 2 and the rollers 3 lightly with a brush 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 Manitowoc ...

Page 318: ...ol unit à Operating Instructions Lubricating Fully extend the step Remove the step 1 and the grille 2 the rails 3 are now exposed Clean the rails 3 Lubricate the rails 3 lightly with a brush Retract and extend the step several times Whilst doing so check that the step is moving easily on the rails Check that the electric spindle motor 4 is running smoothly and without jerking Attach the step 1 and...

Page 319: ...ges on the crane cab s front and the rear window Retaining rods for the rope discs at the head of the main boom 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 or an authorised GROVE dealer or your qualified repair crew Use only authentic replacement pins Lubricating Clean the pins Lubricat...

Page 320: ...tection for the first time in the factory itself These are pumps valve blocks controls and fittings pipes screw connections hose fittings of the hydraulic system of the superstructure à p 8 85 The corrosion protection is solvent free and is water soluble while being sprayed on A transparent waxy protective film is formed after a drying time of one hour Check the condition of the original protectiv...

Page 321: ...ctions pipes hoses of the hydraulic system of the superstructure On the derricking cylinder 2 On the slewing gears 1 On the slewing duct 3 On the hoists 4 Clean surfaces sprayed by accident immediately with water Let the corrosion protection dry for one hour Check that a transparent waxy protective film has covered the entire surface G Risk of injury to the eyes While working with the spray extens...

Page 322: ... on the respective national regulations and the operating location Ask the local fire safety officer about the national and local regulations Observe the instructions 1 on the fire extinguisher Have the fire extinguisher serviced by trained personnel in good time before the maintenance interval specified on the label 2 expires Y 2 S Danger due to the fire extinguisher not working There is no guara...

Page 323: ...25 11 2016 9 Maintenance manual 3 302 364 en GMK 4100L 1 9 Longer out of service periods ...

Page 324: ...25 11 2016 3 302 364 en Maintenancemanual GMK 4100L 1 ...

Page 325: ...ng to the maintenance plans M 3 to M 12 Seal the air filter Increase the tyre pressure by 10 and mark the tyre positioning or support the truck crane and leave it standing on the outriggers Observe the specifications on preservation in the Engine manufacturer s documentation Checks Check the level in the fuel tanks Always keep the tanks filled Check the batteries every week and recharge them if ne...

Page 326: ...ry out all maintenance work in accordance with the maintenance plan M 12 Observe the specifications on preservation in the Engine manufacturer s documentation Putting the truck crane into operation Open the air filter Inflate the tyres up to the prescribed pressure Carry out periodic maintenance work in accordance with the maintenance plans in Chapter 5 Observe the specifications on preservation a...

Page 327: ...25 11 2016 10 Maintenance manual 3 302 364 en GMK 4100L 1 10 Torques 10 1 Torques for the retaining bolts 10 1 10 2 Special torques 10 2 ...

Page 328: ...25 11 2016 3 302 364 en Maintenancemanual GMK 4100L 1 ...

Page 329: ... Bolt quality Hexagon head bolt Cylinder screw 8 8 10 9 12 9 M 8 M 8 x 1 13 6 23 24 32 34 36 41 M 10 M 10 x 1 25 17 8 44 47 62 66 75 79 M 12 M 12 x 1 5 19 10 78 81 110 113 130 135 M 14 M 14 x 1 5 22 12 120 135 170 189 210 225 M 16 M 16 x 1 5 24 14 165 203 190 284 320 342 M 18 M 18 x 1 5 27 14 260 293 365 414 435 495 M 20 M 20 x 1 5 30 17 370 414 520 576 620 693 M 22 M 22 x 1 5 32 17 500 549 700 77...

Page 330: ... strut flange bottom M 20 17 520 Half shell steering lever M 16 14 265 Upper steering arm on suspension strut M 20 30 610 Steering linkage Ball and socket joints and steering track rods M 10 x 1 M 12 x 1 5 M 14 x 1 5 M 24 x 1 5 M 30 x 1 5 45 55 70 85 140 160 250 280 450 500 Others Coolant hose clamps 4 Wheel nuts M 22 x 1 5 32 650 Rim connection bolts only for aluminium rims Aluminium rims with 20...

Page 331: ...Maintenance manual 3 302 364 en GMK 4100L 1 11 Spare parts required for maintenance 11 1 General information 11 1 11 2 Lighting 11 1 11 3 Spare parts for the carrier 11 5 11 4 Spare parts for the superstructure 11 8 ...

Page 332: ...25 11 2016 3 302 364 en Maintenancemanual GMK 4100L 1 ...

Page 333: ...ns list p 6 3 11 2 Lighting Lamps are listed according to the installation point The list includes standard and additional lighting equipment for the truck crane Lighting specific to certain countries can be found in the accompanying Spare parts list in the section on country specific packages s G Risk of accidents from exploding glass bodies and high voltage The glass bodies of gas discharge lamp...

Page 334: ...arker light 03320937 LED Front side indicator lights under the access ladder to the driver s cab Indicator light 03327578 PY21W 24V 21 Tail lights at the rear of the chassis Marker light 03137450 R5W 24V 5 Number plate light 03137450 R5W 24V 5 Rear light 03137450 R5W 24V 5 Brake light 03328445 P21W 24V 21 Indicator light 03327578 8GA 006841241 24 V 21 W Fog tail light 03328445 P21W 24V 21 Reverse ...

Page 335: ...er beam spotlights above the front and rear outrigger beams LED spotlight complete 03143786 M70 LED Yellow rotating beacon on the driver s cab Rotating beacon complete 04156048 Inside light in the driver s cab Cab light 03135111 24V 24V 15W Reading light 03135111 24V 24V 15W Dashboard light in the cab socket 12V Filament lamp 04159964 Xenon 12V 6W s Installation point GROVE part number Designation...

Page 336: ... Marker light complete 03329492 LED Yellow rotating beacon on the turntable Rotating beacon complete 04156048 Inside light in the crane cab Cab light 00550434 K 24V 10 Reading light 00550434 K 24V 10 Spotlight angular shaped permanently installed at the front of the crane cab Filament lamp 01573349 H3 24V 70 Spotlight electrically adjustable at the front of the main boom Halogen bulb 03142726 8GS0...

Page 337: ...el system Filter filter 1 large 04161991 1 Filter filter 2 small 04161566 1 Transmission Gasket 24 x 29 Cu DIN 7603 00117145 1 Transfer case Gasket 30 x 36 Cu DIN 7603 00117151 1 1 Gasket 16 x 20 Cu DIN 7603 00117134 1 Angle gear Gasket 30 x 36 Cu DIN 7603 00117151 1 1 Filter Packing set 03135866 1 04161645 1 Screw with gasket oil cooler 03326356 1 Axle lines Axle centre drive for max 8 x 8 x 8 Ga...

Page 338: ...ed air system Valve if defective Gasket 22 x 27 Cu DIN 7603 01570750 7 00117142 7 Filter cartridge 04157844 1 Hydraulic system Filters 1 and 2 only clean Packing set 03329152 2 04163599 2 Filters 1 and 2 Packing set 03329152 at every oil change and when the symbol lights up 2 04163599 2 Filters 3 and 4 Packing set 03140253 2 03135867 2 Oil tank cover gasket 140 90 x 3 03328286 1 item for every oil...

Page 339: ...mblies and spare parts Carrier GROVE part number Quantity in single parts For maintenance interval Y 2 Y 3 Y 5 Y 6 Y 10 Engine Oil filter with cover gasket 04163013 1 Original oil drain plug complete 04161529 1 Transmission Filter 03328342 1 Spring 03328343 1 Gasket 42 x 49 Al DIN 7603 03328344 1 Gasket 24 x 29 Cu DIN 7603 00117145 2 ...

Page 340: ...IN 7603 00117125 2 Gasket 14 x 20 Cu DIN 7603 00117132 2 Hydraulic system Filter 1 only clean it Packing set 04156358 1 04165792 1 Filter 1 Packing set 04156358 at every oil change and when the symbol lights up 1 04165792 1 Filter 2 Housing packing set 03142356 1 03326049 1 Ventilation filter 03134932 1 Hoist ropes Cover gasket 02315305 1 if damaged for every rope change on the hoist Cable drums C...

Page 341: ...Maintenance manual 3 302 364 en 11 9 GMK 4100L 1 Assemblies and spare parts Superstructure GROVE part number Quantity in single parts For maintenance interval Y 2 Y 3 Y 5 Y 6 Y 10 Slewing angle sensor Gasket 16 x 20 Cu DIN 7603 00117134 1 Electrical system Lithium battery 3 6 V 03143172 1 ...

Page 342: ...Spare parts required for maintenance 11 4 Spare parts for the superstructure 11 10 3 302 364 en Maintenancemanual GMK 4100L 1 25 11 2016 Blank page ...

Page 343: ...25 11 2016 Maintenance manual 3 302 364 en GMK 4100L 1 Appendix ...

Page 344: ...25 11 2016 3 302 364 en Maintenancemanual GMK 4100L 1 ...

Page 345: ...Appendix ...

Page 346: ......

Page 347: ...of the super structure Operating hours of the superstruc ture since the last in spection Operating hours of the winch Winch operating hours since the last inspection Used proportion of theoretical service life D Remaining theoretical service life D i D i 1 S i Name of the expert Signature Comment Name of the approved inspector Signature i Km i h h h h h h h S i Used proportion of theoretical servi...

Page 348: ......

Page 349: ...of the super structure Operating hours of the superstruc ture since the last in spection Operating hours of the winch Winch operating hours since the last inspection Used proportion of theoretical service life D Remaining theoretical service life D i D i 1 S i Name of the expert Signature Comment Name of the approved inspector Signature i Km i h h h h h h h S i Used proportion of theoretical servi...

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Page 351: ...current tilting play as described in Section Measuring tilting play p 8 28 Base value mm Max permissible wear 3 2 mm Max permissible tilting play mm Date Current tilting play Ball slewing bearing Signature 135 A 45 B 45 C 135 D OK defective replaced on ...

Page 352: ......

Page 353: ...current tilting play as described in Section Measuring tilting play p 8 28 Base value mm Max permissible wear 3 2 mm Max permissible tilting play mm Date Current tilting play Ball slewing bearing Signature 135 A 45 B 45 C 135 D OK defective replaced on ...

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