Manitowoc GROVE GMK 6400 Bedienungsanleitung

Maintenance manual

3 302 756 en

16.11.2018

3 302 756 en Maintenance manual

GMK6400

Important note

Any type of duplication or excerpt from

this document, even in electronic form,

is not subject to the revision service of

Manitowoc Crane Group Germany GmbH.

Manitowoc Crane Group Germany GmbH

Industriegelände West

D-26389 Wilhelmshaven, Germany

Phone: [+49] (0)44 21 294-0

Fax: [+49] (0) 44 21 294-301

The passing on or duplication of this document 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.

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GMK6400

Contents:

1General instructions

2Safety and environmental protection

3Cleaning

4Run-in regulations

5Maintenance overview

6Lubricants and consumables

7Maintenance work on the carrier

8Maintenance work on the superstructure

9Longer 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.

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1General instructions

1.1 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 information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 5

1.7 Conversion table for US measuring units. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 6

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General instructions

1.1 Using the maintenance manual

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GMK6400

1General instructions

1.1 Using the maintenance manual

This maintenance manual is not designed to replace proper training and

instructions!

Maintenance personnel for this truck crane must have the relevant,

specialist knowledge and that of proper safety procedures!

Please read Chapters 1 and 2 carefully before beginning maintenance work.

HMaintenance work on the lattice extensions is described in the Lattice

extension operating manual.

1.2 Warnings and symbols

The following definitions and symbols are used in the operating instruc-

tions 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.

GThis symbol indicates hazards related to the described operation, which

can endanger persons. The type of danger (e.g. life-threatening, personal

injury, risk of crushing or electric shocks) generally precedes the warning

sign.

SDangers which could put objects at risk are pointed out here, e.g. damage

to the truck crane or the load.

OThis symbol is to remind you that you are working with substances which

pose a risk to the environment. Exercise special caution.

The measures required for the corresponding maintenance work are indi-

cated next to the symbol. More detailed information is provided in section

Handling substances which are harmful to the environment, p. 2 - 4.

General instructions

1.3 Maintenance instructions

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HThe hand with the pointing finger indicates passages that contain additional

instructions and tips regarding truck crane operation.

sThis symbol indicates that the topic is continued on the next page. So turn

the page!

1.3 Maintenance instructions

This maintenance manual is intended for maintenance personnel.

The maintenance manual does not contain information on repair work.

Repair 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 Manitowoc Crane Group Germany GmbH can only uphold

the warranty provided for the truck crane when the following conditions

are met:

– It is used for the purpose for which it was intended

– Care and maintenance are carried out as prescribed

– Repair work/overhauling is carried out by professionals

General instructions

1.3 Maintenance instructions

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GMK6400

Many defects and failures are caused by improper maintenance such as:

– Insufficient oil, grease or antifreeze

–Dirt

– Rope damage

– Faulty compressed air and hydraulic systems

– Hose damage or loose screw connections

– Faulty brakes

– Faulty tyres or wheel rims

– Exceeded maintenance intervals

For your safety and the safety of others, avoid these errors by carrying out

maintenance work carefully within the specified intervals. Do not put off

maintenance work that is due. If repairs are needed, immediately contact

Manitowoc Crane Care or an authorised GROVE dealer or your repair crew.

This work may only be carried out 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 openings, oil inspection openings, oil drain

openings 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

used.

•Replace all filters within the specified period if cleaning is not explicitly

permitted.

•Always replace all gaskets before assembly.

Clean the sealing surfaces.

•Tighten loose screw connections on hydraulic and compressed air

systems only when the system is depressurised.

•Keep brake and clutch linings free of grease.

•Replace hydraulic hoses immediately once damage or moisture penetra-

tion becomes visible.

•Cleanliness is imperative when handling hydraulic oil. Even fresh

hydraulic oil must be filtered.

General instructions

1.4 Instructions regarding the electronic controls

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16.11.2018

•Cleanliness is imperative when handling grease for the central lubrication

system. Do not remove the caps from the filling hole and grease gun until

immediately before refilling the grease.

•Check fastening and retaining elements (bolts, nuts, lock washers etc.)

before re-using them and replace them if necessary.

Torques can be found in Sections p. 10 - 1 and p. 10 - 2.

The training centre at our factory offers specialised training programmes for

your qualified personnel.

Please contact Manitowoc Crane Care.

The vehicle must meet all current regulations applicable to it before being

put into operation and driven on public roads.

1.4 Instructions regarding the electronic controls

The electronic ESX control is designed for a service life of 10 years. In terms

of use, the control system's service life can be estimated based on the fol-

lowing limiting factors:

– The service life of EEPROM allows 106accesses.

– The maximum number of make-and-break cycles for the safety relay is 107.

– Some conventional capacitors in the ESX have a service life of 10 years.

The device must be serviced or replaced by Manitowoc Crane Care before one

of these limits is reached.

1.5 Safety instructions for welding work

To avoid damage, especially to electronic parts, there are certain measures

you must take before doing any welding work. Before any welding work,

you should therefore always consult Manitowoc Crane Care.

All welding work (especially on load carrying members) may only be

performed by qualified expert personnel with the prior written permission

from Manitowoc Crane Group Germany GmbH.

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