Manitowoc Grove GMK 5200-1 User manual

Maintenance manual
3 302 746 en
09.03.2018

09.03.2018
3 302 746 en Maintenance manual
GMK5200-1
© Copyright reserved by
Manitowoc Crane Group Germany GmbH
Industriegelände West
D-26389 Wilhelmshaven, Germany
Tel.: [+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.
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.

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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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Maintenance manual 3 302 746 en
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1 General instructions
1.1 Instructions 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 control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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

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General instructions
1.1 Instructions for using the maintenance manual
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1General instructions
1.1 Instructions for using the maintenance manual
This maintenance manual is not designed to replace proper training and
instructions.
Maintenance personnel for this truck crane must have the relevant, special-
ist knowledge and that of proper safety procedures.
Please read chapters 1 and 2 carefully before beginning maintenance work.
HMaintenance work on the lattice extensions is described in the Lattice exten-
sion operating manual.
1.2 Warnings and symbols
The following designations and symbols are used in the operating 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
GThis 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) 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. Take particular care.
The measures required for the corresponding maintenance work are indi-
cated next to the symbol. You will find more detailed information 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. Turn to
the next 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 if 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 qualified personnel.

General instructions
1.3 Maintenance instructions
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Many defects and failures are caused by improper maintenance such as:
– Insufficient oil, grease or antifreeze,
–Dirt,
– Damage to the ropes,
– Faulty compressed air and hydraulic systems,
– Damaged hoses 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 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
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 sys-
tems 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 when filling
with fresh hydraulic oil, it must be filtered.
s

General instructions
1.4 Instructions regarding the electronic control
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•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 (nuts, bolts, 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 control
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. You should therefore always
consult Manitowoc Crane Care before any welding work.
All welding work (especially on load carrying members) may only be per-
formed by qualified professional personnel with the prior written permis-
sion from Manitowoc Crane Group Germany GmbH.