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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1
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.

General instructions
1.6 Definition of direction references
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1.6 Definition of direction references
Basic rule Direction information always depends on whether the carrier or the super-
structure is being operated.
On the carrier
The driver's cab is always at the front, which means that:
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, perpendicu-
lar or turned), the following always applies:
1: front 2: right
3: rear 4: left
1: front 2: right
3: rear 4: left
Down: If (1) press – next to the symbol
Up: If (2) press – opposite the symbol

General instructions
1.7 Conversion table for US measuring units
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1.7 Conversion table for US measuring units
The following conversion factors will help you convert from metric to US
units when the truck crane is used in countries that use US units of meas-
urement and vice versa.
Converting from into Multiply by
mm in 0.03937
in mm 25.4
mft 3.28084
ft m0.30479
m² ft² 10.76391
cm² in² 0.155
cm³ in³ 0.061
lgal (US) 0.264178
kg lbs 2.204622
lbs kg 0.45359
tlbs 2204.622
lbs t0.0004536
kN lbf 224.809
daN/cm² lbf/in² 14.50378
lbf/in² daN/cm² 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 1.60935
Nm lbf ft 0.7375
°C °F 1.8 x °C + 32
°F °C (°F-32)/1.8
t/m² lbs/ft² 204.8
m²/t ft²/lbs 0.04882
MPa bar 10
bar MPa 0.1

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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

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Safety and environmental protection
2.1 Safety rules
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2Safety and environmental protection
2.1 Safety rules
When carrying out maintenance work, please observe the applicable
accident prevention regulations.
Observe the following safety rules:
•Familiarise yourself with the truck crane and its operation.
Read the Operating manual carefully and request guidance from the crane
operator.
•Do not carry out maintenance work on the truck crane unless you are
authorised to do so.
•Observe all safety and warning signs on the truck crane.
•Observe all safety instructions contained in this Maintenance manual.
•Familiarise yourself with the conditions under which the superstructure
may be slewed and the boom may be extended 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 heights.
Use your personal fall protection equipment to secure yourself from fall-
ing from the truck crane.
All locations on the truck crane designed for fastening a fall prevention
safety system are marked with a symbol.
•Walk only on those machine parts which are equipped with appropriate
tread grids and railings and therefore guarantee safety. During rigging
and maintenance work on machine parts above body height which have
no apparatus for walking on, always use the supplied extendable ladder
(e.g. when lubricating telescopic slide faces).
s

Safety and environmental protection
2.1 Safety rules
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•Perform maintenance work only after the truck crane has been shut down.
Always ensure that the truck crane is well-protected from unauthorised
operation before beginning maintenance work. Remove the key and put
up warning signs.
If, due to exceptional circumstances, the truck crane needs be put into oper-
ation for certain types of maintenance work, great care must be taken where
there are moving parts (superstructure, outriggers, cardan shafts, slewing
bearing, engines, tiltable crane cab). There is a risk of injury.
•Ensure that all hydraulic components are returned to their initial positions
(e.g. the main boom) or locked (e.g. the outriggers) before starting main-
tenance work.
Escaping hydraulic fluid or compressed air can cause severe injury.
Remember that the hydraulic 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 scald-
ing.
•Observe the applicable safety regulations when working with flammable
fluids.
•Observe the applicable safety regulations when working with consuma-
bles and auxiliary materials.
•Switch off all electrical consumers and first disconnect the earthing ter-
minal before removing any storage batteries.
•Keep in mind the corrosive effect of battery acid.
•Note the fire alarm and fire-fighting facilities on site.
•Return the truck crane to proper working order once maintenance work is
completed. Inform the crane operator accordingly.

Safety and environmental protection
2.1 Safety rules
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2.1.1 Securing against unauthorised use
•Secure the truck crane against unauthorised use by:
– Applying the parking brake,
– Switching the transmission to position N,
– Turning off the engine,
– Removing the ignition key and
– Stowing away the hand-held control in the crane cab or in the 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 infor-
mation 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.
GDanger due to unauthorised use.
Always stow away the hand-held control in the crane cab or in the driver's
cab before leaving the truck crane and lock the doors.
In this way you can prevent unauthorised persons from starting the engine
with the hand-held control.

Safety and environmental protection
2.2 Handling substances which are harmful to the environment
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2.2 Handling substances which are harmful to the
environment
Which substances
are harmful to the
environment?
When you carry out maintenance work on the truck crane you will occasion-
ally work with consumables which are classified as harmful to the environ-
ment by applicable national and regional regulations.
These include oil, fuel, grease, used oil and fuel filters, as well as rags which
have come into contact with these environmentally harmful substances.
•When handling these substances observe the applicable national and
regional regulations as well as the instructions 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 suffi-
cient capacity and resistance to the consumables.
The approximate amount of consumables to be expected is specified in the
maintenance plans.
Filling and
draining
•When filling and draining, make absolutely sure that no substances harm-
ful to the environment seep into the earth, escape into the sewage system
or pollute natural waters.
•Collect consumables (e.g. oils, fuels, coolant) in a suitable receptacle
when draining.
•Always use a drain hose when draining, and a funnel or a pump with
a hose suitable for the respective substance when filling.

Safety and environmental protection
2.2 Handling substances which are harmful to the environment
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Collecting and
storing separately
Substances which are harmful to the environment should always be col-
lected separately from other waste.
•Ask your local environmental protection authority about the different cat-
egories of the substances.
•Also, when collecting substances 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 protection authority about the prescribed
disposal options.
•Once collected, have environmentally harmful substances disposed
of only by disposal companies which are approved by the national or
regional authority responsible.

Safety and environmental protection
2.3 Disposal of the truck crane
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2.3 Disposal of the truck crane
Since you are the owner/operator, you can be faced with the proper, orderly
and final putting out of service and disposal and scrapping of the truck
crane.
Before you decide to finally put your truck crane out of service and to scrap
it:
•Allow Manitowoc Crane Care to advise you about alternatives.
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.
•At 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 dis-
posed of only by disposal companies which are approved by the national
or regional authority responsible; àHandling substances which are harmful
to the environment, p. 2 - 4.
After disposal •Inform Manitowoc Crane Care about the disposal of the truck crane while
specifying the serial number.