Manitowoc Grove GMK 5250L User manual

Maintenance manual
3 302 744 en
09.03.2018

09.03.2018
3 302 744 en Maintenance manual
GMK5250L
© 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.

Additional pages for maintenance manual 3 302 809 en 1
GMK truck cranes
03.09.2018
1Additional maintenance work
on the rope attachment point
Depending on the equipment of the truck crane, a rope attachment point (1)
can be fitted between the lower sheaves on the main boom head.
•Check on both sides whether the rope attachment point (1) is equipped
with a grease nipple (2).
1.1 Main boom
1.1.1 Lubricating the rope attachment point
Grease, tools
– Grease gun from the tool set; 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 freely rotated.
If you discover any damage
•Have the defective rope attachment point re-
placed by Manitowoc Crane Care or an au-
thorised GROVE dealer.
M 3
Lubricating
grease
Designation
to DIN 51502
Specifications
Classification
GROVE part no.
Grease KP - 1K - 50 DIN 51825 03233369

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Additional pages for maintenance manual 3 302 836 en 1
GMK truck cranes
22.11.2018
1Protection of the main boom telescopic sections
1.1 Additional monthly maintenance work (M 1)
1.1.1 Checking the guard strips
The figure shows the main boom on a GMK5250L truck crane.
Other GMK models have a similar arrangement of guard strips (1) on the
upper surface of the telescopic sections.
The guard strips (1) are replaceable parts that must be checked regularly.
Check
•Check all guard strips (1) on all telescopic
sections for damage, wear and formation of
grooves by the hoist rope.
Turn if necessary
You can turn the guard strip, but only when
the bottom of the groove lies significantly
above (X) the telescopic section (2).
•(A) – Remove all screw connections (3).
•Remove the guard strip (1) and clean the
guard strip and the top surface of the
telescopic section.
•(B) – Turn the guard strip (1) by 90° and
fasten all screw connections (3).
s
M 1
SRisk of damage to the telescopic sections and hoist rope!
The hoist rope can form grooves in the guard strips when the crane is used
intensively. The hoist rope and telescopic section will be damaged when
the groove depth reaches the metal of the telescopic section.
You must therefore turn or replace the guard strips in time (1).

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GMK truck cranes
When turning three times is no longer sufficient
•Have the damaged guard strips replaced by Manitowoc Crane Care or an
authorised GROVE dealer or your qualified repair crew.
1.1.2 Conversion from plastic guard strips to steel rollers
GMK 6300L-1 The GMK 6300L-1 truck crane is delivered as standard with steel rollers
running in ball bearing races.
GMK 5250L and
GMK 6300L
The GMK 5250L and GMK 6300L truck cranes can be delivered with/
converted to steel rollers running in ball bearing races as additional
equipment.
•Contact Manitowoc Crane Care for information on the details and cost of a
conversion.
1.1.3 Checking the steel rollers
•Check all steel rollers (1) on all telescopic
sections for damage, wear and mobility of
the ball bearings (2).
•Have damaged, worn, stiff or extremely
steel rollers replaced by Manitowoc Crane
Care or an authorised GROVE dealer or your
repair crew.
M 1

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Maintenance manual 3 302 744 en
GMK5250L
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 3 302 744 en
GMK5250L
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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GMK5250L
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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GMK5250L
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
1 - 4 3 302 744 en Maintenance manual
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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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GMK5250L
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.