GMK2035E

MAINTENANCE & REPAIR WORK

 GENERAL INSTRUCTIONS

Use

• Appropriate workshop equipment

• Special tools

• Spare parts approved by Manitowoc Crane Group Germany GmbH.

Please note that Manitowoc Crane Group Germany GmbH can only
uphold 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 is carried out as prescribed

• repair work/overhauling is carried out by professionals

 GENERAL MAINTENANCE INSTRUCTIONS
1. 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 drain opening, and
the lubricating nipples
2. When changing the oil, let the oil run out at operating temperature

3. Replace all filters within the specified period if cleaning is not explicitly permitted
4. Replace all seals before assembly. Clean the sealing surfaces

5. Only tighten loose screw connections on hydraulic and compressed air

systems when the system is depressurised
6. Keep brake and clutch linings free of grease
7. Replace hydraulic hoses immediately once damage or penetration of
moisture becomes visible
8. When handling hydraulic oil, cleanliness is imperative. Even new hydraulic
oil must be filtered
 GENERAL MAINTENANCE INSTRUCTIONS
- Continued -
9. When handling grease on the central lubrication system, cleanliness is
imperative. Do not remove the caps from the filling hole and filling pump
until immediately before refilling the grease, as the grease could
otherwise become contaminated
10. Check fastening and retaining elements (bolts, nuts, lock washers) before
re-using them and replace them if necessary. Tightening torques can be
found in the Sections p. 10 - 1 and p. 10 - 2
NOTE ABOUT THE MAINTENANCE MANUAL
This manual is not designed to replace proper training and
instruction.
Truck crane maintenance personnel must have the relevant,
specialist knowledge of proper safety procedures.
 SAFETY RULES
• Familiarise yourself with the truck crane and its operation. Read the
Operating Instructions carefully and request guidance from the crane operator
• Do not carry out maintenance work 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 main boom may be extended into horizontal position

• Familiarise yourself with the

conditions under which the
superstructure may be slewed
and the main boom may be
extended into horizontal position
 SAFETY RULES
- Continued -

• Do not carry out maintenance work unless the truck crane is standing on
flat, stable ground and is prevented from rolling
• Keep all handles, steps, landings and ladders free of dirt, grease, snow
and ice

• Use the proper access aids and working platforms when carrying
out overhead work. Wear a harness when carrying out maintenance
work high overhead

• Walk only on those machine parts which are equipped with appropriate
steps and railings and therefore guarantee safety. During rigging and
maintenance work on machine sections above body height which have no
apparatus for accessing, always use the supplied extension ladder (e.g.
when lubricating telescopic slide faces)
• Perform maintenance work only after the truck crane has been shut down

• Always ensure that the truck crane is protected from unauthorised

operation before beginning maintenance work. Remove the key and put
up warning signs
 CLEANING
• In the first three months, the paintwork on the crane continues to harden.
Therefore the crane may only be cleaned with cold water.
• Do not use high-pressure or steam-jet cleaning equipment during this period
• After three months do not use water over 60oC

• Do not use corrosive cleaning elements that might corrode the

paint

• Never hold the spray nozzle of your cleaning unit

at a right angle to the surface you are cleaning and
ensure that you are standing at a sufficient
distance away from the surface you are cleaning.
• To prevent damage to the seals, never point the nozzle directly at them
• Never point the nozzle at electrical equipment, relay and control boxes, suction
and venting filters or control elements and lubricated surfaces
• Relubricate all slide faces after cleaning to prevent corrosion

• After cleaning with a high-pressure device or a steam jet device, activate intermediate lubrication on the central lubrication system
 RUN-IN REGULATIONS
Some parts (hoist, gearboxes etc.) are subject to special run-in regulations
• after the truck crane is put into operation for the first time or
• after part replacement or
• after a general inspection.
This means that maintenance work must be carried out on the carrier and the
superstructure at certain intervals:
Operating Hours Additional maintenance
Driven KM
(oper. hrs.)* work on the CARRIER
after 50 Tighten wheel nuts
after 150 Tighten wheel nuts
after 50 Tighten hose clamps on all coolant
hoses
after 100 after 1000 Change the final drive oil
Lubricate the wheel suspension**
during the first 100 Check the hydraulic oil filters weekly

* 1 oper. hr. corresponds to approx. 40 kilometres driven

** Not required if there is a central lubrication system
 RUN-IN REGULATIONS
- Continued -

Operating Hours Additional maintenance

Driven KM
(oper. hrs.)* work on the SUPERSTRUCTURE
after 100 Ball slewing bearing: Check tightness
of retaining bolts
after 200 Carry out the first oil change on the
hoist gear
after 200 Carry out the first oil change on the
slewing gear transmission
after 1000 Carry out the second oil change on the
hoist gear
* 1 oper. hr. corresponds to approx. 40 kilometers driven

Please note the instructions concerning run-in times/run-in regulations/oil

change intervals in the enclosed documents Engine manufacturer’s
operating
instructions and Engine manufacturer’s maintenance booklet.
RECOMMENDED
LUBRICANTS
 MAINTENANCE PLANS
As a manufacturer, Grove recommends that the cranes are maintained in line
with specific parameters. These parameters are usually classified by: time,
kilometers (driven), operating hours or on display on the display panel lights or
ECOS system. The maintenance interval which occurs first shall determine
when maintenance work is next due.
Maintenance plan D – daily before putting into operation
Maintenance plan W – weekly
Maintenance plan M 1 – monthly or approx. 2k KM or 100 operating hours
Maintenance plan M 3 – every 3 months or 5k-6k KM or 300 hours
Maintenance plan M 6 – every 6 months or 10k-12.5k KM or 500 hours
Maintenance plan M 12 – every 12 months or 20k-25k KM or 1000 hours
Maintenance plan Y 2 – every 24 months or 40k-50k KM
Maintenance plan Y 3 – every 36 months or 300k KM or 3000 hours
Maintenance plan Y 4 – every 48 months or 4000 hours
Maintenance plan Y 5 – every 60 months or 5000 hours
Maintenance plan Y 6 – every 72 months or 6000 hours
Maintenance plan Y 10 – every 120 months or 12000 hours
 MAINTENANCE PLAN D
Maintenance work on the CARRIER: daily/before
Lubricant
putting into operation
Engine
- Checking the oil level A
- Topping up coolant
Fuel System
- Draining off water from fuel prefilter
Wheels
- Checking for tyre damage
Steering
- Checking for leaks
Hydraulic System
- Check the oil level G2
- Check contamination display for hydraulic oil filter
Electrical System
- Checking the lighting and indicators
 MAINTENANCE PLAN D
- Continued -
Maintenance work on the SUPERSTRUCTURE:
Lubricant
daily/before putting into operation
Slewing Gear
- Slewing gear brake indicator lamp
Hydraulic System
- Check contamination display for hydraulic oil filter
Hoist Ropes
- Checking for tyre damage
Hook Blocks
- Checking the sheaves
Electrical System
- Checking the lighting & indicators
 MAINTENANCE PLAN W
Maintenance work on the CARRIER: weekly Lubricant
Engine
- General inspection
Transmission
- General inspection
Transfer Case
- General inspection
Axle Line
- General inspection
Wheels
- Checking the tyre pressures
Compresses Air System
- Draining the compressed air system
- Checking for leaks
Hydraulic System
- Checking the hydraulic hoses
- Check tightness (suspension & outriggers) while engine is running
Central Lubrication
K
- Central lubrication level
Other Maintenance Work
- Check the function of the windscreen washing system in the
operator’s cab and the level of the fluid reservoir
 MAINTENANCE PLAN W
- Continued -
Maintenance work on the SUPERSTRUCTURE: weekly Lubricant
Hoist
- Checking the oil level
E6
- General Inspection
- Checking the hoist brake
Slewing Gear
- Checking the oil level E6
- Checking for leaks
Hydraulic System
- Checking the hydraulic hoses
- Checking for leaks
Hoist Ropes
- Checking the condition
Central Lubrication
K
- Central lubrication with pump
Other Maintenance Work
- Check the function of the windscreen washing system in the operator’s
cab and the level of the fluid reservoir
 MAINTENANCE PLAN M1
Maintenance work on the CARRIER: monthly/after ca. 2 000 km Lubricant
Engine
- Observe specifications in the Engine Manufacturer’s Operating
Instruction and in Engine’s Manufacturer’s Maintenance Booklet
Transfer Case
E3
- Checking the oil level
Axle Lines
- Axles – oil level checks E3
- General inspection E3
Wheels
- Check tightness of wheel nuts
Electrical System
- Batteries – checking the acid level
Towbar Coupling
- Lubricating the towbar coupling J (2 litres)
Air Conditioning System
- Checking the moisture and level of the refrigerants R
- Cleaning the condenser fins
Soot Particle Filter
- Checking the clamp straps
- Check connecting cables for tight fit
Other Maintenance Work
- Checking the auxiliary heater for correct operation
- Lubricating the supports J
 MAINTENANCE PLAN M1
- Continued -

Maintenance work on the SUPERSTRUCTURE:

Lubricant
monthly/after 100 oper. Hrs
Central Lubrication
Y
- Central lubrication with grease distributor
Other Maintenance Work
- Lubricating the piston rod of the derricking Y
cylinder
- Checking the auxiliary heater for correct operation
 MAINTENANCE PLAN M3
Maintenance work on the CARRIER: every three
Lubricant
months/after 5k – 6k KM
Engine
- Observe specifications in the Engine Manufacturer’s
Operating Instruction and in Engine’s Manufacturer’s
Maintenance Booklet
Fuel System
E3
- Fuel prefilter 1 – replacing the filter
Axle Lines
- Lubricating the wheel suspension K
Vehicle Brake
- Check the brake linings
Electrical System
- Batteries – checking the acid concentration
Towbar Coupling
- Checking the bearing
- Checking the cotter pin
- Checking the lower bushing
- Checking the support ring J (2 litres)
- Checking the initial tension of springs
- Checking the function of the coupling jaw/setting the middle
position
 MAINTENANCE PLAN M3
- Continued -

Maintenance work on the CARRIER: every three

Lubricant
months/after 300 hours operation
Ball Slewing Bearing
- Check the tightness of retaining bolts
Main Boom
- Lubricating the telescopic slide faces L2 (24
- Relubricating the hoist rope litres)
- Checking the Sheaves T
 MAINTENANCE PLAN M6
Maintenance work on the CARRIER: every six
Lubricant
months/after 10k – 12.5k KM
Engine
- Observe specifications in the Engine Manufacturer’s Operating
Instruction and in Engine’s Manufacturer’s Maintenance Booklet
Transfer Case
- Changing the oil E3
(6.2 litres)
Wheels
- Changing wheels
Steering
- Check rubber sleeves for damage
Air Conditioning System
- Check hoses R
Soot Particle Filter
- Replace soot particle filtering system
 MAINTENANCE PLAN M6
- Continued -

Maintenance work on the SUPERSTRUCTURE: every six

Lubricant
months/after 500 operating hours

Slewing Gear
- Slewing gear brake indicator lamp
- Lubricating gear teeth V (1 litre)
Main Boom
- Lubricating the deflection sheaves K (4 litres)
- Checking the telescoping rope settings
- Checking the retracting rope
Air Conditioning System
- Check hoses R
Safe Load Indicator
- Maintenance of the slip ring assembly of the cable drums
 MAINTENANCE PLAN M12
Maintenance work on the CARRIER: every twelve
Lubricant
months/after 20k – 25k KM
Engine
- Observe specifications in the Engine Manufacturer’s Operating Instruction and in Engine’s
Manufacturer’s Maintenance Booklet
Fuel System
- Changing the fuel filter
Transmission
- Checking the oil level F7
Axle lines
- Axles – oil change E3 (12L)
- Final drives – changing the oil E3 (1.4 L each)
Suspension
- Pressure accumulator – checking the gas pressure
Compressed Air System
- Replacing the granulate cartridge
Hydraulic System
- Changing the ventilation filter
G2 (450 Litres)
- Taking oil samples
- Changing the hydraulic oil filter
Air Conditioning System
- Checking the entire air conditioning system R
Other Maintenance Work
- Lubricate the door hinges J
- Lubricate the connecting and socket pins J/A
 MAINTENANCE PLAN M12
Maintenance work on the SUPERSTRUCTURE: every twelve
Lubricant
months/after 1k operating hours
Hoist
E6 (1.6
- Changing the oil
Litres)
Check the old oil
Slewing Gear
- Change the oil E6 (0.9 Litre)
Hookblocks
-Lubrication J
Air Conditioning System
- Checking the entire air conditioning system R
Other Maintenance Work
- Lubricate cabin door track rollers A
- Lubricate the connecting and socket pins J/A
 MAINTENANCE PLAN Y2
Maintenance work on the CARRIER: every 24 months/after
Lubricant
40k – 50k KM
Air Conditioning System
- Have the refrigerant level checked by CraneCARE R

Maintenance work on the SUPERSTRUCTURE:

Lubricant
every 24 months/ after 2k operating hours
No maintenance work in this period.
The long-term intervals always include the short-term intervals
 MAINTENANCE PLAN Y3
Maintenance work on the CARRIER: every 36 months/after
Lubricant
360k KM
Transmission
- Changing the oil F7 (11 L)

Maintenance work on the SUPERSTRUCTURE:

Lubricant
every 36 months/after 3k operating hours
Hoist
- Carrying out partial inspection of hoist gears
 MAINTENANCE PLAN Y4
Maintenance work on the CARRIER: every 48 months Lubricant
No maintenance work in this period.
The long-term intervals always include the short-term intervals

Maintenance work on the SUPERSTRUCTURE:

Lubricant
every 48 months/after 4k operating hours
Main Boom
- Checking and lubricating ropes in the main boom
 MAINTENANCE PLAN Y5
Maintenance work on the CARRIER: every 60 months Lubricant
No maintenance work in this period.
The long-term intervals always include the short-term intervals

Maintenance work on the SUPERSTRUCTURE:

Lubricant
every 60 months/after 5k operating hours
Safe Load Indicator
- Carrying out general inspection of hoist gears
 MAINTENANCE PLAN Y6
Maintenance work on the CARRIER: every 72 months Lubricant
No maintenance work in this period.
The long-term intervals always include the short-term intervals

Maintenance work on the SUPERSTRUCTURE:

Lubricant
every 72 months/after 6k operating hours
Hoist
- Carrying out general inspection of hoist gears
 MAINTENANCE PLAN Y10
Maintenance work on the CARRIER: every 120 months/after
Lubricant
12k operating hours
Steel Construction
- Check the load-bearing steel construction. (Contact
CraneCARE for more information)

Maintenance work on the SUPERSTRUCTURE: every 120

Lubricant
months/after 12k operating hours
Steel Construction
- Check the load-bearing steel construction. (Contact
CraneCARE for more information)
Main Boom
- Replacing the ropes in the main boom
Safe Load Indicator
- Have the SLI checked by CraneCARE