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GROVE GMK6400
Manitowoc GROVE GMK6400 User Manual
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Maintenance manual
3 302 756 en
16.11.2018
2
Table of Contents
Table of Contents
3
General Instructions
7
Using the Maintenance Manual
7
Warnings and Symbols
7
Maintenance Instructions
8
Instructions Regarding the Electronic Controls
10
Safety Instructions for Welding Work
10
Definition of Direction Information
11
Conversion Table for US Measuring Units
12
Safety and Environmental Protection
15
Cleaning
23
Run-In Regulations
29
Maintenance Overview
33
6 6 Lubricants and Consumables
61
Lubricants
63
Lubricants List
64
Lubricant Applications List
65
Lubricants and Consumables
63
Consumables
67
Fuel
67
Engine Coolant Admixtures
67
After-Treatment of Exhaust Gases
68
Windscreen Washing System Admixtures
68
Fuel for Crane Cab Heating System
68
Refrigerant
67
7 7 Maintenance Work on the Carrier
69
General Instructions
73
Maintenance Work on the Carrier
73
Covers
74
Overview of Maintenance Work on the Carrier
76
Symbols for Maintenance Work
83
Checking the Oil Level
85
Engine
85
Topping up the Oil
87
Installing the Drain Valve
88
Checking the Air Filter
89
Checking the Coolant Level
90
General Inspection
91
Have the Radiator Checked/Cleaned
92
Changing the Oil and Oil Filter
96
Fuel System
99
Draining Water from Fuel Filter 1
100
Changing Fuel Filter 1
101
Changing Fuel Filter 2
103
Exhaust System with Exhaust Emission Control
107
Checking the Adblue Tank Level
108
Filling up with Adblue
108
Checking the Exhaust System for External Damage
109
Having the Adblue System Checked
111
Transmission
113
General Inspection
114
Checking the Transmission Oil Level
115
Checking the Oil Level - Power Take-Off
116
Changing the Oil and Oil Filter - Transmission
117
Changing the Oil and Oil Filter - Power Take-Off
121
Test Drive
124
Checking the Oil Level
125
General Inspection
125
Transfer Case
125
Changing the Oil
126
Axle Lines
129
Axle Centre Drives - Checking the Oil Level
130
General Inspection
130
Checking the Hydraulic Drives
132
Axle Centre Drives - Changing the Oil
133
Final Drives - Checking the Oil Level
135
Final Drives - Changing the Oil
136
Lubricating the Drive Shafts in the Axle Lines
139
Lubricating the Longitudinal Drive Shafts
140
Checking the Tyres for Damage
141
Wheels
141
Checking the Tyre Pressure
142
Checking the Tightness of Wheel Nuts
143
Changing the Wheels
144
Checking the Brake Lining Thickness
149
Vehicle Brake
149
Suspension
151
Suspension Struts - Checking the Oil Level
151
Suspension Struts - Checking the Fastening
152
Forced Lever - Checking Correct Functioning
153
Pressure Accumulator - Checking the Gas Pressure
154
Checking for Leaks
155
Steering
155
Pressure Accumulator - Checking the Gas Pressure
156
Compressed Air System
157
Draining Water from the Compressed Air System
157
Checking for Leaks
158
Replacing the Compressed Air Dryer Filter Cartridge
159
Checking the Oil Level
161
Hydraulic System
161
Checking for Leaks
162
Checking the Hydraulic Hoses
162
Cleaning the Magnetic Rods
163
Changing the Ventilation Filters
165
Taking Oil Samples
166
Changing the Hydraulic Oil
171
Changing the Hydraulic Oil Filter
175
Central Lubrication System
179
Checking the Filling Level
179
Bleeding the Central Lubrication System
181
Triggering Intermediate Lubrication
181
Checking the Lighting and Indicators
183
Electrical System
183
Checking the Batteries
184
Checking the Charge Level of the Batteries
186
Charging the Batteries Using the Battery Charger
188
Checking the External Starting Socket
189
Air-Conditioning System
191
Checking Hoses
191
Checking the Air Conditioning System
191
Checking the Entire Air-Conditioning System
192
Cleaning the Condenser Fins
192
Changing the Pollen Filter
194
Lubricating the Towbar Coupling
195
Towbar Coupling
195
Checking the Bearing
197
Checking the Cotter Pin
198
Checking the Initial Tension of the Springs
199
Checking the Lower Bushing
199
Checking the Function of the Coupling Jaw / Resetting Central Position
200
Checking the Support Ring
200
Checking the Windscreen Washing System
203
Other Maintenance Work
203
Lubricating the Outrigger Beams
204
Checking the Functioning of the Auxiliary Heater
205
Lubricating the Cab Door
205
Lubricating the Connecting Pins and Socket Pins
206
Renewing the Corrosion Protection
207
Having the Fire Extinguisher Checked
209
8 8 Maintenance Work on the Superstructure
211
General Instructions
213
Covers
213
Maintenance Work on the Superstructure
213
Overview of Maintenance Work on the Superstructure
214
Symbols for Maintenance Work
221
Checking the Oil Level
223
Hoists
223
Checking the Hoist Brake
224
General Inspection
224
Support for Block - Checking the Sheaves
225
Changing the Oil/Checking the Oil
226
Having a General Inspection Carried out
228
Having a Partial Inspection Carried out
228
Checking the Oil Level
229
Slewing Gear
229
Checking for Leaks
230
Checking the Slewing Gear Brake
230
Changing the Oil/Checking the Oil
232
Checking the Bolts
235
Slewing Bearing
235
Lubricating the Gear Teeth
239
General Inspection
241
Measuring Tilting Play
242
Lubricating the Turntable Lock
244
Checking the Oil Filter
247
General Inspection
247
Pump Transfer Case
247
Checking the Oil Level
248
Changing the Oil
249
Changing the Oil Filter
253
Checking the Oil Level
255
Hydraulic System
255
Checking the Hydraulic Hoses
256
Checking the Ventilation Filters
256
Checking for Leaks
257
Cleaning the Magnetic Rods
258
Changing the Ventilation Filters
261
Taking Oil Samples
263
Changing the Hydraulic Oil Filter
265
Changing the Hydraulic Oil
269
Have the Radiator Checked/Cleaned
272
Greasing the Piston Rod of the Derricking Cylinder
277
Main Boom
277
Lubricating the Telescopic Sections
278
Checking the Locking System
282
Checking the Sheaves
282
Checking the Winding
283
Hoist Ropes
283
Checking the Hoist Ropes
284
Lubricating the Hoist Rope
285
Assessing the Condition of the Hoist Rope
286
Replacing the Hoist Rope
292
Setting the Lowering Limit Switch
295
Cable Drums and Slewing Angle Sensor
297
Maintenance of the Slip Ring Assemblies
298
Lubricating the Slewing Angle Sensor
299
Central Lubrication System
301
Checking the Filling Level
301
Checking the Sheaves
303
Hook Blocks
303
Lubricating
303
Checking the Lighting and Indicators
307
Electrical System
307
Air-Conditioning System
309
Checking Hoses
309
Checking the Air Conditioning System
309
Checking the Entire Air-Conditioning System
309
Checking the Windscreen Washing System
311
Other Maintenance Work
311
Checking the Functioning of the Auxiliary Heater
313
Lubricating the Crane Cab Door
314
Lubricating the Step
315
Lubricating the Connecting Pins and Socket Pins
316
Renewing the Corrosion Protection
317
Having the Fire Extinguisher Checked
319
Longer out of Service Periods
323
Torques
327
Spare Parts Required for Maintenance
331
General Information
331
Lighting
331
Spare Parts for the Carrier
335
Spare Parts for the Superstructure
338
Appendix
343
5
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Manitowoc GROVE GMK6400 Specifications
General
Brand
Manitowoc
Model
GROVE GMK6400
Category
Construction Equipment
Language
English
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