GMK2035E MAINTENANCE & REPAIR WORK

GENERAL INSTRUCTIONSAppropriate workshop equipmentSpecial toolsSpare parts approved by Manitowoc Crane Group Germany GmbH.Use

it is used for the purpose for which it was intendedcare and maintenance is carried out as prescribedrepair work/overhauling is carried out by professionalsPlease note that Manitowoc Crane Group Germany GmbH can only uphold warranty provided for the truck crane if the following conditions are met:

GENERAL MAINTENANCE INSTRUCTIONSClean 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 nipplesWhen changing the oil, let the oil run out at operating temperature Replace all filters within the specified period if cleaning is not explicitly permitted Replace all seals before assembly. Clean the sealing surfaces Only tighten loose screw connections on hydraulic and compressed air systems when the system is depressurised Keep brake and clutch linings free of grease Replace hydraulic hoses immediately once damage or penetration of moisture becomes visible When handling hydraulic oil, cleanliness is imperative. Even new hydraulic oil must be filtered

GENERAL MAINTENANCE INSTRUCTIONS- Continued -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 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 MANUALThis 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 RULESFamiliarise 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

CLEANINGIn 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 periodAfter 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 themNever point the nozzle at electrical equipment, relay and control boxes, suction and venting filters or control elements and lubricated surfacesRelubricate all slide faces after cleaning to prevent corrosionAfter cleaning with a high-pressure device or a steam jet device, activate intermediate lubrication on the central lubrication system

RUN-IN REGULATIONSSome parts (hoist, gearboxes etc.) are subject to special run-in regulationsafter the truck crane is put into operation for the first time orafter part replacement orafter a general inspection.This means that maintenance work must be carried out on the carrier and the superstructure at certain intervals:*1 oper. hr. corresponds to approx. 40 kilometres driven **Not required if there is a central lubrication system

RUN-IN REGULATIONS- Continued -*1 oper. hr. corresponds to approx. 40 kilometers drivenPlease note the instructions concerning run-in times/run-in regulations/oilchange intervals in the enclosed documents Engine manufacturers operatinginstructions and Engine manufacturers maintenance booklet.

Operating Hours (oper. hrs.)*Driven KMAdditional maintenance work on the SUPERSTRUCTUREafter 100Ball slewing bearing: Check tightness of retaining boltsafter 200Carry out the first oil change on thehoist gearafter 200Carry out the first oil change on the slewing gear transmissionafter 1000Carry out the second oil change on thehoist gear

RECOMMENDED LUBRICANTS

MAINTENANCE PLANSAs 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 M 1 monthly or approx. 2k KM or 100 operating hoursMaintenance plan W weekly Maintenance plan M 12 every 12 months or 20k-25k KM or 1000 hoursMaintenance plan M 6 every 6 months or 10k-12.5k KM or 500 hoursMaintenance plan Y 2 every 24 months or 40k-50k KMMaintenance plan M 3 every 3 months or 5k-6k KM or 300 hoursMaintenance plan Y 3 every 36 months or 300k KM or 3000 hoursMaintenance plan Y 4 every 48 months or 4000 hoursMaintenance plan Y 10 every 120 months or 12000 hoursMaintenance plan Y 6 every 72 months or 6000 hoursMaintenance plan Y 5 every 60 months or 5000 hours

MAINTENANCE PLAN D

MAINTENANCE PLAN D- Continued -

Maintenance work on the SUPERSTRUCTURE: daily/before putting into operationLubricantSlewing Gear - Slewing gear brake indicator lampHydraulic System- Check contamination display for hydraulic oil filterHoist Ropes - Checking for tyre damageHook Blocks- Checking the sheavesElectrical System- Checking the lighting & indicators

MAINTENANCE PLAN W

Maintenance work on the CARRIER: weeklyLubricantEngine - General inspectionTransmission - General inspectionTransfer Case - General inspectionAxle Line - General inspectionWheels - Checking the tyre pressuresCompresses Air System - Draining the compressed air system - Checking for leaksHydraulic System- Checking the hydraulic hoses - Check tightness (suspension & outriggers) while engine is runningCentral Lubrication - Central lubrication levelKOther Maintenance Work- Check the function of the windscreen washing system in the operators cab and the level of the fluid reservoir

MAINTENANCE PLAN W- Continued -

MAINTENANCE PLAN M1

Maintenance work on the CARRIER: monthly/after ca. 2 000 kmLubricantEngine - Observe specifications in the Engine Manufacturers Operating Instruction and in Engines Manufacturers Maintenance BookletTransfer Case - Checking the oil levelE3Axle Lines - Axles oil level checks - General inspection E3 E3Wheels - Check tightness of wheel nutsElectrical System - Batteries checking the acid levelTowbar Coupling- Lubricating the towbar couplingJ (2 litres)Air Conditioning System- Checking the moisture and level of the refrigerants - Cleaning the condenser finsRSoot Particle Filter - Checking the clamp straps - Check connecting cables for tight fitOther Maintenance Work- Checking the auxiliary heater for correct operation - Lubricating the supports

J

MAINTENANCE PLAN M1- Continued -

Maintenance work on the SUPERSTRUCTURE: monthly/after 100 oper. HrsLubricantCentral Lubrication - Central lubrication with grease distributorYOther Maintenance Work Lubricating the piston rod of the derricking cylinder - Checking the auxiliary heater for correct operationY

MAINTENANCE PLAN M3

Maintenance work on the CARRIER: every three months/after 5k 6k KMLubricantEngine - Observe specifications in the Engine Manufacturers Operating Instruction and in Engines Manufacturers Maintenance BookletFuel System - Fuel prefilter 1 replacing the filterE3Axle Lines - Lubricating the wheel suspensionKVehicle Brake- Check the brake liningsElectrical System - Batteries checking the acid concentrationTowbar Coupling- Checking the bearing - Checking the cotter pin - Checking the lower bushing - Checking the support ring - Checking the initial tension of springs - Checking the function of the coupling jaw/setting the middle positionJ (2 litres)

MAINTENANCE PLAN M3- Continued -

MAINTENANCE PLAN M6

MAINTENANCE PLAN M6- Continued -

MAINTENANCE PLAN M12

Maintenance work on the CARRIER: every twelve months/after 20k 25k KMLubricantEngine - Observe specifications in the Engine Manufacturers Operating Instruction and in Engines Manufacturers Maintenance BookletFuel System - Changing the fuel filterTransmission - Checking the oil levelF7Axle lines- Axles oil change - Final drives changing the oilE3 (12L) E3 (1.4 L each)Suspension - Pressure accumulator checking the gas pressureCompressed Air System - Replacing the granulate cartridgeHydraulic System - Changing the ventilation filter - Taking oil samples - Changing the hydraulic oil filterG2 (450 Litres)Air Conditioning System - Checking the entire air conditioning systemROther Maintenance Work - Lubricate the door hinges - Lubricate the connecting and socket pinsJJ/A

MAINTENANCE PLAN M12

MAINTENANCE PLAN Y2

MAINTENANCE PLAN Y3

Maintenance work on the CARRIER: every 36 months/after 360k KMLubricantTransmission - Changing the oilF7 (11 L)

Maintenance work on the SUPERSTRUCTURE: every 36 months/after 3k operating hoursLubricantHoist- Carrying out partial inspection of hoist gears

MAINTENANCE PLAN Y4

Maintenance work on the CARRIER: every 48 monthsLubricantNo maintenance work in this period.The long-term intervals always include the short-term intervals

Maintenance work on the SUPERSTRUCTURE: every 48 months/after 4k operating hoursLubricantMain Boom- Checking and lubricating ropes in the main boom

MAINTENANCE PLAN Y5

Maintenance work on the CARRIER: every 60 monthsLubricantNo maintenance work in this period.The long-term intervals always include the short-term intervals

Maintenance work on the SUPERSTRUCTURE: every 60 months/after 5k operating hoursLubricantSafe Load Indicator- Carrying out general inspection of hoist gears

MAINTENANCE PLAN Y6

Maintenance work on the CARRIER: every 72 monthsLubricantNo maintenance work in this period.The long-term intervals always include the short-term intervals

Maintenance work on the SUPERSTRUCTURE: every 72 months/after 6k operating hoursLubricantHoist- Carrying out general inspection of hoist gears

MAINTENANCE PLAN Y10

Maintenance work on the CARRIER: every 120 months/after 12k operating hoursLubricantSteel Construction- Check the load-bearing steel construction. (Contact CraneCARE for more information)

Maintenance work on the SUPERSTRUCTURE: every 120 months/after 12k operating hoursLubricantSteel Construction- Check the load-bearing steel construction. (Contact CraneCARE for more information)Main Boom- Replacing the ropes in the main boomSafe Load Indicator- Have the SLI checked by CraneCARE