Grove GMK5180 Index:

1 General instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 – 1
1.1 Using the Maintenance Manual . . . . . . . . . . . . . . . . . . . . . . . . . 1 – 1
1.2 Warnings and symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 – 1
1.3 Maintenance instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 – 2
1.4 Definition of direction information . . . . . . . . . . . . . . . . . . . . . . . . 1 – 4
2 Safety and environmental protection . . . . . . . . . . . . . . . 2 – 1
2.1 Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 – 1
2.2 Handling substances which are harmful to the environment . . . . . . . . . 2 – 2
3 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 1
3.1 Overview of the components that are easily damaged when cleaning . . . . 3 – 2
4 Run-in instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 1
5 Maintenance overview . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 1
5.1 Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 1
5.2 Maintenance plans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 3
5.2.1 Maintenance plan D: daily/before start-up . . . . . . . . . . . . . . . . . . . 5 – 5
5.2.2 Maintenance plan W: weekly . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 6
5.2.3 Maintenance plan M 1: monthly/after 100 Bh/approx. 2000 km . . . . . . . 5 – 8
5.2.4 Maintenance plan M 3: every three months/after 300 Bh/5000–6000 km . . 5 – 10
5.2.5 Maintenance plan M 6: every 6 months/after 500 Bh/10 000–12 500 km . . . 5 – 12
5.2.6 Maintenance plan M 12: every 12 months /after 1000 Bh/20 000–25 000 km . 5 – 14
5.2.7 Maintenance and inspection plan Y 3: every 36 months/after 3000 Bh . . . 5 – 16
5.2.8 Maintenance and inspection plan Y 6: every 72 months/after 6000 Bh . . . 5 – 17
5.3 Periodic inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 19
5.3.1 Load hook inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 20

5.4 Measures required for winch monitoring . . . . . . . . . . . . . . . . . . . . 5 – 21
5.4.1 Theoretical service life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 21
5.4.2 Proportion of the theoretical service life used . . . . . . . . . . . . . . . . . 5 – 22
Determining the operating conditions (collective load) . . . . . . . . . . 5 – 23
Determining the actual operating hours Ti . . . . . . . . . . . . . . . . . 5 – 24
Determining the proportion of the theoretical service life used . . . . . . 5 – 25
5.4.3 Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 26
Table example to determine the remaining theoretical service life
on winch no. 1 (main hoist winch) . . . . . . . . . . . . . . . . . . . . . 5 – 28
6 Lubricant and process materials . . . . . . . . . . . . . . . . . . 6 – 1
6.1 Lubrication chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 1
6.2 Process materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 3
6.2.1 Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 3
6.2.2 Engine coolant admixtures . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 3
6.2.3 Windscreen washing system admixtures . . . . . . . . . . . . . . . . . . . 6 – 3
6.2.4 Fuel for crane cab heating system . . . . . . . . . . . . . . . . . . . . . . . 6 – 3
7 Description of maintenance work on the carrier . . . . . . . 7 – 1
7.1 Vehicle engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 1
7.1.1 Oil level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 2
7.1.2 Adding engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 2
7.1.3 Installing oil drain valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 3
7.1.4 Checking the coolant level . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 4
7.1.5 Checking the dry air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 5
7.2 Checking the overall condition and checking for leakage . . . . . . . . . . . 7 – 6
7.2.1 Cleaning the fuel prefilter screen . . . . . . . . . . . . . . . . . . . . . . . . 7 – 7
Cleaning the fuel prefilter screen . . . . . . . . . . . . . . . . . . . . . . 7 – 7
Bleeding the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 7
7.2.2 Changing the fuel filter insert . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 8
Blocking and emptying the fuel pipe . . . . . . . . . . . . . . . . . . . . 7 – 8
Changing the fuel filter insert . . . . . . . . . . . . . . . . . . . . . . . . 7 – 9
After changing the filter insert . . . . . . . . . . . . . . . . . . . . . . . . 7 – 10
7.3 Automatic gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 11
7.3.1 Oil level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 11
7.3.2 Checking the overall condition and tightness . . . . . . . . . . . . . . . . . 7 – 14
7.3.3 Changing the oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 14
7.3.4 Changing the oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 16
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7.4 Transfer case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 19
7.4.1 Checking the overall condition and tightness . . . . . . . . . . . . . . . . . 7 – 19
7.4.2 Oil level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 19
7.4.3 Changing the oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 20
7.5 Axle lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 21
7.5.1 Checking the overall condition and tightness . . . . . . . . . . . . . . . . . 7 – 21
7.5.2 Axle centre drives – oil level check . . . . . . . . . . . . . . . . . . . . . . . 7 – 21
7.5.3 Axle centre drives – oil change . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 23
7.5.4 Final drives – oil level check . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 25
7.5.5 Final drives – oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 26
7.5.6 Lubricating the cardan shafts on the axle lines . . . . . . . . . . . . . . . . 7 – 27
Number and position of lubrication points . . . . . . . . . . . . . . . . . 7 – 27
Lubricating first axle line cardan shafts . . . . . . . . . . . . . . . . . . 7 – 28
Lubricating second, fourth and fifth axle line cardan shafts . . . . . . . . 7 – 28
7.5.7 Lubricating the longitudinal cardan shafts between the gear units . . . . . 7 – 29
Number and position of lubrication points . . . . . . . . . . . . . . . . . 7 – 29
Lubricating longitudinal cardan shafts . . . . . . . . . . . . . . . . . . . 7 – 30
7.5.8 Lubricating intermediate bearing of the longitudinal cardan shaft . . . . . 7 – 30
7.6 Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 31
7.6.1 Checking the tyres for damage . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 31
7.6.2 Checking the tyre air pressure . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 32
7.6.3 Checking the wheel-bearing clearance . . . . . . . . . . . . . . . . . . . . 7 – 32
7.7 Vehicle brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 33
7.7.1 Checking brake-lining thickness . . . . . . . . . . . . . . . . . . . . . . . . 7 – 33
7.8 Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 34
7.8.1 Checking the oil level in the suspension cylinders . . . . . . . . . . . . . . 7 – 34
7.8.2 Checking the tightness of retaining bolts on the suspension cylinders . . . 7 – 35
7.9 Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 37
7.9.1 Checking for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 37
7.10 Carrier compressed air system . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 39
7.10.1 Draining the compressed air system . . . . . . . . . . . . . . . . . . . . . . 7 – 39
7.10.2 Checking for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 39
7.10.3 Replacing the granulate cartridge of compressed air drier . . . . . . . . . . 7 – 40
7.11 Carrier hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 41
7.11.1 Checking the hydraulic oil level . . . . . . . . . . . . . . . . . . . . . . . . 7 – 41
7.11.2 Checking the hydraulic hoses . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 42
7.11.3 Checking for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 43
7.11.4 Changing the hydraulic oil filters and cleaning the magnetic rod . . . . . . 7 – 44
7.11.5 Replacing the venting filter . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 45

7.11.6 Taking oil samples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 46
Handling the drain valves . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 46
Taking oil samples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 47
7.11.7 Changing the hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 48
7.12 Central lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 51
7.12.1 Checking and topping up level in the grease container . . . . . . . . . . . . 7 – 51
Checking the level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 51
Filling the grease container . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 52
Bleeding the central lubrication system . . . . . . . . . . . . . . . . . . 7 – 54
7.13 Carrier electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 55
7.13.1 Checking the acid level of batteries . . . . . . . . . . . . . . . . . . . . . . 7 – 55
7.13.2 Checking the acid concentration of batteries . . . . . . . . . . . . . . . . . 7 – 56
7.14 Carrier air-conditioning system (additional equipment) . . . . . . . . . . . . 7 – 57
7.14.1 Checking moisture and level of the refrigerant . . . . . . . . . . . . . . . . 7 – 57
7.14.2 Cleaning capacitor cooling fins . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 58
7.14.3 Checking hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 58
7.14.4 Checking the refrigerant compressor . . . . . . . . . . . . . . . . . . . . . 7 – 59
7.14.5 Checking the entire air-conditioning system . . . . . . . . . . . . . . . . . 7 – 59
7.15 Trailer coupling (additional equipment) . . . . . . . . . . . . . . . . . . . . . 7 – 61
7.15.1 Lubricating the trailer coupling . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 61
7.15.2 Checking the bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 62
7.15.3 Checking the cotter pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 63
7.15.4 Checking the lower bushing . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 64
7.15.5 Checking the support ring . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 64
7.15.6 Checking the initial tension of the springs . . . . . . . . . . . . . . . . . . . 7 – 65
7.15.7 Checking the function of the coupling jaw/resetting central position . . . . 7 – 65
Checking function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 65
Resetting central position . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 66
7.16 Other maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 67
7.16.1 Lubricating the outrigger beams . . . . . . . . . . . . . . . . . . . . . . . . 7 – 67
7.16.2 Functional check of additional heating system (additional equipment) . . . 7 – 67
8 Description of maintenance work on the superstructure 8 – 1
8.1 Crane engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 – 1
8.1.1 Oil level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 – 1
Topping up engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 – 2
8.1.2 Checking the coolant level . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 – 3
8.1.3 Checking the dry air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 – 4
8.1.4 Checking the overall condition and checking for leakage . . . . . . . . . . 8 – 5
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8.1.5 Cleaning the fuel prefilter-screen . . . . . . . . . . . . . . . . . . . . . . . 8 – 6
Cleaning the prefilter screen . . . . . . . . . . . . . . . . . . . . . . . . 8 – 6
Bleeding the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . 8 – 6
8.1.6 Changing the fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 – 7
Blocking and emptying the fuel pipe . . . . . . . . . . . . . . . . . . . . 8 – 7
Changing the fuel filter insert . . . . . . . . . . . . . . . . . . . . . . . . 8 – 8
8.2 Hoists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 – 9
8.2.1 Checking the oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 – 9
8.2.2 Checking for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 – 10
8.2.3 Checking the hoist brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 – 10
8.2.4 Lubricating auxiliary hoist gearbox (additional equipment) . . . . . . . . . 8 – 11
8.2.5 Changing the oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 – 11
Oil change on hoist gear . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 – 12
Oil change on the brake unit . . . . . . . . . . . . . . . . . . . . . . . . 8 – 12
Checking the oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 – 13
8.2.6 Carrying out partial inspection of hoists . . . . . . . . . . . . . . . . . . . . 8 – 13
8.2.7 Carrying out general inspection of hoists . . . . . . . . . . . . . . . . . . . 8 – 14
8.3 Slewing gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 – 15
8.3.1 Checking the oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 – 15
8.3.2 Checking for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 – 15
8.3.3 Lubricating slewing gear pinion and gear rim . . . . . . . . . . . . . . . . . 8 – 16
8.3.4 Changing the oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 – 17
8.4 Superstructure hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . 8 – 19
8.4.1 Checking the hydraulic oil level . . . . . . . . . . . . . . . . . . . . . . . . 8 – 19
8.4.2 Checking the hydraulic hoses . . . . . . . . . . . . . . . . . . . . . . . . . 8 – 20
8.4.3 Checking for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 – 20
8.4.4 Bleeding the derricking cylinder . . . . . . . . . . . . . . . . . . . . . . . . 8 – 20
Preconditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 – 21
Bleeding the piston rod chamber . . . . . . . . . . . . . . . . . . . . . . 8 – 21
Bleeding the piston head area . . . . . . . . . . . . . . . . . . . . . . . . 8 – 22
8.4.5 Bleeding telescoping cylinders . . . . . . . . . . . . . . . . . . . . . . . . . 8 – 23
Preconditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 – 23
Bleeding procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 – 23
Location of the bleeder screws . . . . . . . . . . . . . . . . . . . . . . . 8 – 24
Telescoping status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 – 25
8.4.6 Changing the hydraulic oil filters and cleaning the magnetic rod . . . . . . 8 – 26
Return filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 – 27
Hydraulic oil filter for feed circuit and control circuit . . . . . . . . . . . 8 – 28
8.4.7 Replacing the venting filter . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 – 29
8.4.8 Taking oil samples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 – 30
8.4.9 Changing the hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 – 31
8.5 Main boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 – 35
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8.5.1 Lubricating the telescope slide faces . . . . . . . . . . . . . . . . . . . . . . 8 – 35
Position of lubricating nipples . . . . . . . . . . . . . . . . . . . . . . . . 8 – 36
Requirements: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 – 37
Lubricating slide faces of telescope sections . . . . . . . . . . . . . . . . 8 – 38
Lubricating telescope section V . . . . . . . . . . . . . . . . . . . . . . 8 – 38
Lubricating telescope sction IV . . . . . . . . . . . . . . . . . . . . . . . 8 – 38
Lubricating telescope section III . . . . . . . . . . . . . . . . . . . . . . 8 – 39
Lubricating telescope section II . . . . . . . . . . . . . . . . . . . . . . 8 – 40
Lubricating telescope section I . . . . . . . . . . . . . . . . . . . . . . . 8 – 40
8.6 Hoist ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 – 41
8.6.1 Check the position of sheaves and rope drums . . . . . . . . . . . . . . . . 8 – 41
8.6.2 Check the condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 – 42
Assessing the condition of the hoist rope . . . . . . . . . . . . . . . . . 8 – 43
Replacing the hoist rope . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 – 49
Setting the lowering limit switch . . . . . . . . . . . . . . . . . . . . . . 8 – 51
Lowering limit switch function control . . . . . . . . . . . . . . . . . . . 8 – 52
8.7 Safe load indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 – 53
8.7.1 Maintaining the slip ring assembly of the cable drums . . . . . . . . . . . . 8 – 53
Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 – 54
Maintaining slip ring assembly . . . . . . . . . . . . . . . . . . . . . . . 8 – 54
8.8 Central lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 – 56
8.9 Lattice extension (additional equipment) . . . . . . . . . . . . . . . . . . . . 8 – 57
8.9.1 Lubricating joint on 12.5 m section . . . . . . . . . . . . . . . . . . . . . . 8 – 57
8.9.2 Lubricate derricking cylinder in 12.5 m section . . . . . . . . . . . . . . . . 8 – 57
8.10 Hook blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 – 59
8.10.1 Lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 – 59
8.11 Superstructure electrical system . . . . . . . . . . . . . . . . . . . . . . . . 8 – 61
8.11.1 Check the acid level of batteries . . . . . . . . . . . . . . . . . . . . . . . . 8 – 61
8.11.2 Check the acid concentration of batteries . . . . . . . . . . . . . . . . . . . 8 – 61
8.12 Superstructure air-conditioning system (additional equipment) . . . . . . . . 8 – 63
8.12.1 Checking moisture and level of the refrigerant . . . . . . . . . . . . . . . . 8 – 63
8.12.2 Cleaning capacitor cooling fins . . . . . . . . . . . . . . . . . . . . . . . . . 8 – 64
8.12.3 Checking hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 – 64
8.12.4 Checking the refrigerant collector . . . . . . . . . . . . . . . . . . . . . . . 8 – 65
8.12.5 Checking the refrigerant compressor . . . . . . . . . . . . . . . . . . . . . 8 – 65
8.13 Other maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 – 67
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8.13.1 Functional check of the additional heating system (additional equipment) . 8 – 67
9 Longer inoperational periods . . . . . . . . . . . . . . . . . . . . . 9 – 1
Before the truck crane is put out of operation . . . . . . . . . . . . . . . 9 – 1
During inoperational periods . . . . . . . . . . . . . . . . . . . . . . . . 9 – 1
Before putting the truck crane back into operation . . . . . . . . . . . . 9 – 2
10 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 – 1
10.1 Tightening torques for retaining bolts . . . . . . . . . . . . . . . . . . . . . . 10 – 1
10.2 Special tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 – 2