Grove Crane GMK 5100 Maintenance Manual 2084543 – PDF DOWNLOAD

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Grove Crane GMK 5100 Maintenanc e Manual 2084543 – PDF DOWNLOAD

FILE DETAILS:

Grove Crane GMK 5100 Maintenance Manual 2084543 – PDF DOWNLOAD

Language : English
Pages : 200
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Grove Crane GMK 5100 Maintenance Manual 2084543 – PDF DOWNLOAD

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 repair crews (e.g. the local GROVE Product Support).
Repair work also requires:
– appropriate workshop equipment,
– special tools and
– replacement parts authorized by Deutsche GROVE GmbH.
It is your responsibility to maintain and service the truck crane regularly in
order to lengthen its service life and keep it in good working order.
Please note that Deutsche GROVE GmbH can only uphold the warranty
provided for the truck crane if the following conditions are met:
– proper use,
– prescribed care and maintenance,
– professional repair work/overhauling.

Numerous defects and failures are caused by improper maintenance
such as:
– lack of oil, grease or antifreeze,
– dirt,
– rope damage,
– defective compressed air and hydraulic systems,
– hose damage or loose screw connections,
– defective brakes,
– defective 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. Notify either your local GROVE Product Support or your repair crew immediately should repair work become necessary. 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 oil filler, inspection, and drain openings and lubricating
nipples.
· When changing the oil, let the oil run out at operating temperature.
· Ensure that only oils or lubricants specified in the Lubrication chart,
chapter 6 are used.
· 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 systems when the
system is depressurized.
· 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.
· Check fastening and retaining elements (screws, nuts, lock washers etc.)
before re-using them and replace them if necessary.

TABLE OF CONTENTS:

Grove Crane GMK 5100 Maintenance Manual 2084543 – PDF DOWNLOAD

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 hours of operation/approx 2,000 km 5 – 8
5 2 4 Maintenance plan M 3: every three months/after 300 hours of operation/5,000–6,000 km5
10
5 2 5 Maintenance plan M 6: every 6 months/after 500 hours of operation/10,000–12,500 km5 –
12
5 2 6 Maintenance plan M 12:
every 12 months /after 1000 hours of operation / 20,000–25,000 km 5 – 14
5 2 7 Maintenance and inspection plan Y 3:
every 36 months/after 3000 hours of operation 5 – 16
5 2 8 Maintenance and inspection plan Y 5:
every 60 months / after 100,000 – 125,000 km 5 – 17
5 2 9 Maintenance and inspection plan Y 6:
every 72 months/after 6000 hours of operation 5 – 18
5 3 Periodic inspections 5 – 19
10 01 2000
Maintenance Manual GMK 5100 2 084 543 en i – 3
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
5 4 3 Example 5 – 26
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 Checking the oil level 7 – 2
7 1 2 Topping up motor oil 7 – 3
7 1 3 Checking the coolant level 7 – 4
7 1 4 Checking the dry air filter 7 – 5
7 1 5 Checking the overall condition and checking for leakage 7 – 6
7 1 6 Cleaning the fuel prefilter screen 7 – 7
7 1 7 Changing the fuel filter cartridge 7 – 8
7 2 Gearbox 7 – 11
7 2 1 Checking general condition and for leaks 7 – 11
7 2 2 Oil level check 7 – 12
7 2 3 Changing the oil and oil filter 7 – 13
7 2 4 Checking the oil level of the hydraulic clutch operating mechanism 7 – 15
7 2 5 Changing the oil on the hydraulic clutch
operating mechanism 7 – 16
7 3 Transfer case 7 – 17
7 3 1 Checking the overall condition and tightness 7 – 17
7 3 2 Oil level check 7 – 17
7 3 3 Changing the oil 7 – 18
7 4 Axle lines 7 – 19
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i – 4 2 084 543 en Maintenance Manual GMK 5100
7 4 1 Checking the overall condition and tightness 7 – 19
7 4 2 Axle centre drives – oil level check 7 – 19
7 4 3 Axle centre drives – oil change 7 – 21
7 4 4 Final drives – oil level check 7 – 23
7 4 5 Final drives – oil change 7 – 24
7 4 6 Lubricating the cardan shafts on the axle lines 7 – 25
7 4 7 Lubricating the longitudinal cardan shafts between the gear units 7 – 27
7 5 Wheels 7 – 29
7 5 1 Checking the tyres for damage 7 – 29
7 5 2 Checking the tyre air pressure 7 – 30
7 5 3 Checking the wheel-bearing clearance 7 – 30
7 6 Vehicle brakes 7 – 31
7 6 1 Checking brake-lining thickness 7 – 31
7 7 Suspension 7 – 33
7 7 1 Checking the oil level in the suspension cylinders 7 – 33
7 7 2 Checking the tightness of retaining bolts on the suspension cylinders 7 – 34
7 8 Steering 7 – 35
7 8 1 Checking for leaks 7 – 35
7 9 Carrier compressed air system 7 – 37
7 9 1 Draining the compressed air system 7 – 37
7 9 2 Checking for leaks 7 – 37
7 9 3 Replacing the granulate cartridge of compressed
air drier 7 – 38
7 10 Carrier hydraulic system 7 – 39
7 10 1 Checking the hydraulic oil level 7 – 39
7 10 2 Checking the hydraulic hoses 7 – 40
7 10 3 Checking for leaks 7 – 41
7 10 4 Changing the hydraulic oil filters and cleaning the magnetic rod 7 – 42
7 10 5 Replacing the venting filter 7 – 43
7 10 6 Taking oil samples 7 – 44
7 10 7 Changing the hydraulic oil 7 – 46
7 11 Central lubrication system 7 – 49
7 11 1 Checking and topping up level in the grease container 7 – 49
7 12 Carrier electrical system 7 – 53
7 12 1 Checking the acid level of batteries 7 – 53
7 12 2 Checking the acid concentration of batteries 7 – 54
7 13 Carrier air-conditioning system (additional equipment) 7 – 55
10 01 2000
Maintenance Manual GMK 5100 2 084 543 en i – 5
7 13 1 Checking moisture and level of the refrigerant 7 – 55
7 13 2 Cleaning capacitor cooling fins 7 – 56
7 13 3 Checking hoses 7 – 56
7 13 4 Checking the refrigerant compressor 7 – 57
7 13 5 Checking the entire air-conditioning system 7 – 57
7 14 Trailer coupling (additional equipment) 7 – 59
7 14 1 Lubricating the trailer coupling 7 – 59
7 14 2 Checking the bearing 7 – 60
7 14 3 Checking the cotter pin 7 – 61
7 14 4 Checking the lower bushing 7 – 62
7 14 5 Checking the support ring 7 – 62
7 14 6 Checking the initial tension of the springs 7 – 63
7 14 7 Checking the function of the coupling jaw/resetting central position 7 – 63
7 15 Other maintenance work 7 – 65
7 15 1 Lubricating the outrigger beams 7 – 65
7 15 2 Functional check of additional heating system
(additional equipment) 7 – 65
8 Description of maintenance work on the superstructure 8 – 1
8 1 Crane engine 8 – 1
8 1 1 Checking the oil level 8 – 2
8 1 2 Checking the coolant level 8 – 4
8 1 3 Checking the dry air filter 8 – 5
8 1 4 Checking the overall condition and checking for leakage 8 – 6
8 1 5 Cleaning the fuel prefilter screen 8 – 7
8 1 6 Changing the fuel filter cartridge 8 – 9
8 2 Hoists 8 – 11
8 2 1 Checking the oil level 8 – 11
8 2 2 Checking for leaks 8 – 12
8 2 3 Checking the hoist brake 8 – 12
8 2 4 Lubricating auxiliary hoist gearbox 8 – 13
8 2 5 Changing the oil 8 – 13
8 2 6 Carrying out partial inspection of hoists 8 – 15
8 2 7 Carrying out general inspection of hoists 8 – 16
8 3 Slewing gear 8 – 17
8 3 1 Checking the oil level 8 – 17
8 3 2 Checking for leaks 8 – 18
8 3 3 Lubricating slewing gear pinion and gear rim 8 – 18
8 3 4 Changing the oil 8 – 19
8 3 5 Slewing gear brake function check 8 – 21
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8 4 Superstructure hydraulic system 8 – 23
8 4 1 Checking the hydraulic oil level 8 – 23
8 4 2 Checking the hydraulic hoses 8 – 24
8 4 3 Checking for leaks 8 – 24
8 4 4 Bleeding the derricking cylinder 8 – 24
8 4 5 Bleeding telescoping cylinders 8 – 27
8 4 6 Changing the hydraulic oil filters and cleaning the magnetic rod 8 – 30
8 4 7 Replacing the venting filter 8 – 33
8 4 8 Taking oil samples 8 – 34
8 4 9 Changing the hydraulic oil 8 – 35
8 5 Main boom 8 – 39
8 5 1 Lubricating the telescope slide faces 8 – 39
8 6 Hoist ropes 8 – 45
8 6 1 Check the position of sheaves and rope drums 8 – 45
8 6 2 Check the condition 8 – 46
8 7 Safe load indicator 8 – 57
8 7 1 Maintaining the slip ring assembly of the cable drums 8 – 57
8 8 Central lubrication system 8 – 60
8 9 Hook blocks 8 – 61
8 9 1 Lubricate 8 – 61
8 10 Superstructure electrical system 8 – 63
8 10 1 Check the acid level of batteries 8 – 63
8 10 2 Check the acid concentration of batteries 8 – 63
8 11 Superstructure air-conditioning system (additional equipment) 8 – 65
8 11 1 Checking moisture and level of the refrigerant 8 – 65
8 11 2 Cleaning capacitor cooling fins 8 – 66
8 11 3 Checking hoses 8 – 66
8 11 4 Checking the refrigerant collector 8 – 67
8 11 5 Checking the refrigerant compressor 8 – 67
8 12 Other maintenance work 8 – 69
8 12 1 Lubricating the counterweight hoist unit 8 – 69
8 12 2 Functional check of the additional heating system
(additional equipment) 8 – 69
10 01 2000
Maintenance Manual GMK 5100 2 084 543 en i – 7
9 Longer inoperational periods 9 – 1
10 Tightening torques 10 – 1
10 1 Tightening torques for retaining bolts 10 – 1
10 2 Special tightening torques 10 – 2
Appendix

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PLEASE NOTE:

• This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
• Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.

S.V