Maintenance Manual: Vehicle Serial Number

Maintenance Manual
Vehicle serial number:

2 084 543 en
10.01.2000
Important note
Duplications of any kind and excerpts from this

document are not subject to the alterations
service. Original documents of Deutsche GROVE
GmbH are marked with the blue serial number of
the truck crane on the cover page.
Duplications and print-outs of data carriers on

which Deutsche GROVE GmbH has delivered this
document are also not subject to the alterations
service.
©
Copyright reserved by leerleerleerleerleerleer
10.01.2000
The passing on or duplication of this document as well as the use and disclosure of its contents are
prohibited unless expressly permitted. Offenders will be liable for damages. All rights pertaining to registration
of patent or utility model are reserved.
Table of contents
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
every 60 months / after 100,000 - 125,000 km . . . . . . . . . . . . . . . . . . . . . . . . 5 - 17
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every 72 months/after 6000 hours of operation . . . . . . . . . . . . . . . . . . . . . . . 5 - 18
5.3 Periodic inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 19
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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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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
7.9.3 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
7.10.4 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
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7.12.2 Checking the acid concentration of batteries . . . . . . . . . . . . . . . . . 7 - 54
7.13 Carrier air-conditioning system (additional equipment) . . . . . . . . . . . . 7 - 55

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
8.2.3 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
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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

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
8.4.4 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
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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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General instructions
1.1 Using the Maintenance Manual
1 General instructions
1.1 Using the Maintenance Manual

This manual is not designed to replace proper training and instruction!
Truck crane maintenance personnel are required to have relevant specia-
lized knowledge of proper safety procedures!
Please read chapters 1 and 2 carefully before beginning maintenance
H
work.
Maintenance work on the lattice extensions is described in the operating

instructions for the extensions.
1.2 Warnings and symbols

The following definitions and symbols are used in the operating instruc-
tions to highlight particularly important information:
G
This symbol indicates hazards related to the described operation that
may cause personal injury. The type of hazard (e.g. mortal danger,
personal injury, risk of crushing or electrocution) generally precedes the
warning sign.
S
This symbol indicates hazards that may cause damage to objects e. g. to
the truck crane or the load.
O
This symbol is to remind you that you are working with substances which
pose a risk to the environment. Take particular care.
The measures required for the corresponding maintenance work are
indicated next to the symbol. You will find more detailed information in
the section Handling substances which are harmful to the environment, ➠ p. 2-2.
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The vertical line to the left of the text indicates that: This text regardless of
s
its length belongs to the warning symbol.
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1.3 Maintenance instructions
H The hand with the pointing finger indicates passages that contain
additional instructions and tips with regard to truck crane operation.
s
This symbol indicates that the topic is continued on the next page.
So turn to the next page!

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.
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1-2 2 084 543 en Maintenance Manual GMK 5100

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 ne-
cessary. 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 hydrau-
lic oil must be filtered.
• Check fastening and retaining elements (screws, nuts, lock washers etc.)
before re-using them and replace them if necessary.
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1.4 Definition of direction information
Tightening torques may be found in the sections 10.1 and 10.2.
Our training centre at our plant in D-26389 Wilhelmshaven offers

specialized training programmes. For more information, contact your
local GROVE Product Support.
The vehicle must fulfill all current regulations before commissioning and
use on public roads.
1.4 Definition of direction information

Some of the terms which are used to describe the location of components
are defined in this section.
On the carrier, the driver’s cab is always at the front. The terms rear, right
and left are used in relation to the definition of the term “front” on the
carrier.
On the superstructure front always refers to the direction of the main

boom head, regardless of the superstructure position. The terms rear,
right and left are used in relation to the definition of the term “front” on
the superstructure.
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Safety and environmental protection
2.1 Safety rules
2 Safety and environmental protection
2.1 Safety rules

When carrying out maintenance work, it is imperative that you observe
the applicable accident prevention regulation.
The following instructions are general safety rules for maintenance
personnel:
• Familiarize yourself with the truck crane and its operation.

Read the Operating Instructions carefully and have the crane operator
give you proper instruction.
• Do not carry out maintenance work unless you are authorized to do so.
• Observe all safety and warning signs on the truck crane.
• Observe all safety instructions contained in this Maintenance Manual.
• Familiarize yourself with the conditions under which the superstructure
may be slewed and the boom may be extended into horizontal position.
• 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 walking, use the extendable ladder which accompa-
nies the machine (e.g. when lubricating the telescope slide faces).
• Perform maintenance work only after the truck crane has been shut
down. Always ensure that the truck crane is protected from unauthori-
zed operation before beginning maintenance work. Remove the key and
put up warning signs.
10.01.2000
s
2.2 Handling substances which are harmful to the environment
If, as an exception, the truck crane needs to be put into operation for
certain types of maintenance work, great care must be taken where there
are moving parts (superstructure, outrigger, cardan shafts, swivelling
connections, motors, tiltable crane cabs, superstructure lock). There is a
risk of injury!
• Ensure that all hydraulic components are returned to their initial posi-
tions (e.g. the boom) or locked (e.g. the outrigger).
Escaping hydraulic fluid or compressed air can cause severe injury. Re-
member that hydraulic and compressed air systems of the truck crane are
pressurized even when the crane is not in operation. Only tighten loose
screw connections when the system is in depressurized condition. Always
depressurize the hydraulic and compressed air systems before opening
them.
• Do not allow hot materials to escape unchecked! Risk of scalding!

• Observe the applicable safety regulations when working with inflam-
mable fluids.
• Observe the applicable safety regulations when working with process
materials.
• Disconnect the earthing terminal and switch off all electrical consumers
before removing any batteries.
• Keep the corroding effect of battery acid in mind.
• Note the fire alarm and fire fighting facilities on the site.
• Return the truck crane to proper working order once maintenance work
is completed. Inform the crane operator accordingly.
2.2 Handling substances which are harmful to the

environment
What do When you carry out maintenance work on the truck crane you will occa-
environmentally si-onally work with substances which are considered to be harmful to the
harmful environment according to the current national and local regulations.
substances This includes, among others, oil, fuel, grease, used oil and fuel filters as
include? well as cloths which have come into contact with these environmentally
harmful substances.
• When handling these substances observe the current national and

regional regulations as well as the instructions in this chapter.
10.01.2000

Use suitable Substances harmful to the environment can be aggressive. Therefore only
equipment use containers, hoses, pumps, funnels etc. which are resistant to the
respective substance.
Filling and • When filling and draining, make absolutely sure that no substances
draining harmful to the environment seep into the earth, escape into the sewage
system or polute natural waters.
• Collect draining oil in a suitable container.
• Always use a drain hose when draining, a funnel or a filling pump and
hose suitable for the respective substance when filling.
Collect and store Substances which are environmentally harmful should always be
separately collected separately from other waste.
• Collect environmentally harmful substances and separate solid matters

(e. g. elements) and fluids. Disposal costs will be reduced if you collect
liquids separately according to certain categories.
• Ask your local environmental protection authority about the different
categories for the substances.
• Only store environmentally harmful substances in approved containers
and in locations which meet the regulations according to the current
national and regional regulations.
Removal • Ask your local environmental protection authority about the prescribed
disposal possibilities.
Only have collected environmentally harmful substances disposed of by
disposal companies which are approved by the national or regional
authority responsible.
10.01.2000

Blank page
10.01.2000

Cleaning
3 Cleaning
The paint on the truck crane will continue to harden for the first three
months.
• During this period the truck crane may only be cleaned with water.
• Do not use high-pressure or steam-jet cleaning equipment during this
period.
• Avoid water temperatures over 60 °C, even after the first three months.
• Do not use caustic cleansers that might corrode the paint.
• Never hold the spray nozzle of your cleaning unit perpendicular to the
surface you are cleaning and ensure that you are standing at a sufficient
distance away from the surface you are cleaning.
G
Risk of accidents from misdirected high pressure water jet!
When working with high-pressure and steam jet cleaners, the water jet
will be deflected by crane parts and could spray into your face and eyes
at great speed and high pressure.
Always wear a face guard when cleaning the truck crane with high-
pressure and steam-jet cleaning equipment.
• Never point the nozzle at electrical equipment, relay and control boxes,
suction and venting filters or control elements and lubricated surfaces.
The components specified in section 3.1 are to be cleaned

with particular care.
10.01.2000

Cleaning
3.1 Overview of the components that are easily damaged when cleaning
3.1 Overview of the components that are easily damaged

when cleaning
On the truck crane
1 Control box pressure sensors 6 Telescope slide faces

2 Air conditioner capacitor for 7 SLI unit of length measurement
carrier/superstructure
(additional equipment)
3 Suspension struts (on both 8 Angle sensor control box
sides of the truck crane)
4 SLI terminal box 9 Pressure sensors
5 Lifting limit switch and anchor-
to-bracket switch
10.01.2000

Run-in instructions
4 Run-in instructions
Special run-in instructions must be observed for individual components
(hoist, gearbox, etc.)
– after initial start-up or
– after a part replacement or
– after a general inspection
i. e. additional maintenance work must be carried out on the carrier and
the superstructure in certain intervals.
Operating km Additional maintenance work on CARRIER

hours (Bh) travelled
After 50 Tighten wheel nuts
(for tightening torque ➠ p. 10-2)
After 150 Tighten wheel nuts

(tightening torque ➠ p. 10-2)
After 20; 1) Carry out first oil change for transfer case;
➠ Oil change, p. 7-18.
After 50 Tighten clamps on all coolant hoses
(tightening torque 6.5 Nm).
During the Check the hydraulic oil filters weekly;

first 100
➠ Changing hydraulic oil filter, cleaning
magnetic bar, p. 7-42.
1)
1 hour of operation correspond to approx. 40 km driven.
Please note the instructions concerning running-in times / running-in regu-

lations / oil change intervals in the enclosed crane engine operating manu-
al and in the maintenance booklet.
10.01.2000
s
Run-in instructions
Operating km Additional maintentance work on

hours (Bh) travelled SUPERSTRUCTURE
After 50 Tighten hose clamps on all coolant hoses
(tightening torque 6.5 Nm).
During the Check the hydraulic oil filters weekly;

first 100
➠ Changing hydraulic oil filter, cleaning
magnetic bar, p. 8-30.
After 100 Check tightness of retaining bolts;

Tightening torque; ➠ Special tightening
torques, p. 10-2.
After 200 Carry out first oil change on hoist gear

(auxiliary hoist additional equipment only);
After 200 Carry out first oil change on slewing gears;
After 1,0001) Carry out second oil change on hoist gears
(auxiliary hoist only with additional
equipment);
Please note the instructions concerning running-in times / running-in regu-
lations / oil change intervals in the enclosed crane engine operating manu-
al and in the maintenance booklet.
1)
after 1000 operating hours or every 12 months.
10.01.2000

Maintenance overview
5.1 Maintenance intervals
5 Maintenance overview
In this chapter, all periodic maintenance work is described in maintenance
plans as:
– maintenance plans D (= daily),
– maintenance plans W (= weekly) and
– maintenance plans M 1 (= every month)
up to M 12 (= every 12 months) and
– maintenance plans Y 3 (= every 36 months)
up to Y 6 (= every 72 months).
The maintenance plans are represented in table form, differentiated by

– maintenance work on the carrier and
– maintenance work on the superstructure.
In the tables you are directed by cross references to the sections in which
the appropriate maintenance work is described. The cross references consist
of the section number and the corresponding page number, e.g.
Checking hydraulic oil level; ➠ p. 7-39.
Checking the hydraulic oil level is described in Chapter 7, the section

starts on page 39.

The length of the interval depends on the operating conditions of the
truck crane:
The next maintenance check must be carried out after
– a specified time (maintenance deadline) or
– a specified number of km travelled for carrier components with driving
functions
– a specified number of operating hours (hours of operation) for super-
structure (and carrier) components with crane functions
10.01.2000
s
The first maintenance interval shall determine when maintenance work is

next due.
The km travelled may be taken from the trip recorder in the driver’s cab
(front instrument panel).
You can individually call up the operating hours (hours of operation) of
the superstructure’s power units on the crane control display in the crane
operator’s cab (front instrument panel). The operating hours of the crane
engine are simultaneously the total working hours of the superstructure.
The following table sets out the maintenance intervals for the
maintenance plans:
Main- Maintenance km travelled Operating hours

tenance interval (carrier) (hours of
plans operation) crane
engine
(superstructure)
D daily/before — —
start-up
W weekly — —
M1 monthly approx. 2,000 100
M3 every 3 months 5,000–6,000 300
M6 every 6 months 10,000–12,500 500
M 12 every 12 months 20,000–25,000 1000
Y3 every 36 months — 3000
Y5 every 60 months 100,000 - 125,000 —
Y6 every 72 months — 6000
Please note that the long-term maintenance plans always include the
short-term ones!
10.01.2000

5.2 Maintenance plans

The descriptions of specific maintenance work in the maintenance plans
D, W and M 1 to M 12 and Y 3 to Y 6 are contained
– in chapter 7 for the carrier and
– in chapter 8 for the superstructure.
Cross-references for the descriptions of these maintenance tasks may be

found after the respective maintenance tasks for the carrier and the super-
structure (section number in brackets).
For the purpose of clarity, the section titles

– of chapter 7 Description of the maintenance work on the carrier and
– of chapter 8 Description of maintenance work on the superstructure
H
contain the abbreviated forms (D to Y 6) of the relevant maintenance plan.
The description of some daily (D) and weekly (W) checks (preventive
maintenance) can also be found in part in the Operating Instructions.
In addition to the maintenance work on the carrier and the maintenance

work on the superstructure, the maintenance plans also contain:
– the amounts as approximate values for oil amounts (the exact oil amounts
are always determined by the oil level openings, the dipsticks or the oil
level indicators!)
or
the number of existing lubricating points.
– the descriptions of the oils/lubricants in accordance with the Lubrication
H
chart, chapter 6.
Please note that this Maintenance Manual contains only some of the main-
tenance tasks on the diesel engine that go beyond the daily and weekly
checks. These tasks are to be performed in accordance with the enclosed
Mercedes-Benz operating manuals and maintenance booklets!
The Mercedes-Benz operating manuals describe how to carry out these
maintenance tasks and the maintenance booklets specify the relevant
maintenance intervals.
10.01.2000

Blank page
10.01.2000

5.2.1 Maintenance plan D: daily/before start-up
D
Oil/lubricant
Maintenance work on the CARRIER
Quantity (l)/ Designation
number
➠ p. 6-1
Vehicle engine
– Checking the oil level; ➠ p. 7-2. A
– Checking coolant level; ➠ p. 7-4.
– Checking the dry air filter; ➠ p. 7-5.
Wheels
– Checking tyres for damage and sufficient tread depth;
➠ p. 7-29.
Carrier hydraulic system
– Checking hydraulic oil level; ➠ p. 7-39. G2
– Check contamination display for hydraulic oil filter;
➠ S. 7-42.
Carrier electrical system
– Checking lighting and indicators
D
Oil/lubricant
SUPERSTRUCTURE maintenance work
number
➠ p. 6-1
Crane engine
– Check the oil level; ➠ p. 8-2. A
– Check the coolant level; ➠ p. 8-4.
– Check the dry air filter; ➠ p. 8-5.
Slewing gear
– Slewing gear brake funktion check; ➠ p. 8-20.
Superstructure hydraulic system
– Check the hydraulic oil level; ➠ p. 8-23. G2
– Check contamination display of hydraulic oil filter; ➠ p. 8-30.
Hoist ropes
– Check the overall condition and position of sheaves and rope
drums; ➠ p. 8-45.
10.01.2000

5.2.2 Maintenance plan W: weekly
W
Oil/lubricant
Maintenance work on the CARRIER
number
➠ p. 6-1
Vehicle engine
– Check the overall condition and check for leakage; ➠ p. 7-6.
Gearbox
Transfer case
Axle lines
– Check the overall condition and check for leakage; ➠p. 7-19.
Wheels
– Check the tyre pressure; ➠ p. 7-30.
Steering
– Check for leaks; ➠ p. 7-35.
Carrier compressed air system (incl. brake system)
– Drain the compressed air system; ➠ p. 7-37.
– Check the hydraulic hoses; ➠ p. 7-40.
– Check tightness (suspension, steering and outrigger systems)
while engine is running; ➠ p. 7-41.
Carrier central lubrication system
– Check the level of the grease container; ➠ p. 7-49. K
Other maintenance checks

– Check the function of the windscreen washing system of the
operator’s cab and the level of fluid in the supply reservoir.
10.01.2000

W
Oil/lubricant
Maintenance work on the SUPERSTRUCTURE
Quantity (I)/ Designation
number
➠ p. 6-1
Crane engine
– Check the overall condition and check for leakage;
➠ p. 8-6.
Main hoist/Auxiliary hoist (additional equipment)
– Checking the oil level; ➠ p. 8-11.
E6
in the gearbox
G5
in the clutch housing
– Check the hoist brake; ➠ p. 8-12.
– Lubricate hoist gear; ➠ p. 8-13. 1 K
Slewing gear
– Check the oil level;➠ p. 8-17. E6
– Check the hydraulic hoses; ➠ p. 8-23.
– Check for leaks with the engine running; ➠ p. 8-24.
Central lubrication system on superstructure
– Check the level of the grease container; ➠ p. 8-60. K
Hoist ropes
– Check the condition; ➠ p. 8-46.
Other maintenance checks
– Check the function of the windscreen washing system of the
crane operator’s cab and the level of fluid in the supply
reservoir.
10.01.2000

5.2.3 Maintenance plan M 1: monthly/after 100 hours of operation/-

approx. 2,000 km
M1
Oil/lubricant
Maintenance work on the CARRIER:
monthly/after approx. 2000 km Quantity (l)/ Designation
number
➠ p. 6-1
Vehicle engine
– Pay attention to the details in the operating instructions and main-
tenance manual for the vehicle engine. Special notes for the
maintenance group and for rapeseed oil operation; ➠ p. 7-1.
Transfer case
– Check the oil level; ➠ p. 7-17. E3
Axle lines
Axle centre drive – check oil level; ➠ p. 7-19. E3
Final drive – check oil level; ➠ p. 7-23. E3
– Lubricate the cardan shafts in the axle lines; ➠ p. 7-25. 12 K
with additional equipment with 10 x 8 drive 16 K
Wheels
– Check that wheel nuts are secure; ➠ p. 7-34.
For tightening torque see section; ➠ Special tightening torques
p. 10-2.
Suspension
Check oil level in the suspension cylinders; ➠ p. 7-33. H
– Check that retaining bolts of the suspension cylinders are tight,
for tightening torques; ➠ Special tightening torques p. 10-2.
– Check the acid level of batteries; ➠ p. 7-53.
Trailer coupling (additional equipment)
– Lubricate trailer coupling 2); ➠ p. 7-59. 2 J
Carrier air-conditioning system
– Checking moisture and level of the refrigerant; ➠ p. 7-55.
– Cleaning capacitor cooling fins; ➠ p. 7-56.
Other maintenance work
Functional check of the additional heating system (additional
equipment); ➠ p. 7-65.
– Grease outrigger beam1); ➠ p. 7-65. 8 J
– Lubricate door hinges. 4 J
10.01.2000
1)
– Lubricate retaining and socket pins. several J/M
1)
after 100 hours of operation 2) Lubricate the trailer coupling after every high pressure cleaning

M1
Oil/lubricant
Maintenance work on the SUPERSTRUCTURE:
monthly / after 100 hours of operation Quantity (l)/ Designation
number
➠ p. 6-1
Crane engine
– Pay attention to the details in the operating instructions and
maintenance manual for the crane engine.
Special notes for the maintenance group and for rapeseed oil
operation; ➠ p. 8-1.
Hook blocks
– Lubricate; ➠ p. 8-61. several J
Superstructure electrical system
– Check the acid level of batteries; ➠ p. 8-63.
– Ventilate the telescoping cylinders; ➠ p. 8-27.
– Ventilating the derricking cylinder; ➠ p. 8-24.
Superstructure air-conditioning system (additional equipment)
– Checking moisture and level of the refrigerant; ➠ p. 8-65.
– Cleaning capacitor cooling fins; ➠ p. 8-66.
Other maintenance work

– Lubricating the counterweight hoist unit; ➠ p. 8-69. 2 J
– Functional check of the additional heating system (additional
equipment); ➠ p. 8-69.
– Lubricate tread rollers of cab door. 3 M
– Lubricate connecting and socket pins div. Y/M
– Lubricate spring latch div. Y/M
– Lubricate safety hooks on 4,4 t base plate. 1 J
10.01.2000

5.2.4 Maintenance plan M 3: every three months/after 300 hours of

operation/5,000–6,000 km
M3
Oil/lubricant
every 3 months / after 5,000–6,000 km Quantity ( l)/ Designation
number
➠ p. 6-1
Vehicle engine
maintenance manual for the vehicle engine.
– Clean the fuel prefilter-screen; ➠ p. 7-7.
Wheels
– Check the wheel-bearing clearance; ➠ p. 7-30.
Vehicle brakes
– Check brake-lining thickness; ➠ p. 7-31.

– Change the hydraulic oil filter, check the magnetic rods of the
hydraulic oil filter for metal particles;1) ➠ p. 7-42.
– Check the acid concentration of batteries; ➠ p. 7-54.
Trailer coupling (additional equipment)

– Checking the bearing; ➠ p. 7-60.
– Checking the cotter pin; ➠ p. 7-61.
– Checking the lower bushing; ➠ p. 7-62.
– Checking the initial tension of the springs; ➠ p. 7-63.
– Check function of coupling jaw/reset central position;
➠ p. 7-63.
– Checking the support ring; ➠ p. 7-62.
1)
after 300 hours of operation
10.01.2000
5 - 10 2 084 543 en Maintenance Manual GMK 5100

M3
Oil/lubricant
every 3 months / after 300 hours of operation Quantity (l)/ Designation
number
➠ p. 6-1
Crane engine
– Clean the fuel prefilter-screen; ➠ p. 8-7.

– Change the hydraulic oil filter, check the magnetic rods of the
hydraulic oil filter for metal particles;1) ➠ p. 8-30.
Superstructure electrical system
– Check the acid concentration of batteries; ➠ p. 8-63.
Ball bearing slewing
– Check tightness of retaining bolts;
Tightening torque; ➠ Special tightening torques, p. 10-2.
1)
10.01.2000
Maintenance Manual GMK 5100 2 084 543 en 5 - 11

5.2.5 Maintenance plan M 6: every 6 months/after 500 hours of ope-

ration/10,000–12,500 km
M6
Oil/lubricant
every 6 months / after 10,000 - 12,500 km Quantity (l)/ Designation
Number
➠ p. 6-1
Vehicle engine
Transfer case
– Changing the oil; ➠ p. 7-18. 19.0 E3
Axle lines
– Lubricating the longitudinal cardan shafts between the gear
units.
for 10 x 6 drive; ➠ p. 7-27. 8 K
for 10 x 8 drive (additional equipment); ➠ p. 7-27. 10 K
Steering
– Check the tightness of screw connections and that the cotter
pin has been fitted.
– Check all track rods and drag links for play.
– Check rubber sleeves for damage.
Carrier air-conditioning system (additional equipment)

– Checking hoses; ➠ p. 7-56.
– Checking the refrigerant compressor; ➠ p. 7-57.
10.01.2000

M6
Oil/lubricant
number
➠ p. 6-1
Crane engine
Slewing gear
– Lubricate the slewing gear pinion; ➠ p. 8-18. 1 each V
Ball bearing slewing
– Lubricate the gear rim; ➠ p. 8-18. 1 V
Main boom
– Lubricate telescopic slide faces; ➠ p. 8-39. 16 L2
Superstructure air-conditioning system
– Checking hoses; ➠ p. 8-66.
– Checking refrigerant collector; ➠ p. 8-67.
– Checking refrigerant compressor; ➠ p. 8-67.
SLI
– Maintain the slip ring assembly in the cable drums; ➠ p. 8-57. X
10.01.2000

5.2.6 Maintenance plan M 12:

every 12 months /after 1000 hours of operation /
20,000–25,000 km
M 12
Maintenance work on the CARRIER: Oil/lubricant
every 12 months / after 20,000 - 25,000 km Quantity (l)/ Designation
Number
➠ p. 6-1
Vehicle engine
– Replacing the fuel filter elements; ➠ p. 7-8.
Gearbox
– Checking the oil level; ➠ p. 7-13. F4
Hydraulic clutch operating mechanism
– Checking the oil level; ➠ p. 7-15. G6
Axle lines
– Centre axle drive oil change; ➠ p. 7-21.
2nd axle line (only with additional equipment on 10 x 8 drive) 13.0 E3
4th axle line 16.5 E3
5th axle line 13.0 E3
– Final drive oil change; ➠ p. 7-24. 4.1 ea. E3
Carrier compressed air equipment
– Replacing the granulate cartridge of the compressed air dryer;
➠ p. 7-38.
– Have suspension system pressure accumulators checked by
the local GROVE Product Support or by an authorized work-
shop.1)
– Replacing the vent filter for the hydraulic oil tank2);
➠ p. 7-43.
– Oil change1); ➠ pag. 7-46, (depending on the resullts of the 200,0 G2
oil sample examination), ➠ S. 7-44).
Carrier air-conditioning system
– Monitoring the entire air conditioning system; ➠ p. 7-57.
1)
10.01.2000
every 3000 hours of operation, however at the latest every 12 months

2)

M 12
Oil/lubricant
number
➠ p. 6-1
Crane engine
– Replacing fuel filter cartridges; ➠ p. 8-9.
Main hoist / auxiliary hoist (additional equipment)
– Oil change1); ➠ p. 8-13
in the gear box 7.0 E3
in the clutch housing 3.0 G5
Checking the old oil; ➠ p. 8-13
Slewing gear
– Changing the oil; ➠ p. 8-19. 0.9 each E6
– Changing the venting filter of the hydraulic oil tank2)
➠ p. 8-33.
– Oil change2); ➠ p. 8-35, (depending on the test results of the 1 200 G2
oil sample, ➠ p. 8-34).
1)
Carry out at least once per year
2)
Operation under difficult operating conditions:
– In extremely sandy or dusty areas, the ventilation filters should be changed early
– as necessary.
– The oil is to be changed every 500 operating hours for crane operation with frequent
– loading and unloading.
– Oil change intervals are to be halved if the crane is used in tropical or very warm climates.
10.01.2000


every 36 months/after 3000 hours of operation
Y3
Oil/lubricant
CARRIER maintenance work:
every 36 months Quantity (l)/ Designation
number
➠ p. 6-1
No maintenance work in this period.
The long-term intervals always include the short-term intervals!
Y3
Oil/lubricant
SUPERSTRUCTURE maintenance work:
number
➠ p. 6-1
– Carry out partial inspection; ➠ p. 8-15.
10.01.2000


every 60 months / after 100,000 - 125,000 km
Y5
Oil/lubricant
Number
➠ p. 6-1
Gearbox
– Changing the oil and oil filter; ➠ p. 7-13. 55.0 F4
Hydraulic clutch operating mechanism
– Changing the oil; ➠ p. 7-16. 3.0 G6
Y5
Oil/lubricant
Number
➠ p. 6-1
10.01.2000


every 72 months/after 6000 hours of operation
Y6
Oil/lubricant
CARRIER maintenance work:
number
➠ p. 6-1
Y6
Oil/lubricant
SUPERSTRUCTURE maintenance work:
number
➠ p. 6-1
– Carry out general inspection; ➠ p. 8-16.
➠ p. 5-21.
10.01.2000

5.3 Periodic inspections

Your GMK 5100 truck crane has been inspected before delivery.
– Cranes that are to be used in Germany are inspected in accordance with

the regulations of the professional trade association as defined by VBG 9.
– Cranes that are to be used abroad are inspected in accordance with the
regulations of the respective country. If such regulations do not exist,
they are inspected in accordance with the regulations of the professio-
nal trade association as defined by VBG 9.
According to VBG, one periodic inspection must be carried out annually.

The regulations in other countries may prescribe different inspection inter-
vals. If such regulations do not exist, an inspection should be carried out
by an expert at least once a year.
These periodic inspections are generally visual inspections intended to

assess the condition of the truck crane and its components. Their purpose
is to detect defects at an early stage and thus prevent accidents.
Inspections are to be carried out on the following components, where

these are not already contained in the list of routine maintenance tasks:
– the hydraulic and electrical control and safety devices,
– the safe load indicator (SLI),
– securing and safety devices of all bolted components,
– the hoist ropes,
– the load hooks (➠ section Load hook inspection, p. 5-20).
The inspector is to write a record containing the result of the annual
inspection and the measures taken to repair any damage.
10.01.2000

5.3.1 Load hook inspection
The mouth of the load hook must be checked regularly for deformation.
The mouth of the hook may not be expanded by more than 10 .% of the
original dimension y, y1, y2.
The original dimensions y, y1, y2 are held

in field (2) on the load hooks.
• To check, measure the distance between

the marked measuring points (1) on the
shaft of the load hook and the tip of the
hook (3).
The hook block may no longer be used if the
mouth has expanded by over 10 % of the
initial dimension.
The load hook must consequently be

replaced.
G
Accidents may occur if the load is allowed to drop!
Hook blocks with deformed load hooks are no longer operationally safe!
The load hooks could break and drop the load.
Deformed load hooks must always be replaced!
10.01.2000

5.4 Measures required for winch monitoring
H
See also the information on general inspection of hoists; ➠ p. 8-16.
Measures required for winch monitoring (hoists) were drawn up by the

VDMA and apply to all vehicle cranes in accordance with the Accident
prevention regulations for winches, hoists and towing devices VBG 8.
5.4.1 Theoretical service life
The theoretical service life is the result of certain operating conditions and
a theoretical operating time assumed by the design engineer when calcu-
lating and dimensioning the winches of your crane.
The winches of your crane are classified as follows (ISO 4301/1, FEM 1.001,
DIN calculation rules for power units):
Power unit group: M ......

Load spectrum: Q ...... ; L ....
Load spectrum factor: Km =......
H
Theoretical service life: D = ......
The power unit group M 3 and the load spectrum L 1 (Km = 0.125) are
generally given for truck cranes in installation mode, resulting in a
theoretical service life of 3200 h.
S
The theoretical service life is not the same as the real (actual) service life
of a winch!
10.01.2000
s
The real service life of a winch is affected by a number of additional exter-

nal factors, such as:
1. Overloading caused by improper use of the crane.
2. Inadequate maintenance: Oil is not changed at the
specified intervals.
3. Improper operation: Extreme acceleration or
deceleration of the load,
load drops and stops suddenly while
suspended.
4. Improper maintenance: Use of incorrect oil,
incorrect filling quantity,
contamination during oil change.
5. Improper assembly during maintenance and repair work.
6. Leaks which were ignored.
7. Improper adjustment of safety devices.
8. Concealed damage caused by accidents.
9. Extreme environmental conditions: extreme temperatures,
aggressive atmosphere,
dust and dirt.
5.4.2 Proportion of the theoretical service life used
The crane operator is obliged to perform a crane inspection at least once

a year (ISO 9927-1 and VBG 8).
This includes establishing the proportion of the theoretical service life that
has been used. If required, the crane operator is to appoint an expert for
this assessment.
The actual operating conditions (load spectrum) and the operating hours
of the hoists are to be determined for each inspection interval when
establishing the proportion of the theoretical service life that has been
used. The operator is responsible for proper documentation in the crane
logbook.
10.01.2000

Determining The collective load of the crane is divided into groups:

the operating (also refer to ISO 4301/1, FEM 1.001)
conditions
(collective load)
Collective Definition Proportion of operating time Collective Graphic representation
load class load factor
Km =
Power units or parts thereof 10.% of the operating time

Load %
that are rarely subject to with highest load (dead load
maximum load, but are + 1/1 payload)
Light constantly subject to minimal
Q1 loads 40.% of the operating time 0.125
L1 with dead load + 1/3 payload
50.% of the operating time Operating time %

with dead load only
Power units or parts thereof 1/6 of the operating time

Load %
that are fairly often subject with highest load (dead load
to maximum load, but + 1/1 payload)
continuously subject to
minimal loads 1/6 of the operating time with
Medium
dead load + 2/3 payload
Q2 0.25
L2
1/6 of the operating time with Operating time %
dead load + 1/3 payload
50.% of the operating time

with dead load only
Power units or parts therof 50 % of the operating time

Load %
that are often subject to with highest load (dead load
maximum load and + 1/1 payload)
Heavy continuously subject
Q3 to medium loads 50.% of the operating time 0.5
L3 with dead load only
Operating time %
Power units or parts thereof 90.% of the operating time

Load %
that are regularly subject to with highest load (dead load
loads close to maximum load + 1/1 payload)
Very heavy
Q4 10.% of the operating time 1
L4 with dead load only
Operating time %
One of the load spectrums listed above is to be selected on the basis of

the actual operating conditions and entered in the crane logbook for the
10.01.2000
respective inspection interval.
Note for truck cranes:

The load spectrum L 1 and the load spectrum factor Km = 0.125 are
generally applied to truck cranes in installation mode.

Determining the The effective operating hours, determined as follows, must be entered
actual operating into the crane log book for the corresponding inspection interval.
hours Ti
The following two of four possible cases apply to GROVE truck cranes:
Operating hour counter for separate crane operation

Operating hour counter for crane and driving mode together
Operating hour counter is functional for entire period of crane operation:
H
– The proportion of winch operating hours in relation to the total
superstructure operating hours must be estimated.
It can generally be assumed for hoist winches that the percentage of

winch operating hours in relation to the superstructure operating hours
will be 20.% for truck cranes in installation mode.
– The effective working hours Ti of the wind of the winch can be called up
separately and are shown on a display (➠ Operating instructions, chapter
Crane operation, section Crane work with main boom).
Operating hour counter is functional for driving and crane operation.

The proportion of winch operating hours in relation to the total crane
H
operating hours is to be estimated.
It can generally be assumed that the percentage of superstructure opera-

ting hours in relation to the crane operating hours will be 60.% for truck
cranes in installation mode. If the percentage of hoist winch operating
hours is assumed to be 20.% in relation to superstructure operating hours
(➠ Operating hour counter is functional for entire period of crane operation), the
percentage in relation to the total operating hours of the crane will be: 12 %.
10.01.2000

Determining the For an inspection interval i (max. 1 year according to ISO 9927-1 or VBG 8),
proportion of the the proportion of the theoretical service life used Si is calculated using the
theoretical formula:
service life used
Km i
Si = x Ti
Km
Km = Load spectrum factor established during winch calculation.
This factor is given in the Operating Instructions.
Kmi = Load spectrum factor in inspection interval i in accordance with
the section “Determining the operating conditions
(collective load)”
Ti = Actual operating hours for inspection interval i in accordance
with the section “Determining the actual operating hours Ti”
This used proportion is subtracted from the remaining theoretical service
life Di after every inspection interval (see example in the appendix to this
chapter).
A general overhaul must be performed on the winch if the remaining

theoretical service life is not likely to be sufficient for the next operating
period.
If the theoretical service life D has been reached (see section 5.4.1 Theoreti-
cal service life, p. 5-21), the winch must not be operated until after a general
overhaul has been performed.
A general overhaul must be performed at least once every 10 years after

commissioning of the crane.
The general overhaul is to be arranged by the operator and performed by

the manufacturer or his representative. The results are to be entered in
the crane logbook.
After the general overhaul the manufacturer or his representative must

indicate a new theoretical service life D.
The next general overhaul must be performed within 10 years.

10.01.2000

5.4.3 Example
A truck crane with a separate operating hour counter for driving and crane
operation is classified by the manufacturer according to the Operating
Instructions as follows:
Power unit group: M3

Load spectrum: light L 1, Km = 0.125
Theoretical service life: D = 3200 h
The used proportion S of the theoretical service life is calculated over the
individual inspection intervals as follows:
First inspection (first year)
The crane was used for assembly work during the previous year:
Load spectrum L 1, i. e. Km1 = 0.125.
The superstructure operating hour counter reads 800 h. The winch was
operated approx. 20.% of the time, i. e. T1 = 160 h.
The used proportion S1 of the theoretical service life after the first
inspection is therefore:
0.125
Si = x 160 h = 160 h
0.125
Remaining theoretical service life:
D1 = 3200 h – 160 h = 3040 h.
The aforementioned values are entered in the table (see table example,
p. 5-28).
Second inspection (second year)
The crane was used for unloading work on docks: Load spectrum: L 3,
i. e. Km2 = 0.5.
The superstructure operating hour counter reads 2000 h, i. e. during this

period: 2000 h – 800 h = 1200 h (800 h were used during the first year).
The winch was operated approx. 40.% of the time, i. e. T2 = 480 h.

10.01.2000

Therefore the proportion of the theoretical service life used S2 in the

second inspection interval is:
0.5
Si = x 480 h = 1920 h
0.125
D2 = 3040 h – 1920 h = 1120 h.
The aforementioned values are entered in the table (see table example,
p. 5-28).
Third inspection (third year)
The crane was used for assembly work and occasional unloading work on
docks: Load spectrum: L 2, i. e. Km3 = 0.25.
The superstructure operating hour counter reads 3000 h, i. e. during this

period: 3000 h – 2000 h = 1000 h (2000 h were used during the first two
years).
The winch was operated approx. 30.% of the time, i. e. T3 = 300 h.
The proportion of the theoretical service life used S3 in the third inspec-
tion interval is therefore:
0.25
Si = x 300 h = 600 h
0.125
D3 = 1120 h – 600 h = 520 h.
These values are entered in the table (see example table p. 5-28).
The remaining theoretical service life is to be documented in a separate

table for each winch.
This table is to be attached to the crane logbook. This table is found in the
Maintenance Manual appendix for truck cranes that do not require a crane
logbook or similar documentation according to the regulations of the
respective country.
10.01.2000
s
5 - 28
winch)
Table example to determine the remaining theoretical service life on winch no. 1 (main hoist winch)
(main hoist
winch no. 1
Crane model: GMK 3045
Works number: 3045 42 06
cal service life on
Table example to
determine the re-
maining theoreti-
Commissioned on: 10. 06. 1990

Winch serial number in acc. with model plate: 13 301
Last general overhaut performed on: ..................
Winch design data (see operating manual):
Power unit group: M 3
Collective load: Q 1(L1)
Collective load factor: Km = 0,125
Theoretical service life: D = 3200 h
in- Date of Operating Collective load Operating Operating Operating Operating Operating Proportation of Remaining Name of Signature Comments
spec- commis- conditions factor houres of entire houres of houres of houres of houres of the theoretical service theoretical inspector
tion sioning/ since last crane superstrukture superstrukture winch winch since last life (D) used: service life
no. Date of inspection since last inspection T i Km
inspection (collective inspection S i = ____i x T i Di = Di - 1 - Si
load) Km
"i" Km i [h] [h] [h] [h] [h] [h] [h]

0 10. 6. 90 - - - 0 0 3200
160
1 5. 6. 91 L1 0,125 - 800 800 - 160 3040 Jones
(20% of 800)
480
2 20. 5. 92 L2 0,5 - 2000 1200 - 1920 1120 Smith
2 084 543 en
(40% of 1200)
300
3 18. 5. 93 L3 0,25 - 3000 1000 - 600 520 Brown
(30% of 1000)
WARNING: Si = Proportion of theoretical service life used since last inspection

A gneral overhaul must be preformed at least once every 10 years! Di = Remaining theoretical service life
D i -1 = Theoretical service life remaining after previous inspection
Km = Collective load factor established during winch calculation
General overhault preformed on: ................................ This factor is found in the operating manual.
Km i = Collective load factor in inspection interval "i" according to section 2.1
Ti = Actual operating hours in inspection interval "i" according to section 2.2
Maintenance Manual GMK 5100

10.01.2000
Lubricant and process materials
6.1 Lubrication chart
6 Lubricant and process materials

Designa- Lubricating Type of Designation Specification Lubricant type
tion point lubrication in acc. with Classification Viscosity range
DIN 51502
MIL-L 2104 C 1)
A Diesel engine HD - CD
DB 228.5
Axle centre MIL-L 2105 B SAE 90

E3 C - LPF
drive Circulation API-GL-5 ISO - VG 220
lubrication
Slewing gear
E5 GROVE part no. 1 930 6702)
brake
Slewing gear
3) transmission MIL-L 2105 B SAE 75 W-90
E6 C - LPF
API-GL-4/5 ISO - VG 220
Hoist gear Oil quantity
Circulatory DB 235.11
F4 Gear box SAE 75 W - 90
lubrication
Hydraulic
G2 H-LP DIN 51524 T.2 ISO-VG 32
system
Oil quantity
Hoist clutch
G5 Hydraulic oil ATF Typ Suffix A
housing
Hydraulic
clutch
G6 GROVE part no. 03 319 2142)
operating
mechanism
Suspension
H GROVE part no. 2 310 863 2)
strut
Lubricating Grease gun and

J K-L2K DIN 51825
points (grease) manually
K Slideways Use for repairs KP-L2K DIN 51825

with grease
L2 Bearings GROVE parts no. 1373 458 2)
1)
See engine operating manual
2)
Available from your local GROVE Product Support
10.01.2000
3)
Synthetic oil filled at works; do not mix with mineral oil

Designa- Lubricating Type of Designation Specification Lubricant type

tion point lubrication in acc. with Classification Viscosity range
DIN 51502
Lubricating Oil can, As for A
M points High-pressure (diesel
(lubricating oil) oil spray can engine)
Open-running
V GROVE parts no. 0554 205 2)
gear wheels
Adhesive
Mounting lubrication
W screws, GROVE parts no. 1573 046 2)
bushings etc.
Slip ring Corrosion

X GROVE parts no. 3315 060 2)
assembly protection
2)
Available from your local GROVE Product Support
10.01.2000

6.2 Process materials
6.2.1 Fuel
The diesel fuels that may be used and their respective specifications may
be found in the engine operating manual.
6.2.2 Engine coolant admixtures
The specifications and admixture ratios may be found in the engine

operating manual.
6.2.3 Windscreen washing system admixtures
Commercial cleansers and antifreeze may be added to the windscreen

washing water.
Observe the application instructions on the package.
6.2.4 Fuel for crane cab heating system
You should use either the fuel specified in Section 6 or EL heating oil as
heating fuel for the crane cab.
10.01.2000

Blank page
10.01.2000

Description of maintenance work on the carrier
7.1 Vehicle engine
7 Description of maintenance work on the carrier
7.1 Vehicle engine

For work other than daily maintenance work, please consult the opera-
ting instructions that have been supplied for the vehicle engine.
S
Risk of engine damage!
The vehicle engine is in maintenance group II (difficult operation) because
of the high full-load rate or large fuel supply rate.
If the diesel engine is operated with rapeseed oil fatty acid methylester
(RME), the engine oil change intervals must be halved.
Releasing engines for RME operation is regulated by the service informa-
tion for the engine.
For various jobs (e.g. oil change filters) you must remove the guards on the
carrier above the vehicle engine between the first and second axle lines.
• Open the plugs (1) on both sides with a

square spanner and remove the guards.
10.01.2000

7.1 Vehicle engine
7.1.1 Checking the oil level D
The dipstick (1) for the vehicle engine is loca-

ted on the carrier behind the driver’s cab to
the left (when viewed from the direction of
travel).
Pre-check
• Turn off the vehicle engine.

• Check the oil level using the dipstick (1).
The oil level has to be at the max. mark
(arrow marks).
If the oil level is too low, top it up.
Inspection
• Start the vehicle engine and let it run at idling speed. Pay attention to
the oil pressure gauge.
S
Damage may occur to the engine if the oil pressure is too low!
If no oil pressure is displayed after 10 seconds, turn the engine off and
determine the cause; ➠ Operating instructions, Chapter Carrier malfunctions,
10.01.2000
Section Vehicle engine malfunctions.

7.1 Vehicle engine
• Switch off the vehicle engine after about

1 minute.
• After about 5 minutes, check whether the
oil level on the dipstick is at the max. mark
(arrow marking).
• Top up with oil to the max. mark if necessary.
7.1.2 Topping up motor oil
Data concerning the prescribed oil specifications may be found in the ope-
rating manual for the vehicle engine.
The oil filler neck (1) for the vehicle engine is on the left side of the carrier
(looking in the direction of travel) behind the
driver’s cab, next to the dipstick.
• Refill the engine oil via the fillerneck (1).

• Check the oil level on the dipstick.
S
Damage may occur to the engine if the oil level is too high!
Do not overfill; the oil level must not be higher than the highest arrow
marking (max.).
10.01.2000

7.1 Vehicle engine
7.1.3 Checking the coolant level D
The coolant reservoir is located on the left-hand side of the carrier behind
the driver’s cab.
G
Risk of burning when vehicle engine is hot!
The hot radiator is pressurized. Be careful to avoid burns from the hot
radiator, escaping steam or any escaping hot coolant if you remove the
lid of the radiator cap when the vehicle engine is hot.
Wear suitable protective gloves and cover the radiator cap with a cloth
before opening the lid.
Turn the radiator cap lid slowly to the first notch in order to allow the
excess pressure to be released.
Do not open the pressure relief valve (2) on

the side of the compensation container.
• Loosen (do not open!) the cap on the fil-

ling hole (1) with the coolant at operating
temperature to release the pressure.
• Open the cap.
The coolant must reach the lower edge of
the pipe in the filler neck.
If the coolant level is too low:
• Top up coolant.
See the vehicle engine operating manual for the composition of the coo-
lant.
• Screw the filling hole cap on until it reaches end position.
S
If the coolant has to be topped up frequently, the cooling system may be
leaking. Have GROVE Product Support or your repair staff check the coo-
ling system and repair the damage.
10.01.2000

7.1 Vehicle engine
7.1.4 Checking the dry air filter D
The dry air filter is on the right-hand side of the carrier, behind the first
axle line.
The indicator lamp vehicle engine air filter is on the front instrument panel
p of the driver’s cab. If this indicator lamp lights up, the dry air filter must
be replaced.
• Release all clamps (1) on the filter lid.

• Take off the filter lid (2).
• Pull out the filter insert (1).

• Insert a new filter insert.
If the seal on the filter lid is worn:
• Change this seal.

• Place the filter lid back in place and secure
it with all the clamps.
10.01.2000

7.1 Vehicle engine
7.1.5 Checking the overall condition and checking for leakage W
• Check all pipes and hoses for

– tight connection,
– leaks,
– worn spots.
• Replace any damaged pipes and porous or swollen hoses.
• Tighten any connections that are leaking.
If the connection still leaks:

• Change the seal.
• Inspect the vehicle engine visually for any obvious dirt or leaks.
• Listen out for any unusual noises when the vehicle engine is running.
If damage cannot be rectified immediately or further damage is likely:

• Inform your local GROVE Product Support service or your repair crew.
10.01.2000

7.1 Vehicle engine
7.1.6 Cleaning the fuel prefilter screen M3
Cleaning the fuel The primary fuel filter is located behind the driver’s cab on the fuel tank of
prefilter screen the carrier. The primary fuel filter is mounted directly on the fuel tank.
O
Have a container or cleaning rag ready so that you can catch the draining
fuel. Wipe up any fuel which is not caught.
Store used fuel filter inserts in suitable containers and dispose of them
properly.
• Open the tank cap in order to prevent ex-

cess pressure in the fuel tank.
• Unscrew the prefilter’s filter container (1).
• Clean the filter container and filter screen
(2) with clean diesel fuel using a soft
brush. Replace a heavily soiled or dama-
ged filter screen.
• Check and, if necessary, replace the sea-
ling ring (3) in the filter lid.
• Insert the filter screen into the filter contai-
ner and screw it onto the prefilter again.
Tightening torque 10 Nm.
• Bleed the fuel system as described in the
following section.
Bleeding the fuel • Release the hand pump by turning the knurled screw (4, top picture) to
system the left.
The knurled screw is also the hand pump’s handle.
• Pump up and down until the resistance noticeably increases.
• Insert the hand pump and tighten the knurled screw again.
• Start the engine and check the prefilter is tight.
10.01.2000

7.1 Vehicle engine
7.1.7 Changing the fuel filter cartridge M 12
Shutting off and Before changing the fuel filter cartridge, you must:
emptying the fuel – shut off the fuel line to the diesel tank and
line – empty the fuel line.
O
Always use a fuel-resistant container with sufficient capacity into which
the fuel line is emptied. Make sure that no fuel runs out and seeps into
the ground.
Shutting off the fuel line
A shutoff tap is located in the fuel line on the

right side next to the fuel tank.
• Close the tap. Turn the handle (1) so that it

is perpendicular to the fuel line.
Emptying the fuel line
The fuel line is emptied via a hose pipe. The

end of the hose pipe (1) is fixed at the carrier
frame behind the first axle line.
• Place a collecting vessel suitable for fuel

(e. g. a drip pan) underneath the end of the
hose (capacity approx. 5 l).
10.01.2000

7.1 Vehicle engine
For emptying the fuel pipe there is a 3-way

tap (1) at the height of the 1st axle line, under-
neath the truck crane on the right next to the
vehicle engine’s oil pan.
• Turn the handle on the 3-way pipe so that

it is diagonal to the pipe.
The fuel now flows into the collecting vessel
which has been prepared.
• Let the collecting vessel stand underneath

the end of the hose. More fuel can escape
when changing the fuel filter insert.
Changing the fuel The fuel filter insert is underneath the front cover plates at the front left
filter insert on the vehicle engine (➠ Vehicle engine operating instructions).
• Unscrew the screw cap (1) with the filter

insert (3) and pull it a bit out of the filter
housing.
Let the rest of the fuel drain off.
• Remove the screw cap with the filter insert
and remove the filter insert by applying
pressure on the sides of the lower edge of
the filter insert.
• Replace the rubber sealing ring (2) (lubrica-
te lightly).
• Insert a new filter insert into the screw cap.
• Screw the screw cap with filter insert on again and tighten it.
O
Store used fuel filter inserts in suitable containers and dispose of them
10.01.2000
properly.
s
7.1 Vehicle engine
After changing After changing the fuel filter insert you must re-establish operating state.
the filter insert
• Turn the handle on the 3-way tap (1) so

that it is lengthways to the pipe.
• Remove the collecting vessel underneath
the end of the hose.
If you have used a clean collecting vessel
you can use a sieve to fill the diesel tank with
fuel again. Otherwise you must collect the
fuel for disposal.
• Open the two stop cocks in the fuel pipe by

turning the handles (1) so that they are
lengthways to the fuel pipes.
• Bleed the fuel pipe using the hand pump on the fuel prefilter;
➠ Bleeding the fuel system, p. 7-7.
• Start the engine and check the fuel filter is tight.
10.01.2000

7.2 Gearbox
7.2 Gearbox
The gear box is on the carrier between the first and second axle lines.
7.2.1 Checking general condition and for leaks W
• Make a visual inspection for leaks.

• Listen carefully for any abnormal noises when the transmission is enga-
ged.
• Inform your local GROVE Product Support or your repair crew.

10.01.2000

7.2 Gearbox
7.2.2 Oil level check D
The automatic gearbox is located in the carrier between the first and
second axle lines.
S
The correct oil level must be maintained to ensure smooth operation of
the automatic gearbox:
– if the oil level is too low, the gearbox will not function properly,
– if the oil level is too high, the gearbox will lose power and overheat.
Requirements:
To check the oil level:

– the truck crane must be on a horizontally aligned,
– the parking brake must be engaged,
– the automatic gearbox must be in position N,
– the vehicle engine must be turned off running.
G
Risk of scalding!
If the oil is at operating temperature, do not let the oil drain unchecked.
The oil level is checked through an inspecti-

on hole at the back left of the gearbox.
• Remove the cover plate (1) from the gear

box.
• Remove the screw (2) from the inspection
hole.
If the oil level is too low:
• Top up oil through the inspection hole using

only oil as specified in the Maintenance plan,
p. 5-14.
• Close the inspection hole again with the
screw (2).
• Secure the cover plate on the gear box.
10.01.2000

7.2 Gearbox
7.2.3 Changing the oil and oil filter J5
The oil is drained via the oil drain opening in the gear box and filled via the
inspection hole.
Use only oil as specified in the maintenance plan, p. 5-17.
G
Risk of scalding!
If the oil is at operating temperature, do not let it drain unchecked.
O
When changing the oil filter, always use a drip pan which is suitable for
oil and which has a sufficient capacity. When changing the filter and fil-
ling oil, make sure that no oil spills out and soaks into the ground.
H Before starting this work, lift the truck crane with the outrigger or park it
over an inspection pit.
Draining oil
• Insert a funnel into the drain hole in the

base plate under the gear box.
• Place a container (capacity approx. 65 l) un-
derneath the drain hole to collect the oil.
hole before draining the gear lubricant oil.
• Unscrew the oil drain plug (2) and let the
oil flow into the collecting vessel.
10.01.2000
s
7.2 Gearbox
Changing the oil filter
• The oil filter is located between the first

and second axle lines on the left rear side
of the gearbox.
• Unscrew the oil filter (1) from the gearbox.
• Clean the oil filter with a soft brush and
clean gear lubricant oil.
• Replace the gasket on the oil filter and
screw it back on to the gearbox.
O
Collect old oil in approved containers and have used oil and oil filters
disposed of properly.
Topping up oil
• Replace the sealing ring on the oil drain

plug and seal the outlet.
• Top up the oil through the inspection hole
on the gearbox (➠ Maintenance plan,
p. 5-17).
• Check the oil level at the inspection hole.
The oil must be filled to the lower edge of
the inspection hole.
• Replace the sealing ring and close the in-
spection hole with the screw (1).
After topping up the oil, you must carry out the following checks for leak
tightness:
• Start the vehicle engine and let it idle in neutral N.

• Check the tightness of the oil filter and the oil drain screw.
10.01.2000

7.2 Gearbox
7.2.4 Checking the oil level of the hydraulic clutch M 12

operating mechanism
The gear box is equipped with a hydraulic clutch operating mechanism.

The oil level is checked at two separate reservoirs.
One reservoir (1) is in the front behind the

bonnet of the driver’s cab.
• Release the bonnet and open it

(➠ operating manual).
• Check whether the oil level is located be-
tween the min. and max. marks.
• Top up with oil if necessary in accordance
with the (➠ Maintenance plan, p. 5-17).
A second reservoir is located behind a cover

on the rear of the fuel tank on the carrier.
• Remove the cover (1).

• Check whether the oil level is located
at the max. mark.
• Top up with oil if necessary in accordance
with the (➠ Maintenance plan, p. 5-17).
10.01.2000

7.2 Gearbox
7.2.5 Changing the oil on the hydraulic clutch Y5

operating mechanism
Changing the oil on the hydraulic clutch operating mechanism includes a

wide range of aeration tasks. Therefore, this kind of work may be conduc-
ted only by GROVE Product Support or by qualified professionals.
10.01.2000

7.3 Transfer case
7.3 Transfer case

The transfer case is located on the 3rd axle line.
7.3.1 Checking the overall condition and tightness W

• Listen out for any unusual noises from the transfer case.
7.3.2 Oil level check M1
The oil level must be checked on the front of the transfer case with the
engine turned off.

hole.
• Check the oil level, the oil level must be
just underneath the inspection hole.
• Top up oil via the inspection hole using

only oil in the maintenance plan, p. 5-8.
• Close the inspection hole again with the
screw (1).
10.01.2000

7.3 Transfer case
7.3.3 Changing the oil M6
H
Use only oil as specified in the Maintenance plan, p. 5-12.
Raise the truck crane with the outriggers or park it over an inspection pit.
O
Always use oil collection containers, funnels or filling pumps which are
resistant to oil.
Wipe up spilled oil immediately.
The oil must be changed when the engine is turned off. The oil drain plug
is at the bottom of the transfer case.
• Place an oil collection container (capacity

approx. 15 l) underneath the oil drain plug (2).
hole.
oil flow into the collection container.
• Replace the sealing ring and reinsert the
oil drain plug.
• Top up oil using only oil specified in the
Maintenance plan, p. 5-12.
• Check the oil level (➠ Checking the oil level,
p. 7-17).
spection hole again with the screw (1).
O
Collect old oil in approved containers and have it disposed of properly.
10.01.2000

7.4 Axle lines
7.4 Axle lines
7.4.1 Checking the overall condition and tightness W

• Listen out for any unusual noises from the axle centre drives and final
drives.
7.4.2 Axle centre drives – oil level check M1
The position and number of inspection holes sometimes differs with the
axle lines. Checking the oil on the axle centre drive of the 3rd axle line is
H
conducted in conjunction with an oil check on the transfer case.
The axle centre drive on the 2nd axle line is available only as additional
equipment with a 10 x 8 drive.
2nd and 5th axle lines
On the 2nd axle line, the inspection hole is at

the front. The inspection hole is at the back
on the 5th axle line.

hole.
• Check the oil level, the oil level must be
just underneath the inspection hole.

only oil in the Maintenance plan, p. 5-8.
10.01.2000
s
7.4 Axle lines
Fourth axle line
The axle centre drive of the fourth axle line

has two inspection holes:
front – the inspection hole (2)
back – the inspection hole (1).
• Check the oil level in the same way as is

described for the second and fifth axle li-
nes.
10.01.2000

7.4 Axle lines
7.4.3 Axle centre drives – oil change M 12
H
Use only oil specified in the Maintenance plan, p. 5-14.
Raise the truck crane with the outriggers or park it over an inspection pit.
O
Always use oil collecting vessels, funnels or filling pumps which are resi-
stant to oil.
H Checking the oil on the axle centre drive of the 3rd axle line is conducted
in conjunction with an oil check on the transfer case; ➠ p. 7-18
• Switch off vehicle engine to change the oil.
2nd and 5th axle lines

approx. 20 l) underneath the oil drain
plug (2).
hole.
oil flow into the collecting vessel.
• Replace the sealing ring and reinsert the
oil drain screw.
• Fill oil to over the inspection hole (1). Top
up oil using only oil in the maintenance plan,
p. 5-12).
• Check the oil level (➠ Checking the oil level, p. 7-19).

• Replace the sealing ring and close the inspection hole again with the
screw (1).
O
Collect the waste oil in authorized containers and only have it disposed of
10.01.2000
by approved disposal companies.
s
7.4 Axle lines
Fourth axle line

• The axle centre drive of the fourth axle line
has two oil drain plugs:
bottom – the oil drain plug (4)
front – the oil drain plug (3).
approx. 20 l) underneath the oil drain
plugs (3) and (4).
• Change the oil on both oil drain plugs in
the same way as is described for the axle
drives on the second and fifth axle lines.
10.01.2000

7.4 Axle lines
7.4.4 Final drives – oil level check M1
Every final drive has an inspection hole.

• Raise the truck crane with the outrigger and release the parking brake.
• Turn the wheel so that the oil check mark

(2) is horizontal and is on the right next to
the centre of the axle.
hole.
• Check the oil level, the oil level must be at
the check mark (2).

only oil in the Maintenance plan, p. 5-8.

• Check also the oil level on all other final drives.

10.01.2000

7.4 Axle lines
7.4.5 Final drives – oil change M 12
• Raise the truck crane with the outrigger and release the parking brake.
O
Always use oil collecting vessels, funnels or filling pumps which are
resistant to oil.

approx. 4 l) under the wheel.
hole.
• Turn the wheel until the opening is poin-
ting downwards and drain the oil into the
collecting vessel.
• Turn the wheel back so that the oil check

mark (2) is horizontal and is on the right
next to the centre of the axle.
• Top up oil through the inspection hole (1)
and use only oil which is specified in the
• Check the oil level, the oil level must be at
the check mark (2).
• Check the oil level (➠ Checking the oil level,
p. 7-19)
O
Collect the old oil in authorized containers and only have it disposed of
10.01.2000
by approved disposal companies.

7.4 Axle lines
7.4.6 Lubricating the cardan shafts on the axle lines M1
H
The cardan shafts are between the axle centre drives and the final drives.
If the cardan shaft was not equipped at the factory with a lubricating nipp-
le, this is a maintenance-free version. The activities described in the follo-
wing section woul then no longer apply.
The cardan shafts must be lubricated with a grease gun. Use only lubrica-
ting grease according to the Maintenance plan, p. 5-8.
S
Risk of damaging the sealing lips!
Do not apply hard lubricants to avoid damage to the sealing lips
Number and posi- There are two cardan shafts on every driven axle line.
tion of lubricati- The following table shows the position and number of lubricating nipples
on points on both cardan shafts for all driven axle lines.
Cardan shafts Lubricating nipples

internal 1) external 2)
2nd axle line (only with 10 x 8 drive) 2 2
Third axle line 2 2
Fourth axle line 2 2
Fifth axle line 2 2
1)
Joints on the axle central drives
2)
H
Joints on the final drives
The cardan shafts on the 2nd axle line are available only as additional
equipment with a 10 x 8 drive.
10.01.2000
s
7.4 Axle lines
Lubricating On all powered axle lines there is a single joint.

cardan shafts
There is one lubricating nipple (1) on every

single joint.
• Remove the old grease and dirt from the

lubricating nipple.
• Press lubricating grease into the lubrica-
ting nipple until new grease comes out of
the corresponding bearing point.
• Remove the surplus new grease.
10.01.2000

7.4 Axle lines
7.4.7 Lubricating the longitudinal cardan shafts M6

between the gear units
The longitudinal cardan shafts are between the automatic gearbox and
the transfer case, between the transfer case and the axle centre drives and
H
between the axle centre drives.
If the cardan shaft was not equipped at the factory with a lubricating nipp-
le, this is a maintenance-free version. The activities described in the follo-
wing section woul then no longer apply.
The (longitudinal) cardan shafts must be lubricated with a grease gun.

Use only lubricating grease according to the Maintenance plan, p. 5-12.
S
Risk of damaging the sealing lips!
Do not apply hard lubricants to avoid damage to the sealing lips.
Number and positi- The following table shows the location and number of the lubricating
on of lubrication nipples on the individual cardan shafts:
points
(Longitudinal) cardan shaft between ... Lubricating
nipple
front rear
Gearbox and transfer case 1 1
2nd and 3rd axle lines 1) 1 1
3rd and 4th axle lines 1 1
4th and 5th axle lines 1 1
1)
Only with 10 x 8 drive (additional equipment).
10.01.2000
s
7.4 Axle lines
Lubricating longi- Lubrication with all longitudinal cardan shafts is done in the same way.
tudinal cardan
shafts
There are two lubricating nipples (1) and (2)

on every longitudinal cardan shaft.

lubricating nipples.
• Press lubricating grease into the lubrica-
ting nipples until new grease comes out of
the respective bearing points.
• Remove the surplus new grease.
10.01.2000

7.5 Wheels
7.5 Wheels
7.5.1 Checking the tyres for damage D
• Check the tyres for:

– chunking
– dents
– areas with uneven wear.
• Check whether the tyre has worn down to
the wear mark (1).
If the tyre no longer has any tread at the

wear marks:
• Change the tyres.
S
Always replace all the tyres on an axle.
10.01.2000

7.5 Wheels
7.5.2 Checking the tyre air pressure W
S
When replacing tyres, please note that tyres from other manufacturers must
have the same load bearing capacity and thus the same tyre pressure as the
initial equipment.
• Check that the new tyre pressures conform to the values in the table.
Tyres Air pressure (bar)
14.00 R 25 10.0
16.00 R 25 (additional equipment) 9.0
7.0
20.50 R 25 (additional equipment)
MIchelin
8.0
20.50 R 25 (additional equipment)
Bridgestone
7.5.3 Checking the wheel-bearing clearance M3
• Raise the truck crane with the outriggers. Release the parking brake.
• Press against the bottom of the wheel with one foot and, using both
hands, try to move the wheel in the bearing at the same time.
If the check shows there is too much play:

• Have the wheel-bearing clearance adjusted or wheel bearings replaced
by GROVE Product Support service or by your own repair crew.
10.01.2000

7.6 Vehicle brakes
7.6 Vehicle brakes
7.6.1 Checking brake-lining thickness M3
There is an opening on the inside of each wheel (sealed with a rubber

plug) through which the brake-lining thickness can be checked.
• Remove the rubber plug (1), (2), and shine

a torch into the opening.
If the brake-lining thickness has worn down to
the wear marks (stepped edges or grooves) or
the linings have worn down to 3 mm:
• Have the brake linings replaced by

GROVE Product Support or an authorised
service centre.
S
Always replace all brake linings on an axle line.
10.01.2000

7.6 Vehicle brakes
Blank page
10.01.2000

7.7 Suspension
7.7 Suspension
7.7.1 Checking the oil level in the suspension cylinders M1
The suspension cylinders of the individual wheel suspension units are

bolted to the vehicle frame (carrier).
• Use the level adjustment system to lower the truck crane completely
and then raise it to on-the-road level again (➠ Operating manual, Chapter
H
Driving with the truck crane, Section Vehicle height control).
The initial complete lowering is necessary to produce the correct oil level
reading.
S
If the oil level is above the upper marking on the inspection glass the sus-
pension cylinder is defective and must be replaced.
Inform GROVE Product Support.
• Check the oil level at the respective

inspection glasses (1).
The oil level must be between the
markings.
• Screw the high pressure squirt gun

(supplied tool) to the filler connection (2).
• Inject oil up to the level of the lower
marking.
Only use oil specified in the Maintenance
plan, p. 5-8.
S
It is difficult to inject the oil. Even so, do not fill oil through the inspection
glass connections. It would not reach all lubricating points.
10.01.2000

7.7 Suspension
7.7.2 Checking the tightness of retaining bolts M1

on the suspension cylinders
• Check the tightening torques of the

retaining bolts:
– between vehicle frame/upper guide case (1)
– between vehicle frame/lower guide case (2)
– between support element/steering split
shell (3)
– between support element/cab with engine (4)
The tightening torques may be found in
section 10.2.
10.01.2000

7.8 Steering
7.8 Steering
7.8.1 Checking for leaks W
• Check the hydraulic steering system (steering cylinders, pipes and

hoses, and all connections) for leaks.
G
Risk of accidents!
Never tighten leaking connections when the system is under pressure.
Only change pipes and hoses when the system is depressurized.
• Top up hydraulic oil where necessary (➠ Checking hydraulic oil level,

p. 7-39).
After changing pipes and hoses:

• Bleed the carrier hydraulic system (➠ Changing hydraulic oil, p. 7-46).

• Inform GROVE Product Support or your repair crew.
10.01.2000

7.8 Steering
Blank page
10.01.2000

7.9 Carrier compressed air system
7.9.1 Draining the compressed air system W
Moisture must be drained from the compressed air system through the
drain valves of the four compressed air reservoirs and the conditioning
unit. A functional check of the compressed air drier is carried out
simultaneously.
The compressed air reservoirs are located beneath the rear and front
parts of the carrier. The conditioning unit is located on the left under the
driver’s cab and is accessible from below.
• Operate the drain valves (2), the drain

valve of the conditioning unit (1) is shown
here as an example.
If the respective drain valve does not close

after being actuated several times:
• Change the drain valve.
If a lot of moisture escapes from the air reser-

voirs:
• Have the compressed air drier checked or
replaced by your repair personnel.
• Start up the compressed air system.

• Check all points in the compressed air system (connections, pipes,
hoses and valves) where air could possibly escape.
G
Risk of accidents!
Never tighten connections when the system is under pressure.
Only change seals, pipes and hoses when the system is depressurized.
10.01.2000
s

• Inform GROVE Product Support or your repair crew.
7.9.3 Replacing the granulate cartridge of compressed M 12

air drier
The compressed-air drier with the granulate cartridge is located on the

left under the driver’s cab and is accessible from below.
G
Risk of injury!
If the conditioning unit has not been fully bled, the compressed air drier
will be under pressure.
• Release all the air from the conditioning

unit (3) via the drain valve (4).
• Unscrew the granulate cartridge (1)
(attached to the cover hood) using a strap
wrench.
• Change the granulate cartridge. Grease the
sealing ring lightly before screwing into
place.
10.01.2000

7.10 Carrier hydraulic system
7.10.1 Checking the hydraulic oil level D
The hydraulic oil tank is on the left-hand side of the carrier behind the
driver’s cab.
The level can be checked through the inspection glass.
To check the oil level:

– the truck crane must be in a position on-road driving (➠ Operating manual,
– Chapter Driving with the truck crane, Section Vehicle height leveling);
– the outrigger beams and cylinders must be retracted (➠ Operating
instructions, Chapter Rigging work, Section Outrigger).
• Check the level of the hydraulic oil tank

through the inspection glass (1).
The hydraulic oil must be visible in the
centre of the inspection glass.
If the level is too low:
• Top up the hydraulic oil through the filler

opening (2).
Only use hydraulic oil that is specified in
the Maintenance plan, p. 5-5.
S
Be careful not to damage the hydraulic system!
When handling hydraulic oil cleanliness is imperative!
New oil must also be filtered.
10.01.2000

7.10.2 Checking the hydraulic hoses W
Hydraulic hoses are subject to ageing as well as internal and external

demands.
• Check the hydraulic hoses for:

– external damage (cracks, chafed areas,
heat damage, chemical damage),
– leaks and moist areas,
– blistering or unevenness of hose casing,
– signs of ageing (porous surface, rust on
hose fittings).
Hydraulic hoses should not be used for lon-
ger than 72 months from date of manu-
facture. The date of manufacture and the
permitted operating pressure are marked on
the hose fitting:
– The first 4 numbers (1) indicate the month
and year in which the hose was manu-
factured.
– The letters P and N and the last 3 numbers
(2) indicate the permitted operating
pressure.
• Damaged or old hydraulic hoses must be replaced immediately. Always

ensure that the corresponding parts of the hydraulic system are depres-
surized in advance.
10.01.2000

• With the vehicle engine running, carry out a visual inspection for leaks
and escaping hydraulic oil at the suspension cylinders, outriggers,
hydraulic lines (hoses and pipes) and connections.
• If leaks are detected, check the hydraulic oil level and top up if necessary
(➠ Checking hydraulic oil level, p. 7-39).
G
Risk of accidents!
Never tighten any leaking connections when the system is under pressure.
Only change pipes and hoses when the system is depressurized.
After parts have been changed:

• Bleed the carrier hydraulic system (➠ Changing hydraulic oil, p. 7-46).

O
Remove, or have leakages in the hydraulic system removedto ensure that
no hydraulic oil seeps into the ground or reaches waters during crane
deployment.
10.01.2000

7.10.4 Changing the hydraulic oil filters and cleaning M3

the magnetic rod
The hydraulic oil tank has two hydraulic oil filters (return filters).
The hydraulic oil filters must be changed:
– when the warning lamp Hydraulic oil return filter lights up on the front
g instrument panel of the operator’s cab,
– after every hydraulic oil change.
• Turn off the engine and depressurize the hydraulic system.
• Remove the nuts on the filter cover (1) and

remove the hydraulic oil filters from the
hydraulic oil tank.
• Remove screw (1) and take off the top

parts of the filter (2).
• Unscrew the magnetic rods (4) and clean
them. 10.01.2000

S
A large number of metal particles adhering to the magnetic rod is a sign
of damage to the hydraulic system. Have the hydraulic system examined
by GROVE Product Support or by your repair crew.
• Change the hydraulic oil filter elements (5).

• Replace the O-rings (3) in the bottom and
top parts of the filter.
• Reassemble the hydraulic oil filters and
replace them in the hydraulic oil tank.
O
Store used hydraulic oil filters in suitable containers and have them
disposed of properly by qualified personnel.
7.10.5 Replacing the venting filter M 12
The venting filter is situated on the cap of

the filler opening of the hydraulic oil tank.
• Change the venting filter (1).

10.01.2000

7.10.6 Taking oil samples M 12
To determine the usability of the hydraulic oil, samples must be taken

from the hydrailc oil tank and from the hydraulik system ➠ Changing hy-
draulic oil, p. 7-46.
The drain valves can only be opened and closed using the 1/2“ fittings.
The fittings are to be found in the tool box; ➠ Handling the drain valve,
p. 7-45.
• Take the first samplefrom each of the drain

valves (1), (2) and (3) on the hydraulic tank.
The oil sample from the hydraulic system is

taken via a gauge port (1), e. g. on an out-
rigger.
10.01.2000

Handling the The drain valves can only be opened and closed using the 1/2" fittings.
drain valves The fittings are to be found in the tool box.
G
Risk posed by escaping hydraulic oil!
When the fitting is screwed onto the drain valve, the valve opens and the
hydraulic oil immediately flows out of the fitting. Place the fitting hose in
an oil collection container before screwing on the fitting.
• Place an oil drain hose onto the fitting and lead it into an oil collection
container.
• Unscrew the cap from the drain valve.
• Screw the fitting onto the drain valve. The drain valve opens.
• Let the necessary amount of oil run into the collection container.
• Unscrew the fitting from the drain valve. The drain valve shuts.
• Screw the cap back onto the drain valve.
Taking oil • Take one litre of hydraulic oil from each of the three drain valves and
samples from one pressure gauge connection. Before taking the oil sample,
allow 1–2 litres to run into a separate container.
• Label each sample container with
– the date of sampling,
– the number of operating hours since the last oil change and
– the sampling location (hydraulic oil tank or metering nozzle).
• Send the samples to a specialist laboratory for analysis.
Permissible limit values:
– viscosity ISO-VG 32 acc. to DIN 51524 T.2,
– contamination acc. to NAS 1683 Class 9 or ISO 4406 Code 18/15.
If these limits have been reached:

• Change the oil (➠ Changing hydraulic oil, p. 7-46).
10.01.2000

7.10.7 Changing the hydraulic oil M 12
The hydraulic oil only has to be changed if the laboratory analysis shows
that the permissible limits have been exceeded (➠ Taking oil samples,
p. 7-44), or the laboratory has recommended a date for an oil change.
Preconditions: The truck crane must be in on-the-road mode with the engine
off.
Only use hydraulic oil that is specified in the Maintenance plan, p. 5-14.
S
Damage may occur to the hydraulic pumps!
Ensure that the vehicle engine cannot be started by unauthorized personnel.
If the engine is started while the stop cocks in the suction lines are closed,
the hydraulic pumps will be damaged!
• Close the stop cocks in the suction lines to

the hydraulic oil tank.
The four taps (1) to (4) are located on the left
side of the vehicle and are accessible
through a hole in the side panelling.
The taps are closed when the grips are at
right angles to the suction lines.
• Remove the hydraulic oil filters

(➠ Changing the hydraulic oil filters and
cleaning the magnetic rod, p. 7-42).
• Have a container ready to collect the oil
(with a capacity of over 200 l).
O
Always use the supplied 1⁄2 inch fitting with an oil drain hose and an oil
collecting vessel with sufficient capacity to drain the oil. 10.01.2000

• Drain the oil. To do this, screw the oil drain

hose with fitting onto each drain cock (1),
(2) and (3) in turn, drain the oil from the
three tank chambers (➠ Taking oil samples,
p. 7-44).
• Change the filter elements in both filters
and fit new hydraulic oil filters
(➠ Changing the hydraulic oil filters and
S
When handling hydraulic oil cleanliness is imperative.
New oil must also be filtered before it is filled into the tank.
O
Collect waste oil in approved containers and have waste oil and oil filters
disposed of by professional crews.
• Add new hydraulic oil through the filler

opening (2) until the oil level is in the
middle of the inspection glass (1).
• Open the four stop cocks of the suction lines.
• Start the engine and put the hydraulic
system into operation.
• Carry out all functions of the carrier hy-
draulic system several times to remove
any air from the system.
• Check the oil level in the hydraulic oil tank.
Top up oil if necessary.
• Carry out a road test of the truck crane, tur-
ning the steering wheel several times to its
fullest extent.
10.01.2000
s
If the steering is “loose” at the end of the test run you must ventilate the
steering cylinders.
G
Risk of crushing!
When working between the wheels ensure that the steering wheel cannot
be turned by an unauthorized party. The wheels turn when the steering
wheel is operated.
Risk of accidents!
Never undo the hose connections completely. The hydraulic system is un-
der pressure, even when the steering wheel is not turned.
Bleed the steering cylinders individually, one

after the other:
• Start the vehicle engine.
• Bleed each steering cylinder (2) by loose-
ning the cap nuts (1) in turn until the oil
coming out no longer contains any air
bubbles.
If the steering system is still not operating

properly:
• Inform your local GROVE Product Support
or an authorised service centre.
10.01.2000

7.11 Central lubrication system

The grease container is on the right side of
the vehicle between the fourth and fifth axle
lines.
When filling, use only grease as specified in
the Lubrication chart, ➠ p. 5-6.
7.11.1 Checking and topping up level in the grease container W
Checking the level
• Check the level of the grease container (1).

The level must be near the MAX. mark.
If the level is too low, fill the grease container
through the filler connection (2) using a charge
pump.
10.01.2000
s
H
Filling the grease
container
You must connect a connecting piece to the grease container before

refilling the container with the filling pump for the first time. This proce-
dure is explained in the following. The connecting piece and a sealing cap
are enclosed with the filling pump.
• Unscrew the stopper (1) from the grease

container.
• Screw the connecting piece (2) into the
opening.
• Screw the sealing cap (3) onto the connec-
ting piece.
• Unscrew the cap (5) from the filling

pump (1).
• Remove both caps (2) and (4) from the
grease cartridge (3).
H Ensure that the packing is in proper position in the filling pump (8).
The packing must be folded toward the plunger rod (7).
• Push the grease cartridge (3) into the filling pump.

10.01.2000
• Check that the seal (5) is in proper position in the cap (6).
• Screw the cap onto the filling pump.

H The central lubrication system must be running while the grease

container is being filled.
• Turn the diesel engine ignition on.

• Unscrew the bottom sealing cap (2) on the
grease container.
• Press the switch (3) behind the cap. This
triggers a complete lubrication procedure.
• Remove the sealing cap on filler opening
(1) of the grease container.
S
Do not remove the sealing caps from the filler opening and filling pump
until immediately before refilling the grease, as the grease could other-
wise become contaminated.
• Unscrew the sealing cap (1) from the filling

pump.
• Screw the filling pump onto the filler
opening of the grease container.
• Push the grease into the grease container
through the filler opening using the plun-
ger rod.
• Screw the appropriate sealing caps onto
the filler opening of the grease container
and the outlet of the filling pump.
• Seal the lower opening for the button with
the sealing cap.
10.01.2000
s
Bleeding the central The central lubrication system must be bled when the grease container is
lubrication system empty or air is trapped in the grease.
• Fill the grease container (1) (➠ Checking the

level of the grease container and filling, p.7-49).
• Loosen the outlet screw fitting (2) of the
pump element.
• Turn the diesel engine ignition on.
• Press switch (4) to trigger additional lubri-
cation.
• Let the pump run until the grease running
out of the outlet screw fitting (2) no longer
contains any air bubbles.
• Retighten the drain screw fitting (2) and
screw the sealing caps back onto the filler
opening of the grease container and the
switch opening (3).
• Remove any excess grease.
10.01.2000

7.12 Carrier electrical system
7.12.1 Checking the acid level of batteries M1
• Keep the batteries clean and dry.

• Loosen any dirty terminals and clean them. Grease the terminals with
an acid-free, acid-resistant grease.
G
Hydrogen escaping from the batteries is explosive!
Do not place tools on the battery and keep unshielded light away from
the battery.
H It is particularly important to check the acid level during the warmer

months.
• Check the acid level in the individual cells:

– for batteries where the acid level is visible, the acid must be approx.
15 mm above the plates.
– in the case of batteries with an overflow reservoir, the latter must
contain distilled water.
If the acid does not come up to the required level or there is no distilled
water in the overflow reservoir:
• Only fill in distilled water:
– up to the required level above the plates or
– until it stops flowing out of the reservoir.
10.01.2000

7.12.2 Checking the acid concentration of batteries M3
H
• Measure the acid concentration of each cell with an acid tester.
It is particulary important to check the acid concentration with the onset

of the colder months.
The following table gives a guide to battery charge levels.
Acid concentration Specif. gravity Charge

(° Bé) (g/cm3)
32 1.28 good
24 1.20 half, top up
16 1.12 empty, recharge immediately
10.01.2000

7.13 Carrier air-conditioning system (additional equipment)
7.13.1 Checking moisture and level of the refrigerant M1
The coolant is checked while the air-conditioning system is running

through an inspection glass of the unit on the roof of the driver’s cab.
• Start the diesel engine.

• Switch the air-conditioning system and let it run for 10 minutes.
Switching on the air-conditioning system ➠ Operating instructions,
section Air-conditioning system in chapter Driving with the truck crane.
• Check the refrigerant filling and the moisture content of the refrigerant
through the inspection glass (1):
– The flowing refrigerant must be visible and must not contain any
large bubbles or foam.
– A green dot (2) must be visible on the moisture indicator.
If the moisture indicator shows a yellow dot or if bubbles or foam are

visible, the air-conditioning system is defective.
If the air-conditioning system is defective:
• Switch the air-conditioning system off and do not use it again to avoid
further damage.
10.01.2000
Have the air-conditioning system repaired as soon as possible by

GROVE Product Support.
s
After checking:
• Switch the air-conditioning system off and turn the diesel engine off.
7.13.2 Cleaning capacitor cooling fins M1
S
Damage may occur to the capacitor and fan wheel!
Do not use a high pressure or steam jet cleaner. The hard water jet can
damage the cooling fins or the fan wheel. Only use compressed air for
cleaning.
• Switch the air-conditioning system off.

• Clean the cooling fins of the capacitor (2)
and fan wheel (1) with compressed air.
7.13.3 Checking hoses M6
• Check the refrigerant hoses for damage and worn areas.

Have damaged hoses replaced only by GROVE Product Support.
10.01.2000

7.13.4 Checking the refrigerant compressor M6
This check may only be undertaken by GROVE Product Support!
The refrigerant compressor (1) is at the front

on the left side of the diesel engine under-
neath the fuel filter.
Have the refrigerant compressor checked for

tightness. Above all the sealing of the drive
shaft should be checked.
7.13.5 Checking the entire air-conditioning system M 12
This check may only be undertaken by GROVE Product Support!
Have the whole air-conditioning system checked for tightness and proper
functioning.
10.01.2000

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10.01.2000

7.14 Trailer coupling (additional equipment)
7.14.1 Lubricating the trailer coupling M1
G
Danger of injury through activation of the automatic closing device!
Do not reach into the coupling jaw while the trailor coupling is open.
You can thus actuate the automatic closing device, the cotter pin moves
down with great force and can seriously injure your hand.
H To avoid overlubrication, the trailer coupling should only be lubricated

when open.
• Clean the two lubricating nipples (2 and 3) on the trailer coupling.

• Push hand lever (1) up to open the trailer
coupling.
• Press grease into all lubricating nipples
using a grease gun as specified in the
G
Risk of injury when closing the trailer coupling by hand!
When closing, the hand lever moves down with great force in the direc-
tion of the coupling jaw. Therefore start the closing process only by mo-
ving the lever briefly in the direction of the coupling jaw with the hand
balls.
If you hold the hand lever and move it down, it may carry your hand with
it and crush it.
10.01.2000
s
After lubrication you must close the trailer

coupling.
• To do this move the hand lever knob (1)

briefly in the direction of the coupling jaw
(observe direction of arrow).
• Remove any excess grease.
7.14.2 Checking the bearing M3
G
Risk of injury!
Ensure that the coupling is closed for subsequent work (lever points
downward). Otherwise, the lever may come down with great force and
cause serious hand injuries.
• Jiggle the trailer coupling in vertical and

longitudinal direction (arrows) to ensure
proper positioning of the bearing. Hold the
coupling by the coupling head and not by
the coupling jaw.
The coupling should not show longitudinal
clearance; the vertical clearance must not
exceed a value of 3 mm (as measured at the
coupling head).
H
10.01.2000
A vertical clearance of 3 mm at the coupling head corresponds to 1 mm

bearing play.

7.14.3 Checking the cotter pin M3
H For the following tests the coupling must be closed; before closing by
hand check the data in section Lubricating trailer coupling; ➠ p. 7-59.
• Check the wear on the cotter pin (1). The

diameter of the crowned section (arrows)
must not be below the following values:
Model series 400 : 36.5 mm
Model series 700 : 46 mm
If the diameter is below 36.5 or 46 mm, the

pin must be replaced.
• Check the cotter pin for the correct vertical

clearance. Push the cotter pin (1) upwards
using a screwdriver. The vertical clearance
(2) must not exceed 4 mm.
10.01.2000

7.14.4 Checking the lower bushing M3
• Check the internal diameter of the lower

bushing. The dimension (D) can not be
less than the following values:
If the diameter is below 31.5 or 34.2 mm, the

bushing must be replaced.
7.14.5 Checking the support ring M3
• Check the support ring (1) for the draw eye-

let at the bottom of the coupling jaw.
When the trailer is coupled, the draw eye-
let of the trailer may have slight contact
with the lower bushing (2).
Have the support ring changed if:
– the trailer’s draw eyelet touches the lower

bushing because of wear or
– the support ring has reached its wear limit
of H = 14 mm.
10.01.2000

7.14.6 Checking the initial tension of the springs M3
New couplings should show an initial axial torque of at least 100 Nm. The
coupling head should require physical power to twist.
• Twist the coupling head clockwise and counterclockwise to check the

initial tension of the rubber springs.
7.14.7 Checking the function of the coupling jaw/resetting M3

central position
H The following checks are required only on model series 700. If you need
to close the coupling by hand for the checks, make sure you observe the
data in section Lubricating trailer coupling; ➠ p. 7-59.
Checking If you need to close the coupling by hand for the checks, make sure you
function observe the data in section Lubricating trailer coupling; ➠ p. 7-59.
• Close the coupling (position B); ➠ p. 7-59.

The coupling jaw must be able to move
easily in both directions.
• Hold the coupling jaw (1) pressed slightly

to the left or right.
• Open the coupling (position A) and let the
coupling jaw go.
The release lever must automatically lock the
coupling jaw in the central position. The
coupling jaw is locked when the coupling
can no longer move to the side.
H If the release lever does not automatically engage with the coupling jaw,
the central position will need to be reset; ➠ p. 7-64.
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s
Resetting central
position
• Open the coupling (hand lever (1) up).

• Loosen the three screws (2) at the bottom
of the coupling.
• Push the coupling jaw to the right or left
until the release lever snaps into place.
• Retighten the three screws (2) (tightening
torque: 58 Nm).
• After adjusting check the function of the
coupling jaw; ➠ p. 7-63.
10.01.2000

7.15 Other maintenance work
7.15.1 Lubricating the outrigger beams M1
Operation of the outriggers is described in the Outriggers section of the

Operating Instructions, Chapter Rigging work.
Please note the safety instructions given in that section.
G
Risk of crushing!
Ensure that there is sufficient room around the crane. Warn any persons
nearby before extending the outriggers.
• Fully extend the outrigger beams.

• Apply the lubricating grease with a brush
or spatula to both sides of the four slide
faces and to the points of support (1).
Use only lubricating grease according to
• Extend and retract the outrigger beams
several times in order to improve the lubri-
cation effect.
7.15.2 Functional check of additional heating system M1

Operate the additional heating for 20 to 30 minutes in the warm time of

year; (➠ Operating Instructions, chapter Driving with the truck crane, section
additional water heating (additional equipment)
• Check that the system is working properly. Perform a functional check

10.01.2000
of the controls.
• Inform your local GROVE Product Support service if the heating system
is not working properly.

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10.01.2000

Description of maintenance work on the superstructure
8.1 Crane engine
8 Description of maintenance work on the

superstructure
8.1 Crane engine

For maintenance work, please consult the operating instructions for the
crane engine supplied with this manual. In the manual, only selected
types of work are described.
S
Risk of engine damage!
The crane engine is in maintenance group III (normal operation).
If the diesel engine is operated with rapeseed oil fatty acid methylester
(RME), the engine oil change intervals must be halved.
The release of engines for RME operation is regulated by the service in-
formation for the crane engine.
The crane engine is on the right-hand side of the superstructure.

It is accessible via the front side plates and the upper front gate.
• The dipstick (1) is located at the front of the

crane engine and can be reached through
and opening in the panelling.
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8.1 Crane engine
8.1.1 Checking the oil level D
The oil level check must be carried out with

the crane engine at standstill.
The dipstick (1) is located at the front right on

the crane engine.
Pre-check
• Turn off the vehicle engine.

• Check the oil level using the dipstick (1).
The oil level must be up to the max. mark (ar-
row marks).
If the oil level is too low, top it up.
Inspection
• Start the vehicle engine and let it run at id-

ling speed. Pay attention to the oil pressu-
re gauge.
S
Damage may occur to the engine if the oil pressure is too low!
If no oil pressure is displayed after 10 seconds, turn the engine off and
determine the cause; ➠ Operating instructions, Chapter Super-
structure malfunctions, Section on Crane engine malfunctions.
01.11.1999
10.01.2000

8.1 Crane engine
• Switch off the vehicle engine after approx.

1 minute.
• After about five minutes, check whether
the oil level on the dipstick is at the max.
mark (arrow marking).
• Top up with oil to the max. mark if
necessary.
Topping up Only use oil which has been prescribed in the crane engine instruction
motor oil manual or in the Maintenance plan, p. 5-5
G
Risk of burning when the crane engine is hot!
During operation, the crane engine and attachments can reach temperatu-
res of up to 400 °C. Wear appropriate protective gloves and be careful
not to touch hot parts when adding engine oil to a hot crane engine.
The oil filler neck is located at the top of the

crane engine and can be reached through an
opening in the panelling.
• Fill the engine oil through the filler neck (1).

• Check the oil level again.
10.01.2000

8.1 Crane engine
8.1.2 Checking the coolant level D
The coolant reservoir is behind the front service on the crane engine.
G
Risk of burning when vehicle engine is hot!
The hot cooler is pressurized. Be careful to avoid burns from the hot coo-
ler, escaping steam or any escaping hot coolant if you remove the lid of
the cooler when the vehicle engine is hot.
Wear suitable protective gloves and cover the lid of the cooler with a
cloth before opening it.
Turn the radiator cap lid slowly to the first notch in order to allow the
excess pressure to be released.
Do not open the pressure relief valve (2) on

the side of the compensation container.
• Loosen (do not open!) the cap on the

filling hole (1) with the coolant at operating
temperature to release the pressure.
• Open the cap.
The coolant must reach the lower edge of
the pipe in the filler neck.
If the coolant level is too low:
• Top up coolant.
See the Mercedes-Benz operating instructions for the composition of
the coolant.
• Screw the filling hole cap on until it reaches end position.
S
If the coolant has to be topped up frequently, the cooling system may be
leaking. Have GROVE Product Support or your repair crew check the
cooling system and repair the system if required.
10.01.2000

8.1 Crane engine
8.1.3 Checking the dry air filter D
The dry air filter is on the right-hand side of the superstructure outside
above the crane engine.
The indicator lamp Crane engine air filter is on the front instrument panel of
p the crane operator’s cab. If this indicator lamp lights up, the dry air filter
must be replaced.
• Release all clamps (1) on the filter lid.

• Take off the filter cover (2).
• Extract the filter cartridge (1).

• Insert a new filter cartridge.
If the seal on the filter cover is worn:
• Put the filter lid back in place and secure it

with all the clamps.
10.01.2000

8.1 Crane engine
8.1.4 Checking the overall condition and checking W

for leakage
• Check all pipes and hoses for

– tight connection,
– leaks,
– worn spots.
• Replace any damaged pipes and porous or swollen hoses.
• Tighten any connections which are leaking.
If the connection still leaks:
• Inspect the crane engine visually for any obvious dirt or leaks.
• Listen out for any unusual noises from the crane engine.

10.01.2000

8.1 Crane engine
8.1.5 Cleaning the fuel prefilter screen M3
Shutting off and Before cleaning the fuel filter cartridge, the following must be done:
O
the ground.
Underneath the crane engine at the height of

the second service flap there is an outlet (1)
for emptying the fuel line.

(e. g. a drip pan) underneath the outlet
(capacity approx. 5 l).
• Close the tap (1) to the tank in the fuel line.

The tap is closed when the handle is per-
pendicular to the line.
• Open the tap (2) (handle parallel with the
line).
The fuel now flows into the collecting vessel.
• Leave the vessel under the end of the

hose. More fuel can escape when changing
the fuel filter insert.
10.01.2000
s
8.1 Crane engine
Cleaning the The fuel prefilter is on the left side of the crane engine and can be
prefilter screen reached through the opening on the right side of the turntable when the
main boom has been raised.
• Unscrew the prefilter’s filter container (1).

• Clean the filter container and filter screen
(3) with clean diesel fuel using a soft
brush. Replace a heavily soiled or dama-
ged filter screen.
• Check and, if necessary, replace the sea-
ling ring (2) in the filter lid.
• Insert the filter screen into the filter contai-
ner and screw it back onto the prefilter hou-
sing (4).
After changing the fuel filter insert you must

re-establish the state of operation:
• Open the tap (1) in the fuel line to the tank.

The tap is open when the handle is parallel
with the pipe.
• Close the tap (2) (handle perpendicular to
the pipe).
• Start the engine and check that the fuel
filter is leak-tight.
the outlet.
If you have used a clean collecting vessel you can refill the diesel tank
with the same fuel, using a sieve. Otherwise you must collect the fuel for
disposal.
O
Store used fuel filter cartidges in suitable containers and dispose of them
properly.
10.01.2000

8.1 Crane engine
8.1.6 Changing the fuel filter cartridge M 12
Shutting off and Before changing the fuel filter cartridge you must:
O
the ground.
Underneath the crane engine at the height of

the 2nd service flap there is an outlet (1) for
emptying the fuel line.

(e. g. a drip pan) underneath the outlet
(capacity approx. 5 l).
• Close the tap (1) in the fuel line to the tank.

The tap is closed when the handle is per-
pendicular to the line.
• Open the tap (2) (handle parallel to the
pipe).
The fuel now flows into the collecting vessel.
• Leave the vessel under the end of the

hose. More fuel can escape when changing
the fuel filter cartridge.
10.01.2000
s
8.1 Crane engine
Changing the fuel The fuel filter cartridge is located on the left side of the crane engine and
filter cartridge can be accessed through the opening in the right side of the turntable af-
ter lowering the boom.
• Unscrew the cap (1) and filter cartridge (3)

and pull it out a bit from the filter housing.
Let the rest of the fuel drain off.
• Remove the screw cap with the filter
cartridge and remove the cartridge by
applying pressure on the sides of the lower
edge.
• Replace the rubber sealing ring (2) (lubricate
lightly).
• Clip a new filter cartridge onto the screw
cap.
• Replace the cap with cartridge and tighten
it. Tightening torque 25 Nm.
After changing the fuel filter cartridge, you

must re-establish the state of operation:
• Open the tap (1) in the fuel line to the tank.

The tap is open when the handle is parallel
with the pipe.
• Close the tap (2) (handle perpendicular to
the pipe).
• Start the engine and check that the fuel
filter is leak-tight.
the outlet.
If you have used a clean collecting vessel,

you can refill the diesel tank with the same fuel, using a sieve. Otherwise
you must collect the fuel for disposal.
O
Store used fuel filter cartidges in suitable containers and dispose of them
10.01.2000
properly.

8.2 Hoists
8.2 Hoists
The main hoist and the auxiliary hoist of identical construction (additional
equipment) are located on the superstructure turntable. The auxiliary
hoist is located behind the main hoist.
8.2.1 Checking the oil level W
The standpipe used to read the oil level in the hoist gears is located on
the left side of the hoists.
• Check the oil level of the hoist gear on the

standpipe (3). The oil level must be
between the MIN and MAX (4) marks.
• Unscrew the upper sealing screw (1) and

remove the connecting hose (2) from the
standpipe.
• Top up oil via the standpipe (3). Only use
oil specified in the Maintenance plan, p. 5-7.
• Change the sealing rings of the upper sea-
ling plug and screw the top hose back on.
• Check the oil level of the brake unit by

unscrewing the sealing plug out of the
overflow opening (1).
The oil level must be visibly under the
opening.
• Unscrew the sealing screw of the filling

hole (2) and top up with oil.
Only use oil specified in the Maintenance
plan, p. 5-7.
10.01.2000

8.2 Hoists

• If hydraulic oil or gear oil has been lost, check the oil levels and top up
if necessary.

8.2.3 Checking the hoist brake W
Test correct function of the hoist brake by suspending a load on the load
hook for a certain time and measuring whether the load lowers on its own.
Perform the test on the main hoist and the auxiliary hoist.
• Suspend the hook block on the singly reeved hoist rope.

• Lift a test load of approx. 9.2 t approx. 30 cm above the ground.
• Measure the distance from the ground when the test load is hanging
completely still.
• Switch off the diesel engine.
If the test load has not lowered after approx. 2 minutes, the brake applied
is in working order at that time.
10.01.2000

8.2 Hoists
8.2.4 Lubricating auxiliary hoist gearbox W
H The following maintenance work applies to the main hoist and the
auxiliary hoist (additional equipment).
The main hoist has a lubricating nipple (1).

The lubricating nipple is on the left side of
the superstructure on the main hoist.
Use only lubricating grease according to the


lubricating nipple.
• Use a grease gun to apply grease to the
lubricating nipple.
8.2.5 Changing the oil M 12
The hoists have separate oil chambers for the gear box and the clutch
housing.
Only use oil specified in the Maintenance plan, p. 5-15.
S
Be careful not to damage the hoist gear!
The old oil must be tested for abrasion particles. This examination serves
to identify damage early.
O
Always use oil collection containers which are oil-resistant.
10.01.2000
s
8.2 Hoists
Oil change on The oil change is carried out via the connecting hoses to the standpipe (1).
hoist gear
• Have a container (with a capacity of over

8.0 l) ready under the standpipe (3) to col-
lect the oil.
• Release the upper sealing screw (1) and
remove the upper hose (2).
• Unscrew the lower sealing screw (5) and
drain the oil into the container.
• Change the sealing rings of the lower
sealing screw and screw the lower hose (4)
back on.
• Fill oil via the standpipe to the max. mark
(6) on the standpipe.
• Change the sealing rings of the upper sea-
ling screw and screw the uppeer hose back
on.
H
Oil change on the
brake unit
Since the oil is distributed slowly in the clutch housing being filled, the oil
level on the overflow opening will at first rise quickly and then subside a
little; afterwards it will rise to the final filling level.

approx. 1 l) underneath the oil drain (3).
• Unscrew the sealing screws of the filling
hole (1) and the overflow opening (2).
• Remove the screw connection (3) and
drain the oil.
• Screw the screw connection (3) on again.
• Fill slowly with oil through the filler
opening (1) up to the lower edge of the
overflow opening (2).
• If necessary replace the sealing rings for
the sealing screws of the filler and over-
flow openings.
• Screw the sealing screws in again.
10.01.2000

8.2 Hoists
O
Collect waste oil in approved containers and have it disposed of properly.
H
Checking the oil
Check the old oil which was drained from the gear units during the oil
change for abrasion particles, or have it tested in a laboratory.
• Pour the old oil through a clean filter fleece.

• Examine the oil or the residues on the filter fleece using a magnifying
glass.
If you find abrasion particles or solid matter on the fleece, the hoist gear
H
must be dismantled for inspection and examined by the manufacturer.
With the first oil there may be some abrasion particles in the oil. If you
notice any abrasion particles during the first oil change (after 200 opera-
ting hours), contact GROVE Product Support before you take any more
measures.
G
Risk of accidents!
If this examination is not carried out, there is a risk of damage to the
hoist gears and thus the possibility of the load falling.
8.2.6 Carrying out partial inspection of hoists Y3
Certain parts must be inspected for wear during the partial inspection:
– the multiple-disk brake,

– the plug connections between hydraulic engine and multiple-disk brake
and
– the plug connections between the multiple-disk brake and the gearbox
unit (where applicable).
H
These parts must be replaced when worn.
10.01.2000
Inspections and part replacements must only be carried out by trained,

qualified personnel.

8.2 Hoists
8.2.7 Carrying out general inspection of hoists Y6
H See also the information on general inspection of hoists in Necessary

measures for monitoring the winches, p. 5-21.
The hoist gear is to undergo general inspection after the period of time
indicated in the Maintenance plan. This inspection involves disassembly of
H
the gearbox and sending it to the manufacturer for testing.
Run-in specifications require that the oil of new gearboxes and gearboxes
that have undergone a general overhaul be changed after 200 and
1000 operating hours before the yearly interval can be implemented.
10.01.2000

8.3 Slewing gear
8.3 Slewing gear

The slewing gear is on the left-hand side of the superstructure.
8.3.1 Checking the oil level W
H The oil must be cool before carrying out an oil inspection.

Therefore always check the oil level before using the crane.
• Check the oil level through the oil level

sight glass (1) on the slewing gear trans-
mission.
The oil must be visible in the oil level sight
glass.
• Always check the oil level for both slewing
gear units.
• Unscrew the bleeder screw (3) and fill the

oil according to the Maintenance Plan; p. 5-7.
• Close the opening.
• For the slewing gear brake, check the oil

level using the oil level sight glas (1) in the
expansion tank (2).
• Always check the oil level for both slewing
gear units.
• Unscrew the ventilation filter (3) from the

expansion tank (2) and fill the oil according
to the Maintenance Plan; p. 5-7.
• Close the opening.
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8.3 Slewing gear

• If hydraulic oil or gear oil has been lost, check the oil levels and top up
if necessary.
8.3.3 Lubricating slewing gear pinion and gear rim M6
The slewing gear pinions and the gear rim must be lubricated with special
grease (➠ Maintenance plan, p. 5-13). The grease is applied to the gear
teeth with a brush or sprayed on. There are different procedures for the
H
first time and subsequent lubrications.
Observe the instructions and safety advice on the grease packaging.
• Unscrew the screws and remove the guard

(1) in front of the slewing gear pinions (2).
First lubrication:
• Clean the gear teeth of the slewing gear pi-

nions (2) and the gear rim (3) thoroughly
to remove residue of old lubricants.
• Apply a thin layer of adhesive lubricating
grease and leave to penetrate for approx.
10 minutes.
• Apply a second, thicker coat and leave to
penetrate for approx. 30 minutes.
Subsequent lubrication:
• Apply a new layer over the existing layer

of adhesive lubricating grease.
• Leave to penetrate for approx. 30 minutes.
10.01.2000

8.3 Slewing gear
8.3.4 Changing the oil M 12
Slewing gear The oil drain screws of the slewing gear are always above the gear rim of
transmission oil the slewing gear pinion. Only use oil specified in the Maintenance plan,
change p. 5-15.
O
Always use oil collection containers which are oil-resistant.
• Unscrew the guard (2) in front of the sle-

wing gear pinions.
• Have an oil collection container ready (ca-
pacity for all two slewing gears approx. 5 l).
Change the oil one after the other in both sle-
wing gears:
• Unscrew the bleeder screw (4).

• Unscrew the ventilation filter (5) from the
filler neck.
• Unscrew the oil drain plug (3) and drain
the oil into the oil container.
• Replace the sealing ring on the oil drain
plug and screw the plug back in.
• Top up oil and check the level on the oil
level sight glass (1).
• Screw the ventilation filter and the ventila-
tion screw back on with a new sealing ring.
• Change the oil also in the other slewing
gear.
O
Collect waste oil in approved containers and have it disposed of properly.
10.01.2000
s
8.3 Slewing gear
H
Checking the oil
Check the old oil wich was drained from the slewing gear transmission du-
ring the oil change for abrasion particles or have it tested in a laboratory.
• Pour the old oil through a clean filter fleece.

• Examine the oil or the residues on the filter fleece using a magnifying
glass.
If you find abrasion particles or solid matter on the fleece, the slewing
gear transmission must be dismantled for inspection and examined by
the manufacturer.
Slewing gear bra- The slewing gear brake is located on the slewing gear itself. Only use oil
ke oil change specified in the Maintenance Plan, p. 5-15.
O
Drain the oil into the collecting vessel via a draining gutter. Wipe up spil-
led oil immediately.
• Have an oil collection container ready (ca-

pacity approx. 1.5 l).
• Unscrew the vent filter (4) from the expan-
sion tank (3).
• Remove the screw from the oil drain
opening (1) and let the oil run into the oil
collection container via a draining gutter.
• Replace the sealing ring and replace the
screw (1) in the oil drain opening.
• Add new oil through the expansion tank (3)
until the oil level is in the middle of the oil
level sight glas (2).
• Screw the vent filter (4) back on to the ex-
pansion tank.
O
Collect old oil in approved containers and have it disposed of properly.
10.01.2000

8.3 Slewing gear
8.3.5 Slewing gear brake function check D
To check the wear on the slewing gear brake plates you must carry out a
slewing gear service brake function test. This involves slewing movement
against the slewing gear service brake.
G
The truck crane may overturn when turning the superstructure!
The truck crane must be put on outriggers before slewing the superstruc-
ture. Read the instructions in the chapter Crane work with the main boom _
slewing in the Operating Instructions before you carry out the function
check.
• Release the slewing gear permanent brake by pressing the Slewing gear
Y permanent brake rocker switch up.
• The Slewing gear permanent brake indicator lamp goes out.
Y
• Push the Slewing gear service brake pedal down and hold it.
• Active the slewing gear. To do this turn the left-hand control lever
slowly to the left or right as far as it will go.
If the superstructure turns, the slewing gear service brake plates are worn
and must be replaced immediatly.
• Only have the plates changed by GROVE Product Support.

10.01.2000

8.3 Slewing gear
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10.01.2000

8.4 Superstructure hydraulic system
8.4.1 Checking the hydraulic oil level D
The hydraulic oil tank is on the left-hand side of the superstructure.

The level can be checked through the inspection glass.
To check the oil level properly:
– The main boom must be fully retracted and on the boom support.
– The counterweight lifting cylinder must be retracted.
• Check the level of the hydraulic oil tank

through the inspection glass (2).
The hydraulic oil should be visible in the
centre of the inspection glass when cold.
If the level is too low:
• Top up the hydraulic oil through the filler

opening (1).
Only use hydraulic oil that is specified in
S
10.01.2000

8.4.2 Checking the hydraulic hoses W
Checking is described in section Hydraulic system in carrier - checking

hydraulic hoses, p. 7-40.
• With the crane engine running, make a visual inspection for leaks and
escaping hydraulic oil at the hydraulic components of the superstructure
(hydraulic cylinders, lines, connections, hydraulic pumps, motors and
valves).
• If leaks are detected, check the hydraulic oil level and top up if
necessary (➠ Checking the hydraulic oil level, p. 8-23).
G
Risk of accidents!
Never tighten leaking connections when the system is under pressure.
Only change seals, pipes and hoses when the system is depressurized.

O
Remove leakages in the hydraulic system or have them removedto
ensure that no hydraulic oil seeps into the ground or reaches waters
during crane deployment.
8.4.4 Bleeding the derricking cylinder M1
There are bleeder screws on the derricking cylinder for bleeding the cylin-
der chambers.
In the toolbox there is a special key with a transparent hose for opening
the bleeder screws. Only this special key should be used to open the blee-
der screws.
10.01.2000

Preconditions With the following requirements it is assumed that the counterweight and
lattice extension are not rigged.
• Park the truck crane on a flat, even surface.

• Support the truck crane with an outrigger span of at least
7.80 m x 5.10 m.
• Fully retract the main boom.
• Set the SLI code for 0 t counterweight.
• Turn the superstructure to the rear or to the side.
• Lower the boom as far as possible.
Bleeding the
piston rod
chamber
G
Risk of accidents from hydraulic oil being sprayed!
The hydraulic system is under pressure and you may therefore only
loosen the ventilation screws. If you unscrew the ventilation screws,
hydraulic oil will spray out under pressure.
• Remove the cap from the bleeder screw (1)

on the piston rod chamber.
• Fit one end of the transparent plastic hose
over the bleeder screw and hold the other
end in a container filled with oil.
• Loosen the bleeder screw by 1-2 turns.
G
Risk of accidents when raising the main boom!
Move the control lever very carefully. To ventilate only hydraulic oil must
be delivered into the derricking cylinder. The derricking cylinder must not
move!
10.01.2000
• Carefully raise the control lever until the oil flowing through the transpa-
s
rent plastic hose no longer contains any air bubbles.

• Tighten the bleeder screw, remove the plastic hose and replace the cap
on the bleeder screw.
Bleeding the Before ventilation the requirements at the start of this section must be
piston head area fulfilled.
G
Risk of accidents from hydraulic oil being sprayed!
The hydraulic system is under pressure and you may therefore only
loosen the ventilation screws. If you unscrew the ventilation screws,
hydraulic oil will spray out under pressure.
• Check that the boom is lowered as far as it

will go.
• Remove the cap from the upper bleeder
screw (1).
• Fit one end of a plastic transparent hose
over the bleeder screw and hold the other
end in a container filled with oil.
G
Risk of hands and arms being crushed!
Move the control lever very carefully. To ventilate only hydraulic oil must
be delivered into the derricking cylinder. The derricking cylinder must not
move!
• Carefully raise the control lever until the oil flowing through the transpa-
rent plastic hose no longer contains any air bubbles.
• Tighten the bleeder screw, remove the plastic hose and replace the cap
on the bleeder screw.
10.01.2000

8.4.5 Bleeding telescoping cylinders M1
There are bleeder screws on the telescoping cylinder for bleeding the
cylinder chambers. The bleeder screws are accessible through handholes
in the telescope sections.
In the toolbox there is a special key with a transparent hose for opening
the bleeder screws. Only this special key should be used to open the blee-
der screws.
Preconditions With the following requirements it is assumed that the lattice extension is
not rigged.

• Create one of the two following rigging states:
– The truck crane is supported with the outrigger span 7.80 m x 5.10 m
and at least a 24 t counterweight is rigged or
and at least a 11 t counterweight is rigged.
• Enter the SLI rigging code for the current rigging mode of the truck
crane.
• Fully retract all telescope sections.
• Unreeve the hook block.
• Slew the superstructure to the rear or to the side.
• Derrick the boom into horizontal position.
Bleeding Carry out the bleeding procedure on all bleeder screws in turn.
procedure
• Remove the cap from the relevant bleeder screw.
• Place the special key with the transparent hose onto the bleeder screw.
Hold the other end of the hose in a container filled with oil.
• Carefully fill the telescoping cylinder with hydraulic oil until the oil
flowing through the hose no longer contains any bubbles. Extend the
relevant telescope section in the direction specified.
The oil collected in the container must not be used again as it contains air.
10.01.2000
s
Location of the
bleeder screws
Position no. Bleeding for: Access to vent on basic section via:
Manhole in the upper chord

1 Set of piston rings
Basic section
Opening in telescope section IV

2 Piston chamber
Left side
10.01.2000

Telescoping The position numbers indicated below refer to the illustrations for Location
status of the bleeder screws in this section; ➠ p. 8-28.
Bleeder screw position no. 1
G
Retracting boom poses risk of crushing!
Do not reach into the manhole until the boom has been secured so that it
can not retract inadvertently. If you are carrying out this operation with
the help of someone else, communicate with the person in the crane cab
by means of clear hand signals.
• Unscrew manhole cover plate.

• Extend telescope section I approx. 2.0 m so that the access to the man-
hole is free.
• Fit the bleeder key through the manhole onto the bleeder screw (1) on
the telescoping cylinder and open with one or two turns.
• Make sure nobody is in the manhole or is reaching into the manhole.
• Carefully move control lever for telescoping in the retract direction so that
the pressure in the set of piston rings increases and the air is pushed
out through the plastic hose.
• Close the manhole again with the cover plate.
Bleeder screw position no. 2
• Extend telescope section IV approx. 0.5 m.

• Insert bleeder key through the opening on the left side of telescope
section V on the bleeder screw and open 1 or 2 turns.
• Carefully move control lever for telescoping in the extend direction so that
the pressure in the set of piston rings increases and the air is pushed
out through the plastic hose.
10.01.2000

8.4.6 Changing the hydraulic oil filters and cleaning M3

the magnetic rod
Four hydraulic oil filters are built into the hydraulic system:
– a return flow filter and a fine filter in the tank of the crane’s hydraulic
– system,
– two pressure filters in the control oil circuit and feed oil circuit.
• The hydraulic oil filters must be replaced:

– if the warning lamps Hydraulic oil filter light up on the front instrument
g panel of the crane operator’s cab,
– after every hydraulic oil change.
The warning lamps are attached to the front

instrument panel:
– Hydraulic oil filter control circuit warning

lamp (1),
– Hydraulic oil filter feed circuit warning
lamp (2).
O
Catch the oil escaping during filter change and store used fuel filter in-
serts in suitable containers and have them disposed of properly by quali-
fied personnel.
10.01.2000

Return filter
The return filter is on the hydraulic oil tank.
• Switch off the crane engine and secure it

against being started by unauthorized per-
sons (sign in the crane cab).
• Remove the screws on the lid (1) and
remove the hydraulic oil filters from the
hydraulic oil tank.
• Remove the spring (1) from the top part of

the filter (3).
• Remove the nut (2) and the top part of the
filter.
• Unscrew the magnetic rods (5) and clean
them.
S
A large number of metal particles adhering to the magnetic rod is a sign
of damage to the hydraulic system.
Have the hydraulic system examined by GROVE Product Support or by
your repair crew.
• Change the hydraulic-oil filter element (6).

• Replace the O-rings (4) of the bottom and top part of the filter.
Reassemble the hydraulic oil filter and replace it in the hydraulic oil tank.
10.01.2000
s
Hydraulic oil filter

for control circuit
The hydraulic oil filter control circuit (1) is
located on the left side of the superstructure,
behind the crane cab.
• Switch off the superstructure engine and secure it against being started
by unauthorized persons (sign in the crane cab).
• Remove the ring (1).
• Remove the filter container (2).
• Remove the filter from the filter container.
• Insert the new filter into the filter container.
• Fill the filter container up to the edge with
oil.
• Screw the filter container on again.
• Start the superstructure engine and let it
run in neutral gear for 3 minutes in order
to bleed the system. 10.01.2000

8.4.7 Replacing the venting filter M 12
The two venting filters are located on the

hydraulic oil tank.
• Replace the venting filters (1).

10.01.2000

8.4.8 Taking oil samples M 12
Take an oil sample from the hydraulic oil tank and the hydraulic system
(➠ Handling the drain valves, p. 8-35).
The drain valves can only be opened and closed using the 1/2" fittings.
The fittings are to be found in the tool box; ➠ Handling the drain valves,
p. 7-45.
• The sample from the hydraulic oil tank is

taken via the drain valve (1).
• The oil sample from the hydraulic system

is taken via a gauge port (1) on the control
block. The control block is accessible via
an opening in the turntable behind the
crane cab.
• Proceed further as described in section
➠ Carrier hydraulic system – Taking oil
samples, p. 7-45.
10.01.2000

8.4.9 Changing the hydraulic oil M 12
The hydraulic oil only has to be changed if the laboratory analysis shows
that the permissible limits have been exceeded (➠ Taking oil samples,
p. 8-34), or the laboratory has recommended a date for an oil change.
Preconditions: The boom must be fully retracted and resting on the boom
support. The crane engine must be turned off and safeguarded against un-
authorized starting.
S
Damage may occur to the hydraulic pumps!
Ensure that the crane engine cannot be started by an unauthorized party.
If the engine is started while the gate in the suction line is closed, the
hydraulic pumps will be damaged!
The drain valves can only be opened and closed using the 1/2" fittings.
The fittings may be found in the tool box; ➠ Handling the drain valves,
p. 7-45.
G
Risk posed by escaping hydraulic oil!
When the fitting is screwed onto the drain valve, the valve opens and the
hydraulic oil immediately flows out of the fitting. Place the fitting hose in
an oil collection container before screwing on the fitting.
O
Always use the supplied 1/2" fitting with an oil drain hose and an oil col-
lecting vessel with sufficient capacity to drain the oil.
• Only use hydraulic oil that is specified in the Maintenance plan, p. 5-15.
• Remove the hydraulic oil filter and change the filter element. Do not yet
replace the hydraulic oil filter (➠ Changing the hydraulic oil filters and
• Have one or more containers ready to catch the oil (for tank capacity:
1200 l).
10.01.2000
s
The stop cock (2) is located on the inner side

wall of the hydraulic oil tank (1) for the super-
structure behind the cover plate in the sucti-
on line of the hydraulic pump.
• Close the stop cock (2) to the hydraulic

pumps.
The suction line is closed when the cock grip
is at right angles with the line.
• Screw the fitting with the oil drain hose

onto the fitting (1) on the tank and drain
the oil into the collecting vessel. (➠ Hand-
ling the drain valves, p. 7-45.)
Fit the new hydraulic oil filter (➠ Changing
the hydraulic oil filters and cleaning the magnetic
rod, pag. 8-30.
• Fill in new hydraulic oil through the filler opening (1) up to the centre of
the inspection glass (2).
O
Collect waste oil in approved containers and have it disposed of properly
by qualified personnel.
10.01.2000

S
• Open the stop cock (1) in the suction line.

The suction line is open when the cock grip
is parallel to the line.
• Start up the crane engine.

• Carry out all functions of the crane’s hydraulic system to remove any air
from the system.
• Check the oil level through the inspection glass in the hydraulic oil tank
(➠ Checking the hydraulic oil level, p. 8-23). If necessary, top up with oil.
10.01.2000

Blank page
10.01.2000

8.5 Main boom
8.5 Main boom
G
Be careful not to damage the locking pins!
The locking pins of telescope sections I to IV must never be lubricated.
If grease reaches the locking pins during lubrication, it must be removed
completely.
8.5.1 Lubricating the telescope slide faces M6
For lubricating the telescopic slide faces the main boom must be lowered
into horizontal position and the telescope sections must be telescoped
one after the other in a certain order so that the lubricating points are
reached.
G
Danger of overturning!
Before the main boom is lowered or extended, observe the requirements
laid down in this section, p. 8-40.
At the corners of telescope sections I to IV

there are four slide faces. The two lower
slide faces (2) and (3) are lubricated from the
outside in fully extended state.
The two upper slide faces (1) and (4) are lubri-
cated by one lubricating nipple each.
The following section shows the position of

the lubricating nipples.
10.01.2000
s
8.5 Main boom
Position of lubri-
cating nipples
The lubricating nipples (1) are on the upper booms of the telescope sec-
tions and are reached via corresponding lubrication holes (2) in the tele-
scope sections above. The diagram shows the telescope status for the
lubrication of the telescope section IV.
can be reached via

Lubricating nipple for Quantity
the lubrication hole in
Upper boom
Telescope section I 2
basic section
Upper boom
Telescope section II 2
Telescope section I
Upper boom
Telescope section III 2
Telescope section II
Upper boom
Telescope section IV 2
Telescope section III
G
Risk of accidents!
Danger of slipping due to grease residue. Do not climb onto the boom.
10.01.2000
Use the extendable ladder provided with your crane!

8.5 Main boom
Requirements The main boom must be partly extended in the horizontal position when
carrying out maintenance.
G
Risk of overturning when extending in horizontal position!
In the horizontal position the SLI blocks telescoping when there is an at-
tempt to extend a second telescope section.
Override the SLI only when you are prompted to do so in the following
section and do not extend the main boom more than indicated.
Even with 31 t of rigged counterweight and the superstructure slewed to
the rear you cannot extend all telescope sections. The truck crane would
first overturn.
Before lowering or extending the boom, the following conditions must

be met:
• Create one of the two following rigging states:
and at least a 24 t counterweight is rigged or
and at least a 11 t counterweight is rigged.
• Enter the SLI rigging code for the current rigging mode of the truck crane.
• Fully retract all telescope sections.
• Unreeve the hook block.
H
• Lower the main boom to the horizontal position.
To lubricate you must also telescope to intermediate lengths, therefore te-

lescope the main boom with semi-automatic (➠ section Crane work with
main boom in ChapterCrane operation in the Operating Instructions).
10.01.2000
s
8.5 Main boom
Lubricating slide • When lubricating, use only special grease specified in the Maintenance
faces of tele- plan, p. 5-13.
scope sections
• Lower the retracted main boom to the lowest position.
• Start with telescope section IV.
G
Risk of accidents from slipping off!
There is grease residue on the telescope sections. You must therefore
not walk on the boom.
Use the extendable ladder provided with your crane!
Lubricating tele- • Retract all telescope sections.

scope section IV
• Telescope the telescope section IV to the middle locking position and
lock it.
• Override the SLI by turning the override key switch to the right.
• Extend telescope section III to approx. 58 % until the lubricating hole
for telescope section IV can be reached in the upper boom.
• Inject approx. 100 ml of grease into each lubricating nipple (position 1).
• Retract telescope section III fully.
• Do not override the SLI any more.
• Extend telescope section IV fully.
• Use a spatula to apply a thin layer of grease to the bottom two slide
faces of telescopic section IV .
• Extend and retract telescope section IV again so that the grease is
distributed uniformly on the telescope slide faces.
• Retract telescope section IV.
10.01.2000

8.5 Main boom

scope section III
• Telescope the telescope section III to the middle locking position and
lock it.
• Extend telescope section II to approx. 58 % until the lubricating hole for
telescope section III can be reached in the upper boom.
• Retract telescoping section II fully.
• Extend telescope section III fully.
• Apply a thin layer of grease to the bottom two slide faces of telescope
section III with a spatula.
• Extend and retract telescope section III again so that the grease is distri-
buted uniformly on the telescope slide faces.
• Retract telescoping section III fully.

scope section II
• Telescope the telescope section II to the middle locking position and
lock it.
• Extend telescope section I to approx. 58 % until the lubricating hole for
telescope sectio II can be reached in the upper boom.
• Retract telescope section I fully.
• Extend telescoping section II fully.
• Use a spatula to apply a thin layer of grease to the bottom two slide
faces of telescope section II.
• Extend and retract telescope section II again so that the grease is
distributed uniformly on the telescope slide faces.
• Retract telescope section II.
10.01.2000
s
8.5 Main boom

scope section I
• Extend telescope section I to 100 %.
You can now reach the lubricating nipple via the front lubricating holes in
the upper boom of the basic section.
• Use a spatula to apply a thin layer of grease to the bottom two slide fa-
ces of telescopic section I.
• Extend and retract telescope section I twice so that the grease is evenly
spread on the telescope slide faces.
• Retract telescope section I.
10.01.2000

8.6 Hoist ropes
8.6 Hoist ropes
8.6.1 Check the position of sheaves and rope drums D
G
Risk of accidents with turning rope drum!
Keep yourself and other people away from the turning rope drum. If you
take hold of the turning rope drum, your fingers and hands could be
crushed between the rope drum and hoisting gear frame or get caught
and drawn in by the turning drum.
Check the position of the hoist ropes (1) on

the rope drums of the main hoist and the
auxiliary hoist (additional equipment).
• Slowly turn the rope drum at least one turn

in the lowering direction. Check the rope
on the drum as you do this.
– The rope must be wound evenly on the

drum.
– The turns of the rope must all be at an
equal distance of 0 to 2 mm.
– The cross-over points must be at an angle
of approx. 180° to each other.
H The upper layer of rope lies over the lower layer at the cross-over points.
• Check the position of the hoist ropes on the sheaves at the boom head
and in the hook block.
• Check the sheaves for damage and wear, and check that they run freely.
G
Risk of accidents from incorrectly set lowering limit switch!
Never turn the free rope end under the drum. Turns on the drum which
are not unwound with the rope drum stationary can not be detected by
the lowering limit switch. The lowering limit switch becomes adjusted by
this, switches off too late or not at all and the load may fall.
10.01.2000

8.6 Hoist ropes
8.6.2 Check the condition W
• Reeve the hoist rope on the hook block with 6 falls (➠ Operating instruc-
tions, chapter Rigging work, section Rigging work on main boom).
• Support the truck crane and enter the SLI code for the current rigging
mode.
• Raise the boom and extend it fully.
• Reel off the hoist rope and check the rope and rope travel (➠ Assessing
rope condition in this section, p. 8-46). When five turns are left on the
rope drum, the lowering limit switch must switch off.
If the lowering limit switch is not switched off or is switched off too late,
it must be reset (➠ Adjusting the lowering limit switch, p. 8-55).
• Check the mounting of the rope clamp (2)

on the rope drum for damage and ensure
that it is securely attached (Tightening
torque ➠ Special tightening torques,
p. 10-2).
• Check whether the hoist rope can be
wound without kinking and flattening:
The free rope end must not protude out of
the bore (1).
The entire rope loop with wedge must be in

the pouch (3) of the hoist drum.
• Check the rope securing device in the rope

end clamp (2) for proper seating and cor-
rect positioning of rope.
The rope end clamp (1) must be attached to
the free end of the rope and the rope must
secured around the rope wedge (3).
10.01.2000

8.6 Hoist ropes
Assessing the
H
condition of the
hoist rope
In doubt about damage assessment, always consult an expert.
To assess the condition of the hoist rope, you must be familiar with the
following:
– the type of rope (regular lay or long lay),
– the number of bearing wires in the outer strands,
– the rope diameter (➠ Operating instructions, chapter Technical
information, section Superstructure).
In a regular lay rope (1), the wires run

approximately in the longitudinal direction of
the rope.
In a long lay rope (2), the wires run at an

angle of approximately 45° to the longitudi-
nal direction of the rope.
To calculate the number of bearing outer

wires (1), count the number of outer strands
of the rope and multiply by 7.
H
10.01.2000
If there are a number of layers of strands, only the outer layer
s
is counted.

8.6 Hoist ropes
The following tables show the number of wire breaks, in a length 6 times
and 30 times the rope diameter, at which the rope must be replaced, for
the most common rope diameters.
Number of visible wire breaks
Number of Regular lay rope

bearing outer
wires ∅ 13 mm ∅ 16 mm ∅ 19 mm ∅ 22 mm ∅ 24 mm
over over over over over over over over over over
78 mm 390mm 96 mm 480mm 114mm 570mm 132mm 660mm 144mm 720mm
101 – 120 5 10 5 10 5 10 5 10 5 10
121 – 140 6 11 6 11 6 11 6 11 6 11
Number of visible wire breaks
Number of Long lay rope

bearing outer
wires ∅ 13 mm ∅ 16 mm ∅ 19 mm ∅ 22 mm ∅ 24 mm
over over over over over over over over over over
78 mm 390mm 96 mm 480mm 114mm 570mm 132mm 660mm 144mm 720mm
101 – 120 2 5 2 5 2 5 2 5 2 5
121 – 140 3 6 3 6 3 6 3 6 3 6
H The number of visible wire breaks indicated here only applies to the hoist
ropes! It only applies to the initial equipment and original spare parts!
S
Remember that other factors may also make it necessary to replace the
hoist rope before the number of wire breaks requiring rope replacement
has been reached (age of rope, frequency of use or exceptional loading).
10.01.2000

8.6 Hoist ropes
Damage Description Cause Replacement state of wear

Wire Individual wires are General wear due to Replace hoist rope at the
breakage (1) broken and the ageing of rope latest when the maximum
broken ends permissible number of broken
Wire breaka-
protrude from the or wires, is visible from the
ge cluster (2) rope. outside.
Strand brea- consequential
kage (3) damage from rope Replace hoist rope
damage. immediately if wire breakage
clusters or strand breakage
occur.
The frequency of wire
breakage increases with rope
age. For reasons of safety, it is
advisable to replace the hoist
rope while the number of
broken wires is low.
Effect of heat Tarnishing colour Rope has been Replace hoist rope
visible externally subjected to strong immediately.
on rope. heat.
10.01.2000
s
8.6 Hoist ropes

Decrease in The diameter of Structural alterations. Replace hoist rope
diameter (1) the rope has immediately, if the diameter
decreased over has decreased by 15 % or
longer sections. more in comparison to the
specified dimension.
Corrosion or abrasion. Replace hoist rope

immediately, if the diameter
has decreased by 10 % or
more in comparison to the
specified dimension.
Corkscrew- Rope has Consequential Even slight deformation

type rope de- corkscrew-type damage from causes increased abrasion,
deformation along overloading. wire breakage and uneven
formation (2)
its longitudinal running of rope drive.
axis. If the deformation “x” at a
Deformation is position on the hoist rope is
measured with greater than a third of the rope
suspended hook diameter, the hoist rope must
block. be replaced immediately.
Formation of Wires of outer Outer and inner Replace hoist rope

basket-type layer protrude. At layers have been immediately.
other locations the displaced in relation
structure (3)
core is buckled or to each other.
protrudes from the
10.01.2000
rope.

8.6 Hoist ropes

Formation of Wires of the outer General wear due to Replace hoist rope
loops (1) layer protrude in ageing of rope or immediately, if the rope
hairpin form from consequential structure is altered
the side opposite damage due to rope significantly by the loops.
the sheave. damage.
Loosening of Outer wires or Corrosion or abrasion. Replace hoist rope

wires or strands have immediately.
loosened. The
strands (2) Other causes. Number of broken wires
inner strands only
bear the weight. determines replacement state
of wear.
Formation of Repeatedly General wear due to Determine number of broken

nodes (3) occurring nodes in ageing of rope or wires.
rope, core often consequential Replace hoist rope
protrudes. damage due to rope immediately if serious node
Strands bear on damage. formation occurs.
each other at thin
locations, increased
frequency of wire
breakage.
Constriction Decreased General wear due to Replace hoist rope

(4) diameter over ageing of rope. immediately if serious
short sections. constriction occurs.
10.01.2000
s
8.6 Hoist ropes

Flattening (1) Crushed locations, Mechanical damage, Determine number of broken
mostly with broken e.g. due to driving wires, replace hoist rope
wires. over rope. immediately if serious
crushing occurs.
Crinkling Crinkle type rope Loaded hoist rope Replace hoist rope
deformation. was pulled over an immediately.
edge.
Kink (2) Rope deformation Rope was pulled Replace hoist rope
with twisting and straight while twisted immediately.
broken wires. and located in eyes.
Buckle (3) Buckled location in Mechanical damage. Replace hoist rope

rope. immediately. 10.01.2000

8.6 Hoist ropes
Replacing the Even the installation procedure has an influence on the service life of a
hoist rope hoist rope. Errors reduce the service life considerably, therefore:
– Install the hoist rope without twisting.

– Avoid contamination and damage when installing.
– Wind the hoist rope on in the same direction as the direction the hoist
rope was coiled onto the reel.
– Wind the hoist rope on with slight initial tension.
S
Use only a replacement hoist rope which has the same technical specifica-
tions as the defective rope or an original replacement rope.
• Unreeve the hook block (➠ Operating instructions, chapter Rigging work,

section Place hook block).
• Wind out the hoist rope until the lowering limit switch switches off.
• Adjust the lowering limit switch so that the hoist rope can be reeled out
completely (➠ Adjustment of lowering limit switch in this section, p. 8-55).
H
• Wind out the remaining layers from the hoist drum.
Ensure that the rope is not wound on again in the other direction.
G
Risk of accidents from rotating rope drum!
Turn off the crane engine and remove the ignition key so that no
unauthorized operation of the hoist can occur.
• Remove the two screws and the rope

clamp (3).
• Push the hoist rope (1) through the bore (2)
until the rope wedge (4) slides out of the
pouch of the hoist drum.
• Take out the rope wedge and pull the free
end of the hoist rope out of the pouch in
the hoist drum.
• Pull the hoist rope from the boom and the
sheaves at the boom head.
10.01.2000
s
8.6 Hoist ropes
• Place the rope reel with the new hoist rope on a reel stand.
• Place the reel stand in front of the boom head in such a way that the
hoist rope can be guided straight over the boom head sheaves onto the
boom.
• Pull the hoist rope over the boom to the hoist drum.
• Push the hoist rope (1) through the bore (2)
until it extends approx. 1.5 m from the
pouch (4).
• Feed the hoist rope back through the
pouch (4) into the second bore (3).
• The hoist rope must be approx. 50 mm in
the bore (3) but must not protrude over the
edge of the bore.
• Put on the rope clamp (2) and screw it

down (Tightening torques
➠ Special tightening torques, p. 10-2).
• Place the rope wedge (3) into the hoist
rope loop and insert into the pouch in the
hoist drum. The chamfered side of the
rope wedge must point towards the centre
of the hoist drum.
• Using the free end of the hoist rope (1),
pull the rope loop tightly until the rope
wedge slides fully into the pouch in the
hoist drum.
S
Be careful not to damage the hoist rope!
Ensure that the rope wedge, rope loop and rope end do not protude
beyond the diameter of the hoist drum. This protects the new hoist from
damage through kinking or flattening even when being reeled.
10.01.2000
• Restart the crane engine.

8.6 Hoist ropes
• Reel the hoist rope slowly onto the drum, keeping the hoist rope tight.
• Reeve a hook block six times ( ➠ Operating instructions, chapter Rigging
work, section Reeving hoist rope).
• Raise the boom to a steep position and extend it fully.
H
• Wind the hoist rope out until only five turns remain on the rope drum.
Watch the hook block when winding out.

The hook block must not rotate!
• Reset the lowering limit switch so that it switches off when five layers
have been wound on (➠ Setting the lowering limit switch in this section,
p. 8-55).
• Reel the hoist rope in by a few turns and lower it again to check the
lowering limit switch.
When five turns are left on the rope drum the lowering limit switch must
switch off the lowering movement.
G
Risk of accidents!
After installing a new hoist rope the lowering limit switch must always be
reset.
Setting the
lowering
limit switch
G
The lowering limit switch must always be reset after repair work to the
hoist and after rope replacement. A defective lowering limit switch must
always be replaced!
• Reeve the hoist rope with 6 falls.

• Extend boom fully.
• Lower hook block until only five turns remain on the hoist drum.
10.01.2000
s
8.6 Hoist ropes
The lowering limit switch is located on the hoist on the left-hand side of
the turntable.
• Remove the lowering limit switch cover (1).

• Turn the adjusting screw (2) until you hear
the micro-switch activate.
• Attach the cover to the lowering limit
switch again.
Make sure that the seal fits properly.
You must check the functioning of the
lowering limit switch it has been set.
Lowering limit • Raise the hook block until there are approx. 10 turns on the hoist drum.
switch function
• Lower the hook block again and check whether the lowering limit
control
switch is set properly.
The lowering limit switch must switch off the hoist when five rope turns
are still on the drum.
10.01.2000

8.7 Safe load indicator
8.7.1 Maintaining the slip ring assembly of the cable drums M6
The maintenance of the slip ring assembly is to prevent contamination

and corrosion and it also prevents malfunctions on the SLI.
The truck crane GMK 5100 has two cable drums whose slip ring assembly
needs to be maintained.
There is a cable drum (1) on the left side of

the main boom.
The second cable drum (1) is in the main

boom underneath the telescoping cylinder.
You can reach the cable drum through the

manhole if you extend telescope section I
approx. 2.0 m beforehand.
H
10.01.2000
The following sections describe the maintenance for the outer cable
drum. The maintenance on the cable drum in the boom is done in the
s
same way.

Requirements Before maintenance the following requirements must be met:
– The main boom is in the boom support.

– The battery master switch is switched off; ➠ Operating instructions, -
chapter Diesel engine, section Switching off diesel engine.
G
Risk of damaging the safe load indicator!
Before maintenance work on the slip ring assembly, always switch off
the battery master switch so that the cable drum is currentless.
This prevents short circuits which may lead to damage to the central unit.
Maintaining slip Use only lubricants according to the maintenance plan to lubricate the slip
ring assembly ring assembly; ➠ p. 5-13.
• Make sure that the cable drum is current-

less.
• Unscrew all screws (1) and remove the
casing (2).
• Check the seal on the casing for damage
and replace it if necessary.
• Remove any moisture in the casing with a
clean, lint-free cloth.
G
Risk of damage to health with improper handling!
When using and storing the lubricant make sure you observe the informa-
tion on the packaging and the enclosed safety data sheet!
10.01.2000

• Remove visible dirt on the slip rings (2)

with a clean, lint-free cloth.
• Spray the lubricant on all slip rings (2).
• Spread the lubricant by turning the drum
several times by a half revolution.
You can turn the drum by pulling the SLI cable
in the direction of the main boom head. If
you let go of the cable, the drum turns back
because of the initial tension.
• Check all screws (1) are tight.
• Wait until the solvent has evaporated com-

pletely.
• Put the casing (2) back in place. Make sure
that the seal is in the right place.
• Attach the casing with all the screws (1).
10.01.2000


The grease container (1) is located on the
right side of the turntable above the storage
compartment and in front of the crane engine.
Use only grease in accordance with the Table

of lubricants; ➠ p. 5-7.
The maintenance of the central lubrication

system on the superstructure is the same as
the maintenance of the central lubrication
system on the carrier (➠ Central lubrication
system, p. 7-49).
10.01.2000

8.9 Hook blocks
8.9 Hook blocks
8.9.1 Lubricate M1
The sheaves, cross heads and axial bearing of the load hook have to be
lubricated on the hook block.
Only use grease that has been specified in the Maintenance plan, p. 5-9.
The diagram gives an example of the loca-

tion of the lubricating nipples (1), (2) and (3)
on a hook block. There is another lubricating
nipple on the other side.
• Clean the lubricating nipples on all hook

blocks supplied and on the hook tackle and
lubricate them with a grease gun.
10.01.2000

8.9 Hook blocks
Blank page
10.01.2000

8.10 Superstructure electrical system
8.10.1 Check the acid level of batteries M1
This maintenance work is described in section 7.12.1 Checking the acid level
in the battery, p. 7-53.
8.10.2 Check the acid concentration of batteries M3
This maintenance work is described in section 7.12.2 Checking the acid

concentration in the battery, p. 7-54.
10.01.2000

Blank page
10.01.2000

8.11 Superstructure air-conditioning system (additional equipment)
8.11 Superstructure air-conditioning system

8.11.1 Checking moisture and level of the refrigerant M1
The refrigerant is checked through an

inspection glass on the refrigerant collector
while the air-conditioning system is running.
This is located next to the capacitor on the
left of the turntable and above the hydraulic
tank.
• Start the crane engine.

• Switch on the air-conditioning system and
let it run for approx. 10 minutes (Switching
on the air-conditioning system ➠ Operating
instructions, section Air-conditioning system
in chapter Crane operation).
• Check the refrigerant filling and the
moisture content of the refrigerant through
the inspection glass (1):
– The floater (2) must be at the top and
– the indicator pearl (3) must have a blue
colour.
If the floater is at the bottom (no refrigerant can be seen in the inspection
glass) or if the indicator pearl has a pink colouring, the air-conditioning
system is defective.
If the air-conditioning system is faulty:
• Switch the air-conditioning system off and do not use it again to avoid
further damage.
Have the air-conditioning system repaired as soon as possible by GROVE

Product Support.
After checking:
• Switch off the air-conditioning system and stop the crane engine.
10.01.2000

8.11.2 Cleaning capacitor cooling fins M1
S
Damage may occur to the capacitor and fan wheel!
Do not use a high pressure or steam jet cleaner. The hard water jet can
damage the cooling fins or the fan wheel. Use only compressed air for
cleaning.
• Switch the air-conditioning system off.

• Clean the cooling fins of the capacitor (1)
and fan wheel (2) with compressed air.
8.11.3 Checking hoses M6
Check the refrigerant hoses for damage and worn areas.
Have damaged hoses replaced only by GROVE Product Support.

10.01.2000

8.11.4 Checking the refrigerant collector M6
The refrigerant collector may only be

checked by GROVE Product Support!
For this the refrigerant collector (1) must be

examined by a qualified person externally
according to pressure container order (test
group II) for mechanical damage and
corrosion. If the refrigerant collector is not in
a proper condition, it must be replaced by
GROVE Product Support.
8.11.5 Checking the refrigerant compressor M6
The refrigerant compressor may only be

checked by GROVE Product Support!
The refrigerant compressor (1) is directly on

the engine underneath the fuel filter and can
be reached throught the opening on the right
side of the turntable after the main boom has
been raised.
Have the refrigerant compressor checked for

sealing. Above all the sealing of the drive
shaft should be checked.
10.01.2000

Blank page
10.01.2000

8.12.1 Lubricating the counterweight hoist unit M1
A lubricating nipple is located on both pivot bearings of the counter-

weight hoist unit.
Use only lubricating grease according to the Maintenance plan; ➠ p. 5-9.
Both pivot bearings of the counterweight

hoist unit are lubricated via a lubricating
nipple (1).
• Remove the old grease and dirt from the lu-

bricating nipples.
• Use a grease gun to apply grease to the lu-
bricating nipples.
8.12.2 Functional check of the additional heating system

This maintenance work is described in section 7.15.2 Functional check of the

additional water heating system and air heaters, p. 7-65.
For additional information, see section Crane cabin heating and ventilation,
water-additional heating system (additional equipment) in chapter Crane
operation in the Operating instructions.
10.01.2000

Blank page
10.01.2000

Longer inoperational periods
9 Longer inoperational periods

Carry out the following work if the truck crane is to be out of operation for
a long period (months):
Before the truck • Clean the crane thoroughly inside and outside.
crane is put out
• Remove rust and touch up the paintwork.
of operation
• Parts which are not painted must be lubricated with an acid-free grease
or oil.
• If more than half of the oil change interval has passed:
• Change the oil in accordance with maintenance plans M 3 to M 12.
• Seal all air filters.
• Increase the tyre pressure by 10 % and mark the position of the tyres on
.
the ground, or
support the truck crane with the outriggers.
During inoperatio- • Check the levels in the fuel tanks. Always keep the tanks filled.
nal periods
• Check the batteries every week and recharge them if necessary.
• Check tyre pressure every week and inflate the tyres if necessary.
• Perform a full functional check of the truck crane every two weeks.
(Open all air filters before the function test!)
Run the hydraulic systems up to a fluid temperature of approx. 50 °C
and check all functions of the carrier and superstructure hydraulic
systems.
• Ensure that the tyre positioning is different each time the crane is
parked (without outriggers).
• Seal all air filters again.
If the crane is inoperational for more than 12 months:

• Carry out all maintenance work in accordance with maintenance plan M 12.
10.01.2000
s
Longer inoperational periods
Before putting • Open all air filters.

the truck crane
• Inflate the tyres up to the prescribed pressure.
back into
operation • Carry out periodic maintenance work in accordance with the maintenance
plans in chapter 5.
10.01.2000

Tightening torques
10.1 Tightening torques for retaining bolts
10 Tightening torques
10.1 Tightening torques for retaining bolts
Metric standard screw-thread Standard values

B.A. screw thread
Tightening torques
(maximum permissible screw preload)
Spanner size (mm) for lubricated screws (Nm)
Thread size
(mm) Screw quality
Hexagon Cheese-head 8.8 10.9 12.9
screw screw
M8 13 6 23 32 36
M8x1 24 34 41
M 10 17 8 44 62 75
M 10 x 1.25 47 66 79
M 12 19 10 78 110 130
M 12 x 1.5 81 113 135
M 14 22 12 120 170 210

M 14 x 1.5 135 189 225
M 16 24 14 165 190 320

M 16 x 1.5 203 284 342
M 18 27 14 260 365 435

M 18 x 1.5 293 414 495
M 20 30 17 370 520 620

M 20 x 1.5 414 576 693
M 22 32 17 500 700 840

M 22 x 1.5 549 774 945
M 24 36 19 640 900 1080

M 24 x 1.5 702 990 1170
M 30 46 22 1300 1800 2160
M 33 50 24 2700
10.01.2000
M 36 55 27 3300

Tightening torques
10.2 Special tightening torques
10.2 Special tightening torques
Thread Spanner size Tightening

size (mm) torque
Name (mm) (Nm)
Hexagon Cheese-
screw head screw
Suspension cylinder:
– Vehicle frame/guide case (up- M 16 — 17 265

per)
– Vehicle frame/guide case (lower) M 24 — 19 900
– Support element/steering split M 16 — 14 265

shell
– Support element/operating head M 20 30 17 520
Locking screws for steering

linkage spherical-head connection M 12 x 1.5 19 — 70–90
Head = 40 mm
Clamping screws for steering lin-

kage spherical-head connection M 14 x 1.5 22 — 160 - 180
Head = 50 mm
Wheel nuts M 22 x 1.5 32 — 650
Ball slewing connection

M 27 41 — 1395
fixing screws
Rope clamp on the

M 10 17 — 46
hoist drum
10.01.2000

Appendix
1)
Table to determine the remaining theoretical service life on winch no. ...
Crane model: ..................
Works number: ..................
Commissioned on: ..................
Winch serial number in acc. with model plate: ..................
Power unit group: ..................
Collective load: ..................
Collective load factor: ..................
Theoretical service life: ..................
no. Date of inspection since last inspection Ti Km
inspection (collective inspection S i = ____i x T i Di = Di - 1 - S i
load) Km
"i" Km i [h] [h] [h] [h] [h] [h] [h]

1) To be used if this table is not contained in the crane logbook.
1)
Table to determine the remaining theoretical service life on winch no. ...
Crane model: ..................
Works number: ..................
Commissioned on: ..................
Winch serial number in acc. with model plate: ..................
Power unit group: ..................
Collective load: ..................
Collective load factor: ..................
Theoretical service life: ..................
no. Date of inspection since last inspection Ti Km
inspection (collective inspection S i = ____i x T i Di = Di - 1 - S i
load) Km
"i" Km i [h] [h] [h] [h] [h] [h] [h]

1) To be used if this table is not contained in the crane logbook.
Postfach 18 53 * D - 26358 Wilhelmshaven
Industriegelände West * D - 26389 Wilhelmshaven
Telefon (04421) 294 - 0
Telex 253354 * Telefax (04421) 29 43 01

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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

4 Run-in instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

5 Maintenance overview . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5.1 Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 1

5.2 Maintenance plans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

5.2.9 Maintenance and inspection plan Y 6:

5.3 Periodic inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 19

Maintenance Manual GMK 5100 2 084 543 en i-3

5.4 Measures required for winch monitoring . . . . . . . . . . . . . . . . . . . . 5 - 21

6 Lubricant and process materials . . . . . . . . . . . . . . . . . . 6-1

6.1 Lubrication chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 1

6.2 Process materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 3

7 Description of maintenance work on the carrier . . . . . . . 7-1

7.1 Vehicle engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 1

7.3 Transfer case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 17

7.4 Axle lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 19

i-4 2 084 543 en Maintenance Manual GMK 5100

7.6 Vehicle brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 31

7.9 Carrier compressed air system . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 37

7.10 Carrier hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 39

7.11 Central lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 49

7.12 Carrier electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 53

7.12.2 Checking the acid concentration of batteries . . . . . . . . . . . . . . . . . 7 - 54

7.13 Carrier air-conditioning system (additional equipment) . . . . . . . . . . . . 7 - 55

Maintenance Manual GMK 5100 2 084 543 en i-5

7.14 Trailer coupling (additional equipment) . . . . . . . . . . . . . . . . . . . . . 7 - 59

7.15 Other maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 65

8 Description of maintenance work on the superstructure 8-1

8.1 Crane engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

8.3 Slewing gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 17

8.3.2 Checking for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 18

i-6 2 084 543 en Maintenance Manual GMK 5100

8.5 Main boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 39

8.6 Hoist ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 45

8.7 Safe load indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 57

8.8 Central lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 60

8.9 Hook blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 61

8.10 Superstructure electrical system . . . . . . . . . . . . . . . . . . . . . . . . 8 - 63

8.11 Superstructure air-conditioning system (additional equipment) . . . . . . . 8 - 65

8.12 Other maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 69

Maintenance Manual GMK 5100 2 084 543 en i-7

10.1 Tightening torques for retaining bolts . . . . . . . . . . . . . . . . . . . . . . 10 - 1

10.2 Special tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 2

i-8 2 084 543 en Maintenance Manual GMK 5100

1.1 Using the Maintenance Manual

Please read chapters 1 and 2 carefully before beginning maintenance

Maintenance work on the lattice extensions is described in the operating

1.2 Warnings and symbols

Maintenance Manual GMK 5100 2 084 543 en 1-1

1.3 Maintenance instructions

Repair work also requires:

It is your responsibility to maintain and service the truck crane regularly in