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Grove GMK 5200-1
Manitowoc Grove GMK 5200-1 User Manual
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Maintenance manual
3 302 746 en
09.03.2018
2
Table of Contents
Table of Contents
3
General Instructions
7
Instructions for Using the Maintenance Manual
7
Warnings and Symbols
7
Maintenance Instructions
8
Instructions Regarding the Electronic Control
10
Safety Instructions for Welding Work
10
Definition of Direction References
11
Conversion Table for US Measuring Units
12
2 2 Safety and Environmental Protection
13
Safety and Environmental Protection
15
Safety Rules
15
Securing against Unauthorised Use
17
Handling Substances Which Are Harmful to the Environment
18
Disposal of the Truck Crane
20
Cleaning
23
Run-In Regulations
29
Maintenance Overview
33
6 6 Lubricants and Consumables
61
Lubricants
63
Lubricants List
64
Lubricant Applications List
65
Lubricants and Consumables
63
Consumables
67
Fuel
67
Engine Coolant Admixtures
67
After-Treatment of Exhaust Gases
68
Windscreen Washing System Admixtures
68
Fuel for Crane Cab Heating System
68
Refrigerant
67
7 7 Maintenance Work on the Carrier
69
General Instructions
73
Covers
73
Maintenance Work on the Carrier
73
Overview of Maintenance Work on the Carrier
74
Symbols for Maintenance Work
81
Checking the Oil Level
83
Engine
83
Topping up the Oil
85
Installing the Drain Valve
86
Checking the Air Filter
87
Checking the Coolant Level
88
General Inspection
89
Have the Radiator Checked/Cleaned
90
Check V-Belt Tension
94
Changing the Oil and Oil Filter
96
Fuel System
99
Draining off Water from Fuel Filter 1
100
Replacing Fuel Filter 1
101
Replacing Fuel Filter 2
103
Exhaust System with Exhaust Emission Control
105
Checking the Adblue Tank Level
106
Filling up with Adblue
106
Check the Exhaust System for External Damage
107
Having the Adblue System Checked
109
Transmission
111
General Inspection
112
Checking the VIAB Oil Level
113
Checking the Transmission Oil Level
114
Changing the VIAB Oil
115
Transmission Oil Change
118
Checking the Oil Level
121
General Inspection
121
Transfer Case
121
Changing the Oil
122
Angle Gear
125
Checking the Oil Level
126
General Inspection
126
Changing the Oil and the Oil Filter
129
Axle Centre Drives - Checking the Oil Level
133
Axle Lines
133
General Inspection
133
Axle Centre Drives - Changing the Oil
135
Final Drives - Checking the Oil Level
139
Final Drives - Changing the Oil
140
Lubricating the Cardan Shafts in the Axle Lines
142
Lubricating Longitudinal Cardan Shafts
143
Checking the Tyres for Damage
145
Wheels
145
Checking the Tyre Pressure
146
Checking that the Wheel Nuts Are Tight
147
Changing the Wheels
148
Checking the Wear Display
153
Vehicle Brake
153
Checking Disc Brakes
154
Suspension
161
Suspension Struts - Checking the Oil Level
161
Suspension Struts - Checking the Fastening
163
Forced Lever - Checking Correct Functioning
164
Pressure Accumulator - Checking the Gas Pressure
165
Checking for Leaks
167
Steering
167
Pressure Accumulator - Checking the Gas Pressure
168
Compressed Air System
169
Draining Water from the Compressed Air System
169
Checking for Leaks
170
Replacing the Filter Cartridge of the Compressed Air Drier
171
Checking the Oil Level
173
Hydraulic System
173
Checking for Leaks
174
Checking the Hydraulic Hoses
174
Cleaning the Magnetic Rods
175
Changing the Ventilation Filter
177
Taking Oil Samples
178
Changing the Hydraulic Oil
183
Changing the Hydraulic Oil Filter
187
Central Lubrication System
191
Checking the Level
191
Bleeding the Central Lubrication System
193
Triggering Intermediate Lubrication
193
Checking the Lighting and Indicators
195
Electrical System
195
Checking the Batteries
196
Checking the Charge Level of the Batteries
198
Charging the Batteries Using the Battery Charger
200
Check the External Starting Socket
201
Air Conditioning System
203
Checking Hoses
203
Checking the Air Conditioning System
203
Checking the Entire Air Conditioning System
204
Cleaning the Condenser Fins
204
Changing the Pollen Filter
206
Lubricating the Towbar Coupling
207
Towbar Coupling
207
Checking the Bearing
209
Checking the Cotter Pin
210
Checking the Initial Tension of the Springs
211
Checking the Lower Bushing
211
Checking the Function of the Coupling Jaw/ Resetting the Central Position
212
Checking the Support Ring
212
Checking the Windscreen Washing System
215
Other Maintenance Work
215
Lubricating the Outrigger Beams
216
Checking the Auxiliary Heater
217
Lubricating the Cab Door
217
Lubricating the Connecting and Socket Pins
218
Renewing the Corrosion Protection
219
Having the Fire Extinguisher Checked
221
8 8 Maintenance Work on the Superstructure
223
Maintenance Work on the Superstructure
225
Covers
225
Overview of Maintenance Work on the Superstructure
226
General Instructions
225
Symbols for Maintenance Work
231
Checking the Oil Level
233
Hoists
233
Checking the Hoist Brake
234
General Inspection
234
Changing the Oil/Checking the Oil
235
Having a General Inspection Carried out
237
Having a Partial Inspection Carried out
237
Checking the Oil Level
239
Slewing Gear
239
Checking for Leaks
240
Checking the Slewing Gear Brake
240
Changing the Oil/Checking the Oil
243
Checking the Screws
245
Slewing Bearing
245
Lubricating the Gear Teeth
249
General Inspection
251
Measuring Tilting Play
252
Lubricating the Locking of Turntable
254
Checking the Oil Level
255
Hydraulic System
255
Checking the Hydraulic Hoses
256
Checking the Ventilation Filter
256
Checking for Leaks
257
Cleaning the Magnetic Rods
258
Changing the Ventilation Filter
260
Pressure Accumulator - Checking the Gas Pressure
261
Taking Oil Samples
261
Changing the Hydraulic Oil Filter
263
Changing the Hydraulic Oil
268
Greasing the Piston Rod of the Derricking Cylinder
271
Main Boom
271
Lubricating the Telescopic Sections
272
Checking the Locking System
276
Checking the Sheaves
276
Checking the Winding
277
Hoist Ropes
277
Checking the Hoist Ropes
278
Lubricating the Hoist Rope
279
Assessing the Condition of the Hoist Rope
280
Replacing the Hoist Rope
286
Setting the Lowering Limit Switch
289
Cable Drums
291
Maintenance of the Slip Ring Assemblies
292
Central Lubrication System
293
Checking the Level
293
Checking the Sheaves
295
Greasing
295
Hook Blocks
295
Checking the Lighting and Indicators
299
Electrical System
299
Have the Battery on the Electronics Board Replaced
300
Air Conditioning System
301
Checking the Air Conditioning System
301
Cleaning the Condenser Fins
301
Checking Hoses
302
Checking the Entire Air Conditioning System
302
Changing the Pollen Filter
304
Checking the Windscreen Washing System
305
Other Maintenance Work
305
Checking the Auxiliary Heater
306
Lubricating the Crane Cab Door
307
Lubricating the Step
308
Lubricating the Connecting and Socket Pins
309
Renewing the Corrosion Protection
310
Having the Fire Extinguisher Checked
312
Longer out of Service Periods
315
Torques
319
Spare Parts Required for Maintenance
323
General Information
323
Lighting
323
Spare Parts for the Carrier
327
Spare Parts for the Superstructure
330
Appendix
335
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Manitowoc Grove GMK 5200-1 Specifications
General
Brand
Manitowoc
Model
Grove GMK 5200-1
Category
Construction Equipment
Language
English
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