GMK5200-1 - Manual de Serviço

Maintenance manual
3 302 746 en
09.03.2018
Important note
Any type of duplication or excerpt from this

document, even in electronic form,
is not subject to the revision service of
Manitowoc Crane Group Germany GmbH.
© Copyright reserved by
Manitowoc Crane Group Germany GmbH

Industriegelände West
D-26389 Wilhelmshaven, Germany
Tel.: [+49] (0) 44 21 294-0
09.03.2018
Fax: [+49] (0) 44 21 294-301

The passing on or duplication of this document as well as the utilisation and disclosure of its contents is prohibited unless
expressly permitted. Infringement will incur liability for compensation. All rights pertaining to registration of patent or utility
model are reserved. The original language of this document is German.
3 302 746 en Maintenance manual

GMK5200-1
Contents:
1 General instructions
2 Safety and environmental protection
3 Cleaning
4 Run-in regulations
5 Maintenance overview
6 Lubricants and consumables
7 Maintenance work on the carrier
8 Maintenance work on the superstructure
9 Longer out of service periods
10 Torques
11 Spare parts required for maintenance
Appendix
This maintenance manual does not replace the operating manual.
Details of operation and standard safety instructions can be found

in the operating instructions.
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Maintenance manual 3 302 746 en

GMK5200-1
Blank page
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1
1.1 Instructions for using the maintenance manual. . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1
1.2 Warnings and symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1
1.3 Maintenance instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 2
1.4 Instructions regarding the electronic control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 4
1.5 Safety instructions for welding work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 4
1.6 Definition of direction references. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 5
1.7 Conversion table for US measuring units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 6

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General instructions
1.1 Instructions for using the maintenance manual
1.1 Instructions for using the maintenance manual

This maintenance manual is not designed to replace proper training and
instructions.
Maintenance personnel for this truck crane must have the relevant, special-
ist knowledge and that of proper safety procedures.
Please read chapters 1 and 2 carefully before beginning maintenance work.
H
Maintenance work on the lattice extensions is described in the Lattice exten-
sion operating manual.
1.2 Warnings and symbols

The following designations and symbols are used in the operating manual
to highlight particularly important information:
G
This symbol indicates hazards related to the described operation and which
may cause personal injury during execution. The type of danger (e.g. life-
threatening, personal injury, risk of crushing or electric shocks) generally
precedes the warning sign.
S
Dangers which could put objects at risk are pointed out here, e.g. damage
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 indi-
cated next to the symbol. You will find more detailed information in section
Handling substances which are harmful to the environment, p. 2 - 4.
The vertical line to the left of the text indicates that: This text, regardless of
its length, relates to the warning symbol.
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Maintenance manual 3 302 746 en 1-1
GMK5200-1
1.3 Maintenance instructions
H
The hand with the pointing finger indicates passages that contain additional
instructions and tips regarding truck crane operation.
s
This symbol indicates that the topic is continued on the next page. 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 a qualified repair crew
(e.g. Manitowoc Crane Care).
Repair work also requires:

– Appropriate workshop equipment,
– Special tools and
– Spare parts approved by Manitowoc Crane Group Germany GmbH.
It is your responsibility to maintain and service the truck crane regularly and
carefully in order to extend its service life and keep it in good working order.
Please note that Manitowoc Crane Group Germany GmbH can only uphold
the warranty provided for the truck crane if the following conditions are met:
– It is used for the purpose for which it was intended,
– Care and maintenance are carried out as prescribed,
– Repair work/overhauling is carried out by qualified personnel.
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Many defects and failures are caused by improper maintenance such as:
– Insufficient oil, grease or antifreeze,
– Dirt,
– Damage to the ropes,
– Faulty compressed air and hydraulic systems,
– Damaged hoses or loose screw connections,
– Faulty brakes,
– Faulty 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. If repairs are needed, immediately contact
Manitowoc Crane Care or an authorised GROVE dealer or your repair crew.
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 the oil filler opening, the oil inspection opening, the oil drain
opening and the lubricating nipples.
• When changing the oil, it should run out at operating temperature.
• Ensure that only oils and lubricants specified in the Lubricants, p. 6 - 1 are
used.
• Replace all filters within the specified period if cleaning is not explicitly
permitted.
• Always replace all gaskets before assembly. Clean the sealing surfaces.
• Tighten loose screw connections on hydraulic and compressed air sys-
tems only when the system is depressurised.
• Keep brake and clutch linings free of grease.
• Replace hydraulic hoses immediately once damage or moisture penetra-
tion becomes visible.
• Cleanliness is imperative when handling hydraulic oil. Even when filling
with fresh hydraulic oil, it must be filtered.
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1.4 Instructions regarding the electronic control
• Cleanliness is imperative when handling grease for the central lubrication

system. Do not remove the caps from the filling hole and grease gun until
immediately before refilling the grease.
• Check fastening and retaining elements (nuts, bolts, lock washers etc.)
before re-using them and replace them if necessary.
Torques can be found in sections p. 10 - 1 and p. 10 - 2.
The training centre at our factory offers specialised training programmes for
your qualified personnel.
Please contact Manitowoc Crane Care.
The vehicle must meet all current regulations applicable to it before being
put into operation and driven on public roads.
1.4 Instructions regarding the electronic control

The electronic ESX control is designed for a service life of 10 years. In terms
of use, the control system's service life can be estimated based on the fol-
lowing limiting factors:
– The service life of EEPROM allows 106 accesses.
– The maximum number of make-and-break cycles for the safety relay
is 107.
– Some conventional capacitors in the ESX have a service life of 10 years.
The device must be serviced or replaced by Manitowoc Crane Care before
one of these limits is reached.
1.5 Safety instructions for welding work

To avoid damage, especially to electronic parts, there are certain measures
you must take before doing any welding work. You should therefore always
consult Manitowoc Crane Care before any welding work.
All welding work (especially on load carrying members) may only be per-
formed by qualified professional personnel with the prior written permis-
sion from Manitowoc Crane Group Germany GmbH.
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1.6 Definition of direction references
1.6 Definition of direction references
Basic rule Direction information always depends on whether the carrier or the super-
structure is being operated.
On the carrier
The driver's cab is always at the front, which means that:
1: front 2: right
3: rear 4: left
Forwards always means with the driver's cab leading,

Backwards always means with the rear lights on the carrier leading.
On the superstructure
The main boom head is always at the front, which means that:
1: front 2: right
3: rear 4: left
Switches and For switches and buttons, the terms down and up are used.
buttons
Regardless of the fitting position (vertical, horizontal, diagonal, perpendicu-
lar or turned), the following always applies:
Down: If (1) press – next to the symbol

Up: If (2) press – opposite the symbol
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1.7 Conversion table for US measuring units
1.7 Conversion table for US measuring units

The following conversion factors will help you convert from metric to US
units when the truck crane is used in countries that use US units of meas-
urement and vice versa.
Converting from into Multiply by

mm in 0.03937
in mm 25.4
m ft 3.28084
ft m 0.30479
m² ft² 10.76391
cm² in² 0.155
cm³ in³ 0.061
l gal (US) 0.264178
kg lbs 2.204622
lbs kg 0.45359
t lbs 2204.622
lbs t 0.0004536
kN lbf 224.809
daN/cm² lbf/in² 14.50378
lbf/in² daN/cm² 0.06895
bar psi 14.50378
psi bar 0.06895
m/s ft/s 3.28084
km/h or km mph or mi 0.62137
mph or mi km/h or km 1.60935
Nm lbf ft 0.7375
°C °F 1.8 x °C + 32
°F °C (°F-32)/1.8
t/m² lbs/ft² 204.8
m²/t ft²/lbs 0.04882
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MPa bar 10
bar MPa 0.1

GMK5200-1
2
2.1 Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 1
2.1.1 Securing against unauthorised use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 3
2.2 Handling substances which are harmful to the environment. . . . . . . . . . . . . . . . 2 - 4
2.3 Disposal of the truck crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 6

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Safety and environmental protection
2.1 Safety rules
2.1 Safety rules

When carrying out maintenance work, please observe the applicable
accident prevention regulations.
Observe the following safety rules:
• Familiarise yourself with the truck crane and its operation.

Read the Operating manual carefully and request guidance from the crane
operator.
• Do not carry out maintenance work on the truck crane unless you are
authorised to do so.
• Observe all safety and warning signs on the truck crane.
• Observe all safety instructions contained in this Maintenance manual.
• Familiarise yourself with the conditions under which the superstructure
may be slewed and the 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 secured against rolling away.
• Keep all handles, steps, railings and ladders free of dirt, grease, snow and
ice.
• Use the provided, safe access aids and working platforms when carrying
out work above body height. Wear a safety harness when carrying out
maintenance work at a great heights.
Use your personal fall protection equipment to secure yourself from fall-
ing from the truck crane.
All locations on the truck crane designed for fastening a fall prevention
safety system are marked with a symbol.
• Walk only on those machine parts which are equipped with appropriate
tread grids and railings and therefore guarantee safety. During rigging
and maintenance work on machine parts above body height which have
no apparatus for walking on, always use the supplied extendable ladder
(e.g. when lubricating telescopic slide faces).
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2.1 Safety rules
• Perform maintenance work only after the truck crane has been shut down.
Always ensure that the truck crane is well-protected from unauthorised
operation before beginning maintenance work. Remove the key and put
up warning signs.
If, due to exceptional circumstances, the truck crane needs be put into oper-
ation for certain types of maintenance work, great care must be taken where
there are moving parts (superstructure, outriggers, cardan shafts, slewing
bearing, engines, tiltable crane cab). There is a risk of injury.
• Ensure that all hydraulic components are returned to their initial positions
(e.g. the main boom) or locked (e.g. the outriggers) before starting main-
tenance work.
Escaping hydraulic fluid or compressed air can cause severe injury.
Remember that the hydraulic and compressed air systems of the truck crane
are pressurised even when the crane is not in operation. Tighten loose
screw connections only when the systems are depressurised. Always
depressurise the hydraulic and compressed air systems before opening
them.
• Do not allow hot fluids to escape in an uncontrolled manner. Risk of scald-

ing.
• Observe the applicable safety regulations when working with flammable
fluids.
• Observe the applicable safety regulations when working with consuma-
bles and auxiliary materials.
• Switch off all electrical consumers and first disconnect the earthing ter-
minal before removing any storage batteries.
• Keep in mind the corrosive effect of battery acid.
• Note the fire alarm and fire-fighting facilities on site.
• Return the truck crane to proper working order once maintenance work is
completed. Inform the crane operator accordingly.
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2.1 Safety rules
2.1.1 Securing against unauthorised use
• Secure the truck crane against unauthorised use by:

– Applying the parking brake,
– Switching the transmission to position N,
– Turning off the engine,
– Removing the ignition key and
– Stowing away the hand-held control in the crane cab or in the driver's
cab,
– Locking the driver's cab and the crane cab.
G
Danger due to unauthorised use.
Always stow away the hand-held control in the crane cab or in the driver's
cab before leaving the truck crane and lock the doors.
In this way you can prevent unauthorised persons from starting the engine
with the hand-held control.
• Set up warning signs in the driver's cab and in the crane cab with infor-
mation about
– when
– why
– and by whom
the truck crane was secured to prevent unauthorised use.
Remove the warning signs from the driver's cab and the crane cab after
completion of the maintenance work.
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2.2 Handling substances which are harmful to the environment
2.2 Handling substances which are harmful to the

environment
Which substances When you carry out maintenance work on the truck crane you will occasion-
are harmful to the ally work with consumables which are classified as harmful to the environ-
environment? ment by applicable national and regional regulations.
These include oil, fuel, grease, used oil and fuel filters, as well as rags which
have come into contact with these environmentally harmful substances.
• When handling these substances observe the applicable national and

regional regulations as well as the instructions in this chapter.
Using suitable Substances harmful to the environment can sometimes be corrosive. When
equipment doing maintenance work involving these consumables (oils, coolant, fuel)
always use receptacles, hoses, pumps, funnels etc. which have sufficient
capacity and which are resistant to the consumables.
For oil samples, always use receptacles that can be closed and have suffi-
cient capacity and resistance to the consumables.
The approximate amount of consumables to be expected is specified in the

maintenance plans.
Filling and • When filling and draining, make absolutely sure that no substances harm-
draining ful to the environment seep into the earth, escape into the sewage system
or pollute natural waters.
• Collect consumables (e.g. oils, fuels, coolant) in a suitable receptacle
when draining.
• Always use a drain hose when draining, and a funnel or a pump with
a hose suitable for the respective substance when filling.
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2.2 Handling substances which are harmful to the environment
Collecting and Substances which are harmful to the environment should always be col-
storing separately lected separately from other waste.
• Ask your local environmental protection authority about the different cat-
egories of the substances.
• Also, when collecting substances which are harmful to the environment,
keep solid materials (e.g. filter cartridges) separate from fluids. Disposal
costs will be reduced if you collect fluids separately according to defined
categories.
• Store environmentally harmful substances only in approved receptacles
and in locations which meet the requirements of applicable national and
regional regulations.
Disposal • Ask your local environmental protection authority about the prescribed
disposal options.
• Once collected, have environmentally harmful substances disposed
of only by disposal companies which are approved by the national or
regional authority responsible.
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2.3 Disposal of the truck crane
2.3 Disposal of the truck crane

Since you are the owner/operator, you can be faced with the proper, orderly
and final putting out of service and disposal and scrapping of the truck
crane.
Before you decide to finally put your truck crane out of service and to scrap
it:
• Allow Manitowoc Crane Care to advise you about alternatives.
Proper disposal • Find out about the applicable official regulations regarding the final de-
registration and disposal at the place of registration of the truck crane.
• At site, find out about certified vehicle disposal companies.
• Have the vehicle disposal company issue a disposal certificate for the
truck crane.
• Once collected, have all the environmentally harmful substances dis-
posed of only by disposal companies which are approved by the national
or regional authority responsible; àHandling substances which are harmful
to the environment, p. 2 - 4.
After disposal • Inform Manitowoc Crane Care about the disposal of the truck crane while
specifying the serial number.
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3
3 Cleaning
3.1 Overview of assemblies easily damaged when cleaning . . . . . . . . . . . . . . . . . . . 3 - 2
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Cleaning
3 Cleaning
During the first The paintwork on the truck crane will continue to harden for the first three
3 months months.
• During this period the crane may be cleaned only with cold water.
• Do not use high-pressure or steam jet cleaning equipment during this
period.
After the first • Avoid water temperatures above 60 °C (140 °F), even after this period.
3 months
• Do not use corrosive cleaning agents that might damage the paint.
• Never hold the spray nozzle of your cleaning unit at right angles to the sur-
face you are cleaning, and ensure that it is at a sufficient distance away
from the surfaces to be cleaned.
G
Risk of accidents from a 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 high
speed and great pressure.
Always wear a face guard when cleaning the truck crane with high-pressure
and steam-jet cleaning equipment.
• To prevent damage to the gaskets, never point the spray nozzle directly at
them.
• Never point the spray nozzle at electrical equipment, relay and switch
boxes, suction and ventilation filters or control elements and lubricated
surfaces.
• To prevent corrosion, relubricate all slide faces after cleaning.
• Keep all electric and hydraulic connections free of dirt. Check the connect-
ing points for dust, foreign bodies and moisture before installation. This
also applies to protective caps and bridging plugs.
The components specified in the next section are particularly at risk.
• After cleaning with high-pressure or a steam jet equipment, activate inter-

mediate lubrication on the central lubrication system ( à Triggering inter-
mediate lubrication, p. 7 - 121). Lubricate all remaining lubricating points
using a grease gun.
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Cleaning
3.1 Overview of assemblies easily damaged when cleaning
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Cleaning
1 RCL terminal box

2 Telescopic slide faces
3 Pressure sensors on the derricking cylinder
4 Lowering limit switch
5 Suspension struts
6 Heating/air conditioning system under the crane cab
7 Slewing angle sensor
8 Control units for outriggers
9 Angle data transmitter
10 RCL length data transmitter
11 Battery compartment
12 Spotlights, pivoting
13 RCL connections
14 Lifting limit switch
à Operating Instruc-
H
Assemblies at risk of damage on the lattice extension;
tions Lattice Extension.
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Cleaning
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4
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Run-in regulations
There are rules about running in individual parts which must be followed
after:
– First commissioning or
– Replacement of a part or
– General inspection.
This is why you must carry out additional maintenance work on the carrier
and superstructure after specific periods of time have expired:
Operating Driven km Additional maintenance work on the CAR-

hours (mi) RIER
(oper. hrs.)
after 4 Check the V-belt on the second alternator
and 24 (additional equipment);
à Check V-belt tension, p. 7 - 22.
after 50 (30) Tighten the wheel nuts;
à Special torques, p. 10 - 2.
after 150 Tighten the wheel nuts;
(95) à Special torques, p. 10 - 2.
after 50 Tighten the clips on the coolant hoses;
after 100 Lubricate the outrigger beams;
à Lubricating the outrigger beams, p. 7 - 144.
during Check the hydraulic oil filter every week, and
the first 100 change it if necessary;
à Cleaning the magnetic rods, p. 7 - 103,
à Changing the hydraulic oil filter, p. 7 - 115.
after 100 after 1,000 Change the drive oil;
(650) à p. 7 - 50 for the transfer case,
à p. 7 - 63 for the axle centre drives,
à p. 7 - 68 for the final drives.
after 250 after 2,500 Change the engine oil;
(1,550) à Engine manufacturer's documentation.
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Run-in regulations
Operating hours Additional maintenance work on the

(oper. hrs.) SUPERSTRUCTURE
after 50 Tighten the clips on the coolant hoses;
during the first 100 Check the hydraulic oil filter every week, and
change it if necessary;
à Cleaning the magnetic rods, p. 8 - 34,
à Changing the hydraulic oil filter, p. 8 - 39.
after 100 Tighten the bolts on the slewing bearing;
à Checking the screws, p. 8 - 21,
after 100 Hook blocks;
à Greasing, p. 8 - 71.
after 200 First oil change on the hoists;
à Changing the oil/checking the oil, p. 8 - 11.
after 1000 or after 12 Second oil change on the hoists;
months at the latest à Changing the oil/checking the oil, p. 8 - 11.
after 200 Change the slewing gear oil;
à Changing the oil/checking the oil, p. 8 - 19.
after 200 Change the oil on the angle gear
(with the power transmission from the car-
rier to the superstructure at the centre of
rotation); à p. 7 - 53.
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5
5.1 Maintenance intervals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 1
5.2 Maintenance plans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 3

5.2.1 Maintenance plan D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 4
5.2.2 Maintenance plan W . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 6
5.2.3 Maintenance plan M 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 8
5.2.6 Maintenance plan M 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 14
5.2.7 Maintenance plan Y 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 16
5.2.11 Maintenance plan Y 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 18
5.3 Periodic inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 19
5.3.1 Load hook inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 20
5.4 Measures required for winch monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 21
5.4.1 Theoretical service life. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 21
5.4.2 Proportion of theoretical service life used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 22
5.4.3 Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 26
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Maintenance overview
5.1 Maintenance intervals
– Maintenance plans D (= daily),

– Maintenance plans W (= weekly) and
– Maintenance plans M 1 (= once a month) to M 12 (= every 12 months) and
– Maintenance plans Y 2 (= every 24 months) to Y 10 (= every 120 months).
The maintenance plans are given in table form, divided into

– Maintenance work on the carrier and
– Maintenance work on the superstructure.
In the tables, cross references direct you to the sections in which the appro-
priate maintenance work is described. The cross references consist of the
chapter number and the corresponding page number, e.g.
Check hydraulic oil level; à p. 7 - 101.
Checking the hydraulic oil level is described in chapter 7, the section starts
on page 7 - 101.

The length of the maintenance interval depends on the grade of oil used and
operating conditions of the truck crane.
The next maintenance must be carried out after

– a specified time (maintenance interval) or
– a specified number of driven km (mi) or
– a specified number of operating hours (oper. hrs.) or
à p. 7 - 9 or
– an indication on the CCS display in the driver's cab;
– an indication on the CCS display in the crane cab; à p. 8 - 7.
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The maintenance interval which occurs first determines when the next
maintenance is due.
– The driven km (or mi) can be taken from the speedometer.
– You can individually call up the Operating hours (oper. hrs.) of the engine
and power units on the CCS display.
The following table sets out the maintenance intervals for the maintenance
plans:
Mainten- Maintenance Driven km (mi) Engine operating

ance plans interval (carrier) hours (oper. hrs.)
daily/before start-
D — —
ing up
W weekly — —
approx. 2,000
M1 monthly approx. 100
(approx. 1,240)
every three 5,000 – 6,000
M3 250
months (3,100 – 3,730)
10,000 – 12,500
M6 every six months 500
(6,210 – 7,770)
20,000 – 25,000
M 12 every 12 months 1,000
(12,430 – 15,530)
40,000 – 50,000
Y2 every 24 months 2,000
(25,000 – 31,000)
Y3 every 36 months — 3,000
100,000
Y5 every 60 months 5,000
(62,000)
Y6 every 72 months — 6,000
200,000
Y 10 every 120 months 12,000
(124,000)
Please note that the long-term maintenance plans always include the
short-term ones.
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5.2 Maintenance plans

The descriptions for certain maintenance work for the maintenance plans D,
W, M 1 to M 12 and Y 2 to Y 10 are provided for
– the carrier in chapter 7 and for

– the superstructure in chapter 8.
References (chapter and page number) to the description of this mainten-
ance work can be found after the respective maintenance work for carrier
and superstructure.
The section titles

– of chapter 7 Maintenance work on the carrier and
– of chapter 8 Maintenance work on the superstructure
contain the symbol (D to Y 10) of the relevant maintenance plan for better
comprehension.
In addition to the Maintenance work on the carrier and the Maintenance

work on the superstructure chapter 6 also lists the Lubricants and consum-
ables:
– The designations of the oils/lubricants in accordance with Lubricants list,
p. 6 - 2.
– The amounts as approximate values for oil amounts in litres (l) (and US
gallons (gal)) (the exact oil amounts can always be determined by the oil
level inspection holes, the oil dipsticks or the oil level indicators) Lubricant
applications list, p. 6 - 3.
H
Items that are only available with additional equipment are designated
accordingly in chapter 7 and chapter 8.
H
Maintenance work on the engines over and above the daily and weekly
checks is only partially described in this maintenance manual. When carry-
ing out such maintenance work, follow the instructions in the Engine manu-
facturer documentation supplied.
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GMK5200-1
5.2.1 Maintenance plan D D
Maintenance work on the CARRIER:

daily/before putting into operation
Engine
– Checking the oil level à p. 7 - 11
– Checking the air filter à p. 7 - 15
– Checking the coolant level à p. 7 - 16
Fuel system
– Draining off water from fuel filter 1 à p. 7 - 28
Exhaust system with exhaust emission control
– Checking the AdBlue tank level à p. 7 - 34
Wheels
– Checking the tyres for damage à p. 7 - 73
Vehicle brake
– Checking the wear display à p. 7 - 81
Steering
– Checking for leaks à p. 7 - 95
Hydraulic system
Electrical system
– Checking the lighting and indicators à p. 7 - 123
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GMK5200-1
Maintenance work on the SUPERSTRUCTURE:

daily/before putting into operation
Hydraulic system
Hoist ropes
– Checking the winding à p. 8 - 53
Electrical system
– Checking the lighting and indicators à p. 8 - 75
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GMK5200-1
5.2.2 Maintenance plan W W

weekly
Engine
– General inspection à p. 7 - 17
Transmission
Transfer case
Angle gear
Axle lines
Wheels
– Checking the tyre pressure à p. 7 - 74
Compressed air system
– Draining water from the compressed air system à p. 7 - 97
Hydraulic system
– Checking the hydraulic hoses à p. 7 - 102
Central lubrication system
– Checking the level à p. 7 - 119
Other maintenance work
– Checking the windscreen washing system à p. 7 - 143
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GMK5200-1

weekly
Hoists
– Checking the hoist brake à p. 8 - 10
Slewing gear
Hydraulic system
– Checking the hydraulic hoses à p. 8 - 32
– Checking the ventilation filter à p. 8 - 32
Hoist ropes
– Checking the hoist ropes à p. 8 - 54
Central lubrication system
– Checking the level à p. 8 - 69
– Checking the windscreen washing system à p. 8 - 81
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GMK5200-1
5.2.3 Maintenance plan M 1 M1

monthly/after approx. 2,000 km (approx. 1,240 mi)
Engine
– Notes; à Engine manufacturer's documentation à p. 7 - 11
– Check the exhaust system for external damage à p. 7 - 35
Transfer case
Angle gear
Axle lines
– Axle centre drives – checking the oil level à p. 7 - 61
– Final drives – checking the oil level à p. 7 - 67
– Lubricating the cardan shafts in the axle lines à p. 7 - 70
Wheels
– Checking that the wheel nuts are tight à p. 7 - 75
Suspension
– Suspension struts – checking the oil level à p. 7 - 89
– Suspension struts – checking the fastening à p. 7 - 91
Electrical system
– Checking the batteries à p. 7 - 124
Air conditioning system
– Checking the air conditioning system à p. 7 - 131
Towbar coupling
– Lubricating the towbar coupling à p. 7 - 135
– Lubricating the outrigger beams à p. 7 - 144
– Checking the auxiliary heater à p. 7 - 145
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GMK5200-1
M1

monthly/after approx. 100 oper. hrs.
Main boom
– Greasing the piston rod of the derricking cylinder à p. 8 - 47
– Checking the air conditioning system à p. 8 - 77
– Cleaning the condenser fins à p. 8 - 77
– Checking the auxiliary heater à p. 8 - 82
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GMK5200-1

every three months/after 5,000 - 6,000 km (3,100 - 3,730 mi)
Engine
Fuel system
– Replacing fuel filter 1 à p. 7 - 29
Vehicle brake
– Checking disc brakes à p. 7 - 82
Suspension
– Forced lever – checking correct functioning à p. 7 - 92
Hydraulic system
– Cleaning the magnetic rods à p. 7 - 103
Electrical system
– Checking the charge level of the batteries à p. 7 - 126
– Charging the batteries using the battery charger à p. 7 - 128
– Check the external starting socket à p. 7 - 129
Towbar coupling
– Checking the bearing à p. 7 - 137
– Checking the cotter pin à p. 7 - 138
– Checking the lower bushing à p. 7 - 139
– Checking the initial tension of the springs à p. 7 - 139
– Checking the support ring à p. 7 - 140
– Checking the function of the coupling jaw/ resetting the central position à p. 7 - 140
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5 - 10 3 302 746 en Maintenance manual

GMK5200-1
M3

every three months/after 250 oper. hrs.
Slewing bearing
– Checking the screws à p. 8 - 21
Hydraulic system
– Cleaning the magnetic rods à p. 8 - 34
Main boom
– Lubricating the telescopic sections à p. 8 - 48
– Checking the sheaves à p. 8 - 52
Hoist ropes
– Lubricating the hoist rope à p. 8 - 55
Hook blocks
– Checking the sheaves à p. 8 - 71
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Maintenance manual 3 302 746 en 5 - 11

GMK5200-1

every six months/after 10,000 - 12,500 km (6,210 - 7,770 mi)
Engine
Transfer case
– Changing the oil à p. 7 - 50
Angle gear
– Changing the oil and the oil filter à p. 7 - 57
Axle lines
– Lubricating longitudinal cardan shafts à p. 7 - 71
Wheels
– Changing the wheels à p. 7 - 76
– Checking the entire air conditioning system à p. 7 - 132
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GMK5200-1
M6

every six months/after 500 oper. hrs.
Slewing gear
– Checking the slewing gear brake à p. 8 - 16
Slewing bearing
– Lubricating the gear teeth à p. 8 - 25
– Measuring tilting play à p. 8 - 28
Cable drums
– Maintenance of the slip ring assemblies à p. 8 - 67
– Checking hoses à p. 8 - 78
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GMK5200-1
5.2.6 Maintenance plan M 12 M 12

every 12 months/after 20,000 - 25,000 km (12,430 - 15,530 mi)
Engine
– Have the radiator checked/cleaned à p. 7 - 18
– Check V-belt tension à p. 7 - 22
Fuel system
– Replacing fuel filter 2 à p. 7 - 31
– Having the AdBlue system checked à p. 7 - 37
Transmission
– Checking the VIAB oil level à p. 7 - 41
– Checking the transmission oil level à p. 7 - 42
Axle lines
– Axle centre drives – changing the oil à p. 7 - 63
– Final drives – changing the oil à p. 7 - 68
Suspension
– Pressure accumulator – checking the gas pressure à p. 7 - 93
Steering
– Replacing the filter cartridge of the compressed air drier à p. 7 - 99
Hydraulic system
– Changing the ventilation filter à p. 7 - 105
– Taking oil samples: à p. 7 - 106
depending on the oil sample test results:
– Changing the hydraulic oil à p. 7 - 111
– Changing the hydraulic oil filter à p. 7 - 115
– Cleaning the condenser fins à p. 7 - 132
– Changing the pollen filter à p. 7 - 134
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– Lubricating the cab door à p. 7 - 145

– Lubricating the connecting and socket pins à p. 7 - 146
– Renewing the corrosion protection à p. 7 - 147

GMK5200-1
M 12

every 12 months/after 1,000 oper. hrs.
Hoists
– Changing the oil/checking the oil à p. 8 - 11
Slewing gear
– Changing the oil/checking the oil à p. 8 - 19
Slewing bearing
– Lubricating the locking of turntable à p. 8 - 30
Hydraulic system
– Changing the ventilation filter à p. 8 - 36
– Taking oil samples: à p. 8 - 37
depending on the oil sample test results:
– Changing the hydraulic oil à p. 8 - 44
– Changing the hydraulic oil filter à p. 8 - 39
Main boom
– Checking the locking system à p. 8 - 52
Hook blocks
– Greasing à p. 8 - 71
– Changing the pollen filter à p. 8 - 80
– Lubricating the crane cab door à p. 8 - 83
– Lubricating the step à p. 8 - 84
– Lubricating the connecting and socket pins à p. 8 - 85
– Renewing the corrosion protection à p. 8 - 86
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GMK5200-1
5.2.7 Maintenance plan Y 2 Y2

every 24 months/after 40,000 - 50,000 km ( 25,000 - 31,000 mi)
Engine
– Changing the oil and oil filter à p. 7 - 24
– Having the fire extinguisher checked à p. 7 - 149


– Having the fire extinguisher checked à p. 8 - 88

every 36 months
Transmission
– Changing the VIAB oil à p. 7 - 43
– Transmission oil change à p. 7 - 46

Hoists
– Having a partial inspection carried out à p. 8 - 13
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GMK5200-1

every 60 months/100,000 km (62,000 mi)
– Have the cardan shaft between the transmission on the engine and the trans-
fer case replaced by Manitowoc Crane Care or an authorised GROVE dealer.

– Have both the cardan shafts (+ resilient damper) on the angle gear replaced by
Manitowoc Crane Care or an authorised GROVE dealer.

every 72 months
No maintenance work in this period.

The long-term intervals always include the short-term intervals.

Hoists
– Having a general inspection carried out à p. 8 - 13
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GMK5200-1
5.2.11 Maintenance plan Y 10 Y 10

every 120 months/after 200,000 km (124,000 mi)
Steel fabrication
– Check the load-bearing steel fabrication. For further information,
please contact Manitowoc Crane Care.

Electrical system
– Have the battery on the electronics board replaced à p. 8 - 76
Steel fabrication
– Check the load-bearing steel fabrication. For further information,
please contact Manitowoc Crane Care.
Rated capacity limiter (RCL)
– Have the RCL checked by Manitowoc Crane Care.
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GMK5200-1
5.3 Periodic inspections

Your GMK5200-1 truck crane has been inspected before delivery.
– Truck cranes that are to be used in Germany are inspected in accordance

with the regulations of the professional trade association as defined by
BGV D 6 (VBG 9).
– Truck 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 professional
trade association as defined by BGV D 6 (VBG 9).
According to German regulations, an inspection must be carried out once a

year. The regulations in other countries may prescribe different inspection
intervals. 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 must be carried out on the following, if they are not already
included in the list of periodic maintenance work:
– the hydraulic and electrical control and safety devices,
– the rated capacity limiter (RCL),
– the fastening and safety devices of all screwed-on parts,
– the hoist ropes,
– the load hooks ( à Load hook inspection, p. 5 - 20),
– the load-bearing steel fabrication (for cracks, deformation, etc.), including
a special check of all welds.
If damage is found on the steel fabrication, qualified specialists must deter-
mine the extent of the damage using the required material examination
methods. They should then determine what sort of repair should be carried
out.
Prior to carrying out welding work on the truck crane, observe the à Safety
instructions for welding work, p. 1 - 4.
The inspector must write a report containing the result of the annual inspec-
tion that was performed and the measures taken to repair any damage.
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GMK5200-1
5.3.1 Load hook inspection
The hook opening on the load hooks must be checked regularly for defor-
mation.
The hook opening must not have increased by more than 10% of the original
dimension y, y1, y2.
The original dimensions y, y1, y2 are specified

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

between the marked measuring points on
the load hook shaft (1) and the tip of the
hook (3).
The hook block may no longer be used if the
opening has increased by more than 10% of its
original dimension.
G
Risk of accident through falling load.
Hook blocks with deformed load hooks are no longer safe to use. The load
hooks could break and drop the load.
Deformed load hooks must always be replaced.
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GMK5200-1
5.4 Measures required for winch monitoring
H
Also observe the information on the general inspection of the hoists;
à p. 8 - 13.
These measures for monitoring the winches (hoists) were compiled by the
German Machine Builders' Association (VDMA) and are to be used for all
truck cranes according to the German Accident Prevention Regulations for
Winches, Hoists and Tractor Machines, BGV D 6 (VBG 9) and BGV D 8 (VBG 8).
5.4.1 Theoretical service life
The theoretical service life is determined according to certain operating con-

ditions and a theoretical total operating time assumed by the design engi-
neer when calculating and dimensioning the winches of your truck crane.
The power unit group M3 and the load spectrum L1 (Km = 0.125) are gener-
ally given for truck cranes in erection mode, resulting in a theoretical service
life of 3,200 h (ISO 4301/1, FEM 1.001, DIN calculation basis for power units).
S The theoretical service life is not the same as the real (actual) service life of
a winch.
s
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GMK5200-1
The actual 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 truck crane.

2. Insufficient maintenance: Oil is not changed at the specified
intervals.
3. Operating errors: Extreme acceleration or deceleration
of the load,
Load falling into the ropes.
4. Improper maintenance: Wrong oil used,
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. Latent damage caused by accidents.
9. Extreme environmental Low or high temperatures,
conditions: Aggressive ambient conditions,
Dust and dirt.
5.4.2 Proportion of theoretical service life used
The truck crane operator must perform a truck crane inspection at least once
a year (ISO 9927-1 and BGV D 6 (VBG 9) / BGV D 8 (VBG 8)).
This includes determining the proportion of theoretical service life that has
been used. If required, the truck crane operator has to appoint an approved
inspector for this assessment.
The actual operating conditions (load spectrum) and the hoist operating
hours must be determined for each inspection interval when determining
the proportion of theoretical service life that has been used. The operator is
responsible for proper documentation in the crane logbook.
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GMK5200-1
Determining The truck crane's load spectrum is divided into groups (see also ISO 4301/1,
the operating FEM 1.001):
conditions
(load spectrum)
H
When determining the load spectrum, the existing rope pull is used as the
standard, i.e. under certain circumstances, the truck crane can be support-
ing a small load, whereby the winch is actually supporting a heavy load, e.g.
due to insufficient reeving. Therefore, the following graphic representation
of the load spectrum refers to the winch's rope pulls.
Load Definition Timing period proportions Factor of Graphic representation

spec- the load
trum spectrum
class Km =
Power units or parts 10% of the timing period with
thereof that are subject greatest load (dead load +
to high stress in excep- 1/1 payload)
Light tional situations, but
40% of the timing period with
Q1 which are generally sub- 0.125
dead load + 1/3 payload
L1 ject to only low stress
dead load only
Power units or parts 1/6 of the timing period with

to high stress quite fre- 1/1 payload)
quently, but which are
1/6 of the timing period with
Medium generally subject to only
Q2 dead load + 2/3 payload 0.25
low stress
L2
1/6 of the timing period with
dead load + 1/3 payload

dead load only
to high stress frequently 1/1 payload)
Heavy
and medium stress con-
Q3 50% of the timing period with 0.5
tinuously
L3 dead load only

thereof that are regularly greatest load (dead load +
Very subjected to the highest 1/1 payload)
heavy stress from adjacent
10% of the timing period with 1
Q4 stress sources
dead load only
L4
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s
GMK5200-1
One of the load spectrums listed above should be selected on the basis of
the actual operating conditions and entered in the crane logbook for the
respective testing interval.
Note for truck cranes:
The load spectrum L1 and the load spectrum factor Km = 0.125 are generally
applied to truck cranes in assembly mode.
Determining the The effective winch operating hours must be entered in the crane logbook
effective operat- for the respective inspection interval.
ing hours Ti
– The effective winch operating hours Ti displayed in the Operating hours
submenu; à Operating manual.
Determining the For an inspection interval i (max. 1 year according to ISO 9927-1) or BGV D 6
proportion of (VBG 9) / BGV D 8 (VBG 8), the proportion of theoretical service life used Si
theoretical service is calculated using the formula:
life used
Km i
S i = ----------- × T i
Km
Km = Load spectrum factor used as the basis for winch calculation. This
factor is given in the operating manual.
Kmi = Load spectrum factor in inspection interval i in accordance with the
section ”Determining the operating conditions (Load spectrum)”
Ti = Effective operating hours in the testing interval i as described in
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).
If the remaining theoretical service life is not sufficient for the next operating
period, then a general overhaul of the winch must be performed.
If theoretical service life D has been reached ( à

Theoretical service life,
p. 5 - 21), the winch must not be operated until after a general overhaul has
been performed.
A general overhaul must always be performed at least once every 10 years

after putting the truck crane into operation.
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GMK5200-1
The general overhaul is to be arranged by the operator and performed by

the manufacturer or a representative authorised by the manufacturer. The
results are to be entered in the crane logbook.
The manufacturer or an authorised representative will specify a new theo-

retical service life D upon completion of the general overhaul.
The next general overhaul must be performed within 10 years at the latest.
Alternative If, after 10 years, the theoretical service life has not been used up, the winch
provision can continue to be operated without a general overhaul under the following
conditions:
The crane inspector has confirmed that the used proportion of the service
life is correct and proper by signing his/her name in the crane logbook after
every expert inspection.
In this case, the crane inspector must closely inspect the winch. This
includes at least:
– A visual examination of the exterior (for leaks, damage, deformation etc.)

– An oil inspection (especially for metallic residues)
– A load inspection with minimum and maximum rope pull and each at
maximum possible speed. At least one layer must be wound. Investigate
any unusual noises during the load inspection.
This inspection must be confirmed in the crane logbook by the approved
crane inspector and there must be a statement on continued operation for
the winch. The next inspection takes place before the end of the 12th year of
operation and must be repeated every year thereafter.
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GMK5200-1
5.4.3 Example
A GMK5200-1 is equipped with a separate operating hours counter for the

hoist and is classified by Manitowoc Crane Group Germany GmbH as fol-
lows:
Power unit group: M3
Load spectrum: Light L 1, Km = 0.125
Theoretical service life: D = 3,200 h
The used proportion S of theoretical service life is calculated based on the

individual inspection intervals as follows:
1st inspection (1st year)
The truck crane was used for assembly work during the previous year:
Load spectrum L 1, i.e. Km1 = 0.125.
The operating hours counter for the main hoist reads 160 h, i.e. T1 = 160 h.
The used proportion S1 of theoretical service life after the first inspection
therefore is:
0.125
S i = --------------- × 160 h = 160 h
0.125
Remaining theoretical service life:
D1 = 3,200 h -160 h = 3,040 h.
The above values are entered in the table (see table example p. 5 - 28).
2nd inspection (2nd year)
The truck crane was used for unloading work on docks: Load spectrum:
L 3, i.e. Km2 = 0.5.
The operating hours counter for the main hoist reads 640 h, i.e. during this
period: 640 hrs. – 160 h = 480 h (160 h were used during the first year)
T2 = 480 h
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GMK5200-1
The used proportion S2 of theoretical service life after the second inspection
is therefore:
0.5
S i = --------------- × 480 h = 1,920 h
0.125
D2 = 3,040 h –1,920 h = 1,120 h.
The above values are entered in the table (see table example p. 5 - 28).
3rd inspection (3rd year)
The truck crane was used for assembly work and occasional unloading work
on docks: Load spectrum: L 2, i.e. Km3 = 0.25.
The operating hours counter for the main hoist reads 940 h, i.e. during this
period: 940 h - 640 h = 300 h. T3 = 300 h.
The used proportion S3 of theoretical service life after the third inspection is
therefore:
0.25
S i = --------------- × 300 h = 600 h
0.125
D3 = 1,120 h - 600 h = 520 h.
The values are entered in the table (see table example 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 to be found in

the maintenance manual's appendix for truck cranes that do not require a
crane logbook or similar documentation according to the regulations of the
respective country.
s
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GMK5200-1
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Sample table to determine the remaining theoretical service life on winch no. 1 (main hoist winch)
GMK5200-1
Maintenance manual
Crane type: GMK 3045
Work number: 3045 42 06
First commissioned on: 10. 06. 1990
Serial number of the winch in accordance with the model plate: 13 301
Last general overhaul performed on: ........................
Winch design data (see operating manual):
Engine group: M3
Load spectrum: Q1 (L1)
Factor of the load spectrum: Km = 0.125
Theoretical service life: D = 3,200 h
Inspection Date of first Operating Factor of the Crane oper- Superstruc- Superstruc- Winch oper- Operating Used propor- Remaining the- Name of the Signature Comment Name of the Signature
interval no. commis- conditions load spec- ating hours ture operat- ture operat- ating hours hours Ti of the tion Si of theoretical service expert approved
(max. sioning/date since the trum (complete) ing hours ing hours winch since the oretical service life inspector
1 year) of inspec- last inspec- since the last inspection life D:
tion tion last inspec-
Di = Di-1 - Si
tion
”i” Kmi [h] [h] [h] [h] [h] [h] [h]
0(*) 10. 6. 90 – – – – – 0 3,200
1 5. 6. 91 L1 0.125 – – – 160 160 160 3,040 Müller
3 302 746 en
2 20. 5. 92 L3 0.5 – – – 640 480 1,920 11,20 Huber
3 18. 5. 93 L2 0.25 – – – 940 300 600 520 Schmitz
IMPORTANT: Si = Used proportion of theoretical service life since the last inspection
A general overhaul is to be performed every 10 years.
Di = Remaining theoretical service life
Di - 1= Remaining theoretical service life after the previous inspection

For alternative provision, refer to section 5.4.2, p. 5 - 25.
Km = Load spectrum factor used as the basis for winch calculation.
This factor is given in the operating manual.
Kmi= Load spectrum factor in inspection interval ”i” according to section 2.1
Ti = Effective operating hours in inspection interval ”i” according to section 2.2
General overhaul performed on.......................................
(*) Copy the last line of the previous page to the following page.
5 - 28
6
6.1 Lubricants. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 1
6.1.1 Lubricants list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 2
6.1.2 Lubricant applications list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 3
6.2 Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 5
6.3 Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 5
6.3.1 Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 5
6.3.2 Engine coolant admixtures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 5
6.3.3 After-treatment of exhaust gases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 6
6.3.4 Windscreen washing system admixtures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 6
6.3.5 Fuel for crane cab heating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 6
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GMK5200-1
Lubricants and consumables
6.1 Lubricants
6.1 Lubricants
All lubricants that you require for
– Maintenance work on the carrier, p. 7 - 1 and
– Maintenance work on the superstructure, p. 8 - 1
are listed with serial numbers in the lubricants list and the lubricant applica-
tions list.
à Lubricants list, p. 6 - 2.
à Lubricant applications list, p. 6 - 3.
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GMK5200-1
6.1 Lubricants
6.1.1 Lubricants list
Serial GROVE part Lubricant Designation to Specification Viscosity

no. number type DIN 51502 classification
MIL-L 2104 C
1 03329588 Engine oil HD - CD SAE 5 W-30
DB 228.5
Shell Spirax
2 04162043 Gear oil
S6 ATF VM
Fuchs Titan
3 04162042 Gear oil Cytrac MB Synth SAE 75 W-90
API-GL-4
MIL-L 2105 B Hyp SAE 90
4 00552891 Gear oil C - LPF
API-GL-5 ISO - VG 220
MIL-L 2105 C
5 01373344 Gear oil SHC 75 W-90
API-GL-5
Rivolta
6 02310863 Gear oil
S.K.D. 170
MIL-L 2105 B SAE 75 W-90 EP
7 02313611 Gear oil C - LPF API-GL-4/5 ISO - VG 220
(synthetic)
Castrol Hyspin
8 04162158 Hydraulic oil HVLP AWH-M 32 ISO-VG 32
DIN 51524-3
Lubricating DIN 51825 –50 °C to +120 °C

9 03233369 KP - 1K - 50
grease Renolit JP 1619 (–58 °F to +248 °F)
10 00554205 Spray Ceplattyn 300
11 02314698 Slide paste PAL 1
Lubricating
12 03325215 RHUS SW 2
grease
13 01929824 Spray Berulub spray
Lubricating
14 03133770 Elaskon 30
grease
09.03.2018

GMK5200-1
6.1 Lubricants
6.1.2 Lubricant applications list
Serial Lubricant type Usage Filling Mainten-

no. quantity in ance inter-
litres (gal) val
1 Engine oil Diesel engine;à p. 7 - 24 39 (10.3) Y2
2 Gear oil VIAB (Voith); à p. 7 - 43 11 (2.9) Y3
3 Gear oil Transmission; à p. 7 - 46 17.5 (4.6) Y3
3er axle line transfer case
12.8 (3.4) M6
for drive 10 x 6; à p. 7 - 50
3er axle line transfer case
14 (3.7) M6
for drive 10 x 8; à p. 7 - 50
4 Gear oil 3er axle line axle centre drive; à p. 7 - 63 14 (3.7) M 12

2nd axle line axle centre drive; à p. 7 - 63 13.0 (3.5) M 12
5th axle line axle centre drive; à p. 7 - 63 13.0 (3.5) M 12
4th axle line axle centre drive; à p. 7 - 63 16.5 (4.4) M 12
6 or 8 x final drives; à p. 7 - 68 2.7 (0.7) M 12
5 Gear oil Angle gear; à p. 7 - 57 7.7 (2.0) M6
5 x suspension struts; à p. 7 - 89
1.5 (0.4)
M1
each
6 Gear oil
5 x suspension struts; à p. 7 - 89 3.2 (0.84)
each
M1
2 x hoists;à p. 8 - 11 7 (1.8) each M 12

7 Gear oil
3 x slewing gears; à p. 8 - 19
0.9 (0.24)
M 12
each
Carrier hydraulic tank; à p. 7 - 111 200 (53) M 12
8 Hydraulic oil
Superstructure hydraulic tank; à p. 8 - 44 980 (259) M 12
09.03.2018
s
GMK5200-1
6.1 Lubricants
Serial Lubricant type Usage Filling Mainten-

no. quantity in ance inter-
litres (gal) val
Carrier central lubrication; à p. 7 - 119 W
Superstructure central lubrication; à p. 8 - 69 W
Cardan shafts – transverse; à p. 7 - 70 M1
Cardan shafts – longitudinal; à p. 7 - 71 M6
Towbar coupling; à p. 7 - 135 M1
Outrigger beams; à p. 7 - 144
Lubricating
9 M1
grease
Turntable lock; à p. 8 - 30 M 12
Hook blocks; à p. 8 - 71 M 12
Cab door hinges; à p. 7 - 145 M 12
Carrier pins; à p. 7 - 146 M 12
Superstructure pins; à p. 8 - 85 M 12
10 Spray Slewing bearing gear teeth; à p. 8 - 25 M6
11 Slide paste Telescopic slide faces; à p. 8 - 48 M3
Telescope locking pins; à p. 8 - 48 M3
Lubricating Derricking cylinder piston rod; à p. 8 - 47 M1

12
grease Cab door rails; à p. 8 - 83 M 12
Stair tread rails; à p. 8 - 84 M 12
Qutrigger pads/cylinders; à p. 7 - 144 M1
13 Spray
Derricking cylinder piston rod; à p. 8 - 47 M1
Lubricating the hoist ropes; à p. 8 - 55

Lubricating
14 M3
grease
09.03.2018

GMK5200-1
6.2 Refrigerant
6.2 Refrigerant
Refrigerant Usage Quantity to Mainten_an

Designation be filled in ce interval
kg (lbs)
Driver's cab air-conditioning system;
àp. 7 - 132 1.0 (2.2) M 12
Tetrafluoroethane (R134a) (Compressor oil: FUCHS SE 55)
CAS no. 811-97-2
Crane cab air-conditioning system; 1 x 1.0 (2.2)
EC no. 212-377-0
àp. 8 - 78 or M 12
(Compressor oil: EMKARATE RL68H) 2 x 0.95 (2,1)
6.3 Consumables
6.3.1 Fuel
The fuels that can be used, and their respective specifications, can be found
in the Engine manufacturer's documentation.
• Also observe the signs on the diesel tank of the truck crane:
”The use of additives is not permitted and can cause damage to the
engine system.”
6.3.2 Engine coolant admixtures
The specifications and admixture ratios can be found in the Engine manufac-
turer's documentation.
09.03.2018

GMK5200-1
6.3 Consumables
6.3.3 After-treatment of exhaust gases
Designation Usage Filling quantity

in litres (gal)
DEF (Diesel Exhaust Fluid)1)
AdBlue: AdBlue tank on the carrier; à p. 7 - 34 40 (10.5)
GROVE part number: 03140555
1) DEF (Diesel Exhaust Fluid),

Consumable for after-treatment of exhaust gases, e.g. AdBlue.
For AdBlue there are registered trademarks of the following companies
– Kruse GmbH & Co KG
– BASF SE
– and of the Association of the Automotive Industry e. V.
6.3.4 Windscreen washing system admixtures
Commercial cleansers and antifreeze may be added to the windscreen

washing water. Observe the application instructions on the packaging.
6.3.5 Fuel for crane cab heating system
Only if the truck crane is fitted with a separate tank for the auxiliary heater
do you have the option of selecting whether to use the same fuel as in
section 6.3.1 or to use EL heating oil. 09.03.2018

GMK5200-1
7
7.1 General instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 1
7.1.1 Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 1
7.1.2 Overview of maintenance work on the carrier . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 2
7.2 Symbols for maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 9
7.3 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 11
7.3.1 Checking the oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 11
7.3.2 Topping up the oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 13
7.3.3 Installing the drain valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 14
7.3.4 Checking the air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 15
7.3.5 Checking the coolant level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 16
7.3.6 General inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 17
7.3.7 Have the radiator checked/cleaned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 18
7.3.8 Check V-belt tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 22
7.3.9 Changing the oil and oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 24
7.4 Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 27
7.4.1 Draining off water from fuel filter 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 28
7.4.2 Replacing fuel filter 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 29
7.4.3 Replacing fuel filter 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 31
7.5 Exhaust system with exhaust emission control. . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 33
7.5.1 Checking the AdBlue tank level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 34
7.5.2 Filling up with AdBlue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 34
7.5.3 Check the exhaust system for external damage . . . . . . . . . . . . . . . . . . . . . . . . 7 - 35
7.5.4 Having the AdBlue system checked . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 37
7.6 Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 39
7.6.2 Checking the VIAB oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 41
7.6.3 Checking the transmission oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 42
7.6.4 Changing the VIAB oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 43
7.6.5 Transmission oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 46
7.7 Transfer case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 49
7.7.3 Changing the oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 50
7.8 Angle gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 53
7.8.3 Changing the oil and the oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 57
7.9 Axle lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 61
09.03.2018

7.9.2 Axle centre drives – checking the oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 61
7.9.3 Axle centre drives – changing the oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 63
7.9.4 Final drives – checking the oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 67
7.9.5 Final drives – changing the oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 68

GMK5200-1
7.9.6 Lubricating the cardan shafts in the axle lines . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 70
7.9.7 Lubricating longitudinal cardan shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 71
7.10 Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 73
7.10.1 Checking the tyres for damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 73
7.10.2 Checking the tyre pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 74
7.10.3 Checking that the wheel nuts are tight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 75
7.10.4 Changing the wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 76
7.11 Vehicle brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 81
7.11.1 Checking the wear display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 81
7.11.2 Checking disc brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 82
7.12 Suspension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 89
7.12.1 Suspension struts – checking the oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 89
7.12.2 Suspension struts – checking the fastening . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 91
7.12.3 Forced lever – checking correct functioning . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 92
7.12.4 Pressure accumulator – checking the gas pressure . . . . . . . . . . . . . . . . . . . . . 7- 93
7.13 Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 95
7.13.1 Checking for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 95
7.13.2 Pressure accumulator – checking the gas pressure . . . . . . . . . . . . . . . . . . . . . 7 - 96
7.14 Compressed air system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 97
7.14.1 Draining water from the compressed air system . . . . . . . . . . . . . . . . . . . . . . . 7 - 97
7.14.3 Replacing the filter cartridge of the compressed air drier . . . . . . . . . . . . . . . . 7 - 99
7.15 Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 101
7.15.1 Checking the oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 101
7.15.2 Checking the hydraulic hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 102
7.15.4 Cleaning the magnetic rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 103
7.15.5 Changing the ventilation filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 105
7.15.6 Taking oil samples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 106
7.15.7 Changing the hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 111
7.15.8 Changing the hydraulic oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 115
7.16 Central lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 119
7.16.1 Checking the level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 119
7.16.2 Bleeding the central lubrication system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 121
7.16.3 Triggering intermediate lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 121
7.17 Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 123
7.17.1 Checking the lighting and indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 123
7.17.2 Checking the batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 124
7.17.3 Checking the charge level of the batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 126
7.17.4 Charging the batteries using the battery charger . . . . . . . . . . . . . . . . . . . . . . 7 - 128
7.17.5 Check the external starting socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 129
09.03.2018
7.18 Air conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 131

7.18.1 Checking the air conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 131
7.18.2 Checking hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 131
7.18.3 Cleaning the condenser fins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 132

GMK5200-1
7
7.18.4 Checking the entire air conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 132
7.18.5 Changing the pollen filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 134
7.19 Towbar coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 135
7.19.1 Lubricating the towbar coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 135
7.19.2 Checking the bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 137
7.19.3 Checking the cotter pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 138
7.19.4 Checking the lower bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 139
7.19.5 Checking the initial tension of the springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 139
7.19.6 Checking the support ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 140
7.19.7 Checking the function of the coupling jaw / resetting the central position . . . 7 - 140
7.20 Other maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 143
7.20.1 Checking the windscreen washing system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 143
7.20.2 Lubricating the outrigger beams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 144
7.20.3 Checking the auxiliary heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 145
7.20.4 Lubricating the cab door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 145
7.20.5 Lubricating the connecting and socket pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 146
7.20.6 Renewing the corrosion protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 147
7.20.7 Having the fire extinguisher checked . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 149
09.03.2018

GMK5200-1
09.03.2018

GMK5200-1
Maintenance work on the carrier
7.1 General instructions
7.1.1 Covers
Various types of work (e.g. oil change) require that the covers be removed.
Before maintenance work

• Remove the covers (1).
After maintenance work
• Fasten the covers (1) with the locks.
09.03.2018

GMK5200-1
7.1.2 Overview of maintenance work on the carrier
09.03.2018

GMK5200-1
Symbols for maintenance work à p. 7 - 9

1 CCS (Crane Control System) control unit à p. 7 - 9
Engine à p. 7 - 11
4 Diesel engine à p. 7 - 11
14 Covers à p. 7 - 1
2 Dipstick à p. 7 - 11
3 Oil filler opening à p. 7 - 13
19 Air filter à p. 7 - 15
5 Coolant reservoir à p. 7 - 16
18 Oil filter à p. 7 - 24
Fuel system à p. 7 - 27
12 Left fuel tank à p. 7 - 27
20 Right fuel tank à p. 7 - 27
16 Filter 1 à p. 7 - 28
17 Filter 2 à p. 7 - 31
Exhaust system with exhaust emission control à p. 7 - 33

13 AdBlue tank à p. 7 - 34
15 Exhaust silencer with SCR catalytic converter à p. 7 - 35
Transmission à p. 7 - 39
6 VIAB oil-level plug à p. 7 - 41
7 Transmission oil-level plug à p. 7 - 42
8 Oil filter on the transmission à p. 7 - 46
Transfer case à p. 7 - 49
9 Oil-level plug à p. 7 - 49
Angle gear à p. 7 - 53
10 Oil-level plug à p. 7 - 54
11 Filter à p. 7 - 57
s
09.03.2018

GMK5200-1
09.03.2018

GMK5200-1
Axle lines à p. 7 - 61
7 Axle centre drives à p. 7 - 61
6 Final drives à p. 7 - 67
8 Cardan shafts à p. 7 - 70
Vehicle brake à p. 7 - 81
9 Disc brake à p. 7 - 82
Compressed air system à p. 7 - 97

10 Receptacle à p. 7 - 97
14 Drier à p. 7 - 99
Hydraulic system à p. 7 - 101

1 Oil tank with inspection glass à p. 7 - 101
2 Oil filters 1 and 2 à p. 7 - 115
5 Oil filters 3 and 4 à p. 7 - 115
3 Ventilation filter à p. 7 - 105
Central lubrication system à p. 7 - 119

15 Central lubrication pump à p. 7 - 119
Air conditioning system à p. 7 - 131

12 Air-conditioning system in the driver's cab à p. 7 - 131
11 Condenser fins à p. 7 - 132
13 Pollen filter à p. 7 - 134
s
09.03.2018

GMK5200-1
09.03.2018

GMK5200-1
Wheels à p. 7 - 73
6 Wheels à p. 7 - 73
3 Spare wheel (alternatively storage box)
Suspension à p. 7 - 89
10 Suspension struts à p. 7 - 91
12 Forced lever à p. 7 - 92
2 Pressure accumulator à p. 7 - 93
Steering à p. 7 - 95
11 Steering cylinder à p. 7 - 95
Electrical system à p. 7 - 123

14 Carrier lighting à p. 7 - 123
8 Battery box à p. 7 - 124
7 External starting socket à p. 7 - 129
Towbar coupling à p. 7 - 135

15 Towbar coupling1) à p. 7 - 135
Other maintenance work à p. 7 - 143

13 Windscreen washing system receptacle à p. 7 - 143
4 Outrigger beams à p. 7 - 144
9 Cab door hinges à p. 7 - 145
– Driver's cab auxiliary heater1) à p. 7 - 145
– Various connecting pins and socket pins à p. 7 - 146
– Corrosion protection à p. 7 - 147
1 Fire extinguisher à p. 7 - 149
1)
Additional equipment
09.03.2018

GMK5200-1
Blank page
09.03.2018

GMK5200-1
7.2 Symbols for maintenance work
CCS • Check the symbols on the CCS start menu (Crane Control System) in the
driver's cab each day before starting work.
• The Start menu shows the most important measurements and the
Maintenance submenu shows all the outstanding warning messages;
à Operating manual.
Maintenance If one of the symbols is displayed, you must carry out the appropriate main-
submenu tenance work:
– Oil pressure; à p. 7 - 11,
– Coolant level; à p. 7 - 16,
– Air filter; à p. 7 - 15,
– Angle gear; à p. 7 - 54,
– Hydraulic oil filter; à p. 7 - 115,
– AdBlue system; à p. 7 - 34,

09.03.2018
s
GMK5200-1
– Disc brakes wear display; à p. 7 - 81.
09.03.2018

GMK5200-1
7.3 Engine
7.3 Engine
• In addition, carry out the additional maintenance work as specified in the
Engine manufacturer's documentation supplied with the vehicle.
• At the first oil change, fit a drain valve in place of the drain plug;
à p. 7 - 14.
7.3.1 Checking the oil level D
Prerequisites – The truck crane must be level.
Checking the oil • Start the engine from the driver's cab; à Operating manual.
level
S
Risk of damage to the engine if the oil pressure is too low.
Switch off the engine immediately if the symbol (1) is displayed. The engine
can be damaged by running it when the oil pressure is too low.
• Start the engine and watch the symbol (1).

• Stop the engine immediately if the symbol does not disappear after
10 seconds.
If symbol (1) is displayed, the oil pressure is too low.
• Allow the engine to run at idling speed for 2 - 3 minutes.

• Switch off the engine.
09.03.2018
• Check the oil level after approx. 2 minutes.
s
GMK5200-1
7.3 Engine
• On the dipstick (1), check that the oil level is

between the min. and the max. marks
(arrow markings).
• Put the dipstick into the dipstick tube after
checking the oil level.
If the oil level is too low
• Top up the oil; à p. 7 - 13.
09.03.2018

GMK5200-1
7.3 Engine
7.3.2 Topping up the oil
Data on the prescribed oil specification; à Engine manufacturer's documenta-

tion.
Oil
Engine oil in Designation to Specification GROVE part no.
litres (gal) DIN 51502 Classification
39 (10.3) HD - CD MIL-L 2104 C SAE 5 W-30
DB 228.5 03329588

– The engine must be switched off and secured against unauthorised use;
à p. 2 - 3.
Topping up the oil
S
Risk of damage to the engine if the oil level is too high.
Do not overfill; the oil level must not be higher than the max. mark (arrow
marking). Drain off oil if necessary; à
Engine manufacturer's documentation.
G
Risk of burns when the engine is hot.
During operation, the engine and add-on parts reach temperatures up to
400 °C (750 °F). Wear appropriate protective gloves and be careful not to
come into contact with hot parts.
• Add oil through the filler neck (2) up to the

max. mark.
• Close the filler neck with the cap.
• Put the dipstick (1) into the dipstick tube
after checking the oil level.
09.03.2018

GMK5200-1
7.3 Engine
7.3.3 Installing the drain valve
You can replace the drain plug on the oil pan with a valve.
This makes it easier to check the draining oil during subsequent oil changes.
Spare parts and

tools Designation Quantity GROVE part no.
Valve M 20 x 1.5 1 03041579
Gasket 20 x 24 Cu DIN 7603 1 00117139
or:
Valve M 26 x 1.5 1 03046878
Gasket 26 x 31 Cu DIN 7603 1 00117147
– Drain channel.
– Torque wrench for torque of 80 Nm (59 lbf ft).

à p. 2 - 3.
Installing the • Check the thread size (M 20 or M 26).

valve
• Use a drain channel when draining the oil.
• Drain the engine oil as described in the
Engine manufacturer's documentation.
• Fit a new gasket and tighten the valve (1).
M 20 Torque of 60 Nm (44.25 lbf ft)

M 26 Torque of 80 Nm (59.00 lbf ft)
• Check the valve for leaks after filling the oil.

09.03.2018
For the next oil change, you can drain the oil as done for the hydraulic tank;
à Handling the valves, p. 7 - 112.

GMK5200-1
7.3 Engine
7.3.4 Checking the air filter D
• Start the engine and observe the display.

• If the symbol (1) is displayed, you must change the air filter.
Spare parts and

Main filter 1 04161948
Back-up filter 1 04161949
Prerequisites – The engine must be switched off and secured against unauthorised use;
à p. 2 - 3.
Replacing the air

filter
• Undo all the clamps (1) and remove the

cover (2).
• Change the filters (3) and (4).
• Replace the cover and secure it with all the
clamps.
09.03.2018

GMK5200-1
7.3 Engine
7.3.5 Checking the coolant level D
• Start the engine and monitor the display.

• When the symbol (1) is displayed you must top up the coolant.
Topping up
coolant
G
There is a danger of scalding if the cooling circuit is hot.
The hot cooling circuit is under pressure. When you open the expansion
tank, you could be scalded by escaping steam/coolant.
Wear suitable protective gloves and cover the cap on the expansion tank
with a rag before opening it.
Turn the cap slowly to the first detent in order to allow the pressure to be
released.
• Do not open the pressure relief valve (2).

• Loosen (do not open) the cap (1) to reduce
the pressure if the coolant is at operating
temperature.
• Open the cap (1).
The coolant level must be at the lower mark-
ing in the filler neck.
If the coolant level is too low
• Top up the coolant.
Composition of the coolant; à Engine man-
ufacturer's documentation.
• Close the cap (1).
S
Risk of damage to engine due to lack of coolant.
If the coolant has to be topped up frequently, the cooling system may be
leaking. Have the cooling system checked by Manitowoc Crane Care or an
authorised GROVE dealer or your repair crew.
09.03.2018

GMK5200-1
7.3 Engine
7.3.6 General inspection W
• Investigate any unusual running noises from the engine.

• Check the engine and the connections for leaks. If consumables are
leaking;
à Checking the oil level, p. 7 - 11,
à Checking the coolant level, p. 7 - 16.
• Check that pipes and hoses are tightly connected and not damaged.
If any damage is found, report it to Manitowoc Crane Care or an authorised
GROVE dealer or an authorised specialist workshop.
09.03.2018

GMK5200-1
7.3 Engine
7.3.7 Have the radiator checked/cleaned M 12
Reducing the • Under difficult operating conditions – at extremely sandy or dusty loca-
interval tions or if there is a heavy density of fallen leaves – you must have the
radiator fins cleaned earlier than this.
Prerequisites – The truck crane must be supported on outriggers and must be level;
– The main boom must be fully retracted and raised to 75°; à Operating
manual.
à p. 2 - 3.
– The working area on the carrier above the engine covers and between the
radiator units must be freely accessible.
– Trained repair specialists and repair tools must be available.
Check the level of

dirt
09.03.2018

GMK5200-1
7.3 Engine
The two radiator units (1) and (2) are protected by grilles (3) and plates (5).
The fan wheels (4) are located under the grilles. When the engine is running,
the fan wheels rotate under the grilles!
G
Risk of injury due to the fan wheels.
When the fan wheels are rotating they can trap the fingers of your hand and
amputate them. Never reach into the fan wheels when they are rotating. Do
not push any tools through the grilles to clean them.
Always stop the engine before attempting to clean the fan wheels and radi-
ator fins.
Radiator unit 1 (right)

Radiator for engine charge air, radiator for transmission gear oil, radiator
for differential gear oil, radiator for compressed air system.
Radiator unit 2 (left)

Radiator for engine coolant, condenser for refrigerant for the driver's cab
air-conditioning system.
• If necessary remove leaves, twigs and other debris from the grilles (3).
• View the fan wheels (4) through the grilles from above to check their con-
dition. The impeller blades must be clean and undamaged.
H
If the radiator fins are heavily soiled have them cleaned, since further soiling
can lead to overheating; à Have them cleaned, p. 7 - 20.
09.03.2018

GMK5200-1
7.3 Engine
Have them
cleaned
G
Risk of injury due to the fan wheels.
When the fan wheels are rotating they can trap the fingers of your hand and
amputate them. Never reach into the fan wheels when they are rotating. Do
not push any tools through the grilles to clean them.
Always stop the engine before attempting to clean the fan wheels and radi-
ator fins.
S
Risk of damaging the radiator fins.
Do not use a high pressure cleaner or steam jet cleaner. The powerful jet
may damage the fins.
Use only suitable cleaning agents air for cleaning.
09.03.2018

GMK5200-1
7.3 Engine
• Have the radiator units (1) and (2) opened up by the repair specialists, so
that the radiator fins are accessible.
• Have the radiator fins cleaned on both sides, using suitable cleaning
agents.
• Have the fan wheel (4) cleaned.
• Have the cooling air baffle (5) cleaned.
• Have the hoses and connections checked for damage and leaks.
• Have any damaged parts replaced.
After checking/ • Remove all tools and cleaning equipment.

cleaning
• Check that all the grilles (3) and plates (5) are secure.
• Start the engine and wait until the fan wheels are rotating.
• Check that the fan wheels are running freely.
• Check the respective temperature displays in the driver's cab;
• Check the radiator and connections for leaks.
09.03.2018

GMK5200-1
7.3 Engine
7.3.8 Check V-belt tension M 12
• Note the à Run-in regulations, p. 4 - 1.
• Check whether your mobile crane is equipped with a second

alternator (2).
The maintenance on the V-belt of the standard first alternator (1) is
described in the supplied documentation; à
Engine manufacturer's
documentation.
Spare parts
and tools Designation Quantity GROVE part no.
V-belt 1 03301553
– Frequency measuring equipment, GROVE parts no. 04165439;

new V-belt: frequency 102.8 Hz;
used V-belt: frequency 90.2 Hz.
Prerequisites – The engine is not running and is secured against unauthorised use.
Checking
• Check the charge air cooling system (1) for

dirt and damage.
• Install a new V-belt if required (1).
• Roughly set the initial tension with the
tension tube (2). To do this, loosen the
nuts (4) and turn the bolt (3) until you have
achieved the desired initial tension. Secure
the bolt (3) with the nut (4).
09.03.2018

GMK5200-1
7.3 Engine
• Familiarise yourself with the correct operation of the frequency

measuring equipment; à Separate operating manual.
• Turn on the frequency measuring
equipment (1) – it is ready for acoustic
measurement.
• Hold the measuring head (3) over the
V-belt (4).
• Hit the V-belt (4) with an object (tool) so that
it vibrates.
• Read the measured value on the display (2):
new V-belt: 102.8 Hz;
used V-belt: 90.2 Hz.
• Correct the initial tension on the tension tube (if required) until the
prescribed measure value has been achieved.
• Check the tension on a newly installed V-belt only after 4 operating hours
(oper. hrs.) and after 24 operating hours (oper. hrs.).
09.03.2018

GMK5200-1
7.3 Engine
7.3.9 Changing the oil and oil filter Y2
Oil, spare parts,

tools Engine oil in Designation to Specification GROVE part no.
39 (10.3) HD - CD MIL-L 2104 C SAE 5 W-30
DB 228.5 03329588
Designation Quantity GROVE part no.

Oil filter 1 04161614
Cover gasket 1 03328606
Gasket for oil drain plug 1 04161531
– Receptacle, approx. 40 l (11 gal); à p. 2 - 4.

– Torque wrench for torque of 55 Nm (40.5 lbf ft).
– Connecting piece and hose (tool box); à p. 7 - 112.
Prerequisites • Find out the prescribed oil specification and about the necessity of short-
ening the maintenance interval under special operating conditions;
à Engine manufacturer's documentation.
• Find out about the safety instructions and the sequence of steps to change
the oil and the oil filter; à Engine manufacturer's documentation.
– The truck crane must be level.
à p. 2 - 3.
Changing
O
Risk of environmental damage due to leaking consumables.
Always let consumables drain into suitable receptacles. Wipe up any con-
sumables that have leaked.
Store/dispose of consumables and any soaked equipment properly.
Ask about the applicable regulations.
If a valve is already mounted on the oil pan:
O
If a valve is mounted on the oil pan, use the delivered connecting piece with
hose and a receptacle with adequate capacity to drain the oil.
09.03.2018

GMK5200-1
7.3 Engine
Oil filter
• Place a receptacle underneath the engine.
• Change the oil filter (1) using a socket
wrench – torque 55 Nm (40.5 lbf ft);
à Engine manufacturer's documentation.
• Leave the receptacle in place for the oil
change.
Draining oil
• Remove the drain plug (1) or screw the con-
necting piece with hose on the valve (2) and
drain the oil into the receptacle; à
Handling
the valves, p. 7 - 112.
If required, you may replace the drain plug
with a valve; àp. 7 - 14.
• Tighten the drain plug (1) – torques for M 20/
M 26; à p. 7 - 14 or remove the connecting
piece with hose from valve (2) and remove
the receptacle.
Topping up oil
• Top up with fresh oil through the filler
neck (3); à p. 7 - 13.
09.03.2018

GMK5200-1
7.3 Engine
Blank page
09.03.2018

GMK5200-1
7.4 Fuel system
7.4 Fuel system
This section describes the maintenance work

for the standard fuel system with two con-
nected fuel tanks, (1) and (2), which may only
be filled with a single type of fuel.
For additional equipment with a dual tank

system, the fuel tanks, (1) and (2), are separate
and are filled with different types of fuel;
• Obtain information from Manitowoc Crane

Care on the additional fuel filter required for
the dual tank system.
The following elements are installed as

standard in the carrier fuel line:
1 Fuel filter 1 (large)
2 Fuel filter 2 (small)
3 Fuel hand pump
09.03.2018

GMK5200-1
7.4 Fuel system
7.4.1 Draining off water from fuel filter 1 D
Spare parts and – Receptacle, approx. 5 l (1.5 gal); à p. 2 - 4.

tools
Prerequisites – The truck crane must be level and on outriggers; à Operating manual.
– The main boom must be fully raised; à Operating manual.
à p. 2 - 3.
Draining off water
O
• Place a receptacle underneath the filter.

• Open the valve (1).
• If the consumable that emerges is clean,
close the valve by hand.
• Remove the receptacle and properly dis-
pose of the drained consumable.
09.03.2018

GMK5200-1
7.4 Fuel system
7.4.2 Replacing fuel filter 1 M3
Spare parts and

Filter (large) 1 04161567
Alternatively: 1 04180966
Set of both filters 1 + 2 (large + small)
– Receptacle, approx. 5 l (1.5 gal); à p. 2 - 4.

à p. 2 - 3.
– If the fuel is contaminated: Reduce the maintenance interval.
Changing
O

• Open the valve (1) and let the consumable
drain out.
s
09.03.2018

GMK5200-1
7.4 Fuel system
• Remove the cover (1).

• Remove the old filter (2) from the casing.
• Place the old filter (2) in the receptacle.
• Insert a new filter (2) into the casing.
• Attach the cover (1) – torque 55 Nm
(40.5 lbf ft); à Engine manufacturer's docu-
mentation.
• Remove the receptacle.
• Open the two tank covers on the fuel tank;

à p. 7 - 27.
• Operate the hand pump (1) until you sense
definite resistance.
• Close the two tank covers on the fuel tank.
• Start the engine and check for leaks.
09.03.2018

GMK5200-1
7.4 Fuel system
7.4.3 Replacing fuel filter 2 M 12
Spare parts and

Filter (small) 1 04161566
Alternatively: 1 04180966
Set of both filters 1 + 2 (large + small)

– Torque wrench for torque of 15 Nm (11 lbf ft).
à p. 2 - 3.
– The fuel must be drained from the fuel filter 1; à p. 7 - 29.
– If the fuel is contaminated: Reduce the maintenance interval.
Changing
O

• Attach the cover (1) – torque 15 Nm
(11 lbf ft); à Engine manufacturer's documen-
tation.
• Remove the receptacle.
09.03.2018

GMK5200-1
7.4 Fuel system
• Open the two tank covers on the fuel tank;

à p. 7 - 27.
• Operate the hand pump (1) until you sense
definite resistance.
• Close the two tank covers on the fuel tank.
09.03.2018

GMK5200-1
7.5 Exhaust system with exhaust emission control
Overview To comply with the exhaust emission regulations, the truck crane may
only be run with the exhaust system with SCR catalytic converter
(SCR = Selective Catalytic Reduction).
The exhaust gas is cleaned with an AdBlue system (DEF). To do this, AdBlue
(DEF) (Diesel Exhaust Fluid) from the AdBlue tank is injected into the
exhaust system.
The motor output is automatically sharply reduced when there is not
enough AdBlue solution available. Driving with an empty AdBlue tank will
invalidate the truck crane's licence for use on public roads; à
Operating
manual,à Engine manufacturer's documentation.
AdBlue system
1 AdBlue tank
4 Pump unit
for pumping AdBlue to the dosing unit
on the diesel engine and for pumping
engine coolant for preheating the
AdBlue tank.
2 Tank level gauge, AdBlue tank
3 Tank level gauge, AdBlue tank
with warning symbol
6 Diesel engine
with dosing unit for AdBlue (compressed
air supply) and a solenoid valve for pre-
heating the AdBlue tank using engine
coolant.
7 Injection nozzle
for injecting the AdBlue/compressed air
mixture.
8 Exhaust pipes
9 Exhaust silencer
with SCR catalytic converter
09.03.2018

GMK5200-1
7.5.1 Checking the AdBlue tank level D
Check the The display includes a gauge showing the level in the AdBlue tank.
following
H
The tank has a maximum filling volume of approx. 40 l (10.5 gal). Depending
on where the truck crane is used, it may be sensible to carry additional can-
isters of AdBlue.
• Start the engine and check the gauge after the engine starts; à p. 7 - 35.
• Refill with AdBlue before the tank becomes empty.
7.5.2 Filling up with AdBlue
Consumable and
tools AdBlue in Specification GROVE part no.
litres (gal) Classification
40 (10.5) DEF (Diesel Exhaust Fluid); 03140555
e.g. AdBlue.
– As required: Two canisters of approx. 20 l each (5 gal); à p. 2 - 4.
Prerequisites – A service station with a filling pump for AdBlue can be used, or AdBlue
can be filled manually from canisters.
à p. 2 - 3.
09.03.2018

GMK5200-1
Filling up • Find out about filling up in the operating manual and note the warnings;
G
Danger of scalding due to ammonia vapours.
Ammonia vapour can escape if the AdBlue tank is opened when the outside
temperature is high. Ammonia vapours can irritate mucous membranes,
skin and eyes.
Ensure that there is adequate fresh air supply and do not breathe in the
escaping ammonia vapours.
• Fill the AdBlue tank via the filler neck (1) and
close it using the cap.
• Check the level on the gauges (2) and (3) in
the driver's cab; à p. 7 - 34.
7.5.3 Check the exhaust system for external damage M1
Spare parts and

Exhaust silencer with SCR catalytic 1 03140048
converter
(SCR = Selective Catalytic Reduction)
(with diesel particulate filter)
à p. 2 - 3.
– The engine and the exhaust system must be cool.
09.03.2018
s
GMK5200-1
Check the
following
G
Risk of burns if the exhaust system is hot.
During operation, the exhaust system heats up to 400 °C (750 °F). Wear
suitable gloves and wait until the exhaust system has cooled down. Make
sure not to touch any hot parts.
• Check the exhaust pipes (2) from the

engine (1) to the silencer (3) for damage.
The exhaust pipes (2) may not have any
holes or cracks.
• Check that the area around the exhaust
pipes is free of loose components which
could burn by coming into contact with the
hot exhaust system.
• Check the filler neck for injecting AdBlue for
external damage.
After checking
• Start the engine.
• Check the AdBlue system gauge on the display in the driver's cab;
à p. 7 - 34.
• Monitor, if exhaust gases leak from possibly damaged places in the
exhaust system.
If you discover any damage

Have any damaged parts of the exhaust system replaced immediately by
09.03.2018

GMK5200-1
7.5.4 Having the AdBlue system checked M 12
This inspection may only be performed by Manitowoc Crane Care or an

authorised GROVE dealer or an authorised specialist workshop.
• Have the entire AdBlue system checked for leaks and proper functioning;
à Overview, p. 7 - 33.
• Also observe the information on the components mounted on the engine;
à Engine manufacturer's documentation:
– AdBlue dosing unit,
– Solenoid valve for engine coolant for preheating the AdBlue tank.
Maintenance interval for the pump unit

The engine manufacturer specifies additional maintenance intervals for the
pump unit (1); àEngine manufacturer's documentation.
AdBlue filter
• Have the AdBlue filter in the pump unit (1)
changed:
– For the first time after one year (M 12),
– after that, every two years (Y 2).
Pressure accumulator
• Have the pressure accumulator in the pump
unit (1) filled:
– For the first time after one year (M 12),
– after that, every two years (Y 2).
• Have the insulation hood (2) checked for damage and for tight fitting
on the AdBlue tank. The insulation hood prevents the AdBlue tank
freezing up.
• Have the electrically heated AdBlue lines at the pump unit (1) checked for
correct operation.
s
09.03.2018

GMK5200-1
S
Risk of damage to the pump unit.
Oil from the compressed air system can damage the pump unit.
Therefore, a filter cartridge must be installed in the compressed air drier
that removes both water and oil. Manitowoc Crane Care recommends the
suitable filter cartridge with the GROVE part number 04157844.
• Use only the suitable filter cartridge; à Replacing the filter cartridge of the
compressed air drier, p. 7 - 99.
09.03.2018

GMK5200-1
7.6 Transmission
7.6 Transmission
Overview
Engine-transmission unit
– Diesel engine (1),
– VIAB (2),
– Transmission (3).
VIAB
VIAB is the abbreviation for: Verschleißfreies
Integriertes Anfahr- und Bremssystem (wear-
free integrated starting and braking system).
The VIAB is an oil-filled clutch which permits

starting and braking and delicate manoeuv-
ring.
Therefore the VIAB has its own oil supply and

à
is filled with a special grade of oil; Checking
the VIAB oil level, p. 7 - 41.
s
09.03.2018

GMK5200-1
7.6 Transmission
Transmission
The automatic transmission has 16 speeds
and the type designation G 280-16.
The transmission has its own oil supply and is

filled with a special grade of oil, different from
the one used by the VIAB; à Checking the
transmission oil level, p. 7 - 42.
• Investigate any unusual running noises from the VIAB or transmission.

• Check the transmission and the connections for leaks. If consumables are
leaking;
à Checking the VIAB oil level, p. 7 - 41,
à Checking the transmission oil level, p. 7 - 42.
09.03.2018

GMK5200-1
7.6 Transmission
7.6.2 Checking the VIAB oil level M 12
Spare parts and

Gasket 24 x 29 Cu DIN 7603 1 00117145

Prerequisites – The transmission oil must have an operating temperature of at least 60 °C

(140 °F)).
– The truck crane must be raised on outriggers or parked over an inspection
pit.
– The truck crane must not running and secured against unauthorised use;
à p. 2 - 3.
Checking the oil

level
S
Risk of damage to the transmission.
If the oil level is too low or too high, this can lead to malfunctions and dam-
age to the transmission.
Check the oil level at the correct intervals.
• Remove the drain plug (1).

• Check the oil level; it must reach to the lower
edge of the opening.
• Fit a new gasket and tighten the drain plug.
09.03.2018

GMK5200-1
7.6 Transmission
7.6.3 Checking the transmission oil level M 12
Spare parts and

Gasket 24 x 29 Cu DIN 7603 1 00117145

Prerequisites – The gear oil must be at operating temperature (70 to 95 °C (160 to 200 °F)).
pit.
– The truck crane must not running and secured against unauthorised use;
à p. 2 - 3.
Checking the oil

level
S
Risk of damage to the transmission.
If the oil level is too low or too high, this can lead to malfunctions and dam-
age to the transmission.
Check the oil level at the correct intervals.

• Check the oil level; it must reach to the lower
edge of the opening.
• Replace the gasket and tighten the drain
plug – torque 25 Nm (18.4 lbf ft).
09.03.2018

GMK5200-1
7.6 Transmission
7.6.4 Changing the VIAB oil Y3
Oil, spare parts

and tools Gear oil in Specification GROVE part no.
11.0 (2.9) Shell Spirax 04162043
S6 ATF VM

Gasket 24 x 29 Cu DIN 7603 1 00117145
(oil filler neck, top)
Gasket 24 x 29 Cu DIN 7603 1 00117145
(oil level plug, side)
Gasket 24 x 29 Cu DIN 7603 1 00117145
(oil drain cock, bottom)
Gasket 14 x 18 Cu DIN 7603 1 00117131
(heat exchanger oil drain cock)
Filter exchange kit 1 04163770
Vent valve filter 1 04163771
Cover gasket filter 1 04163772

– Torque wrench.
Prerequisites – The transmission oil must have been warmed up in advance and reached
an operating temperature of at least 60 °C (140 °F)).
– The engine must have been run at full throttle in 8th gear for 10 to
15 seconds.
pit.
à p. 2 - 3.
Draining oil
G
Risk of scalding from gear oil at operating temperature.
You could burn yourself by gear oil escaping in an uncontrolled manner at
operating temperature. Wear appropriate protective gloves and take care
not to come into contact with the gear oil.
09.03.2018
s
GMK5200-1
7.6 Transmission
O
• Remove the drain screw (2).

• Place a receptacle under screws (1) and (3).
• Unscrew the screws (1) and (3) and allow the
oil to drain off.
• Clean the drain screws.
• Replace the gaskets and tighten the drain
screw (3) to torque 55 Nm (40.5 lbf ft).
• Replace the gaskets and tighten the drain
screw (1) to torque 24 Nm (17.7 lbf ft).
Changing the filter

• Replace the cover gasket and the vent valve.
• Bolt the cover (1) on.
09.03.2018

GMK5200-1
7.6 Transmission
Topping up the oil

• Top up oil through the hole (2) until oil
comes out of the hole (1).
plug (1) – torque 55 Nm (40.5 lbf ft).
Inspections after
the oil change
After changing oil, check for leakage:
• Start the engine and let it idle in neutral N.
• Check the screw plugs (1) to (4) for leakage.
09.03.2018

GMK5200-1
7.6 Transmission
7.6.5 Transmission oil change Y3
Oil, spare parts

and tools Gear oil in Specification GROVE part no.
17.5 (4.6) Fuchs Titan 04162042
(with oil Cytrac MB Synth
cooler) API-GL-4; SAE 75 W-90

Filter 1 03328342
Spring 1 03328343
Gasket 1 03328344
Gasket 24 x 29 Cu DIN 7603 1 00117145

– Torque wrench for torque of 25 Nm (18.4 ft lbf) and 60 Nm (44.25 ft lbf).
– Connecting piece and hose (tool box); à p. 7 - 112.
Prerequisites – The gear oil must be at operating temperature (70 to 95 °C (160 to 200 °F)).
pit.
à p. 2 - 3.
Draining oil
G
O
09.03.2018

GMK5200-1
7.6 Transmission
• Place a receptacle under the valve (1).

• Screw the connecting piece and hose onto
the valve (1) and drain the oil into the recep-
tacle; à Handling the valves, p. 7 - 112.
• Remove the connecting piece and hose
from the valve (1) and take away the recep-
tacle.
Cleaning the filter
G
Risk of injury due to spring tension
The oil strainer bolt is spring-loaded. Release it carefully and be careful of
the spring tension.

• Take the strainer (2) and the spring (3) out
and clean them.
Replace any damaged parts.
• Insert the spring and strainer into the open-
ing.
plug – torque 60 Nm (44.25 lbf ft).
s
09.03.2018

GMK5200-1
7.6 Transmission
Topping up the oil

• Remove the hose (2).
• Top up oil through the hole (2) until oil
comes out of the hole (1).
• Add an additional 1.5 l (0.4 gal) oil through
the hole (2).
• Attach the hose (2).
Inspections after
the oil change
After changing oil, check for leakage:

• Start the engine and let it idle in neutral N.
• Check the screw plugs (1) to (3) for leakage.
• Check the hoses and connections on the oil
cooler.
09.03.2018

GMK5200-1
7.7 Transfer case
7.7 Transfer case
Variants The truck crane GMK5200-1 is equipped with different transfer cases
depending on whether the drive variant is 10 x 6 x 10 or 10 x 8 x 10:
A Transfer cases for drive 10 x 6 x 10.

B Transfer cases for drive 10 x 8 x 10.
• Note the à Run-in regulations, p. 4 - 1.
• Investigate any unusual noises made by the transfer case.

• Check the transfer case and the connections for leaks. If consumables are
leaking; à Checking the oil level, p. 7 - 49.
7.7.2 Checking the oil level M1
Spare parts and

Gasket 30 x 36 Cu DIN 7603 1 00117151
Prerequisites – The truck crane must be raised on outriggers or parked over an inspection
pit.
à p. 2 - 3.
s
09.03.2018

GMK5200-1
7.7 Transfer case
Checking
• Check that the oil reaches the lower edge of
the opening.

7.7.3 Changing the oil M6
Oil, spare parts,

tools Gear oil in Designation to Specification GROVE part no.
12.8 (3.4) C - LPF MIL-L 2105 B 00552891
for 10 x 6 x 10 API-GL-5
Viscosity:
14.0 (3.7) Hyp SAE 90
for 10 x 8 x 10 ISO - VG 220

Gasket 16 x 20 Cu DIN 7603 1 00117134
Gasket 30 x 36 Cu DIN 7603 1 00117151
pit.
à
09.03.2018
p. 2 - 3.

GMK5200-1
7.7 Transfer case
Changing the oil
G
O
• Place a receptacle under the screw (2).

oil to drain off.
• Fit a new gasket and tighten the drain
screw (2).
• Fill the oil up to the lower edge of the open-
ing.
• Fit a new gasket and tighten the screws (1).
Inspections after
the oil change
• Go for a test drive.
• Switch the engine off and wait for approx.
5 minutes.
• Check the oil level; à p. 7 - 49.
• Check drain plugs (1) and (2) for leaks.
09.03.2018

GMK5200-1
7.7 Transfer case
Blank page
09.03.2018

GMK5200-1
7.8 Angle gear
7.8 Angle gear

• Comply also with the à Run-in regulations, p. 4 - 1.
Access
The angle gear (1) is located in the travel gear

frame at the centre of rotation of the turntable.
Within the oil circuit (2) the gear oil for the
angle gear (1) is routed under the chassis via a
separate oil cooler (3) and through a separate
filter (4).
Access to the angle gear (1) is possible only

when
– the truck crane is resting on outriggers,

– the main boom is raised,
– the turntable is turned to the 0° position to
the rear,
– the cover (2) at the centre of rotation has
been taken off.
09.03.2018

GMK5200-1
7.8 Angle gear
• Investigate any unusual noises in the angle gear.

• Check the transmission and the oil circuit (oil cooler, filter, hoses, connec-
tions) for leaks. If consumables are leaking;
à Checking the oil level, p. 7 - 54.
7.8.2 Checking the oil level M1
Symbols The oil is monitored by sensors in the angle gear and the following warning
messages are displayed in the CCS menu:
– Oil level too low,
– Oil temperature too high.
Spare parts and

Gasket 30 x 36 Cu DIN 7603 1 00117151
09.03.2018

GMK5200-1
7.8 Angle gear
Prerequisites – The crane must be rigged with an outrigger span of at least 8.95 x 7.80 m
(29.4 x 25.6 ft) and be level;àOperating manual.
– The main boom must be fully retracted and fully raised; à Operating
manual.
– The turntable must be turned to the 0° position to the rear; à Operating
manual.
à p. 2 - 3.
– The cover on the turntable over the centre of rotation must be removed.
– The hydraulic drives and the angle gear must have cooled down suffi-
ciently.
– The access opening and the interior space must be clean and free of oil so
that the fitter can work safely in the restricted space where the angle gear
is installed.
Checking

the opening.
s
09.03.2018

GMK5200-1
7.8 Angle gear
Checking the The angle gear is mounted on four resilient dampers.

resilient dampers
• Check the secure fastening and the condi-

tion of the resilient dampers (1).
If the resilient dampers are damaged, have them replaced by Manitowoc

Crane Care or an authorised GROVE dealer.
09.03.2018

GMK5200-1
7.8 Angle gear
7.8.3 Changing the oil and the oil filter M6
Oil, spare parts,

7.7 (2.0) MIL-L 2105 B 01373344
API-GL-5
Viscosity:
Hyp SHC 75-90

Angle gear:
Gasket 30 x 36 Cu DIN 7603 1 00117151
Filter:
Filter 1 03135866
Packing set 1 04161645
– Connecting piece and hose (tool box).

– Two receptacles, approx. 10 l (2.5 gal); à p. 2 - 4.
– Key for the lock on the drain tap; à p. 7 - 58.
(29.4 x 25.6 ft) and be level; à
Operating manual.
– The main boom must be fully retracted and fully raised; à Operating
manual.
– The turntable must be turned to the 0° position to the rear; à Operating
manual.
à p. 2 - 3.
– The cover on the turntable over the centre of rotation must be removed.
– The hydraulic drives and the angle gear must have cooled down suffi-
ciently.
– The access opening and the interior space must be clean and free of oil so
that the fitter can work safely in the restricted space where the angle gear
is installed.
s
09.03.2018

GMK5200-1
7.8 Angle gear
Drain tap
S
Risk of damage to the angle gear!
If the drain tap remains open after changing the oil, the oil circuit will be
interrupted and the upper bearing will not be adequately supplied with oil.
This can lead to malfunctions and transmission damage.
The drain tap must always remain closed and secured with the lock during
driving and crane operation.
You only need to open the drain tap to drain the oil during an oil change.
After this, you must restore the normal operating condition by closing the
drain tap and securing it with the lock.
Before the oil change – open the valve

• Open the lock (1) with the key and remove it.
• Open the valve – lever (2) parallel to the line.
The oil change valve (3) prevents oil from
escaping uncontrollably.
After the oil change – close the valve

• Close the valve– lever (2) at right angles to
the line.
• Fit the opened lock (1) and press it together –
the lever (2) on the valve is now locked in
position.
• Return the key to the storage location
(driver's cab or toolbox) so that it is always
available.
09.03.2018

GMK5200-1
7.8 Angle gear
Changing the oil
G
O
• Place a receptacle under the filter (4).

• Place a receptacle under the oil cooler.
• Remove the screw (1).
the valve (3) and drain the oil.
• Release the filter (4) and allow the oil to
drain from it.
• Change the filter (6).
• Replace the gasket (5).
s
09.03.2018

GMK5200-1
7.8 Angle gear
• Tighten the filter (4).

• Remove the connecting piece and hose
from the valve (3) – the valve (3) is closed.
ing (1).
• Fit a new gasket and tighten the screw (1).
• Close the valve – lever (2) at right angles to
the line.
Inspections after In order to circulate the oil around the oil circuit you must try out operation
the oil change of a hydraulic function on the superstructure (for instance tilting the crane
cab).
• Switch the engine off and wait for approx. 5 minutes.

• Check the oil level; à p. 7 - 54.
• Check the angle gear, the filter and the oil cooler for leaks.
09.03.2018

GMK5200-1
7.9 Axle lines
7.9 Axle lines

• Investigate any unusual running noises from the axle centre drives and
the final drives.
• Check the axle centre drives/final drives and the connections for leaks. If
consumables are leaking;
à Axle centre drives – checking the oil level, p. 7 - 61,
à Final drives – checking the oil level, p. 7 - 67.
7.9.2 Axle centre drives – checking the oil level M1
Spare parts and

tools for drive Designation Quantity GROVE part no.
10 x 6 x 10 Gasket 30 x 36 Cu DIN 7603 3 00117151
10 x 8 x 101) Gasket 30 x 36 Cu DIN 7603 4 00117151
1)
Additional equipment (3rd driven axle line)
pit.
à
p. 2 - 3.
s
09.03.2018

GMK5200-1
7.9 Axle lines
2nd and 5th axle

line

the opening.
3rd axle line This axle centre drive is available only with the 10 x 8 x 10 drive and is
flanged directly to the transfer case; àTransfer case, p. 7 - 49.

the opening.
09.03.2018

GMK5200-1
7.9 Axle lines
4th axle line
The drive has two oil chambers.

the opening.
7.9.3 Axle centre drives – changing the oil M 12
Oil, spare parts,

Axle lines 2+5: C - LPF MIL-L 2105 B 00552891
each 13.0 (3.5) API-GL-5
Axle lines 3: Viscosity:
14 (3.7) Hyp SAE 90
Axle lines 4: ISO - VG 220
16.5 (4.4)
for drive Designation Quantity GROVE part no.

Gasket 30 x 36 Cu DIN 7603 3 00117151
10 x 6 x 10 Gasket 24 x 29 Cu DIN 7603 2 00117145
Gasket 36 x 42 Cu DIN 7603 3 01371208
Gasket 30 x 36 Cu DIN 7603 4 00117151
1)
10 x 8 x 10 Gasket 24 x 29 Cu DIN 7603 2 00117145
Gasket 36 x 42 Cu DIN 7603 4 01371208
1)
Additional equipment (3rd driven axle line)
09.03.2018

s
GMK5200-1
7.9 Axle lines
pit.
à p. 2 - 3.
O
2nd and 5th axle

lines
oil to drain off.
screw (2).
ing.
screw (1).
3rd axle line This axle centre drive is available only with the 10 x 8 x 10 drive and is
flanged directly to the transfer case; à
Transfer case, p. 7 - 49.

oil to drain off.
screw (2).
ing.
screw (1).
09.03.2018

GMK5200-1
7.9 Axle lines
4th axle line The drive has two oil chambers.
S
Risk of oil overheating.
When topping up the oil, both openings must be opened so that both oil
tanks are filled equally. This prevents both oil tanks from being overfilled
and thus the oil from overheating.
• Place a receptacle under screws (3) and (4).

• Remove screws (1), (2), (3) and (4) and let
the oil drain off.
• Fit new gaskets and tighten screws (3)
and (4).
• First add 1.5 l (0.4 gal) oil through the
hole (2).
• Add more oil through the hole (1), up to the
lower edge of the hole (1).
• Fit new gaskets and tighten screws (1)
and (2).
09.03.2018

GMK5200-1
7.9 Axle lines
Blank page
09.03.2018

GMK5200-1
7.9 Axle lines
7.9.4 Final drives – checking the oil level M1
Spare parts and

tools for drive Designation Quantity GROVE part no.
10 x 6 x 10 Gasket 24 x 29 Cu DIN 7603 6 00117145
10 x 8 x 101) Gasket 24 x 29 Cu DIN 7603 8 00117145
1) Additional equipment (3rd driven axle line)
Prerequisites – The truck crane must be raised on outriggers and must be level.
à
p. 2 - 3.
– The parking brake must be released.
Checking the oil

level
• Check the oil level at all other final drives in

the same way.
• Turn the wheel until the mark (2) is horizon-
tal and is on the right, next to the centre of
the axle.
• Check that the oil level is at the mark (2).
09.03.2018

GMK5200-1
7.9 Axle lines
7.9.5 Final drives – changing the oil M 12
Oil, spare parts,

for each final C - LPF MIL-L 2105 B 00552891
drive: API-GL-5
2.7 (0.7) Viscosity:
Hyp SAE 90
ISO - VG 220
for drive Designation Quantity GROVE part no.

10 x 6 x 10 Gasket 24 x 29 Cu DIN 7603 6 00117145
10 x 8 x 101) Gasket 24 x 29 Cu DIN 7603 8 00117145
1) Additional equipment (3rd driven axle line)
– Drain channel.
Prerequisites – The truck crane must be raised on outriggers.

à
p. 2 - 3.
O
Ask about the applicable regulations. 09.03.2018

GMK5200-1
7.9 Axle lines
Draining oil
• Change the oil on all final drives in the same

way.
• Turn the wheel until the screw (1) is at the
bottom.
• Use a drain channel and place a receptacle
under the screw.
• Remove the screw and let the oil drain out.
Topping up the oil
• Turn the wheel until the mark (2) is horizon-

tal and is on the right, next to the centre of
the axle.
• Top up the oil through the opening.
screw (1).
09.03.2018

GMK5200-1
7.9 Axle lines
7.9.6 Lubricating the cardan shafts in the axle lines M1
H
Check all cardan shafts to see if they have grease nipples.
Cardan shafts with grease nipples must be serviced, cardan shafts without
grease nipples are maintenance-free.
Grease, spare
parts, tools Lubricating Designation to Specification GROVE part no.
grease DIN 51502 Classification
Grease KP - 1K - 50 DIN 51825 03233369
– Grease gun from the tool set.
pit.
à p. 2 - 3.
– The wheels must be turned as far as they will go, so that the lubricating
nipples on the sides of the final drives are more easily accessible.
Greasing
Cardan shafts (2) are fitted only to the

10 x 8 x 10 drive.
• Check which cardan shafts (1) and (2) have
lubricating nipples (3).
• Clean the grease nipples (3).
• Inject grease into the grease nipples until
grease escapes from the bearing points.
Do not inject grease with excessive force,
otherwise the lip seals may be damaged.
• Remove the excess grease.
09.03.2018

GMK5200-1
7.9 Axle lines
7.9.7 Lubricating longitudinal cardan shafts M6
H
Check all cardan shafts to see if they have grease nipples.
Cardan shafts with grease nipples must be serviced, cardan shafts without
grease nipples are maintenance-free.
Grease, spare
Grease KP - 1K - 50 DIN 51825 03233369
pit.
à p. 2 - 3.
Greasing
• Check which cardan shafts (1) have grease

nipples (2).
• Clean the grease nipples (2).
• Inject grease into the grease nipples until
grease escapes from the bearing points.
Do not inject grease with excessive force,
otherwise the lip seals may be damaged.
• Remove the excess grease.
09.03.2018

GMK5200-1
7.9 Axle lines
Blank page
09.03.2018

GMK5200-1
7.10 Wheels
7.10 Wheels
7.10.1 Checking the tyres for damage D
Prerequisites – The truck crane must be raised on outriggers.

à p. 2 - 3.
Checking
• Check all tyres for:

– Broken off tread blocks
– Dents
– Areas of uneven wear
– Whether the wear marking (1) has been
reached.
• Replace any damaged tyres.
• If the tyres show varying degrees of wear,
change the wheels; à Changing the wheels,
p. 7 - 76.
S
Risk of accidents due to uneven braking.
When replacing the tyres, only use the same quality of tyres as those
originally fitted (dimensions, load bearing capacity, air pressure) so that
the driving characteristics are maintained.
Always replace all the tyres on an axle line.
09.03.2018

GMK5200-1
7.10 Wheels
7.10.2 Checking the tyre pressure W
S
Risk of damage to the tyres.
The tyre pressure increases during operation. Never release the increased
air pressure of tyres at operating temperature.
Always check the tyre pressure in on-road driving mode with cold tyres.
• Check the tyre pressure using the following table.
Tyres Air pressure of cold tyres in bar

(psi)
14.00 R 25
9,0 (131)
385/95 R25
16.00 R 25
9,0 (131)
445/95 R25
20.50 R 25
7,0 (102)
525/80 R 25
09.03.2018

GMK5200-1
7.10 Wheels
7.10.3 Checking that the wheel nuts are tight M1
Spare parts and

per wheel
Wheel nut with pressure plate 12 01207756
for steel rims
for aluminium rims
– Torque wrench for 650 Nm (480 lbf ft).
à p. 2 - 3.
Checking the
wheel nuts
• Check the wheel nuts and the pressure

plates for damage.
• Replace any damaged wheel nuts or pres-
sure plates.
• Check the wheel nuts in sequence (1-12) for
a tight fit – torque 650 Nm (480 lbf ft).
09.03.2018

GMK5200-1
7.10 Wheels
7.10.4 Changing the wheels M6
The wear on tyres varies depending on whether the axle

– is driven/not driven,
– is steered/not steered,
– is braked/not braked
– and whether it is subject to more or less load.
To achieve even wear, you must swap the wheels to different positions
regularly.
This will have a positive effect on tyre life and performance.
Spare parts and

per wheel
for steel rims
for aluminium rims
– Torque wrench for 650 Nm (480 lbf ft).
à p. 2 - 3.
Changing the
wheels
G
Risk of accidents if the procedure is not carried out correctly.
This section only shows the sequence to be followed when changing
wheels.
When removing/mounting the wheels, observe all the safety instructions
and the procedure stated in the operating manual.
• Remove the wheels from the axles.
Only for two-piece aluminium rims

• Have a specialist workshop check the bolts on the two-piece aluminium
rims, using the appropriate special tool.
Depending on the manufacturer, there are 20 or 22 bolts visible on the
outer face of the rim. On the inner face of the rim there are 20 or 22 nuts.
It is the torque of these that you must have checked in a specialist work-
09.03.2018
shop; à Recognising two-piece aluminium rims, p. 7 - 77.

GMK5200-1
7.10 Wheels
Recognising two-
piece aluminium
rims
The round-head bolts (1) are on the outer face

of the rim.
The round heads must be free of cracks, and

the bolts must be seated securely in the holes.
Around the edge of the aluminium rim there

are impressed marks and safety instructions
which must be complied with by the specialist
workshop.
The nuts (1) are on the inner face of the rim.
The round heads must be free of cracks and

securely seated on the bolts. The torque must
be checked within the specialist workshop.
Aluminium rims with 20 nuts:

550 Nm (406 lbf ft)
Aluminium rims with 22 nuts:
385 Nm (284 lbf ft)
s
09.03.2018

GMK5200-1
7.10 Wheels
• Mount the wheels on another axle, as shown in the diagram. Replace any
damaged parts. Tighten the wheel nuts; à p. 7 - 75.
09.03.2018

GMK5200-1
7.10 Wheels
Optimised wheel To ensure even more even wear on all tyres, you can also rotate the tyres
changes on the wheel rim and mount them on the other side of the vehicle.
G
Risk of accidents if the procedure is not carried out correctly.
This section only shows the sequence to be followed when changing
wheels.
When removing/mounting the wheels, observe all the safety instructions
and the procedure stated in the operating manual.
G
Risk of accidents due to errors when mounting aluminium wheel rims.
Only have tyres fitted to aluminium wheel rims in an authorised workshop
with the correct special tool.
This will prevent tyre damage caused by assembly errors.
G
Risk of tyre damage caused by the tyres running in a different direction.
Turn the tyres on the wheel rims before you put the wheels on the other
side of the vehicle.
This will prevent tyre damage caused by the tyres running in a different
direction.
• Remove the wheels from the axles.

• Turn the tyre on the rim if the wheel is to be used on the other side of the
crane.
• Mount the wheels on another axle, as shown in the diagram. Replace any
damaged parts. Tighten the wheel nuts; à p. 7 - 75.
09.03.2018

GMK5200-1
7.10 Wheels
Blank page
09.03.2018

GMK5200-1
7.11 Vehicle brake
7.11 Vehicle brake
7.11.1 Checking the wear display D
On the brake calliper

Each brake calliper (1) carries two brake pads
(2), arranged one to the left and one to the
right of the brake disc (3).
The lining thickness (A) is monitored by an

electric wear indicator on the brake calliper (1).
If the lining thickness (A) falls below the per-
missible minimum value, a warning message
is displayed on the on-board computer in the
driver's cab.
On the on-board computer

• Familiarise yourself with the correct
operation of the on-board computer;
The Operation and Maintenance menu also
provides information on the condition of the
disc brakes.
• Check the outstanding warning messages
every day.
s
09.03.2018

GMK5200-1
7.11 Vehicle brake
If the symbol (1) is displayed on the on-board computer, one of the disc
brakes has exceeded the brake lining wear limit.
• Check all disc brakes on all axle lines; à Checking disc brakes, p. 7 - 82.
• Have the disc brakes repaired immediately; à Having the brakes repaired,
p. 7 - 87.
7.11.2 Checking disc brakes M3
Spare parts and

Wear contact set 12 03142924
Set of brake pads with a wear contact 12 03142923
set
Guide set and seals set 24 03142922
Brake disc 10 03142916
– Measuring tools for brake pad and brake disc thicknesses.

– Dial gauge for the brake disc runout.
– Ring spanner for adjustment.
Prerequisites – The truck crane must be parked over an inspection pit.

– The truck crane must be raised on outriggers.
à p. 2 - 3.
– The wheels must be removed from all the axle lines.
09.03.2018

GMK5200-1
7.11 Vehicle brake
Safety • Do not perform repair work on the vehicle brakes; à Maintenance instruc-
instructions tions, p. 1 - 2.
G
Risk of accidents due to incorrect work on the vehicle brakes.
Incorrect work on the vehicle brakes can lead to failure of the brakes caus-
ing severe accidents.
Incorrect work invalidates the operating licence of the truck crane and no
claims of liability for damage can then be accepted.
All repair work on the vehicle brakes may only be performed by
Manitowoc Crane Care or an authorised GROVE dealer or an authorised spe-
cialist workshop with specially trained repair crew.
• Perform only maintenance work:

à Checking the brake discs, p. 7 - 83,
à Checking the brake pads, p. 7 - 85,
à Checking the adjustment mechanism, p. 7 - 85.
If damage is discovered then you must have the vehicle brakes repaired;
à Having the brakes repaired, p. 7 - 87.
Checking the • Check the thickness of the brake discs on all axle lines.
brake discs
Measure the thickness
• Measure the thickness (A) of the brake
discs (1).
New brake discs have a thickness of 41 mm
(1.61 in).
You must have the brake disc replaced if the
thickness is less than 33 mm (1.30 in);
09.03.2018
s
GMK5200-1
7.11 Vehicle brake
Checking the surface

• Check for signs of damage such as cracks
and irregularities:
(A) – fine network of cracks,
(B) – radial cracks,
(C) – circular irregularities,
(D) – continuous cracks.
• Check that any damage found lies within the
permissible limit values.
You must have the brake disc replaced if any
limit values are exceeded; à
Having the brakes
repaired, p. 7 - 87.
Limit values for damage:

(A) – permissible,
(B) – only permissible for a crack length up to three-quarters of the length Y.
(B) – only permissible for a crack width of up to 0.5 mm (0.02 in).
(C) – only permissible for a depth of up to 1.5 mm (0.06 in).
(D) – not permissible.
Measure the runout

• Attach the dial gauge (1) to the brake anchor
plate (2).
• Position the measuring probe (3) perpen-
dicular to the brake disc (4).
The distance (A) to the edge of the brake
disc must be 35 mm (1.38 in).
• Rotate the brake disc one full revolution and
read the runout on the dial gauge pointer.
You must have the brake disc replaced if the
runout is greater than 0.15 mm (0.006 in);
09.03.2018

GMK5200-1
7.11 Vehicle brake
Checking the • Check the thickness of the brake pads on all axle lines.
brake pads Each brake calliper (1) carries two brake pads (2), arranged one to the left
and one to the right of the brake disc (3).
This first axle line has two brake callipers per brake disc. The second to
fifth axle lines have one brake calliper per brake disc.
On the brake calliper
• Measure the pad thickness (A).
New brake pads have a pad thickness of
23 mm (0.90 in).
You must have the brake pads replaced if
– the brake pad thickness is less than 2 mm
(0.08 in) or
– the brake pads are burnt, glassy, broken or
oily; à
Having the brakes repaired, p. 7 - 87.
• Check that the electrical cable to the wear
display is undamaged.
H
The brake pad wear (A) is taken up by the automatic adjustment mecha-
nism. When the pad thickness is small, the travel adjustment is large and
you must also check the adjustment mechanism; àChecking the adjustment
mechanism, p. 7 - 85.
Checking the • Using a ring spanner, check all the brake callipers.
adjustment
mechanism
S
There is a risk of damage if an unsuitable tool is used.
The use of an unsuitable tool can damage the hexagon head of the adjust-
ment mechanism. An unsuitable tool can slip off the hexagon head or can
become jammed.
Always use a ring spanner, never an open-jaw spanner.
When you apply the brakes the ring spanner on the hexagon head will
rotate with it. Therefore check in advance that there is sufficient clearance
for this rotational movement.
s
09.03.2018

GMK5200-1
7.11 Vehicle brake
G
Risk of injury due to rotation of the ring spanner.
If you are holding the ring spanner when another person in the driver's cab
applies the brakes your hand could be crushed.
Do not hold the ring spanner when another person in the driver's cab
applies the brakes. Just observe the rotation of the ring spanner from a safe
distance.
On the brake calliper under the brake cylinder

• Remove the cap (1) – the hexagon head (2)
is then exposed.
• Place the ring spanner (3) on the hexagon
head.
• Turn the ring spanner half a turn clockwise.
Leave the ring spanner attached.
• Ask a second person in the driver's cab to
apply the brakes (approx. 5 times at approx.
1 bar) and observe the rotation of the ring
spanner.
• Remove the ring spanner.
• Replace the cap.
The way the ring spanner rotates allows you to assess the condition of the
adjustment mechanism.
The adjustment mechanism is OK if the ring spanner

– turns one step anticlockwise at each brake application,
– rotating a small angle at each step.
The adjustment mechanism is defective if the ring spanner

– fails to turn at any of the brake applications,
– or turns only at the first brake application,
– or at the brake application first turns anticlockwise but then turns back
clockwise again.
If the adjustment mechanism is defective then you must have the vehicle
brakes repaired; à Having the brakes repaired, p. 7 - 87.
09.03.2018

GMK5200-1
7.11 Vehicle brake
Having the brakes • Do not perform repair work on the vehicle brakes; à Safety instructions,
repaired p. 7 - 83.
• All repair work on the vehicle brakes may only be performed by
Manitowoc Crane Care or an authorised GROVE dealer or an authorised
specialist workshop with specially trained repair crew.
• Make sure that only original spare parts are used; à Spare parts and tools,
p. 7 - 82.
G
Risk of accidents due to uneven braking.
If the brake pads and brake discs are replaced on only one side of the axle
then the wheels will brake unevenly.
Always have the brake pads and brake discs replaced on both sides of the
axle. Where axles lines have two brake callipers per brake disc, you must
always have the brake pads changed on both brake callipers.
Running in the New brake linings do not provide optimal braking and must therefore be run
brake pads in by periodic braking.
S
Risk of damage to the brakes when running them in.
Constant or heavy braking at high speeds can overheat the brakes and
damage them.
The brakes must only be run in through periodic braking.
This must first be done at low speed and then later at medium speed.
• Perform a test drive to make sure that the new brake pads are sufficiently
run in before putting the truck crane into normal operation.
09.03.2018

GMK5200-1
7.11 Vehicle brake
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09.03.2018

GMK5200-1
7.12 Suspension
7.12 Suspension
7.12.1 Suspension struts – checking the oil level M1
Oil, spare parts,

tools
Oil in litres (gal) Designation GROVE part no.

5 x suspension
struts (1)
1.5 (0.4) each
Gear oil Rivolta S.K.D. 170 02310863
5 x suspension
struts (2)
3.2 (0.84) each
– Press with connected hose (from toolbox).

Filter 1 03324588
à p. 2 - 3.
– Immediately before the inspection, the truck crane must be completely
lowered and returned to on-road level; à
Operating manual.
Checking the oil

level
S
Risk of damage due to faulty suspension struts.
If the oil level is above the upper marking on the inspection glass, the sus-
pension strut is faulty and must be replaced.
Notify Manitowoc Crane Care or an authorised GROVE dealer.
S
Risk of damage to the suspension struts due to insufficient lubrication.
It is difficult to inject the oil. Even so, do not fill oil through the inspection
glass connections. If you do this, the oil will not reach all the lubricating
points.
09.03.2018
s
GMK5200-1
7.12 Suspension
• Check whether oil is visible in the centre of the inspection glass (1) on
each suspension strut.
• Open the connection (2) – oil escapes – and quickly connect the press with
the hose.
• Inject oil until it reaches the middle of the inspection glass.
• Remove the hose and quickly close the connection (2).
Checking the
bleed overflow oil
collection tank
All suspension struts (1) are connected to the
oil collection tank (3) by a bleed hose (2). The
oil collection tank (3) is accessible from below
through the opening (4).
• Place an oil collection container under the

oil drain plug (5).
• Open the drain plug (5) and allow the oil to
drain; normally this is a very small quantity.
• If there is has been a large quantity of oil
collected, then one or more suspension
struts are defective.
• Close the drain plug (5).

• Change the filter (6) if necessary and fasten the cover.
• Defective suspension struts should be replaced as soon as possible by

09.03.2018

GMK5200-1
7.12 Suspension
7.12.2 Suspension struts – checking the fastening M1
Spare parts and – Torque wrench for torques up to 900 Nm (664 lbf ft).
tools
Prerequisites – The truck crane must be raised on outriggers; à Operating manual.

à p. 2 - 3.
– The wheels must have been removed.
• Check whether the screws on all suspension

struts are fitted tightly; à Special torques,
p. 10 - 2:
1 on the upper bracket,
2 on the lower bracket,
3 on the lower flange,
4 on the half shells for the steering arm,
5 on the upper steering arm.
09.03.2018

GMK5200-1
7.12 Suspension
7.12.3 Forced lever – checking correct functioning M3
On suspension struts with forced levers, the forced levers must be checked
for proper functioning when the suspension is switched on and off.
G
Risk of crushing when releasing the suspension locking system.
When the suspension is switched on, the wheels drop down suddenly.
Ensure that nobody is in close proximity to the wheels when you switch on
the suspension.
S
Risk of damage to the tyres.
Remove sharp-edged or pointed objects from below the wheels before
switching on the suspension.
In this way you prevent the tyres from bursting or being damaged when the
wheels come down.

• Lower the truck crane to the lowest level with the level adjustment sys-
tem; à Operating manual.
• Switch off the suspension; à Operating manual.
The suspension struts and the forced levers (1) are brought together.
• Raise the truck crane with the outriggers; à Operating manual.

• Switch on the suspension; à Operating manual.
• Check whether all suspension struts are extended and the forced levers
(1) are slackened.
If the suspension struts are not extended or only partially extended, the
forced lever is faulty.
• Faulty forced levers should be replaced as soon as possible by Manitowoc

09.03.2018
Crane Care or an authorised GROVE dealer or your qualified repair crew.

GMK5200-1
7.12 Suspension
7.12.4 Pressure accumulator – checking the gas pressure M 12
The gas pressure must be checked every 3,000 operating hours, but in any
case no less frequently than every 12 months.
G
Risk of accidents due to incorrect inspection.
The gas pressure test must be carried out only by an authorised official
inspector of pressure tanks or under his/her supervision or instructions.
The suspension features integrated pressure

accumulators that contain nitrogen (1).
The filling pressure at 20 °C (68 °F) is 50 bar
(725 psi).
• Have the filling pressure checked, and if

necessary corrected, by Manitowoc Crane
Care or an authorised GROVE dealer or an
authorised specialist workshop.
09.03.2018

GMK5200-1
7.12 Suspension
Blank page
09.03.2018

GMK5200-1
7.13 Steering
7.13 Steering
7.13.1 Checking for leaks D
• Check the hydraulic system of the steering (steering cylinders, pipes and
hose lines and their connections) for leaks.
G
Risk of accidents from hydraulic oil spraying out.
Never tighten leaking connections when the system is under pressure.
Change pipes and hose lines only when the system is depressurised.
• Top up oil if necessary; à Checking the oil level, p. 7 - 101.
After changing pipes and hose lines

• Bleed the hydraulic system; à Bleeding the hydraulic system, p. 7 - 114.
If damage cannot be rectified immediately or further damage is likely

• Notify Manitowoc Crane Care or an authorised GROVE dealer or your repair
crew.
09.03.2018

GMK5200-1
7.13 Steering
G
Pressure accumulators containing nitrogen (1)

have been built in for the steering of the 4th
and 5th axle lines.
The filling pressure at 20 °C (68 °F) is 89 bar
(1,290 psi).
• Have the filling pressure checked, and if

necessary corrected, by Manitowoc Crane
Care or an authorised GROVE dealer or an
authorised specialist workshop.
09.03.2018

GMK5200-1
7.14 Compressed air system
7.14.1 Draining water from the compressed air system W
Spare parts and

Valve 8 01570750
Gasket 22 x 27 Cu DIN 7603 8 00117142
pit.
– The compressed-air supply is completely full; à Operating manual.
à p. 2 - 3.
Draining water
from the com-
pressed air system
• Actuate the valves (1) on the air reservoirs
(2) to (9).
If a great deal of moisture escapes
• Have the compressed air drier checked or
replaced by Manitowoc Crane Care or an
authorised GROVE dealer or your qualified
repair crew.
09.03.2018

GMK5200-1
7.14.2 Checking for leaks W
• Start up the compressed air system.

• Check for any possible leaks in the compressed air system (connections,
pipes, hose lines and valves).
G
Risk of accidents due to escaping compressed air.
Never tighten connections when the system is under pressure. Only change
gaskets, pipes and hose lines when the system is depressurised.
If damage cannot be rectified immediately or further damage is likely:

crew.
09.03.2018

GMK5200-1
7.14.3 Replacing the filter cartridge of the compressed M 12

air drier
Spare parts and

Filter cartridge with gasket 1 04157844
– Strap wrench.
pit.
à p. 2 - 3.
Changing the filter

cartridge
G
Risk of injury from escaping compressed air.
If the reservoir (2) is not completely vented, the compressed air drier will be
under pressure.
Bleed the reservoir until air no longer escapes from the valve.
• Using the valve (1), release all the air from

the reservoir (2).
• Replace the filter cartridge (3) using the
strap wrench (lubricate gasket slightly).
09.03.2018

GMK5200-1
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09.03.2018

GMK5200-1
7.15 Hydraulic system
O
Prerequisites – The truck crane must be aligned horizontally at on-road level;

– The outriggers must be retracted; à Operating manual.
à p. 2 - 3.
S
Risk of damage to the hydraulic system.
When working with hydraulic oil, cleanliness is imperative.
Even fresh hydraulic oil should be filtered.
• Check that oil is visible in the middle of the

inspection glass (1) before starting work.

09.03.2018

GMK5200-1
7.15.2 Checking the hydraulic hoses W
Hydraulic hoses are also subject to ageing as well as internal and external
strain.
• Check the hydraulic hoses for
– external damage (tears, abrasion, 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 longer
than 72 months from date of manufacture.
The date of manufacture and the permitted
operating pressure are marked on the hose fit-
ting:
1 Manufacturer's designation.
2 Maximum operating pressure and unit
of measurement (A) (e.g. 250 bar
(3,626 psi)).
Maximum operation pressure and unit
of measurement (B) (e.g. 25.0 MPa
(3,626 psi)).
3 Month and year of manufacture.
• Always ensure that the corresponding parts

of the hydraulic system are depressurised.
• Damaged or old hydraulic hoses must be
replaced immediately.
• When the engine is running, carry out a visual inspection for leaks on the
hydraulic system (pumps, drives, cylinders, control blocks, valves, pipe
and hose lines and connections).
• Check the oil level if there are leaks; à Checking the oil level, p. 7 - 101.
09.03.2018

GMK5200-1
G
Never tighten any leaking connections when the system is under pressure.
O
Immediately repair or have leakages in the hydraulic system repaired to
ensure that no hydraulic oil escapes, seeps into the ground or reaches
waterways when the crane is being used.
After parts have been changed

• Bleed the carrier's hydraulic system; à Bleeding the hydraulic system,
p. 7 - 114.
crew.
7.15.4 Cleaning the magnetic rods M3
Spare parts and

Filter 2 03329152
Prerequisites – The truck crane must be standing on a level surface.

à p. 2 - 3.
– During the first 100 operating hours: Clean the magnetic rods weekly.
s
09.03.2018

GMK5200-1
Cleaning the
magnetic rods
• Loosen the cover and pull out the filters.
• Place the filters in a receptacle.
• Remove the spring (1).
• Undo the nut (4).
• Take the magnetic rod (2) out of the filter
cage (3) and clean it.
• Replace any damaged parts, where neces-
sary.
S
Large amounts of metal particles are a sign of damage in the hydraulic sys-
tem. Have the hydraulic system checked by Manitowoc Crane Care or an
authorised GROVE dealer or your qualified repair crew.
• Assemble the filters (2) and insert them.

• Replace the gaskets if necessary and fasten
the cap (1).
09.03.2018

GMK5200-1
7.15.5 Changing the ventilation filter M 12
interval tions – you must change the ventilation filters earlier than normal.
Spare parts and

Filter 1 03324588
à p. 2 - 3.
O
Risk of damage to the environment from filter residues.
Store used hydraulic oil filter inserts in suitable receptacles and have them
disposed of properly by qualified personnel.

• Change the filter (2) and fasten the cover.
09.03.2018

GMK5200-1
7.15.6 Taking oil samples M 12
Reducing the • Under difficult operating conditions – at tropical or very hot locations –
interval you must halve the oil change interval.
Spare parts and – A hose with a connecting piece for a gauge port.
tools
Hose lengths GROVE part no.
1 m (3.3 ft) 01923003
2 m (6.6 ft) 00551941
4 m (13.2 ft) 01923139
– A sample container 0.3 l (0.08 gal).
GROVE part no.

A set of sample containers with protective mailing bag
03141012
and delivery note to the contracted laboratory

à p. 2 - 3.
Select the To determine the usability of the oil, you must take a sample from the
sampling location hydraulic system. To do that you must connect the hose with the connecting
piece to a gauge port.

The gauge port (1) is located on the cylin-
der (2) of the outrigger.
• Clean the gauge port before connecting the
hose.
09.03.2018

GMK5200-1
Protecting the
hose from dirt
S
Danger of contamination of the oil sample.
If the hose with the connecting piece is dirty, the dirt can contaminate the
oil sample in the sample container during the sampling process. The labo-
ratory analysis would thus be incorrect.
For flushing, always allow 2 litres (0.5 gal) of oil to flow through the hose
into a receptacle before filling the sample container.
When storing the hose

• Close the hose ends (1) with the caps (2).
Connecting the
hose
O
Danger due to escaping hydraulic oil.
When you screw the connecting piece on to the gauge port, the gauge port
opens and oil flows out of the hose. Put the hose end into a receptacle
before screwing on the connecting piece.
• Only use a hose with a connecting piece.

• Remove the caps (4).
• Put the hose end into the receptacle (3).
• Remove the cap from the gauge port (1) and screw the connecting
piece (2) on to the gauge port – the gauge port opens.
s
09.03.2018

GMK5200-1
Taking oil samples

The hose end (1) is connected to the cylinder
(3).
The hose end (2) is in receptacle (4).
• Allow 2 litres (0.5 gal) of oil to flow into the
receptacle.
• Switch off the engine and put the hose end
(2) into the sample container (5).
• Allow 0.3 litres (0.08 gal) of oil to flow into
the sample container.
• Put the hose end back into the receptacle.
• Seal the sample container.
Disconnecting
the hose
• Disconnect the hose (2) – the gauge port (1) closes.
• Close the gauge port with the cap.
• Allow the oil to flow out of the hose into the receptacle (3).
• Close the hose ends with the caps (4).
Remove the receptacle and properly dispose of the oil.
• Fasten the cover (1).

09.03.2018

GMK5200-1
Dispatch the oil Manitowoc Crane Care gives you the opportunity to have the oil sample ana-
sample to the lysed at our contracted laboratory. A delivery note and a protective mailing
laboratory bag are available along with the sample containers (GROVE part no.
03141012). You will get the laboratory analysis via the Internet in a short
time.
• Label the sample container prior to dispatch with

– the truck crane serial number,
– the date of sampling,
– the number of operating hours since the last oil change and
– the sampling location (e.g. gauge port on a control block).
• Have the following properties of the oil sample determined by the labora-
tory
– the viscosity,
– the viscosity index,
– the contamination,
– the water content.
Determining the • Compare the laboratory analysis with the limit values and carry out the
quality of the oil specified measures if necessary.
Viscosity limit values

– Viscosity ISO-VG 32 in accordance with DIN 51524 Part 2.
– Viscosity index Vi ≥ 150.
If one of these limit values has been reached/fallen short of:
• Carry out an oil change; à p. 7 - 111.
Contamination limit value

– Contamination according to NAS 1638 class 7 or ISO 4406:1999
code 18/16/13 (purity class).
If this limit value has been reached/exceeded:
• Replace the filters of the hydraulic system; à p. 7 - 115.
• Have the hydraulic oil cleaned with a mobile filter unit until the required
cleanliness class is achieved.
Water content limit value

– Water content ≤ 100 ppm.
If this limit value has been reached/exceeded:
09.03.2018
• Have the hydraulic oil cleaned with a mobile water separator until the
water content is clearly below the limit value.

GMK5200-1
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09.03.2018

GMK5200-1
7.15.7 Changing the hydraulic oil
The oil only needs to be changed if the laboratory analysis indicates the
need for it; à Determining the quality of the oil, p. 7 - 109.
Oil, spare parts,

tools Hydraulic oil Designation to Specification GROVE part no.
in litres (gal) DIN 51502 Classification
200 (53) HVLP DIN 51524 - 3 04162158
Viscosity: ISO-VG 32 Castrol Hyspin
AWH-M 32

Cover gasket 140 / 90 x 3 1 02313899
– Connecting piece and hose (toolbox).

– One or more receptacles, approx. 200 l (53 gal); à p. 2 - 4.
Prerequisites – The outriggers must be retracted; à Operating manual.

à p. 2 - 3.
Close the valves
S
Risk of damage to the hydraulic pumps.
Be sure to secure the engine against unauthorised use.
If the engine is started while the valves in the suction line are closed, the
hydraulic pumps will be damaged.
• Close the valves – lever (1) at right angles to

the line.
09.03.2018

GMK5200-1
Handling the The valves can only be opened and closed using the connecting piece and
valves hose. The connecting piece is available in the toolbox.
O
Use the supplied connecting piece and hose and a receptacle with sufficient
capacity to drain the hydraulic oil.
G
Danger due to escaping hydraulic oil.
When the connecting piece is screwed on to the valve, the valve opens and
the hydraulic oil immediately flows out of the connecting piece. Holding it
by the connecting piece, place the hose into a suitable receptacle before
screwing on the connecting piece.
• Fit the hose on to the connecting piece and put the other end of the hose
into a receptacle.
• A – Remove the cap and screw the connecting piece and hose on to the
valve – the valve will open.
• Drain the oil.
• B – Remove the connecting piece and hose – the valve will close.
• Screw the cap on to the valve.
Draining oil
O
• Place a receptacle underneath the valves.

• One after the other, screw the connecting
piece and hose onto the valves (1) and (2);
à Handling the valves, p. 7 - 112.
• Change the filters; à p. 7 - 115.
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GMK5200-1
Topping up the oil
S
Cleanliness is of the utmost importance when handling hydraulic oil.
Even fresh hydraulic oil must be filtered before it is added to the tank.

• Add new oil through a filter until the level
reaches the centre of the inspection
glass (1).
• If required, replace the gasket (2) and fasten
the cap.
Establishing the After having changed the oil filters and topping up the oil, you must
operating re-establish the operating conditions.
conditions
S
Open the valves prior to starting the engine.
This prevents damage to the hydraulic pumps.
Opening the valves

• Open the valves – lever (1) parallel with the
line.
09.03.2018
s
GMK5200-1

• Carry out all hydraulic functions several times to remove any air in the
system.
• Test drive the truck crane, turning the steering wheel several times to its
fullest extent.
• Check the oil level through the inspection glass on the hydraulic oil tank.
Top up oil, if necessary; à Checking the oil level, p. 7 - 101.
Bleeding the If the steering is ”spongy” during the test run, you must bleed the hydraulic
hydraulic system system at the steering cylinders.
Preparations – The truck crane must be raised on outriggers; à Operating manual.

– The parking brake must be engaged.
G
Risk of crushing from turning wheels.
When working between the wheels ensure that the steering wheel cannot
be turned by an unauthorised person. The wheels turn when the steering
wheel is operated.
G
Risk of accidents from high oil pressure.
Never undo the hose connections completely. The hydraulic system is
under pressure, even when the steering wheel is not turned.
Bleed the steering cylinders individually, one

after the other
• Bleed each steering cylinder (2) by loosen-
ing each of the collar nuts (1) in turn, until
the oil coming out no longer contains air
bubbles.
If the steering system is still not operating

properly
• Notify Manitowoc Crane Care or an author-
ised GROVE dealer or an authorised special-
ist workshop.
09.03.2018

GMK5200-1
7.15.8 Changing the hydraulic oil filter
Oil filters must be replaced when changing the oil.

If a warning message appears, the symbol (1) in the Warning submenu indi-
cates that you must change oil filters 1 and 2.
Filters 3 and 4 must be replaced after the first 50 hours in driving mode and
then annually (M 12) after this.
Spare parts and

Filter (for filters 1 and 2) 2 03329152
Filter (for filters 3 and 4) 2 03135866
à p. 2 - 3.
s
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GMK5200-1
Changing filters
1 and 2
O
• Loosen the cover and pull out the filters.

• Place the filters in a receptacle.
• Remove the spring (1).
• Undo the nut (5).
• Take the magnetic rod (2) and the filter (3)
out of the filter cage (4).
• Clean the magnetic rod (2) and the filter
cage (4).
• Insert a new filter (3) into the filter cage (4).
sary.
S
tem.
Have the hydraulic system checked by Manitowoc Crane Care or an author-
ised GROVE dealer or your qualified repair crew.
• Assemble the filters (2) and insert them.

• Replace the gaskets and fasten the caps (1).
09.03.2018

GMK5200-1
Changing filters
3 and 4
O
• Remove the receptacle (1).

• Place the filter in a receptacle.
• Replace any defective parts, where neces-
sary.
• Fill the receptacle with clean oil.
• Put the receptacle on and tighten it.
• Change the filter on the opposite side in the

same way.
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GMK5200-1
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GMK5200-1
7.16 Central lubrication system
7.16.1 Checking the level W
Grease, spare
Grease KP - 1K - 50 DIN 51825 03233369
– Filling pump from the tool set.
Prerequisites – The parking brake must be engaged.
Checking the level
• Check the level in the grease container (1).

The grease level must be near the max.
mark.
If it is below the min. mark, the level is too
low.
If the level is too low:
• Add more grease; à p. 7 - 120.
s
09.03.2018

GMK5200-1
Topping up
S
Risk of damage to the central lubrication system.
Cleanliness is of the utmost importance when handling grease and filling
pumps.
Do not remove the caps from the opening and filling pump until immedi-
ately before refilling the grease. This prevents dirt particles from getting
into the grease and damaging the central lubrication system.
Fill the grease container as follows:

1 Filling pump tool set
You must install the connector from the
toolbox.
2 Filling pumps for lubrication nipples
• Switch on the ignition.
• Attach the respective filling pump to the

connection (1) or (2).
• Remove the cap (3).
• Press the button (4) for approx. 2 seconds
once.
Intermediate lubrication will be triggered.
• Fill the grease container up to the max.

mark.
• Remove the filling pump, wipe away any
09.03.2018
excess grease and close the holes.

GMK5200-1
7.16.2 Bleeding the central lubrication system
If the grease container is empty or contains bubbles, you must bleed the
central lubrication system.
The grease container (1) is full.

• Loosen the lubricating pipe at the connec-
tion (2).
• Press the button (3) for approx. 2 seconds.
Repeat the procedure until the grease flow-
ing from the connection (2) no longer con-
tains any bubbles.
• Fasten the lubricating pipe at connection (2).
• Remove any grease that emerges.
7.16.3 Triggering intermediate lubrication
Intermediate lubrication should be activated:

– after high pressure cleaning,
– to check the lubrication system at all lubricating points.

• Press the button (2) for approx. 2 seconds
once.
An intermediate lubrication cycle will be trig-
gered which lasts approx. 3 minutes. Check
whether grease is applied to all lubricating
points (steering arms on the 1st, 4th and 5th
axle lines).

09.03.2018
• Turn off the ignition and remove any excess

grease.

GMK5200-1
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09.03.2018

GMK5200-1
7.17 Electrical system
7.17.1 Checking the lighting and indicators D
G
Risk of accidents if the safety devices are faulty.
Have faulty lights and indicators repaired by Manitowoc Crane Care or an
• Check the following functions every day before operating or driving the
truck crane, and have faulty parts repaired:
– Parking light/headlight, marker lights, rotating beacons, fog tail light,
fog light, outrigger lights,
– Hazard warning system,
– Brake lights,
– Reversing lights,
– Warning buzzer,
– Reverse camera (additional equipment).
– Full-beam headlight,
– Turn signal indicators,
– Windscreen wipers,
– Windscreen washing system,
– Horn.
– Date/time on CCS display.

09.03.2018

GMK5200-1
7.17.2 Checking the batteries M1
G
Risk of poisoning from batteries containing lead .
Battery poles, terminals and parts inside the battery contain lead. Residue
containing lead can stick to your hands and may not be allowed to enter
your body – e.g. by touching food.
Wash your hands after working on batteries.
G
Risk of explosion from escaping hydrogen.
Do not place tools on the battery and keep naked lights away from it.
G
Risk of explosion from static charge.
Only use antistatic cloth to clean the batteries.
This prevents static charging which could result in hydrogen mixtures
exploding.
G
Risk of burns from battery acids.
Battery acid is highly caustic. Wear safety glasses and protective gloves. Do
not tilt the battery. Rinse off or wash out any acid spray on the skin or cloth-
ing using soap suds.
S
Risk of damage to the crane's electrical system.
Always switch off the battery master switches before commencing work on
the truck crane's electrical system.
This prevents short circuits and resulting damage to the electrical system.
Before checking
• Switch off the battery master switch;
• Pull the battery box out.
09.03.2018

GMK5200-1
Checking the connecting terminals

• Keep the batteries clean and dry.
• Remove any dirty connecting terminals (1)
and clean them.
• Fasten any loose connecting terminals.
• Grease the connecting terminals and poles
lightly with a special battery terminal
grease.
Checking the acid level

Batteries without caps (1) are maintenance-
free.
• Remove all caps (1).
The acid level must be above the plates.
If the acid level is too low
• Top it up using only distilled water until the
plates are covered.
• Tightly bolt on all caps (1).
After checking
• Push the battery box in.
• Switch on the battery master switch (1);
• Check the timers on the tachograph and on
the auxiliary heater;à Operating manual.
• Enter the code for the radio; à Separate
operating manual.
09.03.2018

GMK5200-1
7.17.3 Checking the charge level of the batteries M3
Spare parts and – Battery charger (additional equipment); à p. 7 - 128 or

tools
– Acid siphon.
Charge level table The measurement of the acid concentration with the acid siphon will give
you an indication of the charge level of the batteries. The acid siphon can
have a scale in g/cm³, for example. Observe the special scale on your acid
siphon.
Acid concentration (g/cm³) Charge level

1.28 good
1.20 half-charged; recharge
1.12 flat; recharge immediately
G
Risk of poisoning from batteries containing lead.
Battery poles, terminals and parts inside the battery contain lead. Residue
containing lead can stick to your hands and may not be allowed to enter
your body – e.g. by touching food.
Wash your hands after working on batteries.
G
Risk of explosion from escaping hydrogen.
Do not place tools on the battery and keep naked lights away from it.
G
Risk of explosion from static charge.
Only use antistatic cloth to clean the batteries.
This prevents static charging which could result in hydrogen mixtures
exploding.
G
Risk of burns from battery acids.
Battery acid is highly caustic. Wear safety glasses and protective gloves. Do
not tilt the battery. Rinse off or wash out any acid spray on the skin or cloth-
ing using soap suds.
S
Risk of damage to the crane's electrical system.
Always switch off the battery master switches before commencing work on
09.03.2018
the truck crane's electrical system.

This prevents short circuits and resulting damage to the electrical system.

GMK5200-1
Before checking
• Switch off the battery master switch;
• Pull the battery box out.
Checking the acid concentration

Batteries without caps (1) are maintenance-
free.
• Remove all caps (1).
• Read off the cell value on the acid siphon (2)
and compare the value with that in the table;
à Charge level table, p. 7 - 126.
• Check all cells in the same way.
• Tightly bolt on all caps (1).
After checking
• Push the battery box in.
• Switch on the battery master switch (1);
• Check the timers on the tachograph and on
the auxiliary heater;à Operating manual.
• Enter the code for the radio; à Separate
operating manual.
09.03.2018

GMK5200-1
7.17.4 Charging the batteries using the battery charger M3
à p. 2 - 3.
– An external 230 V mains power supply must be available at the location.
– The battery charger (GROVE part no. 03320239; additional equipment)
must be available.
– The location must be well ventilated and protected against moisture. The
battery charger may not be used at locations where there is risk of a gas
or dust explosion.
Battery charger • Familiarise yourself with the correct operation of the battery charger;
à Separate operating manual.
Connecting • Take the battery charger out of its storage compartment in the driver's
cab.
• Insert the plug (1) into the socket (2) on the

battery box.
• Place the battery charger (3) in a protected
place where you can see the indicator
lamp (4).
The battery charger can be suspended from
the ring eyes (5).
• Insert the plug (6) into the socket on the
mains supply 230 V at the location.
The indicator lamp (4) flashes – the charging
process starts.
• If the indicator lamp (4) does not flash, check
the fuse (7).
Charging • Check the charging process at the indicator lamp (4).
Indicator lamp flashing: The batteries are being charged.

Indicator lamp lit continuously: The batteries are fully charged.
09.03.2018
After completion • Remove the plug (6) from the 230 V mains supply.
of charging
• Remove the plug (1) from the battery box.
• Return the battery charger to the storage compartment in the driver's cab.

GMK5200-1
7.17.5 Check the external starting socket M3
The battery box is equipped with an external starting socket (1).
Accessories
A connection cable (1) for the external starting socket is supplied with the
truck crane (tool set).
Designation GROVE part no.

Connecting cable with two plugs; 03143281
length 12 m
The battery box can also be equipped with a battery charger as additional
equipment.
• Consult the operating instructions supplied with the battery charger and
regularly check that all components are functioning correctly to ensure
that the external starting socket, connecting cable and battery charger are
ready for operation if needed; à Operating manual.
Check the
following
• Remove the cap (4) from the socket (1).

• Check that the cap is not damaged and is
secured with the chain (3).
• If necessary, clean the poles (2).
• Attach the cap – the cap must be fitted
tightly and compactly on the socket.
09.03.2018

GMK5200-1
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09.03.2018

GMK5200-1
7.18 Air conditioning system
7.18.1 Checking the air conditioning system M1
• Switch on the air-conditioning system; à Operating manual.

• Check that cooling takes place. If it does not, the air conditioning system
is defective.
• Switch the air conditioning system off.
If the air conditioning system is defective
• Do not start it up again to avoid further damage.
Have the air-conditioning system repaired as soon as possible by Manitowoc
Crane Care or an authorised GROVE dealer or an authorised specialist work-
shop.
7.18.2 Checking hoses M6
G
Risk of burns due to escaping refrigerant.
Wear suitable safety glasses and gloves when checking the hoses and con-
nections.
This will prevent injury from suddenly escaping refrigerant. Seek medical
attention if the skin or eyes come into contact with the refrigerant.
• Check all refrigerant hoses for damage and areas of wear.

Have damaged hoses checked by Manitowoc Crane Care or an authorised
GROVE dealer or an authorised specialist workshop only.
09.03.2018

GMK5200-1
7.18.3 Cleaning the condenser fins M 12
S
Risk of damage to the condenser.
may damage the fins. Use only compressed air for cleaning.

• Clean the condenser fins (1) with com-
pressed air; à Have the radiator checked/
cleaned, p. 7 - 18.
7.18.4 Checking the entire air conditioning system M 12
H
G
nections.
• Have the entire air conditioning system checked for leaks and proper func-
tioning.
The inspection of the air conditioning system particularly includes the
inspection of
– the refrigerant collector, in accordance with the pressure container
regulations (test group II) and
– the refrigerant compressor.
09.03.2018
• Only allow the system to be topped up with suitable refrigerant.

GMK5200-1
Refrigerant
Fill quantity Designation CAS no.
in kg (lbs) EC no.
Tetrafluoroethane (R134a) 811-97-2
1.0 (2.2)
212-377-0
Compressor oil: FUCHS SE 55
Filler connections
The filler connections (1) for refrigerants are

on the refrigerant compressor hoses.
09.03.2018

GMK5200-1
7.18.5 Changing the pollen filter M 12
interval tions – you must change the filter earlier than normal.
Spare parts and

Filter 1 03134974
à p. 2 - 3.
Changing
• Open the cover (1).

• Remove the filter (2) from the housing and
clean the housing with a cloth.
• Insert a new filter.
• Fasten the cover.
09.03.2018

GMK5200-1
7.19 Towbar coupling

Depending on the equipment fitted to your truck crane, it may have towbar
couplings (additional equipment) from different manufacturers.
The wear values for other manufacturers may vary from those specified;
à Separate operating manual.
7.19.1 Lubricating the towbar coupling M1
This maintenance work is not required if the towbar coupling is connected

to the central lubrication system.
Grease, spare
Grease KP - 1K - 50 DIN 51825 03233369
G
Risk of injury when the automatic closing device is triggered.
Do not put your hand into the coupling jaw when the towbar coupling is
open.
This may trigger the automatic closing device, make the cotter pin move
down and seriously injure your hand.
H
To avoid over-lubrication, the towbar coupling may only be lubricated when
open.
• Clean the grease nipples (2) and (3).

• Open the towbar coupling. To do this, move
the lever (1) up.
• Press grease into the grease nipples (2)
and (3).
• Close the towbar coupling.
09.03.2018
s
GMK5200-1
Closing the
towbar coupling
G
Risk of injury when manually closing the towbar coupling.
When closing, the lever moves down with great force in the direction of the
coupling jaw. Start the closing process only by moving the lever briefly in
the direction of the coupling jaw with the ball of your hand.
If you hold the lever and move it down, it may carry your hand with it and
crush it.
After lubrication you must close the towbar

coupling.
• Move the lever (1) briefly in the direction of

the coupling jaw (observe the arrow).
09.03.2018

GMK5200-1
7.19.2 Checking the bearing M3
Prerequisites – The coupling must be closed; à p. 7 - 136.
Checking the
bearing
G
Risk of injury.
Ensure that the towbar coupling is closed for the following work (lever
points downwards). The lever may otherwise come down with great force
and cause serious injury to your hand.
• Check the bearing of the towbar coupling by

vigorously shaking it up and down and in
the longitudinal direction (arrows). Hold the
towbar coupling at the top and bottom of
the coupling head and not by the coupling
jaw.
The vertical play at the coupling head must be
no more than 3 mm (0.1 in).
09.03.2018

GMK5200-1
7.19.3 Checking the cotter pin M3
Checking the
cotter pin
• Check the wear on the cotter pin (1). The

diameter of the crowned section (arrows)
must not be less than the following values:
Model series 400: 36.5 mm (1.44 in)
If the dimension is smaller than that given

above, have the cotter pin replaced by
Manitowoc Crane Care or an authorised GROVE
dealer or your qualified repair personnel.
• Also check the cotter pin for the correct ver-

tical play. Take a screwdriver and press the
pin (1) upwards. The vertical play (2) of the
pin must not exceed 4 mm (0.15 in).
09.03.2018

GMK5200-1
7.19.4 Checking the lower bushing M3
Checking the
bushing
• Check the internal diameter of the lower

bushing. The dimension D must not exceed
the following values:
If the dimension is larger than that given

above, have the bushing replaced by
Manitowoc Crane Care or an authorised
GROVE dealer or your specialist repair
crew.
7.19.5 Checking the initial tension of the springs M3
The coupling head should require physical force to twist it when checking
the torque.
• Twist the coupling head clockwise and anticlockwise to check the initial
tension of the rubber springs.
09.03.2018

GMK5200-1
7.19.6 Checking the support ring M3
Checking the
support ring
• Check the support ring (1) at the bottom of

the coupling jaw.
When the trailer is coupled, the draw eyelet
of the trailer must not be in 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 (0.55 in).
7.19.7 Checking the function of the coupling jaw/ M3

resetting the central position
Spare parts and – Torque wrench for torque of 58 Nm (42.7 lbf ft).
tool

09.03.2018

GMK5200-1
Checking for
correct
functioning
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 lever must automatically lock the coupling
jaw in the middle position. The coupling jaw is
locked when the coupling can no longer move
to the side.
H
If the lever does not automatically engage with the coupling jaw, the central
position must be re-adjusted; à p. 7 - 141.
Resetting the
middle position
• Open the coupling (lever (1) pointing

upwards) and loosen the screws (2).
• Push the coupling jaw to the side until the
lever engages.
• Tighten the screws – torque 58 Nm
(42.7 lbf ft).
• Check the functioning of the coupling jaw;
à p. 7 - 140.
09.03.2018

GMK5200-1
Blank page
09.03.2018

GMK5200-1
7.20 Other maintenance work
7.20.1 Checking the windscreen washing system W
Water, spare
parts, tool Designation Quantity GROVE part no.
Wiper blades 3 02311858
– Water; add commercially available detergent and antifreeze to it.

– A can for mixing and filling.
Topping up
• Open the cap (1) on the filler neck.

• Top up the windscreen washing fluid
through the filler neck.
Wiping
• Press the multipurpose switch of the windscreen wiper/washing system

(6) and (7); à Operating manual.
• Check all the wiping stages (slow, fast, intermittent).
If the windscreen does not wipe clean
• Change the wiper blades.
09.03.2018

GMK5200-1
7.20.2 Lubricating the outrigger beams M1
Grease, spare
Grease KP - 1K - 50 DIN 51825 03233369
Spray Spray on Berulub; 0.5 litres 01929824
(spray-on)
– Brush or roller.
G
Danger of crushing from extending outrigger beams.
Ensure that there is sufficient room around the crane. Warn any persons
nearby before extending the outrigger beams.
Observe the safety instructions in the operating manual.
• Fully extend all outrigger beams;

• Apply the grease to both sides of the slide
faces (1) on all the outrigger beams.
• Extend and retract the outrigger beams
several times.
• Remove any excess grease.
• Clean the uncovered end (2) of the outrigger
cylinder and bearing surfaces on the
outrigger pad by removing old grease,
dirt particles and rust.
• Spray the uncovered end (2), making sure
the grease coating is evenly distributed.
After every high-pressure cleaning operation on the truck crane

• Lubricate the outrigger beams.
09.03.2018

GMK5200-1
7.20.3 Checking the auxiliary heater M1
Depending on the equipment, your truck crane has been fitted with an aux-
iliary heater.
During the warm summer months, run the auxiliary heater for 20 to
30 minutes; à Operating manual.
• Check that the system is working properly. Also perform a functional

check of the controls.
• If the heating system is not working correctly, report it to Manitowoc
Crane Care or an authorised GROVE dealer or an authorised specialist
workshop.
7.20.4 Lubricating the cab door M 12
Grease, tools
Lubricating Designation to Specification GROVE part no.
Grease KP - 1K - 50 DIN 51825 03233369
Greasing
• Open the doors on the driver and passenger

side.
• Clean the grease nipples (1) on the door
hinges.
• Press grease into the grease nipples.
• Close and open the doors several times – the
doors should move easily.
09.03.2018
• In case the doors are stiff or do not close properly after lubrication, have
them adjusted by Manitowoc Crane Care or by an authorised GROVE
dealer.

GMK5200-1
7.20.5 Lubricating the connecting and socket pins M 12
Grease, tools
Grease KP - 1K - 50 DIN 51825 03233369
– Brush.
Check the Depending on the equipment, there are various connecting and socket pins
following on the carrier such as:
– Fastenings to hold the hook block on the bumper while driving on the
road,
– Clamps for ladders on the carrier,
– Hinged warning panels under the bumper,
– Fastenings for the outrigger pads and socket pins on the outrigger,
– Locks on the removable covers,
– Hinges on the doors and covers of the storage box.
• Check the pins for wear such as rust, deformation, broken clips, chains
and pin-type keepers.
• If the pins are damaged, have them replaced by Manitowoc Crane Care or
an authorised GROVE dealer or your qualified repair crew.
• Use only authentic replacement pins.
Greasing
• Clean the pins.

• Lubricate the pins with a brush.
09.03.2018

GMK5200-1
7.20.6 Renewing the corrosion protection M 12
Protective agent,
tools Protective agent GROVE part no.
Corrosion protection 03140192
– Spray gun with spray extension.

– Brush.
– Protective clothing, protective goggles.
Prerequisites – The undercarriage of the truck crane must be thoroughly cleaned.

pit.
à p. 2 - 3.
Check the At the factory, the underside of the carrier was sprayed with corrosion pro-
following tection for the first time.
The corrosion protection is solvent-free and is water soluble while being
sprayed on. A transparent, waxy, protective film is formed after a drying
time of one hour.
• Check the condition of the original protective film.

• If required, remove any rust and touch up the paintwork before you spray
on a new protective film.
Processing • Observe the processing instructions for corrosion protection:

instructions – Processing temperature: above 10 °C (50 °F).
– Removability before drying: With water.
– Removability after drying: With solvent naphtha.
– Drying time: 1 hour.
s
09.03.2018

GMK5200-1
Spraying
G
Risk of injury to the eyes.
While working with the spray extension you could be hit by the spray jet or
spray droplets. Wear protective goggles, protective clothing and gloves.
• Spray the corrosion protection agent on the

underside of the carrier using a spray exten-
sion.
• Clean surfaces sprayed by accident immedi-
ately with water.
• Let the corrosion protection dry for one
hour.
• Check that a transparent waxy protective
film has covered the entire surface.
09.03.2018

GMK5200-1
7.20.7 Having the fire extinguisher checked Y2
Depending on your truck crane's equipment, it has fire extinguishers.
H
The maintenance interval may even be shorter, depending on the respective
national regulations and the operating location. Ask the local fire safety
officer about the national and local regulations.
• Follow the operating manual (1) on the fire

extinguisher.
• Have the fire extinguisher serviced by
trained personnel in good time before the
maintenance interval specified on the label
(2) expires.
S
Danger due to the fire extinguisher not working.
There is no guarantee that the fire extinguisher will still work properly once
the maintenance interval on the label has expired.
09.03.2018

GMK5200-1
Blank page
09.03.2018

GMK5200-1
8
8.1 General instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 1
8.1.1 Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 1
8.1.2 Overview of maintenance work on the superstructure . . . . . . . . . . . . . . . . . . . 8 - 2
8.2 Symbols for maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 7
8.3 Hoists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 9
8.3.3 Checking the hoist brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 10
8.3.4 Changing the oil/checking the oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 11
8.3.5 Having a partial inspection carried out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 13
8.3.6 Having a general inspection carried out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 13
8.4 Slewing gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 15
8.4.2 Checking for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 16
8.4.3 Checking the slewing gear brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 16
8.4.4 Changing the oil/checking the oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 19
8.5 Slewing bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 21
8.5.1 Checking the screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 21
8.5.2 Lubricating the gear teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 25
8.5.4 Measuring tilting play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 28
8.5.5 Lubricating the locking of turntable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 30
8.6 Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 31
8.6.2 Checking the hydraulic hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 32
8.6.3 Checking the ventilation filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 32
8.6.4 Checking for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 33
8.6.5 Cleaning the magnetic rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 34
8.6.6 Changing the ventilation filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 36
8.6.7 Pressure accumulator – checking the gas pressure . . . . . . . . . . . . . . . . . . . . . . 8 - 37
8.6.8 Taking oil samples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 37
8.6.9 Changing the hydraulic oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 39
8.6.10 Changing the hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 44
8.7 Main boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 47
8.7.1 Greasing the piston rod of the derricking cylinder . . . . . . . . . . . . . . . . . . . . . . 8 - 47
8.7.2 Lubricating the telescopic sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 48
8.7.3 Checking the sheaves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 52
8.7.4 Checking the locking system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 52
8.8 Hoist ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 53
09.03.2018
8.8.1 Checking the winding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 53

8.8.2 Checking the hoist ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 54
8.8.3 Lubricating the hoist rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 55
8.8.4 Assessing the condition of the hoist rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 56

GMK5200-1
8.8.5 Replacing the hoist rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 62
8.8.6 Setting the lowering limit switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 65
8.9 Cable drums . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 67
8.9.1 Maintenance of the slip ring assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 67
8.10 Central lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 69
8.10.1 Checking the level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 69
8.11 Hook blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 71
8.11.1 Checking the sheaves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 71
8.11.2 Greasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 71
8.12 Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 75
8.12.1 Checking the lighting and indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 75
8.12.2 Have the battery on the electronics board replaced . . . . . . . . . . . . . . . . . . . . 8 - 76
8.13 Air conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 77
8.13.1 Checking the air conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 77
8.13.2 Cleaning the condenser fins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 77
8.13.3 Checking hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 78
8.13.4 Checking the entire air conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 78
8.13.5 Changing the pollen filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 80
8.14 Other maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 81
8.14.1 Checking the windscreen washing system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 81
8.14.2 Checking the auxiliary heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 82
8.14.3 Lubricating the crane cab door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 83
8.14.4 Lubricating the step . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 84
8.14.5 Lubricating the connecting and socket pins . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 85
8.14.6 Renewing the corrosion protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 86
8.14.7 Having the fire extinguisher checked . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 88
09.03.2018

GMK5200-1
Maintenance work on the superstructure
8.1.1 Covers
Various types of work (e.g. oil change) require that the covers be removed.
Before maintenance work

• Remove the covers (1).
After maintenance work
• Fasten the covers (1) with the locks.
09.03.2018

GMK5200-1
8.1.2 Overview of maintenance work on the superstructure
09.03.2018

GMK5200-1
Symbols for maintenance work à p. 8 - 7

1 CCS (Crane Control System) control unit à p. 8 - 7
Hoists à p. 8 - 9
8 Hoist ropes à p. 8 - 53
2 Rope wedges à p. 8 - 54
19 Rope drums à p. 8 - 53
18 Oil inspection glasses à p. 8 - 9
9 Hook block à p. 8 - 71
7 Rope end fitting à p. 8 - 54
3 Lowering limit switch à p. 8 - 65
Slewing gear à p. 8 - 15
6 Oil inspection glasses à p. 8 - 15
Slewing bearing à p. 8 - 21
10 Gear teeth à p. 8 - 25
5 Slewing angle sensor à p. 8 - 25
4 Locking of turntable à p. 8 - 30
Hydraulic system à p. 8 - 31
14 Oil tank with inspection glass à p. 8 - 31
16 Ventilation filter à p. 8 - 36
16 Oil filter 1 à p. 8 - 40
s
09.03.2018

GMK5200-1
09.03.2018

GMK5200-1
Main boom à p. 8 - 47
1 Telescopic sections 1 to 5 and basic section à p. 8 - 48
16 Derricking cylinder à p. 8 - 47
15 Sheaves à p. 8 - 52
Cable drums à p. 8 - 67
11 Cable drum 1 à p. 8 - 67
4 Cable drum 2 à p. 8 - 67
Central lubrication system à p. 8 - 69

10 Centralised lubrication pump à p. 8 - 69
Electrical system à p. 8 - 75
2 Spotlights on the crane cab à p. 8 - 75
14 Spotlights on the telescopic boom à p. 8 - 75
12 Anemometer, air traffic control light à p. 8 - 75
Air conditioning system à p. 8 - 77

3 Crane cab air-conditioning system à p. 8 - 77
8 Condenser fins à p. 8 - 77
5 Pollen filter à p. 8 - 80
Other maintenance work à p. 8 - 81

9 Windscreen washing system receptacle à p. 8 - 81
– Crane cab auxiliary heater1) à p. 8 - 82
6 Cab door rails à p. 8 - 83
7 Pull-out step à p. 8 - 84
– Various connecting pins and socket pins à p. 8 - 85
– Corrosion protection à p. 8 - 86
13 Fire extinguisher1) à p. 8 - 88
1)
Additional equipment
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GMK5200-1
Blank page
09.03.2018

GMK5200-1

Check the following symbols every day before starting work.
CCS • Check the symbols on the CCS start menu (Crane Control System) in the
crane cab each day before starting work.
• The Start menu shows the most important measurements and the Warn-
ing submenu shows all pending warning messages; à Operating manual.
Warning submenu If a symbol is displayed, you must carry out the maintenance work:
Hydraulic oil filter; à p. 8 - 39.

09.03.2018

GMK5200-1
Blank page
09.03.2018

GMK5200-1
8.3 Hoists
8.3 Hoists
8.3.1 Checking the oil level W
Spare parts and

Oil inspection glass; complete 2 04161717
Prerequisites – The truck crane must be level and in on-road mode; à Operating manual.
à p. 2 - 3.
Checking the oil

level
• Check that the oil level is visible between the

min. and the max. marks (1).

H
The oil level in the hoist gear must be 16 mm below the centre of rotation of
the hoist. If the sight glass is loose in the clamps, or a new sight glass has
been fitted, you must adjust this difference in height before you adjust the
clamps.
09.03.2018

GMK5200-1
8.3 Hoists
• Pay attention to any unusual running noises from the hoists.

• Check the hoists and the connections for leaks. If consumables are leak-
ing; à Checking the oil level, p. 8 - 9.
GROVE dealer or your repair crew.
8.3.3 Checking the hoist brake W
Check that the hoist brake is working correctly on the main hoist and the
auxiliary hoist.
• Attach the hook block to the hoist rope, reeved once.

• Lift a load of approx. 9.5 t (21,000 lbs) to approx. 30 cm (1.0 ft) above the
ground.
• Measure the distance to the ground when the load is hanging completely
still.
If the load has not lowered after approx. 2 minutes, the brake is currently in
working order.
If the load lowers, notify Manitowoc Crane Care or an authorised GROVE
dealer.
09.03.2018

GMK5200-1
8.3 Hoists
8.3.4 Changing the oil/checking the oil M 12
Oil, spare parts,

7 (1.8) C - LPF MIL-L 2105 B 02313611
for each hoist API-GL-4/5
Viscosity: Synthetic oil;
SAE 75 W-90 EP do not mix this
ISO - VG 220 with mineral-
based oils.

Oil inspection glass; complete 2 04161717
à p. 2 - 3.
Changing the oil at

the hoist
S
Risk of damage to the hoist gears.
The waste oil must be checked for abrasion particles. This test is used to
detect any damage at an early stage; à
p. 8 - 12.
O
H
During filling, the oil spreads only slowly in the hoist. The oil level therefore
rises quickly in the standpipe at first, then drops slightly and then eventually
rises again to its true level.
s
09.03.2018

GMK5200-1
8.3 Hoists
Draining oil
• Place a receptacle under the pipe (2).
• Remove the venting neck (1).
• Disconnect the screw fastening (3) and
allow the oil to drain out of the hose (4) and
the pipe (2).
• Replace the gasket if necessary.
• Reconnect the hose (4) to the screw fasten-
ing (3) at the pipe (2).
Topping up oil
• Add oil at the top through the pipe up to the
max. mark.
• Secure the venting neck (1).
Checking the oil
G
Risk of accidents from falling load.
If this inspection is not performed, there is a risk of damage to the hoist gear
which could lead to the load falling.
H
Check the waste oil for abrasion particles or have it tested in a laboratory:
• Pour the waste oil through a clean filter mat.
• Examine the oil, i.e. the residues on the filter mat using a magnifying
glass.
If you find abrasion particles or solid materials on the mat, the hoist gear
must be dismantled and inspected by the manufacturer.
H
Some abrasion particles may appear in the first oil filled. If you notice such
particles during the first oil change (after 200 oper. hrs.), first consult
Manitowoc Crane Care before introducing any specific measures.
09.03.2018

GMK5200-1
8.3 Hoists
8.3.5 Having a partial inspection carried out Y3
Only suitably trained specialists should carry out a partial inspection of

– the multiple-disc brake,
– the plug connections between the hydraulic motor and the multiple-disk
brake,
– the plug connections between the multiple-disk brake and transmission
unit
and be permitted to exchange parts with signs of wear.
8.3.6 Having a general inspection carried out Y6
H
When carrying out the general inspection of the hoists, also observe the
information contained in Measures required for winch monitoring, p. 5 - 21.
The general inspection involves removing the transmission and sending it

to the manufacturer to be examined.
H
For transmissions that have undergone a general overhaul, an oil change
must be carried out after 200 and 1000 operating hours; à
Run-in regula-
tions, p. 4 - 1.
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GMK5200-1
8.3 Hoists
Blank page
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GMK5200-1
8.4 Slewing gear
8.4 Slewing gear
8.4.1 Checking the oil level W
Spare parts and

Gasket 10 x 14 Cu DIN 7603 3 00117125
à p. 2 - 3.
Checking the oil Always check the oil level prior to using the crane.
level
• Check that oil is visible in the inspection

glass (1).
• Always check the oil level for all the slewing
gears.
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GMK5200-1
8.4 Slewing gear
• Pay attention to any unusual running noises from the slewing gears.
• Check the slewing gears and the connections for leaks. If consumables are
leaking; à Checking the oil level, p. 8 - 15.
8.4.3 Checking the slewing gear brake M6
Operating manual.
– The truck crane must be rigged for a slewing range of 360° according to
the Lifting capacity table.
– The RCL code for the current rigging mode must be entered; à Operating
manual.
– The current load must not exceed 1 t (2,200 lbs) – where necessary
unreeve the hook block.
– The slewing range 360° around the truck crane must be secured.
– The main boom must be raised to 45° and fully retracted.
G
Risk of overturning while slewing.
Always set a rigging mode for the slewing range of 360° in accordance with
the Lifting capacity table and enter the corresponding RCL code. Do not over-
ride the rated capacity limiter (RCL).
G
Risk of injury due to swinging hook block.
If a faulty slewing gear brake slips, the superstructure can accidentally, sud-
denly turn and the hook block can suddenly swing. People standing within
the slewing range could be injured.
Secure the slewing range 360°, before you check the slewing gear brake.
09.03.2018

GMK5200-1
8.4 Slewing gear
Check the When checking the slewing gear brake you must perform the slewing move-
following ment against the slewing gear brake.

• Remove the coil (1) from the valve Y 2304.
The slewing gear brake will now not be
released when the slewing gear is switched
on.
• Start the engine and switch on the slewing gear.

• Open the CCS menu Hydraulic pressure.
Display (1) will show the pressure in the slewing gear's hydraulic circuit.
• Move the control lever slowly to the stop and wait until the pressure in the
hydraulic circuit has risen to approx. 200 bar (approx. 2,900 psi).
– If the superstructure still does not slew, the braking force of the slew-
ing gear brake is adequate.
– If the superstructure does slew, the slewing gear brake is defective and
must be repaired immediately by Manitowoc Crane Care or an author-
ised GROVE dealer.
s
09.03.2018

GMK5200-1
8.4 Slewing gear
• Switch the slewing gear off and switch the

engine off.
• Fasten the coil (1) to the valve Y 2304 using
the nut.
• Start the engine and check the slewing gear
for correct operation.
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GMK5200-1
8.4 Slewing gear
8.4.4 Changing the oil/checking the oil M 12
Oil, spare parts,

0.9 (0.24) C - LPF MIL-L 2105 B 02313611
for each API-GL-4/5
slewing gear Viscosity: Synthetic oil;
SAE 75 W-90 EP do not mix this
ISO - VG 220 with mineral-
based oils.

Gasket 10 x 14 Cu DIN 7603 3 00117125
Gasket 14 x 20 Cu DIN 7603 3 00117132
à p. 2 - 3.
Changing the oil
O
• Always change the oil in all slewing gears.
s
09.03.2018

GMK5200-1
8.4 Slewing gear
Draining oil
• Remove the plate (1).
• Place a container under the screws (2).
• Unscrew the filter (4) and screws (3) and (2).
• Drain the oil.
• Replace the gasket and tighten the

screws (2).
Topping up oil
• Top up the oil through the filler neck (4)
until oil is visible in the inspection
glass (5).
• Replace the gaskets and tighten the
screw (3) and the filter (4).
• Replace the plate (1).
Checking the oil Check the waste oil that was drained from the slewing gears for abrasion
particles, or have it tested at a laboratory.
• Pour the waste oil through a clean filter mat.

• Examine the oil, i.e. the residues on the filter mat using a magnifying
glass.
If you find abrasion particles or solid materials on the mat, the slewing gear
09.03.2018
transmission must be removed and inspected by the manufacturer.

GMK5200-1
8.5 Slewing bearing
8.5 Slewing bearing
8.5.1 Checking the screws M3
Tools – Torque wrench.

– Auxiliary tools for the torque wrench; à p. 8 - 23.
Prerequisites – No counterweight has been rigged; à Operating manual.

– The crane must be rigged with an outrigger span of at least 8.95 x 7.80 m
à
(29.4 x 25.6 ft) and be level; Operating manual.
– In addition, the tyres on the 3rd and 4th axle lines must be removed to
improve the freedom of movement under the slewing bearing.
– The main boom must be fully retracted and raised to 75°; à Operating
manual.
– The current load must not exceed 1 t (2,200 lbs) – where necessary
– The slewing range 360° around the truck crane must be secured.
à p. 2 - 3.
Safety
instructions
S
Risk of damage to the screws on the slewing bearing.
All screws were tightened at the factory with a certain torque, and this
should be checked during maintenance. Only slight tightening of the
screws is permissible, if required.
You may not slacken the screws and re-tighten them, or completely
unscrew and then reuse them.
If the superstructure has to be removed from the carrier, only a completely
new set of screws may be used to reinstall the superstructure. Only original
screws should be used, which were manufactured according to the factory
specifications.
s
09.03.2018

GMK5200-1
8.5 Slewing bearing
G
Danger of the slewing bearing being ripped off.
If while checking you notice very loose, broken or missing screws, then the
slewing bearing has been overloaded and is no longer safe to use. During
crane operation, the slewing bearing may rip off suddenly and thus cause
fatal accidents.
Do not put the truck crane back into operation and have the slewing bearing
repaired by Manitowoc Crane Care.
Access
The outer ring is connected to the carrier with

the screws (1).
• Check all 96 screws (1) from above.
To do this, you must rotate the clear area (2)
on the turntable gradually to check all the
screws (1).
The inner ring is connected to the turntable

with the screws (1).
• Check all 95 screws (1) from below.
To do this, you must rotate the turntable
gradually with a pair of screws (1) each on
the opposite side through the openings (2)
in the carrier.
09.03.2018

GMK5200-1
8.5 Slewing bearing
Selecting the tools
Outer ring
The screw heads (1) are easily accessible for fitting a socket wrench. There-
fore, you can use manual or mechanical torque tools (electric or hydraulic
drivers).
Inner ring
The screw head (1) is accessible only via a rectangular, long, narrow open-
ing (2). An extension (4) is required for fitting a socket wrench (3).
A manual torque tool (5) is recommended so that it can be tightened gently,

and slipping from the screw head (1) is avoided.
Torques
Screw type GROVE part number Torque

Nm (lbf ft)
Ball slewing bearing 04192540 or 03246884
Bearing type: KDV, single-row Model plate: Inside the inner ring.
M 27 x 155: 96 pieces on the outer ring 04170754 1150 (848)
M 27 x 155: 95 pieces on the inner ring 04170754 1150 (848)
09.03.2018

GMK5200-1
8.5 Slewing bearing
Checking the • Divide the checking of the 96 screws into 24 working steps of 4 screws
outer ring each.
Between each of the 24 working steps you need to rotate the turntable to
the next group of 4 screws on the opposite side.
• Switch the engine off after every rotation and secure the truck crane
against unauthorised use; à p. 2 - 3.
• Check the tightness of the first group of 4 adjoining screws (1);
à Torques, p. 8 - 23.
• Once they have been checked, mark the screws to avoid subsequent con-
fusion.
• Remove the tool.
• Start the engine and turn the turntable by 180° – the second group on the
opposite side is now accessible.
• Check all other groups in the same way.
Checking the inner • Divide the inspection of the 95 screws into 23 work steps with 4 screws
ring each and 1 work step with 3 screws.
Between each of the 24 working steps you need to rotate the turntable to
the next pair of screws on the opposite side.
• Switch the engine off after every rotation and secure the truck crane
against unauthorised use; à p. 2 - 3.
• Check the tightness of the first pair of screws (1) and (2) on the opposite
side; à Torques, p. 8 - 23.
• Mark the screws that have been checked, to avoid confusion later.
• Remove the tool.
• Start the engine and turn the turntable by 90° – the second pair of screws
on the opposite side is now accessible.
• Check all other screws in the group in the same way.
09.03.2018

GMK5200-1
8.5 Slewing bearing
8.5.2 Lubricating the gear teeth M6
Grease
Adhesive lubricating grease (spray 1 00554205
can)
H
Observe the instructions and safety instructions on the adhesive lubricating
grease packaging.
à p. 2 - 3.
Greasing
G
Risk of crushing from the gear teeth.
Fingers may be crushed or clothing can be drawn into the open, rotating
pinion. For this reason, be sure to remount the plate after lubricating.
Checking the slewing angle sensor

• Check whether the pinion (2) is undamaged
and lies straight and firmly against the gear
teeth of the slewing bearing.
• If need be, remove dirt and foreign bodies
from the pinion (2).
• If any damage is found, report it to
Manitowoc Crane Care or an authorised
GROVE-dealer.
• Attach the plate.
s
09.03.2018

GMK5200-1
8.5 Slewing bearing
First lubrication
• Remove the old grease from all the gear
teeth (2).
• Apply a thin layer of new grease to all the
gear teeth and allow it to penetrate for
approx. 10 minutes.
• Apply a second, thicker layer of grease and
allow it to penetrate for approx. 30 minutes.
Subsequent lubrication
• Apply new grease to all the gear teeth (2).
• Allow it to penetrate for approx. 30 minutes.
09.03.2018

GMK5200-1
8.5 Slewing bearing
8.5.3 General inspection M6
• Pay attention to any unusual running noises from the slewing bearing.
• If unusual noises occur, take a sample of the grease that has escaped.
Have Manitowoc Crane Care examine the sample for metal residue.
• Check the slewing bearing for damage (e.g. gaskets).
H
The maintenance interval specified here must be reduced if the slewing
bearing was subjected to heavy blows (falling load, load slipping).
09.03.2018

GMK5200-1
8.5 Slewing bearing
8.5.4 Measuring tilting play M6
Reducing the • When after several years of intensive crane operation, half of the value for
interval the maximum permissible tilting play is reached, then you must reduce
the maintenance interval.
• Measure the tilting play from then on every three months (M 3).
Spare parts and – Dial gauge (precision 0.01 mm (0.00039 in)) with tripod.
tools
– Measurement report from when the truck crane was put into operation;
àDelivery receipt.
Prerequisites – The slewing bearing must have been previously checked for tightness;
à Checking the screws, p. 8 - 21.
– The truck crane must be rigged with an outrigger span of at least
8.95 x 7.80 m (29.4 x 25.6 ft) and be aligned horizontally; àOperating
manual.
– The counterweight combination of 7.0 t (15,400 lbs) must be rigged
according to the Lifting capacity table.
– The lattice extension must be removed.
– The auxiliary hoist must be removed.
– The main boom is telescoped to 0-0-0-0-0.
– The load being lifted must not exceed 1 t (2,200 lbs) – where necessary
Type The truck crane GMK5200-1 is equipped with a slewing bearing of the bear-
ing type: KDV, single-row.
Type of slewing bearing GROVE part number

Ball slewing bearing 04192540 or 03246884
Bearing type: KDV, single-row Model plate: Inside the inner ring.
09.03.2018

GMK5200-1
8.5 Slewing bearing
Measuring tilting The base value of the tilting play is determined and documented by
play Manitowoc Crane Care or an authorised GROVE dealer when the slewing
bearing is put into operation or replaced.
The maximum permissible wear is 4.0 mm (0.157 in).
This results in the maximum permissible tilting play.
Example: Base value + max. permissible wear = max. permissible tilting play
0.35 mm (0.014 in) + 4.0 mm (0.157 in) 4.35 mm (0.171 in)
Measuring current tilting play

• Raise the main boom to 80° and slew to –
135° – display (A).
• Fasten a dial gauge on the front on the turn-
table (4) and place the button (1) on to the
lower ring (3) as close as possible to the gas-
ket (2).
• Slowly lower the main boom to 30°. The
hook block may not touch the ground.
• Read off from the dial gauge how far the
turntable is inclined and record this value as
the current tilting play;à Appendix – Tilting
play measurement report.
• Remove the dial gauge.
• Repeat the measurement with the slewing

angles
B –45°
C +45°
D +135°
If the current tilting play is greater than the max. permissible tilting play,
you must have the slewing bearing replaced by Manitowoc Crane Care or an
authorised GROVE dealer.
If the current tilting play is half as great as the max. permissible tilting play,
you must reduce the maintenance interval; àReducing the interval, p. 8 - 28.
09.03.2018

GMK5200-1
8.5 Slewing bearing
8.5.5 Lubricating the locking of turntable M 12
Grease, spare
Grease KP - 1K - 50 DIN 51825 03233369
– Brush.
à p. 2 - 3.
Greasing • Familiarise yourself with the correct operation of the turntable lock;
• Grease the lubrication points (1) with the
brush.
09.03.2018

GMK5200-1
O
– The telescoping cylinder must be locked in telescopic section I;
– The truck crane must be standing on a level surface.
à p. 2 - 3.
Checking the oil

level
S
Cleanliness is imperative when handling hydraulic oil.
• Check whether oil is visible in the middle of

the inspection glass (1).

09.03.2018

GMK5200-1
8.6.2 Checking the hydraulic hoses W
The inspection work is described in section Checking the hydraulic hoses,

p. 7 - 102.
8.6.3 Checking the ventilation filter W
• Check the display (1) on the ventilation filter.

If the indicator is coloured
• Replace the filter; à p. 8 - 36.
09.03.2018

GMK5200-1
• When the engine is running, carry out a visual inspection for leaks on the
hydraulic components (tank, pumps, drives, cylinders, control blocks,
valves, pipe and hose lines and connections).
• If leaks are detected, check the oil level and top up if necessary;
à Checking the oil level, p. 8 - 31.
G
Never tighten any leaking connections when the system is under pressure.
O
Immediately repair or have leakages in the hydraulic system repaired to
ensure that no hydraulic oil escapes, seeps into the ground or reaches
waterways when the crane is being used.
After hydraulic components have been changed

• Bleed the hydraulic system; à Establishing the operating conditions,
p. 8 - 46.

crew.
09.03.2018

GMK5200-1
8.6.5 Cleaning the magnetic rods M3
Spare parts and

For oil filter 1:
Filter 1 04156358
Prerequisites – The truck crane must be standing on a level surface.

à p. 2 - 3.
– During the first 100 operating hours: clean the magnetic rod once a week.
O
09.03.2018

GMK5200-1
Cleaning oil filter 1

• Remove the cap (2) and pull out the hydrau-
lic oil filter.
• Remove the filter (4) from the filter cage (5).
• Clean the filter cage (5) and the magnetic
rod (3).
• Replace the filter (4) if necessary.
S
tem.
Have the hydraulic system inspected by Manitowoc Crane Care or by your
qualified repair crew.
• Assemble the filter (3) and insert it.

• Replace the cover gasket if necessary.
• Bolt the cap (2) on.
09.03.2018

GMK5200-1
8.6.6 Changing the ventilation filter M 12
Spare parts and

Filter 1 03134932
à p. 2 - 3.
O

• Change the filter (3) and fasten the cap.
• Reset the display by depressing the pin (1)
on the housing.
09.03.2018

GMK5200-1
G
The superstructure is equipped with pressure

accumulators.
The filling pressure at 20 °C (68°F) is:
1 Pressure accumulator 20 bar (290 psi)
2 Pressure accumulator 180 bar (2,610 psi)
• Have the filling pressure checked and if

necessary corrected by Manitowoc Crane
Care or an authorised GROVE dealer.
8.6.8 Taking oil samples M 12
The oil sample from the superstructure hydraulic system is taken in a way
similar to that for the carrier hydraulic system.
Information for taking samples with the hose and for the laboratory analy-
à
sis; Taking oil samples, p. 7 - 106.
à p. 2 - 3.
Select the To determine the usability of the oil, you must take a sample from the
sampling location hydraulic system. To do that you must connect the hose with the connecting
piece to a gauge port.
09.03.2018
s
GMK5200-1
The MLS gauge port (1) is located on the

bracket (2). When a hydraulic function is run,
oil can be taken at the gauge port.
Taking oil samples

• Clean the gauge port and connect the hose
(1) to the bracket (3); à Connecting the hose,
p. 7 - 107.
• Put the hose end (2) into the receptacle (4).
• Tilt the crane cab.
• Allow 2 litres (0.5 gal) of oil to flow into the
receptacle.
• Switch off the engine and put the hose end
(2) into the sample container (5).
• Tilt the crane cab.
• Allow 0.3 litres (0.08 gal) of oil to flow into
the sample container.
• Remove the hose; à Disconnecting the hose, p. 7 - 108.
• Seal the sample container and dispatch it; à Dispatch the oil sample to the
laboratory, p. 7 - 109.
• Determine the quality of the oil; à Determining the quality of the oil,
p. 7 - 109.
09.03.2018

GMK5200-1
8.6.9 Changing the hydraulic oil filter
All oil filters must be replaced when changing the oil.
If a warning message appears, the red symbols on the CCS control unit indi-
cate whether oil filter 1 or oil filter 2 is clogged. There is no indicator for oil
filter 3.
1 Red – Changing oil filter 1
2 Red – Change oil filters 2 and 3
Spare parts and

For oil filter 1:
Filter 1 04156358
For oil filter 2:
Filter 1 03142356
Housing packing set 1 03326049
For oil filter 3:
Filter 1 03249527
– Torque wrench for 25 Nm (18.4 lbf ft).

Operating manual.
– The main boom must be fully retracted and raised to the maximum;
à p. 2 - 3.
O
s
09.03.2018

GMK5200-1
Changing oil
filter 1
O

• Remove the cap (2) and pull out the hydrau-
lic oil filter.
• Remove the filter (4) from the filter cage (5).
• Clean the filter cage (5) and insert a new fil-
ter (4).
• Clean the magnetic rods 3).
sary.
S
tem.
Have the hydraulic system checked by Manitowoc Crane Care or an author-
• Assemble the filter (3) and insert it.

• Replace the cover gasket if necessary.
• Bolt the cap (2) on.
09.03.2018

GMK5200-1
Changing oil
filter 2
• Release the receptacle (1) at the hexagon.
• Replace the gaskets.
• Fill the receptacle with clean oil and tighten
it – torque 25 Nm (18.4 lbf ft).
Changing oil The oil filter 3 is located in the centre of rotation under the telescopic boom.
filter 3

• Release the receptacle (1) at the hexagon.
• Replace the gaskets.
• Fill the receptacle with clean oil and tighten
it up.
s
09.03.2018

GMK5200-1
After changing the

filter
S
The engine may only be started if the valve in the suction line of the hydrau-
lic pumps is open and there is enough hydraulic oil in the hydraulic oil tank.
• Check the valve on the hydraulic oil tank. Open the valve, if necessary;
à p. 8 - 46.
• Check the oil level. Top up the oil, if necessary; à p. 8 - 45.
• To bleed the system, start the engine and let it idle for 3 minutes.
• Check that none of the oil filters is leaking.
09.03.2018

GMK5200-1
Blank page
09.03.2018

GMK5200-1
8.6.10 Changing the hydraulic oil
The oil only needs to be changed if the laboratory analysis results indicate
this; à Taking oil samples, p. 8 - 37.
Oil, spare parts,

tools Hydraulic oil Designation to Specification GROVE part no.
in litres (gal) DIN 51502 Classification
980 (259) HVLP DIN 51524 - 3 04162158
Viscosity: ISO-VG 32 Castrol Hyspin
AWH-M 32
– Connecting piece and hose (tool box);à p. 7 - 112.

– One or more receptacles, approx. 1,100 l (290 gal); à p. 2 - 4.
à p. 2 - 3.
– The oil filters must be removed; à Changing the hydraulic oil filter,
p. 8 - 39.
Closing the valve
S
Be sure to secure the engine against unauthorised use.
If the engine is started while the valve in the suction line is closed, the
hydraulic pumps will be damaged.
• Close the valve – lever (1) at right angles to

the line.
09.03.2018

GMK5200-1
Draining oil
O
• Place a receptacle underneath the valve.

the valve (1) and drain the oil; à Handling
the valves, p. 7 - 112.
• Change the filters; à p. 8 - 39.
Topping up the oil
S
Cleanliness is of the utmost importance when handling hydraulic oil.
• Remove the cap (1) and the filter (2).

• Add new oil via the filler neck (3) through a
filter until the level reaches the centre of the
inspection glass (4).
• Tighten the cap and filter.
s
09.03.2018

GMK5200-1
Establishing the After having changed the oil filters and topping up the oil, you must
operating re-establish the operating conditions.
conditions
S
Open the valve prior to starting the engine.
This prevents damage to the hydraulic pumps.
Opening the valve


• Carry out all hydraulic functions several times to remove any air in the
system.
• Check that none of the oil filters is leaking.
• Check the oil level through the inspection glass on the hydraulic oil tank.
Top up oil, if necessary; à p. 8 - 45. 09.03.2018

GMK5200-1
8.7 Main boom
8.7 Main boom
8.7.1 Greasing the piston rod of the derricking cylinder M1
Grease, spare
parts and tools Designation GROVE part no.
Lubricant RHUS SW 2; 1 kg 03325215
(Apply the grease with a brush)
or
Spray on Berulub; 0.5 litres 01929824
(spray-on)
– Brush.
S
Risk of damage to the derricking cylinder's gasket due to rust.
Ensure that the uncovered end of the piston rod is always kept covered with
a layer of grease. In this way you can avoid rust which damages the seal in
the derricking cylinder head when fully lowered.
• Clean the uncovered end (1) of the piston

rod by removing old grease, dirt particles
and rust.
• Grease the uncovered end, making sure the
grease coating is evenly distributed.
After every high-pressure cleaning operation

on the truck crane
• Grease the piston rod.
H
You can hinder the formation of rust if you turn the main boom to the side
between maintenance intervals and completely lower it.
09.03.2018

GMK5200-1
8.7 Main boom
8.7.2 Lubricating the telescopic sections M3
Grease, spare
parts, tools Designation GROVE part no.
Lubricant for the locking pins: 03325215
RHUS SW 2, 1 kg can
Slide paste for the telescopic slide faces: 02314698
PAL1, 25 kg bucket
– A grease gun for the lubricating nipples on the locking pins.

– A grease gun for the grease nipples on the upper telescopic slide faces.
– A brush or roller for the outer, upper and lower telescopic slide faces.
H
The Manitowoc Crane Group Germany GmbH recommends pneumatic
grease spray guns for more effective lubrication of the telescopic slide
faces:
Designation GROVE part no.

Grease spray gun, complete: 03325445
Mobile, external compressed air connection
required
Spray extension, length 2 m, splittable 04159862
Manual grease spray gun for cartridge: 03329027
Via the tyre inflator connection on the truck
crane
25 m hose for manual grease spray gun: 03329072
Slide paste for the telescopic slide faces: 03329071
PAL1, 400 ml cartridge, refillable

– The hook block must be unreeved.
– The main boom must be completely retracted and lowered into horizontal
position.
– A rigging mode must be created with a telescoping status which satisfies
the lifting capacity tables necessary for maintenance; à Lifting capacity
table; Section Telescoping sequences for greasing the boom.
– The RCL code for the current rigging mode must be entered.
H
If at the start you set up a rigging mode under which the telescope positions
09.03.2018
50/100/0/0/0 are released in the context of the corresponding lifting capacity

table, this rigging mode allows you to perform the complete maintenance
work on the main boom.

GMK5200-1
8.7 Main boom
H
If the desired telescoping status is not a fixed length, you can first telescope
to the next closest fixed length with the semi-automation and then tele-
scope further to the desired length manually; àOperating manual.
Information
G
Risk of overturning when telescoping if the RCL is overridden.
Do not override the rated capacity limiter (RCL) when telescoping is
switched off. Select a suitable lifting capacity table which contains the
required telescoping. Set the associated rigging mode and enter the RCL
code.
G
Risk of accidents from slipping off the main boom.
There is grease residue on the telescopic sections. For this reason, you
must not walk on the main boom.
Use the extendable ladders provided with your crane.
If the main boom has been telescoped several times, the telescoping mech-
anism and derricking gear can be so heavily loaded that the main boom can
be neither telescoped nor derricked. Therefore note the following instruc-
tions:
• Before retracting the boom, raise it to approximately 15°.
• Do not lower the main boom below 0°.
Telescopic • Observe the following instructions regarding maintenance work.

section I
• Extend the telescopic section I to 100%.
• Use a brush or a roller (PAL1) to lubricate
the outer, upper and outer, lower slide
faces (3).
• Use the grease gun (PAL1) to lubricate the
upper inner slide faces at the lubricating nip-
ples (1) on both sides.
• Use the grease gun (RHUS SW 2) to lubri-
cate the locking pins at the lubricating nip-
• Lock and unlock the telescopic section I sev-
eral times, so that the grease is distributed
09.03.2018
over the locking pins.
s
GMK5200-1
8.7 Main boom
• Extend the telescopic section I to 50%.

• Fully retract telescopic section I.
• Fully extend and retract telescopic section I
again so that the grease is distributed over
the telescope slide faces.
Telescopic section • Observe the following instructions regarding maintenance work.

II-V
The following diagrams show the lubrication of telescopic section V.
The telescopic sections IV, III, II are lubricated in the same way.
• Extend telescopic section V to 100% and

telescopic section IV to approx. 25%.
• Use a brush or a roller (PAL1) to lubricate
the outer, upper and outer, lower slide
faces (3).
• Use the grease gun (RHUS SW 2) to lubri-
cate the locking pins at the lubricating nip-
• Lock and unlock telescopic section V several
times, so that the grease is distributed over
the locking pins.
09.03.2018

GMK5200-1
8.7 Main boom
• Raise the main boom to 15°.

• Extend telescopic section IV to 0% and tele-
scopic section V to approx. 50%.
• Lower the main boom to 0° – do not lower to

below 0°.
• Extend telescopic section IV to approx. 75%.
• Raise the main boom to 15°.

• Retract telescopic sections IV and V to 0%.
• Fully extend and retract telescopic section V again so that the grease is
distributed over the telescope slide faces.
• Lower the main boom to 0°.
• Lubricate telescopic sections IV, III and II in the same way.
Before driving the truck crane

Fully retracting all telescopic sections of the main boom after greasing may
result in excess lubricant paste emerging at the collar (1).
• Remove any excess lubricant paste from the collar (1).
This is to prevent any lumps dropping off on to the windscreen and sud-
09.03.2018
denly obstructing the view when driving.

GMK5200-1
8.7 Main boom
8.7.3 Checking the sheaves M3
• Check all sheaves (1) on the main boom

head (2) for damage, wear, mobility and
heavy soiling.
Have damaged, worn, stiff or extremely soiled sheaves replaced by

8.7.4 Checking the locking system M 12
G
Risk of accidents if maintenance work is not carried out.
Have the maintenance work on the main boom locking system performed
regularly by Manitowoc Crane Care or an authorised GROVE dealer.
This prevents the complete unlocking of a telescopic section in emergency
operation/emergency program mode, which could cause serious accidents
and damage to the truck crane.
• Have the main boom locking system checked regularly by Manitowoc

Crane Care or an authorised GROVE dealer. 09.03.2018

GMK5200-1
8.8 Hoist ropes
8.8 Hoist ropes
8.8.1 Checking the winding D
G
Risk of accidents when the rope drum is turning.
Keep away from the rope drum while it is turning.
This will prevent your limbs from being drawn in and getting crushed.
Prerequisites – The hoist mirrors must be folded out; à Operating manual.

– One hook block must be reeved;à Operating manual.
– The main boom must be raised to approx. 30°; à Operating manual.
– The engine must be started.
Check the
following
Always check the entire length of the winding

of the ropes (1).
• Slowly perform the lowering movement until
the rope has moved over the complete
width (X) of the rope drum.
– The rope needs to be evenly wound.
– The rope turns on the drum must be
evenly spaced at a distance of 0 to 2 mm
(0 to 0.08 in).
– The cross-over points must offset by
approx. 180°.
H
The ropes of the top layer lie over the ropes of the bottom layer at the cross-
over points.
09.03.2018

GMK5200-1
8.8 Hoist ropes
8.8.2 Checking the hoist ropes W
Spare parts and – Torque wrench for 78 Nm (57.5 lbf ft).

tools
Prerequisites – Establish a rigging mode in accordance with the Lifting capacity table and
enter the RCL; à Operating manual.
– A hook block must be reeved 5-fold;
– The main boom must be raised and fully extended; à Operating manual.
Checking the • Start the engine.

ropes
• Unreel the rope and check the rope and the rope spooling; à Assessing
the condition of the hoist rope, p. 8 - 56. When 5 turns are left on the rope
drum, the lowering limit switch must switch off.
If the lowering limit switch does not switch off or switches off too late, it
must be reset; à Setting the lowering limit switch, p. 8 - 65.
• Check the clamp (1) for damage and firm

seating – torque to 78 Nm (57.5 lbf ft).
• The free end of the rope must not project
above the flanged wheel.
• The rope wedge must be in the pocket (2).
• The rope end on the rope wedge must not
show any signs of wear.
• Reel in the rope. At the same time, the rope
may not show any signs of kinking or being
flattened.
• Check the end of the rope and the rope end fitting for damage.
• Make sure the rope end is correctly fitted in the rope end fitting;
09.03.2018

GMK5200-1
8.8 Hoist ropes
8.8.3 Lubricating the hoist rope M3
Grease, spare
parts and tools Designation Quantity GROVE part no.
Grease 1 03133770
– Brush, roller, spray gun, tray or pressure pump.
Lubricating the Lubricating the rope

rope – significantly prolongs its service life and
– keeps the friction between the rope, the sheaves and the hoist drum as
low as possible.
The lubricant is applied to the rope by
– spraying, brushing, rolling or
– by running it through a tray filled with lubricant or
– by means of high-pressure lubrication with a pressure pump.
H
The Manitowoc Crane Group Germany GmbH recommends high-pressure
lubrication with a pressure pump (GROVE part no. 90018525) for reasons of
sustainability, efficiency and environmental protection.
When lubricating the hoist ropes, observe the instructions concerning the
lubricant.
When using the pressure pump, observe the manufacturer's separate oper-
ating instructions.
For further information, contact Manitowoc Crane Care or an authorised

GROVE dealer.
09.03.2018

GMK5200-1
8.8 Hoist ropes
8.8.4 Assessing the condition of the hoist rope
H
If in doubt about damage assessment, always consult an official inspector.
To assess the condition of the rope, you must be familiar with the following:
– The type of rope (regular lay)
– The number of load-bearing wires in the outer strands
– The rope diameter ( à Operating manual).
In a regular lay rope (1), the wires run more or
less in the longitudinal direction of the rope.
You get the number of load-bearing outer

wires (1), by counting the number of outer
strands of the rope and multiplying by 7.
H
If there are multiple layers of strands, only the outer layer is counted.
09.03.2018

GMK5200-1
8.8 Hoist ropes
The tables show by rope diameter the number of wire breaks in a

length 6 times and 30 times the rope diameter which if reached would
require replacement of the rope.
• Familiarise yourself with DIN ISO 4309:2013-06 (rotation-resistant ropes).
This table applies only to the hoist ropes fitted as initial equipment and
original replacement ropes!
Number of visible wire breaks on a rotation-resistant hoist rope

The rope section runs over a rope disc or on a drum wound as a single layer
Number of ∅ 13 mm ∅ 16 mm ∅ 17 mm
load-bearing to to to to to to
outer wires 78 mm 390 mm 96 mm 480 mm 102 mm 510 mm
101-120 3 5 3 5 3 5
121–140 3 5 3 5 3 5
∅ 19 mm ∅ 22 mm ∅ 24 mm
to to to to to to
114 mm 570 mm 132 mm 660 mm 144 mm 720 mm
101-120 3 5 3 5 3 5
121–140 3 5 3 5 3 5
The rope section is running on a drum wound as multiple layers

∅ 13 mm ∅ 16 mm ∅ 17 mm
to to to to to to
78 mm 390 mm 96 mm 480 mm 102 mm 510 mm
101-120 5 10 5 10 5 10
121–140 6 11 6 11 6 11
∅ 19 mm ∅ 22 mm ∅ 24 mm
to to to to to to
114 mm 570 mm 132 mm 660 mm 144 mm 720 mm
101-120 5 10 5 10 5 10
121–140 6 11 6 11 6 11
s
09.03.2018

GMK5200-1
8.8 Hoist ropes
S
Risk of accidents due to reduced load bearing capacity.
Remember that other factors may also make it necessary to replace a rope
before the number of wire breaks requiring rope replacement has been
reached (age of rope, frequency of use or exceptional loading).
Damage Description Cause Replacement

Wire break (1) Individual wires are General wear caused Replace the rope at the latest
broken; the broken by ageing of the rope when the maximum permissi-
Wire break-
ends of the wires or ble number of wire breaks
age cluster (2)
are protruding according to the table are
Strand break- from the rope. consequential dam- visible externally.
age (3) age as a result of dam-
age to the rope. Replace the rope immediately if
wire break clusters or strand
breakages occur.
The frequency of wire breaks
increases with a rope's age. For
reasons of safety, it is advisable
to replace the rope while the
number of wire breaks is still
low.
Effect of heat Tarnished colour is Rope has been sub- Replace the rope immediately.
visible externally jected to excessive
on the rope. heat.
09.03.2018

GMK5200-1
8.8 Hoist ropes

Reduced The diameter of the Structural changes Immediately replace the rope
diameter (1) rope has become if the diameter has decreased
smaller along large by 15% or more compared to
sections. the nominal diameter.
Corrosion or abrasion. Immediately replace the rope
if the diameter has decreased
by 10% or more compared to
the nominal diameter.
Corkscrew- The rope winds its Damage resulting Even a small amount of defor-
type rope way along its longi- from overloading. mation leads to increased
deformation tudinal axis in a way abrasion, wire breaks and
(2) that is similar to a rough operation of the rope
corkscrew. drive.
Deformation is If deformation ”x” at a position
measured with sus- on the rope is greater than
pended hook block. a third of the rope diameter,
the rope must be replaced
immediately.
Basketlike Wires of the outer Outer and inner layers Replace the rope immediately.
deformation layer protrude. In have been displaced
(3) other areas of the in relation to each
rope, the insert has other.
buckled or is pro-
truding from the
rope.
s
09.03.2018

GMK5200-1
8.8 Hoist ropes

Loop forma- Outer layer wires in General wear due to Immediately replace rope if the
tion (1) the form of hair pins ageing of the rope or rope structure has been sub-
are protruding from consequential dam- stantially altered by the loop
the rope away from age as a result of formations.
the sheave. damage to the rope.
Loosening of Outer wires or Corrosion or abra- Replace the rope immediately.
wires or strands have sion.
strands (2) become loose. Only
Other causes. The number of wire breaks
the inner strands
determines when the rope
continue to bear the
must be replaced.
load.
Knot forma- If there is repeatedly General wear due to Determine number of wire
tion (3) occurring knot-like ageing of the rope or breaks; replace rope immedi-
thickening of the consequential dam- ately if serious knot formation
rope; the insert age as a result of occurs.
comes out fre- damage to the rope.
quently.
Strands bear on
each other at thin
points; increased
frequency of wire
breaks.
Constriction Diameter reduction General wear caused Replace rope immediately if
(4) over short sections. by ageing of the rope. serious constrictions are
detected.
09.03.2018

GMK5200-1
8.8 Hoist ropes

Flattening (1) Crushed areas, Mechanical damage, Determine number of wire
mostly with wire e.g. due to driving breaks; replace rope immedi-
breaks. over the rope. ately if serious crushing has
occurred.
Kinks (2) Rope deformation Rope in the eyelets Replace the rope immediately.
with twists and was pulled straight
wire breaks. while twisted.
Buckling (3) Buckled section in Mechanical damage. Replace the rope immediately.
the rope.
Crinkling (4) Crinkling rope Loaded rope was Replace the rope immediately.
deformation. pulled over an edge.
09.03.2018

GMK5200-1
8.8 Hoist ropes
8.8.5 Replacing the hoist rope
Spare parts and – An authentic replacement rope; à Rope certificate.

tools
– A reel stand with braking block.
– Torque wrench for 78 Nm (57.5 lbf ft).
S
Risk of accidents from falling load.
Use only a replacement rope that has the same technical specifications as
the defective rope, or an authentic replacement rope.

– The main boom must be set down on the boom rest.
– The hook block must be unreeved; à Operating manual.
Replacing the old • Unreel the hoist rope until it switches off.
rope
• Adjust the lowering limit switch so that you can unreel the rope com-
pletely; à Setting the lowering limit switch, p. 8 - 65.
• Unreel the remaining layers from the hoist drum.
• Protect the truck crane from unauthorised use; à p. 2 - 3.
G
Risk of accidents due to the rotating rope drum.
Turn off the engine and remove the ignition key so that no unauthorised
operation of the hoist can occur.
09.03.2018

GMK5200-1
8.8 Hoist ropes
• Remove the clamp (4).

• Push the rope through the hole (3) until the
rope wedge (1) slides out of the pocket (2).
• Remove the rope wedge and place the old
rope away from the truck crane.
Inserting a new The service life of a rope can be significantly affected by the insertion pro-
rope cedure. Errors can significantly reduce the service life, therefore:
– Make sure the rope is not twisted when it is inserted.

– Avoid soiling and damage when fitting.
– Wind the rope up in the same direction in which the rope is reeled on to
the reel.
– Tense the rope slightly while winding it up.
• Place the reel stand (1) with the new rope in
front of the main boom head.
The distance (X) between the reel stand (1)
and the head sheave (2) must be at least
30 m (100 ft) so that the rope runs over the
head sheave as straight as possible.
Ensure that the rope is being rolled on to the
drum with the right slewing direction.
• Guide the rope over the head sheave (2) and
under the bracket (3) up to the hoist drum.
s
09.03.2018

GMK5200-1
8.8 Hoist ropes
• Guide the rope through the hole (3) until it

protrudes about 1.5 m (5.0 ft) beyond the
pocket (2).
• Feed the free end of the rope back through
the pocket.
• Secure the clamp (4) and tighten it – torque
to 78 Nm (57.5 lbf ft).
• Place the rope wedge (1) in the loop.
• Push the rope back until the rope wedge (1)

is fully in the pocket (2).
• Ensure that the rope wedge, loop and rope
end do not protrude beyond the flanged
wheel. This will prevent damage.

• Hold the rope taut and wind up the rope slowly.
• Reeve a hook block – reeve it at least 5-fold; à Operating manual.
• Raise the main boom to a steep position and extend it fully.
• Unwind the rope until only five turns remain on the rope drum.
09.03.2018

GMK5200-1
8.8 Hoist ropes
H
Observe the hook block when unreeling.
The hook block must not rotate.
G
Risk of accidents if the lowering limit switch is set incorrectly.
After inserting a new rope, the lowering limit switch must always be reset.
In this way you avoid the lowering limit switch switching off too late or not
at all, the rope being damaged and the load being dropped.
• Set the lowering limit switch; à p. 8 - 65.

• Run in the new rope with small loads so that the rope can settle on the
hoist drum.
8.8.6 Setting the lowering limit switch
A lowering limit switch is mounted both on the main hoist and on the aux-
iliary hoist.
Spare parts and

Prerequisites – A hook block must be reeved 5-fold; à Operating manual.

– The main boom is fully raised and extended; à Operating manual.
– The hook block is lowered until only five turns of the rope remain on the
hoist drum.
s
09.03.2018

GMK5200-1
8.8 Hoist ropes
Setting the
lowering limit
switch
G
Risk of accidents if the rope end fitting is overloaded.
The lowering limit switch must always be reset after repair work on the
hoist and after rope replacement. A faulty lowering limit switch must
always be replaced.

• Turn the screw (2) until you hear the switch
activate.
• Screw the cover on again.
Replace the gasket if necessary.
• Check that the lowering limit switch
switches off the hoist correctly.
Checking • Raise the hook block until there are approx. 10 turns on the hoist drum.
switch-off
• Lower the hook block and check whether the lowering limit switch
switches off properly.
The lowering limit switch must switch off the hoist while five rope turns are
still on the hoist drum.
• Correct the setting of the lowering limit switch if necessary. 09.03.2018

GMK5200-1
8.9 Cable drums
8.9 Cable drums
8.9.1 Maintenance of the slip ring assemblies M6
The slip ring assemblies are located in:

1 Cable drum 1
2 Cable drum 2
Spare parts and

Cover gasket for cable drum 1 1 03325575
Cover gasket for cable drum 2 1 03138894
– Clean, lint-free cloth.

– Dry, oil-free compressed air.
Prerequisites – All counterweight plates must be removed – the opening for cable drum 2
at the rear of the turntable must be accessible; à
Operating manual.
– The main boom must be set down on the support; à Operating manual.
à p. 2 - 3.
– The ignition must be switched off in the driver's cab; à Operating manual.
s
09.03.2018

GMK5200-1
8.9 Cable drums
S
Risk of damage to the RCL.
Before maintenance work on the slip ring assemblies, always switch off the
battery master switch so that the cable drum is without power.
This prevents short circuits which may lead to damage to the rated capacity
limiter (RCL).
G
Risk of crushing from movement of the main boom.
Only perform maintenance work when the main boom is resting in the sup-
port and the truck crane is not running. Always ensure that the truck crane
is protected from unauthorised use before beginning maintenance work.
Remove the keys from the crane cab and put up warning signs.
Maintenance of
the slip ring
assemblies
• Remove the cover (1) or (2).

• Clean and dry the cover.
• Replace the gasket if necessary.
• Only use a cloth and compressed air to

remove any dirt on the slip rings (2).
• Do not use spray oil.
• Check to make sure all screws (1) are tight.
• Attach the cover to the cable drum.
09.03.2018

GMK5200-1
8.10.1 Checking the level W
The maintenance of the pump (1) is similar to

the maintenance on the carrier; à
Central
lubrication system, p. 7 - 119.
Connected lubricating points

– Main hoist drum,
– Auxiliary hoist drum,
– Slewing bearing,
– Telescopic unit – pivot pins,
– Derricking cylinder – pivot pins
09.03.2018

GMK5200-1
Blank page
09.03.2018

GMK5200-1
8.11 Hook blocks
8.11 Hook blocks
8.11.1 Checking the sheaves M3
• Check the sheaves in the hook blocks for damage, wear, mobility and
extreme soiling.
Have damaged, worn, stiff or extremely soiled sheaves replaced by
8.11.2 Greasing M 12
Grease, spare
Grease KP - 1K - 50 DIN 51825 03233369
Prerequisites – The hook block has been reeved at least twice; à Operating manual.
Greasing On the hook blocks supplied, the sheaves, crossheads and load hooks of the
axial bearings are greased.
H
The sheaves on the hook block often have no grease nipple and are main-
tenance-free.
• Check all hook blocks for grease nipples. Hook blocks with grease nipples
must be serviced, hook blocks without grease nipples are maintenance-
free.
s
09.03.2018

GMK5200-1
8.11 Hook blocks
The diagram gives an example of the arrange-

ment of the grease nipples (1), (2) and (3) on a
hook block.
There are more grease nipples on the other
side.
• Clean the grease nipples on all hook blocks

and grease them using a grease gun.
Checking the The truck crane GMK5200-1 can be equipped with hook blocks that can be
fastenings separated.
G
Risk of accidents due to non-secured hook block components
If the removable components of the bottom hook block are not properly
secured, then they can fall from a great height and fatally injure people dur-
ing crane operation.
Always check that the removable components are properly secured during
loading and before crane operation.
The figure shows an example of the removable components on a hook

block.
Separable hook block

• Check the separatable joints (1) for damage.
• Check the bolts (2) and the retaining pins (3)
for damage.
09.03.2018

GMK5200-1
8.11 Hook blocks
Information on Exercise particular care when operating the crane. Check that the hook
crane operation blocks have room to move freely, especially for two-hook operation.
S
Risk of damage to the hook blocks
Check the retainers for the ballast plates regularly for corrosion and condi-
tions. This applies in particular if
– work is frequently carried out in a corrosive environment
– the hook blocks collide during crane operation.
In this way, you avoid damaging the retainers, which can lead to the hook
blocks falling over.
Having them Depending on the manufacturer, there are different maintenance intervals
dismantled for the dismantling of the hook blocks. The maintenance-free sheaves are
also greased at this time. Some manufacturers recommend dismantling
every 4 years or after 500 operating hours.
• Ask Manitowoc Crane Care about the maintenance intervals for the hook
blocks supplied to you.
• Have the hook blocks dismantled by Manitowoc Crane Care or an author-
09.03.2018

GMK5200-1
8.11 Hook blocks
Blank page
09.03.2018

GMK5200-1
8.12.1 Checking the lighting and indicators D
G
Risk of accidents if the safety devices are faulty.
Have faulty lights and indicators repaired by Manitowoc Crane Care or an
• Check the symbols and indicator lamps on the CCS (Crane Control System)
control unit; à Operating manual.
• Check the following functions:

– Windscreen wipers, windscreen washing system
– Spotlight on the crane cab, air traffic control light

– Spotlight on the main boom (xenon light)
– Horn, anemometer
– Camera lights on the main and auxiliary hoists.
– Date/time on CCS display.
– A long-life battery with a service life of 10 years for retaining the con-
trol system data is located next to the fuses in the crane cab; à Have
the battery on the electronics board replaced, p. 8 - 76.
s
09.03.2018

GMK5200-1
G
Risk of accidents from exploding glass bodies and high voltage.
The glass bodies of gas discharge lamps (xenon lights) are pressurised. If
the lamp breaks, the glass splinters explosively and shards scatter.
Xenon lights operate at high voltage. While changing the lamp, there is still
a danger of residual voltage discharging (electric shock) even when the bat-
tery master switch is switched off.
Have faulty lamps replaced only by properly qualified personnel who use
the relevant protective equipment.
• Have faulty lamps in the spotlights replaced only by qualified personnel.
8.12.2 Have the battery on the electronics board replaced Y 10
Spare parts and

Lithium battery 3.6 V 1 03143172
à p. 2 - 3.
Changing
• Open the cover (1) behind the seat in the

crane cab.
• Changing the battery (2) on the electronics
board (3).
• Close the cover.
• Check the correct operation of all controls.
09.03.2018

GMK5200-1
8.13.1 Checking the air conditioning system M1
• Check the air-conditioning system in the same way as when checking it on

the carrier; à Checking the air conditioning system, p. 7 - 131.
8.13.2 Cleaning the condenser fins M1
S
Risk of damage to the condenser.
may damage the fins. Use only compressed air for cleaning.
Depending on the power of the air-conditioning system (3 KW or 6 KW),

different condensers are installed (type A or B).

• Clean the condenser fins (1) with com-
pressed air.
09.03.2018

GMK5200-1
8.13.3 Checking hoses M6
G
nections.
• Check all refrigerant hoses for damage and areas of wear.

Have damaged hoses checked by Manitowoc Crane Care or an authorised
GROVE dealer or an authorised specialist workshop only.
8.13.4 Checking the entire air conditioning system M 12
H
G
nections.
• Have the entire air conditioning system checked for leaks and proper func-
tioning.
The inspection of the air conditioning system particularly includes the
inspection of
– the refrigerant collector, in accordance with the pressure container
regulations (test group II) and
– the refrigerant compressor.
Only allow the system to be topped up with suitable refrigerant. 09.03.2018

GMK5200-1
Refrigerant
Fill quantity Designation CAS no.
in kg (lbs) EC no.
1,0 (2,2)
1-circuit (3 KW) 811-97-2
Tetrafluoroethane (R134a)
2 x 0.95 (2.1) 212-377-0
2-circuit (6 KW)
Compressor oil: POE OIL; EMKARATE RL68H
Filler connections
The filler connections (1) for the refrigerant are

on the compressor behind the cover (2).
Depending on the output (KW) of the

air-conditioning system there may be two
separate refrigerant circuits, which must be
filled separately. There are then four filler
connections (1) instead of two.
09.03.2018

GMK5200-1
8.13.5 Changing the pollen filter M 12
interval tions – you must change the filter earlier than normal.
Spare parts and

Filter 1 04163620
à p. 2 - 3.
Changing
• Open the cover (1).

• Remove the filter (2) from the housing and
clean the housing with a cloth.
• Insert a new filter.
09.03.2018

GMK5200-1
8.14.1 Checking the windscreen washing system W
Water, spare
parts, tool Designation Quantity GROVE part no.
Windscreen wiper blade 1 03268512
Roof wiper blade 1 03326121
– Water; add commercially available detergent and antifreeze to it.

– A can for mixing and filling.
Prerequisites – The crane cab door is pushed back – the filler neck with the cap (1) is
accessible.
Topping up
If the tank is empty

• Open the cap (1) on the filler neck.
• Top up the windscreen washing fluid
through the filler neck.
s
09.03.2018

GMK5200-1
Wiping The wiping/washing system operation is described in the accompanying

operating instructions; à
Operating manual.
• Spray water on the windscreen – press down on the switch.

• Spray water on the skylight – press up on the switch.
• Switch on the windscreen wiper – press the switch down for continuous
operation.
• Also check intermittent operation – press the switch up.
• Switch off the windscreen wiper – push the switch in the middle position.
• Switch on the roof window wiper – press the switch down for continuous
operation.
• Also check intermittent operation – press the switch up.
• Switch off the roof window wiper – push the switch in the middle
position.
In case the windscreen/skylight is not wiped clean

• Change the wiper blade.
8.14.2 Checking the auxiliary heater M1
Check the auxiliary heater (1) in the same way you check it on the carrier;
à Checking the auxiliary heater, p. 7 - 145.
• Familiarise yourself with the CCS Heating/Air-conditioning system menu

in the crane cab; à Operating manual.
09.03.2018

GMK5200-1
8.14.3 Lubricating the crane cab door M 12
Grease, spare
Grease: RHUS SW 2, 1 kg can 03325215
– Brush.
Prerequisites – The turntable is locked.

à p. 2 - 3.
Greasing
• With the door closed, clean the rails (1) out-

side.
• Lubricate the rails (1) lightly with a brush.
• Open the door completely using the
handle (2) – the door locks in place.
• Clean the rails (3).
• Lubricate the rails (3) and the rollers (4)
lightly with a brush.
• Pull the unlocking device (5).
• Check if the door moves smoothly on the
rails and if it locks easily.
If the door is sluggish or does not close properly, have it reset by

Manitowoc Crane Care or an authorised GROVE-dealer.
09.03.2018

GMK5200-1
8.14.4 Lubricating the step M 12
Grease, spare
Lubricant RHUS SW 2; 1 kg 03325215
(Apply the grease with a brush)
– Brush.
Prerequisites – The turntable must be locked.

à p. 2 - 3.
Retracting/ • Familiarise yourself with the description in the operating instructions of

extending retracting/extending the step (from the crane cab or at the outrigger con-
trol unit); à
Operating manual.
Greasing • Fully extend the step.

• Remove the step (1) and the grille (2) – the
rails (3) are now exposed.
• Clean the rails (3).
• Lubricate the rails (3) lightly with a brush.
• Retract and extend the step several times.
Whilst doing so, check that the step is mov-
ing easily on the rails.
• Check that the electric spindle motor (4) is
running smoothly and without jerking.
• Attach the step (1) and the grille (2).
• Fully retract the step.

If the step is stiff, bent or does not retract completely, have the step aligned
and adjusted by Manitowoc Crane Care or an authorised GROVE dealer.
09.03.2018

GMK5200-1
8.14.5 Lubricating the connecting and socket pins M 12
Grease, tools
Grease KP - 1K - 50 DIN 51825 03233369
– Brush.
Check the On the superstructure, depending on the equipment, there are various con-
following necting pins and socket pins such as:
– Locks and supports on the covers,

– Hinges on the crane cab's front and the rear window,
– Retaining rods for the rope discs at the head of the main boom.
• Check the pins for wear such as rust, deformation, broken clips, chains
and pin-type keepers.
• If the pins are damaged, have them replaced by Manitowoc Crane Care or
an authorised GROVE dealer or your qualified repair crew.
• Use only authentic replacement pins.
Greasing
• Clean the pins.

• Lubricate the pins with a brush.
09.03.2018

GMK5200-1
8.14.6 Renewing the corrosion protection M 12
Protective agent,
tools Protective agent GROVE part no.
Corrosion protection 03140192
– Spray gun with spray extension.

– Brush.
– Protective clothing, protective goggles.
Prerequisites – The superstructure must be thoroughly cleaned.

à p. 2 - 3.
Check the Some particular parts of the superstructure were sprayed for corrosion pro-
following tection for the first time in the factory itself.
These are pumps, valve blocks, controls and fittings, pipes, screw connec-
tions, hose fittings of the hydraulic system of the superstructure;
à p. 8 - 87.
The corrosion protection is solvent-free and is water soluble while being
sprayed on. A transparent, waxy, protective film is formed after a drying
time of one hour.
• Check the condition of the original protective film.

• If required, remove any rust and touch up the paintwork before you spray
on a new protective film.
Processing • Observe the processing instructions for corrosion protection;

instructions à Processing instructions, p. 7 - 147. 09.03.2018

GMK5200-1
Spraying
G
Risk of injury to the eyes.
While working with the spray extension you could be hit by the spray jet or
spray droplets. Wear protective goggles, protective clothing and gloves.
• Make sure that you do not spray running

surfaces. There is a risk of slipping.
• Spray the corrosion protection with a spray
gun aimed only at the pumps, valve blocks,
screw connections, pipes, hoses of the
hydraulic system of the superstructure:
– On the derricking cylinder (2)
– On the slewing gears (1)
– On the slewing duct (3)
– On the hoists (4)
• Clean surfaces sprayed by accident immedi-
ately with water.
• Let the corrosion protection dry for one hour.

• Check that a transparent waxy protective film has covered the entire sur-
face.
09.03.2018

GMK5200-1
8.14.7 Having the fire extinguisher checked Y2
Depending on your truck crane's equipment, it has fire extinguishers.
H
The maintenance interval may even be shorter, depending on the respective
national regulations and the operating location. Ask the local fire safety
officer about the national and local regulations.
• Follow the operating manual (1) on the fire

extinguisher.
• Have the fire extinguisher serviced by
trained personnel in good time before the
maintenance interval specified on the label
(2) expires.
S
Danger due to the fire extinguisher not working.
There is no guarantee that the fire extinguisher will still work properly once
the maintenance interval on the label has expired.
09.03.2018

GMK5200-1
9
09.03.2018

GMK5200-1
09.03.2018

GMK5200-1
Longer out of service periods

Carry out the following jobs if the truck crane is going to be out of service
for a long period (months).
Putting the truck • Clean the truck crane thoroughly on the inside and outside.
crane out of
• Remove any rust and touch up the paintwork.
service
• Parts that 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 according to the maintenance plans M 3 to M 12.
• Seal all air filters.
• Increase the tyre pressure by 10% and mark the tyre positioning, or
support the truck crane and let it stand on outriggers.
• Observe the specifications on preservation in the Engine manufacturer's
documentation.
Checks • Check the level in the fuel tanks. Always keep the tanks filled.
• Check the batteries every week and recharge them if necessary.
• Check the tyre pressure every week and correct it if necessary.
• Perform a full functional test on the truck crane every two weeks.
(Open the air filter beforehand).
• Run the hydraulic systems up to a fluid temperature of approx. 50 °C
(122 °F) and then check all functions of the carrier and superstructure
hydraulic systems.
s
09.03.2018

GMK5200-1
Longer out of service periods
• Ensure that the tyre positioning is different each time the crane is parked
(without outriggers).
• Seal the air filter again.
If the truck crane is going to be out of service for more than 12 months:
• Carry out all maintenance work in accordance with the maintenance plan
M 12.
• Observe the specifications on preservation in the Engine manufacturer's
documentation.
Putting the truck • Open the air filter.

crane into
• Inflate the tyres up to the prescribed pressure.
operation
• Carry out periodic maintenance work in accordance with the maintenance
plans in chapter 5.
• Observe the specifications on preservation and putting back into oper-
ation in the Engine manufacturer's documentation.
09.03.2018

GMK5200-1
10
10 Torques
10.1 Torques for the retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 1
10.2 Special torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 2

09.03.2018

GMK5200-1
09.03.2018

GMK5200-1
Torques
10.1 Torques for the retaining bolts
10 Torques
10.1 Torques for the retaining bolts
Metric standard screw-thread Guide values

Metric fine thread
Thread size Torques (maximum permissible
(mm) Spanner wrench size (mm) pre-tensioning for bolts) for oiled bolts (Nm)
Bolt quality
Hexagon Cylinder 8.8 10.9 12.9
head bolt screw
M8 23 32 36
13 6
M8x1 24 34 41
M 10 44 62 75
17 8
M 10 x 1.25 47 66 79
M 12 78 110 130
19 10
M 12 x 1.5 81 113 135
M 14 120 170 210

22 12
M 14 x 1.5 135 189 225
M 16 165 190 320
24 14
M 16 x 1.5 203 284 342
M 18 260 365 435

27 14
M 18 x 1.5 293 414 495
M 20 370 520 620

30 17
M 20 x 1.5 414 576 693
M 22 500 700 840
32 17
M 22 x 1.5 549 774 945
M 24 640 900 1,080

36 19
M 24 x 1.5 702 990 1,170
M 30 46 22 1,300 1,800 2,160

M 33 50 24 2,700
M36 55 27 3,300
09.03.2018

GMK5200-1
Torques
10.2 Special torques
10.2 Special torques
Thread size Spanner wrench size Torque (Nm)

(mm) (mm)
Designation
Hexagon Cylinder
head bolt screw
Suspension strut:
– Bracket for the vehicle chassis,
M 16 — 14 265
top
– Bracket for the vehicle chassis,
M 24 — 19 900
bottom
– Suspension strut flange, bottom M 20 17 520
– Half shell steering lever M 16 14 265
– Upper steering arm on suspen-
M 20 30 610
sion strut
Steering linkage:
– Ball-and-socket joints and M10 x 1 45 - 55
steering track rods M 12 x 1.5 70 - 85
M 14 x 1.5 140 - 160
M 24 x 1.5 250 - 280
M 30 x 1.5 450 - 500
Others:
– Coolant hose clamps 4
– Wheel nuts M 22 x 1.5 32 650
– Rim connection bolts Aluminium rims with 20 nuts 550
(only for aluminium rims)
Aluminium rims with 22 nuts 385
– Retaining bolts for the slewing
M 27 41 — 1,150
bearing
– Hoist drum rope clamp M 14 2 nuts 78
09.03.2018

GMK5200-1
11
11.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 1
11.2 Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 1
11.3 Spare parts for the carrier. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 5
11.4 Spare parts for the superstructure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 8

09.03.2018

GMK5200-1
09.03.2018

GMK5200-1
Spare parts required for maintenance
11.1 General information
11.1 General information

The spare parts required for maintenance are divided into
– lighting,
– spare parts for the carrier and
– spare parts for the superstructure.
The only spare parts listed here are those required for the maintenance
work described.
A more detailed spare parts document can be found in the Spare parts list
supplied.
An overview of the required lubricants can be found in:

– Lubricants list, p. 6 - 2,
– Lubricant applications list, p. 6 - 3.
11.2 Lighting
Lamps are listed according to the installation point. The list includes stand-
ard and additional lighting equipment for the truck crane.
Lighting specific to certain countries can be found in the accompanying

Spare parts list, in the section on country-specific packages.
G
Risk of accidents from exploding glass bodies and high voltage.
The glass bodies of gas discharge lamps (xenon lights) are pressurised. If
the lamp breaks, the glass splinters explosively and shards scatter.
Xenon lights operate at high voltage. While changing the lamp, there is still
a danger of residual voltage discharging (electric shock) even when the bat-
tery master switch is switched off.
Have faulty lamps replaced only by properly qualified personnel who use
the relevant protective equipment.
s
09.03.2018

GMK5200-1
11.2 Lighting
Installation point GROVE part Designation Power (W)

number
CARRIER LIGHTING:
Front spotlights:
(integrated in the bumper)
– Daytime driving light (left) 04163680 LED
– Daytime driving light (right) 04163679 LED
– Low-beam + full-beam headlights 03134828 H7 24V 70
– Low-beam + full-beam headlights (USA) 03143584 H9 12V 65
– Indicator light 03327578 PY21W 24V 21
– Parking light (in direction indicator light) 03140908 LED
– Yellow side marker light 03320937 LED
Front, side indicator lights:
(under the access ladder to the driver's cab)
– Indicator light 04163927 LED
Tail lights:
(at the rear of the chassis)
– Marker light 03137450 R5W 24V 5
– Number plate light 03137450 R5W 24V 5
– Rear light 03137450 R5W 24V 5
– Brake light 03328445 P21W 24V 21
– Indicator light 03137451 PY21W 24V 21
– Fog tail light 03328445 P21W 24V 21
– Reverse light 03328445 P21W 24V 21
Licence plate lamp, external:
– LED licence plate lamp 04163112 LED
Yellow side marker lights:
(at the sides, along the chassis)
– Side marker light 03140042 LED
White rear marker lights:
– Left marker light 04164499 LED
09.03.2018
– Right marker light 04164500 LED

GMK5200-1
11.2 Lighting

number
Red triple light strip for USA:
– Triple light strip 7581100056 LED
White front marker lights:
(at the top on the driver's cab)
– Marker light 03138527 LED
Yellow additional lighting for the USA:
(at the top on the driver's cab)
– Yellow side marker light 03320937 LED
Outrigger beam spotlights:
(above the front and rear outrigger beams)
– LED spotlight; complete 03143786 M 70 LED
– Filament lamp
02316460 8GH002090-251 70
(for a non-LED spotlight)
Yellow rotating beacon:
(on the driver's cab)
– Rotating beacon; complete 04156048
Inside light:
(in the driver's cab)
– Cab light 01207144 R10W 10
– Reading light 00439055 P25-1 21
Dashboard light:
(in the driver's cab; socket 12 V)
– Filament lamp 04159964 Xenon 12 V / 6 W
09.03.2018
s
GMK5200-1
11.2 Lighting

number
SUPERSTRUCTURE LIGHTING:
Yellow marker lights:

(left and right on the main boom head)
– Marker light; complete 03329569 LED
Red rear marker lights:
(on the turntable)
– Marker light; complete 03329492 LED
Yellow rotating beacon:
(on the turntable)
– Rotating beacon; complete 04156048
Inside light:
(in the crane cab)
– Cab light 01207144 R10W 10
– Reading light 00439055 P25-1 21
Spotlight, angular-shaped, permanently installed:
(at the front of the crane cab)
– Filament lamp 01573349 H3 24V 70
Spotlight, electrically adjustable:
(at the front of the main boom)
– Halogen bulb 03142726 8GS009028001 35
09.03.2018

GMK5200-1
11.3 Spare parts for the carrier
Quantity, in single parts

Assemblies and spare parts GROVE part For maintenance interval
Carrier number
W M1 M3 M6 M 12
Engine
Valve M 20 x 1.5 03041579
Once when the oil is changed
Gasket 20 x 24 Cu DIN 7603 00117139 the first time;
Valve M 26 x 1.5 03046878 recommended modification from
oil drain plug to valve
Gasket 26 x 31 Cu DIN 7603 00117147
Air filter – main filter 04161948
1 item when the symbol lights up
Air filter – back-up filter 04161949
Fuel system
Filter (filter 1; large) 04161567 1
Filter (filter 2; small) 04161566 1
Set of both filters (filter 1 + 2) 04180966 alternatively
Transmission – VIAB
Gasket 24 x 29 Cu DIN 7603 00117145 1
Transmission
Gasket 24 x 29 Cu DIN 7603 00117145 1
Transfer case
Gasket 30 x 36 Cu DIN 7603 00117151 1 1
Gasket 16 x 20 Cu DIN 7603 00117134 1
Angle gear
Gasket 30 x 36 Cu DIN 7603 00117151 1 1
Filter 03135866 1
Axle lines axle centre drive (for max. 10 x 8 x 10)
Gasket 30 x 36 Cu DIN 7603 00117151 4 4
Gasket 24 x 29 Cu DIN 7603 00117145 2
Gasket 36 x 42 Cu DIN 7603 01371208 4
Axle lines Final drive (for max. 10 x 8 x 10)
Gasket 24 x 29 Cu DIN 7603 00117145 8 8
09.03.2018
s
GMK5200-1

Carrier number
W M1 M3 M6 M 12
Wheels
Wheel nuts for steel rims 01207756 in case of damage;
Wheel nuts for aluminium rims 7659100000 12 each per wheel
Vehicle brake (for all 5 axle lines)
Wear contact set 03142924 12
Set of brake pads with a wear contact
03142923 12
set only if wear is present
Guide set and seals set 03142922 on the disc brakes 24
Brake disc 03142916 10
Suspension
Ventilation filter 03324588 1 only if blocked
Valve (if defective) 01570750 (8)
Gasket 22 x 27 Cu DIN 7603 00117142 (8)
Filter cartridge with gasket 04157844 1
Hydraulic system
Filters 1 and 2 (only clean) 03329152 (2)
Filters 1 and 2 03329152 2
Packing set 03135778 at every oil change 2
Filters 3 and 4 03135866 and when the symbol lights up 2
Oil tank cover gasket 140 / 90 x 3 1 item for every oil change
02313899
(if damaged)
Ventilation filter 03324588 1
Driver's cab pollen filter 03134974 1
Driver's cab wiper blades 02311858 (3) (if damaged)
09.03.2018

GMK5200-1

Carrier number
Y2 Y3 Y5 Y6 Y 10
Engine
Oil filter 04161614 1
Gasket for oil drain plug 04161531 1
Transmission – VIAB
Gasket 24 x 29 Cu DIN 7603 00117145 3
Gasket 14 x 18 Cu DIN 7603 00117131 1
Filter exchange kit 04163770 1
Vent valve filter 04163771 1
Cover gasket filter 04163772 1
Transmission
Filter 03328342 1
Spring 03328343 1
Gasket 03328344 1
Gasket 24 x 29 Cu DIN 7603 00117145 1
09.03.2018

GMK5200-1
11.4 Spare parts for the superstructure

Superstructure number
W M1 M3 M6 M 12
Hoists
Sight glass with hoses; complete 04161717 (2) (if damaged) (2)
Slewing gear
Gasket 10 x 14 Cu DIN 7603 00117125 (3) (if damaged)
Gasket 10 x 14 Cu DIN 7603 00117125 3
Gasket 14 x 20 Cu DIN 7603 00117132 3
Hydraulic system
Filter 1 (only clean) 04156358 (1)
Packing set 04165792 (1)
Filter 1 04156358 1
at every oil change
Filter 2 03142356 1
and when the symbol lights up
Housing packing set 03326049 1
Filter 3 03249527 1
Ventilation filter 03134932 1
Hoist ropes
Cover gasket 1 (if damaged)
02315305
for every rope change on the hoist
Cable drums
Cover gasket for cable drum 1 03325575 (1)
(if damaged)
Cover gasket for cable drum 2 03138894 (1)
Pollen filter for crane cab 04163620 1
Windscreen wiper blade 03268512 (1)
(if damaged)
Roof wiper blade 03326121 (1)
09.03.2018

GMK5200-1
Assemblies and spare parts GROVE part Quantity, in single parts

Superstructure number For maintenance interval
Y2 Y3 Y5 Y6 Y 10
Electrical system
Lithium battery 3.6 V 03143172 1
09.03.2018

GMK5200-1
Blank page
09.03.2018

GMK5200-1
Appendix
09.03.2018

GMK5200-1
09.03.2018

GMK5200-1
Appendix
Table to determine the remaining theoretical service life on winch no. ..........
Crane type: ........................

Work no.: ........................
First put into operation on: ........................
Winch serial number in accordance with the model plate: ........................
Engine group: ........................
Load spectrum: ........................
Load spectrum factor: ........................
Theoretical service life: ........................
Inspec- Date of first Operating Factor of Crane Super- Superstruc- Winch oper- Winch operat- Used proportion Remaining Name of the Signature Comment Name of Signature
tion inter- commission- conditions the load operating structure ture operat- ating hours ing hours of theoretical theoretical expert the
val no. ing/date of since the spectrum hours operating ing hours since the last service life D: service life approved
(max. inspection last inspec- (complete) hours since the last inspection inspector
1 year) tion inspection
Di = Di-1 - Si
”i” Kmi [h] [h] [h] [h] [h] [h] [h]

(*)
IMPORTANT:
A general overhaul must be performed every 10 years.
Si = Used proportion of theoretical service life since the last inspection
For alternative provision, refer to section 5.4.2, p. 5 - 25.
Di = Remaining theoretical service life
General overhaul performed on.................................. This factor is given in the operating manual.
Table to determine the remaining theoretical service life on winch no. ..........
Crane type: ........................

Work no.: ........................
First put into operation on: ........................
Winch serial number in accordance with the model plate: ........................
Engine group: ........................
Load spectrum: ........................
Load spectrum factor: ........................
Theoretical service life: ........................
Inspec- Date of first Operating Factor of Crane Super- Superstruc- Winch oper- Winch operat- Used proportion Remaining Name of the Signature Comment Name of Signature
tion inter- commission- conditions the load operating structure ture operat- ating hours ing hours of theoretical theoretical expert the
val no. ing/date of since the spectrum hours operating ing hours since the last service life D: service life approved
(max. inspection last inspec- (complete) hours since the last inspection inspector
1 year) tion inspection
Di = Di-1 - Si
”i” Kmi [h] [h] [h] [h] [h] [h] [h]
IMPORTANT:
A general overhaul must be performed every 10 years.
Si = Used proportion of theoretical service life since the last inspection
For alternative provision, refer to section 5.4.2, p. 5 - 25. Di = Remaining theoretical service life
General overhaul performed on.................................. This factor is given in the operating manual.
Tilting play measurement report
• Always measure the current tilting play as described in section Measuring tilting play, p. 8 - 28.
Base value: ............... mm

Max. permissible wear: + 4.0 mm
Max. permissible tilting play: ............... mm
Date Current tilting play Ball slewing bearing Signature

–135° (A) –45° (B) +45° (C) +135° (D) OK defective replaced on
Tilting play measurement report
• Always measure the current tilting play as described in section Measuring tilting play, p. 8 - 28.
Base value: ............... mm

Max. permissible wear: + 4.0 mm
Max. permissible tilting play: ............... mm
Date Current tilting play Ball slewing bearing Signature

–135° (A) –45° (B) +45° (C) +135° (D) OK defective replaced on

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Maintenance manual

Any type of duplication or excerpt from this

Manitowoc Crane Group Germany GmbH

Fax: [+49] (0) 44 21 294-301

3 302 746 en Maintenance manual

This maintenance manual does not replace the operating manual.

Details of operation and standard safety instructions can be found

Maintenance manual 3 302 746 en

3 302 746 en Maintenance manual

1.2 Warnings and symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1

1.3 Maintenance instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 2

1.4 Instructions regarding the electronic control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 4

1.5 Safety instructions for welding work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 4

1.6 Definition of direction references. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 5

1.7 Conversion table for US measuring units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 6

Maintenance manual 3 302 746 en

3 302 746 en Maintenance manual

1.1 Instructions for using the maintenance manual

Please read chapters 1 and 2 carefully before beginning maintenance work.

1.2 Warnings and symbols

1.3 Maintenance instructions

Repair work also requires:

1-2 3 302 746 en Maintenance manual

A few general maintenance instructions:

Maintenance manual 3 302 746 en 1-3

• Cleanliness is imperative when handling grease for the central lubrication

1.4 Instructions regarding the electronic control

1.5 Safety instructions for welding work

1-4 3 302 746 en Maintenance manual

1.6 Definition of direction references

The driver's cab is always at the front, which means that:

Forwards always means with the driver's cab leading,

Down: If (1) press – next to the symbol

Maintenance manual 3 302 746 en 1-5

1.7 Conversion table for US measuring units

Converting from into Multiply by

1-6 3 302 746 en Maintenance manual

2.3 Disposal of the truck crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 6

Maintenance manual 3 302 746 en

3 302 746 en Maintenance manual

2 Safety and environmental protection

2.1 Safety rules

• Familiarise yourself with the truck crane and its operation.

Maintenance manual 3 302 746 en 2-1

• Do not allow hot fluids to escape in an uncontrolled manner. Risk of scald-

2-2 3 302 746 en Maintenance manual

2.1.1 Securing against unauthorised use

• Secure the truck crane against unauthorised use by:

Maintenance manual 3 302 746 en 2-3

2.2 Handling substances which are harmful to the

• When handling these substances observe the applicable national and

The approximate amount of consumables to be expected is specified in the

2-4 3 302 746 en Maintenance manual

Maintenance manual 3 302 746 en 2-5

2.3 Disposal of the truck crane

2-6 3 302 746 en Maintenance manual

Maintenance manual 3 302 746 en

3 302 746 en Maintenance manual

• After cleaning with high-pressure or a steam jet equipment, activate inter-