Grove GMK 3050-1 User manual

Serial number
Maintenance manual
3 112 246 en
31.05.2011
63009129

31.05.2011
Important note
Duplications of any kind and excerpts from this
document are not subject to the revision service.
Original documents of Deutsche GROVE GmbH
are marked with the blue serial number of the
truck crane on the cover sheet.
Duplications and printouts from data carriers on
which Deutsche GROVE GmbH has delivered this
document are also not subject to the revision
service.
© Copyright reserved by Deutsche GROVE GmbH
Dissemination or duplication of this document as well as utilisation and disclosure of its contents are prohibited unless
expressly permitted. Infringement will incur liability for compensation. All rights pertaining to registration of patent or utility
model are reserved.
3 112 246 en Maintenance manual
GMK 6300
63009129

Correction sheet 3 112 249 en 1
GMK truck cranes
12.09.2007
Additional page for maintenance manuals
Topping up oil on the suspension strut
Validity This additional page applies to the truck cranes:
GMK 3050-1, GMK 3055,
GMK 4080-1, GMK 4100, GMK 4100-L,
GMK 5100, GMK 5130-1, GMK 5220,
GMK 6220-L, GMK 6300,
GMK 7450
and is part of the maintenance manual supplied in each case.
Reason for the
modification
Effective immediately, all suspension struts for topping up oil are equipped
with the same connection from the factory. Each truck crane is standardly
equipped with a press and a hose (in the tool box). This press with hose
must be connected sequentially to each suspension strut for topping up if
the oil level on the inspection glass of the relevant suspension strut is too
low.
Maintenance
plan M1
The oil level on the inspection glass should be checked monthly.
You can find the monthly maintenance plan M1 in chapter 5 of the
maintenance manual included in the delivery:
Maintenance work on the CARRIER:
monthly / after ca. 2000 km (approx. 1240 mi)
Lubricant:
– Suspension struts – check oil level; àp. 2.
Oil filling quantity per
suspension strut:
approx. 1.5 litres
(approx. 0.4 gal);
GROVE part no. 02310863.
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12.09.2007
2 3 112 249 en Correction sheet
GMK truck cranes
Suspension struts – check oil level
Spare parts and
tools
– Press with connected hose (from tool box)
Prerequisites – The engine is not running and is secured against unauthorised use.
– Immediately before the inspection, the truck crane was completely
lowered and returned to On-road level; àOperating Instructions.
Checking the
oil level
Use only oil as specified in the maintenance plan M1; àp. 1.
•Check whether oil is visible in the middle of
the inspection glass (1) on each suspension
strut.
If the oil level is too low:
•Open the connection (2) – oil escapes – and
quickly connect the press with hose.
•Inject oil up the centre of the inspection
glass.
•Remove the hose and quickly close the
connection (2).
SRisk of damage due to faulty suspension struts
If the oil level is above the upper marking on the inspection glass the
suspension strut is faulty and must be replaced.
Notify an authorised GROVE dealer or CraneCARE.
SRisk 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.
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Additional pages for maintenance manual 3 112 545 en 1
29.07.2008
Additional maintenance work
Cardan shaft between motor and transfer case
Validity Mobile cranes with 5, 6 and 7 axle lines are affected.
These additional pages are a supplement to the maintenance manual for the
truck cranes
GMK 5100, GMK 5130-1, GMK 5220,
GMK 6220-L, GMK 6300
and are part of the maintenance manual supplied in each case.
For the mobile cranes GMK 5095, GMK 5110-1, GMK 5130-2, GMK 5170,
GMK 7450, this additional maintenance work is adopted directly in the
maintenance plan Y 5 of the maintenance manual included in the delivery.
Maintenance
plan Y 5
This maintenance plan is a supplement to the maintenance plan in chapter 5
of the maintenance manual included in the delivery:
Installation point The illustration shows the installation point of the cardan shaft (2) using the
example of a mobile crane with five axle lines.
s
Maintenance work on the CARRIER:
Every 60 months/100 000 km (62 000 mi)
– Have the cardan shaft between the engine and the transfer case replaced by CraneCARE or an
authorised GROVE dealer.
1 Engine
2 Cardan shaft
3 Transfer case
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29.07.2008
2 3 112 545 en Additional pages for maintenance manual
Spare parts
Mobile crane GROVE part number of the cardan shaft
GMK 5095 03317189
GMK 5100 03317189
GMK 5110-1 03157350
GMK 5130-1 03317189
GMK 5130-2 03317189
GMK 5170 03121278
GMK 5220 03121278
GMK 6220-L 03327413
GMK 6300 03327413
GMK 7450 7810100123
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Additional pages GMK truck cranes 3 112 676 en 1
17.02.2010
Additional maintenance work on the main boom
Validity These additional pages hold for all GMK truck cranes and supplement the
supplied maintenance manuals.
Reason
All the lubricating work for the heavily loaded slide faces on the telescopic
sections of the main boom is described in the relevant supplied mainte-
nance manual.
The heavily loaded slide faces are located on the lower outside slide
faces (2) and the upper inside slide faces (3) of the telescopic sections.
In addition, you must also lubricate the unpainted upper outside faces (1).
The factory-applied film of lubricant can be washed off in the extended
state. Therefore, you must lubricate the upper outside faces of all telescopic
sections to prevent corrosion.
Interval •Lubricate the upper outside faces every three months (M3).
Grease •Apply the grease with a brush or roller.
(Lubricant paste PAL 1, 25 kg bucket, GROVE part no. 02314698).
Lubricating
•Find out about all lubricating points on all telescopic sections in the rele-
vant supplied maintenance manual.
•Always lubricate the upper outside faces (1) before the lower outside slide
faces (2).
•Continue the maintenance work as described in the relevant supplied
maintenance manual.
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17.02.2010
2 3 112 676 en Additional pages GMK truck cranes
Blank page
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Maintenance manual 3 112 246 en
GMK 6300
31.05.2011
The Maintenance manual contains the following
chapters:
a
1 General instructions
2 Safety and environmental protection
3Cleaning
4 Run-in regulations
5 Maintenance overview
6 Lubricants and consumables
7 Description of maintenance work on the carrier
8 Description of maintenance work on the
superstructure
9 Longer periods out of service
10 Tightening torques
Appendix
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3 112 246 en Maintenance manual
GMK 6300
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Blank page
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Maintenance manual 3 112 246 en
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31.05.2011
1
1 General instructions
1.1 Using the maintenance manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1
1.2 Warnings and symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1
1.3 Maintenance instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 3
1.4 Definition of positional references. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 5
1.5 Conversion table for US measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 6
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3 112 246 en Maintenance manual
GMK 6300
31.05.2011
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General instructions
1.1 Using the maintenance manual
Maintenance manual 3 112 246 en 1 - 1
GMK 6300
31.05.2011
1General instructions
1.1 Using the maintenance manual
This manual is not designed to replace proper training and instruction.
Truck crane maintenance personnel must have the relevant, specialist
knowledge of proper safety procedures.
Please read chapters 1 and 2 carefully before beginning maintenance work.
HMaintenance work on the lattice extensions is described in the Operating
instructions lattice extension GMK 6300.
1.2 Warnings and symbols
The following definitions and symbols are used in the operating instruc-
tions to highlight particularly important information:
The vertical line to the left of the text indicates that this text, regardless of
its length, relates to the warning symbol.
s
GThis symbol indicates hazards related to the described operation that may
cause personal injury. The type of hazard (e.g. life-threatening, personal
injury, risk of crushing or electrocution) generally precedes the warning
sign.
SHere dangers which could put objects at risk are pointed out, e.g. damage
to the truck crane or the load.
OThis symbol reminds 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 the
Section àHandling substances which are harmful to the environment, p. 2 - 3.
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General instructions
1.2 Warnings and symbols
1 - 2 3 112 246 en Maintenance manual
GMK 6300
31.05.2011
HThe hand with the pointing finger indicates passages that contain additional
instructions and tips regarding truck crane operation.
sThis symbol indicates that the topic is continued on the next page. Turn to
the next page.
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General instructions
1.3 Maintenance instructions
Maintenance manual 3 112 246 en 1 - 3
GMK 6300
31.05.2011
1.3 Maintenance instructions
This maintenance manual is intended for maintenance personnel. The
maintenance manual does not contain information on repair work. Repair
work may only be carried out by qualified repair personnel (e.g. CraneCARE).
Repair work also requires:
– appropriate workshop equipment
– special tools and
spare parts authorised by Deutsche GROVE GmbH.
It is your responsibility to maintain and service the truck crane regularly in
order to lengthen its service life and keep it in good working order.
Please note that Deutsche GROVE GmbH can only uphold the warranty pro-
vided for the truck crane if the following conditions are met:
– it is used for the purpose for which it was intended
– care and maintenance is carried out as prescribed
– repair work / overhauling is carried out by professionals
Many defects and failures are caused by improper maintenance such as:
– insufficient oil, grease or antifreeze
–dirt
– rope damage
– defective compressed air and hydraulic systems
– hose damage or loose screw connections
– defective brakes
– defective tyres or wheel rims
– exceeded maintenance intervals
For your safety and the safety of others, avoid these errors by carrying out
maintenance work carefully within the specified intervals. Do not put off
maintenance work that is due. Notify CraneCARE or your repair crew imme-
diately should repair work become necessary. This work may only be car-
ried out by trained, qualified personnel.
s
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General instructions
1.3 Maintenance instructions
1 - 4 3 112 246 en Maintenance manual
GMK 6300
31.05.2011
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 drain
opening, and the lubricating nipples.
•When changing the oil, let the oil run out at operating temperature.
•Ensure that only oils and lubricants specified in the Lubrication chart, Chap-
ter 6, are used.
•Replace all filters within the specified period if cleaning is not explicitly
permitted.
•Replace all seals before assembly. Clean the sealing surfaces.
•Only tighten loose screw connections on hydraulic systems when the sys-
tem is depressurised.
•Keep brake and clutch linings free of grease.
•Replace hydraulic hoses immediately once damage or penetration of
moisture becomes visible.
•When handling hydraulic oil, cleanliness is imperative. Even new hydrau-
lic oil must be filtered.
•Check fastening and retaining elements (bolts, nuts, lock washers) before
re-using them and replace them if necessary.
Tightening torques may be found in the Sections 10 and 10.
Our training centre at our plant in D-26389 Wilhelmshaven offers special-
ised training programmes. Ask your local CraneCARE about this.
The vehicle must fulfil all current regulations before being put into opera-
tion and driven on public roads.
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General instructions
1.4 Definition of positional references
Maintenance manual 3 112 246 en 1 - 5
GMK 6300
31.05.2011
1.4 Definition of positional references
This section defines several terms which are used in the descriptions of the
operating elements in these operating instructions.
Basic rule Forwards always means the driver's cab is to the front of the direction of
travel, backwards always means the rear lights on the carrier are to the front
of the direction of travel.
Front, rear, right and left relate to the position of the carrier from the driver's
cab. The driver's cab is always at the front. This also applies when these
terms are used to describe the control levers in the driver's cab.
In the crane cab, front, rear, right and left relate to the position of the super-
structure. The front is always in the direction of the main boom head. This
also applies when these terms are used to describe the control levers in the
crane cab.
Buttons and
switches
Switches and buttons on the instrument panels are always pressed up or
down. In the illustrations of switches and buttons this means:
This applies whether the switch is installed horizontally, vertically or at an
angle. Up and down always refers to the way the switch or button is illus-
trated in these operating instructions.
Up: press (1)
Down: press (2)
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General instructions
1.5 Conversion table for US measurements
1 - 6 3 112 246 en Maintenance manual
GMK 6300
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1.5 Conversion table for US measurements
The following conversion factors will help you convert from metric to
US units and vice versa when the truck crane is being used in countries that
use US units of measurement.
Converting from to Multiply by
mm inches 0.03937
inches 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 0.004882
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Maintenance manual 3 112 246 en
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2
2 Safety and environmental protection
2.1 Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 1
2.2 Handling substances which are harmful to the environment. . . . . . . . . . . . . . . . 2 - 3
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