Manitowoc Grove GMK 4100L-1 User manual

Maintenance manual
3 302 364 en
25.11.2016

25.11.2016
3 302 364 en Maintenance manual
GMK 4100L-1
© Copyright reserved by
Manitowoc Crane Group Germany GmbH
Industriegelände West
D-26389 Wilhelmshaven, Germany
Tel: [+49] (0)44 21 294-0
Fax: +[49] (0) 44 21 294-301
The passing on or reproduction 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.
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.

Additional pages for maintenance manual 3 302 584 en 1
GMK 4100L-1
24.04.2017
1Additional maintenance work on the main boom
Maintenance
personnel
The maintenance work on the telescoping cylinder described here (clean,
check, lubricate) can be performed by the local maintenance personnel.
Customer service
engineers
If the local maintenance personnel discover any damage then trained
customer service engineers from Manitowoc Crane Care or an authorised
GROVE dealer must be requested to perform repairs on the telescoping
cylinder and check the entire locking system; àNote – Having the telescoping
cylinder repaired, p. 1 - 9.
1.1 Maintenance plan
1.1.1 Maintenance plan M 12
M 12
Maintenance work on the SUPERSTRUCTURE:
Every twelve months / after 1 000 oper. hrs.
Main boom
– Check/lubricate the telescoping cylinder àp. 1 - 3

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GMK 4100L-1
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Additional pages for maintenance manual 3 302 584 en 3
GMK 4100L-1
24.04.2017
1.2 Main boom
1.2.1 Check/lubricate the telescoping cylinder
•Consult the Maintenance manual supplied for information on prerequisites,
and observe the safety instructions outlined in Chapter Main boom.
•Familiarise yourself with the slinging points for personal safety
equipment on the GMK 4100L-1 truck crane; àOperating manual.
Grease, Tools
–Brush.
– Feeler gauge.
Prerequisites – The truck crane must be level.
– 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 telescope status that satisfies the
lifting capacity table necessary for maintenance; àLifting capacity table;
Section Telescoping sequences for lubricating the main boom.
– The RCL code for the current rigging mode must be entered.
– Personal safety equipment to secure you from falling is used;
àOperating manual.
s
M 12
Designation GROVE part no.
PAL1 lubricant paste, 25 kg bucket 02314698

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GMK 4100L-1
Extending
•Telescope the telescopic section Ito 50% and
mechanically lock the telescopic section Iin
the basic section; àOperating manual.
•Pull out the telescoping cylinder (4) towards
the rear; àOperating manual.
•Switch the engine off and secure against
unauthorised use of the truck crane.
•Secure yourself to prevent yourself from
falling.
•Remove the lid (1) – the pressure accumula-
tor (2) and head (3) of the telescoping cylin-
der (4) are now accessible.
Checking the
pressure
accumulator
The pressure accumulator (1) is located on the
telescoping cylinder.
Filling pressure at 20 °C (68 °F) – 10 bar
(145 psi).
Tolerances:
•Have the filling pressure checked and if
necessary corrected by Manitowoc Crane
Care or an authorised GROVE dealer.
GRisk 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.
Maximum value: 10 bar (145 psi)
Minimum value: 9 bar (131 psi)

Additional pages for maintenance manual 3 302 584 en 5
GMK 4100L-1
24.04.2017
Head – variants Two different variants of the head can be fitted depending on the truck crane
equipment.
•Check whether type (A) or type (B) is
installed on your truck crane.
Check/lubricate
the head
Disconnect the locking cylinder
•Pull out the pin (2) and disconnect the
locking cylinder (1) from the connecting
link (3).
This allows the connecting link (3) to be
manually moved to both end positions.
s
Type (A) – The connecting link (1) slides on
the head (2) on metal surfaces.
Type (B) – The connecting link (1) slides on
the head (2) over six plastic wear
pads (3).

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GMK 4100L-1
Cleaning
•Clean the head (3) with a clean cloth.
•Clean the running surfaces of the
connecting link (1) and the guides and joints
of the lever (2).
•Check all moving parts and running paths
for damage.
•Check the sensor electrical connectors for
damage.
•Manually push the connecting link (1)
multiple times to both end positions. The
movement must be soft and free. The stroke
of the connecting link must be 44 mm
(1.7 in) .
Check the tappet
•Check the tappet (1) for wear.
•Manually press the tappet (1) down against
the spring force.
•Release the tappet (1) – the spring force
must return the tappet to the end position.
The stroke of the tappet must be 8 mm
(0.3 in) .

Additional pages for maintenance manual 3 302 584 en 7
GMK 4100L-1
24.04.2017
Checking the gap dimensions
•Check the gap dimensions at measuring
points (1) and (2) using a feeler gauge (3).
If the gap dimensions are too large or too small
•Have the head repaired by Manitowoc Crane Care or an authorised
GROVE dealer; àNote – Having the telescoping cylinder repaired, p. 1 - 9.
If the gap dimensions are correct
Lubricate the head
•Lubricate the running surfaces of the
head (3), the connecting link (1) and the
guides and joints of the lever (2) using a
brush (PAL 1 lubricant paste).
•Manually push the connecting link (1)
multiple times to both end positions to
distribute the lubricant paste. The
movement must be soft and free.
s
Head Measuring point
(1)
Measuring point
(2)
Type (A)
1.3 mm
up to 2.2 mm
(0.05 in
to 0.08 in)
0.3 mm
up to 1.2 mm
(0.01 in
to 0.05 in)
Type (B)
0.15 mm
up to 0.25 mm
(0.006 in
to 0.010 in)
0.15 mm
up to 0.25 mm
(0.006 in
to 0.010 in)

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GMK 4100L-1
Connecting the locking cylinder
•Reconnect the locking cylinder (1) to the
connecting link (3) and fasten it with the
pin (2).
Retracting
•Secure yourself to prevent yourself from
falling.
•Fasten the lid (1).
•Start the engine.
•Retract the telescopic section Ito 0% and
mechanically lock the telescopic section Iin
the basic section; àOperating manual.
Testing the
telescoping
cylinder
•Telescope all telescopic sections into different positions one after another
to check for correct operation of the telescoping cylinder; àOperating
manual.
•You will need to put the truck crane out of service if malfunctions occur in
the telescoping system.
•Have any damage repaired immediately by Manitowoc Crane Care or an
authorised GROVE dealer.

Additional pages for maintenance manual 3 302 584 en 9
GMK 4100L-1
24.04.2017
1.2.2 Note – Having the telescoping cylinder repaired
The supplied maintenance manual GMK 4100L-1 already specifies that you
must have the locking system on the main boom inspected annually (M12)
by Manitowoc Crane Care or an authorised GROVE dealer.
Especially the head of the telescoping cylinder is checked and adjusted
during this annual maintenance work. Components can be replaced if
necessary. The gap dimensions are corrected with shims if necessary.
Conversion from head type (A) to type (B) is possible after consultation with
Manitowoc Crane Care; àHead – variants, p. 1 - 5.

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Correction sheet for maintenance manual 3 302 668 en 1
GMK4100L-1/5150/5150L
04.10.2017
1Transmission – shorter maintenance intervals
1.1 Engine-transmission unit – overview
GMK4100L-1,
GMK5150,
GMK5150L
Engine-transmission unit
– Diesel engine type OM 470 (1),
– Transmission (2),
– Water retarder SWR (3);
are the rear of the transmission (additional
equipment);
SWR = Secondary Water Retarder.
Transmission
The automatic transmission has 16 speeds
and the type designation G 280-16.
(A) transmission with Water Retarder SWR
(B) transmission without Water Retarder SWR
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04.10.2017
2 3 302 668 en Correction sheet for maintenance manual
GMK4100L-1/5150/5150L
1.2 Shorter maintenance intervals
Maintenance
information
•Perform the maintenance work as described in the maintenance manual
supplied.
•Also observe the shorter maintenance intervals;
àTransmission oil change,
àReplace coolant.
1.2.1 Transmission oil change
•Change the oil every three years (Y 3).
1.2.2 Replace coolant
In the engine manufacturer's documentation supplied, it is recommended
to replace the coolant in the radiator circuit of the diesel engine every three
years (Y3); àEngine manufacturer's documentation.
If a transmission with Water Retarder SWR is present, you must replace
the coolant after two years (Y 2).
Transmission
with SWR
•Replace the coolant every two years (Y 2).
Transmission
without SWR
•Replace the coolant every three years (Y 3).
Y 3
Y 2/3

Additional page 3 302 704 en 1
GMK truck cranes
11.01.2018
Depending on the type of truck crane, a slewing angle sensor of type (A) or
(B) can be installed on the slewing bearing.
Version (A)
For this version, the specifications in the supplied maintenance manual apply.
Version (B)
Deviating from the specifications in the maintenance manual supplied,
this version of the slewing angle sensor is maintenance-free.
Only use the telephone number 04160234 if in need of spare parts.
Slewing angle sensor
Version (A) and (B)

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GMK truck cranes
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Additional pages for maintenance manual 3 302 809 en 1
GMK truck cranes
03.09.2018
1Additional maintenance work
on the rope attachment point
Depending on the equipment of the truck crane, a rope attachment point (1)
can be fitted between the lower sheaves on the main boom head.
•Check on both sides whether the rope attachment point (1) is equipped
with a grease nipple (2).
1.1 Main boom
1.1.1 Lubricating the rope attachment point
Grease, tools
– Grease gun from the tool set; supplied ladder.
Prerequisites – The main boom must be completely retracted and lowered into horizontal
position.
– The hook block must be unreeved.
– The engine must not be running and must be secured against unauthor-
ised use.
Lubrication
•Lubricate the rope attachment point (1) on
the grease nipple (2) with the grease gun
every three months (M3).
•Check whether the rope attachment point (1)
on the axle can be freely rotated.
If you discover any damage
•Have the defective rope attachment point re-
placed by Manitowoc Crane Care or an au-
thorised GROVE dealer.
M 3
Lubricating
grease
Designation
to DIN 51502
Specifications
Classification
GROVE part no.
Grease KP - 1K - 50 DIN 51825 03233369

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GMK truck cranes
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25.11.2016
Maintenance manual 3 302 364 en
GMK 4100L-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.

25.11.2016
3 302 364 en Maintenance manual
GMK 4100L-1
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