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Manitowoc Grove GMK 5200-1

Manitowoc Grove GMK 5200-1
346 pages
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Maintenance manual
3 302 746 en
09.03.2018

Table of Contents

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Manitowoc Grove GMK 5200-1 Specifications

General IconGeneral
Maximum Lift Capacity200 t
Number of Axles5
Maximum Capacity200 t
Boom Length60 meters
Maximum Tip Height101 meters
Engine Power405 kW
Main Boom Length60 meters
Luffing Jib Length37 meters
EngineMercedes-Benz OM 502 LA
Carrier Width2.75 meters
Carrier Height4 meters

Summary

General Instructions for Grove GMK5200-1 Maintenance

Instructions for Using the Maintenance Manual

Guidance on how to effectively use the maintenance manual for proper operation and upkeep.

Warnings and Symbols in Maintenance Procedures

Explains hazard symbols and designations used to highlight critical safety information and potential dangers.

Key Maintenance Instructions and Requirements

Provides essential guidelines and requirements for maintenance personnel to ensure proper upkeep of the truck crane.

Safety Instructions for Welding Work

Outlines safety measures and precautions to be taken before performing any welding operations on the equipment.

US Measuring Units Conversion Table

Provides conversion factors to switch between metric and US customary units for measurements.

Safety and Environmental Protection for Crane Operation

Essential Safety Rules for Crane Maintenance

Encompasses crucial safety regulations and rules to be observed during maintenance work to prevent accidents.

Handling Environmentally Hazardous Substances

Guidelines for safely handling, collecting, storing, and disposing of environmentally hazardous consumables.

Proper Disposal Procedures for the Truck Crane

Procedures and regulations for the proper, orderly, and final disposal and scrapping of the truck crane.

Cleaning Procedures and Assembly Care

Assemblies Easily Damaged During Cleaning

Identifies components of the truck crane that are particularly susceptible to damage during cleaning operations.

Run-In Regulations and Initial Maintenance

Run-In Regulations and Initial Maintenance Schedule

Outlines rules for running in new parts and specifies additional maintenance for carrier and superstructure after certain periods.

Comprehensive Maintenance Overview and Schedules

Maintenance Intervals Explained

Defines how maintenance intervals are determined based on time, mileage, operating hours, or system indicators.

Detailed Maintenance Plans (D, W, M, Y)

Lists various maintenance plans (D, W, M, Y) and directs to specific work descriptions for carrier and superstructure.

Periodic Inspections for Crane Condition Assessment

Details visual inspections required annually or by country regulations to assess crane condition and prevent issues.

Winch Monitoring Measures and Service Life Calculation

Explains methods for monitoring winch service life, including theoretical life, operating hours, and load spectrum.

Lubricants and Consumables for Crane Maintenance

Lubricants List and Specifications

Lists all required lubricants with serial numbers, their types, specifications, and applications.

Refrigerant Information for Air Conditioning

Provides information on the refrigerant used in air conditioning systems, including quantity and maintenance intervals.

Consumables: Fuel and Coolant Specifications

Lists various consumables such as fuel, engine coolant, and exhaust gas treatment fluids with their specifications.

Carrier Maintenance Procedures and Checks

General Instructions for Carrier Maintenance

Covers general guidelines for maintenance on the carrier, including cover removal and installation procedures.

Engine Maintenance and Checks

Details maintenance tasks for the engine, including oil checks, filter changes, and general inspections.

Transmission and VIAB System Maintenance

Details maintenance procedures for the transmission and VIAB system, including oil level checks and changes.

Wheel Inspection and Replacement Procedures

Covers inspection of tyres for damage, checking tyre pressure, and procedures for changing wheels.

Vehicle Brake System Maintenance and Checks

Outlines procedures for checking wear display, disc brakes, pads, and adjustment mechanisms for the vehicle's braking system.

Hydraulic System Maintenance and Oil Sampling

Details maintenance for the hydraulic system, including oil level checks, filter changes, and oil sampling.

Electrical System Checks and Battery Maintenance

Outlines checks for lighting, indicators, batteries, charging procedures, and external starting sockets.

Superstructure Maintenance Procedures and Checks

General Instructions for Superstructure Maintenance

Covers general guidelines for maintenance on the superstructure, including cover removal and installation procedures.

Hoist Maintenance Procedures and Safety

Details maintenance for hoists, including oil level checks, general inspection, brake checks, and oil changes.

Slewing Gear Maintenance and Inspection

Covers oil level checks, leak checks, and brake checks for the slewing gear system.

Slewing Bearing Screw Checks and Lubrication

Outlines procedures for checking screws and lubricating the slewing bearing and its components.

Superstructure Hydraulic System Maintenance

Details maintenance for the hydraulic system, including oil level checks, filter changes, and oil sampling.

Main Boom Lubrication and Locking System Checks

Provides instructions for greasing piston rods, lubricating telescopic sections, and checking the boom locking system.

Hoist Rope Inspection, Lubrication, and Replacement

Covers checking rope winding, condition, lubrication, and replacement procedures for hoist ropes.

Longer Out of Service Periods for the Truck Crane

Preparing the Truck Crane for Long-Term Storage

Provides instructions for preparing the truck crane for long-term storage and for putting it back into operation.

Torque Specifications for Crane Components

Torques for Retaining Bolts (Metric)

Lists guide values for maximum permissible pre-tensioning torques for various screw thread sizes and bolt qualities.

Special Torque Values for Specific Components

Provides specific torque values for various components such as suspension struts, steering linkage, and slewing bearing.

Spare Parts Required for Maintenance

General Information on Spare Parts

Divides spare parts into categories: lighting, carrier, and superstructure, and refers to detailed spare parts documents.

Lighting Equipment Spare Parts List

Lists lamps according to installation points, including part numbers, designations, and power ratings for carrier and superstructure.

Spare Parts List for the Carrier

Details required spare parts for the carrier, organized by assembly and maintenance interval.

Spare Parts List for the Superstructure

Lists required spare parts for the superstructure, organized by assembly and maintenance interval.

Appendix: Measurement Reports and Forms

Tilting Play Measurement Report

A report form to record measurements of tilting play for the slewing bearing at various intervals.

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