GROVE Published 10-21-2010, Control# 198-04 1-5
5540F/YB5515 SERVICE MANUAL
GENERAL MAINTENANCE
These general suggestions should be helpful in following the
instructions in this manual. In analyzing a system
malfunction, use a systematic approach to locate and correct
the problem.
NOTE: Your safety and that of others is always the number
one consideration when working around machines.
Safety is a matter of thoroughly understanding the
job to be done and the application of good common
sense. It is not just a matter of do’s and don’ts. Stay
clear of all moving parts.
1. Determine the problem.
2. List possible causes.
3. Devise checks.
4. Conduct checks in a logical order to determine the
cause.
5. Consider the remaining service life of components
against the cost of parts and labor necessary to replace
them.
6. Make the necessary repair.
7. Recheck to ensure that nothing has been overlooked.
8. Functionally test the failed part in its system.
Cleanliness
An important item in preserving the long life of the machine is
keeping dirt out of working parts. Enclosed compartments,
seals, and filters have been provided to keep the supply of
air, fuel, and lubricants clean. It is important that these
enclosures be maintained.
Whenever hydraulic, fuel, lubricating oil lines, or air lines are
disconnected, clean the adjacent area, as well as, the point
of connection. As soon as the disconnection is made, cap,
plug, or tape each line or opening to prevent entry of foreign
material. The same recommendations for cleaning and
covering apply when access covers or inspection plates are
removed.
Clean and inspect all parts. Be sure all passages and holes
are open. Cover all parts to keep them clean. Be sure parts
are clean when they are installed. Leave new parts in their
containers until ready for assembly.
Clean the rust preventive compound from all machined
surfaces of new parts before installing them.
After Cleaning
Remove all water or solvent from the parts immediately after
cleaning. Use compressed air or a clean cloth. Make sure
the parts are completely dry and clean. DO NOT use
compressed air on bearings. Spinning bearings without
lubricant will cause damage to the bearing, and could cause
the bearing to fly apart.
Removal and Installation
When performing maintenance, do not attempt to manually
lift heavy parts when hoisting equipment should be used.
Never locate or leave heavy parts in an unstable position.
When raising a crane or portion thereof, ensure the crane is
blocked securely and the weight is supported by blocks or
jack stands rather than by lifting equipment.
When using hoisting equipment, follow the hoist
manufacturers recommendations and use lifting devices that
will allow you to achieve the proper balance of the
assemblies being lifted and to ensure safe handling. Unless
otherwise specified, all removals requiring hoisting
equipment should be accomplished using an adjustable
lifting attachment or straps design for that purpose. All
Item Description Item Description
1 Drop Block 10 Outrigger (4)
2 3rd Boom Section (3 Section Boom)
4th Boom Section (4 Section Boom)
11 Rear Drive Axle (Steerable & Non-Steerable)
12 Enclosed Operator’s Cab (Shown)
Optional Cab Guard (Not Shown)3 Optional Boom Extension
4 Lift Cylinder 13 Main Control Valve Location
5 1st Boom Section 14 Front Steering Drive Axle
6 Engine Compartment 15 Swing Motor and Gearbox Location
7 Main Hoist Assembly 16 2nd Boom Section
8 Mast Assembly 17 3rd Section Boom
9 Main Frame Assembly
CAUTION
Eye Injury Hazard!
When using compressed air use only low air pressure and
keep air stream from direction of face.
Always wear eye and face protection when using
compressed air. Injury to eyes could occur.
Reference Only
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