GMK5170 Maintenance Manual

Maintenance manual
3 112 477 en
Serial number 29.04.2008
Important note
Any type of duplication or excerpt from this

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

29.04.2008
The passing on or duplication of this document as well as the 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. The original language of this document is German.
3 112 477 en Maintenance manual

GMK 5170
Hydraulic Oil – hydraulic system
Deviating to the information in the supplied maintenance manual, the hy-

draulic system in the carrier/superstructure is filled with a different oil type.
This new type of oil is in use since mid january 2015 for the first oil fill during
the cranes production process.
• Please contact Manitowoc Crane Care, if you are in doubt.

This additional page indicates the oil type first filled in at the factory and
contains maintenance information.
Oil type • Only use the oil specified in this document when carrying out mainte-
nance work on the hydraulic system.
Place of use Specification

Castrol Hyspin AWH-M 32
DIN 51524-3
Oiltank:
Hydraulic Oil HVLP
Carrier
ISO VG 32
and superstructure
GROVE Part no. 04162158
available from Manitowoc Crane Care
Maintenance in- • Carry out maintenance work using the oil stated above, as described in
formation the supplied maintenance manual. The maintenance intervals in the sup-
plied maintenance manual apply.
• For maintenance, also observe the following notes:
S
Risk of damage to the hydraulic system
Do not mix this oil with other oils. Oil mixtures can damage the hydraulic
system.
O
Risk of damage to the environment if disposed of improperly
This oil must also be disposed of properly in accordance with legal specifi-
cations.
12.01.2015
Correction sheet Maintenance manual 3 113 198 en 1

GMK truck cranes
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12.01.2015
2 3 113 198 en Correction sheet Maintenance manual

GMK truck cranes
Additional hydraulic oil filters
Deviating from the specifications

– of the accompanying Maintenance manual, and
– of the accompanying Additional pages
the two additional hydraulic oil filters in the carrier
– must be changed at all circumstances every 12 months (M 12).
Validity This additional page refers to the truck cranes GMK 5170 and GMK 5220.
Replacement This additional page replaces the additional pages 3 112 577 and 3 112 427.
This additonal page completes the information about the hydraulic oil filters
3 and 4 (in the carrier) in the maintenance manual GMK 5170-Cummins.
Changing the hydraulic oil filters M 12
Maintenance • Replace the additional hydraulic oil filters

interval
– once after the brand-new truck crane has been in driving position for
50 hours, and
– every 12 months (M 12), and
– every time the hydraulic oil in the carrier is changed in accordance with
the accompanying Maintenance manual.
H
Always comply with the maintenance intervals specified here. The ECOS
display does not have warning messages for the additional hydraulic oil fil-
ters.
Spare parts and

tools Designation Quantity GROVE part no.
Filter 2 03135866
Repair set (if necessary) 2 03135867
04.08.2009
s
Additional page GMK 5170/5220 3 112 612 en 1
Changing the filter Before changing the filter, observe all prerequisites and warnings in the sec-
tion Carrier hydraulic system of the accompanying Maintenance manual.
• Remove the receptacle (1).

• Change the filter (2).
• If necessary, replace any defective parts (re-
pair set).
• Fill the receptacle with clean oil.
• Put the receptacle (1) on and tighten it.
04.08.2009
2 3 112 612 en Additional page GMK 5170/5220

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.
17.02.2010
Additional pages GMK truck cranes 3 112 676 en 1

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17.02.2010
2 3 112 676 en Additional pages GMK truck cranes

Contents:
1 General notes
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 periods out of service
10 Torques
11 Spare parts required for maintenance
Appendix
This maintenance manual does not replace the operating instructions.
Details of operation and standard safety instructions can be found

in the operating instructions.
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1
1 General notes
1.1 Using the maintenance manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1
1.2 Warnings and symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1
1.3 Maintenance instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 2
1.4 Notes concerning the electronic control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 4
1.5 Safety instructions for welding work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 4
1.6 Definition of positional references. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 5
1.7 Conversion table for US measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 6

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General notes
1.1 Using the maintenance manual
1 General notes
1.1 Using the maintenance manual

This maintenance manual does not 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.
H
Maintenance work on the lattice extensions is described in the Lattice exten-
sion operating instructions.
1.2 Warnings and symbols

The following designations and symbols are used in the operating instruc-
tions to highlight particularly important information:
G
This symbol indicates dangers 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.
S
Here, dangers which could put objects at risk are pointed out, e.g. damage
to the truck crane or the load.
O
This 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 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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s
Maintenance manual 3 112 477 en 1-1
GMK 5170
General notes
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 be carried out only by qualified repair personnel (e.g. CraneCARE).
Repair work also requires:

– appropriate workshop equipment
– special tools
– spare parts approved by Manitowoc Crane Group Germany GmbH
It is your responsibility to maintain and service the truck crane regularly in

order to extend its service life and keep it in good working order.
Please note that Manitowoc Crane Group Germany GmbH can uphold the
warranty provided for the truck crane only if the following conditions are
fulfilled:
– 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
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GMK 5170
General notes
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
– faulty brakes
– faulty tyres or wheel rims
– exceeded maintenance intervals
For your safety and the safety of others, avoid these errors by carrying out
service and maintenance work carefully within the specified intervals. Do
not delay maintenance work that is due. If repairs are needed, immediately
contact CraneCARE 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 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 Lubricants, p. 6 - 1
are used.
• Replace all filters within the specified period if cleaning is not explicitly
permitted.
• Replace all gaskets before assembly. Clean the sealing surfaces.
• Tighten loose screw connections on hydraulic and compressed air
systems only when the system is depressurised.
• Keep brake and clutch linings free of grease.
• Replace hydraulic hoses immediately once damage or penetration of
moisture becomes visible.
• Cleanliness is imperative when handling hydraulic oil. Even new
hydraulic oil must be filtered when filling.
s
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General notes
1.4 Notes concerning the electronic control
• Cleanliness is imperative when handling grease on 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 (bolts, nuts, lock washers) before
re-using them and replace them if necessary.
Torques can be found in sections p. 10 - 1 and p. 10 - 2.
Our training centre at our plant offers specialised training programmes.

Please contact CraneCARE.
The vehicle must fulfil all the applicable regulations before being put into
operation and driven on public roads.
1.4 Notes concerning the electronic control

The electronic ESX control generally has 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 105 accesses.
– The safety relay permits a maximum of 107 make-and-brake cycles.
– Some conventional condensers in the ESX have a service life of 10 years.
The device must be serviced or replaced by CraneCARE before one of these
limits is reached.
1.5 Safety instructions for welding work

To avoid damage, especially to electronic parts, there are certain steps you
must take before doing any welding work. You should therefore always con-
sult CraneCARE before welding.
All welding work (especially on load carrying members) may be performed

only by qualified professional personnel with the prior written permission
of Manitowoc Crane Group Germany GmbH.
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General notes
1.6 Definition of positional references
1.6 Definition of positional references
Basic rule Directions always depend on whether the carrier or the superstructure 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 the driver's cab is to the front.

Backwards always means the rear lights on the carrier are to the front.
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: Press (1) – on the symbol

Up: Press (2) – opposite the symbol
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General notes
1.7 Conversion table for US measurements
1.7 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 in 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

GMK 5170
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
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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 instructions 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 prevented from rolling.
• Keep all handles, steps, landings and ladders free of dirt, grease, snow
and ice.
• Use proper access aids and working platforms when carrying out over-
head work. Wear a harness when carrying out maintenance work high
overhead.
• Walk only on those machine parts which are equipped with appropriate
steps and railings and therefore guarantee safety. During rigging and
maintenance work on machine sections above body height which have
no apparatus for accessing, always use the supplied extendable ladder
(e.g. when lubricating telescopic slide faces).
• Perform maintenance work only after the truck crane has been shut down.
Always ensure that the truck crane is protected from unauthorised opera-
tion before beginning maintenance work. Remove the key and put up
warning signs.
s
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2.1 Safety rules
If due to exceptional circumstances, the truck crane must be put into opera-
tion for certain types of maintenance work, great care must be taken where
there are moving parts (superstructure, outriggers, cardan shafts, slewing
bearing, motors, 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).
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. Only tighten loose
screw connections when the systems are depressurised. Always depressur-
ise the hydraulic and compressed air systems before opening them.
• Do not allow hot materials to escape unchecked – Risk of burning yourself

• Observe the applicable safety regulations when working with flammable
fluids.
• Observe the applicable safety regulations when working with process
materials.
• Switch off all electrical consumers and disconnect the earthing terminal
before removing any batteries.
• Keep in mind the corroding effect of battery acid.
• Note the fire alarm and fire-fighting facilities on the 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 neutral 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 before leaving the
truck crane, and lock the door to the crane cab or the driver's cab.
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/crane cab with information about
– when
– why
– 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
What substances When you carry out maintenance work on the truck crane, you will occasion-
are harmful to the ally work with consumables which are classed as harmful to the environ-
environment? ment as per current national and regional regulations.
These include oil, fuel, grease, used oil and fuel filters, as well as cloths
which have come into contact with these environmentally harmful sub-
stances.
• When handling these substances, observe the current national and

regional regulations as well as the instructions in this chapter.
Use suitable Substances harmful to the environment can be caustic. When doing main-
equipment tenance work involving these consumables (oils, coolant, fuel), always use
containers, hoses, pumps, funnels etc. which are large enough and which
are resistant to the consumables.
For oil sampling, always use containers that can be closed and have suffi-
cient capacity and resistance to the consumables.
The approximate amount of consumable 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.
• Catch consumables (e.g. oils, fuels, coolant) in a suitable container when
draining.
• Always use a drain hose when draining, and a funnel or a pump with hose
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GMK 5170
Collect and store Substances which are environmentally harmful should always be collected
separately separately from other waste.
• Ask your local environmental protection authority about the different cat-
egories for the substances.
• Also, when collecting environmentally harmful substances, keep solid
materials (e.g. filter cartridges) separate from liquids. Disposal costs will
be reduced if you collect liquids separately according to certain categor-
ies.
• Only store environmentally harmful substances in approved containers
and in locations which meet the requirements of current national and
regional regulations.
Disposal • Ask your local environmental protection authority about the prescribed
disposal options.
• Once accumulated, have environmentally harmful substances disposed
of only by disposal companies which are approved by the national or
regional authority responsible.
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3
3 Cleaning
3.1 Overview of subassemblies 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
three months months.
• During this period, the truck crane may only be cleaned with cold water.
• Do not use high-pressure or steam-jet cleaning equipment during this
period.
After the first • Avoid water temperatures over 60 °C even after the first three months.
three months
• Do not use corrosive cleaning agents that might attack the paint.
• Never hold the spray nozzle of your cleaning unit at a right angle to the
surface you are cleaning, and ensure that you are standing at a sufficient
distance away from the surface.
G
Risk of accidents from 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 great
speed and high 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 nozzle directly at them.
• Never point the nozzle at electrical equipment, relay and switch boxes,
suction and venting filters or control elements and oiled/lubricated sur-
faces.
• To prevent corrosion, re-oil/relubricate all slide faces after cleaning.
The components specified in the next section are to be cleaned with partic-
ular care.
• After cleaning with a high-pressure device or a steam jet device, activate

intermediate lubrication on the central lubrication systems ( à Triggering
intermediate lubrication, p. 7 - 79).
• Lubricate all remaining lubrication points with a grease gun.
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Cleaning
3.1 Overview of subassemblies easily damaged when cleaning
3.1 Overview of subassemblies easily damaged when

cleaning
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Cleaning
1 SLI terminal box

2 Telescope slide faces
3 SLI length data transmitter
4 Angle data transmitter
5 Pressure sensors
6 Lowering limit switch
7 Suspension struts
8 Superstructure switch box
9 Slewing angle sensor on the superstructure
10 Outriggers control unit
11 Lifting limit switch
12 Housing of the input-output circuit boards on the carrier
13 Swing-away lattice extension proximity switch
14 Spotlights, slewable
15 SLI connections
à Operating
H
Subassemblies at risk of damage on the lattice extension;
Instructions Lattice Extension.
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Cleaning
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4
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Run-in regulations
Individual parts have run-in regulations which must be adhered to after:
– 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 stipulated periods of time have expired:
Operating Driven km Additional maintenance work on the

hours CARRIER
(oper. hrs.)
After 50 Tighten wheel nuts;
à Special torques, p. 10 - 2.
After 150 Tighten wheel nuts;
After 50 Tighten up the clips on the coolant
hoses;
After 100 Lubricate the support bearings;
à Lubricating the support bearings,
p. 7 - 103.
During the Check the hydraulic oil filters weekly;
first 100 à Cleaning the magnetic rods, p. 7 - 64,
à Changing the hydraulic oil filter,
p. 7 - 74.
After 100 After 1 000 Change the drive oil;
à p. 7 - 30 for the transfer case,
à p. 7 - 35 for the axle centre drives,
à p. 7 - 39 for the final drives.
After 250 After 2 500 Change the engine oil;
à Engine manufacturer's documentation.
s
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GMK 5170
Run-in regulations
Operating hours (oper. hrs.) Additional maintenance work on the

SUPERSTRUCTURE
After 50 Tighten up the clips on the coolant
hoses;
During the first 100 Check the hydraulic oil filters weekly;
à Changing the hydraulic oil filter,
p. 8 - 41.
After 100 Tighten up the bolts on the ball bearing
slewing;
à Ball slewing bearing, p. 8 - 31,
After 100 Hook blocks;
à Lubricating, p. 8 - 74.
After 200 First oil change on the hoists;
à Changing the oil/Checking the oil,
p. 8 - 22.
After 1000 or after 12 months at Second oil change on the hoists;
the latest à Changing the oil/Checking the oil,
p. 8 - 22.
After 200 Change the slewing gear oil;
à Changing the oil/Checking the oil,
p. 8 - 28.
After 250 Change the engine oil;
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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 (= monthly) 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, you are directed by cross references to the sections in which
the appropriate maintenance work has been described. The cross references
consist of the chapter number and the corresponding page number, e.g.
Checking hydraulic oil level; à p. 7 - 61.
Checking the hydraulic oil level is described in chapter 7, the section starts
on page 7 - 61.

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

– a specified time (maintenance interval) or
– a specified number of kilometres driven or
– a specified number of operating hours (oper. hrs.) or
– an indication on the on-board computer display, ECOS display or partic-
ulate filter display in the driver's cab;àp. 7 - 3 or
– an indication on the ECOS display in the crane cab; à p. 8 - 3.
s
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GMK 5170
The maintenance interval which occurs first shall determine when mainten-
ance work is next due.
– The km can be taken from the speedometer.
– You can call up the engine and power unit working hours (oper. hrs.) of
the superstructure one by one on the ECOS display in the crane cab.
The operating hours of the engine equal the total operating hours of the
superstructure.
The following table sets out the maintenance intervals for the maintenance
plans:
Mainten- Maintenance Km driven Operating hours

ance plans interval (carrier) (oper. hrs.)
of engine
(superstructure)
Daily/before
D putting into oper- — —
ation
W Weekly — —
M1 Monthly Approx. 2 000 100
Every three
M3 5 000 – 6 000 300
months
M6 Every six months 10 000 – 12 500 500
M 12 Every 12 months 20 000 – 25 000 1 000
Y2 Every 24 months 40 000 – 50 000 2 000
Y3 Every 36 months — 3 000
Y5 Every 60 months 100 000 5 000
Y6 Every 72 months — 6 000
Y 10 Every 120 months 200 000 12 000
Please note that the long-term maintenance plans always include the
short-term ones!
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GMK 5170
5.2 Maintenance plans

The descriptions of certain maintenance work in the maintenance plans D,
W, M 1 to M 12 and Y 2 to Y 10 have been 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 abbreviations (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 descriptions of the oils/lubricants in accordance with Lubricants list,
p. 6 - 2.
– The amounts as approximate values for oil amounts in litres (l) (the exact
oil amounts can always determined by the oil level inspection holes, the
dipsticks or the oil level indicators) Lubricant applications, p. 6 - 3.
H
Items which are only available with additional equipment are designated
accordingly. These designations are made in this section only and are not
repeated in the following sections.
H
Maintenance work on the engine over and above the daily and weekly
checks is only partially described in this maintenance manual. When
carrying out such maintenance work, follow the instructions given in the
Engine manufacturer’s documentation.
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GMK 5170
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 - 5
– Checking the air filter à p. 7 - 9
– Checking the coolant level à p. 7 - 10
Transmission
Fuel system
– Draining off water from fuel filter 1 à p. 7 - 14
Wheels
– Checking the tyres for damage à p. 7 - 43
Steering
– Checking for leaks à p. 7 - 55
Hydraulic system
Electrical system
– Checking the lighting and indicators à p. 7 - 81
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GMK 5170
Maintenance work on the SUPERSTRUCTURE:

daily/before putting into operation
Engine
– Checking the air filter à p. 8 - 8
– Checking the coolant level à p. 8 - 9
Fuel system
– Draining off water from fuel filter 1 à p. 8 - 11
Hydraulic system
Hoist ropes
– Checking the position on the rope drums à p. 8 - 55
Electrical system
– Checking the lighting and indicators à p. 8 - 75
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GMK 5170
5.2.2 Maintenance plan W W

weekly
Engine
– General inspection à p. 7 - 11
Automatic transmission
Transfer case
Axle lines
Wheels
– Checking the tyre air pressure à p. 7 - 44
Compressed air system
– Draining the compressed air system à p. 7 - 57
Hydraulic system
– Checking the hydraulic hoses à p. 7 - 62
Central lubrication system
– Checking the level à p. 7 - 77
Other maintenance work
– Check the correct operation of the driver's cab windscreen washing system
à
and the level of fluid in the reservoir; Operating instructions.
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GMK 5170

weekly
Engine
Hoists
– Checking the hoist brake à p. 8 - 20
Slewing gear
Hydraulic system
– Checking the hydraulic hoses à p. 8 - 36
– Checking ventilation filters à p. 8 - 36
Hoist ropes
– Checking the hoist ropes à p. 8 - 56
Central lubrication system
– Checking the level à p. 8 - 73
– Check the correct operation of the crane cab windscreen washing system
à
and the level of fluid in the reservoir; Operating instructions.
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GMK 5170
5.2.3 Maintenance plan M 1 M1

monthly/after approx. 2 000 km
Engine
– Notes; à Engine manufacturer's documentation à p. 7 - 5
Transfer case
Axle lines
– Checking the oil level on axle centre drives à p. 7 - 33
– Final drives – checking the oil level à p. 7 - 38
– Lubricating the cardan shafts on the axle lines à p. 7 - 41
Wheels
– Check tightness of wheel nuts à p. 7 - 45
Suspension
– Suspension struts – checking the oil level à p. 7 - 51
– Suspension struts – checking the fastening à p. 7 - 52
Electrical system
– Checking the batteries à p. 7 - 82
Air-conditioning system
– Checking the air-conditioning system à p. 7 - 87
– Cleaning the condenser fins à p. 7 - 87
Particulate filter
– Checking the clamp straps à p. 7 - 91
Towbar coupling
– Lubricating the towbar coupling à p. 7 - 95
– Lubricating the support bearings à p. 7 - 103
– Checking the auxiliary heater for correct operation à p. 7 - 104
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GMK 5170
M1

monthly/after 100 oper. hrs.
Engine
Electrical system
– Checking the batteries à p. 8 - 76
– Checking the air-conditioning system à p. 8 - 77
– Cleaning the condenser fins à p. 8 - 77
– Checking the auxiliary heater for correct operation à p. 8 - 79
– Lubricating the piston rod of the derricking cylinder à p. 8 - 79
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GMK 5170

every three months/after 5 000 - 6 000 km
Engine
Fuel system
– Changing fuel filter 1 à p. 7 - 15
Vehicle brake
– Checking brake-lining thickness à p. 7 - 49
Suspension
– Forced lever – checking correct functioning à p. 7 - 53
Hydraulic system
– Cleaning the magnetic rods à p. 7 - 64
Electrical system
– Checking the charge level of the batteries à p. 7 - 84
Towbar coupling
– Checking the bearing à p. 7 - 97
– Checking the cotter pin à p. 7 - 98
– Checking the lower bushing à p. 7 - 99
– Checking the initial tension of the springs à p. 7 - 99
– Checking the support ring à p. 7 - 100
– Checking the function of the coupling jaw/ Resetting central position à p. 7 - 100
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5 - 10 3 112 477 en Maintenance manual

GMK 5170
M3

every 3 months/after 300 oper. hrs.
Engine
Fuel system
Ball slewing bearing
– Check the bolt torques; à Special torques à p. 10 - 2
Main boom
– Lubricating the telescopic sections à p. 8 - 49
– Checking the sheaves à p. 8 - 53
Hoist ropes
– Lubricating the hoist rope à p. 8 - 57
Hook blocks
– Checking the sheaves à p. 8 - 73
Electrical system
– Checking the charge level of the batteries à p. 8 - 76
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Maintenance manual 3 112 477 en 5 - 11

GMK 5170

every six months/after 10 000 - 12 500 km
Engine
Transfer case
– Changing the oil à p. 7 - 30
Axle lines
– Lubricating longitudinal cardan shafts à p. 7 - 42
Wheels
– Tyre change à p. 7 - 46
– Checking hoses à p. 7 - 88
Particulate filter
– Replacing the particulate filter à p. 7 - 92
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GMK 5170
M6

every 6 months/after 500 oper. hrs.
Engine
Hoists
– Lubricating the auxiliary hoist à p. 8 - 20
Slewing gear
– Checking the slewing gear brake à p. 8 - 26
– Lubricating gear teeth à p. 8 - 31
Cable drums and slewing angle sensor
– Maintenance of the slip ring assemblies à p. 8 - 69
– Checking hoses à p. 8 - 78
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GMK 5170
5.2.6 Maintenance plan M 12 M 12

every twelve months/after 20 000 - 25 000 km
Engine
Fuel system
Axle lines
– Axle centre drives – changing the oil à p. 7 - 35
– Final drives – changing the oil à p. 7 - 39
Suspension
– Pressure accumulator – checking the gas pressure à p. 7 - 54
– Replacing the filter cartridge of the compressed air drier à p. 7 - 59
Steering
Hydraulic system
– Changing the ventilation filter à p. 7 - 66
– Taking oil samples: à p. 7 - 67
depending on the oil sample test results:
– Change the oil à p. 7 - 70
– Changing the hydraulic oil filter à p. 7 - 74
– Checking the entire air-conditioning system à p. 7 - 88
– Lubricate the door hinges
– Lubricate the connecting and socket pins
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GMK 5170
M 12

every 12 months/after 1 000 oper. hrs.
Engine
Fuel system
– Changing fuel filters 2 and 3 à p. 8 - 15
Hoists
– Changing the oil/Checking the oil à p. 8 - 22
Slewing gear
– Changing the oil/Checking the oil à p. 8 - 28
– Measuring tilting play à p. 8 - 33
Hydraulic system
– Changing the ventilation filter à p. 8 - 38
– Taking oil samples à p. 8 - 40
– Changing the hydraulic oil filter à p. 8 - 41
– Changing the hydraulic oil à p. 8 - 44
Main boom
– Checking the locking system à p. 8 - 53
Hook blocks
– Lubricating à p. 8 - 74
– Checking the entire air conditioning system à p. 8 - 78
– Lubricate the cabin door track rollers
– Lubricate the connecting and socket pins
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GMK 5170
5.2.7 Maintenance plan Y 2 Y2

every 24 months/after 40 000 – 50 000 km
Engine
– Changing the oil and the oil filter à p. 7 - 26
– Have the refrigerant level checked by CraneCARE.
– Having the fire extinguisher checked à p. 7 - 104

every 24 months/after 2,000 oper. hrs.
Engine
– Have the refrigerant level checked by CraneCARE.
– Having the fire extinguisher checked à p. 8 - 80
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GMK 5170

every 36 months
No maintenance work in this period.
The long-term intervals always include the short-term intervals.

Hoists
– Having a partial inspection carried out à p. 8 - 24

every 60 months/100 000 km
Axle lines
– Have the cardan shaft between the transmission on the engine and the trans-
fer case replaced by CraneCARE.

Cable drums and slewing angle sensor

– Lubricating the slewing angle sensor à p. 8 - 71
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GMK 5170

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 - 24
5.2.11 Maintenance plan Y 10 Y 10

every 120 months/after 200 000 km
Steel construction
– Check the load-bearing steel construction. For more information, please con-
tact CraneCARE.

every 120 months/after 12 000 oper. hrs.
Steel construction
– Check the load-bearing steel construction. For more information, please con-
tact CraneCARE.
Safe load indicator (SLI)
– Have the SLI checked by CraneCARE.
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GMK 5170
5.3 Periodic inspections

Your truck crane GMK 5170 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 per BGV D 6
(VBG 9).
– Truck cranes that are to be used abroad are inspected in accordance with
the national regulations of the respective country. If such regulations do
not exist, they are inspected in accordance with the regulations of the Pro-
fessional Trade Association as per BGV D 6 (VBG 9).
According to German regulations, one periodic inspection must be carried

out annually. 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 parts. The purpose is to detect
defects at an early stage and thus prevent accidents.
Inspections are to be carried out on the following components, where these

are not already contained in the list of routine maintenance tasks:
– the hydraulic and electrical control and safety devices
– the safe load indicator (SLI)
– the mounting 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 construction (for cracks, deformation, etc.), includ-
ing a special check of all welds
If damage is found in the steel construction, qualified specialists must deter-
mine the extent of the damage using the required material examination
methods. They should then determine what sort of repair action 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 is to write a record containing the result of the annual inspec-
tion and the measures taken to repair any damage.
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GMK 5170
5.3.1 Load hook inspection
The hook mouth on the load hooks must be checked regularly for deforma-
tion.
The mouth of the hook may not be more than 10% wider than the original
dimension y, y1, y2.
The original dimensions y, y1, y2 are stated in

field (2) on the load hooks.
• To check, 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
mouth is more than 10% wider than the initial
dimension.
G
Risk of accidents if the load is allowed to drop!
Hook blocks with deformed load hooks are no longer operationally safe.
The load hooks could break and drop the load.
Deformed load hooks must always be replaced!
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GMK 5170
5.4 Measures required for winch monitoring
H
Also observe the information on the general inspection of the hoisting
gears; à p. 8 - 24.
These measures for monitoring the winches (hoists) were compiled by the
German Machine Builders' Association (VDMA) and are to be used for all
vehicle cranes according to the German Accident Prevention Regulations for
Winches, Hoists and Tractor Machines, BGV D 6 (VGB 9) and BGV D 8 (VBG 8).
5.4.1 Theoretical service life
The theoretical service life is determined from certain operating conditions

and a theoretical operating time assumed by the design engineer when cal-
culating and dimensioning the winches of your truck crane.
The power unit group M 3 and the load spectrum L1 (Km = 0.125) are gen-
erally given for truck cranes in erection mode, resulting in a theoretical serv-
ice life of 3200 hrs. (ISO 4301/1, FEM 1.001, DIN calculation bases 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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GMK 5170
The real service life of a winch is affected by a number of additional external

factors, such as:
1. Overloading caused by improper use of the truck crane.

2. Insufficient maintenance: oil not changed at the specified inter-
vals.
3. Operating errors: extreme acceleration or retardation of
the load,
load drops and is caught by 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. Concealed damage caused by accidents.
9. Extreme environmental condi- low or high temperatures
tions: caustic atmosphere
dust and dirt.
5.4.2 Proportion of theoretical service life used
The truck crane operator must inspect the truck crane at least once a year
(ISO 9927-1 and BGV D 6 (VGB 9)/BGV D 8 (VBG 8)).
This includes establishing the proportion of theoretical service life that has
been used. If required, the truck crane operator is to appoint an official
inspector for this assessment.
The actual operating conditions (load spectrum) and the operating hours of
the hoists are to be determined for each inspection interval when establish-
ing the proportion of theoretical service life that has been used. The opera-
tor is responsible for proper documentation in the crane logbook.
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GMK 5170
Determining the The truck crane's load spectrum is divided into groups (see also ISO 4301/1,
operating condi- FEM 1.001):
tions (load spec-
trum)
H
When establishing the load spectrum, the existing wire cable is used as a
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 wire cables.
Load Term designation Timing period proportions Factor of Graphic representation

spectrum the load
class spectrum
Km =
Power units or parts 10% of the timing period with
thereof that are subject greatest load (dead weight +
to high stress in excep- 1/1 payload)
Light
tional situations, but
Q1 40% of the timing period with 0.125
which are generally sub-
L1 dead load + 1/3 payload
ject to only minimal
stress. 50% of the timing period with
dead weight only
Power unit or parts 1/6 of the timing period with
thereof that are subject greatest load (dead load +
to high stress quite 1/1 payload)
often, but which are gen-
1/6 of the timing period with
Medium erally subject to only
Q2 dead load + 2/3 payload 0.25
minimal stress.
L2
1/6 of the timing period with
dead load + 1/3 payload
50% of the timing period with

dead weight only
Power unit or parts 50% of the timing period with
thereof that are subject greatest load (dead weight +
to high stress frequently 1/1 payload)
Heavy
and medium stress gen-
Q3 50% of the timing period with 0.5
erally.
L3 dead weight only
Power unit or parts 90% of the timing period with

thereof that are regularly greatest load (dead weight +
Very subjected to high stress 1/1 payload)
heavy from adjacent stress
10% of the timing period with 1
Q4 sources
dead weight only
L4
29.04.2008
s
GMK 5170
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 factor of the load spectrum Km = 0.125 are
generally applied to truck cranes in assembly mode.
Determination of The effective operating hours of the winches need to be entered in the crane
the effective oper- logbook for the respective inspection interval.
ating hours Ti
– The effective operating hours Ti of the winches are displayed in the
Operating hours submenu; àOperating instructions.
Determining the For an inspection interval i (max. 1 year according to ISO 9927-1 or BGV D 6
proportion of the- (VBG 9)/BGV D 8 (VBG 8), the proportion of theoretical service life used Si is
oretical service life calculated using the formula:
used
Km i
S i = ----------- × T i
Km
Km = Factor of the load spectrum established during winch calculation.

This factor is given in the operating instructions.
Kmi = Factor of the load spectrum in inspection interval i in accordance
with the section “Determining the operating conditions (collective
load)”
Ti = Effective operating hours in the testing interval i as described in
the “Determining the actual operating hours Ti” section
This used proportion is subtracted from the remaining theoretical service

life Di after every testing interval (see example in the appendix to this chap-
ter).
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 be performed at least once every 10 years after

commissioning the truck crane.
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GMK 5170
The general overhaul must be arranged by the operator and performed by

the manufacturer or persons authorised by the manufacturer. The results
are to be entered in the logbook.
The manufacturer or persons authorised by him specify a new theoretical

service life D upon completion of the general overhaul.
The next general overhaul must be performed within 10 years.
Deviating 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 expert has confirmed that the used portion of the service life is
correct and proper by signing his/her name in the logbook after every
inspection.
In this case, the crane expert must closely inspect the winch. This includes
at least:
– a visual examination of the exterior (for leaks, damage, malformation etc.)

– an oil inspection (especially for metallic residue)
– a load inspection with minimum and maximum rope pull and each with
maximum possible speed. At least one position is to be wound. Pay atten-
tion to any unusual noises during the load inspection.
This inspection must be confirmed in the logbook by the crane expert and
there must be a declaration of continued operation for the winch. The next
inspection takes place before the 12th year of operation and must be
repeated every year thereafter.
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GMK 5170
5.4.3 Example
A GMK 5170 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 hrs.
The used proportion S of theoretical service life is calculated based on the

individual inspection intervals as follows:
1. 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 hrs.,
i.e. T1 = 160 hrs.
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 = 3200 hrs. - 160 hrs. = 3040 hrs.
The above values are entered in the table (see table example p. 5 - 28).
2. 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 hrs., i.e. during
this period: 640 hrs. - 160 hrs. = 480 hrs. (160 hrs. were used during the first
year) T2 = 480 hrs.
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GMK 5170
The used proportion S2 of theoretical service life after the second inspection
is therefore:
0.5
S i = --------------- × 480 h = 1920 h
0.125
D2 = 3040 hrs. - 1920 hrs. = 1120 hrs.
The above values are entered in the table (see table example p. 5 - 28).
3. 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 hrs., i.e. during
this period: 940 hrs. - 640 hrs. = 300 hrs.
T3 = 300 hrs.
The used proportion S3 of theoretical service life after the third inspection
interval is therefore:
0.25
S i = --------------- × 300 h = 600 h
0.125
D3 = 1120 hrs. - 600 hrs. = 520 hrs.
These values are entered in the table

(see sample table 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 logbook. This table is found in the main-
tenance manual appendix for truck cranes that do not require a logbook or
similar documentation according to the regulations in the country in which
you are working.
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s
GMK 5170
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Sample table to determine the remaining theoretical service life on winch no. 1 (main hoisting winch)
GMK 5170
Maintenance manual
Crane model: GMK 3045
Work number: 3045 42 06
Commissioned on: 10 June 1990
Serial number of the winch in accordance with model plate: 13 301
Last general overhaul performed on: ........................
Winch design data (see operating instructions):
Engine group: M3
Load spectrum: Q 1 (L1)
Factor of the load spectrum: Km = 0.125
Theoretical service life: D = 3200 hrs.
Inspection Date of Operational Factor of the Operating Operating Operating Operating Operating Used propor- Remaining the- Name of Signature Note Name of the Signature
interval no. commis- condition load spec- hours of the hours of the hours of the hours of the hours Ti of the tion Si of theo- oretical service competent approved
(max. sion/date of since the trum entire crane superstruc- superstruc- winch winch since the retical service life person inspector
1 year) inspection last inspec- ture ture since last inspection life D:
tion the last
Di = Di-1 - Si
inspection
"i" Kmi [hrs.] [hrs.] [hrs.] [hrs.] [hrs.] [hrs.] [hrs.]
0(*) 10. 6. 90 – – – – – 0 3200
1 5. 6. 91 L1 0.125 – – – 160 160 160 3040 Müller
3 112 477 en
2 20. 5. 92 L3 0.5 – – – 640 480 1920 1120 Huber
3 18. 5. 93 L2 0.25 – – – 940 300 600 520 Schmitz
CAUTION: 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

Deviating provision, refer to section 5.4.2, p. 5 - 25.
Km = Factor of the load spectrum used to calculate the winch.
Kmi = Factor of the load spectrum in the inspection interval "i" according to section 2.1
Ti = Effective working hours in the inspection interval "i" according to section 2.2
General overhaul performed on..................................
(*) Copy 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 3
6.2 Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 4
6.3 Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 4
6.3.1 Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 4
6.3.2 Engine coolant admixtures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 4
6.3.3 Windscreen washing system admixtures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 4
6.3.4 Fuel for crane cab heating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 4
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Lubricants and consumables
6.1 Lubricants
6.1 Lubricants
All lubricants that you require for the
– 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
applications list.
à Lubricants list, p. 6 - 2.
à Lubricant applications, p. 6 - 3.
29.04.2008

GMK 5170
6.1 Lubricants
6.1.1 Lubricants list
Serial GROVE Lubrication Designation Specification Viscosity

no. part number type according to Classification
DIN 51502
MIL-L 2104 C
1 03329588 Engine oil HD - CD SAE 5 W - 30
DB 228.5
2 6 829 101 690 Gear oil1)
MIL-L 2105 B Hyp SAE 90
3 00552891 Gear oil C - LPF
API-GL-5 ISO - VG 220
Rivolta
4 02310863 Gear oil
S.K.D. 170
MIL-L 2105 B SAE 75 W-90 EP
5 02313611 Gear oil C - LPF API-GL-4/5 ISO - VG 220
(synthetic)
6 01375719 Hydraulic oil H - LP DIN 51524 T.2 ISO - VG 32
Lubricating
7 00554201 KP - L2K DIN 51825
grease
8 00554205 Spray Ceplattyn 300
9 02314698 Slide paste PAL 1
Lubricating
10 03325215 RHUS SW 2
grease
Lubricating
11 03133770 Elaskon 30
grease
1)
Synthetic oil filled at the factory; do not mix it with mineral oil!
29.04.2008

GMK 5170
6.1 Lubricants
6.1.2 Lubricant applications
Serial Lubrication Application Quantity Mainten-

no. type to be filled ance
in litres interval
Diesel engine for the carrier; à p. 7 - 7 38 Engine
manufac-
1 Engine oil
Diesel engine for the superstructure; à p. 8 - 7 16 turer’s docu-
mentation
2 Gear oil Automatic transmission; à p. 7 - 26 46.0 Y2
3. Axle line transfer case; à p. 7 - 30 19 M6
2. Axle line axle centre drive; à p. 7 - 35 13.0 M 12
3 Gear oil 5. Axle line axle centre drive; à p. 7 - 35 13.0 M 12
4. Axle line axle centre drive; à p. 7 - 35 16.5 M 12
6 or 8 x final drive; à p. 7 - 39 4.1 M 12
4 Gear oil 10 x suspension struts; à p. 7 - 51 1.5 M1
2 x hoists; à p. 8 - 22 7 M 12
5 Gear oil
2 x slewing gears; à p. 8 - 28 0.9 M 12
Carrier hydraulic tank; à p. 7 - 70 150 M 12
6 Hydraulic oil
Superstructure hydraulic tank; à p. 8 - 44 915 M 12
Carrier central lubrication; à p. 7 - 77 W
Superstructure central lubrication; à p. 8 - 73 W
Cardan shafts – transverse; à p. 7 - 41 M1
Cardan shafts – longitudinal; à p. 7 - 42 M6
Towbar coupling; à p. 7 - 95 M1
Lubricating
7
grease Support bearing; à p. 7 - 103 M1
Auxiliary hoist; à p. 8 - 20 M6
Slewing angle sensor; à p. 8 - 71 Y5
Hook blocks; à p. 8 - 74 M 12
Doors: hinges, track rollers,
connecting and socket pins; à p. 5 - 14 M 12
8 Spray Slewing bearing gear teeth; à p. 8 - 31 M6

9 Slide paste Telescopic slide faces; à p. 8 - 49 M3
Lubricating Telescopic locking pins; à p. 8 - 49 M3

10
grease Derricking cylinder piston rod; à p. 8 - 79 M1
29.04.2008
Lubricating the hoist ropes; à p. 8 - 57

Lubricating
11 M3
grease

GMK 5170
6.2 Refrigerant
6.2 Refrigerant
Refrigerant Application Quantity to Mainten-

Designation be filled in ance
kg interval
Tetrafluoroethane Driver's cab air-conditioning system;
(R134a) à p. 7 - 88 1.5 M 12
CAS no. 811-97-2 Crane cab air-conditioning system;

EC no. 212-377-0 à p. 8 - 78
2.0 M 12
6.3 Consumables
6.3.1 Fuel
The useable fuels and their respective specifications can be found in the
Engine manufacturer’s documentation.
6.3.2 Engine coolant admixtures
The specifications and admixture ratios can be found in the Engine manufac-
turer’s documentation.
6.3.3 Windscreen washing system admixtures
Commercial cleansers and antifreeze may be added to the windscreen

washing water. Observe the application instructions on the package.
6.3.4 Fuel for crane cab heating system

29.04.2008
Only if the truck crane is fitted with a separate tank for the auxiliary heater,
you have the option of selecting whether to use the same fuel as in section
6.3.1 or to use the EL heating oil.

GMK 5170
7
7.1 General instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 1
7.1.1 Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 1
7.2 Symbols for maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 3
7.3 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 5
7.3.1 Checking the oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 5
7.3.2 Topping up the oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 7
7.3.3 Installing the drain valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 8
7.3.4 Checking the air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 9
7.3.5 Checking the coolant level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 10
7.3.6 General inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 11
7.4 Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 13
7.4.1 Draining off water from fuel filter 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 14
7.4.2 Changing fuel filter 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 15
7.5 Automatic transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 21
7.5.3 Changing the oil and the oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 26
7.6 Transfer case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 29
7.6.3 Changing the oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 30
7.7 Axle lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 33
7.7.2 Checking the oil level on axle centre drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 33
7.7.3 Axle centre drives – changing the oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 35
7.7.4 Final drives – checking the oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 38
7.7.5 Final drives – changing the oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 39
7.7.6 Lubricating the cardan shafts on the axle lines . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 41
7.7.7 Lubricating longitudinal cardan shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 42
7.8 Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 43
7.8.1 Checking the tyres for damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 43
7.8.2 Checking the tyre air pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 44
7.8.3 Check tightness of wheel nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 45
7.8.4 Tyre change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 46
7.9 Vehicle brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 49
7.9.1 Checking brake-lining thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 49
7.10 Suspension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 51
29.04.2008
7.10.1 Suspension struts – checking the oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 51

7.10.2 Suspension struts – checking the fastening . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 52
7.10.3 Forced lever – checking correct functioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 53
7.10.4 Pressure accumulator – checking the gas pressure . . . . . . . . . . . . . . . . . . . . . . 7 - 54

GMK 5170
7.11 Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 55
7.11.1 Checking for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 55
7.11.2 Pressure accumulator – checking the gas pressure . . . . . . . . . . . . . . . . . . . . . 7 - 56
7.12 Compressed air system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 57
7.12.1 Draining the compressed air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 57
7.12.2 Checking for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 58
7.12.3 Replacing the filter cartridge of the compressed air drier . . . . . . . . . . . . . . . . . 7 - 59
7.13 Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 61
7.13.1 Checking the oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 61
7.13.2 Checking the hydraulic hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 62
7.13.3 Checking for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 63
7.13.4 Cleaning the magnetic rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 64
7.13.5 Changing the ventilation filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 66
7.13.6 Taking oil samples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 67
7.13.7 Changing the hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 70
7.13.8 Changing the hydraulic oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 74
7.14 Central lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 77
7.14.1 Checking the level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 77
7.14.2 Bleeding the central lubrication system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 79
7.14.3 Triggering intermediate lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 79
7.15 Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 81
7.15.1 Checking the lighting and indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 81
7.15.2 Checking the batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 82
7.15.3 Checking the charge level of the batteries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 84
7.16 Air-conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 87
7.16.1 Checking the air-conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 87
7.16.2 Cleaning the condenser fins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 87
7.16.3 Checking hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 88
7.16.4 Checking the entire air-conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 88
7.17 Particulate filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 91
7.17.1 Checking the clamp straps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 91
7.17.2 Replacing the particulate filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 92
7.18 Towbar coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 95
7.18.1 Lubricating the towbar coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 95
7.18.2 Checking the bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 97
7.18.3 Checking the cotter pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 98
7.18.4 Checking the lower bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 99
7.18.5 Checking the initial tension of the springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 99
7.18.6 Checking the support ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 100
7.18.7 Checking the function of the coupling jaw/Resetting central position . . . . . . 7 - 100
7.19 Other maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 103
29.04.2008
7.19.1 Lubricating the support bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 103

7.19.2 Checking the auxiliary heater for correct operation . . . . . . . . . . . . . . . . . . . . . 7 - 104
7.19.3 Having the fire extinguisher checked . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 104

GMK 5170
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.
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GMK 5170
Blank page
29.04.2008

GMK 5170
7.2 Symbols for maintenance work

Check the following symbols daily before starting operations.
On the ECOS
display
• Open the Warning submenu; à Operating instructions.
If one of the symbols is displayed, you must carry out the appropriate main-
tenance work:
– Oil pressure; à p. 7 - 5,
– Coolant level; à p. 7 - 10.
– Air filter; à p. 7 - 9,
– Hydraulic oil filter; à p. 7 - 74.
On the particulate
filter display
If one of the symbols (1) lights up in orange and/or the warning buzzer
sounds, you must carry out the appropriate maintenance work:
1 Particulate filter; à p. 7 - 92.
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GMK 5170
Blank page
29.04.2008

GMK 5170
7.3 Engine
7.3 Engine
• In addition, carry out further maintenance work on the Engine manufac-
turer’s documentation supplied. Pay attention to the information relating to
use of bio-diesel fuel – the oil change interval must be halved.
• At the first oil change, fit a drain valve in place of the drain plug;
à p. 7 - 8.
7.3.1 Checking the oil level D
Prerequisites – The truck crane is horizontal.
Checking the oil • Start the engine.

level
S
Risk of damage to the engine if the oil pressure is too low
If the symbol L still lights up after 10 seconds, turn off the engine and look
for the cause; à Operating instructions – Engine malfunctions.
• Start the engine and observe the display.

• Symbol (1) should not be lit for more than 10 seconds after starting the
engine.
• Allow the engine to run at idling speed for 2 - 3 minutes.

• Switch off the engine.
• Check the oil level after about two minutes.

29.04.2008
s
GMK 5170
7.3 Engine
• On the dipstick, check whether the oil level is

between the min. and the max. marks
(arrows).
• Put the dipstick into the dipstick tube after
checking the oil level.
If the oil level is too low:
• Add more oil, à p. 7 - 7.
29.04.2008

GMK 5170
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 Specification GROVE part no.
litres according to Classification
DIN 51502
38 HD - CD MIL-L 2104 C SAE 15 W-40
DB 228.5 03329588

– The engine is switched off and secured against unauthorised use;
à p. 2 - 3.
Topping up 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).
Drain off oil if necessary;à Engine manufacturer's documentation.
G
Risk of burning yourself when the engine is hot!
During operation, the engine and add-on parts can reach temperatures of
up to 400 °C. Wear appropriate protective gloves and be careful not to touch
hot parts.
• Add oil through the filler neck (1) up to the

max. mark.
• Close the filler neck with the lid.
29.04.2008

GMK 5170
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

Valve 1 03046878
Gasket 26 x 31 Cu DIN 7603 1 00117147
– Drain channel.
– Torque wrench for torque of 60 Nm.

à p. 2 - 3.
Installing the
valve
• Use a drain channel when draining the oil.
• Drain the engine oil as described in Engine
manufacturer’s documentation.
• Replace the gasket and tighten the valve (1)
– torque 60 Nm.
• Check the valve for tightness after filling up
with oil.
Next time you change the oil, you can drain the oil in the same way as
described for taking oil samples from the hydraulic tank; à
Taking oil sam-
ples, p. 7 - 67.
29.04.2008

GMK 5170
7.3 Engine
7.3.4 Checking the air filter D

• The filter must be replaced if the display shows the symbol (1).
Spare parts and

Filter 1 03 328 262
Prerequisites – The engine is switched off and secured against unauthorised use;
à p. 2 - 3.
Replacing the air

filter
• Remove the plate (4).
• Undo all the clamps (1) and remove the lid
(2).
• Place back the lid and secure it with all the
clamps.
• Attach the plate.
29.04.2008

GMK 5170
7.3 Engine
7.3.5 Checking the coolant level D
Coolant must be filled if the display shows the symbol (1).
Topping up cool-
ant
G
Danger of being scalded due to hot radiator circuit!
The hot radiator circuit is under pressure. When you open the expansion
tank, you could be scalded by escaping steam or 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 valves (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 edge
in the filler neck.
If the coolant level is too low:
• Top up the coolant.
Composition of the coolant;
• 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 CraneCARE or your repair
crew.
29.04.2008

GMK 5170
7.3 Engine
7.3.6 General inspection W
• Investigate any unusual noises from the engine.

• Check the engine and the connections for leaks. In the event of leaking
consumables;
à Checking the oil level, p. 7 - 5,
à Checking the coolant level, p. 7 - 10.
• Check that pipes and hoses are tightly connected and not damaged.
If any damage is found, report it CraneCARE.
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GMK 5170
7.3 Engine
Blank page
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GMK 5170
7.4 Fuel system
7.4 Fuel system
Installed in the fuel line are:

1 Fuel filter 1
2 Fuel filter 2
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GMK 5170
7.4 Fuel system
7.4.1 Draining off water from fuel filter 1 D
Spare parts and – Receptacle, approx. 5 l; à p. 2 - 4.

tools

à p. 2 - 3.
Draining off water
O
Risk of environmental damage due to leaking consumables!
Always let consumables drain into suitable receptacles. Wipe up any fluids
that have leaked.
Store/dispose of fluids and any soaked equipment properly.
Ask about the applicable regulations.
• Place a receptacle underneath the filter.

• Open the valve (1).
• If the consumable is clean, close the valve
manually.
• Remove the receptacle and properly dis-
pose of the drained consumable.
29.04.2008

GMK 5170
7.4 Fuel system
7.4.2 Changing fuel filter 1 M3
Spare parts and

Filter 1 03322877
Gasket 1 03322879
Filter element 1 03328656
– Receptacle, approx. 5 l; à p. 2 - 4.

à p. 2 - 3.
– If the fuel is contaminated: shorten the maintenance interval.
Changing
O
that have leaked.

• Close the valve – lever (1) at right angles to
the line.
• Open the screw plug (2) and the valve (3)
and drain the fluid.
s
29.04.2008

GMK 5170
7.4 Fuel system
• (A) – Remove the filter element (2) and the

filter (1).
If necessary, replace any damaged parts.
• (B)) – Screw on a new filter (1) and the filter
element (2).
• Close the valve (3) manually.
• Open the valve (1) – lever parallel with the

line.
• Actuate the pump (3) until the consumable
flowing through the bolt (2) no longer con-
tains any bubbles.
• Secure the bolt.
• Start the engine and check for leaks.
• Remove the receptacle.
H
If you have used a clean receptacle, you can refill the fuel tank with the con-
sumable using a strainer.
Otherwise dispose of the consumable properly.
29.04.2008

GMK 5170
7.4 Fuel system
7.4.3 Changing fuel filter 2 M 12
Spare parts and

Filter and gasket 1 03 045 818
Prerequisites – The truck crane is level and on outriggers; à Operating instructions

– The main boom is fully retracted; à Operating instructions
à p. 2 - 3.
O
Always let consumables drain into suitable receptacles. Wipe up any con-
sumables that have leaked.
Store/dispose of consumables and any soaked equipment properly.
Emptying the fuel

line

the line.
• Open the bolt (2) and let the consumable
drain.
s
29.04.2008

GMK 5170
7.4 Fuel system
• Place a receptacle under the end of the hose

(2).
• (A) – Turn the valve – lever (1) horizontal.
• Let the consumable drain.
• (B) – Turn the valve – lever (1) vertical.
Leave the receptacle under the hose. More
consumable will run out during bleeding.
Changing the filter • Remove the covers that are on the engine; à p. 7 - 1.
• Unscrew the cap (1) and remove the filter
(3).
Let the remaining consumable drain.
• Remove the cap and remove the filter by
applying pressure to the sides of its lower
edge.
• Insert a new gasket (2) (grease lightly) and
clip a new filter into the lid.
• Screw the lid with the filter into the housing
and tighten it – torque 25 Nm.
29.04.2008

GMK 5170
7.4 Fuel system
Bleeding the fuel

line
There is a receptacle under the hose end (2).
• Close the vent screw (4).

• Open the valve – lever (5) parallel to the line.
• Open the valve – lever (1) horizontal.
flowing through the end of the hose no
longer contains any bubbles.
• Turn the valve – lever (1) vertical.

• Start the engine and check that the fuel fil-
ters are not leaking.
• Remove the receptacle underneath the hose
end (2).
H
If you have used a clean receptacle, you can refill the fuel tank with the con-
sumable using a strainer.
Otherwise, dispose of the consumables properly.
29.04.2008

GMK 5170
7.4 Fuel system
Blank page
29.04.2008

GMK 5170
7.5 Automatic transmission
Prerequisites – The oil level pre-check has been carried out; à Prior to starting the engine,
p. 7 - 22.
à p. 2 - 3.
Three types of oil

level inspection
S
Risk of damage to the automatic transmission
The correct oil level must be maintained to ensure smooth operation of the
automatic transmission:
– if the oil level is too low, malfunctions will occur,
– if the oil level is too high, loss of power and overheating will occur.
The oil level can be checked in three different ways, depending on the con-
ditions:
– when the gear oil is cold; à p. 7 - 22,
– when the gear oil is warm; à p. 7 - 23,
– via the oil level sensor; à Operating instructions.
H
Check with warm gear oil for the most accurate reading of the oil level in the
automatic transmission.
s
29.04.2008

GMK 5170
Prior to starting
the engine
S
Risk of damage to the transmission!
The engine must not be started without a prior check of the gear oil level.
This prevents gear damage being caused by undetected loss of oil.
• Remove the dipstick (1) and check whether

the oil level is around the (2) mark.
• Insert the dipstick into the dipstick tube.
• Top up oil via the dipstick tube.
Follow-up check:
• Carry out another check when the gear oil is
cold; à p. 7 - 22.
When the gear oil Gear oil temperature 15 to 50 °C.

is cold
• Pre-check the oil level in the automatic transmission daily before starting
the engine; à p. 7 - 22.
• Start the engine; à Operating instructions.
• Check the gear oil temperature; à Operating instructions.
S
Risk of damage to the transmission when warming up
When the wheels are locked, the full engine output may only be applied in
transmission mode D or R for a maximum of 30 seconds. If this duration is
exceeded, the transmission could become overheated and get damaged.
• First switch to transmission mode D and then to R and allow the engine
to run briefly at approx. 1200 - 1500 min-1 in each transmission mode.
• Switch to neutral position N and let the vehicle run at idling speed.
29.04.2008
If the outside temperature is low, allow the engine to run for a few minutes
longer.

GMK 5170

the oil level is in the (2) range.
If the oil level is too high:
• Drain off oil until it is below the (4) mark;
à p. 7 - 27.
• Top up the oil via the dipstick tube until the
(3) mark is exceeded.
Follow-up check:
• Carry out another check when the gear oil is
warm; à p. 7 - 23.
When the gear oil Gear oil temperature 75 to 95 °C.

is warm
• Pre-check the oil level in the automatic transmission daily before starting
the engine; à Prior to starting the engine, p. 7 - 22.
H
To prevent damage to the transmission, the oil level check is at its most
relevant when the gear oil is warm.
Gear oil is warmed up

– when the vehicle is stationary; à p. 7 - 23,
– or when driving; à p. 7 - 24.
Warming up when stationary
• Start the engine.
• Allow the engine to run at idling speed in the neutral position N until the
gear oil temperature is 75 °C.
• Check the gear oil temperature; à Operating instructions.
• Check the oil level; à p. 7 - 25.
s
29.04.2008

GMK 5170
If you want to accelerate the warming procedure when the vehicle is sta-
tionary:
• Fully depress the service brake pedal, even if the parking brake is on.
S
Risk of damage to the transmission when accelerating the warming up
procedure!
When the wheels are locked, the full engine output may only be applied in
transmission mode D or R for a maximum of 30 seconds. If this duration is
exceeded, the transmission could become overheated and get damaged.
S
Coolant loss through overheating when the warming up procedure is
accelerated!
When the wheels are locked, the coolant can overheat – even when coolant
temperatures are under 70 °C on the display. The coolant then leaks from
the expansion tank.
• First switch to transmission mode D and then to R and allow the engine
to run briefly at approx. 1200 - 1500 min-1 in each transmission mode.
• Allow the engine to run at idling speed in the neutral position N until the
gear oil temperature is 75 °C.
Check the gear oil temperature; à Operating instructions.
Warming up when driving
• Drive the truck crane until the coolant temperature is 70 °C.

Check the gear oil temperature; à Operating instructions.
• Align the truck crane horizontally.

• Engage the parking brake.
• Switch to the neutral position N.
29.04.2008

GMK 5170
Checking the oil level

the oil level is in the (2) range.
• Top up the oil via the dipstick tube until the
(3) mark is exceeded.
If the oil level is too high:
• Drain off oil until it is below the (4) mark;
à p. 7 - 27.
• Pay attention to any unusual noises in the automatic transmission.

• Check the transmission and the connections for leaks. In the event of leak-
ing consumables; à Checking the oil level, p. 7 - 21.
If you detect any worn or damaged parts, contact CraneCARE.
29.04.2008

GMK 5170
7.5.3 Changing the oil and the oil filter Y2
Spare parts and

Filter with set of gaskets 2 03 326 293
Gasket 30 x 36 Cu DIN 7603 1 00 117 151
– Receptacle, approx 50 l; à p. 2 - 4.
– Torque wrench for tightening torque of 25-32 Nm and
50-55 Nm.
Prerequisites – The gear oil is at operating temperature (70 to 95 °C).

– The truck crane is raised on outriggers or parked over an inspection pit.
à p. 2 - 3.
Changing the oil

and the oil filter
G
Risk of burning yourself on gear oil at operating temperature!
You could burn yourself if unchecked gear oil escapes at operating temper-
ature. Wear appropriate protective gloves and be careful not to touch the
gear oil.
O
29.04.2008

GMK 5170
Draining oil
• Pull out the dipstick (1).
• Place a receptacle under the bolt (2).
• Unscrew the bolt and let the oil drain off.
Changing the oil filter

• Loosen the lid (1) and pull out the filters.
• Insert new filters.
• Replace the gaskets and tighten the covers –
torque 50-55 Nm.
• Replace the gasket and tighten the bolt (2) –
torque 25-32 Nm.
Topping up oil
• Top up the oil (46.0 l) through the dipstick
tube (1).
• Wait unit the oil has been evenly distributed.
• Use the dipstick to check whether the oil
level is clearly above the (2) mark, otherwise
the engine may not be started.
s
29.04.2008

GMK 5170
• Check the oil level as described; à When the gear oil is cold, p. 7 - 22
Inspections after
the oil change
G
Risk of accidents when searching for leaks under the truck crane!
Ensure that the parking brake is engaged before you go underneath the
truck crane to search for leaks.
Keep away from rotating parts.
• Check the transmission for leaks on the lids of the oil filters and at the oil
drain plug.
• Check the oil level as described; à When the gear oil is warm, p. 7 - 23
29.04.2008

GMK 5170
7.6 Transfer case
7.6 Transfer case

The transfer case is screwed to the axle centre drive of the third axle line.
The axle centre drive and the transfer case have two separate oil chambers.
Comply also with the à Run-in regulations, p. 4 - 1.
• Pay attention to any unusual noises in the transfer case.

• Check the transfer case and the connections for leaks. In the event of leak-
ing consumables; à Checking the oil level, p. 7 - 29.
7.6.2 Checking the oil level M1
Spare parts and

Gasket 30 x 36 Cu DIN 7603 1 00117151
Prerequisites – The truck crane is raised on outriggers or parked over an inspection pit.
à p. 2 - 3.
s
29.04.2008

GMK 5170
7.6 Transfer case
Checking the oil

level
• Remove the bolt (1).
• Check whether the oil reaches the lower
edge of the opening.
• Fit a new gasket and tighten the bolt.

7.6.3 Changing the oil M6
Oil, spare parts,

tools Gear oil in Designation Specification GROVE part no.
DIN 51502
13 C - LPF MIL-L 2105 B 00552891
API-GL-5
Viscosity:
Hyp SAE 90
ISO - VG 220
Designation Quantity GROVE part no.

Gasket 16 x 20 Cu DIN 7603 1 00 117 134
Gasket 30 x 36 Cu DIN 7603 1 00 117 151
Prerequisites – The gear oil is at operating temperature.

29.04.2008

à p. 2 - 3.

GMK 5170
7.6 Transfer case
Changing the oil
G
Risk of burning yourself on gear oil at operating temperature!
You could burn yourself if unchecked gear oil escapes at operating temper-
ature. Wear appropriate protective gloves and be careful not to touch the
gear oil.
O

• Unscrew the bolts (1) and (2) and let the oil
drain off.
• Fit new gaskets and tighten the bolt (2).
• Top up oil through the opening (1).
• Fit new gaskets and tighten the bolts (1).
29.04.2008

GMK 5170
7.6 Transfer case
Blank page
29.04.2008

GMK 5170
7.7 Axle lines
7.7 Axle lines

• Comply also with the à Run-in regulations, p. 4 - 1.
• Pay attention to 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. In
the event of leaking consumables;
à Checking the oil level on axle centre drives, p. 7 - 33,
à Final drives – checking the oil level, p. 7 - 38.
7.7.2 Checking the oil level on axle centre drives M1
Spare parts and

tools For drive Designation Quantity GROVE part no.
10 x 6 x 10 Gasket 30 x 38 Cu DIN 7603 2 01 925 343
Gasket 16 x 20 Cu DIN 7603 1 00 117 134
Gasket 16 x 22 Cu DIN 7603 1 00 117 135
10 x 8 x 101) Gasket 30 x 38 Cu DIN 7603 3 01 925 343
Gasket 16 x 20 Cu DIN 7603 1 00 117 134
Gasket 16 x 22 Cu DIN 7603 1 00 117 135
1)
Additional equipment (2nd driven axle line)
à
p. 2 - 3.
s
29.04.2008

GMK 5170
7.7 Axle lines
2nd and 5th axle

lines
3rd axle line

29.04.2008

GMK 5170
7.7 Axle lines
4th axle line

The drive has two oil chambers.
• Unscrew bolts (1) and (2).

• Check that the oil reaches the lower edge of
the openings.
• Fit new gaskets and tighten the bolts.
7.7.3 Axle centre drives – changing the oil M 12
Oil, spare parts,

DIN 51502
Axle lines 2+5: C - LPF MIL-L 2105 B 00552891
each 13.0 API-GL-5
Viscosity:
Axle line 3+4: Hyp SAE 90
each 16.5 ISO - VG 220
For drive Designation Quantity GROVE part no.

Gasket 36 x 42 Cu DIN 7603 2 01 371 208
10 x 6 x 10 Gasket 30 x 38 Cu DIN 7603 1 01 925 343
Gasket 16 x 22 Cu DIN 7603 2 00 117 135
Gasket 36 x 42 Cu DIN 7603 3 01 371 208
10 x 8 x 101) Gasket 30 x 38 Cu DIN 7603 2 01 925 343
Gasket 16 x 22 Cu DIN 7603 2 00 117 135
1)
29.04.2008
s
GMK 5170
7.7 Axle lines

Prerequisites
à p. 2 - 3.
O
2nd and 5th axle

lines

drain off.
• Fit a new gasket and tighten the bolt (2).
• Fill the oil up to the lower edge of the open-
ing.
3rd axle line

• Screw the plug out of the hole (1).
• Check the oil level. It must reach the lower
edge of the opening (1).
• Top up oil through the hole (1).

• Replace the gasket and close the hole (1).
29.04.2008

GMK 5170
7.7 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 open so that both oil
chambers are filled equally. This prevents both oil chambers from being
overfilled and thus the oil from overheating.
• Place a receptacle under bolts (3) and (4).

• Unscrew bolts (1), (2), (3) and (4) and let the
oil drain off.
• Fit new gaskets and tighten bolts (3) and (4).
• Top up oil only through hole (2) until it runs
out of hole (1).
• Fit new gaskets and tighten bolts (1) and (2).
29.04.2008

GMK 5170
7.7 Axle lines
7.7.4 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 (2nd driven axle line)
Prerequisites – The truck crane is raised on outriggers and in horizontal position.

à
p. 2 - 3.
– The parking brake is released.
Checking the oil

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

the same way.
• Turn the wheel until the (2) mark is horizon-
tal and is on the right, next to the centre of
the axle.
• Check whether the oil level is at the (2) mark.
29.04.2008

GMK 5170
7.7 Axle lines
7.7.5 Final drives – changing the oil M 12
Oil, spare parts,

DIN 51502
each final C - LPF MIL-L 2105 B 00552891
drive: API-GL-5
4.1 Viscosity:
Hyp SAE 90
ISO - VG 220
For drive Designation Quan- GROVE part no.

tity
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)
– Drain channel.
Prerequisites – The truck crane is raised on outriggers..

à
p. 2 - 3.
O
s
29.04.2008

GMK 5170
7.7 Axle lines
Draining oil
• Change the oil on all final drives in the same
way.
• Turn the wheel until bolt (1) is at the bottom.
• Use a drain channel and place a receptacle
under the bolt.
• Unscrew the bolt and let the oil drain off.
Topping up the oil

• Turn the wheel until the (2) mark is horizon-
tal and is on the right, next to the centre of
the axle.
• Top up the oil through the hole.
29.04.2008

GMK 5170
7.7 Axle lines
7.7.6 Lubricating the cardan shafts on 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 Specification GROVE part no.
grease according to Classification
DIN 51502
Grease KP - L2K DIN 51825 00554201
– Grease gun from the tool set.
à p. 2 - 3.
– The wheels are turned as far as they will go, so that the grease nipples on
the sides of the final drives are more easily accessible.
Lubricating
Cardan shafts (2) are fitted only to the

10 x 8 x 10 drive.
• Check which cardan shafts (1) and (2) have
grease nipples (3).
• Clean the grease nipples (3).
• Inject grease into the grease nipples until
grease escapes from the bearing points. Do
not inject with grease with excessive force,
otherwise the lip seals may be damaged.
• Remove the excess grease.
29.04.2008

GMK 5170
7.7 Axle lines
7.7.7 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
DIN 51502
Grease KP - L2K DIN 51825 00554201
à p. 2 - 3.
Lubricating
The cardan shaft (2) is fitted only to the

10 x 8 x 10 drive.
• Check which cardan shafts (1) and (2) have
grease nipples (3).
• Clean the grease nipples (3).
• Inject grease into the grease nipples until
grease escapes from the bearing points. Do
not inject with grease with excessive force,
otherwise the lip seals may be damaged.
• Remove the excess grease.
29.04.2008

GMK 5170
7.8 Wheels
7.8 Wheels
7.8.1 Checking the tyres for damage D
Prerequisites – The truck crane is raised on outriggers..

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

– chunking
– dents
– areas of uneven wear
– reaching the wear mark (1).
• Replace the damaged tyres.
• If the tyres show varying wear, change the
tyres ( à Tyre change, p. 7 - 46).
S
Risk of accidents due to uneven braking!
When changing the tyres, only use tyres of original equipment quality
(dimensions, load bearing capacity, air pressure) so that driving character-
istics are maintained.
Always replace the tyres on one axle line.
29.04.2008

GMK 5170
7.8 Wheels
7.8.2 Checking the tyre air pressure W
S
Risk of damage to the tyres!
The air pressure increases when the tyres are at operating temperature.
Never release the increased air pressure of tyres at operating temperature!
Always check the air 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

14.00 R 25 10.0
16.00 R 25 9.0
20.50 R 25 7.0
29.04.2008

GMK 5170
7.8 Wheels
7.8.3 Check tightness of wheel nuts M1
Spare parts and

per wheel
Wheel nut with pressure plate 12 01207756
– Torque wrench for 650 Nm.
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.
29.04.2008

GMK 5170
7.8 Wheels
7.8.4 Tyre change 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
Wheel nut with pressure plate 12 01207756
Wheel rim sealing ring1) 1 00558261
1)
required only in case of optimised tyre change.
à
p. 2 - 3.
29.04.2008

GMK 5170
7.8 Wheels
Tyre change
G
Risk of accidents if procedure incorrect!
This section shows only the sequence to be followed when changing tyres.
When removing/installing the wheels, observe all the safety instructions
and the procedure stated in the operating instructions.
• Remove the wheels from the axles.

• Mount the wheels on another axle, as shown in the diagram. Replace any
damaged parts. Tighten the wheel nuts; à p. 7 - 45.
s
29.04.2008

GMK 5170
7.8 Wheels
Optimised tyre To ensure that the wear on all tyres is more or less the same, you can also
change rotate the tyres on the wheel rim and mount them on the other side of the
vehicle.
G
Risk of accidents if procedure incorrect!
This section shows only the sequence to be followed when changing tyres.
When removing/installing the wheels, observe all the safety instructions
and the procedure stated in the operating instructions.
G
Risk of accidents due to errors when installing aluminium wheel rims!
Have tyres fitted to aluminium wheel rims only in a workshop with the cor-
rect special tool.
This will prevent tyre damage caused by fitting errors.
G
Risk of damage to tyres when running direction changed!
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 - 45.
29.04.2008

GMK 5170
7.9 Vehicle brake
7.9 Vehicle brake
7.9.1 Checking brake-lining thickness M3
• Check the brake-lining thickness (from the

inner side) at openings (1).
If the brake-lining thickness has worn down to
the wear marks (stepped edges or grooves), or
if the brake-lining thickness has worn down to
only 3 mm:
• Have CraneCARE or your repair crew change
the brake linings.
• Close off the openings using the covers.
G
Risk of accidents due to uneven braking!
If the brake lining is changed only on one side of the axle line, the wheels
will have an uneven braking effect.
Always replace the brake lining on both sides of an axle line.
29.04.2008

GMK 5170
7.9 Vehicle brake
Blank page
29.04.2008

GMK 5170
7.10 Suspension
7.10 Suspension
7.10.1 Suspension struts – checking the oil level M1
Oil, spare parts,

tools Oil in litres Designation GROVE part no.
for each suspen- Gear oil 02310863
sion strut:
1.5
– Press with connected hose (from tool box).
à p. 2 - 3.
– Immediately before the inspection, the truck crane was completely low-
ered and returned to On-road level; à
Operating instructions.
S
Risk of damage due to faulty suspension struts!
If the oil level is above the upper mark on the inspection glass, the suspen-
sion strut is faulty and must be replaced.
Notify CraneCARE.
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.
• 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 to the hose.
• Inject oil up the centre of the inspection
glass.
• Remove the hose and quickly close the con-
nection (2).
29.04.2008

GMK 5170
7.10 Suspension
7.10.2 Suspension struts – checking the fastening M1
Spare parts and – Torque wrench for tightening torque up to 900 Nm.
tools
Prerequisites – The truck crane is raised on outriggers; à Operating instructions.

à p. 2 - 3.
– The wheels have been removed.
• Check whether the bolts 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.
29.04.2008

GMK 5170
7.10 Suspension
7.10.3 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 close to the wheels when you switch on the suspen-
sion.
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 bursting or being damaged when lower-
ing the wheels.

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

• Switch on the suspension; à Operating instructions.
• Check whether all suspension struts are extended and the forced levers
(1) are relieved.
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 CraneCARE

29.04.2008
your repair crew.

GMK 5170
7.10 Suspension
7.10.4 Pressure accumulator – checking the gas pressure M 12
The gas pressure must be checked every 3000 operating hours, but in any
case at least once every 12 months.
G
Risk of accidents due to incorrect inspection!
The gas pressure test must be carried out only by an authorised inspector
of pressure tanks or under his supervision or instruction.
The suspension features integrated pressure

accumulators that contain nitrogen (1).
The filling pressure at 20 °C is 40 bar.
• Have the filling pressure checked and if nec-

essary, set by CraneCARE.
29.04.2008

GMK 5170
7.11 Steering
7.11 Steering
7.11.1 Checking for leaks D
• Check the hydraulic system of the steering (steering cylinders, pipes and
hoses 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 hoses only when the system is depressurised.
• Top up oil if necessary; à Checking the oil level, p. 7 - 61.
After changing pipes and hoses:

• Bleed the hydraulic system; à Bleeding the hydraulic system, p. 7 - 73.
If damage cannot be rectified immediately or further damage is likely:

• Notify CraneCARE or your repair crew.
29.04.2008

GMK 5170
7.11 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 is 80 bar.
• Have the filling pressure checked by

CraneCARE and corrected if necessary.
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GMK 5170
7.12 Compressed air system
7.12.1 Draining the compressed air system W
Spare parts and

Valve 5 01 570750
Gasket 22 x 27 Cu DIN 7603 5 00117142
– The air reservoir is filled to the maximum à Operating instructions.
à p. 2 - 3.
Draining the com-

pressed air system
• Actuate the valves (1) on the air reservoirs
(2) to (5).
If a lot of moisture escapes:
• Have CraneCARE or your repair crew check
or change the drier.
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GMK 5170
7.12.2 Checking for leaks W
• Start up the compressed air system.

• Look for any possible leaks in the compressed air system (connections,
pipes, hoses 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 hoses when the system is depressurised.

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GMK 5170
7.12.3 Replacing the filter cartridge of the compressed air drier M 12
Spare parts and

Filter cartridge with gasket 1 03043578
– Strap wrench.
à p. 2 - 3.
Changing the filter

cartridge
G
Risk of injury from escaping compressed air!
If the reservoir (2) is not completely empty, the compressed air dryer will
be under pressure.
Ventilate the reservoir until air no longer escapes from the valve.
• Release all the air from the reservoir (2) via

the valve (1).
• Replace the filter cartridge (3) using the
strap wrench (lubricate gasket slightly).
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GMK 5170
7.13 Hydraulic system
O
Prerequisites – The truck crane is aligned horizontally at on-road driving level;

à Operating instructions.
– The outriggers are retracted; à Operating instructions.
à p. 2 - 3.
S
Risk of damage to the hydraulic system!
When working with hydraulic oil, you must make sure that it is clean!
Even new oil should be filtered.

the inspection glass (1) before starting work.

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GMK 5170
7.13.2 Checking the hydraulic hoses W
Hydraulic hoses are 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 fitting)
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 designation.
2 Maximum operating pressure and unit
of measurement (A) (e.g. 250 bar).
Maximum operating pressure and unit
of measurement (B) (e.g. 25.0 MPa).
3 Month and year of manufacture.
• Always ensure that the corresponding parts

of the system are depressurised.
• Damaged or old hydraulic hoses must be
replaced immediately.
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GMK 5170
• 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 - 61.
G
Never tighten any leaking connections when the system is under pressure.
Only change pipes and hoses when the system is depressurised.
O
Immediately repair or have repaired leakages in the hydraulic system to
ensure that no hydraulic oil escapes, seeps into the ground or reaches
water when the crane is being used.
After parts have been changed:

• Bleed the carrier hydraulic system; à Bleeding the hydraulic system,
p. 7 - 73.
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GMK 5170
7.13.4 Cleaning the magnetic rods M3
Spare parts and

Filter 2 03329152
Gasket set 2 03135778
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.
Cleaning the mag-

netic rods
• Remove the lid (1) and pull out the filters.
• Place the filters in a receptacle.
• Remove the spring (2).
• Loosen the nut (5).
• Take the magnetic rod (3) out of the filter
cage (4) and clean it.
• Replace any damaged parts.
S
Large amounts of metal particles are a sign of damage in the hydraulic sys-
tem. Have CraneCARE or your repair crew check the hydraulic system.
29.04.2008

GMK 5170
• Install the filters and insert them.

• Replace the gaskets if necessary and fasten
the lid (1).
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GMK 5170
7.13.5 Changing the ventilation filter M 12
Shortening the • Under difficult operating conditions – at extremely sandy or dusty loca-
interval tions – you must change the ventilation filter 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 filter inserts in suitable receptacles and have them disposed of
properly by qualified personnel.
• Remove the lid (1).

• Change the filter (2) and fasten the lid.
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GMK 5170
7.13.6 Taking oil samples M 12
Shortening the • Under difficult operating conditions – at tropical or very hot locations –
interval you must halve the oil change interval.
Spare parts and – Connecting piece and hose (tool box).

tools – Four sample containers (0.3 litres each).
– Receptacle, approx. 5 litres; à p. 2 - 4.
Prerequisites – The outriggers are retracted; à Operating instructions.

à p. 2 - 3.
Taking oil samples Samples must be taken from the hydraulic oil tank and from the hydraulic
system in order to determine the usability of the oil.
• Take one oil sample from each valve (1), (2)

and (3) of the hydraulic oil tank; à Handling
the valves, p. 7 - 68.
• An oil sample from the hydraulic system is
taken via a gauge port (4), e.g. on a valve
block of the suspension.
s
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GMK 5170
Handling the The valves can be opened and closed only using the connecting piece with
valves the hose. The connecting piece is in the tool box.
G
Danger due to escaping hydraulic oil!
When the connecting piece is screwed onto 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.
• Place the hose onto 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 onto the
valve – the valve opens.
• Drain the required amount of oil.
• B – Remove the connecting piece and hose – the valve closes.
• Screw the cap onto the valve.
Taking oil samples • Before taking the oil sample, allow 1 to 2 litres of oil to drain into a recep-
tacle.
• Take 0.3 litres of hydraulic oil from each of the three valves on the hydrau-
lic tank and from one gauge port.
• Label each sample with
– the date of sampling,
– number of operating hours since last oil change and
– the sampling location (hydraulic oil tank or gauge port).
• Have a technical laboratory determine
– the viscosity,
– the viscosity index,
– the degree of contamination and
– the water content of all the samples.
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GMK 5170
Determining the Compare the quality of the oil with the limit values and carry out the speci-
quality of the oil fied measures if necessary.
Viscosity limit values:

– Viscosity ISO-VG 32 in accordance with DIN 51524 T.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 - 70.
Contamination limit value:

– Contamination in accordance with NAS 1638 Class 7 or ISO 4406:1999
Code 18/16/13 (purity class).
If this limit has been reached/exceeded:
• Replace the filters of the hydraulic system; à p. 7 - 74.
• Have the hydraulic oil cleaned with a mobile filter unit until the required
purity class is reached.
Water content limit value:

– Water content ≤ 100 ppm.
If this limit value has been reached/exceeded:
• Have the hydraulic oil cleaned with a mobile water separator until the
water content is clearly below the limit value.
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GMK 5170
7.13.7 Changing the hydraulic oil
The oil needs to be changed only if the laboratory analysis indicates the
need for it;à Determining the quality of the oil, p. 7 - 69.
Oil, spare parts,

tools Hydraulic oil Designation Specification GROVE part no.
in litres according to Classification
DIN 51502
150 H - LP DIN 51524 T.2 01375719
Viscosity: ISO-VG 32

Cover gasket 140/90 x 3 1 03098598
– Connecting piece with hose (tool box).

– One or more receptacles, approx. 150 l; à p. 2 - 4.
Prerequisites – The outrigger is retracted; à Operating instructions.

à p. 2 - 3.
Closing 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.
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GMK 5170
Draining oil
O
Use the supplied connecting piece and hose and a receptacle with sufficient
capacity to drain the hydraulic oil.
• Place a receptacle underneath the valves.

• One after the other, screw the connecting
piece and hose onto the valves (1), (2) and
(3);à Handling the valves, p. 7 - 68.
• Change the filters; à p. 7 - 74.
Topping up the oil
S
Cleanliness is of the utmost importance when handling hydraulic oil.
Even new oil must be filtered before it is added to the tank.
• Remove the lid (3).

• 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 lid.
s
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GMK 5170
Establishing oper- After having changed the oil filters and topped the oil up, you must re-estab-
ating condition lish the operating condition.
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.

• Carry out all hydraulic functions several times to remove any air in the
system.
• Carry out a road test of 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 - 61.
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GMK 5170
Bleeding the If the steering is “loose” during the test run, you must bleed the hydraulic
hydraulic system system at the steering cylinders.
Preparations – The truck crane is raised on outriggers; à Operating instructions.

– The parking brake is engaged.
G
Risk of crushing from turning wheels!
When working between the wheels, ensure that the steering wheel cannot
be turned by an unauthorised party. 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 the collar nuts (1) until the oil coming out
no longer contains air bubbles.
If the steering system is still not operating

properly:
• Notify CraneCARE authorised repair special-
ist.
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GMK 5170
7.13.8 Changing the hydraulic oil filter
All three oil filters must be replaced when changing the oil.
In the event of a warning message, the symbol (1) in the Warning submenu
indicates that you must change the oil filters.
Spare parts and

Filter 2 03329152
à p. 2 - 3.
Changing the filter
O
Store used filter inserts in suitable receptacles and have them disposed of
properly by qualified personnel.
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GMK 5170
• Remove the lid (1) and pull out the filters.

• Place the filters in a receptacle.
• Undo the bolt (6).
• Take the magnetic rod (3) and the filter (4)
out of the filter cage (5).
• Clean the magnetic rod (2) and the filter
cage (5).
• Insert a new filter (3) into the filter cage (5).
S
tem.
Have CraneCARE or your repair crew check the hydraulic system.
• Install the filters and insert them.

• Replace the gaskets and fasten the lid (1).
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GMK 5170
7.14 Central lubrication system
7.14.1 Checking the level W
Grease, spare
DIN 51502
Grease KP - L2K DIN 51825 00554201
– Filling pump from the tool set.
Prerequisites – The parking brake is engaged.
Checking the level
• Check the level of the grease container (1).

The grease level must be near the max.
mark.
If the level is too low:
• Add more grease; à p. 7 - 78.
s
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GMK 5170
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 hole and filling pump until immediately
before refilling the grease. This prevents dirt particles from getting into the
grease and damaging the central lubrication system.
Fill the container as follows:

1 Filling pump tool set
You must install the connector from the
tool box.
2 Filling pumps for lubrication nipples
• Switch on the ignition.
• When filling with the supplied filling pump,

screw it onto the connecting piece (2).
• Fill the grease container via connection (2)
up to the max. mark.
• Press the button (1) for approx. 2 seconds
once.
Intermediate lubrication is triggered.
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GMK 5170
7.14.2 Bleeding the central lubrication system
When 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 connection
(2).
• Turn on the ignition.
• Trigger intermediate lubrication repeatedly
until the grease flowing from the connection
(2) no longer contains any bubbles.
• Fasten the lubricating pipe at connection (2).
• Remove any excess grease.
7.14.3 Triggering intermediate lubrication
Intermediate lubrication should be activated

– after high-pressure cleaning,
– to check the lubrication at all lubricating points.
• Turn on the ignition.

• Press the button (1) for approx. 2 seconds
once.
An intermediate lubrication cycle will be trig-
gered which lasts approximately 3 minutes.
Check whether grease is applied to all the
lubricating points. (Steering arm at all axle
lines).
• Turn off the ignition and remove any excess

grease.
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• Tighten the cap.

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GMK 5170
7.15 Electrical system
7.15.1 Checking the lighting and indicators D
G
Risk of accidents if the safety devices are faulty!
If the lamps or indicators fail, notify CraneCARE and have the fault rectified.
• Check the following functions daily before operating or driving the truck
crane, and have faulty parts repaired:
!r2 1 – Parking light/headlight, marker lights, rotating beacons, fog tail light, fog
light, outrigger lights
k – Hazard warning system

– Brake lights
– Reversing lights
– Warning buzzer
– Full-beam headlight
– Turn signal indicator
– Windscreen wipers
– Windscreen washing system
– Horn
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GMK 5170
7.15.2 Checking the batteries M1
G
Risk of poisoning from batteries containing lead compounds!
Battery poles, battery clamps and parts inside the battery contain lead com-
pounds. Lead-compound particles on your hands must not be allowed to
enter your body – e.g. by swallowing contaminated food.
Wash your hands after working on batteries.
G
Risk of explosion from escaping hydrogen!
Do not place tools on the battery and keep unshielded light away from the
battery.
G
Risk of explosion from static charge!
Only use anti-static cloths to clean the batteries.
This prevents static charging and possibly resulting hydrogen mixtures
from exploding.
G
Risk of injury from battery acid!
Battery acid is highly caustic. Wear safety goggles and protective gloves.
Do not tilt the battery. Rinse off or wash out the acid spray on the skin or
clothing using soap suds.
S
Risk of damage to the crane electronics!
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 the battery master switch (1) off and
remove the selector handle.
• Open the battery box (2).
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GMK 5170
Checking the connecting terminals

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

• Remove all lids (1).
The acid level must be above the plates.
If the acid level is too low
• Top it up using distilled water only until the
plates are covered.
• Screw on all lids (1) tightly.
After checking
• Close the battery box (2).
• Attach the selector handle and switch on the
battery master switch (1).
• Check the timers on the tachograph and on
the auxiliary heater; à Operating instruc-
tions.
• Enter the code for the radio; à Separate
operating instructions.
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GMK 5170
7.15.3 Checking the charge level of the batteries M3
Spare parts and – Battery testing device; à Separate operating instructions, 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. Therefore, observe the special scale on
your acid siphon.
D
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 compounds
Battery poles, battery clamps and parts inside the battery contain lead com-
pounds. Lead-compound particles on your hands must not be allowed to
enter your body – e.g. by swallowing contaminated food.
Wash your hands after working on batteries.
G
Risk of explosion from escaping hydrogen!
Do not place tools on the battery and keep unshielded light away from the
battery.
G
Risk of explosion from static charge!
Only use anti-static cloths to clean the batteries.
This prevents static charging and possibly resulting hydrogen mixtures
from exploding.
G
Risk of injury from battery acid!
Battery acid is highly caustic. Wear safety goggles and protective gloves.
Do not tilt the battery. Rinse off or wash out the acid spray on the skin or
clothing using soap suds.
S
Risk of damage to the crane electronics!
Always switch off the battery master switches before commencing work on
29.04.2008
the truck crane’s electrical system.

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

GMK 5170
Before checking
• Open the battery box (2).
Checking the acid concentration

• Remove all lids (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 - 84.
• Check all cells in the same way.
• Screw on all lids (1) tightly.
After checking
• Close the battery box (2).
• Attach the selector handle and switch on the
battery master switch (1).
• Check the timers on the tachograph and on
the auxiliary heater; à Operating instruc-
tions.
• Enter the code for the radio; à Separate
operating instructions.
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GMK 5170
7.16 Air-conditioning system
7.16.1 Checking the air-conditioning system M1
• Switch on the air-conditioning system; à Operating instructions

• Check whether cooling is being achieved. If no cooling is being achieved,
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, lest further damage result.
Have the air-conditioning system repaired as soon as possible by
CraneCARE.
7.16.2 Cleaning the condenser fins M1
S
Risk of damage to the condenser!
Do not use a high pressure cleaner or steam jet cleaner. The powerful jet
may damage the fins. Use only compressed air for cleaning.

• Clean the condenser fins with compressed
air (1).
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GMK 5170
7.16.3 Checking hoses M6
G
Danger of burns from escaping refrigerant!
Wear suitable protective goggles and gloves when checking hoses and con-
nections.
This will prevent injury from suddenly escaping refrigerant. Seek medical
attention if skin or eyes come into contact with refrigerant.
• Check all refrigerant hoses for damage and worn areas.

Have damaged hoses replaced only by CraneCARE.
7.16.4 Checking the entire air-conditioning system M 12
H
This check should only be carried out by CraneCARE!
G
nections.
• Have the entire air-conditioning system checked for leaks and proper
functioning.
The inspection of the air-conditioning system includes most importantly
the inspection of
– the refrigerant collector, in accordance with the pressure container reg-
ulations (test group II) and
– the refrigerant compressor.
• Use only suitable refrigerant for topping up.
Refrigerant
Fill quantity Designation CAS no.
in kg EC no.
approx. 1.5 Tetrafluoroethane (R134a) 811-97-2
212-377-0
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Filler connections

GMK 5170
H
This topping up should be done only by CraneCARE.
– Filler connections (1) for refrigerants

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GMK 5170
7.17 Particulate filter

When a particulate filter is fitted as additional equipment, it is incorporated
in the exhaust system silencer.
Have the particulate filter cleaned by service partners.

Information can be obtained from CraneCARE.
7.17.1 Checking the clamp straps M1
Spare parts and

Clamp strap 2 03134864
Checking the
clamp straps
G
Risk of burning yourself if the exhaust system is hot!
During operation, the exhaust system can heat up to 400 °C. Wear suitable
gloves and/or wait until the exhaust system has cooled down. Make sure
not to touch any hot parts.
• Remove the heat shield (1).

• Check the clamp straps (2) for tightness.
Torque 20 Nm.
• Replace any damaged clamp straps;
à p. 7 - 93.
• Attach the heat shield (1).
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GMK 5170
7.17.2 Replacing the particulate filter M6
Spare parts and

Filter 1 03134863
à p. 2 - 3.
Removing the
exhaust silencer
G
Risk of burning yourself if the exhaust system is hot!
During operation, the exhaust system can heat up to 400 °C. Wear suitable
gloves and/or wait until the exhaust system has cooled down. Make sure
not to touch any hot parts.
G
Health hazard due to soot particles!
Soot particles are suspected of being hazardous to health.
Wear appropriate dust respirator masks and be careful not to breathe in or
ingest dust particles.
O
Risk of polluting the environment!
Collect the combustion residues from the particulate filter in a suitable
receptacle and dispose of them according to the relevant regulations.
H
When cleaning or exchanging the particulate filter, also refer to the docu-
ments supplied by the filter manufacturer.
Record the filter exchange in the documents supplied by the filter manufac-
turer.
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GMK 5170
• Remove the heat shield (1).

• Loosen the clamp strap (3) and remove the
part (2).
• Loosen the clamp strap (5) and remove the
filter (4) from part (6).
• After removal and before cleaning, allow the
parts to cool down if necessary.
Cleaning the filter • Clean the filter in a manufacturer-approved cleaning system only.
or exchange it • Replacement filters are available from the filter manufacturer's service
partner if you do not have a cleaning system available.
For more information, please contact CraneCARE.
Installing the filter
• Use only new clamp straps (3) and (5) with

intact gaskets.
• Place the filter (4) on the part (6) and fasten
it with the clamp strap (5) – torque 20 Nm.
• Place the part (2) on the filter (4) and fasten
it with the clamp strap (3) – torque 20 Nm.
• Attach the heat shield (1).
• Carry out a back pressure test; à p. 7 - 94.
s
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GMK 5170
Back pressure test The back pressure test allows you to determine whether the exhaust con-
nection to the filter is gas-tight:
• Engage the parking brake; à Operating instructions.

• Slowly increase the engine speed up to 1800 min-1 and hold this engine
speed for 30 seconds.
• Monitor the exhaust gas flow – there must be no visible smoke.
If smoke was clearly visible:

• Check whether
– the clamp straps are sufficiently tight,
– if the clamp strap gaskets are intact,
– if the particulate filter is intact.
• Rectify any damage you were able to identify.
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GMK 5170
7.18 Towbar coupling

Depending on the scope of equipment of your truck crane, it may have tow-
bar couplings (additional equipment) from various manufacturers.
Their wear values may vary from those specified; à
Separate operating
instructions.
7.18.1 Lubricating the towbar coupling M1
This maintenance work is not required if the towbar coupling is connected

to the central lubrication system.
Grease, spare
DIN 51502
Grease KP - L2K DIN 51825 00554201
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 coupling pin move
down and seriously injure your hand.
H
To avoid over-lubrication, the towbar coupling should be lubricated only
when open!
• Clean the lubricating nipples (2) and (3).

• Open the towbar coupling. To do this, move
the lever (1) upward.
• Squirt grease into the lubricating nipples (2)
and (3).
• Close the towbar coupling.
s
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GMK 5170
Closing the tow-

bar coupling
G
Risk of injury when closing the towbar coupling by hand!
When closing, the lever moves down with great force in the direction of the
coupling jaw. Therefore, start the closing process only by moving the lever
briefly in the direction of the coupling jaw with the balls of your hands.
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).
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GMK 5170
7.18.2 Checking the bearing M3
Prerequisites – The coupling is closed; à p. 7 - 96.
Checking the bear-

ing
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 hand injury.
• 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 clearance at the coupling head
must be no more than 3 mm.
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GMK 5170
7.18.3 Checking the cotter pin M3
Checking the cot-

ter 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
If the dimension is smaller than that given

above, have the cotter pin replaced by
CraneCARE or by your repair crew.
• Also check the cotter pin for the correct ver-

tical clearance. Take a screwdriver and press
the pin (1) upwards. The vertical clearance
(2) of the cotter pin must not exceed 4 mm.
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GMK 5170
7.18.4 Checking the lower bushing M3
Checking the
bushing
• Check the internal diameter of the lower
bushing. The diameter D must not exceed
the following values:
If the dimension is smaller than that given

above, have the bushing replaced by
CraneCARE or by your repair crew.
7.18.5 Checking the initial tension of the springs M3
The coupling head should require physical power to twist when checking
the torque.
• Twist the coupling head clockwise and anticlockwise to check the initial
tension of the rubber springs.
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GMK 5170
7.18.6 Checking the support ring M3
Checking the sup-

port 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.
7.18.7 Checking the function of the coupling jaw/ M3

Resetting central position
Spare parts and – Torque wrench for torque of 58 Nm.

tools

29.04.2008

GMK 5170
Checking for cor-

rect 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 central 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 - 101.
Resetting the cen-

tral position
• Open the coupling (lever (1) pointing
upwards) and loosen the bolts (2).
• Push the coupling jaw to the side until the
lever engages.
• Tighten the bolts – torque 58 Nm.
• Check the function of the coupling jaw;
à p. 7 - 100.
29.04.2008

GMK 5170
Blank page
29.04.2008

GMK 5170
7.19 Other maintenance work
7.19.1 Lubricating the support bearings M1
Grease, spare
DIN 51502
Grease KP - L2K DIN 51825 00554201
– Brush or roller.
G
Risk of crushing due to extending support bearings!
Ensure that there is sufficient room around the crane. Warn any persons
nearby before extending the support bearings.
Observe the safety instructions in the operating instructions.
• Fully extend all support bearings;

• Apply the grease to both sides of the slide
faces (1) on all the support bearings.
• Extend and retract the support bearings sev-
eral times.
After every high-pressure cleaning operation

on the truck crane:
• Lubricate the support bearings.
29.04.2008

GMK 5170
7.19.2 Checking the auxiliary heater for correct operation M1
Your truck crane has fire auxiliary heaters, depending on its scope of equip-
ment.
During the warm summer months, operate the auxiliary heater for 20 to
30 minutes; àOperating instructions.
• Check that the system is working properly. Also perform a functional

check of the controls.
• If the heating system is not functioning correctly, report it CraneCARE.
7.19.3 Having the fire extinguisher checked Y2
Your truck crane has fire extinguishers, depending on its scope of equip-
ment.
H
The maintenance interval may be shorter, depending on the respective
national regulations. Ask about the national and local regulations at the
local Fire Safety Authority.
• Follow the operating instructions (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 is still working properly
after the maintenance interval on the label has expired. 29.04.2008

GMK 5170
8
8.1 General instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 1
8.1.1 Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 1
8.2 Symbols for maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 3
8.3 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 5
8.3.2 Topping up the oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 7
8.3.3 Checking the air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 8
8.3.4 Checking the coolant level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 9
8.4 Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 11
8.4.1 Draining off water from fuel filter 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 11
8.4.3 Changing fuel filters 2 and 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 15
8.5 Hoists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 19
8.5.3 Checking the hoist brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 20
8.5.4 Lubricating the auxiliary hoist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 20
8.5.5 Changing the oil/Checking the oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 22
8.5.6 Having a partial inspection carried out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 24
8.5.7 Having a general inspection carried out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 24
8.6 Slewing gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 25
8.6.2 Checking for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 26
8.6.3 Checking the slewing gear brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 26
8.6.4 Changing the oil/Checking the oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 28
8.7 Ball slewing bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 31
8.7.1 Lubricating gear teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 31
8.7.3 Measuring tilting play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 33
8.8 Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 35
8.8.2 Checking the hydraulic hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 36
8.8.3 Checking ventilation filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 36
8.8.4 Checking for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 37
8.8.5 Changing the ventilation filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 38
8.8.6 Pressure accumulator – checking the gas pressure . . . . . . . . . . . . . . . . . . . . . . 8 - 39
8.8.7 Taking oil samples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 40
8.8.8 Changing the hydraulic oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 41
29.04.2008
8.8.9 Changing the hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 44

GMK 5170
8.9 Main boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 49
8.9.1 Lubricating the telescopic sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 49
8.9.2 Checking the sheaves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 53
8.9.3 Checking the locking system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 53
8.10 Hoist ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 55
8.10.1 Checking the position on the rope drums . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 55
8.10.2 Checking the hoist ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 56
8.10.3 Lubricating the hoist rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 57
8.10.4 Assessing the condition of the hoist rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 58
8.10.5 Replacing the hoist rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 64
8.10.6 Setting the lowering limit switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 67
8.11 Cable drums and slewing angle sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 69
8.11.1 Maintenance of the slip ring assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 69
8.11.2 Lubricating the slewing angle sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 71
8.12 Central lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 73
8.12.1 Checking the level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 73
8.13 Hook blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 73
8.13.1 Checking the sheaves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 73
8.13.2 Lubricating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 74
8.14 Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 75
8.14.1 Checking the lighting and indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 75
8.14.2 Checking the batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 76
8.14.3 Checking the charge level of the batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 76
8.15 Air-conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 77
8.15.1 Checking the air-conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 77
8.15.2 Cleaning the condenser fins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 77
8.15.3 Checking hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 78
8.15.4 Checking the entire air conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 78
8.16 Other maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 79
8.16.1 Checking the auxiliary heater for correct operation . . . . . . . . . . . . . . . . . . . . . 8 - 79
8.16.2 Lubricating the piston rod of the derricking cylinder . . . . . . . . . . . . . . . . . . . . 8 - 79
8.16.3 Having the fire extinguisher checked . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 80
29.04.2008

GMK 5170
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

• Open the service flaps (1) for maintenance
work.
After maintenance work
• Close the service flaps (1) and secure them
with the locks.
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GMK 5170
Blank page
29.04.2008

GMK 5170

Check the following symbols daily before starting operations.
On the ECOS
display
• Open the Warning submenu; à Operating instructions.
You must carry out the associated maintenance work if the symbol is dis-
played in red:
– Oil pressure; à p. 8 - 5,
– Air filter; à p. 8 - 8,
– Coolant level; à p. 8 - 9,
– Hydraulic oil filter; à p. 8 - 41.

29.04.2008

GMK 5170
Blank page
29.04.2008

GMK 5170
8.3 Engine
8.3 Engine
• In addition, carry out further maintenance work as specified in the engine
manufacturer documentation supplied with the vehicle. Pay attention to the
information relating to use of bio-diesel fuel – the oil change interval must
be halved.
Prerequisites – The truck crane is level.
Checking the oil

level
• Immediately after starting the engine, check the lamp (1) on the ECOS dis-
play.
The lamp (1) must go out approx. 10 seconds after starting the engine.
S
Risk of damage to the engine if the oil pressure is too low!
If the lamp (1) does not go out after about 10 seconds, perform the follow-
ing check and switch off the engine.
The engine can be damaged by running it when the oil pressure is too low.
• Press the button (1) once. The Warning submenu opens.

• Switch off the engine immediately if the symbol (2) turns red.
• After the lamp (1) has gone out following the engine start-up, allow the
engine to idle for 2 - 3 min.
• Check the oil level after about 2 minutes.
29.04.2008
s
GMK 5170
8.3 Engine
• On the dipstick (1), check whether the oil

level is between the min. and the max. mark-
ing (arrows).
29.04.2008

GMK 5170
8.3 Engine
8.3.2 Topping up the oil
Data on the prescribed oil specification; à Engine manufacturer's documenta-

tion.
Oil
Engine oil in Designation Specification GROVE part no.
DIN 51502
16 HD - CD MIL-L 2104 C First fill oil:
DB 228.5 SAE 15 W-40
02309375

– The engine is not running and is secured against unauthorized use;
à p. 2 - 3.
Topping up 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).
Drain off oil if necessary; à Engine manufacturer's documentation.
G
Risk of burning yourself when the engine is hot!
During operation, the engine and add-on parts can reach temperatures up
to 400 °C. Wear appropriate protective gloves and be careful not to touch
hot parts.
• Add oil through the filler neck (1) up to the

max. mark.
• Close the filler neck with the lid.
29.04.2008

GMK 5170
8.3 Engine
8.3.3 Checking the air filter D
• Start the engine. On the ECOS display, check whether the lamp (1) lights
up.
You must change the air filter if the symbol is red.
Spare parts and

Filter 1 03 328 263
Prerequisites – The engine is not running and is secured against unauthorized use;
à p. 2 - 3.
Replacing the air

filter
• Undo all clamps (1) and remove the filter
cover (2).
• Replace the cover and secure it with all the
clamps. 29.04.2008

GMK 5170
8.3 Engine
8.3.4 Checking the coolant level D
• Start the engine. On the ECOS display, check whether the lamp (1) lights
up.
You must top up the coolant if the symbol is red.
Topping up cool-
ant
G
Danger of being scalded due to hot radiator circuit!
The hot radiator circuit is under pressure. When you open the expansion
tank, you could be scalded by escaping steam or 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.
• 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 edge
in the filler neck.
If the coolant level is too low:

• Top up the coolant.
Composition of the coolant;
• 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 CraneCARE or your repair
29.04.2008
crew.

GMK 5170
8.3 Engine
• Investigate any unusual noises from the engine.

• Check the engine and the connections for leaks. In the event of leaking
fluids;
à Checking the oil level, p. 8 - 5,
à Checking the coolant level, p. 8 - 9.
If you detect any worn or damaged parts, contact CraneCARE or your repair
crew.
29.04.2008

GMK 5170
8.4 Fuel system
8.4 Fuel system

Installed in the fuel line are:
1 Fuel filter 1
2 Fuel filter 2
3 Fuel filter 3
8.4.1 Draining off water from fuel filter 1 D
Spare parts and – Receptacle, approx. 5 l; à p. 2 - 4.

tools

à p. 2 - 3.
s
29.04.2008

GMK 5170
8.4 Fuel system
Draining off water
O
Risk of environmental damage due to leaking fluids!
Always let fluids drain into suitable receptacles. Wipe up any fluids that
have leaked.

• Open the valve (1).
• If the draining fluid is clean, close the valve
manually.
• Remove the receptacle and properly dis-
pose of the drained fluid.
29.04.2008

GMK 5170
8.4 Fuel system
8.4.2 Changing fuel filter 1 M3
Spare parts and

Filter 1 03322877
Gasket 1 03322879
Filter element 1 03328656

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

the line.
• Open the screw plug (1) and the valve (2)
and drain the fluid.
s
29.04.2008

GMK 5170
8.4 Fuel system
• (A) – Remove the filter element (2) and the

filter (1).
If necessary, replace any damaged parts.
• (B) – Screw on a new filter (1) and the filter
element (2).
• Close the valve (3) manually.

flowing through the plug (1) no longer con-
tains any bubbles.
• Secure the bolt.
• Remove the receptacle.
H
If you have used a clean receptacle, you can refill the fuel tank with the fluid
using a strainer.
Otherwise dispose of the fluid properly.
29.04.2008

GMK 5170
8.4 Fuel system
8.4.3 Changing fuel filters 2 and 3 M 12
Spare parts and

Filter and gasket 1 03328573
Filter and gasket 1 03328574
– Torque wrench for torque of 10 Nm and 25 Nm.
à p. 2 - 3.
O
have leaked.
Emptying the fuel

line
the line.
• Place a receptacle under the end of the hose
(1).
• Turn the valve – lever (2) horizontal.
• Let the fluid drain into the receptacle.
Leave the receptacle under the end of the
hose. More fluid will run out when you bleed
the fuel line.
s
29.04.2008

GMK 5170
8.4 Fuel system
Changing filters 2
and 3
Changing filter 2
• Unscrew the cap (1) and remove the filter (3)

so that the fluid can drain.
• Clean the cap (1) and insert a new filter.
• Replace the gasket (2) (lubricate slightly).
• Screw the cap on and tighten it – torque
10 Nm.
Changing filter 3
• Unscrew the cap (1) and remove the filter (3)

so that the fluid can drain.
• Loosen the filter (3) from the cap (1).
• Carefully take the receptacle (4) out of the
housing, making sure no dirt gets into the
housing.
• Clean the cap and the receptacle.
• Insert a new gasket (2) (grease lightly) and
place a new filter into the cap.
• Insert the receptacle into the housing.
• Screw the cap with the filter into the housing
and tighten it – torque 25 Nm.
29.04.2008

GMK 5170
8.4 Fuel system
Bleeding the fuel

line
A receptacle is underneath the hose end (1).
The lever (2) is parallel with the line.

• Actuate the pump (4) until the fluid flowing
through the end of the hose no longer con-
tains any bubbles (1).
• Turn the valve – lever (2) at right angles to

the line.
• Start the engine and check that the fuel fil-
ters are leak-tight.
• Remove the receptacle underneath the hose
end (1).
H
If you have used a clean receptacle, you can refill the fuel tank with the fluid
using a strainer.
Otherwise dispose of the fluid properly.
29.04.2008

GMK 5170
8.4 Fuel system
Blank page
29.04.2008

GMK 5170
8.5 Hoists
8.5 Hoists
8.5.1 Checking the oil level W
Spare parts and

Gasket 18 x 24 Cu DIN 7603 4 01377793
Prerequisites – The truck crane is level and is in on-road mode; à Operating instructions.
à p. 2 - 3.
Checking the oil

level
• Check whether the oil level is between the

min. and the max. marking (1).

• Top up the oil; à p. 8 - 22.
29.04.2008

GMK 5170
8.5 Hoists
• Investigate any unusual noises from the hoists.

• Check the hoists and the connections for leaks. In the event of leaking
fluids; à Checking the oil level, p. 8 - 19.
crew.
8.5.3 Checking the hoist brake W
Spare parts and – Weight approx 9.5 t

tools
Prerequisites – The truck crane is prepared for crane operation; à Operating instructions.
Checking the hoist Check that the hoist brake is working correctly on the main hoist and the
brake auxiliary hoist.
• Suspend the hook block on the singly reeved hoist rope.

• Lift a load of approx. 9.5 t to approx. 30 cm above the ground.
• Measure the distance from the ground when the load is hanging com-
pletely still.
If the load has not lowered after approx. 2 minutes, the brake is currently in
working order.
If the load has lowered, notify CraneCARE.
8.5.4 Lubricating the auxiliary hoist M6

29.04.2008

GMK 5170
8.5 Hoists
Grease, spare
DIN 51502
Grease KP - L2K DIN 51825 00554201
à p. 2 - 3.
Lubricating
• Clean the lubricating nipple (1) and lubricate

the hoist at the lubricating nipple.
29.04.2008

GMK 5170
8.5 Hoists
8.5.5 Changing the oil/Checking the oil M 12
Oil, spare parts,

tools Transmis- Designation Specification GROVE part no.
sion oil in according to Classification
litres DIN 51502
7 C - LPF MIL-L 2105 B 02313611
for each hoist API-GL-4/5
Viscosity: Synthetic oil; do
SAE 75 W-90 EP not mix this with
ISO - VG 220 mineral-based
oils!

Gasket 18 x 24 Cu DIN 7603 10 01377793
à
p. 2 - 3.
Changing the oil at

the hoist
Risk of damage to the hoist gearbox!
S
The waste oil must be tested for abrasion particles. This test serves to iden-
tify damage at an early stage; à
p. 8 - 23.
O
have leaked.
H
During filling, the oil spreads only slowly in the hoist. The oil level will there-
29.04.2008
fore rise quickly in the standpipe at first, then drop slightly and finally rise
again to its true level.

GMK 5170
8.5 Hoists
Draining oil
• Place a receptacle under the pipe (3).
drain off.
• Replace the gaskets and secure the hoses (5)
with the bolt (6).
Topping up oil
• Fill the oil through the pipe (3) up to the
max. mark (4).
• Replace the gaskets and secure the hoses (2)
with the bolt (1).
Checking the oil

Risk of accidents from falling load!
G
If this test is not performed, there may be a risk of damage to the hoist gear-
box 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 gearbox
must be removed 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 operating hours.), first consult
CraneCARE before introducing any specific measures.
29.04.2008

GMK 5170
8.5 Hoists
8.5.6 Having a partial inspection carried out Y3
Only suitably trained specialists should carry out a partial inspection of

– the multiple-disk 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.
8.5.7 Having a general inspection carried out Y6
H
When carrying out the general inspection of the hoist gears, 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.
29.04.2008

GMK 5170
8.6 Slewing gear
8.6 Slewing gear
8.6.1 Checking the oil level W
Spare parts and

Gasket 10 x 14 Cu DIN 7603 3 01 368 741
à p. 2 - 3.
Checking the oil Always check the oil level prior to using the crane.
level
• Check whether oil is visible in the inspection

glass (1).
• Always check the oil level for all the slewing
gears.
• Top up the oil; à p. 8 - 28.
29.04.2008

GMK 5170
8.6 Slewing gear
• Investigate any unusual noises from the slewing gears.

• Check the slewing gears and the connections for leaks. In the event of
leaking fluids; à Checking the oil level, p. 8 - 25.
crew.
8.6.3 Checking the slewing gear brake M6
Prerequisites – The truck crane is rigged for a 360° slewing range as per the lifting capac-
ity table.
– The SLI code for the current rigging mode is entered; à Operating instruc-
tions.
– The Brake pedal function is switched on à Operating instructions.
– The main boom is raised to 45° and fully retracted.
G
Risk of overturning while slewing!
Always set a rigging mode for the slewing range 360° in accordance with
the lifting capacity table and enter the associated SLI code. Do not override
the SLI.
29.04.2008

GMK 5170
8.6 Slewing gear
Check When checking the slewing gear brake you must perform the slewing move-
ment against the slewing gear brake.

• Remove the coil (1) from the valve Y 2307.
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 Settings submenu.
The display (1) indicates the pressure in the slewing gear 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.
– If the superstructure still does not slew, the braking effect of the slew-
ing gear brake is sufficient.
– If the superstructure does slew, the slewing gear brake is defective and
must be repaired immediately by CraneCARE.
• Switch the slewing gear off and switch the engine off.
• Secure the coil (1) using the nut to the valve

Y 2307.
• Start the engine and check the slewing gear
for correct operation.
29.04.2008

GMK 5170
8.6 Slewing gear
8.6.4 Changing the oil/Checking the oil M 12
Oil, spare parts,

tools Transmis- Designation Specification GROVE part no.
sion oil in according to Classification
litres DIN 51502
0.9 C - LPF MIL-L 2105 B 02313611
for each API-GL-4/5
slewing gear Viscosity: Synthetic oil; do
SAE 75 W-90 EP not mix this with
ISO - VG 220 mineral-based
oils!

Gasket 10 x 14 Cu DIN 7603 3 01 368 741
Gasket 14 x 20 Cu DIN 7603 3 00 117 132
à p. 2 - 3.
Changing the oil
O
have leaked.
• Always change the oil in all slewing gears.

29.04.2008

GMK 5170
8.6 Slewing gear
Draining oil
• Place a receptacle under the plugs (2).
• Unscrew the filter (4) and plugs (3) and (2).
• Drain the oil.
• Replace the gasket and screw the plugs (2)

back in.
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 screw in the plug
(3) and the filter (4).
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
29.04.2008
transmission must be removed for inspection and sent to the manufacturer.

GMK 5170
8.6 Slewing gear
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GMK 5170
8.7 Ball slewing bearing
8.7.1 Lubricating gear teeth M6
Grease
Adhesive lubricating grease (spray 1 00554205
can)
H
Observe the instructions and safety information on the lubricant packaging!
Prerequisites – The truck crane is level and on outriggers; à Operating instructions.

– The main boom is fully retracted; à Operating instructions.
à p. 2 - 3.
Lubricating A distinction is make between the initial lubrication and later lubrications.
G
Risk of crushing from the gear teeth!
Fingers may be crushed or pieces of clothing can be pulled into the open,
rotating pinion. For this reason, be sure to remount the plate after lubricat-
ing.
s
29.04.2008

GMK 5170
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 about
10 minutes.
• Apply a second, thicker layer of grease and
allow it to penetrate for about 30 minutes.
Subsequent lubrication:
• Apply new grease to all the gear teeth (2).
• Allow it to penetrate for about 30 minutes.
29.04.2008

GMK 5170
8.7.2 General inspection M6
• Investigate any unusual noises from the ball slewing bearing.

• In case of unusual noises take a sample of leaked grease. Have CraneCARE
examine the sample for metal residue.
• Check the ball slewing bearing for damage (e.g. gaskets).
crew.
H
The maintenance interval specified here must be shortened if the ball slew-
ing bearing is subjected to heavy blows (falling load, load slipping).
8.7.3 Measuring tilting play M 12
Spare parts and – Dial gauge (precision 0.01 mm) with tripod.
tools
– Measurement report from when the truck crane was put into operation;
à Delivery receipt.
Prerequisites – The truck crane is rigged with an outrigger span of at least 8.55 x 7.80 m
and is aligned level;à Operating instructions.
– The counterweight combination 53.1 tis fitted according to the lifting
capacity table and equipment of the truck crane.
– The lattice extension has been removed.
– The main boom is telescoped to 50-50-50-50-0.
– The load being lifted must not exceed 1 t– where necessary unreeve the
hook block.
s
29.04.2008

GMK 5170
Measuring tilting The base value of the tilting play is determined and documented by
play CraneCARE when the ball slewing bearing is put into operation or replaced.
The maximum permissible wear is 3.2 mm.
This results in the maximum permissible tilting play.
Base value + max. permissible wear = max. permissible tilting play

Example: 0.35 mm + 3.2 mm 3.55 mm
Measuring current tilting play

• Raise the main boom to 80° and slew to
–135° – display (A).
• Fasten a dial gauge on the front of the turn-
table (4) and place the switch (1) on to the
lower ring (3) as close as possible to the gas-
ket (2).
• Slowly lower the main boom to 25°.
• Read off from the dial gauge how far the
turntable inclined and record this value as
à
the current tilting play; Appendix – Tilting
play measurement report.
• Remove the dial gauge.
If the current tilting play is greater than the max. permissible tilting play,
you must have the ball slewing bearing replaced by CraneCARE.
• Repeat the measurement with the slewing

angles
B –45°
C +45°
D +135° 29.04.2008

GMK 5170
– 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!

the inspection glass (1).

• Add more oil; à p. 8 - 46.
29.04.2008

GMK 5170
8.8.2 Checking the hydraulic hoses W
The inspection work is described in section Checking the hydraulic hoses,

p. 7 - 62.
8.8.3 Checking ventilation filters W
• Check the indicator (1) on the ventilation fil-

ter.
If the indicator is red:
• Replace the filter; à p. 8 - 38.
29.04.2008

GMK 5170
• 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 - 35.
G
Never tighten any leaking connections when the system is under pressure.
Only change pipes and hoses when the system is depressurised.
O
Immediately repair or have repaired leakages in the hydraulic system to
ensure that no hydraulic oil escapes, seeps into the ground or reaches
water when the crane is being used.
After hydraulic components have been changed:

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

• Inform CraneCARE or your repair crew.
29.04.2008

GMK 5170
8.8.5 Changing the ventilation filter M 12
Spare parts and

Filter 1 03 319 602
à p. 2 - 3.
O
Store used hydraulic oil filters in suitable receptacles and have them dis-
posed of properly by qualified personnel.
• Remove the cap (2).

• Change the filter (3) and fasten the cap.
• Reset the display by depressing the pin (1)
on the housing.
29.04.2008

GMK 5170
G
The superstructure is equipped with pressure

accumulators.
The filling pressure at 20 °C is:
1 Pressure 20 bar
accumulator
2 Pressure 180 bar
accumulator
• Have the filling pressure checked by

CraneCARE and corrected if necessary.
29.04.2008

GMK 5170
8.8.7 Taking oil samples M 12
Taking oil samples To determine the usability of the oil, take an oil sample from each of the
hydraulic oil tank and the hydraulic system.
H
For detailed information on taking samples (conditions, tools); see
à Taking oil samples, p. 7 - 67.
From the hydraulic oil tank

• Take the sample from the hydraulic oil tank
via the valve (1).
From the hydraulic system

• Take the sample from the hydraulic system
via a gauge port (1), e.g. at a control block.
29.04.2008
Determining the Compare the quality of the oil with the limit values and carry out the speci-
quality of the oil fied measures if necessary; à Determining the quality of the oil, p. 7 - 69.

GMK 5170
8.8.8 Changing the hydraulic oil filter
When changing the oil, all oil filters must be replaced.
In the event of a warning message, the red symbols in the Warning sub-
menu indicate which oil filters you have to change.
1 Red – Change oil filter 1
2 Red – Change oil filter 2
3 Red – Not used
Spare parts and

For oil filter 1:
Filter 1 03 325 700
Gasket for oil filter 1 1 03 328 209
For oil filter 2:
Filter 1 03134850
Gasket set for oil filter 2 1 03 326 049

à p. 2 - 3.
O
Store used hydraulic oil filters in suitable receptacles and have them dis-
posed of properly by qualified personnel.
s
29.04.2008

GMK 5170
Changing
oil filter 1
O
that have leaked.
• Remove the cap (1) and pull out the hydrau-

lic oil filter.
• Place the filter in a receptacle.
• Undo the bolt (6).
• Take the magnetic rods (3) and the filter (4)
out of the filter cage (5).
• Clean the magnetic rods and the filter cage.
S
tem.
Have the hydraulic system inspected by CraneCARE or by your repair crew.
• Replace the gaskets.

• Assemble the hydraulic oil filter and insert it.
• Fasten the cap (1). 29.04.2008

GMK 5170
Changing
oil filter 2
• Undo the receptacle (1) at the hexagon.
• Replace the gaskets.
• Fill the receptacle with clean oil and tighten
it – torque 25 Nm.
After changing a
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 - 46.
• Start the engine and let it idle for 3 minutes to bleed the system.
• Check that none of the oil filters is leaking.
29.04.2008

GMK 5170
8.8.9 Changing the hydraulic oil
The oil only needs to be changed if the laboratory analysis results indicate
this; à Determining the quality of the oil, p. 8 - 40.
Oil, spare parts,

tools Hydraulic oil Designation Specification GROVE part no.
in litres according to Classification
DIN 51502
915 H - LP DIN 51524 T.2 01375719
Viscosity: ISO - VG 32

Gasket 120 x 90 1 03 328 286
– Connecting piece and hose (tool box);à p. 7 - 68.

– One or more receptacles, approx. 915.0 l; à p. 2 - 4.
à p. 2 - 3.
– The oil filters have been removed; à Changing the hydraulic oil filter,
p. 8 - 41.
Closing the valve
S
Be sure to secure the engine against unauthorized use.
If the engine is started while the valve in the suction line is closed, the
hydraulic pumps will be damaged!
29.04.2008

GMK 5170

the line.
Draining oil
O
Use the supplied connecting piece and hose and a receptacle with sufficient
capacity to drain the hydraulic oil.
• Place a receptacle underneath the valve.

• Screw the connecting piece and hose onto
the valve (1) and drain the oil; à Handling
the valves, p. 7 - 68.
• Change the filters; à p. 8 - 41.
s
29.04.2008

GMK 5170
Topping up the oil
S
Cleanliness is of the utmost importance when handling hydraulic oil.
• Remove the cover (3).

• Add the new oil through the filter until the
level reaches the centre of the inspection
glass (1).
• Replace the gasket (2) if necessary and fas-
ten the cap (2).
Establishing the After having changed the oil filters and topped the oil up, you must re-estab-
operating condi- lish the operating condition.
tion
S
Open the valve prior to starting the engine.
This prevents damage to the hydraulic pumps.
29.04.2008

GMK 5170
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 - 46.
29.04.2008

GMK 5170
Blank page
29.04.2008

GMK 5170
8.9 Main boom
8.9 Main boom
8.9.1 Lubricating the telescopic sections M3
Grease, spare
parts, tools Designation GROVE part no.
Grease for locking pins: 03325215
1 kg can
Lubricant paste for the telescopic slide faces:
200 kg barrel 02310394
25 kg bucket 02314698
10 kg bucket 01373458
1 kg cartridge 02314184
0.4 kg refillable cartridge 03329071
– A grease gun for the lubricating nipples on the locking pins.

– A grease gun for the lubricating nipples on the upper telescopic slide
faces.
– A brush or roller for the lower telescopic slide faces.
S
Risk of damage to the wear pads on the telescopic sections!
Label the containers with the different lubricants for the main boom. This
prevents you using the wrong lubricants at the lubrication points.
H
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
Manual grease spray gun: 03329027
0.4 kg cartridges are refillable using the tyre
inflation hose on the truck crane.
29.04.2008
25 m hose for manual grease spray gun: 03329072
s
GMK 5170
8.9 Main boom

– The hook block is unreeved.
– The truck crane is supported with an outrigger span of at least
8.55 x 5.96 m.
– A counterweight of at least 38.1 t is rigged.
– The SLI code for the current rigging mode is entered.
– The main boom must be completely retracted and lowered into horizontal
position.
Warnings
G
Risk of overturning when telescoping with an overridden SLI!
Only override the SLI when you are requested to do so. Never extend the
main boom further than specified when the SLI is overridden. An increased
danger of tipping exists because the SLI will not switch off extension of the
main boom.
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 derricking gear is
so heavily loaded that the main boom cannot be derricked. For this reason:
• Do not lower the main boom below 0°.
29.04.2008

GMK 5170
8.9 Main boom
Telescopic • Note the following information regarding maintenance work.

section I
• Extend telescopic section I to 50%.
• Override the SLI; à Operating instructions.
• Extend telescopic section I to 100%. Do not extend it any further.
• Use a brush or a roller (lubricant paste) to
lubricate the lower slide faces (3).
• Use the grease gun (lubricant paste) to lubri-
cate the upper slide faces at the lubricating
nipples (1) on both sides.
cate the locking pins at the lubricating nip-
ples (2) on both sides.
• Lock and unlock the telescopic section I sev-
eral times, so that the grease is distributed
over the locking pins.
• Extend telescopic section I to 50%.

• Remove the SLI override; à Operating
instructions.
• Fully retract telescopic section I.
• Fully extend and retract the telescopic sec-
tion I again so that the grease is distributed
over the telescope slide faces.
– Override the SLI for this.
– Do not extend it any further.
s
29.04.2008

GMK 5170
8.9 Main boom
Telescopic sec- • Note the following information regarding maintenance work.

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

• Override the SLI; à Operating instructions.
• Extend telescopic section IV to 25%. Do not extend it any further.
• Use a brush or a roller (lubricant paste) to

lubricate the lower slide faces (3).
cate the locking pins at the lubricating nip-
ples (2) on both sides.
• Lock and unlock the telescopic section V
several times, so that the grease is distrib-
uted over the locking pins.
• Retract telescopic section V to 50%.

• Extend telescopic section IV to 50%.
• Remove the SLI override; à Operating
instructions.
• Retract telescopic section IV completely.
• Fully extend and retract telescopic section V
again so that the grease is distributed over
the telescope slide faces.
29.04.2008
• Lubricate the locking pins of telescopic sections II to IV in the same way.

GMK 5170
8.9 Main boom
8.9.2 Checking the sheaves M3
• Check all sheaves on the main boom head for damage, wear, mobility and
extreme soiling.
Have damaged, worn, sluggish or extremely soiled sheaves replaced by
CraneCARE or your repair crew.
8.9.3 Checking the locking system M 12
G
Risk of accidents if maintenance work is not carried out!
Have the additional maintenance work on the main boom's locking system
performed regularly by CraneCARE.
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's locking system checked by CraneCARE.

29.04.2008

GMK 5170
8.9 Main boom
Blank page
29.04.2008

GMK 5170
8.10 Hoist ropes
8.10 Hoist ropes
8.10.1 Checking the position on the rope drums D
G
Risk of accidents when the rope drum is turning!
Keep away from the turning rope drum.
This will prevent your limbs from being drawn in and getting crushed.
Prerequisites – The hoist mirrors are folded out; à Operating instructions.

– One hook block is reeved;
– The main boom is lowered to about 30°; à Operating instructions.
– The engine has been started.
Checking the
position
Check the position of the ropes (1) on at least
one full turn of the rope drum for the hoist
gears.
• Slowly carry out the Lowering movement
and check the rope.
– 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.
– The cross-over points must be at an angle
of about 180°.
H
The ropes of the top layer lie over the ropes of the bottom layer at the cross-
over points.
29.04.2008

GMK 5170
8.10 Hoist ropes
8.10.2 Checking the hoist ropes W
Spare parts and – Torque wrench for 10 Nm.

tools
Prerequisites – Establish a rigging mode in accordance with the Lifting capacity table and
enter the rigging code on the SLI;à Operating instructions.
– The hook block is reeved 5-fold; à Operating instructions.
– The main boom is raised and fully extended; à Operating instructions.
Checking the rope • Start the engine.

• Unreel the rope and check that the rope is not damaged or improperly
reeled (à Assessing the condition of the hoist rope, p. 8 - 58). 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 - 67.
• Check the fastening of the clamp (1) for

damage and firm seating – torque 10 Nm.
• The free end of the rope must not jut out
beyond the flanged wheel.
• The rope wedge must be in the pouch (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 all parts of the rope end clamp.
• Make sure the rope end is correctly fitted in the rope end clamp;
29.04.2008

GMK 5170
8.10 Hoist ropes
8.10.3 Lubricating the hoist rope M3
Grease, spare
parts and tools Designation Quantity GROVE part no.
Grease 1 03133770
– Brush, roller, spray gun, bath 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 tub filled with lubricant or
– by means of high-pressure lubrication with a pressure pump.
H
Manitowoc Crane Group Germany GmbH recommends high-pressure
lubrication with a pressure pump 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 operating

manual.
For more information, please contact CraneCARE.

29.04.2008

GMK 5170
8.10 Hoist ropes
8.10.4 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 or lang lay),
– the number of load-bearing wires in the outer strands,
– the rope diameter ( à Operating instructions).
In a regular lay rope (1), the wires run more or
less in the longitudinal direction of the rope.
In a lang lay rope (2), the wires run at an angle

of approximately 45° to the longitudinal direc-
tion of the rope.
To calculate the number of load-bearing outer

wires (1), count the number of outer strands of
the rope and multiply by 7.
H
If there are multiple layers of strands, only the outer layer is counted.
29.04.2008

GMK 5170
8.10 Hoist ropes
The following tables show the number of wire breaks in a length 6 times or
30 times the rope diameter which would require rope replacement, for the
most common rope diameters.
Number of visible wire breaks

Regular lay rope
Number of
load-bearing ∅ 13 mm ∅ 16 mm ∅ 19 mm ∅ 22 mm ∅ 24 mm
outer wires
over over over over over over over over over over
78 390 96 480 114 570 132 660 144 720
mm mm mm mm mm mm mm mm mm mm
101-120 5 10 5 10 5 10 5 10 5 10
121–140 6 11 6 11 6 11 6 11 6 11
Number of visible wire breaks

Lang lay rope
Number of
load-bearing ∅ 13 mm ∅ 16 mm ∅ 19 mm ∅ 22 mm ∅ 24 mm
outer wires
over over over over over over over over over over
78 390 96 480 114 570 132 660 144 720
mm mm mm mm mm mm mm mm mm mm
101-120 2 5 2 5 2 5 2 5 2 5
121–140 3 6 3 6 3 6 3 6 3 6
H
The number of visible wire breaks indicated here only applies to the hoist
ropes! This information only applies to the initial equipment and original
spare parts!
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).
s
29.04.2008

GMK 5170
8.10 Hoist ropes
Damage Description Cause Replacement

Wire break (1) Individual wires are General wear caused Replace the rope at the latest
broken; the broken by aging of the rope when the maximum permissi-
Wire break
ends of the wires or ble number of wire breaks
cluster (2)
are protruding according to the table are visi-
Strand break- from the rope. subsequent damage ble externally.
age (3) resulting from dam-
age to the rope. Replace the rope immediately if
wire breakage clusters or strand
breakages occur.
The frequency of wire breaks
increases with rope age. For
reasons of safety, it is advisable
to replace the rope while the
number of broken wires is still
low.
Effect of heat Tarnishing colour Rope has been sub- Replace the rope immediately.
is visible externally jected to excessive
on the rope. heat.
29.04.2008

GMK 5170
8.10 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 a
pended hook block. third of the rope diameter, the
rope must be replaced imme-
diately.
Basket-type 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
29.04.2008

GMK 5170
8.10 Hoist ropes

Loop forma- Outer layer wires in General wear due to Immediately replace rope if the
tion (1) the form of hair pins aging of the rope or rope structure has been sub-
are protruding from subsequent damage stantially altered by the loop
the rope away from resulting from dam- formations.
the sheave. age 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 broken wires
the inner strands
determines when the rope
continue to bear the
must be replaced.
load.
Knot forma- Repeatedly occur- General wear due to Determine number of wire
tion (3) ring knot-like thick- aging of the rope or breaks; replace rope immedi-
ening of rope; insert subsequent damage ately if serious knot formation
often protrudes. resulting from dam- occurs.
Strands bear on age to the rope.
each other at thin
locations; increased
frequency of wire
breaks.
Constriction Diameter reduction General wear caused Replace rope immediately if
(4) over short sections. by aging of the rope. serious constriction is
detected.
29.04.2008

GMK 5170
8.10 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.
Kink (2) Rope deformation Rope in the eyes was Replace the rope immediately.
with twisting and pulled straight while
wire breaks. twisted.
Buckle (3) Buckled section in Mechanical damage. Replace the rope immediately.
rope.
Curl forma- Curl-type rope Loaded rope was Replace the rope immediately.
tion (4) deformation. pulled over an edge.
29.04.2008

GMK 5170
8.10 Hoist ropes
8.10.5 Replacing the hoist rope
Spare parts and – An original replacement part; à Rope certificate.

tools – A reel stand with braking block.
Risk of accidents from falling load!
S
Use only a replacement rope that has the same technical specifications as
the defective rope, or an original replacement rope.

– The main boom is set down on the boom rest.
– The hook block is unreeved; à Operating instructions.
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 - 67.
• Unreel the remaining layers from the hoist drum.
• Lock the crane cab to prevent unauthorized use; à p. 2 - 3.
G
Risk of accidents due to rotating rope drum!
Turn off the engine and remove the ignition key so that no unauthorized
operation of the hoist can occur.
29.04.2008

GMK 5170
8.10 Hoist ropes
• Remove the clamp (4).

• Push the rope through the hole (3) until the
rope wedge (1) slides out of the pouch (2).
• Remove the rope wedge and place the rope
away from the truck crane.
Installing a new The service life of a rope can be significantly affected by the installation pro-
rope cedure. Errors during fitting reduce service life considerably. Therefore, the
following is required:
• Make sure the rope is not twisted when it is installed.
• Ensure it does not get dirty or damaged while being installed.
• Wind the rope up in the same direction in which the rope is reeled onto
the reel.
• Tension the rope slightly while winding it up.
• Place the reel stand (1) with the new rope in

front of the main boom head.
Ensure that the rope is being rolled onto the
drum with the right direction of rotation.
• Guide the rope over the right head sheave

(2) up to the hoist drum.
29.04.2008
s
GMK 5170
8.10 Hoist ropes
• Guide the rope through the hole (3) until it

extends about 1.5 m beyond the pouch (2).
• Feed the free end of the rope back through
the pouch.
• Secure the clamp (4) and tighten it – torque
10 Nm.
• Place the rope wedge (1) in the loop.
• Push the rope back until rope wedge (1) is

fully in the pouch (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.
• Reeving a hook block – reeve it at least 7 times; à Operating instructions.
• Raise the main boom to a steep position and extend it fully.
• Unwind the rope out until only five turns remain on the rope drum.
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GMK 5170
8.10 Hoist ropes
H
Watch the hook block when unwinding.
The hook block must not rotate!
Risk of accidents from incorrectly set lowering limit switch!
G
After installing 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 - 67.

• Run in the new rope with small loads so that the hoist rope can settle on
the drum.
8.10.6 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

Cover gasket 2 00550699
Prerequisites – The hook block is reeved 7-fold;à Operating instructions.

– The main boom is fully raised and extended; à Operating instructions.
– The hook block is lowered until only five turns of the rope remain on the
hoist drum.
s
29.04.2008

GMK 5170
8.10 Hoist ropes
Setting the lower-

ing limit switch
Risk of accidents due to rope end fitting being overloaded!
G
The lowering limit switch must always be reset after repair work to the
hoisting gear and after rope replacement. A faulty lowering limit switch
must always be replaced!
• Remove the cover (1).

• Turn the bolt (2) until you hear the switch
activate.
• Screw the cover on again.
Replace the gasket if necessary.
• Check whether the lowering limit switch
switches off the hoist correctly.
Checking • Raise the hook block until there are about 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 hoisting gear when five rope
turns are still on the hoist drum.
• Correct the setting of the lowering limit switch if necessary. 29.04.2008

GMK 5170
8.11 Cable drums and slewing angle sensor
8.11.1 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

Cable drum 1 cover gasket 1 03324704
Cable drum 2 cover gasket 1 03328294
– Clean, lint-free cloth.

– Dry, oil-free compressed air.
Prerequisites For cable drum 1

– The main boom is set down on the support; à Operating instructions.
For cable drum 2
– The main boom is fully retracted; à Operating instructions.
For cable drums 1 and 2

à p. 2 - 3.
29.04.2008
– The selector handle is removed from the battery master switch.
s
GMK 5170
S
tt
Risk of damage to the SLI!

Before maintenance work on the slip ring assemblies, always switch off the
battery master switch so that the cable drum is current-free.
This prevents short circuits which may lead to damage to the SLI's central
unit.
G
Risk of crushing when extending or retracting the main boom!
Perform maintenance work only after the truck crane has been shut down.
Always ensure that the truck crane is protected from unauthorized opera-
tion before beginning maintenance work. Remove the keys from the crane
cab and put up warning signs.
Maintenance of
the slip ring
assemblies
• Remove cover (1) or (2).

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

remove soiling on the slip rings (2).
• Do not use spray oil.
• Check to make sure all screws (1) are tight.
• Attach the cover on the cable drum.
29.04.2008

GMK 5170
8.11.2 Lubricating the slewing angle sensor Y5
Grease, spare
DIN 51502
Grease KP - L2K DIN 51825 00554201

Gasket 16 x 20 Cu DIN 7603 1 00117134

– Sealing agent (e.g. Hylomar).
à p. 2 - 3.
S
Risk of damage to the slewing angle sensor!
Before lubricating, always remove the screw from the slewing angle
sensor.
This prevents the slewing angle sensor from becoming damaged.
Lubricating
• Clean the lubricating nipple (3) and insert
about 5 cm³ of grease.
• Remove any excess grease, and close the
lubricating nipple.
• Tighten the bolt with a new gasket and seal-
ant – torque 25 Nm.
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GMK 5170
Blank page
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GMK 5170
8.12.1 Checking the level W
The maintenance of the pump (1) is the same

as the maintenance on the carrier; à
Central
lubrication system, p. 7 - 77.
8.13 Hook blocks
8.13.1 Checking the sheaves M3
• Check the sheaves in the hook blocks for damage, wear, mobility and
extreme soiling.
Have damaged, worn, sluggish or extremely soiled sheaves replaced by
CraneCARE or your repair crew.
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GMK 5170
8.13 Hook blocks
8.13.2 Lubricating M 12
Grease, spare
DIN 51502
Grease KP - L2K DIN 51825 00554201
Prerequisites – The hook block has been reeved at least twice; à Operating instructions.
Lubricating hook On the hook blocks, the sheaves, cross-members and load hooks of the axial
blocks bearings have to be lubricated.
The diagram gives an example of the location

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

blocks supplied and on the hook tackle and
lubricate them with a grease gun.
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GMK 5170
8.14.1 Checking the lighting and indicators D
G
Risk of accidents if the safety devices are faulty!
If the lamps or the buzzer fail, notify CraneCARE and have the error rectified.
• Check the lamps and displays on the ECOS and SLI control units;
• Check the following functions:

– Windscreen wipers, windscreen washing system,
– spotlight on the crane cabin to light up working area, air traffic control
light,
– spotlight on the main boom (xenon light),
– Horn, anemometer.
G
Danger of accidents from exploding glass bodies and high-voltage!
The glass body for gas discharge lamps (xenon lights) is under pressure. If
the lamp breaks, glass splinters shatter explosively and scatter.
Xenon light operates with high-voltage. There is still a danger of residual
voltage discharging (electrocution) even when the battery master switch is
switched off.
Have faulty lamps replaced only by qualified personnel who have the rele-
vant protective equipment.
• Have faulty lamps in the spotlights replaced only by qualified personnel.

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GMK 5170
8.14.2 Checking the batteries M1

• Check the batteries (1) in the same way as
when checking them on the carrier;
à Checking the batteries, p. 7 - 82.
8.14.3 Checking the charge level of the batteries M3
• Check the charge level in the same way as when checking it on the carrier;
à Checking the charge level of the batteries, p. 7 - 84.
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GMK 5170
8.15.1 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 - 87.
8.15.2 Cleaning the condenser fins M1
S
Risk of damage to the condenser!
Do not use a high pressure cleaner or steam jet cleaner. The powerful jet
may damage the fins. Use only compressed air for cleaning.

• Clean the condenser fins with compressed
air (1).
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GMK 5170
8.15.3 Checking hoses M6
G
nections.
• Check all refrigerant hoses for damage and worn areas.

Have damaged hoses replaced by CraneCARE only.
8.15.4 Checking the entire air conditioning system M 12
H
This check may only be carried out by CraneCARE!
G
nections.
• Have the entire air-conditioning system checked for leaks and proper
functioning.
The inspection of the air-conditioning system includes most importantly
the inspection of
– the refrigerant collector, in accordance with the pressure container reg-
ulations (test group II) and
– the refrigerant compressor.
Use only suitable refrigerant for topping up.
Refrigerant
Fill quantity Designation CAS no.
in kg EC no.
2.0 Tetrafluoroethane (R134a) 811-97-2
212-377-0
29.04.2008

GMK 5170
8.16.1 Checking the auxiliary heater for correct operation M1
Check the auxiliary heating in the same way you would check it on the car-
à
rier; Checking the auxiliary heater for correct operation, p. 7 - 104.
8.16.2 Lubricating the piston rod of the derricking cylinder M1
Grease, spare
parts and tools Designation GROVE part no.
Lubricant RHUS SW 2 03325215
– Brush.
S
Risk of damage to the derricking cylinder's gasket due to rust!
Be sure that the uncovered end of the piston rod is always kept lubricated.
In this way you can avoid rust which damages the gasket in the derricking
cylinder head when lowering completely.
• Clean the uncovered end (1) of the piston

rod of old grease, dirt particles and rust.
• Slightly grease the uncovered end, making
sure the grease coat is evenly distributed.
After every high-pressure cleaning operation

on the truck crane:
• Grease the piston rod.
s
29.04.2008

GMK 5170
H
You can also prevent rust if you turn the main boom to the side between
maintenance intervals and completely lower it.
8.16.3 Having the fire extinguisher checked Y2
Your truck crane has fire extinguishers, depending on its scope of equip-
ment.
H
The maintenance interval may be smaller, depending on the respective
national regulations. Ask about the national and local regulations at the
local Fire Safety Authority.
• Follow the operating instructions (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 is still working properly
after the maintenance interval on the label has expired.
29.04.2008

GMK 5170
9
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29.04.2008

GMK 5170
Longer periods out of service

Carry out the following work if the truck crane is to be out of operation for a
long period (months).
Taking out of • Clean the truck crane thoroughly inside and outside.
service
• Remove rust and touch up the paintwork.
• 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 as per the maintenance plans.
• Seal all air filters.
• Increase the tyre pressure by 10% and mark the tyre positioning, or
support the truck crane and let it stand supported.
• Observe the specifications on preservation in the engine manufacturer's
documentation.
Checking • Check the levels in the fuel tanks. Always keep the tanks filled.
• Check the batteries every week and recharge them if necessary.
• Check the tyre pressure each week and correct if necessary.
• Perform a full functional check of the truck crane every two weeks.
(Open all air filters beforehand!)
• Run the hydraulic systems up to a fluid temperature of approx. 50 °C and
check all functions of the carrier and superstructure hydraulic systems.
s
29.04.2008

GMK 5170
Longer periods out of service
• Ensure that the tyre positioning is different each time the crane is parked
(without outriggers).
• Seal all air filters again.
If the truck crane is out of service for more than 12 months:

• Carry out all maintenance work in accordance with maintenance
plan M 12.
• Observe the specifications on preservation in the engine manufacturer's
documentation.
Starting-up • Open all air filters.

• Inflate the tyres up to the prescribed pressure.
• Carry out periodic maintenance work in accordance with the maintenance
plans in Chapter 5.
• Observe the specifications on preservation and putting back into opera-
tion in the engine manufacturer's documentation.
29.04.2008

GMK 5170
10
10 Torques
10.1 Torques for retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 1
10.2 Special torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 2

29.04.2008

GMK 5170
29.04.2008

GMK 5170
Torques
10.1 Torques for retaining bolts
10 Torques
10.1 Torques for retaining bolts
Metric standard screw-thread Approximate values

Metric fine screw-thread
Thread size Torques
(mm) (greatest permissible pre-tensioning for
Spanner wrench size (mm) bolts) for oiled bolts (Nm)
Bolt quality
Hexagon Cylinder 8.8 10.9 12.9
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 1080

36 19
M 24 x 1.5 702 990 1170
M 30 46 22 1300 1800 2160
M 33 50 24 2700
M 36 55 27 3300
10.09.2013
Correction sheet – Maintenance manual 3 113 013 en 10 - 1

GMK 5170
Torques
10.2 Special torques
10.2 Special torques
Thread size Spanner size Tightening

(mm) (mm) torque
Designation (Nm)
Hexagon Cylinder
bolt screw
Suspension strut:
– Bracket for the vehicle frame, top M 16 — 14 265
– Bracket for the vehicle frame, bot-
M 24 — 19 900
tom
– Flange suspension strut, bottom M 20 17 520
– Half-shell steering arm M 16 14 265
Steering linkage:
– Bolts for clamp straps M 12 x 1.5 19 — 70 - 80
M 14 x 1.5 22 — 160 - 180
Others:
– Coolant hose clamps 4
– Wheel nuts M 22 x 1.5 32 650
– Retaining bolt for the
Please contact Manitowoc Crane Care.
ball slewing bearing
– Hoist drum rope wedge M 10 17 — 10
10.09.2013
10 - 2 3 113 013 en Correction sheet – Maintenance manual

GMK 5170
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 - 7

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GMK 5170
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GMK 5170
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.
Listed here are only the spare parts 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, p. 6 - 3.
11.2 Lighting
Lamps are listed according to the installation position. The list includes
standard and additional lighting equipment for the truck crane.
Lighting specific to certain countries can be found in the Spare parts list, in the
Country specific package section.
G
Danger of accidents from exploding glass bodies and high-voltage!
The glass body for gas discharge lamps (xenon lights) is under pressure. If
the lamp breaks, glass splinters shatter explosively and scatter.
Xenon light operates with high-voltage. There is still a danger of residual
voltage discharging (electrocution) even when the battery master switch is
switched off.
Have faulty lamps replaced only by qualified personnel who have the rele-
vant protective equipment.
s
29.04.2008

GMK 5170
11.2 Lighting
Place of installation GROVE part Designation Output (W)

number
CARRIER LIGHTING:
Front headlight:
(integrated in the bumper)
– Low-beam headlight 00438912 H1 24 V 70
– Low-beam headlight (USA) 00438912 H1 24V 70
– Full-beam headlight 00438912 H1 24 V 70
– Full beam headlight (USA) 00438912 H1 24V 70
– Parking light 00438514 C5W 24 V 5
– Parking light (USA) 01926635 24V 5W 5
– Turn indicator light 00439055 P25-1 24 V 21
– Turn indicator light (USA) 00438912 H1 24V 21
– Yellow side marker light 03320937 LED
Front, side turn indicator lights:
(under the access ladder to the driver's cab)
– Turn indicator light 03327578 8GA 006841241 24V/21W
Rear lights:
(at the rear of the chassis)
– Rear light 01207144 R19/10 24V 10
– Brake light 00439055 P25-1 24V 21
– Turn indicator light 00439055 P25-1 24V 21
– Fog tail light 00439055 P25-1 24V 21
– Reversing light 00439055 P25-1 24V 21
Side marker lights, yellow:
(only at the rear of the chassis)
– Side marker light 03320937 LED
Side marker lights, yellow:
(at the sides, along the chassis)
– Side marker light 03323568 LED
Rear marker lights, red/white:
(at the rear of the chassis)
– Marker light, left 00438897 T8/4 24V 4
29.04.2008
– Marker light, right 00438897 T8/4 24V 4

Front marker lights, white:
(at the top on the driver's cab)
– Marker light 00438514 C5W 24 V 5

GMK 5170
11.2 Lighting

number
Outrigger beam spotlights:
(above the front and rear outrigger beams)
– Filament lamp 02316460 H3 24V 70
Rotating beacon, yellow:
(on the driver's cab)
Inside lights:
(in the driver's cab)
– Interior lamp 00550434 K 24 V 10
– Reading lamp 00550434 K 24 V 10
SUPERSTRUCTURE LIGHTING:
Marker lights, white:

(on the main boom head)
– Marker light, left 03323856 LED
– Marker light, right 03323567 LED
Rear marker lights, red:
(on the turntable)
– Marker light 03329492 LED
Rotating beacon, yellow:
(on the turntable)
Inside lights:
(in the crane cab)
– Inside light 00550434 K 24V 10
– Reading light 03328445 P21W 24V 10
Spotlight, attachable:
(at the front of the crane cab)
– Filament lamp 02316460 8GH002090251 70
s
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GMK 5170
11.2 Lighting

number
Spotlights, electrically adjustable:
(at the front of the main boom)
– Filament lamp 03326694 8GS007949101 35
Spotlight, swinging:
(at the front of the main boom)
– Halogen bulb 02 309 610 810992RSY 100
Hoist lighting:
(behind the hoist)
– Marker light 03 323 856 LED
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GMK 5170
11.3 Spare parts for the carrier
Quantity, in single parts

Subassemblies and spare parts GROVE
for maintenance interval
Carrier part number
W M1 M3 M6 M 12
Engine
Oil drain valve (instead of drain plug) 03046878 1 x when the oil is
Gasket 26 x 31 Cu DIN 7603 changed the first time
00117147
(recommended modification)
Air filter 03326272 1 (when the symbol lights up)
Fuel system
Filter 03 322 877 1
Gasket 03 322 879 1
Filter element 03 328 656 1
Filter and gasket 03 045 818 1
Transfer case
Gasket 30 x 36 Cu DIN 7603 00117151 1 1
Gasket 16 x 20 Cu DIN 7603 00117134 1
Axle lines Axle centre drive (for max. 10 x 8 x 10)
Gasket 36 x 42 Cu DIN 7603 01 371 208 2 3
Gasket 30 x 38 Cu DIN 7603 01 925 343 1 2
Gasket 16 x 22 Cu DIN 7603 00 117 135 1 2
Axle lines Final drive (for max. 10 x 8 x 10)
Gasket 24 x 29 Cu DIN 7603 00117145 8 8
Wheels
Wheel nuts (12 per wheel) 01207756 (in case of damage)
Valve (in case of defect) 01570750 (5)
Gasket 22 x 27 Cu DIN 7603 00117142 (5)
Filter cartridge 03043578 1
29.04.2008
s
GMK 5170

Carrier part number
W M1 M3 M6 M 12
Hydraulic system
Filter 03329152 (2)
Filter 03329152 2 for every oil change
Gasket set 03135778 and when the symbol lights up
Oil tank cover gasket 140/90 x 3 1 for every oil change
03098598
(in case of damage)
Ventilation filter 03324588 1
Particulate filter
Clamp strap 03134864 (2) (in case of damage)
Filter 03134863 1

Carrier part number
Y2 Y3 Y5 Y6 Y 10
Engine
Oil filter 03328365 1
Filter with set of gaskets 03 326 293 2
Gasket 30 x 36 Cu DIN 7603 00 117 151 1
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GMK 5170
11.4 Spare parts for the superstructure

Subassemblies and spare parts GROVE for maintenance interval
Superstructure part number
W M1 M3 M6 M 12
Engine
Air filter 03 328 263 1 (when the symbol lights up)
Fuel system
Filter (Filter 1) 03322877 1
Gasket 03322879 1
Filter part (in case of damage) 03328656 1
Filter with gasket (large; filter 3) 03328573 1
Filter with gasket (small; filter 2) 03328574 1
Hoists
Gasket 18 x 24 Cu DIN 7603 01377793 (4) (in case of damage)
Gasket 18 x 24 Cu DIN 7603 01377793 10
Slewing gear
Gasket 10 x 14 Cu DIN 7603 00117125 (3) (in case of damage)
Gasket 10 x 14 Cu DIN 7603 00117125 3
Gasket 14 x 20 Cu DIN 7603 00117132 3
Hydraulic system
Ventilation filter 03 319 602 1
Oil filter 1 03134850 1
Gasket for oil filter 1 03 328 209 1
Change the oil filter at every oil
Oil filter 2 03134850 change and if a warning mes- 1
sage is displayed.
Housing gasket set, oil filter 2 03326049 1
Gasket 120 x 90 03 328 286 1
Hoist ropes
Grease (20 litre canister) 03133770 1
Cover gasket for the lowering limit 2 (in case of damage)
00550699
switch for every rope change on the hoist
Cable drums
Cable drum 1 cover gasket 03324704 (1)
(in case of damage)
29.04.2008
Cable drum 2 cover gasket 03328294 (1)
s
GMK 5170
Subassemblies and spare parts GROVE Quantity, in single parts

Superstructure part number for maintenance interval
Y2 Y3 Y5 Y6 Y 10
Engine
Oil filter, complete 03328556 1
Slewing angle sensor
Gasket 16 x 20 Cu DIN 7603 00117134 (1)
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GMK 5170
11
Appendix
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29.04.2008

GMK 5170
Appendix
Table to determine the remaining theoretical service life on winch no. ..........
Crane model: ........................

Work number: ........................
Commissioned on: ........................
Winch serial number as shown on model plate: ........................
Engine group: ........................
Load spectrum: ........................
Factor of the load spectrum: ........................
Theoretical service life: ........................
Inspec- Date of com- Opera- Factor of Operating Operating Operating Operating Operating Used proportion Remaining Name of Signature Note Name of Signature
tion inter- mission/date tional con- the load hours of hours of hours of the hours of the hours of the of theoretical theoretical competent the
val no. of inspection dition since spectrum the entire the super- superstruc- winch winch since service life D: service life person approved
(max. the last crane structure ture since the last inspec- inspector
1 year) inspection the last tion
Di = Di-1 - Si
inspection

(*)
CAUTION:
A general overhaul is to be performed every 10 years!
Si =Used proportion of theoretical service life since the last inspection
Alternative provision, refer to Section 5.4.2, p. 5 - 25. Di = Remaining theoretical service life
Di - 1= Remaining theoretical service life after the previous inspection
Last general overhaul performed on.................................. This factor is given in the operating instructions.
Kmi = Load spectrum factor in the inspection interval "i" according to Section 2.1
Ti = Effective working hours in the inspection interval "i" according to Section 2.2
Table to determine the remaining theoretical service life on winch no. ..........
Crane model: ........................

Work number: ........................
Commissioned on: ........................
Winch serial number as shown on model plate: ........................
Engine group: ........................
Load spectrum: ........................
Factor of the load spectrum: ........................
Theoretical service life: ........................
Inspec- Date of com- Opera- Factor of Operating Operating Operating Operating Operating Used proportion Remaining Name of Signature Note Name of Signature
tion inter- mission/date tional con- the load hours of hours of hours of the hours of the hours of the of theoretical theoretical competent the
val no. of inspection dition since spectrum the entire the super- superstruc- winch winch since service life D: service life person approved
(max. the last crane structure ture since the last inspec- inspector
1 year) inspection the last tion
Di = Di-1 - Si
inspection
CAUTION:
A general overhaul is to be performed every 10 years! Si = Used proportion of theoretical service life since the last inspection
Alternative provision, refer to Section 5.4.2, p. 5 - 25. Di = Remaining theoretical service life
Di - 1 = Remaining theoretical service life after the previous inspection
Last general overhaul performed on..................................
Kmi = Load spectrum factor in the inspection interval "i" according to Section 2.1
Ti = Effective working hours in the inspection interval "i" according to Section 2.2
Tilting play measurement report
• Always measure the current tilting play as described in Section Measuring tilting play, p. 8 - 33.
Base value: ............... mm

max. permissible wear: + 3.2 mm
max. permissible tilting play: ............... mm
Date Current tilting play Ball slewing bearing Signature

–135° (A) –45° (B) +45° (C) +135° (D) ok faulty replaced on
Tilting play measurement report
• Always measure the current tilting play as described in Section Measuring tilting play, p. 8 - 33.
Base value: ............... mm

max. permissible wear: + 3.2 mm
max. permissible tilting play: ............... mm
Date Current tilting play Ball slewing bearing Signature

–135° (A) –45° (B) +45° (C) +135° (D) ok faulty replaced on

GMK5170 Maintenance Manual

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Maintenance manual

Any type of duplication or excerpt from this

© Copyright reserved by Manitowoc Crane Group Germany GmbH

3 112 477 en Maintenance manual

Deviating to the information in the supplied maintenance manual, the hy-

• Please contact Manitowoc Crane Care, if you are in doubt.

Place of use Specification

Correction sheet Maintenance manual 3 113 198 en 1

2 3 113 198 en Correction sheet Maintenance manual

Deviating from the specifications

Changing the hydraulic oil filters M 12

Maintenance • Replace the additional hydraulic oil filters

Spare parts and

• Remove the receptacle (1).

2 3 112 612 en Additional page GMK 5170/5220

Grease • Apply the grease with a brush or roller.

Additional pages GMK truck cranes 3 112 676 en 1

2 3 112 676 en Additional pages GMK truck cranes

This maintenance manual does not replace the operating instructions.

Details of operation and standard safety instructions can be found

Maintenance manual 3 112 477 en

3 112 477 en Maintenance manual

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

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

1.4 Notes concerning the electronic control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 4

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

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

1.7 Conversion table for US measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 6

Maintenance manual 3 112 477 en

3 112 477 en Maintenance manual

1.1 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:

It is your responsibility to maintain and service the truck crane regularly in

1-2 3 112 477 en Maintenance manual

A few general maintenance instructions:

Maintenance manual 3 112 477 en 1-3

• Cleanliness is imperative when handling grease on the central lubrication

Our training centre at our plant offers specialised training programmes.

1.4 Notes concerning the electronic control

1.5 Safety instructions for welding work

All welding work (especially on load carrying members) may be performed

1-4 3 112 477 en Maintenance manual

1.6 Definition of positional references

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

Forwards always means the driver's cab is to the front.

Down: Press (1) – on the symbol

Maintenance manual 3 112 477 en 1-5

1.7 Conversion table for US measurements

Converting from in Multiply by

1-6 3 112 477 en Maintenance manual

Maintenance manual 3 112 477 en

3 112 477 en Maintenance manual

2 Safety and environmental protection

2.1 Safety rules

• Familiarise yourself with the truck crane and its operation.

Maintenance manual 3 112 477 en 2-1

• Do not allow hot materials to escape unchecked – Risk of burning yourself

2-2 3 112 477 en Maintenance manual

2.1.1 Securing against unauthorised use

• Secure the truck crane against unauthorised use by: