Maintenance Manual

Maintenance manual
3 112 369 en
Serial number 27.01.2007
Important note
Any type of duplication or excerpt from this docu-

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

27.01.2007
Dissemination or duplication of this document as well as utilization and disclosure of its contents are prohibited
unless expressly permitted. Infringement will incur liability for compensation. All rights pertaining to registration of patent
or utility model are reserved.
3 112 369 en Maintenance manual

GMK 4100/GMK 4100–L
Additional page for maintenance manuals
Topping up oil on the suspension strut
Validity This additional page applies to the truck cranes:
GMK 3050-1, GMK 3055,

GMK 4080-1, GMK 4100, GMK 4100-L,
GMK 5100, GMK 5130-1, GMK 5220,
GMK 6220-L, GMK 6300,
GMK 7450
and is part of the maintenance manual supplied in each case.
Reason for the Effective immediately, all suspension struts for topping up oil are equipped
modification with the same connection from the factory. Each truck crane is standardly
equipped with a press and a hose (in the tool box). This press with hose
must be connected sequentially to each suspension strut for topping up if
the oil level on the inspection glass of the relevant suspension strut is too
low.
Maintenance The oil level on the inspection glass should be checked monthly.
plan M1 You can find the monthly maintenance plan M1 in chapter 5 of the
maintenance manual included in the delivery:
Maintenance work on the CARRIER: Lubricant:

monthly / after ca. 2000 km (approx. 1240 mi)
Oil filling quantity per
– Suspension struts – check oil level; à p. 2. suspension strut:
approx. 1.5 litres
(approx. 0.4 gal);
GROVE part no. 02310863.
12.09.2007
Correction sheet 3 112 249 en 1

GMK truck cranes
Suspension struts – check oil level
Spare parts and – Press with connected hose (from tool box)
tools
Prerequisites – The engine is not running and is secured against unauthorised use.
– Immediately before the inspection, the truck crane was completely
lowered and returned to On-road level; à
Operating Instructions.
Checking the Use only oil as specified in the maintenance plan M1; à p. 1.
oil level
S
Risk of damage due to faulty suspension struts
If the oil level is above the upper marking on the inspection glass the
suspension strut is faulty and must be replaced.
Notify an authorised GROVE dealer or CraneCARE.
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 middle of

the inspection glass (1) on each suspension
strut.
If the oil level is too low:
• Open the connection (2) – oil escapes – and
quickly connect the press with hose.
• Inject oil up the centre of the inspection
glass.
• Remove the hose and quickly close the
connection (2).
12.09.2007
2 3 112 249 en Correction sheet

GMK truck cranes
Contents overview:
1 General instructions
2 Safety and environmental protection
3 Cleaning
4 Run-in instructions
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.
27.01.2007
Maintenance manual 3 112 369 en

GMK 4100/GMK 4100–L
27.01.2007

GMK 4100/GMK 4100–L
1
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 indications for welding work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 4
1.6 Definition of positional references . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 5
1.7 Conversion table for US measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 6

27.01.2007

GMK 4100/GMK 4100–L
27.01.2007

GMK 4100/GMK 4100–L
General instructions
1.1 Using the maintenance manual
1.1 Using the maintenance manual

This manual is not designed to replace proper training and instruction.
Truck crane maintenance personnel must have the relevant, specialist
knowledge of proper safety procedures.
Please read chapters 1 and 2 carefully before beginning maintenance work.
H
Maintenance work on the lattice extensions is described in the Lattice exten-
sion operating instructions.
1.2 Warnings and symbols

The following definitions and symbols are used in the operating instruc-
tions to highlight particularly important information:
G
This symbol indicates hazards related to the described operation that may
cause personal injury. The type of hazard (e.g. life-threatening, personal
injury, risk of crushing or electrocution) generally precedes the warning
sign.
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.
27.01.2007
s
Maintenance manual 3 112 369 en 1-1
GMK 4100/GMK 4100–L
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 only be carried out by qualified repair personnel (e.g. CraneCARE).
Repair work also requires:

– appropriate workshop equipment
– special tools
– spare parts authorised 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 only uphold
the warranty provided for the truck crane if the following conditions are met:
– it is used for the purpose for which it was intended
– care and maintenance is carried out as prescribed
– repair work / overhauling is carried out by professionals
27.01.2007
1-2 3 112 369 en Maintenance manual

GMK 4100/GMK 4100–L
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
maintenance work carefully within the specified intervals. Do not put off
maintenance work that is due. If repairs are needed, immediately contact an
authorised GROVE dealer or CraneCARE your repair personnel. 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 Lubrication chart,
p. 6 - 1 are used.
• Replace all filters within the specified period if cleaning is not explicitly
permitted.
• Replace all seals before assembly. Clean the sealing surfaces.
• Only tighten loose screw connections on hydraulic and compressed air
systems 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 hydrau-
lic oil must be filtered.
s
27.01.2007

GMK 4100/GMK 4100–L
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.
Tightening 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 current regulations before being put into opera-
tion 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 number of make-and-brake cycles
of 107.
– 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 indications 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 any welding work.
All welding work (especially on load carrying members) may only be per-
formed by qualified professional personnel with the prior written permis-
sion of Manitowoc Crane Group Germany GmbH.
27.01.2007

GMK 4100/GMK 4100–L
1.6 Definition of positional references
1.6 Definition of positional references
Basic rules 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:
1: front 2: right
3: rear 4: left
Forwards always means the driver's cab is to the front of the direction of
travel,
backwards always means the rear lights on the carrier are to the front of the
direction of travel.
On the superstructure
The main boom head is always at the front, which means:
1: front 2: right
3: rear 4: left
Switches and The terms down and up are used with switches and buttons.
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
27.01.2007

GMK 4100/GMK 4100–L
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 to 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
27.01.2007

GMK 4100/GMK 4100–L
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
27.01.2007

GMK 4100/GMK 4100–L
27.01.2007

GMK 4100/GMK 4100–L
Safety and environmental protection
2.1 Safety rules
2.1 Safety rules

When carrying out maintenance work, please observe the applicable acci-
dent 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 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 the proper access aids and working platforms when carrying out
overhead 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 extension 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
27.01.2007

GMK 4100/GMK 4100–L
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, swivel-
ling connections, 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 depressu-
rise the hydraulic and compressed air systems before opening them.
• Do not allow hot materials to escape unchecked – Risk of scalding.

• Observe the applicable safety regulations when working with inflamma-
ble 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.
27.01.2007

GMK 4100/GMK 4100–L
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 repair work.
27.01.2007

GMK 4100/GMK 4100–L
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 by 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 corrosive. When doing
equipment maintenance work involving these consumables (engine and hydraulic 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 filling pump
with hose suitable for the respective substance when filling. 27.01.2007

GMK 4100/GMK 4100–L
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 elements) separate from liquids. Disposal costs will
be reduced if you collect liquids separately according to certain catego-
ries.
• 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.
27.01.2007

GMK 4100/GMK 4100–L
Blank page
27.01.2007

GMK 4100/GMK 4100–L
3
3 Cleaning
3.1 Overview of subassemblies easily damaged when cleaning . . . . . . . . . . . . . . . . 3 - 2
27.01.2007

GMK 4100/GMK 4100–L
27.01.2007

GMK 4100/GMK 4100–L
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 (140°F), even after the first three
three months 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 seals, never point the nozzle directly at them.
• Never point the nozzle at electrical equipment, relay and control boxes,
suction and venting filters or control elements and lubricated surfaces.
• To prevent corrosion, 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 system ( à Triggering
intermediate lubrication, p. 7 - 75). Lubricate all remaining lubrication points
with a grease gun.
27.01.2007

GMK 4100/GMK 4100–L
Cleaning
3.1 Overview of subassemblies easily damaged when cleaning
3.1 Overview of subassemblies easily damaged when

cleaning
On the truck crane
1 Lowering limit switch 8 Lifting limit switch

2 Housing of the input-output 9 Telescope slide faces
circuit boards on the carrier
3 Suspension struts (on both 10 SLI length measuring unit
sides of the truck crane)
4 Superstructure switch box 11 Angle sensor switch box
5 Slewing angle sensor on the 12 Swing-away lattice extension
superstructure proximity switch
6 Slewable spotlights 13 Pressure sensors
7 SLI terminal box
27.01.2007
H
Parts at risk of damage on the lattice extension (additional equipment) are
described in the Lattice extension operating instructions.

GMK 4100/GMK 4100–L
4
27.01.2007

GMK 4100/GMK 4100–L
27.01.2007

GMK 4100/GMK 4100–L
Run-in instructions
Some parts (hoist, gearboxes etc.) are subject to special run-in instructions
– after the truck crane is put into operation for the first time or
– after part replacement or
– after a general inspection.
This means that additional maintenance work must be carried out on the
carrier and the superstructure at certain intervals:
Operating Driven km additional maintenance work on the

hours (mi) CARRIER
(oper. hrs)1)
after 50 (30) Tighten wheel nuts ( à Torques for
retaining bolts, p. 10 - 1).
after 150 (95) Tighten wheel nuts (à Torques for
retaining bolts, p. 10 - 1).
after 50 Tighten hose clamps on all coolant
hoses ( à Torques for retaining bolts,
p. 10 - 1).
Check the oil filters weekly; à Cleaning
during the first the magnetic rods, p. 7 - 60.
100 Check the oil filters weekly; à Changing
the hydraulic oil filter, p. 7 - 70.
after 100 1 000 (620) Change oil in all
– final drives; à p. 7 - 37,
à
– Axle centre drives; p. 7 - 34.
after 250 2 500 (1 550) Change engine oil; à Separate engine
operating instructions, provided by the
manufacturer.
1)
1 oper. hr. corresponds to approx. 40 kilometres driven (25 miles)
Please follow the advice on run-in times / run-in instructions / oil change
intervals in the enclosed operating instructions of the engine manufacturer
and in the engine maintenance booklet.
s
27.01.2007

GMK 4100/GMK 4100–L
Run-in instructions
Operating driven km additional maintenance work on the

hours (mi) SUPERSTRUCTURE
(oper. hrs)1)
after 100 Changing the oil filter; à Changing the
filter, p. 8 - 43.
after 100 Check tightness of retaining bolts; tight-
ening torque; à Special torques,
p. 10 - 2.
after 200 Carry out first oil change on the hoisting
gears (auxiliary hoist only with addi-
tional equipment); à Changing the oil,
p. 8 - 24.
after 200 Carry out the first oil change on the
slewing gear transmission; à Changing
the oil, p. 8 - 30.
after 250 Change engine oil; à Separate engine
operating instructions, provided by the
manufacturer.
after 1 0001) Carry out second oil change on hoist
gears (auxiliary hoist only with addi-
tional equipment); àChanging the oil,
p. 8 - 24.
1) after 1 000 oper. hrs; after 12 months at the latest
Please follow the advice on run-in times / run-in instructions / oil change
intervals in the enclosed operating instructions of the engine manufacturer
and in the engine maintenance booklet.
27.01.2007

GMK 4100/GMK 4100–L
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
27.01.2007

GMK 4100/GMK 4100–L
27.01.2007

GMK 4100/GMK 4100–L
Maintenance overview
5.1 Maintenance intervals
– Maintenance plans D (= daily)

– Maintenance plans W (= weekly) and
– Maintenance plans M 1 (= once 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 or pages
in which the appropriate maintenance work is described. The cross refer-
ences consist of the chapter number and the corresponding page number,
e.g.
Check hydraulic oil level; à p. 7 - 57.
Checking the hydraulic oil level is described in chapter 7, the section starts
on page 7 - 57.

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

– a specified time (maintenance deadline) or
– a specified number of kilometres driven (mi) or
– a specified number of operating hours (oper. hrs.) or
– if a reminder is shown on the ECOS or on-board computer display;
à p. 7 - 3.
à p. 7 - 1.
H
Consumables used;
27.01.2007
s
GMK 4100/GMK 4100–L
The maintenance interval which occurs first shall determine when mainte-
nance work is next due.
– The km (or mi) driven 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:
Mainte- Maintenance km (mi) driven Operating hours

nance plans interval (carrier) (oper. hrs)
of engine
(superstructure)
daily / before
D putting into — —
operation
W weekly — —
approx. 2 000
M1 monthly 100
(approx. 1 240)
every three 5 000 – 6 000
M3 300
months (3 100 – 3 730)
10 000 – 12 500
M6 every six months 500
(6 210 – 7 770)
20 000 – 25 000
M 12 every 12 months 1 000
(12 430 – 15 530)
40 000 – 50 000
Y2 every 24 months 2 000
(25 000 – 31 000)
Y3 every 36 months — 3 000
100 000
Y5 every 60 months 5 000
(62 000)
Y6 every 72 months — 6 000
Y 10 every 120 months — 12 000
Please note that the long-term maintenance plans always incorporate the
short-term ones.
27.01.2007

GMK 4100/GMK 4100–L
5.2 Maintenance plans

The descriptions for certain maintenance work in the maintenance plans D,
W, M 1 to M 12 and Y 2 to Y 10 are provided for
– the carrier in chapter 7 and for

– the superstructure chapter 8.
References (chapter and page number) to the description of this mainte-
nance 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 symbol (D to Y 10) of the relevant maintenance plan for better
comprehension.
In addition to Maintenance work on the carrier and Maintenance work on

the superstructure the maintenance plans contain:
– The amounts as approximate values for oil amounts in litres (l) (and gal-
lons (gal)) (the exact oil amounts are always determined by the oil level
inspection holes, the dipstick or the oil level indicators) or
the number of available lubrication points.
– The descriptions of the oils / lubricants in accordance with Lubricants and
consumables, p. 6 - 1.
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 carry-
ing out such maintenance work, follow the instructions given in the operat-
ing instructions and maintenance booklets supplied by the engine
manufacturer!
The engine manufacturer's operating instructions describe how to carry out
these maintenance tasks, while the maintenance booklets specify the rele-
vant maintenance intervals.
27.01.2007

GMK 4100/GMK 4100–L
5.2.1 Maintenance plan D D
Maintenance work on the CARRIER: Lubricant

daily / before putting into operation à p. 6 - 1 in litres (gal)
Engine
à p. 7 - 5.
– Checking the oil level; A
– Checking the coolant level; à p. 7 - 10.
Fuel system
– Draining off water from the fuel prefilter; à p. 7 - 13.
Steering
– Checking for leaks; à p. 7 - 51.
Wheels
– Checking the tyres for damage; à p. 7 - 39.
Hydraulic system
– Checking the oil level; à p. 7 - 57. G2
Electrical system
– Checking the lighting and indicators; à p. 7 - 77.
27.01.2007

GMK 4100/GMK 4100–L
Maintenance work on the SUPERSTRUCTURE: Lubricant

daily / before putting into operation à p. 6 - 1 in litres (gal)
Engine
à p. 8 - 5.
– Checking the oil level; A
– Checking the coolant level; à p. 8 - 9.
Fuel system
– Draining off water from fuel prefilter 1; à p. 8 - 12.
Slewing gear
– Checking the function of the slewing gear brake; à p. 8 - 28.
Hydraulic system
– Checking the oil level; à p. 8 - 37. G2
Hoist ropes
– Checking the position on sheaves and rope drums; à p. 8 - 57.
Hook blocks
– Checking the sheaves; à p. 8 - 77.
Electrical system
– Checking the lighting and indicators; à p. 8 - 79.
27.01.2007

GMK 4100/GMK 4100–L
5.2.2 Maintenance plan W W
Maintenance work on the CARRIER: weekly Lubricant

à p. 6 - 1 in litres (gal)
Engine
– General inspection; à p. 7 - 11.
Transmission
Transfer case
Axle lines
Wheels
– Checking the tyre pressure; à p. 7 - 40.
Compressed air system (including brake system)
– Draining the compressed air system; à p. 7 - 53.
Hydraulic system
– Checking the hydraulic hoses; à p. 7 - 58.
– Check tightness (suspension and outriggers) while engine is
running; àp. 7 - 59.
Central lubrication system
– Checking the level of the grease container; à p. 7 - 73. K
Other maintenance work
– Check the function of the windscreen washing system in the
operator's cab and the level of fluid in the reservoir;
à Operating instructions.
27.01.2007

GMK 4100/GMK 4100–L
Maintenance work on the SUPERSTRUCTURE: weekly Lubricant

à p. 6 - 1 in litres (gal)
Engine
Hoists
à p. 8 - 21.
– Checking the oil level; E6
– Checking the hoist brake; à p. 8 - 22.
Slewing gear
à p. 8 - 27.
– Checking the oil level; E6
Hydraulic system
– Checking the hydraulic hoses; à p. 8 - 38.
– Checking the level of the grease container; à p. 8 - 75. K
Hoist ropes
– Checking the condition; à p. 8 - 58.
– Check the function of the windscreen washing system in the
driver's cab and the level of fluid in the reservoir;àOperating
instructions.
27.01.2007

GMK 4100/GMK 4100–L
5.2.3 Maintenance plan M 1 M1

monthly / after approx. 2 000 km (approx. 1 240 mi) à p. 6 - 1 in litres (gal)
Engine
– Observe specifications in the Engine manufacturer’s operating
instructions and in Engine manufacturer’s maintenance booklet.
Special notes on the maintenance group and FAME-based
operation; à p. 7 - 5.
Transfer case
– Checking the oil level; à p. 7 - 27. E3
Axle lines
– Axle centre drives – checking the oil level; à p. 7 - 31. E3
– Final drives – checking the oil level; à p. 7 - 36. E3
Wheels
– Check tightness of wheel nuts; à p. 7 - 40.
Suspension
– Suspension struts – checking the oil level; à p. 7 - 47. H
Electrical system
– Batteries – checking the acid level; à p. 7 - 78.
1)
Towbar coupling
– Lubricating the towbar coupling; à p. 7 - 91.3) J 2
Air-conditioning system
– Checking the moisture and level of the refrigerant; à p. 7 - 81. R
– Cleaning the condenser fins; à p. 7 - 82.
Soot particle filter1)
– Checking the clamp straps; à p. 7 - 85.
– Check connecting cables for tight fit.
– Checking the auxiliary heater for correct operation;
à p. 7 - 100.1)
– Lubricating outrigger beam; à p. 7 - 99.2) 3) J 16
1)
Additional equipment
2)
after 100 oper. hrs
3)
Lubricate after every high pressure cleaning.
27.01.2007

GMK 4100/GMK 4100–L

monthly / after 100 oper. hrs. à p. 6 - 1 in litres (gal)
Engine
Air-conditioning system1)
– Checking the moisture and level of the refrigerant; à p. 8 - 81. R
– Cleaning the condenser fins; à p. 8 - 82.
– Checking the clamp straps; à p. 8 - 84.
– Check connecting cables for tight fit.
– Lubricating the piston rod of the derricking cylinder; Y
à p. 8 - 85.2)
– Checking the auxiliary heater for correct operation; à p. 8 - 85.1)
1) Additional equipment
2) Lubricate after every high pressure cleaning.
27.01.2007

GMK 4100/GMK 4100–L

every three months / after 5 000 - 6 000 km (3100 - 3730 mi) à p. 6 - 1 in litres (gal)
Engine
Fuel system
– Fuel prefilter – replacing the filter; à p. 7 - 15.2)
Vehicle brake
– Checking brake lining thickness; à p. 7 - 45.
Hydraulic system
– Cleaning the magnetic rods; à p. 7 - 60.3)
Suspension
– Forced lever – checking correct functioning; à p. 7 - 48.
Electrical system
– Batteries – checking the acid concentration; à p. 7 - 80.
Towbar coupling1)
– Checking the bearing; à p. 7 - 93.
– Checking the cotter pin; à p. 7 - 94.
– Checking the lower bushing; à p. 7 - 95.
– Checking the support ring; à p. 7 - 96.
– Checking the initial tension of the springs; à p. 7 - 96.
– Checking the function of the coupling jaw / Resetting central
position; à p. 7 - 97.
2)
The maintenance interval depends on the degree of contamination of
the fuel; the maintenance interval may need to be reduced.
3)
after 300 oper. hrs
27.01.2007
5 - 10 3 112 369 en Maintenance manual

GMK 4100/GMK 4100–L

every 3 months / after 300 oper. hrs à p. 6 - 1 in litres (gal)
Engine
Fuel system
– Fuel filter – changing the filter; à p. 8 - 15.1)
Electrical system
– Batteries – checking the acid concentration; à p. 8 - 80.
Ball slewing bearing
– Check tightness of retaining bolts;
Torque; à Special torques, p. 10 - 2.
Main boom
– Lubricating the telescope slide faces; à p. 8 - 53. L2 24
– Lubricating the locking pins; à p. 8 - 51. Y 12
– Relubricating the hoist rope; à p. 8 - 59. T
– Checking the sheaves; à p. 8 - 77.2) 10
1) The maintenance interval depends on the degree of contamination of

the fuel; the maintenance interval may need to be reduced.
2)
The number of sheaves may vary, depending on your truck crane's
equipment.
27.01.2007
Maintenance manual 3 112 369 en 5 - 11

GMK 4100/GMK 4100–L

every six months / after 10 000 - 12 500 km (6 210 - 7 770 mi) à p. 6 - 1 in litres (gal)
Engine
Transfer case
– Changing the oil; à p. 7 - 28. E3 9.5 (2.5)
Wheels
– Changing wheels; à p. 7 - 41. 10
Steering
– Check rubber sleeves for damage.
Air-conditioning system
– Checking hoses; à p. 7 - 83. R
– Replacing the soot particle filter; à p. 7 - 86.
1)
27.01.2007

GMK 4100/GMK 4100–L

every 6 months / after 500 oper. hrs à p. 6 - 1 in litres (gal)
Engine
Hoists
– Lubricate hoist gear (only auxiliary hoist as additional equip- K 1
ment); à p. 8 - 23.
Slewing gear
– Checking the function of the slewing gear brake; à p. 8 - 28.
– Lubricating gear teeth; à p. 8 - 33. V 1
– Checking hoses; à p. 8 - 83. R
– Replacing the soot particle filter; à p. 8 - 84.
Safe load indicator
– Maintenance of the slip ring assembly of the cable drums;
à p. 8 - 71.
1)
27.01.2007

GMK 4100/GMK 4100–L
5.2.6 Maintenance plan M 12 M 12

every 12 months / after 20 000 - 25 000 km (12 430 - 15 530 mi) à p. 6 - 1 in litres (gal)
Engine
Fuel system
– Changing the fuel filter; à p. 7 - 17.
Transmission
– Checking the oil level; à p. 7 - 21. F4
Axle lines
– Axle centre drives – changing the oil; à p. 7 - 34.
1st Axle line E3 13.0 (3.5)
2nd Axle line1) E3 15.0 (4.0)
3rd Axle line E3 16.5 (4.4)
4th Axle line E3 13.0 (3.5)
– Final drives – changing the oil; à p. 7 - 37. E3 4.1 (1.0) each
Suspension
– Pressure accumulator – checking the gas pressure;
à p. 7 - 49.2)
Compressed air system
– Replacing the granulate cartridge of the compressed air drier;
à p. 7 - 55.
Hydraulic system
– Changing the ventilation filter; à p. 7 - 62.4)
– Taking oil samples; à p. 7 - 634) (change oil, depending on the
G2
145.0
oil sample test results; p. 7 - 66). (38.3)
– Changing the hydraulic oil filter; à p. 7 - 70.
– Checking the entire air conditioning system; à p. 7 - 83. R
– Lubricate the door hinges. J
– Lubricate the connecting and socket pins.3) J/A
27.01.2007
2) every 3 000 oper. hrs or every 12 months at the latest.
3) after 100 oper. hrs

GMK 4100/GMK 4100–L
4) Operation under difficult conditions:

– In extremely sandy or dusty areas, change the venting filters earlier,
if necessary.
– Oil change intervals are to be halved if the crane is used in tropical
or very warm climates.

every 12 months / after 1 000 oper. hrs à p. 6 - 1 in litres (gal)
Engine
Fuel system
– Fuel filter – changing the filter; à p. 8 - 15.
Hoists
– Changing the oil; à p. 8 - 24.2) E6 7.0 (1.8)
Check the old oil; à p. 8 - 25.
Slewing gear
– Changing the oil; à p. 8 - 30. E6 0.9 (0.24)
each
– Measuring tilting play; à p. 8 - 35.
Hydraulic system
à p. 8 - 42.2)
– Air filter – changing the filter element;
– Pressure accumulator – checking the gas pressure; à p. 8 - 41.
– Taking oil samples; à p. 8 - 402), (change oil, depending on the 915.0
G2
oil sample test results; p. 8 - 45). (241.7)
– Changing the filter; à p. 8 - 43.
Main boom
– Checking the locking system; à p. 8 - 55.
Hook blocks
– Lubrication; à p. 8 - 77.3) J
– Checking the entire air conditioning system; à p. 8 - 83. R
– Lubricate cabin door track rollers. A
27.01.2007
– Lubricate connecting and socket bolts, and base plate slinging J/A
points.
s
GMK 4100/GMK 4100–L
2)
carry out at least once per year
3) after 100 oper. hrs
5.2.7 Maintenance plan Y 2 Y2

every 24 months / after 40 000 – 50 000 km (25 000 – 31 000 mi) à p. 6 - 1 in litres (gal)
Engine
– Have the coolant level checked by an authorised GROVE dealer R 1.5 kg
or CraneCARE. (3.3 lbs)
1)

every 24 months à p. 6 - 1 in litres (gal)
Engine
No maintenance work in this period.
The long-term intervals always include the short-term intervals!
– Have the coolant level checked by an authorised GROVE dealer R 2.0 kg
or CraneCARE. (4.4 lbs)
1)
27.01.2007

GMK 4100/GMK 4100–L

The long-term intervals always include the short-term intervals!

Hoists
– Carry out partial inspection; à p. 8 - 26.

every 60 months / 100 000 km (62 000 mi) à p. 6 - 1 in litres (gal)
Transmission
– Changing the oil; à p. 7 - 23. F4 16.6 (4.4)

Safe load indicator
– Lubricating the slewing angle sensor; à p. 8 - 74. 1
27.01.2007

GMK 4100/GMK 4100–L

The long-term intervals always include the short-term intervals.

Hoists
– Carry out general inspection; à p. 8 - 26, à p. 5 - 22.
5.2.11 Maintenance plan Y 10 Y 10

every 120 months / after 200 000 km (124 000 mi) à p. 6 - 1 in litres (gal)
Steel construction
– Check the load-bearing steel construction. For more informa-
tion, please contact CraneCARE.

Steel construction
– Check the load-bearing steel construction. For more informa-
tion, please contact CraneCARE.
Safe load indicator
– Have the SLI checked by CraneCARE.
27.01.2007

GMK 4100/GMK 4100–L
5.3 Periodic inspections

Your GMK 4100/GMK 4100–L truck crane has been inspected before deliv-
ery.
– Truck cranes that are to be used in Germany are inspected in accordance

with the regulations of the professional trade association as defined by
BGV D 6 (VBG 9).
– Truck cranes that are to be used abroad are inspected in accordance with
the regulations of the respective country. If such regulations do not exist,
they are inspected in accordance with the regulations of the professional
trade association as defined by 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 components. Their 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 structural steelwork, qualified specialists must
determine the extent of the damage using the required material examin-
ation 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
indications 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.
27.01.2007

GMK 4100/GMK 4100–L
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.
27.01.2007

GMK 4100/GMK 4100–L
5.4 Measures required for winch monitoring
H
Also observe the information on the general inspection of the hoisting
gears;à p. 8 - 26.
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
service life of 3 200 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
27.01.2007

GMK 4100/GMK 4100–L
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 rope.
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 low or high temperatures,
conditions: caustic atmosphere,
dust and dirt.
5.4.2 Proportion of theoretical service life used
The truck crane operator must perform a truck crane inspection 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 expert 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.
27.01.2007

GMK 4100/GMK 4100–L
Determining the The truck crane's load spectrum is divided into groups (see also ISO 4301/1,
operating FEM 1.001):
conditions
(load spectrum)
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
L1 dead load + 1/3 payload
subject 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 + 1/1
to high stress quite payload)
often, but which are
1/6 of the timing period with
medium generally 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
Q3 50% of the timing period with 0.5
generally.
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
27.01.2007
s
GMK 4100/GMK 4100–L
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 load spectrum factor Km = 0.125 are generally
applied to truck cranes in assembly mode.
Determination The effective operating hours of the winches need to be entered in the crane
of the effective logbook for the respective inspection interval.
operating hours Ti
– The effective operating hours Ti of the winches are displayed in the Oper-
ating hours submenu; à Operating instructions.
Determining the For an inspection interval i (max. 1 year according to ISO 9927-1 or BGV D 6
proportion of (VBG 9) / BGV D 8 (VBG 8), the proportion of theoretical service life used Si
theoretical service is calculated using the formula:
life used
Km i
S i = ----------- × T i
Km
Km = Load spectrum factor established during winch calculation.

This factor is given in the operating instructions.
Kmi = Load spectrum factor in inspection interval i in accordance with the
section “Determining the operating conditions (collective load)”
Ti = Effective operating hours in the testing interval i according to
Section “Determination of the effective operating hours Ti”
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 of the truck crane.
27.01.2007

GMK 4100/GMK 4100–L
The general overhaul is to be arranged by the operator and performed by

the manufacturer or their representative. The results are to be entered in the
crane logbook.
The manufacturer or his representative will specify a new theoretical service

life D upon completion of the general overhaul.
The next general overhaul must be performed within 10 years.
Alternative 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 crane test book after every
inspection.
In this case, the crane expert must closely inspect the winch. This includes
at least:
– a visual inspection 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 crane test book 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.
27.01.2007

GMK 4100/GMK 4100–L
5.4.3 Example
A GMK 4100/GMK 4100–L is equipped with a separate operating hours

counter for the hoist and classified by Manitowoc Crane Group Germany
GmbH as follows:
Power unit group: M3
Load spectrum: light L 1, Km = 0.125
Theoretical service life: D = 3200 hrs
The used proportion S of theoretical service life is calculated based on the

individual inspection intervals as follows:
1st 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).
2nd 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.
27.01.2007

GMK 4100/GMK 4100–L
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).
3rd 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.
The values are entered in the table

(see table example 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 of the respective coun-
try.
27.01.2007
s
GMK 4100/GMK 4100–L
27.01.2007
Sample table to determine the remaining theoretical service life on winch no. 1 (main hoisting winch)
GMK 4100/GMK 4100–L

Maintenance manual
Crane model: GMK 3045
Work number: 3045 42 06
Commissioned on: 10 June 1990
Serial number of the winch in accordance with the type plate: 13 301
Last general overhaul performed on: .....................
Winch design data (see operating instructions):
Power unit group: M3
Load spectrum: Q1 (L1)
Factor of the load spectrum: Km = 0.125
Theoretical service life: D = 3200 hrs
Inspection Date of Operational Factor of Operating Operating Operating Operating Operating Used propor- Remaining Name of Signature Note Name of the Signature
interval no. commis- condition the load hours of the hours of the hours of the hours of the hours Tiof the tion Siof theo- theoretical competent approved
(max. sion/date of since the spectrum entire crane superstruc- superstruc- winch winch since the retical service service life person inspector
1 year) inspection last ture ture since last inspection life D:
inspection the last
Di = Di-1 - Si
inspection
“i” Kmi [h] [h] [h] [h] [h] [h] [h]
0(*) 10. 6. 90 – – – – – 0 3200
1 5. 6. 91 L1 0.125 – – – 160 160 160 3040 Müller
3 112 369 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
IMPORTANT: 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
Alternative 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
Last general overhaul performed on ..................................
(*) Copy last line of the previous page to the following page.
5 - 28
6
6.1 Lubrication chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 1
6.2 Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 2
6.3 Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 3
6.3.1 Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 3
6.3.2 Engine coolant admixtures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 3
6.3.3 Windscreen washing system admixtures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 3
6.3.4 Fuel for crane cab heating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 3
27.01.2007

GMK 4100/GMK 4100–L
27.01.2007

GMK 4100/GMK 4100–L
Lubricants and consumables
6.1 Lubrication chart
6.1 Lubrication chart
Lubricant according to Designation Specification Viscosity

maintenance plan according to Classification
DIN 51502
MIL-L 2104 C 1)
A Oil HD - CD
DB 228.5
Oil MIL-L 2105 B SAE 90
E3 C - LPF
Oil API-GL-5 ISO - VG 220
Oil MIL-L 2105 B SAE 75 W-90 EP

E 63) C - LPF
Oil API-GL-4/5 ISO - VG 220
DB 235.11 SAE 75 W-90

F 43) Oil
03 317 3982)
G2 Oil H-LP DIN 51524 T.2 ISO - VG 32
H Oil 02 310 863 2)
J Grease K - L2K DIN 51825
K Grease KP - L2K DIN 51825
L2 Grease 01 373 4582)
1)
see Engine manufacturer’s operating instructions
2)
GROVE part number, supplied by CraneCARE
3)
synthetic oil filled at the factory; do not mix with mineral oil
H
In the case of the engine in the carrier, go to the Settings submenu in the on-
board computer display to check the oil specification and viscocity;
à p. 7 - 1.
s
27.01.2007

GMK 4100/GMK 4100–L
6.2 Coolant
Lubricant according to Designation Specification Viscosity

maintenance plan according to Classification
DIN 51502
T Grease 03 133 770 1)
V Grease 00 554 205 1)
Y Oil 03 325 216 1)
1) GROVE part number, supplied by CraneCARE
6.2 Coolant
Coolant as per Chemical symbol CAS no.

Maintenance EC no.
schedule
811-97-2
R Tetrafluoroethane (R134a)
212-377-0
27.01.2007

GMK 4100/GMK 4100–L
6.3 Consumables
6.3 Consumables
6.3.1 Fuel
The fuels that are used and their respective specifications can be found in
the Engine manufacturer’s operating instructions.
6.3.2 Engine coolant admixtures
The specifications and admixture ratios can be found in the Engine manufac-
turer’s operating instructions.
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
You should use either the fuel specified in section 6.3.1 or EL heating oil as
heating fuel for the crane cab.
27.01.2007

GMK 4100/GMK 4100–L
6.3 Consumables
Blank page
27.01.2007

GMK 4100/GMK 4100–L
7
7.1 General instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 1
7.1.1 Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 1
7.1.2 Consumables quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 1
7.2 Preterm maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 3
7.3 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 5
7.3.1 Checking the oil level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 5
7.3.2 Topping up 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 the fuel prefilter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 13
7.4.2 Fuel prefilter – replacing the filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 15
7.4.3 Changing the fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 17
7.4.4 Emptying the fuel line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 18
7.4.5 Establishing operating condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 19
7.5 Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 21
7.5.3 Changing the oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 23
7.6 Transfer case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 27
7.6.1 General inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 27
7.6.2 Checking the oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 27
7.6.3 Changing the oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 28
7.7 Axle lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 31
7.7.2 Axle centre drives – checking the oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 31
7.7.3 Axle centre drives – changing the oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 34
7.7.4 Final drives – checking the oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 36
7.7.5 Final drives – changing the oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 37
7.8 Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 39
7.8.1 Checking the tyres for damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 39
7.8.2 Checking the tyre pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 40
7.8.3 Check tightness of wheel nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 40
7.8.4 Changing wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 41
7.9 Vehicle brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 45
7.9.1 Checking brake lining thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 45
27.01.2007
7.10 Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 47
7.10.1 Suspension struts – checking the oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 47
7.10.2 Forced lever – checking correct functioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 48
7.10.3 Pressure accumulator – checking the gas pressure . . . . . . . . . . . . . . . . . . . . . . 7 - 49

GMK 4100/GMK 4100–L
7.11 Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 51
7.11.1 Checking for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 51
7.12 Compressed air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 53
7.12.1 Draining the compressed air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 53
7.12.2 Checking for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 54
7.12.3 Replacing the granulate cartridge of the compressed air drier . . . . . . . . . . . . 7 - 55
7.13 Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 57
7.13.1 Checking the oil level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 57
7.13.2 Checking the hydraulic hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 58
7.13.3 Checking ventilation filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 59
7.13.4 Checking for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 59
7.13.5 Cleaning the magnetic rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 60
7.13.6 Changing the ventilation filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 62
7.13.7 Taking oil samples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 63
7.13.8 Changing the hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 66
7.13.9 Changing the hydraulic oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 70
7.14 Central lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 73
7.14.1 Checking the level of the grease container . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 73
7.14.2 Bleeding the central lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 75
7.14.3 Triggering intermediate lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 75
7.15 Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 77
7.15.1 Checking the lighting and indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 77
7.15.2 Batteries – checking the acid level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 78
7.15.3 Batteries – checking the acid concentration . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 80
7.16 Air-conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 81
7.16.1 Checking the moisture and level of the refrigerant. . . . . . . . . . . . . . . . . . . . . . 7- 81
7.16.2 Cleaning the condenser fins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 82
7.16.3 Checking hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 83
7.16.4 Checking the entire air conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 83
7.17 Soot particle filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 85
7.17.1 Checking the clamp straps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 85
7.17.2 Replacing the soot particle filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 86
7.17.3 Back pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 89
7.18 Towbar coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 91
7.18.1 Lubricating the towbar coupling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 91
7.18.2 Checking the bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 93
7.18.3 Checking the cotter pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 94
7.18.4 Checking the lower bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 95
7.18.5 Checking the support ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 96
7.18.6 Checking the initial tension of the springs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 96
7.18.7 Checking the function of the coupling jaw /Resetting central position . . . . . . 7- 97
27.01.2007
7.19 Other maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 99

7.19.1 Lubricating outrigger beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 99
7.19.2 Checking the auxiliary heater for correct operation . . . . . . . . . . . . . . . . . . . . . 7 - 100
7.19.3 Having the fire extinguisher checked . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 100

GMK 4100/GMK 4100–L
Maintenance work on the carrier
7.1 General instructions
7.1.1 Covers
For various jobs (e.g. oil change), you must remove the covers on the motor
and the transmission.
Before maintenance work

• Remove the covers (1).
After maintenance work
• Replace the coverings (1) and secure them
with the locks.
7.1.2 Consumables quality
S
Risk of damage to the engine/transmission
Have any on-board computer changes to the quality of the consumables
used set by an authorised GROVE dealer or CraneCARE.
That way, you will avoid exceeding maintenance intervals as a result of
incorrect information and seriously damaging the engine and transmis-
sion.
27.01.2007
s
GMK 4100/GMK 4100–L
Use the Consumables submenu on the on-board computer to display the follow-
ing information:
Engine – Oil quality

– Viscosity
– Fuel sulphur content
Transmission – Oil quality
Have the settings changed by an authorised GROVE dealer or CraneCARE if

you are intending to use different quality consumables after a maintenance
service.
27.01.2007

GMK 4100/GMK 4100–L
7.2 Preterm maintenance work
7.2 Preterm maintenance work D

Before work starts, check the following displays and LEDs on the On-board
computer display, the ECOS display and the instrument panel.
On the On-board If one of the symbols lights up, carry out the associated maintenance work:
computer display
– Oil pressure; à p. 7 - 5
– Air filter; à p. 7 - 9
– Coolant level; à p. 7 - 10
On the ECOS
display
• Open the Warning submenu; à Operating instructions.
If symbol (1) is red, carry out the respective maintenance work:
– Hydraulic oil filter; à p. 7 - 70.
On the front Carry out the respective maintenance work if the lamp lights up in orange.
instrument panel
– Soot particle filter; à
p. 7 - 86. Record the maintenance work performed
in the maintenance booklet; à
Separate Operating Instructions.
27.01.2007

GMK 4100/GMK 4100–L
Blank page
27.01.2007

GMK 4100/GMK 4100–L
7.3 Engine
7.3 Engine
For maintenance work beyond the daily scope, follow the supplied Engine
manufacturer’s operating instructions.
S
Risk of engine damage
The engine is in maintenance group C (difficult operation) because of the
high full-load rate and large fuel throughput.
If fatty acid methyl ester (FAME, e.g. bio diesel) is to be used in the engine,
the intervals between oil changes should be halved.
The release of engines for FAME operation is regulated in service informa-
tion provided by the engine manufacturer.
7.3.1 Checking the oil level D
Prerequisites – The truck crane is horizontal.
Checking the
oil level
S
Risk of damage to the engine if the oil pressure is too low
If symbol (1) lights up or the STOP lamp comes on and the warning buzzer
sounds, switch the engine off immediately. The engine can be damaged by
running it when the oil pressure is too low.
• Start the engine.

• Switch off the engine immediately, if
– the symbol (1) is displayed, and
– lamp (2) comes on and the warning buzzer
sounds.
If symbol (1) is displayed, the oil pressure is
too low.
• Allow the engine to run at idling speed for 2 - 3 minutes.

• Switch off the engine.
27.01.2007
• Check the oil level after about two minutes.
s
GMK 4100/GMK 4100–L
7.3 Engine
• On the dipstick (1), check whether the oil

level is between the min. and the max. mark-
ing (arrows).
• Put the dipstick into the dipstick tube after
checking the oil level.
• Add more oil, à p. 7 - 7.
27.01.2007

GMK 4100/GMK 4100–L
7.3 Engine
7.3.2 Topping up oil
Data on the prescribed oil specification; à Separate engine operating instruc-

tions, provided by the manufacturer.

– 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 Separate engine operating instructions, provided by
the manufacturer.
S
Risk of burning yourself on the hot engine
During operation, the engine and add-on parts can reach temperatures up
to 400°C (750°F). 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.
27.01.2007

GMK 4100/GMK 4100–L
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 tools Designation Quantity GROVE part no.
Valve 1 03 046 878
Gasket 26 x 31 Cu DIN 7603 1 00117 147
– Drain channel.
– Torque wrench for torque of 60 Nm (44.25 lbf ft).

à p. 2 - 3.
Installing
the valve
• Use a drain channel when draining the oil.
• Drain the engine oil as described in the
Engine manufacturer’s operating instructions.
• Replace the gasket and tighten the valve (1)
– torque 60 Nm (44.25 lbf ft).
• 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 - 63.
27.01.2007

GMK 4100/GMK 4100–L
7.3 Engine
7.3.4 Checking the air filter D
If the symbol (1) appears on the on-board computer display, change the air
filter.
Spare parts
Filter 1 03 324 183
Prerequisites – The engine is not running and is secured against unauthorized use;
à p. 2 - 3.
Replacing the
air filter
• Undo all the clamps (1) and remove the lid
(2).
• Change the filter (3).
• Replace the lid and secure it with all the
clamps.
27.01.2007

GMK 4100/GMK 4100–L
7.3 Engine
7.3.5 Checking the coolant level D
If the symbol (1) appears on the on-board computer display, top up the
coolant.
G
Risk of scalding when the engine is hot
The hot cooling circuit is under pressure. If you open the expansion tank of
the hot cooling circuit, you may be scalded by the hot steam and any hot
coolant which may escape.
Wear suitable protective gloves and cover the cap of the expansion tank
with a rag before opening it.
Turn the cap slowly to the first detent in order to allow the excess pressure
to be released.
• Do not open the pressure relief valve (2).

• Loosen (do not open!) cap (1) to the coolant
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; à Separate
engine operating instructions, provided by the
manufacturer.
• Close the cap.
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 an authorised GROVE dealer
CraneCARE.
27.01.2007

GMK 4100/GMK 4100–L
7.3 Engine
7.3.6 General inspection W
• Pay attention to any unusual noises made by 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 to an authorised GROVE dealer or
CraneCARE.
27.01.2007

GMK 4100/GMK 4100–L
7.3 Engine
Blank page
27.01.2007

GMK 4100/GMK 4100–L
7.4 Fuel system
7.4 Fuel system
The fuel filters are built into the fuel line:

1 Fuel prefilter
2 Fuel filter
7.4.1 Draining off water from the fuel prefilter D
Spare parts – Receptacle, approx. 5 l (1.5 gal); à p. 2 - 4.

and tools

à p. 2 - 3.
s
27.01.2007

GMK 4100/GMK 4100–L
7.4 Fuel system
Draining off water

from the prefilter
O
Risk of environmental damage due to leaking consumables
Always let consumables drain into suitable receptacles. Wipe up any con-
sumables that have leaked.
Store/dispose of consumables and any soaked equipment properly.
Ask about the applicable regulations.
• Place a receptacle underneath the filter.

• Open the valve (1).
• If the draining consumable is clean, close
the valve manually.
• Remove the receptacle and properly dis-
pose of the drained fluid.
27.01.2007

GMK 4100/GMK 4100–L
7.4 Fuel system
7.4.2 Fuel prefilter – replacing the filter M3
Spare parts
Filter 1 03 322 877
Gasket 1 03 322 879
Filter element 1 03 328 656
– Receptacle, approx. 5 l (1.5 gal); à p. 2 - 4.

à p. 2 - 3.
Changing the filter
O

• Close the valve – lever (1) at right angles to
the line.
• Open the bolt (2) and the valve (3) and drain
the fluid.
s
27.01.2007

GMK 4100/GMK 4100–L
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.
• Close 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.
27.01.2007

GMK 4100/GMK 4100–L
7.4 Fuel system
7.4.3 Changing the fuel filter M 12
Spare parts
Filter and gasket 1 03 319 653

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.
– The fuel line is empty; à p. 7 - 18.
Changing the fuel

filter
O
• 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 cap.
• Screw the cap with the filter into the housing
and tighten it – torque 25 Nm (18.5 lbf ft).
• Restore the operating condition;
à p. 7 - 19.
27.01.2007

GMK 4100/GMK 4100–L
7.4 Fuel system
7.4.4 Emptying the fuel line
Before changing the fuel filters you must do the following:

– shut off the fuel line to the fuel tank and
– empty the fuel line.
O

the line.
• Open the bolt (2) and let the consumable
drain.
• 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 end of the
hose. When bleeding is carried out, more con-
sumable will run out.
27.01.2007

GMK 4100/GMK 4100–L
7.4 Fuel system
7.4.5 Establishing operating condition
After changing and cleaning the fuel filter you must bleed the fuel line.
O
A receptacle is underneath the hose end.

The lever (2) is parallel with 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 leak-tight.
• Remove the receptacle underneath the end
of the hose.
H
27.01.2007

Otherwise you must set the consumable aside for disposal.

GMK 4100/GMK 4100–L
7.4 Fuel system
Blank page
27.01.2007

GMK 4100/GMK 4100–L
7.5 Transmission
7.5 Transmission
• Listen carefully for any abnormal noises from the transmission.

• Check the transmission and the connections for leaks. In the event of leak-
ing consumables; à Checking the oil level, p. 7 - 21.
CraneCARE.
7.5.2 Checking the oil level M 12
Spare parts
Gasket 24 x 29 Al DIN 7603 1 03 328 331

Prerequisites – The gear oil is at operating temperature (70 to 95°C (160 to 200°F)).
– The truck crane is raised on outriggers or parked over an inspection pit.
– The truck crane is not running and is secured against unauthorized use;
à p. 2 - 3.
s
27.01.2007

GMK 4100/GMK 4100–L
7.5 Transmission
Checking the
oil level
S
Risk of damage to the transmission!
The correct oil level must be maintained to ensure smooth operation of the
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.
• Remove the bolt (1).

• Check the oil level; it must reach to the lower
edge of the hole.
• Replace the gasket and tighten the bolt –
torque 50 Nm (36.9 lbf ft).
27.01.2007

GMK 4100/GMK 4100–L
7.5 Transmission
7.5.3 Changing the oil Y5
Spare parts
Filter 1 03 328 342
Spring 1 03 328 343
Gasket 42 x 49 Al DIN 7603 1 03 328 344
Gasket 24 x 29 Al DIN 7603 2 03 328 331
– Receptacle, approx. 20 l (5 gal); à p. 2 - 4.

– Torque wrench for torque of 50 Nm (36.9 lbf ft) and 60 Nm (44.25 lbf ft).
Prerequisites – The gear oil is at operating temperature (70 to 95°C (160 to 200°F)).
à p. 2 - 3.
Draining oil
G
Risk of scalding
Do not let the gear oil at operating temperature escape unchecked.
O
s
27.01.2007

GMK 4100/GMK 4100–L
7.5 Transmission
• Place a receptacle under the bolt (2).

• Undo bolts (1) and (2) and let the oil drain
off.
• Clean the bolts.
• Replace the gasket and tighten the bolt (2) –
Cleaning the filter
O
Risk of injury due to spring tension
The oil strainer bolt is spring-loaded. Release it carefully and be careful of
the spring tension.

• Take the strainer (2) and the spring (3) out
and clean them.
Replace any damaged parts.
• Insert the spring and strainer into the open-
ing.
• Replace the gasket and tighten the bolt –
27.01.2007

GMK 4100/GMK 4100–L
7.5 Transmission
Topping up oil
• Fill the oil up to the lower edge of the open-
ing.
• Replace the gasket and tighten the bolt (1) –
Inspections after
the oil change
After changing oil, check the sealing:
• Start the engine and let it idle in neutral N.
• Check bolts (1), (2) and (3) for leakage.
27.01.2007

GMK 4100/GMK 4100–L
7.5 Transmission
Blank page
27.01.2007

GMK 4100/GMK 4100–L
7.6 Transfer case
7.6 Transfer case
• Pay attention to any unusual noises made by 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 - 27.
CraneCARE.
7.6.2 Checking the oil level M1
Spare parts
Gasket 30 x 36 Cu DIN 7603 1 00 117 151
Prerequisites – The truck crane is raised on outriggers or parked over an inspection pit.
à p. 2 - 3.
s
27.01.2007

GMK 4100/GMK 4100–L
7.6 Transfer case
Checking the
oil level
• Check that the oil reaches the lower edge of
the opening.
• Fit a new gasket and tighten the bolt.

7.6.3 Changing the oil M6
Spare parts
Gasket 16 x 20 Cu DIN 7603 1 00 117 134
Gasket 30 x 36 Cu DIN 7603 2 00 117 151
– Receptacle, about 15 l (4.0 gal); à p. 2 - 4.
Prerequisites – The gear oil is at operating temperature.

à p. 2 - 3.
27.01.2007

GMK 4100/GMK 4100–L
7.6 Transfer case
Changing the oil
G
Risk of scalding
Do not let the gear oil at operating temperature escape unchecked.
O
• Place a receptacle under the bolt (2).

• Unscrew the bolts (1) and (2) and let the oil
drain off.
• Fit a new gasket and tighten the bolt (2).
ing.
Inspections after
an oil change
• Go for a test drive.
• Switch the engine off and wait for about 5
minutes.
• Check the oil level; à p. 7 - 27.
• Check the bolts (1) and (2) for leaks.
27.01.2007

GMK 4100/GMK 4100–L
7.6 Transfer case
Blank page
27.01.2007

GMK 4100/GMK 4100–L
7.7 Axle lines
7.7 Axle lines
• 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 Axle centre drives – checking the oil level, p. 7 - 31,
à Final drives – checking the oil level, p. 7 - 36.
CraneCARE.
7.7.2 Axle centre drives – checking the oil level M1
The 2nd axle line drive is only available if you have additional equipment.
Spare parts
and tools Place of Designation Quan- GROVE part no.
installation tity
1st to 4th axle
Gasket 30 x 36 Cu DIN 7603 5 02 309 476
line
à p. 2 - 3.
s
27.01.2007

GMK 4100/GMK 4100–L
7.7 Axle lines
1st and 4th axle

lines
the opening.
2nd Axle line

the opening.
27.01.2007

GMK 4100/GMK 4100–L
7.7 Axle lines
3rd Axle line The central gear of the 4th axle line comprises a countershaft and differen-
tial transmission. The transmission has two oil chambers with different oil
levels.
S
Risk of oil overheating
To top up the oil in the countershaft, both holes must be open so that the
oil chamber of the differential transmission is not over-filled. This prevents
the oil from overheating.
• Unscrew bolts (1) and (2).

the opening.
• Fit new gaskets and tighten the bolts.

27.01.2007

GMK 4100/GMK 4100–L
7.7 Axle lines
7.7.3 Axle centre drives – changing the oil M 12
The 2nd axle line drive is only available if you have additional equipment.
Spare parts
and tools Place of Designation Quan- GROVE part no.
installation tity
1st to 4th axle Gasket 36 x 42 Cu DIN 7603 5 01 371 208

line Gasket 30 x 38 Cu DIN 7603 5 01 925 343
à p. 2 - 3.
O
1st and 4th

axle lines
• Place a receptacle under the hole (2).

flow into the receptacle.
ing.
27.01.2007

GMK 4100/GMK 4100–L
7.7 Axle lines
2nd Axle line

• Place a receptacle under the hole (2).
flow into the receptacle.
ing.
3rd Axle line The central gear of the 3rd axle line comprises a countershaft and differen-
tial transmission. The transmission has two oil chambers with different oil
levels.
S
Risk of oil overheating
To top up the oil in the countershaft, both holes must be open so that the
oil chamber of the differential transmission is not over-filled. This prevents
the oil 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).
27.01.2007

GMK 4100/GMK 4100–L
7.7 Axle lines
7.7.4 Final drives – checking the oil level M1
The 2nd axle line final drive is only available if you have additional equip-
ment.
Spare parts
per axle
line
Gasket 24 x 29 Cu DIN 7603 2 00 117 145
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 so that the marking (2) is
horizontal and is on the right next to the cen-
tre of the axle.
• Check whether the oil level is on the (2)
mark.
27.01.2007

GMK 4100/GMK 4100–L
7.7 Axle lines
7.7.5 Final drives – changing the oil M 12
The 2nd axle line final drive is only available if you have additional equip-
ment.
Spare parts
per axle
line
Gasket 24 x 29 Cu DIN 7603 2 00 117 145
– Drain channel.
Prerequisites – The truck crane is raised on outriggers.

à p. 2 - 3.
Draining oil
O
• Change the oil on all final drives in the same

way.
• Use a drain channel when draining the oil
and place a receptacle under the wheel.
• Turn the wheel until the hole points down-
wards and drain the oil into the receptacle.
27.01.2007
s
GMK 4100/GMK 4100–L
7.7 Axle lines
Topping up oil
• Turn the wheel so that the marking (2) is
horizontal and is on the right next to the cen-
tre of the axle.
• Top up the oil through the hole.
Use only oil specified in the Maintenance
plan, p. 5 - 14.
27.01.2007

GMK 4100/GMK 4100–L
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 the tyres for:

– chunking
– dents
– areas of uneven wear
• Check whether the tyre has worn down to
the wear mark (1).
If the tyre no longer has any tread at the wear
marks:
• Change the tyres.
• If the tyres on your truck crane show varying
wear, switch the tyres around (à Changing
wheels, p. 7 - 41).
S
Risk of accidents due to uneven braking.
When changing the tyres, make sure that any tyres used from other manu-
facturers have the same load bearing capacity.
Always replace the tyres on one axle line.
27.01.2007

GMK 4100/GMK 4100–L
7.8 Wheels
7.8.2 Checking the tyre pressure W
S
Risk of damage to the tyres
When changing the tyres, make sure that any tyres used from other manu-
facturers have the same load bearing capacity and thus the same tyre pres-
sure as the initial equipment.
Always check the tyre pressure in on-road driving mode with cold tyres.
The tyre pressure increases at operating temperature. Never release the
increased air pressure of tyres at operating temperature.
• Check the tyre pressure using the following table.
Tyres Air pressure in bar (psi)

with cold tyres
14.00 R 25 10.0 (145)
16.00 R 25 9.0 (131)
20.50 R 25 7.0 (102)
7.8.3 Check tightness of wheel nuts M1
Spare parts
per wheel
Wheel nut with pressure plate 12 01 207 756
– Torque wrench for 650 Nm (480 lbf ft).
à p. 2 - 3.
27.01.2007

GMK 4100/GMK 4100–L
7.8 Wheels
Checking the
wheel nuts
• Check the wheel nuts and the pressure
plates for damage.
• Replace any damaged wheel nuts or pres-
sure plates.
• With a torque wrench, check that the wheel
nuts are tight; do this crosswise, in the order
shown in the illustration.
Torque for
wheel nuts: 650 Nm (480 lbf ft)
7.8.4 Changing wheels 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
per wheel
Wheel nut with pressure plate 12 01 207 756
– Torque wrench for 650 Nm (480 lbf ft).
s
27.01.2007

GMK 4100/GMK 4100–L
7.8 Wheels
à p. 2 - 3.
Changing wheels
G
Risk of accidents if procedure incorrect
This section only shows the sequence to be followed when changing
wheels.
When removing/installing the wheels, observe all the safety instructions
and the procedure stated in the Operating Instructions.
• Dismount 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 - 40.
27.01.2007

GMK 4100/GMK 4100–L
7.8 Wheels
Optimised To ensure that the wear on all tyres is more or less the same, you can also
wheel 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 only shows the sequence to be followed when changing
wheels.
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
Only have tyres fitted to aluminium wheel rims 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.
• Dismount 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 - 40.
-
27.01.2007

GMK 4100/GMK 4100–L
7.8 Wheels
Blank page
27.01.2007

GMK 4100/GMK 4100–L
7.9 Vehicle brake
7.9 Vehicle brake
7.9.1 Checking brake lining thickness M3
There is an opening on the inside of each wheel (sealed with a rubber plug)
through which the brake lining thickness can be checked.
• Remove rubber plugs (1) and (2) and shine a

torch into the opening.
If the brake lining has worn down to the wear
marks (stepped edges or grooves), or when
the brake-lining thickness has worn down to
only 3 mm (0.11 in):
• Have an authorised GROVE dealer or
CraneCARE change the brake linings.
G
Risk of accidents from skidding
The brake linings should always to be changed on both the right and left of
the axle line. If the brake lining is only changed on one wheel on the axle
line, the wheels will have an uneven braking effect.
27.01.2007

GMK 4100/GMK 4100–L
7.9 Vehicle brake
Blank page
27.01.2007

GMK 4100/GMK 4100–L
7.10 Suspension
7.10 Suspension
7.10.1 Suspension struts – checking the oil level M1
Spare parts – High pressure squirt gun.

and tools
à p. 2 - 3.
Checking the • Use the level adjustment system to lower the truck crane completely and
oil level then raise it to On-road level; à Operating instructions.
H
The initial complete lowering is necessary to produce the correct oil level.
S
Risk of damage due to faulty suspension struts
If the oil level is above the upper marking on the inspection glass the sus-
pension strut is faulty and must be replaced.
Notify an authorised GROVE dealer or 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.

the inspection glass (1) on each suspension
strut.

• Screw the high pressure squirt gun to the
filler connection (2).
• Inject oil up to the level of the lower mark-
ing.
Use only oil specified in the Maintenance
plan, p. 5 - 8.
27.01.2007

GMK 4100/GMK 4100–L
7.10 Suspension
7.10.2 Forced lever – checking correct functioning M3
A pair of forced levers is fitted to every suspension strut to guide the sus-
pension strut in the longitudinal direction when extending or retracting. The
forced levers of the suspension must be checked for fault-free operation.
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 in close proximity to the wheels when you switch on
the suspension.
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.
1 •
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.

1
• Check whether all suspension struts are extended and the forced levers
(1) are slackened.
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 an author-

27.01.2007
ised GROVE dealer or CraneCARE.

GMK 4100/GMK 4100–L
7.10 Suspension
7.10.3 Pressure accumulator – checking the gas pressure M 12
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).
– 2nd axle line for the 1st and 2nd axle line
– 4th axle line for the 4th and 5th axle line
The filling pressure at 20°C (68°F) is 40 bar

(580 psi).
• Have the filling pressure checked and

adjusted if necessary by an authorised
GROVE dealer or CraneCARE.
27.01.2007

GMK 4100/GMK 4100–L
7.10 Suspension
Blank page
27.01.2007

GMK 4100/GMK 4100–L
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. Only
change pipes and hoses when the system is depressurised.
• Top up oil if necessary; à Checking the oil level, p. 7 - 57.
After changing pipes and hoses:

• Bleed the hydraulic system; à Bleeding the hydraulic system, p. 7 - 69.
If damage cannot be rectified immediately or further damage is likely:

• Notify an authorised GROVE dealer or CraneCARE.
27.01.2007

GMK 4100/GMK 4100–L
7.11 Steering
Blank page
27.01.2007

GMK 4100/GMK 4100–L
7.12 Compressed air system
7.12.1 Draining the compressed air system W
Location of the The compressed air system must be drained at the valves (1). A functional
air reservoirs check of the compressed air drier is carried out simultaneously.
The air reservoirs are located:

2 under the driver's cab
3 on the right behind the access ladder
4 in front of the rear outrigger box
5 on the left under the access ladder (conditioning unit)
s
27.01.2007

GMK 4100/GMK 4100–L
Spare parts
Valve 5 01 570 750
– The air reservoir is filled to the maximum à Operating instructions.
à p. 2 - 3.
Draining the
air reservoir
• Operate the valves (1).
If a large quantity of moisture escapes from the air reservoirs:

• Have an authorised GROVE dealer or CraneCARE check or change the
drier.
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.

27.01.2007

GMK 4100/GMK 4100–L
7.12.3 Replacing the granulate cartridge of the M 12

compressed air drier
Spare parts
Granulate cartridge 1 03 043 578
– Strap wrench
à p. 2 - 3.
Replacing the
granulate
cartridge
G
Risk of injury from escaping compressed air
If the conditioning unit is not completely empty, the compressed air drier
will be under pressure.
Ventilate the conditioning unit until air no longer escapes from the valve.
• Release all the air from the conditioning unit

(2) via the valve (1).
• Replace the granulate cartridge (3) (lubricate
gasket slightly).
27.01.2007

GMK 4100/GMK 4100–L
Blank page
27.01.2007

GMK 4100/GMK 4100–L
7.13 Hydraulic system
O
Prerequisites – The truck crane is aligned horizontally at on-road driving level;

– 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.

27.01.2007

GMK 4100/GMK 4100–L
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
(3626 psi)).
Maximum operating pressure and unit
of measurement (B) (e.g. 25.0 MPa
(3626 psi)).
3 Month and year of manufacture.
• Always ensure that the corresponding parts

of the hydraulic system are depressurised.
• Damaged or old hydraulic hoses must be
replaced immediately.
27.01.2007

GMK 4100/GMK 4100–L
7.13.3 Checking ventilation filters W
• Check the display (1) on the ventilation filter.

If the display is red:
• Replace the filter; à p. 7 - 62.
• With the vehicle running, carry out a visual inspection for leaks and escap-
ing oil at the suspension struts, outriggers, hydraulic lines (hoses and
pipes) and connections.
• Check the oil level if there are leaks; à Checking the oil level, p. 7 - 57.
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.
27.01.2007
s
GMK 4100/GMK 4100–L
After parts have been changed:

• Bleed the carrier hydraulic system à Bleeding the hydraulic system,
p. 7 - 69.
7.13.5 Cleaning the magnetic rods M3
Spare parts
Filter 2 03 329 152
Gasket 2 03 328 216
Gasket 2 02 316 851
Prerequisites – The truck crane must be standing on a level surface.

à p. 2 - 3.
Cleaning the
magnetic rods
• Loosen the cap (1) and pull out the filters.
• Place the filters in a receptacle.
27.01.2007

GMK 4100/GMK 4100–L
• Remove the spring (1).

• Undo the nuts (5).
• Take the magnetic rod (2) 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 an authorised GROVE dealer or CraneCARE check the hydraulic
system.
• Install the filters and insert them.

• Replace the gaskets if necessary and fasten
the cap (1).
27.01.2007

GMK 4100/GMK 4100–L
7.13.6 Changing the ventilation filter M 12
Spare parts
Filter 1 03 134 931
à p. 2 - 3.
O
Risk of damage to the environment from filter residues
Store used hydraulic oil filters in suitable receptacles and have them dis-
posed of properly by qualified personnel.
• Remove the cap (1).

• Change the filter (2) and fasten the cap.
27.01.2007

GMK 4100/GMK 4100–L
7.13.7 Taking oil samples M 12
Spare parts – A ½-inch connecting piece with a drain hose.

and tools – Four sample containers (0.3 litres each (0.08 gal)).
– Receptacle, approx. 5 litres (1.5 gal); 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.
H
The drain valves can only be opened and closed using the ½-inch connect-
ing pieces. The connecting pieces can be found in the tool box; à
Handling
the valves, p. 7 - 64.
• Take one oil sample from each valve (1), (2)

and (3) on the hydraulic oil tank.
s
27.01.2007

GMK 4100/GMK 4100–L
• An oil sample from the hydraulic system is

taken via a gauge port (1), e. g. on a valve
block of the suspension.
Handling the The valves can only be opened and closed using the ½-inch connecting
valves pieces. The connecting pieces are located 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 an oil drain hose on the connecting piece and put the other end of
the hose into a receptacle.
• A – Remove the cap and turn the connecting piece on the valve – the valve
opens.
• Drain the needed amount of oil.
• B – Remove the connecting piece – the valve closes.
• Screw the cap back onto the valve.
27.01.2007

GMK 4100/GMK 4100–L
Taking oil samples • Before taking the oil sample, allow 1 to 2 litres (0.25 to 0.5 gal) of oil to
drain into a receptacle.
• Take 0.3 litres (0.08 gal) of hydraulic oil from each of the three valves 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.
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 V i ≥ 150.
If one of these limits has been reached/fallen short of:
• Carry out an oil change; à p. 7 - 66.
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 - 70.
• 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 has been reached/exceeded:
27.01.2007
• Have the hydraulic oil cleaned with a mobile water separator until the
water content is clearly below the limit value.

GMK 4100/GMK 4100–L
7.13.8 Changing the hydraulic oil
The oil need only be changed if the laboratory analysis shows that the per-
missible limits have been exceeded ( à
Determining the quality of the oil,
p. 7 - 65) or the laboratory has recommended a date for an oil change.
Spare parts – One or more receptacles, approx. 150 l (40 gal); à p. 2 - 4.

and tools
Prerequisites – The main boom is set down on the boom rest.

– The outriggers are retracted; à Operating instructions.
à p. 2 - 3.
S
Risk of damage to the hydraulic pumps
Always lock the crane cab to prevent unauthorised use.
If the engine is started while the shut-off valves in the suction lines are
closed, the hydraulic pumps will be damaged.
Closing the valves

• Close the valves – lever (1) at right angles to
the line.
27.01.2007

GMK 4100/GMK 4100–L
Draining oil
O
Always use the supplied
½-inch connecting piece with an oil drain hose and a receptacle with suffi-
cient capacity to drain the hydraulic oil.
• Place a receptacle underneath the valves.

• Screw the connecting piece and oil drain
hose onto drain valves (1), (2) and (3);
à Handling the valves, p. 7 - 64 in turn.
• Change the filters; à p. 7 - 70.
Topping up 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 cap and filter (2).

• Add the new oil through the filter until it
reaches the middle of the inspection glass
(1).
• Tighten the cap and filter.
27.01.2007
s
GMK 4100/GMK 4100–L
Establishing After having changed the oil filters and topped the oil up, you must re-estab-
operating lish the operating condition.
condition
S
Open the valves in the suction lines before 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 which
may be enclosed 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 - 57.
27.01.2007

GMK 4100/GMK 4100–L
Bleeding the If the steering is “loose“ during the test run, you must bleed the steering
hydraulic system cylinders of the hydraulic system.
Preparations – The truck crane is raised on outriggers; à Operating instructions

and
– 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 each of the cap nuts (1) in turn until the
oil coming out no longer contains air bub-
bles.
If the steering system is still not operating

properly:
• Notify an authorised GROVE dealer or
CraneCARE.
27.01.2007

GMK 4100/GMK 4100–L
7.13.9 Changing the hydraulic oil filter
The oil filters must be changed:

– if the symbol (1) is displayed, and
– after every hydraulic oil change.
Spare parts
Filter 2 03 329 152
Gasket 2 03 328 216
Gasket 2 02 316 851
à p. 2 - 3.
Changing the filter
O
Store used hydraulic oil filters in suitable receptacles and have them dis-
posed of properly by qualified personnel.
• Loosen the cap (1) and pull out the filters.

• Place the filters in a receptacle.
27.01.2007

GMK 4100/GMK 4100–L
• Remove the spring (1).

• Undo the bolt (5).
• Take the magnetic rod (2) and the filter (3)
out of the filter cage (4).
• Clean the magnetic rod (2) and the filter
cage (4).
• Insert a new filter (3) into the filter cage (4).
• Replace any damaged parts.
S
Large amounts of metal particles are a sign of damage in the hydraulic
system.
Have an authorised GROVE dealer or CraneCARE check the hydraulic sys-
tem.
• Install the filters and insert them.

• Replace the gaskets and fasten the cap (1).
27.01.2007

GMK 4100/GMK 4100–L
Blank page
27.01.2007

GMK 4100/GMK 4100–L
7.14 Central lubrication system
7.14.1 Checking the level of the grease container W
Spare parts and

tools Designation Quantity GROVE part no.
Grease cartridge 1 00 554 201
– 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.
marking.
If the level is too low:
• Add more grease, à p. 7 - 74.
s
27.01.2007

GMK 4100/GMK 4100–L
Filling the grease

container
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.
• Turn on the ignition.

• Attach the filling pump to connection (1) or
(2).
• Press the button (4) for approx. 2 seconds
once.
Intermediate lubrication is triggered.
• Fill the grease container up to the Max.

marking.
• Remove the filling pump, wipe away any
excess grease and close the holes.
27.01.2007

GMK 4100/GMK 4100–L
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.

• Undo the connection (2).
• Trigger intermediate lubrication repeatedly
until the grease flowing from the connection
no longer contains any bubbles.
• Tighten the connection, wipe away any
excess grease and close the holes.
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.

• Remove the cap (1) and press once on but-
ton (2) for approx. 2 seconds.
An intermediate lubrication cycle will be trig-
gered which lasts approximately 3 minutes.
Check whether grease is applied to all the
lubricating points.
• Turn off the ignition and remove any excess

grease.
27.01.2007
• Tighten the cap.

GMK 4100/GMK 4100–L
Blank page
27.01.2007

GMK 4100/GMK 4100–L
7.15 Electrical system
7.15.1 Checking the lighting and indicators D
• 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
27.01.2007

GMK 4100/GMK 4100–L
7.15.2 Batteries – checking the acid level M1
G
Danger due to lead and lead compounds in batteries
Battery poles, battery terminals, and parts of the battery itself contain lead
and lead compounds.
Wash hands after working directly or indirectly with these parts.
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.
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.
• Switch the battery master switch (1) off and

remove the selector handle.
• Open the battery box (2).
27.01.2007

GMK 4100/GMK 4100–L
• Keep the batteries clean and dry.

• Loosen any dirty connecting terminals and clean them.
Grease the terminals with an acid-free, acid-resistant grease.
• Fasten the connecting terminals.
• Switch on the battery master switch and set the clock
– on the tachograph; à Operating instructions,
– on the auxiliary heater (additional equipment); à Operating instruc-
tions and
– enter the code for the radio (additional equipment); à Separate Operat-
ing Instructions.
H
It is particularly important to check the acid level during warmer months.
• Check the acid level in the individual cells:

– For batteries in which the acid level is visible, the acid must be approx.
15 mm (0.6 in) above the plates.
– For batteries with an overflow reservoir, distilled water must be
present in the overflow
If the acid is not at the required level or there is no distilled water in the over-
flow reservoir:
• Add only distilled water
– up to the required height above the plates or
– until the water no longer drains from the overflow reservoir.
27.01.2007

GMK 4100/GMK 4100–L
7.15.3 Batteries – checking the acid concentration M3
Spare parts – Acid siphon.

and tools
Checking the acid

concentration
G
and lead compounds.
G
Risk of explosion from escaping hydrogen
Do not place tools on the battery and keep unshielded light away from the
battery.
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.
• Check whether the battery master switch is switched off. Switch it off and
pull off the selector handle as necessary.
• Measure the acid concentration of each cell with an acid siphon.
H
It is particularly important to check the acid concentration with the onset of
the colder months.
The following table gives a guide to battery charge levels.
Acid concentration Specif. gravity Charge level

(° Bé) (g/cm³)
32 1.28 good
24 1.20 half-charged; recharge
27.01.2007
16 1.12 flat; recharge immediately
Switch on the battery master switch if necessary.

GMK 4100/GMK 4100–L
7.16 Air-conditioning system
7.16.1 Checking the moisture and level of the refrigerant M1
The refrigerant is checked through an inspec-

tion glass on the refrigerant drier while the air
conditioning system is running (1).

• Switch on the air-conditioning system and
let it run for about 10 minutes; à Operating
instructions.
• Check the refrigerant filling level and the
moisture content through the inspection
glass (1):
– The flowing refrigerant must be visible
and must not contain any large bubbles or
foam.
– The float ball (3) must be on top.
– A green dot must be visible on the display
(2).
s
27.01.2007

GMK 4100/GMK 4100–L
If the display shows a yellow dot or if bubbles or foam are visible, the air
conditioning system is defective.
If the air conditioning system is defective:

• To avoid further damage, switch the air-conditioning system off and do
not use it again.
Have the air-conditioning system repaired as soon as possible by an author-
When the inspection has been completed:
• Switch the air-conditioning system off and turn the engine off.
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 water
jet may damage the fins. Use only compressed air for cleaning.
The condenser is mounted in front of the cool-

ing water cooler. The cooling water cooler is
found behind the driver's cab.
• Switch the air-conditioning system off.

• Clean the condenser fins with compressed
air (1).
27.01.2007

GMK 4100/GMK 4100–L
7.16.3 Checking hoses M6
G
Danger of burns from escaping coolant
Wear suitable goggles and gloves when checking hoses and connections.
This will prevent injury from suddenly escaping coolant. Seek medical
attention if skin or eyes come into contact with coolant.
• Check all refrigerant hoses for damage and worn areas.

Have damaged hoses replaced by an authorised GROVE dealer or
CraneCARE only.
7.16.4 Checking the entire air conditioning system M 12
H
This check should only be carried out by an authorised GROVE dealer or
CraneCARE!
G
• 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.
27.01.2007

GMK 4100/GMK 4100–L
Blank page
27.01.2007

GMK 4100/GMK 4100–L
7.17 Soot particle filter

If additional equipment is fitted, the exhaust system silencer is replaced
with a soot particle filtering system. Soot particles and other harmful solid
pollutants are removed by filtering exhaust gases through the soot particle
filtering system.
Have the soot particle filter cleaned by service partners.

Information can be obtained from CraneCARE.
7.17.1 Checking the clamp straps M1
Spare parts
Clamp strap 2 03 329 106
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 (750°F). Wear
protective 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 (14.8 lbf ft).
Replace any damaged clamp straps;
à p. 7 - 88.
• Attach the heat shield (1).

27.01.2007

GMK 4100/GMK 4100–L
7.17.2 Replacing the soot particle filter M6
Spare parts
Filter 1 03 326 976
à p. 2 - 3.
Removing the
soot particle filter
G
Health hazard due to soot particles
Soot particles are suspected of causing cancer.
Wear appropriate dust respirator masks and be careful not to breathe in or
ingest dust particles.
G
Risk of burning yourself if the exhaust system is hot!
During operation, the exhaust system can heat up to 400°C (750°F). Wear
appropriate protective gloves and be careful not to touch hot parts when
checking the soot particle filtering system while the exhaust system is hot.
O
Risk of polluting the environment
Collect soot particles and ash in an appropriate receptacle and dispose of
them according to the relevant regulations.
27.01.2007

GMK 4100/GMK 4100–L
• 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 the part (6).
If necessary, let the soot particle filter (4) reach
ambient temperature before cleaning it.
• Remove all soot particles and ash from the

part (6).
Cleaning the soot

particle filter
G
Health hazard due to soot particles
Soot particles are suspected of causing cancer.
Wear appropriate dust respirator masks and be careful not to breathe in or
ingest dust particles.
O
Collect soot particles and ash in an appropriate receptacle and dispose of
them according to the relevant regulations.
• Clean the filter in a manufacturer-approved cleaning system only;

à Separate Operating Instructions.
• Replacement filters are available from the filter manufacturer's service
partner if you do not have the appropriate cleaning system available.
For more information please contact CraneCARE.
s
27.01.2007

GMK 4100/GMK 4100–L
Installing the soot

particle filter
H
When installing the soot particle filter, please observe the instructions sup-
plied by the filter manufacturer and the relevant regulations and laws appli-
cable in the country you are working in.
• Use only new clamp straps (3) and (5) with

intact gaskets.
• Attach the filter (4) to the part (6).
• Fasten the filter (4) to part (6) with a new
clamp strap (5) – torque 20 Nm (14.8 lbf ft).
• Attach the part (2).
• Fasten the part (2) to the filter (4) with a new
clamp strap (3) – torque 20 Nm (14.8 lbf ft).
• Attach the heat shield (1).
• Carry out a back pressure test; à p. 7 - 89.
• Record the filter replacement in the docu-
ments supplied by the filter manufacturer.
27.01.2007

GMK 4100/GMK 4100–L
7.17.3 Back pressure test
Carry out a back pressure test after replacing the soot particle filter. To do
so, proceed as follows:
• Engage the parking brake; à Operating instructions.
• Start the engine; à Operating instructions.

• Slowly increase the engine speed up to 1800 min-1 (rpm) and hold this
engine speed for 30 seconds.
Monitor the exhaust gas stream. There should be no visible fumes. If
fumes are clearly visible, check
– whether the clamp straps have been tightened to the required torque,
– if the clamp strap gaskets are intact,
– if the soot particle filter is intact.

• Rectify any damage you were able to identify.
27.01.2007

GMK 4100/GMK 4100–L
Blank page
27.01.2007

GMK 4100/GMK 4100–L
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
H
This maintenance work is not required if the towbar coupling is connected
to the central lubrication system.
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 only be lubricated
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
27.01.2007

GMK 4100/GMK 4100–L
Closing the
towbar 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).
• Remove any excess grease.
27.01.2007

GMK 4100/GMK 4100–L
7.18.2 Checking the bearing M3
Prerequisites – The coupling is closed; à p. 7 - 92.
Checking the
bearing
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 (0.1 in).
27.01.2007

GMK 4100/GMK 4100–L
7.18.3 Checking the cotter pin M3
Checking the
cotter 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 (1.44 in)
If the dimension is smaller than that given

above, have the cotter pin replaced by an
authorised GROVE dealer or CraneCARE.
• 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
(0.15 in).
27.01.2007

GMK 4100/GMK 4100–L
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 an
27.01.2007

GMK 4100/GMK 4100–L
7.18.5 Checking the support ring M3
Checking the
support 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 (0.55 in).
7.18.6 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.
27.01.2007

GMK 4100/GMK 4100–L
7.18.7 Checking the function of the coupling jaw / M3

Resetting central position
Spare parts – Torque wrench for torque of 58 Nm (42.7 lbf ft).

and tools
Checking
for correct
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 - 98.
s
27.01.2007

GMK 4100/GMK 4100–L
Resetting central
position
• Open the coupling (lever (1) pointing
upwards) and loosen the bolt (2).
• Push the coupling jaw to the side until the
lever engages.
• Tighten the bolts – torque 58 Nm (42.7 lbf ft).
• Check the function of the coupling jaw;
à p. 7 - 97.
27.01.2007

GMK 4100/GMK 4100–L
7.19 Other maintenance work
7.19.1 Lubricating outrigger beam M1
When operating the outriggers, observe the safety instructions specified in

the Operating Instructions.
Operation of the outriggers; à Operating instructions.
G
Risk of crushing
Ensure that there is sufficient room around the crane. Warn any persons
nearby before extending the outriggers.
• Fully extend the outrigger beams.

• Apply the grease to both sides of the slide
faces (1) on all the outriggers.
Only use grease specified in the Maintenance
plan, p. 5 - 8.
• Extend and retract the outriggers several

times.
27.01.2007

GMK 4100/GMK 4100–L
7.19.2 Checking the auxiliary heater for correct operation M1
This maintenance work is only required if your truck crane is equipped with
an auxiliary heater.
During the warm summer months, run the auxiliary heater for 20 to 30 min-
utes; àOperating instructions.
• Check that the system is working properly. Also perform a functional

check of the controls.
• If the heating is not functioning correctly, report it to an authorised
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 smaller, depending on the respective
national regulations. Ask about the national and local regulations at the
local Fire Safety Authority.
• Observe the 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.
27.01.2007

GMK 4100/GMK 4100–L
8
8.1 General instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 1
8.1.1 Service flaps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 1
8.2 Preterm maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 3
8.3 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 5
8.3.2 Topping up 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 prefilter 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 12
8.4.2 Fuel prefilter 1 – replacing the filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 13
8.4.3 Fuel filter – changing the filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 15
8.4.4 Emptying the fuel line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 18
8.4.5 Establishing operating condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 19
8.5 Hoists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 21
8.5.3 Checking the hoist brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 22
8.5.4 Lubricating the auxiliary hoist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 23
8.5.5 Changing the oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 24
8.5.6 Carry out partial inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 26
8.5.7 Carry out general inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 26
8.6 Slewing gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 27
8.6.2 Checking for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 28
8.6.3 Checking the function of the slewing gear brake . . . . . . . . . . . . . . . . . . . . . . . . 8 - 28
8.6.4 Changing the oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 30
8.7 Ball slewing bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 33
8.7.1 Lubricating gear teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 33
8.7.2 General inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 35
8.7.3 Measuring tilting play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 35
8.8 Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 37
8.8.2 Checking the hydraulic hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 38
8.8.3 Checking ventilation filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 38
8.8.4 Checking for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 39
8.8.5 Taking oil samples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 40
8.8.6 Pressure accumulator – checking the gas pressure . . . . . . . . . . . . . . . . . . . . . . 8 - 41
27.01.2007
8.8.7 Air filter – changing the filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 42

8.8.8 Changing the filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 43
8.8.9 Changing the oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 45

GMK 4100/GMK 4100–L
8.9 Main boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 49
8.9.1 Notes on maintenance of the main boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 49
8.9.2 Lubricating the locking pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 51
8.9.3 Lubricating the telescope slide faces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 53
8.9.4 Checking the locking system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 55
8.10 Hoist ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 57
8.10.1 Checking the position on sheaves and rope drums . . . . . . . . . . . . . . . . . . . . . 8- 57
8.10.2 Checking the condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 58
8.10.3 Relubricating the hoist rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 59
8.10.4 Assessing the condition of the hoist rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 60
8.10.5 Replacing the hoist rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 66
8.10.6 Setting the lowering limit switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 69
8.11 Safe load indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 71
8.11.1 Maintenance of the slip ring assembly of the cable drums . . . . . . . . . . . . . . . 8 - 71
8.11.2 Lubricating the slewing angle sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 74
8.12 Central lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 75
8.12.1 Checking the level of the grease container . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 75
8.13 Hook blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 77
8.13.1 Checking the sheaves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 77
8.13.2 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 77
8.14 Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 79
8.14.1 Checking the lighting and indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 79
8.14.2 Batteries – checking the acid level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 80
8.14.3 Batteries – checking the acid concentration . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 80
8.15 Air-conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 81
8.15.1 Checking the moisture and level of the refrigerant . . . . . . . . . . . . . . . . . . . . . 8- 81
8.15.2 Cleaning the condenser fins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 82
8.15.3 Checking hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 83
8.15.4 Checking the entire air conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 83
8.16 Soot particle filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 84
8.16.1 Checking the clamp straps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 84
8.16.2 Replacing the soot particle filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 84
8.17 Other maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 85
8.17.1 Checking the auxiliary heater for correct operation . . . . . . . . . . . . . . . . . . . . . 8 - 85
8.17.2 Lubricating the piston rod of the derricking cylinder . . . . . . . . . . . . . . . . . . . . 8 - 85
8.17.3 Having the fire extinguisher checked . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 86
27.01.2007

GMK 4100/GMK 4100–L
Maintenance work on the superstructure
This operating manual contains illustrations of

the GMK 4100.
The GMK 4100–L is distinguished by its addi-

tional telescope section (1).
8.1.1 Service flaps
Various types of work (e.g. oil change) require that the service flaps be
opened.
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.
27.01.2007

GMK 4100/GMK 4100–L
Blank page
27.01.2007

GMK 4100/GMK 4100–L

Check the following displays and lamps daily before you start work.
On the ECOS
display
• Open the Superstructure warning messages submenu; à Operating instruc-
tions.
Carry out the respective maintenance work if a symbol is displayed in red.

– Oil pressure; à p. 8 - 5.
– Coolant level; à p. 8 - 9.
– Air filter; à p. 8 - 8.
– Hydraulic oil filter; à p. 8 - 43.
On the side panel Carry out the respective maintenance work if the lamp lights up in orange.
– Soot particle filter; à
p. 8 - 84. Record the maintenance work performed
in the maintenance booklet.
27.01.2007

GMK 4100/GMK 4100–L
Blank page
27.01.2007

GMK 4100/GMK 4100–L
8.3 Engine
8.3 Engine
When carrying out maintenance work, please consult the Engine manufac-
turer’s operating instructions supplied. Only certain types of maintenance
work are described in this maintenance manual.
S
Risk of engine damage
The engine is in maintenance group B (discontinuous operation) because
of the high full-load rate and large fuel throughput.
If fatty acid methyl ester (FAME, e.g. bio diesel) is to be used in the engine,
the intervals between oil changes should be halved.
The release of engines for FAME operation is regulated in service informa-
tion provided by the engine manufacturer.
Checking the
oil level
• Start the engine. On the ECOS display, check whether the lamp (1) next to
the Å button goes out about 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 inspection and turn off the engine immediately if necessary.
The engine can be damaged by running it when the oil pressure is too low.
• Press the button Å once. The Warning submenu opens.

• Turn off the engine immediately if the L symbol turns red.
If other symbols are displayed in red in this menu; à Operating instructions.
s
27.01.2007

GMK 4100/GMK 4100–L
8.3 Engine
• Allow the engine to run at idling speed for 2-3 minutes.

• Check the oil level after about two minutes.
• On the dipstick (1), check whether the oil

level is between the min. and the max. mark-
ing (arrows).
• Put the dipstick into the dipstick tube after
checking the oil level.
27.01.2007

GMK 4100/GMK 4100–L
8.3 Engine
8.3.2 Topping up oil
Data on the prescribed oil specification; à Separate engine operating instruc-

tions, provided by the manufacturer.

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 Separate engine operating instructions, provided by
the manufacturer.
G
Risk of burning yourself on the hot engine
During operation, the engine and add-on parts can reach temperatures up
to 400°C (750°F). 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.
27.01.2007

GMK 4100/GMK 4100–L
8.3 Engine
8.3.3 Checking the air filter D
the Å button lights up.

• If the = symbol displays in red, replace the air filter.
Spare parts
Filter 1 03 316 343
à p. 2 - 3.
Replacing the
air filter
• Undo all the clamps (1) and remove the lid
(2).
• Change the filter (3).
• Replace the lid and secure it with all the
clamps.
27.01.2007

GMK 4100/GMK 4100–L
8.3 Engine
8.3.4 Checking the coolant level D
the Å button lights up.

• If the X symbol displays in red, top up the coolant.
Topping
up coolant
G
Danger of being scalded due to hot cooling circuit
The hot cooling circuit is under pressure. If you open the expansion tank of
the hot cooling circuit, you may be scalded by the hot steam and any hot
coolant which may escape.
Wear suitable protective gloves and cover the cap of the expansion tank
with a rag before opening it.
Turn the cap slowly to the first detent in order to allow the excess pressure
to be released.
• Loosen (do not open!) cap (1) to the coolant

at operating temperature.
• Open the cap (1).
The coolant level must be at the lower edge
of the pipe in the filler neck.
If the coolant level is too low:

• Top up the coolant.
Composition of the coolant; à Separate
engine operating instructions, provided by the
manufacturer.
• Close the cap.
s
27.01.2007

GMK 4100/GMK 4100–L
8.3 Engine
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 an authorised GROVE dealer or CraneCARE check and rectify
the problem.
• 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. 8 - 5,
à Checking the coolant level, p. 8 - 9.
CraneCARE.
27.01.2007

GMK 4100/GMK 4100–L
8.4 Fuel system
8.4 Fuel system

The fuel filters are built into the fuel line:
1 Fuel prefilter 1
2 Fuel prefilter 2
3 Fuel filter
There are built-in controls in the case of addi-

tional equipment with the fuel tank on the
superstructure.
1 Valve
2 Valve
3 Fuel tank
s
27.01.2007

GMK 4100/GMK 4100–L
8.4 Fuel system
8.4.1 Draining off water from fuel prefilter 1 D

and tools

à p. 2 - 3.
Draining off
water from fuel
prefilter 1
O

• Open the valve (1).
• If the draining consumable is clean, close
the valve manually.
• Dispose of the drained consumable prop-
erly.
27.01.2007

GMK 4100/GMK 4100–L
8.4 Fuel system
8.4.2 Fuel prefilter 1 – replacing the filter M3
Spare parts
Filter 1 03 322 877
Gasket 1 03 322 879

à p. 2 - 3.
Changing the filter
O

• For additional equipment: Close the valve –
lever (3) at right angles to the line.
• Open the plug (1) and the valve (2), and let
the consumable drain into the receptacle.
s
27.01.2007

GMK 4100/GMK 4100–L
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.
• For additional equipment: Open the valve –

lever (3) parallel to the line.
flowing through the plug no longer contains
any bubbles (2).
• Close the plug.
• Remove the receptacle.
H
27.01.2007

GMK 4100/GMK 4100–L
8.4 Fuel system
8.4.3 Fuel filter – changing the filter M 12
This maintenance interval comprises the filter on the

– fuel prefilter 2 and
– the fuel filter.
Fuel prefilter 2 and the fuel filter are on the left-hand side of the engine and
can be reached through the opening on the right-hand side of the turntable
when the main boom has been raised.
Spare parts

– Torque wrench for torque of 10 Nm (7.4 lbf ft) and 25 Nm (18.5 lbf ft).

à p. 2 - 3.
– The fuel line is empty; à p. 8 - 18.
s
27.01.2007

GMK 4100/GMK 4100–L
8.4 Fuel system
Changing fuel
prefilter 2
O

(3).
• 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 (7.4 lbf ft).
H
27.01.2007

GMK 4100/GMK 4100–L
8.4 Fuel system
Changing the
fuel filter
O

(3).
Let the remaining consumable drain.
• Remove the cap and extract the filter (3) by
applying pressure to the sides of its lower
edge.
• Carefully take the receptacle (4) out of the
housing, making sure no dirt from the recep-
tacle gets into the housing.
• Clean the cap and the receptacle.
• Insert a new gasket (2) (grease lightly) and
clip a new filter into the cap.
• Insert the receptacle into the housing. Make sure that it sits correctly.
• Screw the cap and filter into the housing and tighten it – torque 25 Nm
(18.5 lbf ft).
• Restore the operating condition; à Establishing operating condition,
p. 8 - 19.
27.01.2007

GMK 4100/GMK 4100–L
8.4 Fuel system
8.4.4 Emptying the fuel line

and tools
à p. 2 - 3.
Emptying
O
For standard equipment

• Place a collecting receptacle underneath the
fuel prefilter.
• Open the plug (1) and let the consumable
drain.
Leave the receptacle underneath the fuel pre-
filter. More consumable will run out when you
bleed the fuel line.
With additional equipment

the line.
• Place a receptacle under the end of the hose
(1).
• Turn the valve – lever (2) parallel with the
line.
• Let the consumable drain into the recepta-
cle.
27.01.2007
Leave the receptacle under the end of the

hose. More consumable will run out when you
bleed the fuel line.

GMK 4100/GMK 4100–L
8.4 Fuel system
8.4.5 Establishing operating condition
After changing and cleaning the fuel filter you must bleed the fuel line.
O
For standard equipment

There is a receptacle under the filter and the
plug (1) is open.

flowing through the plug no longer contains
any bubbles (1).
• Close the plug.
• Remove the receptacle underneath the fuel
prefilter.
H
s
27.01.2007

GMK 4100/GMK 4100–L
8.4 Fuel system
With additional equipment

A receptacle is underneath the hose end (1).
The lever (2) is parallel with the line.
• Open the valve – lever (3) parallel to the line.

flowing through the end of the hose no
longer contains any bubbles (1).
• Turn the valve – lever (2) at right angles to

the line.
• Remove the receptacle underneath the hose
end (1).
H
27.01.2007

GMK 4100/GMK 4100–L
8.5 Hoists
8.5 Hoists
8.5.1 Checking the oil level W
Spare parts
Gasket 18 x 24 Cu DIN 7603 2 01 377 793
Prerequisites – The truck crane is horizontal and is in on-road mode; à Operating instruc-
tions.
– The auxiliary hoist (additional equipment) is rigged; à Operating instruc-
tions.
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 - 24.
27.01.2007

GMK 4100/GMK 4100–L
8.5 Hoists
• Investigate any unusual noises from the hoists.

• Check the hoists and the connections for leaks. In the event of leaking con-
sumables; à Checking the oil level, p. 8 - 21.
CraneCARE.
8.5.3 Checking the hoist brake W
Test correct function of the hoist brake by suspending a load on the load
hook for a certain time and measuring whether the load lowers on its own.
Perform the test on the main hoist and the auxiliary hoist:
• Suspend the hook block on the singly reeved hoist rope.
• Lift a test load of approx. 5.5 t (12 125 lbs) to approx. 30 cm (1.0 ft) above
the ground.
• Measure the distance from the ground when the test load is hanging com-
pletely still.
If the test load has not lowered after approx. 2 minutes, the brake is cur-
rently in working order.
If the test load lowers, report it to an authorised GROVE dealer or
CraneCARE.
27.01.2007

GMK 4100/GMK 4100–L
8.5 Hoists
8.5.4 Lubricating the auxiliary hoist M6
Spare parts – Grease gun and grease according to Maintenance plan, p. 5 - 13.
and tools
Prerequisites – The auxiliary hoist is rigged; à Operating instructions.

à p. 2 - 3.
Lubricating the
hoist gear
G
Risk of crushing when hoist is turning
Keep yourself and other people away from the turning rope drum. Your fin-
gers and hands can be crushed between the rope drum and hoist frame or
get caught and drawn in by the turning drum if you grab the turning rope
drum.
• Clean the lubricating nipple (1) and lubricate

the hoist at the lubricating nipple.
27.01.2007

GMK 4100/GMK 4100–L
8.5 Hoists
8.5.5 Changing the oil M 12
Spare parts
Gasket 18 x 24 Cu DIN 7603 10 01 377 793

– Use only oil specified in the Maintenance plan, p. 5 - 15.
tions.
tions.
à p. 2 - 3.
Changing the oil

at the hoist
Risk of damage to the hoist gear
S
The waste oil must be tested for abrasion particles. This test serves to iden-
tify damage at an early stage; à
p. 8 - 25.
O
H
During filling, the oil spreads only slowly in the hoist. The oil level will there-
fore rise quickly in the standpipe at first, then drop slightly and finally rise
again to its actual level.
27.01.2007

GMK 4100/GMK 4100–L
8.5 Hoists
Draining oil
• Place a receptacle under the pipe (3).
• Undo bolts (1) and (6) and let the oil 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).
O
Collect waste oil in approved receptacles and have it disposed of properly.
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
which could lead to the load falling.
H
Check the waste oil 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 hoist gear
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 oper. hrs), first consult
CraneCARE before introducing any specific measures.
27.01.2007

GMK 4100/GMK 4100–L
8.5 Hoists
8.5.6 Carry out partial inspection Y3
Certain parts must be inspected for wear during the partial inspection:
– 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 the transmis-
sion unit (if fitted)
These parts must be replaced when worn.
H
Inspections and part replacements may only be carried out by trained, qual-
ified personnel.
8.5.7 Carry out general inspection 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 hoist gear is to undergo general inspection after the period of time indi-
cated in the Maintenance plan. This inspection involves removing the gear
and sending it to the manufacturer to be examined.
H
The oil of new hoist gears and hoist gears which have undergone a general
overhaul must be changed after 200 and 1000 operating hours, in accord-
ance with run-in times, before the yearly oil change can be implemented.
27.01.2007

GMK 4100/GMK 4100–L
8.6 Slewing gear
8.6 Slewing gear
8.6.1 Checking the oil level W
Spare parts
Gasket 10 x 14 Cu DIN 7603 3 01 368 741
tions.
à p. 2 - 3.
Checking the Always check the oil level prior to using the crane.
oil 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 - 30.
27.01.2007

GMK 4100/GMK 4100–L
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 consumables; à Checking the oil level, p. 8 - 27.
CraneCARE.
8.6.3 Checking the function of the slewing gear brake M6
In order to check the function of the slewing gear brake, you must run the
slewing movement against the slewing gear brake.
Have this maintenance work performed by CraneCARE or specially trained
personnel only.
Prerequisites – The truck crane is supported with an outrigger span of 8.332 x 7.00 m
à
(27.3 x 23.0 ft); Operating instructions.
– A counterweight of at least 6.3 t (13 800 lbs) is rigged; à Operating
instructions.
– The hook block is unreeved; à Operating instructions.
– The rigging code for the current rigging mode is entered at the SLI;
– The main boom is raised to 45°.
27.01.2007

GMK 4100/GMK 4100–L
8.6 Slewing gear
Checking the
slewing gear
brake
G
Risk of overturning when slewing the superstructure
Establish a rigging mode in accordance with the Lifting capacity table and
enter the rigging code on the SLI.
• Start the engine and switch on the slewing gear; à Operating instructions.
When the slewing gear is switched on, the slewing gear brake is released.
• Push the Slewing gear brake pedal down and hold it.
• Slowly move the left control lever to the left or to the right.
If the superstructure turns, the slewing gear brakes are faulty and need to
be repaired immediately by an authorised GROVE dealer or CraneCARE.
• Move the control lever back to central position and switch the slewing
gear off; à Operating instructions.
• Have faulty slewing gear brakes replaced by an authorised GROVE dealer

or CraneCARE only.
27.01.2007

GMK 4100/GMK 4100–L
8.6 Slewing gear
8.6.4 Changing the oil M 12
Spare parts
Gasket 10 x 14 Cu DIN 7603 2 01 368 741
Gasket 14 x 20 Cu DIN 7603 2 00 117 132
tions.
à p. 2 - 3.
Changing the oil
O
• Always change the oil in all slewing gears.

Draining oil
• Remove the plate (1).
• Place a receptacle under the plugs (2).
• Unscrew the filter (4) and plugs (3) and (2).
• Drain the oil.
27.01.2007

GMK 4100/GMK 4100–L
8.6 Slewing gear
• 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).
• Attach the plate.
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
transmission must be removed for inspection and sent to the manufacturer.
27.01.2007

GMK 4100/GMK 4100–L
8.6 Slewing gear
Blank page
27.01.2007

GMK 4100/GMK 4100–L
8.7 Ball slewing bearing
8.7.1 Lubricating gear teeth M6
Spare parts
Adhesive lubricating grease 1 00 554 205
H
Observe the instructions and safety information on the lubricant packaging.

à p. 2 - 3.
Lubrication 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
27.01.2007

GMK 4100/GMK 4100–L
Initial 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.
27.01.2007

GMK 4100/GMK 4100–L
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).
CraneCARE.
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 (0.00039 in)) with tripod.
tools
– Measurement report from when the truck crane was put into operation;
à Delivery receipt.
Prerequisites – The truck crane is supported and levelled with an outrigger span of
8.332 x 7.00 m (27.3 x 23.0 ft); àOperating instructions.
– The maximum counterweight combination per Lifting capacity table and
equipment of the truck crane is rigged; à
Operating instructions.
– The lattice extension and hook block are removed; à Operating instruc-
tions.
s
27.01.2007

GMK 4100/GMK 4100–L
Measuring tilting The base value of the tilting play is determined and documented by an
play authorised GROVE dealer or CraneCARE when the ball slewing bearing is put
into operation or replaced.
The maximum permissible wear is 3.2 mm (0.126 in).
This results in the maximum permissible tilting play.
Base value + max. permissible wear = max. permissible tilting play

Example: 0.35 mm (0.014 in) + 3.2 mm (0.126 in) 2.55 mm (0.140 in)
Measuring current tilting play

• Raise the main boom completely and slew
to -135° – display (A).
• Fasten a dial gauge on the turntable and
place the switch (1) onto the lower ring (3) as
close as possible to the gasket (2)
• Slowly lower the main boom completely.
• Read off from the dial gauge how far the
turntable inclined and record this value as
the current tilting play; àAppendix – 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 an authorised GROVE
dealer or CraneCARE.
• Repeat the measurement with the slewing

angles
B –45°
C +45°
D +135°
27.01.2007

GMK 4100/GMK 4100–L
tions.
– 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).

27.01.2007

GMK 4100/GMK 4100–L
8.8.2 Checking the hydraulic hoses W
The inspection work is described in section Checking the hydraulic hoses,

p. 7 - 58.
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 - 42.
27.01.2007

GMK 4100/GMK 4100–L
• With the engine running, make a visual inspection for leaks and escaping
hydraulic oil on the hydraulic components of the superstructure (hydrau-
lic cylinders, lines, connections, hydraulic pumps, motors, valves, and
control block).
• If leaks are detected, check the oil level and top up if necessary;
à Checking the oil level, p. 8 - 37.
G
Never tighten 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 hydraulic system; à Establishing operating condition, p. 8 - 48.

27.01.2007

GMK 4100/GMK 4100–L
8.8.5 Taking oil samples M 12
Take oil samples from the hydraulic oil tank and the hydraulic system;
à Changing the oil, p. 8 - 45.
The drain valve on the hydraulic oil tank can only be opened and closed
using the ½-inch connecting piece. The connecting piece is in the tool box;
à Handling the valves, p. 7 - 64.
• The sample from the hydraulic oil tank is

taken via the valve (1); à Taking oil samples,
p. 7 - 65.
The oil sample from the hydraulic system is

taken via a gauge port (1), e. g. on the Hydrau-
lic system control circuit.
• Take an oil sample; à Taking oil samples,

p. 7 - 65.
27.01.2007

GMK 4100/GMK 4100–L
8.8.6 Pressure accumulator – checking the gas pressure M 12
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 superstructure is equipped with two pres-

sure accumulators.
The filling pressure at 20°C (68°F) is:
1 Pressure 20 bar (290 psi)
accumulator
2 Pressure 180 bar (2610 psi)
accumulator
• Have the filling pressure checked and

adjusted if necessary by an authorised
27.01.2007

GMK 4100/GMK 4100–L
8.8.7 Air filter – changing the filter element M 12
Spare parts
Filter 1 03 134 932
à p. 2 - 3.
Replacing the
filter element
• Change the filter (2) and fasten the cap.
27.01.2007

GMK 4100/GMK 4100–L
8.8.8 Changing the filter
Oil filters are installed in the hydraulic system:

– a return flow filter
– a filter in the control circuit
• Change the oil filter;

– after every oil change, or when
– one of the symbols g in the Superstructure warning messages submenu
is displayed in red; à
Spare parts
Set of filters with gasket 2 03 134 850
Filter head 2 03 134 849
Filter 1 03 326 047
Gasket 1 03 326 049
– Torque wrench for 25 Nm (18.5 lbf ft).

tions.
à p. 2 - 3.
s
27.01.2007

GMK 4100/GMK 4100–L
Changing the
return flow filter
O
• Place a receptacle under the filter (1).

• Remove the filter and replace the damaged
parts.
• Replace the filter (lightly grease the gasket).
• Check the oil level; à p. 8 - 37.
Filter for control

circuit
• Undo the receptacle (1) at the hexagon.
• Remove the filter (2) from the receptacle.
• Replace the gasket and the filter (lightly
lubricate the gasket).
• Fill the receptacle with clean oil and tighten
it – torque 25 Nm (18.5 lbf ft). 27.01.2007

GMK 4100/GMK 4100–L
After changing
the 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 - 48.
• Check the oil level before starting the engine. Top up the oil if necessary;
à p. 8 - 47.
• Start the engine and let it idle for three minutes in order to bleed the sys-
tem.
• Check the return flow filter and the filter control circuit for leaks.
8.8.9 Changing the oil
The oil only needs to be changed if the laboratory analysis shows that the
permissible limits have been exceeded ( àTaking oil samples, p. 8 - 40) or
the laboratory has recommended a date for an oil change.
Spare parts – The ½-inch connecting piece with hose.

and tools
– One or more receptacles, approx. 600.0 l (158.5 gal); à p. 2 - 4.
tions.
à p. 2 - 3.
– The oil filters have been removed; à Changing the filter, p. 8 - 43.
s
27.01.2007

GMK 4100/GMK 4100–L
Closing the
shut-off valve
S
Be sure to secure the engine against unauthorised use.
If the engine is started while the shut-off valve in the suction line is closed,
the hydraulic pumps will be damaged.

the line.
Draining oil The valve can only be opened and closed using the ½-inch connecting
piece; à Handling the valves, p. 7 - 64.
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 in a receptacle before screwing on
the connecting piece.
O
Always use the supplied
½-inch connecting piece with an oil drain hose and a receptacle with suffi-
cient capacity to collect the hydraulic oil.
27.01.2007

GMK 4100/GMK 4100–L
• Screw the connecting piece onto the con-

nection (1) and let the oil flow into the recep-
tacle;à p. 7 - 64.
• Insert new oil filters; à Changing the filter,
p. 8 - 43.
Topping up oil
S
Cleanliness is of the utmost importance when handling hydraulic oil.
• Remove the cap and filter (2).

• Add the new oil through the filter until it
reaches the middle of the inspection glass
(1).
• Tighten the cap and filter.
27.01.2007
s
GMK 4100/GMK 4100–L
Establishing After having changed the oil filters and topped the oil up, you must re-estab-
operating lish the operating condition.
condition
S
Open the valve in the suction line before starting the engine.
This prevents damage to the hydraulic pumps.
Opening the valve

• Open the valve – lever (1) parallel to the line.

• Carry out all hydraulic functions several times to remove any air in the
system.
• Check the return flow filter and the control circuit oil filter for leaks.
• Check the oil level through the inspection glass on the hydraulic oil tank.
Top up oil if necessary; à Topping up oil, p. 8 - 47. 27.01.2007

GMK 4100/GMK 4100–L
8.9 Main boom
8.9 Main boom
8.9.1 Notes on maintenance of the main boom
Location of the Locking pins

lubricating points
The illustration shows the degree of telescoping required to lubricate the

locking pins on telescopic section V.
To lubricate the locking pins (4), the telescopic sections must be extended
far enough for the locking pins to be accessible at the locking points (1) or
(2). Each of the locking pins has a lubricating nipple (3).
s
27.01.2007

GMK 4100/GMK 4100–L
8.9 Main boom
Telescope slide faces
The illustration shows the degree of telescoping required to lubricate the

slide faces on telescopic section V.
There are four slide faces on the edges of the telescope sections. The two
lower slide faces (4) are lubricated from the outside in fully extended state.
The two upper slide faces (5) are lubricated via one lubricating nipple each.
The lubricating nipples can be accessed through the bore (3) at the locking
points (1) and (2).
H
Two telescopic sections each must be extended for this maintenance work.
This puts a great deal of strain on the derricking cylinder and the telescoping
cylinder. Follow the instructions. Otherwise, it may become impossible to
retract or raise the main boom.
27.01.2007

GMK 4100/GMK 4100–L
8.9 Main boom
Prerequisites – The lattice extension has been removed; à Lattice extension operating
instructions.
– The truck crane must be standing on an even surface.
– A rigging mode in accordance with the Lifting capacity table has been
established where
– telescopic section II can be extended 100% and
– telescopic section I can be extended by approx. 15%.
– The current rigging mode is entered on the SLI.
– All telescope sections are fully retracted.
– The main boom is lowered to the horizontal position.
– The hook block is unreeved.
– The hoist ropes are fully wound up.
H
To lubricate, you must also telescope to intermediate length; telescope the
main boom semi-automatically; à
8.9.2 Lubricating the locking pins M3
Information on the location of the lubricating nipples and on the rigging

mode required can be found in Notes on maintenance of the main boom,
p. 8 - 49.
H
If all maintenance work for the main boom is to be carried out in one ses-
sion, the slide faces can also be lubricated with the telescopings specified
below; à p. 8 - 53.
Prerequisites – Grease gun

Only use grease specified in the Maintenance plan, p. 5 - 11.
G
Risk of overturning when extending in horizontal position
Make sure that all the Prerequisites, p. 8 - 51 are met. If you do not keep to
the rigging mode specified there, the truck crane could overturn.
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.
27.01.2007
Use the extendable ladder provided with your crane.
s
GMK 4100/GMK 4100–L
8.9 Main boom
Pins in telescopic The procedure is explained for telescopic section V. Proceed in the same
section V to II way for telescopic sections IV to II.
• Set a rigging mode in accordance with the Lifting capacity table;

à Prerequisites, p. 8 - 51.
• Telescope telescopic section V to the fixed length of 100% and lock it.
• Lock the telescoping cylinder in telescopic section IV.
• Extend telescopic section IV about 1.50 m (5 ft) until the bores of the lock-
ing points for telescopic section IV are accessible.
• Lubricate the locking pins on the right and
left of the telescopic section via the lubricat-
ing nipple (1).
• Fully retract telescopic section IV and lock it.
• Lock the telescoping cylinder in telescopic
section V.
• Unlock and lock telescopic section V several
times, so that the grease is distributed over
the locking pins.
• Fully retract telescopic section V.
Pins in telescopic • Set a rigging mode in accordance with the Lifting capacity table;
section I à Prerequisites, p. 8 - 51.
Telescope to telescoping 50-0-0-0-0. Otherwise, the locking pins will not be
accessible.
• Lubricate the locking pins on the right and left of the telescopic section via
the lubricating nipple.
• Unlock and lock telescopic section I several times, so that the grease is
distributed over the locking pin.
27.01.2007

GMK 4100/GMK 4100–L
8.9 Main boom
8.9.3 Lubricating the telescope slide faces M3
Information on the location of the lubricating nipples for the upper slide
faces and on the rigging mode required can be found in à
Notes on mainte-
nance of the main boom, p. 8 - 49.
H
If all maintenance work for the main boom is to be carried out in one ses-
sion, the locking pins can also be lubricated with the telescopings specified
below; àp. 8 - 51.
G
.
Risk of overturning when extending in horizontal position

Make sure that all the Prerequisites, p. 8 - 51 are met. If the rigging mode
specified there is not established, the truck crane could overturn.
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.
The upper slide faces are lubricated with a grease gun. On the lower slide
faces, the grease is applied thinly using a spatula or a brush.
• To lubricate, use only special grease as specified in the Maintenance plan,

p. 5 - 11.
Lubricating Lubricating is described for the slide faces of telescopic section V. Proceed
telescopic in the same way for telescopic sections II to IV.
section II to V
• Set a rigging mode in accordance with the Lifting capacity table;
à Prerequisites, p. 8 - 51.
• Enter the current rigging mode of the truck crane on the SLI.
• Fully extend telescopic sections V and IV.
G
Risk of overturning when extending
Do not extend the main boom further than specified. If the main boom is
extended further, the truck crane will overturn.
s
27.01.2007

GMK 4100/GMK 4100–L
8.9 Main boom
• Lock the telescoping cylinder in telescopic section V.

• Lower the main boom into the horizontal position at most. Do not lower
it any further.
• The lubricating nipples (1) are now 100%
visible in the locking hole. Press about
100 cm³ of grease (6 in³) into each lubricat-
ing nipple (1) on the right-hand and left-
hand sides.
• Apply a thin layer of grease to the bottom
slide faces of telescopic section V with a
spatula or a brush.
• Raise the main boom to about 15° and tele-
scope section V to 50%.
• Re-lower the main boom into a horizontal
position. Do not lower it any further.
• The lubricating nipples (1) are now 50% vis-
ible in the locking hole. Press about 100 cm³
of grease (6 in³) into each lubricating nipple
(1) on the right-hand and left-hand sides.
• Apply a thin layer of grease to the bottom slide faces of telescopic section
V with a spatula or a brush.
• Retract telescopic section IV completely.
• Extend and retract telescopic section V again so that the grease is evenly
spread on the telescope slide faces.
Lubricating • Set a rigging mode in accordance with the Lifting capacity table;
telescopic à Prerequisites, p. 8 - 51.
section I
• Enter the current rigging mode of the truck crane on the SLI.
• Only retract telescopic section I.
• The lubricating nipples are accessible through bores in the basic section
of the boom.
27.01.2007

GMK 4100/GMK 4100–L
8.9 Main boom
8.9.4 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 locking system
performed regularly by an authorised GROVE dealer or 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 maintenance work on the main boom performed regularly by

an authorised GROVE dealer or CraneCARE.
27.01.2007

GMK 4100/GMK 4100–L
8.9 Main boom
Blank page
27.01.2007

GMK 4100/GMK 4100–L
8.10 Hoist ropes
8.10 Hoist ropes
8.10.1 Checking the position on sheaves and rope drums D
G
Risk of accidents when the rope drum is turning
Keep yourself and other people away from the turning rope drum. Your fin-
gers and hands can be crushed between the rope drum and hoist frame or
get caught and drawn in by the turning drum if you grab the turning rope
drum.
Prerequisites – The auxiliary hoist (additional equipment) is rigged; à Operating instruc-

tions.
– The hoist mirrors are folded out; à Operating instructions.
– One hook block is reeved;à Operating instructions.
– The main boom is lowered to about 30°; à Operating instructions.
– The engine has been started; à Operating instructions.
Checking the
position
Check the position of the hoist ropes (1) on the
rope drums of the hoists.
• Slowly turn the rope drum at least one turn
in the Lowering direction. Observe the reeled
rope at the same time.
– The rope must be wound evenly onto the
rope drum.
– The rope turns on the drum must be
evenly spaced at a distance of 0 to 2 mm
(0 to 0.08 in).
– 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.
G
Risk of accidents from incorrectly set lowering limit switch
27.01.2007
Never turn the free rope end under the drum. Turns on the drum which are
unwound when the rope drum is stationary cannot be detected by the low-
ering limit switch. This causes the lowering limit switch to become set
incorrectly and to switch off too late or not at all. Consequently the load
may fall.

GMK 4100/GMK 4100–L
8.10 Hoist ropes
8.10.2 Checking the condition W
Spare parts – Torque wrench for 46 Nm (33.9 lbf ft).

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

condition
• Unreel the hoist rope and check that the rope is not damaged or improp-
erly reeled ( àAssessing the condition of the hoist rope, p. 8 - 60). When five
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 - 69).
• Check the fastening of the clamp (1) for

damage and firm seating – torque 46 Nm
(33.9 lbf ft).
• Check whether the hoist rope is wound with-
out kinking or flattening.
• The free end of the rope must not jut out
beyond the flanged wheel.
• The rope wedge had must be in the pouch
(2).
• The rope end on the rope wedge must not
show any signs of wear.
• Check the the rope end clamp for correct rope guiding; à Operating
instructions.
27.01.2007

GMK 4100/GMK 4100–L
8.10 Hoist ropes
8.10.3 Relubricating the hoist rope M3
Spare parts
Grease 1 03 133 770
Relubricating Relubricating the hoist rope

the hoist rope – significantly prolongs its service life and
– keeps the friction between the hoist rope, the sheaves and the hoist drum
as low as possible.
The lubricant is applied to the hoist rope
– with a brush or a glove,
– 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 relubricating the hoist ropes, observe the instructions concerning the
lubricant.
When using the pressure pump, observe the manufacturer's Separate

operating instructions.
For further information, contact an authorised GROVE dealer or CraneCARE.

27.01.2007

GMK 4100/GMK 4100–L
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 hoist rope, you must be familiar with the fol-
lowing:
– The type of rope (regular lay or long 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 long 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.
27.01.2007

GMK 4100/GMK 4100–L
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
along along along along along along along along along along
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

Long lay rope
Number of
load-bearing ∅ 13 mm ∅ 16 mm ∅ 19 mm ∅ 22 mm ∅ 24 mm
outer wires
along along along along along along along along along along
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 hoist
rope before the number of wire breaks requiring rope replacement has
been reached (age of rope, frequency of use or exceptional loading).
s
27.01.2007

GMK 4100/GMK 4100–L
8.10 Hoist ropes
Damage Description Cause Replacement

Wire break (1) Individual wires are General wear caused Replace hoist rope at the latest
Wire break broken; the broken by ageing of the rope when the maximum permissi-
cluster (2) ends of the wires or ble number of wire breaks
are protruding according to the table are visi-
from the rope. subsequent damage ble externally.
Strand break-
resulting from dam-
age (3) Replace hoist rope immediately
age to the rope.
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 hoist rope while
the number of broken wires is
still low.
Effect of heat Tarnishing colour Rope has been sub- Replace the hoist rope
is visible externally jected to excessive immediately.
on the rope. heat.
27.01.2007

GMK 4100/GMK 4100–L
8.10 Hoist ropes

Reduced The diameter of the Structural changes Immediately replace the hoist
diameter (1) rope has become rope if the diameter has de-
smaller along large creased by 15% or more com-
sections. pared to the nominal diameter.
Corrosion or abrasion. Immediately replace the hoist
rope if the diameter has
decreased by 10% or more
compared to the nominal diam-
eter.
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 abra-
deformation tudinal axis in a way sion, wire breaks and rough
(2) which is similar to a operation of the rope drive.
corkscrew. If deformation ‘x’ at a position
Deformation is on the hoist rope is greater than
measured with sus- a third of the rope diameter, the
pended hook block. hoist rope must be replaced
immediately.
Basket-type Wires of the outer Outer and inner layers Replace the hoist rope
deformation layer protrude. In have been displaced immediately.
(3) other areas of the in relation to each
27.01.2007
rope, the insert has other.

buckled or is pro-
truding from the
rope.
s
GMK 4100/GMK 4100–L
8.10 Hoist ropes

Loop forma- Outer layer wires in General wear due to Immediately replace hoist rope
tion (1) the form of hair pins ageing of the rope or if the rope structure has been
are protruding from subsequent damage substantially 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 abrasion. Replace the hoist rope
wires or strands have immediately.
strands (2) become loose. Only
Other causes. The number of broken wires
the inner strands
determines when the rope must
continue to bear the
be replaced.
load.
Knot forma- Repeatedly occur- General wear due to Determine number of wire
tion (3) ring knot-like thick- ageing of the rope or breaks; replace hoist rope
ening of rope; insert subsequent damage immediately if serious knot
often protrudes. resulting from dam- formation 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 hoist rope immediately
27.01.2007
(4) over short sections. by aging of the rope. if serious constriction is

detected.

GMK 4100/GMK 4100–L
8.10 Hoist ropes

Flattening (1) Crushed areas, Mechanical damage, Determine number of wire
mostly with wire e. g. due to driving breaks; replace hoist rope
breaks. over the rope. immediately if serious crushing
has occurred.
Curl Curl-type rope Loaded hoist rope was Replace the hoist rope
formation deformation pulled over an edge. immediately.
Kink (2) Rope deformation Rope in the eyes was Replace the hoist rope
with twisting and pulled straight while immediately.
wire breaks. twisted.
Buckle (3) Buckled section in Mechanical damage. Replace the hoist rope
rope. immediately.
27.01.2007

GMK 4100/GMK 4100–L
8.10 Hoist ropes
8.10.5 Replacing the hoist rope
Even the installation procedure can have a significant influence on the serv-
ice life of a hoist rope. Errors during fitting reduce service life considerably.
Therefore, the following is required:
– Make sure the hoist rope is not twisted when it is installed.
– Ensure it does not get dirty or damaged while being installed.
– Wind the hoist rope up in the same bending direction in which the hoist
rope is reeled onto the reel.
– Pre-tension the rope slightly while reeling it up.
Spare parts – An original replacement part; à Rope certificate.

and tools – A reel stand with braking block.
– Torque wrench for 46 Nm (33.9 lbf ft).
Risk of accidents from falling load
S
Use only a replacement hoist rope which has the same technical specifica-
tions as the faulty rope or an original replacement rope.
Prerequisites – The truck crane is level.

– The hook block is unreeved; à Operating instructions.
Replacing the • Unreel the hoist rope until it switches off.

hoist rope
• Adjust the lowering limit switch so that you can unreel the hoist rope
completely; ( à Setting the lowering limit switch, p. 8 - 69).
• 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 unauthorised
operation of the hoist can occur.
27.01.2007

GMK 4100/GMK 4100–L
8.10 Hoist ropes
• Remove the clamp (4).

• Push the hoist rope through the bore (3)
until the rope wedge (1) slides out of the
pouch (2).
• Remove the rope wedge and put down the
hoist rope from the truck crane.
Positioning the
hoist rope
• Place the reel stand (1) with the new hoist

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 hoist rope over the right head

sheave (2) up to the hoist drum.
s
27.01.2007

GMK 4100/GMK 4100–L
8.10 Hoist ropes
• Guide the hoist rope through the bore (3)

until it extends about 1.5 m (5.0 ft) from the
pouch (2).
• Feed the free end of the hoist rope back
through the pouch.
• Secure the clamp (4) and tighten it – torque
46 Nm (33.9 lbf ft).
• Place the rope wedge (1) in the loop.
• Push the hoist rope back until rope wedge

(1) is fully in the pouch (2).
S
Risk of damage to the hoist rope
Ensure that the rope wedge, rope loop and rope end do not protrude
beyond the flanged wheel.
This will prevent damage.
• Start the engine; à Operating instructions.

• If necessary, roll the hoist rope onto the drum. The hoist rope must be
held taut when rolling onto the drum.
• Reeve a hook block at least 7 times; à Operating instructions.
27.01.2007

GMK 4100/GMK 4100–L
8.10 Hoist ropes
• Raise the main boom to a steep position and extend it fully.

• Unwind the hoist rope out until only five turns remain on the rope drum.
H
Watch the hook block when unwinding.
The hook block must not rotate!
Risk of accidents due to rope end fitting being overloaded
G
After installing a new hoist rope, the lowering limit switch must always be
reset.
• Set the lowering limit switch; à p. 8 - 69.

• Run in the new hoist rope with small loads so that the hoist rope can settle
on the hoist drum.
8.10.6 Setting the lowering limit switch
Spare parts
Gasket 1 00 550 699
Prerequisites à Operating instructions.

– The hoist rope is reeved 7 times,
– The main boom is fully raised and extended; à Operating instructions.
– The hook block is lowered until only five turns remain on the hoist drum.
s
27.01.2007

GMK 4100/GMK 4100–L
8.10 Hoist ropes
Setting the
lowering 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.

• Turn the bolt (2) until you hear the micro-
switch activate.
• Attach the cap to the lowering limit switch.
Make sure that the gasket fits properly.
• Check the lowering limit switch for correct
operation.
Checking the • Raise the hook block until there are about 10 turns on the hoist drum.
lowering limit
• Lower the hook block and check whether the lowering limit switch is set
switch for correct
properly.
operation
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.

27.01.2007

GMK 4100/GMK 4100–L
8.11 Safe load indicator
8.11.1 Maintenance of the slip ring assembly of the M6

cable drums
The truck crane has two cable drums with slip ring assemblies which need
to be maintained.
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 unauthorised opera-
tion before beginning maintenance work. Remove the keys from the crane
cab and put up warning signs.
One of the cable drums (1) is located on the

left side of the main boom.
The second cable drum (1) is located under the

main boom.
• Raise the main boom; à Operating instruc-

tions.
• Lock the crane cab to prevent unauthorized
use; à p. 2 - 3.
s
27.01.2007

GMK 4100/GMK 4100–L
H
The following sections describe the maintenance procedure for the outer
cable drum. Maintenance on the cable drum under the main boom is carried
out in the same way.
Spare parts
Gasket for cable drum, external 1 03 324 704
Gasket for cable drum, internal 1 03 328 294
– Clean, lint-free cloth.

– Dry, oil-free air.

à
p. 2 - 3.
– The selector handle is removed from the battery master switch;
à
p. 8 - 80.
G
tt
Risk of damaging the safe load indicator

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 central unit.
Maintenance To clean, use only dry, oil-free air or a clean, lint-free cloth.
of the slip ring
assemblies
• Make sure that the cable drum is current-

free.
• Undo the screws (1) and remove the cover
(2).
• Check the gasket for damage. Replace any
damaged parts.
• Wipe up any moisture in the cover with a
cloth.
27.01.2007

GMK 4100/GMK 4100–L
• Remove soiling on the slip rings (2).

• Check to make sure all screws (1) are tight.
• Screw the cover (2) on.

• Fasten the cover (1) using the screws.
27.01.2007

GMK 4100/GMK 4100–L
8.11.2 Lubricating the slewing angle sensor Y5
Spare parts
Gasket 16 x 20 Cu 1 00 117 134
– Sealing agent (e.g. Hylomar),

– Torque wrench for 25 Nm (18.5 lbs ft).
à p. 2 - 3.
S
Risk of damage to the slewing angle sensor
Before lubricating, always remove the screw from the slewing angle sen-
sor.
This prevents the slewing angle sensor from becoming damaged.
Lubricating the
slewing angle
sensor
• Remove the plate (1) and unscrew the bolt
(2).
• Clean the lubricating nipple (3) and insert
about 5 cm³ (0.3 in³) of grease.
• Remove any excess grease, then place the
cover on the lubricating nipple.
• Tighten the bolt with a new gasket and seal-
ing – torque 25 Nm (18.5 lbf ft).
27.01.2007

GMK 4100/GMK 4100–L
8.12.1 Checking the level of the grease container W
The maintenance of the pump (1) is the same

as the maintenance on the carrier; à
Central
lubrication system, p. 7 - 73.
27.01.2007

GMK 4100/GMK 4100–L
Blank page
27.01.2007

GMK 4100/GMK 4100–L
8.13 Hook blocks
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 an
8.13.2 Lubrication M 12
Spare parts – Grease gun with grease as specified in the Maintenance plan, p. 5 - 15.
and tools
Prerequisites – The hook block has been reeved at least twice; à Operating instructions.
Lubricating the On the hook blocks, the sheaves, cross-members and load hooks of the axial
hook 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.
27.01.2007

GMK 4100/GMK 4100–L
8.13 Hook blocks
Blank page
27.01.2007

GMK 4100/GMK 4100–L
8.14.1 Checking the lighting and indicators D
• Check the following functions and arrange for faulty parts to be repaired:
rG – Spotlights, aircraft warning light, outrigger lighting,

– Windscreen wipers
– Windscreen washing system
– Horn
• Check the lamps and displays on the ECOS and the SLI control units.
G
Risk of accidents if the safety devices are faulty
If the lamps or the buzzer fail, notify an authorised GROVE dealer or
CraneCARE and have the fault rectified.
In the meantime, pay particular attention to the lamps in the event of a fail-
ure of the buzzer and vice versa.
Spotlights Depending on the equipment of your truck crane, it may feature two electri-
cally slewable spotlights on the main boom base section.
G
Risk of explosion
The glass body of gas discharge lamps (xenon lights) is under pressure (7
to 20 bar (100 - 290 psi)).
Have faulty gas discharge lamps replaced only by specially qualified per-
sonnel who have the relevant protective equipment.
G
Risk of accidents due to high voltage
Spotlights with gas discharge lamps (xenon lights) operate with high volt-
age switchgear. The high voltage switchgear may discharge residual volt-
age even when the ignition and the battery master switch are switched off.
Have faulty gas discharge lamps replaced only by specially qualified per-
sonnel who have the relevant protective equipment.
• Have faulty lamps in the spotlights replaced only by specially qualified

personnel.
27.01.2007

GMK 4100/GMK 4100–L
8.14.2 Batteries – checking the acid level M1
The batteries are in the battery box (1).
G
and lead compounds.
Maintenance work is described in Section Batteries – checking the acid level,

p. 7 - 78.
8.14.3 Batteries – checking the acid concentration M3
Maintenance work is described in Section Batteries – checking the acid concen-

tration, p. 7 - 80. 27.01.2007

GMK 4100/GMK 4100–L

an air-conditioning system in the superstructure.
8.15.1 Checking the moisture and level of the refrigerant M1
The refrigerant is checked through an inspec-

tion glass on the refrigerant collector while the
air-conditioning system is running (1).
• Switch on the air-conditioning system and
let it run for about 10 minutes; à Operating
instructions.
• Check the refrigerant filling level and the

moisture content of the refrigerant through
the inspection glass (1):
– The floater (3) must be at the top and
– the indicator pearl (2) must be blue.
If the floater is at the bottom (no refrigerant
can be seen in the inspection glass) or if the
indicator pearl is a pink colour, the air-condi-
tioning system is faulty.
s
27.01.2007

GMK 4100/GMK 4100–L
If the air conditioning system is defective:

• To avoid further damage, switch the air-conditioning system off and do
not use it again.
Have the air-conditioning system repaired as soon as possible by an author-
When the inspection has been completed:
• Switch the air-conditioning system off and turn the engine off.
8.15.2 Cleaning the condenser fins M1
Prerequisites – The air-conditioning system is switched off; à Operating instructions.

à p. 2 - 3.
Cleaning the
condenser fins
S
Risk of damage to the condenser and fan
Do not use a high pressure cleaner or steam jet cleaner. The powerful water
jet may damage the fins. Use only compressed air for cleaning.
• Clean the condenser fins with compressed

air (1).
27.01.2007

GMK 4100/GMK 4100–L
8.15.3 Checking hoses M6
G
• Check all refrigerant hoses for damage and worn areas.

Have damaged hoses replaced by an authorised GROVE dealer or
CraneCARE only.
8.15.4 Checking the entire air conditioning system M 12
H
This inspection may only be carried out by CraneCARE.
G
• 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.
27.01.2007

GMK 4100/GMK 4100–L

Have the soot particle filter (additional equip-
ment) (1) cleaned by service partners.
Information can be obtained from CraneCARE.
8.16.1 Checking the clamp straps M1
Maintenance work is described in Section Checking the clamp straps, p. 7 - 85.
8.16.2 Replacing the soot particle filter M6
Spare parts
Clamp strap 2
not available
Filter 1

à p. 2 - 3.
27.01.2007
Replacing the soot Maintenance work is described in Section Replacing the soot particle filter,
particle filter p. 7 - 86.

GMK 4100/GMK 4100–L
8.17.1 Checking the auxiliary heater for correct operation M1
an auxiliary heater.
Maintenance work is described in Section à
Checking the auxiliary heater for
correct operation, p. 7 - 100.
8.17.2 Lubricating the piston rod of the derricking cylinder M1
S
Risk of damage to the derricking cylinder's gasket due to surface rust
Be sure that the uncovered end of the piston rod is always kept lubricated.
In this way you can avoid surface rust which damages the gasket in the der-
ricking 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.
H
You can also prevent surface rust if you turn the main boom to the side
between maintenance intervals and completely lower it.
27.01.2007

GMK 4100/GMK 4100–L
8.17.3 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.
• Observe the 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.
27.01.2007

GMK 4100/GMK 4100–L
9
27.01.2007

GMK 4100/GMK 4100–L
27.01.2007

GMK 4100/GMK 4100–L
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):
Before the truck • Clean the truck crane thoroughly inside and outside.
crane is put out of
• Remove rust and touch up the paintwork.
service
• Parts which 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 according to the maintenance plans M 3 to M 12.
• Seal all air filters.
• Increase the tyre pressure by 10% and mark the tyre positioning, or
support the truck crane and let it stand with support.
• Observe the specifications on preservation in the Engine manufacturer’s
operating instructions and in the Engine manufacturer’s maintenance booklet.
When the truck • Check the levels in the fuel tanks. Always keep the tanks filled.
crane is out of
• Check the batteries every week and recharge them if necessary.
service
• 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
(122°F) and check all functions of the carrier and superstructure hydraulic
systems.
s
27.01.2007

GMK 4100/GMK 4100–L
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
operating instructions and in the Engine manufacturer’s maintenance booklet.
Before putting the • Open all air filters.

truck crane back
• Inflate the tyres up to the prescribed pressure.
into operation
• 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 operating instructions and in the Engine
manufacturer’s maintenance booklet.
27.01.2007

GMK 4100/GMK 4100–L
10
10 Torques
10.1 Torques for retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 1
10.2 Special torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 2

27.01.2007

GMK 4100/GMK 4100–L
27.01.2007

GMK 4100/GMK 4100–L
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 (greatest permissible pretensioning
(mm) for bolts) for oiled bolts (Nm)
Spanner width (mm)
Bolt quality
Hexagon bolt Cylinder 8.8 10.9 12.9
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
27.01.2007

GMK 4100/GMK 4100–L
Torques
10.2 Special torques
10.2 Special torques
Thread size Spanner size Tightening

(mm) (mm) torque (Nm)
Description
Hexagon Cylinder
bolt screw
Suspension strut:
– between vehicle chassis / guide
M 16 — 17 265
case (top)
– Vehicle chassis / guide case
M 24 — 19 900
(below)
– Support element / steering split
M 16 — 14 265
shell
– Support element / operating head M 20 30 17 520
Transmission:
– Oil drain plug M 14 22 — 50
– Plugs oil filter in the transmission M 10 x 1.5 16 8 50 - 55
Steering linkage:
– Locking screw for spherical-head
connection steering linkage M 12 x 1.5 19 — 70 - 80
Head = 40 mm
– Locking screw for spherical-head
connection steering linkage M 14 x 1.5 22 — 160 - 180
Head = 50 mm
Others:
– Wheel nuts M 22 x 1.5 32 — 650
9541)
M 24 36 —
– Retaining bolts for the ball 1 0602)
bearing slewing 1 3953)
M 27 41 —
1 5504)
– Hoist drum rope wedge M 10 17 — 46
– Screw for slewing angle sensor M 8 x 1.5 13 — 25
1) Torque for the torque wrench (tightening force F = 239 kN (53 729 lbf))
2) Torque for electric or hydraulic screwdriver (tightening force F = 239 kN
(53 729 lbf))
27.01.2007
3)
Torque for the torque wrench (tightening force F = 315 kN (70 815 lbf))
4)
Tightening torque for electric or hydraulic screwdriver (tightening force
F = 315 kN (70 815 lbf))

GMK 4100/GMK 4100–L
11
11.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 1
11.2 Lights and indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 3
11.3 Spare parts for the carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 5
11.4 Spare parts for the superstructure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 7

27.01.2007

GMK 4100/GMK 4100–L
27.01.2007

GMK 4100/GMK 4100–L
Spare parts required for maintenance
11.1 General information

This chapter lists the spare parts required for the maintenance work
described in chapters 7 and 8.
The list of spare parts is divided into

– Lights and indicators
– Spare parts for the carrier and
– Spare parts for the superstructure
A further division is made according to the truck crane's subassemblies.
Spare parts that are not listed here are contained in the supplied List of spare
parts.
27.01.2007

GMK 4100/GMK 4100–L
Blank page
27.01.2007

GMK 4100/GMK 4100–L
11.2 Lights and indicators

This list includes all lamps that are available as standard or as additional
equipment for the truck crane.
Country-specific additional lights are not listed. Notes on these additional

lights can be found in the Country package section of the spare parts list.
G
Risk of explosion
The glass body of gas discharge lamps (xenon lights) is under pressure
(7 to 20 bar (100 - 290 psi)).
Have faulty gas discharge lamps replaced only by a specially qualified
repair crew who have the relevant protective equipment.
G
Risk of accidents due to high voltage
Spotlights with gas discharge lamps (xenon lights) operate with high volt-
age switchgear. The high voltage switchgear may discharge residual volt-
age even when the ignition and the battery master switch are switched off.
Have faulty gas discharge lamps replaced only by a specially qualified
repair crew who have the relevant protective equipment.
Place of installation GROVE Light type Output (W) Base

part number
Carrier
Low-beam headlight /
00 438 912 H1 24 V 70 P 14.5 s
headlight – full beam
Parking light 00 438 514 C5W 24 V 5 SV 8.5
Front indicator 03 327 578 P25-1 24 V 21 BA 15 s
Front lateral indicator 03 327 578 P25-1 24 V 21 BA 15 s
Rear indicator 00 439 055 P25-1 24 V 21 BA 15 s
Rear light 01 207 144 R19/10 24 V 10 BA 15 s
Brake light 00 439 055 P25-1 24 V 21 BA 15 s
Fog tail light 00 439 055 P25-1 24 V 21 BA 15 s
Reversing lamp 00 439 055 P25-1 24 V 21 BA 15 s
Front marker light 00 438 514 C5W 24 V 5 SV 8.5
Rear marker light 00 438 897 T8/4 24 V 4 BA 9 s
Rear yellow side marker
03 320 937 LED –– ––
light
s
27.01.2007

GMK 4100/GMK 4100–L
Place of installation GROVE Light type Output (W) Base

part number
Yellow side marker light 03 323 568 LED –– ––
Outrigger lighting 02 316 460 H3 24 V 70 PK 22 s
Rotating beacon 00 438 912 H1 24 V 70 P 14.5 s
Interior lamp 00 550 434 K 24 V 10 SV 8.5
Map reading lamp 00 550 434 K 24 V 10 SV 8.5
Superstructure
Rotating beacon 00 438 912 H1 24 V 70 P 14.5 s
Spotlights 02 316 460 H3 24 V 70 PK 22 s
Spotlights, electrically
03 326 694 D2S 53/35 P 32 d-2
adjustable
Rear red marker light 03 323 566 LED –– ––
Main boom head, white,
03 323 856 LED –– ––
right
Main boom head, white,
03 323 567 LED –– ––
left
Interior lamp 00 550 434 K 24 V 10 SV 8.5
Map reading lamp 00 550 434 K 24 V 10 SV 8.5
27.01.2007

GMK 4100/GMK 4100–L
11.3 Spare parts for the carrier
Subassemblies and spare parts GROVE Maintenance interval

part number
W M1 M3 M6 M 12
Engine
Oil drain valve 03 046 878 1
Gasket 26 x 31 Cu DIN 7603 00 117 147 1
Filter 03 324 183 1
Fuel system
Filter 03 322 877 1
Gasket 03 322 879 1
Transmission
Gasket 24 x 29 Al DIN 7603 03 328 331 1
Transfer case
Gasket 30 x 36 Cu DIN 7603 00 117 151 1 2
Gasket 16 x 20 Cu DIN 7603 00 117 134 1
Axle lines
Gasket 30 x 36 Cu DIN 7603 02 309 476 5 5
Gasket 30 x 38 Cu DIN 7603 01 925 343 5
Gasket 24 x 29 Cu DIN 7603 00 117 145 8 8
Wheels
Wheel nut and pressure plate per 01 207 756
12 12
wheel
Compressed air system
Valve 01 570 750 5
Granulate cartridge 03 043 578 1
Hydraulic system
Filter 03 329 152 2
Gasket 03 328 216 2 2
Gasket 02 316 851 2 2
Ventilation filter 03 134 931 1
27.01.2007
s
GMK 4100/GMK 4100–L
Subassemblies and spare parts GROVE Maintenance interval

part number
W M1 M3 M6 M 12
Grease cartridge 00 554 201 1
Soot particle filter
Filter 03 326 976 1
Maintenance work GROVE Maintenance interval

part number
Y2 Y3 Y5 Y6
Engine
Oil filter with gasket 03 325 945 1
Transmission
Filter 03 328 342 1
Spring 03 328 343 1
Gasket 24 x 29 Al DIN 7603 03 328 331 2
Gasket 42 x 49 Al DIN 7603 03 328 344 1
27.01.2007

GMK 4100/GMK 4100–L
11.4 Spare parts for the superstructure
Maintenance work GROVE Maintenance interval

part number
W M1 M3 M6 M 12
Engine
Filter 03 316 343 1
Fuel system
Filter 03 322 877 1
Gasket 03 322 879 1
Hoists
Gasket 18 x 24 Cu DIN 7603 per hoist 01 377 793 2 10
Slewing gear
Gasket 10 x 14 Cu DIN 7603 01 368 741 4 4
Gasket 14 x 20 Cu DIN 7603 00 117 132 2
Hydraulic system
Return flow filter 03 134 850 2 2
Filter for control circuit 03 326 047 1
Gasket for control circuit 03 326 049 1
Ventilation filter 03 134 932 1
Safe load indicator
Gasket for cable drum, external 03 324 704 1
Gasket for cable drum, internal 03 328 294 1
Soot particle filter
Clamp strap 2
not available
Filter 1
Lowering limit switch
Gasket 00 550 699
s
27.01.2007

GMK 4100/GMK 4100–L
Maintenance work GROVE part Maintenance interval

number
Y2 Y3 Y5 Y6
Engine
Safe load indicator
Gasket 16 x 20 Cu 00 117 134 1
27.01.2007

GMK 4100/GMK 4100–L
Appendix
27.01.2007

GMK 4100/GMK 4100–L
27.01.2007

GMK 4100/GMK 4100–L
Appendix
Sample 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: ......................
Last general overhaul performed on: ......................
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 inspector
1 year) inspection the last inspection
Di = Di-1 - Si
inspection
“i” Kmi [h] [h] [h] [h] [h] [h] [h]

(*)
IMPORTANT:
Si = Used proportion of theoretical service life since the last inspection
Di = Remaining theoretical service life
Alternative provision, refer to Section 5.4.2, p. 5 - 25.
Last general overhaul performed on .................................. Kmi= Factor of the load spectrum in the inspection interval “i” according to Section 2.1
Sample 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: ......................
Last general overhaul performed on: ......................
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 inspector
1 year) inspection the last inspection
Di = Di-1 - Si
inspection
“i” Kmi [h] [h] [h] [h] [h] [h] [h]
IMPORTANT:
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
Last general overhaul performed on .................................. Kmi= Factor of the load spectrum in the inspection interval “i” according to Section 2.1
Tilting play measurement report
• Always measure the current tilting play as described in section Measuring tilting play, p. 8 - 35.
Base value: ............... mm

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

–45° (A) –135° (B) 135° (C) 45° (D) ok faulty replaced on
Tilting play measurement report
• Always measure the current tilting play as described in section Measuring tilting play, p. 8 - 35.
Base value: ............... mm

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

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

Maintenance Manual

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Maintenance Manual

Uploaded by

Copyright:

Available Formats

Maintenance manual

Any type of duplication or excerpt from this docu-

© Copyright reserved by Manitowoc Crane Group Germany GmbH

3 112 369 en Maintenance manual

Topping up oil on the suspension strut

Validity This additional page applies to the truck cranes:

GMK 3050-1, GMK 3055,

and is part of the maintenance manual supplied in each case.

Maintenance work on the CARRIER: Lubricant:

Correction sheet 3 112 249 en 1

• Check whether oil is visible in the middle of

2 3 112 249 en Correction sheet

This maintenance manual does not replace the operating instructions.

Details of operation and standard safety instructions can be found