Gmk5220 Crane- Parts Manual

1596K-002

REV-00

Ph: +61 7 3865 2660 www.ade.net.au

Parts Manual Supplement

Grove GMK 5220 All Terrain Crane

Parts GMK 5220 - Supplement

1 GENERAL INFORMATION..................................................................................................................................1

2 MECHANICAL......................................................................................................................................................2

2.1 CRANE CAB ACCESS PLATFORM .....................................................................................................................2 2.2 ENGINE MODULE ACCESS PLATFORM..............................................................................................................5 2.3 CRANE CARRIER HANDRAILS...........................................................................................................................8 2.4 BUMP STOP ENGINE MODULE......................................................................................................................12 2.5 BUMP STOP CRANE CAB.............................................................................................................................14

3 SAFETY...............................................................................................................................................................16

3.1 LABELS .........................................................................................................................................................16 3.2 FLAG HOLDERS .............................................................................................................................................30 3.3 EXHAUST SHIELDING......................................................................................................................................31

4 ELECTRICAL ......................................................................................................................................................32

4.1 ROTATION INTERLOCK ...................................................................................................................................32 4.2 ELECTRICAL PARTS LISTING...........................................................................................................................34

5 HYDRAULIC.......................................................................................................................................................39

5.1 HYDRAULIC MODULE ACCESS PLATFORMS .................................................................................................39 5.2 HYDRAULIC MODULE DECK HANDRAILS ......................................................................................................41 5.3 RADIATOR HEADER TANK RELOCATION..........................................................................................................43 5.4 HYDRAULIC HOSE LISTING ............................................................................................................................44

APPENDIX ..................................................................................................................................................................47

I. HYDRAULIC SCHEMATICS II. ELECTRICAL SCHEMATIC

1 General Information

The Parts Manual Supplement is a compilation of the modifications as fitted to the Grove Crane GMK5220 All

Terrain Crane by Australian Diversified Engineering. This manual is a supplement to the standard Grove Crane

Parts Manual.

NOTE: Site modifications performed to this machine unless under consultation with Australian Diversified

Engineering may not be contained within this manual.

Refer to the Operation and Maintenance Manual Supplement GMK5220-O&MMS-REV00 for operation and

maintenance procedures for the modifications performed to this machine by Australian Diversified Engineering.

Consult Australian Diversified Engineering if replacement manuals are required.

PartsGMK 5220 - Supplement Page 1 of 47

2 Mechanical 2.1 Crane Cab Access Platform

ACCESS PLATFORM 1596A

CRANE CAB


A13

14

72

2

45

9

49

4

51

69 16

56

68

50

26

281830

64

3327

60

67

473755

65

1724

62 60 17

23

6062

32

59

22 31

20

21

60

59

60 59

86160176059

7

36

60 58

19

65

5960

53

534

5

35

15

52

66

6059

59

6017

50 34

5756

55

68

7156

70

4157

59

60

18

11

10

60

1

63

43

25

59

60

60

29 58 60 63

6059

60

18 60

59

54

65

6059

ACCESS PLATFORM - 1596ACRANE CAB

5960

1760

62

51

50

18

3

39

43

40

73

74

74

38

75

76

553545349

53

4

1253

4953


ITEM NO. PART NUMBER QTY.

1 1596A-001 1

2 1596A-002 1

3 1596A-003 1

4 1596A-004-001 8

5 1596A-005 4

6 1596A-006 1

7 1596A-007 1

8 1596A-008 1

9 1596A-009-001 1

10 1596A-010 2

11 1596A-011-001 2

12 1596A-012-001 2

13 1596A-013 1

14 1596A-014-001 1

15 1596A-015 1

16 1596A-016 1

17 1596A-017-001 11

18 1596A-018-001 8

19 1596A-019-001 3

20 1596A-020-001 1

21 1596A-021-001 1

22 1596A-022-001 3

23 1596A-023-001 1

24 1596A-024-001 2

25 1596A-025 1

26 1596A-026 1

27 1596A-027 1

28 1596A-028-001 1

29 1596A-029 1

30 1596A-030 1


31 1596A-031-001 3

32 1596A-032-001 3

33 1596A-033-001 1

34 1596A-034-001 1

35 1596A-035-001 4

36 1596A-036-001 1

37 1596A-037-001 2

38 1596A-038-001 4

39 1596P-001 1

40 1596P-003 1

41 PTE 30 x 1.5 INCH - BARREL 1

42 PTE 30 x 1.5 INCH - ROD 1

43 HYTECO 6 x 1.5 INCH - BARREL 2

44 HYTECO 6 x 1.5 INCH - ROD 2





49 BEARING - GE 40 ES-2RS 6

50 PLAIN BEARING - 12DUB08 4


52 GREASE NIPPLE 1.8 BSPT STRAIGHT 2

53 CIRCLIP - 62mm 12

54 TREAD - TA255ASM 10

55 BOLT M16 x 30 7X2552 6

56 WASHER 16 9X-8257 12

57 BOLT M16 x 50 8T-4193 10

58 BOLT M12 x 110 7X-2550 4

59 NUT M12 NYLOCK 82

60 WASHER 12 162


61 BOLT M12 x 65 4

62 BOLT M12 x 70 8T-4648 6

63 BOLT M12 x 50 6

64 BOLT M12 x 90 8T-4176 2

65 BOLT M12 x 75 55

66 BOLT M12 x 30 8T-4139 4

67 BOLT M12 x 25 8T-4192 4

68 WASHER 24 8T-4167 4

69 NUT M24 NYLOCK 2

70 BOLT M24 x 150 8C-3290 2

71 BOLT M16 x 40 7X-2553 2

72 BOLT M12 x 120 8T-5041 1

73 PROXIMITY SWITCH - RS 3129558 1

74 BONDED BUFFER - M172M8 3

75 WASHER 6 4

76 BOLT M6 x 40 8C-8451 4


2.2 Engine Module Access Platform

ACCESS PLATFORM 1596B

ENGINE MODULE


AACCESS PLATFORM - 1596BENGINE MODULE

15

22

65 54

65 54 15

44

8

19

2920

3056

54 1554

56

5455

5654

6117

42 50

65

9

64

56

3

49

54

40

2

35

13

65

15

5456

6059 5 4 48 52

32

58

57

57

58

49

46

11

6354

16

54

56

10

44

5456

5467

56

54

61

2531

1654

62

55

50

54

2423

16

26

56

54

51

1

71

53

7

33

18

21

5654

56

54

37

70

36

69

68

38

39

53324

5248

6

524

553

34

12

52

4852



1 1596A-001 1

2 1596B-002 1

3 1596A-003 1

4 1596A-004-001 8

5 1596A-005 4

6 1596A-006 1

7 1596B-007 1

8 1596B-008 1

9 1596A-009-001 1

10 1596A-010 2

11 1596A-011-001 2

12 1596A-012-001 2

13 1596B-015 1

14 1596B-016 1

15 1596A-017-001 11

16 1596A-018-001 8

17 1596A-019-001 1

18 1596A-020-001 1

19 1596B-021 1

20 1596A-022-001 3

21 1596A-023-001 1

22 1596A-024-001 2

23 1596A-025 1

24 1596A-026 1

25 1596A-027 1

26 1596A-028-001 1

27 1596A-029 1

28 1596A-030 1

29 1596A-031-001 3

30 1596A-032-001 3


31 1596A-033-001 1

32 1596A-035-001 4

33 1596A-036-001 1

34 1596A-037-001 2

35 1596B-037-001 2

36 1596B-038-001 1

37 1596H-001 1

38 1596P-001 1

39 1596P-002 1

40 PTE 30 x 1.5 INCH - BARREL 1

41 PTE 30 x 1.5 INCH - ROD 1







48 BEARING - GE 40 ES-2RS 6



51 TREAD - TA255ASM 10

52 CIRCLIP - 62mm 10

53 BOLT M16 x 30 7X2552 6

54 WASHER 12 165

55 BOLT M12 x 110 7X-2550 4


57 WASHER 16 9X-8257 6

58 BOLT M16 x 40 7X-2553 6

59 WASHER 24 8T-4167 2

60 BOLT M24 x 150 8C-3290 2


61 BOLT M12 x 75 54

62 BOLT M12 x 90 8T-4176 3

63 BOLT M12 x 50 6

64 BOLT M12 x 30 8T-4139 4

65 BOLT M12 x 70 8T-4648 8

66 BOLT M12 x 65 3

67 BOLT M12 x 25 8T-4192 4

68 BOLT M10 x 20 8T-4137 2

69 WASHER 10 8T-4121 2


71 GREASE NIPPLE 1.8 BSPT STRAIGHT 2


2.3 Crane Carrier Handrails

HANDRAIL ASSEMBLY 1596C

CARRIER DECK

[LEFT]


HANDRAIL ASSEMBLY 1596C

CARRIER DECK

[RIGHT]


36

7

7

4

4

5

5

9

15

10

20 22

24

18

22

2221

1214

21

1322

17

1922

11

2221

25

2

2

2324

15

1

8

9

HAND RAIL ASSEMBLY - 1596CCARRIER DECK



1 1596C-001 1

2 1596C-002 2

3 1596C-003 1

4 1596C-004-001 2

5 1596C-005 2

6 1596C-006 1

7 1596C-007 2

8 1596C-008 1

9 1596C-009 2

10 1596C-010 9

11 1596A-017-001 12

12 1596A-022-001 12

13 1596A-031-001 12

14 1596A-032-001 12



17 BOLT M12 x 110 7X-2550 12

18 BOLT M12 x 70 8T-4648 6

19 BOLT M12 x 65 6

20 BOLT M12 x 30 8T-4139 45


22 WASHER 12 81





2.4 Bump Stop Engine Module

BUMP STOP ASSEMBLY 1596M

ENGINE MODULE ACCESS PLATFORM


811

9

1

6102

5

4

3

7

9

BUMP STOP ASSEMBLY - 1596MENGINE MODULE ACCESS PLATFORM


1 1596M-001 1

2 1596M-002-001 1

3 RUBBER PAD 35 x 35 1



6 BOLT M10 x 20 8T-4137 2

7 BOLT M12 x 50 8T-4194 1

8 BOLT M12 x 70 8T-4648 3

9 NUT M12 8T-4244 4

10 WASHER 10 8T-4121 2

11 WASHER 12 8T-4223 3


2.5 Bump Stop Crane Cab

BUMP STOP ASSEMBLY 1596N

CRANE CAB ACCESS PLATFORM


65

34

1

2

8

7

BUMP STOP ASSEMBLY - 1596NCRANE CAB ACCESS PLATFORM

2


1 1596N-004 1

2 1596N-001-006 2



5 NUT M12 8T-4244 1

6 BOLT M12 x 50 8T-4194 1

7 WASHER 12 8T-4223 2

8 BOLT M12 x 70 8T-4648 2


3 Safety 3.1 Labels

ITEM DETAIL PART NO. QTY

1596J-003

1 2

1596J-004 2 2

1596J-005 3 2

1596J-006 4 2



1596J-007

5 1

1596J-008 6 1

1596J-009 7 3



1596J-010

8 2

1596J-011 9 2

1596J-013 10 1

1596J-014 11 1



1596J-016

12 1

1596J-017 13 1

1596J-018 14 1

1596J-019 1 15



1596J-020

16 1

1596J-021 17 2

18

1596J-025 2


1

Outside face of pivot arm (crane cab platform shown)

2

Top of hydraulic module


3

Lid for the ground level access system controls (right side shown)

4

Main frame of the access system


5

Crane cab right side

6

Crane carrier cab


7

On the inside of the lid for the ground level access system controls (right side shown)

8

17

Handrail hydraulic oil tank


8

17

Access platform hydraulic oil tank

9

Right crane cab window


10

Ancillary compartment at the left rear of the superstructure

11

Front right of the crane carrier


12

Crane carrier centre console

13

Crane cab door


15

14

Crane cab right side

16

Maintenance override cabinet attached to the hydraulic module


18

On the inside of the lid for the ground level access system controls (right side shown)


3.2 Flag Holders

ITEM DESCRIPTION PART NO. QTY

1 FLAG HOLDER FRONT LEFT 1596S-001 1

2 FLAG HOLDER FRONT RIGHT 1596S-002 1

3 FLAG HOLDER REAR 1596S-003 2

1 2

3 3


3.3 Exhaust Shielding


1 EXHAUST SHIELDING 1596E-001 1

2 MOUNTING BUTTONS 1596E-002 4

1 2


4 Electrical 4.1 Rotation Interlock


86

3

6

8

4

1

10

5

7

7

9

2

ROTATION INTERLOCK - 1596TCRANE SUPERSTRUCTURE


1 1596T-001 1

2 1596T-002 1

3 1596T-003 1

4 BOLT M10 x 40 4

5 BOLT M5 x 25 4

6 WASHER 10 8T-4121 8

7 WASHER 5 8

8 NUT M10 NYLOCK 8

9 NUT M5 NYLOCK 4

10 MICRO SWITCH - RS 334-612 2


4.2 Electrical Parts Listing


1 CONTROL BOX 1596G-004 2

2 SWITCH - ARROW ACX3614 10

3 LABEL CONTROL BOX 1596J-022 2

4 SWITCH ACCESS LIGHT ACX3624 1

5 PILOT LED - GREEN 1069 1

6 BUZZER ACX5134 1

7 LED - RED 2220

8 LABEL PARK BRAKE WARNING 1596J-023 1

9 LABEL SLEW BRAKE 1596J-024 1

10 SLEW OVERRIDE SWITCH BOX SJ268 1

11 LIGHT - FLOOD 153-2073 1

12 LED GREEN (110 mm) 8216 4

13 BUZZER SA400 2

14 ANCILLARY COMPARTMENT 1596Q-001 1

1

2

3

Ground level access system control box


2

5

4

Crane cab access system control console

67

8

Crane carrier console


9

10

Maintenance override cabinet attached to the hydraulic module

11

12

Left rear of the superstructure


13

Bottom hydraulic module

13

Rear of the front left mudguard


14

Ancillary compartment at the left rear of the superstructure


5 Hydraulic 5.1 Hydraulic Module Access Platforms

HYDRAULIC MODULE ASSEMBLY 1596F

ACCESS PLATFORMS


515

16

4

11

17

612

13

8

2

14

3

10 9

HYDRAULIC MODULE ASSEMBLY - 1596FACCESS PLATFORMS

14

16

15

14

15

16

1415

14


1 1596F-001 1

2 1596F-002-001 1

3 1596F-002-002 1

4 1596L-001 1

5 FIRE EXTINGUISHER - 4.5kg 1

6 Manifold Block 2

7 Dual Power Pack 1

8 GLAND - 25mm 1

9 GLAND - 32mm 1

10 S10-0707 16

11 S74-0407 4

12 S91-0709 13

13 S90-0709 9

14 BOLT M10 x 25 8

15 WASHER 10 8T-4121 13

16 NUT M10 NYLOCK 5


5.2 Hydraulic Module Deck Handrails

HYDRAULIC MODULE ASSEMBLY 1596R

DECK HANDRAILS


HYDRAULIC MODULE ASSEMBLY - 1596RDECK HAND RAILS

45

8

6

7

9

6

9

63

68

2

1


1 1596R-001 1

2 1596R-002 1

3 1596R-003 1

4 1596R-004 1

5 POWER PACK - DECK HAND RAILS 1

6 WASHER 10 8T-4121 20

7 BOLT M10 x 80 8T-0643 2

8 BOLT M10 x 25 8

9 NUT M10 NYLOCK 10


5.3 Radiator Header Tank Relocation


1 RADIATOR HEADER TANK BRACKET 1596D-001 1

2 HEADER TANK PIPING 1596D-002 1

1

2


5.3 Hydraulic Hose Listing

HOSE PART NO. DESCRIPTION LENGTH

ADEHS-00106 L Pump 'A' to L Block 'Up' 450 mm

ADEHS-00107 L Pump 'B' to L Block 'Down' 475 mm

ADEHS-00108

R Pump 'A' to R Block 'Up'; R Pump 'B' to R Block

'Down' 700 mm

ADEHS-00109 R Block 'B1' to Bulkhead 'R1' 480 mm

ADEHS-00110 R Block 'B' to Bulkhead 'R2' 465 mm

ADEHS-00111 R Block 'B2' to Bulkhead 'R3' 480 mm

ADEHS-00112

R Block 'B3' to Bulkhead 'R4'; 7th Xover Pipe to LH

150 Cyl Pipe; Deck Handrail Pump 'B' to Bulkhead 450 mm

ADEHS-00113

R Block 'A1' to Bulkhead 'R5'; R Block 'A' to

Bulkhead 'R6' 355 mm

ADEHS-00114

R Block 'A2' to Bulkhead 'R7'; Ladder Cyl Rod End

to Ladder Bulkhead 360 mm

ADEHS-00115 R Block 'A3' to Bulkhead 'R8' 410 mm

ADEHS-00116

Bulkhead 'R1' to RH Handrail Pipe; Bulkhead 'R2' to

RH 150 Cyl Pipe 475 mm

ADEHS-00117

Bulkhead 'R5' to RH Handrail Pipe; Bulkhead 'R6' to

RH 150 Cyl Pipe; LH Deck Rail Back Cyl 540 mm

ADEHS-00118

Bulkhead 'R4' to RH Platform Pivot Cyl; Bulkhead

'R8' to RH Platform Pivot Cyl 850 mm

ADEHS-00119

L Block 'B3' to Bulkhead 'L5'; LH Ladder U pipe to

Ladder Handrail Pipe 580 mm

ADEHS-00120

L Block 'B1' to Bulkhead 'L6'; L Block 'B' to

Bulkhead 'L8'; 3rd Xover Pipe to LH Handrail Pipe 520 mm

ADEHS-00121

L Block 'A3' to Bulkhead 'L1'; 4th Xover Pipe to LH

Handrail Pipe 575 mm

ADEHS-00122

L Block 'A1' to Bulkhead 'L2'; L Block 'A2' to

Bulkhead 'L3' 655 mm

ADEHS-00123 R Block 'Drain' to Tank 570 mm

ADEHS-00124 L Block 'Drain' to Tank 400 mm

ADEHS-00125

Bulkhead 'L5' to 2nd Xover Pipe; Bulkhead 'L6' to

4th Xover Pipe; Bulkhead 'L7' to 6th Xover Pipe;

Bulkhead 'L8' to 8th Xover Pipe; 590 mm

ADEHS-00126

Bulkhead 'L1' to Top Xover Pipe; Bulkhead 'L2' to

3rd Xover Pipe; 495 mm


ADEHS-00127 L Block 'A' to Bulkhead 'L4' 680 mm

ADEHS-00128 L Block 'B2' to Bulkhead 'L7' 550 mm

ADEHS-00129

Bulkhead 'L3' to 5th Xover Pipe; Bulkhead 'L4' to 7th

Xover Pipe; 500 mm

ADEHS-00130 Top Xover Pipe to LH Platform Pivot Cyl 355 mm

ADEHS-00131 2nd Xover Pipe to LH Platform Pivot Cyl 610 mm

ADEHS-00132 Ladder Handrail Pipe to Ladder Handrail Cylinder 375 mm

ADEHS-00133

Ladder Handrail Pipe to Ladder Handrail Cylinder;

8th Xover Pipe to LH 150 Cyl Pipe 490 mm

ADEHS-00134 Bulkhead 'R3' to RH Ladder Cyl Rod End 1405 mm

ADEHS-00135 5th Xover Pipe to LH Ladder Cyl Pipe 435 mm

ADEHS-00136 6th Xover Pipe to LH Ladder Cyl Pipe 410 mm

ADEHS-00137 Bulkhead 'R7' to RH Ladder Cyl 1515 mm

ADEHS-00138 Ladder Cyl to Ladder Bulkhead 275 mm

ADEHS-00139 Ladder Bulkhead Xover 560 mm

ADEHS-00140 RH Ladder U pipe to Ladder Handrail Pipe 560 mm

ADEHS-00141 RH Ladder U pipe to Ladder Handrail Pipe 600 mm

ADEHS-00142 Ladder Handrail Pipe to Ladder Handrail Cyl 190 mm

ADEHS-00143 Ladder Handrail Pipe to Ladder Handrail Cyl 230 mm

ADEHS-00144 RH Ladder 150 Cyl Pipe to U Pipe 870 mm


ADEHS-00146 RH Ladder 150 Cyl Pipe to Ladder 150 Cyl 1185 mm

ADEHS-00147 RH Ladder 150 Cyl Pipe to Ladder 150 Cyl 330 mm

ADEHS-00148 Pipe to RH Handrail Cyl 300 mm

ADEHS-00149 LH Ladder U pipe to Ladder Handrail Pipe 620 mm


ADEHS-00151 Pipe to LH Ladder Cyl 1405 mm

ADEHS-00152 Pipe to LH Ladder Cyl 1480 mm

ADEHS-00153 Deck Handrail Front Cylinder Down 670 mm

ADEHS-00154 Deck Handrail Front Cylinder Up 510 mm

ADEHS-00155 Bulkhead to RH Deck Handrail Up Pipe 780 mm

ADEHS-00156 Bulkhead to RH Deck Handrail Down Pipe 740 mm

ADEHS-00157 RH Handrail Rear Cyl up 415 mm

ADEHS-00158 RH Handrail Rear Cyl down 675 mm

ADEHS-00159 Pump A to deck handrail down bulkhead 460 mm

ADEHS-00160 LH Handrail rear cyl down 810 mm


ADEHS-00161 Deck Handrail Xover 5650 mm

ADEHS-00162 Deck Handrail Xover 5650 mm

ADEHS-00163 Pipe to RH Handrail Cyl 650 mm

ADEHS-00164 LH Ladder 150 Cyl Pipe to Ladder 150 Cyl -

ADEHS-00165 LH Ladder 150 Cyl Pipe to Ladder 150 Cyl 185 mm


Appendix


i. Hydraulic Schematic

ii. Electrical Schematics

GMK5220-PMS-REV001 General Information 2 Mechanical 2.1 Crane Cab Access Platform 2.2 Engine Module Access Platform 2.3 Crane Carrier Handrails 2.4 Bump Stop Engine Module 2.5 Bump Stop Crane Cab

3 Safety 3.1 Labels 3.2 Flag Holders

4 Electrical 4.1 Rotation Interlock 4.2 Electrical Parts Listing

5 Hydraulic 5.1 Hydraulic Module Access Platforms 5.2 Hydraulic Module Deck Handrails 5.3 Hydraulic Hose Listing

Appendix i. Hydraulic Schematics S07T88A

ii. Electrical Schematics

Gmk5220 Crane- Parts Manual

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