Additional maintenance work

These additional pages apply to all truck cranes with main booms that are equipped with Twinlock systems.

Additional maintenance work

These truck cranes require additional maintenance work on the main boom locking system.

GRisk of accidents if maintenance work is not carried out!

Have the additional maintenance work on the main boom locking system performed by your authorized GROVE dealer or CraneCARE regularly. This prevents the inadvertent unlocking of a telescoping section in Emergency operation/Emergency program mode, which could cause serious accidents and damage to the truck crane.

These additional pages describe this additional maintenance procedure only and are part of the maintenance manual supplied.

5.2 Maintenance plan

5.2.6

M 12 maintenance plan: Every 12 months / after 1000oper. hrs.

M 12

Maintenance work on the SUPERSTRUCTURE: Every 12 months / after 1000 oper. hrs.

Main boom

–Have the main boom locking system checked by your authorized GROVE dealer or CraneCARE.

The following chapters are contained in this maintenance manual:

1General instructions

2Safety and environmental protection

3Cleaning

4Run-in regulations

5Maintenance overview

6Lubricants and fuels

7Description of maintenance work on the carrier

8Description of maintenance work on thesuperstructure

9Longer periods out of operation

10Tightening torques

Appendix

General instructions

1.1 Using the maintenance manual

This manual is not designed to replace proper training and instruction! Truck crane maintenance personnel are required to have relevant specialised knowledge of proper safety procedures!

Please read chapters 1 and 2 carefully before beginning maintenance work.

HMaintenance work on the lattice extensions is described in the operating instructions for lattice extensions.

1.2 Warnings and symbols

The following definitions and symbols are used in the operating instructions to highlight particularly important information: sThis symbol indicates that the topic is continued on the next page. Turn to the next page.

GThis symbol indicates hazards related to the operation described 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.

SHere dangers which could put objects at risk are pointed out, e.g. damage to the truck crane or the load.

OThis 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 indicated next to the symbol. You will find more detailed information in the section Handling substances which are harmful to the environment, à p.2-2.

The vertical line to the left of the text indicates that this text, regardless of its length, relates to the warning symbol.

HThe hand with the pointing finger indicates passages that contain additional instructions and tips with regard to truck crane operation.

1.3 GROVE customer support maintenance instructions

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. the local GROVE Customer Support).

Repair work also requires:

–appropriate workshop equipment, –special tools and –replacement parts authorized by Deutsche GROVE GmbH.

It is your responsibility to maintain and service the truck crane regularly in order to lengthen its service life and keep it in good working order.

Please note that Deutsche GROVE GmbH can only uphold the warranty provided for the truck crane if the following conditions are met:

–proper use, –prescribed care and maintenance, –professional repair work / overhauling.

Numerous defects and failures are caused by improper maintenance such as:

–lack of oil, grease or antifreeze, –dirt, –rope damage, –defective compressed air and hydraulic systems, –hose damage or loose screw connections, –defective brakes, –defective 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. Notify either your local GROVE Customer Support or your qualified repair personnel immediately should repair work become necessary. 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 oil filler, inspection, and drain openings and 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, Chapter 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 systems when the system is depressurized.

• Keep brake and clutch linings free of grease.

• Replace hydraulic hoses immediately once damage or penetration of moisture becomes visible.

• When handling hydraulic oil, cleanliness is imperative. Even new hydraulic oil must be filtered.

• Check fastening and retaining elements (screws, nuts, lock washers) before re-using them and replace them if necessary.

Tightening torques may be found in sections p. 10-1 and p. 10-2.

Our training centre at our plant in D-26389 Wilhelmshaven offers specialized training programmes. Your local GROVE Customer Support can provide you with any information you may need in this regard.

The vehicle must fulfill all current regulations before commissioning and use on public roads.

1.4 Definitions of stated directions

Some of the terms which are used to describe the location of components are defined in this section.

On the carrier, the driver’s cab is always at the front. The terms rear, right and left are used in relation to the definition of the term "front" on the carrier.

On the superstructure front always refers to the direction of the main boom head, regardless of the superstructure position. The terms rear, right and left are used in relation to the definition of the term "front" on the superstructure.

Safety and environmental protection

2.1 Safety rules

When carrying out maintenance work, it is imperative that you observe the applicable accident prevention regulations. The following instructions are general safety rules for maintenance personnel:

• Familiarize yourself with the truck crane and its operation. Read the operating instructions carefully and request guidance from crane operator.

• Do not carry out maintenance work unless you are authorized to do so.

• Observe all safety and warning signs on the truck crane.

• Observe all safety instructions contained in this maintenance manual.

• Familiarize 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 unauthorized operation before beginning maintenance work. Remove the key and put up warning signs.

2.2 Handling substances which are harmful to the environment

If, as an exception, the truck crane needs to be put into operation for certain types of maintenance work, great care must be taken where there are moving parts (superstructure, outrigger, cardan shafts, swivelling connections, motors, tiltable crane cabs, superstructure lock). There is a risk of injury!

• Ensure that all hydraulic components are returned to their initial positions (e.g. the boom) or locked (e.g. the outrigger).

Escaping hydraulic fluid or compressed air can cause severe injury. Remember that hydraulic and compressed air systems of the truck crane are pressurized even when the crane is not in operation. Only tighten loose screw connections when the system is in depressurized condition. Always depressurize 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 inflammable fluids.

• Observe the applicable safety regulations when working with process materials.

• Disconnect the earthing terminal and switch off all electrical consumers before removing any batteries.

• Keep the corroding effect of battery acid in mind.

• 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.

2.2 Handling substances which are harmful to the environment

What do environmentally harmful substances include?

When you carry out maintenance work on the truck crane you will occasionally work with substances which are considered to be harmful to the environment according to the current national and local regulations. This includes, amongst others, oil, fuel, grease, used oil and fuel filters as well as cloths which have come into contact with these environmentally harmful substances.

• When handling these substances observe the current national and regional regulations as well as the instructions in this chapter.

2.2 Handling substances which are harmful to the environment

Use suitable equipment Substances harmful to the environment can be corrosive. Therefore only use containers, hoses, pumps, funnels etc. which are resistant to the respective substance.

Filling and draining

• When filling and draining, make absolutely sure that no substances harmful to the environment seep into the earth, escape into the sewage system or polute natural waters.

• Collect draining oil in a suitable container.

• Always use a drain hose when draining, a funnel or a filling pump and hose suitable for the respective substance when filling.

Collect and store separately

Substances which are environmentally harmful should always be collected separately from other waste.

• Also collect the environmentally harmful substances divided according to solid materials (e.g. filter elements) and liquids. Disposal costs will be reduced if you collect liquids separately according to certain categories.

• Ask your local environmental protection authority about the different categories for the substances.

• Only store environmentally harmful substances in approved containers and in locations which meet the regulations according to the current national and regional regulations.

Disposal

• Ask your local environmental protection authority about the prescribed disposal possibilities.

• Only have collected environmentally harmful substances disposed of by disposal companies which are approved by the national or regional authority responsible.

2.2 Handling substances which are harmful to the environment

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Cleaning

The paint on the truck crane will continue to harden for the first three 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.

• Avoid water temperatures over 60 °C, even after the first three months.

• Do not use corrosive cleaning agents that might corrode 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 you are cleaning.

GRisk 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.

• Never point the nozzle at electrical equipment, relay and control boxes, suction and venting filters or control elements and lubricated surfaces.

The components specified in section p. 3-2 are to be cleaned with particular care.

• After cleaning with a high-pressure device or a steam jet device, activate an intermediate lubrication at the centralized lubrication system (à Centrallubrication system , p.7-55). Lubricate all remaining lubrication points with a grease gun.

3.1 Overview of the components that are easily damaged when

Run-in regulations

Special running-in instructions must be observed for individual components (hoist, gearbox, etc.)

–after initial start-up or –after part replacement or –after a general inspection

Special run-in instructions must be observed, i.e. additional maintenance work must be carried out on the carrier and the superstructure in certain intervals:

Operation hours (oh)

Travelled km

Additional maintenance work on the CARRIER after 50Tighten wheel nuts

(Tightening torque à p.10-2) after 150Tighten wheel nuts

(Tightening torque à p.10-2) after 20; 1) Carryout the first oil change in the transfer case; à Distributor gearbox – oil change, p.7-22. after 50Tighten hose clamps on all coolant hoses (à Special tightening torques, p.10-2). during the first 100 Check the hydraulic oil filters weekly; à Changing the hydraulic oil filters and cleaning the magnetic rod, p.7-46.

1) 1 oh corresponds to approx. 40 kilometers driven

Please note the instructions concerning run-in times / run-in regulations / oil change intervals in the enclosed operating manual of the engine manufacturer and in the crane diesel engine maintenance booklet.

Operation hours (oh) during the first 100

Travelled km

Additional maintenance work on the SUPERSTRUCTURE after 100Check tightness of retaining bolts; tightening torque; à Special tightening torques, p.10-2. after 200Carry out first oil change on hoist gears (auxiliary hoist only with additional equipment); à Hoisting gear – oil change, p.8-5. after 200Carry out first oil change in slewing gear transmission; à Slewing gear – oil change, p.8-12. after10001)

Check the hydraulic oil filters weekly; à Replacing the hydraulic oil filter, p.8-22.

Carry out second oil change on hoist gears (auxiliary hoist only with additional equipment); à Hoisting gear – oil change, p.8-5.

Please note the instructions concerning run-in times / run-in regulations / oil change intervals in the enclosed operating manual of the engine manufacturer and in the crane diesel engine maintenance booklet.

1) after 1000 operating hours, after 12 months at the latest.

5

Maintenance overview

In this chapter, all periodic maintenance work is described in maintenance plans as:

–Maintenance plans D (=daily),

–Maintenance plans W (=weekly) and

–Maintenance plans M 1 (=once monthly) to M 12 (=every 12 months) and

–Maintenance plans M 2 (=every 24 months) to M 6 (=every 72 months).

The maintenance plans are given in table form, differentiated by

–Maintenance work on the carrier and

–Maintenance work on the superstructure

In the tables you are directed by cross references to the sections in which the appropriate maintenance work is described. The cross references consist of the chapter number and the corresponding page number, e.g.

Checking hydraulic oil level; à p.7-43.

Checking the hydraulic oil level is described in chapter7, the section starts on page p. 7-43.

5.1 Maintenance intervals

The length of the interval depends on the operating conditions of the truck crane:

The next maintenance check must be carried out after

–a specified time (maintenance deadline) or

–a specified number of km travelled for carrier components with driving functions or

–a specified number of operating hours (oh) for superstructure (and carrier) components with crane functions.

The first maintenance interval shall determine when maintenance work is next due.

The km travelled may be taken from the trip recorder in the driver’s cab (front instrument panel).

You can individually call up the operating hours (oh) of the superstructure’s power units on the crane control display in the crane operator’s cab (front instrument panel). The working hours of the crane engine are simultaneously the total working hours of the superstructure.

The following table sets out the maintenance intervals for the maintenance plans:

Please note that the long-term maintenance plans always include the short-term ones!

5.2 Maintenance plans

The descriptions of specific maintenance work in the maintenance plans D , W, M 1 up to M 12 and Y 2 up to Y 6 are for –the carrier in Chapter 7 and for –the superstructure in Chapter 8.

Cross-references for the descriptions of these maintenance tasks may be found after the respective maintenance tasks for the carrier and the superstructure (chapter and page number).

The section titles

–of Chapter 7 Description of the maintenance work on the carrier and –of Chapter 8 Description of the maintenance work on the superstructure contain the symbol (D up to Y 6) of the relevant maintenance plan for better comprehension.

HThe description of some daily (D) and weekly (W ) checks (preventive maintenance) can also be found in part in the Operating Instructions.

In addition to the maintenance work on the carrier and the maintenance work on the superstructure, the maintenance plans also contain:

–the amounts as approximate values for oil amounts (the exact oil amounts are always determined by the oil level openings, the dipstick or the oil level indicators) or the number of existing lubrication points.

–The designations of the oils / lubricants in accordance with the table of lubricants, chapter p. 6-1.

HPlease note that this Maintenance Manual contains only some of the maintenance tasks on the diesel engine that go beyond the daily and weekly checks. These tasks are to be performed in accordance with the supplied diesel engine manufacturer's operating manuals and maintenance booklets. The engine manufacturer's operating manuals describe how to carry out these maintenance tasks and the maintenance booklets specify the relevant maintenance intervals.

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5.2.1 Maintenance plan D: daily / before start-up D

Maintenance work on the CARRIER:Oil / lubricant

Diesel engine

–Check the oil level; à p.7-6. A

–Checking refrigerant level; à p.7-8.

–Checking the dry air filter; à p.7-9.

Wheels

–Check tyres for damage and sufficient tread depth; à p.7-33.

Carrier hydraulic system

–Checking hydraulic oil level; à p.7-43. G 2

–Check contamination display for hydraulic oil filter; à p.7-46.

Carrier electrical system

–Check lighting and indicators

DMaintenance work on the SUPERSTRUCTURE:Oil / lubricant Quantity (l) / Number Designation à p.6-1

Slewing gear

–Slewing gear brake function check; à p.8-14.

Hoist ropes

–Check the overall condition and position of sheaves and rope drums; à p.8-35.

5.2.2

Maintenance plan W: weekly

Maintenance work on the CARRIER:Oil / lubricant

Diesel engine

–Checking the overall condition and tightness; à p.7-10.

Gearbox

–Checking the overall condition and tightness; à p.7-17.

Distributor gearbox

–Checking the overall condition and tightness; à p.7-21.

Axle lines

–Checking the overall condition and tightness; à p.7-23.

Wheels

–Check the tyre pressure; à p.7-33.

Steering

–Check tightness; à p.7-39.

Carrier compressed air system (incl. brake system)

–Drain compressed air system; à p.7-41.

–Check tightness; à p.7-41.

Carrier hydraulic system

–Check hydraulic hoses; à p.7-44.

–Check tightness (suspension, steering and outrigger systems) while engine is running; à p.7-45.

Carrier central lubrication system

–Check the level of the fuel tank; à p.7-56.

Other maintenance checks

–Check the function of the windscreen washing system of the operator's cab and the level of fluid in the supply reservoir.

Maintenance work on the SUPERSTRUCTURE:Oil / lubricant

Main hoist / auxiliary hoist (additional equipment)

–Check the oil level; à p.8-3.

–Check tightness; à p.8-3.

–Check hoist brake; à p.8-4.

–Lubricating the hoist gears; à p.8-4.

Slewing gear –Check the slewing gear oil level; à p.8-9.

–Check the slewing brake oil level; à p.8-9.

–Check tightness; à p.8-10.

Superstructure hydraulic system

–Check hydraulic hoses; à p.8-15.

–Check for leaks with the engine running; à p.8-15.

Central lubrication system superstructure

–Check the level of the fuel tank; à p.8-51.

Hoist ropes

–Check the condition; à p.8-36.

Other maintenance checks

–Check the function of the windscreen washing system of the crane operator's cab and the level of fluid in the supply reservoir.

5.2.3 Maintenance plan M 1: monthly / after 100 oh / approx. 2 000 km

Maintenance work on the CARRIER: monthly / after approx. 2000 km

Diesel engine

–Details in the Diesel Engine Operating Instructions and in the Diesel Engine Maintenance Booklet. Special notes for the maintenance group and for rapeseed oil operation; à p.7-5.

Distributor gearbox lines –Axle centre drive – check oil level; à p.7-23.

–Check the oil level; à p.7-21.

–Check tightness of wheel nuts; à p.7-34. Tightening torque; à Special tightening torques, p.10-2.

Suspension

–Check oil level in the suspension cylinders; à p.7-37.

–Check retaining bolts of the suspension cylinders; Tightening torque; à Special tightening torques, p.10-2.

Carrier electrical system

–Checking the acid level in the batteries; à p.7-63.

Trailer coupling (additional equipment)

–Lubricating the trailer coupling;2) à p.7-69.

Carrier air conditioning system (additional equipment)

–Checking the moisture and level of the refrigerant; à p.7-65.

–Cleaning capacitor disks; à p.7-66.

Other maintenance work

–Checking for correct operation of the auxiliary heater (additional equipment); à p.7-75.

–Lubricating the outrigger beam1); à p.7-75. 8J

–Lubricate door hinges. 4J

–Lubricate retaining and socket pins.1) div.J / M

1) after 100 oh

2) lubricate the trailer coupling after every high pressure cleaning.

Maintenance work on the SUPERSTRUCTURE: monthly / after 100 oh

Switch coupling (does not apply for cranes starting from 9120) –Switch coupling – check oil level; à p.8-1.

Hook blocks –Lubricate; à p.8-53.

Superstructure hydraulic system

–Bleeding telescoping cylinders; à p.8-19.

–Bleeding the derricking cylinder; à p.8-16. Other maintenance work for correct operation of the auxiliary heater (additional equipment); à p.8-57.

5.2.4 Maintenance plan M 3: every 3 months / after 300 oh / 5 000 – 6 000 km

Maintenance work on the CARRIER: every 3 months / after 5 000 – 6 000 km

Diesel engine

–Pay attention to the details in the Diesel Engine Operating Instructions and Maintenance Manual. Special notes for the maintenance group and for rapeseed oil operation; à p.7-5.

–Clean fuel prefilter-screen; à p.7-11.

Wheels

–Checking wheel-bearing clearance; à p.7-34.

Vehicle brakes

–Check brake-lining thickness; à p.7-35.

Carrier hydraulic system

–Change the hydraulic oil filter, check the magnetic rods of the hydraulic oil filter for metal particles1); à p.7-46.

Carrier electrical system

–Check acid concentration of batteries; à p.7-64.

Trailer coupling (additional equipment)

–Checking the bearing; à p.7-70.

–Checking the cotter pin; à p.7-71.

–Checking the lower bushing; à p.7-72.

–Checking the initial tension of the springs; à p.7-73.

–Checking the function of the coupling jaw / Resetting the middle position; à p.7-73.

–Checking the support ring; à p.7-72.

1) after 300 oh

Maintenance work on the SUPERSTRUCTURE: every 3 months / after 300 oh

Ball slewing connection

–Check tightness of retaining bolts; Tightening torque; à Special tightening torques, p.10-2.

Main boom

–Lubricating the locking pins; à p.8-25. Z

5.2.5 Maintenance plan M 6: every 6 months / after 500 oh / 10 000 – 12 500 km M 6

Maintenance work on the CARRIER: every 6 months / after 10 000 – 12 500 km

Diesel engine

–Pay attention to the details in the Diesel Engine Operating Instructions and Maintenance Manual.

Special notes for the maintenance group and for rapeseed oil operation; à p.7-5.

Distributor gearbox

–Changing the oil; à p.7-22.

Axle lines for8 x 6 x 8 drive; à p.7-31. for8 x 8 x 8 drive (additional equipment); à p.7-31.

–Lubricating the longitudinal cardan shafts between the gear units.

Steering

–Check tightness of screw connections and that the locking pin has been fitted.

–Check all track rods and drag links for play.

–Check rubber sleeves for damage.

Carrier air conditioning system (additional equipment)

–Checking hoses; à p.7-67.

–Checking the refrigerant compressor control; à p.7-68.

5.2.6 Maintenance plan M 12: every 12 months / after 1 000 oh / 20 000 – 25 000 km

Maintenance work on the CARRIER: every 12 months / after 20 000 – 25 000 km

Diesel engine

–Pay attention to the details in the Diesel Engine Operating Instructions and Maintenance Manual. Special notes for the maintenance group and for rapeseed oil operation; à p.7-5.

–Replacing the fuel filter elements; à p.7-13.

Gearbox

–Check the oil level; à p.7-19.

Axle lines axle line axle line (only for additional equipment with 8 x 8 x 8 drive) axle line

–Axle centre drives oil change; à p.7-25.

Carrier compressed air system

–Replacing the granulate cartridge of the compressed air dryer; à p.7-42

Carrier hydraulic system

–Have suspension system pressure accumulators checked by the local GROVE Customer Service or by an authorized workshop.1)

–Replacing the vent filter for the hydraulic oil tank2); à p.7-49.

–Oil change1); à p.7-52, (depending on results of oil test, à p.7-50).

Carrier air conditioning system (additional equipment)

–Monitoring the entire air conditioning system; à p.7-68.

1) every 3 000 oh, however at the latest every 12 months

2) Operation under difficult conditions: work on the SUPERSTRUCTURE: every 12 months / after 1000 oh

–In extremely sandy or dusty environments, the vent filters are to be changed as needed.

–If crane operation involves frequent loading and unloading, the oil change must already take place after 500 operating hours.

–If working in tropical or very hot countries, the oil change intervals must be halved.

1) Carry out at least once a year

5.2.7 Maintenance and inspection plan Y 2: every 24 months / after 100 000–125 000 km Y 2

Maintenance work on the CARRIER: every 24 months

Maintenance work on the SUPERSTRUCTURE: every 24 months

No maintenance work in this period.

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

5.2.8 Maintenance and inspection plan Y 3: every 36 months / after 3000 oh Y

Maintenance work on the CARRIER: every 36 months

No maintenance work in this period.

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

Maintenance work on the SUPERSTRUCTURE: every 36 months / after 3000 oh

Main hoist / auxiliary hoist (additional equipment) –Carry out partial inspection; à p.8-7.

5.2.9 Maintenance and inspection plan Y 6: every 72 months / after 6000 oh Y

Maintenance work on the CARRIER: every 72 months

6

Oil / lubricant

Quantity (l) / Number Designation à p.6-1

No maintenance work in this period. The long-term intervals always include the short-term intervals. Y 6

Maintenance work on the SUPERSTRUCTURE: every 72 months / after 6000 oh

Main hoist / auxiliary hoist (additional equipment) –Carry out general inspection; à p.8-7. à p.5-21.

Oil / lubricant

Quantity (l) / Number Designation à p.6-1

5.3 Periodic inspections

Your GMK 4075 truck crane was inspected before delivery.

–Cranes that are to be used in Germany are inspected in accordance with the regulations of the Professional Trade Association as defined BGVD6 (VBG9).

–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 BGVD6 (VBG9).

According to BGV, 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,

–load hooks (à Load hook inspection, p.5-20),

–the load-bearing structural steelwork (for tears, deformation, etc.), including a special check of all welds.

If damage is found in the structural steelwork, have qualified specialists determine the extent of the damage using the required material examination methods. They should then determine what sort of repair action could be done.

The inspector is to write a record containing the result of the annual inspection and the measures taken to repair any damages.

5.3.1 Load hook inspection

The mouth of the load hook must be checked regularly for deformation.

The mouth of the hook may not be expanded by more than 10% of the original dimension y, y1, y2

The original dimensions y, y1, y2 are held 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 has expanded by over 10% of the initial dimension.

The load hook must consequently be replaced.

GAccidents may occur 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!

5.4 Measures required for winch monitoring

5.4 Measures required for winch monitoring

HAlso observe the information on the general inspection of the hoists; à p.8-7.

These measures for monitoring the winches (hoisting gear) were compiled by VDMA and are to be used for all vehicle cranes according to the Accident Prevention regulations Winches, Hoisting and Tractor Machines BGV D 6 (VGB9) and BGVD8 (VBG8)

5.4.1 Theoretical service life

The theoretical service life is the result of certain operating conditions and a theoretical operating time assumed by the design engineer when calculating and dimensioning the winches of your crane.

The winches of your crane are classified as follows (ISO 4301/1, FEM 1.001, DIN calculation rules for power units):

Power unit group:M......

Load spectrum:Q.....; (L.....)

Load spectrum factor:Km=......

Theoretical service life:D=......

H

The power unit group M 3 and the collective load L1 (Km = 0.125) are generally given for truck cranes in erection mode, resulting in a theoretical service life of 3200 h.

SThe theoretical service life is not the same as the real (actual) service life of a winch.

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 crane.

2. Insufficient maintenance:oil is not changed in the specified intervals done.

3. Incorrect operation:extreme acceleration or retardation of the load, load drops and stops suddenly while suspended.

4. Improper maintenance:using wrong oil, incorrect 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 environmentallow or high temperatures, conditions:aggressive atmosphere, dust and dirt.

5.4.2 Proportion of the theoretical service life used

The crane operator must perform a crane inspection at least once a year (ISO 9927-1 and BGVD6 (VGB 9) / BGV D 8 (VBG8)).

This includes establishing the proportion of the theoretical service life that has been used. If required, the 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 establishing the proportion of the theoretical service life that has been used. The operator is responsible for proper documentation in the crane logbook.

Determining the operating conditions (collective load)

The collective load of the crane is divided into groups: (also refer to ISO 4301/1, FEM 1.001)

HWhen establishing the load spectrum, the existing wire cable is used as a standard, i.e. under certain circumstances, the crane can be supporting 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.

Power units or their parts, which are subjected to highest load as an exception, continuously however only very less load

10% of the operating time with highest load (dead load + 1/1 payload)

40% of the operating time with dead load + 1/3 payload

50% of the operating time only with dead load

Power units or their parts, which are very often subjected to highest load, however continuously less load subjected to load

1/6 of the operating time with highest load (dead load + 1/1 payload)

1/6 of the operating time with dead load +2/3 payload)

1/6 of the operating time with dead load +1/3 payload)

50% of the operating time only with dead load heavy very heavy

Power units or their parts, which are frequently subjected to highest load and continuously to medium load

50% of the operating time with highest load (dead load + 1/1 payload)

50% of the operating time only with dead load0.5

Power units or their parts, which are regularly subjected to loads close to maximum loads.

90% of the operating time with highest load (dead load + 1/1 payload)

10% of the operating time only with dead load1

One of the load spectrums listed above is to 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: In case of truck cranes in erection mode, as a rule, the collective load L 1 is to be given with the collective load factor Km = 0.125.

Determining the actual operating hours Ti

The effective operating hours, determined as follows, must be entered into the crane log book for the corresponding testing interval.

The following two of four possible cases apply to GROVE truck cranes:

–Operating hour counter separate for crane operation

–Operating hour counter for driving and crane operation together

Operating hour counter separate for crane operation

–The proportion of winch operating hours in relation to the total superstructure operating hours must be estimated.

HIt can generally be assumed for hoist winches that the percentage of winch operating hours in relation to the superstructure operating hours will be 20% for truck cranes in installation mode.

–The effective operating hours Ti of the winch can be called up separately and are shown on a display (à Operating Instructions, Chapter Crane Operation, Section Crane work with main boom).

Operating hour counter for driving and crane operation together

The proportion of winch operating hours in relation to the total crane operating hours is to be estimated.

HIt can generally be assumed that the percentage of superstructure operating hours in relation to the crane operating hours will be 60% for truck cranes in installation mode. If the percentage of hoist winch operating hours is assumed to be 20% in relation to superstructure operating hours (à Operating hour counter is functional for entire crane operation), the percentage in relation to the total operating hours of the crane will be: 12%.

Determining the proportion of the theoretical service life used

For a testing interval i (max. 1 year according to ISO 9927-1 or BGVD6 (VBG9) / BGVD8 (VBG8)) the used proportion of the theoretical service life Si is calculated using the formula:

Km =Load spectrum factorestablished during winch calculation. was established. This factor is given in the Operating Instructions. zu entnehmen.

Kmi =Load collective factor in inspection interval i according to "Determining the operating conditions (collective load)"

Ti =Actual operating hours for inspection interval i according to Section "Determining the actual 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 chapter).

A general overhaul must be performed on the winch if the remaining theoretical service life is not likely to be sufficient for the next operating period.

If the 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 crane.

The general overhaul is to be arranged by the operator and performed by the manufacturer or his 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 provision

If, after ten years, the theoretical service live is not over, the winch 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 useful by signing his/her name in the crane test book after every inspection.

In this case, the crane expert must closely inspect the winch. At the minimum, this includes:

–a visual inspection of the exterior (for leaks, damage, deformations, etc.)

–an oil inspection (especially for metallic residue)

–a load inspection with minimum and maximum wire cable lengths and each with maximum possible speed. At least one position is to be wound. Pay attention 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.

5.4.3 Example

A truck crane with a separate operating hour counter for driving and crane operation is classified by the manufacturer according to the Operating Instructions as follows:

Power unit group:M 3

Load spectrum:light L 1, Km = 0.125

Theoretical service life:D = 3200 h

The used proportion S of the theoretical service life is calculated over the individual inspection intervals as follows:

1.

The crane was used for assembly work during the previous year: Collective load L 1, i.e. Km1 = 0.125.

The superstructure operating hour counter reads 800 h. The winch was operated 20% of the time, i.e. T1 = 160 h.

The used proportion S1 of the theoretical service life after the first inspection is therefore:

S i 0.125 0.125 - 160 h × 160 h ==

Remaining theoretical service life:

D1 = 3200 h – 160 h = 3040 h.

The aforementioned values are entered in the table (see example table p. 5-29).

2.

The crane was used for unloading work on docks: Load spectrum: L 3, i.e. Km2 = 0.5.

The superstructure operating hour counter reads 2000 h, i.e. during this period: 2000 h – 800 h = 1200 h (800 h were used during the first year).

The winch was operated 40% of the time, i.e. T2 = 480 h.

The used proportion S2 of the theoretical service life after the second inspection interval is therefore:

S i 0.5 0.125 - 480 h × 1120 h ==

Remaining theoretical service life:

D2 = 3040 h – 1920 h = 1120 h.

The aforementioned values are entered in the table (see example table p. 5-29).

3. Inspection (third year)

The crane was used for assembly work and occasional unloading work on docks: Load spectrum: L 2, i.e. Km3 = 0.25.

Three thousand hours are read at the superstructure working hour meter; i.e., during this period: 3.000 h – 2.000 h = 1.000 h (2.000 h are used in the first two years of operation).

The winch was operated 30% of the time, i.e. T3 = 300 h.

The used proportion S3 of the theoretical service life after the third inspection interval is therefore:

S i 0.25 0.125 - 300 h × 600 h ==

Remaining theoretical service life:

D3 = 1120 h – 600 h = 520 h.

The aforementioned values are entered in the table (see example table p. 5-29).

The remaining theoretical service life is to be documented in a separate table for each winch.

This table is to be attached to the crane logbook. This table is found in the Maintenance Manual appendix for truck cranes that do not require a crane logbook or similar documentation according to the regulations of the respective country.

Table example to determine the remaining theoretical service life on winch no. 1 (main hoist winch)

Serial number of the winch in accordance with the model plate:13 301 Last general overhaul performed on:

Winch design data (see Operating Instructions): Drive gear

Copy last line of the previous page to the following pages general overhaul performed on:..................................

CAUTION : A general overhaul is to be performed every 10 years! Alternative provision, refer to section 5.4.2, S.5-22.

Blank page remaining theoreticalservice life of winch no. 1 (main hoist winch)

Lubricants and fuels

6.1 Lubricant table

1) See engine operating instructions

2) Available from local GROVE Customer Support

3) Synthetic oil filled at the factory; do not mix with mineral oil.

Lubricants and fuels

6.1 Lubricant table

NameLubricating point

Type of lubrication

Name according to DIN 51502

Specification Classification

Lubricant type Viscosity range

M Lubricating points (lubricating oil)

Oil can, high pressure jet oil can as A (Diesel engine)

V Open-running gear wheels Adhesive lubrication

W Mounting screws, bushings, etc.

X Slip ring assembly Corrosion protection

Z Locking pins, derricking cylinder

GROVE part no. 0554 2052)

GROVE part no. 1573 0462)

GROVE part no. 3315 0602)

Spray oil containing molybdenum disulphide (MoS2)

6.2 Process materials

6.2.1 Fuel

The diesel fuels that may be used and their respective specifications may be found in the engine operating manual.

6.2.2 Engine coolant admixtures

The specifications and admixture ratios may be found in the engine operating manual.

6.2.3 Windscreen washing system admixtures

Commercial cleansers and antifreeze may be added to the windscreen washing water. Observe the application instructions on the package.

6.2.4 Fuel for crane cab heating system

You should use either the fuel specified in section 6.2.1 or EL heating oil as heating fuel for the crane cab.

Blank page

7

Description of maintenance work on the carrier

7.1 Tilt driver’s cab forward

For carrying out various maintenance work (e.g. oil change switch coupling) you must tilt the driver’s cab forward. This means that the diesel engine needs to be started.

HIf the diesel engine cannot be started, the boom must be raised using the emergency operation facility; à Operating instructions GMK 4075, Carrier operation malfunctions, Emergency operation for lifting the main boom

Prerequisites and information on tilting

Before tilting the driver’s cab the following requirements must be met:

–All loose objects must be removed from the driver's cab.

–The main boom is raised to the extent (approx. 1.5 m) that the driver's cab will not touch the main boom (nor the hose drum if equipped with one) when tilting.

–Ensure that the hook block is at a sufficient distance from the windscreen when tilting.

SThe universal joint on the steering column may break. The steering angle must not be altered when the driver's cab is tilted. Otherwise, the universal joint on the steering column may break.

Unlock the driver's cab mechanically and attach to suitable hoist gear for tilting.

Unlocking / locking the driver’s cab

Unlock the driver’s cab before tilting it forward. Lock the driver’s cab again once you have brought it back to its initial position.

The driver’s cab is locked on both sides at the back with a bolt on the vehicle chassis.

To unlock, release the retaining pins (3) and pull the bolt (1) out of the clamps (2). Also pull the bolt out on the other side.

To lock, push the bolt (1) through the clamps (2) and secure it with the retaining pin (3). Also push the bolt in on the other side.

Driver’s cab tilting Observe the prerequisites stated at the beginning of section à Prerequisites and information on tilting, p.7-1. Before tilting the driver’s cab.

You need to attach and lift the driver’s cab to tilt it. You can attach the driver’s cab to the truck crane yourself and lift it with the main hoist gear or you can use other suitable hoist gear (e.g. an overhead crane in a hall).

• Remove all loose objects from the driver’s cab and close the doors.

GRisk of accidents from toppling objects and doors swinging open. Remove all loose objects (e.g. bags, bottles etc.) from the driver’s cab so that they will not topple when tilting and close all the doors of the driver’s cab.

This prevents liquids from getting into the inserts and doors from swinging open during tilting and injuring people.

GRisk of accidents due to driver’s cab tilting. When you are tilting the driver’s cab forward and while it is actually tilted forward, nobody may be in front of the driver’s cab.

SDanger of damage when the driver’s cab is tilting!

When lifting the driver’s cab, the angle between the roof of the driver’s cab and the slinging rope must always be larger than 45°. Therefore, use only sling gear which is long enough. If the sling gear is too short, the angle will be less than 45° and the ring bolts and the threads may become overloaded.

Two ring bolts (2) are supplied for slinging the driver’s cab.

• Screw the two ring bolts (2) into the threaded bores located at the rear on the driver’s cab.

• Fasten a rope (1) to each ring bolt.

• Fasten the loose ends of the rope to the hook block of the truck crane or to any other suitable lifting gear.

• Ensure that the angle A is always larger than 45° when lifting.

When the driver's cab tilts, the support (2) is pulled apart.

• Tilt the driver’s cab to the extent that it will tilt over the pivot point and the support is pulled under tension.

In this position the spring latch engages (1) (handle points downwards) and secures the driver’s cab against unintentional tilting backwards.

GRisk of accidents due to the driver’s cab tilting back.

You may only stand under the tilted driver's cab if the driver's cab has tightened the wire rope between driver's cab and vehicle chassis.

Lowering the driver’s cab

Before lowering the driver’s cab, you must unlock the support.

GRisk of crushing due to the driver’s cab tilting back. Before unlocking the support, ensure that the driver’s cab is tightening the support or that the driver’s cab is secured against tilting back with the securing equipment.

By doing this, you are preventing the driver’s cab from accidentally tilting back when unlocking the support, and preventing you or other people from being crushed.

• Release the spring latch while also turning the handle (1) upwards.

• Lower the driver’s cab until it is set down on the vehicle chassis.

When the driver’s cab (2) is lowered, the support is pushed in and the stop (3) turns the handle on the spring latch back to the correct position for locking when the cab is next tilted.

• Remove the two ropes (1) from the ring bolts.

• Screw the ring bolts (2) out of the threaded bores.

• Store the ring bolts and the ropes safely, ready for driving.

• Lock the driver’s cab with the two bolts; à Unlocking / locking the driver’s cab, p.7-2.

GAccidents may occur if the driver’s cab is not locked. Relock the driver’s cab to the vehicle chassis with the bolts after having lowered it. This prevents the driver’s cab from tilting forward (unter the boom) when braking.

7.2 Diesel engine

Follow the instructions in the supplied Diesel Engine Operating Instructions for maintenance work which exceeds the scope of the daily work.

SRisk of damage to the engine.

The vehicle engine is in maintenance group II (difficult operation) because of the high full-load rate or large fuel supply rate.

If the diesel engine is operated with rapeseed oil fatty acid methylester (RME), the engine oil change intervals must be halved.

The release of engines for RME operation is regulated by the Diesel engine Service information.

For various jobs (e.g. changing the fuel filter) you must remove the covers on the carrier above the diesel engine, gearbox and the first axle line.

• For this open the plugs on both sides with a hexagon socket spanner and remove the covers (1).

7.2.1 Diesel engine – oil level check

The oil dip stick (1) for the diesel engine is on the left-hand side, in front of the boom support.

SDamage may occur to the engine if the oil pressure is too low! If no oil pressure is displayed after 10 seconds, turn off the diesel engine and look for the cause; à Operating Manual, chapter Carrier malfunctions, Section Diesel engine malfunctions

• Start the diesel engine and let it run for 2-3 minutes at idling speed. Monitor the oil pressure display.

• Turn off the diesel engine.

• Check the oil level after approx. 2 minutes. The oil level must be between min and max (arrow marks).

• Top up engine oil if necessary, à Diesel motor – top up the oil level, p.7-7.

7.2.2 Diesel motor – top up the oil level

For details regarding required oil specifications, refer to the diesel engine operating instructions.

The oil filler (1) for the diesel engine is located at the front right on the carrier, next to the charge air cooler.

• Refill the motor oil through the fillerneck (1).

• Check the oil level on the dipstick.

SDamage may occur to the engine if the oil level is too high. Do not overfill; the oil level must not be higher than the highest arrow marking (max.).

7.2.3 Checking coolant level

The coolant reservoir is located on the left-hand side of the carrier behind the driver’s cab.

GDanger of scalding when diesel engine is hot. The radiator is hot and under pressure. You could burn yourself on the hot radiator, escaping steam or any escaping coolant if you remove the lid of the radiator when the diesel engine is hot. Wear suitable protective gloves and cover the radiator cap with a cloth before opening it. Turn the radiator cap lid slowly to the first notch in order to allow the excess pressure to be released.

Do not open the pressure relief valve (2) on the side of the expansion tank.

• Loosen (do not open) the cap on the filling hole (1) with the coolant at operating temperature to release the pressure.

• Open the cap. The coolant must reach the lower edge of the pipe in the filler neck.

If the coolant level is too low:

• Top up the coolant. See the diesel engine operating instructions for the composition of the coolant.

• Screw on the filling hole cap until it stops.

SRisk of damage to the engine due to lack of coolant. If the coolant has to be topped up frequently, the cooling system may be leaking. Have GROVE Customer Service or your repair crew check the cooling system and repair the damage.

7.2.4 Checking the dry air filter

The dry air filter is on the right-hand side of the carrier, behind the first axle line.

The Diesel engine air filter indicator lamp is on the front instrument panel ofthe driver’s cab. If this indicator lamp lights up, the dry air filter must be replaced.

• Release all clamps (1) on the filter lid.

• Take off the filter lid (2).

• Extract the filter cartridge (1).

• Insert a new filter cartridge.

If the seal on the filter lid is worn:

• Change the seal.

• Put the filter lid back in place and secure it with all the clamps.

7.2.5 Checking general condition and for leaks

• Check the pipe lines and hoses for –tightness, –leaks, –abrasions.

• Replace any damaged pipes and porous or swollen hoses.

• Tighten any connections that are leaking.

If the connection still leaks:

• Change the seal.

• Inspect the diesel engine for any visually obvious fouling or leaks.

• Listen out for any unusual noises from the diesel engine.

If damage cannot be rectified immediately or further damage is likely:

• Inform your local GROVE Customer Service or your repair crew.

7.2.6 Cleaning the fuel prefilter screen

HBefore cleaning the primary fuel filter, you must block off the fuel pipe from the tank, à Shutting off and emptying the fuel line, p.7-13. Cleaning

The fuel prefilter (1) is under the carrier’s rear cover on the right hand side next to the automatic gearbox.

OHave a container or cleaning rag ready so that you can catch the draining fuel. Wipe up any fuel which is not caught. Store used fuel filter cartidges in suitable containers and dispose of them properly.

• Open the tank cap in order to prevent excess pressure in the fuel tank.

• Unscrew the prefilter’s filter container (1).

• Clean the filter container and filter screen (2) with clean diesel fuel using a soft brush. Replace a heavily soiled or damaged filter screen.

• Check and, if necessary, replace the sealing ring (3) in the filter lid.

• Insert the filter screen into the filter container and screw it again onto the prefilter. Tightening torque 10 Nm.

• Bleed the fuel system as described in the following section.

Bleeding the fuel system

• Release the hand pump by turning the knurled screw (4, top picture) to the left.

The knurled screw is also the hand pump’s handle.

• Pump up and down until the resistance noticeably increases.

• Insert the hand pump and tighten the knurled screw again.

• Start the engine and check the prefilter for tightness.

7.2.7 Changing the fuel filter cartridge

Shutting off and emptying the fuel line

Before changing the fuel filter cartridge you must: –shut off the fuel line to the diesel tank and –empty the fuel line

OAlways use a fuel-resistant container with sufficient capacity into which the fuel line is emptied. Make sure that no fuel runs out and seeps into the ground.

Shutting off the fuel line

A shut-off valve is in the fuel line under the carrier's rear cover on the right hand side next to the automatic gearbox.

• Close the tap. Turn the handle (1) so that it is perpendicular to the fuel line.

Emptying the fuel line

The fuel line is emptied via a hose pipe. The end of the hose line (1) is to the right beside the automatic gearbox. The hose is accessible through an opening in the base plate of the carrier frame.

• Slightly cramp the steering.

• Guide the hose through an opening in the base plate.

• Place a container suitable for collecting fuel (e.g. a drip pan) underneath the end of the hose (capacity approx. 5 l).

For the purpose of emptying the fuel line a 3-way-tap(1) is provided at the rear on the automatic gearbox.

• Turn the handle on the 3-way-tap so that it is diagonal to the pipe.

The fuel now flows into the collecting vessel.

• Leave the vessel underneath the end of the hose. More fuel can escape when changing the fuel filter cartridge.

Changing the fuel filter cartridge

The fuel filter insert is underneath the boom support at the front left on the diesel engine ( à Diesel engine operating instructions ). In order to easily access the fuel filter insert tilt the driver’s cab, à Tilt driver’s cab forward, p.7-1.

• Unscrew the screw cap (1) with the filter insert (3) and pull it a bit out of the filter housing.

Let the rest of the fuel drain off.

• Remove the screw cap with the filter cartridge and remove the cartridge by applying pressure on the sides of the lower edge.

• Replace the rubber sealing ring (2) (lubricate lightly).

• Clip a new filter cartridge onto the screw cap.

• Replace the cap with cartridge and tighten it. Tightening torque 25 Nm.

OStore used fuel filter cartidges in suitable containers and dispose of them properly.

After changing the filter insert After changing the fuel filter insert, you must re-establish the state of operation.

• Turn the handle on the 3-way tap (1) so that it is lengthways to the pipe.

• Remove the collecting vessel underneath the end of the hose.

If you have used a clean collecting vessel, you can refill the diesel tank with fuel using a sieve. Otherwise you must collect the fuel for disposal.

• Push the hose end through the opening in the base plate of the carrier frame.

• Attach the hose end to the right frame wall.

• Open the shut off tap in the fuel line by turning the handle (1) until it is parallel to the fuel line.

• Bleed the fuel pipe using the hand pump on the fuel prefilter; à Bleeding the fuel system, p.7-12.

• Start the engine and check that the fuel filter is leak-tight.

7.3 Gearbox

The gearbox is located inside the carrier above the first axle line.

7.3.1 Checking general condition and for leaks

• Make a visual inspection for leaks.

• Listen carefully for any abnormal noises when the transmission is engaged.

If damage cannot be rectified immediately or further damage is likely:

• Inform your local GROVE Customer Service or your repair crew.

7.3.2 Gearbox – oil level check

The gearbox is located inside the carrier above the first axle line.

SDamage may occur to the gearbox. The correct oil level must be maintained to ensure smooth operation of the gearbox:

– too low oil level leads to malfunctions,

– too high oil level leads to drive-through losses and overheating.

Prerequisites:

To check the oil level:

–the truck crane must be aligned horizontally, –the parking brake must be locked, –the gearbox must be in neutral position N, –the diesel engine must be turned off, –the truck crane must be secured to prevent unauthorized use.

GRisk of scalding. If the oil is at operating temperature, do not let it drain unchecked.

The oil level is checked through an inspection hole at the right of the gearbox.

• Remove the cover plate (1) from the gear box.

• Remove the screw (2) from the inspectionhole.

If the oil level is too low:

• Top up oil through the inspection hole using only oil as specified in the Maintenance plan, p.5-14.

• Close the inspection hole again with the screw (2).

• Secure the cover plate (1) on the gearbox.

7.3.3 Gear box – oil change

The oil is drained via the oil drain opening in the gear box and filled via the inspection hole.

Use only oil as specified in the Maintenance plan, p.5-17.

GRisk of scalding.

If the oil is at operating temperature, do not let it drain unchecked.

OWhen changing the oil filter, always use a drip pan which is suitable for oil and which has a sufficient capacity. When changing the filter and filling oil, make sure that no oil spills and soaks into the ground.

HBefore starting this work, lift the truck crane with the outrigger or park it over an inspection pit.

Draining gear lubricant oil

• Insert a funnel into the drain hole in the base plate under the gear box.

• Place a container (capacity approx. 15 l) underneath the drain hole to collect the oil.

• Remove the screw (1) from the inspectionhole.

• Unscrew the oil drain screw (2) and let the oil flow into the collection container.

OCollect old oil in approved containers and have used oil and oil filters disposed of properly.

Topping up gear lubricant oil

• Clean the magnetic plug of the oil drain plug (2), replace the sealing ring and close the outlet (à Special tightening torques, p.10-2).

• Top up the oil through the inspection hole on the gearbox (à Wartungsplan, S.5-16).

• Check the oil level at the inspection hole. The oil must be filled to the lower edge of the inspection hole.

• Replace the sealing ring and close the inspection hole with the screw (1) (à Special tightening torques, p.10-2).

After topping up the oil, you must carry out the following checks for leak tightness:

• Start the diesel engine and let it idle in neutral position N.

• Check the tightness of oil drain screws.

7.4 Transfer case

The transfer case is between the second and third axle lines.

7.4.1 Checking general condition and for leaks

• Make a visual inspection for leaks.

• Listen out for any unusual noises from the transfer case. If damage cannot be rectified immediately or further damage is likely:

• Inform your local GROVE Customer Service or your repair crew.

7.4.2 Distributor gearbox – oil level check

The oil level must be checked on the front of the transfer case with the engine turned off and the truck crane in horizontal position.

• Remove the screw (1) from the inspectionhole.

• Check the oil level. The level must be just underneath the inspection hole.

If the oil level is too low:

• Top up oil via the inspection hole (1). Use only oil as specified in the Maintenance plan, p.5-8.

• Close the inspection hole with the screw ( 1).

7.4.3 Distributor gearbox – oil change

Use only oil as specified in the Maintenance plan, p.5-12.

HRaise the truck crane with the outriggers or park it over an inspection pit.

OAlways use oil collection containers, funnels or filling pumps which are resistant to oil. Wipe up spilled oil immediately.

The oil must be changed when the engine is turned off and the truck crane is in horizontal position. The oil drain screw is at the bottom of the transfer case.

• Place an oil collection container (capacity approx. 15 l) underneath the oil drain screw (3).

• Remove the screw (1) from the inspectionhole.

• Unscrew the oil drain screw (3) and let the oil flow into the collection container.

• Replace the sealing ring and reinsert the oil drain screw.

• Top up oil through the inspection hole using only oil as specified in the Maintenance plan, p.5-12.

• Check the oil level (à Distributor gearbox –oil level check, p.7-21).

• Replace the sealing ring and close the inspection hole with the screw (1).

OCollect old oil in approved containers and have it disposed of properly.

7.5 Axle lines

7.5.1 Checking general condition and for leaks

• Make a visual inspection for leaks.

• Listen out for any unusual noises from the axle centre drives and final drives.

If damage cannot be rectified immediately or further damage is likely:

• Inform your local GROVE Customer Service or your repair crew.

7.5.2 Axle centre drives – oil level check

The position and number of inspection holes sometimes differs with the axle lines.

The first and the fourth axle line

On the first axle line, the inspection hole is at the front. The inspection hole is at the back of the fourth axle line.

• Remove the screw (1) from the inspectionhole.

• Check the oil level, the oil level must be just underneath the inspection hole.

If the oil level is too low:

• Top up oil through the inspection hole using only oil as specified in the Maintenance plan, p.5-8.

• Replace the sealing ring and close the inspection hole again with the screw (1).

HThe axle centre drive on the second axle line is available only as additional equipment with a 8 x 8 x 8 drive.

The second axle line

The inspection hole is at the back of the second axle line.

• Check the oil level in the same way as is described for the first and the fourth axle lines.

The third axle line

The axle centre drive of the third axle line has two inspection holes: in front –the inspection hole (2) at rear – the inspection hole (1).

• Check the oil level in the same way as is described for the first and the fourth axle lines.

7.5.3 Axle centre drives – oil change

Use only oil as specified in the Maintenance plan, p.5-14.

HRaise the truck crane with the outriggers or park it over an inspection pit.

OAlways use oil collection containers, funnels or filling pumps which are resistant to oil.

Wipe up spilled oil immediately.

• Turn off the diesel engine to change the oil.

The first and the fourth axle line

• Place an oil collection container (capacity approx. 20 l) under the oil drainscrew (2).

• Remove the screw (1) from the inspectionhole.

• Unscrew the oil drain screw (2) and let the oil flow into the collection container.

• Replace the sealing ring and reinsert the oil drain screw.

• Top up oil via the inspection hole (1). Use only oil as specified in the Maintenance plan, p.5-12.

• Check the oil level (à Axle centre drives – oil level check , p.7-23).

• Replace the sealing ring and close the inspection hole again with the screw (1).

OCollect the old oil in permitted containers and only have it disposed of by approved disposal companies.

HThe axle centre drive on the second axle line is available only as additional equipment with a 8 x 8 x 8 drive.

The second axle line

• Place an oil collection container (capacity approx. 20 l) underneath the oil drain screw (2).

• Change the oil in the same way as is described for the axle drives on the first and the fourth fifth axle lines.

The third axle line

• The axle centre drive of the third axle line has two oil drain screws: below – the oil change screw (4) in front – the oil change screw (3).

• Place an oil collection container (capacity approx. 20 l) under the oil drainscrews (3) and (4).

• Change the oil on both oil drain screws in the same way as is described for the axle drives on the first and fourth axle lines.

7.5.4 Final drives – oil level check

Every final drive has an inspection hole.

• Raise the truck crane with the outrigger and release the parking brake.

• Turn the wheel so that the oil check mark (2) is horizontal and is on the right next to the centre of the axle.

• Remove the screw (1) from the inspectionhole.

• Check the oil level, the oil level must be at the check mark (2).

If the oil level is too low:

• Top up oil through the inspection hole using only oil as specified in the Maintenance plan, p.5-8.

• Replace the sealing ring and close the inspection hole again with the screw (1).

Also check the oil level on all other final drives.

7.5.5 Final drives – oil change

• Raise the truck crane with the outrigger and release the parking brake.

OAlways use oil collection containers, funnels or filling pumps which are resistant to oil. Wipe up spilled oil immediately.

• Place an oil collection container (capacity approx. 4 l) under the wheel.

• Remove the screw (1) from the inspection hole.

• Turn the wheel until the opening is pointing downwards and drain the oil into the collecting vessel.

• Turn the wheel back so that the oil check mark (2) is horizontal and is on the right next to the centre of the axle.

• Top up oil through the inspection hole (1) and use only oil which is specified in the Maintenance plan, p.5-14.

• Check the oil level, the oil level must be at the check mark (2).

• Check the oil level (à Final drives – oil level check, p.7-27).

• Replace the sealing ring and close the inspection hole again with the screw (1).

OCollect the old oil in permitted containers and only have it disposed of by approved disposal companies.

7.5.6 Lubricating the cardan shafts on the axle lines

The cardan shafts are between the axle centre drives and the final drives.

HIf the cardan shaft was not equipped at the factory with a lubricating nipple, then it is a maintenance-free version. After carrying out repairs on a cardan shaft check if maintenance-free cardan shafts were installed. The activities described in the following section would then no longer apply.

The cardan shafts must be lubricated with a grease gun. Use only oil as specified in the Maintenance plan, p.5-8.

SRisk of damaging the sealing lips. Do not apply hard lubricants to avoid damage to the sealing lips.

Number and position of lubrication points

There are two cardan shafts on every driven axle line. The following table shows the position and number of lubricating nipples on both cardan shafts for all driven axle lines.

Cardan shaftsLubricating nipple inner 1) outer 2)

1st axle line24

2nd axle line (only with 8 x 8 x 8 drive)22

3rd axle line22

4th axle line22

HThe cardan shafts on the second axle line are available only as additional equipment with a 8 x 8 x 8 drive.

Cardan shafts first axle line lubricate

On the first axle line there are outer double joints and inside on the axle centre drive one single joint.

The signle joint on the axle centre drive has a lubricating nipple (3). There are two lubricating nipples (1) and (2) on every double joint. To lubricate the outer lubricating nipple (1) on the joints, the wheels must be turned to their fullest extent.

• Remove the old grease and dirt from the lubricating nipples.

• Press lubricating grease into the lubricating nipples until new grease comes out of the respective bearing points.

• Remove the surplus new grease.

• Lubricate the second cardan joint in the same way.

Cardan shafts second lubricate up to the fourth axle line

There are single joints on the second (additional equipment), fourth and fifth axle lines inside and outside.

There is a lubricating nipple (1) and (2) on every single joint.

• Remove the old grease and dirt from the lubricating nipple.

• Press lubricating grease into the lubricating nipple until new grease comes out of the corresponding bearing point.

• Remove the surplus new grease.

7.5.7 Longitudinal cardan shafts between the gear units lubricate

The longitudinal cardan shafts are between the automatic gearbox and the transfer case, between the transfer case and the axle centre drives and between the axle centre drives.

HIf the (longitudinal) cardan shafts were not equipped at the factory with a lubricating nipple, then it is a maintenance-free version. After carrying out repairs on a cardan shaft check if maintenance-free cardan shafts were installed.

The activities described in the following section would then no longer apply.

The (longitudinal) cardan shafts must be lubricated with a grease gun. Use only oil as specified in the Maintenance plan, p.5-12.

SRisk of damaging the sealing lips. Do not apply hard lubricants to avoid damage to the sealing lips.

The following table shows the location and number of the lubricating nipples on the individual cardan shafts:

(Longitudinal) cardan shaft between ...Lubricating nipple

Gearbox and transfer case11

Transfer case and the first axle line11

Transfer case and the second axle line1) 11

Transfer case and the third axle line11

First axle line and the second axle line1) 11

Third axle line and the fourth axle line11

1) Only for 8 x 8 x 8 drive (additional equipment).

Lubricating longitudinal cardan shafts

Lubrication with all longitudinal cardan shafts is done in the same way.

There are two lubricating nipples (1) and (2) on every longitudinal cardan shaft.

• Remove the old grease and dirt from the lubricating nipples.

• Press lubricating grease into the lubricating nipples until new grease comes out of the respective bearing points.

• Remove any spilling grease.

7.6 Wheels

7.6.1 Checking the tyres for damage

• Check the tyres for:

–chunking

–dents

–areas with 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.

SAlways replace all the tyres on an axle.

7.6.2 Check the tyre pressure

SWhen replacing tyres, please note that tyres from other manufacturers must have the same load bearing capacity and thus the same tyre pressure as the initial equipment.

• Check that the new tyre pressures conform to the values in the table.

7.6.3 Check tightness of wheel nuts

• With a torque wrench, check that the wheel nuts are tight crosswise in the order shown in the illustration.

Torque for wheel nuts: 650 Nm

Check the wheel nuts for tightness after a wheel change after a distance of 50 km and again after a distance of 150 km.

7.6.4 Checking the wheel-bearing clearance

• Raise the truck crane with the outriggers. Release the parking brake.

• Press against the bottom of the wheel with one foot and, using both hands, try to move the wheel in the bearing at the same time.

If the check shows there is too much play:

• Have the wheel-bearing clearance adjusted or wheel bearings replaced by GROVE Customer Support service at the particular location or by your own repair crew.

7.7 Vehicle brakes

7.7.1 Checking brake-lining thickness

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 the rubber plug (1), (2) and shine a torch into the opening.

If the brake-lining thickness has reached the wearmarks (stepped edges or grooves), or if the brake-lining thickness is only 3 mm:

• Have the brake linings replaced by GROVE Customer Support service or an authorised service centre.

SAlways replace all brake-linings on an axle line.

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7.8 Suspension

7.8.1 Telescopic leg – oil level check

The suspension cylinders of the individual wheel suspension units are bolted to the vehicle frame (carrier).

• Use the level adjustment system to lower the truck crane completely and then raise it to on-the-road level again (à Operating manual , Chapter Driving with the truck crane, Section Vehicle height control). H

The initial complete lowering is necessary to prevent incorrect oil level.

SIf the oil level is above the upper marking on the inspection glass the suspension cylinder is defective and must be replaced. Inform the GROVE Customer Support.

• Check the oil level at the relevant inspection glass (1). The oil level must be between the markings.

If the oil level is too low:

• Screw the high pressure squirt gun (supplied tool) to the filler connection (2).

• Inject oil up to the level of the lower marking. Use only oil as specified in the Maintenance plan, p.5-8.

SIt is difficult to inject the oil. Even so, do not fill oil through the inspection glass connections. It would not reach all lubricating points.

7.8.2 Tightness of retaining bolts on the suspension cylinders to be checked

• Check the tightening torques of the retaining bolts:

–Vehicle frame/guide case upper (1)

–Vehicle frame/guide case below (2)

–Support element/steering split shell (3)

–Support element/operating head (4)

The tightening torques can be found in Special tightening torques, p.10-2.

7.9 Steering

7.9.1 Checking for leaks

W• Check the hydraulic steering system (steering cylinders, pipes and hoses, and all connections) for leaks.

GRisk of accidents.

Never tighten leaking connections when the system is under pressure. Change pipes and hoses only when the system is depressurized.

• Top up hydraulic oil according to (à Hydraulic unit – oil level check, p.7-43).

After changing pipes and hoses:

• Bleed the carrier hydraulic system (à Changing the hydraulic oil, p.7-52).

If damage cannot be rectified immediately or further damage is likely:

• Inform your GROVE Customer Support service or your repair crew.

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7.10 Carrier compressed air system

7.10.1 Draining the compressed air system

Moisture must be drained from the compressed air system through the drain valves of the four compressed air reservoirs and the conditioning unit. A functional check of the compressed air drier is carried out simultaneously. The compressed air reservoirs are located beneath the rear and front parts of the carrier. The conditioning unit is located on the right under the driver’s cab and is accessible from below.

• Operate the drain valves (2), the drain valve of the conditioning unit (1) is shown here as an example.

If the respective drain valve does not close after being actuated several times:

• Change the drain valve.

7.10.2

If a lot of moisture escapes from the air reservoirs:

• Have the compressed air drier checked or replaced by your repair crew.

Compressed air system – check for leakage

• Start up the compressed air system.

• Check all points in the compressed air system (connections, pipes, hoses and valves) where air could possibly escape.

Risk of accidents.

Never tighten connections when the system is under pressure. Only change seals, pipes and hoses when the system is depressurized.

If damage cannot be rectified immediately or further damage is likely:

• Inform your GROVE Customer Support service or your repair crew.

7.10.3 Replacing the granulate cartridge of the compressed air dryer

The granulate cartridge is located on the right under the driver’s cab and is accessible from below.

GRisk of injury.

If the conditioning unit is not completely empty, the air drier will be under pressure.

• Release all the air from the conditioning unit(3) via the drain valve (4).

• Unscrew the granulate cartridge (attached to the cover hood) (1) using a strap wrench.

• Change the granulate cartridge. Grease the sealing ring lightly before screwing into place.

7.11 Carrier hydraulic system

7.11.1 Hydraulic unit – oil level check

The hydraulic oil tank is on the left-hand side of the carrier behind the driver’s cab. The level can be checked through the inspection glass.

To check the oil level:

–the truck crane must be in the position On-road driving (à Operating Instructions, Chapter Driving with the truck crane, Section Vehicle height control);

–outrigger beams and outrigger cylinders must be retracted (à Operating Instructions, Chapter Rigging work , Section Outriggers).

• Check the level of the hydraulic oil tank through the inspection glass (1). The hydraulic oil must be visible in the centre of the inspection glass.

If the level is too low:

• Top up the hydraulic oil through the filler opening (2). Use only oil as specified in the Maintenance plan, p.5-5.

SBe careful not to damage the hydraulic system. When handling hydraulic oil cleanliness is imperative. New oil must also be filtered.

7.11.2 Checking the hydraulic hoses

Hydraulic hoses are subject to ageing as well as internal and external stresses.

• Check the hydraulic hoses for –external damages (tears, abrasion) effect of heat, chemical effects), –leaks and moist areas, –blistering or unevenness of hose casing, –signs of ageing (porous upper surface rust on hose fittings).

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 fitting:

–The first 4 numbers (1) indicate the month and year of manufacturing.

–The letters P and N and the last 3 numbers (2) indicate the permitted operating pressure.

• Damaged or old hydraulic hoses must be replaced immediately. Always ensure that the corresponding parts of the hydraulic system are depressurized in advance.

7.11.3 Checking for leaks

• With the diesel engine running, carry out a visual inspection for leaks and escaping hydraulic oil at the suspension cylinders, outriggers, hydraulic lines (hoses and pipes) and connections.

Hydraulic oil through.

• If leaks are detected, check the hydraulic oil level and top up if necessary according to (à Hydraulic unit – oil level check, p.7-43).

GRisk of accidents.

Never tighten any leaking connections when the system is under pressure. Only change pipes and hoses when the system is depressurized.

After parts have been changed:

• Bleed the carrier hydraulic system (à Changing the hydraulic oil, p.7-52).

If damage cannot be rectified immediately or further damage is likely:

• Inform your local GROVE Customer Service or your repair crew.

OImmediately repair or have repaired leakages in the hydraulic system to ensure that no hydraulic oil escapes, seeps into the ground or reaches waters when the crane is being used.

7.11.4 Changing the hydraulic oil filters and cleaning the magnetic rod

There are two hydraulic oil filters (return filters) in the hydraulic tank and a hydraulic oil filter in the control circuit in the superstructure. The hydraulic oil filters must be changed: g–when the warning lamp for the hydraulic oil return filter in the front instrument panel of the driver's cab lights up and –after every hydraulic oil change.

Turn off the diesel engine and depressurize the hydraulic system.

• Remove the nuts on the filter cover (1) and remove the hydraulic oil filters from the hydraulic oil tank.

• Unscrew all screws (1) and remove the top parts of the filter (2).

• Unscrew the magnetic rods (4) and clean them.

SBe careful not to damage the hydraulic system. Large amounts of metal chips adhering to the magnetic rods is a sign of damage to the hydraulic system. Have the hydraulic system examined by Krupp service or by your repair crew.

• Change the filter elements (5).

• Replace the O-rings (3) in the bottom and top parts of the filter.

• Reassemble the hydraulic oil filters and replace them in the hydraulic oil tank.

OStore used hydraulic oil filters in suitable containers and have them disposed of properly by qualified personnel.