Grove GMK4075 Truck Crane Maintenance Manual SN 2084643 - PDF DOWNLOAD

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Maintenance Manual

Vehicle serial number:

2 084 643 en 02.07.2001

Important note

Duplications of any kind and excerpts from this document are not subject to the alterations service. Original documents of Deutsche GROVE GmbH are marked with the blue serial number of the truck crane on the cover page.

© Copyright reserved by Deutsche GROVE GmbH The passing on or duplication of this document as well as the use and disclosure of its contents are prohibited unless expressly permitted. Offenders will be liable for damages. All rights pertaining to registration of patent or utility model are reserved.

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Maintenance Manual GMK 4075

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Duplications and print-outs of data carriers on which Deutsche GROVE GmbH has delivered this document are also not subject to the alterations service.

The following chapters are contained in this maintenance manual: 1

General instructions

2

Safety and environmental protection

3

Cleaning

4

Run-in regulations

5

Maintenance overview

6

Lubricants and fuels

7

Description of maintenance work on the carrier

8

Description of maintenance work on the superstructure

9

Longer periods out of operation

10 Tightening torques

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Appendix

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Maintenance Manual GMK 4075

1 General instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 -

1

1.1

Using the maintenance manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 -

1

1.2

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

1

1.3

GROVE customer support maintenance instructions . . . . . . . . . . . . . . . . . . . . . . 1 -

2

1.4

Definitions of stated directions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 -

4

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1

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Maintenance Manual GMK 4075

General instructions 1.1 Using the maintenance manual

1

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.

H 1.2

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

Warnings and symbols The following definitions and symbols are used in the operating instructions to highlight particularly important information:

G S O

This 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.

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

This symbol reminds you that you are working with substances which pose a risk to the environment. Take particular care.

The measures required for the corresponding maintenance work are indicated next to the symbol. You will find more detailed information in the section Handling substances which are harmful to the environment, S. 2 - 2.

à

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

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1-1

General instructions 1.3 GROVE customer support maintenance instructions

H s 1.3

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

This symbol indicates that the topic is continued on the next page. Turn to the next page.

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,

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– professional repair work / overhauling.

1-2

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Maintenance Manual GMK 4075

General instructions 1.3 GROVE customer support maintenance instructions

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 6 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) be02.07.2001

fore re-using them and replace them if necessary.

Tightening torques may be found in sections 10 - 1 and 1 0 -2.

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1-3

General instructions 1.4 Definitions of stated directions

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.

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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.

1-4

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2 Safety and environmental protection . . . . . . . . . . . . . . . . . . . . . . . 2 -

1

2.1

Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -

1

2.2

Handling substances which are harmful to the environment. . . . . . . . . . . . . . . . 2 -

2

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Maintenance Manual GMK 4075

Safety and environmental protection 2.1 Safety rules

2

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.

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2-1

Safety and environmental protection 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 re02.07.2001

gional regulations as well as the instructions in this chapter.

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Maintenance Manual GMK 4075

Safety and environmental protection 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

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disposal companies which are approved by the national or regional authority responsible.

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2-3

Safety and environmental protection 2.2 Handling substances which are harmful to the environment

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Blank page

2-4

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3 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -

1

3.1

Overview of the components that are easily damaged when cleaning. . . . . . . . 3 -

2

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3

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Maintenance Manual GMK 4075

Cleaning

3

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

G

surface you are cleaning and ensure that you are standing at a sufficient distance away from the surface you are cleaning.

Risk of accidents from misdirected high pressure water jet!

When working with high-pressure and steam jet cleaners, the water jet will be deflected by crane parts and could spray into your face and eyes at great speed and high pressure.

Always wear a face guard when cleaning the truck crane with high-pressure and steam-jet cleaning equipment.

• 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 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 ( Centrallubrication system, S. 7 - 56). Lubricate all remaining lubrication points with a grease gun.

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à

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3-1

Cleaning 3.1 Overview of the components that are easily damaged when cleaning

3.1

Overview of the components that are easily damaged when cleaning

On truck crane

3-2

Lowering limit switch

7

SLI length and angle measuring unit

2

Suspension cylinders (on both sides of the truck crane)

8

Angle sensor control box

3

SLI connecting box

9

Pressure sensors

4

Lifting limit switch

10

Switch box pressure sensor

5

Telescope slide faces

11

Proximity switch for swing-away lattice extension

6

Air-conditioning system capacitor

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1

Maintenance Manual GMK 4075

4 Run-in regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -

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1

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Maintenance Manual GMK 4075

Run-in regulations

4

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 50

Tighten wheel nuts Special tightening torques, S. 10 - 2) (

after 150

Tighten wheel nuts ( Special tightening torques, S. 10 - 2)

à

à

after 20; 1)

Carryout the first oil change in the transfer case; Distributor gearbox – oil change, S. 7 - 22.

after 50

Tighten hose clamps on all coolant hoses Special tightening torques, S. 10 - 2). (

during the first 100

à Changing the hydraulic oil filters and cleaning

à

à

Check the hydraulic oil filters weekly;

the magnetic rod, S. 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.

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4-1

Run-in regulations

Operation hours (oh)

Travelled km

Additional maintenance work on the SUPERSTRUCTURE

during the first 100

Check the hydraulic oil filters weekly; Replacing the hydraulic oil filter, S. 8 - 21.

after 100

Check tightness of retaining bolts; tightening Special tightening torques, S. 10 - 2. torque;

after 200

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

à

à

à

after 200

Carry out first oil change in slewing gear Slewing gear – oil change, transmission; S. 8 - 11.

after10001)

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

à

à

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.

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

4-2

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5 5

Maintenance overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 -

1

5.1

Maintenance intervals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 -

1

5.2

Maintenance plans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 -

3

5.2.1 5.2.2 5.2.3 5.2.4 5.2.5 5.2.6 5.2.7 5.2.8 5.2.9

Maintenance plan D: daily / before start-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 5 Maintenance plan W: weekly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 6 Maintenance plan M 1: monthly / after 100 oh / approx. 2 000 km . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 8 Maintenance plan M 3: every 3 months / after 300 oh / 5 000 – 6 000 km. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 10 Maintenance plan M 6: every 6 months / after 500 oh / 10 000 – 12 500 km . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 12 Maintenance plan M 12: every 12 months / after 1 000 oh / 20 000 – 25 000 km . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 14 Maintenance and inspection plan Y 2: every 24 months / after 100 000 – 125 000 km. . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 16 Maintenance and inspection plan Y 3: every 36 months / after 3 000 oh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 17 Maintenance and inspection plan Y 6: every 72 months / after 6 000 oh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 18 Periodic inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 19

5.3.1

Load hook inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 20

5.4

Measures required for winch monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 21

5.4.1 5.4.2 5.4.3

Theoretical service life. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 21 Proportion of the theoretical service life used. . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 22 Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 26

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5.3

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Maintenance overview 5.1 Maintenance intervals

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 Y 2 (= every 24 months) to Y 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 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.

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5-1

Maintenance overview 5.1 Maintenance intervals

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: Maintenance Maintenance plans interval

Km travelled (carrier)

Diesel engine operating hours (oh) (superstructure)

D

daily / before startup

—

—

W

weekly

—

—

M1

monthly

approx. 2000

100

M3

three monthly

5 000 – 6 000

300

M6

every six months

10 000 – 12 500

500

M 12

every twelve months

20 000 – 25 000

1 000

Y2

every twenty four months

100 000 – 125 000

—

Y3

every thirty six months

—

3 000

Y6

every seventy two months

—

6 000

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

5-2

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Maintenance overview 5.2 Maintenance plans

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.

H

The 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, p. 6 - 1.

à

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H

Please 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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5-3

Maintenance overview 5.2 Maintenance plans

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Blank page

5-4

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Maintenance overview 5.2 Maintenance plans

5.2.1

Maintenance plan D: daily / before start-up

D Maintenance work on the CARRIER:

Oil / lubricant Quantity (l) / Number

Designation p. 6 - 1

à

Diesel engine

à p. 7 - 6.

– Checking refrigerant level; à p. 7 - 8.

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

– Check the oil level;

A

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

à

Carrier hydraulic system – Checking hydraulic oil level;

à p. 7 - 43.

G2

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

à

Carrier electrical system – Check lighting and indicators

D Maintenance work on the SUPERSTRUCTURE:

Oil / lubricant Quantity (l) / Number

Slewing gear – Slewing gear brake function check;

Designation p. 6 - 1

à

à p. 8 - 13.

Hoist ropes – Check the overall condition and position of sheaves and rope drums; p. 8 - 29.

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à

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5-5

Maintenance overview 5.2 Maintenance plans

5.2.2

Maintenance plan W: weekly

W Maintenance work on the CARRIER:

Oil / lubricant Quantity (l) / Number

Diesel engine – Checking the overall condition and tightness; Gearbox – Checking the overall condition and tightness; Distributor gearbox – Checking the overall condition and tightness; Axle lines – Checking the overall condition and tightness; Wheels – Check the tyre pressure; Steering – Check tightness;

Designation p. 6 - 1

à

à p. 7 - 10. à p. 7 - 17. à p. 7 - 21 . à p. 7 - 23.

à p. 7 - 34.

à p. 7 - 39.

Carrier compressed air system (incl. brake system) – Drain compressed air system; – Check tightness;

à p. 7 - 41.

Carrier hydraulic system – Check hydraulic hoses;

à p. 7 - 41.

à p. 7 - 44.

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

à

Carrier central lubrication system – Check the level of the fuel tank;

à p. 7 - 56.

K

Other maintenance checks

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

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Maintenance overview 5.2 Maintenance plans

W Maintenance work on the SUPERSTRUCTURE:

Oil / lubricant Quantity (l) / Number

Designation p. 6 - 1

à

Main hoist / auxiliary hoist (additional equipment)

à p. 8 - 3.

– Check tightness; à p. 8 - 4.

– Check hoist brake; à p. 8 - 4.

– Lubricating the hoist gears; à p. 8 - 5.

– Check the oil level;

E6

2

K

Slewing gear

à p. 8 - 9.

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

– Check tightness; à p. 8 - 10.

– Check the slewing gear oil level;

E6 E5

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; Hoist ropes – Check the condition;

à p. 8 - 45.

K

à p. 8 - 30.

Other maintenance checks

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

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5-7

Maintenance overview 5.2 Maintenance plans

5.2.3

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

M1 Maintenance work on the CARRIER: monthly / after approx. 2 000 km

Oil / lubricant Quantity (l) / Number

Designation p. 6 - 1

à

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; p. 7 - 5.

à

Distributor gearbox – Check the oil level;

à p. 7 - 21.

E3

Axle lines

à p. 7 - 23.

– Axle centre drive – check oil level; – Final drive – check oil level;

à p. 7 - 27.

E3

à p. 7 - 29.

– Lubricate universal joint shaft of the axle line; with additional equipment with 8 x 8 x 8 drive.

Wheels

E3 12 14

K K

à

– Check tightness of wheel nuts; p. 7 - 38.

Special tightening torques, S. 10 - 2.

Tightening torque;

à

Suspension – Check oil level in the suspension cylinders;

à p. 7 - 37.

H

– Check retaining bolts of the suspension cylinders; Special tightening torques, S. 10 - 2.

Tightening torque;

à

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.

2

J

8

J

4

J

div.

J/M

Carrier air conditioning system (additional equipment) – Checking the moisture and level of the refrigerant; – Cleaning capacitor disks;

à p. 7 - 66.

à p. 7 - 65.

Other maintenance work

à

– Lubricating the outrigger beam1);

à p. 7 - 75.

– Lubricate door hinges.

–

Lubricate retaining and socket pins.1) 1) after 100 oh

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

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02.07.2001

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

Maintenance overview 5.2 Maintenance plans

M1 Maintenance work on the SUPERSTRUCTURE: monthly / after 100 oh Switch coupling – Switch coupling – check oil level; Hook blocks – Lubricate;

Oil / lubricant Quantity (l) / Number

à p. 8 - 1.

à p. 8 - 47.

Designation p. 6 - 1

à

G5 div.

J

6

J

– Lubricate tread rollers of cab door.

3

M

– Lubricate retaining and socket pins.

div.

J/M

– Lubricate spring latch.

div.

J/M

Superstructure hydraulic system

à p. 8 - 18.

– Bleeding the derricking cylinder; à p. 8 - 16.

– Bleeding telescoping cylinders; Other maintenance work

– Lubricating the counterweight hoist unit;

à p. 8 - 53.

– Checking for correct operation of the auxiliary heater (addip. 8 - 53. tional equipment);

02.07.2001

à

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5-9

Maintenance overview 5.2 Maintenance plans

5.2.4

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

M3 Maintenance work on the CARRIER: every 3 months / after 5 000 – 6 000 km

Oil / lubricant Quantity (l) / Number

Designation p. 6 - 1

à

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 p. 7 - 5. operation;

à

– Clean fuel prefilter-screen;

à p. 7 - 11.

Wheels – Checking wheel-bearing clearance; Vehicle brakes – Check brake-lining thickness;

à p. 7 - 34.

à p. 7 - 35.

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

à

Carrier electrical system – Check acid concentration of batteries;

à p. 7 - 64.

Trailer coupling (additional equipment)

à p. 7 - 70.

– Checking the cotter pin; à p. 7 - 71.

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

– Checking the bearing;

– Checking the initial tension of the springs;

à p. 7 - 73.

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

à

à p. 7 - 72.

02.07.2001

– Checking the support ring;

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Maintenance overview 5.2 Maintenance plans

M3 Maintenance work on the SUPERSTRUCTURE: every 3 months / after 300 oh Superstructure electrical system – Check acid concentration of batteries;

Oil / lubricant Quantity (l) / Number

Designation p. 6 - 1

à

à p. 8 - 49.

Ball slewing connection – Check tightness of retaining bolts; Tightening torque; Special tightening torques, S. 10 - 2.

à

02.07.2001

1) after 300 oh

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5 - 11

Maintenance overview 5.2 Maintenance plans

5.2.5

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

M6 Maintenance work on the CARRIER: every 6 months / after 10 000 – 12 500 km

Oil / lubricant Quantity (l) / Number

Designation p. 6 - 1

9.5

E3

8 10

K K

à

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 p. 7 - 5. operation;

à

Distributor gearbox – Changing the oil;

à p. 7 - 22.

Axle lines – Lubricating the longitudinal cardan shafts between the gear units. p. 7 - 31. for8 x 6 x 8 drive; p. 7 - 31. for8 x 8 x 8 drive (additional equipment);

à

à

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.

à p. 7 - 68.

02.07.2001

– Checking the refrigerant compressor control;

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Maintenance overview 5.2 Maintenance plans

M6 Maintenance work on the SUPERSTRUCTURE: every 6 months / after 500 oh Slewing gears – Lubricating the slewing gear pinion; Ball slewing connection – Lubricate the gear rim;

Oil / lubricant

à p. 8 - 10.

à p. 8 - 10.

Main boom – Lubricate telescopic slide faces;

à p. 8 - 23.

Quantity (l) / Number

Designation p. 6 - 1

1 each

V

1

V

16

L2

à

Superstructure air conditioning system (additional equipment) – Checking hoses;

à p. 8 - 51.

SLI

à p. 8 - 41.

X

02.07.2001

– Maintain the slip ring assembly in the cable drums;

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5 - 13

Maintenance overview 5.2 Maintenance plans

5.2.6

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

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

Oil / lubricant Quantity (l) / Number

Designation p. 6 - 1

à

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 p. 7 - 5. operation;

à

– Replacing the fuel filter elements; Gearbox – Check the oil level;

à p. 7 - 13.

à p. 7 - 19.

Axle lines

F4

à

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

1st axle line 2nd axle line (only for additional equipment with 8 x 8 x 8 drive) 3rd axle line 4th axle line – Final drive oil change;

à p. 7 - 28.

13.0 15.0 16.5 13.0

E3 E3 E3 E3

4.1 each

E3

660.0

G2

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

à

Carrier hydraulic system – Have suspension system pressure accumulators checked by the local GROVE Customer Support or by an authorized workshop.1) – Replacing the vent filter for the hydraulic oil tank2); p. 7 - 49.

à

– Oil change1); p. 7 - 50).

à

à p. 7 - 52, (depending on results of oil test,

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

–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.

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Maintenance Manual GMK 4075

02.07.2001

2) Operation under difficult conditions:

Maintenance overview 5.2 Maintenance plans

M 12 Maintenance work on the SUPERSTRUCTURE: every 12 months / after 1000 oh Switch coupling – Switch coupling oil change;

Oil / lubricant

à p. 8 - 2.

Quantity (l) / Number

Designation p. 6 - 1

Approx. 0.25

G5

10.0

E6

0.9 each

E6

Approx. 1.0

E5

à

Main hoist / auxiliary hoist (additional equipment)

à

p. 8 - 5 – Oil change1); p. 8 - 7.

– Checking the old oil;

à

Slewing gears

à p. 8 - 11.

– Slewing brake oil change; à p. 8 - 12.

– Slewing gear oil change;

Superstructure air conditioning system (additional equipment) – Monitoring the entire air conditioning system;

à p. 7 - 68.

02.07.2001

1) Carry out at least once a year

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5 - 15

Maintenance overview 5.2 Maintenance plans

5.2.7

Maintenance and inspection plan Y 2: every 24 months / after 100 00 0 –125 000 km

Y2 Maintenance work on the CARRIER: every 24 months Gearbox – Changing the oil and oil filter,

Oil / lubricant

à p. 7 - 19.

Quantity (l) / Number

Designation p. 6 - 1

11.0

F4

à

Y2 Maintenance work on the SUPERSTRUCTURE: every 24 months

Oil / lubricant Quantity (l) / Number

Designation p. 6 - 1

à

No maintenance work in this period.

02.07.2001

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

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Maintenance overview 5.2 Maintenance plans

5.2.8

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

Y3 Maintenance work on the CARRIER: every 36 months

Oil / lubricant Quantity (l) / Number

Designation p. 6 - 1

à

No maintenance work in this period.

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

Y3 Maintenance work on the SUPERSTRUCTURE: every 36 months / after 3000 oh

Oil / lubricant Quantity (l) / Number

Designation p. 6 - 1

à

Main hoist / auxiliary hoist (additional equipment)

à p. 8 - 8.

02.07.2001

– Carry out partial inspection;

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5 - 17

Maintenance overview 5.2 Maintenance plans

5.2.9

Maintenance and inspection plan Y 6: every 72 months / after 6 000 oh

Y6 Maintenance work on the CARRIER: every 72 months

Oil / lubricant Quantity (l) / Number

Designation p. 6 - 1

à

No maintenance work in this period.

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

Y6 Maintenance work on the SUPERSTRUCTURE: every 72 months / after 6000 oh

Oil / lubricant Quantity (l) / Number

Designation p. 6 - 1

à

Main hoist / auxiliary hoist (additional equipment)

à p. 8 - 8. à p. 5 - 21.

02.07.2001

– Carry out general inspection;

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Maintenance Manual GMK 4075

Maintenance overview 5.3 Periodic inspections

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 BGV D 6 (VBG 9).

– Cranes that are to be used abroad are inspected in accordance with the regulations of the respective country. If such regulations do not exist, they are inspected in accordance with the regulations of the Professional Trade Association as defined by BGV D 6 (VBG 9).

According to 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,

à Load hook inspection, S. 5 - 20),

– load hooks (

– 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.

02.07.2001

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

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5 - 19

Maintenance overview 5.3 Periodic inspections

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.

02.07.2001

G

Accidents 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!

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Maintenance overview 5.4 Measures required for winch monitoring

5.4

Measures required for winch monitoring

H 5.4.1

Also observe the information on the general inspection of the hoists; p. 8 - 8.

à

Measures required for winch monitoring (hoists) were drawn up by the VDMA and apply to all vehicle cranes in accordance with the Accident prevention regulations for winches, hoists and towing devices BGV D 8 (VBG 8).

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: Load spectrum: Load spectrum factor: Theoretical service life:

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.

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

s

02.07.2001

S

M ......

Q .....; (L.....)

Km =......

D =......

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5 - 21

Maintenance overview 5.4 Measures required for winch monitoring

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 environmental conditions:

5.4.2

low or high temperatures, aggressive atmosphere, dust and dirt.

Proportion of the theoretical service life used The crane operator is obliged to perform a crane inspection at least once a year (ISO 9927-1 and BG V D8 (V B G8)).

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.

02.07.2001

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.

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Maintenance overview 5.4 Measures required for winch monitoring

Determining the operating conditions (collective load) Collective load Class

light Q1 L1

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

Term designation

Working time proportion

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

Collective load factor Km =

Graphic representation

0.125

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 medium Q2 L2

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)

0.25

1/6 of the operating time with dead load +1/3 payload) 50 % of the operating time only with dead load

heavy Q3 L3

02.07.2001

very heavy Q4 L4

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 load

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

0.5

90 % of the operating time with highest load (dead load + 1/1 payload) 10 % of the operating time only with dead load

1

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 inspection 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.

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5 - 23

Maintenance overview 5.4 Measures required for winch monitoring

Determining the actual operating hours Ti

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

H

It 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 ( Operating Instructions, Chapter Crane Operation, Section Crane work with main boom).

à

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.

à

02.07.2001

H

It 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 2 0% in relation to superstructure operating hours ( Operating hour counter is functional for entire crane operation ), the percentage in relation to the total operating hours of the crane will be: 1 2%.

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Maintenance overview 5.4 Measures required for winch monitoring

Determining the proportion of the theoretical service life used

For an inspection interval i (max. 1 year according to ISO 9927-1 or BGV D 8 (VBG 8)), the proportion of the theoretical service life used Si is calculated using the formula:

Km S i = -----------i × T i Km 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 inspection 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.

à

If the theoretical service life D has been reached ( Theoretical service life, S. 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.

02.07.2001

The next general overhaul must be performed within 10 years.

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5 - 25

Maintenance overview 5.4 Measures required for winch monitoring

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:

M3

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. Inspection (first year) 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:

0.125 S i = --------------- × 160 h = 160 h 0.125 Remaining theoretical service life:

D1 = 3200 h – 160 h = 3040 h.

The aforementioned values are entered in the table (see example table 5 - 28).

2. Inspection (second year)

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.

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02.07.2001

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

Km2 = 0.5.

Maintenance overview 5.4 Measures required for winch monitoring

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

0.5 S i = --------------- × 480 h = 1120 h 0.125 Remaining theoretical service life:

D2 = 3040 h – 1920 h = 1120 h.

The aforementioned values are entered in the table (see example table 5 - 28).

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:

0.25 S i = --------------- × 300 h = 600 h 0.125 Remaining theoretical service life:

D3 = 1120 h – 600 h = 520 h.

The aforementioned values are entered in the table (see example table 5 - 28).

02.07.2001

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.

s

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5 - 27

Maintenance overview 5.4 Measures required for winch monitoring

02.07.2001

Example table to determine the remaining theoretical service life of winch no. 1 (main hoist winch)

5 - 28

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6 Lubricants and fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 -

1

6.1

Lubricant table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 -

1

6.2

Process materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 -

3

6.2.1 6.2.2 6.2.3 6.2.4

Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Engine coolant admixtures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Windscreen washing system admixtures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Fuel for crane cab heating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 -

3 3 3 3

02.07.2001

6

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Lubricants and fuels 6.1 Lubricant table

6

Lubricants and fuels

6.1

Lubricant table

Name

Lubricating point

A

Diesel engine

E3

Axle center drive

E5

E 6 3)

Slewing gear brake

Type of lubrication

Name according to DIN 51502

Specification Classification

Lubricant type Viscosity range

HD - CD

MIL-L 2104 C DB 228.5

1)

C - LPF

MIL-L 2105 B API-GL-5

SAE 90 ISO - VG 220

Circulatory lubrication

Slewing gear Gearbox

GROVE part no. 1 930 6702)

C - LPF

Hoist

Oil quantity

F4

Gearbox

Circulatory lubrication

G2

Hydraulic system

G5

Switch coupling

H

Suspension cylinder

J

Lubricating points (lubricating grease)

K

Roller bearing

L2

Slideways

H-LP Oil quantity

MIL-L 2105 B API-GL-4/5

SAE 75 W-90 ISO - VG 220

MIL - L2105 API-GL-4 TE-ML 02L

SAE 75 W-80W3)

DIN 51524 T.2

ISO - VG 32

API-GL-4 plus

SAE 75 W-903)

GROVE part no. 23108632) Grease gun and manually For repairs, grease when installing

K - L2K

DIN 51825

KP - L2K

DIN 51825

GROVE part no. 1373 458 2)

1) See engine operating instructions

02.07.2001

2) Available from local GROVE Customer Support 3) Synthetic oil filled at the factory; do not mix with mineral oil.

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s 6-1

Lubricants and fuels 6.1 Lubricant table

Name

Lubricating point

Type of lubrication

M

Lubricating Oil can, points (lubricat- high pressure jet ing oil) oil can

V

Open-running gear wheels

W

Mounting screws, bushings, etc.

X

Slip ring assembly

Name according to DIN 51502

Specification Classification

Lubricant type Viscosity range

as A (Diesel engine) GROVE part no. 0554 205 2)

Adhesive lubrication

Corrosion protection

GROVE part no. 1573 046 2) GROVE part no. 3315 060 2)

02.07.2001

2) Available from local GROVE Customer Support

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Lubricants and fuels 6.2 Process materials

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

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

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6-3

Lubricants and fuels 6.2 Process materials

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6-4

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7 7

Description of maintenance work on the carrier . . . . . . . . . . . 7 -

1

7.1

Tilt driver's cab forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 -

1

7.2

Diesel engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 -

5

7.2.1 7.2.2 7.2.3 7.2.4 7.2.5 7.2.6 7.2.7

Diesel engine – oil level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 6 Diesel engine oil – topping up oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 7 Checking coolant level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 8 Checking the dry air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 9 Checking general condition and for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 10 Cleaning the fuel prefilter screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 11 Changing the fuel filter cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 13

7.3

Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 17

7.3.1 7.3.2 7.3.3

Checking general condition and for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 17 Gearbox – oil level check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 18 Gear box – oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 19

7.4

Transfer case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 21

7.4.1 7.4.2 7.4.3

Checking general condition and for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 21 Distributor gearbox – oil level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 21 Distributor gearbox – oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 22

7.5

Axle lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 23

7.5.1 7.5.2 7.5.3 7.5.4 7.5.5 7.5.6 7.5.7

Checking general condition and for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 23 Axle centre drives – oil level check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 23 Axle centre drives – oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 25 Final drives – oil level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 27 Final drives – oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 28 Lubricating the cardan shafts on the axle lines. . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 29 Longitudinal cardan shafts between the gear units lubricate . . . . . . . . . . . . . . 7 - 31

7.6

Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 33

7.6.1 7.6.2 7.6.3

Checking the tyres for damage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 33 Check the tyre pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 34 Checking the wheel-bearing clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 34

7.7

Vehicle brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 35

7.7.1

Checking brake-lining thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 35

7.8

Suspension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 37

7.8.1 7.8.2

Telescopic leg – oil level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 37 Tightness of retaining bolts on the suspension cylinders to be checked . . . . . 7 - 38

7.9

Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 39

7.9.1

Checking for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 39

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Carrier compressed air system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 41

7.10.1 7.10.2 7.10.3

Draining the compressed air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 41 Compressed air system – check for leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 41 Replacing the granulate cartridge of the compressed air dryer . . . . . . . . . . . . 7 - 42

7.11

Carrier hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 43

7.11.1 7.11.2 7.11.3 7.11.4 7.11.5 7.11.6 7.11.7

Hydraulic unit – oil level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 43 Checking the hydraulic hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 44 Checking for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 45 Changing the hydraulic oil filters and cleaning the magnetic rod . . . . . . . . . . . 7 - 46 Replacing the venting filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 49 Taking hydraulic oil samples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 50 Changing the hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 52

7.12

Centrallubrication system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 55

7.12.1 7.12.2 7.12.3

Central lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 55 Version 1 – Checking the level of the grease container and topping up . . . . . . 7 - 56 Version 2 – Checking the level of the grease container and topping up . . . . . . 7 - 59

7.13

Carrier electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 63

7.13.1 7.13.2

Checking the acid level of batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 63 Checking the acid concentration of batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 64

7.14

Carrier air conditioning system (additional equipment) . . . . . . . . . . . . . . . . . . . . 7 - 65

7.14.1 7.14.2 7.14.3 7.14.4 7.14.5 7.14.6

Checking the moisture and level of the refrigerant. . . . . . . . . . . . . . . . . . . . . . . 7 - 65 Cleaning capacitor disks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 66 Checking hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 67 Checking the refrigerant compressor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 67 Checking the refrigerant compressor control . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 68 Checking the entire air conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 68

7.15

Trailer coupling (additional equipment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 69

7.15.1 7.15.2 7.15.3 7.15.4 7.15.5 7.15.6 7.15.7

Lubricating the trailer coupling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 69 Checking the bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 70 Checking the cotter pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 71 Checking the lower bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 72 Checking the support ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 72 Checking the initial tension of the springs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 73 Checking the function of the coupling jaw / re-adjusting the middle position . 7 - 73

7.16

Other maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 75

7.16.1 7.16.2

Lubricating the outrigger beams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 75 Checking for correct operation of the auxiliary heater (additional equipment) 7 - 75

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7.10

Description of maintenance work on the carrier 7.1 Tilt driver's cab forward

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.

H Prerequisites and information on tilting

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

à

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.

S

The 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.

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7-1

Description of maintenance work on the carrier 7.1 Tilt driver's cab forward

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

à

Observe the prerequisites stated at the beginning of section Prerequisites and information on tilting, S. 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).

Risk 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.

Risk 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.

02.07.2001

G G

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

7-2

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Description of maintenance work on the carrier 7.1 Tilt driver's cab forward

S

Danger 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.

02.07.2001

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

G

Risk 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.

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7-3

Description of maintenance work on the carrier 7.1 Tilt driver's cab forward

Lowering the driver's cab

G

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

Risk 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;

G 7-4

Accidents 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.

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à Unlocking / locking the driver's cab, S. 7 - 2.

Description of maintenance work on the carrier 7.2 Diesel engine

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.

S

Risk 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).

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7-5

Description of maintenance work on the carrier 7.2 Diesel engine

7.2.1

Diesel engine – oil level check

D

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

Pre-check

• Check whether the oil level on the dip stick is up to the max mark (arrow marking).

• Top up with motor oil to the max. mark if necessary.

Check

• Start the diesel engine and let it run at idling speed. Pay attention to the

7-6

Damage 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 Operating Manual, chapter Carrier malfunctions, and look for the cause; Section Crane engine malfunctions.

à

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S

oil pressure gauge.

Description of maintenance work on the carrier 7.2 Diesel engine

• Leave the diesel engine running and check the oil level when the diesel engine is warm.

With idling speed, the oil level must lie between min. and max. (arrow marking).

• Top up with oil to the max. mark if necessary.

7.2.2

Diesel engine oil – topping up oil 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).

02.07.2001

• Check the oil level on the dipstick.

S

Damage 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.).

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7-7

Description of maintenance work on the carrier 7.2 Diesel engine

7.2.3

D

Checking coolant level

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

G

Danger 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.

7-8

Risk 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 Support or your repair crew check the cooling system and repair the damage.

02.07.2001

S

• Screw on the filling hole cap until it stops.

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Description of maintenance work on the carrier 7.2 Diesel engine

7.2.4

D

Checking the dry air filter

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

p

The Diesel engine air filter indicator lamp is on the front instrument panel of the 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

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with all the clamps.

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7-9

Description of maintenance work on the carrier 7.2 Diesel engine

7.2.5

W

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:

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

7 - 10

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Description of maintenance work on the carrier 7.2 Diesel engine

7.2.6

Cleaning the fuel prefilter screen

H

M3

Before cleaning the primary fuel filter, you must block off the fuel pipe from Shutting off and emptying the fuel line, S. 7 - 13. the tank,

à

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

O

Have 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.

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7 - 11

Description of maintenance work on the carrier 7.2 Diesel engine

• 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.

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• Start the engine and check the prefilter for tightness.

7 - 12

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Description of maintenance work on the carrier 7.2 Diesel engine

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

O

M 12

Always 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).

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7 - 13

Description of maintenance work on the carrier 7.2 Diesel engine

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 ( Diesel engine operating instructions).

In order to easily access the fuel filter insert tilt the driver's cab, Tilt driver's cab forward, S. 7 - 1.

à

à

• 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.

7 - 14

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

02.07.2001

O

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

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Maintenance Manual GMK 4075

Description of maintenance work on the carrier 7.2 Diesel engine

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.

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7 - 15

Description of maintenance work on the carrier 7.2 Diesel engine

• 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, S. 7 - 12.

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

7 - 16

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Maintenance Manual GMK 4075

Description of maintenance work on the carrier 7.3 Gearbox

7.3

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

7.3.1

Checking general condition and for leaks

W

• 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:

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

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7 - 17

Description of maintenance work on the carrier 7.3 Gearbox

7.3.2

M1

Gearbox – oil level check The gearbox is located inside the carrier above the first axle line.

S

Damage 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.

G

Risk 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, S. 5 - 14.

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

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

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Maintenance Manual GMK 4075

Description of maintenance work on the carrier 7.3 Gearbox

7.3.3

J2

Gear box – oil change

G O H

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, S. 5 - 17.

Risk of scalding.

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

When 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.

Before 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

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oil flow into the collection container.

O

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

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7 - 19

Description of maintenance work on the carrier 7.3 Gearbox

Topping up gear lubricant oil

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

à

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

à Maintenance plan,

• 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) ( tightening torques, S. 10 - 2).

à Special

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.

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• Check the tightness of oil drain screws.

7 - 20

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Maintenance Manual GMK 4075

Description of maintenance work on the carrier 7.4 Transfer case

7.4

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

7.4.1

Checking general condition and for leaks

W

• 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 Support or your repair crew.

7.4.2

Distributor gearbox – oil level check

M1

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, S. 5 - 8.

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

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7 - 21

Description of maintenance work on the carrier 7.4 Transfer case

7.4.3

M6

Distributor gearbox – oil change Use only oil as specified in the Maintenance plan, S. 5 - 12.

H

O

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

Always 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, S. 5 - 12.

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

• Replace the sealing ring and close the inCollect old oil in approved containers and have it disposed of properly.

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spection hole with the screw (1).

7 - 22

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Maintenance Manual GMK 4075

Description of maintenance work on the carrier 7.5 Axle lines

7.5

Axle lines

7.5.1

Checking general condition and for leaks

W

• 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 Support or your repair crew.

7.5.2

Axle centre drives – oil level check

M1

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, S. 5 - 8.

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

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7 - 23

Description of maintenance work on the carrier 7.5 Axle lines

H

The 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 de-

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scribed for the first and the fourth axle lines.

7 - 24

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Maintenance Manual GMK 4075

Description of maintenance work on the carrier 7.5 Axle lines

7.5.3

Axle centre drives – oil change

M 12

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

H

O

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

Always 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, S. 5 - 12.

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

• Replace the sealing ring and close the inspection hole again with the Collect the old oil in permitted containers and only have it disposed of by approved disposal companies.

s

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screw (1).

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7 - 25

Description of maintenance work on the carrier 7.5 Axle lines

H

The 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

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the same way as is described for the axle drives on the first and fourth axle lines.

7 - 26

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Maintenance Manual GMK 4075

Description of maintenance work on the carrier 7.5 Axle lines

7.5.4

Final drives – oil level check

M1

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, S. 5 - 8.

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

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Also check the oil level on all other final drives.

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7 - 27

Description of maintenance work on the carrier 7.5 Axle lines

7.5.5

O

M 12

Final drives – oil change

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

Always 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, S. 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, S. 7 - 27).

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

7 - 28

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O

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

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Maintenance Manual GMK 4075

Description of maintenance work on the carrier 7.5 Axle lines

7.5.6

M1

Lubricating the cardan shafts on the axle lines

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

H

If 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, S. 5 - 8.

S Number and position of lubrication points

Risk of damaging the sealing lips.

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

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 shafts

Lubricating nipple inner 1)

outer 2)

1st axle line

2

4

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

2

2

3rd axle line

2

2

4th axle line

2

2

1) Joint on the axle centre drives 2) Joint on the final drives

H

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

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7 - 29

Description of maintenance work on the carrier 7.5 Axle lines

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.

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• Remove the surplus new grease.

7 - 30

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Maintenance Manual GMK 4075

Description of maintenance work on the carrier 7.5 Axle lines

7.5.7

Longitudinal cardan shafts between the gear units lubricate

M6

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.

H

If 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, S. 5 - 12.

S Number and position of lubrication points

Risk 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 front

rear

Gearbox and transfer case

1

1

Transfer case and the first axle line

1

1

Transfer case and the second axle line1)

1

1

Transfer case and the third axle line

1

1

First axle line and the second axle line1)

1

1

Third axle line and the fourth axle line

1

1

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

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1)

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7 - 31

Description of maintenance work on the carrier 7.5 Axle lines

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.

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• Remove any spilling grease.

7 - 32

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Maintenance Manual GMK 4075

Description of maintenance work on the carrier 7.6 Wheels

7.6

Wheels

7.6.1

Checking the tyres for damage

D

• 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.

02.07.2001

S

Always replace all the tyres on an axle.

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7 - 33

Description of maintenance work on the carrier 7.6 Wheels

7.6.2

S 7.6.3

W

Check the tyre pressure

When 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.

Tyres

Air pressure (bar)

14.00 R 25

10,0

16.00 R 25 (additional equipment)

9,0

20.50 R 25 (additional equipment)

7,0

M3

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

02.07.2001

GROVE Customer Support service at the particular location or by your own repair crew.

7 - 34

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Maintenance Manual GMK 4075

Description of maintenance work on the carrier 7.7 Vehicle brakes

7.7

Vehicle brakes

7.7.1

Checking brake-lining thickness

M3

There is an opening on the inside of each wheel (sealed with a rubber plug) through which the brake-lining thickness can be checked.

• Remove 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.

02.07.2001

S

Always replace all brake-linings on an axle line.

Maintenance Manual GMK 4075

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7 - 35

Description of maintenance work on the carrier 7.7 Vehicle brakes

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7 - 36

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Maintenance Manual GMK 4075

Description of maintenance work on the carrier 7.8 Suspension

7.8

Suspension

7.8.1

Telescopic leg – oil level check

M1

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 ( Operating manual, Chapter Driving with the truck crane, Section Vehicle height control).

à

H

S

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

If 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

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marking.

Use only oil as specified in the Maintenance plan, S. 5 - 8.

S

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

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7 - 37

Description of maintenance work on the carrier 7.8 Suspension

7.8.2

Tightness of retaining bolts on the suspension cylinders to be checked

M1

• 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)

02.07.2001

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

7 - 38

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Maintenance Manual GMK 4075

Description of maintenance work on the carrier 7.9 Steering

7.9

Steering

7.9.1

Checking for leaks

W

• Check the hydraulic steering system (steering cylinders, pipes and hoses,

G

and all connections) for leaks.

Risk 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, S. 7 - 43).

After changing pipes and hoses:

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

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

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

Maintenance Manual GMK 4075

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7 - 39

Description of maintenance work on the carrier 7.9 Steering

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Blank page

7 - 40

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Maintenance Manual GMK 4075

Description of maintenance work on the carrier 7.10 Carrier compressed air system

7.10

Carrier compressed air system

7.10.1

Draining the compressed air system

W

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.

If a lot of moisture escapes from the air reservoirs:

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

7.10.2

Compressed air system – check for leakage

W

• Start up the compressed air system.

• Check all points in the compressed air system (connections, pipes, hoses Risk of accidents.

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

s

02.07.2001

G

and valves) where air could possibly escape.

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7 - 41

Description of maintenance work on the carrier 7.10 Carrier compressed air system

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

M 12

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

G

Risk 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.

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Grease the sealing ring lightly before screwing into place.

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Maintenance Manual GMK 4075

Description of maintenance work on the carrier 7.11 Carrier hydraulic system

7.11

Carrier hydraulic system

7.11.1

Hydraulic unit – oil level check

D

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 ( Operating Instructions, Chapter Driving with the truck crane, Section Vehicle height control); – outrigger beams and outrigger cylinders must be retracted ( Operating Instructions, Chapter Rigging work, Section Outriggers).

à

à

• 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, S. 5 - 5.

02.07.2001

S

Be careful not to damage the hydraulic system.

When handling hydraulic oil cleanliness is imperative.

New oil must also be filtered.

Maintenance Manual GMK 4075

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7 - 43

Description of maintenance work on the carrier 7.11 Carrier hydraulic system

7.11.2

W

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

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ensure that the corresponding parts of the hydraulic system are depressurized in advance.

7 - 44

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Maintenance Manual GMK 4075

Description of maintenance work on the carrier 7.11 Carrier hydraulic system

7.11.3

Checking for leaks

W

• 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

G

according to (

à Hydraulic unit – oil level check, S. 7 - 43).

Risk 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, S. 7 - 52).

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

Immediately 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.

02.07.2001

O

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

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7 - 45

Description of maintenance work on the carrier 7.11 Carrier hydraulic system

7.11.4

Changing the hydraulic oil filters and cleaning the magnetic rod

M3

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

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them.

7 - 46

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Maintenance Manual GMK 4075

Description of maintenance work on the carrier 7.11 Carrier hydraulic system

S

Be 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.

O

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

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7 - 47

Description of maintenance work on the carrier 7.11 Carrier hydraulic system

Hydraulic oil filter for control circuit The hydraulic oil filter control circuit (1) is located on the right side of the superstructure, behind the covering.

• Switch off the diesel engine and secure it against being started by unauthorized persons (sign in the driver's cab).

• Remove the ring (1).

• Take off the filter can (2).

• Remove the filter from the filter can.

• Insert the new filter into the filter can.

• Fill the filter can up to the edge with hydraulic oil.

• Screw the filter can on again.

• Start the diesel engine and let it run in

02.07.2001

neutral gear for 3 minutes in order to bleed the system.

7 - 48

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Maintenance Manual GMK 4075

Description of maintenance work on the carrier 7.11 Carrier hydraulic system

7.11.5

Replacing the venting filter

M 12

The return filter is on the hydraulic oil tank filler opening cover.

02.07.2001

• Change the venting filter (1).

Maintenance Manual GMK 4075

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7 - 49

Description of maintenance work on the carrier 7.11 Carrier hydraulic system

7.11.6

M 12

Taking hydraulic oil samples

To determine the usability of the hydraulic oil, samples must be taken from Changing the hythe hydraulic oil tank and from the hydraulic system ( draulic oil, S. 7 - 52).

à

The drain valves can only be opened and closed using the 1/2" connection plate. Connecting plates are in the toiol box; Handling the drain valves, S. 7 - 51.

à

• Take a sample from each of the drain valves (1), (2) and (3) on the hydraulic oil tank.

02.07.2001

An oil sample from the hydraulic system is taken via a gauge port (1), e. g. on a valve block of the suspension.

7 - 50

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Maintenance Manual GMK 4075

Description of maintenance work on the carrier 7.11 Carrier hydraulic system

Handling the drain valves

G

Drain valves can be opened and closed using 1/2" connection plates. The connection plates are in the tool box.

Risk posed by escaping hydraulic oil.

When the connection plate is screwed onto the drain valve, the valve opens and the hydraulic oil immediately flows out of the connection plate. Place the connection plate hose in an oil collection container before screwing on the connection plate.

• Place an oil drain hose onto the fitting and lead it into an oil collection container.

• Unscrew the cap from the drain valve.

• Screw the fitting onto the drain valve. The drain valve opens.

• Let the necessary amount of oil run into the collection container.

• Unscrew the fitting from the drain valve. The drain valve shuts.

• Screw the protective caps back onto the drain valve.

Taking oil samples

• Take one litre of hydraulic oil from each of the three drain valves and from one pressure gauge connection.

1 litre hydraulic oil Before taking the oil sample, allow 1 – 2 litres to run into a separate container.

• Lable each sample container with – the date of sampling, – the number of operating hours since the last oil change and – the sampling location (hydraulic oil tank or metering nozzle).

• Send the samples to a specialist laboratory for analysis.

Permissible limit values: – Viscosity ISO-VG 32 according to DIN 51524 P.2 – Contamination according to NAS 1683 Class 9 or ISO 4406 Code 18/15.

If these limits have been reached:

02.07.2001

• Carry out an oil change (à Changing the hydraulic oil, S. 7 - 52).

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7 - 51

Description of maintenance work on the carrier 7.11 Carrier hydraulic system

7.11.7

M 12

Changing the hydraulic oil

The hydraulic oil only has to be changed if the laboratory analysis shows Taking hydraulic oil samthat the permissible limits have been exceeded ( ples, S. 7 - 50) or the laboratory has recommended a date for an oil change.

Prerequisites: The truck crane must be in on-the-road mode with the engine off.

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

à

S

Damage may occur to the hydraulic pumps.

Ensure that the diesel engine cannot be started by an unauthorized party.

If the engine is started while the stop cocks in the suction lines are closed, the hydraulic pumps will be damaged.

• Close the stop cocks in the suction lines to the hydraulic oil tank.

The five taps are located on the left side of the vehicle on the hydraulic oil tank.

Four taps are located to the right and one tank in front on the hydraulic tank.

The taps are closed when the grips are at right angles (2) to the suction lines.

• Remove the hydraulic oil filters

à

( Changing the hydraulic oil filters and cleaning the magnetic rod, S. 7 - 46).

• Have a container ready to collect the oil (with a capacity of over 660 l).

02.07.2001

O

To drain the hydraulic oil, always use the supplied 1/2" connection plate with an oil drain hose and an oil collecting vessel with sufficient capacity.

7 - 52

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Maintenance Manual GMK 4075

Description of maintenance work on the carrier 7.11 Carrier hydraulic system

• Drain the oil. To do this, screw the oil drain hose with the connection plate onto each drain cock (1), (2) and (3) in turn, drain the oil from the three tank chambers ( Taking hydraulic oil samples, S. 7 - 50).

à

• Change the filter elements in both filters and fit new hydraulic oil filters (à Changing the hydraulic oil filters and cleaning the magnetic rod, S. 7 - 46).

S O

Be careful not to damage the hydraulic system.

When handling hydraulic oil cleanliness is imperative.

New oil must also be filtered before it is filled into the tank.

Collect old oil in approved containers and have it Used oil and oil filters must be properly disposed of.

• Fill in the new hydraulic oil through the filler opening (2) until the oil level is in the middle of the inspection glass (1).

• Open the four stop cocks of the suction lines.

• Start the engine and put the hydraulic system into operation.

• Carry out all functions of the carrier hydraulic system several times to remove any air from the system.

• Check the oil level in the hydraulic oil tank.

Top up oil if necessary.

02.07.2001

• Carry out a road test of the truck crane, turning the steering wheel several times to its fullest extent.

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Maintenance Manual GMK 4075

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7 - 53

Description of maintenance work on the carrier 7.11 Carrier hydraulic system

If the steering is "loose" at the end of the test run you must ventilate the steering cylinders.

G

Risk of crushing.

When working between the wheels ensure that the steering wheel cannot be turned by an unauthorized party. The wheels turn when the steering wheel is operated.

Risk of accidents.

Never undo the hose connections completely. The hydraulic system is under pressure, even when the steering wheel is not turned.

Bleed the steering cylinders individually, one after the other:

• Start the diesel engine.

• Bleed each steering cylinder (2) by loosening the cap nuts (1) in turn until the oil coming out no longer contains any air bubbles.

If the steering system is still not operating properly:

• Inform your local GROVE Customer Support

02.07.2001

or an authorised service centre.

7 - 54

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Maintenance Manual GMK 4075

Description of maintenance work on the carrier 7.12 Centrallubrication system

7.12

Centrallubrication system The grease container for the central lubrication system is on the right side of the vehicle between the second and third axle lines, behind the access ladder.

Use only oil as specified in the Maintenance plan, S. 5 - 6.

7.12.1

Central lubrication system There are two different versions of the central lubrication system: – Version 1 and – Version 2.

Version 1

à

Version 1 is (1) equipped with a display and control unit; Version 1 – Checking the level of the grease container and topping up, S. 7 - 56.

Version 2 With version 2, the operating instruments are located under a closure flap (1); Version 2 – Checking the level of the grease container and topping up, S. 7 - 59.

02.07.2001

à

Maintenance Manual GMK 4075

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7 - 55

Description of maintenance work on the carrier 7.12 Centrallubrication system

7.12.2

Version 1 – Checking the level of the grease container and topping up

W

Checking the level

• Check the oil level on the grease container (1).

The level must be near the MAX mark.

If the level in the grease container is too low;

à Filling the grease container, S. 7 - 57.

If the level drops below the MIN mark, automatic lubrication is interrupted.

Actuate intermediate lubrication

An intermediate lubrication must be actuated, – after a high pressure cleaning; – for inspecting the lubrication on individual lubrication points.

• Turn the diesel engine ignition on.

• Unscrew the cover (1) in front of the display and control unit.

• Press once the push-button DK (2).

A lubrication cycle is actuated and it lasts for approximately 3 minutes. Check if the lubricating grease comes out on all lubricating points.

• Replace the covering (1).

• Switch off the diesel engine ignition.

02.07.2001

• Remove any spilling grease.

7 - 56

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Maintenance Manual GMK 4075

Description of maintenance work on the carrier 7.12 Centrallubrication system

Filling the grease container

• Unscrew the cap (5) from the filling pump (1).

• Remove both caps (2) and (4) from the grease cartridge (3).

H

Ensure that the packing (8) is in proper position in the filling pump. The packing must be folded toward the plunger rod (7).

• Push the grease cartridge (3) into the filling pump.

• Check that the seal (6) is in proper position in the cap (5).

S

• Screw the cap onto the filling pump.

Do not remove the sealing caps from the filler opening and filling pump until immediately before refilling the grease. This prevents dirt particles from getting into the grease.

• Unscrew the sealing cap (1) on the grease

02.07.2001

container.

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7 - 57

Description of maintenance work on the carrier 7.12 Centrallubrication system

H

The central lubrication system must be running while the grease container is being filled.

• Unscrew the sealing cap (1) from the filling pump.

• Screw the filling pump onto the filler opening of the grease container.

• Actuate the intermediate lubrication;

à Actuate intermediate lubrication, S. 7 - 56.

• Push the grease into the grease container through the filler opening using the plunger rod.

• Screw the appropriate sealing caps onto the filler opening of the grease container and the outlet of the filling pump.

Bleeding the central lubrication system

The central lubrication system must be bled when the grease container is empty or air is trapped in the grease.

• Fill the grease container (1); à Version 1 –

Checking the level of the grease container and topping up, S. 7 - 56.

• Loosen the outlet scr ew fitting (3) of the pump element.

• Press once the push button DK (2) in order to actuate the intermediate lubrication; Actuate intermediate lubrication, S. 7 - 56.

à

• Let the pump run until the grease running out of the outlet screw fitting (3) no longer contains any air bubbles.

• Re-tighten the drain screw fitting (3).

• Remove any spilling grease. lubricant cables and lubrication points in the same way.

7 - 58

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Maintenance Manual GMK 4075

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• Remove the air from the main and auxiliary cables, auxiliary distributor,

Description of maintenance work on the carrier 7.12 Centrallubrication system

7.12.3

Version 2 – Checking the level of the grease container and topping up

W

Checking the level

• Check the oil level on the grease container (1).

The level must be near the MAX. mark.

If the level is too low, fill the grease container through the filler connection (2) using a filling pump.

Filling the grease container

H

You must connect a connecting piece to the grease container before refilling the container with the filling pump for the first time. This procedure is explained in the following. The connecting piece and a sealing cap are enclosed with the filling pump.

• Unscrew the stopper (1) from the grease container.

• Screw the connecting piece (2) into the opening.

• Screw the sealing cap (3) onto the connecting piece.

02.07.2001

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7 - 59

Description of maintenance work on the carrier 7.12 Centrallubrication system

• Unscrew the cap (5) from the filling pump (1).

• Remove both caps (2) and (4) from the grease cartridge (3).

H

Ensure that the packing (8) is in proper position in the filling pump. The packing must be folded toward the plunger rod (7).

• Push the grease cartridge (3) into the filling pump.

• Check that the seal (6) is in proper position in the cap (5).

• Screw the cap onto the filling pump.

H

The central lubrication system must be running while the grease container is being filled.

• Turn the diesel engine ignition on.

• Unscrew the bottom sealing cap (2) on the grease container.

• Press the switch (3) behind the cap. This triggers a complete lubrication procedure.

• Remove the sealing cap on filler opening (1)

02.07.2001

of the grease container.

7 - 60

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Maintenance Manual GMK 4075

Description of maintenance work on the carrier 7.12 Centrallubrication system

S

Do not remove the sealing caps from the filler opening and filling pump until immediately before refilling the grease. This prevents dirt particles from getting into the grease.

• Unscrew the sealing cap (1) from the filling pump.

• Screw the filling pump onto the filler opening of the grease container.

• Push the grease into the grease container through the filler opening using the plunger rod.

• Screw the appropriate sealing caps onto the filler opening of the grease container and the outlet of the filling pump.

• Seal the lower opening for the button with the sealing cap.

Bleeding the central lubrication system

The central lubrication system must be bled when the grease container is empty or air is trapped in the grease.

• Fill the grease container (1) (à Version 2 –

Checking the level of the grease container and topping up, S. 7 - 59).

• Loosen the outlet screw fitting (2) of the pump element.

• Turn the diesel engine ignition on.

• Press the switch (4), to actuate the additional lubrication.

• Let the pump run until the grease running out of the outlet screw fitting (2) no longer contains any air bubbles.

• Retighten the drain screw fitting (2) and

02.07.2001

screw the sealing caps back onto the filler opening of the grease container and the switch opening (3).

• Remove any excess grease.

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7 - 61

Description of maintenance work on the carrier 7.12 Centrallubrication system

02.07.2001

Blank page

7 - 62

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Maintenance Manual GMK 4075

Description of maintenance work on the carrier 7.13 Carrier electrical system

7.13

Carrier electrical system

7.13.1

Checking the acid level of batteries

M1

• Keep the batteries clean and dry.

• Loosen any dirty terminals and clean them.

G H

Grease the terminals with an acid-free, acid-resistant grease.

Hydrogen escaping from the batteries is explosive!

Do not place tools on the battery and keep unshielded light away from the battery.

It is particularly important to check the acid level during the warmer months.

• Check the acid level in the individual cells: –In case of batteries in which the acid level is visible, the acid must be approximately 15 mm above the plates.

–In case of batteries with an overflow reservior, distilled water must be in the overflow reservior.

If the acid does not come up to the required level or there is no distilled water in the overflow reservoir:

• Only fill in distilled water:

02.07.2001

–up to the required height above the plates or –until it no more spills out of the overflow reservior.

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7 - 63

Description of maintenance work on the carrier 7.13 Carrier electrical system

7.13.2

M3

Checking the acid concentration of batteries • Measure the acid concentration of each cell with an acid tester.

The following table gives a guide to battery charge levels.

Acid concentration (° Bé)

Specific weight (g/cm3)

Charge condition

32

1,28

good

24

1,20

half, recharge

16

1,12

enpty, charge immediately

02.07.2001

H

It is particulary important to check the acid concentration with the onset of the colder months.

7 - 64

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Maintenance Manual GMK 4075

Description of maintenance work on the carrier 7.14 Carrier air conditioning system (additional equipment)

7.14

Carrier air conditioning system (additional equipment) The GMK 4075 is equipped with only one refrigerant circuit for the airconditioning system on the carrier and superstructure.

7.14.1

Checking the moisture and level of the refrigerant

M1

The refrigerant is checked through an inspection glass on the refrigerant drier while the air conditioning system is running (1).

The battery box is located on the right-hand side of the vehicle over the first axle line.

• Start the diesel engine.

• Switch on the air-conditioning system and let it run for about 10 minutes. (Switching on the air-conditioning system Operating manual, Section Air conditioning system in chapter Driving with the truck crane).

à

• Check the refrigerant filling and the moisture content of the refrigerant through the inspection glass (1): – The flowing refrigerant must be visible and must not contain any large bubbles or foam.

– The PVC float ball (3) must be at the top.

– A green dot (2) must be visible on the moisture indicator.

02.07.2001

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7 - 65

Description of maintenance work on the carrier 7.14 Carrier air conditioning system (additional equipment)

If the moisture indicator shows a yellow dot or if bubbles or foam are visible, the air conditioning system is defective.

If the air conditioning system is defective:

• Switch the air conditioning system off and do not use it again to avoid further damage.

Have the air conditioning system repaired as soon as possible by GROVE Customer Support.

After checking:

• Switch off the air conditioning system and turn off the diesel engine.

7.14.2

S

M1

Cleaning capacitor disks

Risk of damage to the capacitor.

Do not use a high pressure or steam jet cleaner. The hard water jet can damage the disks or the fan wheel. Use only compressed air for cleaning.

The capacitor is mounted between the radiator and the right tread grille on the carrier.

• Switch off the air conditioning system.

• Clean the disks of the capacitor (1) with com-

02.07.2001

pressed air.

7 - 66

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Maintenance Manual GMK 4075

Description of maintenance work on the carrier 7.14 Carrier air conditioning system (additional equipment)

7.14.3

M6

Checking hoses • Check all refrigerant hoses for damage and worn areas.

Have damaged hoses replaced only by GROVE Customer Support.

7.14.4

Checking the refrigerant compressor

M6

The refrigerant collector may only be checked

by GROVE Customer Support!

02.07.2001

For this, the refrigerant collector (1) must be checked externally by a qualified person according to the pressure container order (test group II) for mechanical damage and corrosion. If the refrigerant collector is not in proper working condition, it must be replaced

by GROVE Customer Support.

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7 - 67

Description of maintenance work on the carrier 7.14 Carrier air conditioning system (additional equipment)

7.14.5

Checking the refrigerant compressor control

H

M6

This check may only be carried out by GROVE Customer Support!

• The refrigerant compressor (1) is at the front on the right side of the vehicle engine underneath the fuel filter.

• Have the refrigerant compressor checked for tightness. Above all the sealing of the drive shaft should be checked.

7.14.6

Checking the entire air conditioning system

M 12

This check may only be undertaken by GROVE Customer Support!

• Have the whole air conditioning system checked for tightness and proper

02.07.2001

functioning.

7 - 68

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Maintenance Manual GMK 4075

Description of maintenance work on the carrier 7.15 Trailer coupling (additional equipment)

7.15

Trailer coupling (additional equipment)

7.15.1

Lubricating the trailer coupling

G H

M1

Risk of injury if the automatic closing device is actuated.

Do not put your hand into the coupling jaw when the trailer coupling is open.

This can actuate the automatic closing device, make the cotter pin move down with great force and seriously injure your hand.

To avoid over-lubrication, the trailer coupling should only be lubricated when open.

• Clean the two lubricating nipples (2 and 3) on the trailer coupling.

• Open the trailer coupling. To do this, move the hand lever (1) upward.

• Press grease according to Maintenance plan, S. 5 - 6 into the two lubricating nipples using a grease gun.

G

Risk of injury when closing the trailer coupling by hand.

When closing, the hand lever moves down with great force in the direction of the coupling jaw. Therefore start the closing process only by moving the lever briefly in the direction of the coupling jaw with the hand balls.

If you hold the hand lever and move it down, it may carry your hand with it and crush it.

02.07.2001

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7 - 69

Description of maintenance work on the carrier 7.15 Trailer coupling (additional equipment)

Closing the trailer coupling After lubrication you must close the trailer coupling.

• To do this move the hand lever knob (1) briefly in the direction of the coupling jaw (observe direction of arrow).

• Remove any excess grease.

7.15.2

M3

Checking the bearing

G

Risk of injury!

Ensure that the coupling is closed for the following work (lever points downwards). Otherwise, the lever may come down with great force and cause serious hand injuries.

• Jiggle the trailer coupling in vertical and longitudinal direction (arrows) to ensure proper positioning of the bearing. Hold the coupling at the top and bottom of the coupling head and not by the coupling jaw.

H 7 - 70

A vertical clearance of 3 mm at the coupling head corresponds to 1 mm bearing play.

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Maintenance Manual GMK 4075

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When shaking the coupling should not show longitudinal clearance; the vertical clearance must not exceed a value of 3 mm (as measured at the coupling head).

Description of maintenance work on the carrier 7.15 Trailer coupling (additional equipment)

7.15.3

M3

Checking the cotter pin

H

For the following tests the coupling must be closed; before closing by hand Lubricating the trailer coupling, S. 7 - 70. check the data in section

à

• Check the wear on the cotter pin (1). The diameter of the crowned section (arrows) must not be below the following values: Model series 400:

36.5 mm

Model series 700:

46.0 mm

If the diameter is below 36.5 or 46.0 mm, the pin must be replaced.

• Also check the cotter pin for the correct ver-

02.07.2001

tical clearance. Push the cotter pin (1) upwards using a screwdriver. The vertical clearance (2) of the pin must not exceed 4 mm.

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7 - 71

Description of maintenance work on the carrier 7.15 Trailer coupling (additional equipment)

7.15.4

M3

Checking the lower bushing

• Check the internal diameter of the lower bushing. The dimension (D) can not be less than the following values: Model series 400:

31.5 mm

Model series 700:

34.2 mm

If the diameter is below 31.5 or 34.2 mm, the bushing must be replaced.

7.15.5

M3

Checking the support ring

• Check the support ring (1) for the draw eyelet at the bottom of the coupling jaw.

When the trailer is coupled, the draw eyelet of the trailer may have slight contact with the lower bushing (2).

Have the support ring changed if: – the trailer's draw eyelet touches the lower bushing because of wear or

02.07.2001

– the support ring has reached its wear limit of H =14 mm.

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Maintenance Manual GMK 4075

Description of maintenance work on the carrier 7.15 Trailer coupling (additional equipment)

7.15.6

Checking the initial tension of the springs

M3

New couplings should show an initial axial torque of at least 100 Nm. The coupling head should require physical power to twist when checking the torque.

• Twist the coupling head clockwise and counterclockwise to check the initial tension of the rubber springs.

7.15.7

Checking the function of the coupling jaw / re-adjusting the middle position

H Function checking

M3

The following checks are required only on model series 700. If you need to close the coupling by hand for the checks, make sure you observe the data in section Lubricating the trailer coupling, S. 7 - 70.

If you need to close the coupling by hand for the checks, make sure you observe the data in section Lubricating the trailer coupling, S. 7 - 70.

• Close the coupling (position B); à p. 7 - 71.

The coupling jaw must be able to move easily in both directions.

• Hold the coupling jaw (1) pressed slightly to the left or right.

• Open the coupling (position A) and let the coupling jaw go.

02.07.2001

The release lever must automatically lock the coupling jaw in the central position. The coupling jaw is locked when the coupling can no longer move to the side.

H

If the release lever does not automatically engage with the coupling jaw, the central position will need to be re-adjusted; p. 7 - 75.

Maintenance Manual GMK 4075

à

s 2 084 643 en

7 - 73

Description of maintenance work on the carrier 7.15 Trailer coupling (additional equipment)

Re-adjusting centrel position

• Open the coupling (hand lever (1) up).

• Loosen the three screws (2) at the bottom of the coupling.

• Push the coupling jaw to the right or left until the release lever snaps into place.

• Retighten the three screws (2) (tightening torque: 58 Nm).

• After adjusting check the function of the

à p. 7 - 74.

02.07.2001

coupling jaw;

7 - 74

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Maintenance Manual GMK 4075

Description of maintenance work on the carrier 7.16 Other maintenance work

7.16

Other maintenance work

7.16.1

Lubricating the outrigger beams

M1

The operation of the supports can be found in the Operating Instructions, Chapter Erecting work, Section Supporting.

Please note the safety instructions given in that section.

G

Risk of crushing.

Ensure that there is sufficient room around the crane. Warn any persons nearby before extending the outriggers.

• Fully extend the outrigger beams.

• Apply the lubricating grease with a brush or spatula to both sides of the four slide faces and to the points (1). Use only lubricating grease according to Maintenance plan, S. 5 - 8.

• Extend and retract the outrigger beams several times in order to improve the lubrication effect.

7.16.2

Checking for correct operation of the auxiliary heater (additional equipment)

M1

Operate the additional heating for 20 to 30 minutes in the warm time of year ( Operating Instructions, Chapter Driving with the truck crane, Section Water auxiliary heating (additional equipment).

02.07.2001

à

• Check that the system is working properly.

• Inform your local GROVE Customer Support if the heating system is not working properly.

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7 - 75

Description of maintenance work on the carrier 7.16 Other maintenance work

02.07.2001

Blank page

7 - 76

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Maintenance Manual GMK 4075

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8 8

Description of maintenance work on the superstructure . . 8 -

1

8.1

Shifting clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 -

1

8.1.1 8.1.2

Shifting clutch – oil level check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Shifting clutch – oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 -

1 2

8.2

Hoists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 -

3

8.2.1 8.2.2 8.2.3 8.2.4 8.2.5 8.2.6 8.2.7

Hoisting gear – oil level check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Checking for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Checking the hoist brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Lubricating the hoist gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Hoisting gear – oil change. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Carrying out partial inspection of hoists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Carrying out general inspection of hoists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 -

3 4 4 5 5 8 8

8.3

Slewing gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 -

9

8.3.1 8.3.2 8.3.3 8.3.4 8.3.5

Slewing gear – oil level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 9 Checking for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 10 Lubricating slewing gear pinion and gear rim . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 10 Slewing gear – oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 11 Slewing gear brake function check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 13

8.4

Superstructure hydraulic system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 15

8.4.1 8.4.2 8.4.3 8.4.4 8.4.5

Checking the hydraulic hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 15 Checking for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 15 Bleeding the derricking cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 16 Bleeding telescoping cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 18 Replacing the hydraulic oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 21

8.5

Main boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 23

8.5.1

Lubricating the telescope slide faces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 23

8.6

Hoist ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 29

8.6.1 8.6.2

Checking the position of sheaves and rope drums. . . . . . . . . . . . . . . . . . . . . . . 8 - 29 Checking the status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 30

8.7

Safe load indicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 41

8.7.1

Maintaining the slip ring assembly of the cable drum . . . . . . . . . . . . . . . . . . . . 8 - 41

8.8

Central lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 45

8.9

Hook blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 47

8.9.1

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 47

8.10

Superstructure electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 49

8.10.1 8.10.2

Checking the acid level of batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 49 Checking the acid concentration of batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 49

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Superstructure air conditioning system (additional equipment) . . . . . . . . . . . . . 8 - 51

8.11.1

Checking hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 51

8.12

Other maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 53

8.12.1 8.12.2

Lubricating the counterweight hoist unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 53 Checking for correct operation of the auxiliary heater (additionalequipment) 8 - 53

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8.11

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Description of maintenance work on the superstructure 8.1 Shifting clutch

8

Description of maintenance work on the superstructure

8.1

Shifting clutch

H 8.1.1

To reach the shifting clutch you must tilt the driver's cab, forward, S. 7 - 1.

à Tilt driver's cab

The shifting clutch is located between the diesel engine and the hydraulic pumps for the superstructure hydraulic system.

Shifting clutch – oil level check

M1

After the diesel engine has been turned off, the oil level of the shifting clutch can be controlled via the inspection glass. The inspection glass is located on the right side of the shifting clutch casing.

G

Danger of burning yourself when the diesel engine is hot!

During operation, the diesel engine and add-on parts can reach temperatures of up to 400 °C. Wear suitable protective gloves and make sure that you do not touch hot parts when you are topping up oil when the diesel engine is hot.

• Tilt the driver's cab; à p. 7 - 1.

• Check the oil level of the shifting clutch through the inspection glass (1). The inspection glass must be completely filled with oil.

If the oil level is too low:

• Remove the screw (2) from the oil filler opening.

• Add oil until the inspection glass is full. Only use oil specified in the Maintenance plan, S. 5 - 9.

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• Reinsert the scre w(2) into the oil filler opening.

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8-1

Description of maintenance work on the superstructure 8.1 Shifting clutch

8.1.2

M 12

Shifting clutch – oil change Only use oil specified in the Maintenance plan, S. 5 - 15.

O G

Always use oil collection containers which are oil-resistant.

Wipe up spilled oil immediately.

Danger of burning yourself when the diesel engine is hot!

During operation, the diesel engine and add-on parts can reach temperatures of up to 400 °C. Wear suitable protective gloves and make sure that you do not touch hot parts when you are topping up oil when the diesel engine is hot.

• Tilt the driver's cab; à p. 7 - 1.

• Have an oil collection container ready (capacity approx. 0.5litres).

• Remove the screw (1) from the oil filler opening.

• Remove the screw (3) from the oil drain opening and drain the oil into the oil container.

• Replace the sealing ring of the screw and reinsert the screw into the oil drain opening.

• Top up oil and check the oil level through the inspection glass (2). Only use oil specified in the Maintenance plan, S. 5 - 9.

• Reinsert the scre w(1) into the oil filler Risk of polluting the environment!

Collect waste oil in approved containers and have it disposed of properly.

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O

opening.

8-2

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Description of maintenance work on the superstructure 8.2 Hoists

8.2

Hoists The main hoist and the auxiliary hoist of identical construction (additional equipment) are located on the superstructure turntable. The auxiliary hoist is located behind the main hoist.

8.2.1

Hoisting gear – oil level check

W

The standpipe used to read the oil level in the hoist gear is located on the right side of the superstructure on the hoist.

• Check the oil level of the hoisting unit transmission at the standpipe (3). The oil level must be between the MAX and MIN marks (4).

If the oil level is too low:

• Unscrew the upper sealing screw (1) and remove the connecting hos e(2) from the standpipe.

• Top up oil via the standpi pe(3).

Only use oil specified in the Maintenance plan, S. 5 - 7.

• Replace the sealing rings of the upper screw plug and screw the upper hose back on.

• Check the oil level of the brake unit by unscrewing the sealing plug out of the overflow opening (1).

The oil level must be visible under the opening.

If the oil level is too low:

• Unscrew the sealing screw of the filling

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hole (2) and top up with oil.

Only use oil specified in the Maintenance plan, S. 5 - 7.

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8-3

Description of maintenance work on the superstructure 8.2 Hoists

8.2.2

W

Checking for leaks • Make a visual inspection for leaks.

• If hydraulic oil or gear oil has been lost, check the oil levels and top up if necessary.

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

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

8.2.3

W

Checking the hoist brake

Test correct function of the hoist brake by suspending a load on the load hook for a certain time and measuring whether the load lowers on its own.

Perform the test on the main hoist and the auxiliary hoist:

• Suspend the hook block on the singly reeved hoist rope.

• Lift a test load of approx. 9.2 t approx. 30 cm above the ground.

• Measure the distance from the ground when the test load is hanging completely still.

• Switch off the diesel engine.

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If the test load has not lowered after approx. 2 minutes, the brake applied is in working order at that time.

8-4

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Description of maintenance work on the superstructure 8.2 Hoists

8.2.4

Lubricating the hoist gears

H

W

The main hoist is connected to the centralised lubrication system. The following maintenance work only applies to the auxiliary hoist (additional equipment).

The auxiliary hoist has a lubricating nipple (1).

The lubricating nipple is located on the left side of the superstructure on the auxiliary hoist.

Only use lubricating grease specified in the Maintenance plan, S. 5 - 7.

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

• Use a grease gun to apply grease to the lubricating nipple.

8.2.5

Hoisting gear – oil change

M 12

The hoists have separate oil chambers for the gear box and the clutch housing.

Only use oil specified in the Maintenance plan, S. 5 - 15.

Always use oil collection containers which are oil-resistant.

Wipe up spilled oil immediately.

s

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S O

Be careful not to damage the hoist gear!

The waste oil must be tested for abrasion particles. This examination serves to identify damage at an early stage.

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8-5

Description of maintenance work on the superstructure 8.2 Hoists

Changing the hoisting unit transmission oil

Oil change is carried out on the right side of the turntable via the connecting hoses to the standpipe.

• Have a container (with a capacity of over 8 l) ready under the standpipe to collect the oil (3).

• Loosen the upper screw plug (1) and remove the upper hose (2).

• Unscrew the lower screw plug (5) and let the oil flow into the collection container.

• Replace the sealing rings of the lower screw plug and screw the lower hose (4) back on.

• Fill the oil up to the max mark (6) through the standpipe.

• Replace the sealing rings of the upper screw plug and screw the upper hose back on.

Changing the oil in the brake unit

H

Since the oil is distributed slowly in the clutch housing being filled, the oil level on the overflow opening will at first rise quickly and then subside a little; afterwards it will rise to the final filling level.

• Place an oil collection container (capacity approx. 1 l) underneath the oil drain (3).

• Unscrew the screw plugs of the filling hole (1) and the overflow opening (2).

• Remove the screw connection (3) and drain the oil.

• Screw the screw connection (3) on again.

• Pour oil slowly through the filler opening (1)

• If necessary, replace the sealing rings for the screw plugs of the filler and overflow openings

• Screw the screw plugs in again.

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until it reaches the lower edge of the overflow opening (2).

Description of maintenance work on the superstructure 8.2 Hoists

O

Risk of polluting the environment!

Collect waste oil in approved containers and have it disposed of properly.

Checking the oil

H

Check the waste oil which was drained from the gear units during the oil change for abrasion particles or have it tested in a laboratory:

• Pour the used oil through a clean filter fleece.

• Examine the oil or the residues on the filter fleece using a magnifying glass.

If you find abrasion particles or solid matter on the fleece, the hoist gear must be dismantled for inspection and examined by the manufacturer.

H

Danger of accidents!

If this examination is not carried out, there is a risk of damage to the hoist gears and thus the possibility of the load falling.

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G

With the first oil there may be some abrasion particles in the oil. If you notice any abrasion particles during the first oil change (after 200 operating hours), contact GROVE Customer Support before you take any more measures.

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8-7

Description of maintenance work on the superstructure 8.2 Hoists

8.2.6

Carrying out partial inspection of hoists

Y3

Certain parts must be inspected for wear during the partial inspection: – the multiple-disk brake, – the plug connections between the hydraulic engine and the multiple-disk brake, and – the plug connections between the multiple-disk brake and the gearbox unit (where applicable).

These parts must be replaced when worn.

H 8.2.7

Inspections and part replacements must only be carried out by trained, qualified personnel.

Carrying out general inspection of hoists

H

Y6

When carrying out general inspection of the hoists, also observe the information contained in the section on Measures required for winch monitoring, S. 5 - 21.

The hoist gear is to undergo general inspection after the period of time indicated in the maintenance plan. This inspection involves disassembly of the gearbox and sending it to the manufacturer for testing.

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H

Run-in specifications require that the oil of new gearboxes and gearboxes that have undergone a general overhaul be changed after 200 and 1 000 operating hours before the yearly interval can be implemented.

8-8

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Description of maintenance work on the superstructure 8.3 Slewing gear

8.3

Slewing gear The slewing gear is on the right-hand side of the superstructure.

8.3.1

W

Slewing gear – oil level check

H

The oil must be cool before carrying out an oil inspection. Therefore always check the oil level before using the crane.

• Check the oil level using the oil level sight glass (1) on the slewing gear transmission.

The oil must be visible in the sight glass.

If the oil level is too low:

• Unscrew the vent screw (3) and fill the oil according to the

à Maintenance plan, S. 5 - 7.

• Close the opening.

• For the slewing gear brake, check the oil level using the oil level sight glass (1) in the expansion tank (2).

The oil must be visible in the sight glass.

If the oil level is too low:

• Unscrew the ventilation filter (3) from the expansion tank and top up with oil as specified in the Maintenance plan, S. 5 - 7.

à

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• Close the opening.

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8-9

Description of maintenance work on the superstructure 8.3 Slewing gear

8.3.2

W

Checking for leaks • Make a visual inspection for leaks.

• If hydraulic oil or gear oil has been lost, check the oil levels and top up if necessary.

• If damage cannot be rectified immediately or further damage is likely: • Inform your local GROVE Customer Support or your repair crew.

8.3.3

Lubricating slewing gear pinion and gear rim

M6

The slewing gear pinion and spur gear must be lubricated with special grease ( Maintenance plan, S. 5 - 13). The grease is applied to the gear teeth with a brush or sprayed on. There are different procedures for the first time and subsequent lubrications.

à

H

Observe the instructions and safety information on the grease packaging.

• Unscrew the screws and remove the guard (1) in front of the slewing gear pinion (2).

First lubrication:

• Clean the gear teeth of the slewing gear pinion (2) and the spur gear (3) thoroughly to remove residue of old lubricants.

• Apply a thin layer of adhesive lubricating grease and leave to penetrate for approx.

10 minutes.

• Apply a second, thicker coat and leave to penetrate for approx. 30 minutes.

Subsequent lubrication:

• Apply a new layer over the existing layer of • Leave to penetrate for approx. 30 minutes.

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adhesive lubricating grease.

Description of maintenance work on the superstructure 8.3 Slewing gear

M 12

8.3.4

Slewing gear – oil change

Slewing gear transmission oil change

The oil drain screw of the slewing gear unit is located above the spur gear of the slewing gear pinion. Only use oil specified in the Maintenance plan, S. 5 - 15.

O

à

Always use oil collection containers which are oil-resistant. Wipe up spilled oil immediately.

• Unscrew the guard (4) in front of the slewing gear pinion.

• Have an oil collection container ready (capacity approx. 5 l).

• Unscrew the vent screw (2).

• Unscrew the ventilation filter (1) from the filler neck.

• Unscrew the oil drain plug (5) and drain the oil into the oil container.

• Replace the sealing ring on the oil drain plug and screw the plug back in.

• Fill with oil (à Maintenance plan, S. 5 - 14)

and check the level of the oil by inspecting the oil level sight glas s(3).

• Screw the ventilation filte r(1) and the ventilation screw (2) back on with a new sealing ring.

s

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O

Risk of polluting the environment!

Collect waste oil in approved containers and have it disposed of properly.

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8 - 11

Description of maintenance work on the superstructure 8.3 Slewing gear

Checking the oil

H

Check the old oil which was drained from the slewing gear transmission for abrasion particles or have it tested in a laboratory.

• Pour the used oil through a clean filter fleece.

• Examine the oil or the residues on the filter fleece using a magnifying glass.

If you find abrasion particles or solid matter on the fleece, the slewing gear transmission must be dismantled for inspection and examined by the manufacturer.

Slewing gear brake oil change

O

The slewing gear brake is located on the slewing gear itself.

Only use oil specified in the Maintenance plan, S. 5 - 15.

à

Risk of polluting the environment!

Drain the oil into the collecting vessel via a draining gutter. Wipe up spilled oil immediately.

• Have an oil collection container ready (capacity approx. 1.5 l).

• Unscrew the vent filter( 4) from the expansion tank (3).

• Remove the screw from the oil drain opening (1) and let the oil run into the oil collection container via a draining gutter.

• Replace the sealing ring and replace the screw (1) in the oil drain opening.

• Add new oil through the expansion ta nk(3) until the oil level is in the middle of the oil level sight glass (2).

• Screw the vent filte r(4) back on to the

8 - 12

Collect waste oil in approved containers and have it disposed of properly.

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O

expansion tank.

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Description of maintenance work on the superstructure 8.3 Slewing gear

8.3.5

Slewing gear brake function check

D

To check the wear on the slewing gear brake plates you must carry out a slewing gear service brake function test. This involves slewing movement against the slewing gear service brake.

G

Risk of overturning when rotating the superstructure!

The truck crane must be on outriggers before slewing the superstructure.

Read the notes in the chapter Crane work with the main boom – slewing in the Operating manual before checking for proper function.

Y • Y ••

Release the slewing gear permanent brake by pressing the Slewing gear permanent brake rocker switch upwards.

The slewing gear permanent brake indicator lamp goes out.

Push the slewing gear service brake pedal down and hold it.

• Active the slewing gear. To do this turn the left-hand control lever slowly to the left or right as far as it will go.

If the superstructure turns, the slewing gear service brake plates are worn and must be replaced immediately.

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• Only have the plates changed by GROVE Customer Support.

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8 - 13

Description of maintenance work on the superstructure 8.3 Slewing gear

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8 - 14

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Description of maintenance work on the superstructure 8.4 Superstructure hydraulic system

8.4

Superstructure hydraulic system

8.4.1

Checking the hydraulic hoses

W

The inspection work is described in section Checking the hydraulic hoses, S. 7 - 44.

8.4.2

Checking for leaks

W

• With the diesel engine running, make a visual inspection for leaks and escaping hydraulic oil on the hydraulic components of the superstructure (hydraulic cylinders, lines, connections, hydraulic pumps, motors, valves, and control block).

• If leaks are detected, check the hydraulic oil level and top up if necessary

G

Danger of accidents!

Never tighten leaking 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 local GROVE Customer Support or your repair crew.

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

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O

à Hydraulic unit – oil level check, S. 7 - 43).

(

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8 - 15

Description of maintenance work on the superstructure 8.4 Superstructure hydraulic system

8.4.3

M1

Bleeding the derricking cylinder

There are bleeder screws on the derricking cylinder for bleeding the cylinder chambers.

In the toolbox there is a special key with a transparent hose for opening the vent screws. Only this special key should be used to open the vent screws.

Prerequisites

With the following requirements it is assumed that the counterweight and lattice extension are not rigged.

• Park the truck crane on a flat, even surface.

• Support the truck crane with at least the outrigger span 8.10 m x 6.00 m.

• Fully retract the main boom.

• Set the SLI code for 0 t counterweight.

• Slew the superstructure to the rear or to the side.

• Lower the boom as far as possible.

Bleeding the piston rod chamber

G

Risk of accidents from hydraulic oil being sprayed!

The hydraulic system is under pressure. For this reason, you may only loosen the vent screws. If you unscrew the vent screws, hydraulic oil will spray out under pressure.

• Remove the cap from the vent screw (1) on the piston rod chamber.

• Fit one end of a plastic transparent hose over the vent screw and hold the other end in a container filled with oil.

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• Loosen the vent screw by 1 – 2 turns.

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Description of maintenance work on the superstructure 8.4 Superstructure hydraulic system

G

Risk of accidents when raising the main boom!

Move the control lever very carefully. To ventilate only hydraulic oil must be delivered into the derricking cylinder. The derricking cylinder must not move!

• Carefully raise the control lever until the oil flowing through the transparent plastic hose no longer contains any air bubbles.

• Tighten the vent screw, remove the plastic hose and replace the cap on the vent screw.

Bleeding the piston head area

G

Before ventilation, the requirements listed at the start of this section must be fulfilled.

Risk of accidents from hydraulic oil being sprayed!

The hydraulic system is under pressure. For this reason, you may only loosen the vent screws. If you unscrew the vent screws, hydraulic oil will spray out under pressure.

• Check that the boom is lowered as far as it will go.

• Remove the cap from the vent scre w(1).

• Fit one end of a plastic transparent hose over the vent screw and hold the other end in a container filled with oil.

• Loosen the vent screw by 1 – 2 turns.

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G

Risk of hands and arms being crushed!

Move the control lever very carefully. To ventilate only hydraulic oil must be delivered into the derricking cylinder. The derricking cylinder must not move!

• Carefully raise the control lever until the oil flowing through the transparent plastic hose no longer contains any air bubbles.

• Tighten the vent screw, remove the plastic hose and replace the cap on the vent screw.

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8 - 17

Description of maintenance work on the superstructure 8.4 Superstructure hydraulic system

8.4.4

M1

Bleeding telescoping cylinders

There are two vent screws on the telescoping cylinder for bleeding the cylinder chambers. The vent screws are accessible through hand holes in the telescopic sections.

In the toolbox there is a special key with a transparent hose for opening the vent screws. Only this special key should be used to open the vent screws.

Prerequisites

With the following requirements it is assumed that the lattice extension is not rigged.

• Park the truck crane on a flat, even surface.

• Create one of the two following rigging states: –The truck crane is supported by an outrigger span of 8.10 m x 6.00 m and there is at least 3.8 t of counterweight or –The truck crane is supported by an outrigger span of 8.10 m x 7.00 m and there is at least 1.8 t of counterweight.

• Enter the SLI rigging code for the current rigging mode of the truck crane.

• Fully retract all telescope sections.

• Unreeve the hook block.

• Slew the superstructure to the rear or to the side.

• Derrick the boom into horizontal position.

Bleeding procedure

Carry out the bleeding procedure on all vent screws in turn.

• Remove the cap from the relevant vent screw.

• Place the special key with the transparent hose onto the vent screw. Hold the other end of the hose in a container filled with oil.

• Loosen the vent screw by 1 – 2 turns.

• Carefully fill the telescoping cylinder with hydraulic oil until the oil flowing through the hose no longer contains any bubbles. Carefully extend the relevant telescope section in the direction specified.

s

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The oil collected in the container must not be used again as it contains air.

Description of maintenance work on the superstructure 8.4 Superstructure hydraulic system

Location of vent screws

Vent for:

Access to vent on basic section via:

1

Set of piston rings

Manhole in top chord Basic section

2

Piston chamber

Opening in telescopic section IV left-hand side

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Position no.

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8 - 19

Description of maintenance work on the superstructure 8.4 Superstructure hydraulic system

Telescoping status

The position numbers indicated below refer to the illustrations for Location p. 8 - 19. of the bleeder screws in this section;

à

Vent screw position no. 1

G

Retracting boom poses risk of crushing!

Do not reach into the manhole until the boom has been secured so that it can not retract inadvertently. If you are carrying out this operation with the help of someone else, communicate with the person in the crane cab by means of clear hand signals.

• Screw off manhole cover plate.

• Extend telescope section I approx. 2.0 m so that the access to the manhole is free.

• Fit the bleeder key through the manhole onto the vent scre w(1) on the telescoping cylinder and open with one or two turns.

• Make sure nobody is in the manhole or is reaching into the manhole.

• Carefully move the control lever for telescoping in the retract direction so that the pressure in the set of piston rings increases and the air is pushed out through the plastic hose.

• Close the manhole again with the cover plate.

Vent screw position no. 2

• Extend telescope section IV approx. 0.5 m.

• Insert bleeder key through the opening on the left side of telescope section IV onto the vent screw and open 1 or 2 turns.

• Carefully move the control lever for telescoping in the extend direction so

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that the pressure in the piston chamber increases and the air is pushed out through the plastic hose.

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Description of maintenance work on the superstructure 8.4 Superstructure hydraulic system

8.4.5

Replacing the hydraulic oil filter

M3

Three hydraulic oil filters are installed in the hydraulic system: – a return flow filter and a fine filter in the oil tank in the carrier, – a pressure filter in the control oil circuit in the superstructure.

• The hydraulic oil filters must be replaced:

g

– if the warning lamps for the Hydraulic oil filter in the front instrument panel of the crane cab light up, – after every hydraulic oil change.

The warning lamp is located on the front instrument panel: – Warning lamp for Hydraulic oil filter in control circuit (1).

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O

Catch the oil escaping during filter change and store used fuel filter inserts in suitable containers and have them disposed of properly by qualified personnel.

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8 - 21

Description of maintenance work on the superstructure 8.4 Superstructure hydraulic system

Hydraulic oil filter for control circuit The hydraulic oil filter control circuit (1) is located on the right side of the superstructure, under the covering (2).

• Switch off the diesel engine and secure it against being started by unauthorized persons (sign in the driver's cab).

• Unscrew the screws and remove the cover (2).

• Remove the ring (1).

• Take off the filter ca n(2).

• Remove the filter from the filter can.

• Insert the new filter into the filter can.

• Fill the filter can up to the edge with hydraulic oil.

• Screw the filter can on again.

• Start the diesel engine and let it run in

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neutral gear for 3 minutes in order to bleed the system.

8 - 22

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Maintenance Manual GMK 4075

Description of maintenance work on the superstructure 8.5 Main boom

8.5

G

8.5.1

Main boom Be careful not to damage the locking pins.

The locking pins of telescope sections I to IV must never be lubricated.

If grease reaches the locking pins during lubrication, it must be removed completely.

Lubricating the telescope slide faces

M6

For lubricating the telescopic slide faces the main boom must be lowered into horizontal position and the telescope sections must be telescoped one after the other in a certain order so that the lubricating points are reached.

G

Danger of overturning!

Before the main boom is lowered or extended, observe the requirements explained in this section, S. 8 - 25.

At the corners of telescope sections I to IV there are four slide faces. The two lower slide faces (2) and (3) are lubricated from the outside in fully extended state.

The two upper slide face s(1) and (4) are lubricated by one lubricating nipple each.

The following section shows the position of the lubricating nipples.

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8 - 23

Description of maintenance work on the superstructure 8.5 Main boom

Position of lubricating nipples

The lubricating nipples (1) are located on the upper booms of the telescope sections and are reached via corresponding lubrication holes (2) in the telescope sections above. The diagram shows the telescope status for the lubrication of telescope section IV.

8 - 24

Quantity

Can be reached via the lubrication hole in

Telescopic section I

2

Top chord Basic section

Telescopic section II

2

Top chord Telescope section I

Telescope section III

2

Top chord Telescope section II

Telescopic section IV

2

Top chord Telescopic section III

Danger of accidents!

Danger of slipping due to grease residue. Do not climb onto the boom.

Use the extendable ladder provided with your crane!

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G

Lubricating nipple for

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Maintenance Manual GMK 4075

Description of maintenance work on the superstructure 8.5 Main boom

Prerequisites

G

The main boom must be partly extended in the horizontal position when carrying out maintenance.

Risk of overturning when extending in horizontal position!

In the horizontal position the SLI blocks telescoping when there is an attempt to extend a second telescope section.

Override the SLI only when you are prompted to do so in the following section and do not extend the main boom more than indicated.

Even with 31 t of rigged counterweight and the superstructure slewed to the rear you cannot extend all telescope sections. The truck crane would first overturn.

Before lowering or extending the boom, the following conditions must be met:

• Park the truck crane on a flat, even surface.

• Create one of the two following rigging states: –The truck crane is supported by an outrigger span of 8.10 m x 6.00 m and there is at least 3.8 t of counterweight or –The truck crane is supported by an outrigger span of 8.10 m x 7.00 m and there is at least 1.8 t of counterweight.

• Enter the SLI rigging code for the current rigging mode of the truck crane.

• Fully retract all telescope sections.

• Unreeve the hook block.

• Lower the main boom into a horizontal position.

H

To lubricate you must also telescope to intermediate lengths. Therefore telescope the main boom with semi-automatic (Operating manual, chapter on Crane operation; section on Crane operation with main boom).

à

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8 - 25

Description of maintenance work on the superstructure 8.5 Main boom

Lubricating slide faces of telescope sections

• To lubricate, use only special grease as specified in the Maintenance plan, S. 5 - 13.

• Lower the retracted main boom to the lowest position.

• Start with telescope setion IV.

G Lubricate telescopic section IV

Risk of accidents from slipping off!

There is grease residue on the telescope sections. For this reason, you must not walk on the boom.

Use the extendable ladder provided with your crane!

• Retract all telescopic sections.

• Enter the SLI rigging code for the current rigging mode of the truck crane.

• Telescope telescopic section IV to the middle locking position and lock it.

• Override the SLI by turning the Override key switch to the right.

• Extend telescopic section III to approx. 58% until the lubricating hole for telescopic section IV can be reached in the top chord.

• Inject approx. 100 ml of grease into each lubricating nipple (position 1).

• Fully retract telescopic section III. • Do not override the SLI anymore.

• Fully extend telescopic section IV. • Use a spatula to apply a thin layer of grease to the two lower slide faces of telescopic section IV .

• Extend and retract telescopic section IV again so that the grease is distributed uniformly on the telescope slide faces.

• Retract telescopic section IV. Lubricate telescopic section III

• Retract all telescopic sections.

• Enter the SLI rigging code for the current rigging mode of the truck crane.

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• Telescope telescopic section III to the middle locking position and lock it.

8 - 26

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Maintenance Manual GMK 4075

Description of maintenance work on the superstructure 8.5 Main boom

• Override the SLI by turning the Override key switch to the right.

• Extend telescopic section II to approx. 58% until the lubricating hole for telescopic section III can be reached in the top chord.

• Inject approx. 100 ml of grease into each lubricating nipple (position 1).

• Fully retract telescopic section II. • Do not override the SLI anymore.

• Fully extend telescopic section III. • Apply a thin layer of grease to the bottom two slide faces of telescopic section III with a spatula.

• Extend and retract telescopic section III again so that the grease is distributed uniformly on the telescope slide faces.

• Fully retract telescopic section III. Lubricate telescopic section II

• Retract all telescopic sections.

• Enter the SLI rigging code for the current rigging mode of the truck crane.

• Telescope telescopic section II to the middle locking position and lock it.

• Override the SLI by turning the Override key switch to the right.

• Extend telescopic section I to approx. 58% until the lubricating hole for telescopic section II can be reached in the top chord.

• Inject approx. 100 ml of grease into each lubricating nipple (position 1).

• Fully retract telescopic section I. • Do not override the SLI anymore.

• Fully extend telescopic section II. • Use a spatula to apply a thin layer of grease to the bottom two slide faces of telescopic section II.

• Extend and retract telescopic section II again so that the grease is distributed uniformly on the telescope slide faces.

• Retract telescopic section II.

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8 - 27

Description of maintenance work on the superstructure 8.5 Main boom

Lubricating telescopic section I

• Retract all telescopic sections.

• Enter the SLI rigging code for the current rigging mode of the truck crane.

• Extend telescopic section I to 100 %.

You can now reach the lubricating nipples via the front lubricating holes in the top chord of the basic section.

• Inject approx. 100 ml of grease into each lubricating nipple (position 1).

• Use a spatula to apply a thin layer of grease to the bottom two slide faces of telescopic section I.

• Extend and retract telescopic section I twice so that the grease is evenly spread on the telescope slide faces.

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• Retract telescopic section I.

8 - 28

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Maintenance Manual GMK 4075

Description of maintenance work on the superstructure 8.6 Hoist ropes

8.6

Hoist ropes

8.6.1

Checking the position of sheaves and rope drums

G

D

Danger of accidents due to turning rope drum.

Keep yourself and other people away from the turning rope drum. If you take hold of the turning rope drum, your fingers and hands could be crushed between the rope drum and hoisting gear frame or get caught and drawn in by the turning drum.

• Check the position of the hoist rope s(1) on the rope drums of the main hoist and the auxiliary hoist (additional equipment).

• Slowly turn the rope drum at least one turn in the lowering direction. Check the rope on the drum as you do this.

– The ropes must be uniformly wound onto the rope drum.

– The turns on the drum must have a uniform distance of 0 to 2 mm.

– The cross-over points must be offset by approx. 180°.

H

• Check the position of the hoist ropes on the sheaves at the boom head and in the hook block.

• Check the sheaves for damage and wear, and check that they run freely.

Risk of accidents from incorrectly set lowering limit switch!

Never turn the free rope end under the drum. Turns on the drum which are unwound when the rope drum is stationary can not be detected by the lowering limit switch. This causes the lowering limit switch to become set incorrectly and to switch off too late or not at all. In addition, the load may fall.

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G

The upper layer of rope lies over the lower layer at the cross-over points.

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8 - 29

Description of maintenance work on the superstructure 8.6 Hoist ropes

8.6.2

W

Checking the status

• Reeve the hoist rope on the hook block six times (à Operating instruc-

tions, chapter on Rigging work, section on Rigging work on the main boom).

• Support the truck crane and enter the SLI code for the current rigging mode.

• Raise the boom and extend it fully.

• Unreel the hoist rope and check that the rope is not damaged or improp-

à

erly reeled ( Assessing the condition of the hoist rope, S. 8 - 31). When five turns are left on the rope drum, the lowering limit switch must switch off.

If the lowering limit switch does not switch off or switches off too late, it Setting the lowering limit switch, S. 8 - 39. must be reset;

à

• Check the mounting of the rope clamp (1) on the rope drum for damage and ensure that it is securely attached (tightening torque; Special tightening torques, S. 10 - 2).

à

• Check whether the hoist rope can be wound without kinking and flattening: – The free end of the rope must protrude from the pocket (2).

• Check the rope securing device in the rope end clamp (2) for proper seating and correct positioning of rope.

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The rope end clam p(1) must be attached to the free end of the rope and the rope must secured around the rope wedge (3).

8 - 30

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Maintenance Manual GMK 4075

Description of maintenance work on the superstructure 8.6 Hoist ropes

Assessing the condition of the hoist rope

H

If in doubt about damage assessment, always consult an expert.

To assess the condition of the hoist rope, you must be familiar with the following: – the type of rope (crosslay rope or Lang’s lay rope), – the number of load bearing wires in the outer strand – the rope diameter ( Operating instructions, chapter on Technical information, section on Superstructure).

à

In a crosslay rope (1), the wires run more or less in the longitudinal direction of the rope.

In a Lang’s lay ro p e(2), the wires run at an angle of approximately 45° to the longitudinal direction of the rope.

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To calculate the number of bearing outer wires (1), count the number of outer strands of the rope and multiply by 7.

H

If there are multiple layers of strands, only the outer layer is counted.

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8 - 31

Description of maintenance work on the superstructure 8.6 Hoist ropes

The following tables show the number of wire breaks, in a length 6 times and 30 times the rope diameter, at which the rope must be replaced, for the most common rope diameters.

Number of visible wire strand fractures Number of load-bearing outer wires

Crosslay rope ∅ 13 mm

∅ 16 mm

∅ 19 mm

∅ 22 mm

∅ 24 mm

on 78 mm

on 390 mm

on 96 mm

on 480 mm

on 114 mm

on 570 mm

on 132 mm

on 660 mm

on 144 mm

on 720 mm

101-120

5

10

5

10

5

10

5

10

5

10

121–140

6

11

6

11

6

11

6

11

6

11

Number of visible wire strand fractures Loadbearing outer wires (Quantity)

Lang's lay rope ∅ 13 mm

∅ 16 mm

∅ 19 mm

∅ 22 mm

∅ 24 mm

on 78 mm

on 390 mm

on 96 mm

on 480 mm

on 114 mm

on 570 mm

on 132 mm

on 660 mm

on 144 mm

on 720 mm

101-120

2

5

2

5

2

5

2

5

2

5

121–140

3

6

3

6

3

6

3

6

3

6

H

Remember that other factors may also make it necessary to replace the hoist rope before the number of wire breaks requiring rope replacement has been reached (age of rope, frequency of use or exceptional loading).

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S

The number of visible wire breaks indicated here only applies to the hoist ropes! This information only applies to the initial equipment and original spare parts!

8 - 32

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Maintenance Manual GMK 4075

Description of maintenance work on the superstructure 8.6 Hoist ropes

Damage

Description

Cause

Wire strand fracture (1) Wire breakage clusters (2) Strand breakage (3)

Individual wires are General wear caused broken; the broken by aging of the rope ends of the wires are protruding from or the rope.

Effect of heat

Tarnishing colour is Rope has been subvisible externally on jected to strong heat. the rope.

Replacement At the latest, replace hoist rope when the maximum permissible number of wire strand fractures according to the table are visible externally.

Subsequent damage Replace hoist rope immediately resulting from damage if wire breakage clusters or to the rope. strand breakage occur.

The frequency of wire breakage increases with rope age. For reasons of safety, it is advisable to replace the hoist rope while the number of broken wires is still low.

Replace hoist rope immediately.

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8 - 33

Description of maintenance work on the superstructure 8.6 Hoist ropes

Damage

Description

Diameter reduction (1)

The diameter of the rope has become smaller in large areas.

Cause Structural changes

Replacement Immediately replace hoist rope if the diameter has decreased by 15% or more with respect to the nominal diameter.

Corrosion or abrasion. Immediately replace hoist rope if the diameter has decreased by 10% or more with respect to the nominal diameter.

The rope is winds its Damage resulting from way along its longi- overloading. tudinal axis in a way which is similar to a corkscrew.

The deformation is measured with the attached hook block.

Even a small amount of deformation leads to increased abrasion, wire strand fractures and rough operation of the cable drive.

If deformation 'x' at a position on the hoist rope is greater than a third of the rope diameter, the hoist rope must be replaced immediately.

Basket-type deformation (3)

Wires from the Outer and inner layers outer layer are pro- have dislocated from truding from the one another. rope. In various areas of the rope, the ply has buckled or is protruding from the rope.

Replace hoist rope immediately.

8 - 34

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Cork-screw deformation of rope (2)

Maintenance Manual GMK 4075

02.07.2001

Description of maintenance work on the superstructure 8.6 Hoist ropes

Damage

Description

Cause

Replacement

Loop formation (1)

Outer layer wires in the form of hair pins are protruding from the rope on the side opposite to the rope pulley.

General wear due to aging of the rope or subsequent damage resulting from damage to the rope.

Immediately replace hoist rope if the rope structure has been substantially altered by the loop formations.

Loosening of wires or strands (2)

Outer wires or Corrosion or abrasion. strands have beOther causes. come loose. Only the inner strands continue to bear the load.

Replace hoist rope immediately.

Formation of nodes (3)

Formation of nodes; repeatedly occurring node-formed thickening of rope; core often protrudes.

The strands bear on each other at narrow locations; increased occurence of wire breakage.

Constriction (4)

Reduction of rope General wear caused diameter over short by aging of the rope. sections.

Maintenance Manual GMK 4075

General wear due to aging of the rope or subsequent damage resulting from damage to the rope.

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The number of broken wires determines when the rope must be replaced.

Determine number of broken wires; replace hoist rope immediately if serious node formation occurs.

Replace hoist rope immediately if serious constriction occurs.

8 - 35

Description of maintenance work on the superstructure 8.6 Hoist ropes

Damage

Description

Cause

Replacement

Crushes areas, mostly with wire breakage.

Mechanical damage, Determine number of broken e.g. due to driving over wires; replace hoist rope immethe rope. diately if serious crushing occurs.

Crinkling

Crinkle type rope deformation.

Loaded hoist rope was Replace hoist rope immediately. pulled over an edge.

Kink (2)

Rope deformation with twisting and broken wires.

Rope was pulled straight while twisted and located in eyes.

Replace hoist rope immediately.

Buckle (3)

Buckled section in rope.

Mechanical damage.

Replace hoist rope immediately.

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Flattening (1)

8 - 36

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Maintenance Manual GMK 4075

Description of maintenance work on the superstructure 8.6 Hoist ropes

Replacing the hoist rope

The installation procedure can have a great influence on the service life of a hoist rope. Errors in installation reduce the service life considerably, therefore: – make sure the hoist rope is not twisted when it is installed.

– ensure it does not get dirty or damaged while being fitted – reel the rope up in the same direction in which it was reeled onto the drum on which it was supplied – tense the rope slightly while reeling it up.

S

Use only a replacement hoist rope which has the same technical specifications as the defective rope or an original replacement rope.

• Unreeve the hook block (à Operating instructions, chapter on Rigging work, section on Setting down the hook block).

• Wind out the hoist rope until the lowering limit switch switches off.

• Adjust the lowering limit switch so that you can unwind the hoist rope

à Setting the lowering limit switch, S. 8 - 39).

completely (

• Wind out the remaining layers from the hoist drum.

H

G

Ensure that the rope is not wound on again in the other direction.

Risk of accidents from rotating rope drum!

Turn off the diesel engine and remove the ignition key so that no unauthorized operation of the hoist can occur.

• Remove the two screws and the rope clamp (5).

• Push the hoist rope (1) through the bore (2) until the rope wedge (4) slides out of the pouch (3) of the hoist drum.

• Take out the rope wedge and pull the free end of the hoist rope out of the p o u ch( 3) and out of the bore hol e(2).

• Pull the hoist rope from the boom and out of 02.07.2001

the sheaves at the boom head.

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8 - 37

Description of maintenance work on the superstructure 8.6 Hoist ropes

• Place the rope reel with the new hoist rope on a reel stand.

• Place the reel stand in front of the boom head in such a way that the hoist rope can be guided straight over the boom head sheaves onto the boom.

• Pull the hoist rope over the boom to the hoist drum.

• Push the hoist rope (1) through the bore (2) until it extends approx. 1.5 m from the pouch (3).

• Feed the free end of the hoist rope back through the pouch (3).

• Put on the rope clamp (5) and screw it down;

à Special tightening torques, S. 10 - 2.

• Place the rope wedge (4) into the hoist rope loop and insert it into the pouch (3) in the hoist drum.

• Push the hoist rope (1) through the bore (2) until the rope wedge slides completely into the pouch (3) of the hoist drum.

8 - 38

• Restart the diesel engine.

2 084 643 en

02.07.2001

S

Danger of damaging the hoist rope.

Ensure that the rope wedge, rope loop and rope end do not protude beyond the diameter of the hoist drum. This protects the new hoist from damage through kinking or flattening even when being reeled.

Maintenance Manual GMK 4075

Description of maintenance work on the superstructure 8.6 Hoist ropes

• Reel the hoist rope slowly onto the drum, keeping the hoist rope tight.

• Reeve the hook block six times (à Operating instructions, chapter on Rigging work, section on Hoist rope reeving).

• Raise the boom to a steep position and extend it fully.

• Wind the hoist rope out until only five turns remain on the rope drum.

H

Watch the hook block when winding out.

The hook block must not rotate!

• Reset the lowering limit switch so that it switches on after five layers have

à Setting the lowering limit switch, S. 8 - 39).

been wound (

• Reel the hoist rope in by a few turns and lower it again to check the lowering limit switch.

When five turns are left on the rope drum, the lowering limit switch must switch off the lowering movement.

G

Danger of accidents!

After installing a new hoist rope, the lowering limit switch must always be reset.

Setting the lowering limit switch

G

The lowering limit switch must always be reset after repair work to the hoist and after rope replacement. A defective lowering limit switch must always be replaced!

• Reeve the hoist rope with 6 falls.

• Extend boom fully.

• Lower hook block until only five turns remain on the hoist drum.

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Maintenance Manual GMK 4075

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8 - 39

Description of maintenance work on the superstructure 8.6 Hoist ropes

The lowering limit switch is located on the hoist on the left-hand side of the turntable.

• Remove the lowering limit switch cover (1).

• Turn the adjusting scre w(2) until you hear the micro-switch activate.

• Attach the cover to the lowering limit switch again.

Make sure that the seal fits properly.

You must check the functioning of the lowering limit switch after it has been set.

Lowering limit switch function control

• Raise the hook block until there are about 10 turns on the hoist drum.

• Lower the hook block again and check whether the lowering limit switch is set properly.

02.07.2001

The lowering limit switch must switch off the hoist when five rope turns are still on the drum.

8 - 40

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Maintenance Manual GMK 4075

Description of maintenance work on the superstructure 8.7 Safe load indicator

8.7

Safe load indicator

8.7.1

Maintaining the slip ring assembly of the cable drum

M6

Maintenance of the slip ring assembly is carried out in order to prevent contamination and corrosion and to prevent malfunctions on the SLI. The truck crane GMK 4075 has two cable drums whose slip ring assembly needs to be maintained.

There is a cable drum (1) on the left side of the main boom.

The second cable drum (1) is located in the main boom underneath the telescoping cylinder.

02.07.2001

You can reach the cable drum through the manhole if you first extend telescopic section I approx. 2.0 m.

H

The following sections describe the maintenance procedure for the outer cable drum. Maintenance on the cable drum in the boom is carried out in the same way.

Maintenance Manual GMK 4075

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8 - 41

Description of maintenance work on the superstructure 8.7 Safe load indicator

Prerequisites

Before maintenance, the following requirements must be met: – The main boom is resting in the boom support.

à

G Maintaining slip ring assembly

Operating instructions, – The battery master switch ist switched off; chapter on Diesel engine, section on Turning off diesel engine. tt

Risk of damaging the safe load indicator!

Before maintenance work on the slip ring assembly, always switch off the battery master switch so that the cable drum is currentless.

This prevents short circuits which may lead to damage to the central unit.

To lubricate the slip ring assembly, only use lubricants specified in the Maintenance plan, S. 5 - 13.

• Make sure that the cable drum is currentless.

• Unscrew all screws (1) and remove the cover (2).

• Check the seal on the casing for damage and replace it if necessary.

• Remove any moisture in the casing with a clean, lint-free cloth.

02.07.2001

G

Risk of damage to health with improper handling!

When using and storing the lubricant make sure you observe the information on the packaging and the enclosed safety data sheet!

8 - 42

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Maintenance Manual GMK 4075

Description of maintenance work on the superstructure 8.7 Safe load indicator

• Remove visible dirt on the slip rings (2) with a clean, lint-free cloth.

• Spray the lubricant on all slip rings (2).

• Spread the lubricant by turning the drum several times by a half revolution.

You can turn the drum by pulling the SLI cable in the direction of the main boom head. If you let go of the cable, the drum turns back because of the initial tension.

• Check to make sure all screws (1) are tight.

• Wait until the solvent has evaporated completely.

• Put the casing (2) back in place. Make sure that the seal is in the right place.

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• Attach the casing with all the screws (1).

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8 - 43

Description of maintenance work on the superstructure 8.7 Safe load indicator

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8 - 44

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Maintenance Manual GMK 4075

Description of maintenance work on the superstructure 8.8 Central lubrication system

8.8

Central lubrication system The grease container (1) is located on the right side of the turntable above the storage compartment.

Only fill with special grease as specified in the Maintenance plan, S. 5 - 7.

The maintenance of the central lubrication system on the superstructure is the same as the maintenance of the central lubrication system on the carrier Centrallubrication system, S. 7 - 55). (

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à

Maintenance Manual GMK 4075

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8 - 45

Description of maintenance work on the superstructure 8.8 Central lubrication system

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8 - 46

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Maintenance Manual GMK 4075

Description of maintenance work on the superstructure 8.9 Hook blocks

8.9

Hook blocks

8.9.1

Lubrication

M1

The sheaves, cross heads and axial bearing of the load hook have to be lubricated on the hook block.

Use lubricating grease specified in the Maintenance plan, S. 5 - 9.

The diagram gives an example of the location of the lubricating nipple s(1), (2) and (3) on a hook block. There are other lubricating nipples on the other side.

• Clean the lubricating nipples on all hook

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blocks supplied and on the hook tackle and lubricate them with a grease gun.

Maintenance Manual GMK 4075

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8 - 47

Description of maintenance work on the superstructure 8.9 Hook blocks

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Blank page

8 - 48

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Maintenance Manual GMK 4075

Description of maintenance work on the superstructure 8.10 Superstructure electrical system

8.10

Superstructure electrical system

8.10.1

Checking the acid level of batteries

M1

Maintenance work is described in section Checking the acid level of batteries, S. 7 - 63.

8.10.2

Checking the acid concentration of batteries

M3

02.07.2001

Maintenance work is described in section Checking the acid concentration of batteries, S. 7 - 64.

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8 - 49

Description of maintenance work on the superstructure 8.10 Superstructure electrical system

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8 - 50

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Maintenance Manual GMK 4075

Description of maintenance work on the superstructure 8.11 Superstructure air conditioning system (additional equipment)

8.11

Superstructure air conditioning system (additional equipment) The GMK 4075 is equipped with only one refrigerant circuit for the airconditioning system on the carrier and superstructure.

For additional maintenance work, see Carrier air conditioning system (additional equipment), S. 7 - 65.

8.11.1

M6

Checking hoses • Check all refrigerant hoses for damage and worn areas.

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• Only allow damaged hoses to be replaced by GROVE Customer Support.

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8 - 51

Description of maintenance work on the superstructure 8.11 Superstructure air conditioning system (additional equipment)

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8 - 52

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Maintenance Manual GMK 4075

Description of maintenance work on the superstructure 8.12 Other maintenance work

8.12

Other maintenance work

8.12.1

Lubricating the counterweight hoist unit

M1

Three lubricating nipples are located on both pivot bearings of the counterweight hoist unit.

Use only lubricating grease specified in the Maintenance plan, S. 5 - 9.

Both pivot bearings of the counterweight hoist unit are lubricated via lubricating nipple s(1).

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

• Use a grease gun to apply grease to the lubricating nipples.

8.12.2

Checking for correct operation of the auxiliary heater (additional equipment)

M1

Maintenance work is described in section Checking for correct operation of the auxiliary heater (additional equipment), S. 7 - 75.

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For additional information, see the section on Crane cabin heating and ventilation, water-additional heating system (additional equipment) in the chapter on Crane operation in the Operating instructions.

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8 - 53

Description of maintenance work on the superstructure 8.12 Other maintenance work

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Blank page

8 - 54

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Maintenance Manual GMK 4075

9 Longer periods out of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 -

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1

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Maintenance Manual GMK 4075

Longer periods out of operation

9

Longer periods out of operation Carry out the following work if the truck crane is to be out of operation for a long period (months):

Before the truck crane is put out of operation

• Clean the crane thoroughly from inside and outside.

• Remove rust and touch up the paintwork.

• Parts which are not painted must be lubricated with an acid-free grease or oil.

• If more than half of the oil change interval has passed: • Change the oil in accordance with maintenance plans M 3 to M 12.

• Seal all air filters.

• Increase the type air pressure by 10% and mark the tyre position or support the truck crane on outriggers and let it stand in this position.

During periods out of operation

• Check the levels in the fuel tanks. Always keep the tanks filled.

• Check the batteries every week and recharge them if necessary.

• Check tyre pressure every week and inflate the tyres if necessary.

• Perform a full functional check of the truck crane every two weeks.

(Open all air filters in advance).

Run the hydraulic systems up to a fluid temperature of approx. 50 °C and check all functions of the carrier and superstructure hydraulic systems.

• Ensure that the tyre positioning is different each time the crane is parked (without outriggers).

• Seal all air filters again.

If the crane is out of operation for more than 12 months:

• Carry out all maintenance work in accordance with maintenance plan M 12.

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s

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9-1

Longer periods out of operation

Before putting the truck crane back into operation

• Open all air filters.

• Inflate the tyres up to the prescribed pressure.

• Carry out periodic maintenance work in accordance with the maintenance

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plans in chapter 5.

9-2

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Maintenance Manual GMK 4075

10 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 -

1

10.1

Tightening torques for retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 -

1

10.2

Special tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 -

2

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10

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Maintenance Manual GMK 4075

Tightening torques 10.1 Tightening torques for retaining bolts

10

Tightening torques

10.1

Tightening torques for retaining bolts

Metric standard screw-thread Metric fine screw-thread

Guiding values

Spanner size (mm) Thread size (mm)

Tightening torques (maximum permissible screw preload) for lubricated screws (Nm) Screw quality

Cylinder screw

8.8

10.9

12.9

M8 M8x1

13

6

23 24

32 34

36 41

M 10 M 10 x 1.25

17

8

44 47

62 66

75 79

M 12 M 12 x 1.5

19

10

78 81

110 113

130 135

M 14 M 14 x 1.5

22

12

120 135

170 189

210 225

M 16 M 16 x 1.5

24

14

165 203

190 284

320 342

M 18 M 18 x 1.5

27

14

260 293

365 414

435 495

M 20 M 20 x 1.5

30

17

370 414

520 576

620 693

M 22 M 22 x 1.5

32

17

500 549

700 774

840 945

M 24 M 24 x 1.5

36

19

640 702

900 990

1080 1170

M 30

46

22

1300

1800

2160

M 33

50

24

2700

M 36

55

27

3300

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Hexagon screw

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10 - 1

Tightening torques 10.2 Special tightening torques

10.2

Special tightening torques

Description

Thread size (mm)

Spanner size (mm) Hexagon screw

Cylinder screw

Tightening torque (Nm)

Suspension strut: – Vehicle frame / guide case (upper)

M 16

—

17

265

– Vehicle frame / guide case (lower)

M 24

—

19

900

– Support element / steering split shell

M 16

—

14

265

– Support element / operating head

M 20

30

17

520

Locking screws for steering linkage spherical-head connection Head → = 40 mm

M 12 x 1.5

19

—

70 – 80

Locking screws for steering linkage spherical-head connection Head → = 50 mm

M 14 x 1.5

22

—

160 – 180

Wheel nuts

M 22 x 1.5

32

—

650

Retaining bolts of ball slewing connection

M 24

36

—

954

Rope clamp on the hoist drum

M 10

17

—

46

10 - 2

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Gearbox

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– Oil filling/inspection screw and oil drain plug

Maintenance Manual GMK 4075

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Appendix

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Maintenance Manual GMK 4075

Appendix

Date of commissioning/ Date of inspection

Operating conditions since last inspection (collective load)

Km i

Collective load factor

[h]

General overhault preformed on: ................................

[h]

Operating Operating houres of entire houres of crane superstructure

WARNING: A gneral overhaul must be preformed at least once every 10 years!

"i"

Inspection no.

.................. .................. .................. ..................

.................. .................. .................. .................. ..................

[h]

Operating houres of superstructure since last inspection [h]

Operating houres of winch

1)

To be used if this table is not contained in the crane logbook.

Collective load factor in inspection interval "i" according to section 2.1 Actual operating hours in inspection interval "i" according to section 2.2

Km i = Ti

=

Collective load factor established during winch calculation This factor is found in the operating manual.

Km =

Remaining theoretical service life Theoretical service life remaining after previous inspection

=

Di

[h]

Name of inspector

Proportion of theoretical service life used since last inspection

[h]

Di = D i - 1 - Si

Remainin g theoretical service life

D i -1 =

=

Si

[h]

Proportation of Operating theoretical service houres of the winch since last life (D) used: inspection Ti Km S i = ____i x T i Km

Table to determine the remaining theoretical service life on winch no. ...

Crane model: Works number: Commissioned on: Winch serial number in acc. with model plate: Last general overhaut performed on: Winch design data (see operating manual): Power unit group: Collective load: Collective load factor: Theoretical service life:

1)

Signature Commen ts

Date of commissioning/ Date of inspection

Operating conditions since last inspection (collective load)

Km i

Collective load factor

[h]

General overhault preformed on: ................................

[h]

Operating Operating houres of entire houres of crane superstructure

WARNING: A gneral overhaul must be preformed at least once every 10 years!

"i"

Inspection no.

.................. .................. .................. ..................

.................. .................. .................. .................. ..................

[h]

Operating houres of superstructure since last inspection [h]

Operating houres of winch

1)

To be used if this table is not contained in the crane logbook.

Collective load factor in inspection interval "i" according to section 2.1 Actual operating hours in inspection interval "i" according to section 2.2

Km i = Ti

=

Collective load factor established during winch calculation This factor is found in the operating manual.

Km =

Remaining theoretical service life Theoretical service life remaining after previous inspection

=

Di

[h]

Name of inspector

Proportion of theoretical service life used since last inspection

[h]

Di = D i - 1 - Si

Remainin g theoretical service life

D i -1 =

=

Si

[h]

Proportation of Operating theoretical service houres of the winch since last life (D) used: inspection Ti Km S i = ____i x T i Km

Table to determine the remaining theoretical service life on winch no. ...

Crane model: Works number: Commissioned on: Winch serial number in acc. with model plate: Last general overhaut performed on: Winch design data (see operating manual): Power unit group: Collective load: Collective load factor: Theoretical service life:

1)

Signature Commen ts