maintenance manual

Vehicle serial number: 2 084 643 en02.07.2001

Maintenance Manual

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01

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.

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

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.

2 084 643 en Maintenance Manual GMK 4075

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01The 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

AppendixMaintenance Manual GMK 4075 2 084 643 en

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102

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20011 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 - 4Maintenance Manual GMK 4075 2 084 643 en

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General instructions1.1 Using the maintenance manual

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011 General instructions

1.1 Using the maintenance manualThis manual is not designed to replace proper training and instruction! Truck crane maintenance personnel are required to have relevant special-ised knowledge of proper safety procedures!

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

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

1.2 Warnings and symbolsThe following definitions and symbols are used in the operating instruc-tions to highlight particularly important information:

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

s

GThis symbol indicates hazards related to the operation described that may cause personal injury. The type of hazard (e.g. life-threatening, personal in-jury, risk of crushing or electrocution) generally precedes the warning sign.

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

OThis symbol reminds you that you are working with substances which pose a risk to the environment. Take particular care.The measures required for the corresponding maintenance work are indi-cated next to the symbol. You will find more detailed information in the sec-tion Handling substances which are harmful to the environment, S. 2 - 2. Maintenance Manual GMK 4075 2 084 643 en 1 - 1

General instructions1.3 GROVE customer support maintenance instructions

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01HThe hand with the pointing finger indicates passages that contain additional instructions and tips with regard to truck crane operation.

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

1.3 GROVE customer support maintenance instructionsThis Maintenance Manual is intended for maintenance personnel. The main-tenance 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 pro-vided for the truck crane if the following conditions are met:

proper use,

prescribed care and maintenance,

professional repair work / overhauling. 1 - 2 2 084 643 en Maintenance Manual GMK 4075

General instructions1.3 GROVE customer support maintenance instructions

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01Numerous 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 per-mitted.

Replace all seals before assembly. Clean the sealing surfaces.

Only tighten loose screw connections on hydraulic systems when the sys-tem is depressurized.

Keep brake and clutch linings free of grease.

Replace hydraulic hoses immediately once damage or penetration of mois-ture 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) be-fore re-using them and replace them if necessary.

Tightening torques may be found in sections 10 - 1 and 1 0 -2. Maintenance Manual GMK 4075 2 084 643 en 1 - 3

General instructions1.4 Definitions of stated directions

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01Our 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 directionsSome of the terms which are used to describe the location of components are defined in this section.

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

On the superstructure front always refers to the direction of the main boom head, regardless of the superstructure position. The terms rear, right and left are used in relation to the definition of the term "front" on the superstructure. 1 - 4 2 084 643 en Maintenance Manual GMK 4075

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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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Safety and environmental protection2.1 Safety rules

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012 Safety and environmental protection

2.1 Safety rulesWhen carrying out maintenance work, it is imperative that you observe the ap-plicable 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 opera-tion before beginning maintenance work. Remove the key and put up warning signs.

sMaintenance Manual GMK 4075 2 084 643 en 2 - 1

Safety and environmental protection2.2 Handling substances which are harmful to the environment

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01If, 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 mov-ing 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. Re-member 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 inflamma-ble fluids.

Observe the applicable safety regulations when working with process ma-terials.

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 environ-mentally harmful substances in-clude?

When you carry out maintenance work on the truck crane you will occasion-ally work with substances which are considered to be harmful to the envi-ronment 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 re-gional regulations as well as the instructions in this chapter. 2 - 2 2 084 643 en Maintenance Manual GMK 4075


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01Use suitable equipment

Substances harmful to the environment can be corrosive. Therefore only use containers, hoses, pumps, funnels etc. which are resistant to the respec-tive substance.

Filling and draining

When filling and draining, make absolutely sure that no substances harm-ful 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 re-duced 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 na-tional and regional regulations.

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

Only have collected environmentally harmful substances disposed of by disposal companies which are approved by the national or regional au-thority responsible. Maintenance Manual GMK 4075 2 084 643 en 2 - 3


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01Blank page2 - 4 2 084 643 en Maintenance Manual GMK 4075


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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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Cleaning02

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20013 CleaningThe 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 pe-riod.

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

Do not use corrosive cleaning agents that might corrode the paint.

Never hold the spray nozzle of your cleaning unit at a right angle to the surface you are cleaning and ensure that you are standing at a sufficient distance away from the surface you are cleaning.

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.

GRisk of accidents from misdirected high pressure water jet! When working with high-pressure and steam jet cleaners, the water jet will be deflected by crane parts and could spray into your face and eyes at great speed and high pressure. Always wear a face guard when cleaning the truck crane with high-pressure and steam-jet cleaning equipment. Maintenance Manual GMK 4075 2 084 643 en 3 - 1

Cleaning3.1 Overview of the components that are easily damaged when cleaning

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01 3.1 Overview of the components that are easily damaged when cleaning

On truck crane

1 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 forswing-away lattice extension

6 Air-conditioning system capacitor3 - 2 2 084 643 en Maintenance Manual GMK 4075


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4 Run-in regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 1


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Run-in regulations02

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20014 Run-in regulationsSpecial running-in instructions must be observed for individual compo-nents (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:

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 manufac-turer and in the crane diesel engine maintenance booklet.

s

Operationhours (oh)

Travelledkm

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)

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

Check the hydraulic oil filters weekly; Changing the hydraulic oil filters and cleaning the magnetic rod, S. 7 - 46. Maintenance Manual GMK 4075 2 084 643 en 4 - 1

Run-in regulations

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01Please note the instructions concerning run-in times / run-in regulations / oil change intervals in the enclosed operating manual of the engine manufac-turer and in the crane diesel engine maintenance booklet.

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

Operationhours (oh)

Travelledkm

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 torque; Special tightening torques, S. 10 - 2.

after 200 Carry out first oil change on hoist gears (auxiliary hoist only with additional equipment); Hoisting gear oil change, S. 8 - 5.

after 200 Carry out first oil change in slewing gear transmission; Slewing gear oil change, 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. 4 - 2 2 084 643 en Maintenance Manual GMK 4075


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5 Maintenance overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 1

5.1 Maintenance intervals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 1

5.2 Maintenance plans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 3

5.2.1 Maintenance plan D: daily / before start-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 5 5.2.2 Maintenance plan W: weekly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 6 5.2.3 Maintenance plan M 1: monthly / after 100 oh /

approx. 2 000 km . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 8 5.2.4 Maintenance plan M 3: every 3 months / after 300 oh /

5 000 6 000 km. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 10 5.2.5 Maintenance plan M 6: every 6 months / after 500 oh /

10 000 12 500 km. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 12 5.2.6 Maintenance plan M 12: every 12 months / after 1 000 oh /

20 000 25 000 km. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 14 5.2.7 Maintenance and inspection plan Y 2:

every 24 months / after 100 000 125 000 km. . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 16 5.2.8 Maintenance and inspection plan Y 3:

every 36 months / after 3 000 oh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 17 5.2.9 Maintenance and inspection plan Y 6:

every 72 months / after 6 000 oh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 18

5.3 Periodic inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 19

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

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

5.4.1 Theoretical service life. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 21 5.4.2 Proportion of the theoretical service life used. . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 22 5.4.3 Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 26


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Maintenance overview5.1 Maintenance intervals

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015 Maintenance overviewIn 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 con-sist of the chapter number and the corresponding page number, e.g.

Checking hydraulic oil level; p. 7 - 43.

Checking the hydraulic oil level is described in Chapter7, the section starts on page 7 - 43.

5.1 Maintenance intervalsThe 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 car-rier) components with crane functions.


Maintenance overview5.1 Maintenance intervals

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01The 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 simulta-neously the total working hours of the superstructure.

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

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

Maintenanceplans

Maintenance interval

Km travelled(carrier)

Diesel engine op-erating hours (oh)(superstructure)

D daily / before start-up

W weekly

M 1 monthly approx. 2000 100

M 3 three monthly 5 000 6 000 300

M 6 every six months 10 000 12 500 500

M 12 every twelve months 20 000 25 000 1 000

Y 2 every twenty four months 100 000 125 000

Y 3 every thirty six months 3 000

Y 6 every seventy two months 6 000 5 - 2 2 084 643 en Maintenance Manual GMK 4075

Maintenance overview5.2 Maintenance plans

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01 5.2 Maintenance plansThe 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 super-structure (chapter and page number).

The section titles

of Chapter 7 Description of the maintenance work on the carrier and

of Chapter 8 Description of the maintenance work on the superstructure

contain the symbol (D up to Y 6) of the relevant maintenance plan for better comprehension.

HThe description of some daily (D) and weekly (W) checks (preventive main-tenance) 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 lu-bricants, p. 6 - 1.

HPlease note that this Maintenance Manual contains only some of the mainte-nance 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. Maintenance Manual GMK 4075 2 084 643 en 5 - 3


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01 5.2.1 Maintenance plan D: daily / before start-up

DMaintenance work on the CARRIER: Oil / lubricant

Quantity (l) / Number

Designation p. 6 - 1

Diesel engine

Check the oil level; p. 7 - 6. A Checking refrigerant level; p. 7 - 8. Checking the dry air filter; p. 7 - 9. Wheels

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

Carrier hydraulic system

Checking hydraulic oil level; p. 7 - 43. G 2 Check contamination display for hydraulic oil filter; p. 7 - 46.

Carrier electrical system

Check lighting and indicators

DMaintenance work on the SUPERSTRUCTURE: Oil / lubricant



Slewing gear

Slewing gear brake function check; p. 8 - 13. Hoist ropes

Check the overall condition and position of sheaves and rope drums; p. 8 - 29. Maintenance Manual GMK 4075 2 084 643 en 5 - 5


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01 5.2.2 Maintenance plan W: weekly

WMaintenance work on the CARRIER: Oil / lubricant



Diesel engine

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

Checking the overall condition and tightness; p. 7 - 17. Distributor gearbox

Checking the overall condition and tightness; p. 7 - 21 .Axle lines

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

Check the tyre pressure; p. 7 - 34. Steering

Check tightness; p. 7 - 39. Carrier compressed air system (incl. brake system)

Drain compressed air system; p. 7 - 41. Check tightness; p. 7 - 41. Carrier hydraulic system

Check hydraulic hoses; p. 7 - 44. Check tightness (suspension, steering and outrigger systems)

while engine is running; p. 7 - 45. Carrier central lubrication system

Check the level of the fuel tank; p. 7 - 56. KOther maintenance checks

Check the function of the windscreen washing system of the op-erator's cab and the level of fluid in the supply reservoir.5 - 6 2 084 643 en Maintenance Manual GMK 4075


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01WMaintenance work on the SUPERSTRUCTURE: Oil / lubricant



Main hoist / auxiliary hoist (additional equipment)

Check the oil level; p. 8 - 3. E 6 Check tightness; p. 8 - 4. Check hoist brake; p. 8 - 4. Lubricating the hoist gears; p. 8 - 5. 2 KSlewing gear

Check the slewing gear oil level; p. 8 - 9. E 6 Check the slewing brake oil level; p. 8 - 9. E 5 Check tightness; p. 8 - 10. Superstructure hydraulic system

Check hydraulic hoses; p. 8 - 15. Check for leaks with the engine running; p. 8 - 15. Central lubrication system superstructure

Check the level of the fuel tank; p. 8 - 45. KHoist ropes

Check the condition; p. 8 - 30. Other maintenance checks

Check the function of the windscreen washing system of the crane operator's cab and the level of fluid in the supply reservoir. Maintenance Manual GMK 4075 2 084 643 en 5 - 7


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01 5.2.3 Maintenance plan M 1: monthly / after 100 oh / approx. 2 000 km

1) after 100 oh 2) lubricate the trailer coupling after every high pressure cleaning.

M 1Maintenance work on the CARRIER:monthly / after approx. 2 000 km

Oil / lubricant



Diesel engine

Details in the Diesel Engine Operating Instructions and in theDiesel Engine Maintenance Booklet. Special notes for the main-tenance group and for rapeseed oil operation; p. 7 - 5.

Distributor gearbox

Check the oil level; p. 7 - 21. E 3Axle lines

Axle centre drive check oil level; p. 7 - 23. E 3 Final drive check oil level; p. 7 - 27. E 3 Lubricate universal joint shaft of the axle line; p. 7 - 29.

with additional equipment with 8 x 8 x 8 drive.1214

KK

Wheels

Check tightness of wheel nuts; p. 7 - 38. Tightening torque; Special tightening torques, S. 10 - 2.

Suspension

Check oil level in the suspension cylinders; p. 7 - 37. H Check retaining bolts of the suspension cylinders;

Tightening torque; Special tightening torques, S. 10 - 2.Carrier electrical system

Checking the acid level in the batteries; p. 7 - 63. Trailer coupling (additional equipment)

Lubricating the trailer coupling;2) p. 7 - 69. 2 JCarrier air conditioning system (additional equipment)

Checking the moisture and level of the refrigerant; p. 7 - 65. Cleaning capacitor disks; p. 7 - 66. Other maintenance work

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

Lubricating the outrigger beam1); p. 7 - 75. 8 J Lubricate door hinges. 4 J

Lubricate retaining and socket pins.1) div. J / M5 - 8 2 084 643 en Maintenance Manual GMK 4075


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01M 1Maintenance work on the SUPERSTRUCTURE:monthly / after 100 oh

Oil / lubricant



Switch coupling

Switch coupling check oil level; p. 8 - 1. G 5Hook blocks

Lubricate; p. 8 - 47. div. JSuperstructure hydraulic system

Bleeding telescoping cylinders; p. 8 - 18. Bleeding the derricking cylinder; p. 8 - 16. Other maintenance work

Lubricating the counterweight hoist unit; p. 8 - 53. 6 J Checking for correct operation of the auxiliary heater (addi-

tional equipment); p. 8 - 53. Lubricate tread rollers of cab door. 3 M

Lubricate retaining and socket pins. div. J / M

Lubricate spring latch. div. J / MMaintenance Manual GMK 4075 2 084 643 en 5 - 9


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01 5.2.4 Maintenance plan M 3: every 3 months / after 300 oh /5 000 6 000 km

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

Oil / lubricant



Diesel engine

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

Clean fuel prefilter-screen; p. 7 - 11. Wheels

Checking wheel-bearing clearance; p. 7 - 34. Vehicle brakes

Check brake-lining thickness; 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.

Carrier electrical system

Check acid concentration of batteries; p. 7 - 64. Trailer coupling (additional equipment)

Checking the bearing; p. 7 - 70. Checking the cotter pin; p. 7 - 71. Checking the lower bushing; p. 7 - 72. Checking the initial tension of the springs; p. 7 - 73. Checking the function of the coupling jaw / Resetting

the middle position; p. 7 - 73. Checking the support ring; p. 7 - 72.5 - 10 2 084 643 en Maintenance Manual GMK 4075


02.0

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011) after 300 oh

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

Oil / lubricant



Superstructure electrical system

Check acid concentration of batteries; p. 8 - 49.Ball slewing connection

Check tightness of retaining bolts;Tightening torque; Special tightening torques, S. 10 - 2.Maintenance Manual GMK 4075 2 084 643 en 5 - 11


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01 5.2.5 Maintenance plan M 6: every 6 months / after 500 oh /10 000 12 500 km

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

Oil / lubricant



Diesel engine

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

Distributor gearbox

Changing the oil; p. 7 - 22. 9.5 E 3Axle lines

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

810

KK

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; p. 7 - 67. Checking the refrigerant compressor control; p. 7 - 68. 5 - 12 2 084 643 en Maintenance Manual GMK 4075


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01M 6Maintenance work on the SUPERSTRUCTURE: every 6 months / after 500 oh

Oil / lubricant



Slewing gears

Lubricating the slewing gear pinion; p. 8 - 10. 1 each VBall slewing connection

Lubricate the gear rim; p. 8 - 10. 1 VMain boom

Lubricate telescopic slide faces; p. 8 - 23. 16 L 2Superstructure air conditioning system (additional equipment)

Checking hoses; p. 8 - 51.SLI

Maintain the slip ring assembly in the cable drums; p. 8 - 41. XMaintenance Manual GMK 4075 2 084 643 en 5 - 13


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01 5.2.6 Maintenance plan M 12: every 12 months / after 1 000 oh /20 000 25 000 km

1) every 3 000 oh, however at the latest every 12 months2) Operation under difficult conditions:

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.

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

Oil / lubricant



Diesel engine

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

Replacing the fuel filter elements; p. 7 - 13.Gearbox

Check the oil level; p. 7 - 19. F 4Axle lines

Axle centre drives oil change; p. 7 - 25. 1st axle line2nd axle line (only for additional equipment with 8 x 8 x 8 drive)3rd axle line4th axle line

13.015.016.513.0

E 3E 3E 3E 3

Final drive oil change; p. 7 - 28. 4.1 each E 3Carrier compressed air system

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

Carrier hydraulic system

Have suspension system pressure accumulators checked by the local GROVE Customer Support or by an authorized work-shop.1)

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

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

660.0 G 2

Carrier air conditioning system (additional equipment)

Monitoring the entire air conditioning system; p. 7 - 68.5 - 14 2 084 643 en Maintenance Manual GMK 4075


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011) Carry out at least once a year

M 12Maintenance work on the SUPERSTRUCTURE:every 12 months / after 1000 oh

Oil / lubricant



Switch coupling

Switch coupling oil change; p. 8 - 2. Approx. 0.25 G 5Main hoist / auxiliary hoist (additional equipment)

Oil change1); p. 8 - 5 Checking the old oil; p. 8 - 7.

10.0 E 6

Slewing gears

Slewing gear oil change; p. 8 - 11. 0.9 each E 6 Slewing brake oil change; p. 8 - 12. Approx. 1.0 E 5Superstructure air conditioning system (additional equipment)

Monitoring the entire air conditioning system; p. 7 - 68.Maintenance Manual GMK 4075 2 084 643 en 5 - 15


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01 5.2.7 Maintenance and inspection plan Y 2: every 24 months / after 100 00 0 125 000 km

Y 2Maintenance work on the CARRIER:every 24 months

Oil / lubricant



Gearbox

Changing the oil and oil filter, p. 7 - 19. 11.0 F 4

Y 2Maintenance work on the SUPERSTRUCTURE:every 24 months

Oil / lubricant



No maintenance work in this period.

The long-term intervals always include the short-term intervalsinclude short-term intervals. 5 - 16 2 084 643 en Maintenance Manual GMK 4075


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01 5.2.8 Maintenance and inspection plan Y 3: every 36 months / after 3000 oh


Oil / lubricant




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

Y 3Maintenance work on the SUPERSTRUCTURE:every 36 months / after 3000 oh

Oil / lubricant




Carry out partial inspection; p. 8 - 8.Maintenance Manual GMK 4075 2 084 643 en 5 - 17


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01 5.2.9 Maintenance and inspection plan Y 6: every 72 months / after 6 000 oh


Oil / lubricant




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

Y 6Maintenance work on the SUPERSTRUCTURE: every 72 months / after 6000 oh

Oil / lubricant




Carry out general inspection; p. 8 - 8. p. 5 - 21. 5 - 18 2 084 643 en Maintenance Manual GMK 4075

Maintenance overview5.3 Periodic inspections

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01 5.3 Periodic inspectionsYour 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 inter-vals. 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 as-sess the condition of the truck crane and its components. Their purpose is to detect defects at an early stage and thus prevent accidents.

Inspections are to be carried out on the following components, where these are not already contained in the list of routine maintenance tasks:

the hydraulic and electrical control and safety devices,

the safe load indicator (SLI),

the mounting and safety devices of all screwed-on parts,

the hoist ropes,

load hooks ( Load hook inspection, S. 5 - 20),

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

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

The inspector is to write a record containing the result of the annual inspec-tion and the measures taken to repair any damages. Maintenance Manual GMK 4075 2 084 643 en 5 - 19

Maintenance overview5.3 Periodic inspections

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01 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 orig-inal 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 ini-tial dimension.

The load hook must consequently be replaced.

GAccidents may occur if the load is allowed to drop!Hook blocks with deformed load hooks are no longer operationally safe! The load hooks could break and drop the load.Deformed load hooks must always be replaced!5 - 20 2 084 643 en Maintenance Manual GMK 4075

Maintenance overview5.4 Measures required for winch monitoring

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01 5.4 Measures required for winch monitoring

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

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

5.4.1 Theoretical service life

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

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

Power unit group: M ...... Load spectrum: Q .....; (L.....) Load spectrum factor: Km =...... Theoretical service life: D =......

HThe power unit group M 3 and the collective load L1 (Km = 0.125) are gen-erally given for truck cranes in erection mode, resulting in a theoretical ser-vice life of 3200 h.

s

SThe theoretical service life is not the same as the real (actual) service life of a winch. Maintenance Manual GMK 4075 2 084 643 en 5 - 21


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01The 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 whilesuspended.

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 low or high temperatures, conditions: aggressive atmosphere,

dust and dirt.

5.4.2 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.

The actual operating conditions (load spectrum) and the operating hours of the hoists are to be determined for each inspection interval when establish-ing the proportion of the theoretical service life that has been used. The op-erator is responsible for proper documentation in the crane logbook. 5 - 22 2 084 643 en Maintenance Manual GMK 4075


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01Determining the operating condi-tions (collective load)

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

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 respec-tive inspection interval. Note for truck cranes: In case of truck cranes in erection mode, as a rule, the collective loadL 1 is to be given with the collective load factor Km = 0.125.

CollectiveloadClass

Term designation Working time proportion Collective load factorKm =

Graphic representation

light

Q 1L 1

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

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

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

50 % of the operating time only with dead load

0.125

medium

Q 2L 2

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

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

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

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


0.25

heavy

Q 3L 3

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



0.5

very heavy

Q 4L 4

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



1

s

Maintenance Manual GMK 4075 2 084 643 en 5 - 23


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01Determining 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 super-structure operating hours must be estimated.

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

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

Operating hour counter for driving and crane operation together

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

HIt can generally be assumed that the percentage of superstructure operating hours in relation to the crane operating hours will be 60% for truck cranes in installation mode. If the percentage of hoist winch operating hours is as-sumed to be 2 0% in relation to superstructure operating hours ( Operating hour counter is functional for entire crane operation), the percent-age in relation to the total operating hours of the crane will be: 1 2%. 5 - 24 2 084 643 en Maintenance Manual GMK 4075


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7.20

01Determining the proportion of the theoretical ser-vice 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 =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 theo-retical service life is not likely to be sufficient for the next operating period.

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.

The next general overhaul must be performed within 10 years.

SiKmiKm----------- Ti=Maintenance Manual GMK 4075 2 084 643 en 5 - 25


02.0

7.20

01 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 In-structions as follows:

Power unit group: M 3

Load spectrum: light L 1, Km = 0.125

Theoretical service life: D = 3200 h

The used proportion S of the theoretical service life is calculated over the in-dividual 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 op-erated 20 % of the time, i.e. T1 = 160 h.

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

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

The superstructure operating hour counter reads 2000 h, i.e. during this pe-riod: 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.

Si0.1250.125--------------- 160 h 160 h= =5 - 26 2 084 643 en Maintenance Manual GMK 4075


02.0

7.20

01The used proportion S2 of the theoretical service life after the second in-spection interval is therefore:


D2 = 3040 h 1920 h = 1120 h.

The aforementioned values are entered in the table (see example table5 - 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 inspec-tion interval is therefore:


D3 = 1120 h 600 h = 520 h.

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

The remaining theoretical service life is to be documented in a separate ta-ble 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 re-spective country.

s

Si0.5

0.125--------------- 480 h 1120 h= =

Si0.250.125--------------- 300 h 600 h= =Maintenance Manual GMK 4075 2 084 643 en 5 - 27


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01Example table to determine the re-maining theoreti-calservice life of winch no. 1 (main hoist winch)5 - 28 2 084 643 en Maintenance Manual GMK 4075


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01

6 Lubricants and fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 1

6.1 Lubricant table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 1

6.2 Process materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 3

6.2.1 Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 3 6.2.2 Engine coolant admixtures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 3 6.2.3 Windscreen washing system admixtures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 3 6.2.4 Fuel for crane cab heating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 3


02.0

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01

Lubricants and fuels6.1 Lubricant table

02.0

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016 Lubricants and fuels

6.1 Lubricant table

1) See engine operating instructions

2) Available from local GROVE Customer Support

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

s

Name Lubricating point

Type oflubrication

Name according toDIN 51502

SpecificationClassification

Lubricanttype

Viscosityrange

A Diesel engine

Circulatorylubrication

HD - CD MIL-L 2104 CDB 228.51)

E 3 Axle center drive C - LPFMIL-L 2105 B

API-GL-5SAE 90

ISO - VG 220

E 5 Slewing gear brake GROVE part no. 1 930 6702)

E 6 3)Slewing gear

Gearbox C - LPF MIL-L 2105 BAPI-GL-4/5SAE 75 W-90ISO - VG 220

Hoist Oil quantity

F 4 Gearbox Circulatorylubrication

MIL - L2105 API-GL-4

TE-ML 02LSAE 75 W-80W3)

G 2 Hydraulicsystem H-LP DIN 51524 T.2 ISO - VG 32

G 5 Switchcoupling Oil quantity API-GL-4 plus SAE 75 W-903)

H Suspension cyl-inder GROVE part no. 23108632)

JLubricating

points (lubricat-ing grease)

Grease gun and manually K - L2K DIN 51825

K Roller bearing For repairs, grease when

installing

KP - L2K DIN 51825

L 2 Slideways GROVE part no. 1373 458 2)Maintenance Manual GMK 4075 2 084 643 en 6 - 1

Lubricants and fuels6.1 Lubricant table

02.0

7.20

012) Available from local GROVE Customer Support

Name Lubricating point

Type oflubrication

Nameaccording toDIN 51502

SpecificationClassification

Lubricanttype

Viscosityrange

M Lubricating points (lubricat-

ing oil)

Oil can,high pressure jet

oil can

as A (Diesel engine)

V Open-running gear wheels

Adhesive lubrica-tion

GROVE part no. 0554 205 2)

W Mounting screws, bush-

ings, etc.GROVE part no. 1573 046 2)

X Slip ringassembly

Corrosion protec-tion GROVE part no. 3315 060

2)6 - 2 2 084 643 en Maintenance Manual GMK 4075

Lubricants and fuels6.2 Process materials

02.0

7.20

01 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 operat-ing manual.

6.2.3 Windscreen washing system admixtures

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

6.2.4 Fuel for crane cab heating system

You should use either the fuel specified in section 6.2.1 or EL heating oil as heating fuel for the crane cab. Maintenance Manual GMK 4075 2 084 643 en 6 - 3

Lubricants and fuels6.2 Process materials

02.0

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02.0

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01

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 Diesel engine oil level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 6 7.2.2 Diesel engine oil topping up oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 7 7.2.3 Checking coolant level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 8 7.2.4 Checking the dry air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 9 7.2.5 Checking general condition and for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 10 7.2.6 Cleaning the fuel prefilter screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 11 7.2.7 Changing the fuel filter cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 13

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

7.3.1 Checking general condition and for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 17 7.3.2 Gearbox oil level check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 18 7.3.3 Gear box oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 19

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

7.4.1 Checking general condition and for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 21 7.4.2 Distributor gearbox oil level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 21 7.4.3 Distributor gearbox oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 22

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

7.5.1 Checking general condition and for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 23 7.5.2 Axle centre drives oil level check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 23 7.5.3 Axle centre drives oil change. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 25 7.5.4 Final drives oil level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 27 7.5.5 Final drives oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 28 7.5.6 Lubricating the cardan shafts on the axle lines. . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 29 7.5.7 Longitudinal cardan shafts between the gear units lubricate . . . . . . . . . . . . . . 7 - 31

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

7.6.1 Checking the tyres for damage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 33 7.6.2 Check the tyre pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 34 7.6.3 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 Telescopic leg oil level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 37 7.8.2 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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01

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

7.10.1 Draining the compressed air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 41 7.10.2 Compressed air system check for leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 41 7.10.3 Replacing the granulate cartridge of the compressed air dryer . . . . . . . . . . . . 7 - 42

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

7.11.1 Hydraulic unit oil level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 43 7.11.2 Checking the hydraulic hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 44 7.11.3 Checking for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 45 7.11.4 Changing the hydraulic oil filters and cleaning the magnetic rod. . . . . . . . . . . 7 - 46 7.11.5 Replacing the venting filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 49 7.11.6 Taking hydraulic oil samples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 50 7.11.7 Changing the hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 52

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

7.12.1 Central lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 55 7.12.2 Version 1 Checking the level of the grease container and topping up . . . . . . 7 - 56 7.12.3 Version 2 Checking the level of the grease container and topping up . . . . . . 7 - 59

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

7.13.1 Checking the acid level of batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 63 7.13.2 Checking the acid concentration of batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 64

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

7.14.1 Checking the moisture and level of the refrigerant. . . . . . . . . . . . . . . . . . . . . . . 7 - 65 7.14.2 Cleaning capacitor disks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 66 7.14.3 Checking hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 67 7.14.4 Checking the refrigerant compressor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 67 7.14.5 Checking the refrigerant compressor control . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 68 7.14.6 Checking the entire air conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 68

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

7.15.1 Lubricating the trailer coupling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 69 7.15.2 Checking the bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 70 7.15.3 Checking the cotter pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 71 7.15.4 Checking the lower bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 72 7.15.5 Checking the support ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 72 7.15.6 Checking the initial tension of the springs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 73 7.15.7 Checking the function of the coupling jaw / re-adjusting the middle position . 7 - 73

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

7.16.1 Lubricating the outrigger beams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 75 7.16.2 Checking for correct operation of the auxiliary heater (additional equipment) 7 - 75

Description of maintenance work on the carrier7.1 Tilt driver's cab forward

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017 Description of maintenance work on the carrier

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

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

Prerequisites and information on tilting

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

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

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

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

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

s

SThe universal joint on the steering column may break. The steering angle must not be altered when the driver's cab is tilted. Otherwise, the universal joint on the steering column may break.Maintenance Manual GMK 4075 2 084 643 en 7 - 1


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01Unlocking / locking the driver's cab

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

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

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

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

Driver's cab tilting Observe the prerequisites stated at the beginning of section 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).

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

GRisk of accidents from toppling objects and doors swinging open. Remove all loose objects (e.g. bags, bottles etc.) from the driver's cab so that they will not topple when tilting and close all the doors of the driver's cab. This prevents liquids from getting into the inserts and doors from swinging open during tilting and injuring people.

GRisk of accidents due to driver's cab tilting. When you are tilting the driver's cab forward and while it is actually tilted forward, nobody may be in front of the driver's cab. 7 - 2 2 084 643 en Maintenance Manual GMK 4075


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7.20

01Two ring bolts (2) are supplied for slinging the driver's cab.

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

Fasten a rope (1) to each ring bolt.

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

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

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

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

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

s

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

GRisk of accidents due to the driver's cab tilting back. You may only stand under the tilted driver's cab if the driver's cab has tight-ened the wire rope between driver's cab and vehicle chassis. Maintenance Manual GMK 4075 2 084 643 en 7 - 3


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7.20

01Lowering the driver's cab

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

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 sup-port 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; Unlocking / locking the driver's cab, S. 7 - 2.

GRisk of crushing due to the driver's cab tilting back. Before unlocking the support, ensure that the driver's cab is tightening the support or that the driver's cab is secured against tilting back with the se-curing 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.

GAccidents may occur if the driver's cab is not locked. Relock the driver's cab to the vehicle chassis with the bolts after having lowered it. This prevents the driver's cab from tilting forward (unter the boom) when braking. 7 - 4 2 084 643 en Maintenance Manual GMK 4075

Description of maintenance work on the carrier7.2 Diesel engine

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7.20

01 7.2 Diesel engineFollow the instructions in the supplied Diesel Engine Operating Instructions for maintenance work which exceeds the scope of the daily work.

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).

s

SRisk of damage to the engine. The vehicle engine is in maintenance group II (difficult operation) because of the high full-load rate or large fuel supply rate. If the diesel engine is operated with rapeseed oil fatty acid methylester (RME), the engine oil change intervals must be halved. The release of engines for RME operation is regulated by the Diesel engine Service information. Maintenance Manual GMK 4075 2 084 643 en 7 - 5


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01 7.2.1 Diesel engine oil level check

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

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 oil pressure gauge.

D

SDamage may occur to the engine if the oil pressure is too low. If no oil pressure is displayed after 10 seconds, turn off the diesel engine and look for the cause; Operating Manual, chapter Carrier malfunctions, Section Crane engine malfunctions. 7 - 6 2 084 643 en Maintenance Manual GMK 4075


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

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

Top up with oil to the max. mark if neces-sary.

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).

Check the oil level on the dipstick.

SDamage may occur to the engine if the oil level is too high. Do not overfill; the oil level must not be higher than the highest arrow marking (max.). Maintenance Manual GMK 4075 2 084 643 en 7 - 7


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7.20

01 7.2.3 Checking coolant level

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

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 tem-perature to release the pressure.

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

If the coolant level is too low:

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

Screw on the filling hole cap until it stops.

D

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

SRisk of damage to the engine due to lack of coolant. If the coolant has to be topped up frequently, the cooling system may be leaking. Have GROVE Customer Support or your repair crew check the cool-ing system and repair the damage. 7 - 8 2 084 643 en Maintenance Manual GMK 4075


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01 7.2.4 Checking the dry air filter

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

pThe 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 with all the clamps.

DMaintenance Manual GMK 4075 2 084 643 en 7 - 9


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01 7.2.5 Checking general condition and for leaks

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

Replace any damaged pipes and porous or swollen hoses.

Tighten any connections that are leaking.

If the connection still leaks:

Change the seal.

Inspect the diesel engine for any visually obviousfouling or leaks.

Listen out for any unusual noises from the diesel engine.

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

Inform your local GROVE Customer Support or your repair crew.

W7 - 10 2 084 643 en Maintenance Manual GMK 4075


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01 7.2.6 Cleaning the fuel prefilter screen

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

Cleaning the pre-filter screen

The fuel prefilter (1) is under the carrier's rear cover on the right hand side next to the auto-matic gearbox.

s

M 3

OHave a container or cleaning rag ready so that you can catch the draining fuel. Wipe up any fuel which is not caught. Store used fuel filter cartidges in suitable containers and dispose of them properly. Maintenance Manual GMK 4075 2 084 643 en 7 - 11


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7.20

01 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. Re-place 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 con-tainer and screw it again onto the prefilter. Tightening torque 10 Nm.

Bleed the fuel system as described in the fol-lowing section.

Bleeding the fuel system

Release the hand pump by turning the knurled screw (4, top picture) to the left.The knurled screw is also the hand pump's handle.

Pump up and down until the resistance noticeably increases.

Insert the hand pump and tighten the knurled screw again.

Start the engine and check the prefilter for tightness. 7 - 12 2 084 643 en Maintenance Manual GMK 4075


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01 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

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).

s

M 12

OAlways use a fuel-resistant container with sufficient capacity into which the fuel line is emptied. Make sure that no fuel runs out and seeps into the ground. Maintenance Manual GMK 4075 2 084 643 en 7 - 13


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01For the purpose of emptying the fuel line a 3-way-tap (1) is provided at the rear on the au-tomatic 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.

Unscrew the screw cap (1) with the filter in-sert (3) and pull it a bit out of the filter hous-ing. Let the rest of the fuel drain off.

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

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

Clip a new filter cartridge onto the screw cap.

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

OStore used fuel filter cartidges in suitable containers and dispose of them properly. 7 - 14 2 084 643 en Maintenance Manual GMK 4075


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7.20

01After 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 dis-posal.

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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7.20

01 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; Bleeding the fuel system, S. 7 - 12.

Start the engine and check that the fuel filter is leak-tight. 7 - 16 2 084 643 en Maintenance Manual GMK 4075

Description of maintenance work on the carrier7.3 Gearbox

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7.20

01 7.3 GearboxThe gearbox is located inside the carrier above the first axle line.

7.3.1 Checking general condition and for leaks

Make a visual inspection for leaks.

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

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

Inform your local GROVE Customer Support or your repair crew.

WMaintenance Manual GMK 4075 2 084 643 en 7 - 17

Description of maintenance work on the carrier7.3 Gearbox

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01 7.3.2 Gearbox oil level check

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

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 t

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