Grove GMK 4075 Truck Crane Maintenance Manual SN 2084643 – PDF DOWNLOAD

Description

Grove GMK 4075 Truck Crane Maintenance Manual SN 2084643 – PDF DOWNLOAD

FILE DETAILS:

Grove GMK 4075 Truck Crane Maintenance Manual SN 2084643 – PDF DOWNLOAD

Language : English
Pages : 212
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Grove GMK 4075 Truck Crane Maintenance Manual SN 2084643 – PDF DOWNLOAD

GROVE customer support maintenance instructions:

This Maintenance Manual is intended for maintenance personnel. The maintenance manual does not contain information on repair work. Repair work may only be carried out by qualified repair personnel (e.g. the local GROVE Customer Support).
Repair work also requires:

– appropriate workshop equipment,
– special tools and
– replacement parts authorized by Deutsche GROVE GmbH.
It is your responsibility to maintain and service the truck crane regularly in
order to lengthen its service life and keep it in good working order.
Please note that Deutsche GROVE GmbH can only uphold the warranty provided
for the truck crane if the following conditions are met:
– proper use,
– prescribed care and maintenance,
– professional repair work / overhauling.

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.

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Grove GMK 4075 Truck Crane Maintenance Manual SN 2084643 – PDF DOWNLOAD

Maintenance Manual.................................................................................................  1
1 General instructions.............................................................................................  7
	1.1 Using the maintenance manual...............................................................................  7
	1.2 Warnings and symbols.......................................................................................  7
	1.3 GROVE customer support maintenance instructions............................................................  8
	1.4 Definitions of stated directions........................................................................... 10
2 Safety and environmental protection.............................................................................. 13
	2.1 Safety rules............................................................................................... 13
	2.2 Handling substances which are harmful to the environment................................................... 14
		What do environmentally harmful substances include?........................................................ 14
		Use suitable equipment..................................................................................... 15
		Filling and draining..................................................................................... 15
		Collect and store separately............................................................................... 15
		Disposal................................................................................................... 15
3 Cleaning......................................................................................................... 19
	3.1 Overview of the components that are easily damaged when cleaning........................................... 20
		On truck crane............................................................................................. 20
4 Run-in regulations............................................................................................... 23
5 Maintenance overview............................................................................................. 27
	5.1 Maintenance intervals...................................................................................... 27
	5.2 Maintenance plans.......................................................................................... 29
		5.2.1 Maintenance plan D: daily / before start-up.......................................................... 31
		5.2.2 Maintenance plan W: weekly........................................................................... 32
		5.2.3 Maintenance plan M 1: monthly / after 100 oh / approx. 2 000 km...................................... 34
		5.2.4 Maintenance plan M 3: every 3 months / after 300 oh / 5 000 – 6 000 km............................... 36
		5.2.5 Maintenance plan M 6: every 6 months / after 500 oh / 10 000 – 12 500 km............................. 38
		5.2.6 Maintenance plan M 12: every 12 months / after 1 000 oh / 20 000 – 25 000 km......................... 40
		5.2.7 Maintenance and inspection plan Y 2: every 24 months / after 100 000–125 000 km.................... 42
		5.2.8 Maintenance and inspection plan Y 3: every 36 months / after 3000 oh................................ 43
		5.2.9 Maintenance and inspection plan Y 6: every 72 months / after 6000 oh................................ 44
	5.3 Periodic inspections....................................................................................... 45
		5.3.1 Load hook inspection................................................................................. 46
	5.4 Measures required for winch monitoring.................................................................... 47
		5.4.1 Theoretical service life............................................................................. 47
		5.4.2 Proportion of the theoretical service life used...................................................... 48
			Determining the operating conditions (collective load)................................................ 49
			Determining the actual operating hours Ti............................................................. 50
			Determining the proportion of the theoretical service life used....................................... 51
		5.4.3 Example.............................................................................................. 52
			Example table to determine the remaining theoretical service life of winch no. 1 (main hoist winch).... 54
6 Lubricants and fuels............................................................................................. 57
	6.1 Lubricant table............................................................................................ 57
	6.2 Process materials.......................................................................................... 59
		6.2.1 Fuel................................................................................................. 59
		6.2.2 Engine coolant admixtures............................................................................ 59
		6.2.3 Windscreen washing system admixtures................................................................. 59
		6.2.4 Fuel for crane cab heating system.................................................................... 59
7 Description of maintenance work on the carrier.................................................................. 63
	7.1 Tilt driver's cab forward.................................................................................. 63
		Prerequisites and information on tilting................................................................... 63
		Unlocking / locking the driver's cab...................................................................... 64
		Driver's cab tilting....................................................................................... 64
		Lowering the driver's cab................................................................................. 66
	7.2 Diesel engine.............................................................................................. 67
		7.2.1 Diesel engine – oil level check...................................................................... 68
		7.2.2 Diesel engine oil – topping up oil................................................................... 69
		7.2.3 Checking coolant level............................................................................... 70
		7.2.4 Checking the dry air filter.......................................................................... 71
		7.2.5 Checking general condition and for leaks............................................................. 72
		7.2.6 Cleaning the fuel prefilter screen................................................................... 73
			Cleaning the prefilter screen......................................................................... 73
			Bleeding the fuel system............................................................................... 74
		7.2.7 Changing the fuel filter cartridge................................................................... 75
			Shutting off and emptying the fuel line................................................................ 75
			Changing the fuel filter cartridge.................................................................... 76
			After changing the filter insert...................................................................... 77
	7.3 Gearbox.................................................................................................... 79
		7.3.1 Checking general condition and for leaks............................................................. 79
		7.3.2 Gearbox – oil level check............................................................................ 80
		7.3.3 Gear box – oil change................................................................................ 81
	7.4 Transfer case.............................................................................................. 83
		7.4.1 Checking general condition and for leaks............................................................. 83
		7.4.2 Distributor gearbox – oil level check................................................................ 83
		7.4.3 Distributor gearbox – oil change..................................................................... 84
	7.5 Axle lines................................................................................................. 85
		7.5.1 Checking general condition and for leaks............................................................. 85
		7.5.2 Axle centre drives – oil level check................................................................. 85
		7.5.3 Axle centre drives – oil change...................................................................... 87
		7.5.4 Final drives – oil level check....................................................................... 89
		7.5.5 Final drives – oil change............................................................................ 90
		7.5.6 Lubricating the cardan shafts on the axle lines...................................................... 91
			Number and position of lubrication points.............................................................. 91
			Cardan shafts first axle line lubricate................................................................ 92
			Cardan shafts second lubricate up to the fourth axle line.............................................. 92
		7.5.7 Longitudinal cardan shafts between the gear units lubricate.......................................... 93
			Number and position of lubrication points.............................................................. 93
			Lubricating longitudinal cardan shafts................................................................. 94
	7.6 Wheels..................................................................................................... 95
		7.6.1 Checking the tyres for damage........................................................................ 95
		7.6.2 Check the tyre pressure.............................................................................. 96
		7.6.3 Checking the wheel-bearing clearance................................................................. 96
	7.7 Vehicle brakes............................................................................................. 97
		7.7.1 Checking brake-lining thickness...................................................................... 97
	7.8 Suspension................................................................................................. 99
		7.8.1 Telescopic leg – oil level check..................................................................... 99
		7.8.2 Tightness of retaining bolts on the suspension cylinders to be checked...............................100
	7.9 Steering...................................................................................................101
		7.9.1 Checking for leaks...................................................................................101
	7.10 Carrier compressed air system.............................................................................103
		7.10.1 Draining the compressed air system..................................................................103
		7.10.2 Compressed air system – check for leakage...........................................................103
		7.10.3 Replacing the granulate cartridge of the compressed air dryer.......................................104
	7.11 Carrier hydraulic system..................................................................................105
		7.11.1 Hydraulic unit – oil level check....................................................................105
		7.11.2 Checking the hydraulic hoses........................................................................106
		7.11.3 Checking for leaks..................................................................................107
		7.11.4 Changing the hydraulic oil filters and cleaning the magnetic rod....................................108
			Hydraulic oil filter for control circuit...............................................................110
		7.11.5 Replacing the venting filter........................................................................111
		7.11.6 Taking hydraulic oil samples........................................................................112
			Handling the drain valves..............................................................................113
			Taking oil samples....................................................................................113
		7.11.7 Changing the hydraulic oil..........................................................................114
	7.12 Centrallubrication system.................................................................................117
		7.12.1 Central lubrication system..........................................................................117
		7.12.2 Version 1 – Checking the level of the grease container and topping up...............................118
			Checking the level....................................................................................118
			Actuate intermediate lubrication.......................................................................118
			Filling the grease container..........................................................................119
			Bleeding the central lubrication system................................................................120
		7.12.3 Version 2 – Checking the level of the grease container and topping up...............................121
			Bleeding the central lubrication system................................................................123
	7.13 Carrier electrical system.................................................................................125
		7.13.1 Checking the acid level of batteries................................................................125
		7.13.2 Checking the acid concentration of batteries........................................................126
	7.14 Carrier air conditioning system (additional equipment)....................................................127
		7.14.1 Checking the moisture and level of the refrigerant..................................................127
		7.14.2 Cleaning capacitor disks............................................................................128
		7.14.3 Checking hoses......................................................................................129
		7.14.4 Checking the refrigerant compressor.................................................................129
		7.14.5 Checking the refrigerant compressor control.........................................................130
		7.14.6 Checking the entire air conditioning system.........................................................130
	7.15 Trailer coupling (additional equipment)...................................................................131
		7.15.1 Lubricating the trailer coupling....................................................................131
			Closing the trailer coupling...........................................................................132
		7.15.2 Checking the bearing................................................................................132
		7.15.3 Checking the cotter pin.............................................................................133
		7.15.4 Checking the lower bushing..........................................................................134
		7.15.5 Checking the support ring...........................................................................134
		7.15.6 Checking the initial tension of the springs.........................................................135
		7.15.7 Checking the function of the coupling jaw / re-adjusting the middle position........................135
			Function checking......................................................................................135
			Re-adjusting centrel position.........................................................................136
	7.16 Other maintenance work....................................................................................137
		7.16.1 Lubricating the outrigger beams.....................................................................137
		7.16.2 Checking for correct operation of the auxiliary heater (additional equipment).......................137
8 Description of maintenance work on thesuperstructure...........................................................141
	8.1 Shifting clutch............................................................................................141
		8.1.1 Shifting clutch – oil level check....................................................................141
		8.1.2 Shifting clutch – oil change.........................................................................142
	8.2 Hoists.....................................................................................................143
		8.2.1 Hoisting gear – oil level check......................................................................143
		8.2.2 Checking for leaks...................................................................................144
		8.2.3 Checking the hoist brake.............................................................................144
		8.2.4 Lubricating the hoist gears..........................................................................145
		8.2.5 Hoisting gear – oil change...........................................................................145
			Changing the hoisting unit transmission oil...........................................................146
			Changing the oil in the brake unit.....................................................................146
			Checking the oil.......................................................................................147
		8.2.6 Carrying out partial inspection of hoists............................................................148
		8.2.7 Carrying out general inspection of hoists............................................................148
	8.3 Slewing gear...............................................................................................149
		8.3.1 Slewing gear – oil level check.......................................................................149
		8.3.2 Checking for leaks...................................................................................150
		8.3.3 Lubricating slewing gear pinion and gear rim.........................................................150
		8.3.4 Slewing gear – oil change............................................................................151
			Slewing gear transmission oilchange...................................................................151
			Checking the oil.......................................................................................152
			Slewing gear brake oil change..........................................................................152
		8.3.5 Slewing gear brake function check....................................................................153
	8.4 Superstructure hydraulic system............................................................................155
		8.4.1 Checking the hydraulic hoses.........................................................................155
		8.4.2 Checking for leaks...................................................................................155
		8.4.3 Bleeding the derricking cylinder.....................................................................156
			Prerequisites..........................................................................................156
			Bleeding the piston rod chamber........................................................................156
			Bleeding the piston head area..........................................................................157
		8.4.4 Bleeding telescoping cylinders.......................................................................158
			Prerequisites..........................................................................................158
			Bleeding procedure....................................................................................158
			Location of vent screws................................................................................159
			Telescoping status....................................................................................160
		8.4.5 Replacing the hydraulic oil filter...................................................................161
			Hydraulic oil filter for control circuit...............................................................162
	8.5 Main boom..................................................................................................163
		8.5.1 Lubricating the telescope slide faces................................................................163
			Position of lubricating nipples.......................................................................164
			Prerequisites..........................................................................................165
			Lubricating slide faces of telescope sections..........................................................166
			Lubricate telescopic sectionIV.......................................................................166
			Lubricate telescopic sectionIII......................................................................166
			Lubricate telescopic sectionII.......................................................................167
			Lubricating telescopic sectionI......................................................................168
	8.6 Hoist ropes................................................................................................169
		8.6.1 Checking the position of sheaves and rope drums......................................................169
		8.6.2 Checking the status..................................................................................170
			Assessing thecondition of thehoist rope.............................................................171
			Replacing the hoist rope...............................................................................177
			Setting the lowering limit switch......................................................................179
			Lowering limit switch function control.................................................................180
	8.7 Safe load indicator........................................................................................181
		8.7.1 Maintaining the slip ring assembly of the cable drum.................................................181
			Prerequisites..........................................................................................182
			Maintaining slip ring assembly.........................................................................182
	8.8 Central lubrication system.................................................................................185
	8.9 Hook blocks................................................................................................187
		8.9.1 Lubrication..........................................................................................187
	8.10 Superstructure electrical system..........................................................................189
		8.10.1 Checking the acid level of batteries................................................................189
		8.10.2 Checking the acid concentration of batteries........................................................189
	8.11 Superstructure air conditioning system (additional equipment).............................................191
		8.11.1 Checking hoses......................................................................................191
	8.12 Other maintenance work....................................................................................193
		8.12.1 Lubricating the counterweight hoist unit............................................................193
		8.12.2 Checking for correct operation of the auxiliary heater (additionalequipment).......................193
9 Longer periods out of operation..................................................................................197
	Before the truck crane is put out of operation.................................................................197
	During periods outof operation................................................................................197
	Before putting the truck crane back into operation.............................................................198
10 Tightening torques..............................................................................................201
	10.1 Tightening torques for retaining bolts....................................................................201
	10.2 Special tightening torques................................................................................202
Appendix...........................................................................................................205

Contact us: [email protected]

https://vimeo.com/847297940?share=copy

PLEASE NOTE:

• This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
• This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
• Require some other service manual or have any queries: please WRITE to us at [email protected]

S.V