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Grove GMK4075 Truck Crane Maintenance Manual SN 2084643 – PDF DOWNLOAD
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Grove GMK4075 Truck Crane Maintenance Manual SN 2084643 – PDF DOWNLOAD
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Description
Grove GMK4075 Truck Crane Maintenance Manual SN 2084643 – PDF DOWNLOAD
FILE DETAILS:
Grove GMK4075 Truck Crane Maintenance Manual SN 2084643 – PDF DOWNLOAD
Language : English
Pages : 212
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Grove GMK4075 Truck Crane Maintenance Manual SN 2084643 – PDF DOWNLOAD
General instructions:
1.1 Using the maintenance manual:
This manual is not designed to replace proper training and instruction! Truck crane maintenance personnel are required to have relevant specialised knowledge of proper safety procedures!
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.
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Grove GMK4075 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
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