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Grove GMK4075 Truck Crane Maintenance Manual SN 2084680 – PDF DOWNLOAD
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Grove GMK4075 Truck Crane Maintenance Manual SN 2084680 – PDF DOWNLOAD
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Description
Grove GMK4075 Truck Crane Maintenance Manual SN 2084680 – PDF DOWNLOAD
FILE DETAILS:
Grove GMK4075 Truck Crane Maintenance Manual SN 2084680 – PDF DOWNLOAD
Language : English
Pages : 234
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Grove GMK4075 Truck Crane Maintenance Manual SN 2084680 – 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 2084680 – PDF DOWNLOAD
GMK 4075 .................................................................................................. 1 Maintenance Manual..................................................................................... 1 Amendment: GMK maintenance manual.................................................................. 3 Validity....................................................................................... 3 Reasons for this additional information........................................................ 3 Correct weight specifications for the test load ............................................... 3 Additional pages: Maintenance work Vent filter on the hydraulic oil tank........................... 5 Validity....................................................................................... 5 Reasons for thisadditional information....................................................... 5 Additional weekly maintenance procedure (W)................................................... 5 Change to the annual maintenance procedures (M 12).......................................... 6 Maintenance work Vent filter on the hydraulic oil tank......................................... 5 Correction sheets Maintenance manual .............................................................. 9 Important information.......................................................................... 11 Validity................................................................................... 11 Reasons for the additional information..................................................... 11 About this correction sheet............................................................... 11 5.2.5 Maintenance and inspection plan M6: every 6 months / after 500oper. hrs............ 12 8.7.1 Maintenance of the slip ring assembly of the cable drum.............................. 13 Prerequisites.......................................................................... 14 Maintenance of the slip ring assembly.................................................. 14 Additional maintenance work........................................................................ 17 Validity....................................................................................... 17 Additional maintenance work.................................................................... 17 5.2 Maintenance plan........................................................................... 17 5.2.6 M 12 maintenance plan: Every 12 months / after 1000oper. hrs........................ 17 1 General instructions............................................................................. 21 1.1 Using the maintenance manual............................................................... 23 1.2 Warnings and symbols....................................................................... 23 1.3 GROVE customer support maintenance instructions............................................ 24 1.4 Definitions of stated directions........................................................... 26 2 Safety and environmental protection.............................................................. 27 2.1 Safety rules............................................................................... 29 2.2 Handling substances which are harmful to the environment................................... 30 What do environmentally harmful substances include?........................................ 30 Use suitable equipment..................................................................... 31 Filling and draining..................................................................... 31 Collect and store separately............................................................... 31 Disposal................................................................................... 31 3 Cleaning......................................................................................... 33 3.1 Overview of the components that are easily damaged when cleaning........................... 36 On truck crane............................................................................. 36 4 Run-in regulations............................................................................... 37 5 Maintenance overview............................................................................. 41 5.1 Maintenance intervals...................................................................... 43 5.2 Maintenance plans.......................................................................... 45 5.2.1 Maintenance plan D: daily / before start-up.......................................... 47 5.2.2 Maintenance plan W: weekly........................................................... 48 5.2.3 Maintenance plan M 1: monthly / after 100 oh / approx. 2 000 km...................... 50 5.2.4 Maintenance plan M 3: every 3 months / after 300 oh / 5 000 – 6 000 km............... 52 5.2.5 Maintenance plan M 6: every 6 months / after 500 oh / 10 000 – 12 500 km............. 54 5.2.6 Maintenance plan M 12: every 12 months / after 1 000 oh / 20 000 – 25 000 km......... 56 5.2.7 Maintenance and inspection plan Y 2: every 24 months / after 100 000–125 000 km.... 58 5.2.8 Maintenance and inspection plan Y 3: every 36 months / after 3000 oh................ 59 5.2.9 Maintenance and inspection plan Y 6: every 72 months / after 6000 oh................ 60 5.3 Periodic inspections....................................................................... 61 5.3.1 Load hook inspection................................................................. 62 5.4 Measures required for winch monitoring.................................................... 63 5.4.1 Theoretical service life............................................................. 63 5.4.2 Proportion of the theoretical service life used...................................... 64 Determining the actual operating hours Ti................................................. 66 Determining the proportion of the theoretical service life used........................... 67 Alternative provision...................................................................... 68 5.4.3 Example.............................................................................. 69 6 Lubricants and fuels............................................................................. 73 6.1 Lubricant table............................................................................ 75 6.2 Process materials.......................................................................... 77 6.2.1 Fuel................................................................................. 77 6.2.2 Engine coolant admixtures............................................................ 77 6.2.3 Windscreen washing system admixtures................................................. 77 6.2.4 Fuel for crane cab heating system.................................................... 77 7 Description of maintenance work on the carrier.................................................. 79 7.1 Tilt driver's cab forward.................................................................. 81 Prerequisites and information on tilting................................................... 81 Unlocking / locking the driver's cab...................................................... 82 Driver's cab tilting....................................................................... 82 Lowering the driver's cab................................................................. 84 7.2 Diesel engine.............................................................................. 85 7.2.1 Diesel engine – oil level check...................................................... 86 7.2.2 Diesel motor – top up the oil level.................................................. 87 7.2.3 Checking coolant level............................................................... 88 7.2.4 Checking the dry air filter.......................................................... 89 7.2.5 Checking general condition and for leaks............................................. 90 7.2.6 Cleaning the fuel prefilter screen................................................... 91 Cleaning the prefilter screen............................................................. 91 Bleeding the fuel system................................................................... 92 7.2.7 Changing the fuel filter cartridge................................................... 93 Shutting off and emptying the fuel line.................................................... 93 Changing the fuel filter cartridge........................................................ 94 After changing the filter insert.......................................................... 95 7.3 Gearbox.................................................................................... 97 7.3.1 Checking general condition and for leaks............................................. 97 7.3.2 Gearbox – oil level check............................................................ 98 7.3.3 Gear box – oil change................................................................ 99 7.4 Transfer case..............................................................................101 7.4.1 Checking general condition and for leaks.............................................101 7.4.2 Distributor gearbox – oil level check................................................101 7.4.3 Distributor gearbox – oil change.....................................................102 7.5 Axle lines.................................................................................103 7.5.1 Checking general condition and for leaks.............................................103 7.5.2 Axle centre drives – oil level check.................................................103 7.5.3 Axle centre drives – oil change......................................................105 7.5.4 Final drives – oil level check.......................................................107 7.5.5 Final drives – oil change............................................................108 7.5.6 Lubricating the cardan shafts on the axle lines......................................109 Number and position of lubrication points..................................................109 Cardan shafts first axle line lubricate....................................................110 Cardan shafts second lubricate up to the fourth axle line..................................110 7.5.7 Longitudinal cardan shafts between the gear units lubricate..........................111 Number and position of lubrication points..................................................111 Lubricating longitudinal cardan shafts.....................................................112 7.6 Wheels.....................................................................................113 7.6.1 Checking the tyres for damage........................................................113 7.6.2 Check the tyre pressure..............................................................113 7.6.3 Check tightness of wheel nuts........................................................114 7.6.4 Checking the wheel-bearing clearance.................................................114 7.7 Vehicle brakes.............................................................................115 7.7.1 Checking brake-lining thickness......................................................115 7.8 Suspension.................................................................................117 7.8.1 Telescopic leg – oil level check.....................................................117 7.8.2 Tightness of retaining bolts on the suspension cylinders to be checked...............118 7.9 Steering...................................................................................119 7.9.1 Checking for leaks...................................................................119 7.10 Carrier compressed air system.............................................................121 7.10.1 Draining the compressed air system..................................................121 7.10.2 Compressed air system – check for leakage...........................................121 7.10.3 Replacing the granulate cartridge of the compressed air dryer.......................122 7.11 Carrier hydraulic system..................................................................123 7.11.1 Hydraulic unit – oil level check....................................................123 7.11.2 Checking the hydraulic hoses........................................................124 7.11.3 Checking for leaks..................................................................125 7.11.4 Changing the hydraulic oil filters and cleaning the magnetic rod....................126 Hydraulic oil filter for control circuit...................................................128 7.11.5 Replacing the venting filter........................................................129 7.11.6 Taking hydraulic oil samples........................................................130 Handling the drain valves..................................................................131 Taking oil samples........................................................................131 7.11.7 Changing the hydraulic oil..........................................................132 7.12 Centrallubrication system.................................................................135 7.12.1 Central lubrication system..........................................................135 7.12.2 Version 1 – Checking the level of the grease container and topping up...............136 Checking the level........................................................................136 Actuate intermediate lubrication...........................................................136 Filling the grease container..............................................................137 Bleeding the central lubrication system....................................................138 7.12.3 Version 2 – Checking the level of the grease container and topping up...............139 Bleeding the central lubrication system....................................................141 7.13 Carrier electrical system.................................................................143 7.13.1 Checking the acid level of batteries................................................143 7.13.2 Checking the acid concentration of batteries........................................144 7.14 Carrier air conditioning system (additional equipment)....................................145 7.14.1 Checking the moisture and level of the refrigerant..................................145 7.14.2 Cleaning capacitor disks............................................................146 7.14.3 Checking hoses......................................................................147 7.14.4 Checking the refrigerant compressor.................................................147 7.14.5 Checking the refrigerant compressor control.........................................148 7.14.6 Checking the entire air conditioning system.........................................148 7.15 Trailer coupling (additional equipment)...................................................149 7.15.1 Lubricating the trailer coupling....................................................149 Closing the trailer coupling...............................................................150 7.15.2 Checking the bearing................................................................150 7.15.3 Checking the cotter pin.............................................................151 7.15.4 Checking the lower bushing..........................................................152 7.15.5 Checking the support ring...........................................................152 7.15.6 Checking the initial tension of the springs.........................................153 7.15.7 Checking the function of the coupling jaw / re-adjusting the middle position........153 Function checking..........................................................................153 Re-adjusting centrel position.............................................................154 7.16 Other maintenance work....................................................................155 7.16.1 Lubricating the outrigger beams.....................................................155 7.16.2 Checking for correct operation of the auxiliary heater (additional equipment).......155 8 Description of maintenance work on thesuperstructure...........................................157 8.1 Shifting clutch............................................................................159 8.1.1 Shifting clutch – oil level check....................................................159 8.1.2 Shifting clutch – oil change.........................................................160 8.2 Hoists.....................................................................................161 8.2.1 Hoisting gear – oil level check......................................................161 8.2.2 Checking for leaks...................................................................161 8.2.3 Checking the hoist brake.............................................................162 8.2.4 Lubricating the hoist gears..........................................................162 8.2.5 Hoisting gear – oil change...........................................................163 Changing the oil in the hoisting unit.....................................................163 Checking the oil...........................................................................164 8.2.6 Carrying out partial inspection of hoists............................................165 8.2.7 Carrying out general inspection of hoists............................................165 8.3 Slewing gear...............................................................................167 8.3.1 Slewing gear – oil level check.......................................................167 8.3.2 Checking for leaks...................................................................168 8.3.3 Lubricating slewing gear pinion and gear rim.........................................168 8.3.4 Slewing gear – oil change............................................................170 Slewing gear transmission oilchange.......................................................170 Checking the oil...........................................................................171 Slewing gear brake oil change..............................................................171 8.3.5 Slewing gear brake function check....................................................172 8.4 Superstructure hydraulic system............................................................173 8.4.1 Checking the hydraulic hoses.........................................................173 8.4.2 Checking for leaks...................................................................173 8.4.3 Bleeding the derricking cylinder.....................................................174 Prerequisites..............................................................................174 Bleeding the piston rod chamber............................................................174 Bleeding the piston head area..............................................................175 8.4.4 Lubricating the piston rod of the derricking cylinder................................176 8.4.5 Bleeding telescoping cylinders.......................................................177 Prerequisites..............................................................................177 Bleeding procedure........................................................................177 Location of vent screws....................................................................178 Telescoping status........................................................................179 8.4.6 Replacing the hydraulic oil filter...................................................180 Hydraulic oil filter for control circuit...................................................181 8.5 Main boom..................................................................................183 8.5.1 Lubricating the locking pins.........................................................183 Position of the locking pins...............................................................183 Prerequisites..............................................................................184 Lubricating the locking pins...............................................................184 Lubricating telescopic section II - IV.....................................................185 Lubricating telescopic section I...........................................................185 8.5.2 Lubricating the telescope slide faces................................................186 Position of lubricating nipples............................................................186 Prerequisites..............................................................................188 Lubricating slide faces of telescope sections..............................................189 Lubricate telescopic sectionIV...........................................................189 Lubricate telescopic sectionIII..........................................................189 Lubricate telescopic sectionII...........................................................190 Lubricating telescopic sectionI..........................................................191 8.6 Hoist ropes................................................................................193 8.6.1 Checking the position of sheaves and rope drums......................................193 8.6.2 Checking the status..................................................................194 Assessing thecondition of thehoist rope.................................................195 Replacing the hoist rope...................................................................201 Setting the lowering limit switch..........................................................203 Lowering limit switch function control.....................................................204 8.7 Safe load indicator........................................................................205 8.7.1 Maintaining the slip ring assembly of the cable drum.................................205 Prerequisites..............................................................................206 Maintaining slip ring assembly.............................................................206 8.8 Central lubrication system.................................................................209 8.9 Hook blocks................................................................................211 8.9.1 Lubrication..........................................................................211 8.10 Superstructure air conditioning system (additional equipment).............................213 8.10.1 Checking hoses......................................................................213 8.11 Other maintenance work....................................................................215 8.11.1 Lubricating the counterweight hoist unit............................................215 8.11.2 Checking for correct operation of the auxiliary heater (additionalequipment).......215 9 Longer periods out of operation..................................................................217 Before the truck crane is put out of operation.................................................219 During periods outof operation................................................................219 Before putting the truck crane back into operation.............................................220 10 Tightening torques..............................................................................221 10.1 Tightening torques for retaining bolts....................................................223 10.2 Special tightening torques................................................................224 Appendix...........................................................................................225
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