GREMO 1250F Instruction manual

Gremo AB
311 51 Ätran
Sweden
Tel. [phone]
Fax. [phone]
www.gremo.com
[email protected]
Release
Workshop manual in
original
1450F 4.1EN
©Gremo 2019
Gremo
1250F/1450F
Workshop manual

Gremo 1250F/1450F Workshop manual Contents
1 Introduction ............................................... 1
1.1 Introduction ....................................... 1
1.2 About the documentation kit ............. 2
1.3 Presentation Gremo 1250F/
1450F............................................... 4
1.4 Intended area of use ......................... 5
1.5 Operator requirements...................... 6
1.6 Safety regulations ............................. 6
1.7 Warning symbols and
information about risks .................... 7
1.8 Construction of the machine ............. 8
1.9 Definitions ......................................... 8
1.10 Environment.................................... 8
1.11 Location of type plates and
serial numbers ................................. 9
2 Safety regulations ................................... 13
2.1 General ........................................... 13
2.2 Clothing........................................... 16
2.3 Seat belt .......................................... 16
2.4 Emergency stop .............................. 17
2.5 Emergency exit ............................... 18
2.6 Emergency alarm............................ 18
2.7 Articulated joint lock ........................ 18
2.8 Boarding the machine..................... 19
2.9 Inspection of parking brake............. 20
2.10 Driving........................................... 23
2.11 Crane operation ............................ 24
2.12 Parking/storage............................. 26
2.13 Trailer transport............................. 27
2.14 Service .......................................... 28
2.15 Oil leaks ........................................ 31
2.16 Oils ................................................ 31
2.17 Batteries........................................ 32
2.18 Welding Repairs............................ 32
2.19 If by accident the machine tips
over................................................ 33
2.20 In the event of fire ......................... 35
2.21 Warning signs ............................... 36
2.22 Recovery and towing .................... 44
2.23 Winch ............................................ 47
2.24 Engine and cab heater.................. 47
2.25 Anti-skid chains............................. 47
2.26 Bogie tracks .................................. 48
2.27 Risk of strain-related injury ........... 48
2.28 Noise ............................................. 48
3 Service, maintenance and technical
information.............................................. 49
3.1 Safety rules during service ............. 49
3.2 Service and maintenance ............... 51
3.3 Volume specifications ..................... 52
3.4 Working with oils ............................. 52
3.5 Oil, requirement
specification................................... 54
3.6 Antifreeze, requirement
specification................................... 55
3.7 Fuel, requirement
specification................................... 56
3.8 Cleaning of Safety Glass
Windows ........................................ 57
3.9 Welding Repairs.............................. 58
3.10 Tyres — Air pressure:
Manufacturer’s
recommendations.......................... 60
4 Engine...................................................... 65
4.1 Fuel system..................................... 65
4.2 Cooling system ............................... 67
4.3 Intercooler ....................................... 68
4.4 Exhaust system with particulate
filter ................................................ 68
4.5 Replacing drive belts....................... 70
5 Transmission 1250F/1450F .................... 73
5.1 Transmission, gearbox.................... 73
5.2 Bogie axles...................................... 74
5.3 Parking brake.................................. 76
6 Electrical system .................................... 79
7.1 Structure of wiring diagram, wire
numbering, revision state .............. 79
6.2 Component position of fuse
groups and relays .......................... 80
7.3 Relay list.......................................... 85
7.4 Connector list .................................. 86
7 Hydraulic system.................................... 91
7.1 Hydraulic system, component
position .......................................... 91
7.2 Hydraulic oil return filters ................ 91
7.3 Breather filter hydraulic oil
tank ................................................ 92
7.4 Off-line filter hydraulic oil................. 92
7.5 Pressure check working
hydraulics....................................... 93
7.6 Pressure check,
transmission .................................. 97
8 Pressurised air system.......................... 99
8.1 General ........................................... 99
8.2 Pressurised air diagram.................. 99
9 Other equipment and optional
equipment.............................................. 101
9.1 Fire extinguishing system ............. 101
10 Wiring diagram .................................... 105
10.1 Power supply .............................. 105
11 Hydraulic diagram ............................... 173
11.1 Hydraulic diagram list.................. 173

Gremo 1250F/1450F Workshop manual 1 Introduction
1.1 Introduction
1 Introduction
1.1 Introduction
For you to get the most out of your Gremo machine as an
owner or an operator, it is very important that you maintain
and handle the machine correctly.
It is also very important that you familiarise yourself with
the performance and the restrictions of the machine.
It is especially important that the owner, the operator and
those who service the machine are familiar with the
contents of this Instruction Manual and study it thoroughly
before starting and driving, or before any preventive
maintenance work is done.
The responsibility for start, driving and service belongs to
the persons performing these steps! Please make yourself
well familiar with the controls and instructions before the
machine is used. It is too late to start looking in the
Instruction Manual when an accident has already
happened.
NOTICE
In order to find out about manual updates, it is important
to inform Gremo AB of any change of address or owner.
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1 Introduction
1.2 About the documentation kit Gremo 1250F/1450F Workshop manual
1.2 About the documentation kit
1.2.1 About the Instruction Manual
The Instruction Manual contains important information
about your new Gremo machine, about operating the
machine, safety when working and the machine's daily
checks. In addition, it offers many valuable tips that
facilitate your daily work.
Incorrect use of the machine may result in personal injury
and product or property damage. For this reason, read the
instructions carefully before operating the machine for the
first time.
The Instruction Manual should always be accessible in the
machine. If it disappears, a new one must be ordered
immediately from the manufacturer.
CAUTION
Never operate a machine without an instruction manual.
Refer to your supervisor or the manufacturer if there is
anything in the text that you do not understand or if you
cannot find what you are looking for.
1.2.2 About the service and maintenance manual
The service and maintenance manual provided with your
machine describes service points and measures that are
important to follow and carry out in order for your new
machine to work smoothly in the future.
1.2.3 About the spare parts catalogue
The spare parts catalogue provided with your machine
helps you to easily identify the right spare part. This unique
catalogue is also available online.
1.2.4 About the workshop manual
A workshop manual describing in detail extensive repair
measures as well as containing wiring and hydraulic
diagrams for the machine is available for purchase.
The workshop manual can be ordered from your service
dealer or from Gremo AB.
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Gremo 1250F/1450F Workshop manual 1 Introduction
1.2 About the documentation kit
1.2.5 Ordering documentation
Documentation can be ordered from your service dealer or
from Gremo AB.
Always specify the machine number and publication
number when ordering. The publication number is printed
on the lower right-hand corner of the cover.
3

1 Introduction
1.3 Presentation Gremo 1250F/1450F Gremo 1250F/1450F Workshop manual
1.3 Presentation Gremo 1250F/1450F
1.3.1 General description of the machine
Fig. 1 Gremo 1250F/1450F
Gremo 1250F/1450F
• is a robust and versatile 12 to 14 tonne forwarder that
easily navigates all types of terrain. The forwarder is
designed and adapted for forwarding timber, the weight
of which does not exceed the machine's maximum load
capacity, from felling site in the forest to the roadside
stacking area.
• is driven by a Cummins QSB 6-cylinder, turbo-charged
6.7 litre diesel engine with intercooler and common rail
fuel system that complies with stage 3B environmental
requirements and is approved for running on
environmentally-friendly fossil-free diesel that complies
with the requirements in EN 15940, e.g. HVO diesel.
• is fitted with Gre-VT, a continual and variable
hydrostatic transmission with 2 speeds that are
controlled by GreControl. Full traction (18.4 tonnes) is
available from the start whatever program is run.
• has electric/hydraulic brakes. Four multi-disc brakes in
oil bath in the front and rear differentials.
• has a load-sensing hydraulic system with hydraulically-
driven variable fan with reversing option to blow out the
coolers controlled by GreControl; the oil is cleaned by a
return filter and a microfilter.
• has a 24 volt electrical system with dual 145 Ah
batteries.
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Gremo 1250F/1450F Workshop manual 1 Introduction
1.4 Intended area of use
1.4 Intended area of use
The machine must only be used for what it has been
designed and adapted for, i.e. forwarding forest raw
materials, the weight of which does not exceed the
machine's maximum load capacity, from felling site in the
forest to the roadside stacking area. All other use is
prohibited.
It is not permitted to rebuild or modify the machine without
Gremo's approval.
It is not permitted to operate the machine on public roads if
it has not been adapted to comply with national road safety
rules.
1.4.1 Improper use
Do not under any circumstances use the machine for
anything it is not designed for, e.g.
The crane
• should never be used to lift loads greater than it was
designed to lift.
• should never be used to tow or push objects.
• should never be used to lift people.
The machine
• should never be used for anything other than it has
been designed for i.e. loading and unloading timber.
• should never be used if any safety feature is out of
order, e.g. if any safety sensor is disconnected.
• should never be used if a window is broken or with the
door open.
• should never be loaded with weights greater than it was
designed to handle.
• should never be parked on a slope, but must always be
parked on level ground to prevent the machine rolling
away or capsizing.
1.4.2 Prohibited operation
It is prohibited to operate the machine if:
• Protection and warning equipment is out of order or
disconnected.
• If brakes or steering system are faulty.
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1 Introduction
1.5 Operator requirements Gremo 1250F/1450F Workshop manual
• If there are any unauthorised people or vehicles within
the machine's operating area.
1.5 Operator requirements
• The machine can only be operated by operators with
permission from work supervisors and the necessary
knowledge.
• National laws and regulations relating to driving
licences, operator certificates, etc. must be complied
with at all times.
• Operators must be aware of and follow all local safety
rules.
• Operators must follow the manufacturer's instructions.
• Operators must read and understand the machine's
warning and information signs, as well as understand
and be able to use the machine's protection and
warning equipment.
1.6 Safety regulations
Each country has its own national and local safety
regulations, and it is the responsibility of both the owner
and the operator to know and follow these regulations. If
the recommendations in this Instruction Manual differ from
the national and local safety regulations, then the national
and local safety regulations take precedence over the
recommendations in this Instruction Manual.
During the design and testing of the machine, a great deal
of effort has been made to make the machine safe and
efficient. These efforts may be completely wasted if the
safety and maintenance regulations are not followed.
Accidents are usually caused by humans, not by the
machine. A well-maintained machine and a safety-aware
owner/operator is a profitable and safe combination.
A Gremo machine meets the requirements of the
Machinery Directive and the harmonised standards, plus
national requirements and provisions.
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Gremo 1250F/1450F Workshop manual 1 Introduction
1.7 Warning symbols and information about
risks
1.7 Warning symbols and information about
risks
The following warning symbols and signal words are used
throughout this manual and on stickers on the machine:
NOTICE
Read this important information carefully.
If a number of risks occur simultaneously, this Instruction
Manual shows the signal word (DANGER, WARNING,
CAUTION) corresponding to the greatest risk.
NOTE! indicates that attention should be given to
anything concerning safety of the surroundings or the
machine or other important information that may
facilitate understanding or performance of a particular
task.
You can prevent accidents by reading these paragraphs
with special care and always following the instructions.
Remember that your safety and the safety of others may
be affected. It is also the responsibility of the operator to
ensure that all warning stickers are in place on the
machine and are readable.
DANGER
Informs of a very serious hazard which, if not avoided,
may be fatal or cause serious bodily harm
WARNING
Informs of a very hazard which, if not avoided, may be
fatal or cause serious bodily harm.
CAUTION
Informs of a minor hazard which, if not avoided, may
cause minor bodily harm.
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1 Introduction
1.8 Construction of the machine Gremo 1250F/1450F Workshop manual
1.8 Construction of the machine
NOTICE
This Instruction Manual is designed to be valid in several
market areas and for most factory-installed equipment.
Please ignore the paragraphs which are not valid for
your machine. We reserve the right to change and
improve the design whenever we find it necessary,
without undertaking to implement these changes on
products which have already been delivered. We also
reserve the right to change data and instructions for
maintenance, service, environment and safety without
further notice.
1.9 Definitions
In this Instruction Manual, the concepts of ‘front’, ‘rear’,
‘right’ and ‘left’ on the machine are defined according to
the principal direction of travel on roads, i.e. the direction
the machine travels when it is steered using the steering
wheel.
Example: the serial number of the machine is punched on
the frame in the front end of the machine, to the right of the
engine compartment.
1.10 Environment
The interplay between human beings, machines and the
environment can be influenced, and is becoming
increasingly important. We have paid attention to this
during the design of the machine and the writing of this
manual, which has a section relating to this subject. By
following these instructions when you drive and maintain
your machine, you will show consideration for humans,
animals and nature in your environment.
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Gremo 1250F/1450F Workshop manual 1 Introduction
1.11 Location of type plates and serial numbers
1.11 Location of type plates and serial
numbers
Fig. 2 Type plates and serial numbers
1. Type plate for the grapple
2. Type plate for the crane
3. Type plate for the cab
4. Type plate for the machine
5. Type plate for the diesel engine (on the rocker cover)
6. Type plate for the climate system on the right hand side of the radiator
7. The machine's serial number is punched on the front of the right-hand branch deflector.
1.11.1 Serial number
Fig. 3 Serial number
The machine's serial number is punched on the top of the
front of the right-hand branch deflector.
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1 Introduction
1.11 Location of type plates and serial numbers Gremo 1250F/1450F Workshop manual
1.11.2 Type plate for the machine
The following details are shown on the machine's type
plate:
Fig. 4 Type plate for the machine
1. Diesel engine’s serial number
2. Machine no. XX of XX
3. Machine's total weight
4. Diesel engine's power in KW
5. Machine model
6. Machine's serial number
7. Place of manufacture
8. Country of manufacture
9. Year and month of manufacture
10.Machine's traction in N
11. Maximum axle load, rear bogie in kg
12.Maximum axle load, front bogie in kg
13.Type approval according to:
14.Manufacturer's address
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Gremo 1250F/1450F Workshop manual 1 Introduction
1.11 Location of type plates and serial numbers
1.11.3 Type plate for the cab
The following details are shown on the cab's type plate:
Fig. 5 Type plate for the cab
1. Approved according to:
2. Model/Type
3. Serial no.
4. Year of manufacture
5. Weight
1.11.4 Example of crane type plate
The following details are shown on the crane's type plate:
Fig. 6 Type plate for the crane
1. Model/Type
2. Serial no.
3. Weight
4. Year of manufacture
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1 Introduction
1.11 Location of type plates and serial numbers Gremo 1250F/1450F Workshop manual
1.11.5 Example of grapple type plate
The following details are shown on the grapple's type
plate:
Fig. 7 Type plate for the grapple
1. Model
2. Serial no.
3. Weight
4. Year of manufacture
1.11.6 Type plate for the diesel engine
The machine’s chassis number (engine type and number
are normally connected to the chassis number) must be
stated when ordering spare parts.
If the engine's type plate is not legible, the engine's serial
number can also be read from the engine block on top of
the lubricating oil cooler housing.
The injection pump is itemised from Gremo AB.
The following details are shown on the engine's type plate:
Fig. 8 Type plate for the diesel engine
1. Engine serial number
2. Engine type
3. CPL number
4. Valve clearance tolerances
5. Power output data
6. Ignition sequence
7. Important information
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Gremo 1250F/1450F Workshop manual 2 Safety regulations
2.1 General
2 Safety regulations
2.1 General
Operators, mechanics and supervisors are obliged to
study and follow the safety regulations and advice given in
this chapter.
The machine is equipped with signs, and you should make
yourself familiar with the meaning and location of these
signs. Make sure that the signs are readable and replace
any damaged signs.
Furthermore you shall always follow the laws, statutes or
other national regulations concerning traffic safety and
occupational safety. Local traffic rules and local workplace
regulations must always be followed.
WARNING
The cab is not intended for passenger transport, which is
why it lacks a seat and seat belt for passengers. There is
a risk of fatal accident for passengers!
WARNING
The bogie lift can be used as a lifting aid during service
and repairs, but always prop up the machine.
WARNING
When you lift or prop up the machine or parts of the
machine, make sure that the equipment you use is
intended for this purpose, is appropriately dimensioned,
and cannot slip or tip over!
WARNING
Risk of serious crushing injury or fatal accident!
Always switch off the engine before releasing the cab to
tip it up.
Never go under a tipped-up cab unless it is propped up.
Ensure that the cab is propped up if you need to go
under it!
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2 Safety regulations
2.1 General
Gremo 1250F/1450F Workshop manual
WARNING
Do not leave the cab without first placing the grapple/
crane safely on the ground or in the loading platform.
WARNING
During all work on the machine, remember the risk of
slipping. You should always use a safety helmet, safety
goggles, gloves, safety boots, breathing protection and
other necessary protective equipment when required.
CAUTION
Never leave the machine unattended with the engine
running or the ignition on.
Never leave the machine unattended with the ignition
key in the ignition lock.
CAUTION
Never operate the machine with loose tools, binders, etc.
in the cab, as these items may injure you if the machine
tips over or brakes suddenly.
Secure them properly.
CAUTION
During servicing, the engine and main power switch
must always be turned off. In some cases this also
applies to fire extinguishing and other electronic
equipment.
CAUTION
The manufacturer is not responsible for alterations to the
electrical system of the machine, if these do not
correspond to the original state. The function of the
machine’s safety system can be affected.
CAUTION
The machine may be operated and repaired only by
personnel who have undergone training approved by the
supplier.
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Gremo 1250F/1450F Workshop manual 2 Safety regulations
2.1 General
NOTICE
For your mobile phone and other portable
communication equipment you should always use
externally mounted aerials in order to prevent
interference with the computers of the machine.
NOTICE
Never use the main power switch to turn off the machine
as this can cause damage to the machine!
NOTICE
Off-road driving requires a lot of experience before you
master the machine. Because of this, you should take it
easy until you are familiar with the limitations of the
machine.
NOTICE
Always bear in mind the danger of fire, and keep the
machine clean. Check the fire extinguishing equipment
as in the instructions.
15

2 Safety regulations
2.2 Clothing
Gremo 1250F/1450F Workshop manual
2.2 Clothing
To prevent clothes getting caught or stuck, clothing should
be intact and tight fitting. Do not use loose garments such
as ties or scarves because they can get caught in levers
and rotating or protruding parts.
Do not wear jewellery as it can conduct electricity or get
stuck in moving parts.
Long hair should be tied back properly as it can easily get
caught in moving parts. Be careful when working with
welders or open flames as hair is flammable.
Always wear gloves, safety footwear, safety goggles, a
safety helmet, ear defenders and other necessary safety
equipment when required.
2.3 Seat belt
Fig. 9 Seat belt
Always use the seat belt.
Replace a damaged or worn seat belt immediately. Order
from you nearest Gremo service dealer or from Gremo AB
using spare part number 92900100.
Before you start operating the machine, check that there is
no one standing close to it. Risk distance 20 m.
Never drive with an open door. The operator’s cab is not a
safety cab if the door is open.
16