Grove GMK4075 User manual

Vehicle serial number: 2 084 643 en
02.07.2001
Maintenance Manual
Home page

02.07.2001
Important note
Duplications of any kind and excerpts from
this document are not subject to the alterations
service. Original documents of Deutsche GROVE
GmbH are marked with the blue serial number of
the truck crane on the cover page.
Duplications and print-outs of data carriers
on which Deutsche GROVE GmbH has delivered
this document are also not subject to the
alterations service.
© Copyright reserved by Deutsche GROVE GmbH
The passing on or duplication of this document as well as the use and disclosure of its contents are prohibited
unless expressly permitted. Offenders will be liable for damages. All rights pertaining to registration of patent or utility
model are reserved.
2 084 643 en Maintenance Manual GMK 4075

Maintenance Manual GMK 4075 2 084 643 en
02.07.2001
The following chapters are contained in this
maintenance manual:
1 General instructions
2 Safety and environmental protection
3 Cleaning
4 Run-in regulations
5 Maintenance overview
6 Lubricants and fuels
7 Description of maintenance work on the carrier
8 Description of maintenance work on the superstructure
9 Longer periods out of operation
10 Tightening torques
Appendix

2 084 643 en Maintenance Manual GMK 4075
02.07.2001

1
Maintenance Manual GMK 4075 2 084 643 en
02.07.2001
1 General instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1
1.1 Using the maintenance manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1
1.2 Warnings and symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1
1.3 GROVE customer support maintenance instructions . . . . . . . . . . . . . . . . . . . . . . 1 - 2
1.4 Definitions of stated directions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 4

2 084 643 en Maintenance Manual GMK 4075
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General instructions
1.1 Using the maintenance manual
Maintenance Manual GMK 4075 2 084 643 en 1 - 1
02.07.2001
1General 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 special-
ised knowledge of proper safety procedures!
Please read chapters 1 and 2 carefully before beginning maintenance work.
HMaintenance work on the lattice extensions is described in the operating in-
structions for lattice extensions.
1.2 Warnings and symbols
The following definitions and symbols are used in the operating instruc-
tions to highlight particularly important information:
The vertical line to the left of the text indicates that this text, regardless of
its length, relates to the warning symbol.
s
GThis symbol indicates hazards related to the operation described that may
cause personal injury. The type of hazard (e.g. life-threatening, personal in-
jury, risk of crushing or electrocution) generally precedes the warning sign.
SHere dangers which could put objects at risk are pointed out, e.g. damage
to the truck crane or the load.
OThis symbol reminds you that you are working with substances which pose
a risk to the environment. Take particular care.
The measures required for the corresponding maintenance work are indi-
cated next to the symbol. You will find more detailed information in the sec-
tion àHandling substances which are harmful to the environment, S. 2 - 2.

General instructions
1.3 GROVE customer support maintenance instructions
1 - 2 2 084 643 en Maintenance Manual GMK 4075
02.07.2001
HThe hand with the pointing finger indicates passages that contain additional
instructions and tips with regard to truck crane operation.
sThis symbol indicates that the topic is continued on the next page. Turn to
the next page.
1.3 GROVE customer support maintenance instructions
This Maintenance Manual is intended for maintenance personnel. The main-
tenance manual does not contain information on repair work. Repair work
may only be carried out by qualified repair personnel (e.g. the local GROVE
Customer Support).
Repair work also requires:
– appropriate workshop equipment,
– special tools and
– replacement parts authorized by Deutsche GROVE GmbH.
It is your responsibility to maintain and service the truck crane regularly in
order to lengthen its service life and keep it in good working order.
Please note that Deutsche GROVE GmbH can only uphold the warranty pro-
vided for the truck crane if the following conditions are met:
– proper use,
– prescribed care and maintenance,
– professional repair work / overhauling.

General instructions
1.3 GROVE customer support maintenance instructions
Maintenance Manual GMK 4075 2 084 643 en 1 - 3
02.07.2001
Numerous defects and failures are caused by improper maintenance such as:
– lack of oil, grease or antifreeze,
–dirt,
– rope damage,
– defective compressed air and hydraulic systems,
– hose damage or loose screw connections,
– defective brakes,
– defective tyres or wheel rims,
– exceeded maintenance intervals.
For your safety and the safety of others, avoid these errors by carrying out
maintenance work carefully within the specified intervals. Do not put off
maintenance work that is due. Notify either your local GROVE Customer
Support or your qualified repair personnel immediately should repair work
become necessary. This work may only be carried out by trained, qualified
personnel.
A few general maintenance instructions:
•Clean the parts of the truck crane that are to be serviced, particularly the
areaaroundoilfiller,inspection,anddrainopeningsandlubricatingnipples.
•When changing the oil, let the oil run out at operating temperature.
•Ensure that only oils and lubricants specified in the Lubrication chart,
Chapter 6 are used.
•Replace all filters within the specified period if cleaning is not explicitly per-
mitted.
•Replace all seals before assembly. Clean the sealing surfaces.
•Only tighten loose screw connections on hydraulic systems when the sys-
tem is depressurized.
•Keep brake and clutch linings free of grease.
•Replace hydraulic hoses immediately once damage or penetration of mois-
ture becomes visible.
•When handling hydraulic oil, cleanliness is imperative. Even new hydraulic
oil must be filtered.
•Check fastening and retaining elements (screws, nuts, lock washers) be-
fore re-using them and replace them if necessary.
Tightening torques may be found in sections 10 - 1 and 1 0 -2.

General instructions
1.4 Definitions of stated directions
1 - 4 2 084 643 en Maintenance Manual GMK 4075
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Our training centre at our plant in D-26389 Wilhelmshaven offers specialized
training programmes. Your local GROVE Customer Support can provide
you with any information you may need in this regard.
The vehicle must fulfill all current regulations before commissioning and
use on public roads.
1.4 Definitions of stated directions
Some of the terms which are used to describe the location of components
are defined in this section.
On the carrier, the driver's cab is always at the front. The terms rear, right and
left are used in relation to the definition of the term "front" on the carrier.
On the superstructure front always refers to the direction of the main boom
head, regardless of the superstructure position. The terms rear, right and left
are used in relation to the definition of the term "front" on the superstructure.

2
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2 Safety and environmental protection . . . . . . . . . . . . . . . . . . . . . . . 2 - 1
2.1 Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 1
2.2 Handling substances which are harmful to the environment. . . . . . . . . . . . . . . . 2 - 2

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Safety and environmental protection
2.1 Safety rules
Maintenance Manual GMK 4075 2 084 643 en 2 - 1
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2Safety and environmental protection
2.1 Safety rules
When carrying out maintenance work, it is imperative that you observe the ap-
plicable accident prevention regulations.
The following instructions are general safety rules for maintenance personnel:
•Familiarize yourself with the truck crane and its operation.
Read the operating instructions carefully and request guidance from
crane operator.
•Do not carry out maintenance work unless you are authorized to do so.
•Observe all safety and warning signs on the truck crane.
•Observe all safety instructions contained in this maintenance manual.
•Familiarize yourself with the conditions under which the superstructure
may be slewed and the boom may be extended into horizontal position.
•Do not carry out maintenance work unless the truck crane is standing on
flat, stable ground and is prevented from rolling.
•Keep all handles, steps, landings and ladders free of dirt, grease, snow
and ice.
•Use the proper access aids and working platforms when carrying out
overhead work. Wear a harness when carrying out maintenance work
high overhead.
•Walk only on those machine parts which are equipped with appropriate
steps and railings and therefore guarantee safety. During rigging and
maintenance work on machine sections above body height which have no
apparatus for accessing, always use the supplied extension ladder (e.g.
when lubricating telescopic slide faces).
•Perform maintenance work only after the truck crane has been shut down.
Always ensure that the truck crane is protected from unauthorized opera-
tion before beginning maintenance work. Remove the key and put up
warning signs.
s

Safety and environmental protection
2.2 Handling substances which are harmful to the environment
2 - 2 2 084 643 en Maintenance Manual GMK 4075
02.07.2001
If, as an exception, the truck crane needs to be put into operation for certain
types of maintenance work, great care must be taken where there are mov-
ing parts (superstructure, outrigger, cardan shafts, swivelling connections,
motors, tiltable crane cabs, superstructure lock). There is a risk of injury!
•Ensure that all hydraulic components are returned to their initial positions
(e.g. the boom) or locked (e.g. the outrigger).
Escaping hydraulic fluid or compressed air can cause severe injury. Re-
member that hydraulic and compressed air systems of the truck crane are
pressurized even when the crane is not in operation. Only tighten loose
screw connections when the system is in depressurized condition. Always
depressurize the hydraulic and compressed air systems before opening
them.
•Do not allow hot materials to escape unchecked. Risk of scalding!
•Observe the applicable safety regulations when working with inflamma-
ble fluids.
•Observe the applicable safety regulations when working with process ma-
terials.
•Disconnect the earthing terminal and switch off all electrical consumers
before removing any batteries.
•Keep the corroding effect of battery acid in mind.
•Note the fire alarm and fire fighting facilities on the site.
•Return the truck crane to proper working order once maintenance work is
completed. Inform the crane operator accordingly.
2.2 Handling substances which are harmful to the
environment
What do environ-
mentally harmful
substances in-
clude?
When you carry out maintenance work on the truck crane you will occasion-
ally work with substances which are considered to be harmful to the envi-
ronment according to the current national and local regulations.
This includes, amongst others, oil, fuel, grease, used oil and fuel filters as
well as cloths which have come into contact with these environmentally
harmful substances.
•When handling these substances observe the current national and re-
gional regulations as well as the instructions in this chapter.

Safety and environmental protection
2.2 Handling substances which are harmful to the environment
Maintenance Manual GMK 4075 2 084 643 en 2 - 3
02.07.2001
Use suitable
equipment
Substances harmful to the environment can be corrosive. Therefore only
use containers, hoses, pumps, funnels etc. which are resistant to the respec-
tive substance.
Filling and
draining
•When filling and draining, make absolutely sure that no substances harm-
ful to the environment seep into the earth, escape into the sewage system
or polute natural waters.
•Collect draining oil in a suitable container.
•Always use a drain hose when draining, a funnel or a filling pump and
hose suitable for the respective substance when filling.
Collect and store
separately
Substances which are environmentally harmful should always be collected
separately from other waste.
•Also collect the environmentally harmful substances divided according to
solid materials (e.g. filter elements) and liquids. Disposal costs will be re-
duced if you collect liquids separately according to certain categories.
•Ask your local environmental protection authority about the different
categories for the substances.
•Only store environmentally harmful substances in approved containers
and in locations which meet the regulations according to the current na-
tional and regional regulations.
Disposal •Ask your local environmental protection authority about the prescribed
disposal possibilities.
•Only have collected environmentally harmful substances disposed of by
disposal companies which are approved by the national or regional au-
thority responsible.

Safety and environmental protection
2.2 Handling substances which are harmful to the environment
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Blank page

3
Maintenance Manual GMK 4075 2 084 643 en
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3 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 1
3.1 Overview of the components that are easily damaged when cleaning. . . . . . . . 3 - 2

2 084 643 en Maintenance Manual GMK 4075
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Cleaning
Maintenance Manual GMK 4075 2 084 643 en 3 - 1
02.07.2001
3Cleaning
The paint on the truck crane will continue to harden for the first three
months.
•During this period the truck crane may only be cleaned with cold water.
•Do not use high-pressure or steam-jet cleaning equipment during this pe-
riod.
•Avoid water temperatures over 60 °C, even after the first three months.
•Do not use corrosive cleaning agents that might corrode the paint.
•Never hold the spray nozzle of your cleaning unit at a right angle to the
surface you are cleaning and ensure that you are standing at a sufficient
distance away from the surface you are cleaning.
•Never point the nozzle at electrical equipment, relay and control boxes,
suction and venting filters or control elements and lubricated surfaces.
The components specified in section 3 - 2 are to be cleaned with particular
care.
•After cleaning with a high-pressure device or a steam jet device, activate
an intermediate lubrication at the centralized lubrication system
(àCentrallubrication system, S. 7 - 56). Lubricate all remaining lubrication
points with a grease gun.
GRisk of accidents from misdirected high pressure water jet!
When working with high-pressure and steam jet cleaners, the water jet will
be deflected by crane parts and could spray into your face and eyes at great
speed and high pressure.
Always wear a face guard when cleaning the truck crane with high-pressure
and steam-jet cleaning equipment.

Cleaning
3.1 Overview of the components that are easily damaged when cleaning
3 - 2 2 084 643 en Maintenance Manual GMK 4075
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3.1 Overview of the components that are easily damaged
when cleaning
On truck crane
1Lowering limit switch 7SLI length and angle
measuring unit
2Suspension cylinders (on both
sides of the truck crane)
8Angle sensor control box
3SLI connecting box 9Pressure sensors
4Lifting limit switch 10 Switch box pressure sensor
5Telescope slide faces 11 Proximity switch for
swing-away lattice extension
6Air-conditioning system
capacitor
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