2 084 680 en 20020114 719 736 870 966

57
90
75
40
Maintenance Manual
Vehicle serial number: 2 084 680 en

14.01.2002
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.
57
90
75
40
© Copyright reserved by Deutsche GROVE GmbH

14.01.2002
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.
2 084 680 en Maintenance Manual GMK 4075

Amendment
GMK maintenance manual
Validity This amendment is valid for the maintenance manuals of the following
types of truck crane:
GMK 2035 GMK 6200-1

GMK 4075 GMK 6220
GMK 5100 GMK 6250
GMK 5180 GMK 6300
GMK 5200
Reasons for
this additional
information
57
An incorrect test load weight is specified in chapter 8, Description of
maintenance work on the superstructure, section Checking the hoist brake.
90
75
Correct weight
specifications for Type of crane Old (wrong) value Correct value
the test load: GMK 2035 4.5 t 3.4 t
GMK 4075 9.2 t 5.1 t
40
GMK 5100 9.2 t 7.1 t

GMK 5180 9.2 t 9.5 t
GMK 5200 9.2 t 9.5 t
GMK 6200-1 9.2 t 9.5 t
GMK 6220 9.2 t 9.5 t
GMK 6250 10.8 t 11.2 t
GMK 6300 9.2 t 11.2 t
10.07.2002
Amendment Maintenance Manual GMK 2 084 719 en

40
75
90
57
Additional pages
Maintenance work
Vent filter on the hydraulic oil tank
Validity These additional pages apply to GMK truck cranes of the following types:
GMK 4075 GMK 5100

GMK 5180 GMK 5200
GMK 6200-1 GMK 6220/6220-L
GMK 6250 GMK 6300
Reasons for The maintenance of the vent filter for the superstructure hydraulic system
this additional for these truck cranes is now different from the procedure described in the
information
57
maintenance manual supplied. The changes cover
– an additional weekly maintenance procedure (W)

– a change to the annual maintenance procedures (M 12)
90
Additional weekly This additional maintenance procedure describes the check to be carried
maintenance out on the vent filter.
procedure (W) On the GMK 4075, the hydraulic oil tank is on the left-hand side of the carrier
75
behind the driver's cab. On all other crane types, the hydraulic oil tank is on
the superstructure, behind the crane cab.
The vent filter (1) is located on the hydraulic oil

tank.
40
• Check the contamination display (2) at the

top of the vent filter.
When the contamination display (2) is red:
• Replace the filter cartridge; à Change to the

annual maintenance procedures (M 12), page 2.
31.10.2002
s
Additional pages 2 084 736 en 1
GMK 4075, 5100, 5180, 5200, 6220-L, 6250, 6300
Additional pages
Change to the This modified maintenance procedure describes how to change the filter
annual main- cartridge for the vent filter.
tenance pro- On the GMK 4075, the hydraulic oil tank is on the left-hand side of the carrier
cedures (M 12) behind the driver's cab. On all other crane types, the hydraulic oil tank is on
the superstructure, behind the crane cab.
• Press down the bleed unit housing (3) and

turn it to the left.
• Lift off the bleed unit housing.
• Replace the filter cartridge (4).
• Set down the bleed unit housing on the base
plate (5).
• Press up the bleed unit housing and turn it
as far as it will go to the right.
• Reset the contamination display (2). To do
57
this, press in the pin (1) at the top of the
bleed unit housing.
The coloured contamination display drops
back into the contamination display.
90
75
40
31.10.2002
2 2 084 736 en Additional pages

GMK 4075, 5100, 5180, 5200, 6220-L, 6250, 6300
40
75
90
57
40
75
90
57
57
90
75
40
Correction sheets Maintenance manual
Serial number: 2 084 870 en

21.04.2004
Important note
Duplications of any kind and excerpts from this

document are not subject to the revision service.
Original documents of Deutsche GROVE GmbH
are marked with the blue serial number of the
truck crane on the cover sheet.
Duplications and printouts of data carriers on

which Deutsche GROVE GmbH has delivered this
document are also not subject to the revision
service.
57
90
75
40
© Copyright reserved by Deutsche GROVE GmbH

21.04.2004
Dissemination or duplication of this document as well as utilization and disclosure of its contents are prohibited unless
expressly permitted. Infringement will incur liability for compensation. All rights pertaining to registration of patent or utility
model are reserved.
2 084 870 en Correction sheets GMK truck cranes

Correction sheets
Maintenance manual: Safe load indicator
Important information
Validity This additional page applies to the maintenance instructions for the
following GMK truck cranes:
GMK 2035 GMK 3050

GMK 4075 GMK 5100
GMK 5180 / 5200 GMK 6200-1/6220/6220–L
GMK 6250 / 6300 GMK 7450
Reasons for the

additional infor-
mation
57
Through product observation, Deutsche GROVE GmbH has discovered that
contact problems can arise on the slip ring assemblies of the cable drums
for the safe load indicator when the lubricant with GROVE part number
3315 060 is used.
90
About this This supplement contains descriptions of the corrections made in chapter 5,
correction sheet Maintenance overview, and chapter 8, Description of maintenance work on the
superstructure, of the maintenance manuals for the truck crane types listed
above.
75
40
21.04.2004
Correction sheets for all 2 084 870 en 1

truck cranes listed
Correction sheets
5.2.5 Maintenance and inspection plan M 6:
every 6 months / after 500 oper. hrs.
M6
Maintenance work on the SUPERSTRUCTURE Oil / lubricant
every 6 months / after 500 oper. hrs.
Amount (l)
Designation
(gal)/
quantity
à p. 6 - 1
SLI
– Service the slip ring assemblies in the cable drums;
à Chapter 8.
57
90
75
40
21.04.2004
2 2 084 870 en Correction sheets for all

truck cranes listed
Correction sheets
8.7.1 Maintenance of the slip ring assembly of M6
the cable drum
Maintenance of the slip ring assembly is carried out in order to prevent

contamination and corrosion and to prevent malfunctions on the SLI.
The GMK truck cranes have two cable drums whose slip ring assemblies
must be serviced.
There is a cable drum (1) on the left side of the

main boom.
57
90
G
Risk of crushing when extending or retracting boom
75
Secure the boom against unintentional movement, so that your fingers will
not be crushed by retracting telescopic sections or by the turning slip ring
assembly. If you are carrying out this operation with the help of someone
else, communicate with the person in the crane cab by means of clear hand
signals.
40
The second cable drum (1) is located in the

main boom underneath the telescoping cylin-
der.
You can reach the cable drum through the

manhole if you first extend telescopic section I
by approx. 2 m (ca. 6.6 ft).
21.04.2004
s
truck cranes listed
Correction sheets
H
The following sections describe the maintenance procedure for the outer
cable drum. Maintenance on the cable drum in the boom is carried out in
the same way.
Prerequisites Before maintenance, the following requirements must be met:

– The main boom must be resting in the boom rest.
– The battery master switch must be switched off; à Operating instructions,
Chapter Crane engine, Section Turning off crane engine.
G
Risk of damaging the safe load indicator
Before maintenance work on the slip ring assembly, always switch off the
battery master switch so that the cable drum is current-free.
This prevents short circuits which may lead to damage to the central unit.
Maintenance of
the slip ring
57
To remove abrasion particles from the contact brushes, use only dry, oil-
free air or a clean, lint-free cloth.
90
assembly
• Make sure that the cable drum is current-
free.
• Unscrew all screws (1) and remove the cas-
75
ing (2).
• Check the seal on the casing for damage and
replace it if necessary.
• Remove any moisture in the casing with a
40
clean, lint-free cloth.

21.04.2004
4 2 084 870 en Correction sheets for all

truck cranes listed
Correction sheets
• Remove visible dirt on the slip rings (2) with
dry, oil-free air or a clean, lint-free cloth.
• Check to make sure all screws (1) are tight.
• Put the casing (2) back in place. Make sure
57 that the seal is in the right place.

• Fasten the casing with all the screws (1).
90
75
40
21.04.2004

truck cranes listed
40
75
90
57
Additional maintenance work
Validity These additional pages apply to all truck cranes with main booms that are
equipped with Twinlock systems.
Additional mainte- These truck cranes require additional maintenance work on the main boom
nance work locking system.
G
Risk of accidents if maintenance work is not carried out!
Have the additional maintenance work on the main boom locking system
performed by your authorized GROVE dealer or CraneCARE regularly.
This prevents the inadvertent unlocking of a telescoping section in Emer-
gency operation/Emergency program mode, which could cause serious ac-
57
cidents and damage to the truck crane.
These additional pages describe this additional maintenance procedure

only and are part of the maintenance manual supplied.
90
5.2 Maintenance plan
75
5.2.6 M 12 maintenance plan: Every 12 months / after 1000 oper. hrs.

40
M 12
Maintenance work on the SUPERSTRUCTURE: Oil / lubricant
Every 12 months / after 1000 oper. hrs.
Amount (l)/ Designation
number à p. 6 – 1
Main boom
– Have the main boom locking system checked by your autho-
4
rized GROVE dealer or CraneCARE.
23.02.2005
Additional pages 2 084 966 en 1

GMK Truck cranes
40
75
90
57
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
8 57
Description of maintenance work on the carrier
Description of maintenance work on the superstructure

90
9 Longer periods out of operation
10 Tightening torques
Appendix
75
40
14.01.2002
Maintenance Manual GMK 4075 2 084 680 en

57
90
75
40
14.01.2002

1
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
57
90
75
40
14.01.2002

57
90
75
40
14.01.2002

General instructions
1.1 Using the maintenance manual
1 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 special-
ised knowledge of proper safety procedures!
Please read chapters 1 and 2 carefully before beginning maintenance work.
H
Maintenance work on the lattice extensions is described in the operating in-
structions for lattice extensions.
1.2 Warnings and symbols 57

The following definitions and symbols are used in the operating instruc-
90
tions to highlight particularly important information:
G
This symbol indicates hazards related to the operation described that may
cause personal injury. The type of hazard (e.g. life-threatening, personal in-
75
jury, risk of crushing or electrocution) generally precedes the warning sign.
S
Here dangers which could put objects at risk are pointed out, e.g. damage
to the truck crane or the load.
40
O
This 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 Handling substances which are harmful to the environment, à
p. 2 - 2.
The vertical line to the left of the text indicates that this text, regardless of
its length, relates to the warning symbol.
s
14.01.2002
Maintenance Manual GMK 4075 2 084 680 en 1-1

1.3 GROVE customer support maintenance instructions
H
The hand with the pointing finger indicates passages that contain additional
instructions and tips with regard to truck crane operation.
s This symbol indicates that the topic is continued on the next page. Turn to
the next page.

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
57
90
– 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.
75
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,
40
– prescribed care and maintenance,

– professional repair work / overhauling.
14.01.2002
1-2 2 084 680 en Maintenance Manual GMK 4075

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
personnel.
57
become necessary. This work may only be carried out by trained, qualified
A few general maintenance instructions:

90
• Clean the parts of the truck crane that are to be serviced, particularly the
area around oil filler, inspection, and drain openings and lubricating nip-
ples.
• When changing the oil, let the oil run out at operating temperature.
75
• Ensure that only oils and lubricants specified in the Lubrication chart,
Chapter p. 6 - 1 are used.
• Replace all filters within the specified period if cleaning is not explicitly
permitted.
• Replace all seals before assembly. Clean the sealing surfaces.
40
• 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
moisture becomes visible.
• When handling hydraulic oil, cleanliness is imperative. Even new hydrau-
lic oil must be filtered.
• Check fastening and retaining elements (screws, nuts, lock washers) be-
fore re-using them and replace them if necessary.
14.01.2002
Tightening torques may be found in sections p. 10 - 1 and p. 10 - 2.

1.4 Definitions of stated directions
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
57
left are used in relation to the definition of the term "front" on the super-
structure.
90
75
40
14.01.2002

2
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
57
90
75
40
14.01.2002

57
90
75
40
14.01.2002

Safety and environmental protection
2.1 Safety rules
2 Safety 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.
57
• 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
90
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
75
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
40
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
14.01.2002

2.2 Handling substances which are harmful to the environment
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.
terials.
57
• Observe the applicable safety regulations when working with process ma-
• Disconnect the earthing terminal and switch off all electrical consumers
before removing any batteries.
90
• 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.
75
2.2 Handling substances which are harmful to the

environment
40
What do environ- When you carry out maintenance work on the truck crane you will occasion-
mentally harmful ally work with substances which are considered to be harmful to the envi-
substances in- ronment according to the current national and local regulations.
clude? 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.
14.01.2002

Use suitable Substances harmful to the environment can be corrosive. Therefore only
equipment use containers, hoses, pumps, funnels etc. which are resistant to the respec-
tive substance.
Filling and • When filling and draining, make absolutely sure that no substances harm-
draining 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 Substances which are environmentally harmful should always be collected
separately separately from other waste.
• Also collect the environmentally harmful substances divided according to
57
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.
90
• Only store environmentally harmful substances in approved containers
and in locations which meet the regulations according to the current na-
tional and regional regulations.
75
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.
40
14.01.2002

57
90
Blank page
75
40
14.01.2002

3
3 Cleaning ........................................................ 3- 1
3.1 Overview of the components that are easily damaged when cleaning. . . . . . . . 3 - 2
57
90
75
40
14.01.2002

57
90
75
40
14.01.2002

Cleaning
3 Cleaning
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.
G
Risk of accidents from misdirected high pressure water jet!
speed and high pressure.

57
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
Always wear a face guard when cleaning the truck crane with high-pressure
and steam-jet cleaning equipment.
90
• 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 p. 3 - 2 are to be cleaned with particular

75
care.
• After cleaning with a high-pressure device or a steam jet device, activate

an intermediate lubrication at the centralized lubrication system
(à Centrallubrication system, p. 7 - 55). Lubricate all remaining lubrication
40
points with a grease gun.

14.01.2002

Cleaning
3.1 Overview of the components that are easily damaged when cleaning
3.1 Overview of the components that are easily damaged

when cleaning
On truck crane
57
90
75
40
1 Lowering limit switch 7 SLI length and angle

measuring unit
2 Suspension cylinders (on both 8 Angle sensor control box
sides of the truck crane)
3 SLI connecting box 9 Pressure sensors
4 Lifting limit switch 10 Switch box pressure sensor
5 Telescope slide faces 11 Proximity switch for
swing-away lattice extension
14.01.2002
6 Air-conditioning system
capacitor

4
4 Run-in regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 1
57
90
75
40
14.01.2002

57
90
75
40
14.01.2002

Run-in regulations
4 Run-in regulations
Special running-in instructions must be observed for individual compo-
nents (hoist, gearbox, etc.)
– after initial start-up or

– after part replacement or
– after a general inspection
Special run-in instructions must be observed, i.e. additional maintenance
work must be carried out on the carrier and the superstructure in certain
intervals:
Operation Travelled Additional maintenance work on the

hours (oh) km CARRIER
after 50 Tighten wheel nuts
à p. 10 - 2)
after 20; 1)
after 150
57(Tightening torque
Tighten wheel nuts
(Tightening torque à p. 10 - 2)
Carryout the first oil change in the transfer
à
90
case; Distributor gearbox – oil change,
p. 7 - 22.
after 50 Tighten hose clamps on all coolant hoses
(à Special tightening torques, p. 10 - 2).
75
during the Check the hydraulic oil filters weekly;

first 100 à Changing the hydraulic oil filters and cleaning
the magnetic rod, p. 7 - 46.
1)
1 oh corresponds to approx. 40 kilometers driven
40
Please note the instructions concerning run-in times / run-in regulations / oil
change intervals in the enclosed operating manual of the engine manufac-
turer and in the crane diesel engine maintenance booklet.
s
14.01.2002

Run-in regulations
Operation Travelled Additional maintenance work on the

hours (oh) km SUPERSTRUCTURE
during the Check the hydraulic oil filters weekly;
first 100 à Replacing the hydraulic oil filter, p. 8 - 22.
after 100 Check tightness of retaining bolts; tightening
torque; à Special tightening torques, p. 10 - 2.
after 200 Carry out first oil change on hoist gears
(auxiliary hoist only with additional
equipment); à Hoisting gear – oil change,
p. 8 - 5.
after 200 Carry out first oil change in slewing gear
transmission; à Slewing gear – oil change,
p. 8 - 12.
after10001) Carry out second oil change on hoist gears
57
(auxiliary hoist only with additional
equipment);
p. 8 - 5.
à Hoisting gear – oil change,
Please note the instructions concerning run-in times / run-in regulations / oil
90
change intervals in the enclosed operating manual of the engine manufac-
turer and in the crane diesel engine maintenance booklet.
1)
after 1000 operating hours, after 12 months at the latest.
75
40
14.01.2002

5
5 Maintenance overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5- 1
5.1 Maintenance intervals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 1
5.2 Maintenance plans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 3

5.2.1 Maintenance plan D: daily / before start-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5- 5
5.2.2 Maintenance plan W: weekly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5- 6
5.2.3 Maintenance plan M 1: monthly / after 100 oh / approx. 2 000 km . . . . . . . . . . 5- 8
5.2.4 Maintenance plan M 3: every 3 months / after 300 oh / 5 000 – 6 000 km. . . . . 5 - 10
5.2.5 Maintenance plan M 6: every 6 months / after 500 oh / 10 000 – 12 500 km. . . 5 - 12
5.2.6 Maintenance plan M 12: every 12 months / after 1 000 oh /
20 000 – 25 000 km . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 14
5.2.7 Maintenance and inspection plan Y 2:
every 24 months / after 100 000 – 125 000 km. . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 16
every 36 months / after 3 000 oh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 17
5.3
5.3.1
5.4
57
every 72 months / after 6 000 oh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 18
Periodic inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 19
Load hook inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 20
Measures required for winch monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 21
90
5.4.1 Theoretical service life. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 21
5.4.2 Proportion of the theoretical service life used. . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 22
5.4.3 Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 27
75
40
14.01.2002

57
90
75
40
14.01.2002

Maintenance overview
5.1 Maintenance intervals
5 Maintenance overview
In this chapter, all periodic maintenance work is described in maintenance
plans as:
– Maintenance plans D (= daily),

– Maintenance plans W (= weekly) and
– Maintenance plans M 1 (= once monthly) to M 12 (= every 12 months) and
– Maintenance plans M 2 (= every 24 months) to M 6 (= every 72 months).
The maintenance plans are given in table form, differentiated by
– Maintenance work on the carrier and

– Maintenance work on the superstructure.
57
In the tables you are directed by cross references to the sections in which
the appropriate maintenance work is described. The cross references con-
sist of the chapter number and the corresponding page number, e.g.
à p. 7 - 43.
90
Checking hydraulic oil level;
Checking the hydraulic oil level is described in chapter 7, the section starts
on page p. 7 - 43.
75

The length of the interval depends on the operating conditions of the truck
crane:
40
The next maintenance check must be carried out after
– a specified time (maintenance deadline) or

– a specified number of km travelled for carrier components with driving
functions or
– a specified number of operating hours (oh) for superstructure (and car-
rier) components with crane functions.
s
14.01.2002

The first maintenance interval shall determine when maintenance work is

next due.
The km travelled may be taken from the trip recorder in the driver’s cab
(front instrument panel).
You can individually call up the operating hours (oh) of the superstructure’s
power units on the crane control display in the crane operator’s cab (front
instrument panel). The working hours of the crane engine are simulta-
neously the total working hours of the superstructure.
The following table sets out the maintenance intervals for the maintenance
plans:
Maintenance Maintenance km travelled Diesel engine op-

plans interval (carrier) erating hours (oh)
(superstructure)
daily / before start-
D — —
up
W weekly — —
M1
M3
monthly
three monthly
57 approx. 2000
5 000 – 6 000
100
300
90
M6 every six months 10 000 – 12 500 500
every twelve
M 12 20 000 – 25 000 1 000
months
every twenty four
Y2 100 000 – 125 000 —
75
months
every thirty six
Y3 — 3 000
months
every seventy two
Y6 — 6 000
months
40
Please note that the long-term maintenance plans always include the
short-term ones!
14.01.2002

5.2 Maintenance plans

The descriptions of specific maintenance work in the maintenance plans D,
W, M 1 up to M 12 and Y 2 up to Y 6 are for
– the carrier in Chapter 7 and for

– the superstructure in Chapter 8.
Cross-references for the descriptions of these maintenance tasks may be
found after the respective maintenance tasks for the carrier and the super-
structure (chapter and page number).
The section titles
– of Chapter 7 Description of the maintenance work on the carrier and

– of Chapter 8 Description of the maintenance work on the superstructure
contain the symbol (D up to Y 6) of the relevant maintenance plan for better
H
comprehension.
57
The description of some daily (D) and weekly (W) checks (preventive main-
tenance) can also be found in part in the Operating Instructions.
90
In addition to the maintenance work on the carrier and the maintenance
work on the superstructure, the maintenance plans also contain:
– the amounts as approximate values for oil amounts (the exact oil
amounts are always determined by the oil level openings, the dipstick or
75
the oil level indicators) or

the number of existing lubrication points.
– The designations of the oils / lubricants in accordance with the table of lu-
bricants, chapter p. 6 - 1.
H
40
Please note that this Maintenance Manual contains only some of the mainte-
nance tasks on the diesel engine that go beyond the daily and weekly checks.
These tasks are to be performed in accordance with the supplied diesel engine
manufacturer's operating manuals and maintenance booklets.
The engine manufacturer's operating manuals describe how to carry out
these maintenance tasks and the maintenance booklets specify the relevant
maintenance intervals.
14.01.2002

57
90
Blank page
75
40
14.01.2002

5.2.1 Maintenance plan D: daily / before start-up
D
Maintenance work on the CARRIER: Oil / lubricant
Quantity (l) / Name
Number
Diesel engine
– Check the oil level; à p. 7 - 6. A
– Checking refrigerant level; à p. 7 - 8.
– Checking the dry air filter; à p. 7 - 9.
Wheels
– Check tyres for damage and sufficient tread depth;
àp. 7 - 33.
Carrier hydraulic system
– Checking hydraulic oil level; à p. 7 - 43.
57
– Check contamination display for hydraulic oil filter;
àp. 7 - 46.
Carrier electrical system
G2
90
– Check lighting and indicators
75
D
40
Quantity (l) / Designation

Number à p. 6 - 1
Slewing gear
– Slewing gear brake function check; à p. 8 - 14.
Hoist ropes
– Check the overall condition and position of sheaves and rope
drums; àp. 8 - 35.
14.01.2002

5.2.2 Maintenance plan W: weekly
W
Number à p. 6 - 1
Diesel engine
– Checking the overall condition and tightness; à p. 7 - 10.
Gearbox
Distributor gearbox
Axle lines
à p. 7 - 23.
– Checking the overall condition and tightness;
Wheels
– Check the tyre pressure;
Steering
à p. 7 - 33.
à p. 7 - 39.
57
90
– Check tightness;
Carrier compressed air system (incl. brake system)
– Drain compressed air system; à p. 7 - 41.
– Check tightness; à p. 7 - 41.
75

– Check hydraulic hoses; à p. 7 - 44.
– Check tightness (suspension, steering and outrigger systems)
while engine is running; à
p. 7 - 45.
40
Carrier central lubrication system

– Check the level of the fuel tank; à p. 7 - 56. K
Other maintenance checks
– Check the function of the windscreen washing system of the op-
erator's cab and the level of fluid in the supply reservoir.
14.01.2002

W
Number à p. 6 - 1
Main hoist / auxiliary hoist (additional equipment)
– Check the oil level; à p. 8 - 3. E6
– Check hoist brake; à p. 8 - 4.
– Lubricating the hoist gears; à p. 8 - 4. 2 K
Slewing gear
– Check the slewing gear oil level; à p. 8 - 9. E6
– Check the slewing brake oil level; à p. 8 - 9. E5
Superstructure hydraulic system
– Check hydraulic hoses; à p. 8 - 15.
– Check for leaks with the engine running;
Central lubrication system superstructure
57
à p. 8 - 15.
90
– Check the level of the fuel tank; à p. 8 - 51. K
Hoist ropes
– Check the condition; à p. 8 - 36.
75
Other maintenance checks

– Check the function of the windscreen washing system of the crane
operator's cab and the level of fluid in the supply reservoir.
40
14.01.2002

5.2.3 Maintenance plan M 1: monthly / after 100 oh /

approx. 2 000 km
M1
monthly / after approx. 2 000 km
Number à p. 6 - 1
Diesel engine
– Details in the Diesel Engine Operating Instructions and in the
Diesel Engine Maintenance Booklet. Special notes for the main-
tenance group and for rapeseed oil operation; à
p. 7 - 5.
Distributor gearbox
– Check the oil level; à p. 7 - 21. E3
Axle lines
– Axle centre drive – check oil level;
– Final drive – check oil level;
à p. 7 - 23.
à p. 7 - 27.
– Lubricate universal joint shaft of the axle line;
with additional equipment with 8 x 8 x 8 drive.
57
à p. 7 - 29. 12
14
E3
E3
K
K
90
Wheels
– Check tightness of wheel nuts; à
p. 7 - 34.
Tightening torque; à
Special tightening torques, p. 10 - 2.
Suspension
à p. 7 - 37.
75
– Check oil level in the suspension cylinders; H

– Check retaining bolts of the suspension cylinders;
Tightening torque; à
Special tightening torques, p. 10 - 2.
– Checking the acid level in the batteries; à p. 7 - 63.
40
Trailer coupling (additional equipment)

– Lubricating the trailer coupling;2) à p. 7 - 69. 2 J
Carrier air conditioning system (additional equipment)
– Checking the moisture and level of the refrigerant; à p. 7 - 65.
– Cleaning capacitor disks; à p. 7 - 66.
Other maintenance work
– Checking for correct operation of the auxiliary heater (addi-
tional equipment); à
p. 7 - 75.
– Lubricating the outrigger beam1); à p. 7 - 75. 8 J
– Lubricate door hinges. 4 J
14.01.2002
1)
– Lubricate retaining and socket pins. div. J/M
1) after 100 oh
2)
lubricate the trailer coupling after every high pressure cleaning.

M1
monthly / after 100 oh
Number à p. 6 - 1
Switch coupling (does not apply for cranes starting from 9120)
– Switch coupling – check oil level; à p. 8 - 1. G5
Hook blocks
– Lubricate; à p. 8 - 53. div. J
Superstructure hydraulic system
– Bleeding telescoping cylinders; à p. 8 - 19.
– Bleeding the derricking cylinder; à p. 8 - 16.
Other maintenance work
– Lubricating the counterweight hoist unit; à p. 8 - 57. 6 J
–
tional equipment); à p. 8 - 57.

– Lubricate tread rollers of cab door.
57
Lubricating piston rods, derricking cylinders; à p. 8 - 18.
– Checking for correct operation of the auxiliary heater (addi-
3
Z
M
90
– Lubricate retaining and socket pins. div. J/M
– Lubricate spring latch. div. J/M
75
40
14.01.2002

5.2.4 Maintenance plan M 3: every 3 months / after 300 oh /

5 000 – 6 000 km
M3
every 3 months / after 5 000 – 6 000 km
Number à p. 6 - 1
Diesel engine
– Pay attention to the details in the Diesel Engine Operating In-
structions and Maintenance Manual.
Special notes for the maintenance group and for rapeseed oil
operation; àp. 7 - 5.
– Clean fuel prefilter-screen; à p. 7 - 11.
Wheels
à p. 7 - 34.
– Checking wheel-bearing clearance;
Vehicle brakes
– Check brake-lining thickness;
à p. 7 - 35. 57
90
– Change the hydraulic oil filter, check the magnetic rods of the
hydraulic oil filter for metal particles1); à
p. 7 - 46.
– Check acid concentration of batteries; à p. 7 - 64.
75
Trailer coupling (additional equipment)

– Checking the bearing; à p. 7 - 70.
– Checking the cotter pin; à p. 7 - 71.
– Checking the lower bushing; à p. 7 - 72.
à p. 7 - 73.
40
– Checking the initial tension of the springs;

– Checking the function of the coupling jaw / Resetting
the middle position; à
p. 7 - 73.
– Checking the support ring; à p. 7 - 72.
1) after 300 oh
14.01.2002
5 - 10 2 084 680 en Maintenance Manual GMK 4075

M3
every 3 months / after 300 oh
Number à p. 6 - 1
Ball slewing connection
– Check tightness of retaining bolts;
Tightening torque; à Special tightening torques, p. 10 - 2.
Main boom
– Lubricating the locking pins; à p. 8 - 25. Z
57
90
75
40
14.01.2002
Maintenance Manual GMK 4075 2 084 680 en 5 - 11

5.2.5 Maintenance plan M 6: every 6 months / after 500 oh /

10 000 – 12 500 km
M6
Number à p. 6 - 1
Diesel engine
– Pay attention to the details in the Diesel Engine Operating In-
structions and Maintenance Manual.
Distributor gearbox
– Changing the oil; à p. 7 - 22. 9.5 E3
Axle lines
units.
for8 x 6 x 8 drive; àp. 7 - 31.
for8 x 8 x 8 drive (additional equipment); à p. 7 - 31.
57
– Lubricating the longitudinal cardan shafts between the gear
8
10
K
K
90
Steering
– Check tightness of screw connections and that the locking pin
has been fitted.
– Check all track rods and drag links for play.
75
– Check rubber sleeves for damage.

– Checking hoses; à p. 7 - 67.
– Checking the refrigerant compressor control; à p. 7 - 68.
40
14.01.2002

M6
Number à p. 6 - 1
Slewing gears
– Lubricating the slewing gear pinion; à p. 8 - 10. 1 each V
Ball slewing connection
– Lubricate the gear rim; à p. 8 - 10. 1 V
Main boom
– Lubricate telescopic slide faces; à p. 8 - 28. 16 L2
Superstructure air conditioning system (additional equipment)
– Checking hoses; à p. 8 - 55.
SLI
57
– Maintain the slip ring assembly in the cable drums; à p. 8 - 47. X
90
75
40
14.01.2002

5.2.6 Maintenance plan M 12: every 12 months / after 1 000 oh /

20 000 – 25 000 km
M 12
Number à p. 6 - 1
Diesel engine
– Pay attention to the details in the Diesel Engine Operating
Instructions and Maintenance Manual.
– Replacing the fuel filter elements; à p. 7 - 13.
Gearbox
à p. 7 - 19.
– Check the oil level;
Axle lines
– Axle centre drives oil change;
1st axle line
à
p. 7 - 25. 57
2nd axle line (only for additional equipment with 8 x 8 x 8 drive)
13.0
15.0
F4
E3
E3
90
3rd axle line 16.5 E3
4th axle line 13.0 E3
– Final drive oil change; à p. 7 - 28. 4.1 each E3
Carrier compressed air system
75
– Replacing the granulate cartridge of the compressed air dryer;

à p. 7 - 42
– Have suspension system pressure accumulators checked by the
local GROVE Customer Service or by an authorized workshop.1)
40
– Replacing the vent filter for the hydraulic oil tank2);

à p. 7 - 49.
– Oil change1); à p. 7 - 52, (depending on results of oil test, 660.0 G2
à p. 7 - 50).
– Monitoring the entire air conditioning system; à p. 7 - 68.
1) every 3 000 oh, however at the latest every 12 months
2)
Operation under difficult conditions:
– In extremely sandy or dusty environments, the vent filters
are to be changed as needed.
– If crane operation involves frequent loading and unloading, the oil
14.01.2002
change must already take place after 500 operating hours.

– If working in tropical or very hot countries, the oil change
intervals must be halved.

M 12
Number à p. 6 - 1
Switch coupling
– Switch coupling oil change; à p. 8 - 2. Approx. 0.25 G5
– Oil change1); à p. 8 - 5. 10.0 E6
– Checking the old oil; àp. 8 - 6.
Slewing gears
– Slewing gear oil change; à p. 8 - 12. 0.9 each E6
– Slewing brake oil change; à p. 8 - 13. Approx. 1.0 E5
Superstructure air conditioning system (additional equipment)
– Monitoring the entire air conditioning system;
1)
57 à p. 7 - 68.
Carry out at least once a year

90
75
40
14.01.2002


Y2
every 24 months
Number à p. 6 - 1
Gearbox
– Changing the oil and oil filter, à p. 7 - 19. 11.0 F4
Y2
Maintenance work on the SUPERSTRUCTURE:
every 24 months
No maintenance work in this period.

57
The long-term intervals always include the short-term intervals
Oil / lubricant
Quantity (l) /
Number
Designation
à p. 6 - 1
90
include short-term intervals.
75
40
14.01.2002


every 36 months / after 3 000 oh
Y3
every 36 months
Number à p. 6 - 1
The long-term intervals always include the short-term intervals
include short-term intervals.
Y3
57
Oil / lubricant
Quantity (l) /
Number
Designation
à p. 6 - 1
90
– Carry out partial inspection; à p. 8 - 7.
75
40
14.01.2002


Y6
every 72 months
Number à p. 6 - 1
The long-term intervals always include the short-term intervals.
Y6

– Carry out general inspection; à p. 8 - 7.
à p. 5 - 21.
57 Oil / lubricant
Quantity (l) /
Number
Designation
à p. 6 - 1
90
75
40
14.01.2002

5.3 Periodic inspections

Your GMK 4075 truck crane was inspected before delivery.
– Cranes that are to be used in Germany are inspected in accordance with

the regulations of the Professional Trade Association as defined BGV D 6
(VBG 9).
– Cranes that are to be used abroad are inspected in accordance with the
regulations of the respective country. If such regulations do not exist, they
are inspected in accordance with the regulations of the Professional Trade
Association as defined by BGV D 6 (VBG 9).
According to BGV, one periodic inspection must be carried out annually.

The regulations in other countries may prescribe different inspection inter-
vals. If such regulations do not exist, an inspection should be carried out by
an expert at least once a year.
57
These periodic inspections are generally visual inspections intended to as-
sess the condition of the truck crane and its components. Their purpose is
to detect defects at an early stage and thus prevent accidents.
Inspections are to be carried out on the following components, where these

90
are not already contained in the list of routine maintenance tasks:
– the hydraulic and electrical control and safety devices,

– the safe load indicator (SLI),
– the mounting and safety devices of all screwed-on parts,
75
– the hoist ropes,

– load hooks ( à Load hook inspection, p. 5 - 20),
– the load-bearing structural steelwork (for tears, deformation, etc.), includ-
40
ing a special check of all welds.

If damage is found in the structural steelwork, have qualified specialists de-
termine the extent of the damage using the required material examination
methods. They should then determine what sort of repair action could be
done.
The inspector is to write a record containing the result of the annual inspec-
tion and the measures taken to repair any damages.
14.01.2002

5.3.1 Load hook inspection
The mouth of the load hook must be checked regularly for deformation.
The mouth of the hook may not be expanded by more than 10 % of the orig-
inal dimension y, y1, y2.
The original dimensions y, y1, y2 are held in

field (2) on the load hooks.
• To check measure the distance between the

marked measuring points on the load hook
shaft (1) and the tip of the hook (3).
The hook block may no longer be used if the
mouth has expanded by over 10 % of the ini-
tial dimension.
57
The load hook must consequently be replaced.
90
75
40
G
Accidents may occur if the load is allowed to drop!
Hook blocks with deformed load hooks are no longer operationally safe!
The load hooks could break and drop the load.
Deformed load hooks must always be replaced!
14.01.2002

5.4 Measures required for winch monitoring
H
Also observe the information on the general inspection of the hoists;
à p. 8 - 7.
These measures for monitoring the winches (hoisting gear) were compiled
by VDMA and are to be used for all vehicle cranes according to the Accident
Prevention regulations Winches, Hoisting and Tractor Machines BGV D 6 (VGB 9)
and BGV D 8 (VBG 8).
5.4.1 Theoretical service life
The theoretical service life is the result of certain operating conditions and
a theoretical operating time assumed by the design engineer when calculat-
ing and dimensioning the winches of your crane.
Power unit group:

57
The winches of your crane are classified as follows (ISO 4301/1, FEM 1.001,
DIN calculation rules for power units):
M ......
90
Load spectrum: Q .....; (L.....)
Load spectrum factor: Km = ......
Theoretical service life: D = ......
H
The power unit group M 3 and the collective load L1 (Km = 0.125) are gen-
75
erally given for truck cranes in erection mode, resulting in a theoretical ser-
vice life of 3200 h.
S
The theoretical service life is not the same as the real (actual) service life of
a winch.
40
s
14.01.2002

The real service life of a winch is affected by a number of additional external

factors, such as:
1. Overloading caused by improper use of the crane.
2. Insufficient maintenance: oil is not changed in the specified

intervals done.
3. Incorrect operation: extreme acceleration or

retardation of the load,
load drops and stops suddenly while
suspended.
4. Improper maintenance: using wrong oil,

incorrect quantity,
contamination during oil change.
5. Improper assembly during maintenance and repair work.
6. Leaks which were ignored.

57
7. Improper adjustment of safety devices.
90
8. Concealed damage caused by accidents.
9. Extreme environmental low or high temperatures,

conditions: aggressive atmosphere,
dust and dirt.
75
5.4.2 Proportion of the theoretical service life used

40
The crane operator must perform a crane inspection at least once a year
(ISO 9927-1 and BGV D 6 (VGB 9) / BGV D 8 (VBG 8)).
This includes establishing the proportion of the theoretical service life that
has been used. If required, the crane operator is to appoint an expert for this
assessment.
The actual operating conditions (load spectrum) and the operating hours of
the hoists are to be determined for each inspection interval when establish-
ing the proportion of the theoretical service life that has been used. The op-
erator is responsible for proper documentation in the crane logbook.
14.01.2002

Determining the The collective load of the crane is divided into groups:
operating condi- (also refer to ISO 4301/1, FEM 1.001)
tions (collective
H
load)
When establishing the load spectrum, the existing wire cable is used as a stan-
dard, i.e. under certain circumstances, the crane can be supporting a small
load, whereby the winch is actually supporting a heavy load, e.g. due to insuf-
ficient reeving. Therefore, the following graphic representation of the load
spectrum refers to the winch’s wire cables.
Collective Term designation Working time proportion Collective Graphic representation

load load factor
Class Km =
Power units or their parts, 10 % of the operating time
which are subjected to highest with highest load (dead load
load as an exception, + 1/1 payload)
continuously however only
light very less load 40 % of the operating time
Q1 with dead load + 1/3 0.125
L1 payload
50 % of the operating time

only with dead load
Power units or their parts,

which are very often subjected
to highest load, however
continuously less load
subjected to load
+ 1/1 payload)
57
1/6 of the operating time
with highest load (dead load
1/6 of the operating time

90
medium with dead load + 2/3
payload)
Q2 0.25
L2 1/6 of the operating time
with dead load + 1/3
payload)
50 % of the operating time

75
only with dead load

which are frequently with highest load (dead load
subjected to highest load and + 1/1 payload)
continuously to medium load
heavy 50 % of the operating time
Q3 only with dead load 0.5
40
L3

which are regularly subjected with highest load (dead load
to loads close to maximum + 1/1 payload)
loads.
very heavy 10 % of the operating time
Q4 only with dead load 1
L4
One of the load spectrums listed above is to be selected on the basis of the
14.01.2002
actual operating conditions and entered in the crane logbook for the respec-
tive testing interval.
Note for truck cranes:
In case of truck cranes in erection mode, as a rule, the collective load
L 1 is to be given with the collective load factor Km = 0.125. s
Determining the The effective operating hours, determined as follows, must be entered into
actual operating the crane log book for the corresponding testing interval.
hours Ti
The following two of four possible cases apply to GROVE truck cranes:
– Operating hour counter separate for crane operation

– Operating hour counter for driving and crane operation together
Operating hour counter separate for crane operation

– The proportion of winch operating hours in relation to the total super-
structure operating hours must be estimated.
H
It can generally be assumed for hoist winches that the percentage of winch
operating hours in relation to the superstructure operating hours will be
20 % for truck cranes in installation mode.
– The effective operating hours Ti of the winch can be called up separately

à
and are shown on a display (
57
Operating Instructions, Chapter Crane Op-
eration, Section Crane work with main boom).
Operating hour counter for driving and crane operation together

90
The proportion of winch operating hours in relation to the total crane oper-
ating hours is to be estimated.
H
It can generally be assumed that the percentage of superstructure operating
75
hours in relation to the crane operating hours will be 60 % for truck cranes
in installation mode. If the percentage of hoist winch operating hours is as-
sumed to be 20 % in relation to superstructure operating hours
(à Operating hour counter is functional for entire crane operation), the percent-
age in relation to the total operating hours of the crane will be: 12 %.
40
14.01.2002

Determining the For a testing interval i (max. 1 year according to ISO 9927-1 or BGV D 6
proportion of the (VBG 9) / BGV D 8 (VBG 8)) the used proportion of the theoretical service life
theoretical ser- Si is calculated using the formula:
vice life used
Km i
S i = ----------- × T i
Km
Km = Load spectrum factorestablished during winch calculation.

was established. This factor is given in the Operating Instructions.
zu entnehmen.
Kmi = Load collective factor in inspection interval i according to

"Determining the operating conditions (collective load)"
Ti = Actual operating hours for inspection interval i according to

Section "Determining the actual operating hours Ti"
57
This used proportion is subtracted from the remaining theoretical service
life Di after every testing interval (see example in the appendix to this chap-
ter).
A general overhaul must be performed on the winch if the remaining theo-

90
retical service life is not likely to be sufficient for the next operating period.
If the theoretical service life D has been reached ( à

Theoretical service life,
p. 5 - 21), the winch must not be operated until after a general overhaul has
been performed.
75
A general overhaul must be performed at least once every 10 years after

commissioning of the crane.
The general overhaul is to be arranged by the operator and performed by

40
the manufacturer or his representative. The results are to be entered in the

crane logbook.
The manufacturer or his representative will specify a new theoretical service

life D upon completion of the general overhaul.
The next general overhaul must be performed within 10 years.

14.01.2002

Alternative If, after ten years, the theoretical service live is not over, the winch can
provision continue to be operated without a general overhaul under the following
conditions.
The crane expert has confirmed that the used portion of the service life is
correct and useful by signing his/her name in the crane test book after every
inspection.
In this case, the crane expert must closely inspect the winch. At the
minimum, this includes:
– a visual inspection of the exterior (for leaks, damage,

deformations, etc.)
– an oil inspection (especially for metallic residue)
– a load inspection with minimum and maximum wire cable lengths and
each with maximum possible speed. At least one position is to be wound.
Pay attention to any unusual noises during the load inspection.
This inspection must be confirmed in the crane test book by the crane expert
57
and there must be a declaration of continued operation for the winch. The
next inspection takes place before the 12th year of operation and must be
repeated every year thereafter.
90
75
40
14.01.2002

5.4.3 Example
A truck crane with a separate operating hour counter for driving and crane
operation is classified by the manufacturer according to the Operating In-
structions as follows:
Power unit group: M3
Load spectrum: light L 1, Km = 0.125
Theoretical service life: D = 3200 h
The used proportion S of the theoretical service life is calculated over the in-
dividual inspection intervals as follows:
1. Inspection (first year)
load L 1, i.e. Km1 = 0.125.

57
The crane was used for assembly work during the previous year: Collective
The superstructure operating hour counter reads 800 h. The winch was op-
erated 20 % of the time, i.e. T1 = 160 h.
90
The used proportion S1 of the theoretical service life after the first inspection
is therefore:
0.125
S i = --------------- × 160 h = 160 h
75
0.125
Remaining theoretical service life:
D1 = 3200 h – 160 h = 3040 h.

40
The aforementioned values are entered in the table (see example table
p. 5 - 29).
2. Inspection (second year)
The crane was used for unloading work on docks: Load spectrum: L 3, i.e.
Km2 = 0.5.
The superstructure operating hour counter reads 2000 h, i.e. during this pe-
riod: 2000 h – 800 h = 1200 h (800 h were used during the first year).
14.01.2002
The winch was operated 40 % of the time, i.e. T2 = 480 h.

The used proportion S2 of the theoretical service life after the second in-
spection interval is therefore:
0.5
S i = --------------- × 480 h = 1120 h
0.125
D2 = 3040 h – 1920 h = 1120 h.
p. 5 - 29).
3. Inspection (third year)
The crane was used for assembly work and occasional unloading work on
docks: Load spectrum: L 2, i.e. Km3 = 0.25.
i.e., during this period: 57

Three thousand hours are read at the superstructure working hour meter;
3.000 h – 2.000 h = 1.000 h (2.000 h are used in the first two years of
operation).
90
The winch was operated 30 % of the time, i.e. T3 = 300 h.
The used proportion S3 of the theoretical service life after the third inspec-
tion interval is therefore:
75
0.25
S i = --------------- × 300 h = 600 h
0.125

40
D3 = 1120 h – 600 h = 520 h.
p. 5 - 29).
The remaining theoretical service life is to be documented in a separate ta-

ble for each winch.
This table is to be attached to the crane logbook. This table is found in the
Maintenance Manual appendix for truck cranes that do not require a crane
14.01.2002
logbook or similar documentation according to the regulations of the re-

spective country.

14.01.2002
Table example to determine the remaining theoretical service life on winch no. 1 (main hoist winch)
Crane model: GMK 3045

Work number: 3045 42 06
Commissioned on: 10. 06. 1990
Serial number of the winch in accordance with the model plate:13 301
Last general overhaul performed on: ........................
Winch design data (see Operating Instructions):
Drive gear group: M 3
Load spectrum: Q 1 (L1)
Factor of the load spectrum: Km= 0.125
Maintenance Manual GMK 4075

Theoretical service life: D = 3 200 h
40
Testing Date of first Operational Collective Operating Operating Operating Operati Operating hours of Used Remaining Name of the Signature Note Name of the Signature
interval no. operation/ condition load factor hours of the hours of the hours of the ng the winch since the proportion of theoretical expert approved
(max. date of since the entire crane superstruct superstruct hours of last inspection the theoretical service life inspector
1 year) inspection last ure ure since the service life:
inspection the last winch
Di = Di-1 - Si
inspection
75
“i” Kmi [h] [h] [h] [h] [h] [h] [h]
0(*) 10. 6. 90 – – – 0 0 3200
1 5. 6. 91 L1 0,125 – 800 800 – 160 160 3040 Müller

(20% of 800)
480
2 084 680 en
2 20. 5. 92 L2 0,5 – 2000 1200 – 1920 1120 Huber
(40% of 1200)
90
300
3 18. 5. 93 L3 0,25 – 3000 1000 – 600 520 Schmitz
(30% of 1000) 57
CAUTION: Si = Used proportion of the theoretical service life since the last inspection
A general overhaul is to be performed every 10 years!
Di = Remaining theoretical service life
Di - 1= Remaining theoretical service life after the previous inspection
Alternative provision, refer to section 5.4.2, S. 5 - 22.
Km = Load spectrum factor established during winch calculation.
This factor is given in the Operating Instructions.
Kmi= Load spectrum factor in the inspection interval “i” according to section 2.1
Ti = Effective working hours in the inspection interval “i” according to section 2.2
Last general overhaul performed on:..................................
(*) Copy last line of the previous page to the following pages
5 - 29
57
90
Blank page
remaining theoreticalservice life of winch no. 1 (main hoist winch)
75
40
14.01.2002

6
6 Lubricants and fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 1
6.1 Lubricant table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 1
6.2 Process materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 3

6.2.1 Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 3
6.2.2 Engine coolant admixtures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 3
6.2.3 Windscreen washing system admixtures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 3
6.2.4 Fuel for crane cab heating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 3
57
90
75
40
14.01.2002

57
90
75
40
14.01.2002

Lubricants and fuels
6.1 Lubricant table
6 Lubricants and fuels
6.1 Lubricant table
Name Lubricating Type of Name Specification Lubricant

point lubrication according to Classification type
DIN 51502 Viscosity
range
MIL-L 2104 C 1)
A Diesel engine HD - CD
DB 228.5
Axle system
MIL-L 2105 B SAE 90
E3 Distributor C - LPF
Circulatory API-GL-5 ISO - VG 220
E5
3)
gearbox
Slewing gear
brake
Slewing gear
Gearbox
lubrication
57 GROVE part no. 1 930 6702)
MIL-L 2105 B SAE 75 W-90

90
E6 C - LPF
API-GL-4/5 ISO - VG 220
Hoist Oil quantity
MIL - L2105
Circulatory
F4 Gearbox API-GL-4 SAE 75 W-80 W3)
lubrication
TE-ML 02L
75
Hydraulic
G2 H-LP DIN 51524 T.2 ISO - VG 32
system
Switch
G5 Oil quantity API-GL-4 plus SAE 75 W-903)
coupling
40
Suspension
H GROVE part no. 2 310 8632)
cylinder
Lubricating
Grease gun and
J points (lubricat- K - L2K DIN 51825
manually
ing grease)
K Roller bearing For repairs, KP - L2K DIN 51825
grease when
L2 Slideways installing GROVE part no. 1373 458 2)
1) See engine operating instructions

2) Available from local GROVE Customer Support
14.01.2002
3) Synthetic oil filled at the factory; do not mix with mineral oil.
s
6.1 Lubricant table
Name Lubricating Type of Name Specification Lubricant

point lubrication according to Classification type
DIN 51502 Viscosity
range
M Lubricating Oil can,
as A (Diesel
points high pressure jet
engine)
(lubricating oil) oil can
V Open-running
GROVE part no. 0554 2052)
gear wheels
Adhesive
W Mounting lubrication
screws, GROVE part no. 1573 0462)
bushings, etc.
X Slip ring
GROVE part no. 3315 0602)
assembly
Corrosion
Z Locking pins, protection Spray oil containing molybdenum disulphide
derricking
cylinder
2)
57
Available from local GROVE Customer Support
(MoS2)
90
75
40
14.01.2002

6.2 Process materials
6.2.1 Fuel
The diesel fuels that may be used and their respective specifications may be
found in the engine operating manual.
6.2.2 Engine coolant admixtures
The specifications and admixture ratios may be found in the engine operat-
ing manual.
6.2.3
57
Windscreen washing system admixtures
Commercial cleansers and antifreeze may be added to the windscreen

90
washing water. Observe the application instructions on the package.
6.2.4 Fuel for crane cab heating system

75
You should use either the fuel specified in section 6.2.1 or EL heating oil as
heating fuel for the crane cab.
40
14.01.2002

57
90
Blank page
75
40
14.01.2002

7
7 Description of maintenance work on the carrier ........... 7- 1
7.1 Tilt driver’s cab forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 1
7.2 Diesel engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 5

7.2.1 Diesel engine – oil level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 6
7.2.2 Diesel motor – top up the oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 7
7.2.3 Checking coolant level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 8
7.2.4 Checking the dry air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 9
7.2.5 Checking general condition and for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 10
7.2.6 Cleaning the fuel prefilter screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 11
7.2.7 Changing the fuel filter cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 13
7.3 Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 17
7.3.1 Checking general condition and for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 17
7.3.2 Gearbox – oil level check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 18
7.3.3 Gear box – oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 19
7.4
7.4.1
7.4.2
7.4.3
57
Transfer case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 21
Checking general condition and for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 21
Distributor gearbox – oil level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 21
Distributor gearbox – oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 22
90
7.5 Axle lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 23
7.5.1 Checking general condition and for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 23
7.5.2 Axle centre drives – oil level check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 23
7.5.3 Axle centre drives – oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 25
75
7.5.4 Final drives – oil level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 27

7.5.5 Final drives – oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 28
7.5.6 Lubricating the cardan shafts on the axle lines. . . . . . . . . . . . . . . . . . . . . . . . . . 7- 29
7.5.7 Longitudinal cardan shafts between the gear units lubricate . . . . . . . . . . . . . . 7- 31
40
7.6 Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 33
7.6.1 Checking the tyres for damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 33
7.6.2 Check the tyre pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 33
7.6.3 Check tightness of wheel nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 34
7.6.4 Checking the wheel-bearing clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 34
7.7 Vehicle brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 35
7.7.1 Checking brake-lining thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 35
7.8 Suspension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 37
7.8.1 Telescopic leg – oil level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 37
14.01.2002
7.8.2 Tightness of retaining bolts on the suspension cylinders to be checked . . . . . 7 - 38

7.9 Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 39
7.9.1 Checking for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 39

7.10 Carrier compressed air system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 41
7.10.1 Draining the compressed air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 41
7.10.2 Compressed air system – check for leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 41
7.10.3 Replacing the granulate cartridge of the compressed air dryer . . . . . . . . . . . . 7 - 42
7.11 Carrier hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 43
7.11.1 Hydraulic unit – oil level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 43
7.11.2 Checking the hydraulic hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 44
7.11.3 Checking for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 45
7.11.4 Changing the hydraulic oil filters and cleaning the magnetic rod. . . . . . . . . . . 7- 46
7.11.5 Replacing the venting filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 49
7.11.6 Taking hydraulic oil samples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 50
7.11.7 Changing the hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 52
7.12 Centrallubrication system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 55
7.12.1 Central lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 55
7.12.2 Version 1 – Checking the level of the grease container and topping up . . . . . . 7 - 56
7.12.3
7.13
7.13.1
7.13.2
57
Version 2 – Checking the level of the grease container and topping up . . . . . . 7 - 59
Carrier electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 63
Checking the acid level of batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 63
Checking the acid concentration of batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 64
90
7.14 Carrier air conditioning system (additional equipment) . . . . . . . . . . . . . . . . . . . . 7 - 65
7.14.1 Checking the moisture and level of the refrigerant. . . . . . . . . . . . . . . . . . . . . . . 7- 65
7.14.2 Cleaning capacitor disks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 66
7.14.3 Checking hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 67
75
7.14.4 Checking the refrigerant compressor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 67

7.14.5 Checking the refrigerant compressor control . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 68
7.14.6 Checking the entire air conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 68
7.15 Trailer coupling (additional equipment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 69
40
7.15.1 Lubricating the trailer coupling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 69

7.15.2 Checking the bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 70
7.15.3 Checking the cotter pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 71
7.15.4 Checking the lower bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 72
7.15.5 Checking the support ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 72
7.15.6 Checking the initial tension of the springs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 73
7.15.7 Checking the function of the coupling jaw / re-adjusting the middle position . 7- 73
7.16 Other maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 75
7.16.1 Lubricating the outrigger beams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 75
7.16.2 Checking for correct operation of the auxiliary heater (additional equipment) 7 - 75
14.01.2002

7.1 Tilt driver’s cab forward
7 Description of maintenance work on the carrier

For carrying out various maintenance work (e.g. oil change switch coupling)
you must tilt the driver’s cab forward.
This means that the diesel engine needs to be started.
H
If the diesel engine cannot be started, the boom must be raised using the
emergency operation facility; à Operating instructions GMK 4075, Carrier op-
eration malfunctions, Emergency operation for lifting the main boom.
Prerequisites and Before tilting the driver’s cab the following requirements must be met:
information on
tilting
57
– All loose objects must be removed from the driver's cab.
– The main boom is raised to the extent (approx. 1.5 m) that the driver's cab
will not touch the main boom (nor the hose drum if equipped with one)
90
when tilting.
– Ensure that the hook block is at a sufficient distance from the windscreen
when tilting.
S
75
The universal joint on the steering column may break.

The steering angle must not be altered when the driver's cab is tilted.
Otherwise, the universal joint on the steering column may break.
40
Unlock the driver's cab mechanically and attach to suitable hoist gear for
tilting.
s
14.01.2002

Unlocking / Unlock the driver’s cab before tilting it forward. Lock the driver’s cab again
locking the once you have brought it back to its initial position.
driver’s cab
The driver’s cab is locked on both sides at the

back with a bolt on the vehicle chassis.
To unlock, release the retaining pins (3) and

pull the bolt (1) out of the clamps (2).
Also pull the bolt out on the other side.
To lock, push the bolt (1) through the clamps (2)

and secure it with the retaining pin (3).
Also push the bolt in on the other side.
Driver’s cab tilting

57
Observe the prerequisites stated at the beginning of section à Prerequisites
90
and information on tilting, p. 7 - 1. Before tilting the driver’s cab.
You need to attach and lift the driver’s cab to tilt it. You can attach the
driver’s cab to the truck crane yourself and lift it with the main hoist gear or
you can use other suitable hoist gear (e.g. an overhead crane in a hall).
75
• Remove all loose objects from the driver’s cab and close the doors.
G
Risk of accidents from toppling objects and doors swinging open.
Remove all loose objects (e.g. bags, bottles etc.) from the driver’s cab so
that they will not topple when tilting and close all the doors of the driver’s
40
cab.
This prevents liquids from getting into the inserts and doors from swinging
open during tilting and injuring people.
G
Risk of accidents due to driver’s cab tilting.
When you are tilting the driver’s cab forward and while it is actually tilted
forward, nobody may be in front of the driver’s cab.
14.01.2002

S
Danger of damage when the driver’s cab is tilting!
When lifting the driver’s cab, the angle between the roof of the driver’s cab
and the slinging rope must always be larger than 45°. Therefore, use only
sling gear which is long enough. If the sling gear is too short, the angle will
be less than 45° and the ring bolts and the threads may become
overloaded.
Two ring bolts (2) are supplied for slinging the

driver’s cab.
• Screw the two ring bolts (2) into the

threaded bores located at the rear on the
driver’s cab.
• Fasten a rope (1) to each ring bolt.
• Fasten the loose ends of the rope to the
hook block of the truck crane or to any other
57 suitable lifting gear.

• Ensure that the angle A is always larger than
45° when lifting.
90
When the driver's cab tilts, the support (2) is
pulled apart.
• Tilt the driver’s cab to the extent that it will

tilt over the pivot point and the support is
75
pulled under tension.

In this position the spring latch engages (1)
(handle points downwards) and secures the
driver’s cab against unintentional tilting back-
40
wards.
G
Risk of accidents due to the driver’s cab tilting back.
You may only stand under the tilted driver's cab if the driver's cab has tight-
ened the wire rope between driver's cab and vehicle chassis.
14.01.2002
s
Lowering the Before lowering the driver’s cab, you must unlock the support.
G
driver’s cab
Risk of crushing due to the driver’s cab tilting back.
Before unlocking the support, ensure that the driver’s cab is tightening the
support or that the driver’s cab is secured against tilting back with the se-
curing equipment.
By doing this, you are preventing the driver’s cab from accidentally tilting
back when unlocking the support, and preventing you or other people from
being crushed.
• Release the spring latch while also turning

the handle (1) upwards.
• Lower the driver’s cab until it is set down on
the vehicle chassis.
When the driver’s cab (2) is lowered, the sup-
port is pushed in and the stop (3) turns the
handle on the spring latch back to the correct
57
position for locking when the cab is next tilted.
90
• Remove the two ropes (1) from the ring
75
bolts.
• Screw the ring bolts (2) out of the threaded
bores.
• Store the ring bolts and the ropes safely,
40
ready for driving.
• Lock the driver’s cab with the two bolts;

à Unlocking / locking the driver’s cab, p. 7 - 2.
G
Accidents may occur if the driver’s cab is not locked.
Relock the driver’s cab to the vehicle chassis with the bolts after having
14.01.2002
lowered it. This prevents the driver’s cab from tilting forward (unter the
boom) when braking.

7.2 Diesel engine
7.2 Diesel engine

Follow the instructions in the supplied Diesel Engine Operating Instructions
for maintenance work which exceeds the scope of the daily work.
S
Risk of damage to the engine.
The vehicle engine is in maintenance group II (difficult operation) because
of the high full-load rate or large fuel supply rate.
If the diesel engine is operated with rapeseed oil fatty acid methylester
(RME), the engine oil change intervals must be halved.
The release of engines for RME operation is regulated by the Diesel engine
Service information.
For various jobs (e.g. changing the fuel filter) you must remove the covers
on the carrier above the diesel engine, gearbox and the first axle line.
• For this open the plugs on both sides with a

hexagon socket spanner and remove the
57 covers (1).
90
75
s
40
14.01.2002

7.2 Diesel engine
7.2.1 Diesel engine – oil level check D
The oil dip stick (1) for the diesel engine is on

the left-hand side, in front of the boom sup-
port.
57
S
Damage may occur to the engine if the oil pressure is too low!
If no oil pressure is displayed after 10 seconds, turn off the diesel engine
à
90
and look for the cause; Operating Manual, chapter Carrier malfunctions,
Section Diesel engine malfunctions.
75
• Start the diesel engine and let it run for 2-3

minutes at idling speed. Monitor the oil
pressure display.
• Turn off the diesel engine.
40
• Check the oil level after approx. 2 minutes.

The oil level must be between min and max
(arrow marks).
• Top up engine oil if necessary, à Diesel mo-

tor – top up the oil level, p. 7 - 7.
14.01.2002

7.2 Diesel engine
7.2.2 Diesel motor – top up the oil level
For details regarding required oil specifications, refer to the diesel engine
operating instructions.
The oil filler (1) for the diesel engine is located

at the front right on the carrier, next to the
charge air cooler.
• Refill the motor oil through the fillerneck (1).

• Check the oil level on the dipstick.
57
S
Damage may occur to the engine if the oil level is too high.
90
Do not overfill; the oil level must not be higher than the highest arrow
marking (max.).
75
40
14.01.2002

7.2 Diesel engine
7.2.3 Checking coolant level D
The coolant reservoir is located on the left-hand side of the carrier behind
the driver’s cab.
G
Danger of scalding when diesel engine is hot.
The radiator is hot and under pressure. You could burn yourself on the hot
radiator, escaping steam or any escaping coolant if you remove the lid of
the radiator when the diesel engine is hot.
Wear suitable protective gloves and cover the radiator cap with a cloth
before opening it.
Turn the radiator cap lid slowly to the first notch in order to allow the excess
pressure to be released.
Do not open the pressure relief valve (2) on the

side of the expansion tank.
• Loosen (do not open) the cap on the filling
57
hole (1) with the coolant at operating tem-
perature to release the pressure.
• Open the cap.
The coolant must reach the lower edge of
90
the pipe in the filler neck.
75
If the coolant level is too low:

40
• Top up the coolant.

See the diesel engine operating instructions for the composition of the
coolant.
• Screw on the filling hole cap until it stops.
S
Risk of damage to the engine due to lack of coolant.
If the coolant has to be topped up frequently, the cooling system may be
leaking. Have GROVE Customer Service or your repair crew check the cool-
ing system and repair the damage.
14.01.2002

7.2 Diesel engine
7.2.4 Checking the dry air filter D
The dry air filter is on the right-hand side of the carrier, behind the first axle
line.
The Diesel engine air filter indicator lamp is on the front instrument panel
p of the driver’s cab. If this indicator lamp lights up, the dry air filter must be
replaced.
• Release all clamps (1) on the filter lid.

• Take off the filter lid (2).
57
90
• Extract the filter cartridge (1).
75
• Insert a new filter cartridge.
If the seal on the filter lid is worn:
• Change the seal.

40
• Put the filter lid back in place and secure it

with all the clamps.
14.01.2002

7.2 Diesel engine
7.2.5 Checking general condition and for leaks W
• Check the pipe lines and hoses for

– tightness,
– leaks,
– abrasions.
• Replace any damaged pipes and porous or swollen hoses.
• Tighten any connections that are leaking.
If the connection still leaks:
• Change the seal.

• Inspect the diesel engine for any visually obvious
fouling or leaks.
• Listen out for any unusual noises from the diesel engine.
57
If damage cannot be rectified immediately or further damage is likely:
• Inform your local GROVE Customer Service or your repair crew.

90
75
40
14.01.2002

7.2 Diesel engine
7.2.6 Cleaning the fuel prefilter screen M3
H
Before cleaning the primary fuel filter, you must block off the fuel pipe from
the tank,à Shutting off and emptying the fuel line, p. 7 - 13.
Cleaning the pre-

filter screen
The fuel prefilter (1) is under the carrier’s rear

cover on the right hand side next to the auto-
matic gearbox.
57
90
O
75
Have a container or cleaning rag ready so that you can catch the draining
fuel. Wipe up any fuel which is not caught.
Store used fuel filter cartidges in suitable containers and dispose of them
properly.
40
s
14.01.2002

7.2 Diesel engine
• Open the tank cap in order to prevent excess

pressure in the fuel tank.
• Unscrew the prefilter’s filter container (1).
• Clean the filter container and filter screen (2)
with clean diesel fuel using a soft brush. Re-
place a heavily soiled or damaged filter
screen.
• Check and, if necessary, replace the sealing
ring (3) in the filter lid.
• Insert the filter screen into the filter con-
tainer and screw it again onto the prefilter.
Tightening torque 10 Nm.
• Bleed the fuel system as described in the fol-
lowing section.
Bleeding the fuel

system left.
57
• Release the hand pump by turning the knurled screw (4, top picture) to the
The knurled screw is also the hand pump’s handle.

90
• Pump up and down until the resistance noticeably increases.
• Insert the hand pump and tighten the knurled screw again.
• Start the engine and check the prefilter for tightness.
75
40
14.01.2002

7.2 Diesel engine
7.2.7 Changing the fuel filter cartridge M 12
Shutting off and Before changing the fuel filter cartridge you must:
emptying the fuel – shut off the fuel line to the diesel tank and
line – empty the fuel line
O
Always use a fuel-resistant container with sufficient capacity into which the
fuel line is emptied. Make sure that no fuel runs out and seeps into the
ground.
Shutting off the fuel line
A shut-off valve is in the fuel line under the

carrier's rear cover on the right hand side next
to the automatic gearbox.
57 • Close the tap. Turn the handle (1) so that it is

perpendicular to the fuel line.
90
75
Emptying the fuel line
The fuel line is emptied via a hose pipe. The

end of the hose line (1) is to the right beside
40
the automatic gearbox.

The hose is accessible through an opening in
the base plate of the carrier frame.
• Slightly cramp the steering.
• Guide the hose through an opening in the
base plate.
• Place a container suitable for collecting fuel
(e.g. a drip pan) underneath the end of the
hose (capacity approx. 5 l).
14.01.2002
s
7.2 Diesel engine
For the purpose of emptying the fuel line a

3-way-tap (1) is provided at the rear on the au-
tomatic gearbox.
• Turn the handle on the 3-way-tap so that it is

diagonal to the pipe.
The fuel now flows into the collecting vessel.
• Leave the vessel underneath the end of the

hose. More fuel can escape when changing
the fuel filter cartridge.
Changing the fuel

filter cartridge diesel engine (
57
The fuel filter insert is underneath the boom support at the front left on the
à Diesel engine operating instructions).
In order to easily access the fuel filter insert tilt the driver’s cab,
driver’s cab forward, p. 7 - 1.
à
Tilt
90
• Unscrew the screw cap (1) with the filter in-
sert (3) and pull it a bit out of the filter hous-
ing.
Let the rest of the fuel drain off.
• Remove the screw cap with the filter car-
75
tridge and remove the cartridge by applying

pressure on the sides of the lower edge.
• Replace the rubber sealing ring (2) (lubricate
lightly).
40
• Clip a new filter cartridge onto the screw

cap.
• Replace the cap with cartridge and tighten it. Tightening torque 25 Nm.
O
Store used fuel filter cartidges in suitable containers and dispose of them
properly.
14.01.2002

7.2 Diesel engine
After changing the After changing the fuel filter insert, you must re-establish the state of
filter insert operation.
• Turn the handle on the 3-way tap (1) so that

it is lengthways to the pipe.
• Remove the collecting vessel underneath
the end of the hose.
If you have used a clean collecting vessel, you
can refill the diesel tank with fuel using a sieve.
Otherwise you must collect the fuel for dis-
posal.
57 • Push the hose end through the opening in

the base plate of the carrier frame.
• Attach the hose end to the right frame wall.
90
75
40
s
14.01.2002

7.2 Diesel engine
• Open the shut off tap in the fuel line by

turning the handle (1) until it is parallel to
the fuel line.
• Bleed the fuel pipe using the hand pump on the fuel prefilter; à Bleeding
the fuel system, p. 7 - 12.
57
• Start the engine and check that the fuel filter is leak-tight.
90
75
40
14.01.2002

7.3 Gearbox
7.3 Gearbox
The gearbox is located inside the carrier above the first axle line.
• Make a visual inspection for leaks.

• Listen carefully for any abnormal noises when the transmission is
engaged.
57
90
75
40
14.01.2002

7.3 Gearbox
7.3.2 Gearbox – oil level check M1
The gearbox is located inside the carrier above the first axle line.
S
Damage may occur to the gearbox.
The correct oil level must be maintained to ensure smooth operation of the
gearbox:
– too low oil level leads to malfunctions,
– too high oil level leads to drive-through losses and overheating.
Prerequisites:
To check the oil level:
– the truck crane must be aligned horizontally,
– the parking brake must be locked,
– the gearbox must be in neutral position N,
– the diesel engine must be turned off,
– the truck crane must be secured to prevent unauthorized use.
57
G
Risk of scalding.
If the oil is at operating temperature, do not let it drain unchecked.
90
The oil level is checked through an inspection
hole at the right of the gearbox.
75
• Remove the cover plate (1) from the gear

box.
• Remove the screw (2) from the inspection-
hole.
40
If the oil level is too low:
• Top up oil through the inspection hole using

only oil as specified in the Maintenance plan,
p. 5 - 14.
• Close the inspection hole again with the
screw (2).
• Secure the cover plate (1) on the gearbox.
14.01.2002

7.3 Gearbox
7.3.3 Gear box – oil change J5
The oil is drained via the oil drain opening in the gear box and filled via the
inspection hole.
G
Use only oil as specified in the Maintenance plan, p. 5 - 17.
Risk of scalding.
If the oil is at operating temperature, do not let it drain unchecked.
O
When changing the oil filter, always use a drip pan which is suitable for oil
and which has a sufficient capacity. When changing the filter and filling oil,
make sure that no oil spills and soaks into the ground.
H
Before starting this work, lift the truck crane with the outrigger or park it
over an inspection pit.
57 Draining gear lubricant oil

90
• Insert a funnel into the drain hole in the base
plate under the gear box.
• Place a container (capacity approx. 15 l) un-
derneath the drain hole to collect the oil.
75

hole.
• Unscrew the oil drain screw (2) and let the
oil flow into the collection container.
40
O
Collect old oil in approved containers and have used oil and oil filters
disposed of properly.
14.01.2002
s
7.3 Gearbox
Topping up gear lubricant oil
• Clean the magnetic plug of the oil drain plug

(2), replace the sealing ring and close the
à
outlet ( Special tightening torques,
p. 10 - 2).
• Top up the oil through the inspection hole
on the gearbox ( à Wartungsplan, S. 5 - 16).
• Check the oil level at the inspection hole.
The oil must be filled to the lower edge of
the inspection hole.
• Replace the sealing ring and close the in-
spection hole with the screw (1) ( à Special
tightening torques, p. 10 - 2).
After topping up the oil, you must carry out the following checks for leak
tightness:
57
• Start the diesel engine and let it idle in neutral position N.
• Check the tightness of oil drain screws.
90
75
40
14.01.2002

7.4 Transfer case
7.4 Transfer case

The transfer case is between the second and third axle lines.

• Listen out for any unusual noises from the transfer case.
7.4.2
57
Distributor gearbox – oil level check
The oil level must be checked on the front of the transfer case with the
engine turned off and the truck crane in horizontal position.
M1
90
hole.
• Check the oil level. The level must be just
underneath the inspection hole.
75

40
• Top up oil via the inspection hole (1). Use

p. 5 - 8.
• Close the inspection hole with the screw (1).
14.01.2002

7.4 Transfer case
7.4.3 Distributor gearbox – oil change M6
H
Raise the truck crane with the outriggers or park it over an inspection pit.
O
Always use oil collection containers, funnels or filling pumps which are re-
sistant to oil.
Wipe up spilled oil immediately.
The oil must be changed when the engine is turned off and the truck crane
is in horizontal position. The oil drain screw is at the bottom of the transfer
case.
• Place an oil collection container (capacity ap-
57
prox. 15 l) underneath the oil drain screw (3).
hole.
90
• Replace the sealing ring and reinsert the oil
drain screw.
75

p. 5 - 12.
• Check the oil level (à Distributor gearbox –
oil level check, p. 7 - 21).
40

spection hole with the screw (1).
O
Collect old oil in approved containers and have it disposed of properly.
14.01.2002

7.5 Axle lines
7.5 Axle lines

• Listen out for any unusual noises from the axle centre drives and final
drives.
7.5.2 Axle centre drives – oil level check M1
axle lines. 57
The position and number of inspection holes sometimes differs with the
The first and the fourth axle line

90
On the first axle line, the inspection hole is at
the front. The inspection hole is at the back of
the fourth axle line.
75

hole.
• Check the oil level, the oil level must be just
underneath the inspection hole.
40

p. 5 - 8.
spection hole again with the screw (1).
s
14.01.2002

7.5 Axle lines
H
The axle centre drive on the second axle line is available only as additional
equipment with a 8 x 8 x 8 drive.
The second axle line
The inspection hole is at the back of the

second axle line.
• Check the oil level in the same way as is de-

scribed for the first and the fourth axle lines.
57
90
The third axle line
The axle centre drive of the third axle line has

two inspection holes:
in front –the inspection hole (2)
75
at rear – the inspection hole (1).
• Check the oil level in the same way as is de-

scribed for the first and the fourth axle lines.
40
14.01.2002

7.5 Axle lines
7.5.3 Axle centre drives – oil change M 12
H
Raise the truck crane with the outriggers or park it over an inspection pit.
O
Always use oil collection containers, funnels or filling pumps which are
resistant to oil.
• Turn off the diesel engine to change the oil.

The first and the fourth axle line
57 • Place an oil collection container (capacity

approx. 20 l) under the oil drainscrew (2).
hole.
90
• Replace the sealing ring and reinsert the oil
drain screw.
75
• Top up oil via the inspection hole (1). Use

p. 5 - 12.
40
• Check the oil level (à Axle centre drives – oil level check, p. 7 - 23).
• Replace the sealing ring and close the inspection hole again with the
screw (1).
O
Collect the old oil in permitted containers and only have it disposed of by
approved disposal companies.
s
14.01.2002

7.5 Axle lines
H
The axle centre drive on the second axle line is available only as additional
The second axle line
• Place an oil collection container (capacity ap-

prox. 20 l) underneath the oil drain screw (2).
• Change the oil in the same way as is de-
scribed for the axle drives on the first and
the fourth fifth axle lines.
57
90
The third axle line
• The axle centre drive of the third axle line

has two oil drain screws:
below – the oil change screw (4)
75
in front – the oil change screw (3).

• Place an oil collection container (capacity
approx. 20 l) under the oil drainscrews (3)
and (4).
40
• Change the oil on both oil drain screws in

the same way as is described for the axle
drives on the first and fourth axle lines.
14.01.2002

7.5 Axle lines
7.5.4 Final drives – oil level check M1
Every final drive has an inspection hole.
• Raise the truck crane with the outrigger and release the parking brake.
• Turn the wheel so that the oil check mark (2)

is horizontal and is on the right next to the
centre of the axle.
hole.
• Check the oil level, the oil level must be at
the check mark (2).
57 only oil as specified in the Maintenance plan,

p. 5 - 8.
90
Also check the oil level on all other final drives.
75
40
14.01.2002

7.5 Axle lines
7.5.5 Final drives – oil change M 12
• Raise the truck crane with the outrigger and release the parking brake.
O
Always use oil collection containers, funnels or filling pumps which are
resistant to oil.
• Place an oil collection container (capacity

approx. 4 l) under the wheel.
• Remove the screw (1) from the inspection
hole.
• Turn the wheel until the opening is pointing
downwards and drain the oil into the collect-
ing vessel.
57
90
• Turn the wheel back so that the oil check
mark (2) is horizontal and is on the right next
75
to the centre of the axle.

• Top up oil through the inspection hole (1) and
use only oil which is specified in the Mainte-
nance plan, p. 5 - 14.
40
• Check the oil level, the oil level must be at

the check mark (2).
• Check the oil level (à Final drives – oil level
check, p. 7 - 27).
O
Collect the old oil in permitted containers and only have it disposed of by
approved disposal companies.
14.01.2002

7.5 Axle lines
7.5.6 Lubricating the cardan shafts on the axle lines M1
The cardan shafts are between the axle centre drives and the final drives.
H
If the cardan shaft was not equipped at the factory with a lubricating nipple,
then it is a maintenance-free version. After carrying out repairs on a cardan
shaft check if maintenance-free cardan shafts were installed.
The activities described in the following section would then no longer apply.
The cardan shafts must be lubricated with a grease gun. Use only oil as
specified in the Maintenance plan, p. 5 - 8.
S
Risk of damaging the sealing lips.
Do not apply hard lubricants to avoid damage to the sealing lips.
Number and posi-

tion of lubrication
57
There are two cardan shafts on every driven axle line.
The following table shows the position and number of lubricating nipples
90
points on both cardan shafts for all driven axle lines.
Cardan shafts Lubricating nipple

inner 1) outer 2)
75
1st axle line 2 4

2nd axle line (only with 8 x 8 x 8 drive) 2 2
3rd axle line 2 2
4th axle line 2 2
40
1) Joint on the axle centre drives

2)
Joint on the final drives
H
The cardan shafts on the second axle line are available only as additional
s
14.01.2002

7.5 Axle lines
Cardan shafts first On the first axle line there are outer double joints and inside on the axle
axle line lubricate centre drive one single joint.
The signle joint on the axle centre drive has a

lubricating nipple (3). There are two lubricat-
ing nipples (1) and (2) on every double joint.
To lubricate the outer lubricating nipple (1) on
the joints, the wheels must be turned to their
fullest extent.
• Remove the old grease and dirt from the lu-

bricating nipples.
• Press lubricating grease into the lubricating
nipples until new grease comes out of the
respective bearing points.
• Remove the surplus new grease.
• Lubricate the second cardan joint in the
Cardan shafts sec-

ond lubricate up to
57
same way.
There are single joints on the second (additional equipment), fourth and
fifth axle lines inside and outside.
90
the fourth axle line
There is a lubricating nipple (1) and (2) on

every single joint.
75
• Remove the old grease and dirt from the

lubricating nipple.
nipple until new grease comes out of the
40
corresponding bearing point.

• Remove the surplus new grease. 14.01.2002

7.5 Axle lines
7.5.7 Longitudinal cardan shafts between the gear units

lubricate M6
The longitudinal cardan shafts are between the automatic gearbox and the
transfer case, between the transfer case and the axle centre drives and be-
tween the axle centre drives.
H
If the (longitudinal) cardan shafts were not equipped at the factory with a
lubricating nipple, then it is a maintenance-free version. After carrying out
repairs on a cardan shaft check if maintenance-free cardan shafts were in-
stalled.
The activities described in the following section would then no longer apply.
The (longitudinal) cardan shafts must be lubricated with a grease gun. Use
only oil as specified in the Maintenance plan, p. 5 - 12.
S 57
Risk of damaging the sealing lips.
Do not apply hard lubricants to avoid damage to the sealing lips.
90
Number and posi- The following table shows the location and number of the lubricating nip-
75
tion of lubrication ples on the individual cardan shafts:

points
(Longitudinal) cardan shaft between ... Lubricating nipple
front rear
40
Gearbox and transfer case 1 1

Transfer case and the first axle line 1 1
Transfer case and the second axle line1) 1 1
Transfer case and the third axle line 1 1
First axle line and the second axle line1) 1 1
Third axle line and the fourth axle line 1 1
1) Only for 8 x 8 x 8 drive (additional equipment).
s
14.01.2002

7.5 Axle lines
Lubricating longi- Lubrication with all longitudinal cardan shafts is done in the same way.
tudinal cardan
shafts
There are two lubricating nipples (1) and (2) on

every longitudinal cardan shaft.
• Remove the old grease and dirt from the lu-

bricating nipples.
nipples until new grease comes out of the
respective bearing points.
• Remove any spilling grease.
57
90
75
40
14.01.2002

7.6 Wheels
7.6 Wheels
7.6.1 Checking the tyres for damage D
• Check the tyres for:

– chunking
– dents
– areas with uneven wear.
• Check whether the tyre has worn down to
the wear mark (1).
If the tyre no longer has any tread at the wear

marks:
57 • Change the tyres.
S
90
Always replace all the tyres on an axle.
75
7.6.2 Check the tyre pressure W

40
S
When replacing tyres, please note that tyres from other manufacturers
must have the same load bearing capacity and thus the same tyre pressure
as the initial equipment.
• Check that the new tyre pressures conform to the values in the table.
Tyres Air pressure (bar)

14.00 R 25 10,0
14.01.2002
16.00 R 25 (additional equipment) 9,0

20.50 R 25 (additional equipment) 7,0

7.6 Wheels
7.6.3 Check tightness of wheel nuts M1
• With a torque wrench, check that the wheel

nuts are tight crosswise in the order shown
in the illustration.
Torque for wheel nuts: 650 Nm
Check the wheel nuts for tightness after a

wheel change after a distance of 50 km and
again after a distance of 150 km.
57
90
7.6.4 Checking the wheel-bearing clearance M3
• Raise the truck crane with the outriggers. Release the parking brake.
• Press against the bottom of the wheel with one foot and, using both
75
hands, try to move the wheel in the bearing at the same time.
If the check shows there is too much play:

40
• Have the wheel-bearing clearance adjusted or wheel bearings replaced by

GROVE Customer Support service at the particular location or by your
own repair crew.
14.01.2002

7.7 Vehicle brakes
7.7 Vehicle brakes
7.7.1 Checking brake-lining thickness M3
There is an opening on the inside of each wheel (sealed with a rubber plug)
through which the brake-lining thickness can be checked.
• Remove the rubber plug (1), (2) and shine a

torch into the opening.
If the brake-lining thickness has reached the
wearmarks (stepped edges or grooves), or
if the brake-lining thickness is only 3 mm:
• Have the brake linings replaced by GROVE

Customer Support service or an authorised
57 service centre.
90
S
75
Always replace all brake-linings on an axle line.

40
14.01.2002

7.7 Vehicle brakes
57
90
Blank page
75
40
14.01.2002

7.8 Suspension
7.8 Suspension
7.8.1 Telescopic leg – oil level check M1
The suspension cylinders of the individual wheel suspension units are

bolted to the vehicle frame (carrier).
• Use the level adjustment system to lower the truck crane completely and
then raise it to on-the-road level again ( à
Operating manual, Chapter Driv-
ing with the truck crane, Section Vehicle height control).
H
The initial complete lowering is necessary to prevent incorrect oil level.
S
If the oil level is above the upper marking on the inspection glass the
57
suspension cylinder is defective and must be replaced.
Inform the GROVE Customer Support.
90
• Check the oil level at the relevant inspection
glass (1).
The oil level must be between the markings.

75
• Screw the high pressure squirt gun

(supplied tool) to the filler connection (2).
• Inject oil up to the level of the lower
40
marking.
Use only oil as specified in the Maintenance
plan, p. 5 - 8.
S
It is difficult to inject the oil. Even so, do not fill oil through the inspection
glass connections. It would not reach all lubricating points.
14.01.2002

7.8 Suspension
7.8.2 Tightness of retaining bolts on the suspension

cylinders to be checked M1
• Check the tightening torques of the retain-

ing bolts:
– Vehicle frame/guide case upper (1)
– Vehicle frame/guide case below (2)
– Support element/steering split shell (3)
– Support element/operating head (4)
The tightening torques can be found in Special
tightening torques, p. 10 - 2.
57
90
75
40
14.01.2002

7.9 Steering
7.9 Steering
7.9.1 Checking for leaks W
• Check the hydraulic steering system (steering cylinders, pipes and hoses,
and all connections) for leaks.
G
Risk of accidents.
Never tighten leaking connections when the system is under pressure.
Change pipes and hoses only when the system is depressurized.
• Top up hydraulic oil according to (à Hydraulic unit – oil level check,

p. 7 - 43).
57
After changing pipes and hoses:
• Bleed the carrier hydraulic system (à Changing the hydraulic oil, p. 7 - 52).
90
• Inform your GROVE Customer Support service or your repair crew.

75
40
14.01.2002

7.9 Steering
57
90
Blank page
75
40
14.01.2002

7.10 Carrier compressed air system
7.10.1 Draining the compressed air system W
Moisture must be drained from the compressed air system through the
drain valves of the four compressed air reservoirs and the conditioning unit.
A functional check of the compressed air drier is carried out simultaneously.
The compressed air reservoirs are located beneath the rear and front parts
of the carrier. The conditioning unit is located on the right under the driver’s
cab and is accessible from below.
• Operate the drain valves (2), the drain valve

of the conditioning unit (1) is shown here as
an example.
If the respective drain valve does not close
57 after being actuated several times:
• Change the drain valve.

90
If a lot of moisture escapes from the air reser-
voirs:
• Have the compressed air drier checked or

75
replaced by your repair crew.
7.10.2 Compressed air system – check for leakage W

40
• Start up the compressed air system.

• Check all points in the compressed air system (connections, pipes, hoses
and valves) where air could possibly escape.
G
Risk of accidents.
Never tighten connections when the system is under pressure. Only change
seals, pipes and hoses when the system is depressurized.
s
14.01.2002

• Inform your GROVE Customer Support service or your repair crew.
7.10.3 Replacing the granulate cartridge of

the compressed air dryer M 12
The granulate cartridge is located on the right under the driver’s cab and is
accessible from below.
G
Risk of injury.
If the conditioning unit is not completely empty, the air drier will be under
pressure.
57
• Release all the air from the conditioning
unit (3) via the drain valve (4).
• Unscrew the granulate cartridge (attached
to the cover hood) (1) using a strap wrench.
90
• Change the granulate cartridge.
Grease the sealing ring lightly before screw-
ing into place.
75
40
14.01.2002

7.11 Carrier hydraulic system
7.11.1 Hydraulic unit – oil level check D
The hydraulic oil tank is on the left-hand side of the carrier behind the
driver’s cab.
The level can be checked through the inspection glass.
To check the oil level:

– the truck crane must be in the position On-road driving ( à
Operating
Instructions, Chapter Driving with the truck crane, Section Vehicle height
control);
– outrigger beams and outrigger cylinders must be retracted ( à
Operating
Instructions, Chapter Rigging work, Section Outriggers).
57 • Check the level of the hydraulic oil tank

through the inspection glass (1).
The hydraulic oil must be visible in the
centre of the inspection glass.
If the level is too low:
90
• Top up the hydraulic oil through the filler
opening (2).
plan, p. 5 - 5.
75
40
S
Be careful not to damage the hydraulic system.
When handling hydraulic oil cleanliness is imperative.
New oil must also be filtered.
14.01.2002

7.11.2 Checking the hydraulic hoses W
Hydraulic hoses are subject to ageing as well as internal and external

stresses.
• Check the hydraulic hoses for

– external damages (tears, abrasion)
effect of heat, chemical effects),
– leaks and moist areas,
– blistering or unevenness of hose casing,
– signs of ageing (porous upper surface
rust on hose fittings).
Hydraulic hoses should not be used for longer
than 72 months from date of manufacture. The
date of manufacture and the permitted operat-
ing pressure are marked on the hose fitting:
57
– The first 4 numbers (1) indicate the month
and year of manufacturing.
– The letters P and N and the last 3 numbers (2)
indicate the permitted operating pressure.
90
• Damaged or old hydraulic hoses must be replaced immediately. Always
ensure that the corresponding parts of the hydraulic system are depres-
surized in advance.
75
40
14.01.2002

• With the diesel engine running, carry out a visual inspection for leaks and
escaping hydraulic oil at the suspension cylinders, outriggers, hydraulic
lines (hoses and pipes) and connections.
Hydraulic oil through.
• If leaks are detected, check the hydraulic oil level and top up if necessary
according to ( à Hydraulic unit – oil level check, p. 7 - 43).
G
Risk of accidents.
Never tighten any leaking connections when the system is under pressure.
Only change pipes and hoses when the system is depressurized.
After parts have been changed:
• Bleed the carrier hydraulic system (à Changing the hydraulic oil, p. 7 - 52).
57
O
90
Immediately repair or have repaired leakages in the hydraulic system to en-
sure that no hydraulic oil escapes, seeps into the ground or reaches waters
when the crane is being used.
75
40
14.01.2002

7.11.4 Changing the hydraulic oil filters and cleaning

the magnetic rod M3
There are two hydraulic oil filters (return filters) in the hydraulic tank and a
hydraulic oil filter in the control circuit in the superstructure. The hydraulic
oil filters must be changed:
g – when the warning lamp for the hydraulic oil return filter in the front
instrument panel of the driver's cab lights up and
– after every hydraulic oil change.
Turn off the diesel engine and depressurize the hydraulic system.
• Remove the nuts on the filter cover (1) and

remove the hydraulic oil filters from the
hydraulic oil tank.
57
90
75
• Unscrew all screws (1) and remove the top

40
parts of the filter (2).

• Unscrew the magnetic rods (4) and clean
them.
14.01.2002

S
Large amounts of metal chips adhering to the magnetic rods is a sign of
damage to the hydraulic system. Have the hydraulic system examined by
Krupp service or by your repair crew.
• Change the filter elements (5).

• Replace the O-rings (3) in the bottom and
top parts of the filter.
• Reassemble the hydraulic oil filters and
replace them in the hydraulic oil tank.
57
90
O
Store used hydraulic oil filters in suitable containers and have them dis-
posed of properly by qualified personnel.
75
s
40
14.01.2002

Hydraulic oil filter

for control circuit
The hydraulic oil filter control circuit (1) is
located on the right side of the superstructure,
behind the covering.
57
• Switch off the diesel engine and secure it against being started by
unauthorized persons (sign in the driver’s cab).
• Remove the ring (1).

90
• Take off the filter can (2).
• Remove the filter from the filter can.
• Insert the new filter into the filter can.
75
• Fill the filter can up to the edge with

hydraulic oil.
• Screw the filter can on again.
• Start the diesel engine and let it run in
40
neutral gear for 3 minutes in order to bleed

the system. 14.01.2002

7.11.5 Replacing the venting filter M 12
The return filter is on the hydraulic oil tank

filler opening cover.
• Change the venting filter (1).
57
90
75
40
14.01.2002

7.11.6 Taking hydraulic oil samples M 12
To determine the usability of the hydraulic oil, samples must be taken from
the hydraulic oil tank and from the hydraulic system ( à
Changing the hy-
draulic oil, p. 7 - 52).
The drain valves can only be opened and closed using the 1/2" connection
plate. Connecting plates are in the toiol box; à
Handling the drain valves,
p. 7 - 51.
• Take a sample from each of the drain valves

(1), (2) and (3) on the hydraulic oil tank.
57
90
An oil sample from the hydraulic system is
75
taken via a gauge port (1), e. g. on a valve

block of the suspension.
40
14.01.2002

Handling the drain Drain valves can be opened and closed using 1/2" connection plates. The
valves connection plates are in the tool box.
G
Risk posed by escaping hydraulic oil.
When the connection plate is screwed onto the drain valve, the valve opens
and the hydraulic oil immediately flows out of the connection plate. Place
the connection plate hose in an oil collection container before screwing on
the connection plate.
• Place an oil drain hose onto the fitting and lead it into an oil collection
container.
• Unscrew the cap from the drain valve.
• Screw the fitting onto the drain valve. The drain valve opens.
• Let the necessary amount of oil run into the collection container.
• Unscrew the fitting from the drain valve. The drain valve shuts.
• Screw the protective caps back onto the drain valve.
Taking oil samples

57
• Take one litre of hydraulic oil from each of the three drain valves and from
90
one pressure gauge connection.
1 litre hydraulic oil Before taking the oil sample, allow 1 – 2 litres to run
into a separate container.
• Lable each sample container with
– the date of sampling,
75
– the number of operating hours since the last oil change and
– the sampling location (hydraulic oil tank or metering nozzle).
• Send the samples to a specialist laboratory for analysis.
Permissible limit values:
40
– Viscosity ISO-VG 32 according to DIN 51524 P.2

– Contamination according to NAS 1683 Class 9 or ISO 4406 Code 18/15.
If these limits have been reached:
• Carry out an oil change (à Changing the hydraulic oil, p. 7 - 52).

14.01.2002

7.11.7 Changing the hydraulic oil M 12
The hydraulic oil only has to be changed if the laboratory analysis shows
that the permissible limits have been exceeded ( à
Taking hydraulic oil sam-
ples, p. 7 - 50) or the laboratory has recommended a date for an oil change.
Prerequisites: The truck crane must be in on-the-road mode with the engine
off.
S
Damage may occur to the hydraulic pumps.
Ensure that the diesel engine cannot be started by an unauthorized party.
If the engine is started while the stop cocks in the suction lines are closed,
the hydraulic pumps will be damaged.
• Close the stop cocks in the suction lines to

the hydraulic oil tank.
The five taps are located on the left side of the
57
vehicle on the hydraulic oil tank.
Four taps are located to the right and one tank
in front on the hydraulic tank.
The taps are closed when the grips are at right
angles (2) to the suction lines.
90
• Remove the hydraulic oil filters
à
( Changing the hydraulic oil filters and clean-
ing the magnetic rod, p. 7 - 46).
75
• Have a container ready to collect the oil

(with a capacity of over 660 l).
O
40
To drain the hydraulic oil, always use the supplied

1/2" connection plate with an oil drain hose and an oil collecting vessel with
sufficient capacity.
14.01.2002

• Drain the oil. To do this, screw the oil drain

hose with the connection plate onto each
drain cock (1), (2) and (3) in turn, drain the oil
from the three tank chambers ( àTaking hy-
draulic oil samples, p. 7 - 50).
• Change the filter elements in both filters and
fit new hydraulic oil filters (à Changing the
hydraulic oil filters and cleaning the magnetic
rod, p. 7 - 46).
S
57
When handling hydraulic oil cleanliness is imperative.
New oil must also be filtered before it is filled into the tank.
O
Collect old oil in approved containers and have it
90
Used oil and oil filters must be properly disposed of.
75
• Fill in the new hydraulic oil through the filler

opening (2) until the oil level is in the middle
of the inspection glass (1).
• Open the four stop cocks of the suction
lines.
40
• Start the engine and put the hydraulic sys-

tem into operation.
• Carry out all functions of the carrier hydrau-
lic system several times to remove any air
from the system.
• Check the oil level in the hydraulic oil tank.
Top up oil if necessary.
• Carry out a road test of the truck crane, turn-
ing the steering wheel several times to its
fullest extent.
s
14.01.2002

If the steering is "loose" at the end of the test run you must ventilate the
steering cylinders.
G
Risk of crushing.
When working between the wheels ensure that the steering wheel cannot
be turned by an unauthorized party. The wheels turn when the steering
wheel is operated.
Risk of accidents.
Never undo the hose connections completely. The hydraulic system is un-
der pressure, even when the steering wheel is not turned.
Bleed the steering cylinders individually, one

after the other:
• Start the diesel engine.

• Bleed each steering cylinder (2) by loosen-
ing the cap nuts (1) in turn until the oil com-
57
ing out no longer contains any air bubbles.
If the steering system is still not operating

properly:
90
• Inform your local GROVE Customer Service
or an authorised service centre.
75
40
14.01.2002

7.12 Centrallubrication system

The grease container for the central lubrica-
tion system is on the right side of the vehicle
between the second and third axle lines, be-
hind the access ladder.
plan, p. 5 - 6.
7.12.1 Central lubrication system 57

90
There are two different versions of the central lubrication system:
– Version 1 and
– Version 2.
75
Version 1
Version 1 is (1) equipped with a display and control unit; à Version 1 –
Checking the level of the grease container and topping up, p. 7 - 56.
40
Version 2
With version 2, the operating instruments are located under a closure flap (1);
à Version 2 – Checking the level of the grease container and topping up, p. 7 - 59.
14.01.2002

7.12.2 Version 1 – Checking the level of the grease container

and topping up W
Checking the level

• Check the oil level on the grease container (1).
The level must be near the MAX mark.
If the level in the grease container is too low;
à Filling the grease container, p. 7 - 57.
If the level drops below the MIN mark, auto-
matic lubrication is interrupted.
57
90
Actuate interme- An intermediate lubrication must be actuated,
diate lubrication
– after a high pressure cleaning;
– for inspecting the lubrication on individual lubrication points.
75
• Turn the diesel engine ignition on.

• Unscrew the cover (1) in front of the display
and control unit.
40
• Press once the push-button DK (2).

A lubrication cycle is actuated and it lasts for
approximately 3 minutes. Check if the lubricat-
ing grease comes out on all lubricating points.
• Replace the covering (1).

• Switch off the diesel engine ignition.
14.01.2002

Filling the grease

container
• Unscrew the cap (5) from the filling pump (1).
• Remove both caps (2) and (4) from the
grease cartridge (3).
H 57
Ensure that the packing (8) is in proper position in the filling pump. The
packing must be folded toward the plunger rod (7).
• Push the grease cartridge (3) into the filling pump.

90
• Check that the seal (6) is in proper position in the cap (5).
• Screw the cap onto the filling pump.
S
Do not remove the sealing caps from the filler opening and filling pump un-
til immediately before refilling the grease. This prevents dirt particles from
75
getting into the grease.
• Unscrew the sealing cap (1) on the grease

40
container.
14.01.2002
s
H
The central lubrication system must be running while the grease container
is being filled.
• Unscrew the sealing cap (1) from the filling

pump.
• Screw the filling pump onto the filler open-
ing of the grease container.
• Actuate the intermediate lubrication;
à Actuate intermediate lubrication, p. 7 - 56.
• Push the grease into the grease container
through the filler opening using the plunger
rod.
• Screw the appropriate sealing caps onto the
filler opening of the grease container and
the outlet of the filling pump.
57
90
Bleeding the cen- The central lubrication system must be bled when the grease container is
tral lubrication empty or air is trapped in the grease.
system
• Fill the grease container (1); à Version 1 –

75
Checking the level of the grease container and top-

ping up, p. 7 - 56.
• Loosen the outlet screw fitting (3) of the
pump element.
40
• Press once the push button DK (2) in order to

actuate the intermediate lubrication;
à Actuate intermediate lubrication, p. 7 - 56.
• Let the pump run until the grease running
out of the outlet screw fitting (3) no longer
contains any air bubbles.
• Re-tighten the drain screw fitting (3).
• Remove the air from the main and auxiliary cables, auxiliary distributor,
lubricant cables and lubrication points in the same way.
14.01.2002

7.12.3 Version 2 – Checking the level of the grease container

and topping up W
Checking the level
• Check the oil level on the grease container (1).

The level must be near the MAX. mark.
If the level is too low, fill the grease container
through the filler connection (2) using a filling
pump.
Filling the grease

57
90
container
H
You must connect a connecting piece to the grease container before refilling
the container with the filling pump for the first time. This procedure is
explained in the following. The connecting piece and a sealing cap are en-
75
closed with the filling pump.
• Unscrew the stopper (1) from the grease

container.
40
• Screw the connecting piece (2) into the

opening.
• Screw the sealing cap (3) onto the connect-
ing piece.
14.01.2002
s
• Unscrew the cap (5) from the filling pump (1).

• Remove both caps (2) and (4) from the
grease cartridge (3).
H
Ensure that the packing (8) is in proper position in the filling pump. The
57
packing must be folded toward the plunger rod (7).
• Push the grease cartridge (3) into the filling pump.

• Check that the seal (6) is in proper position in the cap (5).
90
• Screw the cap onto the filling pump.
H
The central lubrication system must be running while the grease container
is being filled.
75

• Unscrew the bottom sealing cap (2) on the
grease container.
40
• Press the switch (3) behind the cap. This

triggers a complete lubrication procedure.
• Remove the sealing cap on filler opening (1)
of the grease container.
14.01.2002

S
Do not remove the sealing caps from the filler opening and filling pump un-
til immediately before refilling the grease. This prevents dirt particles from
getting into the grease.
• Unscrew the sealing cap (1) from the filling

pump.
• Screw the filling pump onto the filler open-
ing of the grease container.
• Push the grease into the grease container
through the filler opening using the plunger
rod.
• Screw the appropriate sealing caps onto the
filler opening of the grease container and
the outlet of the filling pump.
• Seal the lower opening for the button with
57 the sealing cap.

90
Bleeding the cen- The central lubrication system must be bled when the grease container is
tral lubrication empty or air is trapped in the grease.
system
• Fill the grease container (1) (à Version 2 –

75
Checking the level of the grease container and top-

ping up, p. 7 - 59).
• Loosen the outlet screw fitting (2) of the
pump element.
40

• Press the switch (4), to actuate the additional
lubrication.
• Let the pump run until the grease running
out of the outlet screw fitting (2) no longer
contains any air bubbles.
• Retighten the drain screw fitting (2) and
screw the sealing caps back onto the filler
opening of the grease container and the
switch opening (3).
14.01.2002
• Remove any excess grease.

57
90
Blank page
75
40
14.01.2002

7.13 Carrier electrical system
7.13.1 Checking the acid level of batteries M1
• Keep the batteries clean and dry.

• Loosen any dirty terminals and clean them.
Grease the terminals with an acid-free, acid-resistant grease.
G
Hydrogen escaping from the batteries is explosive!
Do not place tools on the battery and keep unshielded light away from the
battery.
H
It is particularly important to check the acid level during the warmer months.
57
• Check the acid level in the individual cells:
–In case of batteries in which the acid level is visible, the acid must be
approximately 15 mm above the plates.
–In case of batteries with an overflow reservior, distilled water must be
in the overflow reservior.
90
If the acid does not come up to the required level or there is no distilled wa-
ter in the overflow reservoir:
75
• Only fill in distilled water:

–up to the required height above the plates or
–until it no more spills out of the overflow reservior.
40
14.01.2002

7.13.2 Checking the acid concentration of batteries M3
• Measure the acid concentration of each cell with an acid tester.
H
It is particulary important to check the acid concentration with the onset of
the colder months.
The following table gives a guide to battery charge levels.
Acid concentration Specific weight Charge condition

(° Bé) (g/cm3)
32 1,28 good
24 1,20 half, recharge
16 1,12 empty, charge immediately
57
90
75
40
14.01.2002

7.14 Carrier air conditioning system (additional equipment)

The GMK 4075 is equipped with only one refrigerant circuit for the air-
conditioning system on the carrier and superstructure.
7.14.1 Checking the moisture and level of the refrigerant M1
The refrigerant is checked through an inspec-

tion glass on the refrigerant drier while the air
conditioning system is running (1).
57
90
The battery box is located on the right-hand
side of the vehicle over the first axle line.
75
• Start the diesel engine.

• Switch on the air-conditioning system and
let it run for about 10 minutes. (Switching on
à
40
the air-conditioning system Operating

manual, Section Air conditioning system in
chapter Driving with the truck crane).
• Check the refrigerant filling and the mois-
ture content of the refrigerant through the
inspection glass (1):
– The flowing refrigerant must be visible
and must not contain any large bubbles or
foam.
– The PVC float ball (3) must be at the top.
– A green dot (2) must be visible on the
moisture indicator.
s
14.01.2002

If the moisture indicator shows a yellow dot or if bubbles or foam are visi-
ble, the air conditioning system is defective.
If the air conditioning system is defective:
• Switch the air conditioning system off and do not use it again to avoid
further damage.
Have the air conditioning system repaired as soon as possible by GROVE
Customer Service.
After checking:
• Switch off the air conditioning system and turn off the diesel engine.
7.14.2 Cleaning capacitor disks M1
S
Risk of damage to the capacitor.
57
Do not use a high pressure or steam jet cleaner. The hard water jet can
damage the disks or the fan wheel. Use only compressed air for cleaning.
90
The capacitor is mounted between the
radiator and the right tread grille on the
carrier.
75
• Switch off the air conditioning system.

• Clean the disks of the capacitor (1) with com-
pressed air.
40
14.01.2002

7.14.3 Checking hoses M6
• Check all refrigerant hoses for damage and worn areas.

Have damaged hoses replaced only by GROVE Customer Service.
7.14.4 Checking the refrigerant compressor M6
The refrigerant collector may only be checked

by GROVE Customer Support!
For this, the refrigerant collector (1) must be

checked externally by a qualified person
according to the pressure container order
(test group II) for mechanical damage and
corrosion. If the refrigerant collector is not in
57 proper working condition, it must be replaced

by GROVE Customer Support.
90
75
40
14.01.2002

7.14.5 Checking the refrigerant compressor control M6
H
This check may only be carried out by GROVE Customer Support!
• The refrigerant compressor (1) is at the front

on the right side of the vehicle engine under-
neath the fuel filter.
• Have the refrigerant compressor checked
for tightness. Above all the sealing of the
drive shaft should be checked.
57
90
7.14.6 Checking the entire air conditioning system M 12
75
This check may only be undertaken by GROVE Customer Support!
• Have the whole air conditioning system checked for tightness and proper
functioning.
40
14.01.2002

7.15 Trailer coupling (additional equipment)
7.15.1 Lubricating the trailer coupling M1
G
Risk of injury if the automatic closing device is actuated.
Do not put your hand into the coupling jaw when the trailer coupling is
open.
This can actuate the automatic closing device, make the cotter pin move
down with great force and seriously injure your hand.
H
To avoid over-lubrication, the trailer coupling should only be lubricated
when open.
• Clean the two lubricating nipples (2 and 3)
57 on the trailer coupling.

• Open the trailer coupling. To do this, move
the hand lever (1) upward.
• Press grease according to Maintenance plan,
90
p. 5 - 6 into the two lubricating nipples using
a grease gun.
75
40
G
Risk of injury when closing the trailer coupling by hand.
When closing, the hand lever moves down with great force in the direction
of the coupling jaw. Therefore start the closing process only by moving the
lever briefly in the direction of the coupling jaw with the hand balls.
If you hold the hand lever and move it down, it may carry your hand with it
and crush it.
s
14.01.2002

Closing the trailer

coupling
After lubrication you must close the trailer
coupling.
• To do this move the hand lever knob (1)

briefly in the direction of the coupling jaw
(observe direction of arrow).
• Remove any excess grease.
7.15.2 Checking the bearing 57 M3
G
90
Risk of injury!
Ensure that the coupling is closed for the following work (lever points
downwards). Otherwise, the lever may come down with great force and
cause serious hand injuries.
75
• Jiggle the trailer coupling in vertical and

longitudinal direction (arrows) to ensure
proper positioning of the bearing. Hold the
coupling at the top and bottom of the cou-
pling head and not by the coupling jaw.
40
When shaking the coupling should not show

longitudinal clearance; the vertical clearance
must not exceed a value of 3 mm (as mea-
sured at the coupling head).
H
A vertical clearance of 3 mm at the coupling head corresponds to 1 mm
14.01.2002
bearing play.

7.15.3 Checking the cotter pin M3
H
For the following tests the coupling must be closed; before closing by hand
check the data in sectionà Lubricating the trailer coupling, p. 7 - 69.
• Check the wear on the cotter pin (1). The

diameter of the crowned section (arrows)
must not be below the following values:
Model series 400: 36.5 mm
If the diameter is below 36.5 or 46.0 mm, the

pin must be replaced.
57
90
• Also check the cotter pin for the correct ver-
tical clearance. Push the cotter pin (1) up-
75
wards using a screwdriver. The vertical

clearance (2) of the pin must not exceed
4 mm.
40
14.01.2002

7.15.4 Checking the lower bushing M3
• Check the internal diameter of the lower

bushing. The dimension (D) can not be less
than the following values:
If the diameter is below 31.5 or 34.2 mm, the

bushing must be replaced.
57
90
7.15.5 Checking the support ring M3
• Check the support ring (1) for the draw eye-

let at the bottom of the coupling jaw.
75
When the trailer is coupled, the draw eyelet

of the trailer may have slight contact with
the lower bushing (2).
40
Have the support ring changed if:
– the trailer's draw eyelet touches the lower

bushing because of wear or
– the support ring has reached its wear limit of
H =14 mm.
14.01.2002

7.15.6 Checking the initial tension of the springs M3
New couplings should show an initial axial torque of at least 100 Nm. The
coupling head should require physical power to twist when checking the
torque.
• Twist the coupling head clockwise and counterclockwise to check the ini-
tial tension of the rubber springs.
7.15.7 Checking the function of the coupling jaw /

re-adjusting the middle position M3
H
The following checks are required only on model series 700. If you need to
Function
57
close the coupling by hand for the checks, make sure you observe the data
in section Lubricating the trailer coupling, p. 7 - 69.
If you need to close the coupling by hand for the checks, make sure you
90
checking observe the data in section Lubricating the trailer coupling, p. 7 - 69.
• Close the coupling (position B); à p. 7 - 70.

The coupling jaw must be able to move easily
75
in both directions.
• Hold the coupling jaw (1) pressed slightly to

the left or right.
• Open the coupling (position A) and let the
40
coupling jaw go.

The release lever must automatically lock the
coupling jaw in the central position. The cou-
pling jaw is locked when the coupling can no
longer move to the side.
H
If the release lever does not automatically engage with the coupling jaw, the
central position will need to be re-adjusted; à
p. 7 - 74.
14.01.2002
s
Re-adjusting
centrel position
• Open the coupling (hand lever (1) up).

• Loosen the three screws (2) at the bottom of
the coupling.
• Push the coupling jaw to the right or left un-
til the release lever snaps into place.
• Retighten the three screws (2) (tightening
torque: 58 Nm).
• After adjusting check the function of the
coupling jaw; à p. 7 - 73.
57
90
75
40
14.01.2002

7.16 Other maintenance work
7.16.1 Lubricating the outrigger beams M1
The operation of the supports can be found in the Operating Instructions,

Chapter Erecting work, Section Supporting.
Please note the safety instructions given in that section.
G
Risk of crushing.
Ensure that there is sufficient room around the crane. Warn any persons
nearby before extending the outriggers.
• Fully extend the outrigger beams.
57 • Apply the lubricating grease with a brush or

spatula to both sides of the four slide faces
and to the points (1). Use only lubricating
grease according to Maintenance plan,
p. 5 - 8.
90
• Extend and retract the outrigger beams sev-
eral times in order to improve the lubrica-
tion effect.
75
40
7.16.2 Checking for correct operation of the auxiliary

heater (additional equipment) M1
Operate the additional heating for 20 to 30 minutes in the warm time of year
(à Operating Instructions, Chapter Driving with the truck crane, Section Water
auxiliary heating (additional equipment).
• Check that the system is working properly.

14.01.2002
• Inform your local GROVE Customer Service if the heating system is not
working properly.

57
90
Blank page
75
40
14.01.2002

8
8 Description of maintenance work on the superstructure . . 8- 1
8.1 Shifting clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 1

8.1.1 Shifting clutch – oil level check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 1
8.1.2 Shifting clutch – oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 2
8.2 Hoists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 3
8.2.1 Hoisting gear – oil level check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 3
8.2.3 Checking the hoist brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 4
8.2.4 Lubricating the hoist gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 4
8.2.5 Hoisting gear – oil change. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 5
8.2.6 Carrying out partial inspection of hoists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 7
8.2.7 Carrying out general inspection of hoists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 7
8.3 Slewing gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 9
8.3.1 Slewing gear – oil level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 9
8.3.2
8.3.3
8.3.4
8.3.5
57
Checking for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubricating slewing gear pinion and gear rim . . . . . . . . . . . . . . . . . . . . . . . . . .
Slewing gear – oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Slewing gear brake function check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-
8-
8-
8-
10
10
12
14
90
8.4 Superstructure hydraulic system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 15
8.4.1 Checking the hydraulic hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 15
8.4.3 Bleeding the derricking cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 16
75
8.4.4 Lubricating the piston rod of the derricking cylinder . . . . . . . . . . . . . . . . . . . . . 8- 18

8.4.5 Bleeding telescoping cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 19
8.4.6 Replacing the hydraulic oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 22
8.5 Main boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 25
40
8.5.1 Lubricating the locking pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 25

8.5.2 Lubricating the telescope slide faces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 28
8.6 Hoist ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 35
8.6.1 Checking the position of sheaves and rope drums. . . . . . . . . . . . . . . . . . . . . . . 8 - 35
8.6.2 Checking the status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 36
8.7 Safe load indicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 47
8.7.1 Maintaining the slip ring assembly of the cable drum . . . . . . . . . . . . . . . . . . . . 8 - 47
8.8 Central lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 51
8.9 Hook blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 53

14.01.2002
8.9.1 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 53
8.10 Superstructure air conditioning system (additional equipment) . . . . . . . . . . . . . 8 - 55
8.10.1 Checking hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 55

8.11 Other maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 57
8.11.1 Lubricating the counterweight hoist unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 57
8.11.2 Checking for correct operation of the auxiliary heater (additional equipment) 8 - 57
57
90
75
40
14.01.2002

8.1 Shifting clutch
8 Description of maintenance work on

the superstructure
8.1 Shifting clutch
H
Starting from crane 9120, this maintenance work is no longer necessary.
The shifting clutch is then connected to the hydraulic oil circuit.
H
To reach the shifting clutch you must tilt the driver’s cab, à Tilt driver’s cab
forward, p. 7 - 1.
The shifting clutch is located between the diesel engine and the hydraulic
pumps for the superstructure hydraulic system.
8.1.1 57
Shifting clutch – oil level check M1
90
After the diesel engine has been turned off, the oil level of the shifting clutch
can be controlled via the inspection glass. The inspection glass is located on
the right side of the shifting clutch casing.
G
Danger of burning yourself when the diesel engine is hot!
75
During operation, the diesel engine and add-on parts can reach tempera-
tures of up to 400 °C. Wear suitable protective gloves and make sure that
you do not touch hot parts when you are topping up oil when the diesel
engine is hot.
• Tilt the driver’s cab; à p. 7 - 1.

40
• Check the oil level of the shifting clutch

through the inspection glass (2). The inspec-
tion glass must be completely filled with oil.
Remove the screw (1) from the oil filler
opening.
Add oil until the inspection glass is full. Only
use oil specified in the Maintenance plan,
p. 5 - 9.
Reinsert the screw (1) into the oil filler
14.01.2002
opening.

8.1 Shifting clutch
8.1.2 Shifting clutch – oil change M 12
Only use oil specified in the Maintenance plan, p. 5 - 15.
O
Always use oil collection containers which are oil-resistant.
G
Danger of burning yourself when the diesel engine is hot!
During operation, the diesel engine and add-on parts can reach tempera-
tures of up to 400 °C. Wear suitable protective gloves and make sure that
you do not touch hot parts when you are topping up oil when the diesel en-
gine is hot.
• Tilt the driver’s cab; à p. 7 - 1.

• Have an oil collection container ready
57
(capacity approx. 0.5 litres).
• Remove the screw (1) from the oil filler
opening.
• Remove the screw (3) from the oil drain
90
opening and drain the oil into the oil con-
tainer.
• Replace the sealing ring of the screw and
reinsert the screw into the oil drain opening.
75
• Top up oil and check the oil level through

the inspection glass (2). Only use oil speci-
fied in the Maintenance plan, p. 5 - 9.
• Reinsert the screw (1) into the oil filler
40
opening.
O
Risk of polluting the environment!
Collect waste oil in approved containers and have it disposed of properly.
14.01.2002

8.2 Hoists
8.2 Hoists
The main hoist and the auxiliary hoist of identical construction (additional
equipment) are located on the superstructure turntable. The auxiliary hoist
is located behind the main hoist.
8.2.1 Hoisting gear – oil level check W
The standpipe used to read the oil level in the hoist gear is located on the
right side of the superstructure on the hoist.
• Check the oil level of the winch gear at the

standpipe (3). The oil level must be between
the MAX and MIN marks (4).
57 • Unscrew the upper sealing screw (1) and re-

move the connecting hose (2) from the
standpipe.
• Top up oil via the standpipe (3).
90
Only use oil specified in the Maintenance
plan, p. 5 - 7.
• Replace the sealing rings of the upper screw
plug and screw the upper hose back on.
75

40

• If hydraulic oil or gear oil has been lost, check the oil levels and top up
if necessary.

14.01.2002

8.2 Hoists
8.2.3 Checking the hoist brake W
Test correct function of the hoist brake by suspending a load on the load
hook for a certain time and measuring whether the load lowers on its own.
Perform the test on the main hoist and the auxiliary hoist:
• Suspend the hook block on the singly reeved hoist rope.

• Lift a test load of approx. 9.2 t approx. 30 cm above the ground.
• Measure the distance from the ground when the test load is hanging
completely still.
• Switch off the diesel engine.
If the test load has not lowered after approx. 2 minutes, the brake applied is
in working order at that time.
8.2.4
H
Lubricating the hoist gears
57
The main hoist is connected to the centralised lubrication system. The
following maintenance work only applies to the auxiliary hoist
W
90
(additional equipment).
G
Risk of crushing when hoisting gear is turning!
Keep yourself and other people away from the turning rope drum. If you
75
take hold of the turning rope drum, your fingers and hands could be
crushed between the rope drum and hoisting gear frame or get caught and
drawn in by the turning drum.
The auxiliary hoist has a lubricating nipple (1).

The lubricating nipple is located on the left
40
side of the superstructure on the auxiliary

hoist.
Only use lubricating grease specified in the

Maintenance plan, p. 5 - 7.

lubricating nipple.
• Use a grease gun to apply grease to the
lubricating nipple.
14.01.2002

8.2 Hoists
8.2.5 Hoisting gear – oil change M 12
S
Be careful not to damage the hoist gear!
The waste oil must be tested for abrasion particles. This examination
serves to identify damage at an early stage.
O
Always use oil collection containers which are oil-resistant.
Changing the oil in Oil change is carried out on the right side of the turntable via the connecting
the hoisting unit hoses to the standpipe.
H 57
Since the oil is distributed slowly in the hoisting gear being filled, the oil
level in the standpipe will at first rise quickly and then subside a little; after-
wards it will rise to the final filling level.
• Have a container (with a capacity of over 8 l)

90
ready under the standpipe to collect the oil
(3).
• Loosen the upper screw plug (1) and remove
the upper hose (2).
75
• Unscrew the lower screw plug (5) and let the

• Replace the sealing rings of the lower screw
plug and screw the lower hose (4) back on.
40
• Fill the oil up to the max mark (6) through

the standpipe.
• Replace the sealing rings of the upper screw
plug and screw the upper hose back on.
O
s
14.01.2002

8.2 Hoists
Checking the oil
H
Check the waste oil which was drained from the gear units during the oil
change for abrasion particles or have it tested in a laboratory:
• Pour the used oil through a clean filter fleece.

• Examine the oil or the residues on the filter fleece using a magnifying
glass.
If you find abrasion particles or solid matter on the fleece, the hoist gear
must be dismantled for inspection and examined by the manufacturer.
H
With the first oil there may be some abrasion particles in the oil. If you
notice any abrasion particles during the first oil change (after 200 operating
hours), contact GROVE Customer Support before you take any more mea-
sures.
G
Danger of accidents!
57
If this examination is not carried out, there is a risk of damage to the hoist
gears and thus the possibility of the load falling.
90
75
40
14.01.2002

8.2 Hoists
8.2.6 Carrying out partial inspection of hoists Y3
Certain parts must be inspected for wear during the partial inspection:
– the multiple-disk brake,

– the plug connections between the hydraulic engine and the multiple-disk
brake, and
– the plug connections between the multiple-disk brake and the gearbox
unit (where applicable).
These parts must be replaced when worn.
H
Inspections and part replacements must only be carried out by trained,
qualified personnel.
8.2.7
57
Carrying out general inspection of hoists Y6
H
When carrying out general inspection of the hoists, also observe the infor-
90
mation contained in the section on Measures required for winch monitoring,
p. 5 - 21.
The hoist gear is to undergo general inspection after the period of time in-
dicated in the maintenance plan. This inspection involves disassembly of the
75
gearbox and sending it to the manufacturer for testing.
H
Run-in specifications require that the oil of new gearboxes and gearboxes
that have undergone a general overhaul be changed after 200 and 1 000 op-
erating hours before the yearly interval can be implemented.
40
14.01.2002

8.2 Hoists
57
90
Blank page
75
40
14.01.2002

8.3 Slewing gear
8.3 Slewing gear

The slewing gear is on the right-hand side of the superstructure.
8.3.1 Slewing gear – oil level check W
H
The oil must be cool before carrying out an oil inspection. Therefore always
check the oil level before using the crane.
• Check the oil level using the oil level sight

glass (1) on the slewing gear transmission.
The oil must be visible in the sight glass.
• Unscrew the vent screw (3) and fill the oil ac-
57 cording to the
• Close the opening.
à Wartungsplan, S. 5 - 7.
90
75
• For the slewing gear brake, check the oil

level using the oil level sight glass (1) in the
expansion tank (2).
40
The oil must be visible in the sight glass.

• Unscrew the ventilation filter (3) from the

expansion tank and top up with oil as speci-
fied in theà Wartungsplan, S. 5 - 7.
• Close the opening.
14.01.2002

8.3 Slewing gear

• If hydraulic oil or gear oil has been lost, check the oil levels and top up if
necessary.
• If damage cannot be rectified immediately or further damage is likely:
8.3.3 Lubricating slewing gear pinion and gear rim M6
The slewing gear pinion and spur gear must be lubricated with special
grease ( à Wartungsplan, S. 5 - 13). The grease is applied to the gear teeth
with a brush or sprayed on. There are different procedures for the first time
and subsequent lubrications.
H 57
Observe the instructions and safety information on the grease packaging.
G
90
Risk of being crushed by the slewing gear pinion!
Fingers can be crushed or pieces of clothing can be pulled into an open, ro-
tating slewing gear pinion. For this reason, be sure to mount the protective
plate again after lubricating.
75
40
14.01.2002

8.3 Slewing gear
• Unscrew the screws and remove the protec-

tive plate (1) in front of the slewing gear
pinion (2).
First lubrication:
• Clean the gear teeth of the slewing gear

pinion (2) and the spur gear (3) thoroughly
to remove residue of old lubricants.
• Apply a thin layer of adhesive lubricating
grease and leave to penetrate for approx.
10 minutes.
• Apply a second, thicker coat and leave to
penetrate for approx. 30 minutes.
• Attach the protective plate (1) in front of the
slewing gear pinion (2) with the appropriate
57 screws.
Subsequent lubrication:
• Apply a new layer over the existing layer of

90
adhesive lubricating grease.
• Leave to penetrate for approx. 30 minutes.
slewing gear pinion (2) with the appropriate
75
screws.
40
14.01.2002

8.3 Slewing gear
8.3.4 Slewing gear – oil change M 12
Slewing gear The oil drain screw of the slewing gear unit is located above the spur gear
transmission of the slewing gear pinion. Only use oil specified in the à
Wartungsplan,
oil change S. 5 - 15.
O
Always use oil collection containers which are oil-resistant. Wipe up spilled
oil immediately.
• Unscrew the protective plate (4) in front of

the slewing gear pinion.
(capacity approx. 5 l).
• Unscrew the vent screw (2).
57
• Unscrew the ventilation filter (1) from the
filler neck.
• Unscrew the oil drain plug (5) and drain the
oil into the oil container.
90
• Replace the sealing ring on the oil drain plug
and screw the plug back in.
• Fill with oil (à Wartungsplan, S. 5 - 14) and
check the level of the oil by inspecting the oil
75
level sight glass (3).

• Screw the ventilation filter (1) and the
ventilation screw (2) back on with a new
sealing ring.
40

slewing gear pinion.
O
14.01.2002

8.3 Slewing gear
Checking the oil
H
Check the old oil which was drained from the slewing gear transmission for
abrasion particles or have it tested in a laboratory.
• Pour the used oil through a clean filter fleece.

• Examine the oil or the residues on the filter fleece using a magnifying
glass.
If you find abrasion particles or solid matter on the fleece, the slewing gear
transmission must be dismantled for inspection and examined by the man-
ufacturer.
Slewing gear The slewing gear brake is located on the slewing gear itself.
brake oil change Only use oil specified in the àWartungsplan, S. 5 - 15.
O
oil immediately.
57
Drain the oil into the collecting vessel via a draining gutter. Wipe up spilled

90
(capacity approx. 1.5 l).
• Unscrew the vent filter (4) from the expan-
sion tank (3).
• Remove the screw from the oil drain open-
75
ing (1) and let the oil run into the oil collec-
tion container via a draining gutter.
• Replace the sealing ring and replace the
screw (1) in the oil drain opening.
40
• Add new oil through the expansion tank (3)

until the oil level is in the middle of the oil
level sight glass (2).
• Screw the vent filter (4) back on to the
expansion tank.
O
14.01.2002

8.3 Slewing gear
8.3.5 Slewing gear brake function check D
To check the wear on the slewing gear brake plates you must carry out a
slewing gear service brake function test. This involves slewing movement
against the slewing gear service brake.
G
Risk of overturning when rotating the superstructure!
The truck crane must be on outriggers before slewing the superstructure.
Read the notes in the chapter Crane work with the main boom – slewing in the
Operating manual before checking for proper function.
• Release the slewing gear permanent brake by pressing the Slewing gear
Y permanent brake rocker switch upwards.
• The slewing gear permanent brake indicator lamp goes out.

Y • Push the slewing gear service brake pedal down and hold it.
57
• Active the slewing gear. To do this turn the left-hand control lever slowly
to the left or right as far as it will go.
If the superstructure turns, the slewing gear service brake plates are worn
90
and must be replaced immediately.
• Only have the plates changed by GROVE Customer Support.

75
40
14.01.2002

8.4 Superstructure hydraulic system
8.4.1 Checking the hydraulic hoses W
The inspection work is described in section Checking the hydraulic hoses,

p. 7 - 44.
• With the diesel engine running, make a visual inspection for leaks and es-
caping hydraulic oil on the hydraulic components of the superstructure
57
(hydraulic cylinders, lines, connections, hydraulic pumps, motors, valves,
and control block).
• If leaks are detected, check the hydraulic oil level and top up if necessary
(à Hydraulic unit – oil level check, p. 7 - 43).
G
90
Never tighten leaking connections when the system is under pressure. Only
change seals, pipes and hoses when the system is depressurized.
75
O
Immediately repair or have leakages repaired in the hydraulic system to
40
ensure that no hydraulic oil escapes, seeps into the ground or reaches
water when the crane is being used.
14.01.2002

8.4.3 Bleeding the derricking cylinder M1
There are bleeder screws on the derricking cylinder for bleeding the cylinder
chambers.
In the toolbox there is a special key with a transparent hose for opening the
vent screws. Only this special key should be used to open the vent screws.
Prerequisites With the following requirements it is assumed that the counterweight and
lattice extension are not rigged.
• Park the truck crane on a flat, even surface.

• Support the truck crane with at least the outrigger span 8.10 m x 6.00 m.
• Fully retract the main boom.
• Set the SLI code for 0 t counterweight.
57
• Slew the superstructure to the rear or to the side.
• Lower the boom as far as possible.
90
Bleeding the pis-
G
ton rod chamber
Risk of accidents from hydraulic oil being sprayed!
The hydraulic system is under pressure. For this reason, you may only
loosen the vent screws. If you unscrew the vent screws, hydraulic oil will
75
spray out under pressure.
• Remove the cap from the vent screw (1) on

the piston rod chamber.
• Fit one end of a plastic transparent hose
40
over the vent screw and hold the other end

in a container filled with oil.
• Loosen the vent screw by 1 – 2 turns.
14.01.2002

G
Risk of accidents when raising the main boom!
Move the control lever very carefully. To ventilate only hydraulic oil must
be delivered into the derricking cylinder. The derricking cylinder must not
move!
• Carefully raise the control lever until the oil flowing through the trans-
parent plastic hose no longer contains any air bubbles.
• Tighten the vent screw, remove the plastic hose and replace the cap on
the vent screw.
Bleeding the pis- Before ventilation, the requirements listed at the start of this section must
ton head area be fulfilled.
G
Risk of accidents from hydraulic oil being sprayed!
The hydraulic system is under pressure. For this reason, you may only
loosen the vent screws. If you unscrew the vent screws, hydraulic oil will
57
spray out under pressure.
• Check that the boom is lowered as far as it

will go.
90
• Remove the cap from the vent screw (1).
• Fit one end of a plastic transparent hose
over the vent screw and hold the other end
in a container filled with oil.
75

40
G
Risk of hands and arms being crushed!
Move the control lever very carefully. To ventilate only hydraulic oil must
be delivered into the derricking cylinder. The derricking cylinder must not
move!
• Carefully raise the control lever until the oil flowing through the transpar-
ent plastic hose no longer contains any air bubbles.
• Tighten the vent screw, remove the plastic hose and replace the cap on
14.01.2002
the vent screw.

8.4.4 Lubricating the piston rod of the derricking cylinder M1
S
Danger of damage to the derricking cylinder’s gasket due to surface rust!
Be sure that the uncovered end of the piston rod on the derricking cylinder
is always covered with lubrication. In this way, you can avoid surface rust,
which damages the gasket in the derricking cylinder head when lowering
completely.
• Clean the open end (2) of the piston rod of

old grease, protective particles and rust.
• Lubricate the open end (2) of the piston rod
on the derricking cylinder head (1), so that it
is evenly covered with grease.
57
90
75
H
You can also prevent surface rust if you turn the main boom to the side be-
tween maintenance intervals and completely lower it.
40
14.01.2002

8.4.5 Bleeding telescoping cylinders M1
There are two vent screws on the telescoping cylinder for bleeding the cyl-
inder chambers. The vent screws are accessible through hand holes in the
telescopic sections.
In the toolbox there is a special key with a transparent hose for opening the
vent screws. Only this special key should be used to open the vent screws.
Prerequisites With the following requirements it is assumed that the lattice extension is
not rigged.

• Create one of the two following rigging states:
–The truck crane is supported by an outrigger span of 8.10 m x 6.00 m and
there is at least 3.8 t of counterweight or
57
there is at least 1.8 t of counterweight.
• Enter the SLI rigging code for the current rigging mode of the truck crane.
90
• Fully retract all telescope sections.
• Unreeve the hook block.
• Slew the superstructure to the rear or to the side.
• Derrick the boom into horizontal position.
75
Bleeding Carry out the bleeding procedure on all vent screws in turn.
procedure
• Remove the cap from the relevant vent screw.
40
• Place the special key with the transparent hose onto the vent screw. Hold
the other end of the hose in a container filled with oil.
• Carefully fill the telescoping cylinder with hydraulic oil until the oil flowing
through the hose no longer contains any bubbles. Carefully extend the
relevant telescope section in the direction specified.
The oil collected in the container must not be used again as it contains air.
s
14.01.2002

Location of vent
screws
57
90
Position no. Vent for: Access to vent on basic section via:
75
Manhole in top chord

1 Set of piston rings
Basic section
Opening in telescopic section IV
2 Piston chamber
left-hand side
40
14.01.2002

Telescoping The position numbers indicated below refer to the illustrations for Location
status à
of the bleeder screws in this section; p. 8 - 20.
Vent screw position no. 1
G
Retracting boom poses risk of crushing!
Do not reach into the manhole until the boom has been secured so that it
can not retract inadvertently. If you are carrying out this operation with the
help of someone else, communicate with the person in the crane cab by
means of clear hand signals.
• Screw off manhole cover plate.

• Extend telescope section I approx. 2.0 m so that the access to the manhole
is free.
• Fit the bleeder key through the manhole onto the vent screw (1) on the
57
telescoping cylinder and open with one or two turns.
• Make sure nobody is in the manhole or is reaching into the manhole.
• Carefully move the control lever for telescoping in the retract direction so
that the pressure in the set of piston rings increases and the air is pushed
90
out through the plastic hose.
• Close the manhole again with the cover plate.
75
Vent screw position no. 2
• Extend telescope section IV approx. 0.5 m.

• Insert bleeder key through the opening on the left side of telescope sec-
tion IV onto the vent screw and open 1 or 2 turns.
40
• Carefully move the control lever for telescoping in the extend direction so
that the pressure in the piston chamber increases and the air is pushed
out through the plastic hose.
14.01.2002

8.4.6 Replacing the hydraulic oil filter M3
Three hydraulic oil filters are installed in the hydraulic system:

– a return flow filter and a fine filter in the oil tank in the carrier,
– a pressure filter in the control oil circuit in the superstructure.
• The hydraulic oil filters must be replaced:
g – if the warning lamps for the Hydraulic oil filter in the front instrument
panel of the crane cab light up,
– after every hydraulic oil change.
The warning lamp is located on the front in-
57
strument panel:
– Warning lamp for Hydraulic oil filter in control

circuit (1).
90
75
40
O
Catch the oil escaping during filter change and store used fuel filter inserts
in suitable containers and have them disposed of properly by qualified
personnel.
14.01.2002

Hydraulic oil filter

for control circuit
The hydraulic oil filter control circuit (1) is
located on the right side of the superstructure,
under the covering (2).
• Switch off the diesel engine and secure

it against being started by unauthorized
persons (sign in the driver’s cab).
• Unscrew the screws and remove the
cover (2).
57 • Remove the ring (1).

• Take off the filter can (2).
90
• Remove the filter from the filter can.
• Insert the new filter into the filter can.
• Fill the filter can up to the edge with
hydraulic oil.
75
• Screw the filter can on again.

• Start the diesel engine and let it run in
neutral gear for 3 minutes in order to
bleed the system.
40
14.01.2002

57
90
Blank page
75
40
14.01.2002

8.5 Main boom
8.5 Main boom
8.5.1 Lubricating the locking pins M3
To lubricate the locking pins, the main boom must be lowered to the hori-
zontal position and the telescopic sections must be successively extended
to allow access to the locking bolts.
The locking pins between the telescopic sections of the main boom need to
be sprayed with a spray oil containing molybdenum disulphide (MoS2).
Position of the
locking pins
57
90
75
40
The locking pins are on both sides of the telescopic sections. To lubricate,
extend the telescopic sections until the locking pins (1) are accessible. The
illustration shows the degree of telescoping required to lubricate the locking
pins on telescopic section IV.
s
14.01.2002

8.5 Main boom
Prerequisites To lubricate the locking pins on the main boom, it must be partly extended
in horizontal position.
G
Risk of overturning when extending in horizontal position!
In the horizontal position the SLI blocks telescoping when there is an at-
tempt to extend a second telescopic section.
Override the SLI only when you are prompted to do so in the following sec-
tion and do not extend the main boom more than indicated.
Even with 16.1 t of rigged counterweight and the superstructure slewed to
the rear you cannot extend all telescope sections. The truck crane would
first overturn.
Before lowering or extending the boom, the following conditions must be

met:
57
– The truck crane is supported with the outrigger span 8.10 m x 6.00 m
(26.6 ft x 19.7 ft) and there is at least 6.8 t of counterweight or
90
– The truck crane is supported with the outrigger span 8.10 m x 7.00 m
(26.6 ft x 23.0 ft) and there is at least 3.8 t of counterweight.
75

• Lower the main boom into a horizontal position.
40
Lubricating the Keep a spray oil containing molydenum disulphide (MoS2) ready for lubri-
locking pins cating the locking pins. The following section describes the lubricating pro-
cedure for telescopic section IV.
G
Risk of accidents from slipping off!
There is grease residue on the telescope sections. For this reason, you must
not walk on the main boom.
Use the extendable ladders provided with your crane!
14.01.2002

8.5 Main boom
Lubricating tele- • Retract all telescopic sections.

scopic section II -
IV
• To lubricate the locking pins, extend telescopic section IV to the fixed
length of 100% and lock it.
• Lock the telescoping cylinder in the telescopic section III.
• Override the SLI by turning the override key-operated switch to the right.
• Extend telescopic section III about 1.50 m (5 ft) until the bores of the lock-
ing pins for the telescopic section IV are accessible.
• Spray the spray oil into the gap between locking pin and guide bushing
on both sides of the telescopic section IV.
• Fully retract telescopic section III and lock it.
• Do not override the SLI anymore.
• Lock the telescoping cylinder in telescopic section IV.
57
• Unlock and lock telescopic section IV several times, so that the oil gets
distributed over the locking pin.
• Retract telescope section IV completely.
• Proceed in the same way for telescopic sections III and II.
90
Lubricating tele- Telescopic section I does not need to be extended for lubricating the locking
scopic section I pins, because the locking points with the main boom basic section are al-
ways accessible from the outside.
75
• Spray the spray oil into the gap between locking pin and guide bushing
on both sides of the main boom.
• Unlock and lock telescopic section I several times, so that the oil gets dis-
tributed over the locking pin.
40
14.01.2002

8.5 Main boom
8.5.2 Lubricating the telescope slide faces M6
For lubricating the telescopic slide faces the main boom must be lowered
into horizontal position and the telescope sections must be telescoped one
after the other in a certain order so that the lubricating points are reached.
G
Danger of overturning!
Before the main boom is lowered or extended, observe the requirements
explained in this section, p. 8 - 30.
At the corners of telescope sections I to IV

there are four slide faces. The two lower slide
faces (2) and (3) are lubricated from the out-
side in fully extended state.
57
The two upper slide faces (1) and (4) are
lubricated by one lubricating nipple each.
The following section shows the position of

90
the lubricating nipples.
75
Position of lubri-
40
cating nipples
G
Retracting boom poses risk of crushing!
Do not reach into the manhole until the boom has been secured so that it
can not retract inadvertently. If you are carrying out this operation with the
help of someone else, communicate with the person in the crane cab by
means of clear hand signals.
14.01.2002

8.5 Main boom
57
The lubricating nipples (1) are located on the upper booms of the telescope
sections and are reached via corresponding lubrication holes (2) in the tele-
90
scope sections above. The diagram shows the telescope status for the lubri-
cation of telescope section IV.
Lubricating nipple for Quantity Can be reached via the

75
lubrication hole in
Top chord
Telescopic section I 2
Basic section
Top chord
Telescopic section II 2
Telescope section I
40
Top chord
Telescope section III 2
Telescope section II
Top chord
Telescopic section IV 2
Telescopic section III
G
Danger of slipping due to grease residue. Do not climb onto the boom.
Use the extendable ladder provided with your crane!
s
14.01.2002

8.5 Main boom
Prerequisites The main boom must be partly extended in the horizontal position when
carrying out maintenance.
G
Risk of overturning when extending in horizontal position!
In the horizontal position the SLI blocks telescoping when there is an at-
tempt to extend a second telescope section.
Override the SLI only when you are prompted to do so in the following sec-
tion and do not extend the main boom more than indicated.
Even with 16,1 t of rigged counterweight and the superstructure slewed to
the rear you cannot extend all telescope sections. The truck crane would
first overturn.
Before lowering or extending the boom, the following conditions must be

met:

57
there is at least 3.8 t of counterweight or

there is at least 1.8 t of counterweight.
90
75
• Lower the main boom into a horizontal position.
H
To lubricate you must also telescope to intermediate lengths. Therefore
telescope the main boom with semi-automatic (Operating manual, chapter
on Crane operation; à
section on Crane operation with main boom).
40
14.01.2002

8.5 Main boom
Lubricating slide • To lubricate, use only special grease as specified in the Maintenance plan,
faces of telescope p. 5 - 13.
sections
• Lower the retracted main boom to the lowest position.
• Start with telescope setion IV.
G
Risk of accidents from slipping off!
There is grease residue on the telescope sections. For this reason, you must
not walk on the boom.
Use the extendable ladder provided with your crane!
Lubricate • Retract all telescopic sections.

telescopic
section IV
• Telescope telescopic section IV to the middle locking position and lock it.
57
• Override the SLI by turning the Override key switch to the right.
• Extend telescopic section III to approx. 58% until the lubricating hole for
telescopic section IV can be reached in the top chord.
• Inject approx. 100 ml of grease into each lubricating nipple (position 1).
90
• Fully retract telescopic section III.
• Fully extend telescopic section IV.
75
• Use a spatula to apply a thin layer of grease to the two lower slide faces
of telescopic section IV .
• Extend and retract telescopic section IV again so that the grease is distrib-
uted uniformly on the telescope slide faces.
40
• Retract telescopic section IV.
Lubricate • Retract all telescopic sections.

telescopic
section III
• Telescope telescopic section III to the middle locking position and lock it.
s
14.01.2002

8.5 Main boom
• Extend telescopic section II to approx. 58% until the lubricating hole for
telescopic section III can be reached in the top chord.
• Fully retract telescopic section II.
• Fully extend telescopic section III.
• Apply a thin layer of grease to the bottom two slide faces of telescopic
section III with a spatula.
• Extend and retract telescopic section III again so that the grease is distrib-
• Fully retract telescopic section III.
Lubricate
telescopic
section II
• Retract all telescopic sections.
57
• Telescope telescopic section II to the middle locking position and lock it.
90
• Extend telescopic section I to approx. 58% until the lubricating hole for
telescopic section II can be reached in the top chord.
75
• Fully retract telescopic section I.

• Fully extend telescopic section II.
• Use a spatula to apply a thin layer of grease to the bottom two slide faces
40
of telescopic section II.

• Extend and retract telescopic section II again so that the grease is distrib-
• Retract telescopic section II.
14.01.2002

8.5 Main boom
Lubricating • Retract all telescopic sections.

telescopic
section I
• Extend telescopic section I to 100 %.
You can now reach the lubricating nipples via the front lubricating holes in
the top chord of the basic section.
• Use a spatula to apply a thin layer of grease to the bottom two slide faces
of telescopic section I.
• Extend and retract telescopic section I twice so that the grease is evenly
spread on the telescope slide faces.
• Retract telescopic section I.
57
90
75
40
14.01.2002

8.5 Main boom
57
90
Blank page
75
40
14.01.2002

8.6 Hoist ropes
8.6 Hoist ropes
8.6.1 Checking the position of sheaves and rope drums D
G
Danger of accidents due to turning rope drum.
Keep yourself and other people away from the turning rope drum. If you
take hold of the turning rope drum, your fingers and hands could be
crushed between the rope drum and hoisting gear frame or get caught and
drawn in by the turning drum.
• Check the position of the hoist ropes (1) on

the rope drums of the main hoist and the
auxiliary hoist (additional equipment).
• Slowly turn the rope drum at least one turn
in the lowering direction. Check the rope on
57 the drum as you do this.
– The ropes must be uniformly wound onto

the rope drum.
– The turns on the drum must have a
90
uniform distance of 0 to 2 mm.
– The cross-over points must be offset by
approx. 180°.
75
H
The upper layer of rope lies over the lower layer at the cross-over points.
• Check the position of the hoist ropes on the sheaves at the boom head and
40
in the hook block.

• Check the sheaves for damage and wear, and check that they run freely.
G
Risk of accidents from incorrectly set lowering limit switch!
Never turn the free rope end under the drum. Turns on the drum which are
unwound when the rope drum is stationary can not be detected by the low-
ering limit switch. This causes the lowering limit switch to become set in-
correctly and to switch off too late or not at all. In addition, the load may fall.
14.01.2002

8.6 Hoist ropes
8.6.2 Checking the status W
• Reeve the hoist rope on the hook block six times (à Operating instruc-
tions, chapter on Rigging work, section on Rigging work on the main boom).
• Support the truck crane and enter the SLI code for the current rigging
mode.
• Raise the boom and extend it fully.
• Unreel the hoist rope and check that the rope is not damaged or improp-
erly reeled ( à Assessing the condition of the hoist rope, p. 8 - 37). When five
turns are left on the rope drum, the lowering limit switch must switch off.
If the lowering limit switch does not switch off or switches off too late, it
must be reset; àSetting the lowering limit switch, p. 8 - 45.
• Check the mounting of the rope clamp (1) on

the rope drum for damage and ensure that it
is securely attached (tightening torque;
57
à Special tightening torques, p. 10 - 2).
• Check whether the hoist rope can be wound
without kinking and flattening:
– The free end of the rope must protrude from
90
the pocket (2).
75
40
• Check the rope securing device in the rope

end clamp (2) for proper seating and correct
positioning of rope.
The rope end clamp (1) must be attached to
the free end of the rope and the rope must
secured around the rope wedge (3).
14.01.2002

8.6 Hoist ropes
Assessing
the condition of
the hoist rope
H
If in doubt about damage assessment, always consult an expert.
To assess the condition of the hoist rope, you must be familiar with the fol-
lowing:
– the type of rope (crosslay rope or Lang’s lay rope),
– the number of load bearing wires in the outer strand
– the rope diameter ( à Operating instructions, chapter on Technical
information, section on Superstructure).
In a crosslay rope (1), the wires run more or

less in the longitudinal direction of the rope.
In a Lang’s lay rope (2), the wires run at an

angle of approximately 45° to the longitudinal
direction of the rope.
57
90
75
To calculate the number of bearing outer

wires (1), count the number of outer strands of
the rope and multiply by 7.
40
H
If there are multiple layers of strands, only the outer layer is counted.
14.01.2002
s
8.6 Hoist ropes
The following tables show the number of wire breaks, in a length 6 times
and 30 times the rope diameter, at which the rope must be replaced, for the
most common rope diameters.
Number of visible wire strand fractures
Number of Crosslay rope

load-bearing ∅ 13 mm ∅ 16 mm ∅ 19 mm ∅ 22 mm ∅ 24 mm
outer
wires on on on on on on on on on on
78 390 96 480 114 570 132 660 144 720
mm mm mm mm mm mm mm mm mm mm
101-120 5 10 5 10 5 10 5 10 5 10
121–140 6 11 6 11 6 11 6 11 6 11
Load-
bearing outer
wires
(Quantity) on
∅ 13 mm
on
∅ 16 mm
on on on
57
Number of visible wire strand fractures
Lang’s lay rope
∅ 19 mm
on
∅ 22 mm
on on
∅ 24 mm
on on
90
78 390 96 480 114 570 132 660 144 720
mm mm mm mm mm mm mm mm mm mm
101-120 2 5 2 5 2 5 2 5 2 5
121–140 3 6 3 6 3 6 3 6 3 6
75
H
40
The number of visible wire breaks indicated here only applies to the hoist
ropes! This information only applies to the initial equipment and original
spare parts!
S
Remember that other factors may also make it necessary to replace the
hoist rope before the number of wire breaks requiring rope replacement
has been reached (age of rope, frequency of use or exceptional loading).
14.01.2002

8.6 Hoist ropes
Damage Description
57
Cause Replacement
90
Wire strand Individual wires are General wear caused At the latest, replace hoist rope
fracture (1) broken; the broken by aging of the rope when the maximum permissi-
Wire breakage ends of the wires ble number of wire strand frac-
are protruding or tures according to the table are
clusters (2)
from the rope. visible externally.
Strand
75
breakage (3) Subsequent damage Replace hoist rope immediately

resulting from dam- if wire breakage clusters or
age to the rope. strand breakage occur.
The frequency of wire breakage
increases with rope age. For
40
reasons of safety, it is advisable

to replace the hoist rope while
the number of broken wires is
still low.
Effect of heat Tarnishing colour Rope has been sub- Replace hoist rope immedi-
is visible externally jected to strong heat. ately.
on the rope.
s
14.01.2002

8.6 Hoist ropes
Damage Description Cause

57 Replacement
90
Diameter The diameter of Structural changes Immediately replace hoist rope
reduction (1) the rope has be- if the diameter has decreased
come smaller in by 15% or more with respect to
large areas. the nominal diameter.
Corrosion or abrasion. Immediately replace hoist rope
75
if the diameter has decreased

by 10% or more with respect to
the nominal diameter.
Cork-screw The rope is winds Damage resulting Even a small amount of defor-
deformation its way along its from overloading. mation leads to increased abra-
40
of rope (2) longitudinal axis in sion, wire strand fractures and

a way which is sim- rough operation of the cable
ilar to a corkscrew. drive.
The deformation is If deformation ’x’ at a position
measured with the on the hoist rope is greater than
attached hook a third of the rope diameter, the
block. hoist rope must be replaced im-
mediately.
Basket-type Wires from the Outer and inner layers Replace hoist rope immedi-
deformation outer layer are pro- have dislocated from ately.
(3) truding from the one another.
rope. In various ar-
eas of the rope, the
14.01.2002
ply has buckled or

is protruding from
the rope.

8.6 Hoist ropes
Damage Description
57
Cause Replacement
90
Loop Outer layer wires in General wear due to Immediately replace hoist rope
formation (1) the form of hair aging of the rope or if the rope structure has been
pins are protruding subsequent damage substantially altered by the loop
from the rope on resulting from dam- formations.
the side opposite to age to the rope.
75
the rope pulley.

Loosening of Outer wires or Corrosion or abrasion. Replace hoist rope immedi-
wires or strands have be- ately.
strands (2) come loose. Only
the inner strands Other causes. The number of broken wires de-
termines when the rope must
40
continue to bear
the load. be replaced.
Formation Formation of General wear due to Determine number of broken

of nodes (3) nodes; repeatedly aging of the rope or wires;
occurring node- subsequent damage replace hoist rope immediately
formed thickening resulting from dam- if serious node formation oc-
of rope; core often age to the rope. curs.
protrudes.
The strands bear
on each other at
narrow locations;
increased oc-
curence of wire
breakage.
14.01.2002
Constriction Reduction of rope General wear caused Replace hoist rope immediately
(4) diameter over short by aging of the rope. if serious constriction occurs.
sections.

8.6 Hoist ropes
57
90
Damage Description Cause Replacement
Flattening (1) Crushes areas, Mechanical damage, Determine number of broken
mostly with wire e.g. due to driving wires; replace hoist rope imme-
breakage. over the rope. diately if serious crushing oc-
75
curs.
Crinkling Crinkle type rope Loaded hoist rope was Replace hoist rope immedi-
deformation. pulled over an edge. ately.
Kink (2) Rope deformation Rope was pulled Replace hoist rope immedi-
40
with twisting and straight while twisted ately.

broken wires. and located in eyes.
Buckle (3) Buckled section in Mechanical damage. Replace hoist rope immedi-
rope. ately.
14.01.2002

8.6 Hoist ropes
Replacing the The installation procedure can have a great influence on the service life of a
hoist rope hoist rope. Errors in installation reduce the service life considerably, there-
fore:
– make sure the hoist rope is not twisted when it is installed.

– ensure it does not get dirty or damaged while being fitted.
– reel the rope up in the same direction in which it was reeled onto the drum
on which it was supplied.
– tense the rope slightly while reeling it up.
S
Use only a replacement hoist rope which has the same technical specifica-
tions as the defective rope or an original replacement rope.
• Unreeve the hook block (à Operating instructions, chapter on Rigging
57
work, section on Setting down the hook block).
• Wind out the hoist rope until the lowering limit switch switches off.
• Adjust the lowering limit switch so that you can unwind the hoist rope
completely ( à Setting the lowering limit switch, p. 8 - 45).
90
• Wind out the remaining layers from the hoist drum.
H
Ensure that the rope is not wound on again in the other direction.
G
75
Risk of accidents from rotating rope drum!

Turn off the diesel engine and remove the ignition key so that no un-
authorized operation of the hoist can occur.
40
• Remove the two screws and the rope clamp

(5).
• Push the hoist rope (1) through the bore (2)
until the rope wedge (4) slides out of the
pouch (3) of the hoist drum.
• Take out the rope wedge and pull the free
end of the hoist rope out of the pouch (3)
and out of the bore hole (2).
• Pull the hoist rope from the boom and out of
the sheaves at the boom head.
14.01.2002
s
8.6 Hoist ropes
• Place the rope reel with the new hoist rope on a reel stand.
• Place the reel stand in front of the boom head in such a way that the hoist
rope can be guided straight over the boom head sheaves onto the boom.
• Pull the hoist rope over the boom to the hoist drum.
until it extends approx. 1.5 m from the
pouch (3).
• Feed the free end of the hoist rope back
through the pouch (3).
57
• Put on the rope clamp (5) and screw it down;
90
à Special tightening torques, p. 10 - 2.
• Place the rope wedge (4) into the hoist rope
loop and insert it into the pouch (3) in the
hoist drum.
75

until the rope wedge slides completely into
the pouch (3) of the hoist drum.
40
S
Danger of damaging the hoist rope.
Ensure that the rope wedge, rope loop and rope end do not protude beyond
the diameter of the hoist drum. This protects the new hoist from damage
through kinking or flattening even when being reeled.
• Restart the diesel engine.

14.01.2002

8.6 Hoist ropes
• Reel the hoist rope slowly onto the drum, keeping the hoist rope tight.
• Reeve the hook block six times (à Operating instructions, chapter on Rig-
ging work, section on Hoist rope reeving).
• Raise the boom to a steep position and extend it fully.
• Wind the hoist rope out until only five turns remain on the rope drum.
H
Watch the hook block when winding out.
The hook block must not rotate!
• Reset the lowering limit switch so that it switches on after five layers have
been wound ( à Setting the lowering limit switch, p. 8 - 45).
• Reel the hoist rope in by a few turns and lower it again to check the
lowering limit switch.
When five turns are left on the rope drum, the lowering limit switch must
switch off the lowering movement.
G
57
After installing a new hoist rope, the lowering limit switch must always be
reset.
90
Setting the lower-
75
G
ing limit switch
The lowering limit switch must always be reset after repair work to the hoist
and after rope replacement. A defective lowering limit switch must always
be replaced!
40
• Reeve the hoist rope with 6 falls.

• Extend boom fully.
• Lower hook block until only five turns remain on the hoist drum.
s
14.01.2002

8.6 Hoist ropes
The lowering limit switch is located on the hoist on the left-hand side of the
turntable.
• Remove the lowering limit switch cover (1).

• Turn the adjusting screw (2) until you hear
the micro-switch activate.
• Attach the cover to the lowering limit switch
again.
Make sure that the seal fits properly.
You must check the functioning of the lower-
ing limit switch after it has been set.
57
90
Lowering limit • Raise the hook block until there are about 10 turns on the hoist drum.
switch function
• Lower the hook block again and check whether the lowering limit switch
control
is set properly.
The lowering limit switch must switch off the hoist when five rope turns are
75
still on the drum.

40
14.01.2002

8.7 Safe load indicator
8.7.1 Maintaining the slip ring assembly of the cable drum M6
Maintenance of the slip ring assembly is carried out in order to prevent

contamination and corrosion and to prevent malfunctions on the SLI.
The truck crane GMK 4075 has two cable drums whose slip ring assembly
needs to be maintained.
There is a cable drum (1) on the left side of the
main boom.
57
90
G
75
Risk of crushing due to extending or retracting the boom!

Secure the boom against unintentional movement, so that your fingers will
not be crushed by the turning slip ring unit. If you are carrying out this op-
eration with the help of someone else, communicate with the person in the
40
crane cab by means of clear hand signals.
The second cable drum (1) is located in the

main boom underneath the telescoping cylin-
der.
You can reach the cable drum through the

manhole if you first extend telescopic section I
approx. 2.0 m.
14.01.2002
s
H
The following sections describe the maintenance procedure for the outer
cable drum. Maintenance on the cable drum in the boom is carried out in
the same way.
Prerequisites Before maintenance, the following requirements must be met:
– The main boom is resting in the boom support.

– The battery master switch ist switched off; à
Operating instructions,
chapter on Diesel engine, section on Turning off diesel engine.
G
tt
Risk of damaging the safe load indicator!

Before maintenance work on the slip ring assembly, always switch off the
battery master switch so that the cable drum is currentless.
This prevents short circuits which may lead to damage to the central unit.
Maintaining slip
ring assembly
57
To lubricate the slip ring assembly, only use lubricants specified in the
90
• Make sure that the cable drum is current-
less.
• Unscrew all screws (1) and remove the
75
cover (2).
• Check the seal on the casing for damage and
replace it if necessary.
• Remove any moisture in the casing with a
40
clean, lint-free cloth.
G
Risk of damage to health with improper handling!
When using and storing the lubricant make sure you observe the informa-
14.01.2002
tion on the packaging and the enclosed safety data sheet!

• Remove visible dirt on the slip rings (2) with

a clean, lint-free cloth.
• Spray the lubricant on all slip rings (2).
• Spread the lubricant by turning the drum
several times by a half revolution.
You can turn the drum by pulling the SLI cable
in the direction of the main boom head. If you
let go of the cable, the drum turns back be-
cause of the initial tension.
• Check to make sure all screws (1) are tight.
• Wait until the solvent has evaporated
57 completely.
• Put the casing (2) back in place. Make sure
that the seal is in the right place.
• Attach the casing with all the screws (1).
90
75
40
14.01.2002

57
90
Blank page
75
40
14.01.2002

8.8 Central lubrication system

The grease container (1) is located on the right
side of the turntable above the storage com-
partment.
Only fill with special grease as specified in the

(à 57
The maintenance of the central lubrication system on the superstructure is
the same as the maintenance of the central lubrication system on the carrier
Centrallubrication system, p. 7 - 55).
90
75
40
14.01.2002

57
90
Blank page
75
40
14.01.2002

8.9 Hook blocks
8.9 Hook blocks
8.9.1 Lubrication M1
The sheaves, cross heads and axial bearing of the load hook have to be lu-
bricated on the hook block.
Use lubricating grease specified in the Maintenance plan, p. 5 - 9.
The diagram gives an example of the location

of the lubricating nipples (1), (2) and (3) on a
hook block. There are other lubricating nipples
on the other side.
• Clean the lubricating nipples on all hook

blocks supplied and on the hook tackle and
57 lubricate them with a grease gun.

90
75
40
14.01.2002

8.9 Hook blocks
57
90
Blank page
75
40
14.01.2002

8.10 Superstructure air conditioning system (additional equipment)
8.10 Superstructure air conditioning system (additional

equipment)
The GMK 4075 is equipped with only one refrigerant circuit for the air-
conditioning system on the carrier and superstructure.
For additional maintenance work, see Carrier air conditioning system (addi-
tional equipment), p. 7 - 65.
8.10.1 Checking hoses M6
• Check all refrigerant hoses for damage and worn areas.

• Only allow damaged hoses to be replaced by GROVE Customer Support.
57
90
75
40
14.01.2002

8.10 Superstructure air conditioning system (additional equipment)
57
90
Blank page
75
40
14.01.2002

8.11.1 Lubricating the counterweight hoist unit M1
Three lubricating nipples are located on both pivot bearings of the counter-
weight hoist unit.
Use only lubricating grease specified in the Maintenance plan, p. 5 - 9.
Both pivot bearings of the counterweight hoist

unit are lubricated via lubricating nipples (1).

lubricating nipples.
• Use a grease gun to apply grease to the
lubricating nipples.
57
90
75
8.11.2 Checking for correct operation of the auxiliary

heater (additional equipment) M1
40
Maintenance work is described in section Checking for correct operation of the

auxiliary heater (additional equipment), p. 7 - 75.
For additional information, see the section on Crane cabin heating and ventila-
tion, water-additional heating system (additional equipment) in the chapter on
Crane operation in the Operating instructions.
14.01.2002

57
90
Blank page
75
40
14.01.2002

9
9 Longer periods out of operation ............................. 9- 1
57
90
75
40
14.01.2002

57
90
75
40
14.01.2002

Longer periods out of operation
9 Longer periods out of operation

Carry out the following work if the truck crane is to be out of operation for a
long period (months):
Before the truck • Clean the crane thoroughly from inside and outside.
crane is put out of
• Remove rust and touch up the paintwork.
operation
• Parts which are not painted must be lubricated with an acid-free grease
or oil.
• If more than half of the oil change interval has passed:
• Change the oil in accordance with maintenance plans M 3 to M 12.
• Seal all air filters.
57
• Increase the type air pressure by 10 % and mark the tyre position or
support the truck crane on outriggers and let it stand in this position.
90
During periods • Check the levels in the fuel tanks. Always keep the tanks filled.
out of operation
• Check the batteries every week and recharge them if necessary.
• Check tyre pressure every week and inflate the tyres if necessary.
• Perform a full functional check of the truck crane every two weeks.
75
(Open all air filters in advance).

Run the hydraulic systems up to a fluid temperature of approx. 50 °C and
check all functions of the carrier and superstructure hydraulic systems.
• Ensure that the tyre positioning is different each time the crane is parked
40
(without outriggers).
• Seal all air filters again.
If the crane is out of operation for more than 12 months:
• Carry out all maintenance work in accordance with maintenance plan M 12.
s
14.01.2002

Longer periods out of operation
Before putting the • Open all air filters.

truck crane back
• Inflate the tyres up to the prescribed pressure.
into operation
• Carry out periodic maintenance work in accordance with the maintenance
plans in chapter p. 5 - 1.
57
90
75
40
14.01.2002

10
10 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 1
10.1 Tightening torques for retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 1
10.2 Special tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 2
57
90
75
40
14.01.2002

57
90
75
40
14.01.2002

Tightening torques
10.1 Tightening torques for retaining bolts
10 Tightening torques
10.1 Tightening torques for retaining bolts
Metric standard screw-thread Guiding values

Metric fine screw-thread
Tightening torques
(maximum permissible screw preload)
Spanner size (mm) for lubricated screws (Nm)
Thread size
(mm) Screw quality
Hexagon Cylinder 8.8 10.9 12.9
M8
M8x1
M 10
screw
13
17
screw
8
57 23
24
44
32
34
62
36
41
75
90
M 10 x 1.25 47 66 79
M 12 78 110 130
19 10
M 12 x 1.5 81 113 135
M 14 120 170 210
22 12
M 14 x 1.5 135 189 225
75
M 16 165 190 320

24 14
M 16 x 1.5 203 284 342
M 18 260 365 435
27 14
M 18 x 1.5 293 414 495
40
M 20 370 520 620

30 17
M 20 x 1.5 414 576 693
M 22 500 700 840
32 17
M 22 x 1.5 549 774 945
M 24 640 900 1080
36 19
M 24 x 1.5 702 990 1170
M 30 46 22 1300 1800 2160
M 33 50 24 2700
M 36 55 27 3300
14.01.2002

Tightening torques
10.2 Special tightening torques
10.2 Special tightening torques
Thread Spanner size Tightening

size (mm) torque
Description (mm) (Nm)
Hexagon Cylinder
screw screw
Suspension strut:
– Vehicle frame / guide case (upper) M 16 — 17 265
– Vehicle frame / guide case (lower) M 24 — 19 900
– Support element / steering split
M 16 — 14 265
shell
– Support element / operating head M 20 30 17 520
Gearbox
– Oil filling/inspection screw and oil
drain plug
Locking screws for steering linkage
spherical-head connection M 12 x 1.5
5719 — 70 – 80
90
Head → = 40 mm
Locking screws for steering linkage
spherical-head connection M 14 x 1.5 22 — 160 – 180
Head → = 50 mm
75
Wheel nuts M 22 x 1.5 32 — 650

Retaining bolts of
M 24 36 — 954
ball slewing connection
Rope clamp on the
40
M 10 17 — 46
hoist drum
14.01.2002

Appendix
57
90
75
40
14.01.2002

57
90
75
40
14.01.2002

Appendix
57
90
75
40
40
75
90
57
Crane model: ........................

Work number: ........................
Commissioned on: ........................
Winch serial number in accordance with model plate: ........................
Drive gear group: ........................
Load spectrum: ........................
40
Collective load factor: ........................
Theoretical service life: ........................
Inspectio Date of Operationa Collective Operating Operating Operating Operating Operating Used proportion Remaining Name of the Signature Note Name of Signature
n interval commission/ l condition load factor hours of hours of hours of the hours of the hours of the of the theoretical theoretical expert the
no. date of since the the entire the superstructu winch winch since service life: service life approved
(max. inspection last crane superstruct re since the the last inspector
1 year) inspection ure last inspection
Di = Di-1 - Si
75
inspection
“i” Kmi [h] [h] [h] [h] [h] [h] [h]
(*)
90
57
Si = Used proportion of the theoretical service life since the last inspection
CAUTION:
Di - 1=Remaining theoretical service life after the previous inspection
Km =Load spectrum factor established during winch calculation.
Alternative provision, refer to section 5.4.2, p. 5 - 22. This factor is given in the Operating Instructions.
Last general overhaul performed on ..................................
40
75
90
57
Crane model: ........................

Work number: ........................
Commissioned on: ........................
Winch serial number in accordance with model plate: ........................
Drive gear group: ........................
Load spectrum: ........................
40
Collective load factor: ........................
Theoretical service life: ........................
Inspectio Date of Operationa Collective Operating Operating Operating Operating Operating Used proportion Remaining Name of the Signature Note Name of Signature
n interval commission/ l condition load factor hours of hours of hours of the hours of the hours of the of the theoretical theoretical expert the
no. date of since the the entire the superstructu winch winch since service life: service life approved
(max. inspection last crane superstruct re since the the last inspector
1 year) inspection ure last inspection
Di = Di-1 - Si
75
inspection
“i” Kmi [h] [h] [h] [h] [h] [h] [h]
(*)
90
57
Si = Used proportion of the theoretical service life since the last inspection
CAUTION:
Di - 1=Remaining theoretical service life after the previous inspection
Km =Load spectrum factor established during winch calculation.
Alternative provision, refer to section 5.4.2, p. 5 - 22. This factor is given in the Operating Instructions.
Last general overhaul performed on ..................................
40
75
90
57
40
75
90
57
40
75
90
57

2 084 680 en 20020114 719 736 870 966

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

2 084 680 en 20020114 719 736 870 966

Uploaded by

Copyright:

Available Formats

57

Vehicle serial number: 2 084 680 en

Duplications of any kind and excerpts from

Duplications and print-outs of data carriers

© Copyright reserved by Deutsche GROVE GmbH

2 084 680 en Maintenance Manual GMK 4075

GMK maintenance manual

GMK 2035 GMK 6200-1

GMK 5100 9.2 t 7.1 t

Amendment Maintenance Manual GMK 2 084 719 en

GMK 4075 GMK 5100

– an additional weekly maintenance procedure (W)

The vent filter (1) is located on the hydraulic oil

• Check the contamination display (2) at the

• Replace the filter cartridge; à Change to the

• Press down the bleed unit housing (3) and

2 2 084 736 en Additional pages

Correction sheets Maintenance manual

Serial number: 2 084 870 en

Duplications of any kind and excerpts from this

Duplications and printouts of data carriers on

© Copyright reserved by Deutsche GROVE GmbH

2 084 870 en Correction sheets GMK truck cranes

GMK 2035 GMK 3050

Reasons for the

Correction sheets for all 2 084 870 en 1

2 2 084 870 en Correction sheets for all

Maintenance of the slip ring assembly is carried out in order to prevent

There is a cable drum (1) on the left side of the

The second cable drum (1) is located in the

You can reach the cable drum through the

Prerequisites Before maintenance, the following requirements must be met:

clean, lint-free cloth.

4 2 084 870 en Correction sheets for all

• Put the casing (2) back in place. Make sure

57 that the seal is in the right place.

Correction sheets for all 2 084 870 en 5

These additional pages describe this additional maintenance procedure

5.2.6 M 12 maintenance plan: Every 12 months / after 1000 oper. hrs.

Additional pages 2 084 966 en 1

2 Safety and environmental protection

6 Lubricants and fuels

Description of maintenance work on the superstructure

Maintenance Manual GMK 4075 2 084 680 en

2 084 680 en Maintenance Manual GMK 4075

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

Maintenance Manual GMK 4075 2 084 680 en

2 084 680 en Maintenance Manual GMK 4075

1.1 Using the maintenance manual

Please read chapters 1 and 2 carefully before beginning maintenance work.

1.2 Warnings and symbols 57

jury, risk of crushing or electrocution) generally precedes the warning sign.

Maintenance Manual GMK 4075 2 084 680 en 1-1

1.3 GROVE customer support maintenance instructions

Repair work also requires:

– appropriate workshop equipment,

It is your responsibility to maintain and service the truck crane regularly in

– prescribed care and maintenance,

1-2 2 084 680 en Maintenance Manual GMK 4075

– lack of oil, grease or antifreeze,