Maintenance Manual

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Maintenance Manual
Vehicle serial number:
2 084 643 en
02.07.2001
Important note
Duplications of any kind and excerpts from

this document are not subject to the alterations
service. Original documents of Deutsche GROVE
GmbH are marked with the blue serial number of
the truck crane on the cover page.
Copyright reserved by Deutsche GROVE GmbH

The passing on or duplication of this document as well as the use and disclosure of its contents are prohibited
unless expressly permitted. Offenders will be liable for damages. All rights pertaining to registration of patent or utility
model are reserved.
2 084 643 en
Maintenance Manual GMK 4075
02.07.2001
Duplications and print-outs of data carriers

on which Deutsche GROVE GmbH has delivered
this document are also not subject to the
alterations service.
The following chapters are contained in this

maintenance manual:
1
General instructions
Safety and environmental protection
Cleaning
Run-in regulations
Maintenance overview
Lubricants and fuels
Description of maintenance work on the carrier
Description of maintenance work on the superstructure
Longer periods out of operation
10 Tightening torques
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Appendix
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1
General instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-
1.1
Using the maintenance manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 -
1.2
Warnings and symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 -
1.3
GROVE customer support maintenance instructions . . . . . . . . . . . . . . . . . . . . . . 1 -
1.4
Definitions of stated directions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 -
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1.1 Using the maintenance manual
1.1
Using the maintenance manual

This manual is not designed to replace proper training and instruction!
Truck crane maintenance personnel are required to have relevant specialised knowledge of proper safety procedures!
Please read chapters 1 and 2 carefully before beginning maintenance work.
H
1.2
Maintenance work on the lattice extensions is described in the operating instructions for lattice extensions.
Warnings and symbols

The following definitions and symbols are used in the operating instructions to highlight particularly important information:
G
S
O
This symbol indicates hazards related to the operation described that may
cause personal injury. The type of hazard (e.g. life-threatening, personal injury, risk of crushing or electrocution) generally precedes the warning sign.
Here dangers which could put objects at risk are pointed out, e.g. damage
to the truck crane or the load.
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 indicated next to the symbol. You will find more detailed information in the section
Handling substances which are harmful to the environment, S. 2 - 2.
The vertical line to the left of the text indicates that this text, regardless of
its length, relates to the warning symbol.
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1-1
1.3 GROVE customer support maintenance instructions
H
s
1.3
The hand with the pointing finger indicates passages that contain additional
instructions and tips with regard to truck crane operation.
This symbol indicates that the topic is continued on the next page. Turn to
the next page.
GROVE customer support maintenance instructions

This Maintenance Manual is intended for maintenance personnel. The maintenance manual does not contain information on repair work. Repair work
may only be carried out by qualified repair personnel (e.g. the local GROVE
Customer Support).
Repair work also requires:
appropriate workshop equipment,
special tools and
replacement parts authorized by Deutsche GROVE GmbH.
It is your responsibility to maintain and service the truck crane regularly in
order to lengthen its service life and keep it in good working order.
Please note that Deutsche GROVE GmbH can only uphold the warranty provided for the truck crane if the following conditions are met:
proper use,
prescribed care and maintenance,
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professional repair work / overhauling.
1-2
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1.3 GROVE customer support maintenance instructions
Numerous defects and failures are caused by improper maintenance such as:
lack of oil, grease or antifreeze,
dirt,
rope damage,
defective compressed air and hydraulic systems,
hose damage or loose screw connections,
defective brakes,
defective tyres or wheel rims,
exceeded maintenance intervals.
For your safety and the safety of others, avoid these errors by carrying out
maintenance work carefully within the specified intervals. Do not put off
maintenance work that is due. Notify either your local GROVE Customer
Support or your qualified repair personnel immediately should repair work
become necessary. This work may only be carried out by trained, qualified
personnel.
A few general maintenance instructions:
Clean the parts of the truck crane that are to be serviced, particularly the
area around oil filler, inspection, and drain openings and lubricating nipples.
When changing the oil, let the oil run out at operating temperature.
Ensure that only oils and lubricants specified in the Lubrication chart,
Chapter 6 are used.
Replace all filters within the specified period if cleaning is not explicitly permitted.
Replace all seals before assembly. Clean the sealing surfaces.

Only tighten loose screw connections on hydraulic systems when the system 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 hydraulic

oil must be filtered.
Check fastening and retaining elements (screws, nuts, lock washers) be02.07.2001
fore re-using them and replace them if necessary.

Tightening torques may be found in sections 10 - 1 and 1 0 -2.
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1-3
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.
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On the superstructure front always refers to the direction of the main boom
head, regardless of the superstructure position. The terms rear, right and left
are used in relation to the definition of the term "front" on the superstructure.
1-4
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2
....................... 2-
2.1
Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -
2.2
Handling substances which are harmful to the environment. . . . . . . . . . . . . . . . 2 -
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2.1 Safety rules
2
2.1
Safety rules
When carrying out maintenance work, it is imperative that you observe the applicable accident prevention regulations.
The following instructions are general safety rules for maintenance personnel:
Familiarize yourself with the truck crane and its operation.

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

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 moving 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. Remember 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 inflammable fluids.
Observe the applicable safety regulations when working with process materials.
Disconnect the earthing terminal and switch off all electrical consumers
before removing any batteries.
Keep the corroding effect of battery acid in mind.

Note the fire alarm and fire fighting facilities on the site.
Return the truck crane to proper working order once maintenance work is
completed. Inform the crane operator accordingly.
2.2
What do environmentally harmful

substances include?
Handling substances which are harmful to the

environment
When you carry out maintenance work on the truck crane you will occasionally work with substances which are considered to be harmful to the environment according to the current national and local regulations.
This includes, amongst others, oil, fuel, grease, used oil and fuel filters as
well as cloths which have come into contact with these environmentally
harmful substances.
When handling these substances observe the current national and re02.07.2001
gional regulations as well as the instructions in this chapter.
2-2
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Use suitable
equipment
Substances harmful to the environment can be corrosive. Therefore only

use containers, hoses, pumps, funnels etc. which are resistant to the respective substance.
Filling and
draining
When filling and draining, make absolutely sure that no substances harmful to the environment seep into the earth, escape into the sewage system
or polute natural waters.
Collect draining oil in a suitable container.

Always use a drain hose when draining, a funnel or a filling pump and
hose suitable for the respective substance when filling.
Collect and store

separately
Substances which are environmentally harmful should always be collected

separately from other waste.
Also collect the environmentally harmful substances divided according to

solid materials (e.g. filter elements) and liquids. Disposal costs will be reduced if you collect liquids separately according to certain categories.
Ask your local environmental protection authority about the different

categories for the substances.
Only store environmentally harmful substances in approved containers

and in locations which meet the regulations according to the current national and regional regulations.
Disposal
Ask your local environmental protection authority about the prescribed

disposal possibilities.
Only have collected environmentally harmful substances disposed of by
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disposal companies which are approved by the national or regional authority responsible.
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2-3

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Blank page
2-4
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3
Cleaning
........................................................ 3-
3.1
Overview of the components that are easily damaged when cleaning. . . . . . . . 3 -
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Cleaning
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 period.
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.
Risk of accidents from misdirected high pressure water jet!
When working with high-pressure and steam jet cleaners, the water jet will
be deflected by crane parts and could spray into your face and eyes at great
speed and high pressure.
Always wear a face guard when cleaning the truck crane with high-pressure
and steam-jet cleaning equipment.
Never point the nozzle at electrical equipment, relay and control boxes,
suction and venting filters or control elements and lubricated surfaces.
The components specified in section 3 - 2 are to be cleaned with particular
care.
After cleaning with a high-pressure device or a steam jet device, activate

an intermediate lubrication at the centralized lubrication system
(
Centrallubrication system, S. 7 - 56). Lubricate all remaining lubrication
points with a grease gun.
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3-1
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
3-2
Lowering limit switch
SLI length and angle

measuring unit
Suspension cylinders (on both

sides of the truck crane)
Angle sensor control box
SLI connecting box
Pressure sensors
Lifting limit switch
10
Switch box pressure sensor
Telescope slide faces
11
Proximity switch for

swing-away lattice extension
Air-conditioning system
capacitor
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4
Run-in regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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4-
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Run-in regulations
Run-in regulations
Special running-in instructions must be observed for individual components (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
hours (oh)
Travelled
km
Additional maintenance work on the

CARRIER
after 50
Tighten wheel nuts

Special tightening torques, S. 10 - 2)
(
after 150
Tighten wheel nuts

(
Special tightening torques, S. 10 - 2)
after 20; 1)
Carryout the first oil change in the transfer

case;
Distributor gearbox oil change,
S. 7 - 22.
after 50
Tighten hose clamps on all coolant hoses

Special tightening torques, S. 10 - 2).
(
during the
first 100
Changing the hydraulic oil filters and cleaning
Check the hydraulic oil filters weekly;
the magnetic rod, S. 7 - 46.
1)
1 oh corresponds to approx. 40 kilometers driven
Please note the instructions concerning run-in times / run-in regulations / oil
change intervals in the enclosed operating manual of the engine manufacturer and in the crane diesel engine maintenance booklet.
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2 084 643 en
4-1
Run-in regulations
Operation
hours (oh)
Travelled
km
Additional maintenance work on the

SUPERSTRUCTURE
during the
first 100
Check the hydraulic oil filters weekly;

Replacing the hydraulic oil filter, S. 8 - 21.
after 100
Check tightness of retaining bolts; tightening

Special tightening torques, S. 10 - 2.
torque;
after 200
Carry out first oil change on hoist gears

(auxiliary hoist only with additional
equipment);
Hoisting gear oil change,
S. 8 - 5.
after 200
Carry out first oil change in slewing gear

Slewing gear oil change,
transmission;
S. 8 - 11.
after10001)
Carry out second oil change on hoist gears

(auxiliary hoist only with additional
equipment);
Hoisting gear oil change,
S. 8 - 5.
Please note the instructions concerning run-in times / run-in regulations / oil
change intervals in the enclosed operating manual of the engine manufacturer and in the crane diesel engine maintenance booklet.
after 1000 operating hours, after 12 months at the latest
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1)
4-2
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5
5
Maintenance overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-
5.1
Maintenance intervals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 -
5.2
Maintenance plans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 -
Maintenance plan D: daily / before start-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance plan W: weekly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance plan M 1: monthly / after 100 oh /
approx. 2 000 km . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance plan M 3: every 3 months / after 300 oh /
5 000 6 000 km. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 000 12 500 km . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance plan M 12: every 12 months / after 1 000 oh /
20 000 25 000 km . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance and inspection plan Y 2:
every 24 months / after 100 000 125 000 km. . . . . . . . . . . . . . . . . . . . . . . . . . .
every 36 months / after 3 000 oh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
every 72 months / after 6 000 oh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
55-
5
6
5-
5.2.1
5.2.2
5.2.3
5.2.4
5.2.5
5.2.6
5.2.7
5.2.8
5.2.9
5.3
5.3.1
5.4
5 - 12
5 - 14
5 - 16
5 - 17
5 - 18
Periodic inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 19
Load hook inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 20
Measures required for winch monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 21
Theoretical service life. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 21
Proportion of the theoretical service life used. . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 22
Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 26
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5.4.1
5.4.2
5.4.3
5 - 10
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5.1 Maintenance intervals
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 Y 2 (= every 24 months) to Y 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.
In the tables you are directed by cross references to the sections in which
the appropriate maintenance work is described. The cross references consist of the chapter number and the corresponding page number, e.g.
Checking hydraulic oil level;
p. 7 - 43.
Checking the hydraulic oil level is described in Chapter7, the section starts
on page 7 - 43.
5.1
Maintenance intervals
The length of the interval depends on the operating conditions of the truck
crane:
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 carrier) components with crane functions.
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s
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5-1
5.1 Maintenance intervals
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 simultaneously the total working hours of the superstructure.
The following table sets out the maintenance intervals for the maintenance
plans:
Maintenance Maintenance
plans
interval
Km travelled
(carrier)
Diesel engine operating hours (oh)

(superstructure)
daily / before startup
weekly
M1
monthly
approx. 2000
100
M3
three monthly
5 000 6 000
300
M6
every six months
10 000 12 500
500
M 12
every twelve
months
20 000 25 000
1 000
Y2
every twenty four

months
100 000 125 000
Y3
every thirty six

months
3 000
Y6
every seventy two

months
6 000
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Please note that the long-term maintenance plans always include the
short-term ones!
5-2
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5.2 Maintenance plans
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 superstructure (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
comprehension.
The description of some daily (D) and weekly (W) checks (preventive maintenance) can also be found in part in the Operating Instructions.
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
the oil level indicators) or
the number of existing lubrication points.
The designations of the oils / lubricants in accordance with the table of lubricants,
p. 6 - 1.
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Please note that this Maintenance Manual contains only some of the maintenance 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.
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5-3
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Blank page
5-4
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5.2.1
Maintenance plan D: daily / before start-up
D
Maintenance work on the CARRIER:
Oil / lubricant
Quantity (l) /
Number
Designation
p. 6 - 1
Diesel engine
p. 7 - 6.
Checking refrigerant level; p. 7 - 8.
Checking the dry air filter; p. 7 - 9.
Check the oil level;
Wheels
Check tyres for damage and sufficient tread depth;
p. 7 - 33.
Carrier hydraulic system

Checking hydraulic oil level;
p. 7 - 43.
G2
Check contamination display for hydraulic oil filter;

p. 7 - 46.
Carrier electrical system

Check lighting and indicators
D
Maintenance work on the SUPERSTRUCTURE:
Oil / lubricant
Quantity (l) /
Number
Slewing gear
Slewing gear brake function check;
Designation
p. 6 - 1
p. 8 - 13.
Hoist ropes
Check the overall condition and position of sheaves and rope
drums;
p. 8 - 29.
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5-5
5.2.2
Maintenance plan W: weekly
W
Oil / lubricant
Quantity (l) /
Number
Diesel engine
Checking the overall condition and tightness;
Gearbox
Distributor gearbox
Axle lines
Wheels
Check the tyre pressure;
Steering
Check tightness;
Designation
p. 6 - 1
p. 7 - 10.
p. 7 - 17.
p. 7 - 21 .
p. 7 - 23.
p. 7 - 34.
p. 7 - 39.
Carrier compressed air system (incl. brake system)

Drain compressed air system;
Check tightness;
p. 7 - 41.

Check hydraulic hoses;
p. 7 - 41.
p. 7 - 44.
Check tightness (suspension, steering and outrigger systems)

p. 7 - 45.
while engine is running;
Carrier central lubrication system

Check the level of the fuel tank;
p. 7 - 56.
Other maintenance checks
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Check the function of the windscreen washing system of the operator's cab and the level of fluid in the supply reservoir.
5-6
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W
Oil / lubricant
Quantity (l) /
Number
Designation
p. 6 - 1
Main hoist / auxiliary hoist (additional equipment)
p. 8 - 3.
Check tightness; p. 8 - 4.
Check hoist brake; p. 8 - 4.
Lubricating the hoist gears; p. 8 - 5.
E6
Slewing gear
p. 8 - 9.
Check the slewing brake oil level; p. 8 - 9.
Check tightness; p. 8 - 10.
Check the slewing gear oil level;
E6
E5
Superstructure hydraulic system

Check hydraulic hoses;
p. 8 - 15.
Check for leaks with the engine running;
p. 8 - 15.
Central lubrication system superstructure

Check the level of the fuel tank;
Hoist ropes
Check the condition;
p. 8 - 45.
p. 8 - 30.
Other maintenance checks
02.07.2001
Check the function of the windscreen washing system of the crane

operator's cab and the level of fluid in the supply reservoir.
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5-7
5.2.3
Maintenance plan M 1: monthly / after 100 oh /

approx. 2 000 km
M1
monthly / after approx. 2 000 km
Oil / lubricant
Quantity (l) /
Number
Designation
p. 6 - 1
Diesel engine
Details in the Diesel Engine Operating Instructions and in the
Diesel Engine Maintenance Booklet. Special notes for the maintenance group and for rapeseed oil operation;
p. 7 - 5.
Distributor gearbox
p. 7 - 21.
E3
Axle lines
p. 7 - 23.
Axle centre drive check oil level;

Final drive check oil level;
p. 7 - 27.
E3
p. 7 - 29.
Lubricate universal joint shaft of the axle line;

with additional equipment with 8 x 8 x 8 drive.
Wheels
E3
12
14
K
K
Check tightness of wheel nuts;

p. 7 - 38.
Tightening torque;
Suspension
Check oil level in the suspension cylinders;
p. 7 - 37.
Check retaining bolts of the suspension cylinders;

Tightening torque;

Checking the acid level in the batteries;
p. 7 - 63.
Trailer coupling (additional equipment)

Lubricating the trailer coupling;2)
p. 7 - 69.
div.
J/M
Carrier air conditioning system (additional equipment)

Checking the moisture and level of the refrigerant;
Cleaning capacitor disks;
p. 7 - 66.
p. 7 - 65.
Other maintenance work
Lubricating the outrigger beam1);
p. 7 - 75.
Lubricate door hinges.

Lubricate retaining and socket
1)
2)
5-8
pins.1)
after 100 oh
lubricate the trailer coupling after every high pressure cleaning.
2 084 643 en
02.07.2001
Checking for correct operation of the auxiliary heater (additional equipment);

p. 7 - 75.
M1
monthly / after 100 oh
Switch coupling
Switch coupling check oil level;
Hook blocks
Lubricate;
Oil / lubricant
Quantity (l) /
Number
p. 8 - 1.
p. 8 - 47.
Designation
p. 6 - 1
G5
div.
Lubricate tread rollers of cab door.
Lubricate retaining and socket pins.
div.
J/M
Lubricate spring latch.
div.
J/M
p. 8 - 18.
Bleeding the derricking cylinder; p. 8 - 16.
Bleeding telescoping cylinders;

Lubricating the counterweight hoist unit;
p. 8 - 53.
Checking for correct operation of the auxiliary heater (addip. 8 - 53.

tional equipment);
02.07.2001
2 084 643 en
5-9
5.2.4

5 000 6 000 km
M3
every 3 months / after 5 000 6 000 km
Oil / lubricant
Quantity (l) /
Number
Designation
p. 6 - 1
Diesel engine
Pay attention to the details in the Diesel Engine Operating Instructions and Maintenance Manual.
Special notes for the maintenance group and for rapeseed oil
p. 7 - 5.
operation;
Clean fuel prefilter-screen;
p. 7 - 11.
Wheels
Checking wheel-bearing clearance;
Vehicle brakes
Check brake-lining thickness;
p. 7 - 34.
p. 7 - 35.

Change the hydraulic oil filter, check the magnetic rods of the
hydraulic oil filter for metal particles1);
p. 7 - 46.

Check acid concentration of batteries;
p. 7 - 64.
p. 7 - 70.
Checking the cotter pin; p. 7 - 71.
Checking the lower bushing; p. 7 - 72.
Checking the bearing;
Checking the initial tension of the springs;
p. 7 - 73.
Checking the function of the coupling jaw / Resetting

p. 7 - 73.
the middle position;
p. 7 - 72.
02.07.2001
Checking the support ring;
5 - 10
2 084 643 en
M3
every 3 months / after 300 oh
Superstructure electrical system
Check acid concentration of batteries;
Oil / lubricant
Quantity (l) /
Number
Designation
p. 6 - 1
p. 8 - 49.
Ball slewing connection

Check tightness of retaining bolts;
Tightening torque;
after 300 oh
02.07.2001
1)
2 084 643 en
5 - 11
5.2.5

10 000 12 500 km
M6
Oil / lubricant
Quantity (l) /
Number
Designation
p. 6 - 1
9.5
E3
8
10
K
K
Diesel engine
Pay attention to the details in the Diesel Engine Operating Instructions and Maintenance Manual.
p. 7 - 5.
operation;
Distributor gearbox
Changing the oil;
p. 7 - 22.
Axle lines
Lubricating the longitudinal cardan shafts between the gear
units.
p. 7 - 31.
for8 x 6 x 8 drive;
p. 7 - 31.
for8 x 8 x 8 drive (additional equipment);
Steering
Check tightness of screw connections and that the locking pin
has been fitted.
Check all track rods and drag links for play.
Check rubber sleeves for damage.
Checking hoses;
p. 7 - 67.
p. 7 - 68.
02.07.2001
Checking the refrigerant compressor control;
5 - 12
2 084 643 en
M6
Slewing gears
Lubricating the slewing gear pinion;
Ball slewing connection
Lubricate the gear rim;
Oil / lubricant
p. 8 - 10.
p. 8 - 10.
Main boom
Lubricate telescopic slide faces;
p. 8 - 23.
Quantity (l) /
Number
Designation
p. 6 - 1
1 each
16
L2
Superstructure air conditioning system (additional equipment)

Checking hoses;
p. 8 - 51.
SLI
p. 8 - 41.
02.07.2001
Maintain the slip ring assembly in the cable drums;
2 084 643 en
5 - 13
5.2.6
Maintenance plan M 12: every 12 months / after 1 000 oh /

20 000 25 000 km
M 12
Oil / lubricant
Quantity (l) /
Number
Designation
p. 6 - 1
Diesel engine
Pay attention to the details in the Diesel Engine Operating
Instructions and Maintenance Manual.
p. 7 - 5.
operation;
Replacing the fuel filter elements;

Gearbox
p. 7 - 13.
p. 7 - 19.
Axle lines
F4
Axle centre drives oil change;

p. 7 - 25.
1st axle line
2nd axle line (only for additional equipment with 8 x 8 x 8 drive)
3rd axle line
4th axle line
Final drive oil change;
p. 7 - 28.
13.0
15.0
16.5
13.0
E3
E3
E3
E3
4.1 each
E3
660.0
G2
Carrier compressed air system

Replacing the granulate cartridge of the compressed air dryer;
p. 7 - 42

Have suspension system pressure accumulators checked by the
local GROVE Customer Support or by an authorized workshop.1)
Replacing the vent filter for the hydraulic oil tank2);
p. 7 - 49.
Oil change1);
p. 7 - 50).
p. 7 - 52, (depending on results of oil test,

Monitoring the entire air conditioning system;
2)
5 - 14
every 3 000 oh, however at the latest every 12 months

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
change must already take place after 500 operating hours.
If working in tropical or very hot countries, the oil change
intervals must be halved.
2 084 643 en
02.07.2001
1)
p. 7 - 68.
M 12
Switch coupling
Switch coupling oil change;
Oil / lubricant
p. 8 - 2.
Quantity (l) /
Number
Designation
p. 6 - 1
Approx. 0.25
G5
10.0
E6
0.9 each
E6
Approx. 1.0
E5
p. 8 - 5
Oil change1);
p. 8 - 7.
Checking the old oil;
Slewing gears
p. 8 - 11.
Slewing brake oil change; p. 8 - 12.
Slewing gear oil change;
Superstructure air conditioning system (additional equipment)

Monitoring the entire air conditioning system;
Carry out at least once a year
02.07.2001
1)
p. 7 - 68.
2 084 643 en
5 - 15
5.2.7

every 24 months / after 100 00 0 125 000 km
Y2
every 24 months
Gearbox
Changing the oil and oil filter,
Oil / lubricant
p. 7 - 19.
Quantity (l) /
Number
Designation
p. 6 - 1
11.0
F4
Y2
every 24 months
Oil / lubricant
Quantity (l) /
Number
Designation
p. 6 - 1
No maintenance work in this period.
02.07.2001
The long-term intervals always include the short-term intervals

include short-term intervals.
5 - 16
2 084 643 en
5.2.8

Y3
every 36 months
Oil / lubricant
Quantity (l) /
Number
Designation
p. 6 - 1

The long-term intervals always include the short-term intervals
include short-term intervals.
Y3
Oil / lubricant
Quantity (l) /
Number
Designation
p. 6 - 1
p. 8 - 8.
02.07.2001
Carry out partial inspection;
2 084 643 en
5 - 17
5.2.9

every 72 months / after 6 000 oh
Y6
every 72 months
Oil / lubricant
Quantity (l) /
Number
Designation
p. 6 - 1

The long-term intervals always include the short-term intervals.
Y6
Oil / lubricant
Quantity (l) /
Number
Designation
p. 6 - 1
p. 8 - 8.
p. 5 - 21.
02.07.2001
Carry out general inspection;
5 - 18
2 084 643 en
5.3 Periodic inspections
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 intervals. If such regulations do not exist, an inspection should be carried out by
an expert at least once a year.
These periodic inspections are generally visual inspections intended to assess 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
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,
the hoist ropes,
Load hook inspection, S. 5 - 20),
load hooks (
the load-bearing structural steelwork (for tears, deformation, etc.), including a special check of all welds.
If damage is found in the structural steelwork, have qualified specialists determine the extent of the damage using the required material examination
methods. They should then determine what sort of repair action could be
done.
02.07.2001
The inspector is to write a record containing the result of the annual inspection and the measures taken to repair any damages.
2 084 643 en
5 - 19
5.3 Periodic inspections
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 original 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 initial dimension.
The load hook must consequently be replaced.
02.07.2001
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!
5 - 20
2 084 643 en
5.4 Measures required for winch monitoring
5.4
Measures required for winch monitoring
H
5.4.1
Also observe the information on the general inspection of the hoists;

p. 8 - 8.
Measures required for winch monitoring (hoists) were drawn up by the

VDMA and apply to all vehicle cranes in accordance with the Accident prevention regulations for winches, hoists and towing devices BGV D 8 (VBG 8).
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 calculating and dimensioning the winches of your crane.
The winches of your crane are classified as follows (ISO 4301/1, FEM 1.001,
DIN calculation rules for power units):
Power unit group:
Load spectrum:
Load spectrum factor:
Theoretical service life:
......
.....; (L.....)
=......
=......
The power unit group M 3 and the collective load L1 (Km = 0.125) are generally given for truck cranes in erection mode, resulting in a theoretical service life of 3200 h.
The theoretical service life is not the same as the real (actual) service life of
a winch.
02.07.2001
M
Q
Km
D
2 084 643 en
5 - 21
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.
7. Improper adjustment of safety devices.
8. Concealed damage caused by accidents.
9. Extreme environmental
conditions:
5.4.2
low or high temperatures,

aggressive atmosphere,
dust and dirt.
Proportion of the theoretical service life used

The crane operator is obliged to perform a crane inspection at least once a
year (ISO 9927-1 and BG V D8 (V B G8)).
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.
02.07.2001
The actual operating conditions (load spectrum) and the operating hours of
the hoists are to be determined for each inspection interval when establishing the proportion of the theoretical service life that has been used. The operator is responsible for proper documentation in the crane logbook.
5 - 22
2 084 643 en
Determining the
operating conditions (collective
load)
Collective
load
Class
light
Q1
L1
The collective load of the crane is divided into groups:

(also refer to ISO 4301/1, FEM 1.001)
Term designation
Working time proportion
Power units or their parts,

which are subjected to highest
load as an exception,
continuously however only
very less load
10 % of the operating time

with highest load (dead load
+ 1/1 payload)
with dead load + 1/3
payload
Collective
load factor
Km =
Graphic representation
0.125

only with dead load
which are very often subjected
to highest load, however
continuously less load
subjected to load
medium
Q2
L2
1/6 of the operating time

+ 1/1 payload)
with dead load +2/3
payload)
0.25

with dead load +1/3
payload)
only with dead load
heavy
Q3
L3
02.07.2001
very heavy
Q4
L4

which are frequently
subjected to highest load and
continuously to medium load

+ 1/1 payload)
only with dead load

which are regularly subjected
to loads close to maximum
loads.
0.5

+ 1/1 payload)
only with dead load
One of the load spectrums listed above is to be selected on the basis of the
actual operating conditions and entered in the crane logbook for the respective inspection 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.
2 084 643 en
5 - 23
Determining the
actual operating
hours Ti
The effective operating hours, determined as follows, must be entered into

the crane log book for the corresponding inspection interval.
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 superstructure operating hours must be estimated.
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
and are shown on a display (
Operating Instructions, Chapter Crane Operation, Section Crane work with main boom).
Operating hour counter for driving and crane operation together

The proportion of winch operating hours in relation to the total crane operating hours is to be estimated.
02.07.2001
It can generally be assumed that the percentage of superstructure operating

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 assumed to be 2 0% in relation to superstructure operating hours
(
Operating hour counter is functional for entire crane operation ), the percentage in relation to the total operating hours of the crane will be: 1 2%.
5 - 24
2 084 643 en
Determining the
proportion of the
theoretical service life used
For an inspection interval i (max. 1 year according to ISO 9927-1 or BGV D 8

(VBG 8)), the proportion of the theoretical service life used Si is calculated
using the formula:
Km
S i = -----------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"
This used proportion is subtracted from the remaining theoretical service
life Di after every inspection interval (see example in the appendix to this
chapter).
A general overhaul must be performed on the winch if the remaining theoretical service life is not likely to be sufficient for the next operating period.
If the theoretical service life D has been reached (

Theoretical service life,
S. 5 - 21), the winch must not be operated until after a general overhaul has
been performed.
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
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.
02.07.2001
The next general overhaul must be performed within 10 years.
2 084 643 en
5 - 25
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 Instructions as follows:
Power unit group:
M3
Load spectrum:
light L 1, Km = 0.125
D = 3200 h
The used proportion S of the theoretical service life is calculated over the individual inspection intervals as follows:
1. Inspection (first year)

The crane was used for assembly work during the previous year: Collective
load L 1, i.e. Km1 = 0.125.
The superstructure operating hour counter reads 800 h. The winch was operated 20 % of the time, i.e. T1 = 160 h.
The used proportion S1 of the theoretical service life after the first inspection
is therefore:
0.125
S i = --------------- 160 h = 160 h
0.125
Remaining theoretical service life:
D1 = 3200 h 160 h = 3040 h.

The aforementioned values are entered in the table (see example table
5 - 28).
2. Inspection (second year)
The superstructure operating hour counter reads 2000 h, i.e. during this period: 2000 h 800 h = 1200 h (800 h were used during the first year).
The winch was operated 40 % of the time, i.e. T2 = 480 h.
5 - 26
2 084 643 en
02.07.2001
The crane was used for unloading work on docks: Load spectrum: L 3, i.e.
Km2 = 0.5.
The used proportion S2 of the theoretical service life after the second inspection interval is therefore:
0.5
S i = --------------- 480 h = 1120 h
0.125
D2 = 3040 h 1920 h = 1120 h.

5 - 28).
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.
Three thousand hours are read at the superstructure working hour meter;
i.e., during this period:
3.000 h 2.000 h = 1.000 h (2.000 h are used in the first two years of
operation).
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 inspection interval is therefore:
0.25
S i = --------------- 300 h = 600 h
0.125
D3 = 1120 h 600 h = 520 h.

5 - 28).
02.07.2001
The remaining theoretical service life is to be documented in a separate table 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
logbook or similar documentation according to the regulations of the respective country.
2 084 643 en
5 - 27
02.07.2001
Example table to
determine the remaining theoretical
service life of
winch no. 1 (main
hoist winch)
5 - 28
2 084 643 en
6
6
Lubricants and fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-
6.1
Lubricant table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 -
6.2
Process materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 -
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine coolant admixtures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Windscreen washing system admixtures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel for crane cab heating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
3
3
3
02.07.2001
6.2.1
6.2.2
6.2.3
6.2.4
2 084 643 en
6666-
02.07.2001
2 084 643 en

6.1 Lubricant table
6.1
Lubricant table
Name
Lubricating
point
Diesel engine
E3
Axle center
drive
E5
E6
3)
Slewing gear
brake
Type of
lubrication
Lubricant
type
Viscosity
range
HD - CD
MIL-L 2104 C
DB 228.5
1)
C - LPF
MIL-L 2105 B
API-GL-5
SAE 90
ISO - VG 220
GROVE part no. 1 930 6702)
C - LPF
Hoist
Oil quantity
F4
Gearbox
Circulatory
lubrication
G2
Hydraulic
system
G5
Switch
coupling
Suspension cylinder
Lubricating
points (lubricating grease)
Roller bearing
L2
Slideways
H-LP
Oil quantity
1) See
MIL-L 2105 B
API-GL-4/5
SAE 75 W-90
ISO - VG 220
MIL - L2105
API-GL-4
TE-ML 02L
SAE 75 W-80W3)
DIN 51524 T.2
ISO - VG 32
API-GL-4 plus
SAE 75 W-903)
GROVE part no. 23108632)

Grease gun and
manually
For repairs,
grease when
installing
K - L2K
DIN 51825
KP - L2K
DIN 51825
engine operating instructions
2) Available
02.07.2001
Specification
Classification
Circulatory
lubrication
Slewing gear
Gearbox
3)
Name
according to
DIN 51502
from local GROVE Customer Support
Synthetic oil filled at the factory; do not mix with mineral oil.
2 084 643 en
s
6-1

6.1 Lubricant table
Name
Lubricating
point
Type of
lubrication
Lubricating
Oil can,
points (lubricat- high pressure jet
ing oil)
oil can
Open-running
gear wheels
Mounting
screws, bushings, etc.
Slip ring
assembly
Specification
Classification
Lubricant
type
Viscosity
range
as A (Diesel
engine)
Adhesive lubrication
Corrosion protection

Available from local GROVE Customer Support
02.07.2001
2)
Name
according to
DIN 51502
6-2
2 084 643 en

6.2 Process materials
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 operating manual.
6.2.3
Windscreen washing system admixtures

Commercial cleansers and antifreeze may be added to the windscreen
washing water. Observe the application instructions on the package.
6.2.4
Fuel for crane cab heating system
02.07.2001
You should use either the fuel specified in section 6.2.1 or EL heating oil as
heating fuel for the crane cab.
2 084 643 en
6-3

6.2 Process materials
02.07.2001
Blank page
6-4
2 084 643 en
7
7
........... 7-
7.1
Tilt driver's cab forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 -
7.2
Diesel engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 -
7.2.1
7.2.2
7.2.3
7.2.4
7.2.5
7.2.6
7.2.7
7.3
7.3.1
7.3.2
7.3.3
7.4
7.4.1
7.4.2
7.4.3
7.5
7.5.1
7.5.2
7.5.3
7.5.4
7.5.5
7.5.6
7.5.7
7.6
7.6.1
7.6.2
7.6.3
7.7
7.7.1
7.8
02.07.2001
7.8.1
7.8.2
7.9
7.9.1
Diesel engine oil level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Diesel engine oil topping up oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking coolant level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking the dry air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking general condition and for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning the fuel prefilter screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing the fuel filter cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7- 6
7- 7
7- 8
7- 9
7 - 10
7 - 11
7 - 13
Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 17
Checking general condition and for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 17
Gearbox oil level check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 18
Gear box oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 19
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
Axle lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 23
Checking general condition and for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Axle centre drives oil level check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Axle centre drives oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Final drives oil level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Final drives oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubricating the cardan shafts on the axle lines. . . . . . . . . . . . . . . . . . . . . . . . . .
Longitudinal cardan shafts between the gear units lubricate . . . . . . . . . . . . . .
7777777-
23
23
25
27
28
29
31
Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 33
Checking the tyres for damage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 33
Check the tyre pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 34
Checking the wheel-bearing clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 34
Vehicle brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 35
Checking brake-lining thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 35
Suspension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 37
Telescopic leg oil level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 37
Tightness of retaining bolts on the suspension cylinders to be checked . . . . . 7 - 38
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 39
Checking for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 39
2 084 643 en
7.10.1
7.10.2
7.10.3
7.11
7.11.1
7.11.2
7.11.3
7.11.4
7.11.5
7.11.6
7.11.7
7.12
7.12.1
7.12.2
7.12.3
7.13
7.13.1
7.13.2
7.14
7.14.1
7.14.2
7.14.3
7.14.4
7.14.5
7.14.6
7.15
7.15.1
7.15.2
7.15.3
7.15.4
7.15.5
7.15.6
7.15.7
7.16
7.16.1
7.16.2
Carrier compressed air system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 41

Draining the compressed air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 41
Compressed air system check for leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 41
Replacing the granulate cartridge of the compressed air dryer . . . . . . . . . . . . 7 - 42
Carrier hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 43
Hydraulic unit oil level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking the hydraulic hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing the hydraulic oil filters and cleaning the magnetic rod . . . . . . . . . . .
Replacing the venting filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Taking hydraulic oil samples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing the hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7777777-
43
44
45
46
49
50
52
Centrallubrication system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 55
Central lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 55
Version 1 Checking the level of the grease container and topping up . . . . . . 7 - 56
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
Carrier air conditioning system (additional equipment) . . . . . . . . . . . . . . . . . . . . 7 - 65
Checking the moisture and level of the refrigerant. . . . . . . . . . . . . . . . . . . . . . .
Cleaning capacitor disks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking the refrigerant compressor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking the refrigerant compressor control . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking the entire air conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . .
777777-
65
66
67
67
68
68
Trailer coupling (additional equipment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 69

Lubricating the trailer coupling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking the bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking the cotter pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking the lower bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking the support ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking the initial tension of the springs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking the function of the coupling jaw / re-adjusting the middle position .
7777777-
69
70
71
72
72
73
73
Other maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 75

Lubricating the outrigger beams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 75
Checking for correct operation of the auxiliary heater (additional equipment) 7 - 75
2 084 643 en
02.07.2001
7.10

7.1 Tilt driver's cab forward
7.1
Tilt driver's cab forward

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
Prerequisites and
information on
tilting
If the diesel engine cannot be started, the boom must be raised using the
emergency operation facility;
Operating instructions GMK 4075, Carrier operation malfunctions, Emergency operation for lifting the main boom.
Before tilting the driver's cab the following requirements must be met:
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)
when tilting.
Ensure that the hook block is at a sufficient distance from the windscreen
when tilting.
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.
Unlock the driver's cab mechanically and attach to suitable hoist gear for
tilting.
02.07.2001
s
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7-1

Unlocking /
locking the
driver's cab
Unlock the driver's cab before tilting it forward. Lock the driver's cab again
once you have brought it back to its initial position.
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
Observe the prerequisites stated at the beginning of section

Prerequisites
and information on tilting, S. 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).
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
cab.
This prevents liquids from getting into the inserts and doors from swinging
open during tilting and injuring people.
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.
02.07.2001
G
G
Remove all loose objects from the driver's cab and close the doors.
7-2
2 084 643 en

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
suitable lifting gear.
Ensure that the angle A is always larger than

45 when lifting.
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
pulled under tension.
02.07.2001
In this position the spring latch engages (1)

(handle points downwards) and secures the
driver's cab against unintentional tilting backwards.
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 tightened the wire rope between driver's cab and vehicle chassis.
s
2 084 643 en
7-3

Lowering the
driver's cab
Before lowering the driver's cab, you must unlock the support.
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 securing 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 support is pushed in and the stop (3) turns the
handle on the spring latch back to the correct
position for locking when the cab is next tilted.
Remove the two ropes (1) from the ring

bolts.
Screw the ring bolts (2) out of the threaded

bores.
Store the ring bolts and the ropes safely,

ready for driving.
Lock the driver's cab with the two bolts;
G
7-4
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
lowered it. This prevents the driver's cab from tilting forward (unter the
boom) when braking.
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02.07.2001
Unlocking / locking the driver's cab, S. 7 - 2.

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.
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
covers (1).
02.07.2001
2 084 643 en
7-5

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

the left-hand side, in front of the boom support.
Pre-check
Check whether the oil level on the dip stick

is up to the max mark (arrow marking).
Top up with motor oil to the max. mark if

necessary.
Check
Start the diesel engine and let it run at idling speed. Pay attention to the
7-6
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
Operating Manual, chapter Carrier malfunctions,
and look for the cause;
Section Crane engine malfunctions.
2 084 643 en
02.07.2001
oil pressure gauge.

7.2 Diesel engine
Leave the diesel engine running and check

the oil level when the diesel engine is warm.
With idling speed, the oil level must lie between min. and max. (arrow marking).
Top up with oil to the max. mark if necessary.
7.2.2
Diesel engine oil topping up oil

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).
02.07.2001
Check the oil level on the dipstick.
Damage may occur to the engine if the oil level is too high.
Do not overfill; the oil level must not be higher than the highest arrow
marking (max.).
2 084 643 en
7-7

7.2 Diesel engine
7.2.3
Checking coolant level
The coolant reservoir is located on the left-hand side of the carrier behind
the driver's cab.
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

hole (1) with the coolant at operating temperature to release the pressure.
Open the cap.

The coolant must reach the lower edge of
the pipe in the filler neck.
If the coolant level is too low:
Top up the coolant.

See the diesel engine operating instructions for the composition of the
coolant.
7-8
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 Support or your repair crew check the cooling system and repair the damage.
02.07.2001
Screw on the filling hole cap until it stops.
2 084 643 en

7.2 Diesel engine
7.2.4
Checking the dry air filter
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
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).
Extract the filter cartridge (1).

Insert a new filter cartridge.
If the seal on the filter lid is worn:
Change the seal.
Put the filter lid back in place and secure it
02.07.2001
with all the clamps.
2 084 643 en
7-9

7.2 Diesel engine
7.2.5
Checking general condition and for leaks

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.
If damage cannot be rectified immediately or further damage is likely:
02.07.2001
Inform your local GROVE Customer Support or your repair crew.
7 - 10
2 084 643 en

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

The fuel prefilter (1) is under the carrier's rear
cover on the right hand side next to the automatic gearbox.
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.
02.07.2001
2 084 643 en
7 - 11

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. Replace 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 container and screw it again onto the prefilter.
Tightening torque 10 Nm.
Bleed the fuel system as described in the following section.
Bleeding the fuel

system
Release the hand pump by turning the knurled screw (4, top picture) to the
left.
The knurled screw is also the hand pump's handle.
Pump up and down until the resistance noticeably increases.

Insert the hand pump and tighten the knurled screw again.
02.07.2001
Start the engine and check the prefilter for tightness.
7 - 12
2 084 643 en

7.2 Diesel engine
7.2.7
Shutting off and
emptying the fuel
line
Changing the fuel filter cartridge
M 12
Before changing the fuel filter cartridge you must:

shut off the fuel line to the diesel tank and
empty the fuel line
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.
Close the tap. Turn the handle (1) so that it is

perpendicular to the fuel line.
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
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).
02.07.2001
s
2 084 643 en
7 - 13

7.2 Diesel engine
For the purpose of emptying the fuel line a

3-way-tap (1) is provided at the rear on the automatic 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
The fuel filter insert is underneath the boom support at the front left on the
diesel engine (
Diesel engine operating instructions).
In order to easily access the fuel filter insert tilt the driver's cab,
Tilt
driver's cab forward, S. 7 - 1.
Unscrew the screw cap (1) with the filter insert (3) and pull it a bit out of the filter housing.
Let the rest of the fuel drain off.
Remove the screw cap with the filter cartridge and remove the cartridge by applying
pressure on the sides of the lower edge.
Replace the rubber sealing ring (2) (lubricate

lightly).
Clip a new filter cartridge onto the screw

cap.
7 - 14
Store used fuel filter cartidges in suitable containers and dispose of them
properly.
02.07.2001
Replace the cap with cartridge and tighten it. Tightening torque 25 Nm.
2 084 643 en

7.2 Diesel engine
After changing the

filter insert
After changing the fuel filter insert, you must re-establish the state of
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 disposal.
Push the hose end through the opening in

the base plate of the carrier frame.
Attach the hose end to the right frame wall.
02.07.2001
2 084 643 en
7 - 15

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; Bleeding
the fuel system, S. 7 - 12.
02.07.2001
Start the engine and check that the fuel filter is leak-tight.
7 - 16
2 084 643 en

7.3 Gearbox
7.3
Gearbox
The gearbox is located inside the carrier above the first axle line.
7.3.1
Make a visual inspection for leaks.

Listen carefully for any abnormal noises when the transmission is
engaged.
02.07.2001
2 084 643 en
7 - 17

7.3 Gearbox
7.3.2
M1
Gearbox oil level check

The gearbox is located inside the carrier above the first axle line.
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.
Risk of scalding.
If the oil is at operating temperature, do not let it drain unchecked.
The oil level is checked through an inspection

hole at the right of the gearbox.
Remove the cover plate (1) from the gear

box.
Remove the screw (2) from the inspectionhole.

If the oil level is too low:
Top up oil through the inspection hole using

only oil as specified in the Maintenance plan,
S. 5 - 14.
Close the inspection hole again with the

screw (2).
02.07.2001
Secure the cover plate (1) on the gearbox.
7 - 18
2 084 643 en

7.3 Gearbox
7.3.3
J2
Gear box oil change
G
O
H
The oil is drained via the oil drain opening in the gear box and filled via the
inspection hole.
Use only oil as specified in the Maintenance plan, S. 5 - 17.
Risk of scalding.
If the oil is at operating temperature, do not let it drain unchecked.
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.
Before starting this work, lift the truck crane with the outrigger or park it
over an inspection pit.
Draining gear lubricant oil
Insert a funnel into the drain hole in the base

plate under the gear box.
Place a container (capacity approx. 15 l) underneath the drain hole to collect the oil.
Unscrew the oil drain screw (2) and let the
02.07.2001
oil flow into the collection container.
Collect old oil in approved containers and have used oil and oil filters
disposed of properly.
s
2 084 643 en
7 - 19

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
outlet (
Special tightening torques,
S. 10 - 2).
Top up the oil through the inspection hole

on the gearbox (
S. 5 - 16).
Maintenance plan,
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 inspection hole with the screw (1) (
tightening torques, S. 10 - 2).
Special
After topping up the oil, you must carry out the following checks for leak
tightness:
Start the diesel engine and let it idle in neutral position N.
02.07.2001
Check the tightness of oil drain screws.
7 - 20
2 084 643 en

7.4 Transfer case
7.4
Transfer case
The transfer case is between the second and third axle lines.
7.4.1

Listen out for any unusual noises from the transfer case.
7.4.2
Distributor gearbox oil level check
M1
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.
Check the oil level. The level must be just

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

S. 5 - 8.
02.07.2001
Close the inspection hole with the screw (1).
2 084 643 en
7 - 21

7.4 Transfer case
7.4.3
M6
Distributor gearbox oil change

Raise the truck crane with the outriggers or park it over an inspection pit.
Always use oil collection containers, funnels or filling pumps which are resistant 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 approx. 15 l) underneath the oil drain screw (3).

Replace the sealing ring and reinsert the oil

drain screw.

S. 5 - 12.
Check the oil level ( Distributor gearbox

oil level check, S. 7 - 21).
Replace the sealing ring and close the inCollect old oil in approved containers and have it disposed of properly.
02.07.2001
spection hole with the screw (1).
7 - 22
2 084 643 en

7.5 Axle lines
7.5
Axle lines
7.5.1

Listen out for any unusual noises from the axle centre drives and final
drives.
7.5.2
Axle centre drives oil level check
M1
The position and number of inspection holes sometimes differs with the
axle lines.
The first and the fourth axle line
On the first axle line, the inspection hole is at
the front. The inspection hole is at the back of
the fourth axle line.
Check the oil level, the oil level must be just

underneath the inspection hole.

S. 5 - 8.
Replace the sealing ring and close the inspection hole again with the screw (1).
02.07.2001
s
2 084 643 en
7 - 23

7.5 Axle lines
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 described for the first and the fourth axle lines.
The third axle line

The axle centre drive of the third axle line has
two inspection holes:
in front - the inspection hole (2)
at rear the inspection hole (1).
Check the oil level in the same way as is de-
02.07.2001
scribed for the first and the fourth axle lines.
7 - 24
2 084 643 en

7.5 Axle lines
7.5.3
Axle centre drives oil change
M 12
Raise the truck crane with the outriggers or park it over an inspection pit.
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
Place an oil collection container (capacity

approx. 20 l) under the oil drainscrew (2).

Replace the sealing ring and reinsert the oil

drain screw.
Top up oil via the inspection hole (1). Use

S. 5 - 12.
Check the oil level ( Axle centre drives oil level check, S. 7 - 23).
Replace the sealing ring and close the inspection hole again with the
Collect the old oil in permitted containers and only have it disposed of by
approved disposal companies.
02.07.2001
screw (1).
2 084 643 en
7 - 25

7.5 Axle lines
The axle centre drive on the second axle line is available only as additional
The second axle line
Place an oil collection container (capacity approx. 20 l) underneath the oil drain screw (2).
Change the oil in the same way as is described for the axle drives on the first and
the fourth fifth axle lines.
The third axle line
The axle centre drive of the third axle line

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

approx. 20 l) under the oil drainscrews (3)
and (4).
Change the oil on both oil drain screws in
02.07.2001
the same way as is described for the axle

drives on the first and fourth axle lines.
7 - 26
2 084 643 en

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.
Check the oil level, the oil level must be at

the check mark (2).

S. 5 - 8.
02.07.2001
Also check the oil level on all other final drives.
2 084 643 en
7 - 27

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

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 collecting vessel.
Turn the wheel back so that the oil check

mark (2) is horizontal and is on the right next
to the centre of the axle.
Top up oil through the inspection hole (1)

and use only oil which is specified in the
Maintenance plan, S. 5 - 14.
Check the oil level, the oil level must be at

the check mark (2).
Check the oil level ( Final drives oil level

check, S. 7 - 27).
7 - 28
02.07.2001
Collect the old oil in permitted containers and only have it disposed of by
approved disposal companies.
2 084 643 en

7.5 Axle lines
7.5.6
M1
Lubricating the cardan shafts on the axle lines
The cardan shafts are between the axle centre drives and the final drives.
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, S. 5 - 8.
S
Number and position of lubrication
points
Risk of damaging the sealing lips.

Do not apply hard lubricants to avoid damage to the sealing lips.
There are two cardan shafts on every driven axle line.

The following table shows the position and number of lubricating nipples
on both cardan shafts for all driven axle lines.
Cardan shafts
inner 1)
outer 2)
1st axle line
2nd axle line (only with 8 x 8 x 8 drive)
3rd axle line
4th axle line
1)
2)
Lubricating nipple
Joint on the axle centre drives

Joint on the final drives
The cardan shafts on the second axle line are available only as additional
02.07.2001
2 084 643 en
7 - 29

7.5 Axle lines
Cardan shafts first

axle line lubricate
On the first axle line there are outer double joints and inside on the axle
centre drive one single joint.
The signle joint on the axle centre drive has a
lubricating nipple (3). There are two lubricating 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 lubricating 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
same way.
Cardan shafts second lubricate up to

the fourth axle line
There are single joints on the second (additional equipment), fourth and
fifth axle lines inside and outside.
There is a lubricating nipple (1) and (2) on

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

lubricating nipple.

nipple until new grease comes out of the
corresponding bearing point.
02.07.2001
Remove the surplus new grease.
7 - 30
2 084 643 en

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 between the axle centre drives.
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 installed.
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, S. 5 - 12.
S
Number and position of lubrication
points
Risk of damaging the sealing lips.

Do not apply hard lubricants to avoid damage to the sealing lips.
The following table shows the location and number of the lubricating nipples on the individual cardan shafts:
(Longitudinal) cardan shaft between ...
Lubricating nipple
front
rear
Gearbox and transfer case
Transfer case and the first axle line
Transfer case and the second axle line1)
Transfer case and the third axle line
First axle line and the second axle line1)
Third axle line and the fourth axle line
Only for 8 x 8 x 8 drive (additional equipment).
02.07.2001
1)
2 084 643 en
7 - 31

7.5 Axle lines
Lubricating longitudinal cardan

shafts
Lubrication with all longitudinal cardan shafts is done in the same way.
There are two lubricating nipples (1) and (2) on

every longitudinal cardan shaft.
Remove the old grease and dirt from the lubricating nipples.

nipples until new grease comes out of the
respective bearing points.
02.07.2001
Remove any spilling grease.
7 - 32
2 084 643 en

7.6 Wheels
7.6
Wheels
7.6.1
Checking the tyres for damage
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:
Change the tyres.
02.07.2001
Always replace all the tyres on an axle.
2 084 643 en
7 - 33

7.6 Wheels
7.6.2
S
7.6.3
Check the tyre pressure
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
16.00 R 25 (additional equipment)
9,0
20.50 R 25 (additional equipment)
7,0
M3
Checking the wheel-bearing clearance
Raise the truck crane with the outriggers. Release the parking brake.
Press against the bottom of the wheel with one foot and, using both
hands, try to move the wheel in the bearing at the same time.
If the check shows there is too much play:
Have the wheel-bearing clearance adjusted or wheel bearings replaced by
02.07.2001
GROVE Customer Support service at the particular location or by your

own repair crew.
7 - 34
2 084 643 en

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
service centre.
02.07.2001
Always replace all brake-linings on an axle line.
2 084 643 en
7 - 35

7.7 Vehicle brakes
02.07.2001
Blank page
7 - 36
2 084 643 en

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
(
Operating manual, Chapter Driving with the truck crane, Section Vehicle
height control).
The initial complete lowering is necessary to prevent incorrect oil level.
If the oil level is above the upper marking on the inspection glass the
suspension cylinder is defective and must be replaced.
Inform the GROVE Customer Support.
Check the oil level at the relevant inspection

glass (1).
The oil level must be between the markings.
Screw the high pressure squirt gun

(supplied tool) to the filler connection (2).
Inject oil up to the level of the lower
02.07.2001
marking.
Use only oil as specified in the Maintenance
plan, S. 5 - 8.
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.
2 084 643 en
7 - 37

7.8 Suspension
7.8.2
Tightness of retaining bolts on the suspension

cylinders to be checked
M1
Check the tightening torques of the retaining bolts:

Vehicle frame/guide case upper (1)
Vehicle frame/guide case below (2)
Support element/steering split shell (3)
Support element/operating head (4)
02.07.2001
The tightening torques can be found in Special

tightening torques, S. 10 - 2.
7 - 38
2 084 643 en

7.9 Steering
7.9
Steering
7.9.1
Checking for leaks
Check the hydraulic steering system (steering cylinders, pipes and hoses,
and all connections) for leaks.

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 ( Hydraulic unit oil level check,

S. 7 - 43).
After changing pipes and hoses:
Bleed the carrier hydraulic system ( Changing the hydraulic oil, S. 7 - 52).
02.07.2001
Inform your GROVE Customer Support service or your repair crew.
2 084 643 en
7 - 39

7.9 Steering
02.07.2001
Blank page
7 - 40
2 084 643 en

7.10 Carrier compressed air system
7.10
Carrier compressed air system
7.10.1
Draining the compressed air system
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
after being actuated several times:
Change the drain valve.
If a lot of moisture escapes from the air reservoirs:
Have the compressed air drier checked or

replaced by your repair crew.
7.10.2
Compressed air system check for leakage
Start up the compressed air system.

Check all points in the compressed air system (connections, pipes, hoses
Risk of accidents.
Never tighten connections when the system is under pressure. Only change
seals, pipes and hoses when the system is depressurized.
02.07.2001
and valves) where air could possibly escape.
2 084 643 en
7 - 41

7.10 Carrier compressed air system
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.
Risk of injury.
If the conditioning unit is not completely empty, the air drier will be under
pressure.
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.
Change the granulate cartridge.
02.07.2001
Grease the sealing ring lightly before screwing into place.
7 - 42
2 084 643 en

7.11 Carrier hydraulic system
7.11
7.11.1
Hydraulic unit oil level check
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 (
Operating
Instructions, Chapter Driving with the truck crane, Section Vehicle height
control);
outrigger beams and outrigger cylinders must be retracted (
Operating
Instructions, Chapter Rigging work, Section Outriggers).
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:
Top up the hydraulic oil through the filler

opening (2).
plan, S. 5 - 5.
02.07.2001
Be careful not to damage the hydraulic system.

When handling hydraulic oil cleanliness is imperative.
New oil must also be filtered.
2 084 643 en
7 - 43

7.11.2
Checking the hydraulic hoses
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 operating pressure are marked on the hose fitting:
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.
Damaged or old hydraulic hoses must be replaced immediately. Always
02.07.2001
ensure that the corresponding parts of the hydraulic system are depressurized in advance.
7 - 44
2 084 643 en

7.11.3
Checking for leaks
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 (
Hydraulic unit oil level check, S. 7 - 43).
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 ( Changing the hydraulic oil, S. 7 - 52).
Immediately repair or have repaired leakages in the hydraulic system to ensure that no hydraulic oil escapes, seeps into the ground or reaches waters
when the crane is being used.
02.07.2001
2 084 643 en
7 - 45

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:
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.
Unscrew all screws (1) and remove the top

parts of the filter (2).
Unscrew the magnetic rods (4) and clean
02.07.2001
them.
7 - 46
2 084 643 en


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.
Store used hydraulic oil filters in suitable containers and have them disposed of properly by qualified personnel.
02.07.2001
2 084 643 en
7 - 47

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.
Switch off the diesel engine and secure it against being started by
unauthorized persons (sign in the driver's cab).
Remove the ring (1).

Take off the filter can (2).
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.
Screw the filter can on again.

Start the diesel engine and let it run in
02.07.2001
neutral gear for 3 minutes in order to bleed

the system.
7 - 48
2 084 643 en

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

filler opening cover.
02.07.2001
Change the venting filter (1).
2 084 643 en
7 - 49

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

(1), (2) and (3) on the hydraulic oil tank.
02.07.2001
An oil sample from the hydraulic system is

taken via a gauge port (1), e. g. on a valve
block of the suspension.
7 - 50
2 084 643 en

Handling the drain

valves
Drain valves can be opened and closed using 1/2" connection plates. The
connection plates are in the tool box.
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
Take one litre of hydraulic oil from each of the three drain valves and from
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,
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:
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:
02.07.2001
Carry out an oil change ( Changing the hydraulic oil, S. 7 - 52).
2 084 643 en
7 - 51

7.11.7
M 12
Changing the hydraulic oil
The hydraulic oil only has to be changed if the laboratory analysis shows
Taking hydraulic oil samthat the permissible limits have been exceeded (
ples, S. 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.
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
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.
Remove the hydraulic oil filters
(
Changing the hydraulic oil filters and cleaning the magnetic rod, S. 7 - 46).
Have a container ready to collect the oil

(with a capacity of over 660 l).
02.07.2001
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.
7 - 52
2 084 643 en

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 (
Taking hydraulic oil samples, S. 7 - 50).
Change the filter elements in both filters and

fit new hydraulic oil filters ( Changing the
hydraulic oil filters and cleaning the magnetic
rod, S. 7 - 46).
S
O

When handling hydraulic oil cleanliness is imperative.
New oil must also be filtered before it is filled into the tank.
Collect old oil in approved containers and have it

Used oil and oil filters must be properly disposed of.
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.
Start the engine and put the hydraulic system into operation.
Carry out all functions of the carrier hydraulic system several times to remove any air
from the system.
Check the oil level in the hydraulic oil tank.

Top up oil if necessary.
02.07.2001
Carry out a road test of the truck crane, turning the steering wheel several times to its
fullest extent.
2 084 643 en
7 - 53

If the steering is "loose" at the end of the test run you must ventilate the
steering cylinders.
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 under 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 loosening the cap nuts (1) in turn until the oil coming out no longer contains any air bubbles.
If the steering system is still not operating
properly:
Inform your local GROVE Customer Support
02.07.2001
or an authorised service centre.
7 - 54
2 084 643 en

7.12 Centrallubrication system
7.12
Centrallubrication system
The grease container for the central lubrication system is on the right side of the vehicle
between the second and third axle lines, behind the access ladder.
plan, S. 5 - 6.
7.12.1
Central lubrication system

There are two different versions of the central lubrication system:
Version 1 and
Version 2.
Version 1
Version 1 is (1) equipped with a display and control unit;

Version 1
Checking the level of the grease container and topping up, S. 7 - 56.
Version 2
With version 2, the operating instruments are located under a closure flap (1);
Version 2 Checking the level of the grease container and topping up, S. 7 - 59.
02.07.2001
2 084 643 en
7 - 55

7.12.2
Version 1 Checking the level of the grease container

and topping up
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;
Filling the grease container, S. 7 - 57.
If the level drops below the MIN mark, automatic lubrication is interrupted.
Actuate intermediate lubrication
An intermediate lubrication must be actuated,

after a high pressure cleaning;
for inspecting the lubrication on individual lubrication points.
Turn the diesel engine ignition on.

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

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

Switch off the diesel engine ignition.
02.07.2001
7 - 56
2 084 643 en

Filling the grease

container
Unscrew the cap (5) from the filling pump (1).

Remove both caps (2) and (4) from the
grease cartridge (3).
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.

Check that the seal (6) is in proper position in the cap (5).
Screw the cap onto the filling pump.

Do not remove the sealing caps from the filler opening and filling pump until immediately before refilling the grease. This prevents dirt particles from
getting into the grease.
Unscrew the sealing cap (1) on the grease
02.07.2001
container.
2 084 643 en
7 - 57

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 opening of the grease container.
Actuate the intermediate lubrication;
Actuate intermediate lubrication, S. 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.
Bleeding the central lubrication

system
The central lubrication system must be bled when the grease container is
empty or air is trapped in the grease.
Fill the grease container (1); Version 1
Checking the level of the grease container and topping up, S. 7 - 56.
Loosen the outlet scr ew fitting (3) of the

pump element.
Press once the push button DK (2) in order to

actuate the intermediate lubrication;
Actuate intermediate lubrication, S. 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).

lubricant cables and lubrication points in the same way.
7 - 58
2 084 643 en
02.07.2001
Remove the air from the main and auxiliary cables, auxiliary distributor,

7.12.3
Version 2 Checking the level of the grease container

and topping up
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

container
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 enclosed with the filling pump.
Unscrew the stopper (1) from the grease

container.
Screw the connecting piece (2) into the

opening.
Screw the sealing cap (3) onto the connecting piece.
02.07.2001
2 084 643 en
7 - 59

Unscrew the cap (5) from the filling pump (1).

Remove both caps (2) and (4) from the
grease cartridge (3).
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.

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

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

triggers a complete lubrication procedure.
Remove the sealing cap on filler opening (1)
02.07.2001
of the grease container.
7 - 60
2 084 643 en

Do not remove the sealing caps from the filler opening and filling pump until 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 opening 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

the sealing cap.
Bleeding the central lubrication

system
The central lubrication system must be bled when the grease container is
empty or air is trapped in the grease.
Fill the grease container (1) ( Version 2
Checking the level of the grease container and topping up, S. 7 - 59).
Loosen the outlet screw fitting (2) of the

pump element.

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
02.07.2001
screw the sealing caps back onto the filler

opening of the grease container and the
switch opening (3).
Remove any excess grease.
2 084 643 en
7 - 61

02.07.2001
Blank page
7 - 62
2 084 643 en

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

Loosen any dirty terminals and clean them.
G
H
Grease the terminals with an acid-free, acid-resistant grease.

Hydrogen escaping from the batteries is explosive!
Do not place tools on the battery and keep unshielded light away from the
battery.
It is particularly important to check the acid level during the warmer months.
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.
If the acid does not come up to the required level or there is no distilled water in the overflow reservoir:
Only fill in distilled water:
02.07.2001
up to the required height above the plates or

until it no more spills out of the overflow reservior.
2 084 643 en
7 - 63

7.13 Carrier electrical system
7.13.2
M3
Checking the acid concentration of batteries

Measure the acid concentration of each cell with an acid tester.
The following table gives a guide to battery charge levels.
Acid concentration
( B)
Specific weight
(g/cm3)
Charge condition
32
1,28
good
24
1,20
half, recharge
16
1,12
enpty, charge immediately
02.07.2001
It is particulary important to check the acid concentration with the onset of

the colder months.
7 - 64
2 084 643 en

7.14 Carrier air conditioning system (additional equipment)
7.14

The GMK 4075 is equipped with only one refrigerant circuit for the airconditioning system on the carrier and superstructure.
7.14.1
Checking the moisture and level of the refrigerant
M1
The refrigerant is checked through an inspection glass on the refrigerant drier while the air
conditioning system is running (1).
The battery box is located on the right-hand

side of the vehicle over the first axle line.
Start the diesel engine.

Switch on the air-conditioning system and
let it run for about 10 minutes. (Switching on
the air-conditioning system
Operating
manual, Section Air conditioning system in
chapter Driving with the truck crane).
Check the refrigerant filling and the moisture 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.
02.07.2001
s
2 084 643 en
7 - 65

If the moisture indicator shows a yellow dot or if bubbles or foam are visible, 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 Support.
After checking:
Switch off the air conditioning system and turn off the diesel engine.
7.14.2
M1
Cleaning capacitor disks
Risk of damage to the capacitor.

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.
The capacitor is mounted between the

radiator and the right tread grille on the
carrier.
Switch off the air conditioning system.

Clean the disks of the capacitor (1) with com-
02.07.2001
pressed air.
7 - 66
2 084 643 en

7.14.3
M6
Checking hoses
Check all refrigerant hoses for damage and worn areas.
Have damaged hoses replaced only by GROVE Customer Support.
7.14.4
Checking the refrigerant compressor
M6
The refrigerant collector may only be checked

by GROVE Customer Support!
02.07.2001
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
proper working condition, it must be replaced
by GROVE Customer Support.
2 084 643 en
7 - 67

7.14.5
Checking the refrigerant compressor control
M6
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 underneath the fuel filter.
Have the refrigerant compressor checked

for tightness. Above all the sealing of the
drive shaft should be checked.
7.14.6
Checking the entire air conditioning system
M 12
This check may only be undertaken by GROVE Customer Support!
Have the whole air conditioning system checked for tightness and proper
02.07.2001
functioning.
7 - 68
2 084 643 en

7.15 Trailer coupling (additional equipment)
7.15
7.15.1
Lubricating the trailer coupling
G
H
M1
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.
To avoid over-lubrication, the trailer coupling should only be lubricated
when open.
Clean the two lubricating nipples (2 and 3)

on the trailer coupling.
Open the trailer coupling. To do this, move

the hand lever (1) upward.
Press grease according to Maintenance plan,

S. 5 - 6 into the two lubricating nipples using a grease gun.
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.
02.07.2001
2 084 643 en
7 - 69

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
M3
Checking the bearing
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.
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 coupling head and not by the coupling jaw.
H
7 - 70
A vertical clearance of 3 mm at the coupling head corresponds to 1 mm

bearing play.
2 084 643 en
02.07.2001
When shaking the coupling should not show

longitudinal clearance; the vertical clearance
must not exceed a value of 3 mm (as measured at the coupling head).

7.15.3
M3
Checking the cotter pin
For the following tests the coupling must be closed; before closing by hand
Lubricating the trailer coupling, S. 7 - 70.
check the data in section
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
Model series 700:
46.0 mm
If the diameter is below 36.5 or 46.0 mm, the

pin must be replaced.
Also check the cotter pin for the correct ver-
02.07.2001
tical clearance. Push the cotter pin (1) upwards using a screwdriver. The vertical
clearance (2) of the pin must not exceed
4 mm.
2 084 643 en
7 - 71

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

bushing. The dimension (D) can not be less
than the following values:
Model series 400:
31.5 mm
Model series 700:
34.2 mm
If the diameter is below 31.5 or 34.2 mm, the

bushing must be replaced.
7.15.5
M3
Checking the support ring
Check the support ring (1) for the draw eyelet at the bottom of the coupling jaw.
When the trailer is coupled, the draw eyelet
of the trailer may have slight contact with
the lower bushing (2).
Have the support ring changed if:

the trailer's draw eyelet touches the lower
bushing because of wear or
02.07.2001
the support ring has reached its wear limit of

H =14 mm.
7 - 72
2 084 643 en

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 initial tension of the rubber springs.
7.15.7
Checking the function of the coupling jaw /

re-adjusting the middle position
H
Function
checking
M3
The following checks are required only on model series 700. If you need to
close the coupling by hand for the checks, make sure you observe the data
in section Lubricating the trailer coupling, S. 7 - 70.
If you need to close the coupling by hand for the checks, make sure you
observe the data in section Lubricating the trailer coupling, S. 7 - 70.
Close the coupling (position B); p. 7 - 71.

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

the left or right.
Open the coupling (position A) and let the

coupling jaw go.
02.07.2001
The release lever must automatically lock the

coupling jaw in the central position. The coupling jaw is locked when the coupling can no
longer move to the side.
If the release lever does not automatically engage with the coupling jaw, the
central position will need to be re-adjusted;
p. 7 - 75.
s
2 084 643 en
7 - 73

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 until the release lever snaps into place.
Retighten the three screws (2) (tightening

torque: 58 Nm).
After adjusting check the function of the
p. 7 - 74.
02.07.2001
coupling jaw;
7 - 74
2 084 643 en

7.16 Other maintenance work
7.16
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.
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.

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,
S. 5 - 8.
Extend and retract the outrigger beams several times in order to improve the lubrication effect.
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
(
Operating Instructions, Chapter Driving with the truck crane, Section Water
auxiliary heating (additional equipment).
02.07.2001
Check that the system is working properly.

Inform your local GROVE Customer Support if the heating system is not
working properly.
2 084 643 en
7 - 75

02.07.2001
Blank page
7 - 76
2 084 643 en
8
8
Description of maintenance work on the superstructure . .
8-
8.1
Shifting clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 -
Shifting clutch oil level check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Shifting clutch oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 -
1
2
Hoists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 -
Hoisting gear oil level check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking the hoist brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubricating the hoist gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hoisting gear oil change. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Carrying out partial inspection of hoists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Carrying out general inspection of hoists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8888888-
3
4
4
5
5
8
8
Slewing gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 -
Slewing gear oil level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lubricating slewing gear pinion and gear rim . . . . . . . . . . . . . . . . . . . . . . . . . .
Slewing gear oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Slewing gear brake function check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
10
10
11
13
8.1.1
8.1.2
8.2
8.2.1
8.2.2
8.2.3
8.2.4
8.2.5
8.2.6
8.2.7
8.3
8.3.1
8.3.2
8.3.3
8.3.4
8.3.5
8.4
8.4.1
8.4.2
8.4.3
8.4.4
8.4.5
8.5
8.5.1
8.6
8.6.1
8.6.2
8.7
02.07.2001
8.7.1
88888-
Superstructure hydraulic system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 15

Checking the hydraulic hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bleeding the derricking cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bleeding telescoping cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing the hydraulic oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
88888-
15
15
16
18
21
Main boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 23
Lubricating the telescope slide faces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 23
Hoist ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 29
Checking the position of sheaves and rope drums. . . . . . . . . . . . . . . . . . . . . . . 8 - 29
Checking the status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 30
Safe load indicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 41
Maintaining the slip ring assembly of the cable drum . . . . . . . . . . . . . . . . . . . . 8 - 41
8.8
Central lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 45
8.9
Hook blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 47
8.9.1
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 47
8.10
Superstructure electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 49
8.10.1
8.10.2
Checking the acid level of batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 49

Checking the acid concentration of batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 49
2 084 643 en
8.11.1
8.12
8.12.1
8.12.2
Superstructure air conditioning system (additional equipment) . . . . . . . . . . . . . 8 - 51

Checking hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 51
Other maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 53
Lubricating the counterweight hoist unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 53
Checking for correct operation of the auxiliary heater (additionalequipment) 8 - 53
02.07.2001
8.11
2 084 643 en

8.1 Shifting clutch
Description of maintenance work on

the superstructure
8.1
Shifting clutch
H
8.1.1
To reach the shifting clutch you must tilt the driver's cab,
forward, S. 7 - 1.
Tilt driver's cab
The shifting clutch is located between the diesel engine and the hydraulic
pumps for the superstructure hydraulic system.
Shifting clutch oil level check
M1
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.
Danger of burning yourself when the diesel engine is hot!

During operation, the diesel engine and add-on parts can reach temperatures 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; p. 7 - 1.

Check the oil level of the shifting clutch
through the inspection glass (1). The inspection glass must be completely filled with oil.
Remove the screw (2) from the oil filler

opening.
Add oil until the inspection glass is full. Only

use oil specified in the Maintenance plan,
S. 5 - 9.
02.07.2001
Reinsert the scre w(2) into the oil filler

opening.
2 084 643 en
8-1

8.1 Shifting clutch
8.1.2
M 12
Shifting clutch oil change

Only use oil specified in the Maintenance plan, S. 5 - 15.
O
G
Always use oil collection containers which are oil-resistant.

Danger of burning yourself when the diesel engine is hot!

During operation, the diesel engine and add-on parts can reach temperatures 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; p. 7 - 1.

Have an oil collection container ready
(capacity approx. 0.5litres).
Remove the screw (1) from the oil filler

opening.
Remove the screw (3) from the oil drain

opening and drain the oil into the oil container.
Replace the sealing ring of the screw and

reinsert the screw into the oil drain opening.
Top up oil and check the oil level through

the inspection glass (2). Only use oil specified in the Maintenance plan, S. 5 - 9.
Reinsert the scre w(1) into the oil filler

Risk of polluting the environment!
Collect waste oil in approved containers and have it disposed of properly.
02.07.2001
opening.
8-2
2 084 643 en

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
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 hoisting unit transmission at the standpipe (3). The oil level
must be between the MAX and MIN
marks (4).
Unscrew the upper sealing screw (1) and remove the connecting hos e(2) from the
standpipe.
Top up oil via the standpi pe(3).

Only use oil specified in the Maintenance
plan, S. 5 - 7.
Replace the sealing rings of the upper screw

plug and screw the upper hose back on.
Check the oil level of the brake unit by unscrewing the sealing plug out of the overflow opening (1).
The oil level must be visible under the opening.
Unscrew the sealing screw of the filling
02.07.2001
hole (2) and top up with oil.

Only use oil specified in the Maintenance
plan, S. 5 - 7.
2 084 643 en
8-3

8.2 Hoists
8.2.2
Checking for leaks

If hydraulic oil or gear oil has been lost, check the oil levels and top up
if necessary.
8.2.3
Checking the hoist brake
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.
02.07.2001
If the test load has not lowered after approx. 2 minutes, the brake applied is
in working order at that time.
8-4
2 084 643 en

8.2 Hoists
8.2.4
Lubricating the hoist gears
The main hoist is connected to the centralised lubrication system. The

following maintenance work only applies to the auxiliary hoist
(additional equipment).
The auxiliary hoist has a lubricating nipple (1).
The lubricating nipple is located on the left
side of the superstructure on the auxiliary
hoist.
Only use lubricating grease specified in the

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

lubricating nipple.
8.2.5
Hoisting gear oil change
M 12
The hoists have separate oil chambers for the gear box and the clutch housing.
Only use oil specified in the Maintenance plan, S. 5 - 15.
Always use oil collection containers which are oil-resistant.

02.07.2001
S
O
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.
2 084 643 en
8-5

8.2 Hoists
Changing the
hoisting unit
transmission oil
Oil change is carried out on the right side of the turntable via the connecting
hoses to the standpipe.
Have a container (with a capacity of over 8 l)

ready under the standpipe to collect the
oil (3).
Loosen the upper screw plug (1) and

remove the upper hose (2).
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.
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.
Changing the oil in

the brake unit
Since the oil is distributed slowly in the clutch housing being filled, the oil
level on the overflow opening will at first rise quickly and then subside a
little; afterwards it will rise to the final filling level.

approx. 1 l) underneath the oil drain (3).
Unscrew the screw plugs of the filling

hole (1) and the overflow opening (2).
Remove the screw connection (3) and drain

the oil.
Screw the screw connection (3) on again.

Pour oil slowly through the filler opening (1)
If necessary, replace the sealing rings for the screw plugs of the filler and
overflow openings
Screw the screw plugs in again.
8-6
2 084 643 en
02.07.2001
until it reaches the lower edge of the overflow opening (2).

8.2 Hoists

Checking the oil
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.
Danger of accidents!
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.
02.07.2001
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 measures.
2 084 643 en
8-7

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
8.2.7
Inspections and part replacements must only be carried out by trained,

qualified personnel.
Carrying out general inspection of hoists
Y6
When carrying out general inspection of the hoists, also observe the information contained in the section on Measures required for winch monitoring,
S. 5 - 21.
The hoist gear is to undergo general inspection after the period of time indicated in the maintenance plan. This inspection involves disassembly of the
gearbox and sending it to the manufacturer for testing.
02.07.2001
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 operating hours before the yearly interval can be implemented.
8-8
2 084 643 en

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
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 according to the
Close the opening.
For the slewing gear brake, check the oil

level using the oil level sight glass (1) in the
expansion tank (2).
The oil must be visible in the sight glass.
Unscrew the ventilation filter (3) from the

expansion tank and top up with oil as specified in the
02.07.2001
Close the opening.
2 084 643 en
8-9

8.3 Slewing gear
8.3.2
Checking for leaks

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

8.3.3
Lubricating slewing gear pinion and gear rim
M6
The slewing gear pinion and spur gear must be lubricated with special
grease (
Maintenance plan, 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.
Observe the instructions and safety information on the grease packaging.
Unscrew the screws and remove the

guard (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.
Subsequent lubrication:
Apply a new layer over the existing layer of

Leave to penetrate for approx. 30 minutes.
8 - 10
2 084 643 en
02.07.2001
adhesive lubricating grease.

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

gear pinion.

(capacity approx. 5 l).
Unscrew the vent screw (2).

Unscrew the ventilation filter (1) from the
filler neck.
Unscrew the oil drain plug (5) and drain the

oil into the oil container.
Replace the sealing ring on the oil drain plug

and screw the plug back in.
Fill with oil ( Maintenance plan, S. 5 - 14)
and check the level of the oil by inspecting

the oil level sight glas s(3).
Screw the ventilation filte r(1) and the

ventilation screw (2) back on with a new
sealing ring.
02.07.2001

2 084 643 en
8 - 11

8.3 Slewing gear
Checking the oil
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 manufacturer.
Slewing gear
brake oil change
The slewing gear brake is located on the slewing gear itself.

Only use oil specified in the

Drain the oil into the collecting vessel via a draining gutter. Wipe up spilled
oil immediately.

(capacity approx. 1.5 l).
Unscrew the vent filter( 4) from the expansion tank (3).
Remove the screw from the oil drain

opening (1) and let the oil run into the oil
collection container via a draining gutter.
Replace the sealing ring and replace the

screw (1) in the oil drain opening.
Add new oil through the expansion ta nk(3)

until the oil level is in the middle of the oil
level sight glass (2).
Screw the vent filte r(4) back on to the
8 - 12
02.07.2001
expansion tank.
2 084 643 en

8.3 Slewing gear
8.3.5
Slewing gear brake function check
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
Y
Y
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
permanent brake rocker switch upwards.
The slewing gear permanent brake indicator lamp goes out.

Push the slewing gear service brake pedal down and hold it.
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
and must be replaced immediately.
02.07.2001
Only have the plates changed by GROVE Customer Support.
2 084 643 en
8 - 13

8.3 Slewing gear
02.07.2001
Blank page
8 - 14
2 084 643 en

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

S. 7 - 44.
8.4.2
Checking for leaks
With the diesel engine running, make a visual inspection for leaks and escaping hydraulic oil on the hydraulic components of the superstructure
(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
Never tighten leaking connections when the system is under pressure. Only
change seals, pipes and hoses when the system is depressurized.

Immediately repair or have leakages repaired in the hydraulic system to
ensure that no hydraulic oil escapes, seeps into the ground or reaches
water when the crane is being used.
02.07.2001
Hydraulic unit oil level check, S. 7 - 43).
2 084 643 en
8 - 15

8.4.3
M1
Bleeding the derricking cylinder
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.
Slew the superstructure to the rear or to the side.
Lower the boom as far as possible.
Bleeding the piston 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
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

over the vent screw and hold the other end
in a container filled with oil.
02.07.2001
Loosen the vent screw by 1 2 turns.
8 - 16
2 084 643 en

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 transparent 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 piston head area
Before ventilation, the requirements listed at the start of this section must
be fulfilled.
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
spray out under pressure.
Check that the boom is lowered as far as it

will go.
Remove the cap from the vent scre w(1).

Fit one end of a plastic transparent hose
over the vent screw and hold the other end
in a container filled with oil.
02.07.2001
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 transparent plastic hose no longer contains any air bubbles.
Tighten the vent screw, remove the plastic hose and replace the cap on
the vent screw.
2 084 643 en
8 - 17

8.4.4
M1
Bleeding telescoping cylinders
There are two vent screws on the telescoping cylinder for bleeding the cylinder 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
there is at least 1.8 t of counterweight.
Enter the SLI rigging code for the current rigging mode of the truck crane.
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.
Bleeding
procedure
Carry out the bleeding procedure on all vent screws in turn.
Remove the cap from the relevant vent screw.

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.
8 - 18
2 084 643 en
02.07.2001
The oil collected in the container must not be used again as it contains air.

Location of vent
screws
Vent for:
Access to vent on basic section via:
Set of piston rings
Manhole in top chord

Basic section
Piston chamber
Opening in telescopic section IV

left-hand side
02.07.2001
Position no.
2 084 643 en
8 - 19

Telescoping
status
The position numbers indicated below refer to the illustrations for Location
p. 8 - 19.
of the bleeder screws in this section;
Vent screw position no. 1
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 scre w(1) on the
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
out through the plastic hose.
Close the manhole again with the cover plate.
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 section IV onto the vent screw and open 1 or 2 turns.
Carefully move the control lever for telescoping in the extend direction so
02.07.2001
that the pressure in the piston chamber increases and the air is pushed
out through the plastic hose.
8 - 20
2 084 643 en

8.4.5
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:
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 instrument panel:

Warning lamp for Hydraulic oil filter in control
circuit (1).
02.07.2001
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.
2 084 643 en
8 - 21

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).
Remove the ring (1).

Take off the filter ca n(2).
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.
Screw the filter can on again.

Start the diesel engine and let it run in
02.07.2001
neutral gear for 3 minutes in order to

bleed the system.
8 - 22
2 084 643 en

8.5 Main boom
8.5
8.5.1
Main boom
Be careful not to damage the locking pins.
The locking pins of telescope sections I to IV must never be lubricated.
If grease reaches the locking pins during lubrication, it must be removed
completely.
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.
Danger of overturning!
Before the main boom is lowered or extended, observe the requirements
explained in this section, S. 8 - 25.
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 outside in fully extended state.
The two upper slide face s(1) and (4) are
lubricated by one lubricating nipple each.
The following section shows the position of
the lubricating nipples.
02.07.2001
2 084 643 en
8 - 23

8.5 Main boom
Position of
lubricating nipples
The lubricating nipples (1) are located on the upper booms of the telescope
sections and are reached via corresponding lubrication holes (2) in the telescope sections above. The diagram shows the telescope status for the lubrication of telescope section IV.
8 - 24
Quantity
Can be reached via the

lubrication hole in
Telescopic section I
Top chord
Basic section
Telescopic section II
Top chord
Telescope section I
Telescope section III
Top chord
Telescope section II
Telescopic section IV
Top chord
Telescopic section III
Danger of slipping due to grease residue. Do not climb onto the boom.
Use the extendable ladder provided with your crane!
02.07.2001
Lubricating nipple for
2 084 643 en

8.5 Main boom
Prerequisites
The main boom must be partly extended in the horizontal position when
carrying out maintenance.
Risk of overturning when extending in horizontal position!

In the horizontal position the SLI blocks telescoping when there is an attempt to extend a second telescope section.
Override the SLI only when you are prompted to do so in the following section and do not extend the main boom more than indicated.
Even with 31 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:

Create one of the two following rigging states:
there is at least 3.8 t of counterweight or
there is at least 1.8 t of counterweight.
Fully retract all telescope sections.
Unreeve the hook block.
Lower the main boom into a horizontal position.
To lubricate you must also telescope to intermediate lengths. Therefore

telescope the main boom with semi-automatic (Operating manual, chapter
on Crane operation;
section on Crane operation with main boom).
02.07.2001
2 084 643 en
8 - 25

8.5 Main boom
Lubricating slide
faces of telescope
sections
To lubricate, use only special grease as specified in the Maintenance plan,

S. 5 - 13.
Lower the retracted main boom to the lowest position.

Start with telescope setion IV.
G
Lubricate
telescopic
section IV
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!
Retract all telescopic sections.

Telescope telescopic section IV to the middle locking position and lock it.
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).
Fully retract telescopic section III.
Do not override the SLI anymore.
Fully extend telescopic section IV.
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 distributed uniformly on the telescope slide faces.
Retract telescopic section IV.

Lubricate
telescopic
section III

02.07.2001
Telescope telescopic section III to the middle locking position and lock it.
8 - 26
2 084 643 en

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 distributed uniformly on the telescope slide faces.
Fully retract telescopic section III.

Lubricate
telescopic
section II

Telescope telescopic section II to the middle locking position and lock it.
Extend telescopic section I to approx. 58% until the lubricating hole for
telescopic section II can be reached in the top chord.
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
of telescopic section II.
Extend and retract telescopic section II again so that the grease is distributed uniformly on the telescope slide faces.
Retract telescopic section II.
02.07.2001
2 084 643 en
8 - 27

8.5 Main boom
Lubricating
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.
02.07.2001
Retract telescopic section I.
8 - 28
2 084 643 en

8.6 Hoist ropes
8.6
Hoist ropes
8.6.1
Checking the position of sheaves and rope drums
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 rope s(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
the drum as you do this.
The ropes must be uniformly wound onto
the rope drum.
The turns on the drum must have a
uniform distance of 0 to 2 mm.
The cross-over points must be offset by
approx. 180.
Check the position of the hoist ropes on the sheaves at the boom head and
in the hook block.
Check the sheaves for damage and wear, and check that they run freely.
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 lowering limit switch. This causes the lowering limit switch to become set incorrectly and to switch off too late or not at all. In addition, the load may fall.
02.07.2001
The upper layer of rope lies over the lower layer at the cross-over points.
2 084 643 en
8 - 29

8.6 Hoist ropes
8.6.2
Checking the status
Reeve the hoist rope on the hook block six times ( 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 (
Assessing the condition of the hoist rope, S. 8 - 31). 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
Setting the lowering limit switch, S. 8 - 39.
must be reset;
Check the mounting of the rope clamp (1) on

the rope drum for damage and ensure that it
is securely attached (tightening torque;
Special tightening torques, S. 10 - 2).
Check whether the hoist rope can be wound

without kinking and flattening:
The free end of the rope must protrude from
the pocket (2).
Check the rope securing device in the rope

end clamp (2) for proper seating and correct
positioning of rope.
02.07.2001
The rope end clam p(1) must be attached to

the free end of the rope and the rope must
secured around the rope wedge (3).
8 - 30
2 084 643 en

8.6 Hoist ropes
Assessing
the condition of
the hoist rope
If in doubt about damage assessment, always consult an expert.

To assess the condition of the hoist rope, you must be familiar with the following:
the type of rope (crosslay rope or Langs lay rope),
the number of load bearing wires in the outer strand
the rope diameter (
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 Langs lay ro p e(2), the wires run at an
angle of approximately 45 to the longitudinal
direction of the rope.
02.07.2001
To calculate the number of bearing outer

wires (1), count the number of outer strands of
the rope and multiply by 7.
If there are multiple layers of strands, only the outer layer is counted.
s
2 084 643 en
8 - 31

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
load-bearing
outer
wires
Crosslay rope
13 mm
16 mm
19 mm
22 mm
24 mm
on
78
mm
on
390
mm
on
96
mm
on
480
mm
on
114
mm
on
570
mm
on
132
mm
on
660
mm
on
144
mm
on
720
mm
101-120
10
10
10
10
10
121140
11
11
11
11
11
Number of visible wire strand fractures

Loadbearing outer
wires
(Quantity)
Lang's lay rope

13 mm
16 mm
19 mm
22 mm
24 mm
on
78
mm
on
390
mm
on
96
mm
on
480
mm
on
114
mm
on
570
mm
on
132
mm
on
660
mm
on
144
mm
on
720
mm
101-120
121140
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).
02.07.2001
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!
8 - 32
2 084 643 en

8.6 Hoist ropes
Damage
Description
Cause
Wire strand
fracture (1)
Wire breakage
clusters (2)
Strand
breakage (3)
Individual wires are General wear caused

broken; the broken by aging of the rope
ends of the wires
are protruding from or
the rope.
Effect of heat
Tarnishing colour is Rope has been subvisible externally on jected to strong heat.
the rope.
Replacement
At the latest, replace hoist rope
when the maximum permissible
number of wire strand fractures
according to the table are visible
externally.
Subsequent damage
Replace hoist rope immediately
resulting from damage if wire breakage clusters or
to the rope.
strand breakage occur.
The frequency of wire breakage
increases with rope age. For reasons of safety, it is advisable to
replace the hoist rope while the
number of broken wires is still
low.
Replace hoist rope immediately.
02.07.2001
2 084 643 en
8 - 33

8.6 Hoist ropes
Damage
Diameter
reduction (1)
Description
The diameter of
the rope has become smaller in
large areas.
Cause
Structural changes
Replacement
Immediately replace hoist rope
if the diameter has decreased by
15% or more with respect to the
nominal diameter.
Corrosion or abrasion. Immediately replace hoist rope

if the diameter has decreased by
10% or more with respect to the
nominal diameter.
The rope is winds its Damage resulting from
way along its longi- overloading.
tudinal axis in a way
which is similar to a
corkscrew.
The deformation is
measured with the
attached hook block.
Even a small amount of deformation leads to increased abrasion, wire strand fractures and
rough operation of the cable
drive.
If deformation 'x' at a position
on the hoist rope is greater than
a third of the rope diameter, the
hoist rope must be replaced immediately.
Basket-type
deformation
(3)
Wires from the

Outer and inner layers
outer layer are pro- have dislocated from
truding from the
one another.
rope. In various areas of the rope, the
ply has buckled or is
protruding from the
rope.
8 - 34
2 084 643 en
02.07.2001
Cork-screw
deformation
of rope (2)

8.6 Hoist ropes
02.07.2001
Damage
Description
Cause
Replacement
Loop
formation (1)
Outer layer wires in

the form of hair pins
are protruding from
the rope on the side
opposite to the rope
pulley.
General wear due to

aging of the rope or
subsequent damage
resulting from damage
to the rope.
Immediately replace hoist rope

if the rope structure has been
substantially altered by the loop
formations.
Loosening of
wires or
strands (2)
Outer wires or
Corrosion or abrasion.
strands have beOther causes.
come loose. Only
the inner strands
continue to bear the
load.
Formation
of nodes (3)
Formation of nodes;
repeatedly occurring node-formed
thickening of rope;
core often protrudes.
The strands bear on
each other at narrow locations; increased occurence
of wire breakage.
Constriction
(4)
Reduction of rope
General wear caused
diameter over short by aging of the rope.
sections.
General wear due to

aging of the rope or
subsequent damage
resulting from damage
to the rope.
2 084 643 en
The number of broken wires determines when the rope must be

replaced.
Determine number of broken
wires;
replace hoist rope immediately
if serious node formation occurs.
Replace hoist rope immediately

if serious constriction occurs.
8 - 35

8.6 Hoist ropes
Damage
Description
Cause
Replacement
Crushes areas,
mostly with wire
breakage.
Mechanical damage,
Determine number of broken
e.g. due to driving over wires; replace hoist rope immethe rope.
diately if serious crushing occurs.
Crinkling
Crinkle type rope

deformation.
Loaded hoist rope was Replace hoist rope immediately.

pulled over an edge.
Kink (2)
Rope deformation
with twisting and
broken wires.
Rope was pulled

straight while twisted
and located in eyes.
Buckle (3)
Buckled section in
rope.
Mechanical damage.
02.07.2001
Flattening (1)
8 - 36
2 084 643 en

8.6 Hoist ropes
Replacing the
hoist rope
The installation procedure can have a great influence on the service life of a
hoist rope. Errors in installation reduce the service life considerably, therefore:
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.
Use only a replacement hoist rope which has the same technical specifications as the defective rope or an original replacement rope.
Unreeve the hook block ( Operating instructions, chapter on Rigging

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
Setting the lowering limit switch, S. 8 - 39).
completely (
Wind out the remaining layers from the hoist drum.
Ensure that the rope is not wound on again in the other direction.
Risk of accidents from rotating rope drum!

Turn off the diesel engine and remove the ignition key so that no unauthorized operation of the hoist can occur.
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 p o u ch(
3)
and out of the bore hol e(2).
Pull the hoist rope from the boom and out of

02.07.2001
the sheaves at the boom head.
s
2 084 643 en
8 - 37

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).
Put on the rope clamp (5) and screw it down;
Place the rope wedge (4) into the hoist rope

loop and insert it into the pouch (3) in the
hoist drum.

until the rope wedge slides completely into
the pouch (3) of the hoist drum.
8 - 38
Restart the diesel engine.
2 084 643 en
02.07.2001
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.

8.6 Hoist ropes
Reel the hoist rope slowly onto the drum, keeping the hoist rope tight.
Reeve the hook block six times ( Operating instructions, chapter on Rigging 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.
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
Setting the lowering limit switch, S. 8 - 39).
been wound (
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.
After installing a new hoist rope, the lowering limit switch must always be
reset.
Setting the lowering 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!
Reeve the hoist rope with 6 falls.

Extend boom fully.
Lower hook block until only five turns remain on the hoist drum.
02.07.2001
2 084 643 en
8 - 39

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 scre w(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 lowering limit switch after it has been set.
Lowering limit
switch function
control
Raise the hook block until there are about 10 turns on the hoist drum.
Lower the hook block again and check whether the lowering limit switch
is set properly.
02.07.2001
The lowering limit switch must switch off the hoist when five rope turns are
still on the drum.
8 - 40
2 084 643 en

8.7 Safe load indicator
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.
The second cable drum (1) is located in the

main boom underneath the telescoping cylinder.
02.07.2001
You can reach the cable drum through the

manhole if you first extend telescopic section
I approx. 2.0 m.
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.
2 084 643 en
8 - 41

Prerequisites
Before maintenance, the following requirements must be met:

The main boom is resting in the boom support.
G
Maintaining slip
ring assembly
Operating instructions,
The battery master switch ist switched off;
chapter on Diesel engine, section on Turning off diesel engine.
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.
To lubricate the slip ring assembly, only use lubricants specified in the
Make sure that the cable drum is currentless.
Unscrew all screws (1) and remove the

cover (2).
Check the seal on the casing for damage and

replace it if necessary.
Remove any moisture in the casing with a

clean, lint-free cloth.
02.07.2001
Risk of damage to health with improper handling!

When using and storing the lubricant make sure you observe the information on the packaging and the enclosed safety data sheet!
8 - 42
2 084 643 en

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 because of the initial tension.
Check to make sure all screws (1) are tight.
Wait until the solvent has evaporated

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

that the seal is in the right place.
02.07.2001
Attach the casing with all the screws (1).
2 084 643 en
8 - 43

02.07.2001
Blank page
8 - 44
2 084 643 en

8.8 Central lubrication system
8.8
Central lubrication system

The grease container (1) is located on the right
side of the turntable above the storage compartment.
Only fill with special grease as specified in the
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, S. 7 - 55).
(
02.07.2001
2 084 643 en
8 - 45

8.8 Central lubrication system
02.07.2001
Blank page
8 - 46
2 084 643 en

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 lubricated on the hook block.
Use lubricating grease specified in the Maintenance plan, S. 5 - 9.
The diagram gives an example of the location
of the lubricating nipple s(1), (2) and (3) on a
hook block. There are other lubricating nipples
on the other side.
Clean the lubricating nipples on all hook
02.07.2001
blocks supplied and on the hook tackle and

lubricate them with a grease gun.
2 084 643 en
8 - 47

8.9 Hook blocks
02.07.2001
Blank page
8 - 48
2 084 643 en

8.10 Superstructure electrical system
8.10
Superstructure electrical system
8.10.1
Checking the acid level of batteries
M1
Maintenance work is described in section Checking the acid level of batteries,

S. 7 - 63.
8.10.2
Checking the acid concentration of batteries
M3
02.07.2001
Maintenance work is described in section Checking the acid concentration of

batteries, S. 7 - 64.
2 084 643 en
8 - 49

8.10 Superstructure electrical system
02.07.2001
Blank page
8 - 50
2 084 643 en

8.11 Superstructure air conditioning system (additional equipment)
8.11
Superstructure air conditioning system (additional

equipment)
The GMK 4075 is equipped with only one refrigerant circuit for the airconditioning system on the carrier and superstructure.
For additional maintenance work, see Carrier air conditioning system (additional equipment), S. 7 - 65.
8.11.1
M6
Checking hoses
Check all refrigerant hoses for damage and worn areas.
02.07.2001
Only allow damaged hoses to be replaced by GROVE Customer Support.
2 084 643 en
8 - 51

8.11 Superstructure air conditioning system (additional equipment)
02.07.2001
Blank page
8 - 52
2 084 643 en

8.12
8.12.1
Lubricating the counterweight hoist unit
M1
Three lubricating nipples are located on both pivot bearings of the counterweight hoist unit.
Use only lubricating grease specified in the Maintenance plan, S. 5 - 9.
Both pivot bearings of the counterweight hoist
unit are lubricated via lubricating nipple s(1).

lubricating nipples.
Use a grease gun to apply grease to the

lubricating nipples.
8.12.2
Checking for correct operation of the auxiliary

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

auxiliary heater (additional equipment), S. 7 - 75.
02.07.2001
For additional information, see the section on Crane cabin heating and ventilation, water-additional heating system (additional equipment) in the chapter on
Crane operation in the Operating instructions.
2 084 643 en
8 - 53

02.07.2001
Blank page
8 - 54
2 084 643 en
9
02.07.2001
2 084 643 en
............................. 9-
02.07.2001
2 084 643 en

Carry out the following work if the truck crane is to be out of operation for a
long period (months):
Before the truck

crane is put out of
operation
Clean the crane thoroughly from inside and outside.

Remove rust and touch up the paintwork.
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.
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.
During periods
out of operation
Check the levels in the fuel tanks. Always keep the tanks filled.
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.
(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
(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.
02.07.2001
2 084 643 en
9-1
Before putting the

truck crane back
into operation
Open all air filters.

Inflate the tyres up to the prescribed pressure.
Carry out periodic maintenance work in accordance with the maintenance
02.07.2001
plans in chapter 5.
9-2
2 084 643 en
10
Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 -
10.1
Tightening torques for retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 -
10.2
Special tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 -
02.07.2001
10
2 084 643 en
02.07.2001
2 084 643 en
Tightening torques
10.1 Tightening torques for retaining bolts
10
Tightening torques
10.1
Tightening torques for retaining bolts
Metric standard screw-thread

Metric fine screw-thread
Guiding values
Spanner size (mm)

Thread size
(mm)
Tightening torques
(maximum permissible screw preload)
for lubricated screws (Nm)
Screw quality
Cylinder
screw
M8
M8x1
13
M 10
M 10 x 1.25
17
M 12
M 12 x 1.5
8.8
10.9
12.9
23
24
32
34
36
41
44
47
62
66
75
79
19
10
78
81
110
113
130
135
M 14
M 14 x 1.5
22
12
120
135
170
189
210
225
M 16
M 16 x 1.5
24
14
165
203
190
284
320
342
M 18
M 18 x 1.5
27
14
260
293
365
414
435
495
M 20
M 20 x 1.5
30
17
370
414
520
576
620
693
M 22
M 22 x 1.5
32
17
500
549
700
774
840
945
M 24
M 24 x 1.5
36
19
640
702
900
990
1080
1170
M 30
46
22
1300
1800
2160
M 33
50
24
2700
M 36
55
27
3300
02.07.2001
Hexagon
screw
2 084 643 en
10 - 1
Tightening torques
10.2 Special tightening torques
10.2
Special tightening torques
Description
Thread
size
(mm)
Spanner size
(mm)
Hexagon
screw
Cylinder
screw
Tightening
torque
(Nm)
Suspension strut:
Vehicle frame / guide case (upper)
M 16
17
265
Vehicle frame / guide case (lower)
M 24
19
900
Support element / steering split

shell
M 16
14
265
Support element / operating head
M 20
30
17
520
Locking screws for steering linkage

spherical-head connection
Head = 40 mm
M 12 x 1.5
19
70 80
Locking screws for steering linkage

spherical-head connection
Head = 50 mm
M 14 x 1.5
22
160 180
Wheel nuts
M 22 x 1.5
32
650
Retaining bolts of
ball slewing connection
M 24
36
954
Rope clamp on the

hoist drum
M 10
17
46
Gearbox
02.07.2001
Oil filling/inspection screw and oil

drain plug
10 - 2
2 084 643 en
02.07.2001
Appendix
2 084 643 en
02.07.2001
2 084 643 en
Appendix
Date of
commissioning/
Date of
inspection
Operating
conditions
since last
inspection
(collective
load)
Km i
Collective load
factor
[h]
General overhault preformed on: ................................
[h]
Operating
Operating
houres of entire houres of
crane
superstructure
WARNING:
A gneral overhaul must be preformed at least once every 10 years!
"i"
Inspection
no.
..................
..................
..................
..................
..................
..................
..................
..................
..................
[h]
Operating
houres of
superstructure
since last
inspection
[h]
Operating
houres of
winch
1)
To be used if this table is not contained in the crane logbook.
Collective load factor in inspection interval "i" according to section 2.1

Actual operating hours in inspection interval "i" according to section 2.2
Km i =
Ti
Collective load factor established during winch calculation

This factor is found in the operating manual.
Km =
Remaining theoretical service life

Theoretical service life remaining after previous inspection
Di
[h]
Name of
inspector
Proportion of theoretical service life used since last inspection
[h]
Di = D i - 1 - Si
Remainin g
theoretical
service life
D i -1 =
Si
[h]
Proportation of
Operating
theoretical service
houres of the
winch since last life (D) used:
inspection Ti
Km
S i = ____i x T i
Km
Table to determine the remaining theoretical service life on winch no. ...
Crane model:
Works number:
Commissioned on:
Winch serial number in acc. with model plate:
Last general overhaut performed on:
Winch design data (see operating manual):
Power unit group:
Collective load:
Collective load factor:
1)
Signature Commen ts
Date of
commissioning/
Date of
inspection
Operating
conditions
since last
inspection
(collective
load)
Km i
Collective load
factor
[h]
General overhault preformed on: ................................
[h]
Operating
Operating
houres of entire houres of
crane
superstructure
WARNING:
A gneral overhaul must be preformed at least once every 10 years!
"i"
Inspection
no.
..................
..................
..................
..................
..................
..................
..................
..................
..................
[h]
Operating
houres of
superstructure
since last
inspection
[h]
Operating
houres of
winch
1)
To be used if this table is not contained in the crane logbook.
Collective load factor in inspection interval "i" according to section 2.1

Actual operating hours in inspection interval "i" according to section 2.2
Km i =
Ti
Collective load factor established during winch calculation

This factor is found in the operating manual.
Km =
Remaining theoretical service life

Theoretical service life remaining after previous inspection
Di
[h]
Name of
inspector
Proportion of theoretical service life used since last inspection
[h]
Di = D i - 1 - Si
Remainin g
theoretical
service life
D i -1 =
Si
[h]
Proportation of
Operating
theoretical service
houres of the
winch since last life (D) used:
inspection Ti
Km
S i = ____i x T i
Km
Table to determine the remaining theoretical service life on winch no. ...
Crane model:
Works number:
Commissioned on:
Winch serial number in acc. with model plate:
Last general overhaut performed on:
Winch design data (see operating manual):
Power unit group:
Collective load:
Collective load factor:
1)
Signature Commen ts

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Maintenance Manual GMK 4075

Duplications and print-outs of data carriers

The following chapters are contained in this

Safety and environmental protection

Lubricants and fuels

Description of maintenance work on the carrier

Description of maintenance work on the superstructure

Longer periods out of operation

Maintenance Manual GMK 4075

Maintenance Manual GMK 4075

Using the maintenance manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 -

Warnings and symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 -

GROVE customer support maintenance instructions . . . . . . . . . . . . . . . . . . . . . . 1 -

Definitions of stated directions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 -

Maintenance Manual GMK 4075

Maintenance Manual GMK 4075

Using the maintenance manual

Warnings and symbols

Maintenance Manual GMK 4075

GROVE customer support maintenance instructions

professional repair work / overhauling.

Maintenance Manual GMK 4075

Replace all seals before assembly. Clean the sealing surfaces.

Keep brake and clutch linings free of grease.

When handling hydraulic oil, cleanliness is imperative. Even new hydraulic

fore re-using them and replace them if necessary.

Maintenance Manual GMK 4075

Our training centre at our plant in D-26389 Wilhelmshaven offers specialized

Definitions of stated directions

Maintenance Manual GMK 4075

Handling substances which are harmful to the environment. . . . . . . . . . . . . . . . 2 -

Maintenance Manual GMK 4075

Maintenance Manual GMK 4075

Safety and environmental protection

Safety and environmental protection

Familiarize yourself with the truck crane and its operation.

Maintenance Manual GMK 4075

Safety and environmental protection

Do not allow hot materials to escape unchecked. Risk of scalding!

Keep the corroding effect of battery acid in mind.

What do environmentally harmful

Handling substances which are harmful to the

gional regulations as well as the instructions in this chapter.

Maintenance Manual GMK 4075

Safety and environmental protection

Substances harmful to the environment can be corrosive. Therefore only

Collect draining oil in a suitable container.

Collect and store

Substances which are environmentally harmful should always be collected

Also collect the environmentally harmful substances divided according to

Ask your local environmental protection authority about the different

Only store environmentally harmful substances in approved containers

Ask your local environmental protection authority about the prescribed

Only have collected environmentally harmful substances disposed of by

Maintenance Manual GMK 4075

Safety and environmental protection

Maintenance Manual GMK 4075

Overview of the components that are easily damaged when cleaning. . . . . . . . 3 -

Maintenance Manual GMK 4075

Maintenance Manual GMK 4075