Gmk5170 Maintenance Manual
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Maintenance manual
3 112 477 en Serial number
29.04.2008
Important note
© Copyright reserved by Manitowoc Crane Group Germany GmbH The passing on or duplication of this document as well as the utilisation and disclosure of its contents are prohibited unless expressly permitted. Infringement will incur liability for compensation. All rights pertaining to registration of patent or utility model are reserved. The original language of this document is German.
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Maintenance manual GMK 5170
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Any type of duplication or excerpt from this document, also in electronic form, is not subject to the revision service of Manitowoc Crane Group Germany GmbH.
Hydraulic Oil – hydraulic system Deviating to the information in the supplied maintenance manual, the hydraulic system in the carrier/superstructure is filled with a different oil type. This new type of oil is in use since mid january 2015 for the first oil fill during the cranes production process.
• Please contact Manitowoc Crane Care, if you are in doubt. This additional page indicates the oil type first filled in at the factory and contains maintenance information.
Oil type
• Only use the oil specified in this document when carrying out maintenance work on the hydraulic system.
Maintenance information
Place of use
Specification
Oiltank: Carrier and superstructure
Castrol Hyspin AWH-M 32 DIN 51524-3 Hydraulic Oil HVLP ISO VG 32 GROVE Part no. 04162158 available from Manitowoc Crane Care
• Carry out maintenance work using the oil stated above, as described in the supplied maintenance manual. The maintenance intervals in the supplied maintenance manual apply.
• For maintenance, also observe the following notes:
Risk of damage to the environment if disposed of improperly This oil must also be disposed of properly in accordance with legal specifications.
12.01.2015
S O
Risk of damage to the hydraulic system Do not mix this oil with other oils. Oil mixtures can damage the hydraulic system.
Correction sheet Maintenance manual GMK truck cranes
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1
12.01.2015
Blank page
2
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Correction sheet Maintenance manual GMK truck cranes
Additional hydraulic oil filters Deviating from the specifications – of the accompanying Maintenance manual, and – of the accompanying Additional pages the two additional hydraulic oil filters in the carrier – must be changed at all circumstances every 12 months (M 12).
Validity
This additional page refers to the truck cranes GMK 5170 and GMK 5220.
Replacement
This additional page replaces the additional pages 3 112 577 and 3 112 427. This additonal page completes the information about the hydraulic oil filters 3 and 4 (in the carrier) in the maintenance manual GMK 5170-Cummins.
M 12
Changing the hydraulic oil filters Maintenance interval
• Replace the additional hydraulic oil filters – once after the brand-new truck crane has been in driving position for 50 hours, and – every 12 months (M 12), and – every time the hydraulic oil in the carrier is changed in accordance with the accompanying Maintenance manual.
H
Always comply with the maintenance intervals specified here. The ECOS display does not have warning messages for the additional hydraulic oil filters.
Spare parts and tools
Quantity
GROVE part no.
Filter
2
03135866
Repair set (if necessary)
2
03135867
04.08.2009
Designation
s Additional page GMK 5170/5220
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1
Changing the filter
Before changing the filter, observe all prerequisites and warnings in the section Carrier hydraulic system of the accompanying Maintenance manual.
• Remove the receptacle (1). • Change the filter (2). • If necessary, replace any defective parts (repair set).
• Fill the receptacle with clean oil.
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• Put the receptacle (1) on and tighten it.
2
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Additional page GMK 5170/5220
Additional maintenance work on the main boom
Validity
These additional pages hold for all GMK truck cranes and supplement the supplied maintenance manuals.
Reason All the lubricating work for the heavily loaded slide faces on the telescopic sections of the main boom is described in the relevant supplied maintenance manual. The heavily loaded slide faces are located on the lower outside slide faces (2) and the upper inside slide faces (3) of the telescopic sections.
In addition, you must also lubricate the unpainted upper outside faces (1). The factory-applied film of lubricant can be washed off in the extended state. Therefore, you must lubricate the upper outside faces of all telescopic sections to prevent corrosion.
Interval
• Lubricate the upper outside faces every three months (M3).
Grease
• Apply the grease with a brush or roller. (Lubricant paste PAL 1, 25 kg bucket, GROVE part no. 02314698).
Lubricating
• Find out about all lubricating points on all telescopic sections in the relevant supplied maintenance manual.
• Always lubricate the upper outside faces (1) before the lower outside slide faces (2).
• Continue the maintenance work as described in the relevant supplied
17.02.2010
maintenance manual.
Additional pages GMK truck cranes
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1
17.02.2010
Blank page
2
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Additional pages GMK truck cranes
Contents: 1
General notes
2
Safety and environmental protection
3
Cleaning
4
Run-in regulations
5
Maintenance overview
6
Lubricants and consumables
7
Maintenance work on the carrier
8
Maintenance work on the superstructure
9
Longer periods out of service
10
Torques
11
Spare parts required for maintenance Appendix
This maintenance manual does not replace the operating instructions.
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Details of operation and standard safety instructions can be found in the operating instructions.
Maintenance manual GMK 5170
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Blank page
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Maintenance manual GMK 5170
1 General notes
1.1
Using the maintenance manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 -
1
1.2
Warnings and symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 -
1
1.3
Maintenance instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 -
2
1.4
Notes concerning the electronic control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 -
4
1.5
Safety instructions for welding work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 -
4
1.6
Definition of positional references. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 -
5
1.7
Conversion table for US measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 -
6
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1
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Maintenance manual GMK 5170
General notes 1.1 Using the maintenance manual
1
General notes
1.1
Using the maintenance manual This maintenance manual does not replace proper training and instruction! Truck crane maintenance personnel must have the relevant, specialist 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 Lattice extension operating instructions.
Warnings and symbols The following designations and symbols are used in the operating instructions to highlight particularly important information:
G S O
This symbol indicates dangers related to the described operation 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 section Handling substances which are harmful to the environment, p. 2 - 4.
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The vertical line to the left of the text indicates that: This text, regardless of its length, relates to the warning symbol.
s Maintenance manual GMK 5170
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1-1
General notes 1.3 Maintenance instructions
H s 1.3
The hand with the pointing finger indicates passages that contain additional instructions and tips regarding truck crane operation.
This symbol indicates that the topic is continued on the next page. Turn to the next page!
Maintenance instructions This maintenance manual is intended for maintenance personnel. The maintenance manual does not contain information on repair work. Repair work may be carried out only by qualified repair personnel (e.g. CraneCARE). Repair work also requires: – appropriate workshop equipment – special tools – spare parts approved by Manitowoc Crane Group Germany GmbH It is your responsibility to maintain and service the truck crane regularly in order to extend its service life and keep it in good working order. Please note that Manitowoc Crane Group Germany GmbH can uphold the warranty provided for the truck crane only if the following conditions are fulfilled: – it is used for the purpose for which it was intended – care and maintenance is carried out as prescribed
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– repair work/overhauling is carried out by professionals
1-2
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Maintenance manual GMK 5170
General notes 1.3 Maintenance instructions
Many defects and failures are caused by improper maintenance such as: – insufficient oil, grease or antifreeze – dirt – rope damage – defective compressed air and hydraulic systems – hose damage or loose screw connections – faulty brakes – faulty tyres or wheel rims – exceeded maintenance intervals
For your safety and the safety of others, avoid these errors by carrying out service and maintenance work carefully within the specified intervals. Do not delay maintenance work that is due. If repairs are needed, immediately contact CraneCARE or your repair crew. 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 the oil filler opening, the oil inspection opening, the drain opening and the lubricating nipples.
• When changing the oil, let the oil run out at operating temperature. • Ensure that only oils and lubricants specified in the Lubricants, p. 6 - 1 are used.
• Replace all filters within the specified period if cleaning is not explicitly permitted.
• Replace all gaskets before assembly. Clean the sealing surfaces. • Tighten loose screw connections on hydraulic and compressed air systems only when the system is depressurised.
• Keep brake and clutch linings free of grease. • Replace hydraulic hoses immediately once damage or penetration of moisture becomes visible.
• Cleanliness is imperative when handling hydraulic oil. Even new hydraulic oil must be filtered when filling.
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1-3
General notes 1.4 Notes concerning the electronic control
• Cleanliness is imperative when handling grease on the central lubrication system. Do not remove the caps from the filling hole and grease gun until immediately before refilling the grease.
• Check fastening and retaining elements (bolts, nuts, lock washers) before re-using them and replace them if necessary. Torques can be found in sections p. 10 - 1 and p. 10 - 2. Our training centre at our plant offers specialised training programmes. Please contact CraneCARE. The vehicle must fulfil all the applicable regulations before being put into operation and driven on public roads.
1.4
Notes concerning the electronic control The electronic ESX control generally has a service life of 10 years. In terms of use, the control system's service life can be estimated based on the following limiting factors: – The service life of EEPROM allows 105 accesses. – The safety relay permits a maximum of 107 make-and-brake cycles. – Some conventional condensers in the ESX have a service life of 10 years. The device must be serviced or replaced by CraneCARE before one of these limits is reached.
1.5
Safety instructions for welding work To avoid damage, especially to electronic parts, there are certain steps you must take before doing any welding work. You should therefore always consult CraneCARE before welding.
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All welding work (especially on load carrying members) may be performed only by qualified professional personnel with the prior written permission of Manitowoc Crane Group Germany GmbH.
1-4
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Maintenance manual GMK 5170
General notes 1.6 Definition of positional references
1.6 Basic rule
Definition of positional references Directions always depend on whether the carrier or the superstructure is being operated. On the carrier The driver's cab is always at the front, which means that: 1: Front
2: Right
3: Rear
4: Left
Forwards always means the driver's cab is to the front. Backwards always means the rear lights on the carrier are to the front.
On the superstructure The main boom head is always at the front, which means that:
Switches and buttons
1: Front
2: Right
3: Rear
4: Left
For switches and buttons, the terms down and up are used. Regardless of the fitting position (vertical, horizontal, diagonal, perpendicular or turned), the following always applies: Down: Press (1) – on the symbol Press (2) – opposite the symbol
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Up:
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1-5
General notes 1.7 Conversion table for US measurements
1.7
Conversion table for US measurements
1-6
Converting from
in
Multiply by
mm
in
0.03937
in
mm
25.4
m
ft
3.28084
ft
m
0.30479
m²
ft²
10.76391
cm²
in²
0.155
cm³
in³
0.061
l
gal (US)
0.264178
kg
lbs
2.204622
lbs
kg
0.45359
t
lbs
2204.622
lbs
t
0.0004536
kN
lbf
224.809
daN/cm²
lbf/in²
14.50378
lbf/in²
daN/cm²
0.06895
bar
psi
14.50378
psi
bar
0.06895
m/s
ft/s
3.28084
km/h or km
mph or mi
0.62137
mph or mi
km/h or km
1.60935
Nm
lbf ft
0.7375
°C
°F
1.8 x °C + 32
°F
°C
(°F-32)/1.8
t/m²
lbs/ft²
204.8
m²/t
ft²/lbs
0.04882
MPa
bar
10
bar
MPa
0.1
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Maintenance manual GMK 5170
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The following conversion factors will help you convert from metric to US units and vice versa when the truck crane is being used in countries that use US units of measurement.
2 2
Safety and environmental protection
2.1
Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -
1
Securing against unauthorised use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -
3
Handling substances which are harmful to the environment. . . . . . . . . . . . . . . . 2 -
4
2.1.1
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2.2
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Maintenance manual GMK 5170
Safety and environmental protection 2.1 Safety rules
2 2.1
Safety and environmental protection
Safety rules When carrying out maintenance work, please observe the applicable accident prevention regulations. Observe the following safety rules:
• Familiarise yourself with the truck crane and its operation. Read the Operating instructions carefully and request guidance from the crane operator.
• Do not carry out maintenance work on the truck crane unless you are authorised to do so.
• Observe all safety and warning signs on the truck crane. • Observe all safety instructions contained in this Maintenance manual. • Familiarise 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 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 extendable 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 unauthorised operation before beginning maintenance work. Remove the key and put up warning signs.
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s
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2-1
Safety and environmental protection 2.1 Safety rules
If due to exceptional circumstances, the truck crane must be put into operation for certain types of maintenance work, great care must be taken where there are moving parts (superstructure, outriggers, cardan shafts, slewing bearing, motors, tiltable crane cab). There is a risk of injury.
• Ensure that all hydraulic components are returned to their initial positions (e.g. the main boom) or locked (e.g. the outriggers). Escaping hydraulic fluid or compressed air can cause severe injury. Remember that the hydraulic and compressed air systems of the truck crane are pressurised even when the crane is not in operation. Only tighten loose screw connections when the systems are depressurised. Always depressurise the hydraulic and compressed air systems before opening them.
• Do not allow hot materials to escape unchecked – Risk of burning yourself • Observe the applicable safety regulations when working with flammable fluids.
• Observe the applicable safety regulations when working with process materials.
• Switch off all electrical consumers and disconnect the earthing terminal before removing any batteries.
• Keep in mind the corroding effect of battery acid. • Note the fire alarm and fire-fighting facilities on the site. • Return the truck crane to proper working order once maintenance work is
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completed. Inform the crane operator accordingly.
2-2
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Maintenance manual GMK 5170
Safety and environmental protection 2.1 Safety rules
2.1.1
Securing against unauthorised use • Secure the truck crane against unauthorised use by: – applying the parking brake – switching the transmission to neutral position N – turning off the engine – removing the ignition key and – stowing away the hand-held control in the crane cab or in the driver's cab – locking the driver's cab and the crane cab
G
Danger due to unauthorised use! Always stow away the hand-held control in the crane cab before leaving the truck crane, and lock the door to the crane cab or the driver's cab. In this way, you can prevent unauthorised persons from starting the engine with the hand-held control.
• Set up warning signs in the driver's cab/crane cab with information about – when – why – by whom the truck crane was secured to prevent unauthorised use.
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Remove the warning signs from the driver's cab and the crane cab after completion of the maintenance work.
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2-3
Safety and environmental protection 2.2 Handling substances which are harmful to the environment
2.2
What substances are harmful to the environment?
Handling substances which are harmful to the environment When you carry out maintenance work on the truck crane, you will occasionally work with consumables which are classed as harmful to the environment as per current national and regional regulations. These include 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 regional regulations as well as the instructions in this chapter.
Use suitable equipment
Substances harmful to the environment can be caustic. When doing maintenance work involving these consumables (oils, coolant, fuel), always use containers, hoses, pumps, funnels etc. which are large enough and which are resistant to the consumables. For oil sampling, always use containers that can be closed and have sufficient capacity and resistance to the consumables. The approximate amount of consumable to be expected is specified in the maintenance plans.
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 pollute natural waters.
• Catch consumables (e.g. oils, fuels, coolant) in a suitable container when draining.
• Always use a drain hose when draining, and a funnel or a pump with hose
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suitable for the respective substance when filling.
2-4
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Safety and environmental protection 2.2 Handling substances which are harmful to the environment
Collect and store separately
Substances which are environmentally harmful should always be collected separately from other waste.
• Ask your local environmental protection authority about the different categories for the substances.
• Also, when collecting environmentally harmful substances, keep solid materials (e.g. filter cartridges) separate from liquids. Disposal costs will be reduced if you collect liquids separately according to certain categories.
• Only store environmentally harmful substances in approved containers and in locations which meet the requirements of current national and regional regulations.
Disposal
• Ask your local environmental protection authority about the prescribed disposal options.
• Once accumulated, have environmentally harmful substances disposed
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of only by disposal companies which are approved by the national or regional authority responsible.
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2-5
Safety and environmental protection 2.2 Handling substances which are harmful to the environment
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Blank page
2-6
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Maintenance manual GMK 5170
3 Cleaning
3.1
Overview of subassemblies easily damaged when cleaning . . . . . . . . . . . . . . . . 3 -
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3
Maintenance manual GMK 5170
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2
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Maintenance manual GMK 5170
Cleaning
3
Cleaning
During the first three months
The paintwork 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.
After the first three months
• Avoid water temperatures over 60 °C even after the first three months. • Do not use corrosive cleaning agents that might attack 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.
G
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.
• To prevent damage to the gaskets, never point the nozzle directly at them. • Never point the nozzle at electrical equipment, relay and switch boxes, suction and venting filters or control elements and oiled/lubricated surfaces.
• To prevent corrosion, re-oil/relubricate all slide faces after cleaning. The components specified in the next section are to be cleaned with particular care.
• After cleaning with a high-pressure device or a steam jet device, activate
à Triggering
intermediate lubrication on the central lubrication systems ( intermediate lubrication, p. 7 - 79).
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• Lubricate all remaining lubrication points with a grease gun.
Maintenance manual GMK 5170
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3-1
Cleaning 3.1 Overview of subassemblies easily damaged when cleaning
Overview of subassemblies easily damaged when cleaning
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3.1
3-2
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Maintenance manual GMK 5170
Cleaning 3.1 Overview of subassemblies easily damaged when cleaning
1 SLI terminal box 2 Telescope slide faces 3 SLI length data transmitter 4 Angle data transmitter 5 Pressure sensors 6 Lowering limit switch 7 Suspension struts 8 Superstructure switch box 9 Slewing angle sensor on the superstructure 10 Outriggers control unit 11 Lifting limit switch 12 Housing of the input-output circuit boards on the carrier 13 Swing-away lattice extension proximity switch 14 Spotlights, slewable 15 SLI connections
à Operating
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H
Subassemblies at risk of damage on the lattice extension; Instructions Lattice Extension.
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3-3
Cleaning 3.1 Overview of subassemblies easily damaged when cleaning
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3-4
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Maintenance manual GMK 5170
4 Run-in regulations
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4
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Maintenance manual GMK 5170
Run-in regulations
4
Run-in regulations Individual parts have run-in regulations which must be adhered to after: – commissioning or – replacement of a part or – general inspection. This is why you must carry out additional maintenance work on the carrier and superstructure after stipulated periods of time have expired:
Operating hours (oper. hrs.)
Driven km
Additional maintenance work on the CARRIER
After 50
Tighten wheel nuts; Special torques, p. 10 - 2.
After 150
Tighten wheel nuts; Special torques, p. 10 - 2.
After 50
à à
Tighten up the clips on the coolant hoses; Special torques, p. 10 - 2.
à After 100
Lubricate the support bearings; Lubricating the support bearings, p. 7 - 103.
à
During the first 100
Check the hydraulic oil filters weekly; Cleaning the magnetic rods, p. 7 - 64, Changing the hydraulic oil filter, p. 7 - 74.
à à
After 100
After 1 000
Change the drive oil; p. 7 - 30 for the transfer case, p. 7 - 35 for the axle centre drives, p. 7 - 39 for the final drives.
After 250
After 2 500
Change the engine oil; Engine manufacturer's documentation.
à à à à
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s
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4-1
Run-in regulations
Operating hours (oper. hrs.) After 50
Additional maintenance work on the SUPERSTRUCTURE Tighten up the clips on the coolant hoses; Special torques, p. 10 - 2.
à During the first 100
After 100
Check the hydraulic oil filters weekly; Changing the hydraulic oil filter, p. 8 - 41.
à
Tighten up the bolts on the ball bearing slewing; Ball slewing bearing, p. 8 - 31, Special torques, p. 10 - 2.
à à After 100
Hook blocks; Lubricating, p. 8 - 74.
After 200
First oil change on the hoists; Changing the oil/Checking the oil, p. 8 - 22.
After 1000 or after 12 months at the latest
Second oil change on the hoists; Changing the oil/Checking the oil, p. 8 - 22.
After 200
Change the slewing gear oil; Changing the oil/Checking the oil, p. 8 - 28.
After 250
Change the engine oil; Engine manufacturer's documentation.
à à à à
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à
4-2
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Maintenance manual GMK 5170
5 5
Maintenance overview
5.1
Maintenance intervals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 -
1
5.2
Maintenance plans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 -
3
Maintenance plan D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Maintenance plan W . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Maintenance plan M 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Maintenance plan M 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Maintenance plan M 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Maintenance plan M 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Maintenance plan Y 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Maintenance plan Y 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Maintenance plan Y 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Maintenance plan Y 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Maintenance plan Y 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 -
4 6 8 10 12 14 16 17 17 18 18
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 5.2.10 5.2.11 5.3 5.3.1 5.4
Load hook inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 20 Measures required for winch monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 21 Theoretical service life. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 21 Proportion of theoretical service life used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 22 Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 26
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5.4.1 5.4.2 5.4.3
Periodic inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 19
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Maintenance manual GMK 5170
Maintenance overview 5.1 Maintenance intervals
5
Maintenance overview – Maintenance plans D (= daily) – Maintenance plans W (= weekly) and – Maintenance plans M 1 (= monthly) to M 12 (= every 12 months) and – Maintenance plans Y 2 (= every 24 months) to Y 10 (= every 120 months). The maintenance plans are given in table form, divided into – 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 has been described. The cross references consist of the chapter number and the corresponding page number, e.g. Checking hydraulic oil level;
à p. 7 - 61.
Checking the hydraulic oil level is described in chapter 7, the section starts on page 7 - 61.
5.1
Maintenance intervals The length of the interval depends on the quality of the oil used and the operating conditions of the truck crane. The next maintenance must be carried out after – a specified time (maintenance interval) or – a specified number of kilometres driven or – a specified number of operating hours (oper. hrs.) or – an indication on the on-board computer display, ECOS display or particp. 7 - 3 or ulate filter display in the driver's cab;
à
– an indication on the ECOS display in the crane cab;
à p. 8 - 3.
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5-1
Maintenance overview 5.1 Maintenance intervals
The maintenance interval which occurs first shall determine when maintenance work is next due. – The km can be taken from the speedometer. – You can call up the engine and power unit working hours (oper. hrs.) of the superstructure one by one on the ECOS display in the crane cab. The operating hours of the engine equal the total operating hours of the superstructure. The following table sets out the maintenance intervals for the maintenance plans: Maintenance plans
Maintenance interval
Km driven (carrier)
Operating hours (oper. hrs.) of engine (superstructure)
D
Daily/before putting into operation
—
—
W
Weekly
—
—
M1
Monthly
Approx. 2 000
100
M3
Every three months
5 000 – 6 000
300
M6
Every six months
10 000 – 12 500
500
M 12
Every 12 months
20 000 – 25 000
1 000
Y2
Every 24 months
40 000 – 50 000
2 000
Y3
Every 36 months
—
3 000
Y5
Every 60 months
100 000
5 000
Y6
Every 72 months
—
6 000
Y 10
Every 120 months
200 000
12 000
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Please note that the long-term maintenance plans always include the short-term ones!
5-2
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Maintenance manual GMK 5170
Maintenance overview 5.2 Maintenance plans
5.2
Maintenance plans The descriptions of certain maintenance work in the maintenance plans D, W, M 1 to M 12 and Y 2 to Y 10 have been provided for – the carrier in chapter 7 and for – the superstructure in chapter 8. References (chapter and page number) to the description of this maintenance work can be found after the respective maintenance work for carrier and superstructure. The section titles – of chapter 7 Maintenance work on the carrier and – of chapter 8 Maintenance work on the superstructure contain the abbreviations (D to Y 10) of the relevant maintenance plan for better comprehension. In addition to the Maintenance work on the carrier and the Maintenance work on the superstructure chapter 6 also lists the Lubricants and consumables: – The descriptions of the oils/lubricants in accordance with Lubricants list, p. 6 - 2. – The amounts as approximate values for oil amounts in litres (l) (the exact oil amounts can always determined by the oil level inspection holes, the dipsticks or the oil level indicators) Lubricant applications, p. 6 - 3.
Maintenance work on the engine over and above the daily and weekly checks is only partially described in this maintenance manual. When carrying out such maintenance work, follow the instructions given in the Engine manufacturer’s documentation.
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H H
Items which are only available with additional equipment are designated accordingly. These designations are made in this section only and are not repeated in the following sections.
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5-3
Maintenance overview 5.2 Maintenance plans
5.2.1
Maintenance plan D
D
Maintenance work on the CARRIER: daily/before putting into operation Engine
à p. 7 - 5 à p. 7 - 9 à p. 7 - 10
– Checking the oil level – Checking the air filter – Checking the coolant level Transmission
à p. 7 - 21
– Checking the oil level Fuel system
à p. 7 - 14
– Draining off water from fuel filter 1 Wheels
à p. 7 - 43
– Checking the tyres for damage Steering
à p. 7 - 55
– Checking for leaks Hydraulic system
à p. 7 - 61
– Checking the oil level Electrical system
à p. 7 - 81
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– Checking the lighting and indicators
5-4
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Maintenance manual GMK 5170
Maintenance overview 5.2 Maintenance plans
D
Maintenance work on the SUPERSTRUCTURE: daily/before putting into operation Engine
à p. 8 - 5 à p. 8 - 8 à p. 8 - 9
– Checking the oil level – Checking the air filter – Checking the coolant level Fuel system
à p. 8 - 11
– Draining off water from fuel filter 1 Hydraulic system
à p. 8 - 35
– Checking the oil level Hoist ropes – Checking the position on the rope drums
à p. 8 - 55
Electrical system
à p. 8 - 75
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– Checking the lighting and indicators
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5-5
Maintenance overview 5.2 Maintenance plans
5.2.2
Maintenance plan W
W
Maintenance work on the CARRIER: weekly Engine
à p. 7 - 11
– General inspection Automatic transmission
à p. 7 - 25
– General inspection Transfer case
à p. 7 - 29
– General inspection Axle lines
à p. 7 - 33
– General inspection Wheels
à p. 7 - 44
– Checking the tyre air pressure Compressed air system
à p. 7 - 57 à p. 7 - 58
– Draining the compressed air system – Checking for leaks Hydraulic system
à p. 7 - 62 à p. 7 - 63
– Checking the hydraulic hoses – Checking for leaks Central lubrication system
à p. 7 - 77
– Checking the level Other maintenance work – Check the correct operation of the driver's cab windscreen washing system Operating instructions. and the level of fluid in the reservoir;
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à
5-6
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Maintenance manual GMK 5170
Maintenance overview 5.2 Maintenance plans
W
Maintenance work on the SUPERSTRUCTURE: weekly Engine
à p. 8 - 10
– General inspection Hoists
à p. 8 - 19 à p. 8 - 20 à p. 8 - 20
– Checking the oil level – General inspection – Checking the hoist brake Slewing gear
à p. 8 - 25 à p. 8 - 26
– Checking the oil level – Checking for leaks Hydraulic system
à p. 8 - 36 à p. 8 - 36 à p. 8 - 37
– Checking the hydraulic hoses – Checking ventilation filters – Checking for leaks Hoist ropes
à p. 8 - 56
– Checking the hoist ropes Central lubrication system
à p. 8 - 73
– Checking the level Other maintenance work – Check the correct operation of the crane cab windscreen washing system and the level of fluid in the reservoir; Operating instructions.
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à
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5-7
Maintenance overview 5.2 Maintenance plans
5.2.3
Maintenance plan M 1
M1
Maintenance work on the CARRIER: monthly/after approx. 2 000 km Engine – Notes;
à Engine manufacturer's documentation
à p. 7 - 5
Transfer case
à p. 7 - 29
– Checking the oil level Axle lines – Checking the oil level on axle centre drives – Final drives – checking the oil level – Lubricating the cardan shafts on the axle lines
à p. 7 - 33 à p. 7 - 38 à p. 7 - 41
Wheels
à p. 7 - 45
– Check tightness of wheel nuts Suspension – Suspension struts – checking the oil level – Suspension struts – checking the fastening
à p. 7 - 51 à p. 7 - 52
Electrical system
à p. 7 - 82
– Checking the batteries Air-conditioning system
à p. 7 - 87 à p. 7 - 87
– Checking the air-conditioning system – Cleaning the condenser fins Particulate filter
à p. 7 - 91
– Checking the clamp straps Towbar coupling
à p. 7 - 95
– Lubricating the towbar coupling Other maintenance work – Lubricating the support bearings
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– Checking the auxiliary heater for correct operation
à p. 7 - 103 à p. 7 - 104
5-8
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Maintenance manual GMK 5170
Maintenance overview 5.2 Maintenance plans
M1
Maintenance work on the SUPERSTRUCTURE: monthly/after 100 oper. hrs. Engine – Notes;
à Engine manufacturer's documentation
à p. 8 - 5
Electrical system
à p. 8 - 76
– Checking the batteries Air-conditioning system
à p. 8 - 77 à p. 8 - 77
– Checking the air-conditioning system – Cleaning the condenser fins Other maintenance work – Checking the auxiliary heater for correct operation
29.04.2008
– Lubricating the piston rod of the derricking cylinder
à p. 8 - 79 à p. 8 - 79
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5-9
Maintenance overview 5.2 Maintenance plans
5.2.4
Maintenance plan M 3
M3
Maintenance work on the CARRIER: every three months/after 5 000 - 6 000 km Engine – Notes;
à Engine manufacturer's documentation
à p. 7 - 5
Fuel system
à p. 7 - 15
– Changing fuel filter 1 Vehicle brake
à p. 7 - 49
– Checking brake-lining thickness Suspension – Forced lever – checking correct functioning
à p. 7 - 53
Hydraulic system
à p. 7 - 64
– Cleaning the magnetic rods Electrical system – Checking the charge level of the batteries
à p. 7 - 84
Towbar coupling – Checking the bearing – Checking the cotter pin – Checking the lower bushing – Checking the initial tension of the springs – Checking the support ring
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– Checking the function of the coupling jaw/ Resetting central position
à p. 7 - 97 à p. 7 - 98 à p. 7 - 99 à p. 7 - 99 à p. 7 - 100 à p. 7 - 100
5 - 10
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Maintenance overview 5.2 Maintenance plans
M3
Maintenance work on the SUPERSTRUCTURE: every 3 months/after 300 oper. hrs. Engine – Notes;
à Engine manufacturer's documentation
à p. 8 - 5
Fuel system
à p. 8 - 13
– Changing fuel filter 1 Ball slewing bearing – Check the bolt torques;
à Special torques
à p. 10 - 2
Main boom
à p. 8 - 49 à p. 8 - 53
– Lubricating the telescopic sections – Checking the sheaves Hoist ropes
à p. 8 - 57
– Lubricating the hoist rope Hook blocks
à p. 8 - 73
– Checking the sheaves Electrical system
à p. 8 - 76
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– Checking the charge level of the batteries
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5 - 11
Maintenance overview 5.2 Maintenance plans
5.2.5
Maintenance plan M 6
M6
Maintenance work on the CARRIER: every six months/after 10 000 - 12 500 km Engine – Notes;
à Engine manufacturer's documentation
à p. 7 - 5
Transfer case
à p. 7 - 30
– Changing the oil Axle lines
à p. 7 - 42
– Lubricating longitudinal cardan shafts Wheels
à p. 7 - 46
– Tyre change Air-conditioning system
à p. 7 - 88
– Checking hoses Particulate filter
à p. 7 - 92
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– Replacing the particulate filter
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Maintenance manual GMK 5170
Maintenance overview 5.2 Maintenance plans
M6
Maintenance work on the SUPERSTRUCTURE: every 6 months/after 500 oper. hrs. Engine – Notes;
à Engine manufacturer's documentation
à p. 8 - 5
Hoists
à p. 8 - 20
– Lubricating the auxiliary hoist Slewing gear
à p. 8 - 26
– Checking the slewing gear brake Ball slewing bearing
à p. 8 - 31 à p. 8 - 33
– Lubricating gear teeth – General inspection Cable drums and slewing angle sensor – Maintenance of the slip ring assemblies
à p. 8 - 69
Air-conditioning system
à p. 8 - 78
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– Checking hoses
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5 - 13
Maintenance overview 5.2 Maintenance plans
5.2.6
Maintenance plan M 12
M 12
Maintenance work on the CARRIER: every twelve months/after 20 000 - 25 000 km Engine – Notes;
à Engine manufacturer's documentation
à p. 7 - 5
Fuel system
à p. 7 - 17
– Changing fuel filter 2 Axle lines
à p. 7 - 35 à p. 7 - 39
– Axle centre drives – changing the oil – Final drives – changing the oil Suspension – Pressure accumulator – checking the gas pressure
à p. 7 - 54
Compressed air system – Replacing the filter cartridge of the compressed air drier
à p. 7 - 59
Steering – Pressure accumulator – checking the gas pressure
à p. 7 - 56
Hydraulic system – Changing the ventilation filter – Taking oil samples: depending on the oil sample test results: – Change the oil – Changing the hydraulic oil filter
à p. 7 - 66 à p. 7 - 67 à p. 7 - 70 à p. 7 - 74
Air-conditioning system – Checking the entire air-conditioning system
à p. 7 - 88
Other maintenance work – Lubricate the door hinges
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– Lubricate the connecting and socket pins
5 - 14
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Maintenance overview 5.2 Maintenance plans
M 12
Maintenance work on the SUPERSTRUCTURE: every 12 months/after 1 000 oper. hrs. Engine – Notes;
à Engine manufacturer's documentation
à p. 8 - 5
Fuel system
à p. 8 - 15
– Changing fuel filters 2 and 3 Hoists
à p. 8 - 22
– Changing the oil/Checking the oil Slewing gear
à p. 8 - 28
– Changing the oil/Checking the oil Ball slewing bearing
à p. 8 - 33
– Measuring tilting play Hydraulic system – Changing the ventilation filter – Pressure accumulator – checking the gas pressure – Taking oil samples – Changing the hydraulic oil filter – Changing the hydraulic oil
à p. 8 - 38 à p. 8 - 39 à p. 8 - 40 à p. 8 - 41 à p. 8 - 44
Main boom
à p. 8 - 53
– Checking the locking system Hook blocks
à p. 8 - 74
– Lubricating Air-conditioning system – Checking the entire air conditioning system
à p. 8 - 78
Other maintenance work – Lubricate the cabin door track rollers
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– Lubricate the connecting and socket pins
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5 - 15
Maintenance overview 5.2 Maintenance plans
5.2.7
Maintenance plan Y 2
Y2
Maintenance work on the CARRIER: every 24 months/after 40 000 – 50 000 km Engine – Notes;
à Engine manufacturer's documentation
à p. 7 - 5
Automatic transmission
à p. 7 - 26
– Changing the oil and the oil filter Air-conditioning system – Have the refrigerant level checked by CraneCARE. Other maintenance work
à p. 7 - 104
– Having the fire extinguisher checked
Maintenance work on the SUPERSTRUCTURE: every 24 months/after 2,000 oper. hrs. Engine – Notes;
à Engine manufacturer's documentation
à p. 8 - 5
Air-conditioning system – Have the refrigerant level checked by CraneCARE. Other maintenance work
à p. 8 - 80
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– Having the fire extinguisher checked
5 - 16
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Maintenance manual GMK 5170
Maintenance overview 5.2 Maintenance plans
5.2.8
Maintenance plan Y 3
Y3
Maintenance work on the CARRIER: every 36 months No maintenance work in this period. The long-term intervals always include the short-term intervals.
Maintenance work on the SUPERSTRUCTURE: every 36 months/after 3,000 oper. hrs. Hoists
à p. 8 - 24
– Having a partial inspection carried out
5.2.9
Maintenance plan Y 5
Y5
Maintenance work on the CARRIER: every 60 months/100 000 km Axle lines – Have the cardan shaft between the transmission on the engine and the transfer case replaced by CraneCARE.
Maintenance work on the SUPERSTRUCTURE: every 60 months/after 5,000 oper. hrs. Cable drums and slewing angle sensor
à p. 8 - 71
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– Lubricating the slewing angle sensor
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5 - 17
Maintenance overview 5.2 Maintenance plans
5.2.10
Y6
Maintenance plan Y 6
Maintenance work on the CARRIER: every 72 months No maintenance work in this period. The long-term intervals always include the short-term intervals.
Maintenance work on the SUPERSTRUCTURE: every 72 months/after 6,000 oper. hrs. Hoists
à p. 8 - 24
– Having a general inspection carried out
5.2.11
Y 10
Maintenance plan Y 10
Maintenance work on the CARRIER: every 120 months/after 200 000 km Steel construction – Check the load-bearing steel construction. For more information, please contact CraneCARE.
Maintenance work on the SUPERSTRUCTURE: every 120 months/after 12 000 oper. hrs. Steel construction – Check the load-bearing steel construction. For more information, please contact CraneCARE. Safe load indicator (SLI)
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– Have the SLI checked by CraneCARE.
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Maintenance manual GMK 5170
Maintenance overview 5.3 Periodic inspections
5.3
Periodic inspections Your truck crane GMK 5170 has been inspected before delivery. – Truck cranes that are to be used in Germany are inspected in accordance with the regulations of the Professional Trade Association as per BGV D 6 (VBG 9). – Truck cranes that are to be used abroad are inspected in accordance with the national 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 per BGV D 6 (VBG 9). According to German regulations, 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 parts. The 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 – the load hooks (
à Load hook inspection, p. 5 - 20)
– the load-bearing steel construction (for cracks, deformation, etc.), including a special check of all welds If damage is found in the steel construction, qualified specialists must determine the extent of the damage using the required material examination methods. They should then determine what sort of repair action should be carried out. Prior to carrying out welding work on the truck crane, observe the Safety instructions for welding work, p. 1 - 4.
à
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The inspector is to write a record containing the result of the annual inspection and the measures taken to repair any damage.
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5 - 19
Maintenance overview 5.3 Periodic inspections
5.3.1
Load hook inspection The hook mouth on the load hooks must be checked regularly for deformation. The mouth of the hook may not be more than 10% wider than the original dimension y, y1, y2. The original dimensions y, y1, y2 are stated 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 is more than 10% wider than the initial dimension.
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G
Risk of accidents 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
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Maintenance manual GMK 5170
Maintenance overview 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 hoisting gears; p. 8 - 24.
à
These measures for monitoring the winches (hoists) were compiled by the German Machine Builders' Association (VDMA) and are to be used for all vehicle cranes according to the German Accident Prevention Regulations for Winches, Hoists and Tractor Machines, BGV D 6 (VGB 9) and BGV D 8 (VBG 8).
Theoretical service life The theoretical service life is determined from certain operating conditions and a theoretical operating time assumed by the design engineer when calculating and dimensioning the winches of your truck crane. The power unit group M 3 and the load spectrum L1 (Km = 0.125) are generally given for truck cranes in erection mode, resulting in a theoretical service life of 3200 hrs. (ISO 4301/1, FEM 1.001, DIN calculation bases for power units).
S
The theoretical service life is not the same as the real (actual) service life of a winch!
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5 - 21
Maintenance overview 5.4 Measures required for winch monitoring
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 truck crane. 2. Insufficient maintenance:
oil not changed at the specified intervals.
3. Operating errors:
extreme acceleration or retardation of the load, load drops and is caught by the ropes.
4. Improper maintenance:
wrong oil used incorrect filling 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 caustic atmosphere dust and dirt.
Proportion of theoretical service life used The truck crane operator must inspect the truck crane at least once a year (ISO 9927-1 and BGV D 6 (VGB 9)/BGV D 8 (VBG 8)). This includes establishing the proportion of theoretical service life that has been used. If required, the truck crane operator is to appoint an official inspector for this assessment.
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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 theoretical service life that has been used. The operator is responsible for proper documentation in the crane logbook.
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Maintenance overview 5.4 Measures required for winch monitoring
Determining the operating conditions (load spectrum)
H Load
The truck crane's load spectrum is divided into groups (see also ISO 4301/1, FEM 1.001):
When establishing the load spectrum, the existing wire cable is used as a standard, i.e. under certain circumstances, the truck crane can be supporting a small load, whereby the winch is actually supporting a heavy load, e.g. due to insufficient reeving. Therefore, the following graphic representation of the load spectrum refers to the winch's wire cables.
Term designation
Timing period proportions
Factor of
spectrum
the load
class
spectrum
Graphic representation
Km =
Light Q1 L1
Power units or parts
10% of the timing period with
thereof that are subject
greatest load (dead weight +
to high stress in excep-
1/1 payload)
tional situations, but which are generally subject to only minimal stress.
40% of the timing period with
0.125
dead load + 1/3 payload 50% of the timing period with dead weight only
Power unit or parts
1/6 of the timing period with
thereof that are subject
greatest load (dead load +
to high stress quite
1/1 payload)
often, but which are genMedium Q2 L2
erally subject to only minimal stress.
1/6 of the timing period with dead load + 2/3 payload
0.25
1/6 of the timing period with dead load + 1/3 payload 50% of the timing period with dead weight only
Heavy Q3 L3
50% of the timing period with
thereof that are subject
greatest load (dead weight +
to high stress frequently
1/1 payload)
and medium stress generally.
50% of the timing period with
Power unit or parts
90% of the timing period with
thereof that are regularly
greatest load (dead weight +
subjected to high stress
1/1 payload)
from adjacent stress sources
0.5
dead weight only
10% of the timing period with
1
dead weight only
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Very heavy Q4 L4
Power unit or parts
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5 - 23
Maintenance overview 5.4 Measures required for winch monitoring
One of the load spectrums listed above should be selected on the basis of the actual operating conditions and entered in the crane logbook for the respective testing interval. Note for truck cranes: The load spectrum L1 and the factor of the load spectrum Km = 0.125 are generally applied to truck cranes in assembly mode.
Determination of the effective operating hours Ti
The effective operating hours of the winches need to be entered in the crane logbook for the respective inspection interval. – The effective operating hours Ti of the winches are displayed in the Operating hours submenu; Operating instructions.
à
Determining the proportion of theoretical service life used
For an inspection interval i (max. 1 year according to ISO 9927-1 or BGV D 6 (VBG 9)/BGV D 8 (VBG 8), the proportion of theoretical service life used Si is calculated using the formula:
Km i S i = ----------- × T i Km Km = Factor of the load spectrum established during winch calculation. This factor is given in the operating instructions. Kmi = Factor of the load spectrum in inspection interval i in accordance with the section “Determining the operating conditions (collective load)” Ti
= Effective operating hours in the testing interval i as described in the “Determining the actual operating hours Ti” section
This used proportion is subtracted from the remaining theoretical service life Di after every testing interval (see example in the appendix to this chapter). If the remaining theoretical service life is not sufficient for the next operating period, then a general overhaul of the winch must be performed.
à
A general overhaul must be performed at least once every 10 years after commissioning the truck crane.
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Maintenance manual GMK 5170
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If theoretical service life D has been reached ( Theoretical service life, p. 5 - 21), the winch must not be operated until after a general overhaul has been performed.
Maintenance overview 5.4 Measures required for winch monitoring
The general overhaul must be arranged by the operator and performed by the manufacturer or persons authorised by the manufacturer. The results are to be entered in the logbook. The manufacturer or persons authorised by him specify a new theoretical service life D upon completion of the general overhaul. The next general overhaul must be performed within 10 years.
Deviating provision
If, after 10 years, the theoretical service life has not been used up, the winch can continue to be operated without a general overhaul under the following conditions. The crane expert has confirmed that the used portion of the service life is correct and proper by signing his/her name in the logbook after every inspection. In this case, the crane expert must closely inspect the winch. This includes at least: – a visual examination of the exterior (for leaks, damage, malformation etc.) – an oil inspection (especially for metallic residue) – a load inspection with minimum and maximum rope pull and each with maximum possible speed. At least one position is to be wound. Pay attention to any unusual noises during the load inspection.
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This inspection must be confirmed in the logbook by the crane expert and there must be a declaration of continued operation for the winch. The next inspection takes place before the 12th year of operation and must be repeated every year thereafter.
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Maintenance overview 5.4 Measures required for winch monitoring
5.4.3
Example A GMK 5170 is equipped with a separate operating hours counter for the hoist and is classified by Manitowoc Crane Group Germany GmbH as follows: Power unit group:
M3
Load spectrum:
light L 1, Km = 0.125
Theoretical service life:
D = 3 200 hrs.
The used proportion S of theoretical service life is calculated based on the individual inspection intervals as follows: 1. Inspection (1st year) The truck crane was used for assembly work during the previous year: Load spectrum L 1, i.e. Km1 = 0.125. The operating hours counter for the main hoist reads 160 hrs., i.e. T1 = 160 hrs. The used proportion S1 of theoretical service life after the first inspection therefore is:
0.125 S i = --------------- × 160 h = 160 h 0.125 Remaining theoretical service life: D1 = 3200 hrs. - 160 hrs. = 3040 hrs. The above values are entered in the table (see table example p. 5 - 28).
2. Inspection (2nd year) The truck crane was used for unloading work on docks: Load spectrum: L 3, i.e. Km2 = 0.5.
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The operating hours counter for the main hoist reads 640 hrs., i.e. during this period: 640 hrs. - 160 hrs. = 480 hrs. (160 hrs. were used during the first year) T2 = 480 hrs.
5 - 26
3 112 477 en
Maintenance manual GMK 5170
Maintenance overview 5.4 Measures required for winch monitoring
The used proportion S2 of theoretical service life after the second inspection is therefore:
0.5 S i = --------------- × 480 h = 1920 h 0.125 Remaining theoretical service life: D2 = 3040 hrs. - 1920 hrs. = 1120 hrs. The above values are entered in the table (see table example p. 5 - 28). 3. Inspection (3rd year) The truck crane was used for assembly work and occasional unloading work on docks: Load spectrum: L 2, i.e. Km3 = 0.25. The operating hours counter for the main hoist reads 940 hrs., i.e. during this period: 940 hrs. - 640 hrs. = 300 hrs. T3 = 300 hrs. The used proportion S3 of theoretical service life after the third inspection interval is therefore:
0.25 S i = --------------- × 300 h = 600 h 0.125 Remaining theoretical service life: D3 = 1120 hrs. - 600 hrs. = 520 hrs. These values are entered in the table (see sample table p. 5 - 28).
The remaining theoretical service life is to be documented in a separate table for each winch.
29.04.2008
This table is to be attached to the logbook. This table is found in the maintenance manual appendix for truck cranes that do not require a logbook or similar documentation according to the regulations in the country in which you are working.
s Maintenance manual GMK 5170
3 112 477 en
5 - 27
Sample table to determine the remaining theoretical service life on winch no. 1 (main hoisting winch) GMK 3045 3045 42 06 10 June 1990 13 301 ........................ M3 Q 1 (L1) Km = 0.125 D = 3200 hrs.
[hrs.]
Müller
Crane model: Work number: Commissioned on: Serial number of the winch in accordance with model plate: Last general overhaul performed on: Winch design data (see operating instructions): Engine group: Load spectrum: Factor of the load spectrum: Theoretical service life:
3040
3200
Name of competent person
0
Remaining theoretical service life
160
Operating hours of the winch
160
Huber
Operating hours of the entire crane
Operating hours of the superstructure
[hrs.]
Operating hours of the superstructure since the last inspection
160
1120
Schmitz
Factor of the load spectrum
[hrs.]
–
–
1920
520
Di = Di-1 - Si
[hrs.]
–
–
480
600
Used proportion Si of theoretical service life D:
Kmi
–
–
640
300
Operating hours Ti of the winch since the last inspection
–
–
940
Operational condition since the last inspection
0.125
–
–
Date of commission/date of inspection
–
–
–
Inspection interval no. (max. 1 year)
L1 0.5 –
Signature
Note
= Used proportion of theoretical service life since the last inspection
[hrs.]
5. 6. 91
10. 6. 90
L3 0.25
= Remaining theoretical service life
[hrs.]
1
0(*)
20. 5. 92 L2
Si
Name of the approved inspector
(*)
Ti
Copy last line of the previous page to the following page.
= Effective working hours in the inspection interval "i" according to section 2.2
Signature
Kmi = Factor of the load spectrum in the inspection interval "i" according to section 2.1
Km = Factor of the load spectrum used to calculate the winch. This factor is given in the operating instructions.
Di - 1 = Remaining theoretical service life after the previous inspection
Di
[hrs.]
2 18. 5. 93
"i"
3
CAUTION: A general overhaul is to be performed every 10 years! Deviating provision, refer to section 5.4.2, p. 5 - 25.
General overhaul performed on..................................
Maintenance manual GMK 5170
3 112 477 en
5 - 28
29.04.2008
Maintenance overview 5.4 Measures required for winch monitoring
6 6
Lubricants and consumables
6.1
Lubricants. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 -
1
Lubricants list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Lubricant applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 -
2 3
6.2
Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 -
4
6.3
Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 -
4
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Engine coolant admixtures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Windscreen washing system admixtures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Fuel for crane cab heating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 -
4 4 4 4
6.1.1 6.1.2
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6.3.1 6.3.2 6.3.3 6.3.4
Maintenance manual GMK 5170
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29.04.2008
3 112 477 en
Maintenance manual GMK 5170
Lubricants and consumables 6.1 Lubricants
6 6.1
Lubricants and consumables
Lubricants All lubricants that you require for the – Maintenance work on the carrier, p. 7 - 1 and – Maintenance work on the superstructure, p. 8 - 1 are listed with serial numbers in the lubricants list and the lubricant applications list.
à Lubricants list, p. 6 - 2.
29.04.2008
à Lubricant applications, p. 6 - 3.
Maintenance manual GMK 5170
3 112 477 en
6-1
Lubricants and consumables 6.1 Lubricants
6.1.1
Lubricants list
Serial no.
GROVE part number
Lubrication type
Designation according to DIN 51502
1
03329588
Engine oil
HD - CD
MIL-L 2104 C DB 228.5
SAE 5 W - 30
2
6 829 101 690
Gear oil1)
3
00552891
Gear oil
C - LPF
MIL-L 2105 B API-GL-5
Hyp SAE 90 ISO - VG 220
4
02310863
Gear oil
5
02313611
Gear oil
C - LPF
MIL-L 2105 B API-GL-4/5 (synthetic)
SAE 75 W-90 EP ISO - VG 220
6
01375719
Hydraulic oil
H - LP
DIN 51524 T.2
ISO - VG 32
7
00554201
Lubricating grease
KP - L2K
DIN 51825
8
00554205
Spray
Ceplattyn 300
9
02314698
Slide paste
PAL 1
10
03325215
Lubricating grease
RHUS SW 2
11
03133770
Lubricating grease
Elaskon 30
Viscosity
Rivolta S.K.D. 170
Synthetic oil filled at the factory; do not mix it with mineral oil!
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1)
Specification Classification
6-2
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Maintenance manual GMK 5170
Lubricants and consumables 6.1 Lubricants
6.1.2
Serial no.
Lubricant applications
Lubrication type
Application
Diesel engine for the carrier; 1
Engine oil
2
Gear oil
3
Gear oil
4
Gear oil
5
Gear oil
6
Hydraulic oil
7
Lubricating grease
Diesel engine for the superstructure;
29.04.2008
Spray
9
Slide paste
10
Lubricating grease
11
Lubricating grease
Maintenance manual GMK 5170
à p. 8 - 7
à p. 7 - 26 3. Axle line transfer case; à p. 7 - 30 2. Axle line axle centre drive; à p. 7 - 35 5. Axle line axle centre drive; à p. 7 - 35 4. Axle line axle centre drive; à p. 7 - 35 6 or 8 x final drive; à p. 7 - 39 10 x suspension struts; à p. 7 - 51 2 x hoists; à p. 8 - 22 2 x slewing gears; à p. 8 - 28 Carrier hydraulic tank; à p. 7 - 70 Superstructure hydraulic tank; à p. 8 - 44 Carrier central lubrication; à p. 7 - 77 Superstructure central lubrication; à p. 8 - 73 Cardan shafts – transverse; à p. 7 - 41 Cardan shafts – longitudinal; à p. 7 - 42 Towbar coupling; à p. 7 - 95 Support bearing; à p. 7 - 103 Auxiliary hoist; à p. 8 - 20 Slewing angle sensor; à p. 8 - 71 Hook blocks; à p. 8 - 74 Automatic transmission;
Doors: hinges, track rollers, connecting and socket pins;
8
à p. 7 - 7
à p. 5 - 14 Slewing bearing gear teeth; à p. 8 - 31 Telescopic slide faces; à p. 8 - 49 Telescopic locking pins; à p. 8 - 49 Derricking cylinder piston rod; à p. 8 - 79 Lubricating the hoist ropes; à p. 8 - 57
3 112 477 en
Quantity to be filled in litres
Maintenance interval
38
Engine manufacturer’s documentation
16 46.0
Y2
19
M6
13.0
M 12
13.0
M 12
16.5
M 12
4.1
M 12
1.5
M1
7
M 12
0.9
M 12
150
M 12
915
M 12 W W M1 M6 M1 M1 M6 Y5 M 12 M 12 M6 M3 M3 M1 M3
6-3
Lubricants and consumables 6.2 Refrigerant
6.2
Refrigerant
Refrigerant Designation
Application
Quantity to be filled in kg
Maintenance interval
à p. 7 - 88
1.5
M 12
Crane cab air-conditioning system; p. 8 - 78
2.0
M 12
Driver's cab air-conditioning system;
Tetrafluoroethane (R134a) CAS no. 811-97-2 EC no. 212-377-0
à
6.3
Consumables
6.3.1
Fuel The useable fuels and their respective specifications can be found in the Engine manufacturer’s documentation.
6.3.2
Engine coolant admixtures The specifications and admixture ratios can be found in the Engine manufacturer’s documentation.
6.3.3
Windscreen washing system admixtures Commercial cleansers and antifreeze may be added to the windscreen washing water. Observe the application instructions on the package.
Fuel for crane cab heating system Only if the truck crane is fitted with a separate tank for the auxiliary heater, you have the option of selecting whether to use the same fuel as in section 6.3.1 or to use the EL heating oil.
6-4
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Maintenance manual GMK 5170
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6.3.4
7 7
Maintenance work on the carrier
7.1
General instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 -
1
Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 -
1
7.2
Symbols for maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 -
3
7.3
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 -
5
7.1.1
7.3.1 7.3.2 7.3.3 7.3.4 7.3.5 7.3.6 7.4 7.4.1 7.4.2 7.4.3 7.5 7.5.1 7.5.2 7.5.3 7.6 7.6.1 7.6.2 7.6.3 7.7 7.7.1 7.7.2 7.7.3 7.7.4 7.7.5 7.7.6 7.7.7 7.8 7.8.1 7.8.2 7.8.3 7.8.4
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7.9
Checking the oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 5 Topping up the oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 7 Installing the drain valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 8 Checking the air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 9 Checking the coolant level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 10 General inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 11 Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 13 Draining off water from fuel filter 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 14 Changing fuel filter 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 15 Changing fuel filter 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 17 Automatic transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 21 Checking the oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 21 General inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 25 Changing the oil and the oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 26 Transfer case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 29 General inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 29 Checking the oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 29 Changing the oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 30 Axle lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 33 General inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Checking the oil level on axle centre drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Axle centre drives – changing the oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Final drives – checking the oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Final drives – changing the oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Lubricating the cardan shafts on the axle lines . . . . . . . . . . . . . . . . . . . . . . . . . 7 Lubricating longitudinal cardan shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 -
33 33 35 38 39 41 42
Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 43 Checking the tyres for damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Checking the tyre air pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Check tightness of wheel nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Tyre change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 -
43 44 45 46
Vehicle brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 49
7.9.1
Checking brake-lining thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 49
7.10
Suspension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 51
7.10.1 7.10.2 7.10.3 7.10.4
Suspension struts – checking the oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Suspension struts – checking the fastening . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Forced lever – checking correct functioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Pressure accumulator – checking the gas pressure . . . . . . . . . . . . . . . . . . . . . . 7 -
Maintenance manual GMK 5170
3 112 477 en
51 52 53 54
7.11.1 7.11.2 7.12 7.12.1 7.12.2 7.12.3 7.13 7.13.1 7.13.2 7.13.3 7.13.4 7.13.5 7.13.6 7.13.7 7.13.8 7.14 7.14.1 7.14.2 7.14.3 7.15 7.15.1 7.15.2 7.15.3 7.16 7.16.1 7.16.2 7.16.3 7.16.4 7.17 7.17.1 7.17.2 7.18 7.18.1 7.18.2 7.18.3 7.18.4 7.18.5 7.18.6 7.18.7 7.19 7.19.1 7.19.2 7.19.3
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 55 Checking for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 55 Pressure accumulator – checking the gas pressure . . . . . . . . . . . . . . . . . . . . . 7 - 56 Compressed air system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 57 Draining the compressed air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 57 Checking for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 58 Replacing the filter cartridge of the compressed air drier . . . . . . . . . . . . . . . . . 7 - 59 Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 61 Checking the oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking the hydraulic hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning the magnetic rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Changing the ventilation filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Taking oil samples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Changing the hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Changing the hydraulic oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
77777777-
61 62 63 64 66 67 70 74
Central lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 77 Checking the level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 77 Bleeding the central lubrication system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 79 Triggering intermediate lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 79 Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 81 Checking the lighting and indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 81 Checking the batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 82 Checking the charge level of the batteries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 84 Air-conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 87 Checking the air-conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning the condenser fins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking the entire air-conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . .
7777-
87 87 88 88
Particulate filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 91 Checking the clamp straps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 91 Replacing the particulate filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 92 Towbar coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 95 Lubricating the towbar coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking the bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking the cotter pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking the lower bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking the initial tension of the springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking the support ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking the function of the coupling jaw/Resetting central position . . . . . .
7 - 95 7 - 97 7 - 98 7 - 99 7 - 99 7 - 100 7 - 100
Other maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 103 Lubricating the support bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 103 Checking the auxiliary heater for correct operation . . . . . . . . . . . . . . . . . . . . . 7 - 104 Having the fire extinguisher checked . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 104
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Maintenance manual GMK 5170
29.04.2008
7.11
Maintenance work on the carrier 7.1 General instructions
7
Maintenance work on the carrier
7.1
General instructions
7.1.1
Covers Various types of work (e.g. oil change) require that the covers be removed. Before maintenance work
• Remove the covers (1). After maintenance work
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• Fasten the covers (1) with the locks.
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7-1
Maintenance work on the carrier 7.1 General instructions
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7-2
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Maintenance manual GMK 5170
Maintenance work on the carrier 7.2 Symbols for maintenance work
7.2
Symbols for maintenance work Check the following symbols daily before starting operations.
On the ECOS display
• Open the Warning submenu; à Operating instructions. If one of the symbols is displayed, you must carry out the appropriate maintenance work:
– Oil pressure;
à p. 7 - 5,
– Coolant level;
– Air filter;
à p. 7 - 10.
à p. 7 - 9,
– Hydraulic oil filter;
à p. 7 - 74.
On the particulate filter display If one of the symbols (1) lights up in orange and/or the warning buzzer sounds, you must carry out the appropriate maintenance work:
à p. 7 - 92.
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1 Particulate filter;
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7-3
Maintenance work on the carrier 7.2 Symbols for maintenance work
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7-4
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Maintenance manual GMK 5170
Maintenance work on the carrier 7.3 Engine
7.3
Engine • In addition, carry out further maintenance work on the Engine manufacturer’s documentation supplied. Pay attention to the information relating to use of bio-diesel fuel – the oil change interval must be halved.
• At the first oil change, fit a drain valve in place of the drain plug;
à p. 7 - 8.
7.3.1
Checking the oil level
Prerequisites
– The truck crane is horizontal.
Checking the oil level
• Start the engine.
S
D
Risk of damage to the engine if the oil pressure is too low If the symbol L still lights up after 10 seconds, turn off the engine and look for the cause; Operating instructions – Engine malfunctions.
à
• Start the engine and observe the display. • Symbol (1) should not be lit for more than 10 seconds after starting the engine.
• Allow the engine to run at idling speed for 2 - 3 minutes. • Switch off the engine.
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• Check the oil level after about two minutes.
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7-5
Maintenance work on the carrier 7.3 Engine
• On the dipstick, check whether the oil level is between the min. and the max. marks (arrows).
• Put the dipstick into the dipstick tube after checking the oil level. If the oil level is too low:
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• Add more oil, à p. 7 - 7.
7-6
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Maintenance manual GMK 5170
Maintenance work on the carrier 7.3 Engine
7.3.2
Topping up the oil Data on the prescribed oil specification; tion.
à Engine manufacturer's documenta-
Oil Engine oil in litres 38
Prerequisites
Designation according to DIN 51502
Specification Classification
GROVE part no.
HD - CD
MIL-L 2104 C DB 228.5
SAE 15 W-40 03329588
– The truck crane is horizontal. – The engine is switched off and secured against unauthorised use; p. 2 - 3.
à
Topping up oil
S G
Risk of damage to the engine if the oil level is too high! Do not overfill; the oil level must not be higher than the max. mark (arrow). Drain off oil if necessary; Engine manufacturer's documentation.
à
Risk of burning yourself when the engine is hot! During operation, the engine and add-on parts can reach temperatures of up to 400 °C. Wear appropriate protective gloves and be careful not to touch hot parts.
• Add oil through the filler neck (1) up to the max. mark.
• Close the filler neck with the lid. • Put the dipstick into the dipstick tube after
29.04.2008
checking the oil level.
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7-7
Maintenance work on the carrier 7.3 Engine
7.3.3
Installing the drain valve You can replace the drain plug on the oil pan with a valve. This makes it easier to check the draining oil during subsequent oil changes.
Spare parts and tools
Designation
Quantity
GROVE part no.
Valve
1
03046878
Gasket 26 x 31 Cu DIN 7603
1
00117147
– Drain channel. – Torque wrench for torque of 60 Nm.
Prerequisites
– The truck crane is horizontal. – The engine is switched off and secured against unauthorised use; p. 2 - 3.
à
Installing the valve
• Use a drain channel when draining the oil. • Drain the engine oil as described in Engine manufacturer’s documentation.
• Replace the gasket and tighten the valve (1) – torque 60 Nm.
• Check the valve for tightness after filling up with oil.
Next time you change the oil, you can drain the oil in the same way as described for taking oil samples from the hydraulic tank; Taking oil samples, p. 7 - 67. 29.04.2008
à
7-8
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Maintenance manual GMK 5170
Maintenance work on the carrier 7.3 Engine
7.3.4
D
Checking the air filter • Start the engine and observe the display. • The filter must be replaced if the display shows the symbol (1).
• Switch off the engine.
Spare parts and tools
Designation Filter
Prerequisites
Quantity
GROVE part no.
1
03 328 262
– The engine is switched off and secured against unauthorised use; p. 2 - 3.
à
Replacing the air filter
• Remove the plate (4). • Undo all the clamps (1) and remove the lid (2).
• Change the filter (3). • Place back the lid and secure it with all the clamps.
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• Attach the plate.
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7-9
Maintenance work on the carrier 7.3 Engine
7.3.5
D
Checking the coolant level • Start the engine and observe the display.
Coolant must be filled if the display shows the symbol (1).
• Switch off the engine.
Topping up coolant
G
Danger of being scalded due to hot radiator circuit! The hot radiator circuit is under pressure. When you open the expansion tank, you could be scalded by escaping steam or coolant. Wear suitable protective gloves and cover the cap on the expansion tank with a rag before opening it. Turn the cap slowly to the first detent in order to allow the pressure to be released.
• Do not open the pressure relief valves (2). • Loosen (do not open!) the cap (1) to reduce the pressure if the coolant is at operating temperature.
• Open the cap (1). The coolant level must be at the lower edge in the filler neck. If the coolant level is too low:
• Top up the coolant. Composition of the coolant; Engine manufacturer's documentation.
à
S 7 - 10
Risk of damage to engine due to lack of coolant! If the coolant has to be topped up frequently, the cooling system may be leaking. Have the cooling system checked by CraneCARE or your repair crew.
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Maintenance manual GMK 5170
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• Close the cap (1).
Maintenance work on the carrier 7.3 Engine
7.3.6
General inspection
W
• Investigate any unusual noises from the engine. • Check the engine and the connections for leaks. In the event of leaking consumables; Checking the oil level, p. 7 - 5, Checking the coolant level, p. 7 - 10.
à à
• Check that pipes and hoses are tightly connected and not damaged.
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If any damage is found, report it CraneCARE.
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7 - 11
Maintenance work on the carrier 7.3 Engine
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7 - 12
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Maintenance manual GMK 5170
Maintenance work on the carrier 7.4 Fuel system
7.4
Fuel system Installed in the fuel line are: 1 Fuel filter 1
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2 Fuel filter 2
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7 - 13
Maintenance work on the carrier 7.4 Fuel system
7.4.1
D
Draining off water from fuel filter 1
à p. 2 - 4.
Spare parts and tools
– Receptacle, approx. 5 l;
Prerequisites
– The truck crane is horizontal. – The engine is switched off and secured against unauthorised use; p. 2 - 3.
à
Draining off water
O
Risk of environmental damage due to leaking consumables! Always let consumables drain into suitable receptacles. Wipe up any fluids that have leaked. Store/dispose of fluids and any soaked equipment properly. Ask about the applicable regulations.
• Place a receptacle underneath the filter. • Open the valve (1). • If the consumable is clean, close the valve manually.
• Remove the receptacle and properly dis-
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pose of the drained consumable.
7 - 14
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Maintenance manual GMK 5170
Maintenance work on the carrier 7.4 Fuel system
7.4.2 Spare parts and tools
Designation
Quantity
GROVE part no.
Filter
1
03322877
Gasket
1
03322879
Filter element
1
03328656
– Receptacle, approx. 5 l;
Prerequisites
M3
Changing fuel filter 1
à p. 2 - 4.
– The truck crane is horizontal. – The engine is switched off and secured against unauthorised use; p. 2 - 3.
à
– If the fuel is contaminated: shorten the maintenance interval.
Changing
O
Risk of environmental damage due to leaking consumables! Always let consumables drain into suitable receptacles. Wipe up any fluids that have leaked. Store/dispose of fluids and any soaked equipment properly. Ask about the applicable regulations.
• Place a receptacle underneath the filter. • Close the valve – lever (1) at right angles to the line.
• Open the screw plug (2) and the valve (3) and drain the fluid.
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7 - 15
Maintenance work on the carrier 7.4 Fuel system
• (A) – Remove the filter element (2) and the filter (1). If necessary, replace any damaged parts.
• (B)) – Screw on a new filter (1) and the filter element (2).
• Close the valve (3) manually.
• Open the valve (1) – lever parallel with the line.
• Actuate the pump (3) until the consumable flowing through the bolt (2) no longer contains any bubbles.
• Secure the bolt. • Start the engine and check for leaks. • Remove the receptacle.
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H
If you have used a clean receptacle, you can refill the fuel tank with the consumable using a strainer. Otherwise dispose of the consumable properly.
7 - 16
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Maintenance manual GMK 5170
Maintenance work on the carrier 7.4 Fuel system
7.4.3
M 12
Changing fuel filter 2
Spare parts and tools
Designation
Quantity
GROVE part no.
1
03 045 818
Filter and gasket – Receptacle, approx. 5 l;
à p. 2 - 4.
– Torque wrench for torque of 25 Nm.
Prerequisites
– The truck crane is level and on outriggers; – The main boom is fully retracted;
à Operating instructions
à Operating instructions
– The engine is switched off and secured against unauthorised use; p. 2 - 3.
à
O
Risk of environmental damage due to leaking consumables! Always let consumables drain into suitable receptacles. Wipe up any consumables that have leaked. Store/dispose of consumables and any soaked equipment properly. Ask about the applicable regulations.
Emptying the fuel line
• Place a receptacle underneath the filter. • Close the valve – lever (1) at right angles to the line.
• Open the bolt (2) and let the consumable drain.
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7 - 17
Maintenance work on the carrier 7.4 Fuel system
• Place a receptacle under the end of the hose (2).
• (A) – Turn the valve – lever (1) horizontal. • Let the consumable drain. • (B) – Turn the valve – lever (1) vertical. Leave the receptacle under the hose. More consumable will run out during bleeding.
Changing the filter
• Remove the covers that are on the engine; à p. 7 - 1. • Unscrew the cap (1) and remove the filter (3). Let the remaining consumable drain.
• Remove the cap and remove the filter by applying pressure to the sides of its lower edge.
• Insert a new gasket (2) (grease lightly) and clip a new filter into the lid.
• Screw the lid with the filter into the housing
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and tighten it – torque 25 Nm.
7 - 18
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Maintenance manual GMK 5170
Maintenance work on the carrier 7.4 Fuel system
Bleeding the fuel line There is a receptacle under the hose end (2).
• Close the vent screw (4). • Open the valve – lever (5) parallel to the line. • Open the valve – lever (1) horizontal. • Actuate the pump (3) until the consumable flowing through the end of the hose no longer contains any bubbles.
• Turn the valve – lever (1) vertical. • Start the engine and check that the fuel filters are not leaking.
• Remove the receptacle underneath the hose end (2).
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H
If you have used a clean receptacle, you can refill the fuel tank with the consumable using a strainer. Otherwise, dispose of the consumables properly.
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7 - 19
Maintenance work on the carrier 7.4 Fuel system
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7 - 20
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Maintenance manual GMK 5170
Maintenance work on the carrier 7.5 Automatic transmission
7.5
Automatic transmission
7.5.1
Checking the oil level
Prerequisites
– The oil level pre-check has been carried out; p. 7 - 22.
D
à Prior to starting the engine,
– The engine is switched off and secured against unauthorised use; p. 2 - 3.
à
Three types of oil level inspection
S
Risk of damage to the automatic transmission The correct oil level must be maintained to ensure smooth operation of the automatic transmission: – if the oil level is too low, malfunctions will occur, – if the oil level is too high, loss of power and overheating will occur.
The oil level can be checked in three different ways, depending on the conditions:
à p. 7 - 22, – when the gear oil is warm; à p. 7 - 23, – via the oil level sensor; à Operating instructions. – when the gear oil is cold;
H
Check with warm gear oil for the most accurate reading of the oil level in the automatic transmission.
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s
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7 - 21
Maintenance work on the carrier 7.5 Automatic transmission
Prior to starting the engine
S
Risk of damage to the transmission! The engine must not be started without a prior check of the gear oil level. This prevents gear damage being caused by undetected loss of oil.
• Remove the dipstick (1) and check whether the oil level is around the (2) mark.
• Insert the dipstick into the dipstick tube. If the oil level is too low:
• Top up oil via the dipstick tube. Follow-up check:
• Carry out another check when the gear oil is cold;
When the gear oil is cold
à p. 7 - 22.
Gear oil temperature 15 to 50 °C.
• Pre-check the oil level in the automatic transmission daily before starting
à p. 7 - 22. Start the engine; à Operating instructions. Check the gear oil temperature; à Operating instructions. the engine;
• •
S
Risk of damage to the transmission when warming up When the wheels are locked, the full engine output may only be applied in transmission mode D or R for a maximum of 30 seconds. If this duration is exceeded, the transmission could become overheated and get damaged.
• First switch to transmission mode D and then to R and allow the engine • Switch to neutral position N and let the vehicle run at idling speed. If the outside temperature is low, allow the engine to run for a few minutes longer.
7 - 22
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Maintenance manual GMK 5170
29.04.2008
to run briefly at approx. 1200 - 1500 min-1 in each transmission mode.
Maintenance work on the carrier 7.5 Automatic transmission
• Remove the dipstick (1) and check whether the oil level is in the (2) range.
• Insert the dipstick into the dipstick tube. If the oil level is too high:
• Drain off oil until it is below the (4) mark;
à p. 7 - 27.
If the oil level is too low:
• Top up the oil via the dipstick tube until the (3) mark is exceeded. Follow-up check:
• Carry out another check when the gear oil is warm;
When the gear oil is warm
à p. 7 - 23.
Gear oil temperature 75 to 95 °C.
• Pre-check the oil level in the automatic transmission daily before starting the engine;
H
à Prior to starting the engine, p. 7 - 22.
To prevent damage to the transmission, the oil level check is at its most relevant when the gear oil is warm. Gear oil is warmed up – when the vehicle is stationary; – or when driving;
à p. 7 - 23,
à p. 7 - 24.
Warming up when stationary
• Start the engine. • Allow the engine to run at idling speed in the neutral position N until the gear oil temperature is 75 °C.
• Check the gear oil temperature; à Operating instructions. • Check the oil level; à p. 7 - 25.
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7 - 23
Maintenance work on the carrier 7.5 Automatic transmission
If you want to accelerate the warming procedure when the vehicle is stationary:
• Fully depress the service brake pedal, even if the parking brake is on.
S S
Risk of damage to the transmission when accelerating the warming up procedure! When the wheels are locked, the full engine output may only be applied in transmission mode D or R for a maximum of 30 seconds. If this duration is exceeded, the transmission could become overheated and get damaged. Coolant loss through overheating when the warming up procedure is accelerated! When the wheels are locked, the coolant can overheat – even when coolant temperatures are under 70 °C on the display. The coolant then leaks from the expansion tank.
• First switch to transmission mode D and then to R and allow the engine to run briefly at approx. 1200 - 1500 min-1 in each transmission mode.
• Allow the engine to run at idling speed in the neutral position N until the gear oil temperature is 75 °C. Check the gear oil temperature;
à Operating instructions.
• Check the oil level; à p. 7 - 25.
Warming up when driving
• Drive the truck crane until the coolant temperature is 70 °C. Check the gear oil temperature;
à Operating instructions.
• Check the oil level; à p. 7 - 25.
• Align the truck crane horizontally. • Engage the parking brake.
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• Switch to the neutral position N.
7 - 24
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Maintenance manual GMK 5170
Maintenance work on the carrier 7.5 Automatic transmission
Checking the oil level
• Remove the dipstick (1) and check whether the oil level is in the (2) range.
• Insert the dipstick into the dipstick tube. If the oil level is too low:
• Top up the oil via the dipstick tube until the (3) mark is exceeded. If the oil level is too high:
• Drain off oil until it is below the (4) mark;
à p. 7 - 27.
7.5.2
General inspection
W
• Pay attention to any unusual noises in the automatic transmission. • Check the transmission and the connections for leaks. In the event of leaking consumables;
à Checking the oil level, p. 7 - 21.
• Check that pipes and hoses are tightly connected and not damaged.
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If you detect any worn or damaged parts, contact CraneCARE.
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7 - 25
Maintenance work on the carrier 7.5 Automatic transmission
7.5.3
Y2
Changing the oil and the oil filter
Spare parts and tools
Designation
Quantity
GROVE part no.
Filter with set of gaskets
2
03 326 293
Gasket 30 x 36 Cu DIN 7603
1
00 117 151
– Receptacle, approx 50 l;
à p. 2 - 4.
– Torque wrench for tightening torque of 25-32 Nm and 50-55 Nm.
Prerequisites
– The gear oil is at operating temperature (70 to 95 °C). – The truck crane is raised on outriggers or parked over an inspection pit. – The engine is switched off and secured against unauthorised use; p. 2 - 3.
à
Changing the oil and the oil filter
Risk of environmental damage due to leaking consumables! Always let consumables drain into suitable receptacles. Wipe up any consumables that have leaked. Store/dispose of consumables and any soaked equipment properly. Ask about the applicable regulations.
29.04.2008
G O
Risk of burning yourself on gear oil at operating temperature! You could burn yourself if unchecked gear oil escapes at operating temperature. Wear appropriate protective gloves and be careful not to touch the gear oil.
7 - 26
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Maintenance manual GMK 5170
Maintenance work on the carrier 7.5 Automatic transmission
Draining oil
• Pull out the dipstick (1). • Place a receptacle under the bolt (2). • Unscrew the bolt and let the oil drain off.
Changing the oil filter
• Loosen the lid (1) and pull out the filters. • Insert new filters. • Replace the gaskets and tighten the covers – torque 50-55 Nm.
• Replace the gasket and tighten the bolt (2) – torque 25-32 Nm.
Topping up oil
• Top up the oil (46.0 l) through the dipstick tube (1).
• Wait unit the oil has been evenly distributed. • Use the dipstick to check whether the oil level is clearly above the (2) mark, otherwise the engine may not be started.
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7 - 27
Maintenance work on the carrier 7.5 Automatic transmission
Inspections after the oil change
G
• Check the oil level as described; à When the gear oil is cold, p. 7 - 22 Risk of accidents when searching for leaks under the truck crane! Ensure that the parking brake is engaged before you go underneath the truck crane to search for leaks. Keep away from rotating parts.
• Check the transmission for leaks on the lids of the oil filters and at the oil drain plug.
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• Check the oil level as described; à When the gear oil is warm, p. 7 - 23
7 - 28
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Maintenance manual GMK 5170
Maintenance work on the carrier 7.6 Transfer case
7.6
Transfer case The transfer case is screwed to the axle centre drive of the third axle line. The axle centre drive and the transfer case have two separate oil chambers. Comply also with the
7.6.1
à Run-in regulations, p. 4 - 1. W
General inspection • Pay attention to any unusual noises in the transfer case.
• Check the transfer case and the connections for leaks. In the event of leaking consumables;
à Checking the oil level, p. 7 - 29.
• Check that pipes and hoses are tightly connected and not damaged. If any damage is found, report it CraneCARE.
7.6.2 Spare parts and tools
Designation Gasket 30 x 36 Cu DIN 7603
Prerequisites
M1
Checking the oil level
Quantity
GROVE part no.
1
00117151
– The truck crane is raised on outriggers or parked over an inspection pit. – The engine is switched off and secured against unauthorised use; p. 2 - 3.
à
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Maintenance manual GMK 5170
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7 - 29
Maintenance work on the carrier 7.6 Transfer case
Checking the oil level
• Remove the bolt (1). • Check whether the oil reaches the lower edge of the opening.
• Fit a new gasket and tighten the bolt. If the oil level is too low:
• Add more oil, à p. 7 - 31.
Oil, spare parts, tools
M6
Changing the oil
Gear oil in litres 13
Designation according to DIN 51502
Specification Classification
GROVE part no.
C - LPF
MIL-L 2105 B API-GL-5 Viscosity: Hyp SAE 90 ISO - VG 220
00552891
Designation
Quantity
GROVE part no.
Gasket 16 x 20 Cu DIN 7603
1
00 117 134
Gasket 30 x 36 Cu DIN 7603
1
00 117 151
– Receptacle, approx. 20 l;
Prerequisites
à p. 2 - 4.
– The gear oil is at operating temperature. – The truck crane is raised on outriggers or parked over an inspection pit. – The engine is switched off and secured against unauthorised use; p. 2 - 3.
à
7 - 30
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Maintenance manual GMK 5170
29.04.2008
7.6.3
Maintenance work on the carrier 7.6 Transfer case
Changing the oil
G O
Risk of burning yourself on gear oil at operating temperature! You could burn yourself if unchecked gear oil escapes at operating temperature. Wear appropriate protective gloves and be careful not to touch the gear oil. Risk of environmental damage due to leaking consumables! Always let consumables drain into suitable receptacles. Wipe up any consumables that have leaked. Store/dispose of consumables and any soaked equipment properly. Ask about the applicable regulations.
• Place a receptacle under the bolt (2). • Unscrew the bolts (1) and (2) and let the oil drain off.
• Fit new gaskets and tighten the bolt (2). • Top up oil through the opening (1).
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• Fit new gaskets and tighten the bolts (1).
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7 - 31
Maintenance work on the carrier 7.6 Transfer case
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7 - 32
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Maintenance manual GMK 5170
Maintenance work on the carrier 7.7 Axle lines
7.7
Axle lines • Comply also with the à Run-in regulations, p. 4 - 1.
7.7.1
W
General inspection
• Pay attention to any unusual running noises from the axle centre drives and the final drives.
• Check the axle centre drives/final drives and the connections for leaks. In the event of leaking consumables; Checking the oil level on axle centre drives, p. 7 - 33, Final drives – checking the oil level, p. 7 - 38.
à à
• Check that pipes and hoses are tightly connected and not damaged. If any damage is found, report it CraneCARE.
7.7.2 Spare parts and tools
For drive 10 x 6 x 10
10 x 8 x 101)
1)
Prerequisites
M1
Checking the oil level on axle centre drives
Designation
Quantity GROVE part no.
Gasket 30 x 38 Cu DIN 7603
2
01 925 343
Gasket 16 x 20 Cu DIN 7603
1
00 117 134
Gasket 16 x 22 Cu DIN 7603
1
00 117 135
Gasket 30 x 38 Cu DIN 7603
3
01 925 343
Gasket 16 x 20 Cu DIN 7603
1
00 117 134
Gasket 16 x 22 Cu DIN 7603
1
00 117 135
Additional equipment (2nd driven axle line)
– The truck crane is raised on outriggers or parked over an inspection pit. – The engine is switched off and secured against unauthorised use; p. 2 - 3.
à
29.04.2008
s Maintenance manual GMK 5170
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7 - 33
Maintenance work on the carrier 7.7 Axle lines
2nd and 5th axle lines
• Remove the bolt (1). • Check whether the oil reaches the lower edge of the opening.
• Fit a new gasket and tighten the bolt. If the oil level is too low:
• Add more oil, à p. 7 - 36.
3rd axle line
• Remove the bolt (1). • Check whether the oil reaches the lower edge of the opening.
• Fit a new gasket and tighten the bolt. If the oil level is too low:
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• Add more oil, à p. 7 - 36.
7 - 34
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Maintenance manual GMK 5170
Maintenance work on the carrier 7.7 Axle lines
4th axle line The drive has two oil chambers.
• Unscrew bolts (1) and (2). • Check that the oil reaches the lower edge of the openings.
• Fit new gaskets and tighten the bolts. If the oil level is too low:
• Add more oil, à p. 7 - 37.
7.7.3 Oil, spare parts, tools
Gear oil in litres
Designation according to DIN 51502
Specification Classification
GROVE part no.
Axle lines 2+5: each 13.0
C - LPF
MIL-L 2105 B API-GL-5 Viscosity: Hyp SAE 90 ISO - VG 220
00552891
Axle line 3+4: each 16.5 For drive
10 x 6 x 10
10 x 8 x 101)
1) 29.04.2008
M 12
Axle centre drives – changing the oil
Designation
Quantity GROVE part no.
Gasket 36 x 42 Cu DIN 7603
2
01 371 208
Gasket 30 x 38 Cu DIN 7603
1
01 925 343
Gasket 16 x 22 Cu DIN 7603
2
00 117 135
Gasket 36 x 42 Cu DIN 7603
3
01 371 208
Gasket 30 x 38 Cu DIN 7603
2
01 925 343
Gasket 16 x 22 Cu DIN 7603
2
00 117 135
Additional equipment (2nd driven axle line)
– Receptacle, approx 20 l;
à p. 2 - 4.
s Maintenance manual GMK 5170
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7 - 35
Maintenance work on the carrier 7.7 Axle lines
Prerequisites
– The truck crane is raised on outriggers or parked over an inspection pit. – The engine is switched off and secured against unauthorised use; p. 2 - 3.
à
O
Risk of environmental damage due to leaking consumables! Always let consumables drain into suitable receptacles. Wipe up any consumables that have leaked. Store/dispose of consumables and any soaked equipment properly. Ask about the applicable regulations.
2nd and 5th axle lines
• Place a receptacle under the bolt (2). • Unscrew the bolts (1) and (2) and let the oil drain off.
• Fit a new gasket and tighten the bolt (2). • Fill the oil up to the lower edge of the opening.
• Fit a new gasket and tighten the bolt (1).
3rd axle line
• Screw the plug out of the hole (1). • Check the oil level. It must reach the lower edge of the opening (1). If the oil level is too low:
• Top up oil through the hole (1).
29.04.2008
• Replace the gasket and close the hole (1).
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Maintenance manual GMK 5170
Maintenance work on the carrier 7.7 Axle lines
4th axle line
S
The drive has two oil chambers. Risk of oil overheating! When topping up the oil, both openings must be open so that both oil chambers are filled equally. This prevents both oil chambers from being overfilled and thus the oil from overheating.
• Place a receptacle under bolts (3) and (4). • Unscrew bolts (1), (2), (3) and (4) and let the oil drain off.
• Fit new gaskets and tighten bolts (3) and (4). • Top up oil only through hole (2) until it runs out of hole (1).
29.04.2008
• Fit new gaskets and tighten bolts (1) and (2).
Maintenance manual GMK 5170
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7 - 37
Maintenance work on the carrier 7.7 Axle lines
7.7.4 Spare parts and tools
For drive
Designation
Quantity GROVE part no.
10 x 6 x 10
Gasket 24 x 29 Cu DIN 7603
6
00117145
10 x 8 x 101)
Gasket 24 x 29 Cu DIN 7603
8
00117145
1)
Prerequisites
M1
Final drives – checking the oil level
Additional equipment (2nd driven axle line)
– The truck crane is raised on outriggers and in horizontal position. – The engine is switched off and secured against unauthorised use; p. 2 - 3.
à
– The parking brake is released.
Checking the oil level
• Check the oil level at all other final drives in the same way.
• Turn the wheel until the (2) mark is horizontal and is on the right, next to the centre of the axle.
• Remove the bolt (1). • Check whether the oil level is at the (2) mark. • Fit a new gasket and tighten the bolt. If the oil level is too low:
29.04.2008
• Add more oil, à p. 7 - 40.
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Maintenance manual GMK 5170
Maintenance work on the carrier 7.7 Axle lines
7.7.5
M 12
Final drives – changing the oil
Oil, spare parts, tools
Gear oil in litres each final drive:
Designation according to DIN 51502
Specification Classification
GROVE part no.
C - LPF
MIL-L 2105 B API-GL-5 Viscosity: Hyp SAE 90 ISO - VG 220
00552891
4.1
For drive
Designation
Quantity
GROVE part no.
10 x 6 x 10
Gasket 24 x 29 Cu DIN 7603
6
00117145
10 x 8 x 101)
Gasket 24 x 29 Cu DIN 7603
8
00117145
1)
Additional equipment (2nd driven axle line)
– Drain channel. – Receptacle, approx 5 l;
Prerequisites
à p. 2 - 4.
– The truck crane is raised on outriggers.. – The engine is switched off and secured against unauthorised use; p. 2 - 3.
à
– The parking brake is released.
O
Risk of environmental damage due to leaking consumables! Always let consumables drain into suitable receptacles. Wipe up any consumables that have leaked. Store/dispose of consumables and any soaked equipment properly. Ask about the applicable regulations.
29.04.2008
s
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7 - 39
Maintenance work on the carrier 7.7 Axle lines
Draining oil
• Change the oil on all final drives in the same way.
• Turn the wheel until bolt (1) is at the bottom. • Use a drain channel and place a receptacle under the bolt.
• Unscrew the bolt and let the oil drain off.
Topping up the oil
• Turn the wheel until the (2) mark is horizontal and is on the right, next to the centre of the axle.
• Top up the oil through the hole.
29.04.2008
• Fit a new gasket and tighten the bolt (1).
7 - 40
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Maintenance manual GMK 5170
Maintenance work on the carrier 7.7 Axle lines
7.7.6
M1
Lubricating the cardan shafts on the axle lines
H Grease, spare parts, tools
Check all cardan shafts to see if they have grease nipples. Cardan shafts with grease nipples must be serviced, cardan shafts without grease nipples are maintenance-free.
Lubricating grease Grease
Designation according to DIN 51502
Specification Classification
GROVE part no.
KP - L2K
DIN 51825
00554201
– Grease gun from the tool set.
Prerequisites
– The truck crane is raised on outriggers or parked over an inspection pit. – The engine is switched off and secured against unauthorised use; p. 2 - 3.
à
– The wheels are turned as far as they will go, so that the grease nipples on the sides of the final drives are more easily accessible.
Lubricating Cardan shafts (2) are fitted only to the 10 x 8 x 10 drive.
• Check which cardan shafts (1) and (2) have grease nipples (3).
• Clean the grease nipples (3). • Inject grease into the grease nipples until grease escapes from the bearing points. Do not inject with grease with excessive force, otherwise the lip seals may be damaged.
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• Remove the excess grease.
Maintenance manual GMK 5170
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7 - 41
Maintenance work on the carrier 7.7 Axle lines
7.7.7
M6
Lubricating longitudinal cardan shafts
H Grease, spare parts, tools
Check all cardan shafts to see if they have grease nipples. Cardan shafts with grease nipples must be serviced, cardan shafts without grease nipples are maintenance-free.
Lubricating grease Grease
Designation according to DIN 51502
Specification Classification
GROVE part no.
KP - L2K
DIN 51825
00554201
– Grease gun from the tool set.
Prerequisites
– The truck crane is raised on outriggers or parked over an inspection pit. – The engine is switched off and secured against unauthorised use; p. 2 - 3.
à
Lubricating The cardan shaft (2) is fitted only to the 10 x 8 x 10 drive.
• Check which cardan shafts (1) and (2) have grease nipples (3).
• Clean the grease nipples (3). • Inject grease into the grease nipples until grease escapes from the bearing points. Do not inject with grease with excessive force, otherwise the lip seals may be damaged.
29.04.2008
• Remove the excess grease.
7 - 42
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Maintenance manual GMK 5170
Maintenance work on the carrier 7.8 Wheels
7.8
Wheels
7.8.1
Checking the tyres for damage
Prerequisites
D
– The truck crane is raised on outriggers.. – The engine is switched off and secured against unauthorised use; p. 2 - 3.
à
– The parking brake is released.
Checking
• Check all tyres for: – chunking – dents – areas of uneven wear – reaching the wear mark (1).
• Replace the damaged tyres. • If the tyres show varying wear, change the tyres (
Risk of accidents due to uneven braking! When changing the tyres, only use tyres of original equipment quality (dimensions, load bearing capacity, air pressure) so that driving characteristics are maintained. Always replace the tyres on one axle line.
29.04.2008
S
à Tyre change, p. 7 - 46).
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7 - 43
Maintenance work on the carrier 7.8 Wheels
7.8.2
S
W
Checking the tyre air pressure
Risk of damage to the tyres! The air pressure increases when the tyres are at operating temperature. Never release the increased air pressure of tyres at operating temperature! Always check the air pressure in on-road driving mode with cold tyres.
• Check the tyre pressure using the following table. Air pressure of cold tyres in bar
14.00 R 25
10.0
16.00 R 25
9.0
20.50 R 25
7.0
29.04.2008
Tyres
7 - 44
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Maintenance manual GMK 5170
Maintenance work on the carrier 7.8 Wheels
7.8.3
M1
Check tightness of wheel nuts
Spare parts and tools
Designation
Quantity per wheel
GROVE part no.
12
01207756
Wheel nut with pressure plate – Torque wrench for 650 Nm.
Prerequisites
– The engine is switched off and secured against unauthorised use; p. 2 - 3.
à
Checking the wheel nuts
• Check the wheel nuts and the pressure plates for damage.
• Replace any damaged wheel nuts or pressure plates.
• Check the wheel nuts in sequence (1-12) for
29.04.2008
a tight fit – torque 650 Nm.
Maintenance manual GMK 5170
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7 - 45
Maintenance work on the carrier 7.8 Wheels
7.8.4
M6
Tyre change The wear on tyres varies depending on whether the axle
– is driven/not driven, – is steered/not steered, – is braked/not braked, – and whether it is subject to more or less load. To achieve even wear, you must swap the wheels to different positions regularly. This will have a positive effect on tyre life and performance.
Spare parts and tools
Designation
Quantity per wheel
GROVE part no.
Wheel nut with pressure plate
12
01207756
Wheel rim sealing ring1)
1
00558261
1)
required only in case of optimised tyre change.
– Torque wrench for 650 Nm.
– The engine is switched off and secured against unauthorised use; p. 2 - 3.
à
29.04.2008
Prerequisites
7 - 46
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Maintenance manual GMK 5170
Maintenance work on the carrier 7.8 Wheels
Tyre change
G
Risk of accidents if procedure incorrect! This section shows only the sequence to be followed when changing tyres. When removing/installing the wheels, observe all the safety instructions and the procedure stated in the operating instructions.
• Remove the wheels from the axles. • Mount the wheels on another axle, as shown in the diagram. Replace any damaged parts. Tighten the wheel nuts;
à p. 7 - 45.
-
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s
Maintenance manual GMK 5170
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7 - 47
Maintenance work on the carrier 7.8 Wheels
Optimised tyre change
G G G
To ensure that the wear on all tyres is more or less the same, you can also rotate the tyres on the wheel rim and mount them on the other side of the vehicle. Risk of accidents if procedure incorrect! This section shows only the sequence to be followed when changing tyres. When removing/installing the wheels, observe all the safety instructions and the procedure stated in the operating instructions. Risk of accidents due to errors when installing aluminium wheel rims! Have tyres fitted to aluminium wheel rims only in a workshop with the correct special tool. This will prevent tyre damage caused by fitting errors. Risk of damage to tyres when running direction changed! Turn the tyres on the wheel rims before you put the wheels on the other side of the vehicle. This will prevent tyre damage caused by the tyres running in a different direction.
• Remove the wheels from the axles. • Turn the tyre on the rim if the wheel is to be used on the other side of the crane.
• Mount the wheels on another axle, as shown in the diagram. Replace any damaged parts. Tighten the wheel nuts;
à p. 7 - 45.
29.04.2008
-
7 - 48
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Maintenance manual GMK 5170
Maintenance work on the carrier 7.9 Vehicle brake
7.9
Vehicle brake
7.9.1
Checking brake-lining thickness
M3
• Check the brake-lining thickness (from the inner side) at openings (1). If the brake-lining thickness has worn down to the wear marks (stepped edges or grooves), or if the brake-lining thickness has worn down to only 3 mm:
• Have
CraneCARE or your repair crew change
the brake linings.
• Close off the openings using the covers.
29.04.2008
G
Risk of accidents due to uneven braking! If the brake lining is changed only on one side of the axle line, the wheels will have an uneven braking effect. Always replace the brake lining on both sides of an axle line.
Maintenance manual GMK 5170
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7 - 49
Maintenance work on the carrier 7.9 Vehicle brake
29.04.2008
Blank page
7 - 50
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Maintenance manual GMK 5170
Maintenance work on the carrier 7.10 Suspension
7.10
Suspension
7.10.1
Suspension struts – checking the oil level
Oil, spare parts, tools
M1
Oil in litres
Designation
GROVE part no.
for each suspension strut: 1.5
Gear oil
02310863
– Press with connected hose (from tool box).
Prerequisites
– The engine is switched off and secured against unauthorised use; p. 2 - 3.
à
– Immediately before the inspection, the truck crane was completely lowered and returned to On-road level; Operating instructions.
à
S S
Risk of damage due to faulty suspension struts! If the oil level is above the upper mark on the inspection glass, the suspension strut is faulty and must be replaced. Notify CraneCARE. Risk of damage to the suspension struts due to insufficient lubrication! It is difficult to inject the oil. Even so, do not fill oil through the inspection glass connections. If you do this, the oil will not reach all the lubricating points.
• Check whether oil is visible in the centre of the inspection glass (1) on each suspension strut. If the oil level is too low:
• Open the connection (2) – oil escapes – and quickly connect the press to the hose.
• Inject oil up the centre of the inspection glass.
• Remove the hose and quickly close the con29.04.2008
nection (2).
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7 - 51
Maintenance work on the carrier 7.10 Suspension
7.10.2
M1
Suspension struts – checking the fastening
Spare parts and tools
– Torque wrench for tightening torque up to 900 Nm.
Prerequisites
– The truck crane is raised on outriggers;
à Operating instructions.
– The engine is switched off and secured against unauthorised use; p. 2 - 3.
à
– The wheels have been removed.
• Check whether the bolts on all suspension struts are fitted tightly;
à Special torques, p. 10 - 2: 1 on the upper bracket, 2 on the lower bracket, 3 on the lower flange,
29.04.2008
4 on the half shells for the steering arm.
7 - 52
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Maintenance manual GMK 5170
Maintenance work on the carrier 7.10 Suspension
7.10.3
Forced lever – checking correct functioning
M3
On suspension struts with forced levers, the forced levers must be checked for proper functioning when the suspension is switched on and off.
G S
Risk of crushing when releasing the suspension locking system When the suspension is switched on, the wheels drop down suddenly. Ensure that nobody is close to the wheels when you switch on the suspension. Risk of damage to the tyres! Remove sharp-edged or pointed objects from below the wheels before switching on the suspension. In this way, you prevent the tyres bursting or being damaged when lowering the wheels.
• Start the engine. • Lower the truck crane to the lowest level with the level adjustment sys-
à Operating instructions. Switch off the suspension; à Operating instructions. tem;
•
The suspension struts and the forced levers (1) are brought together.
• Raise the truck crane with the outriggers; à Operating instructions. • Switch on the suspension; à Operating instructions.
• Check whether all suspension struts are extended and the forced levers (1) are relieved. If the suspension struts are not extended or only partially extended, the forced lever is faulty. 29.04.2008
• Faulty forced levers should be replaced as soon as possible by CraneCARE your repair crew.
Maintenance manual GMK 5170
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7 - 53
Maintenance work on the carrier 7.10 Suspension
7.10.4
Pressure accumulator – checking the gas pressure
M 12
The gas pressure must be checked every 3000 operating hours, but in any case at least once every 12 months.
G
Risk of accidents due to incorrect inspection! The gas pressure test must be carried out only by an authorised inspector of pressure tanks or under his supervision or instruction.
The suspension features integrated pressure accumulators that contain nitrogen (1). The filling pressure at 20 °C is 40 bar.
• Have the filling pressure checked and if nec-
29.04.2008
essary, set by CraneCARE.
7 - 54
3 112 477 en
Maintenance manual GMK 5170
Maintenance work on the carrier 7.11 Steering
7.11
Steering
7.11.1
Checking for leaks
D
• Check the hydraulic system of the steering (steering cylinders, pipes and hoses and their connections) for leaks.
G
Risk of accidents from hydraulic oil spraying out! Never tighten leaking connections when the system is under pressure. Change pipes and hoses only when the system is depressurised.
• Top up oil if necessary; à Checking the oil level, p. 7 - 61. After changing pipes and hoses:
• Bleed the hydraulic system; à Bleeding the hydraulic system, p. 7 - 73. If damage cannot be rectified immediately or further damage is likely:
29.04.2008
• Notify CraneCARE or your repair crew.
Maintenance manual GMK 5170
3 112 477 en
7 - 55
Maintenance work on the carrier 7.11 Steering
7.11.2
G
Pressure accumulator – checking the gas pressure
M 12
Risk of accidents due to incorrect inspection! The gas pressure test must be carried out only by an authorised inspector of pressure tanks or under his supervision or instruction.
Pressure accumulators containing nitrogen (1) have been built in for the steering of the 4th and 5th axle lines. The filling pressure at 20 °C is 80 bar.
• Have the filling pressure checked by
29.04.2008
CraneCARE and corrected if necessary.
7 - 56
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Maintenance manual GMK 5170
Maintenance work on the carrier 7.12 Compressed air system
7.12
Compressed air system
7.12.1
Draining the compressed air system
Spare parts and tools
Prerequisites
Designation
W
Quantity
GROVE part no.
Valve
5
01 570750
Gasket 22 x 27 Cu DIN 7603
5
00117142
– The truck crane is raised on outriggers or parked over an inspection pit. – The air reservoir is filled to the maximum
à Operating instructions.
– The engine is switched off and secured against unauthorised use; p. 2 - 3.
à
Draining the compressed air system
• Actuate the valves (1) on the air reservoirs (2) to (5). If a lot of moisture escapes:
• Have CraneCARE or your repair crew check
29.04.2008
or change the drier.
Maintenance manual GMK 5170
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7 - 57
Maintenance work on the carrier 7.12 Compressed air system
7.12.2
Checking for leaks
W
• Start up the compressed air system. • Look for any possible leaks in the compressed air system (connections, pipes, hoses and valves).
G
Risk of accidents due to escaping compressed air! Never tighten connections when the system is under pressure. Only change gaskets, pipes and hoses when the system is depressurised.
If damage cannot be rectified immediately or further damage is likely:
29.04.2008
• Notify CraneCARE or your repair crew.
7 - 58
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Maintenance manual GMK 5170
Maintenance work on the carrier 7.12 Compressed air system
7.12.3
Replacing the filter cartridge of the compressed air drier
Spare parts and tools
Designation
M 12
Quantity
GROVE part no.
1
03043578
Filter cartridge with gasket – Strap wrench.
Prerequisites
– The truck crane is raised on outriggers or parked over an inspection pit. – The engine is switched off and secured against unauthorised use; p. 2 - 3.
à
Changing the filter cartridge
G
Risk of injury from escaping compressed air! If the reservoir (2) is not completely empty, the compressed air dryer will be under pressure. Ventilate the reservoir until air no longer escapes from the valve.
• Release all the air from the reservoir (2) via the valve (1).
• Replace the filter cartridge (3) using the
29.04.2008
strap wrench (lubricate gasket slightly).
Maintenance manual GMK 5170
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7 - 59
Maintenance work on the carrier 7.12 Compressed air system
29.04.2008
Blank page
7 - 60
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Maintenance manual GMK 5170
Maintenance work on the carrier 7.13 Hydraulic system
7.13
O 7.13.1 Prerequisites
Hydraulic system Risk of environmental damage due to leaking consumables! Always let consumables drain into suitable receptacles. Wipe up any consumables that have leaked. Store/dispose of consumables and any soaked equipment properly. Ask about the applicable regulations.
D
Checking the oil level – The truck crane is aligned horizontally at on-road driving level; Operating instructions.
à
– The outriggers are retracted;
à Operating instructions.
– The engine is switched off and secured against unauthorised use; p. 2 - 3.
à
S
Risk of damage to the hydraulic system! When working with hydraulic oil, you must make sure that it is clean! Even new oil should be filtered.
• Check whether oil is visible in the centre of the inspection glass (1) before starting work.
If the oil level is too low:
29.04.2008
• Add more oil, à p. 7 - 71.
Maintenance manual GMK 5170
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7 - 61
Maintenance work on the carrier 7.13 Hydraulic system
7.13.2
W
Checking the hydraulic hoses
Hydraulic hoses are subject to ageing as well as internal and external strain.
• Check the hydraulic hoses for: – – – –
external damage (tears, abrasion, heat damage, chemical damage) leaks and moist areas blistering or unevenness of hose casing signs of ageing (porous surface, rust on hose fitting) 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: 1 Manufacturer designation. 2 Maximum operating pressure and unit of measurement (A) (e.g. 250 bar). Maximum operating pressure and unit of measurement (B) (e.g. 25.0 MPa). 3 Month and year of manufacture.
• Always ensure that the corresponding parts of the system are depressurised.
• Damaged or old hydraulic hoses must be
29.04.2008
replaced immediately.
7 - 62
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Maintenance manual GMK 5170
Maintenance work on the carrier 7.13 Hydraulic system
7.13.3
Checking for leaks
W
• When the engine is running, carry out a visual inspection for leaks on the hydraulic system (pumps, drives, cylinders, control blocks, valves, pipe and hose lines and connections).
• Check the oil level if there are leaks; à Checking the oil level, p. 7 - 61.
G O
Risk of accidents from hydraulic oil spraying out! Never tighten any leaking connections when the system is under pressure. Only change pipes and hoses when the system is depressurised.
Risk of environmental damage due to leaking consumables! Immediately repair or have repaired leakages in the hydraulic system to ensure that no hydraulic oil escapes, seeps into the ground or reaches water when the crane is being used. After parts have been changed:
• Bleed the carrier hydraulic system; à Bleeding the hydraulic system, p. 7 - 73. If damage cannot be rectified immediately or further damage is likely:
29.04.2008
• Notify CraneCARE or your repair crew.
Maintenance manual GMK 5170
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7 - 63
Maintenance work on the carrier 7.13 Hydraulic system
7.13.4 Spare parts and tools
Designation
Quantity
GROVE part no.
Filter
2
03329152
Gasket set
2
03135778
– Receptacle, approx 5 l;
Prerequisites
M3
Cleaning the magnetic rods
à p. 2 - 4.
– The truck crane must be standing on a level surface. – The engine is switched off and secured against unauthorised use; p. 2 - 3. – During the first 100 operating hours: clean the magnetic rods weekly.
à
Cleaning the magnetic rods
• Remove the lid (1) and pull out the filters. • Place the filters in a receptacle. • Remove the spring (2). • Loosen the nut (5). • Take the magnetic rod (3) out of the filter cage (4) and clean it.
• Replace any damaged parts.
29.04.2008
S
Risk of damage to the hydraulic system! Large amounts of metal particles are a sign of damage in the hydraulic system. Have CraneCARE or your repair crew check the hydraulic system.
7 - 64
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Maintenance manual GMK 5170
Maintenance work on the carrier 7.13 Hydraulic system
• Install the filters and insert them. • Replace the gaskets if necessary and fasten the lid (1).
29.04.2008
• Start the engine and check for leaks.
Maintenance manual GMK 5170
3 112 477 en
7 - 65
Maintenance work on the carrier 7.13 Hydraulic system
7.13.5 Shortening the interval
• Under difficult operating conditions – at extremely sandy or dusty locations – you must change the ventilation filter earlier than normal.
Spare parts and tools
Designation Filter
Prerequisites
O
M 12
Changing the ventilation filter
Quantity
GROVE part no.
1
03324588
– The engine is switched off and secured against unauthorised use; p. 2 - 3.
à
Risk of damage to the environment from filter residues! Store used filter inserts in suitable receptacles and have them disposed of properly by qualified personnel.
• Remove the lid (1).
29.04.2008
• Change the filter (2) and fasten the lid.
7 - 66
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Maintenance manual GMK 5170
Maintenance work on the carrier 7.13 Hydraulic system
7.13.6
M 12
Taking oil samples
Shortening the interval
• Under difficult operating conditions – at tropical or very hot locations –
Spare parts and tools
– Connecting piece and hose (tool box).
you must halve the oil change interval.
– Four sample containers (0.3 litres each). – Receptacle, approx. 5 litres;
Prerequisites
à p. 2 - 4.
– The outriggers are retracted;
à Operating instructions.
– The engine is switched off and secured against unauthorised use; p. 2 - 3.
à
Taking oil samples
Samples must be taken from the hydraulic oil tank and from the hydraulic system in order to determine the usability of the oil.
• Take one oil sample from each valve (1), (2) and (3) of the hydraulic oil tank; the valves, p. 7 - 68.
à Handling
• An oil sample from the hydraulic system is taken via a gauge port (4), e.g. on a valve block of the suspension.
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s
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7 - 67
Maintenance work on the carrier 7.13 Hydraulic system
Handling the valves
G
The valves can be opened and closed only using the connecting piece with the hose. The connecting piece is in the tool box. Danger due to escaping hydraulic oil! When the connecting piece is screwed onto the valve, the valve opens and the hydraulic oil immediately flows out of the connecting piece. Holding it by the connecting piece, place the hose into a suitable receptacle before screwing on the connecting piece.
• Place the hose onto the connecting piece and put the other end of the hose into a receptacle.
• A – Remove the cap and screw the connecting piece and hose onto the valve – the valve opens.
• Drain the required amount of oil. • B – Remove the connecting piece and hose – the valve closes. • Screw the cap onto the valve.
Taking oil samples
• Before taking the oil sample, allow 1 to 2 litres of oil to drain into a receptacle.
• Take 0.3 litres of hydraulic oil from each of the three valves on the hydraulic tank and from one gauge port.
• Label each sample with – the date of sampling, – number of operating hours since last oil change and – the sampling location (hydraulic oil tank or gauge port).
• Have a technical laboratory determine the viscosity, the viscosity index, the degree of contamination and the water content of all the samples.
29.04.2008
– – – –
7 - 68
3 112 477 en
Maintenance manual GMK 5170
Maintenance work on the carrier 7.13 Hydraulic system
Determining the quality of the oil
Compare the quality of the oil with the limit values and carry out the specified measures if necessary. Viscosity limit values: – Viscosity ISO-VG 32 in accordance with DIN 51524 T.2 – Viscosity index Vi ≥ 150. If one of these limit values has been reached/fallen short of:
• Carry out an oil change; à p. 7 - 70. Contamination limit value: – Contamination in accordance with NAS 1638 Class 7 or ISO 4406:1999 Code 18/16/13 (purity class). If this limit has been reached/exceeded:
• Replace the filters of the hydraulic system; à p. 7 - 74. • Have the hydraulic oil cleaned with a mobile filter unit until the required purity class is reached. Water content limit value: – Water content ≤ 100 ppm. If this limit value has been reached/exceeded:
• Have the hydraulic oil cleaned with a mobile water separator until the
29.04.2008
water content is clearly below the limit value.
Maintenance manual GMK 5170
3 112 477 en
7 - 69
Maintenance work on the carrier 7.13 Hydraulic system
7.13.7
Changing the hydraulic oil The oil needs to be changed only if the laboratory analysis indicates the need for it; Determining the quality of the oil, p. 7 - 69.
à
Oil, spare parts, tools
Hydraulic oil in litres 150
Designation according to DIN 51502
Specification Classification
GROVE part no.
H - LP
DIN 51524 T.2 Viscosity: ISO-VG 32
01375719
Designation
Quantity
GROVE part no.
1
03098598
Cover gasket 140/90 x 3 – Connecting piece with hose (tool box). – One or more receptacles, approx. 150 l;
Prerequisites
– The outrigger is retracted;
à p. 2 - 4.
à Operating instructions.
– The engine is switched off and secured against unauthorised use; p. 2 - 3.
à
Closing the valves
S
Risk of damage to the hydraulic pumps! Be sure to secure the engine against unauthorised use. If the engine is started while the valves in the suction line are closed, the hydraulic pumps will be damaged.
• Close the valves – lever (1) at right angles to
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the line.
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Maintenance manual GMK 5170
Maintenance work on the carrier 7.13 Hydraulic system
Draining oil
O
Risk of environmental damage due to leaking consumables! Use the supplied connecting piece and hose and a receptacle with sufficient capacity to drain the hydraulic oil.
• Place a receptacle underneath the valves. • One after the other, screw the connecting piece and hose onto the valves (1), (2) and Handling the valves, p. 7 - 68. (3);
à
• Change the filters; à p. 7 - 74.
Topping up the oil
S
Risk of damage to the hydraulic system! Cleanliness is of the utmost importance when handling hydraulic oil. Even new oil must be filtered before it is added to the tank.
• Remove the lid (3). • Add new oil through a filter until the level reaches the centre of the inspection glass (1).
• If required, replace the gasket (2) and fasten the lid.
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Maintenance work on the carrier 7.13 Hydraulic system
Establishing operating condition
S
After having changed the oil filters and topped the oil up, you must re-establish the operating condition. Risk of damage to the hydraulic pumps! Open the valves prior to starting the engine. This prevents damage to the hydraulic pumps.
Opening the valves
• Open the valves – lever (1) parallel with the line.
• Start the engine. • Carry out all hydraulic functions several times to remove any air in the system.
• Carry out a road test of the truck crane, turning the steering wheel several times to its fullest extent.
• Check the oil level through the inspection glass on the hydraulic oil tank.
à Checking the oil level, p. 7 - 61.
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Top up oil if necessary;
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Maintenance manual GMK 5170
Maintenance work on the carrier 7.13 Hydraulic system
Bleeding the hydraulic system
If the steering is “loose” during the test run, you must bleed the hydraulic system at the steering cylinders.
Preparations
– The truck crane is raised on outriggers;
à Operating instructions.
– The parking brake is engaged.
G G
Risk of crushing from turning wheels! When working between the wheels, ensure that the steering wheel cannot be turned by an unauthorised party. The wheels turn when the steering wheel is operated. Risk of accidents from high oil pressure! 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 engine. • Bleed each steering cylinder (2) by loosening the collar nuts (1) until the oil coming out no longer contains air bubbles.
If the steering system is still not operating properly:
• Notify CraneCARE authorised repair special-
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ist.
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7 - 73
Maintenance work on the carrier 7.13 Hydraulic system
7.13.8
Changing the hydraulic oil filter All three oil filters must be replaced when changing the oil. In the event of a warning message, the symbol (1) in the Warning submenu indicates that you must change the oil filters.
Spare parts and tools
Designation
Quantity
GROVE part no.
Filter
2
03329152
Gasket set
2
03135778
– Receptacle, approx. 5 l;
Prerequisites
à p. 2 - 4.
– The engine is switched off and secured against unauthorised use; p. 2 - 3.
à
Changing the filter
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O
Risk of damage to the environment from filter residues! Store used filter inserts in suitable receptacles and have them disposed of properly by qualified personnel.
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Maintenance manual GMK 5170
Maintenance work on the carrier 7.13 Hydraulic system
• Remove the lid (1) and pull out the filters. • Place the filters in a receptacle. • Remove the spring (2). • Undo the bolt (6). • Take the magnetic rod (3) and the filter (4) out of the filter cage (5).
• Clean the magnetic rod (2) and the filter cage (5).
• Insert a new filter (3) into the filter cage (5). • Replace any damaged parts.
S
Risk of damage to the hydraulic system! Large amounts of metal particles are a sign of damage in the hydraulic system. Have CraneCARE or your repair crew check the hydraulic system.
• Install the filters and insert them. • Replace the gaskets and fasten the lid (1).
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• Start the engine and check for leaks.
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Maintenance work on the carrier 7.13 Hydraulic system
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Maintenance manual GMK 5170
Maintenance work on the carrier 7.14 Central lubrication system
7.14
Central lubrication system
7.14.1
Checking the level
Grease, spare parts, tools
Lubricating grease Grease
W
Designation according to DIN 51502
Specification Classification
GROVE part no.
KP - L2K
DIN 51825
00554201
– Filling pump from the tool set.
Prerequisites
– The parking brake is engaged.
Checking the level
• Check the level of the grease container (1). The grease level must be near the max. mark. If the level is too low:
• Add more grease; à p. 7 - 78.
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Maintenance work on the carrier 7.14 Central lubrication system
topping up
S
Risk of damage to the central lubrication system! Cleanliness is of the utmost importance when handling grease and filling pumps. Do not remove the caps from the hole and filling pump until immediately before refilling the grease. This prevents dirt particles from getting into the grease and damaging the central lubrication system. Fill the container as follows: 1 Filling pump tool set You must install the connector from the tool box. 2 Filling pumps for lubrication nipples
• Switch on the ignition.
• When filling with the supplied filling pump, screw it onto the connecting piece (2).
• Fill the grease container via connection (2) up to the max. mark.
• Press the button (1) for approx. 2 seconds once.
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Intermediate lubrication is triggered.
7 - 78
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Maintenance manual GMK 5170
Maintenance work on the carrier 7.14 Central lubrication system
7.14.2
Bleeding the central lubrication system When the grease container is empty or contains bubbles, you must bleed the central lubrication system. The grease container (1) is full.
• Loosen the lubricating pipe at connection (2).
• Turn on the ignition. • Trigger intermediate lubrication repeatedly until the grease flowing from the connection (2) no longer contains any bubbles.
• Fasten the lubricating pipe at connection (2). • Remove any excess grease.
7.14.3
Triggering intermediate lubrication Intermediate lubrication should be activated – after high-pressure cleaning, – to check the lubrication at all lubricating points.
• Turn on the ignition. • Press the button (1) for approx. 2 seconds once. An intermediate lubrication cycle will be triggered which lasts approximately 3 minutes. Check whether grease is applied to all the lubricating points. (Steering arm at all axle lines).
• Turn off the ignition and remove any excess 29.04.2008
grease.
• Tighten the cap.
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Maintenance work on the carrier 7.14 Central lubrication system
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Maintenance manual GMK 5170
Maintenance work on the carrier 7.15 Electrical system
7.15
Electrical system
7.15.1
Checking the lighting and indicators
G
D
Risk of accidents if the safety devices are faulty! If the lamps or indicators fail, notify CraneCARE and have the fault rectified.
• Check the following functions daily before operating or driving the truck crane, and have faulty parts repaired:
!r2 1 k
– Parking light/headlight, marker lights, rotating beacons, fog tail light, fog light, outrigger lights – Hazard warning system – Brake lights – Reversing lights – Warning buzzer – Full-beam headlight – Turn signal indicator – Windscreen wipers – Windscreen washing system
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– Horn
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7 - 81
Maintenance work on the carrier 7.15 Electrical system
7.15.2
G G G G S
M1
Checking the batteries
Risk of poisoning from batteries containing lead compounds! Battery poles, battery clamps and parts inside the battery contain lead compounds. Lead-compound particles on your hands must not be allowed to enter your body – e.g. by swallowing contaminated food. Wash your hands after working on batteries. Risk of explosion from escaping hydrogen! Do not place tools on the battery and keep unshielded light away from the battery.
Risk of explosion from static charge! Only use anti-static cloths to clean the batteries. This prevents static charging and possibly resulting hydrogen mixtures from exploding. Risk of injury from battery acid! Battery acid is highly caustic. Wear safety goggles and protective gloves. Do not tilt the battery. Rinse off or wash out the acid spray on the skin or clothing using soap suds. Risk of damage to the crane electronics! Always switch off the battery master switches before commencing work on the truck crane’s electrical system. This prevents short circuits and resulting damage to the electrical system.
Before checking
• Switch the battery master switch (1) off and remove the selector handle.
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• Open the battery box (2).
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Maintenance manual GMK 5170
Maintenance work on the carrier 7.15 Electrical system
Checking the connecting terminals
• Keep the batteries clean and dry. • Loosen any dirty connecting terminals (1) and clean them.
• Fasten the loose connecting terminals. • Grease the connecting terminals and poles lightly with a special battery terminal grease.
Checking the acid level
• Remove all lids (1). The acid level must be above the plates. If the acid level is too low
• Top it up using distilled water only until the plates are covered.
• Screw on all lids (1) tightly.
After checking
• Close the battery box (2). • Attach the selector handle and switch on the battery master switch (1).
• Check the timers on the tachograph and on the auxiliary heater; tions.
à Operating instruc-
• Enter the code for the radio; à Separate 29.04.2008
operating instructions.
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7 - 83
Maintenance work on the carrier 7.15 Electrical system
7.15.3
M3
Checking the charge level of the batteries
à Separate operating instructions, or
Spare parts and tools
– Battery testing device;
Charge level table
The measurement of the acid concentration with the acid siphon will give you an indication of the charge level of the batteries. The acid siphon can have a scale in g/cm³, for example. Therefore, observe the special scale on your acid siphon.
– Acid siphon.
D
7 - 84
Charge level
1.28
good
1.20
half-charged; recharge
1.12
flat; recharge immediately
Risk of poisoning from batteries containing lead compounds Battery poles, battery clamps and parts inside the battery contain lead compounds. Lead-compound particles on your hands must not be allowed to enter your body – e.g. by swallowing contaminated food. Wash your hands after working on batteries. Risk of explosion from escaping hydrogen! Do not place tools on the battery and keep unshielded light away from the battery.
Risk of explosion from static charge! Only use anti-static cloths to clean the batteries. This prevents static charging and possibly resulting hydrogen mixtures from exploding. Risk of injury from battery acid! Battery acid is highly caustic. Wear safety goggles and protective gloves. Do not tilt the battery. Rinse off or wash out the acid spray on the skin or clothing using soap suds. Risk of damage to the crane electronics! Always switch off the battery master switches before commencing work on the truck crane’s electrical system. This prevents short circuits and resulting damage to the electrical system.
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Maintenance manual GMK 5170
29.04.2008
G G G G S
Acid concentration (g/cm³)
Maintenance work on the carrier 7.15 Electrical system
Before checking
• Switch the battery master switch (1) off and remove the selector handle.
• Open the battery box (2).
Checking the acid concentration
• Remove all lids (1). • Read off the cell value on the acid siphon (2) and compare the value with that in the table; Charge level table, p. 7 - 84.
à
• Check all cells in the same way. • Screw on all lids (1) tightly.
After checking
• Close the battery box (2). • Attach the selector handle and switch on the battery master switch (1).
• Check the timers on the tachograph and on the auxiliary heater; à Operating instructions.
• Enter the code for the radio; à Separate 29.04.2008
operating instructions.
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7 - 85
Maintenance work on the carrier 7.15 Electrical system
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Maintenance manual GMK 5170
Maintenance work on the carrier 7.16 Air-conditioning system
7.16
Air-conditioning system
7.16.1
Checking the air-conditioning system
M1
• Switch on the air-conditioning system; à Operating instructions • Check whether cooling is being achieved. If no cooling is being achieved, the air conditioning system is defective.
• Switch the air-conditioning system off. If the air-conditioning system is defective:
• Do not start it up again, lest further damage result. Have the air-conditioning system repaired as soon as possible by CraneCARE.
7.16.2
S
Cleaning the condenser fins
M1
Risk of damage to the condenser! Do not use a high pressure cleaner or steam jet cleaner. The powerful jet may damage the fins. Use only compressed air for cleaning.
• Switch the air-conditioning system off. • Clean the condenser fins with compressed
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air (1).
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7 - 87
Maintenance work on the carrier 7.16 Air-conditioning system
7.16.3
M6
Checking hoses
G
Danger of burns from escaping refrigerant! Wear suitable protective goggles and gloves when checking hoses and connections. This will prevent injury from suddenly escaping refrigerant. Seek medical attention if skin or eyes come into contact with refrigerant.
• Check all refrigerant hoses for damage and worn areas. Have damaged hoses replaced only by CraneCARE.
7.16.4
Checking the entire air-conditioning system
H
G
M 12
This check should only be carried out by CraneCARE!
Danger of burns from escaping refrigerant! Wear suitable protective goggles and gloves when checking hoses and connections. This will prevent injury from suddenly escaping refrigerant. Seek medical attention if skin or eyes come into contact with refrigerant.
• Have the entire air-conditioning system checked for leaks and proper functioning. The inspection of the air-conditioning system includes most importantly the inspection of – the refrigerant collector, in accordance with the pressure container regulations (test group II) and – the refrigerant compressor.
• Use only suitable refrigerant for topping up. Refrigerant Fill quantity in kg
Tetrafluoroethane (R134a)
CAS no. EC no. 811-97-2 212-377-0
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approx. 1.5
Designation
Filler connections 7 - 88
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Maintenance manual GMK 5170
Maintenance work on the carrier 7.16 Air-conditioning system
H
This topping up should be done only by CraneCARE.
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– Filler connections (1) for refrigerants
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7 - 89
Maintenance work on the carrier 7.16 Air-conditioning system
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Maintenance manual GMK 5170
Maintenance work on the carrier 7.17 Particulate filter
7.17
Particulate filter When a particulate filter is fitted as additional equipment, it is incorporated in the exhaust system silencer. Have the particulate filter cleaned by service partners. Information can be obtained from CraneCARE.
7.17.1
M1
Checking the clamp straps
Spare parts and tools
Designation
Quantity
GROVE part no.
2
03134864
Clamp strap – Torque wrench for torque of 20 Nm.
Checking the clamp straps
G
Risk of burning yourself if the exhaust system is hot! During operation, the exhaust system can heat up to 400 °C. Wear suitable gloves and/or wait until the exhaust system has cooled down. Make sure not to touch any hot parts.
• Remove the heat shield (1). • Check the clamp straps (2) for tightness. Torque 20 Nm.
• Replace any damaged clamp straps;
à p. 7 - 93.
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• Attach the heat shield (1).
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7 - 91
Maintenance work on the carrier 7.17 Particulate filter
7.17.2
M6
Replacing the particulate filter
Spare parts and tools
Designation
Quantity
GROVE part no.
Clamp strap
2
03134864
Filter
1
03134863
– Torque wrench for torque of 20 Nm.
Prerequisites
– The engine is switched off and secured against unauthorised use; p. 2 - 3.
à
Removing the exhaust silencer
G G O
Health hazard due to soot particles! Soot particles are suspected of being hazardous to health. Wear appropriate dust respirator masks and be careful not to breathe in or ingest dust particles. Risk of polluting the environment! Collect the combustion residues from the particulate filter in a suitable receptacle and dispose of them according to the relevant regulations.
When cleaning or exchanging the particulate filter, also refer to the documents supplied by the filter manufacturer. Record the filter exchange in the documents supplied by the filter manufacturer.
29.04.2008
H
Risk of burning yourself if the exhaust system is hot! During operation, the exhaust system can heat up to 400 °C. Wear suitable gloves and/or wait until the exhaust system has cooled down. Make sure not to touch any hot parts.
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Maintenance manual GMK 5170
Maintenance work on the carrier 7.17 Particulate filter
• Remove the heat shield (1). • Loosen the clamp strap (3) and remove the part (2).
• Loosen the clamp strap (5) and remove the filter (4) from part (6).
• After removal and before cleaning, allow the parts to cool down if necessary.
Cleaning the filter
• Clean the filter in a manufacturer-approved cleaning system only.
or exchange it
• Replacement filters are available from the filter manufacturer's service partner if you do not have a cleaning system available. For more information, please contact CraneCARE.
Installing the filter
• Use only new clamp straps (3) and (5) with intact gaskets.
• Place the filter (4) on the part (6) and fasten it with the clamp strap (5) – torque 20 Nm.
• Place the part (2) on the filter (4) and fasten it with the clamp strap (3) – torque 20 Nm.
• Attach the heat shield (1). • Carry out a back pressure test; à p. 7 - 94.
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s
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7 - 93
Maintenance work on the carrier 7.17 Particulate filter
Back pressure test
The back pressure test allows you to determine whether the exhaust connection to the filter is gas-tight:
• Engage the parking brake; à Operating instructions.
• Start the engine. • Slowly increase the engine speed up to 1800 min-1 and hold this engine speed for 30 seconds.
• Monitor the exhaust gas flow – there must be no visible smoke. • Switch off the engine. If smoke was clearly visible:
• Check whether – the clamp straps are sufficiently tight, – if the clamp strap gaskets are intact, – if the particulate filter is intact.
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• Rectify any damage you were able to identify.
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Maintenance manual GMK 5170
Maintenance work on the carrier 7.18 Towbar coupling
7.18
Towbar coupling Depending on the scope of equipment of your truck crane, it may have towbar couplings (additional equipment) from various manufacturers. Their wear values may vary from those specified; Separate operating instructions.
à
7.18.1
M1
Lubricating the towbar coupling
This maintenance work is not required if the towbar coupling is connected to the central lubrication system.
Grease, spare parts, tools
Lubricating grease Grease
Designation according to DIN 51502
Specification Classification
GROVE part no.
KP - L2K
DIN 51825
00554201
– Grease gun from the tool set.
G H
Risk of injury when the automatic closing device is triggered! Do not put your hand into the coupling jaw when the towbar coupling is open. This may trigger the automatic closing device, make the coupling pin move down and seriously injure your hand. To avoid over-lubrication, the towbar coupling should be lubricated only when open!
• Clean the lubricating nipples (2) and (3). • Open the towbar coupling. To do this, move the lever (1) upward.
• Squirt grease into the lubricating nipples (2) and (3).
• Close the towbar coupling.
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7 - 95
Maintenance work on the carrier 7.18 Towbar coupling
Closing the towbar coupling
G
Risk of injury when closing the towbar coupling by hand! When closing, the 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 balls of your hands. If you hold the lever and move it down, it may carry your hand with it and crush it. After lubrication, you must close the towbar coupling.
• Move the lever (1) briefly in the direction of the coupling jaw (observe the arrow).
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• Remove any excess grease.
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Maintenance manual GMK 5170
Maintenance work on the carrier 7.18 Towbar coupling
7.18.2 Prerequisites
M3
Checking the bearing – The coupling is closed;
à p. 7 - 96.
Checking the bearing
G
Risk of injury! Ensure that the towbar coupling is closed for the following work (lever points downwards). The lever may otherwise come down with great force and cause serious hand injury.
• Check the bearing of the towbar coupling by vigorously shaking it up and down and in the longitudinal direction (arrows). Hold the towbar coupling at the top and bottom of the coupling head and not by the coupling jaw.
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The vertical clearance at the coupling head must be no more than 3 mm.
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7 - 97
Maintenance work on the carrier 7.18 Towbar coupling
7.18.3 Prerequisites
M3
Checking the cotter pin – The coupling is closed;
à p. 7 - 96.
Checking the cotter pin
• Check the wear on the cotter pin (1). The diameter of the crowned section (arrows) must not be less than the following values: Model series 400:
36.5 mm
Model series 700:
46.0 mm
If the dimension is smaller than that given above, have the cotter pin replaced by CraneCARE or by your repair crew.
• Also check the cotter pin for the correct ver-
29.04.2008
tical clearance. Take a screwdriver and press the pin (1) upwards. The vertical clearance (2) of the cotter pin must not exceed 4 mm.
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Maintenance work on the carrier 7.18 Towbar coupling
7.18.4 Prerequisites
M3
Checking the lower bushing – The coupling is closed;
à p. 7 - 96.
Checking the bushing
• Check the internal diameter of the lower bushing. The diameter D must not exceed the following values: Model series 400:
31.5 mm
Model series 700:
34.2 mm
If the dimension is smaller than that given above, have the bushing replaced by CraneCARE or by your repair crew.
7.18.5
Checking the initial tension of the springs
M3
The coupling head should require physical power to twist when checking the torque.
• Twist the coupling head clockwise and anticlockwise to check the initial
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tension of the rubber springs.
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7 - 99
Maintenance work on the carrier 7.18 Towbar coupling
7.18.6 Prerequisites
M3
Checking the support ring – The coupling is closed;
à p. 7 - 96.
Checking the support ring
• Check the support ring (1) at the bottom of the coupling jaw. When the trailer is coupled, the draw eyelet of the trailer must not be in 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 – the support ring has reached its wear limit of H = 14 mm.
7.18.7
Checking the function of the coupling jaw/ Resetting central position
Spare parts and tools
– Torque wrench for torque of 58 Nm.
Prerequisites
– The coupling is closed;
M3
29.04.2008
à p. 7 - 96.
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Maintenance manual GMK 5170
Maintenance work on the carrier 7.18 Towbar coupling
Checking for correct functioning 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. The 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.
H
If the lever does not automatically engage with the coupling jaw, the central position must be re-adjusted; p. 7 - 101.
à
Resetting the central position
• Open the coupling (lever (1) pointing upwards) and loosen the bolts (2).
• Push the coupling jaw to the side until the lever engages.
• Tighten the bolts – torque 58 Nm. • Check the function of the coupling jaw;
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à p. 7 - 100.
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7 - 101
Maintenance work on the carrier 7.18 Towbar coupling
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7 - 102
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Maintenance manual GMK 5170
Maintenance work on the carrier 7.19 Other maintenance work
7.19
Other maintenance work
7.19.1
Lubricating the support bearings
Grease, spare parts, tools
Lubricating grease Grease
M1
Designation according to DIN 51502
Specification Classification
GROVE part no.
KP - L2K
DIN 51825
00554201
– Brush or roller.
G
Risk of crushing due to extending support bearings! Ensure that there is sufficient room around the crane. Warn any persons nearby before extending the support bearings. Observe the safety instructions in the operating instructions.
• Fully extend all support bearings;
à Operating instructions.
• Apply the grease to both sides of the slide faces (1) on all the support bearings.
• Extend and retract the support bearings several times.
• Remove any excess grease.
After every high-pressure cleaning operation on the truck crane:
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• Lubricate the support bearings.
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7 - 103
Maintenance work on the carrier 7.19 Other maintenance work
7.19.2
Checking the auxiliary heater for correct operation
M1
Your truck crane has fire auxiliary heaters, depending on its scope of equipment. During the warm summer months, operate the auxiliary heater for 20 to 30 minutes; Operating instructions.
à
• Check that the system is working properly. Also perform a functional check of the controls.
• If the heating system is not functioning correctly, report it CraneCARE.
7.19.3
Y2
Having the fire extinguisher checked
Your truck crane has fire extinguishers, depending on its scope of equipment.
H
The maintenance interval may be shorter, depending on the respective national regulations. Ask about the national and local regulations at the local Fire Safety Authority.
• Follow the operating instructions (1) on the fire extinguisher. • Have the fire extinguisher serviced by trained personnel in good time before the maintenance interval specified on the label (2) expires.
29.04.2008
S
Danger due to the fire extinguisher not working! There is no guarantee that the fire extinguisher is still working properly after the maintenance interval on the label has expired.
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Maintenance manual GMK 5170
8 8
Maintenance work on the superstructure
8.1
General instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 -
1
Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 -
1
8.2
Symbols for maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 -
3
8.3
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 -
5
8.1.1
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 8.5 8.5.1 8.5.2 8.5.3 8.5.4 8.5.5 8.5.6 8.5.7 8.6 8.6.1 8.6.2 8.6.3 8.6.4 8.7 8.7.1 8.7.2 8.7.3
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8.8 8.8.1 8.8.2 8.8.3 8.8.4 8.8.5 8.8.6 8.8.7 8.8.8 8.8.9
Checking the oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 5 Topping up the oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 7 Checking the air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 8 Checking the coolant level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 9 General inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 10 Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 11 Draining off water from fuel filter 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 11 Changing fuel filter 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 13 Changing fuel filters 2 and 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 15 Hoists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 19 Checking the oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 General inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Checking the hoist brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Lubricating the auxiliary hoist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Changing the oil/Checking the oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Having a partial inspection carried out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Having a general inspection carried out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 -
19 20 20 20 22 24 24
Slewing gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 25 Checking the oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Checking for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Checking the slewing gear brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Changing the oil/Checking the oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 -
25 26 26 28
Ball slewing bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 31 Lubricating gear teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 31 General inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 33 Measuring tilting play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 33 Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 35 Checking the oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Checking the hydraulic hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Checking ventilation filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Checking for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Changing the ventilation filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Pressure accumulator – checking the gas pressure . . . . . . . . . . . . . . . . . . . . . . 8 Taking oil samples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Changing the hydraulic oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Changing the hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 -
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35 36 36 37 38 39 40 41 44
8.9
Main boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 49
8.9.1 8.9.2 8.9.3
Lubricating the telescopic sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 49 Checking the sheaves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 53 Checking the locking system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 53
8.10
Hoist ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 55
8.11 8.11.1 8.11.2 8.12 8.12.1 8.13 8.13.1 8.13.2 8.14 8.14.1 8.14.2 8.14.3 8.15 8.15.1 8.15.2 8.15.3 8.15.4 8.16 8.16.1 8.16.2 8.16.3
Checking the position on the rope drums . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking the hoist ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubricating the hoist rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assessing the condition of the hoist rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing the hoist rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setting the lowering limit switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
888888-
55 56 57 58 64 67
Cable drums and slewing angle sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 69 Maintenance of the slip ring assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 69 Lubricating the slewing angle sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 71 Central lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 73 Checking the level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 73 Hook blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 73 Checking the sheaves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 73 Lubricating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 74 Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 75 Checking the lighting and indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 75 Checking the batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 76 Checking the charge level of the batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 76 Air-conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 77 Checking the air-conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning the condenser fins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking the entire air conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . .
8888-
77 77 78 78
Other maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 79 Checking the auxiliary heater for correct operation . . . . . . . . . . . . . . . . . . . . . 8 - 79 Lubricating the piston rod of the derricking cylinder . . . . . . . . . . . . . . . . . . . . 8 - 79 Having the fire extinguisher checked . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 80
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8.10.1 8.10.2 8.10.3 8.10.4 8.10.5 8.10.6
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Maintenance manual GMK 5170
Maintenance work on the superstructure 8.1 General instructions
8
Maintenance work on the superstructure
8.1
General instructions
8.1.1
Covers Various types of work (e.g. oil change) require that the covers be removed. Before maintenance work
• Open the service flaps (1) for maintenance work. After maintenance work
• Close the service flaps (1) and secure them
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with the locks.
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8-1
Maintenance work on the superstructure 8.1 General instructions
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8-2
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Maintenance manual GMK 5170
Maintenance work on the superstructure 8.2 Symbols for maintenance work
8.2
Symbols for maintenance work Check the following symbols daily before starting operations.
On the ECOS display
• Open the Warning submenu; à Operating instructions.
You must carry out the associated maintenance work if the symbol is displayed in red: – Oil pressure;
– Air filter;
à p. 8 - 5,
à p. 8 - 8,
– Coolant level;
à p. 8 - 9, à p. 8 - 41.
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– Hydraulic oil filter;
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8-3
Maintenance work on the superstructure 8.2 Symbols for maintenance work
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8-4
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Maintenance manual GMK 5170
Maintenance work on the superstructure 8.3 Engine
8.3
Engine • In addition, carry out further maintenance work as specified in the engine manufacturer documentation supplied with the vehicle. Pay attention to the information relating to use of bio-diesel fuel – the oil change interval must be halved.
8.3.1 Prerequisites
Checking the oil level
D
– The truck crane is level.
Checking the oil level
• Start the engine. • Immediately after starting the engine, check the lamp (1) on the ECOS display. The lamp (1) must go out approx. 10 seconds after starting the engine.
S
Risk of damage to the engine if the oil pressure is too low! If the lamp (1) does not go out after about 10 seconds, perform the following check and switch off the engine. The engine can be damaged by running it when the oil pressure is too low.
• Press the button (1) once. The Warning submenu opens. • Switch off the engine immediately if the symbol (2) turns red.
• After the lamp (1) has gone out following the engine start-up, allow the engine to idle for 2 - 3 min.
• Switch off the engine. 29.04.2008
• Check the oil level after about 2 minutes.
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8-5
Maintenance work on the superstructure 8.3 Engine
• On the dipstick (1), check whether the oil level is between the min. and the max. marking (arrows).
• Put the dipstick into the dipstick tube after checking the oil level. If the oil level is too low:
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• Add more oil, à p. 8 - 7.
8-6
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Maintenance manual GMK 5170
Maintenance work on the superstructure 8.3 Engine
8.3.2
Topping up the oil Data on the prescribed oil specification; tion.
à Engine manufacturer's documenta-
Oil Engine oil in litres 16
Prerequisites
Designation according to DIN 51502
Specification Classification
GROVE part no.
HD - CD
MIL-L 2104 C DB 228.5
First fill oil: SAE 15 W-40 02309375
– The truck crane is level. – The engine is not running and is secured against unauthorized use; p. 2 - 3.
à
Topping up oil
S G
Risk of damage to the engine if the oil level is too high! Do not overfill; the oil level must not be higher than the max. mark (arrow). Drain off oil if necessary; Engine manufacturer's documentation.
à
Risk of burning yourself when the engine is hot! During operation, the engine and add-on parts can reach temperatures up to 400 °C. Wear appropriate protective gloves and be careful not to touch hot parts.
• Add oil through the filler neck (1) up to the max. mark.
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• Close the filler neck with the lid.
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8-7
Maintenance work on the superstructure 8.3 Engine
8.3.3
D
Checking the air filter
• Start the engine. On the ECOS display, check whether the lamp (1) lights up.
• Press the button (2) once. The Warning submenu opens.
You must change the air filter if the symbol is red.
Spare parts and tools
Designation Filter
Prerequisites
Quantity
GROVE part no.
1
03 328 263
– The engine is not running and is secured against unauthorized use; p. 2 - 3.
à
Replacing the air filter
• Undo all clamps (1) and remove the filter cover (2).
• Change the filter (3). • Replace the cover and secure it with all the
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clamps.
8-8
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Maintenance manual GMK 5170
Maintenance work on the superstructure 8.3 Engine
8.3.4
Checking the coolant level
D
• Start the engine. On the ECOS display, check whether the lamp (1) lights up.
• Press the button (2) once. The Warning submenu opens.
You must top up the coolant if the symbol is red.
Topping up coolant
G
Danger of being scalded due to hot radiator circuit! The hot radiator circuit is under pressure. When you open the expansion tank, you could be scalded by escaping steam or coolant. Wear suitable protective gloves and cover the cap on the expansion tank with a rag before opening it. Turn the cap slowly to the first detent in order to allow the pressure to be released.
• Loosen (do not open!) the cap (1) to reduce the pressure if the coolant is at operating temperature.
• Open the cap (1). The coolant level must be at the lower edge in the filler neck. If the coolant level is too low:
• Top up the coolant. Composition of the coolant; Engine manufacturer's documentation.
à
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• Close the cap (1).
S Maintenance manual GMK 5170
Risk of damage to engine due to lack of coolant! If the coolant has to be topped up frequently, the cooling system may be leaking. Have the cooling system checked by CraneCARE or your repair crew.
3 112 477 en
8-9
Maintenance work on the superstructure 8.3 Engine
8.3.5
General inspection
W
• Investigate any unusual noises from the engine. • Check the engine and the connections for leaks. In the event of leaking fluids; Checking the oil level, p. 8 - 5, Checking the coolant level, p. 8 - 9.
à à
• Check that pipes and hoses are tightly connected and not damaged.
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If you detect any worn or damaged parts, contact CraneCARE or your repair crew.
8 - 10
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Maintenance manual GMK 5170
Maintenance work on the superstructure 8.4 Fuel system
8.4
Fuel system Installed in the fuel line are: 1 Fuel filter 1 2 Fuel filter 2 3 Fuel filter 3
8.4.1
Draining off water from fuel filter 1
Spare parts and tools
– Receptacle, approx. 5 l;
Prerequisites
– The truck crane is level.
D
à p. 2 - 4.
– The engine is not running and is secured against unauthorized use; p. 2 - 3.
à
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s
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8 - 11
Maintenance work on the superstructure 8.4 Fuel system
Draining off water
O
Risk of environmental damage due to leaking fluids! Always let fluids drain into suitable receptacles. Wipe up any fluids that have leaked. Store/dispose of fluids and any soaked equipment properly. Ask about the applicable regulations.
• Place a receptacle underneath the filter. • Open the valve (1). • If the draining fluid is clean, close the valve manually.
• Remove the receptacle and properly dis-
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pose of the drained fluid.
8 - 12
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Maintenance manual GMK 5170
Maintenance work on the superstructure 8.4 Fuel system
8.4.2 Spare parts and tools
Designation
Quantity
GROVE part no.
Filter
1
03322877
Gasket
1
03322879
Filter element
1
03328656
– Receptacle, approx. 5 l;
Prerequisites
M3
Changing fuel filter 1
à p. 2 - 4.
– The truck crane is level. – The engine is not running and is secured against unauthorized use; p. 2 - 3.
à
– If the fuel is contaminated: Shorten the maintenance interval.
Changing
O
Risk of environmental damage due to leaking fluids! Always let fluids drain into suitable receptacles. Wipe up any fluids that have leaked. Store/dispose of fluids and any soaked equipment properly. Ask about the applicable regulations.
• Place a receptacle underneath the filter. • Close the valve – lever (3) at right angles to the line.
• Open the screw plug (1) and the valve (2) and drain the fluid.
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8 - 13
Maintenance work on the superstructure 8.4 Fuel system
• (A) – Remove the filter element (2) and the filter (1). If necessary, replace any damaged parts.
• (B) – Screw on a new filter (1) and the filter element (2).
• Close the valve (3) manually.
• Open the valve – lever (3) parallel to the line. • Actuate the pump (2) until the consumable flowing through the plug (1) no longer contains any bubbles.
• Secure the bolt. • Start the engine and check for leaks. • Remove the receptacle.
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H
If you have used a clean receptacle, you can refill the fuel tank with the fluid using a strainer. Otherwise dispose of the fluid properly.
8 - 14
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Maintenance manual GMK 5170
Maintenance work on the superstructure 8.4 Fuel system
8.4.3
M 12
Changing fuel filters 2 and 3
Spare parts and tools
Designation
Quantity
GROVE part no.
Filter and gasket
1
03328573
Filter and gasket
1
03328574
– Receptacle, approx. 5 l;
à p. 2 - 4.
– Torque wrench for torque of 10 Nm and 25 Nm.
Prerequisites
O
– The engine is not running and is secured against unauthorized use; p. 2 - 3.
à
Risk of environmental damage due to leaking fluids! Always let fluids drain into suitable receptacles. Wipe up any fluids that have leaked. Store/dispose of fluids and any soaked equipment properly. Ask about the applicable regulations.
Emptying the fuel line
• Close the valve – lever (3) at right angles to the line.
• Place a receptacle under the end of the hose (1).
• Turn the valve – lever (2) horizontal. • Let the fluid drain into the receptacle. Leave the receptacle under the end of the hose. More fluid will run out when you bleed the fuel line.
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8 - 15
Maintenance work on the superstructure 8.4 Fuel system
Changing filters 2 and 3 Changing filter 2
• Unscrew the cap (1) and remove the filter (3) so that the fluid can drain.
• Clean the cap (1) and insert a new filter. • Replace the gasket (2) (lubricate slightly). • Screw the cap on and tighten it – torque 10 Nm.
Changing filter 3
• Unscrew the cap (1) and remove the filter (3) so that the fluid can drain.
• Loosen the filter (3) from the cap (1). • Carefully take the receptacle (4) out of the housing, making sure no dirt gets into the housing.
• Clean the cap and the receptacle. • Insert a new gasket (2) (grease lightly) and place a new filter into the cap.
• Insert the receptacle into the housing. • Screw the cap with the filter into the housing
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and tighten it – torque 25 Nm.
8 - 16
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Maintenance manual GMK 5170
Maintenance work on the superstructure 8.4 Fuel system
Bleeding the fuel line A receptacle is underneath the hose end (1). The lever (2) is parallel with the line.
• Open the valve – lever (3) parallel to the line. • Actuate the pump (4) until the fluid flowing through the end of the hose no longer contains any bubbles (1).
• Turn the valve – lever (2) at right angles to the line.
• Start the engine and check that the fuel filters are leak-tight.
• Remove the receptacle underneath the hose end (1).
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H
If you have used a clean receptacle, you can refill the fuel tank with the fluid using a strainer. Otherwise dispose of the fluid properly.
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3 112 477 en
8 - 17
Maintenance work on the superstructure 8.4 Fuel system
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8 - 18
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Maintenance manual GMK 5170
Maintenance work on the superstructure 8.5 Hoists
8.5
Hoists
8.5.1
Checking the oil level
Spare parts and tools
W
Designation Gasket 18 x 24 Cu DIN 7603
Prerequisites
Quantity
GROVE part no.
4
01377793
– The truck crane is level and is in on-road mode;
à Operating instructions.
– The engine is not running and is secured against unauthorized use; p. 2 - 3.
à
Checking the oil level
• Check whether the oil level is between the min. and the max. marking (1). If the oil level is too low:
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• Top up the oil; à p. 8 - 22.
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8 - 19
Maintenance work on the superstructure 8.5 Hoists
8.5.2
W
General inspection • Investigate any unusual noises from the hoists.
• Check the hoists and the connections for leaks. In the event of leaking fluids;
à Checking the oil level, p. 8 - 19.
• Check that pipes and hoses are tightly connected and not damaged. If you detect any worn or damaged parts, contact CraneCARE or your repair crew.
8.5.3
W
Checking the hoist brake
Spare parts and tools
– Weight approx 9.5 t
Prerequisites
– The truck crane is prepared for crane operation;
Checking the hoist brake
Check that the hoist brake is working correctly on the main hoist and the auxiliary hoist.
à Operating instructions.
• Suspend the hook block on the singly reeved hoist rope. • Lift a load of approx. 9.5 t to approx. 30 cm above the ground. • Measure the distance from the ground when the load is hanging completely still.
• Switch off the engine. If the load has not lowered after approx. 2 minutes, the brake is currently in working order. If the load has lowered, notify CraneCARE.
Lubricating the auxiliary hoist
M6 29.04.2008
8.5.4
8 - 20
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Maintenance manual GMK 5170
Maintenance work on the superstructure 8.5 Hoists
Grease, spare parts, tools
Lubricating grease Grease
Designation according to DIN 51502
Specification Classification
GROVE part no.
KP - L2K
DIN 51825
00554201
– Grease gun from the tool set.
Prerequisites
– The engine is not running and is secured against unauthorized use; p. 2 - 3.
à
Lubricating
• Clean the lubricating nipple (1) and lubricate the hoist at the lubricating nipple.
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• Remove any excess grease.
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8 - 21
Maintenance work on the superstructure 8.5 Hoists
8.5.5
M 12
Changing the oil/Checking the oil • Comply also with the à Run-in regulations, p. 4 - 1.
Oil, spare parts, tools
Transmission oil in litres 7
Designation according to DIN 51502
Specification Classification
GROVE part no.
C - LPF
MIL-L 2105 B API-GL-4/5 Viscosity: SAE 75 W-90 EP ISO - VG 220
02313611
for each hoist
Designation Gasket 18 x 24 Cu DIN 7603 – Receptacle, approx. 8 l;
Prerequisites
Synthetic oil; do not mix this with mineral-based oils!
Quantity
GROVE part no.
10
01377793
à p. 2 - 4.
– The truck crane is level and is in on-road mode;
à Operating instructions.
– The engine is not running and is secured against unauthorized use; p. 2 - 3.
à
Changing the oil at the hoist
H 8 - 22
à
Risk of environmental damage due to leaking fluids! Always let fluids drain into suitable receptacles. Wipe up any fluids that have leaked. Store/dispose of fluids and any soaked equipment properly. Ask about the applicable regulations.
During filling, the oil spreads only slowly in the hoist. The oil level will therefore rise quickly in the standpipe at first, then drop slightly and finally rise again to its true level.
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Maintenance manual GMK 5170
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S O
Risk of damage to the hoist gearbox! The waste oil must be tested for abrasion particles. This test serves to idenp. 8 - 23. tify damage at an early stage;
Maintenance work on the superstructure 8.5 Hoists
Draining oil
• Place a receptacle under the pipe (3). • Unscrew the bolts (1) and (6) and let the oil drain off.
• Replace the gaskets and secure the hoses (5) with the bolt (6). Topping up oil
• Fill the oil through the pipe (3) up to the max. mark (4).
• Replace the gaskets and secure the hoses (2) with the bolt (1).
Checking the oil
G H
Risk of accidents from falling load! If this test is not performed, there may be a risk of damage to the hoist gearbox which could lead to the load falling.
Check the waste oil for abrasion particles or have it tested in a laboratory:
• Pour the waste oil through a clean filter mat. • Examine the oil, i.e. the residues on the filter mat using a magnifying glass. If you find abrasion particles or solid materials on the mat, the hoist gearbox must be removed and inspected by the manufacturer.
29.04.2008
H
Some abrasion particles may appear in the first oil filled. If you notice such particles during the first oil change (after 200 operating hours.), first consult CraneCARE before introducing any specific measures.
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8 - 23
Maintenance work on the superstructure 8.5 Hoists
8.5.6
Y3
Having a partial inspection carried out
Only suitably trained specialists should carry out a partial inspection of – the multiple-disk brake, – the plug connections between the hydraulic motor and the multiple-disk brake, – the plug connections between the multiple-disk brake and transmission unit and be permitted to exchange parts with signs of wear.
8.5.7
Y6
Having a general inspection carried out
H
The general inspection involves removing the transmission and sending it to the manufacturer to be examined. For transmissions that have undergone a general overhaul, an oil change must be carried out after 200 and 1000 operating hours; Run-in regulations, p. 4 - 1.
à
29.04.2008
H
When carrying out the general inspection of the hoist gears, also observe the information contained in Measures required for winch monitoring, p. 5 - 21.
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Maintenance manual GMK 5170
Maintenance work on the superstructure 8.6 Slewing gear
8.6
Slewing gear
8.6.1
Checking the oil level
Spare parts and tools
W
Designation Gasket 10 x 14 Cu DIN 7603
Prerequisites
Quantity
GROVE part no.
3
01 368 741
– The truck crane is level and is in on-road mode;
à Operating instructions.
– The engine is not running and is secured against unauthorized use; p. 2 - 3.
à
Checking the oil level
Always check the oil level prior to using the crane.
• Check whether oil is visible in the inspection glass (1).
• Always check the oil level for all the slewing gears. If the oil level is too low:
29.04.2008
• Top up the oil; à p. 8 - 28.
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8 - 25
Maintenance work on the superstructure 8.6 Slewing gear
8.6.2
W
Checking for leaks • Investigate any unusual noises from the slewing gears.
• Check the slewing gears and the connections for leaks. In the event of leaking fluids;
à Checking the oil level, p. 8 - 25.
• Check that pipes and hoses are tightly connected and not damaged. If you detect any worn or damaged parts, contact CraneCARE or your repair crew.
8.6.3 Prerequisites
M6
Checking the slewing gear brake
– The truck crane is rigged for a 360° slewing range as per the lifting capacity table. – The SLI code for the current rigging mode is entered; tions. – The Brake pedal function is switched on
à Operating instruc-
à Operating instructions.
– The main boom is raised to 45° and fully retracted.
29.04.2008
G
Risk of overturning while slewing! Always set a rigging mode for the slewing range 360° in accordance with the lifting capacity table and enter the associated SLI code. Do not override the SLI.
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Maintenance manual GMK 5170
Maintenance work on the superstructure 8.6 Slewing gear
Check
When checking the slewing gear brake you must perform the slewing movement against the slewing gear brake.
• Switch off the engine. • Remove the coil (1) from the valve Y 2307. The slewing gear brake will now not be released when the slewing gear is switched on.
• Start the engine and switch on the slewing gear. • Open the Settings submenu. The display (1) indicates the pressure in the slewing gear hydraulic circuit.
• Move the control lever slowly to the stop and wait until the pressure in the hydraulic circuit has risen to approx. 200 bar. – If the superstructure still does not slew, the braking effect of the slewing gear brake is sufficient. – If the superstructure does slew, the slewing gear brake is defective and must be repaired immediately by CraneCARE.
• Switch the slewing gear off and switch the engine off. • Secure the coil (1) using the nut to the valve Y 2307.
• Start the engine and check the slewing gear
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for correct operation.
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8 - 27
Maintenance work on the superstructure 8.6 Slewing gear
8.6.4
M 12
Changing the oil/Checking the oil • Comply also with the à Run-in regulations, p. 4 - 1.
Oil, spare parts, tools
Transmission oil in litres 0.9
Designation according to DIN 51502
Specification Classification
GROVE part no.
C - LPF
MIL-L 2105 B API-GL-4/5 Viscosity: SAE 75 W-90 EP ISO - VG 220
02313611
for each slewing gear
Designation
Quantity
GROVE part no.
Gasket 10 x 14 Cu DIN 7603
3
01 368 741
Gasket 14 x 20 Cu DIN 7603
3
00 117 132
– Receptacle, approx. 5 l;
Prerequisites
Synthetic oil; do not mix this with mineral-based oils!
à p. 2 - 4.
– The truck crane is level and is in on-road mode;
à Operating instructions.
– The engine is not running and is secured against unauthorized use; p. 2 - 3.
à
Changing the oil
O
Risk of environmental damage due to leaking fluids! Always let fluids drain into suitable receptacles. Wipe up any fluids that have leaked. Store/dispose of fluids and any soaked equipment properly. Ask about the applicable regulations.
29.04.2008
• Always change the oil in all slewing gears.
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Maintenance manual GMK 5170
Maintenance work on the superstructure 8.6 Slewing gear
Draining oil
• Remove the plate (1). • Place a receptacle under the plugs (2). • Unscrew the filter (4) and plugs (3) and (2). • Drain the oil.
• Replace the gasket and screw the plugs (2) back in. Topping up oil
• Top up the oil through the filler neck (4) until oil is visible in the inspection glass (5).
• Replace the gaskets and screw in the plug (3) and the filter (4).
• Remove the plate (1).
Checking the oil
Check the waste oil that was drained from the slewing gears for abrasion particles, or have it tested at a laboratory.
• Pour the waste oil through a clean filter mat. • Examine the oil, i.e. the residues on the filter mat using a magnifying glass. 29.04.2008
If you find abrasion particles or solid materials on the mat, the slewing gear transmission must be removed for inspection and sent to the manufacturer.
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8 - 29
Maintenance work on the superstructure 8.6 Slewing gear
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Maintenance manual GMK 5170
Maintenance work on the superstructure 8.7 Ball slewing bearing
8.7
Ball slewing bearing
8.7.1
Lubricating gear teeth
M6
Grease Designation
Quantity
GROVE part no.
1
00554205
Adhesive lubricating grease (spray can)
H Prerequisites
Observe the instructions and safety information on the lubricant packaging!
– The truck crane is level and on outriggers; – The main boom is fully retracted;
à Operating instructions.
à Operating instructions.
– The engine is not running and is secured against unauthorized use; p. 2 - 3.
à
Lubricating
G
A distinction is make between the initial lubrication and later lubrications. Risk of crushing from the gear teeth! Fingers may be crushed or pieces of clothing can be pulled into the open, rotating pinion. For this reason, be sure to remount the plate after lubricating.
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8 - 31
Maintenance work on the superstructure 8.7 Ball slewing bearing
First lubrication:
• Remove the plate (1). • Remove the old grease from all the gear teeth (2).
• Apply a thin layer of new grease to all the gear teeth and allow it to penetrate for about 10 minutes.
• Apply a second, thicker layer of grease and allow it to penetrate for about 30 minutes.
• Attach the plate.
Subsequent lubrication:
• Remove the plate (1). • Apply new grease to all the gear teeth (2). • Allow it to penetrate for about 30 minutes.
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• Attach the plate.
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Maintenance manual GMK 5170
Maintenance work on the superstructure 8.7 Ball slewing bearing
8.7.2
M6
General inspection • Investigate any unusual noises from the ball slewing bearing.
• In case of unusual noises take a sample of leaked grease. Have CraneCARE examine the sample for metal residue.
• Check the ball slewing bearing for damage (e.g. gaskets). If you detect any worn or damaged parts, contact CraneCARE or your repair crew.
H 8.7.3 Spare parts and tools
The maintenance interval specified here must be shortened if the ball slewing bearing is subjected to heavy blows (falling load, load slipping).
Measuring tilting play
M 12
– Dial gauge (precision 0.01 mm) with tripod. – Measurement report from when the truck crane was put into operation; Delivery receipt.
à
Prerequisites
– The truck crane is rigged with an outrigger span of at least 8.55 x 7.80 m Operating instructions. and is aligned level;
à
– The counterweight combination 53.1 tis fitted according to the lifting capacity table and equipment of the truck crane. – The lattice extension has been removed. – The main boom is telescoped to 50-50-50-50-0. – The load being lifted must not exceed 1 t– where necessary unreeve the hook block.
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8 - 33
Maintenance work on the superstructure 8.7 Ball slewing bearing
Measuring tilting play
Example:
The base value of the tilting play is determined and documented by CraneCARE when the ball slewing bearing is put into operation or replaced. The maximum permissible wear is 3.2 mm. This results in the maximum permissible tilting play. Base value + max. permissible wear =
max. permissible tilting play
0.35 mm + 3.2 mm
3.55 mm
Measuring current tilting play
• Raise the main boom to 80° and slew to –135° – display (A).
• Fasten a dial gauge on the front of the turntable (4) and place the switch (1) on to the lower ring (3) as close as possible to the gasket (2).
• Slowly lower the main boom to 25°. • Read off from the dial gauge how far the turntable inclined and record this value as the current tilting play; Appendix – Tilting play measurement report.
à
• Remove the dial gauge. If the current tilting play is greater than the max. permissible tilting play, you must have the ball slewing bearing replaced by CraneCARE.
• Repeat the measurement with the slewing angles –45°
C
+45°
D
+135°
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B
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Maintenance manual GMK 5170
Maintenance work on the superstructure 8.8 Hydraulic system
8.8
Hydraulic system
8.8.1
Checking the oil level
Prerequisites
D
– The truck crane is level and is in on-road mode;
à Operating instructions.
– The truck crane must be standing on a level surface. – The engine is not running and is secured against unauthorized use; p. 2 - 3.
à
Checking the oil level
S
Risk of damage to the hydraulic system! Cleanliness is imperative when handling hydraulic oil! Even new oil must be filtered before it is added to the tank.
• Check whether oil is visible in the centre of the inspection glass (1).
If the oil level is too low:
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• Add more oil; à p. 8 - 46.
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8 - 35
Maintenance work on the superstructure 8.8 Hydraulic system
8.8.2
W
Checking the hydraulic hoses
The inspection work is described in section Checking the hydraulic hoses, p. 7 - 62.
8.8.3
W
Checking ventilation filters
• Check the indicator (1) on the ventilation filter. If the indicator is red:
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• Replace the filter; à p. 8 - 38.
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Maintenance manual GMK 5170
Maintenance work on the superstructure 8.8 Hydraulic system
8.8.4
Checking for leaks
W
• When the engine is running, carry out a visual inspection for leaks on the hydraulic components (tank, pumps, drives, cylinders, control blocks, valves, pipe and hose lines and connections).
• If leaks are detected, check the oil level and top up if necessary;
à Checking the oil level, p. 8 - 35.
G O
Risk of accidents from hydraulic oil spraying out! Never tighten any leaking connections when the system is under pressure. Only change pipes and hoses when the system is depressurised.
Risk of environmental damage due to leaking fluids! Immediately repair or have repaired leakages in the hydraulic system to ensure that no hydraulic oil escapes, seeps into the ground or reaches water when the crane is being used.
After hydraulic components have been changed:
• Bleed the hydraulic system; à Establishing the operating condition, p. 8 - 46.
If damage cannot be rectified immediately or further damage is likely:
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• Inform CraneCARE or your repair crew.
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8 - 37
Maintenance work on the superstructure 8.8 Hydraulic system
8.8.5 Spare parts and tools
Designation Filter
Prerequisites
O
M 12
Changing the ventilation filter
Quantity
GROVE part no.
1
03 319 602
– The engine is not running and is secured against unauthorized use; p. 2 - 3.
à
Risk of damage to the environment from filter residues! Store used hydraulic oil filters in suitable receptacles and have them disposed of properly by qualified personnel.
• Remove the cap (2). • Change the filter (3) and fasten the cap. • Reset the display by depressing the pin (1)
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on the housing.
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Maintenance manual GMK 5170
Maintenance work on the superstructure 8.8 Hydraulic system
8.8.6
G
Pressure accumulator – checking the gas pressure
M 12
Risk of accidents due to incorrect inspection! The gas pressure test must be carried out only by an authorised inspector of pressure tanks or under his supervision or instruction.
The superstructure is equipped with pressure accumulators. The filling pressure at 20 °C is: 1 Pressure accumulator
20 bar
2 Pressure accumulator
180 bar
• Have the filling pressure checked by
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CraneCARE and corrected if necessary.
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8 - 39
Maintenance work on the superstructure 8.8 Hydraulic system
8.8.7
M 12
Taking oil samples
Taking oil samples
H
To determine the usability of the oil, take an oil sample from each of the hydraulic oil tank and the hydraulic system. For detailed information on taking samples (conditions, tools); see Taking oil samples, p. 7 - 67.
à
From the hydraulic oil tank
• Take the sample from the hydraulic oil tank via the valve (1).
From the hydraulic system
• Take the sample from the hydraulic system
Determining the quality of the oil
8 - 40
Compare the quality of the oil with the limit values and carry out the specified measures if necessary; Determining the quality of the oil, p. 7 - 69.
à
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Maintenance manual GMK 5170
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via a gauge port (1), e.g. at a control block.
Maintenance work on the superstructure 8.8 Hydraulic system
8.8.8
Changing the hydraulic oil filter When changing the oil, all oil filters must be replaced. In the event of a warning message, the red symbols in the Warning submenu indicate which oil filters you have to change. 1 Red – Change oil filter 1 2 Red – Change oil filter 2 3 Red – Not used
Spare parts and tools
Designation
Quantity
GROVE part no.
Filter
1
03 325 700
Gasket for oil filter 1
1
03 328 209
Filter
1
03134850
Gasket set for oil filter 2
1
03 326 049
For oil filter 1:
For oil filter 2:
– Torque wrench for 25 Nm. – Receptacle, approx. 5 l;
Prerequisites
à p. 2 - 4.
– The truck crane is level and is in on-road mode;
à Operating instructions.
– The engine is not running and is secured against unauthorized use; p. 2 - 3.
à
O
Risk of damage to the environment from filter residues! Store used hydraulic oil filters in suitable receptacles and have them disposed of properly by qualified personnel.
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8 - 41
Maintenance work on the superstructure 8.8 Hydraulic system
Changing oil filter 1
O
Risk of environmental damage due to leaking fluids! Always let consumables drain into suitable receptacles. Wipe up any fluids that have leaked. Store/dispose of fluids and any soaked equipment properly. Ask about the applicable regulations.
• Remove the cap (1) and pull out the hydraulic oil filter.
• Place the filter in a receptacle. • Remove the spring (2). • Undo the bolt (6). • Take the magnetic rods (3) and the filter (4) out of the filter cage (5).
• Clean the magnetic rods and the filter cage. • Replace any damaged parts.
S
Risk of damage to the hydraulic system! Large amounts of metal particles are a sign of damage in the hydraulic system. Have the hydraulic system inspected by CraneCARE or by your repair crew.
• Replace the gaskets. • Assemble the hydraulic oil filter and insert it.
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• Fasten the cap (1).
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Maintenance manual GMK 5170
Maintenance work on the superstructure 8.8 Hydraulic system
Changing oil filter 2
• Undo the receptacle (1) at the hexagon. • Change the filter (2). • Replace the gaskets. • Fill the receptacle with clean oil and tighten it – torque 25 Nm.
After changing a filter
S
Risk of damage to the hydraulic pumps! The engine may only be started if the valve in the suction line of the hydraulic pumps is open and there is enough hydraulic oil in the hydraulic oil tank!
• Check the valve on the hydraulic oil tank. Open the valve, if necessary;
à p. 8 - 46.
• Check the oil level. Top up the oil if necessary; à p. 8 - 46. • Start the engine and let it idle for 3 minutes to bleed the system.
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• Check that none of the oil filters is leaking.
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8 - 43
Maintenance work on the superstructure 8.8 Hydraulic system
8.8.9
Changing the hydraulic oil The oil only needs to be changed if the laboratory analysis results indicate this; Determining the quality of the oil, p. 8 - 40.
à
Oil, spare parts, tools
Hydraulic oil in litres 915
Designation according to DIN 51502
Specification Classification
GROVE part no.
H - LP
DIN 51524 T.2 Viscosity: ISO - VG 32
01375719
Designation Gasket 120 x 90
Quantity
GROVE part no.
1
03 328 286
à p. 7 - 68. – One or more receptacles, approx. 915.0 l; à p. 2 - 4. – Connecting piece and hose (tool box);
Prerequisites
à
– The truck crane is level and is in on-road mode; Operating instructions. – The engine is not running and is secured against unauthorized use; p. 2 - 3. – The oil filters have been removed; Changing the hydraulic oil filter, p. 8 - 41.
à
à
Closing the valve
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S
Risk of damage to the hydraulic pumps! Be sure to secure the engine against unauthorized use. If the engine is started while the valve in the suction line is closed, the hydraulic pumps will be damaged!
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Maintenance manual GMK 5170
Maintenance work on the superstructure 8.8 Hydraulic system
• Close the valve – lever (1) at right angles to the line.
Draining oil
O
Risk of environmental damage due to leaking fluids! Use the supplied connecting piece and hose and a receptacle with sufficient capacity to drain the hydraulic oil.
• Place a receptacle underneath the valve. • Screw the connecting piece and hose onto the valve (1) and drain the oil; the valves, p. 7 - 68.
à Handling
• Change the filters; à p. 8 - 41.
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8 - 45
Maintenance work on the superstructure 8.8 Hydraulic system
Topping up the oil
S
Risk of damage to the hydraulic system! Cleanliness is of the utmost importance when handling hydraulic oil. Even new oil must be filtered before it is added to the tank.
• Remove the cover (3). • Add the new oil through the filter until the level reaches the centre of the inspection glass (1).
• Replace the gasket (2) if necessary and fasten the cap (2).
Establishing the operating condition
Risk of damage to the hydraulic pumps! Open the valve prior to starting the engine. This prevents damage to the hydraulic pumps.
29.04.2008
S
After having changed the oil filters and topped the oil up, you must re-establish the operating condition.
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Maintenance manual GMK 5170
Maintenance work on the superstructure 8.8 Hydraulic system
Opening the valve
• Open the valve – lever (1) parallel to the line.
• Start the engine. • Carry out all hydraulic functions several times to remove any air in the system.
• Check that none of the oil filters is leaking. • Check the oil level through the inspection glass on the hydraulic oil tank.
à p. 8 - 46.
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Top up oil if necessary;
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8 - 47
Maintenance work on the superstructure 8.8 Hydraulic system
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Maintenance manual GMK 5170
Maintenance work on the superstructure 8.9 Main boom
8.9
Main boom
8.9.1
Lubricating the telescopic sections
Grease, spare parts, tools
Designation Grease for locking pins: 1 kg can
M3
GROVE part no. 03325215
Lubricant paste for the telescopic slide faces: 200 kg barrel
02310394
25 kg bucket
02314698
10 kg bucket
01373458
1 kg cartridge
02314184
0.4 kg refillable cartridge
03329071
– A grease gun for the lubricating nipples on the locking pins. – A grease gun for the lubricating nipples on the upper telescopic slide faces. – A brush or roller for the lower telescopic slide faces.
S 29.04.2008
H
Risk of damage to the wear pads on the telescopic sections! Label the containers with the different lubricants for the main boom. This prevents you using the wrong lubricants at the lubrication points.
Manitowoc Crane Group Germany GmbH recommends pneumatic grease spray guns for more effective lubrication of the telescopic slide faces: Designation
GROVE part no.
Grease spray gun, complete: Mobile, external compressed air connection required
03325445
Manual grease spray gun: 0.4 kg cartridges are refillable using the tyre inflation hose on the truck crane.
03329027
25 m hose for manual grease spray gun:
03329072
s Maintenance manual GMK 5170
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8 - 49
Maintenance work on the superstructure 8.9 Main boom
Prerequisites
– The truck crane is level. – The hook block is unreeved. – The truck crane is supported with an outrigger span of at least 8.55 x 5.96 m. – A counterweight of at least 38.1 t is rigged. – The SLI code for the current rigging mode is entered. – The main boom must be completely retracted and lowered into horizontal position.
Warnings
G G
Risk of overturning when telescoping with an overridden SLI! Only override the SLI when you are requested to do so. Never extend the main boom further than specified when the SLI is overridden. An increased danger of tipping exists because the SLI will not switch off extension of the main boom. Risk of accidents from slipping off the main boom! There is grease residue on the telescopic sections. For this reason, you must not walk on the main boom. Use the extendable ladders provided with your crane!
If the main boom has been telescoped several times, the derricking gear is so heavily loaded that the main boom cannot be derricked. For this reason:
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• Do not lower the main boom below 0°.
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Maintenance manual GMK 5170
Maintenance work on the superstructure 8.9 Main boom
Telescopic section I
• Note the following information regarding maintenance work. • Extend telescopic section I to 50%. • Override the SLI; à Operating instructions. • Extend telescopic section I to 100%. Do not extend it any further. • Use a brush or a roller (lubricant paste) to lubricate the lower slide faces (3).
• Use the grease gun (lubricant paste) to lubricate the upper slide faces at the lubricating nipples (1) on both sides.
• Use the grease gun (lubricant paste) to lubricate the locking pins at the lubricating nipples (2) on both sides.
• Lock and unlock the telescopic section I several times, so that the grease is distributed over the locking pins.
• Extend telescopic section I to 50%. • Remove the SLI override; à Operating instructions.
• Use the grease gun (lubricant paste) to lubricate the upper slide faces at the lubricating nipples (1) on both sides.
• Fully retract telescopic section I. • Fully extend and retract the telescopic section I again so that the grease is distributed over the telescope slide faces. – Override the SLI for this. – Do not extend it any further.
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Maintenance work on the superstructure 8.9 Main boom
Telescopic sections IV - V
• Note the following information regarding maintenance work. The following diagrams show the lubrication of the telescopic section V. The telescopic sections II - IV are lubricated in the same way.
• Extend telescopic section V to 100%. • Override the SLI; à Operating instructions. • Extend telescopic section IV to 25%. Do not extend it any further. • Use a brush or a roller (lubricant paste) to lubricate the lower slide faces (3).
• Use the grease gun (lubricant paste) to lubricate the upper slide faces at the lubricating nipples (1) on both sides.
• Use the grease gun (lubricant paste) to lubricate the locking pins at the lubricating nipples (2) on both sides.
• Lock and unlock the telescopic section V several times, so that the grease is distributed over the locking pins.
• Retract telescopic section V to 50%. • Extend telescopic section IV to 50%. • Remove the SLI override; à Operating instructions.
• Use the grease gun (lubricant paste) to lubricate the upper slide faces at the lubricating nipples (1) on both sides.
• Retract telescopic section IV completely. • Fully extend and retract telescopic section V
• Lubricate the locking pins of telescopic sections II to IV in the same way.
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Maintenance manual GMK 5170
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again so that the grease is distributed over the telescope slide faces.
Maintenance work on the superstructure 8.9 Main boom
8.9.2
Checking the sheaves
M3
• Check all sheaves on the main boom head for damage, wear, mobility and extreme soiling. Have damaged, worn, sluggish or extremely soiled sheaves replaced by CraneCARE or your repair crew.
8.9.3
G
Checking the locking system
M 12
Risk of accidents if maintenance work is not carried out! Have the additional maintenance work on the main boom's locking system performed regularly by CraneCARE. This prevents the complete unlocking of a telescopic section in Emergency operation/Emergency program mode, which could cause serious accidents and damage to the truck crane.
29.04.2008
• Have the main boom's locking system checked by CraneCARE.
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Maintenance work on the superstructure 8.9 Main boom
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Maintenance manual GMK 5170
Maintenance work on the superstructure 8.10 Hoist ropes
8.10
Hoist ropes
8.10.1
Checking the position on the rope drums
G Prerequisites
D
Risk of accidents when the rope drum is turning! Keep away from the turning rope drum. This will prevent your limbs from being drawn in and getting crushed.
– The hoist mirrors are folded out;
à Operating instructions.
à Operating instructions. – The main boom is lowered to about 30°; à Operating instructions. – One hook block is reeved;
– The engine has been started.
Checking the position Check the position of the ropes (1) on at least one full turn of the rope drum for the hoist gears.
• Slowly carry out the Lowering movement and check the rope. – The rope needs to be evenly wound. – The rope turns on the drum must be evenly spaced at a distance of 0 to 2 mm. – The cross-over points must be at an angle of about 180°.
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H
The ropes of the top layer lie over the ropes of the bottom layer at the crossover points.
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Maintenance work on the superstructure 8.10 Hoist ropes
8.10.2
W
Checking the hoist ropes
Spare parts and tools
– Torque wrench for 10 Nm.
Prerequisites
– Establish a rigging mode in accordance with the Lifting capacity table and enter the rigging code on the SLI; Operating instructions.
Checking the rope
• Start the engine.
à – The hook block is reeved 5-fold; à Operating instructions. – The main boom is raised and fully extended; à Operating instructions.
• Unreel the rope and check that the rope is not damaged or improperly
à
reeled ( Assessing the condition of the hoist rope, p. 8 - 58). When 5 turns are left on the rope drum, the lowering limit switch must switch off. If the lowering limit switch does not switch off or switches off too late, it must be reset; Setting the lowering limit switch, p. 8 - 67.
à
• Check the fastening of the clamp (1) for damage and firm seating – torque 10 Nm.
• The free end of the rope must not jut out beyond the flanged wheel.
• The rope wedge must be in the pouch (2). • The rope end on the rope wedge must not show any signs of wear.
• Reel in the rope. At the same time, the rope may not show any signs of kinking or being flattened.
• Check the end of the rope and all parts of the rope end clamp. • Make sure the rope end is correctly fitted in the rope end clamp;
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à Operating instructions.
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Maintenance work on the superstructure 8.10 Hoist ropes
8.10.3
M3
Lubricating the hoist rope
Grease, spare parts and tools
Designation
Quantity
GROVE part no.
1
03133770
Grease
– Brush, roller, spray gun, bath or pressure pump.
Lubricating the rope
Lubricating the rope – significantly prolongs its service life and – keeps the friction between the rope, the sheaves and the hoist drum as low as possible. The lubricant is applied to the rope by – spraying, brushing, rolling or – by running it through a tub filled with lubricant or – by means of high-pressure lubrication with a pressure pump.
H
Manitowoc Crane Group Germany GmbH recommends high-pressure lubrication with a pressure pump for reasons of sustainability, efficiency and environmental protection. When lubricating the hoist ropes, observe the instructions concerning the lubricant. When using the pressure pump, observe the manufacturer's operating manual.
29.04.2008
For more information, please contact CraneCARE.
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Maintenance work on the superstructure 8.10 Hoist ropes
8.10.4
Assessing the condition of the hoist rope
H
If in doubt about damage assessment, always consult an official inspector. To assess the condition of the rope, you must be familiar with the following: – The type of rope (regular lay or lang lay), – the number of load-bearing wires in the outer strands, – the rope diameter ( Operating instructions).
à
In a regular lay rope (1), the wires run more or less in the longitudinal direction of the rope. In a lang lay rope (2), the wires run at an angle of approximately 45° to the longitudinal direction of the rope.
To calculate the number of load-bearing outer wires (1), count the number of outer strands of the rope and multiply by 7.
8 - 58
29.04.2008
H
If there are multiple layers of strands, only the outer layer is counted.
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Maintenance manual GMK 5170
Maintenance work on the superstructure 8.10 Hoist ropes
The following tables show the number of wire breaks in a length 6 times or 30 times the rope diameter which would require rope replacement, for the most common rope diameters.
Number of visible wire breaks Regular lay rope Number of load-bearing outer wires
∅ 13 mm
∅ 16 mm
∅ 19 mm
∅ 22 mm
∅ 24 mm
over 78 mm
over 390 mm
over 96 mm
over 480 mm
over 114 mm
over 570 mm
over 132 mm
over 660 mm
over 144 mm
over 720 mm
101-120
5
10
5
10
5
10
5
10
5
10
121–140
6
11
6
11
6
11
6
11
6
11
Number of visible wire breaks Lang lay rope Number of load-bearing outer wires
∅ 13 mm
∅ 16 mm
∅ 19 mm
∅ 22 mm
∅ 24 mm
over 78 mm
over 390 mm
over 96 mm
over 480 mm
over 114 mm
over 570 mm
over 132 mm
over 660 mm
over 144 mm
over 720 mm
101-120
2
5
2
5
2
5
2
5
2
5
121–140
3
6
3
6
3
6
3
6
3
6
H
S
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! Risk of accidents due to reduced load bearing capacity! Remember that other factors may also make it necessary to replace a rope before the number of wire breaks requiring rope replacement has been reached (age of rope, frequency of use or exceptional loading).
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Maintenance work on the superstructure 8.10 Hoist ropes
Damage
Description
Cause
Wire break (1)
Individual wires are broken; the broken ends of the wires are protruding from the rope.
General wear caused by aging of the rope
Wire break cluster (2) Strand breakage (3)
or subsequent damage resulting from damage to the rope.
Replacement Replace the rope at the latest when the maximum permissible number of wire breaks according to the table are visible externally. Replace the rope immediately if wire breakage clusters or strand breakages occur. The frequency of wire breaks increases with rope age. For reasons of safety, it is advisable to replace the rope while the number of broken wires is still low.
Tarnishing colour is visible externally on the rope.
Rope has been subjected to excessive heat.
Replace the rope immediately.
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Effect of heat
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Maintenance work on the superstructure 8.10 Hoist ropes
Damage Reduced diameter (1)
Description The diameter of the rope has become smaller along large sections.
Cause
Replacement
Structural changes
Immediately replace the rope if the diameter has decreased by 15% or more compared to the nominal diameter.
Corrosion or abrasion.
Immediately replace the rope if the diameter has decreased by 10% or more compared to the nominal diameter.
Corkscrewtype rope deformation (2)
The rope winds its way along its longitudinal axis in a way that is similar to a corkscrew. Deformation is measured with suspended hook block.
Damage resulting from overloading.
Even a small amount of deformation leads to increased abrasion, wire breaks and rough operation of the rope drive. If deformation “x” at a position on the rope is greater than a third of the rope diameter, the rope must be replaced immediately.
Basket-type deformation (3)
Wires of the outer layer protrude. In other areas of the rope, the insert has buckled or is protruding from the rope.
Outer and inner layers have been displaced in relation to each other.
Replace the rope immediately.
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Maintenance work on the superstructure 8.10 Hoist ropes
Damage
Description
Cause
Replacement
Outer layer wires in the form of hair pins are protruding from the rope away from the sheave.
General wear due to aging of the rope or subsequent damage resulting from damage to the rope.
Immediately replace rope if the rope structure has been substantially altered by the loop formations.
Loosening of wires or strands (2)
Outer wires or strands have become loose. Only the inner strands continue to bear the load.
Corrosion or abrasion.
Replace the rope immediately.
Other causes.
The number of broken wires determines when the rope must be replaced.
Knot formation (3)
Repeatedly occurring knot-like thickening of rope; insert often protrudes. Strands bear on each other at thin locations; increased frequency of wire breaks.
General wear due to aging of the rope or subsequent damage resulting from damage to the rope.
Determine number of wire breaks; replace rope immediately if serious knot formation occurs.
Constriction (4)
Diameter reduction over short sections.
General wear caused by aging of the rope.
Replace rope immediately if serious constriction is detected.
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Loop formation (1)
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Maintenance work on the superstructure 8.10 Hoist ropes
Damage
Description
Cause
Replacement
Crushed areas, mostly with wire breaks.
Mechanical damage, e.g. due to driving over the rope.
Determine number of wire breaks; replace rope immediately if serious crushing has occurred.
Kink (2)
Rope deformation with twisting and wire breaks.
Rope in the eyes was pulled straight while twisted.
Replace the rope immediately.
Buckle (3)
Buckled section in rope.
Mechanical damage.
Replace the rope immediately.
Curl formation (4)
Curl-type rope deformation.
Loaded rope was pulled over an edge.
Replace the rope immediately.
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Flattening (1)
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Maintenance work on the superstructure 8.10 Hoist ropes
8.10.5 Spare parts and tools
Replacing the hoist rope – An original replacement part;
à Rope certificate.
– A reel stand with braking block. – Torque wrench for 10 Nm.
S Prerequisites
Risk of accidents from falling load! Use only a replacement rope that has the same technical specifications as the defective rope, or an original replacement rope.
– The truck crane is level. – The main boom is set down on the boom rest. – The hook block is unreeved;
Replacing the old rope
à Operating instructions.
• Unreel the hoist rope until it switches off. • Adjust the lowering limit switch so that you can unreel the rope completely;
à Setting the lowering limit switch, p. 8 - 67.
• Unreel the remaining layers from the hoist drum. • Lock the crane cab to prevent unauthorized use; à p. 2 - 3.
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G
Risk of accidents due to rotating rope drum! Turn off the engine and remove the ignition key so that no unauthorized operation of the hoist can occur.
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Maintenance work on the superstructure 8.10 Hoist ropes
• Remove the clamp (4). • Push the rope through the hole (3) until the rope wedge (1) slides out of the pouch (2).
• Remove the rope wedge and place the rope away from the truck crane.
Installing a new rope
The service life of a rope can be significantly affected by the installation procedure. Errors during fitting reduce service life considerably. Therefore, the following is required:
• Make sure the rope is not twisted when it is installed. • Ensure it does not get dirty or damaged while being installed. • Wind the rope up in the same direction in which the rope is reeled onto the reel.
• Tension the rope slightly while winding it up. • Place the reel stand (1) with the new rope in front of the main boom head. Ensure that the rope is being rolled onto the drum with the right direction of rotation.
• Guide the rope over the right head sheave
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(2) up to the hoist drum.
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Maintenance work on the superstructure 8.10 Hoist ropes
• Guide the rope through the hole (3) until it extends about 1.5 m beyond the pouch (2).
• Feed the free end of the rope back through the pouch.
• Secure the clamp (4) and tighten it – torque 10 Nm.
• Place the rope wedge (1) in the loop.
• Push the rope back until rope wedge (1) is fully in the pouch (2).
• Ensure that the rope wedge, loop and rope end do not protrude beyond the flanged wheel. This will prevent damage.
• Start the engine. • Hold the rope taut and wind up the rope slowly. • Reeving a hook block – reeve it at least 7 times; à Operating instructions. • Raise the main boom to a steep position and extend it fully.
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• Unwind the rope out until only five turns remain on the rope drum.
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Maintenance work on the superstructure 8.10 Hoist ropes
H
G
Watch the hook block when unwinding. The hook block must not rotate! Risk of accidents from incorrectly set lowering limit switch! After installing a new rope, the lowering limit switch must always be reset. In this way you avoid the lowering limit switch switching off too late or not at all, the rope being damaged and the load being dropped.
• Set the lowering limit switch; à p. 8 - 67. • Run in the new rope with small loads so that the hoist rope can settle on the drum.
8.10.6
Setting the lowering limit switch A lowering limit switch is mounted both on the main hoist and on the auxiliary hoist.
Spare parts and tools
Designation Cover gasket
Prerequisites
Quantity
GROVE part no.
2
00550699
à Operating instructions. – The main boom is fully raised and extended; à Operating instructions. – The hook block is reeved 7-fold;
– The hook block is lowered until only five turns of the rope remain on the hoist drum.
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8 - 67
Maintenance work on the superstructure 8.10 Hoist ropes
Setting the lowering limit switch
G
Risk of accidents due to rope end fitting being overloaded! The lowering limit switch must always be reset after repair work to the hoisting gear and after rope replacement. A faulty lowering limit switch must always be replaced!
• Remove the cover (1). • Turn the bolt (2) until you hear the switch activate.
• Screw the cover on again. Replace the gasket if necessary.
• Check whether the lowering limit switch switches off the hoist correctly.
Checking switch-off
• Raise the hook block until there are about 10 turns on the hoist drum. • Lower the hook block and check whether the lowering limit switch switches off properly. The lowering limit switch must switch off the hoisting gear when five rope turns are still on the hoist drum.
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• Correct the setting of the lowering limit switch if necessary.
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Maintenance manual GMK 5170
Maintenance work on the superstructure 8.11 Cable drums and slewing angle sensor
8.11
Cable drums and slewing angle sensor
8.11.1
Maintenance of the slip ring assemblies
M6
The slip ring assemblies are located in: 1 Cable drum 1 2 Cable drum 2
Spare parts and tools
Designation
Quantity
GROVE part no.
Cable drum 1 cover gasket
1
03324704
Cable drum 2 cover gasket
1
03328294
– Clean, lint-free cloth. – Dry, oil-free compressed air.
Prerequisites
For cable drum 1 – The main boom is set down on the support; For cable drum 2 – The main boom is fully retracted;
à Operating instructions.
à Operating instructions.
For cable drums 1 and 2 – The engine is not running and is secured against unauthorized use; p. 2 - 3. 29.04.2008
à
– The selector handle is removed from the battery master switch.
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8 - 69
Maintenance work on the superstructure 8.11 Cable drums and slewing angle sensor
S G
tt
Risk of damage to the SLI! Before maintenance work on the slip ring assemblies, always switch off the battery master switch so that the cable drum is current-free. This prevents short circuits which may lead to damage to the SLI's central unit. Risk of crushing when extending or retracting the main boom! 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 keys from the crane cab and put up warning signs.
Maintenance of the slip ring assemblies
• Remove cover (1) or (2). • Clean and dry the cover. • Replace the gasket if necessary.
• Only use a cloth and compressed air to remove soiling on the slip rings (2).
• Do not use spray oil. • Check to make sure all screws (1) are tight.
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• Attach the cover on the cable drum.
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Maintenance work on the superstructure 8.11 Cable drums and slewing angle sensor
8.11.2 Grease, spare parts, tools
Lubricating the slewing angle sensor
Lubricating grease Grease
Y5
Designation according to DIN 51502
Specification Classification
GROVE part no.
KP - L2K
DIN 51825
00554201
Designation Gasket 16 x 20 Cu DIN 7603
Quantity
GROVE part no.
1
00117134
– Grease gun from the tool set. – Sealing agent (e.g. Hylomar). – Torque wrench for 25 Nm.
Prerequisites
S
– The engine is not running and is secured against unauthorized use; p. 2 - 3.
à
Risk of damage to the slewing angle sensor! Before lubricating, always remove the screw from the slewing angle sensor. This prevents the slewing angle sensor from becoming damaged.
Lubricating
• Remove the plate (1). • Remove the bolt (2). • Clean the lubricating nipple (3) and insert about 5 cm³ of grease.
• Remove any excess grease, and close the lubricating nipple.
• Tighten the bolt with a new gasket and sealant – torque 25 Nm.
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• Attach the plate.
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8 - 71
Maintenance work on the superstructure 8.11 Cable drums and slewing angle sensor
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Blank page
8 - 72
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Maintenance manual GMK 5170
Maintenance work on the superstructure 8.12 Central lubrication system
8.12
Central lubrication system
8.12.1
Checking the level
W The maintenance of the pump (1) is the same Central as the maintenance on the carrier; lubrication system, p. 7 - 77.
à
8.13
Hook blocks
8.13.1
Checking the sheaves
M3
• Check the sheaves in the hook blocks for damage, wear, mobility and extreme soiling.
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Have damaged, worn, sluggish or extremely soiled sheaves replaced by CraneCARE or your repair crew.
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8 - 73
Maintenance work on the superstructure 8.13 Hook blocks
8.13.2
M 12
Lubricating • Comply also with the à Run-in regulations, p. 4 - 1.
Grease, spare parts, tools
Lubricating grease Grease
Designation according to DIN 51502
Specification Classification
GROVE part no.
KP - L2K
DIN 51825
00554201
– Grease gun from the tool set.
à Operating instructions.
Prerequisites
– The hook block has been reeved at least twice;
Lubricating hook blocks
On the hook blocks, the sheaves, cross-members and load hooks of the axial bearings have to be lubricated. The diagram gives an example of the location of the lubricating nipples (1), (2) and (3) on a hook block. There are other lubricating nipples on the other side.
• Clean the lubricating nipples on all hook
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blocks supplied and on the hook tackle and lubricate them with a grease gun.
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Maintenance manual GMK 5170
Maintenance work on the superstructure 8.14 Electrical system
8.14
Electrical system
8.14.1
Checking the lighting and indicators
G
D
Risk of accidents if the safety devices are faulty! If the lamps or the buzzer fail, notify CraneCARE and have the error rectified.
• Check the lamps and displays on the ECOS and SLI control units;
à Operating instructions.
• Check the following functions: – Windscreen wipers, windscreen washing system,
– spotlight on the crane cabin to light up working area, air traffic control light, – spotlight on the main boom (xenon light), – Horn, anemometer.
G
Danger of accidents from exploding glass bodies and high-voltage! The glass body for gas discharge lamps (xenon lights) is under pressure. If the lamp breaks, glass splinters shatter explosively and scatter. Xenon light operates with high-voltage. There is still a danger of residual voltage discharging (electrocution) even when the battery master switch is switched off. Have faulty lamps replaced only by qualified personnel who have the relevant protective equipment.
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• Have faulty lamps in the spotlights replaced only by qualified personnel.
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8 - 75
Maintenance work on the superstructure 8.14 Electrical system
8.14.2
M1
Checking the batteries
• Switch the battery master switch (2) off and remove the selector handle.
• Check the batteries (1) in the same way as when checking them on the carrier; Checking the batteries, p. 7 - 82.
à
8.14.3
Checking the charge level of the batteries
M3
• Check the charge level in the same way as when checking it on the carrier;
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à Checking the charge level of the batteries, p. 7 - 84.
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Maintenance manual GMK 5170
Maintenance work on the superstructure 8.15 Air-conditioning system
8.15
Air-conditioning system
8.15.1
Checking the air-conditioning system
M1
• Check the air-conditioning system in the same way as when checking it on the carrier;
8.15.2
S
à Checking the air-conditioning system, p. 7 - 87.
Cleaning the condenser fins
M1
Risk of damage to the condenser! Do not use a high pressure cleaner or steam jet cleaner. The powerful jet may damage the fins. Use only compressed air for cleaning.
• Switch the air-conditioning system off. • Clean the condenser fins with compressed
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air (1).
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8 - 77
Maintenance work on the superstructure 8.15 Air-conditioning system
8.15.3
M6
Checking hoses
G
Danger of burns from escaping refrigerant! Wear suitable protective goggles and gloves when checking hoses and connections. This will prevent injury from suddenly escaping refrigerant. Seek medical attention if skin or eyes come into contact with refrigerant.
• Check all refrigerant hoses for damage and worn areas. Have damaged hoses replaced by CraneCARE only.
8.15.4
Checking the entire air conditioning system
H
G
M 12
This check may only be carried out by CraneCARE!
Danger of burns from escaping refrigerant! Wear suitable protective goggles and gloves when checking hoses and connections. This will prevent injury from suddenly escaping refrigerant. Seek medical attention if skin or eyes come into contact with refrigerant.
• Have the entire air-conditioning system checked for leaks and proper functioning. The inspection of the air-conditioning system includes most importantly the inspection of – the refrigerant collector, in accordance with the pressure container regulations (test group II) and – the refrigerant compressor. Use only suitable refrigerant for topping up.
Refrigerant Fill quantity in kg
Tetrafluoroethane (R134a)
CAS no. EC no. 811-97-2 212-377-0 29.04.2008
2.0
Designation
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Maintenance manual GMK 5170
Maintenance work on the superstructure 8.16 Other maintenance work
8.16
Other maintenance work
8.16.1
Checking the auxiliary heater for correct operation
M1
Check the auxiliary heating in the same way you would check it on the carChecking the auxiliary heater for correct operation, p. 7 - 104. rier;
à
8.16.2
Lubricating the piston rod of the derricking cylinder
Grease, spare parts and tools
Designation
M1
GROVE part no.
Lubricant RHUS SW 2
03325215
– Brush.
S
Risk of damage to the derricking cylinder's gasket due to rust! Be sure that the uncovered end of the piston rod is always kept lubricated. In this way you can avoid rust which damages the gasket in the derricking cylinder head when lowering completely.
• Clean the uncovered end (1) of the piston rod of old grease, dirt particles and rust.
• Slightly grease the uncovered end, making sure the grease coat is evenly distributed.
After every high-pressure cleaning operation on the truck crane:
• Grease the piston rod. 29.04.2008
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8 - 79
Maintenance work on the superstructure 8.16 Other maintenance work
H 8.16.3
You can also prevent rust if you turn the main boom to the side between maintenance intervals and completely lower it.
Y2
Having the fire extinguisher checked
Your truck crane has fire extinguishers, depending on its scope of equipment.
H
The maintenance interval may be smaller, depending on the respective national regulations. Ask about the national and local regulations at the local Fire Safety Authority.
• Follow the operating instructions (1) on the fire extinguisher. • Have the fire extinguisher serviced by trained personnel in good time before the maintenance interval specified on the label (2) expires.
29.04.2008
S
Danger due to the fire extinguisher not working! There is no guarantee that the fire extinguisher is still working properly after the maintenance interval on the label has expired.
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Maintenance manual GMK 5170
9 Longer periods out of service
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9
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Maintenance manual GMK 5170
Longer periods out of service
9
Longer periods out of service Carry out the following work if the truck crane is to be out of operation for a long period (months).
Taking out of service
• Clean the truck crane thoroughly inside and outside. • Remove rust and touch up the paintwork. • Parts that 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 as per the maintenance plans. • Seal all air filters. • Increase the tyre pressure by 10% and mark the tyre positioning, or support the truck crane and let it stand supported.
• Observe the specifications on preservation in the engine manufacturer's documentation.
Checking
• Check the levels in the fuel tanks. Always keep the tanks filled. • Check the batteries every week and recharge them if necessary. • Check the tyre pressure each week and correct if necessary. • Perform a full functional check of the truck crane every two weeks. (Open all air filters beforehand!)
• Run the hydraulic systems up to a fluid temperature of approx. 50 °C and check all functions of the carrier and superstructure hydraulic systems.
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9-1
Longer periods out of service
• Ensure that the tyre positioning is different each time the crane is parked (without outriggers).
• Seal all air filters again. If the truck crane is out of service for more than 12 months:
• Carry out all maintenance work in accordance with maintenance plan M 12.
• Observe the specifications on preservation in the engine manufacturer's documentation.
Starting-up
• Open all air filters. • Inflate the tyres up to the prescribed pressure. • Carry out periodic maintenance work in accordance with the maintenance plans in Chapter 5.
• Observe the specifications on preservation and putting back into opera-
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tion in the engine manufacturer's documentation.
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Maintenance manual GMK 5170
10 Torques
10.1
Torques for retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 -
1
10.2
Special torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 -
2
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10
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Maintenance manual GMK 5170
Torques 10.1 Torques for retaining bolts
10
Torques
10.1
Torques for retaining bolts Metric standard screw-thread Metric fine screw-thread
Approximate values
Thread size (mm) Spanner wrench size (mm)
Torques (greatest permissible pre-tensioning for bolts) for oiled bolts (Nm)
10.09.2013
Bolt quality Hexagon bolt
Cylinder screw
M8 M8x1
13
6
M 10 M 10 x 1.25
17
M 12 M 12 x 1.5
10.9
12.9
23 24
32 34
36 41
8
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
Correction sheet – Maintenance manual GMK 5170
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8.8
10 - 1
Torques 10.2 Special torques
10.2
Special torques
Designation
Thread size (mm)
Spanner size (mm) Hexagon bolt
Cylinder screw
Tightening torque (Nm)
Suspension strut: – Bracket for the vehicle frame, top
M 16
—
14
265
– Bracket for the vehicle frame, bottom
M 24
—
19
900
– Flange suspension strut, bottom
M 20
17
520
– Half-shell steering arm
M 16
14
265
— —
70 - 80 160 - 180
Steering linkage: – Bolts for clamp straps
M 12 x 1.5 M 14 x 1.5
19 22
Others: – Coolant hose clamps – Wheel nuts
4 M 22 x 1.5
– Retaining bolt for the ball slewing bearing
650
Please contact Manitowoc Crane Care. M 10
17
—
10
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– Hoist drum rope wedge
32
10 - 2
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Correction sheet – Maintenance manual GMK 5170
11 Spare parts required for maintenance
11.1
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 -
1
11.2
Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 -
1
11.3
Spare parts for the carrier. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 -
5
11.4
Spare parts for the superstructure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 -
7
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Spare parts required for maintenance 11.1 General information
11 11.1
Spare parts required for maintenance
General information The spare parts required for maintenance are divided into – Lighting, – spare parts for the carrier and – spare parts for the superstructure. Listed here are only the spare parts required for the maintenance work described. A more detailed spare parts document can be found in the Spare parts list supplied. An overview of the required lubricants can be found in: – Lubricants list, p. 6 - 2, – Lubricant applications, p. 6 - 3.
11.2
Lighting Lamps are listed according to the installation position. The list includes standard and additional lighting equipment for the truck crane. Lighting specific to certain countries can be found in the Spare parts list, in the Country specific package section.
G
Danger of accidents from exploding glass bodies and high-voltage! The glass body for gas discharge lamps (xenon lights) is under pressure. If the lamp breaks, glass splinters shatter explosively and scatter. Xenon light operates with high-voltage. There is still a danger of residual voltage discharging (electrocution) even when the battery master switch is switched off. Have faulty lamps replaced only by qualified personnel who have the relevant protective equipment.
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11 - 1
Spare parts required for maintenance 11.2 Lighting
Place of installation
GROVE part number
Designation
Output (W)
– Low-beam headlight
00438912
H1 24 V
70
– Low-beam headlight (USA)
00438912
H1 24V
70
– Full-beam headlight
00438912
H1 24 V
70
– Full beam headlight (USA)
00438912
H1 24V
70
– Parking light
00438514
C5W 24 V
5
– Parking light (USA)
01926635
24V 5W
5
– Turn indicator light
00439055
P25-1 24 V
21
– Turn indicator light (USA)
00438912
H1 24V
21
– Yellow side marker light
03320937
LED
03327578
8GA 006841241
24V/21W
– Rear light
01207144
R19/10 24V
10
– Brake light
00439055
P25-1 24V
21
– Turn indicator light
00439055
P25-1 24V
21
– Fog tail light
00439055
P25-1 24V
21
– Reversing light
00439055
P25-1 24V
21
03320937
LED
03323568
LED
– Marker light, left
00438897
T8/4 24V
4
– Marker light, right
00438897
T8/4 24V
4
00438514
C5W 24 V
5
CARRIER LIGHTING: Front headlight: (integrated in the bumper)
Front, side turn indicator lights: (under the access ladder to the driver's cab) – Turn indicator light Rear lights: (at the rear of the chassis)
Side marker lights, yellow: (only at the rear of the chassis) – Side marker light Side marker lights, yellow: (at the sides, along the chassis) – Side marker light Rear marker lights, red/white:
Front marker lights, white: (at the top on the driver's cab) – Marker light
11 - 2
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(at the rear of the chassis)
Spare parts required for maintenance 11.2 Lighting
Place of installation
GROVE part number
Designation
Output (W)
02316460
H3 24V
70
00438912
H1 24V
70
– Interior lamp
00550434
K 24 V
10
– Reading lamp
00550434
K 24 V
10
– Marker light, left
03323856
LED
– Marker light, right
03323567
LED
03329492
LED
00438912
H1 24V
70
– Inside light
00550434
K 24V
10
– Reading light
03328445
P21W 24V
10
02316460
8GH002090251
70
Outrigger beam spotlights: (above the front and rear outrigger beams) – Filament lamp Rotating beacon, yellow: (on the driver's cab) – Filament lamp Inside lights: (in the driver's cab)
SUPERSTRUCTURE LIGHTING: Marker lights, white: (on the main boom head)
Rear marker lights, red: (on the turntable) – Marker light Rotating beacon, yellow: (on the turntable) – Filament lamp Inside lights: (in the crane cab)
Spotlight, attachable: (at the front of the crane cab) – Filament lamp
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11 - 3
Spare parts required for maintenance 11.2 Lighting
Place of installation
GROVE part number
Designation
Output (W)
03326694
8GS007949101
35
02 309 610
810992RSY
100
03 323 856
LED
Spotlights, electrically adjustable: (at the front of the main boom) – Filament lamp Spotlight, swinging: (at the front of the main boom) – Halogen bulb Hoist lighting: (behind the hoist)
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– Marker light
11 - 4
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Spare parts required for maintenance 11.3 Spare parts for the carrier
11.3
Spare parts for the carrier
Subassemblies and spare parts Carrier
GROVE part number
Quantity, in single parts for maintenance interval W
M1
M3
M6
M 12
Engine Oil drain valve (instead of drain plug) Gasket 26 x 31 Cu DIN 7603 Air filter
03046878
1 x when the oil is changed the first time (recommended modification)
00117147 03326272
1 (when the symbol lights up)
Filter
03 322 877
1
Gasket
03 322 879
1
Filter element
03 328 656
1
Filter and gasket
03 045 818
Fuel system
1
Transfer case Gasket 30 x 36 Cu DIN 7603
00117151
Gasket 16 x 20 Cu DIN 7603
00117134
1
1 1
Axle lines Axle centre drive (for max. 10 x 8 x 10) Gasket 36 x 42 Cu DIN 7603
01 371 208
2
3
Gasket 30 x 38 Cu DIN 7603
01 925 343
1
2
Gasket 16 x 22 Cu DIN 7603
00 117 135
1
2
8
8
Axle lines Final drive (for max. 10 x 8 x 10) Gasket 24 x 29 Cu DIN 7603
00117145
Wheels Wheel nuts (12 per wheel)
01207756
(in case of damage)
Compressed air system 01570750
(5)
Gasket 22 x 27 Cu DIN 7603
00117142
(5)
Filter cartridge
03043578
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Valve (in case of defect)
1
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11 - 5
Spare parts required for maintenance 11.3 Spare parts for the carrier
Subassemblies and spare parts Carrier
GROVE part number
Quantity, in single parts for maintenance interval W
M1
M3
M6
M 12
Hydraulic system Filter
03329152
(2)
Gasket set
03135778
2
Filter
03329152
Gasket set
03135778
2 for every oil change and when the symbol lights up
Oil tank cover gasket 140/90 x 3 Ventilation filter
1 for every oil change (in case of damage)
03098598 03324588
1
Particulate filter Clamp strap
03134864
Filter
03134863
1
Clamp strap
03134864
2
Subassemblies and spare parts Carrier
GROVE part number
(2)
(in case of damage)
Quantity, in single parts for maintenance interval Y2
Y3
Y5
Y6
Y 10
Engine Oil filter
03328365
1
Gasket set
03328606
1
Filter with set of gaskets
03 326 293
2
Gasket 30 x 36 Cu DIN 7603
00 117 151
1
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Automatic transmission
11 - 6
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Spare parts required for maintenance 11.4 Spare parts for the superstructure
11.4
Spare parts for the superstructure
Subassemblies and spare parts Superstructure
GROVE part number
Quantity, in single parts for maintenance interval W
M1
M3
M6
M 12
Engine 03 328 263
1 (when the symbol lights up)
Filter (Filter 1)
03322877
1
Gasket
03322879
1
Filter part (in case of damage)
03328656
1
Filter with gasket (large; filter 3)
03328573
1
Filter with gasket (small; filter 2)
03328574
1
Air filter Fuel system
Hoists Gasket 18 x 24 Cu DIN 7603
01377793
Gasket 18 x 24 Cu DIN 7603
01377793
(4)
(in case of damage) 10
Slewing gear Gasket 10 x 14 Cu DIN 7603
00117125
Gasket 10 x 14 Cu DIN 7603
00117125
3
Gasket 14 x 20 Cu DIN 7603
00117132
3
Ventilation filter
03 319 602
1
Oil filter 1
03134850
1
Gasket for oil filter 1
03 328 209
Oil filter 2
03134850
Housing gasket set, oil filter 2
03326049
Gasket 120 x 90
03 328 286
(3)
(in case of damage)
Hydraulic system
Change the oil filter at every oil change and if a warning message is displayed.
1 1 1 1
Hoist ropes Grease (20 litre canister)
03133770
1
Cover gasket for the lowering limit switch
00550699
2 (in case of damage) for every rope change on the hoist
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Cable drums Cable drum 1 cover gasket
03324704
Cable drum 2 cover gasket
03328294
(in case of damage)
(1) (1)
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11 - 7
Spare parts required for maintenance 11.4 Spare parts for the superstructure
Subassemblies and spare parts Superstructure
GROVE part number
Quantity, in single parts for maintenance interval Y2
Y3
Y5
Y6
Y 10
Engine Oil filter, complete
03328556
1
Slewing angle sensor 00117134
(1)
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Gasket 16 x 20 Cu DIN 7603
11 - 8
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Appendix
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Maintenance manual GMK 5170
Appendix
Date of commission/date of inspection
Operational condition since the last inspection
Kmi
Factor of the load spectrum
[hrs.]
Operating hours of the entire crane
[hrs.]
Operating hours of the superstructure
[hrs.]
Operating hours of the superstructure since the last inspection
Last general overhaul performed on..................................
[hrs.]
Operating hours of the winch
........................ ........................ ........................ ........................
........................ ........................ ........................ ........................ ........................
CAUTION: A general overhaul is to be performed every 10 years! Alternative provision, refer to Section 5.4.2, p. 5 - 25.
(*)
"i"
Inspection interval no. (max. 1 year)
Crane model: Work number: Commissioned on: Winch serial number as shown on model plate: Last general overhaul performed on: Winch design data (see operating instructions): Engine group: Load spectrum: Factor of the load spectrum: Theoretical service life:
[hrs.]
Operating hours of the winch since the last inspection
Table to determine the remaining theoretical service life on winch no. ..........
[hrs.]
Note
Name of the approved inspector
= Effective working hours in the inspection interval "i" according to Section 2.2 (*) Copy last line of the previous page to the following page.
Ti
Kmi = Load spectrum factor in the inspection interval "i" according to Section 2.1
Km = Factor of the load spectrum used to calculate the winch. This factor is given in the operating instructions.
Di - 1= Remaining theoretical service life after the previous inspection
= Remaining theoretical service life
Signature
Di
Name of competent person
=Used proportion of theoretical service life since the last inspection
[hrs.]
Di = Di-1 - Si
Remaining theoretical service life
Si
Used proportion of theoretical service life D:
Signature
Date of commission/date of inspection
Operational condition since the last inspection
Kmi
Factor of the load spectrum
[hrs.]
Operating hours of the entire crane
[hrs.]
Operating hours of the superstructure
[hrs.]
Operating hours of the superstructure since the last inspection
Last general overhaul performed on..................................
[hrs.]
Operating hours of the winch
........................ ........................ ........................ ........................
........................ ........................ ........................ ........................ ........................
CAUTION: A general overhaul is to be performed every 10 years! Alternative provision, refer to Section 5.4.2, p. 5 - 25.
"i"
Inspection interval no. (max. 1 year)
Crane model: Work number: Commissioned on: Winch serial number as shown on model plate: Last general overhaul performed on: Winch design data (see operating instructions): Engine group: Load spectrum: Factor of the load spectrum: Theoretical service life:
[hrs.]
Operating hours of the winch since the last inspection
Table to determine the remaining theoretical service life on winch no. ..........
[hrs.]
Note
Name of the approved inspector
= Effective working hours in the inspection interval "i" according to Section 2.2 Copy last line of the previous page to the following page.
(*)
Signature
Ti
Kmi = Load spectrum factor in the inspection interval "i" according to Section 2.1
Km = Factor of the load spectrum used to calculate the winch. This factor is given in the operating instructions.
Di - 1 = Remaining theoretical service life after the previous inspection
= Used proportion of theoretical service life since the last inspection
Signature
= Remaining theoretical service life
Name of competent person
Si
[hrs.]
Di = Di-1 - Si
Remaining theoretical service life
Di
Used proportion of theoretical service life D:
Date
–135° (A)
–45° (B)
+135° (D)
ok
............... mm
+ 3.2 mm
............... mm
faulty
replaced on
Ball slewing bearing
max. permissible tilting play:
max. permissible wear:
Base value:
Signature
• Always measure the current tilting play as described in Section Measuring tilting play, p. 8 - 33.
+45° (C)
Current tilting play
Tilting play measurement report
Date
–135° (A)
–45° (B)
+135° (D)
ok
............... mm
+ 3.2 mm
............... mm
faulty
replaced on
Ball slewing bearing
max. permissible tilting play:
max. permissible wear:
Base value:
Signature
• Always measure the current tilting play as described in Section Measuring tilting play, p. 8 - 33.
+45° (C)
Current tilting play
Tilting play measurement report
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Important note
© Copyright reserved by Manitowoc Crane Group Germany GmbH The passing on or duplication of this document as well as the utilisation and disclosure of its contents are prohibited unless expressly permitted. Infringement will incur liability for compensation. All rights pertaining to registration of patent or utility model are reserved. The original language of this document is German.
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Any type of duplication or excerpt from this document, also in electronic form, is not subject to the revision service of Manitowoc Crane Group Germany GmbH.
Hydraulic Oil – hydraulic system Deviating to the information in the supplied maintenance manual, the hydraulic system in the carrier/superstructure is filled with a different oil type. This new type of oil is in use since mid january 2015 for the first oil fill during the cranes production process.
• Please contact Manitowoc Crane Care, if you are in doubt. This additional page indicates the oil type first filled in at the factory and contains maintenance information.
Oil type
• Only use the oil specified in this document when carrying out maintenance work on the hydraulic system.
Maintenance information
Place of use
Specification
Oiltank: Carrier and superstructure
Castrol Hyspin AWH-M 32 DIN 51524-3 Hydraulic Oil HVLP ISO VG 32 GROVE Part no. 04162158 available from Manitowoc Crane Care
• Carry out maintenance work using the oil stated above, as described in the supplied maintenance manual. The maintenance intervals in the supplied maintenance manual apply.
• For maintenance, also observe the following notes:
Risk of damage to the environment if disposed of improperly This oil must also be disposed of properly in accordance with legal specifications.
12.01.2015
S O
Risk of damage to the hydraulic system Do not mix this oil with other oils. Oil mixtures can damage the hydraulic system.
Correction sheet Maintenance manual GMK truck cranes
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1
12.01.2015
Blank page
2
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Correction sheet Maintenance manual GMK truck cranes
Additional hydraulic oil filters Deviating from the specifications – of the accompanying Maintenance manual, and – of the accompanying Additional pages the two additional hydraulic oil filters in the carrier – must be changed at all circumstances every 12 months (M 12).
Validity
This additional page refers to the truck cranes GMK 5170 and GMK 5220.
Replacement
This additional page replaces the additional pages 3 112 577 and 3 112 427. This additonal page completes the information about the hydraulic oil filters 3 and 4 (in the carrier) in the maintenance manual GMK 5170-Cummins.
M 12
Changing the hydraulic oil filters Maintenance interval
• Replace the additional hydraulic oil filters – once after the brand-new truck crane has been in driving position for 50 hours, and – every 12 months (M 12), and – every time the hydraulic oil in the carrier is changed in accordance with the accompanying Maintenance manual.
H
Always comply with the maintenance intervals specified here. The ECOS display does not have warning messages for the additional hydraulic oil filters.
Spare parts and tools
Quantity
GROVE part no.
Filter
2
03135866
Repair set (if necessary)
2
03135867
04.08.2009
Designation
s Additional page GMK 5170/5220
3 112 612 en
1
Changing the filter
Before changing the filter, observe all prerequisites and warnings in the section Carrier hydraulic system of the accompanying Maintenance manual.
• Remove the receptacle (1). • Change the filter (2). • If necessary, replace any defective parts (repair set).
• Fill the receptacle with clean oil.
04.08.2009
• Put the receptacle (1) on and tighten it.
2
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Additional page GMK 5170/5220
Additional maintenance work on the main boom
Validity
These additional pages hold for all GMK truck cranes and supplement the supplied maintenance manuals.
Reason All the lubricating work for the heavily loaded slide faces on the telescopic sections of the main boom is described in the relevant supplied maintenance manual. The heavily loaded slide faces are located on the lower outside slide faces (2) and the upper inside slide faces (3) of the telescopic sections.
In addition, you must also lubricate the unpainted upper outside faces (1). The factory-applied film of lubricant can be washed off in the extended state. Therefore, you must lubricate the upper outside faces of all telescopic sections to prevent corrosion.
Interval
• Lubricate the upper outside faces every three months (M3).
Grease
• Apply the grease with a brush or roller. (Lubricant paste PAL 1, 25 kg bucket, GROVE part no. 02314698).
Lubricating
• Find out about all lubricating points on all telescopic sections in the relevant supplied maintenance manual.
• Always lubricate the upper outside faces (1) before the lower outside slide faces (2).
• Continue the maintenance work as described in the relevant supplied
17.02.2010
maintenance manual.
Additional pages GMK truck cranes
3 112 676 en
1
17.02.2010
Blank page
2
3 112 676 en
Additional pages GMK truck cranes
Contents: 1
General notes
2
Safety and environmental protection
3
Cleaning
4
Run-in regulations
5
Maintenance overview
6
Lubricants and consumables
7
Maintenance work on the carrier
8
Maintenance work on the superstructure
9
Longer periods out of service
10
Torques
11
Spare parts required for maintenance Appendix
This maintenance manual does not replace the operating instructions.
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Details of operation and standard safety instructions can be found in the operating instructions.
Maintenance manual GMK 5170
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Blank page
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Maintenance manual GMK 5170
1 General notes
1.1
Using the maintenance manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 -
1
1.2
Warnings and symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 -
1
1.3
Maintenance instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 -
2
1.4
Notes concerning the electronic control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 -
4
1.5
Safety instructions for welding work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 -
4
1.6
Definition of positional references. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 -
5
1.7
Conversion table for US measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 -
6
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Maintenance manual GMK 5170
General notes 1.1 Using the maintenance manual
1
General notes
1.1
Using the maintenance manual This maintenance manual does not replace proper training and instruction! Truck crane maintenance personnel must have the relevant, specialist 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 Lattice extension operating instructions.
Warnings and symbols The following designations and symbols are used in the operating instructions to highlight particularly important information:
G S O
This symbol indicates dangers related to the described operation 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 section Handling substances which are harmful to the environment, p. 2 - 4.
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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
General notes 1.3 Maintenance instructions
H s 1.3
The hand with the pointing finger indicates passages that contain additional instructions and tips regarding truck crane operation.
This symbol indicates that the topic is continued on the next page. Turn to the next page!
Maintenance instructions This maintenance manual is intended for maintenance personnel. The maintenance manual does not contain information on repair work. Repair work may be carried out only by qualified repair personnel (e.g. CraneCARE). Repair work also requires: – appropriate workshop equipment – special tools – spare parts approved by Manitowoc Crane Group Germany GmbH It is your responsibility to maintain and service the truck crane regularly in order to extend its service life and keep it in good working order. Please note that Manitowoc Crane Group Germany GmbH can uphold the warranty provided for the truck crane only if the following conditions are fulfilled: – it is used for the purpose for which it was intended – care and maintenance is carried out as prescribed
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– repair work/overhauling is carried out by professionals
1-2
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Maintenance manual GMK 5170
General notes 1.3 Maintenance instructions
Many defects and failures are caused by improper maintenance such as: – insufficient oil, grease or antifreeze – dirt – rope damage – defective compressed air and hydraulic systems – hose damage or loose screw connections – faulty brakes – faulty tyres or wheel rims – exceeded maintenance intervals
For your safety and the safety of others, avoid these errors by carrying out service and maintenance work carefully within the specified intervals. Do not delay maintenance work that is due. If repairs are needed, immediately contact CraneCARE or your repair crew. 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 the oil filler opening, the oil inspection opening, the drain opening and the lubricating nipples.
• When changing the oil, let the oil run out at operating temperature. • Ensure that only oils and lubricants specified in the Lubricants, p. 6 - 1 are used.
• Replace all filters within the specified period if cleaning is not explicitly permitted.
• Replace all gaskets before assembly. Clean the sealing surfaces. • Tighten loose screw connections on hydraulic and compressed air systems only when the system is depressurised.
• Keep brake and clutch linings free of grease. • Replace hydraulic hoses immediately once damage or penetration of moisture becomes visible.
• Cleanliness is imperative when handling hydraulic oil. Even new hydraulic oil must be filtered when filling.
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1-3
General notes 1.4 Notes concerning the electronic control
• Cleanliness is imperative when handling grease on the central lubrication system. Do not remove the caps from the filling hole and grease gun until immediately before refilling the grease.
• Check fastening and retaining elements (bolts, nuts, lock washers) before re-using them and replace them if necessary. Torques can be found in sections p. 10 - 1 and p. 10 - 2. Our training centre at our plant offers specialised training programmes. Please contact CraneCARE. The vehicle must fulfil all the applicable regulations before being put into operation and driven on public roads.
1.4
Notes concerning the electronic control The electronic ESX control generally has a service life of 10 years. In terms of use, the control system's service life can be estimated based on the following limiting factors: – The service life of EEPROM allows 105 accesses. – The safety relay permits a maximum of 107 make-and-brake cycles. – Some conventional condensers in the ESX have a service life of 10 years. The device must be serviced or replaced by CraneCARE before one of these limits is reached.
1.5
Safety instructions for welding work To avoid damage, especially to electronic parts, there are certain steps you must take before doing any welding work. You should therefore always consult CraneCARE before welding.
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All welding work (especially on load carrying members) may be performed only by qualified professional personnel with the prior written permission of Manitowoc Crane Group Germany GmbH.
1-4
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General notes 1.6 Definition of positional references
1.6 Basic rule
Definition of positional references Directions always depend on whether the carrier or the superstructure is being operated. On the carrier The driver's cab is always at the front, which means that: 1: Front
2: Right
3: Rear
4: Left
Forwards always means the driver's cab is to the front. Backwards always means the rear lights on the carrier are to the front.
On the superstructure The main boom head is always at the front, which means that:
Switches and buttons
1: Front
2: Right
3: Rear
4: Left
For switches and buttons, the terms down and up are used. Regardless of the fitting position (vertical, horizontal, diagonal, perpendicular or turned), the following always applies: Down: Press (1) – on the symbol Press (2) – opposite the symbol
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Up:
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1-5
General notes 1.7 Conversion table for US measurements
1.7
Conversion table for US measurements
1-6
Converting from
in
Multiply by
mm
in
0.03937
in
mm
25.4
m
ft
3.28084
ft
m
0.30479
m²
ft²
10.76391
cm²
in²
0.155
cm³
in³
0.061
l
gal (US)
0.264178
kg
lbs
2.204622
lbs
kg
0.45359
t
lbs
2204.622
lbs
t
0.0004536
kN
lbf
224.809
daN/cm²
lbf/in²
14.50378
lbf/in²
daN/cm²
0.06895
bar
psi
14.50378
psi
bar
0.06895
m/s
ft/s
3.28084
km/h or km
mph or mi
0.62137
mph or mi
km/h or km
1.60935
Nm
lbf ft
0.7375
°C
°F
1.8 x °C + 32
°F
°C
(°F-32)/1.8
t/m²
lbs/ft²
204.8
m²/t
ft²/lbs
0.04882
MPa
bar
10
bar
MPa
0.1
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Maintenance manual GMK 5170
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The following conversion factors will help you convert from metric to US units and vice versa when the truck crane is being used in countries that use US units of measurement.
2 2
Safety and environmental protection
2.1
Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -
1
Securing against unauthorised use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -
3
Handling substances which are harmful to the environment. . . . . . . . . . . . . . . . 2 -
4
2.1.1
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2.2
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Maintenance manual GMK 5170
Safety and environmental protection 2.1 Safety rules
2 2.1
Safety and environmental protection
Safety rules When carrying out maintenance work, please observe the applicable accident prevention regulations. Observe the following safety rules:
• Familiarise yourself with the truck crane and its operation. Read the Operating instructions carefully and request guidance from the crane operator.
• Do not carry out maintenance work on the truck crane unless you are authorised to do so.
• Observe all safety and warning signs on the truck crane. • Observe all safety instructions contained in this Maintenance manual. • Familiarise 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 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 extendable 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 unauthorised operation before beginning maintenance work. Remove the key and put up warning signs.
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2-1
Safety and environmental protection 2.1 Safety rules
If due to exceptional circumstances, the truck crane must be put into operation for certain types of maintenance work, great care must be taken where there are moving parts (superstructure, outriggers, cardan shafts, slewing bearing, motors, tiltable crane cab). There is a risk of injury.
• Ensure that all hydraulic components are returned to their initial positions (e.g. the main boom) or locked (e.g. the outriggers). Escaping hydraulic fluid or compressed air can cause severe injury. Remember that the hydraulic and compressed air systems of the truck crane are pressurised even when the crane is not in operation. Only tighten loose screw connections when the systems are depressurised. Always depressurise the hydraulic and compressed air systems before opening them.
• Do not allow hot materials to escape unchecked – Risk of burning yourself • Observe the applicable safety regulations when working with flammable fluids.
• Observe the applicable safety regulations when working with process materials.
• Switch off all electrical consumers and disconnect the earthing terminal before removing any batteries.
• Keep in mind the corroding effect of battery acid. • Note the fire alarm and fire-fighting facilities on the site. • Return the truck crane to proper working order once maintenance work is
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completed. Inform the crane operator accordingly.
2-2
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Maintenance manual GMK 5170
Safety and environmental protection 2.1 Safety rules
2.1.1
Securing against unauthorised use • Secure the truck crane against unauthorised use by: – applying the parking brake – switching the transmission to neutral position N – turning off the engine – removing the ignition key and – stowing away the hand-held control in the crane cab or in the driver's cab – locking the driver's cab and the crane cab
G
Danger due to unauthorised use! Always stow away the hand-held control in the crane cab before leaving the truck crane, and lock the door to the crane cab or the driver's cab. In this way, you can prevent unauthorised persons from starting the engine with the hand-held control.
• Set up warning signs in the driver's cab/crane cab with information about – when – why – by whom the truck crane was secured to prevent unauthorised use.
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Remove the warning signs from the driver's cab and the crane cab after completion of the maintenance work.
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2-3
Safety and environmental protection 2.2 Handling substances which are harmful to the environment
2.2
What substances are harmful to the environment?
Handling substances which are harmful to the environment When you carry out maintenance work on the truck crane, you will occasionally work with consumables which are classed as harmful to the environment as per current national and regional regulations. These include 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 regional regulations as well as the instructions in this chapter.
Use suitable equipment
Substances harmful to the environment can be caustic. When doing maintenance work involving these consumables (oils, coolant, fuel), always use containers, hoses, pumps, funnels etc. which are large enough and which are resistant to the consumables. For oil sampling, always use containers that can be closed and have sufficient capacity and resistance to the consumables. The approximate amount of consumable to be expected is specified in the maintenance plans.
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 pollute natural waters.
• Catch consumables (e.g. oils, fuels, coolant) in a suitable container when draining.
• Always use a drain hose when draining, and a funnel or a pump with hose
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suitable for the respective substance when filling.
2-4
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Maintenance manual GMK 5170
Safety and environmental protection 2.2 Handling substances which are harmful to the environment
Collect and store separately
Substances which are environmentally harmful should always be collected separately from other waste.
• Ask your local environmental protection authority about the different categories for the substances.
• Also, when collecting environmentally harmful substances, keep solid materials (e.g. filter cartridges) separate from liquids. Disposal costs will be reduced if you collect liquids separately according to certain categories.
• Only store environmentally harmful substances in approved containers and in locations which meet the requirements of current national and regional regulations.
Disposal
• Ask your local environmental protection authority about the prescribed disposal options.
• Once accumulated, have environmentally harmful substances disposed
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of only by disposal companies which are approved by the national or regional authority responsible.
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2-5
Safety and environmental protection 2.2 Handling substances which are harmful to the environment
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Blank page
2-6
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Maintenance manual GMK 5170
3 Cleaning
3.1
Overview of subassemblies easily damaged when cleaning . . . . . . . . . . . . . . . . 3 -
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3
Maintenance manual GMK 5170
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2
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Maintenance manual GMK 5170
Cleaning
3
Cleaning
During the first three months
The paintwork 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.
After the first three months
• Avoid water temperatures over 60 °C even after the first three months. • Do not use corrosive cleaning agents that might attack 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.
G
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.
• To prevent damage to the gaskets, never point the nozzle directly at them. • Never point the nozzle at electrical equipment, relay and switch boxes, suction and venting filters or control elements and oiled/lubricated surfaces.
• To prevent corrosion, re-oil/relubricate all slide faces after cleaning. The components specified in the next section are to be cleaned with particular care.
• After cleaning with a high-pressure device or a steam jet device, activate
à Triggering
intermediate lubrication on the central lubrication systems ( intermediate lubrication, p. 7 - 79).
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• Lubricate all remaining lubrication points with a grease gun.
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3-1
Cleaning 3.1 Overview of subassemblies easily damaged when cleaning
Overview of subassemblies easily damaged when cleaning
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3.1
3-2
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Maintenance manual GMK 5170
Cleaning 3.1 Overview of subassemblies easily damaged when cleaning
1 SLI terminal box 2 Telescope slide faces 3 SLI length data transmitter 4 Angle data transmitter 5 Pressure sensors 6 Lowering limit switch 7 Suspension struts 8 Superstructure switch box 9 Slewing angle sensor on the superstructure 10 Outriggers control unit 11 Lifting limit switch 12 Housing of the input-output circuit boards on the carrier 13 Swing-away lattice extension proximity switch 14 Spotlights, slewable 15 SLI connections
à Operating
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H
Subassemblies at risk of damage on the lattice extension; Instructions Lattice Extension.
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3-3
Cleaning 3.1 Overview of subassemblies easily damaged when cleaning
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Blank page
3-4
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Maintenance manual GMK 5170
4 Run-in regulations
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4
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Maintenance manual GMK 5170
Run-in regulations
4
Run-in regulations Individual parts have run-in regulations which must be adhered to after: – commissioning or – replacement of a part or – general inspection. This is why you must carry out additional maintenance work on the carrier and superstructure after stipulated periods of time have expired:
Operating hours (oper. hrs.)
Driven km
Additional maintenance work on the CARRIER
After 50
Tighten wheel nuts; Special torques, p. 10 - 2.
After 150
Tighten wheel nuts; Special torques, p. 10 - 2.
After 50
à à
Tighten up the clips on the coolant hoses; Special torques, p. 10 - 2.
à After 100
Lubricate the support bearings; Lubricating the support bearings, p. 7 - 103.
à
During the first 100
Check the hydraulic oil filters weekly; Cleaning the magnetic rods, p. 7 - 64, Changing the hydraulic oil filter, p. 7 - 74.
à à
After 100
After 1 000
Change the drive oil; p. 7 - 30 for the transfer case, p. 7 - 35 for the axle centre drives, p. 7 - 39 for the final drives.
After 250
After 2 500
Change the engine oil; Engine manufacturer's documentation.
à à à à
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4-1
Run-in regulations
Operating hours (oper. hrs.) After 50
Additional maintenance work on the SUPERSTRUCTURE Tighten up the clips on the coolant hoses; Special torques, p. 10 - 2.
à During the first 100
After 100
Check the hydraulic oil filters weekly; Changing the hydraulic oil filter, p. 8 - 41.
à
Tighten up the bolts on the ball bearing slewing; Ball slewing bearing, p. 8 - 31, Special torques, p. 10 - 2.
à à After 100
Hook blocks; Lubricating, p. 8 - 74.
After 200
First oil change on the hoists; Changing the oil/Checking the oil, p. 8 - 22.
After 1000 or after 12 months at the latest
Second oil change on the hoists; Changing the oil/Checking the oil, p. 8 - 22.
After 200
Change the slewing gear oil; Changing the oil/Checking the oil, p. 8 - 28.
After 250
Change the engine oil; Engine manufacturer's documentation.
à à à à
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à
4-2
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Maintenance manual GMK 5170
5 5
Maintenance overview
5.1
Maintenance intervals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 -
1
5.2
Maintenance plans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 -
3
Maintenance plan D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Maintenance plan W . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Maintenance plan M 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Maintenance plan M 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Maintenance plan M 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Maintenance plan M 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Maintenance plan Y 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Maintenance plan Y 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Maintenance plan Y 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Maintenance plan Y 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Maintenance plan Y 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 -
4 6 8 10 12 14 16 17 17 18 18
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 5.2.10 5.2.11 5.3 5.3.1 5.4
Load hook inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 20 Measures required for winch monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 21 Theoretical service life. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 21 Proportion of theoretical service life used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 22 Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 26
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5.4.1 5.4.2 5.4.3
Periodic inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 19
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Maintenance manual GMK 5170
Maintenance overview 5.1 Maintenance intervals
5
Maintenance overview – Maintenance plans D (= daily) – Maintenance plans W (= weekly) and – Maintenance plans M 1 (= monthly) to M 12 (= every 12 months) and – Maintenance plans Y 2 (= every 24 months) to Y 10 (= every 120 months). The maintenance plans are given in table form, divided into – 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 has been described. The cross references consist of the chapter number and the corresponding page number, e.g. Checking hydraulic oil level;
à p. 7 - 61.
Checking the hydraulic oil level is described in chapter 7, the section starts on page 7 - 61.
5.1
Maintenance intervals The length of the interval depends on the quality of the oil used and the operating conditions of the truck crane. The next maintenance must be carried out after – a specified time (maintenance interval) or – a specified number of kilometres driven or – a specified number of operating hours (oper. hrs.) or – an indication on the on-board computer display, ECOS display or particp. 7 - 3 or ulate filter display in the driver's cab;
à
– an indication on the ECOS display in the crane cab;
à p. 8 - 3.
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5-1
Maintenance overview 5.1 Maintenance intervals
The maintenance interval which occurs first shall determine when maintenance work is next due. – The km can be taken from the speedometer. – You can call up the engine and power unit working hours (oper. hrs.) of the superstructure one by one on the ECOS display in the crane cab. The operating hours of the engine equal the total operating hours of the superstructure. The following table sets out the maintenance intervals for the maintenance plans: Maintenance plans
Maintenance interval
Km driven (carrier)
Operating hours (oper. hrs.) of engine (superstructure)
D
Daily/before putting into operation
—
—
W
Weekly
—
—
M1
Monthly
Approx. 2 000
100
M3
Every three months
5 000 – 6 000
300
M6
Every six months
10 000 – 12 500
500
M 12
Every 12 months
20 000 – 25 000
1 000
Y2
Every 24 months
40 000 – 50 000
2 000
Y3
Every 36 months
—
3 000
Y5
Every 60 months
100 000
5 000
Y6
Every 72 months
—
6 000
Y 10
Every 120 months
200 000
12 000
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Please note that the long-term maintenance plans always include the short-term ones!
5-2
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Maintenance manual GMK 5170
Maintenance overview 5.2 Maintenance plans
5.2
Maintenance plans The descriptions of certain maintenance work in the maintenance plans D, W, M 1 to M 12 and Y 2 to Y 10 have been provided for – the carrier in chapter 7 and for – the superstructure in chapter 8. References (chapter and page number) to the description of this maintenance work can be found after the respective maintenance work for carrier and superstructure. The section titles – of chapter 7 Maintenance work on the carrier and – of chapter 8 Maintenance work on the superstructure contain the abbreviations (D to Y 10) of the relevant maintenance plan for better comprehension. In addition to the Maintenance work on the carrier and the Maintenance work on the superstructure chapter 6 also lists the Lubricants and consumables: – The descriptions of the oils/lubricants in accordance with Lubricants list, p. 6 - 2. – The amounts as approximate values for oil amounts in litres (l) (the exact oil amounts can always determined by the oil level inspection holes, the dipsticks or the oil level indicators) Lubricant applications, p. 6 - 3.
Maintenance work on the engine over and above the daily and weekly checks is only partially described in this maintenance manual. When carrying out such maintenance work, follow the instructions given in the Engine manufacturer’s documentation.
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H H
Items which are only available with additional equipment are designated accordingly. These designations are made in this section only and are not repeated in the following sections.
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5-3
Maintenance overview 5.2 Maintenance plans
5.2.1
Maintenance plan D
D
Maintenance work on the CARRIER: daily/before putting into operation Engine
à p. 7 - 5 à p. 7 - 9 à p. 7 - 10
– Checking the oil level – Checking the air filter – Checking the coolant level Transmission
à p. 7 - 21
– Checking the oil level Fuel system
à p. 7 - 14
– Draining off water from fuel filter 1 Wheels
à p. 7 - 43
– Checking the tyres for damage Steering
à p. 7 - 55
– Checking for leaks Hydraulic system
à p. 7 - 61
– Checking the oil level Electrical system
à p. 7 - 81
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– Checking the lighting and indicators
5-4
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Maintenance manual GMK 5170
Maintenance overview 5.2 Maintenance plans
D
Maintenance work on the SUPERSTRUCTURE: daily/before putting into operation Engine
à p. 8 - 5 à p. 8 - 8 à p. 8 - 9
– Checking the oil level – Checking the air filter – Checking the coolant level Fuel system
à p. 8 - 11
– Draining off water from fuel filter 1 Hydraulic system
à p. 8 - 35
– Checking the oil level Hoist ropes – Checking the position on the rope drums
à p. 8 - 55
Electrical system
à p. 8 - 75
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– Checking the lighting and indicators
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5-5
Maintenance overview 5.2 Maintenance plans
5.2.2
Maintenance plan W
W
Maintenance work on the CARRIER: weekly Engine
à p. 7 - 11
– General inspection Automatic transmission
à p. 7 - 25
– General inspection Transfer case
à p. 7 - 29
– General inspection Axle lines
à p. 7 - 33
– General inspection Wheels
à p. 7 - 44
– Checking the tyre air pressure Compressed air system
à p. 7 - 57 à p. 7 - 58
– Draining the compressed air system – Checking for leaks Hydraulic system
à p. 7 - 62 à p. 7 - 63
– Checking the hydraulic hoses – Checking for leaks Central lubrication system
à p. 7 - 77
– Checking the level Other maintenance work – Check the correct operation of the driver's cab windscreen washing system Operating instructions. and the level of fluid in the reservoir;
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à
5-6
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Maintenance manual GMK 5170
Maintenance overview 5.2 Maintenance plans
W
Maintenance work on the SUPERSTRUCTURE: weekly Engine
à p. 8 - 10
– General inspection Hoists
à p. 8 - 19 à p. 8 - 20 à p. 8 - 20
– Checking the oil level – General inspection – Checking the hoist brake Slewing gear
à p. 8 - 25 à p. 8 - 26
– Checking the oil level – Checking for leaks Hydraulic system
à p. 8 - 36 à p. 8 - 36 à p. 8 - 37
– Checking the hydraulic hoses – Checking ventilation filters – Checking for leaks Hoist ropes
à p. 8 - 56
– Checking the hoist ropes Central lubrication system
à p. 8 - 73
– Checking the level Other maintenance work – Check the correct operation of the crane cab windscreen washing system and the level of fluid in the reservoir; Operating instructions.
29.04.2008
à
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5-7
Maintenance overview 5.2 Maintenance plans
5.2.3
Maintenance plan M 1
M1
Maintenance work on the CARRIER: monthly/after approx. 2 000 km Engine – Notes;
à Engine manufacturer's documentation
à p. 7 - 5
Transfer case
à p. 7 - 29
– Checking the oil level Axle lines – Checking the oil level on axle centre drives – Final drives – checking the oil level – Lubricating the cardan shafts on the axle lines
à p. 7 - 33 à p. 7 - 38 à p. 7 - 41
Wheels
à p. 7 - 45
– Check tightness of wheel nuts Suspension – Suspension struts – checking the oil level – Suspension struts – checking the fastening
à p. 7 - 51 à p. 7 - 52
Electrical system
à p. 7 - 82
– Checking the batteries Air-conditioning system
à p. 7 - 87 à p. 7 - 87
– Checking the air-conditioning system – Cleaning the condenser fins Particulate filter
à p. 7 - 91
– Checking the clamp straps Towbar coupling
à p. 7 - 95
– Lubricating the towbar coupling Other maintenance work – Lubricating the support bearings
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– Checking the auxiliary heater for correct operation
à p. 7 - 103 à p. 7 - 104
5-8
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Maintenance manual GMK 5170
Maintenance overview 5.2 Maintenance plans
M1
Maintenance work on the SUPERSTRUCTURE: monthly/after 100 oper. hrs. Engine – Notes;
à Engine manufacturer's documentation
à p. 8 - 5
Electrical system
à p. 8 - 76
– Checking the batteries Air-conditioning system
à p. 8 - 77 à p. 8 - 77
– Checking the air-conditioning system – Cleaning the condenser fins Other maintenance work – Checking the auxiliary heater for correct operation
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– Lubricating the piston rod of the derricking cylinder
à p. 8 - 79 à p. 8 - 79
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5-9
Maintenance overview 5.2 Maintenance plans
5.2.4
Maintenance plan M 3
M3
Maintenance work on the CARRIER: every three months/after 5 000 - 6 000 km Engine – Notes;
à Engine manufacturer's documentation
à p. 7 - 5
Fuel system
à p. 7 - 15
– Changing fuel filter 1 Vehicle brake
à p. 7 - 49
– Checking brake-lining thickness Suspension – Forced lever – checking correct functioning
à p. 7 - 53
Hydraulic system
à p. 7 - 64
– Cleaning the magnetic rods Electrical system – Checking the charge level of the batteries
à p. 7 - 84
Towbar coupling – Checking the bearing – Checking the cotter pin – Checking the lower bushing – Checking the initial tension of the springs – Checking the support ring
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– Checking the function of the coupling jaw/ Resetting central position
à p. 7 - 97 à p. 7 - 98 à p. 7 - 99 à p. 7 - 99 à p. 7 - 100 à p. 7 - 100
5 - 10
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Maintenance manual GMK 5170
Maintenance overview 5.2 Maintenance plans
M3
Maintenance work on the SUPERSTRUCTURE: every 3 months/after 300 oper. hrs. Engine – Notes;
à Engine manufacturer's documentation
à p. 8 - 5
Fuel system
à p. 8 - 13
– Changing fuel filter 1 Ball slewing bearing – Check the bolt torques;
à Special torques
à p. 10 - 2
Main boom
à p. 8 - 49 à p. 8 - 53
– Lubricating the telescopic sections – Checking the sheaves Hoist ropes
à p. 8 - 57
– Lubricating the hoist rope Hook blocks
à p. 8 - 73
– Checking the sheaves Electrical system
à p. 8 - 76
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– Checking the charge level of the batteries
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5 - 11
Maintenance overview 5.2 Maintenance plans
5.2.5
Maintenance plan M 6
M6
Maintenance work on the CARRIER: every six months/after 10 000 - 12 500 km Engine – Notes;
à Engine manufacturer's documentation
à p. 7 - 5
Transfer case
à p. 7 - 30
– Changing the oil Axle lines
à p. 7 - 42
– Lubricating longitudinal cardan shafts Wheels
à p. 7 - 46
– Tyre change Air-conditioning system
à p. 7 - 88
– Checking hoses Particulate filter
à p. 7 - 92
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– Replacing the particulate filter
5 - 12
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Maintenance manual GMK 5170
Maintenance overview 5.2 Maintenance plans
M6
Maintenance work on the SUPERSTRUCTURE: every 6 months/after 500 oper. hrs. Engine – Notes;
à Engine manufacturer's documentation
à p. 8 - 5
Hoists
à p. 8 - 20
– Lubricating the auxiliary hoist Slewing gear
à p. 8 - 26
– Checking the slewing gear brake Ball slewing bearing
à p. 8 - 31 à p. 8 - 33
– Lubricating gear teeth – General inspection Cable drums and slewing angle sensor – Maintenance of the slip ring assemblies
à p. 8 - 69
Air-conditioning system
à p. 8 - 78
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– Checking hoses
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5 - 13
Maintenance overview 5.2 Maintenance plans
5.2.6
Maintenance plan M 12
M 12
Maintenance work on the CARRIER: every twelve months/after 20 000 - 25 000 km Engine – Notes;
à Engine manufacturer's documentation
à p. 7 - 5
Fuel system
à p. 7 - 17
– Changing fuel filter 2 Axle lines
à p. 7 - 35 à p. 7 - 39
– Axle centre drives – changing the oil – Final drives – changing the oil Suspension – Pressure accumulator – checking the gas pressure
à p. 7 - 54
Compressed air system – Replacing the filter cartridge of the compressed air drier
à p. 7 - 59
Steering – Pressure accumulator – checking the gas pressure
à p. 7 - 56
Hydraulic system – Changing the ventilation filter – Taking oil samples: depending on the oil sample test results: – Change the oil – Changing the hydraulic oil filter
à p. 7 - 66 à p. 7 - 67 à p. 7 - 70 à p. 7 - 74
Air-conditioning system – Checking the entire air-conditioning system
à p. 7 - 88
Other maintenance work – Lubricate the door hinges
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– Lubricate the connecting and socket pins
5 - 14
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Maintenance manual GMK 5170
Maintenance overview 5.2 Maintenance plans
M 12
Maintenance work on the SUPERSTRUCTURE: every 12 months/after 1 000 oper. hrs. Engine – Notes;
à Engine manufacturer's documentation
à p. 8 - 5
Fuel system
à p. 8 - 15
– Changing fuel filters 2 and 3 Hoists
à p. 8 - 22
– Changing the oil/Checking the oil Slewing gear
à p. 8 - 28
– Changing the oil/Checking the oil Ball slewing bearing
à p. 8 - 33
– Measuring tilting play Hydraulic system – Changing the ventilation filter – Pressure accumulator – checking the gas pressure – Taking oil samples – Changing the hydraulic oil filter – Changing the hydraulic oil
à p. 8 - 38 à p. 8 - 39 à p. 8 - 40 à p. 8 - 41 à p. 8 - 44
Main boom
à p. 8 - 53
– Checking the locking system Hook blocks
à p. 8 - 74
– Lubricating Air-conditioning system – Checking the entire air conditioning system
à p. 8 - 78
Other maintenance work – Lubricate the cabin door track rollers
29.04.2008
– Lubricate the connecting and socket pins
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5 - 15
Maintenance overview 5.2 Maintenance plans
5.2.7
Maintenance plan Y 2
Y2
Maintenance work on the CARRIER: every 24 months/after 40 000 – 50 000 km Engine – Notes;
à Engine manufacturer's documentation
à p. 7 - 5
Automatic transmission
à p. 7 - 26
– Changing the oil and the oil filter Air-conditioning system – Have the refrigerant level checked by CraneCARE. Other maintenance work
à p. 7 - 104
– Having the fire extinguisher checked
Maintenance work on the SUPERSTRUCTURE: every 24 months/after 2,000 oper. hrs. Engine – Notes;
à Engine manufacturer's documentation
à p. 8 - 5
Air-conditioning system – Have the refrigerant level checked by CraneCARE. Other maintenance work
à p. 8 - 80
29.04.2008
– Having the fire extinguisher checked
5 - 16
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Maintenance manual GMK 5170
Maintenance overview 5.2 Maintenance plans
5.2.8
Maintenance plan Y 3
Y3
Maintenance work on the CARRIER: every 36 months No maintenance work in this period. The long-term intervals always include the short-term intervals.
Maintenance work on the SUPERSTRUCTURE: every 36 months/after 3,000 oper. hrs. Hoists
à p. 8 - 24
– Having a partial inspection carried out
5.2.9
Maintenance plan Y 5
Y5
Maintenance work on the CARRIER: every 60 months/100 000 km Axle lines – Have the cardan shaft between the transmission on the engine and the transfer case replaced by CraneCARE.
Maintenance work on the SUPERSTRUCTURE: every 60 months/after 5,000 oper. hrs. Cable drums and slewing angle sensor
à p. 8 - 71
29.04.2008
– Lubricating the slewing angle sensor
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5 - 17
Maintenance overview 5.2 Maintenance plans
5.2.10
Y6
Maintenance plan Y 6
Maintenance work on the CARRIER: every 72 months No maintenance work in this period. The long-term intervals always include the short-term intervals.
Maintenance work on the SUPERSTRUCTURE: every 72 months/after 6,000 oper. hrs. Hoists
à p. 8 - 24
– Having a general inspection carried out
5.2.11
Y 10
Maintenance plan Y 10
Maintenance work on the CARRIER: every 120 months/after 200 000 km Steel construction – Check the load-bearing steel construction. For more information, please contact CraneCARE.
Maintenance work on the SUPERSTRUCTURE: every 120 months/after 12 000 oper. hrs. Steel construction – Check the load-bearing steel construction. For more information, please contact CraneCARE. Safe load indicator (SLI)
29.04.2008
– Have the SLI checked by CraneCARE.
5 - 18
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Maintenance manual GMK 5170
Maintenance overview 5.3 Periodic inspections
5.3
Periodic inspections Your truck crane GMK 5170 has been inspected before delivery. – Truck cranes that are to be used in Germany are inspected in accordance with the regulations of the Professional Trade Association as per BGV D 6 (VBG 9). – Truck cranes that are to be used abroad are inspected in accordance with the national 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 per BGV D 6 (VBG 9). According to German regulations, 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 parts. The 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 – the load hooks (
à Load hook inspection, p. 5 - 20)
– the load-bearing steel construction (for cracks, deformation, etc.), including a special check of all welds If damage is found in the steel construction, qualified specialists must determine the extent of the damage using the required material examination methods. They should then determine what sort of repair action should be carried out. Prior to carrying out welding work on the truck crane, observe the Safety instructions for welding work, p. 1 - 4.
à
29.04.2008
The inspector is to write a record containing the result of the annual inspection and the measures taken to repair any damage.
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5 - 19
Maintenance overview 5.3 Periodic inspections
5.3.1
Load hook inspection The hook mouth on the load hooks must be checked regularly for deformation. The mouth of the hook may not be more than 10% wider than the original dimension y, y1, y2. The original dimensions y, y1, y2 are stated 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 is more than 10% wider than the initial dimension.
29.04.2008
G
Risk of accidents 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
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Maintenance manual GMK 5170
Maintenance overview 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 hoisting gears; p. 8 - 24.
à
These measures for monitoring the winches (hoists) were compiled by the German Machine Builders' Association (VDMA) and are to be used for all vehicle cranes according to the German Accident Prevention Regulations for Winches, Hoists and Tractor Machines, BGV D 6 (VGB 9) and BGV D 8 (VBG 8).
Theoretical service life The theoretical service life is determined from certain operating conditions and a theoretical operating time assumed by the design engineer when calculating and dimensioning the winches of your truck crane. The power unit group M 3 and the load spectrum L1 (Km = 0.125) are generally given for truck cranes in erection mode, resulting in a theoretical service life of 3200 hrs. (ISO 4301/1, FEM 1.001, DIN calculation bases for power units).
S
The theoretical service life is not the same as the real (actual) service life of a winch!
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s
Maintenance manual GMK 5170
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5 - 21
Maintenance overview 5.4 Measures required for winch monitoring
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 truck crane. 2. Insufficient maintenance:
oil not changed at the specified intervals.
3. Operating errors:
extreme acceleration or retardation of the load, load drops and is caught by the ropes.
4. Improper maintenance:
wrong oil used incorrect filling 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 caustic atmosphere dust and dirt.
Proportion of theoretical service life used The truck crane operator must inspect the truck crane at least once a year (ISO 9927-1 and BGV D 6 (VGB 9)/BGV D 8 (VBG 8)). This includes establishing the proportion of theoretical service life that has been used. If required, the truck crane operator is to appoint an official inspector for this assessment.
29.04.2008
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 theoretical service life that has been used. The operator is responsible for proper documentation in the crane logbook.
5 - 22
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Maintenance manual GMK 5170
Maintenance overview 5.4 Measures required for winch monitoring
Determining the operating conditions (load spectrum)
H Load
The truck crane's load spectrum is divided into groups (see also ISO 4301/1, FEM 1.001):
When establishing the load spectrum, the existing wire cable is used as a standard, i.e. under certain circumstances, the truck crane can be supporting a small load, whereby the winch is actually supporting a heavy load, e.g. due to insufficient reeving. Therefore, the following graphic representation of the load spectrum refers to the winch's wire cables.
Term designation
Timing period proportions
Factor of
spectrum
the load
class
spectrum
Graphic representation
Km =
Light Q1 L1
Power units or parts
10% of the timing period with
thereof that are subject
greatest load (dead weight +
to high stress in excep-
1/1 payload)
tional situations, but which are generally subject to only minimal stress.
40% of the timing period with
0.125
dead load + 1/3 payload 50% of the timing period with dead weight only
Power unit or parts
1/6 of the timing period with
thereof that are subject
greatest load (dead load +
to high stress quite
1/1 payload)
often, but which are genMedium Q2 L2
erally subject to only minimal stress.
1/6 of the timing period with dead load + 2/3 payload
0.25
1/6 of the timing period with dead load + 1/3 payload 50% of the timing period with dead weight only
Heavy Q3 L3
50% of the timing period with
thereof that are subject
greatest load (dead weight +
to high stress frequently
1/1 payload)
and medium stress generally.
50% of the timing period with
Power unit or parts
90% of the timing period with
thereof that are regularly
greatest load (dead weight +
subjected to high stress
1/1 payload)
from adjacent stress sources
0.5
dead weight only
10% of the timing period with
1
dead weight only
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Very heavy Q4 L4
Power unit or parts
s Maintenance manual GMK 5170
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5 - 23
Maintenance overview 5.4 Measures required for winch monitoring
One of the load spectrums listed above should be selected on the basis of the actual operating conditions and entered in the crane logbook for the respective testing interval. Note for truck cranes: The load spectrum L1 and the factor of the load spectrum Km = 0.125 are generally applied to truck cranes in assembly mode.
Determination of the effective operating hours Ti
The effective operating hours of the winches need to be entered in the crane logbook for the respective inspection interval. – The effective operating hours Ti of the winches are displayed in the Operating hours submenu; Operating instructions.
à
Determining the proportion of theoretical service life used
For an inspection interval i (max. 1 year according to ISO 9927-1 or BGV D 6 (VBG 9)/BGV D 8 (VBG 8), the proportion of theoretical service life used Si is calculated using the formula:
Km i S i = ----------- × T i Km Km = Factor of the load spectrum established during winch calculation. This factor is given in the operating instructions. Kmi = Factor of the load spectrum in inspection interval i in accordance with the section “Determining the operating conditions (collective load)” Ti
= Effective operating hours in the testing interval i as described in the “Determining the actual operating hours Ti” section
This used proportion is subtracted from the remaining theoretical service life Di after every testing interval (see example in the appendix to this chapter). If the remaining theoretical service life is not sufficient for the next operating period, then a general overhaul of the winch must be performed.
à
A general overhaul must be performed at least once every 10 years after commissioning the truck crane.
5 - 24
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Maintenance manual GMK 5170
29.04.2008
If theoretical service life D has been reached ( Theoretical service life, p. 5 - 21), the winch must not be operated until after a general overhaul has been performed.
Maintenance overview 5.4 Measures required for winch monitoring
The general overhaul must be arranged by the operator and performed by the manufacturer or persons authorised by the manufacturer. The results are to be entered in the logbook. The manufacturer or persons authorised by him specify a new theoretical service life D upon completion of the general overhaul. The next general overhaul must be performed within 10 years.
Deviating provision
If, after 10 years, the theoretical service life has not been used up, the winch can continue to be operated without a general overhaul under the following conditions. The crane expert has confirmed that the used portion of the service life is correct and proper by signing his/her name in the logbook after every inspection. In this case, the crane expert must closely inspect the winch. This includes at least: – a visual examination of the exterior (for leaks, damage, malformation etc.) – an oil inspection (especially for metallic residue) – a load inspection with minimum and maximum rope pull and each with maximum possible speed. At least one position is to be wound. Pay attention to any unusual noises during the load inspection.
29.04.2008
This inspection must be confirmed in the logbook by the crane expert and there must be a declaration of continued operation for the winch. The next inspection takes place before the 12th year of operation and must be repeated every year thereafter.
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5 - 25
Maintenance overview 5.4 Measures required for winch monitoring
5.4.3
Example A GMK 5170 is equipped with a separate operating hours counter for the hoist and is classified by Manitowoc Crane Group Germany GmbH as follows: Power unit group:
M3
Load spectrum:
light L 1, Km = 0.125
Theoretical service life:
D = 3 200 hrs.
The used proportion S of theoretical service life is calculated based on the individual inspection intervals as follows: 1. Inspection (1st year) The truck crane was used for assembly work during the previous year: Load spectrum L 1, i.e. Km1 = 0.125. The operating hours counter for the main hoist reads 160 hrs., i.e. T1 = 160 hrs. The used proportion S1 of theoretical service life after the first inspection therefore is:
0.125 S i = --------------- × 160 h = 160 h 0.125 Remaining theoretical service life: D1 = 3200 hrs. - 160 hrs. = 3040 hrs. The above values are entered in the table (see table example p. 5 - 28).
2. Inspection (2nd year) The truck crane was used for unloading work on docks: Load spectrum: L 3, i.e. Km2 = 0.5.
29.04.2008
The operating hours counter for the main hoist reads 640 hrs., i.e. during this period: 640 hrs. - 160 hrs. = 480 hrs. (160 hrs. were used during the first year) T2 = 480 hrs.
5 - 26
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Maintenance manual GMK 5170
Maintenance overview 5.4 Measures required for winch monitoring
The used proportion S2 of theoretical service life after the second inspection is therefore:
0.5 S i = --------------- × 480 h = 1920 h 0.125 Remaining theoretical service life: D2 = 3040 hrs. - 1920 hrs. = 1120 hrs. The above values are entered in the table (see table example p. 5 - 28). 3. Inspection (3rd year) The truck crane was used for assembly work and occasional unloading work on docks: Load spectrum: L 2, i.e. Km3 = 0.25. The operating hours counter for the main hoist reads 940 hrs., i.e. during this period: 940 hrs. - 640 hrs. = 300 hrs. T3 = 300 hrs. The used proportion S3 of theoretical service life after the third inspection interval is therefore:
0.25 S i = --------------- × 300 h = 600 h 0.125 Remaining theoretical service life: D3 = 1120 hrs. - 600 hrs. = 520 hrs. These values are entered in the table (see sample table p. 5 - 28).
The remaining theoretical service life is to be documented in a separate table for each winch.
29.04.2008
This table is to be attached to the logbook. This table is found in the maintenance manual appendix for truck cranes that do not require a logbook or similar documentation according to the regulations in the country in which you are working.
s Maintenance manual GMK 5170
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5 - 27
Sample table to determine the remaining theoretical service life on winch no. 1 (main hoisting winch) GMK 3045 3045 42 06 10 June 1990 13 301 ........................ M3 Q 1 (L1) Km = 0.125 D = 3200 hrs.
[hrs.]
Müller
Crane model: Work number: Commissioned on: Serial number of the winch in accordance with model plate: Last general overhaul performed on: Winch design data (see operating instructions): Engine group: Load spectrum: Factor of the load spectrum: Theoretical service life:
3040
3200
Name of competent person
0
Remaining theoretical service life
160
Operating hours of the winch
160
Huber
Operating hours of the entire crane
Operating hours of the superstructure
[hrs.]
Operating hours of the superstructure since the last inspection
160
1120
Schmitz
Factor of the load spectrum
[hrs.]
–
–
1920
520
Di = Di-1 - Si
[hrs.]
–
–
480
600
Used proportion Si of theoretical service life D:
Kmi
–
–
640
300
Operating hours Ti of the winch since the last inspection
–
–
940
Operational condition since the last inspection
0.125
–
–
Date of commission/date of inspection
–
–
–
Inspection interval no. (max. 1 year)
L1 0.5 –
Signature
Note
= Used proportion of theoretical service life since the last inspection
[hrs.]
5. 6. 91
10. 6. 90
L3 0.25
= Remaining theoretical service life
[hrs.]
1
0(*)
20. 5. 92 L2
Si
Name of the approved inspector
(*)
Ti
Copy last line of the previous page to the following page.
= Effective working hours in the inspection interval "i" according to section 2.2
Signature
Kmi = Factor of the load spectrum in the inspection interval "i" according to section 2.1
Km = Factor of the load spectrum used to calculate the winch. This factor is given in the operating instructions.
Di - 1 = Remaining theoretical service life after the previous inspection
Di
[hrs.]
2 18. 5. 93
"i"
3
CAUTION: A general overhaul is to be performed every 10 years! Deviating provision, refer to section 5.4.2, p. 5 - 25.
General overhaul performed on..................................
Maintenance manual GMK 5170
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5 - 28
29.04.2008
Maintenance overview 5.4 Measures required for winch monitoring
6 6
Lubricants and consumables
6.1
Lubricants. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 -
1
Lubricants list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Lubricant applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 -
2 3
6.2
Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 -
4
6.3
Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 -
4
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Engine coolant admixtures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Windscreen washing system admixtures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Fuel for crane cab heating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 -
4 4 4 4
6.1.1 6.1.2
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6.3.1 6.3.2 6.3.3 6.3.4
Maintenance manual GMK 5170
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Maintenance manual GMK 5170
Lubricants and consumables 6.1 Lubricants
6 6.1
Lubricants and consumables
Lubricants All lubricants that you require for the – Maintenance work on the carrier, p. 7 - 1 and – Maintenance work on the superstructure, p. 8 - 1 are listed with serial numbers in the lubricants list and the lubricant applications list.
à Lubricants list, p. 6 - 2.
29.04.2008
à Lubricant applications, p. 6 - 3.
Maintenance manual GMK 5170
3 112 477 en
6-1
Lubricants and consumables 6.1 Lubricants
6.1.1
Lubricants list
Serial no.
GROVE part number
Lubrication type
Designation according to DIN 51502
1
03329588
Engine oil
HD - CD
MIL-L 2104 C DB 228.5
SAE 5 W - 30
2
6 829 101 690
Gear oil1)
3
00552891
Gear oil
C - LPF
MIL-L 2105 B API-GL-5
Hyp SAE 90 ISO - VG 220
4
02310863
Gear oil
5
02313611
Gear oil
C - LPF
MIL-L 2105 B API-GL-4/5 (synthetic)
SAE 75 W-90 EP ISO - VG 220
6
01375719
Hydraulic oil
H - LP
DIN 51524 T.2
ISO - VG 32
7
00554201
Lubricating grease
KP - L2K
DIN 51825
8
00554205
Spray
Ceplattyn 300
9
02314698
Slide paste
PAL 1
10
03325215
Lubricating grease
RHUS SW 2
11
03133770
Lubricating grease
Elaskon 30
Viscosity
Rivolta S.K.D. 170
Synthetic oil filled at the factory; do not mix it with mineral oil!
29.04.2008
1)
Specification Classification
6-2
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Maintenance manual GMK 5170
Lubricants and consumables 6.1 Lubricants
6.1.2
Serial no.
Lubricant applications
Lubrication type
Application
Diesel engine for the carrier; 1
Engine oil
2
Gear oil
3
Gear oil
4
Gear oil
5
Gear oil
6
Hydraulic oil
7
Lubricating grease
Diesel engine for the superstructure;
29.04.2008
Spray
9
Slide paste
10
Lubricating grease
11
Lubricating grease
Maintenance manual GMK 5170
à p. 8 - 7
à p. 7 - 26 3. Axle line transfer case; à p. 7 - 30 2. Axle line axle centre drive; à p. 7 - 35 5. Axle line axle centre drive; à p. 7 - 35 4. Axle line axle centre drive; à p. 7 - 35 6 or 8 x final drive; à p. 7 - 39 10 x suspension struts; à p. 7 - 51 2 x hoists; à p. 8 - 22 2 x slewing gears; à p. 8 - 28 Carrier hydraulic tank; à p. 7 - 70 Superstructure hydraulic tank; à p. 8 - 44 Carrier central lubrication; à p. 7 - 77 Superstructure central lubrication; à p. 8 - 73 Cardan shafts – transverse; à p. 7 - 41 Cardan shafts – longitudinal; à p. 7 - 42 Towbar coupling; à p. 7 - 95 Support bearing; à p. 7 - 103 Auxiliary hoist; à p. 8 - 20 Slewing angle sensor; à p. 8 - 71 Hook blocks; à p. 8 - 74 Automatic transmission;
Doors: hinges, track rollers, connecting and socket pins;
8
à p. 7 - 7
à p. 5 - 14 Slewing bearing gear teeth; à p. 8 - 31 Telescopic slide faces; à p. 8 - 49 Telescopic locking pins; à p. 8 - 49 Derricking cylinder piston rod; à p. 8 - 79 Lubricating the hoist ropes; à p. 8 - 57
3 112 477 en
Quantity to be filled in litres
Maintenance interval
38
Engine manufacturer’s documentation
16 46.0
Y2
19
M6
13.0
M 12
13.0
M 12
16.5
M 12
4.1
M 12
1.5
M1
7
M 12
0.9
M 12
150
M 12
915
M 12 W W M1 M6 M1 M1 M6 Y5 M 12 M 12 M6 M3 M3 M1 M3
6-3
Lubricants and consumables 6.2 Refrigerant
6.2
Refrigerant
Refrigerant Designation
Application
Quantity to be filled in kg
Maintenance interval
à p. 7 - 88
1.5
M 12
Crane cab air-conditioning system; p. 8 - 78
2.0
M 12
Driver's cab air-conditioning system;
Tetrafluoroethane (R134a) CAS no. 811-97-2 EC no. 212-377-0
à
6.3
Consumables
6.3.1
Fuel The useable fuels and their respective specifications can be found in the Engine manufacturer’s documentation.
6.3.2
Engine coolant admixtures The specifications and admixture ratios can be found in the Engine manufacturer’s documentation.
6.3.3
Windscreen washing system admixtures Commercial cleansers and antifreeze may be added to the windscreen washing water. Observe the application instructions on the package.
Fuel for crane cab heating system Only if the truck crane is fitted with a separate tank for the auxiliary heater, you have the option of selecting whether to use the same fuel as in section 6.3.1 or to use the EL heating oil.
6-4
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Maintenance manual GMK 5170
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6.3.4
7 7
Maintenance work on the carrier
7.1
General instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 -
1
Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 -
1
7.2
Symbols for maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 -
3
7.3
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 -
5
7.1.1
7.3.1 7.3.2 7.3.3 7.3.4 7.3.5 7.3.6 7.4 7.4.1 7.4.2 7.4.3 7.5 7.5.1 7.5.2 7.5.3 7.6 7.6.1 7.6.2 7.6.3 7.7 7.7.1 7.7.2 7.7.3 7.7.4 7.7.5 7.7.6 7.7.7 7.8 7.8.1 7.8.2 7.8.3 7.8.4
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7.9
Checking the oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 5 Topping up the oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 7 Installing the drain valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 8 Checking the air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 9 Checking the coolant level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 10 General inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 11 Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 13 Draining off water from fuel filter 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 14 Changing fuel filter 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 15 Changing fuel filter 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 17 Automatic transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 21 Checking the oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 21 General inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 25 Changing the oil and the oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 26 Transfer case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 29 General inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 29 Checking the oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 29 Changing the oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 30 Axle lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 33 General inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Checking the oil level on axle centre drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Axle centre drives – changing the oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Final drives – checking the oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Final drives – changing the oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Lubricating the cardan shafts on the axle lines . . . . . . . . . . . . . . . . . . . . . . . . . 7 Lubricating longitudinal cardan shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 -
33 33 35 38 39 41 42
Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 43 Checking the tyres for damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Checking the tyre air pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Check tightness of wheel nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Tyre change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 -
43 44 45 46
Vehicle brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 49
7.9.1
Checking brake-lining thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 49
7.10
Suspension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 51
7.10.1 7.10.2 7.10.3 7.10.4
Suspension struts – checking the oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Suspension struts – checking the fastening . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Forced lever – checking correct functioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Pressure accumulator – checking the gas pressure . . . . . . . . . . . . . . . . . . . . . . 7 -
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51 52 53 54
7.11.1 7.11.2 7.12 7.12.1 7.12.2 7.12.3 7.13 7.13.1 7.13.2 7.13.3 7.13.4 7.13.5 7.13.6 7.13.7 7.13.8 7.14 7.14.1 7.14.2 7.14.3 7.15 7.15.1 7.15.2 7.15.3 7.16 7.16.1 7.16.2 7.16.3 7.16.4 7.17 7.17.1 7.17.2 7.18 7.18.1 7.18.2 7.18.3 7.18.4 7.18.5 7.18.6 7.18.7 7.19 7.19.1 7.19.2 7.19.3
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 55 Checking for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 55 Pressure accumulator – checking the gas pressure . . . . . . . . . . . . . . . . . . . . . 7 - 56 Compressed air system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 57 Draining the compressed air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 57 Checking for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 58 Replacing the filter cartridge of the compressed air drier . . . . . . . . . . . . . . . . . 7 - 59 Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 61 Checking the oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking the hydraulic hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning the magnetic rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Changing the ventilation filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Taking oil samples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Changing the hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Changing the hydraulic oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
77777777-
61 62 63 64 66 67 70 74
Central lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 77 Checking the level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 77 Bleeding the central lubrication system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 79 Triggering intermediate lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 79 Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 81 Checking the lighting and indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 81 Checking the batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 82 Checking the charge level of the batteries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 84 Air-conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 87 Checking the air-conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning the condenser fins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking the entire air-conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . .
7777-
87 87 88 88
Particulate filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 91 Checking the clamp straps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 91 Replacing the particulate filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 92 Towbar coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 95 Lubricating the towbar coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking the bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking the cotter pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking the lower bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking the initial tension of the springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking the support ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking the function of the coupling jaw/Resetting central position . . . . . .
7 - 95 7 - 97 7 - 98 7 - 99 7 - 99 7 - 100 7 - 100
Other maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 103 Lubricating the support bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 103 Checking the auxiliary heater for correct operation . . . . . . . . . . . . . . . . . . . . . 7 - 104 Having the fire extinguisher checked . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 104
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Maintenance manual GMK 5170
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7.11
Maintenance work on the carrier 7.1 General instructions
7
Maintenance work on the carrier
7.1
General instructions
7.1.1
Covers Various types of work (e.g. oil change) require that the covers be removed. Before maintenance work
• Remove the covers (1). After maintenance work
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• Fasten the covers (1) with the locks.
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7-1
Maintenance work on the carrier 7.1 General instructions
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7-2
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Maintenance manual GMK 5170
Maintenance work on the carrier 7.2 Symbols for maintenance work
7.2
Symbols for maintenance work Check the following symbols daily before starting operations.
On the ECOS display
• Open the Warning submenu; à Operating instructions. If one of the symbols is displayed, you must carry out the appropriate maintenance work:
– Oil pressure;
à p. 7 - 5,
– Coolant level;
– Air filter;
à p. 7 - 10.
à p. 7 - 9,
– Hydraulic oil filter;
à p. 7 - 74.
On the particulate filter display If one of the symbols (1) lights up in orange and/or the warning buzzer sounds, you must carry out the appropriate maintenance work:
à p. 7 - 92.
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1 Particulate filter;
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7-3
Maintenance work on the carrier 7.2 Symbols for maintenance work
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7-4
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Maintenance manual GMK 5170
Maintenance work on the carrier 7.3 Engine
7.3
Engine • In addition, carry out further maintenance work on the Engine manufacturer’s documentation supplied. Pay attention to the information relating to use of bio-diesel fuel – the oil change interval must be halved.
• At the first oil change, fit a drain valve in place of the drain plug;
à p. 7 - 8.
7.3.1
Checking the oil level
Prerequisites
– The truck crane is horizontal.
Checking the oil level
• Start the engine.
S
D
Risk of damage to the engine if the oil pressure is too low If the symbol L still lights up after 10 seconds, turn off the engine and look for the cause; Operating instructions – Engine malfunctions.
à
• Start the engine and observe the display. • Symbol (1) should not be lit for more than 10 seconds after starting the engine.
• Allow the engine to run at idling speed for 2 - 3 minutes. • Switch off the engine.
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• Check the oil level after about two minutes.
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7-5
Maintenance work on the carrier 7.3 Engine
• On the dipstick, check whether the oil level is between the min. and the max. marks (arrows).
• Put the dipstick into the dipstick tube after checking the oil level. If the oil level is too low:
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• Add more oil, à p. 7 - 7.
7-6
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Maintenance manual GMK 5170
Maintenance work on the carrier 7.3 Engine
7.3.2
Topping up the oil Data on the prescribed oil specification; tion.
à Engine manufacturer's documenta-
Oil Engine oil in litres 38
Prerequisites
Designation according to DIN 51502
Specification Classification
GROVE part no.
HD - CD
MIL-L 2104 C DB 228.5
SAE 15 W-40 03329588
– The truck crane is horizontal. – The engine is switched off and secured against unauthorised use; p. 2 - 3.
à
Topping up oil
S G
Risk of damage to the engine if the oil level is too high! Do not overfill; the oil level must not be higher than the max. mark (arrow). Drain off oil if necessary; Engine manufacturer's documentation.
à
Risk of burning yourself when the engine is hot! During operation, the engine and add-on parts can reach temperatures of up to 400 °C. Wear appropriate protective gloves and be careful not to touch hot parts.
• Add oil through the filler neck (1) up to the max. mark.
• Close the filler neck with the lid. • Put the dipstick into the dipstick tube after
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checking the oil level.
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7-7
Maintenance work on the carrier 7.3 Engine
7.3.3
Installing the drain valve You can replace the drain plug on the oil pan with a valve. This makes it easier to check the draining oil during subsequent oil changes.
Spare parts and tools
Designation
Quantity
GROVE part no.
Valve
1
03046878
Gasket 26 x 31 Cu DIN 7603
1
00117147
– Drain channel. – Torque wrench for torque of 60 Nm.
Prerequisites
– The truck crane is horizontal. – The engine is switched off and secured against unauthorised use; p. 2 - 3.
à
Installing the valve
• Use a drain channel when draining the oil. • Drain the engine oil as described in Engine manufacturer’s documentation.
• Replace the gasket and tighten the valve (1) – torque 60 Nm.
• Check the valve for tightness after filling up with oil.
Next time you change the oil, you can drain the oil in the same way as described for taking oil samples from the hydraulic tank; Taking oil samples, p. 7 - 67. 29.04.2008
à
7-8
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Maintenance manual GMK 5170
Maintenance work on the carrier 7.3 Engine
7.3.4
D
Checking the air filter • Start the engine and observe the display. • The filter must be replaced if the display shows the symbol (1).
• Switch off the engine.
Spare parts and tools
Designation Filter
Prerequisites
Quantity
GROVE part no.
1
03 328 262
– The engine is switched off and secured against unauthorised use; p. 2 - 3.
à
Replacing the air filter
• Remove the plate (4). • Undo all the clamps (1) and remove the lid (2).
• Change the filter (3). • Place back the lid and secure it with all the clamps.
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• Attach the plate.
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7-9
Maintenance work on the carrier 7.3 Engine
7.3.5
D
Checking the coolant level • Start the engine and observe the display.
Coolant must be filled if the display shows the symbol (1).
• Switch off the engine.
Topping up coolant
G
Danger of being scalded due to hot radiator circuit! The hot radiator circuit is under pressure. When you open the expansion tank, you could be scalded by escaping steam or coolant. Wear suitable protective gloves and cover the cap on the expansion tank with a rag before opening it. Turn the cap slowly to the first detent in order to allow the pressure to be released.
• Do not open the pressure relief valves (2). • Loosen (do not open!) the cap (1) to reduce the pressure if the coolant is at operating temperature.
• Open the cap (1). The coolant level must be at the lower edge in the filler neck. If the coolant level is too low:
• Top up the coolant. Composition of the coolant; Engine manufacturer's documentation.
à
S 7 - 10
Risk of damage to engine due to lack of coolant! If the coolant has to be topped up frequently, the cooling system may be leaking. Have the cooling system checked by CraneCARE or your repair crew.
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Maintenance manual GMK 5170
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• Close the cap (1).
Maintenance work on the carrier 7.3 Engine
7.3.6
General inspection
W
• Investigate any unusual noises from the engine. • Check the engine and the connections for leaks. In the event of leaking consumables; Checking the oil level, p. 7 - 5, Checking the coolant level, p. 7 - 10.
à à
• Check that pipes and hoses are tightly connected and not damaged.
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If any damage is found, report it CraneCARE.
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7 - 11
Maintenance work on the carrier 7.3 Engine
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7 - 12
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Maintenance manual GMK 5170
Maintenance work on the carrier 7.4 Fuel system
7.4
Fuel system Installed in the fuel line are: 1 Fuel filter 1
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2 Fuel filter 2
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7 - 13
Maintenance work on the carrier 7.4 Fuel system
7.4.1
D
Draining off water from fuel filter 1
à p. 2 - 4.
Spare parts and tools
– Receptacle, approx. 5 l;
Prerequisites
– The truck crane is horizontal. – The engine is switched off and secured against unauthorised use; p. 2 - 3.
à
Draining off water
O
Risk of environmental damage due to leaking consumables! Always let consumables drain into suitable receptacles. Wipe up any fluids that have leaked. Store/dispose of fluids and any soaked equipment properly. Ask about the applicable regulations.
• Place a receptacle underneath the filter. • Open the valve (1). • If the consumable is clean, close the valve manually.
• Remove the receptacle and properly dis-
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pose of the drained consumable.
7 - 14
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Maintenance manual GMK 5170
Maintenance work on the carrier 7.4 Fuel system
7.4.2 Spare parts and tools
Designation
Quantity
GROVE part no.
Filter
1
03322877
Gasket
1
03322879
Filter element
1
03328656
– Receptacle, approx. 5 l;
Prerequisites
M3
Changing fuel filter 1
à p. 2 - 4.
– The truck crane is horizontal. – The engine is switched off and secured against unauthorised use; p. 2 - 3.
à
– If the fuel is contaminated: shorten the maintenance interval.
Changing
O
Risk of environmental damage due to leaking consumables! Always let consumables drain into suitable receptacles. Wipe up any fluids that have leaked. Store/dispose of fluids and any soaked equipment properly. Ask about the applicable regulations.
• Place a receptacle underneath the filter. • Close the valve – lever (1) at right angles to the line.
• Open the screw plug (2) and the valve (3) and drain the fluid.
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7 - 15
Maintenance work on the carrier 7.4 Fuel system
• (A) – Remove the filter element (2) and the filter (1). If necessary, replace any damaged parts.
• (B)) – Screw on a new filter (1) and the filter element (2).
• Close the valve (3) manually.
• Open the valve (1) – lever parallel with the line.
• Actuate the pump (3) until the consumable flowing through the bolt (2) no longer contains any bubbles.
• Secure the bolt. • Start the engine and check for leaks. • Remove the receptacle.
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H
If you have used a clean receptacle, you can refill the fuel tank with the consumable using a strainer. Otherwise dispose of the consumable properly.
7 - 16
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Maintenance manual GMK 5170
Maintenance work on the carrier 7.4 Fuel system
7.4.3
M 12
Changing fuel filter 2
Spare parts and tools
Designation
Quantity
GROVE part no.
1
03 045 818
Filter and gasket – Receptacle, approx. 5 l;
à p. 2 - 4.
– Torque wrench for torque of 25 Nm.
Prerequisites
– The truck crane is level and on outriggers; – The main boom is fully retracted;
à Operating instructions
à Operating instructions
– The engine is switched off and secured against unauthorised use; p. 2 - 3.
à
O
Risk of environmental damage due to leaking consumables! Always let consumables drain into suitable receptacles. Wipe up any consumables that have leaked. Store/dispose of consumables and any soaked equipment properly. Ask about the applicable regulations.
Emptying the fuel line
• Place a receptacle underneath the filter. • Close the valve – lever (1) at right angles to the line.
• Open the bolt (2) and let the consumable drain.
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7 - 17
Maintenance work on the carrier 7.4 Fuel system
• Place a receptacle under the end of the hose (2).
• (A) – Turn the valve – lever (1) horizontal. • Let the consumable drain. • (B) – Turn the valve – lever (1) vertical. Leave the receptacle under the hose. More consumable will run out during bleeding.
Changing the filter
• Remove the covers that are on the engine; à p. 7 - 1. • Unscrew the cap (1) and remove the filter (3). Let the remaining consumable drain.
• Remove the cap and remove the filter by applying pressure to the sides of its lower edge.
• Insert a new gasket (2) (grease lightly) and clip a new filter into the lid.
• Screw the lid with the filter into the housing
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and tighten it – torque 25 Nm.
7 - 18
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Maintenance manual GMK 5170
Maintenance work on the carrier 7.4 Fuel system
Bleeding the fuel line There is a receptacle under the hose end (2).
• Close the vent screw (4). • Open the valve – lever (5) parallel to the line. • Open the valve – lever (1) horizontal. • Actuate the pump (3) until the consumable flowing through the end of the hose no longer contains any bubbles.
• Turn the valve – lever (1) vertical. • Start the engine and check that the fuel filters are not leaking.
• Remove the receptacle underneath the hose end (2).
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H
If you have used a clean receptacle, you can refill the fuel tank with the consumable using a strainer. Otherwise, dispose of the consumables properly.
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7 - 19
Maintenance work on the carrier 7.4 Fuel system
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7 - 20
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Maintenance manual GMK 5170
Maintenance work on the carrier 7.5 Automatic transmission
7.5
Automatic transmission
7.5.1
Checking the oil level
Prerequisites
– The oil level pre-check has been carried out; p. 7 - 22.
D
à Prior to starting the engine,
– The engine is switched off and secured against unauthorised use; p. 2 - 3.
à
Three types of oil level inspection
S
Risk of damage to the automatic transmission The correct oil level must be maintained to ensure smooth operation of the automatic transmission: – if the oil level is too low, malfunctions will occur, – if the oil level is too high, loss of power and overheating will occur.
The oil level can be checked in three different ways, depending on the conditions:
à p. 7 - 22, – when the gear oil is warm; à p. 7 - 23, – via the oil level sensor; à Operating instructions. – when the gear oil is cold;
H
Check with warm gear oil for the most accurate reading of the oil level in the automatic transmission.
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7 - 21
Maintenance work on the carrier 7.5 Automatic transmission
Prior to starting the engine
S
Risk of damage to the transmission! The engine must not be started without a prior check of the gear oil level. This prevents gear damage being caused by undetected loss of oil.
• Remove the dipstick (1) and check whether the oil level is around the (2) mark.
• Insert the dipstick into the dipstick tube. If the oil level is too low:
• Top up oil via the dipstick tube. Follow-up check:
• Carry out another check when the gear oil is cold;
When the gear oil is cold
à p. 7 - 22.
Gear oil temperature 15 to 50 °C.
• Pre-check the oil level in the automatic transmission daily before starting
à p. 7 - 22. Start the engine; à Operating instructions. Check the gear oil temperature; à Operating instructions. the engine;
• •
S
Risk of damage to the transmission when warming up When the wheels are locked, the full engine output may only be applied in transmission mode D or R for a maximum of 30 seconds. If this duration is exceeded, the transmission could become overheated and get damaged.
• First switch to transmission mode D and then to R and allow the engine • Switch to neutral position N and let the vehicle run at idling speed. If the outside temperature is low, allow the engine to run for a few minutes longer.
7 - 22
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Maintenance manual GMK 5170
29.04.2008
to run briefly at approx. 1200 - 1500 min-1 in each transmission mode.
Maintenance work on the carrier 7.5 Automatic transmission
• Remove the dipstick (1) and check whether the oil level is in the (2) range.
• Insert the dipstick into the dipstick tube. If the oil level is too high:
• Drain off oil until it is below the (4) mark;
à p. 7 - 27.
If the oil level is too low:
• Top up the oil via the dipstick tube until the (3) mark is exceeded. Follow-up check:
• Carry out another check when the gear oil is warm;
When the gear oil is warm
à p. 7 - 23.
Gear oil temperature 75 to 95 °C.
• Pre-check the oil level in the automatic transmission daily before starting the engine;
H
à Prior to starting the engine, p. 7 - 22.
To prevent damage to the transmission, the oil level check is at its most relevant when the gear oil is warm. Gear oil is warmed up – when the vehicle is stationary; – or when driving;
à p. 7 - 23,
à p. 7 - 24.
Warming up when stationary
• Start the engine. • Allow the engine to run at idling speed in the neutral position N until the gear oil temperature is 75 °C.
• Check the gear oil temperature; à Operating instructions. • Check the oil level; à p. 7 - 25.
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7 - 23
Maintenance work on the carrier 7.5 Automatic transmission
If you want to accelerate the warming procedure when the vehicle is stationary:
• Fully depress the service brake pedal, even if the parking brake is on.
S S
Risk of damage to the transmission when accelerating the warming up procedure! When the wheels are locked, the full engine output may only be applied in transmission mode D or R for a maximum of 30 seconds. If this duration is exceeded, the transmission could become overheated and get damaged. Coolant loss through overheating when the warming up procedure is accelerated! When the wheels are locked, the coolant can overheat – even when coolant temperatures are under 70 °C on the display. The coolant then leaks from the expansion tank.
• First switch to transmission mode D and then to R and allow the engine to run briefly at approx. 1200 - 1500 min-1 in each transmission mode.
• Allow the engine to run at idling speed in the neutral position N until the gear oil temperature is 75 °C. Check the gear oil temperature;
à Operating instructions.
• Check the oil level; à p. 7 - 25.
Warming up when driving
• Drive the truck crane until the coolant temperature is 70 °C. Check the gear oil temperature;
à Operating instructions.
• Check the oil level; à p. 7 - 25.
• Align the truck crane horizontally. • Engage the parking brake.
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• Switch to the neutral position N.
7 - 24
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Maintenance manual GMK 5170
Maintenance work on the carrier 7.5 Automatic transmission
Checking the oil level
• Remove the dipstick (1) and check whether the oil level is in the (2) range.
• Insert the dipstick into the dipstick tube. If the oil level is too low:
• Top up the oil via the dipstick tube until the (3) mark is exceeded. If the oil level is too high:
• Drain off oil until it is below the (4) mark;
à p. 7 - 27.
7.5.2
General inspection
W
• Pay attention to any unusual noises in the automatic transmission. • Check the transmission and the connections for leaks. In the event of leaking consumables;
à Checking the oil level, p. 7 - 21.
• Check that pipes and hoses are tightly connected and not damaged.
29.04.2008
If you detect any worn or damaged parts, contact CraneCARE.
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7 - 25
Maintenance work on the carrier 7.5 Automatic transmission
7.5.3
Y2
Changing the oil and the oil filter
Spare parts and tools
Designation
Quantity
GROVE part no.
Filter with set of gaskets
2
03 326 293
Gasket 30 x 36 Cu DIN 7603
1
00 117 151
– Receptacle, approx 50 l;
à p. 2 - 4.
– Torque wrench for tightening torque of 25-32 Nm and 50-55 Nm.
Prerequisites
– The gear oil is at operating temperature (70 to 95 °C). – The truck crane is raised on outriggers or parked over an inspection pit. – The engine is switched off and secured against unauthorised use; p. 2 - 3.
à
Changing the oil and the oil filter
Risk of environmental damage due to leaking consumables! Always let consumables drain into suitable receptacles. Wipe up any consumables that have leaked. Store/dispose of consumables and any soaked equipment properly. Ask about the applicable regulations.
29.04.2008
G O
Risk of burning yourself on gear oil at operating temperature! You could burn yourself if unchecked gear oil escapes at operating temperature. Wear appropriate protective gloves and be careful not to touch the gear oil.
7 - 26
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Maintenance manual GMK 5170
Maintenance work on the carrier 7.5 Automatic transmission
Draining oil
• Pull out the dipstick (1). • Place a receptacle under the bolt (2). • Unscrew the bolt and let the oil drain off.
Changing the oil filter
• Loosen the lid (1) and pull out the filters. • Insert new filters. • Replace the gaskets and tighten the covers – torque 50-55 Nm.
• Replace the gasket and tighten the bolt (2) – torque 25-32 Nm.
Topping up oil
• Top up the oil (46.0 l) through the dipstick tube (1).
• Wait unit the oil has been evenly distributed. • Use the dipstick to check whether the oil level is clearly above the (2) mark, otherwise the engine may not be started.
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7 - 27
Maintenance work on the carrier 7.5 Automatic transmission
Inspections after the oil change
G
• Check the oil level as described; à When the gear oil is cold, p. 7 - 22 Risk of accidents when searching for leaks under the truck crane! Ensure that the parking brake is engaged before you go underneath the truck crane to search for leaks. Keep away from rotating parts.
• Check the transmission for leaks on the lids of the oil filters and at the oil drain plug.
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• Check the oil level as described; à When the gear oil is warm, p. 7 - 23
7 - 28
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Maintenance manual GMK 5170
Maintenance work on the carrier 7.6 Transfer case
7.6
Transfer case The transfer case is screwed to the axle centre drive of the third axle line. The axle centre drive and the transfer case have two separate oil chambers. Comply also with the
7.6.1
à Run-in regulations, p. 4 - 1. W
General inspection • Pay attention to any unusual noises in the transfer case.
• Check the transfer case and the connections for leaks. In the event of leaking consumables;
à Checking the oil level, p. 7 - 29.
• Check that pipes and hoses are tightly connected and not damaged. If any damage is found, report it CraneCARE.
7.6.2 Spare parts and tools
Designation Gasket 30 x 36 Cu DIN 7603
Prerequisites
M1
Checking the oil level
Quantity
GROVE part no.
1
00117151
– The truck crane is raised on outriggers or parked over an inspection pit. – The engine is switched off and secured against unauthorised use; p. 2 - 3.
à
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7 - 29
Maintenance work on the carrier 7.6 Transfer case
Checking the oil level
• Remove the bolt (1). • Check whether the oil reaches the lower edge of the opening.
• Fit a new gasket and tighten the bolt. If the oil level is too low:
• Add more oil, à p. 7 - 31.
Oil, spare parts, tools
M6
Changing the oil
Gear oil in litres 13
Designation according to DIN 51502
Specification Classification
GROVE part no.
C - LPF
MIL-L 2105 B API-GL-5 Viscosity: Hyp SAE 90 ISO - VG 220
00552891
Designation
Quantity
GROVE part no.
Gasket 16 x 20 Cu DIN 7603
1
00 117 134
Gasket 30 x 36 Cu DIN 7603
1
00 117 151
– Receptacle, approx. 20 l;
Prerequisites
à p. 2 - 4.
– The gear oil is at operating temperature. – The truck crane is raised on outriggers or parked over an inspection pit. – The engine is switched off and secured against unauthorised use; p. 2 - 3.
à
7 - 30
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Maintenance manual GMK 5170
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7.6.3
Maintenance work on the carrier 7.6 Transfer case
Changing the oil
G O
Risk of burning yourself on gear oil at operating temperature! You could burn yourself if unchecked gear oil escapes at operating temperature. Wear appropriate protective gloves and be careful not to touch the gear oil. Risk of environmental damage due to leaking consumables! Always let consumables drain into suitable receptacles. Wipe up any consumables that have leaked. Store/dispose of consumables and any soaked equipment properly. Ask about the applicable regulations.
• Place a receptacle under the bolt (2). • Unscrew the bolts (1) and (2) and let the oil drain off.
• Fit new gaskets and tighten the bolt (2). • Top up oil through the opening (1).
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• Fit new gaskets and tighten the bolts (1).
Maintenance manual GMK 5170
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7 - 31
Maintenance work on the carrier 7.6 Transfer case
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7 - 32
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Maintenance manual GMK 5170
Maintenance work on the carrier 7.7 Axle lines
7.7
Axle lines • Comply also with the à Run-in regulations, p. 4 - 1.
7.7.1
W
General inspection
• Pay attention to any unusual running noises from the axle centre drives and the final drives.
• Check the axle centre drives/final drives and the connections for leaks. In the event of leaking consumables; Checking the oil level on axle centre drives, p. 7 - 33, Final drives – checking the oil level, p. 7 - 38.
à à
• Check that pipes and hoses are tightly connected and not damaged. If any damage is found, report it CraneCARE.
7.7.2 Spare parts and tools
For drive 10 x 6 x 10
10 x 8 x 101)
1)
Prerequisites
M1
Checking the oil level on axle centre drives
Designation
Quantity GROVE part no.
Gasket 30 x 38 Cu DIN 7603
2
01 925 343
Gasket 16 x 20 Cu DIN 7603
1
00 117 134
Gasket 16 x 22 Cu DIN 7603
1
00 117 135
Gasket 30 x 38 Cu DIN 7603
3
01 925 343
Gasket 16 x 20 Cu DIN 7603
1
00 117 134
Gasket 16 x 22 Cu DIN 7603
1
00 117 135
Additional equipment (2nd driven axle line)
– The truck crane is raised on outriggers or parked over an inspection pit. – The engine is switched off and secured against unauthorised use; p. 2 - 3.
à
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7 - 33
Maintenance work on the carrier 7.7 Axle lines
2nd and 5th axle lines
• Remove the bolt (1). • Check whether the oil reaches the lower edge of the opening.
• Fit a new gasket and tighten the bolt. If the oil level is too low:
• Add more oil, à p. 7 - 36.
3rd axle line
• Remove the bolt (1). • Check whether the oil reaches the lower edge of the opening.
• Fit a new gasket and tighten the bolt. If the oil level is too low:
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• Add more oil, à p. 7 - 36.
7 - 34
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Maintenance manual GMK 5170
Maintenance work on the carrier 7.7 Axle lines
4th axle line The drive has two oil chambers.
• Unscrew bolts (1) and (2). • Check that the oil reaches the lower edge of the openings.
• Fit new gaskets and tighten the bolts. If the oil level is too low:
• Add more oil, à p. 7 - 37.
7.7.3 Oil, spare parts, tools
Gear oil in litres
Designation according to DIN 51502
Specification Classification
GROVE part no.
Axle lines 2+5: each 13.0
C - LPF
MIL-L 2105 B API-GL-5 Viscosity: Hyp SAE 90 ISO - VG 220
00552891
Axle line 3+4: each 16.5 For drive
10 x 6 x 10
10 x 8 x 101)
1) 29.04.2008
M 12
Axle centre drives – changing the oil
Designation
Quantity GROVE part no.
Gasket 36 x 42 Cu DIN 7603
2
01 371 208
Gasket 30 x 38 Cu DIN 7603
1
01 925 343
Gasket 16 x 22 Cu DIN 7603
2
00 117 135
Gasket 36 x 42 Cu DIN 7603
3
01 371 208
Gasket 30 x 38 Cu DIN 7603
2
01 925 343
Gasket 16 x 22 Cu DIN 7603
2
00 117 135
Additional equipment (2nd driven axle line)
– Receptacle, approx 20 l;
à p. 2 - 4.
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7 - 35
Maintenance work on the carrier 7.7 Axle lines
Prerequisites
– The truck crane is raised on outriggers or parked over an inspection pit. – The engine is switched off and secured against unauthorised use; p. 2 - 3.
à
O
Risk of environmental damage due to leaking consumables! Always let consumables drain into suitable receptacles. Wipe up any consumables that have leaked. Store/dispose of consumables and any soaked equipment properly. Ask about the applicable regulations.
2nd and 5th axle lines
• Place a receptacle under the bolt (2). • Unscrew the bolts (1) and (2) and let the oil drain off.
• Fit a new gasket and tighten the bolt (2). • Fill the oil up to the lower edge of the opening.
• Fit a new gasket and tighten the bolt (1).
3rd axle line
• Screw the plug out of the hole (1). • Check the oil level. It must reach the lower edge of the opening (1). If the oil level is too low:
• Top up oil through the hole (1).
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• Replace the gasket and close the hole (1).
7 - 36
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Maintenance manual GMK 5170
Maintenance work on the carrier 7.7 Axle lines
4th axle line
S
The drive has two oil chambers. Risk of oil overheating! When topping up the oil, both openings must be open so that both oil chambers are filled equally. This prevents both oil chambers from being overfilled and thus the oil from overheating.
• Place a receptacle under bolts (3) and (4). • Unscrew bolts (1), (2), (3) and (4) and let the oil drain off.
• Fit new gaskets and tighten bolts (3) and (4). • Top up oil only through hole (2) until it runs out of hole (1).
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• Fit new gaskets and tighten bolts (1) and (2).
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7 - 37
Maintenance work on the carrier 7.7 Axle lines
7.7.4 Spare parts and tools
For drive
Designation
Quantity GROVE part no.
10 x 6 x 10
Gasket 24 x 29 Cu DIN 7603
6
00117145
10 x 8 x 101)
Gasket 24 x 29 Cu DIN 7603
8
00117145
1)
Prerequisites
M1
Final drives – checking the oil level
Additional equipment (2nd driven axle line)
– The truck crane is raised on outriggers and in horizontal position. – The engine is switched off and secured against unauthorised use; p. 2 - 3.
à
– The parking brake is released.
Checking the oil level
• Check the oil level at all other final drives in the same way.
• Turn the wheel until the (2) mark is horizontal and is on the right, next to the centre of the axle.
• Remove the bolt (1). • Check whether the oil level is at the (2) mark. • Fit a new gasket and tighten the bolt. If the oil level is too low:
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• Add more oil, à p. 7 - 40.
7 - 38
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Maintenance manual GMK 5170
Maintenance work on the carrier 7.7 Axle lines
7.7.5
M 12
Final drives – changing the oil
Oil, spare parts, tools
Gear oil in litres each final drive:
Designation according to DIN 51502
Specification Classification
GROVE part no.
C - LPF
MIL-L 2105 B API-GL-5 Viscosity: Hyp SAE 90 ISO - VG 220
00552891
4.1
For drive
Designation
Quantity
GROVE part no.
10 x 6 x 10
Gasket 24 x 29 Cu DIN 7603
6
00117145
10 x 8 x 101)
Gasket 24 x 29 Cu DIN 7603
8
00117145
1)
Additional equipment (2nd driven axle line)
– Drain channel. – Receptacle, approx 5 l;
Prerequisites
à p. 2 - 4.
– The truck crane is raised on outriggers.. – The engine is switched off and secured against unauthorised use; p. 2 - 3.
à
– The parking brake is released.
O
Risk of environmental damage due to leaking consumables! Always let consumables drain into suitable receptacles. Wipe up any consumables that have leaked. Store/dispose of consumables and any soaked equipment properly. Ask about the applicable regulations.
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7 - 39
Maintenance work on the carrier 7.7 Axle lines
Draining oil
• Change the oil on all final drives in the same way.
• Turn the wheel until bolt (1) is at the bottom. • Use a drain channel and place a receptacle under the bolt.
• Unscrew the bolt and let the oil drain off.
Topping up the oil
• Turn the wheel until the (2) mark is horizontal and is on the right, next to the centre of the axle.
• Top up the oil through the hole.
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• Fit a new gasket and tighten the bolt (1).
7 - 40
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Maintenance manual GMK 5170
Maintenance work on the carrier 7.7 Axle lines
7.7.6
M1
Lubricating the cardan shafts on the axle lines
H Grease, spare parts, tools
Check all cardan shafts to see if they have grease nipples. Cardan shafts with grease nipples must be serviced, cardan shafts without grease nipples are maintenance-free.
Lubricating grease Grease
Designation according to DIN 51502
Specification Classification
GROVE part no.
KP - L2K
DIN 51825
00554201
– Grease gun from the tool set.
Prerequisites
– The truck crane is raised on outriggers or parked over an inspection pit. – The engine is switched off and secured against unauthorised use; p. 2 - 3.
à
– The wheels are turned as far as they will go, so that the grease nipples on the sides of the final drives are more easily accessible.
Lubricating Cardan shafts (2) are fitted only to the 10 x 8 x 10 drive.
• Check which cardan shafts (1) and (2) have grease nipples (3).
• Clean the grease nipples (3). • Inject grease into the grease nipples until grease escapes from the bearing points. Do not inject with grease with excessive force, otherwise the lip seals may be damaged.
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• Remove the excess grease.
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7 - 41
Maintenance work on the carrier 7.7 Axle lines
7.7.7
M6
Lubricating longitudinal cardan shafts
H Grease, spare parts, tools
Check all cardan shafts to see if they have grease nipples. Cardan shafts with grease nipples must be serviced, cardan shafts without grease nipples are maintenance-free.
Lubricating grease Grease
Designation according to DIN 51502
Specification Classification
GROVE part no.
KP - L2K
DIN 51825
00554201
– Grease gun from the tool set.
Prerequisites
– The truck crane is raised on outriggers or parked over an inspection pit. – The engine is switched off and secured against unauthorised use; p. 2 - 3.
à
Lubricating The cardan shaft (2) is fitted only to the 10 x 8 x 10 drive.
• Check which cardan shafts (1) and (2) have grease nipples (3).
• Clean the grease nipples (3). • Inject grease into the grease nipples until grease escapes from the bearing points. Do not inject with grease with excessive force, otherwise the lip seals may be damaged.
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• Remove the excess grease.
7 - 42
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Maintenance manual GMK 5170
Maintenance work on the carrier 7.8 Wheels
7.8
Wheels
7.8.1
Checking the tyres for damage
Prerequisites
D
– The truck crane is raised on outriggers.. – The engine is switched off and secured against unauthorised use; p. 2 - 3.
à
– The parking brake is released.
Checking
• Check all tyres for: – chunking – dents – areas of uneven wear – reaching the wear mark (1).
• Replace the damaged tyres. • If the tyres show varying wear, change the tyres (
Risk of accidents due to uneven braking! When changing the tyres, only use tyres of original equipment quality (dimensions, load bearing capacity, air pressure) so that driving characteristics are maintained. Always replace the tyres on one axle line.
29.04.2008
S
à Tyre change, p. 7 - 46).
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7 - 43
Maintenance work on the carrier 7.8 Wheels
7.8.2
S
W
Checking the tyre air pressure
Risk of damage to the tyres! The air pressure increases when the tyres are at operating temperature. Never release the increased air pressure of tyres at operating temperature! Always check the air pressure in on-road driving mode with cold tyres.
• Check the tyre pressure using the following table. Air pressure of cold tyres in bar
14.00 R 25
10.0
16.00 R 25
9.0
20.50 R 25
7.0
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Tyres
7 - 44
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Maintenance manual GMK 5170
Maintenance work on the carrier 7.8 Wheels
7.8.3
M1
Check tightness of wheel nuts
Spare parts and tools
Designation
Quantity per wheel
GROVE part no.
12
01207756
Wheel nut with pressure plate – Torque wrench for 650 Nm.
Prerequisites
– The engine is switched off and secured against unauthorised use; p. 2 - 3.
à
Checking the wheel nuts
• Check the wheel nuts and the pressure plates for damage.
• Replace any damaged wheel nuts or pressure plates.
• Check the wheel nuts in sequence (1-12) for
29.04.2008
a tight fit – torque 650 Nm.
Maintenance manual GMK 5170
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7 - 45
Maintenance work on the carrier 7.8 Wheels
7.8.4
M6
Tyre change The wear on tyres varies depending on whether the axle
– is driven/not driven, – is steered/not steered, – is braked/not braked, – and whether it is subject to more or less load. To achieve even wear, you must swap the wheels to different positions regularly. This will have a positive effect on tyre life and performance.
Spare parts and tools
Designation
Quantity per wheel
GROVE part no.
Wheel nut with pressure plate
12
01207756
Wheel rim sealing ring1)
1
00558261
1)
required only in case of optimised tyre change.
– Torque wrench for 650 Nm.
– The engine is switched off and secured against unauthorised use; p. 2 - 3.
à
29.04.2008
Prerequisites
7 - 46
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Maintenance manual GMK 5170
Maintenance work on the carrier 7.8 Wheels
Tyre change
G
Risk of accidents if procedure incorrect! This section shows only the sequence to be followed when changing tyres. When removing/installing the wheels, observe all the safety instructions and the procedure stated in the operating instructions.
• Remove the wheels from the axles. • Mount the wheels on another axle, as shown in the diagram. Replace any damaged parts. Tighten the wheel nuts;
à p. 7 - 45.
-
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Maintenance manual GMK 5170
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7 - 47
Maintenance work on the carrier 7.8 Wheels
Optimised tyre change
G G G
To ensure that the wear on all tyres is more or less the same, you can also rotate the tyres on the wheel rim and mount them on the other side of the vehicle. Risk of accidents if procedure incorrect! This section shows only the sequence to be followed when changing tyres. When removing/installing the wheels, observe all the safety instructions and the procedure stated in the operating instructions. Risk of accidents due to errors when installing aluminium wheel rims! Have tyres fitted to aluminium wheel rims only in a workshop with the correct special tool. This will prevent tyre damage caused by fitting errors. Risk of damage to tyres when running direction changed! Turn the tyres on the wheel rims before you put the wheels on the other side of the vehicle. This will prevent tyre damage caused by the tyres running in a different direction.
• Remove the wheels from the axles. • Turn the tyre on the rim if the wheel is to be used on the other side of the crane.
• Mount the wheels on another axle, as shown in the diagram. Replace any damaged parts. Tighten the wheel nuts;
à p. 7 - 45.
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-
7 - 48
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Maintenance manual GMK 5170
Maintenance work on the carrier 7.9 Vehicle brake
7.9
Vehicle brake
7.9.1
Checking brake-lining thickness
M3
• Check the brake-lining thickness (from the inner side) at openings (1). If the brake-lining thickness has worn down to the wear marks (stepped edges or grooves), or if the brake-lining thickness has worn down to only 3 mm:
• Have
CraneCARE or your repair crew change
the brake linings.
• Close off the openings using the covers.
29.04.2008
G
Risk of accidents due to uneven braking! If the brake lining is changed only on one side of the axle line, the wheels will have an uneven braking effect. Always replace the brake lining on both sides of an axle line.
Maintenance manual GMK 5170
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7 - 49
Maintenance work on the carrier 7.9 Vehicle brake
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Blank page
7 - 50
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Maintenance manual GMK 5170
Maintenance work on the carrier 7.10 Suspension
7.10
Suspension
7.10.1
Suspension struts – checking the oil level
Oil, spare parts, tools
M1
Oil in litres
Designation
GROVE part no.
for each suspension strut: 1.5
Gear oil
02310863
– Press with connected hose (from tool box).
Prerequisites
– The engine is switched off and secured against unauthorised use; p. 2 - 3.
à
– Immediately before the inspection, the truck crane was completely lowered and returned to On-road level; Operating instructions.
à
S S
Risk of damage due to faulty suspension struts! If the oil level is above the upper mark on the inspection glass, the suspension strut is faulty and must be replaced. Notify CraneCARE. Risk of damage to the suspension struts due to insufficient lubrication! It is difficult to inject the oil. Even so, do not fill oil through the inspection glass connections. If you do this, the oil will not reach all the lubricating points.
• Check whether oil is visible in the centre of the inspection glass (1) on each suspension strut. If the oil level is too low:
• Open the connection (2) – oil escapes – and quickly connect the press to the hose.
• Inject oil up the centre of the inspection glass.
• Remove the hose and quickly close the con29.04.2008
nection (2).
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7 - 51
Maintenance work on the carrier 7.10 Suspension
7.10.2
M1
Suspension struts – checking the fastening
Spare parts and tools
– Torque wrench for tightening torque up to 900 Nm.
Prerequisites
– The truck crane is raised on outriggers;
à Operating instructions.
– The engine is switched off and secured against unauthorised use; p. 2 - 3.
à
– The wheels have been removed.
• Check whether the bolts on all suspension struts are fitted tightly;
à Special torques, p. 10 - 2: 1 on the upper bracket, 2 on the lower bracket, 3 on the lower flange,
29.04.2008
4 on the half shells for the steering arm.
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Maintenance manual GMK 5170
Maintenance work on the carrier 7.10 Suspension
7.10.3
Forced lever – checking correct functioning
M3
On suspension struts with forced levers, the forced levers must be checked for proper functioning when the suspension is switched on and off.
G S
Risk of crushing when releasing the suspension locking system When the suspension is switched on, the wheels drop down suddenly. Ensure that nobody is close to the wheels when you switch on the suspension. Risk of damage to the tyres! Remove sharp-edged or pointed objects from below the wheels before switching on the suspension. In this way, you prevent the tyres bursting or being damaged when lowering the wheels.
• Start the engine. • Lower the truck crane to the lowest level with the level adjustment sys-
à Operating instructions. Switch off the suspension; à Operating instructions. tem;
•
The suspension struts and the forced levers (1) are brought together.
• Raise the truck crane with the outriggers; à Operating instructions. • Switch on the suspension; à Operating instructions.
• Check whether all suspension struts are extended and the forced levers (1) are relieved. If the suspension struts are not extended or only partially extended, the forced lever is faulty. 29.04.2008
• Faulty forced levers should be replaced as soon as possible by CraneCARE your repair crew.
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7 - 53
Maintenance work on the carrier 7.10 Suspension
7.10.4
Pressure accumulator – checking the gas pressure
M 12
The gas pressure must be checked every 3000 operating hours, but in any case at least once every 12 months.
G
Risk of accidents due to incorrect inspection! The gas pressure test must be carried out only by an authorised inspector of pressure tanks or under his supervision or instruction.
The suspension features integrated pressure accumulators that contain nitrogen (1). The filling pressure at 20 °C is 40 bar.
• Have the filling pressure checked and if nec-
29.04.2008
essary, set by CraneCARE.
7 - 54
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Maintenance manual GMK 5170
Maintenance work on the carrier 7.11 Steering
7.11
Steering
7.11.1
Checking for leaks
D
• Check the hydraulic system of the steering (steering cylinders, pipes and hoses and their connections) for leaks.
G
Risk of accidents from hydraulic oil spraying out! Never tighten leaking connections when the system is under pressure. Change pipes and hoses only when the system is depressurised.
• Top up oil if necessary; à Checking the oil level, p. 7 - 61. After changing pipes and hoses:
• Bleed the hydraulic system; à Bleeding the hydraulic system, p. 7 - 73. If damage cannot be rectified immediately or further damage is likely:
29.04.2008
• Notify CraneCARE or your repair crew.
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7 - 55
Maintenance work on the carrier 7.11 Steering
7.11.2
G
Pressure accumulator – checking the gas pressure
M 12
Risk of accidents due to incorrect inspection! The gas pressure test must be carried out only by an authorised inspector of pressure tanks or under his supervision or instruction.
Pressure accumulators containing nitrogen (1) have been built in for the steering of the 4th and 5th axle lines. The filling pressure at 20 °C is 80 bar.
• Have the filling pressure checked by
29.04.2008
CraneCARE and corrected if necessary.
7 - 56
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Maintenance manual GMK 5170
Maintenance work on the carrier 7.12 Compressed air system
7.12
Compressed air system
7.12.1
Draining the compressed air system
Spare parts and tools
Prerequisites
Designation
W
Quantity
GROVE part no.
Valve
5
01 570750
Gasket 22 x 27 Cu DIN 7603
5
00117142
– The truck crane is raised on outriggers or parked over an inspection pit. – The air reservoir is filled to the maximum
à Operating instructions.
– The engine is switched off and secured against unauthorised use; p. 2 - 3.
à
Draining the compressed air system
• Actuate the valves (1) on the air reservoirs (2) to (5). If a lot of moisture escapes:
• Have CraneCARE or your repair crew check
29.04.2008
or change the drier.
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7 - 57
Maintenance work on the carrier 7.12 Compressed air system
7.12.2
Checking for leaks
W
• Start up the compressed air system. • Look for any possible leaks in the compressed air system (connections, pipes, hoses and valves).
G
Risk of accidents due to escaping compressed air! Never tighten connections when the system is under pressure. Only change gaskets, pipes and hoses when the system is depressurised.
If damage cannot be rectified immediately or further damage is likely:
29.04.2008
• Notify CraneCARE or your repair crew.
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Maintenance manual GMK 5170
Maintenance work on the carrier 7.12 Compressed air system
7.12.3
Replacing the filter cartridge of the compressed air drier
Spare parts and tools
Designation
M 12
Quantity
GROVE part no.
1
03043578
Filter cartridge with gasket – Strap wrench.
Prerequisites
– The truck crane is raised on outriggers or parked over an inspection pit. – The engine is switched off and secured against unauthorised use; p. 2 - 3.
à
Changing the filter cartridge
G
Risk of injury from escaping compressed air! If the reservoir (2) is not completely empty, the compressed air dryer will be under pressure. Ventilate the reservoir until air no longer escapes from the valve.
• Release all the air from the reservoir (2) via the valve (1).
• Replace the filter cartridge (3) using the
29.04.2008
strap wrench (lubricate gasket slightly).
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7 - 59
Maintenance work on the carrier 7.12 Compressed air system
29.04.2008
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Maintenance manual GMK 5170
Maintenance work on the carrier 7.13 Hydraulic system
7.13
O 7.13.1 Prerequisites
Hydraulic system Risk of environmental damage due to leaking consumables! Always let consumables drain into suitable receptacles. Wipe up any consumables that have leaked. Store/dispose of consumables and any soaked equipment properly. Ask about the applicable regulations.
D
Checking the oil level – The truck crane is aligned horizontally at on-road driving level; Operating instructions.
à
– The outriggers are retracted;
à Operating instructions.
– The engine is switched off and secured against unauthorised use; p. 2 - 3.
à
S
Risk of damage to the hydraulic system! When working with hydraulic oil, you must make sure that it is clean! Even new oil should be filtered.
• Check whether oil is visible in the centre of the inspection glass (1) before starting work.
If the oil level is too low:
29.04.2008
• Add more oil, à p. 7 - 71.
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7 - 61
Maintenance work on the carrier 7.13 Hydraulic system
7.13.2
W
Checking the hydraulic hoses
Hydraulic hoses are subject to ageing as well as internal and external strain.
• Check the hydraulic hoses for: – – – –
external damage (tears, abrasion, heat damage, chemical damage) leaks and moist areas blistering or unevenness of hose casing signs of ageing (porous surface, rust on hose fitting) 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: 1 Manufacturer designation. 2 Maximum operating pressure and unit of measurement (A) (e.g. 250 bar). Maximum operating pressure and unit of measurement (B) (e.g. 25.0 MPa). 3 Month and year of manufacture.
• Always ensure that the corresponding parts of the system are depressurised.
• Damaged or old hydraulic hoses must be
29.04.2008
replaced immediately.
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Maintenance manual GMK 5170
Maintenance work on the carrier 7.13 Hydraulic system
7.13.3
Checking for leaks
W
• When the engine is running, carry out a visual inspection for leaks on the hydraulic system (pumps, drives, cylinders, control blocks, valves, pipe and hose lines and connections).
• Check the oil level if there are leaks; à Checking the oil level, p. 7 - 61.
G O
Risk of accidents from hydraulic oil spraying out! Never tighten any leaking connections when the system is under pressure. Only change pipes and hoses when the system is depressurised.
Risk of environmental damage due to leaking consumables! Immediately repair or have repaired leakages in the hydraulic system to ensure that no hydraulic oil escapes, seeps into the ground or reaches water when the crane is being used. After parts have been changed:
• Bleed the carrier hydraulic system; à Bleeding the hydraulic system, p. 7 - 73. If damage cannot be rectified immediately or further damage is likely:
29.04.2008
• Notify CraneCARE or your repair crew.
Maintenance manual GMK 5170
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7 - 63
Maintenance work on the carrier 7.13 Hydraulic system
7.13.4 Spare parts and tools
Designation
Quantity
GROVE part no.
Filter
2
03329152
Gasket set
2
03135778
– Receptacle, approx 5 l;
Prerequisites
M3
Cleaning the magnetic rods
à p. 2 - 4.
– The truck crane must be standing on a level surface. – The engine is switched off and secured against unauthorised use; p. 2 - 3. – During the first 100 operating hours: clean the magnetic rods weekly.
à
Cleaning the magnetic rods
• Remove the lid (1) and pull out the filters. • Place the filters in a receptacle. • Remove the spring (2). • Loosen the nut (5). • Take the magnetic rod (3) out of the filter cage (4) and clean it.
• Replace any damaged parts.
29.04.2008
S
Risk of damage to the hydraulic system! Large amounts of metal particles are a sign of damage in the hydraulic system. Have CraneCARE or your repair crew check the hydraulic system.
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Maintenance manual GMK 5170
Maintenance work on the carrier 7.13 Hydraulic system
• Install the filters and insert them. • Replace the gaskets if necessary and fasten the lid (1).
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• Start the engine and check for leaks.
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7 - 65
Maintenance work on the carrier 7.13 Hydraulic system
7.13.5 Shortening the interval
• Under difficult operating conditions – at extremely sandy or dusty locations – you must change the ventilation filter earlier than normal.
Spare parts and tools
Designation Filter
Prerequisites
O
M 12
Changing the ventilation filter
Quantity
GROVE part no.
1
03324588
– The engine is switched off and secured against unauthorised use; p. 2 - 3.
à
Risk of damage to the environment from filter residues! Store used filter inserts in suitable receptacles and have them disposed of properly by qualified personnel.
• Remove the lid (1).
29.04.2008
• Change the filter (2) and fasten the lid.
7 - 66
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Maintenance manual GMK 5170
Maintenance work on the carrier 7.13 Hydraulic system
7.13.6
M 12
Taking oil samples
Shortening the interval
• Under difficult operating conditions – at tropical or very hot locations –
Spare parts and tools
– Connecting piece and hose (tool box).
you must halve the oil change interval.
– Four sample containers (0.3 litres each). – Receptacle, approx. 5 litres;
Prerequisites
à p. 2 - 4.
– The outriggers are retracted;
à Operating instructions.
– The engine is switched off and secured against unauthorised use; p. 2 - 3.
à
Taking oil samples
Samples must be taken from the hydraulic oil tank and from the hydraulic system in order to determine the usability of the oil.
• Take one oil sample from each valve (1), (2) and (3) of the hydraulic oil tank; the valves, p. 7 - 68.
à Handling
• An oil sample from the hydraulic system is taken via a gauge port (4), e.g. on a valve block of the suspension.
29.04.2008
s
Maintenance manual GMK 5170
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7 - 67
Maintenance work on the carrier 7.13 Hydraulic system
Handling the valves
G
The valves can be opened and closed only using the connecting piece with the hose. The connecting piece is in the tool box. Danger due to escaping hydraulic oil! When the connecting piece is screwed onto the valve, the valve opens and the hydraulic oil immediately flows out of the connecting piece. Holding it by the connecting piece, place the hose into a suitable receptacle before screwing on the connecting piece.
• Place the hose onto the connecting piece and put the other end of the hose into a receptacle.
• A – Remove the cap and screw the connecting piece and hose onto the valve – the valve opens.
• Drain the required amount of oil. • B – Remove the connecting piece and hose – the valve closes. • Screw the cap onto the valve.
Taking oil samples
• Before taking the oil sample, allow 1 to 2 litres of oil to drain into a receptacle.
• Take 0.3 litres of hydraulic oil from each of the three valves on the hydraulic tank and from one gauge port.
• Label each sample with – the date of sampling, – number of operating hours since last oil change and – the sampling location (hydraulic oil tank or gauge port).
• Have a technical laboratory determine the viscosity, the viscosity index, the degree of contamination and the water content of all the samples.
29.04.2008
– – – –
7 - 68
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Maintenance manual GMK 5170
Maintenance work on the carrier 7.13 Hydraulic system
Determining the quality of the oil
Compare the quality of the oil with the limit values and carry out the specified measures if necessary. Viscosity limit values: – Viscosity ISO-VG 32 in accordance with DIN 51524 T.2 – Viscosity index Vi ≥ 150. If one of these limit values has been reached/fallen short of:
• Carry out an oil change; à p. 7 - 70. Contamination limit value: – Contamination in accordance with NAS 1638 Class 7 or ISO 4406:1999 Code 18/16/13 (purity class). If this limit has been reached/exceeded:
• Replace the filters of the hydraulic system; à p. 7 - 74. • Have the hydraulic oil cleaned with a mobile filter unit until the required purity class is reached. Water content limit value: – Water content ≤ 100 ppm. If this limit value has been reached/exceeded:
• Have the hydraulic oil cleaned with a mobile water separator until the
29.04.2008
water content is clearly below the limit value.
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7 - 69
Maintenance work on the carrier 7.13 Hydraulic system
7.13.7
Changing the hydraulic oil The oil needs to be changed only if the laboratory analysis indicates the need for it; Determining the quality of the oil, p. 7 - 69.
à
Oil, spare parts, tools
Hydraulic oil in litres 150
Designation according to DIN 51502
Specification Classification
GROVE part no.
H - LP
DIN 51524 T.2 Viscosity: ISO-VG 32
01375719
Designation
Quantity
GROVE part no.
1
03098598
Cover gasket 140/90 x 3 – Connecting piece with hose (tool box). – One or more receptacles, approx. 150 l;
Prerequisites
– The outrigger is retracted;
à p. 2 - 4.
à Operating instructions.
– The engine is switched off and secured against unauthorised use; p. 2 - 3.
à
Closing the valves
S
Risk of damage to the hydraulic pumps! Be sure to secure the engine against unauthorised use. If the engine is started while the valves in the suction line are closed, the hydraulic pumps will be damaged.
• Close the valves – lever (1) at right angles to
29.04.2008
the line.
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Maintenance manual GMK 5170
Maintenance work on the carrier 7.13 Hydraulic system
Draining oil
O
Risk of environmental damage due to leaking consumables! Use the supplied connecting piece and hose and a receptacle with sufficient capacity to drain the hydraulic oil.
• Place a receptacle underneath the valves. • One after the other, screw the connecting piece and hose onto the valves (1), (2) and Handling the valves, p. 7 - 68. (3);
à
• Change the filters; à p. 7 - 74.
Topping up the oil
S
Risk of damage to the hydraulic system! Cleanliness is of the utmost importance when handling hydraulic oil. Even new oil must be filtered before it is added to the tank.
• Remove the lid (3). • Add new oil through a filter until the level reaches the centre of the inspection glass (1).
• If required, replace the gasket (2) and fasten the lid.
29.04.2008
s
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7 - 71
Maintenance work on the carrier 7.13 Hydraulic system
Establishing operating condition
S
After having changed the oil filters and topped the oil up, you must re-establish the operating condition. Risk of damage to the hydraulic pumps! Open the valves prior to starting the engine. This prevents damage to the hydraulic pumps.
Opening the valves
• Open the valves – lever (1) parallel with the line.
• Start the engine. • Carry out all hydraulic functions several times to remove any air in the system.
• Carry out a road test of the truck crane, turning the steering wheel several times to its fullest extent.
• Check the oil level through the inspection glass on the hydraulic oil tank.
à Checking the oil level, p. 7 - 61.
29.04.2008
Top up oil if necessary;
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Maintenance manual GMK 5170
Maintenance work on the carrier 7.13 Hydraulic system
Bleeding the hydraulic system
If the steering is “loose” during the test run, you must bleed the hydraulic system at the steering cylinders.
Preparations
– The truck crane is raised on outriggers;
à Operating instructions.
– The parking brake is engaged.
G G
Risk of crushing from turning wheels! When working between the wheels, ensure that the steering wheel cannot be turned by an unauthorised party. The wheels turn when the steering wheel is operated. Risk of accidents from high oil pressure! 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 engine. • Bleed each steering cylinder (2) by loosening the collar nuts (1) until the oil coming out no longer contains air bubbles.
If the steering system is still not operating properly:
• Notify CraneCARE authorised repair special-
29.04.2008
ist.
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7 - 73
Maintenance work on the carrier 7.13 Hydraulic system
7.13.8
Changing the hydraulic oil filter All three oil filters must be replaced when changing the oil. In the event of a warning message, the symbol (1) in the Warning submenu indicates that you must change the oil filters.
Spare parts and tools
Designation
Quantity
GROVE part no.
Filter
2
03329152
Gasket set
2
03135778
– Receptacle, approx. 5 l;
Prerequisites
à p. 2 - 4.
– The engine is switched off and secured against unauthorised use; p. 2 - 3.
à
Changing the filter
29.04.2008
O
Risk of damage to the environment from filter residues! Store used filter inserts in suitable receptacles and have them disposed of properly by qualified personnel.
7 - 74
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Maintenance manual GMK 5170
Maintenance work on the carrier 7.13 Hydraulic system
• Remove the lid (1) and pull out the filters. • Place the filters in a receptacle. • Remove the spring (2). • Undo the bolt (6). • Take the magnetic rod (3) and the filter (4) out of the filter cage (5).
• Clean the magnetic rod (2) and the filter cage (5).
• Insert a new filter (3) into the filter cage (5). • Replace any damaged parts.
S
Risk of damage to the hydraulic system! Large amounts of metal particles are a sign of damage in the hydraulic system. Have CraneCARE or your repair crew check the hydraulic system.
• Install the filters and insert them. • Replace the gaskets and fasten the lid (1).
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• Start the engine and check for leaks.
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7 - 75
Maintenance work on the carrier 7.13 Hydraulic system
29.04.2008
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Maintenance manual GMK 5170
Maintenance work on the carrier 7.14 Central lubrication system
7.14
Central lubrication system
7.14.1
Checking the level
Grease, spare parts, tools
Lubricating grease Grease
W
Designation according to DIN 51502
Specification Classification
GROVE part no.
KP - L2K
DIN 51825
00554201
– Filling pump from the tool set.
Prerequisites
– The parking brake is engaged.
Checking the level
• Check the level of the grease container (1). The grease level must be near the max. mark. If the level is too low:
• Add more grease; à p. 7 - 78.
29.04.2008
s
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7 - 77
Maintenance work on the carrier 7.14 Central lubrication system
topping up
S
Risk of damage to the central lubrication system! Cleanliness is of the utmost importance when handling grease and filling pumps. Do not remove the caps from the hole and filling pump until immediately before refilling the grease. This prevents dirt particles from getting into the grease and damaging the central lubrication system. Fill the container as follows: 1 Filling pump tool set You must install the connector from the tool box. 2 Filling pumps for lubrication nipples
• Switch on the ignition.
• When filling with the supplied filling pump, screw it onto the connecting piece (2).
• Fill the grease container via connection (2) up to the max. mark.
• Press the button (1) for approx. 2 seconds once.
29.04.2008
Intermediate lubrication is triggered.
7 - 78
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Maintenance manual GMK 5170
Maintenance work on the carrier 7.14 Central lubrication system
7.14.2
Bleeding the central lubrication system When the grease container is empty or contains bubbles, you must bleed the central lubrication system. The grease container (1) is full.
• Loosen the lubricating pipe at connection (2).
• Turn on the ignition. • Trigger intermediate lubrication repeatedly until the grease flowing from the connection (2) no longer contains any bubbles.
• Fasten the lubricating pipe at connection (2). • Remove any excess grease.
7.14.3
Triggering intermediate lubrication Intermediate lubrication should be activated – after high-pressure cleaning, – to check the lubrication at all lubricating points.
• Turn on the ignition. • Press the button (1) for approx. 2 seconds once. An intermediate lubrication cycle will be triggered which lasts approximately 3 minutes. Check whether grease is applied to all the lubricating points. (Steering arm at all axle lines).
• Turn off the ignition and remove any excess 29.04.2008
grease.
• Tighten the cap.
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7 - 79
Maintenance work on the carrier 7.14 Central lubrication system
29.04.2008
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Maintenance manual GMK 5170
Maintenance work on the carrier 7.15 Electrical system
7.15
Electrical system
7.15.1
Checking the lighting and indicators
G
D
Risk of accidents if the safety devices are faulty! If the lamps or indicators fail, notify CraneCARE and have the fault rectified.
• Check the following functions daily before operating or driving the truck crane, and have faulty parts repaired:
!r2 1 k
– Parking light/headlight, marker lights, rotating beacons, fog tail light, fog light, outrigger lights – Hazard warning system – Brake lights – Reversing lights – Warning buzzer – Full-beam headlight – Turn signal indicator – Windscreen wipers – Windscreen washing system
29.04.2008
– Horn
Maintenance manual GMK 5170
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7 - 81
Maintenance work on the carrier 7.15 Electrical system
7.15.2
G G G G S
M1
Checking the batteries
Risk of poisoning from batteries containing lead compounds! Battery poles, battery clamps and parts inside the battery contain lead compounds. Lead-compound particles on your hands must not be allowed to enter your body – e.g. by swallowing contaminated food. Wash your hands after working on batteries. Risk of explosion from escaping hydrogen! Do not place tools on the battery and keep unshielded light away from the battery.
Risk of explosion from static charge! Only use anti-static cloths to clean the batteries. This prevents static charging and possibly resulting hydrogen mixtures from exploding. Risk of injury from battery acid! Battery acid is highly caustic. Wear safety goggles and protective gloves. Do not tilt the battery. Rinse off or wash out the acid spray on the skin or clothing using soap suds. Risk of damage to the crane electronics! Always switch off the battery master switches before commencing work on the truck crane’s electrical system. This prevents short circuits and resulting damage to the electrical system.
Before checking
• Switch the battery master switch (1) off and remove the selector handle.
29.04.2008
• Open the battery box (2).
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Maintenance manual GMK 5170
Maintenance work on the carrier 7.15 Electrical system
Checking the connecting terminals
• Keep the batteries clean and dry. • Loosen any dirty connecting terminals (1) and clean them.
• Fasten the loose connecting terminals. • Grease the connecting terminals and poles lightly with a special battery terminal grease.
Checking the acid level
• Remove all lids (1). The acid level must be above the plates. If the acid level is too low
• Top it up using distilled water only until the plates are covered.
• Screw on all lids (1) tightly.
After checking
• Close the battery box (2). • Attach the selector handle and switch on the battery master switch (1).
• Check the timers on the tachograph and on the auxiliary heater; tions.
à Operating instruc-
• Enter the code for the radio; à Separate 29.04.2008
operating instructions.
Maintenance manual GMK 5170
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7 - 83
Maintenance work on the carrier 7.15 Electrical system
7.15.3
M3
Checking the charge level of the batteries
à Separate operating instructions, or
Spare parts and tools
– Battery testing device;
Charge level table
The measurement of the acid concentration with the acid siphon will give you an indication of the charge level of the batteries. The acid siphon can have a scale in g/cm³, for example. Therefore, observe the special scale on your acid siphon.
– Acid siphon.
D
7 - 84
Charge level
1.28
good
1.20
half-charged; recharge
1.12
flat; recharge immediately
Risk of poisoning from batteries containing lead compounds Battery poles, battery clamps and parts inside the battery contain lead compounds. Lead-compound particles on your hands must not be allowed to enter your body – e.g. by swallowing contaminated food. Wash your hands after working on batteries. Risk of explosion from escaping hydrogen! Do not place tools on the battery and keep unshielded light away from the battery.
Risk of explosion from static charge! Only use anti-static cloths to clean the batteries. This prevents static charging and possibly resulting hydrogen mixtures from exploding. Risk of injury from battery acid! Battery acid is highly caustic. Wear safety goggles and protective gloves. Do not tilt the battery. Rinse off or wash out the acid spray on the skin or clothing using soap suds. Risk of damage to the crane electronics! Always switch off the battery master switches before commencing work on the truck crane’s electrical system. This prevents short circuits and resulting damage to the electrical system.
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Maintenance manual GMK 5170
29.04.2008
G G G G S
Acid concentration (g/cm³)
Maintenance work on the carrier 7.15 Electrical system
Before checking
• Switch the battery master switch (1) off and remove the selector handle.
• Open the battery box (2).
Checking the acid concentration
• Remove all lids (1). • Read off the cell value on the acid siphon (2) and compare the value with that in the table; Charge level table, p. 7 - 84.
à
• Check all cells in the same way. • Screw on all lids (1) tightly.
After checking
• Close the battery box (2). • Attach the selector handle and switch on the battery master switch (1).
• Check the timers on the tachograph and on the auxiliary heater; à Operating instructions.
• Enter the code for the radio; à Separate 29.04.2008
operating instructions.
Maintenance manual GMK 5170
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7 - 85
Maintenance work on the carrier 7.15 Electrical system
29.04.2008
Blank page
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Maintenance manual GMK 5170
Maintenance work on the carrier 7.16 Air-conditioning system
7.16
Air-conditioning system
7.16.1
Checking the air-conditioning system
M1
• Switch on the air-conditioning system; à Operating instructions • Check whether cooling is being achieved. If no cooling is being achieved, the air conditioning system is defective.
• Switch the air-conditioning system off. If the air-conditioning system is defective:
• Do not start it up again, lest further damage result. Have the air-conditioning system repaired as soon as possible by CraneCARE.
7.16.2
S
Cleaning the condenser fins
M1
Risk of damage to the condenser! Do not use a high pressure cleaner or steam jet cleaner. The powerful jet may damage the fins. Use only compressed air for cleaning.
• Switch the air-conditioning system off. • Clean the condenser fins with compressed
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air (1).
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7 - 87
Maintenance work on the carrier 7.16 Air-conditioning system
7.16.3
M6
Checking hoses
G
Danger of burns from escaping refrigerant! Wear suitable protective goggles and gloves when checking hoses and connections. This will prevent injury from suddenly escaping refrigerant. Seek medical attention if skin or eyes come into contact with refrigerant.
• Check all refrigerant hoses for damage and worn areas. Have damaged hoses replaced only by CraneCARE.
7.16.4
Checking the entire air-conditioning system
H
G
M 12
This check should only be carried out by CraneCARE!
Danger of burns from escaping refrigerant! Wear suitable protective goggles and gloves when checking hoses and connections. This will prevent injury from suddenly escaping refrigerant. Seek medical attention if skin or eyes come into contact with refrigerant.
• Have the entire air-conditioning system checked for leaks and proper functioning. The inspection of the air-conditioning system includes most importantly the inspection of – the refrigerant collector, in accordance with the pressure container regulations (test group II) and – the refrigerant compressor.
• Use only suitable refrigerant for topping up. Refrigerant Fill quantity in kg
Tetrafluoroethane (R134a)
CAS no. EC no. 811-97-2 212-377-0
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approx. 1.5
Designation
Filler connections 7 - 88
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Maintenance manual GMK 5170
Maintenance work on the carrier 7.16 Air-conditioning system
H
This topping up should be done only by CraneCARE.
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– Filler connections (1) for refrigerants
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3 112 477 en
7 - 89
Maintenance work on the carrier 7.16 Air-conditioning system
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7 - 90
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Maintenance manual GMK 5170
Maintenance work on the carrier 7.17 Particulate filter
7.17
Particulate filter When a particulate filter is fitted as additional equipment, it is incorporated in the exhaust system silencer. Have the particulate filter cleaned by service partners. Information can be obtained from CraneCARE.
7.17.1
M1
Checking the clamp straps
Spare parts and tools
Designation
Quantity
GROVE part no.
2
03134864
Clamp strap – Torque wrench for torque of 20 Nm.
Checking the clamp straps
G
Risk of burning yourself if the exhaust system is hot! During operation, the exhaust system can heat up to 400 °C. Wear suitable gloves and/or wait until the exhaust system has cooled down. Make sure not to touch any hot parts.
• Remove the heat shield (1). • Check the clamp straps (2) for tightness. Torque 20 Nm.
• Replace any damaged clamp straps;
à p. 7 - 93.
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• Attach the heat shield (1).
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7 - 91
Maintenance work on the carrier 7.17 Particulate filter
7.17.2
M6
Replacing the particulate filter
Spare parts and tools
Designation
Quantity
GROVE part no.
Clamp strap
2
03134864
Filter
1
03134863
– Torque wrench for torque of 20 Nm.
Prerequisites
– The engine is switched off and secured against unauthorised use; p. 2 - 3.
à
Removing the exhaust silencer
G G O
Health hazard due to soot particles! Soot particles are suspected of being hazardous to health. Wear appropriate dust respirator masks and be careful not to breathe in or ingest dust particles. Risk of polluting the environment! Collect the combustion residues from the particulate filter in a suitable receptacle and dispose of them according to the relevant regulations.
When cleaning or exchanging the particulate filter, also refer to the documents supplied by the filter manufacturer. Record the filter exchange in the documents supplied by the filter manufacturer.
29.04.2008
H
Risk of burning yourself if the exhaust system is hot! During operation, the exhaust system can heat up to 400 °C. Wear suitable gloves and/or wait until the exhaust system has cooled down. Make sure not to touch any hot parts.
7 - 92
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Maintenance manual GMK 5170
Maintenance work on the carrier 7.17 Particulate filter
• Remove the heat shield (1). • Loosen the clamp strap (3) and remove the part (2).
• Loosen the clamp strap (5) and remove the filter (4) from part (6).
• After removal and before cleaning, allow the parts to cool down if necessary.
Cleaning the filter
• Clean the filter in a manufacturer-approved cleaning system only.
or exchange it
• Replacement filters are available from the filter manufacturer's service partner if you do not have a cleaning system available. For more information, please contact CraneCARE.
Installing the filter
• Use only new clamp straps (3) and (5) with intact gaskets.
• Place the filter (4) on the part (6) and fasten it with the clamp strap (5) – torque 20 Nm.
• Place the part (2) on the filter (4) and fasten it with the clamp strap (3) – torque 20 Nm.
• Attach the heat shield (1). • Carry out a back pressure test; à p. 7 - 94.
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s
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7 - 93
Maintenance work on the carrier 7.17 Particulate filter
Back pressure test
The back pressure test allows you to determine whether the exhaust connection to the filter is gas-tight:
• Engage the parking brake; à Operating instructions.
• Start the engine. • Slowly increase the engine speed up to 1800 min-1 and hold this engine speed for 30 seconds.
• Monitor the exhaust gas flow – there must be no visible smoke. • Switch off the engine. If smoke was clearly visible:
• Check whether – the clamp straps are sufficiently tight, – if the clamp strap gaskets are intact, – if the particulate filter is intact.
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• Rectify any damage you were able to identify.
7 - 94
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Maintenance manual GMK 5170
Maintenance work on the carrier 7.18 Towbar coupling
7.18
Towbar coupling Depending on the scope of equipment of your truck crane, it may have towbar couplings (additional equipment) from various manufacturers. Their wear values may vary from those specified; Separate operating instructions.
à
7.18.1
M1
Lubricating the towbar coupling
This maintenance work is not required if the towbar coupling is connected to the central lubrication system.
Grease, spare parts, tools
Lubricating grease Grease
Designation according to DIN 51502
Specification Classification
GROVE part no.
KP - L2K
DIN 51825
00554201
– Grease gun from the tool set.
G H
Risk of injury when the automatic closing device is triggered! Do not put your hand into the coupling jaw when the towbar coupling is open. This may trigger the automatic closing device, make the coupling pin move down and seriously injure your hand. To avoid over-lubrication, the towbar coupling should be lubricated only when open!
• Clean the lubricating nipples (2) and (3). • Open the towbar coupling. To do this, move the lever (1) upward.
• Squirt grease into the lubricating nipples (2) and (3).
• Close the towbar coupling.
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s
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7 - 95
Maintenance work on the carrier 7.18 Towbar coupling
Closing the towbar coupling
G
Risk of injury when closing the towbar coupling by hand! When closing, the 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 balls of your hands. If you hold the lever and move it down, it may carry your hand with it and crush it. After lubrication, you must close the towbar coupling.
• Move the lever (1) briefly in the direction of the coupling jaw (observe the arrow).
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• Remove any excess grease.
7 - 96
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Maintenance manual GMK 5170
Maintenance work on the carrier 7.18 Towbar coupling
7.18.2 Prerequisites
M3
Checking the bearing – The coupling is closed;
à p. 7 - 96.
Checking the bearing
G
Risk of injury! Ensure that the towbar coupling is closed for the following work (lever points downwards). The lever may otherwise come down with great force and cause serious hand injury.
• Check the bearing of the towbar coupling by vigorously shaking it up and down and in the longitudinal direction (arrows). Hold the towbar coupling at the top and bottom of the coupling head and not by the coupling jaw.
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The vertical clearance at the coupling head must be no more than 3 mm.
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3 112 477 en
7 - 97
Maintenance work on the carrier 7.18 Towbar coupling
7.18.3 Prerequisites
M3
Checking the cotter pin – The coupling is closed;
à p. 7 - 96.
Checking the cotter pin
• Check the wear on the cotter pin (1). The diameter of the crowned section (arrows) must not be less than the following values: Model series 400:
36.5 mm
Model series 700:
46.0 mm
If the dimension is smaller than that given above, have the cotter pin replaced by CraneCARE or by your repair crew.
• Also check the cotter pin for the correct ver-
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tical clearance. Take a screwdriver and press the pin (1) upwards. The vertical clearance (2) of the cotter pin must not exceed 4 mm.
7 - 98
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Maintenance manual GMK 5170
Maintenance work on the carrier 7.18 Towbar coupling
7.18.4 Prerequisites
M3
Checking the lower bushing – The coupling is closed;
à p. 7 - 96.
Checking the bushing
• Check the internal diameter of the lower bushing. The diameter D must not exceed the following values: Model series 400:
31.5 mm
Model series 700:
34.2 mm
If the dimension is smaller than that given above, have the bushing replaced by CraneCARE or by your repair crew.
7.18.5
Checking the initial tension of the springs
M3
The coupling head should require physical power to twist when checking the torque.
• Twist the coupling head clockwise and anticlockwise to check the initial
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tension of the rubber springs.
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3 112 477 en
7 - 99
Maintenance work on the carrier 7.18 Towbar coupling
7.18.6 Prerequisites
M3
Checking the support ring – The coupling is closed;
à p. 7 - 96.
Checking the support ring
• Check the support ring (1) at the bottom of the coupling jaw. When the trailer is coupled, the draw eyelet of the trailer must not be in 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 – the support ring has reached its wear limit of H = 14 mm.
7.18.7
Checking the function of the coupling jaw/ Resetting central position
Spare parts and tools
– Torque wrench for torque of 58 Nm.
Prerequisites
– The coupling is closed;
M3
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à p. 7 - 96.
7 - 100
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Maintenance manual GMK 5170
Maintenance work on the carrier 7.18 Towbar coupling
Checking for correct functioning 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. The 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.
H
If the lever does not automatically engage with the coupling jaw, the central position must be re-adjusted; p. 7 - 101.
à
Resetting the central position
• Open the coupling (lever (1) pointing upwards) and loosen the bolts (2).
• Push the coupling jaw to the side until the lever engages.
• Tighten the bolts – torque 58 Nm. • Check the function of the coupling jaw;
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à p. 7 - 100.
Maintenance manual GMK 5170
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7 - 101
Maintenance work on the carrier 7.18 Towbar coupling
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7 - 102
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Maintenance manual GMK 5170
Maintenance work on the carrier 7.19 Other maintenance work
7.19
Other maintenance work
7.19.1
Lubricating the support bearings
Grease, spare parts, tools
Lubricating grease Grease
M1
Designation according to DIN 51502
Specification Classification
GROVE part no.
KP - L2K
DIN 51825
00554201
– Brush or roller.
G
Risk of crushing due to extending support bearings! Ensure that there is sufficient room around the crane. Warn any persons nearby before extending the support bearings. Observe the safety instructions in the operating instructions.
• Fully extend all support bearings;
à Operating instructions.
• Apply the grease to both sides of the slide faces (1) on all the support bearings.
• Extend and retract the support bearings several times.
• Remove any excess grease.
After every high-pressure cleaning operation on the truck crane:
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• Lubricate the support bearings.
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7 - 103
Maintenance work on the carrier 7.19 Other maintenance work
7.19.2
Checking the auxiliary heater for correct operation
M1
Your truck crane has fire auxiliary heaters, depending on its scope of equipment. During the warm summer months, operate the auxiliary heater for 20 to 30 minutes; Operating instructions.
à
• Check that the system is working properly. Also perform a functional check of the controls.
• If the heating system is not functioning correctly, report it CraneCARE.
7.19.3
Y2
Having the fire extinguisher checked
Your truck crane has fire extinguishers, depending on its scope of equipment.
H
The maintenance interval may be shorter, depending on the respective national regulations. Ask about the national and local regulations at the local Fire Safety Authority.
• Follow the operating instructions (1) on the fire extinguisher. • Have the fire extinguisher serviced by trained personnel in good time before the maintenance interval specified on the label (2) expires.
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S
Danger due to the fire extinguisher not working! There is no guarantee that the fire extinguisher is still working properly after the maintenance interval on the label has expired.
7 - 104
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Maintenance manual GMK 5170
8 8
Maintenance work on the superstructure
8.1
General instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 -
1
Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 -
1
8.2
Symbols for maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 -
3
8.3
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 -
5
8.1.1
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 8.5 8.5.1 8.5.2 8.5.3 8.5.4 8.5.5 8.5.6 8.5.7 8.6 8.6.1 8.6.2 8.6.3 8.6.4 8.7 8.7.1 8.7.2 8.7.3
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8.8 8.8.1 8.8.2 8.8.3 8.8.4 8.8.5 8.8.6 8.8.7 8.8.8 8.8.9
Checking the oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 5 Topping up the oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 7 Checking the air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 8 Checking the coolant level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 9 General inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 10 Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 11 Draining off water from fuel filter 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 11 Changing fuel filter 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 13 Changing fuel filters 2 and 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 15 Hoists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 19 Checking the oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 General inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Checking the hoist brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Lubricating the auxiliary hoist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Changing the oil/Checking the oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Having a partial inspection carried out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Having a general inspection carried out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 -
19 20 20 20 22 24 24
Slewing gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 25 Checking the oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Checking for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Checking the slewing gear brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Changing the oil/Checking the oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 -
25 26 26 28
Ball slewing bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 31 Lubricating gear teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 31 General inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 33 Measuring tilting play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 33 Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 35 Checking the oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Checking the hydraulic hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Checking ventilation filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Checking for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Changing the ventilation filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Pressure accumulator – checking the gas pressure . . . . . . . . . . . . . . . . . . . . . . 8 Taking oil samples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Changing the hydraulic oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Changing the hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 -
Maintenance manual GMK 5170
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35 36 36 37 38 39 40 41 44
8.9
Main boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 49
8.9.1 8.9.2 8.9.3
Lubricating the telescopic sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 49 Checking the sheaves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 53 Checking the locking system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 53
8.10
Hoist ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 55
8.11 8.11.1 8.11.2 8.12 8.12.1 8.13 8.13.1 8.13.2 8.14 8.14.1 8.14.2 8.14.3 8.15 8.15.1 8.15.2 8.15.3 8.15.4 8.16 8.16.1 8.16.2 8.16.3
Checking the position on the rope drums . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking the hoist ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubricating the hoist rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assessing the condition of the hoist rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing the hoist rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setting the lowering limit switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
888888-
55 56 57 58 64 67
Cable drums and slewing angle sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 69 Maintenance of the slip ring assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 69 Lubricating the slewing angle sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 71 Central lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 73 Checking the level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 73 Hook blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 73 Checking the sheaves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 73 Lubricating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 74 Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 75 Checking the lighting and indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 75 Checking the batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 76 Checking the charge level of the batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 76 Air-conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 77 Checking the air-conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning the condenser fins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking the entire air conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . .
8888-
77 77 78 78
Other maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 79 Checking the auxiliary heater for correct operation . . . . . . . . . . . . . . . . . . . . . 8 - 79 Lubricating the piston rod of the derricking cylinder . . . . . . . . . . . . . . . . . . . . 8 - 79 Having the fire extinguisher checked . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 80
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8.10.1 8.10.2 8.10.3 8.10.4 8.10.5 8.10.6
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Maintenance manual GMK 5170
Maintenance work on the superstructure 8.1 General instructions
8
Maintenance work on the superstructure
8.1
General instructions
8.1.1
Covers Various types of work (e.g. oil change) require that the covers be removed. Before maintenance work
• Open the service flaps (1) for maintenance work. After maintenance work
• Close the service flaps (1) and secure them
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with the locks.
Maintenance manual GMK 5170
3 112 477 en
8-1
Maintenance work on the superstructure 8.1 General instructions
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8-2
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Maintenance manual GMK 5170
Maintenance work on the superstructure 8.2 Symbols for maintenance work
8.2
Symbols for maintenance work Check the following symbols daily before starting operations.
On the ECOS display
• Open the Warning submenu; à Operating instructions.
You must carry out the associated maintenance work if the symbol is displayed in red: – Oil pressure;
– Air filter;
à p. 8 - 5,
à p. 8 - 8,
– Coolant level;
à p. 8 - 9, à p. 8 - 41.
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– Hydraulic oil filter;
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3 112 477 en
8-3
Maintenance work on the superstructure 8.2 Symbols for maintenance work
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Blank page
8-4
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Maintenance manual GMK 5170
Maintenance work on the superstructure 8.3 Engine
8.3
Engine • In addition, carry out further maintenance work as specified in the engine manufacturer documentation supplied with the vehicle. Pay attention to the information relating to use of bio-diesel fuel – the oil change interval must be halved.
8.3.1 Prerequisites
Checking the oil level
D
– The truck crane is level.
Checking the oil level
• Start the engine. • Immediately after starting the engine, check the lamp (1) on the ECOS display. The lamp (1) must go out approx. 10 seconds after starting the engine.
S
Risk of damage to the engine if the oil pressure is too low! If the lamp (1) does not go out after about 10 seconds, perform the following check and switch off the engine. The engine can be damaged by running it when the oil pressure is too low.
• Press the button (1) once. The Warning submenu opens. • Switch off the engine immediately if the symbol (2) turns red.
• After the lamp (1) has gone out following the engine start-up, allow the engine to idle for 2 - 3 min.
• Switch off the engine. 29.04.2008
• Check the oil level after about 2 minutes.
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8-5
Maintenance work on the superstructure 8.3 Engine
• On the dipstick (1), check whether the oil level is between the min. and the max. marking (arrows).
• Put the dipstick into the dipstick tube after checking the oil level. If the oil level is too low:
29.04.2008
• Add more oil, à p. 8 - 7.
8-6
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Maintenance manual GMK 5170
Maintenance work on the superstructure 8.3 Engine
8.3.2
Topping up the oil Data on the prescribed oil specification; tion.
à Engine manufacturer's documenta-
Oil Engine oil in litres 16
Prerequisites
Designation according to DIN 51502
Specification Classification
GROVE part no.
HD - CD
MIL-L 2104 C DB 228.5
First fill oil: SAE 15 W-40 02309375
– The truck crane is level. – The engine is not running and is secured against unauthorized use; p. 2 - 3.
à
Topping up oil
S G
Risk of damage to the engine if the oil level is too high! Do not overfill; the oil level must not be higher than the max. mark (arrow). Drain off oil if necessary; Engine manufacturer's documentation.
à
Risk of burning yourself when the engine is hot! During operation, the engine and add-on parts can reach temperatures up to 400 °C. Wear appropriate protective gloves and be careful not to touch hot parts.
• Add oil through the filler neck (1) up to the max. mark.
29.04.2008
• Close the filler neck with the lid.
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8-7
Maintenance work on the superstructure 8.3 Engine
8.3.3
D
Checking the air filter
• Start the engine. On the ECOS display, check whether the lamp (1) lights up.
• Press the button (2) once. The Warning submenu opens.
You must change the air filter if the symbol is red.
Spare parts and tools
Designation Filter
Prerequisites
Quantity
GROVE part no.
1
03 328 263
– The engine is not running and is secured against unauthorized use; p. 2 - 3.
à
Replacing the air filter
• Undo all clamps (1) and remove the filter cover (2).
• Change the filter (3). • Replace the cover and secure it with all the
29.04.2008
clamps.
8-8
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Maintenance manual GMK 5170
Maintenance work on the superstructure 8.3 Engine
8.3.4
Checking the coolant level
D
• Start the engine. On the ECOS display, check whether the lamp (1) lights up.
• Press the button (2) once. The Warning submenu opens.
You must top up the coolant if the symbol is red.
Topping up coolant
G
Danger of being scalded due to hot radiator circuit! The hot radiator circuit is under pressure. When you open the expansion tank, you could be scalded by escaping steam or coolant. Wear suitable protective gloves and cover the cap on the expansion tank with a rag before opening it. Turn the cap slowly to the first detent in order to allow the pressure to be released.
• Loosen (do not open!) the cap (1) to reduce the pressure if the coolant is at operating temperature.
• Open the cap (1). The coolant level must be at the lower edge in the filler neck. If the coolant level is too low:
• Top up the coolant. Composition of the coolant; Engine manufacturer's documentation.
à
29.04.2008
• Close the cap (1).
S Maintenance manual GMK 5170
Risk of damage to engine due to lack of coolant! If the coolant has to be topped up frequently, the cooling system may be leaking. Have the cooling system checked by CraneCARE or your repair crew.
3 112 477 en
8-9
Maintenance work on the superstructure 8.3 Engine
8.3.5
General inspection
W
• Investigate any unusual noises from the engine. • Check the engine and the connections for leaks. In the event of leaking fluids; Checking the oil level, p. 8 - 5, Checking the coolant level, p. 8 - 9.
à à
• Check that pipes and hoses are tightly connected and not damaged.
29.04.2008
If you detect any worn or damaged parts, contact CraneCARE or your repair crew.
8 - 10
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Maintenance manual GMK 5170
Maintenance work on the superstructure 8.4 Fuel system
8.4
Fuel system Installed in the fuel line are: 1 Fuel filter 1 2 Fuel filter 2 3 Fuel filter 3
8.4.1
Draining off water from fuel filter 1
Spare parts and tools
– Receptacle, approx. 5 l;
Prerequisites
– The truck crane is level.
D
à p. 2 - 4.
– The engine is not running and is secured against unauthorized use; p. 2 - 3.
à
29.04.2008
s
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8 - 11
Maintenance work on the superstructure 8.4 Fuel system
Draining off water
O
Risk of environmental damage due to leaking fluids! Always let fluids drain into suitable receptacles. Wipe up any fluids that have leaked. Store/dispose of fluids and any soaked equipment properly. Ask about the applicable regulations.
• Place a receptacle underneath the filter. • Open the valve (1). • If the draining fluid is clean, close the valve manually.
• Remove the receptacle and properly dis-
29.04.2008
pose of the drained fluid.
8 - 12
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Maintenance manual GMK 5170
Maintenance work on the superstructure 8.4 Fuel system
8.4.2 Spare parts and tools
Designation
Quantity
GROVE part no.
Filter
1
03322877
Gasket
1
03322879
Filter element
1
03328656
– Receptacle, approx. 5 l;
Prerequisites
M3
Changing fuel filter 1
à p. 2 - 4.
– The truck crane is level. – The engine is not running and is secured against unauthorized use; p. 2 - 3.
à
– If the fuel is contaminated: Shorten the maintenance interval.
Changing
O
Risk of environmental damage due to leaking fluids! Always let fluids drain into suitable receptacles. Wipe up any fluids that have leaked. Store/dispose of fluids and any soaked equipment properly. Ask about the applicable regulations.
• Place a receptacle underneath the filter. • Close the valve – lever (3) at right angles to the line.
• Open the screw plug (1) and the valve (2) and drain the fluid.
29.04.2008
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8 - 13
Maintenance work on the superstructure 8.4 Fuel system
• (A) – Remove the filter element (2) and the filter (1). If necessary, replace any damaged parts.
• (B) – Screw on a new filter (1) and the filter element (2).
• Close the valve (3) manually.
• Open the valve – lever (3) parallel to the line. • Actuate the pump (2) until the consumable flowing through the plug (1) no longer contains any bubbles.
• Secure the bolt. • Start the engine and check for leaks. • Remove the receptacle.
29.04.2008
H
If you have used a clean receptacle, you can refill the fuel tank with the fluid using a strainer. Otherwise dispose of the fluid properly.
8 - 14
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Maintenance manual GMK 5170
Maintenance work on the superstructure 8.4 Fuel system
8.4.3
M 12
Changing fuel filters 2 and 3
Spare parts and tools
Designation
Quantity
GROVE part no.
Filter and gasket
1
03328573
Filter and gasket
1
03328574
– Receptacle, approx. 5 l;
à p. 2 - 4.
– Torque wrench for torque of 10 Nm and 25 Nm.
Prerequisites
O
– The engine is not running and is secured against unauthorized use; p. 2 - 3.
à
Risk of environmental damage due to leaking fluids! Always let fluids drain into suitable receptacles. Wipe up any fluids that have leaked. Store/dispose of fluids and any soaked equipment properly. Ask about the applicable regulations.
Emptying the fuel line
• Close the valve – lever (3) at right angles to the line.
• Place a receptacle under the end of the hose (1).
• Turn the valve – lever (2) horizontal. • Let the fluid drain into the receptacle. Leave the receptacle under the end of the hose. More fluid will run out when you bleed the fuel line.
29.04.2008
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8 - 15
Maintenance work on the superstructure 8.4 Fuel system
Changing filters 2 and 3 Changing filter 2
• Unscrew the cap (1) and remove the filter (3) so that the fluid can drain.
• Clean the cap (1) and insert a new filter. • Replace the gasket (2) (lubricate slightly). • Screw the cap on and tighten it – torque 10 Nm.
Changing filter 3
• Unscrew the cap (1) and remove the filter (3) so that the fluid can drain.
• Loosen the filter (3) from the cap (1). • Carefully take the receptacle (4) out of the housing, making sure no dirt gets into the housing.
• Clean the cap and the receptacle. • Insert a new gasket (2) (grease lightly) and place a new filter into the cap.
• Insert the receptacle into the housing. • Screw the cap with the filter into the housing
29.04.2008
and tighten it – torque 25 Nm.
8 - 16
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Maintenance manual GMK 5170
Maintenance work on the superstructure 8.4 Fuel system
Bleeding the fuel line A receptacle is underneath the hose end (1). The lever (2) is parallel with the line.
• Open the valve – lever (3) parallel to the line. • Actuate the pump (4) until the fluid flowing through the end of the hose no longer contains any bubbles (1).
• Turn the valve – lever (2) at right angles to the line.
• Start the engine and check that the fuel filters are leak-tight.
• Remove the receptacle underneath the hose end (1).
29.04.2008
H
If you have used a clean receptacle, you can refill the fuel tank with the fluid using a strainer. Otherwise dispose of the fluid properly.
Maintenance manual GMK 5170
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8 - 17
Maintenance work on the superstructure 8.4 Fuel system
29.04.2008
Blank page
8 - 18
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Maintenance manual GMK 5170
Maintenance work on the superstructure 8.5 Hoists
8.5
Hoists
8.5.1
Checking the oil level
Spare parts and tools
W
Designation Gasket 18 x 24 Cu DIN 7603
Prerequisites
Quantity
GROVE part no.
4
01377793
– The truck crane is level and is in on-road mode;
à Operating instructions.
– The engine is not running and is secured against unauthorized use; p. 2 - 3.
à
Checking the oil level
• Check whether the oil level is between the min. and the max. marking (1). If the oil level is too low:
29.04.2008
• Top up the oil; à p. 8 - 22.
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8 - 19
Maintenance work on the superstructure 8.5 Hoists
8.5.2
W
General inspection • Investigate any unusual noises from the hoists.
• Check the hoists and the connections for leaks. In the event of leaking fluids;
à Checking the oil level, p. 8 - 19.
• Check that pipes and hoses are tightly connected and not damaged. If you detect any worn or damaged parts, contact CraneCARE or your repair crew.
8.5.3
W
Checking the hoist brake
Spare parts and tools
– Weight approx 9.5 t
Prerequisites
– The truck crane is prepared for crane operation;
Checking the hoist brake
Check that the hoist brake is working correctly on the main hoist and the auxiliary hoist.
à Operating instructions.
• Suspend the hook block on the singly reeved hoist rope. • Lift a load of approx. 9.5 t to approx. 30 cm above the ground. • Measure the distance from the ground when the load is hanging completely still.
• Switch off the engine. If the load has not lowered after approx. 2 minutes, the brake is currently in working order. If the load has lowered, notify CraneCARE.
Lubricating the auxiliary hoist
M6 29.04.2008
8.5.4
8 - 20
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Maintenance manual GMK 5170
Maintenance work on the superstructure 8.5 Hoists
Grease, spare parts, tools
Lubricating grease Grease
Designation according to DIN 51502
Specification Classification
GROVE part no.
KP - L2K
DIN 51825
00554201
– Grease gun from the tool set.
Prerequisites
– The engine is not running and is secured against unauthorized use; p. 2 - 3.
à
Lubricating
• Clean the lubricating nipple (1) and lubricate the hoist at the lubricating nipple.
29.04.2008
• Remove any excess grease.
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8 - 21
Maintenance work on the superstructure 8.5 Hoists
8.5.5
M 12
Changing the oil/Checking the oil • Comply also with the à Run-in regulations, p. 4 - 1.
Oil, spare parts, tools
Transmission oil in litres 7
Designation according to DIN 51502
Specification Classification
GROVE part no.
C - LPF
MIL-L 2105 B API-GL-4/5 Viscosity: SAE 75 W-90 EP ISO - VG 220
02313611
for each hoist
Designation Gasket 18 x 24 Cu DIN 7603 – Receptacle, approx. 8 l;
Prerequisites
Synthetic oil; do not mix this with mineral-based oils!
Quantity
GROVE part no.
10
01377793
à p. 2 - 4.
– The truck crane is level and is in on-road mode;
à Operating instructions.
– The engine is not running and is secured against unauthorized use; p. 2 - 3.
à
Changing the oil at the hoist
H 8 - 22
à
Risk of environmental damage due to leaking fluids! Always let fluids drain into suitable receptacles. Wipe up any fluids that have leaked. Store/dispose of fluids and any soaked equipment properly. Ask about the applicable regulations.
During filling, the oil spreads only slowly in the hoist. The oil level will therefore rise quickly in the standpipe at first, then drop slightly and finally rise again to its true level.
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Maintenance manual GMK 5170
29.04.2008
S O
Risk of damage to the hoist gearbox! The waste oil must be tested for abrasion particles. This test serves to idenp. 8 - 23. tify damage at an early stage;
Maintenance work on the superstructure 8.5 Hoists
Draining oil
• Place a receptacle under the pipe (3). • Unscrew the bolts (1) and (6) and let the oil drain off.
• Replace the gaskets and secure the hoses (5) with the bolt (6). Topping up oil
• Fill the oil through the pipe (3) up to the max. mark (4).
• Replace the gaskets and secure the hoses (2) with the bolt (1).
Checking the oil
G H
Risk of accidents from falling load! If this test is not performed, there may be a risk of damage to the hoist gearbox which could lead to the load falling.
Check the waste oil for abrasion particles or have it tested in a laboratory:
• Pour the waste oil through a clean filter mat. • Examine the oil, i.e. the residues on the filter mat using a magnifying glass. If you find abrasion particles or solid materials on the mat, the hoist gearbox must be removed and inspected by the manufacturer.
29.04.2008
H
Some abrasion particles may appear in the first oil filled. If you notice such particles during the first oil change (after 200 operating hours.), first consult CraneCARE before introducing any specific measures.
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8 - 23
Maintenance work on the superstructure 8.5 Hoists
8.5.6
Y3
Having a partial inspection carried out
Only suitably trained specialists should carry out a partial inspection of – the multiple-disk brake, – the plug connections between the hydraulic motor and the multiple-disk brake, – the plug connections between the multiple-disk brake and transmission unit and be permitted to exchange parts with signs of wear.
8.5.7
Y6
Having a general inspection carried out
H
The general inspection involves removing the transmission and sending it to the manufacturer to be examined. For transmissions that have undergone a general overhaul, an oil change must be carried out after 200 and 1000 operating hours; Run-in regulations, p. 4 - 1.
à
29.04.2008
H
When carrying out the general inspection of the hoist gears, also observe the information contained in Measures required for winch monitoring, p. 5 - 21.
8 - 24
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Maintenance manual GMK 5170
Maintenance work on the superstructure 8.6 Slewing gear
8.6
Slewing gear
8.6.1
Checking the oil level
Spare parts and tools
W
Designation Gasket 10 x 14 Cu DIN 7603
Prerequisites
Quantity
GROVE part no.
3
01 368 741
– The truck crane is level and is in on-road mode;
à Operating instructions.
– The engine is not running and is secured against unauthorized use; p. 2 - 3.
à
Checking the oil level
Always check the oil level prior to using the crane.
• Check whether oil is visible in the inspection glass (1).
• Always check the oil level for all the slewing gears. If the oil level is too low:
29.04.2008
• Top up the oil; à p. 8 - 28.
Maintenance manual GMK 5170
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8 - 25
Maintenance work on the superstructure 8.6 Slewing gear
8.6.2
W
Checking for leaks • Investigate any unusual noises from the slewing gears.
• Check the slewing gears and the connections for leaks. In the event of leaking fluids;
à Checking the oil level, p. 8 - 25.
• Check that pipes and hoses are tightly connected and not damaged. If you detect any worn or damaged parts, contact CraneCARE or your repair crew.
8.6.3 Prerequisites
M6
Checking the slewing gear brake
– The truck crane is rigged for a 360° slewing range as per the lifting capacity table. – The SLI code for the current rigging mode is entered; tions. – The Brake pedal function is switched on
à Operating instruc-
à Operating instructions.
– The main boom is raised to 45° and fully retracted.
29.04.2008
G
Risk of overturning while slewing! Always set a rigging mode for the slewing range 360° in accordance with the lifting capacity table and enter the associated SLI code. Do not override the SLI.
8 - 26
3 112 477 en
Maintenance manual GMK 5170
Maintenance work on the superstructure 8.6 Slewing gear
Check
When checking the slewing gear brake you must perform the slewing movement against the slewing gear brake.
• Switch off the engine. • Remove the coil (1) from the valve Y 2307. The slewing gear brake will now not be released when the slewing gear is switched on.
• Start the engine and switch on the slewing gear. • Open the Settings submenu. The display (1) indicates the pressure in the slewing gear hydraulic circuit.
• Move the control lever slowly to the stop and wait until the pressure in the hydraulic circuit has risen to approx. 200 bar. – If the superstructure still does not slew, the braking effect of the slewing gear brake is sufficient. – If the superstructure does slew, the slewing gear brake is defective and must be repaired immediately by CraneCARE.
• Switch the slewing gear off and switch the engine off. • Secure the coil (1) using the nut to the valve Y 2307.
• Start the engine and check the slewing gear
29.04.2008
for correct operation.
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8 - 27
Maintenance work on the superstructure 8.6 Slewing gear
8.6.4
M 12
Changing the oil/Checking the oil • Comply also with the à Run-in regulations, p. 4 - 1.
Oil, spare parts, tools
Transmission oil in litres 0.9
Designation according to DIN 51502
Specification Classification
GROVE part no.
C - LPF
MIL-L 2105 B API-GL-4/5 Viscosity: SAE 75 W-90 EP ISO - VG 220
02313611
for each slewing gear
Designation
Quantity
GROVE part no.
Gasket 10 x 14 Cu DIN 7603
3
01 368 741
Gasket 14 x 20 Cu DIN 7603
3
00 117 132
– Receptacle, approx. 5 l;
Prerequisites
Synthetic oil; do not mix this with mineral-based oils!
à p. 2 - 4.
– The truck crane is level and is in on-road mode;
à Operating instructions.
– The engine is not running and is secured against unauthorized use; p. 2 - 3.
à
Changing the oil
O
Risk of environmental damage due to leaking fluids! Always let fluids drain into suitable receptacles. Wipe up any fluids that have leaked. Store/dispose of fluids and any soaked equipment properly. Ask about the applicable regulations.
29.04.2008
• Always change the oil in all slewing gears.
8 - 28
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Maintenance manual GMK 5170
Maintenance work on the superstructure 8.6 Slewing gear
Draining oil
• Remove the plate (1). • Place a receptacle under the plugs (2). • Unscrew the filter (4) and plugs (3) and (2). • Drain the oil.
• Replace the gasket and screw the plugs (2) back in. Topping up oil
• Top up the oil through the filler neck (4) until oil is visible in the inspection glass (5).
• Replace the gaskets and screw in the plug (3) and the filter (4).
• Remove the plate (1).
Checking the oil
Check the waste oil that was drained from the slewing gears for abrasion particles, or have it tested at a laboratory.
• Pour the waste oil through a clean filter mat. • Examine the oil, i.e. the residues on the filter mat using a magnifying glass. 29.04.2008
If you find abrasion particles or solid materials on the mat, the slewing gear transmission must be removed for inspection and sent to the manufacturer.
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8 - 29
Maintenance work on the superstructure 8.6 Slewing gear
29.04.2008
Blank page
8 - 30
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Maintenance manual GMK 5170
Maintenance work on the superstructure 8.7 Ball slewing bearing
8.7
Ball slewing bearing
8.7.1
Lubricating gear teeth
M6
Grease Designation
Quantity
GROVE part no.
1
00554205
Adhesive lubricating grease (spray can)
H Prerequisites
Observe the instructions and safety information on the lubricant packaging!
– The truck crane is level and on outriggers; – The main boom is fully retracted;
à Operating instructions.
à Operating instructions.
– The engine is not running and is secured against unauthorized use; p. 2 - 3.
à
Lubricating
G
A distinction is make between the initial lubrication and later lubrications. Risk of crushing from the gear teeth! Fingers may be crushed or pieces of clothing can be pulled into the open, rotating pinion. For this reason, be sure to remount the plate after lubricating.
29.04.2008
s
Maintenance manual GMK 5170
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8 - 31
Maintenance work on the superstructure 8.7 Ball slewing bearing
First lubrication:
• Remove the plate (1). • Remove the old grease from all the gear teeth (2).
• Apply a thin layer of new grease to all the gear teeth and allow it to penetrate for about 10 minutes.
• Apply a second, thicker layer of grease and allow it to penetrate for about 30 minutes.
• Attach the plate.
Subsequent lubrication:
• Remove the plate (1). • Apply new grease to all the gear teeth (2). • Allow it to penetrate for about 30 minutes.
29.04.2008
• Attach the plate.
8 - 32
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Maintenance manual GMK 5170
Maintenance work on the superstructure 8.7 Ball slewing bearing
8.7.2
M6
General inspection • Investigate any unusual noises from the ball slewing bearing.
• In case of unusual noises take a sample of leaked grease. Have CraneCARE examine the sample for metal residue.
• Check the ball slewing bearing for damage (e.g. gaskets). If you detect any worn or damaged parts, contact CraneCARE or your repair crew.
H 8.7.3 Spare parts and tools
The maintenance interval specified here must be shortened if the ball slewing bearing is subjected to heavy blows (falling load, load slipping).
Measuring tilting play
M 12
– Dial gauge (precision 0.01 mm) with tripod. – Measurement report from when the truck crane was put into operation; Delivery receipt.
à
Prerequisites
– The truck crane is rigged with an outrigger span of at least 8.55 x 7.80 m Operating instructions. and is aligned level;
à
– The counterweight combination 53.1 tis fitted according to the lifting capacity table and equipment of the truck crane. – The lattice extension has been removed. – The main boom is telescoped to 50-50-50-50-0. – The load being lifted must not exceed 1 t– where necessary unreeve the hook block.
29.04.2008
s
Maintenance manual GMK 5170
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8 - 33
Maintenance work on the superstructure 8.7 Ball slewing bearing
Measuring tilting play
Example:
The base value of the tilting play is determined and documented by CraneCARE when the ball slewing bearing is put into operation or replaced. The maximum permissible wear is 3.2 mm. This results in the maximum permissible tilting play. Base value + max. permissible wear =
max. permissible tilting play
0.35 mm + 3.2 mm
3.55 mm
Measuring current tilting play
• Raise the main boom to 80° and slew to –135° – display (A).
• Fasten a dial gauge on the front of the turntable (4) and place the switch (1) on to the lower ring (3) as close as possible to the gasket (2).
• Slowly lower the main boom to 25°. • Read off from the dial gauge how far the turntable inclined and record this value as the current tilting play; Appendix – Tilting play measurement report.
à
• Remove the dial gauge. If the current tilting play is greater than the max. permissible tilting play, you must have the ball slewing bearing replaced by CraneCARE.
• Repeat the measurement with the slewing angles –45°
C
+45°
D
+135°
29.04.2008
B
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Maintenance manual GMK 5170
Maintenance work on the superstructure 8.8 Hydraulic system
8.8
Hydraulic system
8.8.1
Checking the oil level
Prerequisites
D
– The truck crane is level and is in on-road mode;
à Operating instructions.
– The truck crane must be standing on a level surface. – The engine is not running and is secured against unauthorized use; p. 2 - 3.
à
Checking the oil level
S
Risk of damage to the hydraulic system! Cleanliness is imperative when handling hydraulic oil! Even new oil must be filtered before it is added to the tank.
• Check whether oil is visible in the centre of the inspection glass (1).
If the oil level is too low:
29.04.2008
• Add more oil; à p. 8 - 46.
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8 - 35
Maintenance work on the superstructure 8.8 Hydraulic system
8.8.2
W
Checking the hydraulic hoses
The inspection work is described in section Checking the hydraulic hoses, p. 7 - 62.
8.8.3
W
Checking ventilation filters
• Check the indicator (1) on the ventilation filter. If the indicator is red:
29.04.2008
• Replace the filter; à p. 8 - 38.
8 - 36
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Maintenance manual GMK 5170
Maintenance work on the superstructure 8.8 Hydraulic system
8.8.4
Checking for leaks
W
• When the engine is running, carry out a visual inspection for leaks on the hydraulic components (tank, pumps, drives, cylinders, control blocks, valves, pipe and hose lines and connections).
• If leaks are detected, check the oil level and top up if necessary;
à Checking the oil level, p. 8 - 35.
G O
Risk of accidents from hydraulic oil spraying out! Never tighten any leaking connections when the system is under pressure. Only change pipes and hoses when the system is depressurised.
Risk of environmental damage due to leaking fluids! Immediately repair or have repaired leakages in the hydraulic system to ensure that no hydraulic oil escapes, seeps into the ground or reaches water when the crane is being used.
After hydraulic components have been changed:
• Bleed the hydraulic system; à Establishing the operating condition, p. 8 - 46.
If damage cannot be rectified immediately or further damage is likely:
29.04.2008
• Inform CraneCARE or your repair crew.
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8 - 37
Maintenance work on the superstructure 8.8 Hydraulic system
8.8.5 Spare parts and tools
Designation Filter
Prerequisites
O
M 12
Changing the ventilation filter
Quantity
GROVE part no.
1
03 319 602
– The engine is not running and is secured against unauthorized use; p. 2 - 3.
à
Risk of damage to the environment from filter residues! Store used hydraulic oil filters in suitable receptacles and have them disposed of properly by qualified personnel.
• Remove the cap (2). • Change the filter (3) and fasten the cap. • Reset the display by depressing the pin (1)
29.04.2008
on the housing.
8 - 38
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Maintenance manual GMK 5170
Maintenance work on the superstructure 8.8 Hydraulic system
8.8.6
G
Pressure accumulator – checking the gas pressure
M 12
Risk of accidents due to incorrect inspection! The gas pressure test must be carried out only by an authorised inspector of pressure tanks or under his supervision or instruction.
The superstructure is equipped with pressure accumulators. The filling pressure at 20 °C is: 1 Pressure accumulator
20 bar
2 Pressure accumulator
180 bar
• Have the filling pressure checked by
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CraneCARE and corrected if necessary.
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8 - 39
Maintenance work on the superstructure 8.8 Hydraulic system
8.8.7
M 12
Taking oil samples
Taking oil samples
H
To determine the usability of the oil, take an oil sample from each of the hydraulic oil tank and the hydraulic system. For detailed information on taking samples (conditions, tools); see Taking oil samples, p. 7 - 67.
à
From the hydraulic oil tank
• Take the sample from the hydraulic oil tank via the valve (1).
From the hydraulic system
• Take the sample from the hydraulic system
Determining the quality of the oil
8 - 40
Compare the quality of the oil with the limit values and carry out the specified measures if necessary; Determining the quality of the oil, p. 7 - 69.
à
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via a gauge port (1), e.g. at a control block.
Maintenance work on the superstructure 8.8 Hydraulic system
8.8.8
Changing the hydraulic oil filter When changing the oil, all oil filters must be replaced. In the event of a warning message, the red symbols in the Warning submenu indicate which oil filters you have to change. 1 Red – Change oil filter 1 2 Red – Change oil filter 2 3 Red – Not used
Spare parts and tools
Designation
Quantity
GROVE part no.
Filter
1
03 325 700
Gasket for oil filter 1
1
03 328 209
Filter
1
03134850
Gasket set for oil filter 2
1
03 326 049
For oil filter 1:
For oil filter 2:
– Torque wrench for 25 Nm. – Receptacle, approx. 5 l;
Prerequisites
à p. 2 - 4.
– The truck crane is level and is in on-road mode;
à Operating instructions.
– The engine is not running and is secured against unauthorized use; p. 2 - 3.
à
O
Risk of damage to the environment from filter residues! Store used hydraulic oil filters in suitable receptacles and have them disposed of properly by qualified personnel.
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Maintenance work on the superstructure 8.8 Hydraulic system
Changing oil filter 1
O
Risk of environmental damage due to leaking fluids! Always let consumables drain into suitable receptacles. Wipe up any fluids that have leaked. Store/dispose of fluids and any soaked equipment properly. Ask about the applicable regulations.
• Remove the cap (1) and pull out the hydraulic oil filter.
• Place the filter in a receptacle. • Remove the spring (2). • Undo the bolt (6). • Take the magnetic rods (3) and the filter (4) out of the filter cage (5).
• Clean the magnetic rods and the filter cage. • Replace any damaged parts.
S
Risk of damage to the hydraulic system! Large amounts of metal particles are a sign of damage in the hydraulic system. Have the hydraulic system inspected by CraneCARE or by your repair crew.
• Replace the gaskets. • Assemble the hydraulic oil filter and insert it.
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• Fasten the cap (1).
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Maintenance work on the superstructure 8.8 Hydraulic system
Changing oil filter 2
• Undo the receptacle (1) at the hexagon. • Change the filter (2). • Replace the gaskets. • Fill the receptacle with clean oil and tighten it – torque 25 Nm.
After changing a filter
S
Risk of damage to the hydraulic pumps! The engine may only be started if the valve in the suction line of the hydraulic pumps is open and there is enough hydraulic oil in the hydraulic oil tank!
• Check the valve on the hydraulic oil tank. Open the valve, if necessary;
à p. 8 - 46.
• Check the oil level. Top up the oil if necessary; à p. 8 - 46. • Start the engine and let it idle for 3 minutes to bleed the system.
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• Check that none of the oil filters is leaking.
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8 - 43
Maintenance work on the superstructure 8.8 Hydraulic system
8.8.9
Changing the hydraulic oil The oil only needs to be changed if the laboratory analysis results indicate this; Determining the quality of the oil, p. 8 - 40.
à
Oil, spare parts, tools
Hydraulic oil in litres 915
Designation according to DIN 51502
Specification Classification
GROVE part no.
H - LP
DIN 51524 T.2 Viscosity: ISO - VG 32
01375719
Designation Gasket 120 x 90
Quantity
GROVE part no.
1
03 328 286
à p. 7 - 68. – One or more receptacles, approx. 915.0 l; à p. 2 - 4. – Connecting piece and hose (tool box);
Prerequisites
à
– The truck crane is level and is in on-road mode; Operating instructions. – The engine is not running and is secured against unauthorized use; p. 2 - 3. – The oil filters have been removed; Changing the hydraulic oil filter, p. 8 - 41.
à
à
Closing the valve
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S
Risk of damage to the hydraulic pumps! Be sure to secure the engine against unauthorized use. If the engine is started while the valve in the suction line is closed, the hydraulic pumps will be damaged!
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Maintenance work on the superstructure 8.8 Hydraulic system
• Close the valve – lever (1) at right angles to the line.
Draining oil
O
Risk of environmental damage due to leaking fluids! Use the supplied connecting piece and hose and a receptacle with sufficient capacity to drain the hydraulic oil.
• Place a receptacle underneath the valve. • Screw the connecting piece and hose onto the valve (1) and drain the oil; the valves, p. 7 - 68.
à Handling
• Change the filters; à p. 8 - 41.
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Maintenance work on the superstructure 8.8 Hydraulic system
Topping up the oil
S
Risk of damage to the hydraulic system! Cleanliness is of the utmost importance when handling hydraulic oil. Even new oil must be filtered before it is added to the tank.
• Remove the cover (3). • Add the new oil through the filter until the level reaches the centre of the inspection glass (1).
• Replace the gasket (2) if necessary and fasten the cap (2).
Establishing the operating condition
Risk of damage to the hydraulic pumps! Open the valve prior to starting the engine. This prevents damage to the hydraulic pumps.
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S
After having changed the oil filters and topped the oil up, you must re-establish the operating condition.
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Maintenance work on the superstructure 8.8 Hydraulic system
Opening the valve
• Open the valve – lever (1) parallel to the line.
• Start the engine. • Carry out all hydraulic functions several times to remove any air in the system.
• Check that none of the oil filters is leaking. • Check the oil level through the inspection glass on the hydraulic oil tank.
à p. 8 - 46.
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Top up oil if necessary;
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Maintenance work on the superstructure 8.8 Hydraulic system
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Maintenance manual GMK 5170
Maintenance work on the superstructure 8.9 Main boom
8.9
Main boom
8.9.1
Lubricating the telescopic sections
Grease, spare parts, tools
Designation Grease for locking pins: 1 kg can
M3
GROVE part no. 03325215
Lubricant paste for the telescopic slide faces: 200 kg barrel
02310394
25 kg bucket
02314698
10 kg bucket
01373458
1 kg cartridge
02314184
0.4 kg refillable cartridge
03329071
– A grease gun for the lubricating nipples on the locking pins. – A grease gun for the lubricating nipples on the upper telescopic slide faces. – A brush or roller for the lower telescopic slide faces.
S 29.04.2008
H
Risk of damage to the wear pads on the telescopic sections! Label the containers with the different lubricants for the main boom. This prevents you using the wrong lubricants at the lubrication points.
Manitowoc Crane Group Germany GmbH recommends pneumatic grease spray guns for more effective lubrication of the telescopic slide faces: Designation
GROVE part no.
Grease spray gun, complete: Mobile, external compressed air connection required
03325445
Manual grease spray gun: 0.4 kg cartridges are refillable using the tyre inflation hose on the truck crane.
03329027
25 m hose for manual grease spray gun:
03329072
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Maintenance work on the superstructure 8.9 Main boom
Prerequisites
– The truck crane is level. – The hook block is unreeved. – The truck crane is supported with an outrigger span of at least 8.55 x 5.96 m. – A counterweight of at least 38.1 t is rigged. – The SLI code for the current rigging mode is entered. – The main boom must be completely retracted and lowered into horizontal position.
Warnings
G G
Risk of overturning when telescoping with an overridden SLI! Only override the SLI when you are requested to do so. Never extend the main boom further than specified when the SLI is overridden. An increased danger of tipping exists because the SLI will not switch off extension of the main boom. Risk of accidents from slipping off the main boom! There is grease residue on the telescopic sections. For this reason, you must not walk on the main boom. Use the extendable ladders provided with your crane!
If the main boom has been telescoped several times, the derricking gear is so heavily loaded that the main boom cannot be derricked. For this reason:
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• Do not lower the main boom below 0°.
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Maintenance manual GMK 5170
Maintenance work on the superstructure 8.9 Main boom
Telescopic section I
• Note the following information regarding maintenance work. • Extend telescopic section I to 50%. • Override the SLI; à Operating instructions. • Extend telescopic section I to 100%. Do not extend it any further. • Use a brush or a roller (lubricant paste) to lubricate the lower slide faces (3).
• Use the grease gun (lubricant paste) to lubricate the upper slide faces at the lubricating nipples (1) on both sides.
• Use the grease gun (lubricant paste) to lubricate the locking pins at the lubricating nipples (2) on both sides.
• Lock and unlock the telescopic section I several times, so that the grease is distributed over the locking pins.
• Extend telescopic section I to 50%. • Remove the SLI override; à Operating instructions.
• Use the grease gun (lubricant paste) to lubricate the upper slide faces at the lubricating nipples (1) on both sides.
• Fully retract telescopic section I. • Fully extend and retract the telescopic section I again so that the grease is distributed over the telescope slide faces. – Override the SLI for this. – Do not extend it any further.
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Maintenance work on the superstructure 8.9 Main boom
Telescopic sections IV - V
• Note the following information regarding maintenance work. The following diagrams show the lubrication of the telescopic section V. The telescopic sections II - IV are lubricated in the same way.
• Extend telescopic section V to 100%. • Override the SLI; à Operating instructions. • Extend telescopic section IV to 25%. Do not extend it any further. • Use a brush or a roller (lubricant paste) to lubricate the lower slide faces (3).
• Use the grease gun (lubricant paste) to lubricate the upper slide faces at the lubricating nipples (1) on both sides.
• Use the grease gun (lubricant paste) to lubricate the locking pins at the lubricating nipples (2) on both sides.
• Lock and unlock the telescopic section V several times, so that the grease is distributed over the locking pins.
• Retract telescopic section V to 50%. • Extend telescopic section IV to 50%. • Remove the SLI override; à Operating instructions.
• Use the grease gun (lubricant paste) to lubricate the upper slide faces at the lubricating nipples (1) on both sides.
• Retract telescopic section IV completely. • Fully extend and retract telescopic section V
• Lubricate the locking pins of telescopic sections II to IV in the same way.
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again so that the grease is distributed over the telescope slide faces.
Maintenance work on the superstructure 8.9 Main boom
8.9.2
Checking the sheaves
M3
• Check all sheaves on the main boom head for damage, wear, mobility and extreme soiling. Have damaged, worn, sluggish or extremely soiled sheaves replaced by CraneCARE or your repair crew.
8.9.3
G
Checking the locking system
M 12
Risk of accidents if maintenance work is not carried out! Have the additional maintenance work on the main boom's locking system performed regularly by CraneCARE. This prevents the complete unlocking of a telescopic section in Emergency operation/Emergency program mode, which could cause serious accidents and damage to the truck crane.
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• Have the main boom's locking system checked by CraneCARE.
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Maintenance work on the superstructure 8.9 Main boom
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Maintenance manual GMK 5170
Maintenance work on the superstructure 8.10 Hoist ropes
8.10
Hoist ropes
8.10.1
Checking the position on the rope drums
G Prerequisites
D
Risk of accidents when the rope drum is turning! Keep away from the turning rope drum. This will prevent your limbs from being drawn in and getting crushed.
– The hoist mirrors are folded out;
à Operating instructions.
à Operating instructions. – The main boom is lowered to about 30°; à Operating instructions. – One hook block is reeved;
– The engine has been started.
Checking the position Check the position of the ropes (1) on at least one full turn of the rope drum for the hoist gears.
• Slowly carry out the Lowering movement and check the rope. – The rope needs to be evenly wound. – The rope turns on the drum must be evenly spaced at a distance of 0 to 2 mm. – The cross-over points must be at an angle of about 180°.
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H
The ropes of the top layer lie over the ropes of the bottom layer at the crossover points.
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Maintenance work on the superstructure 8.10 Hoist ropes
8.10.2
W
Checking the hoist ropes
Spare parts and tools
– Torque wrench for 10 Nm.
Prerequisites
– Establish a rigging mode in accordance with the Lifting capacity table and enter the rigging code on the SLI; Operating instructions.
Checking the rope
• Start the engine.
à – The hook block is reeved 5-fold; à Operating instructions. – The main boom is raised and fully extended; à Operating instructions.
• Unreel the rope and check that the rope is not damaged or improperly
à
reeled ( Assessing the condition of the hoist rope, p. 8 - 58). When 5 turns are left on the rope drum, the lowering limit switch must switch off. If the lowering limit switch does not switch off or switches off too late, it must be reset; Setting the lowering limit switch, p. 8 - 67.
à
• Check the fastening of the clamp (1) for damage and firm seating – torque 10 Nm.
• The free end of the rope must not jut out beyond the flanged wheel.
• The rope wedge must be in the pouch (2). • The rope end on the rope wedge must not show any signs of wear.
• Reel in the rope. At the same time, the rope may not show any signs of kinking or being flattened.
• Check the end of the rope and all parts of the rope end clamp. • Make sure the rope end is correctly fitted in the rope end clamp;
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à Operating instructions.
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Maintenance work on the superstructure 8.10 Hoist ropes
8.10.3
M3
Lubricating the hoist rope
Grease, spare parts and tools
Designation
Quantity
GROVE part no.
1
03133770
Grease
– Brush, roller, spray gun, bath or pressure pump.
Lubricating the rope
Lubricating the rope – significantly prolongs its service life and – keeps the friction between the rope, the sheaves and the hoist drum as low as possible. The lubricant is applied to the rope by – spraying, brushing, rolling or – by running it through a tub filled with lubricant or – by means of high-pressure lubrication with a pressure pump.
H
Manitowoc Crane Group Germany GmbH recommends high-pressure lubrication with a pressure pump for reasons of sustainability, efficiency and environmental protection. When lubricating the hoist ropes, observe the instructions concerning the lubricant. When using the pressure pump, observe the manufacturer's operating manual.
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For more information, please contact CraneCARE.
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Maintenance work on the superstructure 8.10 Hoist ropes
8.10.4
Assessing the condition of the hoist rope
H
If in doubt about damage assessment, always consult an official inspector. To assess the condition of the rope, you must be familiar with the following: – The type of rope (regular lay or lang lay), – the number of load-bearing wires in the outer strands, – the rope diameter ( Operating instructions).
à
In a regular lay rope (1), the wires run more or less in the longitudinal direction of the rope. In a lang lay rope (2), the wires run at an angle of approximately 45° to the longitudinal direction of the rope.
To calculate the number of load-bearing outer wires (1), count the number of outer strands of the rope and multiply by 7.
8 - 58
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H
If there are multiple layers of strands, only the outer layer is counted.
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Maintenance manual GMK 5170
Maintenance work on the superstructure 8.10 Hoist ropes
The following tables show the number of wire breaks in a length 6 times or 30 times the rope diameter which would require rope replacement, for the most common rope diameters.
Number of visible wire breaks Regular lay rope Number of load-bearing outer wires
∅ 13 mm
∅ 16 mm
∅ 19 mm
∅ 22 mm
∅ 24 mm
over 78 mm
over 390 mm
over 96 mm
over 480 mm
over 114 mm
over 570 mm
over 132 mm
over 660 mm
over 144 mm
over 720 mm
101-120
5
10
5
10
5
10
5
10
5
10
121–140
6
11
6
11
6
11
6
11
6
11
Number of visible wire breaks Lang lay rope Number of load-bearing outer wires
∅ 13 mm
∅ 16 mm
∅ 19 mm
∅ 22 mm
∅ 24 mm
over 78 mm
over 390 mm
over 96 mm
over 480 mm
over 114 mm
over 570 mm
over 132 mm
over 660 mm
over 144 mm
over 720 mm
101-120
2
5
2
5
2
5
2
5
2
5
121–140
3
6
3
6
3
6
3
6
3
6
H
S
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! Risk of accidents due to reduced load bearing capacity! Remember that other factors may also make it necessary to replace a rope before the number of wire breaks requiring rope replacement has been reached (age of rope, frequency of use or exceptional loading).
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Maintenance work on the superstructure 8.10 Hoist ropes
Damage
Description
Cause
Wire break (1)
Individual wires are broken; the broken ends of the wires are protruding from the rope.
General wear caused by aging of the rope
Wire break cluster (2) Strand breakage (3)
or subsequent damage resulting from damage to the rope.
Replacement Replace the rope at the latest when the maximum permissible number of wire breaks according to the table are visible externally. Replace the rope immediately if wire breakage clusters or strand breakages occur. The frequency of wire breaks increases with rope age. For reasons of safety, it is advisable to replace the rope while the number of broken wires is still low.
Tarnishing colour is visible externally on the rope.
Rope has been subjected to excessive heat.
Replace the rope immediately.
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Effect of heat
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Maintenance work on the superstructure 8.10 Hoist ropes
Damage Reduced diameter (1)
Description The diameter of the rope has become smaller along large sections.
Cause
Replacement
Structural changes
Immediately replace the rope if the diameter has decreased by 15% or more compared to the nominal diameter.
Corrosion or abrasion.
Immediately replace the rope if the diameter has decreased by 10% or more compared to the nominal diameter.
Corkscrewtype rope deformation (2)
The rope winds its way along its longitudinal axis in a way that is similar to a corkscrew. Deformation is measured with suspended hook block.
Damage resulting from overloading.
Even a small amount of deformation leads to increased abrasion, wire breaks and rough operation of the rope drive. If deformation “x” at a position on the rope is greater than a third of the rope diameter, the rope must be replaced immediately.
Basket-type deformation (3)
Wires of the outer layer protrude. In other areas of the rope, the insert has buckled or is protruding from the rope.
Outer and inner layers have been displaced in relation to each other.
Replace the rope immediately.
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Maintenance work on the superstructure 8.10 Hoist ropes
Damage
Description
Cause
Replacement
Outer layer wires in the form of hair pins are protruding from the rope away from the sheave.
General wear due to aging of the rope or subsequent damage resulting from damage to the rope.
Immediately replace rope if the rope structure has been substantially altered by the loop formations.
Loosening of wires or strands (2)
Outer wires or strands have become loose. Only the inner strands continue to bear the load.
Corrosion or abrasion.
Replace the rope immediately.
Other causes.
The number of broken wires determines when the rope must be replaced.
Knot formation (3)
Repeatedly occurring knot-like thickening of rope; insert often protrudes. Strands bear on each other at thin locations; increased frequency of wire breaks.
General wear due to aging of the rope or subsequent damage resulting from damage to the rope.
Determine number of wire breaks; replace rope immediately if serious knot formation occurs.
Constriction (4)
Diameter reduction over short sections.
General wear caused by aging of the rope.
Replace rope immediately if serious constriction is detected.
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Loop formation (1)
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Maintenance work on the superstructure 8.10 Hoist ropes
Damage
Description
Cause
Replacement
Crushed areas, mostly with wire breaks.
Mechanical damage, e.g. due to driving over the rope.
Determine number of wire breaks; replace rope immediately if serious crushing has occurred.
Kink (2)
Rope deformation with twisting and wire breaks.
Rope in the eyes was pulled straight while twisted.
Replace the rope immediately.
Buckle (3)
Buckled section in rope.
Mechanical damage.
Replace the rope immediately.
Curl formation (4)
Curl-type rope deformation.
Loaded rope was pulled over an edge.
Replace the rope immediately.
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Flattening (1)
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Maintenance work on the superstructure 8.10 Hoist ropes
8.10.5 Spare parts and tools
Replacing the hoist rope – An original replacement part;
à Rope certificate.
– A reel stand with braking block. – Torque wrench for 10 Nm.
S Prerequisites
Risk of accidents from falling load! Use only a replacement rope that has the same technical specifications as the defective rope, or an original replacement rope.
– The truck crane is level. – The main boom is set down on the boom rest. – The hook block is unreeved;
Replacing the old rope
à Operating instructions.
• Unreel the hoist rope until it switches off. • Adjust the lowering limit switch so that you can unreel the rope completely;
à Setting the lowering limit switch, p. 8 - 67.
• Unreel the remaining layers from the hoist drum. • Lock the crane cab to prevent unauthorized use; à p. 2 - 3.
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G
Risk of accidents due to rotating rope drum! Turn off the engine and remove the ignition key so that no unauthorized operation of the hoist can occur.
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Maintenance work on the superstructure 8.10 Hoist ropes
• Remove the clamp (4). • Push the rope through the hole (3) until the rope wedge (1) slides out of the pouch (2).
• Remove the rope wedge and place the rope away from the truck crane.
Installing a new rope
The service life of a rope can be significantly affected by the installation procedure. Errors during fitting reduce service life considerably. Therefore, the following is required:
• Make sure the rope is not twisted when it is installed. • Ensure it does not get dirty or damaged while being installed. • Wind the rope up in the same direction in which the rope is reeled onto the reel.
• Tension the rope slightly while winding it up. • Place the reel stand (1) with the new rope in front of the main boom head. Ensure that the rope is being rolled onto the drum with the right direction of rotation.
• Guide the rope over the right head sheave
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(2) up to the hoist drum.
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Maintenance work on the superstructure 8.10 Hoist ropes
• Guide the rope through the hole (3) until it extends about 1.5 m beyond the pouch (2).
• Feed the free end of the rope back through the pouch.
• Secure the clamp (4) and tighten it – torque 10 Nm.
• Place the rope wedge (1) in the loop.
• Push the rope back until rope wedge (1) is fully in the pouch (2).
• Ensure that the rope wedge, loop and rope end do not protrude beyond the flanged wheel. This will prevent damage.
• Start the engine. • Hold the rope taut and wind up the rope slowly. • Reeving a hook block – reeve it at least 7 times; à Operating instructions. • Raise the main boom to a steep position and extend it fully.
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• Unwind the rope out until only five turns remain on the rope drum.
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Maintenance work on the superstructure 8.10 Hoist ropes
H
G
Watch the hook block when unwinding. The hook block must not rotate! Risk of accidents from incorrectly set lowering limit switch! After installing a new rope, the lowering limit switch must always be reset. In this way you avoid the lowering limit switch switching off too late or not at all, the rope being damaged and the load being dropped.
• Set the lowering limit switch; à p. 8 - 67. • Run in the new rope with small loads so that the hoist rope can settle on the drum.
8.10.6
Setting the lowering limit switch A lowering limit switch is mounted both on the main hoist and on the auxiliary hoist.
Spare parts and tools
Designation Cover gasket
Prerequisites
Quantity
GROVE part no.
2
00550699
à Operating instructions. – The main boom is fully raised and extended; à Operating instructions. – The hook block is reeved 7-fold;
– The hook block is lowered until only five turns of the rope remain on the hoist drum.
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Maintenance work on the superstructure 8.10 Hoist ropes
Setting the lowering limit switch
G
Risk of accidents due to rope end fitting being overloaded! The lowering limit switch must always be reset after repair work to the hoisting gear and after rope replacement. A faulty lowering limit switch must always be replaced!
• Remove the cover (1). • Turn the bolt (2) until you hear the switch activate.
• Screw the cover on again. Replace the gasket if necessary.
• Check whether the lowering limit switch switches off the hoist correctly.
Checking switch-off
• Raise the hook block until there are about 10 turns on the hoist drum. • Lower the hook block and check whether the lowering limit switch switches off properly. The lowering limit switch must switch off the hoisting gear when five rope turns are still on the hoist drum.
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• Correct the setting of the lowering limit switch if necessary.
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Maintenance work on the superstructure 8.11 Cable drums and slewing angle sensor
8.11
Cable drums and slewing angle sensor
8.11.1
Maintenance of the slip ring assemblies
M6
The slip ring assemblies are located in: 1 Cable drum 1 2 Cable drum 2
Spare parts and tools
Designation
Quantity
GROVE part no.
Cable drum 1 cover gasket
1
03324704
Cable drum 2 cover gasket
1
03328294
– Clean, lint-free cloth. – Dry, oil-free compressed air.
Prerequisites
For cable drum 1 – The main boom is set down on the support; For cable drum 2 – The main boom is fully retracted;
à Operating instructions.
à Operating instructions.
For cable drums 1 and 2 – The engine is not running and is secured against unauthorized use; p. 2 - 3. 29.04.2008
à
– The selector handle is removed from the battery master switch.
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Maintenance work on the superstructure 8.11 Cable drums and slewing angle sensor
S G
tt
Risk of damage to the SLI! Before maintenance work on the slip ring assemblies, always switch off the battery master switch so that the cable drum is current-free. This prevents short circuits which may lead to damage to the SLI's central unit. Risk of crushing when extending or retracting the main boom! 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 keys from the crane cab and put up warning signs.
Maintenance of the slip ring assemblies
• Remove cover (1) or (2). • Clean and dry the cover. • Replace the gasket if necessary.
• Only use a cloth and compressed air to remove soiling on the slip rings (2).
• Do not use spray oil. • Check to make sure all screws (1) are tight.
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• Attach the cover on the cable drum.
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Maintenance manual GMK 5170
Maintenance work on the superstructure 8.11 Cable drums and slewing angle sensor
8.11.2 Grease, spare parts, tools
Lubricating the slewing angle sensor
Lubricating grease Grease
Y5
Designation according to DIN 51502
Specification Classification
GROVE part no.
KP - L2K
DIN 51825
00554201
Designation Gasket 16 x 20 Cu DIN 7603
Quantity
GROVE part no.
1
00117134
– Grease gun from the tool set. – Sealing agent (e.g. Hylomar). – Torque wrench for 25 Nm.
Prerequisites
S
– The engine is not running and is secured against unauthorized use; p. 2 - 3.
à
Risk of damage to the slewing angle sensor! Before lubricating, always remove the screw from the slewing angle sensor. This prevents the slewing angle sensor from becoming damaged.
Lubricating
• Remove the plate (1). • Remove the bolt (2). • Clean the lubricating nipple (3) and insert about 5 cm³ of grease.
• Remove any excess grease, and close the lubricating nipple.
• Tighten the bolt with a new gasket and sealant – torque 25 Nm.
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• Attach the plate.
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8 - 71
Maintenance work on the superstructure 8.11 Cable drums and slewing angle sensor
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Blank page
8 - 72
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Maintenance manual GMK 5170
Maintenance work on the superstructure 8.12 Central lubrication system
8.12
Central lubrication system
8.12.1
Checking the level
W The maintenance of the pump (1) is the same Central as the maintenance on the carrier; lubrication system, p. 7 - 77.
à
8.13
Hook blocks
8.13.1
Checking the sheaves
M3
• Check the sheaves in the hook blocks for damage, wear, mobility and extreme soiling.
29.04.2008
Have damaged, worn, sluggish or extremely soiled sheaves replaced by CraneCARE or your repair crew.
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8 - 73
Maintenance work on the superstructure 8.13 Hook blocks
8.13.2
M 12
Lubricating • Comply also with the à Run-in regulations, p. 4 - 1.
Grease, spare parts, tools
Lubricating grease Grease
Designation according to DIN 51502
Specification Classification
GROVE part no.
KP - L2K
DIN 51825
00554201
– Grease gun from the tool set.
à Operating instructions.
Prerequisites
– The hook block has been reeved at least twice;
Lubricating hook blocks
On the hook blocks, the sheaves, cross-members and load hooks of the axial bearings have to be lubricated. The diagram gives an example of the location of the lubricating nipples (1), (2) and (3) on a hook block. There are other lubricating nipples on the other side.
• Clean the lubricating nipples on all hook
29.04.2008
blocks supplied and on the hook tackle and lubricate them with a grease gun.
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Maintenance manual GMK 5170
Maintenance work on the superstructure 8.14 Electrical system
8.14
Electrical system
8.14.1
Checking the lighting and indicators
G
D
Risk of accidents if the safety devices are faulty! If the lamps or the buzzer fail, notify CraneCARE and have the error rectified.
• Check the lamps and displays on the ECOS and SLI control units;
à Operating instructions.
• Check the following functions: – Windscreen wipers, windscreen washing system,
– spotlight on the crane cabin to light up working area, air traffic control light, – spotlight on the main boom (xenon light), – Horn, anemometer.
G
Danger of accidents from exploding glass bodies and high-voltage! The glass body for gas discharge lamps (xenon lights) is under pressure. If the lamp breaks, glass splinters shatter explosively and scatter. Xenon light operates with high-voltage. There is still a danger of residual voltage discharging (electrocution) even when the battery master switch is switched off. Have faulty lamps replaced only by qualified personnel who have the relevant protective equipment.
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• Have faulty lamps in the spotlights replaced only by qualified personnel.
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8 - 75
Maintenance work on the superstructure 8.14 Electrical system
8.14.2
M1
Checking the batteries
• Switch the battery master switch (2) off and remove the selector handle.
• Check the batteries (1) in the same way as when checking them on the carrier; Checking the batteries, p. 7 - 82.
à
8.14.3
Checking the charge level of the batteries
M3
• Check the charge level in the same way as when checking it on the carrier;
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à Checking the charge level of the batteries, p. 7 - 84.
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Maintenance manual GMK 5170
Maintenance work on the superstructure 8.15 Air-conditioning system
8.15
Air-conditioning system
8.15.1
Checking the air-conditioning system
M1
• Check the air-conditioning system in the same way as when checking it on the carrier;
8.15.2
S
à Checking the air-conditioning system, p. 7 - 87.
Cleaning the condenser fins
M1
Risk of damage to the condenser! Do not use a high pressure cleaner or steam jet cleaner. The powerful jet may damage the fins. Use only compressed air for cleaning.
• Switch the air-conditioning system off. • Clean the condenser fins with compressed
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air (1).
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8 - 77
Maintenance work on the superstructure 8.15 Air-conditioning system
8.15.3
M6
Checking hoses
G
Danger of burns from escaping refrigerant! Wear suitable protective goggles and gloves when checking hoses and connections. This will prevent injury from suddenly escaping refrigerant. Seek medical attention if skin or eyes come into contact with refrigerant.
• Check all refrigerant hoses for damage and worn areas. Have damaged hoses replaced by CraneCARE only.
8.15.4
Checking the entire air conditioning system
H
G
M 12
This check may only be carried out by CraneCARE!
Danger of burns from escaping refrigerant! Wear suitable protective goggles and gloves when checking hoses and connections. This will prevent injury from suddenly escaping refrigerant. Seek medical attention if skin or eyes come into contact with refrigerant.
• Have the entire air-conditioning system checked for leaks and proper functioning. The inspection of the air-conditioning system includes most importantly the inspection of – the refrigerant collector, in accordance with the pressure container regulations (test group II) and – the refrigerant compressor. Use only suitable refrigerant for topping up.
Refrigerant Fill quantity in kg
Tetrafluoroethane (R134a)
CAS no. EC no. 811-97-2 212-377-0 29.04.2008
2.0
Designation
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Maintenance manual GMK 5170
Maintenance work on the superstructure 8.16 Other maintenance work
8.16
Other maintenance work
8.16.1
Checking the auxiliary heater for correct operation
M1
Check the auxiliary heating in the same way you would check it on the carChecking the auxiliary heater for correct operation, p. 7 - 104. rier;
à
8.16.2
Lubricating the piston rod of the derricking cylinder
Grease, spare parts and tools
Designation
M1
GROVE part no.
Lubricant RHUS SW 2
03325215
– Brush.
S
Risk of damage to the derricking cylinder's gasket due to rust! Be sure that the uncovered end of the piston rod is always kept lubricated. In this way you can avoid rust which damages the gasket in the derricking cylinder head when lowering completely.
• Clean the uncovered end (1) of the piston rod of old grease, dirt particles and rust.
• Slightly grease the uncovered end, making sure the grease coat is evenly distributed.
After every high-pressure cleaning operation on the truck crane:
• Grease the piston rod. 29.04.2008
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8 - 79
Maintenance work on the superstructure 8.16 Other maintenance work
H 8.16.3
You can also prevent rust if you turn the main boom to the side between maintenance intervals and completely lower it.
Y2
Having the fire extinguisher checked
Your truck crane has fire extinguishers, depending on its scope of equipment.
H
The maintenance interval may be smaller, depending on the respective national regulations. Ask about the national and local regulations at the local Fire Safety Authority.
• Follow the operating instructions (1) on the fire extinguisher. • Have the fire extinguisher serviced by trained personnel in good time before the maintenance interval specified on the label (2) expires.
29.04.2008
S
Danger due to the fire extinguisher not working! There is no guarantee that the fire extinguisher is still working properly after the maintenance interval on the label has expired.
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Maintenance manual GMK 5170
9 Longer periods out of service
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9
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Maintenance manual GMK 5170
Longer periods out of service
9
Longer periods out of service Carry out the following work if the truck crane is to be out of operation for a long period (months).
Taking out of service
• Clean the truck crane thoroughly inside and outside. • Remove rust and touch up the paintwork. • Parts that 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 as per the maintenance plans. • Seal all air filters. • Increase the tyre pressure by 10% and mark the tyre positioning, or support the truck crane and let it stand supported.
• Observe the specifications on preservation in the engine manufacturer's documentation.
Checking
• Check the levels in the fuel tanks. Always keep the tanks filled. • Check the batteries every week and recharge them if necessary. • Check the tyre pressure each week and correct if necessary. • Perform a full functional check of the truck crane every two weeks. (Open all air filters beforehand!)
• Run the hydraulic systems up to a fluid temperature of approx. 50 °C and check all functions of the carrier and superstructure hydraulic systems.
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9-1
Longer periods out of service
• Ensure that the tyre positioning is different each time the crane is parked (without outriggers).
• Seal all air filters again. If the truck crane is out of service for more than 12 months:
• Carry out all maintenance work in accordance with maintenance plan M 12.
• Observe the specifications on preservation in the engine manufacturer's documentation.
Starting-up
• Open all air filters. • Inflate the tyres up to the prescribed pressure. • Carry out periodic maintenance work in accordance with the maintenance plans in Chapter 5.
• Observe the specifications on preservation and putting back into opera-
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tion in the engine manufacturer's documentation.
9-2
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Maintenance manual GMK 5170
10 Torques
10.1
Torques for retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 -
1
10.2
Special torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 -
2
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10
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Maintenance manual GMK 5170
Torques 10.1 Torques for retaining bolts
10
Torques
10.1
Torques for retaining bolts Metric standard screw-thread Metric fine screw-thread
Approximate values
Thread size (mm) Spanner wrench size (mm)
Torques (greatest permissible pre-tensioning for bolts) for oiled bolts (Nm)
10.09.2013
Bolt quality Hexagon bolt
Cylinder screw
M8 M8x1
13
6
M 10 M 10 x 1.25
17
M 12 M 12 x 1.5
10.9
12.9
23 24
32 34
36 41
8
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
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3 113 013 en
8.8
10 - 1
Torques 10.2 Special torques
10.2
Special torques
Designation
Thread size (mm)
Spanner size (mm) Hexagon bolt
Cylinder screw
Tightening torque (Nm)
Suspension strut: – Bracket for the vehicle frame, top
M 16
—
14
265
– Bracket for the vehicle frame, bottom
M 24
—
19
900
– Flange suspension strut, bottom
M 20
17
520
– Half-shell steering arm
M 16
14
265
— —
70 - 80 160 - 180
Steering linkage: – Bolts for clamp straps
M 12 x 1.5 M 14 x 1.5
19 22
Others: – Coolant hose clamps – Wheel nuts
4 M 22 x 1.5
– Retaining bolt for the ball slewing bearing
650
Please contact Manitowoc Crane Care. M 10
17
—
10
10.09.2013
– Hoist drum rope wedge
32
10 - 2
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Correction sheet – Maintenance manual GMK 5170
11 Spare parts required for maintenance
11.1
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 -
1
11.2
Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 -
1
11.3
Spare parts for the carrier. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 -
5
11.4
Spare parts for the superstructure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 -
7
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11
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Maintenance manual GMK 5170
Spare parts required for maintenance 11.1 General information
11 11.1
Spare parts required for maintenance
General information The spare parts required for maintenance are divided into – Lighting, – spare parts for the carrier and – spare parts for the superstructure. Listed here are only the spare parts required for the maintenance work described. A more detailed spare parts document can be found in the Spare parts list supplied. An overview of the required lubricants can be found in: – Lubricants list, p. 6 - 2, – Lubricant applications, p. 6 - 3.
11.2
Lighting Lamps are listed according to the installation position. The list includes standard and additional lighting equipment for the truck crane. Lighting specific to certain countries can be found in the Spare parts list, in the Country specific package section.
G
Danger of accidents from exploding glass bodies and high-voltage! The glass body for gas discharge lamps (xenon lights) is under pressure. If the lamp breaks, glass splinters shatter explosively and scatter. Xenon light operates with high-voltage. There is still a danger of residual voltage discharging (electrocution) even when the battery master switch is switched off. Have faulty lamps replaced only by qualified personnel who have the relevant protective equipment.
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11 - 1
Spare parts required for maintenance 11.2 Lighting
Place of installation
GROVE part number
Designation
Output (W)
– Low-beam headlight
00438912
H1 24 V
70
– Low-beam headlight (USA)
00438912
H1 24V
70
– Full-beam headlight
00438912
H1 24 V
70
– Full beam headlight (USA)
00438912
H1 24V
70
– Parking light
00438514
C5W 24 V
5
– Parking light (USA)
01926635
24V 5W
5
– Turn indicator light
00439055
P25-1 24 V
21
– Turn indicator light (USA)
00438912
H1 24V
21
– Yellow side marker light
03320937
LED
03327578
8GA 006841241
24V/21W
– Rear light
01207144
R19/10 24V
10
– Brake light
00439055
P25-1 24V
21
– Turn indicator light
00439055
P25-1 24V
21
– Fog tail light
00439055
P25-1 24V
21
– Reversing light
00439055
P25-1 24V
21
03320937
LED
03323568
LED
– Marker light, left
00438897
T8/4 24V
4
– Marker light, right
00438897
T8/4 24V
4
00438514
C5W 24 V
5
CARRIER LIGHTING: Front headlight: (integrated in the bumper)
Front, side turn indicator lights: (under the access ladder to the driver's cab) – Turn indicator light Rear lights: (at the rear of the chassis)
Side marker lights, yellow: (only at the rear of the chassis) – Side marker light Side marker lights, yellow: (at the sides, along the chassis) – Side marker light Rear marker lights, red/white:
Front marker lights, white: (at the top on the driver's cab) – Marker light
11 - 2
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Maintenance manual GMK 5170
29.04.2008
(at the rear of the chassis)
Spare parts required for maintenance 11.2 Lighting
Place of installation
GROVE part number
Designation
Output (W)
02316460
H3 24V
70
00438912
H1 24V
70
– Interior lamp
00550434
K 24 V
10
– Reading lamp
00550434
K 24 V
10
– Marker light, left
03323856
LED
– Marker light, right
03323567
LED
03329492
LED
00438912
H1 24V
70
– Inside light
00550434
K 24V
10
– Reading light
03328445
P21W 24V
10
02316460
8GH002090251
70
Outrigger beam spotlights: (above the front and rear outrigger beams) – Filament lamp Rotating beacon, yellow: (on the driver's cab) – Filament lamp Inside lights: (in the driver's cab)
SUPERSTRUCTURE LIGHTING: Marker lights, white: (on the main boom head)
Rear marker lights, red: (on the turntable) – Marker light Rotating beacon, yellow: (on the turntable) – Filament lamp Inside lights: (in the crane cab)
Spotlight, attachable: (at the front of the crane cab) – Filament lamp
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11 - 3
Spare parts required for maintenance 11.2 Lighting
Place of installation
GROVE part number
Designation
Output (W)
03326694
8GS007949101
35
02 309 610
810992RSY
100
03 323 856
LED
Spotlights, electrically adjustable: (at the front of the main boom) – Filament lamp Spotlight, swinging: (at the front of the main boom) – Halogen bulb Hoist lighting: (behind the hoist)
29.04.2008
– Marker light
11 - 4
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Maintenance manual GMK 5170
Spare parts required for maintenance 11.3 Spare parts for the carrier
11.3
Spare parts for the carrier
Subassemblies and spare parts Carrier
GROVE part number
Quantity, in single parts for maintenance interval W
M1
M3
M6
M 12
Engine Oil drain valve (instead of drain plug) Gasket 26 x 31 Cu DIN 7603 Air filter
03046878
1 x when the oil is changed the first time (recommended modification)
00117147 03326272
1 (when the symbol lights up)
Filter
03 322 877
1
Gasket
03 322 879
1
Filter element
03 328 656
1
Filter and gasket
03 045 818
Fuel system
1
Transfer case Gasket 30 x 36 Cu DIN 7603
00117151
Gasket 16 x 20 Cu DIN 7603
00117134
1
1 1
Axle lines Axle centre drive (for max. 10 x 8 x 10) Gasket 36 x 42 Cu DIN 7603
01 371 208
2
3
Gasket 30 x 38 Cu DIN 7603
01 925 343
1
2
Gasket 16 x 22 Cu DIN 7603
00 117 135
1
2
8
8
Axle lines Final drive (for max. 10 x 8 x 10) Gasket 24 x 29 Cu DIN 7603
00117145
Wheels Wheel nuts (12 per wheel)
01207756
(in case of damage)
Compressed air system 01570750
(5)
Gasket 22 x 27 Cu DIN 7603
00117142
(5)
Filter cartridge
03043578
29.04.2008
Valve (in case of defect)
1
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11 - 5
Spare parts required for maintenance 11.3 Spare parts for the carrier
Subassemblies and spare parts Carrier
GROVE part number
Quantity, in single parts for maintenance interval W
M1
M3
M6
M 12
Hydraulic system Filter
03329152
(2)
Gasket set
03135778
2
Filter
03329152
Gasket set
03135778
2 for every oil change and when the symbol lights up
Oil tank cover gasket 140/90 x 3 Ventilation filter
1 for every oil change (in case of damage)
03098598 03324588
1
Particulate filter Clamp strap
03134864
Filter
03134863
1
Clamp strap
03134864
2
Subassemblies and spare parts Carrier
GROVE part number
(2)
(in case of damage)
Quantity, in single parts for maintenance interval Y2
Y3
Y5
Y6
Y 10
Engine Oil filter
03328365
1
Gasket set
03328606
1
Filter with set of gaskets
03 326 293
2
Gasket 30 x 36 Cu DIN 7603
00 117 151
1
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Automatic transmission
11 - 6
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Maintenance manual GMK 5170
Spare parts required for maintenance 11.4 Spare parts for the superstructure
11.4
Spare parts for the superstructure
Subassemblies and spare parts Superstructure
GROVE part number
Quantity, in single parts for maintenance interval W
M1
M3
M6
M 12
Engine 03 328 263
1 (when the symbol lights up)
Filter (Filter 1)
03322877
1
Gasket
03322879
1
Filter part (in case of damage)
03328656
1
Filter with gasket (large; filter 3)
03328573
1
Filter with gasket (small; filter 2)
03328574
1
Air filter Fuel system
Hoists Gasket 18 x 24 Cu DIN 7603
01377793
Gasket 18 x 24 Cu DIN 7603
01377793
(4)
(in case of damage) 10
Slewing gear Gasket 10 x 14 Cu DIN 7603
00117125
Gasket 10 x 14 Cu DIN 7603
00117125
3
Gasket 14 x 20 Cu DIN 7603
00117132
3
Ventilation filter
03 319 602
1
Oil filter 1
03134850
1
Gasket for oil filter 1
03 328 209
Oil filter 2
03134850
Housing gasket set, oil filter 2
03326049
Gasket 120 x 90
03 328 286
(3)
(in case of damage)
Hydraulic system
Change the oil filter at every oil change and if a warning message is displayed.
1 1 1 1
Hoist ropes Grease (20 litre canister)
03133770
1
Cover gasket for the lowering limit switch
00550699
2 (in case of damage) for every rope change on the hoist
29.04.2008
Cable drums Cable drum 1 cover gasket
03324704
Cable drum 2 cover gasket
03328294
(in case of damage)
(1) (1)
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11 - 7
Spare parts required for maintenance 11.4 Spare parts for the superstructure
Subassemblies and spare parts Superstructure
GROVE part number
Quantity, in single parts for maintenance interval Y2
Y3
Y5
Y6
Y 10
Engine Oil filter, complete
03328556
1
Slewing angle sensor 00117134
(1)
29.04.2008
Gasket 16 x 20 Cu DIN 7603
11 - 8
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11
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Appendix
Maintenance manual GMK 5170
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Maintenance manual GMK 5170
Appendix
Date of commission/date of inspection
Operational condition since the last inspection
Kmi
Factor of the load spectrum
[hrs.]
Operating hours of the entire crane
[hrs.]
Operating hours of the superstructure
[hrs.]
Operating hours of the superstructure since the last inspection
Last general overhaul performed on..................................
[hrs.]
Operating hours of the winch
........................ ........................ ........................ ........................
........................ ........................ ........................ ........................ ........................
CAUTION: A general overhaul is to be performed every 10 years! Alternative provision, refer to Section 5.4.2, p. 5 - 25.
(*)
"i"
Inspection interval no. (max. 1 year)
Crane model: Work number: Commissioned on: Winch serial number as shown on model plate: Last general overhaul performed on: Winch design data (see operating instructions): Engine group: Load spectrum: Factor of the load spectrum: Theoretical service life:
[hrs.]
Operating hours of the winch since the last inspection
Table to determine the remaining theoretical service life on winch no. ..........
[hrs.]
Note
Name of the approved inspector
= Effective working hours in the inspection interval "i" according to Section 2.2 (*) Copy last line of the previous page to the following page.
Ti
Kmi = Load spectrum factor in the inspection interval "i" according to Section 2.1
Km = Factor of the load spectrum used to calculate the winch. This factor is given in the operating instructions.
Di - 1= Remaining theoretical service life after the previous inspection
= Remaining theoretical service life
Signature
Di
Name of competent person
=Used proportion of theoretical service life since the last inspection
[hrs.]
Di = Di-1 - Si
Remaining theoretical service life
Si
Used proportion of theoretical service life D:
Signature
Date of commission/date of inspection
Operational condition since the last inspection
Kmi
Factor of the load spectrum
[hrs.]
Operating hours of the entire crane
[hrs.]
Operating hours of the superstructure
[hrs.]
Operating hours of the superstructure since the last inspection
Last general overhaul performed on..................................
[hrs.]
Operating hours of the winch
........................ ........................ ........................ ........................
........................ ........................ ........................ ........................ ........................
CAUTION: A general overhaul is to be performed every 10 years! Alternative provision, refer to Section 5.4.2, p. 5 - 25.
"i"
Inspection interval no. (max. 1 year)
Crane model: Work number: Commissioned on: Winch serial number as shown on model plate: Last general overhaul performed on: Winch design data (see operating instructions): Engine group: Load spectrum: Factor of the load spectrum: Theoretical service life:
[hrs.]
Operating hours of the winch since the last inspection
Table to determine the remaining theoretical service life on winch no. ..........
[hrs.]
Note
Name of the approved inspector
= Effective working hours in the inspection interval "i" according to Section 2.2 Copy last line of the previous page to the following page.
(*)
Signature
Ti
Kmi = Load spectrum factor in the inspection interval "i" according to Section 2.1
Km = Factor of the load spectrum used to calculate the winch. This factor is given in the operating instructions.
Di - 1 = Remaining theoretical service life after the previous inspection
= Used proportion of theoretical service life since the last inspection
Signature
= Remaining theoretical service life
Name of competent person
Si
[hrs.]
Di = Di-1 - Si
Remaining theoretical service life
Di
Used proportion of theoretical service life D:
Date
–135° (A)
–45° (B)
+135° (D)
ok
............... mm
+ 3.2 mm
............... mm
faulty
replaced on
Ball slewing bearing
max. permissible tilting play:
max. permissible wear:
Base value:
Signature
• Always measure the current tilting play as described in Section Measuring tilting play, p. 8 - 33.
+45° (C)
Current tilting play
Tilting play measurement report
Date
–135° (A)
–45° (B)
+135° (D)
ok
............... mm
+ 3.2 mm
............... mm
faulty
replaced on
Ball slewing bearing
max. permissible tilting play:
max. permissible wear:
Base value:
Signature
• Always measure the current tilting play as described in Section Measuring tilting play, p. 8 - 33.
+45° (C)
Current tilting play
Tilting play measurement report
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