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GROVE GMK4090
Manitowoc GROVE GMK4090 Maintenance Manual
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Maintenance manual
3 302 649 en
07.12.2017
2
Table of Contents
Table of Contents
3
6 Lubricants and Consumables
15
11 Spare Parts Required for Maintenance
27
Default Chapter
31
General Instructions
31
Using the Maintenance Manual
31
Warnings and Symbols
31
Maintenance Instructions
32
Instructions Regarding the Electronic Controls
34
Safety Instructions for Welding Work
34
Definition of Direction Information
35
Conversion Table for US Measuring Units
36
Safety and Environmental Protection
37
Safety Rules
37
Securing against Unauthorised Use
39
Handling Substances Which Are Harmful to the Environment
40
Disposal of the Truck Crane
42
Cleaning
43
Run-In Regulations
47
Maintenance Overview
49
Lubricants
77
Lubricants List
78
Lubricant Applications List
79
Lubricants and Consumables
77
Refrigerant
81
Torques
311
Spare Parts Required for Maintenance
313
General Information
313
Lighting
313
Spare Parts for the Carrier
317
Spare Parts for the Superstructure
320
Consumables
81
Fuel
81
Engine Coolant Admixtures
81
After-Treatment of Exhaust Gases
82
Windscreen Washing System Admixtures
82
Fuel for Crane Cab Heating System
82
Maintenance Work on the Carrier
83
General Instructions
83
Covers
83
Tilting/Lowering the Driver's Cabin
84
Overview of Maintenance Work on the Carrier
86
Symbols for Maintenance Work
93
Engine
95
Check the Oil Level
95
Topping up the Oil
97
Checking the Air Filter
98
Checking the Coolant Level
99
General Inspection
100
Have the Radiator Checked/Cleaned
100
Checking the V-Belt Tension
105
Changing the Oil and Oil Filter
107
Fuel System
109
Draining off Water from Fuel Filter 1
110
Replacing Fuel Filter 1
111
Replacing Fuel Filter 2
113
Exhaust System with Exhaust Emission Control
115
Checking the Adblue Tank Level
116
Filling up with Adblue
116
Check the Exhaust System for External Damage
117
Having the Adblue System Checked
119
Transmission
121
General Inspection
122
Check the Oil Level
123
Changing the Oil
124
Transfer Case
127
General Inspection
127
Check the Oil Level
127
Changing the Oil
128
Angle Gear
131
General Inspection
132
Check the Oil Level
132
Changing the Oil and the Oil Filter
134
Axle Lines
137
General Inspection
137
Axle Centre Drives - Checking the Oil Level
137
Axle Centre Drives - Changing the Oil
139
Final Drives - Checking the Oil Level
143
Final Drives - Changing the Oil
144
Lubricating the Cardan Shafts in the Axle Lines
146
Lubricating Longitudinal Cardan Shafts
147
Wheels
149
Checking the Tyres for Damage
149
Checking the Tyre Pressure
150
Checking that the Wheel Nuts Are Tight
151
Changing the Wheels
152
Vehicle Brake
157
Checking Brake Lining Thickness
157
Suspension
159
Suspension Struts - Checking the Oil Level
159
Suspension Struts - Checking the Fastening
161
Forced Lever - Checking Correct Functioning
162
Pressure Accumulator - Checking the Gas Pressure
163
Steering
165
Checking the Steering Monitoring
165
Checking the Angle Sensors
166
Checking for Leaks
167
Compressed Air System
169
Draining Water from the Compressed Air System
169
Checking for Leaks
170
Replacing the Filter Cartridge of the Compressed Air Drier
171
Hydraulic System
173
Check the Oil Level
173
Checking the Hydraulic Hoses
174
Checking for Leaks
174
Cleaning the Magnetic Rods
175
Changing the Ventilation Filter
177
Taking Oil Samples
178
Changing the Hydraulic Oil
183
Changing the Hydraulic Oil Filter
188
Central Lubrication System
191
Checking the Filling Level
191
Bleeding the Central Lubrication System
193
Triggering Intermediate Lubrication
194
Electrical System
195
Checking the Lighting and Indicators
195
Checking the Batteries
196
Checking the Charge Level of the Batteries
198
Charging the Batteries Using the Battery Charger
200
Check the External Starting Socket
201
Air Conditioning System
203
Checking the Air Conditioning System
203
Checking Hoses
203
Cleaning the Condenser Fins
204
Checking the Entire Air Conditioning System
204
Changing the Pollen Filter
206
Towbar Coupling
207
Lubricating the Towbar Coupling
207
Checking the Bearing
209
Checking the Cotter Pin
210
Checking the Lower Bushing
211
Checking the Initial Tension of the Springs
211
Checking the Support Ring
212
Checking the Function of the Coupling Jaw/ Resetting the Middle Position
212
Other Maintenance Work
215
Checking Windscreen Washing System
215
Lubricating the Outrigger Beams
216
Checking the Auxiliary Heater
217
Lubricating the Cab Door
217
Lubricating the Connecting and Socket Pins
218
Renewing the Corrosion Protection
219
Having the Fire Extinguisher Checked
221
Maintenance Work on the Superstructure
223
General Instructions
223
Covers
223
Overview of Maintenance Work on the Superstructure
224
Symbols for Maintenance Work
229
Hoists
231
Checking the Oil Level
231
General Inspection
232
Checking the Hoist Brake
232
Changing the Oil/Checking the Oil
234
Having a Partial Inspection Carried out
235
Having a General Inspection Carried out
235
Slewing Gear
237
Checking the Oil Level
237
Checking for Leaks
238
Checking the Slewing Gear Brake
238
Changing the Oil/Checking the Oil
242
Slewing Bearing
243
Checking the Screws
243
Lubricating the Gear Teeth
247
General Inspection
249
Measuring Tilting Play
250
Lubricating the Locking of Turntable
252
Hydraulic System
253
Check the Oil Level
253
Checking the Hydraulic Hoses
254
Checking Ventilation Filters
254
Checking for Leaks
255
Cleaning the Magnetic Rods
256
Changing the Ventilation Filter
258
Pressure Accumulator - Checking the Gas Pressure
259
Taking Oil Samples
259
Changing the Hydraulic Oil Filter
261
Changing the Hydraulic Oil
264
Main Boom
267
Grease the Piston Rod of the Derricking Cylinder
267
Lubricating the Telescopic Sections
268
Lubricating the Sheaves
272
Checking the Locking System
272
Hoist Ropes
273
Checking the Winding
273
Checking the Hoist Ropes
274
Lubricating the Hoist Rope
275
Assessing the Condition of the Hoist Rope
276
Replacing the Hoist Rope
282
Setting the Lowering Limit Switch
285
Cable Drums
287
Maintenance of the Slip Ring Assemblies
287
Central Lubrication System
289
Checking the Filling Level
289
Hook Blocks
291
Checking the Sheaves
291
Lubricating Hook Blocks
291
Electrical System
295
Checking the Lighting and Indicators
295
Have the Battery on the Electronics Board Replaced
296
Air Conditioning System
297
Checking the Air Conditioning System
297
Cleaning the Condenser Fins
297
Checking Hoses
298
Checking the Entire Air Conditioning System
298
Changing the Pollen Filter
300
Other Maintenance Work
301
Checking Windscreen Washing System
301
Checking the Auxiliary Heater
302
Lubricating the Crane Cab Door
303
Lubricating the Step
304
Lubricating the Connecting and Socket Pins
305
Renewing the Corrosion Protection
306
Having the Fire Extinguisher Checked
308
Longer Out-Of-Service Periods
309
Appendix
323
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Manitowoc GROVE GMK4090 Specifications
General
Brand
Manitowoc
Model
GROVE GMK4090
Category
Construction Equipment
Language
English
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