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Grove GMK 4100L-1
Manitowoc Grove GMK 4100L-1 User Manual
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Maintenance manual
3 302 364 en
25.11.2016
2
Table of Contents
Table of Contents
19
General Instructions
23
Instructions for Using the Maintenance Manual
23
Warnings and Symbols
23
Maintenance Instructions
24
Instructions Regarding the Electronic Controls
26
Safety Instructions for Welding Work
26
Definition of Direction References
27
2 2 Safety and Environmental Protection
29
Safety and Environmental Protection
31
Safety Rules
31
Securing against Unauthorised Use
33
Handling Substances Which Are Harmful to the Environment
34
Disposal of the Truck Crane
36
Cleaning
39
Run-In Regulations
45
Maintenance Overview
49
6 6 Lubricants and Consumables
77
Lubricants
79
Lubricants List
80
Lubricant Applications List
81
Lubricants and Consumables
79
Consumables
83
Fuel
83
Engine Coolant Admixtures
83
Exhaust Gas Emission Control
84
Windscreen Washing System Admixtures
84
Fuel for Crane Cab Heating System
84
Refrigerant
83
7 7 Maintenance Work on the Carrier
85
General Instructions
89
Covers
89
Maintenance Work on the Carrier
89
Tilting and Lowering the Driver's Cab
90
Overview of Maintenance Work on the Carrier
92
Symbols for Maintenance Work
99
Checking the Oil Level
101
Engine
101
Topping up the Oil
103
Checking the Air Filter
104
Checking the Coolant Level
105
General Inspection
106
Have the Radiator Checked/Cleaned
106
Checking the V-Belt Tension
111
Changing the Oil and Oil Filter
113
Fuel System
115
Draining off Water from Fuel Filter 1
116
Replacing Fuel Filter 1
117
Replacing Fuel Filter 2
119
Exhaust System with Exhaust Emission Control
121
Checking the Adblue Tank Level
122
Filling up with Adblue
122
Check the Exhaust System for External Damage
123
Having the Adblue System Checked
125
Transmission
127
General Inspection
128
Checking the Oil Level
129
Changing the Oil
130
Checking the Oil Level
133
General Inspection
133
Transfer Case
133
Changing the Oil
134
Angle Gear
137
Checking the Oil Level
138
General Inspection
138
Changing the Oil and the Oil Filter
140
Axle Centre Drives - Checking the Oil Level
143
Axle Lines
143
General Inspection
143
Axle Centre Drives - Changing the Oil
145
Final Drives - Checking the Oil Level
149
Final Drives - Changing the Oil
150
Lubricating the Cardan Shafts in the Axle Lines
152
Lubricating Longitudinal Cardan Shafts
153
Checking the Tyres for Damage
155
Wheels
155
Checking the Tyre Pressure
156
Checking that the Wheel Nuts Are Tight
157
Changing the Wheels
158
Checking the Wear Display
163
Vehicle Brake
163
Checking Disc Brakes
164
Suspension
171
Suspension Struts - Checking the Oil Level
171
Suspension Struts - Checking the Fastening
173
Forced Lever - Checking Correct Functioning
174
Pressure Accumulator - Checking the Gas Pressure
175
Checking the Steering Monitoring
177
Steering
177
Checking the Angle Sensors
178
Checking for Leaks
179
Compressed Air System
181
Draining Water from the Compressed Air System
181
Checking for Leaks
182
Replacing the Filter Cartridge of the Compressed Air Drier
183
Checking the Oil Level
185
Hydraulic System
185
Checking for Leaks
186
Checking the Hydraulic Hoses
186
Cleaning the Magnetic Rods
187
Changing the Ventilation Filter
189
Taking Oil Samples
190
Changing the Hydraulic Oil
195
Changing the Hydraulic Oil Filter
199
Central Lubrication System
203
Checking the Level
203
Bleeding the Central Lubrication System
205
Triggering Intermediate Lubrication
206
Checking the Lighting and Indicators
207
Electrical System
207
Checking the Batteries
208
Checking the Charge Level of the Batteries
210
Charging the Batteries Using the Battery Charger
212
Check the External Starting Socket
213
Air-Conditioning System
215
Checking Hoses
215
Checking the Air-Conditioning System
215
Checking the Entire Air-Conditioning System
216
Cleaning the Condenser Fins
216
Changing the Pollen Filter
218
Lubricating the Towbar Coupling
219
Towbar Coupling
219
Checking the Bearing
221
Checking the Cotter Pin
222
Checking the Initial Tension of the Springs
223
Checking the Lower Bushing
223
Checking the Function of the Coupling Jaw/ Resetting the Middle Position
224
Checking the Support Ring
224
Checking the Windscreen Washing System
227
Other Maintenance Work
227
Lubricating the Outrigger Beams
228
Checking the Auxiliary Heater
229
Lubricating the Cab Door
229
Lubricating the Connecting and Socket Pins
230
Renewing the Corrosion Protection
231
Having the Fire Extinguisher Checked
233
8 8 Maintenance Work on the Superstructure
235
Maintenance Work on the Superstructure
237
Covers
237
Overview of Maintenance Work on the Superstructure
238
General Instructions
237
Symbols for Maintenance Work
243
Checking the Oil Level
245
Hoists
245
Checking the Hoist Brake
246
General Inspection
246
Changing the Oil/Checking the Oil
247
Having a General Inspection Carried out
249
Having a Partial Inspection Carried out
249
Checking the Oil Level
251
Slewing Gear
251
Checking for Leaks
252
Checking the Slewing Gear Brake
252
Changing the Oil/Checking the Oil
255
Checking the Screws
257
Slewing Bearing
257
Lubricating the Gear Teeth
261
General Inspection
263
Measuring Tilting Play
264
Lubricating the Locking of Turntable
266
Checking the Oil Level
267
Hydraulic System
267
Checking the Hydraulic Hoses
268
Checking the Ventilation Filter
268
Checking for Leaks
269
Cleaning the Magnetic Rods
270
Changing the Ventilation Filter
272
Pressure Accumulator - Checking the Gas Pressure
273
Taking Oil Samples
273
Changing the Hydraulic Oil Filter
275
Changing the Hydraulic Oil
278
Greasing the Piston Rod of the Derricking Cylinder
281
Main Boom
281
Lubricating the Telescopic Sections
282
Checking the Locking System
286
Lubricating the Sheaves
286
Checking the Winding
287
Hoist Ropes
287
Checking the Hoist Ropes
288
Lubricating the Hoist Rope
289
Assessing the Condition of the Hoist Rope
290
Replacing the Hoist Rope
296
Setting the Lowering Limit Switch
299
Cable Drums and Slewing Angle Sensor
301
Maintenance of the Slip Ring Assemblies
301
Lubricating the Slewing Angle Sensor
303
Central Lubrication System
305
Checking the Level
305
Checking the Sheaves
307
Hook Blocks
307
Lubricating
307
Checking the Lighting and Indicators
309
Electrical System
309
Have the Battery on the Electronics Board Replaced
310
Air Conditioning System
311
Checking the Air Conditioning System
311
Cleaning the Condenser Fins
311
Checking Hoses
312
Checking the Entire Air Conditioning System
312
Changing the Pollen Filter
314
Checking the Windscreen Washing System
315
Other Maintenance Work
315
Checking the Auxiliary Heater
316
Lubricating the Crane Cab Door
317
Lubricating the Step
318
Lubricating the Connecting and Socket Pins
319
Renewing the Corrosion Protection
320
Having the Fire Extinguisher Checked
322
Longer out of Service Periods
325
Torques
329
Spare Parts Required for Maintenance
333
General Information
333
Lighting
333
Spare Parts for the Carrier
337
Spare Parts for the Superstructure
340
Appendix
345
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Manitowoc Grove GMK 4100L-1 Specifications
General
Brand
Manitowoc
Model
Grove GMK 4100L-1
Category
Construction Equipment
Language
English
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