Manitowoc Grove GRT8100 SERVICE Manual - PDF DOWNLOAD

Manitowoc Grove GRT8100 SERVICE Manual - PDF DOWNLOAD

FILE DETAILS:

Manitowoc Grove GRT8100 SERVICE Manual - PDF DOWNLOAD

Language : English
Pages :340
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Manitowoc Grove GRT8100 SERVICE Manual - PDF DOWNLOAD

Table of Contents 5
SECTION 1 13
Introduction 13
General 13
Overview of Manuals 13
Customer Support 14
General Crane Design 14
Specific Crane Description 14
Lifting Capacities (Load Chart) 14
Basic Components 14
Axle Weight Distribution 14
Serial Number Location 14
Transportation and Lifting Data 14
List Of Specifications 15
General 15
Dimensions 15
Capacities 15
Torque Converter 15
Transmission 15
Engine 15
Cummins QSB 67 - Tier 4F 15
Cummins QSB 67 - Tier 3 15
Axles 15
Brakes 15
Wheels and Tires 15
Swing Gearbox 15
Boom 15
Swivel Assembly 15
Hydraulic Pumps 16
Pump #1 16
Pump #2 16
Pump #3 16
Hoists 16
Crane Nomenclature 19
General Maintenance 20
Cleanliness 20
After Cleaning 20
Removal and Installation 20
Disassembly and Assembly 20
Pressing Parts 21
Locking Devices 21
Wires and Cables 21
Shims 21
Hoses and Tubes 21
Inspection 21
Installation 22
Bearings 22
Antifriction Bearings 22
Double Row, Tapered Roller 22
Heating Bearings 22
Installation 22
Preload 22
Sleeve Bearings 22
Gaskets 22
Batteries 22
Hydraulic Systems 23
Cleanliness 23
Keep the System Clean 23
Sealing Elements 23
Hydraulic Lines 23
Visual Inspection of Hoses and Fittings 23
Hydraulic Fittings 24
Flats from Finger Tight (FFFT) Method 24
37° Flared Steel Fitting: Tube or Hose to Fitting 24
Adjustable Straight Thread O-ring Fittings 25
Nonadjustable Straight Thread O-ring Fitting: Fitting to Port 25
Electrical System 26
Harnesses, Wires, and Connectors 26
Fatigue of Welded Structures 26
Loctite® 26
Application of Medium Strength Loctite 26
Fasteners and Torque Values 27
Torque Wrenches 27
Torque Values 27
Weld Studs 41
Wire Rope 42
General 42
Environmental Conditions 42
Dynamic Shock Loads 42
Lubrication 42
Precautions and Recommendations During Inspection or Replacement 42
Wire Rope Inspection (Running Ropes and Pendant Cables) 43
Keeping Records 43
Frequent Inspection 43
Periodic Inspection 44
Wire Rope Inspection (Boom Extension and Retraction Cables) 44
Periodic Inspection 44
Wire Rope Inspection/Replacement (All Wire Rope) 44
Seizing Wire Rope 45
Method 1 45
Method 2 45
Installing 35x7 Class Wire Rope 46
Procedures for Cutting and Preparing 35x7 Class Wire Rope 46
SECTION 2 47
Hydraulic System 47
Description 49
Hydraulic Symbols 49
Maintenance 51
Preparation 51
Hydraulic System Maintenance Precautions 51
Label Parts when Disassembling 51
Hydraulic Oil Recommendations 51
Draining and Flushing 51
Removing Air From the Hydraulic System 52
Parts Replacement 53
Directional Control Valves 53
Inspection 53
Valve Leakage 53
Binding Spools 53
Visual Inspection of Hoses and Fittings 54
Supply Pressure And Return Circuit 55
Description 55
Hydraulic Reservoir, Filter, and Temperature Switches 55
Hydraulic Pump Distribution 57
No 1 Pump 57
No 2 Pump 57
No 3 Pump 57
Troubleshooting 58
Symptoms and Solutions 58
Troubleshooting Aids 59
Troubleshooting Procedures 59
Hydraulic Oil Return Filter Assembly 60
Element Removal 60
Element Installation 60
Fill Cap/Breather 60
Removal and Replacement 60
Oil Cooler 62
Description 62
Maintenance 62
Hydraulic Pumps 64
Description 64
Pumps No 1 and No 2 64
Pump No 3 64
Maintenance 66
No 1 and No 2 Pump Removal 66
No 1 and No 2 Pump Installation 66
No 3 Pump Removal 66
No 3 Pump Installation 66
Priming the Hydraulic Piston Pump 66
Priming/Starting-Up the Hydraulic Gear Pump 67
Pressure Setting Procedures 69
Checking/Setting the Piston Pumps Cut-off and Differential Pressures 70
Checking/Setting the Main Directional Control Valve, Hoists, Lift, and Telescope Pressures 72
Checking/Setting the Pilot Supply Pressure 76
Checking/Setting the Front Steer Pressure 76
Checking/Setting the Swing Brake Release Pressure 77
Checking the Swing Work Pressure 77
Checking the Service Brake Accumulator Charging Valve Pressure 78
Checking the Service Brake Accumulators Pre-charge 79
Pre-charging the Accumulators 80
Checking/Setting Cab Tilt, Counterweight Removal, and Counterweight Pinning Pressures 81
Checking/Setting the Outriggers, Rear Steer, and Hydraulic Transmission Oil Cooler Fan Motor Pressures 82
Checking/Setting the Axle Lockout Circuit Pressure 84
Checking/Setting the Luffing Jib Pressure 84
Valves 85
General 85
Main Directional Control Manifold Valve 88
Description 88
Maintenance 88
Main Directional Control Manifold Valve Removal 88
Main Directional Control Manifold Valve Installation 88
Functional Check 88
Swing Manifold Valve 92
Description 92
The swing manifold valve (Figure 2-22 and Figure 2-23) is located on the superstructure side plate near the turntable bearing (Figure 2-18) A dual pilot-operated, proportional control valve controls the oil flow from the No 3 gear pump to maintain 92
Maintenance 92
Swing Manifold Valve Removal 92
Swing Manifold Valve Installation 92
Functional Check 92
Compact Manifold Valve 95
Description 95
Maintenance 95
Compact Manifold Valve Removal 95
Compact Manifold Valve Installation 95
Functional Check 95
Accessory Manifold Valve 98
Description 98
Front Steer 98
Swing Brake 98
Pilot Supply 98
Fill Tube 98
Maintenance 98
Removal 98
Installation 98
Function Check - Front Steer 98
Function Check - Swing Brake Release Valve 98
Function Check - Pilot Supply and Telescope Fill Tube Valve 99
Lift Cylinder and Telescope Cylinder Control Valves102
Description102
Maintenance102
Removal102
Installation102
Carrier Combination Manifold Valve103
Description103
Maintenance103
Removal103
Installation103
Functional Check104
Outrigger Control Manifold107
Description107
Maintenance107
Removal107
Inspection107
Installation107
Functional Check107
Range Shift/Park Brake Manifold Valve109
Description109
Maintenance109
Removal109
Installation109
Functional Tests109
Telescope and Tele Fill Stage Select Manifold Valve110
Description110
Maintenance110
Removal110
Installation110
Dual Accumulator Charge Manifold Valve112
Description112
Maintenance112
Removal112
Installation112
Hydraulic Brake Accumulator114
Description114
Maintenance114
Removal114
Installation114
Servicing114
Cylinders115
Cylinder Rod Surface Protection115
Leak Check115
Temperature Effects On Hydraulic Cylinders116
SECTION 3119
Electrical System119
Description119
General119
Alternator119
Batteries and Battery Disconnect Switch120
Cab Electrical Panel120
Carrier Electrical Panel125
Maintenance129
General129
Visual Inspection and Replacement of Electrical Harnesses and Cables129
General Troubleshooting130
Tools for Troubleshooting130
Swivel Electrical Troubleshooting130
Connector Troubleshooting130
Alternator/Charging System Troubleshooting132
Required Tools132
Visual Check132
Engine Off Tests132
Batteries132
Voltage Drop Test132
Replace Alternator132
Removal132
Installation133
Check133
Starter Replacement133
Removal133
Installation133
Check133
Battery Replacement133
Removal133
Installation134
Relay Panel Components134
Accessory Relay134
Buzzer Replacement134
Steering Column and Dashboard134
Rocker Switch134
Removal134
Inspection134
Installation135
Check135
Ignition Switch135
Removal135
Inspection135
Installation135
Check135
Turn Signal and Transmission Shift Levers136
Removal136
Installation136
Check136
Windshield Wiper Assembly Replacement138
Removal138
Inspection138
Installation138
Check138
Windshield Washer Assembly Replacement138
Removal138
Inspection139
Installation139
Check139
Skylight Wiper Assembly Replacement139
Removal139
Inspection139
Installation139
Check139
Adjusting Electronic Joysticks140
Fault Codes140
Optional Equipment144
Beacon Light144
Boom Mounted Floodlights144
Rear View Mirror144
Air Conditioner144
Cold Weather Operation145
Component Coolant Heater145
Troubleshooting145
Maintenance Instructions145
SECTION 4147
Boom147
Description147
Theory of Operation148
Maintenance150
Removal150
Disassembly165
Boom Nose Sheaves174
Removal174
Installation175
Assembly175
Installation191
Functional Check191
Inspection191
Boom Alignment and Servicing192
Boom Extension and Retraction Cable192
Maintenance192
Inspection192
Cable Tensioning Check and Adjustment192
Telescope Circuit195
Description195
Theory of Operation195
Boom Control Modes195
Auto A Mode195
Auto B Mode195
Auto Mode X195
Manual Mode195
Anti-Thermal Contraction195
Maintenance196
Troubleshooting196
Removal And Installation197
Disassembly And Assembly197
Lift Circuit198
Description198
Theory of Operation198
Maintenance198
Lift Cylinder Removal200
Lift Cylinder Installation200
Hook Block202
Description202
Maintenance202
Periodic Maintenance202
Adjusting Boom Extension Stowage Mounts203
SECTION 5207
Hoist and Counterweight207
Description207
Theory of Operation207
Maintenance208
Warm-up Procedure208
Hoist Area Access208
Working Position208
Travel Position209
Installing Cable On Hoist209
Removing/Installing the Hoist210
Removing210
Installing210
Functional Check210
Hoist Fluid Level Check210
Usage and Inspection212
Preventative Maintenance212
Oil Sampling213
Oil Change213
Gear Oil Sampling and Analysis213
General Guidelines for Iron Contaminant Level214
Brake Test Procedure214
Motor, Motor Control Valve, And Brake214
Description214
Removal214
Installation214
Hoist Rotation and Minimum Wrap Indicator System215
Description215
Maintenance215
General215
Adjusting Minimum Wrap Switch215
Hoist Control Valves216
Description216
Hydraulic Hoist Motor Control Valve216
Hoist Directional Control Valve216
Removable Counterweight217
Counterweight Control Panel217
Remove218
Install218
Install Optional Counterweight Slab219
Remove Optional Counterweight Slab219
SECTION 6221
Swing System221
Description221
Theory of Operation222
Swing Drive222
Swing Brake222
Maintenance224
Swing Motor227
Description227
Maintenance227
Removal227
Installation227
Test227
Swing Gearbox And Brake228
Description228
Maintenance228
Swing Brake228
Removal228
Installation228
Testing228
Gearbox228
Removal228
Installation228
Servicing228
Checking the Oil Level229
Testing229
Swing Bearing230
Description230
Maintenance230
General230
Torquing Turntable Bolts230
General230
Tools Required231
Inner Race Torquing231
Outer Race Torquing231
Removal231
Inspection233
Installation233
Testing234
Swivels235
Description235
Hydraulic Swivel237
Description237
Theory of Operation237
Maintenance237
Removal237
Installation238
Two Port Water Swivel239
Description239
Maintenance239
Removal239
Disassembly239
Cleaning and Inspection239
Assembly239
Installation239
Electrical Swivel240
Description240
Theory of Operation240
Maintenance240
Removal240
Installation240
Preventive Maintenance241
Slew Angle Zero Adjustment Procedure241
Slew Angle Verification241
Swing Lock Pin241
Description241
Maintenance242
360° Swing Lock Control (Positive Lock Type) (Optional)242
Description242
Maintenance242
SECTION 7243
Power Train243
Engine243
Description243
Maintenance244
Engine Removal244
Engine Installation244
Engine Drive Belts245
Electronic Control System246
Description246
Engine Control System Indicator Lights246
Engine Stop Light246
Engine Warning Light246
Exhaust System Cleaning Required Indicator246
Fuel System247
Description247
Fuel Tank247
Injection Fuel Pump247
Fuel Filter-Water Separator247
Maintenance247
Fuel Tank247
Removal247
Installation247
Fuel Filter-Water Separator247
Draining247
Air Intake and Exhaust System249
Description249
Air Intake249
Air Cleaner Checks249
Check For Filter Restriction249
Filter Element Replacement253
Element Cleaning253
Air Cleaner Body253
Pre-cleaner253
Vacuator Valve253
Duct Work254
Charge-Air Cooler System254
Maintenance254
Exhaust System255
Tier 3 Exhaust System255
Tier 4 Exhaust System255
Removal255
Installation255
Slip Joint Exhaust Connectors - Tier 3 and 4255
After 1000 Hours, or One Year255
2000 Hours or 2 Years255
4000 Hours or 4 Years255
5000 Hours or 5 Years255
Water Cooling System258
Description258
Maintenance258
General258
Effects of Cooling System Neglect258
Overheating258
Overcooling258
Antifreeze/Coolant258
Rust Prevention258
Engine Antifreeze/Coolant Fill Procedure259
Antifreeze/Supplemental Coolant Additives Maintenance Summary259
Cooling System Level Check Interval259
SCA Level Check Interval259
Cleaning259
Pressure Flushing260
Component Inspection260
Radiator/Surge Tank260
Engine Water Jacket260
Water Pump261
Fans and Belts261
Thermostat261
Hoses and Clamps261
Radiator Removal and Installation261
Removal261
Installation261
Radiator Fill and Servicing262
Drive Train264
Description264
Maintenance264
Transmission264
Drive Shafts265
Removal265
Installation265
Lubrication265
Transmission/Torque Converter265
Description265
Theory of Operation265
Maintenance266
General Information266
Troubleshooting266
Hydraulic Checks266
Removal268
Installation268
Servicing the Crane after Transmission/torque Converter Overhaul270
Lubrication270
Type of Oil and Capacities270
Normal Drain Period270
Towing or Pushing270
SECTION 8271
Undercarriage271
Axles271
Description271
Maintenance271
Removal272
Cleaning272
Installation272
Wheel Alignment Check Procedure272
Rear Steer Indicator Adjustment Procedure273
Wheels And Tires274
Description274
Maintenance274
Mounting Wheel Assemblies274
Typical Wear Patterns274
Incorrect Tire Pressure274
Incorrect Camber275
Incorrect Toe and Axle Alignment275
Incorrect Caster and Wheel Imbalance275
Cuts in the Tire Tread276
Spot Wear276
Feathered Edges276
Cupping276
Steering Systems277
Description277
Front Steering System277
Rear Steering System277
Secondary Steering System (CE Units)277
Maintenance277
Front Steering System277
Troubleshooting277
Functional Check278
Secondary Steering System (CE Units) Maintenance278
Front Steering Control Valve278
Removal278
Installation278
Rear Steering System279
Troubleshooting279
Steer Cylinders279
Removal279
Installation279
Rear Axle Oscillation Lockout System280
Description280
Theory Of Operation280
Axle Oscillation Lockout Cylinders282
Description282
Removal282
Installation282
Axle Oscillation Lockout Valve282
Description282
When the axle oscillation solenoid valves are energized and open, hydraulic oil is allowed in and out of the cylinders, allowing them to oscillate282
Brake System282
Description282
Service Brakes282
Parking Brake283
Theory Of Operation283
Service Brakes283
Parking Brake283
Maintenance284
Troubleshooting284
General284
Bleeding the Brake System284
Pressure Bleeding The Brake System285
Manually Bleeding the Brake System285
Service Brakes285
Description285
Maintenance285
Removal285
Linings285
Caliper286
Disassembly286
Caliper286
Inspection287
Periodic On-Vehicle287
Shoes, Linings, and End Plates287
Caliper for Leaks287
Dust Seals288
Disc288
Caliper Parts288
Cleaning289
Corrosion Protection289
Assembly289
Caliper289
Installation290
Linings290
Caliper291
Parking Brake Actuator291
Description291
Maintenance291
Removal291
Installation291
Adjustment291
Parking Brake292
Description292
Maintenance292
Removal292
Installation292
Park Brake Solenoid Valve294
Outrigger295
Outrigger Circuit295
Description295
Theory Of Operation295
Maintenance296
Troubleshooting296
Outrigger Beam299
Description299
Theory Of Operation299
Maintenance299
Removal299
Inspection299
Installation299
Extension Cylinder302
Description302
Maintenance302
Removal302
Installation302
Functional Check302
Outrigger Monitoring System (Optional— Standard in North America)302
Description302
Removal302
Installation303
Jack Cylinder303
Description303
Maintenance303
Removal303
Installation303
Functional Check304
SECTION 9305
Lubrication305
General305
Environmental Protection305
Lubricants and Lubrication Intervals305
Standard Lubricants307
Arctic Lubricants and Conditions309
Temperatures Below -9°C (15°F)309
Cold Weather Package and Lubricants309
Cylinder Rod Surface Protection312
Wire Rope Lubrication312
Lubrication Points312
CraneLUBE312
Cummins Oil Registration List312
Safety312
Drive Train313
Drive Train (Continued)314
Drive Train (Continued)316
Drive Train (Continued)317
Steering and Suspension318
Steering and Suspension (Continued)319
Axles320
Turntable321
Turntable (Continued)322
Cab Tilt322
Outriggers323
Lift Cylinder323
Boom324
Boom (Continued)325
Boom (Continued)329
Hoist330
Hydraulic331
Diesel Exhaust Fluid (DEF) Tank332
Rust Protection333
Cleaning Procedures333
Inspection and Repair334
Application334
Areas of Application334
Alphabetical Index337

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