Manitowoc Grove GRT880 SERVICE Manual - PDF DOWNLOAD

Manitowoc Grove GRT880 SERVICE Manual - PDF DOWNLOAD

FILE DETAILS:

Manitowoc Grove GRT880 SERVICE Manual - PDF DOWNLOAD

Language : English
Pages :342Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Manitowoc Grove GRT880 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 40
Wire Rope 41
General 41
Environmental Conditions 41
Dynamic Shock Loads 41
Lubrication 41
Precautions and Recommendations During Inspection or Replacement 41
Wire Rope Inspection (Running Ropes and Pendant Cables) 42
Keeping Records 42
Frequent Inspection 42
Periodic Inspection 43
Wire Rope Inspection (Boom Extension and Retraction Cables) 43
Periodic Inspection 43
Wire Rope Inspection/Replacement (All Wire Rope) 43
Seizing Wire Rope 44
Method 1 44
Method 2 44
Installing 35x7 Class Wire Rope 45
Procedures for Cutting and Preparing 35x7 Class Wire Rope 45
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
Boom Removal148
Boom Disassembly161
Boom Nose Sheaves Removal and Installation175
Removal175
Installation175
Boom Assembly175
Boom Installation195
Boom Functional Check197
Boom Inspection197
Boom Alignment and Servicing197
Boom Extension and Retraction Cables197
Maintenance197
Inspection197
Cable Tensioning Check and Adjustment197
Telescope Circuit199
Description199
Theory of Operation199
Boom Control Modes199
Auto B Mode199
Manual Mode199
Maintenance200
Troubleshooting200
Removal And Installation201
Disassembly And Assembly201
Lift Circuit202
Description202
Theory of Operation202
Maintenance202
Lift Cylinder Removal204
Lift Cylinder Installation204
Hook Block207
Description207
Maintenance207
Periodic Maintenance207
Adjusting Boom Extension Stowage Mounts208
SECTION 5211
Hoist and Counterweight211
Description211
Theory of Operation211
Maintenance212
Warm-up Procedure212
Hoist Area Access212
Working Position212
Travel Position213
Installing Cable On Hoist213
Removing/Installing the Hoist214
Removing214
Installing214
Functional Check214
Hoist Fluid Level Check214
Usage and Inspection216
Preventative Maintenance216
Oil Sampling217
Oil Change217
Gear Oil Sampling and Analysis217
General Guidelines for Iron Contaminant Level218
Brake Test Procedure218
Motor, Motor Control Valve, And Brake218
Description218
Removal218
Installation219
Hoist Rotation and Minimum Wrap Indicator System219
Description219
Maintenance219
General219
Adjusting Minimum Wrap Switch219
Hoist Control Valves220
Description220
Hydraulic Hoist Motor Control Valve220
Hoist Directional Control Valve220
Removable Counterweight221
Counterweight Control Panel221
Removing222
Installing222
SECTION 6223
Swing System223
Description223
Theory of Operation224
Swing Drive224
Swing Brake224
Maintenance226
Swing Motor229
Description229
Maintenance229
Removal229
Installation229
Test229
Swing Gearbox And Brake230
Description230
Maintenance230
Swing Brake230
Removal230
Installation230
Testing230
Gearbox230
Removal230
Installation230
Servicing230
Checking the Oil Level231
Testing231
Swing Bearing232
Description232
Maintenance232
General232
Torquing Turntable Bolts232
General232
Tools Required233
Inner Race Torquing233
Outer Race Torquing233
Removal233
Inspection235
Installation235
Testing236
Swivels237
Description237
Hydraulic Swivel239
Description239
Theory of Operation239
Maintenance239
Removal239
Installation240
Two Port Water Swivel241
Description241
Maintenance241
Removal241
Disassembly241
Cleaning and Inspection241
Assembly241
Installation241
Electrical Swivel242
Description242
Theory of Operation242
Maintenance242
Removal242
Installation242
Preventive Maintenance243
Slew Angle Zero Adjustment Procedure243
Slew Angle Verification243
Swing Lock Pin243
Description243
Maintenance244
360° Swing Lock Control (Positive Lock Type) (Optional)244
Description244
Maintenance244
SECTION 7245
Power Train245
Engine245
Description245
Maintenance246
Engine Removal246
Engine Installation246
Engine Drive Belts247
Electronic Control System248
Description248
Engine Control System Indicator Lights248
Engine Stop Light248
Engine Warning Light248
Exhaust System Cleaning Required Indicator248
Fuel System249
Description249
Fuel Tank249
Injection Fuel Pump249
Fuel Filter-Water Separator249
Maintenance249
Fuel Tank249
Removal249
Installation249
Fuel Filter-Water Separator249
Draining249
Air Intake and Exhaust System251
Description251
Air Intake251
Air Cleaner Checks251
Check For Filter Restriction251
Filter Element Replacement255
Element Cleaning255
Air Cleaner Body255
Pre-cleaner255
Vacuator Valve255
Duct Work256
Charge-Air Cooler System256
Maintenance256
Exhaust System257
Tier 3 Exhaust System257
Tier 4 Exhaust System257
Removal257
Installation257
Slip Joint Exhaust Connectors - Tier 3 and 4257
After 1000 Hours, or One Year257
2000 Hours or 2 Years257
4000 Hours or 4 Years257
5000 Hours or 5 Years257
Water Cooling System260
Description260
Maintenance260
General260
Effects of Cooling System Neglect260
Overheating260
Overcooling260
Antifreeze/Coolant260
Rust Prevention260
Engine Antifreeze/Coolant Fill Procedure261
Antifreeze/Supplemental Coolant Additives Maintenance Summary261
Cooling System Level Check Interval261
SCA Level Check Interval261
Cleaning261
Pressure Flushing262
Component Inspection262
Radiator/Surge Tank262
Engine Water Jacket262
Water Pump263
Fans and Belts263
Thermostat263
Hoses and Clamps263
Radiator Removal and Installation263
Removal263
Installation263
Radiator Fill and Servicing264
Drive Train266
Description266
Maintenance266
Transmission266
Drive Shafts267
Removal267
Installation267
Lubrication267
Transmission/Torque Converter267
Description267
Theory of Operation267
Maintenance268
General Information268
Troubleshooting268
Hydraulic Checks268
Removal270
Installation270
Servicing the Crane after Transmission/torque Converter Overhaul272
Lubrication272
Type of Oil and Capacities272
Normal Drain Period272
Towing or Pushing272
SECTION 8273
Undercarriage273
Axles273
Description273
Maintenance273
Removal274
Cleaning274
Installation274
Wheel Alignment Check Procedure274
Rear Steer Indicator Adjustment Procedure275
Wheels And Tires276
Description276
Maintenance276
Mounting Wheel Assemblies276
Typical Wear Patterns276
Incorrect Tire Pressure276
Incorrect Camber277
Incorrect Toe and Axle Alignment277
Incorrect Caster and Wheel Imbalance277
Cuts in the Tire Tread278
Spot Wear278
Feathered Edges278
Cupping278
Steering Systems279
Description279
Front Steering System279
Rear Steering System279
Secondary Steering System (CE Units)279
Maintenance279
Front Steering System279
Troubleshooting279
Functional Check280
Secondary Steering System (CE Units) Maintenance280
Front Steering Control Valve280
Removal280
Installation280
Rear Steering System281
Troubleshooting281
Steer Cylinders281
Removal281
Installation281
Rear Axle Oscillation Lockout System282
Description282
Theory Of Operation282
Axle Oscillation Lockout Cylinders284
Description284
Removal284
Installation284
Axle Oscillation Lockout Valve284
Description284
When the axle oscillation solenoid valves are energized and open, hydraulic oil is allowed in and out of the cylinders, allowing them to oscillate284
Brake System284
Description284
Service Brakes284
Parking Brake285
Theory Of Operation285
Service Brakes285
Parking Brake285
Maintenance286
Troubleshooting286
General286
Bleeding the Brake System286
Pressure Bleeding The Brake System287
Manually Bleeding the Brake System287
Service Brakes287
Description287
Maintenance287
Removal287
Linings287
Caliper288
Disassembly288
Caliper288
Inspection289
Periodic On-Vehicle289
Shoes, Linings, and End Plates289
Caliper for Leaks289
Dust Seals290
Disc290
Caliper Parts290
Cleaning291
Corrosion Protection291
Assembly291
Caliper291
Installation292
Linings292
Caliper293
Parking Brake Actuator293
Description293
Maintenance293
Removal293
Installation293
Adjustment293
Parking Brake294
Description294
Maintenance294
Removal294
Installation294
Park Brake Solenoid Valve296
Outrigger297
Outrigger Circuit297
Description297
Theory Of Operation297
Maintenance298
Troubleshooting298
Outrigger Beam301
Description301
Theory Of Operation301
Maintenance301
Removal301
Inspection301
Installation301
Extension Cylinder304
Description304
Maintenance304
Removal304
Installation304
Functional Check304
Outrigger Monitoring System (Optional— Standard in North America)304
Description304
Removal304
Installation305
Jack Cylinder305
Description305
Maintenance305
Removal305
Installation305
Functional Check306
SECTION 9307
Maintenance and Lubrication307
General307
Environmental Protection307
Lubricants and Lubrication Intervals308
Standard Lubricants309
Arctic Lubricants and Conditions311
Temperatures Below -9°C (15°F)311
Cold Weather Package and Lubricants311
Cylinder Rod Surface Protection314
Wire Rope Lubrication314
Lubrication Points314
CraneLUBE314
Cummins Oil Registration List315
Safety315
Drive Train316
Drive Train (continued)317
Drive Train (Continued)319
Drive Train (Continued)320
Steering and Suspension321
Steering and Suspension (Continued)322
Axles323
Turntable324
Turntable (Continued)325
Cab Tilt325
Outriggers326
Lift Cylinder327
Boom328
Boom (Continued)329
Boom (Continued)332
Hoist333
Hydraulic334
Rust Protection335
Cleaning Procedures335
Inspection and Repair336
Application336
Areas of Application336
Alphabetical Index339

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