Manitowoc Grove RT765E-2 Service Manual – PDF DOWNLOAD

Manitowoc Grove RT765E-2 Service Manual – PDF DOWNLOAD

FILE DETAILS:

Manitowoc Grove RT765E-2 Service Manual – PDF DOWNLOAD

Language : English
Pages :330
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Manitowoc Grove RT765E-2 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 15
Axles 15
Brakes 15
Wheels and Tires 15
Swing Gearbox 15
Boom 15
Swivel Assembly 15
Hydraulic Pumps 15
Pump #1 15
Pump #2 15
Pump #3 15
Hoists 16
Crane Nomenclature 19
General Maintenance 21
Cleanliness 21
After Cleaning 21
Removal and Installation 21
Disassembly and Assembly 21
Pressing Parts 22
Locking Devices 22
Wires and Cables 22
Shims 22
Hoses and Tubes 22
Inspection 22
Installation 23
Bearings 23
Antifriction Bearings 23
Double Row, Tapered Roller 23
Heating Bearings 23
Installation 23
Preload 23
Sleeve Bearings 23
Gaskets 23
Batteries 23
Hydraulic Systems 24
Cleanliness 24
Keep the System Clean 24
Sealing Elements 24
Hydraulic Lines 24
Visual Inspection of Hoses and Fittings 24
Hydraulic Fittings 25
Flats from Finger Tight (FFFT) Method 25
37° Flared Steel Fitting: Tube or Hose to Fitting 25
Adjustable Straight Thread O-ring Fittings 25
Nonadjustable Straight Thread O-ring Fitting: Fitting to Port 26
Electrical System 26
Harnesses, Wires, and Connectors 26
Fatigue of Welded Structures 27
Loctite® 27
Application of Medium Strength Loctite® 27
Primer Application 27
Adhesive/Sealant Application 27
Fasteners and Torque Values 28
Torque Wrenches 28
Torque Values 28
Weld Studs 31
Wire Rope 32
General 32
Environmental Conditions 32
Dynamic Shock Loads 32
Lubrication 32
Precautions and Recommendations During Inspection or Replacement 32
Wire Rope Inspection (Running Ropes and Pendant Cables) 33
Keeping Records 33
Frequent Inspection 33
Periodic Inspection 34
Wire Rope Inspection (Boom Extension and Retraction Cables) 34
Periodic Inspection 34
Wire Rope Inspection/Replacement (All Wire Rope) 34
Seizing Wire Rope 35
Method 1 35
Method 2 35
Installing 35×7 Class Wire Rope 36
Procedures for Cutting and Preparing 35×7 Class Wire Rope 36
SECTION 2 39
Hydraulic System 39
Description 40
Hydraulic Symbols 41
Maintenance 43
Preparation 43
Hydraulic System Maintenance Precautions 43
Label Parts When Disassembling 43
Hydraulic Oil Recommendations 43
Draining And Flushing 43
Removing Air From The Hydraulic System 44
Parts Replacement 45
Directional Control Valves 45
Inspection 45
Valve Leakage 45
Binding Spools 45
Visual Inspection of Hoses and Fittings 46
Supply Pressure And Return Circuit 47
Description 47
Hydraulic Reservoir And Filter 47
Pump Distribution 48
No 1 Pump 48
No 2 Pump 48
No 3 Pump 48
Troubleshooting 48
Symptoms and Solutions 48
Troubleshooting Aids 50
Troubleshooting Procedures 50
Hydraulic Oil Return Filter Assembly 51
Element Removal 51
Element Installation 51
Fill Cap/Breather 51
Removal and Replacement 51
Oil Cooler 53
Description 53
Oil Temperature Switches 53
Hydraulic Pumps 55
Description 55
Pump No 1 55
Pump No 2 55
Pump No 3 55
Maintenance 55
No 1 Pump Removal 55
No 1 Pump Installation 55
No 1 Pump and Pump Disconnect Assembly Removal (Optional) 55
No 1 Pump and Pump Disconnect Assembly Installation (Optional) 56
No 2 Pump Removal 56
No 2 Pump Installation 56
No 3 Pump Removal 57
No 3 Pump Installation 57
Testing After Repair or Replacement 57
Pump Disconnect Assembly 59
Disassembly 59
Assembly 59
Pressure Setting Procedures 61
Procedure A – Main Control Valve Reliefs 62
Procedure B – Main Directional Control Valve Pilot Supply Pressure 63
Procedure C – Swing Brake Pilot Supply Pressure 63
Procedure D – Brake Charge Supply Valve Relief Pressure 63
Procedure E – Charge Air Cooler Valve Relief Pressure 64
Procedure F – Brake Dual Accumulator Charge Valve Pressure Limits 64
Procedure G – Accumulator Pre-Charge Pressure 64
Procedure H – PreCharging The Accumulator 65
Procedure I – Swing Valve Work Port Reliefs Pressure 65
Procedure J – Front Steer Relief Valve Pressure 66
Procedure K – Outrigger/Rear Steer Valve Relief 66
Procedure L – Hydraulic Oil Cooler Fan Motor Control Valve 66
Procedure M – Counterweight Removal Valve 67
Valves 68
General 68
Directional Control Valves 71
Description 71
Lift/Telescope/Hoist Directional Valve 71
Swing/Steer Directional Valve 71
Counterweight Removal Directional Valve (Optional) 71
Maintenance 71
Swing/Steer Directional Valve Removal 71
Swing/Steer Directional Valve Installation 71
Hoist/Lift/Telescope Directional Valve Removal 71
Hoist/Lift/Telescope Directional Valve Installation 71
Counterweight Removal Directional Valve Removal 71
Counterweight Removal Directional Valve Installation 71
Functional Check (All Directional Valves) 71
Hydraulic Remote Control Valve 76
Description 76
Dual Axis Controllers (CE Units) 76
Maintenance 76
Armrest Control Valve Removal 76
Armrest Control Valve Installation 76
Armrest Control Valve Functional Check 76
Telescope Pedal Control Valve Removal (With Auxiliary Hoist Option) 76
Telescope Pedal Control Valve Installation (With Auxiliary Hoist Option) 76
Telescope Pedal Control Valve Functional Check (With Auxiliary Hoist Option) 76
Dual Accumulator Charge Valve 79
Description 79
Maintenance 79
Removal 79
Installation 79
Swing Brake And Armrest Lockout Valve Manifold 81
Description 81
Maintenance 81
Removal 81
Installation 81
Function Check – Swing Brake Release Valve 81
Function Check – Crane Function Valve 81
Inlet Filter Screen Replacement 81
Holding Valve 83
Description 83
Maintenance 83
Removal 83
Installation 83
Test the holding valve and port block or manifold by operating the lift cylinder and/or the telescope cylinder, as applicable Verify lift cylinder and/or telescope cylinder works without problems; verify there is no leaking Make repairs as needed 83
Boom Lock Valve 83
Description 83
Outrigger/Rear Steer Valve 85
Description 85
Maintenance 86
Removal 86
Installation 86
Functional Check 86
Outrigger Control Manifold 87
Description 87
Maintenance 88
Removal 88
Inspection 88
Installation 88
Functional Check 88
Parking Brake/Range Shift Valve 89
Description 89
Maintenance 89
Removal 89
Installation 89
Functional Tests 89
Axle Oscillation Lockout Valve 91
Description 91
Maintenance 91
Removal 91
Installation 91
High Speed Boost Selector Valve 92
Description 92
Maintenance 92
Removal 92
Installation 92
Hydraulic Accumulator 93
Description 93
Maintenance 93
Removal 93
Installation 93
Servicing 93
Service Brake and CAC Fan Motor Priority Flow Control Valve 94
Description 94
Maintenance 94
Removal 94
Installation 94
Oil Cooler Fan Motor Priority Flow Control Valve 95
Description 95
Maintenance 95
Removal 95
Installation 95
Telescope Cylinder Charge Valve Manifold (If Equipped) 96
Description 96
Maintenance 96
Removal 96
Installation 96
Cylinders 99
General 99
Maintenance 99
General 99
Surface Protection For Cylinder Rods 99
Leakage Check 99
Temperature Effects On Hydraulic Cylinders100
Lift Cylinder102
Description102
Maintenance102
Disassembly102
Inspection102
Assembly104
Lower Telescope Cylinder106
Description106
Maintenance106
Disassembly106
Inspection106
Assembly106
Upper Telescope Cylinder110
Description110
Maintenance110
Disassembly110
Inspection110
Assembly110
Axle Oscillation Lockout Cylinder113
Description113
Maintenance113
Disassembly113
Inspection113
Assembly115
Steer Cylinder116
Description116
Maintenance116
Disassembly116
Inspection116
Assembly118
Outrigger Extension Cylinder119
Description119
Maintenance119
Disassembly119
Inspection119
Assembly121
Outrigger Jack Cylinder122
Description122
Maintenance122
Disassembly122
Inspection122
Assembly124
Test124
Counterweight Removal Cylinder125
Description125
Maintenance125
Disassembly125
Inspection125
Assembly125
SECTION 3129
Electrical System129
Description129
General129
Alternator131
Batteries131
Cab Electrical Panel131
Carrier Electrical Panel133
Maintenance135
General135
Visual Inspection and Replacement of Electrical Harnesses and Cables135
General Troubleshooting136
Troubleshooting Swivel-Caused Electrical Problems136
Connector Troubleshooting136
Alternator/Charging System Troubleshooting137
Required Tools137
Visual Check137
Engine Off Tests138
Batteries138
Voltage at Alternator138
Battery Drain138
Engine On Tests138
Output Voltage Test138
Maximum Amperage Test138
Voltage Drop Test138
Alternator Replacement139
Removal139
Installation139
Check139
Starter Replacement139
Removal139
Installation139
Check139
Battery Replacement140
Removal140
Installation140
Relay Panel Component Replacement140
Accessory Relay140
Buzzer Replacement140
Gauge Cluster Replacement141
Removal141
Installation141
Check141
Rocker Switch Replacement141
Removal141
Inspection142
Installation142
Check142
Ignition Switch Replacement142
Removal142
Inspection142
Installation143
Check143
Turn Signal Lever and Transmission Shift Lever Replacement143
Removal143
Installation143
Check144
Windshield Wiper Assembly Replacement145
Removal145
Inspection145
Installation145
Check146
Windshield Washer Assembly Replacement146
Removal146
Inspection146
Installation146
Check146
Skylight Wiper Assembly Replacement146
Removal146
Inspection146
Installation146
Check147
Telescope Cylinder Charge System – Electrical Schematic (If Equipped)148
Tools for Troubleshooting149
Optional Equipment149
Beacon Light149
Boom Mounted Floodlights149
Rear View Mirror149
Air Conditioner149
Cold Weather Operation149
Component Coolant Heater149
Troubleshooting150
Maintenance Instructions150
SECTION 4151
Boom151
Description151
Theory of Operation151
Boom Extension151
Boom Retraction152
Maintenance152
Removal152
Disassembly157
Boom Nose Sheaves159
Removal159
Installation160
Assembly160
Installation163
Functional Check164
Inspection164
Boom Alignment and Servicing164
Cam Operated Check Valve Adjustment165
Guide Block Adjustment165
Boom Extension and Retraction Cable166
Maintenance166
Inspection166
Adjustment166
Telescope Circuit167
Description167
Theory Of Operation167
Maintenance168
Troubleshooting168
Removal And Installation170
Disassembly And Assembly170
Description170
Theory of Operation170
Maintenance170
Lift Cylinder Removal172
Disassembly and Assembly172
Lift Cylinder Installation172
Swingaway Boom Extension174
Description174
Maintenance174
Removal174
Installation180
Boom Extension Alignment Device Adjustment181
Swingaway Mounting Adjustment182
Description182
Maintenance182
Periodic Maintenance182
SECTION 5183
Hoist and Counterweight183
Description183
Theory of Operation183
Maintenance184
Warm-up Procedure184
Hoist Area Access184
Removal186
Installation186
Functional Check186
Fluid Level186
Usage and Inspection187
Preventative Maintenance187
Oil Sampling189
Oil Change189
Gear Oil Sampling and Analysis189
General Guidelines for Iron Contaminant Level189
Brake Test Procedure189
Hoist to Boom Alignment190
Preparation190
Tools Required190
Procedure190
Motor and Brake192
Description192
Maintenance192
Removal192
Installation192
Idler Drum and Cable Follower193
Description193
Maintenance193
Idler Drum193
Removal and Disassembly193
Cleaning and Inspection193
Assembly and Installation193
Cable Follower193
Removal and Disassembly193
Cleaning and Inspection193
Assembly and Installation193
Complete Assembly195
Removal195
Installation195
Third Wrap Indicator (Optional— Standard on CE)196
Description196
Maintenance196
Hoist Drum Rotation Indicator System197
Description197
Maintenance197
General197
Troubleshooting197
Removal197
Installation197
Hoist Control Valves199
Description199
Hydraulic Hoist Motor Control Valve199
Hoist Directional Control Valve199
Fixed Counterweight200
Description200
Maintenance200
Removal200
Installation200
Counterweight Plate200
Removable Counterweight (Optional)202
Removal202
Installation202
SECTION 6205
Swing System205
Description205
Theory of Operation205
Swing Drive205
Swing Brake205
Maintenance207
Swing Motor211
Description211
Maintenance211
Removal211
Installation211
Test211
Swing Gearbox And Brake212
Description212
Maintenance212
Swing Brake212
Removal212
Installation212
Testing212
Gearbox212
Removal212
Installation212
Servicing213
Checking The Oil Level213
Testing213
Swing Bearing214
Description214
Maintenance214
General214
Torquing Turntable Bolts214
General214
Tools Required215
Inner Race Torquing215
Outer Race Torquing215
Removal215
Inspection217
Installation217
Testing218
Swivels219
Description219
Hydraulic Swivel221
Description221
Theory Of Operation221
Maintenance221
Removal221
Installation222
Two Port Water Swivel223
Description223
Maintenance223
Removal223
Disassembly223
Cleaning And Inspection223
Assembly223
Installation223
Electrical Swivel224
Description224
Theory of Operation224
Maintenance224
Removal224
Installation224
Preventive Maintenance225
Slew Angle Zero Adjustment Procedure225
Slew Angle Verification225
Swing Lock Pin226
Description226
Maintenance226
360° Swing Lock Control (Positive Lock Type) (Optional)226
Description226
Maintenance226
SECTION 7227
Power Train227
Engine227
Description227
Maintenance228
Engine Removal228
Engine Installation228
Engine Drive Belts229
Electronic Control System230
Description230
Engine Control System Switches And Indicator Lights230
Engine Diagnostic/Speed Control Switch230
Increment/Decrement Switch230
Engine Stop Light230
Engine Warning Light230
Diesel Particulate Filter Indicator (Tier 4 Engines Only)230
Diesel Particulate Filter Regeneration Switch (Tier 4 Engines Only)231
Inhibit Regeneration Indicator232
High Exhaust System Temperature232
Fuel System233
Description233
Fuel Tank233
Injection Fuel Pump233
Fuel Filter-water Separator233
Maintenance233
Fuel Tank233
Removal233
Installation233
Fuel Filter-Water Separator233
Draining233
Air Intake and Exhaust System235
Description235
Air Intake235
Air Cleaner Checks235
Check For Filter Restriction235
Filter Element Replacement237
Element Cleaning237
Air Cleaner Body237
Precleaner237
Vacuator Valve237
Duct Work238
Charge-Air Cooler System239
Maintenance239
Muffler240
Removal240
Installation240
Water Cooling System243
Description243
Maintenance243
General243
Effects of Cooling System Neglect243
Overheating243
Overcooling243
Antifreeze/Coolant243
Rust Prevention243
Engine Antifreeze/Coolant Fill Procedure (when level is low)243
Antifreeze/Supplemental Coolant Additives Maintenance Summary244
Cooling System Level Check Interval244
SCA Level Check Interval244
Cleaning244
Pressure Flushing244
Component Inspection245
Radiator/Surge Tank245
Engine Water Jacket245
Water Pump245
Fans and Belts245
Thermostat245
Hoses and Clamps246
Drive Train248
Description248
Maintenance248
Transmission248
Drive Shafts249
Removal249
Installation249
Lubrication249
Transmission/torque Converter250
Description250
Theory of Operation250
Maintenance251
General Information251
Troubleshooting251
Hydraulic Checks251
Troubleshooting Procedures251
Removal252
Installation252
Servicing The Crane After Transmission/torque Converter Overhaul254
Lubrication254
Type of Oil and Capacities254
Normal Drain Period254
Towing or Pushing254
SECTION 8255
Undercarriage255
Axles255
Description255
Maintenance256
Removal256
Cleaning256
Installation256
Wheel Alignment Check Procedure257
Rear Steer Indicator Adjustment Procedure257
Wheels and Tires258
Description258
Maintenance258
Mounting Wheel Assemblies258
Typical Wear Patterns258
Incorrect Tire Pressure258
Incorrect Camber259
Incorrect Toe and Axle Alignment259
Incorrect Caster and Wheel Imbalance259
Cuts in the Tire Tread260
Spot Wear260
Feathered Edges260
Cupping260
Steering Systems261
Description261
Front Steering System261
Rear Steering System261
Secondary Steering System (CE Units)261
Theory of Operation261
Front Steering System261
Rear Steering System261
Secondary Steering System (CE Units)261
Maintenance262
Front Steering System262
Troubleshooting262
Functional Check262
Secondary Steering System263
Rear Steering System263
Troubleshooting263
Hydraulic Pumps264
Description264
Front Steer264
Rear Steer264
Front Steering Control Valve264
Description264
Maintenance264
Removal264
Installation264
Integrated Outrigger/Rear Steer Control Valve264
Description264
Maintenance264
Functional Check264
Steer Cylinders264
Description264
Maintenance264
Removal265
Installation265
Rear Axle Oscillation Lockout System265
Description265
Theory of Operation265
Axle Oscillation Lockout Cylinders267
Description267
Maintenance267
Removal267
Installation267
Axle Oscillation Lockout Valve267
Description267
When the axle oscillation solenoid valves are energized and open, hydraulic oil is allowed in and out of the cylinders, allowing them to oscillate267
Maintenance267
Brake System267
Description267
Service Brakes267
Parking Brake268
Theory of Operation268
Service Brakes268
Parking Brake268
Maintenance269
Troubleshooting269
General269
Bleeding the Brake System269
Pressure Bleeding the Brake System270
Manually Bleeding the Brake System270
Service Brakes270
Description270
Maintenance270
Removal270
Linings270
Caliper271
Disassembly271
Caliper271
Inspection272
Periodic On-Vehicle272
Shoes, Linings, and End Plates272
Caliper for Leaks272
Dust Seals273
Disc273
Caliper Parts273
Cleaning274
Corrosion Protection274
Assembly274
Caliper274
Installation275
Linings275
Caliper276
Parking Brake Actuator276
Description276
Maintenance276
Removal276
Installation276
Adjustment276
Parking Brake277
Description277
Maintenance277
Removal277
Installation277
Park Brake Solenoid Valve280
Description280
Maintenance280
Removal280
Installation280
Outrigger280
Outrigger Circuit280
Description280
Theory of Operation280
Maintenance281
Troubleshooting281
Outrigger Beam284
Description284
Theory of Operation284
Maintenance284
Removal284
Inspection285
Installation285
Wear Pad Adjustment285
Extension Cylinder288
Description288
Maintenance288
Removal288
Installation288
Functional Check288
Outrigger Monitoring System (Optional— Standard in North America)288
Description288
Removal288
Installation289
Jack Cylinder289
Description289
Maintenance289
Removal289
Installation289
Functional Check290
Outrigger Control Valves290
Description290
Pilot Operated Check Valve290
Integrated Outrigger/Rear Steer Valve290
Outrigger Control Manifold290
SECTION 9291
Lubrication291
General291
Environmental Protection291
Lubricants and Lubrication Intervals291
Standard Lubricants291
Arctic Lubricants and Conditions293
Temperatures Below -9°C (15°F)293
Cold Weather Package and Lubricants293
Surface Protection for Cylinder Rods296
Wire Rope Lubrication296
lubrication Points297
CraneLUBE297
Safety297
Steering and Suspension298
Axles300
Drive Train302
Drive Train (continued)304
Turntable306
Outriggers308
Boom310
Boom (continued)312
Boom (continued)314
Hoist316
Hydraulic318
Carwell® Rust Inhibitor321
Protecting Cranes From Rusting321
Cleaning Procedures321
Inspection and Repair322
Application322
Areas of Application322

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