Manitowoc Grove RT770E Service Manual – PDF DOWNLOAD

Manitowoc Grove RT770E Service Manual – PDF DOWNLOAD

FILE DETAILS:

Manitowoc Grove RT770E Service Manual – PDF DOWNLOAD

Language : English
Pages :360
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Manitowoc Grove RT770E Service Manual – PDF DOWNLOAD

SECTION 1 Introduction
General 1-1
Overview of Manuals 1-1
Customer Support 1-2
General Crane Design 1-2
Specific Crane Description 1-2
Lifting Capacities (Load Chart) 1-2
Basic Components 1-2
Axle Weight Distribution 1-2
Serial Number Location 1-2
Transportation and Lifting Data 1-2
List Of Specifications 1-3
General 1-3
Dimensions 1-3
Capacities 1-3
Torque Converter 1-3
Transmission 1-3
Engine 1-3
Axles 1-3
Brakes 1-3
Wheels and Tires 1-3
Swing Gearbox 1-3
Boom 1-3
Swivel Assembly 1-3
Hydraulic Pumps 1-3
Hoists 1-4
Crane Nomenclature 1-7
General Maintenance 1-9
Cleanliness 1-9
After Cleaning 1-9
Removal and Installation 1-9
Disassembly and Assembly 1-9
Pressing Parts 1-10
Locking Devices 1-10
Wires and Cables 1-10
Shims 1-10
Hoses and Tubes 1-10
Bearings 1-11
Gaskets 1-11
Batteries 1-11
Hydraulic Systems 1-12
Hydraulic Fittings 1-13
Electrical System 1-14
Fatigue of Welded Structures 1-15
Loctite® 1-15
Fasteners and Torque Values 1-16
Weld Studs 1-19
Wire Rope 1-20
General 1-20
Environmental Conditions 1-20
Dynamic Shock Loads 1-20
Lubrication 1-20
Reference Only
TABLE OF CONTENTS RT770E SERVICE MANUAL
TOC-2
Precautions and Recommendations During Inspection or Replacement 1-20
Wire Rope Inspection (Running Ropes and Pendant Cables) 1-21
Wire Rope Inspection (Boom Extension and Retraction Cables) 1-22
Wire Rope Inspection/Replacement (All Wire Rope) 1-22
Seizing Wire Rope 1-23
Installing 35×7 Class Wire Rope 1-24
Procedures for Cutting and Preparing 35×7 Class Wire Rope 1-24
SECTION 2 Hydraulic System
Description 2-2
Hydraulic Symbols 2-3
Maintenance 2-5
Preparation 2-5
Hydraulic System Maintenance Precautions 2-5
Label Parts When Disassembling 2-5
Hydraulic Oil Recommendations 2-5
Draining and Flushing 2-5
Removing Air From the Hydraulic System 2-6
Parts Replacement 2-7
Directional Control Valves 2-7
Visual Inspection of Hoses and Fittings 2-8
Supply Pressure And Return Circuit 2-9
Description 2-9
Pump Distribution 2-10
Troubleshooting 2-10
Troubleshooting Aids 2-12
Troubleshooting Procedures 2-12
Hydraulic Oil Return Filter Assembly 2-13
Fill Cap/Breather 2-13
Oil Cooler 2-15
Description 2-15
Oil Temperature Switches 2-15
Maintenance 2-15
Hydraulic Pumps 2-17
Description 2-17
Maintenance 2-17
Pump Disconnect Assembly 2-21
Disassembly 2-21
Assembly 2-21
Pressure Setting Procedures 2-23
Procedure A – Main Control Valve Reliefs 2-24
Procedure B – Main Directional Control Valve Pilot Supply Pressure 2-25
Procedure C – Swing Brake Pilot Supply Pressure 2-25
Procedure D – Brake Charge Supply Valve Relief Pressure 2-25
Procedure E – Charge Air Cooler Valve Relief Pressure 2-26
Procedure F – Brake Dual Accumulator Charge Valve Pressure Limits 2-26
Procedure G – Accumulator Pre-Charge Pressure 2-26
Procedure H – PreCharging The Accumulator 2-27
Procedure I – Swing Valve Work Port Reliefs Pressure 2-27
Procedure J – Front Steer Relief Valve Pressure 2-28
Procedure K – Outrigger/Rear Steer Valve Relief 2-28
Procedure L – Hydraulic Oil Cooler Fan Motor Control Valve 2-28
Procedure M – Counterweight Removal Valve 2-29
Valves 2-30
General 2-30
Directional Control Valves 2-33
Reference Only
TOC-3
RT770E SERVICE MANUAL TABLE OF CONTENTS
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Description 2-33
Maintenance 2-33
Hydraulic Remote Control Valve 2-38
Description 2-38
Maintenance 2-38
Dual Accumulator Charge Valve 2-42
Description 2-42
Maintenance 2-42
Swing Brake And Armrest Lockout Valve Manifold 2-44
Description 2-44
Maintenance 2-44
Holding Valve 2-46
Description 2-46
Maintenance 2-46
Outrigger/Rear Steer Valve 2-47
Description 2-47
Maintenance 2-48
Outrigger Control Manifold 2-49
Description 2-49
Maintenance 2-50
Parking Brake/Range Shift Valve 2-51
Description 2-51
Maintenance 2-51
Axle Oscillation Lockout Valve 2-53
Description 2-53
Maintenance 2-53
High Speed Boost Selector Valve 2-54
Description 2-54
Maintenance 2-54
Telescope Stage Selector Valve Manifold 2-55
Description 2-55
Maintenance 2-55
Telescope Fill Tube Control Valve Manifold 2-56
Description 2-56
Maintenance 2-57
Hydraulic Accumulator 2-58
Description 2-58
Maintenance 2-58
Service Brake and CAC Fan Motor Priority Flow Control Valve 2-59
Description 2-59
Maintenance 2-59
Oil Cooler Fan Motor Priority Flow Control Valve 2-60
Description 2-60
Maintenance 2-60
Cylinders 2-61
General 2-61
Maintenance 2-61
Surface Protection For Cylinder Rods 2-61
Temperature Effects On Hydraulic Cylinders 2-62
Lift Cylinder 2-64
Description 2-64
Maintenance 2-64
Telescope Cylinder 2-68
Description 2-68
Maintenance 2-68
Axle Oscillation Lockout Cylinder 2-69
Description 2-69
Reference Only
TABLE OF CONTENTS RT770E SERVICE MANUAL
TOC-4
Maintenance 2-69
Steer Cylinder 2-72
Description 2-72
Maintenance 2-72
Outrigger Extension Cylinder 2-75
Description 2-75
Maintenance 2-75
Outrigger Jack Cylinder 2-78
Description 2-78
Maintenance 2-78
Counterweight Removal Cylinder 2-81
Description 2-81
Maintenance 2-81
SECTION 3 Electrical System
Description 3-1
General 3-1
Alternator 3-3
Batteries 3-3
Cab Electrical Panel 3-3
Carrier Electrical Panel 3-5
Maintenance 3-7
General 3-7
General Troubleshooting 3-8
Tools for Troubleshooting 3-8
Troubleshooting Swivel-Caused Electrical Problems 3-8
Connector Troubleshooting 3-8
Alternator/Charging System Troubleshooting 3-9
Alternator Replacement 3-11
Starter Replacement 3-11
Battery Replacement 3-12
Relay Panel Component Replacement 3-12
Gauge Cluster Replacement 3-13
Rocker Switch Replacement 3-13
Ignition Switch Replacement 3-14
Turn Signal Lever and Transmission Shift Lever Replacement 3-15
Windshield Wiper Assembly Replacement 3-16
Windshield Washer Assembly Replacement 3-18
Skylight Wiper Assembly Replacement 3-18
Tools for Troubleshooting 3-19
Optional Equipment 3-19
Beacon Light 3-19
Boom Mounted Floodlights 3-19
Rear View Mirror 3-19
Air Conditioner 3-19
SECTION 4 Boom
Description 4-1
Theory of Operation 4-2
Maintenance 4-4
Removal 4-4
Disassembly 4-13
Boom Nose Sheaves 4-21
Assembly 4-21
Installation 4-32
Functional Check 4-33
Reference Only
TOC-5
RT770E SERVICE MANUAL TABLE OF CONTENTS
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OC
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Inspection 4-33
Boom Alignment and Servicing 4-33
Boom Extension and Retraction Cables 4-33
Maintenance 4-33
Inspection 4-33
Adjustment 4-34
Telescope Circuit 4-37
Description 4-37
Theory of Operation 4-37
Maintenance 4-39
Removal And Installation 4-40
Disassembly And Assembly 4-40
Lift Circuit 4-41
Description 4-41
Theory of Operation 4-41
Maintenance 4-41
Lift Cylinder Removal 4-43
Disassembly and Assembly 4-43
Lift Cylinder Installation 4-43
Bi-Fold Boom Extension 4-45
Description 4-45
Boom Extension Rigging Mode 4-45
Erecting the Boom Extension 4-45
Stowing the Boom Extension 4-52
Setting the Folding Swingaway Offset 4-54
Boom Extension Alignment Device Adjustment 4-55
Swingaway Mounting Adjustment 4-55
Hook Block 4-56
Description 4-56
Maintenance 4-56
SECTION 5 Hoist and Counterweight
Description 5-1
Theory of Operation 5-1
Maintenance 5-2
Warm-up Procedure 5-2
Hoist Area Access 5-2
Removal 5-4
Installation 5-4
Functional Check 5-4
Fluid Level 5-4
Preventive Maintenance 5-5
Hoist To Boom Alignment 5-6
Preparation 5-6
Tools Required 5-6
Procedure 5-6
Motor And Brake 5-8
Description 5-8
Idler Drum And Cable Follower 5-9
Description 5-9
Maintenance 5-9
Third Wrap Indicator (Optional—Standard on CE) 5-12
Description 5-12
Maintenance 5-12
Hoist Drum Rotation Indicator System 5-13
Description 5-13
Reference Only
TABLE OF CONTENTS RT770E SERVICE MANUAL
TOC-6
Maintenance 5-13
Hoist Control Valves 5-15
Description 5-15
Fixed Counterweight 5-16
Description 5-16
Maintenance 5-16
Counterweight Plate 5-16
Removable Counterweight (Optional) 5-18
Removal 5-18
Installation 5-18
SECTION 6 Swing System
Description 6-1
Theory of Operation 6-1
Swing Drive 6-1
Swing Brake 6-1
Maintenance 6-3
Swing Motor 6-7
Description 6-7
Maintenance 6-7
Swing Gearbox And Brake 6-8
Description 6-8
Maintenance 6-8
Swing Bearing 6-10
Description 6-10
Maintenance 6-10
Swivels 6-15
Description 6-15
Hydraulic Swivel 6-17
Description 6-17
Theory Of Operation 6-17
Maintenance 6-17
Two Port Water Swivel 6-19
Description 6-19
Maintenance 6-19
Electrical Swivel 6-20
Description 6-20
Theory of Operation 6-20
Maintenance 6-20
Swing Lock Pin 6-22
Description 6-22
Maintenance 6-22
360° Swing Lock Control (Positive Lock Type) (Optional) 6-22
Description 6-22
Maintenance 6-22
SECTION 7 Power Train
Engine 7-1
Description 7-1
Maintenance 7-2
Electronic Control System 7-4
Description 7-4
Engine Control System Switches And Indicator Lights 7-4
Fuel System 7-7
Description 7-7
Maintenance 7-7
Reference Only
TOC-7
RT770E SERVICE MANUAL TABLE OF CONTENTS
T
OC
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Air Intake and Exhaust System 7-9
Description 7-9
Air Intake 7-9
Charge-Air Cooler System 7-13
Muffler 7-14
Water Cooling System 7-17
Description 7-17
Maintenance 7-17
Radiator Fill and Servicing 7-21
Drive Train 7-23
Description 7-23
Maintenance 7-23
Transmission/torque Converter 7-25
Description 7-25
Theory of Operation 7-25
Maintenance 7-26
Troubleshooting Procedures 7-26
Towing or Pushing 7-29
SECTION 8 Undercarriage
Axles 8-1
Description 8-1
Maintenance 8-2
Wheels And Tires 8-4
Typical Wear Patterns 8-4
Steering Systems 8-7
Description 8-7
Theory Of Operation 8-7
Maintenance 8-8
Rear Steering System 8-9
Troubleshooting 8-9
Hydraulic Pumps 8-10
Front Steering Control Valve 8-10
Integrated Outrigger/Rear Steer Control Valve 8-10
Steer Cylinders 8-10
Rear Axle Oscillation Lockout System 8-11
Description 8-11
Theory Of Operation 8-11
Axle Oscillation Lockout Cylinders 8-13
Axle Oscillation Lockout Valve 8-13
Maintenance 8-13
Brake System 8-13
Description 8-13
Theory Of Operation 8-14
Maintenance 8-15
Service Brakes 8-16
Description 8-16
Maintenance 8-16
Corrosion Protection 8-20
Parking Brake Actuator 8-22
Description 8-22
Maintenance 8-22
Parking Brake 8-23
Description 8-23
Maintenance 8-23
Park Brake Solenoid Valve 8-26
Reference Only
TABLE OF CONTENTS RT770E SERVICE MANUAL
TOC-8
Description 8-26
Maintenance 8-26
Outrigger 8-26
Outrigger Circuit 8-26
Maintenance 8-27
Outrigger Beam 8-30
Extension Cylinder 8-34
Outrigger Monitoring System (Optional—Standard in North America) 8-34
Jack Cylinder 8-35
Outrigger Control Valves 8-36
SECTION 9 Lubrication
General 9-1
Environmental Protection 9-1
Lubricants and Lubrication Intervals 9-1
Standard Lubricants 9-2
Arctic Lubricants and Conditions 9-3
Surface Protection for Cylinder Rods 9-6
Wire Rope Lubrication 9-6
lubrication Points 9-7
CraneLUBE 9-7
Safety 9-7
Steering and Suspension 9-8
Axles 9-10
Drive Train 9-12
Drive Train (continued) 9-14
Turntable 9-16
Outriggers 9-18
Boom 9-20
Hoist 9-30
Hydraulic 9-32
Carwell® Rust Inhibitor 9-35
Protecting Cranes From Rusting 9-35
Cleaning Procedures 9-35
Inspection and Repair 9-36
Application 9-36
Areas of Application 9-36
Reference Only
Published 11/25/2014, Control # 522-01 1-1
RT770E SERVICE MANUAL INTRODUCTION
1
GROVE
SECTION 1
INTRODUCTION
SECTION CONTENTS
General 1-1
Overview of Manuals 1-1
Customer Support 1-1
General Crane Design 1-2
Specific Crane Description 1-2
Lifting Capacities (Load Chart) 1-2
Basic Components 1-2
Axle Weight Distribution 1-2
Serial Number Location 1-2
Transportation and Lifting Data 1-2
List Of Specifications 1-3
General 1-3
Dimensions 1-3
Capacities 1-3
Torque Converter 1-3
Transmission 1-3
Engine 1-3
Axles 1-3
Brakes 1-3
Wheels and Tires 1-3
Swing Gearbox 1-3
Boom 1-3
Swivel Assembly 1-3
Hydraulic Pumps 1-3
Hoists 1-4
Crane Nomenclature 1-7
General Maintenance 1-9
Cleanliness 1-9
After Cleaning 1-9
Removal and Installation 1-9
Disassembly and Assembly 1-9
Pressing Parts 1-10
Locking Devices 1-10
Wires and Cables 1-10
Shims 1-10
Hoses and Tubes 1-10
Bearings 1-11
Gaskets 1-11
Batteries 1-11
Hydraulic Systems 1-12
Hydraulic Fittings 1-13
Electrical System 1-14
Fatigue of Welded Structures 1-15
Loctite® 1-15
Fasteners and Torque Values 1-16
Weld Studs 1-19
Wire Rope 1-20
General 1-20
Environmental Conditions 1-20
Dynamic Shock Loads 1-20
Lubrication 1-20
Precautions and Recommendations During
Inspection or Replacement 1-20
Wire Rope Inspection (Running Ropes and
Pendant Cables) 1-21
Wire Rope Inspection (Boom Extension and
Retraction Cables) 1-22
Wire Rope Inspection/Replacement
(All Wire Rope) 1-22
Seizing Wire Rope 1-23
Installing 35×7 Class Wire Rope 1-24
Procedures for Cutting and Preparing
35×7 Class Wire Rope 1-24

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