Manitowoc Grove RT9150E SERVICE Manual – PDF DOWNLOAD

Manitowoc Grove RT9150E SERVICE Manual – PDF DOWNLOAD

FILE DETAILS:

Manitowoc Grove RT9150E SERVICE Manual – PDF DOWNLOAD

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

TABLE OF CONTENTS:

Manitowoc Grove RT9150E SERVICE Manual – PDF DOWNLOAD

TABLE OF CONTENTS 5
SECTION 1 13
Introduction 13
General 13
Overview of Manuals 13
Delivery Report 14
Customer Support 14
New Owners 14
Safety Information 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 15
List Of Specifications 16
General 16
Dimensions 16
Capacities 16
Torque Converter 16
Transmission 16
Engine 16
Cummins QSC 16
Axles 16
Brakes 16
Wheels and Tires 16
Swing Gearbox 16
Boom 16
Swivel Assembly 16
Hydraulic Pumps 16
Pump #1 16
Pump #2 17
Pump #3 17
Pump #4 17
Hoists 17
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 28
Harnesses, Wires, and Connectors 28
Fatigue of Welded Structures 28
Loctite 28
Application of Medium Strength Loctite 28
Primer Application 28
Adhesive/Sealant Application 28
Fasteners and Torque Values 29
Torque Wrenches 29
Torque Values 29
Weld Studs 32
General 32
Environmental Conditions 32
Dynamic Shock Loads 32
Lubrication 33
Precautions and Recommendations During Inspection or Replacement 33
Wire Rope Inspection (Running Ropes and Pendant Cables) 34
Keeping Records 34
Frequent Inspection 34
Periodic Inspection 34
Wire Rope Inspection (Boom Extension and Retraction Cables) 35
Periodic Inspection 35
Wire Rope Inspection/Replacement (All Wire Rope) 35
Seizing Wire Rope 35
Method 1 35
Method 2 36
Installing 35×7 Class Wire Rope 36
Procedures for Cutting and Preparing 35×7 Class Wire Rope 37
SECTION 2 39
Hydraulic System 39
Description 40
Maintenance 43
Preparation 43
Hydraulic System Maintenance Precautions 43
Label Parts when Disassembling 43
Hydraulic Fluid Recommendations 43
Draining and Flushing 43
Removing Air from the Hydraulic System 44
Parts Replacement 45
Directional Control Valves 45
Inspection 46
Valve Leakage 46
Binding Spools 46
Visual Inspection of Hoses and Fittings 46
Supply Pressure And Return Circuit 47
Description 47
Hydraulic Reservoir and Filter 47
Pump Distribution 48
Pump No 1 48
Pump No 2 49
Pump No 3 49
Pump No 4 49
Maintenance 49
Troubleshooting 49
Troubleshooting Aids 50
Troubleshooting Procedures 50
Filter Maintenance 51
Maintenance Interval 51
Filter Element Removal 51
Filter Element Installation 51
Fill Cap Breather 51
Removal and Replacement 51
Hydraulic Reservoir Removal 53
Hydraulic Reservoir Installation 53
Oil Cooler 53
Description 53
Hydraulic Pumps 55
Description 55
Pump No 1 55
Pump No 2 55
Pump No 3 55
Pump No 4 55
Maintenance 55
Pump No 1 Removal 55
Pump No 1 Installation 55
Pump No 2 Removal 57
Pump No 2 Installation 57
No 3 Pump Removal 57
No 3 Pump Installation 57
No 4 Pump Removal 58
No 4 Pump Installation 58
Piston Pump Start-up Procedure 58
Pressure Setting Procedures 60
Connecting laptop to Crane Service Junction 62
Procedure A – Checking/Setting Piston Pump Differential and Cut-off Pressures 62
Procedure B – For Checking/Setting the Outrigger/Rear Steer/Axle Lockout Pressures 62
Superstructure Hydraulic System 65
Procedure C – Checking/Setting Main Hoist Lower Pressure 65
Procedure D – Checking/Setting Main Hoist Raise Pressure 66
Procedure E – Checking/Setting Auxiliary Hoist Lower Pressure 66
Procedure F – Checking/Setting Auxiliary Hoist Raise Pressure 66
Procedure G – Checking/Setting Telescope Pressure 66
Procedure H – Checking/Setting Control Pressure 68
Procedure I – Checking/Setting Raise Boom (Derricking) Pressure 68
Procedure J – Checking/Setting Counterweight Raise Pressure 68
Procedure K – Checking/Setting Counterweight Lower Pressure 68
Procedure L – Checking/Setting Counterweight Locking/Unlocking Pressures 68
Procedure M – Checking/Setting Cab Tilt Pressures 69
Procedure N – Checking/Setting Luffing Jib Pressures 69
Procedure O – Checking/Setting Slewing Pressure 69
Procedure P – Checking/Setting Slewing Pressure 69
Procedure Q – Checking/Setting Steering Pressure 70
Procedure R – Checking/Setting Service Brake Pressure 70
Procedure S – Checking Service Brake Accumulator Charge Pressures 70
Procedure T – Checking Service Brake Accumulator Pre-Charge Pressures 71
Procedure for Pre-Charging the Service Brake Accumulators, If Required 71
Valves 72
General 72
Outrigger/Rear Steer/Outrigger Box Pin Removal Valve 75
Description 75
Maintenance 75
Removal 75
Installation 75
Functional Check 75
Outrigger Control Manifold 78
Description 78
Maintenance 78
Removal 78
Inspection 78
Installation 78
Functional Check 78
Park Brake/Axle Disconnect valve 79
Description 79
Maintenance 79
Removal 79
Inspection 79
Installation 79
Axle Oscillation Lockout Valve 80
Description 80
Maintenance 80
Removal 80
Installation 80
Pressure Bleed-Off Valve 81
Description 81
Maintenance 81
Removal 81
Installation 81
Main Directional Control Valve 83
Description 83
General 83
Maintenance 83
Removal 83
Installation 83
Swing Directional Control Valve 87
Description 87
General 87
Maintenance 87
Removal 87
Installation 87
Compact Block Manifold 89
Description 89
Maintenance 89
Removal 89
Installation 89
Accessory Manifold 92
Description 92
Maintenance 92
Removal 92
Installation 92
Case Drain Manifold 94
Description 94
Maintenance 94
Removal 94
Installation 94
Dual Accumulator Charge Valve 95
Description 95
Maintenance 95
Removal 95
Installation 95
Control Block 97
Description 97
Maintenance 97
Removal 97
Installation 97
Tandem Brake Valve w/ Treadle Pedal 98
Description 98
Maintenance 98
Removal 98
Installation 98
Hydraulic Accumulator Service Brake100
Description100
Maintenance100
Removal100
Installation100
Servicing100
Cylinders101
General101
Maintenance101
General101
Surface Protection For Cylinder Rods101
Leakage Check101
Temperature Effects on Hydraulic Cylinders102
Axle Oscillation Lockout Cylinder103
Description103
Maintenance103
Disassembly103
Inspection103
Assembly104
Steer Cylinder107
Description107
Maintenance107
Disassembly107
Inspection107
Assembly107
Outrigger Extension Cylinder110
Description110
Maintenance110
Disassembly110
Inspection110
Assembly110
Outrigger Jack Cylinder113
Description113
Maintenance113
Disassembly113
Inspection113
Assembly115
Cab Tilt Cylinder116
Description116
Maintenance116
Disassembly116
Inspection116
Assembly118
Power Pin Cylinder119
Description119
Maintenance119
Disassembly119
Inspection119
Assembly121
Counterweight Pin Cylinder122
Description122
Maintenance122
Disassembly122
Assembly122
Lift Cylinder124
Description124
Maintenance124
Disassembly124
Assembly124
Counterweight Lift Cylinder126
Proximity Switches126
Adjustment for Switch 1126
Adjustment for Switch 2127
SECTION 3129
Electrical System129
Description129
General129
Alternator129
Batteries130
Fuses/Relays130
Battery Box130
Engine Compartment131
Cab Relay/Fuse Panel131
Junction Box Fuse/Relay Panel133
Maintenance134
General134
Visual Inspection and Replacement of Electrical Harnesses and Cables134
General Troubleshooting135
Tools for Troubleshooting135
Troubleshooting Engine Starting Problems135
Alternator/Charging System Troubleshooting136
Required Tools136
Visual Check136
Engine Off Tests136
Batteries136
Voltage at Alternator136
Battery Drain136
Engine On Tests136
Output Voltage Test136
Maximum Amperage Test136
Voltage Drop Test137
Troubleshooting Accessories137
Troubleshooting Swivel-Caused Electrical Problems137
Connector Troubleshooting137
ECOS Control Panel138
Warning Messages139
Error Messages139
Diagnostic Connector and Equipment140
Troubleshooting Vehicle Lights140
Troubleshooting Alarms, Indicators, and Emergency Components140
Troubleshooting Crane Components and Accessories140
Alternator Replacement140
Removal140
Installation140
Check141
Starter Replacement141
Removal141
Installation141
Check141
Battery Replacement141
Removal141
Installation142
Relay Panel Component Replacement142
Accessory Relay142
Buzzer Replacement142
Switch Replacement142
Rocker Switch Replacement142
Removal142
Inspection143
Installation143
Check143
Turn Signal Indicator Replacement143
Removal143
Inspection143
Installation143
Check144
Ignition Switch Replacement144
Removal144
Inspection144
Installation144
Check144
Turn Signal Lever and Transmission Shift Lever Replacement144
Removal145
Installation145
Check145
Windshield Wiper Assembly Replacement146
Removal146
Inspection147
Installation147
Check147
Windshield Washer Assembly Replacement148
Removal148
Inspection148
Installation148
Check148
Skylight Wiper Assembly Replacement148
Removal148
Inspection148
Installation148
Check149
SECTION 4151
Boom151
Description151
Main Boom151
Mechanical Luffing Lattice Extension151
Optional Hydraulic Luffing Lattice Extension151
Optional Boom Equipment151
Boom Controls151
Description and Theory of Operation151
Maintenance154
Boom Removal154
Boom Disassembly158
Initial Disassembly158
Remove Telescope Sections and Cylinder from Base Section161
Remove Sections 2, 3, 4, and 5 from Section 1162
Remove Sections 3, 4, and 5 from Section 2162
Remove Sections 4 and 5 from Section 3163
Remove Section 5 from Section 4163
Disassembly of Sections163
Section 5163
Section 4164
Section 3164
Section 2165
Remove top and bottom centering bolts and jam nuts from both sides165
Section 1165
Base Section Disassembly166
Boom Nose Disassembly166
Assembling the Boom166
Boom Nose Assembly167
Section 5 Assembly171
Section 4 Assembly175
Section 3 Assembly176
Section 2 and 1 Assembly176
Base Section Assembly176
Boom Assembly176
Assemble Section 5 Into Section 4176
Assembly of Remaining Sections180
Install Telescope Cylinder Assembly into Sections180
Assemble Telescope Assembly and Base Section182
Final Assembly and Test184
Boom Installation185
Functional Check187
Inspection188
Boom Alignment and Servicing188
Bi-Fold Swingaway Boom Extension189
Description189
Hook Block/Overhaul ball189
Description189
Maintenance189
SECTION 5191
Hoist and Counterweight191
Description191
Theory of Operation191
Maintenance191
Warm-up Procedure191
Hoist Access Area192
Hoist Removal192
Installation194
Functional Check195
Changing the Hoist Oil195
Draining the Hoist195
Filling the Hoist195
Preventive Maintenance195
Hoist Cable (Wire Rope)195
Check the Position on the Hoist Drums195
Check the Rope195
Adjusting the Lowering Limit Switch196
Setting the Lowering Limit Switch196
Prerequisites196
Check the Lowering Limit Shuts Off196
Checking the Hoist Brake196
General Inspection197
Counterweight Removal and Installation197
Counterweight Stand Installation197
Standard 39,000 lb (17,690 kg) Counterweight Installation197
Standard 39,000 lb (17,690 kg) Counterweight Removal198
Heavy 63,000 lb (28,576 kg) Counterweight Installation199
Heavy 63,000 lb (28,576 kg) Counterweight Removal200
Counterweight Stand Removal200
SECTION 6201
Swing System201
Description201
Theory of Operation201
Swing Drive201
Swing Brake201
Maintenance203
Troubleshooting203
Swing Box Assemblies207
Description207
Swing Motor Maintenance207
Removal207
Installation207
Testing207
Swing Brake Assembly Maintenance208
Removal208
Installation208
Testing208
Swing Gearbox Maintenance208
Removal208
Installation208
Servicing209
Normal maintenance should only consist of proper lubrication and a periodic check of mounting bolt torque values Lubrication consists of maintaining the gearbox oil level Oil in a new gearbox should be drained and flushed out after approximately 25209
Oil Changing209
Checking Oil Level209
Testing209
Swing Bearing210
Description210
Maintenance210
General210
Torquing Turntable Bolts210
General210
Torque Values211
Tools Required211
Inner Race Torquing211
Outer Race Torquing211
Removal212
Inspection213
Installation213
Testing214
Swivels215
Description215
Hydraulic Swivel217
Description217
Theory of Operation217
Maintenance217
Removal217
Installation217
Two-Port Water Swivel218
Description218
Maintenance218
Removal218
Disassembly218
Cleaning and Inspection218
Assembly218
Installation219
Electrical Swivel219
Description219
Theory of Operation219
Maintenance219
Removal219
Installation220
Preventive Maintenance220
Swing Lock Pin221
Description221
Maintenance221
360° Swing Lock Control (Positive Lock Type)221
Description221
Maintenance221
SECTION 7223
Power Train223
Description223
Maintenance224
Engine Removal224
Engine Installation227
Engine Drive Belts228
Electronic Control System230
Fuel System230
Description230
Fuel Tank230
Injection Fuel Pump230
Fuel Filter-Water Separator230
Electric Lift Pump230
Maintenance230
Fuel Tank230
Removal230
Installation230
Fuel Filter-Water Separator231
Draining231
Air Intake and Exhaust System232
Description232
Maintenance232
Air Cleaner Checks232
Check for Filter Restriction232
Tier 3 Filter Element Replacement234
Air Cleaner Body235
Tier 4 Filter Element Replacement236
Element Cleaning236
Air Cleaner Body236
Precleaner236
Vacuator Valve236
Duct Work237
Charge-Air Cooler System238
Maintenance238
Muffler239
Removal239
Installation239
Water Cooling System242
Description242
Maintenance242
General242
Effects of Cooling System Neglect242
Overheating242
Overcooling242
Rust Prevention242
Engine Antifreeze/Coolant Fill Procedure242
Cooling/SCA Maintenance Summary243
Supplemental Coolant Additives (SCA)243
DCA4243
SCA Level Check/Coolant Filter Change Interval243
Cleaning243
Pressure Flushing243
Component Inspection244
Radiator/Surge Tank244
Engine Water Jacket244
Water Pump244
Fans and Belts244
Thermostat245
Hoses and Clamps245
Test Equipment245
Antifreeze/Coolant245
Radiator Removal and Installation245
Removal245
Installation245
Drive Train248
Description248
Maintenance248
Drive Lines248
Removal248
Installation248
Lubrication248
Torque Converter249
Description249
Theory of Operation249
Maintenance250
General Information250
Troubleshooting250
Hydraulic Checks250
Troubleshooting Procedures250
Removal251
Installation251
Servicing the Crane after Transmission/Torque Converter Overhaul253
Lubrication253
Type of Oil253
Capacity253
Check Period254
Normal Drain Period254
Transmission255
Description255
Maintenance255
Removal255
Installation255
Towing or Pushing255
SECTION 8257
Undercarriage257
Axles257
Description257
Maintenance258
Removal258
Cleaning258
Installation258
Wheel Alignment Check Procedure259
Rear Wheels Not Centered Switch Adjustment Procedure259
Wheels and Tires260
Description260
Maintenance260
Mounting Wheel Assemblies260
Steering Systems261
Description261
Front Steering System261
Rear Steering System261
Theory of Operation261
Front Steering System261
Rear Steering System261
Maintenance261
Front Steering System261
Functional Check262
Rear Steering System263
Hydraulic Pump264
Pump #2264
Front Steering Control Valve264
Description264
Maintenance264
Removal264
Installation264
Integrated Outrigger/Rear Steer Control Valve264
Description264
Maintenance264
Removal264
Installation264
Functional Check265
Steer Cylinders265
Description265
Maintenance265
Removal265
Installation265
Rear Axle Oscillation Lockout System265
Description265
Theory of Operation265
Axle Oscillation Lockout Cylinders267
Description267
Maintenance267
Removal267
Installation267
Axle Oscillation Lockout Valve267
Description267
Maintenance267
Removal267
Installation267
Brake System268
Description268
Service Brakes268
Parking Brake268
Theory of Operation268
Service Brakes268
Parking Brake268
Maintenance269
Troubleshooting269
General269
Bleeding the Brake System269
Service Brakes270
Description270
Maintenance270
Removal270
Linings270
Caliper270
Disassembly270
Caliper270
Inspection272
Periodic On-Vehicle272
Linings, and End Plates272
Caliper For Leaks273
Dust Seals273
Disc273
Caliper Parts273
Cleaning274
Corrosion Protection274
Assembly274
Caliper274
Installation275
Caliper275
Linings276
Parking Brake Actuator276
Description276
Maintenance276
Removal276
Installation276
Adjustment276
Parking Brake276
Description276
Maintenance277
Removal277
Installation277
Park Brake Solenoid Valve278
Description278
Maintenance278
Removal278
Installation278
Outriggers279
Description279
Theory of Operation279
Maintenance279
Outrigger Beam282
Description282
Theory of Operation282
Maintenance282
Removal282
Inspection285
Installation285
Wear Pad Adjustment285
Extension Cylinder286
Description286
Maintenance286
Removal286
Installation286
Functional Check287
Jack Cylinder287
Description287
Maintenance287
Removal287
Installation287
Functional Check287
Outrigger Control Valves288
Description288
Pilot Operated Check Valve288
Integrated Outrigger/Rear Steer Valve288
Outrigger Control Manifold288
Outrigger Monitoring System (Optional— Standard in North America)288
Description288
OMS String Potentiometers288
Removal288
Installation288
SECTION 9289
Lubrication289
General289
Environmental Protection289
Lubrication Intervals289
Standard Lubricants Package290
Arctic Conditions290
Below -9°C (15°F)290
Down to –29C° (–20°F)291
ALL Weather Package & Lubricants291
Surface Protection for Cylinder Rods293
Wire Rope Lubrication293
Lubrication Points294
CraneLUBE294
Cummins Oil Registration List294
Safety294
Steering and Suspension295
Axles297
Drive Train299
Drive Train (continued)301
Outriggers303
Hydraulic305
Turntable307
Cab Tilt309
Lift Cylinder311
Hoist313
Boom315
Boom (continued)317
Boom Extension319
Boom321
Carwell® Rust Inhibitor323
Description323
Cleaning Procedures323
Inspection and Repair324
Carwell Application324
Areas of Application324

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