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Manitowoc Grove GRT9165, Service Manual

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POWER TRAIN

GRT9165 SERVICE MANUAL

7-16

Published 10-01-2020 Control # 699-00

AFTERTREATMENT DIESEL EXHAUST 
FLUID (DEF) 

DEF Tank

This engine uses a Selective Catalytic Reduction (SCR)
system. SCR is a technology that uses a urea based DEF
and a catalytic converter to significantly reduce oxides of
nitrogen (NOx) emissions.

The DEF tank (1, Figure 7-15) incorporates a fluid level
sending unit and a heating element to keep the DEF from
freezing.

Removal

1.

Tag  and  disconnect  the  electrical  connector  (2) on  the
DEF tank (1).

2.

Tag and disconnect the fluid lines (3, 6, 7, 8) on the tank.

3.

Remove the hardware (4) holding the tank straps (5) in
place.

4.

Remove the tank (1).

Installation

1.

Place the DEF tank (1) onto the location on the frame.

2.

Place  the  tank  straps  (5)  around  the  tank  and  secure
with the hardware (4).

3.

Connect  the  fluid  lines  (3,  6,  7,  8)  as  tagged  during
removal.

4.

Connect  the  electrical  connector  (2)  as  tagged  during
removal.

10193

FIGURE 7-15

7

1

DEF Tank

2

Electrical Connector

3

Coolant Inlet

4

Tank Strap Mounting Hardware

4

2

3

5

5

Tank Straps

6

Coolant Outlet

7

Suction Port

8

Return Port

6

8

1

10194

Summary of Contents for Grove GRT9165

Page 1: ...Service Manual Grove GRT9165 9897 ...

Page 2: ...s necessary For more information go to www P65warnings ca gov diesel Batteries battery posts terminals and related accessories can expose you to chemicals including lead and lead compounds which are known to the State of California to cause cancer and birth defects or other reproductive harm Wash hands after handling For more information go to www P65warnings ca gov California Spark Arrestor Opera...

Page 3: ... to the operator s cab Always furnish crane serial number when ordering parts or communicating service problems with your distributor or the factory An untrained operator subjects himself and others to death or serious injury Do not operate this crane unless You are trained in the safe operation of this crane Manitowoc is not responsible for qualifying personnel You read understand and follow the ...

Page 4: ...THIS PAGE BLANK ...

Page 5: ...Boom 1 4 Outriggers 1 4 Swivel Assembly 1 4 Hydraulic Pumps 1 4 Hoists 1 4 GRT9165 Crane Components 1 8 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 ...

Page 6: ...ler 2 12 Description 2 12 Maintenance 2 12 Hydraulic Pumps 2 14 Maintenance 2 14 Hydraulic Pump Distribution 2 18 Troubleshooting 2 19 Troubleshooting Aids 2 20 Troubleshooting Procedures 2 20 Valves 2 21 Carrier Valves 2 22 Outrigger Control Manifold Valves 2 23 Carrier Manifold Valve 2 25 Suspension Manifold Valve 2 28 Fan Control Manifold Valve 2 29 Differential Lock Manifold Valve 2 30 Bleed O...

Page 7: ...ription 3 1 General 3 1 Alternator 3 1 Batteries and Battery Disconnect Switch 3 2 Jump Starting Hazard 3 2 Charging the Batteries 3 2 Cab Electrical Panels 3 2 Carrier Electrical Panel 3 5 Maintenance 3 9 General 3 9 Dielectric Grease 3 9 Visual Inspection and Replacement of Electrical Harnesses and Cables 3 10 General Troubleshooting 3 10 Tools for Troubleshooting 3 11 Swivel Electrical Troubles...

Page 8: ...Installing Cable On Hoist 5 2 Removing Installing the Hoist 5 2 Removing 5 2 Installing 5 2 Functional Check 5 3 Hoist Fluid Level Check 5 3 Usage and Inspection 5 6 Preventative Maintenance 5 6 Hoist Oil Sampling 5 7 Brake Test Procedure 5 8 Hoist Motor Motor Control Valve And Brake 5 8 Description 5 8 Hoist Rotation and 3rd Wrap Indicator System 5 8 Description 5 8 Maintenance 5 9 Hoist Control ...

Page 9: ...Engine 7 1 Description 7 1 Maintenance 7 2 Electronic Control System 7 4 Description 7 4 Engine Control System Indicator Lights 7 4 Fuel System 7 5 Description 7 5 Maintenance 7 5 Air Intake and Exhaust System 7 7 Description 7 7 Air Intake 7 7 Charge Air Cooler System 7 11 Exhaust System 7 12 Slip Joint Exhaust Connectors 7 13 Aftertreatment Diesel Exhaust Fluid DEF 7 16 DEF Tank 7 16 DEF Supply ...

Page 10: ...neral 9 1 Environmental Protection 9 1 Lubricants and Lubrication Intervals 9 1 Standard Lubricants 9 2 Arctic Lubricants and Conditions 9 4 Arctic Conditions Below 9 C 15 F 9 4 Cylinder Rod Surface Protection 9 7 Wire Rope Lubrication 9 7 Lubrication Points 9 7 CraneLUBE 9 7 Cummins Oil Registration List 9 7 Safety 9 8 Drive Train 9 9 Steering and Suspension 9 19 Axle Lubrication 9 21 Superstruct...

Page 11: ...3 Electrical System 1 15 Fatigue of Welded Structures 1 15 Loctite 1 15 Fasteners and Torque Values 1 16 Weld Studs 1 27 Wire Rope 1 28 General 1 28 Environmental Conditions 1 28 Dynamic Shock Loads 1 28 Lubrication 1 28 Precautions and Recommendations During Inspection or Replacement 1 28 Wire Rope Inspection Running Ropes and Pendant Cables 1 29 Wire Rope Inspection Boom Extension and Retraction...

Page 12: ...been designed for maximum performance with minimum maintenance With proper care years of trouble free service can be expected Constant improvement and engineering progress makes it necessary that we reserve the right to make specification and equipment changes without notice Specific Crane Description The crane incorporates an all welded parallel box construction steel frame utilizing two drive st...

Page 13: ...Converter 44 5 L 11 75 gal Diesel Exhaust Fluid DEF Tank 37 9 L 10 gal Transmission Gear Ratios Forward and Reverse Low Range 1st 12 64 1 2nd 6 11 1 3rd 2 25 1 High Range 4th 4 30 1 5th 2 08 1 6th 0 76 1 Torque Converter Stall Ratio 1 784 1 Charge Pump Capacity 80 L min 21 gal min 2000 rpm Engine Cummins QSB 6 7L Stage V Tier 4F Type 4 cycle Diesel with After Treatment System 6 cylinder Turbocharg...

Page 14: ...d 738 4 kN 166 000 lb or 166 kip Swivel Assembly Electrical 20 Slip Rings Hydraulic 10 ports Water 2 ports Air Conditioning 2 ports Hydraulic Pumps NOTE Pump flow rate output figures are theoretical Pump 1 Type Piston Sections 1 Output loaded engine speed Section 1 flow rate 253 L min 66 8 gal min Pump 2 Type Piston Sections 1 Output loaded engine speed Section 1 flow rate 184 L min 48 6 gal min P...

Page 15: ...CE 5 EXTEND OUTRIGGER BEAMS 48 CM 18 IN AND SLING AROUND BEAMS TO LIFT 6 DO NOT USE PINTLE HOOKS OR CWT LUGS FOR LIFTING OR TYING DOWN THE ENTIRE CRANE 7 REMOVE OUTRIGGERS AND COUNTERWEIGHT FOR TRANSPORT AS REQUIRED TRANSPORTATION AND LIFTING DATA GRT9165 TOTAL UNIT D E 1673cm 659 in A 377 cm 148 in 87 223 kg 192 292 lb 676cm 266 in 16 206kg 35 728 lb 25 750kg 56 770 lb 3 955kg 8 720 lb 3 483kg 7 ...

Page 16: ... 26 5x 25 44 ply Titan Tires Main Hoist with 294 m 965 ft of 19 mm 3 4 in 35 x 7 cable Aux Hoist with 233 m 764 ft of 19 mm 3 4 in 35x7 cable Full Fuel and Hydraulic Oil 148 62 58 51 83470 184017 23960 52822 59510 131195 Add To Basic Unit Weight Boom Extensions 10 9 to 17 8 m 35 7 to 58 4 ft Manually Offsetable Boom Extension 840 21 330 79 1658 3655 2786 6142 1128 2487 10 9 to 17 8 m 35 7 to 58 4 ...

Page 17: ...9 116 84 46 00 67 147 15 34 51 113 Cold Weather Package Carrier 40 182 88 72 00 113 250 41 91 72 159 Cold Weather Package S S 149 05 58 68 38 84 11 25 27 59 Driver 218 44 86 00 113 250 49 109 64 141 Substitutions and Removals from Basic Unit Weight REM Front Outrigger Box and Beam Assembly 662 99 261 02 3955 8720 5245 11563 1290 2843 REM Rear Outrigger Box and Beam Assembly 262 99 103 54 3955 8720...

Page 18: ...21 Boom Extension Sheaves 8 Counterweight 22 Boom Extension Fly Section 9 Outrigger Pads 23 Boom Extension Base Section 10 Crane Steps and Grab Handles 24 Lift Cylinder 11 Outrigger Jack Cylinders 25 Hydraulic Tank 12 Exhaust Aftertreatment 26 Axle 1 Front Drive and Steer 13 Battery Disconnect Switch 27 Axle 2 Steer only 14 Battery and Control Module Compartment 28 Axle 3 Rear Drive and Steer Stag...

Page 19: ...clean cloth Make sure the parts are completely dry and clean DO NOT use compressed air on bearings Spinning bearings without lubricant will cause damage to the bearing and could cause the bearing to fly apart Removal and Installation When performing maintenance do not attempt to manually lift heavy parts when hoisting equipment should be used Never locate or leave heavy parts in an unstable positi...

Page 20: ... to ensure proper identification during assembly Shims When shims are removed tie them together and identify them as to location Keep shims clean and flat until they are reinstalled Hoses and Tubes Inspection Check hoses carefully Do not use your bare hands to check for leaks Tighten all connections to recommended torque If the hose end connections are damaged always replace the hose or tube Damag...

Page 21: ...cool and contract Installation Lubricate new or used bearings before installation Bearings that are to be preloaded must have a film of oil over the entire assembly to obtain accurate pre loading When installing a bearing spacer or washer against a shoulder on a shaft be sure the chamfered side is toward the shoulder When pressing bearings into a retainer or bore uniformly apply pressure to the ou...

Page 22: ...cked damaged or badly corroded fittings Fitting slippage on hose Other signs of significant deterioration If any of the above conditions exist evaluate hose assemblies for correction or replacement For replacement of hose assemblies refer to your Manitowoc Crane Care Parts Manual 2 At the same service interval visually inspect all other hydraulic components and valves for the following Leaking por...

Page 23: ... of the fitting 3 Finger tighten the nut onto the fitting If necessary a wrench should be used to seat the nut snugly against the fitting This is considered the Finger Tight condition 4 Using a permanent type ink marker make a mark on one of the flats of the nut and continue it onto the hex of the static fitting or port 5 Tighten the joint by the number of flats as specified in Table 1 3 and 1 4 f...

Page 24: ... 5 To orientate the fitting unscrew the fitting the required amount but not more than one full turn 6 Hold the fitting in the desired position and tighten the nut D following the F F F T method starting with step 4 Nonadjustable Straight Thread O ring Fitting Fitting to Port Refer to Table 1 5 for the following procedure 1 Make sure both threads and sealing surfaces are free of burrs nicks scratch...

Page 25: ...r pad retaining structures hydraulic cylinder attaching points boom pivot shaft retaining structures Outrigger pads beams boxes and attachment structures Main frame generally in the area of doubler plates and crossmembers at the junction of front and rear frame members on truck cranes Turntable bearing connection where bearing is bolted to the crane superstructure or chassis Counterweight support ...

Page 26: ...ven though they might have a pre set feature must be pulled at right angle and the force must be applied at the center of the handle Force value readings must be made while the tool is in motion Rigid handle type with torque limiting devices that can be pre set to required values eliminate dial readings and provide more reliable less variable readings NOTE If multipliers and or special tools are u...

Page 27: ...UNC 5 24 0 23 4 22 8 8 33 9 33 1 32 2 7 16 14 UNC 5 38 4 37 4 36 5 8 54 3 52 9 51 5 1 2 13 UNC 5 58 6 57 1 55 7 8 82 8 80 7 78 6 9 16 12 UNC 5 84 5 82 4 80 3 8 119 4 116 5 113 5 5 8 11 UNC 5 116 6 113 7 110 8 8 164 8 160 7 156 6 3 4 10 UNC 5 206 8 201 7 196 5 8 292 3 284 9 277 6 7 8 9 UNC 5 333 8 325 4 317 1 8 471 6 459 8 448 0 1 8 UNC 5 500 3 487 8 475 3 8 707 0 689 3 671 6 SAE Grade 1 and Grade ...

Page 28: ...5 7 5 7 3 7 1 8 10 6 10 4 10 1 5 16 24 UNF 5 15 0 14 6 14 2 8 21 1 20 6 20 1 3 8 24 UNF 5 27 2 26 5 25 8 8 38 4 37 5 36 5 7 16 20 UNF 5 42 9 41 8 40 7 8 60 6 59 1 57 6 1 2 20 UNF 5 66 0 64 4 62 7 8 93 3 90 9 88 6 9 16 18 UNF 5 94 3 91 9 89 6 8 133 2 129 9 126 6 5 8 18 UNF 5 132 1 128 8 125 5 8 186 7 182 0 177 3 3 4 16 UNF 5 231 0 225 2 219 4 8 326 4 318 2 310 1 7 8 14 UNF 5 367 7 358 5 349 3 8 519...

Page 29: ... 8 8 8 3 8 1 7 9 10 9 12 2 11 9 11 6 12 9 14 3 13 9 13 6 M8x1 25 8 8 20 2 19 7 19 2 10 9 29 6 28 9 28 2 12 9 34 7 33 8 33 0 M10x1 5 8 8 40 0 39 0 38 0 10 9 58 7 57 2 55 8 12 9 68 7 67 0 65 3 M12x1 75 8 8 69 7 68 0 66 2 10 9 102 4 99 8 97 2 12 9 119 8 116 8 113 8 M14x2 8 8 111 4 108 6 105 8 10 9 163 6 159 5 155 4 12 9 191 5 186 7 181 9 M16x2 8 8 172 8 168 5 164 1 10 9 253 8 247 4 241 1 12 9 296 9 2...

Page 30: ...5 3 10 9 2976 4 2902 0 2827 6 12 9 3483 0 3395 9 3308 9 Nominal Size Threads per Inch and Series Designation Property Class Torque N m Maximum Nominal Minimum M8x1 0 8 8 21 6 21 1 20 5 10 9 31 7 30 9 30 1 12 9 37 1 36 2 35 3 M10x 75 8 8 46 8 45 6 44 4 10 9 68 7 67 0 65 3 12 9 80 4 78 4 76 4 M10x1 25 8 8 42 2 41 1 40 1 10 9 62 0 60 4 58 9 12 9 72 5 70 7 68 9 M12x1 0 8 8 79 5 77 5 75 5 10 9 116 7 11...

Page 31: ...2x1 5 8 8 520 8 507 8 494 8 10 9 741 7 723 2 704 7 12 9 868 0 846 3 824 6 M24x2 8 8 655 8 639 4 623 0 10 9 934 0 910 6 887 3 12 9 1092 9 1065 6 1038 3 M27x2 8 8 951 4 927 6 903 8 10 9 1355 0 1321 1 1287 2 12 9 1585 6 1546 0 1506 3 M30x1 5 8 8 1369 2 1334 9 1300 7 10 9 1950 0 1901 3 1852 5 12 9 2281 9 2224 9 2167 8 M30x2 8 8 1324 6 1291 5 1258 4 10 9 1886 6 1839 4 1792 2 12 9 2207 7 2152 5 2097 3 M...

Page 32: ...ese torque and preload values result in an 80 utilization of the yield strength Stainless steel fasteners tend to gall while being tightened To reduce this risk lubricate the threads and torque at low speeds without interruptions Do not use excessive pressure Impact wrenches are not recommended Table 1 12 Inch Series Bearing Bolts Untreated black finish Size Torque N m M2 5x0 45 0 4 M3x0 5 0 9 M4x...

Page 33: ...256 1206 M27X3 10 9 1591 1530 1469 Size Grade Torque ft lb Maximum Nominal Minimum 1 4 20 5 9 0 8 4 7 7 8 12 5 12 11 5 5 16 18 5 19 18 17 8 26 25 24 3 8 16 5 32 31 30 8 48 46 44 7 16 14 5 52 50 48 8 73 70 67 1 2 13 5 78 75 72 8 120 115 110 9 16 12 5 114 110 106 8 161 152 143 5 8 11 5 156 150 144 8 234 225 216 3 4 10 5 270 259 5 249 8 385 370 355 7 8 9 5 416 400 384 8 615 591 567 1 8 5 606 583 560 ...

Page 34: ...5 34 8 53 51 49 7 16 20 5 57 55 53 8 85 82 79 1 2 20 5 88 84 5 81 8 125 120 115 9 16 18 5 126 121 116 8 177 170 163 5 8 18 5 182 174 5 167 8 250 240 230 3 4 16 5 312 299 5 287 8 425 409 393 7 8 14 5 458 439 5 421 8 672 646 620 1 12 5 658 632 606 8 1009 970 931 1 14 5 670 644 5 619 8 945 908 5 872 1 1 8 12 5 882 848 814 8 1500 1440 1380 1 1 4 12 5 1251 1203 1155 8 2092 2008 5 1925 1 3 8 12 5 1704 1...

Page 35: ... 10 9 16 15 14 12 9 19 18 17 M8x1 25 8 8 27 26 25 10 9 38 36 5 35 12 9 45 43 5 42 M10x1 5 8 8 53 51 49 10 9 75 72 69 12 9 89 86 83 M12x1 75 8 8 93 89 85 10 9 130 125 120 12 9 156 150 144 M14x2 8 8 148 142 136 10 9 212 203 5 195 12 9 248 238 228 M16x2 8 8 230 221 212 10 9 322 310 298 12 9 387 372 357 M18x2 5 8 8 319 306 5 294 10 9 455 436 5 418 12 9 532 511 490 M20x2 5 8 8 447 430 413 10 9 629 605 ...

Page 36: ...ze Property Class Torque N m Maximum Nominal Minimum M8x1 8 8 29 28 27 10 9 41 39 5 38 12 9 49 47 45 M10x0 75 8 8 57 55 53 10 9 81 78 75 12 9 96 93 90 M10x1 25 8 8 57 55 53 10 9 81 78 75 12 9 96 93 90 M12x1 8 8 101 97 5 94 10 9 150 144 138 12 9 175 168 161 M12X1 25 8 8 100 96 92 10 9 147 141 5 136 12 9 172 165 5 159 M12x1 5 8 8 100 96 92 10 9 140 135 130 12 9 168 162 156 M14x1 5 8 8 160 153 5 147 ...

Page 37: ...653 627 12 9 816 785 754 M22x1 5 8 8 657 632 607 10 9 924 888 5 853 12 9 1111 1068 1025 M24x2 8 8 836 803 5 771 10 9 1176 1130 5 1085 12 9 1410 1356 1302 M27x2 8 8 1225 1171 5 1130 10 9 1718 1652 5 1587 12 9 2063 1983 5 1904 M30x1 5 8 8 1530 1471 5 1413 10 9 2253 2166 5 2080 12 9 2637 2536 2435 M30x2 8 8 1661 1597 5 1534 10 9 2336 2246 5 2157 12 9 2800 2695 2590 M33x2 8 8 2141 2059 1977 10 9 3155 ...

Page 38: ...ricant applied as part of a maintenance program shall be compatible with the original lubricant and to this end the rope manufacturer should be consulted Lubricant applied shall be of the type which does not hinder visual inspection Those sections of rope which are located over sheaves or otherwise hidden during inspection and maintenance procedures require special attention when lubricating rope ...

Page 39: ...ope should be inspected frequently daily and periodically yearly in accordance with the following information excerpted from a National Consensus Standard as referenced by Federal Government Agencies Recommended inspection intervals may vary from machine to machine and may vary based on environmental conditions frequency of lifts and exposure to shock loads The inspection time intervals may also b...

Page 40: ...es This inspection shall cover the entire length of the extension and retraction cables This inspection should be used to monitor progressive degradation and to discover severe damages necessitating wire rope replacement or equipment repair Inspection criteria are as follows Inspect for reduction of rope diameter below nominal diameter Inspect for severely corroded or broken wires at end connectio...

Page 41: ...to seize the ends of rotation resistant wire ropes to prevent the displacement and unraveling of the individual wires and strands at the ends All preformed and non preformed styles of wire rope should be seized prior to cutting Seizings must be placed on both sides of the point where the wire rope is to be cut The two preferred methods for seizing wire ropes are Method 1 Using a length of soft ann...

Page 42: ... ground Allow to stand for several minutes Then cycle the load between the full up and down positions several times Observe the drum winding and rope travel for any potential problems After making the lifts with a light load increase the load and cycle it up and down a few times This procedure will train the rope and help assure smooth operation during its useful life Ideally you should run these ...

Page 43: ...nifold Valve 2 39 Swing Directional Control Valve 2 43 Dual Accumulator Charger Manifold Valve 2 45 Check Valve Assembly 2 47 Telescope Cylinder Control Valve 2 48 Lift Cylinder Manifold 2 50 Hydraulic Boom Extension Valve Optional 2 51 Removal 2 51 Installation 2 51 Functional Test 2 51 Pressure Setting Procedures 2 52 Accessing the Diagnostic Connector 2 54 Connecting the Manitowoc Crane Service...

Page 44: ...directional Pump Disconnect Disconnects pump from power source Continuous Line Supply or return lines Connecting Lines Branch lines connected to main line Dashed Line Pilot pressure Dotted Line Case drain or load sense Chain Line Enclosure of two or more functions contained in one unit Pressure Transducer Hydraulic electrical located in lift cylinder circuit for cranes RCL circuit 1 2 1 2 2 1 1 2 ...

Page 45: ... to tank with an unloader valve cartridge Closed Center Motor Spool Pressure compensated directional control valve for motor with open port for flow back to tank Allows flow back to tank when the crane is shut down Single Acting Cylinder Extended hydraulically and retracted with a spring Double Acting Cylinder Extended and retracted hydraulically Double Acting Telescope Cylinder Anchored rod pushe...

Page 46: ... bolts at the rigid end the adjustable end and the mounting brackets After tubes are mounted install the hoses Connect both ends of the hose with all bolts finger tight Position the hose so it does not rub the machine or another hose and has a minimum of bending and twisting Tighten bolts in both couplings Due to manufacturing methods there is a natural curvature to a hydraulic hose The hose shoul...

Page 47: ... centered and forward Replenish the reservoir hydraulic oil level as necessary When hydraulic oils are changed recheck the reservoir hydraulic oil level after brief system operation and add hydraulic oil as required Working reservoir capacity Capacity to full mark is 838 6 L 221 53 gal Ensure the crane is level and in the travel mode of operation when the hydraulic system is being filled The syste...

Page 48: ...als are susceptible since they are subject to wear Seals may be damaged by temperatures that are too high or by dirt or paint accumulation on the spool Damaged or torn seals must be replaced A component functioning at reduced efficiency may indicate that the control valve for that component is leaking internally If preliminary check out reveals that adequate volume is being supplied to the affecte...

Page 49: ...aulic hose assemblies are recommended to be replaced after 8000 hours of service life Working conditions ambient temperatures and high duty circuits can affect service life of hose assemblies and must be taken into account when inspecting and replacing hoses High duty circuits can include but are not limited to outriggers hoist s boom lift swing pump suction and discharge to directional valves and...

Page 50: ...emperature switch and thermistor are installed in the lower rear of the hydraulic reservoir The temperature switch 190 F rising 7 Figure 2 1 turns the hydraulic oil cooler fan on and off as needed see Hydraulic Oil Cooler page 2 12 The thermistor 200 F rising 6 Figure 2 1 will cause a warning light in the cab to illuminate if the hydraulic oil temperature is too high The thermistor will also turn ...

Page 51: ...d 10 01 2020 Control 699 00 FIGURE 2 1 10091 1 Return Hose 2 Return Filter 3 Cover 4 Fill Cap Breather 5 Hydraulic Tank 6 Thermistor 200 F High Oil Temp Indicator Light 7 Temperature Switch 190 F Oil Cooler Fan On Off 8 Oil Level Gauge 10092 2 3 4 6 7 8 5 3 5 1 ...

Page 52: ...spect the bypass valve attached to the cap for any damage Replace if necessary 5 Remove and discard the O ring between the cap and the return filter head 6 Remove the element from the return filter head Element Installation 1 Replace the filter with one having the same part number as the one removed Lube the O rings on both ends of the element and insert the element into the return filter head 2 I...

Page 53: ...ANUAL HYDRAULIC SYSTEM 2 Published 10 01 2020 Control 699 00 1 Gasket 2 By pass Assembly 3 O ring 4 Plug 5 Cap Assembly 6 Cap 7 O ring 8 Filter Head 9 Gauge Assembly 10 Spring 11 Element FIGURE 2 2 2 1 3 5 6 4 8 7 9 11 10 8804 75 ...

Page 54: ...be disassembled and treated with a liquid cleaner then cleaned of debris using compressed air Take care when using compressed air a high pressure washer or a steam cleaner as the fins of the cooler may be damaged To ensure effective cleaning the direction of air water or steam must be opposite to the direction of normal airflow through the cooler On cranes that operate in corrosive environments sa...

Page 55: ...ard Hydraulic Oil Fan Assembly 1 Fan Assembly Two places 2 Fan Electrical Connector Two places 3 Core Assembly 4 Fan Shroud Assembly 5 Nut 6 Washer 7 Lockwasher 8 Capscrew 2 5 6 7 8 9 15 14 14 15 13 11 10 12 9 Superstructure Frame 10 Capscrew 11 Lockwasher x2 12 Washer 13 Nut 14 Capscrew 15 Washer 5 6 7 8 10097 10094 ...

Page 56: ...e pump 5 Clean the gasket material from the drive pad of the torque converter and from the pump 6 Cover the drive pad s opening to prevent dirt from entering Pump No 1 Installation 1 Clean the pump and the torque converter drive pad with Loctite cleaning solvent 7070 or similar non chlorinated solvent 2 Apply gasket material Loctite Master Gasket 518 to pump and drive pad mounting surfaces This ma...

Page 57: ...ts attaching the pump to the drive pad on the torque converter Remove the pump 5 Clean the gasket material from the drive pad of the drive through charge pump and from the pump FIGURE 2 4 Item Description 1 Hydraulic Pump No 1 2 Hydraulic Pump No 2 3 Hydraulic Pump No 3 4 Hydraulic Pump No 4 5 Engine 1 4 2 3 Note hoses and drive shaft not shown for clarity 5 10095 10096 CAUTION Absolute cleanlines...

Page 58: ...d mounting surfaces This material partially cures in 4 hours and fully cures in 48 hours 3 Apply Loctite 243 to the threads of the capscrews Install pump and gasket on drive pad with capscrews and washers Make sure the splines mesh properly 4 Torque capscrews to recommended torque 5 Connect the distribution and supply lines to the pump as tagged during removal On lines that use them discard any ol...

Page 59: ...unning to the hydraulic reservoir 4 Start the engine and idle it for two or three minutes without running any hydraulic functions Check for leaks as needed stop the engine and make repairs 5 Place your hand on the pump to check for excessive heat buildup caused by binding or other problems If the pump is too hot to keep a hand on stop the engine 6 Listen for abnormal noises indicating low hydrauli...

Page 60: ... Pump The torque converter drives the No 2 variable displacement piston pump which supplies oil to the following manifolds and valves Steer brake pilot supply valve on the superstructure which includes valves for controlling the front steering disc brakes and swing brake Main directional control valve on the superstructure which includes valves for controlling the auxiliary hoist main hoist boom t...

Page 61: ... up system As needed troubleshoot cooler circuit If too high troubleshoot cooler circuit Likely suspects are in line check valve and related hydraulic circuits c Faulty pump c Repair or replace pump 3 Pump noise accompanied by hydraulic oil foaming in reservoir a Low hydraulic oil level a Check system for leaks Make repairs as needed Fill reservoir b Excessive engine speed b Regulate engine speed ...

Page 62: ...a visual inspection Look for a restriction in the linkages low level of hydraulic oil bent tubes collapsed or ballooned hoses leakage around the hydraulic components etc Second make an analysis of symptoms The function of each component in the system must be known before a correct analysis can be made Remember 1 If a problem is common to all circuits the component which is causing the problem must...

Page 63: ...g Brake Suspension Fill Inside turret on carrier Outrigger Control Manifolds Outrigger Front and rear outrigger boxes Differential Lock Valve Axle differential lock Front side rear center frame cross member on carrier Suspension Valve Suspension Center of carrier frame near the turntable bearing Fan Control Valve Radiator Fans Superstructure Main Directional Control Manifold Valves Hoist Lift Tele...

Page 64: ...s describe the hydraulic manifold valves on the GRT9165 carrier 10098 2 1 4 3 FIGURE 2 6 Valve Installation Carrier Page 1 Outrigger Control Manifold Valve 2 places 2 23 2 Carrier Manifold Valve 2 25 3 Suspension Manifold Valve 2 28 4 Fan Control Manifold Valve 2 29 5 Differential Lock Manifold Valve 2 30 6 Bleed Off Valve 2 31 6 5 ...

Page 65: ...rity of the electrical connections Inspect the wiring for any evidence of cracks or breaks Installation 1 Position the manifold on the outrigger box and secure with the washers hex nuts and capscrews Torque capscrews refer to Fasteners and Torque Values page 1 16 for proper torque value 2 Connect the electrical connectors to the solenoids as marked during removal 3 Connect the hydraulic lines to t...

Page 66: ...ULIC SYSTEM GRT9165 SERVICE MANUAL 2 24 Published 10 01 2020 Control 699 00 Rear Outrigger Control Manifold Cont 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 Front Outrigger Control Manifold Cont FIGURE 2 7 continued ...

Page 67: ...an circuit consists of a proportional flow control valve in sequence with a solenoid operated proportional flow control valve which is controlled by the crane control system based on inputs from the transmission oil temperature sending unit and the hydraulic oil sending unit Return oil from the motor goes to tank Park Brake The park brake solenoid valve controls the flow of hydraulic oil to the pa...

Page 68: ... MANUAL 2 26 Published 10 01 2020 Control 699 00 14 15 2 4 1 5 7 18 6 16 17 22 20 23 Carrier Manifold Valve 3 26 FIGURE 2 8 10100 9 13 21 25 10 12 11 24 33 27 28 29 19 34 8 30 31 32 Carrier Manifold Valve Bottom Forward Forward 10099 ...

Page 69: ... 14 Solenoid Valve Rear Steer 15 Flow Control 16 Solenoid Valve Load Sense Dump 17 Pressure Reducing Valve 18 Solenoid Transmission Fan Coil 19 Gauge Port G4 20 Load Sense Port LS 21 Gauge Port G1 22 Gauge Port G3 23 SUS Port Suspension 24 RB Port Rear Steer 25 FA Port Single Axle Reversal 26 Load Sense Port LS1 27 FB Port Single Axle Reversal 28 SA Port to Swivel Port 7 29 OA Port Outrigger Retra...

Page 70: ... securing valve to the frame Remove valve Installation 1 Secure valve to frame with nuts flatwashers lockwashers and capscrews Torque capscrews refer to Fasteners and Torque Values page 1 16 for proper torque value 2 Connect hydraulic hoses to ports on valve as tagged during removal 3 Connect electrical connectors to valve as tagged during removal Functional Tests 1 Start and idle engine 2 With un...

Page 71: ...ers flatwashers and nuts securing valve to the frame Remove valve Installation 1 Secure valve to frame with nuts flatwashers lockwashers and capscrews Torque capscrews refer to Fasteners and Torque Values page 1 16 for proper torque value 2 Connect hydraulic hoses to ports on valve as tagged during removal 3 Connect electrical connectors to valve as tagged during removal Functional Tests 1 Start a...

Page 72: ...s retract the axles are unlocked Removal 1 Tag and disconnect electrical connectors to the valve 2 Tag and disconnect hydraulic hoses from the valve Cap or plug lines and ports 3 Remove capscrews lockwashers flatwashers and nuts securing valve to the frame Remove valve Installation 1 Secure valve to frame with nuts flatwashers lockwashers and capscrews Torque capscrews refer to Fasteners and Torqu...

Page 73: ...ounted at the highest point within the hydraulic system The trapped air can be relieved while the system is running at low pressure To bleed loosen the bleed screw 1 2 turn counterclockwise After the hydraulic fluid begins to run freely from the bleed screw the bleed screw should be re tightened Removal 1 Tag and disconnect hydraulic lines from valve Cap or plug all openings 2 Remove the capscrews...

Page 74: ... following sections describe the hydraulic manifold valves located in the superstructure FIGURE 2 13 Valve Installation Superstructure 1 Main Directional Control Manifold Valve 2 Compact Manifold Valve 3 Accessory Manifold Valve 4 Swing Manifold Valve 5 Dual Accumulator Charge Manifold Valve 6 Check Valve 2 1 4 3 5 10097 6 ...

Page 75: ...ines from the valve Cap or plug the lines and ports 2 Tag and disconnect electrical connectors from the valve 3 Remove the capscrews flatwashers and lockwashers securing the valve Remove the valve Main Directional Control Manifold Valve Installation 1 Install the valve on the turntable upright and secure with the capscrews flatwashers and lockwashers Torque capscrews Refer to Fasteners and Torque ...

Page 76: ...ort 4A Lift Cylinder Up 8 Port 4B Lift Cylinder Down 9 Solenoid Valve Telescope 10 Solenoid Valve Telescope 11 Solenoid Valve Auxiliary Hoist 12 Solenoid Valve Auxiliary Hoist 13 Solenoid Valve Main Hoist 14 Solenoid Valve Main Hoist 15 Solenoid Valve Lift Cylinder 16 Solenoid Valve Lift Cylinder 17 Telescope Extend Relief Valve 18 Telescope Retract Relief Valve 19 Gauge Port Inlet Diagnostic 20 L...

Page 77: ...GRT9165 SERVICE MANUAL HYDRAULIC SYSTEM 2 Published 10 01 2020 Control 699 00 Main Directional Control Manifold Valve Cont FIGURE 2 14 continued 10110 2 1 10 18 22 23 24 19 26 17 4 3 6 5 8 7 9 12 11 14 13 16 15 21 ...

Page 78: ...ctions The valve is located on the left side of the superstructure 2 Figure 2 13 The valve bank is removed and installed as an assembly Removal 1 Tag and disconnect the hydraulic lines from the valve Cap or plug the lines and ports 2 Remove the capscrews and washers securing the valve Remove the valve bank Installation 1 Install the valve and secure with the capscrews and washers Torque capscrews ...

Page 79: ... Control 9 Solenoid Valve Tele Fill Drain 10 Solenoid Valve Counterweight Pin Extend 11 Solenoid Valve Right Counterweight Raise 12 Solenoid Valve Left Counterweight Raise 13 Solenoid Valve Cab Tilt Raise 14 Pressure Port P2 for Hydraulic Boom Extension 15 Pressure Port P1 16 Gauge Port Load Sense GPLS 17 Tank Port T1 18 Cab Tilt Raise C1 19 Tank Port T2 for Hydraulic Boom Extension 20 Cab Tilt Lo...

Page 80: ...YDRAULIC SYSTEM GRT9165 SERVICE MANUAL 2 38 Published 10 01 2020 Control 699 00 FIGURE 2 15 continued 10114 Compact Manifold Valve 21 9 5 4 3 2 1 13 20 18 27 25 26 23 24 22 11 10 13 14 8 16 17 15 6 7 19 ...

Page 81: ...16 for proper torque value 2 Connect the hydraulic lines to the manifold as tagged during removal 3 Connect the electrical connectors to the manifold as tagged during removal Function Check Priority Steer 1 Start the engine 2 Drive the crane at a slow speed and verify the front steering function works properly Function Check Swing Brake Release Valve 1 Start the engine 2 Enable all crane functions...

Page 82: ...YDRAULIC SYSTEM GRT9165 SERVICE MANUAL 2 40 Published 10 01 2020 Control 699 00 FIGURE 2 16 Accessory Manifold Valve 10115 1 9 10 11 7 5 6 3 4 16 17 18 20 21 33 10116 12 25 2 35 19 31 30 28 27 29 10119 8 ...

Page 83: ...heck Valve 12 Gauge Port GP6 13 Priority Valve Steering 14 Load Sense Port 3 15 Load Sense Port LS 16 Check Valve 17 Load Sense 5 18 Drain Port Inlet 2 19 Check Valve 20 Pilot Supply Port PS1 21 Outlet Port CB 22 Gauge Port GP7 23 Inlet Port P 24 Pressure Relief Valve 3000 psi 25 Work Port SW2 26 Gauge Port GP5 27 Work Port Swing Brake Apply SB 28 Gauge Port GP3 29 Work Port Swing Brake Release SB...

Page 84: ...M GRT9165 SERVICE MANUAL 2 42 Published 10 01 2020 Control 699 00 10 11 7 3 4 8 13 19 2 9 20 21 12 26 27 29 30 31 35 28 36 17 22 1 5 6 14 18 15 23 25 24 33 10120 FIGURE 2 16 continued Accessory Manifold Valve 16 34 32 ...

Page 85: ...operated proportional control valve to send full flow from the No 3 gear pump to the swing circuit Swing Directional Control Valve Removal 1 Tag and disconnect the hydraulic lines from the valves Cap or plug the lines and ports 2 Tag and disconnect electrical connectors from the valve 3 Remove the capscrews flatwashers and lockwashers securing the valve Remove the valve Swing Directional Control V...

Page 86: ...enoid Valve Left Swing 6 Solenoid Valve Right Swing 7 Pressure Transducer 8 Gauge Port GP4 9 Orifice 0 020 in 10 Drain Port D3 11 Gauge Port GP2 12 Drain Port D2 13 Work Port MB Left Swing 14 Pressure Compensating Valve 15 Gauge Port GP3 16 Work Port MA Right Swing 17 Shuttle Valve 18 Drain Port D5 19 Drain Port D1 20 Drain Port D6 21 Gauge Port GP1 22 Drain Port D7 23 Drain Port D4 24 Accumulator...

Page 87: ... valve to the turntable Remove the valve Installation 1 Position the valve on the superstructure with ports A1 A2 and B3 facing up and secure with three bolts washers and lockwashers Torque bolts 2 Connect the hydraulic hoses to the valve ports as tagged during removal 3 Start the engine and check for leaks Make repairs as needed 4 Depress the brake pedal several times to cause the brake valve to ...

Page 88: ...ed 10 01 2020 Control 699 00 FIGURE 2 18 7752 01 7752 02 7752 03 Dual Accumulator Charge Valve 1 Load Sense Port LS 2 Tank Port T 3 Pressure Port P 4 Accumulator Port A1 5 Accumulator Port A2 6 Pressure Switch These ports plugged 2 1 5 3 4 6 2 1 5 3 4 6 ...

Page 89: ...Installation 1 Install the valve on the turntable upright and secure with the capscrews flatwashers and lockwashers Torque capscrews Refer to Fasteners and Torque Values page 1 16 for proper torque value 2 Connect the hydraulic lines to the valves as tagged during removal 3 Secure the valve using capscrews and nuts Check Valve Assembly 1 Check Valve 30 PSI 2 Work Port A2 to Compact Valve T1 3 Chec...

Page 90: ... 2 20 is a cartridge style holding valve located on the rear of the boom telescope cylinder FIGURE 2 20 3 1 2 5 4 Telescope Cylinder Valve 1 Work Port K2 Extend 6000 PSI 2 Lock Valve V2 3 Work Port R1 Retract 6000 PSI 4 Lock Valve V1 5 Work Port K1 Extend 6000 PSI 6 Work Port Tele Fill A From Compact Manifold 6 3 1 3 5 4 2 6 10129 10128 10130 10127 ...

Page 91: ... or telescope cylinder as applicable Verify lift cylinder and or telescope cylinder works without problems verify there is no leaking Make repairs as needed WARNING Falling Boom Never remove a telescope cylinder valve from the lift or telescope cylinder circuits without first fully retracting the cylinders Death or serious injury can occur WARNING High Hydraulic Pressure Never remove a telescope c...

Page 92: ...e lift cylinder 2 Raise the hydraulic boom extension to 0 offset 3 Shut off engine 4 Tag and remove hydraulic hoses from the hydraulic boom extension manifold valve 5 Tag and disconnect electrical connections Installation 1 Connect hydraulic hoses as tagged 2 Connect electrical connectors as tagged 3 Re calibrate the transducers Functional Test 1 Start the engine and run it at normal speed 2 Raise...

Page 93: ...ifold valve 5 Tag and disconnect electrical connects 6 Remove capscrews lockwashers washers and hydraulic boom extension manifold from bracket Installation 1 Install hydraulic boom extension manifold valve on bracket with capscrews washers lockwashers and nuts 2 Connect hydraulic hoses as tagged 3 Connect electrical connectors as tagged Functional Test 1 Start the engine and run it at normal speed...

Page 94: ...ecking Setting the Piston Pumps Cut off and Differential Pressures page 2 54 Pump No 2 differential pressure 500 34 5 25 2 Checking Setting the Piston Pumps Cut off and Differential Pressures page 2 54 Pilot supply pressure 450 31 50 4 Checking Setting the Pilot Supply Pressure page 2 56 Load Sense max system pressure 4350 300 50 4 Load Sense Relief Max System Pressure page 2 59 Telescope Retract ...

Page 95: ...Front 1500 to 1550 103 to 107 Rear 1400 to 1450 97 100 See range Checking Setting Outrigger Pressure Rear Steer and Suspension Raise page 2 65 Suspension Fill Pressure 2500 172 50 4 Checking Setting Outrigger Pressure Rear Steer and Suspension Raise page 2 65 Suspension Accumulator Pre Charge 1300 1350 90 93 See Range Service Brake Accumulators Pre charge page 2 62 Outrigger Box Pinning Extend 300...

Page 96: ... more information see Removing the Upper Electrical Cover page 2 54 2 Connect the USB end of the diagnostic cable to the PC 3 Connect cOSI connector to the diagnostic port 1 Figure 2 23 4 Launch the Manitowoc Crane Service Tool Checking Setting the Piston Pumps Cut off and Differential Pressures Use the following procedure to check and set the cut off and differential pressures for both piston pum...

Page 97: ... PD240 or equivalent still installed in the GP port of the main directional control valve 1 Figure 2 26 start the engine b At idle RPM adjust the piston pump 2 4 Figure 2 26 differential setting screw in to increase or out to decrease so that a gauge reading cited in Table 2 3 is achieved It may be necessary to back out the stand by adjustment screw for pump 1 if the pressure cannot be achieved c ...

Page 98: ...hoses If the cylinder is installed omit this step 3 Start engine and idle 4 Gradually increase to raise or lower and hold If the cylinder is fully stroked in either direction the RCL override switch will need to be active to assure that the pilot supply will not be cut off before the cylinder can be fully extended The reading at GP4 should be the value cited in Table 2 3 If it is not adjust the pi...

Page 99: ...L HYDRAULIC SYSTEM 2 Published 10 01 2020 Control 699 00 FIGURE 2 26 10136 Main Directional Control Valve 1 Main Directional Valve GP Diagnostic Port 2 Telescope Extend Relief 3 Telescope Retract Relief 4 Load Sense LS Relief 2 1 3 4 ...

Page 100: ...00 Accessory Manifold 1 GP1 Port 2 Swing Brake Pressure Reducing Valve 3 Pilot Supply Pressure Reducing Valve 4 Accessory Pressure Reducing Valve 5 GP6 Port 6 Port 4 Load Sense 7 Steer Priority Relief Valve 8 GP4 Port 9 GP5 Port 10 GP3 Port FIGURE 2 27 2 1 6 4 10139 3 9 7 10 8 5 ...

Page 101: ...t to decrease until the reading is achieved 5 If the pressure cannot be achieved ensure each piston pump s cut off max setting is correct with the following procedure a Loosen both pump s jam nuts on the cut off pressure adjusting screws Figure 2 25 b Turn both pumps in one quarter turn at a time one pump a quarter turn then the other pump a quarter turn repeat etc until the specified LS pressure ...

Page 102: ...ngine to full RPM The reading at port 4 should be the value cited in Table 2 3 If it is not adjust the Tele retract relief 2 Figure 2 26 in to increase or out to decrease until the reading is achieved 2 Make sure that the cylinder is fully retracted length reads 0 mm 3 Return the boom pinning to its normal state 4 Navigate to the Lower display menu screen and select the Boom lost icon 2 Figure 2 2...

Page 103: ... 3 adjust the maximum software current output Imax value in the joystick EEPROMs can be adjusted Raise the Imax to raise the pressure or reducing the Imax to decrease pressure to adjust the lmax value in the joystick EEPROM If adjusting the Imax does not work contact Manitowoc Crane Care 3 Repeat step 2 for swing left function 4 Stop engine Remove the diagnostic coupler Checking Setting the Front ...

Page 104: ... verify the low charging limit is the value cited in Table 2 3 when it starts to recharge 5 Stop the engine Remove the pressure gauge Service Brake Accumulators Pre charge Use the following procedure to pre charge the service brake accumulators 1 With the engine off depress the service brake pedal four to six times to discharge all of the pressurized oil stored in the accumulators Remove the gas v...

Page 105: ...ry manifold 6 Figure 2 27 Cab Tilt Lower 2 Start engine and idle Activate the cab lower function until full stroke of the cylinder is achieved and hold Slowly accelerate the engine to full RPM The reading at port 4 should read the value cited in Table 2 3 If it is not in the value range use the service tool to adjust a Remove the upper electrical panel to access the diagnostic connector b Connect ...

Page 106: ...sure is achieved If the value needs adjusted by more than 100 mA there may other issues in the circuit b After the pressure is achieved make sure to Save active to customer and Save active to factory 2 Stop the engine Counterweight Pin 1 Start engine and idle Active the counterweight pin function until full stroke of the cylinder is achieved and hold Slowly accelerate the engine to full RPM The re...

Page 107: ...PWM Control carrier Pressure Sol Outrigger Beams Extend Target In the params row increase the value to increase the pressure or decrease the value to decrease the pressure adjustment by 10 mA increments is suggested Make sure to write the column to active settings Repeat this step until the pressure is achieved If the value needs adjusted by more than 100 mA contact your Grove Crane distributor or...

Page 108: ...ur Grove Crane distributor or Manitowoc Crane Care c After the pressure is achieved make sure to Save active to customer and Save active to factory Rear Steer Pressure 1 Start engine and idle Slowly accelerate the engine to full RPM operate rear steer switch until reaching an axle stop and hold The reading at LS should port 1 Figure 2 33 should read the value cited in Table 2 3 If it is not use th...

Page 109: ... coil in on the suspension valve manifold Checking Setting Park Brake Pressure and Transmission Fan Max Pressure 1 With the engine off install a pressure check diagnostic coupler such as a Parker PD240 with gauge onto the diagnostic nipple at the PS port of the main carrier valve Figure 2 34 2 Unplug transmission fan coil from harness Figure 2 34 3 Start engine and idle Release pressurize the park...

Page 110: ...draulic oil expands when heated and contracts when cooled This is a natural phenomena that happens to all liquids The coefficient of expansion for API Group 1 hydraulic oil is approximately 0 00043 cubic inches per cubic inch of volume for 1 F of temperature change Thermal contraction will allow a cylinder to retract as the hydraulic fluid which is trapped in the cylinder cools The change in lengt...

Page 111: ... 6 45 7 74 9 03 10 32 11 61 12 90 30 1 55 3 10 4 64 6 19 7 74 9 29 10 84 12 38 13 93 15 48 35 1 81 3 61 5 42 7 22 9 03 10 84 12 64 14 45 16 25 18 06 40 2 06 4 13 6 19 8 26 10 32 12 38 14 45 16 51 18 58 20 64 45 2 32 4 64 6 97 9 29 11 61 13 93 16 25 18 58 20 90 23 22 50 2 58 5 16 7 74 10 32 12 90 15 48 18 06 20 64 23 22 25 80 55 2 84 5 68 8 51 11 35 14 19 17 03 19 87 22 70 25 54 28 38 60 3 10 6 19 ...

Page 112: ...HYDRAULIC SYSTEM GRT9165 SERVICE MANUAL 2 70 Published 10 01 2020 Control 699 00 THIS PAGE BLANK ...

Page 113: ...rating ODM Sensors 3 20 Diagnostics 3 20 Viewing Diagnostic Fault Codes 3 20 About the Manitowoc Diagnostic Code Mobile Application 3 20 Optional Equipment 3 22 Beacon Light 3 22 Boom Mounted Floodlights 3 22 Rear View Mirror 3 22 Air Conditioner 3 22 Cold Weather Operation 3 22 Wind Speed Indicator and Boom Position Indicator Light 3 23 Cameras 3 23 RCL Light Tower 3 25 DESCRIPTION General The el...

Page 114: ...mpt to charge them Remove the battery s from the crane allow them to thaw and then charge the battery s to full capacity Slow charging is preferred to fast charging Fast charging saves time but risks overheating the battery s Slow charging at six 6 amps or less develops less heat inside the battery and breaks up the sulfate on the battery plates more efficiently to bring the battery up to full cha...

Page 115: ...Swivel Connector 8 Superstructure A 9 Superstructure B 10 Cold Weather Module 11 Crane Star Module 12 Camera Option 13 Options 14 Wireless Remote 15 Remote Charger 16 Converter 17 D1 Connector 18 D2 Connector 19 Cab Fuse Panel 20 Electronic Control Unit MWIOL 21 Electronic Control Unit MWSCM 22 CAN A 23 CAN B 24 CAN C 25 CAN D 26 CAN E 27 Diagnostic Connector 1 2 3 4 5 6 7 8 9 10 11 12 16 13 14 15...

Page 116: ...Wiper F24 10 Windshield Wiper Power F25 5 Sky Light Washer Relay Fuse Power F26 15 UB T T CCM10 F27 15 UB T T CCM10 F28 20 24V Supply 12V DC Converter F29 15 UB IOS20 UE UB IOS21 F30 5 Diagnostic Conn Power F31 10 UB IOL32 F32 20 Actuator 1 2 3 Relay Fuse Power F33 5 Display Jog Dial Relay Fuse Power F34 5 Fused B K1 Windshield Washer Relay K2 Sky Light Wiper Relay K3 Sky Light Wiper Low K4 Windsh...

Page 117: ...s of the two batteries battery disconnect switch fuse and relay boxes starter and grid heater relays and electronic control units 1 Batteries 12V 2 Battery Disconnect Switch 3 Fuse and Relay Box 2 see Figure 3 8 4 Electronic Control Unit CCM and IOL 5 Electronic Control Unit MWCCM 6 J1939 Diagnostic Connector 7 Fuse and Relay Box 1 see Figure 3 7 8 Fuse Panel see Figure 3 6 FIGURE 3 5 1 4 5 3 6 Ca...

Page 118: ...1 125 Amp Intake Air Heater Relay Power 6 F51 125 Amp Alternator Power 7 Grid Heater Relay 8 Starter Relay 9 10 14 13 11 15 16 9 FA 15 Amp Module Battery Power 10 FB 15 Amp UB Carrier CCM11 IOL31 Module Battery Power 11 FC 5 Amp Starter Lockout Fused Relay Power 12 FD 15 Amp Cold Weather Power 13 FE 15 Amp Cold Weather Power 14 FF 5 Amp Diagnostic Tool Power 15 Connector Relay Panel 16 Connector R...

Page 119: ...FIGURE 3 7 2 1 3 4 5 6 Carrier Fuse and Relay Box 1 1 K108 24V Starter Lockout Relay 2 20 Amp Fused Battery Power 3 15 Amp UE Carrier CCM3 IOL31 Module Battery Power 4 30 Amp Engine ECM Power 5 15 Amp UB Carrier CCM12 Module Battery Power 6 15 Amp UB Carrier CCM12 Module Battery Power 10153 ...

Page 120: ...eater Relay 2 K110 DEF Supply Module 3 K111 After treatment Sensors Power Relay 4 F1 15 Amp DEF Lines Heater Fused Relay Power 5 F2 5 Amp DEF Lines Heater Fused Relay Coil Power 6 F3 15 Amp DEF Supply Module Fused Relay Power 7 F4 15 Amp After treatment Sensors Fused Relay Power 8 D1 Pressure Line Heater 9 D2 Return Line Heater 10 D3 Suction Line Heater 10154 ...

Page 121: ...ion of the grease If moisture is found clean or replace the connector as necessary 2 Screw a tip or trigger assembly on to the can of dielectric grease if necessary 3 Apply the grease onto socket female contacts 4 Use a clean towel to remove excess grease from the surface of the connector and wipe grease into the terminal sockets Figure 3 9 5 Ensure grease is applied to each terminal socket The to...

Page 122: ...s recommended to replace these assemblies after 8000 hours of service life Cranes operating in climate zones D and E cold climates should expect a degradation of mechanical properties long term exposure to these cold temperatures will negatively impact service life Therefore it is recommended these electrical harnesses and cable assemblies be inspected regularly as service life may be less than 10...

Page 123: ...r corroded connection in pin or socket connectors Check connectors to ensure pins and sockets are properly seated and engaged If pins and sockets show any signs of corrosion use a good quality electrical contact cleaner or fine sandpaper to clean them When pins or sockets show signs of arcing or burning replace them Refer to the following tables listing required tools for connector maintenance Pin...

Page 124: ...ive Side 1 Set multimeter to the 2 volt range 2 Connect positive lead to alternator output terminal and negative lead to battery positive terminal or post Do not connect meter to battery cable 3 Run engine at 2000 rpm 4 Load system with carbon pile load or lights and heater blower Allowable drop is 0 2 to 0 5 volts Higher voltage drop indicates loose corroded or broken connections Description Deut...

Page 125: ... then carefully return t tensioner to its normal position Make sure belt is centered on tensioner 5 Check belt tension at center of longest distance between pulleys Push in on belt with your thumb Belt should deflect no more than 3 8 in 1 2 in 10 mm 13 mm Or using a belt tension gauge verify 60 lb 130 lb 267 N 578 N tension Replace belt if it is too loose overstretched 6 Verify tensioner bolt is t...

Page 126: ...ct switch to OFF position NOTE Only remove as much as needed to access switch being replaced 3 Remove four screws 11 from dashboard cover 1 4 Remove locking lever 15 5 Remove four screws 14 from left side cover 16 6 Remove left side cover 16 from steering column 7 Disconnect wire harness from back of ignition switch 12 8 Remove right side cover 10 from steering column assembly 9 9 Disconnect wire ...

Page 127: ...hown from back of ignition switch 12 7 Remove lock nut not shown from ignition switch and remove switch Inspection 1 Visually check ignition switch for evidence of cracks damaged connectors or other damage Replace switch as needed 2 Check wiring for damaged insulation or damaged connectors Repair as needed 3 Use a multimeter to check for continuity between switch terminals with switch ON Meter sho...

Page 128: ...ecure levers with two screws 6 and locknuts 8 3 Connect wire harnesses to levers 7 4 Install switch cover 6 on steering column 5 Install wire harnesses on switches 21 24 and turn signal indicators 2 as tagged during removal 6 Install right side cover 10 on steering column 9 7 Connect wire harness to ignition switch 12 8 Install left side cover 16 on steering column overlapping right side cover 9 I...

Page 129: ...l Nut 5 Steering Wheel 6 Screw 7 Three Speed Transmission Shift Switch 8 Locknut 9 Column Assembly 10 Right Side Cover 11 M4 Button Head Screw 12 Ignition Key Switch Assembly 13 Spacer 14 M6 Button Head Screw 15 Lock Handle 16 Left Side Cover 17 Steering Column Tilt and Telescope 18 Turn Signal Lights Wiper Switch 19 Knob 20 Switch Blank 21 Hazard On Off Switch 22 2WD 4WD Switch 23 Headlight Switc...

Page 130: ...he pivot shaft s pivot pin mounts in the hole nearest the end of the pivot shaft s lever 2 Connect wiper motor to motor bracket with screws and washers Connect wiper motor shaft to wiper motor kit crank with nut and washer 3 Secure adapter and gasket of the pantograph adapter kit to the cab exterior with capscrews and lockwashers 4 Install motor bracket and attached parts in cab interior with atta...

Page 131: ...ab roof 6 Remove nut and lockwasher securing motor bracket to cab roof and remove motor from cab roof Remove large nylon flat washer from motor shaft and flat washer and smaller nylon flat washer from mounting screw 7 Remove mounting screw and nylon flat washer from outside cab roof 8 Clean any sealing material from around holes in cab roof Inspection 1 Visually check motor housing for evidence of...

Page 132: ...or component being measured is replaced adjusted removed or reinstalled individual sensor only must be calibrated The software has been updated all sensors must be calibrated The ODM display is replaced all sensors must be calibrated Detailed information about the calibration process is available to technicians who have attended the Grove New Technology training course DIAGNOSTICS The following se...

Page 133: ...e device The Diagnostic Code Application splash screen appears 3 Click CCS The CCS screen appears 4 Complete the following using information from the error code displayed on the ODM Select Crane Type Select the crane model from the dropdown list Component Enter the component information from the fault code Condition Enter the condition information from the fault code Device Enter the device number...

Page 134: ...lowing specifications Minimum Evacuation Time 60 minutes Refrigerant Charge Levels 2 5 pounds 0 5 oz Additional Pag Oil Required Above the 6 ounces in Compressor 5 0 ounces Cold Weather Operation Regions with ambient temperatures below 9 C 15 F are considered arctic The following recommendations are for operating Grove cranes in very low temperatures Use particular care to ensure that cranes being...

Page 135: ...tion air supply and exhaust system after longer standstill periods Clean if necessary If heater remains faulty after these points have been checked or another malfunction occurs in your heater contact an authorized Grove distributor or Manitowoc Crane Care Maintenance Instructions Switch heater on once a month for about 10 minutes even outside heating period Before heating period starts heater sho...

Page 136: ...ht rear camera is located on the right side of the superstructure Removing Right Rear Camera 1 Remove the maintenance cover on the right side of the superstructure 2 Disconnect the data cable 3 Remove capscrews 2 washers 3 and camera 1 from bracket Installing Right Rear Camera 1 Install camera 1 on bracket using washers 3 and capscrews 2 2 Connect the data cable 3 Install the maintenance cover on ...

Page 137: ...era 1 from the bracket Installing the Back up Camera 1 Install the camera 1 on the bracket with washers 4 and capscrews 3 2 Connect the data cable 2 RCL Light Tower When installed the RCL light tower is located on the right side of the operator cab Disconnect the data cable and remove the tower from the bracket For more information see Operator Manual FIGURE 3 14 2 3 4 1 Forward 10160 ...

Page 138: ...ELECTRICAL SYSTEM GRT9165 SERVICE MANUAL 3 26 Published 10 01 2020 Control 699 00 THIS PAGE BLANK ...

Page 139: ...brication page 9 1 Additional information can be found in the Operator Manual and Parts Book BOOM REMOVAL NOTE The boom with no boom extension weighs approximately 15662 kg 34528 lbs 1 Extend and set the outriggers to level the crane and ensure the boom is fully retracted locked and in a horizontal position over the front of the crane 2 Remove the counterweight For more information see the Operato...

Page 140: ...en removed and is supported on cribbing 10 Install the front 1 Figure 4 2 and rear 2 boom lift brackets as follows a Remove retaining pin 4 and pin 5 Loosen nut 6 Expand the front boom lift bracket 1 to fit over the boom NOTE Make sure the visual position indicators 3 are pointed forward for the front bracket b Insert bracket mounting feet 7 in the boom at the pin hole Position A in the boom c Ins...

Page 141: ...RE 4 2 4 6 5 3 3 3 2 3 9 7 3 1 8 9 10 10 1 Front Boom Lift Bracket 2 Rear Boom Lift Bracket 3 Visual Position Indicator 4 Retaining Pin 5 Pin 6 Nut 7 Bracket Mounting Foot 8 Bracket Installation Pin Hole 9 Lifting Shackles 10 Lifting Straps Position B Position A 10236 10237 10238 ...

Page 142: ...le jack on the lift cylinder support Raise the bottle jack 4 and wood cribbing up to the lift cylinder The bottle jack and wood cribbing should be in firm contact with the lift cylinder 14 Remove capscrew 1 Figure 4 4 and washer 2 that secures pin 15 Turn the direction lever 3 to the correct position Use the hand pump 4 to remove the lift cylinder pivot pin Tag and identify the locations of shims ...

Page 143: ...he boom pin removal tool 3 in the capscrew holes Thread the rods into the capscrew holes NOTE The hydraulic ports for the pin removal tool have red caps d Connect the hydraulic hoses 4 and 5 19 Start the engine 20 If necessary verify that the hydraulic pin removal tools are operational In the ODM For more information see the Boom Removal Installation Function section in the Operator Manual 21 For ...

Page 144: ...ide pin disconnect the removal tool hydraulic connections 4 and 5 Figure 4 5 and remove the hydraulic tools g For the right side pin secure the pivot pin to the superstructure with busings 2 Figure 4 4 and capscrews 1 Torque the capscrews For more information see Fasteners and Torque Values page 1 16 h For the left cab side pin secure the pivot pin to the superstructure with busings 2 Figure 4 5 a...

Page 145: ...ins 1 Figure 4 8 from the cable retainer pins 2 and 3 and remove the cable retainer pins from the upper and lower part of the boom nose 2 Pull the lever to retract the lower inside cable retainer pin 4 3 Remove the hex head screws 5 securing the cover plate 6 to the upper boom nose sheave 7 Remove the cover plate NOTE The upper boom nose sheave shafts weigh approximately 11 kg 24 lb and 7 kg 15 lb...

Page 146: ...steps 1 and 2 for the upper boom nose sheaves and shaft 4 Install the cable retainer pins 2 3 4 and 5 into the upper and lower part of the boom nose and secure in place with the retaining pins 1 1 5 FIGURE 4 8 4 1 2 1 3 8 6 7 9 9 12 11 10 1 Retaining Pin 2 Cable Retaining Pin 3 Cable Retaining Pin 4 Cable Retaining Pin 5 Cable Retaining Pin 6 Screw 7 Cover Plate Upper Sheave 8 Upper Sheave Shaft 9...

Page 147: ...telescopic section is unable to retract independently Maintenance For manual unlocking two capscrews M8x110 Grade 8 8 are supplied for all pins and sections Figure 4 9 125 mm length for telescopic section 5 140 mm length for telescopic section 4 170 mm length for telescopic section 3 200 mm length for telescopic section 2 270 mm length for telescopic section 1 You can only lock or unlock a telesco...

Page 148: ...MPONENTS Maintenance of the Slip Ring Assembly of the Cable Drum Maintenance of the slip ring assembly is carried out to prevent contamination and corrosion and to prevent malfunctions on the RCL Two cable drums feature slip ring assemblies that require maintenance The cable drum 1 Figure 4 11 on the left side of the main boom The second cable drum 1 Figure 4 12 is located in the main boom underne...

Page 149: ...d replace it if necessary 4 Remove any moisture in the casing with a clean lint free cloth 5 Remove visible dirt on the slip rings 2 Figure 4 14 with a clean lint free cloth WARNING Risk of accidents due to rope end fitting being overloaded After installing a new hoist rope the lowering limit switch must always be reset WARNING Crushing Hazard Secure the boom against unintentional movement so that...

Page 150: ...then start pulling the cable off to route out alongside the boom section BOOM EXTENSION For instructions on installing removing or deployment of the boom extension s refer to the Operator Manual For lubrication information see Maintenance and Lubrication page 9 1 HOOK BLOCK OVERHAUL BALL For information about removing and installing the hook blocks see the Operator Manual For lubrication informati...

Page 151: ...s available for both the main and auxiliary Figure 5 1 The hoist incorporates one single displacement piston motor which drives a reduction unit within the hoist The hoist utilizes planetary reduction with a multi disc automatic brake that is spring applied and hydraulically released The hoist motor controls both speed and torque of the hoist THEORY OF OPERATION Flow from pump number one and two i...

Page 152: ...on indicator sensor electrical wires 10 Remove hoist rotation indicator sensor 5 11 Remove upper shaft 7 12 Remove hoist roller 11 13 Using an adequate lifting device slightly lift hoist assembly NOTE Hoist assembly weighs approximately 412 kg 908 lb 14 Remove bearing support 8 capscrews 15 and 31 Install three long capscrews into the three short capscrew holes Use capscrews as jack screws to pull...

Page 153: ...lines to the motor and brake as tagged during removal 16 Ensure the bearing is full of grease 17 Ensure gear box is filled with oil to the proper level Refer to section titled Hoist Lubrication page 9 44 18 Install cable onto hoist assembly Refer to Installing Cable On Hoist page 5 2 19 Adjust the minimum wrap switch refer to Adjusting 3rd Wrap Switch page 5 9 Functional Check 1 Attach a test weig...

Page 154: ...4 Published 10 01 2020 Control 699 00 HOIST AND COUNTERWEIGHT GRT9165 SERVICE MANUAL FIGURE 5 1 10162 10163 1 1 7 30 6 22 9 8 11 12 10 12 2 20 30 20 20 24 27 28 25 26 17 18 24 20 2 10 12 11 7 3 5 4 10166 ...

Page 155: ...ntrol Valve 10 Shaft 11 Hoist Roller 12 Spring Pin 13 Capscrew M6x16 SS 14 Capscrew M12x45 8 8 15 Capscrew M12x35 10 9 16 Capscrew M20x40 10 9 17 Straight Thread Adapter 18 Lock Pin 19 Flat Washer 20 Flat Washer 21 Narrow Flat Washer 22 O Ring 23 Lockwasher 24 Sight Glass 25 SHCS M6x45 8 8 26 Washer 27 Lockwasher 28 Nut 29 Standoff Fitting 30 Cotter Pin 31 Capscrew M12x12 SS FIGURE5 1 continued 6 ...

Page 156: ...due to accelerated wear from insufficient lubricating oil in the hoist Hoists with a sight glass check oil level daily Hoists without a sight glass check oil level monthly if no external oil leaks are detected Lubricant level must be maintained between the minimum and maximum levels midway up sight glass or at bottom of level plug port as equipped Use ONLY the recommended type of lubricant Refer t...

Page 157: ...nged after the first 100 operating hours then on an annual basis at a minimum thereafter In severe duty applications the gear oil should be changed every six months Use the recommended lubricants Refer to Maintenance and Lubrication page 9 1 Gear Oil Sampling and Analysis Proper gear oil sampling and analysis is a vital part of a comprehensive preventive maintenance program Information obtained fr...

Page 158: ...NTROL VALVE AND BRAKE Description Each hoist has a hydraulic motor a motor control valve a brake cylinder and a brake clutch which controls motion of the hoist s drum These parts mount on or in the gearbox The hydraulic motor connects to the hoist s brake which in turn connects to the gear train of the hoist The entire hoist assembly must be removed from the crane to service the assembly Removal 1...

Page 159: ... symbol on the ODM display to indicate that three wraps of cable remain on the respective hoist The encoder must be properly adjusted for this system to function properly Refer to Adjusting 3rd Wrap Switch page 5 9 Maintenance General Proper circuit operation can be checked for each individual electrical component If a malfunction occurs within the system repairs should be limited to finding and r...

Page 160: ...The hoist directional control valve is used to control the operation of the hoist It is a four way pilot operated valve and is mounted on the right side of the turntable REMOVABLE COUNTERWEIGHT Counterweight is installed and removed using hydraulic cylinders controlled by a counterweight controls in the ODM or remote control Hydraulic cylinders and locking pins hold the counterweight assembly in p...

Page 161: ...or 6 seconds or the Swing Brake Pedal is depressed Swing is activated when the Swing Enable Disable switch on the left armrest is pressed once When enabled the Swing Enable Disable Indicator appears on the ODM Use the swing controller joystick in the cab to rotate the superstructure When the Swing joystick is actuated hydraulic pressure is routed to the Swing Motors to drive the gearboxes in the a...

Page 162: ...lied hydraulic released while the service dynamic brake is pressure applied A two position solenoid valve controls the pressure to release the swing brake A pressure reducing valve maintains a pressure of 260 to 300 psi to the inlet of both the brake releases and brake apply valves The circuit is designed such that when the engine is running and the swing enable switch is activated pressure is sup...

Page 163: ...5 4 5 Parts Removed for Clarity 10169 10168 3 10 11 12 13 14 15 1 Breather Plug 2 Level and Fill Plug and Dipstick 3 Swing Brake 4 Hydraulic Apply Brake Port 5 Hydraulic Release Brake Port 6 Motor 7 Pinion 8 Drain Plug 9 Swing Gearbox 10 Pinion Guard 11 Capscrew 12 Washer 13 Capscrew 14 Washer 15 Bushing 16 O ring 16 ...

Page 164: ...e 1 16 3 Replace plugs and extensions Fill assembly with oil Refer to Maintenance and Lubrication page 9 1 4 Connect hydraulic lines to swing motor as tagged during removal Test 1 Test swing of superstructure in each direction Stop and start swing several times 2 Inspect for hydraulic leaks and repair as necessary SWING GEARBOX AND BRAKE Description The Swing Gearbox and Brake Figure 6 1 used with...

Page 165: ...o the gearbox Installation 1 If removed install the swing brake For more information see Swing Brake page 6 4 2 If removed install the swing motor For more information see Swing Motor page 6 4 3 Attach a suitable lifting device to the swing gearboxes and lift and position the swing gearboxes in place on the mounting plate Adjust the pinions as necessary so the pinions mesh with the turntable beari...

Page 166: ... level g Level crane using outriggers h Damaged swing motor h Repair or replace swing motor i Excessive overload i Reduce load Refer to load capacity chart j Restricted or partly clogged hydraulic hose or fittings j Replace hose or fittings Refer to the Manitowoc Crane Care Parts Manual k Pump cavitation in swing section k Tighten suction hose or replace damaged fittings Check hydraulic tank level...

Page 167: ...urntable bearing i Replace turntable bearing j Excessive overload j Reduce load Refer to load capacity chart 4 Swing operation slow in either direction a Damaged relief valve a Adjust repair or replace valve b Improperly adjusted swing brake b Readjust c Damaged hydraulic remote control valve c Replace hydraulic remote control valve d Improperly lubricated swing bearing d Lubricate bearing per rec...

Page 168: ...Damaged glide swing power brake valve a Repair or replace the glide swing power brake valve b Damaged swing brake release valve b Replace release valve c Internal damage to the swing brake assembly c Repair or replace affected parts d Loose or restricted brake lines or fittings d Tighten or replace brake lines and fittings 10 Boom swings slowly a Insufficient hydraulic volume a Check delivery of h...

Page 169: ... When marked as a high strength bolt grade 8 the serviceman must be aware of bolt classifications and that he is installing a high strength heat treated tempered component and the bolt must be installed according to specifications Special attention should be given to the existence of lubricant and plating that will cause variation from dry torque values When a high strength bolt is removed or un t...

Page 170: ...uing The inner race bearing bolts are located on top of the inner race Figure 6 3 1 Extend and set the outriggers 2 Fully elevate the boom 3 Torque all bolts to 80 of the full torque value following a star pattern sequence as shown in Figure 6 3 starting with bolt number 1 For more information about torque values see Fasteners and Torque Values page 1 16 Tools used are the socket multiplier backla...

Page 171: ...riggers 2 Ensure the boom is in the travel position and the turntable lock pin is engaged 3 Elevate the boom slightly and shut down the engine 4 Tag and disconnect the battery cables from the batteries 5 Remove the boom and lift cylinder following the procedures outlined in Section 4 Boom page 4 1 6 Remove the counterweight Refer to the Operator Manual 7 Tag and disconnect all water and oil lines ...

Page 172: ...ove 71 bolts and washers securing turntable bearing to superstructure 17 Using lifting device remove turntable bearing from under superstructure Inspection Check bearing teeth for chipping or cracking If any evidence of these is found replace bearing Ensure bolt holes are free of dirt oil or foreign material Installation NOTE If the same bearing is to be used again align the marked teeth on the pi...

Page 173: ...ion replacement contact your local distributor SWIVELS Description The swivel assembly consists of a 12 port hydraulic swivel Figure 6 6 a 2 port water swivel and a 20 conductor slip ring electrical swivel Solid connections cannot be used to transfer oil heater hot water and electricity between the carrier and superstructure due to the continuous 360 degree swing Use of swivels efficiently accompl...

Page 174: ...1 20 Conductor Slip Ring Assembly 2 Center Post 3 Capscrew 4 Flatwasher 5 Swivel Assembly 6 Retainer Plate 7 Capscrew 8 Flat Washer 9 Plate 10 Swivel Linkage Assembly 11 Capscrew 12 Washer 13 Locknut 14 Capscrew 15 Washer 16 Locknut 17 Capscrew 18 Washer 19 Bushing 8 1 7 9 5 2 4 3 9 10 11 13 12 14 15 16 17 19 18 ...

Page 175: ...lines and openings 6 Tag and disconnect the hydraulic lines and water lines from the spool of the hydraulic swivel Cap or plug all lines and openings 7 Tag and disconnect water lines from case of water swivel Cap or plug all lines and openings 8 Disconnect swivel wiring harness connectors from carrier receptacles and yellow ground wire from connector mounting bracket on carrier frame If necessary ...

Page 176: ...roove on the water spool exterior through an internally drilled passage in the 12 port hydraulic swivel spool This groove corresponds with a mating port on the outer case of the water swivel Spool grooves are separated by a quad ring Teflon bronze ring seal The lip seal prevents coolant from leaking externally Return engine coolant flow from the hot water heater is accomplished in the same manner ...

Page 177: ...ration The electrical swivel is located on top of the water swivel and transfers electricity between the carrier and superstructure Wiring harnesses transmit the electricity between the carrier and superstructure Maintenance Removal 1 Perform steps 1 through 4 of Hydraulic Swivel page 6 15 2 Disconnect batteries Refer to Electrical System page 3 1 3 Locate connectors which join the collector ring ...

Page 178: ...ne operating hours When this time limit is reached perform the following 1 Check collector ring and brush assembly for any corrosion pitting arcing and wear 2 Check collector ring setscrews are tight 3 Check brush and arm assembly springs Ensure they are holding brushes firmly against the collector rings Slew Angle Verification 1 Rotate superstructure over front and engage house lock pin 2 Set RCL...

Page 179: ...he gear teeth when the control lever is up Verify the linkage can put the blade of the swing lock assembly as far as possible between the gear teeth when the control lever is down Verify all attaching hardware is secure and undamaged Make adjustments as needed When the lever is fully up the top diagonal surface of the blade of the swing lock assembly the beveled surface from the blade s top horizo...

Page 180: ...nsor 1 3 Remove capscrews 6 washers 7 and plate 8 as necessary Installing the Slew Sensor 1 Install plate 8 on superstructure with washers 7 and capscrews 6 2 Install slew sensor assembly 1 and left pinion protection shield 5 with washers 4 and capscrews 3 3 Connect transducer connectors to slew sensor assembly 4 If install new transducers you must re calibrate the sensors For more information see...

Page 181: ...t Of Specifications page 1 3 This Service Manual does not include detailed information on the engine itself A separate manual as prepared in detail by the engine manufacturer is supplied with this Service Manual However a short description and maintenance of certain components of the fuel system air intake system and water cooling system is provided in this section The engine is electronically con...

Page 182: ...e and air cleaner Remove and lay aside 5 On Non certified engines disconnect exhaust tubing at engine and muffler 6 On Stage V Tier 4 Final engines disconnect the muffler exhaust tubing at the engine and aftertreatment assembly muffler remove the tubing from the engine Lay to the side 7 Tag and disconnect engine electrical harness connector from carrier harness connector and battery cables 8 Unbol...

Page 183: ...ngine secure engine mount to frame with nuts Secure the securing plate 4 with capscrew 1 washers 2 and locknuts 3 5 Remove lifting device 6 Connect all lines and tubing to the engine torque con verter and all other components in accordance with identification marks made during removal 7 Apply a moderate coat of to the male hose adapter and install the hydraulic hoses Do not apply sealant to the in...

Page 184: ... control system is an electronically operated fuel control system that also provides many operator and vehicle features as well as reducing exhaust emissions while optimizing engine performance The ECM performs diagnostic tests on most of its circuits and will activate a fault code if a problem is detected in one of these circuits Along with the fault code identifying the problem a snapshot of eng...

Page 185: ...he pump The continuous flow of fuel through the injectors helps to cool the injectors and to purge air from the system Fuel Filter Water Separator The fuel filter water separator removes impurities from the fuel and also removes water from the fuel before it reaches the engine The filter is mounted near the fuel tank on the left side of the crane The fuel mixture passes through the outer wrap of t...

Page 186: ...bottom of the tank 1 in accordance with the identification marks made during removal 4 Service the tank 1 Fuel Filter Water Separator Draining The sump of the fuel filter water separator 6 Figure 7 5 should be drained daily 30 minutes after the engine is shut down to remove any water and sediment Adhere to the following procedure 1 Open the drain plug 2 Drain until fuel appears 3 Close the drain p...

Page 187: ... connections between the air cleaner and the engine are tight and sealed If these connections are all well sealed and there is still evidence of dust leakage check the following places for possible trouble NOTE Dust that gets by the air cleaner system can often be detected by looking for dust streaks on the air transfer tubing or just inside the intake manifold inlet 1 Inspect the air cleaner outl...

Page 188: ...he air cleaner and the engine 4 Ensure all inlet accessories are the correct size and are not plugged by any foreign object FIGURE 7 6 10182 3 1 2 6 10 12 11 4 5 7 7 7 5 1 Air Cleaner 2 TBAP Sensor 3 Clamp 4 Elbow 5 Clamp 6 Elbow 7 T bolt Clamp 8 Muffler Clamp 9 Air Intake Tube 10 Elbow 11 Air Inlet Tube 12 Adapter 7 8 8 9 9 10183 ...

Page 189: ...L POWER TRAIN 7 Published 10 01 2020 Control 699 00 GROVE Air Filter Assembly FIGURE 7 7 1 Temp Air Pressure Sensor 2 Pre cleaner 3 Evacuator Valve 4 Primary Air Filter 5 Secondary Air Filter 6 Service Door 3 1 4 2 6 5 8804 120 ...

Page 190: ...y for dents or other damage that would interfere with air flow or with the fins on the element or inside the body Repair any body dents being careful not to damage the sealing surfaces Be sure to clean the sealing surface of the outlet tube and the inside of the outlet tube taking care not to damage the sealing area on the tube Pre cleaner The pre cleaner 1 Figure 7 9 prevents large debris from en...

Page 191: ...ler System The charge air cooler CAC 1 Figure 7 11 is used to cool engine air after it has passed through a turbocharger but before it enters the engine The charge air cooler provides better horsepower increased fuel efficiency and reduces engine emissions The CAC system consists of the ducting to and from the charge air cooler and a hydraulically driven fan The charge air cooler system must be ai...

Page 192: ... clamps Removal 1 Remove the sheet metal guard to gain access to the exhaust system 2 Remove clamps 2 to free the exhaust tailpipe 3 3 Tag and disconnect electrical connections 4 Disconnect the DEF hoses 1 and 2 Figure 7 12 5 Remove nut 3 lockwasher 4 washer 5 and capscrew 6 6 Remove capscrew 7 lockwasher 8 and washer 9 7 Remove nut 10 lockwasher 11 washer 12 capscrew 13 and clamp 14 from hose 2 8...

Page 193: ...the tube 10 and gasket 12 to engine exhaust with clamp 11 6 Secure the aftertreatment unit 1 with mounting band clamps 5 7 Secure tail pipe 2 with tail pipe clamps 3 8 Install the support bracket 20 Figure 7 12 in place Secure DEF fluid hoses 1 and 2 with nuts 15 lockwashers 16 washers 17 capscrews 18 clamps 19 and support bracket 20 9 Secure one end of the mounting bracket 2 with nut 3 lockwasher...

Page 194: ...ol 699 00 Exhaust System Non Certified Engine FIGURE 7 13 7 1 2 3 5 4 6 6 8 11 10 9 12 1 Jam Nut 2 Clamp V Band 3 Gasket 4 Flex Coupler 5 Clamp V Band 6 Clamp Slip Joint 7 Muffler 8 Clamp Mounting Band 9 Muffler Clamp 10 Nut 11 Tail Pipe Tube 12 Tail Pipe 10189 10190 ...

Page 195: ...l 699 00 GROVE FIGURE 7 14 9 10192 2 8 11 Exhaust System Stage 5 Tier 4 3 1 4 5 7 6 10 12 1 Aftertreatment Unit 2 Tailpipe 3 Tailpipe Clamp 4 Clamp Slip Joint 5 Clamp Mounting Band 6 Clamp V Band 7 Gasket 8 Tube 9 Coupler 10 Mounting Bands 11 Clamp V band 12 Gasket 10191 ...

Page 196: ...1 Tag and disconnect the electrical connector 2 on the DEF tank 1 2 Tag and disconnect the fluid lines 3 6 7 8 on the tank 3 Remove the hardware 4 holding the tank straps 5 in place 4 Remove the tank 1 Installation 1 Place the DEF tank 1 onto the location on the frame 2 Place the tank straps 5 around the tank and secure with the hardware 4 3 Connect the fluid lines 3 6 7 8 as tagged during removal...

Page 197: ...ng system Debris can cause permanent damage and premature failure to either the DEF supply pump or the aftertreatment DEF dosing valve The filter should be replaced every 480 000 km 300 000 miles or 6750 hours of crane operation FIGURE 7 16 1 DEF Supply Pump 24V 2 DEF Filter 3 Protective Cover 4 Filter Housing 5 Ventilation Cap 10196 10195 1 5 4 3 2 6 O Ring 7 Filter Screen 8 Quick Disconnect Conn...

Page 198: ...DEF filter prior to discarding the filter 1 Check the DEF for evidence of contaminated DEF Use visual and aroma characteristics of the filter to determine if contaminated fluid has passed through the dosing system 2 Inspect the DEF filter for debris If debris is evident also check DEF tank filter screen 7 The DEF dosing unit inlet quick disconnect connector 8 3 Discard the DEF filter 4 Inspect the...

Page 199: ... cooling system relies entirely upon the water pump The water pump draws water from the radiator and forces it through the water jacket and cylinder head There it accumulates heat and flows to the radiator tank Then the water flows across through the radiator core and is cooled by air from the fan This process of removing heat from water as it circulates holds the engine to its efficient operating...

Page 200: ...ntified by odor or color If condemned flush the system using a commercially available flushing agent Refill system with fully formulated extended life coolant Refer to Radiator Fill and Servicing page 7 25 NOTE Remove radiator caps when draining system to ensure proper draining Cleaning 1 Coolant shut off valves to heaters and other accessories should be open to allow complete circulation during c...

Page 201: ...at of which is below the overflow pipe in the filler neck This prevents the escape of air or liquid while the cap is in position When the cooling system pressure reaches a predetermined point the cap valve opens and will again close when the pressure falls below the predetermined point When removing the pressure type cap perform the operation in two steps Loosening the cap to its first notch raise...

Page 202: ...heating and loss of coolant is sometimes due to an inoperative thermostat To check for this condition remove the thermostat and test by submerging it in hot water and noting the temperature at which the thermostat opens and closes Use an accurate high temperature thermometer for making this test Hoses and Clamps Hoses and their connections must be checked regularly because they are often the sourc...

Page 203: ...VICE MANUAL POWER TRAIN 7 Published 10 01 2020 Control 699 00 GROVE Radiator Removal and Installation 5 2 3 4 6 7 8 FIGURE 7 17 9 1 15 22 12 13 14 18 19 16 17 10 11 20 21 23 24 25 26 27 28 29 30 10198 10197 10200 10199 ...

Page 204: ...move clamps 18 and hose 19 from radiator 11 Remove the hose clamps 20 and hose 21 from radiator 12 Remove capscrews 23 washers 24 lock nuts 25 and angle mounts 26 13 If not already removed remove capscrews 27 lockwashers 28 and washers from drain valve cover and radiator flange 14 Remove clamp 30 from bracket 15 Disconnect the electrical harness from the coolant level sensor 22 NOTE The radiator w...

Page 205: ...s and check for leaks 14 Install the hood assembly 15 Install the bolts and nuts holding the rear engine hood panel to the engine hood 16 Install the hood top door assembly Radiator Fill and Servicing Use the following to drain and fill the radiator Refer to Maintenance and Lubrication page 9 1 for complete fill and service procedures Antifreeze Coolant Drain Procedure 1 Loosen the radiator reserv...

Page 206: ...right side of the steering column and an axle drive mode selector rocker switch located on the steering wheel console The transmission torque converter oil is cooled by passing the oil through an externally mounted transmission cooler that is located on the left side of the crane An oil filter is mounted on the left frame rail near the fuel tank Four drive lines are used Two drive lines are connec...

Page 207: ... 699 00 GROVE 1 Driveshaft 2 Driveshaft Slip 3 Driveshaft 4 Driveshaft Slip 5 Capscrew M14x50 6 Lockwasher FIGURE 7 20 1 2 3 4 10205 5 6 7 8 9 10 11 9 10 11 8 8 7 Nut 8 Capscrew 1 2 20UNFx2 G8 9 Capscrew M12x45 10 9 10 Lockwasher 11 Nut 10204 10203 10206 10207 10208 10209 ...

Page 208: ...with washers 2 capscrews 1 and nuts 3 Torque nuts to 66 2 Nm to 69 7 Nm 48 8 ft lbs to 51 4 ft lbs 4 Install slip driveshaft 4 Figure 7 20 on the rear driveshaft and bearing assembly with capscrews 8 Torque capscrews 8 to 155 9 Nm to 183 0 Nm 115 ft lb to 135 ft lb 5 Install slip driveshaft 2 to transmission with capscrews 9 washers 10 and nuts 11 Torque nuts to 101 7 Nm to 128 8 Nm 75 to 95 ft lb...

Page 209: ...00 GROVE Troubleshooting and Maintenance For transmission maintenance information see Maintenance and Lubrication page 9 1 For troubleshooting steps see Table 7 2 FIGURE 7 22 1 Transmission 2 Transmission Fluid Dipstick 3 Transmission Drain Plug 2 1 3 Front Looking Back 10211 ...

Page 210: ...2 Low converter charging pump pressure a Low oil level a Fill to proper level Refer to Maintenance and Lubrication page 9 1 b Suction screen plugged b Clean suction screen c Defective oil pump c Replace pump 3 Overheating a Worn oil sealing rings a Remove disassemble and rebuild converter assembly b Worn oil pump b Replace pump c Low oil level c Fill to proper level 4 Noisy converter a Worn oil pu...

Page 211: ...1 12 13 1 6 7 8 5 10 11 12 13 1 Transmission 2 Capscrew M10x30 SS 3 Flange Split 4 O Ring 5 Dipstick Tube 6 Capscrew M12x45 10 9 7 Locknut 8 Driveshaft 9 Driveshaft Coupler 10 Locknut 11 Washer 12 Shock Mount 13 Capscrew 5 8 11UNC G8 14 Capscrew M20x45 10 9 15 Washer 16 Installation Bracket 14 15 16 10212 10213 10214 ...

Page 212: ...4 64 kg 1377 1 lb dry 1 If a new transmission 1 Figure 7 23 is to be installed remove all fittings and brackets from the old one and install them in the same locations on the new transmission 2 Install the engine torque converter to the carrier frame as an assembly Refer to Engine Removal page 7 2 3 If necessary apply Loctite 243 or equivalent to capscrew 14 threads Install installation brackets 1...

Page 213: ...g Engine Flywheel Pilot Bore Flywheel 6 4 cm 2 1 2 in Aligning Studs Drive Plate 10 2 cm 4 in Stud Converter Housing Flywheel Special Stud Washer And Self lock Nut Furnished By Engine Manufacturer Flywheel Housing Impeller Cover 3 Intermediate Drive Plates Figure 1 FIGURE 7 25 Figure 4 Figure 3 Flywheel Housing Figure 2 10216 ...

Page 214: ...ties which can result from the presence of such foreign material in the system 6 Assemble all components and use only the type oil recommended Fill the transmission through the fill pipe until fluid is at the top of the fill range on the dipstick Run the engine for two minutes at 600 rpm to 800 rpm to prime the torque converter and hydraulic lines Recheck the level of oil in the transmission with ...

Page 215: ...cylinders to provide six wheel steering 2 wheel front 4 wheel rear 6 wheel coordinated 6 wheel crab Drag links connect the middle and rear axles to enable synchronized steering The GRT9165 crane can be driven in the Standard Driving Configuration with the boom centered over the front single axle Figure 8 1 or in the Alternate Driving Configuration with the boom centered over the rear tandem axles ...

Page 216: ...hydraulic braking system A disc type parking brake is mounted on the front axle input shaft 1 2 3 4 4 4 5 1 Front Axle Assembly 2 Middle Axle Assembly 3 Rear Axle Assembly 4 Torque Rod 5 Drag Link Assembly 6 Cotter Pin 7 Spacer 8 Suspension Pin 9 Washer 10 Capscrew 1 1 4 7 UNC x 13 G8 FIGURE 8 3 6 7 8 9 10 10217 10218 10219 ...

Page 217: ...e hydraulic lines to the steer cylinders 6 On the front axle only tag and disconnect the hydraulic line from the park brake actuator 7 On the left side of the rear axle only tag and disconnect the electrical wires from the rear wheels not centered switch NOTE Each tire and wheel assembly weighs approximately 749 kg 1651 lb 8 Remove the wheels from the axle NOTE The front axle weighs approximately ...

Page 218: ...5 Connect the hydraulic lines to the steer cylinder as tagged during removal 6 Connect the hydraulic brake line to each wheel as marked during removal 7 On the front axle only connect the hydraulic line to the parking brake actuator 8 On the left side of the rear axle only connect the electrical wires to the rear wheels not centered switch Adjust the switch as outlined under Rear Steer Sensor Adju...

Page 219: ...3 in diameter x 136 7 mm 5 38 inch 6 Install rig pin 11 through the hole 10 in the relay arm mounting bracket and relay arm 5 7 Install drag links 3 and 4 on relay arm 5 8 With the rig pin 11 inserted verify the left rear wheels are aligned and in the straight ahead position by using a straight edge long enough to lay across the wheel mounting surfaces of both rear axles Adjust drag links to fit b...

Page 220: ... Axle Assembly 2 Middle Axle Assembly 3 Drag Link 1311 mm 51 6 in 4 Drag Link 731 mm 28 8 in 5 Relay Arm 4 2 1 3 5 3 4 6 7 8 9 11 FIGURE 8 5 6 Pin 7 Capscrew 8 Washer 9 Shim 10 Rig Tool Hole 11 Rig Tool 1 5 mm 0 06 in 9 Looking Up 6 10 4 3 Looking Down Forward 10221 10224 10222 10223 ...

Page 221: ... as needed Wheels And Tires Description The standard tire size for this unit is 26 5x25 44 ply Each wheel assembly tire and rim is mounted on the planetary hub with 24 3 4 16UNF lug nuts NOTE The tire diameters widths and weights may vary slightly depending on the tire manufacturer Off highway tires are designed to operate with a certain sidewall deflection or bulge Correct air pressure ensures pr...

Page 222: ...ard and alternate driving modes are also supported when rear steering is used For more information about rear steering see the Operator Manual Front Steering System The front steering system consists of a load sense steer priority flow valve part of the accessory manifold valve load sense steering control valve single axle reversal valve part of the Main Carrier Manifold and two steer cylinders Re...

Page 223: ... engine speeds this may indicate a defective pump drive Refer to Checking Setting the Front Steer Pressure page 2 61 Front Steering Control Valve The steering control valve is located under the dash and is actuated by a conventional steering wheel and steering column providing precise full hydraulic steering Precise steering is accomplished by a metering system within the valve that is directly co...

Page 224: ...e steering column 1 Remove the control valve leaving the steering column in the cab Installation 1 Position the control valve to the bracket and steering column 1 and install the flatwashers 8 lockwashers 7 and capscrews 6 Torque capscrews refer to Fasteners and Torque Values page 1 16 for proper torque 2 Install washers 5 lockwashers 4 and hex nuts 3 3 Connect the hydraulic hoses to the control v...

Page 225: ...lines or fittings c Steer cylinder locked c Repair or replace cylinders d Defective control valve d Repair or replace valve e Defective steer cylinder s e Repair or replace cylinder s f Lack of electrical signal f Check electrical connections wiring 2 Difficult to steer left and right a Hydraulic oil low a Check system for leaks Make repairs as needed Fill reservoir b Clogged or loose hydraulic li...

Page 226: ...ION RAISE LOWER SYSTEM The rear axle oscillation and height adjustment system Figure 8 10 and consists of four hydraulic struts two per axle suspension valve and on two of the struts length sensors The main carrier manifold controls the flow of the hydraulic oil to the suspension valve The suspension manifold features oscillation lockout solenoids For more information about the suspension valve se...

Page 227: ...ers 8 suspension pin 9 and cotter pins 7 2 Install the length sensor 2 on to the bottom of the strut 1 bracket with washer 6 and nut 5 3 Install the length sensor 2 on to the top strut 1 bracket with washer 4 and nut 3 4 Uncap and install hydraulic hose 10 5 Remove blocks or rigging from under the axle 6 Install wheels For more information see Wheels And Tires page 8 7 BRAKE SYSTEM Description The...

Page 228: ...to activate the solenoid valve which controls the park brake actuator which applies and releases the park brake NOTE For Description and Maintenance of the tandem brake valve with treadle pedal the accumulators and the dual accumulator charge valve refer to Valves page 2 21 Maintenance Troubleshooting Table 8 3 Symptom Probable Cause Solution 1 Brakes are insufficient a Lining thickness less than ...

Page 229: ...w fluid to flow into the jar while depressing the brake pedal Depress the brake pedal and close the bleeder screw then release the brake pedal Torque the bleeder screw 11 3 N m to 13 6 N m 100 lb in to 120 lb in 3 Repeat step 2 until a solid stream free of air bubbles is obtained 4 Repeat steps 1 thru 3 for the remaining wheel calipers actuators SERVICE BRAKES Description The brakes utilized on th...

Page 230: ... wood against two pistons on the mounting side of the housing Ensure the C clamp is not in the area in front of the piston bore Refer to Figure 8 12 b Apply compressed air to the inlet fitting to force the pistons out of the other housing If one piston comes out before the other piston put a piece of wood in front of the piston that comes out first Apply compressed air to force the other piston ou...

Page 231: ...lining wear replace worn bent or cracked end plates and distorted backing plates Inspect end plate bolts for wear Replace the bolts if worn Inspect the linings for Lining Wear Replace the linings when the thickness of the lining is less than 3 2 mm 0 125 in from the back plate Refer to Figure 8 17 Lining Wear Not Even Replace the linings if the thickness of the two linings is significantly differe...

Page 232: ...ar limits replace the disc Refer to Figure 8 19 Caliper Parts 1 Inspect the pistons housing bores and o ring grooves for scratches or corrosion Remove small scratches or corrosion with fine emery cloth Replace the components if they are worn beyond wear limits or if there are large scratches or large amount of corrosion 2 Measure the diameter of the piston Replace the piston if the outer diameter ...

Page 233: ... material that prevents corrosion to all surfaces Do Not apply the material to the brake linings or the disc Store the parts inside special paper or other material that prevents corrosion Assembly Caliper NOTE The O rings back up rings pistons and bores must be lubricated before installing the pistons 1 Lubricate all pistons bores O rings and back up rings with silicone grease If silicone grease i...

Page 234: ...100 lb in to 120 lb in 8 Install the O ring and the inlet fitting in the cylinder cap Installation Linings 1 Block the wheels 2 Install the linings in the caliper housing 3 Apply Loctite 271 or equivalent to the bolt threads Position the end plates on the housing and secure with bolts Tighten the bolts to 224 N m to 285 N m 165 lb ft to 210 lb ft 4 Ensure the linings move freely in the housing 5 B...

Page 235: ...LENOID VALVE The park brake solenoid valve is part of the Carrier Manifold Valve Refer to Carrier Manifold Valve page 2 25 for a description of the park brake solenoid valve its function and maintenance information OUTRIGGER Outrigger Circuit The outrigger circuit consists of four extension cylinders four jack cylinders an extend retract directional control valve front and rear outrigger control m...

Page 236: ...Clean outrigger beams j Binding outrigger beam j Do one of the following Adjust wear pads Repair or replace outrigger beam k Damaged outrigger valve k Repair or replace valve l Damaged valve coil l Replace coil m Main hydraulic pump cavitation m Replace or tighten hose or fitting Refer to your Manitowoc Crane Care Parts Manual n Partially shifted hydraulic spool in selector valve or manifolds n Di...

Page 237: ...e valve c Damaged holding valve seals c Replace holding valve seals d Bent cylinder rod d Replace cylinder rod and seals e Bent outrigger housing e Repair or replace outrigger housing f Excessive material on beams f Clean outrigger beams g Sticking solenoid valve spool g Repair or replace valve spool h Damaged wiring to solenoid h Repair or replace wiring i Directional selector switch sticking i C...

Page 238: ... b Loose or broken wire on control switch or solenoid valve b Repair or replace wiring c Damaged solenoid valve c Repair or replace valve d Damaged control switch d Replace switch e Damaged hydraulic cylinder e Repair or replace cylinder 10 Outriggers will not set a Improper sequence of activation a Activate individual control switch then activate system control switch 11 Two outriggers activate f...

Page 239: ...hers 8 spacers 9 and grab handles 6 from ladder 10 4 Remove capscrews 3 lockwashers 4 washers 5 and the outrigger beam end cover 12 5 On the jack cylinder end of the beam loosen the two jam nuts 14 plates and wear pads 16 6 On the opposite end of the beam remove capscrews 17 plates 18 and wear pads 19 from the top of outrigger beam 7 Extend the outrigger slightly and attach an adequate lifting dev...

Page 240: ... Box 2 Outrigger Jack Cylinder 3 Capscrew 10 x 30 8 8 4 Lockwasher 5 Washer 6 Grab Handle 7 Capscrew M10x70 SS 8 Washer 9 Spacer 10 Ladder 11 Retaining Nut 12 Lower Outrigger Cover 13 Outrigger End Cover 14 Jam Nut 15 Plate 16 Wear Pad 17 Capscrew M10x25 10 9 18 Plate 19 Wear Pad 20 Hydraulic Hose 21 Cotter Pin 22 Clevis Pin 23 Outrigger Extension Cylinder 10231 10232 10233 ...

Page 241: ...der hydraulic hoses do not get trapped against the outrigger box during insertion 5 Apply anti seeze compound to the clevis pin 22 Figure 8 26 Secure the cylinder barrel to the housing with the clevis pin 22 and cotter pins 21 6 Connect the hydraulic lines 20 as tagged during removal Connect the OMS electrical cable as tagged during removal 7 Fully extend and retract the outrigger beam ensuring th...

Page 242: ... 6 2 Place the extension cylinder 1 in the beam 3 Position the extension cylinder 1 so the hydraulic ports on the rod end of the cylinder can be accessed Connect the hydraulic hoses 4 to the ports as tagged during removal 4 Push the extension cylinder 1 into the outrigger beam Align the cylinder rod with the clevis in the beam Apply anti seeze to the clevis pin 2 and secure in place with the clevi...

Page 243: ...ear ring in groove in bottom of support tube and in groove at top on jack cylinder 3 Place a jack beneath the cylinder tube on the outrigger beam Using the same method as described under Removal lower the jack cylinder into the cylinder tube on the outrigger beam until the retaining pin is just above the tube Position the jack so that it will support the cylinder in this position Remove lifting de...

Page 244: ... SERVICE MANUAL 8 30 Published 10 01 2020 Control 699 00 FIGURE 8 29 8804 115 Item Description 1 Jack Cylinder Cap 2 Cap Bracket 3 Pin 4 Head Wear Ring 5 Jack Cylinder 6 Bearing 7 Jack Cylinder Hydraulic Hoses 2 1 3 5 4 6 7 ...

Page 245: ...rication points frequency of lubrication and other information Refer to your Inspection and Lubrication Service Log for routine checks which will help maintain the safety dependability and productivity designed into your crane One copy of the Inspection and Lubrication Service Log is provided in the original package of manuals shipped with the crane Additional copies are available through the Grov...

Page 246: ...F CAUTION Possible Equipment Damage The multipurpose grease installed during manufacture of this crane contains a lithium base Do not apply chassis grease lubricants with air pressure devices as chassis contains sealed fittings Use of non approved lubricant may damage components and or invalidate published lubricant intervals Failure to follow this instruction may cause damage to equipment Table 9...

Page 247: ...encool 3000 LCC Diesel Exhaust Fluid DEF 80019225 Fleetguard StableGuard Urea 32 Premix AdBlue TerraCair Ultrapure DEF DEF Extreme Pressure 3 Moly Grease EM 3MG 6829015304 Citgo Lithoplex CM2 Mobil Mobilgrease CM P Phillips 66 Megaplex XD3 Ipiranga IPIFLEX LI COMP MOLY 2 Gray NLGI 2 NLGI 2 NLGI 1 NLGI 2 GC LB Certified GC LB Certified BECHEM PAL1 01373458 BECHEM High Lub LM 2 EP 400g 03313195 NLGI...

Page 248: ...to 29 C 20 F Refer to Table 9 2 for a list of these recommended Cold Weather lubricants Additionally Grove recommends specific Cold Weather lubricants for use in ambient temperatures down to 40 C 40 F Refer to Table 9 3 for a list of these recommended Cold Weather lubricants These recommended Cold Weather lubricants alone are not sufficient to operate the crane in extreme low temperatures arctic c...

Page 249: ...rpillar DEAC Fleetguard Compleat EG Mix 50 50 Liquid Coolant Conditioner 6829012858 Fleetguard DCA4 Fleetguard DCA2 Penray Pencool 3000 Diesel Exhaust Fluid DEF 80019225 Fleetguard StableGuard Urea 32 Premix AdBlue TerraCair Ultrapure DEF Extreme Pressure 3 Moly Grease 6829104275 Mobil Mobilith SHC 220 Petro Canada Precision Synthetic EP1 NLGI 2 Windshield Washer fluid 90037773 Splash De icer Dies...

Page 250: ... Must Meet John Deere Std JDM J20C J20D Swing Drive Oil 6829103636 Petro Canada ENDURATEX Synthetic EP 150 Mobil SHC629 AGMA No 4 EP Grease Extreme Pressure Multipurpose 6829104275 Petro Canada Precision Synthetic EP1 Mobil Mobilith SHC 220 NLGI 2 Open Gear Lube 6829102971 Fuchs Ceplattyn 300 Spray NLGI 1 2 Antifreeze Coolant 6829104212 Old World Industries Inc Fleet Charge SCA Pre charged Fleetgu...

Page 251: ... The log must use the engine hourmeter to ensure coverage of lube points that will receive attention based on their readings Other lubrication requirements must be made on a time basis for example weekly monthly etc Check all oil levels with crane parked on a level surface in transport position while oil is cold unless otherwise specified On plug type check points oil levels are to be at the botto...

Page 252: ...m moving parts when these parts are operated during lubrication of the crane Failure to follow this instruction may cause serious injury or death to personnel Ref Approved Lubricant Lube Specification Down To 9 C 15 F Lube Specification Down To 29 C 20 F Lube Specification Down To 40 C 40 F A Extreme Pressure Multipurpose Grease 6829003477 6829104275 6829104275 B Gear Lube GL 5 6829012964 68290140...

Page 253: ... DIPSTICK F 15 L 4 gal Every 500 hours DRAIN engine crankcase REPLACE oil filter See NOTE 7 FILL engine crank case through fill cap to FULL on DIPSTICK See NOTE 7 NOTE 1 If installed ladder must be removed to access the Engine Air Cleaner Filter element NOTE 2 Engine Anti Freeze Coolant capacities indicated are for a fully formulated mixture of 50 AFC and 50 water NOTE 3 If coolant LEVEL in the la...

Page 254: ...MAINTENANCE AND LUBRICATION GRT9165 SERVICE MANUAL 9 10 Published 10 01 2020 Control 699 00 FIGURE 9 1 9900 01 TOP VIEW OF CARRIER FRONT 4 2 1 3 ...

Page 255: ...etic drain plug INSTALL magnetic plug in drain port FILL transmission sump to FULL on DIPSTICK Then every 1000 hours or 6 months thereafter whichever interval comes first DRAINtransmission sump See NOTE 11 REPLACE transmission and torque converter filter See NOTE 11 FILL transmission sump to FULL on DIPSTICK See NOTE 12 NOTE 8 Check Transmission Fluid level using the transmission oil dipstick loca...

Page 256: ... and lines c Check fluid level with engine running at 850 rpm and torque converter fluid at 65 C to 90 C 150 F to 200 F d Add transmission fluid as necessary FILL to FULL on DIPSTICK Item Lube Point Description Figure No Approved Lubricant Approximate Capacity Service Interval Service Application CAUTION Possible Equipment Damage Do not operate torque converter at stall condition for longer than 3...

Page 257: ... and torque converter filter See NOTE 11 REPEAT after another 50 hours for a total of 100 hours of service REPLACE transmission and torque converter filter THEN every 1000 hours or 6 months thereafter whichever interval comes first REPLACE transmission and torque converter filter 5c Transmission Fluid FILL and DIPSTICK Figure 9 3 J 44 5 L 11 75 gal As necessary in DRAIN and FILL routines FILL tran...

Page 258: ...MAINTENANCE AND LUBRICATION GRT9165 SERVICE MANUAL 9 14 Published 10 01 2020 Control 699 00 FIGURE 9 3 BOTTOM VIEW OF CARRIER FRONT 9900 03 5b 5c ...

Page 259: ...very 10 hours daily DRAIN water trap 7 Diesel Exhaust Fluid DEF Tank Figure 9 4 K 37 9 L 10 gal Every 10 hours daily CHECK DEF level and FILL Indicator in cab comes on when DEF level is low See NOTE 14 DEF Tank Filter Figure 9 4 Every 2000 hours or 1 year whichever interval comes first CHECK DEF tank filter NOTE 14 The Diesel Exhaust Fluid DEF Level Indicator in the Crane Vitals Area of the Operat...

Page 260: ...MAINTENANCE AND LUBRICATION GRT9165 SERVICE MANUAL 9 16 Published 10 01 2020 Control 699 00 FIGURE 9 4 SIDE VIEW OF CARRIER FRONT 9900 02 6 7 ...

Page 261: ...Filter Figure 9 5 Every 500 hours of service or 6 months whichever interval comes first REPLACE fuel filter See NOTE 16 NOTE 15 The Engine Oil Filter is located on the lower inside left side of the frame adjacent to the torque converter NOTE 16 The Fuel Filter is located on the lower inside right side of the frame adjacent to the torque converter NOTE 17 DO NOT USE non semi synthetic lubricant Use...

Page 262: ...MAINTENANCE AND LUBRICATION GRT9165 SERVICE MANUAL 9 18 Published 10 01 2020 Control 699 00 FIGURE 9 5 BOTTOM VIEW OF CARRIER FRONT 9900 03 8 1 9 10 10 11 ...

Page 263: ...se extrudes Every 500 hours or 3 months whichever interval comes first LUBRICATE 2 grease fittings per axle 3 axles 6 service points 17 Panhard Rod Pivots See NOTE 18 Figure 9 7 A Until grease extrudes Every 500 hours or 3 months whichever interval comes first LUBRICATE 2 grease fittings per rod pivot 2 axles 1 rod pivot Axle 2 1 rod pivot Axle 3 4 service points 18 Drag Link Pivots See NOTE 18 Fi...

Page 264: ...INTENANCE AND LUBRICATION GRT9165 SERVICE MANUAL 9 20 Published 10 01 2020 Control 699 00 FIGURE 9 7 9900 05 REAR DRIVE AXLE REAR VIEW 16 16 17 FIGURE 9 8 9900 06 REAR DRIVE AXLE SIDE VIEW FRONT 19 18 18 ...

Page 265: ...e hub To provide sufficient lubrication final fluid level MUST BE LEVEL with the filler plug hole at the Wheel End with fluid even slightly dripping from the hole CLEAN magnetic plug then INSTALL magnetic plug in drain port NOTE 20 Before operating crane in cold weather arctic ambient temperatures below 9 C 15 F Standard bearing lubricant must be fully purged and replaced with Cold Weather lubrica...

Page 266: ...20 Control 699 00 FIGURE 9 9 9900 07 FRONT DRIVE AXLE FRONT VIEW DIFFERENTIAL 20 FIGURE 9 10 9900 08 FRONT DRIVE AXLE FRONT VIEW PLANETARY HUBS WHEEL BEARINGS 21 21 FIGURE 9 11 9900 09 SIDE VIEW AXLE HUB PLANETARY DRAIN AND FILL PORTS 21A OIL FILL 21B OIL DRAIN LEGEND 21A 21B ...

Page 267: ...a full rotation NOTE 24 The swing drive bearing in this crane is supplied with Cold Weather arctic bearing grease capable of ambient temperatures between 40 C and 49 C 40 F to 120 F If operating the crane in regions expecting sustained winter cold season temperatures below 15 F top off bearing grease using Table 9 2 Cold Weather Lubricants in Arctic Conditions Down to 29 C 20 F If temperatures bel...

Page 268: ...MAINTENANCE AND LUBRICATION GRT9165 SERVICE MANUAL 9 24 Published 10 01 2020 Control 699 00 FIGURE 9 12 TOP VIEW SUPERSTRUCTURE 22 9900 10 ...

Page 269: ...ure 9 13 H 0 3 L 0 63 pt each gearbox After first 50 hours of service REMOVE Breather at 24 and DRAIN swing drive brake assembly FILL swing drive brake assembly at 24 to top of elbow See NOTE 27 Then every 50 hours of service thereafter CHECK oil level FILL swing drive brake assembly at 24 to top of elbow See NOTE 27 Every 1000 hours or 6 months of service whichever interval comes first REMOVE Bre...

Page 270: ...lly purged and replaced with Cold Weather lubricant meeting Grove U S L L C specifications as shown in Table 9 4 Approved Lubricant Reference Table page 9 8 in this Operator Manual See also your Service Manual for maintenance and lubrication instructions Item Lube Point Description Figure No Approved Lubricant Approximate Capacity Service Interval Service Application CAUTION Possible Equipment Dam...

Page 271: ...9 27 GRT9165 SERVICE MANUAL MAINTENANCE AND LUBRICATION 9 Published 10 01 2020 Control 699 00 GROVE FIGURE 9 13 9900 11 RIGHT SIDE VIEW SUPERSTRUCTURE 25 26 23b 24 23a ...

Page 272: ...e extrudes Every 500 hours or 3 months of service whichever interval comes first LUBRICATE 2 service points See NOTE 31 See NOTE 33 See NOTE 35 31 Cab Door Tracks and Rollers Figure 9 15 Light Oil Every 6 months LUBRICATE 2 service points See NOTE 36 32 Air Conditioner Condenser Filter Figure 9 15 Every 1000 hours or 6 months of service whichever interval comes first CHECK CLEAN air conditioner co...

Page 273: ...SERVICE MANUAL MAINTENANCE AND LUBRICATION 9 Published 10 01 2020 Control 699 00 GROVE FIGURE 9 14 LEFT SIDE SUPERSTRUCTURE 9900 12 27 28 29 30 FIGURE 9 15 UNDERSIDE OPERATOR CAB SUPERSTRUCTURE 9900 13 9900 29 32 31 ...

Page 274: ... Brush on Every 50 hours or 1 week of service whichever interval comes first BRUSH ON beam top plate as beam is fully extended See NOTE 37 See NOTE 39 See NOTE 40 See NOTE 41 See NOTE 42 Outrigger Beams Bump outs Figure 9 16 L Brush on Every 50 hours or 1 week of service whichever interval comes first BRUSH ON 3 TOP and 3 BOTTOM bump outs on each side of outrigger beam 12 service points each beam ...

Page 275: ...er when the beam is fully extended NOTE 41 Perform same service for each of four 4 Outrigger Beams for a total of 48 service points NOTE 42 Before operating crane in cold weather arctic ambient temperatures below 9 C 15 F Standard grease must be fully purged and replaced with Cold Weather grease meeting Grove U S L L C specifications as shown in Table 9 4 Approved Lubricant Reference Table page 9 ...

Page 276: ... semi synthetic lubricant Use of non approved lubricant may damage components NOTE 44 Before operating crane in cold weather arctic ambient temperatures below 9 C 15 F Standard grease must be fully purged and replaced with Cold Weather grease meeting Grove U S L L C specifications as shown in Table 9 4 Approved Lubricant Reference Table page 9 8 in this Operator Manual See also your GRT9165 Servic...

Page 277: ...9 33 GRT9165 SERVICE MANUAL MAINTENANCE AND LUBRICATION 9 Published 10 01 2020 Control 699 00 GROVE FIGURE 9 17 LIFT CYLINDER 39b 9900 15 39a ...

Page 278: ...d lock Tele 5 to the 0 pinning location 8 Raise boom to 70 Boom Lubrication READ FIRST IMPORTANT CRANE SET UP INFORMATION 1 With crane set on a firm level surface and counterweight installed fully extend the outriggers and level the crane 2 Center the boom over the front of the crane engage the turntable swing lock pin and disable the swing function 3 Fully retract the boom and set boom angle to 7...

Page 279: ...eral times to make sure that grease is properly distributed 6 When Tele 3 greasing is complete retract and lock Tele 3 to the 0 pinning locations 7 Raise boom to 70 Telescope Section 2 Tele 2 1 Make sure that the tele cylinder is locked to Tele 2 2 Extend and lock Tele 2 to the 100 pinning location 3 Extend and lock Tele 1 to the 55 pinning location 4 Lower the boom to 0 and perform the following ...

Page 280: ...front faces that contact wear pads inside the boom Follow the boom Tele Section positioning and lubrication instruction given in the section titled READ FIRST IMPORTANT CRANE SET UP INFORMATION page 9 34 If the weather is very bad or operating conditions are poor then more frequent intervals are necessary Monitor the service points and adjust lubrication intervals as necessary CAUTION Possible Equ...

Page 281: ...9 37 GRT9165 SERVICE MANUAL MAINTENANCE AND LUBRICATION 9 Published 10 01 2020 Control 699 00 GROVE FIGURE 9 19 TELESCOPIC SECTION SLIDE FRONT FACES 9900 16 41 ...

Page 282: ...umps each fitting Every 250 hours or 3 months whichever interval comes first LUBRICATE 2 service points See NOTE 48 48 Tele 2 Lock Pin Figure 9 20 P 1 or 2 pumps each fitting Every 250 hours or 3 months whichever interval comes first LUBRICATE 2 service points See NOTE 48 49 Tele 3 Lock Pin Figure 9 20 P 1 or 2 pumps each fitting Every 250 hours or 3 months whichever interval comes first LUBRICATE...

Page 283: ...9 39 GRT9165 SERVICE MANUAL MAINTENANCE AND LUBRICATION 9 Published 10 01 2020 Control 699 00 GROVE LEFT SIDE BOOM REAR UPPER WEAR PADS AND LOCK PINS 9900 20 43 44 45 46 FIGURE 9 20 48 47 51 50 49 42 ...

Page 284: ...igure 9 21 Every 250 hours or 3 months of service whichever interval comes first CHECK 1 service point CHECK sheave for dry points of operation CHECK sheave for grease leaks See NOTE 49 55 Boom Nose Sheave Figure 9 21 Every 250 hours or 3 months of service whichever interval comes first CHECK 7 service points CHECK sheave for dry points of operation CHECK sheave for grease leaks See NOTE 49 56 Aux...

Page 285: ...ension Screw Figure 9 21 A Brush on entire screw BRUSH ON as necessary BRUSH ON 1 service point NOTE 49 Slowly turn the sheave and examine it for rough or dry points of operation and grease leaks If rough or dry points of operation are found then replace the sheave If grease leaks are found then replace the sheave Item Lube Point Description Figure No Approved Lubricant Approximate Capacity Servic...

Page 286: ...4 Overhaul Ball NOTE 50 DO NOT USE non semi synthetic lubricant Use of non approved lubricant may damage components NOTE 51 Before operating crane in cold weather arctic ambient temperatures below 9 C 15 F Standard grease must be fully purged and replaced with Cold Weather grease meeting Grove U S L L C specifications as shown in Table 9 4 Approved Lubricant Reference Table page 9 8 in this Operat...

Page 287: ...T9165 SERVICE MANUAL MAINTENANCE AND LUBRICATION 9 Published 10 01 2020 Control 699 00 GROVE FIGURE 9 22 HOOK BLOCK and OVERHAUL BALLS 9900 21 9900 23 60 9900 22 9900 28 9900 27 60 62 63 64 61C 61D 61E 61A 61B ...

Page 288: ...nterval comes first BRUSH ON 2 service points See NOTE 54 See NOTE 56 67 Hoist Bearings Figure 9 23 A Until grease extrudes from entire bearing circumference Every 250 hours or 3 months of service whichever interval comes first LUBRICATE 2 service points See NOTE 54 See NOTE 57 NOTE 54 DO NOT USE non semi synthetic lubricant Use of non approved lubricant may damage components NOTE 55 Check oil lev...

Page 289: ...RT9165 SERVICE MANUAL MAINTENANCE AND LUBRICATION 9 Published 10 01 2020 Control 699 00 GROVE FIGURE 9 23 HOIST DRUMS MAIN and AUXILIARY 9900 24 9900 25 HOIST DRUM RIGHT SIDE HOIST DRUM LEFT SIDE 65 66 65 67 ...

Page 290: ...nvironmental conditions can dramatically affect the performance and condition of hydraulic oil filters and breathers Therefore specific intervals for servicing changing hydraulic oil filters and hydraulic tank breathers cannot be set Thus it is imperative for the continued satisfactory performance of Grove cranes that service inspections be performed on the basis of how and where each crane is use...

Page 291: ...9 47 GRT9165 SERVICE MANUAL MAINTENANCE AND LUBRICATION 9 Published 10 01 2020 Control 699 00 GROVE HYDRAULIC TANK FIGURE 9 24 9900 26a 68 69 70 ...

Page 292: ...s or moving components Damage caused by personal abuse such as using the decks to transport rigging gear tools or cribbing and Exposure to harsh environmental hazards such as alkaline acids or other chemicals that can attack the crane s paint finish While crane surfaces that are easily seen have the biggest impact on appearance particular attention should be given to the undercarriage to minimize ...

Page 293: ...ored in harsh environments such as islands coastal regions industrial areas areas where winter road salt is regularly used etc reapplication of treatment is recommended sooner than 12 months for example repeat treatment in 6 to 9 months Do not apply to recently primered and painted areas for at least 48 hours after paint is properly dried and cured For minor touch up areas a 24 hour period is need...

Page 294: ...UBRICATION GRT9165 SERVICE MANUAL 9 50 Published 10 01 2020 Control 699 00 7650 75 Figure 9 25 Picture may not be same model as your crane it is for reference only 1 5 4 1 13 11 6 4 10 9 12 2 3 18 14 5 7 8 5 8 15 16 17 ...

Page 295: ...le Bearing Fasteners 3 Hook Block Overhaul Ball 14 Powertrain Hardware Inside Compartment 4 Boom Extension Hanger Hardware 15 Valve Bank 5 Pivot Shaft 16 Hoist Hose Connections 6 Hose Connections Inside Turntable 17 Tension Spring 7 All Hardware Clips Pins Hose Connections not painted Outrigger Pins Clips 18 Wire Rope 8 Outrigger Hose Connections 19 Counterweight Mounting Hardware 9 Hook Block Tie...

Page 296: ...MAINTENANCE AND LUBRICATION GRT9165 SERVICE MANUAL 9 52 Published 10 01 2020 Control 699 00 THIS PAGE BLANK ...

Page 297: ...Mounted Floodlights 3 22 Nose Sheaves 4 7 ODM Components 4 10 Pivot Pin Removal tool 4 4 Position Indicator Light 3 23 Removal 4 1 Second Cable Drum 4 10 Brake Hoist 5 8 Parking 8 21 System 8 13 C Cab Electrical Panels 3 2 Cab Tilt Pressure Checking 2 63 Cable Installing on Cable 5 2 Camera 3 23 Back up 3 24 Hoist 3 23 Right Rear 3 24 Carrier Electrical Panel 3 5 Manifold Valve 2 25 Valves Carrier...

Page 298: ...unt 7 3 Front Steer Pressure Checking 2 61 Front Steering Control Valve 8 9 Front Steering System 8 9 Front Wheel Alignment 8 4 Fuel Filter Water Separator 7 5 7 6 Fuel Pump Injection 7 5 Fuel System 7 5 Fuel Tank 7 5 G Grease Dielectric 3 9 H Hoist Area Access 5 2 Brake 5 8 Cable Installing on 5 2 Camera 3 23 Control Valves 5 10 Fluid Level Check 5 3 Installing 5 2 Maintenance 5 2 Motor 5 8 Motor...

Page 299: ...8 Jack Cylinder 8 29 Pressure Checking 2 65 Overhaul Ball 4 12 Overview of Manuals 1 1 P Park Brake Pressure Checking 2 67 Parking Brake 8 21 Pilot Supply Pressure 2 56 Piston Pump Cut off and Differential Pressures 2 54 Startup Procedure 2 17 Pressure Setting Procedures 2 52 Pump Filter DEF Supply 7 17 Pumps Hydraulic 2 14 Pushing 7 34 R Radiator 7 23 Fill and Service 7 25 Removal 7 24 RCL Light ...

Page 300: ...e 2 43 Gearbox 6 4 Lock Control 360 degree 6 19 Lock Pin 6 18 Manifold Valve 2 21 Motor 6 4 Work Pressure Checking 2 61 Swivel 6 13 Electrical 6 17 Hydraulic 6 15 Two Port Water 6 16 Symbols Hydraulic 2 2 T Telescope Cylinder Control Valve 2 48 Telescope Extend and Relief Pressures 2 59 Temperature Switches 2 8 Tires 8 7 Tool Boom Pivot Pin Removal 4 4 Torque Values 1 16 Towing 7 34 Transmission 7...

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