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Manitowoc Grove RT770E, Service Maintenance Manual

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Manitowoc Grove RT770E Service Maintenance Manual Download Page 125

3-1

Published 11/26/2014, Control # 447-05

RT770E SERVICE MANUAL

ELECTRICAL SYSTEM

3

GROVE

SECTION 3

ELECTRICAL SYSTEM

SECTION CONTENTS

Description  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-1

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-1
Alternator  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-3
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-3
Cab Electrical Panel . . . . . . . . . . . . . . . . . . . . . . .  3-3
Carrier Electrical Panel . . . . . . . . . . . . . . . . . . . . .  3-5

Maintenance  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-7

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-7
General Troubleshooting  . . . . . . . . . . . . . . . . . . .  3-8
Tools for Troubleshooting . . . . . . . . . . . . . . . . . . .  3-8
Troubleshooting Swivel-Caused Electrical

Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-8
Connector Troubleshooting  . . . . . . . . . . . . . . . . .  3-8
Alternator/Charging System Troubleshooting . . . .  3-9
Alternator Replacement  . . . . . . . . . . . . . . . . . . .  3-11
Starter Replacement . . . . . . . . . . . . . . . . . . . . . .  3-11
Battery Replacement  . . . . . . . . . . . . . . . . . . . . .  3-12

Relay Panel Component Replacement . . . . . . . . 3-12
Gauge Cluster Replacement . . . . . . . . . . . . . . . . 3-13
Rocker Switch Replacement . . . . . . . . . . . . . . . . 3-13
Ignition Switch Replacement . . . . . . . . . . . . . . . . 3-14
Turn Signal Lever and Transmission Shift

Lever Replacement . . . . . . . . . . . . . . . . . . . . . . . 3-15
Windshield Wiper Assembly Replacement  . . . . . 3-16
Windshield Washer Assembly Replacement . . . . 3-18
Skylight Wiper Assembly Replacement . . . . . . . . 3-18
Tools for Troubleshooting  . . . . . . . . . . . . . . . . . . 3-19

Optional Equipment  . . . . . . . . . . . . . . . . . . . . . . . 3-19

Beacon Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Boom Mounted Floodlights  . . . . . . . . . . . . . . . . . 3-19
Rear View Mirror . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Air Conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Cold Weather Operation  . . . . . . . . . . . . . . . . . . . 3-19

DESCRIPTION

General

The electrical system is 12-volt operation with 12-volt
starting, consisting of an alternator and three lead-acid
batteries. Electrical power is transferred to and from the

carrier and superstructure through the electrical swivel. The
CAN bus system consists of many control modules which are
located on the carrier, superstructure, and operator’s cab.
Refer to Figure 3-1 for a list of the different control modules
and their locations. For more detailed information on the
electrical swivel, refer to 

Swing System

, page 6-1.

Summary of Contents for Grove RT770E

Page 1: ...e for qualifying personnel You read understand and follow the safety and operating recommendations contained in the crane manufacturer s manuals and load charts your employer s work rules and applicable government regulations You are sure that all safety signs guards and other safety features are in place and in proper condition The Operator Manual and Load Chart are in the holder provided on cran...

Page 2: ... install valve in each of the following lines if present Extend between main directional valve and stage select valve Retract between main directional valve and cylinder retract port Fill Tube between fill valve and cylinder port Drain between case drain and tank port on cylinder 7 Close all valves 8 Repeat steps 1 thru 5 Verify zero drift 9 Open Drain Tank valve 10 Repeat steps 1 thru 5 Drift on ...

Page 3: ...Service Maintenance Manual Grove RT770E ...

Page 4: ......

Page 5: ...e 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 safety...

Page 6: ...e known to the State of California to cause cancer birth defects and other reproductive harm CALIFORNIA PROPOSITION 65 WARNING Battery posts terminals and related accessories contain chemical lead and lead compounds chemicals known to the State of California to cause cancer birth defects or other reproductive harm Wash hands after handling ...

Page 7: ...ion 1 3 Engine 1 3 Axles 1 3 Brakes 1 3 Wheels and Tires 1 3 Swing Gearbox 1 3 Boom 1 3 Swivel Assembly 1 3 Hydraulic Pumps 1 3 Hoists 1 4 Crane Nomenclature 1 7 General Maintenance 1 9 Cleanliness 1 9 After Cleaning 1 9 Removal and Installation 1 9 Disassembly and Assembly 1 9 Pressing Parts 1 10 Locking Devices 1 10 Wires and Cables 1 10 Shims 1 10 Hoses and Tubes 1 10 Bearings 1 11 Gaskets 1 11...

Page 8: ...10 Troubleshooting Aids 2 12 Troubleshooting Procedures 2 12 Hydraulic Oil Return Filter Assembly 2 13 Fill Cap Breather 2 13 Oil Cooler 2 15 Description 2 15 Oil Temperature Switches 2 15 Maintenance 2 15 Hydraulic Pumps 2 17 Description 2 17 Maintenance 2 17 Pump Disconnect Assembly 2 21 Disassembly 2 21 Assembly 2 21 Pressure Setting Procedures 2 23 Procedure A Main Control Valve Reliefs 2 24 P...

Page 9: ...on Lockout Valve 2 53 Description 2 53 Maintenance 2 53 High Speed Boost Selector Valve 2 54 Description 2 54 Maintenance 2 54 Telescope Stage Selector Valve Manifold 2 55 Description 2 55 Maintenance 2 55 Telescope Fill Tube Control Valve Manifold 2 56 Description 2 56 Maintenance 2 57 Hydraulic Accumulator 2 58 Description 2 58 Maintenance 2 58 Service Brake and CAC Fan Motor Priority Flow Contr...

Page 10: ...roblems 3 8 Connector Troubleshooting 3 8 Alternator Charging System Troubleshooting 3 9 Alternator Replacement 3 11 Starter Replacement 3 11 Battery Replacement 3 12 Relay Panel Component Replacement 3 12 Gauge Cluster Replacement 3 13 Rocker Switch Replacement 3 13 Ignition Switch Replacement 3 14 Turn Signal Lever and Transmission Shift Lever Replacement 3 15 Windshield Wiper Assembly Replaceme...

Page 11: ... 45 Description 4 45 Boom Extension Rigging Mode 4 45 Erecting the Boom Extension 4 45 Stowing the Boom Extension 4 52 Setting the Folding Swingaway Offset 4 54 Boom Extension Alignment Device Adjustment 4 55 Swingaway Mounting Adjustment 4 55 Hook Block 4 56 Description 4 56 Maintenance 4 56 SECTION 5 Hoist and Counterweight Description 5 1 Theory of Operation 5 1 Maintenance 5 2 Warm up Procedur...

Page 12: ...N 6 Swing System Description 6 1 Theory of Operation 6 1 Swing Drive 6 1 Swing Brake 6 1 Maintenance 6 3 Swing Motor 6 7 Description 6 7 Maintenance 6 7 Swing Gearbox And Brake 6 8 Description 6 8 Maintenance 6 8 Swing Bearing 6 10 Description 6 10 Maintenance 6 10 Swivels 6 15 Description 6 15 Hydraulic Swivel 6 17 Description 6 17 Theory Of Operation 6 17 Maintenance 6 17 Two Port Water Swivel 6...

Page 13: ...nance 7 26 Troubleshooting Procedures 7 26 Towing or Pushing 7 29 SECTION 8 Undercarriage Axles 8 1 Description 8 1 Maintenance 8 2 Wheels And Tires 8 4 Typical Wear Patterns 8 4 Steering Systems 8 7 Description 8 7 Theory Of Operation 8 7 Maintenance 8 8 Rear Steering System 8 9 Troubleshooting 8 9 Hydraulic Pumps 8 10 Front Steering Control Valve 8 10 Integrated Outrigger Rear Steer Control Valv...

Page 14: ...brication General 9 1 Environmental Protection 9 1 Lubricants and Lubrication Intervals 9 1 Standard Lubricants 9 2 Arctic Lubricants and Conditions 9 3 Surface Protection for Cylinder Rods 9 6 Wire Rope Lubrication 9 6 lubrication Points 9 7 CraneLUBE 9 7 Safety 9 7 Steering and Suspension 9 8 Axles 9 10 Drive Train 9 12 Drive Train continued 9 14 Turntable 9 16 Outriggers 9 18 Boom 9 20 Boom con...

Page 15: ...s 1 16 Weld Studs 1 19 Wire Rope 1 20 General 1 20 Environmental Conditions 1 20 Dynamic Shock Loads 1 20 Lubrication 1 20 Precautions and Recommendations During Inspection or Replacement 1 20 Wire Rope Inspection Running Ropes and Pendant Cables 1 21 Wire Rope Inspection Boom Extension and Retraction Cables 1 22 Wire Rope Inspection Replacement All Wire Rope 1 22 Seizing Wire Rope 1 23 Installing...

Page 16: ...rates an all welded parallel box construction steel frame utilizing two drive steer axles Axle steering is accomplished utilizing hydraulic steer cylinders The engine is mounted at the rear of the crane carrier and provides motive power through a six speed forward and reverse transmission The outriggers are single stage double box telescopic beam type outriggers The superstructure is capable of 36...

Page 17: ... Charge Pump Capacity 76 L min 20 gpm 2000 rpm Transmission Gear Ratios Forward and Reverse Low Range 1st 12 59 2nd 6 06 3rd 2 22 High Range 4th 4 33 5th 2 08 6th 0 76 Engine Cummins QSB 6 7 Type 4 cycle Diesel Turbocharged Number of Cylinders 6 Horse Power Rating 179 kW 240 hp 2500 rpm Oil Pan Capacity 15 6 L 18 5 qt Coolant System 38 L 40 qt Axles Total Ratio 24 817 1 Carrier Ratio 5 86 1 Planet...

Page 18: ...rol 447 05 Hoists Drum Dimensions Diameter 381 mm 15 in Length Standard 467 mm 18 38 in Cable Diameter 19 mm 0 75 in Length Main 198 m 650 ft Length Aux 199 m 653 ft Max Permissible Line Pull 6x36 74 7 kN 16 800 lb Max Single Line Speed 153 m min 500 fpm FIGURE 1 1 ...

Page 19: ...om Extension 665 73 262 10 1132 2495 1854 4087 722 1592 10 0 m 33 ft Fixed Boom Extension 739 42 291 11 782 1723 1422 3135 640 1412 Boom Extension Carrier Brackets Bolt On Bi fold Ext 561 34 221 00 133 293 184 405 51 112 Boom Extension Carrier Brackets Bolt On Fixed Ext 581 66 229 00 104 229 149 328 45 99 Auxiliary Boom Nose Installed 1191 26 469 00 59 130 173 381 101 223 6 1 m 20 ft Boom Ext Inse...

Page 20: ...e IPO Cwt with Aux Hoist and Cable 143 00 56 30 258 568 91 200 348 768 Rem Removable Counterweight System Ctwt only 138 84 54 66 6729 14835 2299 5068 9028 19903 Rem Main Hoist Cable 198 m 650 ft of 3 4 in 6x37 66 04 26 00 307 676 50 110 357 786 Rem Aux Hoist Cable 153 m 502 ft of 3 4 in 35x7 149 86 59 00 278 612 103 226 380 838 Sub Optional Cable on Main Hoist 199 m 653 ft of 3 4 in 35x7 66 04 26 ...

Page 21: ...1 7 Published 11 26 2014 Control 447 05 RT770E SERVICE MANUAL INTRODUCTION 1 GROVE Crane Nomenclature FIGURE 1 2 8251 2 18 17 15 14 12 13 20 26 25 24 22 21 16 11 1 2 3 4 5 10 9 6 7 8 1 23 8251 1 12 ...

Page 22: ...cess Platform Fixed Counterweight Units Only 8 Main Hoist 9 Auxiliary Hoist 10 Counterweight 11 Muffler 12 Outrigger Jack Cylinder 13 Battery Item Description 14 Fuel Tank 15 Crane Steps 16 Boom Pivot Pin 17 Hydraulic Valves and Swing Motor Cover 18 Swingaway Extension 19 Auxiliary Boom Nose 20 Job Extension 21 Outrigger Pads 22 Lift Cylinder 23 Front Axle 24 Hydraulic Fuel Tank 25 Rear Axle 26 Ai...

Page 23: ...r a 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 po...

Page 24: ...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 Damage...

Page 25: ...ool 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 out...

Page 26: ...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 27: ...ting 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 for size and type of fitting 6 Optionally for future t...

Page 28: ...onadjustable 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 scratches or any foreign particles 2 Lubricate O ring with clean oil Figure 1 6 3 Turn fitting until finger tight 4 Using the assembly torque method tighten to given torque for size from Table 1 5 Table 1 5 Straight Thread ...

Page 29: ...nterweight support structures Chassis axle and suspension mounting structures Hydraulic cylinder end connections The above is provided only as a guide and your inspection plan should not be limited to the areas listed A thorough visual inspection of all weldments is good practice Anyone requiring more detailed inspection instructions and or repair procedures may request same by contacting your loc...

Page 30: ...ossible to the torque values shown to allow for wrench calibration tolerance Torque Wrenches Flexible beam type wrenches even 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 valu...

Page 31: ... Untreated 5 9 0 7 7 19 17 32 30 52 48 78 72 114 106 156 144 270 249 416 384 606 560 813 751 1141 1053 2028 1865 8 12 5 11 5 26 24 48 44 73 67 120 110 161 143 234 216 385 355 615 567 929 857 1342 1234 2043 1885 3276 3024 Bolt Diameter Inches Torque Values Pounds Foot Maximum Minimum SAE Grade 1 4 5 16 3 8 7 16 1 2 9 16 5 8 3 4 7 8 1 1 1 8 1 1 4 1 1 2 Zinc Flake 5 8 15 28 44 66 95 132 229 364 543 7...

Page 32: ... 1046 1538 1420 10 9 4 5 4 1 9 2 8 5 16 14 26 24 38 35 75 69 130 120 212 195 322 298 455 418 629 581 856 790 1089 1005 1591 1469 2163 1997 12 9 5 4 4 9 11 10 19 17 31 28 45 42 89 83 156 144 248 228 387 357 532 490 756 698 1029 949 1306 1206 1910 1763 2595 2395 Bolt Diameter Metric Torque Values Nm Class M8x1 M10x1 M10x1 25 M12x1 5 M14x1 5 M16x1 5 M18x1 5 M20x1 5 M22x1 5 M24x2 M27x2 M30x2 M33x2 M36...

Page 33: ...s for Stainless Steel Fasteners with Oil Lubrication NOTE Stainless steel fasteners tend to gall while being tightened To reduce this risk lubricate the threads with oil or molybdenum disulfide and torque at low speeds without interruptions Do not use excessive pressure Impact wrenches are not recommended Weld Studs Unless otherwise specified the following grade 2 torque values 10 apply Table 1 14...

Page 34: ...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 35: ...pe 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 be...

Page 36: ...s 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 connection...

Page 37: ...o 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 anne...

Page 38: ...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 l...

Page 39: ...ylene torch The cut is to be made in such a way that both ends of the rope are completely fused so that all inner and outer strands are bonded together preventing any movement between strands NOTE The outer strands must not be allowed to move with respect to the inner strands The fused end must not exceed the diameter of the rope 3 Once the cuts have been completed the seizing bands are to be left...

Page 40: ...INTRODUCTION RT770E SERVICE MANUAL 1 26 Published 11 26 2014 Control 447 05 THIS PAGE BLANK ...

Page 41: ... D Brake Charge Supply Valve Relief Pressure 2 25 Procedure E Charge Air Cooler Valve Relief Pressure 2 26 Procedure F Brake Dual Accumulator Charge Valve Pressure Limits 2 26 Procedure G Accumulator Pre Charge Pressure 2 26 Procedure H PreCharging The Accumulator 2 27 Procedure I Swing Valve Work Port Reliefs Pressure 2 27 Procedure J Front Steer Relief Valve Pressure 2 28 Procedure K Outrigger R...

Page 42: ...68 Axle Oscillation Lockout Cylinder 2 69 Description 2 69 Maintenance 2 69 Steer Cylinder 2 72 Description 2 72 Maintenance 2 72 Outrigger Extension Cylinder 2 75 Description 2 75 Maintenance 2 75 Outrigger Jack Cylinder 2 78 Description 2 78 Maintenance 2 78 Counterweight Removal Cylinder 2 81 Description 2 81 Maintenance 2 81 DESCRIPTION This section describes the hydraulic system the component...

Page 43: ... 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 Filter Removes contamination from hydraulic fluid Filter with Bypass Valve Bypass valve allows hydraulic fluid to bypass the filter if the filter becomes clogged Accumulator Used to either develop flow or absorb shock Check Valve Creates b...

Page 44: ...h 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 pushes barrel out...

Page 45: ...ighten the 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 ...

Page 46: ...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 770 L 190 gal Ensure the crane is level and in the travel mode of operation when the hydraulic system is being filled The system must be fille...

Page 47: ...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 affected va...

Page 48: ...ose 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 direct...

Page 49: ...hat will alert the operator to a high hydraulic oil temperature condition The switch is normally closed and will open and cause the circuit to lose ground when the hydraulic oil temperature exceeds 93 C 200 F When the circuit loses ground the CAN bus system will turn on power to illuminate the Hydraulic Oil High Temperature Indicator in the gauge display in the operator s cab See Section 3 Operati...

Page 50: ...2 pump The No 2 hydraulic pump supplies the front steer swing directional control valve A load sense flow divider located in the swing directional control valve ensures the front steer valve gets priority flow upon demand and the swing directional control valve gets any excess flow No 3 Pump The torque converter drives the No 3 pump The No 3 hydraulic pump supplies the service brake dual accumulat...

Page 51: ...cessive engine speed b Regulate engine speed c Air entering at suction lines c Check all lines for security and proper repair Tighten repair or replace as needed 4 Excessive pressure buildup a System relief valve set too high a Using adequate pressure gauge adjust system relief valve as necessary b Restricted pump to control valve supply line b Clean repair or replace line as necessary 5 Specific ...

Page 52: ... 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 also be...

Page 53: ...t 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 Insta...

Page 54: ...ol 447 05 7834 1 5 6 3 7 8 4 2 10 9 11 12 13 FIGURE 2 2 Item Description 1 Filter Head 2 Bowl w Extension 3 Gauge Assembly 4 Square O ring 5 Gasket 6 Element 7 Cap Item Description 8 O ring 9 Capscrew 10 Bypass Valve Assembly 11 Spacer 12 Capscrew 13 Washer ...

Page 55: ...mperature switch will open causing the CAN bus system to increase the RPM of the oil cooler fan motor to high The hydraulic oil high temperature indicator switch is normally closed and will open when the hydraulic oil temperature reaches 87 8 C 190 F causing the CAN bus system to turn on the hydraulic oil high temperature indicator in the gauge cluster to alert the operator to the condition The te...

Page 56: ...2 16 Published 11 26 2014 Control 447 05 FIGURE 2 3 5 1 2 3 6 7 4 7839 Item Description 1 Outlet Port 2 Fan Motor 3 Inlet Port 4 Drain Port Item Description 5 Temperature Switch 6 Transmission Oil Cooler 7 Hydraulic Oil Cooler ...

Page 57: ...rque converter Remove the pump 5 Clean the gasket material from the drive pad on the torque converter and the pump 6 Cover the drive pad s opening to prevent dirt from entering No 1 Pump Installation 1 Clean the drive pad and the pump with Loctite cleaning solvent 7070 or similar non chlorinated solvent 2 Apply a light coating of Loctite primer N7649 to drive pad and pump mounting surface Allow pr...

Page 58: ...ey seat properly on the drive pad 7 Route pump and its gasket on the studs Make sure the pump s splined drive shaft meshes with the pump disconnect assembly s splined coupler Press the pump and its gasket into place so they seat properly on the pump disconnect assembly 8 Secure pump drive assembly and pump to torque converter drive pad with nuts and washers Torque nuts refer to Fasteners and Torqu...

Page 59: ...eplacement for pump start up procedure Testing After Repair or Replacement 1 Ensure the reservoir is filled with the proper hydraulic fluid to the high level mark on the reservoir sight gauge 2 Ensure no air is entering the pump inlet and that the pump suction or inlet fluid is not bleeding back to the reservoir when the engine is stopped by making sure all suction or inlet lines are air tight 3 R...

Page 60: ...ise it is probably sucking air into its inlet keeping it from priming In case of abnormal noise stop engine and inspect the pump and the suction line for a loose connection a leak or a damaged or missing O ring 7 If the pump seems to be running properly increase the RPM to 1500 to 1800 rpm for one to two minutes while operating no hydraulic functions Repeat checks in steps 4 5 and 6 8 Increase eng...

Page 61: ...shaft 3 Pin collar to shaft with roll pin 4 Install shifter lock on handle 5 Install handle on free end of shaft Pin handle to shaft with roll pin 6 Adjust shifter lock so handle can lock it into the IN detent position and into the OUT detent position Then place handle at the OUT position 7 Pin shifter assembly to shaft with roll pin 8 Verify shifting parts shift properly In other words verify the...

Page 62: ...14 Control 447 05 7528 FIGURE 2 5 1 7530 2 6 9 10 3 4 8 5 11 2 7 Item Description 1 Pump Disconnect Assembly 2 Housing 3 Shaft 4 Oil Seal 5 Handle 6 Collar Item Description 7 Shifter Assembly 8 Shifter Lock 9 Roll Pin 10 Plug 11 Pipe Plug 12 Engine ...

Page 63: ...ion Load Sense Relief 27 6 4000 0 4 50 Main Control Valve Inlet Gauge Port Lift Down Relief 13 8 2000 4 8 0 700 0 Telescope Retract Relief 24 1 3500 0 4 50 Main Control Valve Telescope Retract Port Telescope Extend Relief 18 6 2700 0 4 50 Main Control Valve Telescope Extend Port Hoist Raise 24 1 3500 0 4 50 Main Control Valve Hoist Raise Port Hoist Lower 24 1 3500 0 4 50 Main Control Valve Hoist L...

Page 64: ...re gauge 4 Install pressure check diagnostic quick disconnect with gauge onto test nipple at main directional control valve load sense relief test port Figure 2 7 Disconnect Hoist Brake Release Line FIGURE 2 6 6659 1 Right Side View of Main Hoist FIGURE 2 7 8252 8 7 1 9 10 6 5 4 3 2 11 Item Description 1 Auxiliary Hoist Down Port Relief 2 Main Hoist Down Port Relief 3 Load Sense Relief Test Port 4...

Page 65: ...the load sense test port Procedure B Main Directional Control Valve Pilot Supply Pressure 1 Install pressure check diagnostic quick disconnect with gauge onto test nipple at pilot supply test port Figure 2 7 2 Disconnect the hoist brake release line at the main hoist Figure 2 6 Cap fitting and plug hose 3 While attempting to hoist down with the engine running at full RPM check the pilot supply pre...

Page 66: ...20 psi 72 145 when the valve stops charging The accumulator charge valve is non adjustable 4 With the engine running bleed off the hydraulic pressure stored in the accumulators by pushing the service brake pedal on the cab floor until the gauge reads about 134 bar 1950 psi Listen to hear when the service brake dual accumulator charge valve starts to recharge Push the service brake pedal once more ...

Page 67: ...e accumulator gas valve and tighten to 1 1 to 1 7 Nm 10 to 15 lb in 5 Turn the gas chuck T handle all the way in clockwise which will depress the core in the gas valve 6 Crack open the nitrogen bottle valve and slowly fill the accumulator Shut off the valve when the pre charge pressure is 62 bar 4 0 900 psi 50 0 7 If the pre charge pressure is higher than 62 bar 4 0 900 psi 50 0 close the nitrogen...

Page 68: ... relief valve to 172 bar 4 2500 psi 50 3 Remove pressure gauge from the pressure check port Procedure L Hydraulic Oil Cooler Fan Motor Control Valve 1 Make sure that machine is up to operating temperature then unplug oil cooler valve solenoid located near oil cooler fan motor to assure fan is running at full speed 2 Run the engine at idle and using a photo tachometer adjust flow control valve unti...

Page 69: ...t with gauge onto test nipple at main directional control valve load sense relief test port Figure 2 7 2 With engine at full RPM retract counterweight cylinder and set relief valve on counterweight valve Figure 2 15 to 121 bar 4 1750 psi 50 turn in to raise or out to lower pressure 3 Remove pressure gauge from main directional valve FIGURE 2 15 7532 3 Relief Valve ...

Page 70: ...ng Telescope Right Armrest Left Armrest Dual Accumulator Charge Valve Service Brakes Superstructure inside left side Swing Brake Armrest Lockout Manifold Swing Brake Release Crane Function Swing Each hoist swing lift and telescope controller circuit Superstructure right side Superstructure right side Holding Valves Lift Telescope Lift cylinder bolt on Telescope cylinder port blocks Carrier Integra...

Page 71: ... Carrier 5 7 Rear 9 Item Description 1 Front Outrigger Control Valve 2 Integrated Outrigger Rear Steer Valve 3 Fan Bypass Valve 4 Priority Flow Divider Valve 5 Adjustable Flow Valve Item Description 6 Park Brake Range Shift Valve 7 Differential Lock Valve Optional 8 Axle Lockout Valve 9 Rear Outrigger Control Valve ...

Page 72: ...IGURE 2 17 2 3 4 6 5 1 Item Description 1 Counterweight Removal Manifold 2 Directional Control Valve Hoist Lift Tele 3 Swing Brake and Armrest Lockout Manifold Item Description 4 Steering Priority Swing Control Valve 5 Dual Accumulator Control Valve 6 Telescope Fill Control Manifold ...

Page 73: ...ts all four working sections Maintenance Swing Steer Directional Valve Removal 1 Tag and disconnect the hydraulic lines from the valves Cap or plug the lines and ports 2 Remove the capscrews flatwashers and lockwashers and bushings securing the valve Remove the valve Swing Steer Directional Valve Installation 1 Install the valve on the turntable upright and secure with the capscrews flatwashers lo...

Page 74: ... FIGURE 2 18 1 2 3 12 4 6 27 5 7 17 19 28 10 18 23 16 25 21 26 25 30 14 25 22 24 24 20 24 31 24 15 12 13 25 29 13 25 15 25 26 27 25 16 17 25 18 19 23 8 9 28 10 24 7 24 6 24 5 24 4 1 2 3 14 31 33 32 20 21 22 11 11 Main Hoist Aux Hoist Lift Telescope Valve Assembly 9 ...

Page 75: ...ort 13 Pilot Drain 14 Port 1A Hoist Down 15 Port 1B Hoist Up 16 Port 3A Telescope Extend 17 Port 3B Telescope Retract Item Description 18 Port 4A Lift Extend 19 Port 4B Lift Retract 20 Relief Valve Auxiliary Hoist Up 21 Relief Valve Telescope Extend 22 Relief Valve Telescope Retract 23 Boom Lift Thermal Relief 24 Pilot to B Ports On Controller 25 Pilot to A Ports On Controller 26 Port 2A Auxiliary...

Page 76: ... 7 6 4 5 8 1 2 3 4 5 6 7 6671 2 6671 3A 2200 2200 2500 8 9 10 Item Description 1 Port 1A Load Sense 2 Port 1B Priority Flow 3 Inlet Port 4 Outlet Port 5 Port 2A Work Port Item Description 6 Port 2B Work Port 7 Steer Priority Flow Divider 8 Swing WP Relief Valve 9 Swing WP Relief Valve 10 Swing Directional Valve ...

Page 77: ...32 1 6 5 7 8 1 9 4 Counterweight Removal Manifold Item Description 1 Port P Pressure to Directional Valve 2 Port LS Load Sense 3 Port T Tank to Swivel Port 4 4 Pressure Compensated Regulator 5 Port 1A Solenoid Valve SV2 Item Description 6 Port 1B Solenoid Valve SV1 7 Port 2B Solenoid Valve SV3 8 Port 2A Solenoid Valve SV4 9 Load Shuttle ...

Page 78: ...ates both functions simultaneously The valve in the left armrest controls swing and telescope Pushing the control lever straight forward or back controls the telescope function Pushing the control lever to either side operates swing Positioning the lever diagonally operates both functions simultaneously NOTE If the crane is equipped with an optional auxiliary hoist the auxiliary hoist function rep...

Page 79: ...bracket Remove the valve Telescope Pedal Control Valve Installation With Auxiliary Hoist Option 1 Place the valve on the mounting bracket and secure in place with the bolts and washers 2 Connect the hydraulic lines to the valve as tagged during removal 3 Connect the pedal linkage to the control valve with the pin and cotter pin Telescope Pedal Control Valve Functional Check With Auxiliary Hoist Op...

Page 80: ...3 1 7393 2 6 10 3 7 11 4 8 12 SWING AUX HOIST TELESCOPE BOOM HOIST 10 9 8 12 7 11 2 1 1 2 3 4 5 6 6403 3 Left Right In Out Ext Retract Up Down 5 9 Item Description 1 P Port Pressure 2 T Port Tank 3 A Port Hoist Down 4 B Port Hoist Up 5 A Port Boom Retract 6 B Port Boom Extend Item Description 7 B Port Telescope Out 8 A Port Telescope In 9 A Port Swing Right 10 B Port Swing Left 11 A Port Aux Hoist...

Page 81: ...t A2 Auxiliary Hoist Cable Out 7 Port B2 Boom Lift Up 8 Port B1 Boom Lift Down 9 Port A1 Main Hoist Cable In 10 Port A2 Main Hoist Cable Out Left Forward Right 1 3 4 2 FIGURE 2 22 Back Right Back Forward Left Back Forward 9 8 7 6 5 10 5 9 4 8 6 10 3 7 2 1 6671 2 6676 Telescope Foot Controller Item Description 1 Telescope In 2 Pressure Port 3 Telescope Out 4 Port To Tank FIGURE 2 23 3 4 2 1 2 4 1 3...

Page 82: ...arge flow to charge the accumulators When the cut out setting of 160 bar 2320 psi is reached the cut in cut out spool shifts to vent the LS line to tank The sequence valves isolate the two accumulators If one of the accumulator loses pressure the other accumulator will continue to charge and provide flow to the brake circuit when required Maintenance Removal 1 Tag and disconnect the hydraulic hose...

Page 83: ...6 2014 Control 447 05 FIGURE 2 24 Valve Hydraulic Schematic 7752 01 7752 02 7752 03 4 6 2 1 3 5 Item Description 1 Load Sense Port 2 Tank Port 3 Pressure Port 4 Accumulator Port 1A 5 Accumulator Port 2A 6 Pressure Switch 4 6 2 1 3 5 These ports plugged ...

Page 84: ...lockout valve manifold 2 Tag and disconnect the hydraulic lines from the manifold Cap or plug the lines and ports 3 Remove the capscrews lockwashers and flatwashers securing the manifold Remove the manifold and two spacer bushings Installation 1 Position the manifold and spacer bushings on turntable and secure with the capscrews flatwashers and lockwashers Torque capscrews refer to Fasteners and T...

Page 85: ...blished 11 26 2014 Control 447 05 FIGURE 2 25 1 2 3 4 5 3 2 1 4 5 7540 2 7540 1 Item Description 1 Port P Inlet Port 2 Port G Gauge Port 3 Port REG 1 Swing Brake Release Item Description 4 Port REG 2 Controller Armrest Lockout Valve 5 Drain ...

Page 86: ...cate the holding valve and O rings with clean hydraulic oil NOTE The holding valve should turn by hand until compression of the O rings begins 4 Carefully install the holding valve into the port block or manifold until fully seated 5 Test the holding valve and port block or manifold by operating the lift cylinder and or the telescope cylinder as applicable Verify lift cylinder and or telescope cyl...

Page 87: ...valve is normally open bypassing oil from the inlet port to the tank port Activation of either the outriggers or the rear steer energizes the solenoid valve to close and allow oil to flow to the selected circuit The rear steer section contains a three position four way solenoid controlled directional valve The outrigger section contains a three position four way solenoid controlled directional val...

Page 88: ...alue 2 Connect the hydraulic lines to the integrated outrigger rear steer valve as tagged during removal 3 Connect the electrical connectors to the integrated outrigger rear steer valve as tagged during removal Functional Check 1 Cycle an outrigger cylinder several times Verify the cylinder extends and retracts properly 2 Rear steer the crane to the left and to the right several times Verify the c...

Page 89: ...uator which allows the valve to be opened if there is a loss of electrical power FIGURE 2 27 6544 2 6544 1 2 7 2 3 3 4 5 1 1 4 6 5 7 8 9 6 8 9 Item Description 1 Solenoid Valve Left Front or Left Rear Extension Cylinder 2 Solenoid Valve Left Front or Left Rear Jack Cylinder 3 Solenoid Valve Right Front of Right Rear Jack Cylinder 4 Solenoid Valve Right Front or Right Rear Extension Cylinder 5 Inle...

Page 90: ...urity 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 ...

Page 91: ...tor while the B port is drained to the reservoir along with the axle disconnect actuator for two wheel drive high range When the solenoid is energized pressurized oil is directed to the B port of the range shift actuator and the axle disconnect actuator while port A of the range shift actuator is drained to the reservoir for four wheel drive low range Maintenance Removal 1 Tag and disconnect the e...

Page 92: ...3 2 4 5 6 7 8 6697 2 6697 1 Hydraulic Schematic FIGURE 2 28 Item Description 1 Port P Pressure 2 Port T Tank 3 Port A Range Shift Actuator 4 Port B Range Shift Actuator Item Description 5 Port PB To Park Brake 6 Solenoid Valve Range Shift 7 Solenoid Valve Park Brake 8 Pressure Switch ...

Page 93: ...tches OFF the digital output thus de energizing the axle oscillation solenoids When the axle oscillation normally closed solenoid valves are de energized the lockout cylinders are isolated from hydraulic oil supply This keeps the cylinders from oscillating moving up and down to damp axle movement because hydraulic oil cannot leave the cylinders Instead the cylinders remain full of hydraulic oil an...

Page 94: ...two way two position solenoid valve and a pilot to close poppet check valve Maintenance Removal 1 Tag and disconnect the electrical connectors to the valve 2 Tag and disconnect the hydraulic hoses from the valve Cap or plug the lines and ports 3 Remove the hydraulic fitting securing the valve to the 6 port of the hydraulic swivel spool Remove the valve Installation 1 Install the valve to the 6 por...

Page 95: ...d stage Whether extending or retracting pilot oil from one of the working lines passes through the shuttle valve s to the solenoid controlled directional control valve which diverts the pilot oil to close the appropriate poppet valve which then allows oil to flow to or from the selected cylinder stage through the other poppet valve Maintenance Removal 1 Tag and disconnect the electrical connectors...

Page 96: ...ased on inputs from the cylinder length sensing components will cause the relief valve to maintain a low pressure 100 psi if the first stage is fully retracted or a high pressure 2200 psi if the first stage is fully extended Conversely the Telescope Fill Tube Control Valve Manifold also prevents the first stage from extending as the second stage retracts by varying the excess flow it receives from...

Page 97: ... Remove the capscrews lockwashers flatwashers and nuts securing the valve to the frame Remove the valve Installation 1 Secure the valve to the frame with the nuts flatwashers lockwashers and capscrews Torque capscrews refer to Fasteners and Torque Values page 1 16 for proper torque value 2 Connect the hydraulic hoses to the ports on the valve as tagged during removal 3 Connect the electrical conne...

Page 98: ...onsists of a piston seals gas valve and a gas valve guard Maintenance Removal 1 With the engine shutdown deplete the hydraulic pressure in the accumulators by depressing the service brake pedal several times 2 Tag and disconnect the hydraulic hose from the accumulator Cap or plug the line and port 3 Remove the two nuts securing each clamp half Remove each clamp half and accumulator from the turnta...

Page 99: ...r cooler fan motor Maintenance NOTE Maintenance procedures are limited to the removal and replacement of the valve Removal 1 Tag and disconnect the hydraulic lines attached to the valve Cap or plug the lines and ports 2 Remove the capscrews washers flatwashers and nuts securing the valve to the valve mounting plate and remove the valve Installation 1 Place the priority flow control valve on the mo...

Page 100: ...rs flatwashers and nuts securing the valve to the valve mounting plate and remove the valve Installation 1 Place the priority flow control valve on the mounting plate and secure it with the capscrews washers flatwashers and nuts Torque capscrews refer to Fasteners and Torque Values page 1 16 for proper torque value 2 Connect the hydraulic lines to the valve as tagged during removal 3 Start the cra...

Page 101: ...posed rods protected more frequently by applying a protectant Unless the machine is operated daily exposed rod surfaces will corrode Some cylinders will have rods exposed even when completely retracted Assume all cylinders have exposed rods as corrosion on the end of the rod can ruin the cylinder It is recommended that all exposed cylinder rods be protected using Boeshield T 9 Premium Metal Protec...

Page 102: ...g smoothly Proper boom lubrication and wear pad adjustment is important to permit the boom sections to slide freely Slow movement of the boom may be undetected by the operator unless a load is suspended for a long period of time To minimize the effects of thermal contraction or Stick slip it is recommended that the telescope control lever is activated periodically in the extend position to mitigat...

Page 103: ...Length change in inches Stroke Ft X Temperature Change F X Coeff in 3 in 3 F X 12 in ft Coeff 0 000774 1 C STROKE Temperature Change C m 5 10 15 20 25 30 35 40 45 50 55 1 5 5 81 11 61 17 42 23 22 29 03 34 83 40 64 46 44 52 25 58 05 63 86 3 11 61 23 22 34 83 46 44 58 05 69 66 81 27 92 88 104 49 116 10 127 71 4 5 17 42 34 83 52 25 69 66 87 08 104 49 121 91 139 32 156 74 174 15 191 57 6 23 22 46 44 6...

Page 104: ...eplacement seals and rings improperly 7 Remove the setscrew securing the piston to the rod 8 Unscrew the piston from the rod 9 Remove the piston seal from the inside of the piston 10 Remove the head from the rod 11 Remove the O ring and backup ring from the outside of the head and the wear rings buffer seal and deep Z rod seal from the inside of the head 12 Remove and discard the two threaded inse...

Page 105: ... 11 26 2014 Control 447 05 FIGURE 2 34 21 26 17 27 1 10 11 29 19 14 18 13 12 16 9 4 3 5 7 22 23 25 24 25 20 28 2 6 15 21 26 Item Description 1 Barrel 2 Rod 3 Piston 4 Head Item Description 5 Holding Valve 6 Retaining Ring 7 Seal Assembly 8 Not Used ...

Page 106: ... Screw the piston onto the rod tightly Secure the piston with the setscrew 11 Install the replacement hydrolock seals on the outside of the piston Figure 2 36 Make sure the vees on the two hydrolock seals point at each other 12 Lubricate all parts freely with clean hydraulic oil Item Description 9 T Seal 10 O ring Low Temperature 11 Back up Ring 12 Wear Ring 13 Seal 14 Rod Seal 15 Back up Ring 16 ...

Page 107: ...ad retainer ring to the head with two socket head capscrews Torque screws to 60 to 65 Nm 44 to 48 lb ft 16 Using a spanner wrench or chain wrench continue to screw the retainer ring head into place in the barrel 17 Position the holding valve on the cylinder barrel and secure with screws and washers 18 Connect the tubing to the holding valve 19 Pressurize and cycle the cylinder with hydraulic oil p...

Page 108: ...PE CYLINDER Description The boom telescope cylinder is not field serviceable and must be returned to the manufacturer for repair The cylinder with oil weighs approximately 1745 kg 3847 lb retracted Maintenance For removal and installation instructions refer to Boom page 4 1 ...

Page 109: ...oid contamination 10 Remove the retaining ring from the rod 11 The head can be pulled off the rod assembly by hand NOTE Arranging discarded seals and rings in the order of disassembly will aid in installation of new seals and rings Pay attention to how each seal and ring is installed to avoid installing replacement seals and rings improperly 12 Remove the wear rings and lip seals from the outside ...

Page 110: ...8 4 6 2 9 17 10 5 11 1 12 13 14 15 16 17 5 Item Description 1 Barrel 2 Rod 3 Head 4 Lip Seal 5 Wear Ring 6 O ring 7 Backup Ring 8 Wear Ring 9 Buffer Seal Item Description 10 Lip Seal 11 Wiper Ring 12 Retainer Ring 13 Bleeder Plug 14 Grease Fitting 15 Grease Fitting 16 Setscrew 17 O ring ...

Page 111: ...lace the spanner wrench on the head and turn counterclockwise until the thread clicks then reverse direction to clockwise and thread in until there is no gap between the shoulder of the head and the top of the barrel 9 Install the retaining ring 10 Make sure the setscrew hole is clean of all debris Using a screwdriver or 1 4 inch wrench install the setscrew in the head 11 Pressurize and cycle the ...

Page 112: ...cknut from the rod 10 Remove the O ring from the rod 11 The head piston and spacer can be pulled off the rod assembly by hand NOTE Arranging discarded seals and rings in the order of disassembly will aid in installation of new seals and rings Pay attention to how each seal and ring is installed to avoid installing replacement seals and rings improperly 12 Remove the wear ring and piston seal from ...

Page 113: ...ontrol 447 05 FIGURE 2 38 7548 13 12 11 10 2 7 6 5 4 3 8 9 1 15 14 Item Description 1 O ring 2 O ring 3 Backup Ring 4 Wiper RIng 5 Seal 6 O ring 7 Seal 8 Wear Ring Item Description 9 Locknut 10 Retainer Ring 11 Grease Fitting 12 Barrel 13 Rod 14 Piston 15 Head ...

Page 114: ...ls on the piston and head with clean light hydraulic oil and lower the assembly into the barrel Stop just before the head enters the barrel 9 Place the spanner wrench on the head and turn counterclockwise until the thread clicks then reverse direction to clockwise and thread in until there is no gap between the shoulder of the head and the top of the barrel 10 Pressurize and cycle the cylinder wit...

Page 115: ... seals and rings in the order of disassembly will aid in installation of new seals and rings Pay attention to how each seal and ring is installed to avoid installing replacement seals and rings improperly 11 Remove the wear rings and piston seal from the outside of the piston 12 Remove the O ring and backup ring from the outside of the head Remove the rod seal wear ring and wiper ring from the ins...

Page 116: ...ntrol 447 05 FIGURE 2 39 14 13 12 11 10 8 9 1 2 3 4 5 6 7 6931 15 8 Item Description 1 Barrel 2 Rod 3 Piston 4 Head 5 Spacer 6 Nut 7 Piston Seal 8 Wear Ring Item Description 9 O ring 10 O ring 11 Backup Ring 12 Rod Seal 13 Wiper Ring 14 Wear Ring 15 Cap ...

Page 117: ... and piston 7 Remove the cover from the barrel 8 Lubricate the OD of the seals on the piston and head with clean light hydraulic oil and lower the assembly into the barrel Stop just before the head enters the barrel 9 Place the spanner wrench on the head and turn counterclockwise until the thread clicks then reverse direction to clockwise and thread in until there is no gap between the shoulder of...

Page 118: ...age the surface of the rod Cover the barrel opening to avoid contamination 7 Remove the piston seal to gain access to the setscrew Using a 3 16 inch allen wrench remove the setscrew from the piston 8 Turn the piston counterclockwise and remove with a fitted spanner wrench 9 Remove the spacer and head from the rod 10 Remove the seals from the outside of the piston and the back up rings and O ring f...

Page 119: ... 6801 4 3 1 6 2 5 9 16 12 15 14 13 18 10 10 11 17 7 8 Item Description 1 Barrel 2 Rod 3 Head 4 Piston 5 Spacer 6 Check Valve 7 Setscrew 8 Nylon Insert 9 Plug Item Description 10 Backup Ring 11 O ring 12 Wiper Ring 13 Rod Seal 14 Buffer Seal 15 Wear RIng 16 O ring 17 Backup Ring 18 Seal ...

Page 120: ... and the top of the barrel 12 Install the setscrew with a 5 32 inch allen wrench until hand tight 13 Slowly lower the rod to the fully retracted position NOTE Oil or oil air mixture may rapidly exit out of the ports during retract Shield the work area from the exiting oil 14 Install the plugs Test 1 Set test stand pressure to 310 1 bar 4500 psi 2 Attach hose fittings to cylinder 3 Connect a ball v...

Page 121: ... outside of the piston 7 Remove the spacer from the rod 8 Remove the head from the rod 9 Remove the O rings and the backup ring from the outside of the head Remove the rod seal wiper ring and O ring from the inside of the head Inspection 1 Clean all parts with solvent and dry with compressed air Inspect all parts for serviceability 2 Inspect the barrel carefully for scoring If barrel is scored it ...

Page 122: ...19 8 5 10 11 12 14 13 15 16 2 4 6 9 7347 20 3 Item Description 1 Barrel 2 Rod 3 Head 4 Lug 5 Piston 6 Spacer 7 Nut 8 Bolt 9 Locknut 10 Holding Valve Item Description 11 O ring 12 Wear Ring 13 Piston Seal 14 O ring 15 Backup Ring 16 Rod Seal 17 Wiper Ring 18 Bleeder Plug 19 Plug 20 O ring ...

Page 123: ... holding valve 12 Lubricate the holding valve and O rings with clean hydraulic oil NOTE The holding valve should turn by hand until compression of the O rings begins 13 Carefully install the holding valve into the port block until fully seated 14 Install the rod end lug on the cylinder rod and secure with the bolts washers and nuts 15 Pressurize and cycle the cylinder with hydraulic oil pressure T...

Page 124: ...HYDRAULIC SYSTEM RT770E 2 84 Published 11 26 2014 Control 447 05 THIS PAGE BLANK ...

Page 125: ...ver and Transmission Shift Lever Replacement 3 15 Windshield Wiper Assembly Replacement 3 16 Windshield Washer Assembly Replacement 3 18 Skylight Wiper Assembly Replacement 3 18 Tools for Troubleshooting 3 19 Optional Equipment 3 19 Beacon Light 3 19 Boom Mounted Floodlights 3 19 Rear View Mirror 3 19 Air Conditioner 3 19 Cold Weather Operation 3 19 DESCRIPTION General The electrical system is 12 ...

Page 126: ...ELECTRICAL SYSTEM RT770E SERVICE MANUAL 3 2 Published 11 26 2014 Control 447 05 FIGURE 3 1 7983 ...

Page 127: ...ectrical schematic in the back of this manual for a diagram of the electrical system The cab electrical panel 6 Figure 3 4 contains the cab and superstructure relays fuse box wiring harness connector bulkhead RCL module RCL Override switch and the fast pulse buzzer alarm It is located inside the crane cab behind the operator s seat Access is gained to the back of the panel by removing the two scre...

Page 128: ...mponent 1 Diode Box 2 Fuse Box 3 Panel Screw 4 Fast Pulse Buzzer Alarm 5 RCL Override Switch 6 Electrical Panel 7 RCL Controller 8 CAN Junction Box 9 ACC Relay CAB and T T Modules Power KS1 10 ACC Relay Jib Stow RCL Override Jib Option 11 Relay Windshield Wiper Low Speed 12 Relay Windshield Wiper High Speed 13 CAB Module 14 Connector Bulkhead 15 Cab Interior Harness 16 Swivel Harness 17 Seat Harne...

Page 129: ...of the crane inside the battery box assembly The coil of the main power relay 1 Figure 3 6 is energized when the ignition switch is at the RUN or ACC position or while the crane s control system Master Module commands it to be on or when the head lights tail lights or brake lights are activated The fuse panel consists of Fuses 1 through 5 are energized anytime the battery disconnect switch is clos...

Page 130: ...3 5 100 Amp Fuse F54 6 100 Amp Fuse F55 7 100 Amp Fuse F56 8 100 Amp Fuse F52 9 250 Amp Fuse F51 10 Fuse and Relay Panel see Figure 3 7 FIGURE 3 6 10 FIGURE 3 7 5 6 7 4 3 2 1 Item Description 1 ECM 30 Amp Fuse F1 2 Cranestar 5 Amp Fuse F2 3 Carrier Rear Module 25 Amp Fuse F3 4 Carrier Rear Module 30 Amp Fuse F4 5 Carrier Front Module 30 Amp Fuse F5 6 Power Control Relay 5 Amp Fuse F6 7 120 Ohm Res...

Page 131: ...d other factors affect the life of electrical harness and cable assemblies Use the following information for the inspection and replacement of these assemblies Cranes operating in climate zone C should have the harness and cable assemblies replaced after 10 000 hours of service life Cranes operating in climate zones A or B with high ambient temperatures could see electrical service life reduced by...

Page 132: ... on the brush assembly and loose setscrews on the slip ring assembly Refer to the electrical schematic and wiring diagram for slip ring connections and amperages Connector Troubleshooting The cause of an electrical problem may be a loose or corroded connection in the pin or socket connectors Check the connectors to ensure that the pins and sockets are properly seated and engaged If the pins and so...

Page 133: ...luminated on the steering column display while the engine is running 4 to 9 circuit in line connectors 453300 1 N A 15 circuit in line connectors 458944 1 N A Description AMP Part Number Manitowoc Part Number Description AMP Part Number Manitowoc Part Number Tool Die Tool Die 14 to 12 gauge wire 69710 1 90145 1 9999100177 N A 10 to 8 gauge wire 69710 1 90140 1 9999100177 9999100178 4 to 9 circuit ...

Page 134: ...fully charged batteries and no loads on the system the multimeter should read 14 V Maximum Amperage Test 1 Connect an adjustable carbon pile load tester to the batteries positive and negative cables 2 Run engine at 2000 rpm 3 Adjust carbon pile to obtain maximum amperage while not letting voltage fall below 13 volts 4 Amperage should be within 10 to 15 amps of alternator rating this alternator is ...

Page 135: ...re than 3 8 to 1 2 in 10 to 13 mm with your thumb Or using a belt tension gauge verify there is 60 to 130 lb 267 to 578 N of tension on the belt in the middle of its longest span Replace belt if it is too loose overstretched 6 Verify tensioner bolt is torqued to 32 lb ft 43 Nm 7 Connect the electrical leads to the terminals as tagged during removal 8 Close the engine compartment 9 Reconnect the gr...

Page 136: ...er and remove the cover 4 Tag and disconnect the electrical leads from the suspect relay 5 Remove the hardware securing the suspect relay to the relay panel assembly Remove suspect relay 6 Install replacement relay on relay panel and secure it with attaching hardware 7 Connect the electrical leads to the relay as tagged during removal 8 Position the cover on the panel and secure with the attaching...

Page 137: ...the wire harness to the bottom of the gauge cluster 5 3 Install the right side cover 9 on the steering column 4 Connect the wire harness to the ignition switch 10 5 Install the left side cover 8 on the steering column 6 Secure the gauge switch cover 6 to the left and right side covers 8 9 using six screws 14 7 Secure the left and right side covers 8 9 together using four screws 13 8 Install the st...

Page 138: ...lumn tilt telescope function 11 Pull the rubber boot 11 up and over the bottom of the left and right side covers 8 9 12 Turn the battery disconnect switch to the ON position Check 1 Operate the switch per the Operator s Manual Verify each of its functions works 2 As needed troubleshoot further any system or circuit malfunction not corrected by repair or replacement of the switch or associated wiri...

Page 139: ...ove the steering wheel cap 1 using a twisting motion by pushing on the side of the cap closest to you with your thumbs while simultaneously pulling on the side of the cap farthest from you with your fingers b Remove the securing nut from the steering column shaft and remove the steering wheel 2 6 Remove the four screws 13 securing the left and right side covers 8 9 together 7 Remove the six screws...

Page 140: ...system or circuit malfunction not corrected by repair or replacement of the switch or associated wiring Windshield Wiper Assembly Replacement Removal 1 Ensure that the key switch has been in the OFF position for 2 minutes 2 Turn the battery disconnect switch to the OFF position 3 Tag and disconnect the electrical leads from the motor 4 Disconnect the washer hose on the wiper arm also called the pa...

Page 141: ...n 1 Verify the pivot shaft and the wiper motor kit link and crank are in place on the motor bracket Washers and clip springs fasten the link to the pivot pins on the crank and the pivot shaft The pivot shaft s pivot pin mounts in the hole nearest the end of the pivot shaft s lever 2 Connect the wiper motor to the motor bracket with screws and washers see Figure 3 10 Connect the wiper motor s shaft...

Page 142: ...er 2 Make repairs if windshield washer doesn t work Skylight Wiper Assembly Replacement Removal 1 Ensure that the key switch has been in the OFF position for 2 minutes 2 Turn the battery disconnect switch to the OFF position 3 Tag and disconnect the electrical leads from the motor 4 Remove the wiper arm from the motor shaft 5 Remove the nut spacer leather washer and nylon flat washer from the moto...

Page 143: ...riority flow and the air conditioner circuit receives the excess flow 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 i e sub zero temperatures Use particular care to ensure that cranes being operated in very cold temperatures are operated and maintained in accordance with the pro...

Page 144: ... The electrical cables connections etc are OK Anything is clogging the combustion air supply or exhaust system Check the openings of the combustion air supply and exhaust system after longer standstill periods clean if necessary If the heater remains faulty even after these points have been checked or another malfunction occurs in your heater contact an authorized Manitowoc distributor or Manitowo...

Page 145: ... 56 Maintenance 4 56 DESCRIPTION A five section 11 m to 42 m 35 9 ft to 138 ft full power sequenced and synchronized boom Figure 4 1 is installed on this crane The boom utilizes one telescope cylinder to extend and retract Tele 1 and Tele 2 and a synchronized cable system to extend and retract Tele and 4 The telescoping boom sections are supported on graphite impregnated nylatron wear pads Side we...

Page 146: ...ion cables qty 6 8 Figure 4 1 are secured to the rear of tele 2 on one end run around the extension sheaves on the front of the telescope cylinder and are secured to the rear of tele 3 on the other end the tele 4 extension cables qty 4 9 Figure 4 1 are secured to the rear of tele 2 on one end run around the extension sheaves on the front of tele 3 and are secured to the rear of tele 4 on the other...

Page 147: ... 4 1 7985 1 2 3 4 5 6 7 8 9 10 11 Item Description 1 Base Section 2 Section 1 3 Section 2 4 Section 3 5 Section 4 6 Telescope Cylinder 1st Stage 7 Telescope Cylinder 2nd Stage 8 Section 3 Extend Cables 9 Section 4 Extend Cables 10 Section 3 Retract Cables 11 Section 4 Retract Cables ...

Page 148: ...upper lift cylinder shaft to the side of the attachment fitting on the boom 10 Remove the upper lift cylinder shaft 11 Activate the hydraulic system and retract the lift cylinder rod enough to clear the attachment fitting For removal of the lift cylinder from the crane refer Lift Cylinder Removal page 4 43 NOTE Shut down the crane before proceeding 12 Take up the slack on the boom lifting device 1...

Page 149: ...4 5 Published 11 26 2014 Control 447 05 RT770E SERVICE MANUAL BOOM 4 GROVE FIGURE 4 2 ...

Page 150: ...BOOM RT770E SERVICE MANUAL 4 6 Published 11 26 2014 Control 447 05 FIGURE 4 2 continued ...

Page 151: ...4 7 Published 11 26 2014 Control 447 05 RT770E SERVICE MANUAL BOOM 4 GROVE FIGURE 4 2 continued ...

Page 152: ...BOOM RT770E SERVICE MANUAL 4 8 Published 11 26 2014 Control 447 05 FIGURE 4 2 continued ...

Page 153: ...4 9 Published 11 26 2014 Control 447 05 RT770E SERVICE MANUAL BOOM 4 GROVE FIGURE 4 2 continued ...

Page 154: ...BOOM RT770E SERVICE MANUAL 4 10 Published 11 26 2014 Control 447 05 FIGURE 4 2 continued ...

Page 155: ...ipe Clamp 41 Tube Assy 42 Tube Assy 43 SHCS M10x50 10 9 ISO 10642 44 SHCS M10x35 8 8 A3c ISO 4762 45 SHCS M12x55 8 8 A3c ISO 4762 46 Male 90 Deg Elbow ORFS BSPP 47 Pipe Clamp 1 2 I D 48 Tube Assy 49 Tube Assy 50 Pipe Clamp 51 Male 90 Deg Elbow ORFS BSPP 52 Tube Assy 53 Shim Tele 1 54 Front Lower Wear Pad Tele 1 55 Front Lower Wear Pad Tele 1 56 Stop Block 57 Plate Dc03 A M 58 HHCS M12x55 8 8 ISO 4...

Page 156: ...ear Pad Assy 129 Plate S690 Ql 130 SFHCS M10x30 10 9 ISO 10642 131 Retract Cable Tele 4 132 F Washer 1 Hard 133 Hex Nut M24 8 ISO 4032 134 Wear Pad Assy 135 Lubricant Hose L 195 Item Description 136 Tele Sheave Mgt Weld 137 F Washer 3 4 Hard ASTM F 436 138 HHCS M20x50 10 9 ISO 4014 139 Sheave Assy 140 Spacer 154mm I D 141 Hollow Tele Shaft 142 Sled Weld 143 F Washer 1 2 Hard ASTM F 436 144 Upper S...

Page 157: ...t and right sides see Figure 4 3 11 Remove the two bolts 27 and nuts 28 securing the upper wear pad 11 to the front of the base section 1 left and right sides see Figure 4 3 12 Remove the two bolts 20 and flat washers 16 securing the plate 12 to the inside of the base section 1 left and right sides 13 Slightly lower tele 1 2 14 Remove the bolts 19 flat washers 16 lock washers 17 and nuts 18 securi...

Page 158: ... of tele 1 2 left and right sides 26 Remove the two bolts 69 four flat washers 67 and two nuts 18 securing the anchor plate 64 to the top of tele 1 2 see Figure 4 5 27 Remove the nuts 66 securing the anchor plate 64 to the studs of the retract anchor weldment 63 see Figure 4 6 28 Remove the four tele 3 retract cables 65 from the slots of the retract anchor weldment 63 see Figure 4 54 29 Slightly l...

Page 159: ...tele 4 extend cables 109 110 from the holes in the rear of tele 2 3 left and right sides see Figure 4 8 39 Remove the two bolts 76 from the anchor plate 73 see Figure 4 9 40 Remove the two bolts 85 and lock washers 25 securing the plate cover 84 to the anchor plate 73 then remove the four tele 3 extend cables 150 labeled 1 3 4 and 6 from the anchor plate 73 see Figure 4 10 41 Remove the two bolts ...

Page 160: ...igure 4 13 45 Coil the four tele 3 retract cables 65 and set them on top of the telescope cylinder 6 46 Remove the two tele 4 extend cables 109 110 from the holes in the rear of tele 2 3 left and right sides see Figure 4 14 47 Extend tele 3 4 one quarter of the way out of tele 2 3 48 Remove the two bolts 58 four washers 16 two lock washers 17 and two nuts 18 securing the stop block 56 to the front...

Page 161: ... assembly 126 79 80 77 78 from the attaching bracket on each side of the rear of tele 3 4 56 Remove the two capscrews 83 and lock washers 72 securing the wear pad assembly 71 to each side of the bottom rear of tele 3 4 57 Remove the two capscrews 83 securing the wear pad assembly 82 to each side of the bottom rear of tele 3 4 58 Remove the two cotter pins 122 two flat washers 121 and pin 120 secur...

Page 162: ...f tele 3 4 see Figure 4 20 67 Remove the front lower wear pads 101 102 and shims 100 from the bottom of tele 3 4 68 Using an adequate lift and sling slightly raise the front of tele 4 5 for the purpose of removing the wear pads from the front of tele 3 4 69 Remove the three bolts 19 six flat washers 16 three lock washers 17 and three nuts 18 securing the keeper plate 15 to the front of tele 3 4 le...

Page 163: ...pscrew 113 securing the rear guard weldment 111 over the tele 4 extend cable 109 left and right sides see Figure 4 22 79 Pull the tele 4 forward extend cables 109 away from the rear sheaves 107 see Figure 4 23 80 Remove the six capscrews 105 and shaft 104 securing the rear sheave 107 to the inside of tele 3 4 left and right sides see Figure 4 23 81 Remove tele 4 5 from tele 3 4 set tele 4 5 on ade...

Page 164: ...ttings 106 from each end of the hollow shaft 141 90 Remove the four capscrews 19 lock washers 17 and flat washers 16 securing the upper sled pad 144 to the telescope cylinder sheave mounting weldment 136 see Figure 4 25 91 Remove the capscrews 44 146 securing the lower sled pad 145 to the sled weldment 142 see Figure 4 25 92 Remove the four capscrews 19 and flat washers 143 securing the bumper pad...

Page 165: ...l the cable retainer pins into the upper and lower part of the boom nose and secure in place with the clip pins Assembly NOTE The boom assembly must be rotated 180 upside down before performing any assembly or disassembly procedures NOTE Apply Loctite 243 to the threads of all attaching hardware except cable ends and cable lock nuts NOTE Apply multipurpose grease MPG to all wear surfaces NOTE Use ...

Page 166: ... bumper pads 147 to the sides of the sled weldment 142 with the four capscrews 19 and flat washers 143 ensure the taper side of each pad faces outward see Figure 4 29 8 Mount the lower sled pad 145 to the sled weldment 142 using the capscrews 44 146 see Figure 4 29 9 Mount the upper sled pad 144 to the telescope cylinder sheave mounting weldment 136 using the four capscrews 19 lock washers 17 and ...

Page 167: ...pad assembly 134 to each side of the bottom rear of tele 4 5 using the two capscrews 124 and lock washers 25 see Figure 4 33 17 Mount the wear pad assembly 128 to the bottom rear of tele 4 5 using the two capscrews 124 18 Install the two sets of tele 4 extend cables 109 110 to each side of the rear of tele 4 5 secure each set of cables to tele 4 5 using the cable anchor 129 and capscrew 130 see Fi...

Page 168: ...rear sheave 107 to the inside of tele 3 4 left and right sides using the rear set of mounting holes see Figure 4 34 ensure the rectangular tab on the shaft 104 slides into the groove in tele 3 4 29 Working at the rear of tele 3 4 pull the tele 4 extend cables 109 until they seat into the sheaves 107 30 Install the rear guard weldment 111 left and right sides over the tele 4 extend cable 109 where ...

Page 169: ...3 4 43 Install the left right and bottom keeper plates 2x 14 13 to the front of tele 3 4 using the bolts 19 flat washers 16 lock washers 17 and nuts 18 see Figure 4 37 44 Install the stop block 56 to the front of tele 3 4 using the two bolts 58 four washers 16 two lock washers 17 and two nuts 18 left and right sides see Figure 4 37 45 Fully insert tele 4 5 into tele 3 4 ensuring the telescope cyli...

Page 170: ...e two bolts 124 and lock washers 25 54 Attach the two tele 3 retract cables 65 to the rear of tele 3 4 using the pin 120 two flat washers 121 and two cotter pins 122 left and right sides see Figure 4 41 55 Coil the four tele 3 retract cables 65 and set them on top of the telescope cylinder 6 see Figure 4 42 56 Mount the wear pad assembly 82 to each side of the bottom rear of tele 3 4 using the two...

Page 171: ... plate 15 to the front of tele 2 3 using the three bolts 19 six flat washers 16 three lock washers 17 and three nuts 18 left and right sides see Figure 4 43 67 Lower tele 3 4 down onto the newly installed wear pads 92 68 Install the shims 89 and the front lower wear pads 90 91 into the bottom of tele 2 3 69 Install the left right and bottom keeper plates 2x 14 13 to the front of tele 2 3 using the...

Page 172: ...ful not to cross the cables install the two tele 3 extend cables 150 labeled 2 and 5 into the anchor plate 73 and secure in place using the plate cover 84 two bolts 85 and two lock washers 25 see Figure 4 49 79 Being careful not to cross the cables install the four tele 3 extend cables 150 labeled 1 3 4 and 6 into the anchor plate 73 and secure in place using the plate cover 84 two bolts 85 and tw...

Page 173: ... cables 109 110 see Figure 4 52 86 Mount the wear pad assembly 82 to each side of the bottom rear of tele 2 3 using the two capscrews 83 see Figure 4 53 87 Mount the wear pad assembly 71 to each side of the bottom rear of tele 2 3 using the two capscrews 83 and lock washers 72 see Figure 4 53 88 Pull the four tele 3 retract cables 65 toward the front of the boom sections in preparation for future ...

Page 174: ...ashers 16 lock washers 17 and nuts 18 98 Install the stop block 56 and shim 57 to the front of tele 1 2 using the two bolts 58 four washers 16 two lock washers 17 and two nuts 18 left and right sides 99 After ensuring that the tele 3 retract cables 65 are not crossed install the four cable ends into the slots of the retract anchor weldment 63 wrap duct tape around the anchor weldment to secure the...

Page 175: ...here the tele 1 rear wear pads will touch upon assembly 113 Align the base section and tele 1 with each other then partially insert the tele 1 2 into the base section 1 114 Use the shims 70 to adjust the tele 1 rear wear pad assemblies 71 82 such that the wear pads are within 2 mm 0 08 in of the sides and the bottom of the base section An equal number of shims should be used on each side 115 Inser...

Page 176: ...nifold 37 and telescope cylinder 6 as tag during disassembly replace all O rings 128 Once the boom assembly is positioned right side up adjust the top front wear pads 11 92 103 of each boom tele section using the upper and side adjustment bolts 27 Adjust the wear so that they are just touching or are no more than 2 mm 0 08 in away from contacting the next inner tele section Tighten the jam nuts In...

Page 177: ... check of fine adjustment is as follows 1 Fully extend the boom horizontally 2 Lubricate the boom bottom channels and top corners 3 Shim the front top wear pads such that wear pad is just touching or is no more than 2 mm 0 078 in from contacting the next tele section both at the top and side surfaces of the top radius 4 Retract and extend the boom check for the high point where the boom has brushe...

Page 178: ... retract the boom a few feet Tighten Tele 3 extend cables Extend the boom a few feet and tighten Tele 3 retract cables Retract the boom fully Repeat until the section bottoms out properly Re torque the Tele 3 retract cables and the Tele 3 extend cables to verify that the minimum torque value is achieved as specified in Table 4 1 b If Tele 3 does not bottom out completely loosen Tele 3 extend and r...

Page 179: ...10 Add jam nuts and tighten Coat threads with Never Seize All threaded cable ends must be equipped with retainer nuts and jam nuts Table 4 1 Cable Tensioning Minimum Torque Values Cables Extend Retract Minimum Torque Values Tele 4 Retract Cables 34 Nm 25 lb ft Tele 4 Extend Cables 13 5 Nm 10 lb ft Tele 3 Retract Cables 13 5 Nm 10 lb ft Tele 3 Extend Cables 40 5 Nm 30 lb ft ...

Page 180: ...5 FIGURE 4 59 7985 1 2 3 4 5 6 7 8 9 10 11 Item Description 1 Base Section 2 Tele 1 3 Tele 2 4 Tele 3 5 Tele 4 6 Telescope Cylinder 1st Stage 7 Telescope Cylinder 2nd Stage 8 Tele 3 Extend Cables 9 Tele 4 Extend Cables 10 Tele 3 Retract Cables 11 Tele 4 Retract Cables ...

Page 181: ...ffers four methods of telescoping the boom Auto Mode A Auto Mode B Manual Mode and Recovery Mode Auto A Mode In the auto A mode the boom extends to full length by extending Tele 2 first then Tele 1 The crane decides how and when to stop extending Tele 2 and start extending Tele 1 This mode is an option for normal crane work The boom control system uses length feedback to ramp the telescoping speed...

Page 182: ...i rotation features on the base section The jib rigging state is entered when the stop block is disengaged pulled down from the base section and Tele 1 is retracted to align the boom extension mounting holes When the control system detects a length less than the fully retracted length with the stop block engaged the jib rigging state is activated When jib rigging is active Tele 2 is prevented from...

Page 183: ...ic lines or fittings k Clean tighten or replace lines or fittings l Damaged control valve l Repair or replace control valve 2 Erratic operation of retracting telescoping cylinder a Low hydraulic oil level a Check system for leaks Make repairs as needed Fill reservoir b Damaged relief valve b Repair or replace relief valve c Air in cylinder c Bleed by lowering telescoping cylinder below horizontal ...

Page 184: ...Replace piston s and all cylinder seals h Bent boom section s h Replace damaged boom section s i Broken hydraulic pump coupling i Replace broken hydraulic pump coupling j Worn or damaged hydraulic pump section j Repair or replace pump section 4 Telescope cylinder will not retract a Low hydraulic oil level a Check system for leaks Make repairs as needed Fill reservoir b Relief valve damaged b Repai...

Page 185: ...etracted or holding cylinder rod stationary Theory of Operation The directional control valve bank housing the lift control valve is supplied by flow from the hydraulic pump When booming up oil unseats the poppet check valve in the holding valve letting oil flow to the piston side of the cylinder Pressure is applied to the piston forcing the rod to extend raising the boom When booming down oil ent...

Page 186: ...mended level c Damaged relief valve c Repair or replace relief valve d Operating two functions within the same control valve bank assembly d Feather controls to obtain desired speed of both functions e Extremely cold hydraulic oil e Operate unit to bring oil to operating temperature f Improper hose or fittings installed f Replace hose or fittings Refer to Manitowoc Crane Care Manual g Restriction ...

Page 187: ... Cylinders page 2 61 and Valves page 2 30 respectively Lift Cylinder Installation 1 Attach an adequate lifting device to the lift cylinder and position the cylinder over the attach fitting on the turntable 2 Lower the lift cylinder into the attach fittings on the turntable and align the lift cylinder bushing with the attach fitting holes NOTE Install pivot shaft with tapped hole on the right side ...

Page 188: ...NUAL 4 44 Published 11 26 2014 Control 447 05 FIGURE 4 60 4 5 1 2 3 7 A B Detail B Detail A 6 8 8 Item Description 1 Capscrew 2 Locknut 3 Shaft 4 Capscrew 2 Item Description 5 Washer 2 6 Stop Plate 7 Shaft 8 Grease Fitting 2 ...

Page 189: ... causing the section 1 and section 2 proximity switches to be activated Upon exiting the Boom Extension Rigging Mode restrictions of boom operating modes are removed Erecting the Boom Extension 1 Fully extend and set the outriggers 2 Position the boom over the front 3 Set the boom manual automatic mode selector switch to the AUTO position 4 Set the boom A B mode selector switch to the B mode 5 If ...

Page 190: ...ins 2 Boom Extension Base Section 3 Boom Extension Fly Section 4 Fly Rear Stowage Bracket 5 Stinger Section Front Stowage Bracket 6 Front Stowage Bracket 7 Swingaway Base Sheave Item Description 8 Mast Assembly 9 Boom Nose To Boom Extension Attachment Anchor Fittings 10 Boom Nose To Boom Extension Attachment Pins 11 Offset Links 12 Offset Pivot Point 13 Stinger Sheave ...

Page 191: ... 6058 5 6 4 2 2 3 1 7 Item Description 1 Boom Extension Base Section 2 Adjusting Bolt 3 Upper Hanger 4 Main Hanger 5 Lower Support 6 Lock Hitch Pin 7 Adapter 6160 Item Description 1 Boom Extension Fly Section 2 Adjusting Bolt 3 Adjusting Bolts 4 Front Mount 5 Hanger 1 3 2 3 4 5 FIGURE 4 62 continued ...

Page 192: ...Boom Extension Fly Section 3 Shock Wear Pad and Shim 4 Ramp Wear Pad and Shim DETAIL C 2 4 3 1 1 2 3 4 5 6 7 8 4 Item Description 1 Boom Extension Base Section 2 Boom Extension Fly Section 3 Fly Attachment Pin and Hitch Pin 4 Adjusting Bolts 5 Pin Stowage Lug 6 Upper Support 7 Lower Mount Ramp 8 Wear Pad FIGURE 4 62 continued ...

Page 193: ...sion Fly Section 3 Fly Sheave 4 Cable Retainer Pins 5 Latch Hook 6 Spring 7 Latch Bar 1 6 5 2 4 7 3 4 2 9 8 1 10 11 6 4 3 5 7 Item Description 1 Boom Nose Upper Sheaves 2 Mast Assembly 3 Offset Links 4 Offset Pivot Points 5 Offset Link Pins Stowage Lugs 6 Mast Assembly Pin 7 Boom Nose Lower Sheaves 8 Boom Extension Attachment Pins 9 Boom Extension Attachment Pins Stowage Lugs 10 Offset Link Pins 1...

Page 194: ...g 13 Ensure the pin attaching the fly section to the boom base section rear stowage bracket Figure 4 62 Detail D is in place 14 At fly section sheave end Figure 4 62 Detail E push in on the spring loaded latch hook to release latch allowing the base to separate from the fly Skip to step 16 15 Remove the pin attaching the fly extension section to the boom base section rear storage bracket Figure 4 ...

Page 195: ...oute through boom extension b Remove dummy plug 1 Figure 4 64 from junction box on boom nose c Install cable end connector 1 Figure 4 65 from boom extension where dummy plug was removed 26 Erect the boom extension fly section as follows a Attach a length of rope to the tip of the extension fly section to aid in swinging the fly into place ahead of the base section Ensure that the right base to fly...

Page 196: ...ng it over the front 2 Set the boom manual automatic mode selector switch to the AUTO position 3 Set the boom A B mode selector switch to the B mode 4 Lower the boom then extend the boom only enough to disengage the spring loaded boom stop block 5 Pull down on the handle to disengage the spring loaded boom extension stop block Figure 4 66 Place the end of the handle in the retainer plate 6 Fully r...

Page 197: ... front of the guide ramps and pins on the stowage brackets when the swingaway is positioned to the side of the boom 16 Extend the boom extension alignment jack until the bottom left side attachment pin is free Remove the bottom left side boom retainer clip pin and attach pin 17 Retract the alignment jack to its original position then return the jack handle to its stowed position 18 Pull down on th...

Page 198: ...e crane using normal operating procedures Setting the Folding Swingaway Offset 1 Extend and set the outriggers and swing the boom to over the front Position the boom to above horizontal 2 Block under the tip of the extension assembly section 3 To set the offset from a lesser degree to higher degree perform the following procedures a Slowly lower the boom until the pressure is relieved on the offse...

Page 199: ...a clearance of 12 mm 0 5 in between wear pad and ramp on swingaway base 3 Install the shock wear pad Figure 4 62 Detail C on the extension base bracket Shim the wear pad to provide a clearance of 3 mm 1 8 in between shock wear pad and ramp wear pad installed in step 2 4 With the stinger supported on the base ramp wear pad and held tight against the shock wear pad adjust the stinger latch hook Figu...

Page 200: ...ll moving parts Maintenance Periodic Maintenance It is recommended that the hook block and or headache ball be inspected every 50 hours A complete disassembly inspection should be conducted every quarter or 500 hours in the area of the hook hex nut and threaded areas for corrosion and proper fit After assembly of the hook a liberal coating of multipurpose grease should be applied to the nut and th...

Page 201: ... without releasing the brake while at the same time holding the load until there is sufficient pressure to release the brake when hoisting down The hoist motor controls both speed and torque of the hoist There are two modes in which the hoist operates One mode is high speed The pilot solenoid valve shifts the selector spool on the motor to provide minimum motor displacement This gives high line sp...

Page 202: ...eral times to prime all lines with warm hydraulic oil and to circulate gear lubricant through the planetary gear sets Hoist Area Access Use the hoist access platform 1 Figure 5 1 when working in the hoist area WARNING Failure to properly warm up the hoist particularly under low ambient temperature conditions may result in temporary brake slippage due to high back pressures attempting to release th...

Page 203: ...l 447 05 GROVE Main Hoist Only Installation Item Description 1 Hoist 2 Capscrew 3 Shim 4 Washer 5 Nut 6 Turntable 7 Capscrew 8 Counterweight Plate 9 Shim 8 4 5 4 7 5 4 9 6 1 2 3 4 5 5 4 3 2 2 1 2 2 6 3 3 6929 1 6929 2 Main and Auxiliary Hoist Installation FIGURE 5 2 ...

Page 204: ...d the mounting plate 8 Add shims to satisfy any existing gaps Altering the shim thickness to fit a tapering gap is acceptable Install the capscrews washers and nuts refer to Fasteners and Torque Values page 1 16 for proper torque value 9 Remove the lifting device from the hoist 10 Connect the hydraulic lines to the hoist ensuring the proper lines are connected to the correct ports as marked during...

Page 205: ...s Do not fill above 3 mm 1 8 in from the top of the site glass Refer to Hoist page 9 30 for the correct type of oil Oil is visible in the sight glass and the level is no more than 3 mm 1 8 in from the top of the sight glass The oil level is correct No action is required Oil level is more than 3 mm 1 8 in from the top of the sight glass or the oil is escaping from the vent plug 4 The hoist is overf...

Page 206: ...rag clutches which do not have an infinite life span Although these components have been designed to achieve long service life reliability can be substantially reduced by a variety of influencing factors such as High cycle operation Operating in high ambient temperatures High external contaminations such as dusty or sandy conditions Level of maintenance The following should be carried out followin...

Page 207: ...g and that the hoist control is correct The function of the hoist brake should be checked more often if abnormal operating conditions or characteristics exist 6 Every 10 000 hours or every ten years it is recommended that the hoist assembly be disassembled and that all major components be examined for damage and or wear i e gears spline couplings shafts etc New components must be installed if any ...

Page 208: ...ld be taken to determine what has changed NOTE Oil analysis alone cannot detect nor warn against a fatigue failure Brake Test Procedure These planetary hoists have a spring applied hydraulically released multiple disc brake inside the hoist housing This brake holds a suspended load when the directional control valve is in neutral or when hydraulic power is lost An over running brake clutch assembl...

Page 209: ...m the drum Extend the boom half way to provide a center point of adjustment to check the fleet angle of the cable 2 All the cable must be removed from the hoist drum to check the fleet angle Using mason cord or cat gut fishing line you will be able to pull the line tight to make an accurate measurement of the fleet angle Find the centerline of the hoist drum by using a square and drawing a line ho...

Page 210: ...ublished 11 26 2014 Control 447 05 HOIST AND COUNTERWEIGHT RT770E Locating Centerline With Square Main Hoist Is Aligned To The Right Hand Sheave Auxiliary Hoist Is Aligned To The Center Sheave FIGURE 5 5 6019 ...

Page 211: ...he O ring 5 Cover the motor opening in the brake cylinder to protect drive components inside the hoist drum As needed secure the brake clutch from inside the brake cylinder Installation NOTE Assure the primary thrust plate remains properly located in its counterbore when installing the motor If operating the hoist with the primary thrust plate wedged between the primary gears and the planet carrie...

Page 212: ...securing the arms to the angles on each end of the roller Remove the cable follower roller 4 Disassemble the cable follower roller as follows a Remove the two bolts and washers securing the angle to the right side of the shaft b Remove the shims and roller from the shaft c If necessary remove the bearing and bearing housing from both ends of the roller 5 Remove the bolt and locknut securing the ar...

Page 213: ...05 GROVE 7837 1 8 2 11 12 3 7 10 6 5 8 9 1 7 4 3 FIGURE 5 6 7837 2 1 0 cm 0 42 inch 1 Item Description 1 Pivot Bracket 2 Drum 3 Follower Roller 4 Arm 5 Spring 6 Spring Adjusting Rod Item Description 7 Lever 8 Idler Roller 9 Nut 10 Bracket 11 3rd Wrap Limit Switch Optional ...

Page 214: ...should not exceed 10 12 in 25 7 cm Adjust rods as necessary and tighten jam nuts to secure this setting Complete Assembly Removal 1 Remove all tension from the springs on each side by loosening the nuts and jam nuts 2 Support the weight of the assembly and remove the two bolts and washers securing each side plate to the hoist Remove the idler drum and cable follower assembly from the hoist 3 If ne...

Page 215: ... no more rope should be reeled out In addition to the warning light in the cab illuminating when down to the third wrap hoist down operation will be locked out Maintenance The third wrap indicator switch mechanism must be adjusted such that only when the hoist has three wraps of cable remaining on the drum the switch is actuated Once adjusted properly ensure there is no continuity through the swit...

Page 216: ...ntenance 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 replacing the faulty component s To determine which component is at fault refer to the troubleshooting section of your CAN bus CD Troubleshooting NOTE This machine incorporates a CAN bus Multiplex system In order to eff...

Page 217: ...70E HOIST AND COUNTERWEIGHT 5 Published 11 26 2014 Control 447 05 GROVE Single Axis Controller Control Lever Handle Button Thumb Thumper Rotation Indicator Solenoid Drum Rotation Sensor FIGURE 5 9 7792 2 7792 3 ...

Page 218: ... was affixed with isopropyl alcohol remove the paper from the adhesive back of the new display and stick it into the panel Connect the wires to the display Replace the panel and secure with the hardware HRI Control Module The control module is located in the fuse and relay panel behind the driver s seat in the cab Figure 5 12 To replace the control module tag and disconnect the wires from the modu...

Page 219: ...even flow of oil to the hoist motor in both directions This is a different valve than the hoist motor control valve that applies and releases the hydraulic piston and hydraulic cylinder Hoist Directional Control Valve 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 FIGURE 5 13 ...

Page 220: ...iggers 2 Rotate the superstructure so the counterweight will be over the front of the carrier to gain additional clearance NOTE The counterweight weighs approximately 6540 kg 14 400 lb Use of a forklift to install or remove the counterweight is not recommended damage or misalignment of the counterweight can result 3 Attach an adequate lifting device to the counterweight and lift the counterweight ...

Page 221: ... 26 2014 Control 447 05 GROVE FIGURE 5 14 2 4 3 1 7064 2 2 5 6 7 10 9 8 7 8 11 Item Description 1 Fixed Counterweight 2 Pin Assembly 3 Capscrew 4 Counterweight Plate 5 Flatwasher Item Description 6 Locknut 7 Capscrew 8 Flatwasher 9 Locknut 10 Turntable ...

Page 222: ...Position the crane on a firm level surface Fully extend and set the outriggers 2 Select the proper Without Counterweight operating code on the RCL NOTE The counterweight weighs approximately 6895 kg 15 200 lb 3 Using the crane s boom and hoist or other crane lift the counterweight from the auxiliary transport vehicle and position the counterweight 4 Rotate and align the rear of the superstructure ...

Page 223: ...ent between the counterweight and the turntable The crane is now ready for operation with the counterweight installed 1 2 3 5 4 places 4 1 FIGURE 5 16 6 6670 1 Item Description 1 Removal Cylinders 2 Cylinder Attach Pins 3 Counterweight Attach Pins 4 6042 kg 13 300 lb Counterweight 5 Leveling Bolts 4 places 6 Counterweight Lifting Lugs 4 places FIGURE 5 17 Leveling Bolts ...

Page 224: ...5 24 Published 11 26 2014 Control 447 05 HOIST AND COUNTERWEIGHT RT770E This Page Blank ...

Page 225: ...ure The maximum rotation is 2 5 rpm Braking is accomplished by depressing a Swing Brake Pedal which is a proportionate control valve that provides a controlled braking of the swing motion The swing system consists of a hydraulic remote controller a directional control valve the swing drive the swing brake assembly the brake pedal and power brake valve and a swing brake release solenoid valve The c...

Page 226: ...directed from the pressure reducing sequence valve to the brake release port overcoming the brake spring pressure and releasing the swing brake Regulated flow from the pressure reducing sequence valve is also provided to the power brake valve where it is available for the activation of the swing brake when the pedal is depressed 9 2 4 1 6 7 5 8 FIGURE 6 1 6470 1 1 3 Item Description 1 Breather Plu...

Page 227: ...wing 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 any damaged fitting Check hydraulic tank level l Improperly torqued turntable bolts l Torque turntable bolts evenly m Excess...

Page 228: ...amaged hydraulic pump f Replace pump section g Damaged swing directional control valve g Replace swing directional control valve h Damaged swing pinion h Replace pinion i Damaged turntable 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...

Page 229: ...ke 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 lines and fittings 8 Swing brake pedal is spongy a Damaged glide swing power brake valve a Repair or replace the glide swing power brake valve b Loose or restricted brake lines or fittings b Tighten or replace brake lines and fittings 9 Swing ...

Page 230: ...on a Improper port connections a Reverse port connection b Improper wiring connection b Inspect wiring and connections 13 Swing motor noisy a Air in system a Refer to Hydraulic System page 2 1 for removal of air from the system b Motor binding b Repair or replace motor Symptom Probable Cause Solution ...

Page 231: ... the swing brake Installation 1 Install a new O ring in the groove of the swing brake Position the swing motor on the swing brake 2 Apply Loctite 243 on the two screws Install the screws and secure the motor to the brake housing Torque the screws to 88 Nm to 107 Nm 65 lb ft to 79 lb ft 3 Replace plugs extensions and fill the assembly with oil Refer to Lubrication page 9 1 4 Connect the hydraulic l...

Page 232: ...o the motor and brake 4 Bleed all air from the brake assembly Testing 1 With the Swing Brake switch in the ON position position the swing control lever in both directions Superstructure rotation should not occur 2 Position the Swing Brake switch to OFF and swing the superstructure in both directions Use the swing brake pedal to stop rotation 3 Check for hydraulic leaks and repair as necessary Gear...

Page 233: ...e more frequent changes to minimize moisture or contaminate accumulation Change the oil as follows a Unscrew drain plug remove breather and dipstick to ensure all oil has been removed b Flush the case with a light flushing oil NOTE Cleaning of the gearbox with a solvent is recommended to prevent an accumulation of grit and grime Avoid steam cleaning where moisture and dirt might be driven into the...

Page 234: ...n 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 used to reach hard to get at areas ensure torque readings are accurate Torque wrenches are precision instruments and must be handled with care To ensure accuracy calibrations must be made...

Page 235: ... eight bolts to 80 of their specified torque value using the following sequence pattern 11 31 11 21 1 16 36 26 and 6 refer to Fasteners and Torque Values page 1 16 for proper torque value Tools used are the socket multiplier backlash adapter necessary extensions and torque wrench 3 Return to bolt 1 and torque all bolts sequentially in a clockwise direction to their final torque value specified The...

Page 236: ...le NOTE If a lifting device capable of lifting the entire superstructure is not available superstructure weight may be reduced by removing various components such as the hoist s 6633 FIGURE 6 3 7 1 3 6 5 2 4 The Manitowoc Company Inc 1565 Buchanan Trail East Shady Grove PA 17256 Phone 717 597 8121 Fax 717 593 5929 Description 1 1 Socket 3 4 Drive 2 4 to 1 Torque Multiplier 1 2 Input 3 4 Output 3 B...

Page 237: ...TE If the same bearing is to be used again align the marked teeth on the pinion shaft and the marked teeth on the bearing Installation is in the travel position Ensure the swing lock is disengaged before attempting to mate the bearing to the superstructure 1 Using an appropriate lifting device position the turntable bearing under the superstructure If the same bearing is being used position it as ...

Page 238: ...asher and nut 8 Install the clamp securing the swivel wiring harness to the retainer plate on the bottom of the hydraulic swivel 9 Connect all water and hydraulic lines to the ports on the bottom of the swivel as tagged during removal 10 Install the boom and lift cylinder following the procedures outlined in Section 4 Boom NOTE The fixed counterweight weighs approximately 6540 kg 14 400 lb The rem...

Page 239: ...ich engages the carrier frame lugs with bolts and jam nuts This allows the spool to remain stationary with the carrier as the case rotates with the superstructure The spool portion of the water swivel is attached to the spool of the hydraulic swivel by four bolts The hydraulic and water swivel spools remain stationary with the carrier as the superstructure rotates The water swivel case contains a ...

Page 240: ...Control 447 05 SWING SYSTEM RT770E FIGURE 6 5 3 4 2 6 1 7 8 9 7897 3 5 Item Description 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 ...

Page 241: ...hes Cut two pieces of 10 x 10 cm 4 x 4 in oak to fit NOTE It might be necessary to raise the boom slightly to allow installation of the blocking NOTE This blocking is to add extra support for the boom Any seepage or leakage in the holding valves or internally in the cylinders will allow the boom to settle over a period of time 4 Use the oak blocking to block between the barrel of the lift cylinder...

Page 242: ...nsuring they engage the lugs on the carrier frame NOTE Allow a 1 32 max gap between bolt and the retaining lug on the frame Do not tighten bolt against lug 4 Secure the retainer plate with four bolts two bolt retainers Apply Loctite 271 to the bolt threads Torque the bolts to 270 Nm 199 lb ft Bend all the retainer tabs to make contact with the bolt heads Snug the four retainer plate bolts against ...

Page 243: ...nd rings 3 Remove the seals and rings from the spool Cleaning And Inspection 1 Clean the spool and case with a suitable solution and dry with compressed air Plug all ports with plastic caps 2 Check the spool and inside of the case for scratches grooves scoring etc If any grooves have developed with a depth of 0 127 mm 0 005 in the unit should be replaced Assembly NOTE Lubricate the interior of the...

Page 244: ...The connectors are too large to go through the center of the hydraulic swivel They must be removed 5 Remove the clamp securing the wiring harness to the retainer plate on the bottom of the hydraulic swivel assembly 6 Tag each wire on each of the connectors Using the appropriate pin removal tools remove the pins with wires still attached and mark each wire with the pin socket number in the connecto...

Page 245: ...mately 100 to 150 engine operating hours When this time limit is reached perform the following 1 Check the collector ring and brush assembly for any corrosion pitting arcing and wear 2 Check the collector ring setscrews and ensure they are tight 3 Check the brush and arm assembly springs Ensure they are holding the brushes firmly against the collector rings Slew Angle Zero Adjustment Procedure 1 R...

Page 246: ...secure the superstructure in position at one of the positions in its rotation There are roughly 120 spots about 3 0 degrees apart for the superstructure to lock to in its 360 degree of rotation The 360 degree swing lock control lever is on the right side of cab Pushing the swing lock control lever down engages the lock between the teeth of the swing gear Pulling the swing lock control lever up dis...

Page 247: ...lso controlled by the idle switch which is a three position rocker switch located on the front of the steering column The idle switch allows the operator to infinitely vary and hold the engine speed between the engine s minimum and maximum idle settings refer to Section 3 Operating Controls and Procedures in the applicable Operation Manual for details on the operation of the idle switch The foot t...

Page 248: ...ng the transmission torque converter to the frame 16 Using the lifting device lift the engine and transmission torque converter as an assembly from the crane 17 If a new engine is to be installed remove all compo nents fittings etc from the old engine and install them on the new engine in the same locations Ensure that the same grade hardware torque values and Loctite as were installed by the fact...

Page 249: ... levels Engine Drive Belts The proper operation of engine belt driven components such as the alternator fan and water pump depend on the proper condition and tension of the engine drive belt NOTE Belt tension is maintained with an automatic belt tension device The engine drive belt should be inspected visually on a daily basis The drive belt should be inspected for cracks frayed areas and glazed o...

Page 250: ...lt codes If there are no engine fault codes zeroes will be shown in the steering column display Engine low idle function With the engine running and the top of the Engine Diagnostic Speed Control Switch pressed the engine low idle is adjusted using the Increment Decrement Switch Engine rpm function With the engine running and the bottom of the Engine Diagnostic Speed Control Switch pressed the eng...

Page 251: ... to the DPF indicator and the engine will shut down The regeneration process can take place in three different modes Passive The exhaust is hot enough during normal working operation to burn off any hydrocarbon soot accumulation Active Active self regeneration occurs when there is not sufficient heat in the exhaust to convert all the hydrocarbon being collected in the DPF Exhaust temperatures are ...

Page 252: ...crane and surrounding area are monitored during manual regeneration If any unsafe condition occurs shut off the engine immediately During this period the sound of the engine may change When regeneration is complete the engine will return to its idle speed Inhibit Regeneration Indicator The Inhibit Regeneration indicator is located in the steering column gauge display When the Diesel Particulate Fi...

Page 253: ...ed from the fuel The water falls out into the void between the two paper elements and goes to a reservoir in the bottom of the housing where it can be drained through a drain plug at the bottom of the housing The water in fuel sensor is located in the fuel filter housing Once the storage space in the bottom of the filter housing fills with a certain amount of water the sensor will signal the ECM T...

Page 254: ...6 2014 Control 447 05 FIGURE 7 2 7875 1 1 2 3 5 6 7 4 8 9 FRONT Item Description 1 Fuel Tank 2 Fuel Quantity Sender 3 Cooler 4 Fuel Return 5 Filler Cap Item Description 6 Fuel Supply 7 Fuel Water Separator 8 Step 9 Step Extension To Engine ...

Page 255: ...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 outlet tube for damage 2 Ensure the element sealing surf...

Page 256: ... 7 11 14 15 8 12 9 13 1 5 2 3 4 6 7 6 14 7841 Item Description 1 Air Cleaner Assembly 2 Mounting Bracket 3 Clamp 4 Service Restriction Indicator 5 Reducer 6 Clamp 7 Muffler Clamp 8 Mounting Bracket Item Description 9 Air intake Tube 10 Adapter 11 Bracket 12 Air Intake Tube 13 Elbow 14 T bolt clamp 15 Adapter ...

Page 257: ...material leaves lint or other foreign matter that may have collected inside the air cleaner body Inspect the inside of the body 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...

Page 258: ...alve is lost or damaged replace it with a new valve of the same part number Duct Work 1 Check the intake pipe cap and screen for accumulation of leaves trash and other debris that could restrict air flow Repair the screen or replace the cap if any large holes are found in the screen 2 Check all mounting hardware for security to eliminate possible vibration of intake piping Such vibration leads to ...

Page 259: ...ust be air tight in order to work efficiently The ducting consists of metal tubing hose clamps and bellows The recommended installation torque of the spring loaded T bolt clamps is 100 lb in 11 3 Nm Do not compress the spring completely the bellows and or clamp may be damaged from thermal expansion of the CAC tube Maintenance Check the hose clamps for proper torque Inspect the bellows for cracks o...

Page 260: ...tions 5 Remove mounting bands to free muffler from muffler mounting bracket 6 Inspect muffler exhaust tailpipe exhaust tubes bracket and attaching hardware Repair or replace any of these parts if damaged or missing Installation 1 Secure the muffler to the exhaust tube with a clamp 2 Install the exhaust tailpipe on the muffler Secure the exhaust tailpipe to the muffler with clamp Adjust the clamp a...

Page 261: ...ol 447 05 GROVE Tier 3 Muffler FIGURE 7 8 6 10 7 11 8 9 1 5 2 3 4 2 2 2 2 3 7844 Item Description 1 Exhaust Tube 2 Clamp 3 Muffler Clamp 4 Elbow 5 Flex Tube 6 Elbow Item Description 7 Exhaust Elbow 8 Muffler 9 Mounting Band 10 Exhaust Bracket 11 Bracket ...

Page 262: ...culate Filter Muffler FIGURE 7 9 6 10 7 11 8 9 1 5 2 3 4 12 3 7843 Item Description 1 Elbow 2 Wire Tie Bar 3 Mounting Band Clamp 4 Diesel Particulate Filter 5 Muffler Clamp 6 Exhaust Tube Item Description 7 Gasket 8 V Band Clamp 9 Bellows 10 Exhaust Tube 11 Gasket 12 V Band Clamp ...

Page 263: ...tem components the effects of cooling system neglect and procedures to be followed for cooling system maintenance Effects of Cooling System Neglect Whenever an engine does not perform at top efficiency a neglected cooling system may be at fault even though the part directly responsible is not a part of the cooling system Most of these problems can be traced to overheating however an engine that is...

Page 264: ...culation during cleaning flushing and draining Run the engine with radiator covered if necessary until temperature is up to operating range 71 to 82 C 160 to 180 F Stop the engine remove the radiator cap and drain the system by opening the drain cocks on the radiator and engine block NOTE Use a cleaning compound that is not corrosive to aluminum to prevent damage to the radiator 2 Allow the engine...

Page 265: ...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 raises the valve from the gasket and releases the pressure through the overflow pipe In the first stage position of the cap it should be possible to depress the cap approximately 3 mm 0 13 in The prongs on the c...

Page 266: ...the mounting bracket on the left side of the engine hood 10 Remove the engine hood assembly 11 Remove the nuts washers and muffler clamps securing the two charge air cooler tubes to the left and right sides of the fan shroud 12 Remove the hose clamps and bellows connecting the radiator to the charge air cooler tubes 13 Remove the nuts washers and muffler clamp securing the radiator return tube 14 ...

Page 267: ...f the radiator 12 Install the hood assembly 13 Mount the surge tank to the side of the engine hood using the capscrews washers flatwashers and nuts 14 Connect the hoses between the surge tank and engine and the surge tank and the radiator 15 Install the capscrews nuts and washers holding the rear engine hood panel to the engine hood 16 Install the transmission filter to the mounting bracket on the...

Page 268: ...0E 7 22 Published 11 26 2014 Control 447 05 2 7838 1 FIGURE 7 10 1 3 5 4 6 7 Item Description 1 Fan Fan Guard 2 Shroud 3 Drain Valve 4 Radiator Item Description 5 Surge Tank 6 Upper radiator Hose 7 Lower Radiator Hose ...

Page 269: ...he left side of the front console The transmission torque converter oil is cooled by passing the oil through an externally mounted transmission cooler The cooler is located beside the hydraulic oil tank An oil filter is located on the left side of the engine hood Access to the filter is gained by opening the top left side hood door Three drive lines are used Two drive lines are connected between t...

Page 270: ...any drive shaft which has mating marks arrows align these mating marks to ensure proper phasing of coupler yokes 2 Position the drive shaft between the couplers on the two components it is joining 3 For the coupling shaft secure its bearing to the frame with bolts locknuts and washers 4 Secure the drive shaft to the coupler with bolts Torque the bolts to 149 Nm to 163 Nm 110 lb ft to 120 lb ft Lub...

Page 271: ...ding in the turbine and reaction member is the means by which the hydraulic torque converter multiplies torque The reaction member of the torque converter is located between and at the center of the inner diameters of the impeller and turbine elements Its function is to take the fluid which is exhausting from the inner portion of the turbine and change its direction to allow correct entry for reci...

Page 272: ...o not attempt these checks with cold oil 2 To bring the oil temperature to this level it is necessary to either work the machine or stall out the converter When it is impractical to work the machine stall out the converter as follows a Apply the parking brake and service brakes b Position the shift lever to forward and high speed c Accelerate the engine to between half and three quarter throttle d...

Page 273: ...ll the 12 studs in the engine flywheel housing Rotate the engine flywheel to align a drive plate mounting screw hole with the flywheel housing front access hole 7 Install a 101 6 mm 4 00 in long drive plate locating stud 3 8 24 UNF in a drive plate nut 8 Rotate the transmission torque converter to align the locating stud in the drive plate with the flywheel drive plate mounting screw hole position...

Page 274: ...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 12 Figure 4 Figure 3 Flywheel Housing Figure 2 ...

Page 275: ...sassembled and cleaned thoroughly It is realized this entails extra labor however such labor is a minor cost compared to the cost of difficulties 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 engi...

Page 276: ...POWER TRAIN RT770E 7 30 Published 11 26 2014 Control 447 05 THIS PAGE BLANK ...

Page 277: ...rable The rear axle is mounted on a pivoting cradle fifth wheel which allows the axle to oscillate while traversing uneven terrain The front axle is bolted directly to the frame All four wheels utilize a disc type hydraulic braking system A disc type parking brake is mounted of the front axle input shaft Each axle incorporates a single reduction carrier with hypoid gearing mounted in the axle cent...

Page 278: ...ng brake actuator front axle only Refer to Brake System page 8 13 in this section Cleaning Completely assembled axles may be steam cleaned on the outside only to facilitate initial removal and disassembly providing all openings are closed Breathers vented shift units and all other openings should be tightly covered or closed to prevent the possibility of water entering the assembly Installation 1 ...

Page 279: ...o see that they are not bottomed out To check the steer cylinders remove the pin at the rod end and apply pressure to move the cylinder rod The cylinder rod should travel a minimum of 3 0 mm 0 12 in Rear Steer Indicator Adjustment Procedure 1 Ensure the wheels are straight ahead NOTE When performing rear steer indicator adjustment using the following steps refer to Figure 8 1 2 Slide the proximity...

Page 280: ...ft to 360 lb ft in the sequence shown in Figure 8 2 5 Lower the crane onto its tires Retract and stow the outrigger assemblies and the floats 6 Road test the tire then retorque to 461 Nm to 488 Nm 340 lb ft to 360 lb ft 7 Maintain proper torque on wheel lugs and check for proper wheel mounting Retorque the lug nuts 80 km to 160 km 50 miles to 100 miles after the wheels are removed and reinstalled ...

Page 281: ...r or across the tire Incorrect axle alignment has a scrubbing effect on all wheels Incorrect Caster and Wheel Imbalance Incorrect caster or wheel imbalance shows as spot wear that is either in the middle of the tire or extends to the shoulder This rapidly wears the mechanical parts of steering linkage kingpin and wheel bearing FIGURE 8 3 FIGURE 8 4 Item Description 1 Incorrect Toe In 2 Incorrect T...

Page 282: ...t Wear Sudden braking locking brakes or out of round brake drums give spot wear Feathered Edges Normal occurrence on non driving wheels on good roads and high mileage Cupping Cupping is a normal occurrence that depends on the tread pattern the higher the load the greater the wear Item Description 1 Cuts 2 Flaking Cuts 3 Rubber Flaking FIGURE 8 7 FIGURE 8 8 FIGURE 8 9 FIGURE 8 10 ...

Page 283: ...or charge valve and the load sense steering control valve Theory Of Operation Front Steering System A hydraulic oil flow from pump number 2 flows through port 5 of the hydraulic swivel to the steer swing directional control valve Regulated flow from the steer priority flow divider valve is routed to the steering control valve upon turning of the steering wheel and pressurizing of the load sense li...

Page 284: ...ines or fittings b Clean or tighten lines or fittings c Defective flow divider valve s c Repair or replace valve s d Defective steering control valve d Repair or replace valve e Defective hydraulic pump e Repair or replace pump 2 Hard to steer either left or right a Clogged or loose hydraulic lines or fittings a Clean or tighten lines or fittings b Defective steer cylinder b Repair or replace cyli...

Page 285: ...hooting Table 8 2 Symptom Probable Cause Solution 1 Rear steering inoperative a Hydraulic oil low a Check system for leaks Make repairs as needed Fill reservoir b Clogged broken or loose hydraulic lines or fittings b Clean tighten or replace 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 Rep...

Page 286: ... and capscrews Torque capscrews refer to Fasteners and Torque Values page 1 16 for proper torque 2 Connect the hydraulic hoses to the control valve as tagged during removal 3 Start the engine and check for proper operation and any leakage Integrated Outrigger Rear Steer Control Valve Description The outrigger rear steer valve controls the outrigger circuit and the rear steer circuit The valve is m...

Page 287: ...d on a cradle fifth wheel allowing maximum oscillation of 5 9 in 15 cm total while traveling over uneven terrain Oscillation is provided only when the superstructure is within 2 degrees left or right of directly over the front When the superstructure is within 2 degrees left or right of directly over the front the RCL sends a CAN bus message to the Crane Control System to allow axle oscillation Wh...

Page 288: ...UNDERCARRIAGE RT770E 8 12 Published 11 26 2014 Control 447 05 Supply From Pump Lockout Valve Lockout Cylinder Rear Axle Lockout Cylinder FIGURE 8 12 ...

Page 289: ... axle oscillation system in accordance with the Operator s Manual to ensure proper operation Axle Oscillation Lockout Valve Description The axle oscillation lockout valve also called the double solenoid valve is used in the rear axle oscillation lockout circuit The valve is mounted on the left rear face of the carrier frame rear cross member forward of the rear axle It consists of a valve body and...

Page 290: ...rges the accumulators from the open center circuit upon demand and within its present operating charge rate and the high limit pressure setting However when the open center circuit pressure reaches the brake relief setting which is higher than the high accumulator charge limit then the accumulators will be charged to the relief valve setting The dual accumulator charge valve regulates flow to the ...

Page 291: ... in lines c Check all lines for leaks and restrictions d Low hydraulic oil flow d Check the hydraulic oil level in reservoir and check flow from the tandem brake valve e Air in brake lines e Bleed the brakes f Brake pads linings are grease soaked f Replace pads linings g Engine not running g Start engine Due to the operation the engine must be running to provide full brake power h Brake relief val...

Page 292: ...r Manually Bleeding the Brake System NOTE Before bleeding the brake system ensure the hydraulic accumulators are fully charged 1 Connect the end of the bleeder hose to the bleed screw on the caliper Submerge the other end in a jar partially filled with clean hydraulic oil 2 Open the bleed screw on the caliper actuator and allow fluid to flow into the jar while depressing the brake pedal Depress th...

Page 293: ...ing to the following procedure a Use a C clamp to hold a 12 7 mm 0 5 in block of 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 14 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 t...

Page 294: ...gs and End Plates Remove the shoes and linings To help prevent abnormal 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 0 125 in 3 2 mm from the back plate Refer to Figure 8 19 Lining Wear Not Even Replace ...

Page 295: ...imits replace the disc Refer to Figure 8 21 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 is w...

Page 296: ...events 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 is not available u...

Page 297: ...lb ft 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 Nm to 285 Nm 165 lb ft to 210 lb ft 4 Ensure the linings move freely in the housing 5 Bleed t...

Page 298: ... pressurize the brake actuator to release the tension on the brake linkage Engine must remain running Air pressure of 1862 kPa 270 psi may be used to pressurize the actuator 3 Remove the capscrews holding actuator to the brake caliper and slide the actuator off the actuator rod 4 Position the Park Brake Switch to ON and shut down the engine 5 Disconnect the hydraulic line from the brake actuator t...

Page 299: ...6 until they make contact with the urethane springs 33 then tighten 4 flats approximately 1 778 mm 0 07 in more This puts the proper amount of pre load on the urethane springs 5 Tighten jam nut sleeves 35 against mounting surface and torque 271 1 Nm 200 lb ft 6 Attach brake line to inlet port located on the top of the hydraulic cylinder 26 7 Apply hydraulic pressure to the brake 8 Set the running ...

Page 300: ...UNDERCARRIAGE RT770E 8 24 Published 11 26 2014 Control 447 05 FIGURE 8 28 ...

Page 301: ... 9 Ball Bearing 10 Cam 11 Dowel Pin 12 Setscrew 13 Nut 14 Disc Spring 15 Housing 16 Plug 17 Lever 18 Retainer Ring 19 Clevis Item Description 20 Clevis Pin 21 Cotter Pin 22 Jam nut 23 Rod 24 Excluder Rod 25 Retainer Ring 26 Cylinder Housing 27 Piston 28 Seal 29 Ring 30 Capscrew 31 Flatwasher 32 Spring 33 O ring Seal 34 Jam Nut 35 Capscrew 36 Lining and Carrier Assembly 37 Capscrew 38 Nut ...

Page 302: ... and rear outrigger beams are mounted on their respective outrigger boxes in turn the jack cylinders are mounted on the end of each outrigger beam The integrated outrigger rear steer valve is mounted on the front face of the carrier frame front cross member The front and rear outrigger control manifolds are mounted on the inside center of their respective outrigger box The OMS if equipped consists...

Page 303: ...Remove extension cylinder and repair as necessary j Bent cylinder rods j Replace piston rods and seals k Excessive material on outrigger beams k Clean outrigger beams l Binding outrigger beam l Repair or replace outrigger beam m Damaged outrigger valve m Repair or replace valve n Damaged valve coil n Replace coil o Main hydraulic pump cavitation o Replace or tighten hose or fitting Refer to your M...

Page 304: ...oid c Replace coil d Loss of solenoid force d Decrease time of solenoid energization decrease cycle rate 5 Outrigger jack cylinder slow or erratic a Low in hydraulic oil a Check system for leaks Make repairs as needed Fill reservoir b Damaged main relief valve b Repair or replace valve c Damaged holding valve seals c Replace holding valve seals d Bent cylinder rod d Replace cylinder rod and seals ...

Page 305: ...lace lines or fittings d Damaged relief valve or damaged control valve d Repair or replace valve 9 Outrigger system activates but selected outrigger will not stow or extend and lower as desired a Clogged broken or loose hydraulic lines or fittings a Clean tighten or replace lines or fittings b Loose or broken wire on control switch or solenoid valve b Repair or replace wiring c Damaged solenoid va...

Page 306: ...ydraulic lines at the cylinder barrel end of the extension cylinder Cap all lines and fittings NOTE Do not allow the end of the outrigger extension cylinder to fall when the cylinder mounting shaft is removed Use blocking to limit the drop or an adequate soft support to cushion any distance the rod will drop 7 Remove the OMS string potentiometer cable if equipped from the attaching point on the ou...

Page 307: ... over range of cable 8 Connect the hydraulic lines as tagged prior to removal 9 Install the side adjustable wear pad in the outrigger box 10 Adjust the wear pads refer to Wear Pad Adjustment in this Section 11 Install the end cover NOTE At installation be sure that the outrigger jack cylinder hydraulic hoses are not trapped against the outrigger box when the beam is fully retracted Wear Pad Adjust...

Page 308: ...16 20 12 17 18 19 Item Description 1 Retainer Pin 2 Cotter Pin 3 Pin 4 Extend Port 5 Retract Port 6 Outrigger Box 7 Side Wear Pad 8 Setscrew 9 Wear Pad 10 Setscrew 11 Extension Cylinder 12 Jack Cylinder 13 Cotter Pin 14 Clevis Pin 15 Pin 16 OMS Potentiometer 17 Capscrew 18 Lockwasher 19 Flatwasher 20 Spring Snap Item Description ...

Page 309: ...ished 11 26 2014 Control 447 05 GROVE FIGURE 8 30 Rear Outriggers Shown FIGURE 8 31 6065 0 06 in 1 5 mm Gap 0 06 in 1 5 mm Gap 1 1 2 2 1 Item Description 1 Side Wear Pads and Setscrews Item Description 2 Bottom Wear Pads and Setscrews ...

Page 310: ...er 2 Observe the operation of the outrigger beam If hydraulic lines are reversed stop immediately and connect lines properly per instructions Verify no jack cylinder hose is trapped by full outrigger beam retraction if any is stop immediately and install lines properly to avoid trapping 3 Check the hydraulic connections and hoses for any evidence of leakage Make repairs as needed Outrigger Monitor...

Page 311: ...enough to relieve any pressure on the cylinder retaining pin 5 Remove the cotter pins securing the cylinder retaining pin and remove the cylinder retaining pin and cylinder cap retaining bracket 6 Jack the jack cylinder up just enough to insert the retaining pin back into the cylinder Insert the retaining pin into the lugs on the cylinder and secure the pin in place with the cotter pins 7 Fasten a...

Page 312: ...r valve assemblies responsible for controlling the outrigger system the integrated outrigger rear steer valve the front and rear outrigger control manifolds and the pilot operated check valves NOTE For a more detailed description and maintenance of the valves refer to Hydraulic System page 2 1 Pilot Operated Check Valve The pilot operated check valves are located in the outrigger jack cylinder por...

Page 313: ...tially harmful waste used in Manitowoc cranes includes but is not limited to oil fuel grease coolant air conditioning refrigerant filters batteries and cloths which have come into contact with these environmentally harmful substances Handle and dispose of waste according to local state and federal environmental regulations When filling and draining crane components observe the following Do not pou...

Page 314: ...ier 4 Engine Oil 6829104182 Conoco Fleet Supreme EC Mobil Delvac 1300 Super 15W 40 CJ 4 Hydraulic Transmission Oil 6829006444 Kendall Hyken 052 Exxon Torque Fluid 56 Esso Torque Fluid 56 BP Eldoran UTH Trak Tran 9 BP Blend 7367 10W 20 Must Meet John Deere Std JDM J20c Exxon Mobil 424 10W 30 Hoist Gear Swing Drive Oil 6829100213 Mobil Mobilfluid 629 Texaco Meropa 150 AGMA No 4 EP Grease Multipurpos...

Page 315: ...cation during system warm up and proper operation of all crane functions Cold Weather Package and Lubricants Manitowoc recommends the following cold weather lubricants for use with ambient temperatures down to 29 C 20 F TABLE 9 2 and 40 C 40 F TABLE 9 3 But these cold weather lubricants alone are not sufficient to operate the crane in extreme low temperatures Therefore it is also recommended that ...

Page 316: ...F Chevron All Weather THF Texaco TDH Oil SS Must Meet John Deere Std JDM J20c J20d Hoist Gear Swing Drive Oil 6829103636 Petro Canada ENDURATEX Synthetic EP 150 Mobil SHC629 AGMA No 4 EP Grease Multipurpose 6829104275 Petro Canada Precision Syn thetic EP1 Mobil Mobilith SHC 220 NLGI 2 Open Gear Lube 6829102971 Fuchs Ceplattyn 300 Spray NLGI 1 2 Antifreeze Coolant 6829101130 Old World Industries In...

Page 317: ...ic THF Chevron All Weather THF Texaco TDH Oil SS Must Meet John Deere Std JDM J20c J20d Hoist Gear Swing Drive Oil 6829103636 Petro Canada ENDURATEX Synthetic EP 150 Mobil SHC629 AGMA No 4 EP Grease Multipurpose 6829104275 Petro Canada Precision Syn thetic EP1 Mobil Mobilith SHC 220 NLGI 2 Open Gear Lube 6829102971 Fuchs Ceplattyn 300 Spray NLGI 1 2 Antifreeze Coolant 6829104212 Old World Industri...

Page 318: ... have rods exposed even when completely retracted Assume all cylinders have exposed rods as corrosion on the end of the rod can ruin the cylinder It is recommended that all exposed cylinder rods be protected using Boeshield T 9 Premium Metal Protectant Manitowoc Crane Care has Boeshield T 9 Premium Metal Protectant available in 12 oz aerosol cans by ordering part number 9999101803 through the Part...

Page 319: ...ealed fittings will not harm the fittings or components but underlubrication will definitely lead to a shorter lifetime Unless otherwise indicated items not equipped with grease fittings such as linkages pins levers etc should be lubricated with oil once a week Motor oil applied sparingly will provide the necessary lubrication and help prevent the formation of rust An Anti Seize compound may be us...

Page 320: ...0 hours or 3 months 8 grease fittings 2 Upper and Lower King Pins Figure 9 1 EP MPG Extreme Pressure Multipurpose Grease 6829003477 Until grease extrudes 500 hours or 3 months 8 grease fittings 3 Fifth Wheel Pivots Figure 9 1 EP MPG Extreme Pressure Multipurpose Grease 6829003477 Until grease extrudes 500 hours or 3 months 2 grease fittings 4 Lockout Cylinder Pivot Pins Figure 9 1 EP MPG Extreme P...

Page 321: ...9 9 RT770E LUBRICATION 9 Published 11 26 2014 Control 447 05 GROVE 7114 17 1 4 2 7114 20 7114 10 3 FIGURE 9 1 ...

Page 322: ...t be level with the hole When checking lube level also check and clean housing breathers CAUTION Use of non approved lubricant may damage components and or invalidate published lubricant intervals CAUTION If the makeup amount is substantially more than 0 23 L 0 5 pt check for leaks 12 Planetary Hubs and Wheel Bearings Figure 9 2 GL 5 Extended Service Interval Gear Lubricant 6829012964 3 8 L 8 pt C...

Page 323: ...9 11 RT770E LUBRICATION 9 Published 11 26 2014 Control 447 05 GROVE 7114 17 11 12 7114 9 FIGURE 9 2 8130 1 ...

Page 324: ...ever in forward high range with the brakes applied and then accelerating the engine to half or three quarter throttle Hold the stall until the required converter temperature is reached and stabilized Do not operate the converter at stall condition for longer than 30 seconds at one time Shift to neutral for 15 seconds and repeat the procedure until the desired temperature is reached Excessive tempe...

Page 325: ...9 13 RT770E LUBRICATION 9 Published 11 26 2014 Control 447 05 GROVE Fill Location 7795 20a 7649 25 20b 8130 1 Other Side 7114 23 21a 7114 10 23 FIGURE 9 3 21b 7649 26 7649 27 22 Other Side ...

Page 326: ... the pre cleaner may need to be serviced Right hand side of engine hood 25a 25b a Fuel Filter b Water Separator Figure 9 4 Change filter every 500 hours or 6 months Drain water trap every 10 hours or daily Fuel filter is located on the intake manifold of engine Water Separator is located near oil cooler NOTE During replacement of the water separator take note of the direction of the arrow The arro...

Page 327: ...9 15 RT770E LUBRICATION 9 Published 11 26 2014 Control 447 05 GROVE 25b 7649 28 7114 11 7114 10 7649 15 26b 24a 26a FIGURE 9 4 8130 1 25a 7795 24b Other Side Other Side ...

Page 328: ...g 41a Turntable Gear and Drive Pinion Figure 9 5 EP OGL Open Gear Lubricant 6829102971 Coat all teeth 500 hours or 6 months Spray on 41b Turntable Swivel Lock Pin Not shown EP OGL Open Gear Lubricant 6829102971 Coat pin 500 hours or 6 months Spray on 42 Turntable Bearing Figure 9 5 EP MPG Extreme Pressure Multipurpose Grease 6829003477 Until grease extrudes the whole circumfer ence of the bearing ...

Page 329: ...9 17 RT770E LUBRICATION 9 Published 11 26 2014 Control 447 05 GROVE 42 7114 25 7114 24 41a 7649 21 FIGURE 9 5 40 8130 2 ...

Page 330: ...pose Grease 6829003477 50 hours or 1 week Brush lubricant on bottom of outrigger beams 51 Jack Cylinder Support Tubes Figure 9 6 EP MPG Extreme Pressure Multipurpose Grease 6829003477 50 hours or 1 week Brush lubricant on ID of jack cylinder support tubes 4 places and wear bands before installing jack cylinders 52 Jack Cylinder Barrels Figure 9 6 EP MPG Extreme Pressure Multipurpose Grease 6829003...

Page 331: ...9 19 RT770E LUBRICATION 9 Published 11 26 2014 Control 447 05 GROVE FIGURE 9 6 8130 1 51 52 50 ...

Page 332: ...reme Pressure Multipurpose Grease 6829003477 Until greases extrudes 500 hours or 3 months 2 grease fittings 61 Lower Lift Cylinder Pin Figure 9 7 Until greases extrudes 500 hours or 3 months 2 grease fittings 70 Hook Block Swivel Bearing Figure 9 7 Until grease extrudes 250 hours or 3 months 1 grease fitting 71 Hook Block Sheaves Figure 9 7 Until grease extrudes 250 hours or 3 months 5 grease fitt...

Page 333: ...9 21 RT770E LUBRICATION 9 Published 11 26 2014 Control 447 05 GROVE 8130 1 60 7114 16 7114 25 61 7114 32 71 70 FIGURE 9 7 ...

Page 334: ...AUTION Do not operate the crane in RCL bypass to lubricate the boom 72 Telescope Cylinder Wear Pads Figure 9 8 EP MPG Extreme Pressure Multipurpose Grease 6829003477 Thoroughly coat 125 hours 3 months 12 places Extend boom for access through holes in side of sections 3 4 N A 73A Tel 1 Rear internal Side and Bottom Wear Pads Figure 9 8 Thoroughly coat all areas the wear pad moves on 250 hours or 3 ...

Page 335: ...se 6829003477 Thoroughly coat all areas the wear pad moves on 50 hours or 1 week 4 Points 16 places Extend boom aligning grease fittings with holes in side of each boom section A 34 2 m 112 5 ft NOTE Lubricate items more frequently than interval indicated in table if environmental conditions and or operating conditions necessitate CAUTION Do not apply excessive pressure or force when greasing the ...

Page 336: ...LUBRICATION RT770E 9 24 Published 11 26 2014 Control 447 05 72 73 74 73 74 72 73 74 73 74 FIGURE 9 8 8133 ...

Page 337: ...ads move on B 18 7 m 61 4 ft 75B Boom Section Lower Front and Upper Front Wear Pads Thoroughly coat all areas the wear pad moves on 50 hours or 1 week A 34 2 m 112 5 ft NOTE Lubricate items more frequently than interval indicated in table if environmental conditions and or operating conditions necessitate 76a Extend Cable Sheaves Figure 9 9 EP MPG Extreme Pressure Multipurpose Grease 6829003477 Un...

Page 338: ... grease fittings are accessible through large access hole in side of Tele 1 B 26 2 m 86 ft 77b Retract Cable Sheaves Figure 9 9 Until grease extrudes 250 hours or 3 months 2 Points 2 grease fittings Fully extend Tele 2 and Tele 4 then access grease fittings at back of Tele 3 through access holes toward the front of Tele 2 A 34 3 m 112 5 ft Item Lube Point Description Figure No Approved Lubricant L...

Page 339: ...9 27 RT770E LUBRICATION 9 Published 11 26 2014 Control 447 05 GROVE 75 76a 75 75 75 75 75 77a 75 75 76b 77b FIGURE 9 9 8133 ...

Page 340: ...rease extrudes 250 hours or 3 months 2 grease fittings 79 Boom Extension Sheave Figure 9 10 Until grease extrudes 250 hours or 3 months 1 grease fitting 81 Upper Boom Nose Sheave Figure 9 10 Until grease extrudes 250 hours or 3 months 2 grease fittings 1 per sheave 82 Lower Boom Nose Sheave Figure 9 10 Until grease extrudes 250 hours or 3 months 5 grease fittings 83 Auxiliary Boom Nose Sheave Figu...

Page 341: ...9 29 RT770E LUBRICATION 9 Published 11 26 2014 Control 447 05 GROVE 8130 2 79 7114 15 82 81 83 7114 27 75 75 FIGURE 9 10 78 7649 17 ...

Page 342: ...oved Lubricant Lube Capacity Lube Interval Application Boom continued 84 Mast Sheave Figure 9 11 EP MPG Extreme Pressure Multipurpose Grease 6829003477 Until grease extrudes 500 hours or 12 months 1 grease fitting 85 Headache Ball Figure 9 11 Until grease extrudes 250 hours or 3 months 1 grease fitting ...

Page 343: ...9 31 RT770E LUBRICATION 9 Published 11 26 2014 Control 447 05 GROVE 84 7114 30 FIGURE 9 11 85 7115 33 8130 2 ...

Page 344: ...the top of the sight glass NOTE Line up the Fill Drain Plug with the upper access hole A Let hoist sit idle for 20 minutes for an accurate reading If oil level is not visible in sight glass the hoist is underfilled Oil escaping from vent plug B or is more than 3 mm 0 13 in from the top of the sight glass is an indication the hoist is overfilled If hoist is over filled drain the oil from the Fill D...

Page 345: ...9 33 RT770E LUBRICATION 9 Published 11 26 2014 Control 447 05 GROVE FIGURE 9 12 92 7114 7 93a 93b 93b A C A C 8130 1 B B ...

Page 346: ...e inspections should be for air borne and or ingested particles and water that deteriorate and contaminate the oil e g oil appears milky or no longer has a transparent clear to amber color The return filter by pass indicator should be observed daily to determine if the contaminants content may be high If the indicator reaches the red zone or indicates a by pass condition the hydraulic oil must be ...

Page 347: ...9 35 RT770E LUBRICATION 9 Published 11 26 2014 Control 447 05 GROVE 7649 22 101 100 FIGURE 9 13 8130 2 ...

Page 348: ...LUBRICATION RT770E 9 36 Published 11 26 2014 Control 447 05 FIGURE 9 14 102 8130 2 ...

Page 349: ...ls dirt and moisture trapped in the hard to reach areas Chipping or wear of paint cased by minor incidents 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 the surfaces of the crane that are easi...

Page 350: ...mer only will allow air and water to penetrate the repair over time Application Depending upon the environment in which a crane is used and or stored the initial factory application of Carwell T32 CP 90 should help inhibit corrosion for up to approximately 12 months It is recommended that the treatment be periodically reapplied by the crane owner after that time to help continue to protect against...

Page 351: ... and fittings wire rope on hoist roller tensioning springs on hoists all unpainted fasteners and hardware valves slew ring fasteners and all bare metal surfaces Boom applications areas are pivot pins hose end and fittings jib pins and shafts all bare metal surfaces headache ball pins hook block pins and fasteners All hardware clips pins hose connections not painted will have treatment applied 7650...

Page 352: ...LUBRICATION RT770E 9 40 Published 11 26 2014 Control 447 05 7650 76 3 Figure 9 16 7 18 9 7 7 15 9 22 20 4 1 11 12 21 13 19 THIS PAGE BLANK ...

Page 353: ...re Clips Pins Hose Connections not painted O R Pins Clips 8 Turntable Bearing Fasteners 9 O R Hose Connections 10 Hookblock Tiedown Cable 11 O R Pins Clips 12 O R Beam Wear Pad Adjustment Hardware 13 Entire underside of unit 14 Powertrain Hardware Inside Compartment 15 Valve Bank 16 Hoist Hose Connections 17 Tension Spring 18 Wire Rope 19 Counterweight Mounting Hardware 20 Counterweight Pins 21 Ho...

Page 354: ...al 9 1 High Speed Boost Selector Valve 2 54 Hoist Control Valves 5 19 Hoist Drum Rotation Indicator System 5 16 Hoist Rotation Indicator HRI and Display System 5 16 Hoist To Boom Alignment 5 9 Holding Valve 2 46 Hook Block 4 56 Hydraulic Accumulator 2 58 Hydraulic Pumps 2 17 Hydraulic Remote Control Valve 2 38 Hydraulic Swivel 6 17 Hydraulic Symbols 2 3 Idler Drum And Cable Follower 5 12 Lift Circ...

Page 355: ...sure And Return Circuit 2 9 Surface Protection for Cylinder Rods 9 6 Swing Bearing 6 10 Swing Brake And Armrest Lockout Valve Manifold 2 44 Swing Gearbox And Brake 6 8 Swing Lock Pin 6 22 Swing Motor 6 7 Swivels 6 15 Telescope Circuit 4 37 Telescope Cylinder 2 68 Telescope Fill Tube Control Valve Manifold 2 56 Telescope Stage Selector Valve Manifold 2 55 Theory of Operation 4 2 Theory of Operation...

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