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Grove GRT8100
Manitowoc Grove GRT8100 Service Manual
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Published 3/26/2018, Control # 596-05
GRT8100 SER
VICE MANUAL
BOOM
4
GROVE
FIGURE
4-
103
1
4
4
4
1
1
1
Lock Hitch
Pin
Lock Hitch
Pin
204
206
Table of Contents
Table of Contents
5
Section 1
13
Overview of Manuals
13
Customer Support
14
General Crane Design
14
Specific Crane Description
14
Lifting Capacities (Load Chart)
14
Basic Components
14
Axle Weight Distribution
14
Serial Number Location
14
Transportation and Lifting Data
14
List of Specifications
15
General
15
Dimensions
15
Capacities
15
Torque Converter
15
Transmission
15
Engine
15
Axles
15
Brakes
15
Wheels and Tires
15
Hydraulic Pumps
16
Hoists
16
Crane Nomenclature
19
General Maintenance
20
Cleanliness
20
After Cleaning
20
Removal and Installation
20
Disassembly and Assembly
20
Pressing Parts
21
Locking Devices
21
Wires and Cables
21
Shims
21
Hoses and Tubes
21
Bearings
22
Gaskets
22
Batteries
22
Hydraulic Systems
23
Hydraulic Fittings
24
Electrical System
26
Fatigue of Welded Structures
26
Loctite
26
Fasteners and Torque Values
27
Weld Studs
41
Wire Rope
42
General
42
Environmental Conditions
42
Dynamic Shock Loads
42
Lubrication
42
Precautions and Recommendations During Inspection or Replacement
42
Wire Rope Inspection (Running Ropes and pendant Cables)
43
Wire Rope Inspection (Boom Extension and Retraction Cables)
44
Wire Rope Inspection/Replacement (All Wire Rope)
44
Wire Rope Inspection (Running Ropes and pendant Cables)
44
Wire Rope Inspection
44
Wire Rope Inspection/Replacement
44
Seizing Wire Rope
45
Installing 35X7 Class Wire Rope
46
Procedures for Cutting and Preparing 35X7 Class Wire Rope
46
Section 2
47
Description
49
Hydraulic Symbols
49
Maintenance
51
Preparation
51
Hydraulic System Maintenance Precautions
51
Label Parts When Disassembling
51
Hydraulic Oil Recommendations
51
Draining and Flushing
51
Removing Air from the Hydraulic System
52
Parts Replacement
53
Directional Control Valves
53
Visual Inspection of Hoses and Fittings
54
Supply Pressure and Return Circuit
55
Description
55
Hydraulic Pump Distribution
57
Troubleshooting
58
Troubleshooting Aids
59
Troubleshooting Procedures
59
Hydraulic Oil Return Filter Assembly
60
Fill Cap/Breather
60
Oil Cooler
62
Description
62
Maintenance
62
Hydraulic Pumps
64
Description
64
Maintenance
66
Pressure Setting Procedures
69
Checking/Setting the Piston Pumps Cut-Off and Differential Pressures
70
Checking/Setting the Main Directional Control Valve, Hoists, Lift, and Telescope Pressures
72
Checking/Setting the Pilot Supply Pressure
76
Checking/Setting the Front Steer Pressure
76
Checking/Setting the Swing Brake Release Pressure
77
Checking the Swing Work Pressure
77
Checking the Service Brake Accumulator Charging Valve Pressure
78
Checking the Service Brake Accumulators Pre-Charge
79
Pre-Charging the Accumulators
80
Checking/Setting Cab Tilt, Counterweight Removal, and Counterweight Pinning Pressures
81
Checking/Setting the Outriggers, Rear Steer, and Hydraulic Transmission Oil Cooler Fan Motor Pressures
82
Checking/Setting the Axle Lockout Circuit Pressure
84
Checking/Setting the Luffing Jib Pressure
84
Valves
85
General
85
Main Directional Control Manifold Valve
88
Description
88
Maintenance
88
Swing Manifold Valve
92
Description
92
Maintenance
92
Compact Manifold Valve
95
Description
95
Maintenance
95
Accessory Manifold Valve
98
Description
98
Maintenance
98
Lift Cylinder and Telescope Cylinder Control Valves
102
Description
102
Maintenance
102
Lift Cylinder and Telescope Cylinder
102
Carrier Combination Manifold Valve
103
Description
103
Maintenance
103
Outrigger Control Manifold
107
Description
107
Maintenance
107
Range Shift/Park Brake Manifold Valve
109
Description
109
Maintenance
109
Telescope and Tele Fill Stage Select Manifold Valve
110
Description
110
Maintenance
110
Dual Accumulator Charge Manifold Valve
112
Description
112
Maintenance
112
Hydraulic Brake Accumulator
114
Description
114
Maintenance
114
Cylinders
115
Cylinder Rod Surface Protection
115
Leak Check
115
Temperature Effects on Hydraulic Cylinders
116
Description
119
Alternator
119
Batteries and Battery Disconnect Switch
120
Cab Electrical Panel
120
Carrier Electrical Panel
125
Maintenance
129
General
129
General Troubleshooting
130
Tools for Troubleshooting
130
Swivel Electrical Troubleshooting
130
Connector Troubleshooting
130
Alternator/Charging System Troubleshooting
132
Replace Alternator
132
Starter Replacement
133
Battery Replacement
133
Relay Panel Components
134
Steering Column and Dashboard
134
Windshield Wiper Assembly Replacement
138
Windshield Washer Assembly Replacement
138
Skylight Wiper Assembly Replacement
139
Adjusting Electronic Joysticks
140
Fault Codes
140
Optional Equipment
144
Beacon Light
144
Boom Mounted Floodlights
144
Rear View Mirror
144
Air Conditioner
144
Cold Weather Operation
145
Section 4
147
Description
147
Theory of Operation
148
Maintenance
150
Removal
150
Disassembly
165
Boom Nose Sheaves
174
Assembly
175
Installation
175
Installation
191
Functional Check
191
Inspection
191
Boom Alignment and Servicing
192
Boom Extension and Retraction Cable
192
Maintenance
192
Inspection
192
Cable Tensioning Check and Adjustment
192
Telescope Circuit
195
Description
195
Theory of Operation
195
Maintenance
196
Removal and Installation
197
Disassembly and Assembly
197
Lift Circuit
198
Description
198
Theory of Operation
198
Maintenance
198
Lift Cylinder Removal
200
Lift Cylinder Installation
200
Hook Block
202
Description
202
Maintenance
202
Adjusting Boom Extension Stowage Mounts
203
Description
207
Theory of Operation
207
Maintenance
208
Warm-Up Procedure
208
Hoist Area Access
208
Installing Cable on Hoist
209
Removing/Installing the Hoist
210
Removing
210
Installing
210
Functional Check
210
Hoist Fluid Level Check
210
Usage and Inspection
212
Preventative Maintenance
212
Oil Sampling
213
Brake Test Procedure
214
Motor, Motor Control Valve, and Brake
214
Description
214
Hoist Rotation and Minimum Wrap Indicator System
215
Description
215
Maintenance
215
Hoist Rotation and Minimum Wrap
215
Indicator System
215
Hoist Control Valves
216
Description
216
Removable Counterweight
217
Counterweight Control Panel
217
Remove
218
Install
218
Install Optional Counterweight Slab
219
Remove Optional Counterweight Slab
219
Description
221
Theory of Operation
222
Swing Drive
222
Swing Brake
222
Maintenance
224
Swing Motor
227
Description
227
Maintenance
227
Swing Gearbox and Brake
228
Description
228
Maintenance
228
Swing Bearing
230
Description
230
Maintenance
230
Swivels
235
Description
235
Description
236
Hydraulic Swivel
237
Description
237
Theory of Operation
237
Maintenance
237
Two Port Water Swivel
239
Description
239
Maintenance
239
Electrical Swivel
240
Description
240
Theory of Operation
240
Maintenance
240
Swing Lock Pin
241
Description
241
Maintenance
242
360° Swing Lock Control (Positive Lock Type) (Optional)
242
Description
242
360° Swing Lock Control (Positive Lock Type)
242
Engine
243
Description
243
Maintenance
244
Electronic Control System
246
Description
246
Engine Control System Indicator Lights
246
Fuel System
247
Description
247
Maintenance
247
Air Intake and Exhaust System
249
Description
249
Air Intake
249
Charge-Air Cooler System
254
Exhaust System
255
Slip Joint Exhaust Connectors - Tier 3 and 4
255
Water Cooling System
258
Description
258
Maintenance
258
Radiator Fill and Servicing
262
Drive Train
264
Description
264
Maintenance
264
Transmission/Torque Converter
265
Description
265
Theory of Operation
265
Maintenance
266
Towing or Pushing
270
Description
271
Maintenance
271
Wheels and Tires
274
Typical Wear Patterns
274
Description
274
Maintenance
274
Steering Systems
277
Description
277
Maintenance
277
Rear Axle Oscillation Lockout System
280
Description
280
Theory of Operation
280
Axle Oscillation Lockout Cylinders
282
Axle Oscillation Lockout Valve
282
Brake System
282
Description
282
Theory of Operation
283
Service Brakes
283
Maintenance
284
Service Brakes
285
Description
285
Maintenance
285
Corrosion Protection
289
Parking Brake Actuator
291
Description
291
Maintenance
291
Parking Brake
292
Description
292
Maintenance
292
Park Brake Solenoid Valve
294
Outrigger
295
Outrigger Circuit
295
Maintenance
296
Outrigger Beam
299
Extension Cylinder
302
Outrigger Monitoring System (Optional-Standard in North America)
302
Jack Cylinder
303
General
305
Environmental Protection
305
Lubricants and Lubrication Intervals
305
Standard Lubricants
307
Arctic Lubricants and Conditions
309
Cylinder Rod Surface Protection
312
Wire Rope Lubrication
312
Lubrication Points
312
Cranelube
312
Cummins Oil Registration List
312
Safety
312
Drive Train
313
Drive Train (Continued)
314
Drive Train (Continued)
316
Steering and Suspension
318
Steering and Suspension (Continued)
319
Axles
320
Turntable (Continued)
321
Cab Tilt
322
Outriggers
323
Lift Cylinder
323
Boom (Continued)
324
Hoist
330
Hydraulic
331
Diesel Exhaust Fluid (DEF) Tank
332
Rust Protection
333
Cleaning Procedures
333
Inspection and Repair
334
Application
334
Areas of Application
334
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Manitowoc Grove GRT8100 Specifications
General
Brand
Manitowoc
Model
Grove GRT8100
Category
Construction Equipment
Language
English
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