Manitowoc Grove GRT8100

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Published 3/26/2018, Control # 596-05

HOIST AND COUNTERWEIGHT GRT8100 SERVICE MANUAL

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Table of Contents5
Section 113
Overview of Manuals13
Customer Support14
General Crane Design14
Specific Crane Description14
Lifting Capacities (Load Chart)14
Basic Components14
Axle Weight Distribution14
Serial Number Location14
Transportation and Lifting Data14
List of Specifications15
General15
Dimensions15
Capacities15
Torque Converter15
Transmission15
Engine15
Axles15
Brakes15
Wheels and Tires15
Hydraulic Pumps16
Hoists16
Crane Nomenclature19
General Maintenance20
Cleanliness20
After Cleaning20
Removal and Installation20
Disassembly and Assembly20
Pressing Parts21
Locking Devices21
Wires and Cables21
Shims21
Hoses and Tubes21
Bearings22
Gaskets22
Batteries22
Hydraulic Systems23
Hydraulic Fittings24
Electrical System26
Fatigue of Welded Structures26
Loctite26
Fasteners and Torque Values27
Weld Studs41
Wire Rope42
General42
Environmental Conditions42
Dynamic Shock Loads42
Lubrication42
Precautions and Recommendations During Inspection or Replacement42
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 Inspection44
Wire Rope Inspection/Replacement44
Seizing Wire Rope45
Installing 35X7 Class Wire Rope46
Procedures for Cutting and Preparing 35X7 Class Wire Rope46
Section 247
Description49
Hydraulic Symbols49
Maintenance51
Preparation51
Hydraulic System Maintenance Precautions51
Label Parts When Disassembling51
Hydraulic Oil Recommendations51
Draining and Flushing51
Removing Air from the Hydraulic System52
Parts Replacement53
Directional Control Valves53
Visual Inspection of Hoses and Fittings54
Supply Pressure and Return Circuit55
Description55
Hydraulic Pump Distribution57
Troubleshooting58
Troubleshooting Aids59
Troubleshooting Procedures59
Hydraulic Oil Return Filter Assembly60
Fill Cap/Breather60
Oil Cooler62
Description62
Maintenance62
Hydraulic Pumps64
Description64
Maintenance66
Pressure Setting Procedures69
Checking/Setting the Piston Pumps Cut-Off and Differential Pressures70
Checking/Setting the Main Directional Control Valve, Hoists, Lift, and Telescope Pressures72
Checking/Setting the Pilot Supply Pressure76
Checking/Setting the Front Steer Pressure76
Checking/Setting the Swing Brake Release Pressure77
Checking the Swing Work Pressure77
Checking the Service Brake Accumulator Charging Valve Pressure78
Checking the Service Brake Accumulators Pre-Charge79
Pre-Charging the Accumulators80
Checking/Setting Cab Tilt, Counterweight Removal, and Counterweight Pinning Pressures81
Checking/Setting the Outriggers, Rear Steer, and Hydraulic Transmission Oil Cooler Fan Motor Pressures82
Checking/Setting the Axle Lockout Circuit Pressure84
Checking/Setting the Luffing Jib Pressure84
Valves85
General85
Main Directional Control Manifold Valve88
Description88
Maintenance88
Swing Manifold Valve92
Description92
Maintenance92
Compact Manifold Valve95
Description95
Maintenance95
Accessory Manifold Valve98
Description98
Maintenance98
Lift Cylinder and Telescope Cylinder Control Valves102
Description102
Maintenance102
Lift Cylinder and Telescope Cylinder102
Carrier Combination Manifold Valve103
Description103
Maintenance103
Outrigger Control Manifold107
Description107
Maintenance107
Range Shift/Park Brake Manifold Valve109
Description109
Maintenance109
Telescope and Tele Fill Stage Select Manifold Valve110
Description110
Maintenance110
Dual Accumulator Charge Manifold Valve112
Description112
Maintenance112
Hydraulic Brake Accumulator114
Description114
Maintenance114
Cylinders115
Cylinder Rod Surface Protection115
Leak Check115
Temperature Effects on Hydraulic Cylinders116
Description119
Alternator119
Batteries and Battery Disconnect Switch120
Cab Electrical Panel120
Carrier Electrical Panel125
Maintenance129
General129
General Troubleshooting130
Tools for Troubleshooting130
Swivel Electrical Troubleshooting130
Connector Troubleshooting130
Alternator/Charging System Troubleshooting132
Replace Alternator132
Starter Replacement133
Battery Replacement133
Relay Panel Components134
Steering Column and Dashboard134
Windshield Wiper Assembly Replacement138
Windshield Washer Assembly Replacement138
Skylight Wiper Assembly Replacement139
Adjusting Electronic Joysticks140
Fault Codes140
Optional Equipment144
Beacon Light144
Boom Mounted Floodlights144
Rear View Mirror144
Air Conditioner144
Cold Weather Operation145
Section 4147
Description147
Theory of Operation148
Maintenance150
Removal150
Disassembly165
Boom Nose Sheaves174
Assembly175
Installation175
Installation191
Functional Check191
Inspection191
Boom Alignment and Servicing192
Boom Extension and Retraction Cable192
Maintenance192
Inspection192
Cable Tensioning Check and Adjustment192
Telescope Circuit195
Description195
Theory of Operation195
Maintenance196
Removal and Installation197
Disassembly and Assembly197
Lift Circuit198
Description198
Theory of Operation198
Maintenance198
Lift Cylinder Removal200
Lift Cylinder Installation200
Hook Block202
Description202
Maintenance202
Adjusting Boom Extension Stowage Mounts203
Description207
Theory of Operation207
Maintenance208
Warm-Up Procedure208
Hoist Area Access208
Installing Cable on Hoist209
Removing/Installing the Hoist210
Removing210
Installing210
Functional Check210
Hoist Fluid Level Check210
Usage and Inspection212
Preventative Maintenance212
Oil Sampling213
Brake Test Procedure214
Motor, Motor Control Valve, and Brake214
Description214
Hoist Rotation and Minimum Wrap Indicator System215
Description215
Maintenance215
Hoist Rotation and Minimum Wrap215
Indicator System215
Hoist Control Valves216
Description216
Removable Counterweight217
Counterweight Control Panel217
Remove218
Install218
Install Optional Counterweight Slab219
Remove Optional Counterweight Slab219
Description221
Theory of Operation222
Swing Drive222
Swing Brake222
Maintenance224
Swing Motor227
Description227
Maintenance227
Swing Gearbox and Brake228
Description228
Maintenance228
Swing Bearing230
Description230
Maintenance230
Swivels235
Description235
Description236
Hydraulic Swivel237
Description237
Theory of Operation237
Maintenance237
Two Port Water Swivel239
Description239
Maintenance239
Electrical Swivel240
Description240
Theory of Operation240
Maintenance240
Swing Lock Pin241
Description241
Maintenance242
360° Swing Lock Control (Positive Lock Type) (Optional)242
Description242
360° Swing Lock Control (Positive Lock Type)242
Engine243
Description243
Maintenance244
Electronic Control System246
Description246
Engine Control System Indicator Lights246
Fuel System247
Description247
Maintenance247
Air Intake and Exhaust System249
Description249
Air Intake249
Charge-Air Cooler System254
Exhaust System255
Slip Joint Exhaust Connectors - Tier 3 and 4255
Water Cooling System258
Description258
Maintenance258
Radiator Fill and Servicing262
Drive Train264
Description264
Maintenance264
Transmission/Torque Converter265
Description265
Theory of Operation265
Maintenance266
Towing or Pushing270
Description271
Maintenance271
Wheels and Tires274
Typical Wear Patterns274
Description274
Maintenance274
Steering Systems277
Description277
Maintenance277
Rear Axle Oscillation Lockout System280
Description280
Theory of Operation280
Axle Oscillation Lockout Cylinders282
Axle Oscillation Lockout Valve282
Brake System282
Description282
Theory of Operation283
Service Brakes283
Maintenance284
Service Brakes285
Description285
Maintenance285
Corrosion Protection289
Parking Brake Actuator291
Description291
Maintenance291
Parking Brake292
Description292
Maintenance292
Park Brake Solenoid Valve294
Outrigger295
Outrigger Circuit295
Maintenance296
Outrigger Beam299
Extension Cylinder302
Outrigger Monitoring System (Optional-Standard in North America)302
Jack Cylinder303
General305
Environmental Protection305
Lubricants and Lubrication Intervals305
Standard Lubricants307
Arctic Lubricants and Conditions309
Cylinder Rod Surface Protection312
Wire Rope Lubrication312
Lubrication Points312
Cranelube312
Cummins Oil Registration List312
Safety312
Drive Train313
Drive Train (Continued)314
Drive Train (Continued)316
Steering and Suspension318
Steering and Suspension (Continued)319
Axles320
Turntable (Continued)321
Cab Tilt322
Outriggers323
Lift Cylinder323
Boom (Continued)324
Hoist330
Hydraulic331
Diesel Exhaust Fluid (DEF) Tank332
Rust Protection333
Cleaning Procedures333
Inspection and Repair334
Application334
Areas of Application334

Manitowoc Grove GRT8100

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