Manitowoc Grove GRT880

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TABLE OF CONTENTS GRT880 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 Studs40
Wire Rope41
General41
Environmental Conditions41
Dynamic Shock Loads41
Lubrication41
Precautions and Recommendations During Inspection or Replacement41
Wire Rope Inspection (Running Ropes and pendant Cables)42
Wire Rope Inspection (Boom Extension and Retraction Cables)43
Wire Rope Inspection/Replacement (All Wire Rope)43
Seizing Wire Rope44
Installing 35X7 Class Wire Rope45
Procedures for Cutting and Preparing 35X7 Class Wire Rope45
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
Carrier Combination Manifold Valve103
Description103
Maintenance103
Outrigger Control Manifold107
Description107
Maintenance107
Range Shift/Park Brake Manifold Valve109
Maintenance109
Description109
Maintenance110
Telescope and Tele Fill Stage Select Manifold Valve110
Description110
Maintenance112
Dual Accumulator Charge Manifold Valve112
Description112
Maintenance114
Hydraulic Brake Accumulator114
Description114
Cylinders115
Cylinder Rod Surface Protection115
Leak Check115
Temperature Effects on Hydraulic Cylinders116
Description119
General119
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
Boom Removal148
Boom Disassembly161
Boom Nose Sheaves Removal and Installation175
Removal175
Installation175
Boom Assembly175
Boom Installation195
Boom Functional Check197
Boom Inspection197
Boom Alignment and Servicing197
Boom Extension and Retraction Cables197
Maintenance197
Inspection197
Cable Tensioning Check and Adjustment197
Telescope Circuit199
Description199
Theory of Operation199
Maintenance200
Removal and Installation201
Disassembly and Assembly201
Lift Circuit202
Description202
Theory of Operation202
Maintenance202
Lift Cylinder Removal204
Lift Cylinder Installation204
Hook Block207
Description207
Maintenance207
Adjusting Boom Extension Stowage Mounts208
Description211
Theory of Operation211
Maintenance212
Warm-Up Procedure212
Hoist Area Access212
Installing Cable on Hoist213
Removing/Installing the Hoist214
Removing214
Installing214
Functional Check214
Hoist Fluid Level Check214
Usage and Inspection216
Preventative Maintenance216
Oil Sampling217
Brake Test Procedure218
Motor, Motor Control Valve, and Brake218
Description218
Hoist Rotation and Minimum Wrap Indicator System219
Description219
Maintenance219
Hoist Rotation and Minimum Wrap Indicator219
Hoist Control Valves220
Description220
Removable Counterweight221
Counterweight Control Panel221
Removing222
Installing222
Description223
Theory of Operation224
Swing Drive224
Swing Brake224
Maintenance226
Swing Motor229
Description229
Maintenance229
Swing Gearbox and Brake230
Description230
Maintenance230
Swing Bearing232
Description232
Maintenance232
Swivels237
Description237
Hydraulic Swivel239
Description239
Theory of Operation239
Maintenance239
Two Port Water Swivel241
Description241
Maintenance241
Electrical Swivel242
Description242
Theory of Operation242
Maintenance242
Swing Lock Pin243
Description243
Maintenance244
360° Swing Lock Control (Positive Lock Type) (Optional)244
Description244
360° Swing Lock Control (Positive Lock Type)244
Engine245
Description245
Maintenance246
Electronic Control System248
Description248
Engine Control System Indicator Lights248
Fuel System249
Description249
Maintenance249
Air Intake and Exhaust System251
Description251
Air Intake251
Charge-Air Cooler System256
Exhaust System257
Slip Joint Exhaust Connectors - Tier 3 and 4257
Water Cooling System260
Description260
Maintenance260
Radiator Fill and Servicing264
Drive Train266
Description266
Maintenance266
Transmission/Torque Converter267
Description267
Theory of Operation267
Maintenance268
Towing or Pushing272
Description273
Maintenance273
Wheels and Tires276
Typical Wear Patterns276
Description276
Maintenance276
Steering Systems279
Description279
Maintenance279
Rear Axle Oscillation Lockout System282
Description282
Theory of Operation282
Axle Oscillation Lockout Cylinders284
Axle Oscillation Lockout Valve284
Brake System284
Description284
Theory of Operation285
Maintenance286
Service Brakes287
Description287
Maintenance287
Corrosion Protection291
Parking Brake Actuator293
Description293
Maintenance293
Parking Brake294
Description294
Maintenance294
Park Brake Solenoid Valve296
Outrigger297
Outrigger Circuit297
Maintenance298
Outrigger Beam301
Extension Cylinder304
Outrigger Monitoring System (Optional-Standard in North America)304
Jack Cylinder305
General307
Environmental Protection307
Lubricants and Lubrication Intervals308
Standard Lubricants309
Arctic Lubricants and Conditions311
Cylinder Rod Surface Protection314
Wire Rope Lubrication314
Lubrication Points314
Cranelube314
Cummins Oil Registration List315
Safety315
Drive Train317
Drive Train (Continued)319
Drive Train (Continued)320
Steering and Suspension321
Steering and Suspension (Continued)322
Axles323
Turntable324
Turntable (Continued)324
Cab Tilt325
Outriggers326
Lift Cylinder327
Boom (Continued)328
Hoist333
Hydraulic334
Rust Protection335
Cleaning Procedures335
Inspection and Repair336
Application336
Areas of Application336

Manitowoc Grove GRT880 - Page 12

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