Manitowoc Grove GRT9165 - Service Manual

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Service Manual

Grove GRT9165

9897

Main Page

Table of Contents5
Section 111
Overview of Manuals11
Customer Support12
General Crane Design12
Specific Crane Description12
Lifting Capacities (Load Chart)12
Basic Components12
Axle Weight Distribution12
Serial Number Location12
Transportation and Lifting Data12
List of Specifications13
General13
Dimensions13
Capacities13
Transmission13
Torque Converter13
Engine13
Axles13
Steering13
Brakes13
Boom14
Outriggers14
Swivel Assembly14
Hydraulic Pumps14
Hoists14
GRT9165 Crane Components18
General Maintenance19
Cleanliness19
After Cleaning19
Removal and Installation19
Disassembly and Assembly19
Pressing Parts20
Locking Devices20
Wires and Cables20
Shims20
Hoses and Tubes20
Bearings21
Gaskets21
Batteries21
Hydraulic Systems22
Hydraulic Fittings23
Electrical System25
Fatigue of Welded Structures25
Loctite25
Fasteners and Torque Values26
Weld Studs37
Wire Rope38
General38
Environmental Conditions38
Dynamic Shock Loads38
Lubrication38
Precautions and Recommendations During Inspection or Replacement38
Wire Rope Inspection (Running Ropes and pendant Cables)39
Wire Rope Inspection (Boom Extension and Retraction Cables)40
Wire Rope Inspection/Replacement (All Wire Rope)40
Seizing Wire Rope41
Installing 35X7 Class Wire Rope42
Procedures for Cutting and Preparing 35X7 Class Wire Rope42
Section 243
Description44
Hydraulic Symbols44
Maintenance46
Preparation46
Hydraulic System Maintenance Precautions46
Label Parts When Disassembling46
Hydraulic Oil Recommendations46
Draining and Flushing46
Removing Air from the Hydraulic System47
Parts Replacement48
Directional Control Valves48
Visual Inspection of Hoses and Fittings49
Supply Pressure and Return Circuit50
Description50
Hydraulic Oil Return Filter Assembly52
Fill Cap/Breather52
Hydraulic Oil Cooler54
Description54
Maintenance54
Hydraulic Pumps56
Maintenance56
Hydraulic Pump Distribution60
Troubleshooting61
Troubleshooting Aids62
Troubleshooting Procedures62
Valves63
Carrier Valves64
Outrigger Control Manifold Valves65
Carrier Manifold Valve67
Suspension Manifold Valve70
Fan Control Manifold Valve71
Differential Lock Manifold Valve72
Bleed off Valve73
Superstructure Valves74
Main Directional Control Valve75
Compact Manifold Valve78
Accessory Manifold Valve81
Swing Directional Control Valve85
Dual Accumulator Charger Manifold Valve87
Check Valve Assembly89
Telescope Cylinder Control Valve90
Lift Cylinder Manifold92
Hydraulic Boom Extension Valve (Optional)93
Removal93
Installation93
Functional Test93
Pressure Setting Procedures94
Accessing the Diagnostic Connector96
Connecting the Manitowoc Crane Service Tool96
Checking/Setting the Piston Pumps Cut-Off and Differential Pressures96
Checking/Setting the Pilot Supply Pressure98
Load Sense Relief (Max System Pressure)101
Telescope Extend and Retract Relief Pressures101
Checking / Setting the Swing Brake Release Pressure102
Checking the Swing Work Pressure103
Checking/Setting the Front Steer Pressure103
Check the Service Brake Accumulator Charging Valve Pressure103
Service Brake Accumulators Pre-Charge104
Checking/Setting Cab Tilt Raise and Lower Pressures105
Checking/Setting Counterweight and Hydraulic Boom Extension Pressures105
Checking/Setting Outrigger Pressure, Rear Steer, and Suspension Raise107
Suspension Raise Pressure109
Checking/Setting Park Brake Pressure and Transmission Fan Max Pressure109
Adjusting Controller Functions109
Cylinders110
Cylinder Rod Surface Protection110
Leak Check110
Temperature Effects on Hydraulic Cylinders110
Description113
General113
Alternator113
Batteries and Battery Disconnect Switch114
Jump Starting Hazard114
Charging the Batteries114
Cab Electrical Panels114
Carrier Electrical Panel117
Maintenance121
General121
Dielectric Grease121
Visual Inspection and Replacement of Electrical Harnesses and Cables122
General Troubleshooting122
Tools for Troubleshooting123
Swivel Electrical Troubleshooting123
Connector Troubleshooting123
Alternator/Charging System Troubleshooting124
Alternator Replacement125
Starter Replacement125
Battery Replacement126
Steering Column and Dashboard126
Windshield Wiper Assembly Replacement130
Windshield Washer Assembly Replacement130
Skylight Wiper Assembly Replacement131
Adjusting Electronic Joysticks132
Calibrating ODM Sensors132
Diagnostics132
Viewing Diagnostic Fault Codes132
About the Manitowoc Diagnostic Code Mobile Application132
Optional Equipment134
Beacon Light134
Boom Mounted Floodlights134
Rear View Mirror134
Air Conditioner134
Cold Weather Operation134
Wind Speed Indicator and Boom Position Indicator Light135
Cameras135
RCL Light Tower137
Section 4139
Boom Removal139
Boom Installation144
Functional Check145
Boom Nose Sheaves145
Boom Nose Sheaves Removal145
Boom Nose Sheaves Installation145
Mechanical Emergency Unlocking and Locking of the Telescopic Sections147
Prerequisites147
Maintenance147
Mechanical Emergency Unlocking and Locking of147
Check the Locking System148
ODM Components148
Boom Extension150
Hook Block/Overhaul Ball150
Hoist Description151
Theory of Operation151
Hoist Maintenance152
Warm-Up Procedure152
Hoist Area Access152
Installing Cable on Hoist152
Removing/Installing the Hoist152
Removing152
Installing152
Functional Check153
Hoist Fluid Level Check153
Usage and Inspection156
Preventative Maintenance156
Hoist Oil Sampling157
Brake Test Procedure158
Hoist Motor, Motor Control Valve, and Brake158
Description158
Hoist Rotation and 3Rd Wrap Indicator System158
Maintenance159
Hoist Control Valves160
Description160
Removable Counterweight160
Section 6161
Theory of Operation162
Swing Drive162
Swing Brake162
Swing Motor164
Description164
Maintenance164
Swing Gearbox and Brake164
Maintenance166
Maintenance169
Swing Bearing169
Description169
Swing Bearing Bolts170
Swivels173
Description173
Hydraulic Swivel175
Description175
Theory of Operation175
Maintenance175
Two Port Water Swivel176
Description176
Maintenance176
Electrical Swivel177
Description177
Theory of Operation177
Maintenance177
Swing Lock Pin178
Description178
Maintenance178
360° Swing Lock Control (Positive Lock Type) (Optional)179
Maintenance179
Description179
Removing the Slew Sensor180
Installing the Slew Sensor180
Section 7181
Engine181
Description181
Maintenance182
Engine182
Electronic Control System184
Description184
Engine Control System Indicator Lights184
Fuel System185
Description185
Maintenance185
Air Intake and Exhaust System187
Description187
Air Intake187
Charge-Air Cooler System191
Exhaust System192
Slip Joint Exhaust Connectors193
Aftertreatment Diesel Exhaust Fluid (DEF)196
DEF Tank196
DEF Supply Pump Filter197
Water Cooling System199
Description199
Maintenance199
Radiator Fill and Servicing205
Drive Train206
Description206
Maintenance206
Transmission208
Description208
Troubleshooting and Maintenance209
Towing or Pushing214
Axles215
Maintenance217
Wheels and Tires221
Steering Systems222
Description222
Maintenance223
Rear Axle Oscillation Lockout and Suspension Raise/Lower System226
Removing the Hydraulic Strut227
Installing the Hydraulic Strut227
Brake System227
Description227
Maintenance228
Service Brakes229
Description229
Maintenance229
Corrosion Protection233
Parking Brake235
Park Brake Solenoid Valve235
Outrigger235
Outrigger Circuit235
Maintenance236
Outrigger Beam239
Outrigger Extension Cylinder242
Outrigger Jack Cylinder243
General245
Environmental Protection245
Lubricants and Lubrication Intervals245
Standard Lubricants246
Arctic Lubricants and Conditions248
Arctic Conditions below -9°C (+15°F)248
Cylinder Rod Surface Protection251
Wire Rope Lubrication251
Lubrication Points251
Cranelube251
Cummins Oil Registration List251
Safety252
Drive Train253
Steering and Suspension263
Axle Lubrication265
Superstructure Lubrication267
Superstructure and Cab Tilt Lubrication272
Outrigger Lubrication274
Lift Cylinder Lubrication276
Boom Lubrication278
Boom Lubrication280
Hoist Lubrication288
Hydraulics Lubrication290
Rust Protection292
Protecting Cranes from Rusting292
Cleaning Procedures292
Inspection and Repair293
Application293
Areas of Application293

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Manitowoc Grove GRT9165 - Service Manual

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