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Grove GRT9165
Manitowoc Grove GRT9165 Service Manual
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5-4
Published 10-01-2020 Control # 699-00
HOIST AND COUNTERWEIG
HT
GRT9165 SER
VICE MANUAL
FIGURE
5-1
10162
10163
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1
7
30
6
22
9
8
11
12
10
12
2
20
30
20
20
24
27
28
25
26
17
18
24
20
2
10
12
11
7
3
5
4
10166
153
155
Table of Contents
Table of Contents
5
Section 1
11
Overview of Manuals
11
Customer Support
12
General Crane Design
12
Specific Crane Description
12
Lifting Capacities (Load Chart)
12
Basic Components
12
Axle Weight Distribution
12
Serial Number Location
12
Transportation and Lifting Data
12
List of Specifications
13
General
13
Dimensions
13
Capacities
13
Transmission
13
Torque Converter
13
Engine
13
Axles
13
Steering
13
Brakes
13
Boom
14
Outriggers
14
Swivel Assembly
14
Hydraulic Pumps
14
Hoists
14
GRT9165 Crane Components
18
General Maintenance
19
Cleanliness
19
After Cleaning
19
Removal and Installation
19
Disassembly and Assembly
19
Pressing Parts
20
Locking Devices
20
Wires and Cables
20
Shims
20
Hoses and Tubes
20
Bearings
21
Gaskets
21
Batteries
21
Hydraulic Systems
22
Hydraulic Fittings
23
Electrical System
25
Fatigue of Welded Structures
25
Loctite
25
Fasteners and Torque Values
26
Weld Studs
37
Wire Rope
38
General
38
Environmental Conditions
38
Dynamic Shock Loads
38
Lubrication
38
Precautions and Recommendations During Inspection or Replacement
38
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 Rope
41
Installing 35X7 Class Wire Rope
42
Procedures for Cutting and Preparing 35X7 Class Wire Rope
42
Section 2
43
Description
44
Hydraulic Symbols
44
Maintenance
46
Preparation
46
Hydraulic System Maintenance Precautions
46
Label Parts When Disassembling
46
Hydraulic Oil Recommendations
46
Draining and Flushing
46
Removing Air from the Hydraulic System
47
Parts Replacement
48
Directional Control Valves
48
Visual Inspection of Hoses and Fittings
49
Supply Pressure and Return Circuit
50
Description
50
Hydraulic Oil Return Filter Assembly
52
Fill Cap/Breather
52
Hydraulic Oil Cooler
54
Description
54
Maintenance
54
Hydraulic Pumps
56
Maintenance
56
Hydraulic Pump Distribution
60
Troubleshooting
61
Troubleshooting Aids
62
Troubleshooting Procedures
62
Valves
63
Carrier Valves
64
Outrigger Control Manifold Valves
65
Carrier Manifold Valve
67
Suspension Manifold Valve
70
Fan Control Manifold Valve
71
Differential Lock Manifold Valve
72
Bleed off Valve
73
Superstructure Valves
74
Main Directional Control Valve
75
Compact Manifold Valve
78
Accessory Manifold Valve
81
Swing Directional Control Valve
85
Dual Accumulator Charger Manifold Valve
87
Check Valve Assembly
89
Telescope Cylinder Control Valve
90
Lift Cylinder Manifold
92
Hydraulic Boom Extension Valve (Optional)
93
Removal
93
Installation
93
Functional Test
93
Pressure Setting Procedures
94
Accessing the Diagnostic Connector
96
Connecting the Manitowoc Crane Service Tool
96
Checking/Setting the Piston Pumps Cut-Off and Differential Pressures
96
Checking/Setting the Pilot Supply Pressure
98
Load Sense Relief (Max System Pressure)
101
Telescope Extend and Retract Relief Pressures
101
Checking / Setting the Swing Brake Release Pressure
102
Checking the Swing Work Pressure
103
Checking/Setting the Front Steer Pressure
103
Check the Service Brake Accumulator Charging Valve Pressure
103
Service Brake Accumulators Pre-Charge
104
Checking/Setting Cab Tilt Raise and Lower Pressures
105
Checking/Setting Counterweight and Hydraulic Boom Extension Pressures
105
Checking/Setting Outrigger Pressure, Rear Steer, and Suspension Raise
107
Suspension Raise Pressure
109
Checking/Setting Park Brake Pressure and Transmission Fan Max Pressure
109
Adjusting Controller Functions
109
Cylinders
110
Cylinder Rod Surface Protection
110
Leak Check
110
Temperature Effects on Hydraulic Cylinders
110
Description
113
General
113
Alternator
113
Batteries and Battery Disconnect Switch
114
Jump Starting Hazard
114
Charging the Batteries
114
Cab Electrical Panels
114
Carrier Electrical Panel
117
Maintenance
121
General
121
Dielectric Grease
121
Visual Inspection and Replacement of Electrical Harnesses and Cables
122
General Troubleshooting
122
Tools for Troubleshooting
123
Swivel Electrical Troubleshooting
123
Connector Troubleshooting
123
Alternator/Charging System Troubleshooting
124
Alternator Replacement
125
Starter Replacement
125
Battery Replacement
126
Steering Column and Dashboard
126
Windshield Wiper Assembly Replacement
130
Windshield Washer Assembly Replacement
130
Skylight Wiper Assembly Replacement
131
Adjusting Electronic Joysticks
132
Calibrating ODM Sensors
132
Diagnostics
132
Viewing Diagnostic Fault Codes
132
About the Manitowoc Diagnostic Code Mobile Application
132
Optional Equipment
134
Beacon Light
134
Boom Mounted Floodlights
134
Rear View Mirror
134
Air Conditioner
134
Cold Weather Operation
134
Wind Speed Indicator and Boom Position Indicator Light
135
Cameras
135
RCL Light Tower
137
Section 4
139
Boom Removal
139
Boom Installation
144
Functional Check
145
Boom Nose Sheaves
145
Boom Nose Sheaves Removal
145
Boom Nose Sheaves Installation
145
Mechanical Emergency Unlocking and Locking of the Telescopic Sections
147
Prerequisites
147
Maintenance
147
Mechanical Emergency Unlocking and Locking of
147
Check the Locking System
148
ODM Components
148
Boom Extension
150
Hook Block/Overhaul Ball
150
Hoist Description
151
Theory of Operation
151
Hoist Maintenance
152
Warm-Up Procedure
152
Hoist Area Access
152
Installing Cable on Hoist
152
Removing/Installing the Hoist
152
Removing
152
Installing
152
Functional Check
153
Hoist Fluid Level Check
153
Usage and Inspection
156
Preventative Maintenance
156
Hoist Oil Sampling
157
Brake Test Procedure
158
Hoist Motor, Motor Control Valve, and Brake
158
Description
158
Hoist Rotation and 3Rd Wrap Indicator System
158
Maintenance
159
Hoist Control Valves
160
Description
160
Removable Counterweight
160
Section 6
161
Theory of Operation
162
Swing Drive
162
Swing Brake
162
Swing Motor
164
Description
164
Maintenance
164
Swing Gearbox and Brake
164
Maintenance
166
Maintenance
169
Swing Bearing
169
Description
169
Swing Bearing Bolts
170
Swivels
173
Description
173
Hydraulic Swivel
175
Description
175
Theory of Operation
175
Maintenance
175
Two Port Water Swivel
176
Description
176
Maintenance
176
Electrical Swivel
177
Description
177
Theory of Operation
177
Maintenance
177
Swing Lock Pin
178
Description
178
Maintenance
178
360° Swing Lock Control (Positive Lock Type) (Optional)
179
Maintenance
179
Description
179
Removing the Slew Sensor
180
Installing the Slew Sensor
180
Section 7
181
Engine
181
Description
181
Maintenance
182
Engine
182
Electronic Control System
184
Description
184
Engine Control System Indicator Lights
184
Fuel System
185
Description
185
Maintenance
185
Air Intake and Exhaust System
187
Description
187
Air Intake
187
Charge-Air Cooler System
191
Exhaust System
192
Slip Joint Exhaust Connectors
193
Aftertreatment Diesel Exhaust Fluid (DEF)
196
DEF Tank
196
DEF Supply Pump Filter
197
Water Cooling System
199
Description
199
Maintenance
199
Radiator Fill and Servicing
205
Drive Train
206
Description
206
Maintenance
206
Transmission
208
Description
208
Troubleshooting and Maintenance
209
Towing or Pushing
214
Axles
215
Maintenance
217
Wheels and Tires
221
Steering Systems
222
Description
222
Maintenance
223
Rear Axle Oscillation Lockout and Suspension Raise/Lower System
226
Removing the Hydraulic Strut
227
Installing the Hydraulic Strut
227
Brake System
227
Description
227
Maintenance
228
Service Brakes
229
Description
229
Maintenance
229
Corrosion Protection
233
Parking Brake
235
Park Brake Solenoid Valve
235
Outrigger
235
Outrigger Circuit
235
Maintenance
236
Outrigger Beam
239
Outrigger Extension Cylinder
242
Outrigger Jack Cylinder
243
General
245
Environmental Protection
245
Lubricants and Lubrication Intervals
245
Standard Lubricants
246
Arctic Lubricants and Conditions
248
Arctic Conditions below -9°C (+15°F)
248
Cylinder Rod Surface Protection
251
Wire Rope Lubrication
251
Lubrication Points
251
Cranelube
251
Cummins Oil Registration List
251
Safety
252
Drive Train
253
Steering and Suspension
263
Axle Lubrication
265
Superstructure Lubrication
267
Superstructure and Cab Tilt Lubrication
272
Outrigger Lubrication
274
Lift Cylinder Lubrication
276
Boom Lubrication
278
Boom Lubrication
280
Hoist Lubrication
288
Hydraulics Lubrication
290
Rust Protection
292
Protecting Cranes from Rusting
292
Cleaning Procedures
292
Inspection and Repair
293
Application
293
Areas of Application
293
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Manitowoc Grove GRT9165 Specifications
General
Brand
Manitowoc
Model
Grove GRT9165
Category
Construction Equipment
Language
English
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