Manitowoc Grove RT765E-2

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INTRODUCTION RT765E-2 SERVICE MANUAL

1-26

Published 9-04-2014, Control # 422-08

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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
Hoists16
Crane Nomenclature19
General Maintenance21
Cleanliness21
After Cleaning21
Removal and Installation21
Disassembly and Assembly21
Pressing Parts22
Locking Devices22
Wires and Cables22
Shims22
Hoses and Tubes22
Bearings23
Gaskets23
Batteries23
Hydraulic Systems24
Hydraulic Fittings25
Electrical System26
Fatigue of Welded Structures27
Loctite27
Fasteners and Torque Values28
Weld Studs31
Wire Rope32
General32
Environmental Conditions32
Dynamic Shock Loads32
Lubrication32
Precautions and Recommendations During Inspection or Replacement32
Wire Rope Inspection (Running Ropes and pendant Cables)33
Wire Rope Inspection (Boom Extension and Retraction Cables)34
Wire Rope Inspection/Replacement (All Wire Rope)34
Seizing Wire Rope35
Installing 35X7 Class Wire Rope36
Procedures for Cutting and Preparing 35X7 Class Wire Rope36
Section 239
Description40
Hydraulic Symbols41
Maintenance43
Preparation43
Hydraulic System Maintenance Precautions43
Label Parts When Disassembling43
Hydraulic Oil Recommendations43
Draining and Flushing43
Removing Air from the Hydraulic System44
Parts Replacement45
Directional Control Valves45
Supply Pressure and Return Circuit47
Description47
Pump Distribution48
Troubleshooting48
Troubleshooting Aids50
Troubleshooting Procedures50
Hydraulic Oil Return Filter Assembly51
Fill Cap/Breather51
Oil Cooler53
Description53
Oil Temperature Switches53
Hydraulic Pumps55
Description55
Maintenance55
Pump Disconnect Assembly59
Disassembly59
Assembly59
Pressure Setting Procedures61
Procedure a - Main Control Valve Reliefs62
Procedure B - Main Directional Control Valve Pilot Supply Pressure63
Procedure C - Swing Brake Pilot Supply Pressure63
Procedure D - Brake Charge Supply Valve Relief Pressure63
Procedure E - Charge Air Cooler Valve Relief Pressure64
Procedure F - Brake Dual Accumulator Charge Valve Pressure Limits64
Procedure G - Accumulator Pre-Charge Pressure64
Procedure H - Precharging the Accumulator65
Procedure I - Swing Valve Work Port Reliefs Pressure65
Procedure J - Front Steer Relief Valve Pressure66
Procedure K - Outrigger/Rear Steer Valve Relief66
Procedure L - Hydraulic Oil Cooler Fan Motor Control Valve66
Procedure M - Counterweight Removal Valve67
Valves68
General68
Directional Control Valves71
Description71
Maintenance71
Hydraulic Remote Control Valve76
Description76
Maintenance76
Dual Accumulator Charge Valve79
Description79
Maintenance79
Swing Brake and Armrest Lockout Valve Manifold81
Description81
Maintenance81
Holding Valve83
Description83
Maintenance83
Boom Lock Valve83
Outrigger/Rear Steer Valve85
Description85
Maintenance86
Outrigger Control Manifold87
Description87
Maintenance88
Parking Brake/Range Shift Valve89
Description89
Maintenance89
Axle Oscillation Lockout Valve91
Description91
Maintenance91
High Speed Boost Selector Valve92
Description92
Maintenance92
Hydraulic Accumulator93
Description93
Maintenance93
Service Brake and CAC Fan Motor Priority Flow Control Valve94
Description94
Maintenance94
Oil Cooler Fan Motor Priority Flow Control Valve95
Description95
Maintenance95
Oil Cooler Fan Motor Priority Flow Control95
Telescope Cylinder Charge Valve Manifold (if Equipped)96
Description96
Maintenance96
Valve96
Description98
Cylinders99
General99
Maintenance99
Surface Protection for Cylinder Rods99
Temperature Effects on Hydraulic Cylinders100
Lift Cylinder102
Description102
Maintenance102
Lower Telescope Cylinder106
Description106
Maintenance106
Upper Telescope Cylinder110
Description110
Maintenance110
Axle Oscillation Lockout Cylinder113
Description113
Maintenance113
Steer Cylinder116
Description116
Maintenance116
Outrigger Extension Cylinder119
Description119
Maintenance119
Outrigger Jack Cylinder122
Description122
Maintenance122
Counterweight Removal Cylinder125
Description125
Maintenance125
Description129
General129
Alternator131
Batteries131
Cab Electrical Panel131
Carrier Electrical Panel133
Maintenance135
General135
General Troubleshooting136
Troubleshooting Swivel-Caused Electrical Problems136
Connector Troubleshooting136
Alternator/Charging System Troubleshooting137
Alternator Replacement139
Starter Replacement139
Battery Replacement140
Relay Panel Component Replacement140
Gauge Cluster Replacement141
Rocker Switch Replacement141
Ignition Switch Replacement142
Turn Signal Lever and Transmission Shift Lever Replacement143
Windshield Wiper Assembly Replacement145
Windshield Washer Assembly Replacement146
Skylight Wiper Assembly Replacement146
Telescope Cylinder Charge System - Electrical Schematic (if Equipped)148
Tools for Troubleshooting149
Optional Equipment149
Beacon Light149
Boom Mounted Floodlights149
Rear View Mirror149
Air Conditioner149
Cold Weather Operation149
Section 4151
Description151
Theory of Operation151
Boom Extension151
Boom Retraction152
Maintenance152
Removal152
Boom Extension152
Disassembly157
Boom Nose Sheaves159
Assembly160
Installation160
Installation163
Functional Check164
Inspection164
Boom Alignment and Servicing164
Cam Operated Check Valve Adjustment165
Guide Block Adjustment165
Boom Extension and Retraction Cable166
Maintenance166
Inspection166
Adjustment166
Telescope Circuit167
Description167
Theory of Operation167
Maintenance168
Description170
Theory of Operation170
Maintenance170
Lift Cylinder Removal172
Disassembly and Assembly172
Lift Cylinder Installation172
Swingaway Boom Extension174
Description174
Maintenance174
Description182
Description183
Theory of Operation183
Maintenance184
Warm-Up Procedure184
Hoist Area Access184
Removal186
Installation186
Functional Check186
Fluid Level186
Description186
Usage and Inspection187
Preventative Maintenance187
Oil Sampling189
Brake Test Procedure189
Hoist to Boom Alignment190
Preparation190
Tools Required190
Procedure190
Motor and Brake192
Description192
Idler Drum and Cable Follower193
Description193
Maintenance193
Description194
Third Wrap Indicator (Optional-Standard on CE)196
Description196
Maintenance196
Third Wrap Indicator196
On CE)196
Hoist Drum Rotation Indicator System197
Description197
Maintenance197
Hoist Control Valves199
Description199
Fixed Counterweight200
Description200
Maintenance200
Counterweight Plate200
Removable Counterweight (Optional)202
Removal202
Installation202
Description205
Theory of Operation205
Swing Drive205
Swing Brake205
Swing Drive206
Maintenance207
Swing Brake209
Swing Motor211
Description211
Maintenance211
Swing Gearbox and Brake212
Description212
Maintenance212
Swing Bearing214
Description214
Maintenance214
Swivels219
Description219
Description220
Hydraulic Swivel221
Description221
Theory of Operation221
Maintenance221
Two Port Water Swivel223
Description223
Maintenance223
Electrical Swivel224
Description224
Theory of Operation224
Maintenance224
Swing Lock Pin226
Description226
Maintenance226
360° Swing Lock Control (Positive Lock Type) (Optional)226
Engine227
Description227
Maintenance228
Electronic Control System230
Description230
Engine Control System Switches and Indicator Lights230
Fuel System233
Description233
Maintenance233
Description234
Air Intake and Exhaust System235
Description235
Air Intake235
Charge-Air Cooler System239
Muffler240
Water Cooling System243
Description243
Maintenance243
Drive Train248
Description248
Maintenance248
Transmission/Torque Converter250
Description250
Theory of Operation250
Maintenance251
Troubleshooting Procedures251
Towing or Pushing254
Description255
Maintenance256
Wheels and Tires258
Typical Wear Patterns258
Description258
Maintenance258
Steering Systems261
Description261
Theory of Operation261
Maintenance262
Rear Steering System263
Troubleshooting263
Hydraulic Pumps264
Front Steering Control Valve264
Integrated Outrigger/Rear Steer Control Valve264
Steer Cylinders264
Rear Axle Oscillation Lockout System265
Description265
Theory of Operation265
Axle Oscillation Lockout Cylinders267
Axle Oscillation Lockout Valve267
Maintenance267
Brake System267
Description267
Theory of Operation268
Maintenance269
Service Brakes270
Description270
Maintenance270
Corrosion Protection274
Parking Brake Actuator276
Description276
Maintenance276
Parking Brake277
Description277
Maintenance277
Park Brake Solenoid Valve280
Description280
Maintenance280
Outrigger280
Outrigger Circuit280
Maintenance281
Outrigger Beam284
Extension Cylinder288
Outrigger Monitoring System (Optional-Standard in North America)288
Jack Cylinder289
Outrigger Control Valves290
General291
Environmental Protection291
Standard Lubricants291
Arctic Lubricants and Conditions293
Surface Protection for Cylinder Rods296
Wire Rope Lubrication296
Lubrication Points297
Cranelube297
Safety297
Steering and Suspension298
Drive Train302
Drive Train (Continued)304
Turntable306
Outriggers308
Boom310
Boom (Continued)312
Hoist316
Hydraulic318
Carwell® Rust Inhibitor321
Protecting Cranes from Rusting321
Cleaning Procedures321
Inspection and Repair322
Application322
Areas of Application322

Manitowoc Grove RT765E-2 - Page 38

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