Manitowoc Grove RT880E

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INTRODUCTION RT880E SERVICE MANUAL

1-26 Published 11-10-2014, Control # 524-00

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Table of Contents5
Section 113
General13
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 Converter/Transmission15
Engine15
Axles15
Brakes15
Wheels and Tires15
Swing Gearbox15
Hydraulic Pumps16
General Maintenance21
Cleanliness21
Removal and Installation21
Disassembly and Assembly21
Pressing Parts21
Locks21
Wires and Cables22
Shims22
Hoses and Tubes22
Bearings22
Gaskets23
Batteries23
Hydraulic Systems23
Hydraulic Fittings25
Electrical System26
Fatigue of Welded Structures26
Loctite27
Fasteners and Torque Values27
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
Theory of Operation43
Maintenance43
Hydraulic Oil Recommendations43
Draining and Flushing43
Removing Air from the Hydraulic System44
Parts Replacement45
Directional Control Valves45
Supply Pressure and Return Circuit47
Hydraulic Reservoir47
Hydraulic Oil Return Filter Assembly48
Oil Cooler50
Hydraulic Pumps51
Troubleshooting58
Pressure Setting Procedures59
Procedure a - Main Control Valve Pressure for Hoists, Boom Lift, Telescope - Check/Adjust60
Procedure B - Outrigger Pressures - Adjust60
Procedure C - Oil Cooler Motor Pressure - Adjust60
Procedure D - Set Service Brake Accumulator Charge Valve Limits - Check/Adjust61
Procedure E - Accumulator Pre-Charge Pressure - Check61
Procedure F - Pre-Charging the Accumulator61
Procedure G - Front Steer Pressure - Check/Adjust61
Procedure H - Swing Work Port Pressure - Check/Adjust62
Procedure I - Swing Brake Release Pressure - Check/Adjust62
Procedure J - Controller Supply Pressure - Check/Adjust62
Procedure K - Counterweight Removal Cylinder Extend/Retract Pressure - Check62
Procedure L - Cab Tilt Cylinder Extend/Retract and Counterweight Pin Removal Pressure - Check/Adjust62
Valves69
General69
Directional Control Valves73
Description73
Maintenance73
Front Steer/Swing/Brake Manifold80
Description80
Maintenance80
Steering Control Valve84
Description84
Maintenance84
Hydraulic Remote Control Valve85
Description85
Maintenance85
Swing Power Brake Valve with Treadle Pedal89
Description89
Maintenance89
Speed Swing Valve90
Description90
Maintenance90
Tandem Brake Valve with Treadle Pedal91
Description91
Maintenance91
Dual Accumulator Charge Valve92
Description92
Maintenance92
Hydraulic Accumulator Service Brake94
Description94
Maintenance94
Holding Valves95
Description95
Maintenance96
Cross Axle Differential Lock Valve97
Description97
Maintenance97
Outrigger Control Manifold98
Description98
Maintenance98
Pilot Operated Check Valve101
Description101
Maintenance101
Axle Lockout, Rear Steer and Oil Cooler Fan Motor Control Manifold102
Description102
Maintenance102
Check Valves105
Description105
Maintenance105
Range Shift/Parking Brake Valve106
Description106
Maintenance106
Load Sense Dump Valve107
Description107
Maintenance107
Cylinders109
General109
Maintenance109
Surface Protection for Cylinder Rods109
Lift Cylinder112
Description112
Maintenance112
Trombone Telescope Cylinder115
Description115
Maintenance115
Upper Telescope Cylinder119
Description119
Maintenance120
Description120
Axle Oscillation Lockout Cylinder123
Description123
Maintenance123
Steer Cylinder126
Description126
Maintenance126
Outrigger Extension Cylinder129
Description129
Maintenance129
Outrigger Jack Cylinder132
Description132
Maintenance132
Cab Tilt Cylinder135
Description135
Maintenance135
Counterweight Removal Cylinder138
Description138
Maintenance138
Counterweight Pin Cylinder141
Description141
Maintenance141
Axle Oscillation Lockout Cylinder (CE Option)144
Description144
Maintenance144
Park Brake Cylinder146
Description146
Description147
General147
Alternator149
Batteries149
Cab Electrical Panel149
Carrier Electrical Panel152
Maintenance153
General153
General Troubleshooting155
Troubleshooting Swivel-Caused Electrical Problems155
Connector Troubleshooting155
Troubleshooting Swivel-Caused Electrical155
Problems155
Alternator/Charging System Troubleshooting157
Alternator Replacement158
Starter Replacement158
Battery Replacement159
Relay Panel Component Replacement159
Gauge Cluster Replacement160
Rocker Switch Replacement160
Ignition Switch Replacement161
Turn Signal Lever and Transmission Shift Lever Replacement162
Windshield Wiper Assembly Replacement165
Windshield Washer Assembly Replacement166
Skylight Wiper Assembly Replacement166
Troubleshooting167
Optional Equipment167
Description167
Beacon Light167
Boom Mounted Floodlights167
Rear View Mirror167
Air Conditioner167
Cold Weather Operation167
Section 4169
Description169
Lattice Extension169
Optional Lattice Extension Inserts169
Theory of Operation169
Boom Extension169
Boom Retraction170
Maintenance170
Removal170
Boom Disassembly170
Boom Nose Sheaves178
Boom Assembly179
Installation182
Functional Check182
Inspection183
Boom Alignment and Servicing183
Cam Operated Check Valve Adjustment183
Stop Block Adjustment183
Front Upper Pad Adjustment183
Read Side Wear Pad Adjustment183
Boom Extension and Retraction Cable184
Maintenance184
Inspection184
Adjustment184
Telescope Circuit186
Description186
Theory of Operation186
Maintenance186
Lift Circuit189
Description189
Theory of Operation189
Maintenance189
Auxiliary Boom Nose193
Description193
Installing the Bi-Fold Manual Boom Extension193
Checking the Transport Condition196
Boom Extension Erecting and Stowing Procedure196
Monthly Maintenance Work196
Boom Extension Erecting and Stowing196
Hook Block197
Description197
Maintenance197
Description199
Theory of Operation199
Maintenance200
Warm-Up Procedure200
Routine Maintenance and Inspection200
Removal200
Installation201
Functional Check202
Fluid Level202
Hoist to Boom Alignment203
Preparation203
Tools Required203
Procedure203
Piston Motor and Control Valve204
Description204
Maintenance204
Idler Drum and Cable Follower204
Maintenance205
Hoist Drum Rotation Indicator System207
Description207
Maintenance207
Counterweight Removal209
Removal of Standard Counterweight and Auxiliary Hoist209
Installation of Standard Counterweight and Auxiliary Hoist Mounting Structure209
Removal of Counterweight Without Auxiliary Hoist209
Removal of Counterweight Without Auxiliary209
Hoist209
Hoist210
Installation of Counterweight Without Auxiliary Hoist211
Third Wrap Indicator (Optional-Standard on CE)213
Description213
Maintenance213
Section 6215
Description215
Theory of Operation215
Maintenance217
Troubleshooting217
Swing Motor220
Description220
Maintenance220
Swing Gearbox and Brake220
Swing Bearing222
Description222
Maintenance222
Swivels226
Description226
Hydraulic Swivel228
Two Port Water Swivel229
Electrical Swivel230
Section 7233
Engine233
Description233
Maintenance234
Electronic Control System236
Engine Control System Switches and Indicator Lights236
Fuel System239
Description239
Maintenance240
Air Intake and Exhaust System240
Description240
Air Intake241
Charge-Air Cooler System245
Exhaust System246
Diesel Exhaust Fluid (DEF) System249
Water Cooling System251
Description251
Maintenance251
Drive Train257
Description257
Maintenance257
Transmission/Torque Converter259
Description259
Theory of Operation259
Maintenance260
Troubleshooting Procedures260
Towing or Pushing262
Engine Block Heater265
Axles267
Description267
Maintenance268
Wheels and Tires270
Description270
Maintenance270
Typical Wear Patterns271
Steering Systems273
Description273
Theory of Operation273
Maintenance274
Troubleshooting274
Rear Steering System275
Troubleshooting275
Hydraulic Pumps276
Front Steering Control Valve276
Rear Steer/ Axle Lockout/Fan Drive Valve276
Steer Cylinders277
Rear Axle Oscillation Lockout System277
Description277
Theory of Operation277
Axle Oscillation Lockout Cylinders279
Axle Oscillation Lockout Valve279
Brake System280
Description280
Theory of Operation280
Maintenance281
Service Brakes282
Description282
Maintenance282
Corrosion Protection286
Parking Brake Actuator288
Description288
Maintenance288
Parking Brake289
Description289
Maintenance289
Park Brake Solenoid Valve292
Description292
Maintenance292
Outriggers293
Outrigger Circuit293
Outrigger Beam297
Extension Cylinder301
Outrigger Monitoring System (Optional-Standard in North America)302
Jack Cylinder302
Outrigger Control Valves304
Optional Equipment304
Pintle Hook304
Secondary Front Steer (CE Option)304
Section 9305
General305
Environmental Protection305
Lubrication Intervals305
Standard Lubricants306
Arctic Lubricants and Conditions307
Surface Protection for Cylinder Rods310
Wire Rope Lubrication311
Lubrication Points311
Cranelube311
Safety311
Steering and Suspension312
Axles314
Drive Train316
Drive Train (Continued)319
Turntable321
Cab Tilt323
Outriggers325
Boom327
Boom (Continued)327
Hoist333
Hydraulic335
Diesel Exhaust Fluid (DEF)337
Carwell® Rust Inhibitor339
Protecting Cranes from Rusting339
Cleaning Procedures339
Inspection and Repair340
Application340
Areas of Application340

Manitowoc Grove RT880E - Page 38

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