Manitowoc Grove RT9130E-2

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7-32 Published 11-22-2016, Control # 345-12

POWER TRAIN RT9130E-2 SERVICE MANUAL

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Table of Contents5
Section 115
List of Specifications16
General16
Dimensions16
Capacities16
Torque Converter16
Transmission16
Engine16
Axles16
Brakes17
Wheels and Tires17
Swing Gearbox17
Boom17
Swivel Assembly17
Hydraulic Pumps17
Hoists17
Component Location21
General Maintenance24
Cleanliness24
After Cleaning24
Removal and Installation24
Disassembly and Assembly24
Pressing Parts25
Locking Devices25
Wires and Cables25
Shims25
Hoses and Tubes25
Bearings26
Gaskets26
Batteries26
Hydraulic Systems27
Hydraulic Fittings29
Electrical System31
Fatigue of Welded Structures31
Loctite31
Fasteners and Torque Values32
Weld Studs35
Wire Rope36
General36
Environmental Conditions36
Dynamic Shock Loads36
Lubrication36
Precautions and Recommendations During Inspection or Replacement36
Wire Rope Inspection-Running Ropes and pendant Cables37
Keeping Records37
Frequent Inspection37
Wire Rope Inspection-Boom Extension and Retraction Cables38
Wire Rope Inspection/Replacement (All Wire Rope)38
Wire Rope Inspection/Replacement38
Rope)38
Seizing Wire Rope39
Installing 35X7 Class Wire Rope Wire Rope40
Procedures for Cutting and Preparing 35X7 Class Wire Rope40
Description44
Hydraulic Oil Recommendations44
Draining and Flushing47
Removing Air from the Hydraulic System48
Parts Replacement48
Directional Control Valves48
Supply Pressure and Return Circuit50
Description50
Pump Distribution51
Maintenance52
Troubleshooting52
Filter Maintenance54
Oil Cooler57
Description57
Hydraulic Pumps58
Description58
Maintenance58
Pressure Setting Procedures63
Procedure a - for Setting Main Directional Control Valve Relief Pressures64
Procedure B - for Checking Pressure Reducing/Sequence Valve Setting66
Procedure C - for Checking Swing Brake Supply Pressure66
Procedure D - for Checking Service Brake and Air Conditioning Circuit Relief Valve Pressure66
Procedure E - for Checking Service Brake Dual Accumulator Charge Valve Pressure Limits67
Procedure F - for Checking Accumulator Pre-Charge Pressure68
Procedure G - for Pre-Charging Accumulator68
Procedure H - for Checking Front Steer Relief Valve Pressure68
Procedure I - for Checking Swing Valve Work Port Relief Pressure69
Procedure J - for Checking Relief Setting for Counterweight Supply Control Valve69
Procedure K - for Checking Outrigger/Rear Steer Relief Valve Pressure71
Procedure L - for Checking/Setting the Make-Up Oil Manifold (Thermal Contraction)71
Procedure M - for Checking Charge Air Cooler Circuit Relief Valve Pressure (Tier 3 Only)72
Checking Charge Air Cooler (CAC) Motor Control Valve - Tier 3 Only72
Procedure M - for Checking Charge Air72
Cooler Circuit Relief Valve Pressure (Tier 3 Only)72
Checking Charge Air Cooler (CAC) Motor Control72
Valves73
General73
Directional Control Valves76
Description76
Maintenance76
Swing Series Parallel Selector Valve81
Description81
Maintenance81
Pressure Reducing Sequence Valve with Solenoid Controls Manifold82
Description82
Maintenance82
Swing Brake Release Valve-Function Check82
Crane Function Valve-Function Check82
Steering Control Valve-Dual Displacement84
Description84
Maintenance84
Dual Motor Control Valve85
Description85
Maintenance85
Hydraulic Remote Control Valve86
Single Axis Control Valves86
Dual Axis Control Valves (Optional)86
Maintenance86
Swing Power Brake Valve88
Description88
Maintenance88
Double Pilot Operated Check Valve89
Description89
Maintenance89
Tandem Brake Valve W/ Treadle Pedal90
Description90
Maintenance90
Dual Accumulator Charge Valve91
Description91
Maintenance91
Service Brake Hydraulic Accumulator92
Description92
Maintenance92
Load Sense Hydraulic Accumulator92
Holding Valves93
Description93
Maintenance93
Shuttle Valve94
Description94
Maintenance94
Installation94
Solenoid Valves95
Description95
Maintenance95
Cross Axle Differential Lock Valve96
Description96
Maintenance96
Check Valves96
Outrigger/Rear Steer/Outrigger Box Pin Removal Valve97
Description97
Maintenance97
Outrigger/Rear Steer/Outrigger Box Pin97
Removal Valve97
Outrigger Control Manifold99
Description99
Maintenance99
Pilot Operated Check Valve100
Description100
Maintenance100
Pressure Bleed-Off Valve101
Description101
Maintenance101
Axle Oscillation Lockout Valve103
Description103
Maintenance103
Relief Valve103
Telescope Cylinder Charge Valve Manifold (if Equipped)104
Description104
Checking/Setting the Charge Valve Manifold104
Maintenance104
Telescope Cylinder Charge Valve Manifold104
Checking Charge Air Cooler Motor Control Valve - for Tier 3 ONLY107
Cylinders108
General108
Maintenance108
Surface Protection for Cylinder Rods108
Lift Cylinder111
Description111
Maintenance111
Dual Rod Telescope Cylinder115
Description115
Maintenance115
Upper Telescope Cylinder119
Description119
Maintenance119
Axle Oscillation Lockout Cylinder122
Description122
Maintenance122
Steer Cylinder124
Description124
Maintenance124
Outrigger Extension Cylinder128
Description128
Maintenance128
Outrigger Stabilizer Cylinder130
Description130
Maintenance130
Tilt Cylinder133
Description133
Maintenance133
Power Pin Cylinder137
Description137
Maintenance137
Park Brake Cylinder139
Description141
Section 3141
General141
Alternator141
Batteries142
Fuse Panel142
Relays143
Description144
Maintenance146
General146
General Troubleshooting146
Troubleshooting Engine Starting Problems146
Troubleshooting Engine Charging Problems147
Troubleshooting Accessories147
Troubleshooting Swivel-Caused Electrical Problems147
Connector Troubleshooting147
Troubleshooting Swivel-Caused Electrical147
Problems147
Indicator Lights149
Troubleshooting Crane Components and Accessories150
Alternator Replacement150
Starter Replacement150
Battery Replacement151
Relay Panel Component Replacement151
Gauge Cluster Replacement152
Rocker Switch Replacement153
Ignition Switch Replacement153
Turn Signal Lever and Transmission Shift Lever Replacement154
Windshield Wiper Assembly Replacement157
Windshield Washer Assembly Replacement158
Skylight Wiper Assembly Replacement158
Telescope Cylinder Charge System - Electrical Schematic (if Equipped)159
Tools for Troubleshooting161
Optional Equipment161
Beacon Light161
Boom Mounted Floodlights161
Rear View Mirror161
Air Conditioner161
Cold Weather Operation161
Section 4163
Description163
Lattice Extension163
Optional Lattice Extension163
Optional Lattice Extension Inserts163
Boom Control Switches164
Theory of Operation164
Boom Extension164
Boom Retraction165
Rated Capacity Limiter (RCL) System (with Boom Control System)165
General165
Telescoping Control System Description165
Extension Sequence for the Main Boom166
Extension Sequence for the Main Boom with Boom Extensions or Offset Jibs166
Electronic Control System168
Boom Maintenance169
Removal169
Boom Disassembly170
Boom Nose Sheaves177
Additional Maintenance, Disassembled Boom178
Boom Assembly178
Installation182
Functional Check183
Inspection183
Boom Alignment and Servicing183
Cam Operated Check Valve Adjustment184
Guide Block Adjustment184
Boom Extension and Retraction Cables184
Maintenance184
Telescope Circuit186
Description186
Theory of Operation186
Maintenance187
Hose Reel190
Description190
Maintenance190
Lift Circuit194
Description194
Theory of Operation194
Maintenance194
Boom Removal System201
Description201
Maintenance201
Bi-Fold Swingaway Boom Extension203
Description203
Identification203
Hookblock203
Maintenance203
Description205
Theory of Operation205
Maintenance206
Warm-Up Procedure206
Description210
Functional Check211
Usage and Inspection211
Preventative Maintenance211
Oil Sampling213
Brake Test Procedure213
Hoist to Boom Alignment214
Preparation214
Tools Required214
Procedure214
Motor and Brake216
Description216
Maintenance216
Idler Drum and Cable Follower217
Description217
Maintenance217
Third Wrap Indicator220
Description220
Maintenance220
Hoist Drum Rotation Indicator System222
Description222
Maintenance222
Hoist Rotation Indicator (HRI) Display System223
Counterweight Removal and Installation225
Counterweight Stand Installation225
Standard and Heavy Counterweight and Auxiliary Hoist Structure226
Counterweight Stand Removal230
Section 6231
Theory of Operation232
Swing Drive232
Swing Brake232
Maintenance234
Troubleshooting234
Swing Box Assemblies238
Description238
Swing Motor Maintenance238
Swing Brake Assembly Maintenance239
Swing Gearbox Maintenance239
Swing Bearing241
Description241
Maintenance241
Swivels246
Description246
Hydraulic Swivel248
Two-Port Water Swivel249
Electrical Swivel250
Swing Lock Pin253
Description253
Maintenance253
360° Swing Lock Control-Positive Lock Type (Optional)253
Description255
Maintenance256
Engine Drive Belts258
Electronic Control System259
Engine Control System Switches and Indicator Lamps259
Fuel System259
Description259
Engine Control System Switches and Indicator259
Maintenance260
Air Intake and Exhaust System263
Description263
Maintenance263
Description264
Charge-Air Cooler System269
Maintenance269
Muffler270
Removal270
Installation270
Water Cooling System272
Description272
Maintenance273
Drive Train279
Description279
Maintenance279
Torque Converter280
Description280
Theory of Operation280
Maintenance281
Transmission285
Description285
Maintenance288
Cleaning288
Installation288
Wheel Alignment Check Procedure288
Rear Wheels Not Centered Switch Adjustment Procedure289
Wheels and Tires290
Description290
Maintenance290
Steering Systems291
Description291
Theory of Operation291
Maintenance291
Hydraulic Pumps294
Front Steering Control Valve294
Integrated Outrigger/Rear Steer Control Valve294
Maintenance294
Steer Cylinders295
Rear Axle Oscillation Lockout System295
Axle Oscillation Lockout Cylinders297
Axle Oscillation Lockout Valve297
Brake System298
Description298
Theory of Operation298
Maintenance299
Service Brakes300
Parking Brake Actuator306
Parking Brake306
Park Brake Solenoid Valve308
Outrigger Circuit309
Description309
Theory of Operation309
Maintenance310
General321
Environmental Protection321
Standard Lubricants322
Arctic Lubricants and Conditions323
Surface Protection for Cylinder Rods325
Wire Rope Lubrication325
Lubrication Points325
Cranelube326
Cummins Oil Registration List326
Safety326
Steering and Suspension327
Axles329
Drive Train331
Drive Train (Continued)333
Turntable335
Cab Tilt337
Outriggers339
Boom341
Boom (Continued)341
Boom (Continued)343
Hoist347
Hydraulic349
Instructions for Accessing Lubrication Points on Boom351
Carwell® Rust Inhibitor352
Protecting Cranes from Rusting352
Cleaning Procedures352
Inspection and Repair353
Application353
Areas of Application353

Manitowoc Grove RT9130E-2 - Page 286

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