Grove Crane 7755B & YB7722 Service Manual – PDF DOWNLOAD

Description

Grove Crane 7755B & YB7722 Service Manual – PDF DOWNLOAD

FILE DETAILS:

Grove Crane 7755B & YB7722 Service Manual – PDF DOWNLOAD

Language : English
Pages : 434
Downloadable : Yes
File Type : PDF
Size: 33.8 MB

DESCRIPTION:

Grove Crane 7755B & YB7722 Service Manual – PDF DOWNLOAD

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Grove Crane 7755B & YB7722 Service Manual – PDF DOWNLOAD

SECTION 1 INTRODUCTION
SECTION 2 SAFETY PRACTICES
SECTION 3 ELECTRIC SYSTEM
SECTION 4 HYDRAULIC SYSTEM
SECTION 5 PREVENTATIVE MAINTENANCE
SECTION 6 ENGINE AND ENGINE SYSTEMS
SECTION 7 TRANSMISSION AND TORQUE CONVERTER
SECTION 8 AXLES/DRIVE SHAFTS/WHEELS AND TIRES
SECTION 9 BRAKE SYSTEM
SECTION 10 STEERING SYSTEM
SECTION 11 STRUCTURALS
SECTION 12 SCHEMATICS/WIRING DIAGRAMS

SECTION 1 Introduction
Directional Reference 1-1
Identification Plates 1-1
Specifications 1-2
General Service Information 1-4
Cleaning Instructions 1-4
Complete Assemblies 1-4
Parts with Machined Surfaces 1-4
Bearings 1-4
Rough Parts 1-4
Rubber Parts 1-4
After Cleaning 1-4
To Prevent Corrosion 1-4
O-ring, Seal and Elastic Nut Replacement 1-4
Hoses and Tubes 1-5
Inspection 1-5
Installation 1-5
Bearings 1-5
Removal 1-5
Cleaning 1-5
Installation 1-5
Hydraulic Pressure Testing 1-5
Torques 1-6
Bolts and Nuts (Table 1-1 and Table 1-2) 1-6
Weld Studs (Table 1-3) 1-7
Hydraulic Fitting 1-7
SECTION 2 Safety Practices
Introduction 2-1
Signal Words 2-1
Personal Considerations 2-2
Equipment Considerations 2-2
General Considerations 2-3
Operational Considerations 2-3
Final Word 2-4
SECTION 3 Electric System
General 3-1
Comparing Electrical System to a Hydraulic System 3-1
Magnetism 3-1
Main Electrical System 3-1
General 3-1
Wire Harnesses 3-2
Fuses 3-2
Charging System 3-3
Alternator and Voltage Regulator 3-3
Battery(s) 3-3
Voltmeter 3-3
Pressure Switch 3-3
Resistor (Diesel Only) 3-3
Special Precautions 3-3
Battery Maintenance and Charging 3-4
Starting Circuit 3-4
General Inspections 3-4
Starting Circuit Check 3-4
Instrument and Light Circuits 3-5
Reference Only
TABLE OF CONTENTS 7755 & YB7722
TOC-2
General 3-5
Light Bulbs 3-5
Gauges 3-5
Wire Harnesses 3-6
Engine Wire Harness 3-6
Main Frame Wire Harness 3-6
Instrument Panel Wire Harness 3-6
Outrigger Wire Harnesses 3-6
Heater 3-11
Troubleshooting 3-11
SECTION 4 Hydraulic System
Technical Data 4-1
Hydraulic Pressures: 4-1
Rated Pump Output at 2500 RPM: 4-1
General Description 4-1
General 4-1
Hydraulic System 4-2
Troubleshooting 4-2
Troubleshooting Aids 4-2
Troubleshooting Procedures 4-2
Troubleshooting Guides 4-4
General Hydraulic System Troubleshooting 4-4
Lift Circuit Troubleshooting 4-6
Telescope (Crowd) Circuit Troubleshooting 4-6
Standard Outrigger Circuit Troubleshooting 4-7
Independent Outrigger Circuit 4-8
Main Winch Circuit Troubleshooting 4-9
Swing Circuit Troubleshooting 4-9
Hydraulic System 4-10
System Description 4-10
Description of Operation 4-10
Suction, Return and Pump Pressure Circuits 4-13
General 4-13
Hydraulic Pumps 4-16
System Pressure Relief Valves 4-20
Three Section Main Control Valve 4-20
Lift Circuit 4-28
General 4-28
Oil Flow 4-28
Counterbalance Valve 4-28
Lift Cylinder Leakage Test 4-28
4-29
Hydraulic Swivel 4-32
Telescope Circuit 4-32
General 4-32
Oil Flow 4-32
Counterbalance Valve 4-33
Port Relief Valve 4-38
Hydraulic Swivel 4-38
Main Winch (Hoist) Circuit 4-38
General 4-38
Oil Flow 4-38
Drain Line 4-38
Brake Holding Valve 4-38
Hydraulic Swivel 4-38
Reference Only
GROVE TOC-3
7755 & YB7722 TABLE OF CONTENTS
T
OC
Swing Circuit 4-42
General 4-42
Oil Flow 4-42
Pilot Control System 4-44
General 4-44
Oil Flow 4-44
Pressure Reducing Valve 4-44
Anti-Double Block System 4-46
General 4-46
System Function 4-46
Outrigger and Axle Lock Out Circuits 4-49
General 4-49
Oil Flow 4-49
Outrigger Valve 4-55
Load Holding Valves 4-57
Vertical Outrigger Cylinder Leakage Check 4-57
Component Repair 4-57
Main Hydraulic Pump Repair 4-57
Secondary Hydraulic Pump(s) Repair 4-58
Main Control Valves 4-59
Outrigger Control Valve 4-64
Swing Motor 4-65
Winch Motor 4-70
Hydraulic Swivel 4-71
Hydraulic Cylinders 4-73
SECTION 5 Preventative Maintenance
Introduction 5-1
Spark Arresting Mufflers 5-1
Safety List 5-1
Lubricants 5-1
Maintenance Records 5-1
Special Maintenance 5-1
Delivery Inspection 5-1
After First 50 Hours of Operation (New Cranes) 5-2
After First 100 Hours of Operation (New Cranes) 5-2
Cranes Not In Regular Use 5-2
Preventive Maintenance 5-2
Maintenance Schedule and Checklist 5-2
Lubrication Points 5-5
Scheduled Maintenance 5-8
Daily (Walk-around) Inspection 5-8
50 Hours of Operation (Weekly) 5-13
100 Hours of Operation (Two Weeks) 5-16
250 Hours of Operation (Monthly) 5-17
500 Hours of Operation (3 Months) 5-21
1000 Hours of Operation (6 Months) 5-24
2000 Hours of Operation (Yearly) 5-29
Miscellaneous Maintenance 5-30
Batteries/Charging System 5-30
Fuel System 5-31
Fuse Replacement 5-31
SECTION 6 Engine and Engine Systems
General 6-1
Engine Performance 6-1
Reference Only
TABLE OF CONTENTS 7755 & YB7722
TOC-4
Engine RPM 6-1
Governor 6-1
Engine Crankcase System 6-1
Crankcase Oil Data 6-1
Engine Cooling System 6-2
Coolant Requirements 6-2
Radiator Cap and Overflow Bottle 6-2
Thermostat 6-3
Engine Electrical System 6-3
Engine Fuel System 6-3
QSB Engine Electronic Controlled Fuel System Units (Current Production) 6-4
Types of Fuel to Use 6-4
Engine Air Intake System 6-5
Engine Exhaust System 6-5
Removal and Installation 6-7
Removal 6-7
Installation 6-7
SECTION 7 Transmission and Torque Converter
Towing or Pushing 7-1
Safety Precautions 7-1
4 Speed FPS Longdrop 7-2
Cleaning and Inspection 7-3
Cleaning 7-3
Inspection 7-3
Technical Specifications 7-4
Identification of the Unit 7-4
Weight, Dimensions, Oil Capacity 7-4
Tightening Torques 7-5
Pressure and Temperature Specifications 7-8
Electrical Specifications 7-8
Hydraulic Cooler and Filter Line Specifications 7-8
Maintenance 7-9
Oil Specification 7-9
Maintenance Intervals 7-10
Servicing Machine After Components Overhaul 7-10
Installation Details 7-11
Converter Drive Coupling 7-11
Transmission to Engine Installation Procedure 7-12
External Plumbing 7-13
Speed Sensor Installation 7-14
Operation of the Transmission 7-16
The Transmission Assembly 7-16
Electric Solenoid Controls 7-20
Powerflows, Activated Solenoids and Hydraulic Circuit 7-21
Gear and Clutch Lay-Out 7-33
Troubleshooting Guide 7-34
Troubleshooting Procedures 7-34
Troubleshooting Guide 7-36
Check Points 7-37
Speed Sensor – Static Standalone Test 7-39
Sectional Views and Parts Identification 7-40
Group – Converter Housing 7-40
Group – Transmission Case and Rear Cover 7-41
Group – Turbine Shaft 7-42
Group – Drive Plate 7-43
Reference Only
GROVE TOC-5
7755 & YB7722 TABLE OF CONTENTS
T
OC
Group – Torque Converter 7-44
Group – Auxiliary Pump Drive 7-45
Group – Pump Drive 7-46
Group – Forward Shaft 7-47
Group – Reverse and 2nd Shaft 7-48
Group – Reverse Idler 7-49
Group – High Idler 7-50
Group – Low Speed Shaft 7-51
Group – 4th-High and 3rd Shaft 7-52
Group – Idler Shaft 7-53
Group – Output Shaft 7-54
Group – Charging Pump and Filter 7-55
Group – Electric Control Valve Mounting 7-56
Group – Electric Control Valve Assembly 7-57
Assembly Instructions 7-58
Disassembly and Assembly 7-62
Disassembly of Converter Housing 7-73
Disassembly of Low (1st) Clutch 7-78
Reassembly of Low (1st) Clutch 7-81
Disassembly of Reverse Clutch 7-84
Disassembly of 2nd Clutch 7-86
Reassembly of 2nd Clutch 7-88
Reassembly of Reverse Clutch 7-89
Disassembly of 3rd Clutch 7-93
Disassembly of 4th-High 7-94
Reassembly of 4th-High 7-96
Reassembly of 3rd Clutch 7-99
Disassembly of Forward Clutch 7-101
Reassembly of Forward Clutch 7-103
Reassembly of Converter Housing 7-105
Disassembly of Output Shaft 7-112
Reassembly of Output Shaft 7-113
Reassembly of Transmission 7-114
Service Tools 7-127
Reverse Idler Shaft Nut Socket (Tg 1304 – 54) 7-127
Removal 7-127
Installation 7-128
SECTION 8 Axles/Drive Shafts/Wheels and Tires
Description 8-1
Front Axle and Rear Axle 8-1
Technical Data 8-2
Front and Rear Drive Axle 8-2
Front and Rear Drive Axle Repair 8-3
Removal 8-3
Installation 8-3
Special Tools 8-3
Drive Head – Disassembly 8-5
Drive Head – Assembly 8-7
Axle Hub and Driveshaft – Disassembly 8-13
Axle Hub and Driveshaft – Assembly 8-14
Drive Shafts 8-16
Removal 8-16
Disassembly 8-16
Inspection 8-17
Assembly 8-17
Reference Only
TABLE OF CONTENTS 7755 & YB7722
TOC-6
Installation 8-18
Lubrication Procedure 8-18
Wheel and Tires 8-19
Tire Inflation 8-19
Wheel Stud Nuts 8-19
SECTION 9 Brake System
Technical Data 9-1
Axle Brakes 9-1
Accumulator 9-1
Accumulator Charging Valve 9-1
Description 9-2
Service Brake System 9-2
Parking Brake System 9-4
Maintenance and Adjustments 9-5
Service Brake Bleeding 9-5
Parking Brake Bleeding 9-5
Parking Brake Adjustment 9-6
Accumulator Charging 9-6
Residual Brake System Pressure 9-6
Service Brake Repair 9-6
Parking Brake Repair 9-7
Brake Modulating Valve Repair 9-11
Troubleshooting 9-13
Service Brakes 9-13
SECTION 10 Steering System
Technical Data 10-1
Description 10-1
General 10-1
Steering Modes 10-1
Two-Wheel Steering 10-1
Four-Wheel Steering 10-4
Crab Steering 10-4
Relief Valve Pressure Check and Adjustment 10-7
Pressure Check 10-7
Steering Proximity Switches 10-7
General 10-7
Principle of Operation 10-7
Sensor Operation and Spacing Checks 10-10
Steering Orbitrol 10-13
Description 10-13
Orbitrol Repair 10-13
Steering Cylinder 10-20
Technical Data 10-20
Special Tools 10-20
Cylinder/Power Track Repair 10-21
Bleeding Steering System 10-25
SECTION 11 Structurals
Booms 11-1
Five -Section Boom 11-1
Maintenance 11-1
Boom Adjustment 11-2
Boom Repair 11-5
Wire Rope, Sheave and Hoist Blocks 11-21
Reference Only
Wire Rope Description 11-21
Wire Rope Safety 11-21
Inspecting Wire Rope 11-22
Inspection of Sheaves 11-22
Wire Rope Lubrication 11-23
Wire Rope Installation 11-23
Main Winch (Braden Model) 11-25
Theory of Operation 11-25
Winch Operation 11-25
Repair 11-28
Troubleshooting 11-46
Bearing, Mast and Related Parts 11-48
General 11-48
Mast Bearing 11-48
Mast Bearing Bolts 11-48
Inspection for Bearing Wear 11-49
Replacing the Mast Bearing 11-49
Swing Gearbox and Pinion 11-50
Swing Gearbox Repair 11-53
Brake Cylinder Service 11-57
Planet Assembly Service 11-59
Outriggers 11-60
SECTION 12 Schematics/Wiring Diagrams
Reference

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