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Grove Crane RT 770E Service & Maintenance Manual – PDF DOWNLOAD
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Description
Grove Crane RT 770E Service & Maintenance Manual – PDF DOWNLOAD
FILE DETAILS:
Grove Crane RT 770E Service & Maintenance Manual – PDF DOWNLOAD
Language : English
Pages : 350
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Grove Crane RT 770E Service & Maintenance Manual – PDF DOWNLOAD
INTRODUCTION:
GENERAL MAINTENANCE:
These general suggestions should be helpful in following the instructions in this manual. In
analyzing a system malfunction, use a systematic approach to locate and correct the problem.
1. Determine the problem.
2. List possible causes.
3. Devise checks.
4. Conduct checks in a logical order to determine the cause.
5. Consider the remaining service life of components against the cost of parts and
labor necessary to replace them.
6. Make the necessary repair.
7. Recheck to ensure that nothing has been overlooked.
8. Functionally test the failed part in its system.
Cleanliness:
- An important item in preserving the long life of the machine is keeping dirt out of working parts.
Enclosed compartments, seals, and filters have been provided to keep the supply of air, fuel, and
lubricants clean. It is important that these enclosures be maintained. - Whenever hydraulic, fuel, lubricating oil lines, or air lines are disconnected, clean the adjacent
area, as well as, the point of connection. As soon as the disconnection is made, cap, plug, or tape
each line or opening to prevent entry of foreign material. The same recommendations for cleaning
and covering apply when access covers or inspection plates are removed. - Clean and inspect all parts. Be sure all passages and holes are open. Cover all parts to keep them
clean. Be sure parts are clean when they are installed. Leave new parts in their containers until
ready for assembly. - Clean the rust preventive compound from all machined surfaces of new parts before installing them.
After Cleaning:
- Remove all water or solvent from the parts immediately after cleaning. Use compressed air or a
clean cloth. - Make sure the parts are completely dry and clean. DO NOT use
compressed air on bearings. Spinning bearings without lubricant will cause damage to the bearing,
and could cause the bearing to fly apart.
TABLE OF CONTENTS:
Grove Crane RT 770E Service & Maintenance Manual – PDF DOWNLOAD
Table of Contents...................................................................................................................................................... 5 SECTION 1.............................................................................................................................................................. 13 Introduction....................................................................................................................................................... 13 General........................................................................................................................................................ 13 Overview of Manuals........................................................................................................................................ 13 Customer Support........................................................................................................................................... 14 General Crane Design....................................................................................................................................... 14 Specific Crane Description................................................................................................................................. 14 Lifting Capacities (Load Chart)............................................................................................................................ 14 Basic Components........................................................................................................................................... 14 Axle Weight Distribution................................................................................................................................... 14 Serial Number Location..................................................................................................................................... 14 Transportation and Lifting Data............................................................................................................................ 14 List Of Specifications......................................................................................................................................... 15 General.................................................................................................................................................... 15 Dimensions................................................................................................................................................. 15 Capacities................................................................................................................................................. 15 Torque Converter........................................................................................................................................... 15 Transmission............................................................................................................................................... 15 Engine..................................................................................................................................................... 15 Cummins QSB 6.7........................................................................................................................................ 15 Axles...................................................................................................................................................... 15 Brakes..................................................................................................................................................... 15 Wheels and Tires........................................................................................................................................... 15 Swing Gearbox.............................................................................................................................................. 15 Boom....................................................................................................................................................... 15 Swivel Assembly............................................................................................................................................ 15 Hydraulic Pumps............................................................................................................................................ 15 Pump #1................................................................................................................................................ 15 Pump #2................................................................................................................................................ 15 Pump #3................................................................................................................................................ 15 Hoists..................................................................................................................................................... 16 Crane Nomenclature......................................................................................................................................... 19 General Maintenance............................................................................................................................................ 21 Cleanliness................................................................................................................................................ 21 After Cleaning............................................................................................................................................. 21 Removal and Installation................................................................................................................................... 21 Disassembly and Assembly................................................................................................................................... 21 Pressing Parts............................................................................................................................................. 22 Locking Devices............................................................................................................................................ 22 Wires and Cables........................................................................................................................................... 22 Shims...................................................................................................................................................... 22 Hoses and Tubes............................................................................................................................................ 22 Inspection............................................................................................................................................. 22 Installation........................................................................................................................................... 23 Bearings................................................................................................................................................... 23 Antifriction Bearings.................................................................................................................................. 23 Double Row, Tapered Roller............................................................................................................................. 23 Heating Bearings....................................................................................................................................... 23 Installation........................................................................................................................................... 23 Preload................................................................................................................................................ 23 Sleeve Bearings........................................................................................................................................ 23 Gaskets.................................................................................................................................................... 23 Batteries.................................................................................................................................................. 23 Hydraulic Systems.......................................................................................................................................... 24 Cleanliness............................................................................................................................................ 24 Keep the System Clean.................................................................................................................................. 24 Sealing Elements....................................................................................................................................... 24 Hydraulic Lines........................................................................................................................................ 24 Visual Inspection of Hoses and Fittings................................................................................................................ 24 Hydraulic Fittings......................................................................................................................................... 25 Flats from Finger Tight (F.F.F.T.) Method.............................................................................................................. 25 37° Flared Steel Fitting: Tube or Hose to Fitting...................................................................................................... 25 Adjustable Straight Thread O-ring Fittings............................................................................................................. 25 Nonadjustable Straight Thread O-ring Fitting: Fitting to Port.......................................................................................... 26 Electrical System.......................................................................................................................................... 26 Harnesses, Wires, and Connectors....................................................................................................................... 26 Fatigue of Welded Structures............................................................................................................................... 27 Loctite®................................................................................................................................................... 27 Application of Medium Strength Loctite®................................................................................................................ 27 Primer Application................................................................................................................................. 27 Adhesive/Sealant Application....................................................................................................................... 27 Fasteners and Torque Values................................................................................................................................ 28 Torque Wrenches........................................................................................................................................ 28 Torque Values.......................................................................................................................................... 28 Weld Studs................................................................................................................................................. 31 Wire Rope...................................................................................................................................................... 32 General.................................................................................................................................................... 32 Environmental Conditions................................................................................................................................... 32 Dynamic Shock Loads........................................................................................................................................ 32 Lubrication................................................................................................................................................ 32 Precautions and Recommendations During Inspection or Replacement........................................................................................... 32 Wire Rope Inspection (Running Ropes and Pendant Cables).................................................................................................... 33 Keeping Records........................................................................................................................................ 33 Frequent Inspection.................................................................................................................................... 33 Periodic Inspection.................................................................................................................................... 34 Wire Rope Inspection (Boom Extension and Retraction Cables)................................................................................................ 34 Periodic Inspection.................................................................................................................................... 34 Wire Rope Inspection/Replacement (All Wire Rope)........................................................................................................... 34 Seizing Wire Rope.......................................................................................................................................... 35 Method 1............................................................................................................................................... 35 Method 2............................................................................................................................................... 35 Installing 35x7 Class Wire Rope............................................................................................................................ 36 Procedures for Cutting and Preparing 35x7 Class Wire Rope.................................................................................................. 36 SECTION 2.............................................................................................................................................................. 39 Hydraulic System................................................................................................................................................... 39 Description.................................................................................................................................................... 40 Hydraulic Symbols.............................................................................................................................................. 41 Maintenance.................................................................................................................................................... 43 Preparation................................................................................................................................................ 43 Hydraulic System Maintenance Precautions................................................................................................................... 43 Label Parts When Disassembling............................................................................................................................. 43 Hydraulic Oil Recommendations.............................................................................................................................. 43 Draining and Flushing...................................................................................................................................... 43 Removing Air From the Hydraulic System..................................................................................................................... 44 Parts Replacement.......................................................................................................................................... 45 Directional Control Valves................................................................................................................................. 45 Inspection............................................................................................................................................. 45 Valve Leakage.......................................................................................................................................... 45 Binding Spools......................................................................................................................................... 45 Visual Inspection of Hoses and Fittings.................................................................................................................... 46 Supply Pressure And Return Circuit............................................................................................................................. 47 Description................................................................................................................................................ 47 Hydraulic Reservoir and Filter......................................................................................................................... 47 Pump Distribution.......................................................................................................................................... 48 No. 1 Pump............................................................................................................................................. 48 No. 2 Pump............................................................................................................................................. 48 No. 3 Pump............................................................................................................................................. 48 Troubleshooting............................................................................................................................................ 48 Symptoms and Solutions................................................................................................................................. 48 Troubleshooting Aids....................................................................................................................................... 50 Troubleshooting Procedures................................................................................................................................. 50 Hydraulic Oil Return Filter Assembly....................................................................................................................... 51 Element Removal........................................................................................................................................ 51 Element Installation................................................................................................................................... 51 Fill Cap/Breather.......................................................................................................................................... 51 Removal and Replacement................................................................................................................................ 51 Oil Cooler..................................................................................................................................................... 53 Description................................................................................................................................................ 53 Oil Temperature Switches................................................................................................................................... 53 Maintenance................................................................................................................................................ 53 Hydraulic Pumps................................................................................................................................................ 55 Description................................................................................................................................................ 55 Pump No. 1............................................................................................................................................. 55 Pump No. 2............................................................................................................................................. 55 Pump No. 3............................................................................................................................................. 55 Maintenance................................................................................................................................................ 55 No. 1 Pump Removal..................................................................................................................................... 55 No. 1 Pump Installation................................................................................................................................ 55 No. 1 Pump and Pump Disconnect Assembly Removal (Optional)............................................................................................. 55 No. 1 Pump and Pump Disconnect Assembly Installation (Optional)........................................................................................ 56 No. 2 Pump Removal..................................................................................................................................... 56 No. 2 Pump Installation................................................................................................................................ 56 No. 3 Pump Removal..................................................................................................................................... 57 No. 3 Pump Installation................................................................................................................................ 57 Testing After Repair or Replacement.................................................................................................................... 57 Pump Disconnect Assembly................................................................................................................................... 59 Disassembly................................................................................................................................................ 59 Assembly................................................................................................................................................... 59 Pressure Setting Procedures.................................................................................................................................... 61 Procedure A - Main Control Valve Reliefs................................................................................................................... 62 Procedure B - Main Directional Control Valve Pilot Supply Pressure......................................................................................... 63 Procedure C - Swing Brake Pilot Supply Pressure............................................................................................................ 63 Procedure D - Brake Charge Supply Valve Relief Pressure.................................................................................................... 63 Procedure E - Charge Air Cooler Valve Relief Pressure...................................................................................................... 64 Procedure F - Brake Dual Accumulator Charge Valve Pressure Limits.......................................................................................... 64 Procedure G - Accumulator Pre-Charge Pressure.............................................................................................................. 64 Procedure H - PreCharging The Accumulator.................................................................................................................. 65 Procedure I - Swing Valve Work Port Reliefs Pressure....................................................................................................... 65 Procedure J - Front Steer Relief Valve Pressure............................................................................................................ 66 Procedure K - Outrigger/Rear Steer Valve Relief............................................................................................................ 66 Procedure L - Hydraulic Oil Cooler Fan Motor Control Valve................................................................................................. 66 Procedure M - Counterweight Removal Valve.................................................................................................................. 67 Valves......................................................................................................................................................... 68 General.................................................................................................................................................... 68 Directional Control Valves..................................................................................................................................... 71 Description................................................................................................................................................ 71 Lift/Telescope/Hoist Directional Valve................................................................................................................. 71 Swing/Steer Directional Valve.......................................................................................................................... 71 Counterweight Removal Directional Valve (Optional)..................................................................................................... 71 Maintenance................................................................................................................................................ 71 Swing/Steer Directional Valve Removal.................................................................................................................. 71 Swing/Steer Directional Valve Installation............................................................................................................. 71 Hoist/Lift/Telescope Directional Valve Removal......................................................................................................... 71 Hoist/Lift/Telescope Directional Valve Installation.................................................................................................... 71 Counterweight Removal Directional Valve Removal........................................................................................................ 71 Counterweight Removal Directional Valve Installation................................................................................................... 71 Functional Check (All Directional Valves).............................................................................................................. 71 Hydraulic Remote Control Valve................................................................................................................................. 76 Description................................................................................................................................................ 76 Dual Axis Controllers (CE Units)....................................................................................................................... 76 Maintenance................................................................................................................................................ 76 Armrest Control Valve Removal.......................................................................................................................... 76 Armrest Control Valve Installation..................................................................................................................... 76 Armrest Control Valve Functional Check................................................................................................................. 76 Telescope Pedal Control Valve Removal (With Auxiliary Hoist Option).................................................................................... 77 Telescope Pedal Control Valve Installation (With Auxiliary Hoist Option)............................................................................... 77 Telescope Pedal Control Valve Functional Check (With Auxiliary Hoist Option)........................................................................... 77 Dual Accumulator Charge Valve.................................................................................................................................. 80 Description................................................................................................................................................ 80 Maintenance................................................................................................................................................ 80 Removal................................................................................................................................................ 80 Installation........................................................................................................................................... 80 Swing Brake And Armrest Lockout Valve Manifold................................................................................................................. 82 Description................................................................................................................................................ 82 Maintenance................................................................................................................................................ 82 Removal................................................................................................................................................ 82 Installation........................................................................................................................................... 82 Function Check - Swing Brake Release Valve............................................................................................................. 82 Function Check - Crane Function Valve.................................................................................................................. 82 Inlet Filter Screen Replacement........................................................................................................................ 82 Holding Valve.................................................................................................................................................. 84 Description................................................................................................................................................ 84 Maintenance................................................................................................................................................ 84 Removal................................................................................................................................................ 84 Installation........................................................................................................................................... 84 Outrigger/Rear Steer Valve..................................................................................................................................... 85 Description................................................................................................................................................ 85 Maintenance................................................................................................................................................ 86 Removal................................................................................................................................................ 86 Installation........................................................................................................................................... 86 Functional Check....................................................................................................................................... 86 Outrigger Control Manifold..................................................................................................................................... 87 Description................................................................................................................................................ 87 Maintenance................................................................................................................................................ 88 Removal................................................................................................................................................ 88 Inspection............................................................................................................................................. 88 Installation........................................................................................................................................... 88 Functional Check....................................................................................................................................... 88 Parking Brake/Range Shift Valve................................................................................................................................ 89 Description................................................................................................................................................ 89 Maintenance................................................................................................................................................ 89 Removal................................................................................................................................................ 89 Installation........................................................................................................................................... 89 Functional Tests....................................................................................................................................... 89 Axle Oscillation Lockout Valve................................................................................................................................. 91 Description................................................................................................................................................ 91 Maintenance................................................................................................................................................ 91 Removal................................................................................................................................................ 91 Installation........................................................................................................................................... 91 High Speed Boost Selector Valve................................................................................................................................ 92 Description................................................................................................................................................ 92 Maintenance................................................................................................................................................ 92 Removal................................................................................................................................................ 92 Installation........................................................................................................................................... 92 Telescope Stage Selector Valve Manifold........................................................................................................................ 93 Description................................................................................................................................................ 93 Maintenance................................................................................................................................................ 93 Removal................................................................................................................................................ 93 Installation........................................................................................................................................... 93 Telescope Fill Tube Control Valve Manifold..................................................................................................................... 94 Description................................................................................................................................................ 94 Maintenance................................................................................................................................................ 95 Removal................................................................................................................................................ 95 Installation........................................................................................................................................... 95 Hydraulic Accumulator.......................................................................................................................................... 96 Description................................................................................................................................................ 96 Maintenance................................................................................................................................................ 96 Removal................................................................................................................................................ 96 Installation........................................................................................................................................... 96 Servicing.............................................................................................................................................. 96 Service Brake and CAC Fan Motor Priority Flow Control Valve.................................................................................................... 97 Description................................................................................................................................................ 97 Maintenance................................................................................................................................................ 97 Removal................................................................................................................................................ 97 Installation........................................................................................................................................... 97 Oil Cooler Fan Motor Priority Flow Control Valve............................................................................................................... 98 Description................................................................................................................................................ 98 Maintenance................................................................................................................................................ 98 Removal................................................................................................................................................ 98 Installation........................................................................................................................................... 98 Procedure for checking Hydraulic Oil Cooler Fan Control Valve.......................................................................................... 98 Cylinders...................................................................................................................................................... 99 General.................................................................................................................................................... 99 Maintenance................................................................................................................................................ 99 General................................................................................................................................................ 99 Surface Protection For Cylinder Rods....................................................................................................................... 99 Leakage Check.......................................................................................................................................... 99 Temperature Effects On Hydraulic Cylinders.................................................................................................................100 Lift Cylinder..................................................................................................................................................102 Description................................................................................................................................................102 Maintenance................................................................................................................................................102 Disassembly............................................................................................................................................102 Inspection.............................................................................................................................................102 Assembly...............................................................................................................................................104 Telescope Cylinder.............................................................................................................................................106 Description................................................................................................................................................106 Maintenance................................................................................................................................................106 Axle Oscillation Lockout Cylinder..............................................................................................................................107 Description................................................................................................................................................107 Maintenance................................................................................................................................................107 Disassembly............................................................................................................................................107 Inspection.............................................................................................................................................107 Assembly...............................................................................................................................................109 Steer Cylinder.................................................................................................................................................110 Description................................................................................................................................................110 Maintenance................................................................................................................................................110 Disassembly............................................................................................................................................110 Inspection.............................................................................................................................................110 Assembly...............................................................................................................................................112 Outrigger Extension Cylinder...................................................................................................................................113 Description................................................................................................................................................113 Maintenance................................................................................................................................................113 Disassembly............................................................................................................................................113 Inspection.............................................................................................................................................113 Assembly...............................................................................................................................................115 Outrigger Stabilizer Cylinder..................................................................................................................................116 Description................................................................................................................................................116 Maintenance................................................................................................................................................116 Disassembly............................................................................................................................................116 Inspection.............................................................................................................................................116 Assembly...............................................................................................................................................118 Test...................................................................................................................................................118 Counterweight Removal Cylinder.................................................................................................................................119 Description................................................................................................................................................119 Maintenance................................................................................................................................................119 Disassembly............................................................................................................................................119 Inspection.............................................................................................................................................119 Assembly...............................................................................................................................................119 SECTION 3..............................................................................................................................................................123 Electrical System..................................................................................................................................................123 Description....................................................................................................................................................123 General....................................................................................................................................................123 Alternator.................................................................................................................................................125 Batteries..................................................................................................................................................125 Cab Electrical Panel.......................................................................................................................................125 Carrier Electrical Panel...................................................................................................................................127 Maintenance....................................................................................................................................................129 General....................................................................................................................................................129 Visual Inspection and Replacement of Electrical Harnesses and Cables...................................................................................129 General Troubleshooting....................................................................................................................................130 Tools for Troubleshooting..................................................................................................................................130 Troubleshooting Swivel-Caused Electrical Problems..........................................................................................................130 Connector Troubleshooting..................................................................................................................................130 Alternator/Charging System Troubleshooting.................................................................................................................131 Required Tools.........................................................................................................................................131 Visual Check...........................................................................................................................................131 Engine Off Tests.......................................................................................................................................132 Batteries..........................................................................................................................................132 Voltage at Alternator..............................................................................................................................132 Battery Drain......................................................................................................................................132 Engine On Tests........................................................................................................................................132 Output Voltage Test................................................................................................................................132 Maximum Amperage Test..............................................................................................................................132 Voltage Drop Test..................................................................................................................................132 Alternator Replacement.....................................................................................................................................133 Removal................................................................................................................................................133 Installation...........................................................................................................................................133 Check..................................................................................................................................................133 Starter Replacement........................................................................................................................................133 Removal................................................................................................................................................133 Installation...........................................................................................................................................133 Check..................................................................................................................................................133 Battery Replacement........................................................................................................................................134 Removal................................................................................................................................................134 Installation...........................................................................................................................................134 Relay Panel Component Replacement..........................................................................................................................134 Accessory Relay........................................................................................................................................134 Buzzer Replacement.....................................................................................................................................134 Gauge Cluster Replacement..................................................................................................................................135 Removal................................................................................................................................................135 Installation...........................................................................................................................................135 Check..................................................................................................................................................135 Rocker Switch Replacement..................................................................................................................................135 Removal................................................................................................................................................135 Inspection.............................................................................................................................................136 Installation...........................................................................................................................................136 Check..................................................................................................................................................136 Ignition Switch Replacement................................................................................................................................136 Removal................................................................................................................................................136 Inspection.............................................................................................................................................136 Installation...........................................................................................................................................137 Check..................................................................................................................................................137 Turn Signal Lever and Transmission Shift Lever Replacement.................................................................................................137 Removal................................................................................................................................................137 Installation...........................................................................................................................................137 Check..................................................................................................................................................138 Windshield Wiper Assembly Replacement......................................................................................................................138 Removal................................................................................................................................................138 Inspection.............................................................................................................................................139 Installation...........................................................................................................................................139 Check..................................................................................................................................................139 Windshield Washer Assembly Replacement.....................................................................................................................140 Removal................................................................................................................................................140 Inspection.............................................................................................................................................140 Installation...........................................................................................................................................140 Check..................................................................................................................................................140 Skylight Wiper Assembly Replacement........................................................................................................................140 Removal................................................................................................................................................140 Inspection.............................................................................................................................................140 Installation...........................................................................................................................................140 Check..................................................................................................................................................141 Tools for Troubleshooting..................................................................................................................................141 Optional Equipment.............................................................................................................................................141 Beacon Light...............................................................................................................................................141 Boom Mounted Floodlights...................................................................................................................................141 Rear View Mirror...........................................................................................................................................141 Air Conditioner............................................................................................................................................141 SECTION 4..............................................................................................................................................................143 Boom...............................................................................................................................................................143 Description....................................................................................................................................................143 Theory of Operation............................................................................................................................................144 Maintenance....................................................................................................................................................146 Removal....................................................................................................................................................146 Disassembly................................................................................................................................................155 Boom Nose Sheaves..........................................................................................................................................163 Removal................................................................................................................................................163 Installation...........................................................................................................................................163 Assembly...................................................................................................................................................163 Installation...............................................................................................................................................174 Functional Check...........................................................................................................................................175 Inspection.................................................................................................................................................175 Boom Alignment and Servicing...............................................................................................................................175 Boom Extension and Retraction Cables...........................................................................................................................175 Maintenance................................................................................................................................................175 Inspection.................................................................................................................................................175 Adjustment.................................................................................................................................................176 Telescope Circuit..............................................................................................................................................179 Description................................................................................................................................................179 Theory of Operation........................................................................................................................................179 Boom Control Modes.....................................................................................................................................179 Auto A Mode........................................................................................................................................179 Auto B Mode........................................................................................................................................179 Manual Mode........................................................................................................................................179 Recovery Mode......................................................................................................................................180 Boom Control System Features...........................................................................................................................180 Jib Rigging........................................................................................................................................180 Anti-Thermal Contraction...........................................................................................................................180 Maintenance................................................................................................................................................181 Troubleshooting........................................................................................................................................181 Removal And Installation...................................................................................................................................182 Disassembly And Assembly...................................................................................................................................182 Lift Circuit...................................................................................................................................................183 Description................................................................................................................................................183 Theory of Operation........................................................................................................................................183 Maintenance................................................................................................................................................183 Lift Cylinder Removal......................................................................................................................................185 Disassembly and Assembly...................................................................................................................................185 Lift Cylinder Installation.................................................................................................................................185 Bi-Fold Boom Extension.........................................................................................................................................187 Description................................................................................................................................................187 Boom Extension Rigging Mode................................................................................................................................187 Erecting the Boom Extension................................................................................................................................187 Stowing the Boom Extension.................................................................................................................................194 Setting the Folding Swingaway Offset.......................................................................................................................196 Boom Extension Alignment Device Adjustment.................................................................................................................197 Swingaway Mounting Adjustment..............................................................................................................................197 Hook Block.....................................................................................................................................................198 Description................................................................................................................................................198 Maintenance................................................................................................................................................198 Periodic Maintenance...................................................................................................................................198 SECTION 5..............................................................................................................................................................199 Hoist and Counterweight............................................................................................................................................199 Description....................................................................................................................................................199 Theory of Operation............................................................................................................................................199 Maintenance....................................................................................................................................................200 Warm-up Procedure..........................................................................................................................................200 Hoist Area Access..........................................................................................................................................200 Removal....................................................................................................................................................202 Installation...............................................................................................................................................202 Functional Check...........................................................................................................................................202 Fluid Level................................................................................................................................................202 Preventive Maintenance.....................................................................................................................................203 Hoist To Boom Alignment........................................................................................................................................204 Preparation................................................................................................................................................204 Tools Required.............................................................................................................................................204 Procedure..................................................................................................................................................204 Motor And Brake................................................................................................................................................206 Description................................................................................................................................................206 Maintenance............................................................................................................................................206 Removal................................................................................................................................................206 Installation...........................................................................................................................................206 Idler Drum And Cable Follower..................................................................................................................................207 Description................................................................................................................................................207 Maintenance................................................................................................................................................207 Idler Drum.............................................................................................................................................207 Removal and Disassembly............................................................................................................................207 Cleaning and Inspection............................................................................................................................207 Assembly and Installation..........................................................................................................................207 Cable Follower.........................................................................................................................................207 Removal and Disassembly............................................................................................................................207 Cleaning and Inspection............................................................................................................................207 Assembly and Installation..........................................................................................................................207 Complete Assembly......................................................................................................................................209 Removal............................................................................................................................................209 Installation.......................................................................................................................................209 Third Wrap Indicator (Optional— Standard on CE)................................................................................................................210 Description................................................................................................................................................210 Maintenance................................................................................................................................................210 Hoist Drum Rotation Indicator System...........................................................................................................................211 Description................................................................................................................................................211 Maintenance................................................................................................................................................211 General................................................................................................................................................211 Troubleshooting........................................................................................................................................211 Removal................................................................................................................................................211 Installation...........................................................................................................................................211 Hoist Control Valves...........................................................................................................................................213 Description................................................................................................................................................213 Hydraulic Hoist Motor Control Valve....................................................................................................................213 Hoist Directional Control Valve........................................................................................................................213 Fixed Counterweight............................................................................................................................................214 Description................................................................................................................................................214 Maintenance................................................................................................................................................214 Removal................................................................................................................................................214 Installation...........................................................................................................................................214 Counterweight Plate........................................................................................................................................214 Removable Counterweight (Optional).............................................................................................................................216 Removal....................................................................................................................................................216 Installation...............................................................................................................................................216 SECTION 6..............................................................................................................................................................219 Swing System.......................................................................................................................................................219 Description....................................................................................................................................................219 Theory of Operation............................................................................................................................................219 Swing Drive................................................................................................................................................219 Swing Brake................................................................................................................................................219 Maintenance....................................................................................................................................................221 Swing Motor....................................................................................................................................................225 Description................................................................................................................................................225 Maintenance................................................................................................................................................225 Removal................................................................................................................................................225 Installation...........................................................................................................................................225 Test...................................................................................................................................................225 Swing Gearbox And Brake........................................................................................................................................226 Description................................................................................................................................................226 Maintenance................................................................................................................................................226 Swing Brake............................................................................................................................................226 Removal............................................................................................................................................226 Installation.......................................................................................................................................226 Testing............................................................................................................................................226 Gearbox................................................................................................................................................226 Removal............................................................................................................................................226 Installation.......................................................................................................................................226 Servicing..........................................................................................................................................227 Checking The Oil Level.............................................................................................................................227 Testing............................................................................................................................................227 Swing Bearing..................................................................................................................................................228 Description................................................................................................................................................228 Maintenance................................................................................................................................................228 General................................................................................................................................................228 Torquing Turntable Bolts...............................................................................................................................228 General............................................................................................................................................228 Tools Required.....................................................................................................................................229 Inner Race Torquing................................................................................................................................229 Outer Race Torquing................................................................................................................................229 Removal................................................................................................................................................229 Inspection.............................................................................................................................................231 Installation...........................................................................................................................................231 Testing................................................................................................................................................232 Swivels........................................................................................................................................................233 Description................................................................................................................................................233 Hydraulic Swivel...............................................................................................................................................235 Description................................................................................................................................................235 Theory Of Operation........................................................................................................................................235 Maintenance................................................................................................................................................235 Removal................................................................................................................................................235 Installation...........................................................................................................................................236 Two Port Water Swivel..........................................................................................................................................237 Description................................................................................................................................................237 Maintenance................................................................................................................................................237 Removal................................................................................................................................................237 Disassembly............................................................................................................................................237 Cleaning And Inspection................................................................................................................................237 Assembly...............................................................................................................................................237 Installation...........................................................................................................................................237 Electrical Swivel..............................................................................................................................................238 Description................................................................................................................................................238 Theory of Operation........................................................................................................................................238 Maintenance................................................................................................................................................238 Removal................................................................................................................................................238 Installation...........................................................................................................................................238 Preventive Maintenance.................................................................................................................................239 Slew Angle Zero Adjustment Procedure...................................................................................................................239 Slew Angle Verification................................................................................................................................239 Swing Lock Pin.................................................................................................................................................240 Description................................................................................................................................................240 Maintenance................................................................................................................................................240 360° Swing Lock Control (Positive Lock Type) (Optional)........................................................................................................240 Description................................................................................................................................................240 Maintenance................................................................................................................................................240 SECTION 7..............................................................................................................................................................241 Power Train........................................................................................................................................................241 Engine.........................................................................................................................................................241 Description................................................................................................................................................241 Maintenance................................................................................................................................................242 Engine Removal.........................................................................................................................................242 Engine Installation....................................................................................................................................242 Engine Drive Belts.....................................................................................................................................243 Electronic Control System......................................................................................................................................244 Description................................................................................................................................................244 Engine Control System Switches And Indicator Lights........................................................................................................244 Engine Diagnostic/Speed Control Switch.................................................................................................................244 Increment/Decrement Switch.............................................................................................................................244 Engine Stop Light......................................................................................................................................245 Engine Warning Light...................................................................................................................................245 Diesel Particulate Filter Indicator (Tier 4 Engines Only)..............................................................................................245 Diesel Particulate Filter Regeneration Switch (Tier 4 Engines Only)....................................................................................246 Inhibit Regeneration Indicator.........................................................................................................................246 High Exhaust System Temperature........................................................................................................................246 Fuel System....................................................................................................................................................247 Description................................................................................................................................................247 Fuel Tank..............................................................................................................................................247 Injection Fuel Pump....................................................................................................................................247 Fuel Filter-water Separator............................................................................................................................247 Maintenance................................................................................................................................................247 Fuel Tank..............................................................................................................................................247 Removal............................................................................................................................................247 Installation.......................................................................................................................................247 Fuel Filter-Water Separator............................................................................................................................247 Draining...........................................................................................................................................247 Air Intake and Exhaust System..................................................................................................................................249 Description................................................................................................................................................249 Air Intake.................................................................................................................................................249 Air Cleaner Checks.....................................................................................................................................249 Check For Filter Restriction.......................................................................................................................249 Filter Element Replacement.............................................................................................................................251 Element Cleaning...................................................................................................................................251 Air Cleaner Body.......................................................................................................................................251 Precleaner.............................................................................................................................................251 Vacuator Valve.........................................................................................................................................251 Duct Work..............................................................................................................................................252 Charge-Air Cooler System...................................................................................................................................253 Maintenance............................................................................................................................................253 Muffler....................................................................................................................................................254 Removal................................................................................................................................................254 Installation...........................................................................................................................................254 Water Cooling System...........................................................................................................................................257 Description................................................................................................................................................257 Maintenance................................................................................................................................................257 General................................................................................................................................................257 Effects of Cooling System Neglect......................................................................................................................257 Overheating........................................................................................................................................257 Overcooling........................................................................................................................................257 Antifreeze/Coolant.....................................................................................................................................257 Rust Prevention........................................................................................................................................257 Engine Antifreeze/Coolant Fill Procedure (when level is low)...........................................................................................257 Antifreeze/Supplemental Coolant Additives Maintenance Summary..........................................................................................258 Cooling System Level Check Interval................................................................................................................258 SCA Level Check Interval...........................................................................................................................258 Cleaning...............................................................................................................................................258 Pressure Flushing......................................................................................................................................258 Component Inspection...................................................................................................................................259 Radiator/Surge Tank................................................................................................................................259 Engine Water Jacket................................................................................................................................259 Water Pump.........................................................................................................................................259 Fans and Belts.....................................................................................................................................259 Thermostat.........................................................................................................................................260 Hoses and Clamps...................................................................................................................................260 Radiator Removal and Installation......................................................................................................................260 Removal............................................................................................................................................260 Installation.......................................................................................................................................260 Radiator Fill and Servicing................................................................................................................................261 Drive Train....................................................................................................................................................263 Description................................................................................................................................................263 Maintenance................................................................................................................................................263 Transmission...........................................................................................................................................263 Drive Shafts...........................................................................................................................................264 Removal............................................................................................................................................264 Installation.......................................................................................................................................264 Lubrication........................................................................................................................................264 Transmission/torque Converter..................................................................................................................................265 Description................................................................................................................................................265 Theory of Operation........................................................................................................................................265 Maintenance................................................................................................................................................266 General Information....................................................................................................................................266 Troubleshooting........................................................................................................................................266 Hydraulic Checks...................................................................................................................................266 Troubleshooting Procedures.................................................................................................................................266 Removal................................................................................................................................................267 Installation...........................................................................................................................................267 Servicing The Crane After Transmission/torque Converter Overhaul.......................................................................................269 Lubrication............................................................................................................................................269 Type of Oil and Capacities.........................................................................................................................269 Normal Drain Period................................................................................................................................269 Towing or Pushing..........................................................................................................................................269 SECTION 8..............................................................................................................................................................271 Undercarriage......................................................................................................................................................271 Axles..........................................................................................................................................................271 Description................................................................................................................................................271 Maintenance................................................................................................................................................272 Removal................................................................................................................................................272 Cleaning...............................................................................................................................................272 Installation...........................................................................................................................................272 Wheel Alignment Check Procedure........................................................................................................................273 Rear Steer Indicator Adjustment Procedure..............................................................................................................273 Wheels And Tires...........................................................................................................................................274 Description............................................................................................................................................274 Maintenance............................................................................................................................................274 Mounting Wheel Assemblies..........................................................................................................................274 Typical Wear Patterns......................................................................................................................................274 Incorrect Tire Pressure................................................................................................................................274 Incorrect Camber.......................................................................................................................................275 Incorrect Toe and Axle Alignment.......................................................................................................................275 Incorrect Caster and Wheel Imbalance...................................................................................................................275 Cuts in the Tire Tread.................................................................................................................................276 Spot Wear..............................................................................................................................................276 Feathered Edges........................................................................................................................................276 Cupping................................................................................................................................................276 Steering Systems...............................................................................................................................................277 Description................................................................................................................................................277 Front Steering System..................................................................................................................................277 Rear Steering System...................................................................................................................................277 Secondary Steering System (CE Units)...................................................................................................................277 Theory Of Operation........................................................................................................................................277 Front Steering System..................................................................................................................................277 Rear Steering System...................................................................................................................................277 Secondary Steering System (CE Units)...................................................................................................................277 Maintenance................................................................................................................................................278 Front Steering System..................................................................................................................................278 Troubleshooting....................................................................................................................................278 Functional Check...................................................................................................................................278 Secondary Steering System..........................................................................................................................279 Rear Steering System...........................................................................................................................................279 Troubleshooting............................................................................................................................................279 Hydraulic Pumps............................................................................................................................................280 Description............................................................................................................................................280 Front Steer........................................................................................................................................280 Rear Steer.........................................................................................................................................280 Front Steering Control Valve...............................................................................................................................280 Description............................................................................................................................................280 Maintenance............................................................................................................................................280 Removal............................................................................................................................................280 Installation.......................................................................................................................................280 Integrated Outrigger/Rear Steer Control Valve..............................................................................................................280 Description............................................................................................................................................280 Maintenance............................................................................................................................................280 Functional Check...................................................................................................................................280 Steer Cylinders............................................................................................................................................280 Description............................................................................................................................................280 Maintenance............................................................................................................................................280 Removal............................................................................................................................................281 Installation.......................................................................................................................................281 Rear Axle Oscillation Lockout System...........................................................................................................................281 Description................................................................................................................................................281 Theory Of Operation........................................................................................................................................281 Axle Oscillation Lockout Cylinders.........................................................................................................................283 Description............................................................................................................................................283 Maintenance............................................................................................................................................283 Removal............................................................................................................................................283 Installation.......................................................................................................................................283 Axle Oscillation Lockout Valve.............................................................................................................................283 Description............................................................................................................................................283 When the axle oscillation solenoid valves are energized and open, hydraulic oil is allowed in and out of the cylinders, allowing them to oscillate.....283 Maintenance................................................................................................................................................283 Brake System...................................................................................................................................................283 Description................................................................................................................................................283 Service Brakes.........................................................................................................................................283 Parking Brake..........................................................................................................................................284 Theory Of Operation........................................................................................................................................284 Service Brakes.........................................................................................................................................284 Parking Brake..........................................................................................................................................284 Maintenance................................................................................................................................................285 Troubleshooting........................................................................................................................................285 General................................................................................................................................................285 Bleeding the Brake System..............................................................................................................................285 Pressure Bleeding The Brake System.................................................................................................................286 Manually Bleeding the Brake System.................................................................................................................286 Service Brakes.................................................................................................................................................286 Description................................................................................................................................................286 Maintenance................................................................................................................................................286 Removal................................................................................................................................................286 Linings............................................................................................................................................286 Caliper............................................................................................................................................287 Disassembly............................................................................................................................................287 Caliper............................................................................................................................................287 Inspection.............................................................................................................................................288 Periodic On-Vehicle................................................................................................................................288 Shoes, Linings, and End Plates.....................................................................................................................288 Caliper for Leaks..................................................................................................................................288 Dust Seals.........................................................................................................................................289 Disc...............................................................................................................................................289 Caliper Parts......................................................................................................................................289 Cleaning...............................................................................................................................................290 Corrosion Protection.......................................................................................................................................290 Assembly...............................................................................................................................................290 Caliper............................................................................................................................................290 Installation...........................................................................................................................................291 Linings............................................................................................................................................291 Caliper............................................................................................................................................292 Parking Brake Actuator.........................................................................................................................................292 Description................................................................................................................................................292 Maintenance................................................................................................................................................292 Removal................................................................................................................................................292 Installation...........................................................................................................................................292 Adjustment.............................................................................................................................................292 Parking Brake..................................................................................................................................................293 Description................................................................................................................................................293 Maintenance................................................................................................................................................293 Removal................................................................................................................................................293 Installation...........................................................................................................................................293 Park Brake Solenoid Valve......................................................................................................................................296 Description................................................................................................................................................296 Maintenance................................................................................................................................................296 Removal................................................................................................................................................296 Installation...........................................................................................................................................296 Outrigger......................................................................................................................................................296 Outrigger Circuit..........................................................................................................................................296 Description............................................................................................................................................296 Theory Of Operation....................................................................................................................................296 Maintenance................................................................................................................................................297 Troubleshooting........................................................................................................................................297 Outrigger Beam.............................................................................................................................................300 Description............................................................................................................................................300 Theory Of Operation....................................................................................................................................300 Maintenance............................................................................................................................................300 Removal............................................................................................................................................300 Inspection.........................................................................................................................................301 Installation.......................................................................................................................................301 Wear Pad Adjustment................................................................................................................................301 Extension Cylinder.........................................................................................................................................304 Description............................................................................................................................................304 Maintenance............................................................................................................................................304 Removal............................................................................................................................................304 Installation.......................................................................................................................................304 Functional Check...................................................................................................................................304 Outrigger Monitoring System (Optional— Standard in North America)..........................................................................................304 Description............................................................................................................................................304 Removal............................................................................................................................................304 Installation.......................................................................................................................................305 Stabilizer Cylinder........................................................................................................................................305 Description............................................................................................................................................305 Maintenance............................................................................................................................................305 Removal............................................................................................................................................305 Installation.......................................................................................................................................305 Functional Check...................................................................................................................................306 Outrigger Control Valves...................................................................................................................................306 Description............................................................................................................................................306 Pilot Operated Check Valve.............................................................................................................................306 Integrated Outrigger/Rear Steer Valve..................................................................................................................306 Outrigger Control Manifold.............................................................................................................................306 SECTION 9..............................................................................................................................................................307 Lubrication........................................................................................................................................................307 General........................................................................................................................................................307 Environmental Protection.......................................................................................................................................307 Lubricants and Lubrication Intervals...........................................................................................................................307 Standard Lubricants........................................................................................................................................308 Arctic Lubricants and Conditions...........................................................................................................................309 Temperatures Below -18°C (0°F).........................................................................................................................309 Cold Weather Package and Lubricants................................................................................................................309 Surface Protection for Cylinder Rods...........................................................................................................................312 Wire Rope Lubrication..........................................................................................................................................312 lubrication Points.............................................................................................................................................313 CraneLUBE..................................................................................................................................................313 Safety.....................................................................................................................................................313 Steering and Suspension....................................................................................................................................314 Axles......................................................................................................................................................316 Drive Train................................................................................................................................................318 Drive Train (continued)....................................................................................................................................320 Turntable..................................................................................................................................................322 Outriggers.................................................................................................................................................324 Boom.......................................................................................................................................................326 Boom (continued)...........................................................................................................................................328 Boom (continued)...........................................................................................................................................330 Boom (continued)...........................................................................................................................................332 Boom (continued)...........................................................................................................................................334 Hoist......................................................................................................................................................336 Hydraulic..................................................................................................................................................338 Carwell® Rust Inhibitor........................................................................................................................................341 Protecting Cranes From Rusting.............................................................................................................................341 Cleaning Procedures........................................................................................................................................341 Inspection and Repair......................................................................................................................................342 Application................................................................................................................................................342 Areas of Application.......................................................................................................................................342
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