Grove Crane RT 880E Service & Maintenance Manual – PDF DOWNLOAD

Description

Grove Crane RT 880E Service & Maintenance Manual – PDF DOWNLOAD

FILE DETAILS:

Grove Crane RT 880E Service & Maintenance Manual – PDF DOWNLOAD

Language : English
Pages : 348
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Grove Crane RT 880E 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/Transmission 15
Engine 15
Cummins QSB6 7 15
Axles 15
Brakes 15
Wheels and Tires 15
Swing Gearbox 15
Boom 15
Swivel Assembly 15
Hydraulic Pumps 16
Pump #1 16
Pump #2 16
Hoists 16
General Maintenance 21
Cleanliness 21
Removal and Installation 21
Disassembly and Assembly 21
Pressing Parts 21
Locks 21
Wires and Cables 22
Shims 22
Hoses and Tubes 22
Inspection 22
Installation 22
Bearings 22
Antifriction Bearings 22
Double Row, Tapered Roller 23
Heating Bearings 23
Installation 23
Preload 23
Sleeve Bearings 23
Gaskets 23
Batteries 23
Hydraulic Systems 23
Cleanliness 23
Keep the System Clean 23
Sealing Elements 23
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 26
Loctite® 27
Application of Medium Strength Loctite 27
Primer Application 27
Adhesive/Sealant Application 27
Fasteners and Torque Values 27
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 35×7 Class Wire Rope 36
Procedures for Cutting and Preparing 35×7 Class Wire Rope 36
SECTION 2 39
Hydraulic System 39
Description 40
Theory of Operation 43
Maintenance 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 45
Supply Pressure and Return Circuit 47
Hydraulic Reservoir 47
Hydraulic Oil Return Filter Assembly 48
Element Removal 48
Element Installation 48
Oil Cooler 50
Hydraulic Pumps 51
Pump No 1 Troubleshooting 52
Pump No 1 Removal 53
Pump No 1 Installation 53
Pump No 2 Removal 53
Pump No 2 Installation 53
Pump No 1 Bleeding and Start-up 54
Pump No 2 Bleeding and Start-up 54
Troubleshooting 58
Pressure Setting Procedures 59
Procedure A – Main Control Valve Pressure for Hoists, Boom Lift, Telescope – Check/ Adjust 60
Extend 60
Retract 60
Procedure B – Outrigger Pressures – Adjust 60
Procedure C – Oil Cooler Motor Pressure – Adjust 60
Procedure D – Set Service Brake Accumulator Charge Valve Limits – Check/ Adjust 61
Procedure E – Accumulator Pre-Charge Pressure – Check 61
Procedure F – Pre-Charging the Accumulator 61
Procedure G – Front Steer Pressure – Check/ Adjust 61
Procedure H – Swing Work Port Pressure – Check/Adjust 62
Procedure I – Swing Brake Release Pressure – Check/Adjust 62
Procedure J – Controller Supply Pressure – Check/Adjust 62
Procedure K – Counterweight Removal Cylinder Extend/Retract Pressure – Check 62
Procedure L – Cab Tilt Cylinder Extend/ Retract and Counterweight Pin Removal Pressure – Check/Adjust 62
Valves 69
General 69
Directional Control Valves 73
Description 73
Maintenance 73
Boom Lift/Telescope/Hoist Valve Bank Removal 73
Boom Lift/Telescope/Hoist Valve Bank Installation 73
Counterweight Removal Valve Bank Removal 73
Counterweight Removal Valve Bank Installation 73
Functional Check (All Valve Banks) 74
Function Check – RCL Lockout Valves 74
Front Steer/Swing/Brake Manifold 80
Description 80
Maintenance 80
Removal 80
Installation 80
Steering Control Valve 84
Description 84
Maintenance 84
Removal 84
Installation 84
Hydraulic Remote Control Valve 85
Description 85
Single Axis Controller 85
Dual Axis Controller 85
Maintenance 85
Armrest Control Valve Removal 85
Armrest Control Valve Installation 85
Armrest Control Valve Functional Check 85
Telescope Pedal Control Valve Removal 85
Telescope Pedal Control Valve Installation 85
Telescope Pedal Control Valve Functional Check 85
Swing Power Brake Valve With Treadle Pedal 89
Description 89
Maintenance 89
Removal 89
Installation 89
Function Check 89
2 Speed Swing Valve 90
Description 90
Maintenance 90
Removal 90
Installation 90
Tandem Brake Valve with Treadle Pedal 91
Description 91
Maintenance 91
Removal 91
Installation 91
Dual Accumulator Charge Valve 92
Description 92
Maintenance 92
Removal 92
Installation 92
Hydraulic Accumulator Service Brake 94
Description 94
Maintenance 94
Removal 94
Installation 94
Servicing 94
Holding Valves 95
Description 95
Lower Lift Cylinder Holding Valve 95
Removal 95
Installation 95
Maintenance 96
Removal 96
Installation 96
Cross Axle Differential Lock Valve 97
Description 97
Maintenance 97
Removal 97
Installation 97
Outrigger Control Manifold 98
Description 98
Maintenance 98
Removal 98
Inspection 98
Installation 98
Functional Check 98
Pilot Operated Check Valve 101
Description 101
Maintenance 101
Removal 101
Installation 101
Axle Lockout, Rear Steer and Oil Cooler Fan Motor Control Manifold 102
Description 102
Maintenance 102
Removal 102
Installation 102
Check Valves 105
Description 105
Maintenance 105
Removal 105
Installation 105
Range Shift/Parking Brake Valve 106
Description 106
Maintenance 106
Removal 106
Installation 106
Functional Tests 106
Load Sense Dump Valve 107
Description 107
Maintenance 107
Removal 107
Installation 107
Functional Tests 107
Cylinders 109
General 109
Maintenance 109
General 109
Surface Protection for Cylinder Rods 109
Leakage Check 109
Temperature Effects on Hydraulic Cylinders 110
Lift Cylinder 112
Description 112
Maintenance 112
Disassembly 112
Inspection 112
Assembly 112
Trombone Telescope Cylinder 115
Description 115
Maintenance 115
Disassembly 115
Inspection 115
Assembly 116
Upper Telescope Cylinder 119
Description 119
Maintenance 120
Disassembly 120
Inspection 120
Assembly 121
Axle Oscillation Lockout Cylinder 123
Description 123
Maintenance 123
Disassembly 123
Inspection 123
Assembly 125
Steer Cylinder 126
Description 126
Maintenance 126
Disassembly 126
Inspection 126
Assembly 128
Outrigger Extension Cylinder 129
Description 129
Maintenance 129
Disassembly 129
Inspection 129
Assembly 129
Outrigger jack Cylinder 132
Description 132
Maintenance 132
Disassembly 132
Inspection 132
Assembly 134
Cab Tilt Cylinder 135
Description 135
Maintenance 135
Disassembly 135
Inspection 135
Assembly 135
Counterweight Removal Cylinder 138
Description 138
Maintenance 138
Disassembly 138
Inspection 138
Assembly 140
Counterweight Pin Cylinder 141
Description 141
Maintenance 141
Disassembly 141
Inspection 141
Assembly 141
Axle Oscillation Lockout Cylinder (CE Option) 144
Description 144
Maintenance 144
Disassembly 144
Inspection 144
Assembly 145
Park Brake Cylinder 146
Description 146
SECTION 3 147
Electric System 147
Description 147
General 147
Alternator 149
Batteries 149
Cab Electrical Panel 149
Carrier Electrical Panel 152
Maintenance 153
General 153
Visual Inspection and Replacement of Electrical Harnesses and Cables 153
General Troubleshooting 155
Troubleshooting Swivel-Caused Electrical Problems 155
Connector Troubleshooting 155
Alternator/Charging System Troubleshooting 157
Required Tools 157
Visual Check 157
Engine Off Tests 157
Batteries 157
Load Test 157
Voltage at Alternator 157
Battery Drain 157
Engine On Tests 157
Output Voltage Test 157
Maximum Amperage Test 157
Voltage Drop Test 158
Alternator Replacement 158
Removal 158
Installation 158
Check 158
Starter Replacement 158
Removal 158
Installation 159
Check 159
Battery Replacement 159
Removal 159
Installation 159
Relay Panel Component Replacement 159
Accessory Relay 159
Buzzer Replacement 160
Gauge Cluster Replacement 160
Removal 160
Installation 160
Check 160
Rocker Switch Replacement 160
Removal 160
Inspection 161
Installation 161
Check 161
Ignition Switch Replacement 161
Removal 161
Inspection 162
Installation 162
Check 162
Turn Signal Lever and Transmission Shift Lever Replacement 162
Removal 162
Installation 162
Check 163
Windshield Wiper Assembly Replacement 165
Removal 165
Inspection 165
Installation 165
Check 166
Windshield Washer Assembly Replacement 166
Removal 166
Inspection 166
Installation 166
Check 166
Skylight Wiper Assembly Replacement 166
Removal 166
Inspection 166
Installation 166
Check 167
Troubleshooting 167
Optional Equipment 167
Description 167
Beacon Light 167
Boom Mounted Floodlights 167
Rear View Mirror 167
Air Conditioner 167
Cold Weather Operation 167
Component Coolant Heater 167
Troubleshooting 168
Maintenance Instructions 168
SECTION 4 169
Boom 169
Description 169
Lattice Extension 169
Optional Lattice Extension Inserts 169
Theory of Operation 169
Boom Extension 169
Boom Retraction 170
Maintenance 170
Removal 170
Boom Disassembly 170
Boom Nose Sheaves 178
Removal 178
Installation 179
Boom Assembly 179
Installation 182
Functional Check 182
Inspection 183
Boom Alignment and Servicing 183
Cam Operated Check Valve Adjustment 183
Stop Block Adjustment 183
Front Upper Pad Adjustment 183
Read Side Wear Pad Adjustment 183
Boom Extension and Retraction Cable 184
Maintenance 184
Inspection 184
Adjustment 184
Telescope Circuit 186
Description 186
Theory of Operation 186
Maintenance 186
Troubleshooting 186
Removal and Installation 188
Disassembly and Assembly 188
Lift Circuit 189
Description 189
Theory of Operation 189
Maintenance 189
Troubleshooting 189
Lift Cylinder Removal 191
Lift Cylinder Installation 191
Auxiliary Boom Nose 193
Description 193
Installing the Bi-Fold Manual Boom Extension 193
Checking the Transport Condition 196
Transport Condition with Lattice Extension Folded at the Side 196
If 23 ft (7 m) Section and 33 ft (10 1 m) Section are Folded at the Side: 196
If the 23 ft (7 m) Section Only is Folded at the Side: 196
If the 23 ft (7 m) Section Only is Folded at the Side: 196
Boom Extension Erecting and Stowing Procedure 196
Monthly Maintenance Work 196
Pins 196
Hook Block 197
Description 197
Maintenance 197
Periodic Maintenance 197
SECTION 5 199
Hoists and Counterweight 199
Description 199
Theory of Operation 199
Maintenance 200
Warm-up Procedure 200
Routine Maintenance and Inspection 200
Weekly or at 40 Hours of Operation (whichever comes first) 200
Every Three Months or 300 Hours of Operation (whichever comes first) 200
Annually 200
Every Ten Years or 10,000 Hours (whichever comes first) 200
Removal 200
Installation 201
Functional Check 202
Fluid Level 202
Hoist to Boom Alignment 203
Preparation 203
Tools Required 203
Procedure 203
Piston Motor and Control Valve 204
Description 204
Maintenance 204
Removal 204
Installation 204
Idler Drum and Cable Follower 204
Description 204
Maintenance 205
Idler Drum 205
Removal and Disassembly 205
Cleaning and Inspection 205
Assembly and Installation 205
Cable Follower 205
Removal and Disassembly 205
Cleaning and Inspection 205
Assembly and Installation 205
Complete Assembly 206
Removal 206
Installation 206
Hoist Drum Rotation Indicator System 207
Description 207
Maintenance 207
General 207
Troubleshooting 207
Removal 207
Installation 207
Counterweight Removal 209
Removal of Standard Counterweight and Auxiliary Hoist 209
Installation of Standard Counterweight and Auxiliary Hoist Mounting Structure 209
Removal of Counterweight without Auxiliary Hoist 209
Installation of Counterweight Without Auxiliary Hoist 211
Third Wrap Indicator (Optional— Standard on CE) 213
Description 213
Maintenance 213
SECTION 6 215
Swing System 215
Introduction 215
Description 215
Theory of Operation 215
Swing Drive 215
Swing Brake 215
Maintenance 217
Troubleshooting 217
Swing Motor 220
Description 220
Maintenance 220
Removal 220
Installation 220
Test 220
Swing Gearbox and Brake 220
Description 220
Maintenance 220
Swing Brake 220
Removal 220
Installation 221
Testing 221
Gearbox 221
Removal 221
Installation 221
Servicing 221
Checking the Oil Level 222
Testing 222
Swing Bearing 222
Description 222
Maintenance 222
General 222
Torquing Turntable Bolts 222
General 222
Tools Required 223
Inner Race Torquing 223
Outer Race Torquing 223
Removal 224
Inspection 225
Installation 225
Testing 226
Swivels 226
Description 226
Hydraulic Swivel 228
Description 228
Theory of Operation 228
Maintenance 228
Removal 228
Installation 229
Two Port Water Swivel 229
Description 229
Maintenance 229
Removal 229
Disassembly 230
Cleaning and Inspection 230
Assembly 230
Installation 230
Electrical Swivel 230
Description 230
Theory of Operation 230
Maintenance 230
Removal 230
Installation 231
Preventive Maintenance 232
Slew Potentiometer Adjustment 232
SECTION 7 233
Power Train 233
Engine 233
Description 233
Maintenance 234
Engine Removal 234
Engine Installation 234
Engine Drive Belt 235
Electronic Control System 236
Engine Control System Switches and Indicator Lights 236
Engine Diagnostic/Speed Control Switch 236
Increment/Decrement Switch 236
Engine Stop Light 236
Engine Warning Light 236
Fault Code Flashing Sequence 237
The Engine Warning Light (amber) flashes at the beginning of a fault code sequence There will be a short 1- or 2-second pause after which the number of the recorded fault code will flash in the Engine Stop Light (red) To interpret the flash code, c 237
Exhaust System Cleaning Indicator 237
Exhaust System Cleaning Switch 237
Inhibit Exhaust System Cleaning Indicator 238
High Exhaust System Temperature 238
Fuel System 239
Description 239
Fuel Tank 239
Injection Fuel Pump 240
Fuel Filter-Water Separator 240
Maintenance 240
Fuel Tank 240
Removal 240
Installation 240
Fuel Filter-Water Separator 240
Draining 240
Air Intake and Exhaust System 240
Description 240
Air Intake 241
Air Cleaner Checks 241
Check for Filter Restriction 241
Filter Element Replacement 243
Element Cleaning 243
Air Cleaner Body 243
Precleaner 244
Duct Work 244
Charge-Air Cooler System 245
Maintenance 245
Exhaust System 246
Tier 3 246
Removal 246
Installation 246
Tier 4 247
Removal 247
Installation 247
Diesel Exhaust Fluid (DEF) System 249
DEF Tank 249
Removal 249
Installation 249
DEF Supply Module 249
Removal 249
Installation 250
Filter Replacement 250
Clean and Inspect for Reuse 250
Filter Installation 251
Water Cooling System 251
Description 251
Maintenance 251
General 251
Effects of Cooling System Neglect 251
Overheating 251
Overcooling 251
Rust Prevention 251
Test Equipment 252
Engine Antifreeze/Coolant Fill Procedure 252
Cooling/SCA Maintenance Summary 252
6 Months or 500 Hours 252
1 Year or 1000 Hours 252
Cleaning 252
Pressure Flushing 253
Component Inspection 253
Radiator/Surge Tank 253
Engine Water Jacket 253
Water Pump 254
Fans and Belts 254
Thermostat 254
Hoses and Clamps 254
Test Equipment 254
Antifreeze/Coolant 254
Radiator Removal and Installation 254
Removal 254
Installation 256
Drive Train 257
Description 257
Maintenance 257
Drive Lines 257
Removal 257
Installation 257
Lubrication 257
Transmission/torque Converter 259
Description 259
Theory of Operation 259
Maintenance 260
General Information 260
Troubleshooting 260
Troubleshooting Procedures 260
Hydraulic Checks 261
Removal 261
Installation 262
Towing or Pushing 262
Servicing the Crane After Transmission/Torque Converter Overhaul 264
Lubrication 264
Type of Oil 264
Capacity 264
Check Period 264
Normal Drain Period 264
Engine Block Heater 265
SECTION 8 267
Undercarriage 267
Axles 267
Description 267
Maintenance 268
Removal 268
Cleaning 268
Installation 268
Wheel Alignment Check Procedure 269
Rear Wheels Not Centered Switch Adjustment Procedure 269
Wheels and Tires 270
Description 270
Maintenance 270
Mounting Wheel Assemblies 270
Typical Wear Patterns 271
Incorrect Tire Pressure 271
Incorrect Camber 271
Incorrect Toe and Axle Alignment 271
Incorrect Caster and Wheel Imbalance 271
Cuts in the Tire Tread 272
Spot Wear 272
Feathered Edges 272
Cupping 272
Steering Systems 273
Description 273
Front Steering System 273
Rear Steering System 273
Secondary Steering System (CE Units) 273
Theory of Operation 273
Front Steering System 273
Rear Steering System 273
Secondary Steering System (CE Units) 273
Maintenance 274
Front Steering System 274
Troubleshooting 274
Functional Check 275
Rear Steering System 275
Troubleshooting 275
Hydraulic Pumps 276
Description 276
Front Steer 276
Rear Steer 276
Front Steering Control Valve 276
Description 276
Maintenance 276
Removal 276
Installation 276
Rear Steer/ Axle Lockout/Fan Drive Valve 276
Description 276
Maintenance 276
Removal 276
Installation 276
Functional Check 277
Steer Cylinders 277
Description 277
Maintenance 277
Removal 277
Installation 277
Rear Axle Oscillation Lockout System 277
Description 277
Theory of Operation 277
Axle Oscillation Lockout Cylinders 279
Description 279
Maintenance 279
Removal 279
Installation 279
Axle Oscillation Lockout Valve 279
Description 279
Maintenance 279
Removal 279
Installation 279
Brake System 280
Description 280
Service Brakes 280
Parking Brake 280
Theory of Operation 280
Service Brakes 280
Parking Brake 280
Maintenance 281
Troubleshooting 281
General 281
Bleeding the Brake System 281
Pressure Bleeding the Brake System 282
Manually Bleeding the Brake System 282
Service Brakes 282
Description 282
Maintenance 282
Removal 282
Linings 282
Caliper 282
Disassembly 283
Caliper 283
Inspection 284
Periodic On-Vehicle 284
Shoes, Linings, and End Plates 284
Caliper for Leaks 284
Dust Seals 285
Disc 285
Caliper Parts 285
Cleaning 286
Corrosion Protection 286
Assembly 286
Caliper 286
Installation 287
Linings 287
Caliper 287
Parking Brake Actuator 288
Description 288
Maintenance 288
Removal 288
Installation 288
Adjustment 288
Parking Brake 289
Description 289
Maintenance 289
Removal 289
Installation 289
Park Brake Solenoid Valve 292
Description 292
Maintenance 292
Removal 292
Installation 292
Outriggers 293
Outrigger Circuit 293
Theory of Operation 293
Maintenance 294
Troubleshooting 294
Outrigger Beam 297
Description 297
Theory of Operation 297
Maintenance 297
Removal 297
Inspection 297
Installation 298
Wear Pad Adjustment 298
Extension Cylinder 301
Description 301
Maintenance 301
Removal 301
Installation 301
Functional Check 301
Outrigger Monitoring System (Optional— Standard in North America) 302
Description 302
Removal 302
Installation 302
Jack Cylinder 302
Description 302
Maintenance 302
Removal 302
Installation 303
Functional Check 303
Outrigger Jack Cylinder Internal Leak Test 303
Checking Cylinder for Internal Piston Seal Leak 303
Testing Pilot Operated Check Valve For Leakage 304
Outrigger Control Valves 304
Description 304
Pilot Operated Check Valve 304
Integrated Outrigger/Rear Steer Valve 304
Outrigger Control Manifold 304
Optional Equipment 304
Pintle Hook 304
Secondary Front Steer (CE Option) 304
SECTION 9 305
Lubrication 305
General 305
Environmental Protection 305
Lubrication Intervals 305
Standard Lubricants 306
Arctic Lubricants and Conditions 307
Temperatures Below -9°C (15°F) 307
Cold Weather Package and Lubricants 307
Surface Protection for Cylinder Rods 310
Wire Rope Lubrication 311
Lubrication Points 311
CraneLUBE 311
Safety 311
Steering and Suspension 312
Axles 314
Drive Train 316
Drive Train (continued) 319
Turntable 321
Cab Tilt 323
Outriggers 325
Boom 327
Boom (continued) 329
Boom (continued) 331
Hoist 333
Hydraulic 335
Diesel Exhaust Fluid (DEF) 337
Carwell® Rust Inhibitor 339
Protecting Cranes From Rusting 339
Cleaning Procedures 339
Inspection and Repair 340
Application 340
Areas of Application 340

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