Grove Crane RT890E Service Manual 069-01 – PDF DOWNLOAD

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Grove Crane RT890E Service Manual 069-01 – PDF DOWNLOAD

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Grove Crane RT890E Service Manual 069-01 – PDF DOWNLOAD

Language : English
Pages : 346
Downloadable : Yes
File Type : PDF

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DESCRIPTION:

Grove Crane RT890E Service Manual 069-01 – PDF DOWNLOAD

INTRODUCTION:
DESCRIPTION:

• This Manual provides information for the maintenance of the Model RT890E Series Grove Crane.
• The lift capacities are listed on the Load Chart in the cab.
• The crane incorporates an all welded parallel box construction steel frame, using planetary
  drive axles to provide four-wheel drive. Axle steering is accomplished utilizing hydraulic steer
  cylinders. The engine is mounted at the rear of the crane carrier and provides motive power through
  a six speed forward and reverse transmission.
• The carrier frame incorporates an integral fifth wheel, to which the rear axle is mounted, to
  provide axle oscillation. Axle oscillation lockout is automatic when the superstructure rotates
  from the travel position.
• The superstructure is capable of 360 degree rotation in either direction. All crane functions are
  controlled from the fully-enclosed cab mounted on the superstructure. The crane is equipped with a
  five-section, full power, sequenced and synchronized boom. Additional reach is obtained by
  utilizing an optional swingaway boom extension. Lifting is provided by a main hoist and an optional auxiliary hoist.

TABLE OF CONTENTS:

Grove Crane RT890E Service Manual 069-01 – PDF DOWNLOAD

SECTION 1 INTRODUCTION
SECTION 2 HYDRAULIC SYSTEM
SECTION 3 ELECTRIC SYSTEM
SECTION 4 BOOM
SECTION 5 HOIST AND COUNTERWEIGHT
SECTION 6 SWING
SECTION 7 POWER TRAIN
SECTION 8 UNDERCARRIAGE
SECTION 9 LUBRICATION

SECTION 1 Introduction
Description 1-1
List of Specifications 1-1
General 1-1
Dimensions 1-1
Capacities 1-1
Torque Converter/Transmission 1-1
Engine 1-1
Axles 1-1
Brakes 1-1
Wheels and Tires 1-1
Swing Gearbox 1-1
Boom 1-2
Swivel Assembly 1-2
Hydraulic Pumps 1-2
General Maintenance 1-5
Cleanliness 1-5
Removal and Installation 1-6
Disassembly and Assembly 1-7
Pressing Parts 1-7
Locks 1-7
Wires and Cables 1-7
Shims 1-7
Bearings 1-7
Gaskets 1-8
Batteries 1-8
Hydraulic Systems 1-8
Fatigue of Welded Structures 1-8
Loctite 1-9
Fasteners and Torque Values 1-9
Wire Rope 1-13
General 1-13
Environmental Conditions 1-13
Dynamic Shock Loads 1-13
Lubrication 1-13
Precautions and Recommendations During Inspection or Replacement 1-14
Wire Rope Inspection (Running Ropes and Pendant Cables) 1-15
Wire Rope Inspection (Boom Extension and Retraction Cables) 1-15
Wire Rope Replacement (All Wire Rope) 1-15
Seizing Wire Rope 1-16
Installing FLEX-X 35 Wire Rope 1-17
Procedures for Cutting and Preparing FLEX-X 35 1-17
SECTION 2 Hydraulic System
Description 2-1
Theory Of Operation 2-1
Maintenance 2-4
Hydraulic Oil Recommendations 2-4
Draining and Flushing 2-4
Removing Air from the Hydraulic System 2-5
Parts Replacement 2-5
Directional Control Valves 2-5
Supply Pressure and Return Circuit 2-7
Description 2-7
TABLE OF CONTENTS RT890E
TOC-2
Maintenance 2-9
Oil Cooler 2-11
Description 2-11
Hydraulic Pumps 2-12
Description 2-12
Maintenance 2-12
Pressure Setting Procedures 2-17
Procedure A – For Checking/Setting The Main Control Valve For Hoists(s),
Boom Lift and Telescope(s) Pressures 2-18
Procedure B – For Setting The Outrigger Pressures 2-19
Procedure C – For Setting The Oil Cooler Motor Pressure 2-19
Procedure D – For Checking/Setting The Load Sense Reduction Manifold 2-19
Procedure E – For Checking/Setting The Service Brake Accumulator Charging
Valve Charging Limits 2-19
Procedure F – For Checking Accumulator Pre-Charge Pressure 2-20
Procedure G – For Pre-Charging The Accumulator 2-20
Procedure H – For Checking/Setting The Front Steer Pressure 2-20
Procedure I – For Checking/Setting The Swing Work Port Pressure 2-20
Procedure J – For Checking/Setting The Swing Brake Release Pressure 2-21
Procedure K – For Checking/Setting The Controller Supply Pressure 2-21
Procedure L – For Checking/Setting The Hose Reel Brake and Motor Supply 2-21
Procedure M – For Checking/Setting The Counterweight Removal Cylinder
Extend Pressure 2-21
Procedure N – For Checking/Setting The Counterweight Pin Cylinder Pressure 2-21
Procedure O – For Checking/Setting The Cab Tilt Cylinder Extend/Retract
Pressure 2-21
Procedure P – For Checking/Setting The Luffing Jib Lower Pressure 2-22
Valves 2-29
General 2-29
Directional Control Valves 2-33
Description 2-33
Maintenance 2-33
Front Steer, Swing and Accessory Manifold 2-39
Description 2-39
Maintenance 2-39
Steering Control Valve 2-43
Description 2-43
Maintenance 2-43
Hydraulic Remote Control Valve 2-44
Description 2-44
Maintenance 2-44
Swing Power Brake Valve With Treadle Pedal 2-47
Description 2-47
Maintenance 2-47
2 Speed Swing Valve 2-48
Description 2-48
Maintenance 2-48
Cab Tilt Double Pilot Operated Check Valve 2-49
Description 2-49
Maintenance 2-49
Tandem Brake Valve with Treadle Pedal 2-50
Description 2-50
Maintenance 2-50
Dual Accumulator Charge Valve 2-51
Description 2-51
Maintenance 2-51
Hydraulic Accumulator Service Brake 2-53
TOC-3
RT890E TABLE OF CONTENTS
T
OC
Description 2-53
Maintenance 2-53
Holding Valves 2-54
Description 2-54
Maintenance 2-54
Cross Axle Differential Lock Valve 2-55
Description 2-55
Maintenance 2-55
Outrigger Control Manifold 2-56
Description 2-56
Maintenance 2-56
Pilot Operated Check Valve 2-59
Description 2-59
Maintenance 2-59
Axle Lockout, Rear Steer and Oil Cooler Fan Motor Control Manifold 2-60
Description 2-60
Maintenance 2-60
Check Valves 2-63
Description 2-63
Maintenance 2-63
Hi-Low Range, Axle Disconnect and Parking Brake Valve 2-64
Description 2-64
Maintenance 2-64
Load Sense Reduction Manifold 2-65
Description 2-65
Maintenance 2-65
Cylinders 2-67
General 2-67
Maintenance 2-67
Surface Protection for Cylinder Rods 2-67
Lift Cylinder 2-69
Description 2-69
Maintenance 2-69
Dual Rod Telescope Cylinder 2-73
Description 2-73
Maintenance 2-73
Upper Telescope Cylinder 2-77
Description 2-77
Maintenance 2-77
Axle Oscillation Lockout Cylinder 2-80
Description 2-80
Maintenance 2-80
Steer Cylinder 2-83
Description 2-83
Maintenance 2-83
Outrigger Extension Cylinder 2-87
Description 2-87
Maintenance 2-87
Outrigger Stabilizer Cylinder 2-90
Description 2-90
Maintenance 2-90
Cab Tilt Cylinder 2-94
Description 2-94
Maintenance 2-94
Counterweight Removal Cylinder 2-98
Description 2-98
Maintenance 2-98
TABLE OF CONTENTS RT890E
TOC-4
Counterweight Pin Cylinder 2-101
Description 2-101
Maintenance 2-101
Park Brake Cylinder 2-104
Description 2-104
SECTION 3 Electric System
Description 3-1
General 3-1
Alternator 3-1
Batteries 3-1
Relay Panel And Fuse Panel 3-1
Relays 3-2
Maintenance 3-3
General 3-3
General Troubleshooting 3-4
Troubleshooting Swivel-Caused Electrical Problems 3-4
Connector Troubleshooting 3-4
Control Module Diagnostic Light 3-6
Alternator Replacement 3-7
Starter Replacement 3-8
Battery Replacement 3-8
Relay Panel Component Replacement 3-8
Instrument Replacement 3-9
Switch Replacement 3-9
Windshield Wiper Assembly Replacement 3-10
Windshield Washer Assembly Replacement 3-11
Skylight Wiper Assembly Replacement 3-12
Troubleshooting 3-12
Optional Equipment 3-12
Description 3-12
Strobe Light 3-12
Spotlight 3-12
Boom Mounted Floodlights 3-12
Rear View Mirror 3-12
Air Conditioner 3-12
SECTION 4 Boom
Description 4-1
Lattice Extension 4-1
Optional Lattice Extension 4-1
Optional Lattice Extension Inserts 4-1
Boom Control Switches 4-1
Boom Auto/Manual Telescope Mode Switches 4-1
Center Mid/Inner Mid Boom Telescope Sections Select Switch 4-1
Theory of Operation 4-1
Boom Extension 4-1
Boom Retraction 4-2
LMI System (With Boom Control System) 4-2
General 4-2
Telescoping Control System Description 4-2
Extension Sequence for the Main Boom (Figure 4-1) 4-3
Extension Sequence for the Main Boom with Boom Extensions or Offset Jibs 4-3
Electronic Control System 4-4
Maintenance 4-6
Removal 4-6
TOC-5
RT890E TABLE OF CONTENTS
T
OC
Boom Disassembly 4-7
Boom Nose Sheaves 4-14
Boom Assembly 4-15
Installation 4-18
Functional Check 4-19
Inspection 4-19
Boom Alignment And Servicing 4-19
Cam Operated Check Valve Adjustment 4-20
Guide Block Adjustment 4-20
Boom Extension And Retraction Cable 4-20
Maintenance 4-20
Inspection 4-20
Adjustment 4-21
Telescope Circuit 4-23
Description 4-23
Theory of Operation 4-23
Maintenance 4-23
Hose Reel 4-25
Description 4-25
Maintenance 4-25
Lift Circuit 4-29
Description 4-29
Theory of Operation 4-29
Maintenance 4-29
Auxiliary Boom Nose 4-34
Description 4-34
Counterweight and Auxiliary Hoist 4-35
Counterweight Without Auxiliary Hoist 4-35
Installing the Bi-Fold Manual Boom Extension 4-38
Checking the Transport Condition 4-40
Erecting Procedure 4-40
Stowing Procedure 4-46
Hose Drum for Hydraulic Luffing Boom Extension 4-51
Raising and Lowering the Hydraulic Boom Extension 4-53
Transportation on a Separate Vehicle 4-53
Connecting and Disconnecting the Hydraulic Boom Extension 4-53
Hydraulic Connection at the Boom Extension 4-55
Lifting Limit Switch on the Lattice Extension 4-56
Folding Out/In the Deflection Sheaves on the 33 ft (10 1 m) Section 4-57
Positioning/Remove the Hoist Cable 4-58
Setting the Folding Swingaway Extension Offset (Figure 4-75) 4-59
Removing the Bi-Fold Manual Boom Extension 4-60
Installing/Removing 16 ft (4 9 m) Sections 4-60
Installing the 16 ft (4 9 m) Sections 4-61
Removing the 16 ft (4 9 m) Sections 4-61
Boom Extension (Additional Equipment) 4-61
Identification and Slinging Points 4-61
Assembly Of Boom Extensions (Figure 4-78) 4-62
Electrical Connection at the Boom Extension 4-62
Unfolding/Folding the Deflection Sheave on the 16 ft (4 9 m) Section 4-63
Positioning/Removing the Hoist Cable 4-64
Traveling with Hydraulic Luffing or Manually Offsettable Boom Extension
and/or Inserts Erected 4-65
Adjustment Procedure for Stowage Brackets for Hydraulic Luffing Jib 4-65
Auxiliary Single-Sheave Boom Nose (Additional Equipment) 4-66
Identification 4-66
Installing/Removing Auxiliary Single-Sheave Boom Nose 4-66
TABLE OF CONTENTS RT890E
TOC-6
Removing the Auxiliary Single-Sheave Boom Nose 4-67
Rigging The Auxiliary Single-Sheave Boom Nose 4-67
Rigging in Transport Position 4-67
Rigging in Working Position 4-68
Attaching and Removing Hoist Cable 4-69
Possible Reeving Methods on the Auxiliary Single-Sheave Boom Nose 4-69
Lifting Limit Switch 4-69
Raising And Setting Down The Main Boom With Rigged Lattice Extension 4-70
Telescoping With Rigged Lattice Extension 4-70
Operating With The Lattice Extension 4-70
Procedure if the Permissible Wind Speed is Exceeded 4-71
Monthly Maintenance Work 4-72
SECTION 5 Hoist And Counterweight
Description 5-1
Theory of Operation 5-1
Maintenance 5-1
Warm-up Procedure 5-1
Removal 5-1
Installation 5-3
Functional Check 5-3
Servicing 5-3
Hoist to Boom Alignment 5-3
Preparation 5-3
Tools Required 5-3
Procedure 5-3
Piston Motor and Control Valve 5-5
Description 5-5
Maintenance 5-5
Idler Drum and Cable Follower 5-5
Description 5-5
Maintenance 5-5
Hoist Drum Rotation Indicator System 5-8
Description 5-8
Maintenance 5-8
Counterweight Removal 5-11
Removal of Standard Counterweight and Auxiliary Hoist 5-11
Installation of Standard Counterweight and Auxiliary Hoist Mounting Structure 5-11
Removal of Counterweight Without Auxiliary Hoist 5-11
Installation of Counterweight Without Auxiliary Hoist 5-13
Third Wrap Indicator (Optional) 5-13
Description 5-13
SECTION 6 Swing System
Introduction 6-1
Description 6-1
Theory of Operation 6-1
Maintenance 6-3
Troubleshooting 6-3
Swing Motor 6-6
Description 6-6
Maintenance 6-6
Swing Gearbox And Brake 6-6
Description 6-6
Maintenance 6-6
Swing Bearing 6-8
TOC-7
RT890E TABLE OF CONTENTS
T
OC
Description 6-8
Maintenance 6-8
Swivels 6-13
Description 6-13
Hydraulic Swivel 6-15
Two Port Water Swivel 6-16
Electrical Swivel 6-17
SECTION 7 Power Train
Engine 7-1
Description 7-1
Maintenance 7-1
Electronic Control System 7-5
Engine Control System Switches and Indicator Lights 7-5
Fuel System 7-6
Description 7-6
Maintenance 7-7
Air Intake System 7-9
Description 7-9
Maintenance 7-9
Water Cooling System 7-13
Description 7-13
Maintenance 7-13
Test Equipment 7-16
Antifreeze/Coolant 7-16
Radiator Removal and Installation 7-16
Drive Train 7-18
Description 7-18
Maintenance 7-19
Transmission/Torque Converter 7-19
Description 7-19
Theory of Operation 7-19
Maintenance 7-20
Towing or Pushing 7-22
Servicing the Crane After Transmission/Torque Converter Overhaul 7-24
Optional Equipment 7-25
Description 7-25
Engine Block Heater 7-25
SECTION 8 Undercarriage
Axles 8-1
Description 8-1
Maintenance 8-1
Wheels and Tires 8-3
Steering Systems 8-5
Description 8-5
Theory of Operation 8-5
Maintenance 8-6
Rear Steering System 8-7
Troubleshooting 8-7
Hydraulic Pumps 8-7
Front Steering Control Valve 8-8
Rear Steer/ Axle Lockout/Fan Drive Valve 8-8
Steer Cylinders 8-9
Rear Axle Oscillation Lockout System 8-9
Description 8-9
TABLE OF CONTENTS RT890E
TOC-8
Theory of Operation 8-9
Axle Oscillation Lockout Cylinders 8-11
Axle Oscillation Lockout Valve 8-11
Brake System 8-12
Description 8-12
Theory of Operation 8-12
Maintenance 8-13
Service Brakes 8-14
Description 8-14
Maintenance 8-14
Corrosion Protection 8-18
Parking Brake Actuator 8-20
Description 8-20
Maintenance 8-20
Parking Brake 8-20
Description 8-20
Maintenance 8-21
Park Brake solenoid Valve 8-21
Description 8-21
Maintenance 8-21
Outriggers 8-22
Outrigger Circuit 8-22
Outrigger Beam 8-25
Extension Cylinder 8-29
Stabilizer Cylinder 8-30
Outrigger Control Valves 8-31
Optional Equipment 8-32
Description 8-32
Pintle Hook 8-32
Table of Contents 9-i
SECTION 9 Lubrication
General 9-1
Arctic Conditions – Below -18°C (0°F) 9-1
Lubrication Points 9-1
Surface Protection for Cylinder Rods 9-1
Wire Rope Lubrication 9-10

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