Grove Crane RT9150E Service & Maintenance Manual – PDF DOWNLOAD

Description

Grove Crane RT9150E Service & Maintenance Manual – PDF DOWNLOAD

FILE DETAILS:

Grove Crane RT9150E Service & Maintenance Manual – PDF DOWNLOAD

Language : English
Pages : 324
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Grove Crane RT9150E Service & Maintenance Manual – PDF DOWNLOAD

GENERAL:
This manual provides important information concerning your Grove Crane.
Overview of Manuals:

• Before servicing the crane, take time to thoroughly familiarize yourself with the contents
  of this manual.
• After all sections have been read and understood, retain the manual for future reference in a readily accessible location.

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.
NOTE: Your safety and that of others is always the number one consideration when working around
machines. Safety is a matter of thoroughly understanding the job to be done and the application of
good common sense. It is not just a matter of do’s and don’ts. Stay clear of all moving parts.
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.

TABLE OF CONTENTS:

Grove Crane RT9150E Service & Maintenance Manual – PDF DOWNLOAD

TABLE OF CONTENTS.............................................................................  5
Introduction.................................................................................. 13
	General................................................................................... 13
		Overview of Manuals................................................................... 13
		Delivery Report....................................................................... 14
		Customer Support...................................................................... 14
		Safety Information.................................................................... 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....................................................... 15
	List Of Specifications.................................................................... 16
		General............................................................................... 16
		Dimensions............................................................................ 16
		Capacities............................................................................ 16
		Torque Converter...................................................................... 16
		Transmission.......................................................................... 16
		Engine................................................................................ 16
		Axles................................................................................. 16
		Brakes................................................................................ 16
		Wheels and Tires...................................................................... 16
		Swing Gearbox......................................................................... 16
		Boom.................................................................................. 16
		Swivel Assembly....................................................................... 16
		Hydraulic Pumps....................................................................... 16
		Hoists................................................................................ 17
	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
		Bearings.............................................................................. 23
		Gaskets............................................................................... 23
		Batteries............................................................................. 23
		Hydraulic Systems..................................................................... 24
		Hydraulic Fittings.................................................................... 25
		Electrical System..................................................................... 28
		Fatigue of Welded Structures.......................................................... 28
		Loctite............................................................................... 28
		Fasteners and Torque Values........................................................... 29
		Weld Studs............................................................................ 32
	Wire Rope................................................................................. 33
		General............................................................................... 33
		Environmental Conditions.............................................................. 33
		Dynamic Shock Loads................................................................... 33
		Lubrication........................................................................... 33
		Precautions and Recommendations During Inspection or Replacement...................... 33
		Wire Rope Inspection (Running Ropes and Pendant Cables)............................... 34
		Keeping Records....................................................................... 34
		Frequent Inspection................................................................... 34
		Wire Rope Inspection/Replacement (All Wire Rope)...................................... 35
		Seizing Wire Rope..................................................................... 35
		Installing Low Rotation Class Wire Rope............................................... 36
		Procedures for Cutting and Preparing Low Rotation Class Wire Rope..................... 37
Hydraulic System.............................................................................. 39
	Description............................................................................... 40
	Maintenance............................................................................... 43
		Preparation........................................................................... 43
		Hydraulic System Maintenance Precautions.............................................. 43
		Label Parts when Disassembling........................................................ 43
		Hydraulic Fluid Recommendations....................................................... 43
		Draining and Flushing................................................................. 43
		Removing Air from the Hydraulic System................................................ 44
		Parts Replacement..................................................................... 45
		Directional Control Valves............................................................ 45
	Supply Pressure And Return Circuit........................................................ 47
		Description........................................................................... 47
		Pump Distribution..................................................................... 48
	Maintenance............................................................................... 49
		Troubleshooting....................................................................... 49
		Troubleshooting Aids.................................................................. 50
		Troubleshooting Procedures............................................................ 50
		Filter Maintenance.................................................................... 51
		Fill Cap Breather..................................................................... 51
	Oil Cooler................................................................................ 53
		Description........................................................................... 53
	Hydraulic Pumps........................................................................... 55
		Description........................................................................... 55
		Maintenance........................................................................... 55
	Pressure Setting Procedures............................................................... 60
		Connecting laptop to Crane Service Junction........................................... 62
		Procedure A - Checking/Setting Piston Pump Differential and Cut-off Pressures......... 62
		Procedure B - For Checking/Setting the Outrigger/Rear Steer/Axle Lockout Pressures.... 62
		Superstructure Hydraulic System....................................................... 65
		Procedure C - Checking/Setting Main Hoist Lower Pressure.............................. 65
		Procedure D - Checking/Setting Main Hoist Raise Pressure.............................. 66
		Procedure E - Checking/Setting Auxiliary Hoist Lower Pressure......................... 66
		Procedure F - Checking/Setting Auxiliary Hoist Raise Pressure......................... 66
		Procedure G - Checking/Setting Telescope Pressure..................................... 66
		Procedure H - Checking/Setting Control Pressure....................................... 68
		Procedure I - Checking/Setting Raise Boom (Derricking) Pressure....................... 68
		Procedure J - Checking/Setting Counterweight Raise Pressure........................... 68
		Procedure K - Checking/Setting Counterweight Lower Pressure........................... 68
		Procedure L - Checking/Setting Counterweight Locking/Unlocking Pressures.............. 68
		Procedure M - Checking/Setting Cab Tilt Pressures..................................... 69
		Procedure N - Checking/Setting Luffing Jib Pressures.................................. 69
		Procedure O - Checking/Setting Slewing Pressure....................................... 69
		Procedure P - Checking/Setting Slewing Pressure....................................... 69
		Procedure Q - Checking/Setting Steering Pressure...................................... 70
		Procedure R - Checking/Setting Service Brake Pressure................................. 70
		Procedure S - Checking Service Brake Accumulator Charge Pressures..................... 70
		Procedure T - Checking Service Brake Accumulator Pre-Charge Pressures................. 71
		Procedure for Pre-Charging the Service Brake Accumulators, If Required................ 71
	Valves.................................................................................... 72
		General............................................................................... 72
	Outrigger/Rear Steer/Outrigger Box Pin Removal Valve...................................... 75
		Description........................................................................... 75
		Maintenance........................................................................... 75
	Outrigger Control Manifold................................................................ 78
		Description........................................................................... 78
		Maintenance........................................................................... 78
	Park Brake/Axle Disconnect valve.......................................................... 79
		Description........................................................................... 79
		Maintenance........................................................................... 79
	Axle Oscillation Lockout Valve............................................................ 80
		Description........................................................................... 80
		Maintenance........................................................................... 80
	Pressure Bleed-Off Valve.................................................................. 81
		Description........................................................................... 81
		Maintenance........................................................................... 81
	Main Directional Control Valve............................................................ 82
		Description........................................................................... 82
		Maintenance........................................................................... 82
	Swing Directional Control Valve........................................................... 86
		Description........................................................................... 86
		Maintenance........................................................................... 86
	Compact Block Manifold.................................................................... 88
		Description........................................................................... 88
		Maintenance........................................................................... 88
	Accessory Manifold........................................................................ 91
		Description........................................................................... 91
		Maintenance........................................................................... 91
	Case Drain Manifold....................................................................... 93
		Description........................................................................... 93
		Maintenance........................................................................... 93
	Dual Accumulator Charge Valve............................................................. 94
		Description........................................................................... 94
		Maintenance........................................................................... 94
	Control Block............................................................................. 96
		Description........................................................................... 96
		Maintenance........................................................................... 96
	Tandem Brake Valve w/ Treadle Pedal....................................................... 97
		Description........................................................................... 97
		Maintenance........................................................................... 97
	Hydraulic Accumulator Service Brake....................................................... 99
		Description........................................................................... 99
		Maintenance........................................................................... 99
	Cylinders.................................................................................100
		General...............................................................................100
		Maintenance...........................................................................100
		Surface Protection For Cylinder Rods..................................................100
	Axle Oscillation Lockout Cylinder.........................................................102
		Description...........................................................................102
		Maintenance...........................................................................102
	Steer Cylinder............................................................................105
		Description...........................................................................105
		Maintenance...........................................................................105
	Outrigger Extension Cylinder..............................................................108
		Description...........................................................................108
		Maintenance...........................................................................108
	Outrigger Stabilizer Cylinder.............................................................111
		Description...........................................................................111
		Maintenance...........................................................................111
	Cab Tilt Cylinder.........................................................................114
		Description...........................................................................114
		Maintenance...........................................................................114
	Power Pin Cylinder........................................................................117
		Description...........................................................................117
		Maintenance...........................................................................117
	Counterweight Pin Cylinder................................................................120
		Description...........................................................................120
		Maintenance...........................................................................120
	Lift Cylinder.............................................................................122
		Description...........................................................................122
		Maintenance...........................................................................122
Electrical System.............................................................................125
	Description...............................................................................125
		General...............................................................................125
		Alternator............................................................................125
		Batteries.............................................................................126
		Fuses/Relays..........................................................................126
	Maintenance...............................................................................130
		General...............................................................................130
		Visual Inspection and Replacement of Electrical Harnesses and Cables..................130
		General Troubleshooting...............................................................131
		Tools for Troubleshooting.............................................................131
		Troubleshooting Engine Starting Problems..............................................131
		Alternator/Charging System Troubleshooting............................................132
		Troubleshooting Accessories...........................................................133
		Troubleshooting Swivel-Caused Electrical Problems.....................................133
		Connector Troubleshooting.............................................................133
		ECOS Control Panel....................................................................134
		Diagnostic Connector and Equipment....................................................136
		Troubleshooting Vehicle Lights........................................................136
		Troubleshooting Alarms, Indicators, and Emergency Components..........................136
		Troubleshooting Crane Components and Accessories......................................136
		Alternator Replacement................................................................136
		Starter Replacement...................................................................137
		Battery Replacement...................................................................137
		Relay Panel Component Replacement.....................................................138
		Switch Replacement....................................................................138
		Rocker Switch Replacement.............................................................138
		Turn Signal Indicator Replacement.....................................................139
		Ignition Switch Replacement...........................................................139
		Turn Signal Lever and Transmission Shift Lever Replacement............................140
		Windshield Wiper Assembly Replacement.................................................142
		Windshield Washer Assembly Replacement................................................143
		Skylight Wiper Assembly Replacement...................................................144
Boom..........................................................................................145
	Description...............................................................................145
		Main Boom.............................................................................145
		Mechanical Luffing Lattice Extension..................................................145
		Optional Hydraulic Luffing Lattice Extension..........................................145
		Optional Boom Equipment...............................................................145
		Boom Controls.........................................................................145
	Description and Theory of Operation.......................................................145
	Maintenance...............................................................................148
		Boom Removal..........................................................................148
		Boom Disassembly......................................................................152
		Assembling the Boom...................................................................160
		Boom Assembly.........................................................................170
		Boom Installation.....................................................................179
		Functional Check......................................................................181
		Inspection............................................................................182
		Boom Alignment and Servicing..........................................................182
	Bi-Fold Swingaway Boom Extension..........................................................183
		Description...........................................................................183
	Hook Block/Overhaul ball..................................................................183
		Description...........................................................................183
		Maintenance...........................................................................183
Hoist and Counterweight.......................................................................185
	Description...............................................................................185
	Theory of Operation.......................................................................185
	Maintenance...............................................................................185
		Warm-up Procedure.....................................................................185
		Hoist Access Area.....................................................................186
		Hoist Removal.........................................................................186
		Installation..........................................................................188
		Functional Check......................................................................189
		Preventive Maintenance................................................................189
	Hoist Cable (Wire Rope)...................................................................189
		Check the Position on the Hoist Drums.................................................189
		Check the Rope........................................................................189
	Adjusting the Lowering Limit Switch.......................................................190
		Setting the Lowering Limit Switch.....................................................190
		Check the Lowering Limit Shuts Off....................................................190
	Checking the Hoist Brake..................................................................190
	General Inspection........................................................................191
	Counterweight Removal and Installation....................................................191
		Counterweight Stand Installation......................................................191
		Standard 39,000 lb (17,690 kg) Counterweight Installation.............................191
		Standard 39,000 lb (17,690 kg) Counterweight Removal..................................192
		Heavy 63,000 lb (28,576 kg) Counterweight Installation................................193
		Heavy 63,000 lb (28,576 kg) Counterweight Removal.....................................194
		Counterweight Stand Removal...........................................................194
Swing System..................................................................................195
	Description...............................................................................195
	Theory of Operation.......................................................................195
		Swing Drive...........................................................................195
		Swing Brake...........................................................................195
	Maintenance...............................................................................197
		Troubleshooting.......................................................................197
	Swing Box Assemblies......................................................................201
		Description...........................................................................201
		Swing Motor Maintenance...............................................................201
		Swing Brake Assembly Maintenance......................................................202
		Swing Gearbox Maintenance.............................................................202
	Swing Bearing.............................................................................204
		Description...........................................................................204
		Maintenance...........................................................................204
	Swivels...................................................................................209
		Description...........................................................................209
		Hydraulic Swivel......................................................................211
		Two-Port Water Swivel.................................................................212
		Electrical Swivel.....................................................................213
	Swing Lock Pin............................................................................215
		Description...........................................................................215
		Maintenance...........................................................................215
	360° Swing Lock Control (Positive Lock Type)..............................................215
		Description...........................................................................215
		Maintenance...........................................................................215
Power Train...................................................................................217
	Description...............................................................................217
	Maintenance...............................................................................218
		Engine Removal........................................................................218
		Engine Installation...................................................................221
		Engine Drive Belts....................................................................222
	Electronic Control System.................................................................224
	Fuel System...............................................................................224
		Description...........................................................................224
		Maintenance...........................................................................224
	Air Intake and Exhaust System.............................................................226
		Description...........................................................................226
		Maintenance...........................................................................226
		Charge-Air Cooler System..............................................................232
	Muffler...................................................................................233
		Removal...............................................................................233
		Installation..........................................................................233
	Water Cooling System......................................................................236
		Description...........................................................................236
		Maintenance...........................................................................236
	Drive Train...............................................................................242
		Description...........................................................................242
		Maintenance...........................................................................242
	Torque Converter..........................................................................243
		Description...........................................................................243
		Theory of Operation...................................................................243
		Maintenance...........................................................................244
	Transmission..............................................................................249
		Description...........................................................................249
		Maintenance...........................................................................249
Undercarriage.................................................................................251
	Axles.....................................................................................251
		Description...........................................................................251
	Maintenance...............................................................................252
		Removal...............................................................................252
		Cleaning..............................................................................252
		Installation..........................................................................252
		Wheel Alignment Check Procedure.......................................................253
		Rear Wheels Not Centered Switch Adjustment Procedure..................................253
	Wheels and Tires..........................................................................254
		Description...........................................................................254
		Maintenance...........................................................................254
	Steering Systems..........................................................................255
		Description...........................................................................255
		Theory of Operation...................................................................255
		Maintenance...........................................................................255
		Hydraulic Pump........................................................................258
		Front Steering Control Valve..........................................................258
		Integrated Outrigger/Rear Steer Control Valve.........................................258
		Steer Cylinders.......................................................................259
		Rear Axle Oscillation Lockout System..................................................259
		Axle Oscillation Lockout Cylinders....................................................261
		Axle Oscillation Lockout Valve........................................................261
	Brake System..............................................................................262
		Description...........................................................................262
		Theory of Operation...................................................................262
		Maintenance...........................................................................263
		Service Brakes........................................................................264
		Parking Brake Actuator................................................................270
		Parking Brake.........................................................................270
		Park Brake Solenoid Valve.............................................................272
	Outriggers................................................................................273
		Description...........................................................................273
		Theory of Operation...................................................................273
		Maintenance...........................................................................273
		Outrigger Monitoring System (Optional— Standard in North America).....................282
Lubrication...................................................................................283
	General...................................................................................283
		Environmental Protection..............................................................283
		Lubrication Intervals.................................................................283
	Standard Lubricants Package...............................................................284
	Arctic Conditions.........................................................................284
		Below 0°F (–18°C).....................................................................284
		Down to –40°F.........................................................................284
	Surface Protection for Cylinder Rods......................................................286
	Wire Rope Lubrication.....................................................................286
	Lubrication Points........................................................................287
		CraneLUBE.............................................................................287
		Safety................................................................................287
		Steering and Suspension...............................................................288
		Axles.................................................................................290
		Drive Train...........................................................................292
		Drive Train (continued)...............................................................294
		Outriggers............................................................................296
		Hydraulic.............................................................................298
		Turntable.............................................................................300
		Cab Tilt..............................................................................302
		Lift Cylinder.........................................................................304
		Hoist.................................................................................306
		Boom..................................................................................308
		Boom (continued)......................................................................310
		Boom Extension........................................................................312
		Boom..................................................................................314
	Carwell® Rust Inhibitor...................................................................316
		Description...........................................................................316
		Cleaning Procedures...................................................................316
		Inspection and Repair.................................................................317
		Carwell Application...................................................................317
		Areas of Application..................................................................317

Contact us: [email protected]

PLEASE NOTE:

• This is the same manual used by the DEALERSHIPS to SERVICE your vehicle.
• The manual can be all yours – Once payment is complete, you will be taken to the download page from where you can download the manual. All in 2-5 minutes time!!
• Need any other service / repair / parts manual, please feel free to contact us at heydownloadss @gmail.com . We may surprise you with a nice offer

S.V