Page 1 Grove GRT9165 Service Manual 9897...
Page 2 WARNING California Proposition 65 Breathing diesel engine exhaust exposes you to chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. • Always start and operate the engine in a well-ventilated area. • If in an enclosed area, vent the exhaust to the outside.
Page 3 An untrained operator subjects himself and others to death or serious injury. Do not operate this crane unless: • You are trained in the safe operation of this crane. Manitowoc is not responsible for qualifying personnel. • You read, understand, and follow the safety and operating recommendations contained in the crane manufacturer’s manuals and...
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Page 5: Table Of Contents
GRT9165 SERVICE MANUAL TABLE OF CONTENTS Table of Contents SECTION 1 ........Introduction General .
Page 6 Accessing the Diagnostic Connector ........2-54 Connecting the Manitowoc Crane Service Tool......2-54 Checking/Setting the Piston Pumps Cut-off and Differential Pressures .
Page 7 Viewing Diagnostic Fault Codes ........3-20 About the Manitowoc Diagnostic Code Mobile Application....3-20 Optional Equipment .
Page 8 TABLE OF CONTENTS GRT9165 SERVICE MANUAL SECTION 4..........Boom Boom Removal .
Page 9 GRT9165 SERVICE MANUAL TABLE OF CONTENTS Description ............6-13 Hydraulic Swivel .
Page 10 TABLE OF CONTENTS GRT9165 SERVICE MANUAL Description............8-8 Maintenance .
Page 11: Section 1
GRT9165 SERVICE MANUAL INTRODUCTION SECTION 1 INTRODUCTION SECTION CONTENTS General ........1-1 Disassembly and Assembly.
Page 12: Customer Support
For basic Crane Component locations see Figure 1-2. If you are the new owner of a Grove crane, please register it Axle Weight Distribution with Manitowoc Crane Care so we have the ability to contact you if the need arises. For Axle Weight Distribution see Table 1-2.
Page 13: List Of Specifications
GRT9165 SERVICE MANUAL INTRODUCTION LIST OF SPECIFICATIONS Torque Converter Stall Ratio......1.784:1 General Charge Pump Capacity .
Page 14: Boom
INTRODUCTION GRT9165 SERVICE MANUAL Boom Hydraulic Pumps Length ..13.7 m to 62.5 m (44.9 ft to 205 ft) NOTE: Pump flow rate (output) figures are theoretical. Sections ... . 6 Section, MEGAFORM™ Pinning .
Page 15 GRT9165 SERVICE MANUAL INTRODUCTION TRANSPORTATION AND LIFTING DATA GRT9165 TOTAL CARRIER BOOM CWT FITTING CAPACITY (TONS) UNIT LIFT BOOM USING APPROPRIATE 676cm LIFTING DEVICE. DO NOT LIFT BY (266 in) TIE DOWN LIFT PINNING HOLES. (BOTH SIDES) 16,206kg (35,728 lb) (BOTH SIDES) SEE NOTE #5 BOOM...
Page 16 INTRODUCTION GRT9165 SERVICE MANUAL Table 1-1 Axle Weight Distribution Table CG To CL Rear Weight Front Axle Rear Axle Description Bogie cm (in) kg (lb) kg (lb) kg (lb) Basic Unit Maximum Axle Allowable at 16 km/h 33113 (73000) 66225 (146000) (10 mph) Maximum Axle Allowable at 4 km/h 43727 (96400)
Page 17 GRT9165 SERVICE MANUAL INTRODUCTION CG To CL Rear Weight Front Axle Rear Axle Description Bogie cm (in) kg (lb) kg (lb) kg (lb) 120 t (134 USt) Hookblock (8 sheave) - in 469.90 (185.00) 1180 (2601) 1109 (2444) 71 (157) stowage tray 100 t (112 USt) Hookblock (7 sheave) - in 469.90 (185.00)
Page 18: Grt9165 Crane Components
INTRODUCTION GRT9165 SERVICE MANUAL GRT9165 CRANE COMPONENTS 9903-01 9903-02 FIGURE 1-2 Item Description Item Description Auxiliary Boom Nose Sheaves Diesel Exhaust Fluid (DEF) Tank* Boom Nose Sheaves Fuel Tank* Boom Outrigger Box Pinning Control Boom Work Lights Air Conditioning Condenser Superstructure Valve Covers Main Hoist Hydraulic Oil Cooler...
Page 19: General Maintenance
GRT9165 SERVICE MANUAL INTRODUCTION GENERAL MAINTENANCE compressed air on bearings. Spinning bearings without lubricant will cause damage to the bearing, and could cause These general suggestions should be helpful in following the the bearing to fly apart. i ns t r u c t io n s i n th i s m a nu a l . I n a n al y z i ng a s y s te m malfunction, use a systematic approach to locate and correct the problem.
Page 20: Pressing Parts
INTRODUCTION GRT9165 SERVICE MANUAL Pressing Parts Hoses and Tubes When pressing one part into another, use an anti-seize DANGER compound or a molybdenum disulfide base compound to lubricate the mating surfaces. High Pressure/Temperature Hazard! Assemble tapered parts dry. Before assembling parts with Exercise extreme care around pressurized hydraulic tapered splines, be sure the splines are clean, dry, and free hoses or tubes.
Page 21: Bearings
GRT9165 SERVICE MANUAL INTRODUCTION Installation assembly to obtain accurate pre-loading. When installing a bearing, spacer, or washer against a shoulder on a shaft, be When installing a new hose, loosely connect each end sure the chamfered side is toward the shoulder. and make sure the hose takes up the designed position When pressing bearings into a retainer or bore, uniformly before tightening the connection.
Page 22: Hydraulic Systems
If any of the above conditions exist, evaluate hose assemblies for correction or replacement. For replacement Contaminants in a hydraulic system affect operation and will of hose assemblies, refer to your Manitowoc Crane Care result in serious damage to the system components. Dirty Parts Manual.
Page 23: Hydraulic Fittings
Polar: Extremely cold winters and summers. Latitude 60° - 75° North & South Hydraulic Fittings Flats from Finger Tight (F.F.F.T.) Method Manitowoc recommends that the F.F.F.T. tightening method described here be used when assembling all hydraulic fittings. This method will minimize the risk of fitting damage or failure due to under or over-tightening.
Page 24 INTRODUCTION GRT9165 SERVICE MANUAL Adjustable Straight Thread O-ring Fittings Hold the fitting in the desired position and tighten the nut (D) following the F.F.F.T. method starting with step 4. Refer to Figure 1-5 and Table 1-4 for the following procedure. Nonadjustable Straight Thread O-ring Fitting: Fitting to Port Table 1-4: Adjustable Straight Thread O-ring Fittings...
Page 25: Electrical System
Loctite® brand adhesives are available from caused by twisting, shock, bending, and intentional and/or the Parts Department of the local Manitowoc distributor. unintentional overloads, often become subject to weld Application of Medium Strength Loctite®...
Page 26: Fasteners And Torque Values
• Torque wrenches must be those specified and forces The torque tables are provided by Manitowoc for reference must be applied at the handle grip. The use of handle when performing maintenance.
Page 27 GRT9165 SERVICE MANUAL INTRODUCTION SAE Grade 1 SAE Grade 5 SAE Grade 7 SAE Grade 8 and Grade 2 HHCS HHCS HHCS HHCS Socket Head Socket Head Serrated Capscrew Shoulder Flange Head Screw FIGURE 1-8 Table 1-6 Inch Series with Coarse Threads (UNC) – Zinc Flake Coated Nominal Size, Threads per Torque (ft/lb) Inch, and Series...
Page 28 INTRODUCTION GRT9165 SERVICE MANUAL Nominal Size, Threads per Torque (ft/lb) Inch, and Series Grade Maximum Nominal Minimum Designation 624.0 608.4 592.8 1 1/8-7 UNC 1001.4 976.4 951.4 880.5 858.5 836.5 1 1/4-7 UNC 1413.1 1377.8 1342.5 1154.5 1125.6 1096.7 1 3/8-6 UNC 1852.8 1806.5 1760.2...
Page 29 GRT9165 SERVICE MANUAL INTRODUCTION Nominal Size, Threads per Torque (ft/lb) Inch, and Series Grade Maximum Nominal Minimum Designation 1314.4 1281.5 1248.6 1 3/8-12 UNF 2109.5 2056.7 2004.0 1723.9 1680.8 1637.7 1 1/2-12 UNF 2766.8 2697.6 2628.4 Table 1-8 Metric Series with Coarse Threads – Zinc Flake Coated Nominal Size, Threads per Torque (N-m) Property...
Page 30 INTRODUCTION GRT9165 SERVICE MANUAL Nominal Size, Threads per Torque (N-m) Property Inch, and Series Class Maximum Nominal Minimum Designation 474.4 462.6 450.7 M22x2.5 10.9 675.7 658.8 641.9 12.9 790.7 770.9 751.2 601.3 586.3 571.3 M24x3 10.9 856.4 835.0 813.6 12.9 1002.2 977.1 952.1...
Page 31 GRT9165 SERVICE MANUAL INTRODUCTION Nominal Size, Threads per Torque (N-m) Property Inch, and Series Class Maximum Nominal Minimum Designation 120.2 117.2 114.2 M14x1.5 10.9 176.5 172.1 167.7 12.9 206.6 201.4 196.2 184.4 179.8 175.2 M16x1.5 10.9 270.9 264.1 257.3 12.9 317.0 309.1 301.2...
Page 32 INTRODUCTION GRT9165 SERVICE MANUAL Table 1-10 Metric Series Screws of STAINLESS STEEL A2-70/A4-70 with Coarse Threads Size Torque (N-m) M2.5x0.45 M3x0.5 M4x0.7 M5x0.8 M6x1 M8x1.25 M10x1.5 Torque Values for fasteners with lubrication these torque values result in an 80% utilization of the yield strength. Stainless steel fasteners tend to gall while being tightened.
Page 33 GRT9165 SERVICE MANUAL INTRODUCTION Table 1-13 Metric Series Bearing Bolts– Untreated (black finish) Nominal Size, Threads per Torque (N-m) Inch, and Series Grade Maximum Nominal Minimum Designation M20X2.5 12.9 M24X3 10.9 1089 1047 1005 M24X3 12.9 1306 1256 1206 M27X3 10.9 1591 1530...
Page 34 INTRODUCTION GRT9165 SERVICE MANUAL Inch Series with Fine Threads (UNF) – Untreated (black finish) Table 1-15 Torque (ft/lb) Size Grade Maximum Nominal Minimum 1/4-28 14.5 13.5 5/16-24 3/8-24 7/16-20 84.5 1/2-20 9/16-18 174.5 5/8-18 299.5 3/4-16 439.5 7/8-14 1-12 1009 644.5 1-14 908.5...
Page 35 GRT9165 SERVICE MANUAL INTRODUCTION Metric Series with Coarse Threads – Untreated (black finish) Table 1-16 Torque (N-m) Property Size Class Maximum Nominal Minimum M4x0.7 10.9 12.9 M5x0.8 10.9 12.9 10.5 10.5 M6x1 10.9 12.9 M8x1.25 10.9 36.5 12.9 43.5 M10x1.5 10.9 12.9 M12x1.75...
Page 36 INTRODUCTION GRT9165 SERVICE MANUAL Torque (N-m) Property Size Class Maximum Nominal Minimum 1134 1090 1046 M27x3 10.9 1591 1530 1469 12.9 1910 1836.5 1763 1538 1479 1420 M30x3.5 10.9 2163 2080 1997 12.9 2595 2495 2395 2681 2578.5 2476 M36x4 10.9 3964 3812...
Page 37: Weld Studs
GRT9165 SERVICE MANUAL INTRODUCTION Torque (N-m) Property Size Class Maximum Nominal Minimum 331.5 M18x1.5 10.9 12.9 M20X1 10.9 667.5 12.9 464.5 M20x1.5 10.9 12.9 M22x1.5 10.9 888.5 12.9 1111 1068 1025 803.5 M24x2 10.9 1176 1130.5 1085 12.9 1410 1356 1302 1225 1171.5...
Page 38: Wire Rope
ANSI/ASME B30.5, federal regulations, and amount depends on the rope’s size, type, and anticipated Manitowoc. The inspection interval shall be determined by a use. This in-process treatment will provide the finished rope qualified person and shall be based on such factors as...
Page 39: Wire Rope Inspection (Running Ropes And Pendant Cables)
When replacing fixed length cable assemblies (e.g. pendants) having permanently attached end fittings use only pre-assembled lengths of wire rope as supplied from Manitowoc. Do not build lengths from individual components. Replace an entire wire rope assembly. Do not attempt to rework damaged wire rope or wire rope ends.
Page 40: Wire Rope Inspection (Boom Extension And Retraction Cables)
Wire Rope Inspection (Boom Extension and Standard as referenced by Federal Government Agencies Retraction Cables) and as recommended by Manitowoc. All wire rope will eventually deteriorate to a point where it is no longer usable. Periodic Inspection Wire rope shall be taken out of service when any of the...
Page 41: Seizing Wire Rope
• Severe corrosion as evidenced by pitting. Method 2 • Manitowoc recommends that for cable extended booms, a single damaged wire rope assembly shall require replacement of the entire set of extension cables. • Manitowoc recommends for cable extended booms, that boom extension cables be replaced every seven (7) years.
Page 42: Installing 35X7 Class Wire Rope
INTRODUCTION GRT9165 SERVICE MANUAL seriously damage the rope.) The tensioning load should range from 1 to 2% of the rope’s minimum breaking force. For ropes in multi-part systems: Reeve the traveling block and boom tip sheaves so the rope spacing is maximized and the traveling (hook) block hangs straight and level to help assure block stability.
Page 43: Section 2
Directional Control Valves....2-6 Connecting the Manitowoc Crane Visual Inspection of Hoses and Fittings ..2-7 Service Tool.
Page 44: Description
HYDRAULIC SYSTEM GRT9165 SERVICE MANUAL DESCRIPTION operation of individual hydraulic circuits are discussed within their individual sections as applicable. A complete hydraulic T h i s s e c t i o n d e s c r i b e s t h e h y d r a u l i c s y s t e m , t h e system schematic showing all options is at the back of this components which make up the hydraulic system, and the manual.
Page 45 GRT9165 SERVICE MANUAL HYDRAULIC SYSTEM Description Symbol Description Symbol Single Acting Cylinder - Extended Manually Operated - Valve shifted hydraulically and retracted with a spring. manually with check to allow flow back to tank. Double Acting Cylinder - Extended and retracted hydraulically.
Page 46: Maintenance
Use only port for the side walls to drain. Manitowoc supplied parts to repair the crane. Clean and install the reservoir plug and fill the reservoir Hydraulic System Maintenance Precautions with a 50/50 mixture of fuel oil and clean hydraulic oil.
Page 47: Removing Air From The Hydraulic System
GRT9165 SERVICE MANUAL HYDRAULIC SYSTEM Disconnect the return line from an outrigger extension 26. Repeat Steps 24 and 25 for the auxiliary hoist as cylinder and fully extend the outrigger. necessary. Connect the outrigger return line and retract the 27. Disconnect one of the lines from the swing motor and outrigger.
Page 48: Parts Replacement
HYDRAULIC SYSTEM GRT9165 SERVICE MANUAL Directional Control Valves Operate all hydraulic circuits several times in both directions. The control valves that control the crane functions are • This action should return any entrapped air to the installed on the right side of the turntable. reservoir where it can be removed from the hydraulic oil Inspection by the baffles.
Page 49: Visual Inspection Of Hoses And Fittings
For replacement temperatures will negatively impact service life. Therefore it of hose assemblies, refer to your Manitowoc Crane Care is recommended for these hoses to be inspected thoroughly Parts Manual.
Page 50: Supply Pressure And Return Circuit
HYDRAULIC SYSTEM GRT9165 SERVICE MANUAL SUPPLY PRESSURE AND RETURN CIRCUIT (190°F rising) (7, Figure 2-1) turns the hydraulic oil cooler fan on and off as needed (see Hydraulic Oil Cooler, page 2-12). Description The thermistor (200°F rising) (6, Figure 2-1) will cause a warning light in the cab to illuminate if the hydraulic oil The supply pressure and return circuit routes hydraulic oil temperature is too high.
Page 51 GRT9165 SERVICE MANUAL HYDRAULIC SYSTEM 10091 Return Hose Return Filter Cover Fill Cap/Breather Hydraulic Tank Thermistor (200°F) - High Oil Temp. Indicator Light Temperature Switch (190°F) - Oil Cooler Fan On/Off 10092 Oil Level Gauge FIGURE 2-1 GROVE Published 10-01-2020 Control # 699-00...
Page 52: Hydraulic Oil Return Filter Assembly
HYDRAULIC SYSTEM GRT9165 SERVICE MANUAL Hydraulic Oil Return Filter Assembly Remove and discard the O-ring between the cap and the return filter head. The hydraulic oil return filter assembly (see Figure 2-1 and Remove the element from the return filter head. Figure 2-2) is located in the reservoir.
Page 53 GRT9165 SERVICE MANUAL HYDRAULIC SYSTEM 8804-75 Gasket O-ring By-pass Assembly Filter Head O-ring Gauge Assembly Plug Spring Cap Assembly Element FIGURE 2-2 2-11 GROVE Published 10-01-2020 Control # 699-00...
Page 54: Hydraulic Oil Cooler
HYDRAULIC SYSTEM GRT9165 SERVICE MANUAL HYDRAULIC OIL COOLER Removal Tag and disconnect electrical connectors (2, Figure 2-3) Description from the fans (1). An air cooled hydraulic oil cooler (Figure 2-3) is located on Tag and disconnect hydraulic lines. the right side of the superstructure. NOTE: The hydraulic oil cooler fan assembly weighs The hydraulic oil filter is connected to the T1 port on the Main...
Page 55 GRT9165 SERVICE MANUAL HYDRAULIC SYSTEM 10097 10094 10093 Forward Hydraulic Oil Fan Assembly Superstructure Frame Fan Assembly (Two places) Capscrew Fan Electrical Connector (Two places) Lockwasher (x2) Core Assembly Fan Shroud Assembly Washer Capscrew Washer Washer Lockwasher Capscrew FIGURE 2-3 2-13 GROVE Published 10-01-2020 Control # 699-00...
Page 56: Hydraulic Pumps
HYDRAULIC SYSTEM GRT9165 SERVICE MANUAL HYDRAULIC PUMPS NOTE: Refer to Figure 2-4 for pump locations. CAUTION Keep the pump as level as possible to avoid damaging Pumps No. 1, 2, and 3 are mounted on drive pads of the the input spline. torque converter.
Page 57 GRT9165 SERVICE MANUAL HYDRAULIC SYSTEM 10096 Item Description 10095 Hydraulic Pump No. 1 Note: hoses and drive shaft Hydraulic Pump No. 2 not shown for clarity Hydraulic Pump No. 3 Hydraulic Pump No. 4 Engine FIGURE 2-4 Pump No. 2 Removal Tag and disconnect the pump distribution lines from the pump.
Page 58 HYDRAULIC SYSTEM GRT9165 SERVICE MANUAL Cover the drive pad’s opening to prevent dirt from No. 3 Pump Installation entering. Clean the pump and the torque converter drive pad with Lo ct ite ® c le an in g so lv en t 70 70 o r s im ilar n on- Pump No.
Page 59 GRT9165 SERVICE MANUAL HYDRAULIC SYSTEM Apply Loctite® 243 or equivalent to the threads of the Piston Pump Start-up Procedure capscrews. Install pump and gasket on drive pad with capscrews and washers. Make sure the splines mesh CAUTION properly. Do not feed hot hydraulic fluid into a cold pump. This may Torque capscrews to recommended torque.
Page 60: Hydraulic Pump Distribution
HYDRAULIC SYSTEM GRT9165 SERVICE MANUAL 10. Check pressure settings. Refer to Pressure Setting No. 2 Pump Procedures in this section. The torque converter drives the No. 2 variable displacement piston pump, which supplies oil to the following manifolds and valves: Hydraulic Pump Distribution •...
Page 61: Troubleshooting
GRT9165 SERVICE MANUAL HYDRAULIC SYSTEM Troubleshooting Symptoms and Solutions Symptom Probable Cause Solution No hydraulic oil Low hydraulic oil level. Check system for leaks. Make repairs flows in systems. as needed. Fill reservoir. b. Reservoir-to-pump suction lines b. Clean, repair, or replace lines as broken or restricted.
Page 62: Troubleshooting Aids
HYDRAULIC SYSTEM GRT9165 SERVICE MANUAL Troubleshooting Aids or ballooned hoses, leakage around the hydraulic components, etc. Hydraulic schematics — an exact illustration of the Second, make an analysis of symptoms. The function of arrangement of the system. The schematic shows all the each component in the system must be known before a components in relation to the system.
Page 63: Valves
GRT9165 SERVICE MANUAL HYDRAULIC SYSTEM VALVES The description of each valve given here is for the valve itself. For information on how each valve functions in the This section describes several of the main hydraulic valves individual circuits, refer to the description and operation used on this crane.
Page 64: Carrier Valves
HYDRAULIC SYSTEM GRT9165 SERVICE MANUAL CARRIER VALVES Figure 2-6 and the following sections describe the hydraulic manifold valves on the GRT9165 carrier. 10098 Valve Installation - Carrier Page Outrigger Control Manifold Valve (2 places) 2-23 Carrier Manifold Valve 2-25 Suspension Manifold Valve 2-28 Fan Control Manifold Valve 2-29...
Page 65: Outrigger Control Manifold Valves
GRT9165 SERVICE MANUAL HYDRAULIC SYSTEM Outrigger Control Manifold Valves electrical connections. Inspect the wiring for any evidence of cracks or breaks. There are two outrigger control manifold valves (Figure 2-7) Installation used on the crane: one located on the front outrigger box for controlling the front outriggers and one located on the rear Position the manifold on the outrigger box and secure outrigger box for controlling the rear outriggers (Figure 2-6).
Page 66 HYDRAULIC SYSTEM GRT9165 SERVICE MANUAL Front Outrigger Control Manifold Cont. Rear Outrigger Control Manifold Cont. FIGURE 2-7 continued Published 10-01-2020 Control # 699-00 2-24...
Page 67: Carrier Manifold Valve
GRT9165 SERVICE MANUAL HYDRAULIC SYSTEM Carrier Manifold Valve proportional flow control valve, which is controlled by the crane control system, based on inputs from the transmission The carrier manifold valve (Figure 2-8) is located on the oil temperature sending unit and the hydraulic oil sending inside carrier frame rail at the turntable bearing (Figure 2-6).
Page 68 HYDRAULIC SYSTEM GRT9165 SERVICE MANUAL Carrier Manifold Valve Forward 10100 Forward Carrier Manifold Valve — Bottom 10099 FIGURE 2-8 Published 10-01-2020 Control # 699-00 2-26...
Page 69 GRT9165 SERVICE MANUAL HYDRAULIC SYSTEM 10101 Carrier Manifold Valve Solenoid — Transmission Fan Coil Transmission Fan Port Gauge Port — G4 T Port — Tank Load Sense Port — LS Load Sense Port — LS3 Gauge Port — G1 PS Port — Park Brake Gauge Port —...
Page 70: Suspension Manifold Valve
HYDRAULIC SYSTEM GRT9165 SERVICE MANUAL Suspension Manifold Valve Installation Secure valve frame with nuts, flatwashers, The suspension manifold valve controls the flow of oil to the lockwashers, and capscrews. Torque capscrews - refer suspension system, locks out the suspension, and connects/ to Fasteners and Torque Values, page 1-16 for proper disconnects the suspension to a damping/oscillation torque value.
Page 71: Fan Control Manifold Valve
GRT9165 SERVICE MANUAL HYDRAULIC SYSTEM Fan Control Manifold Valve Installation Secure valve frame with nuts, flatwashers, The fan control manifold valve (Figure 2-10) controls the flow lockwashers, and capscrews. Torque capscrews - refer of oil to the radiator fan motors. The fan control manifold to Fasteners and Torque Values, page 1-16 for proper receives hydraulic oil from hydraulic pump #4.
Page 72: Differential Lock Manifold Valve
HYDRAULIC SYSTEM GRT9165 SERVICE MANUAL Differential Lock Manifold Valve Remove capscrews, lockwashers, flatwashers, and nuts securing valve to the frame. Remove valve. The differential lock switch in the cab activates the Installation differential locks on the front and rear axles for additional traction.
Page 73: Bleed Off Valve
GRT9165 SERVICE MANUAL HYDRAULIC SYSTEM Bleed Off Valve NOTE: Make sure the outrigger box pressure bleed off valve is shut before checking the cut-off and WARNING differential settings. For more information, see the When bleeding hydraulic fluid, operate the system below Operator Manual.
Page 74: Superstructure Valves
HYDRAULIC SYSTEM GRT9165 SERVICE MANUAL SUPERSTRUCTURE VALVES Figure 2-13 and the following sections describe the hydraulic manifold valves located in the superstructure. 10097 Valve Installation - Superstructure Main Directional Control Manifold Valve Compact Manifold Valve Accessory Manifold Valve Swing Manifold Valve Dual Accumulator Charge Manifold Valve Check Valve FIGURE 2-13...
Page 75: Main Directional Control Valve
GRT9165 SERVICE MANUAL HYDRAULIC SYSTEM Main Directional Control Valve Main Directional Control Manifold Valve Installation Install the valve on the turntable upright and secure with The main directional control valve (Figure 2-14) is located on the capscrews, flatwashers, and lockwashers. Torque the right side of the superstructure (1, Figure 2-13).
Page 76 HYDRAULIC SYSTEM GRT9165 SERVICE MANUAL 10108 Item Description Solenoid Valve - Telescope Solenoid Valve - Telescope Solenoid Valve - Auxiliary Hoist Solenoid Valve - Auxiliary Hoist Solenoid Valve - Main Hoist Solenoid Valve - Main Hoist Solenoid Valve - Lift Cylinder Solenoid Valve - Lift Cylinder 10109 Telescope Extend Relief Valve...
Page 77 GRT9165 SERVICE MANUAL HYDRAULIC SYSTEM 10110 FIGURE 2-14 continued 2-35 GROVE Published 10-01-2020 Control # 699-00...
Page 78: Compact Manifold Valve
HYDRAULIC SYSTEM GRT9165 SERVICE MANUAL Compact Manifold Valve Removal Tag and disconnect the hydraulic lines from the valve. The compact block manifold (Figure 2-15) directs and Cap or plug the lines and ports. controls hydraulic fluid flow for the counterweight pin lock, counterweight raise/lower, cab tilt and telescope pinning Remove the capscrews and washers securing the valve.
Page 79 GRT9165 SERVICE MANUAL HYDRAULIC SYSTEM 10113 10112 Forward Compact Manifold Valve Relief Valve Solenoid Valve — Counterweight Pin Retract 10111 Solenoid Valve — Right Counterweight Lower Solenoid Valve — Left Counterweight Lower Forward Top View Solenoid Valve — Cab Tilt Lower Gauge Port Load Sense —...
Page 80 HYDRAULIC SYSTEM GRT9165 SERVICE MANUAL 10114 Compact Manifold Valve FIGURE 2-15 continued Published 10-01-2020 Control # 699-00 2-38...
Page 81: Accessory Manifold Valve
GRT9165 SERVICE MANUAL HYDRAULIC SYSTEM Accessory Manifold Valve Function Check — Priority Steer Start the engine. The accessory manifold valve (Figure 2-16) is located on the superstructure side plate (3, Figure 2-13) and includes Drive the crane at a slow speed and verify the front valves for controlling the priority steer, swing brake, and pilot steering function works properly.
Page 82 HYDRAULIC SYSTEM GRT9165 SERVICE MANUAL 10115 Accessory Manifold Valve 10119 10116 FIGURE 2-16 Published 10-01-2020 Control # 699-00 2-40...
Page 83 GRT9165 SERVICE MANUAL HYDRAULIC SYSTEM 10117 10118 Accessory Manifold Valve Check Valve Drain Port Outlet (DR) Pilot Supply Port (PS1) Gauge Port (GP1) Outlet Port (CB) Solenoid Valve - Swing Brake Apply Gauge Port (GP7) Solenoid Valve - Swing Brake Release Inlet Port (P) Pressure Reducing Valve - 280 psi Pressure Relief Valve - 3000 psi...
Page 84 HYDRAULIC SYSTEM GRT9165 SERVICE MANUAL FIGURE 2-16 continued Published 10-01-2020 Control # 699-00 2-42...
Page 85: Swing Directional Control Valve
GRT9165 SERVICE MANUAL HYDRAULIC SYSTEM Swing Directional Control Valve Swing Directional Control Valve Installation Install the valve on the turntable upright and secure with The swing directional control valve (Figure 2-17) is located the capscrews, flatwashers, and lockwashers. Torque on the superstructure side plate near the turntable bearing capscrews.
Page 86 HYDRAULIC SYSTEM GRT9165 SERVICE MANUAL Forward Forward 1021 Front View Swing Directional Control Manifold Valve 10122 Solenoid Valve - Swing Enable Tank Port — T Bottom View Inlet Port — P1 Gauge Port — GP5 Solenoid Valve - Left Swing Solenoid Valve - Right Swing Pressure Transducer Shuttle Valve...
Page 87: Dual Accumulator Charger Manifold Valve
GRT9165 SERVICE MANUAL HYDRAULIC SYSTEM 10123 Swing Directional Control Manifold Valve FIGURE 2-17 continued Dual Accumulator Charger Manifold Valve Installation Position the valve on the superstructure with ports A1, The dual accumulator charge manifold valve (Figure 2-18) is A2, and B3 facing up and secure with three bolts, located on the inside of the left superstructure side plate washers, and lockwashers.
Page 88 HYDRAULIC SYSTEM GRT9165 SERVICE MANUAL 7752-02 7752-01 These ports plugged Dual Accumulator Charge Valve Load Sense Port (LS) Tank Port (T) Pressure Port (P) Accumulator Port (A1) Accumulator Port (A2) Pressure Switch 7752-03 FIGURE 2-18 Published 10-01-2020 Control # 699-00 2-46...
Page 89: Check Valve Assembly
GRT9165 SERVICE MANUAL HYDRAULIC SYSTEM Check Valve Assembly Installation Install the valve on the turntable upright and secure with The check valve assembly (Figure 2-19) is located on the the capscrews, flatwashers, and lockwashers. Torque right side of the superstructure (Figure 2-13). capscrews.
Page 90: Telescope Cylinder Control Valve
HYDRAULIC SYSTEM GRT9165 SERVICE MANUAL Telescope Cylinder Control Valve The telescope cylinder valve (Figure 2-20) is a cartridge style holding valve located on the rear of the boom telescope cylinder. 10127 10128 10129 Telescope Cylinder Valve Work Port — K2 Extend (6000 PSI) Lock Valve —...
Page 91 GRT9165 SERVICE MANUAL HYDRAULIC SYSTEM Removal Tag and remove hoses. Installation Check inside of port block or manifold for sharp edges or WARNING burrs. Remove as necessary with emery cloth. Falling Boom Install new O-rings on telescope cylinder valve. Never remove a telescope cylinder valve from the lift or Lubricate telescope cylinder valve O-rings with clean telescope cylinder circuits without first fully retracting the hydraulic oil.
Page 92: Lift Cylinder Manifold
Contact your Grove Crane distributor or Check the valve and lines for leakage. Make repairs as Manitowoc Crane Care if the lift cylinder needs repair. needed. Removal Start the engine and fully retract the telescope the lift cylinders using the joysticks.
Page 93: Hydraulic Boom Extension Valve (Optional)
GRT9165 SERVICE MANUAL HYDRAULIC SYSTEM HYDRAULIC BOOM EXTENSION VALVE Remove capscrews, lockwashers, washers, hydraulic boom extension manifold from bracket. (OPTIONAL) Installation When installed, the hydraulic boom extension valve (Figure 2-22) is located on the upper right side of the Install hydraulic boom extension manifold valve on superstructure.
Page 94: Pressure Setting Procedures
HYDRAULIC SYSTEM GRT9165 SERVICE MANUAL PRESSURE SETTING PROCEDURES NOTE: When checking the directional control valve relief settings, unless otherwise specified, start with the The following procedures should be used to properly check, engine at idle RPM and move the controller to its adjust and set the hydraulic system pressures.
Page 95 GRT9165 SERVICE MANUAL HYDRAULIC SYSTEM Table 2-3 Hydraulic Valve Pressure Settings (Continued) GAUGE TOLERANCE VALVE TO BE SET PRESSURE PROCEDURE PSI (bar) PSI (bar) Checking/Setting Outrigger Pressure, Outrigger Beam/Jack Retract Pressure 2500 (172) ±100 (7) Rear Steer, and Suspension Raise, page 2-65.
Page 96: Accessing The Diagnostic Connector
Differential Pressures Use the following procedure to connect the diagnostic cable Use the following procedure to check and set the cut-off and and Manitowoc Crane Service Tool to the crane diagnostic differential pressures for both piston pumps (1 and 2, port.
Page 97 GRT9165 SERVICE MANUAL HYDRAULIC SYSTEM b. Back the adjusting screw out until there is 8.0 ± directional control valve (1, Figure 2-26), start the 0.5 mm (0.32 in ±0.02 in) from the end of the engine. adjusting screw to the top of the jam nut seated b.
Page 98: Checking/Setting The Pilot Supply Pressure
HYDRAULIC SYSTEM GRT9165 SERVICE MANUAL Front View Looking Up 10137 Jam Nut Piston Pumps 8.0 mm Piston Pump 1 ±0.5 mm Piston Pump 2 (0.32 in) (±0.02 in) Cut-off Pressure Adjustment Screw Differential (Standby) Pressure Adjustment Screw Cut-Off Screw Adjustments 10138 FIGURE 2-25 Checking/Setting the Pilot Supply Pressure...
Page 99 GRT9165 SERVICE MANUAL HYDRAULIC SYSTEM 10136 Main Directional Control Valve Main Directional Valve GP Diagnostic Port Telescope Extend Relief Telescope Retract Relief Load Sense (LS) Relief FIGURE 2-26 2-57 GROVE Published 10-01-2020 Control # 699-00...
Page 100 HYDRAULIC SYSTEM GRT9165 SERVICE MANUAL 10139 Accessory Manifold GP1 Port Swing Brake Pressure Reducing Valve Pilot Supply Pressure Reducing Valve Accessory Pressure Reducing Valve GP6 Port Port 4 Load Sense Steer Priority Relief Valve GP4 Port GP5 Port GP3 Port FIGURE 2-27 Published 10-01-2020 Control # 699-00 2-58...
Page 101: Load Sense Relief (Max System Pressure)
GRT9165 SERVICE MANUAL HYDRAULIC SYSTEM Load Sense Relief (Max System Pressure) With the engine off, install pressure check diagnostic quick disconnect (such as Parker PD240) with gauge Use the following procedure to check and set the load sense onto test the nipple at Port 4 of the Accessory manifold relief pressure.
Page 102: Checking / Setting The Swing Brake Release Pressure
HYDRAULIC SYSTEM GRT9165 SERVICE MANUAL The Boom Recovery screen appears. RPM. The reading at port 4 should be the value cited in Table 2-3. If it is not, adjust the Tele retract relief (2, Figure 2-26) “in” to increase or “out” to decrease until the reading is achieved Make sure that the cylinder is fully retracted, length reads 0 mm.
Page 103: Checking The Swing Work Pressure
With the engine off, install a pressure check diagnostic coupler (such as Parker PD240) with gauge onto the the joystick EEPROM. If adjusting the Imax does not work, contact Manitowoc Crane Care. Repeat step 2 for swing left function. Stop engine. Remove the diagnostic coupler.
Page 104: Service Brake Accumulators Pre-Charge
HYDRAULIC SYSTEM GRT9165 SERVICE MANUAL Service Brake Accumulators Pre-charge NOTE: This accumulator charge valve is non-adjustable. With engine off, depress the service break pedal 12 to Use the following procedure to pre-charge the service brake 15 times to discharge all the pressurized fluid stored in accumulators.
Page 105: Checking/Setting Cab Tilt Raise And Lower Pressures
Connect the Manitowoc Crane Tool to the diagnostic on the charging assembly (Figure 2-32) until the connector. pressure is to specification. In the In the Manitowoc Crane Tool, open Tools > Remove charging valve assembly (turn EEprom >...
Page 106 Start engine and idle. Activate the counterweight lower function (see Operator Manual) until full stroke of the In the Manitowoc Crane Tool, open Tools > EEprom > cylinder is achieved and hold. Slowly accelerate the View Parameters > Super > Counterweight > Pin engine to full RPM.
Page 107: Checking/Setting Outrigger Pressure, Rear Steer, And Suspension Raise
Table 2-3. If it is not, use the service tool as follows to service tool as follows to adjust: adjust: In the Manitowoc Crane Tool, open Tools > EEprom In the Manitowoc Crane Tool, open Tools > EEprom > View Parameters > Cabin > Solenoid PWM >...
Page 108 After the pressure is achieved, make sure to “Save In the Manitowoc Crane Tool, open Tools > EEprom active to customer” and “Save active to factory.” > View Parameters > Cabin > Solenoid PWM Control (carrier) >...
Page 109: Suspension Raise Pressure
Read gauge and adjust the pressure reducing valve (Figure 2-34) “in” to increase or “out” to decrease In the Manitowoc Crane Tool, open Tools > EEprom to the value cited in Table 2-3. > View Parameters > Cabin > Solenoid PWM Control (carrier) >...
Page 110: Cylinders
HYDRAULIC SYSTEM GRT9165 SERVICE MANUAL If an issue persists after performing the above procedures, contact your local Grove distributor or Manitowoc Crane Care. DANGER CYLINDERS Ensure pressure is only applied to retract (rod) side of cylinder and extend hose is capped.
Page 111 GRT9165 SERVICE MANUAL HYDRAULIC SYSTEM This situation will also occur in reverse. If a crane is set up in The chart is for dry rod cylinders. If the cylinder rod is filled the mornin g wit h cool oil a nd the da ytime ambient with hydraulic oil, the contraction rate is somewhat greater.
Page 112 HYDRAULIC SYSTEM GRT9165 SERVICE MANUAL THIS PAGE BLANK Published 10-01-2020 Control # 699-00 2-70...
Page 113: Description
Maintenance ......3-9 About the Manitowoc Diagnostic Code Mobile General ....... . . 3-9 Application .
Page 114: Batteries And Battery Disconnect Switch
ELECTRICAL SYSTEM GRT9165 SERVICE MANUAL Jump Starting Hazard Do not attempt to jump start the crane. CAUTION It is strongly recommended that the batteries not be “jumped” with a different vehicle, portable power pack, etc. The surge of power from these sources can irreparably damage the various electronic controls and computer systems.
Page 115 GRT9165 SERVICE MANUAL ELECTRICAL SYSTEM Side Panel 10148 Cab Electrical Panel RCL Override Switch Cab Rear Ground SPL-B Ground SPL-A Cab-to-Swivel Connector 10147 Circulation Fan Connector Swivel Connector Behind Seat Superstructure A Superstructure B Cab Fuse Panel Cold Weather Module Electronic Control Unit (MWIOL) Crane Star Module Electronic Control Unit (MWSCM)
Page 116 ELECTRICAL SYSTEM GRT9165 SERVICE MANUAL Fuse Description Cab Work Lights E-Stop Switch Signal Boom Motorized Work Lights Accessory Lights Map Light and USB Power Radio Ignition Power System Wake-up Key Switch Signal Circulation Fan Heater / AC Switch Power Dome Light Windshield Washer Relay Fuse Power Heated Seat Power...
Page 117: Carrier Electrical Panel
GRT9165 SERVICE MANUAL ELECTRICAL SYSTEM Carrier Electrical Panel consists of the two batteries, battery disconnect switch, fuse and relay boxes, starter and grid heater relays, and The carrier electrical panel (Figure 3-5) is located on the fuel electronic control units. tank side of the crane, inside the electrical compartment.
Page 118 ELECTRICAL SYSTEM GRT9165 SERVICE MANUAL 10150 Carrier Electrical Panel FA - 15 Amp Module Battery Power Carrier Electrical Panel FB - 15 Amp UB+ Carrier CCM11/IOL31 Module Battery Power F4 - 100 Amp Power FC - 5 Amp Starter Lockout Fused Relay F3 - 100 Amp Power Power F2 - 100 Amp Power...
Page 119 GRT9165 SERVICE MANUAL ELECTRICAL SYSTEM 10153 Carrier Fuse and Relay Box 1 30 Amp - Engine ECM Power K108 - 24V Starter Lockout Relay 15 Amp - UB+ Carrier CCM12 Module Battery Power 20 Amp - Fused Battery Power 15 Amp - UB+ Carrier CCM12 Module Battery 15 Amp - UE+ Carrier CCM3/IOL31 Module Power Battery Power...
Page 120 ELECTRICAL SYSTEM GRT9165 SERVICE MANUAL 10154 Carrier Fuse and Relay Box 2 F3 - 15 Amp - DEF Supply Module Fused Relay Power K109 - DEF Lines Heater Relay F4 - 15 Amp - After-treatment Sensors Fused K110 - DEF Supply Module Relay Power K111 - After-treatment Sensors Power Relay D1 - Pressure Line Heater...
Page 121: Maintenance
GRT9165 SERVICE MANUAL ELECTRICAL SYSTEM MAINTENANCE prior to securing the connector. Ensure that grease is applied to all terminal sockets (Figure 3-9). General Check the connection for moisture before application of the grease. If moisture is found, clean or replace the Electrical system maintenance includes troubleshooting and connector as necessary.
Page 122: Visual Inspection And Replacement Of Electrical Harnesses And Cables
For replacement of life may be less than 10,000 hours. harness assemblies, refer to your Manitowoc Crane Care • Cranes operating in salt water climates could see a Parts Manual.
Page 123: Tools For Troubleshooting
RDM. Descriptions for the replace them. diag nost ics code s ca n be found on t he Manitowoc Diagnostic Code smart phone application. You can also use Refer to the following tables listing required tools for a Windows-based PC, CAN-link service software, and a connector maintenance.
Page 124: Alternator/Charging System Troubleshooting
ELECTRICAL SYSTEM GRT9165 SERVICE MANUAL Table 3-4. Deutsch Extraction Tool Table Description Deutsch Part Number Manitowoc Part Number 12 gauge wire 114010 9999100194 16 gauge wire 0411-204-1605 9999100195 8-10 gauge wire 114008 7902000012 4-6 gauge wire 114009 7902000009 Table 3-5. Deutsch Crimping Tool Table...
Page 125: Alternator Replacement
GRT9165 SERVICE MANUAL ELECTRICAL SYSTEM Negative Side 578 N) tension. Replace belt if it is too loose (overstretched). Set multimeter to 2 volt range. Verify tensioner bolt is torqued to 32 lb-ft (43 N-m). – ) lead to alternator case and positive Connect negative ( Connect electrical leads to terminals as tagged during ) lead to battery negative terminal or post.
Page 126: Battery Replacement
ELECTRICAL SYSTEM GRT9165 SERVICE MANUAL ignition (run) position, or some other problem. Install Connect leads to battery terminals starting with the starter properly as needed. positive terminals. Install ECM power fuse. Battery Replacement Close battery compartment door. Removal Turn battery disconnect switch ON. CAUTION Verify replacement batteries work by starting crane’s engine and operating various crane components.
Page 127 GRT9165 SERVICE MANUAL ELECTRICAL SYSTEM Installation Inspection Note orientation of rocker markings to switch. Remove Visually check ignition switch for evidence of cracks, rocker from old switch (21 – 24). Hold switch by its sides damaged connectors, or other damage. Replace switch in one hand.
Page 128 ELECTRICAL SYSTEM GRT9165 SERVICE MANUAL Remove four screws (11) from dashboard cover (1). Install wire harnesses on switches (21 – 24) and turn signal indicators (2) as tagged during removal. Remove locking lever (15). Install right side cover (10) on steering column (9). Remove four screws (14) from left side cover (16).
Page 129 GRT9165 SERVICE MANUAL ELECTRICAL SYSTEM Item Component Ignition Key Switch Assembly Spacer 10155 M6 Button Head Screw Lock Handle Item Component Left Side Cover Dashboard Cover Steering Column Tilt and Telescope Turn Signal Indicator Turn Signal, Lights, Wiper Switch Steering Wheel Cap Knob Steering Wheel Nut Switch Blank...
Page 130: Windshield Wiper Assembly Replacement
ELECTRICAL SYSTEM GRT9165 SERVICE MANUAL Windshield Wiper Assembly Replacement Secure adapter and gasket of the pantograph adapter kit to the cab exterior with capscrews and lockwashers. Removal Install motor bracket and attached parts in cab interior Ensure key switch has been in OFF position for two with attaching hardware.
Page 131: Skylight Wiper Assembly Replacement
GRT9165 SERVICE MANUAL ELECTRICAL SYSTEM Inspection nylon flat washer from motor shaft and flat washer and smaller nylon flat washer from mounting screw. Visually check pump for evidence of cracks, leaks, or Remove mounting screw and nylon flat washer from other damage.
Page 132: Adjusting Electronic Joysticks
Apple stores and compatible with most Android and Apple • The software has been updated (all sensors must be mobile devices. calibrated) To look up a fault code with the Manitowoc Diagnostic Code mobile application: Published 10-01-2020 Control # 699-00 3-20...
Page 133 Find the fault code you want to research in the RCL Click CCS. diagnostics screen. For more information, see Viewing The CCS screen appears. Diagnostic Fault Codes, page 3-20. Open the Manitowoc Diagnostics Code Application on your mobile device. The Diagnostic Code Application splash screen appears. 10157...
Page 134: Optional Equipment
Use particular care to ensure that cranes being operated in 10158 very cold temperatures are operated and maintained in accordance with the procedures as provided by Manitowoc. Always ensure adequate lubrication during system warm-up and proper operation of all crane functions when operating in cold weather.
Page 135: Wind Speed Indicator And Boom Position Indicator Light
Before switching on, check if heater can be operated at checked or another malfunction occurs in your heater, the work site. There is a danger of explosion when using contact an authorized Grove distributor or Manitowoc the heater around combustible objects! Do not park Crane Care.
Page 136 ELECTRICAL SYSTEM GRT9165 SERVICE MANUAL Removing Hoist Camera Disconnect the data cable (1, Figure 3-12). Hoist Camera 1 Data Cable 2 Capscrew 3 Washer 4 Camera 10161 Forward 5 Setscrew FIGURE 3-13 6 Bushing 7 Hoist Camera Arm Removing Right Rear Camera Remove the maintenance cover on the right side of the 10159 FIGURE 3-12...
Page 137: Rcl Light Tower
GRT9165 SERVICE MANUAL ELECTRICAL SYSTEM Installing the Back-up Camera Install the camera (1) on the bracket with washers (4) and capscrews (3). Connect the data cable (2). RCL Light Tower When installed, the RCL light tower is located on the right side of the operator cab.
Page 138 ELECTRICAL SYSTEM GRT9165 SERVICE MANUAL THIS PAGE BLANK Published 10-01-2020 Control # 699-00 3-26...
Page 139: Section 4
GRT9165 SERVICE MANUAL BOOM SECTION 4 BOOM SECTION CONTENTS Boom Removal ......4-1 Prerequisites .
Page 140 BOOM GRT9165 SERVICE MANUAL 10234 10235 FIGURE 4-1 Remove the rear maintenance cover from the right side NOTE: Make sure the visual position indicators (3) are of the superstructure. Disconnect the boom electrical pointed forward for the front bracket. connectors (2 and 3, Figure 4-1). Route the electrical b.
Page 141 GRT9165 SERVICE MANUAL BOOM Position B 3.3° Position A 10236 10237 Front Boom Lift Bracket Rear Boom Lift Bracket Visual Position Indicator Retaining Pin Bracket Mounting Foot Bracket Installation Pin Hole 10238 Lifting Shackles Lifting Straps FIGURE 4-2 Grove Published 10-01-2020 Control # 699-00...
Page 142 BOOM GRT9165 SERVICE MANUAL 11. If necessary, install the lift cylinder support (1, jack (4) and wood cribbing up to the lift cylinder. The Figure 4-3) on the carrier as follows: bottle jack and wood cribbing should be in firm contact with the lift cylinder.
Page 143 GRT9165 SERVICE MANUAL BOOM Remove the right rear valve maintenance cover. d. Connect hydraulic hoses (4 and 5). b. Remove capscrews (1, Figure 4-5) and bushings (2) 18. Install the boom pin removal tool (3, Figure 4-6) to the from the pivot pin. left (cab) side of the superstructure as follows: Remove the nuts from the end of the push rods.
Page 144: Boom Installation
BOOM GRT9165 SERVICE MANUAL b. Install the boom pivot pin removal tool on the right side of the superstructure (Figure 4-6). For more information, see step 18 on page 4-5. For the right side pin, move the control handle (1, Figure 4-7) on the removal tool to extend the pivot pin.
Page 145: Functional Check
GRT9165 SERVICE MANUAL BOOM BOOM NOSE SHEAVES Do not attempt to work on the boom without experienced supervision. CAUTION Pinch Hazard! Use caution when installing pin, high pinch point risk. DANGER Accident Hazard! NOTE: Install a piece of wood between the lift cylinder and To prevent serious injury or death, always wear personal the bottle jack on the lift cylinder support.
Page 146 BOOM GRT9165 SERVICE MANUAL Install the spacers, rope fixed point assembly, and Repeat steps 1 and 2 for the upper boom nose sheaves sheaves (9) onto the lower sheave shaft (12) while and shaft. installing the sheave shaft into the lower boom nose. Install the cable retainer pins (2, 3, 4, and 5) into the Secure the shaft (12) with the cover (11) and screws upper and lower part of the boom nose and secure in...
Page 147: Mechanical Emergency Unlocking And Locking Of The Telescopic Sections
GRT9165 SERVICE MANUAL BOOM MECHANICAL EMERGENCY UNLOCKING • 270 mm length for telescopic section 1. AND LOCKING OF THE TELESCOPIC SECTIONS The mechanical emergency operation must be used 125 mm 140 mm whenever the telescoping cylinder can no longer be moved. 170 mm 200 mm For manual unlocking and locking of the telescopic sections,...
Page 148: Check The Locking System
This prevents the complete unlocking of a telescoping section in Emergency operation/Emergency program mode, which could cause serious accidents and damage to the truck crane. Your authorized Grove Crane distributor or Manitowoc Crane Care should check the main boom locking system. 10249 FIGURE 4-12...
Page 149 GRT9165 SERVICE MANUAL BOOM WARNING Risk of accidents due to rope end fitting being overloaded! After installing a new hoist rope, the lowering limit switch must always be reset. You can reach the cable drum through the manhole if you first extend telescopic section by approximately 2.0 m (6.6 ft).
Page 150: Boom Extension
BOOM GRT9165 SERVICE MANUAL BOOM EXTENSION You can turn the drum by pulling the RCL cable in the direction of the main boom head. If you let go of the cable, the drum turns back because of the initial tension. Check to make sure all screws (1) are tight.
Page 151: Hoist Description
GRT9165 SERVICE MANUAL HOIST AND COUNTERWEIGHT SECTION 5 HOIST AND COUNTERWEIGHT SECTION CONTENTS Hoist Description ......5-1 Usage and Inspection .
Page 152: Hoist Maintenance
HOIST AND COUNTERWEIGHT GRT9165 SERVICE MANUAL HOIST MAINTENANCE Removing Remove cable from hoist drum. Warm-up Procedure Tag and disconnect hoist hydraulic lines from motor and A warm-up procedure is recommended at each start-up and brake. Cap or plug all lines and openings. is essential at ambient temperatures below 4°C (40°F).
Page 153: Functional Check
If components not included in the kit are found to be worn or damaged, contact your Manitowoc Cranes 16. Ensure the bearing is full of grease. distributor or Manitowoc Crane Care to order a replacement. Published 10-01-2020 Control # 699-00 GROVE...
Page 154 HOIST AND COUNTERWEIGHT GRT9165 SERVICE MANUAL 10166 10162 10163 FIGURE 5-1 Published 10-01-2020 Control # 699-00...
Page 155 GRT9165 SERVICE MANUAL HOIST AND COUNTERWEIGHT 10164 Hoist Roller Spring Pin Capscrew M6x16 SS Capscrew M12x45 8.8 Capscrew M12x35 10.9 Capscrew M20x40 10.9 Straight Thread Adapter Lock Pin Flat Washer 10165 Flat Washer Narrow Flat Washer O-Ring Hoist Lockwasher Cotter Pin Sight Glass O-Ring SHCS M6x45 8.8...
Page 156: Usage And Inspection
HOIST AND COUNTERWEIGHT GRT9165 SERVICE MANUAL Usage and Inspection • High external contaminations, such as dusty or sandy conditions. Inspection procedures for hoists are divided into five general • Level of maintenance. categories based on usage or duty cycle which determines appropriate intervals for inspections.
Page 157: Hoist Oil Sampling
GRT9165 SERVICE MANUAL HOIST AND COUNTERWEIGHT Semi-Annual Inspections (every six months). New components must be installed if any are found to be worn or if there is evidence of heat or other damage. The Must include but is not limited to the following inspections hoist should be reassembled using all new seals, that must be performed by a qualified crane operator or bearings, fasteners, washers, brake discs, brake...
Page 158: Brake Test Procedure
HOIST AND COUNTERWEIGHT GRT9165 SERVICE MANUAL 800+ ppm The hydraulic motor connects to the hoist’s brake, which in turn connects to the gear train of the hoist. The entire hoist Unacceptable. Remove hoist from service and perform tear- assembly must be removed from the crane to service the down inspection to determine source of contamination.
Page 159: Maintenance
GRT9165 SERVICE MANUAL HOIST AND COUNTERWEIGHT Hoist Rotation Indicator Adjusting 3rd Wrap Switch The hoist rotation indicator system provides the operator Install hoist rope on the hoist. with a touch indication of the hoist drum rotation so he or she Reeve hook block with six or more parts of line from knows if and at what speed the hoist drum is rotating.
Page 160: Hoist Control Valves
HOIST AND COUNTERWEIGHT GRT9165 SERVICE MANUAL Hydraulic Hoist Motor Control Valve The hydraulic hoist motor control valve is mounted on the hoist motor and is designed to provide an even flow of oil to the hoist motor in both directions. This is a different valve than the hoist brake valve that applies and releases the hydraulic piston and hydraulic cylinder.
Page 161: Section 6
GRT9165 SERVICE MANUAL SWING SYSTEM SECTION 6 SWING SYSTEM SECTION CONTENTS Description ....... 6-1 Theory of Operation.
Page 162: Theory Of Operation
SWING SYSTEM GRT9165 SERVICE MANUAL THEORY OF OPERATION Swing Brake The GRT9165 features two combination swing drives and The (static) swing brake is spring-applied, hydraulic released brakes located on the right side of the superstructure. while the service (dynamic) brake is pressure applied. A two position solenoid valve controls the pressure to release the Swing Drive swing brake.
Page 163 GRT9165 SERVICE MANUAL SWING SYSTEM 10169 10168 Parts Removed for Clarity Breather Plug Level and Fill Plug and Dipstick Swing Brake Hydraulic Apply Brake Port 10170 Hydraulic Release Brake Port Motor Pinion Drain Plug Capscrew Swing Gearbox Washer Pinion Guard Bushing Capscrew O-ring...
Page 164: Swing Motor
SWING SYSTEM GRT9165 SERVICE MANUAL SWING MOTOR Connect hydraulic lines to swing motor as tagged during removal. Description Test The Swing Motors are mounted on the swing brake housings Test swing of superstructure in each direction. Stop and and drives the swing gearboxes through the brake start swing several times.
Page 165 GRT9165 SERVICE MANUAL SWING SYSTEM Remove bolts (3) securing the brake (1) to gearbox (2). Installation Remove brake assembly (1). If removed, install the swing brake. For more Remove and discard the O-ring (4) from the brake information, see Swing Brake, page 6-4. housing.
Page 166: Maintenance
Restricted or partly clogged hydraulic j. Replace hose or fittings. Refer to the hose or fittings. Manitowoc Crane Care Parts Manual. k. Pump cavitation in swing section. k. Tighten suction hose or replace damaged fittings. Check hydraulic tank level.
Page 167 Replace hose or fittings. Refer to the installed. Manitowoc Crane Care Parts Manual. f. Clogged or restricted hydraulic hoses or f. Clean or replace damaged parts. fittings. g. Worn or damaged output shaft bearings g. Replace bearings.
Page 168 SWING SYSTEM GRT9165 SERVICE MANUAL Symptom Probable Cause Solution Swing brake a. Improper brake adjustment. a. Adjust brake. operation erratic. b. Air in swing brake system. b. Bleed brake system. c. Brake pedal not fully retracted. c. Check brake pedal return spring; repair or replace spring.
Page 169: Maintenance
GRT9165 SERVICE MANUAL SWING SYSTEM SWING BEARING binding, or complete separation of the superstructure from the carrier. Description The swing bearing is an anti-friction roller bearing that mates CAUTION the superstructure to the carrier. The bearing inner race is Repeated re-torquing may cause bolts to stretch. If bolts bolted to the superstructure and the outer race is bolted to keep working loose, they must be replaced with new bolts the carrier.
Page 170: Swing Bearing Bolts
SWING SYSTEM GRT9165 SERVICE MANUAL FIGURE 6-3 10172 Swing Bearing Bolts Extend and set the outriggers. Fully elevate the boom. The inner race of the bearing is secured to the turntable by a quantity of 71, M12x75mm, 8.8 grade bolts. The outer race Torque all bolts to 80% of the full torque value following a of the bearing is secured to the carrier frame by a quantity of star pattern sequence as shown in (Figure 6-3) starting...
Page 171 Orders for special tools 1. 1½” Socket 3/4” Drive 9999100143 shall be referred to: 2. 4 to 1 Torque Multiplier (1/2” Input 3/4” Output) 9999100134 The Manitowoc Company, Inc 3. Backlash Adapter 9999100141 1565 Buchanan Trail East 4. 1/2” Drive Torque Wrench 9999100136 Shady Grove, PA 17256 5.
Page 172 SWING SYSTEM GRT9165 SERVICE MANUAL Disconnect swivel wiring harness connectors from superstructure to tilt or shift, or rest on the swivel. Leave carrier wiring receptacles. Remove ground wire from lifting device attached. ground stud. NOTE: If same bearing is to be used again, mark position 10.
Page 173: Swivels
GRT9165 SERVICE MANUAL SWING SYSTEM NOTE: If a new bearing is being installed, a new pinion 12. Reconnect batteries. gear must also be used. Align the high point 13. Check slew potentiometer in the for proper orientation. (maximum eccentricity) on the bearing with the Refer to Swivels, page 6-13.
Page 174 SWING SYSTEM GRT9165 SERVICE MANUAL Item Description 20 Conductor Slip Ring Assembly Center Post Capscrew Flatwasher Swivel Assembly Retainer Plate Capscrew Flat Washer Plate Swivel Linkage Assembly Capscrew Washer Locknut Capscrew Washer Locknut Capscrew Washer Bushing 10173 FIGURE 6-6 Published 10-01-2020 Control # 699-00 6-14...
Page 175: Hydraulic Swivel
GRT9165 SERVICE MANUAL SWING SYSTEM HYDRAULIC SWIVEL Measure distance from top of lift cylinder to base of boom section where lift cylinder attaches. Cut two pieces Description of 10 x 10 cm (4 x 4 in) oak to fit. NOTE: It may be necessary to raise boom slightly to allow Each port on the spool and case of the swivel is stamped installation of blocking.
Page 176: Two Port Water Swivel
SWING SYSTEM GRT9165 SERVICE MANUAL Maintenance lb to 443.5 ft-lb). Refer to Fasteners and Torque Values, page 1-16 for proper torque. Removal Position retainer plate on hydraulic swivel spool ensuring they engage the lugs on the carrier frame. Perform steps 1 thru 4 of Hydraulic Swivel, page 6-15 -. Remove electrical swivel.
Page 177: Electrical Swivel
GRT9165 SERVICE MANUAL SWING SYSTEM Assembly converts this data into a slew angle which is used to determine the working area definition and also for controlling NOTE: Lubricate interior of swivel to prevent rusting from the rear axle oscillation. condensation. Theory of Operation Lubricate spool, seals, and rings.
Page 178: Swing Lock Pin
SWING SYSTEM GRT9165 SERVICE MANUAL Preventive Maintenance It is recommended a normal inspection of the electrical CAUTION swivel collector ring and brush assembly be established. An When pulling wiring harness through center of hydraulic example of this could be at approximately 100 to 150 engine and water swivels, ensure wires are not damaged.
Page 179: 360° Swing Lock Control (Positive Lock Type) (Optional)
GRT9165 SERVICE MANUAL SWING SYSTEM will stick out about 5.89 cm (2.32 in) from the bottom of its If the swing lock assembly is damaged, install a replacement. bushing in the turntable; verify the superstructure can lock Align the blade of the swing lock assembly so it will fall properly and the superstructure can rotate without lock pin between gear teeth.
Page 180: Removing The Slew Sensor
SWING SYSTEM GRT9165 SERVICE MANUAL Removing the Slew Sensor Installing the Slew Sensor Disconnect transducer connectors (2) from slew sensor Install plate (8) on superstructure with washers (7) and (1). capscrews (6). Remove capscrews (3), washers (4), left pinion Install slew sensor assembly (1) and left pinion protection shield (5), and slew sensor (1).
Page 181: Section 7
GRT9165 SERVICE MANUAL POWER TRAIN SECTION 7 POWER TRAIN SECTION CONTENTS Engine ........7-1 Aftertreatment Diesel Exhaust Fluid (DEF) .
Page 182: Maintenance
POWER TRAIN GRT9165 SERVICE MANUAL Engine 10176 Torque Converter Transmission FIGURE 7-1 Driveshaft The air intake filter is mounted on the right rear fender. The Disconnect air filter tubing at engine and air cleaner. muffler is mounted on the left side of the carrier between the Remove and lay aside.
Page 183 GRT9165 SERVICE MANUAL POWER TRAIN 19. Using lifting device, lift engine/torque converter as an assembly from the crane. 20. If a new engine is installed, remove all components, fit- DANGER tings, etc., from old engine and install them on new Lifting device must be able to support combined weight of engine in same locations.
Page 184: Electronic Control System
POWER TRAIN GRT9165 SERVICE MANUAL 12. Connect electrical wiring to the hourmeter as tagged NOTE: Belt tension is maintained with an automatic belt during removal. tension device. 13. Connect air filter tubing at engine and air filter. Connect The engine drive belt should be inspected visually on a daily exhaust tubing to engine and muffler.
Page 185: Fuel System
GRT9165 SERVICE MANUAL POWER TRAIN remain shut down until the fault can be repaired. For more of the tank provides for fuel supply to the engine. Surplus fuel information, see the Operator Manual. from the engine is provided to the bottom of the fuel tank below the fuel level.
Page 186 POWER TRAIN GRT9165 SERVICE MANUAL If a new tank is to be installed, remove the two fittings, Service the tank (1). the fuel quantity sender (3), and steps from the tank and Fuel Filter-Water Separator install them in the new tank. Draining Installation The sump of the fuel filter-water separator (6, Figure 7-5)
Page 187: Air Intake And Exhaust System
GRT9165 SERVICE MANUAL POWER TRAIN AIR INTAKE AND EXHAUST SYSTEM NOTE: Dust that gets by the air cleaner system can often be detected by looking for dust streaks on the air Description transfer tubing or just inside the intake manifold inlet.
Page 188 POWER TRAIN GRT9165 SERVICE MANUAL Ensure the correct size connections are used between Ensure all inlet accessories are the correct size and are the air cleaner and the engine. not plugged by any foreign object. 10182 Air Cleaner TBAP Sensor Clamp Elbow Clamp...
Page 189 GRT9165 SERVICE MANUAL POWER TRAIN 8804-120 Air Filter Assembly Temp/Air Pressure Sensor Pre-cleaner Evacuator Valve Primary Air Filter Secondary Air Filter Service Door FIGURE 7-7 GROVE Published 10-01-2020 Control # 699-00...
Page 190 POWER TRAIN GRT9165 SERVICE MANUAL Filter Element Replacement dents or other damage that would interfere with air flow or with the fins on the element or inside the body. Repair any body dents, being careful not to damage the sealing CAUTION surfaces.
Page 191: Charge-Air Cooler System
GRT9165 SERVICE MANUAL POWER TRAIN Charge-Air Cooler System effectiveness, but does allow the element to get dirty faster and reduces serviceable life. If a valve is lost or damaged, The charge-air cooler (CAC) (1, Figure 7-11) is used to cool replace it with a new valve of the same part number.
Page 192: Exhaust System
POWER TRAIN GRT9165 SERVICE MANUAL Maintenance Check hose clamps for proper torque. Inspect bellows for cracks or holes. Clean charge-air cooler. Remove any dirt or debris. Verify fan is operating correctly and there are no hydraulic leaks. Exhaust System Non-Certified Engine Exhaust System The exhaust system on non-certified engines (Figure 7-13) is made of a muffler and various tubes, elbows, and clamps.
Page 193: Slip Joint Exhaust Connectors
GRT9165 SERVICE MANUAL POWER TRAIN 13. Remove clamp (6), gasket (7), and tube (8) from the Secure tail pipe (2) with tail pipe clamps (3). aftertreatment unit (1). Install the support bracket (20, Figure 7-12) in place. Secure DEF fluid hoses (1 and 2) with nuts (15), lockwashers (16), washers (17), capscrews (18), clamps NOTE: The aftertreatment unit weighs approximately...
Page 194 POWER TRAIN GRT9165 SERVICE MANUAL 10189 10190 Exhaust System - Non-Certified Engine Jam Nut Muffler Clamp, V-Band Clamp, Mounting Band Gasket Muffler Clamp Flex Coupler Clamp, V-Band Tail Pipe Tube Clamp, Slip Joint Tail Pipe FIGURE 7-13 Published 10-01-2020 Control # 699-00 7-14...
Page 195 GRT9165 SERVICE MANUAL POWER TRAIN 10191 10192 Exhaust System - Stage 5/Tier 4 Aftertreatment Unit Gasket Tailpipe Tube Tailpipe Clamp Coupler Clamp, Slip Joint Mounting Bands Clamp, Mounting Band Clamp, V-band Clamp, V-Band Gasket FIGURE 7-14 GROVE Published 10-01-2020 Control # 699-00 7-15...
Page 196: Aftertreatment Diesel Exhaust Fluid (Def)
POWER TRAIN GRT9165 SERVICE MANUAL AFTERTREATMENT DIESEL EXHAUST Remove the hardware (4) holding the tank straps (5) in place. FLUID (DEF) Remove the tank (1). DEF Tank Installation This engine uses a Selective Catalytic Reduction (SCR) Place the DEF tank (1) onto the location on the frame. system.
Page 197: Def Supply Pump Filter
GRT9165 SERVICE MANUAL POWER TRAIN DEF Supply Pump Filter Debris can cause permanent damage and premature failure to either the DEF supply pump or the aftertreatment DEF The DEF supply pump filter (2, Figure 7-16) is a 10-micron dosing valve. filter designed to prevent foreign objects that may be The filter should be replaced every 480,000 km (300,000 suspended in the DEF from entering the dosing system.
Page 198 POWER TRAIN GRT9165 SERVICE MANUAL Initial Check Clean and Inspect for Reuse Inspect the area around the seal and vent of the DEF supply If there is the possibility that contaminated DEF has gone pump filter housing for signs of leakage. through the DEF dosing system, check the DEF filter prior to discarding the filter.
Page 199: Water Cooling System
GRT9165 SERVICE MANUAL POWER TRAIN usually occur gradually. The cooling system needs to be maintained with the same attention as other systems. CAUTION The circulation of water through the cooling system relies entirely upon the water pump. The water pump draws water Machine damage hazard! from the radiator and forces it through the water jacket and Do not use the flow test portion of the INSITE™...
Page 200 POWER TRAIN GRT9165 SERVICE MANUAL not use more than 50 percent antifreeze/coolant in the formulated extended life coolant. Refer to Radiator Fill mixture unless additional freeze protection is required. Never and Servicing, page 7-25. use more than 68 percent antifreeze/coolant under any NOTE: Remove radiator caps when draining system to condition.
Page 201 GRT9165 SERVICE MANUAL POWER TRAIN Pressure Flushing escape of air or liquid while the cap is in position. When the cooling system pressure reaches a predetermined point, the Disconnect both radiator hoses that connect the radiator cap valve opens and will again close when the pressure falls to the engine.
Page 202 POWER TRAIN GRT9165 SERVICE MANUAL Water Pump inoperative thermostat. To check for this condition, remove the thermostat and test by submerging it in hot water and The pump should be checked carefully for leaks and proper noting the temperature at which the thermostat opens and lubrication.
Page 203 GRT9165 SERVICE MANUAL POWER TRAIN Radiator Removal and Installation 10197 10198 10200 10199 FIGURE 7-17 GROVE Published 10-01-2020 Control # 699-00 7-23...
Page 204 POWER TRAIN GRT9165 SERVICE MANUAL Loosen the radiator cap (11) and surge tank cap (10). Table 7-1 Legend for Figure 7-17 Open the drain valve (9) and drain the coolant into a Bleeder Valve suitable container. Dispose of the coolant in accordance with local and EPA regulations.
Page 205: Radiator Fill And Servicing
GRT9165 SERVICE MANUAL POWER TRAIN 19. If a new radiator is to be installed, remove all fittings and Antifreeze/Coolant Drain Procedure hoses from the old one and install them in the same locations on the new one. Installation Ensure all fittings and hoses are installed on the radiator. Apply Loctite®...
Page 206: Drive Train
POWER TRAIN GRT9165 SERVICE MANUAL DRIVE TRAIN The transmission/torque converter oil is cooled by passing the oil through an externally mounted transmission cooler Description that is located on the left side of the crane. An oil filter is mounted on the left frame rail near the fuel tank. The drive train consists of the transmission/torque converter Four drive lines are used.
Page 207 GRT9165 SERVICE MANUAL POWER TRAIN 10206 10209 10205 10207 10203 10208 10204 Driveshaft Capscrew 1/2-20UNFx2 G8 Driveshaft, Slip Capscrew M12x45 10.9 Driveshaft Lockwasher Driveshaft, Slip Capscrew M14x50 Lockwasher FIGURE 7-20 GROVE Published 10-01-2020 Control # 699-00 7-27...
Page 208: Transmission
POWER TRAIN GRT9165 SERVICE MANUAL Drive Shafts Remove capscrews (8) and slip driveshaft (4) from driveshaft and bearing assembly. Remove capscrews (1, Figure 7-21), washers (2), nuts CAUTION (3), and driveshaft and bearing assembly (4) from the Do not disassemble drive lines when removing them from carrier bearing weldment.
Page 209: Troubleshooting And Maintenance
GRT9165 SERVICE MANUAL POWER TRAIN Troubleshooting and Maintenance For transmission maintenance information, see Maintenance and Lubrication, page 9-1. For troubleshooting steps, see Table 7-2. 10211 Front Looking Back Transmission Transmission Fluid Dipstick Transmission Drain Plug FIGURE 7-22 GROVE Published 10-01-2020 Control # 699-00 7-29...
Page 210 POWER TRAIN GRT9165 SERVICE MANUAL Table 7-2Troubleshooting SYMPTOM PROBABLE CAUSE REMEDY Low clutch pressure. Low oil level. Fill to proper level. b. Clutch pressure regulating b. Clean valve spool and housing. valve spool stuck open. Faulty charging pump. Replace pump. d.
Page 211 GRT9165 SERVICE MANUAL POWER TRAIN 10212 Transmission Capscrew M10x30 SS 10213 Flange, Split O-Ring Dipstick Tube Capscrew M12x45 10.9 Locknut Driveshaft Driveshaft Coupler Locknut Washer Shock Mount Capscrew 5/8-11UNC G8 10214 Capscrew M20x45 10.9 Washer Installation Bracket FIGURE 7-23 GROVE Published 10-01-2020 Control # 699-00 7-31...
Page 212 POWER TRAIN GRT9165 SERVICE MANUAL Transmission Removal 11. Using a suitable lifting device, remove the transmission from the carrier frame. Place the transmission on a Extend and set outriggers just enough to take up the suitable platform. slack in the outrigger pads. Chock the wheels. 12.
Page 213 GRT9165 SERVICE MANUAL POWER TRAIN Mount Flywheel Dial Housing Indicator Here Engine Flywheel Pilot Bore Flywheel Figure 1 Flywheel 10.2 cm Converter Housing (4 in.) Housing Stud 6.4 cm (2-1/2 in) Aligning Studs Drive Flywheel Plate Special Stud, Washer And Figure 2 Self-lock Nut Furnished By Flywheel...
Page 214: Towing Or Pushing
POWER TRAIN GRT9165 SERVICE MANUAL Servicing the Crane after Transmission Overhaul until fluid is at the top of the fill range on the dipstick. Run the engine for two minutes at 600 rpm to 800 rpm to The transmission and its allied hydraulic system are prime the torque converter and hydraulic lines.
Page 215: Axles
GRT9165 SERVICE MANUAL UNDERCARRIAGE SECTION 8 UNDERCARRIAGE SECTION CONTENTS Axles ........8-1 Service Brakes.
Page 216 UNDERCARRIAGE GRT9165 SERVICE MANUAL The front and rear wheels feature a disc type hydraulic braking system. A disc-type parking brake is mounted on the front axle input shaft. 10217 10219 10218 Cotter Pin Front Axle Assembly Spacer Middle Axle Assembly Suspension Pin Rear Axle Assembly Washer...
Page 217: Maintenance
GRT9165 SERVICE MANUAL UNDERCARRIAGE Each axle incorporates a single reduction carrier with hypoid On the front axle only, tag and disconnect the hydraulic gearing mounted in the axle center. The final reduction is of line from the park brake actuator. planetary design spur gearing built into the wheel hubs.
Page 218 UNDERCARRIAGE GRT9165 SERVICE MANUAL Axle Installation On the front axle only, connect the hydraulic line to the parking brake actuator. If a new axle is to be installed, remove the following from On the left side of the rear axle only, connect the the old axle and install them on the new one.
Page 219 GRT9165 SERVICE MANUAL UNDERCARRIAGE create a maximum gap of 1.5 mm (0.06 in) closest to the frame and no gap on the outside. Strut Cylinder (REF) NOTE: The rig pin should be 8.33 mm (0.33 in) diameter x 136.7 mm (5.38 inch). Install rig pin (11) through the hole (10) in the relay arm mounting bracket and relay arm (5).
Page 220 UNDERCARRIAGE GRT9165 SERVICE MANUAL 1.5 mm (0.06 in) 10223 10224 Looking Up 10222 Forward Looking Down 10221 Rear Axle Assembly Capscrew Middle Axle Assembly Washer Drag Link, 1311 mm (51.6 in) Shim Drag Link, 731 mm (28.8 in) Rig Tool Hole Relay Arm Rig Tool FIGURE 8-5...
Page 221: Wheels And Tires
GRT9165 SERVICE MANUAL UNDERCARRIAGE Rear Steer Sensor Adjustment Procedure Slide the proximity switch through hole in the mounting bracket and secure with nuts and washers. Use the following procedure the adjust the rear steer sensor. A proximity switch on the rear axle senses the position of the Set face of proximity switch from 4 mm (0.16 in) to 6 mm rear wheels.
Page 222: Steering Systems
UNDERCARRIAGE GRT9165 SERVICE MANUAL Maintenance Continue to torque the lug nuts 610 N-m to 680 N-m (450 lb-ft to 500 lb-ft) in the sequence shown in Figure 8-7. Lower the crane onto its tires. Retract and stow the DANGER outrigger assemblies and the floats. Do not attempt to demount or mount tires without proper Retorque lug nuts after approximately one hour of travel.
Page 223: Maintenance
GRT9165 SERVICE MANUAL UNDERCARRIAGE Maintenance Front Steering System Troubleshooting Table 8-1 Symptom Probable Cause Solution Hard to steer left and Hydraulic oil low. Check system for leaks. Make right. repairs as needed. Fill reservoir. b. Clogged or loose hydraulic lines or b.
Page 224 UNDERCARRIAGE GRT9165 SERVICE MANUAL steering column (1). Remove the control valve, leaving the steering column in the cab. Installation Forward Position the control valve to the bracket and steering column(1) and install the flatwashers (8), lockwashers (7), and capscrews (6). Torque capscrews; refer to Fasteners and Torque Values, page 1-16 for proper torque.
Page 225 GRT9165 SERVICE MANUAL UNDERCARRIAGE Rear Steering System Troubleshooting Table 8-2 Symptom Probable Cause Solution Rear steering Hydraulic oil low. Check system for leaks. Make inoperative. repairs as needed. Fill reservoir. b. Clogged, broken, loose b. Clean, tighten, or replace lines or hydraulic lines or fittings.
Page 226: Rear Axle Oscillation Lockout And Suspension Raise/Lower System
UNDERCARRIAGE GRT9165 SERVICE MANUAL Installation Position the cylinder onto the attachment fittings on the axle and install both pin welds (5). On the rod end, install a thrust washers (6) top and bottom of lug. Secure each pin weld with the capscrew (2), flatwasher (3), and lockwasher (4).
Page 227: Removing The Hydraulic Strut
GRT9165 SERVICE MANUAL UNDERCARRIAGE To Suspension Manifold Valve Hydraulic Strut Length Sensor Washer Washer Cotter Pin Spacer Suspension Pin 10230 Hydraulic Hose FIGURE 8-10 Removing the Hydraulic Strut Install the bottom of the strut (1) on the axle with spacers (8), suspension pin (9), and cotter pins (7).
Page 228: Maintenance
UNDERCARRIAGE GRT9165 SERVICE MANUAL charge valve, two hydraulic accumulators, the brake Parking Brake assemblies, and all the associated hoses and tubing. The The parking brake is a hydraulically-controlled, disc-type operator depresses the pedal on the tandem brake valve, brake, located on the front axle. It is spring applied and located on the cab floor, and the valve modulates the brake hydraulically released.
Page 229: Service Brakes
GRT9165 SERVICE MANUAL UNDERCARRIAGE Symptom Probable Cause Solution Uneven braking or pad wear. Lining thickness less than Replace the lining. 0.125 in (3 mm). b. Grease on the pads/linings. b. Replace the pads/linings. Maintenance General A schedule for the periodic adjustment, cleaning, inspection, NOTE: To perform maintenance on the brake caliper, and lubrication of brake equipment should be established by...
Page 230 UNDERCARRIAGE GRT9165 SERVICE MANUAL Caliper b. Apply compressed air to the inlet fitting to force the pistons out of the other housing. If one piston comes Block the wheels out before the other piston, put a piece of wood in front of the piston that comes out first.
Page 231 GRT9165 SERVICE MANUAL UNDERCARRIAGE Shoes, Linings, and End Plates Remove the shoes and linings. To help prevent abnormal Wood Block lining wear, replace worn, bent, or cracked end plates and distorted backing plates. Inspect end plate bolts for wear. Replace the bolts if worn. Inspect the linings for: •...
Page 232 UNDERCARRIAGE GRT9165 SERVICE MANUAL Minimum Disc Bleeder Screw Piston Fluid Thickness Fluid Leaks Leaks Maximum Disc Wear Each Side Inlet Cylinder Fitting Maximum Fluid Disc Wear Fluid Original Leaks Leaks Disc Thickness 15.875 mm (0.625 in) Typical Section Through Disc Showing Piston Fluid Recommended Maximum Wear Limits Leaks...
Page 233: Corrosion Protection
GRT9165 SERVICE MANUAL UNDERCARRIAGE Measure the diameter of the housing bore. Replace the • Use soap and water to clean parts that are not made housing if the diameter is worn to more than 3.003 in of metal. (76.276 mm). Refer to Figure 8-21. •...
Page 234 UNDERCARRIAGE GRT9165 SERVICE MANUAL Install a new dust seal in the top groove of the bore. Install a new O-ring in the groove of the cylinder cap. Refer to Figure 8-22. Ensure the O-ring is not cut by the threads on the cylinder cap.
Page 235: Parking Brake
GRT9165 SERVICE MANUAL UNDERCARRIAGE Caliper Apply and release the brakes three times to ensure the caliper operates correctly. Check for fluid leaks. Ensure Position the caliper housing on the mounting bracket. If the linings move freely. shims where used, place them as marker during removal.
Page 236: Maintenance
Damaged outrigger valve. Repair or replace valve. Damaged valve coil. Replace coil. m. Main hydraulic pump m. Replace or tighten hose or fitting. cavitation. Refer to your Manitowoc Crane Care Parts Manual. n. Partially shifted hydraulic n. Disassemble, clean, polish...
Page 237 GRT9165 SERVICE MANUAL UNDERCARRIAGE Symptom Probable Cause Solution Sticking spool. Dirt in the system. Change oil and flush system. b. Flow in excess of valve rating. b. Limit flow through valve to that recommended. Check pump output and cylinder ratio. Pressure in excess of valve Check relief valve setting or pump rating.
Page 238 UNDERCARRIAGE GRT9165 SERVICE MANUAL Symptom Probable Cause Solution Outrigger system will not Hydraulic oil low. Check system for leaks. Make activate (from stowed or repairs as needed. Fill reservoir. extended down b. Loose or broken wire on b. Repair or replace wiring. position).
Page 239: Outrigger Beam
GRT9165 SERVICE MANUAL UNDERCARRIAGE Outrigger Beam On the jack cylinder end of the beam, loosen the two jam nuts (14), plates, and wear pads (16). Description On the opposite end of the beam, remove capscrews The outrigger box assembly(1, Figure 8-26) consists of an (17), plates (18), and wear pads (19) from the top of outrigger beam, a jack cylinder (2), an extension cylinder outrigger beam.
Page 240 UNDERCARRIAGE GRT9165 SERVICE MANUAL 10231 10232 Outrigger Box Outrigger Jack Cylinder Capscrew 10 x 30 8.8 Lockwasher Washer Grab Handle Capscrew M10x70 SS Washer 10233 Spacer Capscrew M10x25 10.9 Ladder Plate Retaining Nut Wear Pad Lower Outrigger Cover Hydraulic Hose Outrigger End Cover Cotter Pin Jam Nut...
Page 241 GRT9165 SERVICE MANUAL UNDERCARRIAGE 11. Pull the outrigger beam out of the outrigger box, re- cylinder hydraulic hoses do not get trapped against the adjusting the lifting attachment to prevent the extension outrigger box during insertion. cylinder from sliding out of the outrigger beam when the Apply anti-seeze compound to the clevis pin (22, beam clears the outrigger box.
Page 242: Outrigger Extension Cylinder
UNDERCARRIAGE GRT9165 SERVICE MANUAL Outrigger Extension Cylinder provide the force for the outrigger beam’s horizontal movement. The cylinder weighs approximately 54 kg Description (119 lb). Two outrigger extension cylinders(1, Figure 8-28) are utilized within each outrigger box assembly. The extension cylinders 10232 Capscrew M8x25 8.8 Outrigger Extension Cylinder...
Page 243: Outrigger Jack Cylinder
GRT9165 SERVICE MANUAL UNDERCARRIAGE Outrigger Jack Cylinder Installation Apply grease (EP-MPG) to ID of jack cylinder support Description tube. Four jack cylinders are used on the crane, one at the end of If removed, install wear ring in groove in bottom of each outrigger beam.
Page 244 UNDERCARRIAGE GRT9165 SERVICE MANUAL 8804-115 Item Description Jack Cylinder Cap Cap Bracket Head Wear Ring Jack Cylinder Bearing Jack Cylinder Hydraulic Hoses FIGURE 8-29 8-30 Published 10-01-2020 Control # 699-00...
Page 245: General
Additional copies are available through the Grove Use lubricants as listed in this section. See also the distributor network or Manitowoc Crane Care. appropriate section for maintenance and lubrication instructions.
Page 246: Standard Lubricants
NOTE: All fluids and lubricants may be purchased by equipment. contacting an authorized Grove distributor or Manitowoc Crane Care Parts Department. Grove recommends the use of Standard lubricants for Grove cranes operating in regions where moderate ambient Standard Lubricants temperature, humidity, and atmospheric conditions prevail.
Page 247 GRT9165 SERVICE MANUAL MAINTENANCE AND LUBRICATION Table 9-1 : Standard Lubricants [Down to -9°C (+15°F)] (Continued) Recommended Lubricant Lubricant/Fluid Grove Spec. Type Grade Classification Old World Industries, Inc. Fleet Charge SCA (red) AFC - 50/50 Antifreeze Coolant 6829101130 Caterpillar DEAC (magenta) Mix 50/50 Fleetguard ES Compleat EG (blue)
Page 248: Arctic Lubricants And Conditions
-40°C (- doubt about the suitability of a specific fluid or lubricant, 40°F). Refer to Table 9-3 for a list of these recommended check with an authorized Grove distributor or Manitowoc Cold Weather lubricants. Crane Care.
Page 249 GRT9165 SERVICE MANUAL MAINTENANCE AND LUBRICATION Table 9-2 : Cold Weather Lubricants in Arctic Conditions [Down to -29°C (-20°F)] (Continued) Recommended Lubricant Lubricant/Fluid Grove Spec. Type Grade Classification Mobil Mobilith SHC 220 (red) Petro-Canada Precision Extreme Pressure Synthetic EP1 Multipurpose Grease (Cold 6829104275 NLGI 2 GC-LB Certified...
Page 250 MAINTENANCE AND LUBRICATION GRT9165 SERVICE MANUAL Table 9-3 : Cold Weather Lubricants in Arctic Conditions [Down to -40°C (-40°F)] Recommended Lubricant Lubricant/Fluid Grove Spec. Type Grade Classification Petro-Canada Traxon E Synthetic CITGO Synthetic Gear Lube Axle Gear Oil 6829014058 75W-90 GL-5 Eaton Roadranger EP Hoist Gear Oil...
Page 251: Cylinder Rod Surface Protection
Boeshield® T-9 Premium Metal Protectant. will provide the necessary lubrication and help prevent the Manitowoc Crane Care has Boeshield® T-9 Premium Metal formation of rust. An Anti-Seize compound may be used if Protectant available in 12 oz. aerosol cans by ordering part rust has not formed, otherwise the component must be number 9999101803 through the Parts Department.
Page 252: Safety
MAINTENANCE AND LUBRICATION GRT9165 SERVICE MANUAL Cummins Engineering Specification numbers. Select the one To lubricate many of the locations on the crane, the engine that applies to your engine, and view the registered oils. must be started. Parts of the crane, to include the boom, superstructure, outriggers, and the like, must be retracted or Safety extended, or swung left or right, which movement may cause...
Page 253: Drive Train
GRT9165 SERVICE MANUAL MAINTENANCE AND LUBRICATION Lube Point Approved Approximate Service Item Figure No. Service Interval Description Lubricant Capacity Application Drive Train REPLACE engine Engine Air When indicator air cleaner filter Cleaner Filter Figure 9-1 — — ” shows red (25 Element See NOTE 1.
Page 254 MAINTENANCE AND LUBRICATION GRT9165 SERVICE MANUAL FRONT 9900-01 TOP VIEW OF CARRIER FIGURE 9-1 Published 10-01-2020 Control # 699-00 9-10...
Page 255 GRT9165 SERVICE MANUAL MAINTENANCE AND LUBRICATION Lube Point Approved Approximate Service Item Figure No. Service Interval Description Lubricant Capacity Application Drive Train (Continued) CHECK fluid level See NOTE 8. See NOTE 9. See NOTE 10. Every 10 hours/daily FILL transmission sump to FULL on DIPSTICK See NOTE 12.
Page 256 MAINTENANCE AND LUBRICATION GRT9165 SERVICE MANUAL Lube Point Approved Approximate Service Item Figure No. Service Interval Description Lubricant Capacity Application CAUTION Possible Equipment Damage! Do not operate torque converter at stall condition for longer than 30 seconds at one time. Shift to neutral for 15 seconds, and repeat procedure until desired fluid temperature is reached.
Page 257 GRT9165 SERVICE MANUAL MAINTENANCE AND LUBRICATION Lube Point Approved Approximate Service Item Figure No. Service Interval Description Lubricant Capacity Application Drive Train (Continued) REPLACE transmission and PERFORM after first torque converter 50 hours of service, filter See NOTE 11. REPEAT after REPLACE Transmission and another 50 hours for...
Page 258 MAINTENANCE AND LUBRICATION GRT9165 SERVICE MANUAL FRONT 9900-03 BOTTOM VIEW OF CARRIER FIGURE 9-3 Published 10-01-2020 Control # 699-00 9-14...
Page 259 GRT9165 SERVICE MANUAL MAINTENANCE AND LUBRICATION Lube Point Approved Approximate Service Item Figure No. Service Interval Description Lubricant Capacity Application Drive Train (Continued) Fuel Filter/ Water Separator Figure 9-4 — — Every 10 hours/daily DRAIN water trap (showing Side View) CHECK DEF level and FILL Diesel Exhaust...
Page 260 MAINTENANCE AND LUBRICATION GRT9165 SERVICE MANUAL FRONT 9900-02 SIDE VIEW OF CARRIER FIGURE 9-4 Published 10-01-2020 Control # 699-00 9-16...
Page 261 GRT9165 SERVICE MANUAL MAINTENANCE AND LUBRICATION Lube Point Approved Approximate Service Item Figure No. Service Interval Description Lubricant Capacity Application Drive Train (Continued) Every 4500 hours of DEF Supply service, or 3 years, CHECK DEF Figure 9-5 — — Module Filter whichever interval Supply Module filter comes first...
Page 262 MAINTENANCE AND LUBRICATION GRT9165 SERVICE MANUAL FRONT 9900-03 BOTTOM VIEW OF CARRIER FIGURE 9-5 Published 10-01-2020 Control # 699-00 9-18...
Page 263: Steering And Suspension
GRT9165 SERVICE MANUAL MAINTENANCE AND LUBRICATION Lube Point Approved Approximate Service Item Figure No. Service Interval Description Lubricant Capacity Application Steering and Suspension LUBRICATE Upper and Lower Every 500 hours, or Until grease 4 grease fittings King Pins Figure 9-6 3 months, whichever extrudes per axle, 3 axles...
Page 264 MAINTENANCE AND LUBRICATION GRT9165 SERVICE MANUAL 9900-05 REAR DRIVE AXLE – REAR VIEW FIGURE 9-7 FRONT 9900-06 REAR DRIVE AXLE – SIDE VIEW FIGURE 9-8 Published 10-01-2020 Control # 699-00 9-20...
Page 265: Axle Lubrication
GRT9165 SERVICE MANUAL MAINTENANCE AND LUBRICATION Lube Point Approved Approximate Service Item Figure No. Service Interval Description Lubricant Capacity Application Axle Lubrication Every 250 hours, or CHECK and FILL 1 month, whichever 2 service points interval comes first 44.8 L DRAIN and FILL (11.8 gal) ea 2 service points...
Page 266 MAINTENANCE AND LUBRICATION GRT9165 SERVICE MANUAL 9900-07 FRONT DRIVE AXLE – FRONT VIEW – DIFFERENTIAL FIGURE 9-9 9900-08 FRONT DRIVE AXLE – FRONT VIEW – PLANETARY HUBS & WHEEL BEARINGS FIGURE 9-10 LEGEND 21A - OIL FILL 21B - OIL DRAIN 9900-09 SIDE VIEW –...
Page 267: Superstructure Lubrication
GRT9165 SERVICE MANUAL MAINTENANCE AND LUBRICATION Lube Point Approved Approximate Service Item Figure No. Service Interval Description Lubricant Capacity Application Superstructure Lubrication LUBRICATE ROTATE the 4 grease fittings S/S 90° then at front of super- grease again Every 500 hours, or structure (S/S) Swing Drive Figure 9-12...
Page 268 MAINTENANCE AND LUBRICATION GRT9165 SERVICE MANUAL 9900-10 TOP VIEW – SUPERSTRUCTURE FIGURE 9-12 Published 10-01-2020 Control # 699-00 9-24...
Page 269 GRT9165 SERVICE MANUAL MAINTENANCE AND LUBRICATION Lube Point Approved Approximate Service Item Figure No. Service Interval Description Lubricant Capacity Application Superstructure Lubrication CHECK oil level FILL swing drive Every 50 hours of gearbox to LEVEL service on DIPSTICK (23a) 2 service points Swing Drive See NOTE 26.
Page 270 MAINTENANCE AND LUBRICATION GRT9165 SERVICE MANUAL Lube Point Approved Approximate Service Item Figure No. Service Interval Description Lubricant Capacity Application NOTE 26: CHECK fluid level in each of two (2) Swing Drive Gearboxes, and FILL to MAX LEVEL on DIPSTICK. NOTE 27: CHECK level in each of two (2) Swing Drive Gearbox Brake Assemblies, and FILL to TOP of ELBOW.
Page 271 GRT9165 SERVICE MANUAL MAINTENANCE AND LUBRICATION 9900-11 RIGHT SIDE VIEW – SUPERSTRUCTURE FIGURE 9-13 9-27 Published 10-01-2020 Control # 699-00 GROVE...
Page 272: Superstructure And Cab Tilt Lubrication
MAINTENANCE AND LUBRICATION GRT9165 SERVICE MANUAL Lube Point Approved Approximate Service Item Figure No. Service Interval Description Lubricant Capacity Application Superstructure and Cab Tilt Lubrication LUBRICATE 2 grease fittings per Until grease Every 500 hours, or Pillow Block pillow block bearing, extrudes from 3 months of service, Bearings...
Page 273 GRT9165 SERVICE MANUAL MAINTENANCE AND LUBRICATION 9900-12 LEFT SIDE – SUPERSTRUCTURE FIGURE 9-14 9900-13 9900-29 UNDERSIDE OPERATOR CAB – SUPERSTRUCTURE FIGURE 9-15 9-29 Published 10-01-2020 Control # 699-00 GROVE...
Page 274: Outrigger Lubrication
MAINTENANCE AND LUBRICATION GRT9165 SERVICE MANUAL Lube Point Approved Approximate Service Item Figure No. Service Interval Description Lubricant Capacity Application Outrigger Lubrication Brush on I.D. BRUSH ON I.D. of of each Every 50 hours, or 4 service points Jack Cylinder cylinder 1 week of service, Figure 9-16...
Page 275 GRT9165 SERVICE MANUAL MAINTENANCE AND LUBRICATION Lube Point Approved Approximate Service Item Figure No. Service Interval Description Lubricant Capacity Application Extend Cylinder BRUSH ON Every 50 hours, or Supports 8 service points 1 week of service, Figure 9-16 BRUSH ON whichever interval See NOTE 40.
Page 276: Lift Cylinder Lubrication
MAINTENANCE AND LUBRICATION GRT9165 SERVICE MANUAL Lube Point Approved Approximate Service Item Figure No. Service Interval Description Lubricant Capacity Application Lift Cylinder Lubrication LUBRICATE 1 grease fitting, Every 100 hours, or Lower Lift Until grease 1 service point Figure 9-17 1 month, whichever Cylinder Pivot Pin extrudes...
Page 277 GRT9165 SERVICE MANUAL MAINTENANCE AND LUBRICATION 9900-15 LIFT CYLINDER FIGURE 9-17 9-33 Published 10-01-2020 Control # 699-00 GROVE...
Page 278: Boom Lubrication
MAINTENANCE AND LUBRICATION GRT9165 SERVICE MANUAL Boom Lubrication READ FIRST! IMPORTANT CRANE SET-UP INFORMATION! With crane set on a firm level surface and counterweight installed, fully extend the outriggers, and level the crane. Center the boom over the front of the crane, engage the turntable swing lock pin, and disable the swing function. Fully retract the boom and set boom angle to 70°.
Page 279 GRT9165 SERVICE MANUAL MAINTENANCE AND LUBRICATION Telescope Section 4 (Tele 4) Telescope Section 2 (Tele 2) Make sure that the tele cylinder is locked to Tele 4. Make sure that the tele cylinder is locked to Tele 2. Extend and lock Tele 4 to the 100% pinning location. Extend and lock Tele 2 to the 100% pinning location.
Page 280: Boom Lubrication
MAINTENANCE AND LUBRICATION GRT9165 SERVICE MANUAL Lube Point Approved Approximate Service Item Figure No. Service Interval Description Lubricant Capacity Application Boom Lubrication (Continued) Telescopic BRUSH ON front Every 500 hours, or Slide Faces faces in a thin line Figure 9-19 BRUSH ON 6 months, whichever interval comes first...
Page 281 GRT9165 SERVICE MANUAL MAINTENANCE AND LUBRICATION 9900-16 TELESCOPIC SECTION SLIDE FRONT FACES FIGURE 9-19 9-37 Published 10-01-2020 Control # 699-00 GROVE...
Page 282 MAINTENANCE AND LUBRICATION GRT9165 SERVICE MANUAL Lube Point Approved Approximate Service Item Figure No. Service Interval Description Lubricant Capacity Application Boom Lubrication (Continued) Only until Every 500 hours, or LUBRICATE Tele 5 Rear Upper Figure 9-20 resistance 6 months, whichever 2 service points Wear Pad is felt...
Page 283 GRT9165 SERVICE MANUAL MAINTENANCE AND LUBRICATION 9900-20 LEFT SIDE BOOM – REAR UPPER WEAR PADS AND LOCK PINS FIGURE 9-20 9-39 Published 10-01-2020 Control # 699-00 GROVE...
Page 284 MAINTENANCE AND LUBRICATION GRT9165 SERVICE MANUAL Lube Point Approved Approximate Service Item Figure No. Service Interval Description Lubricant Capacity Application Boom Lubrication (Continued) Every 500 hours, or Coat areas Tele Cylinder 6 months of service, BRUSH ON Figure 9-21 that the wear Wear Pad whichever interval 5 service points...
Page 285 GRT9165 SERVICE MANUAL MAINTENANCE AND LUBRICATION Lube Point Approved Approximate Service Item Figure No. Service Interval Description Lubricant Capacity Application Boom Lubrication (Continued) CHECK 3 service points CHECK sheaves Every 250 hours, or for dry points of Boom Extension 3 months of service, Figure 9-21 —...
Page 286 MAINTENANCE AND LUBRICATION GRT9165 SERVICE MANUAL Lube Point Approved Approximate Service Item Figure No. Service Interval Description Lubricant Capacity Application Boom Lubrication (Continued) LUBRICATE 1 to Every 250 hours, or 2 service points Hook Block Until grease 3 months of service, Figure 9-22 See NOTE 50.
Page 287 GRT9165 SERVICE MANUAL MAINTENANCE AND LUBRICATION 9900-28 9900-27 9900-21 9900-22 9900-23 HOOK BLOCK and OVERHAUL BALLS FIGURE 9-22 9-43 Published 10-01-2020 Control # 699-00 GROVE...
Page 288: Hoist Lubrication
MAINTENANCE AND LUBRICATION GRT9165 SERVICE MANUAL Lube Point Approved Approximate Service Item Figure No. Service Interval Description Lubricant Capacity Application Hoist Lubrication CHECK oil level 2 service points REMOVE vent or hose from top of the sight glass to FILL Every 50 hours of FILL hoist drums service, or weekly,...
Page 289 GRT9165 SERVICE MANUAL MAINTENANCE AND LUBRICATION 9900-24 HOIST DRUM – RIGHT SIDE 9900-25 HOIST DRUM – LEFT SIDE HOIST DRUMS – (MAIN and AUXILIARY) FIGURE 9-23 9-45 Published 10-01-2020 Control # 699-00 GROVE...
Page 290: Hydraulics Lubrication
MAINTENANCE AND LUBRICATION GRT9165 SERVICE MANUAL Lube Point Approved Lube Item Figure No. Lube Interval Application Description Lubricant Capacity Hydraulics Lubrication CHECK oil level Every 10 hours of FILL hydraulic tank to Hydraulic Tank service, or daily, LEVEL in SIGHT SIGHT GLASS whichever interval GLASS...
Page 291 GRT9165 SERVICE MANUAL MAINTENANCE AND LUBRICATION 9900-26a HYDRAULIC TANK FIGURE 9-24 9-47 Published 10-01-2020 Control # 699-00 GROVE...
Page 292: Rust Protection
To help protect against corrosion of Grove cranes, undercarriage and various other areas of each new crane Manitowoc Crane Care recommends washing the crane at before shipment. When applied, the product has a red tint to least monthly to remove all foreign matter. More frequent allow applicators to view coverage.
Page 293: Inspection And Repair
To the extent any damage is structural in nature, Grove • Carwell treatment is available in 16-ounce spray crane must be contacted and consulted as to what repairs bottles from Manitowoc Crane Care (order part number may be required. 8898904099). • After treatment application is complete, wash or clean...
Page 294 MAINTENANCE AND LUBRICATION GRT9165 SERVICE MANUAL 7650-75 Picture may not be same model as your crane, it is Figure 9-25 for reference only. Published 10-01-2020 Control # 699-00 9-50...
Page 295 GRT9165 SERVICE MANUAL MAINTENANCE AND LUBRICATION Picture may not be same model as your crane, it is for reference only. Figure 9-26 Table 9-1 Rust Inhibitor Application Locations Boom Extension Pins, Clips Entire underside of crane Boom Nose Pins, Clips Turntable Bearing Fasteners Hook Block/Overhaul Ball Powertrain Hardware Inside Compartment...
Page 296 MAINTENANCE AND LUBRICATION GRT9165 SERVICE MANUAL THIS PAGE BLANK Published 10-01-2020 Control # 699-00 9-52...
Page 297 Mounted Floodlights ..........3-22 Diagnostics ..............3-20 Nose Sheaves ............4-7 Connector, Accessing ..........2-54 ODM Components ..........4-10 Manitowoc Mobile Application ........3-20 Pivot Pin Removal tool ..........4-4 Viewing Fault Codes ..........3-20 Position Indicator Light ........... 3-23 Dielectric Grease .............3-9 Removal ..............4-1...
Page 298 GRT9165 OPERATOR MANUAL Diesel Exhaust Fluid (DEF) ..........7-1 Differential Lock Manifold Valve ........2-30 Grease, Dielectric ............3-9 Drag Links, Rear Axles ........... 8-4 Drive Belts, Engine ............7-4 Drive Shafts Hoist Installation .............. 7-28 Area Access .............5-2 Removal ..............7-28 Brake ................5-8 Drive Train ..............
Page 299 Main Direction Control Valve ......... 2-21 Removing Hoist ...............5-2 Swing Valve ..........2-21 2-32 Reservoir, Hydraulic ............2-8 Manitowoc Return Filter Assembly, Hydraulic Oil ......2-10 Crane Service Tool ..........2-54 Rope, Wire ..............1-28 Mobile Application, Diagnostics Codes ....3-20 Rotation Indicator, Hoist ..........5-8 Middle Axle ..............
Page 300 GRT9165 OPERATOR MANUAL Steer Cylinders ..............8-11 Telescope Cylinder Control Valve .........2-48 Rear Sensor Adjustment .......... 8-7 Telescope Extend and Relief Pressures .......2-59 Steering Temperature Switches ............2-8 Column ..............3-14 Tires ................8-7 Front Control Valve ..........8-9 Tool Systems ..............8-8 Boom Pivot Pin Removal ..........4-4 Stop Light, Engine ............

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