Manitowoc Grove RT880E Service And Maintenance Manual

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Grove RT880E

Service/Maintenance Manual

Table of Contents

Troubleshooting

Summary of Contents for Manitowoc Grove RT880E

Page 1 Grove RT880E Service/Maintenance Manual...
Page 3 DANGER An untrained operator subjects himself and others to death or serious injury. Do not operate this crane unless: Manitowoc is not • You are trained in the safe operation of this crane. responsible for qualifying personnel. •...
Page 4 CALIFORNIA PROPOSITION 65 WARNING Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. CALIFORNIA PROPOSITION 65 WARNING Battery posts, terminals, and related accessories contain chemical lead and lead compounds, chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.
Page 5: Table Of Contents
RT880E TABLE OF CONTENTS TABLE OF CONTENTS RT880E SERVICE MANUAL SECTION 1 ........Introduction General .
Page 6 TABLE OF CONTENTS RT880E Seizing Wire Rope ..........1-23 Installing 35x7 Class Wire Rope .
Page 7 RT880E TABLE OF CONTENTS Tandem Brake Valve with Treadle Pedal ........2-53 Description .
Page 8 TABLE OF CONTENTS RT880E Maintenance ........... . . 2-94 Cab Tilt Cylinder .
Page 9 RT880E TABLE OF CONTENTS Maintenance ............4-2 Removal .
Page 10 TABLE OF CONTENTS RT880E Description............5-9 Maintenance .
Page 11 RT880E TABLE OF CONTENTS Maintenance ............7-28 Troubleshooting Procedures.
Page 12 TABLE OF CONTENTS RT880E Environmental Protection ..........9-1 Lubrication Intervals .
Page 13: Section 1
RT880E SERVICE MANUAL INTRODUCTION SECTION 1 INTRODUCTION SECTION CONTENTS General ........1-1 Wires and Cables .
Page 14: Customer Support
The outriggers are single stage, double box, telescopic beam type outriggers. Manitowoc and our Distributor Network want to ensure your The superstructure is capable of 360 degree rotation in either satisfaction with our products and customer support. Your direction.
Page 15: List Of Specifications
RT880E SERVICE MANUAL INTRODUCTION LIST OF SPECIFICATIONS Hi 1st......4.33 Hi 2nd ......2.08 Hi 3rd .
Page 16: Hydraulic Pumps
INTRODUCTION RT880E SERVICE MANUAL Hydraulic Pumps Hoists Drum Dimensions Pump #1 Diameter ....15 in (381 mm) Type ....... Piston Length (Standard) .
Page 17 RT880E SERVICE MANUAL INTRODUCTION Table 1-1 : AXLE WEIGHT DISTRIBUTION TABLE CG From Rear Weight Front Axle Rear Axle Description Axle cm (in) kg (lb) kg (lb) kg (lb) Basic Unit Maximum Axle Loads Allowed 29484 (65000) 29484 (65000) Maximum Axle Loads while Towing 27216 (60000) 27216 (60000) Maximum Tire Loads Allowed...
Page 18 INTRODUCTION RT880E SERVICE MANUAL CG From Rear Weight Front Axle Rear Axle Description Axle cm (in) kg (lb) kg (lb) kg (lb) Substitutions, Deletions, and Removals from Basic Unit Weight Sub: Removable Ctwt (includes Cylinders & -201.42 (-79.30) -115 (-254) 55 (121) -170 (-375) IPO Ctwt)
Page 19 RT880E SERVICE MANUAL INTRODUCTION Item Description Counterweight Auxiliary Hoist Main Hoist Boom Pivot Lift Cylinder Boom Boom Nose Sheaves Aux. Boom Nose (Not Shown) Outrigger Jack Cylinder Front Axle Fuel Tank Oil Cooler Rear Axle Outrigger Float Work Lights Tailpipe Windshield Washer Fluid FIGURE 1-2 Grove...
Page 20 INTRODUCTION RT880E SERVICE MANUAL Item Description Boom Nose Sheaves Boom Extension Mast Sheave Lift Cylinder Swingaway Nose Boom Pivot Main Hoist Auxiliary Hoist Counterweight Outrigger Jack Cylinder Rear Axle Hydraulic Tank Hydraulic Filter Front Axle Swingaway Extension Air Cleaner Diesel Exhaust Fluid Tank FIGURE 1-3 Published 11-10-2014, Control # 524-00...
Page 21: General Maintenance
RT880E SERVICE MANUAL INTRODUCTION GENERAL MAINTENANCE When raising a portion of a crane or a complete crane, ensure the crane is blocked securely and the weight is These general suggestions should be helpful in following the supported by blocks rather than by lifting equipment. i ns t r u c t io n s i n th i s m a nu a l .
Page 22: Wires And Cables
INTRODUCTION RT880E SERVICE MANUAL Flat metal locks must be installed properly to be effective. Replace hoses if any of the following is evident Figure 1-4: Bend one end of the lock around the edge of the part. Bend • Evidence of kinking or crushing (1) the other end against one flat surface of the nut or bolt head.
Page 23: Gaskets
RT880E SERVICE MANUAL INTRODUCTION Double Row, Tapered Roller When removed, always install new cylinder head and manifold gaskets using recommended gasket compound on Double row, tapered roller bearings are precision fit during head gaskets to allow uniform sealing. manufacture and components are not interchangeable. The cups, cones, and spacers are usually etched with the same Batteries serial number and letter designator.
Page 24 INTRODUCTION RT880E SERVICE MANUAL components. Installation of new elements is always of hose assemblies, refer to your Manitowoc Crane Care recommended. Parts Manual. Hydraulic Lines At the same service interval, visually inspect all other hydraulic components and valves for the following: When installing metal tubes, tighten all fittings finger-tight.
Page 25: Hydraulic Fittings
37° Flared Steel Fitting: Tube or Hose to Fitting Flats from Finger Tight (F.F.F.T.) Method Follow the F.F.F.T. method, described above. Manitowoc recommends that the F.F.F.T. tightening method Table 1-3: Tube and Swivel Nut/Hose Fittings described here be used when assembling all hydraulic fittings.
Page 26: Electrical System
INTRODUCTION RT880E SERVICE MANUAL Table 1-5: Straight Thread Fittings BACK OFF Adjustable Fitting to Port FIGURE 1-6 a0030 Inspect both mating parts for burrs, nicks, scratches, or foreign particles. Lubricate O-ring with a light coat of clean oil. T-2-7 Back off locknut as far as possible (A). Electrical System Screw the fitting into port by hand until the backup washer contacts the face of the port and is pushed all the...
Page 27: Loctite
Torque values should correspond to the type bolts, studs, following types of Loctite brand adhesives are available from and nuts being used. the Parts Department of the local Manitowoc Cranes The torque tables are provided by Manitowoc for reference distributor. when performing maintenance. Application of Medium Strength Loctite Use of proper torque values is extremely important.
Page 28 INTRODUCTION RT880E SERVICE MANUAL NOTE: Some special applications require variation from made on a scheduled basis. Whenever there is a possibility standard torque values. Reference should always that a torque wrench may have been either overstressed or be made to component overhaul procedures for damaged, it should immediately be removed from service recommendations.
Page 29 RT880E 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 1-9 Table 1-6: UNC (Coarse) Thread: Torque Values for Zinc-Flake Coated and Untreated Fasteners Bolt Diameter - Inches Torque Values (Pounds-Foot, Maximum/Minimum) SAE Grade...
Page 30 INTRODUCTION RT880E SERVICE MANUAL Table 1-8: Metric Fasteners, Coarse Thread, Zinc-Flake Coating Bolt Diameter - Metric Torque Values (Nm) Class 21.6 42.4 73.1 1195 1608 2072 10.9 12.5 31.5 62.0 1325 1800 2450 3150 12.9 15.0 36.0 75.0 1060 1550 2125 2850 3700...
Page 31: Weld Studs
RT880E SERVICE MANUAL INTRODUCTION Table 1-12: UNC (Coarse) Thread: Torque Values for Table 1-13: Metric Coarse Thread: Torque Values for Stainless Steel Fasteners with Oil Lubrication Stainless Steel Fasteners with Oil Lubrication Torque Value Torque Size Value Size lb-in lb-ft #5 (0.125) —...
Page 32: Wire Rope
ANSI/ASME B30.5, federal amount depends on the rope’s size, type, and anticipated regulations, and Manitowoc. The inspection interval shall be use. This in-process treatment will provide the finished rope determined by a qualified person and shall be based on such...
Page 33: 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 34: Wire Rope Inspection (Boom Extension And Retraction Cables)
Standard as referenced by Federal Government Agencies deterioration of the wire rope. and as recommended by Manitowoc. All wire rope will eventually deteriorate to a point where it is no longer usable. Wire Rope Inspection (Boom Extension and...
Page 35: Seizing Wire Rope
30 rope diameters. • Severe corrosion as evidenced by pitting. • 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 36: Installing 35X7 Class Wire Rope
INTRODUCTION RT880E SERVICE MANUAL Installing 35x7 Class Wire Rope train the rope and help assure smooth operation during its useful life. Ideally, you should run these loads with reeving that lets CAUTION you place the loads on the block with all rope off the Any cutting of this specific wire rope is not recommended.
Page 37 RT880E SERVICE MANUAL INTRODUCTION FIGURE 1-15 Grove 1-25 Published 11-10-2014, Control # 524-00...
Page 38 INTRODUCTION RT880E SERVICE MANUAL THIS PAGE BLANK 1-26 Published 11-10-2014, Control # 524-00...
Page 39: Section 2
RT880E SERVICE MANUAL HYDRAULIC SYSTEM SECTION 2 HYDRAULIC SYSTEM SECTION CONTENTS Description ....... 2-2 Maintenance .
Page 40: Description
HYDRAULIC SYSTEM RT880E SERVICE MANUAL Maintenance ......2-68 Maintenance......2-88 Load Sense Dump Valve .
Page 41 RT880E SERVICE MANUAL HYDRAULIC SYSTEM FIGURE 2-1 Grove Published 11-10-2014, Control # 524-00...
Page 42 HYDRAULIC SYSTEM RT880E SERVICE MANUAL FIGURE 2-2 Published 11-10-2014, Control # 524-00...
Page 43: Theory Of Operation
RT880E SERVICE MANUAL HYDRAULIC SYSTEM THEORY OF OPERATION Draining and Flushing Three different control systems are used in the hydraulic If a component has been changed because of a failure that system; load sense (LS), constant pressure unloaded might allow metal or abrasive particles to enter the system, (CPU), and open center (OC).
Page 44: Removing Air From The Hydraulic System
HYDRAULIC SYSTEM RT880E SERVICE MANUAL 12. Repeat Steps 10 and 11 for the remaining two outrigger with all cylinders retracted. Fill the reservoir to the full mark cylinders. on the reservoir sight gauge. After the reservoir is filled, operate all circuits and recheck the reservoir sight gauge. 13.
Page 45: Parts Replacement
If the spool bores are badly scored or galled, the valve must is being performed should be replaced. Refer to the be removed for servicing. Manitowoc Crane Care Parts Catalog for proper replacement parts. Warping occurs when mounting plates are not level or they become distorted from machine damage.
Page 46 If any of the above conditions exist, evaluate hose replaced after 8000 hours of service life. assemblies for correction or replacement. For replacement of hose assemblies, refer to your Manitowoc Crane Care Hydraulic hose assemblies operating in climate zones “A” Parts Manual.
Page 47: Supply Pressure And Return Circuit
RT880E SERVICE MANUAL HYDRAULIC SYSTEM SUPPLY PRESSURE AND RETURN CIRCUIT Hydraulic Reservoir The supply pressure and return circuit is made up of several The reservoir (see Figure 2-3), attached to the right side of circuits which route hydraulic oil from the hydraulic pumps to the carrier frame, has a capacity of 253.3 gallons (958.7 l) the directional control valves for the individual operating total, 228 gal (863.8 l) to the full mark.
Page 48: Hydraulic Oil Return Filter Assembly
HYDRAULIC SYSTEM RT880E SERVICE MANUAL A temperature switch (15), located in the tube that routes reservoir through the bypass outlet instead. A bypass filter return oil to the hydraulic oil return filter in the reservoir, is screen prevents gross contamination from passing through part of a circuit that controls the oil cooler fan speed;...
Page 49 RT880E SERVICE MANUAL HYDRAULIC SYSTEM 7820 FIGURE 2-4 Item Description Item Description Filter Head Plug Bowl Assembly O-ring Compression Spring Element Bypass Valve Assembly I.D. Plate O-ring Gasket Screw Gauge Assembly Washer Grove 2-11 Published 11-10-2014, Control # 524-00...
Page 50: Oil Cooler
HYDRAULIC SYSTEM RT880E SERVICE MANUAL Oil Cooler A temperature switch (15, Figure 2-3), located in the tube that routes return oil to the hydraulic oil return filter in the An air cooled oil cooler (see Figure 2-5) is located on the left reservoir, is part of a circuit that controls the oil cooler fan side of the crane and consists of a transmission oil cooler motor.
Page 51: Hydraulic Pumps
RT880E SERVICE MANUAL HYDRAULIC SYSTEM Hydraulic Pumps /rev) delivering a theoretic flow of 96 gpm (363 lpm) @ 2500 engine RPM. It has an integral inlet impeller to insure Pump No. 1 and 2 are mounted off drive pads of the torque proper self-priming.
Page 52 Check and replace damaged fittings or O-rings. b. Oil seal rings deteriorated by excess b. Replace oil seals by disassembling heat. pump. Contact Manitowoc Crane Care for instructions, or refer to Volume 2 of the Service Maintenance Manual Bolt loose...
Page 53 RT880E SERVICE MANUAL HYDRAULIC SYSTEM Pump No. 1 Removal Connect the distribution and supply lines as tagged during removal. Pump No. 2 Removal CAUTION Absolute cleanliness is essential when working on the hydraulic pumps. Always work in a clean area. The CAUTION presence of dirt and foreign materials in the system can Absolute cleanliness is essential when working on the...
Page 54 HYDRAULIC SYSTEM RT880E SERVICE MANUAL seconds. If the pump does not prime in 30 seconds, stop the engine and repeat procedure until the CAUTION pump primes. Do not feed hot hydraulic oil into a cold pump. This may b. Increase the RPM to 1500-1800 for 1 to 2 minutes cause the pump to seize.
Page 55 RT880E SERVICE MANUAL HYDRAULIC SYSTEM If gear pump is equipped with 7/16-20 UN-2B port(s), With the compressed air supply (nominal 100 psi (6.9 wait for a solid stream of fluid, free of air bubbles, to exit bar), maximum 300 psi (20.7 bar)) still attached to the the port, then re-install the plug while oil is still coming Pump Priming Tool, start the engine and let it idle for two out;...
Page 56 HYDRAULIC SYSTEM RT880E SERVICE MANUAL 7748-02 7748-01 7748-03 Item Description Dr Port Tair Port FIGURE 2-7 2-18 Published 11-10-2014, Control # 524-00...
Page 57 RT880E SERVICE MANUAL HYDRAULIC SYSTEM Pump Priming Tool (Grove P/N 80030367) FIGURE 2-8 Grove 2-19 Published 11-10-2014, Control # 524-00...
Page 58: Troubleshooting
HYDRAULIC SYSTEM RT880E SERVICE MANUAL Troubleshooting Symptom Probable Cause Solution No hydraulic oil Low hydraulic oil level. Fill reservoir. flows in systems. b. Reservoir-to-pump suction lines b. Clean, repair, or replace lines as broken or restricted. Air entering at necessary. Check lines for security, suction lines.
Page 59: Pressure Setting Procedures
RT880E SERVICE MANUAL HYDRAULIC SYSTEM 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 60: Procedure A - Main Control Valve Pressure For Hoists, Boom Lift, Telescope - Check/Adjust
HYDRAULIC SYSTEM RT880E SERVICE MANUAL Pressure Tolerance Valve To Be Set Setting PSI Adjustment Location PSI (MPa) (MPa) Cab Tilt & Counterweight Removal Pin 2500 (17.2) +0, -25 (0.2) Cab Tilt Valve (see Figure 2-16) Make-up Oil Manifold Make-up Oil Manifold, Pressure 200 (2.8) ±...
Page 61: Procedure D - Set Service Brake Accumulator Charge Valve Limits - Check/Adjust
RT880E SERVICE MANUAL HYDRAULIC SYSTEM Procedure D - Set Service Brake Secure the gas valve, loosen the swivel nut and remove the charging assembly. Replace the gas valve cap and Accumulator Charge Valve Limits - Check/ guard. Adjust Procedure F - Pre-Charging the Accumulator With the engine off, discharge all of the pressurized oil stored in the accumulators by depressing the service With the engine off, discharge all of the pressurized oil...
Page 62: Procedure H - Swing Work Port Pressure - Check/Adjust
HYDRAULIC SYSTEM RT880E SERVICE MANUAL Procedure H - Swing Work Port Pressure - gauge pressure reading of 350 to 400 psi is achieved (see Figure 2-9). Check/Adjust Stop engine. Remove diagnostic couplers. Install pressure check diagnostic quick disconnect with gauge onto test port at GP5 port of the Front Steer, Procedure K - Counterweight Removal Swing and Accessory Manifold (see Figure 2-9).
Page 63 RT880E SERVICE MANUAL HYDRAULIC SYSTEM Front Steer, Swing and Accessory Manifold Item Description Procedure C - Oil Cooler Motor Pressure - Adjust - Step No. 1 Procedure G - Front Steer Pressure - Check/Adjust - Step No. 1 & No. 2 Procedure H - Swing Work Port Pressure - Check/Adjust - Step No.
Page 64 HYDRAULIC SYSTEM RT880E SERVICE MANUAL P1 Piston Pump Item Description Procedure A - Main Control Valve Pressure for Hoists, Boom Lift, Telescope - Check/Adjust - Step No. 3 (Maximum Pressure) Procedure I - Swing Brake Release Pressure - Check/Adjust - Step No. 3 7748-02 FIGURE 2-10 2-26...
Page 65 RT880E SERVICE MANUAL HYDRAULIC SYSTEM Boom lift/Telescope/Hoist Valve Bank Item Description Procedure A - Main Control Valve Pressure for Hoists, Boom Lift, Telescope - Check/Adjust - Step No. 1 Procedure I - Swing Brake Release Pressure - Check/Adjust - Step No. 3 Procedure A - Main Control Valve Pressure for Hoists, Boom Lift, Telescope - Check/Adjust - Step No.
Page 66 HYDRAULIC SYSTEM RT880E SERVICE MANUAL Outrigger Control Manifold Valve Item Description Procedure B - Outrigger Pressures - Adjust - Step No. 1 & No. 3 Procedure B - Outrigger Pressures - Adjust - Step No. 2 Procedure C - Oil Cooler Motor Pressure - Adjust - Step No.
Page 67 RT880E SERVICE MANUAL HYDRAULIC SYSTEM Checking and Pre-Charging the Accumulator Item Description Gas Valve Guard Gas Valve 6385-8 FIGURE 2-14 Counterweight Removal Valve Bank Item Description Non-Adjustable Port Relief Location 7776 FIGURE 2-15 Grove 2-29 Published 11-10-2014, Control # 524-00...
Page 68 HYDRAULIC SYSTEM RT880E SERVICE MANUAL Cab Tilt Manifold Item Description Procedure L - Cab Tilt Cylinder Extend/ Retract and Counterweight Pin Removal Pressure - Check/Adjust - Step No. 1 & No. 3 FIGURE 2-16 2-30 Published 11-10-2014, Control # 524-00...
Page 69: Valves
RT880E SERVICE MANUAL HYDRAULIC SYSTEM VALVES locations pictorial. The description of each valve given here is for the valve itself. For information on how each valve General functions in the individual circuits, refer to the description and operation procedures of that circuit. This subsection provides descriptive information for all the NOTE: On each valve illustration in this section, each item...
Page 70 HYDRAULIC SYSTEM RT880E SERVICE MANUAL Valve Name Circuit Used In Physical Location Hoist Motor Control Valve Hoist(s) Both Hoists (see Hoist section) Check Valves Return Circuit One in Parallel With Oil Cooler Outrigger Control Manifold Outrigger On Rear Face of Carrier Frame Front Cross Member Load Sense Dump Manifold Load Sense line to Pump No.
Page 71 RT880E SERVICE MANUAL HYDRAULIC SYSTEM Valve Installation 6339-01 SUPERSTRUCTURE FIGURE 2-17 Grove 2-33 Published 11-10-2014, Control # 524-00...
Page 72 HYDRAULIC SYSTEM RT880E SERVICE MANUAL 6338 CARRIER FIGURE 2-17 continued Item Description Item Description Cab Tilt Directional Valve Rear Steer/Axle Lockout/Fan Drive Valve Cab Tilt Check Valve Range Shift/Park Brake Manifold Counterweight Removal Directional Valve Differential Lock Valve Telescope Rod Manifold Drain Load Sense Dump Valve Accumulator Brake Charge Valve Two Speed Swing Valve...
Page 73: Directional Control Valves
RT880E SERVICE MANUAL HYDRAULIC SYSTEM DIRECTIONAL CONTROL VALVES plumbed in parallel with the boom lift/telescope/hoist directional control valve and the cab tilt directional control Description valve. The first and second sections control the left and right removal cylinders, while the third section controls the The directional control valves direct and control hydraulic oil counterweight pin cylinder.
Page 74 HYDRAULIC SYSTEM RT880E SERVICE MANUAL torque value. Function Check - RCL Lockout Valves Connect the hydraulic lines to the valves as tagged Remove fuse F13 from the power panel in the cab. This during removal. cuts off power to the RCL. Connect the electrical connectors and manual control Start the engine.
Page 75 RT880E SERVICE MANUAL HYDRAULIC SYSTEM Counterweight Removal Valve Bank 6481-1 1160 psi 1800 psi 1160 psi 1800 psi CWT Removal Pin CWT Removal 6481-2 Valve Hydraulic Schematic FIGURE 2-18 Grove 2-37 Published 11-10-2014, Control # 524-00...
Page 76 HYDRAULIC SYSTEM RT880E SERVICE MANUAL Item Description Item Description Port P3 Pin Counterweight Cylinder - B Port - Retract Port T2 Counterweight Pin Removal Solenoid Port P1 Counterweight Removal Right Cylinder Solenoid Port P2 Counterweight Removal Left Cylinder Solenoid Port T1 Pressure Relief Valve - Counterweight Removal Port T2 Left Hand Cylinder - Retract...
Page 77 RT880E SERVICE MANUAL HYDRAULIC SYSTEM Boom Lift/Telescope/Hoist Valve Bank 10 2 6480-1 Item Description Item Description Port T1 Port LS Lift Port PB - Boom Extend Port T3 Port P1 Lift Port PA - Boom Retract Aux Hoist - Down - Port A Main Hoist Port PA - Hoist Down Aux Hoist - Up - Port B...
Page 78 HYDRAULIC SYSTEM RT880E SERVICE MANUAL 7060 Boom Lift/Telescope/Hoist Main Valve Hydraulic Schematic FIGURE 2-19 continued 2-40 Published 11-10-2014, Control # 524-00...
Page 79 RT880E SERVICE MANUAL HYDRAULIC SYSTEM Cab Tilt Valve Bank .031 4, 5 6482-2 Cab Tilt 1, 6 Valve Hydraulic Schematic 6482-1 FIGURE 2-20 Item Description Item Description Orifice OR2 - Tilt Cylinder Retract Line Port A - Cab Tilt Cylinder Retract Port P2 - From Counterweight Removal Valve Solenoid Valve SV1 Port P1 - From Main Valve...
Page 80: Front Steer/Swing/Brake Manifold
HYDRAULIC SYSTEM RT880E SERVICE MANUAL FRONT STEER/SWING/BRAKE MANIFOLD functions. It has a separate connection, before the 100 mesh screen that supplies the service brake charge valve. Description One pressure reducing valve and solenoid are used for the swing brake and brake release, one pressure reducing valve The front steer, swing and brake manifold (Figure 2-21) feeds solenoids for the controllers and telescope two stage houses cartridge components that control the front steer,...
Page 81 RT880E SERVICE MANUAL HYDRAULIC SYSTEM 32 56 7392-1 7392-2 20 18 FIGURE 2-21 continued Grove 2-43 Published 11-10-2014, Control # 524-00...
Page 82 HYDRAULIC SYSTEM RT880E SERVICE MANUAL 36 37 12 13 14 15 8 27 3 73923 Valve Hydraulic Schematic FIGURE 2-21 continued Item Description Item Description Cooler Port - Return Swivel Port #4 D2 - Drain Pump P2 Inlet D3 - Drain STR - Front Steer Control valve D4 - Drain STR-R - Steer Relief...
Page 83 RT880E SERVICE MANUAL HYDRAULIC SYSTEM Item Description Item Description SB - Swing Brake LS-B - Hose Reel Brake Load Sense Drain - Front Steer Control Valve LS - Load Sense Hoist/Telescope Lift Direction Valve PA - Swing Pilot LS-Aux - Auxiliary Load Sense PB - Swing Pilot SH3 - Shuttle Valve - Hose Reel/Telescope GP1 - Gauge Port 1 - Steer Inlet Pressure...
Page 84: Steering Control Valve
HYDRAULIC SYSTEM RT880E SERVICE MANUAL STEERING CONTROL VALVE Remove the four mounting bolts and remove the valve from the steering column. Description Installation The load sense steering control unit (see Figure 2-22) Secure the valve to the steering column and secure with controls hydraulic flow to the front steering cylinders.
Page 85: Hydraulic Remote Control Valve
RT880E SERVICE MANUAL HYDRAULIC SYSTEM HYDRAULIC REMOTE CONTROL VALVE Remove the bolts securing the control valve to the armrest. Remove the control valve. Description Armrest Control Valve Installation Single Axis Controller Place the valve on the armrest. Secure the valve to the armrest with the attaching bolts.
Page 86 HYDRAULIC SYSTEM RT880E SERVICE MANUAL Single Axis Controller NOTE: R.H. and L.H. controllers oriented from seated operator. Ports of control lever seen facing aft looking at seat with armrest in up position. 4, 8, 12 7393-2 3, 7, 11 7393-1 5, 9 6, 10 AUX HOIST/...
Page 87 RT880E SERVICE MANUAL HYDRAULIC SYSTEM Dual Axis Controller Left Back Right Forward 6403-7 6403-4 6403-2 Item Description Tank Port Pump Port Tele Out, Hoist Down, Aux Hoist Down Swing Right, Boom Down Tele In, Hoist Up, Aux Hoist Up Swing Left, Boom Up FIGURE 2-24 Grove 2-49...
Page 88 HYDRAULIC SYSTEM RT880E SERVICE MANUAL Telescope Foot Controller 7766-01 7766-02 FIGURE 2-25 Item Description Item Description Telescope In Telescope Out Pressure Port Port To Tank 2-50 Published 11-10-2014, Control # 524-00...
Page 89: Swing Power Brake Valve With Treadle Pedal
RT880E SERVICE MANUAL HYDRAULIC SYSTEM SWING POWER BRAKE VALVE WITH Engage the swing lock. TREADLE PEDAL Install the brake valve and secure in place with the three bolts, flat washers, spring lockwashers, and nuts. Torque Description bolts; refer to Fasteners and Torque Values, page 1-15 for proper torque value.
Page 90: Speed Swing Valve
HYDRAULIC SYSTEM RT880E SERVICE MANUAL 2 SPEED SWING VALVE Swing speed is selected in the cab via the dashboard Swing High/Low Speed Switch. In the deenergized position or LOW Description SPEED switch position, the two solenoid actuated two position two-way valves allow oil to pass across the The 2-speed swing valve (see Figure 2-27) is used to select adjustable flow control to the opposite side of the motor thus the swing motor speed.
Page 91: Tandem Brake Valve With Treadle Pedal
RT880E SERVICE MANUAL HYDRAULIC SYSTEM TANDEM BRAKE VALVE WITH TREADLE The tandem brake valve consists of a tandem valve body, a closed center spool, a treadle pedal, an integral proximity PEDAL switch and a mechanical spring assembly to limit the output pressure to the brake actuators to 1500 psi ±75 (10,342 kPa Description ±517).
Page 92: Dual Accumulator Charge Valve
HYDRAULIC SYSTEM RT880E SERVICE MANUAL DUAL ACCUMULATOR CHARGE VALVE Maintenance Removal Description Tag and disconnect the hydraulic hoses from the valve. The load sensing dual accumulator charging valve is located Cap or plug the lines and ports. on the inside of the left superstructure side plate. The purpose of the valve is to provide pressure regulation to the Remove the three bolts, washers, and lockwashers service brake circuit.
Page 93 RT880E SERVICE MANUAL HYDRAULIC SYSTEM 7752-02 7752-01 These ports plugged Item Description Load Sense Port Tank Port Pressure Port Accumulator Port 1A Accumulator Port 2A Pressure Switch 7752-03 Valve Hydraulic Schematic FIGURE 2-29 Grove 2-55 Published 11-10-2014, Control # 524-00...
Page 94: Hydraulic Accumulator Service Brake
HYDRAULIC SYSTEM RT880E SERVICE MANUAL HYDRAULIC ACCUMULATOR SERVICE Maintenance BRAKE Removal Description With the engine shutdown, deplete the hydraulic pressure in the accumulators by depressing the service The service brake hydraulic accumulators are located on the brake pedal several times. outside of the left superstructure side plate behind the cab.
Page 95: Holding Valves
RT880E SERVICE MANUAL HYDRAULIC SYSTEM HOLDING VALVES Description A bolt-on manifold style holding valve is installed on the boom lift and luffing jib cylinders. A cartridge style holding valve is used on each telescope cylinder installed in the piston side of the cylinder. The counterweight removal cylinders have two cartridge style holding valves installed in rod side of each cylinder.
Page 96: Maintenance
HYDRAULIC SYSTEM RT880E SERVICE MANUAL Removal Unscrew holding valve from its port block or manifold. CAUTION Do not damage the O-rings during installation of the Installation holding valve. If the holding valve turns freely then gets Check the inside of the port block or manifold for any hard to turn, then easy to turn;...
Page 97: Cross Axle Differential Lock Valve
RT880E SERVICE MANUAL HYDRAULIC SYSTEM CROSS AXLE DIFFERENTIAL LOCK VALVE Maintenance Removal Description Tag and disconnect the electrical connector from the The cross axle differential lock valve Figure 2-32 is mounted valve. off the carrier bulkhead plate forward of the engine. The valve is a four-way, two position solenoid valve.
Page 98: Outrigger Control Manifold
HYDRAULIC SYSTEM RT880E SERVICE MANUAL solenoid shifts the spool to open allowing extension or retraction of the outrigger cylinders. Item Description To Front and Rear Axle Maintenance Port T - To Port T Of Park Brake Range Shift Removal Valve Tag and disconnect the electrical connectors or manual control levers.
Page 99 RT880E SERVICE MANUAL HYDRAULIC SYSTEM S80029392-1 S80029392-3 80029392-1 Hydraulic Schematic FIGURE 2-33 Grove 2-61 Published 11-10-2014, Control # 524-00...
Page 100 HYDRAULIC SYSTEM RT880E SERVICE MANUAL Item Description Item Description Pump Port Pressure Reducing Valve PR2 Tank Port Pressure Reducing Valve PR1 RET Port Solenoid Valve SV12 P STAB Port Solenoid Valve SV11 T STAB Port Solenoid Valve SV10 Left Rear Extension Cylinder Port Solenoid Valve SV9 Left Rear jack Cylinder Port Pilot Operated Check Valve POCV...
Page 101: Pilot Operated Check Valve
RT880E SERVICE MANUAL HYDRAULIC SYSTEM PILOT OPERATED CHECK VALVE Lubricate the check valve and O-rings with clean hydraulic oil. Description A pilot operated (PO) check valve is located in each CAUTION outrigger jack cylinder port block. The check valve functions Do not damage the O-rings during installation of the check as a holding valve for the jack cylinder.
Page 102: Axle Lockout, Rear Steer And Oil Cooler Fan Motor Control Manifold
HYDRAULIC SYSTEM RT880E SERVICE MANUAL AXLE LOCKOUT, REAR STEER AND OIL supply and prevents the lockout cylinders from oscillating because oil is trapped in the cylinders. COOLER FAN MOTOR CONTROL MANIFOLD The rear steer is controlled by a three position four-way solenoid actuated directional control valve.
Page 103 RT880E SERVICE MANUAL HYDRAULIC SYSTEM NOTE: Models without axle lockout do not have solenoid SV1 and SV2 installed on the manifold 6371-1 6371-3 FIGURE 2-35 Grove 2-65 Published 11-10-2014, Control # 524-00...
Page 104 HYDRAULIC SYSTEM RT880E SERVICE MANUAL 6371-2 FIGURE 2-35 continued Item Description Item Description P STAB Port - Pressure to jack cylinders Solenoid Valve SV3 - Rear Steer T STAB Port - To Tank Solenoid Valve SV1 - Axle Lockout - Right STEER A Port - Rear Steer Cylinder Solenoid Valve SV2 - Axle Lockout - Left STEER B Port - Rear Steer Cylinder...
Page 105: Check Valves
RT880E SERVICE MANUAL HYDRAULIC SYSTEM CHECK VALVES if the steer cylinder pressure rises above the inlet port pressure. Description Maintenance There are two check valves utilized in the crane hydraulic Removal system. The check valves are used to block flow in one direction and allow free flow in the opposite direction.
Page 106: Range Shift/Parking Brake Valve
HYDRAULIC SYSTEM RT880E SERVICE MANUAL RANGE SHIFT/PARKING BRAKE VALVE Maintenance Description Removal The range shift/parking brake valve Figure 2-36 controls the Tag and disconnect the electrical connectors to the flow of oil to the parking brake, hi-low range and axle valve.
Page 107: Load Sense Dump Valve
RT880E SERVICE MANUAL HYDRAULIC SYSTEM LOAD SENSE DUMP VALVE Installation Secure the valve to the frame rail with the washers, Description spring washers and capscrews. Torque capscrews; refer to Fasteners and Torque Values, page 1-15 for proper The Load Sense Dump Valve prevents Pump No. 1 from torque value.
Page 108 HYDRAULIC SYSTEM RT880E SERVICE MANUAL 7768-01 7768-02 Hydraulic Schematic Item Description LS-PUMP Port - To Pump No. 1 DRAIN Port - To Reservoir LS-IN Port - Load Sense In To Manifold FIGURE 2-37 2-70 Published 11-10-2014, Control # 524-00...
Page 109: Cylinders
It is recommended that all exposed cylinder rods be CAUTION protected using Boeshield® T-9 Premium Metal Protectant. Manitowoc Crane Care has Boeshield® T-9 Premium Metal Ensure pressure is applied to the retract (rod) side of the Protectant available in 12 oz. cans by ordering part number cylinder only and that the extend hose is capped.
Page 110 HYDRAULIC SYSTEM RT880E SERVICE MANUAL Temperature Effects on Hydraulic Cylinders periodically in the extend position to mitigate the effects of cooling oil. Hydraulic oil expands when heated and contracts when If a load and the boom is allowed to remain stationary for a cooled.
Page 111 RT880E SERVICE MANUAL HYDRAULIC SYSTEM Table 2-6Boom Drift Chart (Cylinder length change in millimeters) 0.000774 (1/ °C) Coeff. = STROKE Temperature Change (°C) 5.81 11.61 17.42 23.22 29.03 34.83 40.64 46.44 52.25 58.05 63.86 11.61 23.22 34.83 46.44 58.05 69.66 81.27 92.88 104.49...
Page 112: Lift Cylinder
HYDRAULIC SYSTEM RT880E SERVICE MANUAL LIFT CYLINDER NOTE: Arranging discarded seals and rings in the order of disassembly will aid in installation of new seals and Description rings. Pay attention to how each seal and ring is installed to avoid installing replacement seals and The lift cylinder Figure 2-38 has a bore of 12.0 in (30.48 cm).
Page 113 RT880E SERVICE MANUAL HYDRAULIC SYSTEM 27, 28 26, 27 FIGURE 2-38 7397 Item Description Item Description Barrel Buffer Seal Rod Seal Piston Backup Ring Head Wiper Ring Holding Valve Socket Head Capscrew Retaining Ring Insert Seal Assembly Capscrew T-Seal Flatwasher O-ring Plug Backup Ring...
Page 114 HYDRAULIC SYSTEM RT880E SERVICE MANUAL Item Description Tube Assembly CAUTION Exercise extreme care when handling the rod. Damage to Adapter the rod surface may cause unnecessary maintenance Plug and expense. Also, take care to avoid damaging grooved Elbow or gland surfaces or rings or seals during rod insertion. Cap Assembly 11.
Page 115: Trombone Telescope Cylinder
RT880E SERVICE MANUAL HYDRAULIC SYSTEM TROMBONE TELESCOPE CYLINDER Remove the setscrew and unscrew the piston from the cylinder rod. Description Remove the hydrolock seals and wear rings from the outside of the piston and the O-ring and backup ring The boom trombone telescope cylinder (lower telescope from the inside of the piston.
Page 116 HYDRAULIC SYSTEM RT880E SERVICE MANUAL Inspect the barrel for scoring. Assembly If removed, install the holding valves. Refer to HOLDING VALVES in this section. CAUTION Backup Ring When installing new seals and rings, clean all surfaces Buffer Seal and carefully remove burrs and nicks. Parts displaying Wiper Ring Wear Ring excessive wear or damage should be replaced.
Page 117 RT880E SERVICE MANUAL HYDRAULIC SYSTEM 6649-1 FIGURE 2-43 Item Description Item Description Capscrew Backup Ring Flatwasher Spacer Holding valve Wear Ring Plate Seal Retainer Wear Ring Backup Ring Hydrolock Seal O-ring Setscrew Plug Piston Inner Rod O-ring Backup Ring Grove 2-79 Published 11-10-2014, Control # 524-00...
Page 118 HYDRAULIC SYSTEM RT880E SERVICE MANUAL 115 lb-ft (144 to 156 Nm) in the sequence shown (see Item Description Figure 2-45). O-ring Polyseal Ring Guidelock Ring Wear Ring 7/16 inch capscrew Rod Seal Wear Ring Buffer Seal Backup Ring Rod Seal 5/8 inch Backup Ring capscrew...
Page 119: Upper Telescope Cylinder
RT880E SERVICE MANUAL HYDRAULIC SYSTEM UPPER TELESCOPE CYLINDER the cylinder during rod retraction by a wiper ring in the head and O-ring seals prevent internal and external leakage. The Description retracted length of the telescope cylinder is 399 in (1013.5 cm) and the extended length is 746.5 in (1896.1 cm) from the The upper boom telescope cylinder Figure 2-46 has a 17.7 end of the barrel to the end of the port block on the rod.
Page 120: Maintenance
HYDRAULIC SYSTEM RT880E SERVICE MANUAL Item Description Barrel CAUTION Piston Do not use air pressure to remove the cylinder rod. Use only controlled hydraulic pressure. Setscrew Do not damage the cylinder rod chrome surface. Seal Wear Ring Remove the cylinder rod assembly from the cylinder barrel and cover the barrel to avoid contamination.
Page 121 RT880E SERVICE MANUAL HYDRAULIC SYSTEM Assembly Install the O-ring and backup rings into the inside of the piston. If removed, install the holding valve. Refer to Valves, NOTE: Use a new self-locking soft-tip setscrew. page 2-31. Screw the piston onto cylinder rod and secure with a new setscrew.
Page 122 HYDRAULIC SYSTEM RT880E SERVICE MANUAL 16. Pressurize and cycle the cylinder with hydraulic oil pressure. Test the cylinder at 4500 psi (31026.4 kPa). Check for proper operation and any leakage. Make WARNING repairs as needed. Do not use air pressure to cycle the cylinder. Use only controlled hydraulic pressure.
Page 123: Axle Oscillation Lockout Cylinder
RT880E SERVICE MANUAL HYDRAULIC SYSTEM AXLE OSCILLATION LOCKOUT CYLINDER Using a hoist, extend the rod assembly slowly until the piston is free of the barrel. Description Remove the rod and attached parts from the barrel. The two oscillation lockout cylinders Figure 2-49 each have NOTE: Cover the barrel opening to avoid contamination.
Page 124 HYDRAULIC SYSTEM RT880E SERVICE MANUAL 6731 FIGURE 2-49 Item Description Item Description Barrel Lip Seal Wiper Ring Head Retainer Ring Lip Seal Bleeder Plug Wear Ring Grease Fitting O-ring Grease Fitting Backup Ring Screw Wear Ring O-ring Buffer Seal 2-86 Published 11-10-2014, Control # 524-00...
Page 125 RT880E SERVICE MANUAL HYDRAULIC SYSTEM Stone out minor blemishes and polish with a fine crocus cloth. CAUTION Clean with solvent and dry with compressed air any Exercise extreme care when handling the rod. Damage to parts that have been stoned and polished. the rod surface may cause unnecessary maintenance and expense.
Page 126: Steer Cylinder
HYDRAULIC SYSTEM RT880E SERVICE MANUAL STEER CYLINDER With a hoist, extend rod slowly until the piston is free of the barrel. Description Place the rod assembly on a surface that will not dam- age the chrome or allow the rod assembly to drop. The steer cylinders Figure 2-50 are mounted on the axles, two cylinders on each axle.
Page 127 RT880E SERVICE MANUAL HYDRAULIC SYSTEM 14, 15 7074 FIGURE 2-50 Item Description Item Description Barrel Piston Seal O-ring Head Backup Ring Piston Rod Seal Spacer Wiper O-ring Grease Fitting Wear Ring Grove 2-89 Published 11-10-2014, Control # 524-00...
Page 128 HYDRAULIC SYSTEM RT880E SERVICE MANUAL Assembly CAUTION CAUTION Ensure there are no rags or other contaminants left in the cylinder barrel before installing rod assembly. Lubricate When installing new seals and rings, avoid stretching the barrel ID with hydraulic oil to ease the rod assembly seals or scratching the grooved or gland surfaces.
Page 129: Outrigger Extension Cylinder
RT880E SERVICE MANUAL HYDRAULIC SYSTEM OUTRIGGER EXTENSION CYLINDER Remove the piston, spacer and head from the rod. Remove the O-ring and the backup ring from the outside Description of the head. The four extension cylinders Figure 2-51 have 2.5 in (63.5 Remove the rod seal, wear ring and wiper ring from the mm) diameter bores.
Page 130 HYDRAULIC SYSTEM RT880E SERVICE MANUAL 7073 FIGURE 2-51 Item Description Item Description Barrel O-ring O-ring Piston Backup Ring Head Rod Seal Spacer Wiper Ring Wear Ring Piston Seal Wear Ring 2-92 Published 11-10-2014, Control # 524-00...
Page 131 RT880E SERVICE MANUAL HYDRAULIC SYSTEM Install the replacement piston seal and wear rings on the 11. Push the head into the barrel. outside of the piston. Lubricate all parts freely with clean hydraulic oil. WARNING CAUTION Do not use air pressure to cycle or pressurize the cylinder. Exercise extreme care when handling the rod.
Page 132: Outrigger Jack Cylinder
HYDRAULIC SYSTEM RT880E SERVICE MANUAL OUTRIGGER JACK CYLINDER on a workbench taking care not to damage the surface of the rod. Description Cover the open end of the barrel. The four outrigger jack cylinders Figure 2-52 each have a Secure the rod assembly using the pinholes. Do not use hollow rod for internal porting.
Page 133 RT880E SERVICE MANUAL HYDRAULIC SYSTEM 7389 FIGURE 2-52 Item Description Item Description Barrel Wiper Ring Seal Head Seal Piston Wear Ring Spacer O-ring Check Valve Backup Ring Setscrew Seal Insert O-ring Plug Backup Ring Plug Grove 2-95 Published 11-10-2014, Control # 524-00...
Page 134 HYDRAULIC SYSTEM RT880E SERVICE MANUAL Thoroughly rinse parts, allow to drain, and wipe with a 11. Lubricate the ID of the head seals with clean light oil and lint-free rag. Inspect all parts for serviceability. slide the head onto the rod. The head will need to be tapped on with a rubber mallet to engage the seals.
Page 135: Cab Tilt Cylinder
RT880E SERVICE MANUAL HYDRAULIC SYSTEM CAB TILT CYLINDER CAUTION Description When removing seals and rings, avoid scratching the The cab tilt cylinder Figure 2-53 has a 2.50 in (6.35 cm) grooved and gland surfaces. diameter bore. The retracted length of each cylinder is 20.94 in (53.1 cm) from the center of the rod bushing to the Remove the seal from the outside of the piston.
Page 136 HYDRAULIC SYSTEM RT880E SERVICE MANUAL 6722 FIGURE 2-53 Item Description Item Description Barrel Piston Seal O-ring Head Backup Ring Piston Rod Seal Locknut Wiper O-ring 2-98 Published 11-10-2014, Control # 524-00...
Page 137 RT880E SERVICE MANUAL HYDRAULIC SYSTEM Install the O-ring and backup ring onto the outside of the 10. Remove the cover from the barrel. Insert the rod and head. attached parts into the barrel with a slight twisting motion. Install the O-ring in the inside of the piston. 11.
Page 138: Counterweight Removal Cylinder
HYDRAULIC SYSTEM RT880E SERVICE MANUAL COUNTERWEIGHT REMOVAL CYLINDER the tube. Place the rod assembly on a surface that will not damage the chrome or allow the rod assembly to Description drop. NOTE: Cover the barrel opening to avoid contamination. The counterweight removal cylinder, Figure 2-54, has a 3.50 in (8.89 cm) diameter bore.
Page 139 RT880E SERVICE MANUAL HYDRAULIC SYSTEM 7063 FIGURE 2-54 Barrel O-ring Backup Ring Piston Rod Seal Spacer Wiper Ring Head Counterbalance Valve O-ring Plug Wear Ring O-ring Piston Seal Setscrew Grove 2-101 Published 11-10-2014, Control # 524-00...
Page 140 HYDRAULIC SYSTEM RT880E SERVICE MANUAL Install the other replacement wear ring on the outside of the piston over the setscrew. CAUTION Lubricate all parts freely with clean hydraulic oil. Before installing new seals and rings, clean all surfaces and carefully remove burrs and nicks. Parts displaying excessive wear or damage should be replaced.
Page 141: Counterweight Pin Cylinder
RT880E SERVICE MANUAL HYDRAULIC SYSTEM COUNTERWEIGHT PIN CYLINDER Remove the head and spacer from the rod. Remove the O-ring and the backup ring from the outside Description of the head. Remove the seal and wiper ring from the inside of the head. The counterweight pin removal cylinder Figure 2-55 has a bore of 3.0 in (7.62 cm).
Page 142 HYDRAULIC SYSTEM RT880E SERVICE MANUAL 7062 FIGURE 2-55 Barrel Piston Seal Wear Ring Rod End O-ring Piston Backup Ring Spacer Rod Seal Head Wiper Ring O-ring O-ring 2-104 Published 11-10-2014, Control # 524-00...
Page 143 RT880E SERVICE MANUAL HYDRAULIC SYSTEM Install the replacement seal and wiper ring in the inside 10. Remove the cover from the barrel. Insert the rod and of the head. attached parts into the barrel with a slight twisting motion. Install the replacement O-rings and the backup ring on the outside of the head.
Page 144: Axle Oscillation Lockout Cylinder (Ce Option)
HYDRAULIC SYSTEM RT880E SERVICE MANUAL AXLE OSCILLATION LOCKOUT CYLINDER NOTE: Cover the barrel opening to avoid contamination. (CE OPTION) CAUTION Description When removing seals and rings, avoid scratching the The lockout cylinders Figure 2-56 have 5 in (12.7 cm) grooved and gland surfaces. diameter bores.
Page 145 RT880E SERVICE MANUAL HYDRAULIC SYSTEM 7097 FIGURE 2-56 Clean with solvent and dry with compressed air any parts that have been stoned and polished. Item Description Assembly Barrel CAUTION Hydrolock Seal When installing new seals and rings, avoid stretching Guidelock Ring seals or scratching the grooved or gland surfaces.
Page 146: Park Brake Cylinder
HYDRAULIC SYSTEM RT880E SERVICE MANUAL Slide the head, onto the rod. Tap the head with a rubber mallet to engage the seals. Push the head about half CAUTION way down the length of the rod assembly. Do not use air pressure to cycle or pressurize the cylinder. Remove the cover from the barrel.
Page 147: Description
RT880E SERVICE MANUAL ELECTRIC SYSTEM SECTION 3 ELECTRIC SYSTEM SECTION CONTENTS Description ....... 3-1 Gauge Cluster Replacement .
Page 148 ELECTRIC SYSTEM RT880E SERVICE MANUAL FIGURE 3-1 Published 11-10-2014, Control # 524-00...
Page 149: Alternator
RT880E SERVICE MANUAL ELECTRIC SYSTEM Alternator The alternator (Figure 3-2) is mounted on the engine and is belt driven. It is a 145 ampere alternator with an integral transformer - rectifier unit. When the engine is running, and the alternator is turning, the alternator’s 12-volt output terminal supplies the crane’s electrical circuits.
Page 150 ELECTRIC SYSTEM RT880E SERVICE MANUAL 7892 7693-6 FIGURE 3-4 7693-8 Figure 3-4 Item Numbers Item Component Item Component Electrical Panel Diode Box RCL Controller Fuse Box (see Figure 3-5) ACC Relay, Cab Modules & T/T Modules Power Panel Screw ACC Relay, Jib Stow, RCL, Jib Option Fast Pulse Buzzer Alarm Relay, Windshield Wiper Low Speed RCL Override Switch...
Page 151 RT880E SERVICE MANUAL ELECTRIC SYSTEM The following fuse assignments apply: Item Component • Fuse 1 - Ignition Power in circuit Connector Bulkhead Cab Interior Harness • Fuse 2 - Steering Column Power circuit Swivel Harness • Fuse 3 - Dome Light and Working Lights Seat Harness •...
Page 152: Carrier Electrical Panel
ELECTRIC SYSTEM RT880E SERVICE MANUAL Carrier Electrical Panel equipped with a Tier 4 engine, the starter lockout signal from engine ECM must be present. The carrier electrical panel contains the battery disconnect The coil of the grid heater relay (8) (Figure 3-6) is energized switch, main power relay, and fuses that control power to the when the batteries are connected, the ignition switch is in the crane’s entire electrical system.
Page 153: Maintenance
RT880E SERVICE MANUAL ELECTRIC SYSTEM Figure 3-6 Item Numbers Fuse Block 2 (Figure 3-6) Item Description Number Description Battery Disconnect Switch 15 Amp, KC6 DEF Lines Heater Fuse Block 1 (See Table) 5 Amp, KC6 Relay Fuse Panel Assembly 10 Amp, KC7 DEF Supply Battery Box Module 250 Amp Fuse, Grid Heater...
Page 154 , l o n g t e r m e x p o s u r e t o t h e s e c o l d harness assemblies, refer to your Manitowoc Crane Care temperatures will negatively impact service life.
Page 155: General Troubleshooting
RT880E SERVICE MANUAL ELECTRIC SYSTEM General Troubleshooting and slip rings, worn brushes, improper spring tension on the brush assembly, and loose setscrews on the slip ring NOTE: Make voltage checks at terminations when compo- assembly. Refer to the electrical schematic and wiring nents are installed and operating.
Page 156 ELECTRIC SYSTEM RT880E SERVICE MANUAL Table 3-2 AMP Extraction Tool Table Description AMP Part Number Manitowoc Part Number 14 gauge wire (connectors) 305183 9999100176 12 to 8 gauge wire (connectors) 91019-3 9999100175 4 to 9 circuit (in-line connectors) 453300-1 15 circuit (in-line connectors)
Page 157: Alternator/Charging System Troubleshooting
RT880E SERVICE MANUAL ELECTRIC SYSTEM Alternator/Charging System following load test. If the voltage is lower than 12.4 V, recharge the battery(s) before performing the load test. Troubleshooting Load Test Anytime there is a problem with the charging system the batteries, alternator and cables should be tested. Refer to the load tester manual for instructions on per- forming the load test.
Page 158: Alternator Replacement
ELECTRIC SYSTEM RT880E SERVICE MANUAL NOTE: If the correct readings were not obtained in the Remove the alternator mounting capscrews. Remove Engine On Tests, perform the following two tests. the alternator. Installation Voltage Drop Test Inspect the belt. Verify it has no cracks or other damage. Positive Side Replace damaged belt as needed.
Page 159: Battery Replacement
RT880E SERVICE MANUAL ELECTRIC SYSTEM Remove the bolts holding the starter to the mounting Ensure that the key switch has been off for 2 minutes. pad. Remove the starter. Turn the battery disconnect switch to the OFF position. Installation Remove the ECM power fuse. Place the starter on its mounting pad.
Page 160: Gauge Cluster Replacement
ELECTRIC SYSTEM RT880E SERVICE MANUAL Buzzer Replacement 12. Disconnect the wire harness from the bottom of the gauge cluster (5). Working behind the operator’s seat, remove the hard- 13. Remove the gauge cluster (5) from the gauge/switch ware securing the panel cover and remove the cover. cover (6) by pushing in on the left and right sides of the Tag and disconnect the electrical leads from the buzzer.
Page 161: Ignition Switch Replacement
RT880E SERVICE MANUAL ELECTRIC SYSTEM Remove the lever (12) and spacer that locks/unlocks the Install the right side cover (9) on the steering column. steering column tilt/telescope function. Connect the wire harness to the ignition switch (10). Remove the four screws (13) securing the left and right Install the left side cover (8) on the steering column.
Page 162: Turn Signal Lever And Transmission Shift Lever Replacement
ELECTRIC SYSTEM RT880E SERVICE MANUAL Inspection Removal Visually check the ignition switch for evidence of cracks, Turn the ignition switch to the OFF position and remove damaged connections, or other damage. Replace dam- the ignition key. aged ignition switch as needed. Wait two minutes.
Page 163 RT880E SERVICE MANUAL ELECTRIC SYSTEM Connect the wire harness to the bottom of the gauge 13. Install the steering wheel cap (1). cluster (5). 14. Install the lever (12) and spacer that locks/unlocks the Install the wire harnesses on the switches (4) as tagged steering column tilt/telescope function.
Page 164 ELECTRIC SYSTEM RT880E SERVICE MANUAL 7794-1 FIGURE 3-8 3-18 Published 11-10-2014, Control # 524-00...
Page 165: Windshield Wiper Assembly Replacement
RT880E SERVICE MANUAL ELECTRIC SYSTEM Windshield Wiper Assembly Replacement Installation Removal Verify the pivot shaft and the wiper motor kit link and crank are in place on the motor bracket. (Washers and Turn the ignition switch to the OFF position. clip springs fasten the link to the pivot pins on the crank and the pivot shaft.
Page 166: Windshield Washer Assembly Replacement
ELECTRIC SYSTEM RT880E SERVICE MANUAL Connect the wiper arm’s washer hose to the washer Check nozzle fitting assembly. Squirt some cleaning fluid onto the windshield with the Connect the electrical leads to the wiper motor as windshield washer. marked before removal. Make repairs if windshield washer doesn’t work.
Page 167: Troubleshooting
(Part No. 80026376). accordance with the procedures as provided by Manitowoc. Manitowoc Crane Care requests you have, as part of your Therefore, always ensure adequate lubrication during service tool kit inventory, the CAN-Link service tool kit for the system warm-up and proper operation of all crane functions RT880E4.
Page 168 If the heater remains faulty even after these points have system is de-activated. The shutdown cycle may take been checked, or another malfunction occurs in your approximately 2 minutes. heater, contact an authorized Manitowoc distributor or NOTE: Accelerated discharging of battery will occur when Manitowoc Crane Care.
Page 169: Section 4
RT880E SERVICE MANUAL BOOM SECTION 4 BOOM SECTION CONTENTS Description ....... 4-1 Inspection .
Page 170: Boom Retraction
BOOM RT880E SERVICE MANUAL boom section and the barrel is secured to the outer mid Remove the hook block or headache ball and wind all boom section by a trunnion. The extension cables are the wire rope onto the hoist drum. secured to the back of the fly section and run around Position the boom to make sure that the lift cylinder is extension sheaves on the cylinder mounted fly sheave...
Page 171 RT880E SERVICE MANUAL BOOM NOTE: The boom assembly must be rotated 180° (upside 14. Lift up on the front of the inner mid and remove the bot- down) before performing any assembly or disas- tom and side wear pads and shims from the base sec- sembly procedures.
Page 172 BOOM RT880E SERVICE MANUAL 31. Remove the capscrews and washers securing the bot- adjusting plate to top of base section. Remove two tom rear wear pad to the inner mid and remove the wear adjusting plates. Remove upper wear pad assembly. If pad and spacer.
Page 173 RT880E SERVICE MANUAL BOOM 43, 44 41, 42 41, 42 38, 39 41, 42 41, 42 35 33 53 52 38, 39 45, 46, 47 43, 44 7081-3 View A See View B See View C 14, 15, 16 7081-1 9, 10, 11, 12, 13 18, 19, 20, 21 24, 14, 15, 16, 17...
Page 174 BOOM RT880E SERVICE MANUAL Item Description Item Description Base Section Shim Inner Mid Section Lower Wear Pad Outer Mid Section Front Upper Pad Nose To Fly Section Top Front Pad Support Retract Cables Capscrew Cable Retainer Pin Flatwasher Sheave Assembly Capscrew Anti-Two Block Plate Cable Pad...
Page 175 RT880E SERVICE MANUAL BOOM See View C See View D 6471-3 See View B 78, 79 80, 81, 82 73, 74, 75 70, 71 63, 64 60, 61 58, 59 View B 6471-2 FIGURE 4-1 continued Grove Published 11-10-2014, Control # 524-00...
Page 176 BOOM RT880E SERVICE MANUAL Item Description Item Description Cable Retainer Hex Nut Capscrew Retract Cable Washer Cotter Pin Capscrew Washer Washer Pin Cylinder Mount Plate Bolt Capscrew Cylinder Support Washer Capscrew Sheave Assembly Washer Extend Cables Plate Cover Upper Telescope Cylinder Capscrew Lower Telescope Cylinder Washer...
Page 177 RT880E SERVICE MANUAL BOOM 110, 111 94, 95, 96, 97 94, 95, 96, 97 84, 85 101, 102, 103 98, 99, 100 102, 103 102, 103 6471-4 98, 99, 100 105, 106 FIGURE 4-1 continued View D Item Description Item Description Cam Operating Plate Grease Fitting...
Page 178: Boom Nose Sheaves
BOOM RT880E SERVICE MANUAL 53. Remove the shaft from the lower telescope cylinder. Item Description 54. Using an adequate lifting device, remove the upper cyl- Sheave Mount inder from the lower cylinder. Boom Pivot 55. On the front of the fly section, remove the nut and washer from the end of each retract cable and remove the retract cables from the fly section.
Page 179: Boom Assembly
RT880E SERVICE MANUAL BOOM Installation NOTE: Apply multipurpose grease (MPG) to all wear sur- faces. NOTE: Use standard Grade 5 and/or 8 torque values spec- CAUTION ified in Section 1 of this Manual unless otherwise Do not install the boom nose sheaves over the threaded specified.
Page 180 BOOM RT880E SERVICE MANUAL 25. Slide the telescope cylinder assembly all the way in. Place blocking under the rear of the telescope cylinders to aid in assembly. DANGER 26. Place the mounting plates on the upper telescope cylin- Ensure the telescope cylinders are securely blocked and der barrel mounting lugs.
Page 181 RT880E SERVICE MANUAL BOOM 40. Remove the retract cable sheave mounts from the fly 54. Align upper cylinder rod trunnion mounting plates holes section and attach them to the rear of the outer mid with with holes in inner mid. Secure with the capscrews and capscrews and washers.
Page 182: Installation
BOOM RT880E SERVICE MANUAL Torque Values, page 1-15 for proper torque value. The boom may need to be raised or lowered to aid in the installation of the pivot shaft. Install pivot shaft. 69. Connect hydraulic tubes to the lower cylinder as tagged during disassembly.
Page 183: Inspection
RT880E SERVICE MANUAL BOOM Ensure all electrical components disconnected during inner mid is fully extended, the valve on the right side of the removal are operating properly. boom is held open to supply flow to the lower telescope cylinder. When the inner mid is fully extended, the valve on Inspection the left side of the boom opens to supply flow to the upper telescope cylinder.
Page 184: Boom Extension And Retraction Cable
Manitowoc recommends that for cable extended booms, a single damaged wire rope assembly shall require Retract the boom approximately 1 in (25 mm) to relieve replacement of the entire set of extension cables.
Page 185 RT880E SERVICE MANUAL BOOM If stop block on the fly cannot be properly adjusted with- cables and return to step 4. In step 5, adjust the exten- out excessive thread 4.5 in (32 mm) protruding out from sion cable to 5 in (127 mm) and continue with procedure. the jam nuts, backoff the nuts on the retract cables 1 in NOTE: If grease fittings are not fully accessible at full...
Page 186: Telescope Circuit
BOOM RT880E SERVICE MANUAL TELESCOPE CIRCUIT A holding valve is threaded into a port block on the rod end of the upper telescope cylinder. The holding valve for the Description second stage of the lower telescope cylinder is mounted into the port block on the barrel end of the second stage barrel.
Page 187 Repair or replace relief valve. Excessive load. Reduce load. d. Clogged hose and fittings. d. Replace hose or fittings. (Refer to Manitowoc Crane Care Parts Manual). Broken valve spool. Replace valve. Damaged piston seals. Replace all cylinder seals. g. Damaged piston(s).
Page 188 Reduce load. (Refer to load chart). d. Inoperative check valve. d. Replace check valve. Clogged hose and fittings. Replace hose or fittings. (Refer to Manitowoc Crane Care Parts Manual). Broken valve spool. Replace valve section. g. Broken piston(s). g. Replace piston(s) and all cylinder seals.
Page 189: Lift Circuit
RT880E SERVICE MANUAL BOOM LIFT CIRCUIT The holding valve is a balanced poppet type hydraulic valve. It is threaded into the port block which is an integral portion of Description the lift cylinder barrel. The holding valve functions when booming up (cylinder rod extended), booming down (cylinder The boom lift circuit consists of the lift hydraulic remote rod retracted), or holding (cylinder rod stationary).
Page 190 Operate unit to bring oil to operating temperature. Improper hose or fittings, installed. Replace hose or fittings. (Refer to Manitowoc Crane Care Parts Manual). Operating two functions with in the Feather controls to obtain desired same control valve bank assembly.
Page 191 RT880E SERVICE MANUAL BOOM Symptom Probable Cause Solution Boom will not Low hydraulic oil. Replenish hydraulic oil to proper level. lower. b. Main relief valve or circuit relief valve b. Repair or replace relief valve. damaged. Worn or damaged hydraulic pump Repair or replace pump section.
Page 192 BOOM RT880E SERVICE MANUAL Item Description Lift Cylinder Shaft Bolt Boom Pivot Shaft Attach Point Capscrew Washer 6455-1 5, 6, 7 6454-2 3, 4 Cutaway Shown For Clarity Lift Cylinder Installation FIGURE 4-2 4-24 Published 11-10-2014, Control # 524-00...
Page 193: Auxiliary Boom Nose
RT880E SERVICE MANUAL BOOM AUXILIARY BOOM NOSE cable usage. The rooster sheave is installed on the main boom nose and is secured by attach pins that pass through Description the rooster sheave and the main boom nose. The auxiliary boom nose (rooster sheave) (see Figure 4-3) is used on the boom to simplify single part and maximum part Item Description...
Page 194 BOOM RT880E SERVICE MANUAL you are changing directly from the 56 ft (17.1 m) bi- fold swingaway extension to a boom insert. 4-26 Published 11-10-2014, Control # 524-00...
Page 195 RT880E SERVICE MANUAL BOOM 6510-3 6510-7 6510-8 6916-1 Item Description Item Description Stinger Bumper Pad Front Mount Holding Plate Upper Hangar Boom Extension Lower Support Rear Hangar Carrier Bracket FIGURE 4-5 Grove 4-27 Published 11-10-2014, Control # 524-00...
Page 196: Checking The Transport Condition
BOOM RT880E SERVICE MANUAL Checking the Transport Condition The pins (4) are inserted on the pivot point between the 23 ft (7 m) section and the 33 ft (10.1 m) section For transportation you must establish certain connections (Figure 4-5). between both parts of the lattice extension.
Page 197: Hook Block
For hook blocks and other load handling devices not block utilizes a one-piece pivot block and the hook is manufactured by Manitowoc Cranes, Inc.; follow the equipped with a safety latch. The hook block is the quick manufacturer’s inspection and testing recommendations to reeve design.
Page 198 BOOM RT880E SERVICE MANUAL 4-30 Published 11-10-2014, Control # 524-00...
Page 199: Description
RT880E SERVICE MANUAL HOISTS AND COUNTERWEIGHT SECTION 5 HOISTS AND COUNTERWEIGHT SECTION CONTENTS Description ....... 5-1 Description.
Page 200: Maintenance
It is extremely important that maintenance Manitowoc Crane Care offers prepackaged kits that include personnel recognize that deterioration of critical internal all the seals, bearings, fasteners, washers, brake disks, components within the hoist reduction unit can occur.
Page 201: Installation
RT880E SERVICE MANUAL HOISTS AND COUNTERWEIGHT Item Description Main Hoist Auxiliary Hoist Counterweight Cylinder Cable Follower Idler Drum Shims Capscrew 6, 7, 8, 9 Washer Counterweight Counterweight Cylinder Pin 6319-1 FIGURE 5-1 Remove the hoist mounting nuts, capscrews, washers, With the hoist level, check to determine if all the hoist and shims (if shims are used, mark their location).
Page 202: Functional Check
HOISTS AND COUNTERWEIGHT RT880E SERVICE MANUAL Functional Check The oil level should be visible in the sight glass (3). Compare your reading with Table 5-1 below and take the Attach a test weight to the hook and raise and lower the required action.
Page 203: Hoist To Boom Alignment
RT880E SERVICE MANUAL HOISTS AND COUNTERWEIGHT HOIST TO BOOM ALIGNMENT The hoist must be checked in two directions, one at 0 degree and the other is above 45 degrees boom angle on any crane Preparation that the hoist is not mounted directly to the boom, stationary mounted.
Page 204: Piston Motor And Control Valve
HOISTS AND COUNTERWEIGHT RT880E SERVICE MANUAL All the cable must be removed from the hoist drum to The motor control valve is bolted to the motor. check the fleet angle. Using mason cord or cat gut fish- Maintenance ing line you will be able to pull the line tight to make an accurate measurement of the fleet angle.
Page 205: Maintenance
RT880E SERVICE MANUAL HOISTS AND COUNTERWEIGHT Maintenance Cleaning and Inspection Idler Drum Clean all grease from the shaft, bearing, and roller. Check the shaft, roller, and bearings for cracks, scoring, Removal and Disassembly or grooving. Replace if necessary. Remove the bolt, washer, and lockwasher from the right Check the spring tension.
Page 206 HOISTS AND COUNTERWEIGHT RT880E SERVICE MANUAL Complete Assembly If necessary to completely disassemble or remove any part of the assembly, refer to the applicable paragraphs Removal in this Sub-section. Remove all tension from the springs on each side by Installation loosening the nuts and jam nuts.
Page 207: Hoist Drum Rotation Indicator System
Manitowoc Crane Care to those ser- and at what speed the hoist drum is rotating, even under the vice technicians who have attended the Grove New most distracting conditions.
Page 208 HOISTS AND COUNTERWEIGHT RT880E SERVICE MANUAL 7792-2 Drum Rotation Sensor 7792-3 Button Control Lever Thumb Thumper Handle Rotation Indicator Solenoid Single Axis Controller FIGURE 5-6 5-10 Published 11-10-2014, Control # 524-00...
Page 209: Counterweight Removal
RT880E SERVICE MANUAL HOISTS AND COUNTERWEIGHT COUNTERWEIGHT REMOVAL Removal of Standard Counterweight and DANGER Auxiliary Hoist Assemble the counterweight and auxiliary hoist structure Position the crane on a firm, level surface. Fully extend on the ground or on a suitable transport vehicle. Do not and set the outriggers.
Page 210: Hoist
HOISTS AND COUNTERWEIGHT RT880E SERVICE MANUAL 10, 11, 12 6, 7 Item Description Item Description Counterweight Ball Detent Pin Counterweight Cylinder Assembly Shim Capscrew Cylinder Support Pin Removal Cylinder Washer Capscrew Washer Hoist Superstructure Weldment Capscrew FIGURE 5-7 5-12 Published 11-10-2014, Control # 524-00...
Page 211: Installation Of Counterweight Without Auxiliary Hoist
RT880E SERVICE MANUAL HOISTS AND COUNTERWEIGHT Ensure that the counterweight removal cylinder support Properly attach the slings to the counterweight lifting pins are securely attaching the counterweight to the holes and use a crane to carefully transfer the counter- turntable wing/support brackets. Disengage the counter- weight to the frame counterweight supports over the rear weight mounting pins using the pinning control lever outrigger box.
Page 212 HOISTS AND COUNTERWEIGHT RT880E SERVICE MANUAL 8, 9, 10, 11 6, 7 FIGURE 5-8 Item Description Item Description Counterweight Washer Counterweight Pin Cylinder Capscrew Counterweight Removal Cylinder Flatwasher Cylinder Support Weld Lockwasher Ball Detent Pin Hex Nut Screw IPO Counterweight 5-14 Published 11-10-2014, Control # 524-00...
Page 213: Third Wrap Indicator (Optional-Standard On Ce)
RT880E SERVICE MANUAL HOISTS AND COUNTERWEIGHT THIRD WRAP INDICATOR (OPTIONAL— illuminating when down to the third wrap, a lockout valve is actuated to stop hoist down operation. STANDARD ON CE) Maintenance Description The third wrap indicator switch mechanism must be adjusted The third wrap indicator (Figure 5-9) is installed to give the such that only when the hoist has three wraps of cable operator an indication that the wire rope is down to the last...
Page 214 HOISTS AND COUNTERWEIGHT RT880E SERVICE MANUAL 5-16 Published 11-10-2014, Control # 524-00...
Page 215: Section 6
RT880E SERVICE MANUAL SWING SYSTEM SECTION 6 SWING SYSTEM SECTION CONTENTS Introduction....... 6-1 Maintenance .
Page 216 SWING SYSTEM RT880E SERVICE MANUAL Regulated flow from the pressure reducing/sequence valve for the activation of the swing brake when the pedal is is also provided to the power brake valve where it is available depressed. 6493-1 FIGURE 6-1 Item Description Item Description...
Page 217: Maintenance
RT880E SERVICE MANUAL SWING SYSTEM Maintenance Troubleshooting Symptom Probable Cause Solution Boom swing opera- Damaged relief valve. Replace relief valve. tion erratic in either b. Swing brake dragging (not releasing b. Readjust and/or replace necessary direction. properly). parts. Low engine rpm. Increase engine rpm to obtain smooth swing operation.
Page 218 SWING SYSTEM RT880E SERVICE MANUAL Symptom Probable Cause Solution Boom will not swing Damaged relief valve. Remove, clean, and repair or replace in either direction. relief valve. b. Damaged swing motor. b. Repair or replace swing motor. Swing brake not releasing properly. Repair as necessary.
Page 219 RT880E SERVICE MANUAL SWING SYSTEM Symptom Probable Cause Solution Swing brake opera- Improper brake adjustment. Adjust brake. tion erratic. b. Air in swing brake system. b. Bleed brake system. Brake pedal not fully retracted. Check brake pedal return spring; repair or replace spring.
Page 220: Swing Motor
SWING SYSTEM RT880E SERVICE MANUAL SWING MOTOR Test Test swing of superstructure in each direction. Stop and Description start swing several times. The swing motor is mounted on the swing brake housing and Inspect for hydraulic leaks and repair as necessary. drives the swing gearbox through the brake assembly.
Page 221 RT880E SERVICE MANUAL SWING SYSTEM Installation Installation Install a new O-ring onto the brake housing. If removed, install the swing brake according to the installation procedures found under Swing Gearbox and Place motor support plate on brake housing. Brake, page 6-6. Apply Loctite 270 to socket capscrews.
Page 222: Swing Bearing
SWING SYSTEM RT880E SERVICE MANUAL provides the only attachment between the superstructure and carrier. Therefore, proper care of the bearing and periodic maintenance of the turntable-to-bearing attach bolts Dipstick Oil -IS A MUST -to ensure safe and efficient operation. Level Breather Oil Torquing Turntable Bolts Fill...
Page 223 RT880E SERVICE MANUAL SWING SYSTEM turntable bolts must be inspected for looseness and 52, 34, and 70; refer to Fasteners and Torque Values, retorqued to specifications. page 1-15 for proper torque value. Tools used are the socket, multiplier, backlash adapter, necessary exten- The inner race of the bearing is secured to the turntable by sions, and torque wrench.
Page 224 SWING SYSTEM RT880E SERVICE MANUAL 6633 Quantity Required Description Manitowoc Part Number Orders for special tools 1. M24 Socket 3/4” Drive 9-999-101798 shall be referred to: 2. 4 to 1 Torque Multiplier (1/2” Input 3/4” Output) 9-999-100134 Manitowoc Crane Care 3.
Page 225 RT880E SERVICE MANUAL SWING SYSTEM NOTE: The swivel assembly will be removed with the turn- NOTE: bearing weighs approximately 1550 lb table. (703 kg). Ensure the bearing lifting device is capa- ble of supporting the weight. 16. Place an adequate lifting device under the bearing and remove the 72 bolts and washers securing the turntable DANGER bearing to the superstructure.
Page 226: Swivels
SWING SYSTEM RT880E SERVICE MANUAL NOTE: The counterweight/auxiliary hoist and structure weighs approximately 24,398 lb (11067 kg). Maximum Eccentricity Point Pinion 11. Install the counterweight and auxiliary hoist following procedures outlined in Installation of Standard Counter- weight and Auxiliary Hoist Mounting Structure, page 5- 12.
Page 227 RT880E SERVICE MANUAL SWING SYSTEM Item Description Nut and Washer Electric Swivel Capscrew and Washer Spacer Bushing Frame Mounting Lugs Hex Head Screw and Jam Retainer Plate Hydraulic Swivel Mounting Bolts Water and Hydraulic Case Turntable Base Plate Carrier Top Plate Bolt and Bolt Retainer Plate Tubing Clamp, Bolt,...
Page 228: Hydraulic Swivel
SWING SYSTEM RT880E SERVICE MANUAL Hydraulic Swivel Description Each of the ports on the spool and case of the swivel is stamped with the port number. The function of each port is described below. Standard Working Pressure Port # Function psi (kPa) 2901 (20000) Brake - Front...
Page 229: Two Port Water Swivel
RT880E SERVICE MANUAL SWING SYSTEM NOTE: The hydraulic swivel weighs approximately 213 lb Connect the hydraulic lines and water lines to the spool (97 kg). The hydraulic, water, and electrical swivel of the hydraulic swivel as tagged during removal. combined weigh approximately 239 lb (108 kg). Connect the hydraulic lines to the hydraulic swivel case On the bottom of the swivel, bend the retainer tabs away as tagged during removal.
Page 230: Electrical Swivel
SWING SYSTEM RT880E SERVICE MANUAL Remove the four bolts and washers securing the water Installation swivel and electrical swivel center post to the hydraulic Install the water swivel on top of the hydraulic swivel. swivel. Remove the water swivel case and center post. Secure the water swivel and the electrical swivel center Disassembly post with the capscrews and washers.
Page 231 RT880E SERVICE MANUAL SWING SYSTEM Disconnect the batteries. (Refer to Batteries, page 3-3.) Apply medium strength Loctite® to the setscrews secur- ing the electrical swivel to the center post and tighten Locate the connectors which join the collector ring har- them 44 to 53 lb-in (5 to 6 Nm).
Page 232 SWING SYSTEM RT880E SERVICE MANUAL Disengage the house lock pin and swing the superstruc- ture approximately 10 degrees to the right (clockwise). CAUTION Slowly swing back to the left and engage the house lock pin. It is imperative that the slew potentiometer be adjusted anytime work is done to the electrical swivel.
Page 233: Section 7
RT880E SERVICE MANUAL POWER TRAIN SECTION 7 POWER TRAIN SECTION CONTENTS Engine ........7-1 Diesel Exhaust Fluid (DEF) System .
Page 234: Maintenance
POWER TRAIN RT880E SERVICE MANUAL before extinguishing the Wait-to-Start Lamp. Once the 15. With the lifting device supporting the weight of the engine is started, the electric air heating element will be engine, remove the four sets of bolts, washers, and nuts energized again for a time period determined by intake air securing the front of the engine to the frame.
Page 235 RT880E SERVICE MANUAL POWER TRAIN Attach the fuel filter and engine lubrication filter to the Engine Drive Belt frame. Connect the battery cables and engine electrical The proper operation of engine belt-driven components such harness connector in accordance with the identification as the alternator, fan, and water pump depend on the proper marks made during removal.
Page 236: Electronic Control System
POWER TRAIN RT880E SERVICE MANUAL ELECTRONIC CONTROL SYSTEM Diagnostic function — With the Ignition Switch in the RUN position, the engine off, and the top of the Engine Diagnostic/ The engine control system is an electronically operated fuel Speed Control Switch pressed, press the top or bottom of the control system that also provides many operator and vehicle Increment/Decrement Switch to toggle forward and features, as well as, reducing emissions while optimizing...
Page 237 RT880E SERVICE MANUAL POWER TRAIN In addition to alerting the operator of system faults, the If even more clogging occurs, the engine warning light (14) Engine Warning Light, in conjunction with the Engine Stop will illuminate in addition to the indicator (15) and severe Light, is used in the diagnostic operation of the engine engine derate will occur.
Page 238 POWER TRAIN RT880E SERVICE MANUAL To manually clean, set the crane parking brake, the crane Inhibit Exhaust System Cleaning Indicator transmission must be in neutral and have all pedals The Inhibit Exhaust System Cleaning Indicator is located in released. Refer to Exhaust System Cleaning Indicator, the steering column gauge display.
Page 239: Fuel System
RT880E SERVICE MANUAL POWER TRAIN FUEL SYSTEM Fuel Tank The fuel tank (Figure 7-2) is a steel cylinder-type tank Description located on the left side of the machine. The fuel tank has a draw capacity of 74 gal (280 l). A connection on the bottom The fuel system consists of the fuel tank, fuel-water of the tank provides for fuel supply to the engine.
Page 240: Maintenance
POWER TRAIN RT880E SERVICE MANUAL Injection Fuel Pump Installation The fuel is finely atomized as it is injected into the cylinder Position the new tank on the mounting brackets and and ignited by the heat of compression. It is metered during install the capscrews and washers on the two straps.
Page 241: Air Intake
RT880E SERVICE MANUAL POWER TRAIN The Air Cleaner (Figure 7-3) is the dry-type with a places a recommended limit on the amount of restriction the replaceable element and is located on the right rear fender. engine will stand without loss in performance before the An Air Intake Restriction Monitor (AIRM) system is designed element must be cleaned or replaced.
Page 242 POWER TRAIN RT880E SERVICE MANUAL Detail A See Detail A B - B 7693-13 FIGURE 7-3 Air Intake Installation - Typical 7-10 Published 11-10-2014, Control # 524-00...
Page 243 RT880E SERVICE MANUAL POWER TRAIN Figure 7-4 Item Numbers Item Description Air Cleaner Service Indicator* Nylon Tube* Clamp T-Bolt 6.25-6.66 Elbow, Reducing 6” - 5” Clamp 5.75” Clamp Hardware Intake Tube Support Intake Bracket Intake Tube Elbow 5” - 4” Muffler Clamp 4”...
Page 244 POWER TRAIN RT880E SERVICE MANUAL Precleaner The precleaner (1) (Figure 7-5) prevents large debris from entering the air cleaner and should be cleaned periodically, especially when working in severe dust conditions. Remove the top half of the precleaner by releasing the two latches on the sides of the precleaner.
Page 245: Charge-Air Cooler System
RT880E SERVICE MANUAL POWER TRAIN Charge-Air Cooler System The charge-air cooler (CAC) (Figure 7-7) is used to cool engine air after it has passed through a turbocharger, but before it enters the engine. The charge-air cooler provides better horsepower, increased fuel efficiency, and reduces engine emissions.
Page 246: Exhaust System
POWER TRAIN RT880E SERVICE MANUAL Exhaust System Remove clamp to free muffler from exhaust tube. Remove mounting bands to free muffler from muffler Tier 3 mounting bracket. The Tier 3 exhaust system (Figure 7-8) is made of tubing, Inspect muffler, exhaust tailpipe, exhaust tubes, bracket, elbows, and a muffler.
Page 247 RT880E SERVICE MANUAL POWER TRAIN Tier 4 Loosen the V-band clamps to remove the exhaust tube and flex hose. The Tier 4 exhaust system (Figure 7-9) is made of a diesel If necessary loosen the V-band clamp and remove the oxidation catalyst (DOC), decomposition reactor tube, a exhaust tube from the turbocharger.
Page 248 POWER TRAIN RT880E SERVICE MANUAL FIGURE 7-9 Tier 4 Exhaust System Item Description Item Description Insulation Tail Pipe Exhaust Tube V-Band Clamp V-Band Clamp Elbow Flex Hose V-Band Clamp V-Band Clamp Decomposition Reactor Tube Exhaust Tube Elbow Insulation Diesel Oxidation Catalyst (DOC) Selective Catalytic Reduction (SCR) unit Mounting Band Muffler Clamp...
Page 249: Diesel Exhaust Fluid (Def) System
RT880E SERVICE MANUAL POWER TRAIN Diesel Exhaust Fluid (DEF) System Diesel Exhaust Fluid (DEF) is an emissions control liquid required by modern diesel engines. It is injected into the exhaust stream. DEF is never added to diesel fuel. It is a non-hazardous solution of 32.5% urea in 67.5% de-ionized water.
Page 250 POWER TRAIN RT880E SERVICE MANUAL Disconnect the electrical connection from the supply NOTE: There may be residual DEF in the filter housing. A module (Figure 7-11). collection container placed below the DEF filter cap is recommended. Tag and disconnect the hoses from the supply module. Remove the hardware attaching the supply module to the frame.
Page 251: Water Cooling System
RT880E SERVICE MANUAL POWER TRAIN Clean the aftertreatment DEF dosing unit cap with warm The cooling system is often neglected because the effects or water and a clean cloth. damage that result from an improperly maintained system usually occur gradually. The cooling system needs to be Filter Installation maintained with the same attention as other systems.
Page 252 POWER TRAIN RT880E SERVICE MANUAL and oxygen, and can only be prevented by maintaining full If condemned, flush the system using a mixture of sodium strength corrosion protection at all times. carbonate and water or an equivalent commercially available flushing agent. Refill system with fully formulated extended For maximum rust, freeze, and boiling point protection, an life coolant.
Page 253 RT880E SERVICE MANUAL POWER TRAIN Pressure Flushing and preventing loss of solution due to evaporation and overflow. Disconnect both radiator hoses that connect the radiator The cap has a spring-loaded valve, the seat of which is to the engine. below the overflow pipe in the filler neck. This prevents the Clamp a convenient length of hose to the radiator core escape of air or liquid while the cap is in position.
Page 254 POWER TRAIN RT880E SERVICE MANUAL a torque wrench is essential for preventing leaks around Radiator Removal and Installation. the head gasket. Removal Water Pump Set the outriggers and position the boom to over the The pump should be checked carefully for leaks and proper side.
Page 255 RT880E SERVICE MANUAL POWER TRAIN 18, 24 18, 23 FIGURE 7-13 Grove 7-23 Published 11-10-2014, Control # 524-00...
Page 256 POWER TRAIN RT880E SERVICE MANUAL mounting brackets using two bolts, washers, lockwash- ers, nuts and mounting bushings. Item Description Reconnect the two plates between the top of the radiator Radiator and the top of the frame rail using bolts, washers, lock- Surge Tank washers and nuts.
Page 257: Drive Train
RT880E SERVICE MANUAL POWER TRAIN DRIVE TRAIN Maintenance Drive Lines Description The drive train consists of the transmission/torque converter assembly and three drive lines (Figure 7-14). CAUTION Do not disassemble drive lines when removing them from The transmission/torque converter is mounted on and driven the crane.
Page 258 POWER TRAIN RT880E SERVICE MANUAL Transmission Rear Slip Shaft 7058 Front Slip Shaft Bearing Coupling Shaft FIGURE 7-14 7-26 Published 11-10-2014, Control # 524-00...
Page 259: Transmission/Torque Converter
RT880E SERVICE MANUAL POWER TRAIN TRANSMISSION/TORQUE CONVERTER reaction member is the means by which the hydraulic torque converter multiplies torque. Description The reaction member of the torque converter is located between and at the center of the inner diameters of the The transmission/torque converter assembly is mounted to impeller and turbine elements.
Page 260: Maintenance
POWER TRAIN RT880E SERVICE MANUAL There are bleed balls in the clutch piston which allow quick Troubleshooting escape for oil when the pressure to the piston is released. The following data is presented as an aid to locating the source of difficulty in a malfunctioning unit. It is necessary to Maintenance consider the torque converter charging pump, transmission, oil cooler, and connecting lines as a complete system when...
Page 261 RT880E SERVICE MANUAL POWER TRAIN Hydraulic Checks NOTE: Always make all troubleshooting checks with the converter outlet temperature at least 180 to 200°F Before checking the transmission/torque converter and (82.3 to 93.3°C). associated hydraulic system for pressures and rate of oil flow, it is essential that the following preliminary checks be Removal made.
Page 262: Towing Or Pushing
POWER TRAIN RT880E SERVICE MANUAL Installation sion to flywheel housing nuts and washers. Tighten the nuts to 30 lb-ft (40.7 Nm). NOTE: transmission/torque converter assembly Remove the drive plate locating stud. Install one drive weighs approximately 990 lb (450 kg) dry. plate attaching screw and hardened flatwasher.
Page 263 RT880E SERVICE MANUAL POWER TRAIN Mount Dial Indicator Here Flywheel Housing Engine Flywheel Pilot Bore Flywheel Converter Housing Flywheel 4 in (10.2 cm) Stud 2-1/2 in (6.4 cm) Aligning Studs Drive Plate Flywheel Housing Special Stud, Washer and Self-lock Nut Furnished by Engine Manufacturer Flywheel Housing...
Page 264 POWER TRAIN RT880E SERVICE MANUAL Servicing the Crane After Transmission/Torque the LOW mark on the dipstick. After the oil temperature reaches 180 to 200°F (82 to 93°C), add oil to bring the Converter Overhaul level to the FULL mark on the dipstick. The transmission/torque converter and its allied hydraulic Recheck all drain plugs, lines, connections, etc., for system are important links in the drive line between the...
Page 265: Engine Block Heater
RT880E SERVICE MANUAL POWER TRAIN ENGINE BLOCK HEATER block to preheat the coolant water. The immersion heater is provided with a short power cord equipped with a three The pre-heater is an 120 volt (240 volt, optional) immersion prong ground plug. The heater is 1500 watts. type heater.
Page 266 POWER TRAIN RT880E SERVICE MANUAL 7-34 Published 11-10-2014, Control # 524-00...
Page 267: Axles
RT880E SERVICE MANUAL UNDERCARRIAGE SECTION 8 UNDERCARRIAGE SECTION CONTENTS Axles ........8-1 Service Brakes.
Page 268: Maintenance
UNDERCARRIAGE RT880E SERVICE MANUAL reduction, through the revolving planet gears, and into the The steer cylinders. planetary spider which drives the wheel hub. b. The rear wheels not centered switch actuator As an option, the front axle and rear axle may be provided bracket (rear axle only).
Page 269 RT880E SERVICE MANUAL UNDERCARRIAGE Wheel Alignment Check Procedure Rear Wheels Not Centered Switch Adjustment Procedure Check the axle for wheel alignment. The wheels are to be straight ahead with no toe-in or toe-out. Adjust if nec- Ensure the wheels are straight ahead. essary by turning the tie rod ends in the direction neces- NOTE: Refer to (Figure 8-1) to perform the following...
Page 270: Wheels And Tires
UNDERCARRIAGE RT880E SERVICE MANUAL Wheels and Tires Wheel End Horizontal Oil Fill Level and Drain Plug Description The standard tire size for this unit is 29.5 x 25-34 ply. CAUTION Do not mix tires and rims of different manufacturers. Each wheel assembly (tire and rim) is mounted on the planetary hub with 24 grade 8 lug nuts.
Page 271: Typical Wear Patterns
RT880E SERVICE MANUAL UNDERCARRIAGE Typical Wear Patterns Incorrect Tire Pressure Too high air pressure (Figure 8-3, View 1) gives rapid wear in the middle of the tire. Too low air pressure (Figure 8-3, View 2) gives rapid shoulder wear. FIGURE 8-5 Item Description Incorrect Toe-In...
Page 272 UNDERCARRIAGE RT880E SERVICE MANUAL Cuts in the Tire Tread Feathered Edges Cuts are due to poor roads, air pressure too high or incorrect Normal occurrence on non-driving wheels on good roads tire type for the application. and high mileage. FIGURE 8-7 Item Description Cuts...
Page 273: Steering Systems
RT880E SERVICE MANUAL UNDERCARRIAGE STEERING SYSTEMS Theory of Operation Front Steering System Description A hydraulic oil flow from pump number 2 flows through port 5 To maximize maneuverability, the crane can be steered by of the hydraulic swivel to the steer/swing directional control the front axle, the rear axle, or by the front and rear axles valve.
Page 274: Maintenance
UNDERCARRIAGE RT880E SERVICE MANUAL Maintenance Front Steering System Troubleshooting Symptom Probable Cause Solution Hard to steer left and right. Hydraulic oil low. Refill hydraulic reservoir. b. Clogged or loose hydraulic b. Clean or tighten lines or lines or fittings. fittings. Defective flow divider...
Page 275: Rear Steering System
RT880E SERVICE MANUAL UNDERCARRIAGE Functional Check Ensure the system has adequate power. If there is an indication of hard steering, this can be caused by either A normal periodic functional check of the entire steering a reduced oil flow to the control valve or a reduced sys- system will generally be adequate to ensure satisfactory tem relief pressure.
Page 276: Hydraulic Pumps
UNDERCARRIAGE RT880E SERVICE MANUAL Hydraulic Pumps Rear Steer/ Axle Lockout/Fan Drive Valve Description Description Front Steer The rear steer valve/axle lockout/fan drive directionally controls the outrigger circuit, outrigger pin circuit, and the The hydraulic pump is mounted off of drive pads of the rear steer circuit.
Page 277: Steer Cylinders
RT880E SERVICE MANUAL UNDERCARRIAGE Functional Check Connect the hydraulic lines to the cylinder as tagged during removal. Cycle each outrigger cylinder several times. Verify each Operate the steering system and check the cylinder for cylinder extends and retracts properly. proper operation and any leakage. Rear steer the crane to the left and to the right several times.
Page 278 UNDERCARRIAGE RT880E SERVICE MANUAL Oscillation Carrier Frame Lockout Cylinder Pivot Point Pivot Point Fifth Wheel FIGURE 8-11 Axle Lockout Valve Axle Lockout Cylinders Supply from Pump FIGURE 8-12 8-12 Published 11-10-2014, Control # 524-00...
Page 279: Axle Oscillation Lockout Cylinders
RT880E SERVICE MANUAL UNDERCARRIAGE Axle Oscillation Lockout Cylinders Lubricate both ends of the cylinder using the fittings pro- vided. Description Function test the axle oscillation system in accordance Two 5.0 in (12.7 cm) hydraulic lockout cylinders are installed with the Operator Manual to ensure proper operation. on the rear axle, one left side and one right side.
Page 280: Brake System
UNDERCARRIAGE RT880E SERVICE MANUAL BRAKE SYSTEM created by the lever action of the brake pedal to the hydraulic brake valve which modulates the brake line pressure to the Description brake assemblies at each wheel. Hydraulic oil from Pump No. 1 flows to swivel port 7 to the The brake system includes all the components necessary for dual accumulator charge valve.
Page 281: Maintenance
RT880E SERVICE MANUAL UNDERCARRIAGE Maintenance Troubleshooting Symptom Probable Cause Solution Brakes are poor. Lining thickness less than Replace lining. 0.125 in (3mm). b. Brake pedal operation. b. Free mechanical linkage. Restriction or leaks in lines. Check all lines for leaks and restrictions.
Page 282: Service Brakes
UNDERCARRIAGE RT880E SERVICE MANUAL SERVICE BRAKES actuator on every wheel. When you complete a bleeder screw, go to the next closest bleeder screw on the same Description caliper/actuator. When you complete a wheel, go to the furthest bleeder screw on the next closest wheel. The brakes utilized on the axles are hydraulic disc-type Pressure Bleeding the Brake System brakes.
Page 283 RT880E SERVICE MANUAL UNDERCARRIAGE mounting bracket. If shims are used mark the position of out before the other piston, put a piece of wood in the shims. front of the piston that comes out first. Apply compressed air to force the other piston out of the Disassembly housing (Figure 8-15).
Page 284 UNDERCARRIAGE RT880E SERVICE MANUAL • Lining Wear. Replace the linings when the thickness of the lining is less than 0.125 in (3.2 mm) from the back plate (Figure 8-19). Wood Block • Lining Wear Not Even. Replace the linings if the thickness of the two linings is significantly different.
Page 285 RT880E SERVICE MANUAL UNDERCARRIAGE • Pistons. If fluid leaks at a piston, disassemble the Caliper Parts caliper. Inspect the piston, the bore, the O-rings, Inspect the pistons, housing bores, and O-ring grooves and back-up rings. Service as necessary. for scratches or corrosion. Remove small scratches or •...
Page 286: Corrosion Protection
UNDERCARRIAGE RT880E SERVICE MANUAL Cleaning Assembly Caliper DANGER CAUTION Use of cleaning solvents, hot solution tanks, or alkaline Use only specified components when assembling the solutions incorrectly, can cause serious personal injury. To calipers. Do not mix components from other calipers. prevent serious personal injury, follow the instructions Installing the wrong components may cause the caliper supplied by the manufacturer of these products.
Page 287 RT880E SERVICE MANUAL UNDERCARRIAGE Install the bleeder screws in the housing. Tighten to 100 to 120 lb-in (11.3 to 13.6 Nm). Install the O-ring and the inlet fitting in the cylinder cap. Installation Linings CAUTION Always replace both linings. If only one lining is replaced, possible disc damage can occur.
Page 288: Parking Brake Actuator
UNDERCARRIAGE RT880E SERVICE MANUAL Remove the capscrews holding actuator to the brake caliper, and slide the actuator off the actuator rod. Position the Park Brake Switch to ON and shut down the engine. Disconnect the hydraulic line from the brake actuator, then cap or plug all openings.
Page 289: Parking Brake
RT880E SERVICE MANUAL UNDERCARRIAGE PARKING BRAKE Tighten hex mounting bolts (36) until they make contact with the urethane springs (33), then tighten 4 flats Description approximately 0.07 in (1.778 mm) more. This puts the proper amount of pre-load on the urethane springs. The parking brake is mounted on the front axle input shaft in Tighten jam nut/sleeves (35) against mounting surface line between the front axle and the driveline from the...
Page 290 UNDERCARRIAGE RT880E SERVICE MANUAL FIGURE 8-28 8-24 Published 11-10-2014, Control # 524-00...
Page 291 RT880E SERVICE MANUAL UNDERCARRIAGE Item Description Item Description Torque Plate Clevis Pin O-ring Seal Cotter Pin Washer Jam nut Bearing Thrust Cam Excluder Rod O-ring Seal Retainer Ring Piston Assembly Cylinder Housing Magnet Piston Ball Bearing Seal Ring Dowel Pin Capscrew Setscrew Flatwasher...
Page 292: Park Brake Solenoid Valve
UNDERCARRIAGE RT880E SERVICE MANUAL PARK BRAKE SOLENOID VALVE Apply and release the park brake several times. Verify the park brake holds the crane when applied. Verify the Description park brake doesn’t drag when released. Check for leaks. Make repairs as needed. The park brake solenoid valve (Figure 8-29) is located on the front side of the carrier aft center frame cross member.
Page 293: Outriggers
RT880E SERVICE MANUAL UNDERCARRIAGE OUTRIGGERS A sight bubble level is mounted on the left side of the cab by the door latch plate. The sight bubble level provides the Outrigger Circuit operator with a visual indication of crane level attitude. Theory of Operation The outrigger circuit consists of four extension cylinders, four jack cylinders, an integrated outrigger/rear steer valve, front...
Page 294 UNDERCARRIAGE RT880E SERVICE MANUAL Maintenance Troubleshooting Symptom Probable Cause Solution Slow or erratic operation of outrig- Damaged relief valve. Remove relief valve; clean or ger extension cylinders. replace. b. Low hydraulic oil. b. Replenish oil to proper level. Sticking solenoid valve spool. Repair or replace valve spool.
Page 295 RT880E SERVICE MANUAL UNDERCARRIAGE Symptom Probable Cause Solution Sticking spool. Dirt in the system. Change oil and flush system. b. Distortion caused by tie bolts b. Retorque tie bolts. being overtorqued. Flow in excess of valve rating. Limit flow through valve to that recommended.
Page 296 UNDERCARRIAGE RT880E SERVICE MANUAL Symptom Probable Cause Solution Outrigger jack cylinder retracts Damaged piston seals. Replace all cylinder seals. under load. b. Damaged holding valve seals. b. Replace seals. Damaged holding valve. Replace valve assembly. d. Scored cylinder barrel. d. Repair or replace cylinder. Cracked or damaged piston.
Page 297: Outrigger Beam
RT880E SERVICE MANUAL UNDERCARRIAGE Outrigger Beam NOTE: Do not allow the end of the outrigger extension cyl- inder to fall when the cylinder mounting shaft is Description removed. Use blocking to limit the drop or an ade- quate soft support to cushion any distance the rod The outrigger beam assembly consists of an outrigger beam, will drop, a jack cylinder, an extension cylinder, an Outrigger...
Page 298 UNDERCARRIAGE RT880E SERVICE MANUAL Installation Apply grease (EPMPG) to the bottom of the outrigger CAUTION beam. Be sure that the piston side of all outrigger cylinders are If removed, install the side adjustable wear pad in the connected to the solenoid valve bank. Reversal of port outrigger beam.
Page 299 RT880E SERVICE MANUAL UNDERCARRIAGE 6, 7 2, 3 10, 11, 12 4, 5 2, 3 2, 3 FIGURE 8-30 Item Description Item Description Outrigger Beam Assembly Wear Pad Cover Plate Setscrew Screw Clevis Pin Lockwasher Cotter Pin Retaining Nut Capscrew Extension Cylinder Hex Nut Grove...
Page 300 UNDERCARRIAGE RT880E SERVICE MANUAL NOTE: Outrigger removal and installation similar for both front and rear out- riggers. NOTE: Lifting belts or straps should be used for lifting purposes so as to avoid nicking or scratching the bottom edges of the out- rigger beam.
Page 301: Extension Cylinder
RT880E SERVICE MANUAL UNDERCARRIAGE Extension Cylinder Extend Port Jack Cylinder Extend Port Jack Cylinder and Extension Cylinder Retract Port Jack Cylinder and Extension Cylinder Jack Cylinder Extend Port Retract Port Extension Cylinder Extend Port FIGURE 8-33 Extension Cylinder plate, and for proper tracking during beam exten- sion and retraction.
Page 302: Outrigger Monitoring System (Optional-Standard In North America)
UNDERCARRIAGE RT880E SERVICE MANUAL Check the hydraulic connections for any evidence of leakage. Outrigger Monitoring System (Optional— Standard in North America) Description The Outrigger Monitoring System (OMS) aids the operator in accurately programming the Rated Capacity Limiter (RCL) by automatically identifying the position of each outrigger beam.
Page 303 RT880E SERVICE MANUAL UNDERCARRIAGE Remove the cylinder cap. Check all hydraulic connections and hoses for evidence of leakage. Place a jack capable of supporting the weight of the jack cylinder at the base of the cylinder barrel. Jack up the Outrigger Jack Cylinder Internal Leak Test cylinder just enough to relieve any pressure on the cylin- Use the following procedure to troubleshoot and diagnose an...
Page 304: Outrigger Control Valves
UNDERCARRIAGE RT880E SERVICE MANUAL If oil stops flowing, the cylinder’s internal piston seal functions; the first function is a holding valve, the second is sealing properly. function provides a thermal relief of the jack cylinder. b. If oil continues to flow out the rod port, the cylinder’s Integrated Outrigger/Rear Steer Valve internal piston seal is leaking.
Page 305: Section 9
Lube intervals are to be used as a guideline only. Actual lube Potentially harmful waste used in Manitowoc cranes includes intervals should be formulated by the operator to correspond — but is not limited to — oil, fuel, grease, coolant, air...
Page 306: Standard Lubricants
LUBRICATION RT880E SERVICE MANUAL STANDARD LUBRICANTS TABLE 9-1: Standard Lubricants [Down to -9°C (15°F)] Recommended Lubricant Lubricant/Fluid Grove Spec. Type Grade Classification Axle/Swing Box Gear Oil Century Unigear Semi-synthetic 6829012964 Texaco Multigear SS 80W-90 Chevron DELO Engine Oil Conoco Fleet Supreme EC CJ-4 6829104182 15W-40...
Page 307: Arctic Lubricants And Conditions
Therefore, always check with an authorized -40°C (-40°F) Package Manitowoc distributor or Manitowoc Crane Care if in doubt of • Coolant heater (to circulate warm coolant through the suitability of a specific fluid or lubricant.
Page 308 LUBRICATION RT880E SERVICE MANUAL Table 9-1: Cold Weather Lubricants [Down to -29°C (-20°F)] Recommended Lubricant Lubricant/Fluid Grove Spec. Type Grade Classification Axle Gear Oil Petro-Canada Traxon E Syn- thetic CITGO, Syntetic Gear Lube Eaton, Roadranger EP 6829014058 75W-90 Mobil, Mobilube SCH Shell, Spirax S Sunoco Duragear EP Tier 3/Tier 4 Engine Oil...
Page 309 RT880E SERVICE MANUAL LUBRICATION Table 9-2: Cold Weather Lubricants [Down to -40°C (-40°f)] Recommended Lubricant Lubricant/Fluid Grove Spec. Type Grade Classification Axle Gear Oil Petro-Canada Traxon E Syn- thetic CITGO, Syntetic Gear Lube Eaton, Roadranger EP 6829014058 75W-90 Mobil, Mobilube SCH Shell, Spirax S Sunoco Duragear EP Tier 3/Tier 4 Engine Oil...
Page 310: Surface Protection For Cylinder Rods
Boeshield® T-9 Premium Metal Protectant. can allow moisture to corrode the underlying steel. At typical Manitowoc Crane Care has Boeshield® T-9 Premium Metal ambient temperatures, hydraulic oil is too thick to penetrate Protectant available in 12 oz. cans by ordering part number these cracks.
Page 311: Wire Rope Lubrication
The log must use the engine hourmeter to ensure coverage of lube points that will receive attention based on Manitowoc highly recommends the use of CraneLUBE their hours operated. Other lubrication requirements must be l u b r i c a n ts t o i n c r e a s e y o u r c r a n e ’s r e l i a b i l i t y a n d made on a time interval basis, i.e.
Page 312: Steering And Suspension
LUBRICATION RT880E SERVICE MANUAL Steering and Suspension Lube Point Figure Approved Lube Item Lube Interval Application Description Lubricant Capacity EP-MPG Extreme Until Steer Cylinder Pressure Figure 9-1 grease 500 hours or 3 months 8 grease fittings Pivot Pins Multipurpose extrudes Grease 6829003477 EP-MPG...
Page 313 RT880E SERVICE MANUAL LUBRICATION 7061-4 7061-22 7061-7 7061-10 FIGURE 9-1 Grove Published 11-10-2014, Control # 524-00...
Page 314: Axles
LUBRICATION RT880E SERVICE MANUAL Lube Point Figure Approved Lube Item Lube Interval Application Description Lubricant Capacity Axles • Check level every GL-5 500 hours or 3 Extended 52.0 pt Fill to bottom of hole months Differentials Figure 9-2 Service Interval 24.6 l in housing on the •...
Page 315 RT880E SERVICE MANUAL LUBRICATION 7061-7 7061-22 FIGURE 9-2 Grove 9-11 Published 11-10-2014, Control # 524-00...
Page 316: Drive Train
LUBRICATION RT880E SERVICE MANUAL Lube Point Figure Approved Lube Item Lube Interval Application Description Lubricant Capacity Drive Train • Through valve EO-15W/40 • Check level every 10 cover to FULL a. Engine Engine Oil hours or daily 21.1 qt mark on dipstick Crankcase Figure 9-3 SAE 15W-40...
Page 317 RT880E SERVICE MANUAL LUBRICATION Lube Point Figure Approved Lube Item Lube Interval Application Description Lubricant Capacity • Fill surge tank to AFC 50/50 bottom of filler 50 qt 50/50 Blended neck. 47.3 l Fully • Check coolant level • Run engine Formulated every 10 hours or through two (2)
Page 318 LUBRICATION RT880E SERVICE MANUAL 7803-1 7061-45 7061-36 7856-1 FIGURE 9-3 9-14 Published 11-10-2014, Control # 524-00...
Page 319: Drive Train (Continued)
RT880E SERVICE MANUAL LUBRICATION Lube Point Figure Approved Lube Item Lube Interval Application Description Lubricant Capacity Drive Train (continued) Clean strainer screen Close shutoff valves. Coolant Strainer after first 100 hours and Figure 9-4 Unscrew hex plug to (Cab Heater) every 2000 hours or 12 clean filter.
Page 320 LUBRICATION RT880E SERVICE MANUAL 7695-1 7061-37 Opposite Side 7856-2 Step-cover removed FIGURE 9-4 9-16 Published 11-10-2014, Control # 524-00...
Page 321: Turntable
RT880E SERVICE MANUAL LUBRICATION Lube Point Figure Approved Lube Item Lube Interval Application Description Lubricant Capacity Turntable • Check and fill every GL-5 50 hours Extended Turntable Gear 5.7 qt • Drain and fill after Figure 9-5 Service Interval Use Dipstick 5.4 l first 250 hours and Gear Lubricant...
Page 322 LUBRICATION RT880E SERVICE MANUAL 7061-25 7061-24 FIGURE 9-5 9-18 Published 11-10-2014, Control # 524-00...
Page 323: Cab Tilt
RT880E SERVICE MANUAL LUBRICATION Lube Point Figure Approved Lube Item Lube Interval Application Description Lubricant Capacity Cab Tilt EP-MPG Extreme Until Cab Tilt Cylinder Pressure Figure 9-6 grease 500 hours or 3 months 2 grease fittings Pivot Pins Multipurpose extrudes Grease 6829003477 EP-MPG...
Page 324 LUBRICATION RT880E SERVICE MANUAL 7061-18 7061-47 FIGURE 9-6 9-20 Published 11-10-2014, Control # 524-00...
Page 325: Outriggers
RT880E SERVICE MANUAL LUBRICATION Lube Point Figure Approved Lube Item Lube Interval Application Description Lubricant Capacity Outriggers EP-MPG Extreme Brush lubricant on Pressure Outrigger Beams Figure 9-7 50 hours or 1 week bottom of outrigger Multipurpose beams Grease 6829003477 EP-MPG Brush lubricant on Extreme ID of jack cylinder...
Page 326 LUBRICATION RT880E SERVICE MANUAL 7061-57 FIGURE 9-7 9-22 Published 11-10-2014, Control # 524-00...
Page 327: Boom
RT880E SERVICE MANUAL LUBRICATION Lube Point Figure Approved Lube Item Lube Interval Application Description Lubricant Capacity Boom EP-MPG Until Extreme Pressure Hook Block Figure 9-8 grease 250 hours or 3 months 1 grease fitting Multipurpose Swivel Bearing Grease extrudes 6829003477 EP-MPG Until 1 grease fitting per...
Page 328 LUBRICATION RT880E SERVICE MANUAL 7136-1 7136-3 7061-66 7136-2 7116-6 FIGURE 9-8 9-24 Published 11-10-2014, Control # 524-00...
Page 329 RT880E SERVICE MANUAL LUBRICATION Lube Point Figure Approved Lube Item Lube Interval Application Description Lubricant Capacity Boom (continued) Thoroughly EP-MPG Boom Section coat all 12 places by brush; Extreme Pressure Upper and Lower Figure 9-9 areas the 50 hours or 1 week with boom in Multipurpose Grease...
Page 330 LUBRICATION RT880E SERVICE MANUAL 7136-1 7116-13 7136-2 FIGURE 9-9 9-26 Published 11-10-2014, Control # 524-00...
Page 331 RT880E SERVICE MANUAL LUBRICATION Lube Point Approved Lube Item Figure No. Lube Interval Application Description Lubricant Capacity Boom (continued) EP-MPG Extreme Until 1 grease fitting per Lower Boom Pressure Figure 9-10 grease 250 hours or 3 months sheave (5 sheaves) Nose Sheave Multipurpose extrudes...
Page 332 LUBRICATION RT880E SERVICE MANUAL 7116-1 6265-3 7116-8 7061-61 FIGURE 9-10 9-28 Published 11-10-2014, Control # 524-00...
Page 333: Hoist
RT880E SERVICE MANUAL LUBRICATION Lube Point Approved Lube Item Figure No. Lube Interval Application Description Lubricant Capacity Hoist • Check and fill every AGMA 50 hours or weekly Extreme Oil level must be 15.5 qt Main Hoist Figure 9-11 Pressure Gear visible in the sight •...
Page 334 LUBRICATION RT880E SERVICE MANUAL 7116-10 FIGURE 9-11 9-30 Published 11-10-2014, Control # 524-00...
Page 335: Hydraulic
“milky” with only a small layer of transparent oil on top. If the “milky” appearance was due to air foaming, it will dissipate and the oil should closely match the fresh oil. Should you have any questions, please contact your local authorized Manitowoc distributor.
Page 336 LUBRICATION RT880E SERVICE MANUAL 7806-1 FIGURE 9-12 9-32 Published 11-10-2014, Control # 524-00...
Page 337: Diesel Exhaust Fluid (Def)
RT880E SERVICE MANUAL LUBRICATION Lube Point Approved Lube Item Figure No. Lube Interval Application Description Lubricant Capacity Diesel Exhaust Fluid (DEF) Fill when level is low DEF Tank Figure 9-13 5 gal (19 l) 80019225 per indicator. Grove 9-33 Published 11-10-2014, Control # 524-00...
Page 338 LUBRICATION RT880E SERVICE MANUAL FIGURE 9-13 9-34 Published 11-10-2014, Control # 524-00...
Page 339: Carwell® Rust Inhibitor
Protecting Cranes From Rusting minimize the harmful effects of corrosion. Manitowoc Crane Group's cranes are manufactured to high Exercise special care and increase the frequency of cleaning quality standards, including the type of paint finish if the crane is operated: demanded by today's industry.
Page 340: Inspection And Repair
• Prepare the surface prior to applying the finish coat of paint. Please contact Manitowoc Crane Care should you have any questions. • Apply a finish coat of paint using accepted blending techniques. Use of original paint colors is recommended Areas of Application to insure the best color match possible.
Page 341 RT880E SERVICE MANUAL LUBRICATION unpainted fasteners and hardware, valves, slew ring • All hardware, clips, pins, hose connections not painted fasteners and all bare metal surfaces. will have treatment applied. • Boom applications areas are; pivot pins, hose end and fittings, jib pins and shafts, all bare metal surfaces, headache ball pins/ hook block pins and fasteners.
Page 342 LUBRICATION RT880E SERVICE MANUAL Figure 9-15 7650-14 9-38 Published 11-10-2014, Control # 524-00...
Page 343 RT880E SERVICE MANUAL LUBRICATION Item Description Item Description Mirror Mounting Hardware Pivot Shaft Entire underside of unit Boom Extension Pins, Clips Valve Bank Boom Nose Pins, Clips Powertrain Hardware Inside Compartment Boom Extension Hanger Hardware Counterweight Mounting Hardware All Hardware, Clips, Pins, Hose Connections Hoist Hose Connections not painted O/R Pins, Clips Tension Spring...
Page 344 LUBRICATION RT880E SERVICE MANUAL 9-40 Published 11-10-2014, Control # 524-00...
Page 345 RT880E SERVICE MANUAL ALPHABETICAL INDEX 2 Speed Swing Valve........... 2-52 Air Intake and Exhaust System .
Page 346 SERVICE MANUAL RT880E Range Shift/Parking Brake Valve ......... 2-68 Rear Axle Oscillation Lockout System .

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