1. Manuals
  2. Brands
  3. Manitowoc Manuals
  4. Construction Equipment
  5. Grove RT765E-2
  6. Service and maintenance manual

Manitowoc Grove RT765E-2 Service And Maintenance Manual

Hide thumbs Also See for Grove RT765E-2:
Table of Contents

Advertisement

Quick Links

Download this manual
Grove RT765E-2
Service/Maintenance Manual

Advertisement

Table of Contents
loading

Related Manuals for Manitowoc Grove RT765E-2

Summary of Contents for Manitowoc Grove RT765E-2

  • Page 1 Grove RT765E-2 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

    RT765E-2 SERVICE MANUAL TABLE OF CONTENTS TABLE OF CONTENTS RT765E-2 SERVICE MANUAL SECTION 1 ........Introduction General .
  • Page 6 TABLE OF CONTENTS RT765E-2 SERVICE MANUAL Precautions and Recommendations During Inspection or Replacement ..1-20 Wire Rope Inspection (Running Ropes and Pendant Cables)....1-21 Wire Rope Inspection (Boom Extension and Retraction Cables) .
  • Page 7 RT765E-2 SERVICE MANUAL TABLE OF CONTENTS Maintenance ............2-33 Hydraulic Remote Control Valve .
  • Page 8 TABLE OF CONTENTS RT765E-2 SERVICE MANUAL Description............2-75 Maintenance .
  • Page 9 RT765E-2 SERVICE MANUAL TABLE OF CONTENTS Assembly ............4-10 Installation.
  • Page 10 TABLE OF CONTENTS RT765E-2 SERVICE MANUAL Hoist Control Valves ........... 5-17 Description.
  • Page 11 RT765E-2 SERVICE MANUAL TABLE OF CONTENTS Description ............7-9 Air Intake.
  • Page 12 TABLE OF CONTENTS RT765E-2 SERVICE MANUAL Outrigger............8-26 Outrigger Circuit.

  • Page 13: Section 1

    RT765E-2 SERVICE MANUAL INTRODUCTION SECTION 1 INTRODUCTION SECTION CONTENTS General ........1-1 Pressing Parts .

  • Page 14: Customer Support

    One boom is Manitowoc and our Distributor Network want to ensure your a v a i l a b l e o n t h e c r a n e ; a f o u r s e c t i o n , f u l l p o w e r, satisfaction with our products and customer support.

  • Page 15: List Of Specifications

    RT765E-2 SERVICE MANUAL INTRODUCTION LIST OF SPECIFICATIONS Horse Power Rating. 179 kW (240 hp) @ 2500 rpm Oil Pan Capacity ....18.5 qt (15.6 l) Coolant System ....40 qt (38 l) General Axles Model .

  • Page 16: Hoists

    INTRODUCTION RT765E-2 SERVICE MANUAL Hoists Drum Dimensions Diameter ....15 in (381 mm) Length (Standard) ..18.38 in (467 mm) Cable Diameter .
  • Page 17 RT765E-2 SERVICE MANUAL INTRODUCTION Table 1-1Axle 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 23360 (51500) 23360 (51500) Maximum Tire Loads Allowed 24313 (53600) 24313 (53600) Standard Carrier 4 x 4, w/O/R Beams, plus...
  • Page 18 INTRODUCTION RT765E-2 SERVICE MANUAL CG From Rear Weight Front Axle Rear Axle Description Axle cm (in) kg (lb) kg (lb) kg (lb) Rem: Removable Counterweight System - -138.34 (-54.66) -6729 (-14835) 2299 (5068) -9028 (-19903) Cwt Weldment only Sub: Add’l Hoist Access Platform Weight w/ -84.18 (-213.82) 44 (20) -23 (-10)

  • Page 19: Crane Nomenclature

    RT765E-2 SERVICE MANUAL INTRODUCTION Crane Nomenclature 7671-1 7671-2 FIGURE 1-2 GROVE Published 9-04-2014, Control # 422-08...
  • Page 20 INTRODUCTION RT765E-2 SERVICE MANUAL Item Description Item Description Boom Nose Sheaves Fuel Tank Boom Crane Steps Work Lights Boom Pivot Pin Hydraulic Valves and Swing Motor Cover Air Conditioning Components Swingaway Extension Windshield Washer Fluid Container Auxiliary Boom Nose Hoist Access Platform (Fixed Counterweight Job Extension Units Only) Outrigger Pads...

  • Page 21: General Maintenance

    RT765E-2 SERVICE MANUAL INTRODUCTION GENERAL MAINTENANCE compressed air on bearings. Spinning bearings without lubricant will cause damage to the bearing, and could cause These general suggestions should be helpful in following the the bearing to fly apart. i ns t r u c t io n s i n th i s m a nu a l . I n a n al y z i ng a s y s te m malfunction, use a systematic approach to locate and correct the problem.

  • Page 22: Pressing Parts

    INTRODUCTION RT765E-2 SERVICE MANUAL Pressing Parts Hoses and Tubes When pressing one part into another, use an anti-seize DANGER compound or a molybdenum disulfide base compound to lubricate the mating surfaces. High Pressure/Temperature Hazard! Assemble tapered parts dry. Before assembling parts with Exercise extreme care around pressurized hydraulic tapered splines, be sure the splines are clean, dry, and free hoses or tubes.

  • Page 23: Bearings

    RT765E-2 SERVICE MANUAL INTRODUCTION Installation assembly to obtain accurate pre-loading. When installing a bearing, spacer, or washer against a shoulder on a shaft, be When installing a new hose, loosely connect each end sure the chamfered side is toward the shoulder. and make sure the hose takes up the designed position before tightening the connection.

  • Page 24: Hydraulic Systems

    If any of the above conditions exist, evaluate hose assemblies for correction or replacement. For replacement Contaminants in a hydraulic system affect operation and will of hose assemblies, refer to your Manitowoc Crane Care result in serious damage to the system components. Dirty Parts Manual.

  • Page 25: Hydraulic Fittings

    Flats from Finger Tight (F.F.F.T.) Method Optionally for future tightening of the same connection: Manitowoc recommends that the F.F.F.T. tightening method extend the line from the nut at its new location onto the described here be used when assembling all hydraulic hex of the static fitting or port ((Figure 1-4)).

  • Page 26: Electrical System

    INTRODUCTION RT765E-2 SERVICE MANUAL Make sure both threads and sealing surfaces are free of burrs, nicks, scratches or any foreign particles. Lubricate O-ring with clean oil ((Figure 1-6)). Non-Adjustable Fitting to Port FIGURE 1-6 a0032 Turn fitting until finger tight. Using the assembly torque method, tighten to given T-2-6 torque for size from (Table 1-5).

  • Page 27: Fatigue Of Welded Structures

    Loctite® are specified throughout the Service • Salt water conditions after 8,000 hours of service. Manual. The following types of Loctite® brand adhesives are available from the Parts Department of the local Manitowoc Fatigue of Welded Structures distributor.

  • Page 28: Fasteners And Torque Values

    Whenever there is a possibility that a torque wrench may have been either overstressed or The torque tables are provided by Manitowoc for reference damaged, it should immediately be removed from service when performing maintenance.
  • Page 29 RT765E-2 SERVICE MANUAL INTRODUCTION SAE Grade 1 SAE Grade 5 SAE Grade 7 SAE Grade 8 and Grade 2 HHCS HHCS HHCS HHCS Socket Head Socket Head Serrated Capscrew Shoulder Flange Head Screw FIGURE 1-8 Table 1-6: 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 RT765E-2 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

    RT765E-2 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 regulations, and amount depends on the rope’s size, type, and anticipated Manitowoc. The inspection interval shall be determined by a use. This in-process treatment will provide the finished rope qualified person and shall be based on such factors as...

  • Page 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 Wire Rope Inspection (Boom Extension and eventually deteriorate to a point where it is no longer usable.

  • 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 RT765E-2 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 RT765E-2 SERVICE MANUAL INTRODUCTION FIGURE 1-14 GROVE 1-25 Published 9-04-2014, Control # 422-08...
  • Page 38 INTRODUCTION RT765E-2 SERVICE MANUAL THIS PAGE BLANK 1-26 Published 9-04-2014, Control # 422-08...

  • Page 39: Section 2

    RT765E-2 SERVICE MANUAL HYDRAULIC SYSTEM SECTION 2 HYDRAULIC SYSTEM SECTION CONTENTS Description ....... 2-2 Procedure J - Front Steer Relief Valve Pressure.

  • Page 40: Description

    HYDRAULIC SYSTEM RT765E-2 SERVICE MANUAL Service Brake and CAC Fan Motor Priority Flow Description ......2-68 Control Valve .

  • Page 41: Hydraulic Symbols

    RT765E-2 SERVICE MANUAL HYDRAULIC SYSTEM HYDRAULIC SYMBOLS The following pages show basic hydraulic symbols as use on the schematics. Description Symbol Description Symbol Hydraulic Reservoir - Stores, cools, and Filter - Removes contamination from cleans machines hydraulic fluid supply. hydraulic fluid. Hydraulic Return Lines - Terminated at (1) Filter with Bypass Valve - Bypass valve below fluid level (2) above fluid level.
  • Page 42 HYDRAULIC SYSTEM RT765E-2 SERVICE MANUAL Description Symbol Description Symbol Single Acting Cylinder - Extended Manually Operated - Valve shifted hydraulically and retracted with a spring. manually with check to allow flow back to tank. Double Acting Cylinder - Extended and retracted hydraulically.

  • Page 43: Maintenance

    Use only port for the side walls to drain. Manitowoc supplied parts to repair the crane. Clean and install the reservoir plug and fill the reservoir Hydraulic System Maintenance Precautions with a 50/50 mixture of fuel oil and clean hydraulic oil.

  • Page 44: Removing Air From The Hydraulic System

    HYDRAULIC SYSTEM RT765E-2 SERVICE MANUAL Connect the cylinder return line and lower the boom to 25. Connect the return line to the main hoist motor and fully its stowed position. Replenish the reservoir hydraulic oil hoist down the hoist, then hoist up again. Replenish the level as required.

  • Page 45: Parts Replacement

    RT765E-2 SERVICE MANUAL HYDRAULIC SYSTEM the pressure, repair any leaks found, and reopen any Directional Control Valves openings (such as a vent) closed for inspection. Refill The control valves that control the crane functions are the reservoir after completing any repairs or service. installed on the right side of the turntable.
  • Page 46 For replacement temperatures will negatively impact service life. Therefore it of hose assemblies, refer to your Manitowoc Crane Care is recommended for these hoses to be inspected thoroughly Parts Manual.

  • Page 47: Supply Pressure And Return Circuit

    RT765E-2 SERVICE MANUAL HYDRAULIC SYSTEM SUPPLY PRESSURE AND RETURN CIRCUIT A filler neck and breather on the top of the reservoir are for filling the reservoir and for venting it. The filler neck includes Description a strainer for catching contaminants and gaskets to prevent leaking.

  • Page 48: Pump Distribution

    HYDRAULIC SYSTEM RT765E-2 SERVICE MANUAL Section two of the No. 1 hydraulic pump supplies the rear Item Description axle oscillation lockout valve and the integrated outrigger/ Temperature Switch- Low Fan Speed rear steer valve. Temperature Switch-High Fan Speed Output from pump number 1, section 2 passes through a priority flow control valve for the hydraulic oil cooler motor Hydraulic Tank and the high speed boost selector valve.
  • Page 49 RT765E-2 SERVICE MANUAL HYDRAULIC SYSTEM Symptom Probable Cause Solution Slow response. Low hydraulic oil level. Check system for leaks. Make repairs as needed. Fill reservoir. b. Hydraulic oil temperature too high b. If too low, warm up system. As (watery thin oil) or too low (thick needed, troubleshoot cooler circuit.

  • Page 50: Troubleshooting Aids

    HYDRAULIC SYSTEM RT765E-2 SERVICE MANUAL Troubleshooting Aids or ballooned hoses, leakage around the hydraulic components, etc. Hydraulic schematics - an exact illustration of the Second, make an analysis of symptoms. The function of arrangement of the system. The schematic shows all the each component in the system must be known before a components in relation to the system.

  • Page 51: Hydraulic Oil Return Filter Assembly

    RT765E-2 SERVICE MANUAL HYDRAULIC SYSTEM Hydraulic Oil Return Filter Assembly Remove and discard the O-ring between the cap and the return filter head. The hydraulic oil return filter assembly (see Figure 2-1 and Remove the element from through the return filter head. Figure 2-2) is located in the reservoir.
  • Page 52 HYDRAULIC SYSTEM RT765E-2 SERVICE MANUAL 7834 FIGURE 2-2 Item Description Item Description Filter Head O-ring Bowl, w/Extension Capscrew Gauge Assembly Bypass Valve Assembly Square O-ring Spacer Gasket Capscrew Element Washer 2-14 Published 9-04-2014, Control # 422-08...

  • Page 53: Oil Cooler

    RT765E-2 SERVICE MANUAL HYDRAULIC SYSTEM OIL COOLER (6 and 7) are installed in the return tube. The two oil cooler fan motor temperature switches are normally closed at low Description oil temperatures. When the hydraulic oil temperature reaches 120 °F (48.9 °C), one of the oil cooler fan motor An air cooled hydraulic/transmission cooler (Figure 2-3) is temperature switch will open, causing the CANbus system to located next to the hydraulic tank.
  • Page 54 HYDRAULIC SYSTEM RT765E-2 SERVICE MANUAL 7839 FIGURE 2-3 Item Description Item Description Outlet Port Temperature Switch Fan Motor Transmission Oil Cooler Inlet Port Hydraulic Oil Cooler Drain Port 2-16 Published 9-04-2014, Control # 422-08...

  • Page 55: Hydraulic Pumps

    RT765E-2 SERVICE MANUAL HYDRAULIC SYSTEM HYDRAULIC PUMPS CAUTION Description Keep the pump as level as possible to avoid damaging The No. 1 and No. 3 hydraulic pumps Figure 2-4 are the input spline. mounted on a drive pad of the torque converter. The No. 2 hydraulic pump Figure 2-4 is mounted on a drive pad of the Remove the capscrews and washers attaching the No.
  • Page 56 HYDRAULIC SYSTEM RT765E-2 SERVICE MANUAL and its gasket into place so they seat properly on the pump disconnect assembly. CAUTION Secure pump drive assembly and pump to torque Keep the pump as level as possible to avoid damaging converter drive pad with nuts and washers. Torque nuts; the input spline.
  • Page 57 RT765E-2 SERVICE MANUAL HYDRAULIC SYSTEM Install pump and gasket on engine drive pad with Install pump and gasket on torque converter drive pad capscrews and washers. Make sure the splines mesh with capscrews and washers. Make sure the splines mesh properly. Torque capscrews; refer to Fasteners properly.
  • Page 58 HYDRAULIC SYSTEM RT765E-2 SERVICE MANUAL Place your hand on the pump to check for excessive If the pump seems to be running properly, increase the heat buildup caused by binding or other problems. If the rpm to 1500 to 1800 rpm for one to two minutes while pump is too hot to keep a hand on, stop the engine.

  • Page 59: Pump Disconnect Assembly

    RT765E-2 SERVICE MANUAL HYDRAULIC SYSTEM Remove oil seals from housing. Item Description Assembly Engine Install two oil seals into holes in housing. Transmission Pin shifter assembly in housing with shaft. Hydraulic Pump No. 3 Pin collar to shaft with roll pin. Hydraulic Pump No.
  • Page 60 HYDRAULIC SYSTEM RT765E-2 SERVICE MANUAL 7530 7528 FIGURE 2-5 Item Description Item Description Pump Disconnect Assembly Shifter Assembly Housing Shifter Lock Shaft Roll Pin Oil Seal Plug Handle Pipe Plug Collar Engine 2-22 Published 9-04-2014, Control # 422-08...

  • Page 61: Pressure Setting Procedures

    RT765E-2 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 62: Procedure A - Main Control Valve Reliefs

    HYDRAULIC SYSTEM RT765E-2 SERVICE MANUAL Procedure A - Main Control Valve Reliefs Install pressure check diagnostic quick disconnect with gauge onto test nipple at main directional control valve inlet gauge port Figure 2-7. Completely extend lift cylinder (or cap hose from “A” port to the lift cylinder), attempt to lift up with engine running Disconnect at full rpm.

  • Page 63: Procedure B - Main Directional Control Valve Pilot Supply Pressure

    RT765E-2 SERVICE MANUAL HYDRAULIC SYSTEM Disconnect and cap the hose running from the main clockwise to increase or counterclockwise to decrease directional control valve to the hoist(s) port “A” on the the pressure setting. hoist motor control valve. Disconnect the hoist brake Remove pressure gauge from the pilot supply test port.

  • Page 64: Procedure E - Charge Air Cooler Valve Relief Pressure

    HYDRAULIC SYSTEM RT765E-2 SERVICE MANUAL CF1 Port Test Port CF2 Port 7798 Adjustable Inlet Adjustable Relief Valve CAC Fan Relief Valve FIGURE 2-9 Procedure E - Charge Air Cooler Valve Relief Pressure With engine off, disconnect hose at port “CF2” at the brake charge/CAC fan motor supply valve Figure 2-9;...

  • Page 65: Procedure H - Precharging The Accumulator

    RT765E-2 SERVICE MANUAL HYDRAULIC SYSTEM Close the charging assembly bleed valve. Attach the Procedure H - PreCharging The Accumulator swivel nut onto the gas valve and tighten to 10 to 15 lb-in With the engine off, discharge all of the pressurized oil (1.1 to 1.7 Nm).

  • Page 66: Procedure J - Front Steer Relief Valve Pressure

    HYDRAULIC SYSTEM RT765E-2 SERVICE MANUAL Remove the pressure gauge from the swing inlet test port. Procedure K - Outrigger/Rear Steer Valve Relief Install pressure check diagnostic quick disconnect with gauge onto test nipple at outrigger/rear steer valve pressure check port Figure 2-14. With the boost switch OFF and the engine running at full rpm, press the extend switch and adjust the outrigger/ rear steer relief valve to 2500 psi ±50 (17.2 MPa ±0.4).

  • Page 67: Procedure M - Counterweight Removal Valve

    RT765E-2 SERVICE MANUAL HYDRAULIC SYSTEM Remove pressure gauge from main directional valve. Adjustable Relief Valve 7532-3 Port CF 7797 Flow Control Valve FIGURE 2-15 Procedure M - Counterweight Removal Valve Install pressure check diagnostic quick disconnect with gauge onto test nipple at main directional control valve load sense relief test port Figure 2-7.

  • Page 68: Valves

    HYDRAULIC SYSTEM RT765E-2 SERVICE MANUAL VALVES location, refer to Table 2-3. Refer to Figure 2-17 and Figure 2-18 for valve locations. General The description of each valve given here is for the valve itself. For information on how each valve functions in the This subsection provides descriptive information for several individual circuits, refer to the description and operation of the main hydraulic valves used on this crane.
  • Page 69 RT765E-2 SERVICE MANUAL HYDRAULIC SYSTEM Valve Installation - Carrier Rear 7840 FIGURE 2-17 Item Description Item Description Front Outrigger Control Valve Park Brake Range Shift Valve Integrated Outrigger/Rear Steer Valve Differential Lock Valve (Optional) Fan Bypass Valve Axle Lockout Valve Priority Flow Divider Valve Rear Outrigger Control Valve Adjustable Flow Valve...
  • Page 70 HYDRAULIC SYSTEM RT765E-2 SERVICE MANUAL 7539-2 Superstructure 7539-1 FIGURE 2-18 Item Description Item Description Counterweight Removal Manifold Steering Priority/Swing Control Valve Directional Control Valve (Hoist/Lift/Tele) Dual Accumulator Control Valve Swing Brake and Armrest Lockout Manifold 2-32 Published 9-04-2014, Control # 422-08...

  • Page 71: Directional Control Valves

    RT765E-2 SERVICE MANUAL HYDRAULIC SYSTEM DIRECTIONAL CONTROL VALVES Swing/Steer Directional Valve Installation Install the valve on the turntable upright and secure with Description the capscrews, flatwashers, lockwashers and bushings. Torque capscrews; refer to Fasteners and Torque The directional control valves direct and control hydraulic oil Values, page 1-16 for proper torque value.
  • Page 72 HYDRAULIC SYSTEM RT765E-2 SERVICE MANUAL 9, 28 3, 12 8193-2 25 18 16 17 26 27 INLET AUX HOIST TELESCOPE LIFT OUTLET HOIST 8193-4 Main Hoist/Aux Hoist/Lift/Telescope Valve Assembly FIGURE 2-19 2-34 Published 9-04-2014, Control # 422-08...
  • Page 73 RT765E-2 SERVICE MANUAL HYDRAULIC SYSTEM Item Description Item Description Load Sense Gauge Port Port 4A - Lift Extend From Pump Port 4B - Lift Retract Gauge Port Relief Valve - Auxiliary Hoist Up Main Hoist Directional Valve Relief Valve - Telescope Extend Auxiliary Hoist Directional Valve Relief Valve - Telescope Retract Telescope Directional Valve...
  • Page 74 HYDRAULIC SYSTEM RT765E-2 SERVICE MANUAL 2200 2200 2500 6671-3A 6671-2 Swing/Steer Valve Assembly FIGURE 2-20 Item Description Item Description Port 1A - Load Sense Port 2B - Work Port Port 1B - Priority Flow Steer Priority Flow Divider Inlet Port Swing WP Relief Valve Outlet Port Swing WP Relief Valve...
  • Page 75 RT765E-2 SERVICE MANUAL HYDRAULIC SYSTEM 7532-1 7532-3 7532-2 Counterweight Removal Manifold FIGURE 2-21 Item Description Item Description Port P - Pressure to Directional Valve Port 1B - Solenoid Valve SV1 Port LS - Load Sense Port 2B - Solenoid Valve SV3 Port T - Tank to Swivel Port #4 Port 2A - Solenoid Valve SV4 Pressure Compensated Regulator...

  • Page 76: Hydraulic Remote Control Valve

    HYDRAULIC SYSTEM RT765E-2 SERVICE MANUAL HYDRAULIC REMOTE CONTROL VALVE Remove the bolts securing the control valve to the armrest. Remove the control valve. Description Armrest Control Valve Installation The crane has four single axis hydraulic remote control Place the valve on the armrest. Secure the valve to the valves (Figure 2-21).
  • Page 77 RT765E-2 SERVICE MANUAL HYDRAULIC SYSTEM 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/ TELESCOPE BOOM...
  • Page 78 HYDRAULIC SYSTEM RT765E-2 SERVICE MANUAL Dual Axis Item Description Tank Port 4, 8 5, 9 Pump Port Port B2 - Swing Left Port B1 - Swing Right Port A1 - Auxiliary Hoist Cable In Port A2 - Auxiliary Hoist Cable Out Port B2 - Boom Lift Up Port B1 - Boom Lift Down 3, 7...

  • Page 79: Dual Accumulator Charge Valve

    RT765E-2 SERVICE MANUAL HYDRAULIC SYSTEM 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 80 HYDRAULIC SYSTEM RT765E-2 SERVICE MANUAL 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 2-25 2-42 Published 9-04-2014, Control # 422-08...

  • Page 81: Swing Brake And Armrest Lockout Valve Manifold

    RT765E-2 SERVICE MANUAL HYDRAULIC SYSTEM SWING BRAKE AND ARMREST LOCKOUT lockwashers. Torque capscrews; refer to Fasteners and Torque Values, page 1-16 for proper torque value. VALVE MANIFOLD Connect the hydraulic lines to the manifold as tagged Description during removal. The swing brake and armrest lockout valve manifold Connect the electrical connectors to the manifold as Figure 2-26 is located on the right side of the turntable.
  • Page 82 HYDRAULIC SYSTEM RT765E-2 SERVICE MANUAL 7540-1 7540-2 FIGURE 2-26 Item Description Item Description Port P - Inlet Port Port REG 2 - Controller Armrest Lockout Valve Port G - Gauge Port Drain Port REG 1 - Swing Brake Release 2-44 Published 9-04-2014, Control # 422-08...

  • Page 83: Holding Valve

    RT765E-2 SERVICE MANUAL HYDRAULIC SYSTEM HOLDING VALVE NOTE: The holding valve should turn by hand until Description compression of the O-rings begins. A bolt-on externally piloted manifold style holding valve is Carefully install the holding valve into the port block or installed on the lift cylinder and a cartridge style holding valve manifold until fully seated.
  • Page 84 HYDRAULIC SYSTEM RT765E-2 SERVICE MANUAL 8185-2 8185-1 FIGURE 2-27 Item Description Item Description Port V- Inlet Port Relief Valve Port C- Outlet Port Manifold Body 2-46 Published 9-04-2014, Control # 422-08...

  • Page 85: Outrigger/Rear Steer Valve

    RT765E-2 SERVICE MANUAL HYDRAULIC SYSTEM OUTRIGGER/REAR STEER VALVE the solenoid valve to close and allow oil to flow to the selected circuit. Description The rear steer section contains a three position four-way solenoid controlled directional valve. The outrigger/rear steer valve Figure 2-28 controls the outrigger circuit and the rear steer circuit.

  • Page 86: Maintenance

    HYDRAULIC SYSTEM RT765E-2 SERVICE MANUAL Remove the capscrews, nuts, and washers securing the valve to the frame. Remove the valve as a complete Item Description assembly. Port T - Tank Installation Port P - Pressure from High Speed Boost Install the integrated outrigger/rear steer valve to the Selector Valve f r a m e .

  • Page 87: Outrigger Control Manifold

    RT765E-2 SERVICE MANUAL HYDRAULIC SYSTEM OUTRIGGER CONTROL MANIFOLD closed two position two way solenoid valve assemblies, one for each cylinder. They are mounted inside the frame on their Description respective outrigger box. Each solenoid valve contains a manual override actuator which allows the valve to be There are two outrigger control manifolds Figure 2-29 opened if there is a loss of electrical power.

  • Page 88: Maintenance

    HYDRAULIC SYSTEM RT765E-2 SERVICE MANUAL Maintenance Installation Position the manifold on the outrigger box and secure Removal with the washers, hex nuts, and capscrews. Torque Tag and disconnect the hydraulic lines to the solenoid capscrews; refer to Fasteners and Torque Values, page valves;...

  • Page 89: Parking Brake/Range Shift Valve

    RT765E-2 SERVICE MANUAL HYDRAULIC SYSTEM PARKING BRAKE/RANGE SHIFT VALVE Maintenance Description Removal The parking brake/range shift valve controls the flow of oil to Tag and disconnect the electrical connectors to the the parking brake, hi-low range and axle disconnect valve. actuators by the use of two solenoid valves Figure 2-30.
  • Page 90 HYDRAULIC SYSTEM RT765E-2 SERVICE MANUAL 6697-2 Hydraulic Schematic 6697-1 FIGURE 2-30 Item Description Item Description Port P - Pressure Port PB - To Park Brake Port T - Tank Solenoid Valve - Range Shift Port A - Range Shift Actuator Solenoid Valve -Park Brake Port B - Range Shift Actuator Pressure Switch...

  • Page 91: Axle Oscillation Lockout Valve

    RT765E-2 SERVICE MANUAL HYDRAULIC SYSTEM AXLE OSCILLATION LOCKOUT VALVE hydraulic oil cannot leave the cylinders. Instead, the cylinders remain full of hydraulic oil and more rigid. Description When the axle oscillation solenoid valves are energized and open, hydraulic oil is allowed in and out of the cylinders, The axle oscillation lockout valve Figure 2-31(also called the allowing them to oscillate.

  • Page 92: High Speed Boost Selector Valve

    HYDRAULIC SYSTEM RT765E-2 SERVICE MANUAL HIGH SPEED BOOST SELECTOR VALVE Maintenance Removal Description Tag and disconnect the electrical connectors to the The high speed boost selector valve Figure 2-32 is located valve. on port #6 of the hydraulic swivel spool. Output from pump number 1, section 2 passes through the high speed boost Tag and disconnect the hydraulic hoses from the valve.

  • Page 93: Hydraulic Accumulator

    RT765E-2 SERVICE MANUAL HYDRAULIC SYSTEM HYDRAULIC ACCUMULATOR Remove the two nuts securing each clamp half. Remove the each clamp half and accumulator from the turntable. Description Installation The hydraulic accumulators are loc ated inside the Position the accumulator in the clamps and secure with superstructure on the left side under the main hoist.

  • Page 94: Service Brake And Cac Fan Motor Priority Flow Control Valve

    HYDRAULIC SYSTEM RT765E-2 SERVICE MANUAL SERVICE BRAKE AND CAC FAN MOTOR Removal PRIORITY FLOW CONTROL VALVE Tag and disconnect the hydraulic lines attached to the valve. Cap or plug the lines and ports. Description Remove the capscrews, washers, flatwashers and nuts The priority flow control valve is located inside the left frame securing the valve to the valve mounting plate and rail at the center of the frame.

  • Page 95: Oil Cooler Fan Motor Priority Flow Control Valve

    RT765E-2 SERVICE MANUAL HYDRAULIC SYSTEM OIL COOLER FAN MOTOR PRIORITY FLOW Removal CONTROL VALVE Tag and disconnect the hydraulic lines attached to the valve. Cap or plug the lines and ports. Description Remove the capscrews, washers, flatwashers and nuts The priority flow control valve is located inside the right frame securing the valve to the valve mounting plate and rail at the center of the frame.

  • Page 96: Telescope Cylinder Charge Valve Manifold (If Equipped)

    HYDRAULIC SYSTEM RT765E-2 SERVICE MANUAL TELESCOPE CYLINDER CHARGE VALVE MANIFOLD (IF EQUIPPED) Description The telescope cylinder charge valve manifold is used in the telescope cylinder charge system. The charge valve manifold is mounted to the stiffener bracket, which is located behind the swivel, that connects the two vertical sections of the turret together (1, Figure 2-33).
  • Page 97 RT765E-2 SERVICE MANUAL HYDRAULIC SYSTEM 8017 8017-2 Item Description Manifold Solenoid Valve Pressure Reducing Valve Check Valves Pressure Switch FIGURE 2-34 GROVE 2-59 Published 9-04-2014, Control # 422-08...

  • Page 98: Description

    HYDRAULIC SYSTEM RT765E-2 SERVICE MANUAL 8020-2 Item Description Main Directional Control Valve Center Mid/Outer Mid Tele Extend Circuit Inner Mid Tele Extend Circuit Case Drain Manifold Tele Cyl Charge Valve Manifold Swivel Pressure Reducing Sequence Valve FIGURE 2-35 2-60 Published 9-04-2014, Control # 422-08...

  • Page 99: Cylinders

    Fully retract the cylinder rod (except the telescope protected using Boeshield® T-9 Premium Metal Protectant. cylinder). Remove the extend hose from the cylinder. Manitowoc Crane Care has Boeshield® T-9 Premium Metal Cap the extend hose. Protectant available in 12 oz. aerosol cans by ordering part number 9999101803.

  • Page 100: Temperature Effects On Hydraulic Cylinders

    HYDRAULIC SYSTEM RT765E-2 SERVICE MANUAL Apply hydraulic pressure to the retract (rod) side of the the boom sections to slide freely. Slow movement, of the cylinder and observe the open cylinder port for leakage. boom may be undetected by the operator unless a load is suspended for a long period of time.
  • Page 101 RT765E-2 SERVICE MANUAL HYDRAULIC SYSTEM Table 2-5 Boom Drift Chart (Cylinder length change in inches) Coeff. = 0.00043 (in / °F) STROKE Temperature Change (°F) (FT.) 0.26 0.52 0.77 1.03 1.29 1.55 1.81 2.06 2.32 2.58 0.52 1.03 1.55 2.06 2.58 3.10 3.61...

  • Page 102: Lift Cylinder

    HYDRAULIC SYSTEM RT765E-2 SERVICE MANUAL LIFT CYLINDER CAUTION Description When removing seals and rings, avoid scratching the The lift cylinder Figure 2-36 has a bore of 12.0 in (30.5 cm). grooved and gland surfaces. The retracted length of the cylinder from the center of the barrel bushing to the center of the rod bushing is 116.0 in Remove the two hydrolock seals from the outside of the (294.6 cm).
  • Page 103 RT765E-2 SERVICE MANUAL HYDRAULIC SYSTEM 7546 FIGURE 2-36 Item Description Item Description Barrel Holding Valve Retaining Ring Piston Seal Assembly Head Piston Seal GROVE 2-65 Published 9-04-2014, Control # 422-08...
  • Page 104 HYDRAULIC SYSTEM RT765E-2 SERVICE MANUAL Item Description O-ring Backup Ring Wear Ring Buffer Seal Rod Seal Backup Ring FIGURE 2-37 Wiper Ring Capscrew Item Description Insert Buffer Seal Deep Z Rod Seal Capscrew Flatwasher Backup RIng Plug Wiper Ring Plug Install the replacement wear rings, buffer seal and deep Z rod seal in the inside of the head.
  • Page 105 RT765E-2 SERVICE MANUAL HYDRAULIC SYSTEM 15. Screw the head retainer ring into the barrel and align holes in retainer ring with holes in head. Secure the CAUTION head retainer ring to the head with two socket head capscrews. Torque screws to 44 to 48 lb-ft (60 to Exercise extreme care when handling the rods.

  • Page 106: Lower Telescope Cylinder

    HYDRAULIC SYSTEM RT765E-2 SERVICE MANUAL LOWER TELESCOPE CYLINDER Remove the guide lock ring from the piston to gain access to the setscrew. Description Remove the setscrew and unscrew the piston from the rod. The boom lower telescope cylinder Figure 2-39 has a 6 in (152 mm) bore and is internally ported.
  • Page 107 RT765E-2 SERVICE MANUAL HYDRAULIC SYSTEM 27 28 7551 FIGURE 2-39 Item Description Item Description Barrel Backup Ring Piston Buffer Seal Setscrew Rod Seal Seal Assembly Backup Ring Wear Ring Wiper Ring O-ring Retainer Seal Backup Ring Counterbalance Valve Spacer O-ring Wear Ring Backup Ring Head...
  • Page 108 HYDRAULIC SYSTEM RT765E-2 SERVICE MANUAL Item Description Capscrew Washer Capscrew Washer O-ring FIGURE 2-41 Backup Ring Dowel Pin Item Description Seal Buffer Seal Counterbalance Valve Rod Seal Wear Ring Backup Ring Wiper Ring If removed, install the holding valve. Refer to Holding Valve, page 2-45 in this section.
  • Page 109 RT765E-2 SERVICE MANUAL HYDRAULIC SYSTEM 13. Clean all oil from the threads of the cylinder head and 16. Secure the rod retaining plate to the cylinder barrel with apply Loctite #290 to the threads. the 7/16 inch capscrews and washers. Torque the capscrews to 48 to 52 lb-ft (65 to 70 Nm).

  • Page 110: Upper Telescope Cylinder

    HYDRAULIC SYSTEM RT765E-2 SERVICE MANUAL UPPER TELESCOPE CYLINDER Remove the setscrew and discard. Unscrew the piston from the rod. Description Remove the remaining guide lock ring, the hydrolock The upper boom telescope cylinder Figure 2-43 has a 6 in seal assembly, and the wear rings from the outside of (15.2 cm) bore and is internally ported (rod ported).
  • Page 111 RT765E-2 SERVICE MANUAL HYDRAULIC SYSTEM 17, 18 8186-1 FIGURE 2-43 Item Description Item Description Barrel Head Piston Wear Ring Setscrew O-ring Seal Assembly Backup Ring Wear Ring Backup Ring O-ring Rod Seal Backup Ring Counterbalance Valve Spacer Adapter Wiper Ring Wear Ring GROVE 2-73...
  • Page 112 HYDRAULIC SYSTEM RT765E-2 SERVICE MANUAL Install the buffer seal assembly and backup ring in the inside of the head Figure 2-44. FIGURE 2-45 FIGURE 2-44 Item Description Item Description Setscrew Buffer Seal Hydro-lock Seals Rod Seal Backup Ring Backup Ring Guidelock Ring Wiper Ring Wear Ring...

  • Page 113: Axle Oscillation Lockout Cylinder

    RT765E-2 SERVICE MANUAL HYDRAULIC SYSTEM AXLE OSCILLATION LOCKOUT CYLINDER Turn the head counterclockwise with a fitted spanner wrench until the threads disengage. Description NOTE: Residual oil will spill over the end of the barrel. Make Provisions to contain the oil. The oscillation lockout cylinder Figure 2-46 has a 5 in (12.7 cm) diameter bore.
  • Page 114 HYDRAULIC SYSTEM RT765E-2 SERVICE MANUAL 6731 FIGURE 2-46 Item Description Item Description Lip Seal Barrel Wiper Ring Retainer Ring Head Bleeder Plug Lip Seal Grease Fitting Wear Ring Grease Fitting O-ring Setscrew Backup Ring O-ring Wear Ring Buffer Seal 2-76 Published 9-04-2014, Control # 422-08...
  • Page 115 RT765E-2 SERVICE MANUAL HYDRAULIC SYSTEM Clean all oil from the threads of the head. Coat the threads with an anti-seize compound (ex: Never-Seez CAUTION paste lubricant or similar lubricant). Before installing new seals and rings, clean all surfaces Slide the head onto the rod. The head will have to be and carefully remove burrs and nicks.

  • Page 116: Steer Cylinder

    HYDRAULIC SYSTEM RT765E-2 SERVICE MANUAL STEER CYLINDER NOTE: Residual oil will spill over the end of the barrel. Make Provisions to contain the oil. Description Using a hoist, extend the rod assembly slowly until the piston is free of the barrel. The steer cylinders Figure 2-47 are mounted on the axles, two cylinders on each axle.
  • Page 117 RT765E-2 SERVICE MANUAL HYDRAULIC SYSTEM 7548 FIGURE 2-47 Item Description Item Description O-ring Locknut O-ring Retainer Ring Backup Ring Grease Fitting Wiper RIng Barrel Seal O-ring Piston Seal Head Wear Ring GROVE 2-79 Published 9-04-2014, Control # 422-08...
  • Page 118 HYDRAULIC SYSTEM RT765E-2 SERVICE MANUAL Assembly Push the head about half way down the length of the rod assembly.Install the spacer and piston onto the rod. Install the locknut on the rod. CAUTION With the hoist, raise the rod assembly back into a When installing new seals and rings, avoid stretching vertical position taking care not to damage the OD of the seals or scratching the grooved or gland surfaces.

  • Page 119: Outrigger Extension Cylinder

    RT765E-2 SERVICE MANUAL HYDRAULIC SYSTEM OUTRIGGER EXTENSION CYLINDER Place the rod assembly horizontally on a workbench taking care not to damage the surface of the rod. Cover Description the open end of the barrel to avoid contamination. Remove the locknut from the rod. The extension cylinder Figure 2-48 has a 2.5 in (63.5 mm) diameter bores.
  • Page 120 HYDRAULIC SYSTEM RT765E-2 SERVICE MANUAL 6931 FIGURE 2-48 Item Description Item Description Barrel O-ring O-ring Piston Backup Ring Head Rod Seal Spacer Wiper Ring Wear Ring Piston Seal Wear Ring 2-82 Published 9-04-2014, Control # 422-08...
  • Page 121 RT765E-2 SERVICE MANUAL HYDRAULIC SYSTEM Stone out minor blemishes and polish with a fine crocus Slide the head onto the rod. The head will have to be cloth. tapped on with a rubber mallet to engage the seals. Push the head about half way down the length of the rod Clean with solvent and dry with compressed air any assembly.Install the spacer and piston onto the rod.

  • Page 122: Outrigger Jack Cylinder

    HYDRAULIC SYSTEM RT765E-2 SERVICE MANUAL OUTRIGGER JACK CYLINDER NOTE: Do not extend the rod completely. Oil or oil/air mixture may rapidly exit out of the ports during Description extension. Shield the work area from the exiting oil. Turn the head counterclockwise with a fitted spanner The outrigger jack cylinder Figure 2-49 has a 4.5 in (11.4 cm) wrench until the threads disengage.
  • Page 123 RT765E-2 SERVICE MANUAL HYDRAULIC SYSTEM 7, 8 6801 FIGURE 2-49 Item Description Item Description Barrel Backup Ring O-ring Head Wiper Ring Piston Rod Seal Spacer Buffer Seal Check Valve Wear RIng Setscrew O-ring Nylon Insert Backup Ring Plug Seal GROVE 2-85 Published 9-04-2014, Control # 422-08...
  • Page 124 HYDRAULIC SYSTEM RT765E-2 SERVICE MANUAL Assembly 11. Continue turning the head counterclockwise until the thread clicks, then reverse direction to clockwise and thread in until there is no gap between the head CAUTION shoulder and the top of the barrel. When installing new seals and rings, avoid stretching 12.

  • Page 125: Counterweight Removal Cylinder

    RT765E-2 SERVICE MANUAL HYDRAULIC SYSTEM COUNTERWEIGHT REMOVAL 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 counterweight cylinder Figure 2-50 has a 3.5 in (8.9 cm) rings improperly.
  • Page 126 HYDRAULIC SYSTEM RT765E-2 SERVICE MANUAL 7347 FIGURE 2-50 Item Description Item Description Barrel O-ring Wear Ring Head Piston Seal O-ring Piston Backup Ring Spacer Rod Seal Wiper Ring Bolt Bleeder Plug Locknut Plug Holding Valve O-ring 2-88 Published 9-04-2014, Control # 422-08...
  • Page 127 RT765E-2 SERVICE MANUAL HYDRAULIC SYSTEM Install the rod seal, wiper ring and o-ring in the inside of 11. Install new O-rings onto the holding valve. the head. 12. Lubricate the holding valve and O-rings with clean Install the O-ring and backup ring on the outside of the hydraulic oil.
  • Page 128 HYDRAULIC SYSTEM RT765E-2 SERVICE MANUAL THIS PAGE BLANK 2-90 Published 9-04-2014, Control # 422-08...

  • Page 129: Description

    RT765E-2 SERVICE MANUAL SERVICE MANUAL ELECTRICAL SYSTEM SECTION 3 ELECTRICAL SYSTEM SECTION CONTENTS Description ....... 3-1 Gauge Cluster Replacement .
  • Page 130 ELECTRICAL SYSTEM RT765E-2 SERVICE MANUAL FIGURE 3-1 Published 9-04-2014, Control # 422-08...

  • Page 131: Alternator

    RT765E-2 SERVICE MANUAL SERVICE MANUAL ELECTRICAL 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 132 ELECTRICAL SYSTEM RT765E-2 SERVICE MANUAL 7888-3 7888 FIGURE 3-4 7888-2 Figure 3-4 Item Numbers Item Component Item Component ACC Relay, CAB and T/T Modules Power(KS1) Diode Box ACC Relay, Jib Stow, RCL Override, Jib Option Fuse Box Relay, Windshield Wiper Low Speed Panel Screw Relay, Windshield Wiper High Speed Fast Pulse Buzzer Alarm...

  • Page 133: Carrier Electrical Panel

    RT765E-2 SERVICE MANUAL SERVICE MANUAL ELECTRICAL SYSTEM • Fuse 9 - Cab Control Modules Power Item Component • Fuse 10 - Turntable I/O Module Seat Harness Superstructure Harness • Fuse 11 - Turntable Power Module (Horn, Fan Motor) Overhead Harness •...
  • Page 134 ELECTRICAL SYSTEM RT765E-2 SERVICE MANUAL Ignition key switch is in the ACC and RUN positions. ACC Relay #2 is not energized while in START position. 7860 Item Description ECM, 30 Amp Fuse (F1) Cranestar, 5 Amp Fuse (F2) Carrier, Rear Module, 25 Amp Fuse (F3) Carrier, Rear Module, 30 Amp Fuse (F4) Carrier, Front Module, 30 Amp Fuse (F5) Power Control Relay, 5 Amp Fuse (F6)

  • Page 135: Maintenance

    If any of these conditions exist, evaluate the harness assemblies for repair or replacement. For replacement of harness assemblies, refer to your Manitowoc Crane Care Parts Manual. DANGER At the same service interval, visually inspect all Controller...

  • Page 136: General Troubleshooting

    Troubles common to the swivel are improper mounting, foreign material between the brushes 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...

  • Page 137: Alternator/Charging System Troubleshooting

    RT765E-2 SERVICE MANUAL SERVICE MANUAL ELECTRICAL SYSTEM Table 3-3 AMP Crimping Tool Table Description AMP Part Number Manitowoc Part Number Tool Tool 14 to 12 gauge wire 69710-1 90145-1 9999100177 10 to 8 gauge wire 69710-1 90140-1 9999100177 9999100178 4 to 9 circuit...
  • Page 138 ELECTRICAL SYSTEM RT765E-2 SERVICE MANUAL Engine Off Tests Engine On Tests Batteries Output Voltage Test Connect multimeter to negative and positive battery terminals. DANGER Connect ammeter clamp around output wire of alternator to the batteries. Do not smoke or allow sparks or open flame near Start engine and increase speed to 2000 rpm.

  • Page 139: Alternator Replacement

    RT765E-2 SERVICE MANUAL SERVICE MANUAL ELECTRICAL SYSTEM If any voltage drop is greater than the normal range, Close the engine compartment. troubleshoot the system and repair any problems. Reconnect the ground cables to the battery. Turn battery After correcting any problems, perform the Engine On Tests disconnect switch to the connected position.

  • Page 140: Battery Replacement

    ELECTRICAL SYSTEM RT765E-2 SERVICE MANUAL Battery Replacement Turn the battery disconnect switch to ON. Verify replacement batteries work by starting crane’s Removal engine and operating various crane components. Relay Panel Component Replacement CAUTION Accessory Relay To avoid possible engine fault codes and undesirable operation, ensure the keyswitch has been off 2 minutes Turn the ignition switch to the OFF position.

  • Page 141: Gauge Cluster Replacement

    RT765E-2 SERVICE MANUAL SERVICE MANUAL ELECTRICAL SYSTEM Gauge Cluster Replacement Secure the gauge/switch cover (6) to the left and right side covers (8, 9) using six screws (14). Use the following procedures and refer to Figure 3-9 when Secure the left and right side covers (8, 9) together using removing/installing the gauge cluster.

  • Page 142: Ignition Switch Replacement

    ELECTRICAL SYSTEM RT765E-2 SERVICE MANUAL Inspection Check Visually check the switch for evidence of cracks, Operate the switch per the Operator’s Manual. Verify damaged connections, or other damage. Replace each of its functions works. damaged switch as needed. As needed, troubleshoot further any system or circuit Check wiring for damaged insulation or damaged malfunction not corrected by repair or replacement of connectors.

  • Page 143: Turn Signal Lever And Transmission Shift Lever Replacement

    RT765E-2 SERVICE MANUAL SERVICE MANUAL ELECTRICAL SYSTEM b. Place switch at OFF or deactivated position. on the side of the cap farthest from you with your Ohmmeter should register infinity (no continuity). fingers. Replace switch if it fails either part of the check. b.
  • Page 144 ELECTRICAL SYSTEM RT765E-2 SERVICE MANUAL 12. Install the steering wheel (2); torque the securing nut to 16. Turn the battery disconnect switch to the ON position. 30 lb-ft ±4 (40 Nm ±5). Check 13. Install the steering wheel cap (1). Operate the turn signal lever or transmission shift lever 14.

  • Page 145: Windshield Wiper Assembly Replacement

    RT765E-2 SERVICE MANUAL SERVICE MANUAL ELECTRICAL SYSTEM Windshield Wiper Assembly Replacement Installation Verify the pivot shaft and the wiper motor kit link and Removal 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 146: Windshield Washer Assembly Replacement

    ELECTRICAL SYSTEM RT765E-2 SERVICE MANUAL Connect the wiper arm’s washer hose to the washer Turn the battery disconnect switch to the ON position. nozzle fitting assembly. Fill the container with cleaning fluid. Connect the electrical leads to the wiper motor as Check marked before removal.
  • Page 147 RT765E-2 SERVICE MANUAL SERVICE MANUAL ELECTRICAL SYSTEM Install nylon flat washer, leather washer, spacer, and nut Turn the battery disconnect switch to the ON position. on motor shaft. Tighten nut. Check Install wiper arm and blade on motor shaft. Operate the skylight wiper. Verify it works. (Replace Connect the electrical leads to the wiper motor as wiper blade as needed if it streaks or otherwise wipes marked before removal.

  • Page 148: Telescope Cylinder Charge System - Electrical Schematic (If Equipped)

    ELECTRICAL SYSTEM RT765E-2 SERVICE MANUAL Telescope Cylinder Charge System - conditions. Refer to the sub-section titled Lock the retract cable adjustments with the jam nut., page 4-17 for detailed Electrical Schematic (If Equipped) information of this system’s operation. Refer to Figure 3-11 The telescope cylinder charge system prevents boom for an electrical schematic of the telescope cylinder charge retraction due to thermal contraction under certain operating...

  • Page 149: Tools For Troubleshooting

    Manitowoc Crane Care requests you have, as part of your viscosity of the crane’s lubricants, always follow the cold service tool kit inventory, the CAN-Link service tool kit for the weather start-up and operating procedures described in the RT765E-2.
  • Page 150 If the heater remains faulty even after these points have short periods of time. been checked, or another malfunction occurs in your heater, contact an authorized Manitowoc distributor or Troubleshooting Manitowoc Crane Care. In case of faults, please check the following points: Maintenance Instructions •...

  • Page 151: Section 4

    RT765E-2 SERVICE MANUAL BOOM SECTION 4 BOOM SECTION CONTENTS Description ....... 4-1 Inspection .

  • Page 152: Boom Retraction

    BOOM RT765E-2 SERVICE MANUAL allowing the lower cylinder to extend. When the lower cylinder is fully extended, the check valve for the upper CAUTION cylinder opens allowing the upper cylinder to extend. The check valve for the lower cylinder closes after the upper A rollover fixture with webbing is recommended to rotate cylinder starts to extend and shuts off the flow to the lower boom and sections.
  • Page 153 RT765E-2 SERVICE MANUAL BOOM FIGURE 4-1 GROVE Published 9-04-2014, Control # 422-08...
  • Page 154 BOOM RT765E-2 SERVICE MANUAL Item Description Item Description Fly Section RCL Cable Mounting Angles Outer Mid Section Upper Wear Pad Keeper Plates Inner Mid Section Lower and Side Wear Pad Keeper Plates Base Section Upper Boom Nose Sheaves Upper Telescope Cylinder Lower Boom Nose Sheaves‘...
  • Page 155 RT765E-2 SERVICE MANUAL BOOM FIGURE 4-1 continued GROVE Published 9-04-2014, Control # 422-08...
  • Page 156 BOOM RT765E-2 SERVICE MANUAL NOTE: Boom assembly must be r o t a t e d 1 8 0 ° b e f o r e performing assembly or disassembly procedures. NOTE: Inner Mid extend cable anchor plate not shown for clarity.

  • Page 157: Disassembly

    RT765E-2 SERVICE MANUAL BOOM NOTE: The combined weight of the boom inner mid, outer mid, and fly sections, including the telescope cylinders, is approximately 13,871 lb (6292 kg). WARNING Slide the assembly out of the base part way. Ensure the boom lift cylinder is properly supported before 10.
  • Page 158 BOOM RT765E-2 SERVICE MANUAL 25. On the left side of the inner mid, remove the valve 40. Place blocking under the lower and upper cylinder pusher rod from the tube. barrel. 26. On the right side of the inner mid, remove the valve 41.

  • Page 159: Boom Nose Sheaves

    RT765E-2 SERVICE MANUAL BOOM 67. Remove the two flat headed screws securing the rear bottom wear pad on the fly section and remove the wear pad. WARNING 68. If necessary, remove both grease fittings, connectors, Ensure the telescope cylinders are securely blocked and and grease lines from the rear of the fly section.

  • Page 160: Assembly

    BOOM RT765E-2 SERVICE MANUAL Repeat steps 2 and 3 and remove the lower boom nose sheave shaft. CAUTION Remove the shim, keyed washer, washer, and locknut A rollover fixture with webbing is recommended to rotate from both sheave shafts. boom and sections. Chains are not recommended. If a rollover fixture is not available, rotate sections using Installation adequate support with webbing.
  • Page 161 RT765E-2 SERVICE MANUAL BOOM shaft with a plate and the capscrews and washers on the rod end of the cylinders will aid in sliding these each side of the cylinder mount. together. Turn the lower telescope cylinder rod so the trunnion is 20.
  • Page 162 BOOM RT765E-2 SERVICE MANUAL NOTE: Use shims as necessary to adjust wear pad so that grease line). Stop and install rear side wear pads and the wear pad is just touching or is within 0.078 in (2 shims on outer mid section with two flat headed screws. mm) of the fly section side plate at both the top and NOTE: Use shims as necessary to adjust wear pad so it is...

  • Page 163: Installation

    RT765E-2 SERVICE MANUAL BOOM 63. Install the cam valves on the mounting plates on each 0.078 in (2 mm) clearance to block on the inner mid side of the inner mid using the capscrews. section. 64. If removed, install hydraulic fittings in the ports of the 76.

  • Page 164: Functional Check

    BOOM RT765E-2 SERVICE MANUAL Functional Check Activate the hydraulic system and check for proper operation and any leaks. DANGER Ensure the boom will extend and retract properly. Block the boom before doing any work under the boom. Failure to properly support the boom may result in death Ensure the lift cylinder will not allow the boom to drift or serious injury.

  • Page 165: Cam Operated Check Valve Adjustment

    RT765E-2 SERVICE MANUAL BOOM Cam Operated Check Valve Adjustment Right side valve: through the access hole in the base section on the right rear of the inner mid, loosen the lock There are two cam operated check valves mounted on the nut and adjust the bolt until it just contacts the valve back of the inner mid boom section.

  • Page 166: Boom Extension And Retraction Cable

    BOOM RT765E-2 SERVICE MANUAL BOOM EXTENSION AND RETRACTION inside of the boom section. This will make a somewhat audible noise, however this will not cause any damage and is CABLE acceptable. If the cables do not make a slapping noise under these conditions, it is an indication that the extension cables Maintenance may be too tight and should be readjusted.

  • Page 167: Telescope Circuit

    RT765E-2 SERVICE MANUAL BOOM The telescope cylinder charge system will prevent the boom from retracting under these conditions by automatically CAUTION replenishing the volume of hydraulic oil lost in the telescope cylinders due to thermal contraction. Over tightening of the retract cable will damage the cable. take care when retracting the boom fully, while adjusting Additionally, the system utilizes a pressure switch plumbed the cable, to avoid full boom retraction if the fly section...

  • Page 168: Maintenance

    BOOM RT765E-2 SERVICE MANUAL Maintenance Troubleshooting SYMPTOM PROBABLE CAUSE SOLUTION Erratic operation Low hydraulic oil level. Check system for leaks. Make repairs as e x t e n d i n g needed. Fill reservoir. t e l e s c o p i n g b.
  • Page 169 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 170: Description

    BOOM RT765E-2 SERVICE MANUAL Removal And Installation both the piston and cylinder head prevent internal and external hydraulic oil leakage. Refer to Telescope Cylinder Removal and installation of the telescope cylinder from the Charge Valve Manifold (If Equipped), page 2-58 for a boom is described under disassembly and assembly of the complete description of the lift cylinder.
  • Page 171 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 172: Lift Cylinder Removal

    BOOM RT765E-2 SERVICE MANUAL Symptom Probable Cause Solution Boom will not Low hydraulic oil. Check system for leaks. Make repairs lower. as needed. Fill reservoir. 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 173 RT765E-2 SERVICE MANUAL BOOM 4, 5 Detail A Detail B FIGURE 4-3 Item Description Item Description Capscrew Washer (2) Locknut Stop Plate Shaft Shaft Capscrew (2) Grease Fitting (2) GROVE Published 9-04-2014, Control # 422-08 4-23...

  • Page 174: Swingaway Boom Extension

    BOOM RT765E-2 SERVICE MANUAL SWINGAWAY BOOM EXTENSION Description A 33 ft (10.1 m) fixed offsetable or a 10.1 to 17.1 m (33 to 56 ft) folding offsetable swingaway boom extension is provided to obtain additional boom reach. The boom extension mounts directly to the boom nose utilizing a four point attachment.
  • Page 175 RT765E-2 SERVICE MANUAL BOOM 6056 FIGURE 4-5 Item Description Item Description Base To Fly Attachment Pins Mast Assembly Boom Extension Base Section Boom Nose To Boom Extension Attachment Anchor Fittings Boom Extension Fly Section Boom Nose To Boom Extension Attachment Fly Rear Stowage Bracket Pins Stinger Section Front Stowage Bracket...
  • Page 176 BOOM RT765E-2 SERVICE MANUAL 6160 Item Description Boom Extension Base Section Adjusting Bolt Upper Hanger Main Hanger Lower Support Lock Hitch Pin Detail A 6058 Adapter Item Description Boom Extension Fly Section Adjusting Bolt Adjusting Bolts Front Mount Hanger Detail B 6058 FIGURE 4-5 continued 4-26...
  • Page 177 RT765E-2 SERVICE MANUAL BOOM Item Description Boom Extension Base Section Boom Extension Fly Section Shock Wear Pad and Shim Ramp Wear Pad and Shim Detail C Item Description Boom Extension Base Section Boom Extension Fly Section Fly Attachment Pin and Hitch Pin Adjusting Bolts Pin Stowage Lug Upper Support...
  • Page 178 BOOM RT765E-2 SERVICE MANUAL Item Description Boom Extension Base Section Boom Extension Fly Section Fly Sheave Cable Retainer Pins Latch Hook Spring Latch Bar Detail E Item Description Boom Nose Upper Sheaves Mast Assembly Offset Links Offset Pivot Points Offset Link Pins Stowage Lugs Mast Assembly Pin Boom Nose Lower Sheaves...
  • Page 179 RT765E-2 SERVICE MANUAL BOOM Working Position 5, 6 Item Description Pusher Bar Collar Clamp 6658-2 Adjustment Bar Push Bar Assembly 5, 6 Hitch Pin Clip Pin Stowed Position FIGURE 4-5 continued 12. Remove lock hitch pin securing the extension base to 14.
  • Page 180 BOOM RT765E-2 SERVICE MANUAL Lower the boom to minimum elevation. Attach a length of rope to the extension base tip. WARNING Raise the boom to horizontal. When erecting the boom extension, ensure that all Remove the retainer clips and attachment pins from the personnel and equipment are kept clear of the swing path.
  • Page 181 RT765E-2 SERVICE MANUAL BOOM 13. Pull down on the handle to disengage the spring loaded boom stop block. Place the end of the handle in the CAUTION retainer plate. Fully retract the boom. Failure to maintain the proper clearance between the NOTE: When the boom retracts, the handle will be swingaway anchor fittings and the boom nose attach...

  • Page 182: Description

    BOOM RT765E-2 SERVICE MANUAL Swingaway Mounting Adjustment attach pin. Position extension base on stowage brackets on side of boom. The following procedures may be used to adjust the existing 12. Lift up on sheave end of stinger until attachment pin is installation or for installing a new swingaway and/or stinger.

  • Page 183: Description

    RT765E-2 SERVICE MANUAL HOIST AND COUNTERWEIGHT SECTION 5 HOIST AND COUNTERWEIGHT SECTION CONTENTS Description ....... 5-1 Idler Drum and Cable Follower.

  • Page 184: Maintenance

    HOIST AND COUNTERWEIGHT RT765E-2 SERVICE MANUAL MAINTENANCE Use the hoist access platform (1) (Figure 5-1) when working in the hoist area. Warm-up Procedure A warm-up procedure is recommended at each start-up and is essential at ambient temperatures below 40°F (4°C). The prime mover should be run at its lowest recommended RPM with the hydraulic hoist control valve in neutral allowing sufficient time to warm up the system.
  • Page 185 RT765E-2 SERVICE MANUAL HOIST AND COUNTERWEIGHT Main and Auxiliary Hoist Installation 6929-1 Item Description Hoist Capscrew Shim Washer Turntable Capscrew Counterweight Plate Shim 6929-2 FIGURE 5-2 Main Hoist Only Installation GROVE Published 9-04-2014, Control # 422-08...

  • Page 186: Removal

    HOIST AND COUNTERWEIGHT RT765E-2 SERVICE MANUAL With the hoist level, check to determine if all the hoist mounting pads are in contact with the mounting plate by Item Description rocking the hoist. Hoist Keeping the hoist level, use a feeler gauge to determine Capscrew the amount of gap existing between the pads and the Shim...

  • Page 187: Usage And Inspection

    RT765E-2 SERVICE MANUAL HOIST AND COUNTERWEIGHT Table 5-1 Reading Diagnosis Action Required Fill the hoist with oil from the upper access hole until the oil level rises within the sight glass. Do not fill above 1/8 in The hoist is under Oil is not visible in the sight glass.
  • Page 188 HOIST AND COUNTERWEIGHT RT765E-2 SERVICE MANUAL • High external contaminations, such as dusty or sandy • Take a sample of the lubricant from the hoist gear cavity conditions. as described in Gear Oil Sampling and Analysis, page 5- 7 and analyze it for wear metals content, correct •...

  • Page 189: Oil Sampling

    RT765E-2 SERVICE MANUAL HOIST AND COUNTERWEIGHT hoist line pull and load holding test must be conducted General Guidelines for Iron Contaminant following the repair work. Level Oil Sampling 100-500 ppm Normal Oil Change 500-800 ppm The hoist gear oil must be changed after the first 100 Caution - Abnormal Sample.

  • Page 190: Hoist To Boom Alignment

    Manitowoc Crane Care offers prepackaged kits that include the drum at a 90 degree angle. The boom has the ability all the seals, bearings, fasteners, washers, brake disks,...
  • Page 191 RT765E-2 SERVICE MANUAL HOIST AND COUNTERWEIGHT by using a tape measure. With the boom at 0 degree, tie mounting bolts will have to be loosened and the hoist the line tight to the boom nose and have it in the center moved so it is.

  • Page 192: Motor And Brake

    HOIST AND COUNTERWEIGHT RT765E-2 SERVICE MANUAL MOTOR AND BRAKE Cover the motor opening in the brake cylinder to protect drive components inside the hoist drum. As needed, Description secure the brake clutch from inside the brake cylinder. Each hoist has a hydraulic motor, a brake valve, a brake Installation cylinder, and a brake clutch which control motion of the NOTE:...

  • Page 193: Idler Drum And Cable Follower

    RT765E-2 SERVICE MANUAL HOIST AND COUNTERWEIGHT IDLER DRUM AND CABLE FOLLOWER Disassemble the cable follower roller as follows. Remove the two bolts and washers securing the Description angle to the right side of the shaft. The main and auxiliary hoists (Figure 5-6) are each b.

  • Page 194: Description

    HOIST AND COUNTERWEIGHT RT765E-2 SERVICE MANUAL 1.0 cm (0.42 inch) 7837-2 7837-1 FIGURE 5-6 Item Description Item Description Pivot Bracket Lever Drum Idler Roller Follower Roller Bracket Spring 3rd Wrap Limit Switch (Optional) Spring Adjusting Rod 5-12 Published 9-04-2014, Control # 422-08...
  • Page 195 RT765E-2 SERVICE MANUAL HOIST AND COUNTERWEIGHT Using a grease gun, apply grease to the fittings on each Complete Assembly side plate bushing. Removal Adjust the roller as outlined in steps 9 and 10. Remove all tension from the springs on each side by With one layer of cable on the hoist drum, adjust the loosening the nuts and jam nuts.

  • Page 196: Third Wrap Indicator (Optional-Standard On Ce)

    HOIST AND COUNTERWEIGHT RT765E-2 SERVICE MANUAL THIRD WRAP INDICATOR (OPTIONAL— illuminating when down to the third wrap, hoist down operation will be locked out. STANDARD ON CE) Maintenance Description The third wrap indicator switch mechanism must be adjusted The third wrap indicator (Figure 5-7) 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 remaining on the drum, the switch is actuated.

  • Page 197: 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 198 HOIST AND COUNTERWEIGHT RT765E-2 SERVICE MANUAL 7792-2 Drum Rotation Sensor 7792-3 Button Control Lever Thumb Thumper Handle Rotation Indicator Solenoid Single Axis Controller FIGURE 5-9 5-16 Published 9-04-2014, Control # 422-08...

  • Page 199: Hoist Control Valves

    RT765E-2 SERVICE MANUAL HOIST AND COUNTERWEIGHT HOIST CONTROL VALVES hoist motor in both directions. This is a different valve than the hoist motor control valve that applies and releases the Description hydraulic piston and hydraulic cylinder. Hoist Directional Control Valve NOTE: For more detailed information, refer to Valves, page 2-30 in Section 2 - Hydraulic System.

  • Page 200: Fixed Counterweight

    HOIST AND COUNTERWEIGHT RT765E-2 SERVICE MANUAL FIXED COUNTERWEIGHT remove each pin assembly, push it in and turn it so its roll pin disengages from the related catch on the Description counterweight. Lower counterweight enough clear The counterweight Figure 5-10 is pinned to the rear of the superstructure and remove the counterweight from the superstructure and weighs about 14,400 lb (6540 kg).
  • Page 201 RT765E-2 SERVICE MANUAL HOIST AND COUNTERWEIGHT 7064 FIGURE 5-10 Item Description Item Description Fixed Counterweight Counterweight Leveling Hardware Counterweight Pin Assembly GROVE Published 9-04-2014, Control # 422-08 5-19...

  • Page 202: Removable Counterweight (Optional)

    HOIST AND COUNTERWEIGHT RT765E-2 SERVICE MANUAL REMOVABLE COUNTERWEIGHT Stow the counterweight pin assemblies in the bushings on the side of the superstructure. (OPTIONAL) Using the counterweight removal control valve switches, slowly lower the counterweight onto the support weldment. Make sure the counterweight’s weight fully rests on the support weldment.
  • Page 203 RT765E-2 SERVICE MANUAL HOIST AND COUNTERWEIGHT 6 (4 places) 7889 FIGURE 5-12 Item Description Item Description Control Valve Switch Panel Leveling Bolts (4 places) Counterweight Cylinders Counterweight Lifting Lugs (4 places) Counterweight Pin Assemblies Hoist(s) Cylinder Pin Assemblies Superstructure Removable Counterweight GROVE Published 9-04-2014, Control # 422-08 5-21...
  • Page 204 HOIST AND COUNTERWEIGHT RT765E-2 SERVICE MANUAL Secure the counterweight to the superstructure with the two counterweight pin assemblies. To secure each pin assembly, push it in and turn it so its roll pin engages the related catch on the counterweight. Then release the pin assembly so its spring can hold the pin assembly in place.

  • Page 205: Description

    RT765E-2 SERVICE MANUAL SWING SYSTEM SECTION 6 SWING SYSTEM SECTION CONTENTS Description ....... 6-1 Description.

  • Page 206: Swing Drive

    SWING SYSTEM RT765E-2 SERVICE MANUAL pressure in the swing brake applies the brake. When the Regulated flow from the pressure reducing/sequence valve Swing Brake Selector Switch is positioned to OFF, the is also provided to the power brake valve where it is available regulated flow is directed from the pressure reducing/ for the activation of the swing brake when the pedal is sequence valve to the brake release port, overcoming the...

  • Page 207: Maintenance

    Reduce load. Refer to load capacity chart. Restricted or partly clogged hydraulic Replace hose or fittings. Refer to the hose or fittings. Manitowoc Crane Care Parts Manual. Pump cavitation in swing section. Tighten suction hose or replace any damaged fitting. Check hydraulic tank level.
  • Page 208 Lubricate bearing per recommendations. Refer to Lubrication, page 9-1. Improper size hose and/or fittings Replace hose or fittings. Refer to the installed. Manitowoc Crane Care Parts Manual. Clogged or restricted hydraulic hoses Clean or replace damaged parts. or fittings. g. Worn damaged...

  • Page 209: Swing Brake

    RT765E-2 SERVICE MANUAL SWING SYSTEM Symptom Probable Cause Solution Swing operation Crane not level. Level crane. slow in one b. Damaged hydraulic remote control b. Replace hydraulic remote control direction only. valve. valve. Damaged swing directional control Replace the swing directional control valve.
  • Page 210 SWING SYSTEM RT765E-2 SERVICE MANUAL Symptom Probable Cause Solution 12. Swing motor Improper port connections. Reverse port connection. turning in wrong b. Improper wiring connection b. Inspect wiring and connections direction. 13. Swing motor noisy. Air in system. Refer to Hydraulic System, page 2-1, for removal of air from the system.

  • Page 211: Swing Motor

    RT765E-2 SERVICE MANUAL SWING SYSTEM SWING MOTOR Remove the two screws and separate the motor from the brake flange. Remove and discard the O-ring from Description the groove in the swing brake. Installation The Swing Motor is mounted on the swing brake housing and drives the swing gearbox through the brake assembly (Figure 6-1).

  • Page 212: Swing Gearbox And Brake

    SWING SYSTEM RT765E-2 SERVICE MANUAL SWING GEARBOX AND BRAKE Testing With the Swing Brake switch in the ON position, position Description the swing control lever in both directions. Superstructure rotation should not occur. The Swing Gearbox and Brake (Figure 6-1), used in conjunction with the Swing Motor, rotates and stops the Position the Swing Brake switch to OFF and swing the superstructure.
  • Page 213 RT765E-2 SERVICE MANUAL SWING SYSTEM Connect the hydraulic lines to the swing brake. NOTE: Cleaning of the gearbox with a solvent is recommended to prevent an accumulation of grit Connect the hydraulic lines to the swing motor. and grime. Avoid steam cleaning where moisture and dirt might be driven into the vent of the swing Service the gearbox as indicated under Servicing.

  • Page 214: Swing Bearing

    SWING SYSTEM RT765E-2 SERVICE MANUAL SWING BEARING a high strength bolt is removed, or un-torqued, the bolt must be replaced with a new bolt of the same classification. Description The swing bearing is an anti-friction roller bearing that mates the superstructure to the carrier. The bearing inner race is WARNING bolted to the superstructure and the outer race is bolted to It is mandatory that bearing attaching bolts be inspected...
  • Page 215 RT765E-2 SERVICE MANUAL SWING SYSTEM Inner Race Outer Race FIGURE 6-2 Multiplier bar handles must be propped or supported socket, multiplier, backlash adapter, necessary within the outer 1/4 of the handle length, or serious extensions, and torque wrench. under or over tightening will occur. Return to bolt 1 and torque all bolts sequentially in a The inner race of the bearing is secured to the turntable clockwise direction to their final torque value specified.
  • Page 216 Orders for special tools 1. 1½” Socket 3/4” Drive 9999100143 shall be referred to: 2. 4 to 1 Torque Multiplier (1/2” Input 3/4” Output) 9999100134 The Manitowoc Company, Inc 3. Backlash Adapter 9999100141 1565 Buchanan Trail East 4. 1/2” Drive Torque Wrench 9999100136 Shady Grove, PA 17256 5.
  • Page 217 RT765E-2 SERVICE MANUAL SWING SYSTEM 13. Attach a suitable lifting device to the four superstructure Installation lifting lugs (two at the boom pivot shaft bushings and two at the lower lift cylinder pivot shaft bushings). Take in cable or chain to remove slack. Do not pull up on the superstructure.
  • Page 218 SWING SYSTEM RT765E-2 SERVICE MANUAL Install the gearbox pinion aligning the high point 10. Install the boom and lift cylinder following the procedures (maximum eccentricity) on the turntable bearing. Using outlined in Section 4 - Boom. a 0.008 in (0.203 mm) thick shim, check the backlash NOTE: The fixed counterweight weighs approximately (Figure 6-4).

  • Page 219: Swivels

    RT765E-2 SERVICE MANUAL SWING SYSTEM SWIVELS stationary with the carrier as the case rotates with the superstructure. Description The spool portion of the water swivel is attached to the spool of the hydraulic swivel by four bolts. The hydraulic and water The swivel assembly consists of a 12 port hydraulic swivel swivel spools remain stationary with the carrier as the (Figure 6-5), a 2 port water swivel, and a 20 conductor slip...

  • Page 220: Description

    SWING SYSTEM RT765E-2 SERVICE MANUAL Item Description 7, 8 3, 4 20 Conductor Slip Ring Assembly Center Post Capscrew Flatwasher Swivel Assembly Retainer Plate Capscrew Flat Washer Plate 7897-3 FIGURE 6-5 Published 9-04-2014, Control # 422-08 6-16...

  • Page 221: Hydraulic Swivel

    RT765E-2 SERVICE MANUAL SWING SYSTEM 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. Test Pressure Port # Function psi (kPa) 3625 (25,000) Brake-Front (Primary) 3625 (25,000)
  • Page 222 SWING SYSTEM RT765E-2 SERVICE MANUAL NOTE: The hydraulic swivel weighs approximately 386 lb Position the retainer plate on the hydraulic swivel spool (175 kg). The hydraulic, water, and electrical swivel ensuring they engage the lugs on the carrier frame. combined weigh approximately 454 lb (206 kg). Secure the retainer plate with four bolts two bolt retainers.

  • Page 223: Two Port Water Swivel

    RT765E-2 SERVICE MANUAL SWING SYSTEM TWO PORT WATER SWIVEL Cleaning And Inspection Description The 2 port water swivel allows engine coolant to flow from WARNING the carrier-mounted engine to the hot water heater in the Cleaning solvents can be toxic, flammable, an irritant to operator’s cab.

  • Page 224: Electrical Swivel

    SWING SYSTEM RT765E-2 SERVICE MANUAL Activate all systems, cycle all functions, and observe for Tag the connectors and their receptacles with numbers. proper operation and any leakage. Disconnect the connectors from the chassis wiring receptacles. ELECTRICAL SWIVEL NOTE: The connectors are too large to go through the center of the hydraulic swivel.
  • Page 225 RT765E-2 SERVICE MANUAL SWING SYSTEM Ensure the anti-rotation pin in the bottom of the electrical 10. Activate all systems, cycle all functions, and observe for swivel base is aligned with the mounting hole in the proper operation. Adjust the slew angle in accordance with Slew Angle Verification, page 6-21.

  • Page 226: Swing Lock Pin

    SWING SYSTEM RT765E-2 SERVICE MANUAL SWING LOCK PIN Maintenance Verify cable is routed to avoid damage from superstructure Description rotation and is undamaged. Verify swing lock assembly is T h e p u r p o s e o f t h e s w i n g l o c k p i n i s t o l o c k t h e u n d am a g e d a n d w o r k i ng p r op e r l y.

  • Page 227: Engine

    RT765E-2 SERVICE MANUAL POWER TRAIN SECTION 7 POWER TRAIN SECTION CONTENTS Engine ........7-1 Muffler .

  • Page 228: Maintenance

    POWER TRAIN RT765E-2 SERVICE MANUAL energized again for a time period determined by intake air the four sets of capscrews, locknuts, and washers (two temperature. sets on each side) securing the transmission/torque converter to the frame. Maintenance 16. Using the lifting device, lift the engine and transmission/ torque converter as an assembly from the crane.
  • Page 229 RT765E-2 SERVICE MANUAL POWER TRAIN Attach the fuel filter and engine lubrication filter to the Engine Drive Belts 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 230: Electronic Control System

    POWER TRAIN RT765E-2 SERVICE MANUAL ELECTRONIC CONTROL SYSTEM Increment/Decrement Switch The Increment/Decrement Switch is a three position Description momentary rocker switch with center maintained position being off. Use this switch to toggle backward and forward The engine control system is an electronically operated fuel through active engine fault codes or adjust engine speed.
  • Page 231 RT765E-2 SERVICE MANUAL POWER TRAIN amber when the diesel particulate filter is getting filled with option, if needed, of performing regeneration outside the soot and needs to be cleaned out. normal duty cycle. Diesel Particulate Filter Regeneration Switch (Tier 4 CAUTION Engines Only) Engine Shut-down Condition!
  • Page 232 POWER TRAIN RT765E-2 SERVICE MANUAL Inhibit Regeneration Indicator During regeneration it is possible for the engine exhaust to reach temperatures exceeding 1200°F. The HEST indicator The Inhibit Regeneration indicator is located in the steering will illuminate red to warn the operator of when temperatures column gauge display.

  • Page 233: Fuel System

    RT765E-2 SERVICE MANUAL POWER TRAIN FUEL SYSTEM Maintenance NOTE: The entire fuel system must be maintained air tight Description to prevent loss of prime. The fuel system consists of the fuel tank, fuel-water Fuel Tank separator, secondary filter, lift pump, high-pressure pump, high-pressure common fuel rail (Tier 4 only) and the fuel The fuel tank should be kept filled, especially overnight, to injectors.

  • Page 234: Description

    POWER TRAIN RT765E-2 SERVICE MANUAL FRONT 7875-1 FIGURE 7-2 Item Description Item Description Fuel Tank Fuel Supply Fuel Quantity Sender Fuel Water Separator Cooler Step Fuel Return Step Extension To Engine Filler Cap Published 9-04-2014, Control # 422-08...

  • Page 235: Air Intake And Exhaust System

    RT765E-2 SERVICE MANUAL POWER TRAIN AIR INTAKE AND EXHAUST SYSTEM transfer tubing or just inside the intake manifold inlet. Description Inspect the air cleaner outlet tube for damage. The air intake system (Figure 7-3) controls the quality and Ensure the element sealing surface is not damaged and amount of air available for combustion.
  • Page 236 POWER TRAIN RT765E-2 SERVICE MANUAL 7841 Air Intake Installation - Typical FIGURE 7-3 Item Description Item Description Air Cleaner Assembly 5 in Air intake Tube Mounting Bracket Adapter Clamp Bracket Service (Restriction) Indicator Air Intake Tube Reducer Elbow Clamp T-bolt clamp Muffler Clamp Adapter Mounting Bracket...
  • Page 237 RT765E-2 SERVICE MANUAL POWER TRAIN Filter Element Replacement with the fins on the element or inside the body. Repair any body dents, being careful not to damage the sealing surfaces. Be sure to clean the sealing surface of the outlet CAUTION tube and the inside of the outlet tube, taking care not to damage the sealing area on the tube.
  • Page 238 POWER TRAIN RT765E-2 SERVICE MANUAL Check the condition of the valve and lips frequently and keep flow. Repair the screen or replace the cap if any large them clean. The valve lips should be open only when the holes are found in the screen. engine is shut down, or running at low idle speed.

  • Page 239: Charge-Air Cooler System

    RT765E-2 SERVICE MANUAL POWER TRAIN Charge-Air Cooler System The CAC system consists of the ducting to and from the charge-air cooler and a hydraulically driven fan. The charge- The charge-air cooler (CAC) (Figure 7-7) is used to cool air cooler system must be air-tight in order to work efficiently. engine air after it has passed through a turbocharger, but The ducting consists of metal tubing, hose clamps and before it enters the engine.

  • Page 240: Muffler

    POWER TRAIN RT765E-2 SERVICE MANUAL Muffler Remove clamp to free muffler from exhaust tube. Tier 4 only—tag and disconnect electrical connections. NOTE: Tier 3 muffler (Figure 7-8) and Tier 4 muffler (Figure 7-9) are similar in removal and installation Remove mounting bands to free muffler from muffler despite the differences in the two mufflers, the mounting bracket.
  • Page 241 RT765E-2 SERVICE MANUAL POWER TRAIN 7844 Tier 3 Muffler FIGURE 7-8 Item Description Item Description Exhaust Tube Exhaust Elbow Clamp Muffler Muffler Clamp Mounting Band Elbow Exhaust Bracket Flex Tube Bracket Elbow GROVE 7-15 Published 9-04-2014, Control # 422-08...
  • Page 242 POWER TRAIN RT765E-2 SERVICE MANUAL 7843 Tier 4 Diesel Particulate Filter/Muffler FIGURE 7-9 Item Description Item Description Elbow Gasket Wire Tie Bar V-Band Clamp Mounting Band Clamp Bellows Diesel Particulate Filter Exhaust Tube Muffler Clamp Gasket Exhaust Tube V-Band Clamp 7-16 Published 9-04-2014, Control # 422-08...

  • Page 243: Water Cooling System

    RT765E-2 SERVICE MANUAL POWER TRAIN WATER COOLING SYSTEM Poor lubrication - increased engine wear. Sticking valves. Description Short injector life. The cooling system consists of a Radiator, Surge Tank, Engine hot spots. engine cooling circuit, the connecting hoses and connecting tubes (Figure 7-10).
  • Page 244 POWER TRAIN RT765E-2 SERVICE MANUAL Antifreeze/Supplemental Coolant Additives Coolant shut-off valves to heaters and other accessories should be open to allow complete circulation during Maintenance Summary cleaning, flushing, and draining. Run the engine with Cooling System Level Check Interval radiator covered if necessary until temperature is up to operating range 160 to 180°...
  • Page 245 RT765E-2 SERVICE MANUAL POWER TRAIN Clamp the flushing gun nozzle firmly to a hose attached securely to the engine water outlet opening. Fill the engine block with water, partly covering the water inlet opening to permit complete filling. CAUTION Burn Hazard! Turn on compressed air to blow out water and loose sediment.
  • Page 246 POWER TRAIN RT765E-2 SERVICE MANUAL retarding or restricting the circulation of coolant during Hoses and Clamps engine warm up. Engine overheating and loss of coolant is Hoses and their connections must be checked regularly sometimes due to an inoperative thermostat. To check for because they are often the source of hidden trouble.
  • Page 247 RT765E-2 SERVICE MANUAL POWER TRAIN 7838-1 FIGURE 7-10 Item Description Item Description Fan & Fan Guard Surge Tank Shroud Upper radiator Hose Drain Valve Lower Radiator Hose Radiator GROVE 7-21 Published 9-04-2014, Control # 422-08...

  • Page 248: Drive Train

    POWER TRAIN RT765E-2 SERVICE MANUAL DRIVE TRAIN The cooler is located beside the hydraulic oil tank. An oil filter is located on the left side of the engine hood. Access to the Description filter is gained by opening the top left side hood door. Three drive lines are used.
  • Page 249 RT765E-2 SERVICE MANUAL POWER TRAIN Drive Shafts Remove the bolts from the bearing cap on each end of the drive line. Note the lengths of the bolts and if they have lockwashers. Remove the drive line. CAUTION Installation Do not disassemble drive lines when removing them from For any drive shaft which has mating marks (arrows), the crane.

  • Page 250: Transmission/Torque Converter

    POWER TRAIN RT765E-2 SERVICE MANUAL 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 251: Maintenance

    RT765E-2 SERVICE MANUAL POWER TRAIN Maintenance flow, it is essential that the following preliminary checks be made. General Information Check oil level in transmission. This should be done with Always check the oil level with the engine idling, and the oil temperature at 180 to 200°F (82 to 93°C).
  • Page 252 POWER TRAIN RT765E-2 SERVICE MANUAL SYMPTOM PROBABLE CAUSE REMEDY Noisy converter. Worn oil pump. Replace pump. b. Worn or damaged bearings. b. A complete disassembly will be necessary to determine what bearing is faulty. Lack of power. Low engine RPM at converter Tune engine and check stall.
  • Page 253 RT765E-2 SERVICE MANUAL POWER TRAIN Mount Flywheel Dial Housing Indicator Here Engine Flywheel Pilot Bore Flywheel Figure 1 Converter Housing Flywheel 10.2 Cm (4 In.) Stud 6.4 Cm (2-1/2 In.) Aligning Studs Drive Plate Flywheel Special Stud, Washer And Housing Self-lock Nut Furnished By Engine Manufacturer Figure 2...

  • Page 254: Towing Or Pushing

    POWER TRAIN RT765E-2 SERVICE MANUAL 14. Cycle all functions and observe for proper operation. Assemble all components and use only the type oil recommended. Fill the transmission through the fill pipe Servicing The Crane After Transmission/torque until fluid is at the top of the fill range on the dipstick. Run Converter Overhaul the engine for two minutes at idle (950 rpm) to prime the torque converter and hydraulic lines.

  • Page 255: Description

    RT765E-2 SERVICE MANUAL UNDERCARRIAGE SECTION 8 UNDERCARRIAGE SECTION CONTENTS Axles ........8-1 Maintenance .

  • Page 256: Maintenance

    UNDERCARRIAGE RT765E-2 SERVICE MANUAL reduction, through the revolving planet gears, and into the 12. If a new axle is to be installed, remove the following from planetary spider which drives the wheel hub. the old axle and install them on the new one. As an option, the front axle and rear axle may be provided The steer cylinders.
  • Page 257 RT765E-2 SERVICE MANUAL UNDERCARRIAGE Wheel Alignment Check Procedure pin at the rod end and apply pressure to move the cylinder rod. The cylinder rod should travel a minimum of Check the axle for wheel alignment. The wheels are to 0.12 in (3.0 mm). be straight ahead with no toe-in or toe-out.

  • Page 258: Wheels And Tires

    UNDERCARRIAGE RT765E-2 SERVICE MANUAL Wheels and Tires Mounting Wheel Assemblies NOTE: Do not lubricate the wheel studs or lug nuts. Description Raise the crane on outriggers so the wheels are off the The standard tire size for this unit is 29.5 x 25; also available ground.
  • Page 259 RT765E-2 SERVICE MANUAL UNDERCARRIAGE FIGURE 8-5 FIGURE 8-3 Item Description Incorrect Camber Incorrect Toe-In Incorrect camber gives abnormal wear on one half of the tire. Incorrect Toe-Out Out-of-line Axles Steering Arm Defect Incorrect Caster and Wheel Imbalance Incorrect caster or wheel imbalance shows as spot wear that is either in the middle of the tire or extends to the shoulder.
  • Page 260 UNDERCARRIAGE RT765E-2 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 261: Steering Systems

    RT765E-2 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 262: Maintenance

    UNDERCARRIAGE RT765E-2 SERVICE MANUAL Maintenance Front Steering System Troubleshooting Table 8-1 Symptom Probable Cause Solution Hard to steer left and Hydraulic oil low. Check system for leaks. Make right. repairs as needed. Fill reservoir. b. Clogged or loose hydraulic lines or b.

  • Page 263: Rear Steering System

    RT765E-2 SERVICE MANUAL UNDERCARRIAGE system relief pressure. Adequate oil flow under all the travel limit briefly, just long enough to read the conditions can best be checked by timing the full travel pressure gauge. Never hold the system at relief pressure for more than a few seconds at a time.

  • Page 264: Hydraulic Pumps

    UNDERCARRIAGE RT765E-2 SERVICE MANUAL Hydraulic Pumps Start the engine and check for proper operation and any leakage. Description Integrated Outrigger/Rear Steer Control NOTE: Pump output figures are theoretical. Valve Front Steer Description The hydraulic pump is mounted on and driven by the engine. Pump number 2 provides the hydraulic flow necessary to The outrigger/rear steer valve controls the outrigger circuit power the front steer cylinders and the swing drive system.

  • Page 265: Rear Axle Oscillation Lockout System

    RT765E-2 SERVICE MANUAL UNDERCARRIAGE Removal i s m o u n t e d o n t h e l e ft i n n e r c e n t e r f r a m e r a i l a n d hydraulically controls the oscillating abilities of the lockout Tag and disconnect the hydraulic lines from the steer cylinders.
  • Page 266 UNDERCARRIAGE RT765E-2 SERVICE MANUAL Supply From Pump Lockout Valve Lockout Cylinder Lockout Cylinder FIGURE 8-12 Rear Axle 8-12 Published 9-04-2014, Control # 422-08...

  • Page 267: Axle Oscillation Lockout Cylinders

    RT765E-2 SERVICE MANUAL UNDERCARRIAGE Axle Oscillation Lockout Cylinders Function test the axle oscillation system in accordance with the Operator’s Manual to ensure proper operation. Description Axle Oscillation Lockout Valve Two 5.0 in (12.7 cm) hydraulic lockout cylinders are installed on the rear axle, one left side and one right side. The base Description end of each cylinder is attached to each side of the carrier The axle oscillation lockout valve (also called the double...

  • Page 268: Theory Of Operation

    UNDERCARRIAGE RT765E-2 SERVICE MANUAL tandem brake valve with treadle pedal, the dual accumulator accumulator charge valve charges the accumulators from charge valve, two hydraulic accumulators, the brake the open center circuit upon demand and within its present assemblies, and all the associated hoses and tubing. The operating charge rate and the high limit pressure setting.

  • Page 269: Maintenance

    RT765E-2 SERVICE MANUAL UNDERCARRIAGE Maintenance Troubleshooting Table 8-3 Symptom Probable Cause Solution Brakes are poor. Lining thickness less than Replace lining. 0.125 in (3 mm). b. Brake pedal operation. b. Free mechanical linkage. Restriction or leaks in lines. Check all lines for leaks and restrictions.

  • Page 270: Service Brakes

    UNDERCARRIAGE RT765E-2 SERVICE MANUAL brake valve. Bleed every bleeder screw on every caliper/ 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 The brakes utilized on the later model axles are hydraulic furthest bleeder screw on the next closest wheel.
  • Page 271 RT765E-2 SERVICE MANUAL UNDERCARRIAGE Caliper Block the wheels DANGER Disconnect the hydraulic brake line from the inlet fitting on the caliper. Cap or plug all openings. Do not place hand in front of pistons when forcing them out. Serious personal injury may occur. Remove the linings as described under linings.
  • Page 272 UNDERCARRIAGE RT765E-2 SERVICE MANUAL Remove the pistons from the mounting plate side of the Inspection housing. Push on the ends of the pistons to force them Periodic On-Vehicle out of the disc side of the housing. Refer to Figure 8-17. Inspect the caliper, linings, and disc for any damage.
  • Page 273 RT765E-2 SERVICE MANUAL UNDERCARRIAGE Minimum Disc Bleeder Screw Piston Fluid Thickness Fluid Leaks Leaks Maximum Disc Wear Each Side Inlet Cylinder Fitting Maximum Fluid Disc Wear Fluid Original Leaks Leaks Disc Thickness 0.625 in (15.875 mm) Typical Section Through Disc Showing Piston Fluid Recommended Maximum Wear Limits Leaks...

  • Page 274: Corrosion Protection

    UNDERCARRIAGE RT765E-2 SERVICE MANUAL Measure the diameter of the housing bore. Replace the • Use soap and water to clean parts that are not made housing if the diameter is worn to more than 3.003 in of metal. (76.276 mm). Refer to Figure 8-23. •...
  • Page 275 RT765E-2 SERVICE MANUAL UNDERCARRIAGE Install a new dust seal in the top groove of the bore. NOTE: Apply extra grease on O-ring before installing Refer to Figure 8-24. cylinder caps. this will keep O-ring from catching on threads as cylinder cap is threaded into housing. Install the cylinder caps in the caliper housing.

  • Page 276: Parking Brake Actuator

    UNDERCARRIAGE RT765E-2 SERVICE MANUAL Caliper Maintenance Position the caliper housing on the mounting bracket. If Removal shims where used, place them as marked during Chock the wheels to prevent crane movement. removal. Start the engine, ensure the transmission is in neutral, Secure the caliper housing with the bolts and tighten and position the Park Brake Switch to OFF.

  • Page 277: Parking Brake

    RT765E-2 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 278 UNDERCARRIAGE RT765E-2 SERVICE MANUAL FIGURE 8-28 8-24 Published 9-04-2014, Control # 422-08...
  • Page 279 RT765E-2 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 280: Park Brake Solenoid Valve

    UNDERCARRIAGE RT765E-2 SERVICE MANUAL PARK BRAKE SOLENOID VALVE and rear outrigger control manifolds, pilot operated check valves and an Outrigger Monitoring System (OMS) Description (Optional—Standard in North America). The front two extension cylinders are mounted in the front outrigger beams The park brake solenoid valve is located on the front side of and the rear two extension cylinders are mounted in the rear the carrier aft center frame cross member.

  • Page 281: Maintenance

    Damaged outrigger valve. m. Repair or replace valve. n. Damaged valve coil. n. Replace coil. o. Main hydraulic pump o. Replace or tighten hose or fitting. cavitation. Refer to your Manitowoc Crane Care Parts Manual. p. Partially shifted hydraulic p. Disassemble, clean,...
  • Page 282 UNDERCARRIAGE RT765E-2 SERVICE MANUAL 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 283 RT765E-2 SERVICE MANUAL UNDERCARRIAGE Symptom Probable Cause Solution Outrigger jack cylinder Damaged piston seals. Replace all cylinder seals. retracts 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 284: Outrigger Beam

    UNDERCARRIAGE RT765E-2 SERVICE MANUAL Outrigger Beam Tag and disconnect the hydraulic lines at the cylinder barrel end of the extension cylinder. Cap all lines and Description fittings. The outrigger beam assembly consists of an outrigger beam, NOTE: Do not allow the end of the outrigger extension a jack cylinder, a extension cylinder, an Outrigger Monitoring cylinder to fall when the cylinder mounting shaft is System (OMS) (Optional—Standard in North America) string...
  • Page 285 RT765E-2 SERVICE MANUAL UNDERCARRIAGE Inspection Inspect the outrigger beams for bends, evidence of cracks, CAUTION or other damage. Check the outrigger beam internally for Be sure that the piston side of all outrigger cylinders are hydraulic fluid, which may indicate a leaking cylinder, loose connected to the solenoid valve bank.
  • Page 286 UNDERCARRIAGE RT765E-2 SERVICE MANUAL 1, 2, 3 1, 2, 3 7, 8 13, 14 13, 14 17,18,19 9, 10 7683-2 FIGURE 8-29 Item Description Item Description Extension Cylinder Retainer Pin Jack Cylinder Cotter Pin Cotter Pin Clevis Pin Extend Port Retract Port OMS Potentiometer Outrigger Box...
  • Page 287 RT765E-2 SERVICE MANUAL UNDERCARRIAGE Rear Outriggers Shown FIGURE 8-30 0.06 in (1.5 mm) Gap 6065 0.06 in (1.5 mm) Gap FIGURE 8-31 Item Description Item Description Side Wear Pads and Setscrews Bottom Wear Pads and Setscrews GROVE Published 9-04-2014, Control # 422-08 8-33...

  • Page 288: Extension Cylinder

    UNDERCARRIAGE RT765E-2 SERVICE MANUAL Extension Cylinder Install the outrigger beam. Refer to Outrigger Beam, page 8-30. Verify no jack cylinder hose will be trapped Description by full outrigger beam retraction. Two outrigger extension cylinders are utilized within each Functional Check outrigger box assembly.

  • Page 289: Jack Cylinder

    RT765E-2 SERVICE MANUAL UNDERCARRIAGE Removal Extend the outrigger beam slightly for improved access to the jack cylinder; shut down the engine. Tag and disconnect the hydraulic hoses from the jack cylinder. Remove the fittings from the ports. Cap or plug all openings.

  • Page 290: Outrigger Control Valves

    UNDERCARRIAGE RT765E-2 SERVICE MANUAL Install the fittings in the cylinder ports and connect the valve, the front and rear outrigger control manifolds, and the hoses as tagged during removal. Verify the piston side of pilot operated check valves. the jack cylinder is connected to the solenoid valve bank NOTE: For a more detailed description and maintenance to prevent damage.

  • Page 291: General

    • Always drain waste fluids into leak proof containers that are clearly marked with what they contain. Standard lubricants are used on all Manitowoc cranes unless the crane is ordered with a cold weather package. These • Always fill or add fluids with a funnel or a filling pump.
  • Page 292 LUBRICATION RT765E-2 SERVICE MANUAL standard lubricants are effective in temperatures down to -9°C (15°F). Refer to Table 9-1 for a list of the recommended standard lubricants. Table 9-1: Standard Lubricants [Down to -9°C (15°F)] Recommended Lubricant Lubricant/Fluid Grove Spec. Type Grade Classification Axle Gear Oil...

  • Page 293: Arctic Lubricants And Conditions

    Therefore, always check with an authorized Arctic fuel Manitowoc distributor or Manitowoc Crane Care if in doubt of -40°C (-40°F) Package the suitability of a specific fluid or lubricant.
  • Page 294 LUBRICATION RT765E-2 SERVICE MANUAL Table 9-2: 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 295 RT765E-2 SERVICE MANUAL LUBRICATION Table 9-3: 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 CJ-4...

  • Page 296: Surface Protection For Cylinder Rods

    LUBRICATION RT765E-2 SERVICE MANUAL Surface Protection for Cylinder Rods Manitowoc Crane Care has Boeshield® T-9 Premium Metal Protectant available in 12 oz. aerosol cans by ordering part Steel cylinder rods include a thin layer of chrome plating on number 9999101803 through the Parts Department.

  • Page 297: Lubrication Points

    CraneLUBE unless otherwise specified. Manitowoc highly recommends the use of CraneLUBE On plug type check points, the oil levels are to be at the 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 bottom edge of the check port.

  • Page 298: Steering And Suspension

    LUBRICATION RT765E-2 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 299 RT765E-2 SERVICE MANUAL LUBRICATION 7114-17 7883 7671-1 7114-10 FIGURE 9-1 GROVE Published 9-04-2014, Control # 422-08...
  • Page 300 LUBRICATION RT765E-2 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 Fill to bottom of hole months 48 pt Differentials Figure 9-2 Service Interval in housing on the (22.7 l) •...
  • Page 301 RT765E-2 SERVICE MANUAL LUBRICATION 7671-1 7114-17 7114-9 FIGURE 9-2 GROVE 9-11 Published 9-04-2014, Control # 422-08...

  • Page 302: Drive Train

    LUBRICATION RT765E-2 SERVICE MANUAL Lube Point Figure Approved Lube Item Lube Interval Application Description Lubricant Capacity Drive Train EO-15W/40 • Through fill cap to Engine Oil • Check level every 10 FULL mark on a. Engine SAE 15W-40 hours or daily dipstick 20 qt Crankcase...
  • Page 303 RT765E-2 SERVICE MANUAL LUBRICATION 7649-27 7649-26 7114-23 Other Side 7671-1 Other Side 7114-10 7649-25 7795 Fill Location FIGURE 9-3 GROVE 9-13 Published 9-04-2014, Control # 422-08...

  • Page 304: Drive Train (Continued)

    LUBRICATION RT765E-2 SERVICE MANUAL Lube Point Figure Approved Lube Item Lube Interval Application Description Lubricant Capacity Drive Train (continued) • Replace primary filter element when indicator shows red (25 in of H Air Cleaner Replace secondary Filters filter every third time Right hand side of Figure 9-4 primary filter is...
  • Page 305 RT765E-2 SERVICE MANUAL LUBRICATION 7649-15 7114-11 Other Side 7649-18 7114-10 7649-28 7795 FIGURE 9-4 GROVE 9-15 Published 9-04-2014, Control # 422-08...

  • Page 306: Turntable

    LUBRICATION RT765E-2 SERVICE MANUAL Lube Point Figure Approved Lube Item Lube Interval Application Description Lubricant Capacity Turntable • Check and fill every AGMA No. 4 50 hours Extreme Turntable Gear 5.25 qt Fill to max level on • Drain and fill after Figure 9-5 Pressure Gear (4.9 l)
  • Page 307 RT765E-2 SERVICE MANUAL LUBRICATION 7114-25 7114-24 7671-2 7649-21 FIGURE 9-5 GROVE 9-17 Published 9-04-2014, Control # 422-08...

  • Page 308: Outriggers

    LUBRICATION RT765E-2 SERVICE MANUAL Lube Point Figure Approved Lube Item Lube Interval Application Description Lubricant Capacity Outriggers EP-MPG Extreme Brush lubricant on Pressure Outrigger Beams Figure 9-6 50 hours or 1 week bottom of outrigger Multipurpose beams Grease 6829003477 Brush lubricant on EP-MPG ID of jack cylinder Extreme...
  • Page 309 RT765E-2 SERVICE MANUAL LUBRICATION 7671-1 GROVE 9-19 Published 9-04-2014, Control # 422-08...

  • Page 310: Boom

    LUBRICATION RT765E-2 SERVICE MANUAL Lube Point Figure Approved Lube Item Lube Interval Application Description Lubricant Capacity Boom Until Upper Lift Figure 9-7 greases 500 hours or 3 months 2 grease fittings Cylinder Pin extrudes Until Lower Lift Figure 9-7 greases 500 hours or 3 months 2 grease fittings Cylinder Pin...
  • Page 311 RT765E-2 SERVICE MANUAL LUBRICATION 7114-25 7114-16 7114-32 7649-18 7114-36 FIGURE 9-7 GROVE 9-21 Published 9-04-2014, Control # 422-08...

  • Page 312: Boom (Continued)

    LUBRICATION RT765E-2 SERVICE MANUAL Lube Point Figure Approved Lube Item Lube Interval Application Description Lubricant Capacity Boom (continued) EP-MPG Thoroughly Brush grease on the Extreme coat all outside of sections Boom Section Pressure Figure 9-8 areas the 50 hours or 1 week 1, 2, &...
  • Page 313 RT765E-2 SERVICE MANUAL LUBRICATION 7114-27 7114-15 Other Side 7469-19 7649-17 7114-36 FIGURE 9-8 GROVE 9-23 Published 9-04-2014, Control # 422-08...
  • Page 314 LUBRICATION RT765E-2 SERVICE MANUAL Lube Point Figure Approved Lube Item Lube Interval Application Description Lubricant Capacity Boom (continued) Until EP-MPG Mast Sheave Figure 9-9 grease 500 hours or 12 months 1 grease fitting Extreme extrudes Pressure Multipurpose Until Grease Headache Ball Figure 9-9 grease 250 hours or 3 months...
  • Page 315 RT765E-2 SERVICE MANUAL LUBRICATION 7114-30 7469-19 7115-33 FIGURE 9-9 GROVE 9-25 Published 9-04-2014, Control # 422-08...

  • Page 316: Hoist

    LUBRICATION RT765E-2 SERVICE MANUAL 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 must be visible in 15.5 qt Main Hoist Figure 9-10 Pressure Gear the sight glass (see •...
  • Page 317 RT765E-2 SERVICE MANUAL LUBRICATION 7114-7 7649-19 FIGURE 9-10 GROVE 9-27 Published 9-04-2014, Control # 422-08...

  • Page 318: 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 distibutor.
  • Page 319 RT765E-2 SERVICE MANUAL LUBRICATION 7649-19 7649-22 FIGURE 9-11 GROVE 9-29 Published 9-04-2014, Control # 422-08...
  • Page 320 LUBRICATION RT765E-2 SERVICE MANUAL FIGURE 9-12 Published 9-04-2014, Control # 422-08 9-30...

  • Page 321: Carwell® Rust Inhibitor

    While the surfaces of the crane that are easily seen have the biggest impact on the appearance of the crane, particular Manitowoc Crane Group's cranes are manufactured to high attention should be given to the undercarriage of the crane to quality standards, including the type of paint finish minimize the harmful effects of corrosion.

  • Page 322: Inspection And Repair

    • and allow to dry thoroughly. Please contact Manitowoc Crane Care should you have any • Prepare the surface prior to applying the finish coat of questions. paint.
  • Page 323 RT765E-2 SERVICE MANUAL LUBRICATION • Frame application areas are; hose ends and fittings, all • Boom applications areas are; pivot pins, hose end and unpainted fasteners and hardware, all bare metal fittings, jib pins and shafts, all bare metal surfaces, surfaces, outrigger pads, and back up alarm hardware.
  • Page 324 LUBRICATION RT765E-2 SERVICE MANUAL 7650-76 Figure 9-14 Published 9-04-2014, Control # 422-08 9-34...
  • Page 325 RT765E-2 SERVICE MANUAL LUBRICATION Item Description O/R Pins, Clips Item Description O/R Beam Wear Pad Adjustment Hardware Pivot Shaft Entire underside of unit Boom Extension Pins, Clips Powertrain Hardware Inside Compartment Boom Nose Pins, Clips Valve Bank Hook Block/Headache Ball Hoist Hose Connections Boom Extension Hanger Hardware Tension Spring...
  • Page 326 LUBRICATION RT765E-2 SERVICE MANUAL THIS PAGE BLANK Published 9-04-2014, Control # 422-08 9-36...
  • Page 327 RT765E-2 SERVICE MANUAL Alphabetical Index 360° Swing Lock Control (Positive Lock Type) (Optional) ..... . . 6-22 Air Intake and Exhaust System ..........7-9 Axle Oscillation Lockout Cylinder .
  • Page 328 SERVICE MANUAL RT765E-2 Service Brakes ............8-16 Steer Cylinder.

Table of Contents