Page 1 Grove GRT8100 Service Manual...
Page 3 An untrained operator subjects himself and others to death or serious injury. Do not operate this crane unless: • You are trained in the safe operation of this crane. Manitowoc is not responsible for qualifying personnel. • You read, understand, and follow the safety and operating recommendations contained in the crane manufacturer’s manuals and...
Page 4 WARNING California Proposition 65 Breathing diesel engine exhaust exposes you to chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. • Always start and operate the engine in a well- ventilated area. •...
Page 5: Table Of Contents
GRT8100 SERVICE MANUAL TABLE OF CONTENTS TABLE OF CONTENTS SECTION 1 ........Introduction General .
Page 6 TABLE OF CONTENTS GRT8100 SERVICE MANUAL Seizing Wire Rope ..........1-33 Installing 35x7 Class Wire Rope .
Page 7 GRT8100 SERVICE MANUAL TABLE OF CONTENTS Description ............2-49 Maintenance .
Page 8 TABLE OF CONTENTS GRT8100 SERVICE MANUAL Rear View Mirror ..........3-26 Air Conditioner .
Page 9 GRT8100 SERVICE MANUAL TABLE OF CONTENTS Hoist Control Valves ........... 5-10 Description .
Page 10 TABLE OF CONTENTS GRT8100 SERVICE MANUAL Exhaust System........... 7-13 Slip Joint Exhaust Connectors - Tier 3 and 4 .
Page 11 GRT8100 SERVICE MANUAL TABLE OF CONTENTS Cylinder Rod Surface Protection ......... . . 9-8 Wire Rope Lubrication .
Page 12 TABLE OF CONTENTS GRT8100 SERVICE MANUAL THIS PAGE BLANK. TOC-8...
Page 13: Section 1
GRT8100 SERVICE MANUAL INTRODUCTION SECTION 1 INTRODUCTION SECTION CONTENTS General ........1-1 Pressing Parts .
Page 14: Customer Support
The superstructure is capable of 360 degree rotation in either Customer Support direction. All crane functions are controlled from the fully - Manitowoc and our Dealer Network want to ensure your enclosed cab mounted on the superstructure. One boom is satisfaction with our products and customer support. Your available on the crane;...
Page 15: List Of Specifications
GRT8100 SERVICE MANUAL INTRODUCTION LIST OF SPECIFICATIONS Engine Cummins QSB 6.7 - Tier 4F General Type ... . . 4-cycle, Diesel, Turbocharged Model ......GRT8100 Number of Cylinders .
Page 16: Hydraulic Pumps
INTRODUCTION GRT8100 SERVICE MANUAL Hydraulic Pumps Pump #3 Type ....... . Gear NOTE: Pump output figures are theoretical.
Page 17 GRT8100 SERVICE MANUAL INTRODUCTION Table 1-1Axle Weight Distribution Table CG To CL Rear Weight Front Axle Rear Axle Description Bogie cm (in) kg (lb) kg (lb) kg (lb) Basic Unit Maximum Axle Loads Allowed 31752 (70000) 31752 (70000) Maximum Axle Loads Allowed while Towing 27216 (60000) 27216 (60000) Maximum Tire Loads Allowed...
Page 18 INTRODUCTION GRT8100 SERVICE MANUAL CG To CL Rear Weight Front Axle Rear Axle Description Bogie cm (in) kg (lb) kg (lb) kg (lb) Driveline Retarder 266.06 (89.00) 546 (1203) 293 (645) 253 (558) Counterweight Stand -167.64 (-66.00) 118 (260) -47 (-103) 165 (363) Air Conditioning - Carrier 50.80 (27.80)
Page 19: Crane Nomenclature
GRT8100 SERVICE MANUAL INTRODUCTION Crane Nomenclature FIGURE 1-2 Item Description Item Description Boom Nose Sheaves Fuel Tank Boom Crane Steps Work Lights Hydraulic Valves and Swing Motor Cover Tilt Cab Auxiliary Boom Nose Windshield Washer Fluid Container Auxiliary Hoist Air Conditioning Condenser Main Hoist Counterweight Boom Pivot Pin...
Page 20: General Maintenance
INTRODUCTION GRT8100 SERVICE MANUAL 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 21: Pressing Parts
GRT8100 SERVICE MANUAL INTRODUCTION 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! Exercise extreme care around pressurized hydraulic Assemble tapered parts dry.
Page 22: Bearings
INTRODUCTION GRT8100 SERVICE MANUAL Installation assembly to obtain accurate pre-loading. When installing a bearing, spacer, or washer against a shoulder on a shaft, be When installing a new hose, loosely connect each end sure the chamfered side is toward the shoulder. and make sure the hose takes up the designed position When pressing bearings into a retainer or bore, uniformly before tightening the connection.
Page 23: Hydraulic Systems
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 hydraulic systems are a major cause of component failures.
Page 24: Hydraulic Fittings
Polar: Extremely cold winters and summers. Latitude 60° - 75° North & South Hydraulic Fittings Flats from Finger Tight (F.F.F.T.) Method Manitowoc recommends that the F.F.F.T. tightening method described here be used when assembling all hydraulic fittings. This method will minimize the risk of fitting damage or failure due to under or overtightening.
Page 25 GRT8100 SERVICE MANUAL INTRODUCTION Adjustable Straight Thread O-ring Fittings Hold the fitting in the desired position and tighten the nut (D) following the F.F.F.T. method starting with step 4. Refer to Figure 1-5 and Table 1-4 for the following procedure. Nonadjustable Straight Thread O-ring Fitting: Fitting to Port Table 1-4: Adjustable Straight Thread O-ring Fittings...
Page 26: Electrical System
Loctite brand adhesives are available from caused by twisting, shock, bending, and intentional and/or the Parts Department of the local Manitowoc distributor. unintentional overloads, often become subject to weld Application of Medium Strength Loctite cracking which may be attributed to fatigue of the welded joint.
Page 27: Fasteners And Torque Values
• Torque wrenches must be those specified and forces The torque tables are provided by Manitowoc for reference must be applied at the handle grip. The use of handle when performing maintenance.
Page 28 INTRODUCTION GRT8100 SERVICE MANUAL 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 1-16 Published 3/26/2018, Control # 596-05...
Page 29 GRT8100 SERVICE MANUAL INTRODUCTION Table 1-6 Inch Series with Coarse Threads (UNC) – Zinc Flake Coated Nominal Size, Threads per Torque (ft/lb) Inch, and Series Grade Maximum Nominal Minimum Designation 1/4-20 UNC 13.5 13.2 12.8 5/16-18 UNC 19.1 18.6 18.1 24.0 23.4 22.8...
Page 30 INTRODUCTION GRT8100 SERVICE MANUAL Table 1-7 Inch Series with Fine Threads (UNF) – Zinc Flake Coated Nominal Size, Threads per Torque (ft/lb) Inch, and Series Grade Maximum Nominal Minimum Designation 1/4-28 UNF 10.6 10.4 10.1 15.0 14.6 14.2 5/16-24 UNF 21.1 20.6 20.1...
Page 31 GRT8100 SERVICE MANUAL INTRODUCTION Nominal Size, Threads per Torque (Nm) Property Inch, and Series Class Maximum Nominal Minimum Designation M6x1.0 10.9 12.2 11.9 11.6 12.9 14.3 13.9 13.6 20.2 19.7 19.2 M8x1.25 10.9 29.6 28.9 28.2 12.9 34.7 33.8 33.0 40.0 39.0 38.0...
Page 32 INTRODUCTION GRT8100 SERVICE MANUAL Nominal Size, Threads per Torque (Nm) Property Inch, and Series Class Maximum Nominal Minimum Designation 2089.8 2037.6 1985.3 M36x4 10.9 2976.4 2902.0 2827.6 12.9 3483.0 3395.9 3308.9 Table 1-9 Metric Series with Fine Threads – Zinc Flake Coated Nominal Size, Threads per Torque (Nm) Property...
Page 33 GRT8100 SERVICE MANUAL INTRODUCTION Nominal Size, Threads per Torque (Nm) Property Inch, and Series Class Maximum Nominal Minimum Designation 386.0 376.3 366.7 M20x1.5 10.9 549.7 535.9 522.2 12.9 643.3 627.2 611.1 520.8 507.8 494.8 M22x1.5 10.9 741.7 723.2 704.7 12.9 868.0 846.3 824.6...
Page 34 INTRODUCTION GRT8100 SERVICE MANUAL Table 1-10 Metric Series Screws of STAINLESS STEEL A2-70/A4-70 with Coarse Threads Size Torque (Nm) M2.5x0.45 M3x0.5 M4x0.7 M5x0.8 M6x1 M8x1.25 M10x1.5 Torque Values for fasteners with lubrication these torque values result in an 80% utilization of the yield strength. Stainless steel fasteners tend to gall while being tightened.
Page 35 GRT8100 SERVICE MANUAL INTRODUCTION Table 1-12 Inch Series Bearing Bolts – Untreated (black finish) Nominal Size, Threads per Torque (ft/lb) Inch, and Series Grade Maximum Nominal Minimum Designation 5/8-11 UNC 5/8-18 UNF 3/4-10 UNC 7/8-9 UNC 1-8 UNC 1 1/4-7 UNC 2043 1964 1885...
Page 36 INTRODUCTION GRT8100 SERVICE MANUAL Inch Series with Coarse Threads (UNC) – Untreated (black finish) Table 1-14 Torque (ft/lb) Size Grade Maximum Nominal Minimum 1/4-20 12.5 11.5 5/16-18 3/8-16 7/16-14 1/2-13 9/16-12 5/8-11 259.5 3/4-10 7/8-9 1 1/8-7 1342 1288 1234 1141 1097 1053...
Page 37 GRT8100 SERVICE MANUAL INTRODUCTION Inch Series with Fine Threads (UNF) – Untreated (black finish) Table 1-15 Torque (ft/lb) Size Grade Maximum Nominal Minimum 1/4-28 14.5 13.5 5/16-24 3/8-24 7/16-20 84.5 1/2-20 9/16-18 174.5 5/8-18 299.5 3/4-16 439.5 7/8-14 1-12 1009 644.5 1-14 908.5...
Page 38 INTRODUCTION GRT8100 SERVICE MANUAL Metric Series with Coarse Threads – Untreated (black finish) Table 1-16 Torque (Nm) Property Size Class Maximum Nominal Minimum M4x0.7 10.9 12.9 M5x0.8 10.9 12.9 10.5 10.5 M6x1 10.9 12.9 M8x1.25 10.9 36.5 12.9 43.5 M10x1.5 10.9 12.9 M12x1.75...
Page 39 GRT8100 SERVICE MANUAL INTRODUCTION Torque (Nm) Property Size Class Maximum Nominal Minimum 1134 1090 1046 M27x3 10.9 1591 1530 1469 12.9 1910 1836.5 1763 1538 1479 1420 M30x3.5 10.9 2163 2080 1997 12.9 2595 2495 2395 2681 2578.5 2476 M36x4 10.9 3964 3812...
Page 40 INTRODUCTION GRT8100 SERVICE MANUAL Metric Series with Fine Threads – Untreated (black finish) Table 1-17 Torque (Nm) Property Size Class Maximum Nominal Minimum M8x1 10.9 39.5 12.9 M10x0.75 10.9 12.9 M10x1.25 10.9 12.9 97.5 M12x1 10.9 12.9 M12X1.25 10.9 141.5 12.9 165.5 M12x1.5*...
Page 41: Weld Studs
GRT8100 SERVICE MANUAL INTRODUCTION Torque (Nm) Property Size Class Maximum Nominal Minimum 803.5 M24x2 10.9 1176 1130.5 1085 12.9 1410 1356 1302 1225 1171.5 1130 M27x2 10.9 1718 1652.5 1587 12.9 2063 1983.5 1904 1530 1471.5 1413 M30x1.5 10.9 2253 2166.5 2080 12.9...
Page 42: 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 43: 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 44: Wire Rope Inspection (Boom Extension And Retraction Cables)
Wire Rope Inspection (Boom Extension and Standard as referenced by Federal Government Agencies Retraction Cables) and as recommended by Manitowoc. All wire rope will eventually deteriorate to a point where it is no longer usable. Periodic Inspection Wire rope shall be taken out of service when any of the...
Page 45: Seizing Wire Rope
• Severe corrosion as evidenced by pitting. Method 2 • Manitowoc recommends that for cable extended booms, a single damaged wire rope assembly shall require replacement of the entire set of extension cables. • Manitowoc recommends for cable extended booms, that boom extension cables be replaced every seven (7) years.
Page 46: Installing 35X7 Class Wire Rope
INTRODUCTION GRT8100 SERVICE MANUAL seriously damage the rope.) The tensioning load should range from 1 to 2% of the rope’s minimum breaking force. For ropes in multi-part systems: Reeve the traveling block and boom tip sheaves so the rope spacing is maximized and the traveling (hook) block hangs straight and level to help assure block stability.
Page 47: Section 2
GRT8100 SERVICE MANUAL HYDRAULIC SYSTEM SECTION 2 HYDRAULIC SYSTEM SECTION CONTENTS Description ....... 2-3 Checking/Setting the Outriggers, Rear Steer, and Hydraulic Transmission Oil Cooler Hydraulic Symbols .
Page 48 HYDRAULIC SYSTEM GRT8100 SERVICE MANUAL Cylinders ....... . 2-69 Leak Check ......2-69 Cylinder Rod Surface Protection .
Page 49: Description
GRT8100 SERVICE MANUAL HYDRAULIC SYSTEM DESCRIPTION valves, and all hydraulic cylinders. Detailed descriptions and operation of individual hydraulic circuits are discussed within T h i s s e c t i o n d e s c r i b e s t h e h y d r a u l i c s y s t e m , t h e their individual sections as applicable.
Page 50 HYDRAULIC SYSTEM GRT8100 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 51: 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 52: Removing Air From The Hydraulic System
HYDRAULIC SYSTEM GRT8100 SERVICE MANUAL Disconnect the return line from an outrigger extension 26. Repeat Steps 24 and 25 for the auxiliary hoist as cylinder and fully extend the outrigger. necessary. Connect the outrigger return line and retract the 27. Disconnect one of the lines from the swing motor and outrigger.
Page 53: Parts Replacement
GRT8100 SERVICE MANUAL HYDRAULIC SYSTEM Directional Control Valves Operate all hydraulic circuits several times in both directions. The control valves that control the crane functions are • This action should return any entrapped air to the installed on the right side of the turntable. reservoir where it can be removed from the hydraulic oil Inspection by the baffles.
Page 54: Visual Inspection Of Hoses And Fittings
For replacement temperatures will negatively impact service life. Therefore it of hose assemblies, refer to your Manitowoc Crane Care is recommended for these hoses to be inspected thoroughly Parts Manual.
Page 55: Supply Pressure And Return Circuit
GRT8100 SERVICE MANUAL HYDRAULIC SYSTEM SUPPLY PRESSURE AND RETURN CIRCUIT (120°F rising) (8, Figure 2-1) turns the hydraulic oil cooler fan on and off as needed (see Oil Cooler, page 2-16). The Description thermistor (200°F rising) (7, Figure 2-1) will cause a warning light in the cab to illuminate if the hydraulic oil temperature is The supply pressure and return circuit routes hydraulic oil too high.
Page 56 HYDRAULIC SYSTEM GRT8100 SERVICE MANUAL 8804-73 Return Hose Return Filter Cover Fill Cap/Breather Step Hydraulic Tank Thermistor (200°F) - High Oil Temp. Indicator Light Temperature Switch (120°F) - Oil Cooler Fan On/Off Oil Level Gauge 8804-79 FIGURE 2-1 Published 3/26/2018, Control # 596-05 2-10...
Page 57: Hydraulic Pump Distribution
GRT8100 SERVICE MANUAL HYDRAULIC SYSTEM Hydraulic Pump Distribution No. 2 Pump The torque converter drives the No. 2 variable displacement No. 1 Pump piston pump, which supplies oil to the following manifolds The torque converter drives the No. 1 variable displacement and valves: piston pump, which supplies oil to the following manifolds •...
Page 58: Troubleshooting
HYDRAULIC SYSTEM GRT8100 SERVICE MANUAL Troubleshooting Symptoms and Solutions Symptom Probable Cause Solution No hydraulic oil Low hydraulic oil level. Check system for leaks. Make repairs flows in systems. as needed. Fill reservoir. b. Reservoir-to-pump suction lines b. Clean, repair, or replace lines as broken or restricted.
Page 59: Troubleshooting Aids
GRT8100 SERVICE MANUAL HYDRAULIC SYSTEM 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 60: Hydraulic Oil Return Filter Assembly
HYDRAULIC SYSTEM GRT8100 SERVICE MANUAL Hydraulic Oil Return Filter Assembly Remove and discard the O-ring between the cap and the return filter head. The hydraulic oil return filter assembly (see Figure 2-1 and Remove the element from the return filter head. Figure 2-2) is located in the reservoir.
Page 61 GRT8100 SERVICE MANUAL HYDRAULIC SYSTEM 8804-75 Gasket O-ring By-pass Assembly Filter Head O-ring Gauge Assembly Plug Spring Cap Assembly Element FIGURE 2-2 2-15 GROVE Published 3/26/2018, Control # 596-05...
Page 62: Oil Cooler
HYDRAULIC SYSTEM GRT8100 SERVICE MANUAL OIL COOLER is installed in the hydraulic oil tank which will cause a warning light in the cab to illuminate if the hydraulic oil temperature is Description too high. The thermistor will also turn on the oil cooling fan if the temperature switch fails.
Page 63 GRT8100 SERVICE MANUAL HYDRAULIC SYSTEM 8804-77 Fan hydraulic motor Wire fan shroud Transmission cooler Metal fan shroud Hydraulic oil cooler FIGURE 2-3 2-17 GROVE Published 3/26/2018, Control # 596-05...
Page 64: Hydraulic Pumps
HYDRAULIC SYSTEM GRT8100 SERVICE MANUAL HYDRAULIC PUMPS Pumps No. 1 and No. 2 NOTE: Pump output figures are theoretical. Description The No . 1 and No. 2 hy draulic pumps are v ariable The No. 1 and No. 2 hydraulic pumps are mounted to the displacement piston pumps with SAE-C 2-bolt mounting torque converter (Figure 2-4).
Page 65 GRT8100 SERVICE MANUAL HYDRAULIC SYSTEM 8804-74 8804-135 Engine Transmission Charge Pump Torque Converter Hydraulic Pump No. 2 Hydraulic Pump No. 1 Hydraulic Pump No. 3 FIGURE 2-4 2-19 GROVE Published 3/26/2018, Control # 596-05...
Page 66: Maintenance
HYDRAULIC SYSTEM GRT8100 SERVICE MANUAL Maintenance No. 3 Pump Removal No. 1 and No. 2 Pump Removal CAUTION Absolute cleanliness is essential when working on the CAUTION hydraulic pumps. Always work in a clean area. The Absolute cleanliness is essential when working on the presence of dirt and foreign materials in the system can hydraulic pumps.
Page 67 GRT8100 SERVICE MANUAL HYDRAULIC SYSTEM Priming/Starting-Up the Hydraulic Gear Pump CAUTION The Pump Priming Tool is set to 1-2 psi to prevent the CAUTION reservoir from being over-pressurized and damaged. Do Failure to follow this procedure can cause the pump to not adjust the Pump Priming Tool.
Page 68 HYDRAULIC SYSTEM GRT8100 SERVICE MANUAL then re-tighten the hose fitting while oil is still Start the engine. Slowly increase the engine speed to coming out. Refer to Hydraulic Fittings, page 1-12 1500 rpm and hold for 1 minute while making sure the for proper tightening specification.
Page 69: Pressure Setting Procedures
GRT8100 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 70: Checking/Setting The Piston Pumps Cut-Off And Differential Pressures
HYDRAULIC SYSTEM GRT8100 SERVICE MANUAL GAUGE TOLERANCE GAUGE PORT & ADJUSTMENT VALVE TO BE SET PRESSURE PSI (bar) LOCATION PSI (bar) 1500 to 1550 Service brake accumulator pre-charge See range Accumulator (see Figure 2-12) (103 to 107) G2 port on carrier combo valve (see Outriggers, rear steer &...
Page 71 GRT8100 SERVICE MANUAL HYDRAULIC SYSTEM 8804-62 Piston Pumps Cut-off pressure adjustment screw Differential pressure adjustment screw Piston pump #1 Pump #1 gauge port Piston pump #2 Pump #2 gauge port FIGURE 2-5 2-25 GROVE Published 3/26/2018, Control # 596-05...
Page 72: Checking/Setting The Main Directional Control Valve, Hoists, Lift, And Telescope Pressures
HYDRAULIC SYSTEM GRT8100 SERVICE MANUAL Checking/Setting the Main Directional Stop engine. Remove the diagnostic coupler. Control Valve, Hoists, Lift, and Telescope If crane is equipped with a telescope extend relief on the Pressures main directional valve (see Figure 2-6), turn relief screw fully clockwise until completely seated.
Page 73 GRT8100 SERVICE MANUAL HYDRAULIC SYSTEM 8804-63 Main Directional Valve Main directional valve GP port GP1a GP2a GP3a GP4a Telescope extend relief LS relief FIGURE 2-6 2-27 GROVE Published 3/26/2018, Control # 596-05...
Page 74 HYDRAULIC SYSTEM GRT8100 SERVICE MANUAL 8804-64 Main Directional Control Valve Tele retract relief FIGURE 2-7 Published 3/26/2018, Control # 596-05 2-28...
Page 75 GRT8100 SERVICE MANUAL HYDRAULIC SYSTEM 8804-65 Steer/Swing Brake/Pilot Supply Manifold (bottom) GP1 port GP5 port Steering relief valve GP7 port FIGURE 2-8 2-29 GROVE Published 3/26/2018, Control # 596-05...
Page 76: Checking/Setting The Pilot Supply Pressure
HYDRAULIC SYSTEM GRT8100 SERVICE MANUAL Checking/Setting the Pilot Supply Pressure Checking/Setting the Front Steer Pressure With the engine off, install pressure check diagnostic With the engine off, install pressure check diagnostic quick disconnect (9999101806) with gauge onto test quick disconnect (9999101806) with gauge onto test nipple at GP4 port of the front steer/swing brake/pilot nipple at GP6 port of the front steer/swing brake/pilot supply manifold (see Figure 2-9).
Page 77: Checking/Setting The Swing Brake Release Pressure
Imax to raise the pressure or Stop engine. Remove the diagnostic coupler. reducing the Imax to decrease the pressure. If adjusting the Imax does not work, contact your Manitowoc distributor or Manitowoc Crane Care. Repeat step 2 for swing left.
Page 78: Checking The Service Brake Accumulator Charging Valve Pressure
HYDRAULIC SYSTEM GRT8100 SERVICE MANUAL Checking the Service Brake Accumulator If after performing the procedure Checking the Service Brake Accumulators Pre-charge, page 2-33, the valve Charging Valve Pressure does not charge to the high charge limit specification, With engine off, discharge all of the pressurized fluid turn the accessory manifold pressure reducing valve stored in the accumulators by depressing the service clockwise a half turn at a time (see Figure 2-9) and...
Page 79: Checking The Service Brake Accumulators Pre-Charge
GRT8100 SERVICE MANUAL HYDRAULIC SYSTEM 8804-68 Brake Pressure Port Location Brake pressure port FIGURE 2-11 Checking the Service Brake Accumulators Fully turn the gas chuck “T” handle clockwise which will depress the core in the gas valve. Pre-charge Check the pre-charge pressure. The gauge should read With the engine off, discharge all of the pressurized oil 1500 to 1550 psi (103 to 107 bar).
Page 80: Pre-Charging The Accumulators
HYDRAULIC SYSTEM GRT8100 SERVICE MANUAL Brake Accumulator Gas valve guard Gas valve Accumulator Gauge Gas Chuck Bleed valve 6659-6 FIGURE 2-12 Pre-charging the Accumulators Fully turn the gas chuck “T” handle clockwise which will depress the core in the gas valve. With the engine off, discharge all of the pressurized oil Slowly open the nitrogen bottle valve and fill the stored in the accumulators by depressing the service...
Page 81: Checking/Setting Cab Tilt, Counterweight Removal, And Counterweight Pinning Pressures
GRT8100 SERVICE MANUAL HYDRAULIC SYSTEM Checking/Setting Cab Tilt, Counterweight Start engine and throttle up to full rpm. Slowly actuate the cab tilt lower function until full controller stroke is Removal, and Counterweight Pinning reached and hold. Turn the counterweight circuit Pressures pressure reducing valve (see Figure 2-13) clockwise to increase or counter-clockwise to decrease until a gauge...
Page 82: Checking/Setting The Outriggers, Rear Steer, And Hydraulic Transmission Oil Cooler Fan Motor Pressures
HYDRAULIC SYSTEM GRT8100 SERVICE MANUAL Checking/Setting the Outriggers, Rear Steer, Fully retract the outrigger jacks. and Hydraulic Transmission Oil Cooler Fan Actuate the outrigger jack retract function and hold. Motor Pressures Slowly accelerate the engine to full rpm. Turn the outriggers/rear steer/fan pressure...
Page 83 GRT8100 SERVICE MANUAL HYDRAULIC SYSTEM 8804-71 Carrier Combination Valve (top) Outriggers/rear steer/fan pressure reducing valve Axle lockout pressure reducing valve FIGURE 2-15 2-37 GROVE Published 3/26/2018, Control # 596-05...
Page 84: Checking/Setting The Axle Lockout Circuit Pressure
HYDRAULIC SYSTEM GRT8100 SERVICE MANUAL Checking/Setting the Axle Lockout Circuit Checking/Setting the Luffing Jib Pressure Pressure With the engine off, install a pressure check diagnostic coupler (9999101806) with gauge onto the diagnostic With the engine off, install a pressure check diagnostic nipple at the G port of the luffing jib valve (see coupler (9999101806) with gauge onto the diagnostic Figure 2-16)
Page 85: Valves
GRT8100 SERVICE MANUAL HYDRAULIC SYSTEM 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 86 HYDRAULIC SYSTEM GRT8100 SERVICE MANUAL 8804-76 Valve Installation - Carrier Outrigger Control Manifold Valve - Front Combination Manifold Valve Range Shift/Park Brake Manifold Valve Outrigger Control Manifold Valve - Rear FIGURE 2-17 Published 3/26/2018, Control # 596-05 2-40...
Page 87 GRT8100 SERVICE MANUAL HYDRAULIC SYSTEM 8804-80 Valve Installation - Superstructure Compact Manifold Valve Main Directional Manifold Valve Accessory Manifold Valve Swing Manifold Valve Dual Accumulator Charge Manifold Valve Brake Accumulators FIGURE 2-18 2-41 GROVE Published 3/26/2018, Control # 596-05...
Page 88: Main Directional Control Manifold Valve
HYDRAULIC SYSTEM GRT8100 SERVICE MANUAL MAIN DIRECTIONAL CONTROL MANIFOLD Maintenance VALVE Main Directional Control Manifold Valve Removal Description Tag and disconnect the hydraulic lines from the valve. Cap or plug the lines and ports. The lift, telescope, and hoist directional valves (Figure 2-19 through Figure 2-21) located on the superstructure side plate Tag and disconnect electrical connectors from the valve.
Page 89 GRT8100 SERVICE MANUAL HYDRAULIC SYSTEM 8804-82 Main Directional Control Manifold Valve Work Port - Auxiliary Hoist Lower Work Port - Tele Extend Work Port - Main Hoist Lower Work Port - Lift Up Pilot Pressure Port - Auxiliary Hoist Lower Outlet Port Pilot Pressure Port - Main Hoist Lower LS Relief...
Page 90 HYDRAULIC SYSTEM GRT8100 SERVICE MANUAL 8804-81 Main Directional Control Manifold Valve Cont. Inlet Gauge Port Pilot Supply Port Pressure Relief Valve - Telescope Extend FIGURE 2-20 Inlet Port 4300 psi Pressure Relief Valve - Lift Down 3250 psi Pressure Relief Valve - Telescope Retract Inlet Port LS Input Port Published 3/26/2018, Control # 596-05...
Page 91 GRT8100 SERVICE MANUAL HYDRAULIC SYSTEM 8804-85 FIGURE 2-21 2-45 GROVE Published 3/26/2018, Control # 596-05...
Page 92: Swing Manifold Valve
HYDRAULIC SYSTEM GRT8100 SERVICE MANUAL SWING MANIFOLD VALVE Remove the capscrews, flatwashers, and lockwashers securing the valve. Remove the valve. Description Swing Manifold Valve Installation The swing manifold valve (Figure 2-22 and Figure 2-23) is Install the valve on the turntable upright and secure with located on the superstructure side plate near the turntable the capscrews, flatwashers, and lockwashers.
Page 93 GRT8100 SERVICE MANUAL HYDRAULIC SYSTEM 8804-86 8804-87 Swing Directional Control Manifold Valve Orifice - Left Swing Work Port (MB) - Left Swing Tank Port (T) Pressure Compensating Valve Inlet Port (P) Gauge Port (GP3) Gauge Port (GP5) Work Port (MA) - Right Swing Pressure Reducing Valve - Left Swing Shuttle Valve Pressure Reducing Valve - Right Swing...
Page 94 HYDRAULIC SYSTEM GRT8100 SERVICE MANUAL Swing Directional Control Manifold Valve FIGURE 2-23 Published 3/26/2018, Control # 596-05 2-48...
Page 95: Compact Manifold Valve
GRT8100 SERVICE MANUAL HYDRAULIC SYSTEM COMPACT MANIFOLD VALVE Compact Manifold Valve Installation Install the valve to the turntable and secure with the Description capscrews and nuts. Torque capscrews. Refer to Fasteners and Torque Values, page 1-15 for proper The compact manifold valve (Figure 2-24 and Figure 2-25) is torque value.
Page 96 HYDRAULIC SYSTEM GRT8100 SERVICE MANUAL 8804-88 Compact Manifold Valve Directional Control Valve - Right Ctwt Removal Flow Control Valve - Right Ctwt Removal Cyl Cylinder Check Valve - Cab Tilt Down Directional Control Valve - Left Ctwt Removal Check Valve - Ctwt Pin Cylinder Retract Cylinder Inlet Port (P) Directional Control Valve - Ctwt Pin Cylinder...
Page 97 GRT8100 SERVICE MANUAL HYDRAULIC SYSTEM Shuttle Valve Shuttle Valve Dual Pilot Piston - Ctwt Pin Cylinder Check Valve - Ctwt Pin Cylinder Extend Shuttle Valve Dual Pilot Piston - Cab Tilt Cylinder Check Valve - Cab Tilt Up 8804-89 Compact Manifold Valve FIGURE 2-25 2-51 GROVE...
Page 98: Accessory Manifold Valve
HYDRAULIC SYSTEM GRT8100 SERVICE MANUAL ACCESSORY MANIFOLD VALVE Fill Tube The fill tube pressure regulating valve is a two-position, Description solenoid controlled, proportional valve that works with the telescope and tele stage select valve manifold to prevent the The accessory manifold valve (Figure 2-26 through movement of the first stage (boom tele sections 2, 3, and 4) Figure 2-28) is located on the superstructure side plate when the second stage (tele section 1) extends or retracts by...
Page 99 GRT8100 SERVICE MANUAL HYDRAULIC SYSTEM Function Check - Pilot Supply and Telescope Fill Verify the following crane functions operate properly: Tube Valve Telescope in and out Start the engine. b. Boom raise and lower Try to telescope the boom in and out, lower and raise the Hoist up and down boom, and lower and raise the hoist rope.
Page 100 HYDRAULIC SYSTEM GRT8100 SERVICE MANUAL 8804-95 8804-93 Accessory Manifold Valve Gauge Port (GP7) Work Port - Brakes (BR) Inlet Port (P) Gauge Port (GP4) Pressure Relief Valve - 2800 psi Tank Port (T) Gauge Port (GP8) Work Port - Tele Stage Selector (CF) Gauge Port (GP5) Check Valve Work Port - Swing Brake Apply (SB)
Page 101 GRT8100 SERVICE MANUAL HYDRAULIC SYSTEM FIGURE 2-28 2-55 GROVE Published 3/26/2018, Control # 596-05...
Page 102: Lift Cylinder And Telescope Cylinder Control Valves
HYDRAULIC SYSTEM GRT8100 SERVICE MANUAL LIFT CYLINDER AND TELESCOPE Start the engine and fully retract the telescope the lift cylinders using the joysticks. Use the RCL override CYLINDER CONTROL VALVES function to fully retract the lit cylinder. Description Shut off engine. A externally-piloted cartridge style holding valve is installed Unscrew holding valve from its port block or manifold.
Page 103: Carrier Combination Manifold Valve
GRT8100 SERVICE MANUAL HYDRAULIC SYSTEM CARRIER COMBINATION MANIFOLD VALVE digital output thus de-energizing the axle oscillation solenoids. Description When the axle oscillation normally-closed solenoid valves are de-energized, the lockout cylinders are isolated from The carrier combination manifold valve (Figure 2-29 through hydraulic oil supply.
Page 104 HYDRAULIC SYSTEM GRT8100 SERVICE MANUAL Functional Check Ensure the axle lockout function operates properly by performing the procedures under Axle Oscillation Cycle an outrigger cylinder several times. Verify the Lockouts Operation in section 3 of the Operator Manual. cylinder extends and retracts properly. Rear steer the crane to the left and to the right several times.
Page 105 GRT8100 SERVICE MANUAL HYDRAULIC SYSTEM Work Port - Axle Lockout (B2) Check Valve Work Port - Axle Lockout (A2) Work Port - Outriggers Retract (A1) Gauge Port (G2) Orifice Check Valve Shuttle Valve Drain Port (DR1) Check Valve Work Port - Outriggers Extend (B1) 8804-100 Carrier Combination Valve Cont.
Page 106 HYDRAULIC SYSTEM GRT8100 SERVICE MANUAL FIGURE 2-31 Published 3/26/2018, Control # 596-05 2-60...
Page 107: Outrigger Control Manifold
GRT8100 SERVICE MANUAL HYDRAULIC SYSTEM OUTRIGGER CONTROL MANIFOLD Inspection Visually inspect the valves and hydraulic connections for any Description evidence of leaks or other damage. Check security of the electrical connections. Inspect the wiring for any evidence of There are two outrigger control manifolds (Figure 2-32 and cracks or breaks.
Page 108 HYDRAULIC SYSTEM GRT8100 SERVICE MANUAL Front Outrigger Control Manifold Cont. Rear Outrigger Control Manifold Cont. FIGURE 2-33 Published 3/26/2018, Control # 596-05 2-62...
Page 109: Range Shift/Park Brake Manifold Valve
GRT8100 SERVICE MANUAL HYDRAULIC SYSTEM RANGE SHIFT/PARK BRAKE MANIFOLD Maintenance VALVE Removal Description Tag and disconnect electrical connectors to the valve. The parking brake/range shift manifold valve controls the Tag and disconnect hydraulic hoses from the valve. Cap flow of oil to the parking brake, hi-low range and axle or plug lines and ports.
Page 110: Telescope And Tele Fill Stage Select Manifold Valve
HYDRAULIC SYSTEM GRT8100 SERVICE MANUAL TELESCOPE AND TELE FILL STAGE extends or retracts by maintaining oil pressure in the fill tube of the first stage. SELECT MANIFOLD VALVE • prevents the second stage from moving as the first stage Description extends or retracts by maintaining oil pressure in the fill tube of the second stage.
Page 111 GRT8100 SERVICE MANUAL HYDRAULIC SYSTEM Telescope and Tele Fill Stage Select Control Manifold Control Valve - Tele Fill Stage Select Control valve - Tele Fill Tube Enable Pilot-Operated Control Valve Pilot Pressure Port (PS) Pressure Port (P) Drain Port (DR) Pressure Transducer Port (SW) Work Port - Cylinder Stage 1 (SA) Pressure Port (B)
Page 112: Dual Accumulator Charge Manifold Valve
HYDRAULIC SYSTEM GRT8100 SERVICE MANUAL DUAL ACCUMULATOR CHARGE MANIFOLD Maintenance VALVE Removal Description Tag and disconnect the hydraulic hoses from the valve. Cap or plug the lines and ports. The dual accumulator charge manifold valve (Figure 2-36) is located on the inside of the left superstructure side plate Remove the three bolts, washers, and lockwashers (Figure 2-18).
Page 113 GRT8100 SERVICE MANUAL HYDRAULIC SYSTEM 7752-02 7752-01 These ports plugged Item Description Load Sense Port (LS) Tank Port (T) Pressure Port (P) Accumulator Port (1A) Accumulator Port (2A) Pressure Switch 7752-03 Dual Accumulator Charge Valve FIGURE 2-36 2-67 GROVE Published 3/26/2018, Control # 596-05...
Page 114: Hydraulic Brake Accumulator
HYDRAULIC SYSTEM GRT8100 SERVICE MANUAL HYDRAULIC BRAKE ACCUMULATOR Remove two nuts securing each clamp half. Remove each clamp half and accumulator from turntable. Description Installation The hydraulic brake accumulators are located inside the Position accumulator in the clamps. Secure with superstructure side plates near the turntable bearing removable clamp halves and nuts.
Page 115: Cylinders
Remove extend hose from cylinder. Cap extend hose. It is recommended that all exposed cylinder rods be protected using Boeshield® T-9 Premium Metal Protectant. Manitowoc Crane Care has Boeshield® T-9 Premium Metal DANGER Protectant available in 12 oz. aerosol cans by ordering part number 9999101803.
Page 116: Temperature Effects On Hydraulic Cylinders
HYDRAULIC SYSTEM GRT8100 SERVICE MANUAL Temperature Effects On Hydraulic Cylinders To minimize the effects of thermal contraction or “Stick-slip” it is recommended that the telescope joystick is activated Hydraulic oil expands when heated and contracts when periodically in the extend position to mitigate the effects of cooled.
Page 117 GRT8100 SERVICE MANUAL HYDRAULIC SYSTEM Table 2-5 Boom Drift Chart (Cylinder length change in millimeters) 0.000774 (1/ °C) Coeff. = STROKE Temperature Change (°C) 5.81 11.61 17.42 23.22 29.03 34.83 40.64 46.44 52.25 58.05 63.86 11.61 23.22 34.83 46.44 58.05 69.66 81.27 92.88...
Page 118 HYDRAULIC SYSTEM GRT8100 SERVICE MANUAL THIS PAGE BLANK. Published 3/26/2018, Control # 596-05 2-72...
Page 119: Description
GRT8100 SERVICE MANUAL ELECTRICAL SYSTEM SECTION 3 ELECTRICAL SYSTEM SECTION CONTENTS Description ....... 3-1 Battery Replacement .
Page 120: Batteries And Battery Disconnect Switch
ELECTRICAL SYSTEM GRT8100 SERVICE MANUAL Disconnect Switch OFF. Turn switch ON to connect the batteries. Cab Electrical Panel NOTE: Refer to the electrical schematic in the back of this manual for a diagram of the electrical system. The cab electrical panel (Figure 3-2) is located inside the crane cab, behind the operator’s seat.
Page 121 GRT8100 SERVICE MANUAL ELECTRICAL SYSTEM Front Back Cab Electrical Panel Fuse and Relay Box 2 (see Figure 3-5) Battery for MWISCM Module Memory Fuse and Relay Box 1 (see Figure 3-4) Electronic Control Unit - MWI0L Diagnostic Connector Box Electronic Control Unit - MWISCM RCL Bypass Key Switch 24V to 12V Converter Crane Star Module...
Page 122 ELECTRICAL SYSTEM GRT8100 SERVICE MANUAL Connector Bulkhead Plate Swivel Wire Harness Overhead Wire Harness Cab Interior Wire Harness Cab Interior Wire Harness Cab Interior Wire Harness Superstructure Wire Harness Superstructure Wire Harness Ground Wire Harness Cab Interior Wire Harness Superstructure Wire Harness Overhead Wire Harness Seat Wire Harness Connector Bulkhead Plate...
Page 123 GRT8100 SERVICE MANUAL ELECTRICAL SYSTEM Cab Fuse and Relay Box 1 F1 - UB + T/T CCM10 Module Battery Power F14 - UE + T/T CCM10/IOL30 Module Battery Power F2 - UB + T/T CCM10 Module Battery Power F15 - Jog Dial/Status Light Bar/Operator F3 - UB + Cab IOL32/SCM0 Module/Operator Displayed Fused Relay Power F4 - UB + Cab IOL32/SCM0 Module/Operator...
Page 124 ELECTRICAL SYSTEM GRT8100 SERVICE MANUAL Cab Fuse and Relay Box 2 K102 - Accessory Relay D1 - Fused Keyswitch Ignition K105 - Boom Extension Actuator In Relay D2 - Brake Pedal Pressure Switch K106 - Boom Extension Actuator Out Relay D5 - Horn K107 - Horn Relay D3 - Hazard/Signal Lights...
Page 125: Carrier Electrical Panel
GRT8100 SERVICE MANUAL ELECTRICAL SYSTEM Carrier Electrical Panel consists of the two batteries, battery disconnect switch, fuse and relay boxes, starter and grid heater relays, and The carrier electrical panel (Figure 3-6) is located on the fuel electronic control units. tank side of the crane, inside the electrical compartment.
Page 126 ELECTRICAL SYSTEM GRT8100 SERVICE MANUAL Carrier Fuse Panel F52 - 100A Power F55 - Intake Air Heater Relay Power F53 - 100A Power F51 - 125A Alternator Power F54 - 100A Power Grid Heater Relay F56 - 100A Power Starter Relay FIGURE 3-7 Published 3/26/2018, Control # 596-05...
Page 127 GRT8100 SERVICE MANUAL ELECTRICAL SYSTEM Carrier Fuse and Relay Box 1 K108 - 24V Starter Lockout Relay F5 - UB + Carrier CCM11/IOL31 Module Battery Power F11 - Retarder Option Power F6 - Engine ECM Power F1 - Refinery Option Power F7 - UE +Carrier CCM11/IOL31 Module Battery F2 - Fused Battery Power Power...
Page 128 ELECTRICAL SYSTEM GRT8100 SERVICE MANUAL Carrier Fuse and Relay Box 2 K109 - DEF Lines Heater Relay F4 - After-treatment Sensors Fused Relay Power K110 - DEF Supply Module F5 - After-treatment Sensors Fused Relay Coil K111 - After-treatment Sensors Power Relay Power F1 - DEF Lines Heater Fused Relay Power D1 - Pressure Line Heater...
Page 129: 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 DANGER Parts Manual. At the same service interval, visually inspect all Controller...
Page 130: General Troubleshooting
ELECTRICAL SYSTEM GRT8100 SERVICE MANUAL Table 3-1 Zone Classification Tropical Moist: All months average above 18° C. Latitude 15° - 25° North and South Dry or Arid: Deficient precipitation most of the year. Latitude: 20° - 35° North and South Moist Mid-Latitude: Temperature with mild winters.
Page 131 GRT8100 SERVICE MANUAL ELECTRICAL SYSTEM Table 3-2. AMP Extraction Tool Table Description AMP Part Number Manitowoc Part Number 14 gauge wire (connectors) 305183 9999100176 12 to 8 gauge wire (connectors) 91019-3 9999100175 4 to 9 circuit (in-line connectors) 453300-1 15 circuit (in-line connectors) 458944-1 Table 3-3.
Page 132: Alternator/Charging System Troubleshooting
Connect positive ( ) lead to alternator output terminal system: and negative ( – ) lead to battery positive terminal or post. Do not connect meter to battery cable. Manitowoc Equipment Example Part No. Run engine at 2000 rpm. Digital Multimeter...
Page 133: Starter Replacement
GRT8100 SERVICE MANUAL ELECTRICAL SYSTEM Installation Installation Inspect belt. Verify it has no cracks or other damage. Place starter on mounting pad. Secure starter with bolts. Replace damaged belt as needed. Torque to 32 lb-ft (43 Nm). Install alternator using mounting bolts and washers. Connect electrical leads to terminals as tagged during Torque bolts;...
Page 134: Relay Panel Components
ELECTRICAL SYSTEM GRT8100 SERVICE MANUAL Open battery compartment door. Buzzer Replacement Ensure key switch has been in the OFF position for 2 Behind operators seat, loosen thumbscrews securing minutes. panel cover. Lower cover. Turn battery disconnect switch to OFF position. Tag and disconnect electrical leads from buzzer.
Page 135 GRT8100 SERVICE MANUAL ELECTRICAL SYSTEM Use a multimeter to check for continuity between switch Remove four screws (11) from dashboard cover (1) and terminals with switch ON. Meter should register zero pull up cover. ohms. Place switch OFF. Meter should register infinity Remove four screws (14) from side covers and column (no continuity).
Page 136 ELECTRICAL SYSTEM GRT8100 SERVICE MANUAL Turn Signal and Transmission Shift Levers Installation Refer to Figure 3-11. Ensure locking pin (17) is installed in turn signal lever assembly (18). Removal Align turn signal lever assembly (18) and transmission Ensure key switch has been in OFF position for 2 shift levers assembly (7) with holes in steering column minutes.
Page 137 GRT8100 SERVICE MANUAL ELECTRICAL SYSTEM FIGURE 3-11 8673 Item Component Item Component Dashboard Cover Spacer Turn Signal Indicator M6 Button Head Screw Steering Wheel Cap Lock Handle Steering Wheel Nut Left Side Cover Steering Wheel Locking Pin Screw Turn Signal, Lights, Wiper Switch Three-Speed Transmission Shift Switch Engine Idle/Deceleration Switch Locknut...
Page 138: Windshield Wiper Assembly Replacement
ELECTRICAL SYSTEM GRT8100 SERVICE MANUAL Windshield Wiper Assembly Replacement Secure adapter and gasket of the pantograph adapter kit to the cab exterior with capscrews and lockwashers. Removal Install motor bracket and attached parts in cab interior Ensure key switch has been in OFF position for two with attaching hardware.
Page 139: Skylight Wiper Assembly Replacement
GRT8100 SERVICE MANUAL ELECTRICAL SYSTEM Inspection nylon flat washer from motor shaft and flat washer and smaller nylon flat washer from mounting screw. Visually check pump for evidence of cracks, leaks, or Remove mounting screw and nylon flat washer from other damage.
Page 140: Adjusting Electronic Joysticks
(7, Figure 3-14). are required. The CAN-Link service software and connection cable are available through Manitowoc Crane Care to those A list of all fault codes and their definitions are available service technicians who have attended the Grove New through Manitowoc Crane Care to those service technicians Technology training course.
Page 141 GRT8100 SERVICE MANUAL ELECTRICAL SYSTEM FIGURE 3-12 Published 3/26/2018, Control # 596-05 3-23 GROVE...
Page 142 ELECTRICAL SYSTEM GRT8100 SERVICE MANUAL FIGURE 3-13 Published 3/26/2018, Control # 596-05 3-24...
Page 143 GRT8100 SERVICE MANUAL ELECTRICAL SYSTEM FIGURE 3-14 Published 3/26/2018, Control # 596-05 3-25 GROVE...
Page 144: Optional Equipment
ELECTRICAL SYSTEM GRT8100 SERVICE MANUAL OPTIONAL EQUIPMENT adjusted for optimum view from cab while boom is over front of crane. This section is provided to give a brief description of optional equipment for the crane which is not discussed elsewhere in Air Conditioner this service manual.
Page 145: Cold Weather Operation
The green light will turn off indicating system is deactivated. very cold temperatures are operated and maintained in Shutdown cycle may take approximately 2 minutes. accordance with the procedures as provided by Manitowoc. NOTE: Accelerated discharging of battery will occur when Always ensure adequate lubrication during system warm-up crane engine is switched off.
Page 146 ELECTRICAL SYSTEM GRT8100 SERVICE MANUAL THIS PAGE BLANK. Published 3/26/2018, Control # 596-05 3-28...
Page 147: Section 4
GRT8100 SERVICE MANUAL BOOM SECTION 4 BOOM SECTION CONTENTS Description ....... 4-1 Telescope Circuit.
Page 148: Theory Of Operation
BOOM GRT8100 SERVICE MANUAL THEORY OF OPERATION telescope cylinder, and are secured to the rear of tele 3 on the other end; the tele 4 extension cables (qty 4) (9, Boom extension and retraction is accomplished with one Figure 4-1) are secured to the rear of tele 2 on one end, run two-stage telescope cylinder, 10 extension cables, and 6 around the extension sheaves on the front of tele 3, and are retraction cables.
Page 149 GRT8100 SERVICE MANUAL BOOM Item Description Base Section tele 1 tele 2 tele 3 tele 4 Telescope Cylinder - 1st Stage Telescope Cylinder - 2nd Stage Tele 3 Extend Cables Tele 4 Extend Cables Tele 3 Retract Cables Tele 4 Retract Cables FIGURE 4-1 Published 3/26/2018, Control # 596-05 GROVE...
Page 150: Maintenance
BOOM GRT8100 SERVICE MANUAL MAINTENANCE Removal DANGER Ensure lifting device is capable of supporting the boom NOTE: The boom assembly must be rotated 180° (upside assembly. Death or serious injury may result if the lifting d o w n ) b e f o r e p e r f o r m i n g a n y a s s e m b l y o r device cannot support the load.
Page 151 GRT8100 SERVICE MANUAL BOOM FIGURE 4-2 Published 3/26/2018, Control # 596-05 GROVE...
Page 152 BOOM GRT8100 SERVICE MANUAL FIGURE 4-2 continued Published 3/26/2018, Control # 596-05...
Page 153 GRT8100 SERVICE MANUAL BOOM FIGURE 4-2 continued Published 3/26/2018, Control # 596-05 GROVE...
Page 154 BOOM GRT8100 SERVICE MANUAL FIGURE 4-2 continued Published 3/26/2018, Control # 596-05...
Page 155 GRT8100 SERVICE MANUAL BOOM FIGURE 4-2 continued Published 3/26/2018, Control # 596-05 GROVE...
Page 156 BOOM GRT8100 SERVICE MANUAL FIGURE 4-2 continued 4-10 Published 3/26/2018, Control # 596-05...
Page 157 GRT8100 SERVICE MANUAL BOOM Published 3/26/2018, Control # 596-05 4-11 GROVE...
Page 158 BOOM GRT8100 SERVICE MANUAL 4-12 Published 3/26/2018, Control # 596-05...
Page 159 GRT8100 SERVICE MANUAL BOOM Published 3/26/2018, Control # 596-05 4-13 GROVE...
Page 160 BOOM GRT8100 SERVICE MANUAL 4-14 Published 3/26/2018, Control # 596-05...
Page 161 GRT8100 SERVICE MANUAL BOOM Published 3/26/2018, Control # 596-05 4-15 GROVE...
Page 162 BOOM GRT8100 SERVICE MANUAL 4-16 Published 3/26/2018, Control # 596-05...
Page 163 GRT8100 SERVICE MANUAL BOOM Item Description Item Description 45 SHIM BASE SECTION WELD 46 WEAR PAD ASSEMBLY TELE 1 WELD 47 ANCHOR WELD TELE 2 WELD 48 F Washer 1” Hard TELE 3 WELD 49 Hex Nut M24 8 ISO 4032 TELE 4 WELD 50 F WASHER, 20 ST ISO 7089 CYL HYD, DISCRETE CTL 2 STAGE...
Page 164 BOOM GRT8100 SERVICE MANUAL Item Description Item Description 89 SHAFT 133 SHEAVE MOUNT WELD 90 ROLLER ASSEMBLY 134 SHEAVE ASSY - 2 GROOVE 91 F Washer 5/16” Wide MS 135 SPACER-154mm I.D. 92 TRUNNION PLATE 136 SHAFT 93 SHIM 137 PLATE 94 WEAR PAD 138 F WASHER 1/2”...
Page 165: Disassembly
GRT8100 SERVICE MANUAL BOOM Disassembly Working at front of base and tele sections 1, 2, 3, 4, loosen two jam nuts (21) and bolts (22) on all upper wear NOTE: Boom assembly must be rotated 180° (upside pads (19, 46, 78, 100) (left and right sides) (see d o w n ) b e f o r e p e r f o r m i n g a n y a s s e m b l y o r Figure 4-4).
Page 166 BOOM GRT8100 SERVICE MANUAL 13. Remove two bolts (18) securing stop block (14) and 18. Detach grease hose assembly (66, 69, 70) from wear shim (15) to front of base section (1) (left and right sides) pad (63) at rear of tele 1 (2) (left and right sides) (see (see Figure 4-5).
Page 167 GRT8100 SERVICE MANUAL BOOM 31. Remove tele 2 (3) from tele section 1 (2). Set tele 2 (3) on adequate supports. 32. Remove rear trunnion plate (71) from rear of telescope cylinder (6) (left and right sides) (see Figure 4-12). 8804-45 FIGURE 4-10 24.
Page 168 BOOM GRT8100 SERVICE MANUAL 41. Remove capscrews (121), lock washers (11), and plates (173) securing the anchor ends of the two tele 3 retract cables (87) to rear of tele 3 (4) (see Figure 4-16). Detach the two tele 3 retract cables (87). 8804-43 FIGURE 4-14 37.
Page 169 GRT8100 SERVICE MANUAL BOOM 47. Lift rear of telescope cylinder (6) so that the front trunnion blocks (148) lift out of the pockets at the inside rear of tele 2 (3). (see Figure 4-21). 8804-37 FIGURE 4-18 45. Remove eight nuts (88) and four washers (72) from ends of the tele 4 extend cables (2x-104, 2x-105) (see Figure 4-19).
Page 170 BOOM GRT8100 SERVICE MANUAL 59. Detach grease hose assembly (66, 69, 70) from wear pad (125) at rear of tele 3 (4) (left and right sides) (see Figure 4-24). 60. Remove two capscrews (56) securing wear pad (2x-53) and wear pad (4x-54) to rear of tele 3 (4) (see Figure 4-24).
Page 171 GRT8100 SERVICE MANUAL BOOM 115 90 8804-28 FIGURE 4-27 63. Remove grease fitting (109) from shaft of sheave mount weldment (112) (left and right sides). 8804-31 FIGURE 4-29 64. Remove four capscrews (113) and flat washers (16) 68. Remove shaft (117), which is holding the anchor ends of securing sheave assembly (81, 112) to rear of tele 3 (4) the six tele 3 extend cables (139), from its keeper at rear (left and right sides) (see Figure 4-28).
Page 172 BOOM GRT8100 SERVICE MANUAL 79. Remove two bolts (18) securing stop block (14) and shim (15) to front of tele 3 (4) (left and right sides) (see Figure 4-32). 80. Remove wear pads (98, 2x-96, 2x-99) and shims (2x-97) from front of tele 3 (4) (see Figure 4-32). 81.
Page 173 GRT8100 SERVICE MANUAL BOOM 84. Remove six bolts (108) securing rear shaft (101) and sheave assembly (103) to tele 3 (4). Pull tele 4 extend cable (105) out the front of tele 3 (4), then remove shaft (101) and sheave assembly (103) (left and right sides) (see Figure 4-34).
Page 174: Boom Nose Sheaves
BOOM GRT8100 SERVICE MANUAL 100.Remove six tele 3 extend cables (139) from sheave assemblies (134) at front of telescope cylinder (6) (see Figure 4-40). 8804-5 FIGURE 4-38 95. Remove grease fitting (109) from each end of hollow shaft (136). 8804-1 FIGURE 4-40 101.Remove plate (137), two capscrews (111), and two hardened flat washers (138) securing hollow shaft (136)
Page 175: Assembly
GRT8100 SERVICE MANUAL BOOM Installation NOTE: Use standard Grade 5 and/or 8 torque values specified in Section 1 of this manual unless NOTE: boom nose sheave shafts weigh otherwise specified. approximately 46 kg (100 lb) each. The boom nose Use the following procedures and refer to Figure 4-2 when sheaves weigh approximately 7.7 kg (17 lb) each.
Page 176 BOOM GRT8100 SERVICE MANUAL 11. Position tele 4 (5) up side down and in front of telescope cylinder (6). Set tele 4 (5) on adequate supports. 12. Apply multipurpose grease to inside of tele 4 (see Figure 4-44). 8804-2 FIGURE 4-42 Install wear pad (142) onto telescope cylinder sheave mounting weldment (133) using four capscrews (13) and flat washers (10) (see Figure 4-43).
Page 177 GRT8100 SERVICE MANUAL BOOM 18. Mount wear pad (4x-128) to rear of tele 4 (5) using two capscrews (129) (left and right sides). Mount wear pad (127) to rear of tele 4 (5) using two capscrews (129) (see Figure 4-48). NOTE: When installing tele 4 (5) into tele 3 (4), add equal number of shims (55) underneath wear pads (127,...
Page 178 BOOM GRT8100 SERVICE MANUAL 8804-12 FIGURE 4-50 8804-7 FIGURE 4-52 21. Secure all wear pads to tele 4 (5) using strap (D). Place 23. Further insert telescope cylinder (6) into tele 4 (5). Use a strap around edge of wear pads farthest from the rear large c-clamp (E) or similar to ensure two tele 4 retract end of tele 4 (5) (see Figure 4-51).
Page 179 GRT8100 SERVICE MANUAL BOOM 8804-16 FIGURE 4-56 8804-13 FIGURE 4-54 28. Position tele 3 (4) up side down and in back of tele 4 (5). 25. To ease installation of tele 4 (5) into tele 3 (4), insert Set tele 3 (4) on adequate supports. shaft (117) through anchor ends of the six tele 3 extend 29.
Page 180 BOOM GRT8100 SERVICE MANUAL 8804-24 FIGURE 4-58 8804-19 FIGURE 4-60 31. Using a grease gun or brush, apply grease to inside of 33. Assemble small and large sheaves (2x-103, 2x-102), tele 3 (4) in the areas where the tele 4 rear wear pads four spacers (172), and four shafts (101) together.
Page 181 GRT8100 SERVICE MANUAL BOOM (103), and secure with the capscrew (141) (left and right sides) (see Figure 4-62). 8804-22 FIGURE 4-63 43. Install wear pad assembly (100) into front of tele 3 (4) (left and right sides) (see Figure 4-63). 8804-21 FIGURE 4-62 44.
Page 182 BOOM GRT8100 SERVICE MANUAL 8804-25 FIGURE 4-65 8804-31 FIGURE 4-67 49. Lift rear of telescope cylinder (6) and remove blocks of 52. Attach wear pads (53) to sheave mount weldments (112) wood. using four capscrews (123). 50. Slide shaft (117) out of the anchor ends of the six tele 3 53.
Page 183 GRT8100 SERVICE MANUAL BOOM 59. Lower cylinder on to blocks of wood measuring 7 in. in height (L) (see Figure 4-72). 90 115 8804-28 FIGURE 4-69 8804-32 FIGURE 4-72 60. Apply anti-seize to trunnions at rear of telescope cylinder (6). Install trunnion blocks (4x-148). Apply anti- seize to trunnion blocks (left and right sides) (see Figure 4-72).
Page 184 BOOM GRT8100 SERVICE MANUAL 67. Place wear pad (76) and the two shims (75) against tele 3 (4) and secure them using a strap (Q). Place two blocks of wood or similar, with rubber pads on both sides, directly in front of and against the wear pads and shims and secure them with a strap (see Figure 4-75).
Page 185 GRT8100 SERVICE MANUAL BOOM (148) drop into the pockets at inside rear of tele 2 (3) (see Figure 4-79). 8804-19 FIGURE 4-77 73. Install two stop blocks (14) and shims (15) to front of tele 2 (3) using four bolts (18) (left and right sides) (see 8804-36 FIGURE 4-79 Figure 4-77).
Page 186 BOOM GRT8100 SERVICE MANUAL 8804-37 FIGURE 4-81 78. Apply anti-seize to shaft (89), then install the roller (90) 8804-37 FIGURE 4-83 and shaft (89) into rear of tele 2 (3). Index shaft (89) so that it can be secured in place using two capscrews (85) 81.
Page 187 GRT8100 SERVICE MANUAL BOOM 89. Secure all of loose wear pads (94, 95) and shims (93) to tele 2 (3) using a strap. Place strap around edge of wear pads farthest from rear end of tele 2 (3). 90. Apply anti-seize to rear trunnions at rear of telescope cylinder (6).
Page 188 BOOM GRT8100 SERVICE MANUAL slip into tele 1 (2), then remove strap. Continue to insert 99. Continue to insert tele 2 (3) into tele 1 (2) until anchor tele 2 (3) into tele 1 (2) until wear pads and shims are weldment (47) with two tele 3 retract cables (87) secured fully inserted.
Page 189 GRT8100 SERVICE MANUAL BOOM in front of and against the wear pads and shims and secure them with a strap (V) (see Figure 4-94). 108.Mount wear pad (2x - 53) and wear pad (4x - 54) to rear of tele 1 (2) using capscrews (56) (see Figure 4-95). NOTE: When installing tele 1 (2) into base section 1, add equal number of shims (55) underneath wear pads...
Page 190 BOOM GRT8100 SERVICE MANUAL 119.Continue to insert tele 1 (2) into base section (1), ensuring telescope cylinder (6) seats into the hole in the rear of the base section. Remove special tool (part number MT102678) from end of telescope cylinder. 120.Install plate (35) to rear of telescope cylinder (6) using four bolts (22) and hardened flat washers (33) (see Figure 4-98).
Page 191: Installation
GRT8100 SERVICE MANUAL BOOM 125.Install all hydraulic tube assemblies to tele stage selection manifold (39) and telescope cylinder (6) as tag during disassembly. Replace all O-rings. DANGER 126.Once boom assembly is positioned right-side up, adjust If the hydraulic system must be activated to extend or top front wear pads (19, 46, 78, 100) of each boom tele retract the lift cylinder, ensure the rod end is properly section using upper and side adjustment bolts (22).
Page 192: Boom Alignment And Servicing
BOOM GRT8100 SERVICE MANUAL Should boom chatter or rubbing noises in the boom occur, it All wire rope will eventually deteriorate to a point where it is will be necessary to lubricate the telescope cylinder wear no longer usable. Wire rope shall be taken out of service pads.
Page 193 GRT8100 SERVICE MANUAL BOOM ensure all sections bottom out properly and do not drift cables. Retract the boom fully. Repeat until the out when the hydraulic valve is in neutral. section bottoms out properly. Re-torque the tele 4 retract cables and the tele 4 extend cables to verify NOTE: Add or remove shims as required so that stop that the minimum torque value is achieved as...
Page 194 BOOM GRT8100 SERVICE MANUAL 8804-61 Item Description Base Section tele 1 tele 2 tele 3 tele 4 Telescope Cylinder - 1st Stage Telescope Cylinder - 2nd Stage Tele 3 Extend Cables Tele 4 Extend Cables Tele 3 Retract Cables Tele 4 Retract Cables FIGURE 4-100 4-48 Published 3/26/2018, Control # 596-05...
Page 195: Telescope Circuit
GRT8100 SERVICE MANUAL BOOM TELESCOPE CIRCUIT retracted or fully extended positions, and near the transition point. This mode has the best stability performance. Description Auto B Mode The boom telescope circuit consists of the telescope In the auto B mode, the boom extends to full length by hydraulic remote controller, telescope directional control extending Tele 1 first then Tele 2.
Page 196: Maintenance
BOOM GRT8100 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 197: Removal And Installation
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 198: Lift Circuit
BOOM GRT8100 SERVICE MANUAL LIFT CIRCUIT The holding valve is a balanced poppet type hydraulic valve. It is threaded into the port block which is an integral portion of Description the lift cylinder barrel. The holding valve functions when booming up (cylinder rod extended), booming down (cylinder The boom lift circuit consists of the lift hydraulic remote rod retracted), or holding (cylinder rod stationary).
Page 199 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 200: Lift Cylinder Removal
BOOM GRT8100 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 201 GRT8100 SERVICE MANUAL BOOM 4, 5 Detail A Detail B FIGURE 4-101 Item Description Item Description Capscrew Washer (2) Locknut Stop Plate Shaft Shaft Capscrew (2) Grease Fitting (2) Published 3/26/2018, Control # 596-05 4-55 GROVE...
Page 202: Hook Block
BOOM GRT8100 SERVICE MANUAL HOOK BLOCK hook block weighs 620 kg (1,367 lb). Grease fittings are provided to ensure lubrication of all moving parts. Description Maintenance A 11 t (12.1 US ton) overhaul swivel hook ball and the Periodic Maintenance following hook blocks are available for the crane: •...
Page 203: Adjusting Boom Extension Stowage Mounts
GRT8100 SERVICE MANUAL BOOM ADJUSTING BOOM EXTENSION STOWAGE Install the two attachment pins. MOUNTS d. Tighten torque mounting bolts specification. NOTE: Refer to Figure 4-102 and Figure 4-103. Tighten locking nut on jack bolt. NOTE: Tighten and torque all bolts and nuts to the specifications defined under Fasteners and Torque 10.
Page 204 BOOM GRT8100 SERVICE MANUAL Fly Section to Main Boom Attachment Pin Fly Section to Main Boom Attachment Pin Main Boom Attachment Bar Item Description Base Section Front Stowage Bracket Assembly Fly Section Front Stowage Ramp Assembly Boom Base to Fly Section Attachment Bracket Assembly Middle Stowage Bracket and Actuator Assembly Fly Section Rear Stowage Bracket Assembly FIGURE 4-102...
Page 205 GRT8100 SERVICE MANUAL BOOM Lock Hitch Lock Hitch FIGURE 4-103 Published 3/26/2018, Control # 596-05 4-59 GROVE...
Page 206 BOOM GRT8100 SERVICE MANUAL THIS PAGE BLANK. 4-60 Published 3/26/2018, Control # 596-05...
Page 207: Description
GRT8100 SERVICE MANUAL HOIST AND COUNTERWEIGHT SECTION 5 HOIST AND COUNTERWEIGHT SECTION CONTENTS Description ....... 5-1 Brake Test Procedure .
Page 208: Maintenance
HOIST AND COUNTERWEIGHT GRT8100 SERVICE MANUAL MAINTENANCE Warm-up Procedure A warm-up procedure is recommended at each start-up and is essential at ambient temperatures below 4°C (40°F). 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 209: Installing Cable On Hoist
GRT8100 SERVICE MANUAL HOIST AND COUNTERWEIGHT Travel Position (5). Ensure cable is routed over guide in side of drum. End of cable should extend approximately 50 mm (2 in) Refer to (Figure 5-2). beyond clamp. Tighten clamp. Lower two hoist mirrors (1). Adjust cable so clamp side is snug against guide.
Page 210: Removing/Installing The Hoist
HOIST AND COUNTERWEIGHT GRT8100 SERVICE MANUAL REMOVING/INSTALLING THE HOIST Install the bearing support assembly (8) to the drum shaft with grease fittings at the 11-o’clock position. Align Refer to Figure 5-4, on page 5-5. and install the six long capscrews into the threaded turntable holes.
Page 211 GRT8100 SERVICE MANUAL HOIST AND COUNTERWEIGHT 14 19 FIGURE 5-4 8743 Hoist Shaft Flat Washer Cotter Pin Hoist Roller Flat Washer O-Ring Roll Pin Narrow Flat Washer Cable Wedge Capscrew O-Ring Limit Switch Assembly Capscrew Lockwasher 2 Speed Motor Piston Capscrew Sight Glass Shaft...
Page 212: Usage And Inspection
Although these components are designed for long service be worn or damaged, contact your Manitowoc Cranes life, reliability can be reduced by a variety of factors such as: distributor or Manitowoc Crane Care to order a replacement. • High cycle operation.
Page 213: Oil Sampling
GRT8100 SERVICE MANUAL HOIST AND COUNTERWEIGHT • Perform pre-use inspection. • Check for correct function of hoist brake by conducting a high line pull load test. Ensure brake holds without • Inspect for corrosion of fasteners, hoist base, drum, etc. creeping and hoist control is correct.
Page 214: Brake Test Procedure
HOIST AND COUNTERWEIGHT GRT8100 SERVICE MANUAL General Guidelines for Iron Contaminant Reassemble the brake and hoist and repeat the above steps. Level When testing is complete, reattach the brake release line to the brake release port. 100-500 ppm Normal MOTOR, MOTOR CONTROL VALVE, AND BRAKE 500-800 ppm Caution - Abnormal Sample.
Page 215: Hoist Rotation And Minimum Wrap Indicator System
GRT8100 SERVICE MANUAL HOIST AND COUNTERWEIGHT HOIST ROTATION AND MINIMUM WRAP system, repairs should be limited to finding and replacing the faulty component(s). To determine which component is at INDICATOR SYSTEM fault, refer to the troubleshooting section of your CAN bus Description Adjusting Minimum Wrap Switch The main and auxiliary hoists are each equipped with an...
Page 216: Hoist Control Valves
HOIST AND COUNTERWEIGHT GRT8100 SERVICE MANUAL HOIST CONTROL VALVES Description NOTE: For more detailed information, refer to Valves, page 2-39 in Section 2 - Hydraulic System. Hydraulic Hoist Motor Control Valve The hydraulic hoist motor control valve is mounted on the hoist motor and is designed to provide an even flow of oil to the hoist motor in both directions.
Page 217: Removable Counterweight
GRT8100 SERVICE MANUAL HOIST AND COUNTERWEIGHT REMOVABLE COUNTERWEIGHT Counterweight Control Panel Counterweight control panels are located on each side of the superstructure between the boom pivot and main hoist. Only DANGER one control panel can be used at a time. The crane engine Falling counterweight can crush and cause death or must be running with parking brake ON and no other serious injury.
Page 218: Remove
HOIST AND COUNTERWEIGHT GRT8100 SERVICE MANUAL Remove Install Refer to Figure 5-8. Refer to Figure 5-8. Position crane on a firm level surface. Fully extend and Position crane on a firm level surface. Fully extend and set outriggers. set outriggers. Place superstructure in normal travel position with NOTE: Counterweight...
Page 219: Install Optional Counterweight Slab
GRT8100 SERVICE MANUAL HOIST AND COUNTERWEIGHT Install Optional Counterweight Slab Remove Optional Counterweight Slab Position crane on a firm level surface. Fully extend and Follow operating instructions for Remove and Install set outriggers. Counterweight on previous page, except DO NOT remove lock pins and retaining pins from lift cylinders Operate crane to place slab on rear deck centering pins.
Page 220 HOIST AND COUNTERWEIGHT GRT8100 SERVICE MANUAL THIS PAGE BLANK Published 3/26/2018, Control # 596-05 5-14...
Page 221: Description
GRT8100 SERVICE MANUAL SWING SYSTEM SECTION 6 SWING SYSTEM SECTION CONTENTS Description ....... 6-1 Description.
Page 222: Theory Of Operation
SWING SYSTEM GRT8100 SERVICE MANUAL THEORY OF OPERATION position solenoid valve controls the pressure to release the swing brake. A pressure reducing valve maintains a pressure Swing Drive of 260 to 300 psi to the inlet of both the brake release and brake apply valves.
Page 223 GRT8100 SERVICE MANUAL SWING SYSTEM Picture may not be same model as your machine, it is for reference only. 6470-1 FIGURE 6-1 Breather Plug Level Plug Filler Plug Motor Swing Drive and Brake Pinion Hydraulic Apply Brake Port Drain Plug Hydraulic Release Brake Port GROVE Published 3/26/2018, Control # 596-05...
Page 224: Maintenance
Restricted or partly clogged hydraulic j. Replace hose or fittings. Refer to the hose or fittings. Manitowoc Crane Care Parts Manual. k. Pump cavitation in swing section. k. Tighten suction hose or replace damaged fittings. Check hydraulic tank level.
Page 225 Replace hose or fittings. Refer to the installed. Manitowoc Crane Care Parts Manual. f. Clogged or restricted hydraulic hoses or f. Clean or replace damaged parts. fittings. g. Worn or damaged output shaft bearings g. Replace bearings.
Page 226 SWING SYSTEM GRT8100 SERVICE MANUAL Symptom Probable Cause Solution Swing brake a. Improper brake adjustment. a. Adjust brake. operation erratic. b. Air in swing brake system. b. Bleed brake system. c. Brake pedal not fully retracted. c. Check brake pedal return spring; repair or replace spring.
Page 227: Swing Motor
GRT8100 SERVICE MANUAL SWING SYSTEM SWING MOTOR Remove two screws and separate motor from brake flange. Remove and discard O-ring from groove in the Description 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 228: Swing Gearbox And Brake
SWING SYSTEM GRT8100 SERVICE MANUAL SWING GEARBOX AND BRAKE Check for hydraulic leaks and repair as necessary. Gearbox Description Removal The Swing Gearbox and Brake Figure 6-1, used with the Swing Motor, rotates and stops the superstructure. A pedal Engage turntable lock pin. on the cab floor activates the Swing Brake.
Page 229 GRT8100 SERVICE MANUAL SWING SYSTEM consists of maintaining the gearbox oil level. Oil in a new c. After oil is drained, replace drain plug and any other g e a r b o x s h o u l d b e d r a i n e d a n d f l u s h e d o u t a f t e r plugs removed to drain oil.
Page 230: Swing Bearing
SWING SYSTEM GRT8100 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 DANGER bolted to the superstructure and the outer race is bolted to It is mandatory that bearing attaching bolts be inspected...
Page 231 GRT8100 SERVICE MANUAL SWING SYSTEM Front of Crane 8804-136 FIGURE 6-2 Outer Race Torquing Multiplier bar handles must be propped or supported within the outer 1/4 of the handle length, or serious Extend and set the outriggers. Fully elevate the boom. under or over tightening will occur.
Page 232 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 233 GRT8100 SERVICE MANUAL SWING SYSTEM 13. Attach a suitable lifting device to four superstructure Installation lifting lugs (two at boom pivot shaft bushings and two at lower lift cylinder pivot shaft bushings). Take in cable or chain to remove slack. Do not pull up on superstructure. DANGER Anytime a turntable bolt has been removed, it must be replaced with a new grade 8 bolt.
Page 234 SWING SYSTEM GRT8100 SERVICE MANUAL Install gearbox pinion, aligning high point (maximum 10. Install boom and lift cylinder following procedures eccentricity) on turntable bearing. Using a 0.203 mm outlined in Section 4 - Boom. (0.008 in) thick shim, check backlash Figure 6-4. If NOTE: Removable counterweight weighs approximately pinion must be moved to achieve proper backlash,...
Page 235: Swivels
GRT8100 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 ring...
Page 236: Description
SWING SYSTEM GRT8100 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 Picture may not be same model as your machine, it is for reference only. 7897-3 FIGURE 6-5 Published 3/26/2018, Control # 596-05...
Page 237: Hydraulic Swivel
GRT8100 SERVICE MANUAL SWING SYSTEM HYDRAULIC SWIVEL Description Each port 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 Bar (psi) 35 (100) Return 35 (100) Return...
Page 238 SWING SYSTEM GRT8100 SERVICE MANUAL connector mounting bracket on carrier frame. If Position retainer plate on hydraulic swivel spool necessary, remove electrical swivel. Refer to Electrical ensuring they engage the lugs on the carrier frame. Swivel in this Section. NOTE: Allow a 1/32”...
Page 239: Two Port Water Swivel
GRT8100 SERVICE MANUAL SWING SYSTEM TWO PORT WATER SWIVEL Cleaning and Inspection Description The two 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 240: Electrical Swivel
SWING SYSTEM GRT8100 SERVICE MANUAL ELECTRICAL SWIVEL Locate connectors which join the collector ring harness to carrier receptacles. Description Tag connectors and their receptacles with numbers. Disconnect connectors from chassis wiring receptacles. The swivel assembly consists of a 20 conductor slip ring and cover assembly.
Page 241: Swing Lock Pin
GRT8100 SERVICE MANUAL SWING SYSTEM Ensure the anti-rotation pin in the bottom of the electrical Preventive Maintenance swivel base is aligned with the mounting hole in the It is recommended a normal inspection of the electrical bracket on the water swivel case Figure 6-6. swivel collector ring and brush assembly be established.
Page 242: Maintenance
SWING SYSTEM GRT8100 SERVICE MANUAL pin, a control handle in the right side of the cab, and control u n d am a g e d a n d w o r k i ng p r op e r l y. Ver i f y s p r i n g i s linkage that allows the crane operator to set and free the pin.
Page 243: Engine
GRT8100 SERVICE MANUAL POWER TRAIN SECTION 7 POWER TRAIN SECTION CONTENTS Engine ........7-1 Slip Joint Exhaust Connectors - Tier 3 and 4 .
Page 244: Maintenance
POWER TRAIN GRT8100 SERVICE MANUAL Maintenance 16. Using lifting device, lift engine and transmission/torque converter as an assembly from the crane. Engine Removal 17. If a new engine is installed, remove all components, fit- Set outriggers and position boom over the side. tings, etc., from old engine and install them on new engine in same locations.
Page 245 GRT8100 SERVICE MANUAL POWER TRAIN Attach fuel filter and engine lubrication filter to the frame. Connect battery cables and engine electrical harness connector in accordance with identification marks made during removal. 10. Connect electrical wiring to the hourmeter as tagged during removal.
Page 246: Electronic Control System
POWER TRAIN GRT8100 SERVICE MANUAL ELECTRONIC CONTROL SYSTEM gives the operator a signal that there is a engine or transmission problem which must be corrected. Description Exhaust System Cleaning Required Indicator The engine control system is an electronically operated fuel The Exhaust System Cleaning Required indicator is located control system that also provides many operator and vehicle in the crane control system display.
Page 247: Fuel System
GRT8100 SERVICE MANUAL POWER TRAIN FUEL SYSTEM Fuel Tank The fuel tank should be kept filled, especially overnight, to Description reduce condensation to a minimum. Refer to the applicable engine manual for the recommended schedule for draining The fuel system consists of the fuel tank, fuel-water any water or sediment from the tank.
Page 248 POWER TRAIN GRT8100 SERVICE MANUAL Fuel Tank Filler Cap Fuel Level Sending Unit Fuel Cooler Ball Valve 8804-109 FIGURE 7-4 Published 3/26/2018, Control # 596-05...
Page 249: Air Intake And Exhaust System
GRT8100 SERVICE MANUAL POWER TRAIN AIR INTAKE AND EXHAUST SYSTEM connections are all well sealed, and there is still evidence of dust leakage, check the following places for possible trouble. Description NOTE: Dust that gets by the air cleaner system can often be detected by looking for dust streaks on the air The air intake system (Figure 7-7) controls the quality and transfer tubing or just inside the intake manifold...
Page 250 POWER TRAIN GRT8100 SERVICE MANUAL If the initial restriction on a new or clean filter reads above the Ensure the correct size connections are used between maximum allowed for the engine, check the following items. the air cleaner and the engine. Ensure the air cleaner inlet is not plugged.
Page 251 GRT8100 SERVICE MANUAL POWER TRAIN 8804-120 Air Filter Assembly - Tier 3 Temp/Air Pressure Sensor Pre-cleaner Vacuator Valve Primary Air Filter Secondary Air Filter Service Door FIGURE 7-6 GROVE Published 3/26/2018, Control # 596-05...
Page 252 POWER TRAIN GRT8100 SERVICE MANUAL 8804-118 Air Intake Assembly - Tier 4 Elbow Clamp T-bolt Clamp Tube Tube Reducer Muffler Clamp Clamp Elbow Air Cleaner Assembly FIGURE 7-7 Air Filter Assembly - Tier 4 Service Door Pre-cleaner Vacuator Valve Primary Air Filter TAP Sensor Secondary Air Filter FIGURE 7-8...
Page 253 GRT8100 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 254: Charge-Air Cooler System
POWER TRAIN GRT8100 SERVICE MANUAL Check the condition of the valve and lips frequently and keep them clean. The valve lips should be open only when the engine is shut down, or running at low idle speed. If the valve is turned outside in, check for a clogged air cleaner inlet.
Page 255: Exhaust System
GRT8100 SERVICE MANUAL POWER TRAIN Exhaust System Ti g h t e n V- b a n d c l a m p s t o 1 3 . 5 ± 1 . 5 N m (9.96±1.10 ft-lb). Tier 3 Exhaust System Tighten slip joint to 9 to 11.3 Nm (85 to 100 ft-lb).
Page 256 POWER TRAIN GRT8100 SERVICE MANUAL Exhaust System - Tier 3 Exhaust Tube Weldment Downpipe Tube Muffler Clamp Muffler Downpipe Tube Tailpipe Tube Muffler Clamp Mounting Band Clamp FIGURE 7-13 Published 3/26/2018, Control # 596-05 7-14...
Page 257 GRT8100 SERVICE MANUAL POWER TRAIN 8804-111 Exhaust System - Tier 4 V-band Clamp V-band Clamp Slip Joint Decomp Reactor Tube V-band Clamp V-band Clamp V-band Clamp Selective Catalytic Reduction (SCR) Device Oxidation Catalyst Mounting Bands FIGURE 7-14 GROVE Published 3/26/2018, Control # 596-05 7-15...
Page 258: Water Cooling System
POWER TRAIN GRT8100 SERVICE MANUAL WATER COOLING SYSTEM however, an engine that is running too cold can be just as troublesome. Description Overheating The cooling system (Figure 7-16) consists of a radiator, An engine that is overheating may lead to troubles such as surge tank, engine cooling circuit, and the connecting hoses the following: and connecting tubes.
Page 259 GRT8100 SERVICE MANUAL POWER TRAIN Engine Antifreeze/Coolant Fill Procedure Cleaning Fill system with a 50/50 blended, fully formulated extended life antifreeze/coolant. Fill to bottom of the surge tank filler neck. Fill slowly. Flow exceeding 3 gpm CAUTION (11.2 L/min) can give a false reading. Burn Hazard! Wait one minute and recheck the antifreeze/coolant The cooling system contains very hot pressurized liquid...
Page 260 POWER TRAIN GRT8100 SERVICE MANUAL Pressure Flushing cooling system pressure reaches a predetermined point, the cap valve opens and will again close when the pressure falls Disconnect both radiator hoses that connect the radiator below the predetermined point. to the engine. When removing the pressure type cap, perform the Clamp a convenient length of hose to the radiator core operation in two steps.
Page 261 GRT8100 SERVICE MANUAL POWER TRAIN Water Pump Remove the hose clamps and bellows connecting the radiator to the charge air cooler tubes. Remove the hose The pump should be checked carefully for leaks and proper clamps and radiator hose connecting the radiator to the lubrication.
Page 262: Radiator Fill And Servicing
POWER TRAIN GRT8100 SERVICE MANUAL 10. Tighten the drain cock at the bottom of the radiator. 11. Mount the surge tank to the frame using the two bolts, washers, lockwashers and nuts. 12. Connect the hose between the surge tank and the radiator and the hose from the engine to the surge tank.
Page 263 GRT8100 SERVICE MANUAL POWER TRAIN 8804-123 FIGURE 7-16 GROVE Published 3/26/2018, Control # 596-05 7-21...
Page 264: Drive Train
POWER TRAIN GRT8100 SERVICE MANUAL DRIVE TRAIN The transmission/torque converter oil is cooled by passing the oil through an externally mounted transmission cooler Description that is located on the left side of the crane. An oil filter is mounted on the left frame rail near the fuel tank. The drive train consists of the transmission/torque converter Three drive lines are used.
Page 265: Transmission/Torque Converter
GRT8100 SERVICE MANUAL POWER TRAIN Drive Shafts suction screen and directs it through the pressure regulating valve and oil filter. The pressure regulating valve maintains pressure to the CAUTION transmission control for actuating the direction and speed Do not disassemble drive lines when removing them from clutches.
Page 266: Maintenance
POWER TRAIN GRT8100 SERVICE MANUAL detent ball and spring in the direction spool provides three Troubleshooting positions, one each for forward, neutral, and reverse. Following is an aid to locating the source of difficulty in a With the engine running and the directional control lever in malfunctioning unit.
Page 267 GRT8100 SERVICE MANUAL POWER TRAIN Table 7-1Troubleshooting SYMPTOM PROBABLE CAUSE REMEDY Low clutch pressure. Low oil level. Fill to proper level. b. Clutch pressure regulating b. Clean valve spool and housing. valve spool stuck open. Faulty charging pump. Replace pump. d.
Page 268 POWER TRAIN GRT8100 SERVICE MANUAL Removal Install a 101.6 mm (4.00 in) long drive plate locating stud 3/8-24 UNF in a drive plate nut. Extend and set outriggers just enough to take up the Rotate transmission/torque converter to align locating slack in the outrigger pads.
Page 269 GRT8100 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 270: Towing Or Pushing
POWER TRAIN GRT8100 SERVICE MANUAL Servicing the Crane after Transmission/torque temperature reaches 82°C to 93°C (180°F to 200°F), add oil to bring the level to the FULL mark on the Converter Overhaul dipstick. The transmission/torque converter and its allied hydraulic Recheck all drain plugs, lines, connections, etc., for system are important links in the drive line between the leaks and tighten where necessary.
Page 271: Description
GRT8100 SERVICE MANUAL UNDERCARRIAGE SECTION 8 UNDERCARRIAGE SECTION CONTENTS Axles ........8-1 Description.
Page 272 UNDERCARRIAGE GRT8100 SERVICE MANUAL Removal units, and all other openings should be tightly covered or closed to prevent the possibility of water entering the Using the outriggers, raise the wheels off the ground. assembly. Install blocking under the frame at the outboard ends of Installation the four outrigger boxes.
Page 273 GRT8100 SERVICE MANUAL UNDERCARRIAGE Clearance should be 25.4 mm (1.00 in) minimum, If Rear Steer Indicator Adjustment Procedure n e c e s s a r y, a d j u s t t h e a x l e s t o p t o p r o v i d e Ensure the wheels are straight ahead.
Page 274: Wheels And Tires
UNDERCARRIAGE GRT8100 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. ground.
Page 275 GRT8100 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 276 UNDERCARRIAGE GRT8100 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 277: Steering Systems
GRT8100 SERVICE MANUAL UNDERCARRIAGE STEERING SYSTEMS valves; and two steer cylinders. Refer to Carrier Combination Manifold Valve, page 2-57 for a description of the rear steer Description hydraulic components, their function, and maintenance information. A rear steer indicator system is provided to To maximize maneuverability, the crane can be steered by indicate when the rear wheels are not centered.
Page 278 UNDERCARRIAGE GRT8100 SERVICE MANUAL Symptom Probable Cause Solution Noisy hydraulic pump Hydraulic oil low. Refill hydraulic reservoir. Refer to caused by cavitation. Lubrication, page 9-1. b. Suction line plugged or too small. b. Clean line and check for size. Hydraulic pump shaft Worn shaft seal.
Page 279 GRT8100 SERVICE MANUAL UNDERCARRIAGE Rear Steering System Troubleshooting Table 8-2 Symptom Probable Cause Solution Rear steering Hydraulic oil low. Check system for leaks. Make inoperative. repairs as needed. Fill reservoir. b. Clogged, broken, loose b. Clean, tighten, or replace lines or hydraulic lines or fittings.
Page 280: Rear Axle Oscillation Lockout System
UNDERCARRIAGE GRT8100 SERVICE MANUAL REAR AXLE OSCILLATION LOCKOUT directly over the front, the RCL sends a CAN bus message to the Crane Control System to allow axle oscillation. When the SYSTEM Crane Control System receives this message it switches ON a digital output thus energizing the axle oscillation solenoids.
Page 281 GRT8100 SERVICE MANUAL UNDERCARRIAGE Supply From Pump Lockout Valve Lockout Cylinder Lockout Cylinder FIGURE 8-12 Rear Axle Published 3/26/2018, Control # 596-05 8-11 GROVE...
Page 282: Axle Oscillation Lockout Cylinders
UNDERCARRIAGE GRT8100 SERVICE MANUAL Axle Oscillation Lockout Cylinders Axle Oscillation Lockout Valve Description Description Two hydraulic lockout cylinders are installed on the rear axle, The axle oscillation lockout valve (also called the double one left side and one right side. The base end of each solenoid valve), located on the carrier combination manifold cylinder is attached to each side of the carrier frame and the valve, is used in the rear axle oscillation lockout circuit.
Page 283: Theory Of Operation
GRT8100 SERVICE MANUAL UNDERCARRIAGE powered brake system supplies a high brake system rate and the high limit pressure setting. However, when the pressure with relatively low reactive pedal forces, while open center circuit pressure reaches the brake relief setting, controlling the maximum brake line pressure. The service which is higher than the high accumulator charge limit, then brake dual accumulator charge valve regulates flow to the the accumulators will be charged to the relief valve setting.
Page 284: Maintenance
UNDERCARRIAGE GRT8100 SERVICE MANUAL 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 285: Service Brakes
GRT8100 SERVICE MANUAL UNDERCARRIAGE SERVICE BRAKES brake valve. Bleed every bleeder screw on every caliper/ actuator on every wheel. When you complete a bleeder Description screw, go to the next closest bleeder screw on the same 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 286 UNDERCARRIAGE GRT8100 SERVICE MANUAL 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 287 GRT8100 SERVICE MANUAL UNDERCARRIAGE 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 288 UNDERCARRIAGE GRT8100 SERVICE MANUAL Minimum Disc Bleeder Screw Piston Fluid Thickness Fluid Leaks Leaks Maximum Disc Wear Each Side Inlet Cylinder Fitting Maximum Fluid Disc Wear Fluid Original Leaks Leaks Disc Thickness 15.875 mm (0.625 in) Typical Section Through Disc Showing Piston Fluid Recommended Maximum Wear Limits Leaks...
Page 289: Corrosion Protection
GRT8100 SERVICE MANUAL UNDERCARRIAGE Measure the diameter of the housing bore. Replace the • Use soap and water to clean parts that are not made housing if the diameter is worn to more than 3.003 in of metal. (76.276 mm). Refer to Figure 8-23. •...
Page 290 UNDERCARRIAGE GRT8100 SERVICE MANUAL Install a new dust seal in the top groove of the bore. Install a new O-ring in the groove of the cylinder cap. Refer to Figure 8-24. Ensure the O-ring is not cut by the threads on the cylinder cap.
Page 291: Parking Brake Actuator
GRT8100 SERVICE MANUAL UNDERCARRIAGE Maintenance Caliper Position the caliper housing on the mounting bracket. If Removal shims where used, place them as marker 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 292: Parking Brake
UNDERCARRIAGE GRT8100 SERVICE MANUAL PARKING BRAKE approximately 1.778 mm (0.07 in) more. This puts the proper amount of pre-load on the urethane springs. Description Tighten jam nut/sleeves (35) against mounting surface and torque 271.1 Nm (200 lb-ft). The parking brake is mounted on the front axle input shaft in line between the front axle and the driveline from the transmission.
Page 293 GRT8100 SERVICE MANUAL UNDERCARRIAGE FIGURE 8-28 Published 3/26/2018, Control # 596-05 8-23 GROVE...
Page 294: Park Brake Solenoid Valve
UNDERCARRIAGE GRT8100 SERVICE MANUAL 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 Spring Disc Spring O-ring Seal Housing...
Page 295: Outrigger
GRT8100 SERVICE MANUAL UNDERCARRIAGE OUTRIGGER A sight bubble level is mounted inside the cab on the right side by the emergency stop switch. The sight bubble level Outrigger Circuit provides the operator with a visual indication of crane level attitude. Description Theory Of Operation The outrigger circuit consists of four extension cylinders, four...
Page 296: 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 297 GRT8100 SERVICE MANUAL UNDERCARRIAGE Symptom Probable Cause Solution Sticking spool. Dirt in the system. Change oil and flush system. b. Distortion caused by tie bolts b. Retorque tie bolts. being overtorqued. Flow in excess of valve rating. Limit flow through valve to that recommended.
Page 298 UNDERCARRIAGE GRT8100 SERVICE MANUAL 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 299: Outrigger Beam
GRT8100 SERVICE MANUAL UNDERCARRIAGE Outrigger Beam Description DANGER The outrigger beam assembly consists of an outrigger beam, a jack cylinder, an extension cylinder, an Outrigger Be sure any blocking material used is capable of supporting the weight of the outrigger beam. Do not allow Monitoring System (OMS) (Optional—Standard in North it to tilt or slide.
Page 300 UNDERCARRIAGE GRT8100 SERVICE MANUAL beam from riding on the bottom of the box during System (Optional—Standard in North America), page 8- installation. If removed, install two wear pads and plates to the top of NOTE: Avoid free-release of cable to prevent damage to the outrigger beam using two flat head socket screws.
Page 301 GRT8100 SERVICE MANUAL UNDERCARRIAGE 8804-114 Item Description Cylinder Clevis Pin (rod end) Mid-extend Pin Plates and Wear Pads (beam mounted) Cylinder Clevis Pin (piston end) Wear Pad Assembly (O/R box mounted) FIGURE 8-30 Published 3/26/2018, Control # 596-05 8-31 GROVE...
Page 302: Extension Cylinder
UNDERCARRIAGE GRT8100 SERVICE MANUAL Extension Cylinder properly per instructions. Verify no jack cylinder hose is trapped by full outrigger beam retraction. If any is, stop Description immediately and install lines properly to avoid trapping. Two outrigger extension cylinders are utilized within each Check the hydraulic connections and hoses for any outrigger box assembly.
Page 303: Jack Cylinder
GRT8100 SERVICE MANUAL UNDERCARRIAGE Maintenance NOTE: Refer to Cylinders, page 2-69 for Disassembly and Assembly of the cylinders. Removal Slightly extend outrigger beam for improved access to the jack cylinder. Shut down the engine. Tag and disconnect the hydraulic hoses from the jack cylinder (see Figure 8-32).
Page 304 UNDERCARRIAGE GRT8100 SERVICE MANUAL Apply anti-seeze compound to retaining pin. Secure Functional Check cylinder and cylinder cap retaining bracket to support Activate the hydraulic system. Fully extend and retract tube with retaining pin and cotter pins. the jack cylinder. Install cylinder cap. Observe the operation of the jack cylinder.
Page 305: General
Potentially harmful waste used in Manitowoc cranes includes For information on extreme condition lubrication, contact — but is not limited to — oil, fuel, grease, coolant, air...
Page 306 LUBRICATION GRT8100 SERVICE MANUAL CAUTION Possible Equipment Damage! Chassis grease lubricants must not be applied with air pressure devices as this lubricant is used on sealed fittings. The multipurpose grease applied during manufacturing is of a lithium base. Use of a noncompatible grease could result in damage to equipment.
Page 307: Standard Lubricants
Standard Lubricants Standard lubricants are used on all Manitowoc cranes unless the crane is ordered with a cold weather package. These 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.
Page 308 LUBRICATION GRT8100 SERVICE MANUAL Table 9-1: Standard Lubricants [Down to -9°C (15°F)] Recommended Lubricant Lubricant/Fluid Grove Spec. Type Grade Classification Diesel Exhaust Fluid (DEF) Fleetguard StableGuard™ Urea 32 Premix 80019225 AdBlue® TerraCair Ultrapure® DEF Extreme Pressure 3% Moly Citgo Lithoplex CM2 Grease Mobil Mobilgrease CM-P 6829015304...
Page 309: Arctic Lubricants And Conditions
• Hydraulic reservoir heater bands. Therefore, always check with an authorized Manitowoc distributor or Manitowoc Crane Care if in doubt of • Engine hood insulation the suitability of a specific fluid or lubricant.
Page 310 LUBRICATION GRT8100 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 Hoist Gear Oil CITGO, Syntetic Gear Lube Eaton, Roadranger EP 6829014058 75W-90 Mobil, Mobilube SCH Shell, Spirax S...
Page 311 GRT8100 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 Hoist Gear Oil CITGO, Syntetic Gear Lube Eaton, Roadranger EP 6829014058 75W-90 Mobil, Mobilube SCH Shell, Spirax S...
Page 312: Cylinder Rod Surface Protection
Where wear pads are used, cycle the components and It is recommended that all exposed cylinder rods be protected relubricate to ensure complete lubrication of the entire wear using Boeshield® T-9 Premium Metal Protectant. Manitowoc area. Crane Care has Boeshield® T-9 Premium Metal Protectant available in 12 oz.
Page 313: Drive Train
GRT8100 SERVICE MANUAL LUBRICATION Table 9-4Approved Lubricant Reference Table Lube Specification Lube Specification Lube Specification Ref. Approved Lubricant Down To TO -29˚C Down To -40˚C Down To -9˚C (15˚F) (-20˚F) (-40˚F) Extreme Pressure Multipurpose Grease 6829003477 6829104275 6829104275 Gear Lube (GL-5) 6829014058 6829014058 6829014058...
Page 314: Drive Train (Continued)
LUBRICATION GRT8100 SERVICE MANUAL Lube Point Figure Approved Lube Item Lube Interval Application Description Lubricant Capacity Drive Train (Continued) • Check level every 10 Through fill pipe to hours or daily Transmission, 37.9 L Figure 9-1 FULL mark on Torque Converter (55.6 qt) •...
Page 315 GRT8100 SERVICE MANUAL LUBRICATION FRONT 8591 FIGURE 9-1 9-11 Published 3/26/2018, Control # 596-05 GROVE...
Page 316: Drive Train (Continued)
LUBRICATION GRT8100 SERVICE MANUAL Lube Point Figure Approved Lube Item Lube Interval Application Description Lubricant Capacity Drive Train (Continued) Change transmission filter after Transmission Refer to Item 5 first 50 and 100 hours of Figure 9-2 Filter NOTE. service, then every 500 hours thereafter Clean strainer screen after Close shutoff valves.
Page 317 GRT8100 SERVICE MANUAL LUBRICATION Drive Train (Continued) Lube Point Figure Approved Lube Item Lube Interval Application Description Lubricant Capacity DEF Supply Module Filter Figure 9-3 Check filter every 4500 hours. (Tier 4) Indicator in cab DEF Tank 18.9 L Check and fill every 10 hours or Figure 9-3 illuminates when (Tier 4)
Page 318: Steering And Suspension
LUBRICATION GRT8100 SERVICE MANUAL Steering and Suspension Lube Point Figure Approved Lube Item Lube Interval Application Description Lubricant Capacity Steer Cylinder Until grease Figure 9-4 500 hours or 3 months 8 grease fittings Pivot Pins extrudes Upper and Lower Until grease Figure 9-4 500 hours or 3 months 8 grease fittings...
Page 319: Steering And Suspension (Continued)
GRT8100 SERVICE MANUAL LUBRICATION Steering and Suspension (Continued) Lube Point Figure Approved Lube Item Lube Interval Application Description Lubricant Capacity Fifth Wheel Until grease Figure 9-5 500 hours or 3 months 2 grease fittings Pivots extrudes 8595 FIGURE 9-5 9-15 Published 3/26/2018, Control # 596-05 GROVE...
Page 320: Axles
LUBRICATION GRT8100 SERVICE MANUAL Lube Point Figure Approved Lube Item Lube Interval Application Description Lubricant Capacity Axles • Check level every 500 Fill to bottom of hole hours or 3 months 24.6 L Differentials Figure 9-6 in rear right-hand side (52 pt) •...
Page 321: Turntable (Continued)
GRT8100 SERVICE MANUAL LUBRICATION Lube Point Figure Approved Item Lube Capacity Lube Interval Application Description Lubricant Turntable • Check and fill every 50 hours Turntable Gear 5.4 L Fill to max level on • Drain and fill after Figure 9-7 (5.7 qt) level plug.
Page 322: Cab Tilt
LUBRICATION GRT8100 SERVICE MANUAL Lube Point Figure Approved Item Lube Capacity Lube Interval Application Description Lubricant Turntable (Continued) Turntable Swivel Figure 9-8 Coat pin 500 hours or 6 months Spray on Lock Pin Cab Tilt Until grease Tilt Cylinder extrudes from Figure 9-8 500 hours or 6 months Spray on...
Page 323: Outriggers
GRT8100 SERVICE MANUAL LUBRICATION Lube Point Figure Approved Lube Item Lube Interval Application Description Lubricant Capacity Outriggers Wear Pads Figure 9-9 50 hours or 1 week Brush on Outrigger Beams Figure 9-9 50 hours or 1 week Brush on 8600 FIGURE 9-9 Lube Point Approved...
Page 324: Boom (Continued)
LUBRICATION GRT8100 SERVICE MANUAL Boom NOTE: Crane Setup: Machine shall be set up on firm level surface with fully extended outriggers and minimum 9979 kg (22,000 lb) counterweight installed. Ensure crane is level. • Boom must be directly over the front with house lock engaged. •...
Page 325 GRT8100 SERVICE MANUAL LUBRICATION Boom (Continued) NOTE: Crane Setup: Machine shall be set up on firm level surface with fully extended outriggers and minimum 9979 kg (22,000 lb) counterweight installed. Ensure crane is level. • Boom must be directly over the front with house lock engaged. •...
Page 326 LUBRICATION GRT8100 SERVICE MANUAL • 4 grease fittings • Extend Tele 2 to 38.2 Meters Figure 9-12 Retract Cable Until grease (125.3 FT) so & 250 hours or 3 months Sheaves extrudes the access Figure 9-13 holes align with the grease fittings.
Page 327 GRT8100 SERVICE MANUAL LUBRICATION FRONT 8608 8610 8610 8611 8611 FIGURE 9-12 9-23 Published 3/26/2018, Control # 596-05 GROVE...
Page 328 LUBRICATION GRT8100 SERVICE MANUAL FRONT 8608 8612 8613 FIGURE 9-13 Published 3/26/2018, Control # 596-05 9-24...
Page 329 GRT8100 SERVICE MANUAL LUBRICATION Boom (Continued) NOTE: Crane Setup: Machine shall be set up on firm level surface with fully extended outriggers and minimum 9979 kg (22,000 lb) counterweight installed. Ensure crane is level. • Boom must be directly over the front with house lock engaged. •...
Page 330: Hoist
LUBRICATION GRT8100 SERVICE MANUAL Lube Point Approved Lube Item Figure No. Lube Interval Application Description Lubricant Capacity Hoist • Check and fill every Oil level must be 50 hours or weekly 4.7 L between the high and Main Hoist Figure 9-15 •...
Page 331: Hydraulic
“milky” with only a small layer of transparent oil on top. If the “milky” appearance was due to air foaming, it will dissipate and the oil should closely match the fresh oil. Should you have any questions, please contact your local authorized Manitowoc distributor. •...
Page 332: Diesel Exhaust Fluid (Def) Tank
LUBRICATION GRT8100 SERVICE MANUAL Lube Point Approved Lube Item Figure No. Lube Interval Application Description Lubricant Capacity Diesel Exhaust Fluid (DEF) Tank 19 L Fill when level is low DEF Tank Figure 9-15 Left rear side of carrier. (5 gal) per indicator.
Page 333: Rust Protection
While crane surfaces that are easily seen have the biggest impact on appearance, particular attention should be given Manitowoc Crane Group's cranes are manufactured to high to the undercarriage to minimize harmful effects of corrosion. quality standards, including the type of paint finish Exercise special care and increase frequency of cleaning if demanded by today's industry.
Page 334: Inspection And Repair
® • Carwell treatment is available in 16 ounce spray Manitowoc Crane Care must be contacted and consulted bottles from Manitowoc Crane Care (order part number as to what repairs may be required. 8898904099). For scratches and marks in highly visible areas: •...
Page 335 GRT8100 SERVICE MANUAL LUBRICATION • All hardware, clips, pins, hose connections not painted will have treatment applied. 7650-75 Picture may not be same model as your Figure 9-18 machine, it is for reference only. 9-31 Published 3/26/2018, Control # 596-05 GROVE...
Page 336 LUBRICATION GRT8100 SERVICE MANUAL Picture may not be same model as your machine, it is for reference only. Figure 9-19 TABLE 9-1. Rust Inhibitor Application Locations Pivot Shaft O/R Beam Wear Pad Adjustment Hardware Boom Extension Pins, Clips Entire underside of unit Boom Nose Pins, Clips Powertrain Hardware Inside Compartment Hook Block/Headache Ball...
Page 337 GRT8100 SERVICE MANUAL ALPHABETICAL INDEX 360° Swing Lock Control (Positive Lock Type) (Optional) ..... . . 6-22 Accessory Manifold Valve ..........2-52 Adjusting Boom Extension Stowage Mounts .
Page 338 SERVICE MANUAL GRT8100 Supply Pressure And Return Circuit........2-9 Swing Bearing .

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