Page 1 Grove GRT880 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 CALIFORNIA PROPOSITION 65 WARNING Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. CALIFORNIA PROPOSITION 65 WARNING Battery posts, terminals, and related accessories contain chemical lead and lead compounds, chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.
Page 5: Table Of Contents
GRT880 SERVICE MANUAL TABLE OF CONTENTS TABLE OF CONTENTS SECTION 1 ........Introduction General .
Page 6 TABLE OF CONTENTS GRT880 SERVICE MANUAL Seizing Wire Rope ..........1-32 Installing 35x7 Class Wire Rope .
Page 7 GRT880 SERVICE MANUAL TABLE OF CONTENTS Compact Manifold Valve ..........2-49 Description .
Page 8 TABLE OF CONTENTS GRT880 SERVICE MANUAL Boom Mounted Floodlights ......... . 3-26 Rear View Mirror .
Page 9 GRT880 SERVICE MANUAL TABLE OF CONTENTS Description ............5-9 Maintenance .
Page 10 TABLE OF CONTENTS GRT880 SERVICE MANUAL Exhaust System........... 7-13 Slip Joint Exhaust Connectors - Tier 3 and 4 .
Page 11 GRT880 SERVICE MANUAL TABLE OF CONTENTS Cylinder Rod Surface Protection ......... . . 9-8 Wire Rope Lubrication .
Page 12 TABLE OF CONTENTS GRT880 SERVICE MANUAL THIS PAGE BLANK. TOC-8...
Page 13: Section 1
GRT880 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
GRT880 SERVICE MANUAL INTRODUCTION LIST OF SPECIFICATIONS Engine Cummins QSB 6.7 - Tier 4F General Type ... . . 4-cycle, Diesel, Turbocharged Model ......GRT880 Number of Cylinders .
Page 16: Hydraulic Pumps
INTRODUCTION GRT880 SERVICE MANUAL Hydraulic Pumps Pump #3 Type ....... . Gear NOTE: Pump output figures are theoretical.
Page 17 GRT880 SERVICE MANUAL INTRODUCTION CG to CL Weight Front Axle Rear Axle Description Rear Bogie kg (lb) kg (lb) kg (lb) cm (in) Maximum Axle Loads Allowed 31752 (70000) 31752 (70000) Maximum Axle Loads Allowed while Towing 27216 (60000) 27216 (60000) Maximum Tire Loads Allowed 32006...
Page 18 INTRODUCTION GRT880 SERVICE MANUAL CG to CL Weight Front Axle Rear Axle Description Rear Bogie kg (lb) kg (lb) kg (lb) cm (in) SUB: Synthetic Rope on Main Hoist (220 m (722 ft) of -76.71 (-30.20) -318 (-702) (128) -376 (-830) 22 mm (7/8 in) K-100) SUB: Synthetic Rope on Aux Hoist (220 m (722 ft) of...
Page 19: Crane Nomenclature
GRT880 SERVICE MANUAL INTRODUCTION Crane Nomenclature FIGURE 1-2 Item Description Item Description Fuel Tank Boom Nose Sheaves 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 GRT880 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
GRT880 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 GRT880 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
Contaminants in a hydraulic system affect operation and will assemblies for correction or replacement. For replacement result in serious damage to the system components. Dirty of hose assemblies, refer to your Manitowoc Crane Care hydraulic systems are a major cause of component failures. Parts Manual.
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 GRT880 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 1-3 for the following procedure. Nonadjustable Straight Thread O-ring Fitting: Fitting to Port Table 1-3: 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 GRT880 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 10/19/2017, Control # 618-00...
Page 29 GRT880 SERVICE MANUAL INTRODUCTION Table 1-5 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 GRT880 SERVICE MANUAL Table 1-6 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 GRT880 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 GRT880 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 1-8 Metric Series with Fine Threads – Zinc Flake Coated Nominal Size, Threads per Torque (Nm) Property...
Page 33 GRT880 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 GRT880 SERVICE MANUAL Table 1-9 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 GRT880 SERVICE MANUAL INTRODUCTION Table 1-11 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 GRT880 SERVICE MANUAL Inch Series with Coarse Threads (UNC) – Untreated (black finish) Table 1-13 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 GRT880 SERVICE MANUAL INTRODUCTION Inch Series with Fine Threads (UNF) – Untreated (black finish) Table 1-14 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 UNS 908.5...
Page 38 INTRODUCTION GRT880 SERVICE MANUAL Metric Series with Coarse Threads – Untreated (black finish) Table 1-15 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 GRT880 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: Weld Studs
INTRODUCTION GRT880 SERVICE MANUAL Torque (Nm) Property Size Class Maximum Nominal Minimum 331.5 M18x1.5 10.9 12.9 M20X1 10.9 667.5 12.9 464.5 M20x1.5 10.9 12.9 M22x1.5 10.9 888.5 12.9 1111 1068 1025 803.5 M24x2 10.9 1176 1130.5 1085 12.9 1410 1356 1302 1225 1171.5...
Page 41: 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 42: 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 43: 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 44: 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 45: Installing 35X7 Class Wire Rope
GRT880 SERVICE MANUAL INTRODUCTION 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 46 INTRODUCTION GRT880 SERVICE MANUAL THIS PAGE BLANK. 1-34 Published 10/19/2017, Control # 618-00...
Page 47: Section 2
GRT880 SERVICE MANUAL HYDRAULIC SYSTEM SECTION 2 HYDRAULIC SYSTEM SECTION CONTENTS Description ....... 2-3 Checking/Setting the Outriggers, Rear Steer, and Hydraulic Transmission Oil Cooler Fan Hydraulic Symbols .
Page 48 HYDRAULIC SYSTEM GRT880 SERVICE MANUAL Cylinders ....... . 2-69 Leak Check ......2-69 Cylinder Rod Surface Protection .
Page 49: Description
GRT880 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 GRT880 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 GRT880 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
GRT880 SERVICE MANUAL HYDRAULIC SYSTEM Operate all hydraulic circuits several times in both Directional Control Valves 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
GRT880 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 GRT880 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 2-10 Published 10/19/2017, Control # 618-00...
Page 57: Hydraulic Pump Distribution
GRT880 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 GRT880 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
GRT880 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 GRT880 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 GRT880 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 Published 10/19/2017, Control # 618-00 GROVE...
Page 62: Oil Cooler
HYDRAULIC SYSTEM GRT880 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 GRT880 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 Published 10/19/2017, Control # 618-00 GROVE...
Page 64: Hydraulic Pumps
HYDRAULIC SYSTEM GRT880 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 GRT880 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 Published 10/19/2017, Control # 618-00 GROVE...
Page 66: Maintenance
HYDRAULIC SYSTEM GRT880 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 GRT880 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 GRT880 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
GRT880 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 GRT880 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 GRT880 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 Published 10/19/2017, Control # 618-00 GROVE...
Page 72: Checking/Setting The Main Directional Control Valve, Hoists, Lift, And Telescope Pressures
HYDRAULIC SYSTEM GRT880 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 GRT880 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 Published 10/19/2017, Control # 618-00 GROVE...
Page 74 HYDRAULIC SYSTEM GRT880 SERVICE MANUAL 8804-64 Main Directional Control Valve Telescope retract relief FIGURE 2-7 2-28 Published 10/19/2017, Control # 618-00...
Page 75 GRT880 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 Published 10/19/2017, Control # 618-00 GROVE...
Page 76: Checking/Setting The Pilot Supply Pressure
HYDRAULIC SYSTEM GRT880 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 GRT880 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
GRT880 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 GRT880 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
GRT880 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 GRT880 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 GRT880 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 Published 10/19/2017, Control # 618-00 GROVE...
Page 84: Checking/Setting The Axle Lockout Circuit Pressure
HYDRAULIC SYSTEM GRT880 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
GRT880 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 GRT880 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 2-40 Published 10/19/2017, Control # 618-00...
Page 87 GRT880 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 Published 10/19/2017, Control # 618-00 GROVE...
Page 88: Main Directional Control Manifold Valve
HYDRAULIC SYSTEM GRT880 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 GRT880 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 GRT880 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 2-44...
Page 91 GRT880 SERVICE MANUAL HYDRAULIC SYSTEM 8804-85 FIGURE 2-21 2-45 Published 10/19/2017, Control # 618-00 GROVE...
Page 92: Swing Manifold Valve
HYDRAULIC SYSTEM GRT880 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 GRT880 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 GRT880 SERVICE MANUAL Swing Directional Control Manifold Valve FIGURE 2-23 2-48 Published 10/19/2017, Control # 618-00...
Page 95: Compact Manifold Valve
GRT880 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 GRT880 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 GRT880 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 Published 10/19/2017, Control # 618-00...
Page 98: Accessory Manifold Valve
HYDRAULIC SYSTEM GRT880 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 GRT880 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 GRT880 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 GRT880 SERVICE MANUAL HYDRAULIC SYSTEM FIGURE 2-28 2-55 Published 10/19/2017, Control # 618-00 GROVE...
Page 102: Lift Cylinder And Telescope Cylinder Control Valves
HYDRAULIC SYSTEM GRT880 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
GRT880 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 GRT880 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 GRT880 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 GRT880 SERVICE MANUAL FIGURE 2-31 2-60 Published 10/19/2017, Control # 618-00...
Page 107: Outrigger Control Manifold
GRT880 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 GRT880 SERVICE MANUAL Front Outrigger Control Manifold Cont. Rear Outrigger Control Manifold Cont. FIGURE 2-33 2-62 Published 10/19/2017, Control # 618-00...
Page 109: Range Shift/Park Brake Manifold Valve
GRT880 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: Maintenance
HYDRAULIC SYSTEM GRT880 SERVICE MANUAL TELESCOPE AND TELE FILL STAGE • prevents the second stage from moving as the first stage extends or retracts by maintaining oil pressure in the fill SELECT MANIFOLD VALVE tube of the second stage. Description Maintenance The telescope and tele stage select manifold valve (see Removal...
Page 111 GRT880 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: Maintenance
HYDRAULIC SYSTEM GRT880 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 GRT880 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 Published 10/19/2017, Control # 618-00 GROVE...
Page 114: Maintenance
HYDRAULIC SYSTEM GRT880 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 GRT880 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 GRT880 SERVICE MANUAL HYDRAULIC SYSTEM Table 2-5 Boom Drift Chart (Cylinder length change in millimeters) Coeff. = 0.000774 (1/ °C) 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 GRT880 SERVICE MANUAL THIS PAGE BLANK. 2-72 Published 10/19/2017, Control # 618-00...
Page 119: Description
GRT880 SERVICE MANUAL ELECTRICAL SYSTEM SECTION 3 ELECTRICAL SYSTEM SECTION CONTENTS Description ....... 3-1 Battery Replacement .
Page 120: Batteries And Battery Disconnect Switch
ELECTRICAL SYSTEM GRT880 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 GRT880 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 GRT880 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 GRT880 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 GRT880 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
GRT880 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 GRT880 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 10/19/2017, Control # 618-00...
Page 127 GRT880 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 GRT880 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 Parts Manual. DANGER At the same service interval, visually inspect all Controller...
Page 130: General Troubleshooting
ELECTRICAL SYSTEM GRT880 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 GRT880 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
GRT880 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 GRT880 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 GRT880 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 GRT880 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 GRT880 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 GRT880 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
GRT880 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 GRT880 SERVICE MANUAL ELECTRICAL SYSTEM FIGURE 3-12 Published 10/19/2017, Control # 618-00 3-23 GROVE...
Page 142 ELECTRICAL SYSTEM GRT880 SERVICE MANUAL FIGURE 3-13 Published 10/19/2017, Control # 618-00 3-24...
Page 143 GRT880 SERVICE MANUAL ELECTRICAL SYSTEM FIGURE 3-14 Published 10/19/2017, Control # 618-00 3-25 GROVE...
Page 144: Optional Equipment
ELECTRICAL SYSTEM GRT880 SERVICE MANUAL OPTIONAL EQUIPMENT Rear View Mirror This section is provided to give a brief description of optional The rear view mirror installation consists of a rear view mirror equipment for the crane which is not discussed elsewhere in mounted on the top left corner of the cab.
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 GRT880 SERVICE MANUAL THIS PAGE BLANK. Published 10/19/2017, Control # 618-00 3-28...
Page 147: Section 4
GRT880 SERVICE MANUAL BOOM SECTION 4 BOOM SECTION CONTENTS Description ....... 4-1 Cable Tensioning Check and Adjustment .
Page 148: Theory Of Operation
BOOM GRT880 SERVICE MANUAL THEORY OF OPERATION is for the boom without the swingaway boom extension attached. Boom extension and retraction is accomplished with two Extend and set outriggers to level the crane. Ensure telescope cylinders, five extension cables, and two retraction boom is fully retracted and in a horizontal position over cables.
Page 149 GRT880 SERVICE MANUAL BOOM 12. Take up slack on the boom lifting device. from the opposite side of each pivot shafts. Remove the two pivot shafts. 13. Remove capscrew, washer, and wear pads from each of the two pivot shafts that secure the boom to the 14.
Page 150 BOOM GRT880 SERVICE MANUAL 9044-84 FIGURE 4-1 continued Published 10/19/2017, Control # 618-00...
Page 151 GRT880 SERVICE MANUAL BOOM 141 124 128 9044-85 FIGURE 4-1 continued Published 10/19/2017, Control # 618-00 GROVE...
Page 152 BOOM GRT880 SERVICE MANUAL 244 249 234 246 9044-87 FIGURE 4-1 continued Published 10/19/2017, Control # 618-00...
Page 153 GRT880 SERVICE MANUAL BOOM 9044-88 FIGURE 4-1 continued Published 10/19/2017, Control # 618-00 GROVE...
Page 154 BOOM GRT880 SERVICE MANUAL 339 351 341 355 338 337 350 9044-89 FIGURE 4-1 continued Published 10/19/2017, Control # 618-00...
Page 155 GRT880 SERVICE MANUAL BOOM 327 356 9044-90 FIGURE 4-1 continued Published 10/19/2017, Control # 618-00 GROVE...
Page 156 BOOM GRT880 SERVICE MANUAL 9044-91 FIGURE 4-1 continued 4-10 Published 10/19/2017, Control # 618-00...
Page 157 GRT880 SERVICE MANUAL BOOM 9044-92 FIGURE 4-1 continued Published 10/19/2017, Control # 618-00 4-11 GROVE...
Page 158 BOOM GRT880 SERVICE MANUAL 9044-93 FIGURE 4-1 continued 4-12 Published 10/19/2017, Control # 618-00...
Page 159 GRT880 SERVICE MANUAL BOOM Item Description Item Description 145 HHCS M8X30 8.8 ISO 4017 101 BASE WELDMENT 201 TELE 1 SECTION WELDMENT 102 ASSY BOOM CABLE GUIDE 202 WEAR PAD 103 WEAR PAD - ASSY 203 WEAR PAD 104 WEAR PAD - ASSY 204 WEAR PAD - ASSY 105 WEAR PAD 205 WEAR PAD - ASSY...
Page 160 BOOM GRT880 SERVICE MANUAL Item Description Item Description 246 HEX NUT, 8 8 ISO 4032 338 F WASHER, 12 ST ISO 7089 247 HEX NUT M12 8 ISO 4032 339 L WASHER 12 -HRC44-51 DIN 127 248 HEX NUT M16 8 ISO 4032 340 HHCS M8X30 8.8 ISO 4017 249 HEX JAM NUT, 16-8 ISO 4035 341 HSSS-FLAT M12X35 -45H...
Page 161: Boom Disassembly
GRT880 SERVICE MANUAL BOOM BOOM DISASSEMBLY Item Description 509 SHEAVE ASSY - 5 GROOVE NOTE: Boom assembly must be rotated 180° (upside 510 LUBRICANT HOSE L=260 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 disassembly procedures.
Page 162 BOOM GRT880 SERVICE MANUAL Remove six bolts (134) and washers (119) from left and 10. Remove shims (110), flexible wear pads (105, 106, 109), right sides of base (101) (see Figure 4-129). and bars (111, 112) from between base (101) and tele 1 (201) (see Figure 4-5).
Page 163 GRT880 SERVICE MANUAL BOOM 13. Remove plates (513) from left and right sides of shims (212) and wear pads (202, 203) from bottom (as telescope cylinder 2 (501) (see Figure 4-7). oriented) of tele 1 (201) (see Figure 4-9). 208 227 9044-65 FIGURE 4-9 9044-67...
Page 164 BOOM GRT880 SERVICE MANUAL 18. Remove bolts (225) securing top and side wear pads 21. Remove bolts, washers, lock washers, and nuts (238, (224) and shims (222, 223) to tele 1 (201) (see 235, 236, 247) securing bottom left and right side stop Figure 4-119).
Page 165 GRT880 SERVICE MANUAL BOOM removal of tele 2 (301) from tele 1 (201) (see Figure 4-17). Remove tele 2 (301) from tele 1 (201). 9044-60 FIGURE 4-15 25. Slightly raise tele 2 (301), then remove left and right side 9044-59 FIGURE 4-17 wear pads (204, 205) from between tele 1 (201) and tele 27.
Page 166 BOOM GRT880 SERVICE MANUAL shims (317) and wear pads (304, 305) from bottom of #2 (501) (see Figure 4-21). Using an adequate crane tele 2 (301) (see Figure 4-19). and chains, slightly lift telescope cylinder #2 by its lugs (see Figure 4-101). 9044-57 FIGURE 4-19 9044-46...
Page 167 GRT880 SERVICE MANUAL BOOM 32. Remove two bolts (346) and plate (322) from left and 35. Remove two plates (504, 508) from lugs of telescope right sides of tele 2 (301), then remove pins (314) (see cylinder #1 (502) (see Figure 4-25). Figure 4-23).
Page 168 BOOM GRT880 SERVICE MANUAL 37. Remove washer (335), sheave (302) and two washers 40. Using blocks of wood or similar (F) on each side of (335) from sheave shaft (313) (see Figure 4-26 and telescope cylinder #1 (502), block up telescope cylinder Figure 4-27).
Page 169 GRT880 SERVICE MANUAL BOOM 43. Remove bolts (349) securing top left and right side shims (320) and stop blocks (316) to front of tele 2 (301) (see Figure 4-31). 9044-39 FIGURE 4-33 46. Slightly raise tele 3 (401), then remove left and right side wear pads (306, 307) from between tele 2 (301) and tele 9044-43 FIGURE 4-31...
Page 170 BOOM GRT880 SERVICE MANUAL removal of tele 3 (401) from tele 2 (301) (see cylinder #1 (502), then remove block of wood (E) from Figure 4-35). Remove tele 3 (401) from tele 2 (301). underneath it. (see Figure 4-37). 9044-35 FIGURE 4-35 9044-30 FIGURE 4-37...
Page 171 GRT880 SERVICE MANUAL BOOM 52. Remove bolts (536) and washers (512) securing the two 56. Remove bolts and washers (537, 531) securing left and retract cables (7) to pin (511) at front of telescope right brackets (507) to sheave head weldment (506). Remove the wear pads (523) from the two brackets cylinder #2 (501) (see Figure 4-39).
Page 172 BOOM GRT880 SERVICE MANUAL 58. Remove five extend cables (6) from their keepers at 60. Remove two long bolts (517) from pin (511) at end of bottom rear of tele 3 (401) (see Figure 4-43). telescope cylinder #2 (501) (see Figure 4-45). 9044-16 FIGURE 4-43 9044-13...
Page 173 GRT880 SERVICE MANUAL BOOM 64. Remove grease hose (402) and fittings (410, 411, 412) 66. Remove two nuts (8) and washer (9) from each of the from rear of tele 3 (401) (see Figure 4-47). two retract cables (7) at front of tele 3 (401) (see Figure 4-49).
Page 174 BOOM GRT880 SERVICE MANUAL 68. Remove two bolts, washers, and lock washers (530, 69. Remove two bolts (524) securing each wear pad (515) to 531, 538) securing cable retaining plate (520) to sheave left and right sides of sheave head weldment (506) (see head weldment (506) (see Figure 4-51).
Page 175: Boom Nose Sheaves Removal And Installation
GRT880 SERVICE MANUAL BOOM 72. Remove four bolts and washers (542, 529) securing spacers, shims, and boom nose sheaves following their sheave head weldment (506) to front of telescope location noted during disassembly. cylinder #1 (502) (see Figure 4-55). Slowly insert upper boom nose sheave shaft through boom nose while adding spacers, shims, and boom nose sheaves following their location noted during disassembly.
Page 176 BOOM GRT880 SERVICE MANUAL Position telescope cylinder #1 (502) up side down on 540) to each side of the sheave head weldment (506) to adequate supports. Ensure vent plug (A) at rear of secure sheave pin in place (see Figure 4-58). cylinder #1 is facing downward (see Figure 4-56).
Page 177 GRT880 SERVICE MANUAL BOOM the cylinder. Do not allow extend cables to cross each two bolts, washers, and lock washers (537, 531, 530) other. (see Figure 4-62). Install cable retaining plate (520) to sheave head weldment (506) using two bolts, washers, and lock washers (530, 531, 538) (see Figure 4-60).
Page 178 BOOM GRT880 SERVICE MANUAL 10. Install six wear pads (407) with shims (408, 409) to rear of telescope cylinders #1 (502) and #2 (501) will touch of tele 3 (401) using two bolts (414) per pad (see (see Figure 4-65). Figure 4-64).
Page 179 GRT880 SERVICE MANUAL BOOM 15. Position telescope cylinder #2 (501) up side down on 20. Starting at the halfway point and working toward the adequate supports. Ensure wear pad plate (C) at front of front, apply multipurpose grease to top (as oriented) and sides of telescope cylinder #1 (502) in the areas where cylinder #2 is facing upward (see Figure 4-68).
Page 180 BOOM GRT880 SERVICE MANUAL 22. Insert telescope cylinder #1 (502) into rear of tele 3 (401) (507) using bolts and washers (537, 531), then install such that the cylinder head sheave (509) is inside tele 3 brackets (507) onto the left and right sides of sheave (401) (see Figure 4-71).
Page 181 GRT880 SERVICE MANUAL BOOM 26. Secure rear of telescope cylinder #1 (502) such that it 28. Install cable keeper (518) onto the two long bolts (517) will not move when pushing tele 3 (401) toward it (see and secure with two nuts (543) (see Figure 4-78). Figure 4-75).
Page 182 BOOM GRT880 SERVICE MANUAL 30. Move telescope cylinder #2 (501) rearward, away from (501) and hold them together above cylinder #2 (501) tele 3 (401), to take up slack in the five extend cables (6) using a C-clamp or similar (see Figure 4-83). and ensure they are not crossed (see Figure 4-80).
Page 183 GRT880 SERVICE MANUAL BOOM similar (F) on each side of telescope cylinder #1 (502), block up telescope cylinder #2 (501) so that it does not sit on top of cylinder #1 (502) (see Figure 4-85). 9044-28 FIGURE 4-83 33. Insert telescope cylinders #1 (502) and #2 (501) into tele 3 (401) until the loop in the two retract cables (7) are 9044-30 FIGURE 4-85...
Page 184 BOOM GRT880 SERVICE MANUAL 9044-35 FIGURE 4-89 9044-33 FIGURE 4-87 36. Position tele 2 (301) upside down on adequate supports behind tele 3 (401). 37. Apply multipurpose grease to inside top, sides, and bottom of tele 2 (301) in the areas where the wear pads of tele 3 (401) will touch.
Page 185 GRT880 SERVICE MANUAL BOOM bolts and nuts (348, 353) on each side of tele 2 (301), 42. Set flexible wear pads (308, 309, 310) with bars (311, but do not tighten. 312) on top of tele 3 (401) and tap into place between tele 2 (301) and tele 3 (401) (see Figure 4-93, Figure 4-94, and Figure 4-95).
Page 186 BOOM GRT880 SERVICE MANUAL 46. Slightly tighten the left and right side bottom and middle wear pad adjusting bolts (348). Slightly tighten the twelve set screw (341). Final tightening of these bolts and sets screws is done after assembly is completed and boom is installed on to the crane.
Page 187 GRT880 SERVICE MANUAL BOOM (501, 502) are centered and do not hit tele 2 (301) as they pass through it (see Figure 4-99). 9044-47 FIGURE 4-101 52. Remove all supporting blocks that were supporting 9044-45 FIGURE 4-99 telescope cylinder #2 (501). 50.
Page 188 BOOM GRT880 SERVICE MANUAL 54. Install two washers (335) on to the sheave pin (313) 57. At front of tele 2 (301), install side wear pad (356 - K) and followed by sheave (302) and another washer (335) (see shims (325, 324) to top set of mounting holes using bolts Figure 4-103).
Page 189 GRT880 SERVICE MANUAL BOOM 62. Simultaneously push cylinders #1 (502) and #2 (501) into tele 2 (301) and tele 3 (401). Align holes in plates (504, 508) with holes in tele 2 (301) (see Figure 4-107). 9044-56 FIGURE 4-109 65. Install zip-tie (M) around the two plates (503) (see Figure 4-109).
Page 190 BOOM GRT880 SERVICE MANUAL 69. Apply multipurpose grease to inside top, sides, and 72. Insert tele 2 (301) into tele 1 (201) until all wear pads bottom of tele 1 (201) in the areas where the wear pads around rear of tele 2 are inside tele 1. Slightly raise tele 2 of tele 2 (301) will touch.
Page 191 GRT880 SERVICE MANUAL BOOM of wood. Fully loosen left side middle wear pad adjusting bolt (244). 78. Install, but do not tighten, twelve set screws (239) through tele 2 (301) and into the three bars (211, qty 2 - 210) holding the wear pads. Install a washer (235) and jam nut (251) onto each set screw (239).
Page 192 BOOM GRT880 SERVICE MANUAL Secure each pin (213) with two bolts and washers (231, (501) together. Secure each pin (214) with a plate (215) 243) (see Figure 4-118). and two bolts (242) (see Figure 4-120). 9044-62 FIGURE 4-118 9044-64 FIGURE 4-120 84.
Page 193 GRT880 SERVICE MANUAL BOOM 91. Spray multipurpose grease on outside of tele 1 (201). 94. Insert tele 1 (201) until wear pads on the bottom outside Measuring approximately 1/4 of the distance of the of tele 1 (201) are inside base (101). Remove ratchet strap (S) and further insert tele 1 (201) into base (101) boom from the front tip, leave a 5 ft.
Page 194 BOOM GRT880 SERVICE MANUAL adjusting bolts (132) and nuts (138) on each side of base 103.Install top left and right (as oriented) side shims (128) (101), but do not tighten (see Figure 4-126). and stop blocks (124) on front of base (101) using bolts (141).
Page 195: Boom Installation
GRT880 SERVICE MANUAL BOOM 106.Install six bolts (134) and washers (119) through left and right sides of base (101) and into the plates (513) (see Figure 4-129). Tighten all bolts to 1800 Nm (1325 ft-lb). DANGER Ensure the lifting device is capable of supporting the boom assembly.
Page 196 BOOM GRT880 SERVICE MANUAL Evenly tighten the setscrews on the opposite side until 12. Connect the hydraulic lines to the telescope cylinder as both setscrews make contact with the cylinder, then tagged prior to removal. loosen both setscrews until a gap of 2 mm (0.08 in) is 13.
Page 197: Boom Functional Check
GRT880 SERVICE MANUAL BOOM BOOM FUNCTIONAL CHECK Example: If the boom deflects to the left, the top left wear pad would have shims added and the top right wear pad would Activate the hydraulic system and check for proper have shims removed. operation and any leaks.
Page 198 BOOM GRT880 SERVICE MANUAL acceptable. If the cables do not make a slapping noise under Extend the boom until tele 2 and 3 extend several these conditions, it is an indication that the extension cables centimeters (inches). may be too tight and should be readjusted. Be aware that Adjust retract cables so that tele 3 stop block bottoms there may also be a similar noise made by the telescope out 3 to 4 mm (0.12 to 0.19 in) before the stop block tele...
Page 199: Telescope Circuit
GRT880 SERVICE MANUAL BOOM TELESCOPE CIRCUIT c o n t r o l s y s t e m a n d a r e c o n t r o l l e d t o m a i n t a i n synchronization of the boom in Auto and Manual Modes.
Page 200: Maintenance
BOOM GRT880 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 201: 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 202: Lift Circuit
BOOM GRT880 SERVICE MANUAL LIFT CIRCUIT the lift cylinder barrel. The holding valve functions when booming up (cylinder rod extended), booming down (cylinder Description rod retracted), or holding (cylinder rod stationary). The boom lift circuit consists of the lift hydraulic remote Theory of Operation controller, lift directional control valve, holding valve, and the The directional control valve bank housing the lift control...
Page 203 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 204: Lift Cylinder Removal
BOOM GRT880 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 205 GRT880 SERVICE MANUAL BOOM 9080-6 9080-7 Item Description Item Description Shim - 2 mm Flat Washer Spacer Capscrew Lift Cylinder Foot Pin Setscrew Shim - 1 mm FIGURE 4-132 Published 10/19/2017, Control # 618-00 4-59 GROVE...
Page 206 BOOM GRT880 SERVICE MANUAL 9080-1 9080-5 9080-4 9080-2 Item Description Item Description Capscrew Spacer Pivot Pin Plate Spacer Cylinder Pivot Pin Flat Washer Lock Washer FIGURE 4-133 4-60 Published 10/19/2017, Control # 618-00...
Page 207: Hook Block
GRT880 SERVICE MANUAL BOOM 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 following hook blocks are available for the crane: Periodic Maintenance •...
Page 208: Adjusting Boom Extension Stowage Mounts
BOOM GRT880 SERVICE MANUAL ADJUSTING BOOM EXTENSION STOWAGE Install the two attachment pins. MOUNTS d. Tighten torque mounting bolts specification. NOTE: Refer to Figure 4-134 and Figure 4-135. Tighten locking nut on jack bolt. NOTE: Tighten and torque all bolts and nuts to the specifications defined under Fasteners and Torque 10.
Page 209 GRT880 SERVICE MANUAL BOOM 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 4-134...
Page 210 BOOM GRT880 SERVICE MANUAL Lock Hitch Lock Hitch FIGURE 4-135 4-64 Published 10/19/2017, Control # 618-00...
Page 211: Description
GRT880 SERVICE MANUAL HOIST AND COUNTERWEIGHT SECTION 5 HOIST AND COUNTERWEIGHT SECTION CONTENTS Description ....... 5-1 Oil Sampling .
Page 212: Maintenance
HOIST AND COUNTERWEIGHT GRT880 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 213: Installing Cable On Hoist
GRT880 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 214: Removing/Installing The Hoist
HOIST AND COUNTERWEIGHT GRT880 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 215 GRT880 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 Capscrew O-Ring Cable Wedge Limit Switch Assembly Capscrew Lockwasher 2 Speed Motor Piston Capscrew Sight Glass Shaft...
Page 216: 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 217: Oil Sampling
GRT880 SERVICE MANUAL HOIST AND COUNTERWEIGHT Must include but is not limited to the following inspections that must be performed by a qualified crane operator or qualified crane technician. DANGER • Perform pre-use inspection. Failure to use proper type and viscosity of planetary gear •...
Page 218: Brake Test Procedure
HOIST AND COUNTERWEIGHT GRT880 SERVICE MANUAL Remove and cap or plug the brake release line from fitting in the hoist brake release port. With hydraulic power unit running, move directional control CAUTION valve handle slowly to the full open, lowering position. Hot oil may cause personal injury and/or burns to Increase the engine speed, if necessary, to bring system unprotected skin.
Page 219: Hoist Rotation And Minimum Wrap Indicator System
GRT880 SERVICE MANUAL HOIST AND COUNTERWEIGHT Installation function properly. Refer to Adjusting Minimum Wrap Switch, page 5-9. Uncover the motor opening in the gearbox. Verify these parts are clean. Maintenance Install a replacement O-ring on the motor’s pilot after General lubricating it with gear oil or petroleum jelly.
Page 220: Hoist Control Valves
HOIST AND COUNTERWEIGHT GRT880 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 221: Removable Counterweight
GRT880 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 222: Removing
HOIST AND COUNTERWEIGHT GRT880 SERVICE MANUAL Removing Installing 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 weighs 9,979 kg (22,000 lb).
Page 223: Description
GRT880 SERVICE MANUAL SWING SYSTEM SECTION 6 SWING SYSTEM SECTION CONTENTS Description ....... 6-1 Description.
Page 224: Theory Of Operation
SWING SYSTEM GRT880 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 225 GRT880 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 10/19/2017, Control # 618-00...
Page 226: 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 227 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 228 SWING SYSTEM GRT880 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 229: Swing Motor
GRT880 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 230: Swing Gearbox And Brake
SWING SYSTEM GRT880 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 231 GRT880 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 232: Swing Bearing
SWING SYSTEM GRT880 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 233 GRT880 SERVICE MANUAL SWING SYSTEM Front of Crane 8804-136 FIGURE 6-2 Multiplier bar handles must be propped or supported Outer Race Torquing 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 234 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 235 GRT880 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 236 SWING SYSTEM GRT880 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 237: Swivels
GRT880 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 238 SWING SYSTEM GRT880 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 10/19/2017, Control # 618-00...
Page 239: Hydraulic Swivel
GRT880 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 240 SWING SYSTEM GRT880 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 241: Two Port Water Swivel
GRT880 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 242: Electrical Swivel
SWING SYSTEM GRT880 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 243: Swing Lock Pin
GRT880 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 244: Maintenance
SWING SYSTEM GRT880 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 245: Engine
GRT880 SERVICE MANUAL POWER TRAIN SECTION 7 POWER TRAIN SECTION CONTENTS Engine ........7-1 Slip Joint Exhaust Connectors - Tier 3 and 4 .
Page 246: Maintenance
POWER TRAIN GRT880 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 247 GRT880 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 248: Electronic Control System
POWER TRAIN GRT880 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 249: Fuel System
GRT880 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 250 POWER TRAIN GRT880 SERVICE MANUAL Fuel Tank Filler Cap Fuel Level Sending Unit Fuel Cooler Ball Valve 8804-109 FIGURE 7-4 Published 10/19/2017, Control # 618-00...
Page 251: Air Intake And Exhaust System
GRT880 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 252 POWER TRAIN GRT880 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 253 GRT880 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 10/19/2017, Control # 618-00...
Page 254 POWER TRAIN GRT880 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 255 GRT880 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 256: Charge-Air Cooler System
POWER TRAIN GRT880 SERVICE MANUAL Check the condition of the valve and lips frequently and keep clamp may be damaged from thermal expansion of the CAC them clean. The valve lips should be open only when the tube. 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 257: Exhaust System
GRT880 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 258 POWER TRAIN GRT880 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 7-14 Published 10/19/2017, Control # 618-00...
Page 259 GRT880 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 7-15 GROVE Published 10/19/2017, Control # 618-00...
Page 260: Water Cooling System
POWER TRAIN GRT880 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 261 GRT880 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 262 POWER TRAIN GRT880 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 263 GRT880 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 264: Radiator Fill And Servicing
POWER TRAIN GRT880 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 265 GRT880 SERVICE MANUAL POWER TRAIN 8804-123 FIGURE 7-16 7-21 GROVE Published 10/19/2017, Control # 618-00...
Page 266: Drive Train
POWER TRAIN GRT880 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 267: Transmission/Torque Converter
GRT880 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 268: Maintenance
POWER TRAIN GRT880 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 269 GRT880 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 270 POWER TRAIN GRT880 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 271 GRT880 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 272: Towing Or Pushing
POWER TRAIN GRT880 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 273: Description
GRT880 SERVICE MANUAL UNDERCARRIAGE SECTION 8 UNDERCARRIAGE SECTION CONTENTS Axles ........8-1 Description.
Page 274 UNDERCARRIAGE GRT880 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 275 GRT880 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 276: Wheels And Tires
UNDERCARRIAGE GRT880 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 277 GRT880 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 278 UNDERCARRIAGE GRT880 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 279: Steering Systems
GRT880 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 280 UNDERCARRIAGE GRT880 SERVICE MANUAL Symptom Probable Cause Solution Noisy hydraulic pump Hydraulic oil low. Refill hydraulic reservoir. Refer to caused by cavitation. Maintenance and 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 281 GRT880 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 282: Rear Axle Oscillation Lockout System
UNDERCARRIAGE GRT880 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 283 GRT880 SERVICE MANUAL UNDERCARRIAGE Supply From Pump Lockout Valve Lockout Cylinder Lockout Cylinder FIGURE 8-12 Rear Axle Published 10/19/2017, Control # 618-00 8-11 GROVE...
Page 284: Axle Oscillation Lockout Cylinders
UNDERCARRIAGE GRT880 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 285: Theory Of Operation
GRT880 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, which is higher than the high accumulator charge limit, then controlling the maximum brake line pressure.
Page 286: Maintenance
UNDERCARRIAGE GRT880 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 287: Service Brakes
GRT880 SERVICE MANUAL UNDERCARRIAGE brake valve. Bleed every bleeder screw on every caliper/ SERVICE BRAKES 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 288 UNDERCARRIAGE GRT880 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 289 GRT880 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 290 UNDERCARRIAGE GRT880 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 291: Corrosion Protection
GRT880 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 292 UNDERCARRIAGE GRT880 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 293: Parking Brake Actuator
GRT880 SERVICE MANUAL UNDERCARRIAGE Caliper Maintenance 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 294: Parking Brake
UNDERCARRIAGE GRT880 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 295 GRT880 SERVICE MANUAL UNDERCARRIAGE FIGURE 8-28 Published 10/19/2017, Control # 618-00 8-23 GROVE...
Page 296: Park Brake Solenoid Valve
UNDERCARRIAGE GRT880 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 297: Outrigger
GRT880 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 298: 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 299 GRT880 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 300 UNDERCARRIAGE GRT880 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 301: Outrigger Beam
GRT880 SERVICE MANUAL UNDERCARRIAGE Outrigger Beam Description DANGER The outrigger beam assembly consists of an outrigger beam, Be sure any blocking material used is capable of a jack cylinder, an extension cylinder, an Outrigger supporting the weight of the outrigger beam. Do not allow Monitoring System (OMS) (Optional—Standard in North it to tilt or slide.
Page 302 UNDERCARRIAGE GRT880 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 303 GRT880 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 10/19/2017, Control # 618-00 8-31 GROVE...
Page 304: Extension Cylinder
UNDERCARRIAGE GRT880 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 305: Jack Cylinder
GRT880 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 306 UNDERCARRIAGE GRT880 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 307: General
Potentially harmful waste used in Manitowoc cranes includes information on the types of lubricants used, the location of — but is not limited to — oil, fuel, grease, coolant, air...
Page 308: Lubricants And Lubrication Intervals
NOTE: All fluids and lubricants may be purchased by contacting an authorized Manitowoc distributor or Manitowoc Crane Care Parts Department. CAUTION Possible Equipment Damage! Chassis grease lubricants must not be applied with air pressure devices as this lubricant is used on sealed fittings.
Page 309: 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 310 MAINTENANCE AND LUBRICATION GRT880 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...
Page 311: Arctic Lubricants And Conditions
Always check with an authorized Manitowoc • Radiator air shutters distributor or Manitowoc Crane Care if in doubt of the suitability of a specific fluid or lubricant. • Air diverter box (to allow intake air to be taken in from...
Page 312 MAINTENANCE AND LUBRICATION GRT880 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 CITGO, Syntetic Gear Lube Eaton, Roadranger EP 6829014058 75W-90 Mobil, Mobilube SCH...
Page 313 GRT880 SERVICE MANUAL MAINTENANCE AND 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 CITGO, Synthetic Gear Lube Eaton, Roadranger EP 6829014058 75W-90 Mobil, Mobilube SCH...
Page 314: Cylinder Rod Surface Protection
It is recommended that all exposed cylinder rods be protected Over lubrication on non-sealed fittings will not harm the fittings using Boeshield® T-9 Premium Metal Protectant. Manitowoc or components, but under lubrication will definitely lead to a Crane Care has Boeshield® T-9 Premium Metal Protectant shorter lifetime.
Page 315: Cummins Oil Registration List
GRT880 SERVICE MANUAL MAINTENANCE AND LUBRICATION Cummins Oil Registration List Safety Cummins has a program that lists engine oils that it has To lubricate many locations, the engine must be started. After tested to meet its engineering specifications. Listing of positioning areas of the unit for lubrication, the engine must recommended oils is on QuickServe®...
Page 316 MAINTENANCE AND LUBRICATION GRT880 SERVICE MANUAL Drive Train Lube Point Figure Approved Lube Item Lube Interval Application Description Lubricant Capacity Replace filter element Air Cleaner Filter Figure 9-1 when indicator shows red. Fuel filter is located Change filter every 500 on inside right hand Fuel Filter Figure 9-1...
Page 317: Drive Train
GRT880 SERVICE MANUAL MAINTENANCE AND LUBRICATION Drive Train (continued) Lube Point Figure Approved Lube Item Lube Interval Application Description Lubricant Capacity • 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 318 MAINTENANCE AND LUBRICATION GRT880 SERVICE MANUAL FRONT 8591 FIGURE 9-1 Published 10/19/2017, Control # 618-00 9-12...
Page 319: Drive Train (Continued)
GRT880 SERVICE MANUAL MAINTENANCE AND LUBRICATION Drive Train (Continued) Lube Point Figure Approved Lube Item Lube Interval Application Description Lubricant Capacity Change transmission filter after Transmission first 50 and 100 hours of Figure 9-2 Filter service, then every 500 hours thereafter.
Page 320: Drive Train (Continued)
MAINTENANCE AND LUBRICATION GRT880 SERVICE MANUAL 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...
Page 321: Steering And Suspension
GRT880 SERVICE MANUAL MAINTENANCE AND LUBRICATION 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.
Page 322: Steering And Suspension (Continued)
MAINTENANCE AND LUBRICATION GRT880 SERVICE MANUAL 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 Published 10/19/2017, Control # 618-00 9-16...
Page 323: Axles
GRT880 SERVICE MANUAL MAINTENANCE AND LUBRICATION Axles Lube Point Figure Approved Lube Item Lube Interval Application Description Lubricant Capacity • 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 324: Turntable
MAINTENANCE AND LUBRICATION GRT880 SERVICE MANUAL Turntable Lube Point Figure Approved Item Lube Capacity Lube Interval Application Description Lubricant • 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 325: Cab Tilt
GRT880 SERVICE MANUAL MAINTENANCE AND LUBRICATION Turntable (Continued) Lube Point Figure Approved Item Lube Capacity Lube Interval Application Description Lubricant 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 3 months.
Page 326: Outriggers
MAINTENANCE AND LUBRICATION GRT880 SERVICE MANUAL Outriggers Lube Point Figure Approved Lube Item Lube Interval Application Description Lubricant Capacity Wear Pads Figure 9-9 50 hours or 1 week. Brush on. NOTE: Remove outrigger box end cover. Reach inside outrigger box and brush lubricant on underside of top plate. Outrigger Beams Figure 9-9 50 hours or 1 week.
Page 327: Lift Cylinder
GRT880 SERVICE MANUAL MAINTENANCE AND LUBRICATION Lift Cylinder Lube Point Approved Lube Item Figure No. Lube Interval Application Description Lubricant Capacity Lower Lift Until grease Figure 9-10 500 hours or 3 months. 1 grease fitting. Cylinder Pin extrudes. 8601 FIGURE 9-10 9-21 Published 10/19/2017, Control # 618-00 GROVE...
Page 328: Boom (Continued)
MAINTENANCE AND LUBRICATION GRT880 SERVICE MANUAL Boom NOTE: Crane Setup: Machine shall be set up on firm level surface with fully extended outriggers and 9979 kg (22,000 lb) counterweight installed. Ensure crane is level. • Boom must be directly over the front with house lock engaged. •...
Page 329 GRT880 SERVICE MANUAL MAINTENANCE AND LUBRICATION Boom (Continued) NOTE: Crane Setup: Machine shall be set up on firm level surface with fully extended outriggers and 9979 kg (22,000 lb) counterweight installed. Ensure crane is level. • Boom must be directly over the front with house lock engaged. •...
Page 330 MAINTENANCE AND LUBRICATION GRT880 SERVICE MANUAL FRONT XXXX 8900-2 8900-3 FIGURE 9-12 Published 10/19/2017, Control # 618-00 9-24...
Page 331 GRT880 SERVICE MANUAL MAINTENANCE AND LUBRICATION 8900-4 8900-5 FIGURE 9-13 9-25 Published 10/19/2017, Control # 618-00 GROVE...
Page 332 MAINTENANCE AND LUBRICATION GRT880 SERVICE MANUAL 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 333: Hoist
GRT880 SERVICE MANUAL MAINTENANCE AND LUBRICATION Hoist Lube Point Approved Lube Item Figure No. Lube Interval Application Description Lubricant Capacity • Check and fill every Oil must be visible in 50 hours or weekly sight glass and level no 4.7 L Main Hoist Figure 9-15 more than 3 mm...
Page 334: 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 335: 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 336: 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 337 GRT880 SERVICE MANUAL MAINTENANCE AND LUBRICATION • All hardware, clips, pins, hose connections not painted will have treatment applied. 7650-75 Picture may not be same model as your Figure 9-17 machine, it is for reference only. 9-31 Published 10/19/2017, Control # 618-00 GROVE...
Page 338 MAINTENANCE AND LUBRICATION GRT880 SERVICE MANUAL Picture may not be same model as your machine, it is for reference only. Figure 9-18 TABLE 9-5. 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...
Page 339 GRT880 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 340 SERVICE MANUAL GRT880 Rust Protection ............9-29 Service Brakes .

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