Professional Documents
Culture Documents
Grove RT 9130E PDF
Grove RT 9130E PDF
SERVICE MANUAL
This Manual has been prepared for and is considered part of -
RT9130E
Crane Model Number 2
Crane Serial Number
This Manual is Divided into the following Sections:
3
SECTION 1 INTRODUCTION
SECTION 2 HYDRAULIC SYSTEM
SECTION 3 ELECTRICAL SYSTEM
SECTION 4 BOOM
SECTION 5 HOIST AND COUNTERWEIGHT
SECTION 6 SWING SYSTEM 4
SECTION 7 POWER TRAIN
SECTION 8 UNDERCARRIAGE
SECTION 9 LUBRICATION
NOTICE
5
The crane serial number is the only method your distributor or the
factory has of providing you with correct parts and service informa-
tion.
10
2009 Manitowoc
Published 08-25-2009 Control # 077-04
THIS PAGE BLANK
RT9130E SERVICE MANUAL TABLE OF CONTENTS
SECTION 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Introduction
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
List Of Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Torque Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 T
Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Wheels And Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Swing Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
O
Boom. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Swivel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 C
Hydraulic Pumps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Hoists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Component Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
General Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Pressing Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Locks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Wires And Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Shims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Gaskets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Hydraulic Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Fatigue Of Welded Structures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Loctite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Fasteners And Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
Environmental Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
Dynamic Shock Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
Precautions and Recommendations During Inspection or Replacement . . . . . . . . 1-16
Wire Rope Inspection (Running Ropes and Pendant Cables) . . . . . . . . . . . . . . . . 1-17
Wire Rope Inspection (Boom Extension and Retraction Cables) . . . . . . . . . . . . . . 1-18
Wire Rope Inspection/Replacement (All Wire Rope) . . . . . . . . . . . . . . . . . . . . . . . 1-18
Seizing Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
Installing FLEX-X 35 Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
Procedures for Cutting and Preparing FLEX-X 35 . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
GROVE TOC-1
TABLE OF CONTENTS RT9130E SERVICE MANUAL
TOC-2
RT9130E SERVICE MANUAL TABLE OF CONTENTS
GROVE TOC-3
TABLE OF CONTENTS RT9130E SERVICE MANUAL
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-74
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-74
Steer Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-77
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-77
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-77
Outrigger Extension Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-80
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-80
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-80
Outrigger Stabilizer Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-83
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-83
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-83
Tilt Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-86
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-86
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-86
Power Pin Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-89
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-89
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-89
Park Brake Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-92
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-92
SECTION 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boom
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Lattice Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Optional Lattice Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Optional Lattice Extension Inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
TOC-4
RT9130E SERVICE MANUAL TABLE OF CONTENTS
GROVE TOC-5
TABLE OF CONTENTS RT9130E SERVICE MANUAL
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-54
TOC-6
RT9130E SERVICE MANUAL TABLE OF CONTENTS
SECTION 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Undercarriage
Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Wheel Alignment Check Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Rear Wheels Not Centered Switch Adjustment Procedure. . . . . . . . . . . . . . . . . . . . 8-2
Wheels And Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Steering Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Theory Of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Hydraulic Pumps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
Front Steering Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
Integrated Outrigger/Rear Steer Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
Steer Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
Rear Axle Oscillation Lockout System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
Axle Oscillation Lockout Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
Axle Oscillation Lockout Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
GROVE TOC-7
TABLE OF CONTENTS RT9130E SERVICE MANUAL
SECTION 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubrication
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Lubrication Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Arctic Conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Arctic Conditions - Below -18°C (0°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Arctic Conditions Down To -40°F. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Surface Protection for Cylinder Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Wire Rope Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
CraneLUBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Steering and Suspension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
Drive Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
Drive Train (continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10
Turntable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12
Cab Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14
Outriggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16
Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-18
Boom (continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-20
Boom (continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-22
Hoist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-24
Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-26
Instructions for Accessing Lubrication Points on Boom. . . . . . . . . . . . . . . . . . . . . 9-28
TOC-8
SECTION 1
1
INTRODUCTION
TABLE OF CONTENTS
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
List Of Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Torque Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Cummins QSC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Wheels And Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Swing Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Boom. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Swivel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Hydraulic Pumps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Pump #1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Pump #2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Pump #3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Pump #4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Hoists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Component Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
General Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Pressing Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Locks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Wires And Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Shims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Antifriction Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Double Row, Tapered Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Heating Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Sleeve Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Gaskets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Hydraulic Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Keep The System Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Sealing Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Hydraulic Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Fatigue Of Welded Structures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Loctite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Application of Medium Strength Loctite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Primer Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Fasteners And Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
For Standard Metric Hex Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
GROVE 1-i
INTRODUCTION RT9130E SERVICE MANUAL
1-ii
RT9130E SERVICE MANUAL INTRODUCTION
SECTION 1
1
INTRODUCTION
DESCRIPTION Overall Crane Height . . . . . 4172 mm (164 in) (Std)
. . . . . . . . . . . . . . . . . . . . . . 4089 mm (161 in) (Opt)
This Manual provides information for the maintenance of the Tail-Swing . . . . . . . . . . . . . . . . 4331 mm (170.5 in)
Model RT9000E Series Grove Crane. Outrigger Spread
Retracted . . . . . . . . . . . . . . . 3.56 m (11 ft 8 in)
The lift capacities are listed on the Load Chart in the cab. Mid Extend . . . . . . . . . . . . . . 6.02 m (19 ft 9 in)
Fully Extended . . . . . . . . . .8.49 m (27 ft 10 in)
T h e c r an e i n c o r p or at e s a n al l w el d e d par al l e l b o x
construction steel frame, using planetary drive axles to Capacities
provide four-wheel drive. Axle steering is accomplished Fuel Tank . . . . . . . . . . . . . . . . . . 378 liters (100 gal)
utilizing hydraulic steer cylinders. The engine is mounted at Coolant System . . . . . . . . . . . . . . . . . . See Engine
the rear of the crane carrier and provides motive power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications
through a six speed forward and a three speed reverse Engine Lubrication System . . . . . . . . . See Engine
Specifications
transmission. Hydraulic, double box, and sliding beam Hydraulic Tank (Reservoir Capacity)
outriggers are removable. Total . . . . . . . . . . . . . . . . . 1363 liters (360 gal)
at Full Level . . . . . . . . . 1226 liters (324.1 gal)
The carrier frame incorporates an integral fifth wheel, to at Low Level . . . . . . . . . 1176 liters (310.6 gal)
which the rear axle is mounted, to provide axle oscillation. Expansion Space . . . . . . . . 51 liters (13.5 gal)
Axle oscillation lockout is automatic when the superstructure Hoists . . . . . . . . . . . . . . . . . . . . . . . . 21 liters (22 qt)
rotates from the travel position. Swing Gearbox . . . . . . . . . . . . . . .5 liters (5-1/4 qt)
Axle Planetary Hubs . . . . . . . . . . . . 11 liters (12 qt)
The superstructure is capable of 360 degree rotation in either Axle Differentials . . . . . . . . . . . .27-1/2 liters (29 qt)
direction. All crane functions are controlled from the fully- Transmission (Includes Torque Converter)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 liters (34 qt)
enclosed cab mounted on the superstructure. The crane is
equipped with a five-section, full power, sequenced and Torque Converter
synchronized boom. Additional reach is obtained by utilizing
Stall Ratio. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29:1
an optional swingaway boom extension. Lifting is provided Charge Pump Capacity . . . . . 117.3 l/min (31 gpm)
by a main hoist and an optional auxiliary hoist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . @ 2000 rpm
NOTE: Throughout this manual, reference is made to left, Transmission
right, front, and rear when describing locations.
When operating the crane, these reference Gear Ratios:
Forward
locations are to be considered as those viewed 1st . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.87
from the operator’s seat with the superstructure 2nd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.94
facing forward over the front of the carrier frame. 3rd. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.98
4th. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25
NOTE: The Transportation and Lifting Data Decal is shown 5th. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.95
in (Figure 1-1). Basic nomenclature is shown in 6th. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.73
(Figure 1-2). Reverse
1st . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.87
2nd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.98
LIST OF SPECIFICATIONS 3rd. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.95
General Engine
Model . . . . . . . . . . . . . . . . . . . . . . RT9000E Series
Rated Capacity. . . . . . . . . . . See Load Chart in cab Cummins QSC
Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 x 4 x 4 HP Rating . . . . . . . . . . . . . . . . 300 hp @ 2200 rpm
Gross Weight . . . . . . . . . . . . . . . . See Axle Weight Peak Torque. . . . . . . . . . 1000 pounds @ 1400 rpm
. . . . . . . . . . . . . . . . . . . . . . . . . . . Distribution Table Lube Amount . . . . . . . . . . . . . . . . 19.9 liters (21 qt)
Coolant System . . . . . . . . . . . . . . 34.1 liters (36 qt)
Dimensions
Axles
NOTE: Dimensions listed are for a crane with all
components fully retracted in the travel mode with Total Ratio (w/differential lock) . . . . . . . . . . . 33.43:1
Total Ration (standard). . . . . . . . . . . . . . . . . 31.94:1
33.25 x 29 tires. Carrier Ratio (w/differential lock) . . . . . . . . . 6.429:1
Wheelbase . . . . . . . . . . . . . . . . 4940 mm (194.5 in) Carrier Ratio (standard) . . . . . . . . . . . . . . . . 6.143:1
Overall Crane Length . . . . . . . . 16,484 mm (649 in) Planetary Ratio . . . . . . . . . . . . . . . . . . . . . . . 5.20:1
Overall Crane Width . . . . . . . . . 3797 mm (149.5 in)
Brakes Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Output - @ 2710 rpm w/no load
Type . .Hydraulic/Split system acting on all four wheels Section 1 . . . . . . . . . . . . . 209 l/min (58.1 gpm)
Size . . . . . . . . . . . . . 470 x 40 mm (18.5 x 1.575 in) Section 2 . . . . . . . . . . . . . 125 l/min (34.7 gpm)
Wheels And Tires Pump #2
Lugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear
Torque . . . . 515 to 542 Nm (380 - 400 foot-pounds) Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tire Size Output - @ 2710 rpm w/no load
Standard. . . . . . . . . . . 33.25 x 29-38 ply rating Section 1 . . . . . . . . . . . . 94.6 l/min (26.3 gpm)
Optional . . . . . . . . . . . . . . . . . . . . . . . 29.5R29
NOTE: For roading and lifting pressures, refer to the Load Pump #3
Chart Book in the cab. Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear
Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Swing Gearbox Output - @ 2710 rpm w/no load
Section 1 . . . . . . . . . . . . . 209 l/min (58.1 gpm)
Reduction Ratio . . . . . . . . . . . . . . . . . . . . . . . .36:2 Section 2 . . . . . . . . . . . . 62.5 l/min (17.4 gpm)
Output Torque . . . . . . . . . . . . . . . 4152 foot-pounds
Boom Pump #4
Length
Retracted . . . . . . . . . . . . . . . . . . 12.8 m (42 ft) Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear
Extended . . . . . . . . . . . . . . . . 48.5 m (159.3 ft) Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Power . . . . . . . . . . . . . . . . . . 5 Section, Full Power Output - @2400 rpm w/no load
Elevation . . . . . . . . . . . . . . . . . . . -3 to +78 degrees Section 1 . . . . . . . . . . . . 39.0 l/min (10.3 gpm)
Extensions
Fixed*. . . . . . . . . . . . . . . . . .11 meters (36.1 ft) Hoists
Folding* . . . . . 11 or 18 meters (36.1 or 59.1 ft) Drum Dimensions
*Extensions are offsettable at 0, 20, or 40 Length . . . . . . . . . . . . . . . . . 626 mm (26.65 in)
degrees. Diameter . . . . . . . . . . . . . . . . . 381 mm (15 in)
Extension Insert . . . . . . . . . . . . . . . . . 8 m (26.2 ft) Length (Standard) . . . . . . . . 676 mm (26.63 in)
Cable
Swivel Assembly Diameter . . . . . . . . . . . . . . . . . . 19 mm (3/4 in)
Electrical . . . . . . . . . . . . . . . . . . . . . . .15 Slip Rings Length-Main. . . . . . . . . . . . . . . . 290 m (951 ft)
Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 ports Length-Aux. . . . . . . . . . . . . . . . . 214 m (702 ft)
Water. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ports Max. Permissible Line Pull (6x36)
. . . . . . . . . . . . . . . . . . . . . . . . . 7760 kg (17,070 lb)
Max. Single Line Speed . . . 171.3 m/min (562 fpm)
Hydraulic Pumps Hoist Motor Displacement
NOTE: Pump output figures are theoretical. Low . . . . . . . . 80.3 cm3 (4.9 in3) per revolution
High . . . . . . . . . 46 cm3 (2.8 in3) per revolution
Pump #1 Oil Capacity . . . . . . . . . . . . . . . . . . . . . . 21 l (22 qt)
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear
FIGURE 1-1
Table 1-1
Axle Weight Distribution Table
Description
CG to CL Bogie
cm (in)
Weight
kg (lb)
Front Axle
kg (lb)
Rear Axle
kg (lb) 1
-14026
Delete: Counterweight (24,000 pounds) -142.5 (-56.10) -10886 (-24000) 3140 (6922)
(-30922)
Delete: Auxiliary Hoist Cable (700 ft) -159.4 (-62.76) -397 (-875) 128 (282) -525 (-1157)
Delete: Air Conditioning -54.3 (-21.37) -93 (-205) 10 (23) -103 (-228)
Delete: General 33.25 X 29 (38) Tires (for
247.0 (97.25) -4318 (-9520) -2159 (-4760) -2159 (-4760)
travel)
Heavy Counterweight Package (16000 lb) -137.2 (-54.03) 7258 (16000) -2016 (-4445) 9274 (20445)
Lift Cylinder Travel Support 570.9 (224.75) 57 (125) 65 (144) -8 (-19)
Counterweight Stand (pinned to carrier) 616.6 (242.74) 78 (172) 97 (214) -19 (-43)
26 ft Boom Extension Insert w/LMI 652 (1437)
Tire Removal Tool 247 (545)
Component Location
(Figure 1-2) shows the location of some of the main
components of the RT9130 Crane.
2
3
1
4
18
6018-1
7
5 6 7
11
9 10 12 8
13
14
7
6018-4
17 16 15
7 FIGURE 1-2
18 6
19
9
13 10
6018-3
3 21
22
8
18 11 10
12 3 21 1
14
25
15 24 20
5
17 5
23
6018-2
When shims are removed, tie them together and identify To determine whether a bearing requires preload or end
them as to location. Keep shims clean and flat until they are c l e ar a nc e , c on s u l t t h e d i s a s s em b l y a n d a s s e m b l y
reinstalled. instructions pertaining to that bearing.
Care should be exercised in applying preload. Misapplication
Bearings of preload to bearings requiring end clearance can result in
bearing failure.
Antifriction Bearings
When an antifriction bearing is removed, cover it to keep out Sleeve Bearings
dirt and abrasives. Wash bearings in non-flammable Do not install sleeve bearings with a hammer. Use a press
cleaning solution and allow them to drain dry. The bearing and be sure to apply the pressure directly in line with the
may be dried with compressed air BUT do not spin the bore. If it is necessary to drive on a bearing, use a bearing
bearing. Discard the bearings if the races and balls or rollers driver or a bar with a smooth flat end. If a sleeve bearing has
are pitted, scored, or burned. If the bearing is serviceable, an oil hole, align it with the oil hole in the mating part.
coat it with oil and wrap it in clean waxed paper. Do not
unwrap new bearings until time of installation. The life of an Gaskets
antifriction bearing will be shortened if not properly
lubricated. Dirt in an antifriction bearing can cause the Be sure the holes in the gaskets correspond with the
bearing to lock resulting in the shaft turning in the inner race lubricant passages in the mating parts. If it is necessary to
or the outer race turning within the cage. make gaskets, select material of the proper type and
thickness. Be sure to cut holes in the right places. Blank
Double Row, Tapered Roller gaskets can cause serious damage.
Double row, tapered roller bearings are precision fit during When removed, always install new cylinder head and
manufacture and components are not interchangeable. The manifold gaskets using recommended gasket compound on
cups, cones, and spacers are usually etched with the same head gaskets to allow uniform sealing.
serial number and letter designator. If no letter designators
are found, wire the components together to assure correct Batteries
installation. Reusable bearing components should be Clean batteries by scrubbing them with a solution of baking
installed in their original positions. soda and water. Rinse with clear water. After cleaning, dry
thoroughly and coat terminals and connections with an anti
Heating Bearings corrosion compound or grease.
Bearings which require expansion for installation should be If the machine is to be stored or not used for an extended
heated in oil not to exceed 121 °C (250 °F). When more than period of time, the batteries should be removed. Store the
one part is heated to aid in assembly, they must be allowed batteries in a warm, dry place, preferably on wooden
to cool and then pressed together again. Parts often shelves. Never store on concrete. A small charge should be
separate as they cool and contract. introduced periodically to keep the specific gravity rating at
recommended level.
Experience has shown that highly stressed welded Application of Medium Strength Loctite
structures when repeatedly subjected to varying stresses
caused by twisting, shock, bending, and intentional and/or NOTE: The fastener may be re-used; the adhesive may be
unintentional overloads, often become subject to weld re-applied over cured adhesive residue.
cracking which may be attributed to fatigue of the welded
The following procedure covers the proper application and
joint. This condition is not uncommon in construction
curing method for medium strength Loctite adhesive/sealant
equipment.
(Loctite #242) and primer (Locquic Primer T7471).
Use bolts of the correct length. A bolt which is too long may NOTE: To convert foot-pounds of torque to newton meters
bottom before the head is tight against the part it is to hold. If (Nm), multiply the foot-pounds quantity by 1.3558.
a bolt is too short, there may not be enough threads engaged NOTE: To convert pounds-inch of torque to newton meters
to hold the part securely. Threads can be damaged. Inspect (Nm), multiply the pounds-inch quantity by
them and replace fasteners, as necessary. 0.11298.
Torque values should correspond to the type bolts, studs, NOTE: When multipliers and/or special tools are used to
and nuts being used (Figure 1-4) and (Figure 1-5). reach hard to get at spots, ensure torque readings
The torque tables, (Table 1-2), (Table 1-3), (Table 1-4), and are precisely calculated.
(Table 1-5) are provided by Grove Manitowoc for reference
when performing maintenance.
1
Grade 5
120° 120°
60° 60°
FIGURE 1-4
Table 1-2
Torque Values For Unfinished Fasteners With No Special Lubrication - Coarse Threads
Table 1-3
Torque Values For Unfinished Fasteners With No Special Lubrication - Fine Threads
SAE 5.2
Serrated 15 28 52 81 125 — 251 — — — — — — —
Flange Head 11 21 39 61 94 189
NOTE 1: Studs shall be torqued using capscrew figures when grade is known.
NOTE 2: Torque values for zinc plated fasteners are the same as for unfinished fasteners.
Table 1-4
Torque Values For Metric Fasteners With No Special Lubrication - Coarse Threads 1
Bolt Diameter - Metric
TORQUE VALUES (Nm)
M4 M5 M6 M7 M8 M10 M12 M14 M16 M18 M20 M22 M24 M27 M30
Grade
0.157 0.197 0.236 0.276 0.315 0.394 0.472 0.551 0.630 0.709 0.787 0.866 0.945 1.06 1.18
3.1 6.5 11 19 27 53 93 148 230 391 447 608 774 1134 1538
8.8
2.8 5.9 10 17 25 49 85 136 212 294 413 562 714 1046 1420
4.5 9.2 16 26 38 75 130 212 322 455 629 856 1089 1591 2163
10.9
4.1 8.5 14 24 35 69 120 195 298 418 581 790 1005 1469 1997
5.4 11 19 31 45 89 156 248 387 532 756 1029 1306 1910 2595
12.9
4.9 10 17 28 42 83 144 228 357 490 698 949 1206 1763 2395
NOTE 1: Torque values for fine threads are 8% higher.
Table 1-5
Torque Values For Metric Fasteners With No Special Lubrication - Coarse Threads
1. High velocity movement e.g.; hoisting or swinging of a pouring, swabbing, painting or pressure spray methods.
load followed by abrupt stops. Whenever possible, the lubricant should be applied at the
top of a bend in the rope, because at that point the strands
2. Suspending loads while traveling over irregular surfaces
are spread by bending and are more easily penetrated.
such as railroad tracks, potholes, and rough terrain.
There should be no load on the rope while it is being
3. Moving a load that is beyond the rated capacity of the lubricated. It should be noted, the service life of wire rope will
lifting mechanism, i.e.; overloading. be directly proportional to the effectiveness of the method
used and amount of lubricant reaching the working parts of
Lubrication the rope.
A wire rope cannot be lubricated sufficiently during Precautions and Recommendations During
manufacture to last it’s entire life. Therefore, new lubricant
must be added throughout the life of a rope to replace factory
Inspection or Replacement
lubricant which is used or lost. It is important that lubricant 1. Always lock out equipment power when removing or
applied as part of a maintenance program shall be installing wire rope assemblies.
compatible with the original lubricant, and to this end, the
rope manufacturer should be consulted. Lubricant applied 2. Always use safety glasses for eye protection.
shall be of the type which does not hinder visual inspection. 3. Wear protective clothing, gloves, and safety shoes as
Those sections of rope which are located over sheaves or appropriate.
otherwise hidden during inspection and maintenance
procedures require special attention when lubricating rope. 4. Use supports and clamps to prevent uncontrolled
The object of rope lubrication is to reduce internal friction and movement of wire rope, parts, and equipment.
to prevent corrosion. 5. When replacing fixed length cable assemblies (e.g.
During fabrication, ropes receive lubrication; the kind and pendants) having permanently attached end fittings use
amount depends on the rope’s size, type, and anticipated only pre-assembled lengths of wire rope as supplied
use. This in-process treatment will provide the finished rope from Manitowoc. Do not build lengths from individual
with ample protection for a reasonable time if it is stored components.
under proper conditions. But, when the rope is put into 6. Replace an entire wire rope assembly. Do not attempt to
service, the initial lubrication may be less than needed for the rework damaged wire rope or wire rope ends.
full useful life of the rope. Because of this possibility, periodic
applications of a suitable rope lubricant are necessary. 7. Never electroplate wire rope assemblies.
The following are important characteristics of a good wire 8. Do not weld any wire rope assembly or component
rope lubricant: unless welding is recommended by the wire rope
manufacturer. Welding spatter shall never be allowed to
1. It should be free from acids and alkalis. come in contact with the wire rope or wire rope ends. In
2. It should have sufficient adhesive strength to remain on addition, be sure that the wire rope is not an electrical
the ropes. path during other welding operations.
3. It should be of a viscosity capable of penetrating the 9. Wire ropes are manufactured from special steels. If
interstices between wires and strands. heating a wire rope assembly is absolutely necessary for
removal, the entire wire rope assembly shall be
4. It should not be soluble in the medium surrounding it discarded.
under the actual operating conditions (i.e. water).
10. On systems equipped with two or more wire rope
5. It should have a high film strength. assemblies operating as a matched set, they shall be
6. It should resist oxidation. replaced as an entire set.
Before applying lubrication, accumulations of dirt or other 11. Do not paint or coat wire ropes with any substance
abrasive material should be removed from the rope. except approved lubricants.
Cleaning can be accomplished by using a stiff wire brush and 12. Measure the rope’s diameter across crowns (1) of the
solvent, compressed air, or live steam. Immediately after the strands when determining if rope has become damaged
wire rope is cleaned, it should be lubricated. Many (Figure 1-6).
techniques may be used; these include bath, dripping,
FIGURE 1-7 Pay particular attention to areas of the rope where wear and
other damage is likely to occur:
Wire Rope Inspection (Running Ropes and 7. Pick-up Points: Sections of wire rope that are
Pendant Cables) repeatedly stressed during each lift, such as those
sections in contact with sheaves.
Wire rope should be inspected frequently/daily and
periodically/yearly in accordance with the following 8. End Attachments: The point where a fitting is
information excerpted from a National Consensus Standard attached to the wire rope or the point where the wire
as referenced by Federal Government Agencies. rope is attached to the drum.
Recommended inspection intervals may vary from machine
9. Abuse Points: The point where the wire rope is
to m a ch i ne a nd m a y v ar y ba s ed o n e nv i r o nm en ta l
subjected to abnormal scuffing and scraping.
conditions, frequency of lifts, and exposure to shock loads.
The inspection time intervals may also be predetermined by Periodic Inspection
state and local regulatory agencies.
Wire rope should be inspected periodically/annually or at a
NOTE: Wire rope may be purchased through Manitowoc shorter time interval if necessitated by environmental or
CraneCARE. other adverse conditions, and shall cover the entire length of
Any deterioration observed in the wire rope should be noted the wire rope. Only the outer surface of the wire rope need
in the equipment inspection log and an assessment be inspected, and no attempt should be made to open the
rope. Periodic inspection should include all items listed
under frequent inspection plus the following:
1. Inspect for reduction of rope diameter below nominal 6. Inspect for unusual cable sag/stretch and be sure cables
diameter. used in sets all have an equal tension applied. Repeated
need for adjustment of an individual cable is evidence of
2. Inspect for severely corroded or broken wires at end
cable stretch and indicates the need for additional and
connections.
more thorough inspection in order to determine and
3. Inspect for severely corroded, cracked, bent, worn, or correct the cause.
improperly applied end connections.
Wire Rope Inspection/Replacement (All Wire
4. Inspect wire rope in areas subjected to rapid
deterioration such as:
Rope)
• Sections in contact with saddles, equalizer sheaves, No precise rules can be given for determination of the exact
or other sheaves where wire rope travel is limited. time for replacement of wire rope since many variable factors
are involved. Determination regarding continued use or
• Sections of wire rope at or near terminal ends where replacement of wire rope depends largely upon the good
corroded or broken wires may protrude. judgement of an appointed and qualified person who
5. Inspect boom nose sheaves, hook block sheaves, boom evaluates the remaining strength in a used rope after
extension/jib sheaves, auxiliary boom nose sheaves, allowance for any deterioration disclosed by inspection.
and hoist drums for wear. Damaged sheaves or hoist Wire rope replacement should be determined by the
drums can accelerate wear and cause rapid following information excerpted from a National Consensus
deterioration of the wire rope. Standard as referenced by Federal Government Agencies
and as recommended by Manitowoc. All wire rope will
Wire Rope Inspection (Boom Extension and eventually deteriorate to a point where it is no longer usable.
Retraction Cables) Wire rope shall be taken out of service when any of the
following conditions exist:
Periodic Inspection.
1. In running ropes, six randomly distributed broken wires
It is recommended that a periodic inspection of all boom in one lay or three broken wires in one strand in one lay.
extension and retraction cables be performed using the
following guidelines. This inspection shall cover the entire 2. Wear of one-third the original diameter of outside
length of the extension and retraction cables. This inspection individual wires. Kinking, crushing, bird caging, or any
should be used to monitor progressive degradation and to other damage resulting in distortion of the rope
d i s c o v e r s e v e r e d a m a g e s n e c e s s i ta t i n g w i r e r o p e structure.
replacement or equipment repair. Inspection criteria are as 3. Evidence of any heat damage from any cause.
follows:
4. Reductions from nominal diameter of more than:
1. Inspect for reduction of rope diameter below nominal
diameter. • 1/64 inch for diameters up to and including 5/16
inch.
2. Inspect for severely corroded or broken wires at end
connections. • 1/32 inch for diameters 3/8 and 1/2 inch inclusive.
3. Inspect for severely corroded, cracked, bent, worn, or • 3/64 inch for diameters 9/16 to 3/4 inch inclusive.
improperly applied end connections. • 1/16 inch for diameters 7/8 to 1 1/8 inches inclusive.
4. Inspect wire rope in areas subjected to rapid • 3/32 inch for diameters 1/14 to 1 1/2 inches
deterioration such as: inclusive.
• Sections in contact with saddles, equalizer sheaves, 5. In running rope, six randomly distributed broken wires in
or other sheaves where wire rope travel is limited. one lay or three broken wires in one strand in one lay.
• Sections of wire rope at or near terminal ends where 6. In standing ropes, more than two broken wires in one lay
corroded or broken wires may protrude. in sections beyond end connections or more than one
• Sections of wire rope in contact with stationary broken wire at an end connection.
surfaces where abrasion or chafing may take place 7. In rotation resistant rope, two randomly distributed
as a result of equipment vibration. broken wires in six rope diameters or four randomly
5. Inspect for damaged or wobbly boom extension and distributed broken wires in 30 rope diameters.
retraction sheaves that may cause rapid deterioration of 8. Severe corrosion as evidenced by pitting.
the wire rope.
Method 1
Using a length of soft annealed wire ((Figure 1-8)), place one
end in the groove between two strands of the wire rope. Turn
the long end of the annealed wire at right angles to the wire
and wrap it tightly over the portion in the groove.
FIGURE 1-9
The two ends of the annealed wire should be twisted
together tightly. Cut off the excess wire and pound the twist
Wind a length of soft annealed wire ((Figure 1-9)) around the
flat against the wire rope.
wire rope at least seven times. The two ends should be
twisted together in the center of the seizing. Tighten the
seizing by alternately prying and twisting. Cut off both ends
of the wire and pound the twist flat against the rope.
NOTE: Non-preformed wire rope (1) ((Figure 1-10)) should
have three seizings (3) located on each side of the
cut (4) as compared to performed wire rope (2).
1 4 3
FIGURE 1-8
7204
FIGURE 1-10
Installing FLEX-X 35 Wire Rope 7. Breaking in your new Flex-X 35: After installation, you
should properly break in your rope, which allows the
rope’s component parts to adjust themselves to your
CAUTION operating conditions.
Any cutting of this specific wire rope is not recommended. With the boom fully raised and fully extended, attach a
If FLEX-X 35 wire rope must be cut for any reason, it is light load at the hook and raise it a few inches off the
necessary to follow the attached instructions. Also, unlike ground. Allow to stand for several minutes. Then cycle
other types of wire rope, the ends on this wire rope must the load between the full “up” and “down” positions
be welded. several times. Stand back and watch the drum winding
and rope travel for any potential problems.
1. Unload properly and relieve any twists. Pull the rope off
After making the lifts with a light load, increase the load
the shipping reel or unroll it from a shipping coil. (If done
and cycle it up and down a few times. This procedure will
improperly, you may kink the rope, which will result in
train the rope and help assure smooth operation during
permanent damage to the rope.) Then lay the rope on
its useful life.
the ground in direct line with the boom. This helps
release any twist in the rope. Ideally, you should run these loads with reeving that lets
you place the loads on the block with all rope off the
2. Attach rope’s end to drum. Pull the rope over the point
drum except the last three wraps. If this is not possible,
sheave and attach the end to the drum. Be sure not to
alternate methods must be used to assure proper
remove the welded end.
tensioning of the rope on the drum.
3. Wind rope onto drum slowly and carefully. At this point, it
isn’t necessary to provide additional load other than the Procedures for Cutting and Preparing
weight of the rope being pulled across the ground. FLEX-X 35
4. Spool first layer tightly. It is essential on smooth-faced Flex-X 35 is a special wire rope that must be handled
drums that the first layer is spooled with wraps tight and differently than any other rope we manufacture. One
close together since the first layer forms the foundation characteristic that makes this rope special is that the outer
for succeeding layers. If need be, use a rubber, lead or strands are not preformed. It is because of this that the
brass mallet (but never a steel hammer) to tap the rope following procedures for cutting and preparing Flex-X 35
in place. must be followed:
5. Spool multiple layers with sufficient tension. It’s very 1. The welded ends prepared by the manufacturer are not
important to apply a tensioning load to the ropes during to be removed.
the rope breaking-in process. (If not, the lower layers
may be loose enough that the upper layers become 2. Before cutting the rope, make three separate bands with
wedged into the lower layers under load, which can seizing strand on each side of where the cut is to be
seriously damage the rope.) The tensioning load should made (total of six bands for each cut). Each band is to
range from 1 to 2% of the rope’s minimum breaking have a minimum length of one and one half times the
force. rope diameter. The two bands closest to the cut should
be located at a distance equal to one rope diameter
6. For ropes in multi-part systems: Reeve the traveling away from the cut. The four remaining bands should be
block and boom tip sheaves so the rope spacing is evenly spaced at a distance equal to three rope
maximized and the traveling (hook) block hangs straight diameters.
and level to help assure block stability.
FIGURE 1-11
GROVE 2-i
HYDRAULIC SYSTEM RT9130E SERVICE MANUAL
2-ii
RT9130E SERVICE MANUAL HYDRAULIC SYSTEM
GROVE 2-iii
HYDRAULIC SYSTEM RT9130E SERVICE MANUAL
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52
Check Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53
Outrigger/Rear Steer/Outrigger Box Pin Removal Valve . . . . . . . . . . . . . . . . . . . . . . . 2-54
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54
Functional Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54
Outrigger Control Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56
Functional Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56
Pilot Operated Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57
Pressure Bleed-Off Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58
Axle Oscillation Lockout Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-59
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-59
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-59
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-59
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-59
Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60
Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-61
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-61
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-61
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-61
Surface Protection For Cylinder Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-61
Leakage Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-61
Temperature Effects on Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . 2-62
Lift Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-63
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-63
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-63
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-63
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-63
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-65
Dual Rod Telescope Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-67
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-67
2-iv
RT9130E SERVICE MANUAL HYDRAULIC SYSTEM
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-67
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-67
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-68
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-68
Upper Telescope Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-71
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-71
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-71
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-71 2
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-71
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-71
Axle Oscillation Lockout Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-74
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-74
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-74
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-74
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-74
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-74
Steer Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-77
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-77
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-77
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-77
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-77
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-77
Outrigger Extension Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-80
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-80
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-80
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-80
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-80
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-80
Outrigger Stabilizer Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-83
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-83
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-83
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-83
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-83
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-85
Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-86
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-86
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-86
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-86
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-86
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-86
Power Pin Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-89
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-89
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-89
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-89
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-89
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-89
Park Brake Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-92
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-92
GROVE 2-v
HYDRAULIC SYSTEM RT9130E SERVICE MANUAL
2-vi
RT9130E SERVICE MANUAL HYDRAULIC SYSTEM
SECTION 2
HYDRAULIC SYSTEM
DESCRIPTION 5. Disconnect the return line from the lift cylinder and raise
the boom to maximum elevation.
This section describes the hydraulic system, the
components which make up the hydraulic system, and the 6. Connect the cylinder return line and lower the boom to
its stowed position. Replenish the reservoir hydraulic oil
2
components dependent upon the hydraulic system for their
operation. This includes descriptions of the supply pressure level as required.
and return hydraulic circuit, hydraulic pumps, all hydraulic 7. Disconnect the return line from an outrigger extension
valves, and all hydraulic cylinders. Detailed descriptions and cylinder and fully extend the outrigger.
operation of individual hydraulic circuits are discussed within
their individual sections as applicable. A complete hydraulic 8. Connect the outrigger return line and retract the
system schematic showing all options is at the back of this outrigger. Replenish the reservoir hydraulic oil level as
manual and (Figure 2-1) and (Figure 2-2) provides A.N.S.I. necessary.
Graphical Symbols information for this section. 9. Repeat Steps 7 and 8 for the remaining outriggers.
MAINTENANCE
CAUTION
Hydraulic Oil Recommendations When draining the outrigger cylinders, always operate
either both front or both rear cylinders together to prevent
For the hydraulic oil specifications, refer to Section 9 - twisting the crane.
LUBRICATION.
10. Disconnect the return lines from a pair of outrigger
Draining and Flushing stabilizer cylinders and activate the cylinders to their
If a component has been changed because of a failure that maximum down positions.
might allow metal or abrasive particles to enter the system, 11. Connect the return lines and raise the outrigger
all systems must be thoroughly checked, drained, and stabilizer cylinders to the stowed position. Replenish the
flushed. reservoir hydraulic oil level as necessary.
1. Remove the reservoir drain plug. Allow about three 12. Repeat Steps 10 and 11 for the remaining two outrigger
minutes after hydraulic oil stops flowing from the drain cylinders.
port for the side walls to drain.
13. Disconnect the return line from the telescope cylinder
2. Clean and install the reservoir plug and fill the reservoir and fully extend the boom.
with a 50/50 mixture of fuel oil and clean hydraulic oil.
14. Connect the return line and retract the boom. Replenish
3. Cycle the crane through all functions several times. the reservoir hydraulic oil level as necessary.
Then return the crane to its stowed position and turn the
front and rear wheels to the extreme left. Shut down the 15. Disconnect the return lines from both front steer
engine. cylinders and turn the front wheels to the extreme right.
4. Remove the reservoir drain plug and drain the reservoir. 16. Connect the return lines and turn the front wheels to the
Clean and install the drain plug and fill the reservoir with extreme left and then back to center. Replenish the
clean hydraulic oil. reservoir hydraulic oil level as necessary.
17. Repeat steps 15 and 16 for the rear steering cylinders.
CAUTION 18. Raise the crane on outriggers.
Hydraulic oil supply lines must be connected to the
cylinders when flushing the system. 19. Disconnect the line from port A of the axle lockout valve.
20. Using a jack under the rear wheel on one side of the
NOTE: Draining the various components will be aided by crane, jack up the wheel to maximum travel.
connecting a drain line in place of the disconnected
return line. 21. Connect the line to port A of the axle lockout valve and
disconnect the line from Port B.
22. Repeat step 19 using the other rear wheel.
FIGURE 2-1
FIGURE 2-2
23. Connect the line to port B of the axle lockout valve. fittings for evidence of leaks. A soap solution applied to
Energize the axle lockout valve. Replenish the reservoir the fittings and joints may also prove helpful in detecting
hydraulic oil level as necessary. minute leaks while the system is pressurized. Remove
the pressure, repair any leaks found, and reopen any
24. Disconnect the return line from the main hoist motor and
openings (such as a vent) closed for inspection. Refill
fully hoist up the hoist.
the reservoir after completing any repairs or service.
25. Connect the return line to the main hoist motor and fully Operate all hydraulic circuits several times in both
hoist down the hoist, then hoist up again. Replenish the directions.
reservoir hydraulic oil level as necessary.
This action should return any entrapped air to the
26. Repeat Steps 24 and 25 for the auxiliary hoist as reservoir where it can be removed from the hydraulic oil
necessary. by the baffles.
27. Disconnect one of the lines from each of the swing
motors and drive the motors in the direction they will go.
28. Connect the lines to the swing motors, then drive the
DANGER
swing motors in the opposite direction until the boom is Locate the machine on a firm supporting surface and
centered and forward. Replenish the reservoir hydraulic position the boom over the front on outriggers when
oil level as necessary. extending the boom at low angles.
Parts Replacement Warping occurs when mounting plates are not level or they
become distorted from machine damage. As mentioned
Parts found damaged or out of tolerance when maintenance previously, the valve can be shimmed level.
is being performed should be replaced. Refer to the
Manitowoc Parts Catalog for proper replacement parts. Also, check the valve for rust. Rust or dirt collecting on the
valves can prevent free movement of the spool, and keep it
Directional Control Valves from the true center position. Excessive system pressure
Dripping hydraulic oil indicates some type of external a. Leaks at hose fitting or in hose
leakage. The machine should be removed from service for b. Damaged, cut, or abraded cover
immediate repairs. External leaks sometimes develop at
fittings and seals. Spool seals are susceptible since they are c. Exposed reinforcement
subject to wear. Seals may be damaged by temperatures d. Kinked, crushed, flattened, or twisted hose
that are too high, or by dirt or paint accumulation on the
spool. Damaged or torn seals must be replaced. e. Hard, stiff, heat cracked, or charred hose
A component functioning at reduced efficiency may indicate f. Blistered, soft, degraded, or loose cover
that the control valve for that component is leaking internally. g. Cracked, damaged, or badly corroded fittings
If preliminary check-out reveals that adequate volume is
being supplied to the affected valve bank, relief valves are h. Fitting slippage on hose
properly adjusted, and the component is not at fault, check i. Other signs of significant deterioration
the valve for scored or worn parts. Scoring is a sign of the
number one problem in hydraulics - contamination (external If any of the above conditions exist, evaluate hose
contamination by dust or internal contamination by debris assemblies for correction or replacement. For replacement
from deteriorating components or oxidized hydraulic oil). of hose assemblies, refer to your Manitowoc Crane Care
Scored or severely worn valve components must be Parts Manual.
replaced.
2. At the same service interval, visually inspect all other
Check valves in the control valves are designed to permit a hydraulic components and valves for the following:
flow of hydraulic oil in one direction only. If a piece of dirt or
a. Leaking Ports
rust has worked its way into the check valve and lodges
between the poppet and seat, it will keep the valve open and b. Leaking valve sections or manifolds and valves
allow a return flow of hydraulic oil. The remedy is to clean the installed into cylinders or onto motors.
valve, but it is also a good idea to follow through and ensure
c. Damaged or missing hose clamps, guard, or
the hydraulic system filter is still serviceable.
shields.
Binding Spools d. Excessive dirt and debris around the hose
Some of the most common causes for stiff spool movement assemblies.
or jammed spool action are system overheating, excessive If any of these conditions exist, address them appropriately.
pressure, contaminated or deteriorated hydraulic oil, or
warped mountings. When scorched, deteriorated hydraulic 3. Hydraulic hose assemblies operating in a temperature
oil or contamination is the cause, flushing the system and climate zone “C” (Table 2-1) are recommended to be
replenishing with clean hydraulic oil may solve the problem. replaced after 8000 hours of service life.
If the spool bores are badly scored or galled, the valve must
be removed for servicing.
4. Hydraulic hose assemblies operating in climate zones 5. Hydraulic hose assemblies operating in climate zones
“A” and “B” (Table 2-1) with high ambient temperatures, “D” and “E” (Table 2-1) cold climates should expect a
could see hose service life reduced by 40 to 50%, degrade of mechanical properties such as elasticity,
therefore, it is recommended to replace these hoses therefore, it is recommended these hoses be inspected
after 4000 to 5000 hours of service life. and addressed accordingly.
Table 2-1
Zone Classification
A Tropical Moist: All months average above 18° C. Latitude 15° - 25° North and South
B Dry or Arid: Deficient precipitation most of the year. Latitude: 20° - 35° North and South
C Moist Mid-Latitude: Temperature with mild winters. Latitude: 30° - 50° North & South
D Moist Mid-Latitude: Cold winters. Latitude 50° - 70° North & South
E Polar: Extremely cold winters and summers. Latitude: 60° - 75° North & South
SUPPLY PRESSURE AND RETURN CIRCUIT flow goes through the filter at the top of the reservoir. The
return line that goes directly into the reservoir (instead of
Description through the filter) is from the No. 4 port (drain) of the 11-port
swivel.
The supply pressure and return circuit is made up of several
circuits which route hydraulic oil from the four hydraulic A magnetized drain plug in the bottom of the reservoir
pumps to the directional control valves for the individual collects metal particles from the hydraulic oil if it becomes
operating circuits. The supply pressure and return circuit contaminated.
consists of the reservoir and integral filter, four hydraulic A sight gauge is located on the right side of the reservoir to
pumps, a hydraulic oil cooler, and a 11-port hydraulic swivel. indicate hydraulic oil level.
Refer to Hydraulic Pumps in this section for descriptions and
maintenance instructions for each hydraulic pump. Refer to A filler neck and breather on the top of the reservoir are for
Section 6 - Swing System for description and maintenance filling the reservoir and for venting it. The filler neck includes
instructions for the 11-port hydraulic swivel. a strainer for catching contaminants and gaskets to prevent
leaking. The breather, which screws onto the filler neck,
The supply pressure and return circuit uses Ports 2 and 3 for allows air to enter or exhaust from the reservoir. It is most
pump supply and the dual Port 1 for return. Each operating important that the breather be kept clean to prevent damage
circuit’s description and components begin with the circuit’s to the reservoir.
directional control valve.
Two large round access covers on the top of the reservoir
Hydraulic Reservoir and Filter provide access for cleaning. The covers are bolted to the top
of the reservoir and have a gasket to prevent leaking. The
The reservoir (Figure 2-3), attached to the right side of the
access holes can also be used to fill the reservoir after it has
carrier frame, has a total capacity of 1363 liters (360 gallons)
been completely drained.
total, or 1226 liters (324 gallons) to the full mark. The all-steel
reservoir has an internally mounted full-flow filter and integral The hydraulic oil filter is located in the reservoir. It bolts to the
baffles that help cool the hydraulic oil and prevent hydraulic top of the reservoir. The filter contains a replaceable filter
oil foaming. element. Returning hydraulic oil flows through the filter’s filter
element into the reservoir. Bypass fluid internal to the filter
Hydraulic oil flows through four tubes at the lower rear of the
flows to the reservoir also.
reservoir to the four hydraulic pumps. Almost all of the return
8
12
5
2
2
7305
11
1
10
FIGURE 2-3
MAINTENANCE
Troubleshooting
Table 2-2
Symptom Probable Cause Solution
1. No hydraulic oil flows in a. Low hydraulic oil level. a. Check system for leaks. Make repairs
systems. as needed. Fill reservoir.
2. Slow response. a. Low hydraulic oil level. a. Check system for leaks. Make repairs
as needed. Fill reservoir.
3. Pump noise accompanied a. Low hydraulic oil level. a. Check system for leaks. Make repairs
by hydraulic oil foaming in as needed. Fill reservoir.
reservoir.
b. Excessive engine b. Regulate engine speed.
speed. .
4. Excessive pressure a. System relief valve set a. Using adequate pressure gauge,
buildup. too high. adjust system relief valve as
necessary.
5. Specific hydraulic system a. Leak in system. a. Check system for leaks. Make repairs
(lift, hoist, telescope, as needed. Fill reservoir.
swing) not working.
b. Faulty hydraulic b. Adjust or replace valve.
remote control valve.
3
1, 2
4
5
7
2
6
11
9
10
OIL COOLER the filter in the reservoir. When several hydraulic functions
are being used at one time (i.e., hoisting, lifting, and
Description telescoping), more oil has to flow through this return line,
causing a pressure buildup. When this pressure reaches 100
An air cooled hydraulic oil cooler is the right rear portion of kPa (15 psi), the normally closed check valve in the return
the hydraulic/transmission oil cooler (Figure 2-5). When the line (in parallel with the return line through the hydraulic oil
oil temperature reaches 120°F, the oil cooler solenoid valve cooler) will open, letting some hydraulic oil bypass the
is de-energized, via a NC pressure switch, to allow
pressurized oil from pump No. 4 to the oil cooler motor which
hydraulic oil cooler and flow directly into the reservoir filter. 2
drives the oil cooler fan. When fewer functions are being used, the pressure in the
system will decrease below 100 kPa (15 psi) and the check
The oil cooler fan pulls cool air through the cooling fins on the valve will close again.
cooler. Normally, most hydraulic oil from components is
routed through the oil cooler by way of a return line and on to
8
5
Air Flow
4
7308
FIGURE 2-5
NOTE: Refer to (Figure 2-6) for pump locations. 2. Tag and disconnect the supply line from the pump. Cap
or plug the line and port.
Pumps No. 1 and No. 2 are mounted on drive pads of the
torque converter. Pump No. 3 is mounted off of the torque 3. Tag and disconnect the pump distribution lines from the
converter via pump disconnect. Pump No. 4 is mounted on a pump. Cap or plug the lines and ports.
drive pad of the engine.
The purpose of these pumps is to convert mechanical CAUTION
energy into fluid energy for the operation of the crane’s When removing the pump, keep the pump as level as
hydraulic components. possible to avoid damaging the input spline.
All four pumps are positive displacement gear-type pumps. 4. Remove the four bolts and washers attaching the pump
Pumps No. 1 and No. 3 have two sections and pumps No. 2 to the drive pad on the torque converter. Remove the
and No. 4 have only one section. pump.
Pump No. 1 5. Clean the gasket material from the drive pad of the
The first section of pump no. 1, the closest to the mounting torque converter and from the pump.
face, is a 81.1 cm3/rev (4.95 in3/rev) section with an output of 6. Cover the drive pad’s opening to prevent dirt from
209 l/min (55.2 gpm) at 2710 rpm. The second section is a entering.
48.5 cm3/rev (2.96 in3/rev) section with an output of 125 l/
Pump No. 1 Installation
min (33.0 gpm) at 2710 rpm.
1. Clean the pump and the torque converter drive pad with
Pump No. 2 Loctite cleaning solvent 7070 or similar non chlorinated
solvent.
Pump No. 2 is a 36.7 cm3/rev (2.241 in3/rev) pump with an
output of 95 l/min (25 gpm) at 2710 rpm. An integral flow 2. Apply a light coating of Loctite primer N7649 to pump
divider/relief valve ensured a constant 38 l/min (10 gpm) at and drive pad. Allow primer to dry for one to two
20,670 kPa (3000 psi) at the primary port. minutes. Primer must be dry. Mating of parts should
occur within five minutes.
Pump No. 3
3. Apply gasket material Loctite Master Gasket 518 to
The first section of pump No. 3, the closest to the mounting pump and drive pad mounting surfaces. (This material
face, is an 81.1 cm3/rev (4.95 in3/rev) section with an output partially cures in 4 hours and fully cures in 48 hours.)
of 209 l/min (55.2 gpm) at 2710 rpm. The second section is a
4. Install pump and gasket on drive pad with bolts and
24.3 cm3/rev (1.48 in3/rev) section with an output of 62 l/min washers. Make sure the splines mesh properly.
(16.5 gpm) at 2710 rpm.
5. Torque bolts to 72 to 78 foot-pounds (98 to 106 Nm).
Pump No. 4
6. Connect the distribution and supply lines to the pump as
Pump No. 4 is a 14.4 cm3/rev (0.878 in3/rev) pump with an tagged during removal. On lines that use them, discard
output of 37 l/min (9.8 gpm) at 2712 rpm. An integral flow any old o-ring and install a new o-ring in its place.
divider/relief valve ensured a constant 23l/min (6 gpm) at
18,600 kPa (2700 psi) at the primary port. Pump No. 2 Removal
Maintenance CAUTION
Pump No. 1 Removal Absolute cleanliness is essential when working on the
hydraulic pumps. Always work in a clean area. The
presence of dirt and foreign materials in the system can
CAUTION result in serious damage or inadequate operation.
Absolute cleanliness is essential when working on the
hydraulic pumps. Always work in a clean area. The
presence of dirt and foreign materials in the system can
result in serious damage or inadequate operation.
7. Adjust the push-pull cable as needed so the torque surface of the spacer that will be next to the vellomoid
converter pump disconnect shaft sticks 1.50 inch farther gasket, but not to the surface of the spacer that will be
out of the torque converter in the disengaged position next to the rubber/steel gasket. Do not coat either side of
than it does in the engaged position. the rubber/steel gasket or the facing sides of the parts
that will touch it. Allow primer to dry for one to two
8. Connect the distribution and supply lines to the pump as
minutes. Primer must be dry. Mating of parts should
tagged during removal. On lines that use them, discard
occur within five minutes.
any old o-ring and install a new o-ring in its place.
4. Apply gasket material Loctite Master Gasket 518 to
No. 4 Pump Removal Pump No. 4’s mounting surface, but do not apply any to
the engine’s drive pad. Also apply a light coating of
CAUTION Loctite Master Gasket 518 to both surfaces of the
vellomoid gasket, and apply a light coating of Loctite
Absolute cleanliness is essential when working on the
Master Gasket 518 to the surface of the spacer that will
hydraulic pumps. Always work in a clean area. The
be next to the vellomoid gasket, but not to the surface of
presence of dirt and foreign materials in the system can
the spacer that will be next to the rubber/steel gasket.
result in serious damage or inadequate operation.
Do not coat either side of the rubber/steel gasket or the
facing sides of the parts that will touch it. (This material
1. Remove hardware as needed to gain access to the
partially cures in 4 hours and fully cures in 48 hours.)
pump. The pump is bolted to the engine.
5. Around the pilot of the pump, install the vellomoid
2. Tag and disconnect the supply line from the pump. Cap
gasket, then install the spacer (coated surface away
or plug the line and port.
from rubber/steel gasket), then install the rubber/steel
3. Tag and disconnect the pump distribution lines from the gasket. Then secure the pump and gaskets and spacer
pump. Cap or plug the lines and ports. on the drive pad with bolts and washers. Make sure the
teeth of the gear on the pump mesh properly with the
mating gear inside the engine.
CAUTION
When removing the pump, keep the pump as level as 6. Torque bolts to 63 to 69 foot-pounds (85 to 93 Nm).
possible to avoid damaging the input spline.
7. Connect the distribution and supply lines to the pump as
tagged during removal. On lines that use them, discard
4. Remove the two bolts and washers attaching the pump any old o-ring and install a new o-ring in its place.
to the drive pad of the engine. Remove the pump.
5. Remove the two gaskets and spacer from the pump (or CAUTION
the.engine drive pad). Discard them.
Do not feed hot hydraulic oil into a cold pump. This may
6. Cover the drive pad’s opening to prevent dirt from cause the pump to seize.
entering.
Testing After Repair or Replacement
7. Remove the nut, key, and gear from the pump.
CAUTION
6. Listen for abnormal noises indicating low hydraulic oil
level or internal pump problems. If the pump is making 2
For Pump No. 2, pay special attention to the service brake excessive noise, it is probably sucking air into its inlet,
charge pump if your crane has the dual accumulator keeping it from priming. In case of abnormal noise, stop
charging valve for hydraulic service brakes. engine, and inspect the pump and the suction line for a
If the dual accumulator charge is set too high, the pump loose connection, a leak, or a damaged or missing o-
will continually push all its flow through an integral relief ring.
valve that dumps the heated fluid back into the pump’s 7. If the pump seems to be running properly, increase the
inlet. This causes a “hot loop” problem that will very rpm to 1500 to 1800 rpm for one to two minutes while
quickly heat the pump section above hydraulic reservoir operating no hydraulic functions. Repeat checks in steps
temperature. If this happens, stop the engine immediately. 4, 5, and 6.
Adjust the dual accumulator charging valve socket head
screw in the valve’s tank port, out (CCW) to lower the 8. Increase engine speed in steps to full RPM. Repeat
pressure. (See Procedure E of the Pressure Setting checks in steps 4, 5, and 6.
Procedure portion of this section.) 9. Cycle the components the pump sections power to verify
Restart the engine; listen for the dual accumulator charge the pump sections drive them properly. Verify there is no
valve to cycle on and off (cycle changes one to two leaking.
seconds.) Perform Step 5 again.
10. Check pressure settings. Refer to PRESSURE
SETTING PROCEDURES in this section.
1
9 3
2
7 7283-1
6
8
10
9
5 7283-2
FIGURE 2-6
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. fully stroked position. Then slowly accelerate the
The following equipment is required for checking the engine to the specified RPM. Read gauge and
hydraulic pressure settings. make adjustments to specified setting.
• Three dial pressure gauge, 0-5000 psi When checking the outrigger relief valve setting,
start with the engine at idle RPM and activate and 2
• Pressure check diagnostic quick disconnect - Grove P/N hold the extend switch. Then slowly accelerate the
9999101806 and straight adapter fitting 7447040401 engine to the specified RPM. Read gauge and
• ORFS reducers as required to attach work port hoses to make adjustment as required.
the gauge.
Table 2-3
Valve Pressure Setting Table
Pressure
Tolerance
Valve To Be Set Setting PSI Adjustment Location
PSI (MPa)
(MPa)
Load Sense Relief* 4800 (33.1) ± 50 (0.4) Main Valve Inlet Section
Lift Down Relief 4000 (27.6) ± 50 (0.4) Main Valve Lift Retract Port
Lift Up Relief 4000 (27.6) ± 50 (0.4) Main Valve Lift Extend Port
Telescope Inner Mid Retract 3500 (24.1) ± 50 (0.4) Main Valve Tele Inner Mid Retract Port
Tele Inner Mid Extend 3000 (20.7) ± 50 (0.4) Main Valve Tele Inner Mid Extend Port
Telescope Center/Outer Mid Retract 3500 (24.1) ± 50 (0.4) Main Valve Tele Center/Outer Mid
Retract Port
Tele Center Mid Extend 2500 (17.2) ± 50 (0.4) Main Valve Tele Center Mid Extend
Port
Tele Outer Mid Extend 3000 (20.7) ± 50 (0.4) Main Valve Tele Center/Outer Mid
Extend Port
Pressure Reducing Sequence 1250 (8.6) +50/-0 (+0.4/-0) Pressure Reducing Sequence Valve
Hose Reel Motor Pressure Reducing 1200 (8.3) ± 50 (0.4) Pressure Reducing Sequence Valve
Hose Reel Brake Pressure Reducing 1200 (8.3) ± 50 (0.4) Pressure Reducing Sequence Valve
Swing Brake Supply Pressure Reducing 250 (1.7) +50/-0 (+0.4/-0) Pressure Reducing Sequence Valve
Controller Supply Pressure Reducing 400 (2.7) ± 50 (0.4) Pressure Reducing Sequence Valve
Front Steer Relief Valve 2500 (17.2) ± 50 (0.4) Swing/Steer Control Valve
Swing "Left" Relief 2500 (17.2) ± 50 (0.4) Swing/Steer Control Valve
Swing "Right" Relief 2500 (17.2) ± 50 (0.4) Swing/Steer Control Valve
Outrigger Beam Extend 2000 (13.8) ± 50 (0.4) Outrigger/Rear Steer Valve Inlet
Outrigger/Rear Steer/Pin Removal 3500 (24.2) ± 50 (0.4) Outrigger/Rear Steer Valve Inlet
Service Brake & A/C Relief 3000 (20.7) ± 50 (0.4) Service Brake & A/C Pump
Service Brake High Charge Limit 2700 (19.0) +50/-0 (+0.4/-0) Dual Accumulator Charge Valve
Service Brake Low Charge Limit 2200 - 2350 See Range Dual Accumulator Charge Valve
(11 - 12.1)
Accumulator Pre-charge 1400 (9.7) +50/-0 (+0.4/-0) Accumulator
Pressure
Tolerance
Valve To Be Set Setting PSI Adjustment Location
PSI (MPa)
(MPa)
Oil Cooler Relief 2700 (19.0) ± 50 (0.4) Oil Cooler Pump
Counterweight Removal Relief 3800 (26.2) ± 50 (0.4) Counterweight Removal Valve
Luffing Extension Lower Relief 1450 (10.0) ± 50 (0.4) Counterweight Removal Valve
Cab Tilt Relief 2500 (17.2) ± 50 (0.4) Counterweight Removal Valve
Counterweight Removal Pin Relief 2500 (17.2) ± 50 (0.4) Counterweight Removal Valve
*This setting is for Hoist “UP” and “DOWN” circuits. valve to 24.1 ± 0.4 MPa (3500 ± 50 PSI). Remove caps
and reconnect plumbing.
NOTE: Procedures A through M in the following text
correlate with (Figure 2-7) through (Figure 2-16). 7. Telescope mid section full out and disconnect and cap
the hoses from the main directional control valve inner
Procedure A - For Setting Main Directional mid extend port “B” to each telescope cylinder. In the
Control Valve Reliefs cab, on the left armrest, set the boom mode switches to
“Manual” and “IM”. With the engine running at full RPM,
1. Remove cap and install pressure gauge on the main attempt to telescope OUT, adjust the telescope inner
directional control valve load sense test port mid port “B” relief in the main directional control valve to
(Figure 2-7). 20.7 ± 0.4 MPa (3000 ± 50 PSI). With the hoses still
2. Disconnect the hoist brake release line at the main hoist capped, continue on to step 8.
(Figure 2-7). Cap tee fitting and plug hose. 8. In the cab, on the right armrest, set the boom mode
3. With the engine running at full RPM, attempt to run main switches to “Manual” and “CM”. With the engine running
hoist down, adjust the load sense relief in the main at full RPM, attempt to telescope OUT or disconnect and
directional control valve to 4800 ± 50 PSI to (33.1 ± 0.4 cap hoses, adjust the telescope center/outer mid two
MPa). stage port “B” relief (Figure 2-7) in the main directional
control valve to 17.2 ± 0.4 MPa (2500 ± 50 PSI). If
4. Completely retract the lift cylinder or disconnect and cap adjustment is required, loosen the low pressure jam
the hose from the main directional control valve retract nut, then turn the low pressure adjustment nut until
port “A” to the lift cylinder. With the engine running at full
the relief setting is reached and tighten the jam nut.
RPM, attempt to operate lift down, adjust the lift down
With the hoses still capped, and the boom mode
port relief in the main directional control valve to 27.6 ±
switches set to “Manual and “CM”, continue on to step
0.4 MPa (4000 ± 50 PSI). Remove cap and reconnect
9.
plumbing.
9. Telescope outer mid out and disconnect the Deutsch
5. Completely extend the lift cylinder or disconnect and cap
connectors for the telescope center/outer mid 3-way
the hose from the main directional control valve extend
solenoid and the hose reel brake solenoid (see
port “B” to the lift cylinder. With the engine running at full
(Figure 2-8). Actuate the telescope center/outer mid 3-
RPM, attempt to operate lift up, adjust the lift up port
way solenoid by connecting it to the “Battery Hot” wire
relief in the main directional control valve to 27.6 ± 0.4
harness for the hose reel brake solenoid. With the
MPa (4000 ± 50 PSI). Remove cap and reconnect engine running at full RPM, attempt to telescope OUT,
plumbing. adjust the telescope center/outer two stage port “B”
6. Completely retract the boom or disconnect and cap relief (Figure 2-7) in the main directional control valve to
hoses from the main directional control valve retract 20.7 ± 0.4 MPa (3000 ± 50 PSI). If adjustment is
ports “A” to each telescope cylinder. In the cab, on the required, loosen the high pressure jam nut, then turn the
left armrest, set the boom mode switches to “Manual” high pressure adjustment nut until the relief setting is
and “IM”. With the engine running at full RPM, attempt to reached and tighten the jam nut. Reconnect the Deutsch
telescope IN, adjust the telescope inner mid port “A” connectors on both solenoids to their correct wire
relief in the main directional control valve to 24.1 ± 0.4 harness. Remove caps and reconnect telescope
MPa (3500 ± 50 PSI). Set the boom mode switches to plumbing.
“Manual” and “CM”, then adjust the telescope center/ 10. Remove pressure gauge from the load sense test port
outer mid port “A” relief in the main directional control and reinstall cap. Reconnect the hoist brake release
line.
5 4
6 3 Item Description
2
1 Lift Up Port Relief
Telescope Inner Mid Extend Port
7 2
1 Relief
3 High Pressure Jam Nut
8 4 High Pressure Adjustment Nut
Telescope Center Outer Mid
5
Extend 2 Stage Port Relief
6 Low Pressure Adjustment Nut
7 Low Pressure Jam Nut
13 8 Valve Inlet Section
9 Load Sense Relief
Telescope Center/Outer Mid
10
Retract Port Relief
12
9 Telescope Inner Mid Retract Port
11
Relief
14 7128-1
12 Lift Down Port Relief
10 11 13 System Pressure Test Port
Main Directional Control Valve 14 Load Sense Test Port
FIGURE 2-7
Procedure B - For Checking Pressure Procedure for Checking Hose Reel Motor and Hose
Reducing/Sequence Valve Setting Reel Brake Pressure Reducing Valve Setting
(Figure 2-8)
Procedure for Checking Sequence Valve Setting (see
(Figure 2-8) 1. Remove cap and install pressure gauge on the hose reel
brake and motor test port (Figure 2-8).
1. Remove cap and install pressure gauge on the
outrigger/rear steer valve pressure test port 2. With the engine at full RPM, adjust the hose reel motor
(Figure 2-15). and brake pressure reducing valve cartridge to 8.3 ± 0.4
MPa (1200 ± 50 PSI).
2. With the engine running at idle, adjust the sequence
valve cartridge to 8.6 +0.4/-0 MPa (1250 +50/-0 PSI). If 3. Remove pressure gauge from the test port and reinstall
adjustment is required, use a shim with an outside cap.
diameter 0.56 inch, an inside diameter of 0.375 inch,
Procedure for Checking Controller Supply Pressure
and a thickness of 0.06 inch to increase pressure about
Reducing Valve Setting (Figure 2-8)
50 PSI.
1. Remove cap and install pressure gauge on the controller
3. Remove pressure gauge from the Outrigger/Rear Steer
supply test port.
Valve Test Port and reinstall cap.
2. With the engine running at full RPM, adjust the controller
supply pressure reducing valve cartridge to 2.8 ± 0.4
MPa (400 ± 50 PSI) (Figure 2-8).
3. Remove pressure gauge from the test port and reinstall
cap.
4
5
1
6
2
6098
FIGURE 2-10
2 4
5
A A
VIEW A-A
FIGURE 2-11
9. Hold gas valve to keep it from turning. Loosen swivel nut 7. If the pre-charge pressure is higher than 9.7 + 0.4/-0
and remove charging assembly. Reinstall gas valve cap MPa (1400 + 50/-0 PSI), then close the nitrogen bottle
and guard. valve and slowly open the bleed valve on the charging
assembly (Figure 2-12) until the pre-charge pressure is
Procedure G - For Pre-Charging correct.
Accumulator 8. Remove charging assembly by turning “T” handle all the
1. With the engine off, discharge all oil stored in the
accumulators by pushing the service brake pedal
way out (counterclockwise) on gas chuck and then open
bleed valve. 2
several times. Remove the gas valve guard and gas 9. Hold gas valve to keep it from turning, loosen swivel nut,
valve cap on the accumulator (Figure 2-12). and remove charging assembly. Replace gas valve cap
2. Check that the nitrogen supply bottle valve is shut off, and guard.
then attach charging assembly hose to nitrogen bottle.
Procedure H - For Checking Front Steer
3. Before attaching charging assembly (Figure 2-12) to the Relief Valve Pressure
accumulator gas valve, back the gas chuck “T” handle
all the way out (counterclockwise). 1. Remove cap and install pressure gauge on steer valve
load sense test port (Figure 2-13).
4. Close the charging assembly bleed valve. Without
twisting hose, attach the swivel nut onto the gas valve 2. With the engine running @ 1000 RPM, turn the steering
and tighten to 10-15 inch-pounds (1.1 to 1.7 Nm). wheel to LOCK position and adjust pressure at the steer
priority flow divider section relief to 17.2 ± 0.4 MPa (2500
5. Turn the gas chuck “T” handle all the way down
± 50 PSI).
(clockwise) to depress the core in the gas valve.
3. Remove pressure gauge from the Load Sense Test Port
6. Crack open the nitrogen bottle valve and slowly fill the
and reinstall cap.
accumulator. Shut off the valve when the pre-charge
pressure is 9.7 + 0.4/-0 MPa (1400 +50 PSI/-0).
1
4
2
3
7128-4
Item Description
Item Description 4 Swing Relief “A” Port
1 Steer Priority Flow Divider Section Relief 5 Swing Relief “B” Port
2 Steering Load Sense Test Port
3 Swing Inlet Test Port
Procedure I - For Checking Swing Valve Procedure J - For Checking Relief Setting
Work Port Relief Pressure for Counterweight Supply Control Valve
1. Remove cap and install pressure gauge on swing valve 1. Remove cap and install gauge on load sense relief test
inlet test port (Figure 2-13). port on main directional control valve (Figure 2-14).
2. With the swing lock Engaged and the engine running at 2. Operate the counterweight directional control valve by
FULL RPM, swing LEFT and adjust “A” port swing relief fully raising or lowering the counterweight cylinders.
to 17.2 ± 0.4 MPa (2500 ± 50 PSI). Adjust the counterweight removal directional control
valve load sense relief valve to 26.2 ± 0.4 MPa (3800 ±
3. With the swing lock Engaged and the engine running @
50 PSI).
FULL RPM, swing RIGHT and adjust “B” port swing
relief to 17.2 ± 0.4 MPa (2500 ± 50 PSI). 3. In the cab, press the luffing extension switch to ON and
the luffing raise/lower switch to LOWER in the LH
4. Remove pressure gauge from the swing inlet test port
armrest. Adjust the luffing extension “B” port relief valve
and reinstall cap.
to 10.0 ± 0.4 MPa (1450 ± 50 PSI).
4. In the cab, press the cab tilt switch to the RAISE position
and adjust the cab tilt “A” port relief valve to 17.2 ± 0.4
MPa (2500 ± 50 PSI).
5. In the cab, press the cab tilt switch to the LOWER
position and adjust the cab tilt “B” port relief valve to 17.2
± 0.4 MPa (2500 ± 50 PSI).
7
Counterweight Removal Directional Control Valve
FIGURE 2-14
Pressure Check
7128-5
6. Disconnect the couplers for the counterweight pin from 3. With the engine running at full RPM, fully extend one
the cylinder located at the rear of the turntable. DO NOT outrigger stabilizer. Adjust the outrigger two stage relief
PERFORM THIS TEST IF THE COUPLERS ARE valve to 24.2 ± 0.4 MPa (3500 ± 50 PSI). If adjustment is
CONNECTED TO EITHER THE COUNTERWEIGHT required, loosen locknut and use 1/4 inch Allen wrench
PIN CYLINDER OR THE BOOM PIVOT CYLINDER! to turn adjustment screw in (CW) to increase pressure or
Operate the counterweight pin lever to retract. Adjust the out (CCW) to decrease pressure. When complete,
counterweight pin “B” port relief to 17.2 ± 0.4 MPa (2500 tighten locknut.
± 50 PSI).
4. Remove pressure gauge from outrigger/rear steer valve
7. Operate the counterweight pin lever to extend. Adjust and reinstall cap.
the counterweight pin “A” port relief to 17.2 ± 0.4 MPa
(2500 ± 50 PSI). Connect the couplers to the Procedure L - For Setting Hoist Motor
counterweight pin cylinder. Control Valve
8. Remove gauge and reconnect plumbing.
CAUTION
Procedure K - For Checking Outrigger/Rear This procedure should only be performed if the hoist is
Steer Relief Valve Pressure rough (chatter, jumpy, or unstable load). Omit if hoist
1. Remove cap and install pressure gauge (Figure 2-15) operation is acceptable.
on outrigger/rear steer valve pressure check port.
1. Remove SAE #4 plug on the top side of the hoist valve
2. With engine running at full RPM, fully extend one block (hoist brake release) (Figure 2-7) and install
outrigger beam. Adjust the sequence relief valve to 13.8 pressure gauge.
± 0.4 MPa (2000 ± 50 PSI). If adjustment is required,
remove socket head plug from end of cartridge. Adjust 2. With engine at idle RPM, very slowly meter into the hoist
internal socket head plug in (CW) to increase pressure DOWN direction while monitoring the brake valve
or out (CCW) to decrease pressure. When complete, opening pressure. The gauge should read 3.8 - 4.5 MPa
reinstall socket head plug into end of cartridge. (550 - 650 PSI); adjust as required.
3. Remove pressure gauge and reinstall SAE #4 plug.
Procedure M - For Checking Oil Cooler Adjust the oil cooler relief valve in the pump on the side
Circuit Relief Valve Pressure of the engine (Figure 2-16) to 19.0 ± 0.4 MPa (2700 ± 50
PSI). Remove pressure gauge and reconnect the
1. Disconnect pressure hose at the Oil Cooler motor “Inlet” pressure line. If this step needs to be repeated, make
port (Figure 2-16) and attach a pressure gauge. sure pump is Not Hot to touch. If it is, allow to cool
before proceeding.
2. Run the engine at idle (950 RPM), for 5 - 10 seconds
since the flow will be “hot looped”. Check the pressure.
2
1
8 6
In In
7
6699
Oil Cooler and Solenoid Valve
FIGURE 2-16
Table 2-4
2
Valve Usage Table
Valve Name Circuit Used In Physical Location
Boom Lift
Telescope (Floor)
Hydraulic Remote Controllers
Main Hoist Cab Seat Arm Rests (2)
(HRC)
Auxiliary Hoist
Swing
Dual Accumulator Charging Valve Service Brakes Superstructure inside Left Side Plate
Solenoid Valves:
In-line on the Hydraulic Return
Oil Cooler Motor Oil Cooler
Manifold
Superstructure Right Side
Telescope Rod Drain Telescope
In-line on the Hydraulic Reservoir
Outrigger Boost Outrigger
Carrier Inside Right Side Rail
Parking Brake Parking Brake
Carrier Inside Right Side Rail
Axle Disconnect Two/Four Wheel Drive
Superstructure Right Side
Telescope Two Stage Relief Telescope
Carrier Inside Right Side Rail
Cross Axle Differential Lock Differential Lock (Optional)
Hoist Motor Control Valve Hoist(s) Both Hoists (see Hoist section)
Outrigger/Rear
On Rear Face of Carrier Frame Front
Steer/Outrigger Box Pin Outrigger/Rear Steer
Cross Member
Removal Valve
Outrigger Control Manifold Outrigger Inside of Front & Rear Outrigger Box
Axle Lockout Valve Rear Axle Lockout Carrier Left Side Rail
Hose Reel Motor Relief Valve Telescope Hose Reel In-Line at the Hose Reel
4 3 2
6687
6
CARRIER
9
7
8
10
11 12 13 6606
14 5
15
SUPERSTRUCTURE FIGURE 2-17
Counterweight Removal/Cab Tilt Directional Valve Function Check - LMI Lockout Valves
Installation
1. Remove circuit breaker F16 from the power panel in the
1. Place the valve on the turntable and secure it with the cab. This cuts off power to the LMI.
capscrews, flatwashers, nuts and lockwashers. Torque
2. Start the engine.
the capscrews 23 to 25.7 Nm (17 to 19 pounds-foot).
3. Try to telescope the boom out, lower the boom, hoist up
2. Connect the hydraulic lines to the valves as tagged
during removal.
the main hoist, and hoist the auxiliary hoist up (if
installed). Verify none of these functions work.
2
Functional Check (Both Valve Banks) 4. Shut down the engine. Reinstall F16.
1. Start the engine and run it at normal speed. 5. Telescope the boom out, lower the boom, hoist up the
2. Operate the control levers of the valve bank(s). Check main hoist, and hoist the auxiliary hoist up (if installed).
for smooth operation of cylinders and motors. Verify all of these functions work.
3. Check the valve bank(s) and lines for leakage. Make 6. Check for leaks. Make repairs as needed.
repairs as needed.
3 1 2
1A 1B 2A 2B 3
4 2
2500 2500
8 1
PB
2500
PSI
IN OUT
7316
7 7
8 Steer Priority Flow Divider Swing
5 6
PA
6095-3
5
6
FIGURE 2-18
9 7 5 3
1
11
12
18
15
17
13
16
14
8 4 2 6096-1
10 6
9 10 1 2
7 8 5 6 3 4
15 18
17
13
14
12
16
11
6096-2
Hydraulic Schematic
FIGURE 2-19
12
1, 2 11
3, 4
9, 10 5, 6, 7,8
11 10
8
6
4
2
9
7
5
3
1 12
13
9 10 7 8 5 6 3 4 1 2
12
13
11
5 9 2
6 10
8
7
3
10
9
4
5
1 8
4 3 7
6
1 FIGURE 2-21
PRESSURE REDUCING SEQUENCE VALVE 3. Remove the capscrews, lockwashers and flatwashers
WITH SOLENOID CONTROLS MANIFOLD securing the valve. Remove the valve and two spacer
bushings.
Description Installation
The pressure reducing sequence with solenoid controls 1. Position the valve and spacer bushings on the turntable
manifold (Figure 2-22) is located on the outside of the and secure it with the capscrews, flatwashers and
superstructure right hand side plate. It is used to control a lockwashers.
regulated pressure and flow of hydraulic oil to the swing
brake 1723.6 kPa/17.2 bar (250 psi), cab hydraulic remote 2. Connect the hydraulic lines to the valve as tagged during
controllers (HRCs), telescope two stage relief 2757.9 kPa/ removal.
27.5 bar (400 psi), telescope hose reel motor 8273.7 kPa/ 3. Connect the electrical connectors to the valve as tagged
82.7 bar (1200 psi) and hose reel brake 8273.7 kPa/82.7 bar during removal.
(1200 psi). An inlet port contains a 100 mesh screen protects
large contaminates from damaging the cab HRCs. Function Check - Swing Brake Release
The swing brake, HRCs, and hose reel motor are controlled Valve
by a two position three way normally open to tank solenoid
1. Position the SWING BRAKE switch to OFF. Verify the
valve. When energized, pressurized oil is allowed to flow to
LED in the switch goes out.
the respective functions.
2. Swing the turntable to verify the swing brake has
The two position three way swing brake release solenoid
released. Step on the power brake valve to stop the
valve serves as the swing brake release. When de-
turntable.
energized and the SWING BRAKE switch is on, the springs
in the swing brake push oil to the tank allowing each brake to 3. Position the SWING BRAKE switch to ON. Verify the
e n g a g e . W h e n t h e S W I N G B R A K E s w i t c h i s O F F, LED in the switch comes on.
pressurized oil is directed to the swing brakes, releasing
them. 4. Activate swing and ensure the turntable will not rotate,
indicating the swing brake is on.
The HRC two position three way solenoid valve serves as
the controller armrest lockout valve. When the CRANE 5. Check for leaks. Make repairs as needed.
FUNCTION switch is OFF, or the armrest is raised, the valve
is de-energized which prevents pressurized oil from reaching
Function Check - Crane Function Valve
the HRC’s. When the CRANE FUNCTION switch is ON, 1. Turn off the CRANE FUNCTION switch.
pressurized oil is directed to the HRC’s allowing crane
operation. This valve, when de-energized, prevents 2. Start the engine.
accidental turntable, hoist, or boom movement. 3. Try to telescope the boom in and out, lower and raise the
boom, hoist each hoist up and down, and swing the
Maintenance turntable left and right. Verify none of these functions
work.
Removal
4. Turn on the CRANE FUNCTION switch, put the armrest
1. Tag and disconnect the electrical connectors to the
down, and set in the seat.
swing brake and armrest lockout valve.
5. Telescope the boom in and out, lower and raise the
2. Tag and disconnect the hydraulic lines from the valve.
boom, hoist each hoist up and down, and swing the
Cap or plug the lines and ports.
turntable left and right. Verify all of these functions work.
6. Check for leaks. Make repairs as needed.
2 2
4 8
5
7
6
1
10
11
9
11
3
6 7 2
5 4 8
9
10 FIGURE 2-22
1 2
1 2
3
4 6099
5
4 5
6099-1
Hydraulic Schematic
FIGURE 2-23
HYDRAULIC REMOTE CONTROL VALVE 3. Install the plastic cover on the bottom of the armrest.
Secure it with screws, washers and nuts.
Description
Armrest Control Valve Functional Check
The crane has four single axis hydraulic remote control
1. Start the engine and run it at normal speed.
valves (Figure 2-24). Each crane function has a control lever
for the operator’s use. 2. Move each control lever to operate the function
The four hydraulic remote control valves are single function
controlled by the corresponding control valve. Verify
proper operation of the hoist motor, swing motors, lift
2
type valves. Moving the control lever forward or back
cylinder, and telescope cylinder.
operates the selected function. Two valves are located in
each armrest. The valves in the right armrest control the 3. Check valve and lines for leakage. Make repairs as
main hoist and boom lift. The valves in the left armrest needed.
control swing and auxiliary hoist.
Telescope Pedal Control Valve Removal.
The telescope function is controlled by a pedal operated
single function control valve. The pedal is on the cab floor. 1. Disconnect the pedal linkage from the control valve by
The control valve is mounted on the left rear underside of the removing the pin and cotter pin.
cab and is connected to the pedal by linkage. 2. Tag and disconnect the hydraulic lines from the control
When the armrests are up, the crane function switch is off, or valve. Cap or plug the lines and ports.
the operator leaves his seat, the controller lockout valve is 3. Remove the four bolts and washers securing the control
de-energized and the functions are disabled. valve to the mounting bracket. Remove the valve.
Maintenance Telescope Pedal Control Valve Installation
Armrest Control Valve Removal 1. Place the valve on the mounting bracket and secure in
place with the bolts and washers.
1. Gain access to the base of the control valve by raising
the armrest and removing the plastic cover screwed 2. Connect the hydraulic lines to the valve as tagged during
onto the bottom of the armrest. removal.
2. Tag and disconnect the hydraulic lines to the control 3. Connect the pedal linkage to the control valve with the
valve. Cap or plug the lines and ports. pin and cotter pin.
3. Remove the bolts securing the control valve to the Telescope Pedal Control Valve Functional Check
armrest. Remove the control valve.
1. Start the engine and run it at normal speed.
Armrest Control Valve Installation 2. Telescope the boom the whole way out and then the
1. Place the valve on the armrest. Secure the valve to the whole way back in. Verify proper telescoping.
armrest with the attaching bolts. 3. Check valve and lines for leakage. Make repairs as
2. Connect the hydraulic lines to the valve as tagged during needed.
removal.
Swing Telescope or
Aux Hoist
3
4
3 6461-1
1 2 5 6
4
FWD BACK FWD BACK 4
6, 10
2, 8
4
3 6461-2
6461-3
7 8 9 10 FIGURE 2-24
Maintenance DANGER
Engage the swing lock before adjusting the swing brake
Removal valve.
1. Tag and disconnect hydraulic lines attached to the brake
valve. Cap or plug the lines and ports. 4. Test the valve by engaging the swing brake control valve
and operating the swing brake. Verify the swing brake
2. Remove the four bolts, lockwashers, flat washers, and works when the pedal is pressed. Verify the brake is off
nuts which secure the brake valve to the cab floor. when the pedal is not pressed. Engage the swing lock
Remove the brake valve. and make adjustments to the pedal as needed.
Installation 5. Check for leaks. Make repairs as needed.
DANGER
Engage the swing lock before installing the swing brake
valve.
Pressure
From
Pressure
Reducing
Sequence
Valve
To Swing Brake
Drain To
Tank
6100-1
6100
FIGURE 2-25
C1
C1 C2 V1
30
PSI V2
C2
6101-2
V1 V2
Hydraulic Schematic
6101-1
FIGURE 2-26
TANDEM BRAKE VALVE W/ TREADLE The tandem brake valve consists of a tandem valve body, a
PEDAL closed center spool, a treadle pedal, an integral proximity
switch and a mechanical spring assembly to limit the output
Description pressure to the brake actuators to 14,483 ± 517 kPa (2100 ±
75 psi).
The tandem brake valve with treadle pedal (Figure 2-27) is
located on the floor of the cab. The tandem brake valve Maintenance
provides split system braking for the primary (front) brakes
Removal
2
and the secondary (rear) brakes. The valve is a closed
center spool design which modulates the output pressure 1. Tag and disconnect the electrical connector to the valve.
14,483 ± 517 kPa (2100 ± 75 psi) to the brake actuators.
2. Tag and disconnect the hydraulic hoses from the valve.
The valve is mechanically actuated by a treadle pedal. The Cap or plug the lines and ports.
direct acting spool provides a pedal feel which accurately
represents the brake pressure, similar to automotive style 3. Remove the nuts and bolts securing the valve to the cab
pedal feedback as the brake pedal pressure increases, the floor. Remove the valve.
pedal effort increases proportionally.
Installation
As the pedal is initially actuated, the tank ports are closed off
1. Secure the valve to the cab floor with the nuts and bolts.
from the brake ports. With further application of the pedal,
the pressure ports are opened to the brake ports until the 2. Connect the hydraulic hoses to the ports on the valve as
pedal actuation force and the hydraulic pressure force are tagged during removal.
balanced. Also when the pedal is actuated, the integral
proximity switch is engaged to provide an electrical signal for 3. Connect the electrical connector to the valve as tagged
brake lights. When the pedal is released, the valve and the during removal.
pedal return to the non-applied position. In normal operation, 4. Start the engine and check valve and hoses for leaks.
the secondary system is piloted from the primary section Make repairs as needed.
providing pressure to both systems.
1
5
2
5 1
6 6 3
3 4
4
6703
6703-1
FIGURE 2-27
DUAL ACCUMULATOR CHARGE VALVE When the accumulators are charged to the high limit
pressure of 19,000 kPa (2750 psi), pilot pressure will open
Description the high limit check ball and close the low limit check ball.
The inverted shuttle senses the pressure in the
The dual accumulator charge valve (Figure 2-28) is located accumulators and the brake circuits to pilot close the
on the turntable left side, inside the superstructure. The cartridge when the maximum pressure is reached. After the
purpose of the valve is to provide a priority regulated flow accumulators are fully charged, the high limit check ball
dependent on the maximum pressure required to the service opens and the proportional flow divider spool is fully opened
brake circuit and a secondary source of flow for the front to direct all of the pump flow to the excess flow port and on to
steer and swing circuits. The dual accumulator charge valve the air conditioning circuits.
regulates flow to the hydraulic accumulators at a rate of 8.3
to 12.1 l/min (2.2 to 3.2 gpm) to provide stored energy for the Maintenance
primary (front) and the secondary (rear) service brake
circuits. Removal
The dual accumulator charge valve consists of a charging 1. Tag and disconnect the hydraulic hoses from the valve.
section with a proportional flow divided spool and a main Cap or plug the lines and ports.
check valve, a control section with a pilot spool with a low
2. Remove the capscrews, flatwashers and lockwashers
limit check ball and a high limit check ball, and an inverted
securing the valve to the turntable. Remove the valve.
shuttle cartridge.
W h e n t h e v a l v e i s c h a r gi n g t he a c c um u l a to r s , t h e Installation
proportional flow divider spool, in the charging section, is in 1. Position the valve on the turntable and secure with the
neutral to allow the charging flow to pass through the main capscrews, washers and lockwashers.
check valve and on to the pilot control section and the
inverted shuttle cartridge. The pilot control section controls 2. Connect the hydraulic hoses to the valve ports as tagged
the opening and closing of the low and high limit check balls. during removal.
The pilot spool permits only one of these balls to be open at 3. Start the engine and check for leaks. Make repairs as
any one time. When the low limit check ball is open, the needed.
pressure from the accumulators is applied to shift the
charging section flow divider spool and allow pump flow to 4. Depress the brake pedal several times, make several
the inverted shuttle cartridge which is normally open to turns with the steering wheel, and swing the
charge the accumulators. superstructure left and right. Verify the brakes, swing,
and front steering work properly.
4 2
3 2
5
6
5, 6 1
1
6436
FIGURE 2-28
HYDRAULIC ACCUMULATOR SERVICE 3. Remove the two nuts securing each clamp half. Remove
BRAKE the each clamp half and accumulator from the turntable.
Installation
Description
1. Position the accumulator in the clamps and secure with
The service brake hydraulic accumulators are located on the the removable clamp halves and nuts.
outside of the left superstructure side plate behind the cab.
The purpose of each accumulator is to provide stored 2. Connect the hydraulic hose to the port on the
accumulator as tagged during removal.
2
energy, an oil volume of 3.8 liters (231 cu in) at a maximum
pressure of 18,966 kPa (2750 psi), to actuate the service 3. Pre-charge the accumulator. Refer to paragraph titled
brake circuits. The dual accumulator charge valve regulates Pre-Charging Accumulator in Sub-Section titled
flow to the hydraulic accumulators to provide fully powered Hydraulic Pressure Adjustment.
independently separate, primary (front) and secondary
(rear), service brake circuits. 4. Start the engine and check accumulator and hoses for
leaks. Make repairs as needed.
Each accumulator has two chambers divided by a piston.
One side is pre-charged to 9655 kPa (1400 psi) with high 5. Depress the brake pedal several times, make several
purity nitrogen. This maintains a constant pressure in the turns with the steering wheel, and swing the
other chamber which is connected to the modulating brake superstructure left and right. Verify the brakes, swing,
valve. After the accumulators are fully charged, they will and front steering work properly.
provide the necessary brake system flow and pressure to
actuate the brakes. Servicing
The accumulator consists of a tube, piston, seals, gas The pre-charge nitrogen pressure should be checked every
charging valve, and a gas valve guard. 200 hours or once a month, whichever comes first. Refer to
Pressure Setting Procedures
Maintenance
Removal
1. With the engine shutdown, deplete the hydraulic
pressure in the accumulators by depressing the service
brake pedal several times.
2. Tag and disconnect the hydraulic hose from the
accumulator. Cap or plug the line and port.
HYDRAULIC ACCUMULATOR LOAD SENSE 3. Remove the two nuts securing each clamp half. Remove
the each clamp half and accumulator from the turntable.
Description
Installation
The main directional control valve load sense accumulator is
1. Position the accumulator in the clamps and secure with
located on the right hand superstructure side plate beside
the removable clamp halves and nuts.
the main directional control valve. The purpose of the
accumulator is to dampen the load sense signals from the 2. Connect the hydraulic hose to the port on the
cylinders and motors to the inlet unloader. The accumulator accumulator as tagged during removal.
has two chambers divided by a piston. One side is
3. Pre-charge the accumulator. Refer to paragraph titled
precharged to 4,138 kPa (600 psi) with high purity nitrogen
Pre-Charging Accumulator in Sub-Section titled
while the other chamber is connected to the load sense port
Hydraulic Pressure Adjustment.
of the directional valve.
4. Start the engine and check accumulator and hoses for
The accumulator consists of a tube, piston, seals, gas
leaks. Make repairs as needed.
charging valve, and charging valve guard.
5. Depress the brake pedal several times, make several
Maintenance turns with the steering wheel, and swing the
superstructure left and right. Verify the brakes, swing,
Removal and front steering work properly.
1. With the engine shutdown, deplete the hydraulic
Servicing
pressure in the accumulators by depressing the service
brake pedal several times. The pre-charge nitrogen pressure should be checked every
200 hours or once a month, whichever comes first. Refer to
2. Tag and disconnect the hydraulic hose from the
Pressure Setting Procedures
accumulator. Cap or plug the line and port.
The holding valve installed on the outlet of the cylinder 3. Lubricate the holding valve and o-rings with clean
provides meter out control, will lock the cylinder in place, hydraulic oil.
prevents a load from running ahead of the oil supply, and
relieves excess pressure caused by thermal expansion. CAUTION
Do not damage the o-rings during installation of the
Maintenance holding valve. If the holding valve turns freely then gets
hard to turn, then easy to turn, remove the holding valve
and check the o-rings. They have probably been
damaged by a sharp edge of a port.
DANGER
Boom must be fully lowered and fully retracted before NOTE: The holding valve should turn by hand until
removing lift cylinder and telescope cylinder holding compression of the o-rings begins.
valves. The counterweight must be removed or pinned
before removing counterweight removal cylinder holding 4. Carefully install the holding valve into the port block or
valves. manifold until fully seated.
5. Test the holding valve and port block or manifold by
operating the lift cylinder and/or the telescope cylinder,
as applicable. Verify lift cylinder and/or telescope
cylinder works without problems; verify there is no
leaking. Make repairs as needed.
The in-lined plumbed shuttle valve is used as a directional 1. Tag and disconnect hydraulic lines from valve and cap or
selector valve. It is located at the inlet of the telescope rod plug all openings, and remove valve.
drain solenoid valve. It is used to direct the higher trapped
pressure of the rod side telescope cylinders to the telescope Installation
rod drain solenoid valve inlet. 1. Connect the hydraulic lines as tagged during removal.
It consists of a ball that moves between two opposing check 2. Check valve and hydraulic connections for leaks. Make
seats. When one port is pressurized, the ball is forced repairs as needed.
against the opposite seat, blocking that inlet and providing a
flow path to the outlet port.
The cross axle differential lock valve is located on the right 1. Tag and disconnect the electrical connector from the
side of the rear frame. The valve is a three-way, two position valve.
solenoid valve. The valve is used to control the application of 2. Tag and disconnect the hydraulic lines attached to the
the crane’s hydraulically applied and released cross axle valve. Cap or plug lines and ports.
differential lock actuators.
3. Remove the capscrews, flatwashers and nuts securing
Positioning the AXLE DIFF switch to LOCK shifts the three- the valve to the frame. Remove the valve.
way, two-position solenoid valve so hydraulic oil can flow to
the engage port of the cross axle differential lock actuators, Installation
extending them. When the actuators extend, they engage
1. Secure the valve to the frame with the capscrews,
the splines on the differential case and the axle shafts to lock
flatwashers and nuts.
the differential assemblies together.
2. Connect the hydraulic lines to the valve as tagged during
Positioning the AXLE DIFF switch to UNLOCK shifts the
removal.
three-way, two-position solenoid valve so hydraulic oil can
flow to the disengage port of the actuators, retracting them. 3. Connect the electrical connector to the valve as tagged
As the actuators retract, they unlock the axles. during removal.
4. Apply and release the cross axle differential lock several
times. Verify the cross axle differential lock holds the
axle from moving when applied so there is no differential
action between the wheels.
5. Check for leaks. Make repairs as needed.
9
11
10
2 7 12
1 8
2
19, 20
17
6
15, 16
14
13
18
21
22 4
5 7306-2
19 20 15 18
21 11 22
6 12 16
19 20
17
13
7306-2
9 8 7
4 3 10 1
14
FIGURE 2-29
3 4 5
2
7319
5
1 4
6109-1
3
2
1
FIGURE 2-30
PILOT OPERATED CHECK VALVE 3. Lubricate the check valve and o-rings with clean
hydraulic oil.
Description
A pilot operated (PO) check valve is located in each CAUTION
outrigger stabilizer cylinder port block (Figure 2-31). The Do not damage the o-rings during installation of the
check valve functions as a holding valve for the stabilizer holding valve. If the holding valve turns freely then gets
cylinder. Oil flow is directed from the “V” port to the “C” ports,
while blocking flow in the opposite direction. Flow is reversed
hard to turn, then easy to turn, remove the holding valve
and check the o-rings. They have probably been
2
from “C” to “V” when pressure pilot oil is applied to the damaged by a sharp edge of a port.
opposite side “V” port.
NOTE: The check valve should turn by hand until
Maintenance compression of the o-rings begins.
Removal 4. Carefully install the check valve into the port block until
fully seated.
1. Unscrew the check valve from the stabilizer cylinder port
block. 5. Test the check valve and port block by operating the
affected outrigger’s stabilizer cylinder. Verify it extends
Installation and retracts without problems; verify there is no leaking.
Make repairs as needed.
1. Check the inside of the port block for any sharp edges or
burrs and remove as necessary with emery cloth.
2. Install new o-rings onto the check valve.
Cylinder
Pilot 6155
C
V
6155-1
Valve
FIGURE 2-31
PRESSURE BLEED-OFF VALVE shuttle valve acts as a directional selector, allowing only the
pressurized circuit to open to the flow control drain valve.
Description
Maintenance
The pressure bleed-off valve (Figure 2-32) is used to
manually drain to reservoir any trapped pressure from Removal
behind the outrigger box removal quick disconnects or the
1. Tag and disconnect hydraulic lines from valve. Cap or
telescope boom removal quick disconnects.
plug all openings and remove valve.
The in-line plumbed pressure bleed-off valve consists of a
knob adjustable flow control valve and a shuttle valve. The Installation
1. Connect the hydraulic lines as tagged during removal.
1
6110-2
4
Hydraulic Schematic
5
2 7318
FIGURE 2-32
The axle oscillation lockout valve (also called the double 1. Tag and disconnect the electrical connectors to the
solenoid valve) is used in the rear axle oscillation lockout valve.
circuit. The valve is mounted on the right rear face of the 2. Tag and disconnect the hydraulic hoses from the valve.
carrier frame forward of the rear axle. It consists of a valve
body and two normally-closed, two-way, two-position
Cap or plug the lines and ports. 2
solenoid valves. It keeps the lockout cylinders from 3. Remove the capscrews, nuts and washers securing the
oscillating unless the turntable is centered forward. valve to the frame bracket. Remove the valve.
The in-line plumbed direct acting relief valve is installed at 1. Tag and disconnect hydraulic lines from the valve. Cap
the hydraulic hose reel motor. It is used to protect the motor or plug all openings and remove valve.
in case of a pressure surge.
Installation
The valve consists of a manifold and cartridge. When
1. Connect the hydraulic lines as tagged during removal.
pressure at the inlet port exceeds the bias spring force or
setting holding the valve closed, the valve will open, directing 2. Check valve and hydraulic connections for leaks. Make
pressurized oil to the reservoir. repairs as needed.
CYLINDERS Maintenance
General General
This subsection provides descriptive information for all the There must be a gap between the ends of each wear ring
hydraulic cylinders used on this crane. The description of the when it is installed onto the piston (as applicable) or head
cylinder given here is for the cylinder itself. For information (Table 2-5). In addition, each wear ring gap is to be located
as follows: Divide 360 degrees by the number of wear rings
on how the cylinder functions in the individual circuits, refer
to the Description and Operation of that circuit. on the component. The resulting value is the number of 2
degrees each wear ring gap is to be located with respect to
each other.
The approximate wear ring gaps are as follows:
Table 2-5
Wear Ring Gap
Surface Protection For Cylinder Rods 1. Extend the rod to its maximum stroke. Remove the
retract hose from the cylinder. Cap the retract hose.
Steel cylinder rods include a thin layer of chrome plating on
their surfaces to protect them from corroding. However,
chrome plating inherently has cracks in its structure which
can allow moisture to corrode the underlying steel. At typical DANGER
ambient temperatures, hydraulic oil is too thick to penetrate Ensure pressure is applied to the piston side of the
these cracks. Normal hydraulic operating temperatures will cylinder only and the retract hose is capped.
allow hydraulic oil to warm sufficiently to penetrate these
cracks and if machines are operated daily, protect the rods. 2. Apply hydraulic pressure to the piston side of the
Machines that are stored, transported, or used in a corrosive cylinder and observe the open cylinder port for leakage.
environment (high moisture, rain, snow, or coastline If leakage is observed, the seals in the cylinder must be
conditions) need to have the exposed rods protected more replaced.
frequently by applying a protectant. Unless the machine is
operated daily, exposed rod surfaces will corrode. Some 3. Fully retract the cylinder rod (except the telescope
cylinders will have rods exposed even when completely cylinder). Remove the extend hose from the cylinder.
retracted. Assume all cylinders have exposed rods, as Cap the extend hose.
corrosion on the end of the rod can ruin the cylinder.
It is recommended that all exposed cylinder rods be
protected using Boeshield® T-9 Premium Metal Protectant. DANGER
Manitowoc CrareCARE has Boeshield® T-9 Premium Metal Ensure pressure is applied to the retract (rod) side of the
Protectant available in 12 oz. aerosol cans by ordering part cylinder only and the extend hose is capped.
number 9999101803.
4. Apply hydraulic pressure to the retract (rod) side of the
NOTE: Cylinder operation and inclement weather will
cylinder and observe the open cylinder port for leakage.
remove the Boeshield® protectant; therefore,
If leakage is observed, the seals in the cylinder must be
inspect machines once a week and reapply
replaced.
Boeshield® to unprotected rods.
5. Reconnect all cylinder ports.
Leakage Check
A hydraulic cylinder should not be disassembled unless it is
essential. The following checks will provide a means of
determining if a cylinder has a faulty or leaking piston seal.
Temperature Effects on Hydraulic Cylinders the telescope control lever is activated periodically in the
extend position to mitigate the effects of the cooling oil.
Hydraulic oil expands when heated and contracts when
cooled. This is a natural phenomena that happens to all If a load and the boom is allowed to remain stationary for a
liquids. The coefficient of expansion for API Group 1 period of time and the ambient temperature is cooler than the
hydraulic oil is approximately 0.00043 cubic inches per cubic trapped oil temperature, the trapped oil in the cylinders will
inch of volume for 1°F of temperature change. Thermal cool. The load will lower as the telescope cylinder(s) retracts
contraction will allow a cylinder to retract as the allowing the boom to come in. Also, the boom angle will
hydraulic fluid which is trapped in the cylinder cools. decrease as the lift cylinder(s) retracts causing an increase
The change in the length of a cylinder is proportional to the in radius and a decrease in load height.
extended length of the cylinder and to the change in
This situation will also occur in reverse. If a crane is set up in
temperature of the oil in the cylinder. For example, a cylinder
the morning with cool oil and the daytime ambient
extended 25 feet in which the oil cools 60°F would retract
temperature heats the oil, the cylinders will extend in similar
approximately 7 3/4 inches (see chart below). A cylinder
proportions.
extended 5 feet in which the oil cools 60°F would only retract
approximately 1 1/2 inches. The rate at which the oil cools (Table 2-6) has been prepared to assist you in determining
depends on many factors and will be more noticeable with a the approximate amount of retraction/extension that may be
larger difference in oil temperature verses the ambient expected from a hydraulic cylinder as a result of change in
temperature. the temperature of the hydraulic oil inside the cylinder. The
chart is for dry rod cylinders. If the cylinder rod is filled with
Thermal contraction coupled with improper or inadequate
hydraulic oil, the contraction rate is somewhat greater.
lubrication or improper wear pad adjustments and operation
at low boom angles may, under certain conditions, cause a NOTE: Operators and service personnel must be aware
“stick-slip” condition in the boom. This “stick-slip” condition that load movement, as a result of this phenomena,
could result in the load not moving smoothly. Proper boom can be easily mistaken as leaking cylinder seals or
lubrication and wear pad adjustment is important to permit faulty holding valves. If leaking seals or faulty
the boom sections to slide freely. Slow movement, of the holding valves are suspected to be the problem,
boom may be undetected by the operator unless a load is refer to Service Bulletin 98-036 dealing with testing
suspended for a long period of time. To minimize the effects telescope cylinders.
of thermal contraction of “slip stick” it is recommended that
Table 2-6
Length change in inches = Stroke (Ft.) X Temperature Change ( °F) X Coeff. (in3/in3/ °F) X 12 in/ft
LIFT CYLINDER
CAUTION
Description When removing seals and rings, avoid scratching the
grooved and gland surfaces.
The lift cylinder has a bore of 35.56 cm (14.0 inches)
(Figure 2-34). The retracted length of the cylinder from the 6. Remove the two hydrolock seals from the outside of the
center of the barrel bushing to the center of the rod bushing piston.
is 494.2 cm (194.6 inches). Its stroke is 390.6 cm (153.8
inches). A wiper ring prevents foreign material from entering NOTE: Arranging discarded seals and rings in the order of 2
the cylinder. O-rings and other seals prevent internal and disassembly will aid in installation of new seals and
external leakage. rings. Pay attention to how each seal and ring is
installed to avoid installing replacement seals and
The cylinder weighs approximately 1766 kg (3893 pounds). rings improperly.
NOTE: Cover the barrel opening to avoid contamination. 5. Stone out minor blemishes and polish with a fine crocus
cloth.
CAUTION 6. Clean with solvent and dry with compressed air any
Do not damage the o-rings during installation of the parts that have been stoned and polished.
holding valve. If the holding valve turns freely then gets
hard to turn, then easy to turn, remove the holding valve
and check the o-rings. They have probably been
damaged by a sharp edge of a port.
11
9
10
11
8
12
13
16, 17
18
15
14
3, 4 20
23, 26
2, 3
21
18 5
6 19
23
7
27 24
22
24
23, 25, 26
7277
FIGURE 2-34
Item Description
Wiper Ring
1 Barrel
2 Rod
3 Piston
4 Setscrew
Buffer Seal
2
5 Piston Seal Deep Z Seal Back-Up Ring
6 T-Seal FIGURE 2-35
7 Spacer
3. Install the replacement wear rings, buffer seal, deep Z
8 Cylinder Head rod seal, backup ring, and wiper ring (Figure 2-35) in the
9 O-ring inside of the head. Make sure the buffer seal’s step is
closer to the deep Z rod seal. Make sure the deep Z rod
10 Backup Ring seal’s rim groove is closer to the buffer seal.
11 Wear Ring 4. Install the replacement o-ring and the backup ring on the
12 Buffer Seal Assembly outside of the head.
13 Rod Seal 5. Install the replacement T-seal in the inside of the piston.
14 Backup Ring 6. Lubricate the rod with clean hydraulic oil.
15 Wiper Ring 7. Slide the head, wiper ring end first, onto the rod.
16 Retainer Ring 8. Screw the piston onto the rod tightly. Secure the piston
17 Insert with the set screw.
18 Socket Head Capscrew
Hydrolock Piston Seals
19 Holding Valve
20 Capscrew
21 Flatwasher
22 Tube Assembly
23 Plug
24 Adapter FIGURE 2-36
25 Plug 9. Install the replacement hydrolock seals (Figure 2-36) on
26 Plug the outside of the piston. Make sure the “vees” on the
two hydrolock seals point at each other.
27 Grease Fitting
10. Lubricate all parts freely with clean hydraulic oil.
Assembly
CAUTION
CAUTION Exercise extreme care when handling the rod. Damage to
When installing new seals and rings, avoid stretching the rod surface may cause unnecessary maintenance
seals or scratching the grooved or gland surfaces. Make and expense. Also, take care to avoid damaging grooved
sure parts are clean before and during assembly. Make or gland surfaces or rings or seals during rod insertion.
sure seals and rings are installed in the proper order.
11. Remove the cover from the barrel. Insert the rod and
NOTE: Lubricate seals and rings with clean hydraulic oil. attached parts into the barrel with a slight twisting
motion.
1. Install head retainer ring on rod.
12. Install new gasket material to the cylinder head retainer
2. Install two new threaded inserts into head. ring flange as follows.
a. Clean the barrel and retainer ring with Loctite 14. Using a spanner wrench or chain wrench, continue to
cleaning solvent 7070 or similar non-chlorinated screw the retainer ring/head into place in the barrel.
solvent.
b. Apply a light coating of Loctite primer N7649 to both CAUTION
surfaces. Allow primer to dry for one to two minutes. Do not use air pressure to cycle or pressurize the cylinder.
Primer must be dry. Mating of parts should occur
within five minutes. 15. Position the holding valve on the cylinder barrel and
c. Apply gasket material Loctite Master Gasket 518 to secure with the capscrews and flatwashers. Connect
one surface. Partial cure is obtained in four hours, tubing to holding valve.
with full cure in 48 hours. 16. Pressurize and cycle the cylinder with hydraulic oil
13. Screw the head retainer ring into the barrel and align pressure. Test the cylinder at 31026 kPa/31.0 bar (4500
holes in retainer ring with holes in head. Install two psi). Check for proper operation and any leakage. Make
socket head capscrews.Torque the capscrews 59.6 to repairs as needed.
65 Nm (44 to 48 pounds-foot). Re-torque after
completion of cylinder hydraulic test procedure.
Maintenance
DANGER
Disassembly Do not use air pressure to remove the cylinder rod
NOTE: Any maintenance requiring disassembly of the assembly. Use only a source of controlled hydraulic oil
cylinder should include replacement of all cylinder pressure if the rod is hard to move.
seals and o-rings.
1. Using a spanner wrench, unscrew the outer cylinder CAUTION
head from the cylinder barrel. Exercise extreme care when handling or setting down the
cylinder rod. Do not damage the chrome surface.
DANGER 10. Remove the inner cylinder rod assembly from the outer
cylinder rod and cover the opening to avoid
Do not use air pressure to remove the rod. Use only a
contamination.
source of controlled hydraulic oil pressure if the rod is
hard to move. 11. Remove the hydrolock piston seal to gain access to the
setscrew securing the piston to the inner cylinder rod.
CAUTION 12. Remove the setscrew and unscrew the piston from the
cylinder rod.
Exercise extreme care when handling or setting down the
cylinder rod. Do not damage the chrome surface. 13. Remove the remaining hydrolock seal from the outside
of the piston and the o-ring and two backup rings from
2. Remove the cylinder rod assembly from the cylinder the cylinder rod
barrel and cover the barrel to avoid contamination.
14. Remove the spacer from the rod and remove the wear
ring from the spacer.
15. Remove the cylinder head from the inner rod.
16. Remove the o-ring and backup ring from the outside of
the head and the wear rings, buffer seal, deep Z rod
CAUTION
seal, and the wiper ring from the inside of the head.
Improper seal installation can cause faulty cylinder
17. If necessary, remove the holding valve from the inner operation.
cylinder rod and from the cylinder barrel.
4. Install the buffer seal and deep Z rod seal inside the
Inspection head ensuring the seals are assembled properly and
1. Clean all parts with solvent and dry with compressed air. installed in the correct direction.
Inspect for damaged or worn parts and replace as 5. Install the o-ring and backup ring onto the outside of the
required. head.
6. Install the inner cylinder head onto the inner cylinder rod.
CAUTION
Clean all surfaces and remove all burrs and nicks before 7. Install the wear ring onto the spacer and install the
installing new seals and rings. Replace all damaged or spacer onto the rod.
worn parts. 8. Install the o-ring and backup rings onto the rod and
install the piston onto the inner cylinder rod. Secure the
2. Stone out minor blemishes and polish with fine crocus piston in place with the setscrew.
cloth.
3. Clean all with solvent and dry with compressed air any Hydrolock Piston Seals
parts that have been stoned and polished.
4. Inspect the barrel for scoring.
Assembly
1. If removed, install the holding valves. Refer to HOLDING
VALVES in this section.
FIGURE 2-38
CAUTION
When installing new seals and rings, clean all surfaces 9. Install the hydrolock seals onto the piston. Refer to
and carefully remove burrs and nicks. Parts displaying (Figure 2-38) for proper seal orientation.
excessive wear or damage should be replaced.
CAUTION
NOTE: Lubricate new seals and rings with clean hydraulic
Avoid scratching or damaging the grooved and gland
oil.
surfaces or the seals and rings.
NOTE: Locate the gap of wear ring 180 degrees with
respect to each other. 10. Lubricate the inner cylinder rod assembly with clean
hydraulic oil and install the rod assembly into the outer
2. Install the wiper ring into the cylinder head.
cylinder rod with a slight twisting motion.
3. Install the wear rings into the head.
11. Using a spanner wrench, secure the inner cylinder head
to the outer cylinder rod.
Wiper Ring 12. Install the wiper ring into the outer cylinder head.
13. Install the wear rings into the head.
Buffer Seal
Deep Z Seal Back-Up Ring
FIGURE 2-37
33
36
2
16
32
31
30
26
29
26
25
28
27 14
26
24
23
22
18
21
18
17 10
15
20
19 13
12
18 11
3, 8
11
7
5 6
4
2, 3
9
4 7279
33
1
36
FIGURE 2-39
15 Spacer
16 Inner Rod
17 Outer Cylinder head
18 Wear Ring
19 O-ring FIGURE 2-40
20 Backup Ring
19. Install the hydrolock seals onto the piston. Refer to
21 Buffer Seal (Figure 2-40) for proper seal orientation.
22 Rod Seal
23 Backup Ring CAUTION
Avoid scratching or damaging the grooved or gland
24 Wiper Ring surfaces or the ring and seals.
25 Inner Cylinder Head
20. Lubricate the outer cylinder rod assembly with clean
26 Wear Ring
hydraulic oil and install the rod assembly into the
27 O-ring cylinder barrel with a slight twisting motion.
28 Backup Ring 21. Using a spanner wrench, secure the outer cylinder head
29 Buffer Seal to the cylinder barrel.
30 Rod Seal
31 Backup RIng
DANGER
32 Wiper Ring Do not use air pressure to cycle or pressurize the cylinder.
33 Counterbalance Valve
22. Pressurize and cycle the cylinder with hydraulic oil
34 Adapter
pressure. Test pressure should be 36197.4 kPa/361.9
bar (5250 psi) (rod side pressure) and 24131.6 kPa/
241.3 bar (3500 psi) extended (piston side pressure).
Check for proper operation and any leakage.
DANGER 3. Clean with solvent and dry with compressed air parts
Do not use air pressure to remove the cylinder rod. Use that have been stoned and polished.
only controlled hydraulic pressure. 4. Inspect the barrel for scoring.
Assembly
CAUTION
1. If removed, install the holding valve. Refer to VALVES in
Do not damage the cylinder rod chrome surface.
this section.
2. Remove the cylinder rod assembly from the cylinder
barrel and cover the barrel to avoid contamination. CAUTION
Do not scratch the grooved and gland surfaces or
CAUTION damage the seals and o-rings.
Do not scratch the grooved and gland surfaces.
NOTE: Lubricate new seals and rings with clean hydraulic
oil. Orient wear ring gaps 180° apart.
NOTE: Align old seals in order of removal to facilitate
installation of new seals. 2. Install the wiper ring and wear ring on the inside of the
cylinder head.
3. Remove the guide lock ring at the top of the piston to
gain access to the setscrew securing the piston to the 3. Install the buffer seal assembly and deep Z rod seal
cylinder rod. inside the head. Make sure the seals are properly
assembled and installed in the correct direction.
4. Remove the set screw and discard.
8
19, 20
18
17
16 15
14
13
9
10
12
11
6
5
6
4
2, 3
7278
FIGURE 2-41
2
Buffer Seal Deep Z Rod Seal
FIGURE 2-43
FIGURE 2-42
4. Install the low temperature o-ring and backup rings onto CAUTION
the outside of the head. Do not scratch the grooved and gland surfaces or
5. Install the cylinder head onto the cylinder rod. damage the seals and o-rings.
6. Install the spacer onto the cylinder rod. 10. Clean all oil from the threads of the cylinder head and
apply Loctite #290 to the threads.
CAUTION 11. Lubricate the piston seals and cylinder head o-ring with
Improper seal installation could cause faulty cylinder clean hydraulic oil and install the rod assembly into the
operation. cylinder barrel with a slight twisting motion.
12. Using a chain wrench, secure the cylinder head to the
7. Install the o-ring and backup rings into the inside of the
cylinder barrel.
piston.
NOTE: Use a new self-locking soft-tip setscrew.
8. Screw the piston onto cylinder rod and secure with a DANGER
new setscrew. Do not use air pressure to cycle the cylinder. Use only
9. Install the guide lock rings and hydrolock seals onto the controlled hydraulic pressure.
outside of the piston. Refer to (Figure 2-43).
13. Pressurize and cycle the cylinder with hydraulic oil
pressure. Test the cylinder at 36197.4 kPa/36.1 bar
(5250 psi) retracted (rod side pressure) or 25855.3 kPa/
25.8 bar (3750 psi) extended (piston side pressure).
Check for proper operation and any leakage. Make
repairs as needed.
AXLE OSCILLATION LOCKOUT CYLINDER rings. Pay attention to how each seal and ring is
installed to avoid installing replacement seals and
Description rings improperly.
The two oscillation lockout cylinders (Figure 2-44) each have 4. Remove the head from the rod. Remove the o-ring and
177.8 mm (7 inch) diameter bores. The retracted length of backup ring from the outside of the head. Remove the
each cylinder is 671.6 mm (26.31 inches) from the center of wear rings, seal and wiper ring from the inside of the
the lug holes to the center of the barrel bushing. The head.
extended length of each cylinder from the center of the lug
Inspection
holes to the center of the barrel bushing is 866.1 mm (34
inches). Its stroke is 193.5 mm (7.62 inches). A wiper ring 1. Clean all parts with solvent and dry with compressed air.
prevents foreign material from entering each cylinder. O- Inspect all parts for serviceability.
rings and other seals prevent internal and external leakage.
2. Inspect the barrel carefully for scoring. If barrel is
The cylinder weighs approximately 87.1 kg (192.0 pounds). scored, it must be repaired or replaced.
DANGER 5. Stone out minor blemishes and polish with a fine crocus
Do not use air pressure to remove the rod. Use only a cloth.
source of controlled hydraulic oil pressure if the rod is
hard to remove. 6. Clean with solvent and dry with compressed air any
parts that have been stoned and polished.
CAUTION Assembly
Exercise extreme care when handling or setting down the
rod. Do not damage the chrome surface. CAUTION
When installing new seals and rings, avoid stretching
2. Remove the rod and attached parts from the barrel. seals or scratching the grooved or gland surfaces. Make
sure parts are clean before and during assembly. Make
NOTE: Cover the barrel opening to avoid contamination.
sure seals and rings are installed in the proper order.
CAUTION
When removing seals and rings, avoid scratching the NOTE: Lubricate seals and rings with clean hydraulic oil.
grooved and gland surfaces. 1. Install the replacement wiper ring, wear rings, and seal,
in the inside of the head.
3. Remove the seal and wear rings from the outside of the
2. Install the replacement o-ring and the backup ring on the
piston.
outside of the head.
NOTE: Arranging discarded seals and rings in the order of
3. Lubricate the rod with clean hydraulic oil.
disassembly will aid in installation of new seals and
15 10 4
13 12 10
2
1 5
11, 14
1
7
17
9
18
9
9
13
8
6
2
3 16
6705
FIGURE 2-44
4. Install the replacement seal and wear ring on the outside 8. Clean all oil from the threads of the head. Coat the
of the piston. threads with an anti-seize compound (ex: Never-Seez
paste lubricant or similar lubricant). Screw the head into
5. Slide the head onto the rod.
place on the barrel tightly so it holds the head’s larger
6. Lubricate freely all parts with clean hydraulic oil. OD end flush with the end of the barrel.
CAUTION CAUTION
Exercise extreme care when handling the rod. Damage to Do not use air pressure to cycle or pressurize the cylinder.
the rod surface may cause unnecessary maintenance
and expense. Also, take care to avoid damaging grooved 9. Pressurize and cycle the cylinder with hydraulic oil
or gland surfaces or rings or seals during rod insertion. pressure. Test the cylinder at 25855.3 kPa/25.8 bar
(3750 psi). Check for proper operation and any leakage.
7. Remove the cover from the barrel. Insert the rod and Make repairs as needed.
attached parts into the barrel with a slight twisting
motion.
STEER CYLINDER NOTE: Arranging discarded seals and rings in the order of
disassembly will aid in installation of new seals and
Description rings. Pay attention to how each seal and ring is
installed to avoid installing replacement seals and
The steer cylinders (Figure 2-45) are mounted on the axles, rings improperly.
two cylinders on each axle.
5. Loosen and remove the nut securing the piston.
The front and rear steer cylinders each have 8.89 cm (3.5
inch) diameter bores. The front and rear steer cylinders each
Remove the piston from the rod.
2
have a retracted length of 711.2 mm (28 inches) from 6. Remove the o-ring from the inside of the piston.
bushing center to bushing center. The front and rear steer 7. Remove the head from the rod.
cylinders each have an extended length of 1073.2 mm
(42.25 inches) from bushing center to bushing center. Each 8. Remove the o-ring and backup ring from the outside of
cylinder has a stroke of 362 mm (14.25 inches). the head and the wiper ring and rod seal from the inside
of the head.
A wiper ring prevents foreign material from entering each
cylinder. O-rings and other seals prevent internal and Inspection
external leakage.
1. Clean all parts with solvent and dry with compressed air.
The cylinder weighs approximately 20 kg (40 pounds). Inspect all parts for serviceability.
Assembly
CAUTION
Exercise extreme care when handling or setting down the CAUTION
rod. Damage to the rod surface may cause unnecessary When installing new seals and rings, avoid stretching
maintenance and expense. seals or scratching the grooved or gland surfaces. Make
sure parts are clean before and during assembly. Make
3. Remove rod and attached parts from the barrel. sure seals and rings are installed in the proper order.
NOTE: Cover the barrel opening to avoid contamination.
NOTE: Lubricate seals and rings with clean hydraulic oil.
1. Install the replacement wiper ring and rod seal in the
CAUTION inside of the head. Make sure the lips of the seal face the
When removing seals and rings, avoid scratching the piston.
grooved and gland surfaces.
2. Install the replacement o-ring and the backup ring on the
4. Remove the seal and two wear ring from the outside of outside of the head.
the piston.
6
9
8
4
10
7 5
11
13
12
14, 15
2
7276
FIGURE 2-45
3. Install the replacement o-ring in the inside of the piston. 9. Remove the cover from the barrel. Insert the rod and
attached parts into the barrel with a slight twisting
4. Lubricate the rod with clean hydraulic oil.
motion.
5. Slide the head, larger OD end first, onto the rod.
10. Thread the head into the barrel and using a spanner
6. Install the piston onto the rod. Secure the piston with the wrench or chain wrench, tighten the head.
nut.
7. Install the replacement piston seal and wear ring on the CAUTION 2
outside of the piston. Do not use air pressure to cycle or pressurize the cylinder.
8. Lubricate all parts freely with clean hydraulic oil.
11. Pressurize and cycle the cylinder with hydraulic oil
pressure. Static pressure test the cylinder at 24131.6
CAUTION kPa/24.1 bar (3500 psi). Check for proper operation and
Exercise extreme care when handling the rod. Damage to any leakage. Make repairs as needed.
the rod surface may cause unnecessary maintenance
and expense. Also, take care to avoid damaging grooved
or gland surfaces or rings or seals during rod insertion.
OUTRIGGER EXTENSION CYLINDER rings. Pay attention to how each seal and ring is
installed to avoid installing replacement seals and
Description rings improperly.
The four extension cylinders have 63.5 mm (2.5-inch) 3. Remove the head from the rod.
diameter bores. 4. Remove the o-ring and backup ring from the outside of
Each cylinder (Figure 2-46) has a retracted length of 2765.5 the head and the wear ring, rod seal and wiper ring from
mm (108.88 inches) from the center of the rod bushing to the the inside of the head.
center of the barrel bushing. Each cylinder’s extended length
Inspection
is 5229.3 mm (205.9 inches). The stroke of each cylinder is
177.8 mm (97 inches). 1. Clean all parts with solvent and dry with compressed air.
Inspect all parts for serviceability.
A wiper ring prevents foreign material from entering each
cylinder. O-rings and other seals prevent internal and 2. Inspect the barrel carefully for scoring. If barrel is
external leakage. scored, it must be repaired or replaced.
The cylinder weighs approximately 47.6 kg (104.9 pounds). 3. Check rod’s piston area for damage. If it is damaged,
determine if it can be repaired or must be replaced.
Maintenance
4. Inspect rod for straightness. Determine if it can be
Disassembly straightened or must be replaced.
DANGER 5. Stone out minor blemishes and polish with a fine crocus
Do not use air pressure to remove the rod. Use only a cloth.
source of controlled hydraulic oil pressure if the rod is
6. Clean with solvent and dry with compressed air any
hard to remove.
parts that have been stoned and polished.
Assembly
DANGER
Exercise extreme care when handling or setting down the CAUTION
rod. Damage to the rod surface may cause unnecessary When installing new seals and rings, avoid stretching
maintenance and expense. seals or scratching the grooved or gland surfaces. Make
sure parts are clean before and during assembly. Make
1. Rapidly pull the rod against the head to free it. Remove sure seals and rings are installed in the proper order.
rod and attached parts from the barrel.
NOTE: Lubricate seals and rings with clean hydraulic oil.
NOTE: Cover the barrel opening to avoid contamination.
1. Install the replacement wear ring, rod seal and wiper ring
in the inside of the head. Make sure the rod seal’s rim
CAUTION groove is closer to the wear ring.
When removing seals and rings, avoid scratching the
2. Install the replacement o-ring and the backup ring on the
grooved and gland surfaces.
outside of the head.
2. Remove the wear rings and piston seal from the outside 3. Lubricate the rod with clean hydraulic oil.
of the piston.
4. Slide the head, wear ring end first, onto the rod.
NOTE: Arranging discarded seals and rings in the order of
disassembly will aid in installation of new seals and
8 2
7
8
5
10
14 11
12
13
7282
4
FIGURE 2-46
5. Install the replacement wear rings and seal on the 7. Remove the cover from the barrel. Insert the rod and
outside of the piston. attached parts into the barrel with a slight twisting
motion.
6. Lubricate all parts freely with clean hydraulic oil.
8. Push the head into the barrel.
CAUTION
Exercise extreme care when handling the rod. Damage to
CAUTION
the rod surface may cause unnecessary maintenance Do not use air pressure to cycle or pressurize the cylinder.
and expense. Also, take care to avoid damaging grooved
or gland surfaces or rings or seals during rod insertion. 9. Pressurize and cycle the cylinder with hydraulic oil
pressure. Static pressure test the cylinder at 20684 kPa/
20.6 bar (3000 psi). Check for proper operation and any
leakage. Make repairs as needed.
NOTE: Any maintenance requiring disassembly of the 10. Remove the o-ring and the backup ring from the outside
cylinders should include replacement of all seals of the head and the two wear rings, buffer seal, rod seal
and rings. A seal kit will supply the required items. and wiper ring from the inside of the head.
18
21, 22
7, 8 5
19
20
19
4 16
15
17
3
12
14
13
2
9
11. Remove the cover from the barrel. Insert the rod and
attached parts into the barrel with a slight twisting
motion.
Buffer Seal 12. Clean all oil from the threads of the head. Coat the
Wiper Ring
threads with an anti-seize compound (Never-Seez paste
Deep Z Rod Seal
lubricant or similar lubricant). Using a chain wrench,
FIGURE 2-48 screw the head into place on the barrel so its larger OD
end is flush with the end of the barrel.
1. Install the replacement wear rings, buffer seal, rod seal
13. Check the inside of the port block for any sharp edges or
and wiper ring in the inside of the head (Figure 2-48).
burrs and remove as necessary with emery cloth.
Make sure the buffer seal’s step is away from the wear
rings. Make sure the deep Z rod seal rim groove is closer 14. Install new o-rings onto the check valve.
to the wear rings.
15. Lubricate the check valve and o-rings with clean
2. Install the replacement o-ring and the backup ring on the hydraulic oil.
outside of the head.
3. Install the replacement o-ring and backup rings in the CAUTION
inside of the piston. Do not damage the o-rings during installation of the check
valve. If the check valve turns freely then gets hard to turn,
Hydrolock Piston Seals then easy to turn, remove the check valve and check the
o-rings. They have probably been damaged by a sharp
edge of a port.
TILT CYLINDER
Description CAUTION
When removing seals and rings, avoid scratching the
The tilt cylinder (Figure 2-50) installed beneath the cab has a grooved and gland surfaces.
6.3 cm (2.5 inch) diameter bores.
The cylinder has a retracted length of 53.1cm (20.94 inches) 7. Remove the seal from the outside of the piston.
and an extended length of 74.1cm (29.19 inches from
NOTE: Arranging discarded seals and rings in the order of
bushing center to bushing center. Each cylinder has a stroke
disassembly will aid in installation of new seals and
of 20.9 cm (8.25 inches).
rings. Pay attention to how each seal and ring is
A wiper ring prevents foreign material from entering each installed to avoid installing replacement seals and
cylinder. O-rings and other seals prevent internal and rings improperly.
external leakage.
8. Loosen and remove the nut securing the piston.
The cylinder weighs approximately 9.07 kg (19.9 pounds). Remove the piston from the rod.
9. Remove the o-ring from the inside of the piston.
Maintenance
10. Remove the head from the rod.
Disassembly 11. Remove the o-ring and backup ring from the outside of
NOTE: Any maintenance requiring disassembly of the the head. Remove the wiper ring and the rod seal from
cylinders should include replacement of all seals the inside of the head.
and rings. A seal kit will supply the required items.
Inspection
1. Secure the cylinder in a clean work area by use of
clamps or a chain vise to prevent rolling. 1. Clean all parts with solvent and dry with compressed air.
Inspect for damaged or worn parts and replace as
2. Retract the cylinder fully to avoid damaging the rod
required.
during removal.
NOTE: Mark or note the piston and head relationship to the
rod and barrel. CAUTION
Clean all surfaces and remove all burrs and nicks before
3. Clean away all dirt from the head. Place protective
installing new seals and rings. Replace all damaged or
padding around the rod near the head to prevent
worn parts.
damaging the chrome during head removal.
2. Stone out minor blemishes and polish with fine crocus
cloth.
DANGER 3. Clean all with solvent and dry with compressed air any
Do not use air pressure to remove the rod. Use only a parts that have been stoned and polished.
source of controlled hydraulic oil pressure if the rod is 4. Inspect the barrel for scoring.
hard to move.
CAUTION Assembly
Exercise extreme care when handling or setting down the
rod. Damage to the rod surface may cause unnecessary
maintenance and expense. CAUTION
When installing new seals and rings, clean all surfaces
4. Position the rod mount with the ports facing down. and carefully remove burrs and nicks. Parts displaying
5. Using a means of collecting the oil, remove the port excessive wear or damage should be replaced.
plugs and allow cylinder to drain.
NOTE: Lubricate new seals and rings with clean hydraulic
6. Rapidly pull the rod against the head to free it. Remove oil.
rod and attached parts from the barrel. Place the rod on
a surface that will not damage the chrome or allow the 1. Install the replacement wiper ring into the head.
rod assembly to drop. 2. Install the rod seal in the inside of the head. Make sure
NOTE: Cover the barrel opening to avoid contamination. the lips of the seal face the piston.
5 6 8
10 11
6722
FIGURE 2-50
3. Install the o-ring and backup ring onto the outside of the 10. Remove the cover from the barrel. Insert the rod and
head. attached parts into the barrel with a slight twisting
motion.
4. Install the o-ring in the inside of the piston.
11. Push the head into the barrel. Torque the head 27.1 Nm
5. Lubricate the rod with clean hydraulic oil.
(20 pounds-foot).
6. Slide the head, larger OD end first, onto the rod.
7. Install the piston onto the rod. Secure the piston with the CAUTION
nut. Lubricate the threads and torque the nut to 176.2 ±
Do not use air pressure to cycle or pressurize the cylinder.
6.7 Nm (130 ± 5 pounds-foot).
8. Install the seal on the outside of the piston. 12. Pressurize and cycle the cylinder with hydraulic oil
pressure. Static pressure test the cylinder at 20,684 kPa/
9. Lubricate all parts freely with clean hydraulic oil.
206.8 bar (3000 psi). Check for proper operation and
any leakage. Make repairs as needed.
CAUTION
Exercise extreme care when handling the rod. Damage to
the rod surface may cause unnecessary maintenance
and expense. Also, take care to avoid damaging grooved
or gland surfaces or rings or seals during rod insertion.
NOTE: Any maintenance requiring disassembly of the 12. Remove the head from the rod.
cylinders should include replacement of all seals 13. Remove the o-ring, backup ring and wire wrap from the
and rings. A seal kit will supply the required items. outside of the head.
1. Secure the cylinder in a clean work area by use of 14. Remove the wiper ring and rod seal from the inside of
clamps or a chain vise to prevent rolling. the head.
2. Retract the cylinder fully to avoid damaging the rod
during removal. Inspection
NOTE: Mark or note the piston and head relationship to the 1. Clean all parts with solvent and dry with compressed air.
rod and barrel. Inspect for damaged or worn parts and replace as
required.
3. Clean away all dirt from the head. Place protective
padding around the rod near the head to prevent
damaging the chrome during head removal. CAUTION
Clean all surfaces and remove all burrs and nicks before
installing new seals and rings. Replace all damaged or
worn parts.
DANGER
Do not use air pressure to remove the rod. Use only a 2. Stone out minor blemishes and polish with fine crocus
source of controlled hydraulic oil pressure if the rod is cloth.
hard to move.
3. Clean all with solvent and dry with compressed air any
CAUTION parts that have been stoned and polished.
Exercise extreme care when handling or setting down the
rod. Damage to the rod surface may cause unnecessary 4. Inspect the barrel for scoring.
maintenance and expense.
Assembly
4. Position the rod mount with the ports facing down.
5. Using a means of collecting the oil, remove the port
plugs and allow cylinder to drain.
CAUTION
When installing new seals and rings, clean all surfaces
6. Remove the setscrew from the flange. and carefully remove burrs and nicks. Parts displaying
7. Remove rod assembly and attached parts from the excessive wear or damage should be replaced.
barrel. Place the rod on a surface that will not damage
the chrome or allow the rod assembly to drop. NOTE: Lubricate new seals and rings with clean hydraulic
oil.
NOTE: Cover the barrel opening to avoid contamination.
13
8 14
5
10
11
6
15
9
12 16
11
7280
FIGURE 2-51
1. Install the replacement wiper ring and rod seal into the
inside of the head.
CAUTION
2. Install the o-ring, backup ring and wire wrap on the
outside of the head. Exercise extreme care when handling the rod. Damage to
the rod surface may cause unnecessary maintenance
3. Install the o-ring in the inside of the piston. and expense. Also, take care to avoid damaging grooved
or gland surfaces or rings or seals during rod insertion.
4. Lubricate the rod with clean hydraulic oil.
2
5. Install the head onto the rod. Torque to 271.1 ± 27.1 Nm 10. Remove the cover from the barrel. Insert the rod and
(200 ± 20 pounds-foot). attached parts into the barrel with a slight twisting
motion.
6. Install the piston onto the rod. Secure the piston with the
nut. Lubricate the threads and torque the nut to 332.1 ±
20.3 Nm (245 ± 15 pounds-foot).
CAUTION
7. Install the seal and wear rings on the outside of the Do not use air pressure to cycle or pressurize the cylinder.
piston.
8. Lubricate all parts freely with clean hydraulic oil. 11. Pressurize and cycle the cylinder with hydraulic oil
pressure. Static pressure test the cylinder at 15,513 kPa/
9. Apply 1/8 bead of Loctite thread adhesive #277 or 15.5 bar (2250 psi). Check for proper operation and any
equivalent across the length of the threads on the rod leakage. Make repairs as needed.
end side of the rod. Install the rod end on the rod and
torque 508.4 to 610.1 Nm (375 to 450 pounds-foot).
PARK BRAKE CYLINDER hydraulic force from the cylinder’s piston. This allows the
cylinder’s spring to extend, retracting the cylinder lever, and
Description applying the park brake to hold the crane in place. When the
operator positions the PARK BRAKE switch to OFF, the park
The park brake cylinder, mounted on the front axle, releases brake solenoid valve energizes and opens the valve to apply
and applies the park brake. The park brake cylinder consists hydraulic force to the cylinder’s piston. This allows the piston
of a hydraulic cylinder and a lever. When the operator to compress the spring, extend the cylinder lever, and
positions the PARK BRAKE switch to ON, the park brake release the park brake.
solenoid valve de-energizes and closes the valve, removing
GROVE 3-i
ELECTRIC SYSTEM RT9130E SERVICE MANUAL
3-ii
RT9130E SERVICE MANUAL ELECTRICAL SYSTEM
SECTION 3
ELECTRICAL SYSTEM
DESCRIPTION Batteries
General The batteries (Figure 3-2) are located in a box on the left side
of the crane behind the fuel tank. Each battery is the
The electrical system is 12-volt operation with 12-volt maintenance free type and is completely sealed except for a
starting, consisting of an alternator and two lead-acid small vent hole in the side. The vent hole allows what small
batteries. The system is the single wire ground return type, amount of gases that are produced in the battery to escape.
using the machine’s structure as ground. On some batteries, a test indicator located on the top of the
battery is used to determine if the battery can be tested in
Electrical power is transferred to and from the carrier and
superstructure through the electrical swivel. For more
case of a starting problem. 3
detailed information on the electrical swivel, refer to Section
6- SWING SYSTEM.
The superstructure control module is located behind the front
console in the cab and the carrier control module is located
near the hydraulic oil tank.
Alternator
The alternator (Figure 3-1) is mounted on the engine and is
belt driven. It is a 130 ampere alternator with an integral
transformer - rectifier unit. When the engine is running, and
the alternator is turning, the alternator’s 12-volt output
terminal supplies the crane’s electrical circuits. The output
terminal also supplies the voltage to recharge the batteries
and maintains them at a full state of charge.
FIGURE 3-2
FIGURE 3-1
7010-1
FIGURE 3-3
For a machine with the retarder option, there is a second pair Fuse Amp Fuse Assignment
of batteries installed in a box on the left side of the crane
ahead of the fuel tank. 9 10 Windshield Wiper/Washer
Beacon Light, Drive Select,
Fuse Panel 10 5
Differential Lock, and Park Brake
Most electrical circuits are protected by the components of Cab Circulation Fan and Skylight
the relay panel assembly and the fuse panel. 11 7.5
Wiper
The fuse panel (Figure 3-4) is located in front of the pin type 12 5 Defroster Fan
swing lock control tee handle and contains up to 20 fuses. To
13 7.5 Swing Speed Solenoid
gain access to the fuses, remove the snap-on cover. A decal
in the cover identities each fuse and its function. Indicator Lamps, Buzzer, Gauges,
14 10 Drive Enable, Outriggers, Rear
Fuses 1, 2, 3, 4, 5, 6, 7 and 8 are energized when the battery Steer Luffing Jib (option)
is connected. When the battery is connected and the ignition
switch is in the ignition (run) or accessory power position, 15 10 12 V Power Outlet (8A max)
fuses 9 to 12 & fuse 20 are energized through ACC relay #1 16 15 LMI CPU Power
(K1) and 13 to 19 are energized through ACC relay #2 (K2).
17 15 LMI CPU, Hoist Control
18 5 Hoist Rotation Indicators
19 25 Heater and A/C Fan
20 30 A/C Condenser Fan
Fuses 51, 52 and 53 are inside the battery box compartment
located behind the fuel tank on the left side of the crane.
These 100-amp fuses protect the superstructure electrical
power system (Figure 3-5).
Table 3-1
5 -- Spare Fuse 54 and 55 are under the engine hood on the left side of
engine on frame rail. These 125-amp fuses protect the
6 20 Superstructure Control Module
engine grid heaters.
7 10 Boom Lights (option)
Fuses 56 (50A) and 57 (30 A) are located inside the battery
8 5 Ignition, Start and Accessories box compartment behind the batteries on the left side of
crane. These fuses protect the Cummins engine electronic K601, K602, and K301 are located under the engine hood on
control module (ECM) and carrier control module (CCM). the engine relay panel on the left side of the engine
(Figure 3-7).
For machines with the retarder option, a 10A fuse in line 180
protects the retarder circuit parts. For the start relay coil to energize, the battery must be
connected. The coil of the start relay (K301) is energized
Relays when the transmission is in neutral and the ignition switch is
at the START (2) position.
The relay panel (Figure 3-6) contains 2 relays (K1 and K2), a
terminal block with 3 or 4 or 5 diodes, and a buzzer. It is The coil of the accessory relays (K1 and K2) are energized
located in front of the front console in the cab. Access is when the ignition switch is at the RUN (1) or ACC (3)
gained by removing the front console cover. position.
The crane has 5 or 6 relays which control many of its For cranes with air conditioning, there is an optional AC Fans
functions. In addition to relays K1 and K2 in the cab, relays relay (A/C).
3
7 6 5 4
1 3
4 5
DANGER
Ensure the batteries are disconnected before performing
any maintenance on an electrical circuit which is not fused
or when performing continuity checks.
CAUTION
Never replace original wiring with wiring of a smaller size
(gauge).
General Troubleshooting
1 2 3 7333-6
FIGURE 3-7
DANGER
Many steps in the troubleshooting procedures require
Item Description
testing live (energized) components. Perform these steps
1 Grid Heater Relay 2 (K602) observing good safety practices to avoid electrical shock
2 Grid Heater Relay 1 (K601) injury.
3 Engine Starter Relay (K301) NOTE: Make voltage checks at terminations when
4 125 Amp Fuse (F55) components are installed and operating. Make
continuity checks (with batteries disconnected)
5 125 Amp Fuse (F54) when components are isolated or removed.
For the grid heater relay coils to energize, the battery must Troubleshoot per the following guidelines:
be connected and signals from the engine ECM must be 1. First, use reported symptoms to identify a problem or a
sent. suspect component.
2. Try to turn on the head lights, tail lights, marker lights, start engine. Troubleshoot the starter relay and
dome light, work light, or gauge lights and panel lights to ignition switch for closed contacts. If these
verify the batteries have at least some charge. If none of components check out, replace the starter.
these lights comes on, suspect the batteries. Charge
batteries as needed, or replace the batteries if you can Troubleshooting Engine Charging Problems
jump-start the crane from another crane.
1. Verify battery terminals are connected and clean and all
3. If you hear the starter relay clicking repeatedly, power is wires in the charging system are in good repair and are
reaching the starter, but not enough. Suspect the connected properly.
batteries. Charge batteries as needed, or replace the
2. Verify the alternator belt is properly installed and is
batteries if you can jump-start the crane from another
under proper tension.
crane.
3. Verify each battery puts out 12 volts minimum. Charge
4. Check Fuse 53 (100 amp) inside battery box. If fuse is
batteries as needed so they can supply a minimum
blown, replace it.
excitation voltage to the engine’s charging system. 3
5. Turn the ignition switch to RUN (1). Check the voltmeter.
4. Verify there is a minimum of 12 volts at the alternator
If it doesn’t move (but the head lights, tail lights, marker
from the batteries, and that the alternator is properly
lights, dome light, work light, or gauge lights and panel
grounded.
lights will come on), suspect the ignition switch and the
power circuit to it starting at the ignition switch fuse 5. Replace the alternator if the other conditions check out.
(Fuse 8). Repair or replace circuit, switch, or fuse as
6. Refer to the engine manual for further instructions.
needed.
NOTE: If the alternator runs noisily, check belt tension. If
6. If the battery, fuses, ignition switch, and power circuit to
problem persists, replace alternator.
the ignition switch check out, do one of the following:
NOTE: If the alternator overcharges (voltmeter reads high,
a. If you hear no noise when you try to turn the starter,
light bulbs burn out quickly), look for a ground
troubleshoot the start circuit (ignition switch, electric
where one shouldn’t exist. If external wiring checks
s h i f t e r, a n d w i r i n g f r o m i g n i t i o n s w i t c h t o
out, replace alternator. (The alternator probably
superstructure control module (connector A)
has an internal ground or a faulty internal voltage
through carrier control module (connector A) to
regulator.)
starter relay (K301). Make repairs as needed.
b. If the engine still won’t start, and you hear no noise Troubleshooting Accessories
o r j u s t a s i n g l e c l i c k , s u s p e c t t h e s t a r t e r.
If the crane’s engine starts and charges properly, but none of
Troubleshoot the start circuit from the starter relay
its components except the horn or lights work, the accessory
through the starter solenoid to the starter motor and
circuitry may be faulty. Check as follows:
ground. Make repairs as needed. If the starter
solenoid or the starter motor is faulty, replace the 1. Turn the ignition switch to the ACC (3) position. Try to
starter. turn on the cab circulating fan, the heater fan, the
defroster fan, or the windshield wipers or washer. If none
c. If the starter engages but can’t turn the engine (and
of these come on (but the head lights, tail lights, marker
the lights dim, signaling power drain during start
lights, dome light, work light, or gauge lights and panel
attempt), check the starter’s feed circuit from the
lights will come on), there is an accessory circuitry
batteries for resistance. If the resistance is high,
problem.
make repairs. If the circuit checks out, replace the
starter. If the engine still won’t start, suspect a 2. Check the primary power circuit to the accessory relays
seized engine. K1 and K2. Make circuit repairs as needed.
d. If the starter turns the engine, but it still won’t start, 3. If the problem remains, check the ignition switch and the
check fuses 54, 55, 56, and 57 in the battery box. accessory control circuit from the ignition switch through
Replace if required. Ensure fuel system can draw the coil of the accessory relays K1 and K2 to ground.
fuel from the tank and pump it to the engine; make Turn the ignition switch to the ACC (3) position and listen
repairs as needed. for audible click of relays K1 and K2. If neither relay
clicks, then there is no power through the switch when it
7. Refer to the engine manual for further instructions.
is in the ACC (3) position. Replace ignition switch if there
NOTE: If the starter won’t disengage during running, verify is no power through it when in the ACC (3) position. If
the starter is mounted properly so its gear won’t one relay clicks and the other does not, check continuity
mesh with the engine’s flywheel when not trying to of the coil of the relay that does not click. If there is no
continuity through its coil, replace the relay. Make circuit Connector Troubleshooting
repairs to accessory control circuit as needed.
The cause of an electrical problem may be a loose or
4. If the problem remains, check the accessory relay K1 or corroded connection in the pin or socket connectors. Check
K2 contacts and the accessory power circuit. Replace the connectors to ensure that the pins and sockets are
relay if its contacts stay open when the coil is energized. properly seated and engaged. If the pins and sockets show
Make circuit repairs as needed. any signs of corrosion, use a good quality electrical contact
cleaner or fine sandpaper to clean them. When the pins or
Troubleshooting Swivel-Caused Electrical sockets show signs of arcing or burning, it will probably be
Problems necessary to replace them.
Many crane component electrical troubles can be traced to After cutting the pin or socket off, the wire will most likely be
the electrical swivel. Troubles common to the swivel are too short. Using a wire that is too short will allow pressure to
improper mounting, foreign material between the brushes be applied to the pin or socket and wire where they are
and slip rings, incorrect wiring from the swivel to the crimped when the pin or socket is inserted in the plug or
components, incorrect wire size, worn brushes, improper receptacle. Add a short length of the same size wire to the
spring tension on the brush assembly, and loose setscrews short wire by crimp splice or solder. Use heat shrinkable
on the slip ring assembly. Refer to the electrical schematic tubing or other suitable material to insulate the splice.
and wiring diagram for slip ring connections and amperages.
Table 3-2
Deutsch Extraction Tool Table
Table 3-3
Deutsch Crimping Tool Table
FIGURE 3-8
The Electrical System Diagnostic lamp is located in the cab 3. Check the switch and circuit for continuity problems and
in the center of the front console. The lamp is used for other problems. Repair any faulty switch or other
troubleshooting the superstructure and carrier control component. Repair wiring if faulty.
modules. A red indicator light illuminates, giving the operator
The following circuit designs apply (connecting wiring
a signal that there is a problem with the crane’s operation
and passage through superstructure and carrier
which must be corrected. The Electrical System Diagnostic
modules -- as applicable -- is understood):
lamp can have four symptoms.
- Head lights. Fuse F4, HEADLIGHTS switch, lamps,
1. Only the Electrical System Diagnostic lamp is flashing
grounds.
(ignition switch may be in the on or off position) - crane
electrical system output diagnostic error, possible open - Tail lights. Fuse F4, HEADLIGHTS switch, lamps,
load, short to battery or short to ground. Use service grounds.
software to locate error.
- Marker lights. Fuse F4, HEADLIGHTS switch,
2. The Electrical System Diagnostic lamp is on solid and
the turn signal indicators are flashing (ignition switch
lamps, grounds. 3
- Gauge and panel lights. Fuse F4, lamps/LEDs,
may be in the on or off position) - no communications
grounds.
from the carrier control module.
- Turn signal lights. Fuse F4, turn signal switch,
3. The Electrical System Diagnostic lamp is not on but the
lamps, grounds. Suspect turn signal switch if hazard
turn signal indicators are flashing and the ignition switch
light circuit functions properly.
is on - no communication from the engine’s ECM.
- Hazard lights. Fuse F4, flasher, HAZARD lights
4. The Electrical System Diagnostic lamp is not on but the
switch, lamps, grounds. Suspect HAZARD lights
turn signal indicators are flashing and the ignition switch
switch if turn signal lights circuit functions properly.
is off - there is communication from the carrier control
module to the superstructure control module but no - Stop lights. Fuse F4, stop light switch, turn signal
communications from the superstructure control module switch, lamps (suspect stop circuit problem if turn
to the carrier control module. signal or tail light function works), grounds.
- Work light. Fuse F1, WORK light switch, lamp,
CAUTION grounds.
When welding on the crane, turn battery disconnect off to - Dome light. Fuse F3, switch on dome light, lamp,
prevent damage to the CAN-Bus system. grounds.
- Spotlight. Fuse F3, switch on spotlight, lamp,
This machine has a CAN-Bus Multiplex electronic control
grounds.
system. This system takes multiple information signals and
combines them into one signal. The benefits of this system - Boom flood lights. Fuse F7, BOOM LIGHT switch,
include less wiring, fewer relays, and fewer slip ring lamps, grounds.
connectors.
4. Repair is straightforward. Turn off light switch, remove
When troubleshooting the control modules, a Laptop with the old light, install new light, turn on light switch to test light.
CAN link service tool software and a service cable will be
needed to access the CAN system by the two Vehicle Data Troubleshooting Gauges and Meters
Link connections located in the cab and by the battery
1. Check all other gauges and meters (besides the
disconnect switch. When performing this type of
suspect). If none of them are working, replace Fuse F14.
troubleshooting, the battery disconnect switch must not be
deactivated so there is power for the service tool. For 2. Check the gauge or meter, its sensing component, and
ordering the service tool software and service cable, contact circuit for continuity problems and other problems. A
Manitowoc Crane Care. sender is probably at fault when it shows infinite
resistance, or resistance out of specifications for
Troubleshooting Lights condition. Repair any faulty gauge, meter or other
component. Repair wiring if faulty.
1. Check lamp first. Replace any defective lamp.
3. The circuit design for a gauge’s light or a panel light is
2. If all lamps in a circuit do not work, suspect fuse and
fuse F4, light, ground.
switch. Replace fuse if blown.
4. The following circuit designs apply (connecting wiring - Park brake indicator. Fuse F10, indicator, normally
and passage through superstructure and carrier closed park brake pressure switch, ground.
modules -- as applicable -- is understood):
- Low brake pressure alarm light. Fuse F14, alarm
- Voltmeter. Fuse F14, voltmeter, ground. Branch for light, brake pressure switch, ground.
reading from batteries.
- Rear wheels not centered indicator. Fuse F14,
- Fuel level gauge. Fuse F14, gauge. Gauge is indicator, rear steer not centered switch, ground.
grounded. Branch from gauge to sending unit in fuel
- Engine stop indicator (such as low oil level, high
tank to ground.
engine coolant temperature) alarm. Fuse F14,
- Transmission oil temperature gauge. Fuse F14, buzzer and parallel indicator; ground controlled by
gauge. Gauge is grounded. Branch from gauge to Cummins ECU.
temperature sending unit to ground.
- Engine warning indicator (engine service, engine
- Engine coolant temperature gauge. Fuse F14, warning, water in fuel, wait to start). Fuse F14,
gauge. Gauge is grounded. Branch from gauge to indicator, switch, ground controlled by Cummins
coolant temperature sending unit to ground. ECU.
- Tachometer. Fuse F14, tachometer. Meter is - Axle differential lock indicator. Fuse F10, indicator,
grounded. Branch from tachometer to tachometer switch(s) on axle(s), ground.
sender to ground.
- Steering wheel horn. Horn switch, ground.
- Hourmeter. branch from carrier control module, Superstructure control module, horn, ground.
hourmeter, ground.
- Swing brake on indicator. Fuse F13, swing brake
5. Repair is straightforward. For a gauge or meter, remove release switch, indicator, ground.
gauge or meter, install new gauge or meter, install new
- Low brake pressure alarm circuit. Fuse F14,
fuse, then test gauge or meter. For a sender, remove
indicator, switch, ground. Parallel buzzer circuit fuse
sender, install new sender, install new fuse, then test
F14, buzzer, switch, ground.
sender and gauge or meter. See INSTRUMENT
REPLACEMENT in this section for details on removing - Low steer pressure for CE units. Fuse F14,
and installing gauges and meters. indicator, switch, ground. Parallel buzzer circuit fuse
F14, buzzer, switch, ground.
Troubleshooting Alarms, Indicators, and
- Hose reel brake on alarm circuit. Fuse F14,
Emergency Components indicator, switch, ground. Parallel buzzer circuit fuse
1. If an indicator won’t work when it is supposed to, check F14, buzzer, switch, ground.
its lamp first. Replace any defective lamp. Then check - Transmission service (low oil pressure, high oil
and replace fuse as applicable, especially if all other temp) alarm. Fuse F14, buzzer and parallel
components downstream from the fuse are not working. indicator; ground. Branch to oil pressure switch to
2. If an alarm or an emergency component won’t work ground, branch to oil temperature switch to ground.
when it is supposed to, check and replace fuse, 5. Repair is straightforward.
especially when all other components downstream from
the fuse are not working. a. ALARM: Remove blown fuse, remove faulty alarm
or faulty sensor (switch, sending unit), install new
3. Check the alarm or indicator or emergency component, alarm or sensor, install new fuse, test alarm.
its sensing component, and circuit for continuity
problems and other problems. Repair any faulty alarm or b. INDICATOR: Remove blown fuse, remove faulty
indicator or emergency component or sensing device light or faulty sensor (switch, sending unit), install
(switch, sending unit). Repair wiring if faulty. new light or sensor, install new fuse, test indicator.
4. The following circuit designs apply (connecting wiring c. BACKUP LIGHT: Remove blown fuse, remove
and passage through superstructure and carrier faulty light or faulty sensor (electric shifter), install
modules, as applicable, is understood): new light or sensor, install new fuse, test lights.
- Backup light and backup alarm. Fuse F8, electric d. HORN: Remove blown fuse, remove faulty horn or
shifter, then to backup alarm in parallel with reverse faulty trigger (switch, relay), install new horn or
solenoid, then from lights and alarm to ground. trigger, install new fuse, test horn.
Lights circuit parallel with backup alarm and reverse e. BUZZER: Remove blown fuse, remove buzzer,
solenoid circuits. install new buzzer, install new fuse, test buzzer.
Troubleshooting Crane Components and - Main and Auxiliary Hoist Rotation Indicators. Fuse
Accessories F18 branch for each hoist (driver assembly, sensor,
driver assembly, ground). Parallel branch through
1. If a crane component or accessory won’t work when it is thumper to driver assembly.
supposed to, check and replace fuse. Also check and
- Main Hoist. For hoist up, Fuse F16, LMI CPU, MAIN
replace its relay as needed.
HOIST switch, main hoist up solenoid valve,
2. Check the component or accessory, its control or ground. For hoist down, Fuse F17, MAIN HOIST
triggering component, and its circuit for continuity switch, main hoist down solenoid valve, ground.
problems and other problems. Repair any faulty Parallel circuit to LED indicator in switch to ground.
component or accessory or trigger. Repair wiring if For main hoist high speed up and down, Fuse F17,
faulty. MAIN HOIST switch, main hoist high speed
solenoid valve, ground. Series circuit through diode
The following circuit designs apply (connecting wiring
to main hoist down solenoid valve.
and passage through swivel slip ring per control module
-- as applicable -- is understood): - Auxiliary Hoist. For hoist up, fuse F16, LMI CPU,
3
AUX HOIST switch, auxiliary hoist up solenoid
- Windshield wiper motor and windshield washer
valve, ground. For hoist down, fuse F17, AUX
pump motor. Fuse F9, wiper/washer switch, motors
HOIST switch, auxiliary hoist down solenoid valve,
in parallel, grounds.
ground. Parallel circuit to LED indicator in switch to
- Heater or A/C fan. Fuse F19, FAN switch, fan motor, ground. For auxiliary hoist high speed up and down,
ground. Fuse F17, AUX HOIST switch, auxiliary hoist high
speed solenoid valve, ground. Series circuit through
- Cab circulating fan. Fuse F11, switch, motor,
diode to auxiliary hoist down solenoid valve.
ground.
- LMI. Fuse F16, LMI CPU and LMI crane
- Defroster fan. Fuse F12, switch, motor, ground.
components, grounds.
Parallel circuit to LED indicator in switch to ground.
- Lockout function. Fuse F16, LMI CPU, three lockout
- Grid heaters. 125 amp fuses, relays K601 and
solenoid valves in parallel (inner mid telescope out,
K602, grid heaters, ground (relays controlled by
outer mid telescope out, lift down), grounds. (During
Cummins ECM.
lockout, this circuit must be open.)
- Transmission gear shift function. Fuse F8, electric
- Rear axle oscillation lockout function. Fuse F16,
s h i f t e r, f i v e s o l e n o i d v a l v e s i n p a r a l l e l i n
LMI CPU, oscillation solenoids, ground.
transmission, ground.
- Swing brake release function. Fuse F13, SWING
- Transmission drive select function. Fuse F10,
BRAKE release switch, swing brake release
DRIVE AXLE select switch, 2WD solenoid valve,
solenoid valve, ground.
ground. Parallel circuit to LED indicator in switch to
ground. - Park brake release function. Fuse F10, PARK
BRAKE switch, park brake release solenoid valve,
- Outrigger extend/retract function. Fuse F14,
ground.
RETRACT/EXTEND switch, extend solenoid valves
in parallel with retract solenoid valves in integrated - Axle differential lock function (option). Fuse F10,
valve, grounds. DRIVE AXLE select switch, AXLE DIFF switch, axle
differential lock solenoid valve, ground. Parallel
- Outrigger extension cylinder functions. Fuse F14,
indicator branch fuse F10, indicator, differential lock
selector switch for left front, left rear, right rear, and
indicator switches, ground.
right front cylinders, cylinder solenoid valves,
grounds. - Skylight wiper motor. Fuse F11, wiper switch (on
motor), motor, grounds.
- Outrigger stabilizer cylinder functions. Fuse F14,
selector switch for left front, left rear, right rear, and - Hydraulic oil cooler control. Transmission
right front cylinders, cylinder solenoid valves, temperature switch, hydraulic oil temperature
grounds. switch, oil cooler solenoid valve, ground. Each
normally closed switch opens on rising hydraulic oil
- Crane function. Fuse F13, CRANE FUNCTION
switch, seat switch, armrest switch, ground. Parallel temperat ure (transmis sion switch at 230 ° F,
circuit to LED indicator in switch to ground. hydraulic switch at 120 ° F) to de-energize the oil
cooler solenoid valve so fluid from Pump No. 4 flows
through the hydraulically driven cooler fan motor to
cool hydraulic fluid instead of bypassing the motor 3. Install the belt on all engine pulleys except the alternator
and flowing through the oil cooler solenoid valve. pulley for now.
3. Repair is straightforward. 4. Turn the tensioner clockwise. Slip the belt onto the
alternator pulley, then carefully return the tensioner to its
a. MOTOR: Remove faulty motor or faulty trigger
normal position so it puts tension on the belt. Make sure
(switch or relay), install new motor or trigger, install
the belt is centered on the tensioner.
new fuse, test motor. For further information, see
the applicable section in this manual. 5. Check belt tension at the belt’s longest span (longest
distance between pulleys). At the center point of the
b. SOLENOID VALVE: Remove faulty valve or
longest span, push in on the belt with your thumb. Verify
solenoid, install new valve or solenoid, install new
you can deflect the belt no more than 10 to 13 mm (3/8
fuse, fill fluid system, test valve.
to 1/2 inch) with your thumb. (Or, using a belt tension
c. LMI: Repair per LMI manual, install new fuse, test gauge, verify there is 267 to 578 N (60 to 130 pounds) of
per LMI manual. tension on the belt in the middle of its longest span.)
Replace belt if it is too loose (overstretched).
d. ROTATION INDICATOR: Remove driver assembly
or sensor, install driver assembly or sensor, install 6. Verify tensioner bolt is torqued to 43 Nm (32 foot-
new fuse, test thumper. For further information on pounds).
rotation indicator, refer to Section 5 - HOIST AND
7. Connect the electrical leads to the terminals as tagged
COUNTERWEIGHT.
during removal.
Alternator Replacement 8. Connect the batteries. Close the engine compartment.
Removal Check
1. Disconnect the batteries. 1. Run engine. Verify reading of voltmeter on front console
is 12 volts or greater. Make repairs as needed.
2. Open the engine compartment.
2. Continue troubleshooting charging system as needed if
3. Tag and disconnect the electrical leads from the
replacement of alternator did not correct problem in
terminals on the alternator.
charging system.
4. Turn the tensioner above the alternator clockwise to
remove tension from the belt. Slip the belt off of the Starter Replacement
alternator pulley, then let the tensioner return to its
normal position. Removal
5. Remove and tag all wires. Remove the alternator link 1. Disconnect the batteries.
capscrew and the mounting capscrew. Remove the
2. Open the engine compartment.
alternator.
3. Tag and disconnect the electrical leads from the
Installation terminals on the starter.
1. Inspect the belt. Verify it has no cracks or other damage. 4. Remove the bolts holding the starter to the mounting
Replace damaged belt as needed. pad. Remove the starter.
NOTE: Install alternator on the mounting bracket with head
towards turbocharger.
Installation
1. Place the starter on its mounting pad. Secure the starter
2. To assemble the alternator, the mounting components
with the bolts. Torque the bolts to 43 Nm (32 foot-
must be tightened in the following sequence.
pounds).
a. Alternator-to-alternator bracket capscrew.
2. Connect the electrical leads to the terminals as tagged
b. Lower brace-to-alternator capscrew. during removal.
c. Lower alternator brace-to-water pump capscrew. 3. Connect the batteries. Close the engine compartment.
d. Torque brace-to-alternator bolt to 43 Nm (32 foot-
pounds). Torque alternator-to-alternator bracket bolt
to 77 Nm (57 foot-pounds).
1. Try to start the engine. Verify the starter starts the Installation
engine.
1. Place the batteries in the battery box.
2. Start engine again, and listen for starter noises. Verify
there is no abnormal noise indicating the starter’s gear is 2. Install the hold down bracket so it can hold down the
meshing improperly with the flywheel, that the starter’s batteries. Secure the bracket (and batteries) to the
gear hasn’t disengaged from the flywheel after the bracket hold down rods with nuts and washers.
ignition switch is in the ignition. (run) position, or some 3. Connect leads to the battery terminals starting with the
other problem. Install starter properly as needed. negative terminals.
Battery Replacement 4. Close the battery box cover.
Removal
5. Verify replacement batteries work by starting crane’s
engine and operating various crane components. 3
Relay Panel Component Replacement
Accessory Relay
1. Disconnect the batteries.
2. Remove the hardware securing the console front cover
and remove the cover.
3. Tag and disconnect the electrical leads from the suspect
relay.
4. Remove the hardware securing the suspect relay to the
relay panel assembly. Remove suspect relay.
5. Install replacement relay on relay panel and secure it
with attaching hardware.
7010-1
Buzzer Replacement
1. Remove the hardware securing the console front cover
and remove the cover.
2. Tag and disconnect the electrical leads from the buzzer.
3. Unscrew the plastic collar ring from under the panel and
remove the buzzer from the hole in the panel.
4. Install replacement buzzer through the hole in panel and
secure with the plastic collar ring.
5. Connect the electrical leads to the buzzer as tagged
FIGURE 3-10
during removal.
3. Remove the nuts and washers from the bracket hold
6. Position the console front cover on the console and
down rods. Remove the hold down bracket.
secure with the attaching hardware.
1. Examine the instrument for cracked and broken lenses. 2. Check wiring for damaged insulation or damaged
Check instrument terminals, bracket or clamp, and connectors. Repair as needed.
mounting studs for damage. Replace damaged 3. Perform the following check to determine switch
instrument; repair or replace damaged connecting serviceability.
hardware.
a. Using an ohmmeter, check for continuity between
2. Check wiring for damaged insulation or damaged the switch terminals with switch at ON or activated
connectors. Make repairs as needed. position(s). Ohmmeter should register zero ohms
(continuity).
Installation
b. Place switch at OFF or deactivated position.
1. Put the instrument in place on the console panel and Ohmmeter should register infinity (no continuity).
secure it with the attaching hardware.
c. Replace switch if it fails either part of the check.
2. Connect the electrical wiring to the instrument as
marked during removal. Installation
3. Position the console front cover on the console and 1. Place the switch on the front console panel and secure it
secure with the attaching hardware. by pushing the switch into the panel, until it snaps into
place.
4. Connect the batteries.
2. Connect the electrical connector or wires to the switch.
Check 3. Position the console front cover on the console and
1. Start the engine and verify that the instrument works. secure with the attaching hardware.
Refer to Section 3 - OPERATING CONTROLS AND 4. Connect the batteries.
PROCEDURES in the Operator’s Manual.
Check
2. As needed, troubleshoot further any system malfunction
not corrected by repair or replacement of the instrument 1. Operate the switch. Verify that each of its functions
or associated wiring. works. Refer to Section 3 - OPERATING CONTROLS
AND PROCEDURES in the Operator’s Manual.
2. As needed, troubleshoot further any system or circuit
malfunction not corrected by repair or replacement of
the switch or associated wiring.
Inspection Inspection
1. Visually check the pump for evidence of cracks, leaks, or 1. Visually check the motor housing for evidence of cracks
other damage. Replace pump if damaged. or other damage. Check for excessive shaft end play
indicating worn or damaged bearings. Replace motor if
2. Inspect the container for leaking. Replace pump seal if it
damaged.
is leaking. Replace container if it is damaged and
leaking. 2. Inspect the wiper blade for serviceability. Replace wiper
blade when worn.
3. Inspect spray nozzle on the wiper arm. As needed, clean
the nozzle with a fine piece of wire and compressed air. 3. Inspect the wiper arm and parts for damage. Replace as
needed.
Installation
Installation
1. Install pump and pump seal on container.
2. Install windshield washer container on the cab. Secure
1. Install sealant material around both holes in cab roof, 3
both inside and outside.
the container with four self tapping screws.
2. Install screw with nylon flat washer (from outside)
3. Attach the hose to the windshield washer pump.
through mounting hole in cab roof.
4. Connect the pump’s electrical lead and ground wire as
3. Install flat nylon washer on motor shaft and insert motor
tagged during removal.
shaft through hole in cab roof. Position small nylon
5. Connect the batteries. washer and flat washer on screw between mounting
bracket and cab roof. Secure with lockwasher and nut.
6. Fill the container with cleaning fluid.
4. Install nylon flat washer, leather washer, spacer, and nut
Check on motor shaft. Tighten nut.
1. Squirt some cleaning fluid onto the windshield with the 5. Install wiper arm and blade on motor shaft.
windshield washer. 6. Connect the electrical leads to the wiper motor as
2. Make repairs if windshield washer doesn’t work. marked before removal.
7. Connect the batteries.
Skylight Wiper Assembly Replacement
Check
Removal
1. Operate the skylight wiper and verify it works. Replace
1. Disconnect the batteries. wiper blade as needed if it streaks or otherwise wipes
2. Tag and disconnect the electrical leads from the motor. poorly.
3. Remove the wiper arm from the motor shaft. Tooling For Troubleshooting
4. Remove the nut, spacer, leather washer, and nylon flat This machine incorporates a CAN-bus Multiplex system.
washer from the motor shaft outside the cab roof.
To effectively troubleshoot the electrical system, you need a
5. Remove the nut and lockwasher securing the motor Windows-based personal computer, CAN-Link service
bracket to the cab roof and remove the motor from the s oft w ar e ( P ar t N o . 9 9 91 0 22 9 7 f or RT9 00 0 ) , a n d a
cab roof. Remove large nylon flat washer from motor connection cable (Part No. 9999102296).
shaft and flat washer and smaller nylon flat washer from
mounting screw. Manitowoc Crane Care requests you have as part of your
service tool kit inventory the CAN-Link service tool kit for the
6. Remove mounting screw and nylon flat washer from RT9000. The software will allow you to see in real time the
outside cab roof. status of all inputs and outputs on the system, and it will allow
7. Clean any sealing material from around holes in cab you to detect any errors on input or output. The CAN-Link
roof. service software and connection cable are available through
Crane Care.
GROVE 4-i
BOOM RT9130E SERVICE MANUAL
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
Hose Reel Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Lift Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
Theory Of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
Boom Removal System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37
Upper Lift Cylinder Pin And Cylinder Disassembly . . . . . . . . . . . . . . . . . . . . 4-37
Upper Lift Cylinder Pin And Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . 4-37
Bi-Fold Swingaway Boom Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40
Connecting and Disconnecting the Hydraulic Boom Extension. . . . . . . . . . . . . . . 4-45
Connecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-45
Disconnecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-45
Swingaway Mounting Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-46
Boom Extension (With Inserts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-47
Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-47
Serial Numbers On the 8m Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-47
Slinging Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-47
Assembly of Boom Extensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-47
Checklists For Rigging Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-48
Installing the 26 m/34 m Boom Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-48
Removing the 26 m/34 m Boom Extension . . . . . . . . . . . . . . . . . . . . . . . . . . 4-49
Description of Rigging Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-49
Installing/Disassembling 8 m Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-49
Installing 8 m Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-49
Removing 8 m Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-49
Installing/Removing Two-Stage Swingaway Lattice Extension for Boom
Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-50
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-50
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-50
Hydraulic Connection On the Boom Extension (If Unit Is Equipped With
Hydraulic Luffing Boom Extension) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-50
Connections On the 8 m Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-50
Electrical Connection On the Boom Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-51
Connections On the 8 m Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-51
Establishing Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-51
Folding Out/In the Deflection Sheaves On the 8 m Sections. . . . . . . . . . . . . . . . . 4-51
Folding Out Deflection Sheave . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-52
Folding In Deflection Sheave . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-52
Positioning/Removing the Hoist Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-52
Positioning the Hoist Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-52
Removing the Hoist Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-52
Hook Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-54
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-54
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-54
4-ii
RT9130E SERVICE MANUAL BOOM
SECTION 4
BOOM
DESCRIPTION When in the manual mode, the red LED square in the switch
will illuminate. The boom telescope section select switch is
One boom is available on the crane; a five section, full positioned to either the center mid or inner mid position in
power, sequenced and synchronized, 12.8 to 48.5 m (42 to order to extend or retract the selected section until it is
159.3 foot) boom. The boom assembly utilizes a mega form returned to the proper position for normal boom
design. The five section boom utilizes two sequenced synchronization to occur.
telescope cylinders for telescoping and retracting of the
boom plus cable synchronization for the extension and Center Mid/Inner Mid Boom Telescope
retraction of the fly section. Boom lift is provided by a single
lift cylinder and boom elevation is from - 3 degrees to +78
Sections Select Switch
degrees. The center mid/inner mid boom telescope section select
switch is located on the right armrest. This switch is a three
Lattice Extension position rocker switch that is used in conjunction with the
boom auto/manual telescope mode switch. When the boom
The 11 to 18 m (36 to 59 ft.) offsettable bifold lattice
mode switch is positioned to manual, the boom telescope
swingaway extension stows alongside base boom section.
Offsets are 0°, 20°, and 40°.
section select switch is positioned to either of the two
positions. When placed in the upper position, the center mid
4
Optional Lattice Extension can be extended. When the center mid is fully extended, the
outer mid and fly can be controlled. The red LED square will
11 to 18 m (36 - 59 ft.) hydraulically offsettable bifold lattice illuminate when the switch is positioned in either the inner
swingaway extension stows alongside base boom section. mid or center mid position.
Offsets are from 0° to 40°.
Luffing Jib Switches
Optional Lattice Extension Inserts
The luffing jib raise/lower switch is located on the left
The 8 m (2 x 26 ft.) lattice extension inserts install between armrest. It is a three position, momentary switch (LOWER/
the boom nose and bifold extension, non-stowable. A OFF/RAISE) that will energize a solenoid to raise or lower
standard auxiliary boom nose (rooster sheave) is available the jib, if the jib ON/OFF switch is on.
for the boom to simplify single part cable usage. The rooster
sheave is installed on the main boom nose and is secured by The luffing jib two position on/off switch is located on the left
pins that pass through the rooster sheave and main boom armrest. When in the ON position and used in conjunction
nose. with the luffing jib RAISE/LOWER switch, the switch will
allow operation of the luffing jib. When in the ON position, the
Boom Control Switches red LED square will illuminate. It has a lock to prevent
accidental activation.
The following switches and indicators are located in the
crane’s superstructure cab and are used together to control THEORY OF OPERATION
the boom telescope function.
Boom Extension
Boom Auto/Manual Telescope Mode
Switches Boom extension and retraction is accomplished with two
telescope cylinders, five extension cables, and two retraction
The boom auto/manual telescope mode switch is located on cables. The lower telescope cylinder is a two stage cylinder.
the right armrest. The switch is a two-position rocker switch The rod for the first stage is secured to the rear of the boom
placarded auto and manual. This switch has a lock to base section and the barrel of the first stage is secured to the
prevent accidental activation. inner mid boom section by a trunnion. The second stage of
the first telescope cylinder barrel is secured to the rear of the
When the switch is in the AUTO mode, the boom sections
center mid boom section by a trunnion. The rod end of the
extend in a predetermined sequence when telescoping the
upper telescope cylinder is attached to the rear of the center
boom; the inner mid extends 75% and stops, then the center
mid and the barrel is secured to the outer mid boom section
mid extends to 75% and stops, then the inner mid extends to
by a trunnion. The extension cables are secured to the back
100%, the center mid extends to 100%, and then the outer
of the fly section and run around extension sheaves on the
mid and fly section extend in a synchronized fashion. The
front of the upper telescope cylinder to the front of the
sections retract in the same manner in reverse order.
second stage barrel of the lower telescope cylinder.
The hydraulic fluid for the first stage of the lower cylinder is Extension/Retraction Modes
supplied by hoses from the turntable. The hydraulic fluid for
the second stage of the lower cylinder and the upper cylinder The boom telescoping system operates in either of two
is routed through the hose reel that is mounted in the modes selected by the operator, Automatic or Manual.
turntable into a manifold that is attached at the rear of the a. In Automatic (AUTO) mode, a single telescope
center mid section. There are two cam operated check controller extends or retracts the boom at the
valves mounted at the rear of the center mid which control correct speeds, in the correct sequence of section
flow to the second stage of the lower cylinder and the upper movements, with no action by the operator other
telescope cylinder. With both cylinders retracted, the check than to actuate the controller and to cease actuating
valve for the second stage of the lower telescope cylinder is it when the desired boom length is achieved. The
open and the check valve for the upper cylinder is closed system also automatically enforces a “soft”
allowing the second stage of the lower cylinder to extend. transition at each section changeover point in the
When the lower cylinder is fully extended, the check valve for sequence, resulting in smooth changes from section
the upper cylinder opens allowing the upper cylinder to to section without the need for the operator to
extend. The check valve for the lower cylinder closes after “feather” the telescope control.
the upper cylinder starts to extend and shuts off the flow to
the lower cylinder. As the upper telescope cylinder barrel b. In Manual (MANUAL) mode, the operator has the
extends, the extend cables around the extend sheaves on selective capability to adjust the extension of the
the end of the cylinder barrel push on the extend cables to inner mid and center mid sections independently.
pull the fly section out at the same time the outer mid is Manual mode adjustment is utilized on ly to
extending. reconfigure the boom sections into a synchronized
relationship according to the programmed criteria
Boom Retraction for automatic mode operation (if the boom has for
any rea son bec ome unsyn chronize d during
The upper telescope cylinder retracts the outer-mid and two operation in the Automatic mode), or to extend the
retract cables pull the fly section in at the same time. When boom intentionally in non-synchronized mode, so
the upper cylinder is fully retracted, the check valve for the that access holes in the boom sections align, and
lower telescope cylinder is opened and the lower cylinder serviceable internal components of the boom are
starts to retract. The check valve for the upper cylinder is made accessible for maintenance. To prevent
closed as the lower cylinder starts to retract. The outer mid overloading of the boom while the sections are
and fly retract first and then the center mid and lastly the unsynchronized, when the Manual mode has been
inner mid. selected, the LMI electronic controller limits the
allowable gross load to 10,000kg, or 50% of the load
LMI SYSTEM (WITH BOOM CONTROL chart allowable capacity at the applicable measured
SYSTEM) boom length, whichever figure is less. In the Manual
mode, the smoothness of the changeover from
General section to section is entirely under the control of the
operator.
The crane has a 5-section sequence synchronized boom
assembly. The electronic control system interfaces with the Extension/Retraction Sequence (Automatic
actuating systems, and provides the necessary controls,
according to the following system standards.
Mode)
Boom extension in the Automatic mode does not follow the
Telescoping Control System Description customary sequence whereby all the boom sections are
extended by the same proportion for any given boom length.
Boom Configuration Instead, in order to optimize the crane structural and/or
stability limitations, the sections extend in particular
The boom is a five section configuration (i.e. one fixed
proportions according to the following sequences (as
section and four telescoping sections). The fully retracted
directed by the particular load chart/crane configuration
length of the boom is 12.8 m (42 ft) and the fully extended
selected by the operator; i.e. these sequences reside in the
length is 48.5 m (159.33 ft). The full extension value of all
system data software, not in the control software):
four telescoping sections is the same (i.e. 48,564 - 12,805)/4
or 8,940mm (29.33 ft).
4
Center Mid Extends to 100%
Outer Mid and Fly Section Extend Synchronized Until Fully Extended
6081
FIGURE 4-1
Extension Sequence For The Main Boom Automatic mode extension sequence is activated whenever
an offset jib load chart is selected by the operator:
a. The inner mid section alone extends to 75% of its
maximum, all other sections remain retracted. a. The inner mid section alone extends to its full
extension, all other sections remaining retracted.
b. The center mid section alone extends to 75% of its
maximum, the inner mid section remaining at 75% b. The center mid section alone extends to its full
of its maximum, the outer mid and fly sections extension, the outer mid and fly sections remaining
remain retracted. retracted.
c. The inner mid section alone extends to its full c. The outer mid and fly sections extends
extension, the center mid section remaining at 75% simultaneously, synchronized, to their full extension.
of its maximum, and the outer mid and fly sections The boom retraction sequences are the reverse of the above
remain retracted. extension sequences.
d. The center mid section alone extends to its full
extension, the outer mid and fly sections remain Rated Boom Lengths
retracted. The boom carries capacity ratings according to the boom
e. The outer mid and fly sections extends section extension proportions shown in the table titled Boom
simultaneously, synchronized, to their full extension. Section Extension Proportions (again shown as a
percentage of extension of each section).
Extension Sequence For The Main Boom
With Boom Extensions Or Offset Jibs Capacities At Intermediate Boom Lengths
There are no discrete boom extension or jib capacity charts It is not mandatory that only the specified discrete boom
for boom lengths less than 100% extension of the center mid lengths are utilized for lifting, and intermediate boom lengths
section. Therefore, to reduce telescoping time, the following will be usable. The allowable capacities at intermediate
lengths behave in accordance with customary practice, in signal, the pressure reducing valves effectively
that they reduce to the figure applicable to that adjacent override the pilot pressure signal being transmitted
boom length having lower capacities (either the next longer from the operator’s pilot controller to the telescope
or shorter rated boom length, according to the particular load control valves, automatically opening, feathering
chart in use), whenever the actual boom length differs from and closing so as to initiate, control and halt motion
the rated length by more than 500 mm. (For any given boom of th e re sp ect iv e s ec tio ns ac co rdin g t o t he
length, the capacities vary steplessly with load radius predetermined sequence.
according to the particular calibration curves).
c. Mechanically actuated valves sensing the status of
the center mid and outer mid sections (i.e. outer mid
Hydraulic Actuation And Control System section fully retracted, and center mid section fully
Extension of the inner mid, center mid, and outer mid extended) and diverting the flow of oil, when
sections occurs by way of three hydraulic cylinders (one 2- extending, from the center mid section cylinder to
stage cylinder moving the inner mid and center mid sections, the outer mid cylinder when the center mid section
and one single-stage cylinder, moving the outer mid section). (and therefore also the inner mid section) is fully
The fly section is cable extended and retracted by the extended, and vice versa during boom retraction.
movement of the outer mid section and center mid sections, Thus the outer mid section is not able to receive any
and thus is mechanically synchronized with the outer mid oil to extend until the center mid section is already
section, but the other sections are electro-hydraulically fully extended; and similarly, no “retract” oil will flow
sequenced/synchronized by the boom telescoping control to the center mid section until the outer mid section
system. is fully retracted.
Controlling the telescope cylinders, the boom telescoping d. A normally closed, solenoid operated 2-way, 2-
hydraulic actuating system consists of the following position control valve, which bleeds off residual rod
elements: side pressure from the telescope cylinders (as
selected by a double check valve, according to the
a. A single pilot pressure joystick or foot pedal cylinder being telescoped, and an orifice to prevent
controller, which actuates two pilot operated 4-way, significant loss of oil to tank that would compromise
3-position, pressure compensated proportional cylinder retraction speed). The purpose of this valve
control valves controlling the flow and pressure of is to allow residual pressure trapped in the rod side
hydraulic oil respectively to the inner mid and center of the cylinders to escape, preventing subsequent
mid/outer mid section telescope circuits. unseating of the holding valve and transfer of the
b. The propositional control valve(s) noted in a. above, trapped oil to the piston side, which can cause a
in which are incorporated solenoid operated slight spontaneous and unwanted extension of the
proportional pressure reducing valves in both of the boom sections
valves’ pilot pressure spool actuator sections (i.e. e. Unless overridden by the pilot signal pressure
both “extend” and “retract” directions), acting to vary reducing valves in paragraph b. (above), the oil flow
the pilot pressure being applied to shift the valve and pressure applied to the telescoping cylinders is
spool, and thereby controlling the flow of oil to the under the direct control of the joystick pilot
inner mid center mid, outer mid section telescope controller.
cylinders. Thus, when so directed by electrical
Table 4-1
Boom
42 56.68 71.34 86 100.67 115.34 130 144.67 159.33
Length (ft)
Outer-Mid 0 0 0 0 0 25 50 75 100
Fly 0 0 0 0 0 25 50 75 100
Electronic Control System value, giving a smooth acceleration of that section. This
system prevents out of sequence conditions occurring as a
As mentioned previously, the electro-hydraulic sequencing result of overshoot of the section that is coming to a halt, and
and synchronization of the inner mid and center mid section also enforces a smooth transition from section to section.
telescope cylinders are controlled through a combination
LMI/boom control system electronic processor/controller, An additional benefit occurs in situations in which the
since both systems need to sense the various section operator is simultaneously operating the hoist, in order to
extensions (i.e. to determine the boom length and its keep the load at a constant height while telescoping the
configuration [sectional extension relationships] in order to boom. Since telescoping speed inevitably varies from
compute allowable load moment and the corresponding section to section according to the bore of the cylinder, and
allowable hook load for LMI purposes, and to close the also whether a section is indirectly moved by a cable
telescope sequencing/synchronization system feedback extension system, the compensating speed of the hoist has
control loop). to be varied by the operator as each successive section
change occurs, so that the load does not immediately rise or
System Interfaces and Logic fall. The smooth changeover effect enforced by the
telescope control system allows the operator a wider band in
The electronic system is supplied with electrical power at 12 which to adjust compensatory speed of the hoist so that the
VDC. load can be more easily kept at a constant height.
The electronic system collects electrical inputs from boom The inner mid and center mid sections are extended by a 2-
length sensors that separately measure overall boom length,
and extension of the inner mid section. Since the outer mid
stage cylinder, the larger diameter cylinder being the center
mid section stage. Therefore this stage has the capability to
4
and fly sections are mechanically [cable-] synchronized, and exert higher load than the inner mid section stage, for a given
change over of hydraulic oil supply to or from the outer mid/ hydraulic pressure. Such loads would exceed the buckling
fly section telescope cylinder is mechanically effected by trip resistance of the smaller inner mid section stage, which in
valves upon full extension of the center mid section, or full Automatic mode is already at 75% extension before the
retraction of the outer mid section, it is assumed that these center mid section cylinder is actuated. For this reason, the
sections cannot become unsynchronized. Therefore, on this system provides an additional electrical output to a dual
basis the computed difference between the measured boom pressure relief valve integrated in the telescope control valve
extension value and the measured inner mid section block, causing it to reduce the maximum pressure that can
extension value allows the system to infer the extension of be applied to the center mid section telescope cylinder, so
the center mid section. that the cylinder is protected from such excessive buckling
The system also collects electrical inputs of boundary loads. The system programming always ensures that the
conditions (operator selection, by switch, of “Automatic” or lower pressure is selected before the center mid section
Manual mode, electrical sensing, by proximity switches, of cylinder is pressurized, and that the center mid section
retracted condition of the inner mid section relative to the cylinder is isolated or fully extended, before the higher
base section, and of the center mid section relative to the pressure is selected and applied to the other cylinders.
inner mid section, and of telescope extend or retract pilot The system also provides a control signal to the solenoid
pressure being applied). The system then produces current operated telescope cylinder rod drain valve, opening the
controlled electrical outputs to the appropriate pilot system valve whenever either the inner mid or center mid section is
proportional pressure reducing valves, allowing the pilot not fully retracted (i.e. either of the section “retracted”
pressure to shift the telescoping control valve spools switches is open), and closing the valve whenever both the
appropriately to direct oil to the inner mid or to the center mid switches are closed, indicating complete boom retraction
section telescope cylinder, according to prevailing boom condition.
length and to the direction of motion selected.
If for any reason loss of synchronization of the inner mid/
In Automatic mode, the control system output current being center mid section telescoping system is detected by the
applied to the applicable valve is automatically reduced as boom length sensing and computing system, the system
each section approaches a position at which the selected inhibits all telescoping control signals to all four of the pilot
telescope sequence would require it to stop and the next system proportional control valves, preventing any further
section to begin to move. This causes the pilot oil pressure telescoping motion. To correct the condition, manual
being applied to the control valve spool to be proportionately switches are incorporated, which, when actuated, change
reduced according to the current, (overriding the operator’s the system from Automatic to Manual mode, and select
pilot control valve), so that the section telescoping speed either the inner mid or center mid section for correction in
reduces smoothly before the section finally comes to rest. In Manual mode. The selected section can then be telescoped
the same way the current supply to the valve controlling the individually, by passing the automatic synchronization
following section is initiated just before the previous section system, until it is brought into correct synchronization (the
finally comes to a halt, and rises smoothly to its regulated system constantly displays the prevailing percentage of
extension of the sections, an indictor light on the console 3. Remove the hook block or headache ball and wind all
remains illuminated as long as the unsynchronized condition the wire rope onto the hoist drum.
persists, and the inner mid or center mid section telescope
4. Position the boom to make sure that the lift cylinder is
cylinder selection is indicated by respective lights on the arm
resting securely in the lift cylinder support.
rest, thereby allowing the operator to telescope the section[s]
appropriately). As long as the system continues to detect the
unsynchronized condition, and/or the manual mode is
selected, the load moment monitoring/lockout system also DANGER
limits the allowable load moment to 10,000 kg or 50% of the Ensure blocking and lifting devices are capable of
rated capacity at the particular prevailing boom length, the supporting the boom assembly.
intent being that, while the sections are unsynchronized, any
hook load will be deposited, only the hookblock remaining 5. Attach a lifting device to the boom to provide for equal
suspended while the necessary adjustment of the boom weight distribution.
sections occurs: only when synchronization has been
achieved will the system reset and normalize the load 6. Tag and disconnect any electrical wiring from the boom.
monitoring system when switched back to Automatic mode.
7. Tag and disconnect the hydraulic lines to the lower
The standard used by the system to define an telescope cylinder and plug.
unsynchronized condition is an error or +/-3% of the full
8. Remove the capscrews, washers and nut fasteners
extension value of one section. Since the inner mid, center
securing the base cover to the top of the boom base
mid, and the outer mid/fly combination all extend individually,
section near the pivot shaft. Remove the cover.
compliance with the criterion can only be assessed at
s e c t i o n e x t e n s i o n s c o r r e s p o n d i n g t o t h e p o i n ts o f 9. Secure the hose reel in the turntable to prevent the reel
changeover of movement from section to section. Therefore, from rotating before proceeding to the next step. Reach
the system reviews the extension of each section prior to through the hole in the top of the base section and
permitting the changeover, and unless all section extension disconnect the hose reel lines from the hydraulic
values are within 3% of their programmed changeover manifold that is mounted on the rear of the center mid.
length, the system defaults to the out-of-synchronization Cap all lines and openings. Feed the hoses through the
condition described above. The same default occurs if, in the rollers at the rear of the base.
course of operation, any boom section moves out of
synchronization to a length corresponding to one of its own
changeover lengths (since it then invokes the +/-3% criterion
against the other sections), or moves away from such a DANGER
changeover length by more than the 3% margin. Ensure the boom lift cylinder is properly supported before
disconnecting it from the boom.
MAINTENANCE
10. Block the lift cylinder.
Removal 11. Remove the capscrew and washer securing the upper
lift cylinder shaft to the side of the attach fitting on the
NOTE: The boom weighs approximately 16,606 kg
boom.
(36,610 pounds). Removal of the swingaway boom
extension will simplify boom removal, therefore, the 12. Insert the pump lever (found in cab) into the hand pump
above weight is for the boom without the located on the left side of the boom. Turn the pump flow
swingaway boom extension attached. control lever clockwise and pump the lever until the
upper lift cylinder pin is clear of the boom’s left side lift
1. Extend and set the outriggers to level the crane and
cylinder attachment lug. The lift cylinder may need to be
ensure the boom is fully retracted and in a horizontal
raised or lowered to aid in the release of the lift cylinder
position over the front of the crane.
pivot shaft from the attachment lug. This can be done by
2. If equipped, remove the swingaway boom extension and using the jack on the lift cylinder support.
aux nose according to the removal procedures in this
13. Once the shaft is clear of the attachment lug, activate the
section.
hydraulic system and retract the lift cylinder enough to
clear the attachment lugs. For removal of the lift cylinder
from the crane refer to the removal procedures outlined
DANGER in LIFT CIRCUIT - Removal in this section.
Wear gloves when handling wire rope. 14. Take up the slack on the boom lifting device.
DANGER
Shut down the crane before proceeding. DANGER
A secure fixture that will prevent damage to the boom is
16. Raise the boom clear of the crane and lower to ground recommended to stabilize and hold the boom from moving
and set cribbing to support the boom and prevent during removal of section or sections.
tipping.
3. On the top front of the base section, remove the
Boom Disassembly capscrews, washers, nuts and three cable pads.
NOTE: Boom assembly illustration shown in (Figure 4-2) 4. Repeat step 3 on the inner mid, removing three cable
pads.
4
1. Remove the boom in accordance with the REMOVAL
procedures outlined in this section. 5. Repeat step 3 on the center mid, removing two cable
pads.
2. If necessary, on the left side of the boom remove the two
bolts and washers securing the LMI cable angle 6. Repeat step 3 on outer mid, removing two cable pads.
brackets to the base, inner mid, center mid, and outer 7. On the top front of the base section, remove clip pins
mid. washers and the cable guide assembly.
NOTE: The boom weighs approximately 15420 kg (34,000 8. Remove the capscrews, washers and the tele lock plate
pounds). The above weight is for the boom without from the lower telescope cylinder.
the swingaway boom extension attached.
NOTE: The combined weight of the boom inner mid, center
mid, outer mid, and fly sections, including the
telescope cylinders, is approximately 11,882 kg
DANGER (26,200 pounds).
The boom assembly must be rotated 180° (upside down)
before performing any assembly or disassembly
procedures.
40 24 23
36 1
26
38
2
23
38
3
37
36
38
37 39 25
39 40
4
29 5 25
27
25 6
7
29 21
10
17
25 16
30
10
31
30
28 14 20
29
17
18
33 19
13
34 35
8
10
11 22
15 10 32
12 9 10
6084
FIGURE 4-2
43 1
NOTE: Boom assembly must be rotated 180° 2
52
before performing assembly or
disassembly procedures. 43
47 45
Illustrations shown in upright position for 3
documentation clarity.
48
4 43
43 6692
5
10
6 41
16
44 53
10
42
49
10
51
41 46
42 50
41
17
7 Item Description
41 Bottom Wear Pads
42 Rear Side Wear Pads
43 Top Rear Wear Pads
44 Manifold Block
45 Cam Operated Check Valve
46 Retract Cable Sheave
47 Pusher Rod
48 Upper Cylinder Mounting Plate
49 Lower Cylinder Mounting Plate
50 Retract Cable Sheave Mounting Plate
51 Retract Cable Sheave Shaft
52 Upper Cylinder Rod Mounting Plate
53 Lower Cylinder Rod Mounting Plate
55 56 61
54 60 62
57
58
66
4
59
64 63
64
65
65 6084-2
9. Slide the assembly out of the base part way. 24. Remove the nine capscrews and washers securing the
bottom and side wear pad keeper plates to the inner
10. Remove the two capscrews and washers securing each
mid. Remove the keeper plates.
top wear pad keeper plate to the base section. Remove
the keeper plates. 25. Remove the four capscrews and washers securing each
front top wear pad to the inner mid. Remove the wear
11. Remove the ten capscrews and washers securing the
pads and shims, noting quantity, size, and location of
bottom and side wear pad keeper plates to the base
shims.
section. Remove the keeper plates.
26. Lift up on the front of the inner mid and remove the
12. Remove the two capscrews and washers securing each
bottom and side wear pads and shims from the inner
front top wear pad to the base section. Remove the wear
mid, noting quantity, size, and location of shims.
pads and shims, noting quantity, size, and location of
shims. 27. Continue to pull the assembly from the inner mid,
removing the top rear wear pads from the center mid as
13. Lift up on the front of the base and remove the bottom
they clear the inner mid.
and side wear pads and shims from the base section,
noting quantity, size, and location of shims. 28. Remove the two flat head screws securing the rear side
wear pads to the center mid section. Remove the wear
14. Continue to pull the assembly from the base section
pads and shims, noting quantity and size of shims.
removing the top rear wear pads from the inner mid
section as they clear the base section. 29. Remove the two capscrews and washers securing each
of the bottom wear pads to the center mid and remove
15. Remove the two flat headed screws securing the rear
the wear pads noting quantity and size of shims.
side wear pads to the inner mid section. Remove the
wear pads and shims, noting quantity and size of shims. 30. If necessary, remove both grease fittings, connectors,
and grease lines from the rear of the inner mid.
16. Remove the two capscrews, washers, spacer, and lower
wear pad from the inner mid, noting the quantity and size 31. Remove the mounting plates from the lugs on the lower
of shims. cylinder barrel.
17. Remove the cotter pins, shaft, and roller from the rear of 32. Tag and disconnect the hydraulic hoses and tubes from
the inner mid. the telescope cylinders, the two cam valves and the
hydraulic manifold. Cap and plug all openings.
18. Remove the four capscrews and hardened washers
securing each trunnion mounting plate and block from 33. Remove the bolts and nuts securing each cam valve to
the lower cylinder barrel. its mounting plate and remove the valves.
19. Reach in through the rear of the inner mid to the bottom 34. Remove the four capscrews and washers securing the
rear pad mounted on the center mid section. Remove hydraulic manifold to the mounting plate and remove the
the two capscrews and washers for that pad. Remove hydraulic manifold and the shims, noting the quantity of
pad and shims, noting the number of shims. the shims.
20. Remove the bolts, washers, pusher block, and shims 35. On the right side of the center mid, remove the valve
from the front left side grease access hole, noting the pusher rod from the tube.
quantity of the shims.
36. On the left side of the center mid, remove spring and the
NOTE: Together the boom center mid, outer mid and fly valve pusher weld from the tube. Disassemble as
sections, and telescope cylinders weigh necessary.
approximately 9388 kg (20,700 pounds).
37. Place blocking under the lower second stage cylinder
21. Slide the assembly out of the inner mid part way. barrel.
22. If necessary, remove the four capscrews, washers and 38. Remove the four capscrews and washers securing each
hex nuts securing the stop block to the lower front of the lower cylinder barrel mounting plate and block to the
inner mid. Remove the guide block and note the position center mid.
it was in.
39. Remove four capscrews, washers, and the tele lock
23. Remove the two capscrews and washers securing each plate from the upper telescope cylinder.
top wear pad keeper plate to the inner mid. Remove the
NOTE: Together the boom, outer mid, fly section, and
keeper plates.
telescope cylinders weigh approximately 6991 kg
(15,415 pounds).
40. Slide the assembly out of the center mid part way.
41. If necessary, remove the four capscrews, washers and 57. Remove the four capscrews and washers securing each
nuts securing the guide block to the lower front of the front top wear pad to the outer mid. Remove the wear
center mid. Remove the guide block and note the pads and shims, noting quantity, size, and location of
position it was in. shims.
42. Remove the two capscrews and washers securing each 58. Remove the four capscrews and hardened washers
top wear pad keeper plate to the center mid. Remove securing the stop block to the bracket on the bottom
the keeper plates. front of the outer mid section.
43. Remove the nine capscrews and washers securing the 59. Lift up on the front of the outer mid section and remove
bottom and side wear pad keeper plates to the center the bottom and side wear pads and shims from the outer
mid. Remove the keeper plates. mid, noting quantity, size, and location of shims.
44. Remove the four capscrews and washers securing each 60. Continue to pull the assembly from the outer mid,
front top wear pad to the center mid. Remove the wear removing the top rear wear pads from the fly section as
pads and shims, noting quantity, size, and location of they clear the outer mid.
shims.
61. Remove the two flat head screws securing the three rear
45. Lift up on the front of the center mid section and remove wear pads to the fly section. Remove the wear pads and
the bottom and side wear pads and shims from the shims, noting quantity and size of shims.
center mid, noting quantity, size, and location of shims.
62. If necessary, remove both grease fittings connectors,
46. Continue to pull the assembly from the center mid, and grease lines from the rear of the fly section. 4
removing the top rear wear pads from the outer mid
section as they clear the center mid.
47. Remove the two flat head screws securing the rear side DANGER
wear pads to the outer section. Remove the wear pads Ensure the telescope cylinders are securely blocked and
and shims, noting quantity and size of shims. some means used to hold them together to prevent any
48. Remove the two capscrews and hardened washers accidental movement. Severe injury can occur if the
securing the bottom wear pad to the outer mid and cylinders drop.
remove the wear pad.
NOTE: The telescope cylinder assembly weighs
49. If necessary, remove both grease fittings, connectors, approximately 2041 kg (4500 pounds).
and grease lines from the rear of the outer mid.
63. Slide the telescope cylinder assembly part way out
50. Remove the retract cable sheave mounts from the rear (approximately ten feet) of the rear of the fly. Support the
of the outer mid section, remove retract sheaves. end of the telescope cylinders with adequate blocking.
51. Remove the mounting plates from the second stage of NOTE: The telescope cylinder assembly weighs
the lower cylinder barrel mounting lugs. approximately 1043 kg (2300 pounds).
52. Place blocking under the upper telescope cylinder 64. Slide the lower two stage cylinder farther out of the fly
barrel. until the end of the cylinder is out of the fly.
53. Remove the four capscrews and hardened washers 65. Remove the four capscrews and washers holding the
securing each trunnion mounting plate from the upper top plate cover to the cylinder mount. Remove the two
cylinder barrel mounting plate to the outer mid. flat head screws securing each wear pad if necessary.
NOTE: Together the boom, fly section, and telescope 66. Remove the two nuts and swivel nuts that attach the sled
cylinders weigh approximately 5087 kg (11,217 weld to the two adjusting bolts at the end of the lower
pounds). cylinder.
54. Slide the assembly out of the outer mid part way. 67. Slide the sled weld off the two adjusting bolts and
55. Remove the two capscrews and washers securing each remove the adjusting bolts from the shaft on the lower
top wear pad keeper plate to the outer mid. Remove the cylinder.
keeper plates. 68. Rotate the dead ends of the two retract cables so the
56. Remove the eight capscrews and washers securing the ends can clear the cylinder mount, remove the retract
bottom and side wear pad keeper plates to the outer cables from the cylinder mount.
mid. Remove the keeper plates. 69. Remove the lower cylinder assembly and place on
adequate support.
70. If necessary, remove one cotter pin from the shaft that 84. Remove the two capscrews and washers that retain the
holds the cylinder mount to the lower cylinder. plate cover to the sled weld. Remove the plate cover and
remove the five extension cables.
NOTE: The telescope cylinder assembly weighs
approximately 998 kg (2200 pounds). 85. If removal of the boom nose sheaves are required, refer
to BOOM NOSE SHEAVES - Removal in this section.
71. Remove the shaft and cylinder mount from the lower
cylinder. If necessary, remove the flat head screws 86. Refer to BOOM EXTENSION AND RETRACTION
securing each pad to the cylinder mount. CABLE MAINTENANCE in this section for cable
inspection.
72. Remove the two capscrews and hardened washers
securing the extend cable keeper plate to the rear of the Boom Nose Sheaves
fly. Remove the keeper plate and remove the extend
cable ends from the slots in the fly.
Removal
73. Continue to slide the upper cylinder out of the fly making
1. Remove the clip pins from the cable retainer pins and
sure that the cables are moving with the cylinder. Slide
remove the cable retainer pins from the upper and lower
the telescope cylinder outward until the foot weld at the
part of the boom nose.
end of the upper telescope cylinder is approximately two
feet from the rear of the fly. 2. Flatten out the tab on the lockwasher.
74. Remove the two capscrews and washers from each side 3. Backoff locknut until there is no pressure on the
of the foot weld and remove both wear pad supports. If lockwasher.
necessary, remove two flat head screws and pad from
each support. 4. Remove the bolt, washer, and nut securing the upper
boom nose sheave shaft. Remove the collar.
75. Continue to slide the telescope cylinder assembly out of
the fly section. Raising the rear of the fly section and NOTE: The boom nose sheave shafts weigh
lowering the rod end of the cylinder will aid in removal. approximately 73 kg (161 pounds) each. The boom
nose sheaves weigh approximately 13 kg (28
76. On the front of the fly section, remove the two nuts and pounds) apiece.
hardened washers from the end of each retract cable
and remove the retract cables from the fly section. 5. Carefully pull the upper boom nose sheave shaft from
the boom nose, removing the spacers, shims, and boom
77. Remove the four capscrews and hardened washers nose sheaves.
securing the guide block to the bracket on the rear of the
boom nose. 6. Repeat steps 2 and 3 and remove the lower boom nose
sheave shaft.
78. Remove the two capscrews and washers on both sides
of the sheave mount on the end of the upper cylinder 7. Remove the shim, keyed washer and locknut from both
that holds the cable guide and shaft plates. Remove the sheave shafts.
cable guide and shaft plates.
Installation
79. Remove the two capscrews and washers securing the
extend cable retainer plate to the front of the sheave
mount. Remove the retainer plate.
80. Remove the five extend cables from the sheave
CAUTION
assembly. Do not install the boom nose sheaves over the threaded
end of the boom nose sheave shaft.
81. Remove the grease fitting from the shaft. Remove the
sheave shaft and the sheave assembly from the NOTE: The boom nose sheave shafts weigh
mounting assembly. approximately 73 kg (161 pounds) each. The boom
82. Remove the four capscrews and hardened washers nose sheaves weigh approximately 13 kg (28
securing the sheave mounting assembly and the pounds) apiece.
support foot to the front of the telescope cylinder. 1. Install the spacers and sheaves onto the sheave shaft
Remove the two capscrews and washers holding the while installing the sheave shafts into the boom nose.
cylinder support foot to the sheave mount. Remove the
sheave mounting assembly and the support foot. NOTE: The lockwasher can be used more than once but
must be replaced if not in good condition.
83. If necessary, remove the two screws securing each wear
pad to the support foot and remove the wear pads. NOTE: Install the lockwasher onto the sheave shaft with
the tabs facing out.
2. Install the locknut, washer, keyed washer, and shims (if 1. Install wear pads on the bottom of the upper telescope
necessary) onto the boom nose sheave shaft with the cylinder support foot using two screws each.
chamfer side out. Install the collar onto the opposite end
2. Install the support foot and the sheave mounting
of the sheave shafts and secure in place with the bolt,
assembly on the front of the upper telescope cylinder
washer, and nut.
assembly, with four capscrews and washers. Attach the
NOTE: If more than one shim is required, install an equal support foot and the sheave mounting assembly
amount on each side of the boom nose. together using two capscrews and washers.
3. Tighten the locknut until the play in the entire assembly NOTE: The sheave shaft should be installed with grease
is within 1 to 2 mm (0.03 to 0.06 in) total. Install shims as fitting hole to the left side.
necessary to achieve the correct dimension. Bend the
3. Using the sheave shaft, install the sheave assembly in
lockwasher tabs to secure the locknut in place.
the sheave mounting assembly, making sure the grease
4. Install the cable retainer pins into the upper and lower fitting hole is toward the left of the assembly.
part of the boom nose and secure in place with the hitch
Secure the shaft and the cable guide with a plate and
pins.
two capscrews and washers on each side of the sheave
Boom Assembly mounting assembly. Install grease fitting in the shaft and
apply grease.
4. Route the end of the five extension cables up and
around the upper telescope cylinder sheaves about one 4
DANGER foot on to cylinder. To aid in assembly, secure the cables
When adjusting cables, hold the cable end and turn the to the end of the cylinder by wrapping tape around the
nut. Do not turn cable. Turning cable while adjusting will cylinder.
result in damage or failure of cable.
5. Position the cable retainer plate on the front of the
sheave mounting assembly and secure with two
capscrews and washers.
6. If removed, install the two wear pads on the top of the
DANGER cable guide by using two flathead screws.
Install cables in their natural untwisted condition. Do not
twist cable. Twisting of cable will result in damage or 7. Install the other ends of the extension cables into the
failure of cable. sled weld, making sure the extension cables are not
crossed and twisted.
NOTE: Apply Loctite 242 to the threads of all attaching 8. Install the plate cover on the sled weld and secure with
hardware except cable ends and cable lock nuts. two capscrews and washers.
NOTE: Apply multipurpose grease (MPG) to all wear 9. At the rear of the fly section, install the upper wear pad
surfaces. grease line, connector and grease fitting on each side.
NOTE: Use standard Grade 5 and/or 8 torque values NOTE: The grease lines are designed to be used only on
specified in Section 1- INTRODUCTION in this one side or the other (i.e. RH or LH).
Manual unless otherwise specified.
10. Install the three lower rear wear pads and shims on the
fly section with two flat head screws.
11. Route the two retract cables (threaded ends) through
DANGER the fly section to the front. Insert the threaded ends
The boom assembly must be rotated 180° (upside down) through the holes on the front of the fly section and
before performing any assembly or disassembly install a hardened washer and two nuts on each cable
procedures. end.
12. Using an adequate lifting device, position the upper
telescope cylinder into the rear of the fly section.
DANGER 13. Slide telescope cylinder assembly into the rear of the fly
section until foot support clears the gussets at the rear of
A secure fixture that will prevent damage to the boom is
the fly section. Raising the rear of the fly and lowering
recommended to stabilize and hold the boom from moving
the rod end of the cylinders will aid in sliding these
during insertion of section or sections.
together.
14. Place the extend cable lug ends in the slots at the top of 29. At the rear of the outer mid section, install the upper
the fly section and secure them with the keeper plate wear pad grease line, connector and grease fitting on
and two capscrews and hardened washers. each side.
15. Install a wear pad on the two upper telescope cylinder NOTE: The grease lines are designed to be used only on
wear pad holders using two flat head screws. one side or the other (i.e. RH or LH).
16. Position the wear pad holders on each side of the upper 30. Install the bottom rear wear pad on the outer mid section
telescope cylinder support foot and secure each with with two capscrews and hardened washers.
two capscrews and washers.
31. Position the front end of the outer mid at the rear of the
17. Slide the upper telescope cylinder assembly part way in fly/telescope cylinder assembly.
(approximately ten feet). Place blocking under the rear
32. Place the mounting plates on the upper telescope
of the telescope cylinder to aid in assembly.
cylinder barrel mounting lugs.
18. Using the cylinder mount shaft attach the lower cylinder
33. Slide the fly/telescope cylinder assembly into the outer
mount to the end of the lower cylinder. Attach cotter pins
mid section installing top rear wear pads in pockets of fly
to secure shaft.
section (cutout should align with grease line). Stop and
19. Install the wear pad and skid pad with flathead screws to check rear wear pad clearance and shim if needed.
the lower cylinder mount.
NOTE: Use shims as they are necessary to adjust wear
20. Lift lower telescope cylinder assembly and place on pads within 2 mm (0.078 in) of the outer mid
upper telescope cylinder. section side plate. Use equal number of shims on
side pads.
21. Install the wear pads with flathead screws to the top
plate cover. 34. Continue to slide together being careful not to damage
cables.
22. Install the top plate cover assembly with four capscrews
and washers to the lower cylinder mount, to attach the 35. Install bottom and side front wear pads in outer mid. Lift
upper and lower cylinders together. up on the front of the fly section assembly and check
clearance between the pads and the pad box weldment
23. Install both ends of the retract cables to the appropriate
on the outer mid section. Install shims as necessary so
holes in the lower cylinder mount, making sure that the
there is no more than 1 mm (0.03 in) clearance between
cables are not crossed or twisted.
the wear pads and the fly section.
24. Install the adjusting bolts through the holes in the lower
36. Install outer mid front top wear pads and shims as noted
mount shaft.
during disassembly. Secure with four capscrews and
25. Install the sled assembly onto the adjusting bolts and hardened washers each.
install both swivel nuts, making sure that the extension
NOTE: Use shims as necessary to adjust wear pad so that
cables are not crossed and twisted.
the wear pad is just touching or is within 2 mm
(0.078 in) of the fly section side plate at both the top
and side surfaces of the top radius.
DANGER 37. Install bottom and side wear pad keeper plate on each
Ensure the telescope cylinders are securely blocked and side of the outer mid and secure with eight capscrews
some means used to hold them together to prevent any and washers each.
accidental movement. Severe injury can occur if the
cylinders drop. 38. Install top wear pad keeper plate on each side of the
outer mid and secure with two capscrews and washers
26. Secure each retract cable to the side of the upper each.
cylinder assembly near the trunnion with tape or ty- 39. Continue to completely slide together.
wraps.
40. Lift up on end of the upper cylinder to align barrel
27. Slide the telescope cylinders into the fly section until the mounting plate holes with holes in outer mid. Secure
trunnion on the upper cylinder is three feet from the back each with four capscrews and hardened washers.
of the fly.
41. Remove any blocking under the upper cylinder.
28. Block up the telescope cylinders at the rear of the fly
section to aid in installing the fly section assembly into 42. Detach the retract cables from the upper telescope
the outer mid. cylinder, place the cables around each retract sheave,
place the sheave onto the shaft weld and use four bolts
and washers to secure each shaft weld assembly into 53. Install top wear pad keeper plate on each side of the
the rear of the outer mid, making sure that the retract center mid and secure with two capscrews and washers
cables are not crossed and twisted. each.
43. Position the guide blocks on the boom nose to the 54. Continue to slide together aligning the upper cylinder rod
correct clearance (0 mm to 2 mm, 0.00 in. to 0.06 in.) end with bushing in center mid trunnion. Slide
with respect to the guide bars on the outer mid. Secure completely together.
with four capscrews and washers for each.
NOTE: Use shims as necessary to adjust guide block so
44. Place the mounting plates and blocks on the second that the guide block is within 3 to 5 mm (0.118 to
stage lower cylinder barrel mounting lugs. 0.197 in) of the top of the outer mid section.
45. At the rear of the outer mid install the fittings and hoses 55. Secure the telescope lock plate to the upper cylinder rod
to both retract sheaves, grease sheaves. end with four capscrews and hardened washers.
46. At the rear of the center mid section, install the upper 56. Install bolt, nut, and hardened washer in right side valve
wear pad grease line, connector and grease fitting on tapped pusher rod. Install the rod assembly through hole
each side. on right side of center mid.
NOTE: The grease lines are designed to be used only on 57. Install left side valve pusher weld assembly in tube on
one side or the other (i.e. RH or LH). left side of center mid, attach return spring.
47. Install the two side lower side wear pads and shims on
the rear of the center mid with two capscrews and
58. Lift up on end of the lower cylinder to align barrel
mounting plate holes with holes in inner mid. Secure
4
washers. The bottom rear pad and shims will be installed each with four capscrews and hardened washers.
after the center mid assembly is inserted into the inner
59. Remove any blocking under cylinder.
mid.
60. Access through the rear of the inner mid to install the
48. Position the front end of the center mid at the rear of the
bottom wear pad and shims onto the rear of the center
outer mid/fly/telescope cylinder assembly.
mid with two capscrews.
49. Slide the outer mid/fly/telescope cylinder assembly into
NOTE: Use shims as necessary to adjust wear pad so that
the center mid section installing top rear wear pads in
the wear pad is just touching or is within 2 mm
pockets of outer mid section (cutout should align with
(0.078 in) of the outer mid section side plate at both
grease line). Stop and install rear side wear pads and
the top and side surfaces of the top radius.
shims on outer mid section with two flat head screws
each. 61. Install the cam valves on the mounting plates on each
side of the inner mid using three bolts, hardened
NOTE: Use shims as they are necessary to adjust wear
washers, and nuts (early models only) each.
pads within 2 mm (0.078 in) of the center mid
section side plate. Use equal number of shims on 62. Install hydraulic manifold and shims on the mount plate
each side. at the rear of the center mid with four capscrews and
washers.
50. Install bottom and side front wear pads in center mid. Lift
up in the front of the outer mid section assembly, check 63. If removed, install hydraulic fittings in the ports of the
clearance between the pads and the pad box weldment valves, hydraulic manifold, and the cylinders as tagged
on the center mid section. Install shims as necessary so during disassembly.
there is no more than 1 mm (0.03 in) clearance between
64. Connect the hydraulic hoses and tubing to the valves,
the wear pads and the outer mid section.
hydraulic manifold, and cylinders as tagged during
51. Install center mid front top wear pads and shims as disassembly.
noted during disassembly. Secure with four capscrews
65. Place the mounting plates and blocks on the lower
and washers each.
cylinder barrel mounting lugs.
NOTE: Use shims as necessary to adjust wear pad so that
66. Position the guide blocks on the front of the outer mid to
the wear pad is just touching or is within 2 mm
the correct clearance (0 mm to 2 mm, 0.00 in. to 0.06 in.)
(0.078 in) of the outer mid section side plate at both
with respect to the guide bars on the center mid. Secure
the top and side surfaces of the top radius.
with four capscrews, washers and nuts for each.
52. Install bottom and side wear pad keeper plate on each
67. At the rear of the inner mid section, install the upper
side of the inner mid and secure with nine capscrews
wear pad grease line, connector, and fitting on each
and washers each.
side.
NOTE: The grease lines are designed to be used only on 81. Position the front end of the base at the rear of the inner
one side or the other (i.e. RH or LH). mid/center mid/outer mid/fly/telescope cylinder
assembly.
68. Install the bottom rear wear pad on the inner mid section
with two capscrews and hardened washers. 82. Slide the inner mid/center mid/outer mid/fly/telescope
cylinder assembly into the base section installing top
69. Position the front end of the inner mid at the rear of the
rear wear pads in pockets of inner mid section (cutout
center mid/outer mid/fly/telescope cylinder assembly.
should align with grease line). Stop and install rear side
70. Slide the center mid/outer mid/fly/telescope cylinder wear pads and shims on inner mid section with two flat
assembly into the inner mid section installing top rear head screws each.
wear pads in pockets of the center mid section (cutout
NOTE: Use shims as necessary to adjust wear pad so it is
should align with grease line). Stop and install rear side
within 2 mm (0.078 in) of the base section side
wear pads and shims on center mid section with two flat
plate. Use equal number of shims on each side.
head screws each.
83. If removed, install the roller shaft and cotter pins at the
NOTE: Use shims as necessary to adjust wear pad so it is
rear of the inner mid.
within 2 mm (0.078 in) of the inner mid section side
plate. Use equal number of shims on each side. 84. Continue to slide together.
71. Continue to slide together. 85. Install bottom and side front wear pads in base. Lift up in
the front of the inner mid section assembly, check
72. Install bottom and side front wear pads in the inner mid.
clearance between the pads and the pad box weldment
Lift up in the front of the center mid section assembly,
on the base section. Install shims as necessary so there
check clearance between the pads and the pad box
is no more than 1 mm (0.03 in) clearance between the
weldment on the inner mid section. Install shims as
wear pads and the inner mid section.
necessary so there is no more than 1 mm (0.03 in)
clearance between the wear pads and the center mid 86. Install base section front top wear pads and shims as
section. noted during disassembly. Secure with four capscrews
and washers each.
73. Install inner mid front top wear pads and shims as noted
during disassembly. Secure with four capscrews and NOTE: Use shims as necessary to adjust wear pad so that
washers each. the wear pad is just touching or is within 2mm
(0.078 in) of the inner mid section side plate at both
NOTE: Use shims as necessary to adjust wear pad so that
the top and side surfaces of the top radius.
the wear pad is just touching or is within 2 mm
(0.078 in) of the outer mid section side plate at both 87. Install bottom and side wear pad keeper plate on each
the top and side surfaces of the top radius. side of the base section and secure with ten capscrews
and washers each.
74. Install bottom and side wear pad keeper plate on each
side of the inner mid and secure with nine capscrews 88. Install top wear pad keeper plate on each side of the
and washers each. base section and secure with two capscrews and
washers each.
75. Install top wear pad keeper plate on each side of the
inner mid and secure with two capscrews and washers 89. Continue to completely slide together.
each.
90. Continue to slide together aligning the lower cylinder rod
76. Continue to completely slide together. end with bushing in base trunnion block. Slide
completely together.
77. Lift up on end of the lower cylinder to align barrel
mounting plate holes with holes in inner mid. Secure 91. Install hydraulic fittings if removed from lower telescope
each with four capscrews and hardened washers. cylinder rod.
78. Remove any blocking under cylinder. 92. Secure the telescope lock plate to the lower cylinder rod
end with four capscrews and hardened washers.
79. Install the pusher block at the front left grease access
hole on the inner mid. Replace the shims and secure 93. If removed, install the five rollers, spindle roller, and
with two bolts and washers. cotter pins to the rear of the base section.
80. Position the guide blocks on the front of the center mid to 94. Position the guide blocks on the front of the inner mid to
the correct clearance (0 mm to 2 mm, 0.00 in. to 0.06 in.) the correct clearance (0 mm to 2 mm, 0.00 in. to 0.06 in.)
with respect to the guide bars on the inner mid. Secure with respect to the guide bars on the base. Secure with
with four capscrews and washers for each. four capscrews and washers for each.
95. On the top front of the base section, install bolts, 3. Lubricate the pivot shafts and related pivot bushings in
washers, and three cable pads. the boom assembly and the turntable weldment.
96. Repeat step 95 on the inner mid, installing three cable
pads.
97. Repeat step 95 on the center mid, installing two cable DANGER
pads. Block the boom before doing any work under the boom.
98. Repeat step 95 on outer mid, installing two cable pads. 4. Block the boom in place.
5. The boom may need to be raised or lowered to aid in the
installation of the pivot shafts. Remove the hoses from
DANGER the counterweight removal cylinder, match up the quick
The boom assembly must be rotated 180° right side up to disconnects of the hoses to the disconnects on the pivot
install on crane. shaft removal cylinder.
6. Activate the cylinder to install the pivot shafts. Ensure
the pivot shafts seat fully in the pivot bushings in the
boom assembly and the turntable weldment; the pivot
DANGER shafts are stepped because the bushings are of different
A rollover fixture with webbing is recommended to rotate diameters.
4
boom and sections. Chains are not recommended. If a 7. Remove the hoses from the pivot shaft cylinder. Match
rollover fixture is not available, rotate sections using up the quick disconnects of the hoses to the disconnects
adequate support with webbing. on the counterweight removal cylinder.
NOTE: The boom weighs approximately 15420 kg (34,000 8. Install the two pivot lock weldments to secure the pivot
pounds). The above weight is for the boom without shafts to the turntable weldment. Fasten them to the
the swingaway boom extension attached. pivot shafts with capscrews and washers.
99. Lower the boom to ground level and secure with cribbing
to prevent tipping.
100.On the top front of the base section, install clip pins, DANGER
washers, and the cable guide assembly. Failure to properly support the boom lift cylinder may
result in death or injury to personnel.
101.On the left side only, install a LMI cable angle bracket on
the base, inner mid, and outer mid using two capscrews
and washers each.
102.Install the boom in accordance with the INSTALLATION DANGER
procedures outlined in this section. If the hydraulic system must be activated to extend or
retract the lift cylinder, ensure the rod end is properly
Installation aligned with the lift cylinder attach fitting.
NOTE: The following procedure applies to a boom totally
9. Lubricate the upper lift cylinder pin and related bushings
removed from the crane.
in the lift cylinder rod end and the boom’s lift cylinder
attach lugs.
10. Using the lifting device attached to the boom, lower the
DANGER boom onto the lift cylinder rod end. Activate the crane’s
Ensure blocking and lifting devices are capable of hydraulic system and align the lift cylinder rod end with
supporting the boom assembly. the boom’s lift cylinder attachment lug holes as needed.
11. Using the hand pump located on the left side of the
1. Attach an adequate lifting device to the boom and
boom, insert the pump lever (found in cab) into the hand
suspend the boom over the machine.
pump. Turn the pump flow control lever
2. Lower the boom into position and align the boom pivot counterclockwise and pump the pump lever until the
shaft mounting holes for installation of the pivot shaft to upper lift cylinder pin pins the rod end of the lift cylinder
the superstructure assembly. to the boom’s lift cylinder attachment lugs, and the upper
lift cylinder pin’s flange portion fits completely against
the left side of the boom’s left lift cylinder attachment lug. check security of boom wear pads. Check boom nose
The lift cylinder may need to be raised or lowered to aid sheaves for security and freedom of movement.
in the installation of the upper lift cylinder pin. This can
Should boom chatter or rubbing noises in the boom occur, it
be done by using the jack on the lift cylinder support.
will be necessary to lubricate the telescope cylinder wear
Shut down the engine.
pads. Refer to Section 9 - LUBRICATION.
12. Apply Grove-approved threadlocking compound to the
upper lift cylinder pin’s related capscrew. Secure the Boom Alignment And Servicing
upper pivot shaft to the boom with the capscrew and
Refer to Section 9 - LUBRICATION for the proper lubricant.
washer.
Boom alignment is done as the boom sections are being
13. Lower the jack on the lift cylinder support.
assembled into one another. A check and fine adjustment is
14. Remove the boom lifting device. as follows.
15. Activate the hydraulic system and remove the boom and 1. Fully extend the boom horizontally.
lift cylinder blocking devices. Lower the boom to
2. Lubricate the boom bottom channels and top corners.
horizontal. Shut down the crane.
3. Shim the front top wear pads such that wear pad is just
16. Connect the hydraulic lines to the lower telescope
touching or is no more than 2 mm (0.078 in) from
cylinder as tagged prior to removal.
contacting the next section both at the top and side
17. Feed the hoses through the rollers at the rear of the surfaces of the top radius.
base. Reach through the hole in the top of the base
section and attach the hose reel lines to the hydraulic
CAUTION
manifold as tagged prior to removal. Release the hose
reel in the turntable. When extending and retrac ti ng the boom during
alignment, movement should be stopped if a restriction is
18. Install the base cover on top of the boom base section, encountered, and wear pads adjusted as necessary to
secure with four bolts and washers. provide free travel of the affected boom section(s).
19. Connect any electrical wires as tagged prior to removal.
4. Retract and extend the boom; check for the high point
where the boom has brushed the wear pads at the
CAUTION widest point.
If removed, ensure the large access covers on each side
5. Retract the boom sections to align the high point on the
of the boom base section are installed before extending
boom section with the adjacent wear pads.
the boom.
6. Add or subtract shims as necessary.
20. Refer to BOOM EXTENSION AND RETRACTION
7. Attach a weight and extend the boom full length. Check
CABLE ADJUSTMENT in this section for cable
for side deflection.
adjustments.
Example: If the boom deflects to the left, the top left wear
21. Refer to CAM OPERATED CHECK VALVE
pad would have shims added and the top right wear pad
ADJUSTMENT in this section for valve adjustment.
would have shims removed.
Functional Check Cam Operated Check Valve Adjustment
1. Activate the hydraulic system and check for proper
There are two cam operated valves mounted on the back of
operation and any leaks.
the center mid section. When the boom is fully retracted or
2. Ensure the boom will extend and retract properly. the center mid is fully extended and the outer mid is fully
retracted, the valve on the right side of the boom is held open
3. Ensure the lift cylinder will not allow the boom to drift
to supply flow to the second stage of the lower cylinder.
down until the operator lowers it.
When the center mid is fully extended, the valve on the left
4. Ensure all electrical components disconnected during side of the boom opens to supply flow to the upper telescope
removal are operating properly. cylinder. For a short period of time, both valves are open
because the booms second stage lower cylinder is fully
Inspection extended before the upper cylinder starts to extend. As the
outer mid starts to extend, the valve on the right side closes
Visually inspect telescoping sections for adequate lubrication
to shut off the flow to the second stage of the lower cylinder.
of all wear surfaces. Observe extended sections for
evidence of cracks, warping, or other damage. Periodically
1. Align and service the boom. Refer to BOOM - 0.4 mm (0.016 in) for diameters up to and including
ALIGNMENT AND SERVICING in this section. 8 mm (0.3125-in).
2. Rotate the guide block at the top and bottom of the inner - 0.79 mm (0.031 in) for diameters 10 and 13 mm
mid/center mid section, and outer mid section so that the (0.375 and 0.5-in) inclusive.
guide block is within 0 to 2 mm (0 to 0.078 in) of the - 1.19 mm (0.047 in) for diameters 14 to 19 mm
welded block on the top of the next section. (0.5625 to 0.75-in) inclusive.
3. Repeat the same for the fly section guide blocks at the - 1.59 mm (0.063 in) for diameters 22 to 29 mm
top and left side of the back of the boom nose. (0.875 to 1.125 in) inclusive.
NOTE: The guide block hole pattern is so designed that - 2.38 mm (0.094 in) for diameters 32 to 38 mm (1.25
the guide block has four mounting positions which to 1.5 in) inclusive.
provide 3.175 m (0.125 in) incremental settings.
5. In standing ropes, more than two broken wires in one lay
4. After obtaining proper clearance, tighten the four bolts. in sections beyond end connections or more than one
broken wire at an end connection.
BOOM EXTENSION AND RETRACTION
CABLE Adjustment
At near fully extended boom length, during sudden extension
Maintenance after retracting the boom some distance, and with high
NOTE: For more detailed information concerning telescoping speeds, the extension cables may slap the
maintenance of the extension and retraction inside of the boom section. This will make a somewhat
cables, refer to WIRE ROPE in Section 1 - audible noise, however this will not cause any damage and is
INTRODUCTION. acceptable. If the cables do not make a slapping noise under
these conditions, it is an indication that the extension cables
may be too tight and should be readjusted. Be aware that
there may also be a similar noise made by the telescope
cylinder rod mount at the rear of the base section and center
mid section and confusion between the two could be
experienced.
TELESCOPE CIRCUIT A holding valve is threaded into a port block on the rod end of
the upper telescope cylinder and the first stage rod end on
Description the lower telescope cylinder. The holding valve for the
second stage of the lower telescope cylinder is mounted into
The boom telescope circuit consists of the telescope the port block on the barrel end of the second stage barrel.
hydraulic remote controller, telescope directional control The holding valves function during the retraction, extension,
valve, holding valve, hose reel, and the upper and lower or holding operation. When holding the boom section at a
telescope cylinders. given length, oil is trapped in the cylinder by the holding
The telescope control valve is the closed spool type and is valve. Refer to VALVES in Section 2 for a complete
described under VALVES in Section 2. description of the holding valve.
Maintenance
Table 4-2
Troubleshooting
HOSE REEL spring maintained when the boom is level and fully
retracted.
Description 3. Assemble brake (Figure 4-4) onto brake disc and adjust
The hydraulic hose reel (Figure 4-4) supplies the boom as follows:
manifold for the upper telescope cylinder. The hose reel is a. Ensure the brake pads and disc are free of grease
mounted in the turntable center section, under the boom. and oil.
The hose reel is spring return. The spring return provides b. Loosen setscrew and unscrew spring brake housing
drag on the hoses so that no slack develops when the enough to slide brake over brake disc.
telescope cylinders are being extended or the boom is being
lowered, and retrieves the hoses as the telescope cylinders c. Pressurize brake housing to 8274 kPa/82.7 bar
are being retracted or when the boom is raised. (1200 psi).
d. Screw in spring brake housing until a total gap of
Maintenance 30.4 cm (.012 inch) exists between disc and pads.
4. Remove the capscrews and washers securing the hose 6. Connect the hydraulic supply hoses to the hose reel
reel to the turntable, remove the hose reel. assembly.
NOTE: Ensure there is enough hose unwound from the
Installation hose reel to attach the hoses to the telescope
1. Position the hose reel assembly on the turntable and cylinders.
secure with the washer and capscrews. Torque the
capscrews 97.6 to 105.7 Nm (72 to 78 pounds-foot).
2. Pre-tension twin-line hose by rotating the twin line DANGER
section of hose reel only two complete revolutions Ensure the retaining bolt remains installed until the hoses
counterclockwise (as seen from left side of crane looking are attached to the telescope cylinders.
in). There must be two complete revolutions of the reel
11 12
4, 6 5 14
3
12
9, 10, 11
2
2
13
FIGURE 4-3
1, 8
12
9, 10, 11
0.25±Chain Slack
Measure near the center of span
12
7 9, 10, 11 VIEW A
2.2 mm 2.2 mm
(0.09 inches) (0.09 inches)
15
7. Connect the hydraulic hoses to the manifold block Hose Reel Alignment
assembly located at the rear of the boom inner mid
section. After hose reel is installed and the attaching bolts properly
torqued, check hose reel to hose guide roller alignment
8. Remove the retaining bolt from the hose reel to allow (Figure 4-3).
tension to be applied to the hoses.
1. Check measurements between the hose reel’s hose
9. Secure the retaining bolt to the hose reel so the hose flanges and its guide roller (Figure 4-3).
reel is allowed to rotate. 2. Add shims as required to align the hose reel assembly to
the roller within 2.2 mm (0.09 inches).
10. Adjust and secure the hose retainer.
6
5
7
4 8
3 10
13
11 14
12
2.2 mm 2.2 mm
6693
(0.09 inches) (0.09 inches)
15
LIFT CIRCUIT The holding valve is a balanced poppet type hydraulic valve.
It is threaded into the port block which is an integral portion of
Description the lift cylinder barrel. The holding valve functions when
booming up (cylinder rod extended), booming down (cylinder
The boom lift circuit consists of the lift hydraulic remote rod retracted), or holding (cylinder rod stationary).
controller, lift directional control valve, holding valve, and the
lift cylinder. These components enable the boom to be raised Theory Of Operation
or lowered to various degrees of elevation ranging from -3 to
+78 degrees from horizontal. The directional control valve bank housing the lift control
valve is supplied by flow from the hydraulic pump.
The lift directional control valve is the closed spool type and
is described under VALVES in Section 2 - HYDRAULIC When booming up, oil unseats the poppet (check) valve in
SYSTEM. the holding valve, letting oil flow to the piston side of the
cylinder. Pressure is applied to the piston, forcing the rod to
Refer to VALVES in Section 2 - HYDRAULIC SYSTEM for a extend, raising the boom.
complete description of the hydraulic remote controller.
When booming down, oil enters the retract port of the port
The lift cylinder has a 35.56 cm (14.0 in) bore. The cylinder is block and flows to the cylinder rod side. When pilot pressure
a double acting type. Dirt and other foreign material is reaches a pre-determined value, the main poppet unseats
prevented from entering the cylinder and causing internal and oil flows from the piston side of the cylinder to the
damage by a wiper seal during rod retraction. Oil Seals on reservoir.
both the piston and cylinder head prevent internal and
external hydraulic oil leakage. Refer to CYLINDERS in All return flow from the control valve goes to the reservoir.
Section 2 - HYDRAULIC SYSTEM for a complete description
of the lift cylinder.
Maintenance
Table 4-3
Troubleshooting
NOTE: Refer to Section 2 - HYDRAULIC SYSTEM for lift pivot shaft from the attachment lug. This can be done by
cylinder Disassembly and Assembly procedures. using the jack on the lift cylinder support.
Maintenance not requiring removal of the cylinder
8. Once the shaft is clear of the attachment lug, activate the
barrels, such as packing, may be performed
hydraulic system and retract the lift cylinder enough to
without removing the cylinders from the turntable.
clear the attachment lugs.
However, all disassembly and assembly should be
conducted in a clean dust-free area. 9. Tag and disconnect all the hydraulic lines to the lift
cylinder. Cap or plug all openings with high pressure
Removal fittings.
1. Extend and set the outriggers and level the crane. 10. Pull the lower lift cylinder pivot shaft out far enough to
remove the lift cylinder.
2. Elevate the boom slightly so that the lift cylinder is
extended approximately 0.3 m (1 ft). 11. Move the lift cylinder to a clean work area.
6. Lubricate the upper lift cylinder pin and related bushings The lift cylinder may need to be raised or lowered to aid
in the boom’s lift cylinder attachment lugs and in the lift in the installation of the upper lift cylinder pin. This can
cylinder rod end. be done by using the jack on the lift cylinder support.
Shut down the engine.
7. Activate the crane’s hydraulic system and align the lift
cylinder rod end with the boom’s lift cylinder attachment 9. Apply medium strength adhesive/sealant to the upper lift
lug holes as needed. cylinder pin’s related capscrew. Secure the upper lift
cylinder pin to the boom with the capscrews and
8. Using the hand pump located on the left side of the
washers. Torque the capscrews 481 to 522 Nm (355 to
boom, insert the pump lever (found in cab) into the hand
385 pounds-foot).
pump. Turn the pump flow control lever
counterclockwise and pump the pump lever until the 10. Remove the lifting and supporting devices from the
upper lift cylinder pin pins the rod end of the lift cylinder boom and lift cylinder. Activate the hydraulic system and
to the boom’s lift cylinder attachment lugs, and the upper check the lift cylinder for proper operation and any leaks.
lift cylinder pin’s flange portion fits completely against
11. Lubricate the pivot shafts at their grease fittings.
the left side of the boom’s left lift cylinder attachment lug.
6, 7
Detail A
Cutaway For
Clarity
1, 2 Top of
Boom
9 18
19, 20
16 22
12 16
21
24
13, 14
25 4
17
23
9
29, 30, 31
27, 28 26
36
35
34
37
BOOM REMOVAL SYSTEM 4. Install the lid weldment and cylinder onto the upper lift
cylinder pin. Secure lid weldment with capscrews and
Description lock washers.
The boom removal system (Figure 4-6) uses hydraulic 5. Secure the pin removal cylinder to the latch plate with
cylinders to extend and retract the upper lift cylinder pin and two snap rings.
the pivot shafts. The upper lift cylinder pin uses a hand 6. Secure the latch plate to the two support rods with two
activated pump. The pivot shaft cylinder uses the hydraulic nuts and lock washers.
lines from the counterweight removal system.
7. Connect the hydraulic lines from the hand pump to the
Maintenance cylinder as tagged before removal.
NOTE: The upper lift cylinder pin and the boom pivot shafts 8. Install upper lift cylinder pin into lift cylinder attach lugs of
should only be serviced when the boom is off of the boom and secure with the capscrews and washers.
crane. These procedures assume the lift cylinder Torque the capscrews 481 to 522 Nm (355 to 385
has been removed from the boom. pounds-foot).
Upper Lift Cylinder Pin And Cylinder Disassembly Boom Pivot Shafts And Cylinder Disassembly
1. Tag and disconnect the hydraulic lines from the hand 1. If attached, remove capscrews, washers and nut
pump to the cylinder used to remove the upper lift fasteners from the base cover. Remove base cover.
cylinder pin at this cylinder. Plug these lines. 2. If installed, remove capscrews and washers from each 4
2. Remove capscrew and washer from upper lift cylinder pivot lock weldment. Remove pivot lock weldments from
pin as needed. pivot shafts.
3. Remove the two nuts and lockwashers from the two 3. Working through the pivot pins, remove nuts and
support rods. washers from both of the cylinder’s rod ends. Pull both
pivot shafts outward to free cylinder. Remove cylinder
4. Pull the upper lift cylinder pin and its pin removal cylinder through the base access hole.
(jack cylinder) away from the boom until the latch plate
clears the threads on the support rods. 4. Remove capscrews, washers, and nuts from each set of
brackets. Remove brackets from cylinder, noting
5. Remove the snap rings from the latch plate. Remove the position of brackets.
latch plate from the pin removal cylinder.
5. If needed, tag and disconnect hydraulic line and fittings
6. Remove the capscrews and lockwashers from the lid from cylinder.
weldment. Remove the lid weldment and pin removal
cylinder from the upper lift cylinder pin. 6. Remove capscrews and washers from each lock plate
weldment. Remove lock plate weldments from the pivot
7. Remove hitch pin clip, washer, and clevis pin from the lid shafts.
weldment. Remove pin removal cylinder from lid
weldment. 7. Remove pivot shafts if needed. Remove grease fittings
from the pivot shafts if needed.
8. Remove upper lift cylinder pin from boom’s lift cylinder
attachment lugs as needed. Boom Pivot Shafts And Cylinder Assembly
9. Remove support rods from the boom’s left lift cylinder 1. Install grease fittings in the pivot shafts.
attachment lug as needed. 2. Coat the pivot shafts and the boom pivot bushings with
grease. Install the pivot shafts into the boom’s pivot
Upper Lift Cylinder Pin And Cylinder Assembly
bushings.
1. If removed, secure support rods to the boom’s left lift
3. Install each lock plate weldment onto the pivot shafts.
cylinder attachment lug.
Secure lock plate weldments to pivot shafts with
2. If upper lift cylinder pin was removed, coat upper lift capscrews and washers.
cylinder pin and surfaces of bushings in boom’s lift
4. Install pivot shaft cylinder through base access hole and
cylinder attachment lugs with grease. Install this pin onto
position the rod end flats to match with the tabs on each
support rods.
lock plate weldment. Slide pivot shafts onto the rod
3. Install pin removal cylinder (jack cylinder) on lid ends. Secure both cylinder rod ends to the pivot pins
weldment. Secure cylinder to lid weldment with hitch pin with nuts and washers.
clip, washer, and clevis pin.
5. Install brackets as positioned before removal. Secure 7. Install each pivot lock weldment and secure with
both sets of brackets with capscrews and washers. capscrews and washers. Torque capscrews 293 to 317
Nm (216 to 234 pounds-foot)
6. Connect hydraulic line and fittings to cylinder as tagged
prior to removal. 8. Install base cover and secure with capscrews, washers
and nut fasteners.
11 9, 10
12, 13
12, 13
1
15 5, 6, 7, 8
3, 4
14
6123
FIGURE 4-6
DANGER DANGER
When erecting the swingaway, ensure that all personnel Make sure the connection between the boom 11 m
and equipment are kept clear of the swing path. extension and the main boom extension stowage bracket
is engaged and secure before removing the attach pins on
15. Slightly raise and/or lower the boom to help control the the right hand side boom nose. This will prevent the boom
swingaway. Using the rope attached to the tip of the extension from falling.
swingaway, swing the swingaway into place ahead of
the boom nose, engaging the anchor fittings with the
anchor lugs on the left side of the boom nose.
DANGER
When stowing the swingaway, ensure that all personnel
DANGER and equipment are kept clear of the swing path.
Do not modify the attach points to permit the installation of
the attach pins.
CAUTION
16. Install the short attach pin into the upper extension
anchor fitting and boom anchor lug on the left side of the Do not allow the swingaway to slam into the stowage
boom nose. Install retainer clip in attach pin. brackets when swinging into the stowed position.
17. Hammer the long attach pin in the lower extension 5. Raise and/or lower the boom to help control the 11 m
anchor fitting and boom anchor lug on the left side of the extension and using the rope attached to the tip of the
boom nose. Install the retainer clip in the attach pin. extension, swing the extension to the side of the boom.
18. Extend and lower the boom until blocking can be placed 6. Swing the 11m extension until it contacts the front
under the swingaway. Remove the rope from the tip of stowage bracket. Lift up on the lever and push the boom
the swingaway base. extension until its mounting holes align with the
19. Lower the swingaway onto the cribbing. Remove and extension hanger pivot mounting holes on the main
stow the pins securing the 11m section to the boom boom (Detail A) (Figure 4-7). Pull downward on the lever
nose. to insert the spring pin into its mounting holes. Make
sure the spring pin is secure and engaged properly
20. Retract the boom, freeing the swingaway from the boom between the boom extension and main boom. Secure
nose. the connection with retaining pin and clip pin.
Installation 7. Remove the retaining clips from the attaching pins at the
boom anchor lugs and extension anchor fittings on the
1. Position the crane so the swingaway lies in front of the right side of the boom nose. Hammer the two attach pins
crane with the swingaway base facing the crane. Fully out of the attaching points and insert them into the
extend and set the outriggers. holders on the base of the boom extension, securing
them with retaining clip.
2. Extend and lower the boom to engage the boom anchor
lugs and the extension anchor fittings. 8. With the guide rail in the out position, push the 11m
extension onto the guide rail until it comes in contact
3. Install the attach pins and retainer clips to secure the
with all of the boom extension to main boom stowage
11 m extension section to the boom nose. Attach a
connections.
length of rope to the extension tip. Raise the boom,
lifting the extension from the cribbing on which it was NOTE: If the 7m section (fly) remained on the boom
resting. Retract the boom. stowage brackets, perform steps 9 and 10, if not
skip to step 11.
4. Remove the retainer clips from the attach pins on the left
side of the boom at the anchor fittings for the boom 9. At the rear stowage support bracket, insert the pins and
extension. Hammer the pins out of the lower and upper retaining pins stowed in the 7m section stowage lugs
anchor lugs and anchor fitting. Install both attach pins and into the connection between the11 m extension and
into holders on the base of the boom extension and 7m section (fly) attaching fittings (Detail C) (Figure 4-7).
secure with retainer clips.
DETAIL C
13
DETAIL B
4
6
1
DETAIL A
5 12
7
4
DETAIL D
14
9
11
10
View Taken From Boom Side. Boom Not 11 Meter Extension Front Stowage
Shown For Clarity. Bracket
Boom
21
20
23
22
16
Cutaway For Clarity
15
17
19
18
22 11 Meter Extension
24
DETAIL A 25
23 FIGURE 4-7
7 Meter
Section Jib Showed in Stowed Position
Boom
DETAIL B 11
6
6
13,14 10
1
8
9
13 2
11 Meter
Section
6
15
Out Position
14 4
8
4
3 In Position
16
23 23
17
16
24 20
21
18
20
19
17 21 18
16 22
25
DETAIL C
20
7 Meter
Section
(Fly)
Fly
Sheave
26
27
28
29
30
31
32
DETAIL D
10. At the fly section sheave end (Detail D) (Figure 4-7), Establish an Electrical Connection Between the
swivel the catch hook to engage the latch securing the Lattice Extension and the Main Boom
base extension to fly section.
1. Remove the 17 pin bypass (Figure 4-8) plug from the
11. Ensure the attach pins and retaining clips attaching the electrical junction box on the boom nose.
7m section (fly) to the guide rail bracket (Detail B)
(Figure 4-7) are in place. 2. Unwind the electrical cable from the lattice extension.
12. Ensure the pin and retaining pin attaching the fly section 3. Disconnect the cable from the dummy plug on the boom
to the boom base section rear support bracket (Detail C) extension adapter.
(Figure 4-7) are in place. 4. Connect the boom extension cable to the boom nose
13. At the guide rail, pull downwards against the spring force junction box (Figure 4-8).
of the eye bolt and fold in the guide rail and release the Establish an Electrical Connection Between the
eye bolt to lock the guide rail in the stowed position Lattice Extension and Anti-Two Block Switch
(Detail B) (Figure 4-7).
NOTE: The anti-two block switch supplied with the boom
14. Rig the boom nose and hoist cable as desired and extension is used for operation of the 11 m and 18
operate the crane using normal operating procedures. m sections. The junction box connection for the
section that is not in use must be overridden with a
Connecting and Disconnecting the bypass plug.
Hydraulic Boom Extension
1. Install the anti-two block switch on the appropriate pin 4
near the nose sheave of the section being used. Secure
Connecting the switch to the boom extension with a retaining pin.
2. Remove the bypass plug and connect the wire for the
anti-two block switch to the junction box located near the
DANGER nose sheave.
If the hose couplings are detached from the boom after
the hose drum lock pin has been released, do not release Disconnecting
the hose couplings until they have been attached to the
boom. If the hose couplings are released after being Disconnect the Electrical Connection Between the
detached from the boom, the hoses will spring back Lattice Extension and the Main Boom
uncontrollably due to the spring force in the hose drum. 1. Disconnect the boom extension cable from the boom
nose junction box (Figure 4-8).
When working with the main boom for longer periods of time,
the hydraulic connection between the hose drum and the 2. Wind the cable onto the boom extension for storage.
main boom should be disconnected. This prevents 3. Connect the cable to the dummy plug on the boom
unnecessary reeling and unreeling of the hose. extension adapter.
Establish a Hydraulic Connection Between the Lattice 4. Install the 17 pin bypass plug into the open connector on
Extension and the Main Boom the boom nose junction box (Figure 4-8).
If the hoses are stowed on the holder on the boom base Disconnect the Hydraulic Connection Between the
section, release the hose drum lock pin and pull the hydraulic Lattice Extension and the Main Boom
hoses toward the boom nose. Anchor the hydraulic
couplings at the holder on the boom nose. Guide the
hydraulic hoses through the guide rollers.
1. Unwind the hoses on the lattice extension.
DANGER
If the hose couplings are detached from the boom after
2. Remove the dust caps from the couplings on the lattice the hose drum lock pin has been released, do not release
extension and the drum hoses. the hose couplings until they have been attached to the
3. Connect the hose drum hoses to the hoses on the lattice boom. If the hose couplings are released after being
extension. Do not detach the drum hoses from the detached from the boom, the hoses will spring back
holder on the boom nose. uncontrollably due to the spring force in the hose drum.
Junction Box
Guide Rollers
Guide Rollers
6218
FIGURE 4-8
1. Disconnect the hoses from the lattice extension from the loose condition when the boom extension anchor fittings
drum hoses. Do not detach the drum hoses from the engage the boom anchor lugs.
boom nose.
3. Secure the guide rail on the middle boom extension
When working with the main boom for longer periods of time, stowage bracket in the out position.
the hydraulic connection between the hose drum and the
4. Swing the boom extension until it contacts the guide rail
boom nose should be disconnected. This prevents
at the middle boom extension stowage bracket (Detail B)
unnecessary reeling and unreeling of the hose.
(Figure 4-7).
2. Remove the hoses from the boom nose. Retract the
NOTE: When pushing the jib extension onto the guide rail,
hydraulic hoses to the holder on the boom base section.
make sure contact does not occur at the rear boom
3. Engage hose drum lock pin into hole on drum. extension mounting bracket and prevent proper
alignment.
4. Wind the hoses onto the boom extension for storage.
5. Adjust the middle stowage bracket so the roller supports
5. Install dust caps attached to all couplings on the lattice
on the 11 m section role on the guide rail and aligns the
extension and the drum hoses.
roller support on the 7 m section. This should align the
hole in the mounting lug on the 7 m section with the hole
Swingaway Mounting Adjustment
in the mounting piece on the stowage bracket. When
For the referenced details, refer to (Figure 4-7). adjusted properly, the pin can be inserted to make the
stowage connection.
1. Set the 11 m section with the 7 m section stowed on the
side, on cribbing. Use an adequate lifting device to place 6. Refer to (Detail C) (Figure 4-7) (rear stowage bracket)
the boom extension at the side of the boom. Make the and adjust the adjustment bolts on the rear support
connection at the front stowage bracket and support with bracket to support the boom extension and provide
lifting device (Detail A) (Figure 4-7). installation of attach pins.
2. Refer to Detail A (front stowage bracket) and pivot the 7. Remove the lifting device used for support when the
boom extension on the front support bracket. Adjust the boom extension is secured.
front support bracket adjustment bolts to maintain a
BOOM EXTENSION (WITH INSERTS) On the 8 m sections the serial number (1) is at the front on a
sheet (Figure 4-9).
Identification
Slinging Points
The boom extension consists of the 18 m two-stage
swingaway lattice extension and two boom extension
sections. The boom extension is designed for the crane it
was delivered with. The parts belonging to the crane have DANGER
the same serial number as the crane. This section shows the slinging points on the 8 m
The following parts are labelled with the serial number: sections. Attach the sections on these slinging points only.
They will then automatically have the correct center of
• all parts of the 128 m two-stage swingaway lattice gravity. use only lifting gear with sufficient load bearing
extension capacity.
• both sections of the boom extension (8 m sections)
CAUTION
Operate the crane only with those sections of the boom
extension which have the same serial number as the
crane. This prevents malfunctions and damage.
4
NOTE: For technical reasons a crane may only be set with
one boom extension. w1519a
CAUTION The 8 m sections have two slinging points (1) (each slightly
Have the adjustment of the boom extension carried out offset on each side) (Figure 4-10).
only by your local Manitowoc Crane Care.
ASSEMBLY OF BOOM EXTENSIONS
Serial Numbers On the 8m Sections NOTE: The lengths of 26 m and 34 m respectively equal
the distance between the center of the locking pin
(on the main boom head) and the front edge of the
head sheave.
1
The designations 11 m section, 7 m section and 8
m section have been adapted top these lengths.
The total lengths of the individual sections are
greater (Figure 4-11).
w1520a
FIGURE 4-9
22 m boom extension
(85 ft boom extension)
5 m Section 10 m Section 7 m Section
(16 ft Section (33 ft Section (23 ft Section
27 m boom extension
(89 ft boom extension)
w3351b
FIGURE 4-11
Checklists For Rigging Work 4. Attach guide rope to the head of the 7 m section.
5. Release connection between 7 m section and 11 m
Installing the 26 m/34 m Boom Extension section.
Requirements 6. Swivel the 7 m section in front of the 11 m section.
NOTE: An auxiliary crane must be ready 7. Fasten 7 m section with pin on left-hand side in front of
1. If the lattice extension is folded up at the side of the main 11 m section.
boom, remove the lattice extension. 8. If unit is equipped with a hydraulic luffing boom
2. Installing 8 m sections in front of the main boom: extension, establish a hydraulic connection between
lattice extension and main boom.
For 26 m boom extension an 8 m section
9. Establish electrical connections.
For 34 m boom extension both 8 m sections
10. Fold out deflection sheaves on all sections.
3. Attach folded two-stage swingaway lattice extension in
front of 8 m section. 11. Place hoist cable over all the deflection sheaves and the
head sheave of the 7 m section.
12. Install the limit switch to the head of the 7 m section. • To rig the 34 m boom extension you must also mount the
8 m section without support roller in front of the 8 m
13. Reeve the hoist cable on the hook block.
section with support roller.
14. Attach lifting limit switch weight and guide hoist cable
NOTE: An auxiliary crane must be used to install and
through the weight.
remove the 8 m sections.
Removing the 26 m/34 m Boom Extension The securing pins (1) for the connection are in the holders on
the foot of the 8 m sections and are secured with retaining
Requirements pins (Figure 4-12).
• The crane is on outriggers or the main boom.
• An auxiliary crane must be ready
1. Fully retract and set down main boom.
2. Remove lifting limit switch weight.
3. Reeve out hoist cable from the hook block. 3
4. Remove hoist cable and fold in deflection sheaves on all
parts of the boom extension. 1
11. Establish connection between 7 m section and 11 m • Insert the securing pins on both sides into the bearing
section. points.
12. Remove folded two-stage swingaway lattice extension • Secure all pins with retaining pins.
from 8 m section. • For the 34 m boom extension, install the second 8 m
13. Remove 8 m sections from the main boom: section in the same way as the first 8 m section.
Installing/Disassembling 8 m Sections • Release the pins and knock them out of the bearing
points (2) and (3) on both sides (Figure 4-12).
• In order to rig the 26 m boom extension you must install
the 8 m section with support roller in front of the main • Insert the pins into the holders on the foot of the 8 m
boom head. sections and secure them with retaining pins.
Installing/Removing Two-Stage Swingaway • Insert the securing pins on both sides into the bearing
Lattice Extension for Boom Extension points (2) and (3) (Figure 4-14).
• Secure all pins with retaining pins.
Removing
• Sling the two-stage swingaway lattice extension onto an
auxiliary crane.
• Lift the two-stage swingaway lattice extension until the
f0142 load has been relieved from the bearing points.
FIGURE 4-13 • Release the pins and knock them out of the bearing
points (2) and (3) on both sides (Figure 4-14).
This section described the installation and removal of the
folded two-stage swingaway lattice extension. • Insert the pins into the holders on the 11 m section and
secure them with retaining pins.
You can also install the two-stage swingaway lattice
extension which has been folded in front of the other in front Hydraulic Connection On the Boom
of an 8 m section (e.g. when you are changing directly from Extension (If Unit Is Equipped With
the 18 m two-stage swingaway lattice extension to a boom
extension) (Figure 4-13).
Hydraulic Luffing Boom Extension)
The hydraulic connection is required for raising and lowering
NOTE: An auxiliary crane must be used to install and
the lattice extension. If the hydraulic connections for the
remove the two-stage swingaway lattice extension.
hose drum were separated on the left side, they have to be
The securing pins (1) for the connection are in the holders on re-established.
the foot of the 11 m sections and are secured with retaining
NOTE: The connections are made via quick couplings.
pins (Figure 4-14).
Half couplings which belong together are color
coded.
1
2
2
w2449a
FIGURE 4-14
Installation
• Sling the two-stage swingaway lattice extension onto an
auxiliary crane.
w1542a
• Lift the two-stage swingaway lattice extension in front of
the 8 m section so that the bearing points (2) and (3) FIGURE 4-15
align on both sides (Figure 4-14).
For transportation, the hydraulic hoses are clamped in the
holders (2) (Figure 4-15).
1 w1539a 1
w2451a
At the front of the 8 m sections there are two quick couplings For transportation, the cable is wound around the holders (1)
4
(1) (Figure 4-16). and the plug is inserted in the dummy socket (2)
(Figure 4-17).
Here you can connect the hydraulic hoses of the 11 m
section or a second 8 m section. At the front of the 8 m sections there is a plug socket (1)
(Figure 4-18).
Electrical Connection On the Boom
Here you can connect the cable of the 11 m section or a
Extension second 8 m section.
This section describes the electrical connections on the 8 m
sections. Establishing Electrical Connections
For the 26 m Boom Extension
Connections On the 8 m Sections
• Connect the cable of the 8 m section to the socket on the
main boom head.
• Connect the cable of the 11 m section on the socket at
the front of the 8 m section.
For the 34 m boom extension
• Connect the cable of the first 8 m section to the socket
on the main boom head.
3
• Connect the cable of the second 8 m section to the
socket at the front of the first 8 m section.
• Connect the cable of the 11 m section on the socket at
the front of the second 8 m section.
At the rear of the 8 m sections there is a cable with a plug (3) If you intend to work with the boom extension, you need to
(Figure 4-17). fold out the deflection sheaves on the rear 8 m sections.
Fold the deflection sheave in for transportation.
1
1
2
3
w2453a
FIGURE 4-20
1 1 1 1
5 4 3 2
1 1 1 1
5 4 3 2
f0133a
FIGURE 4-21 4
GROVE 5-i
HOIST AND COUNTERWEIGHT RT9130E SERVICE MANUAL
5-ii
RT9130E SERVICE MANUAL HOIST AND COUNTERWEIGHT
SECTION 5
HOIST AND COUNTERWEIGHT
DESCRIPTION Each hoist motor control valve is used to stop or slow its
hoist when the load is trying to drive the hoist down too
One hoist is available, the model HP35-26G. The hoist quickly. The motor control valve is piloted open by the hoist
incorporates one dual displacement piston motor which down pressure. If the load lowers faster than the flow of oil in
drives a reduction unit within the hoist. The hoist utilizes the hoist down line, the pilot pressure decreases and the
planetary reduction with a multi-disc automatic brake that is motor control valve partially closes to restrict the oil leaving
spring applied and hydraulically released. An overrunning the motor until a balance occurs. This results in the load
clutch allows the hoist to be raised without releasing the lowering at a uniform speed based on the position of the
brake while at the same time holding the load until there is hoist control lever.
sufficient pressure to release the brake when hoisting down.
The hoist motor controls both speed and torque of the hoist. During stopping, when the hoist down flow ceases, the pilot
pressure holding the motor control valve open decays to
There are two modes in which the hoist operates. One mode zero and the motor control valve spool closes, thus blocking
is high speed. The pilot solenoid valve shifts the selector all flow of oil out of the hoist motor. This same pressure
spool on the motor to provide minimum motor displacement. decay allows the spring applied pressure released hoist
This gives high line speed and low torque. brake to apply when the load is fully stopped. This brake acts
The second mode is low speed. The pilot solenoid valve as a “parking brake” and holds the load in the stopped
shifts the selector spool on the motor to provide maximum position.
motor displacement. This gives low line speeds and high
torque. MAINTENANCE
Warm-up Procedure
THEORY OF OPERATION 5
Each hoist is controlled by controls in the cab. A warm-up procedure is recommended at each start-up and
is essential at ambient temperatures below +40°F (4°C).
When the main hoist control lever in the cab is moved from
neutral, it causes the main hoist section of the directional The prime mover should be run at its lowest recommended
control valve to shift the valve spool to route hydraulic flow to RPM with the hydraulic hoist control valve in neutral allowing
the main hoist motor control valve. The hoist motor control sufficient time to warm up the system. The hoist should then
valve routes the hydraulic flow to the hoist motor. The motor be operated at low speeds, forward and reverse, several
turns one direction to hoist up, and turns the other direction times to prime all lines with warm hydraulic oil, and to
to hoist down, depending on whether the hoist controls route circulate gear lubricant through the planetary gear sets.
fluid to the hoist up or hoist down port of the hoist motor
control valve.
When the auxiliary hoist control lever in the cab is moved
from neutral, it causes the auxiliary hoist section of the
DANGER
directional control valve to shift the valve spool to route Failure to properly warm up the hoist, particularly under
hydraulic flow to the auxiliary hoist motor control valve. The low ambient temperature conditions, may result in
hoist motor control valve routes the hydraulic flow to the hoist temporary brake slippage due to high back pressures
motor. The motor turns one direction to hoist up, and turns attempting to release the brake, which could result in
the other direction to hoist down, depending on whether the property damage, severe personal injury or death.
hoist controls route fluid to the hoist up or hoist down port of
the hoist motor control valve.
Troubleshooting
Table 5-1
Removal NOTE: To remove the right front capscrew, the hose reel
rear cover must first be removed.
1. Remove all cable from the hoist drum.
5. Remove the hoist mounting nuts, capscrews, washers,
2. Tag and disconnect the hydraulic lines to the hoist. Cap and shims (if shims are used, mark their location).
or plug all lines and openings.
NOTE: The hoist assembly, less the cable, weighs
3. Tag and disconnect the electrical wires to the hoist approximately 835 kg (1841 pounds).
rotation indicator sensor box.
6. Using an adequate lifting device, remove the hoist from
4. Tag and disconnect the electrical wires to the hoist motor the crane.
high speed solenoid valve.
4 1 4 2
3 3
14
11, 12 10 9
5
11, 12
13
View A-A
FIGURE 5-1
HOIST TO BOOM ALIGNMENT center point of adjustment to check the fleet angle of the
cable.
Preparation 2. All the cable must be removed from the hoist drum to
Boom alignment (Figure 5-2) must be completed before check the fleet angle. Using mason cord or cat gut
attempting hoist alignment. If the hoist is not properly fishing line you will be able to pull the line tight to make
aligned, the cable can be damaged or fine control could be an accurate measurement of the fleet angle. Find the
affected. centerline of the hoist drum by using a square and
drawing a line horizontal on the drum. Put a line vertical
The crane must be set on outriggers fully extended and the to the horizontal line in the absolute center of the drum
crane must be leveled. The boom must be over the front on by using a tape measure. With the boom at 0 degree, tie
RT models. the line tight to the boom nose and have it in the center
of the right hand boom nose sheave.
Tools Required
NOTE: If this special equipment is not available, sufficient
• Two foot square accuracy in locating a centerline may be obtained
• Mason cord by using a steel square against the machine’s inner
surfaces of both flanges. It is advisable to avoid
• Chalk using any cast surfaces in this procedure unless a
• Protractor check from both flanges indicates that the resultant
line is straight.
Procedure 3. Tie the line around the hoist drum so that the line is very
The hoist mounting location will determine the alignment tight and the line is crossing the absolute center of the
procedure used. Shift one side of the hoist back or forward to drum at the centerline mark you put on the drum.
align the hoist with the boom sheave for cranes that have the 4. Using a protractor, lay it on the vertical line on the hoist
hoist mounted either directly to the boom or on a mount
attached to the boom. It may be necessary to shim under
drum so the string line is in the center of the protractor.
The string line will be at the 90 degree mark on the
5
one side of the hoist to make it level. protractor if the hoist is straight with the boom nose
The hoist must be checked in two directions, one at 0 degree sheave. If it is not at the 90 degree mark, the hoist
and the other is above 45 degrees boom angle on any crane mounting bolts will have to be loosened and the hoist
that the hoist is not mounted directly to the boom, stationary moved so it is.
mounted. NOTE: This test is for cable leaving gaps while spooling.
Check the hoist at 0 degrees to see if the hoist is aligned to
the boom nose sheave. The main hoist is aligned to the right
hand sheave and the auxiliary hoist is aligned to the center CAUTION
sheave. Do not alter holes or stop blocks on the crane mounting
plate, as very small adjustments result in large angular
NOTE: The hoist cable will have gaps in it during spooling
changes. Extreme care should be taken to avoid over-
if the alignment is not correct.
correction.
NOTE: The hoist is not level if the cable is piling up on one
side of the drum. 5. Elevate the boom above 45 degrees boom angle to
check if the hoist is level. Reposition the hoist drum and
1. The boom must be extended one half of full extension on
tighten the cord so you can have the cord in the center of
all hoist alignments. This length is used because when
the protractor at the 90 degree mark. If the cord is not at
the main hoist cable is positioned on the top right hand
the 90 degree mark, the hoist will have to be shimmed
boom nose sheave, the cable must leave the center of
until the cord is at the 90 degree mark.
the drum at a 90 degree angle. The boom has the ability
to extend, retract, and change the angle of departure NOTE: This test is for cable piling up on one side of the
from the drum. Extend the boom half way to provide a hoist drum.
6019
Auxiliary Hoist Is Aligned To The Center Sheave
FIGURE 5-2
MOTOR AND BRAKE secure the brake clutch located inside the brake
cylinder.
Description
Installation
Each hoist has a hydraulic motor, a brake valve, a brake
cylinder, and a brake clutch which control motion of the NOTE: Assure the primary thrust plate remains properly
hoist’s drum. These parts mount on one of the support end located in its counterbore when installing the motor.
brackets of the hoist. The hydraulic motor connects to the If operating the hoist with the primary thrust plate
hoist’s brake clutch, which in turn connects to the gear train wedged between the primary gears and the planet
of the hoist. carrier, or with a thrust washer out of position,
severe damage to internal hoist parts could result.
Maintenance 1. Uncover the motor opening in the brake cylinder. Verify
Removal the brake clutch is secure in the brake cylinder. Verify
these parts are clean.
1. Drain the oil from the hoist drum by removing the plugs.
2. Install a replacement O-ring on the motor’s pilot after
Reinstall the plugs when the drum is finished draining.
lubricating it with gear oil or petroleum jelly.
2. Power-wash the hoist on the motor side to wash away
3. Engage the motor shaft with the inner race of the over-
potential contaminants from the drive components of the
running clutch and lower the motor into place. Apply
hoist. Dry the area with compressed or forced air.
Loctite No. 242 to the capscrews for the motor. Secure
3. If needed, tag and disconnect wires from the hoist drum the motor and brake valve to the brake cylinder with
indicator parts. Then remove these parts from the hoist. capscrews and washers.
4. Tag and disconnect wiring from the hoist motor’s high 4. Connect the hydraulic lines to the motor and brake valve
speed solenoid valve. as tagged during removal.
5. Tag and disconnect the hydraulic lines from the motor
and the brake valve. Cap or plug all lines and openings.
5. Reinstall any hoist drum rotation indicator parts removed
during removal. Connect electrical wires as tagged
5
during removal. Torque CPU bolt to 72 to 78 foot-pounds
6. Remove the four capscrews and lockwashers to free the
(98 to 106 Nm). Adjust sensor per instructions in HOIST
motor and brake valve from the brake cylinder and brake
DRUM INDICATOR SYSTEM.
clutch on the support end bracket. Remove the motor
and brake valve as a unit. Discard the O-ring. 6. Reinstall electrical wiring to hoist motor’s high speed
solenoid valve as tagged during removal.
7. Cover the motor opening in the brake cylinder to protect
drive components inside the hoist drum. As needed, 7. Fill the drum with oil. Refer to Section 9- LUBRICATION
in this manual.
IDLER DRUM AND CABLE FOLLOWER a. For a cable follower roller that has bearings, support
the cable follower roller and remove the bolts and
Description washers securing the arms to the angles on each
end of the roller. Remove the cable follower roller.
The main and auxiliary hoists are equipped with an idler Remove the two bolts and washers securing the
drum (Figure 5-3) on the forward side of the hoist. The main angle to the right side of the shaft. Remove the
hoist idler drum is used to keep the hoist cable from coming shims and roller from the shaft. If necessary, remove
in contact with the boom. the bearing and bearing housing from both ends of
When the crane is also equipped with an auxiliary hoist, the the roller.
idler drum on the auxiliary hoist is used to keep the hoist b. For a cable follower roller that has bushings instead
cable from coming in contact with the main hoist. The cable of bearings, support the cable follower roller and
follower (Figure 5-3) is mounted on the rear side of its remove the bolts and washers securing the pivot
respective hoist. The cable follower applies a downward arms to the mounting brackets on each end of the
spring pressure against the cable onto the hoist drum, to roller. Remove the cable follower roller. Remove
ensure that the cable will be uniformly wound onto the hoist cotter pins and washers from roller shaft, then
drum, and also prevent cable from jumping under abnormal remove mounting brackets from roller shaft.
line conditions.
4. Remove the bolt and locknut securing the arm to the
Maintenance spring attaching lever on each side of the hoist. Remove
arms and levers from the side plates.
Idler Drum NOTE: Be sure to mark each arm and lever as to what side
Removal and Disassembly (left or right) they were removed from. This will be
helpful during installation.
1. Remove the bolt, washer, and lockwasher from the right
side of the idler roller. 5. Remove grease fittings if present.
2. Support the idler roller and withdraw the shaft from the Cleaning and Inspection
left side. Take care not to lose the dowel pin on the end. 1. Clean all grease from the shaft, bearings or bushings,
3. Remove the roller from between the side plates. and roller.
Cleaning and Inspection 2. Check the shaft, roller, and bearings or bushings for
cracks, scoring, or grooving. Replace if necessary.
1. Clean all rust and dirt from the shaft.
3. Check the spring tension. If the springs will not provide
2. Inspect the shaft and roller for cracks, scoring, or sufficient tension when adjusted, replace them.
grooving. Replace if necessary.
Assembly and Installation
Assembly and Installation
1. Install grease fittings if needed.
1. Position the roller between the side plates
2. Install the left arm through the bushing on the left side
2. Install the shaft through the left side plate and the roller. plate. Install left spring attaching lever on the arm and
Ensure the flat on the shaft end aligns with the stop secure with a bolt and locknut. Apply Loctite 242 to the
welded on the side plate, align the dowel pin. bolt threads.
3. Secure the shaft to the right side plate with a bolt, 3. Repeat step 2 on the right side.
washer and lockwasher. Apply Loctite 242 to the bolt
threads. 4. For a cable follower roller that has bearings, assemble
the cable follower roller as follows:
Cable Follower a. Apply high strength retaining compound Loctite 680
to the bearing housings and the bearings. Install
Removal And Disassembly
them in both ends of the roller.
1. Loosen the adjusting nuts and remove the tension
b. Install the shaft into the roller with a least one shim
spring and adjusting rod from both sides of the hoist.
on each end.
2. Remove the tack welds from the bolt heads securing the
c. Apply Loctite 242 to the bolt threads. Position the
arm to the cable follower roller.
angle on the right side of the shaft and secure with
3. Remove and disassemble the cable follower roller as two bolts and washers.
follows:
5. Position the cable follower roller on the arms. Secure the b. Final adjust each rod and nut and spring so the end
cable follower roller shaft to its mounting angles or of the rod is 33 mm (1.30 inch) from the near surface
mounting brackets with fasteners removed earlier. (For a of the nut.
roller with bushings instead of bearings, there are two
washers and two cotter pins.) Complete Assembly
6. Secure the mounting angles or mounting brackets to the Removal
pivot arms with four bolts and washers. Center the roller
between the hoist drum flanges and tighten the bolts. 1. Remove all tension from the springs on each side by
loosening the nuts and jam nuts.
7. Tack weld the bolt heads.
2. Support the weight of the cable follower assembly and
8. Attach one end of each tension springs to the lever on remove the two bolts and washers securing each side
each side. Install each adjusting rod through the lug on plate to the hoist. Remove cable follower assembly from
each side plate and connect to the other end of the the hoist.
spring. Install the adjusting nuts on each rod and tighten
enough to take the slack out of the spring. 3. If necessary to completely disassemble or remove any
part of the assembly, refer to the applicable paragraphs
9. Using a grease gun, apply grease to any fittings. in this Sub-section.
10. Adjust the roller as follows: Installation
a. With one layer of cable on the hoist drum, adjust the 1. Position cable follower assembly on the hoist and
bolts on the front of each side plate (that push secure each side plate to the hoist with two bolts and
against each arm) so the roller applies pressure on washers.
the layer of cable, and does not interfere with filler/
riser protrusions on the hoist drum flanges. Tighten 2. Adjust the tension on the cable follower. Refer to
jam nuts to secure setting. instructions in paragraph titled CABLE FOLLOWER -
Assembly and Installation in this Sub-Section.
5
33 mm (1.30 in)
Item Description
1 Pivot Bracket
9
2 Drum
1 8
3 Follower Roller
4 Pivot Arm
5 Spring
Spring Adjusting
6
7 Rod
7 Lever
4
8 Idler Roller
9 Nut
3 10 Bracket
11 Rotation Sensor
12 Hydraulic Motor
13 Mounting Bracket
8
10
5 2
4
13
3
12
11
6083
FIGURE 5-3
THIRD WRAP INDICATOR 1. Install the capscrew and washer to secure the sensor
shaft to the hoist housing. Torque the capscrew 117 to
Description 127 Nm (86 to 94 foot-pounds).
The third wrap indicator (Figure 5-4) is installed to give the NOTE: Apply antiseize grease to inside of indicator arm
operator an indication that the wire rope is down to the last before installing onto sensor shaft.
three wraps on the hoist drum and no more rope should be NOTE: Position center of roller approximately 7.6 cm (3 in)
reeled out. In addition to the warning light in the cab, a from the inside flange of the hoist drum such that
lockout valve is actuated to stop hoist down operation. the roller drops to the drum after the fourth wrap is
unwound from the drum.
Maintenance
NOTE: Adjust actuating cam and/or limit switch collar such
Removal that switch plunger drops into notch when roller
drops to bare hoist drum.
1. Disconnect third wrap indicator from power by removing
fuses F17 and F16. Tape over the sockets of the NOTE: Adjust spring holder collar such that spring applies
removed fuses. ample pressure to arm.
2. Remove the control unit cover. Tag and disconnect the 2. Slide spring holder collar, spring, arm (with roller),
wiring to the limit switch. actuating cam, limit switch bracket and limit switch onto
the sensor shaft. Secure with the related setscrews.
3. Loosen and remove the outside nut and washer
securing the threaded rod to the hoist mounting. 3. Install the threaded rod through the opening in the hoist
housing and thread the washer and two nuts onto the
4. Loosen and back off the inside nut on the threaded rod. rod.
5. Loosen and back off the nut holding the sensor shaft in 4. Screw the threaded rod into the sensor shaft.
place against the side plate.
6. Unscrew the threaded rod from the sensor shaft.
5. Tighten the nut to hold the sensor shaft to the side plate. 5
6. Tighten the nut securing the threaded rod to the hoist
7. While removing the nuts and remaining washer from the housing.
inside end of the threaded rod, pull the threaded rod out
through the hoist housing. 7. Install the remaining washer and nut onto the outside
end of the threaded rod. Adjust so the centerline of the
8. Remove the setscrews and slide the limit switch bracket roller is 3.0 inches (7.6 cm) from the inside face of the
and limit switch, actuating cam, arm (with roller), spring, nearby side plate. Torque the set screws in the limit
and spring holder collar from the sensor shaft. switch bracket, actuating cam, arm (with roller), and
9. Loosen and remove the capscrew and washer securing spring holder to 10-13 inch-pounds (1.1 to 1.5 Nm after
the sensor shaft to the hoist housing. final adjustment.
8. Torque the three nuts 117 to 127 Nm (86 to 94 foot-
Installation pounds). Ensure the centerline of the roller is still 3.0
NOTE: All fasteners must be treated with medium strength inches (7.6 cm) from the inside face of the nearby side
threadlocking adhesive sealant and primer. plate.
9. Reconnect the wires to the third wrap indicator limit
switch and reinstall the control unit cover.
10. Restore power to third wrap indicator by installing fuses
F17 and F16.
10
5, 6
4
16
1
7
8
Refer to View A 9
6928-1
2, 3
13 11
12
14
9
15
8
7131
View A FIGURE 5-4
High Speed
Solenoid
5
Sensor
Sensor
To Thumb Thumper
Amber LED
Thumb Thumper
Red LED Rotation Indicator
Soleniod12±2 Ohms
Single Axis
Control Module - CPU
Controller FIGURE 5-6
COUNTERWEIGHT REMOVAL AND 3. Adjust the foot plate (5) (Figure 5-7) and adjusting screw
INSTALLATION (6) (Figure 5-7) into or out of the counterweight support
until the counterweight pads on top of the counterweight
Counterweight Stand Installation support are level. Do not exceed 5.72 cm (2.25 inches).
4. Tighten jam nut (7) (Figure 5-7) against counterweight
NOTE: The counterweight stand must be installed on the
support.
front of the carrier before removing either the
standard or heavy counterweight assembly.
Standard and Heavy Counterweight and
1. Using an adequate lifting device, install the Auxiliary Hoist Structure
counterweight stand (1) (Figure 5-7) to the front of the
carrier frame (3) (Figure 5-7) and secure with the hitch Removal
pins (4) (Figure 5-7).
DANGER
Read and understand the following when removing and
installing the counterweight, auxiliary hoist structure or
counterweight stand, to avoid serious injury or death.
• Outriggers must be properly extended and set and
c r a ne l e ve l b ef or e i ns ta ll a ti o n or r e m o v al of
counterweight or auxiliary hoist structure.
• Lifting operations are not permitted with any
counterweight on the carrier deck except for the
removal or installation of the counterweight and/or
auxiliary hoist structure.
• Boom is not permitted over carrier deck when the
boom angle is less than 30° and any counterweight is
1 2 3 4 5, 6, 7 7229 positioned on deck.
FIGURE 5-7 • Hookblock is not permitted to come in contact with
2. Rotate foot plates (5) (Figure 5-7) on the counterweight counterweight, auxiliary hoist or auxiliary hoist
stand (1) (Figure 5-7) until they come to rest on top of structure during removal or installation.d
the front outrigger box (2) (Figure 5-7). • When installing counterweight (1) (Figure 5-8), make
sure that both auxiliary hoist structure (7) (Figure 5-9)
hydraulic mounting pins are fully extended and
retainer pins are in place before counterweight is
DANGER lifted.
Adjustment of the counterweight stand (1) (Figure 5-7) • Before unpinning auxiliary hoist structure (7)
supports is prohibited when the counterweight (1) (Figure 5-9), all counterweights must be fully lowered
(Figure 5-8) is resting on them. and firmly supported. Before lowering, make sure the
auxiliary hoist structure (7) (Figure 5-9) is properly
supported by counterweight removal cylinders (5)
(Figure 5-8) and both hydraulic mounting pins are
completely retracted.
• Travel is not permitted with any counterweight on the
carrier deck.
10 6
7
5
2
11
12
7229-1
FIGURE 5-8
1. Position the crane on a firm level surface. 10. Use the counterweight removal levers (6) (Figure 5-9) to
retract the pins on the rod ends of the pin removal
2. Fully extend and set the outriggers. Level the crane.
cylinder (2) (Figure 5-9) and unpin the auxiliary hoist
3. Position the superstructure over the rear with the structure (7) (Figure 5-9) from the turntable.
counterweight positioned over the counterweight
11. Retract the counterweight removal cylinders (5)
support on the front of the carrier frame.
(Figure 5-8) and carefully lower the auxiliary hoist
4. Remove any load handling device from the auxiliary structure (7) (Figure 5-9) onto the counterweight.
hoist cable and retract all cable onto the hoist drum.
12. Tag, disconnect and secure the counterweight removal
Secure the cable.
cylinder hydraulic lines. Cap or plug all line openings.
5. Tag and disconnect the auxiliary hoist hydraulic lines
and electrical harnesses. Cap or plug all line openings.
Secure lines so they will not be damaged during
auxiliary hoist structure removal. DANGER
6. Do not disconnect the lines to the counterweight Travel is not permitted with any counterweight on the
removal cylinders (5) (Figure 5-8) at this time. carrier.
NOTE: It may be necessary to retract the counterweight 13. Secure the counterweight (1) (Figure 5-8) to the
removal cylinders (5) (Figure 5-8) to relieve weight auxiliary hoist structure (7) (Figure 5-9) with the
from the counterweight to auxiliary hoist structure counterweight to hoist structure pins (12) (Figure 5-8)
pins (12) (Figure 5-8). and hitch pins (11) (Figure 5-8).
7. Remove the hitch pins (11) (Figure 5-8) and the
counterweight to hoist structure pins (12) (Figure 5-8).
These are accessible through the holes in the back of
the counterweight (1) (Figure 5-8). DANGER
Do not attempt to separate the auxiliary hoist structure (7)
5 (Figure 5-9) from the counterweight (1) (Figure 5-8) while
on the counterweight stand (1) (Figure 5-7). The auxiliary
hoist structure (7) (Figure 5-9) may hit the counterweight
(1) (Figure 5-8) and knock it off the stand.
DANGER
7 2 Death or serious injury may result with improper use.
1
On the heavy removable counterweight option (2)
(Figure 5-8), do not use the lifting lugs on the heavy
counterweights to lift the entire heavy counterweight and
4
auxiliary hoist structure. The heavy counterweight lifting
6 7229-3
Lever Operation RH Side
FIGURE 5-9 lugs are designed to lift the heavy removable
counterweight only.
8. Using the counterweight removal levers (6) (Figure 5-9),
extend the counterweight removal cylinders (5) 15. Attach an adequate lifting device with slings to the
(Figure 5-8) and carefully lower the counterweight (1) auxiliary hoist structure (7) (Figure 5-9). Use the crane
(Figure 5-8) onto the counterweight supports. to carefully transfer the auxiliary hoist structure (7)
9. Remove the detent pins (4) (Figure 5-9) to allow the pin (Figure 5-9) and counterweight (1) (Figure 5-8) to the
removal cylinder (2) (Figure 5-9) to retract the pins on its ground or suitable transport vehicle.
rod ends. NOTE: Step 16 applies to the heavy removable
counterweight (2) (Figure 5-8).
16. If desired, lessen the weight on the counterweight by place the auxiliary hoist structure (7) (Figure 5-9) onto
removing the two heavy counterweight weldments (2) the counterweight (1) (Figure 5-8).
(Figure 5-8). To remove the weldments, attach an
5. Secure the counterweight (1) (Figure 5-8) to the
adequate lifting device with slings attached to the lifting
counterweight removal cylinders (5) (Figure 5-8) with
lugs. Free the weldments from the counterweight by
the cylinder to counterweight pins (9) (Figure 5-8) and
removing the pins. Using the lifting device, remove the
hitch pins (8) (Figure 5-8). Secure the counterweight (1)
weldments.
(Figure 5-8) to the auxiliary hoist structure (7)
(Figure 5-9) with the counterweight to hoist structure
Installation pins (12) (Figure 5-8)and hitch pins (11) (Figure 5-8).
1. Position the crane on a firm level surface.
2. Fully extend and set the outriggers. Level the crane.
DANGER
The main boom must not be lowered below horizontal
while swinging over the front while the counterweight
DANGER
supports are installed.
Assemble the standard removable counterweight (1)
(Figure 5-8) and auxiliary hoist structure (7) (Figure 5-9)
6. Install the counterweight stand (1) (Figure 5-7) on the
on the ground or on a suitable transport vehicle. Do not
front of the carrier. Refer to Counterweight Stand
attempt to assemble on the counterweight stand. The
Installation.
auxiliary hoist structure may hit the counterweight and
knock it off the stand. 7. Using an adequate lifting device with slings, carefully
transfer the auxiliary hoist and counterweight to the
counterweight stand.
5
DANGER
Assemble the heavy removable counterweight (2) DANGER
(Figure 5-8) and auxiliary hoist structure (7) (Figure 5-9) The main boom must not be elevated above horizontal
on the ground or on a suitable transport vehicle. Do not while swinging into the auxiliary hoist mounting structure.
attempt to assemble on the counterweight stand (1)
(Figure 5-7). The auxiliary hoist structure (7) (Figure 5-9) 8. Swing the superstructure over the rear and engage the
may hit the counterweight and knock it off the stand. swing lock pin.
9. Connect the counterweight removal cylinder hydraulic
lines disconnected and tagged earlier.
10. Remove the hitch pins (8) (Figure 5-8) and the
DANGER counterweight to hoist structure pins (9) (Figure 5-8) to
The heavy removable counterweight assembly (2) free the auxiliary hoist structure (7) (Figure 5-8) from the
( F i g u r e 5 -8 ) m u s t b e i n s t a l l e d w i t h b o t h h e a v y counterweight (1) (Figure 5-8).
counterweights. Using only one heavy counterweight may 11. Using the counterweight levers (6) (Figure 5-9), fully
cause the crane to become unstable. extend the counterweight removal cylinders (5)
(Figure 5-8) and carefully raise the auxiliary hoist
NOTE: Step number 3 applies to the heavy removable structure (7) (Figure 5-9) to meet the mating plates on
counterweight (2) (Figure 5-8). the turntable.
3. Attach an adequate lifting device with slings to each 12. Use the pin control lever (6) (Figure 5-9) to extend the
heavy counterweight weldment’s lift lugs. Using the pins on the rod ends of the pin removal cylinder (5)
lifting device, carefully install the two heavy (Figure 5-9) and pin the auxiliary hoist structure (7)
counterweight weldments (2) (Figure 5-8) in place on (Figure 5-9) to the turntable.
the counterweight auxiliary hoist structure (7)
(Figure 5-9). Pin the counterweight weldments in place 13. Install the detent pins (4) (Figure 5-9) to secure the pins
with the pins. on the rod ends of the pin removal cylinder (2)
(Figure 5-9) to keep the auxiliary hoist structure (7)
4. Using an adequate lifting device with slings attached to (Figure 5-9) secured.
the auxiliary hoist structure (7) (Figure 5-9), carefully
14. Retract the counterweight removal cylinders (5) 17. Connect the auxiliary hoist hydraulic lines and electrical
(Figure 5-8) and carefully raise the counterweight (1) wires as tagged and disconnected earlier.
(Figure 5-8) to its installed (working) position.
18. Remove the counterweight support from the front of the
15. Secure the counterweight (1) (Figure 5-8) to the carrier. Refer to Counterweight Stand Removal.
auxiliary hoist structure (7) (Figure 5-9) with the
counterweight to hoist structure pins (12) (Figure 5-8). Counterweight Stand Removal
1. Attach an adequate lifting device with slings to the
counterweight stand (1) (Figure 5-7).
CAUTION
Do not power the counterweight into the counterweight to 2. Loosen jam nut (7) (Figure 5-7).
hoist mounting pins.
3. Rotate foot plates (5) (Figure 5-7) on the counterweight
stand (1) (Figure 5-7) away from the outrigger box (2)
16. Slowly extend the counterweight removal cylinders (5) (Figure 5-7).
(Figure 5-8) so the counterweight to hoist mounting pins
(12) (Figure 5-8) take the weight of the counterweight (1) 4. Remove the counterweight stand (1) (Figure 5-7) to
(Figure 5-8). carrier frame hitch pins (4) (Figure 5-7).
5. Using the lifting device with slings, remove the
counterweight stand (1) (Figure 5-7).
GROVE 6-i
SWING SYSTEM RT9130E SERVICE MANUAL
6-ii
RT9130E SERVICE MANUAL SWING SYSTEM
SECTION 6
SWING SYSTEM
DESCRIPTION THEORY OF OPERATION
The purpose of the swing system is to allow the crane Swing Drive
superstructure to rotate atop the carrier frame. The
superstructure swing system provides full 360 degree The hydraulic power for the swing drive is supplied by the
rotation in both directions and is equipped with free swing engine driven hydraulic Pump No. 1. Oil flows from the pump
capabilities. The term free swing means that, with the to the hydraulic Port 5 swivel. Flow from the swivel is routed
SWING BRAKE switch in the OFF position, the to the front steering flow divider valve in the swing directional
superstructure will swing freely after the SWING control lever control valve. Bypass flow from the flow divider valve is used
is released until it coasts to a stop or the glide swing brake to supply the swing directional control valve.
pedal is depressed.
When the hydraulic remote control is positioned to select
Swing is activated using the control lever in the cab. When right or left swing, the flow through the control valve is
the swing lever is actuated, hydraulic pressure is routed to directed to the series/parallel valve, and then routed to the
the swing motors to drive the swing gearboxes in the swing motors. If the SWING BRAKE selector switch is in the
appropriate direction. As the gearboxes rotate, their pinion OFF position, the superstructure will rotate in the desired
gears mesh with the teeth on the swing bearing and rotate direction. Shifting the control to neutral and depressing the
the superstructure. Swing speed can be controlled by the brake pedal will stop the swing.
control lever and a HIGH/LOW swing speed switch on the
front console. The maximum rotation speed is 2.5 rpm in Swing Brake
HIGH speed and 1.25 rpm in LOW speed. Braking is
The hydraulic power for the swing brake is supplied by the
accomplished by depressing a glide swing brake pedal
pressure reducing/sequence valve in the swing brake and
which is a proportionate control valve that provides a
armrest lockout manifold. With the SWING BRAKE selector
controlled braking of the swing motion.
switch positioned to ON, the swing brake release valve
The swing system consists of a hydraulic remote controller, blocks the regulated flow to the brake release ports and
swing speed switch, series/parallel selector valve, a spring pressure in the swing brakes applies the brakes.
directional control valve, the swing drives, the swing brake When the SWING BRAKE selector switch is positioned to
assemblies, the brake pedal and power brake valve, and a
swing brake release solenoid valve.
OFF, the regulated flow is directed from the pressure
reducing/sequence valve to the brake release ports, 6
overcoming the brake spring pressures and releasing the
The crane is equipped with a pin type swing lock as standard
swing brakes. Regulated flow from the pressure reducing/
and a standard 360 degree positive swing lock. The 360
sequence valve is also provided to the power brake valve
degree positive swing lock meshes with the swing gear teeth
where it is available for the activation of the swing brake
at any point of rotation. The pin type swing lock will only lock
when the pedal is depressed.
the turntable in a straight ahead position over the front or
rear of machine. Both swing locks are operated from the cab.
1
2
6
3
5 8
7 5
10
11 6470-1
MAINTENANCE
Troubleshooting
Table 6-1
6. Cover the opening of the swing gearbox to ensure no 6. Remove the capscrews, flatwashers and bushings
dirt, dust or other foreign material get into the gearbox. securing the swing gearbox to the superstructure base
plate. Remove the swing gearbox.
Installation
7. Remove the counter-sunk allen bolts and bottom plate
1. Install a new O-ring onto the brake assembly’s housing attaching the pinion gear to the swing gearbox shaft.
and insert the brake assembly into the gearbox. Remove the pinion gear.
2. Secure the brake assembly with the socket head 8. Cover the opening of the swing gearbox to ensure no
capscrews. dirt, dust, or foreign material gets into the gearbox.
3. Install the swing motor on the swing brake assembly per Installation
the procedure in this section.
1. Install the pinion gear and bottom plate on the swing
4. Connect the hydraulic lines to the swing motor and gearbox splined shaft. Secure pinion gear with the
swing brake assembly. counter-sunk allen bolts.
5. Bleed all air from the swing brake assembly. 2. Install the swing brake assembly on the swing gearbox
per instructions in this section.
Testing
3. Install the swing motor on the swing brake assembly per
1. With the SWING BRAKE switch in the ON position,
instructions in this section.
move the swing control lever in both directions.
Superstructure rotation should not occur. 4. Attach a suitable lifting device to the swing gearbox and
position the swing gearbox on the superstructure base
2. Put the SWING BRAKE switch to OFF and swing the
plate.
superstructure in both directions. Use the swing brake
pedal to stop rotation. 5. Install the capscrews, washers and bushings removed
earlier to secure the swing gearbox to the superstructure
3. Check for hydraulic leaks and repair as necessary.
base plate.
6. Connect the hydraulic lines to the swing brake.
7. Connect the hydraulic lines to the swing motor.
8. Service the gearbox per the following instructions.
Servicing and dirt might be driven into the vent of the swing
bearing.
Normal maintenance should only consist of proper
lubrication and a periodic check of mounting bolt torque 3. After oil is drained, reinstall the drain plug and any other
values. Lubrication consists of maintaining the gearbox oil plugs that were removed to drain the oil.
level. Oil in a new gearbox should be drained and flushed 4. To refill with oil, make sure the breather is open. Fill until
out after approximately 250 hours of operation, and proper location on dipstick.
replaced with premium quality SSGL-5 after about 500
hours of operation or each year, whichever occurs first. 5. Tighten breather and dipstick.
Operation in high humidity or polluted air areas will Checking Oil Level
require more frequent changes to minimize moisture or
contaminate accumulation. 1. Check level on dipstick
SWING BEARING
Description
DANGER
The swing bearing is an anti-friction roller bearing that mates
the superstructure to the carrier. The bearing inner race is It is mandatory that bearing attaching bolts be inspected
bolted to the superstructure and the outer race is bolted to for lack of torque and retorqued, as required, after the first
the carrier. The inner race contains grease fittings for 300 hours of crane operation. The bolts may loosen in
lubrication of the bearing which are hosed to two fittings at service due to vibration, shock-loads, and temperature
the front of the turntable center section. The outer race has changes, therefore, periodic inspection should be
gear teeth that mesh with the pinion gear of the swing accomplished every 500 hours thereafter, ensuring the
gearbox to provide rotation. bolts are properly torqued.
The inner race of the bearing is secured to the turntable by 3. Tighten the other 32 bolts, working to the same star
40 1.25” Grade 8 bolts. The outer race of the bearing is pattern, until all of them are torqued to 2045 to 2217 Nm
secured to the carrier frame by 36 1.25” Grade 8 bolts. (1508 to 1635 foot-pounds).
Torque Values 4. Return to bolt 1 and torque all 40 bolts sequentially in a
clockwise direction to the final torque of 2556 to 2770
Torque all turntable bolts to a final torque of 2556 to 2770 Nm
Nm (1885 to 2043 foot-pounds).
(1885 to 2043 foot-pounds).
Outer Race Torquing
Using the 4 to 1 multiplier and no step wrenches, set the
torque wrench for 746 Nm (550 foot-pounds). 1. Extend and set the outriggers. Fully elevate the boom.
Tools Required 2. Torque eight bolts to 2045 to 2217 Nm (1508 to 1635
foot-pounds) using the following sequence pattern: 10,
Special Turntable Bolt Torquing Tools (Figure 6-3) illustrates
28, 19, 1, 15, 33, 24 and 6 (Figure 6-2). Tools used are
and lists the complete set of special tools required to torque
the socket, multiplier, backlash adapter, necessary
the turntable bolts.
extensions, and torque wrench.
Inner Race Torquing 3. Tighten the other 28 bolts, working to the same star
1. Extend and set the outriggers. Fully elevate the boom. pattern, until all of them are torqued to 2045 to 2217 Nm
(1508 to 1635 foot-pounds).
2. Torque eight bolts to 2045 to 2217 Nm (1508 to 1635
foot-pounds) using the following sequence pattern: 4. Return to bolt 1 and torque all 36 bolts sequentially in a
using the following sequence pattern; 11, 31, 21, 1, 16, clockwise direction to the final torque of 2556 to 2770
36, 26, and 6 (Figure 6-2). Tools used are the socket, Nm (1885 to 2043 foot-pounds).
multiplier, backlash adapter, necessary extensions, and
torque wrench.
9 10 11
8 12
7 13
Outer Race 6
14
5
15
Inner Race
4
8
9 10 11 12 13
14
16 6
7
15
3 6 16 17
5
17
4 18
2
3 19 18
2 20
1 1 21
19
40 22
36 39 23
20
24
38
35 25
37
26 21
36 27
35
34 34 28
33 29
32 31 30 22
33
23
32
24
31
25
30
26
29 28 27 7382
FIGURE 6-2
1 3 6
5
6633
Orders for special tools Description Grove Part Number Quantity Required
shall be referred to: 1. 1 13/16 “Socket 3/4” Drive 9-999-101988 1
Grove U.S L.L.C. 2. 4 to 1 Torque Multiplier (1/2” Input 3/4” Output) 9-999-100134 1
Customer Support 3. Backlash Adapter 9-999-100141 1
1565 Buchanan Trail East 4. 1/2” Drive Torque Wrench 9-999-100136 1
Shady Grove, PA 17256 5. 10” Extension 3/4” Drive 9-999-100138 A/R
Phone: (717) 597-8121 6. 13“Extension 3/4” Drive 9-999-100137 A/R
Fax: (717) 593-5929 7. Tool Box (Optional) 9-999-100146 1
FIGURE 6-3
NOTE: The swivel assembly will be removed with the NOTE: The bearing weighs approximately 921 kg (2030
turntable. pounds). Ensure the bearing lifting device is
capable of supporting the weight.
16. Place an adequate lifting device under the bearing and
remove the 40 bolts and washers securing the turntable
DANGER bearing to the superstructure.
Ensure the lifting device is capable of fully supporting the
17. Using the lifting device, remove the turntable bearing
weight of the superstructure. Ensure the superstructure
from under the superstructure.
will not tilt or slide during lifting and moving. Failure to do
so may result in death or injury to personnel and damage Inspection
to equipment.
Check the bearing teeth for chipping or cracking. If any
NOTE: If a lifting device capable of lifting the entire evidence of these is found, replace the bearing. Ensure the
superstructure is not available, superstructure bolt holes are free of dirt, oil, or foreign material.
weight may be reduced by removing various
Installation
components such as the hoist(s).
13. Attach a suitable lifting device to the four superstructure
lifting lugs (two near the boom pivot shaft bushings and
two near the lower lift cylinder pivot shaft bushings). DANGER
Take in cable or chain to remove slack. Do not pull up on Anytime a grade 8 turntable bolt has been removed, it
the superstructure. must be replaced with a new grade 8 bolt.
1 Bearing 10. Install the boom and lift cylinder following the procedures
outlined in Section 4, BOOM.
2 Swing Gearbox
11. Install the counterweight and auxiliary hoist following
3 Pinion Guard
procedures outlined in Section 5, HOIST AND
4 Turntable COUNTERWEIGHT.
5. Orient ring gear such that its point of max eccentricity 12. Reconnect the batteries.
(“high point”) is located between the swing drives.
13. Check the slew potentiometer in the electrical swivel for
Position swing drives so that pinion is centered within
proper orientation. Refer to SWIVELS in this section.
cutout in base plate and motor ports face towards the
outboard side (Figure 6-4). Testing
Activate the crane and check for proper function.
CAUTION NOTE: If the superstructure does not turn freely after
Do not clamp over pinion. bearing and pinion replacement, contact your local
dealer.
a. Using shims, set backlash by moving the swing
drive assemblies toward the bearing in order to
mesh the pinion with the ring gear teeth.
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
The swivel assembly consists of a 11 port hydraulic swivel, a of the hydraulic swivel by four bolts. The hydraulic and water
2 port water swivel, and a 15 conductor slip ring electrical swivel spools remain stationary with the carrier as the
swivel (Figure 6-5). Solid connections cannot be used to superstructure rotates. The water swivel case contains a lug
transfer oil, heater hot water and electricity between the which is keyed to a corresponding lug on the hydraulic swivel
carrier and superstructure due to the continuous 360 degree case, causing the water swivel to rotate with the
swing. The use of swivels efficiently accomplishes this superstructure.
function. The electrical swivel center or collector ring assembly is
The barrel portion of the hydraulic swivel is attached to the secured by setscrews to a center post which is bolted to the
turntable base plate by four bolts, washers and bushings, spool of the hydraulic swivel. This allows the collector ring
which connect to mounting lugs on the case. The spool assembly to remain stationary with the carrier. The outer
portion of the swivel rides upon a thrust ring at the top of the portion or brush assembly is mounted on two studs which
swivel case. The spool portion is held stationary with the are located on the mounting plate assembly which is
carrier by bolts, and bolt retainer plates attached to the retained to the water swivel barrel by a bolt. This allows the
swivel retainer plate which engages the carrier frame lugs brush assembly to rotate with the superstructure around the
with bolts and jam nuts. This allows the spool to remain stationary collector core.
1, 2
3
4, 5
8
13
10
11, 12
14
15
10
16, 17, 18
19
21, 22 20
6080
FIGURE 6-5
Hydraulic Swivel
Description
Each of the ports on the spool and case of the swivel is
stamped with the port number. The function of each port is
described below.
Table 6-2
Test Pressure
Port # Function
kPa (bar) (psi)
1 3400 (34) (500) Dual Return
2 27500 (275) (4000) Hoist/Lift/Tele
3 27500 (275) (4000) Hoist/Lift/Tele
4 3400 (34) (500) Case Drain
5 27500 (275) (4000) Steer/Swing
6 17000 (170) (2500) Pilot, Swing Brake, Hose Reel
7 27500 (275) (4000) Front- Steer Left
8 27500 (275) (4000) Front- Steer Right
9 17000 (170) (2500) Brakes/Air Conditioning
10 17000 (170) (2500) Brakes, Front
11 17000 (170) (2500) Brakes, Rear
A ----- Heater Supply (Coolant)
B ----- Heater Return (Coolant)
10. Position an adequate supporting device beneath the Two-Port Water Swivel
swivel.
Description
11. Remove the four capscrews, washers, and bushings
securing the swivel barrel to the turntable base plate and The two-port water swivel allows engine coolant to flow from
lower the swivel to the ground. the carrier-mounted engine to the hot water heater in the
operator’s cab. Through an internally drilled passage in the
Installation 11 port hydraulic swivel spool, coolant is transferred to a
NOTE: The hydraulic swivel weighs approximately 195 kg circumferential groove on the water spool exterior. This
(430 lb). The hydraulic, water, and electrical swivel groove corresponds with a mating port on the outer case of
combined weigh approximately 236 kg (520 the water swivel. The spool grooves are separated by a quad
pounds). ring/telflon bronze ring seal. The lip seal prevents coolant
from leaking externally. Return engine coolant flow from the
1. Raise the swivel into position. hot water heater is accomplished in the same manner
2. Secure the hydraulic swivel to the turntable base plate through the opposite port of the water swivel.
with the bushings, capscrews, and washers. Torque the
Maintenance
bolts to 760 to 814 Nm (560 to 600 foot-pounds).
3. Position the two retainer plates on the hydraulic swivel Removal
spool ensuring they engage the lugs on the carrier 1. Perform steps 1 thru 4 of HYDRAULIC SWIVEL -
frame. Secure the retainer plates with eight capscrews REMOVAL in this section.
and four capscrew retainers.
2. Remove the electrical swivel. Refer to ELECTRICAL
Apply Loctite 271 to the capscrew threads. Torque the SWIVEL - REMOVAL in this section.
capscrews to 122 Nm (90 foot-pounds). Bend all the
retainer tabs to make contact with the capscrew heads. 3. Tag and disconnect the lines from the case of the water
Sung the four retainer plate capscrews against the lugs swivel. Cap or plug all lines and openings.
on the carrier frame and tighten the locking nuts. 4. Remove the bolt and shim(s) from the water/hydraulic
4. If removed, install the electrical swivel. Refer to swivel keying lugs.
ELECTRICAL SWIVEL in this Section. Connect the 5. Remove the four capscrews and washers securing the
swivel wiring harness connectors to the carrier water swivel and electrical swivel center post to the
receptacles and the yellow ground wire to the mounting hydraulic swivel. Remove the water swivel and center
bracket on the carrier frame. Use the bolt and star
washers taken off at removal and refer to Grove
post. 6
Engineering Specification A-829-100386 for proper Disassembly
electrical termination of grounds. NOTE: Any maintenance requiring disassembly of the
5. Install the clamp, lockwasher, flat washer and capscrew water swivel should include replacement of all
to the bottom of the swivel retainer plate securing the seals and rings.
wiring harness. 1. Withdraw the spool from the case.
6. Connect the hydraulic lines and water lines to the spool 2. Place the spool on a clean work surface in a dust-free
of the hydraulic swivel as tagged during removal. area and block the spool to prevent movement during
7. Connect the hydraulic lines to the hydraulic swivel case disassembly.
as tagged during removal.
8. Connect the water lines to the water swivel case as CAUTION
tagged during removal. When removing seals and rings, avoid scratching
9. Remove the blocking material from the lift cylinder. grooved and gland surfaces.
10. Activate all systems; cycle all functions and observe for NOTE: Aligning discarded seals and rings in the order of
proper operation and any leakage. disassembly will assist with installation of new
seals and rings.
3. Remove the seals and rings from the spool.
7. Tag and disconnect the connectors from the receptacles 4. Apply Loctite to the set screws securing the electrical
on the cab bulkhead mounting plate. swivel to the center post and tighten them 5 to 6 Nm (45
to 55 pounds-inch)
8. Remove the nuts and washers, and remove the cover
from the electrical swivel. 5. Install the swivel cover and secure with two nuts and
washers.
9. Loosen the setscrews securing the electrical swivel
mounting tube to the center post on the water swivel. 6. Connect the wiring harness connectors to the
receptacles on the cab bulkhead mounting plate as
10. Remove the bolt and nut securing the electrical swivel
tagged during removal.
case to the bracket on the case of the water swivel.
7. Plug the connector into the carrier wiring receptacle,
connect the wires as tag during removal. Install the
CAUTION yellow ground wire to the connector mounting bracket on
When withdrawing the wiring harness through the center the carrier frame using the bolt and star washers taken
of the hydraulic and water swivels, ensure the wires do of at removal and refer to Grove Engineering
not get caught and damaged. Specification A-829-100386 for proper electrical
termination of grounds.
6
11. Remove the swivel and wiring harness from the crane. If
8. Install the clamp securing the harness to the retainer
necessary, remove the spacer bushing from the center
plate on the bottom of the hydraulic swivel assembly.
post.
9. Connect the batteries.
Installation
1. If removed, install the spacer bushing on the center post.
Route the collector core wiring harness through the CAUTION
center of the hydraulic and water swivels. It is imperative that the slew potentiometer be adjusted
anytime work is done to the electrical swivel.
NOTE: The boom should be centered directly over the
front of the crane before adjustment is made to the
10. Activate all systems, cycle all functions, and observe for
slew potentiometer.
proper operation. Adjust the slew potentiometer in
2. Slide the electrical swivel mounting shaft onto the center accordance with SLEW POTENTIOMETER
post. ADJUSTMENT procedures in this Sub-Section.
3. Ensure the threaded hole on the bottom of the electrical Preventive Maintenance
swivel base is aligned with the mounting hole in the
It is recommended that a normal inspection of the electrical
bracket on the water swivel case. Install the bolt through
swivel collector ring and brush assembly be established. An
the hole in the bracket and install the nut. Screw the bolt
example of this could be at approximately 100 to 150 engine
into the hole in the electrical swivel base until the bolt
operating hours. When this time limit is reached, perform the
head is approximately 6.4 mm (0.25 in) from the bracket.
following.
Tighten the nut against the electrical swivel (Figure 6-6).
1. Check the collector ring and brush assembly for any 4. Disengage the swing lock pin and swing the
corrosion, pitting, arcing, and wear. superstructure approximately 10 degrees to the right
(clockwise). Slowly swing back to the left and engage
2. Check the collector ring setscrews and ensure they are
the swing lock pin.
tight.
NOTE: If the superstructure swings past the swing lock pin
3. Check the brush and arm assembly springs. Ensure
engaged position, step 4 must be repeated.
they are holding the brushes firmly against the collector
rings. 5. Loosen the three screws that secure the slew
potentiometer to the mounting plate.
Slew Potentiometer Preliminary Zero Adjustment
Procedure 6. Rotate the body of the slew potentiometer until the slew
angle indicates 0.6 ± 0.1 degree.
1. Rotate the superstructure over the front and engage the
swing lock pin. NOTE: The slew angle indication in step 6 may not be
obtainable due to limited wire length on the
NOTE: Refer to the PAT Load Moment Indicator p o t e n t i o m e t e r, o r t h e e l e c t r i c a l t e r m i n a l s
Operator’s Handbook for detailed instructions. interference with one of the three mounting screws.
Complete the LMI console setup according to the If this occurs, reposition the collar set screwed to
crane’s current operating configuration. the potentiometer shaft and repeat steps 4 thru 6.
2. Press the 1 keypad button on the LMI console. 7. Tighten the three screws that secure the slew
3. Press the CTRL keypad button on the LMI console. potentiometer to the mounting plate. Install the electrical
swivel cover.
4. Enter authorization code 64356, then press the return
keypad button on the LMI console. 8. Disengage the swing lock pin and swing approximately
10 degrees to the left (counterclockwise). Slowly swing
5. Press the return keypad button two more times to back to the right and engage the swing lock pin.
display the slew adjustment screen.
NOTE: If the superstructure swings past the swing lock pin
6. Press the + and the - keypad buttons on the LMI console engaged position, step 8 must be repeated.
simultaneously. Note the indicator line moves to zero on
the bar graph on the slew adjustment screen. 9. If the angle indicated on the console does not exceed ±
1.0 degree, proceed to step 10. If the indicated angle
7. Press the ESC keypad button on the LMI console. exceeds ± 1.0 degree, return to step 4.
Slew Potentiometer Adjustment 10. Disengage the swing lock pin and swing approximately
1. Rotate the superstructure over the front and engage the 10 degrees to the right (clockwise). Slowly swing back to
swing lock pin. the left and engage the swing lock pin.
2. Set the LMI console to read slewing angle as follows: NOTE: If the superstructure swings past the swing lock pin
engaged position, step 10 must be repeated.
NOTE: Refer to the PAT Load Moment Indicator DS350/
1319 Operator ’s Handbook for detailed 11. If the angle indicated on the console does not exceed ±
instructions. 1.0 degree, proceed to step 12. If the indicated angle
exceeds ± 1.0 degree, return to step 3.
• Complete the LMI console setup according to the
crane’s current operating configuration. 12. Disengage the swing lock pin and swing approximately
10 degrees to the left (counterclockwise). Slowly swing
• Press limits LIM. back to the right and engage the swing lock pin.
• Press 4 for slew angle/work area definition limits. NOTE: If the superstructure swings past the swing lock pin
• Press 1 for slew angle. engaged position, step 12 must be repeated.
• Press 2 or 3 to display slewing angle. 13. Verify the angle indicated on the console does not
exceed ± 1.0 degree. If the indicated angle exceeds ±
3. Remove the electrical swivel cover. 1.0 degree, return to step 3.
CAUTION
Do not attempt to rotate the slotted shaft in the center of
the slew potentiometer.
GROVE 7-i
POWER TRAIN RT9130E SERVICE MANUAL
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
Drive Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
Torque Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24
Theory Of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26
Servicing The Crane After Transmission/Torque Converter Overhaul . . . . . 7-28
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30
Towing Or Pushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30
7-ii
RT9130E SERVICE MANUAL POWER TRAIN
SECTION 7
POWER TRAIN
DESCRIPTION ignition switch is in the ON position during cold weather
starting. The ECM checks intake manifold temperature to
The engine is a Cummins QSC diesel engine (Figure 7-1). determine how long to energize the air heater before
This Service Manual does not include detailed information extinguishing the WAIT-TO-START lamp. Once the engine is
on the engine itself. A separate manual as prepared in detail started, the electric air heating element will be energized
by the engine manufacturer, is supplied with this Service again for a time period determined by intake air temperature.
Manual. However, a short description and maintenance of
certain components of the fuel system, air intake system,
MAINTENANCE
and water cooling system is provided in this section.
The engine is electronically controlled by the Electronic Engine Removal
Control Module (ECM), it is the control center of the system.
1. Set the outriggers and position the boom to over the
It processes all of the inputs and sends commands to the fuel
side.
systems as well as vehicle and engine control devices.
2. Open the hood top door assembly.
Engine speed is controlled by the foot throttle pedal in the
cab. It controls engine RPM which increases or decreases 3. Disconnect the air filter tubing at the engine and air
proportionately with the amount of foot pressure applied to cleaner (Figure 7-4). Remove and lay aside.
the pedal. Engine speed is also controlled by a hand
4. Disconnect the exhaust tubing at the engine and muffler.
controlled knob located to the right of the ignition switch. A
Remove and lay aside.
rocker switch located beside the ignition switch is used to
choose between HAND or FOOT control. An increase in 5. Tag and disconnect the hourmeter wiring, the engine
engine rpm occurs when the hand throttle is turned electrical harness connector from the carrier harness
clockwise. A decrease in engine rpm occurs when the hand connector, the starter and grid heater relay harness from
throttle is turned counter clockwise. The foot throttle pedal the carrier harness and the battery cables from the
and hand throttle control knob are electrically connected to batteries and the engine.
the superstructure control module which sends the signal to
the engine ECM via the J1939 data link. 6. Tag and disconnect the left and right rear backup lights,
stop lights and the backup alarm from the carrier
The engine and its components are enclosed in a hood harness. Take off the clamps holding the harness to the
assembly with a grill in the rear of the hood for adequate air engine hood.
circulation. Access to the engine is gained through a door
assembly in the top of the hood that opens from both sides. 7. Remove the capscrews and washers securing the
remote secondary fuel filter and mounting bracket to the
The air intake filter is mounted on the front of the left rear engine hood. Tie strap the filter and bracket to the
fender. The muffler is mounted on the left side of the frame
behind the left rear fender.
engine so it is out of the way for removal of the engine.
7
8. Remove the engine hood assembly and pump cover
from the machine.
9. Drain the engine coolant system into a suitable
DANGER container.
Do not spray starting fluid into the air inlet. The spray will 10. Drain the engine lubrication system into a suitable
contact the heater elements and could explode causing container.
personal injury.
11. Drain the transmission/torque converter oil system into a
The engine is equipped with electric air heating elements suitable container.
that are located in the engine’s intake air stream to aid in cold 12. Tag and disconnect the oil lines from the torque
starting and reduce white smoke at start-up. In the preheat converter. Cap or plug all openings.
mode, the engine should not be cranked until the WAIT-TO-
START lamp turns off. The WAIT-TO-START lamp is 13. Remove the driveline between the torque converter and
illuminated during the preheat time that takes place when the the transmission. Refer to DRIVE LINES in this section.
13
1 4, 5, 6
23, 24, 25
7 30, 31
27, 28, 29
8 32, 33
26, 27
7383-2
17 23, 24, 25
9
10
7383-1
11
12
FIGURE 7-1
22 16
2
14
26, 27
18
20
20 21 4, 5, 6
21 19
15 27, 28, 29
7383-2
14. Tag and disconnect all lines from hydraulic pump No. 4 24. Attach a lifting device capable of supporting the weight
on the right side of the engine. Place a suitable container of the engine, to the engine and torque converter.
under the hydraulic pumps to catch any oil that is spilled.
25. With the lifting device supporting the weight of the
Cap or plug all openings. Position the hydraulic lines so
engine, remove the four capscrews, nuts and washers
the disconnected end is higher than the hydraulic tank.
securing the front of the engine to the frame. Remove
Refer to HYDRAULIC PUMPS in Section 2 -
the capscrews, nuts, washers, shock mounts, and dock
HYDRAULIC SYSTEM.
washers (one set on each side) securing the rear of the
15. Remove the capscrews and flatwashers securing the engine to the frame.
three hydraulic pumps to the torque converter. Remove
26. Using the lifting device, lift the engine and torque
the pumps from the torque converter and position them
converter as an assembly from the crane.
so they do not interfere with removing the engine.
27. Remove the torque converter from the engine. Refer to
16. Unhook the hydraulic pump disconnect. Remove the pin
TORQUE CONVERTER in this section.
and clip and lever securing the disconnect cable to the
torque converter. Next remove the capscrew and 28. If a new engine is to be installed, remove all
flatwasher securing the pump disconnect mounting components, fittings, etc., from the old engine and install
bracket to the torque converter and lay aside. them on the new engine in the same location.
17. Tag and disconnect all lines from the radiator. Cap or
Engine Installation
plug all openings. Disconnect the coolant level sensor
harness from the engine harness and tie up excess NOTE: Use the same grade hardware, torque values, and
harness so it is out of the way. Loctite used by the factory.
18. Remove the fan guard and fan ring. Refer to RADIATOR
- Removal in this Section.
19. Tag and disconnect all fuel lines at the engine. Place a DANGER
suitable container under the fuel line connection to catch
The lifting device must be able to support the combined
any spills. Cap or plug all openings. Position the fuel
weight of the engine and torque converter.
lines so the disconnected end is higher than the fuel
tank.
NOTE: The engine and torque converter assembly weighs
20. Tag and disconnect all lines and tubing from the engine. approximately 1170 kg (2579 pounds).
Cap or plug all openings.
1. Install the torque converter on the engine. Refer to
21. If equipped with optional engine block heater, tape and TORQUE CONVERTER in this section.
stow the electrical plug to the engine so it is out of the
2. With all components and fittings installed on the new
way for engine removal.
engine, lift the engine into the crane.
22. Remove the capscrews, flatwashers and lockwashers
3. With the engine in position, secure the rear of the engine
securing the remote engine oil filter bracket to the side of
with the capscrews, nuts, washers, shock mounts, and
the frame. Tie strap the oil filter and mounting bracket to
dock washers (one set on each side). Torque the
the side of the engine so it is out of the way for removal
capscrews 481 to 522 Nm (355 to 385 foot-pounds).
of the engine.
At the front of the engine secure the engine mount to the
23. Remove the three capscrews attaching the remote water
frame with the four capscrews, nuts and washers.
conditioner to the left side frame rail. Tie strap the filter
Torque the capscrews 40.6 to 43.3 Nm (30 to 32 foot-
and mounting bracket to the engine so it is out of the way
pounds).
for removal of the engine.
4. Remove the lifting device.
5. Secure the remote engine oil filter and mounting bracket
to the side of the engine frame with the capscrews,
DANGER flatwashers and lockwashers. Torque the capscrews
The lifting device must be able to support the combined 40.6 to 43.3 Nm (30 to 32 foot-pounds).
weight of the engine and torque converter.
6. Secure the remote water conditioner filter and mounting
NOTE: The engine and torque converter assembly weighs bracket to the side of the frame with three capscrews.
approximately 1170 kg (2579 pounds). Torque the capscrews 10.4 to 12.2 Nm (7.7 to 9.0
pounds-foot).
7. Install the three hydraulic pumps on the torque 16. Secure the remote secondary fuel filter to the engine
converter. Refer to HYDRAULIC PUMPS in Section 2 - hood with four capscrews, washers, and lockwashers.
HYDRAULIC SYSTEM. Torque the capscrews 40.6 to 43.3 Nm (30 to 32 foot-
pounds).
8. Connect the hydraulic lines to hydraulic pump No.4 as
marked at REMOVAL. Remove all caps or plugs placed 17. Connect the left and right rear backup lights, stop lights
on openings during REMOVAL so no blockage can and left side backup alarm at the rear of the engine
occur in the hydraulic system. Refer to HYDRAULIC hood. Use clamps acquired during removal to route
PUMPS in Section 2 - HYDRAULIC SYSTEM. harness along engine hood.
9. Rehook the hydraulic pump disconnect. Install the lever 18. Connect the start and grid heater relay panel to the
and clip and secure the disconnect cable to the torque carrier harness.
converter. Install the capscrew and flatwasher securing
19. Connect all electrical connections as tagged during
the pump disconnect mounting bracket to the torque
REMOVAL.
converter. Adjust the pump disconnect cable as needed
for proper operation. 20. Reconnect battery cables as tagged during REMOVAL.
10. Connect the fuel lines to the engine as tagged during 21. If equipped with engine block heater, reroute the cord for
removal. Remove all caps or plugs placed on openings the heater.
during removal so no blockage can occur in the fuel
22. Connect the muffler exhaust piping to the engine.
system.
23. Connect the air filter tubing at the engine and the air
11. Connect all lines and tubing to the engine, torque
filter.
converter, and all other components in accordance with
the identification marks made during removal. Remove 24. Service the transmission, engine lubrication system, and
all caps or plugs placed on openings during removal so engine cooling system.
no blockage can occur.
25. Start the engine. Check all hoses and fittings for leaks.
Recheck all fluid levels. Refer to Section 9 -
CAUTION LUBRICATION.
Do not apply sealant to the inside of the hydraulic suction Engine Drive Belts
hoses.
The proper operation of engine belt-driven components such
12. Apply a moderate coat of Permatex Type No. 2 to the as the alternator, fan, and water pump depend on the proper
male hose adapter and install the hydraulic hoses. Do condition and tension of the engine drive belt.
not apply sealant to the inside of the hydraulic hose and
NOTE: Belt tension is maintained with an automatic belt
push it onto the male adapter. This can result in excess
tension device.
sealant being pushed ahead of the male adapter and
being exposed to the hydraulic oil. The engine drive belt (Figure 7-2) should be inspected
13. Install the radiator. Refer to RADIATOR - Installation in
visually on a daily basis. The drive belt should be inspected
for cracks, frayed areas, and glazed or shiny surfaces. A
7
this section. Connect all hoses and electrical harnesses
drive belt that is glazed or shiny indicates belt slippage.
to the radiator as tagged during REMOVAL. Remove all
caps or plugs placed on openings during REMOVAL so Engine drive belt damage can be caused by various factors
no blockage can occur in the radiator system. such as incorrect tension, incorrect belt size, misaligned
engine pulleys, incorrectly installed belt, or by oil, grease, or
14. Connect the drive shaft between the torque converter
hydraulic fluid on the belt.
and the transmission. Refer to DRIVE LINES in this
section. Refer to the engine manufacturer’s manual for any special
tools or belt tension specification.
15. Install the hood assembly. Install the pump cover.
OK OK OK
FIGURE 7-2
ELECTRONIC CONTROL SYSTEM WARNING light, is used in the diagnostic operation of the
engine control system.
The engine control system is an electronically operated fuel
control system that also provides many operator and vehicle NOTE: When not using the diagnostic system, turn the
features as well as reducing exhaust emissions while ENGINE DIAGNOSTIC TEST MODE switch to the
optimizing engine performance. OFF position.
The ECM performs diagnostic tests on most of its circuits To check for active fault codes, turn the keyswitch to the OFF
and will activate a fault code if a problem is detected in one of position, and move the ENGINE DIAGNOSTIC TEST MODE
these circuits. Along with the fault code identifying the switch to the ON position. Turn the vehicle keyswitch to the
problem, a snapshot of engine operating parameters at the ON position. If no active fault codes are recorded, both
time of fault activation is also stored in memory. Some fault lamps stay off. If active fault codes are recorded, both lamps
codes will cause a diagnostic lamp to activate to signal the will come on momentarily, then begin to flash one code of the
driver. The fault codes can be read using the fault lamps in recorded faults.
the cab panel or with the correct service tools. The ECM
Engine Warning Light
communicates with service tools through a SAE J1939
datalink. The ENGINE WARNING light is located at the top of the front
console. It is a yellow indicator light that is a part of the
Engine Control System Switches And engine’s electronic control system and when illuminated,
Indicator Lights gives the operator a signal that there is an engine problem
which must be corrected.
Engine Diagnostic Test Mode Switch
In addition to alerting the operator of system faults, the
The ENGINE DIAGNOSTIC TEST MODE switch is located ENGINE WARNING light, in conjunction with the ENGINE
at the center of the front console panel. The switch is to be STOP light, is used in the diagnostic operation of the engine
used when servicing the engine’s electronic control system. control system.
It is a two position (ON-OFF) switch used to activate the
testing mode. NOTE: When not using the diagnostic system, turn the
ENGINE DIAGNOSTIC TEST MODE switch to the
Engine Diagnostic Idle Switch OFF position.
The ENGINE DIAGNOSTIC IDLE switch is located at the To check for active fault codes, the keyswitch must be in the
center of the front console panel. The switch is to be used OFF position, and move the ENGINE DIAGNOSTIC TEST
when servicing the engine’s electronic control system. It is a MODE switch to the ON position. Turn the vehicle keyswitch
two position momentary switch that provides idle-control to the ON position. If no active fault codes are recorded, both
inputs or diagnostic-mode inputs, depending upon operating lamps stay off. If active fault codes are recorded, both lamps
conditions at the time it is activated. will come on momentarily, then begin to flash one code of the
recorded faults.
Engine Service Light
Fault Code Flashing Sequence
The ENGINE SERVICE light is located at the center of the
front console panel. It is an amber indicator light that is a part The ENGINE WARNING light (yellow) flashes at the 7
of the engine’s electronic control system and will illuminate beginning of a fault code sequence. There will be a short 1-
when an engine protection fault code is active. When or 2-second pause after which the number of the recorded
illuminated, there is an engine fluid (coolant or lubricant) fault code will flash in the ENGINE STOP light (red). To
level problem which must be corrected. interpret the flash code, count the first sequence of red
flashes for the first digit and after a two second delay, count
Engine Stop Light the second sequence of red flashes for the second digit.
The ENGINE STOP light is located at the center of the front When the number has finished flashing in red, the ENGINE
console panel. It is a red indicator light that illuminates to WARNING light (yellow) flashes again. The lamps flash each
signify a serious engine problem that requires the vehicle fault code 3 times before advancing to the next code. To skip
and the engine to be stopped as soon as safely possible. to the next fault code, move the ENGINE DIAGNOSTIC
The engine should remain shut down until the fault can be IDLE switch in either position (+/-) to see other fault codes. If
repaired. only one active fault is recorded, the control system will
continuously display the same fault code when pressing the
In addition to alerting the operator of system faults, the ENGINE DIAGNOSTIC IDLE switch. Reference the engine
ENGINE STOP light, in conjunction with the ENGINE manufacturers service manual for explanation and correction
of the fault codes.
FUEL SYSTEM few seconds to make sure the low pressure fuel lines are
fully primed. The electric lift pump shuts off after the engine is
Description started.
The fuel system consists of the fuel tank, primary fuel filter Maintenance
with water separator, secondary fuel filter with water
separator and water in fuel sensor, lift pump, injection fuel NOTE: The entire fuel system must be maintained air tight
pump, fuel injectors, and return fuel cooler. All components to prevent loss of prime.
except the fuel tank and primary fuel filter are installed on the
Fuel Tank
engine or supplied with the engine for remote mounting.
The fuel tank should be kept filled, especially overnight, to
Fuel Tank reduce condensation to a minimum. Refer to the applicable
The fuel tank (Figure 7-3) is a steel cylinder-type tank engine manual for the recommended schedule for draining
located on the left side of the machine. The fuel tank has a any water or sediment from the tank.
draw capacity of 379 liters (100 gallons). A connection on the Removal
bottom of the tank provides for fuel supply to the engine.
Surplus fuel from the engine is provided to the bottom of the 1. Position a suitable container under the fuel tank and
fuel tank below the fuel level. The tank is equipped with a drain all fuel from the tank.
non-vented filler cap, chain-attached to the tank, and a fuel 2. Tag and disconnect the two lines from the bottom of the
quantity sender unit which provides a signal to a fuel quantity tank.
gauge on the instrument panel in the cab.
3. Disconnect the electrical lead from the fuel quantity
Injection Fuel Pump sender unit.
The fuel oil is finely atomized as it is injected into the cylinder 4. Support the weight of the tank, loosen and remove the
and ignited by the heat of the compression. It is also metered nuts, washers and capscrews securing the straps to the
before injection, to meet the load requirements imposed mounting brackets. Remove the tank and steps.
upon the engine. Surplus fuel, returning from the injectors, is
bypassed back to the fuel tank or to the inlet side of the 5. If a new tank is to be installed, remove the two fittings,
pump. The continuous flow of fuel through the injectors helps the fuel quantity sender, and steps from the tank and
to cool the injectors and to purge air from the system. install them in the new tank.
Installation
Fuel Filter-water Separator
1. Position the new tank on the mounting brackets and
Both fuel filters have water separators that remove impurities
install the nuts, washers and capscrews on the three
from the fuel and also remove water from the fuel before it
straps. Torque the capscrews 97.6 to 105.7 Nm (72 to 78
reaches the engine. The primary fuel filter is located on the
pounds-foot)
frame beside the fuel tank. The secondary fuel filter is
mounted on the right side of the engine hood. 2. Connect the electrical lead to the fuel quantity sender
unit.
The fuel mixture passes through the outer wrap of the first
stage of the filter paper, where large droplets of water are 3. Connect the two lines to the fittings on the bottom of the
formed as it is stripped from the fuel. The water falls out into tank in accordance with the identification marks made
the void between the two paper elements and goes to a during removal.
reservoir in the bottom of the housing, where it can be
4. Service the tank.
drained through a drain plug at the bottom of the housing.
The water in fuel sensor is located in the secondary fuel filter Fuel Filter-Water Separator
housing on the right side of the engine hood. Once the
Draining
storage space in the bottom of the filter housing fills with a
certain amount of water, the sensor will signal the ECM. The The sump of the fuel filter-water separators should be
WATER IN FUEL lamp will illuminate at the operator drained daily, 30 minutes after the engine is shut down, to
controls, indicating that the water should be drained from the remove any water and sediment. Adhere to the following
fuel filter assembly. procedure.
The ECM controls the electric lift pump located between the 2. Drain into suitable container until fuel appears.
fuel tank and the injection pump. Whenever the keyswitch is 3. Close the drain plug.
turned to the ON position, the lift pump will be energized for a
12
10
7
7
1
3, 4 6
17
18
11
13
9 5
2
13
15
14 16
8
6076
FIGURE 7-3
7
Item Description Item Description
1 Fuel Quantity Sending Unit 10 Oil Cooler
2 Filler Cap 11 Line To Engine
3 Fuel Filter 12 Line To Return Port On Tank
4 Fuel-Water Separator 13 Bracket
5 Fuel Supply 14 Drain Port
6 Fuel Return 15 Return
7 Strap Assembly 16 Supply
8 Steps 17 Vent
9 Fuel Tank
FRONT
18
19
20
22 23
6689-3
21
AIR INTAKE AND EXHAUST SYSTEM 1. Inspect the air cleaner outlet tube for damage.
2. Ensure the element gasket washer is not damaged and
Description the washer’s rubber face seals against the element.
The air intake system (Figure 7-4) controls the quality and 3. Inspect the element gasket for damage.
amount of air available for combustion. System components
are the air cleaner, turbocharger, charge air cooler, cylinder 4. Check for structural failures and replace damaged parts.
head, and exhaust manifold. Inlet air is pulled through the air 5. Inspect the restriction indicator tap for leaks.
cleaner, compressed and heated in the compressor side of
the turbocharger. The air is pushed through the air-to-air Check For Filter Restriction
charge air cooler to the air inlet manifold. Cooling the inlet air
increases combustion efficiency, lowers fuel consumption, As a dry cleaner element becomes loaded with dust, the
and increases the horsepower. The air is forced into the vacuum on the engine side of the air cleaner (at the air
cylinder head to fill the inlet ports. Air flow from the inlet port cleaner outlet) increases.
into the cylinder is controlled by the intake valves. The vacuum is generally measured as restriction in
Each cylinder has two intake valves and two exhaust valves. kilopascals or inches of water. The engine manufacturer
When the intake valves open, cooled compressed air from places a recommended limit on the amount of restriction the
the inlet port is pulled into the cylinder. The intake valves engine will stand without loss in performance before the
close and the piston begins to move up on the compression element must be cleaned or replaced. Cummins allows a
stroke. Fuel is injected into the cylinder and combustion vacuum of 6.2 kPa (25 inches of water) maximum with a dirty
starts. The piston is forced down and is on the exhaust stroke air cleaner at maximum governed RPM.
when it moves up again. The exhaust valve opens and A service indicator on the air cleaner housing will indicate
exhaust is expelled through the exhaust port into the exhaust when the filter needs to be cleaned or replaced. Reset the
manifold. indicator each time the air cleaner is serviced. If the
The exhaust gas from the exhaust manifold enter the turbine indicator’s accuracy is suspect, a water manometer is the
side of the turbocharger and cause the turbine to turn driving most accurate and dependable method of measuring
the compressor. Exhaust from the turbocharger pass vacuum.
through the exhaust pipe and muffler into the atmosphere. To use the manometer, hold it vertically and fill both legs
The air cleaner is the dry-type with a replaceable element approximately half full with water. One of the upper ends is
and is located on the left rear fender. A service indicator, connected to the restriction tap on the outlet side of the air
designed to indicate red when servicing is required, is cleaner by means of a flexible hose. The other end is left
installed in the left center deck and is connected to the air open to the atmosphere.
cleaner by plastic air line. Maximum restriction in the air cleaner occurs at maximum air
On the Cummins QSC engine there are electric air heating flow. On this turbocharged diesel engine, the maximum air
elements that are located in the engine’s intake air stream. flow occurs only at maximum engine power.
These elements heat the intake air when starting the engine With the manometer held vertically and the engine drawing
in cold ambient conditions. Startability and white smoke maximum air, the difference in the height of the water 7
control are enhanced by the use of an intake air heater. A columns in the two legs, measured in inches or centimeters,
WAIT-TO-START lamp is located on the center front console is the air cleaner restriction. Restriction indicators are
to indicate when to crank the engine. generally marked with the restriction at which the red signal
flag locks up. If the initial restriction on a new or clean filter
Maintenance reads above the maximum allowed for the engine, check the
following items.
Air Cleaner Checks
1. Ensure the air cleaner inlet is not plugged.
Dust passing the air cleaner can cause rapid engine wear. All
connections between the air cleaner and the engine must be 2. Inspect the air cleaner outlet to be sure it is not plugged
tight and sealed. If these connections are well sealed, and by paper, rags, etc.
there is still evidence of dust leakage, check the following
3. Ensure the correct size connections are used between
places for possible trouble.
the air cleaner and the engine.
NOTE: Dust that gets by the air cleaner system can often
4. Ensure all inlet accessories are the correct size and are
be detected by looking for dust streaks on the air
not plugged by any foreign object.
transfer tubing or just inside the intake manifold
inlet.
6
9
10
4 11, 12 17, 18
13
14
7
19
2
15
2
3
1 16
1. Unlatch the latches, open the air cleaner body and b. INSERT THE FILTER PROPERLY. The seal area is
withdraw the element as follows (Figure 7-5): on the inside of the open end of the primary filter. A
new filter has a dry lubricant to aid installation. The
a. RELEASE THE SEAL GENTLY. The filter element critical sealing area will stretch slightly, adjust itself
fits tightly over the outlet tube, creating the critical and distribute the sealing pressure evenly. To
seal on the inside diameter of the filter endcap. The complete a tight seal, apply pressure at the outer
filter should be removed gently to reduce the rim of the filter, not the flexible center. No cover
amount of dust dislodged. There will be some initial pressure is required to hold the seal (Figure 7-7).
resistance, similar to breaking the seal on a jar.
FIGURE 7-7
FIGURE 7-5
b. AVOID DISLODGING DUST FROM THE FILTER. 5. Install the cover on the air cleaner body with the two
Gently pull the filter off the outlet tube and out of the arrows pointing up. Secure the cover with the latches.
housing. Avoid knocking the filter against the 6. Check all connections and ducts for an air tight fit. Make
housing (Figure 7-6). sure that all clamps, bolts, and connections are tight.
Check for holes in piping. Leaks in the air intake system
may send dust directly to the engine.
Element Cleaning
Washing in a water-detergent solution or blowing out with
compressed air are two accepted methods for cleaning the 7
element of the air cleaners. If the element contains
substantial amounts of soot or oil fumes, washing in water
works better than compressed air. If the contaminant is found
to be mostly loose dust, either method works equally well.
FIGURE 7-6 Elements that are cleaned with compressed air can be put
back into service immediately. Elements cleaned by washing
2. Clean the element as outlined in ELEMENT CLEANING. must be dried before returning them to service.
Replace the element after six cleanings or annually,
NOTE: Some elements are partially covered by a plastic
whichever comes first.
sleeve with fins. The covered portion can be
3. Inspect all parts of the intake system and air cleaner. Be cleaned with water or air without removing the
sure to clean the sealing surface of the outlet tube and sleeve. Use a stiff fiber (not wire) brush to remove
the inside of the outlet tube. oil and grease deposits from the sleeve and fins.
Never remove the sleeve and fins from the
4. Install the cleaned or new element into the air cleaner
element.
body as follows:
Cleaning With Compressed Air 3. Add warm water (approximately 38°C [100°F]) to get the
proper proportions of detergent and water (about one
cup of detergent to five gallons of water).
4. Soak the element for at least 15 minutes.
5. Agitate the element for about two minutes to loosen the
dirt.
CAUTION
Water pressure from a hose or tap should not exceed
276 kPa (40 PSI).
FIGURE 7-8
6. Rinse the element with clean water until the water
coming through the element is clean. Air-dry the element
thoroughly before using (Figure 7-10).
CAUTION
Pressure at the air nozzle must not exceed 690 KPA
(100 PSI).
1. Direct a jet of clean, dry air from the inside of the filter
element, perpendicular to the pleats (Figure 7-8).
2. Move the air jet up and down along the pleats, slowly
rotating the element, until no more dust is being
removed. Do not rupture the element with the nozzle or
the air jet.
Cleaning With Water
FIGURE 7-10
CAUTION
Heated air (maximum temperature 71°C [160°F]) must
have circulation. Do not use light bulbs for drying
elements.
Inspection
FIGURE 7-9 Element
Duct Work
1. Check the intake pipe cap and screen for accumulation
of leaves, trash, and other debris that could restrict air
flow. Repair the screen or replace the cap if any large
holes are found in the screen.
2. Check all mounting hardware for security to eliminate
possible vibration of intake piping. Such vibration leads
to early failure of hoses, clamps, and mounting parts,
and can cause hoses to slip off the connecting pipes,
FIGURE 7-11
allowing un-filtered air into the engine air intake.
Air Cleaner Body 3. Check hoses for cracks, chafing, or deterioration, and
replace at the first sign of probable failure.
Before installing the filter element, remove foreign material
(leaves, lint or other foreign matter) that may have collected
inside the air cleaner body. Inspect the inside of the body for MUFFLER
dents or other damage that would interfere with air flow or NOTE: Standard muffler and CE muffler are similar in
with the fins on the element or inside the body. Repair any removal and installation (Figure 7-13) despite the
body dents, being careful not to damage the sealing differences in the two mufflers, the exhaust
surfaces. Be sure to clean the sealing surface of the outlet tailpipes, and the mounting bracket weldments.
tube and the inside of the outlet tube, taking care not to
damage the sealing area on the tube. Removal
Vacuator Valve
Vacuator valves are designed to expel loose dust and dirt
from the air cleaner body automatically, thus lengthening the
element service life. The valve lips must point straight down
DANGER
and be kept free from debris to operate effectively. Mud and Do not touch muffler or exhaust parts until they are at
chaff can lodge in these lips periodically and hold them open ambient temperature. Severe burning may result.
during engine operation (Figure 7-12).
1. Remove muffler clamps to free exhaust tailpipe from
muffler and muffler mounting bracket.
2. Remove seal clamp to free muffler from exhaust tube.
3. Remove mounting bands to free muffler from muffler
mounting bracket. As needed, remove capscrews and
nuts to free muffler mounting bracket from its mountings.
4. Inspect muffler, exhaust tailpipe, exhaust tubes, bracket,
and attaching hardware. Repair or replace any of these
7
parts if damaged or missing.
8
6
4
5
7
1
3
7383-2
2
5
3
7
7383-1 1
FIGURE 7-13
Whenever an engine does not perform at top efficiency, a 3. Run the engine for 5 minutes and recheck the
neglected cooling system may be at fault even though the antifreeze/coolant level. Refill as necessary repeating
part directly responsible is not a part of the cooling system. step 1. Refer to Section 9 - Lubrication.
• Change coolant filter (replace with Coolant Filter/DCA4 NOTE: Use a cleaning compound that is not corrosive to
Corrosion Resistor Cartridge, GROVE Service Part aluminum to prevent damage to the radiator.
Number 9414101675). 2. Allow the engine to cool, close the drain cocks, and pour
• Check SCA Levels (use only the DCA4 Coolant Test Kit, the cleaning compound into the surge tank according to
GROVE Service Part Number 9414101675, to check the the directions. Fill the system with water.
coolant additive concentration in the cooling system). 3. Place a clean drain pan to catch the overflow, and use it
If SCA levels are less than 1.2 Units/Gal, add Cummins to maintain the level in the radiator. Do not spill the
DCA4 to maintain desired level. solution on the vehicle paint.
NOTE: Inadequate concentration of the coolant additive 4. Replace the radiator cap and run the engine at moderate
can result in major corrosive damage to the cooling speed, covering the radiator if necessary, so the system
system components. Overconcentration can cause reaches a temperature of 82 °C (180 °F) or above, but
formation of a “gel” that can cause restriction, does not reach the boiling point. Allow the engine to run
plugging of coolant passages, and overheating. at least two hours, or according to recommendations of
the manufacturer of the cleaning compound, at 82 °C
1 year or 1000 hours
(180 °F) so the cleaning solution may take effect. Do not
• Change coolant filter (replace with Coolant Filter/DCA4 drive the vehicle or allow the liquid level in the radiator to
Corrosion Resistor Cartridge, GROVE Service Part drop low enough to reduce circulation.
Number 9414101675).
5. Stop the engine as often as necessary to prevent boiling.
• Test coolant for contamination.
6. With the engine stopped, feel the radiator core with bare
Condemning limits are: hands to check for cold spots, and then observe the
temperature gauge reading. When there is no change in
- Sulfate level greater than or equal to 1500 ppm. temperature for some time, drain the cleaning solution.
- Chloride level greater than or equal to 200 ppm. 7. If clogging of the core is relieved but not fully corrected,
- The ph level is less than 6.5 allow the engine to cool, pressure-flush the system (see
Pressure Flushing) and repeat the cleaning operation.
- Oil or fuel contamination can be identified by odor or
color. 8. If problem persists, replace radiator.
3. Connect the flushing gun to compressed air and water through the overflow pipe. In the first stage position of the
pressure, and clamp the gun nozzle to the hose cap, it should be possible to depress the cap approximately 3
attached to the radiator outlet opening. mm (0.13 in). The prongs on the cap can be bent to adjust
this condition. Care must be taken that the cap is not too
4. Fill the core with water. Turn on air pressure in short
loose as this would prevent proper sealing.
blasts to prevent core damage.
5. Continue filling the radiator with water and applying air
pressure as above until the water comes out clear.
6. Clamp the flushing gun nozzle firmly to a hose attached DANGER
securely to the engine water outlet opening. Fill the Loosen cap slowly and pause a moment to avoid possible
engine block with water, partly covering the water inlet burning by hot water or steam. Continue to turn the cap to
opening to permit complete filling. the left until it can be removed.
7. Turn on compressed air to blow out water and loose
4. Tubes are very small and can become easily clogged by
sediment. Continue filling with water and blowing out
rust and scale. The general condition of the cooling
with air until flushing stream comes out clear.
system and operating temperature are indications as to
8. When the vehicle is equipped with a water heater whether or not tubes are clean. Another good test is to
connected to the cooling system, flush the heater, feel the core for cold spots.
following the same procedure as for the radiator core.
5. Fins are thin metal sheets that dissipate heat picked up
9. After completing the flushing operation, clean out the by the tubes. They should be kept free of bugs, leaves,
surge tank overflow pipe; inspect the water pump; clean straw etc., so as to allow the free passage of air. Bent
the thermostat and the radiator cap control valves. fins should be straightened.
Check the thermostat for proper operation before
Engine Water Jacket
installation.
The water jacket permits coolant to be circulated around the
10. Blow insects and dirt from the radiator core air
cylinder walls, combustion chamber, and valve assemblies.
passages, using water, if necessary, to soften
Some of these coolant passages are small and can easily
obstructions.
become clogged, if the cooling system does not receive the
Component Inspection proper maintenance.
9 6 7 6 4 5
8 3 1 2
6
14
6688-2
6 10 12
6 13 15 16 2
9 11 6
9 16
6 11 6 15
6 19 17 18
25
7
20, 21
22
23
6688-1
24
FIGURE 7-14
Item Description
Item Description
22 Radiator Hose
1 Surge Tank
23 Shroud
2 Baffle
24 Lower Radiator Hose
3 Clamp
25 Plate
4 Bellows
7. Connect the two radiator tubes to the radiator with hose
5 Overflow Hose
clamps and the radiator hose.
6 Clamp
8. Secure the radiator return tube to the top of the engine
7 Muffler Clamp using nuts, washers and a muffler clamp.
8 CAC Tube - Hot 9. Reinstall surge tank and connect the hoses between the
9 Bellows surge tank and engine and the surge tank and the
radiator.
10 Hose Clamp
10. Reconnect the charge air cooler tubes to the charge air
11 CAC Tube - Cold
cooler using hose clamps and bellows.
12 Hose
11. Tighten the drain cock at the bottom of the radiator drain
13 Clamp hose.
14 Drain Cock 12. Install the hood assembly.
15 Bellows 13. Install the hardware holding the rear engine hood panel
16 Clamp to the engine hood.
17 Fan Guard 14. Connect the hourmeter wiring.
18 Radiator 15. Install the hood top door assembly.
19 Radiator Hose 16. Service the engine coolant system, as necessary. Refer
20 Flange Screw to Section 9 - Lubrication. Start the engine, operate all
systems and check for leaks.
21 Flatwasher
TORQUE CONVERTER reaction member is the means by which the hydraulic torque
converter multiplies torque.
Description The reaction member of the torque converter is located
The torque converter assembly is mounted on and driven by between and at the center of the inner diameters of the
the engine The torque converter is mounted on and driven by impeller and turbine elements. Its function is to take the fluid
the engine. The torque converter provides for mounting and which is exhausting from the inner portion of the turbine and
driving hydraulic pumps No. 1, No. 2, and No. 3. change its direction to allow correct entry for recirculation
into the impeller element.
Theory Of Operation The torque converter will multiply engine torque to its
The transmission and torque converter function together and designed maximum multiplication ratio when the output shaft
operate through a common hydraulic system. Therefore, it is is at zero rpm. Therefore, as the output shaft is decreasing in
necessary to consider both units in discussing operation. speed, the torque multiplication is increasing.
With the engine running, the converter charging pump draws The shift control valve assembly consists of a valve body
oil from the transmission pump through the removable oil with selector valve spools. A detent ball and spring in the
suction screen and directs it through the pressure regulating selector spool provides one position for each speed range. A
valve and oil filter. detent ball and spring in the direction spool provides three
positions, one each for forward, neutral, and reverse.
The pressure regulating valve maintains pressure to the
transmission control for actuating the direction and speed With the engine running and the directional control lever in
clutches. This requires a small portion of the total volume of the neutral position, oil pressure from the regulating valve is
oil used in this system. The remaining volume of oil is blocked at the control valve, and the transmission is in
directed through the torque converter circuit to the oil cooler neutral. Movement of the forward and reverse spool will
and returns to the transmission for positive lubrication. This direct oil, under pressure, to either the forward or reverse
regulator valve consists of a hardened valve spool operating direction clutch, as desired. When either directional clutch is
in a closely fitted bore. The valve spool is spring loaded to selected, the opposite clutch is relieved of pressure and
hold the valve in a closed position. When a specific pressure vents back through the direction selector spool. The same
is achieved, the valve spool works against the spring until a procedure is used in the speed selector.
port is exposed along the side of the bore. This sequence of The direction or speed clutch assembly consists of a drum
events provides the proper system pressure. with internal splines and a bore to receive a hydraulically
After entering the converter housing, the oil is directed actuated piston. The piston is oil tight by the use of sealing
through the reaction member support to the converter blade rings. A steel disc with external splines is inserted into the
cavity and exits in the passage between the turbine shaft and drum and rests against the piston. Next, a friction disc with
reaction member support. The oil then flows out of the splines at the inner diameter is inserted. Discs are alternated
converter to the oil cooler. After leaving the cooler, the oil is until the required total is achieved. A heavy back-up plate is
directed to a fitting on the transmission. Through a series of then inserted and secured with a snap ring. A hub with OD
tubes and passages, the transmission bearings and clutches splines is inserted into the splines of discs with teeth on the
are lubricated. The oil then drains to the transmission sump inner diameter. The discs and hub are free to increase in
by gravity. speed or rotate in the opposite direction as long as no
pressure is present in that specific clutch.
The torque converter consists basically of three elements
and their related parts to multiply engine torque. The engine To engage the clutch, the control valve is placed in the
power is transmitted from the engine flywheel to the impeller desired position. This allows oil under pressure to flow from
element through the impeller cover. This element is the the control valve, through a tube, to a chosen clutch shaft.
pump portion of the hydraulic torque converter and is the This shaft has a drilled passageway for oil under pressure to
primary component which starts the oil flowing to the other enter the shaft. Oil pressure sealing rings are located on the
components which results in torque multiplication. This clutch shaft. These rings direct oil under pressure to the
element can be compared to a centrifugal pump, in that it desired clutch. Pressure of the oil forces the piston and discs
picks up fluid at its center and discharges at its outer against the heavy back-up plate. The discs, with teeth on the
diameter. outer diameter, clamping against discs with teeth on the
inner diameter, enables the hub and clutch shaft to be locked
The torque converter turbine is mounted opposite the together and allows them to drive as a unit.
impeller and is connected to the output shaft of the torque
converter. This element receives fluid at its outer diameter There are bleed balls in the clutch piston which allow quick
and discharges at its center. Fluid directed by the impeller escape for oil when the pressure to the piston is released.
out into the particular design of blading in the turbine and
The following data is presented as an aid to locating the b. Position the shift lever to forward and high speed.
source of difficulty in a malfunctioning unit. It is necessary to c. Accelerate the engine to between half and three-
consider the torque converter charging pump, transmission, quarter throttle.
oil cooler, and connecting lines as a complete system when
checking for the source of trouble, since the proper operation
of any unit therein depends greatly on the condition and CAUTION
operation of the others. By studying the principles of
Full throttle stall speeds for an excessive length of time
operation together with the data in this section, it may be
will overheat the torque converter.
possible to correct any malfunction which may occur in the
system. Troubleshooting procedures basically consist of
d. Hold converter stalled until desired temperature is
hydraulic checks.
reached.
Hydraulic Checks
NOTE: Always make all troubleshooting checks with the
Before checking the transmission/torque converter and converter outlet temperature at least 82.3 to 93.3
associated hydraulic system for pressures and rate of oil °C (180 to 200 °F).
Troubleshooting Procedures
Table 7-1
Flywheel Mount
Housing Dial
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
Flywheel Plate
Special Stud, Washer And
Housing Self-lock Nut Furnished By
Figure 2 Engine Manufacturer
Flywheel
Housing
7
Impeller
Cover
(3) Intermediate
Drive Plates
Figure 3 Figure 4
FIGURE 7-15
8. Remove the drive plate locating stud. Install one drive The following are considered the minimum steps to be taken:
plate attaching bolt. Snug the bolt but do not tighten.
1. Drain the entire system thoroughly.
NOTE: Some engine flywheel housings have a hole
2. Disconnect and clean all hydraulic lines. Where feasible,
located on the flywheel housing circumference in-line
hydraulic lines should be removed from the machine for
with the drive plate bolt access hole. A screwdriver or
cleaning.
pry bar used to hold the drive plate against the flywheel
will facilitate installation of the drive plate bolts. Rotate 3. Replace oil filter elements, cleaning out the filter cases
the engine flywheel and install the remaining seven thoroughly.
flywheel to drive plate attaching bolts and washers.
4. The oil cooler must be thoroughly cleaned. The cooler
Snug the bolts but do not tighten. After all eight bolts
should be back flushed with oil and compressed air until
and washers have been installed, torque the bolts to 37
all foreign material has been removed. Flushing in the
to 41 Nm (28 to 30 foot-pounds). This will require
direction of normal oil flow will not adequately clean the
torquing each bolt, then rotating the engine flywheel until
cooler. If necessary, the cooler assembly should be
all eight bolts have been torqued.
removed for cleaning, using oil, compressed air and a
9. Measure the engine crankshaft end play after the torque steam cleaner for that purpose.
converter has been completely installed on the engine
flywheel. This value must be within 0.025 mm (0.001
inch) of the end play recorded in step 4. CAUTION
10. Install the two section hydraulic pumps and the single Do not use flushing compounds for cleaning purposes.
section hydraulic pump on the torque converter. Refer to
Hydraulic Pumps in Section 2 - HYDRAULIC SYSTEM 5. Remove the drain plug from the transmission/torque
for installation of the hydraulic pumps. converter and inspect the interior of the unit housing,
gears, etc. If the presence of considerable foreign
11. Install the hydraulic lines to the torque converter. material is noted, it will be necessary for the unit to be
12. Connect the drive line to the torque converter. Refer to removed, disassembled, and cleaned thoroughly. It is
DRIVE LINES in this section for installation of the drive realized this entails extra labor, however, such labor is a
line. minor cost compared to the cost of difficulties which can
result from the presence of such foreign material in the
13. Install the front section of the engine hood. system.
14. Service the crane. Refer to Servicing The Crane After 6. Assemble all components and use only the type oil
Transmission/Torque Converter Overhaul in this section. recommended. Fill the transmission through the fill pipe
15. Cycle all functions and observe for proper operation. until fluid is at the top of the fill range on the dipstick. Run
the engine for two minutes at idle (950 rpm) to prime the
Servicing The Crane After Transmission/Torque torque converter and hydraulic lines. Recheck the level
Converter Overhaul of oil in the transmission with the engine running at idle
(950 rpm). Add oil as necessary to bring the level to the
The transmission/torque converter and its allied hydraulic LOW mark on the dipstick. After the oil temperature
system are important links in the drive line between the reaches 82 to 93 °C (180 to 200 °F), add oil to bring the
engine and the wheels. The proper operation of either the level to the FULL mark on the dipstick.
unit or the system depends greatly on the condition and
operation of the other; therefore, whenever repair or 7. Recheck all drain plugs, lines, connections, etc., for
overhaul of the transmission/torque converter is performed, leaks and tighten where necessary.
the balance of the system must be considered before the job
Lubrication
can be considered completed.
After the overhauled or repaired transmission/torque Type Of Oil
converter has been installed in the crane, the oil cooler and Hydraulic Oil (HYDO) or equivalent. Refer to Section 9 -
connecting hydraulic system must be thoroughly cleaned. LUBRICATION.
This can be accomplished in several ways, and a degree of
good judgement must be exercised as to the method Capacity
employed. System Capacity (includes torque converter, lines, and
transmission) - Approximately 32 liters (34 quarts).
TRANSMISSION Installation
NOTE: The transmission weighs approximately 591 kg
Description (1,303 pounds) dry.
The transmission is a powershift with six forward and three 1. If a new transmission is to be installed, remove all fittings
reverse speeds. and brackets from the old transmission and install them
The transmission is controlled electrically by a shift lever/ in the same locations on the new transmission.
knob located on the right side of the steering column and an 2. Using a transmission jack or suitable device capable of
axle drive mode selector rocker switch located on the left supporting the transmission weight, position the
side of the front console. transmission under the frame and raise it into position.
Maintenance 3. Install the capscrews, washers and nuts and secure the
transmission mount to the frame mount. Torque the
Removal capscrews to 97.6 to 105.7 Nm (72 to 78 foot-pounds).
1. Extend and set the outriggers just enough to take up the 4. Remove the supporting device from under the
slack in the outrigger pads. Chock the wheels. transmission.
2. Refer to DRIVE LINES in this section and disconnect the 5. Connect all the transmission oil lines to appropriate
three drive lines from the torque converter and axles. fittings.
3. Tag and disconnect the electrical leads and connectors 6. Connect all electrical leads and connectors to the valve
from the valve body. body.
4. Tag and disconnect all hydraulic lines to the 7. Connect the oil fill tube to the frame mount.
transmission. Cap all lines and openings.
8. Connect the three drive lines to the transmission.Refer
5. Remove the bolt attaching the oil fill tube to the frame to DRIVE LINES in this section for installation of the
mount. drive line.
NOTE: The transmission weighs approximately 591 kg 9. Service the crane. Refer to Servicing The Crane After
(1,303 pounds) dry. Transmission/Torque Converter Overhaul in this section.
6. Position a transmission jack or some other means of 10. Cycle all functions and observe for proper operation.
support that is capable of supporting the weight of the
transmission, under the transmission. Towing Or Pushing
7. With the weight of the transmission on the supporting Before towing the crane, disconnect both front and rear drive
device, remove the capscrews, washers and nuts lines. The engine cannot be started by pushing or towing
securing the transmission mounts to the frame mounts. because of the design of the hydraulic system.
GROVE 8-i
UNDERCARRIAGE RT9130E SERVICE MANUAL
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14
Service Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
Parking Brake Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21
Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22
Park Brake Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
Outrigger Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24
Theory Of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24
Outrigger Beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27
Extension Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-31
Stabilizer Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-32
Outrigger Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-33
8-ii
RT9130E SERVICE MANUAL UNDERCARRIAGE
SECTION 8
UNDERCARRIAGE
AXLES
Description CAUTION
Do not disassemble drive lines when removing them from
To provide maximum maneuverability, both the front and rear the crane. Dirt can enter the spline and cannot be purged.
axles are steerable. The rear axle is mounted on a pivoting In addition, the drive lines are assembled in a specific
cradle (fifth wheel) which allows the axle to oscillate while orientation when manufactured and can easily be
traversing uneven terrain. The front axle is bolted directly to incorrectly reassembled.
the frame. All four wheels utilize a hydraulic braking system.
Cranes are equipped with disc type brakes. A disc-type
3. Disconnect and remove the drive line from the
parking brake is mounted of the front axle input shaft.
applicable axle. Do not disassemble the drive lines.
Each axle incorporates a single reduction carrier with hypoid Refer to DRIVE LINES in Section 7 - POWER TRAIN.
gearing mounted in the axle center. The final reduction is of
4. Tag, disconnect, and cap the hydraulic brake line at
planetary design spur gearing built into the wheel hubs.
each wheel.
The design of these axles permits the hypoid gearing of the
5. Tag, disconnect, and cap the hydraulic lines to the steer
differential carrier and the axle shafts to carry only a nominal
cylinders.
torsional load while at the same time providing the highest
practical numerical gear reduction at the wheels. 6. On the front axle only, tag and disconnect the hydraulic
line from the park brake actuator.
The hypoid pinion and differential assembly of the first
reduction are supported by tapered roller bearings. The 7. On the right side of the rear axle only, tag and disconnect
pinion bearing preload is adjusted and maintained by a the electrical wires from the rear wheels not centered
hardened precision spacer between the inner and outer switch.
bearing. The differential tapered bearing preload is adjusted
8. On machines equipped with cross-axle differential locks
and maintained by the positioning of the threaded adjusting
remove hoses and wires from the differentials.
rings in the carrier leg and cap bores.
NOTE: Each tire and wheel assembly weighs
In the planetary wheel ends, the spur teeth of the sun gear
approximately 1089 kg (2400 pounds).
mesh with teeth of the planet spur gears. The planet spur
gears rotate on planet pins which are mounted in a spider. 9. Remove the wheels from the axle.
The planet spur gear teeth in turn mesh with teeth of the
NOTE: Each axle weighs approximately 2750 kg (6050
floating ring gear.
pounds) with oil. Refer to Wheels And Tires in this
Power is transmitted by the hypoid gear set in the differential section.
carrier to the axle shafts and the sun gear of the final
10. Position jacks, which are capable of handling the weight
reduction, through the revolving planet gears, and into the
of the axle, under the axle for support.
planetary spider which drives the wheel hub.
11. Remove the eight nuts, washers, and bolts securing the
As an option, the front axle and rear axle may be provided
axle to the frame/cradle.
with a differential lock. When in the locked mode, the axle
shafts and the differential are locked together and there is no 12. Lower the axle to the ground and remove it to a clean
differential action between the wheels. working area. 8
13. If a new axle is to be installed, remove the following from
MAINTENANCE the old axle and install them on the new one.
NOTE: The axles do not have to be removed from the a. The steer cylinders.
crane to remove the planetary wheel ends or the
drive units. b. The rear wheels not centered switch actuator
bracket (rear axle only).
Removal c. The parking brake actuator (front axle only). Refer
1. Using the outriggers, raise the wheels off the ground. to BRAKE SYSTEM in this section.
b. The rear wheels not centered switch actuator 2. Check pre-set axle stop by turning the wheels to the
bracket (rear axle only). extreme left. Check the clearance between the inside of
the tire and the nearest object. If the clearance is less
c. The parking brake actuator (front axle only). Refer than 25.4 mm (1.0 inch), adjust the axle stop to provide
to BRAKE SYSTEM in this section. clearance.
2. Position the axle under the crane on jacks which are 3. Turn the wheels to the extreme right and repeat step 2
capable of handling the weight of the axle. for the right side.
3. Raise the axle into place and secure with the eight
attaching bolts, washers, and nuts. Torque the bolts to Rear Wheels Not Centered Switch
2556 to 2770 Nm (1885 to 2043 foot-pounds). Adjustment Procedure
4. Install the wheels onto the axle. Refer to WHEELS AND 1. Ensure the wheels are straight ahead.
TIRES in this section.
NOTE: Refer to (Figure 8-1) for rear wheels not centered
5. Connect the hydraulic lines to the steer cylinder as switch adjustment.
tagged during REMOVAL.
2. Ensure proximity sensor switch is centered in the slot of
6. Connect the hydraulic brake line to each wheel as the sensor plate bolted to the axle oscillation lockout
marked during removal. cylinder. Adjust by moving the sensor mounting bracket.
7. On the front axle only, connect the hydraulic line to the 3. Ensure a maximum gap of 4.8 mm (0.19 in) exists
parking brake actuator. between the sensor switch and the sensor plate. Adjust
by loosening switch mounting bolts and moving switch
8. On the right side of the rear axle only, connect the
up or down on the mounting bracket. Tighten the
electrical wires to the rear wheels not centered switch.
mounting bolts.
Refer to Rear Wheels Not Centered Switch Adjustment
Procedure in this section and adjust the switch. 4. Turn the rear wheels to verify proper operation. REAR
WHEELS NOT CENTERED light in cab should be out
9. Connect the drive line to the applicable axle. Refer to
when rear wheels are centered and the sensor switch is
DRIVE LINES in Section 7 - POWER TRAIN.
centered in the slot of the sensor plate.
4, 5, 6
1
2
6128
FIGURE 8-1
WHEELS AND TIRES 1. Raise the crane on outriggers so the wheels are off the
ground.
Description 2. The 29.5R29 tire and wheel is a directional assembly.
The standard tire size for this unit is 33.25 x 29-38 ply; also These tires must be properly oriented on the left hand or
available as an option, is a 29.5R29 tire. right hand side of the crane.
3. Install the wheel assembly on the mounting studs. Install
the lug nuts and tighten them to 50 foot-pounds (68 Nm)
CAUTION in the sequence shown in (Figure 8-2).
Do not mix tires and rims of different manufacturers.
4. Ensure the wheel assembly is properly on the hub.
Each wheel assembly (tire and rim) is mounted on the 5. Torque the lug nuts to 380 to 400 foot-pounds (515 to
planetary hub with 24 grade 8 lug nuts. 542 Nm) in the sequence shown in (Figure 8-2).
NOTE: The tire diameters, widths, and weights may vary 6. Lower the crane onto its tires. Retract and stow the
slightly depending on the tire manufacturer. outrigger assemblies and the floats.
Off-highway tires are designed to operate with a certain 7. Road-test the tire, then retorque to 380 to 400 foot-
sidewall deflection or bulge. Correct air pressure ensures pounds (515 to 542 Nm). Maintain proper torque on
prior deflection which, in turn, ensures proper traction, wheel lugs and check for proper wheel mounting.
flotation, support of load, and prevents excessive flexing of Retorque the lug nuts after about an hour of travel after
the tire. Over inflation increases rim stresses, which results the wheels are removed and reinstalled. This will reseat
in lowered rim life. the lug nuts. Check the torque every 500 miles (800 km)
thereafter.
Refer to and adhere to the inflation pressures in the Load
Chart Book in the crane cab.
Maintenance
DANGER
Do not attempt to demount or mount tires without proper
training. The high pressures involved can cause tire and
rim parts and tools to fly with explosive force, if proper
procedures are not used, causing severe injury or death
to personnel and damage to the crane and surrounding
area.
6126
FIGURE 8-2
Maintenance
Front Steering System
Table 8-1
Troubleshooting
Table 8-2
Troubleshooting
Symptom Probable Cause Solution
1. Rear steering inoperative. a. Hydraulic oil low. a. Check system for leaks. Make
repairs as needed. Fill
reservoir.
b. Clogged, broken, or loose b. Clean, tighten, or replace
hydraulic lines or fittings. lines or fittings.
c. Steer cylinder locked. c. Repair or replace cylinders.
Refer to your Manitowoc
Crane Care Parts Manual.
d. Defective control valve. d. Repair or replace valve.
e. Defective steer cylinder(s). e. Repair or replace cylinder(s).
f. Lack of electrical signal f. Check electrical connections/
wiring
2. Hard to steer left and right. a. Hydraulic oil low. a. Check system for leaks. Make
repairs as needed. Fill
reservoir.
b. Clogged or loose hydraulic b. Clean or tighten lines or
lines or fittings. fittings.
c. Defective steering control c. Repair or replace valve.
valve.
d. Defective hydraulic pump. d. Repair or replace pump.
e. Clogged or loose hydraulic e. Clean or tighten lines or
lines or fittings. fittings.
f. Defective steer cylinder. f. Repair or replace cylinder.
g. Damaged relief. g. Replace relief valve.
3. Steering is erratic left and right. a. Hydraulic oil low. a. Check system for leaks. Make
repairs as needed. Fill
reservoir.
b. Clogged or loose hydraulic b. Clean or tighten lines or
lines or fittings. fittings.
c. Defective steering control c. Repair or replace valve.
valve.
d. Defective hydraulic pump. d. Repair or replace pump. 8
Section 2 of pump #1 provides the hydraulic flow necessary The integrated outrigger/rear steer valve directionally
to power the front steer cylinders and the swing drive controls the outrigger circuit, outrigger pin circuit, and the
system. The pump is a gear type pump; the section provides rear steer circuit. The valve is mounted on the rear of the
a flow of approximately 125 l/min (33.0 gpm). carrier frame front cross member.
Rear Steer The inlet section of the valve contains two solenoid valves
and two relief valves. The solenoid valve is normally open,
Section 2 of pump # 3 provides the hydraulic flow necessary bypassing oil to the reservoir. Operation of either system
to power the rear steer cylinders, the outrigger circuit, the energizes the solenoid valve to close it and route oil to the
front and rear pairs of outrigger box pin cylinders, and the applicable circuit.
rear axle oscillation lockout system. The pump is a gear type
pump; the section provides a flow of approximately 62.5 l/ The valve also contains four three position four-way solenoid
min (16.5 gpm). valves that control the following:
• The rear steer solenoid valve is controlled by the Rear
Front Steering Control Valve Steer switch in the operator’s cab through port AST and
BST of the valve.
Description
• The removal pin solenoid valve for the front outrigger
The steering control valve is located under the dash and is box is controlled by the Pin Unlock switch in the
actuated by a conventional steering wheel and steering outrigger control box in front of the left front fender
column, providing precise, full hydraulic steering. Precise through ports A1 and B1 of the valve.
steering is accomplished by a metering system within the
valve that is directly connected to the steering column and • The removal pin solenoid for the rear outrigger box is
wheel. controlled by the Pin Unlock switch in the outrigger
control box behind the right rear fender through ports A2
Maintenance and B2 of the valve.
Removal • The outrigger section solenoid valve is controlled by the
1. Thoroughly clean the steering control valve and the Extend/Retract switch in the operator’s cab through
surrounding area before removing the hydraulic hoses ports A and B of the valve.
from the valve. The valve also contains double pilot operated check valves
2. Tag and disconnect the five hydraulic hoses from the in the rear steer and outrigger lines.
steering control valve. Cap or plug each hose and the Maintenance
five ports of the valve.
Removal
3. Remove the capscrews, lockwashers, and flat washers
securing the valve to the bracket and the steering 1. Tag and disconnect the electrical connectors to the
column. Remove the control valve, leaving the steering integral outrigger/rear steer valve.
column in the cab.
2. Tag and disconnect the hydraulic lines to the integrated
Installation outrigger/rear steer valve. Cap or plug the lines and
ports.
1. Position the control valve to the bracket and steering
column and install the flat washers, lockwashers, and 3. Remove the capscrews, nuts and washers securing the
capscrews. Torque the capscrews to 66.4 to 71.8 Nm integrated outrigger/rear steer valve to the carrier frame.
(49 to 53 pounds--foot). Remove the valve as a complete assembly.
2. Connect the five hydraulic hoses to the control valve as Installation
tagged during removal.
1. Position the integrated outrigger/rear steer valve on the
3. Start the engine and check for proper operation and any frame. Secure the valve with the capscrews, nuts and
leakage. washers. Torque the capscrews 23 to 25.7 Nm (17 to 19
foot-pounds).
2. Connect the hydraulic lines to the integrated outrigger/
rear steer valve as tagged during removal.
3. Connect the electrical connectors to the integrated 3. Connect the hydraulic lines to the cylinder as tagged
outrigger/rear steer valve as tagged during removal. during removal.
Functional Check 4. Operate the steering system and check the cylinder for
proper operation and any leakage.
1. Cycle each outrigger cylinder several times. Verify each
cylinder extends and retracts properly. Rear Axle Oscillation Lockout System
2. Activate the rear steer function and steer to the left and
right several times. Verify the crane steers properly in Description
both directions. The rear axle oscillation system (Figure 8-3) consists of two
3. Check the valve and lines for leakage. Make repairs as lockout cylinders, a lockout valve, an axle oscillation relay,
needed. and an area definition potentiometer. The lockout cylinders
are mounted between a cradle (fifth wheel) and the carrier
NOTE: For further information on the integrated outrigger/ frame. The lockout valve is mounted on the left inner center
rear steer valve, refer to Section 2 - HYDRAULIC frame rail and hydraulically controls the oscillating abilities of
SYSTEM. the lockout cylinders. The axle oscillation relay is located on
the relay panel under the front console cover in the cab and
Steer Cylinders the area definition potentiometer is located in the electrical
swivel assembly.
Description
The steer cylinders are mounted on the axles, two cylinders Theory Of Operation
on each axle. The barrel end of each cylinder is attached to The rear axle is mounted on a cradle (fifth wheel) allowing
the axle housing and the rod end is attached to the steering maximum oscillation of 25 cm (10 inches) total while
lug on the axle end. The front steer cylinders are controlled traveling over uneven terrain. Oscillation is provided only
hydraulically by the front steer control valve through the when the superstructure is within 6 degrees left or right of
swing/steer directional valve. The rear steer cylinders are directly over the front. When the superstructure is within 6
controlled by a solenoid valve located in the integrated degrees left or right of directly over the front, the area
outrigger /rear steer valve. definition potentiometer energizes the axle oscillation relay
which in turn energizes the solenoids on the lockout valve.
Maintenance When the solenoids are energized, the valve spools are
NOTE: For Disassembly and Assembly procedures, refer shifted to allow hydraulic transfer between the two lockout
to CYLINDERS in Section 2 - HYDRAULIC cylinders.
SYSTEM. As one side of the axle is forced up by traveling over uneven
Removal terrain, the hydraulic oil flows from the rod end of cylinder A
to the barrel end of cylinder B and from the rod end of
1. Tag and disconnect the hydraulic lines going into the cylinder B to the barrel end of cylinder A (Figure 8-4). The
steer cylinder. Cap or plug all openings. system is not pressurized and oil is moved from one cylinder
2. Remove the capscrew, flatwasher, and lockwashers to the other by the action of the axle moving the cylinder.
securing each pin weld in the rod end and barrel end of When the superstructure is more than 6 degrees left or right
the cylinder. of directly over the front, the area definition potentiometer
NOTE: Steer cylinder weighs approximately 20 kg (44 deenergizes the axle oscillation relay. This deenergizes the
pounds). solenoids on the lockout valve and allows the springs in the
valve to shift the valve spools to the closed position to
3. Remove both pin welds and two thrust washers (rod end prevent hydraulic oil flow between the cylinders. By stopping 8
only), and remove the cylinder from the axle. the flow of oil, a hydraulic lock is created and the axle is held
Installation rigid in that position.
4
4
1
2 2 2
3 FIGURE 8-3
Pump Supply
Axle Lockout Valve
Lockout Cylinders
REAR AXLE LH RH
FIGURE 8-4
Axle Oscillation Lockout Cylinders 6. Install the wheel and tire assembly on the axle. Tighten
the lug nuts using the procedure under Wheels And
Description Tires in this section.
Two 17.8 cm (7.0 inch) hydraulic lockout cylinders are 7. Lubricate both ends of the cylinder using the fittings
installed on the rear axle, one left side and one right side. provided.
The barrel end of each cylinder is attached to each side of
8. Function test the axle oscillation system. Refer to
the carrier frame and the rod ends are attached to each side
Section 3 - Operating Controls And Procedures in the
of the cradle (fifth wheel).
Operator’s Manual.
The lockout cylinders are connected hydraulically so that
hydraulic oil flows from the rod side of the left cylinder to the Axle Oscillation Lockout Valve
barrel side of the right cylinder and from the rod side of the
right cylinder to the barrel side of the left cylinder. Description
Each cylinder weighs approximately 87 kg (192 pounds). The axle oscillation lockout valve, also called the double
solenoid valve, is used in the rear axle oscillation lockout
Maintenance circuit. The valve consists of a valve body and two solenoid
valves, which keep the lockout cylinders from oscillating
NOTE: For disassembly and assembly procedures, refer
unless the superstructure is within 6 degrees left or right of
to AXLE OSCILLATION LOCKOUT CYLINDER in
directly over the front. The lockout valve is located on the left
Section 2 - HYDRAULIC SYSTEM.
side of the frame in front of the front rear axle cross member.
Removal
When the superstructure is within 6 degrees left or right of
1. Raise the crane up on outriggers. directly over the front, the area definition potentiometer
energizes the axle oscillation relay which energizes the
2. Rotate the turntable more than 6 degrees in either
solenoids on the axle oscillation lockout valve. This allows
direction from directly over the front to lock out the
hydraulic oil to flow in and out of the lockout cylinders,
oscillation cylinders.
allowing the axle to oscillate.
3. Remove the wheel and tire assembly from the axle.
When the superstructure is more than 6 degrees left or right
Refer to Wheels And Tires in this section.
of directly over the front, the area definition potentiometer
4. Tag and disconnect both hydraulic hoses from the ports deenergizes the axle oscillation relay which deenergizes the
on the cylinder. Cap or plug both hoses and the ports on solenoids on the axle oscillation lockout valve. This keeps
the cylinder. the axle from oscillating because hydraulic oil cannot leave
the cylinders.
5. At the rod end of the cylinder, remove one of the cotter
pins securing the retaining pin to the cradle attach fitting. Maintenance
6. Tap out the retaining pin, freeing the rod end from the Removal
cradle.
1. Tag and disconnect the electrical connector to the valve.
7. At the barrel end of the cylinder, remove one of the cotter
pins securing the retaining pin to the frame attach fitting. 2. Tag and disconnect the hydraulic hoses from the valve.
Cap or plug the lines and ports.
8. Tap out the retaining pin and remove the cylinder.
3. Remove the two capscrews, nuts and washers securing
Installation the valve to the carrier frame.
1. Position the barrel end of the cylinder in the frame attach Installation 8
fitting and tap in the retaining pin.
1. Secure the valve to the carrier frame using two
2. Secure the retaining pin with the cotter pin. capscrews, washers and nuts. Torque the capscrews
10.4 to 12.2 Nm (7.7 to 9.0 foot-pounds).
3. Align the rod end of the cylinder in the cradle attach
fitting and tap in the retaining pin. 2. Connect the hydraulic hoses to the applicable valve
ports as tagged during removal.
4. Secure the retaining pin with the cotter pin.
3. Connect the electrical connector to the valve as tagged
5. Remove the caps or plugs from the two hydraulic hoses
during removal.
and the cylinder ports and connect the hoses to the
appropriate cylinder ports as tagged during removal.
4. Function test the axle oscillation system. Refer to 5. Check the valve and hoses for signs of leakage. Tighten
Section 3 - Operating Controls And Procedures in the fittings as required.
Operator’s Manual.
BRAKE SYSTEM Hydraulic oil from hydraulic pump number 2 flows to swivel
port 9 to the dual accumulator charge valve. The dual
Description accumulator charge valve charges the accumulators from
the open center circuit upon demand and within its present
The brake system includes all the components necessary for operating charge rate and the high limit pressure setting.
the application of the service brakes and the parking brake. When the open center circuit pressure reaches the brake
relief setting, which is higher than the high accumulator
Service Brakes
charge limit, the accumulators will be charged to the
The service brakes are full power hydraulic disc brakes regulated maximum pressure setting. The dual accumulator
which are hydraulically controlled and are used to apply the charge valve regulates flow to the hydraulic accumulators to
brake assemblies on all four wheels. The system consists of provide fully powered independently separate, primary
the tandem brake valve with treadle pedal, the dual (front) and secondary (rear), service brake circuits. Hydraulic
accumulator charge valve, two hydraulic accumulators, the pressure is constantly maintained in the brake circuits by the
brake assemblies, and all the associated hoses and tubing. accumulators and the charging valve. The charged
accumulators supply pressurized fluid to the closed tandem
The operator depresses the pedal on the tandem brake
brake valve.
valve, located on the cab floor, and the valve modulates the
brake line pressure to the brake assemblies at each wheel. After the accumulators are fully charged, the high limit check
The full powered brake system supplies a high brake system opens and all of the pump flow is directed to the excess flow
pressure with relatively low reactive pedal forces, while port and on to the front steer and swing circuits. When
controlling the maximum brake line pressure. The service pressure to the steering or swing circuit becomes greater
brake dual accumulator charge valve regulates flow to the than accumulator pressure, the main check valve opens and
hydraulic accumulators to provide fully powered charges the accumulator without the aid of the charging
independently separate, primary (front) and secondary valve. In this condition, the maximum accumulator pressure
(rear), service brake circuits. Hydraulic pressure is is the brake circuit relief valve setting of 20,700 kPa (207 bar)
c o n s ta n t l y m a i n ta i n e d i n t h e b r a k e c i r c u i ts b y t h e (3000 psi).
accumulators and the charging valve.
Once the operator depresses the brake pedal, the tandem
Parking Brake brake valve modulates fluid out to the brakes to provide the
means of braking. The tandem brake valve will modulate the
The parking brake is a hydraulic release, spring apply, disc- pressure in the brake system by increasing or decreasing
type brake, located on the front axle. It is spring applied and pressure as required in proportion to the input force from the
hydraulically released. The system consists of a two-position operator via the brake pedal. The hydraulic force acts within
switch, a three-way solenoid valve, actuator, two brake the brake assemblies to force the brake pads against the
assemblies, and all the associated hardware and tubing. The brake discs, acting to slow wheel rotation. Fully powered
selector switch, located on the front console in the cab, is separate primary (front) and secondary (rear) braking circuits
used to activate the solenoid valve which controls the park are provided with independent accumulators. A low pressure
brake actuator, which applies and releases the park brake. warning switch is used to sense the accumulator pressures
There are two brake actuators on the front axle. and warn the operator through visual brake warning indicator
NOTE: For Description and Maintenance of the tandem light on the cab console in the event the pressure in the
brake valve with treadle pedal, the accumulators, accumulators drops to an unsafe operating level. In the
and the dual accumulator charge valve, refer to event of engine failure, the accumulators are pre-charged
VALVES in Section 2 - HYDRAULIC SYSTEM. with dry nitrogen gas and properly sized to provide power-off
stopping capacity for secondary braking.
Theory Of Operation
Parking Brake 8
Service Brakes Hydraulic flow from the transmission charge pump is routed
Braking begins when the operator depresses the brake to the parking brake control valve. When the PARK BRAKE
pedal in the cab. Mechanical linkage transfers the force switch is in the ON position, the parking brake solenoid valve
created by the lever action of the brake pedal to the hydraulic shifts to route flow from the hydraulic parking brake actuator
brake valve which modulates the brake line pressure to the back to the transmission sump. The actuator spring pulls on
brake assemblies at each wheel. the lever on the brake assembly, applying the parking brake.
Maintenance
Troubleshooting
Table 8-3
a spongy feeling during brake pedal application), whenever 3. Use a piece of wood against the linings as a pry bar to
any brake system line has been opened, or whenever any push the pistons completely into the housing. Tighten
brake component has been replaced. the bleeder screws.
Always start at the point in the system that is furthest from 4. Remove the linings from the caliper housing. If
the tandem brake valve and work back toward the tandem necessary, discard the linings.
brake valve. Bleed every bleeder screw on every caliper/ Caliper
actuator on every wheel. When you complete a bleeder
screw, go to the next closest bleeder screw on the same NOTE: To lighten caliper weight, remove the brake linings
caliper/actuator. When you complete a wheel, go to the from the caliper before removing the caliper from
furthest bleeder screw on the next closest wheel. the vehicle.
1. Disconnect the hydraulic brake line from the inlet fitting
Service Brakes on the caliper. Cap or plug all openings.
Description 2. Remove the linings as described previously.
The brakes utilized are hydraulic disc-type brakes. Two 3. Remove the bolts securing the caliper housing to the
brake assemblies are used at the end of each axle. The mounting bracket. Remove the caliper housing from the
action of the brake pads riding against the brake discs acts to mounting bracket. If shims are used mark the position of
slow the rotation of the wheels. the shims.
Maintenance Disassembly
NOTE: To perform maintenance on the brake caliper, Caliper
remove the tire and wheel assembly. Refer to
1. Remove the inlet fitting and o-ring from the cylinder cap.
AXLES in this section.
2. Drain and discard the hydraulic fluid.
Removal
3. Clean the outside of the housing with isopropyl alcohol.
Linings
Dry the housing with a clean cloth.
1. Remove the bolts securing the end plates to one side of
4. If installed, remove the bolts that secure the end plates
the caliper housing. Remove the end plates.
to the housing. Remove the end plates and linings.
2. Loosen the bleeder screws to release hydraulic
5. Remove the pistons from the side of the housing
pressure in the caliper (Figure 8-5).
opposite the mounting plate according to the following
procedure.
a. Use a C-clamp to hold a 12.7 mm (0.5 in) block of
Wood Block wood against three pistons on the mounting side of
Loosen the housing. Ensure the C-clamp is not in the area in
Bleeder front of the piston bore (Figure 8-6).
Screws
C-Clamp
8
Push wood Wood
block against Block
linings to push
pistons into
bores
FIGURE 8-5
FIGURE 8-6
7
1
9
2
10
11
FIGURE 8-7
6. Remove the cylinder caps from the housing. Remove large scratches or large amounts of rust. Refer to
and discard the o-rings (Figure 8-9). Caliper Parts - Inspection in this section.
Inspection
Cylinder Cap Holes Periodic On-vehicle
Inspect the caliper, linings, and disc for any damage.
Shoes, Linings, and End Plates
Remove the shoes and linings. To help prevent abnormal
50.80 mm 11.23 mm lining wear, replace worn, bent, or cracked end plates and
(2.00 in) (0.442 in) DIA.
distorted backing plates. Inspect end plate bolts for wear.
Replace the bolts if worn. Inspect the linings for:
• Lining Wear. Replace the linings when the thickness of
the lining is less than 3.2 mm (0.125 in) from the back
plate (Figure 8-11).
FIGURE 8-9
• Lining Wear Not Even. Replace the linings if the
7. Remove the pistons from the mounting plate side of the thickness of the two linings is significantly different.
housing. Push on the cap ends of the pistons to force Check the pistons for correct operation. Replace the
them out of the disc side of the housing. piston and/or housing if a piston is cocked in the
bore. Check that the disc surface is flat and parallel
8. Remove the dust seals from the housing. to the linings (Figure 8-11).
9. Remove and discard the o-ring and the backup rings
(Figure 8-10).
Minimum Lining Thickness
NOTE: Use a soft tool to prevent scratching the housing 3.2 mm (0.125 in) from
Backing Plate
and grooves.
O-Ring
Backup Ring
FIGURE 8-10
FIGURE 8-11
10. Inspect the ring grooves in the housing for scratches and
rust. Remove small scratches and rust with emery cloth.
Replace the housing if there are large scratches or large • Oil or Grease on Linings. Replace the linings. 8
amounts of rust. Refer to Caliper Parts - Inspection in • Cracks on Linings. Replace linings that have large or
this section. deep cracks.
11. Inspect the pistons and the bores for scratches and rust. NOTE: Small, tight cracks on the surface of the lining are
Remove small scratches and rust with emery cloth. normal when the caliper is used under high
Replace the components if they are worn or if there are temperature conditions.
Micrometer
Piston
3. Measure the diameter of the housing bore. Replace the polished parts are the piston and the piston bore in the
housing if the diameter is worn to more than 76.276 mm caliper.
(3.003 in) (Figure 8-15).
• Metal parts with rough surfaces can be cleaned with
Replace solvent cleaners or with weak alkaline solutions.
Housing If Bore
Is Worn To • Use a wire brush to clean the threads of fasteners and
More Than fittings.
76.276 Mm
(3.003 In) • Use soap and water to clean parts that are not made of
metal.
• Scrape away build-ups of mud and dirt on the linings.
Replace all linings contaminated with oil or grease.
• Immediately after cleaning, dry all parts with clean paper
Telescoping or rags.
Gauge
Corrosion Protection
Apply brake system fluid to the cleaned and dried parts that
are not damaged and are to be immediately assembled. Do
Not apply fluid to the brake linings or the disc.
If parts are to be stored, apply a special material that
prevents corrosion to all surfaces. Do Not apply the material
FIGURE 8-15 to the brake linings or the disc. Store the parts inside special
paper or other material that prevents corrosion.
4. Inspect the linings as described previously.
Assembly
5. Inspect the threads of the caliper, cylinder caps, and all
fittings. Replace any component that has thread Caliper
damage that cannot be repaired.
6. Discard all back-up rings, o-rings, and dust seals. Use CAUTION
new ones when assembling the caliper. Use only specified components when assembling the
Cleaning calipers. Do not mix components from other calipers.
installing the wrong components may cause the caliper
not to operate correctly and may cause damage to
equipment. Use of non manufacturer’s parts can cause
damage, loss of braking, and serious personal injury.
DANGER
Use of cleaning solvents, hot solution tanks, or alkaline NOTE: The o-rings, back-up rings, pistons, and bores
solutions incorrectly, can cause serious personal injury. To must be lubricated before installing the pistons.
prevent serious personal injury, follow the instructions
supplied by the manufacturer of these products. Do not 1. Lubricate all pistons, bores, o-rings, and back-up rings
use gasoline to clean parts. Gasoline can explode and with silicone grease. If silicone grease is not available,
cause serious personal injury. use the same type of fluid that is used in the brake
system.
2. Install new o-ring and a new back-up ring in the groove
8
CAUTION
in the middle of the bore. The o-ring is installed toward
Use only solvent cleaners to clean ground or polished
the outboard end of the bore. The back-up ring is
metal parts. Hot solution tanks or water and alkaline
installed toward the lining side of the bore. Refer to the
solutions will damage these parts. Isopropyl alcohol,
following figure.
kerosene, or diesel fuel can be used for this purpose.
• Use solvent cleaners to clean all metal parts that have CAUTION
ground or polished surfaces. Examples of ground or
Do not use silicone grease on the dust seal.
3. Install a new dust seal in the top groove of the bore 5. Install a new o-ring in the groove of the cylinder cap.
(Figure 8-16). Ensure the o-ring is not cut by the threads on the
cylinder cap.
Backup Ring - O-Ring-
Install Toward Lining Install Toward NOTE: Apply extra grease on o-ring before installing
Side of Bore O-Ring Outboard End of Bore cylinder caps. this will keep o-ring from catching on
threads as cylinder cap is threaded into housing.
O-Ring
6. Install the cylinder caps in the caliper housing. Tighten
the cylinder caps to 680 Nm (500 foot-pounds) minimum
as shown in the following figure.
Disc Centered
When Correctly Between Linings
Installed the End of the
Piston is Even with the
Top of the Dust Seal FIGURE 8-17 FIGURE 8-18
5. Connect the hydraulic brake line to the inlet fitting. 5. Position the PARK BRAKE switch to ON and shut down
the engine.
6. Bleed the brake system.
6. Disconnect the hydraulic line from the brake actuator,
7. Apply and release the brakes three times to ensure the
then cap or plug all openings.
caliper operates correctly. Check for fluid leaks. Ensure
the linings move freely. Installation
Linings 1. Connect the hydraulic line to the brake actuator.
2. Start the engine, ensure the transmission is in neutral,
CAUTION and position the PARK BRAKE switch to OFF. This will
pressurize brake the brake actuator to release the
Always replace both linings. if only one lining is replaced,
brake. Engine must remain running. Air pressure of 1172
possible disc damage can occur.
to 1862 kPa/11.7 to 18.6 bar (170 to 270 psi) may be
used to pressurize the actuator.
1. Install the linings in the caliper housing with the metal
backing against the piston and not toward the disc. 3. It will be necessary to tilt the actuator so the ball joint will
clear the linkage lever bolt. Position the brake actuator
2. Position the end plates on the housing and secure with
on the mounting bracket and secure in place with the
bolts. Apply Loctite 271 or equivalent to the bolt threads.
attaching nuts, washers, and lockwashers.
Tighten the bolts to 224 to 285 Nm (165 to 210 foot-
pounds). 4. Secure the brake actuator rod ball joint to the brake
linkage lever with the washer and nut.
3. Ensure the linings move freely in the housing.
5. Position the PARK BRAKE switch to ON and shut down
4. Bleed the brake system.
the engine.
5. Apply and release the brakes three times to ensure the
Adjustment
caliper operates correctly. Check for fluid leaks. Ensure
the linings move freely. 1. Chock the wheels to prevent crane movement.
Parking Brake Actuator 2. Start the engine, ensure the transmission is in neutral,
and position the PARK BRAKE switch to OFF. This will
Description pressurize the brake actuator to release the tension on
the brake linkage. Air pressure of 1172 to 1862 kPa/11.7
The spring-applied, hydraulically-released parking brake to 18.6 bar) (170 to 270 psi) may be used to pressurize
actuators are located on the front axle and are used to apply the actuator. Screw the caging nut up under the actuator
and release the parking brake. chamber.
Maintenance 3. Install the rod ball joint until the ball joint will just connect
to the brake linkage with the brake lever in a horizontal
Removal
position.
1. Chock the wheels to prevent crane movement.
4. Lock the rod ball joint with the jam nut and back off the
2. Start the engine, ensure the transmission is in neutral, caging nut.
and position the PARK BRAKE switch to OFF. This will
5. Position the PARK BRAKE switch to ON and shut down
pressurize the brake actuator to release the brake.
the engine.
Engine must remain running. Air pressure of 1172 to
1862 kPa/11.7 to 18.6 bar (170 to 270 psi) may be used
to pressurize the actuator.
Parking Brake 8
3. Remove the washer and nut securing the brake actuator Description
rod ball joint to the brake linkage lever. The parking brake is mounted on the front axle. The brake is
4. Remove the nuts, washers, and lockwashers securing a disc-type brake that is controlled by a switch on the front
the brake actuator to the mounting bracket and tilt the console in the cab and is spring-applied and hydraulically
actuator so the ball joint will clear the linkage lever bolt. released by an actuator.
Adjusting Bolt
Mounting Bolt
FIGURE 8-19
Maintenance 2. Start the hex mounting bolts into the mounting bracket
far enough to just support the brake.
Removal
3. Remove plug, loosen the coupling nut and tighten
1. Chock the wheels to prevent crane movement. socket setscrew until linings are clamped to the disc.
2. Start the engine, ensure the transmission is in neutral, This locates and holds the brake in the proper position to
and position the PARK BRAKE switch to OFF. This will set the hex mounting bolts and hex nuts.
pressurize the brake actuator to release the tension on 4. Tighten hex mounting bolts until they make contact with
the brake linkage. Air pressure of 1172 to 1862 kPa/11.7 the urethane springs, then tighten 4 flats (approximately
to 18.6 bar) (170 to 270 psi) may be used to pressurize 0.07 inch) more. This puts the proper amount of pre-load
the actuator. Screw the caging nut up under the actuator on the urethane springs.
chamber.
5. Tighten jam nut/sleeves against mounting surface.
3. Position the PARK BRAKE switch to ON and shut down Torque 271 Nm (200 pounds-foot) dry.
the engine.
4. Tag and disconnect the hydraulic hose from the actuator.
Cap or plug all openings. CAUTION
Brake linings are susceptible to contamination. When
5. Unthread the two mounting bolts securing the brake
installing or servicing brakes, keep all oil and fluids away
assembly to the mounting bracket, then carefully
from the linings. Poor brake performance may result if
remove the brake assembly from the mounting bracket
linings are contaminated.
and the brake disc.
6. Repeat steps 4 and 5 for second caliper. 6. Attach brake line to inlet port located on the top of the
hydraulic cylinder.
Installation
1. Slide the brake over the disc and align with mounting
bracket holes. CAUTION
To avoid damage to the brake, do not exceed 1861kPa/
NOTE: Mount the brake so that the linings are parallel with
18.6 bar (270 psi) hydraulic pressure.
the disc within 0.015 inch.
7. Apply hydraulic pressure to the brake. A pressure switch is installed in the line to the actuator.
When the park brake is applied, a lack of hydraulic oil
8. With plug removed, loosen coupling nut and set running
pressure keeps the pressure switch closed, which turns on
clearance 0.020 - 0.030 inch total by adjusting the
the red LED indicator on the switch.When the park brake is
socket setscrew. Torque the coupling nut 67.7 to 74.5
released, pressure buildup opens the switch, which turns off
Nm (50 to 55 pounds-foot) while holding the socket
the indicator.
setscrew in position.
9. Replace plug. Torque 61 to 67.7 Nm (45 to 50 pounds- Maintenance
foot). Removal
10. Even up the running clearance of the pads 0.254 to 1. Tag and disconnect the electrical connector from the
0.381 mm (0.010 to 0.015 inch) each side by adjusting valve.
the socket head capscrew.
2. Tag and disconnect the hydraulic lines attached to the
11. Readjust the brake when running clearance reaches a valve. Cap or plug lines and ports.
total of 2.54 mm (0.100 inch).
3. Remove the capscrews, nuts and washers securing the
Park Brake Solenoid Valve valve to the frame. Remove the valve.
Description Installation
The park brake solenoid valve is located on the right side 1. Secure the valve to the frame and secure with the
frame rail in front of the rear axle. The valve is a three-way, washers, nuts and capscrews. Torque the capscrews
two position solenoid valve. The park brake valve is used to Torque the capscrews 10.4 to 12.2 Nm (7.7 to 9.0 foot-
control the application of the crane’s spring-applied, pounds).
hydraulically-released parking brake. 2. Connect the hydraulic lines to the valve as tagged during
Positioning the PARK BRAKE switch to OFF shifts the three- removal.
way, two-position solenoid valve so hydraulic oil can flow to 3. Connect the electrical connector to the valve as tagged
the parking brake actuator, extending it. When the actuator during removal.
extends, it releases the park brake.
4. Apply and release the park brake several times. Verify
Positioning the PARK BRAKE switch to ON shifts the three- the park brake holds the crane when applied. Verify the
way, two-position solenoid valve so hydraulic oil can drain park brake doesn’t drag when released.
from the actuator. The parking brake actuator’s rod retracts,
forcing hydraulic oil through the valve and the case drain 5. Check for leaks. Make repairs as needed.
manifold back to the transmission reservoir. As the actuator
retracts, it applies the parking brake.
Maintenance
Table 8-4
Troubleshooting
Symptom Probable Cause Solution
1. Slow or erratic operation of a. Damaged relief valve. a. Remove relief valve; clean or
outrigger extension cylinders. replace.
b. Low hydraulic oil. b. Check system for leaks. Make
repairs as needed. Fill
reservoir. Refer to Section 9 -
Lubrication.
c. Sticking solenoid valve spool. c. Repair or replace valve spool.
d. Improper ground to base of d. Ground properly.
solenoid.
e. Directional selector switch e. Clean or replace switch.
sticking.
f. Collector ring dirty or glazed. f. Clean and deglaze collector
ring.
g. Damaged wiring to solenoid. g. Replace wiring.
h. Weak brush springs on h. Replace brush springs. Refer
collector ring. to your Manitowoc Crane
Care Parts Manual.
Outrigger Beam of events provides for lifting and stabilizing the crane for
operation.
Description
Maintenance
The outrigger beam assembly (Figure 8-20) consists of an
Removal
outrigger beam, a stabilizer cylinder, a extension cylinder,
and the required hoses and mounting hardware. 1. On the stabilizer cylinder end of the beam, remove the
8
Theory Of Operation set screw from the side adjustable wear pad and back off
the wear pad from the outrigger box.
When the outrigger extension is activated, it extends or
retracts the outrigger beam within the outrigger box. The 2. Remove the cover from the opposite end of the outrigger
outrigger beam can be extended to the mid-extend position box. Remove the setscrew from the side adjustable wear
by allowing the lock pin to ride on the top of the beam while pad and back off the wear pad from the beam.
it’s extending. The lock pin will automatically drop into the 3. Remove the setscrews from the bottom adjustable wear
hole when the beam reaches the mid-extend position. pads and back off the wear pads leaving approximately
The stabilizer cylinder is mounted to the end of the beam and 3.2 mm (0.125 in) protruding.
applies force to the outrigger beam vertically. This sequence
10
6120
5, 6
11, 12 11, 12
8, 9 15, 16, 17
3 4
1, 2
7
3 8, 9
4
13
1, 2
13
14
7384
FIGURE 8-20
FIGURE 8-21
6. Tag and disconnect the hydraulic lines at the cylinder 8. After attaching a suitable lifting device of straps or belts
barrel end of the extension cylinder. Cap all lines and instead of chains to prevent nicking the bottom edges of
fittings. the outrigger beam, pull the outrigger beam out of the
outrigger box, re-adjusting the lifting attachment to
3. Install the bottom wear pads with approximately 3.2 mm NOTE: At installation, be sure that the outrigger stabilizer
(0.125 in) protruding. This will prevent the beam side cylinder hydraulic hoses are not trapped against
plates from riding on the bottom of the box. the outrigger box when the beam is fully retracted.
4. Attach a suitable lifting device of straps or belts instead Wear Pad Adjustment
of chains to prevent nicking the bottom edges of the NOTE: When adjusting wear pads, refer to (Figure 8-22).
outrigger beam.
1. Adjust each of the bottom wear pads (about 1/2 turn)
5. Slide the beam into the outrigger housing and align the until there is a gap of 0.12 to 0.18 inch (3.0 to 4.5 mm)
cylinder bushing with the mounting hole. between the top of the beam and the top of the outrigger
6. Apply anti-seize compound to the clevis pin. Secure the box. Install and lock set screws against wear pads.
cylinder barrel to the housing with the clevis pin and 2. Adjust outrigger box side wear pad until there is a gap of
cotter pin. 0.12 to 0.18 inch (3.0 to 4.5 mm) between beam and
shims welded in top and bottom of box. Install and lock
set screw against wear pad.
3. Adjust outrigger beam side wear pad until there is a gap
of 0.12 to 0.18 inch (3.0 to 4.5 mm) between shim
welded on beam and side of box. Install and lock set
screw against wear pad.
2 2
6065
3.0 to 4.5 mm
(0.12 to 0.18 in) Gap
FIGURE 8-22
is connected to the solenoid valve bank to prevent pin into the lugs on the cylinder and secure the pin in
damage. place with the cotter pins.
3. Push the cylinder into the outrigger beam. Align the
cylinder rod with the clevis in the beam. Apply anti-seize
CAUTION
compound to the clevis pin and secure in place with the
clevis pin and cotter pin. Use a nylon strap to remove the cylinder. This will ensure
the retaining pin is not damaged.
4. Install the outrigger beam. Refer to OUTRIGGER BEAM
- INSTALLATION in this section. Verify no stabilizer 7. Fasten a nylon strap onto the cylinder retaining pin and
cylinder hose will be trapped by full outrigger beam use an adequate lifting device to lift the stabilizer
retraction. cylinder out of the tube on the beam assembly.
Functional Check Installation
1. Activate the hydraulic system; extend and retract the 1. Apply grease (EP-MPG) to the ID of the stabilizer
outrigger. cylinder support tube.
2. Observe the operation of the outrigger beam. 2. If removed, install wear ring in groove in bottom of
3. Check the hydraulic connections for any evidence of support tube and in groove at top on stabilizer cylinder.
leakage. 3. Place a jack beneath the cylinder tube on the outrigger
beam. Using the same method as described under
Stabilizer Cylinder REMOVAL, lower the stabilizer cylinder into the cylinder
Description tube on the outrigger beam until the retaining pin is just
above the tube. Position the jack so that it will support
Four stabilizer cylinders are used on the crane, one at the the cylinder in this position. Remove the lifting device
end of each outrigger beam. The stabilizer cylinders provide from the cylinder.
the force for the outrigger beam’s vertical movement. The
cylinder weighs approximately 100 kg (220.4 pounds). 4. Remove the retaining pin and cotter pins from the
cylinder.
Maintenance
5. Lower the jack until the holes in the cylinder rod align
NOTE: Refer to CYLINDERS in Section 2 - HYDRAULIC with the holes in the outrigger beam.
SYSTEM for Disassembly and Assembly of the
cylinders. 6. Apply anti-seize compound to the retaining pin. Secure
the cylinder and cylinder cap retaining bracket to the
Removal support tube with the retaining pin and cotter pins.
1. Extend the outrigger beam slightly for improved access 7. Install the cylinder cap.
to the stabilizer cylinder; shut down the engine.
8. Install the fittings in the cylinder ports and connect the
2. Tag and disconnect the hydraulic hoses from the hoses as tagged during removal. Verify the piston side of
stabilizer cylinder. Remove the fittings from the ports. the stabilizer cylinder is connected to the solenoid valve
Cap or plug all openings. bank to prevent damage. Verify no stabilizer cylinder
3. Remove the cylinder cap. hose will be trapped by full outrigger beam retraction.
Outrigger Control Valves functions; the first function is a holding valve, the second
function provides a thermal relief of the stabilizer.
Description
Integrated Outrigger/Rear Steer Valve
There are four valve assemblies responsible for controlling
the outrigger system, the integrated outrigger/rear steer The integrated outrigger/rear steer valve is mounted on the
valve, the front and rear outrigger control manifolds, and the rear face of the carrier frame front cross member. The
pilot operated check valves. outrigger portion of the valve consists of a 4-way two position
solenoid valve. The inlet section contains the main relief
NOTE: For a more detailed DESCRIPTION and valve.
MAINTENANCE of the valves, refer to VALVES in
Section 2 - HYDRAULIC SYSTEM. Outrigger Control Manifold
Pilot Operated Check Valve The front and rear outrigger control manifolds are located
on the respective outrigger boxes. Each manifold consists of
The pilot operated check valves are located in the outrigger four 12 volt solenoid valves and an assembly mounting kit.
stabilizer port blocks. The check valve provides two
GROVE 9-i
LUBRICATION RT9130E SERVICE MANUAL
9-ii
RT9130E SERVICE MANUAL LUBRICATION
SECTION 9
LUBRICATION
GENERAL Regardless of temperature and oil viscosity, always use
suitable start-up procedures to ensure adequate lubrication
Following the designated lubrication procedures is important during system warm-up.
in ensuring maximum crane lifetime and utilization. The
procedures and lubrication charts in this section include Arctic Conditions Down To -40°F.
information on the types of lubricants used, the location of
the lubrication points, the frequency of lubrication, and other ALL Weather Package & Lubricants
information.
Engineering recommends the following lubricants for
components for ambient temperatures to -40F. Special
LUBRICATION INTERVALS lubricants alone are not sufficient to operate at extreme low
The service intervals specified are for normal operation temperatures. We also recommend the use of appropriately
where moderate temperature, humidity, and atmospheric sized heaters for the hydraulic tank, engine oil pan, engine
conditions prevail. In areas of extreme conditions, the jacket water and batteries. The operator needs to follow the
service periods and lubrication specifications should be guide lines as stated in the operator’s manual. We assume
altered to meet existing conditions. For information on that the customer has take steps for use of an appropriate
extreme condition lubrication, contact your local Grove engine antifreeze coolant, have taken care of the fuel, fuel
distributor or Manitowoc Crane Care. system and starting system. And has done whatever they
feel necessary to add insulation for under hood temperatures
Lube intervals are to be used as a guideline only. Actual lube and meet the engine manufacture's intake air temperature.
intervals should be formulated by the operator to correspond Other lubricants may be used if they meet the specification of
accordingly to conditions such as continuous duty cycles the lubricant that is requested. Please consult factory.
and/or hazardous environments.
Axles and Swing Box -- Petro- Canada Traxon E Synthetic
75W-90; CITGO, Syntetic Gear Lube 75W-90; Eaton,
CAUTION Roadranger EP75W-90; Mobil, Mobilube SCH 75W-90;
Shell, Spirax S 75W-90; Sunoco Duragear EP75W-90; --
Chassis grease lubricants must not be applied with air
Spec 6829014058
pressure devices as this lubricant is used on sealed
fittings. Engine -- Petro-Canada Duron Synthetic CI-4- 5W-40; Mobil
Delvac 1, 5W-40; -- Spec 6829101560
Hydraulic tank and Transmission -- Petro-Canada
Duratran Synthetic THF; Chevron All Weather THF; Texaco
CAUTION TDH Oil SS; -- Spec 6829101559
The multipurpose grease installed during manufacture is
of a lithium base. Use of a noncompatible grease could Hoist -- Petro-Canada ENDURATEX Synthetic EP 150;
result in damage to equipment. Mobil SHC629; -- Spec 6829103636
Grease -- Petro-Canada Precision Synthetic EP1; Mobil:
ARCTIC CONDITIONS Mobilith SHC 220; -- Spec 6829104275
Open Gear Lube -- (bearing/swing drive teeth) ---Vultrex....
Arctic Conditions - Below -18°C (0°F) OGL Synthetic All Season -- No Spec
In general, petroleum based fluids developed especially for
Antifreeze Coolant -- Petro-Canada AFC 60/40; Old World
low temperature service may be used with satisfactory
Industries, Inc Fleet Charge SCA Pre-charged Antifreeze/
results. However, certain fluids, such as halogenated
Coolant-60/40; Fleetguard Compleat EG Antifreeze/Coolant
hydrocarbons, nitro hydrocarbons, and phosphate ester
Premix 60/40; -- Spec 6829104212
hydraulic fluids, might not be compatible with hydraulic
system seals and wear bands. If you are in doubt about the
suitability of a specific fluid, check with your authorized
Standard Lubricants Package 9
Grove distributor or Manitowoc Crane Care. Axle and Swing Box -- Century Unigear Semi-synthetic
SAE 80W-90; Texaco Multigear SS 80W-90; Chevron DELO
NOTE: All fluids and lubricants may be purchased by
80W-90; -- Spec 6829012964
contacting the Manitowoc Crane Care Parts
Department.
Engine -- CI-4 Rated 15W-40 Engine Oil Exxon XD-3; allow hydraulic oil to warm sufficiently to penetrate these
Conoco Fleet Supreme; -- Spec 6829003483 cracks and if machines are operated daily, protect the rods.
Machines that are stored, transported, or used in a corrosive
Hydraulic Tank and Transmission -- To meet John Deere
environment (high moisture, rain, snow, or coastline
Standard JDM J20C – Hyden 052-10W-20; Exxon Torque
conditions) need to have the exposed rods protected more
Fluid 56- 10W-20; Esso Torque Fluid 56- 10W-20; BP-
frequently by applying a protectant. Unless the machine is
Eldoran UTH & Trak-Tran 9 – 10W20; BP- Blend- 7367 -
operated daily, exposed rod surfaces will corrode. Some
10W20; Exxon Mobil 424- 10W-30 -- Spec 6829006444
cylinders will have rods exposed even when completely
Hoist -- AGMA No. 4 EP Extreme Pressure Gear Lube- retracted. Assume all cylinders have exposed rods, as
Mobil: Mobilfluid 629 ; Texaco: Meropa 150; -- Spec corrosion on the end of the rod can ruin the cylinder.
6829100213
It is recommended that all exposed cylinder rods be
Grease -- EP-MPG- Multipurpose Grease – Citgo Lithoplex protected using Boeshield® T-9 Premium Metal Protectant.
MP # 2; Texaco Starplex Moly # 2; Phillips 66 Philube M Manitowoc Crane Care has Boeshield® T-9 Premium Metal
Grease; Mobil Mobilgrese XHP 222 Special, # 53055-0; Protectant available in 12 oz. aerosol by ordering part
Chemtool Inc, Lube-A-Boom-Grease; -- Spec 6829003477 number 9999101803 through Manitowoc Crane Care.
Open Gear Lube -- (bearing / swingdrive teeth -- FUCHS: Cylinder operation and inclement weather will remove the
CEPLATTYN 300 SPRAY -- Spec 6829102971 Boeshield® protectant; therefore, inspect machines once a
week and reapply Boeshield® to unprotected rod.
Antifreeze Coolant -- AFC – 50/50 Old World Industries,
Inc. Fleet Charge SCA Pre-charged Antifreeze/Coolant;
Caterpillar DEAC Antifreeze/Coolant; Fleetguard Complete WIRE ROPE LUBRICATION
EG Antifreeze/Coolant; -- Spec 6829101130 Wire rope is lubricated during manufacturing so that the
strands, and individual wires in strands, may move as the
SURFACE PROTECTION FOR CYLINDER rope moves and bends. A wire rope cannot be lubricated
RODS sufficiently during manufacture to last its entire life.
Therefore, new lubricant must be added periodically
Steel cylinder rods include a thin layer of chrome plating on throughout the life of a rope to replace factory lubricant which
their surfaces to protect them from corroding. However, is used or lost. For more detailed information concerning the
chrome plating inherently has cracks in its structure which lubrication and inspection of wire rope, refer to WIRE ROPE
can allow moisture to corrode the underlying steel. At typical in Section 1- INTRODUCTION in the Service Manual.
ambient temperatures, hydraulic oil is too thick to penetrate
these cracks. Normal machine operating temperatures will
LUBRICATION POINTS Unless otherwise indicated, items not equipped with grease
fittings, such as linkages, pins, levers, etc., should be
A regular frequency of lubrication must be established for all lubricated with oil once a week. Motor oil, applied sparingly,
lubrication points. Normally, this is based on component will provide the necessary lubrication and help prevent the
operating time. The most efficient method of keeping track of formation of rust. An Anti-Seize compound may be used if
lube requirements is to maintain a job log indicating crane rust has not formed, otherwise the component must be
usage. The log must use the engine hourmeter to ensure cleaned first.
coverage of lube points that will receive attention based on
their readings. Other lubrication requirements must be made Grease fittings that are worn and will not hold the grease
on a time basis, i.e. weekly, monthly, etc. gun, or those that have a stuck check ball, must be replaced.
All oil levels are to be checked with the crane parked on a Where wear pads are used, cycle the components and
level surface in transport position, tires on the ground, and relubricate to ensure complete lubrication of the entire wear
the suspension set at the proper ride height. area.
7117-11
2 5 1 7117-13
7117-1
9
7061-13
3
FIGURE 9-1
11 7117-13
12 7117-8
7117-1
FIGURE 9-2
22a
21a 7117-20
7117-25
7117-1
21b 7117-14
20b 7117-19 9
FIGURE 9-3
26a 7117-12
26b 7117-31
25a 24 7117-20
7117-1
Other Side
27
7117-3
7116-2
9
25b 7117-30
23 7117-28
FIGURE 9-4
31 30 31 30 7117-4
7117-2
Other Side
9
32 7117-5
34 7117-9
FIGURE 9-5
41 7117-10
40 7117-17
7117-1
FIGURE 9-6
7117-1
51
50
52
9
7117-29
FIGURE 9-7
EP-MPG
Extreme Pressure Until
72 Headache Ball Figure 9-8 Multipurpose grease 250 hours or 3 months 1 grease fitting
Grease extrudes
A6-829-003477
EP-MPG
Telescope Extreme Pressure
Thoroughly
73 Cylinder Wear Figure 9-8 Multipurpose Every boom teardown 5 places by brush.
Grease
coat
Pads
A6-829-003477
! WARNING
Crane Setup for Items 74 & 75: Crane to be set up on firm level surface with fully extended outriggers and 40,000 lbs
counterweight installed. Ensure crane is level. Boom must be directly over the front and the house lock engaged. Set boom
angle at zero degrees. No load is permitted on the boom. The weight of the hookblock, overhaul ball and rigging must not be
supported by the boom. Do not extend the boom until the weight of these components is totally removed from the boom.
Internal Side EP-MPG Thoroughly
14 places by brush;
and Bottom Extreme Pressure coat all
with boom in extended
74 Wear Pads Figure 9-8 Multipurpose areas the 250 hours or 3 months
Grease
position through
(Inner wear pad
A6-829-003477 access holes
Sections) moves on
NOTE:
! WARNING
See Table 9-1, page 9-28 at the end of this sections for how to access lubrication points 74 & 75
EP-MPG 8 grease fittings; with
Boom Section Extreme Pressure Until
boom in extended
75 Upper Wear Figure 9-8 Multipurpose grease 50 hours or 1 week
Grease position through
Pads extrudes
A6-829-003477 access holes
73 73
72
7117-27
74
73
73
71
74
70
6692-1 60 7117-23
7117-26
Other Side
Other Side
7117-2
75
75
75
75
74
74
74
61 7117-5
74
9
74 6692-2
FIGURE 9-8
! WARNING
Crane Setup for Items 76, 77, 78: Crane to be set up on firm level surface with fully extended outriggers and 40,000 lbs
counterweight installed. Ensure the crane is level. Boom must be directly over the front and the house lock engaged. Set
boom angle at zero degrees. No load is permitted on the boom. The weight of the hookblock, overhaul ball and rigging must
not be supported by the boom. Do not extend the boom until the weight of these components is totally removed from the
boom.
EP-MPG Thoroughly
Boom Section Extreme Pressure coat all
76 Upper and Lower Figure 9-9 Multipurpose areas the 50 hours or 1 week 12 places by brush
Wear Pads Grease wear pad
A6-829-003477 moves on
NOTE:
! WARNING
See Table 9-1, page 9-28 at the end of this sections for how to access lubrication points 76, 77, 78
EP-MPG
Extreme Pressure Until
Extend Cable 250 hours or 3
77 Figure 9-9 Multipurpose grease 1 grease fitting
Sheaves Grease
months
extrudes
A6-829-003477
EP-MPG
Extreme Pressure Until
Retract Cable 250 hours or 3 2 grease fittings
78 Figure 9-9 Multipurpose grease
Sheaves Grease
months (1) on each side
extrudes
A6-829-003477
76
76
76 7117-39
76
76
76
7117-21
7117-40
7117-1
77
78
6692-2
9
6692-1
FIGURE 9-9
EP-MPG
Extreme
Until 1 grease fitting per
Lower Boom Pressure
81 Figure 9-10 grease 250 hours or 3 months sheave (7 sheaves)
Nose Sheave Multipurpose
extrudes total
Grease
A6-829-003477
EP-MPG
Extreme
Until
Pressure
82 Hose Rollers Figure 9-10 grease 250 hours or 3 months 4 grease fittings
Multipurpose
extrudes
Grease
A6-829-003477
EP-MPG
Extreme
Until
Auxiliary Boom Pressure
83 Figure 9-10 grease 250 hours or 3 months 1 grease fitting
Nose Sheave Multipurpose
extrudes
Grease
A6-829-003477
80
82 7117-7
81 83
7117-21
7117-1
9
79 7117-18
FIGURE 9-10
A B 90 92 A B 91 92
92
7117-18
7117-1
FIGURE 9-11
102
102 7117-41
7117-2
9
101 100 7117-15
FIGURE 9-12
Instructions for Accessing Lubrication NOTE: During this extension you must override the LMI
Points on Boom system.
6. Once the center mid is fully extended, continue
1. Set LMI operating code to 0001.
extending the outer mid and fly section to reach the
2. Set auto boom mode. Extend the boom sections to gain points indicated in the table above. The center, outer,
access to the Lubrication points as indicated in the table and fly section lube points may be fully extended during
above for “Auto Mode”. The LMI system will lockout at this step.
approximately 145’ boom extension.
3. After performing the lubrication requirements accessible ! WARNING
in one of the above, fully retract all boom sections. Do NOT extend the inner mid. The inner mid must remain
4. Set boom configuration to manual boom mode and fully retracted.
select the center mid switch to fully extend the center
mid section. 7. Once lubrication is complete, fully retract all boom
sections and return boom to auto boom mode.
5. Fully extend the center mid section.
Alphabetical Index
GROVE 1
SERVICE MANUAL RT9130E
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Motor And Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Muffler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Outrigger Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24
Outrigger Control Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56
Outrigger Extension Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-80
Outrigger Stabilizer Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-83
Outrigger/Rear Steer/Outrigger Box Pin Removal Valve . . . . . . . . . . . . . . . . . . . . . . . 2-54
Park Brake Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-92
Pilot Operated Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57
Power Pin Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-89
Pressure Bleed-Off Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58
Pressure Reducing Sequence Valve With Solenoid Controls Manifold . . . . . . . . . . . . 2-38
Pressure Setting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60
Shuttle Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-50
Solenoid Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51
Steer Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-77
Steering Control Valve-Dual Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40
Steering Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Supply Pressure And Return Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Surface Protection for Cylinder Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Swing Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Swing Box Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Swing Lock Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
Swing Power Brake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43
Swing Series Parallel Selector Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37
Swivels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Tandem Brake Valve w/ Treadle Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45
Telescope Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Theory Of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Theory Of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Theory Of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Third Wrap Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Tilt Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-86
Torque Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30
Upper Telescope Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-71
Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
Water Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
Wheels And Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Wire Rope Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Wire Rope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15