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Grove Crane RT 600E Service & Maintenance Manual – PDF DOWNLOAD
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Description
Grove Crane RT 600E Service & Maintenance Manual – PDF DOWNLOAD
FILE DETAILS:
Grove Crane RT 600E Service & Maintenance Manual – PDF DOWNLOAD
Language : English
Pages : 300
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Grove Crane RT 600E Service & Maintenance Manual – PDF DOWNLOAD
DESCRIPTION:
This Manual provides information for the maintenance of the Model RT600E Grove Crane. The lift capacities are listed on the Load Chart in the cab. The crane incorporates an all welded parallel box construction steel frame, utilizing two drive steer axles. Axle steering is accomplished utilizing hydraulic steer cylinders.
- The engine is mounted at the rear of the crane carrier and provides motive power through a six speed forward and three speed reverse transmission. The outriggers are single stage, double box, telescopic beam type outriggers. The superstructure is capable of 360 degree rotation in either direction. All crane functions are controlled from the fully – enclosed cab mounted on the superstructure.
- One boom is available on the crane; a four section, full power, synchronized, 10.06 to 32.0 meter (33 to 105 foot) boom. Additional reach is obtained by utilizing one of two optional boom extensions; a 8.8 meter (29 foot) fixed length offsettable swingaway and a 8.8 to 15.5 meter (29 to 51 foot) offsettable telescoping swingaway.
TABLE OF CONTENTS:’
Grove Crane RT 600E Service & Maintenance Manual – PDF DOWNLOAD
See end of this Manual for Alphabetical Index............................................................. 5 SECTION 1................................................................................................. 13 Introduction.......................................................................................... 13 Description....................................................................................... 13 List Of Specifications............................................................................ 14 General....................................................................................... 14 Dimensions.................................................................................... 14 Capacities.................................................................................... 14 Torque Converter.............................................................................. 14 Transmission.................................................................................. 14 Engine........................................................................................ 14 Cummins QSB6.7............................................................................ 14 Axles......................................................................................... 14 Brakes........................................................................................ 14 Wheels and Tires.............................................................................. 14 Swing Gearbox................................................................................. 14 Boom.......................................................................................... 14 Swivel Assembly............................................................................... 14 Hydraulic Pumps............................................................................... 14 Pump #1................................................................................... 14 Pump #2................................................................................... 14 Pump #3................................................................................... 15 Hoists........................................................................................ 15 Axle Weight Distribution Table (Continued)................................................ 18 General Maintenance............................................................................... 20 Cleanliness................................................................................... 20 Removal and Installation...................................................................... 20 Disassembly and Assembly...................................................................... 20 Pressing Parts................................................................................ 20 Locks......................................................................................... 20 Wires and Cables.............................................................................. 21 Shims......................................................................................... 21 Bearings...................................................................................... 21 Antifriction Bearings..................................................................... 21 Double Row, Tapered Roller................................................................ 21 Heating Bearings.......................................................................... 21 Installation.............................................................................. 21 Preload................................................................................... 21 Sleeve Bearings........................................................................... 21 Gaskets....................................................................................... 21 Batteries..................................................................................... 21 Hydraulic Systems............................................................................. 22 Cleanliness............................................................................... 22 Keep the System Clean..................................................................... 22 Sealing Elements.......................................................................... 22 Hydraulic Lines........................................................................... 22 Visual Inspection of Hoses and Fittings................................................... 22 Electrical System............................................................................. 23 Cables, Harnesses, Wires, and Connectors.................................................. 23 Fatigue of Welded Structures.................................................................. 23 Loctite®...................................................................................... 24 Application of Medium Strength Loctite.................................................... 24 Primer Application.................................................................... 24 Adhesive/Sealant Application.......................................................... 24 Fasteners and Torque Values................................................................... 24 Torque Wrenches........................................................................... 24 Torque Values............................................................................. 25 Weld Studs.................................................................................... 28 Wire Rope......................................................................................... 29 General....................................................................................... 29 Environmental Conditions...................................................................... 29 Dynamic Shock Loads........................................................................... 29 Lubrication................................................................................... 29 Precautions and Recommendations During Inspection or Replacement.............................. 29 Wire Rope Inspection (Running Ropes and Pendant Cables)....................................... 30 Keeping Records........................................................................... 30 Frequent Inspection....................................................................... 30 Periodic Inspection....................................................................... 31 Wire Rope Inspection (Boom Extension and Retraction Cables)................................... 31 Periodic Inspection....................................................................... 31 Wire Rope Inspection/Replacement (All Wire Rope).............................................. 31 Seizing Wire Rope............................................................................. 32 Method 1.................................................................................. 32 Method 2.................................................................................. 32 Installing 35x7 Class Wire Rope............................................................... 33 Procedures for Cutting and Preparing 35x7 Class Wire Rope..................................... 33 SECTION 2................................................................................................. 35 Hydraulic System...................................................................................... 35 Description....................................................................................... 36 Maintenance....................................................................................... 36 Hydraulic Oil Recommendations................................................................. 36 Draining and Flushing......................................................................... 36 Removing Air from the Hydraulic System........................................................ 40 Parts Replacement............................................................................. 40 Directional Control Valves.................................................................... 40 Inspection................................................................................ 40 Valve Leakage............................................................................. 40 Binding Spools............................................................................ 41 Visual Inspection of Hoses and Fittings................................................... 41 Supply Pressure and Return Circuit................................................................ 42 Description................................................................................... 42 Hydraulic Reservoir and Filter................................................................ 42 Pump Distribution............................................................................. 42 No. 1 Pump................................................................................ 42 No. 2 Pump................................................................................ 43 No. 3 Pump................................................................................ 43 Maintenance................................................................................... 44 Troubleshooting........................................................................... 44 Hydraulic Reservoir Removal............................................................... 45 Hydraulic Reservoir Installation.......................................................... 45 Breather Removal and Replacement.......................................................... 45 Return Hydraulic Filter Assembly.............................................................. 46 Element Removal........................................................................... 46 Element Installation...................................................................... 47 Oil Cooler........................................................................................ 48 Description................................................................................... 48 Removal....................................................................................... 48 Installation.................................................................................. 48 Hydraulic Pumps................................................................................... 49 Description................................................................................... 49 Maintenance................................................................................... 49 No. 1 Pump Removal........................................................................ 49 No. 1 Pump Installation................................................................... 49 No. 1 Pump and Pump Disconnect Assembly Removal........................................... 49 No. 1 Pump and Pump Disconnect Assembly Installation...................................... 50 No. 2 Pump Removal........................................................................ 50 No. 2 Pump Installation................................................................... 52 No. 3 Pump Removal........................................................................ 52 No. 3 Pump Installation................................................................... 52 Testing After Repair or Replacement....................................................... 52 Pressure Setting Procedures....................................................................... 54 Valve Pressure Setting Table.................................................................. 54 Procedure A - For Checking Main Control Valve Reliefs......................................... 54 Procedure B - For Checking Directional Control Valve Pilot Supply Pressure.................... 55 Procedure C - For Checking Swing Brake Pilot Supply Pressure.................................. 56 Procedure D - For Checking Service Brake and Air Conditioning Circuit Relief Pressure......... 56 Procedure E- For Checking the Service Brake Dual Accumulator Charge Valve Pressure Limits..... 57 Procedure F- For Checking Accumulator Pre-Charge Pressure..................................... 57 Procedure G- For Pre-charging Accumulator..................................................... 58 Procedure H - For Checking the Front Steer Pressure........................................... 58 Procedure I - For Checking Swing Valve Work Port Relief Pressure.............................. 58 Procedure J- For Checking Outrigger and Rear Steer Valve Relief............................... 59 Procedure K - For checking Transmission Oil Cooler Valve Relief............................... 60 Valves............................................................................................ 61 General....................................................................................... 61 Valve Usage Table (Continued)............................................................. 61 Directional Control Valves........................................................................ 64 Description................................................................................... 64 Maintenance................................................................................... 64 Swing/Steer Valve Bank Removal............................................................ 64 Swing/Steer Valve Bank Installation....................................................... 64 Hoist/Lift/Telescope Valve Bank Removal................................................... 64 Hoist/Lift/Telescope Valve Bank Installation.............................................. 64 Valve Bank Functional Checks.............................................................. 64 Hydraulic Remote Control Valve.................................................................... 68 Description................................................................................... 68 Single Axis Controllers................................................................... 68 Dual Axis Controllers..................................................................... 68 Maintenance................................................................................... 68 Armrest Control Valve Removal............................................................. 68 Armrest Control Valve Installation........................................................ 68 Armrest Control Valve Functional Check.................................................... 68 Telescope Pedal Control Valve Removal (with Auxiliary Hoist Option)....................... 68 Telescope Pedal Control Valve Installation (with Auxiliary Hoist Option).................. 68 Telescope Pedal Control Valve Functional Check (with Auxiliary Hoist Option).............. 70 Outrigger/Rear Steer Valve........................................................................ 71 Description................................................................................... 71 Maintenance................................................................................... 71 Removal................................................................................... 71 Installation.............................................................................. 71 Functional Check.............................................................................. 71 Outrigger Control Manifold........................................................................ 73 Description................................................................................... 73 Maintenance................................................................................... 73 Removal................................................................................... 73 Inspection................................................................................ 73 Installation.............................................................................. 73 Functional Check.......................................................................... 73 Pilot Operated Check Valve........................................................................ 75 Description................................................................................... 75 Maintenance................................................................................... 75 Removal................................................................................... 75 Installation.............................................................................. 75 Holding Valve..................................................................................... 76 Description................................................................................... 76 Maintenance................................................................................... 76 Removal................................................................................... 76 Installation.............................................................................. 76 Swing Power Brake Valve........................................................................... 77 Description................................................................................... 77 Maintenance................................................................................... 77 Removal................................................................................... 77 Installation.............................................................................. 77 Function Check............................................................................ 77 Throttle Foot Valve............................................................................... 78 Description................................................................................... 78 Maintenance................................................................................... 78 Removal................................................................................... 78 Installation.............................................................................. 78 Function Check............................................................................ 78 Tandem Brake Valve with Treadle Pedal............................................................. 79 Description................................................................................... 79 Maintenance................................................................................... 79 Removal................................................................................... 79 Installation.............................................................................. 79 Service Brake Dual Accumulator Charge Valve....................................................... 80 Description................................................................................... 80 Maintenance................................................................................... 80 Removal................................................................................... 80 Installation.............................................................................. 80 Service Brake Hydraulic Accumulator............................................................... 81 Description................................................................................... 81 Maintenance................................................................................... 81 Removal................................................................................... 81 Installation.............................................................................. 81 Servicing..................................................................................... 81 Swing Brake and RCL Lockout Valve................................................................. 82 Description................................................................................... 82 Maintenance................................................................................... 82 Removal................................................................................... 82 Installation.............................................................................. 82 Function Check - Swing Brake Release Valve................................................ 82 Function Check - RCL Lockout Valves....................................................... 82 Function Check - Crane Function Valve..................................................... 82 Inlet Filter Screen Replacement........................................................... 84 Axle Oscillation Lockout Valve.................................................................... 85 Description................................................................................... 85 Maintenance................................................................................... 85 Removal................................................................................... 85 Installation.............................................................................. 85 High Speed Boost Selector Valve................................................................... 86 Description................................................................................... 86 Maintenance................................................................................... 86 Removal................................................................................... 86 Installation.............................................................................. 86 Cross Axle Differential Lock Valve................................................................ 87 Description................................................................................... 87 Maintenance................................................................................... 87 Removal................................................................................... 87 Installation.............................................................................. 87 Solenoid Valves................................................................................... 88 Description................................................................................... 88 Maintenance................................................................................... 88 Removal................................................................................... 88 Installation.............................................................................. 88 Check Valves...................................................................................... 88 Description................................................................................... 88 Maintenance................................................................................... 88 Removal................................................................................... 88 Installation.............................................................................. 88 Flow Control Valve................................................................................ 88 Description................................................................................... 88 Maintenance................................................................................... 88 Removal................................................................................... 88 Installation.............................................................................. 88 Cylinders......................................................................................... 89 General....................................................................................... 89 Maintenance................................................................................... 89 General................................................................................... 89 Wear Ring Gap......................................................................... 89 Surface Protection for Cylinder Rods.......................................................... 89 Leakage Check............................................................................. 89 Temperature Effects On Hydraulic Cylinders.................................................... 90 Lift Cylinder..................................................................................... 92 Description................................................................................... 92 Maintenance................................................................................... 92 Disassembly............................................................................... 92 Inspection................................................................................ 92 Assembly.................................................................................. 92 Telescope Cylinder................................................................................ 95 Description................................................................................... 95 Maintenance................................................................................... 95 Disassembly............................................................................... 95 Inspection................................................................................ 97 Assembly.................................................................................. 97 Axle Oscillation Lockout Cylinder.................................................................100 Description...................................................................................100 Maintenance...................................................................................100 Disassembly...............................................................................100 Inspection................................................................................100 Assembly..................................................................................100 Steer Cylinder....................................................................................103 Description...................................................................................103 Maintenance...................................................................................103 Disassembly...............................................................................103 Inspection................................................................................103 Assembly..................................................................................103 Outrigger Extension Cylinder......................................................................106 Description...................................................................................106 Maintenance...................................................................................106 Disassembly...............................................................................106 Inspection................................................................................106 Assembly..................................................................................106 Outrigger Stabilizer Cylinder.....................................................................109 Description...................................................................................109 Maintenance...................................................................................109 Disassembly...............................................................................109 Inspection................................................................................109 Assembly..................................................................................109 Park Brake Cylinder...............................................................................112 Description...................................................................................112 SECTION 3.................................................................................................113 Electrical System.....................................................................................113 Description.......................................................................................113 General.......................................................................................113 Alternator....................................................................................115 Batteries.....................................................................................115 Cab Electrical Panel..........................................................................115 Rated Capacity Limiter (RCL) Emergency Override Switch (Non-CE Certified Cranes)..............117 Rated Capacity Limiter (RCL) Emergency Override Switch and Indicator (CE Certified Cranes)....118 Carrier Electrical Panel......................................................................118 Maintenance.......................................................................................120 General.......................................................................................120 Visual Inspection and Replacement of Electrical Harnesses and Cables......................120 General Troubleshooting.......................................................................121 Troubleshooting Swivel-Caused Electrical Problems.............................................121 Connector Troubleshooting.....................................................................121 Alternator/Charging System Troubleshooting....................................................123 Required Tools............................................................................123 Visual Check..............................................................................123 Engine Off Tests..........................................................................123 Batteries.............................................................................123 Voltage at Alternator.................................................................123 Battery Drain.........................................................................123 Engine On Tests...........................................................................123 Output Voltage Test...................................................................123 Maximum Amperage Test.................................................................123 Voltage Drop Test.....................................................................124 Alternator Replacement........................................................................124 Removal...................................................................................124 Installation..............................................................................124 Check.....................................................................................124 Starter Replacement...........................................................................124 Removal...................................................................................124 Installation..............................................................................125 Check.....................................................................................125 Battery Replacement...........................................................................125 Removal...................................................................................125 Installation..............................................................................125 Relay Panel Component Replacement.............................................................125 Accessory Relay...........................................................................125 Buzzer Replacement........................................................................126 Gauge Cluster Replacement.....................................................................126 Removal...................................................................................126 Installation..............................................................................126 Check.....................................................................................126 Rocker Switch Replacement.....................................................................126 Removal...................................................................................126 Inspection................................................................................127 Installation..............................................................................127 Check.....................................................................................127 Ignition Switch Replacement...................................................................127 Removal...................................................................................127 Inspection................................................................................128 Installation..............................................................................128 Check.....................................................................................128 Turn Signal Lever and Transmission Shift Lever Replacement....................................128 Removal...................................................................................128 Installation..............................................................................128 Check.....................................................................................129 Windshield Wiper Assembly Replacement.........................................................131 Removal...................................................................................131 Inspection................................................................................131 Installation..............................................................................131 Check.....................................................................................132 Windshield Washer Assembly Replacement........................................................132 Removal...................................................................................132 Inspection................................................................................132 Installation..............................................................................132 Check.....................................................................................132 Skylight Wiper Assembly Replacement...........................................................132 Removal...................................................................................132 Inspection................................................................................132 Installation..............................................................................132 Check.....................................................................................133 Tools for Troubleshooting.....................................................................133 Optional Equipment................................................................................134 Beacon Light..................................................................................134 Boom Mounted Floodlights......................................................................134 Rear View Mirror..............................................................................134 Air Conditioner...............................................................................134 SECTION 4.................................................................................................135 Boom..................................................................................................135 Description.......................................................................................135 Theory of Operation...............................................................................135 Boom Extension................................................................................135 Boom Retraction...............................................................................135 Maintenance.......................................................................................139 Removal.......................................................................................139 Disassembly...................................................................................139 Boom Nose Sheaves.................................................................................141 Removal.......................................................................................141 Installation..................................................................................141 Assembly......................................................................................142 Installation..................................................................................144 Functional Check..............................................................................144 Inspection....................................................................................145 Boom Alignment and Servicing..................................................................145 Boom Extension and Retraction Cable...............................................................146 Maintenance...................................................................................146 Inspection....................................................................................146 Adjustment....................................................................................146 Telescope Circuit.................................................................................147 Description...................................................................................147 Theory of Operation...........................................................................147 Maintenance...................................................................................147 Troubleshooting (Continued)...............................................................147 Removal and Installation..................................................................149 Disassembly and Assembly..................................................................149 Lift Circuit......................................................................................150 Description...................................................................................150 Theory of Operation...........................................................................150 Maintenance...................................................................................150 Troubleshooting (Continued)...............................................................150 Removal...................................................................................152 Disassembly and Assembly..................................................................152 Installation..............................................................................152 Swingaway Boom Extension..........................................................................154 Description...................................................................................154 Maintenance...................................................................................154 Removal...................................................................................154 Installation..............................................................................155 Hook Block........................................................................................159 Description...................................................................................159 Maintenance...................................................................................159 Periodic Maintenance......................................................................159 SECTION 5.................................................................................................161 Hoist And Counterweight...............................................................................161 Description.......................................................................................161 Theory of Operation...............................................................................161 Maintenance.......................................................................................161 Warm-up Procedure.............................................................................161 Removal...................................................................................162 Installation..............................................................................162 Functional Check..........................................................................162 Preventive Maintenance........................................................................164 Hoist to Boom Alignment...........................................................................165 Preparation...................................................................................165 Tools Required................................................................................165 Procedure.....................................................................................165 Motor and Brake...................................................................................167 Description...................................................................................167 Maintenance...................................................................................167 Removal...................................................................................167 Installation..............................................................................167 Idler Drum and Cable Follower.....................................................................168 Description...................................................................................168 Maintenance...................................................................................168 Idler Drum................................................................................168 Removal and Disassembly...............................................................168 Cleaning and Inspection...............................................................168 Assembly and Installation.............................................................168 Cable Follower............................................................................168 Removal and Disassembly...............................................................168 Cleaning and Inspection...............................................................168 Assembly and Installation.............................................................168 Complete Assembly.........................................................................170 Removal...............................................................................170 Installation..........................................................................170 Third Wrap Indicator (Optional— Standard on CE)...................................................171 Description...................................................................................171 Maintenance...................................................................................171 Hoist Drum Rotation Indicator System..............................................................172 Description...................................................................................172 Maintenance...................................................................................172 General...................................................................................172 Rotation Sensor.......................................................................172 Drum Rotation Indicator Control Module (CPU)..........................................172 Thumb Thumper Solenoid................................................................172 Troubleshooting...............................................................................172 Green LED.................................................................................172 Red LED...................................................................................174 Amber LED.................................................................................174 Hoist Control Valves..............................................................................174 Description...................................................................................174 Hydraulic Hoist Motor Control Valve.......................................................174 Hoist Directional Control Valve...........................................................174 Counterweight.....................................................................................175 Description...................................................................................175 Maintenance...................................................................................175 Removal...................................................................................175 Installation..............................................................................175 SECTION 6.................................................................................................179 Swing System..........................................................................................179 Description.......................................................................................179 Theory of Operation...............................................................................179 Swing Drive...................................................................................179 Swing Brake...................................................................................180 Maintenance.......................................................................................181 Troubleshooting (Continued)...................................................................181 Swing Motor.......................................................................................185 Description...................................................................................185 Maintenance...................................................................................185 Removal...................................................................................185 Installation..............................................................................185 Test......................................................................................185 Swing Gearbox and Brake...........................................................................187 Description...................................................................................187 Maintenance...................................................................................187 Removal...................................................................................187 Disassembly...............................................................................187 Assembly..................................................................................187 Installation..............................................................................187 Servicing.................................................................................187 Checking the Oil Level....................................................................188 Testing...................................................................................188 Swing Bearing.....................................................................................189 Description...................................................................................189 Maintenance...................................................................................189 General...................................................................................189 Torquing Turntable Bolts..................................................................189 General...............................................................................189 Torque Values.........................................................................190 Tools Required........................................................................190 Inner Race Torquing...................................................................190 Outer Race Torquing...................................................................190 Removal...................................................................................191 Inspection................................................................................192 Installation..............................................................................192 Testing...................................................................................193 Swivels...........................................................................................194 Description...................................................................................194 Hydraulic Swivel..................................................................................196 Description...................................................................................196 Theory of Operation...........................................................................196 Maintenance...................................................................................196 Removal...................................................................................196 Installation..............................................................................197 Two Port Water Swivel.............................................................................198 Description...................................................................................198 Maintenance...................................................................................198 Removal...................................................................................198 Disassembly...............................................................................198 Cleaning and Inspection...................................................................198 Assembly..................................................................................198 Installation..............................................................................198 Electrical Swivel.................................................................................199 Description...................................................................................199 Theory of Operation...........................................................................199 Maintenance...................................................................................199 Removal...................................................................................199 Installation..............................................................................199 Preventive Maintenance....................................................................200 Slew Potentiometer Preliminary Zero Adjustment Procedure..................................200 Slew Potentiometer Adjustment.............................................................200 Swing Lock Pin....................................................................................201 Description...................................................................................201 Maintenance...................................................................................201 360° Swing Lock Control (Positive Lock Type) (Optional)...........................................201 Description...................................................................................201 Maintenance...................................................................................201 SECTION 7.................................................................................................203 Power Train...........................................................................................203 Description.......................................................................................203 Maintenance.......................................................................................203 Engine Removal................................................................................203 Engine Installation...........................................................................204 Engine Drive Belts............................................................................205 Electronic Control System.........................................................................207 Description...................................................................................207 Engine Control System Switches and Indicator Lights...........................................207 Engine Diagnostic/Speed Control Switch....................................................207 Increment/Decrement Switch................................................................207 Engine Stop Light.........................................................................207 Engine Warning Light......................................................................207 Fuel System.......................................................................................208 Description...................................................................................208 Fuel Tank.................................................................................208 Injection Fuel Pump.......................................................................208 Fuel Filter-Water Separator...............................................................208 Maintenance...................................................................................208 Fuel Tank.................................................................................208 Removal...............................................................................208 Installation..........................................................................208 Fuel Filter-Water Separator...............................................................208 Draining..............................................................................208 Air Intake System.................................................................................209 Description...................................................................................209 Air Intake....................................................................................209 Air Cleaner Checks........................................................................209 Check For Filter Restriction..........................................................209 Filter Element Replacement................................................................211 Element Cleaning......................................................................211 Air Cleaner Body..........................................................................211 Precleaner................................................................................211 Vacuator Valve............................................................................211 Duct Work.................................................................................212 Charge-Air Cooler System......................................................................212 Maintenance...............................................................................212 Muffler.......................................................................................212 Removal...................................................................................212 Installation..............................................................................212 Exhaust Coupler...........................................................................212 Water Cooling System..............................................................................215 Description...................................................................................215 Maintenance...................................................................................215 General...................................................................................215 Effects Of Cooling System Neglect.........................................................215 Overheating...........................................................................215 Overcooling...........................................................................215 Rust Prevention...........................................................................215 Engine Antifreeze/Coolant Fill Procedure..................................................215 Cooling System Care.......................................................................216 SCA Level Check/Coolant Filter Change Interval........................................216 Cleaning..................................................................................216 Pressure Flushing.........................................................................216 Component Inspection......................................................................217 Radiator/Surge Tank...................................................................217 Engine Water Jacket...................................................................217 Water Pump............................................................................217 Fans and Belts........................................................................218 Thermostat............................................................................218 Hoses and Clamps......................................................................218 Test Equipment............................................................................218 Antifreeze/Coolant........................................................................218 Radiator Removal and Installation.........................................................218 Removal...............................................................................218 Installation..........................................................................218 Radiator Filling..............................................................................219 Radiator Servicing............................................................................221 Drive Train.......................................................................................222 Description...................................................................................222 Maintenance...................................................................................222 Removal...................................................................................222 Installation..............................................................................222 Lubrication...............................................................................222 Transmission/Torque Converter.....................................................................224 Description...................................................................................224 Theory of Operation...........................................................................224 Maintenance...................................................................................225 General Information.......................................................................225 Troubleshooting...........................................................................225 Hydraulic Checks......................................................................225 Troubleshooting Procedures (Continued)................................................225 Removal...................................................................................226 Installation..............................................................................226 Servicing the Crane After Transmission/Torque Converter Overhaul..........................228 Lubrication...............................................................................228 Type Of Oil...........................................................................228 Capacity..............................................................................228 Check Period..........................................................................228 Normal Drain Period...................................................................228 SECTION 8.................................................................................................231 Undercarriage.........................................................................................231 Axles.............................................................................................231 Descriptions..................................................................................231 Maintenance...................................................................................232 Removal...................................................................................232 Cleaning..................................................................................232 Installation..............................................................................232 Wheel Alignment Check Procedure...........................................................232 Rear Steer Indicator Adjustment Procedure.................................................232 Wheels and Tires..............................................................................233 Description...............................................................................233 Maintenance...............................................................................233 Mounting Wheel Assemblies.............................................................233 Steering Systems..................................................................................235 Description...................................................................................235 Front Steering System.....................................................................235 Rear Steering System......................................................................235 Secondary Steering System (CE Units)......................................................235 Theory Of Operation...........................................................................235 Front Steering System.....................................................................235 Rear Steering System......................................................................235 Secondary Steering System (CE Units)......................................................235 Maintenance...................................................................................236 Front Steering System.....................................................................236 Troubleshooting.......................................................................236 Functional Check......................................................................237 Rear Steering System......................................................................237 Troubleshooting.......................................................................237 Hydraulic Pumps...............................................................................238 Description...............................................................................238 Front Steer...........................................................................238 Rear Steer............................................................................238 Front Steering Control Valve......................................................................239 Description...................................................................................239 Maintenance...................................................................................239 Removal...................................................................................239 Installation..............................................................................239 Integrated Outrigger/Rear Steer Control Valve.....................................................239 Description...................................................................................239 Maintenance...................................................................................239 Removal...................................................................................239 Installation..............................................................................239 Functional Check..........................................................................239 Steer Cylinders...................................................................................240 Description...................................................................................240 Maintenance...................................................................................240 Removal...................................................................................240 Installation..............................................................................240 Rear Axle Oscillation Lockout System..............................................................240 Description...................................................................................240 Theory of Operation...........................................................................240 Axle Oscillation Lockout Cylinders................................................................242 Description...................................................................................242 Maintenance...................................................................................242 Removal...................................................................................242 Installation..............................................................................242 Axle Oscillation Lockout Valve....................................................................242 Description...................................................................................242 Maintenance...................................................................................242 Removal...................................................................................242 Installation..............................................................................242 Brake System......................................................................................243 Description...................................................................................243 Service Brakes............................................................................243 Parking Brake.............................................................................243 Theory Of Operation...........................................................................243 Service Brakes............................................................................243 Parking Brake.............................................................................243 Maintenance...................................................................................244 Troubleshooting...........................................................................244 General...................................................................................244 Bleeding the Brake System.................................................................244 Pressure Bleeding the Brake System....................................................245 Manually Bleeding the Brake System....................................................245 Service Brakes................................................................................245 Description...............................................................................245 Maintenance...............................................................................245 Removal...............................................................................245 Disassembly...........................................................................246 Inspection............................................................................247 Cleaning..............................................................................249 Corrosion Protection......................................................................249 Assembly..............................................................................249 Installation..........................................................................250 Parking Brake Actuator........................................................................251 Description...............................................................................251 Maintenance...............................................................................251 Removal...............................................................................251 Installation..........................................................................251 Adjustment................................................................................251 Parking Brake.................................................................................252 Description...............................................................................252 Maintenance...............................................................................252 Removal...................................................................................252 Installation..............................................................................252 Park Brake Solenoid Valve.....................................................................253 Description...............................................................................253 Maintenance...............................................................................253 Removal...............................................................................253 Installation..........................................................................253 Outrigger Circuit.................................................................................254 Description...................................................................................254 Theory of Operation...........................................................................254 Maintenance...................................................................................255 Troubleshooting (Continued)...............................................................255 Outrigger Beam................................................................................259 Description...............................................................................259 Theory Of Operation.......................................................................259 Maintenance...............................................................................259 Removal...............................................................................259 Inspection............................................................................259 Installation..........................................................................260 Wear Pad Adjustment...................................................................260 Extension Cylinder............................................................................264 Description...............................................................................264 Maintenance...............................................................................264 Removal...............................................................................264 Installation..........................................................................264 Functional Check......................................................................264 Outrigger Monitoring System (Optional— Standard in North America).............................264 Description...............................................................................264 Removal...............................................................................264 Installation..........................................................................265 Stabilizer Cylinder...........................................................................266 Description...............................................................................266 Maintenance...............................................................................266 Removal...............................................................................266 Installation..........................................................................266 Functional Check......................................................................266 SECTION 9.................................................................................................267 Lubrication...........................................................................................267 General...........................................................................................267 Environmental Protection..........................................................................267 Lubrication Intervals.............................................................................267 Arctic Conditions Below -18°C (0°F)...........................................................267 Arctic Conditions Down To -40°C (-40°F).......................................................268 All Weather Package & Lubricants..........................................................268 Standard Lubricants Package...............................................................268 Surface Protection for Cylinder Rods..........................................................268 Wire Rope Lubrication.............................................................................269 Lubrication points................................................................................269 CraneLUBE.....................................................................................269 Safety........................................................................................269 Steering and Suspension.......................................................................270 Axles.........................................................................................272 Drive Train...................................................................................274 Drive Train (continued).......................................................................276 Turntable.....................................................................................278 Outriggers....................................................................................280 Boom..........................................................................................282 Boom (continued)..............................................................................284 Hoist.........................................................................................286 Hoist.........................................................................................288 Hydraulic.....................................................................................290 Carwell® Rust Inhibitor...........................................................................292 Protecting Cranes From Rusting................................................................292 Cleaning Procedures...........................................................................292 Inspection and Repair.........................................................................293 Application...................................................................................293 Areas of Application..........................................................................293
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