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Description
Grove Crane RT 880E Service & Maintenance Manual 358-05 – PDF DOWNLOAD
FILE DETAILS:
Grove Crane RT 880E Service & Maintenance Manual 358-05 – PDF DOWNLOAD
Language : English
Pages : 342
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Grove Crane RT 880E Service & Maintenance Manual 358-05 – PDF DOWNLOAD
INTRODUCTION:
GENERAL MAINTENANCE:
These general suggestions should be helpful in following the instructions in this manual. In
analyzing a system malfunction, use a systematic procedure to locate and correct the problem.
1. Determine the problem.
2. List possible causes.
3. Devise checks.
4. Conduct checks in a logical order to determine the cause.
5. Consider the remaining service life of components against the cost of parts and
labor necessary to replace them.
6. Make the necessary repair.
7. Recheck to ensure that nothing has been overlooked.
8. Functionally test the failed part in its system.
Cleanliness:
- An important item in preserving the long life of the machine is keeping dirt out of working parts.
Enclosed compartments, seals, and filters have been provided to keep the supply of air, fuel, and
lubricants clean. It is important that these enclosures be maintained. - Whenever hydraulic, fuel, lubricating oil lines, or air lines are disconnected, clean the adjacent
area as well as the point of disconnect. As soon as the disconnection is made, cap, plug, or tape
each line or opening to prevent entry of foreign material. The same recommendations for cleaning
and covering apply when access covers or inspection plates are removed. - Clean and inspect all parts. Be sure all passages and holes are open. Cover all parts to keep them
clean. Be sure parts are clean when they are installed. Leave new parts in their containers until
ready for assembly. - Clean the rust preventive compound from all machined surfaces of new parts before installing them.
Removal and Installation:
- When performing maintenance, do not attempt to manually lift heavy parts when hoisting equipment
should be used. Never locate or leave heavy parts in an unstable position. - When raising a portion of a crane or a complete crane, ensure the crane is blocked securely and the
weight is supported by blocks rather than by lifting equipment. - When using hoisting equipment, follow the hoist manufacturers recommendations and use lifting
devices that will allow you to achieve the proper balance of the assemblies being lifted
and to ensure safe handling. Unless otherwise specified, all removals requiring hoisting
equipment should be accomplished using an adjustable lifting attachment. All supporting members
(chains and cables) should be parallel to each other and as near perpendicular as possible
to the top of the object being lifted.
TABLE OF CONTENTS:
Grove Crane RT 880E Service & Maintenance Manual 358-05 – PDF DOWNLOAD
Table of Contents................................................................................................................................................................................................................................................................ 5 SECTION 1........................................................................................................................................................................................................................................................................ 13 Introduction................................................................................................................................................................................................................................................................. 13 General.................................................................................................................................................................................................................................................................. 13 Overview of Manuals.................................................................................................................................................................................................................................................. 13 Customer Support..................................................................................................................................................................................................................................................... 14 General Crane Design................................................................................................................................................................................................................................................. 14 Specific Crane Description........................................................................................................................................................................................................................................... 14 Lifting Capacities (Load Chart)...................................................................................................................................................................................................................................... 14 Basic Components..................................................................................................................................................................................................................................................... 14 Axle Weight Distribution............................................................................................................................................................................................................................................. 14 Serial Number Location............................................................................................................................................................................................................................................... 14 Transportation and Lifting Data...................................................................................................................................................................................................................................... 14 List of Specifications................................................................................................................................................................................................................................................... 15 General.............................................................................................................................................................................................................................................................. 15 Dimensions........................................................................................................................................................................................................................................................... 15 Capacities........................................................................................................................................................................................................................................................... 15 Torque Converter/Transmission........................................................................................................................................................................................................................................ 15 Engine............................................................................................................................................................................................................................................................... 15 Cummins QSB6.7................................................................................................................................................................................................................................................... 15 Axles................................................................................................................................................................................................................................................................ 15 Brakes............................................................................................................................................................................................................................................................... 15 Wheels and Tires..................................................................................................................................................................................................................................................... 15 Swing Gearbox........................................................................................................................................................................................................................................................ 15 Boom................................................................................................................................................................................................................................................................. 15 Swivel Assembly...................................................................................................................................................................................................................................................... 15 Hydraulic Pumps...................................................................................................................................................................................................................................................... 16 Pump #1.......................................................................................................................................................................................................................................................... 16 Pump #2.......................................................................................................................................................................................................................................................... 16 Hoists........................................................................................................................................................................................................................................................... 16 General Maintenance...................................................................................................................................................................................................................................................... 21 Cleanliness.......................................................................................................................................................................................................................................................... 21 Removal and Installation............................................................................................................................................................................................................................................. 21 Disassembly and Assembly............................................................................................................................................................................................................................................. 21 Pressing Parts....................................................................................................................................................................................................................................................... 21 Locks................................................................................................................................................................................................................................................................ 21 Wires and Cables..................................................................................................................................................................................................................................................... 22 Shims................................................................................................................................................................................................................................................................ 22 Hoses and Tubes...................................................................................................................................................................................................................................................... 22 Inspection....................................................................................................................................................................................................................................................... 22 Installation..................................................................................................................................................................................................................................................... 22 Bearings............................................................................................................................................................................................................................................................. 22 Antifriction Bearings............................................................................................................................................................................................................................................ 22 Double Row, Tapered Roller....................................................................................................................................................................................................................................... 23 Heating Bearings................................................................................................................................................................................................................................................. 23 Installation..................................................................................................................................................................................................................................................... 23 Preload.......................................................................................................................................................................................................................................................... 23 Sleeve Bearings.................................................................................................................................................................................................................................................. 23 Gaskets.............................................................................................................................................................................................................................................................. 23 Batteries............................................................................................................................................................................................................................................................ 23 Hydraulic Systems.................................................................................................................................................................................................................................................... 23 Cleanliness...................................................................................................................................................................................................................................................... 23 Keep the System Clean............................................................................................................................................................................................................................................ 23 Sealing Elements................................................................................................................................................................................................................................................. 23 Hydraulic Lines.................................................................................................................................................................................................................................................. 24 Visual Inspection of Hoses and Fittings.......................................................................................................................................................................................................................... 24 Hydraulic Fittings................................................................................................................................................................................................................................................... 25 Flats from Finger Tight (F.F.F.T.) Method........................................................................................................................................................................................................................ 25 37° Flared Steel Fitting: Tube or Hose to Fitting................................................................................................................................................................................................................ 25 Adjustable Straight Thread O-ring Fittings....................................................................................................................................................................................................................... 25 Nonadjustable Straight Thread O-ring Fitting: Fitting to Port.................................................................................................................................................................................................... 26 Electrical System.................................................................................................................................................................................................................................................... 26 Harnesses, Wires, and Connectors................................................................................................................................................................................................................................. 26 Fatigue of Welded Structures......................................................................................................................................................................................................................................... 26 Loctite.............................................................................................................................................................................................................................................................. 27 Application of Medium Strength Loctite........................................................................................................................................................................................................................... 27 Primer Application........................................................................................................................................................................................................................................... 27 Adhesive/Sealant Application................................................................................................................................................................................................................................. 27 Fasteners and Torque Values.......................................................................................................................................................................................................................................... 27 Torque Wrenches.................................................................................................................................................................................................................................................. 28 Torque Values.................................................................................................................................................................................................................................................... 28 Weld Studs........................................................................................................................................................................................................................................................... 31 Wire Rope................................................................................................................................................................................................................................................................ 32 General.............................................................................................................................................................................................................................................................. 32 Environmental Conditions............................................................................................................................................................................................................................................. 32 Dynamic Shock Loads.................................................................................................................................................................................................................................................. 32 Lubrication.......................................................................................................................................................................................................................................................... 32 Precautions and Recommendations During Inspection or Replacement..................................................................................................................................................................................................... 32 Wire Rope Inspection (Running Ropes and Pendant Cables).............................................................................................................................................................................................................. 33 Keeping Records.................................................................................................................................................................................................................................................. 33 Frequent Inspection.............................................................................................................................................................................................................................................. 33 Periodic Inspection.............................................................................................................................................................................................................................................. 34 Wire Rope Inspection (Boom Extension and Retraction Cables).......................................................................................................................................................................................................... 34 Periodic Inspection.............................................................................................................................................................................................................................................. 34 Wire Rope Inspection/Replacement (All Wire Rope)..................................................................................................................................................................................................................... 34 Seizing Wire Rope.................................................................................................................................................................................................................................................... 35 Method 1......................................................................................................................................................................................................................................................... 35 Method 2......................................................................................................................................................................................................................................................... 35 Installing 35x7 Class Wire Rope...................................................................................................................................................................................................................................... 36 Procedures for Cutting and Preparing 35x7 Class Wire Rope............................................................................................................................................................................................................ 36 SECTION 2........................................................................................................................................................................................................................................................................ 39 Hydraulic System............................................................................................................................................................................................................................................................. 39 Description.............................................................................................................................................................................................................................................................. 40 Theory of Operation...................................................................................................................................................................................................................................................... 43 Maintenance.............................................................................................................................................................................................................................................................. 43 Hydraulic Oil Recommendations........................................................................................................................................................................................................................................ 43 Draining and Flushing................................................................................................................................................................................................................................................ 43 Removing Air from the Hydraulic System............................................................................................................................................................................................................................... 44 Parts Replacement.................................................................................................................................................................................................................................................... 45 Directional Control Valves........................................................................................................................................................................................................................................... 45 Inspection....................................................................................................................................................................................................................................................... 45 Valve Leakage.................................................................................................................................................................................................................................................... 45 Binding Spools................................................................................................................................................................................................................................................... 45 Visual Inspection of Hoses and Fittings.......................................................................................................................................................................................................................... 45 Supply Pressure and Return Circuit....................................................................................................................................................................................................................................... 47 Hydraulic Reservoir.................................................................................................................................................................................................................................................. 47 Hydraulic Oil Return Filter Assembly................................................................................................................................................................................................................................. 48 Element Removal.................................................................................................................................................................................................................................................. 48 Element Installation............................................................................................................................................................................................................................................. 48 Oil Cooler........................................................................................................................................................................................................................................................... 50 Hydraulic Pumps...................................................................................................................................................................................................................................................... 51 Pump No. 1 Troubleshooting....................................................................................................................................................................................................................................... 52 Pump No. 1 Removal............................................................................................................................................................................................................................................... 53 Pump No. 1 Installation.......................................................................................................................................................................................................................................... 53 Pump No. 2 Removal............................................................................................................................................................................................................................................... 53 Pump No. 2 Installation.......................................................................................................................................................................................................................................... 53 Pump No. 1 Bleeding and Start-up................................................................................................................................................................................................................................. 54 Pump No. 2 Bleeding and Start-up................................................................................................................................................................................................................................. 54 Troubleshooting...................................................................................................................................................................................................................................................... 57 Pressure Setting Procedures.............................................................................................................................................................................................................................................. 58 Procedure A - Main Control Valve Pressure for Hoists, Boom Lift, Telescope - Check/ Adjust........................................................................................................................................................................... 59 Extend........................................................................................................................................................................................................................................................... 59 Retract.......................................................................................................................................................................................................................................................... 59 Procedure B - Outrigger Pressures - Adjust........................................................................................................................................................................................................................... 59 Procedure C - Oil Cooler Motor Pressure - Adjust..................................................................................................................................................................................................................... 59 Procedure D - Set Service Brake Accumulator Charge Valve Limits - Check/ Adjust...................................................................................................................................................................................... 59 Procedure E - Accumulator Pre-Charge Pressure - Check................................................................................................................................................................................................................ 60 Procedure F - Pre-Charging the Accumulator........................................................................................................................................................................................................................... 60 Procedure G - Front Steer Pressure - Check/ Adjust................................................................................................................................................................................................................... 60 Procedure H - Swing Work Port Pressure - Check/Adjust................................................................................................................................................................................................................ 60 Procedure I - Swing Brake Release Pressure - Check/Adjust............................................................................................................................................................................................................ 61 Procedure J - Controller Supply Pressure - Check/Adjust.............................................................................................................................................................................................................. 61 Procedure K - Counterweight Removal Cylinder Extend/Retract Pressure - Check......................................................................................................................................................................................... 61 Procedure L - Cab Tilt Cylinder Extend/ Retract and Counterweight Pin Removal Pressure - Check/Adjust................................................................................................................................................................ 61 Valves................................................................................................................................................................................................................................................................... 68 General.............................................................................................................................................................................................................................................................. 68 Directional Control Valves............................................................................................................................................................................................................................................... 72 Description.......................................................................................................................................................................................................................................................... 72 Maintenance.......................................................................................................................................................................................................................................................... 72 Boom Lift/Telescope/Hoist Valve Bank Removal..................................................................................................................................................................................................................... 72 Boom Lift/Telescope/Hoist Valve Bank Installation................................................................................................................................................................................................................ 72 Counterweight Removal Valve Bank Removal......................................................................................................................................................................................................................... 72 Counterweight Removal Valve Bank Installation.................................................................................................................................................................................................................... 72 Functional Check (All Valve Banks)............................................................................................................................................................................................................................... 73 Function Check - RCL Lockout Valves.............................................................................................................................................................................................................................. 73 Front Steer/Swing/Brake Manifold......................................................................................................................................................................................................................................... 79 Description.......................................................................................................................................................................................................................................................... 79 Maintenance.......................................................................................................................................................................................................................................................... 79 Removal.......................................................................................................................................................................................................................................................... 79 Installation..................................................................................................................................................................................................................................................... 79 Steering Control Valve................................................................................................................................................................................................................................................... 83 Description.......................................................................................................................................................................................................................................................... 83 Maintenance.......................................................................................................................................................................................................................................................... 83 Removal.......................................................................................................................................................................................................................................................... 83 Installation..................................................................................................................................................................................................................................................... 83 Hydraulic Remote Control Valve........................................................................................................................................................................................................................................... 84 Description.......................................................................................................................................................................................................................................................... 84 Single Axis Controller........................................................................................................................................................................................................................................... 84 Dual Axis Controller............................................................................................................................................................................................................................................. 84 Maintenance.......................................................................................................................................................................................................................................................... 84 Armrest Control Valve Removal.................................................................................................................................................................................................................................... 84 Armrest Control Valve Installation............................................................................................................................................................................................................................... 84 Armrest Control Valve Functional Check........................................................................................................................................................................................................................... 84 Telescope Pedal Control Valve Removal............................................................................................................................................................................................................................ 84 Telescope Pedal Control Valve Installation....................................................................................................................................................................................................................... 84 Telescope Pedal Control Valve Functional Check................................................................................................................................................................................................................... 84 Swing Power Brake Valve With Treadle Pedal............................................................................................................................................................................................................................... 88 Description.......................................................................................................................................................................................................................................................... 88 Maintenance.......................................................................................................................................................................................................................................................... 88 Removal.......................................................................................................................................................................................................................................................... 88 Installation..................................................................................................................................................................................................................................................... 88 Function Check................................................................................................................................................................................................................................................... 88 2 Speed Swing Valve...................................................................................................................................................................................................................................................... 89 Description.......................................................................................................................................................................................................................................................... 89 Maintenance.......................................................................................................................................................................................................................................................... 89 Removal.......................................................................................................................................................................................................................................................... 89 Installation..................................................................................................................................................................................................................................................... 89 Tandem Brake Valve with Treadle Pedal.................................................................................................................................................................................................................................... 90 Description.......................................................................................................................................................................................................................................................... 90 Maintenance.......................................................................................................................................................................................................................................................... 90 Removal.......................................................................................................................................................................................................................................................... 90 Installation..................................................................................................................................................................................................................................................... 90 Dual Accumulator Charge Valve............................................................................................................................................................................................................................................ 91 Description.......................................................................................................................................................................................................................................................... 91 Maintenance.......................................................................................................................................................................................................................................................... 91 Removal.......................................................................................................................................................................................................................................................... 91 Installation..................................................................................................................................................................................................................................................... 91 Hydraulic Accumulator Service Brake...................................................................................................................................................................................................................................... 93 Description.......................................................................................................................................................................................................................................................... 93 Maintenance.......................................................................................................................................................................................................................................................... 93 Removal.......................................................................................................................................................................................................................................................... 93 Installation..................................................................................................................................................................................................................................................... 93 Servicing........................................................................................................................................................................................................................................................ 93 Holding Valves........................................................................................................................................................................................................................................................... 94 Description.......................................................................................................................................................................................................................................................... 94 Lower Lift Cylinder Holding Valve................................................................................................................................................................................................................................ 94 Removal...................................................................................................................................................................................................................................................... 94 Installation................................................................................................................................................................................................................................................. 94 Maintenance.......................................................................................................................................................................................................................................................... 95 Removal.......................................................................................................................................................................................................................................................... 95 Installation..................................................................................................................................................................................................................................................... 95 Cross Axle Differential Lock Valve....................................................................................................................................................................................................................................... 96 Description.......................................................................................................................................................................................................................................................... 96 Maintenance.......................................................................................................................................................................................................................................................... 96 Removal.......................................................................................................................................................................................................................................................... 96 Installation..................................................................................................................................................................................................................................................... 96 Outrigger Control Manifold............................................................................................................................................................................................................................................... 97 Description.......................................................................................................................................................................................................................................................... 97 Maintenance.......................................................................................................................................................................................................................................................... 97 Removal.......................................................................................................................................................................................................................................................... 97 Inspection....................................................................................................................................................................................................................................................... 97 Installation..................................................................................................................................................................................................................................................... 97 Functional Check................................................................................................................................................................................................................................................. 97 Pilot Operated Check Valve...............................................................................................................................................................................................................................................100 Description..........................................................................................................................................................................................................................................................100 Maintenance..........................................................................................................................................................................................................................................................100 Removal..........................................................................................................................................................................................................................................................100 Installation.....................................................................................................................................................................................................................................................100 Axle Lockout, Rear Steer and Oil Cooler Fan Motor Control Manifold.......................................................................................................................................................................................................101 Description..........................................................................................................................................................................................................................................................101 Maintenance..........................................................................................................................................................................................................................................................101 Removal..........................................................................................................................................................................................................................................................101 Installation.....................................................................................................................................................................................................................................................101 Check Valves.............................................................................................................................................................................................................................................................104 Description..........................................................................................................................................................................................................................................................104 Maintenance..........................................................................................................................................................................................................................................................104 Removal..........................................................................................................................................................................................................................................................104 Installation.....................................................................................................................................................................................................................................................104 Range Shift/Parking Brake Valve..........................................................................................................................................................................................................................................105 Description..........................................................................................................................................................................................................................................................105 Maintenance..........................................................................................................................................................................................................................................................105 Removal..........................................................................................................................................................................................................................................................105 Installation.....................................................................................................................................................................................................................................................105 Functional Tests.................................................................................................................................................................................................................................................105 Load Sense Dump Valve....................................................................................................................................................................................................................................................106 Description..........................................................................................................................................................................................................................................................106 Maintenance..........................................................................................................................................................................................................................................................106 Removal..........................................................................................................................................................................................................................................................106 Installation.....................................................................................................................................................................................................................................................106 Functional Tests.................................................................................................................................................................................................................................................106 Cylinders................................................................................................................................................................................................................................................................108 General..............................................................................................................................................................................................................................................................108 Maintenance..........................................................................................................................................................................................................................................................108 General..........................................................................................................................................................................................................................................................108 Surface Protection for Cylinder Rods.................................................................................................................................................................................................................................108 Leakage Check....................................................................................................................................................................................................................................................108 Temperature Effects on Hydraulic Cylinders.......................................................................................................................................................................................................................109 Lift Cylinder............................................................................................................................................................................................................................................................111 Description..........................................................................................................................................................................................................................................................111 Maintenance..........................................................................................................................................................................................................................................................111 Disassembly......................................................................................................................................................................................................................................................111 Inspection.......................................................................................................................................................................................................................................................111 Assembly.........................................................................................................................................................................................................................................................111 Trombone Telescope Cylinder..............................................................................................................................................................................................................................................114 Description..........................................................................................................................................................................................................................................................114 Maintenance..........................................................................................................................................................................................................................................................114 Disassembly......................................................................................................................................................................................................................................................114 Inspection.......................................................................................................................................................................................................................................................114 Assembly.........................................................................................................................................................................................................................................................115 Upper Telescope Cylinder.................................................................................................................................................................................................................................................118 Description..........................................................................................................................................................................................................................................................118 Maintenance..........................................................................................................................................................................................................................................................119 Disassembly......................................................................................................................................................................................................................................................119 Inspection.......................................................................................................................................................................................................................................................119 Assembly.........................................................................................................................................................................................................................................................120 Axle Oscillation Lockout Cylinder........................................................................................................................................................................................................................................121 Description..........................................................................................................................................................................................................................................................121 Maintenance..........................................................................................................................................................................................................................................................121 Disassembly......................................................................................................................................................................................................................................................121 Inspection.......................................................................................................................................................................................................................................................121 Assembly.........................................................................................................................................................................................................................................................123 Steer Cylinder...........................................................................................................................................................................................................................................................124 Description..........................................................................................................................................................................................................................................................124 Maintenance..........................................................................................................................................................................................................................................................124 Disassembly......................................................................................................................................................................................................................................................124 Inspection.......................................................................................................................................................................................................................................................124 Assembly.........................................................................................................................................................................................................................................................126 Outrigger Extension Cylinder.............................................................................................................................................................................................................................................127 Description..........................................................................................................................................................................................................................................................127 Maintenance..........................................................................................................................................................................................................................................................127 Disassembly......................................................................................................................................................................................................................................................127 Inspection.......................................................................................................................................................................................................................................................127 Assembly.........................................................................................................................................................................................................................................................127 Outrigger Stabilizer Cylinder............................................................................................................................................................................................................................................130 Description..........................................................................................................................................................................................................................................................130 Maintenance..........................................................................................................................................................................................................................................................130 Disassembly......................................................................................................................................................................................................................................................130 Inspection.......................................................................................................................................................................................................................................................130 Assembly.........................................................................................................................................................................................................................................................132 Cab Tilt Cylinder........................................................................................................................................................................................................................................................133 Description..........................................................................................................................................................................................................................................................133 Maintenance..........................................................................................................................................................................................................................................................133 Disassembly......................................................................................................................................................................................................................................................133 Inspection.......................................................................................................................................................................................................................................................133 Assembly.........................................................................................................................................................................................................................................................133 Counterweight Removal Cylinder...........................................................................................................................................................................................................................................136 Description..........................................................................................................................................................................................................................................................136 Maintenance..........................................................................................................................................................................................................................................................136 Disassembly......................................................................................................................................................................................................................................................136 Inspection.......................................................................................................................................................................................................................................................136 Assembly.........................................................................................................................................................................................................................................................138 Counterweight Pin Cylinder...............................................................................................................................................................................................................................................139 Description..........................................................................................................................................................................................................................................................139 Maintenance..........................................................................................................................................................................................................................................................139 Disassembly......................................................................................................................................................................................................................................................139 Inspection.......................................................................................................................................................................................................................................................139 Assembly.........................................................................................................................................................................................................................................................139 Axle Oscillation Lockout Cylinder (CE Option)............................................................................................................................................................................................................................142 Description..........................................................................................................................................................................................................................................................142 Maintenance..........................................................................................................................................................................................................................................................142 Disassembly......................................................................................................................................................................................................................................................142 Inspection.......................................................................................................................................................................................................................................................142 Assembly.........................................................................................................................................................................................................................................................143 Park Brake Cylinder......................................................................................................................................................................................................................................................145 Description..........................................................................................................................................................................................................................................................145 SECTION 3........................................................................................................................................................................................................................................................................147 Electric System..............................................................................................................................................................................................................................................................147 Description..............................................................................................................................................................................................................................................................147 General..............................................................................................................................................................................................................................................................147 Alternator...........................................................................................................................................................................................................................................................149 Batteries............................................................................................................................................................................................................................................................149 Cab Electrical Panel.................................................................................................................................................................................................................................................149 Carrier Electrical Panel.............................................................................................................................................................................................................................................152 Maintenance..............................................................................................................................................................................................................................................................153 General..............................................................................................................................................................................................................................................................153 Visual Inspection and Replacement of Electrical Harnesses and Cables.............................................................................................................................................................................................153 General Troubleshooting..............................................................................................................................................................................................................................................155 Troubleshooting Swivel-Caused Electrical Problems....................................................................................................................................................................................................................155 Connector Troubleshooting............................................................................................................................................................................................................................................155 Alternator/Charging System Troubleshooting...........................................................................................................................................................................................................................157 Required Tools...................................................................................................................................................................................................................................................157 Visual Check.....................................................................................................................................................................................................................................................157 Engine Off Tests.................................................................................................................................................................................................................................................157 Batteries....................................................................................................................................................................................................................................................157 Load Test....................................................................................................................................................................................................................................................157 Voltage at Alternator........................................................................................................................................................................................................................................157 Battery Drain................................................................................................................................................................................................................................................157 Engine On Tests..................................................................................................................................................................................................................................................157 Output Voltage Test..........................................................................................................................................................................................................................................157 Maximum Amperage Test........................................................................................................................................................................................................................................157 Voltage Drop Test............................................................................................................................................................................................................................................158 Alternator Replacement...............................................................................................................................................................................................................................................158 Removal..........................................................................................................................................................................................................................................................158 Installation.....................................................................................................................................................................................................................................................158 Check............................................................................................................................................................................................................................................................158 Starter Replacement..................................................................................................................................................................................................................................................158 Removal..........................................................................................................................................................................................................................................................158 Installation.....................................................................................................................................................................................................................................................159 Check............................................................................................................................................................................................................................................................159 Battery Replacement..................................................................................................................................................................................................................................................159 Removal..........................................................................................................................................................................................................................................................159 Installation.....................................................................................................................................................................................................................................................159 Relay Panel Component Replacement....................................................................................................................................................................................................................................159 Accessory Relay..................................................................................................................................................................................................................................................159 Buzzer Replacement...............................................................................................................................................................................................................................................160 Gauge Cluster Replacement............................................................................................................................................................................................................................................160 Removal..........................................................................................................................................................................................................................................................160 Installation.....................................................................................................................................................................................................................................................160 Check............................................................................................................................................................................................................................................................160 Rocker Switch Replacement............................................................................................................................................................................................................................................160 Removal..........................................................................................................................................................................................................................................................160 Inspection.......................................................................................................................................................................................................................................................161 Installation.....................................................................................................................................................................................................................................................161 Check............................................................................................................................................................................................................................................................161 Ignition Switch Replacement..........................................................................................................................................................................................................................................161 Removal..........................................................................................................................................................................................................................................................161 Inspection.......................................................................................................................................................................................................................................................162 Installation.....................................................................................................................................................................................................................................................162 Check............................................................................................................................................................................................................................................................162 Turn Signal Lever and Transmission Shift Lever Replacement...........................................................................................................................................................................................................162 Removal..........................................................................................................................................................................................................................................................162 Installation.....................................................................................................................................................................................................................................................162 Check............................................................................................................................................................................................................................................................163 Windshield Wiper Assembly Replacement................................................................................................................................................................................................................................165 Removal..........................................................................................................................................................................................................................................................165 Inspection.......................................................................................................................................................................................................................................................165 Installation.....................................................................................................................................................................................................................................................165 Check............................................................................................................................................................................................................................................................166 Windshield Washer Assembly Replacement...............................................................................................................................................................................................................................166 Removal..........................................................................................................................................................................................................................................................166 Inspection.......................................................................................................................................................................................................................................................166 Installation.....................................................................................................................................................................................................................................................166 Check............................................................................................................................................................................................................................................................166 Skylight Wiper Assembly Replacement..................................................................................................................................................................................................................................166 Removal..........................................................................................................................................................................................................................................................166 Inspection.......................................................................................................................................................................................................................................................166 Installation.....................................................................................................................................................................................................................................................166 Check............................................................................................................................................................................................................................................................167 Troubleshooting......................................................................................................................................................................................................................................................167 Optional Equipment.......................................................................................................................................................................................................................................................167 Description..........................................................................................................................................................................................................................................................167 Beacon Light.........................................................................................................................................................................................................................................................167 Boom Mounted Floodlights.............................................................................................................................................................................................................................................167 Rear View Mirror.....................................................................................................................................................................................................................................................167 Air Conditioner......................................................................................................................................................................................................................................................167 SECTION 4........................................................................................................................................................................................................................................................................169 Boom.........................................................................................................................................................................................................................................................................169 Description..............................................................................................................................................................................................................................................................169 Lattice Extension....................................................................................................................................................................................................................................................169 Optional Lattice Extension Inserts...................................................................................................................................................................................................................................169 Theory of Operation......................................................................................................................................................................................................................................................169 Boom Extension.......................................................................................................................................................................................................................................................169 Boom Retraction......................................................................................................................................................................................................................................................170 Maintenance..............................................................................................................................................................................................................................................................170 Removal..............................................................................................................................................................................................................................................................170 Boom Disassembly.....................................................................................................................................................................................................................................................170 Boom Nose Sheaves....................................................................................................................................................................................................................................................178 Removal..........................................................................................................................................................................................................................................................178 Installation.....................................................................................................................................................................................................................................................179 Boom Assembly........................................................................................................................................................................................................................................................179 Installation.........................................................................................................................................................................................................................................................182 Functional Check.....................................................................................................................................................................................................................................................182 Inspection...........................................................................................................................................................................................................................................................183 Boom Alignment and Servicing.........................................................................................................................................................................................................................................183 Cam Operated Check Valve Adjustment..................................................................................................................................................................................................................................183 Stop Block Adjustment................................................................................................................................................................................................................................................183 Front Upper Pad Adjustment...........................................................................................................................................................................................................................................183 Read Side Wear Pad Adjustment........................................................................................................................................................................................................................................183 Boom Extension and Retraction Cable......................................................................................................................................................................................................................................184 Maintenance..............................................................................................................................................................................................................................................................184 Inspection...........................................................................................................................................................................................................................................................184 Adjustment...........................................................................................................................................................................................................................................................184 Telescope Circuit........................................................................................................................................................................................................................................................186 Description..........................................................................................................................................................................................................................................................186 Theory of Operation..................................................................................................................................................................................................................................................186 Maintenance..........................................................................................................................................................................................................................................................186 Troubleshooting..................................................................................................................................................................................................................................................186 Removal and Installation.........................................................................................................................................................................................................................................188 Disassembly and Assembly.........................................................................................................................................................................................................................................188 Lift Circuit.............................................................................................................................................................................................................................................................189 Description..........................................................................................................................................................................................................................................................189 Theory of Operation..................................................................................................................................................................................................................................................189 Maintenance..........................................................................................................................................................................................................................................................189 Troubleshooting..................................................................................................................................................................................................................................................189 Lift Cylinder Removal............................................................................................................................................................................................................................................191 Lift Cylinder Installation.......................................................................................................................................................................................................................................191 Auxiliary Boom Nose......................................................................................................................................................................................................................................................193 Description..........................................................................................................................................................................................................................................................193 Counterweight with Auxiliary Hoist...................................................................................................................................................................................................................................194 Removal..........................................................................................................................................................................................................................................................194 Installation.....................................................................................................................................................................................................................................................194 Counterweight without Auxiliary Hoist................................................................................................................................................................................................................................194 Removal..........................................................................................................................................................................................................................................................194 Installation.....................................................................................................................................................................................................................................................197 Installing the Bi-Fold Manual Boom Extension.............................................................................................................................................................................................................................197 Checking the Transport Condition.....................................................................................................................................................................................................................................199 Transport Condition with Lattice Extension Folded at the Side....................................................................................................................................................................................................199 If 23 ft (7 m) Section and 33 ft (10.1 m) Section are Folded at the Side:........................................................................................................................................................................................199 If the 23 ft (7 m) Section Only is Folded at the Side:...........................................................................................................................................................................................................199 If the 23 ft (7 m) Section Only is Folded at the Side:...........................................................................................................................................................................................................199 Boom Extension Erecting and Stowing Procedure............................................................................................................................................................................................................................199 Monthly Maintenance Work.................................................................................................................................................................................................................................................199 Pins.................................................................................................................................................................................................................................................................199 Hook Block...............................................................................................................................................................................................................................................................200 Description..........................................................................................................................................................................................................................................................200 Maintenance..........................................................................................................................................................................................................................................................200 Periodic Maintenance.............................................................................................................................................................................................................................................200 SECTION 5........................................................................................................................................................................................................................................................................201 Hoists and Counterweight.....................................................................................................................................................................................................................................................201 Description..............................................................................................................................................................................................................................................................201 Theory of Operation......................................................................................................................................................................................................................................................201 Maintenance..............................................................................................................................................................................................................................................................202 Warm-up Procedure....................................................................................................................................................................................................................................................202 Routine Maintenance and Inspection...................................................................................................................................................................................................................................202 Weekly or at 40 Hours of Operation (whichever comes first).......................................................................................................................................................................................................202 Every Three Months or 300 Hours of Operation (whichever comes first).............................................................................................................................................................................................202 Annually.........................................................................................................................................................................................................................................................202 Every Ten Years or 10,000 Hours (whichever comes first)..........................................................................................................................................................................................................202 Removal..............................................................................................................................................................................................................................................................202 Installation.........................................................................................................................................................................................................................................................203 Functional Check.....................................................................................................................................................................................................................................................204 Fluid Level..........................................................................................................................................................................................................................................................204 Hoist to Boom Alignment..................................................................................................................................................................................................................................................205 Preparation..........................................................................................................................................................................................................................................................205 Tools Required.......................................................................................................................................................................................................................................................205 Procedure............................................................................................................................................................................................................................................................205 Piston Motor and Control Valve...........................................................................................................................................................................................................................................206 Description..........................................................................................................................................................................................................................................................206 Maintenance..........................................................................................................................................................................................................................................................206 Removal..........................................................................................................................................................................................................................................................206 Installation.....................................................................................................................................................................................................................................................206 Idler Drum and Cable Follower............................................................................................................................................................................................................................................206 Description..........................................................................................................................................................................................................................................................206 Maintenance..........................................................................................................................................................................................................................................................207 Idler Drum.......................................................................................................................................................................................................................................................207 Removal and Disassembly......................................................................................................................................................................................................................................207 Cleaning and Inspection......................................................................................................................................................................................................................................207 Assembly and Installation....................................................................................................................................................................................................................................207 Cable Follower...................................................................................................................................................................................................................................................207 Removal and Disassembly......................................................................................................................................................................................................................................207 Cleaning and Inspection......................................................................................................................................................................................................................................207 Assembly and Installation....................................................................................................................................................................................................................................207 Complete Assembly................................................................................................................................................................................................................................................208 Removal......................................................................................................................................................................................................................................................208 Installation.................................................................................................................................................................................................................................................208 Hoist Drum Rotation Indicator System.....................................................................................................................................................................................................................................209 Description..........................................................................................................................................................................................................................................................209 Maintenance..........................................................................................................................................................................................................................................................209 General..........................................................................................................................................................................................................................................................209 Troubleshooting..................................................................................................................................................................................................................................................209 Removal..........................................................................................................................................................................................................................................................209 Installation.....................................................................................................................................................................................................................................................209 Counterweight Removal....................................................................................................................................................................................................................................................211 Removal of Standard Counterweight and Auxiliary Hoist................................................................................................................................................................................................................211 Installation of Standard Counterweight and Auxiliary Hoist Mounting Structure........................................................................................................................................................................................211 Removal of Counterweight without Auxiliary Hoist.....................................................................................................................................................................................................................211 Installation of Counterweight Without Auxiliary Hoist................................................................................................................................................................................................................213 Third Wrap Indicator (Optional— Standard on CE)..........................................................................................................................................................................................................................214 Description..........................................................................................................................................................................................................................................................214 Maintenance..........................................................................................................................................................................................................................................................214 SECTION 6........................................................................................................................................................................................................................................................................215 Swing System.................................................................................................................................................................................................................................................................215 Introduction.............................................................................................................................................................................................................................................................215 Description..........................................................................................................................................................................................................................................................215 Theory of Operation..................................................................................................................................................................................................................................................215 Swing Drive......................................................................................................................................................................................................................................................215 Swing Brake......................................................................................................................................................................................................................................................215 Maintenance..........................................................................................................................................................................................................................................................217 Troubleshooting......................................................................................................................................................................................................................................................217 Swing Motor..............................................................................................................................................................................................................................................................220 Description..........................................................................................................................................................................................................................................................220 Maintenance..........................................................................................................................................................................................................................................................220 Removal..........................................................................................................................................................................................................................................................220 Installation.....................................................................................................................................................................................................................................................220 Test.............................................................................................................................................................................................................................................................220 Swing Gearbox And Brake..................................................................................................................................................................................................................................................220 Description..........................................................................................................................................................................................................................................................220 Maintenance..........................................................................................................................................................................................................................................................220 Swing Brake......................................................................................................................................................................................................................................................220 Removal......................................................................................................................................................................................................................................................220 Installation.................................................................................................................................................................................................................................................221 Testing......................................................................................................................................................................................................................................................221 Gearbox..........................................................................................................................................................................................................................................................221 Removal......................................................................................................................................................................................................................................................221 Installation.................................................................................................................................................................................................................................................221 Servicing....................................................................................................................................................................................................................................................221 Checking the Oil Level.......................................................................................................................................................................................................................................222 Testing......................................................................................................................................................................................................................................................222 Swing Bearing............................................................................................................................................................................................................................................................222 Description..........................................................................................................................................................................................................................................................222 Maintenance..........................................................................................................................................................................................................................................................222 General..........................................................................................................................................................................................................................................................222 Torquing Turntable Bolts.........................................................................................................................................................................................................................................222 General......................................................................................................................................................................................................................................................222 Tools Required...............................................................................................................................................................................................................................................223 Inner Race Torquing..........................................................................................................................................................................................................................................223 Outer Race Torquing..........................................................................................................................................................................................................................................223 Removal..........................................................................................................................................................................................................................................................224 Inspection.......................................................................................................................................................................................................................................................225 Installation.....................................................................................................................................................................................................................................................225 Testing..........................................................................................................................................................................................................................................................226 Swivels..................................................................................................................................................................................................................................................................226 Description..........................................................................................................................................................................................................................................................226 Hydraulic Swivel.....................................................................................................................................................................................................................................................228 Description......................................................................................................................................................................................................................................................228 Theory of Operation..............................................................................................................................................................................................................................................228 Maintenance......................................................................................................................................................................................................................................................228 Removal......................................................................................................................................................................................................................................................228 Installation.................................................................................................................................................................................................................................................229 Two Port Water Swivel................................................................................................................................................................................................................................................229 Description......................................................................................................................................................................................................................................................229 Maintenance......................................................................................................................................................................................................................................................229 Removal......................................................................................................................................................................................................................................................229 Disassembly..................................................................................................................................................................................................................................................229 Cleaning and Inspection......................................................................................................................................................................................................................................230 Assembly.....................................................................................................................................................................................................................................................230 Installation.................................................................................................................................................................................................................................................230 Electrical Swivel....................................................................................................................................................................................................................................................230 Description......................................................................................................................................................................................................................................................230 Theory of Operation..............................................................................................................................................................................................................................................230 Maintenance......................................................................................................................................................................................................................................................230 Removal......................................................................................................................................................................................................................................................230 Installation.................................................................................................................................................................................................................................................231 Preventive Maintenance.......................................................................................................................................................................................................................................232 Slew Potentiometer Adjustment................................................................................................................................................................................................................................232 SECTION 7........................................................................................................................................................................................................................................................................233 Power Train..................................................................................................................................................................................................................................................................233 Engine...................................................................................................................................................................................................................................................................233 Description..........................................................................................................................................................................................................................................................233 Maintenance..........................................................................................................................................................................................................................................................234 Engine Removal...................................................................................................................................................................................................................................................234 Engine Installation..............................................................................................................................................................................................................................................234 Engine Drive Belts...............................................................................................................................................................................................................................................235 Electronic Control System................................................................................................................................................................................................................................................236 Engine Control System Switches and Indicator Lights..................................................................................................................................................................................................................236 Engine Diagnostic/Speed Control Switch...........................................................................................................................................................................................................................236 Increment/Decrement Switch.......................................................................................................................................................................................................................................236 Engine Stop Light................................................................................................................................................................................................................................................236 Engine Warning Light.............................................................................................................................................................................................................................................236 Fault Code Flashing Sequence.....................................................................................................................................................................................................................................237 The Engine Warning Light (amber) flashes at the beginning of a fault code sequence. There will be a short 1- or 2-second pause after which the number of the recorded fault code will flash in the Engine Stop Light (red). To interpret the flash code, c.......237 Diesel Particulate Filter Indicator (Tier 4 Engines Only)........................................................................................................................................................................................................237 Diesel Particulate Filter Regeneration Switch (Tier 4 Engines Only)..............................................................................................................................................................................................237 Inhibit Regeneration Indicator...................................................................................................................................................................................................................................238 High Exhaust System Temperature..................................................................................................................................................................................................................................238 Fuel System..............................................................................................................................................................................................................................................................239 Description..........................................................................................................................................................................................................................................................239 Fuel Tank........................................................................................................................................................................................................................................................239 Injection Fuel Pump..............................................................................................................................................................................................................................................240 Fuel Filter-Water Separator......................................................................................................................................................................................................................................240 Electric Lift Pump...............................................................................................................................................................................................................................................240 Maintenance..........................................................................................................................................................................................................................................................240 Fuel Tank........................................................................................................................................................................................................................................................240 Removal......................................................................................................................................................................................................................................................240 Installation.................................................................................................................................................................................................................................................240 Fuel Filter-Water Separator......................................................................................................................................................................................................................................240 Draining.....................................................................................................................................................................................................................................................240 Air Intake and Exhaust System............................................................................................................................................................................................................................................240 Description..........................................................................................................................................................................................................................................................240 Air Intake...........................................................................................................................................................................................................................................................241 Air Cleaner Checks...............................................................................................................................................................................................................................................241 Check For Filter Restriction.................................................................................................................................................................................................................................241 Filter Element Replacement.......................................................................................................................................................................................................................................243 Element Cleaning.................................................................................................................................................................................................................................................243 Air Cleaner Body.............................................................................................................................................................................................................................................243 Precleaner...................................................................................................................................................................................................................................................244 Duct Work........................................................................................................................................................................................................................................................244 Charge-Air Cooler System.............................................................................................................................................................................................................................................245 Maintenance......................................................................................................................................................................................................................................................245 Muffler..............................................................................................................................................................................................................................................................246 Removal..........................................................................................................................................................................................................................................................246 Installation.....................................................................................................................................................................................................................................................246 Water Cooling System.....................................................................................................................................................................................................................................................249 Description..........................................................................................................................................................................................................................................................249 Maintenance..........................................................................................................................................................................................................................................................249 General..........................................................................................................................................................................................................................................................249 Effects of Cooling System Neglect................................................................................................................................................................................................................................249 Overheating..................................................................................................................................................................................................................................................249 Overcooling..................................................................................................................................................................................................................................................249 Rust Prevention..................................................................................................................................................................................................................................................249 Test Equipment...................................................................................................................................................................................................................................................249 Engine Antifreeze/Coolant Fill Procedure.........................................................................................................................................................................................................................249 Cooling/SCA Maintenance Summary..................................................................................................................................................................................................................................250 6 Months or 500 Hours........................................................................................................................................................................................................................................250 1 Year or 1000 Hours.........................................................................................................................................................................................................................................250 Cleaning.........................................................................................................................................................................................................................................................250 Pressure Flushing................................................................................................................................................................................................................................................250 Component Inspection.............................................................................................................................................................................................................................................251 Radiator/Surge Tank..........................................................................................................................................................................................................................................251 Engine Water Jacket..............................................................................................................................................................................................................................................251 Water Pump.......................................................................................................................................................................................................................................................251 Fans and Belts...................................................................................................................................................................................................................................................251 Thermostat.......................................................................................................................................................................................................................................................251 Hoses and Clamps.................................................................................................................................................................................................................................................252 Test Equipment...................................................................................................................................................................................................................................................252 Antifreeze/Coolant...............................................................................................................................................................................................................................................252 Radiator Removal and Installation................................................................................................................................................................................................................................252 Removal......................................................................................................................................................................................................................................................252 Installation.................................................................................................................................................................................................................................................254 Drive Train..............................................................................................................................................................................................................................................................255 Description..........................................................................................................................................................................................................................................................255 Maintenance..........................................................................................................................................................................................................................................................255 Drive Lines......................................................................................................................................................................................................................................................255 Removal......................................................................................................................................................................................................................................................255 Installation.................................................................................................................................................................................................................................................255 Lubrication..................................................................................................................................................................................................................................................255 Transmission/torque Converter............................................................................................................................................................................................................................................257 Description..........................................................................................................................................................................................................................................................257 Theory of Operation..................................................................................................................................................................................................................................................257 Maintenance..........................................................................................................................................................................................................................................................258 General Information..............................................................................................................................................................................................................................................258 Troubleshooting..................................................................................................................................................................................................................................................258 Troubleshooting Procedures...........................................................................................................................................................................................................................................258 Hydraulic Checks.................................................................................................................................................................................................................................................259 Removal..........................................................................................................................................................................................................................................................259 Installation.....................................................................................................................................................................................................................................................260 Towing or Pushing....................................................................................................................................................................................................................................................260 Servicing the Crane After Transmission/Torque Converter Overhaul.................................................................................................................................................................................................262 Lubrication......................................................................................................................................................................................................................................................262 Type of Oil..................................................................................................................................................................................................................................................262 Capacity.....................................................................................................................................................................................................................................................262 Check Period.....................................................................................................................................................................................................................................................262 Normal Drain Period..........................................................................................................................................................................................................................................262 Optional Equipment.......................................................................................................................................................................................................................................................263 Description..........................................................................................................................................................................................................................................................263 Engine Block Heater..................................................................................................................................................................................................................................................263 SECTION 8........................................................................................................................................................................................................................................................................265 Undercarriage................................................................................................................................................................................................................................................................265 Axles....................................................................................................................................................................................................................................................................265 Description..........................................................................................................................................................................................................................................................265 Maintenance..........................................................................................................................................................................................................................................................266 Removal..........................................................................................................................................................................................................................................................266 Cleaning.........................................................................................................................................................................................................................................................266 Installation.....................................................................................................................................................................................................................................................266 Wheel Alignment Check Procedure..................................................................................................................................................................................................................................267 Rear Wheels Not Centered Switch Adjustment Procedure.............................................................................................................................................................................................................267 Wheels and Tires.....................................................................................................................................................................................................................................................268 Description......................................................................................................................................................................................................................................................268 Maintenance......................................................................................................................................................................................................................................................268 Mounting Wheel Assemblies....................................................................................................................................................................................................................................268 Typical Wear Patterns................................................................................................................................................................................................................................................269 Incorrect Tire Pressure..........................................................................................................................................................................................................................................269 Incorrect Camber.................................................................................................................................................................................................................................................269 Incorrect Toe and Axle Alignment.................................................................................................................................................................................................................................269 Incorrect Caster and Wheel Imbalance.............................................................................................................................................................................................................................269 Cuts in the Tire Tread...........................................................................................................................................................................................................................................270 Spot Wear........................................................................................................................................................................................................................................................270 Feathered Edges..................................................................................................................................................................................................................................................270 Cupping..........................................................................................................................................................................................................................................................270 Steering Systems.........................................................................................................................................................................................................................................................271 Description..........................................................................................................................................................................................................................................................271 Front Steering System............................................................................................................................................................................................................................................271 Rear Steering System.............................................................................................................................................................................................................................................271 Secondary Steering System (CE Units).............................................................................................................................................................................................................................271 Theory of Operation..................................................................................................................................................................................................................................................271 Front Steering System............................................................................................................................................................................................................................................271 Rear Steering System.............................................................................................................................................................................................................................................271 Secondary Steering System (CE Units).............................................................................................................................................................................................................................271 Maintenance..........................................................................................................................................................................................................................................................272 Front Steering System............................................................................................................................................................................................................................................272 Troubleshooting..............................................................................................................................................................................................................................................272 Functional Check.............................................................................................................................................................................................................................................273 Rear Steering System.....................................................................................................................................................................................................................................................273 Troubleshooting......................................................................................................................................................................................................................................................273 Hydraulic Pumps......................................................................................................................................................................................................................................................274 Description......................................................................................................................................................................................................................................................274 Front Steer..................................................................................................................................................................................................................................................274 Rear Steer...................................................................................................................................................................................................................................................274 Front Steering Control Valve.........................................................................................................................................................................................................................................274 Description......................................................................................................................................................................................................................................................274 Maintenance......................................................................................................................................................................................................................................................274 Removal......................................................................................................................................................................................................................................................274 Installation.................................................................................................................................................................................................................................................274 Rear Steer/ Axle Lockout/Fan Drive Valve.............................................................................................................................................................................................................................274 Description......................................................................................................................................................................................................................................................274 Maintenance......................................................................................................................................................................................................................................................274 Removal......................................................................................................................................................................................................................................................274 Installation.................................................................................................................................................................................................................................................275 Functional Check.............................................................................................................................................................................................................................................275 Steer Cylinders......................................................................................................................................................................................................................................................275 Description......................................................................................................................................................................................................................................................275 Maintenance......................................................................................................................................................................................................................................................275 Removal......................................................................................................................................................................................................................................................275 Installation.................................................................................................................................................................................................................................................275 Rear Axle Oscillation Lockout System.....................................................................................................................................................................................................................................275 Description..........................................................................................................................................................................................................................................................275 Theory of Operation..................................................................................................................................................................................................................................................275 Axle Oscillation Lockout Cylinders...................................................................................................................................................................................................................................277 Description......................................................................................................................................................................................................................................................277 Maintenance......................................................................................................................................................................................................................................................277 Removal......................................................................................................................................................................................................................................................277 Installation.................................................................................................................................................................................................................................................277 Axle Oscillation Lockout Valve.......................................................................................................................................................................................................................................277 Description......................................................................................................................................................................................................................................................277 Maintenance......................................................................................................................................................................................................................................................277 Removal......................................................................................................................................................................................................................................................277 Installation.................................................................................................................................................................................................................................................277 Brake System.............................................................................................................................................................................................................................................................278 Description..........................................................................................................................................................................................................................................................278 Service Brakes...................................................................................................................................................................................................................................................278 Parking Brake....................................................................................................................................................................................................................................................278 Theory of Operation..................................................................................................................................................................................................................................................278 Service Brakes...................................................................................................................................................................................................................................................278 Parking Brake....................................................................................................................................................................................................................................................278 Maintenance..........................................................................................................................................................................................................................................................279 Troubleshooting..................................................................................................................................................................................................................................................279 General..........................................................................................................................................................................................................................................................279 Bleeding the Brake System........................................................................................................................................................................................................................................279 Pressure Bleeding the Brake System...........................................................................................................................................................................................................................280 Manually Bleeding the Brake System...........................................................................................................................................................................................................................280 Service Brakes...........................................................................................................................................................................................................................................................280 Description..........................................................................................................................................................................................................................................................280 Maintenance..........................................................................................................................................................................................................................................................280 Removal..........................................................................................................................................................................................................................................................280 Linings......................................................................................................................................................................................................................................................280 Caliper......................................................................................................................................................................................................................................................280 Disassembly......................................................................................................................................................................................................................................................281 Caliper......................................................................................................................................................................................................................................................281 Inspection.......................................................................................................................................................................................................................................................282 Periodic On-Vehicle..........................................................................................................................................................................................................................................282 Shoes, Linings, and End Plates...............................................................................................................................................................................................................................282 Caliper for Leaks............................................................................................................................................................................................................................................282 Dust Seals...................................................................................................................................................................................................................................................283 Disc.........................................................................................................................................................................................................................................................283 Caliper Parts................................................................................................................................................................................................................................................283 Cleaning.........................................................................................................................................................................................................................................................284 Corrosion Protection.................................................................................................................................................................................................................................................284 Assembly.........................................................................................................................................................................................................................................................284 Caliper......................................................................................................................................................................................................................................................284 Installation.....................................................................................................................................................................................................................................................285 Linings......................................................................................................................................................................................................................................................285 Caliper......................................................................................................................................................................................................................................................285 Parking Brake Actuator...................................................................................................................................................................................................................................................286 Description..........................................................................................................................................................................................................................................................286 Maintenance..........................................................................................................................................................................................................................................................286 Removal..........................................................................................................................................................................................................................................................286 Installation.....................................................................................................................................................................................................................................................286 Adjustment.......................................................................................................................................................................................................................................................286 Parking Brake............................................................................................................................................................................................................................................................287 Description..........................................................................................................................................................................................................................................................287 Maintenance..........................................................................................................................................................................................................................................................287 Removal..........................................................................................................................................................................................................................................................287 Installation.....................................................................................................................................................................................................................................................287 Park Brake Solenoid Valve................................................................................................................................................................................................................................................290 Description..........................................................................................................................................................................................................................................................290 Maintenance..........................................................................................................................................................................................................................................................290 Removal..........................................................................................................................................................................................................................................................290 Installation.....................................................................................................................................................................................................................................................290 Outriggers...............................................................................................................................................................................................................................................................291 Outrigger Circuit....................................................................................................................................................................................................................................................291 Theory of Operation..............................................................................................................................................................................................................................................291 Maintenance......................................................................................................................................................................................................................................................292 Troubleshooting..............................................................................................................................................................................................................................................292 Outrigger Beam.......................................................................................................................................................................................................................................................295 Description......................................................................................................................................................................................................................................................295 Theory of Operation..............................................................................................................................................................................................................................................295 Maintenance......................................................................................................................................................................................................................................................295 Removal......................................................................................................................................................................................................................................................295 Inspection...................................................................................................................................................................................................................................................295 Installation.................................................................................................................................................................................................................................................296 Wear Pad Adjustment..........................................................................................................................................................................................................................................296 Extension Cylinder...................................................................................................................................................................................................................................................299 Description......................................................................................................................................................................................................................................................299 Maintenance......................................................................................................................................................................................................................................................299 Removal......................................................................................................................................................................................................................................................299 Installation.................................................................................................................................................................................................................................................299 Functional Check.............................................................................................................................................................................................................................................299 Outrigger Monitoring System (Optional— Standard in North America)....................................................................................................................................................................................................300 Description......................................................................................................................................................................................................................................................300 Removal......................................................................................................................................................................................................................................................300 Installation.................................................................................................................................................................................................................................................300 Stabilizer Cylinder..................................................................................................................................................................................................................................................300 Description......................................................................................................................................................................................................................................................300 Maintenance......................................................................................................................................................................................................................................................300 Removal......................................................................................................................................................................................................................................................300 Installation.................................................................................................................................................................................................................................................301 Functional Check.............................................................................................................................................................................................................................................301 Outrigger Stabilizer Cylinder Internal Leak Test.............................................................................................................................................................................................................301 Checking Cylinder for Internal Piston Seal Leak..............................................................................................................................................................................................................301 Testing Pilot Operated Check Valve For Leakage...............................................................................................................................................................................................................302 Outrigger Control Valves.............................................................................................................................................................................................................................................302 Description......................................................................................................................................................................................................................................................302 Pilot Operated Check Valve...................................................................................................................................................................................................................................302 Integrated Outrigger/Rear Steer Valve........................................................................................................................................................................................................................302 Outrigger Control Manifold...................................................................................................................................................................................................................................302 Optional Equipment.......................................................................................................................................................................................................................................................302 Pintle Hook..........................................................................................................................................................................................................................................................302 Secondary Front Steer (CE Option)....................................................................................................................................................................................................................................302 SECTION 9........................................................................................................................................................................................................................................................................303 Lubrication..................................................................................................................................................................................................................................................................303 General..................................................................................................................................................................................................................................................................303 Environmental Protection.................................................................................................................................................................................................................................................303 Lubrication Intervals....................................................................................................................................................................................................................................................303 Standard Lubricants Package..............................................................................................................................................................................................................................................305 Arctic Conditions........................................................................................................................................................................................................................................................306 Below –18°C (0°F)....................................................................................................................................................................................................................................................306 Down to –40°F........................................................................................................................................................................................................................................................306 ALL Weather Package & Lubricants.................................................................................................................................................................................................................................306 Surface Protection for Cylinder Rods.....................................................................................................................................................................................................................................307 Wire Rope Lubrication....................................................................................................................................................................................................................................................308 Lubrication Points.......................................................................................................................................................................................................................................................308 CraneLUBE............................................................................................................................................................................................................................................................308 Safety...............................................................................................................................................................................................................................................................308 Steering and Suspension..............................................................................................................................................................................................................................................309 Axles................................................................................................................................................................................................................................................................311 Drive Train..........................................................................................................................................................................................................................................................313 Drive Train (continued)..............................................................................................................................................................................................................................................315 Turntable............................................................................................................................................................................................................................................................317 Cab Tilt.............................................................................................................................................................................................................................................................319 Outriggers...........................................................................................................................................................................................................................................................321 Boom.................................................................................................................................................................................................................................................................323 Boom (continued).....................................................................................................................................................................................................................................................325 Boom (continued).....................................................................................................................................................................................................................................................327 Hoist................................................................................................................................................................................................................................................................329 Hydraulic............................................................................................................................................................................................................................................................331 Carwell® Rust Inhibitor..............................................................................................................................................................................................................................................333 Protecting Cranes From Rusting.......................................................................................................................................................................................................................................333 Cleaning Procedures..................................................................................................................................................................................................................................................333 Inspection and Repair................................................................................................................................................................................................................................................334 Application..........................................................................................................................................................................................................................................................334 Areas of Application.................................................................................................................................................................................................................................................334
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