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Grove Crane RT880E Service & Maintenance Manual – PDF DOWNLOAD
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Description
Grove Crane RT880E Service & Maintenance Manual – PDF DOWNLOAD
FILE DETAILS:
Grove Crane RT880E Service & Maintenance Manual – PDF DOWNLOAD
Language : English
Pages : 348
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Grove Crane RT880E Service & Maintenance Manual – PDF DOWNLOAD
GENERAL :
This Manual provides important information concerning your Grove Crane.
Overview of Manuals:
Before placing the crane in service, take time to thoroughly familiarize yourself with the contents of this manual. After all sections have been read and understood, retain the manual for future reference in a readily accessible location.
Customer Support:
Manitowoc and our Distributor Network want to ensure your satisfaction with our products and customer support. Your local distributor is the best equipped and most knowledgeable to assist you for parts, service and warranty issues. They have the facilities, parts, factory trained personnel, and the information to assist you in a timely manner. We request that you first contact them for assistance. If you feel you need factory assistance, please ask the distributor’s service management to coordinate the contact on your behalf.
General Crane Design:
The Grove crane has been designed for maximum performance with minimum maintenance. With proper care, years of trouble-free service can be expected.
Constant improvement and engineering progress makes it necessary that we reserve the right to make specification and equipment changes without notice.
Manitowoc and our Distributor Network want to ensure your satisfaction with our products and customer support. Your local distributor is the best equipped and most knowledgeable to assist you for parts, service and warranty issues. They have the facilities, parts, factory trained personnel, and the information to assist you in a timely manner. We request that you first contact them for assistance. If you feel you need factory assistance, please ask the distributor’s service management to coordinate the contact on your behalf.
General Crane Design:
The Grove crane has been designed for maximum performance with minimum maintenance. With proper care, years of trouble-free service can be expected.
Constant improvement and engineering progress makes it necessary that we reserve the right to make specification and equipment changes without notice.
TABLE OF CONTENTS:
Grove Crane RT880E Service & Maintenance Manual – 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...................................................................................................................................................................................................................................................... 58 Pressure Setting Procedures.............................................................................................................................................................................................................................................. 59 Procedure A - Main Control Valve Pressure for Hoists, Boom Lift, Telescope - Check/ Adjust........................................................................................................................................................................... 60 Extend........................................................................................................................................................................................................................................................... 60 Retract.......................................................................................................................................................................................................................................................... 60 Procedure B - Outrigger Pressures - Adjust........................................................................................................................................................................................................................... 60 Procedure C - Oil Cooler Motor Pressure - Adjust..................................................................................................................................................................................................................... 60 Procedure D - Set Service Brake Accumulator Charge Valve Limits - Check/ Adjust...................................................................................................................................................................................... 61 Procedure E - Accumulator Pre-Charge Pressure - Check................................................................................................................................................................................................................ 61 Procedure F - Pre-Charging the Accumulator........................................................................................................................................................................................................................... 61 Procedure G - Front Steer Pressure - Check/ Adjust................................................................................................................................................................................................................... 61 Procedure H - Swing Work Port Pressure - Check/Adjust................................................................................................................................................................................................................ 62 Procedure I - Swing Brake Release Pressure - Check/Adjust............................................................................................................................................................................................................ 62 Procedure J - Controller Supply Pressure - Check/Adjust.............................................................................................................................................................................................................. 62 Procedure K - Counterweight Removal Cylinder Extend/Retract Pressure - Check......................................................................................................................................................................................... 62 Procedure L - Cab Tilt Cylinder Extend/ Retract and Counterweight Pin Removal Pressure - Check/Adjust................................................................................................................................................................ 62 Valves................................................................................................................................................................................................................................................................... 69 General.............................................................................................................................................................................................................................................................. 69 Directional Control Valves............................................................................................................................................................................................................................................... 73 Description.......................................................................................................................................................................................................................................................... 73 Maintenance.......................................................................................................................................................................................................................................................... 73 Boom Lift/Telescope/Hoist Valve Bank Removal..................................................................................................................................................................................................................... 73 Boom Lift/Telescope/Hoist Valve Bank Installation................................................................................................................................................................................................................ 73 Counterweight Removal Valve Bank Removal......................................................................................................................................................................................................................... 73 Counterweight Removal Valve Bank Installation.................................................................................................................................................................................................................... 73 Functional Check (All Valve Banks)............................................................................................................................................................................................................................... 74 Function Check - RCL Lockout Valves.............................................................................................................................................................................................................................. 74 Front Steer/Swing/Brake Manifold......................................................................................................................................................................................................................................... 80 Description.......................................................................................................................................................................................................................................................... 80 Maintenance.......................................................................................................................................................................................................................................................... 80 Removal.......................................................................................................................................................................................................................................................... 80 Installation..................................................................................................................................................................................................................................................... 80 Steering Control Valve................................................................................................................................................................................................................................................... 84 Description.......................................................................................................................................................................................................................................................... 84 Maintenance.......................................................................................................................................................................................................................................................... 84 Removal.......................................................................................................................................................................................................................................................... 84 Installation..................................................................................................................................................................................................................................................... 84 Hydraulic Remote Control Valve........................................................................................................................................................................................................................................... 85 Description.......................................................................................................................................................................................................................................................... 85 Single Axis Controller........................................................................................................................................................................................................................................... 85 Dual Axis Controller............................................................................................................................................................................................................................................. 85 Maintenance.......................................................................................................................................................................................................................................................... 85 Armrest Control Valve Removal.................................................................................................................................................................................................................................... 85 Armrest Control Valve Installation............................................................................................................................................................................................................................... 85 Armrest Control Valve Functional Check........................................................................................................................................................................................................................... 85 Telescope Pedal Control Valve Removal............................................................................................................................................................................................................................ 85 Telescope Pedal Control Valve Installation....................................................................................................................................................................................................................... 85 Telescope Pedal Control Valve Functional Check................................................................................................................................................................................................................... 85 Swing Power Brake Valve With Treadle Pedal............................................................................................................................................................................................................................... 89 Description.......................................................................................................................................................................................................................................................... 89 Maintenance.......................................................................................................................................................................................................................................................... 89 Removal.......................................................................................................................................................................................................................................................... 89 Installation..................................................................................................................................................................................................................................................... 89 Function Check................................................................................................................................................................................................................................................... 89 2 Speed Swing Valve...................................................................................................................................................................................................................................................... 90 Description.......................................................................................................................................................................................................................................................... 90 Maintenance.......................................................................................................................................................................................................................................................... 90 Removal.......................................................................................................................................................................................................................................................... 90 Installation..................................................................................................................................................................................................................................................... 90 Tandem Brake Valve with Treadle Pedal.................................................................................................................................................................................................................................... 91 Description.......................................................................................................................................................................................................................................................... 91 Maintenance.......................................................................................................................................................................................................................................................... 91 Removal.......................................................................................................................................................................................................................................................... 91 Installation..................................................................................................................................................................................................................................................... 91 Dual Accumulator Charge Valve............................................................................................................................................................................................................................................ 92 Description.......................................................................................................................................................................................................................................................... 92 Maintenance.......................................................................................................................................................................................................................................................... 92 Removal.......................................................................................................................................................................................................................................................... 92 Installation..................................................................................................................................................................................................................................................... 92 Hydraulic Accumulator Service Brake...................................................................................................................................................................................................................................... 94 Description.......................................................................................................................................................................................................................................................... 94 Maintenance.......................................................................................................................................................................................................................................................... 94 Removal.......................................................................................................................................................................................................................................................... 94 Installation..................................................................................................................................................................................................................................................... 94 Servicing........................................................................................................................................................................................................................................................ 94 Holding Valves........................................................................................................................................................................................................................................................... 95 Description.......................................................................................................................................................................................................................................................... 95 Lower Lift Cylinder Holding Valve................................................................................................................................................................................................................................ 95 Removal...................................................................................................................................................................................................................................................... 95 Installation................................................................................................................................................................................................................................................. 95 Maintenance.......................................................................................................................................................................................................................................................... 96 Removal.......................................................................................................................................................................................................................................................... 96 Installation..................................................................................................................................................................................................................................................... 96 Cross Axle Differential Lock Valve....................................................................................................................................................................................................................................... 97 Description.......................................................................................................................................................................................................................................................... 97 Maintenance.......................................................................................................................................................................................................................................................... 97 Removal.......................................................................................................................................................................................................................................................... 97 Installation..................................................................................................................................................................................................................................................... 97 Outrigger Control Manifold............................................................................................................................................................................................................................................... 98 Description.......................................................................................................................................................................................................................................................... 98 Maintenance.......................................................................................................................................................................................................................................................... 98 Removal.......................................................................................................................................................................................................................................................... 98 Inspection....................................................................................................................................................................................................................................................... 98 Installation..................................................................................................................................................................................................................................................... 98 Functional Check................................................................................................................................................................................................................................................. 98 Pilot Operated Check Valve...............................................................................................................................................................................................................................................101 Description..........................................................................................................................................................................................................................................................101 Maintenance..........................................................................................................................................................................................................................................................101 Removal..........................................................................................................................................................................................................................................................101 Installation.....................................................................................................................................................................................................................................................101 Axle Lockout, Rear Steer and Oil Cooler Fan Motor Control Manifold.......................................................................................................................................................................................................102 Description..........................................................................................................................................................................................................................................................102 Maintenance..........................................................................................................................................................................................................................................................102 Removal..........................................................................................................................................................................................................................................................102 Installation.....................................................................................................................................................................................................................................................102 Check Valves.............................................................................................................................................................................................................................................................105 Description..........................................................................................................................................................................................................................................................105 Maintenance..........................................................................................................................................................................................................................................................105 Removal..........................................................................................................................................................................................................................................................105 Installation.....................................................................................................................................................................................................................................................105 Range Shift/Parking Brake Valve..........................................................................................................................................................................................................................................106 Description..........................................................................................................................................................................................................................................................106 Maintenance..........................................................................................................................................................................................................................................................106 Removal..........................................................................................................................................................................................................................................................106 Installation.....................................................................................................................................................................................................................................................106 Functional Tests.................................................................................................................................................................................................................................................106 Load Sense Dump Valve....................................................................................................................................................................................................................................................107 Description..........................................................................................................................................................................................................................................................107 Maintenance..........................................................................................................................................................................................................................................................107 Removal..........................................................................................................................................................................................................................................................107 Installation.....................................................................................................................................................................................................................................................107 Functional Tests.................................................................................................................................................................................................................................................107 Cylinders................................................................................................................................................................................................................................................................109 General..............................................................................................................................................................................................................................................................109 Maintenance..........................................................................................................................................................................................................................................................109 General..........................................................................................................................................................................................................................................................109 Surface Protection for Cylinder Rods.................................................................................................................................................................................................................................109 Leakage Check....................................................................................................................................................................................................................................................109 Temperature Effects on Hydraulic Cylinders.......................................................................................................................................................................................................................110 Lift Cylinder............................................................................................................................................................................................................................................................112 Description..........................................................................................................................................................................................................................................................112 Maintenance..........................................................................................................................................................................................................................................................112 Disassembly......................................................................................................................................................................................................................................................112 Inspection.......................................................................................................................................................................................................................................................112 Assembly.........................................................................................................................................................................................................................................................112 Trombone Telescope Cylinder..............................................................................................................................................................................................................................................115 Description..........................................................................................................................................................................................................................................................115 Maintenance..........................................................................................................................................................................................................................................................115 Disassembly......................................................................................................................................................................................................................................................115 Inspection.......................................................................................................................................................................................................................................................115 Assembly.........................................................................................................................................................................................................................................................116 Upper Telescope Cylinder.................................................................................................................................................................................................................................................119 Description..........................................................................................................................................................................................................................................................119 Maintenance..........................................................................................................................................................................................................................................................120 Disassembly......................................................................................................................................................................................................................................................120 Inspection.......................................................................................................................................................................................................................................................120 Assembly.........................................................................................................................................................................................................................................................121 Axle Oscillation Lockout Cylinder........................................................................................................................................................................................................................................123 Description..........................................................................................................................................................................................................................................................123 Maintenance..........................................................................................................................................................................................................................................................123 Disassembly......................................................................................................................................................................................................................................................123 Inspection.......................................................................................................................................................................................................................................................123 Assembly.........................................................................................................................................................................................................................................................125 Steer Cylinder...........................................................................................................................................................................................................................................................126 Description..........................................................................................................................................................................................................................................................126 Maintenance..........................................................................................................................................................................................................................................................126 Disassembly......................................................................................................................................................................................................................................................126 Inspection.......................................................................................................................................................................................................................................................126 Assembly.........................................................................................................................................................................................................................................................128 Outrigger Extension Cylinder.............................................................................................................................................................................................................................................129 Description..........................................................................................................................................................................................................................................................129 Maintenance..........................................................................................................................................................................................................................................................129 Disassembly......................................................................................................................................................................................................................................................129 Inspection.......................................................................................................................................................................................................................................................129 Assembly.........................................................................................................................................................................................................................................................129 Outrigger jack Cylinder..................................................................................................................................................................................................................................................132 Description..........................................................................................................................................................................................................................................................132 Maintenance..........................................................................................................................................................................................................................................................132 Disassembly......................................................................................................................................................................................................................................................132 Inspection.......................................................................................................................................................................................................................................................132 Assembly.........................................................................................................................................................................................................................................................134 Cab Tilt Cylinder........................................................................................................................................................................................................................................................135 Description..........................................................................................................................................................................................................................................................135 Maintenance..........................................................................................................................................................................................................................................................135 Disassembly......................................................................................................................................................................................................................................................135 Inspection.......................................................................................................................................................................................................................................................135 Assembly.........................................................................................................................................................................................................................................................135 Counterweight Removal Cylinder...........................................................................................................................................................................................................................................138 Description..........................................................................................................................................................................................................................................................138 Maintenance..........................................................................................................................................................................................................................................................138 Disassembly......................................................................................................................................................................................................................................................138 Inspection.......................................................................................................................................................................................................................................................138 Assembly.........................................................................................................................................................................................................................................................140 Counterweight Pin Cylinder...............................................................................................................................................................................................................................................141 Description..........................................................................................................................................................................................................................................................141 Maintenance..........................................................................................................................................................................................................................................................141 Disassembly......................................................................................................................................................................................................................................................141 Inspection.......................................................................................................................................................................................................................................................141 Assembly.........................................................................................................................................................................................................................................................141 Axle Oscillation Lockout Cylinder (CE Option)............................................................................................................................................................................................................................144 Description..........................................................................................................................................................................................................................................................144 Maintenance..........................................................................................................................................................................................................................................................144 Disassembly......................................................................................................................................................................................................................................................144 Inspection.......................................................................................................................................................................................................................................................144 Assembly.........................................................................................................................................................................................................................................................145 Park Brake Cylinder......................................................................................................................................................................................................................................................146 Description..........................................................................................................................................................................................................................................................146 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 Cold Weather Operation...............................................................................................................................................................................................................................................167 Component Coolant Heater.........................................................................................................................................................................................................................................167 Troubleshooting..................................................................................................................................................................................................................................................168 Maintenance Instructions.........................................................................................................................................................................................................................................168 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 Installing the Bi-Fold Manual Boom Extension.............................................................................................................................................................................................................................193 Checking the Transport Condition.....................................................................................................................................................................................................................................196 Transport Condition with Lattice Extension Folded at the Side....................................................................................................................................................................................................196 If 23 ft (7 m) Section and 33 ft (10.1 m) Section are Folded at the Side:........................................................................................................................................................................................196 If the 23 ft (7 m) Section Only is Folded at the Side:...........................................................................................................................................................................................................196 If the 23 ft (7 m) Section Only is Folded at the Side:...........................................................................................................................................................................................................196 Boom Extension Erecting and Stowing Procedure............................................................................................................................................................................................................................196 Monthly Maintenance Work.................................................................................................................................................................................................................................................196 Pins.................................................................................................................................................................................................................................................................196 Hook Block...............................................................................................................................................................................................................................................................197 Description..........................................................................................................................................................................................................................................................197 Maintenance..........................................................................................................................................................................................................................................................197 Periodic Maintenance.............................................................................................................................................................................................................................................197 SECTION 5........................................................................................................................................................................................................................................................................199 Hoists and Counterweight.....................................................................................................................................................................................................................................................199 Description..............................................................................................................................................................................................................................................................199 Theory of Operation......................................................................................................................................................................................................................................................199 Maintenance..............................................................................................................................................................................................................................................................200 Warm-up Procedure....................................................................................................................................................................................................................................................200 Routine Maintenance and Inspection...................................................................................................................................................................................................................................200 Weekly or at 40 Hours of Operation (whichever comes first).......................................................................................................................................................................................................200 Every Three Months or 300 Hours of Operation (whichever comes first).............................................................................................................................................................................................200 Annually.........................................................................................................................................................................................................................................................200 Every Ten Years or 10,000 Hours (whichever comes first)..........................................................................................................................................................................................................200 Removal..............................................................................................................................................................................................................................................................200 Installation.........................................................................................................................................................................................................................................................201 Functional Check.....................................................................................................................................................................................................................................................202 Fluid Level..........................................................................................................................................................................................................................................................202 Hoist to Boom Alignment..................................................................................................................................................................................................................................................203 Preparation..........................................................................................................................................................................................................................................................203 Tools Required.......................................................................................................................................................................................................................................................203 Procedure............................................................................................................................................................................................................................................................203 Piston Motor and Control Valve...........................................................................................................................................................................................................................................204 Description..........................................................................................................................................................................................................................................................204 Maintenance..........................................................................................................................................................................................................................................................204 Removal..........................................................................................................................................................................................................................................................204 Installation.....................................................................................................................................................................................................................................................204 Idler Drum and Cable Follower............................................................................................................................................................................................................................................204 Description..........................................................................................................................................................................................................................................................204 Maintenance..........................................................................................................................................................................................................................................................205 Idler Drum.......................................................................................................................................................................................................................................................205 Removal and Disassembly......................................................................................................................................................................................................................................205 Cleaning and Inspection......................................................................................................................................................................................................................................205 Assembly and Installation....................................................................................................................................................................................................................................205 Cable Follower...................................................................................................................................................................................................................................................205 Removal and Disassembly......................................................................................................................................................................................................................................205 Cleaning and Inspection......................................................................................................................................................................................................................................205 Assembly and Installation....................................................................................................................................................................................................................................205 Complete Assembly................................................................................................................................................................................................................................................206 Removal......................................................................................................................................................................................................................................................206 Installation.................................................................................................................................................................................................................................................206 Hoist Drum Rotation Indicator System.....................................................................................................................................................................................................................................207 Description..........................................................................................................................................................................................................................................................207 Maintenance..........................................................................................................................................................................................................................................................207 General..........................................................................................................................................................................................................................................................207 Troubleshooting..................................................................................................................................................................................................................................................207 Removal..........................................................................................................................................................................................................................................................207 Installation.....................................................................................................................................................................................................................................................207 Counterweight Removal....................................................................................................................................................................................................................................................209 Removal of Standard Counterweight and Auxiliary Hoist................................................................................................................................................................................................................209 Installation of Standard Counterweight and Auxiliary Hoist Mounting Structure........................................................................................................................................................................................209 Removal of Counterweight without Auxiliary Hoist.....................................................................................................................................................................................................................209 Installation of Counterweight Without Auxiliary Hoist................................................................................................................................................................................................................211 Third Wrap Indicator (Optional— Standard on CE)..........................................................................................................................................................................................................................213 Description..........................................................................................................................................................................................................................................................213 Maintenance..........................................................................................................................................................................................................................................................213 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..................................................................................................................................................................................................................................................230 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 Belt................................................................................................................................................................................................................................................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 Exhaust System Cleaning Indicator................................................................................................................................................................................................................................237 Exhaust System Cleaning Switch...................................................................................................................................................................................................................................237 Inhibit Exhaust System Cleaning Indicator........................................................................................................................................................................................................................238 High Exhaust System Temperature..................................................................................................................................................................................................................................238 Fuel System..............................................................................................................................................................................................................................................................239 Description..........................................................................................................................................................................................................................................................239 Fuel Tank........................................................................................................................................................................................................................................................239 Injection Fuel Pump..............................................................................................................................................................................................................................................240 Fuel Filter-Water Separator......................................................................................................................................................................................................................................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 Exhaust System.......................................................................................................................................................................................................................................................246 Tier 3...........................................................................................................................................................................................................................................................246 Removal..........................................................................................................................................................................................................................................................246 Installation.....................................................................................................................................................................................................................................................246 Tier 4...........................................................................................................................................................................................................................................................247 Removal......................................................................................................................................................................................................................................................247 Installation.................................................................................................................................................................................................................................................247 Diesel Exhaust Fluid (DEF) System....................................................................................................................................................................................................................................249 DEF Tank.........................................................................................................................................................................................................................................................249 Removal......................................................................................................................................................................................................................................................249 Installation.................................................................................................................................................................................................................................................249 DEF Supply Module................................................................................................................................................................................................................................................249 Removal......................................................................................................................................................................................................................................................249 Installation.................................................................................................................................................................................................................................................250 Filter Replacement...........................................................................................................................................................................................................................................250 Clean and Inspect for Reuse..................................................................................................................................................................................................................................250 Filter Installation..........................................................................................................................................................................................................................................251 Water Cooling System.....................................................................................................................................................................................................................................................251 Description..........................................................................................................................................................................................................................................................251 Maintenance..........................................................................................................................................................................................................................................................251 General..........................................................................................................................................................................................................................................................251 Effects of Cooling System Neglect................................................................................................................................................................................................................................251 Overheating..................................................................................................................................................................................................................................................251 Overcooling..................................................................................................................................................................................................................................................251 Rust Prevention..................................................................................................................................................................................................................................................251 Test Equipment...................................................................................................................................................................................................................................................252 Engine Antifreeze/Coolant Fill Procedure.........................................................................................................................................................................................................................252 Cooling/SCA Maintenance Summary..................................................................................................................................................................................................................................252 6 Months or 500 Hours........................................................................................................................................................................................................................................252 1 Year or 1000 Hours.........................................................................................................................................................................................................................................252 Cleaning.........................................................................................................................................................................................................................................................252 Pressure Flushing................................................................................................................................................................................................................................................253 Component Inspection.............................................................................................................................................................................................................................................253 Radiator/Surge Tank..........................................................................................................................................................................................................................................253 Engine Water Jacket..............................................................................................................................................................................................................................................253 Water Pump.......................................................................................................................................................................................................................................................254 Fans and Belts...................................................................................................................................................................................................................................................254 Thermostat.......................................................................................................................................................................................................................................................254 Hoses and Clamps.................................................................................................................................................................................................................................................254 Test Equipment...................................................................................................................................................................................................................................................254 Antifreeze/Coolant...............................................................................................................................................................................................................................................254 Radiator Removal and Installation................................................................................................................................................................................................................................254 Removal......................................................................................................................................................................................................................................................254 Installation.................................................................................................................................................................................................................................................256 Drive Train..............................................................................................................................................................................................................................................................257 Description..........................................................................................................................................................................................................................................................257 Maintenance..........................................................................................................................................................................................................................................................257 Drive Lines......................................................................................................................................................................................................................................................257 Removal......................................................................................................................................................................................................................................................257 Installation.................................................................................................................................................................................................................................................257 Lubrication..................................................................................................................................................................................................................................................257 Transmission/torque Converter............................................................................................................................................................................................................................................259 Description..........................................................................................................................................................................................................................................................259 Theory of Operation..................................................................................................................................................................................................................................................259 Maintenance..........................................................................................................................................................................................................................................................260 General Information..............................................................................................................................................................................................................................................260 Troubleshooting..................................................................................................................................................................................................................................................260 Troubleshooting Procedures...........................................................................................................................................................................................................................................260 Hydraulic Checks.................................................................................................................................................................................................................................................261 Removal..........................................................................................................................................................................................................................................................261 Installation.....................................................................................................................................................................................................................................................262 Towing or Pushing....................................................................................................................................................................................................................................................262 Servicing the Crane After Transmission/Torque Converter Overhaul.................................................................................................................................................................................................264 Lubrication......................................................................................................................................................................................................................................................264 Type of Oil..................................................................................................................................................................................................................................................264 Capacity.....................................................................................................................................................................................................................................................264 Check Period.....................................................................................................................................................................................................................................................264 Normal Drain Period..........................................................................................................................................................................................................................................264 Engine Block Heater......................................................................................................................................................................................................................................................265 SECTION 8........................................................................................................................................................................................................................................................................267 Undercarriage................................................................................................................................................................................................................................................................267 Axles....................................................................................................................................................................................................................................................................267 Description..........................................................................................................................................................................................................................................................267 Maintenance..........................................................................................................................................................................................................................................................268 Removal..........................................................................................................................................................................................................................................................268 Cleaning.........................................................................................................................................................................................................................................................268 Installation.....................................................................................................................................................................................................................................................268 Wheel Alignment Check Procedure..................................................................................................................................................................................................................................269 Rear Wheels Not Centered Switch Adjustment Procedure.............................................................................................................................................................................................................269 Wheels and Tires.....................................................................................................................................................................................................................................................270 Description......................................................................................................................................................................................................................................................270 Maintenance......................................................................................................................................................................................................................................................270 Mounting Wheel Assemblies....................................................................................................................................................................................................................................270 Typical Wear Patterns................................................................................................................................................................................................................................................271 Incorrect Tire Pressure..........................................................................................................................................................................................................................................271 Incorrect Camber.................................................................................................................................................................................................................................................271 Incorrect Toe and Axle Alignment.................................................................................................................................................................................................................................271 Incorrect Caster and Wheel Imbalance.............................................................................................................................................................................................................................271 Cuts in the Tire Tread...........................................................................................................................................................................................................................................272 Spot Wear........................................................................................................................................................................................................................................................272 Feathered Edges..................................................................................................................................................................................................................................................272 Cupping..........................................................................................................................................................................................................................................................272 Steering Systems.........................................................................................................................................................................................................................................................273 Description..........................................................................................................................................................................................................................................................273 Front Steering System............................................................................................................................................................................................................................................273 Rear Steering System.............................................................................................................................................................................................................................................273 Secondary Steering System (CE Units).............................................................................................................................................................................................................................273 Theory of Operation..................................................................................................................................................................................................................................................273 Front Steering System............................................................................................................................................................................................................................................273 Rear Steering System.............................................................................................................................................................................................................................................273 Secondary Steering System (CE Units).............................................................................................................................................................................................................................273 Maintenance..........................................................................................................................................................................................................................................................274 Front Steering System............................................................................................................................................................................................................................................274 Troubleshooting..............................................................................................................................................................................................................................................274 Functional Check.............................................................................................................................................................................................................................................275 Rear Steering System.....................................................................................................................................................................................................................................................275 Troubleshooting......................................................................................................................................................................................................................................................275 Hydraulic Pumps......................................................................................................................................................................................................................................................276 Description......................................................................................................................................................................................................................................................276 Front Steer..................................................................................................................................................................................................................................................276 Rear Steer...................................................................................................................................................................................................................................................276 Front Steering Control Valve.........................................................................................................................................................................................................................................276 Description......................................................................................................................................................................................................................................................276 Maintenance......................................................................................................................................................................................................................................................276 Removal......................................................................................................................................................................................................................................................276 Installation.................................................................................................................................................................................................................................................276 Rear Steer/ Axle Lockout/Fan Drive Valve.............................................................................................................................................................................................................................276 Description......................................................................................................................................................................................................................................................276 Maintenance......................................................................................................................................................................................................................................................276 Removal......................................................................................................................................................................................................................................................276 Installation.................................................................................................................................................................................................................................................276 Functional Check.............................................................................................................................................................................................................................................277 Steer Cylinders......................................................................................................................................................................................................................................................277 Description......................................................................................................................................................................................................................................................277 Maintenance......................................................................................................................................................................................................................................................277 Removal......................................................................................................................................................................................................................................................277 Installation.................................................................................................................................................................................................................................................277 Rear Axle Oscillation Lockout System.....................................................................................................................................................................................................................................277 Description..........................................................................................................................................................................................................................................................277 Theory of Operation..................................................................................................................................................................................................................................................277 Axle Oscillation Lockout Cylinders...................................................................................................................................................................................................................................279 Description......................................................................................................................................................................................................................................................279 Maintenance......................................................................................................................................................................................................................................................279 Removal......................................................................................................................................................................................................................................................279 Installation.................................................................................................................................................................................................................................................279 Axle Oscillation Lockout Valve.......................................................................................................................................................................................................................................279 Description......................................................................................................................................................................................................................................................279 Maintenance......................................................................................................................................................................................................................................................279 Removal......................................................................................................................................................................................................................................................279 Installation.................................................................................................................................................................................................................................................279 Brake System.............................................................................................................................................................................................................................................................280 Description..........................................................................................................................................................................................................................................................280 Service Brakes...................................................................................................................................................................................................................................................280 Parking Brake....................................................................................................................................................................................................................................................280 Theory of Operation..................................................................................................................................................................................................................................................280 Service Brakes...................................................................................................................................................................................................................................................280 Parking Brake....................................................................................................................................................................................................................................................280 Maintenance..........................................................................................................................................................................................................................................................281 Troubleshooting..................................................................................................................................................................................................................................................281 General..........................................................................................................................................................................................................................................................281 Bleeding the Brake System........................................................................................................................................................................................................................................281 Pressure Bleeding the Brake System...........................................................................................................................................................................................................................282 Manually Bleeding the Brake System...........................................................................................................................................................................................................................282 Service Brakes...........................................................................................................................................................................................................................................................282 Description..........................................................................................................................................................................................................................................................282 Maintenance..........................................................................................................................................................................................................................................................282 Removal..........................................................................................................................................................................................................................................................282 Linings......................................................................................................................................................................................................................................................282 Caliper......................................................................................................................................................................................................................................................282 Disassembly......................................................................................................................................................................................................................................................283 Caliper......................................................................................................................................................................................................................................................283 Inspection.......................................................................................................................................................................................................................................................284 Periodic On-Vehicle..........................................................................................................................................................................................................................................284 Shoes, Linings, and End Plates...............................................................................................................................................................................................................................284 Caliper for Leaks............................................................................................................................................................................................................................................284 Dust Seals...................................................................................................................................................................................................................................................285 Disc.........................................................................................................................................................................................................................................................285 Caliper Parts................................................................................................................................................................................................................................................285 Cleaning.........................................................................................................................................................................................................................................................286 Corrosion Protection.................................................................................................................................................................................................................................................286 Assembly.........................................................................................................................................................................................................................................................286 Caliper......................................................................................................................................................................................................................................................286 Installation.....................................................................................................................................................................................................................................................287 Linings......................................................................................................................................................................................................................................................287 Caliper......................................................................................................................................................................................................................................................287 Parking Brake Actuator...................................................................................................................................................................................................................................................288 Description..........................................................................................................................................................................................................................................................288 Maintenance..........................................................................................................................................................................................................................................................288 Removal..........................................................................................................................................................................................................................................................288 Installation.....................................................................................................................................................................................................................................................288 Adjustment.......................................................................................................................................................................................................................................................288 Parking Brake............................................................................................................................................................................................................................................................289 Description..........................................................................................................................................................................................................................................................289 Maintenance..........................................................................................................................................................................................................................................................289 Removal..........................................................................................................................................................................................................................................................289 Installation.....................................................................................................................................................................................................................................................289 Park Brake Solenoid Valve................................................................................................................................................................................................................................................292 Description..........................................................................................................................................................................................................................................................292 Maintenance..........................................................................................................................................................................................................................................................292 Removal..........................................................................................................................................................................................................................................................292 Installation.....................................................................................................................................................................................................................................................292 Outriggers...............................................................................................................................................................................................................................................................293 Outrigger Circuit....................................................................................................................................................................................................................................................293 Theory of Operation..............................................................................................................................................................................................................................................293 Maintenance......................................................................................................................................................................................................................................................294 Troubleshooting..............................................................................................................................................................................................................................................294 Outrigger Beam.......................................................................................................................................................................................................................................................297 Description......................................................................................................................................................................................................................................................297 Theory of Operation..............................................................................................................................................................................................................................................297 Maintenance......................................................................................................................................................................................................................................................297 Removal......................................................................................................................................................................................................................................................297 Inspection...................................................................................................................................................................................................................................................297 Installation.................................................................................................................................................................................................................................................298 Wear Pad Adjustment..........................................................................................................................................................................................................................................298 Extension Cylinder...................................................................................................................................................................................................................................................301 Description......................................................................................................................................................................................................................................................301 Maintenance......................................................................................................................................................................................................................................................301 Removal......................................................................................................................................................................................................................................................301 Installation.................................................................................................................................................................................................................................................301 Functional Check.............................................................................................................................................................................................................................................301 Outrigger Monitoring System (Optional— Standard in North America)....................................................................................................................................................................................................302 Description......................................................................................................................................................................................................................................................302 Removal......................................................................................................................................................................................................................................................302 Installation.................................................................................................................................................................................................................................................302 Jack Cylinder........................................................................................................................................................................................................................................................302 Description......................................................................................................................................................................................................................................................302 Maintenance......................................................................................................................................................................................................................................................302 Removal......................................................................................................................................................................................................................................................302 Installation.................................................................................................................................................................................................................................................303 Functional Check.............................................................................................................................................................................................................................................303 Outrigger Jack Cylinder Internal Leak Test...................................................................................................................................................................................................................303 Checking Cylinder for Internal Piston Seal Leak..............................................................................................................................................................................................................303 Testing Pilot Operated Check Valve For Leakage...............................................................................................................................................................................................................304 Outrigger Control Valves.............................................................................................................................................................................................................................................304 Description......................................................................................................................................................................................................................................................304 Pilot Operated Check Valve...................................................................................................................................................................................................................................304 Integrated Outrigger/Rear Steer Valve........................................................................................................................................................................................................................304 Outrigger Control Manifold...................................................................................................................................................................................................................................304 Optional Equipment.......................................................................................................................................................................................................................................................304 Pintle Hook..........................................................................................................................................................................................................................................................304 Secondary Front Steer (CE Option)....................................................................................................................................................................................................................................304 SECTION 9........................................................................................................................................................................................................................................................................305 Lubrication..................................................................................................................................................................................................................................................................305 General..................................................................................................................................................................................................................................................................305 Environmental Protection.................................................................................................................................................................................................................................................305 Lubrication Intervals....................................................................................................................................................................................................................................................305 Standard Lubricants......................................................................................................................................................................................................................................................306 Arctic Lubricants and Conditions.....................................................................................................................................................................................................................................307 Temperatures Below -9°C (15°F)...................................................................................................................................................................................................................................307 Cold Weather Package and Lubricants..............................................................................................................................................................................................................................307 Surface Protection for Cylinder Rods.....................................................................................................................................................................................................................................310 Wire Rope Lubrication....................................................................................................................................................................................................................................................311 Lubrication Points.......................................................................................................................................................................................................................................................311 CraneLUBE............................................................................................................................................................................................................................................................311 Safety...............................................................................................................................................................................................................................................................311 Steering and Suspension..............................................................................................................................................................................................................................................312 Axles................................................................................................................................................................................................................................................................314 Drive Train..........................................................................................................................................................................................................................................................316 Drive Train (continued)..............................................................................................................................................................................................................................................319 Turntable............................................................................................................................................................................................................................................................321 Cab Tilt.............................................................................................................................................................................................................................................................323 Outriggers...........................................................................................................................................................................................................................................................325 Boom.................................................................................................................................................................................................................................................................327 Boom (continued).....................................................................................................................................................................................................................................................329 Boom (continued).....................................................................................................................................................................................................................................................331 Hoist................................................................................................................................................................................................................................................................333 Hydraulic............................................................................................................................................................................................................................................................335 Diesel Exhaust Fluid (DEF)...........................................................................................................................................................................................................................................337 Carwell® Rust Inhibitor..............................................................................................................................................................................................................................................339 Protecting Cranes From Rusting.......................................................................................................................................................................................................................................339 Cleaning Procedures..................................................................................................................................................................................................................................................339 Inspection and Repair................................................................................................................................................................................................................................................340 Application..........................................................................................................................................................................................................................................................340 Areas of Application.................................................................................................................................................................................................................................................340
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