Grove Service Manual RT530E 2 CTRL556 00

Grove RT530E-2
Service/Maintenance Manual
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THIS PAGE BLANK

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SERVICE MANUAL
This Manual has been prepared for and is considered part of -
RT530E-2 2
Crane Model Number
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This Manual is divided into the following Sections:
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SECTION 1 INTRODUCTION
SECTION 2 HYDRAULIC SYSTEM
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SECTION 3
SECTION 4
ELECTRIC SYSTEM
BOOM
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SECTION 5 HOIST AND COUNTERWEIGHT
SECTION 6 SWING SYSTEM
SECTION 7 POWER TRAIN
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SECTION 8 UNDERCARRIAGE
SECTION 9 LUBRICATION 5
NOTICE
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The crane serial number is the only method your distributor or the factory
has of providing you with correct parts and service information.
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The crane serial number is stamped on the top of the outrigger box.
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Always furnish crane serial number when ordering parts or

communicating service problems with your distributor or the factory.
! DANGER 7
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An untrained operator subjects himself and others to death or

serious injury. Do not operate this crane unless:
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• You are trained in the safe operation of this crane. Manitowoc is not
responsible for qualifying personnel. 8
• You read, understand, and follow the safety and operating
recommendations contained in the crane manufacturer’s manuals and
load charts, your employer’s work rules, and applicable government
regulations.
• You are sure that all safety signs, guards, and other safety features are 9
in place and in proper condition.
• The Operator’s Manual and Load Chart are in the holder provided on
crane.
© 2015 Manitowoc
Published 4-22-15, Control #556-00
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CALIFORNIA
PROPOSITION 65 WARNING
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Diesel engine exhaust and some of its constituents are
known to the State of California to cause cancer, birth
defects, and other reproductive harm.
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CALIFORNIA
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PROPOSITION 65 WARNING
Battery posts, terminals, and related accessories contain
chemical lead and lead compounds, chemicals known to
the State of California to cause cancer, birth defects or
other reproductive harm. Wash hands after handling.
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The original language of this publication is English.

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RT530E-2 SERVICE MANUAL TABLE OF CONTENTS
See back of this manual for Alphabetical Index
SECTION 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Introduction
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
List of Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Torque Converter/Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 T
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Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Swing Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Boom. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
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Swivel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Hydraulic Pumps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 C
General Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
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Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Pressing Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Locks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
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Wires and Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Shims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Gaskets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
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Hydraulic Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Fatigue of Welded Structures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Loctite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Fasteners and Torque Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
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Weld Studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
Environmental Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
Dynamic Shock Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
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Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
Precautions and Recommendations During Inspection or Replacement . . . . . . . . 1-16
Wire Rope Inspection (Running Ropes and Pendant Cables) . . . . . . . . . . . . . . . . 1-17
Wire Rope Inspection (Boom Extension and Retraction Cables) . . . . . . . . . . . . . . 1-18
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Wire Rope Inspection/Replacement (All Wire Rope) . . . . . . . . . . . . . . . . . . . . . . . 1-18

Seizing Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
Installing 35x7 Class Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
Procedures for Cutting and Preparing 35x7 Class Wire Rope . . . . . . . . . . . . . . . . 1-20
SECTION 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic System

Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Hydraulic Oil Recommendations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Draining and Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Removing Air from the Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Parts Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Directional Control Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Supply Pressure and Return Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
GROVE TOC-1
TABLE OF CONTENTS RT530E-2 SERVICE MANUAL
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Hydraulic Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Pressure Setting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Procedure A - For Checking/Setting The Main Control Valve For Hoists(s),
Boom Lift and Piston Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Procedure B - For Setting The Outrigger/Rear Steer/Oil Cooler Motor Pressures 2-19
Procedure C - For Checking/Setting The Swing Directional Control Valve Work
Port Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
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Procedure D - For Checking/Setting The Service Brake Dual Accumulator Charge
Valve Charging Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
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Procedure E - For Checking/Pre-Charging The Service Brake Accumulators . . . 2-20
Procedure F - For Checking/Setting the Front Steer Pressure . . . . . . . . . . . . . . . 2-21
Procedure G - For Checking/Setting the Pilot Supply Pressure . . . . . . . . . . . . . . 2-21
Procedure H - For Checking/Setting The Swing Brake Release Pressure . . . . . . 2-21
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Procedure J - For Setting Threshold on Electronic Controllers . . . . . . . . . . . . . . . 2-21
Procedure K - Setting Threshold and Max on Swing Brake Pedal . . . . . . . . . . . . 2-22
Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
Directional Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30
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Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30
Accessory With Swing Directional Control Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
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Steering Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35

Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35
Tandem Brake Valve with Treadle Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36
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Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36
Dual Accumulator Charge Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37
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Hydraulic Accumulator Service Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39

Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39
Holding Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40
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Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40
Cross Axle Differential Lock Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41
Outrigger Control Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43
Pilot Operated Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44
Integrated Outrigger/Rear Steer Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45
Check Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48
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Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48
Range Shift/Parking Brake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49
Axle Oscillation Lockout Valve (Standard Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-50
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-50
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-50
Axle Oscillation Lockout Valve (Optional CE Units). . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54
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Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54
Surface Protection for Cylinder Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54 O
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Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57
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Dual Rod Telescope Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60
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Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60
Axle Oscillation Lockout Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-64
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-64
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-64
ce
Steer Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-68
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-68
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-68
Outrigger Extension Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-71
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-71
en
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-71
Outrigger jack Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-73
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-73
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-73
er
SECTION 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electric System

Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
ef
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Fuse Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
R
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
General Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Troubleshooting Swivel-Caused Electrical Problems . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Connector Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Troubleshooting Engine Starting Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Troubleshooting Engine Charging Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Troubleshooting Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Alternator Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Starter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Battery Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Relay Panel Component Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Rocker Switch Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Ignition Switch Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Turn Signal Lever and Transmission Shift Lever Replacement . . . . . . . . . . . . . . . 3-10
GROVE TOC-3
Windshield Wiper Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Windshield Washer Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Skylight Wiper Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Appendix A: Crane Control System (CCS) Fault Codes . . . . . . . . . . . . . . . . . . . . 3-16
SECTION 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boom
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Theory Of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Boom Extension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Boom Retraction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
y
Boom Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Remove the Base Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Disconnect Inner Mid Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
nl
Remove the Inner Mid Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Remove Outer Mid Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Remove Telescope Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Boom Nose Sheaves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
O
Boom Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Install Telescope Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Install Outer Mid Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Install Inner Mid Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Connect Inner Mid Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
ce
Install Base Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Boom Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Functional Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
en
Boom Alignment And Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

Boom Extension And Retraction Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Extension Cable Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Retract Cable Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
er
Telescope Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21

Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Theory Of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
ef
Lift Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25

Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Theory Of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
R
Swingaway Boom Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29

Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
Hook Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
SECTION 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . Hoist And Counterweight

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Warm-up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
TOC-4
Functional Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Fluid Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Usage and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Oil Sampling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Brake Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Hoist to Boom Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Piston Motor and Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
T
y
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 O
nl
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Hoist Drum Rotation Indicator System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
C
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
O
Counterweight Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
SECTION 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Swing System

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
ce
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Swing Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
en
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Swing Gearbox And Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Swing Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
er
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Swivels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
ef
Hydraulic Swivel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16

Electrical Swivel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
SECTION 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Train

R
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Air Intake and Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Air Intake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Charge-Air Cooler System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
Muffler and Diesel Oxidation Catalyst - Tier 4 Interim . . . . . . . . . . . . . . . . . . . . . . 7-14
Slip Joint Exhaust Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
Water Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
GROVE TOC-5
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
Antifreeze/Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
Radiator Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
Drive Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
Transmission/Torque Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22
Servicing the Crane After Transmission/Torque Converter Overhaul . . . . . . . . . . 7-25
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SECTION 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Undercarriage
Axles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
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Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Wheels and Tires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
Steering Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
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Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
Rear Steering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
Hydraulic Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
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Front Steering Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
Integrated Outrigger/Rear Steer Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
Steer Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
Rear Axle Oscillation Lockout System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
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Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
Axle Oscillation Lockout Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14
Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
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Service Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16

Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16
Corrosion Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20
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Parking Brake Actuator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22

Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22
Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
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Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
Park Brake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24
Outriggers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24
Outrigger Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24
Outrigger Beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-28
Extension Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-32
Jack Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-33
Outrigger Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-35
TOC-6
SECTION 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubrication
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Lubrication Intervals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Arctic Conditions Below -18°C (0°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Arctic Conditions Down To -40° C (-40°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Surface Protection For Cylinder Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Wire Rope Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
CraneLUBE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Steering and Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6 T
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Drive Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
Drive Train (continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10
Outriggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12 O
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Turntable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14
Boom. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16
Boom (continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-18
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Hoist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-20
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Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-22
Carwell® Rust Inhibitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-24
Protecting Cranes From Rusting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-24
Cleaning Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-24
Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-25
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Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-25
Areas of Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-25
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TOC-8
RT530E-2 SERVICE MANUAL INTRODUCTION
SECTION 1
1
INTRODUCTION
SECTION CONTENTS
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Batteries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
List of Specifications . . . . . . . . . . . . . . . . . . . . . . . 1-2 Hydraulic Systems . . . . . . . . . . . . . . . . . . . . . . . . 1-10
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Fatigue of Welded Structures . . . . . . . . . . . . . . . 1-11
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Loctite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
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Torque Converter/Transmission . . . . . . . . . . . . . . 1-2 Fasteners and Torque Values . . . . . . . . . . . . . . . 1-12
Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Weld Studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
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Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Wire Rope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Environmental Conditions . . . . . . . . . . . . . . . . . . 1-17
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Swing Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Dynamic Shock Loads . . . . . . . . . . . . . . . . . . . . . 1-17
Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
Swivel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Precautions and Recommendations During
Hydraulic Pumps. . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Inspection or Replacement . . . . . . . . . . . . . . . . . 1-17
Wire Rope Inspection
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General Maintenance . . . . . . . . . . . . . . . . . . . . . . . 1-8
(Running Ropes and Pendant Cables) . . . . . . . . 1-18
Cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Wire Rope Inspection (Boom Extension and
Removal and Installation . . . . . . . . . . . . . . . . . . . 1-8 Retraction Cables) . . . . . . . . . . . . . . . . . . . . . . . . 1-19
Disassembly and Assembly . . . . . . . . . . . . . . . . . 1-8 Wire Rope Inspection/Replacement
Pressing Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 (All Wire Rope) . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
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Locks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 Seizing Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . 1-20

Wires and Cables . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 Installing 35x7 Class Wire Rope . . . . . . . . . . . . . 1-21
Shims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 Procedures for Cutting and Preparing 35x7 Class
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
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Gaskets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
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DESCRIPTION The superstructure is capable of 360 degree rotation in either

direction. All crane functions are controlled from the fully-
This Manual provides information for the maintenance of the enclosed cab mounted on the superstructure. The crane is
Model RT530E-2 Series Grove Crane.
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equipped with a four-section, full power, sequenced and

The lift capacities are listed on the Load Chart in the cab. synchronized boom. Additional reach is obtained by utilizing
an optional swingaway boom extension. Lifting is provided
T h e c r an e i n c o r p or at e s a n al l w el d e d par al l e l b o x by a main hoist and an optional auxiliary hoist.
construction steel frame, using planetary drive axles to
provide four-wheel drive. Axle steering is accomplished NOTE: Throughout this manual, reference is made to left,
utilizing hydraulic steer cylinders. The engine is mounted at right, front, and rear when describing locations.
the rear of the crane carrier and provides motive power When operating the crane, these reference
through a six speed forward and reverse transmission. locations are to be considered as those viewed
from the operator’s seat with the superstructure
The carrier frame incorporates an integral fifth wheel, to facing forward over the front of the carrier frame.
which the rear axle is mounted, to provide axle oscillation.
Axle oscillation lockout is automatic when the superstructure NOTE: Transportation and Lifting Decal is shown in
rotates from the travel position. (Figure 1-1).
GROVE Published 4-22-15, Control # 556-00 1-1

INTRODUCTION RT530E-2 SERVICE MANUAL
LIST OF SPECIFICATIONS Engine

General Cummins QSB6.7
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . RT530E-2 Displacement . . . . . . . . . . . . . . . . . 6.7 l (409 cu in)
Rated Capacity . . . . . . . . . . See Load Chart in cab Firing Order. . . . . . . . . . . . . . . . . . . . . . 1-5-3-6-2-4
Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 x 4 Lube Amount . . . . . . . . . . . . . . . . . . 17.5 l (18.5 qt)
Gross Weight . . . . . . . . . . . . . . . . See Axle Weight Coolant System . . . . . . . . . . . . . . . . . 28.5 l (30 qt)
Distribution Table
Axles
Dimensions Total Ratio. . . . . . . . . . . . . . . . . . . . . . . . . . 20.06:1
NOTE: Dimensions listed are for a crane with all Carrier Ratio . . . . . . . . . . . . . . . . . . . . . . . . . 5.57:1
Wheel End Ratio. . . . . . . . . . . . . . . . . . . . . . 3.60:1
components fully retracted in the travel mode with
20.5 x 25-24 Earthmover bias ply tires. Brakes
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Wheelbase . . . . . . . . . . . . . . . . . . . 3.66 m (144 in) Type . . . . . . . . .Hydraulic/Split system acting on all
Overall Crane Length . . . . . . . . .12.29 m (483.7 in) four wheels
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Overall Crane Width . . . . . . . . . . . . 2.54 m (100 in)
Overall Crane Height . . . . . . . . . . . 3.24 m (127 in)
Tail-Swing . . . . . . . . . . . . . . . . . . . . 3.66 m (144 in) Wheels and Tires
Outrigger Spread Lugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Retracted . . . . . . . . . . . . . . . 2.39 m (7 ft 10 in) Torque. . . . . . . . . . . 461 to 488 Nm (340 - 360 lb-ft)
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Mid Extend . . . . . . . . . . . . . . . . . 4.27 m (14 ft) Tire Size
Fully Extended . . . . . . . . . . . . . . 6.10 m (20 ft) Standard . . . . . . . . . . . .20.5 x 25-24 ply rating
For roading and lifting pressures, refer to the Load
Capacities Chart Book in the cab.
Fuel Tank . . . . . . . . . . . . . . . . . . . . . .220 l (58 gal)
Swing Gearbox
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Coolant System. . . . . . . . . . . . . . . . . . . See Engine
Specifications Reduction Ratio . . . . . . . . . . . . . . . . . . . . . . . . 36:1
Engine Lubrication System . . . . . . . . . . See Engine Output Torque . . . . . . . . . . . . . .755 Nm (6680 in-lb)
Specifications
Hydraulic Tank (Reservoir Capacity) Boom
Total . . . . . . . . . . . . . . . . . . . . . . 442 l (117 gal)
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at Full Level . . . . . . . . . . . . . . . .396 l (105 gal) Length. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

at Low Level. . . . . . . . . . . . . . . . .369 l (97 gal) Retracted . . . . . . . . . . . . . . . . . . . .8.8 m (29 ft)
Expansion Space . . . . . . . . . . . . . .46 l (12 gal) Extended . . . . . . . . . . . . . . . . . . .29.0 m (95 ft)
Hoists . . . . . . . . . . . . . . . . . . . . . . . . . .5.2 l (5.5 qt) Power . . . . . . . . . . . . . . . . . . 4 Section, Full Power
Swing Gearbox . . . . . . . . . . . . . . . . . . . 4 l (4.25 qt) Elevation . . . . . . . . . . . . . . . . . . . -3 to +76 degrees
Axle Planetary Hubs . . . . . . . . . . . . . . .1.7 l (3.5 pt) Extensions
Fixed Offsettable . . . . . . . . . .7.9 meters (26 ft)
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Axle Differentials . . . . . . . . . . . . . . . . . . 9.5 l (20 pt)

Transmission (includes Torque Converter) Folding* . . . . . . . . 7.9 - 13.7 meters (26 - 45 ft)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 l (25 qt) *Extensions are offsettable at 0, 15, or 30
degrees.
Torque Converter/Transmission
Swivel Assembly
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Stall Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . 2.024:1

Charge Pump Capacity . . . . . . .70 l/min (14.5 gpm) Electrical . . . . . . . . . . . . . . . . . . . . . . . 20 Slip Rings
@ 2000 rpm Hydraulic. . . . . . . . . . . . . . . . . . . . . . . . . . . 10 ports
Gear Ratios Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ports
Air Conditioning . . . . . . . . . . . . . . . . . . . . . . 2 ports
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Forward/Reverse
Lo 1st . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.07
Lo 2nd . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.64
Lo 3rd. . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.00
Hi 1st . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.05
Hi 2nd. . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.86
Hi 3rd . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.80
1-2 Published 4-22-15, Control # 556-00

Hydraulic Pumps Pump #3

Type . . . . . . . . . . . . . .Gear with priority flow divider 1
Pump #1 Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Output - @ 199.9 bar (2,900 psi) w/no load
NOTE: Pump output is theoretical @ no-load engine Section 1. . . . . . . . . . . . . 57.2 l/min (15.1 gpm)
speed.
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Piston Hoists
Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 Drum Dimensions
Output - @ 275.8 bar (4,000 psi) w/no load Diameter . . . . . . . . . . . . . . . 270 mm (10.63 in)
Section 1 . . . . . . . . . . . .283.7 l/min (62.4 gpm) Length (Standard) . . . . . . . . 437 mm (17.20 in)
Cable
Pump #2 Diameter . . . . . . . . . . . . . . . . . . 16 mm (5/8 in)
Length-Main . . . . . . . . . . . . . . . .138 m (452 ft)
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Gear Length-Aux. . . . . . . . . . . . . . . . .138 m (452 ft)
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Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 Max. Permissible Line Pull (6x36)
Output - @ 172.4 bar (2,500 psi) w/no load . . . . . . . . . . . . . . . . . . . . . . . . . .51.7 kN (11,640 lb)
Section 1 . . . . . . . . . . . . .82.8 l/min (21.9 gpm) Max. Single Line Speed . . . .156.7 m/min (514 fpm)
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Hoist Motor Displacement
Low . . . . . . . . 54.0 cm3 (3.3 in3) per revolution
High . . . . . . . 39.3 cm3 (2.4 in3) per revolution
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FIGURE1-1

Table 1-1
Axle Weight Distribution Table
CG From Rear Weight Front Axle Rear Axle

Description
Axle cm (in) kg (lb) kg (lb) kg (lb)
Basic Unit
Maximum Axle Loads Allowed 16783 (37000) 16783 (37000)
Maximum Axle Loads Allowed while Towing 14969 (33000) 14969 (33000)
Maximum Tire Loads Allowed 15604 (34400) 15604 (34400)
Standard Carrier Assy. 4 x 4; Plus all Fluids 158.83 (62.53) 12451 (27449) 5406 (11919) 7044 (15530)
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Superstructure w/Cab Plus w/Main Hoist 68.66 (27.03) 3862 (8514) 725 (1598) 3137 (6916)
Pinned on Counterweight -119.63 (-47.10) 3817 (8416) -1249 (-2753) 5066 (11169)
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Boom Assembly; w/(2/3) Sheaves, RCL,
427.43 (168.28) 5081 (11202) 5938 (13091) -857 (-1889)
Pivot Pins
Lift Cylinder & Lower Shaft 218.29 (85.94) 587 (1293) 350 (772) 236 (521)
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Complete Basic Machine
4 x 4 chassis; Cummins QSB 6.7 Tier
4engine w/ transmission; front and rear 158.37 (62.35) 25798 (56874) 11171 (24627) 14627 (32247)
axles; 20.5 x 25 tires; main hoist
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w/137 m (450 ft) of 5/8 in. 6 X 37 cable; full
fuel and hydraulic oil
Add To Basic Unit Weight
7.9 to 13.7 m (26 to 45 ft)Tele Boom
565.15 (222.50) 794 (1750) 1227 (2704) -433 (-954)
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Extension
Boom Ext. Carrier Brackets (Bolt On) 441.96 (174.00) 116 (256) 140 (309) -24 (-53)
Auxiliary Boom Nose - Installed 916.94 (361.00) 48 (105) 119 (263) -72 (-158)
30 metric ton (33 ton), CE Hookblock (3
396.24 (156) 292 (644) 317 (698) -24 (-54)
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sheave) Stowed in Tray

27.3 metric ton (30 ton), Hookblock Stowed
396.24 (156.00) 263 (580) 285 (628) -22 (-48)
in Tray
13.5 metric ton (15 ton), Hookblock Stowed
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396.24 (156.00) 193 (425) 209 (460) -16 (-35)

in Tray
7 metric ton (7.5 Ton), Headache Ball
581.66 (229.00) 167 (369) 266 (587) -99 (-218)
(Swivel) - Attached to Front O/R Box
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Storage Tray Mats 337.82 (133.00) 20 (43) 18 (40) 1 (3)

Rear Mounted Pintle Hook -162.56 (-64.00) 5 (11) -2 (-5) 7 (16)
Driver Controlled Differential Locks 177.80 (70.00) 19 (41) 9 (20) 10 (21)
Russian Certification Package 127.00 (50.00) 28 (61) 10 (21) 18 (40)
Air Conditioning - Carrier and superstructure
38.10 (15.00) 44 (98) 5 (10) 40 (88)
components
360 Degree Swing Lock 205.74 (81.00) 29 (64) 16 (36) 13 (28)
Driver 187.96 (74.00) 113 (250) 58 (128) 55 (122)
CE Components - w/Main Hoist 10.16 (4.00) 285 (628) 8 (17) 277 (611)
CE Components - w/Main & w/Aux Hoists 15.24 (6.00) 274 (603) 11 (25) 262 (578)

CG From Rear Weight Front Axle Rear Axle

Description
Axle cm (in) kg (lb) kg (lb) kg (lb) 1
Remove: Auxiliary Hoist Cable (453 ft) of 5/8
-121.92 (-48.00) -179 (-394) 59 (131) -238 (-525)
35 x 7
Remove: Main Hoist Cable (450 ft) of 5/8 6 X
-60.96 (-24.00) -174 (-383) 29 (64) -203 (-447)
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Add: Aux Hoist (Replace IPO Cwt With Aux
-109.22 (-43.00) 174 (383) -52 (-114) 225 (497)
Hoist and Cable)
Sub: Optional Cable on Main Hoist (453 ft of
-60.96 (-24.00) 5 (11) -1 (-2) 6 (13)
5/8 inch 35 X 7)
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Sub: Tier 3 Engine -157.48 (-62.00) -17 (-37) 7 (16) -24 (-53)
Sub: 16.00 X 25 Titan Tires 182.9 (72.00) -63 (-140) -32 (-70) -32 (-70)
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Sub: Kessler Axles 175.26 (69.00) -86 (-190) -41 (-91) -45 (-99)
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8047-2
Item Description
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1 Cab
2 Outrigger Float
3 Outrigger Jack Cylinder
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4 Steps
5 Valve Cover
6 Counterweight
FIGURE 1-2

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1 3 4
2 6
5
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6
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8046-1 7
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8 11 10 9 8
Item Description Item Description Item Description

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1 Counterweight 6 Boom Nose Sheaves 11 Rear Axle
2 Auxiliary Hoist 7 Swingaway
3 Main Hoist 8 Outrigger Jack Cylinder
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4 Boom Pivot 9 Front Axle

5 Lift Cylinder 10 Hydraulic Tank
FIGURE 1-2 continued

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1 2 4 5
3
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8047-1
9
4 8
7 6
Item Description Item Description Item Description

1 Swingaway 4 Outrigger Jack 7 Main Hoist
2 Boom 5 Counterweight 8 Cab
3 Stinger 6 Auxiliary Hoist 9 Auxiliary Boom Nose

GENERAL MAINTENANCE ensure the crane is blocked securely and the weight is
supported by blocks rather than by lifting equipment.
These general suggestions should be helpful in following the
i ns t r u c t io n s i n th i s m a nu a l . I n a n al y z i ng a s y s te m When using hoisting equipment, follow the hoist
malfunction, use a systematic procedure to locate and manufacturers recommendations and use lifting devices that
correct the problem. will allow you to achieve the proper balance of the
assemblies being lifted and to ensure safe handling. Unless
1. Determine the problem. otherwise specified, all removals requiring hoisting
2. List possible causes. equipment should be accomplished using an adjustable
lifting attachment. All supporting members (chains and
3. Devise checks.
cables) should be parallel to each other and as near
4. Conduct checks in a logical order to determine the perpendicular as possible to the top of the object being lifted.
cause.
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5. Consider the remaining service life of components
against the cost of parts and labor necessary to replace CAUTION
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them. The capacity of an eyebolt diminishes as the angle
between the supporting members and the object
6. Make the necessary repair.
becomes less than 90. Eyebolts and brackets should
7. Recheck to ensure that nothing has been overlooked. never be bent and should only have stress in tension.
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8. Functionally test the failed part in its system.
Some removals require the use of lifting fixtures to obtain
NOTE: Your safety and that of others is always the number proper balance. The weights of some components are given
one consideration when working around machines. in their respective sections of the manual.
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Safety is a matter of thoroughly understanding the
If a part resists removal, check to be certain all nuts and bolts
job to be done and the application of good common
have been removed and that an adjacent part is not
sense. It is not just a matter of do’s and don’ts. Stay
interfering.
clear of all moving parts.
Disassembly and Assembly
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Cleanliness
When assembling or disassembling a component or system,
An important item in preserving the long life of the machine is
complete each step in turn. Do not partially assemble one
keeping dirt out of working parts. Enclosed compartments,
part and start assembling some other part. Make all
seals, and filters have been provided to keep the supply of
adjustments as recommended. Always check the job after it
air, fuel, and lubricants clean. It is important that these
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is completed to see that nothing has been overlooked.

enclosures be maintained.
Recheck the various adjustments by operating the machine
Whenever hydraulic, fuel, lubricating oil lines, or air lines are before returning it to the job.
disconnected, clean the adjacent area as well as the point of
disconnect. As soon as the disconnection is made, cap, plug, Pressing Parts
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or tape each line or opening to prevent entry of foreign

When pressing one part into another, use an anti-seize
material. The same recommendations for cleaning and
compound or a molybdenum disulfide base compound to
covering apply when access covers or inspection plates are
lubricate the mating surfaces.
removed.
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Assemble tapered parts dry. Before assembling parts with

Clean and inspect all parts. Be sure all passages and holes
tapered splines, be sure the splines are clean, dry, and free
are open. Cover all parts to keep them clean. Be sure parts
from burrs. Position the parts together by hand to mesh the
are clean when they are installed. Leave new parts in their
splines before applying pressure.
containers until ready for assembly.
Parts which are fitted together with tapered splines are
Clean the rust preventive compound from all machined
always very tight. If they are not tight, inspect the tapered
surfaces of new parts before installing them.
splines and discard the part if the splines are worn.
Removal and Installation Locks
When performing maintenance, do not attempt to manually
Lockwashers, flat metal locks, or cotter pins are used to lock
lift heavy parts when hoisting equipment should be used.
nuts and bolts.
Never locate or leave heavy parts in an unstable position.
When raising a portion of a crane or a complete crane,

Flat metal locks must be installed properly to be effective. Installation

Bend one end of the lock around the edge of the part. Bend
Lubricate new or used bearings before installation. Bearings
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the other end against one flat surface of the nut or bolt head.
that are to be preloaded must have a film of oil over the entire
Always use new locking devices on components which have assembly to obtain accurate pre-loading. When installing a
moving parts. bearing, spacer, or washer against a shoulder on a shaft, be
Wh en insta lling loc kwashe rs o n ho usings made of sure the chamfered side is toward the shoulder.
aluminum, use a flat washer between the lockwasher and When pressing bearings into a retainer or bore, uniformly
the housing. apply pressure to the outer race. If the bearing is pressed on
the shaft, uniformly apply pressure on the inner race.
Wires and Cables
Batteries should always be disconnected prior to working on Preload
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the electrical system. Preload is an initial load placed on the bearing at the time of
When removing or disconnecting a group of wires or cables, assembly. Whether a tapered roller bearing should have
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tag each one to ensure proper identification during assembly. preload could depend on any of several conditions: rigidity of
the housings and shaft, bearing spread, speed of operation,
Shims etc.
When shims are removed, tie them together and identify To determine whether a bearing requires preload or end
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them as to location. Keep shims clean and flat until they are c l e ar a nc e , c on s u l t t h e d i s a s s em b l y a n d a s s e m b l y
reinstalled. instructions pertaining to that bearing.
Care should be exercised in applying preload. Misapplication
Bearings of preload to bearings requiring end clearance can result in
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bearing failure.
Antifriction Bearings
When an antifriction bearing is removed, cover it to keep out Sleeve Bearings
dirt and abrasives. Wash bearings in non-flammable Do not install sleeve bearings with a hammer. Use a press
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cleaning solution and allow them to drain dry. The bearing and be sure to apply the pressure directly in line with the
may be dried with compressed air BUT do not spin the bore. If it is necessary to drive on a bearing, use a bearing
bearing. Discard the bearings if the races and balls or rollers driver or a bar with a smooth flat end. If a sleeve bearing has
are pitted, scored, or burned. If the bearing is serviceable, an oil hole, align it with the oil hole in the mating part.
coat it with oil and wrap it in clean waxed paper. Do not
unwrap new bearings until time of installation. The life of an Gaskets
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antifriction bearing will be shortened if not properly

lubricated. Dirt in an antifriction bearing can cause the Be sure the holes in the gaskets correspond with the
bearing to lock resulting in the shaft turning in the inner race lubricant passages in the mating parts. If it is necessary to
or the outer race turning within the cage. make gaskets, select material of the proper type and
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thickness. Be sure to cut holes in the right places. Blank

Double Row, Tapered Roller gaskets can cause serious damage.
Double row, tapered roller bearings are precision fit during When removed, always install new cylinder head and
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manufacture and components are not interchangeable. The manifold gaskets using recommended gasket compound on
cups, cones, and spacers are usually etched with the same head gaskets to allow uniform sealing.
serial number and letter designator. If no letter designators
are found, wire the components together to assure correct Batteries
installation. Reusable bearing components should be Clean batteries by scrubbing them with a solution of baking
installed in their original positions. soda and water. Rinse with clear water. After cleaning, dry
thoroughly and coat terminals and connections with an anti
Heating Bearings corrosion compound or grease.
Bearings which require expansion for installation should be If the machine is to be stored or not used for an extended
heated in oil not to exceed 121 °C (250 °F). When more than period of time, the batteries should be removed. Store the
one part is heated to aid in assembly, they must be allowed batteries in a cool (not subfreezing), dry place, preferably on
to cool and then pressed together again. Parts often wooden shelves. Never store on concrete. A small charge
separate as they cool and contract. should be introduced periodically to keep the specific gravity
rating at recommended level.

Hydraulic Systems Visual Inspection of Hoses and Fittings
CAUTION
Ensure that the hydraulic hose is depressurized before
DANGER loosening the connections.
Exercise extreme care around pressurized hydraulic
systems. Do not work on a hydraulic system while it is in 1. Visually inspect hoses and fittings once a month or
operation or until all pressure is released. every 250 hours for the following:
a. Leaks at hose fitting or in hose
Cleanliness
b. Damaged, cut, or abraded cover
Contaminants in a hydraulic system affect operation and will
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result in serious damage to the system components. Dirty c. Exposed reinforcement
hydraulic systems are a major cause of component failures. d. Kinked, crushed, flattened, or twisted hose
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Keep the System Clean e. Hard, stiff, heat cracked, or charred hose
When removing components of a hydraulic system, cover all f. Blistered, soft, degraded, or loose cover
openings on both the component and the crane. g. Cracked, damaged, or badly corroded fittings
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If evidence of foreign particles is found in the hydraulic h. Fitting slippage on hose
system, flush the system.
i. Other signs of significant deterioration
Disassemble and assemble hydraulic components on a
clean surface. If any of the above conditions exist, evaluate hose
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assemblies for correction or replacement. For replacement
Clean all metal parts in a nonflammable cleaning fluid. Then of hose assemblies, refer to your Manitowoc Crane Care
lubricate all components to aid in assembly. Parts Manual.
Sealing Elements 2. At the same service interval, visually inspect all other
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hydraulic components and valves for the following:

Inspect all sealing elements (O-ring, gaskets, etc.) when
disassembling and assembling the hydraulic system a. Leaking Ports
components. Installation of new elements is always b. Leaking valve sections or manifolds and valves
recommended. installed into cylinders or onto motors.
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Hydraulic Lines c. Damaged or missing hose clamps, guard, or

shields.
When installing metal tubes, tighten all bolts finger-tight.
Then, in order, tighten the bolts at the rigid end, the d. Excessive dirt and debris around the hose
assemblies.
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adjustable end, and the mounting brackets. After tubes are

mounted, install the hoses. Connect both ends of the hose If any of these conditions exist, address them appropriately.
with all bolts finger-tight. Position the hose so it does not rub
the machine or another hose and has a minimum of bending 3. All hydraulic hose assemblies are recommended to be
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and twisting. Tighten bolts in both couplings. replaced after 8000 hours of service life.
Due to manufacturing methods there is a natural curvature to

a hydraulic hose. The hose should be installed so any bend
is with this curvature.

Table 1-2
Zone Classification
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A Tropical Moist: All months average above 18° C. Latitude 15° - 25° North and South
B Dry or Arid: Deficient precipitation most of the year. Latitude: 20° - 35° North and South
C Moist Mid-Latitude: Temperature with mild winters. Latitude: 30° - 50° North & South
D Moist Mid-latitude: Cold winters. Latitude 50° - 70° North & South
E Polar: Extremely cold winters and summers. Latitude: 60° - 75° North & South
4. Hydraulic hose assemblies operating in a temperature Fatigue of Welded Structures

climate zone “C” (Table 1-2) are recommended to be
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replaced after 8000 hours of service life. Experience has shown that highly stressed welded
structures when repeatedly subjected to varying stresses
5. Hydraulic hose assemblies operating in climate zones caused by twisting, shock, bending, and intentional and/or
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“A” and “B” (Table 1-2) with high ambient temperatures, unintentional overloads, often become subject to weld
could see hose service life reduced by 40 to 50%, cracking which may be attributed to fatigue of the welded
therefore, it is recommended to replace these hoses joint. This condition is not uncommon in construction
after 4000 to 5000 hours of service life. equipment.
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6. Hydraulic hose assemblies operating in climate zones Equipment should be periodically inspected for evidence of
“D” and “E” (Table 1-2) cold climates should expect a weld fatigue. The frequency of these inspections should be
degrade of mechanical properties such as elasticity, commensurate with the age of the equipment, the severity of
therefore, it is recommended these hoses be inspected the application, and the experience of the operators and
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and addressed accordingly. maintenance personnel.The following are known high stress
areas applicable to Manitowoc/Grove machines, and a visual
Electrical System inspection of these areas should be made part of an owner’s
planned preventive maintenance program:
Connectors, Harnesses, Wires, and
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1. Power Telescope Boom - wear pad retaining structures,

Connectors hydraulic cylinder attaching points, boom pivot shaft
Visually inspect all electrical harnesses, cables, and retaining structures.
connectors every month or 250 hours for the following:
2. Outrigger pads, beams, boxes and attachment
• Damaged, cut, blistered, or cracked insulation. structures.
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• Exposed bare wires. 3. Main frames - generally in the area of doubler plates and
crossmembers; at the junction of front and rear frame
• Kinked or crushed wires and cables. members on truck cranes.
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• Cracked or corroded connectors, battery terminals, and 4. Turntable bearing connection (where bearing is welded
ground connections. to the crane superstructure or chassis).
If any the above conditions exist, evaluate and replace as 5. Counterweight support structures.
necessary.
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6. Chassis axle and suspension mounting structures.

The climate in which the crane operates affects the service
life of the electrical components. The climate zones are 7. Hydraulic cylinder end connections.
defined in Table 1-2. Recommended replacement of harness The above is provided only as a guide, and your inspection
and cables is as follows: plan should not be limited to the areas listed. A thorough
• Climate zone C after 10,000 hours of service. visual inspection of all weldments is good practice.
• Climate zones A and C with high ambient temperatures Anyone requiring more detailed inspection instructions and/
and duty cycles after 8000 hours of service. or repair procedures may request them by contacting the
local Manitowoc/Grove distributor.
• Climate zones D and E after 10,000 hours of service.
• Salt water conditions after 8,000 hours of service.

Loctite to engagement. Fixturing may take up to 30 minutes on

unprimed parts.
4. Time required to achieve full strength is 24 hours.
Maximum ultimate strength is achieved using no primer
DANGER with this specific threadlocking adhesive.
Loctite type adhesives contain chemicals that may be
harmful if misused. Read and follow the instructions on Fasteners and Torque Values
the container. Use bolts of the correct length. A bolt which is too long may
bottom before the head is tight against the part it is to hold. If
Always follow the directions on the Loctite container as not a bolt is too short, there may not be enough threads engaged
all Loctite types are suitable for all applications.Various types to hold the part securely. Threads can be damaged. Inspect
of Loctite are specified throughout the Service Manual.The them and replace fasteners, as necessary.
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following types of Loctite brand adhesives are available from
the Parts Department of the local Manitowoc/Grove Torque values should correspond to the type bolts, studs,
and nuts being used.
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distributor.
The torque tables are provided by Manitowoc for reference
Application of Medium Strength Loctite when performing maintenance.
NOTE: The fastener may be re-used; the adhesive may be
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Use of proper torque values is extremely important. Improper
re-applied over cured adhesive residue. torquing can seriously affect performance and reliability.
The following procedure covers the proper application and Identification of fastener grade is always necessary. When
curing method for medium strength Loctite adhesive/sealant marked as a high strength bolt (grade 5, 8, etc.), the
(Loctite #243) and primer (Locquic Primer T7471). mechanic must be aware that he/she is working with a highly
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Primer Application stressed component and the fastener should be torqued
accordingly.
NOTE: It is not necessary to bathe the threads in primer.
NOTE: Some special applications require variation from
1. Ensure the threaded surface, both male and female, is standard torque values. Reference should always
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clean and free of dirt and oil. Apply a light spray coating be made to component overhaul procedures for
of primer to both male and female parts to be joined to recommendations.
clean and accelerate the curing process.
Special attention should be given to the existence of
2. Allow the part to dry prior to adhesive/sealant lubricant, plating, or other factors that might require variation
application. from standard torque values.
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Adhesive/Sealant Application The use of lubricants on zinc-flake coated parts shall be

prohibited since this will change the required torque value.
Bead Application When maximum recommended torque values have been
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exceeded, the fastener should be replaced.

Previously installed bolts and nuts of Grade 8 or Class 10.9
and higher may not be reused.
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When referring to the applicable torque charts, use values as

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close as possible to the torque values shown to allow for
FIGURE 1-3 wrench calibration tolerance.
1. Apply a bead perpendicular to the thread, several Torque Wrenches

threads wide, in the approximate area of threaded
engagement (Figure 1-3). Flexible beam type wrenches, even though they might have
a pre-set feature, must be pulled at right angle and the force
2. In a blind hole application, a bead of several drops of must be applied at the center of the handle. Force value
adhesive should be applied into the bottom of the hole to readings must be made while the tool is in motion. Rigid
be hydraulically forced up during engagement. handle type, with torque limiting devices that can be pre-set
to required values, eliminate dial readings and provide more
3. After application and engagement of mated threads,
reliable, less variable readings.
fixturing will occur within five (5) minutes if primed prior

NOTE: If multipliers and/or special tools are used to reach • All handles must be parallel to the step wrench during
hard to get at areas, ensure torque readings are final tightening. Multiplier reaction bars may be 1
accurate. misaligned no more than 30 degrees without causing
serious error in torque.
Torque wrenches are precision instruments and must be
handled with care. To ensure accuracy, calibrations must be • Multiplier bar handles must be propped or supported
made on a scheduled basis. Whenever there is a possibility within the outer 1/4 of the handle length, or serious
that a torque wrench may have been either overstressed or under or over tightening will occur.
damaged, it should immediately be removed from service
To convert pounds-foot (lb-ft) of torque to newton meters
until recalibrated. When using a torque wrench, any erratic or
(Nm), multiply the pounds-foot quantity by 1.3558.
jerking motion can result in the application of excessive or
improper torque. ALWAYS use a slow, even movement and To convert pounds-inch (lb-in) of torque to Newton meters
STOP when the predetermined value has been reached. (Nm), multiply the pounds-inch quantity by 0.11298.
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When using step wrenches, calculated wrench settings are
valid only when the following conditions are met:
Torque Values
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• Torque wrenches must be those specified and forces The following tables list the torque values for both ASME
must be applied at the handle grip. The use of handle standard and metric fasteners. The tables list the values for
extensions will change applied torque to the bolt. grade 5 and grade 8 zinc-flake coated, untreated (black)
finish and stainless steel fasteners.: UNC (Coarse) Thread:
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SAE Grade 1 SAE Grade 5 SAE Grade 7 SAE Grade 8
and Grade 2 HHCS HHCS HHCS
HHCS
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Socket Head Socket Head Serrated

Capscrew Shoulder Flange Head
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Screw
FIGURE 1-4
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Torque Values for Zinc-Flake Coated and Untreated

Fasteners
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Bolt Diameter - Inches

Torque Values (Pounds-Foot, Maximum/Minimum)
SAE Grade 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1 1-1/8 1-1/4 1-1/2
5 7 14 25 40 61 88 121 213 342 512 636 884 1532
Zinc-Flake
8 10 20 36 57 86 124 171 301 483 723 1032 1433 2488
9.0 19 32 52 78 114 156 270 416 606 813 1141 2028
5
7.7 17 30 48 72 106 144 249 384 560 751 1053 1865
Untreated
12.5 26 48 73 120 161 234 385 615 929 1342 2043 3276
8
11.5 24 44 67 110 143 216 355 567 857 1234 1885 3024
NOTE: Studs shall be torqued using capscrew values when grade is known.

Table 1-3: UNF (Fine) Thread: Torque Values for Zinc-Flake Coated and Untreated Fasteners
Bolt Diameter - Inches

Torque Values (Pounds-Foot, Maximum/Minimum)
SAE Grade 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1 1-1/8 1-1/4 1-1/2
5 8 15 28 44 66 95 132 229 364 543 785 944 1654
Zinc-Flake
8 11 22 39 61 94 134 186 323 514 766 1109 1530 2682
10 21 36 57 88 126 182 312 458 658 882 1251 2288
5
9 19 34 53 81 116 167 287 421 606 814 1155 2105
Untreated
14.5 26 53 85 125 177 250 425 672 1009 1500 2092 3640
8
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13.5 24 49 79 115 163 230 393 620 931 1380 1925 3360
NOTE: Studs shall be torqued using capscrew values when grade is known.
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Table 1-4: Metric Fasteners, Coarse Thread, Zinc-Flake Coating
Bolt Diameter - Metric
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Torque Values (Nm)
Class M4 M5 M6 M8 M10 M12 M14 M16 M18 M20 M22 M24 M27 M30 M33 M36
8.8 2.6 5.2 9.0 21.6 42.4 73.1 116 178 250 349 467 600 877 1195 1608 2072
10.9 3.7 7.5 12.5 31.5 62.0 110 170 265 365 520 700 900 1325 1800 2450 3150
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12.9 4.3 9.0 15.0 36.0 75.0 128 205 315 435 615 830 1060 1550 2125 2850 3700
Table 1-5: Metric Fasteners, Coarse Thread, Untreated

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Torque Values (Nm, Maximum/Minimum)
Class M4 M5 M6 M7 M8 M10 M12 M14 M16 M18 M20 M22 M24 M27 M30
3.1 6.5 11 19 27 53 93 148 230 319 447 608 774 1134 1538
8.8
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2.8 5.9 10 17 25 49 85 136 212 294 413 562 714 1046 1420
4.5 9.2 16 26 38 75 130 212 322 455 629 856 1089 1591 2163
10.9
4.1 8.5 14 24 35 69 120 195 298 418 581 790 1005 1469 1997
5.4 11 19 31 45 89 156 248 387 532 756 1029 1306 1910 2595
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12.9
4.9 10 17 28 42 83 144 228 357 490 698 949 1206 1763 2395
Table 1-6: Metric Fasteners, Fine Thread, Zinc-Flake Coating

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Torque Values (Nm)
Class M8x1 M10x1 M10x1.25 M12x1.5 M14x1.5 M16x1.5 M18x1.5 M20x1.5 M22x1.5 M24x2 M27x2 M30x2 M33x2 M36x3
8.8 23 46 44 75 123 185 270 374 496 635 922 1279 1707 2299
10.9 34 71 66 113 188 285 415 575 770 980 1425 2025 2500 3590
12.9 41 84 79 135 220 335 485 675 900 1145 1675 2375 2900 4200

Table 1-7: Metric Fasteners, Fine Thread, Untreated

1
Torque Values (Nm, Maximum/Minimum)
Class M8x1 M10x1 M10x1.25 M12x1.5 M14x1.5 M16x1.5 M18x1.5 M20x1.5 M22x1.5 M24x2 M27x2 M30x2 M33x2 M36x3
29 57 57 100 160 248 345 483 657 836 1225 1661 — —
8.8
27 53 53 92 147 229 318 446 607 771 1130 1534 — —
41 81 81 1140 229 348 491 679 924 1176 1718 2336 — —
10.9
38 75 75 130 211 322 451 627 853 1085 1587 2157 — —
49 96 96 168 268 418 575 816 1111 1410 2063 2800 — —
12.9
45 90 90 156 246 386 529 754 1025 1302 1904 2590 — —
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Table 1-8: UNC (Coarse) Thread: Torque Values for Table 1-9: Metric Coarse Thread: Torque Values for
Stainless Steel Fasteners with Oil Lubrication Stainless Steel Fasteners with Oil Lubrication
Torque Value Torque

Size Value
lb-in lb-ft Size
#5 (0.125) 6.9 —
Nm
#8 (0.164) 18 — M2.5 0.4
#10 (0.190) 21 — M3 0.9
1/4 68 — M4 1.5
5/16 120 10 M5 3.1

M6 5.3
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3/8 210 17.5
7/16 340 28 M8 13.0
M10 27.0
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1/2 — 39
5/8 — 74 M12 45.0
3/4 — 114 M14 71.1
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M16 109
NOTE: Stainless steel fasteners tend to gall while being
M18 157
tightened. To reduce this risk, lubricate the threads
with oil or molybdenum disulfide and torque at low M20 220
speeds without interruptions. Do not use excessive
NOTE: Stainless steel fasteners tend to gall while being
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pressure. Impact wrenches are not recommended.
tightened. To reduce this risk, lubricate the threads
with oil or molybdenum disulfide and torque at low
speeds without interruptions. Do not use excessive
pressure. Impact wrenches are not recommended.
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Weld Studs
Unless otherwise specified the following grade 2 torque
values (± 10%) apply.
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Table 1-10: Weld Stud Torque Values

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T-2-4
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WIRE ROPE shall be of the type which does not hinder visual inspection.
Those sections of rope which are located over sheaves or 1
General otherwise hidden during inspection and maintenance
procedures require special attention when lubricating rope.
The following information is a compendium of information The object of rope lubrication is to reduce internal friction and
from various wire rope manufacturers and includes to prevent corrosion.
inspection, replacement, and maintenance guidelines for
wire rope as established by ANSI/ASME B30.5, federal During fabrication, ropes receive lubrication; the kind and
regulations, and Manitowoc. The inspection interval shall be amount depends on the rope’s size, type, and anticipated
determined by a qualified person and shall be based on such use. This in-process treatment will provide the finished rope
factors as expected rope life as determined by experience on with ample protection for a reasonable time if it is stored
the particular installation or similar installations, severity of under proper conditions. But, when the rope is put into
environment, percentage of capacity lifts, frequency rates of service, the initial lubrication may be less than needed for the
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operation, and exposure to shock loads. Periodic full useful life of the rope. Because of this possibility, periodic
Inspections need not be at equal calendar intervals and applications of a suitable rope lubricant are necessary.
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should be performed at shorter time intervals as the wire The following are important characteristics of a good wire
rope approaches the end of its useful life. A periodic rope lubricant:
inspection shall be performed at least once a year. The
following provides inspection and maintenance procedures 1. It should be free from acids and alkalis.
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for wire ropes used on Grove products (e.g. wire rope used 2. It should have sufficient adhesive strength to remain on
as load lines [hoisting cables], boom extension and the ropes.
retraction cables, pendant cables, tow winch cables, and
hook block tie down cables). 3. It should be of a viscosity capable of penetrating the
interstices between wires and strands.
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Environmental Conditions 4. It should not be soluble in the medium surrounding it
The life expectancy of wire rope may vary due to the degree under the actual operating conditions (i.e. water).
of environmental hostility and other conditions to which these 5. It should have a high film strength.
mechanical devices are subjected. Variation in temperature,
6. It should resist oxidation.
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continuous excessive moisture levels, exposure to corrosive

chemicals or vapors or subjecting the wire rope to abrasive
Before applying lubrication, accumulations of dirt or other
material may shorten normal wire rope life. Frequent/
abrasive material should be removed from the rope.
periodic inspections and maintenance of your wire rope is
Cleaning can be accomplished by using a stiff wire brush and
recommended for preventing premature wear and to insure
solvent, compressed air, or live steam. Immediately after the
long-term satisfactory performance.
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wire rope is cleaned, it should be lubricated. Many

techniques may be used; these include bath, dripping,
Dynamic Shock Loads pouring, swabbing, painting or pressure spray methods.
Subjecting wire rope to abnormal loads beyond the Whenever possible, the lubricant should be applied at the
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endurance limit will shorten the wire ropes, life expectancy. top of a bend in the rope, because at that point the strands
Examples of this type of loading are listed below. are spread by bending and are more easily penetrated.
There should be no load on the rope while it is being
1. High velocity movement e.g.; hoisting or swinging of a lubricated. It should be noted, the service life of wire rope will
load followed by abrupt stops.
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be directly proportional to the effectiveness of the method

2. Suspending loads while traveling over irregular surfaces used and amount of lubricant reaching the working parts of
such as railroad tracks, potholes, and rough terrain. the rope.
3. Moving a load that is beyond the rated capacity of the Precautions and Recommendations During
lifting mechanism, i.e.; overloading.
Inspection or Replacement
Lubrication 1. Always lock out equipment power when removing or
installing wire rope assemblies.
A wire rope cannot be lubricated sufficiently during
manufacture to last it’s entire life. Therefore, new lubricant 2. Always use safety glasses for eye protection.
must be added throughout the life of a rope to replace factory
lubricant which is used or lost. It is important that lubricant 3. Wear protective clothing, gloves, and safety shoes as
applied as part of a maintenance program shall be appropriate.
compatible with the original lubricant, and to this end, the 4. Use supports and clamps to prevent uncontrolled
rope manufacturer should be consulted. Lubricant applied movement of wire rope, parts, and equipment.

5. When replacing fixed length cable assemblies (e.g.

pendants) having permanently attached end fittings use
2
only pre-assembled lengths of wire rope as supplied
from Manitowoc. Do not build lengths from individual 4
components.
6. Replace an entire wire rope assembly. Do not attempt to
rework damaged wire rope or wire rope ends. A925
5
7. Never electroplate wire rope assemblies.

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8. Do not weld any wire rope assembly or component
unless welding is recommended by the wire rope FIGURE 1-6
manufacturer. Welding spatter shall never be allowed to
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come in contact with the wire rope or wire rope ends. In
addition, be sure that the wire rope is not an electrical
Wire Rope Inspection (Running Ropes and
path during other welding operations. Pendant Cables)
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9. Wire ropes are manufactured from special steels. If Wire rope should be inspected frequently/dally and
heating a wire rope assembly is absolutely necessary for periodically/yearly in accordance with the following
removal, the entire wire rope assembly shall be information excerpted from a National Consensus Standard
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discarded. as referenced by Federal Government Agencies.
Recommended inspection intervals may vary from machine
10. On systems equipped with two or more wire rope t o m a ch i ne an d m a y v ar y b as ed on e n vi r o nm en ta l
assemblies operating as a matched set, they shall be conditions, frequency of lifts, and exposure to shock loads.
replaced as an entire set. The inspection time intervals may also be predetermined by
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11. Do not paint or coat wire ropes with any substance state and local regulatory agencies.
except approved lubricants. NOTE: Wire rope may be purchased through Manitowoc
12. Measure the rope’s diameter across crowns (1) of the Crane Care.
strands when determining if rope has become damaged Any deterioration observed in the wire rope should be noted
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(Figure 1-5). in the equipment inspection log and an assessment

concerning wire rope replacement should be made by a
qualified person.
Keeping Records
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A signed and dated report of the wire rope’s condition at

each periodic inspection must be kept on file at all times. The
report must cover all inspection points listed in this section.
The information in the records can then be used to establish
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data which can be used to determine when a wire rope

1 should be replaced.
It is recommended that the wire rope inspection program
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include reports on the examination of wire rope removed

from service. This information can be used to establish a
FIGURE 1-5 relationship between visual inspection and the rope’s actual
internal condition at the time of removal from service.
13. When checking for broken wires (5) (Figure 1-6) relax
the rope, move it off “pick-up points”, and flex it as much
as possible. Use a sharp awl to pick and probe between
Frequent Inspection
wires and strands, lifting any wire which appears loose A frequent daily visual inspection is recommended for all
or moves excessively. Defect in the rope is spoke of in running ropes in service. This inspection should be made on
relations to “Lay Length” (2) which is the distance all wire rope which can be expected to be in use during the
measured along rope in which one strand (3) makes one day’s operation. This inspection should be used to monitor
complete revolution around core (4). progressive degradation and to discover severe damages
necessitating wire rope replacement such as:
• Distortion, Kinking, Crushing, Un-stranding, Bird caging,
Reduction of diameter, etc.

• General corrosion. following guidelines. This inspection shall cover the entire
• Broken or cut strands.
length of the extension and retraction cables. This inspection 1
should be used to monitor progressive degradation and to
• Number, distribution and type of broken wires. d i s c o v e r s e v e r e d a m a g e s n e c e s s i ta t i n g w i r e r o p e
replacement or equipment repair. Inspection criteria are as
• Evidence of core failure.
follows:
• End fitting wear/abrasion.
1. Inspect for reduction of rope diameter below nominal
Pay particular attention to areas of the rope where wear and diameter.
other damage is likely to occur:
2. Inspect for severely corroded or broken wires at end
• Pick-up Points: Sections of wire rope that are repeatedly connections.
stressed during each lift, such as those sections in
3. Inspect for severely corroded, cracked, bent, worn, or
contact with sheaves.
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improperly applied end connections.
• End Attachments: The point where a fitting is attached to
4. Inspect wire rope in areas subjected to rapid
the wire rope or the point where the wire rope is attached
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deterioration such as:
to the drum.
• Sections in contact with saddles, equalizer sheaves,
• Abuse Points: The point where the wire rope is or other sheaves where wire rope travel is limited.
subjected to abnormal scuffing and scraping.
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• Sections of wire rope at or near terminal ends where
Periodic Inspection corroded or broken wires may protrude.
Wire rope should be inspected periodically/annually or at a • Sections of wire rope in contact with stationary
shorter time interval if necessitated by environmental or surfaces where abrasion or chafing may take place
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other adverse conditions, and shall cover the entire length of as a result of equipment vibration.
the wire rope. Only the outer surface of the wire rope need 5. Inspect for damaged or wobbly boom extension and
be inspected, and no attempt should be made to open the retraction sheaves that may cause rapid deterioration of
rope. Periodic inspection should include all items listed the wire rope.
under frequent inspection plus the following:
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6. Inspect for unusual cable sag/stretch and be sure cables

1. Inspect for reduction of rope diameter below nominal used in sets all have an equal tension applied. Repeated
diameter. need for adjustment of an individual cable is evidence of
2. Inspect for severely corroded or broken wires at end cable stretch and indicates the need for additional and
connections. more thorough inspection in order to determine and
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correct the cause.

3. Inspect for severely corroded, cracked, bent, worn, or
improperly applied end connections. Wire Rope Inspection/Replacement (All Wire
4. Inspect wire rope in areas subjected to rapid Rope)
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deterioration such as: No precise rules can be given for determination of the exact
• Sections in contact with saddles, equalizer sheaves, time for replacement of wire rope since many variable factors
or other sheaves where wire rope travel is limited. are involved. Determination regarding continued use or
replacement of wire rope depends largely upon the good
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• Sections of wire rope at or near terminal ends where

judgement of an appointed and qualified person who
corroded or broken wires may protrude.
evaluates the remaining strength in a used rope after
5. Inspect boom nose sheaves, hook block sheaves, boom allowance for any deterioration disclosed by inspection.
extension/jib sheaves, auxiliary boom nose sheaves,
Wire rope replacement should be determined by the
and hoist drums for wear. Damaged sheaves or hoist
following information excerpted from a National Consensus
drums can accelerate wear and cause rapid
Standard as referenced by Federal Government Agencies
deterioration of the wire rope.
and as recommended by Grove Worldwide. All wire rope will
eventually deteriorate to a point where it is no longer usable.
Wire Rope Inspection (Boom Extension and Wire rope shall be taken out of service when any of the
Retraction Cables) following conditions exist:
Periodic Inspection 1. Kinking, crushing, bird caging, or any other damage

resulting in distortion of the rope structure.
It is recommended that a periodic inspection of all boom
extension and retraction cables be performed using the 2. Evidence of any heat damage from any cause.

3. Reductions from nominal diameter of more than 5%. Method 2

4. In running rope, six randomly distributed broken wires in
one lay or three broken wires in one strand in one lay.
5. In standing ropes, more than two broken wires in one lay
in sections beyond end connections or more than one
broken wire at an end connection.
6. In rotation resistant rope, two randomly distributed
broken wires in six rope diameters or four randomly
distributed broken wires in 30 rope diameters.
7. Severe corrosion as evidenced by pitting.
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8. Manitowoc recommends that for cable extended booms,
a single damaged wire rope assembly shall require
replacement of the entire set of extension cables.
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9. Manitowoc recommends for cable extended booms, that
boom extension cables be replaced every seven (7)
years.
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Seizing Wire Rope
It is important to seize the ends of rotation resistant wire
ropes to prevent the displacement and unraveling of the FIGURE 1-8
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individual wires and strands at the ends. All preformed and
non-preformed styles of wire rope should be seized prior to Wind a length of soft annealed wire (Figure 1-8) around the
cutting. Seizings must be placed on both sides of the point wire rope at least seven times. The two ends should be
where the wire rope is to be cut. twisted together in the center of the seizing. Tighten the
The two preferred methods for seizing wire ropes are: seizing by alternately prying and twisting. Cut off both ends
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of the wire and pound the twist flat against the rope.
Method 1 NOTE: Non-preformed wire rope (1) (Figure 1-9) should
Using a length of soft annealed wire (Figure 1-7), place one have three seizings (3) located on each side of the
end in the groove between two strands of the wire rope. Turn cut (4) as compared to performed wire rope (2).
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the long end of the annealed wire at right angles to the wire
and wrap it tightly over the portion in the groove.
1 4 3
The two ends of the annealed wire should be twisted
together tightly. Cut off the excess wire and pound the twist
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flat against the wire rope.

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7204
FIGURE 1-7
FIGURE 1-9

Installing 35x7 Class Wire Rope train the rope and help assure smooth operation during
its useful life. 1
Ideally, you should run these loads with reeving that lets
CAUTION you place the loads on the block with all rope off the
Any cutting of this specific wire rope is not recommended. drum except the last three wraps. If this is not possible,
If 35x7class wire rope must be cut for any reason, it is alternate methods must be used to assure proper
necessary to follow the attached instructions. Also, unlike tensioning of the rope on the drum.
other types of wire rope, the ends on this wire rope must
be welded to retain the rotation resistant characteristics. Procedures for Cutting and Preparing 35x7
Class Wire Rope
1. Unload properly and relieve any twists. Pull the rope off
the shipping reel or unroll it from a shipping coil. (If done 35x7 class rope is a special wire rope that must be handled
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improperly, you may kink the rope, which will result in differently than any other rope we manufacture. One
permanent damage to the rope.) Then lay the rope on characteristic that makes this rope special is that the outer
the ground in direct line with the boom. This helps strands are not preformed. It is because of this that the
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release any twist in the rope. following procedures for cutting and preparing 35x7 class
rope must be followed:
2. Attach rope’s end to drum. Pull the rope over the point
sheave and attach the end to the drum. Be sure not to 1. The welded ends prepared by the manufacturer are not
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remove the welded end. to be removed.
3. Wind rope onto drum slowly and carefully. At this point, it 2. Before cutting the rope, make three separate bands with
isn’t necessary to provide additional load other than the seizing strand on each side of where the cut is to be
weight of the rope being pulled across the ground. made (total of six bands for each cut). Each band is to
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have a minimum length of one and one half times the
4. Spool first layer tightly. It is essential on smooth-faced rope diameter. The two bands closest to the cut should
drums that the first layer is spooled with wraps tight and be located at a distance equal to one rope diameter
close together since the first layer forms the foundation away from the cut. The four remaining bands should be
for succeeding layers. If need be, use a rubber, lead or evenly spaced at a distance equal to three rope
brass mallet (but never a steel hammer) to tap the rope
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diameters.
in place.
a. If a welder is available, the cut should be made with
5. Spool multiple layers with sufficient tension. It’s very an abrasive saw. Immediately after the cut, both
important to apply a tensioning load to the ropes during ends of the rope are to be cap welded so that all
the rope breaking-in process. (If not, the lower layers inner and outer strands are welded together,
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may be loose enough that the upper layers become preventing any movement between them.
wedged into the lower layers under load, which can
seriously damage the rope.) The tensioning load should NOTE: The outer strands must not be able to move with
range from 1 to 2% of the rope’s minimum breaking respect to the inner strands. The weld must not
exceed the diameter of the rope.
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force.
6. For ropes in multi-part systems: Reeve the traveling b. If a welder is not available, the cut is to be made with
block and boom tip sheaves so the rope spacing is an acetylene torch. The cut is to be made in such a
maximized and the traveling (hook) block hangs straight way that both ends of the rope are completely fused
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and level to help assure block stability. so that all inner and outer strands are bonded
together, preventing any movement between
7. Breaking in your new 35x7 class rope: After installation, strands.
you should properly break in your rope, which allows the
rope’s component parts to adjust themselves to your NOTE: The outer strands must not be allowed to move
operating conditions. with respect to the inner strands. The fused end
must not exceed the diameter of the rope.
With the boom fully raised and fully extended, attach a
light load at the hook and raise it a few inches off the 3. Once the cuts have been completed, the seizing bands
ground. Allow to stand for several minutes. Then cycle are to be left in place for shipment of the rope.
the load between the full “up” and “down” positions 4. Attach a “Do not remove welded ends” tag on each reel
several times. Stand back and watch the drum winding flange.
and rope travel for any potential problems.
After making the lifts with a light load, increase the load
and cycle it up and down a few times. This procedure will

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FIGURE 1-10
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RT530E-2 SERVICE MANUAL HYDRAULIC SYSTEM
SECTION 2
HYDRAULIC SYSTEM
SECTION CONTENTS
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33 2
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Steering Control Valve . . . . . . . . . . . . . . . . . . . . . 2-35
Hydraulic Oil Recommendations. . . . . . . . . . . . . . 2-5 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35
Draining and Flushing . . . . . . . . . . . . . . . . . . . . . . 2-5 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35
Removing Air from the Hydraulic System . . . . . . . 2-6 Tandem Brake Valve with Treadle Pedal. . . . . . . 2-36
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Parts Replacement . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36
Directional Control Valves. . . . . . . . . . . . . . . . . . . 2-6 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36
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Supply Pressure and Return Circuit . . . . . . . . . . . 2-8 Dual Accumulator Charge Valve . . . . . . . . . . . . . 2-37
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37
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Oil Cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 Hydraulic Accumulator Service Brake . . . . . . . . 2-39
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39
Hydraulic Pumps . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 Holding Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40
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Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40
Pressure Setting Procedures . . . . . . . . . . . . . . . 2-17 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40
Procedure A - For Checking/Setting The Main Control Cross Axle Differential Lock Valve . . . . . . . . . . . 2-41
Valve For Hoists(s), Boom Lift and Piston Pump 2-19 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41
Procedure B - For Setting The Outrigger/Rear Steer/ Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41
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Oil Cooler Motor Pressures. . . . . . . . . . . . . . . . . 2-19

Outrigger Control Manifold. . . . . . . . . . . . . . . . . . 2-43
Procedure C - For Checking/Setting The Swing Direc- Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43
tional Control Valve Work Port Relief Valves . . . 2-20
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43
Procedure D - For Checking/Setting The Service
Brake Dual Accumulator Charge Valve Charging Pilot Operated Check Valve . . . . . . . . . . . . . . . . . 2-44
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Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44

Procedure E - For Checking/Pre-Charging The Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44
Service Brake Accumulators. . . . . . . . . . . . . . . . 2-20 Integrated Outrigger/Rear Steer Manifold . . . . . . 2-45
Procedure F - For Checking/Setting the Front Steer Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45
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Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45

Procedure G - For Checking/Setting the Pilot Supply
Check Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48
Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48
Procedure H - For Checking/Setting The Swing Brake
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Release Pressure . . . . . . . . . . . . . . . . . . . . . . . . 2-21 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48

Procedure J - For Setting Threshold on Electronic Range Shift/Parking Brake Valve . . . . . . . . . . . . . 2-49
Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49
Procedure K - Setting Threshold and Max on Swing Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49
Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22 Axle Oscillation Lockout Valve (Standard Units) 2-50
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-50
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-50
Directional Control Valves . . . . . . . . . . . . . . . . . . 2-30 Axle Oscillation Lockout Valve
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30 (Optional CE Units) . . . . . . . . . . . . . . . . . . . . . . . . 2-52
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52
Accessory With Swing Directional Control Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52
Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33 Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54

HYDRAULIC SYSTEM RT530E-2 SERVICE MANUAL
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-64

Surface Protection for Cylinder Rods . . . . . . . . . 2-54 Steer Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-68
Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-68
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-68
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57 Outrigger Extension Cylinder . . . . . . . . . . . . . . . . 2-71
Dual Rod Telescope Cylinder . . . . . . . . . . . . . . . 2-60 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-71
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60 Outrigger jack Cylinder . . . . . . . . . . . . . . . . . . . . . 2-73
Axle Oscillation Lockout Cylinder . . . . . . . . . . . . 2-64 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-73
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DESCRIPTION operation of individual hydraulic circuits are discussed within
their individual sections as applicable. A complete hydraulic
This section describes the hydraulic system, the system schematic showing all options is at the back of this
components which make up the hydraulic system, and the manual and a figure titled A.N.S.I. Graphical Symbols
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components dependent upon the hydraulic system for their provides hydraulic symbol information for this section
operation. This includes descriptions of the supply pressure (Figure 2-1) and (Figure 2-2).
and return hydraulic circuit, hydraulic pumps, all hydraulic
valves, and all hydraulic cylinders. Detailed descriptions and
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FIGURE 2-1

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FIGURE 2-2

MAINTENANCE 10. Disconnect the return lines from a pair of outrigger jack
cylinders and activate the cylinders to their maximum
Hydraulic Oil Recommendations. down positions.
For the hydraulic oil specifications, refer to Section 9 - 11. Connect the return lines and raise the outrigger jack
LUBRICATION. cylinders to the stowed position. Replenish the reservoir
hydraulic oil level as necessary.
Draining and Flushing 12. Repeat Steps 10 and 11 for the remaining two outrigger 2
If a component has been changed because of a failure that cylinders.
might allow metal or abrasive particles to enter the system, 13. Disconnect the return line from the telescope cylinder
all systems must be thoroughly checked, drained, and and fully extend the boom.
flushed.
14. Connect the return line and retract the boom. Replenish
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1. Remove the reservoir drain plug. Allow about three the reservoir hydraulic oil level as necessary.
minutes after hydraulic oil stops flowing from the drain
15. Disconnect the return lines from both front steer
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port for the side walls to drain.
cylinders and turn the front wheels to the extreme right.
2. Clean and install the reservoir plug and fill the reservoir
with a 50/50 mixture of fuel oil and clean hydraulic oil. 16. Connect the return lines and turn the front wheels to the
extreme left and then back to center. Replenish the
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3. Cycle the crane through all functions several times. reservoir hydraulic oil level as necessary.
Then return the crane to its stowed position and turn the
front and rear wheels to the extreme left. Shut down the 17. Repeat Steps 15 and 16 for the rear steering cylinders.
engine. 18. Raise the crane on outriggers.
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4. Remove the reservoir drain plug and drain the reservoir. 19. Disconnect the line from port A of the axle lockout valve.
Clean and install the drain plug and fill the reservoir with
clean hydraulic oil. 20. Using a jack under the rear wheel on one side of the
crane, jack up the wheel to maximum travel.
21. Connect the line to port A of the axle lockout valve and
CAUTION
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disconnect the line from Port B.

Hydraulic oil supply lines must be connected to the
cylinders when flushing the system. 22. Repeat step 19 using the other rear wheel.
23. Connect the line to port B of the axle lockout valve.
NOTE: Draining the various components will be aided by Energize the axle lockout valve. Replenish the reservoir
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connecting a drain line in place of the disconnected hydraulic oil level as necessary.
return line.
24. Disconnect the return line from the main hoist motor and
5. Disconnect the return line from the lift cylinder and raise fully hoist up the hoist.
the boom to maximum elevation.
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25. Connect the return line to the main hoist motor and fully
6. Connect the cylinder return line and lower the boom to hoist down the hoist, then hoist up again. Replenish the
its stowed position. Replenish the reservoir hydraulic oil reservoir hydraulic oil level as necessary.
level as required.
26. Repeat Steps 24 and 25 for the auxiliary hoist as
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7. Disconnect the return line from an outrigger extension necessary.

cylinder and fully extend the outrigger.
27. Disconnect one of the lines from the swing motor and
8. Connect the outrigger return line and retract the drive the motor in the direction it will go.
outrigger. Replenish the reservoir hydraulic oil level as
necessary. 28. Connect the line to the swing motor, then drive the swing
motor in the opposite direction until the boom is centered
9. Repeat Steps 7 and 8 for the remaining outriggers. and forward. Replenish the reservoir hydraulic oil level
as necessary.
CAUTION
When draining the outrigger cylinders, always operate CAUTION
either both front or both rear cylinders together to prevent When hydraulic oils are changed or added, ensure that
twisting the crane. hydraulic oils of different manufacturers are of the same
specifications. Discoloration may occur.

When hydraulic oils are changed, recheck the reservoir • If the air is not readily removed, lower the boom to below
hydraulic oil level after brief system operation and add horizontal, extend the telescope cylinders as far as
hydraulic oil as required. Working reservoir capacity practicable, and allow the boom to remain in this position
(capacity to full mark) is 395.99 l (104.6 U.S. gal). Ensure the overnight. This should allow entrapped air to find its way
crane is level and in the travel mode of operation when the to the holding valve so that telescoping the boom IN the
hydraulic system is being filled. The system must be filled next morning should force the air back to the reservoir.
with all cylinders retracted. Fill the reservoir to the full mark Ensure the boom is first telescoped IN (not OUT) in the
on the reservoir sight gauge. After the reservoir is filled, morning. Telescoping OUT may cause air to be forced
operate all circuits and recheck the reservoir sight gauge. back into a cylinder.
Add hydraulic oil as required.
Removing Air from the Hydraulic System

DANGER
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Air entering the hydraulic oil will normally be removed
automatically by passage of the hydraulic oil over the baffles Pressurized fluid can cause serious injury or death.
in the hydraulic reservoir. If a component has been replaced, Extreme care must be used when removing any plugs or
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the reservoir level is too low, or a leak develops in the suction restrictions from a hydraulic system suspected to have
lines to the pumps, air can enter the system. If air becomes entrapped air that may be pressurized.
entrapped in the hydraulic oil, it may be detectable in pumps
and motor operated components such as the swing • Entrapped air may be removed from cylinders having
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mechanism and hoist(s), because it can cause these units to wet rods by cycling. On certain cylinders, a plugged port
become noisy during operation. If noisy operation occurs, is provided on the rod end to bleed off entrapped air.
first check the level of the hydraulic reservoir and replenish
as necessary. Then inspect for leaks in the suction lines
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leading to the pumps.
Minute leaks may be hard to locate. If a leak is not readily
DANGER
detectable, use the following way to check for it: Pressurized fluid can cause serious injury or death. Do
not attempt to loosen fittings in pressurized lines or while
• Seal all normal openings in the hydraulic system and the the hydraulic pumps are in operation.
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reservoir. Using a positive means to control the pressure

(like a regulator), pressurize the hydraulic system to • In the event that air entrapment should persist, bleeding
13.8 to 27.6 kPa (0.14 to 0.28 bar) (2 to 4 psi) and of air by loosening various clamp and screw type fittings
inspect all joints and fittings for evidence of leaks. A may become necessary.
soap solution applied to the fittings and joints may also
• If the above procedures fail to eliminate air entrapment,
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prove helpful in detecting minute leaks while the system

is pressurized. Remove the pressure, repair any leaks contact your authorized Grove Distributor.
found, and reopen any openings (such as a vent) closed
for inspection. Refill the reservoir after completing any Parts Replacement
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repairs or service. Operate all hydraulic circuits several Parts found damaged or out of tolerance when maintenance
times in both directions. is being performed should be replaced. Refer to the
• This action should return any entrapped air to the Manitowoc Crane Care Parts Catalog for proper replacement
reservoir where it can be removed from the hydraulic oil parts.
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by the baffles.
Directional Control Valves
The control valves that control the crane functions are
installed on the right side on the outside of the superstructure
DANGER side plate, and between the left and right superstructure side
Tipping Hazard plates under the main hoist.
To avoid death or serious injury, locate the machine on a
firm supporting surface and position the boom over the
Inspection
front on outriggers when extending the boom at low Inspect the control valves for visible damage, binding spools,
angles. and evidence of leakage. If excessive internal leakage is
suspected during operation with a spool in its center position,
• To remove entrapped air from telescope cylinders, lower it is possible that the area between the spool and working
the boom to below horizontal and fully telescope the section bore of the valve body is worn beyond serviceable
boom in and out several times.

limits. If this condition exists, the spool and body must be between the poppet and seat, it will keep the valve open and
replaced as an assembly. allow a return flow of hydraulic oil. The remedy is to clean the
valve, but it is also a good idea to follow through and ensure
Valve Leakage the hydraulic system filter is still serviceable.
Dripping hydraulic oil indicates some type of external Binding Spools
leakage. The machine should be removed from service for
immediate repairs. External leaks sometimes develop at Some of the most common causes for stiff spool movement
fittings and seals. Seals may be damaged by temperatures or jammed spool action are system overheating, excessive
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that are too high, or by dirt or paint accumulation on the pressure, contaminated or deteriorated hydraulic oil, or
spool. Damaged or torn seals must be replaced. warped mountings. When scorched, deteriorated hydraulic
oil or contamination is the cause, flushing the system and
A component functioning at reduced efficiency may indicate
replenishing with clean hydraulic oil may solve the problem.
that the control valve for that component is leaking internally.
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If the spool bores are badly scored or galled, the valve must
If preliminary check-out reveals that adequate volume is
be removed for servicing.
being supplied to the affected valve bank, relief valves are
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properly adjusted, and the component is not at fault, check Warping occurs when mounting plates are not level or they
the valve for scored or worn parts. Scoring is a sign of the become distorted from machine damage. As mentioned
number one problem in hydraulics - contamination (external previously, the valve can be shimmed level.
contamination by dust or internal contamination by debris
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Also, check the valve for rust. Rust or dirt collecting on the
from deteriorating components or oxidized hydraulic oil).
valves can prevent free movement of the spool, and keep it
Scored or severely worn valve components must be
from the true center position. Excessive system pressure
replaced.
can create both internal and external leaks in valves that are
Check valves in the control valves are designed to permit a otherwise sound. Only qualified technicians using the correct
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flow of hydraulic oil in one direction only. If a piece of dirt or equipment should make pressure adjustments when
rust has worked its way into the check valve and lodges pressure adjustments are needed.
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SUPPLY PRESSURE AND RETURN CIRCUIT An oil temperature gauge is located on the lower front of the
reservoir to indicate oil temperature.
Description The hydraulic oil filter (Figure 2-4) is located in the top of the
The supply pressure and return circuit is made up of several reservoir. The filter housing contains a replaceable filter
circuits which route hydraulic oil from the hydraulic pumps to element. Returning hydraulic oil flows through the filter head,
the directional control valves for the individual operating through the filter element and into the reservoir.
circuits. The supply pressure and return circuit consists of An element condition indicator on the filter head indicates
the reservoir and integral filter, three hydraulic pumps, a when to change the filter element. When back pressure
hydraulic oil cooler, and a 12-port hydraulic swivel. Refer to caused by a dirty filter element exceeds 172.3 kPa/1.72 bar
HYDRAULIC PUMPS in this section for descriptions and (25 psid), the filter head’s bypass feature functions to allow
maintenance instructions for each hydraulic pump. Refer to the hydraulic oil to bypass the filter element and flow into the
Section 6 - SWING for description and maintenance reservoir through the bypass outlet instead. A bypass filter
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instructions for the 12-port hydraulic swivel. screen prevents gross contamination from passing through
The supply pressure and return circuit uses Ports 5 and 6 for the filter even during bypass. Refer to Return Hydraulic Filter
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pump supply and the dual Port 4 for return. Each operating for filter changing instructions.
circuit’s description and components begin with the circuit’s
directional control valve. Pump Distribution
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Pump No. 1 is mounted off drive pads of the torque
Hydraulic Reservoir and Filter converter. Pump No. 2 is mounted on the left front side of the
The reservoir (Figure 2-3), attached to the right side of the engine.
carrier frame, has a capacity of 442.3 l (116.8 gal) total, Pump No. 1
395.9 l (104.6 gal) to the full mark. The all-steel reservoir has
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an internally mounted full-flow filter and integral baffles that Pump No. 1 is a variable displacement axial piston pump
help cool the hydraulic oil and prevent hydraulic oil foaming. with a maximum displacement of 112 cm3/rev (6.83 in3/rev).
The pump differential or standby pressure is 2413 kPa/24
Hydraulic oil flows through two tubes at the rear of the
bar (350 psi). Pump No. 1 supplies oil to the integrated
reservoir to the two hydraulic pumps. Almost all of the return
outrigger/rear steer valve, boom lift, telescope, hoist, brakes
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flow goes through the filter at the top of the reservoir. The
and pilot functions.
return line that goes directly into the reservoir (instead of
through the filter) is from the No. 10 port (drain) of the 12-port Pump No. 2
swivel.
Pump No. 2 is a single positive displacement gear pump with
A magnetized drain plug in the bottom of the reservoir a displacement of 39 cm 3 /rev (2.40 in 3 /rev) delivering a
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collects metal particles from the hydraulic oil if it becomes theoretic flow of 84 lpm (21.9 gpm). Pump No. 2 supplies oil
contaminated. to the front steer and swing circuits.
A sight gauge is located on the front of the reservoir to Pump No. 3
indicate hydraulic oil level.
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1. A breather/fill cap located on the top of the reservoir
allows air to enter or exhaust the reservoir. It consists of a displacement of 19 cm 3 /rev (1.16 in 3 /rev) delivering a
a breather, fill neck, gaskets and strainer. It is important theoretic flow of 57.2 lpm (10.6 gpm). Pump No. 3 supplies
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that the breather be kept clean to prevent damage to the oil to the transmission oil cooler fan motor.
reservoir. The breather/fill cap also provides for filling the
reservoir.
A large access cover on top of the reservoir provides for
cleaning. The access cover can also be used to fill the
reservoir after it has been completely drained.

Maintenance
Troubleshooting
Symptom Probable Cause Solution

1. No hydraulic oil a. Low hydraulic oil level. a. Fill reservoir.
flows in systems.
b. Reservoir-to-pump suction lines b. Clean, repair, or replace lines as
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broken or restricted. Air entering at necessary. Check lines for security,
suction lines. Pump not priming. absence of cracks, and proper
a t ta c h m e n t . Ti g h t e n , r e pa i r, o r
replace parts as necessary.
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c. Pump shaft sheared or disengaged. c. If drive shaft is damaged or sheared,
remove and repair or replace as
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necessary
d. Internal contamination. d. Drain, flush with recommended oil
mixture, then drain and refill system
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with recommended hydraulic oil.
2. Slow response. a. Low hydraulic oil level. a. Fill reservoir.
b. Hydraulic oil temperature too high b. If too low, warm up system. As
(watery thin oil) or too low (thick needed, troubleshoot cooler circuit. If
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sluggish oil). too high, troubleshoot cooler circuit.
Likely suspects are in-line check
valve and related hydraulic circuits.
c. Faulty pump section(s). c. Repair or replace pump section(s) or
entire pump.
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3. Pump noise a. Low hydraulic oil level. a. Fill reservoir.

accompanied by
b. Excessive engine speed. b. Regulate engine speed.
hydraulic oil
foaming in c. Air entering at suction lines. c. Check all lines for security and proper
repair. Tighten, repair, or replace as
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reservoir.
needed.
4. Excessive a. System relief valve set too high. a. Using adequate pressure gauge,
pressure buildup. adjust system relief valve as
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necessary.
b. Restricted pump-to-control b. Clean, repair, or replace line as
valve supply line. necessary.
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5. Specific hydraulic a. Leak in system. a. Repair leak.

system (lift, hoist,
b. Faulty electric controls/signals. b. Adjust or replace controls signals.
telescope, swing)
not working. c. Faulty directional control valve. c. Replace valve.
d. Poorly adjusted control in circuit. d. Troubleshoot circuit with schematic.
Adjust hydraulic component per
schematic.
e. Faulty hydraulic cylinder, motor, or e. Replace faulty component.
valve.

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FIGURE 2-3
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Item Description Item Description

1 Access Cover 7 Hex Locknut
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2 Breather/Fill Cap 8 Flatwasher

3 Return Line Filter 9 Thermometer (Temperature Gauge)
4 Reservoir 10 Ladder
5 Sight Gauge 11 Magnetic Plug
6 Capscrew

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3
11
2
4
5, 6
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6728
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FIGURE 2-4

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1 Capscrew 8 Filter Head

2 Washer 9 Gauge
3 Cap 10 O-ring
4 O-ring 11 Element
5 Bypass Valve 12 Bowl
6 Spacer 13 Gasket
7 Capscrew

Return Hydraulic Filter Assembly Element Installation
Element Removal 1. Place a new element into the filter bowl (housing).
2. Install new O-ring in the cap assembly.
3. If by-pass valve was removed from cap, install by-pass
capscrews to cap.
DANGER
Ensure that all hydraulic systems are shut down and the 4. Install cap assembly on filter head and secure with the
pressure is relieved. four bolts. Torque bolts 14.9 Nm ±2.7 (11.00 lb-ft ±2.0)
until the gasket starts to bulge slightly. Do not over
1. Shut down all hydraulic systems. torque. Torque bolt in a criss-cross pattern.
2. Wipe any dirt from the filter head and cap assembly. 5. Activate the hydraulic system and check for leaks. make
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repairs as necessary.
NOTE: The bypass valve assembly is installed to the cap
and is removed with the cap. Hydraulic Reservoir Removal
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3. Remove the four bolts securing the cap assembly to the 1. Remove the capscrews, flatwashers, lockwashers and
filter head. Remove the cap and bypass valve assembly. hex nuts securing the reservoir to the fame. Using a
4. Remove the filter element from the filter bowl (housing). suitable lifting device, remove the reservoir.
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5. Ensure the new filter element is correct by comparing Hydraulic Reservoir Installation
their part numbers with the part numbers of the used
element. 1. Using a suitable lifting device, install the reservoir to the
frame and secure with the capscrews, flatwashers,
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6. Discard the element. lockwashers and hex nuts. Torque the capscrews. Refer
to Fasteners and Torque Values, page 1-12.
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OIL COOLER the filter in the reservoir. When several hydraulic functions
are being used at one time (i.e., hoisting, lifting, and
Description telescoping), more oil has to flow through this return line,
causing a pressure buildup. When this pressure reaches
An air cooled hydraulic oil cooler (Figure 2-5) is installed on 206.8 kPa/2.0 bar (30 psi), the normally closed check valve
the rear of the superstructure behind the hoists. in the return line (in parallel with the return line through the
When the oil temperature reaches 48.8° C (120° F), the hydraulic oil cooler) will open, letting some hydraulic oil
normally closed temperature switch opens to turn on the oil bypass the hydraulic oil cooler and flow directly into the 2
cooler electric motor which drives the oil cooler fan. reservoir filter.
The oil cooler fan pulls cool air through the cooling fins on the When fewer functions are being used, the pressure in the
cooler. Normally, most hydraulic oil from components is system will decrease below 206.8 kPa/2.0 bar (30 psi) and
routed through the oil cooler by way of a return line and on to the check valve will close again.
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1, 2, 3, 4 6770
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FIGURE 2-5
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1 Flatwasher 5 Mounting Bracket
2 Lockwasher 6 Mounting Bracket
3 Capscrew 7 Shield Plate
4 Hex Nut 8 Oil Cooler

HYDRAULIC PUMPS NOTE: Charge pump and two studs must be removed for
wrench access to piston pump mounting bolts.
Description 4. Remove the capscrews and washers attaching the
Pump No. 1 is mounted off drive pads of the torque pump to the drive pad on the torque converter. Remove
converter. Pump No. 2 is mounted on the left front side of the the pump.
engine (Figure 2-6). 5. Clean the gasket material from the drive pad on the
Pump No. 1 torque converter.
Pump No. 1 is a variable displacement axial piston pump 6. Cover the drive pad’s opening to prevent dirt from
entering.
with a maximum displacement of 112 cm3/rev. (6.83 in3/rev).
The pump differential or standby pressure is 2413 kPa/24
bar (350 psi). Pump No. 1 supplies oil to the integrated
No. 1 Pump Installation
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outrigger/rear steer valve, boom lift, telescope, hoist, brakes 1. Install new gasket material to the pump mounting flange.
and pilot functions.
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2. Install pump on torque converter drive pad with
Pump No. 2 capscrews and washers. Make sure the splines mesh
properly. Torque capscrews 292 to 317.2 Nm (216 to 234
ft-lb).
a displacement of 39 cm 3 /rev. (2.40 in 3 /rev) delivering a
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theoretic flow of 84 lpm (21.9 gpm). Pump No. 2 supplies oil 3. Replace the charge pump and studs.
to the front steer and swing circuits. 4. Connect the distribution and supply lines as tagged
Pump No. 3 during removal.
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Pump No. 3 is a single positive displacement gear pump with No. 2 Pump Removal
a displacement of 19 cm 3 /rev. (1.16 in 3 /rev) delivering a
theoretic flow of 57.2 lpm (10.6 gpm). Pump No. 3 supplies
oil to the transmission oil cooler fan motor. CAUTION
Absolute cleanliness is essential when working on the
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Maintenance
hydraulic pumps. Always work in a clean area. The
presence of dirt and foreign materials in the system can
No. 1 Pump Removal result in serious damage or inadequate operation.
1. For ease of removal, gain access to the pump by

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CAUTION removing the engine hood.

Absolute cleanliness is essential when working on the
hydraulic pumps. Always work in a clean area. The 2. Tag and disconnect the supply line from the pump. Cap
presence of dirt and foreign materials in the system can or plug the line and port.
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result in serious damage or inadequate operation. 3. Tag and disconnect the pump distribution line(s) from
the pump. Cap or plug the line(s) and port.
removing the engine hood. The pump is bolted to the
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engine’s torque converter. CAUTION

2. Tag and disconnect the supply line from the pump. Cap When removing the pump, keep the pump as level as
or plug the line and port. possible to avoid damaging the input spline.
3. Tag and disconnect the pump distribution lines from the 4. Remove the capscrews and washers attaching the No. 2
pump. Cap or plug the lines and ports. pump to the drive pad on the torque converter. Remove
the pump.
CAUTION 5. Remove the gasket material from the drive pad on the
When removing the pump, keep the pump as level as torque converter.
possible to avoid damaging the input spline. 6. Cover the drive pad’s opening to prevent dirt from
entering.

No. 2 Pump Installation 4. Connect the distribution and supply lines as tagged
during removal.
1. Install new gasket material to the pump mounting flange.
2. Install pump on to left front of engine with capscrews and
washers. Make sure gear teeth mesh properly. Torque CAUTION
capscrews to 85 to 93 Nm (63 to 69 pounds-foot). Do not feed hot hydraulic oil into a cold pump. This may
cause the pump to seize.
3. Connect the distribution and supply lines as tagged
during removal.
2
Testing After Rebuild or Replacement
1. Operate the pump for at least two minutes at zero
CAUTION pressure and moderate speed (not over 1500 rpm).
Do not feed hot hydraulic oil into a cold pump. This may
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cause the pump to seize.
CAUTION
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No. 3 Pump Removal If the pump becomes hot to the touch, it is binding and
may seize. Stop engine, disassemble pump, and repair it
so it will not bind.
CAUTION
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Absolute cleanliness is essential when working on the 2. Touch pump to verify it has not become hot from binding.
hydraulic pumps. Always work in a clean area. The Listen for abnormal noises indicating low hydraulic oil
presence of dirt and foreign materials in the system can level or internal pump problems. If the pump appears to
result in serious damage or inadequate operation. be operating satisfactorily, increase the rpm by steps,
until reaching governed rpm. Operate pump about five
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minutes while checking for proper operation and
leakage. Fix leaks; make repairs as needed.
removing the engine hood.
3. Cycle the components the pump powers to verify the
2. Tag and disconnect the supply line from the pump. Cap
pump drives them all properly.
or plug the line and port.
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3. Tag and disconnect the pump distribution line(s) from Hydraulic Gear Pump Start-up Procedure
the pump. Cap or plug the line(s) and port.
1. Ensure the reservoir is filled with the proper hydraulic
fluid to the high level mark on the reservoir sight gauge.
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CAUTION 2. Ensure no air is entering the pump inlet, and that the
When removing the pump, keep the pump as level as pump suction or inlet fluid is not bleeding back to the
possible to avoid damaging the input spline. reservoir when the engine is stopped, by making sure all
suction or inlet lines are air tight.
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4. Remove the capscrews and washers attaching the No. 3

NOTE: The following step can be done before the pump is
pump to the No. 1 pump. Remove the pump.
installed by removing the plastic cap from “T1” port,
5. Remove the gasket material from the drive pad on the and checking to ensure “T2” port on the opposite
No. 1 pump. side of the pump is plugged. Fill housing full of
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hydraulic oil through “T1” port. Re-install the plastic

6. Cover the drive pad’s opening to prevent dirt from
cap and then install the pump.
entering.
3. Remove adapter and hose from “T1” port, and check to
No. 3 Pump Installation ensure “T2” port on the opposite side of the pump is
plugged. Fill housing full of hydraulic oil through “T1”
1. Clean and prime the mounting surfaces with Loctite port. Re-install the adapter and hose into the “T1” port.
7649 primer.
4. Start the engine.
2. Apply Loctite 518 sealant to the pump mounting flange.
a. Idle engine for two to three minutes with no
3. Install pump on to pump No. 1 with capscrews and functions actuated. Check for leaks and repair if
washers. Make sure gear teeth mesh properly. Torque required. Lay hand on pump to check for excessive
capscrews to spec listed in Fasteners and Torque heat build-up. If the pump section is too hot to keep
Values, page 1-12. your hand on, stop immediately. If the pump makes
excessive noise, air is probably entering the pump

keeping it from priming. If this occurs, stop engine, hydraulic oil that was used to fill the hydraulic reservoir
and inspect all connections of the suction hose/tube to the bottom of the O-ring case drain port. Install the
for a loose connection, or a missing or damaged O- case drain adapter and hose.
ring. Re-start the engine and run until the pump
4. Start the engine.
takes prime for a maximum of 30 seconds. If the
pump does not prime in 30 seconds, stop the engine a. Idle engine for two to three minutes with no
and repeat until the pump primes. functions actuated. Check for leaks and repair if
required. Lay hand on pump to check for excessive
b. Increase the RPM to 1500-1800 for 1 to 2 minutes
heat build-up. If the pump section is too hot to keep
with no functions actuated and make checks again
your hand on, stop immediately. If the pump makes
as outlined in step a. Incrementally increase throttle
excessive noise, air is probably entering the pump
to full RPM and then cycle the functions that the
keeping it from priming. If this occurs, stop engine,
pump supples to verify proper speed. Verify pump
and inspect all connections of the suction hose/tube
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flow.
for a loose connection, or a missing or damaged O-
5. Check pressure settings. Refer to PRESSURE ring. Re-start the engine and run until the pump
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SETTING PROCEDURES in this section. takes prime for a maximum of 30 seconds. If the
pump does not prime in 30 seconds, stop the engine
Piston Pump Start-up Procedure and repeat until the pump primes.
b. Increase the RPM to 1500-1800 for 1 to 2 minutes
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1. Ensure the reservoir is filled with the proper hydraulic
fluid to the high level mark on the reservoir sight gauge. with no functions actuated and make checks again
as outlined in step a. Incrementally increase throttle
2. Ensure no air is entering the pump inlet, and that the to full RPM and then cycle the functions that the
pump suction or inlet fluid is not bleeding back to the pump supples to verify proper speed. Verify pump
reservoir when the engine is stopped, by making sure all
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flow.
suction or inlet lines are air tight.
5. Check pressure settings. Refer to Pressure Setting
3. Remove the case drain hose and adapter from port DR Procedures (pg 2- 17) in this section.
on the pump (Figure 2-7), and fill housing with the same
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Pump Location On Engine
FIGURE 2-6

Item Description
1 Pump No. 1 - Piston Pump
2 Pump No. 2 - Gear Pump
3 Pump No. 3 - Gear Pump
4 Transmission
5 Engine 2
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Pump Case Drain
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Hose To Reservoir
FIGURE 2-7
PRESSURE SETTING PROCEDURES NOTE: When checking the directional control valve relief
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settings, unless otherwise specified, start with the

The following procedures should be used to properly check, engine at idle RPM and move the controller to its
adjust and set the hydraulic system pressures. fully stroked position. Then slowly accelerate the
NOTE: A Digital Pressure Gauge and accessories may be engine to the specified RPM. Read gauge and
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purchased through Manitowoc Crane Care. make adjustments to specified setting.
The following equipment is required for checking the When checking the outrigger relief valve setting,
hydraulic pressure settings. start with the engine at idle RPM and activate and
hold the extend switch. Then slowly accelerate the
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• Pressure Gauge engine to the specified RPM. Read gauge and

• Three dial gauge 0-34.5 MPa (0-5000 psi) make adjustment as required.
• Pressure check diagnostic quick disconnect - Grove P/N NOTE: GP (gauge Port) and number corresponds to
9999101806 and straight adapter fitting 7447040401 gauge ports on the valve and on the hydraulic
schematic.
• ORFS reducers as required to attach work port hoses to
the gauge.

Table 2-1
Valve Pressure Setting Table
Pressure
Tolerance
Valve To Be Set Setting Adjustment Location
PSI (MPa)
PSI (MPa)
GP2 - Superstructure mounted main
Hoist (s), and Lift Pressure Setting 4000 (27.6) ± 50 (0.4) directional control valve load sense
relief valve (Figure 2-9)
Telescope Extend Pressure Setting GP7 - Superstructure mounted main
2700 (18.6) ± 50 (0.4) directional control valve port relief
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valve (Figure 2-10)
Telescope Retract Pressure Setting GP7 - Superstructure mounted main
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3000 (20.7) ± 50 (0.4) directional control valve port relief
valve (Figure 2-10)
Outrigger Extend/Retract/Rear Steer/Oil GP2 - Carrier mounted outrigger
2500 (17.3) ± 50 (0.4)
Cooler Motor Pressure control manifold (Figure 2-11)
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Swing Left and Right Work Port Relief GP1 - Superstructure mounted
2100-2450
Pressures See Range accessory manifold with swing
(14.5 - 16.9)
directional control valve (Figure 2-9)
Front Steer Pressure Setting GP5 - Superstructure mounted
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2500 (17.3) ± 50 (0.4) accessory manifold with swing
Swing Brake Supply Pressure Setting GP4 - Superstructure mounted
250 - 275
See Range accessory manifold with swing
(1.7 - 2.1)
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Pilot Supply Pressure Setting GP3 - Superstructure mounted
2500 - 2550
See Range accessory manifold with swing
(17.3 - 17.6)
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Non-CE Cranes 325 - 400 See Range GP2 - Carrier mounted piston pump
Piston Pump P Pressure Setting (2.2 - 2.8) (Figure 2-13)
CE Cranes 525 - 550

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Piston Pump P Pressure Setting (3.6 - 3.8)
Service Brake High Charge Limit +72, -145

2320 (17.4) GP7 (Figure 2-10) Non-adjustable
(0.5) (1.00)
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Service Brake Low Charge Limit 1950 (13.5) ±145 PSI (1.00) GP7 - (Figure 2-10) Non-adjustable
800 - 850
Service Brake Accumulator Pre-charge See Range Accumulator (Figure 2-12)
(5.5 - 5.8)

NOTE: Procedures A through H in the following text 8. Cap hose (the larger of the two) running from port A,
correlate with Figures 2-6 through 2-10. telescope section of the main directional control valve to
the cylinder port block at the back of the base section.
Procedure A - For Checking/Setting The
9. Start engine and throttle up to full RPM. Attempt to
Main Control Valve For Hoists(s), Boom Lift telescope OUT by feathering into the controller to full
and Piston Pump controller stroke. Adjust the work port relief “in” to
increase or “out” to decrease so that a gauge pressure
NOTE: Procedure A for max. and  P settings.
of 24.2 ±0.4 MPa (2700 ±50 psi) is achieved 2
Set hoist(s) and boom lift as follows: (Figure 2-10).
1. Install pressure check diagnostic quick disconnect with 10. If the boom is installed, start engine and throttle up to full
gauge onto test nipple @ the G2 Port of the accessory RPM. Telescope out to fully extend the boom and hold.
manifold with swing directional control valve Adjust the work port relief valve “in” to increase or “out”
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(Figure 2-9). to decrease so that a gauge pressure reading of
24.2 ±0.4 MPa (2700 ±50 psi) is achieved (Figure 2-10).
2. Assure piston pump cut-off max.(Figure 2-13) factory
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setting is correct. Loosen the jam nut on the cut-off max 11. Stop engine and remove pressure gauge and re-connect
adjusting screw and turn it in until it softly seats or plumbing.
bottoms out. Then back the adjusting screw out 1/4 to 1/
Retract
2 turn and lock in place with jam nut. This will ensure that
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full system pressure of 27.6 MPa (4000 psi) can be 12. If the boom is not installed, install a pressure check
obtained in step #4. diagnostic quick disconnect with gauge onto test nipple
@ the GP7 port of the main directional control valve
3. Assure piston pump ΔP (stand-by) factory setting is
(Figure 2-10).
correct. With diagnostic quick disconnect still installed @
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the GP2 port of the accessory manifold with swing 13. Cap hose (the smaller of the two) running from port B,
directional control valve (Figure 2-9), start engine and @ telescope section of the main directional control valve to
idle RPM adjust the piston pump differential setting the cylinder port block at the back of the base section.
screw “in” to increase or “out” to decrease so that a 14. Start engine and throttle up to full RPM. Attempt to
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gauge reading of 2.2 - 2.8 MPa (325 - 400 psi) telescope IN by feathering into the controller to full
(Figure 2-13). For CE machines, this pressure is 3.6-3.8 controller stroke. Adjust the work port relief valve “in” to
MPa (525-550 psi) increase or “out” to decrease so that a gauge pressure
4. If the lift cylinder is not installed, plug the extend hose reading of 22.5 ±0.4 MPa (3000 ±50 psi) is achieved
(the larger of the two). If lift cylinder is installed, omit this (Figure 2-10).
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step and continue to step #5. 15. If the boom is installed, start engine and throttle up to full
5. With diagnostic quick disconnect still installed @ the RPM. Telescope in to fully retract the boom and hold.
GP2 port of the accessory manifold with swing Adjust the work port relief valve “in” to increase or “out”
directional control valve (Figure 2-9), start engine and to decrease so that a gauge pressure reading of 22.5
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throttle up to full RPM. Feather into the boom lift ±0.4 MPa (3000 ±50 psi) is achieved (Figure 2-10).
controller to full controller stroke (up or down) and hold. 16. Stop the engine and remove pressure gauge and re-
If the boom is installed, boom up to max elevation and connect plumbing.
hold or boom down to minimum elevation and hold.
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Adjust the load sense relief valve “in” to increase or “out” Procedure B - For Setting The Outrigger/
to decrease so that a gauge pressure reading of 27.6±
0.4 MPa (4000 ± 50 psi) is achieved (Figure 2-10).
Rear Steer/Oil Cooler Motor Pressures
6. Stop engine and remove the diagnostic couplers from 1. Install a pressure check diagnostic quick disconnect with
the test nipples gauge onto test nipple at G2 port of the outrigger control
manifold (Figure 2-11).
Set telescope extend and retract as follows:
2. Start engine and throttle up to full RPM. Select and
Extend activate the outrigger “extend or retract” switch on the
cab dash. Adjust the pressure reducing valve integrated
7. If boom is not installed, install a pressure check
in the outrigger control manifold “in” to increase or “out”
diagnostic quick disconnect with gauge onto test nipple
to decrease so that a gauge pressure of 17.3 MPa ± 0.4
@ the GP7 port of the main directional control valve
(2500 ±50 PSI) is achieved (Figure 2-11).
(Figure 2-10).
3. Stop engine. Remove the diagnostic coupler.

Procedure C - For Checking/Setting The 3. Close the charging assembly bleed valve. Attach the
Swing Directional Control Valve Work Port swivel nut onto the gas valve and tighten 1.1 - 1.6 Nm
(10-15 pounds-inch).
Relief Valves
4. Turn the gas chuck “T” handle all the way down
1. With engine off, Install a pressure check diagnostic (clockwise) which will depress the core in the gas valve
coupler with gauge onto test nipple at GP1 port of the
accessory manifold with swing directional control valve 5. Check the pre-charge pressure. The gauge should read
(Figure 2-9). 5.5 +0.4, -0 MPa (800 +50, -0 psi).
2. Start engine, throttle up to full RPM. With the swing 6. If the pressure is 5.5 +0.4, -0 MPa (800 +50, -0 psi),
house lock engaged, swing full right and hold controller. remove the charging valve assembly by turning the “T”
Adjust the “B” port work port relief “in” to increase or handle all the way out on the gas chuck and then
“out” to decrease so that a gauge pressure reading of opening the bleed valve (Figure 2-13).
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14.5 - 16.9 MPa (2100 - 2450 psi) is achieved. 7. Secure the gas valve, loosen the swivel nut and remove
3. Repeat step #2 for swing left adjusting the “A” port relief. the charging assembly. Replace the gas valve cap and
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guard.
Procedure D - For Checking/Setting The Procedure For Pre-charging the Accumulator, If required
Service Brake Dual Accumulator Charge
1. With the engine off, discharge all of the pressurized oil
Valve Charging Limits
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stored in the accumulators by depressing the service
1. With engine off, discharge all of the pressurized fluid brake pedal on the cab floor 4 - 6 times. Remove the gas
stored in the accumulators by depressing the service valve and cap on the accumulator (Figure 2-12).
brake pedal on the cab floor 8 - 10 times.
2. Ensure the nitrogen supply bottle is shut off, then attach
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2. Install a pressure check diagnostic quick disconnects the charging valve assembly to it.
with gauge onto test nipple at GP7 port of the main
3. Before attaching the charging assembly to the
directional control valve (Figure 2-10).
accumulator gas valve, back the gas chuck “T” handle
3. Start engine and idle. The charging valve will all the way out (counterclockwise).
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immediately start to charge the accumulators. Watch the

4. Close the charging assembly bleed valve. Without
pressure gauge. The high charge limit should read 17.4
looping or twisting the hose, attach the swivel nut to the
MPa +0.5- 1.00 (2320 +72, -145 psi) when the pressure
accumulator gas valve and tighten 1.1 - 1.6 Nm (10-15
stops rising. This accumulator charge valve is non-
pounds-inch).
adjustable.
5. Turn the gas check “T” handle al the way down
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4. With the engine still at idle, repeatedly depress the

(clockwise) which will depress the core in the gas valve.
service brake pedal on the cab floor until the gauge
pressure reads approximately 13.5 ±1.00 MPa (1950 6. Slowly open the nitrogen bottle valve and fill the
±145 psi) when it starts to recharge. This accumulator accumulator. Close the valve when the pre-charge is 5.5
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charge valve is non-adjustable. +0.4, -0 MPa (800 +50, -0 psi).

5. Stop engine. Remove pressure gauge. 7. If the precharge is higher than specified in step #6, close
the nitrogen bottle and slowly open the bleed valve on
Procedure E - For Checking/Pre-Charging the charging assembly (Figure 2-12) until the pressure is
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The Service Brake Accumulators to specification.
1. With the engine off, discharge all of the pressurized oil 8. Remove the charging valve assembly by turning the “T”
stored in the accumulators by depressing the service handle all the way out (counterclockwise) on the gas
brake pedal on the cab floor 4-6 times. Remove the gas check and then open the bleed valve.
valve guard and cap on the accumulator (Figure 2-13) 9. Secure the gas valve, loosen the swivel nut and remove
2. Before attaching the gas charging assembly the charging assembly. Replace the gas valve cap and
(Figure 2-13) onto the gas valve, back out the gas chuck guard.
“T” handle all the way our (counterclockwise).

Procedure F - For Checking/Setting the detection procedure should detect RT->RT540i/RT530i-

Front Steer Pressure >Superstructure.
3. Start engine and run at @ idle rpm's, make sure to lower
1. Install pressure check diagnostic quick disconnect with
left armrest.
gauge onto test nipple @ GP5 port of the accessory
manifold with swing directional control valve 4. For each function, attach a test fitting and pressure
(Figure 2-9). gauge in the Pilot End Caps one at a time: GPA for Main
2. Start engine and throttle up to full RPM. Fully turn the
Hoist Up, GPB for Aux Hoist Up, GPC Tele Retract, 2
GPD Lift Down (Figure 2-10).
steering wheel left or right against the axle stop. Adjust
the steering load sense relief valve in the accessory 5. Current range settings for each function can be found in
manifold with swing directional control “in” to increase or the Crane Service Tool in the menu bar under View-
“out” to decrease so that a gauge pressure of 17.3 MPa >Superstructure. Select the function and a child window
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(2500 psi) is achieved (Figure 2-9). will open. Select the Speed Control solenoid icon,
normally located in the lower left of the window. An
3. Stop engine. Remove diagnostic couplers.
example is shown for Main Hoist.
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Procedure G - For Checking/Setting the Pilot 6. Adjust the max current for Main Hoist Up (Figure 2-10).
Supply Pressure Move the joystick to the full on position and monitor the
pressure gauge and adjust the Imax [mA] to reach
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1. Install pressure check diagnostic quick disconnect with 295psi then adjust to 300psi +0/–5psi. Note that you will
gauge onto test nipple @ GP3 port of the accessory need to press the Set button at the bottom of the window
manifold with swing directional control valve before it will take effect.
(Figure 2-9).
7. Next set the current threshold of Main Hoist Up. Monitor
2. Start engine and @ idle RPM, lower left armrest, fully
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the pressure gauge and move the joystick just off center
stroke and hold the boom lift raise or lower joystick. for Main Hoist in the up position. Watch the pressure
Adjust the pilot pressure reducing valve of the accessory gauge, move until it reaches approx 100 PSI. Hold the
manifold with swing directional control valve “in” to joystick at this position and note the value for MH
increase or “out” to decrease so that the gauge pressure Solenoid Current in the Main Hoist Data window. Enter
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of 17.3 - 17.6 MPa (2500 - 2550 psi) is achieved this setting for Imin [mA] and press the green Set button
(Figure 2-9). at the bottom of the window.
3. Stop engine. remove diagnostic couplers. 8. Repeat this process for Aux Hoist Up (GPB,) Tele
Retract (GPC,) and Boom Down (GPD) (Figure 2-10)
Procedure H - For Checking/Setting The
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Swing Brake Release Pressure 9. Next adjust the slew brake current range. Attach test
fitting and pressure gauge GP4 (Figure 2-9)port with
1. Install pressure check diagnostic quick disconnect with engine running at idle. Fully depress swing brake pedal.
gauge onto test nipple @ GP6 port of the accessory Monitor the press gauge and adjust the swing brake
manifold with swing directional control valve
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solenoid Imax [mA] setting to reach to reach 250psi.

(Figure 2-9). Next slowly depress swing brake pedal down until you
2. Start engine and idle, select and depress the swing reach 25psi on the gauge. Note the swing brake current
brake release switch and adjust the swing brake value, and set Imin [mA] to this value.
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pressure reducing valve “in” to increase or “out” to 10. After setting all of the functions, save the EE
decrease so that a gauge pressure of 1.7 - 2.1 MPa (250 configuration to the controller’s Factory and Customer
- 275 psi) (Figure 2-9). settings area. This is done by selecting Tools-
3. Stop engine. Remove diagnostic couplers. >Calibration and Adjustment->EEPROM and pressing
the Save active to Customer and Save active to Factory
Procedure J - For Setting Threshold on buttons.
Electronic Controllers 11. Next save the configuration to a file by right clicking on
the ‘Active’ column and Write->Write column to file from
1. Attach laptop to diagnostic connector in cab and make the context menu. Save the file in a folder under the
sure CAN C is selected (position 3 on CAN selector model designation (In this case RT530E-2). Name the
knob) (Figure 2-8). file as follows: (Sales order number_Date). Sample:
2. Open the CCS Crane Service Tool. From the menu bar, (123456_2006aug17)
select Settings->Crane Model->Auto Detect. The auto

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FIGURE 2-8
Procedure K - Setting Threshold and Max on pressure of 1.7-1.9 MPa (250-275 PSI) is achieved
(Figure 2-9).
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Swing Brake Pedal

3. If adjustment can’t obtain the setting in step #2, stop
1. Install pressure check diagnostic quick disconnect
engine and install a pressure check diagnostic quick
(Parker PD240) with gauge onto test nipple @ GP6 port
disconnect (Parker PD240) with gauge onto the test
of the accessory manifold with swing directional control
nipple @ the GP2 at the accessory manifold valve
valve (Figure 2-9).
(Figure 2-9). Follow procedure A step 3 to set pump
2. Start engine and idle, enable swing (left armrest switch) stand-by and then repeat this step.
and adjust the swing brake pressure reducing valve “in”
4. Stop engine. Remove diagnostic couplers.
to increase or “out” to decrease so that a gauge

Item Description
1 Procedure G- Pilot Supply PSI Reducing Valve
2 Procedure H - Swing Brake PSI Reducing Valve
3 Procedure C - Swing Left Port Relief Valve 2
4 Procedure F - Front Steer Load Sense Relief Valve
5 Procedure C - Swing Right Port Relief Valve
6 Gauge Port 2
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7 Gauge Port 3
8 Gauge Port 6
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9 Pilot End Cap GP8 - Swing Left
10 Pilot End Cap GP9 - Swing Right
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10
FIGURE 2-9

Item Description
1 Procedure A - Telescope Extend Port Relief
2 Procedure A - Load Sense Relief Valve
3 Procedure A - Telescope Retract Port Relief
4 Gauge Port 7
5 Pilot End Cap GPD Lift Down
6 Pilot End Cap GPC Telescope Retract
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7 Pilot End Cap GPA Main Hoist Up
8 Pilot End Cap GPB Aux Hoist Up
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6
7
8
FIGURE 2-10

Procedure B - Outrigger PSI Reducing Valve
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G2
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6739-3
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FIGURE 2-11
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Item Description
1 Gas Valve Guard
2 Gas Valve
6739-4
FIGURE 2-12

Item Description
1 Procedure A -Pump Cut-Off Max Setting Adjustment
2 Procedure A - Pump P (Stand-by) Adjustment
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6739-5 FIGURE 2-13

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VALVES description of each valve given here is for the valve itself. For
information on how each valve functions in the individual
General circuits, refer to the description and operation procedures of
that circuit.
This subsection provides descriptive information for all the
hydraulic valves used on this crane. For a listing of all valves, NOTE: On each valve illustration in this section, each item
the circuit they are used in, and their physical location, refer number in table correlates to location on the valve,
and to the valve hydraulic schematic.
to (Table 2-2). Refer to (Figure 2-14) for valve locations. The
2
Table 2-2
Valve Usage Table
Valve Name Circuit Used In Physical Location
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Boom Lift/Telescope(s)/Hoist(s) Superstructure Right Side Plate
Directional Control Valves
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Swing/Steer Superstructure Right Side Plate
Steering Control Valve Front Axle Steer Control Cab Steering Column
Front Axle Steer Supply
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Swing Directional Control
Front Steer/Swing/Accessory Manifold Superstructure Right Side Plate
Swing Brake Release
Pilot Supply
Tandem Brake Valve with Treadle Service Brakes Cab Floor
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Dual Accumulator Charging Valve Service Brakes Superstructure Left Side Plate
Accumulator(s) Service Brake Rear Superstructure
Boom Lift Lift Cylinder (Bolt on Manifold)
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Holding Valves Telescope (3) Cylinder Port Blocks (Cartridge style)

Counterweight Removal (2) Cylinder Port Blocks (Cartridge style)
Axle Lockout Control
Axle Lockout, Rear Steer and Oil
Rear Steer Control Left Hand Carrier Frame Rail
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Cooler Fan Motor Control Manifold

Oil Cooler Motor Control
Solenoid Valves:
Cross Axle Differential Lock Differential Lock (Optional) Carrier Inside Right Side Rail
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Hoist Motor Control Valve Hoist(s) Both Hoists (see Hoist section)
Check Valves Return Circuit One in Parallel With Oil Cooler
On Front and Rear Face of Carrier
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Outrigger Control Manifold Outrigger

Frame Front and Rear Cross Member
Pilot Operated Check Valve Outrigger Port Block of each Jack Cylinder (4)
Carrier Bulkhead Plate Forward Of
Cross Axle Differential Lock Valve Differential Lock (Optional)
The Engine
Range Shift and Parking Brake Valve Parking Brake Axle Disconnect Center of Rear Frame

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6726
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SUPERSTRUCTURE
FIGURE 2-14

1 Hoist/Telescope/Lift Directional Valve 4 Secondary Steer Valve (CE Option)
2 Swing/Steer Directional Valve 5 Accumulator
3 Service Brake Dual Accumulator Charge Valve 6 Superstructure

5 2
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6725
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CARRIER

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1 Front Outrigger Control Manifold 5 Axle Lockout Valve

2 Outrigger/Rear Steer Valve 6 Rear Outrigger Control manifold
3 Differential Lock Valve 7 Frame
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4 Park Brake Range Shift Valve

DIRECTIONAL CONTROL VALVES NOTE: The lift/telescope/hoist valve bank weighs

approximately 81.30 kg (179.2 pounds).
Description 3. Remove the capscrews, washers and nuts securing the
The directional control valves direct and control hydraulic oil valve bank and remove the valve bank.
flow from the pumps to the boom lift and telescope cylinders,
each hoist motor, the swing motor, and the front steer Boom Lift/Telescope/Hoist Valve Bank
cylinders from the front steer control valve. The boom lift/ Installation
telescope/hoist directional control valve (Figure 2-15) is
located on the outside of the right superstructure side plate. 1. Place the valve bank on the superstructure side plate
The valve bank is removed and installed as an assembly. and secure it with the capscrews, washers and nuts.
Torque the capscrews see Fasteners and Torque Values
The boom lift/telescope/hoist control valve is a three position (pg 1- 12).
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four way pressure compensated, closed center directional
valve. It receives pump flow from hydraulic swivel port 6 and 2. Connect the hydraulic lines to the valves as tagged
pump No. 1. Lift, telescope and hoist (s) functions are during removal.
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controlled by proportional two position two way solenoid 3. Connect the electrical connectors as tagged during
cartridges installed into the valve’s casting under each spool. removal.
These valves receive an electrical signal from the controllers
on the cab armrest. Functional Check (All Valve Banks)
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RCL lockout is achieved by de-energizing the proportional 1. Start the engine and run it at normal speed.
solenoids.
2. Operate the control levers of the valve bank(s). Check
The inlet section of the boom lift/telescope/hoist directional for smooth operation of cylinders and motors.
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control valve contains a load sense relief valve set at 27,579
kPa/275.7 bar (4000 psi) protecting the main and auxiliary 3. Check the valve bank(s) and lines for leakage. Make
hoist and boom lift sections. The boom lift retract has a repairs as needed.
thermal port relief set of 29,647.4kPa/296.4 bar (4300 psi).
The telescope section has port reliefs set at 18,616 kPa/ Function Check - RCL Lockout Valves
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186.2 bar (2700 psi) and 20,684 kPa/207 bar (3000 psi). 1. Remove circuit breaker F11 from the power panel in the
The swing directional control valve is installed on the outside cab. This cuts off power to the RCL.
of the right superstructure side plate. Refer to Accessory 2. Start the engine.
With Swing Directional Control Manifold, page 2-33.
3. Try to telescope the boom out, lower the boom, hoist up
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Maintenance the main hoist, and hoist the auxiliary hoist up (if
installed). Verify none of these functions work.
Boom Lift/Telescope/Hoist Valve Bank 4. Shut down the engine. Reinstall F11.
Removal
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5. Telescope the boom out, lower the boom, hoist up the

1. Tag and disconnect all of the electrical connectors from main hoist, and hoist the auxiliary hoist up (if installed).
the valve. Verify all of these functions work.
2. Tag and disconnect the hydraulic lines from the valves. 6. Check for leaks. Make repairs as needed.
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Cap or plug the lines and ports.

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10 FIGURE 2-15
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1 Port 1A -Main Hoist Up 11 Load Sense - Inlet Port

2 Port 1B - Main Hoist Down 12 Port PS - Pilot Supply
3 Port 2A - Aux Hoist Up 13 Gauge Port
4 Port 2B - Aux Hoist Down 14 Relief Valve - Telescope Extend
5 Port 3A - Telescope Extend 15 Relief Valve - Telescope Retract
6 Port 3B - Telescope Retract 16 Relief Valve - Lift
7 Port 4A - Lift Up 17 Relief Valve - Load Sense
8 Port 4B - Lift Down
9 Load Sense - Outlet Port
10 Port P1 - From Swivel Port 6

3 4 2 14 5 6 7 8 16
12 1 15
18 18 18 18
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Inlet Hoist Auxiliary Hoist Telescope Lift Outlet

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Boom Lift/Telescope/Hoist Main Valve Hydraulic Schematic

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ACCESSORY WITH SWING DIRECTIONAL resistance check valve providing make-up oil to the swing
CONTROL MANIFOLD motor for motor over-run when the valve is centered. It
receives oil from pump #1 through swivel port 5. This section
Description is controlled by two proportional two position, three way
solenoid valves. These valves receive an electrical signal
The accessory manifold with swing directional valve from the cab armrest controllers.
(Figure 2-16) is located on the right side of the turntable. The
manifold contains two adjustable pressure reducing valves, Maintenance 2
five 3-way two position solenoid valves, 3-way four position
swing directional valve, and a check valve. Removal
One pressure reducing valve provides 1.72 MPa (250 psi) for 1. Tag and disconnect all of the electrical connectors or
operation of the swing brake. The other provides 17.2 MPa manual control levers.
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(2500 psi) for the pilot circuit.
2. Tag and disconnect the hydraulic lines from the valves.
Each solenoid valve is held in its normally closed position by Cap or plug the lines and ports.
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a spring. When the solenoid is energized, the plunger
assembly forces the spool to shift, causing the valve to shift. NOTE: The swing/steer/brake valve manifold weighs
De-energizing the solenoid causes spring pressure to shift approximately 10.0 kg (22.0 lb).
the spool to its normally closed position. 3. Remove the capscrews, lockwashers and flatwashers
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One two position, three way solenoid valve serves as the securing the manifold. Remove the manifold.
swing brake release valve. This normally closed valve, when
de-energized, prevents hydraulic oil pressure from releasing Installation
the swing brake. When the swing brake switch is off, this 1. Place the manifold on the superstructure side plate and
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valve opens to allow hydraulic oil pressure to release the secure with the capscrews, lockwashers and
swing brake. flatwashers. Torque the capscrews see Fasteners and
One proportional two position, three way solenoid valve Torque Values (pg 1- 12).
actuated by the cab swing foot brake proportionally supplies 2. Connect the hydraulic lines to the valves as tagged
pressurized oil to the swing drive brake.
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during removal.
The three position four-way swing directional valve is 3. Connect the electrical connectors to the valve as tagged
installed onto the manifold. Both swing working ports have during removal.
check valves that are flooded by a.41 MPa (60 psi)
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19 9 16 4 23 2 25 21 5 20 8 6 27
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14 10 26
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8462 17 FIGURE 2-16

8 23 21
20 11
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8492
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1 Pilot Supply Relief Valve 15 Drain Port - D7 (Swing Brake/Lift Cylinder Pilot)
2 Gauge Port- GP4 16 Drain Port - D3 (Plugged)
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3 Swing Brake Relief Valve 17 Gauge Port - GP2

4 Solenoid Valve - Swing Brake 18 Gauge Port - GP5
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5 Solenoid Valve - Swing Brake Release 19 Drain Port - D1

6 Solenoid Valve - Pilot Supply 20 Gauge Port - GP3
7 Gauge Port - GP1 21 Swing Brake Release Port - SBR
8 Pilot Supply Port - PS 22 Drain Port - D5
9 Drain - D2 23 Swing Brake Supply Port -SBS
10 Port 2B - Swing Left 24 Tank Port
11 Port 2A - Swing Right 25 Gauge Port - GP6 (Plugged)
12 Swing Directional Valve 26 Gauge Port - GP8 (Plugged)
13 Drain Port - D4 (Swing Motor Pilot Supply) 27 Proportional Two Position Two Way Solenoid
14 Drain Port - D6 (Hoist/Tele/Lift valve Pilot Supply) 28 Steering Priority Valve
29 Steer Circuit Load Sense Relief

STEERING CONTROL VALVE 3. Remove the capscrews and washers and remove the
valve from the steering column.
Description
Installation
The steering control unit (Figure 2-17) controls hydraulic flow
to the front steering cylinders. It is located on the steering 1. Secure the valve to the steering column and secure with
column of the cab. the capscrews and washers. Torque the capscrews 40.6
to 43.3 Nm (30 to 32 pounds-foot).
Both work ports are connected to the rod side of one steer 2
cylinder and to the piston side of the other steer cylinder. A 2. Connect the hydraulic hoses to the ports on the valve as
steering wheel input will connect the load sense port #5 to tagged during removal.
the steering cylinder load demand by way of the steer priority 3. Connect the electrical connector to the valve as tagged
valve located in the swing/steer manifold. during removal.
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Displacement of the valve is 315 cm³ (19.22 in³). 4. Verify proper operation of the valve.
Maintenance
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5. Check valve and hydraulic connections for leaks. Make
repairs as needed.
Removal
1. Tag and disconnect the electrical connector to the valve.
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2. Tag and disconnect the hydraulic hoses from the valve.
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6747-2
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Valve Hydraulic Schematic 1
6747
Item Description
1 Port T - Tank Port - To Swivel Port 4
2 Port P - Pressure From Port 1B- Accessory Manifold
3 Port R - To Right Front Steer Cylinder
4 Port L - To Left Front Steer Cylinder
5 Port LS - From Port 1A - Accessory Manifold
FIGURE 2-17

TANDEM BRAKE VALVE WITH TREADLE The tandem brake valve consists of a tandem valve body, a
PEDAL closed center spool, a treadle pedal and a mechanical spring
assembly to limit the output pressure to the brake actuators
Description to 10,342 kPa/103.4 bar (1500 psi).
The tandem brake valve with treadle pedal (Figure 2-18) is Maintenance
located on the floor of the cab. The tandem brake valve
provides split system braking for the primary (front) brakes Removal
and the secondary (rear) brakes.
The valve modulates the output pressure 10,342 kPa/103.4
bar (1500 psi) to the brake actuators. The valve is 2. Tag and disconnect the hydraulic hoses from the valve.
mechanically actuated by a treadle pedal (Figure 2-18). The Cap or plug the lines and ports.
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direct acting spool provides a pedal feel which accurately 3. Remove the capscrews, lockwashers, flatwashers and
represents the brake pressure, similar to automotive style nuts securing the valve to the cab Floor. Remove the
pedal feedback as the brake pedal pressure increases, the valve.
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pedal effort increases proportionally. As the pedal is initially
actuated, the tank ports are closed off from the brake ports. Installation
With further application of the pedal, the pressure ports are
opened to the brake ports until the pedal actuation force and 1. Secure the valve to the cab floor with the capscrews,
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the hydraulic pressure force are balanced. lockwashers, fl atwas hers and nuts. Torque the
capscrews 10 to 11 Nm (7.4 to 8.1 pounds-foot).
Also when the pedal is actuated, a pressure switch located
off a tee in port F2 provides an electrical signal for brake 2. Connect the hydraulic hoses to the ports on the valve as
lights. When the pedal is released, the valve and the pedal tagged during removal.
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return to the non-applied position. In normal operation, the 3. Connect the electrical connector to the valve as tagged
secondary system is piloted from the primary section during removal.
providing pressure to both systems.
4. Start the engine and check valve and hoses for leaks.
Make repairs as needed.
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Valve Hydraulic Schematic
Item Description 1
5
1 Pressure Port P1
2 Pressure Port P2 4
3
3 Port F1- Front Brakes
4 Port F2 - Rear Brakes
6745-1
5 Port T - Tank
FIGURE 2-18

DUAL ACCUMULATOR CHARGE VALVE pressure also pilots the control pilot spool to open the load
sense line to tank, destroking the piston pump No. 1.
Description
Maintenance
The load sensing dual accumulator charging valve is located
on the inside of the left superstructure side plate. The Removal
purpose of the valve is to provide pressure regulation to the
service brake circuit.
2
The dual accumulator charge valve consists of an inlet main
check valve, a load sense control section with a pilot spool 2. Remove the capscrews, flatwashers and lockwashers
that controls the pump stroke and an inverted shuttle that securing the valve to the turntable. Remove the valve.
controls the accumulator charging (Figure 2-19).
Installation
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When the valve is charging the accumulators, the load sense
control section is in neutral position, connecting the load to 1. Position the valve on the turntable and secure with the
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the pump by way of the load sense line. This brings the capscrews, flatwashers, and lockwashers. Torque
piston pump No. 1 on stroke to supply fluid for charging. capscrews see Fasteners and Torque Values (pg 1- 12).
Fluid passes through the main check valve connecting to the
2. Connect the hydraulic hoses to the valve ports as tagged
pilot end and through the spool onward to the inverted
during removal.
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shuttle that connects the accumulators.
3. Start the engine and check for leaks. Make repairs as
When the control pilot spool bias spring senses the low limit
needed.
pressure of 13,445 kPa/134 bar (1950 psi), the spool shifts to
the neutral position, allowing the pump to charge the 4. Depress the brake pedal several times to cause the
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accumulators to a maximum of 16,000 kPa/160 bar (2320 brake valve to charge. Make several turns with the
psi). The inverted shuttle cartridge senses the pressure in steering wheel, and swing the superstructure left and
the accumulators to pilot the cartridge closed when right. Verify the brakes, swing, and front steering work
maximum charge pressure is reached. Maximum charge properly.
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2
Item Description
1 Port LS - Load Sense Port 5 4
2 Port T - Tank Port

3 Port P - Pressure Port
3
4 Accumulator Port A1
5 Accumulator Port A2
6 Pressure Switch
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6696-1
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Valve Hydraulic Schematic

FIGURE 2-19
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HYDRAULIC ACCUMULATOR SERVICE 3. Remove the two nuts securing each clamp half. Remove
BRAKE the each clamp half and accumulator from the turntable.
Description Installation
The service brake hydraulic accumulators are located on the 1. Position the accumulator in the clamps and secure with
outside of the left superstructure side plate behind the cab. the removable clamp halves and nuts.
The purpose of each accumulator is to provide stored 2. Connect the hydraulic hose to the port on the 2
energy, an oil volume of 1.23 l (75.1 cu in) at a maximum accumulator as tagged during removal.
pressure of 27,579 kPa/275 bar (4000 psi), to actuate the
service brake circuits. The dual accumulator charge valve 3. Pre-charge the accumulator. Refer to paragraph titled
regulates flow to the hydraulic accumulators to provide fully Pre-Charging Accumulator in Sub-Section titled
powered independently separate, primary (front) and Pressure Setting Procedures.
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secondary (rear), service brake circuits. 4. Start the engine and check accumulator and hoses for
Each accumulator has two chambers divided by a piston. leaks. Make repairs as needed.
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One side is pre-charged to 5,515.8 kPa/55.1 bar (800 psi) 5. Depress the brake pedal several times, make several
with high purity nitrogen. This maintains a constant pressure turns with the steering wheel, and swing the
in the other chamber which is connected to the modulating superstructure left and right. Verify the brakes, swing,
brake valve. After the accumulators are fully charged, they
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and front steering work properly.
will provide the necessary brake system flow and pressure to
actuate the brakes. Servicing
The accumulator consists of a tube, piston, seals, gas The pre-charge nitrogen pressure should be checked every
charging valve, and a gas valve guard.
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200 hours or once a month, whichever comes first. Refer to
Pressure Setting Procedures in this section.
Maintenance
Removal
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1. With the engine shutdown, deplete the hydraulic

pressure in the accumulators by depressing the service
brake pedal several times.
2. Tag and disconnect the hydraulic hose from the
accumulator. Cap or plug the line and port.
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HOLDING VALVES Removal

Description 1. Unscrew holding valve from its port block or manifold.
A bolt-on manifold style holding valve is installed on the Installation

boom lift cylinder. A cartridge style holding valve is used on
the telescope cylinder installed in the piston side of the 1. Check the inside of the port block or manifold for any
cylinder. sharp edges or burrs and remove as necessary with
emery cloth.
The holding valve provides meter out control, will lock the
cylinder in place, prevent a load from running ahead of the oil 2. Install new O-rings onto the holding valve.
supply, and will relieve excess pressure caused by thermal 3. Lubricate the holding valve and O-rings with clean
expansion. hydraulic oil.
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Maintenance
CAUTION
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Do not damage the O-rings during installation of the
holding valve. If the holding valve turns freely then gets
DANGER hard to turn, then easy to turn, remove the holding valve
and check the O-rings. They have probably been
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Boom must be fully lowered and fully retracted before
removing lift cylinder and telescope cylinder holding damaged by a sharp edge of a port.
valves.
NOTE: The holding valve should turn by hand until
compression of the O-rings begins.
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4. Carefully install the holding valve into the port block or
manifold until fully seated.
5. Test the holding valve and port block or manifold by
operating the lift cylinder and/or the telescope cylinder,
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as applicable. Verify lift cylinder and/or telescope

cylinder works without problems; verify there is no
leaking. Make repairs as needed.
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CROSS AXLE DIFFERENTIAL LOCK VALVE Maintenance

Description Removal
The optional cross axle differential lock valve is mounted on 1. Tag and disconnect the electrical connector from the
the right side of the aft center frame cross member. The valve.
valve consists of a three way, two position valve without a
2. Tag and disconnect the hydraulic lines attached to the
reducing valve (Figure 2-21). The valve is used to control the
application of the crane’s hydraulically applied and released valve. Cap or plug lines and ports. 2
cross axle differential lock actuators. 3. Remove the capscrews, flatwashers, lockwashers and
Pressing the top of the cross axle differential lock switch on nuts securing the valve to the frame. Remove the valve.
the front console shifts the three-way, two-position solenoid
Installation
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valve so hydraulic oil can flow to the engage port of the cross
axle differential lock actuators, extending them. When the 1. Secure the valve to the frame with the capscrews
actuators extend, they engage the splines on the differential flatwashers, lockwas hers and nuts. Torque the
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case and the axle shafts to lock the differential assemblies capscrews 10 to 11 Nm (7.4 to 8.1 pounds-foot).
together.
2. Connect the hydraulic lines to the valve as tagged during
Releasing the cross axle differential lock switch unlocks the removal.
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three-way, two-position solenoid valve to apply hydraulic
pressure to the spring release of the actuators, retracting 3. Connect the electrical connector to the valve as tagged
them. As the actuators retract, they unlock the axles. during removal.
4. Apply and release the cross axle differential lock several
times. Verify the cross axle differential lock holds the
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axle from moving when applied so there is no differential
action between the wheels.
5. Check for leaks. Make repairs as needed.
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Item Description
1 Three-Way Solenoid Valve
2 Pressure Reducing Valve
3 Port P - From Pressure Port On Trans
4 Port C - To Diff Lock Actuator On Axles
5 Port T - To Tank Port On Transmission
6 Port G - Gauge Port
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7 100 Mesh Screen
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Hydraulic Schematic 6718-2

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FIGURE 2-20
Item Description
Port 1 to Front and Rear Axle Differential
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2 Port 2 to Park Brake/Shift Valve Port T
3 Port 3 to Park Brake/Shift Valve Port P
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4 Solenoid Valve (Connector not shown)

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1 1
2
3
8473
Hydraulic Schematic
7011-2 FIGURE 2-21

OUTRIGGER CONTROL MANIFOLD Inspection

Description Visually inspect the valves and hydraulic connections for any
evidence of leaks or other damage. Check security of the
There are two outrigger control manifolds utilized on the electrical connections. Inspect the wiring for any evidence of
crane, one for the front outriggers and one for the rear cracks or breaks.
outriggers. The manifold consists of four normally closed two
position two way solenoid valves (Figure 2-22). They are Installation 2
mounted inside the frame of their respective outrigger box.
1. Position the manifold on the mounting and secure with
When energized, the solenoid shifts the spool to open the lockwashers, flatwashers, nuts and capscrews.
allowing extension or retraction of the outrigger cylinders. Torque capscrews see Fasteners and Torque Values (pg
1- 12).
Maintenance
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2. Connect the electrical connectors to the solenoids as
Removal marked during removal.
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3. Connect the hydraulic lines to the valves as marked
1. Tag and disconnect the hydraulic lines to the solenoid
during removal.
valves; cap all lines and openings.
2. Tag and disconnect the electrical connectors. Functional Check
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3. Remove the capscrews, nuts, lockwashers and Activate the hydraulic system and cycle the affected
flatwashers securing the manifold to the outrigger box; cylinder(s) several times. Observe for proper functioning of
remove the manifold. the affected cylinder(s). Ensure the solenoid valve hydraulic
connections are secure.
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6544-2 8
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6544-1
FIGURE 2-22

1 Solenoid Valve - Left Front or Rear Extension Cyl 6 Outlet Port Left Front or Rear Jack Cyl
2 Solenoid Valve - Left Front or Rear Jack Cyl 7 Outlet Port Right Front or Rear Jack Cyl
3 Solenoid Valve Right Front or Rear Jack Cyl 8 Outlet Port Right Front or Rear Extension Cyl
4 Solenoid Valve Right Front or Rear Extension Cyl In Port (Far Side) - From Port B of Outrigger
9
Selector Valve
5 Outlet Port - Left Front or Rear Extension Cyl

PILOT OPERATED CHECK VALVE 3. Lubricate the check valve and O-rings with clean
hydraulic oil.
Description
A pilot operated (PO) check valve is located in each CAUTION
outrigger jack cylinder port block. The check valve functions Do not damage the O-rings during installation of the check
as a holding valve for the jack cylinder. Oil flow is directed valve. If the check valve turns freely then gets hard to turn,
from the “V” port to the “C” ports, while blocking flow in the then easy to turn, remove the check valve and check the
opposite direction. Flow is reversed from “C” to “V” when O-rings. They have probably been damaged by a sharp
pressure pilot oil is applied to the opposite side “V” port edge of a port.
(Figure 2-23)
NOTE: The check valve should turn by hand until
Maintenance compression of the O-rings begins.
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Removal 4. Carefully install the check valve into the port block until
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fully seated.
1. Unscrew the check valve from the jack cylinder port
block. 5. Test the check valve and port block by operating the
affected outrigger’s jack cylinder. Verify it extends and
Installation retracts without problems; verify there is no leaking.
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1. Check the inside of the port block for any sharp edges or
burrs and remove as necessary with emery cloth.
2. Install new O-rings onto the check valve.
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Item Description
1 Port C - Cylinder
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2 Port P - Pilot
1
3 Port V - Valve
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6155
6155-2 3
3 FIGURE 2-23

INTEGRATED OUTRIGGER/REAR STEER Maintenance

MANIFOLD
Removal
Description 1. Tag and disconnect the electrical connectors to the
The integrated outrigger/rear steer manifold (Figure 2-24) valve.
controls the outrigger and rear steer circuit. The valve is 2. Tag and disconnect the hydraulic hoses from the valve.
mounted on the frame center section to the rear of the front Cap or plug the lines and ports. 2
axle.
3. Remove the capscrews and washers securing the valve
The manifold is made up of two sections; an inlet section and to the frame bracket. Remove the valve.
a working section.
The inlet section contains a 17,200 kPa/172 bar (2500 psi) Installation
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pressure reducing valve and a load sense shuttle valve. The
1. Secure the valve to the frame bracket with the washers
solenoid valve is a normally closed two position two way
and capscrews. Torque the capscrews see Fasteners
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valve. It unloads the load sense line to the pump to ensure
and Torque Values (pg 1- 12).
the pump is de-stroked during engine start.
2. Connect the hydraulic hoses to the ports on the valve as
The rear steer section contains a three position four way
tagged during removal.
solenoid controlled directional valve that controls left and
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right rear steer. The rear steer cylinders are positive locked 3. Connect the electrical connectors to the valve as tagged
by the double pilot operated check valves integral to the work during removal.
ports.
4. Verify operation as follows:
The outrigger section contains a three position four way pilot
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• Operate the rear steer left and right to verify smooth
controlled directional valve, two check valves, two load
operation.
sense shuttle valves, and two, two position three way
solenoids for pilot control of the outrigger extend and retract • On outriggers, swing over the front outriggers to ensure
function. the oscillation cylinders lockout.
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• Remove the electrical connection from the oil cooler

motor two position three-way solenoid valve to verify
that it operation.
5. Check valve and hoses for leaks. Make repairs as
needed.
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18 19
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16
21
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6751-3
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View A
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See View A
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for this side
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20 11
8, 9 6751-1
FIGURE 2-24

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20
22
11
3 22
2
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16
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22 23
8467

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1 Pressure Reducing Valve - PR1 12 Load Sense - LS0
2 Check Valve - CV1 13 Load Sense - LS1
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3 Orifice - ORF1 14 Port ALO - To Axle Lockout Valve

4 Solenoid Valve - Rear Steer S1 15 Port T - Tank
5 Solenoid Valve - Rear Steer S2 16 Port G1 - Gauge Port
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6 Solenoid Valve - SV2 17 Port P - Pressure From Pump #1

7 Solenoid Valve - SV1 18 Port A - Outrigger Retract
8 Gauge Port - G2 19 Port B - Outrigger Extend
9 Orifice - ORF2 20 Port RSA - Left Rear Steer
10 Solenoid - SF1 21 Port RSB - Right Rear Steer
11 Check Valve - CV4 22 Load Sense Shuttle valve
23 Pressure Reducing Valve - PR2

CHECK VALVES Maintenance

Description Removal
Check valves are used in the crane hydraulic system to block 1. Tag and disconnect hydraulic lines from the valve and
flow in one direction and allow free flow in the opposite cap or plug all openings and remove valve.
direction.
A check valve is plumbed in-line at the inlet of the front steer
Installation
control valve. It prevents steering wheel kick-back if the steer 1. Connect the hydraulic lines as tagged during removal.
cylinder pressure rises above the inlet port pressure.
2. Check valve and hydraulic connections for leaks. Make
repairs as needed.
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RANGE SHIFT/PARKING BRAKE VALVE Maintenance

Description Removal
The range shift/parking brake valve controls the flow of oil to 1. Tag and disconnect the electrical connectors to the
the parking brake, hi-low range and axle disconnect valve.
actuators by the use of two solenoid valves (Figure 2-25).
The valve is located on the center of the frame. Pressure is
supplied to the valve from the transmission charge pump. Cap or plug the lines and ports. 2
The parking brake solenoid valve is a two position three-way 3. Remove the capscrews, lockwashers, flatwashers and
valve. In its de-energized position, the inlet port is blocked nuts securing the valve to the frame. Remove the valve.
and the parking brake actuator is drained to the reservoir.
Installation
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When the solenoid is energized, the reservoir port is blocked
and pressurized oil is directed to the actuator, releasing the 1. Secure the valve to the frame with the nuts, flatwashers,
parking brake. lockwashers and capscrews. Torque the capscrews see
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The range shift solenoid valve is a two position four-way Fasteners and Torque Values (pg 1- 12).
valve. In its de-energized position, pressurized oil flows to 2. Connect the hydraulic hoses to the ports on the valve as
the “B” port of the range shift actuator, while the “A” port is tagged during removal.
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drained to the reservoir along with the axle disconnect
actuator for two wheel drive/high range. When the solenoid 3. Connect the electrical connectors to the valve as tagged
is energized, pressurized oil is directed to the “A” port of the during removal.
range shift actuator hydraulic spring release while port “B” of
the range shift actuator is drained to the reservoir for four Functional Tests
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wheel drive/low range. 1. Start and idle engine.
2. With units on outriggers, check for proper two/four wheel
operation.
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Item Description
1 Port P - Pressure 7
6
2 Port T - Tank
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3 Port A - Range Shift Actuator

4 Port B - Range Shift Actuator
5 Port PB - To Park Brake
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6 Solenoid Valve - Range Shift 8

7 Solenoid Valve - Park Brake
8 Pressure Switch
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8 5 3 4
7 6
2
5
1
3
1 4 6697-1
2
6697-2
Hydraulic Schematic
FIGURE 2-25

AXLE OSCILLATION LOCKOUT VALVE Maintenance

(STANDARD UNITS)
Removal
The axle oscillation lockout valve is used in the rear axle valve.
oscillation lockout circuit. The valve is located on the left 2. Tag and disconnect the hydraulic hoses from the valve.
inner center frame rail. It consists of a valve body and two Cap or plug the lines and ports.
normally-closed, three way, two position solenoid valves. It
keeps the lockout cylinders from oscillating unless the 3. Remove the capscrews, hex nuts, flatwashers and
turntable is centered forward. lockwashers securing the valve to the frame. Remove
the valve.
The area definition potentiometer in the electrical swivel
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energizes and deenergizes the axle oscillation relay. When Installation
the superstructure is more than 6 degrees left or right of
directly over the front, the axle oscillati on relay is 1. Secure the valve to the crane with the capscrews, hex
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deenergized. nuts, flatwashers and loc kwashers. Torque the
capscrews see Fasteners and Torque Values (pg 1- 12).
When the axle oscillation lockout valve is open, the normally
closed solenoid valves are deenergized and isolate the 2. Connect the hydraulic hoses to the ports on the valve as
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lockout cylinders from hydraulic oil supply. This keeps the tagged during removal.
cylinders from oscillating (moving up and down) because
3. Connect the electrical connectors to the valve as tagged
hydraulic oil cannot leave the cylinders. Instead, the
during removal.
cylinders remain full of hydraulic oil and rigid.
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When the axle oscillation lockout valve is closed, the
needed.
solenoid valves are energized and open. This allows
hydraulic oil in and out of the cylinders, allowing them to
oscillate.
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4
1
4
4 2
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3
3
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1
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Hydraulic Schematic 6694-2
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6694-1
FIGURE 2-26
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Port C- Pressure From Axle Lockout Port On 3 Port B - To Left Hand Lockout Cylinder
1
Outrigger Selector Valve
4 Solenoid Valve
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2 Port A - To Right Hand Lockout Cylinder

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AXLE OSCILLATION LOCKOUT VALVE Maintenance

(OPTIONAL CE UNITS)
Removal
The axle oscillation lockout valve is used in the rear axle valve.
oscillation lockout circuit. The valve is located on the left 2. Tag and disconnect the hydraulic hoses from the valve.
inner center frame rail. It consists of a valve body, a normally- Cap or plug the lines and ports.
closed three-way, two position solenoid valve and a pressure
reducing valve. It keeps the lockout cylinders from oscillating 3. Remove the capscrews, hex nuts, flatwashers and
unless the turntable is centered forward. lockwashers securing the valve to the frame. Remove
the valve.
The area definition potentiometer in the electrical swivel
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energizes and deenergizes the axle oscillation relay. When Installation
the superstructure is more than 6 degrees left or right of
directly over the front, the axle oscillati on relay is 1. Secure the valve to the crane with the capscrews, hex
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deenergized. nuts, flatwashers and loc kwashers. Torque the
When the axle oscillation lockout valve is open, the normally
closed solenoid valves are deenergized and isolate the 2. Connect the hydraulic hoses to the ports on the valve as
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lockout cylinders from hydraulic oil supply. This keeps the tagged during removal.
cylinders from oscillating (moving up and down) because
hydraulic oil cannot leave the cylinders. Instead, the
during removal.
cylinders remain full of hydraulic oil and rigid.
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When the axle oscillation lockout valve is closed, the
needed.
oscillate.
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5 4
4
2
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2
6
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1 1
5
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2 6719-1
3
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3
6719-2
Hydraulic Schematic
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FIGURE 2-27
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Item Description
Item Description 4 Solenoid Valve
Port P - Pressure From Axle Lockout Port On 5 Port B - To Lockout Cylinder Pilot
1
Outrigger Selector Valve
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6 Port P1 - To Lockout Cylinder

2 Port T - Tank
3 Pressure Reducing Valve
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CYLINDERS Maintenance
General General
This subsection provides descriptive information for all the There must be a gap between the ends of each wear ring
hydraulic cylinders used on this crane. The description of the when it is installed onto the piston (as applicable) or head. In
cylinder given here is for the cylinder itself. For information addition, each wear ring gap is to be located as follows:
on how the cylinder functions in the individual circuits, refer Divide 360 degrees by the number of wear rings on the
to the Description and Operation of that circuit. component. The resulting value is the number of degrees
each wear ring gap is to be located with respect to each
other.
The approximate wear ring gaps are as follows:
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Table 2-3
Wear Ring Gap
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Head (or Piston) Size Wear Ring Gap
Inch mm Inch mm
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1 to 4.75 25.4 to 120.7 0.125 3.18
5 to 10.0 127.0 to 254.0 0.187 4.75
greater than 10.0 greater than 254.0 0.250 6.35
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Surface Protection for Cylinder Rods Leakage Check
Steel cylinder rods include a thin layer of chrome plating on A hydraulic cylinder should not be disassembled unless it is
their surfaces to protect them from corroding. However, essential. The following checks will provide a means of
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chrome plating inherently has cracks in its structure which determining if a cylinder has a faulty or leaking piston seal.
can allow moisture to corrode the underlying steel. At typical
1. Extend the rod to its maximum stroke. Remove the
ambient temperatures, hydraulic oil is too thick to penetrate
retract hose from the cylinder. Cap the retract hose.
these cracks. Normal machine operating temperatures will
allow hydraulic oil to warm sufficiently to penetrate these
cracks and if machines are operated daily, protect the rods.
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Machines that are stored, transported, or used in a corrosive

environment (high moisture, rain, snow, or coastline DANGER
conditions) need to have the exposed rods protected more Ensure pressure is applied to the piston side of the
frequently by applying a protectant. Unless the machine is cylinder only and the retract hose is capped.
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operated daily, exposed rod surfaces will corrode. Some

cylinders will have rods exposed even when completely 2. Apply hydraulic pressure to the piston side of the
retracted. Assume all cylinders have exposed rods, as cylinder and observe the open cylinder port for leakage.
corrosion on the end of the rod can ruin the cylinder. If leakage is observed, the seals in the cylinder must be
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replaced.
It is recommended that all exposed cylinder rods be
protected using Boeshield® T-9 Premium Metal Protectant. 3. Fully retract the cylinder rod (except the telescope
Manitowoc Crane Care has Boeshield® T-9 Premium Metal cylinder). Remove the extend hose from the cylinder.
Protectant available in 12 oz. cans that can be ordered Cap the extend hose.
through the Parts Department.
NOTE: Cylinder operation and inclement weather will
remove the Boeshield® protectant; therefore,
inspect machines once a week and reapply
DANGER
Boeshield® to unprotected rods. Ensure pressure is applied to the retract (rod) side of the
cylinder only and that the extend hose is capped.
4. Apply hydraulic pressure to the retract (rod) side of the

cylinder and observe the open cylinder port for leakage.

If leakage is observed, the seals in the cylinder must be minimize the effects of thermal contraction or “Stick-slip” it is
replaced. recommended that the telescope control lever is activated
periodically in the extend position to mitigate the effects of
5. Reconnect all cylinder ports.
cooling oil.
Temperature Effects on Hydraulic Cylinders If a load and the boom is allowed to remain stationary for a
period of time and the ambient temperature is cooler than the
Hydraulic oil expands when heated and contracts when trapped oil temperature, the trapped oil in the cylinders will
cooled. This is a natural phenomena that happens to all cool. The load will lower as the telescope cylinder(s) retracts 2
liquids. The coefficient of expansion for API Group 1 allowing the boom to come in. Also, the boom angle will
hydraulic oil is approximately 0.00043 cubic inches per cubic decrease as the lift cylinder(s) retracts causing an increase
inch of volume for 1°F of temperature change. Thermal in radius and a decrease in load height.
contraction will allow a cylinder to retract as the
hydraulic fluid which is trapped in the cylinder cools. This situation will also occur in reverse. If a crane is set up in
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The change in the length of a cylinder is proportional to the the morning with cool oil and the daytime ambient
extended length of the cylinder and to the change in temperature heats the oil, the cylinders will extend in similar
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temperature of the oil in the cylinder. For example, a cylinder proportions.
extended 25 feet in which the oil cools 60°F would retract
The charts below have been prepared to assist you in
approximately 7 3/4 inches (see chart below). A cylinder
determining the approximate amount of retraction/extension
extended 5 feet in which the oil cools 60°F would only retract
that may be expected from a hydraulic cylinder as a result of
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approximately 1 1/2 inches. The rate at which the oil cools
change in the temperature of the hydraulic oil inside the
depends on many factors and will be more noticeable with a
cylinder. The chart is for dry rod cylinders. If the cylinder rod
larger difference in oil temperature verses the ambient
is filled with hydraulic oil, the contraction rate is somewhat
temperature.
greater.
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Thermal contraction coupled with improper lubrication or
NOTE: Operators and service personnel must be aware
improper wear pad adjustments may, under certain
that load movement, as a result of this phenomena,
conditions, cause a “stick-slip” condition in the boom. This
can be easily mistaken as leaking cylinder seals or
“stick-slip” condition could result in the load not moving
faulty holding valves. If leaking seals or faulty
smoothly. Proper boom lubrication and wear pad adjustment
holding valves are suspected to be the problem,
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is important to permit the boom sections to slide freely. Slow

refer to Service Bulletin 98-036 dealing with testing
movement, of the boom may be undetected by the operator
telescope cylinders.
unless a load is suspended for a long period of time. To
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Table 2-4 Boom Drift Chart (Cylinder length change in inches)
3 3
Coeff. = 0.00043 (in /in / °F)
STROKE Temperature Change (°F)
(FT.) 10 20 30 40 50 60 70 80 90 100
5 0.26 0.52 0.77 1.03 1.29 1.55 1.81 2.06 2.32 2.58
10 0.52 1.03 1.55 2.06 2.58 3.10 3.61 4.13 4.64 5.16
15 0.77 1.55 2.32 3.10 3.87 4.64 5.42 6.19 6.97 7.74
20 1.03 2.06 3.10 4.13 5.16 6.19 7.22 8.26 9.29 10.32
25 1.29 2.58 3.87 5.16 6.45 7.74 9.03 10.32 11.61 12.90
30 1.55 3.10 4.64 6.19 7.74 9.29 10.84 12.38 13.93 15.48
35 1.81 3.61 5.42 7.22 9.03 10.84 12.64 14.45 16.25 18.06
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40 2.06 4.13 6.19 8.26 10.32 12.38 14.45 16.51 18.58 20.64
45 2.32 4.64 6.97 9.29 11.61 13.93 16.25 18.58 20.90 23.22
50 2.58 5.16 7.74 10.32 12.90 15.48 18.06 20.64 23.22 25.80
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55 2.84 5.68 8.51 11.35 14.19 17.03 19.87 22.70 25.54 28.38
60 3.10 6.19 9.29 12.38 15.48 18.58 21.67 24.77 27.86 30.96
3 3
Length change in inches = Stroke (Ft.) X Temperature Change ( °F) X Coeff. (in /in / °F) X 12 in/ft
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Table 2-5 Boom Drift Chart (Cylinder length change in millimeters)
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Coeff. = 0.000774 (1/ °C)
STROKE Temperature Change (°C)
(m) 5 10 15 20 25 30 35 40 45 50 55
1.5 5.81 11.61 17.42 23.22 29.03 34.83 40.64 46.44 52.25 58.05 63.86
3 11.61 23.22 34.83 46.44 58.05 69.66 81.27 92.88 104.49 116.10 127.71
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4.5 17.42 34.83 52.25 69.66 87.08 104.49 121.91 139.32 156.74 174.15 191.57
6 23.22 46.44 69.66 92.88 116.10 139.32 162.54 185.76 208.98 232.20 255.42
7.5 29.03 58.05 87.08 116.10 145.13 174.15 203.18 232.20 261.23 290.25 319.28
9 34.83 69.66 104.49 139.32 174.15 208.98 243.81 278.64 313.47 348.30 383.13
10.5 40.64 81.27 121.91 162.54 203.18 243.81 284.45 325.08 365.72 406.35 446.99
12 46.44 92.88 139.32 185.76 232.20 278.64 325.08 371.52 417.96 464.40 510.84
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13.5 52.25 104.49 156.74 208.98 261.23 313.47 365.72 417.96 470.21 522.45 574.70
15 58.05 116.10 174.15 232.20 290.25 348.30 406.35 464.40 522.45 580.50 638.55
16.5 63.86 127.71 191.57 255.42 319.28 383.13 446.99 510.84 574.70 638.55 702.41
18 69.66 139.32 208.98 278.64 348.30 417.96 487.62 557.28 626.94 696.60 766.26
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Length change in mm = Stroke (m) X Temperature Change ( °C) X Coeff. (1/ °C) X 1000 mm/m
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LIFT CYLINDER NOTE: Arranging discarded seals and rings in the order of
disassembly will aid in installation of new seals and
Description rings. Pay attention to how each seal and ring is
installed to avoid installing replacement seals and
The lift cylinder (Figure 2-28) has a bore of 22.8 cm (9.0 rings improperly.
inches). The retracted length of the cylinder from the center
of the barrel bushing to the center of the rod bushing is 6. Remove the set screw securing the piston to the rod.
265.1cm (104.4 inches). The extended length of the cylinder
from the center of the barrel bushing to the center of the rod
7. Unscrew the piston from the rod. 2
bushing is 464.5 cm (182.9 inches). Its stroke is 199.3 cm 8. Remove the O-ring and two backup rings from the inside
(78.5 inches). A wiper ring prevents foreign material from of the piston.
entering the cylinder. O-rings and other seals prevent 9. Remove the head from the rod.
internal and external leakage.
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10. Remove the O-ring and the backup ring from the outside
The cylinder weighs approximately 521 kg (1149 lb). of the head and the wear rings, buffer seal, rod seal, and
wiper ring from the inside of the head.
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Maintenance
Inspection
Disassembly
1. Clean all parts with solvent and dry with compressed air.
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NOTE: Any maintenance requiring disassembly of the Inspect all parts for serviceability.
cylinders should include replacement of all seals
and rings. A seal kit will supply the required items. 2. Inspect the barrel carefully for scoring. If barrel is
scored, it must be repaired or replaced.
1. Disconnect the tube assembly from the holding valve.
3. Check piston for damage. If piston is damaged,
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2. Remove the capscrews and washers securing the determine if it can be repaired or must be replaced.
holding valve and remove the holding valve from the
cylinder barrel. 4. Inspect rod for straightness. Determine if it can be
straightened or must be replaced.
3. Using a spanner wrench or chain wrench, unscrew the
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head from the barrel.

CAUTION
Before installing new seals and rings, clean all surfaces
and carefully remove burrs and nicks. Parts displaying
DANGER excessive wear or damage should be replaced.
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Do not use air pressure to remove the rod. Use only a

source of controlled hydraulic oil pressure if the rod is 5. Stone out minor blemishes and polish with a fine crocus
hard to move. cloth.
CAUTION 6. Clean with solvent and dry with compressed air any
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Exercise extreme care when handling or setting down the parts that have been stoned and polished.
rod. Damage to the rod surface may cause unnecessary
maintenance and expense. Assembly
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4. Remove the rod and attached parts from the barrel.

NOTE: Cover the barrel opening to avoid contamination. CAUTION
When installing new seals and rings, avoid stretching
seals or scratching the grooved or gland surfaces. Make
CAUTION sure parts are clean before and during assembly. Make
When removing seals and rings, avoid scratching the sure seals and rings are installed in the proper order.
grooved and gland surfaces.
NOTE: Lubricate seals and rings with clean hydraulic oil.
5. Remove the two hydrolock seals and guidelock ring from
the outside of the piston.

6
5
1
5 3
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11 9 8
12 8
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4
13 7
14
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15 18
10 19
20
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16
21
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22, 23, 24
17
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6865-1
FIGURE 2-28
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1 Grease Fitting 10 Head
2 Rod 11 Backup Ring
3 Setscrew 12 O-ring
4 Piston 13 Wear Ring
5 Seal Assembly 14 Buffer Seal
6 Guidelock Ring 15 Rod Seal
7 Capscrew 16 Wiper Ring
8 Backup Ring 17 Barrel
9 O-ring 18 Washer

Item Description
19 Plug Hydrolock Piston Seals
20 Holding Valve
21 Tube Assembly
22 Nut
23 Capscrew 2
24 Pipe Clamp
1. Install the replacement wear rings, buffer seal, rod seal FIGURE 2-30
and wiper ring in the inside of the head. Make sure the
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buffer seal’s step is closer to the rod seal. Make sure the 7. Install the replacement hydrolock seals on the outside of
rod seal’s rim groove is closer to the buffer seal the piston. Make sure the “vees” on the two hydrolock
(Figure 2-29).
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seals point at each other (Figure 2-30).
Wear Ring
8. Lubricate all parts freely with clean hydraulic oil.
Rod Seal Wiper Ring
Buffer Seal
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CAUTION
Exercise extreme care when handling the rod. Damage to
the rod surface may cause unnecessary maintenance
and expense. Also, take care to avoid damaging grooved
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or gland surfaces or rings or seals during rod insertion.
6865-2
9. Remove the cover from the barrel. Insert the rod and
FIGURE 2-29
attached parts into the barrel with a slight twisting
2. Install the replacement O-ring and the backup ring on motion.
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the outside of the head. 10. Using a spanner wrench or chain wrench, screw the
3. Install the replacement O-ring and backup rings in the head into place in the barrel.
inside of the piston.
4. Lubricate the rod with clean hydraulic oil. CAUTION
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5. Slide the head, wiper ring end first, onto the rod. Do not use air pressure to cycle or pressurize the cylinder.
6. Screw the piston onto the rod until tight. Secure the 11. Position the holding valve on the cylinder barrel and
piston with the set screw. secure with four capscrews and washers. Torque
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capscrews 97.6 to 105.7 Nm (72 to 78 pounds-foot).

Connect tubing to holding valve.
12. Pressurize and cycle the cylinder with hydraulic oil
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pressure. Test the cylinder at 41,368 kPa/413.6 bar

(6000 psi). Check for proper operation and any leakage.

DUAL ROD TELESCOPE CYLINDER NOTE: Aligning discarded seals and rings in the order of
disassembly will facilitate installation of new seals
Description and rings.
The boom dual rod telescope cylinder has a 16.0 cm (6.31 3. Remove the hydrolock piston seal to gain access to the
inch) bore. The cylinder is internally ported (rod ported). Oil setscrew securing the piston to the outer cylinder rod.
from the telescope control valve is routed to the cylinder by 4. Remove the setscrew and unscrew the piston from the
external lines. Foreign material is prevented from entering cylinder rod.
the cylinder rod during retraction by a wiper ring in the head.
O-ring seals prevent internal and external leakage 5. Remove the remaining hydrolock seal and wear ring
(Figure 2-31). from the outside of the piston and the O-ring and two
backup rings from the inside of the piston.
The cylinder incorporates two cylinder rods with separate
6. Remove the spacer from the rod.
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strokes. One rod has a stroke of 674.8 cm (265.7 in), and
one rod has a stroke of 687.7 cm (270.75 in), which provides 7. Remove the O-ring from the rod.
a combined overall stroke of 1362.7 cm (536.5 in).
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8. Remove the cylinder head from the outer rod.
9. Remove the O-ring and backup ring from the outside of
CAUTION the head and the wear ring, buffer seal, rod seal and
Do not retract the cylinder completely if it is not attached
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to the boom. Maintain a spacer that is split or hinged 6.88”
long to prevent cylinder from retracting completely. 10. Using a spanner wrench, unscrew the inner cylinder
head from the outer cylinder rod.
The cylinder weighs approximately 907 kg (1995.5 lb) wet.
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Maintenance CAUTION
Do not use air pressure to remove the cylinder rod
Disassembly assembly. Use only a source of controlled hydraulic oil
pressure if the rod is hard to remove.
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NOTE: Any maintenance requiring disassembly of the CAUTION

cylinder should include replacement of all cylinder
Exercise extreme care when handling or setting down the
seals and O-rings.
cylinder rod. Do not damage the chrome surface.
1. Using a spanner wrench, unscrew the outer cylinder
head from the cylinder barrel. 11. Remove the inner cylinder rod assembly from the outer
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cylinder rod and cover the opening to avoid

contamination.
12. Remove the hydrolock piston seal to gain access to the
DANGER setscrew securing the piston to the inner cylinder rod.
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Do not use air pressure to remove the cylinder rod

assembly. Use only a source of controlled hydraulic oil 13. Remove the setscrew and unscrew the piston from the
pressure if the rod is hard to remove. cylinder rod.
CAUTION 14. Remove the remaining hydrolock seal from the outside
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Exercise extreme care when handling or setting down the of the piston and the O-ring and two backup rings from
cylinder rod. Do not damage the chrome surface. the cylinder rod.
15. Remove the O-ring from the rod.
2. Remove the cylinder rod assembly from the cylinder
barrel and cover the barrel to avoid contamination. 16. Remove the spacer from the rod and remove the wear
ring from the spacer.
17. Remove the cylinder head from the inner rod.
CAUTION
When removing seals and rings, avoid scratching 18. Remove the O-ring and backup ring from the outside of
grooved and gland surfaces. the head and the wear rings, buffer seal, rod seal and
19. If necessary, remove the socket head capscrews and
remove the counterbalance valve.

31
30
2
24
25
23
18 21
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26
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17
9
7 27
10
32
8
29
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25
3 22
20
19
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15 16
17
12 11
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6 14
13
2
7 5
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1 6867
FIGURE 2-31
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1 Barrel 12 Rod Seal
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2 Piston 13 Buffer Seal

3 Seal Assembly 14 Wear Ring
4 O-ring 15 Rod
5 Backup Ring 16 Piston
6 Spacer 17 Setscrew
7 O-ring 18 Seal Assembly
8 Head 19 O-ring
9 Backup Ring 20 Backup Ring
10 O-ring 21 Spacer
11 Wiper Ring 22 O-ring

Item Description 3. Install the O-ring and backup ring onto the outside of the
head.
23 Head
24 Backup Ring
CAUTION
25 O-ring
Improper seal installation can cause faulty cylinder
26 Wiper Ring operation.
27 Rod Seal
28 Buffer Seal
29 Wear Ring
Backup Ring
30 Rod
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31 plug
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32 Counterbalance Valve
Inspection
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Inspect for damaged or worn parts and replace as Wear Ring Wiper Ring
Buffer Seal Rod Seal
required.
6488-2
FIGURE 2-32
CAUTION
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4. Install the inner cylinder head onto the inner cylinder rod.
Clean all surfaces and remove all burrs and nicks before
installing new seals and rings. Replace all damaged or 5. Install the spacer onto the rod.
worn parts.
6. Install the O-rings onto the rod. Secure the piston in
place with the setscrew.
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2. Stone out minor blemishes and polish with fine crocus

cloth.
Hydrolock Piston Seals
3. Clean all with solvent and dry with compressed air any
parts that have been stoned and polished.
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4. Inspect the barrel for scoring.
Assembly
1. If removed, install the counterbalance valve with the
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socket head capscrews.
CAUTION FIGURE 2-33

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When installing new seals and rings, clean all surfaces 7. Install the hydrolock seals onto the piston (Figure 2-33).
excessive wear or damage should be replaced.
CAUTION
NOTE: Lubricate new seals and rings with clean hydraulic Avoid scratching or damaging the grooved and gland
oil. surfaces or the seals and rings.
NOTE: Locate the gap of wear ring 180 degrees with
respect to each other. 8. Lubricate the inner cylinder rod assembly with clean
hydraulic oil and install the rod assembly into the outer
2. Install the wiper ring, wear rings, buffer seal, rod seal cylinder rod with a slight twisting motion.
and wiper ring in the inner cylinder head ensuring the
seals are assembled properly and installed in the correct 9. Using a spanner wrench, secure the inner cylinder head
direction (Figure 2-32). to the outer cylinder rod.

10. Install the wiper ring, wear ring, buffer seal and rod seal
into the head ensuring the seals are assembled properly
and installed in the correct direction (Figure 2-34). Hydrolock Piston Seals
CAUTION
Improper installation of seals could cause faulty cylinder
operation. 2
Backup Ring
Backup Ring
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FIGURE 2-35
15. Install the hydrolock seals onto the piston (Figure 2-35).
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CAUTION
Wear Ring Wiper Ring Avoid scratching or damaging the grooved or gland
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Buffer Seal Rod Seal
6488-1
surfaces or the ring and seals.
FIGURE 2-34 16. Lubricate the outer cylinder rod assembly with clean
11. Install the O-ring and backup ring onto the outside of the hydraulic oil and install the rod assembly into the
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outer cylinder head. cylinder barrel with a slight twisting motion.
12. Install the outer cylinder head onto the outer cylinder 17. Using a spanner wrench, secure the outer cylinder head
rod. to the cylinder barrel.
13. Install the spacer onto the rod.

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14. Install the O-ring and backup rings into the inside of the
piston. Install the piston onto the outer cylinder rod. DANGER
Secure the piston in place with the setscrew. Do not use air pressure to cycle or pressurize the cylinder.

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pressure. Test the cylinder at 24,132 kPa/241 bar (3500

psi). Check for proper operation and any leakage.
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AXLE OSCILLATION LOCKOUT CYLINDER 7. Using a hoist, extend the rod assembly slowly until the
piston is free of the barrel.
Description 8. Remove the rod and attached parts from the barrel.
The two oscillation lockout cylinders (Figure 2-36) standard NOTE: Cover the barrel opening to avoid contamination.
or (Figure 2-37) (CE Option) each have 12.7 cm (5 inch)
diameter bores. The retracted length of each cylinder is 48.8
cm (19.25 inches) from the center of the lug holes to the
CAUTION
center of the barrel bushing. The extended length of each
cylinder from the center of the lug holes to the center of the When removing seals and rings, avoid scratching the
barrel bushing is 65.5 cm (25.8 inches). Its stroke is 16.8 cm grooved and gland surfaces.
(6.62 inches). A wiper ring prevents foreign material from
entering each cylinder. O-rings and other seals prevent 9. Remove the lip seals and wear ring from the outside of
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internal and external leakage. the piston.
The cylinder weighs approximately 38.8 kg (85.5 pounds). NOTE: Arranging discarded seals and rings in the order of
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disassembly will aid in installation of new seals and
Maintenance rings. Pay attention to how each seal and ring is
Disassembly rings improperly.
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10. Remove the retaining ring from the rod.
NOTE: Any maintenance requiring disassembly of the
cylinder should include replacement of all cylinder 11. Remove the head from the rod. Remove the O-ring and
seals. backup ring from the outside of the head. Remove the
wear ring, buffer seal, lip seal and wiper ring from the
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1. Clean away all dirt from the head. Place protective
inside of the head.
padding around the rod near the head to prevent
damaging the chrome. Using a spanner wrench,
unscrew the head from the barrel.
Inspection
1. Inspect the rod. There should be no scratches or pits
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deep enough to catch the fingernail. Pits that go to the

base metal are unacceptable. Chrome should be
DANGER present over the entire surface of the rod. If lack of
Do not use air pressure to remove the rod. Use only a chrome on rod, the rod should be replaced.
source of controlled hydraulic oil pressure if the rod is 2. Inspect rod for straightness. Determine if it can be
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hard to remove. straightened or must be replaced.

CAUTION
3. Inspect the head. Visually inspect the inside bore for
Exercise extreme care when handling or setting down the scratching or polishing. Deep scratches are
rod. Do not damage the chrome surface.
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unacceptable. Polishing indicates uneven loading, and

the bore should be checked for out-of-roundness.
2. Open both ports on the side of the cylinder barrel and
drain the oil from the cylinder. 4. Inspect the piston. Visually inspect the outside surface
for scratches or polishing, Deep scratches are
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3. Secure cylinder barrel in a chain vise without putting unacceptable. Polishing indicates uneven loading, and
pressure on the side feeder tube preferably in the the diameter should be checked for out-of roundness.
vertical position with the rod assembly up.
5. Inspect the barrel carefully for scoring. If barrel is
4. Using a screwdriver, or 1/4 inch wrench, remove the scored, it must be repaired or replaced.
screw from the head.
6. Thoroughly rinse parts, allow to drain, and wipe with a
5. Remove the grease fitting from the rod lint-free rag. Inspect all parts for serviceability.
6. Turn the head counterclockwise with a fitted spanner
wrench until the threads disengage.
CAUTION
NOTE: Residual oil will spill over the end of the barrel
wh en th e r od as se mbly is ex te nde d. Mak e
provisions to contain the oil.

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FIGURE 2-36

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1 Barrel 10 Lip Seal Ring

2 Rod 11 Wiper Ring
3 Head 12 Retainer Ring
4 Lip Seal Ring 13 Bleeder Plug
5 Wear Ring 14 Grease Fitting
6 O-ring 15 Grease Fitting
7 Backup Ring 16 Screw
8 Buffer Ring 17 O-ring
9 Wear Ring 18 Cap Assembly

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17 17
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6732
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FIGURE 2-37

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1 Barrel 11 Wiper Ring

2 Rod Assembly 12 Retainer Ring
3 Head 13 Bleeder Plug
4 Lip Seal 14 Grease Fitting
5 Wear Ring 15 Grease Fitting
6 O-ring 16 Screw
7 Backup Ring 17 O-ring
8 Wear Ring 18 Plug
9 Buffer Ring 19 Plug
10 Lip Seal 20 Check Valve

7. Stone out minor blemishes and polish with a fine crocus

cloth.
CAUTION
8. Clean with solvent and dry with compressed air any
parts that have been stoned and polished. Exercise extreme care when handling the rod. Damage to
Assembly and expense. Also, take care to avoid damaging grooved
2
7. With a hoist, raise the rod assembly back into a vertical
CAUTION position taking care not to damage the OD seals on the
When installing new seals and rings, avoid stretching head and piston.
sure parts are clean before and during assembly. Make 8. Lubricate the OD seals on the piston and head with
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sure seals and rings are installed in the proper order. clean light oil and lower the assembly into the barrel.
Stop just before the head enters the barrel.
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NOTE: Lubricate seals and rings with clean hydraulic oil. 9. Place a spanner wrench on the head and turn
1. Install the replacement wiper ring, lip seal, buffer seal counterclockwise until the thread clicks, then reverse
and wear ring in the inside of the head. direction to clockwise and thread in until there is no gap
between the head shoulder and top of barrel.
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2. Install the replacement O-rings and backup ring on the
outside of the head. 10. Install the retaining ring onto the rod.
3. Install the lip seals and wear ring onto the outside of the 11. Install the setscrew into the head.
piston.
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4. Lubricate the rod with clean hydraulic oil. CAUTION
5. Slide the head, onto the rod. Tap the head with a rubber Do not use air pressure to cycle or pressurize the cylinder.
mallet to engage the seals. Push the head about half
way down the length of the rod assembly. 12. Pressurize and cycle the cylinder with hydraulic oil
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pressure. Test the cylinder at 25,856 kPa/259 bar (3750

6. Remove the cover from the barrel. psi). Check for proper operation and any leakage. Make
repairs as needed.
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STEER CYLINDER NOTE: Cover the barrel opening to avoid contamination.
Description
CAUTION
The steer cylinders (Figure 2-38) are mounted on the axles,
When removing seals and rings, avoid scratching the
two cylinders on each axle. The front and rear steer cylinders
each have 6.3 cm (2.5 inch) diameter bores. The front and
rear steer cylinders each have a retracted length of 53.1cm
(20.94 inches) from bushing center to bushing center. The 7. Remove the seal from the outside of the piston.
front and rear steer cylinders each have an extended length NOTE: Arranging discarded seals and rings in the order of
of 74.1cm (29.19 inches) from bushing center to bushing disassembly will aid in installation of new seals and
center. Each cylinder has a stroke of 20.9 cm (8.25 inches). rings. Pay attention to how each seal and ring is
A wiper ring prevents foreign material from entering each installed to avoid installing replacement seals and
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cylinder. O-rings and other seals prevent internal and rings improperly.
external leakage.
8. Loosen and remove the nut securing the piston.
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The cylinder weighs approximately 9.07 kg (19.9 pounds). Remove the piston from the rod.
Maintenance 9. Remove the O-ring from the inside of the piston.

10. Remove the head from the rod. Remove the O-ring and
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Disassembly backup ring from the outside of the head. Remove the
wiper ring and the rod seal from the inside of the head.
cylinders should include replacement of all seals
and rings. A seal kit will supply the required items.
Inspection
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1. Secure the cylinder in a clean work area by use of 1. Clean all parts with solvent and dry with compressed air.
clamps or a chain vise to prevent rolling. Inspect for damaged or worn parts and replace as
required.
2. Retract the cylinder fully to avoid damaging the rod
during removal.
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NOTE: Mark or note the piston and head relationship to the

CAUTION
rod and barrel. Clean all surfaces and remove all burrs and nicks before
installing new seals and rings. Replace all damaged or
3. Clean away all dirt from the head. Place protective worn parts.
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damaging the chrome during head removal. 2. Stone out minor blemishes and polish with fine crocus
cloth.
3. Clean all with solvent and dry with compressed air any
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DANGER parts that have been stoned and polished.

Do not use air pressure to remove the rod. Use only a 4. Inspect the barrel for scoring.
source of controlled hydraulic oil pressure if the rod is
hard to move. Assembly
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CAUTION
Exercise extreme care when handling or setting down the
rod. Damage to the rod surface may cause unnecessary CAUTION
maintenance and expense. When installing new seals and rings, clean all surfaces
4. Position the rod mount with the ports facing down. excessive wear or damage should be replaced.
5. Using a means of collecting the oil, remove the port NOTE: Lubricate new seals and rings with clean hydraulic
plugs and allow cylinder to drain. oil.
6. Rapidly pull the rod against the head to free it. Remove 1. Install the replacement wiper ring into the head.
rod and attached parts from the barrel. Place the rod on
a surface that will not damage the chrome or allow the 2. Install the rod seal in the inside of the head. Make sure
rod assembly to drop. the lips of the seal face the piston.

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6722
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FIGURE 2-38

1 Barrel 7 Piston Seal Ring
2 Rod 8 O-ring
3 Head 9 Back-up Ring
4 Piston 10 Rod Seal Ring
5 Nut 11 Wiper Ring
6 O-ring

3. Install the O-ring and backup ring onto the outside of the 10. Remove the cover from the barrel. Insert the rod and
head. attached parts into the barrel with a slight twisting
motion.
4. Install the O-ring in the inside of the piston.
11. Push the head into the barrel. Torque the head 27.1 Nm
5. Lubricate the rod with clean hydraulic oil.
(20 pounds-foot).
6. Slide the head, larger OD end first, onto the rod.
7. Install the piston onto the rod. Secure the piston with the CAUTION
nut. Lubricate the threads and torque the nut to 176.2 ±
Do not use air pressure to cycle or pressurize the cylinder.
6.7 Nm (130 ± 5 pounds-foot).
8. Install the seal on the outside of the piston. 12. Pressurize and cycle the cylinder with hydraulic oil
9. Lubricate all parts freely with clean hydraulic oil.
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CAUTION
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OUTRIGGER EXTENSION CYLINDER 6. Remove the piston and spacer from the rod.
7. Remove the O-ring and the backup ring from the outside
Description of the head.
The four extension cylinders (Figure 2-39) have 6.4 cm (2.5- 8. Remove the rod seal, wear ring and wiper ring from the
inch) diameter bores. Each cylinder has a retracted length of inside of the head.
218.1 ± 0.30 cm (85.88 ± 0.12 inches) from the center of the
9. Remove the O-ring from the rod.
rod bushing to the center of the barrel bushing. Each
cylinder’s extended length is 403.5 cm (157.87 inches). The
2
stroke of each cylinder is 185.4 cm (73.0 inches). A wiper Inspection
ring prevents foreign material from entering each cylinder. O-
rings and other seals prevent internal and external leakage.
Inspect all parts for serviceability.
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The cylinder weighs approximately 42 kg (112.5 pounds).
Maintenance
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3. Check rod’s piston area for damage. If it is damaged,
Disassembly determine if it can be repaired or must be replaced.
NOTE: Any maintenance requiring disassembly of the 4. Inspect rod for straightness. Determine if it can be
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cylinders should include replacement of all seals straightened or must be replaced.
and rings. A seal kit will supply the required items.
1. Remove all dirt, grease and other contaminants from CAUTION
around the ports and the head
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DANGER 5. Stone out minor blemishes and polish with a fine crocus
Do not use air pressure to remove the rod. Use only a cloth.
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source of controlled hydraulic oil pressure if the rod is

hard to move. 6. Clean with solvent and dry with compressed air any
CAUTION
Exercise extreme care when handling or setting down the Assembly
rod. Damage to the rod surface may cause unnecessary
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maintenance and expense.

CAUTION
2. Using a spanner wrench, unscrew the cylinder head.
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3. Remove rod and attached parts from the barrel. seals or scratching the grooved or gland surfaces. Make
sure parts are clean before and during assembly. Make
NOTE: Cover the barrel opening to avoid contamination.
sure seals and rings are installed in the proper order.
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CAUTION
When removing the seals and rings, avoid scratching the 1. Install the replacement wear ring, rod seal and wiper ring
grooved and gland surfaces. in the inside of the head.
2. Install the replacement O-ring and the backup ring on
4. Remove the wear rings and piston seal from the outside the outside of the head.
of the piston.
3. Install the O-ring onto the rod.
NOTE: Arranging discarded seals and rings in the order of
disassembly will aid in installation of new seals and 4. Lubricate the rod with clean hydraulic oil.
rings. Pay attention to how each seal and ring is 5. Slide the head onto the rod.
rings improperly. 6. Install the spacer and piston on the rod.
5. Remove the nut from the rod. 7. Install the locknut onto the rod.

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FIGURE 2-39

1 Barrel 8 Wear Ring
2 Rod 9 O-ring
3 Piston 10 O-ring
4 Head 11 Backup Ring
5 Spacer 12 Seal
6 Nut 13 Wiper
7 Piston Seal 14 Wear Ring
8. Install the replacement piston seal and wear rings on the outside of the piston.

9. Lubricate all parts freely with clean hydraulic oil. damaging the chrome. Using a spanner wrench,
unscrew the head from the barrel.
CAUTION
the rod surface may cause unnecessary maintenance DANGER
and expense. Also, take care to avoid damaging grooved Do not use air pressure to remove the rod. Use only a
or gland surfaces, rings or seals during rod insertion. source of controlled hydraulic oil pressure if the rod is 2
hard to remove.
10. Remove the cover from the barrel. Insert the rod and
attached parts into the barrel with a slight twisting
CAUTION
motion. Exercise extreme care when handling or setting down the
rod. Do not damage the chrome surface.
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11. Push the head into the barrel.
2. Open ports on the side of the cylinder barrel and drain
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the oil from the cylinder.
CAUTION
3. Secure cylinder barrel in a chain vise without putting
pressure on the side feeder tube in the vertical position
with the rod assembly up.
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pressure. Test the cylinder at 20,700 kPa (270 bar) 4. Using a 5/32 inch Allen wrench, remove the setscrew on
(3000 psi). Check for proper operation and any leakage. the barrel OD at the head.
NOTE: Oil or oil/air mixture may rapidly exit out of the ports
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during rod extension. Shield the work area from the
OUTRIGGER JACK CYLINDER exiting oil.
Description 5. With the ports open, extend the rod assembly with a
hoist enough to access the top of the head with spanner
The four outrigger jack cylinders (Figure 2-40) each have a wrench. Do not extend completely.
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hollow rod for internal porting. Each cylinder has a 10.1 cm

(4.0 inch) diameter bore. A port block is welded to the rod of 6. Turn the head counterclockwise with a fitted spanner
each cylinder and a pilot operated check valve is threaded wrench until the threads disengage.
into each port block. The retracted length of the cylinder from
7. Extend the rod assembly slowly until the piston is free of
the end of the barrel to the center of the rod’s port block rod
the barrel assembly. Place the rod assembly horizontally
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bushing is 122.2 ± 30.8 cm (48.12 ±.12 in). The extended

length of the cylinder from the end of the barrel to the center on a workbench taking care not to damage the surface
of the rod’s port block rod bushing is 185.7 cm (73.12 in). Its of the rod.
stroke is 63.5 cm (25 in). A wiper ring prevents foreign NOTE: Cover the barrel opening to avoid contamination.
material from entering the cylinder. O-rings and other seals
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prevent internal and external leakage 8. Remove the piston seal to gain access to the piston
setscrew Using a 3/16 inch Allen wrench, remove the
The cylinder weighs approximately 64.6 kg (142.52 lb). setscrew from the piston.
Maintenance
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9. Remove the piston by turning counterclockwise with a

fitted spanner wrench.
Disassembly 10. Remove the spacer and head from the rod.
cylinder should include replacement of all cylinder
seals. CAUTION
When removing seals and rings, avoid scratching the
1. Clean away all dirt from the head. Place protective
11. Remove the seal assembly from the outside of the
piston and the O-ring and backup rings from he inside of
the piston.

NOTE: Arranging discarded seals and rings in the order of present over the entire surface of the rod. If lack of
disassembly will aid in installation of new seals and chrome on rod, the rod should be replaced.
rings. Pay attention to how each seal and ring is
2. Inspect rod for straightness. Determine if it can be
straightened or must be replaced.
rings improperly.
3. Inspect the head. Visually inspect the inside bore for
12. Remove the O-ring and backup ring from the outside of
scratching or polishing. Deep scratches are
the head. Remove the wear rings, buffer seal, rod seal
and wiper ring from the inside of the head.
the bore should be checked for out-of-roundness.
Inspection 4. Inspect the piston. Visually inspect the outside surface
for scratches or polishing, Deep scratches are
1. Inspect the rod. There should be no scratches or pits
deep enough to catch the fingernail. Pits that go to the
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the diameter should be checked for out-of roundness.
base metal are unacceptable. Chrome should be
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6744
FIGURE 2-40


Item Description 1. Install the replacement wiper ring, rod seal, buffer seal
1 Barrel and wear rings in the inside of the head.
2 Rod 2. Install the replacement O-ring and backup ring on the

outside of the head.
3 Head
3. Lubricate the rod with clean hydraulic oil.
4 Piston 2
4. Slide the head, onto the rod. Tap the head with a rubber
5 Spacer
mallet to engage the seals. Push the head about half
6 Check Valve way down the length of the rod assembly.
7 Setscrew 5. Install the spacer onto the rod with the ID lip at the piston
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8 Insert end.
9 Plug 6. Install the setscrew in the piston with a 3/16 inch Allen
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wrench until hand tight. Install the seal assemblies onto
10 Wiper Ring the piston.
11 Rod Seal 7. Remove the cover from the barrel.
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12 Buffer Seal
13 Wear Ring
CAUTION
14 O-ring Exercise extreme care when handling the rod. Damage to
15 Backup Ring the rod surface may cause unnecessary maintenance
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16 Seal Assembly or gland surfaces or rings or seals during rod insertion.
17 Backup Ring
8. With a hoist, raise the rod assembly back into a vertical
18 O-ring
position taking care not to damage the OD seals on the
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19 Setscrew head and piston.

20 Insert 9. Lubricate the OD seals on the piston and head with
clean light oil and lower the assembly into the barrel.
6. Thoroughly rinse parts, allow to drain, and wipe with a
Stop just before the head enters the barrel.
lint-free rag. Inspect all parts for serviceability.
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10. Place a spanner wrench on the head and turn

counterclockwise until the thread clicks, then reverse
CAUTION direction to clockwise and thread in until there is no gap
Before installing new seals and rings, clean all surfaces between the head shoulder and top of barrel.
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11. Using a 5/32 inch Allen wrench install the setscrew into
the head until hand tight.
7. Stone out minor blemishes and polish with a fine crocus 12. Slowly lower the rod down to the fully retracted position.
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cloth.
8. Clean with solvent and dry with compressed air any CAUTION
Assembly
CAUTION Make repairs as needed.
sure parts are clean before and during assembly. Make
sure seals and rings are installed in the proper order.

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RT530E-2 SERVICE MANUAL ELECTRIC SYSTEM
SECTION 3
ELECTRIC SYSTEM
SECTION CONTENTS
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Troubleshooting Accessories. . . . . . . . . . . . . . . . . 3-5
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Alternator Replacement . . . . . . . . . . . . . . . . . . . . . 3-6
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Starter Replacement . . . . . . . . . . . . . . . . . . . . . . . 3-6
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Battery Replacement . . . . . . . . . . . . . . . . . . . . . . . 3-7
Fuse Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Relay Panel Component Replacement . . . . . . . . . 3-7
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Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Rocker Switch Replacement . . . . . . . . . . . . . . . . . 3-8 3
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Ignition Switch Replacement . . . . . . . . . . . . . . . . . 3-8
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General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Turn Signal Lever and Transmission Shift Lever
General Troubleshooting . . . . . . . . . . . . . . . . . . . 3-4 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Troubleshooting Swivel-Caused Electrical Windshield Wiper Assembly Replacement . . . . . 3-11
Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Windshield Washer Assembly Replacement . . . . 3-12
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Connector Troubleshooting . . . . . . . . . . . . . . . . . 3-4 Skylight Wiper Assembly Replacement . . . . . . . . 3-13
Troubleshooting Engine Starting Problems . . . . . 3-4 Appendix A: Crane Control System (CCS)
Troubleshooting Engine Charging Problems . . . . 3-5 Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
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DESCRIPTION used to determine if the battery can be tested in case of a
starting problem.
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General There is a battery disconnect switch (1) (Figure 3-2) located

The electrical system is 24-volt operation with 24-volt on the right of the battery box. To disconnect the batteries,
starting, consisting of an alternator and two lead-acid turn the battery disconnect switch to OFF. Turn the switch to
batteries. The system is the single wire ground return type, ON to connect the batteries.
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using the machine’s structure as ground
Alternator
The alternator is mounted on the engine and is belt driven. It
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is a 70 ampere alternator with an integral transformer -

rectifier unit. When the engine is running, and the alternator
is turning, the alternator's 24-volt output terminal supplies the
crane’s electrical circuits. The output terminal also supplies
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current to recharge the batteries and maintains them at a full

state of charge.
Batteries
The batteries (1) (Figure 3-1) are located in a box on the left
side of the crane. The batteries are the maintenance free
type and completely sealed except for a small vent hole in
the side. The vent hole allows what small amount of gases
that are produced in the battery to escape. On some 8090-3
1
batteries, a test indicator located on the top of the battery is FIGURE 3-1

ELECTRIC SYSTEM RT530E-2 SERVICE MANUAL
The following fuse assignments apply:

1
Table 3-1: Superstructure Cab Power Panel
Fuse Protects Amps Location

F1 Dome Light 5 (Figure 3-3)
ACC Power Outlet/
F2 10 (Figure 3-3)
Heater Motor
F3 Work Lights 10 (Figure 3-3)
F4 Steering Column Power 5 (Figure 3-3)
F5 Key Switch Power 10 (Figure 3-3)
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Turntable Module
F6 15 (Figure 3-3)
Battery Power
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Master/Cab Slave
F7 15 (Figure 3-3)
Module Battery Power
F8 Skylight Wiper 10 (Figure 3-3)
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Turntable Option Module
F9 15 (Figure 3-3)
Battery Power
FIGURE 3-2
Turntable Option Module
F10 15 (Figure 3-3)
Fuse Panel Battery Power
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Turntable Module
Fuses are located behind the seat in the cab (Figure 3-3) F11 15 (Figure 3-3)
Battery Power
and in the battery box fuse panel (3) (Figure 3-4) in the
battery box. F12 Diagnostic Tool Power 15 (Figure 3-3)
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F13 Accessory Lights Power 15 (Figure 3-3)

2 1
F14 Oil Cooler 25 (Figure 3-3)
F15 Heater/AC Panel 10 (Figure 3-3)
F16 Circulating Fan 5 (Figure 3-3)
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Joystick/Jogdial/
F17 5 (Figure 3-3)
Operator Display Power
Master/Cab Slave
F18 5 (Figure 3-3)
Module PCB Power
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Turntable Module PCB

F19 5 (Figure 3-3)
Power
F20 Spare (Figure 3-3)
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8091-1 FIGURE 3-3

Table 3-2: Superstructure Cab Fuse Box Table 3-4: Carrier Fuses and Relays
Fuse Protects Amps Location Fuse Protects Amps Location

F1 Keyswitch Ignition Relay 3 (Figure 3-3) F51 Alternator 100 (Figure 3-4)
F2 Open (Figure 3-3) F52 Swivel 100 (Figure 3-4)
F3 Ignition On Signal 3 (Figure 3-3) F53 Swivel 100 (Figure 3-4)
Keyswitch Ignition On F54 Swivel 100 (Figure 3-4)
D1 (Figure 3-3)
Signal
F55 Main Power 125 (Figure 3-4)
Brake Pedal Press
D2 (Figure 3-3) F56 Grid Heater Power 100 (Figure 3-4)
Switch Signal
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Hazard Lights On
D3
Switch Signal
(Figure 3-3) 3
Relays
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Marker Lights On Switch
D4 (Figure 3-3) The relays are located at the back of the battery box
Signal
(Figure 3-4): Includes K-301 start relay (1) and K-302 grid
D5 Horn On Signal (Figure 3-3)
heater relay (2).
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Table 3-3: Carrier Fuses and Relays
4
Fuse Protects Amps Location
Superstructure Module
F1 20 (Figure 3-4)
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PCB Power
F2 CraneStar Power 5 (Figure 3-4)
F3 Diagnostic Tool Power 5 (Figure 3-4)
Carrier Module Battery
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F4 15 (Figure 3-4)
Power
Carrier Module Battery
F5 15 (Figure 3-4)
Power
F6 Engine ECM Power 30 (Figure 3-4)
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F7 Relay Power 10 (Figure 3-4)

F8 Reverse Power 15 (Figure 3-4)
Carrier Module PCB
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F9 15 (Figure 3-4)
Power
1 4 2 3
KC1 Headlight Relay (Figure 3-4) 8090-4A FIGURE 3-4
KC2 Starter Lockout Relay (Figure 3-4)
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KC3 Reverse Relay (Figure 3-4)

KC4 Ignition On Relay (Figure 3-4)

MAINTENANCE 5. If wiring proves faulty, this is typically the result of

another failure within the electrical system. Identify and
General investigate the root cause of failure. Make necessary
component repairs as outlined in the following sections.
Electrical system maintenance includes troubleshooting and Proceed to make appropriate wiring fault repair. Wiring
replacement of damaged components. Observe standard repairs must be made using Manitowoc approved
wiring practices when replacing components. materials.
6. Splicing sections of broken wire must have terminations
that meet minimum pull test requirements listed in table
3-5. Splices must be completely covered with adhesive
CAUTION lined shrink tubing. Tubing must extend beyond any bar
If it is necessary to perform electrical maintenance on live conductors by at least ¼”.
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or hot circuits, remove all rings, watches, and other
jewelry before performing maintenance as serious burns Table 3-5 Minimum Pull Values (In lbs)
result from accidental grounding or shorting circuits.
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Two Wire
Wire Gauge Single Wire
Termination
24 10 8
CAUTION 22 15 10
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20 20 17
Ensure the batteries are disconnected before performing
18 30 20
any maintenance on an electrical circuit which is not fused 16 40 30
or when performing continuity checks. 14 60 50
Never replace original wiring with wiring of a smaller size 12 70 60
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(gauge). 10 80 70
8 90 80
6 100 90
4 140 120
General Troubleshooting 7. After troubleshooting, test the repaired harness. Verify
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the circuit works properly.
Troubleshooting Swivel-Caused Electrical

CAUTION Problems
Many steps in the troubleshooting procedures require
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Many crane component electrical troubles can be traced to

testing live (energized) components. Perform these steps
the electrical swivel. Troubles common to the swivel are
observing good safety practices to avoid electrical shock
improper mounting, foreign material between the brushes
injury.
and slip rings, incorrect wiring from the swivel to the
components, incorrect wire size, worn brushes, improper
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NOTE: Make voltage checks at terminations when

spring tension on the brush assembly, and loose setscrews
components are installed and operating. Make
on the slip ring assembly. Refer to the electrical schematic
continuity checks (with batteries disconnected)
and wiring diagram for slip ring connections and amperages.
when components are isolated or removed.
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Troubleshoot per the following guidelines: Connector Troubleshooting

1. First, use reported symptoms to identify a problem or a
The cause of an electrical problem may be a loose or
suspect component.
corroded connection in the pin or socket connectors. Check
2. Test the suspect component per instructions in this the connectors to ensure that the pins and sockets are
section. The instructions identify the circuit breakers and properly seated and engaged. If the pins and sockets show
components and guide you from the easiest and most any signs of corrosion, use a good quality electrical contact
likely problems to the hardest and least likely problems. cleaner or fine sandpaper to clean them. When the pins or
sockets show signs of arcing or burning, it indicates another
3. Using a multimeter, test the circuit for continuity if you
failure within the electrical system that might cause the
suspect a broken circuit or for voltage if you suspect a
condition. Identify and investigate the root cause of the
power problem. Check the electrical schematic and
failure, make necessary component repairs and then
wiring diagram for most accurate wiring information.
proceed to make the necessary wire terminal repairs.
4. If the component proves faulty, replace it with a known
working component.

When replacing wire terminals, use the proper crimp tool to a. If you hear no noise when you try to turn the starter,
ensure the proper crimping method. Refer to the tables at the troubleshoot the start circuit (ignition switch, electric
end of this section listing tools necessary for connector shifter, and wiring from ignition switch to starter
maintenance. These tables list common tools; however, relay). Make repairs as needed.
contact Manitowoc CraneCare to ensure the proper crimp
b. If the engine still won’t start, and you hear no noise
tool is available.
o r j u s t a s i n g l e c l i c k , s u s p e c t t h e s t a r t e r.
Because the pins and sockets are crimped to the wires, it is Troubleshoot the starter circuit from the starter relay
not possible to remove them. Using the proper extraction through the starter solenoid to the starter motor and
tool, remove the pin(s) or socket(s) from the plug or ground. Make repairs as needed. If the starter
receptacle. Cut the wire as close to the pin or socket as solenoid or the starter motor is faulty, replace the
possible. After cutting the pin or socket off, the wire will most starter.
likely be too short. Using a wire that is too short will allow
c. If the starter engages but can’t turn the engine (and
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pressure to be applied to the pin or socket and wire where
they are crimped when the pin or socket is inserted in the
the lights dim, signaling power drain during start
attempt), check the starter’s feed circuit from the
3
plug or receptacle. Splice a short length of wire to the short
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batteries for resistance. If the resistance is high,
wire according to the guidelines in the General
greater than .002Ω, make repairs. If the circuit
Troubleshooting section.
checks out, replace the starter. If the engine still
Troubleshooting Engine Starting Problems won’t start, suspect a seized engine.
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d. If the starter turns the engine, but it still won’t start,
1. Verify the battery terminals are connected and clean,
suspect a fuel problem. Ensure fuel system can
none of the fuses are blown, the transmission is in
draw fuel from the tank and pump it to the engine;
neutral, and the machine is fueled.
make repairs as needed.
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2. Try to turn on the head lights, tails lights, marker lights,
e. If the engine starts, then shuts down, suspect a fuel
dome light, work light, or gauge lights and panel lights to
problem. Ensure fuel system can draw fuel from the
verify the battery has at least some charge. If none of
tank and pump it to the engine; make repairs as
these lights comes on, suspect the battery. Charge
needed.
battery as needed, jump-start the crane or replace the
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battery when possible. 7. Refer to the engine manual for further instructions.
NOTE: The crane is a 24V machine which requires a 24V NOTE: If the starter won’t disengage during running, verify
source for jump starting. the starter is mounted properly so its gear won’t
mesh with the engine’s flywheel when not trying to
3. If you hear the starter relay clicking repeatedly, power is
start engine. Troubleshoot the starter relay and
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reaching the starter, but not enough; suspect the battery.

ignition switch for closed contacts. If these
Charge battery as needed, jump-start the crane or
components check out, replace the starter.
replace the battery when possible.
4. If the problem remains, troubleshoot the starter lockout Troubleshooting Engine Charging Problems
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relay. Use service tool for starter lockout input signal to

1. Verify battery terminals are connected and clean and all
CCM11. Also, check starter lockout relay to ensure it is
wires in the charging system are in good repair and are
energized.
connected properly.
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5. Using the service tool (see “Using Service Tool

2. Verify the alternator belt is properly installed and is
Section”), check for proper Keyswitch input signals and
under proper tension.
Start output signals. With the Service Tool connected to
the crane A channel, Select View, Cab, Steering 3. Verify the battery puts out 24 volts minimum. Charge
Column. Watch the Keystate value for each position of battery as needed so the battery can supply a minimum
the Keyswitch: excitation voltage to the engine’s charging system.
0=OFF 4. Verify when the crane is running that the alternator is
putting out a minimum of 24 volts DC on the voltmeter.
1=ON
5. Replace the alternator if the other conditions check out.
2=START
6. Refer to the engine manual for further instructions.
6. If the battery, fuses, secondary circuit, ignition switch,
and power circuit to the ignition switch check out, do one NOTE: If the alternator runs noisily, check belt tension. If
of the following: problem persists, replace alternator.

NOTE: If the alternator overcharges (voltmeter reads high, 3. If the problem remains, check the ignition switch and the
light bulbs turn out quickly), look for a ground accessory control circuit from the ignition switch through
where one shouldn’t exist. If external wiring checks the coil of the accessory relay (KS1) to ground. Turn the
out, replace alternator. (The alternator probably ignition switch to ON (Position 1) and shift the electric
has an internal ground or a faulty internal voltage shifter to reverse; if the backup lights and backup alarm
regulator.) do not turn on, then there is no power through the switch
when it is on (Position 1). Replace ignition switch if there
Troubleshooting Accessories is no power through it when it is ON (Position 1).
Replace accessory relay if there is no continuity through
If the crane’s engine starts and charges properly, but none of
it’s coil. Make circuit repairs to accessory control circuit
its components except the horn or lights work, the accessory
as needed.
circuitry may be faulty. Check as follows:
4. If the problem remains, check the accessory relay
1. Turn the ignition switch to ON (Position 1). Try to turn on
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(K101) contacts and the accessory power circuit.
the cab circulating fan, the heater fan, the defroster fan,
Replace relay if its contacts stay open when the coil is
or the windshield wipers or washer. If none of these
energized. Make circuit repairs as needed.
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come on (but the head lights, tail lights, marker lights,
dome light or work light will come on), there is accessory
circuitry problem.
2. Check the primary power circuit to the accessory relay
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K101 in the Cab fuse & relay panel. Make circuit repairs
as needed.
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Alternator Replacement 7. Connect the electrical leads to the terminals as tagged

during removal.
Removal 8. Close the engine compartment.
1. Ensure that the key switch has been in the OFF position 9. Reconnect the ground cables to the battery.
for 2 minutes.
10. Install the ECM power fuse.
2. Turn the battery disconnect switch to the OFF position.
11. Turn the battery disconnect switch to the ON position.
3. Remove the ECM power fuse.
4. Remove and isolate the negative battery cables. Check
5. Open the engine compartment. 1. Run engine. Verify reading of voltmeter on front console
is 24 volts or greater. Make repairs as needed.
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6. Tag and disconnect the electrical leads from the
terminals on the alternator. 2. Continue troubleshooting charging system as needed if 3
replacement of alternator did not correct problem in
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7. Turn the tensioner below the alternator clockwise to charging system.
remove tension from the belt. Slip the belt off of the
alternator pulley, then let the tensioner return to its Starter Replacement
normal position.
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8. Remove and tag all wires. Remove the alternator link Removal
capscrew and the mounting capscrew. Remove the 1. Ensure that the key switch has been in the OFF position
alternator. for 2 minutes.
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Installation 2. Turn the battery disconnect switch to the OFF position.
1. Inspect the belt. Verify it has no cracks or other damage. 3. Remove the ECM power fuse.
Replace damaged belt as needed. 4. Remove and isolate the negative battery cables.
2. To assemble the alternator, the mounting components 5. Open the engine compartment.
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must be tightened in the following sequence.

6. Tag and disconnect the electrical leads from the
a. Alternator-to-alternator bracket capscrew. terminals on the starter.
b. Lower brace-to-alternator capscrew. 7. Remove the bolts holding the starter to the mounting
c. Lower alternator brace-to-water pump capscrew. pad. Remove the starter.
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d. Torque brace-to-alternator bolt, see Fasteners and Installation

Torque Values (pg 1- 12).
1. Place the starter on its mounting pad. Secure the starter
e. Torque alternator-to-alternator bracket, see
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with the bolts. Torque the bolts to 43 Nm (32 lb-ft).

Fasteners and Torque Values (pg 1- 12).
2. Connect the electrical leads to the terminals as tagged
3. Install the belt on all engine pulleys except the alternator during removal.
pulley for now.
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3. Connect the batteries.

4. Turn the tensioner clockwise. Slip the belt onto the
alternator pulley, then carefully return the tensioner to its 4. Install the ECM power fuse.
normal position so it puts tension on the belt. Make sure 5. Turn the battery disconnect switch to the ON position.
the belt is centered on the tensioner.
6. Close the engine compartment.
5. Check belt tension at the belt’s longest span (longest
distance between pulleys). At the center point of the Check
longest span, push in on the belt with your thumb. Verify
you can deflect the belt no more than 10 to 13 mm (3/8 1. Try to start the engine. Verify the starter starts the
to 1/2 inch) with your thumb. (Or, using a belt tension engine.
gauge, verify there is 267 to 578 N (60 to 130 lb) of
2. Start engine again, and listen for starter noises. Verify
tension on the belt in the middle of its longest span.)
there is no abnormal noise indicating the starter’s gear is
Replace belt if it is too loose (overstretched).
meshing improperly with the flywheel, that the starter’s
6. Verify tensioner bolt is torqued to 43 Nm (32 lb-ft). gear hasn’t disengaged from the flywheel after the
ignition switch is in the ignition (run) position, or some
other problem. Install starter properly as needed.

Battery Replacement Installation

1. Place the batteries in the battery box.
Removal
2. Install the hold down brackets so they can hold down the
batteries. Secure the brackets (and batteries) to the
bracket hold down rods with nuts and washers.
CAUTION
To avoid possible engine fault codes and undesirable 3. Connect leads to the battery terminals starting with the
operation, ensure the keyswitch has been off 2 minutes negative terminals (Figure 3-5)
before disconnecting batteries. 4. Install the ECM power fuse.
Disconnect batteries, if machine will be inactive for over
5. Close the battery box cover.
24 hours.
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6. Turn the battery disconnect switch to ON.
7. Verify replacement batteries work by starting crane’s
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engine and operating various crane components.
Relay Panel Component Replacement
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Accessory Relay
1. Ensure that the key switch has been in the OFF position
for 2 minutes.
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3. Remove the hardware securing the console front cover
and remove the cover.
4. Tag and disconnect the electrical leads from the suspect
relay.
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5. Remove the hardware securing the suspect relay to the

relay panel assembly. Remove suspect relay.
6. Install replacement relay on relay panel and secure it
with attaching hardware.
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FIGURE 3-5 7. Connect the electrical leads to the relay as tagged

1. Ensure that the key switch has been in the OFF position during removal.
for 2 minutes. 8. Position the console front cover on the console and
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2. Turn the battery disconnect switch to the OFF position. secure with the attaching hardware.
3. Remove the ECM power fuse. 9. Connect the batteries.
4. Remove the negative battery cables. 10. Turn the battery disconnect switch to the ON position.
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5. Remove the positive battery cables. 11. Verify proper installation by operating all components
involved with the replacement relay verifying they all
6. Tag and disconnect leads from the battery terminals work.
starting with the positive terminals.
7. Remove the nuts and washers from the bracket hold Rocker Switch Replacement
down rods. Remove the hold down bracket. Use the following procedures and refer to Figure 3-6 when
8. Remove the batteries. removing/installing a switch.
Removal
for 2 minutes.

3. Pull the rubber boot (11) off the bottom of the left and 4. Connect the wire harness to the bottom of the switch (4).
right side covers (8, 9).
5. Install the right side cover (9) on the steering column.
4. Remove the lever (12) and spacer that locks/unlocks the
6. Connect the wire harness to the ignition switch (10).
steering column tilt/telescope function.
7. Install the left side cover (8) on the steering column.
5. Remove the four screws (13) securing the left and right
side covers (8, 9) together. 8. Secure the switch cover (6) to the left and right side
covers (8, 9) using six screws (14).
6. Remove the six screws (14) securing the left and right
side covers (8, 9) to the switch cover (6). 9. Secure the left and right side covers (8, 9) together using
four screws (13).
7. Remove the left side cover (8) from the steering column.
10. Install the lever (12) and spacer that locks/unlocks the
8. Disconnect the wire harness from the back of the ignition
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switch (10).
11. Pull the rubber boot (11) up and over the bottom of the 3
9. Remove the right side cover (9) from the steering
left and right side covers (8, 9).
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column.
10. Disconnect the wire harness from the bottom of the
switch (4) that must be replaced. Remove the switch by Check
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squeezing the retaining clips on each side of switch and
pushing upwards until switch is free of cover. 1. Operate the switch per the Operator’s Manual. Verify
each of its functions works.
Inspection
2. As needed, troubleshoot further any system or circuit
1. Visually check the switch for evidence of cracks, malfunction not corrected by repair or replacement of
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damaged connections, or other damage. Replace the switch or associated wiring.
damaged switch as needed.
Ignition Switch Replacement
2. Check wiring for damaged insulation or damaged
connectors. Repair as needed. Use the following procedures and refer to Figure 3-6 when
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removing/installing the ignition switch.

3. Check all connectors for corrosion. Replace corroded
components as needed. Removal
4. Perform the following check to determine switch 1. Ensure that the key switch has been in the OFF position
serviceability. for 2 minutes.
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a. Using an ohmmeter, check for continuity between 2. Turn the battery disconnect switch to the OFF position.
the switch terminals with switch at ON or activated
position(s). Ohmmeter should register zero ohms 3. Pull the rubber boot (11) off the bottom of the left and
(continuity). right side covers (8, 9).
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b. Place switch at OFF or deactivated position. 4. Remove the lever (12) and spacer that locks/unlocks the
Ohmmeter should register infinity (no continuity). steering column tilt/telescope function.
c. Replace switch if it fails either part of the check. 5. Remove the four screws (13) securing the left and right
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side covers (8, 9) together.

Installation
6. Remove the six screws (14) securing the left and right
1. Remove the rocker (3) from the old switch by holding the side covers (8, 9) to the switch cover (6).
switch by its sides in one hand and then squeezing the
7. Remove the left side cover (8) from the steering column.
left and right sides of the rocker with the other hand and
pulling up. 8. Disconnect the wire harness from the back of the ignition
switch (10).
2. Orient the rocker (3) correctly relative to the new switch
(4), then install rocker in switch. 9. Remove the right side cover (9) from the steering
column.
3. Install the switch (4) in the switch cover (6) by pushing
the switch (4) down through the top of the switch cover 10. Remove the locking nut that secures the ignition switch
(6) until the switch’s retaining clips click in place. (10) to the right cover (9) and remove the ignition switch
(10).

Inspection Removal
1. Visually check the ignition switch for evidence of cracks, 1. Ensure that the key switch has been in the OFF position
damaged connections, or other damage. Replace for 2 minutes.
damaged ignition switch as needed.
2. Check wiring for damaged insulation or damaged
3. Pull the rubber boot (11) off the bottom of the left and
connectors. Repair as needed.
right side covers (8, 9).
3. Check all connectors for corrosion. Replace corroded
4. Remove the lever (12) and spacer that locks/unlocks the
components as needed.
4. Perform the following check to determine ignition switch
5. Remove the steering wheel by doing the following:
serviceability.
a. Remove the steering wheel cap (1) using a twisting
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a. Using an ohmmeter, check for continuity between
motion by pushing on the side of the cap closest to
the switch terminals with switch at ON or activated
you with your thumbs while simultaneously pulling
position(s). Ohmmeter should register zero ohms
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on the side of the cap farthest from you with your
(continuity).
fingers.
b. Place switch at OFF or deactivated position.
b. Remove the securing nut from the steering column
Ohmmeter should register infinity (no continuity).
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shaft and remove the steering wheel (2).
c. Replace switch if it fails either part of the check.
6. Remove the four screws (13) securing the left and right
Installation side covers (8, 9) together.
1. Install the ignition switch (10) in the right side cover (9) 7. Remove the six screws (14) securing the left and right
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and secure with the locking nut. side covers (8, 9) to the switch cover (6).
2. Install the right side cover (9) on the steering column. 8. Remove the left side cover (8) from the steering column.
3. Connect the wire harness to the ignition switch (10). 9. Disconnect the wire harness from the back of the ignition
switch (10).
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4. Install the left side cover (8) on the steering column.

10. Remove the right side cover (9) from the steering
5. Secure the switch cover (6) to the left and right side column.
covers (8, 9) using six screws (14).
11. Tag and disconnect the wire harness from the bottom of
6. Secure the left and right side covers (8, 9) together using each switch (4).
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four screws (13).

12. Remove the switch cover (6) from the steering column.
7. Install the lever (12) and spacer that locks/unlocks the
steering column tilt/telescope function. 13. Disconnect the wire harnesses from the bottom of the
turn signal and transmission shift levers (7).
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8. Pull the rubber boot (11) up and over the bottom of the
left and right side covers (8, 9). 14. Remove the two bolts and nuts securing the two levers
(7) together.
Installation
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Check
1. Align the location pins of the turn signal and
1. Operate the ignition switch per the Operator’s Manual. transmission shift levers (7) with the holes in the steering
Verify each of its functions works. column.
2. As needed, troubleshoot further any system or circuit 2. Secure the two levers (7) together using the two bolts
malfunction not corrected by repair or replacement of and nuts.
the switch or associated wiring.
3. Connect the wire harnesses to the levers (7).
Turn Signal Lever and Transmission Shift 4. Install the switch cover (6) on the steering column.
Lever Replacement
5. Install the wire harnesses on the switches (4) as tagged
Use the following procedures and refer to Figure 3-6 when during removal.
removing/installing the turn signal lever or transmission shift
lever. 6. Install the right side cover (9) on the steering column.
7. Connect the wire harness to the ignition switch (10).

8. Install the left side cover (8) on the steering column. 14. Pull the rubber boot (11) up and over the bottom of the
left and right side covers (8, 9).
9. Secure the switch cover (6) to the left and right side
covers (8, 9) using six screws (14). 15. Turn the battery disconnect switch to the ON position.
10. Secure the left and right side covers (8, 9) together using Check
four screws (13).
1. Operate the turn signal lever or transmission shift lever
11. Install the steering wheel (2); torque the securing nut to per the Operator’s Manual. Verify each of its functions
40 Nm ±5 (30 lb-ft ±4). work.
12. Install the steering wheel cap (1). 2. As needed, troubleshoot further any system or circuit
13. Install the lever (12) and spacer that locks/unlocks the malfunction not corrected by repair or replacement of
steering column tilt/telescope function. the switch or associated wiring.
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3
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1
3
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6 2
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4
14
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14
9
12
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14 12
13
11
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10
5
8494
FIGURE 3-6

Windshield Wiper Assembly Replacement Installation
Removal
1. Ensure that the key switch has been in the OFF position Windshield Wiper Arm
for 2 minutes. Serrated Collar

3. Tag and disconnect the electrical leads from the motor. Mounting Plate Washer
4. Disconnect the washer hose on the wiper arm (also Nuts
called the pantograph arm assembly) from the washer
nozzle fitting assembly.
Washer
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5. Remove the cap nut and washer securing the wiper arm
to the pantograph adapter kit. (The nut and washer are Screws
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part of the pantograph adapter kit.) Remove the cap nut,
washer, and tapered sleeve securing the wiper arm to
the pivot shaft kit. (The nut, washer, and sleeve are part Gasket
of the pivot shaft kit.) Mounting Bracket
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6. Remove the wiper arm from the pantograph adapter kit
and the pivot shaft kit. Motor
7. Remove the flanged sleeve, nut, and two flat washers 3653
from the pivot shaft kit. (The sleeve, nut, and washers FIGURE 3-7
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are part of the pivot shaft kit.)
1. Verify the pivot shaft and the wiper motor kit link and
8. Remove the two capscrews and lockwashers securing crank are in place on the motor bracket. (Washers and
the pantograph adapter kit’s adapter to the cab exterior. clip springs fasten the link to the pivot pins on the crank
Remove the pantograph adapter kit’s adapter and and the pivot shaft. The pivot shaft’s pivot pin mounts in
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gasket. the hole nearest the end of the pivot shaft’s lever.)
9. Remove attaching hardware to free the windshield wiper 2. Connect the wiper motor to the motor bracket with
motor bracket from the cab interior. Remove the bracket, screws and washers. Connect the wiper motor’s shaft to
with motor and pivot shaft connected, from the cab. the wiper motor kit crank with the nut and washer.
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NOTE: You may have to remove or move other parts to get 3. Secure the adapter and the gasket of the pantograph
the bracket and attached parts around the steering adapter kit to the cab exterior with capscrews and
column. Take care not to damage any parts. lockwashers.
10. Remove the nut to free the wiper motor’s shaft from the 4. Install the motor bracket and attached parts in the cab
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wiper motor kit crank. Remove the three screws and interior with attaching hardware. Ensure the pivot shaft
washers to free the wiper motor from its bracket. sticks through the hole in the pantograph adapter kit.
Remove the wiper motor from its bracket. Leave the
other parts attached to the bracket for now. NOTE: Take care not to damage any parts while moving
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the bracket and attached parts around the steering

Inspection column.
5. Secure the pivot shaft to the pantograph adapter with the
1. Visually check the motor housing for evidence of cracks
pivot shaft kit’s nut and washers. Install the flanged
or other damage. Check for excessive shaft end play
sleeve on the pivot shaft.
indicating worn or damaged bearings. Replace motor if
damaged. 6. Install the wiper arm on the shafts of the pantograph
adapter kit and the pivot shaft kit. Secure the wiper arm
2. Inspect the wiper blade for serviceability. Replace wiper
to the pantograph adapter kit shaft with the kit’s own
blade when worn.
washer and cap nut. Secure the wiper arm to the pivot
3. Inspect the wiper arm and parts of the linking component shaft with the pivot shaft kit’s own tapered sleeve,
kits (pantograph adapter kit, pivot shaft kit, wiper motor washer, and cap nut.
kit link and crank, wiper motor bracket) for damage.
7. Connect the wiper arm’s washer hose to the washer
Replace as needed.
nozzle fitting assembly.

8. Connect the electrical leads to the wiper motor as 5. Turn the battery disconnect switch to the ON position.
marked before removal.
6. Fill the container with cleaning fluid.
Check
Check
1. Squirt some cleaning fluid onto the windshield with the
1. Squirt some cleaning fluid onto the windshield with the windshield washer.
windshield washer.
2. Make repairs if windshield washer doesn’t work.
2. Operate the windshield wiper. Verify it works. (Replace
wiper blade as needed if it streaks or otherwise wipes Skylight Wiper Assembly Replacement
poorly.)
Removal
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Windshield Washer Assembly Replacement
1. Ensure that the key switch has been in the OFF position 3
Removal for 2 minutes.
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for 2 minutes. 3. Tag and disconnect the electrical leads from the motor.
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2. Turn the battery disconnect switch to the OFF position. 4. Remove the wiper arm from the motor shaft.
3. Locate the windshield washer container and pump on 5. Remove the nut, spacer, leather washer, and nylon flat
the left rear side of the cab. washer from the motor shaft outside the cab roof.
4. Tag and disconnect the pump’s electrical lead and 6. Remove the nut and lockwasher securing the motor
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ground wire. bracket to the cab roof and remove the motor from the
cab roof. Remove large nylon flat washer from motor
5. Disconnect the hose from the windshield washer pump.
shaft and flat washer and smaller nylon flat washer from
Point it so it won’t spill cleaning fluid. Catch cleaning fluid
mounting screw.
from the windshield washer container with a suitable
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container. 7. Remove mounting screw and nylon flat washer from

outside cab roof.
6. Remove four self tapping screws securing the
windshield washer container to the cab. Remove the 8. Clean any sealing material from around holes in cab
windshield washer container and pump. roof.
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7. Remove pump and pump seal from container.

Inspection
Inspection 1. Visually check the motor housing for evidence of cracks
or other damage. Check for excessive shaft end play
1. Visually check the pump for evidence of cracks, leaks, or
indicating worn or damaged bearings. Replace motor if
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other damage. Replace pump if damaged.

damaged.
2. Inspect the container for leaking. Replace pump seal if it
2. Inspect the wiper blade for serviceability. Replace wiper
is leaking. Replace container if it is damaged and
blade when worn.
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leaking.
3. Inspect the wiper arm and parts for damage. Replace as
3. Inspect spray nozzle on the wiper arm. As needed, clean
needed.
the nozzle with a fine piece of wire and compressed air.
Installation Installation
1. Install sealant material around both holes in cab roof,
1. Install pump and pump seal on container.
both inside and outside.
2. Install windshield washer container on the cab. Secure
2. Install screw with nylon flat washer (from outside)
the container with four self tapping screws.
through mounting hole in cab roof.
3. Attach the hose to the windshield washer pump.
3. Install flat nylon washer on motor shaft and insert motor
4. Connect the pump’s electrical lead and ground wire as shaft through hole in cab roof. Position small nylon
tagged during removal. washer and flat washer on screw between mounting
bracket and cab roof. Secure with lockwasher and nut.

4. Install nylon flat washer, leather washer, spacer, and nut 7. Turn the battery disconnect switch to the ON position.
on motor shaft. Tighten nut.
5. Install wiper arm and blade on motor shaft.
Check
1. Operate the skylight wiper. Verify it works. (Replace
6. Connect the electrical leads to the wiper motor as
wiper blade as needed if it streaks or otherwise wipes
marked before removal.
poorly.)
y
nl
O
ce
en
er
ef
R

Table 3-6Amp Extraction Tool Table
Description Amp Part Number Grove Part Number

14 gauge wire (connectors) 305183 9999100176
12 to 8 gauge wire (connectors) 91019-3 9999100175
4 to 9 circuit (in-line connectors) 453300-1 N/A
15 circuit (in-line connectors) 458944-1 N/A
Table 3-7
Amp Crimping Tool Table
y
Description Amp Part Number Grove Part Number
Tool Die Tool Die 3
nl
14 to 12 gauge wire 69710-1 90145-1 9999100177 N/A
10 to 8 gauge wire 69710-1 90140-1 9999100177 9999100178
4 to 9 circuit
O
69710-1 90306-1 9999100177 N/A
(in-line connectors
15 circuit
90299-1 -- N/A --
(in-line connectors
ce
Table 3-8
Deutsch Extraction Tool Table
Description Deutsch Part Number Grove Part Number

en
12 gauge wire 114010 9999100194

16 gauge wire 0411-204-1605 9999100195
8-10 gauge wire 114008 7902000012
4-6 gauge wire 114009 7902000009
er
Table 3-9
Deutsch Crimping Tool Table
ef
Description Deutsch Part Number Grove Part Number

12, 14, 16, 18, 20 gauge wire HDT48-00 9999100808
4, 6, 8, 10 gauge wire HDT 04-08 9999100842
R

Appendix A: Crane Control System (CCS) Fault Codes

There are four codes for every fault in the Crane Control Index Code reveals the type of fault. For example, a code
System (CCS) diagnostic. The Component Code number reading “7111. 2. 0. 129” correlates to “RCL Display”, “Cable
informs the operator which component is in fault mode; the Break”, “SCMO”, “CANbus 1”. This means the RCL display
Condition Code explains the actual malfunction; the Device CANbus cable to the SCMO module is broken.
Code indicates which module contains the fault; and the
Component Codes
Fault Code Component Description
y
5000 Key switch On input
5001 Key switch Accessory input
nl
5002 Key switch Start input
5003 Horn switch input
5005 Transmission Forward input
O
5006 Transmission Neutral input
5007 Transmission Reverse input
5008 Transmission 1st gear input
ce
5009 Transmission 2nd gear input
5010 Transmission 3rd gear input
5011 Transmission 4th gear input
5012 Transmission 5th gear input
en
5013 Transmission speed gears (all)

5014 Transmission direction gears (all)
5015 Turn Signal left input
er
5016 Turn Signal right input

5017 Headlights input
5018 Marker lights input
ef
5019 Hazard lights input

5020 Parking light switch
5021 Fog tail light switch
R
5022 Fog light switch

5023 Low beam headlight switch
5024 High beam headlight switch
5025 Windshield wiper low speed input
5026 Windshield wiper high speed input
5027 Windshield washer spray input
5028 Windshield wiper intermittent input
5030 Engine speed increment switch input
5031 Engine speed decrement switch input
5032 Rear steer left switch input


5033 Rear steer right switch input
5034 Park brake release switch input
5035 2 wheel drive switch input
5036 Differential lock switch input
5037 Brake pedal switch input
5038 Retarder / Thelma brake switch
5040 Outrigger extend switch input
5041 Outrigger retract switch input
y
5042 Cabin lower switch input 3
nl
5043 Cabin raise switch input
5050 Crane functions switch input
5051 Boom lights switch input
O
5052 Bypass hoist limiter switch input
5053 Bypass RCL inside switch input
5054 Bypass RCL outside switch input
ce
5055 Bypass Derricking switch input
5056 Aircraft warning light switch input
5057 Working light switch input
5058 Rotating flashing light switch
en
5059 High beam flasher switch

5060 Air Condition Switch (Carrier)
5061 Air Condition Switch (Superstructure)
er
5100 Enable Extend switch input

5101 Enable Retract switch input
5102 Enable Aux Hoist switch input
ef
5103 Enable Main Hoist switch input

5104 Enable Derricking switch input
5105 Enable Slewing switch input
R
5106 Enable Telescoping switch input

5107 Enable Freeswing switch input
5108 Enable Jib switch input
5109 Jib Identity
5110 Jib Remote Control down switch input
5111 Jib Remote Control up switch input
5112 Cab Tilt Down switch input
5113 Cab Tilt Up switch input
5150 Left Joystick Deadman input
5151 Right Joystick Deadman input


5152 Seat Switch deadman input
5153 Armrest deadman switch input
5154 Both Deadman switches input
5160 Carrier Emergency Off Switch
5161 Carrier Emergency Off Relay input
5162 Carrier Emergency Operation input
5163 AMOT active input
5170 DPF Regen Init switch input
y
5171 DPF Regen Inhibit switch input
nl
5300 Gas Pedal PWM input
5301 Slew Brake pedal PWM input
5302 Telescoping pedal PWM input
O
5303 Gas Pedal ANA input
5304 Service brake pedal ANA input
5305 Slewing brake pedal ANA input
ce
5500 Cold Weather switch input
5501 Rear Wheels Not Centered switch input
5502 Differential Lock Front switch input
5503 Differential Lock Rear switch input
en
5504 Oil Temperature switch input

5505 Hydraulic oil temperature switch input
5506 Slewing system temperature switch input
er
5507 Starter Lockout

5509 All wheel drive active input switch
5510 Axle locking input switch
ef
5511 Cross Diff Lock switch input Axle 1

R

5522 Long Diff Lock switch input Axle 2


5530 Drag link unlocked
5531 Drag link locked
5533 Steering Rod Lock switch input Axle 3
y
5535 Steering Rod Lock switch input Axle 5 3
nl
O
5600 Park Brake Pressure switch input
5601 ABS Trolley input
ce
5602 Suspension group too high (front left) input
5603 Suspension group too high (front right) input
5604 Suspension group too high (rear left) input
5605 Suspension group too high (rear right) input
en
5606 Suspension group too low (front left) input

5607 Suspension group too low (front right) input
5608 Suspension group too low (rear left) input
er
5609 Suspension group too low (rear right) input

5700 Cab Sensor for Humidity
5800 Outrigger length left front analog input
ef
5801 Outrigger length left rear analog input

5802 Outrigger length right front analog input
5803 Outrigger length right rear analog input
R
5804 Hoist limiter analog input

5805 Telescoping cylinder length analog input
5806 Stabilizer pressure sensor input, front left
5807 Stabilizer pressure sensor input, rear left
5808 Stabilizer pressure sensor input, front right
5809 Stabilizer pressure sensor input, rear right
5810 Anemometer analog input
5811 Angle sensor axle 1


5820 Fuel Level analog input
5821 Sensor Supply Voltage analog input
y
5822 Pressure Sensor Axle 1 Left
nl
5823 Pressure Sensor Axle 1 Right
5824 Pressure Sensor Axle 2-3 Left
5825 Pressure Sensor Axle 2-3 Right
O
ce
5833 Cabin Temperature Sensor Head
en
5834 Cabin Temperature Sensor Feet

5835 Cabin Temperature Sensor Back
5836 Cabin Sensor Humidity
er
5840 Service Brake Circle 1

5841 Service Brake Circle 2
5845 Transmission Temperature
ef
5850 LIM override simulated output

5900 Main Hoist Counter / encoder
5901 Main Hoist direction input
R
5902 Aux Hoist Counter / encoder

5903 Aux Hoist direction input
5904 Main hoist 3rd wrap input
5905 Aux hoist 3rd wrap input
5906 System Release input (signal from SCM0)
5907 Emergency Stop input
5908 Main Hoist Lower pressure switch
5909 Main Hoist Raise pressure switch
5910 Aux Hoist Lower pressure switch
5911 Aux Hoist Raise pressure switch


5912 Derricking Down pressure switch
5913 Derricking Up pressure switch
5914 Telescoping Extend pressure switch
5915 Telescoping Retract pressure switch
5916 Hydraulic Oil Temp switch
5917 Brake Pressure switch
5918 AC Clutch Required switch
5919 Swing Right pressure switch
y
5920 Swing Left pressure switch 3
nl
5921 Swing Brake pressure switch
5922 Hydraulic Oil Filter pressure switch
5923 Steering Pressure low switch
O
5924 Boom Section Locked redundant switch
5925 Left Tele Cylinder Locked redundant switch
5926 Right Tele Cylinder Locked redundant switch
ce
5927 Left Tele Cylinder Pins Low switch
5928 Left Tele Cylinder Pins High switch
5929 Boom Section Locked switch
5930 Boom Section Unlocked switch
en
5931 Left Tele Cylinder Pin Unlocked switch

5932 Right Tele Cylinder Pin Unlocked switch
5933 Left Tele Cylinder Pin Locked switch
er
5934 Right Tele Cylinder Pin Locked switch

5935 Right Tele Cylinder Pins Low switch
5936 Right Tele Cylinder Pins High switch
ef
5937 Jib mounted & folded switch

5938 Turntable Locked switch
5939 Turntable Unlocked switch
R
5940 Pump 1 Pressure analog input

5941 Telescoping Pressure analog input
5942 Slewing Pressure analog input
5943 Hoist Limiter (A2B) analog input
5944 Piston Length Sensor analog input
5945 8.5V External Feedback analog input
5946 Accumulator pressure sensor analog input
5947 Mechanical locking head TUSL switch
5948 Mechanical locking head TLSL switch
5949 Mechanical locking head TLSU switch


5950 Auxiliary Hoist Indenitifier input
5951 New York House Lock Pin Bolted input
5952 New York House Lock Locked input
5953 New York House Lock Unlocked input
5954 Counterweight Left Unlock input
5955 Counterweight Right Unlock input
5956 Counterweight Left Lock input
5957 Counterweight Right Lock input
y
5958 Counterweight Left Bottom Proximity Switch input
nl
5959 Counterweight Right Bottom Proximity Switch input
5960 Counterweight Left Top Proximity Switch input
5961 Counterweight Right Top Proximity Switch input
O
5962 Hoist Limiter (A2B) Switch input - Stop
5963 Steering Filter switch input
5964 Flow indicator steering circle 1
ce
5965 Flow indicator steering circle 2
5966 Air Filter switch input
5967 Cabin locked left switch input
5968 Cabin locked right switch input
en
5969 Bridge collision switch input

5970 Filter backpressure switch input 1
5971 Filter backpressure switch input 2
er
5972 Length Hydraulic pivot cylinder

5973 Auxhoist right locked
5974 Auxhoist left locked
ef
5975 Auxhoist right unlocked

5976 Auxhoist left unlocked
5977 Auxhoist carrier retracted
R
5978 Counterweight installed input

5979 Counterweight in position input
5980 Counterweight position left analog input
5981 Counterweight position right analog input
5982 Derricking valve spool position analog input
5983 Slew left pressure analog input
5984 Slew right pressure analog input
5985 Hoist Limiter (A2B) Switch input - Slow
6000 PERM 24V voltage output
6001 Release LMI output


6002 Gearshift power supply output
6003 SCM0 ignition to CCM10 output
6004 SCM0 ignition to CCM11 output
6005 Oil Cooler Off relay output
6006 SCM0 ignition to IOS modules output
6007 SCM0 ignition to displays output
6008 Accessory output
6010 Turn signal left output
y
6011 Turn signal right output 3
nl
6020 Left armrest lamps output
6021 Right armrest lamps output
6030 Perm VCC output
O
6031 Boom Lights 1 output
6032 Boom Lights 2 output
6033 IOL30 Sensor supply output
ce
6034 Aircraft Warning Light output
6035 Horn output
6036 AC Condenser Motor output
6037 Windshield Washer output
en
6038 Beacon Lights output

6039 IOS20 Sensor Supply output
6040 Lamp Main hoist output
er
6041 Lamp Derricking output

6042 Lamp Telescoping output
6043 Lamp Jib output
ef
6044 Lamp Park Brake output

6045 Lamp Slewing output
6046 Lamp Aux Hoist output
R
6047 Flight traffic light output

6048 Release hoist limiter
6049 IOL34 Sensor supply output
6050 New York House Lock change direction output
6051 New York House Lock release direction output
6060 Windshield Wash front Wiper
6061 Windshield Wash top Wiper
6062 Delay Front Wiper
6063 Delay Top Wiper
6064 Windshield Wash front Wiper low speed


6065 Windshield Wash front Wiper high speed
6066 Windshield Wash front Wiper park
6100 Headlight Low Beam Left output
6101 Headlight Low Beam Right output
6102 Brake Lights output
6103 Engine Start output
6104 AC Clutch output
6105 Marker Lights output
y
6106 Reverse Lights output
nl
6107 Derricking Release output
6108 Daytime Driving Light output
6109 Fuel Heater Relay output
O
6110 Enable Cross (Transverse) Differential Locks Output
6111 Enable Longitudinal Differential Locks Output
6112 Enable Axle Blocking Output
ce
6113 Unlock Axle 3 Steering Output
en

6118 Unlock Axle 8Steering Output
er
6120 Superstructure Maneuvering Enable Output (EDM)

6121 Select Gear D Output (EDM)
6122 Select Gear N Output (EDM)
ef
6123 Select Gear R Output (EDM)

6124 PTO Request Output (EDM)
6125 Inhibit Upshift Output (EDM)
R
6126 Inhibit Engine Start Output

6127 Switch carrier/super cabin
6128 Central lubrication
6130 Air Conditioning ON output
6131 Air Conditioning (Superstructure) output
6132 Air Conditioning (Carrier) output
6133 Retarder (Telma brake) output
6134 Fog tail lights output
6135 Fog lights output
6136 High beam headlight


6137 Outrigger Light Front Left Output
6138 Outrigger Light Front Right Output
6139 Outrigger Light Rear Left Output
6140 Outrigger Light Rear Right Output
6200 Four Wheel Drive output
6201 Rear Axle Oscillation output
6202 Rear Steer Right output
6203 Rear Steer Left output
y
6204 Park Brake Release output 3
nl
6205 Differential Lock output
6206 Load Sense output
6210 Stabilizer Left Front solenoid
O
6211 Stabilizer Right Front solenoid
6212 Stabilizer Left Rear solenoid
6213 Stabilizer Right Rear solenoid
ce
6215 Beam Left Front solenoid
6216 Beam Right Front solenoid
6217 Beam Left Rear solenoid
6218 Beam Right Rear solenoid
en
6220 Outrigger Extend solenoid

6221 Outrigger Retract solenoid
6225 Transmission Forward solenoid
er
6226 Transmission Reverse solenoid

6227 Transmission First Gear solenoid
6228 Transmission Second Gear solenoid
ef
6229 Transmission Third Gear solenoid

6230 Transmission Fourth Gear solenoid
6231 Transmission Fifth Gear solenoid
R
6240 Pressure buildup solenoid

6241 Release All Wheel steering solenoid
6244 Steering Control Valve 1 solenoid
6247 Slewing System Release solenoid
6248 Block Steering Circuit 1 solenoid
6249 Service Brake solenoid
6250 AMOT valve solenoid (Air intake valve)
6251 Steer Left solenoid Axle 1


y
6261 Steer Right solenoid Axle 1
nl
O
ce
6270 Stabilizer Left Front extend solenoid
6271 Stabilizer Right Front extend solenoid
en
6272 Stabilizer Left Rear extend solenoid

6273 Stabilizer Right Rear extend solenoid
6274 Stabilizer Left Front retract solenoid
er
6275 Stabilizer Right Front retract solenoid

6276 Stabilizer Left Rear retract solenoid
6277 Stabilizer Right Rear retract solenoid
ef
6278 Extension Beam Left Front extend solenoid

6279 Extension Beam Right Front extend solenoid
6280 Extension Beam Left Rear extend solenoid
R
6281 Extension Beam Right Rear extend solenoid

6282 Extension Beam Left Front retract solenoid
6283 Extension Beam Right Front retract solenoid
6284 Extension Beam Left Rear retract solenoid
6285 Extension Beam Right Rear retract solenoid
6286 Suspension Group Left Front solenoid
6287 Suspension Group Right Front solenoid
6288 Suspension Group Left Rear solenoid
6289 Suspension Group Right Rear solenoid
6290 Axle Lifting Front Left solenoid


6291 Axle Lifting Front Right solenoid
6292 Axle Lifting Rear Left solenoid
6293 Axle Lifting Rear Right solenoid
6294 Pressure Axle Lifting Front Left solenoid
6295 Pressure Axle Lifting Front Right solenoid
6296 Pressure Axle Lifting Rear Left solenoid
6297 Pressure Axle Lifting Rear Right solenoid
6298 Drive out cylinder, Jib moves ahead from boom
y
6299 Retract cylinder, jib moves to boom 3
nl
6400 Main Hoist Down solenoid
6401 Main Hoist Up solenoid
6402 Aux Hoist Down solenoid
O
6403 Aux Hoist Up solenoid
6404 Derricking Down solenoid
6405 Derricking Up solenoid
ce
6406 Tele Cylinder Extend solenoid
6407 Tele Cylinder Retract solenoid
6408 Slewing Right solenoid
6409 Slewing Left solenoid
en
6410 Lower Brake Main Hoist solenoid

6411 Raise Lower Brake Main Hoist solenoid
6412 Lower Brake Aux Hoist solenoid
er
6413 Raise Lower Brake Aux Hoist solenoid

6414 Pilot Supply solenoid
6415 Slew Brake Release solenoid
ef
6416 Enable high Speed Tele solenoid

6417 Lock Telecylinder Boom Section solenoid
6418 Charge Cylinder Tube solenoid
R
6419 Release Boom Down solenoid

6420 Hold Unlock Position solenoid
6421 Select Boom Section Telecylinder solenoid
6422 Jib Down solenoid
6423 Jib Up solenoid
6424 Cabin Down solenoid
6425 Cabin Up solenoid
6426 Turntable Lock solenoid
6427 Turntable Unlock solenoid
6428 Counterweight Lower solenoid


6429 Counterweight Raise solenoid
6430 Counterweight Unlock solenoid
6431 Counterweight Lock solenoid
6432 Aux hoist carrier raise
6433 Aux hoist carrier lower
6434 Aux hoist lock
6435 Aux hoist unlock
6436 Main hoist Fast Moving
y
6437 Aux hoist Fast Moving
nl
6438 Pressure Limiter Valve
6600 Main Hoist Speed Control PWM output
6601 Aux Hoist Speed Control PWM output
O
6602 Derricking Speed Control PWM output
6603 Telescoping Speed Control PWM output
6604 Slewing Speed Control PMW output
ce
6605 Boom Down Release PWM output
6606 Tele Pressure Extend PWM output
6607 Slew Brake PWM output
6608 Aux Drives Speed Control PWM output
en
6609 Oil Cooler 1A PWM output

6610 Oil Cooler 1B PWM output
6611 Oil Cooler 2A PWM output
er
6612 Oil Cooler 2B PWM output

6614 Oil heater cooler
7001 Hydac Pressure Sensor (default node ID)
ef
7002 SCM0
7003 SCM1
7004 SCM2
R
7005 SCM3
7013 Pressure sensor lower chamber 0
7014 Pressure sensor lower chamber 1
7015 Pressure sensor upper chamber
7017 Length sensor BOOM length
7018 Length sensor telecylinder length
7019 Telescoping Cylinder CAN length sensor
7020 Boom angle sensor 0
7021 Boom angle sensor 1
7022 Jib angle sensor


7025 CCM10
7026 CCM11
7027 CCM12
7028 CCM13
7032 IOL30
7033 IOL31
7034 IOL32
7035 IOL33
y
7036 IOL34 3
nl
7037 IOL35
7038 IOL36
7039 IOL37
O
7040 IOL38
7041 IOL39
7042 IOL40
ce
7043 IOL41
7044 IOL42
7045 IOL43
7046 IOL44
en
7047 IOL45
7048 Slew Angle Sensor
7052 IOS20
er
7053 IOS21
7054 IOS22
7055 IOS23
ef
7056 IOS24
7057 IOS25
7058 IOS26
R
7059 IOS27
7065 Slew angle sensor
7066 Boom angle sensor 0 GMK
7067 Boom angle sensor 1 GMK
7068 Boom length sensor
7075 Machine Display Extended
7081 Boom Handset
7082 Turntable Handset
7084 Carrier Left Handset
7085 Carrier Right Handset


7090 Simulated Joystick
7091 Left joystick
7092 Right joystick
7093 Left joystick
7100 Remote Control -or- Slew Angle Sensor (default node ID)
7101 MMI Left
7102 MI Right
7106 External Light Tower
y
7108 Service Software
nl
7109 Outside Light bar
7111 RCL display
7112 Operating display
O
7113 Carrier Display
7119 Jogdial
7123 Inside Light bar
ce
7124 Cranestar
7129 J1939 Communications
7400 Engine RPM speed sensor
7401 Alternator Charge Frequency input
en
8000 RCL software

8001 Error List
8002 Operating system task 1
er

ef

8007 Speed limit software
8008 RCL load charts
R
8009 AddReadSDO software function

8010 AddWriteSDO software function
8011 Telescoping software
8012 Interpolator / CCM closed loop current control
8013 Pinning program
8014 Slewing control system
8015 Derricking control system
8016 Main Hoist control system
8017 Aux Hoist control system
8100 Main Software Program


8400 Eeprom
8401 CPU watchdog
8402 Data Flash
8600 RCL Boom Length
8601 RCL Slewing Range
8602 RCL Outrigger
8603 RCL Jib
8700 Telescoping Length Sensor Comparison
y
8701 Pinning Proxy Switches Left 3
nl
8702 Pinning Proxy Switches Right
8900 Engine Type Selection (eeprom setting)
10100 Proximity Sensor Drum 0 (A)
O
10101 Proximity Sensor Drum 0 (B)
ce
en

er

ef

R

10120 Luffing Jib Min
10121 Luffing Jib Max
10123 Fixed Jib Confirm
10125 Boom Strap Load Cell Right
10126 Boom Strap Load Cell Left
10130 Proximity Sensor Output (V+) Drum 0


y
10140 Boom Strap Load Cell Output (V+)
nl
10141 Lower/Upper Boom Point A2B Slow Output (V+)
10142 Lower/Upper Boom Point A2B Stop Output (V+)
10143 Luffing Jib Max Output (V+)
O
10144 Luffing Jib Min Output (V+)
ce
en
er
ef
R

Condition Codes
Fault Code Condition Description

0 No Error
1 Over Current
2 Cable Break
3 Short to Battery
4 Short to Ground
y
5 Resistor Low
6 Resistor High 3
nl
7 Below minimum level
8 Above maximum level
10 Undefined Area
O
11 Initialization failed
12 System
13 Function Error
ce
14 Logic
15 Fuse
16 PWM Signal
17 8.5V supply below the minimum allowed voltage
en
18 8.5V supply above the maximum allowed voltage

19 Relay failure
20 The total current of all outputs is too high
er
21 Out of tolerance
22 Too many write SDOs for this device
23 Too many read SDOs for this device
ef
24 Component is not calibrated

A sensor with redundant inputs has both at the same
25
state: They must be opposite to each other
R
Two opposite input switches are both active. Example:

26
Outrigger Extend & Retract
27 Joystick X axis fault
28 Joystick Y axis fault
Calibration invalid: The calibration points are too close to
29
each other.
30 The power supply voltage is too low
31 The internal supply voltage UE is too low
32 The internal supply voltage UB1 is too low
33 The internal supply voltage UB2 is too low
34 The internal supply voltage UC1 is too low


35 The internal supply voltage UC2 is too low
36 Analog Input error
37 Digital Input error
38 Digital Output error
39 PWM Output error
40 Task Time too long
41 Data is not valid
42 Device is not operational
y
43 Could not get semaphore
nl
44 Data does not match required data
The counter from a connected CAN device is no longer
45
being updated. The data is considered no longer valid.
46 A CAN device is reporting a self-detected error
O
The pinning system could not unlock within the required
47
time limit
48 The current operating mode is invalid
ce
49 Movement in opposite direction
50 Unintentional Lock
52 The internal supply voltage UF is too low
en
53 The internal supply voltage UE is too low

54 The internal supply voltage UF is out of range
55 The internal supply voltage UB1 is out of range
56 The internal supply voltage UB2 is out of range
er
57 The internal supply voltage UC1 is out of range

58 The internal supply voltage UC2 is out of range
59 The external supply voltage EXT is out of range
ef
60 Outrigger base too small

61 Jib angle tolerance
The last reset was because the watchdog detected that
R
128
Ue was above the maximum allowed value
129
Ue was below the minimum allowed value
130 the system voltage was above the maximum allowed
value
131
the system voltage was below the minimum allowed value
The last reset was because the watchdog detected an
132
error as defined by the user
The last reset was because the watchdog detected a
133
system error


The last reset was because the watchdog detected a
134
configuration error
137 Unexpected NULL pointer
Command not zero. The joystick or tele pedal command
140
must be zero to enable a function.
150 Pressure negative and positive
151 Pressure negative at positive
152 Pressure positive at negative
y
153 Pressure positive at stop
154 Pressure negative at stop
3
nl
O
ce
en
er
ef
R

Device Codes
Fault Code Device Description

SCM0
1 SCM1
2 SCM2
3 SCM3
10 CCM10
11 CCM11
y
12 CCM12
nl
13 CCM13
20 IOS20
21 IOS21
O
22 IOS22
23 IOS23
24 IOS24
ce
25 IOS25
26 IOS26
27 IOS27
30 IOL30
en
31 IOL31
32 IOL32
33 IOL33
er
34 IOL34
35 IOL35
36 IOL36
ef
37 IOL37
38 IOL38
39 IOL39
R
40 IOL40
41 IOL41
42 IOL42
43 IOL43
44 IOL44
45 IOL45
50 Joystick Left
51 Joystick Right

Index Codes
Fault Code Index Description

0-29 Digital Inputs
48-95 Digital Outputs
96-110 Analog Inputs
128 Internal measurement
129 CAN bus 1
y
130 CAN bus 2
131 CAN bus 3 3
nl
132 CAN bus 4
140 Eeprom Read - backup area
141 Eeprom Read - customer area
O
142 Eeprom Write - backup area
143 Eeprom Write - customer area
144 Not Applicable
ce
145 Internal Software
150 Pressure logic
en
er
ef
R

y
nl
O
ce
en
THIS PAGE BLANK

er
ef
R

RT530E-2 SERVICE MANUAL BOOM
SECTION 4
BOOM
SECTION CONTENTS
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Theory Of Operation. . . . . . . . . . . . . . . . . . . . . . . . 4-1 Boom Alignment And Servicing . . . . . . . . . . . . . . 4-19
Boom Extension . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Boom Extension And Retraction Cable. . . . . . . . 4-20
Boom Retraction . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
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Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Extension Cable Adjustment . . . . . . . . . . . . . . . . 4-20
Boom Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Retract Cable Adjustment . . . . . . . . . . . . . . . . . . 4-21
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Remove the Base Section . . . . . . . . . . . . . . . . . . 4-6 Telescope Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Disconnect Inner Mid Section . . . . . . . . . . . . . . . . 4-8 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Remove the Inner Mid Section . . . . . . . . . . . . . . . 4-9 Theory Of Operation . . . . . . . . . . . . . . . . . . . . . . 4-21
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Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Remove Outer Mid Section. . . . . . . . . . . . . . . . . 4-10
Remove Telescope Cylinder. . . . . . . . . . . . . . . . 4-12 Lift Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
4
Boom Nose Sheaves . . . . . . . . . . . . . . . . . . . . . 4-13 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Boom Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 Theory Of Operation . . . . . . . . . . . . . . . . . . . . . . 4-25
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Install Telescope Cylinder. . . . . . . . . . . . . . . . . . 4-13 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Install Outer Mid Section. . . . . . . . . . . . . . . . . . . 4-14 Swingaway Boom Extension . . . . . . . . . . . . . . . . 4-29
Install Inner Mid Section . . . . . . . . . . . . . . . . . . . 4-16 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
Connect Inner Mid Section . . . . . . . . . . . . . . . . . 4-17 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
Install Base Section . . . . . . . . . . . . . . . . . . . . . . 4-18 Hook Block. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
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Boom Installation . . . . . . . . . . . . . . . . . . . . . . . . 4-19 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34

Functional Check . . . . . . . . . . . . . . . . . . . . . . . . 4-19 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
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DESCRIPTION extension mounts directly to the boom nose utilizing a four

point attachment. The boom extensions may be offset at 0 to
A four section 8.81 to 29.0 m (28.7 to 95.0 ft), synchronized 30 degrees. In addition, the swingaway can be stowed on the
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full power, cable extended boom is installed on this crane. right side of the boom base section.
The boom is rectangular in design and utilizes one two-
stage double-acting, rod ported telescope cylinder. The THEORY OF OPERATION
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telescoping sections are supported on graphite impregnated

nylatron wear pads. Adjustable side wear pads prevent metal Boom Extension
to metal contact between the sections.
The outer rod end of the telescope cylinder is secured to the
Boom assembly lift is provided by one lift cylinder. Boom boom base section, the inner rod end is secured to the inner
elevation is from -3 to 76 degrees. mid section, and the cylinder barrel is secured to the outer
mid section. The five fly section extension cables secured to
An optional auxiliary boom nose (rooster sheave) is available
the inner mid section are routed around a five groove sheave
for the boom to simplify single part cable usage. The rooster
assembly at the barrel end of the telescope cylinder and are
sheave is installed on the main boom nose and is secured by
secured at the opposite end to the fly section. The long
pins that pass through the rooster sheave and bolt on
extend synchronizing cable is routed around two sheaves on
adapter plates on the main boom nose.
the top front of the inner mid, around a half sheave at the top
A 7.92 m (26 ft) offsetable or a 7.92 to 13.7 m (26 to 45 ft) rear of the outer mid, and secured to the rear of the base
telescoping offsetable swingaway boom extension is section. The four retraction cables are secured at the outside
provided to obtain additional boom reach. The boom front of the inner mid section, are routed around sheaves

BOOM RT530E-2 SERVICE MANUAL
mounted on the end of the outer mid section and are secured Boom Retraction
at the opposite end to the fly section. The six retraction
cables are secured at the outside front of the base section, The four fly retraction cables are secured at the outside front
are routed around sheaves mounted on the end of the inner of the inner mid section, are routed around sheaves mounted
mid section and are secured at the opposite end to the outer on the end of the outer mid section and are secured at the
mid section. rear end to the fly section. The six outer mid retraction cables
are secured at the outside front of the base section, are
As the telescope cylinder extends, the cylinder barrel, which routed around sheaves mounted on the end of the inner mid
is attached to the outer mid section and the inner cylinder rod section and are secured at the rear end to the outer mid
which is attached to the inner mid section, pulls the mid section. As the telescope cylinder is retracted, the outer mid
sections out along with it. At the same time, the five groove section, which is secured to the cylinder barrel and the inner
sheave assembly at the end of the telescope cylinder pulls mid section, which is secured to the inner cylinder rod, are
on the five fly extension cables around it. This causes the fly pulled in. At the same time, the sheaves at the rear of the mid
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extension cables to pull the fly section out at the same time sections pull on the four fly and six outer mid retraction
and rate that the telescope cylinder is pulling out the mid cables around the sheaves. This causes the retraction
sections. The long extend synchronizing cable ensures the
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cables to pull the fly section and the outer mid section in at
mid se ct ions an d t he t ele sc op e cy lin de r r ema in in the same time and rate the telescope cylinder is pulling in the
synchronization. mid sections and the telescope cylinder stages remain in
synchronization.
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24 4
21 3
20
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25
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2 10
26
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18
19
4
17 22 27
1 23
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15 26
13 18
5 27 19
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18
19 26
6 12
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7 8 11
9
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14 8476-2
13
16
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FIGURE 4-1


1 Fly Section 15 Upper Boom Nose Sheaves
2 Outer Mid Section 16 Lower Boom Nose Sheaves
3 Inner Mid Section 17 Kicker Plate
4 Base Section 18 Front Top and Bottom Side Wear Pads
5 Telescope Cylinder Barrel 19 Bottom Front Wear Pads
6 Sheave Mounting Assembly 20 Grease Fittings
7 Extend Cable Sheave Assembly 21 Extend Synchronizing Cable
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8 Extend Sheave Shaft 22 Fly Retract Cables
9 Cable Retainer 23 Outer Mid Retract Cables
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10 Fly Extend Cables 24 Kicker Plates
11 Support Foot Weldment 25 Extend Synchronizing Cable Sheave Assembles
12 Wear Pads 26 A2B Roller Guide Mounting Angle
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13 Cable Retainer Pin 27 Retract Cable Anchor Plates
14 End Cap
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45
44
43
35
36
34
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21 35
36
34
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41
29
33 40
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35 38 4
36
34 37
31
30
10 4
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23
39
32 28
30
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37
38
31
22 5
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8476-1
30
32 31
10
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1 2 3

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28 Telescope Cylinder Inner Rod Retract Cable Sheaves, Shaft, Thrust Washers
37
and Spacers
29 Telescope Cylinder Outer Rod
38 Cable Retainer Bushings and Bolts
30 Lower Rear Side Wear Pads
39 Fly Extend Cable Sled
31 Bottom Wear Pads
40 Fly Extend Cable Sled Adjusting Bolt
32 Pins
41 Holding valve Port Block
33 Fly Extend Cables Keeper Plate
42 Keeper Bolts
34 Adjustable Wear Pads
43 Pivot Shaft
35 Keeper Plates
44 Pin
36 Offset Washers
45 Cotter Pin

MAINTENANCE 8. Block the lift cylinder.

9. Remove the bolt and washer securing the upper lift
Removal cylinder shaft to the side of the attach fitting on the
NOTE: The boom may be disassembled with the base boom.
section left on the crane if repair of the base section 10. Remove the upper lift cylinder shaft.
is not necessary.
11. Activate the hydraulic system and withdraw the lift
NOTE: The boom weighs approximately 4978 kg (10,974 cylinder rod enough to clear the attach fitting. For
lb). Removal of the boom extension will simplify removal of the lift cylinder from the crane refer to the
boom removal, therefore, the above weight is for removal procedures outlined in LIFT CIRCUIT -
the boom without the swingaway boom extension Removal in this section.
attached.
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1. Extend and set the outriggers to level the crane and
ensure the boom is fully retracted and in a horizontal
DANGER
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position over the front of the crane.
2. If equipped, remove the boom extension according to Shut down the crane before proceeding.
the removal procedures in this section.
12. Take up the slack on the boom lifting device.
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13. Remove the clip pin and retaining pin securing the boom
pivot shaft on the boom to the superstructure assembly.
DANGER Remove the grease fittings from the pivot shaft. Remove
Wear gloves when handling wire rope. the boom pivot shaft.
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14. Raise the boom clear of the crane and lower to blocking
3. Remove the hook block or headache ball and wind all or cribbing for service.
the wire rope onto the hoist drum.
4. Elevate the boom slightly so that the lift cylinder is BOOM DISASSEMBLY
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extended approximately 30.48 cm (12 in) to allow for

NOTE: The complete boom assembly without the
withdrawal of the lift cylinder rod end from the lift cylinder
swingaway boom extension attached weighs
attach fitting on the bottom of the boom.
approximately 4978 kg (10,974 lb).
1. Remove the boom in accordance with the REMOVAL
procedures outlined in this section.
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DANGER 2. Remove the bolts and washers securing the telescope

Ensure all blocking and lifting devices are capable of cylinder outer rod to the rear of the base section.
supporting the boom assembly.
3. Remove the nuts and washers securing the
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5. Attach a lifting device to the boom to provide for equal synchronizing cable ends to the base section.
weight distribution.
Remove the Base Section
6. Disconnect any electrical wiring from the boom.
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NOTE: The combined weight of the boom inner mid, outer

7. Tag and disconnect the hydraulic lines to the telescope mid, and fly sections, including the telescope
cylinder. Cap or plug the lines and openings. cylinder, is approximately 3680 kg (8110 lb).
1. Remove the access cover on the top rear of the base
section. Slide the assembly out of the base section
enough to gain access to the top rear adjustable wear
DANGER
pads on the inner mid.
Ensure the boom lift cylinder is properly supported before
disconnecting it from the boom.

12
11
6960-1
17
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21
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18
14
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4
9 10
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13
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6
12
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7 2
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6960-2
19
8 3
5
20
15
16 29 m (95 foot)
17 FIGURE 4-2

4. Remove the capscrews securing the outer mid retract

Item Description cable anchor plates to the lower front of the base
section. Remove the cable locknuts and the anchor
1 Telescope Cylinder - Rod End plates from the cables.
2 Base Section
5. Remove the capscrews and washers securing each top
3 Telescope Cylinder - Inner Rod (1) and bottom (2) side wear pads at the front of the base
4 Inner Mid Section section (Figure 4-4). Remove wear pads, shims, and
mounting angle (top left side only).
5 Telescope Cylinder Barrel
6 Outer Mid Section
7 Extension Cables
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8 Inner Mid Section
9 Sheave Assembly 1
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10 Telescope Cylinder
11 Fly Section Base End
12 Synchronizing Cables
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13 Base Section - Rear
14 Retraction Cables
15 Sheave
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16 Retraction Cable to Fly Section
6960-5 2
17 Fly Section
FIGURE 4-4
Retraction Cables to Outside Front of Base
18
Section 6. Lift up on the front of the assembly and remove the wear
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19 Sheave pads from the pockets in the bottom of the base section.
20 Retract Cables to Outer Mid Section 7. Continue to pull the assembly from the base section.
21 Base Section Top and Bottom Wear Pads
Disconnect Inner Mid Section
2. Remove the capscrews, washers, and offset washers
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1. At the rear of the inner mid, remove the capscrew and

(1) (Figure 4-3) securing each top rear adjustable wear
cable retainer bushing (1) from the rear of each retract
pad and remove the wear pads, keeper plates and
cable sheave assembly (2)(Figure 4-5).
capscrews from the top of the inner mid. Note location of
wear pads and shims for installation.
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11
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FIGURE 4-3
2
3. On the top front of the base section, remove the two
1 6960-12
capscrews securing each kicker plate and remove the
plates. FIGURE 4-5

2. On both sides, remove the capscrews (1) securing each Remove the Inner Mid Section
retract sheave assembly shaft weldment. Remove the
shaft, spacer bushing, sheave assembly, and two thrust NOTE: Together the boom outer mid and fly sections, and
washers (3) (Figure 4-6). If necessary, remove the telescope cylinder weigh approximately 2550 kg
grease fitting from the shaft weldment. (5610 lb).
6. Slide the assembly out of the inner mid enough to gain
access to the top rear adjustable wear pads on the outer
mid through the hole in the top of the inner mid.
7. Remove the capscrews, washers, and offset washers
(1) securing each top rear adjustable wear pad (2).
Remove the wear pads, keeper plates (3) and
capscrews from the top of the outer mid (4) (Figure 4-8).
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1
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4
3 2 6960-6
FIGURE 4-6
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3. Remove the two capscrews and washers (1) securing 3 2
the cylinder inner rod (2) to the rear of the inner mid (3)
(Figure 4-7).
4
4. Remove the nuts (4) from the extend cable sled FIGURE 4-8
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weldment adjusting bolts Figure 4-7. 8. At the top front of the inner mid, remove the four bolts
and washers (1) securing the synchronizing cable (2)
sheave assembly (3). Lay the assembly with cables on
2 top of the outer mid (4) (Figure 4-9).
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1
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3
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1
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4 3
2
4
6960-13 FIGURE 4-9
4 FIGURE 4-7
9. Remove the capscrews and washers (1) securing the fly
5. Pull the retract cables up through the holes in the bottom retract cable anchor plates (2) to the lower front of the
of the inner mid and lay them out to the rear. inner mid section. Remove the cable locknuts and the
anchor plates (3) from the cables (Figure 4-10).

14. Remove the two adjusting bolts (1) from the extend
cable sled weldment (2) (Figure 4-12).
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4
6960-8
5
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6 4
2 2 1
3 1 FIGURE 4-10
6960-6
3
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10. Remove the capscrews and washers (4) securing each
top (5) and bottom (6) side wear pad at the front of the FIGURE 4-12
inner mid (Figure 4-10). Remove wear pads, shims, and 15. Remove the two bolts securing the keeper plate (3) to
mounting angle (top left side only) (7). the bottom of the sled and remove it from the cable ends
(Figure 4-12).
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11. Lift up on the front of the assembly and remove the wear
pads from the pockets in the bottom of the inner mid. 16. If necessary, remove the retract cables from the inside of
12. Continue to pull the assembly from the inner mid section the inner mid.
until access to the rear of the outer mid is gained to 17. If necessary, remove the two bolts securing the bottom
disconnect the six retract cables.
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wear pad to the inner mid. Remove wear pad.

13. Remove the cotter pins and pins (1) securing the retract 18. If necessary, remove the two bolts securing each lower
cables (2) to the rear of the outer mid (Figure 4-11). rear side wear pad to the inner mid. Remove wear pads
and shims. Note location of shims for installation.
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Remove Outer Mid Section

1. At the rear of the outer mid, remove the capscrew and
cable retainer bushing from above each retract cable
sheave assembly (1) (Figure 4-13).
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2. On both sides, remove the capscrews securing each

retract sheave assembly shaft weldment (2)
(Figure 4-13). Remove the shaft, spacer bushing,
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sheave assembly, and two thrust washers. If necessary,

remove the grease fitting (3) from the shaft weldment.
1
6960-16
2
FIGURE 4-11

2 3
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1
2
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3
6960-9
FIGURE 4-13
6960-14 FIGURE 4-15
3. Place blocking (1) under cylinder (2) (Figure 4-14) and
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8. At the top front of the outer mid, remove the capscrews
remove the two bolts and washers securing the cylinder
barrel to the rear of the outer mid. securing the kickback plate (1) (Figure 4-16). Remove 4
the kickback plate.
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FIGURE 4-16
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9. Remove the capscrews securing each top (1) and

bottom (2) (Figure 4-17) side wear pads at the front of
the outer mid. Remove wear pads, shims, and mounting
angle (3) (top left side only).
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1 2
FIGURE 4-14
4. Pull the retract cables up through the holes in the bottom

of the outer mid and lay them out to the rear.
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NOTE: Together the boom fly section and telescope

cylinder weigh approximately 1690 kg (3720
pounds).
5. Turn cylinder rod mounting lugs so they are vertical to
clear mounting bracket in the outer mid. 1
6. Slide the fly assembly out of the outer mid enough to 3

gain access to the top rear adjustable wear pads on the 2
fly through the hole in the top of the outer mid.
7. Remove the capscrews washers, and offset washers (1) 4
6960-10 FIGURE 4-17
securing each top rear adjustable wear pad (2). Remove
the wear pads and wear pad holder from the top of the fly
(3) (Figure 4-15).

10. Lift up on the front of the fly assembly and remove the
wear pads (4) (Figure 4-17) from the pockets in the
bottom of the outer mid.
11. Continue to pull the assembly from the outer mid section
until access to the rear of the fly is gained to disconnect
the four retract cables.
12. Remove the clip pins and pins (1) securing the four fly
retract cables (2) to the rear of the fly (Figure 4-18).
1 2 1
FIGURE 4-19
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4. Lift up on the sheave end of the cylinder and remove the
two lower capscrews securing the support foot
weldment and sheave mounting assembly to the
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cylinder barrel. Remove the support foot weldment.
5. If necessary, remove the capscrews securing each wear
pad to the support foot weldment. Remove the wear
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pads.
6. Continue to pull the cylinder from the fly section until
access to the rear of the fly is gained to disconnect the
five extend cables.
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2 7. If necessary, remove the screws securing the bottom
1 rear wear pad to the fly. Remove wear pad.
6960-14 FIGURE 4-18
8. If necessary, remove the capscrews (1) securing each
13. If necessary, remove the synchronizing cable and lower rear side wear pad (2) to the fly section (3)
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sheave assembly from the top of the outer mid. (Figure 4-20). Remove wear pads and shims. Note
location of shims for installation.
14. If necessary, remove the four fly retract cables from the
inside of the outer mid.
15. If necessary, remove the two bolts securing the bottom
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wear pad to the outer mid. Remove wear pad.

16. If necessary, remove the two bolts securing each lower
rear side wear pad to the outer mid. Remove wear pads
and shims. Note location of shims for installation.
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Remove Telescope Cylinder

3
1. Attach a suitable lifting device to the telescope cylinder.
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Raise the cylinder and remove the blocking device from

under the cylinder
2
2. Slide the cylinder out the rear of the fly until the extend
cable sheave assembly is aligned with the side access 1
hole in the fly section.
6960-14
NOTE: The telescope cylinder weighs approximately 899 FIGURE 4-20
kg (1980 lb).
9. If new cylinder is to be installed, remove the cable
3. Remove the capscrews and washers (1) securing the retainer, cables, extend sheave assembly, and sheave
extend cable keeper plate (2) to the rear of the fly mounting assembly from the barrel end of the cylinder.
(Figure 4-19). Remove the keeper plate and remove the
10. If removal of the boom nose sheaves are required, refer
five extend cable ends from the slots in the fly.
to BOOM NOSE SHEAVES - Removal in this section.

11. Refer to BOOM EXTENSION AND RETRACTION

CABLE MAINTENANCE in this section for cable 5
inspection. 1
Boom Nose Sheaves

6
NOTE: Refer to BOOM NOSE SHEAVES in this section.
BOOM ASSEMBLY 3
4
2
CAUTION
When adjusting cables, hold the cable end and turn the
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nut. do not turn cable. Turning cable while adjusting will
result in damage or failure of cable. 6748-32
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FIGURE 4-21
3. Install the telescope sheave assembly to the telescope
cylinder as follows:
CAUTION
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Install cables in their natural untwisted condition. Do not a. Using the extend sheave shaft, install the extend 4
twist cable. Twisting of cable will result in damage or cable sheave assembly with spacer on each side,
failure of cable. on the sheave mounting assembly.
b. Install grease fitting (4) (Figure 4-21) in shaft.
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NOTE: Apply Loctite 243 to the threads of all attaching
hardware except cable ends and cable lock nuts. c. Lubricate sheave.
NOTE: Apply multipurpose grease (MPG) to all wear pads 4. Route the five extension cables (5) (Figure 4-21) up and
and the surfaces the wear pads slide on. around the extend cable sheave assembly about one
foot on to cylinder. To aid in assembly, secure the cables
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NOTE: Use standard torque values specified in Section 1- to the top end of the cylinder by wrapping tape around
INTRODUCTION of this Manual unless otherwise the cylinder.
specified.
5. Position the cable retainer (6) (Figure 4-21) over the
NOTE: When installing upper and lower side wear pad, sheave shaft and secure it to the sheave mounting
use shims as necessary so wear pad is within 1.5 assembly with four capscrews and washers. The
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mm (0.06 inch) from side plate of next inner retainer secures the sheave shaft.
section. Use equal number of shims on each side.
6. Install the lower rear side wear pads and shims (1) on
Install Telescope Cylinder the fly section with two capscrews (2) each
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(Figure 4-22).
1. Measure and mark the center line of the fly section. This
mark will be used to set the adjustable wear pads after .
the section is installed in the outer mid section.
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2. If removed from the telescope cylinder (3) assembly,

install the sheave mounting assembly (1) with four
capscrews and washers (2). Do not tighten lower two
capscrews at this time. They will be torqued later.
6960-14
FIGURE 4-22

7. Install the bottom rear wear pad on the fly section with capscrews. Torque all four capscrews at this time to
two screws. standard torque. A 1-1/8” box x 3/4 drive 6” step wrench
will be required. It can be ordered from Grove using part
number 9-999-100122. Lower cylinder so it rests on
CAUTION support foot weldment wear pads.
The five extend cables must be marked at both ends prior 13. Slide cylinder all the way in. Place blocking under the
to installation. If the cables are not marked, they will be rear of the telescope cylinder to aid in assembly.
difficult to install in the correct order.
Do not allow the cables to become entangled or overlap. 14. Turn rod ends so they are aligned vertically to clear
Cable or boom failure could result. mounting brackets in outer mid.
Install Outer Mid Section
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NOTE: When installing upper and lower side wear pad,
use shims as necessary so wear pad is within 1.5
CAUTION mm (0.06 inch) from side plate of next inner
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When adjusting cables, hold the cable end and turn the section. Use equal number of shims on each side.
nut. do not turn cable. 1. Install the lower rear side wear pads and shims (1) on
Turning or twisting of the cable while adjusting will result the outer mid section with two screws (2) each
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in damage or failure of cable. (Figure 4-24).
Install cables in their natural untwisted condition.
8. Position the sheave end of the telescope cylinder (with

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port block up) at the rear of the fly section. Place the five
extend cable dead ends in the slots at the top of the fly
section and secure them with keeper plate (2),
capscrews and washers (1) (Figure 4-23).
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2
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1 2 1 1
FIGURE 4-23
FIGURE 4-24
9. Install the telescope cylinder into the fly section until the
sheave end is aligned with the side access hole in the 2. Install the bottom rear wear pad on the outer mid section
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fly. with two screws.
10. Install the two wear pads on the support foot weldment 3. Lay four fly retract cables inside the bottom of the outer
with two capscrews each. mid section, threaded ends out the back.
11. Lift up on the sheave end of the telescope cylinder and 4. Install two extend synchronizing cable sheaves (1) on
remove the two lower capscrews securing the sheave the shafts of the sheave mount weld (2). Install a grease
mounting assembly. fitting (3) in each shaft. Lay this assembly on top front of
outer mid section (Figure 4-25).
12. Install the support foot weldment through the side
access hole and secure with the two removed

10. Lift up on the front of the fly and install the bottom front
wear pads (1) (Figure 4-27) in the pockets of the outer
mid.
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4
1
2 3
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2
FIGURE 4-25
1
5. Lay out the extend synchronizing cable on top of the
6960-10
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FIGURE 4-27
outer mid with both threaded ends at the rear and
loop at the front. Route the looped end through
the
the
4
11. Install outer mid front top (4) and bottom (2) side wear
inside of the sheaves installed in step 4. Place the
pads with two screws each. On top left side attach
looped end around the fixed half sheave at rear of the
mounting angle (3) with top wear pad screw
outer mid. Be careful to not twist cable.
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(Figure 4-27). Shim as noted during disassembly.
6. Install a socket head keeper bolt on each side of the half
12. Install kicker plate in top of outer mid with capscrews.
sheave to retain the cable.
13. Completely slide assembly together.
7. Position the front end of the outer mid at the rear of the
fly/telescope cylinder assembly. 14. Turn cylinder rod mounting lugs so they are horizontal
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with port block holding valve being at the top.

8. Using pins, cotter pins, and safety clip (1) attach the four
fly retract cables (2) laying in the bottom of the outer mid 15. Loosen plugs in cylinder port block and manually extend
to the lugs in the rear of the fly (3) (Figure 4-26). the inner rod approximately 15 to 20 cm (6 to 8 in).
Tighten plugs.
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6 16. Lift up on end of cylinder to align barrel mounting holes

7 4 with tabs and holes in lugs of outer mid. Secure with two
6
bolts and washers.
5
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17. Remove any blocking under cylinder.

18. Through the top access hole in the outer mid, position
the two adjustable wear pads (4) on the top rear of the
fly. Install each wear pad holder (5) and loosely install
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each with two capscrews and washers (6) (Figure 4-26).

Install offset washers, capscrews and washers (7).
3
Using the offset washers, adjust the wear pads such that
the wear pads are within 1 mm (0.03 in) from each side
plate of the next outer section. Tighten the offset washer
2
and capscrews.
1
6960-14 19. Route the four fly retract cables through the holes in the
FIGURE 4-26 bottom of the outer mid and pull them toward the front of
the assembly. Install the anchor plates on the cables
9. Slide the fly/telescope cylinder into the outer mid being with cable locknuts. Be careful not to tangle cables.
careful not to damage any of the cables. As the sections
slide together pull the retract cables out the rear of the 20. Apply grease to four thrust washers and place one on
outer mid. Do not fully slide together. each side of the two groove retract cable sheave
assemblies. Grease will keep the thrust washer in place
during installation.

3. Lay outer mid retract cables inside the bottom of the

inner mid section, threaded ends out the back.
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5
2
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1 4
6960-9 3
FIGURE 4-28 1 4
21. Install grease fitting (1) in two shaft weldments. Position 2 6960-6
3
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retract cables (2) around sheave assemblies (3) FIGURE 4-29
(Figure 4-28). Install spacer bushing and install shaft
weldment through mounting lugs in outer mid and the 4. Position the extend cable sled weldment (1) on the five
sheave assembly and spacer bushing (4). Secure each large extend cables (2), slots down, and secure the
shaft weldment with a bolt. Apply grease to fittings. cables to the sled with keeper plate and two bolts (3)
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(Figure 4-29). Be careful not to tangle cables.
22. Position cable retainer bushing (5) (Figure 4-28) on top
of each sheave assembly and secure with a capscrew. 5. Install two long adjusting bolts (4) through holes in sled,
heads from the front (Figure 4-29).
Install Inner Mid Section
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6. Temporarily fasten the sled up under the cylinder so it

1. Install the lower rear side wear pads and shims on the does not interfere with installation.
inner mid section with two screws each.
7. Position the front of the inner mid at the rear of the
2. Install the bottom rear wear pad on the inner mid section assembly.
with two screws.
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8. Using pins and cotter pins (1) (Figure 4-30), attach the 11. Install inner mid front top (2) and bottom (3) side wear
outer mid retract cables (2) laying in the bottom of the pads with two screws each. On top left side attach
inner mid to the lugs in the rear of the outer mid. mounting angle (4) with bottom wear pad screw
(Figure 4-31).
12. Attach fly retract cable anchor plates (5) to front of inner
mid with two bolts each (6) (Figure 4-31).
13. Using four bolts and washers, attach the extend
synchronizing cable sheave assembly laying on top of
the outer mid to top front inside of the inner mid.
14. Through the top access hole in the inner mid, position
the two adjustable wear pads (2) on the top rear of the
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outer mid (4). Install each wear pad holder (3) and
loosely install each with two capscrews and washers.
Install offset washers, capscrews, and washers (1)
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(Figure 4-32). Using the offset washers, adjust the wear
pads such that the wear pads are within 1 mm (0.03 in)
from each side plate of the next outer section. Tighten
the offset washer and capscrews.
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1 4
6960-16
2
FIGURE 4-30 1
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9. Slide the assembly into the inner mid being careful not to
damage any of the cables. As the sections slide together
pull the retract cables out the rear of the inner mid. Do
not fully slide together.
10. Lift up on the front of the assembly and install the bottom
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front wear pads (1) in the pockets of the inner mid

(Figure 4-31).
3 2
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4
FIGURE 4-32
Connect Inner Mid Section

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1. Route outer mid retract cables through the holes in the

bottom of the inner mid and pull them toward the front of
the assembly. Install the anchor plates on the cables
with cable locknuts. Be careful not to tangle cables.
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2. While continuing to slide together, route extend cable

4 sled adjusting bolts through mounting holes in rear of
inner mid. Install nuts on the bolts.
2
3 3. Align the cylinder inner rod (1) mounting holes with the
6960-8
tabs and holes in the rear of the inner mid and secure
5 1
6 FIGURE 4-31 with two capscrews and washers (2) (Figure 4-33).

2
3
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6960-5
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FIGURE 4-33 2
4. Apply grease to four thrust washers and place one on 4 5 FIGURE 4-34
each side of the three groove retract cable sheave
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assemblies. Grease will keep the thrust washer in place 3. Attach outer mid retract cable anchor plates (4) to front
during installation. of base section with two capscrews (5) each
(Figure 4-34).
5. Install grease fitting in two shaft weldments. Position
retract cables around sheave assemblies, install spacer 4. Install kicker plate on top of each side of base section
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bushing, and install shaft weldment through mounting with two capscrews each.
lugs in inner mid and the sheave assembly and spacer 5. Through the top access hole in the base section,
bushing. Secure each shaft weldment with a capscrew. position the two adjustable wear pads on the top rear of
Apply grease to fittings. the inner mid. Install each wear pad holder and loosely
6. Position cable retainer bushing to the rear of each install each with two capscrews and washers. Install
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sheave assembly and secure with a capscrew offset washers, capscrews, and washers. Using the
offset washers, adjust the wear pads such that the wear
7. Loosen plugs in cylinder port block and manually extend pads are within 1mm (0.03 in) from each side plate of the
the outer rod approximately 15 to 20 cm (6 to 8 in). next outer section. Tighten the offset washer and
Tighten plugs. capscrews. Install top access hole cover.
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8. Position the front of the base section at the rear of the 6. Continue to slide together and route synchronizing cable
assembly and slide together being careful not to threaded ends through holes in rear of base section.
damage any cables. Install locknuts on cable ends.
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Install Base Section 7. Align cylinder outer rod mounting holes with mounting
holes in rear of base section and secure with two bolts
1. Lift up on the front of the assembly and install the bottom and washers.
front wear pads in the pockets of the base section.
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8. Reattach the RCL, A2B/ Length cable to the boom nose.

2. Install base section front top (1) and bottom (2) side
wear pads with two screws each (Figure 4-34). On top 9. Refer to Section 9 - LUBRICATION section for
left side attach mounting angle (3) with both wear pad lubrication of wear pads and other plates on boom.
screws. 10. Install the boom in accordance with the INSTALLATION
procedures outlined in this section.

Boom Installation 9. Lubricate and install the upper lift cylinder shaft. Secure
in place with the bolt and washer. Refer to LIFT
NOTE: The following procedure applies to a boom totally CIRCUIT INSTALLATION in this section.
removed from the crane.
10. Remove the boom lifting device.
1. If the lift cylinder was removed from the crane, refer to
installation procedures in LIFT CYLINDER 11. Activate the hydraulic system to remove the boom and
INSTALLATION in this section. lift cylinder blocking devices. Lower the boom to
horizontal. Shut down the crane.
12. Connect the hydraulic lines to the telescope cylinder as
tagged prior to removal.
DANGER
13. Connect any electrical wires as tagged prior to removal.
Ensure blocking and lifting devices are capable of
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supporting the boom assembly. 14. Refer to BOOM EXTENSION AND RETRACTION
CABLE ADJUSTMENT in this section for cable
2. Extend and set the outriggers to level the crane and adjustments.
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position superstructure toward front of crane.
Functional Check
3. Attach an adequate lifting device to the boom and
suspend the boom over the machine. 1. Activate the hydraulic system and check for proper
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4. Lower the boom into position and align the boom pivot
operation and any leaks. 4
shaft mounting holes for installation of the pivot shaft to 2. Ensure the boom will extend and retract properly.
the superstructure assembly.
3. Ensure the lift cylinder will not allow the boom to drift
5. Lubricate and install the boom pivot shaft. Secure in down until the operator lowers it.
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place with the retaining pin and clip pin Install the grease
4. Ensure all electrical components disconnected during
fitting in each end of the shaft.
removal are operating properly.
Inspection
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DANGER Visually inspect telescoping sections for adequate lubrication

Block the boom before doing any work under the boom. of all wear surfaces. Observe extended sections for
evidence of cracks, warping, or other damage. Periodically
6. Block the boom in place. check security of boom wear pads. Check boom nose
sheaves for security and freedom of movement.
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7. Attach a suitable lifting device to the lift cylinder.

Boom Alignment And Servicing
Boom alignment is achieved by adjustment of the wear pads
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located at various points in the boom assembly. Adjustment

DANGER of the wear pads is as follows:
Failure to properly support the boom lift cylinder may
result in death or injury to personnel. 1. Fully extend the boom horizontally.
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2. Lubricate the boom bottom plates (sides and bottom).

8. Using the lifting device attached to the boom, lower the
boom onto the lift cylinder rod end and extend the lift 3. Shim the front lower side wear pads to within 1.52 mm
cylinder as necessary to align rod with attach fitting on (0.06 in) from side plate of next inner boom section, then
boom. shim the front upper wear pads in the same manner. Use
equal number of shims on each side.
DANGER CAUTION
When extending and retrac ting the boom during
If the hydraulic system must be activated to extend or
alignment, movement should be stopped if a restriction is
retract the lift cylinder, ensure the rod end is properly
encountered, and wear pads re-shimmed as necessary to
aligned with the lift cylinder attach fitting.
provide free travel of the affected boom section(s).

NOTE: Deflection exaggerated

for illustration purposes.
4. Retract and extend the boom; check for the high point other damage resulting in distortion of the rope
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where the boom has brushed the wear pads at the structure.
widest point.
3. Evidence of any heat damage from any cause.
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5. Retract the boom sections to align the high point on the
4. Reductions from nominal diameter of more than:
boom section with the adjacent wear pads.
- 0.4 mm (0.016-in) for diameters up to and including
6. Add or subtract shims as necessary.
8 mm (0.3125-in).
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7. Attach a weight and extend the boom full length. Check
- 0.79 mm (0.031-in) for diameters 10 and 13 mm
for side deflection.
(0.375 and 0.5-in) inclusive.
Example: If the boom deflects to the left, the forward left wear
- 1.19 mm (0.047-in) for diameters 14 to 19 mm
pad would be shimmed in and the rear left adjustable wear
(0.5625 to 0.75-in) inclusive.
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pad would be adjusted out, away from the internal boom
section in a similar manner. The forward right wear pad will - 1.59 mm (0.063-in) for diameters 22 to 29 mm
be shimmed out and the right rear adjustable pad adjusted (0.875 to 1.125 in) inclusive.
in.
- 2.38 mm (0.094-in) for diameters 32 to 38 mm (1.25
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to 1.5 in) inclusive.

BOOM EXTENSION AND RETRACTION
CABLE 5. In standing ropes, more than two broken wires in one lay
in sections beyond end connections or more than one
Maintenance broken wire at an end connection.
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NOTE: For more detailed information concerning Extension Cable Adjustment

maintenance of the extension and retraction
cables, refer to Wire Rope (pg 1- 17).
CAUTION
Inspection
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When adjusting cables, hold the cable end and turn the
nut. Do not turn cable. Turning cable while adjusting will
result in damage or failure of cable.
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DANGER NOTE: The extension cables must be adjusted properly

Never handle wire rope with bare hands. before the retract cables can be adjusted.
1. Extend and set the outriggers, ensuring the crane is
Th e following information is taken from a Na tional level.
Consensus standard as referenced by Federal Government
Agencies. 2. Ensure the boom is over the front and at a horizontal
position (boom angle elevation 0 degrees).
All wire rope will eventually deteriorate to a point where it is
no longer usable. Wire rope shall betaken out of service 3. There needs to be some initial tension on the retract
when any of the following conditions exist. cables before the extension cables can be adjusted. At
any boom length, extend the boom 15 cm (6 in). This will
1. In running ropes, six randomly distributed broken wires cause a slack condition in the retract cables. Torque nuts
in one lay or three broken wires in one strand in one lay. on retract cables at front of inner and base sections to
2. Wear of one-third the original diameter of outside approximately 1.4Nm (1.0 lb-ft)
individual wires. Kinking, crushing, bird caging, or any

4. Fully extend the boom and then retract it approximately NOTE: If the crane is equipped with an auxiliary hoist, the
15 cm (6 in). This will create the loosest condition for telescope function is controlled by a foot pedal
synchronizing and extension cables. Adjust the two instead of a controller.
extend synchronizing cables at the top rear of the base
The telescope control valve is the closed spool type and is
section. Adjust until 9 cm (3.5 in) of threaded cable end
described under VALVES in Section 8.
is exposed and lock with jam nuts.
Refer to VALVES in Section 8 for a complete description of
5. To adjust the five fly extend cables, fully retract the boom
the hydraulic remote controller.
to have access to the two extend cable sled adjusting
bolts at the back of the inner mid section through the The boom telescope cylinder is a two stage double acting,
rear of the base section. Adjust these bolts to have 5 cm rod ported cylinder. Foreign material is prevented from
(23 in) of bolt thread exposed from the sled. entering the cylinder by a wiper seal during rod retraction. O-
ring seals prevent internal and external leakage. Refer to
6. Check through the side access holes in the boom, that
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CYLINDERS in Section 8 for a complete description of the
the fly extension cables have approximately 12 mm (0.5
telescope cylinder.
in) slack and lock with jam nuts.
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The holding valve is threaded into a port block on the inner
Retract Cable Adjustment rod end of the telescope cylinder. The holding valve
functions during the retraction, extension, or holding
1. Extend each boom section approximately 900 mm (35.4
operation. When holding the boom section at a given length,
inches).
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2. Adjust the outer mid retract cables at the front of the
oil is trapped in the cylinder by the holding valve. Refer to
VALVES in Section 8 for a complete description of the
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base section to have approximately 65 mm (2.5 inches) holding valve.
of threaded cable end exposed from the retract cable
mounting plate. Theory Of Operation
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3. Adjust the fly retract cables at the front of the inner mid Flow from the pump travels to the telescope directional
section to have approximately 76 mm (2.9 inches) of control valve. Movement of the control lever for telescope
threaded cable exposed from the retract cable anchor functions from neutral sends a pilot pressure signal to the
plate. directional control valve to shift the spool in the directional
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control valve. This aligns the appropriate passages in the

4. Fully retract the boom. All sections should bottom out on
control valve to route oil to the telescope cylinder holding
the next inner section at the same time.
valve. The holding valve, with its’ internal make-up of valves
5. If one or more sections do not fully retract, tighten the and springs, passes oil to and from the telescope cylinder.
adjusting nut of the retraction cables for the section until During extension, oil unseats the poppet (check) valve in the
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the section bottoms out. Repeat until al sections bottom holding valve. This oil is routed to the piston sides of the
out at the same time. cylinder which forces the rods out of the cylinder, causing the
boom section to extend.
6. Check through the side access holes in the boom, that
the tension is the same for all retract cables for a given During retraction, oil enters the retract port and flows to the
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section. Lock all adjustments with jam nuts. rod sides of the cylinder. When pilot pressure reaches a pre-
determined value, the main poppet unseats, and oil flows
TELESCOPE CIRCUIT from the piston sides of the cylinder to the reservoir causing
the boom section to retract. All return flow from the
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Description directional control valve goes to the reservoir.
The boom telescope circuit consists of the telescope

hydraulic remote controller, telescope directional control
valve, holding valve, and the telescope cylinder.

Maintenance
Telescope Circuit Troubleshooting

Table 4-1
SYMPTOM PROBABLE CAUSE SOLUTION

1. Erratic operation of a. Low hydraulic oil level. a. Replenish hydraulic oil to proper level.
extending
b. Damaged relief valves. b. Repair or replace relief valves.
telescoping
cylinder. c. Air in telescope cylinder. c. Bleed by lowering telescope cylinder
below horizontal.
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d. Low engine rpm. d. Increase engine rpm to recommended
setting.
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e. Lack of lubrication on boom sections. e. Properly lubricate all boom sections.
f. Extremely tight boom extension f. Inspect and properly lubricate boom
sheaves. extension sheaves.
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g. Improper boom alignment caused from g. Reduce and properly hoist load.
side loading.
h. Worn boom wear pads. h. Replace wear pads and properly
lubricate.
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i. Distorted boom section. i. Replace distorted section.
j. Damaged telescope cylinder. j. Repair or replace cylinder.
k. Clogged, broken, or loose hydraulic k. Clean, tighten, or replace lines or
lines or fittings. fittings.
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l. Damaged control valve. l. Repair or replace control valve.

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2. Erratic operation of a. Low hydraulic oil level. a. Replenish hydraulic oil to proper level.
retracting
b. Damaged relief valve. b. Repair or replace relief valve.
telescoping
cylinder. c. Air in cylinder. c. Bleed by lowering telescoping cylinder
below horizontal and cycle telescope
cylinder.
d. Low engine rpm. d. Increase engine rpm to recommended
setting.
e. Lack of lubrication. e. Properly lubricate all boom sections.
f. Check valve malfunctioning. f. Repair or replace check valve.
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g. Improper boom alignment caused from g. Reduce and properly hoist load.
side loading.
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h. Extremely tight boom retraction h. Inspect and properly lubricate.
sheave.
i. Distorted boom section. i. Replace distorted section.
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j. Worn boom wear pads. j. Replace wear pads and properly 4
lubricate.
k. Bent cylinder rod(s). k. Replace cylinder rod(s) and all cylinder
seals.
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l. Scored cylinder barrel. l. Repair or replace cylinder barrel.
m. Damaged piston seals. m. Replace all cylinder seals.
n. Loose or damaged piston(s). n. Replace all seals and re-torque or
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replace piston(s).
3. Telescope cylinder a. Low hydraulic oil level. a. Replenish oil to proper level.
will not extend.
b. Relief valve malfunctioning. b. Repair or replace relief valve.
c. Excessive load. c. Reduce load.
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d. Clogged hose and fittings. d. Replace hose or fittings. (Refer to

Manitowoc Crane Care Parts Manual).
e. Broken valve spool. e. Replace valve.
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f. Damaged piston seals. f. Replace all cylinder seals.

g. Damaged piston(s). g. Replace piston(s) and all cylinder
seals.
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h. Bent boom section(s). h. Replace damaged boom section(s).

i. Broken hydraulic pump coupling. i. Replace broken hydraulic pump
coupling.
j. Worn or damaged hydraulic pump j. Repair or replace pump section.
section.


4. Telescope cylinder a. Low hydraulic oil level. a. Replenish oil to proper level.
will not retract.
b. Relief valve damaged. b. Repair or replace relief valve.
c. Excessive load. c. Reduce load. (Refer to load chart).
d. Inoperative check valve. d. Replace check valve.
e. Clogged hose and fittings. e. Replace hose or fittings. (Refer to
f. Broken valve spool. f. Replace valve section.
g. Broken piston(s). g. Replace piston(s) and all cylinder
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seals.
h. Damaged piston seals. h. Replace all cylinder seals.
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i. Bent boom section(s). i. Replace damaged boom section(s).
j. Broken hydraulic pump coupling. j. Replace broken hydraulic pump
coupling.
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k. Worn or damaged hydraulic pump. k. Repair or replace pump.
l. Broken hydraulic pump shaft. l. Replace pump shaft.
Removal And Installation Disassembly And Assembly

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Removal and installation of the telescope cylinder from the Disassembly and assembly procedures of the telescope
boom is described under disassembly and assembly of the cylinder and control valve are provided in Section 2 under
boom. Refer to BOOM MAINTENANCE in this Section. CYLINDERS and VALVES respectively.
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LIFT CIRCUIT The holding valve is a balanced poppet type hydraulic valve.
It is threaded into the port block which is an integral portion of
Description the lift cylinder barrel. The holding valve functions when
booming up (cylinder rod extended), booming down (cylinder
The boom lift circuit consists of the lift hydraulic remote rod retracted), or holding (cylinder rod stationary).
controller, lift directional control valve, holding valve, and the
lift cylinder. These components enable the boom to be raised Theory Of Operation
or lowered to various degrees of elevation ranging from -3 to
+76 degrees from horizontal. The directional control valve bank housing the lift control
valve is supplied by flow from the hydraulic pump.
The lift directional control valve is the closed spool type and
is described under VALVES in Section 8 - HYDRAULIC When booming up, oil unseats the poppet (check) valve in
SYSTEM. the holding valve, letting oil flow to the piston side of the
cylinder. Pressure is applied to the piston, forcing the rod to
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Refer to VALVES in Section 8 for a complete description of extend, raising the boom.
the hydraulic remote controller.
When booming down, oil enters the retract port of the port
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The lift cylinder is the double acting type. Dirt and other block and flows to the cylinder rod side. When pilot pressure
foreign material is prevented from entering the cylinder and reaches a pre-determined value, the main poppet unseats
causing internal damage by a wiper seal during rod and oil flows from the piston side of the cylinder to the
retraction. Oil Seals on both the piston and cylinder head reservoir.
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prevent internal and external hydraulic oil leakage. Refer to
All return flow from the control valve goes to the reservoir.
4
CYLINDERS in Section 8 for a complete description of the lift
cylinder.
Maintenance
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Lift Circuit Troubleshooting
Table 4-2
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1. Boom raises a. Low hydraulic oil. a. Replenish hydraulic oil to proper level.
erratically.
b. Low engine rpm. b. Increase engine rpm to recommended
setting.
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c. Main relief valve damaged. c. Replace relief valve.

d. Air in cylinder rod. d. Bleed cylinder rod.
e. Bent boom pivot shaft. e. Replace pivot shaft.
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2. Boom lowers a. Low hydraulic oil. a. Replenish hydraulic oil to proper oil
erratically. level.
b. Low engine rpm. b. Increase engine rpm to recommended
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level.
c. Circuit and/or relief valve inoperative. c. Repair or replace relief valve.
d. Air in hydraulic cylinder. d. Bleed air from cylinder.
e. Damaged hydraulic pump section. e. Repair or replace pump section.


3. Boom raises a. Low hydraulic oil level. a. Replenish hydraulic oil to proper level.
slowly.
b. Low engine rpm. b. Increase and maintain engine rpm.
c. Damaged relief valve. c. Repair or replace relief valve.
d. Extremely cold hydraulic oil. d. Operate unit to bring oil to operating
temperature.
e. Improper hose or fittings, installed. e. Replace hose or fittings. (Refer to
f. Operating two functions with in the f. Feather controls to obtain desired
same control valve bank assembly. speed of both functions.
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g. Restriction in return hose. g. Replace return hose.
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h. Cylinder piston seals leaking. h. Replace all cylinder seals.
i. Scored cylinder barrel. i. Hone or replace barrel.
j. Worn hydraulic pump section. j. Repair or replace pump section.
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4. Boom lowers a. Low hydraulic oil level. a. Replenish hydraulic oil to proper level.
slowly.
b. Low engine rpm. b. Increase rpm to recommended level.
c. Damaged relief valve. c. Repair or replace relief valve.
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d. Operating two functions within the d. Feather controls to obtain desired
same control valve bank assembly. speed of both functions.
e. Extremely cold hydraulic oil. e. Operate unit to bring oil to operating
temperature.
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f. Improper hose or fittings installed. f. Replace hose or fittings. (Refer to

g. Restriction in return hose. g. Replace return hose.
h. Cylinder piston seals worn. h. Replace all cylinder seals.
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i. Scored cylinder barrel. i. Hone or replace barrel.

j. Worn hydraulic pump section. j. Repair or replace pump section.
k. Piston rod broken (loose from piston). k. Replace piston rod and all cylinder
seals.
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5. Boom will not raise. a. Low hydraulic oil. a. Replenish hydraulic oil to proper level.
b. Main relief valve or circuit relief valve b. Repair or replace relief valve.
damaged.
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c. Excessive load. c. Reduce load as required.

d. Worn or damaged hydraulic pump d. Repair or replace pump section.
section.
e. Broken pump shaft. e. Replace pump shaft and seals.
f. Broken pump drive coupling. f. Replace drive coupling.
g. Broken control valve spool. g. Replace control valve.


6. Boom will not a. Low hydraulic oil. a. Replenish hydraulic oil to proper level.
lower.
b. Main relief valve or circuit relief valve b. Repair or replace relief valve.
damaged.
c. Worn or damaged hydraulic pump c. Repair or replace pump section.
section.
d. Broken pump shaft. d. Replace pump shaft and seals.
e. Broken pump drive coupling. e. Replace drive coupling.
f. Broken control valve spool. f. Replace control valve.
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NOTE: Refer to Section 2 - HYDRAULIC AND 8. Tag and disconnect all the hydraulic lines to the cylinder.
PRESSURE SETTINGS for lift cylinder Cap or plug all openings with high pressure fittings.
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disassembly and assembly procedures.
9. Pull the lower lift cylinder pivot shaft out far enough to
Maintenance not requiring removal of the cylinder
remove the cylinder.
barrels, such as packing, may be performed
without removing the cylinders from the turntable. 10. Move the lift cylinder to a clean work area.
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However, all disassembly and assembly should be
conducted in a clean dust-free area. Disassembly And Assembly 4
Removal Disassembly and assembly procedures of the lift cylinder
holding valve, and control valve are provided in Section 2
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1. Extend and set the outriggers and level the crane. under CYLINDERS and VALVES respectively.
2. Elevate the boom slightly so that the lift cylinder is
extended approximately 0.3 m (1 ft). The lift cylinder is
Installation
521 kg (1149 lb). 1. Attach an adequate lifting device to the lift cylinder and
position the cylinder over the attach fitting on the
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turntable.
2. Lower the lift cylinder into the attach fittings on the
DANGER turntable and align the lift cylinder bushing with the
Ensure any blocking or cribbing used is capable of attach fitting holes.
supporting the boom.
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NOTE: Install lower pivot shaft (Figure 4-35) (Detail B) with

3. Ensure the boom is fully supported by placing blocking tapped hole on the right side, side opposite the
or cribbing under the boom. Rest the boom on the cab.
blocking or cribbing.
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3. Install the lift cylinder lower pivot shaft and secure with
4. Remove the bolt and washer securing the lift cylinder the bolt and locknut.
upper pivot shaft to the boom. 4. Connect the extend and retract hoses to the lift cylinder.
5. Remove the bolt and locknut securing the lift cylinder
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5. Activate the crane’s hydraulic system and align the lift

lower pivot shaft to the turntable. cylinder rod end with the attach point on the boom.
Install the upper pivot shaft through the cylinder and
boom attach points. Shut down the engine.
DANGER 6. Secure the upper pivot shaft with the bolt and washer.
Ensure the lifting/supporting device is capable of 7. Remove the lifting and supporting devices from the
supporting the lift cylinder. boom and lift cylinders. Activate the hydraulic system
and check the lift cylinders for proper operation and any
6. Attach an adequate lifting/supporting device to the lift leaks.
cylinder being removed.
8. Lubricate the pivot shafts using grease fittings.
7. Remove the upper pivot shaft. Activate the hydraulic
system and retract the lift cylinder enough to clear the
upper attach point.

Retaining Bolt
Lower Pivot Shaft

DETAIL B DETAIL A Upper Pivot Shaft
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FIGURE 4-35
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SWINGAWAY BOOM EXTENSION NOTE: The auxiliary boom nose (rooster sheave) does not
have to be removed. However, if reeved, the hoist
Description cable must be removed from the sheave.
A 7.92 m (26 ft) 0 or 30 degrees offsetable or a 7.92 to 13.7 4. On the rear stowage bracket, remove the retainer pin
m (26 to 45 ft) telescoping, 0 or 30 degrees offsetable securing the sliding support in the “IN” position
swingaway boom extension is provided to obtain additional (Figure 4-36). Pull out on the handle to pull the
boom reach. swingaway away from the rear of the boom and engage
the swingaway anchor fittings with the boom nose
The boom extension mounts directly to the boom nose attachment lugs. Install the retainer pin securing the
utilizing a four point attachment. In addition, the swingaway sliding support in the “OUT” position.
can be stowed on the right side of the boom base section.
5. Remove the clip pins from the two right side attachment
Removing the attach pins from the attach points on the left pins stowed in the base of the swingaway and remove
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side of the boom nose allows the swingaway to be rotated the two attachment pins from the swingaway. Insert the
and stowed on the right side of the boom base section. two right side attachment pins through the right side
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The fixed swingaway weighs approximately 588 kg (1296 lb) boom attachment and swingaway anchor fittings. Install
and the telescoping swingaway weighs approximately 810 the clip pins in the attachment pins.
kg (1790 lb). 6. Remove the clip pins from the hitch pin that secures the
boom extension to the rear stowage bracket. Remove
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Maintenance the hitch pin, unlocking the boom extension from the 4
boom and stow in the stowage lug.
7. Attach a length of rope to the boom extension tip to aid in
swinging the boom extension into place ahead of the
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DANGER boom nose.
Before attempting to erect or stow the swingaway, read
and strictly adhere to all danger decals installed on the 8. Raise the boom to horizontal and extend the boom
swingaway and stowage brackets. approximately 51 to 64 cm (20 to 25 in). Make certain
that the boom extension stowage lugs clear the guide
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Removal pins and ramp on the front and rear stowage brackets.
NOTE: If an adequate lifting device is available, the

swingaway boom extension can be dismounted
directly from the side DANGER
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1. Fully extend and set the outriggers and level the crane. When erecting the boom extension, ensure that all
personnel and equipment are kept clear of the swing path.
2. Position the boom over the front.
3. If extended, fully retract all the boom sections and lower 9. Slightly raise and/or lower the boom to help control the
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the boom to minimum elevation to permit ease of boom extension. Using the rope attached to the top of
installation of pins and access to the boom nose. the boom extension, manually swing the extension into
place ahead of the boom nose, engaging the attachment
fittings with the anchor fittings on the left side of the
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boom nose.

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DETAIL A
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DETAIL B
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6032
FIGURE 4-36
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Swingaway Pin on Nose Assembly or 6 Right Side Attachment Pins
1
Telescoping Section
7 Left Side Attachment Pins
2 Swingaway Base
8 Mast Assembly
3 Main Boom base Section
9 Telescoping Section Pin (Optional)
4 Upper Boom nose Sheaves
10 Rear Stowage Bracket
5 Lower Boom Nose Sheaves
11 Front Stowage Bracket

3
5
13
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14 4
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15 10 8
9
FIGURE 4-37
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1 Boom Base Section 9 Alignment Jack
2 Inner Mid Section 10 Offset Pin
3 Outer Mid Section 11 Mast Assembly Stowage Pin
4 Fly Section 12 Mast Assembly
5 Upper Sheave Cable Retainer 13 Mast Assembly Cable Retainer
6 Left SIde Attachment Pins 14 Right Side Attachment Pins
7 Boom Nose Dead End Lug 15 Jack handle
8 Lower Sheave Cable Retainer

5 7 5 7 4
4
6
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2
3 2
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OUT POSITION IN POSITION
1. Handle 5. Swingaway
2. Retainer Pin
6. Sliding Support and Ramp
3. Wear Pads
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7. Stowage Lug For Item #4

4. Clip Pin and Hitch Pin
6034 DETAIL A 6035
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1. Hanger Weld
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2. Vertical Adjustment Bolt

3
3. Horizontal Adjustment Bolt
4. Lower Support Weld
5. Base Boom Section 4
6. Swingaway
6036
DETAIL B
FIGURE 4-38

line up in front of the guide pins and ramp on the

stowage brackets when the boom extension is
positioned to the side of the boom.
DANGER 7. Ensure the hitch pin and clip pin are removed from the
Do not modify the attachment points to permit the rear stowage bracket.
installation of the attachment pins.
8. Extend the boom extension alignment jack until the
bottom left side attachment pin is free. Remove the
bottom left side boom extension clip pin and attachment
pin.
DANGER 9. Release pressure on the boom extension alignment
Do not place blocking under the boom extension sheave jack. Completely retract the jack and properly stow the
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wheel. jack handle.
10. Remove the top left side attachment pin and clip pin from
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10. Install the top left side attachment pin and clip pin into the upper anchor and attachment fittings of the boom
the upper anchor and attachment fittings of the boom nose.
nose.
11. Extend the boom extension alignment jack until the
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lower left side boom nose and boom extension adapter 4
lugs are aligned. DANGER
12. Install the bottom left side attachment pin and clip pin When stowing the boom extension, ensure that all
into the lower anchor and attachment fittings of the personnel and equipment are kept clear of the swing path.
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boom nose.
13. Release pressure on the boom extension alignment jack
and properly stow the jack handle. CAUTION
14. Extend and lower the boom until blocking can be placed Do not allow the boom extension to slam into the stowage
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under the swingaway. Remove the rope from the tip of bracket when swinging into the stowed position.
the boom extension.
11. Using the rope attached to the tip of the boom extension,
15. Lower the swingaway onto the cribbing. Remove and manually swing the extension to the side of the boom.
stow the pins securing the swingaway to the boom nose.
12. Align the stowage lugs on the boom extension with the
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16. Retract the boom, freeing the swingaway from the boom guide pins and ramp on the stowage brackets and fully
nose. retract the boom.
Installation 13. Install the hitch pin and clip pin securing the boom
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extension to the rear stowage bracket.

1. Position the crane so the swingaway lies in front of the
crane with the swingaway base facing the crane. Fully 14. Remove the attachment pins and clip pins from the
extend and set the outriggers. anchor and attachment fittings on the right side of the
boom nose and stow them in the base of the swingaway.
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2. Extend and lower the boom to engage the anchor and Stow left side attachment pins and clips in outside
attachment fittings on the swingaway. attachment fittings on swingaway.
3. Install the four attachment pins and clip pins to secure 15. On the rear stowage bracket, remove the retainer pin
the swingaway to the boom nose. Raise the boom, lifting securing the sliding support in the “OUT” position. Push
the swingaway from the cribbing on which it was resting. in on the handle to push the swingaway against the rear
(Use boom extension alignment jack if required, see of the boom and disengage the swingaway anchor
step 11 above.) fittings from the boom nose attachment lugs. Install the
4. Attach a length of rope to the boom extension tip. retainer pin securing the sliding support in the “IN”
position.
5. Raise the boom to horizontal.
16. Rig the boom nose and hoist cable as desired and
6. Extend the boom approximately 51 to 64 cm (20 to 25”). operate the crane using normal operating procedures.
Make certain that the boom extension stowage lugs will

HOOK BLOCK Maintenance

Description Periodic Maintenance
A 27 metric ton (30 ton) hook block, a 30 metric ton (33 ton) It is recommended that the hook block and/or headache ball
hook block, and a 6.8 metric ton (7.5 ton) headache ball are be inspected every 50 hours. A complete disassembly
available for the crane. The hook blocks utilizes a one-piece inspection should be conducted every quarter or 500 hours
pivot block and the hook is equipped with a safety latch. Both in the area of the hook, hex nut, and threaded areas for
hook blocks are the quick reeve design. Grease fittings are corrosion and proper fit. After assembly of the hook, a liberal
provided to ensure lubrication of all moving parts. coating of multipurpose grease should be applied to the nut
and threaded areas by brush or hand to prevent corrosion.
For hook blocks and other load handling devices not
CAUTION
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manufactured by Grove Worldwide; follow the
Do not use a swivel type headache ball with 18 x 19 wire manufacturer’s inspection and testing recommendations to
rope. assure an adequate preventative maintenance program is
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established.
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RT530E-2 SERVICE MANUAL HOIST AND COUNTERWEIGHT
SECTION 5
HOIST AND COUNTERWEIGHT
SECTION CONTENTS
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Hoist to Boom Alignment . . . . . . . . . . . . . . . . . . . . 5-7
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Warm-up Procedure . . . . . . . . . . . . . . . . . . . . . . . 5-1
Piston Motor and Control Valve . . . . . . . . . . . . . . . 5-9
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Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Functional Check . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
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Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Fluid Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Usage and Inspection . . . . . . . . . . . . . . . . . . . . . . 5-4 Hoist Drum Rotation Indicator System . . . . . . . . 5-12
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Preventative Maintenance . . . . . . . . . . . . . . . . . . 5-4 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Oil Sampling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Brake Test Procedure . . . . . . . . . . . . . . . . . . . . . . 5-6 Counterweight Removal . . . . . . . . . . . . . . . . . . . . 5-14
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DESCRIPTION control valve is piloted open by the hoist down pressure. If
the load lowers faster than the flow of oil in the hoist down
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One hoist is available; the HP15C-17G (Figure 5-1). The line, the pilot pressure decreases and the motor control valve
hoist incorporates one dual displacement piston motor which partially closes to restrict the oil leaving the motor until a
drives a reduction unit within the hoist. The hoist utilizes balance occurs. This results in the load lowering at a uniform
planetary reduction with a multi-disc automatic brake that is speed based on the position of the hoist control lever.
spring applied and hydraulically released. An overrunning
clutch allows the hoist to be raised without releasing the During stopping, when the hoist down flow ceases, the pilot
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brake while at the same time holding the load until there is pressure holding the motor control valve open decays to
sufficient pressure to release the brake when hoisting down. zero and the motor control valve spool closes, thus blocking
The hoist motor controls both speed and torque of the hoist. all flow of oil out of the hoist motor. This same pressure
decay allows the spring applied pressure released hoist
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There are two modes in which the hoist operates. One mode brake to apply when the load is fully stopped. This brake acts
is high speed. The pilot solenoid valve shifts the selector as a “parking brake” and holds the load in the stopped
spool on the motor to provide minimum motor displacement. position.
This gives high line speed and low torque.
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The second mode is low speed. The pilot solenoid valve MAINTENANCE
shifts the selector spool on the motor to provide maximum
motor displacement. This gives low line speeds and high Warm-up Procedure
torque.
A warm-up procedure is recommended at each start-up and
is essential at ambient temperatures below +40°F (4°C).
THEORY OF OPERATION
The prime mover should be run at its lowest recommended
The hoist assembly is controlled by electric remote RPM with the hydraulic hoist control valve in neutral allowing
controllers located in the cab. When the control lever in the sufficient time to warm up the system. The hoist should then
cab is moved from neutral, it causes the main hoist section of be operated at low speeds, forward and reverse, several
the directional control valve to shift the valve spool to route times to prime all lines with warm hydraulic oil, and to
hydraulic flow to the hoist motor control valve. The hoist circulate gear lubricant through the planetary gear sets.
motor control valve is used to stop or slow the hoist when the
load is trying to drive the hoist down too quickly. The motor

HOIST AND COUNTERWEIGHT RT530E-2 SERVICE MANUAL
3. Tag and disconnect the hydraulic lines to the hoist. Cap

or plug all lines and openings.
DANGER 4. Tag and disconnect the electrical wires to the hoist

rotation indicator.
Failure to properly warm up the hoist, particularly under
low ambient temperature conditions, may result in 5. Tag and disconnect the electrical wires to the hoist hi-
temporary brake slippage due to high back pressures speed solenoid valve.
attempting to release the brake, which could result in
property damage, severe personal injury or death. 6. Remove the hoist mounting nuts, capscrews, washers,
and shims (if shims are used, mark their location).
Removal NOTE: The HP15C-17G hoist assembly, less the cable,
1. If the CE option is provided, remove the hoist covers. weighs approximately 300 kg (661 pounds).
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2. Remove all cable from the hoist drum. 7. Using an adequate lifting device, remove the hoist from
the crane.
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4, 5, 6, 7 6952
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FIGURE 5-1
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Item Description
1 Auxiliary Hoist
2 Main Hoist
3 Turntable
4 Capscrew
5 Washer
6 Hex Nut
7 Shims

Installation 12. Connect the electrical wires to the hoist rotation indicator
sensor box as tagged during removal.
1. Ensure the mounting plate and hoist pads are clean and
free from debris and the hoist has not been damaged 13. Install the cable, following the procedures outlined under
during handling. INSTALLING CABLE ON THE HOIST, in the Operator’s
Manual.
2. With the hoist supported by a suitable lifting device,
position the hoist on the mount. Functional Check
3. Check the hoist to boom alignment according to the 1. Attach a test weight to the hook and raise and lower the
HOIST TO BOOM ALIGNMENT procedure in this load several times.
section.
2. Check the hoist for smooth operation of the hoist motor
4. Place a level between the boom pivot shaft bushings. and brake system.
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5. Place a level across the top of the hoist drum and 3. Ensure the hydraulic connections are secure and free
determine if the hoist is sitting in the same plane in from leaks.
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relation to the level positioned between the boom pivot
shaft bushings. Servicing
6. With the hoist level, check to determine if all the hoist Remove the large plug from the center of the drum support.
mounting pads are in contact with the mounting plate by
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Fill with AGMA EO-4 (Grove Spec 6829100213) gear
rocking the hoist. lubricant until level with the plug opening. Check every 1000
7. Keeping the hoist level, use a feeler gauge to determine hours or 12 months.
the amount of gap existing between the pads and the
mounting plate. Fluid Level
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8. Add shims to satisfy any existing gaps. Altering the shim NOTE: Failure to align the fill/drain plug (1) with the upper
thickness to fit a tapering gap is acceptable. Install the access hole (2) as shown in (Figure 5-2) prior to
checking the oil level will result in an inaccurate
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capscrews, washers and nuts and torque see Fasteners
and Torque Values (pg 1- 12). reading.
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9. Remove the lifting device from the hoist. 1. Rotate the hoist drum until the fill/drain plug (1) appears
in the upper access hole (2) shown in (Figure 5-2).
10. Connect the hydraulic lines to the hoist ensuring the
proper lines are connected to the correct ports as This will ensure that the planetary gears are in proper
marked during removal. alignment and will permit an accurate reading of the oil
level in the hoist.
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11. Connect the electrical wires to the hoist hi speed

solenoid valve as marked during removal. 2. Allow the hoist to stand idle for 20 minutes before
checking the oil.
3. The oil level should be visible in the sight glass (3).
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Table 5-1
Reading Diagnosis Action Required

Fill the hoist with oil from the upper access hole until the
The hoist is under oil level rises within the sight glass. Do not fill above 1/8 in
Oil is not visible in the sight glass. (3 mm) from the top of the site glass.
filled.
Refer to Hoist, page 9-20 for the correct type of oil.
Oil is visible in the sight glass and the
The oil level is
level is no more than 1/8 in (3 mm) No action is required.
correct.
from the top of the sight glass.
Oil level is more than 1/8 in (3 mm) Drain the hoist drum from the upper access hole until the
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from the top of the sight glass or the The hoist is overfilled. oil level falls to within 1/8 in (3 mm) from the top of the
oil is escaping from the vent plug (4). sight glass.
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Compare your reading with Table 5-1 and take the required Severe Usage - Crane/hoist is operated more than 200
action. hours per month OR where 50% of the lifts exceed 75% of
2 1 4 the rated capacity for the hoist.
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The following chart lists the inspections that are required for
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FIGURE 5-2
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Usage and Inspection

Inspection procedures for hoists are divided into five general
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categories based upon their usage or duty cycle, which in FIGURE 5-3
turn determines appropriate intervals for inspections. The
usage categories must be assigned by the crane user on a
Preventative Maintenance
consistent crane-by-crane basis. The five crane/hoist usage
categories are as follows: It is extremely important to be aware of the possibility that
deterioration of internal critical components within the hoist
Idled - The crane/hoist has not been used for three months.
reduction unit can occur. Hoist reduction units incorporate
Infrequent Usage - The crane/hoist is used less than ten planetary gears, multi-disc brake assemblies, and sprag
hours per month based on a three month average clutches which do not have an infinite life span. Although
these components have been designed to achieve long
Moderate Usage - Crane/hoist used 10 - 50 hours per month
service life, reliability can be substantially reduced by a
based on a three month average.
variety of influencing factors such as:
Heavy Usage - Crane/hoist used 50 - 200 hours per month.
• High cycle operation.
• Operating in high ambient temperatures.

• High external contaminations, such as dusty or sandy Must include but is not limited to the following inspections
conditions. that must be performed by a qualified crane operator or
qualified crane technician.
• Level of maintenance.
• Perform the Pre-Use and Quarterly inspections.
The following should be carried out following instructions in
Lubrication, page 9-1 and/or manufacturers instructions. • Take a sample of the lubricant from the hoist gear cavity
as described in Gear Oil Sampling and Analysis, page 5-
1. Pre-Use or Daily Inspection.
6 and analyze it for wear metals content, correct
Must include but is not limited to the following inspections viscosity, lubricant deterioration, moisture and other
that will be performed prior to placing the crane into service contaminants. If the oil sample contains a high amount
and then as necessary during extended operation. This of metallic particles, the hoist must be taken out of
inspection must be performed by a qualified crane operator service to undergo a tear down inspection.
or qualified crane technician.
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NOTE: Oil analysis alone cannot detect nor warn against a
• Check for external oil leaks and repair as necessary. fatigue failure.
This is extremely important due to the accelerated wear
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5. Annual Inspection.
that will result from insufficient lubricating oil in the hoist.
Hoists with a sight glass; check oil level daily. Hoists This inspection must be carried out by a qualified crane
without a sight glass; check oil level monthly if no technician. The annual inspection MUST include, but not be
external oil leaks are detected. Lubricant level must be limited, to the following:
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maintained between the minimum and maximum levels;
• Perform the Pre-Use/Daily Inspection, Quarterly
midway up sight glass or at bottom of level plug port as
inspection and Semi-Annual Inspection.
equipped. Use ONLY the recommended type of
lubricant. Refer to Lubrication, page 9-1. • Change the lubricating oil in the hoist gear cavity after an
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oil sample has been taken as described in Gear Oil
• Check hydraulic fittings and hoses for chaffing,
Sampling and Analysis, page 5-6. Refill the hoist to the
deterioration or corrosion and repair as necessary.
proper level with recommended lubricant. Refer to 5
• Visually inspect for corroded, loose or missing bolts, pins Lubrication, page 9-1.
or other fasteners and replace or tighten as necessary.
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• Visually inspect rotation indicator transmitters, anti-two-

blocking switches and other safety equipment and repair
as necessary. WARNING
Failure to use the proper type and viscosity of planetary
2. Quarterly Inspection (every three months). gear oil may contribute to intermittent brake clutch
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Must include but is not limited to the following inspections slippage which could result in property damage, severe
that must be performed by a qualified crane operator or personal injury or death. Some gear lubricants contain
qualified crane technician. large amounts of EP (extreme pressure) and anti-friction
additives which may contribute to brake clutch slippage or
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• Perform the pre-use inspection. damage to brake friction discs or seals. Oil viscosity with
• Inspect for corrosion of fasteners, hoist base, drum, etc. regard to ambient temperature is also critical to reliable
and repair/replace as required to maintain the structural brake clutch operation. Our tests indicate that excessively
integrity of the hoist. heavy or thick gear oil may contribute to intermittent brake
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clutch slippage. Make certain that the gear oil viscosity

• Check the hoist oil level. Inspect for any oil leaks from used in your hoist is correct for your prevailing ambient
the hoist gearbox. temperature.
3. Every 250 hours or 3 months.
• Check for correct function of the hoist brake by
• If applicable, lubricate the cable guide roller and cable conducting a high line pull load test, ensuring the brake
guard roller bearings. holds without creeping and that the hoist control is
4. Semi-Annual Inspections (every six months). correct. The function of the hoist brake should be
checked more often if abnormal operating conditions or
characteristics exist.

6. Every 10,000 hours or every ten years, it is General Guidelines for Iron Contaminant
recommended that the hoist assembly be disassembled Level
and that all major components be examined for damage
and/or wear, i.e. gears, spline couplings, shafts, etc. 100-500 ppm
New components must be installed if any are found to be
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worn or if there is evidence of heat or other damage. The
hoist should be reassembled using all new seals, 500-800 ppm
bearings, fasteners, washers, brake discs, brake
Caution - Abnormal Sample. Change oil and retake sample
stators, sprag clutch, and springs. A comprehensive
after 50 hours of operation. If second sample is above 500
hoist line pull and load holding test must be conducted
ppm, remove hoist from service and perform tear-down
following the repair work.
inspection to determine source of contamination.
Oil Sampling 800+ ppm
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Unacceptable. Remove hoist from service and perform tear-
Oil Change
down inspection to determine source of contamination.
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The hoist gear oil must be changed after the first 100
Iron contaminant levels will be on the high side of “Normal'
operating hours then on an annual basis, at a minimum
during initial break-in.
thereafter. In severe duty applications, the gear oil should be
cha nge d e very six mont hs. Us e t he reco mmend ed
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Equally important as the level of contamination is the change
lubricants. Refer to Lubrication, page 9-1. in level of contamination. An effective oil analysis program
should provide the technician with a view of the progression
Gear Oil Sampling and Analysis of wear or a trend. If a sample shows a sudden rise in
contaminant level action should be taken to determine what
Proper gear oil sampling and analysis is a vital part of a
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has changed.
comprehensive preventive maintenance program.
Information obtained from the oil analysis allows the NOTE: Oil analysis alone cannot detect nor warn against a
maintenance technician to substitute preventive fatigue failure.
maintenance for more costly unscheduled down time or a far
Brake Test Procedure
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more dangerous failure. Early detection of accelerated

component wear allows the scheduling of corrective
These planetary hoists have a spring applied, hydraulically
maintenance.
released, multiple disc brake inside the hoist housing. This
brake holds a suspended load when the directional control
valve is in neutral, or when hydraulic power is lost. An over-
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running brake clutch assembly permits the power train and

CAUTION drum to rotate in the direction to lift a load, while the brake
Hot oil may cause personal injury and/or burns to remains fully applied. A load cannot be lowered, however,
unprotected skin. Make certain the oil has cooled to a safe without applying hydraulic pressure to the release port and
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temperature (typically less than 110°F or 43°C) before releasing the brake.
taking an oil sample, changing oil or servicing the hoist.
(Test to be performed with no load on the hoist)
Prepare the hoist by cleaning the drain plug area and drain Remove and cap or plug the brake release line from fitting in
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extension tube in order to obtain an uncontaminated sample. the hoist brake release port.
Operate the hoist in both directions for one or two minutes to
With the hydraulic power unit running, move the directional
thoroughly mix the gear oil then take the sample from the
control valve handle slowly to the full open, lowering position.
midstream flow of the oil to obtain an accurate representation
of the oil condition. After taking the oil sample continue with Increase the engine speed, if necessary, to bring system
the oil change or refill the hoist gear cavity to the proper level pressure up to the relief valve setting. The hoist drum should
with recommended lubricant. remain stationary.
If the hoist drum rotates, the hoist should be disassembled
and the brake components should be examined for wear. In
addition, the brake springs should be measured for the
correct free length in those hoist using helical compression
springs.

Replace any parts showing excessive wear and any spring

whose length is shorter than the minimum shown in the
applicable hoist Service Manual.
Reassemble the brake and hoist and repeat the above steps. WARNING
Failure to implement and adhere to a hoist inspection and
When testing is complete, reattach the brake release line to maintenance program may result in damage to the crane,
the brake release port. other property damage, and/or serious injury or death to
The following should be carried out along with the persons working on or near the crane.
instructions in Lubrication, page 9-1.
A comprehensive hoist line pull and load holding test must
1. Annually, have the hoist oil condition tested. This will be carried out following any such repair work.
give advance warning of developing wear patterns. Any
signs of abnormal contamination should be treated Manitowoc Crane Care offers prepackaged kits that include
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seriously and the internal components of the hoist all the seals, bearings, fasteners, washers, brake disks,
should be examined carefully, at the earliest opportunity. brake stators, sprag clutch, and springs that are required for
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reassembling the hoist after inspection. During the
2. Annually, check for correct function of the hoist brake by inspection, if components not included in the kit are found to
conducting a high line pull load test, ensuring the brake be worn or damaged, contact your Manitowoc Cranes
holds without creeping and that the hoist control is distributor or Manitowoc Crane Care to order replacement.
correct. The function of the hoist brake should be
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checked more often if abnormal operating conditions or
characteristics exist.
HOIST TO BOOM ALIGNMENT
3. Every 10,000 hours or every ten years as part of a Preparation
preventative maintenance program, we recommend that
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Boom alignment must be completed before attempting hoist
hoist assemblies be opened in a properly controlled
alignment. If the hoist is not properly aligned, the cable can
workshop environment. The major internal components
(gears, spline couplings, shafts, etc.) should be
be damaged or fine control could be affected. 5
examined for damage and/or wear. New components The crane must be set on outriggers fully extended and the
should be installed if any are found to be worn or if there
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crane must be leveled. The boom must be over the rear on

is evidence of heat or other damage. Reassemble the TM/TMS models and over the front on RT/Industrial models.
hoist using all new seals, bearings, fasteners, washers,
brake discs, brake stators, sprag clutch, and springs. Tools Required
• two foot square
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• mason cord
• chalk
• protractor
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MAIN HOIST IS ALIGNED TO THE RIGHT HAND

SHEAVE
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LOCATING CENTERLINE WITH
SQUARE
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AUXILIARY HOIST IS ALIGNED TO THE CENTER
SHEAVE
6019
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FIGURE 5-4
Procedure the drum at a 90 degree angle. The boom has the ability
to extend, retract, and change the angle of departure
The hoist mounting location will determine the alignment from the drum. Extend the boom half way to provide a
procedure used. Shift one side of the hoist back or forward to
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center point of adjustment to check the fleet angle of the

align the hoist with the boom sheave for cranes that have the cable.
hoist mounted either directly to the boom or on a mount
attached to the boom. It may be necessary to shim under 2. All the cable must be removed from the hoist drum to
one side of the hoist to make it level. check the fleet angle. Using mason cord or cat gut
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fishing line you will be able to pull the line tight to make
The hoist must be checked in two directions, one at 0 degree an accurate measurement of the fleet angle. Find the
and the other is above 45 degrees boom angle on any crane centerline of the hoist drum by using a square and
that the hoist is not mounted directly to the boom, stationary drawing a line horizontal on the drum. Put a line vertical
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mounted. to the horizontal line in the absolute center of the drum

Check the hoist at 0 degree to see if the hoist is aligned to by using a tape measure. With the boom at 0 degree, tie
the boom nose sheave. The main hoist is aligned to the right the line tight to the boom nose and have it in the center
hand sheave and the auxiliary hoist is aligned to the center of the right hand boom nose sheave.
sheave (Figure 5-4) NOTE: If this special equipment is not available, sufficient
NOTE: The hoist cable will have gaps in it during spooling accuracy in locating a centerline may be obtained
if the alignment is not correct. by using a steel square against the machine’s inner
surfaces of both flanges. It is advisable to avoid
NOTE: The hoist is not level if the cable is piling up on one using any cast surfaces in this procedure unless a
side of the drum. check from both flanges indicates that the resultant
1. The boom must be extended one half of full extension on line is straight.
all hoist alignments. This length is used because when 3. Tie the line around the hoist drum so that the line is very
the main hoist cable is positioned on the top right hand tight and the line is crossing the absolute center of the
boom nose sheave, the cable must leave the center of drum at the centerline mark you put on the drum.

4. Using a protractor, lay it on the vertical line on the hoist operated with the primary thrust plate wedged
drum so the string line is in the center of the protractor. between the primary gears and the planet carrier,
The string line will be at the 90 degree mark on the or with a thrust washer out of position severe
protractor if the hoist is straight with the boom nose damage to internal winch components could result.
sheave. If it is not at the 90 degree mark, the hoist
1. Install a new O-ring on the motor pilot then lubricate with
mounting bolts will have to be loosened and the hoist
petroleum jelly or gear oil. Engage the motor shaft with
moved so it is.
the brake clutch inner race and lower into place.
NOTE: This test is for cable leaving gaps while spooling.
2. Apply Loctite No. 243 to the mounting bolts, and install
the bolts and lockwashers. Torque the bolts to 102 Nm
(75 lb-ft).
CAUTION
Do not alter holes or stop blocks on the crane mounting 3. Connect the hydraulic lines as tagged during removal.
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plate, as very small adjustments result in large angular 4. Fill the drum with oil. Refer to Section 9 - LUBRICATION
changes. Extreme care should be taken to avoid over- in this manual.
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correction.
5. Idler Drum and Cable Follower
5. Elevate the boom above 45 degrees boom angle to
check if the hoist is level. Reposition the hoist drum and Description
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tighten the cord so you can have the cord in the center of The main and auxiliary hoists are equipped with an idler
the protractor at the 90 degree mark. If the cord is not at drum on the forward side of the hoist. The main hoist idler
the 90 degree mark, the hoist will have to be shimmed drum is used to keep the hoist cable from coming in contact
until the cord is at the 90 degree mark. with the boom. When the crane is also equipped with an
auxiliary hoist, the idler drum on the auxiliary hoist is used to
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NOTE: This test is for cable piling up on one side of the
hoist drum. keep the hoist cable from coming in contact with the main
hoist. The cable follower is mounted on the rear side of it’s
respective hoist. The cable follower applies a downward
5
PISTON MOTOR AND CONTROL VALVE
spring pressure against the cable onto the hoist drum, to
ensure that the cable will be uniformly wound onto the hoist
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Description
drum, and also prevent cable from jumping under abnormal
The piston motor is a bent axis, bidirectional, variable line conditions.
displacement heavy-duty motor. The motor is bolted to the
hoist and is geared directly to the hoist planetary. Maintenance
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The motor control valve is bolted to the motor.

Idler Drum
Maintenance Removal and Disassembly
Removal 1. Remove the bolt, washer, and lockwasher from the right
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side of the idler roller (Figure 5-5).

1. Thoroughly clean the external surfaces of the drum and
2. Support the idler roller and withdraw the shaft from the
motor with steam or clean solvent and blow dry.
left side. Take care not to lose the dowel pin on the end.
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2. Tag and disconnect the hydraulic lines connected to the

3. Remove the roller from between the side plates.
hoist motor and the motor control valve.
Cleaning and Inspection
3. Remove the capscrews and lockwashers that secures
the motor and motor control valve to the hoist. 1. Clean all rust and dirt from the shaft.
NOTE: The HP15C-17G hoist motor weighs approximately 2. Inspect the shaft and roller for cracks, scoring, or
28 kg (62 lb). grooving. Replace if necessary.
4. Place the motor and motor control valve in a clean, dry Assembly and Installation
suitable work area.
1. Position the roller between the side plates
Installation 2. Install the shaft through the left side plate and the roller.
Ensure the flat on the shaft end aligns with the stop
NOTE: Care must be taken to assure the primary thrust
welded on the side plate, align the dowel pin.
plate remains properly located in its counterbore
when the motor is re-installed. If the winch is

3. Secure the shaft to the right side plate with a bolt, 3. Check the spring tension. If the springs will not provide
washer and lockwasher. Apply Loctite 243 to the bolt sufficient tension when adjusted, replace them.
threads.
Assembly and Installation
Cable Follower 1. Install the left arm through the bushing on the left side
plate. Install left spring attaching lever on the arm and
Removal and Disassembly
secure with a bolt and locknut. Apply Loctite 243 to the
1. Loosen the adjusting nuts and remove the tension bolt threads.
spring and adjusting rod from both sides of the hoist
2. Repeat step 2 on the right side.
(Figure 5-5).
3. Assemble the cable follower roller as follows.
2. Remove the tack welds from the bolt heads securing the
arm to the cable follower roller. a. Apply high strength retaining compound Loctite 680
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to the bearing housings and the bearings. Install
3. Support the cable follower roller and remove the bolts
them in both ends of the roller.
and washers securing the arms to the angles on each
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end of the roller. Remove the cable follower roller. b. Install the shaft into the roller with a least one shim
on each end.
4. Disassemble the cable follower roller as follows.
c. Position the angle on the right side of the shaft and
a. Remove the two bolts and washers securing the
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secure with two bolts and washers. Apply Loctite
angle to the right side of the shaft.
243 to the bolt threads.
b. Remove the shims and roller from the shaft.
4. Position the cable follower roller on the arms and secure
c. If necessary, remove the bearing and bearing with four bolts and washers. Center the roller between
the hoist drum flanges and tighten the bolts. Tack weld
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housing from both ends of the roller.
the bolt heads.
5. Remove the bolt and locknut securing the arm to the
spring attaching lever on each side of the hoist. Remove 5. Attach one end of the tension springs to the levers on
arms and levers from the side plates. each side. Install the adjusting rod through the lug on
each side plate and connect to the other end of the
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NOTE: Be sure to mark each arm and lever as to what side spring. Install the adjusting nuts on each rod and tighten
(left or right) they were removed from. This will be enough to take the slack out of the springs.
helpful during installation.
6. Using a grease gun, apply grease to the fittings on each
Cleaning and Inspection side plate bushing.
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1. Clean all grease from the shaft, bearing, and roller. 7. Adjust the roller as follows.
2. Check the shaft, roller, and bearings for cracks, scoring,
or grooving. Replace if necessary.
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10
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11
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Item Description
1 Pivot Bracket
2 Drum
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3 Follower Roller
6957-1
4 Arm 5
8 5 Spring
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6 Spring Adjusting Rod
2 7 Lever
8 Idler Roller
10 9 Nut
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9
10 Bracket
11 Hydraulic Motor
1
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3
5
6957-2
FIGURE 5-5

a. With one layer of cable on the hoist drum, adjust the and at what speed the hoist drum is rotating, even under the
bolts on the front of each side plate (that push most distracting conditions.
against each arm) so the roller applies pressure on
The rotation indicator system consists of the rotation
the layer of cable, and does not interfere with filler/ indicator sensor and thumb thumper solenoid. The rotation
riser protrusions on the hoist drum flanges. Tighten sensor is located on the hoist. The pulsing thumb thumper
jam nuts to secure setting. solenoid is located in the applicable hoist control lever
b. With a full drum of cable, the adjusting spring length handle. Actuation of the thumb thumper is controlled by the
from eye to eye should not exceed 25.7 cm (10.12 Can-Bus system from input supplied by the rotation indicator
in). Adjust rods as necessary and tighten jam nuts to sensor.
secure this setting.
Maintenance
Complete Assembly General
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Removal
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1. Remove all tension from the springs on each side by
loosening the nuts and jam nuts.
DANGER
2. Support the weight of the assembly and remove the two D i s c o nn e c t t h e b a t t er i e s b e f or e p e r fo r m i n g a n y
bolts and washers securing each side plate to the hoist. maintenance on this system. Serious burns may result
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Remove the idler drum and cable follower assembly from accidental shorting or grounding of live circuits.
from the hoist.
Proper circuit operation can be checked for each individual
3. If necessary to completely disassemble or remove any
electrical component. If a malfunction occurs within the
part of the assembly, refer to the applicable paragraphs
system, repairs should be limited to finding and replacing the
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in this Sub-section.
faulty component(s). To determine which component is at
Installation fault, refer to the troubleshooting section of your Can-Bus
CD.
1. Position the idler drum and cable roller assembly on the
hoist and secure each side plate to the hoist with two Rotation Sensor in Hydraulic Motor
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bolts and washers.

The rotation sensor is screwed into the hoist housing and
2. Adjust the tension on the cable follower. Refer to senses the rotation of the primary drive end driven gear.
instructions in paragraph titled CABLE FOLLOWER - When installing the sensor, ensure it contacts the top land of
Assembly and Installation in this Sub-Section. a gear tooth and not between teeth (Figure 5-6). Screw the
sensor in until contact is made, then back out 1/2 turn and
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HOIST DRUM ROTATION INDICATOR tighten lock nut.

SYSTEM Thumb Thumper Solenoid
The thumb thumper solenoid provides feedback proportional
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Description
to the hoist line speed by pulsing the rubber button on top of
The hoist drum rotation indicator system (Figure 5-6) is an the hoist controller. The thumb thumper will cease operation
electrically operated system that provides the operator with a at high line speeds to prevent damage to the solenoid.
touch indication of drum rotation so the operator will know if
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8479
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Hoist
3
4
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8478-1
Controller
5
FIGURE 5-6
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Item Description
1 Thumb Thumper
2 Controller
3 Rotation Sensor Connection
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4 Two Speed Solenoid Connection

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COUNTERWEIGHT REMOVAL 7. Slowly raise counterweight until pin assembly can be

removed by pushing and turning the pin.
Fixed Counterweight Description 8. Remove pin assembly from opposite side.
The counterweight is pinned to the rear of the turntable and 9. Lower counterweight until attaching lugs are clear of the
weighs 3810 kg (8400 pounds). For cranes without an turntable.
auxiliary hoist, an additional 350.6 kg (773 pounds)
counterweight is bolted to the hoist mounting area in lieu of 10. Back counterweight away from turntable until it is clear
the auxiliary hoist. of crane.
11. Replace pin assembly in turntable counterweight
Fixed Counterweight Removal mounting lugs.
12. Move counterweight far enough from crane to allow the
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turntable/superstructure to clear during repositioning.
DANGER 13. Rotate superstructure to the normal travel position.
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Death or serious injury could result from being crushed by
a falling counterweight. Fixed Counterweight Installation
1. Fully extend and set the outriggers.
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2. Rotate the superstructure so the counterweight will be
over the front of the carrier to gain additional clearance.
DANGER 3. Shut down crane.
Ensure the retainer pin is properly installed to secure the
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counterweight mounting pin.
CAUTION
NOTE: Use of a forklift to remove/install the fixed When lifting/handling the counterweight, keep the chains/
counterweight is not recommended. straps vertical to minimize side pull on the lifting lugs.
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NOTE: Refer to (Figure 5-7) for counterweight removal.

NOTE: The counterweight weighs approximately 3810 kg
1. Fully extend and set the outriggers. (8400 pounds).
NOTE: Turntable lock pin can only be engaged with boom NOTE: Use of a forklift to remove/install the fixed
over front. counterweight is not recommended.
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2. Rotate the superstructure so the counterweight is over 4. Attach an adequate lifting device to the counterweight
the front of the carrier to gain additional clearance. and lift the counterweight into place on the
Engaging the pin type turntable lock will aid alignment. superstructure, aligning the mounting holes on the
counterweight to the holes in the superstructure.
NOTE: The counterweight weighs approximately 3810 kg
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(8400 pounds). 5. Install the counterweight mounting pins and secure them
in place with hitch pin retainers.
3. Lower and fully retract the boom
6. Remove the lifting device from the counterweight.
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4. Shut down crane.

7. Using the four counterweight leveling bolts, level the
5. Attach an adequate lifting device to the counterweight.
counterweight and eliminate any relative movement
6. Ensure the four counterweight leveling capscrews are between the counterweight and turntable. Maximum
set for maximum clearance with the turntable. width of counterweight shall not exceed 6.0 mm (0.25 in)
out of level with the turntable bearing when measured
from either counterweight outer edge.

2, 11
7, 8, 9, 10
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6
3, 4, 5
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2, 11
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3, 4, 5 6830
FIGURE 5-7
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Item Description
1 Counterweight
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2 Pin Assembly
3 Capscrew
4 Hex Nut
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5 Jam Nut
6 Grill
7 Retaining Nut
8 Flat Washer
9 Lock Washer
10 Capscrew
11 Lock Pin

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RT530E-2 SERVICE MANUAL SWING SYSTEM
SECTION 6
SWING SYSTEM
SECTION CONTENTS
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . 6-1 Swing Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
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Swing Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Swivels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
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Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Hydraulic Swivel . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Swing Gearbox And Brake. . . . . . . . . . . . . . . . . . . 6-7 Electrical Swivel. . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
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INTRODUCTION The crane is equipped with a pin type turntable lock as
standard and an optional 360 degree positive swing lock.
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Description The 360 degree positive swing lock meshes with the swing
gear teeth at any point of rotation. The pin type turntable lock
The purpose of the swing system is to allow the crane will only lock the turntable in a straight ahead position over
superstructure to rotate atop the carrier frame. The the front of machine. Both swing locks are operated from the
superstructure swing system provides full 360 degree cab.
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rotation in both directions and is equipped with free swing

capabilities. Theory of Operation
Swing is activated using the Swing Enable Switch. When the
swing lever is actuated, hydraulic pressure is routed to the Swing Drive 6
swing motor to drive the gearbox in the appropriate direction. The hydraulic power for the swing drive (Figure 6-1) is
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As the gearbox rotates, the pinion gear meshes with the supplied by the engine driven hydraulic pump. Oil flows from
teeth on the swing bearing and rotates the superstructure. the pump to the hydraulic Port 5 swivel. Flow from the swivel
Swing speed is regulated by the Control Lever (Joystick). is routed to the service brake dual accumulator charge valve.
The maximum rotation speed is 2.0 - 2.5 rpm with no load. Bypass flow from the dual accumulator charge valve is
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Positioning the lever to the left or right actuates a control routed to the front steering flow divider valve in the swing
valve through electric signal to provide 360 degree directional control valve. Bypass flow from the flow divider
continuous rotation in the desired direction. Braking is valve is used to supply the swing directional control valve.
accomplished by moving the control lever to the center and
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applying Swing Brake Pedal or engaging the Swing Brake When the electronic control is positioned to select right or left
Switch. swing, the flow through the control valve is directed to the
swing motor. If the SWING BRAKE selector switch is in the
The swing system consists of an electric remote controller, a OFF position, the superstructure will rotate in the desired
directional control valve, the swing drive, the swing brake direction. Shifting the control to neutral and depressing the
assembly, the brake pedal and power brake valve, and a brake pedal will stop the swing.
swing brake release solenoid valve.

SWING SYSTEM RT530E-2 SERVICE MANUAL
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6713
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FIGURE 6-1

1 Plug 8 Dipstick
2 Plug 9 Breather
3 Plug 10 Plug
4 Elbow 11 Motor
5 Pipe 12 Gearbox and Brake
6 Breather 13 Pinion
7 Plug

Maintenance
Troubleshooting

1. Boom swing a. Damaged relief valve. a. Replace relief valve.
operation erratic in
b. Swing brake dragging (not releasing b. Readjust and/or replace necessary
either direction.
properly). parts.
c. Low engine rpm. c. Increase engine rpm to obtain smooth
swing operation.
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d. Low hydraulic oil. d. Replenish hydraulic oil to proper level.
e. Improper movement of control to e. Feather controls to neutral to maintain
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neutral. smooth stopping action.
f. Insufficient lubricant on swing bearing. f. Lubricate bearing properly. Refer to
Section 9 - LUBRICATION.
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g. Crane not level. g. Level crane using outriggers.
h. Damaged swing motor. h. Repair or replace swing motor.
i. Excessive overload. i. Reduce load. Refer to load capacity
chart.
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j. Restricted or partly clogged hydraulic j. Replace hose or fittings.
hose or fittings.
k. Pump cavitation in swing section. k. Tighten suction hose or replace any
damaged fitting. Check hydraulic tank
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level.
l. Improperly torqued turntable bolts. l. Torque turntable bolts evenly.
m. Excessive preload on upper and lower m. Adjust as necessary. 6
pinion shaft bearing.
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n. Improperly torqued swing motor n. Torque swing motor attachment bolts.

attachment bolts.
o. Malfunction of the swing box. o. Remove swing box and make
necessary repairs.
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p. Worn or damaged pump. p. Repair or replace damaged pump.

q. Damaged swing directional control q. Repair or replace swing directional
valve. control valve.
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r. Damaged swing pinion. r. Replace pinion.

s. Damaged turntable bearing. s. Replace turntable bearing.
2. Boom swing a. Crane not level. a. Level crane using outriggers.
operation erratic in
b. Turntable bearing binding due to b. Rotate machine 360 degrees in both
one direction only.
continuous limited swing. (Example: directions several times and lubricate
concrete pourer.) bearing.
c. Restricted hose or fitting. c. Replace hose or fitting.
d. Damaged swing directional control d. Replace swing directional control
valve. valve.
e. Damaged swing pinion. e. Replace pinion.
f. Damaged turntable bearing. f. Replace turntable bearing.


3. Boom will not swing a. Damaged relief valve. a. Remove, clean, and repair or replace
in either direction. relief valve.
b. Damaged swing motor. b. Repair or replace swing motor.
c. Swing brake not releasing properly. c. Repair as necessary.
d. Damaged hydraulic remote control d. Replace hydraulic remote control
valve. valve.
e. Internal damage to swing box. e. Remove swing box and repair.
f. Worn or damaged hydraulic pump. f. Replace pump section.
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g. Damaged swing directional control g. Replace swing directional control
valve. valve.
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h. Damaged swing pinion. h. Replace pinion.
i. Damaged turntable bearing. i. Replace turntable bearing.
j. Excessive overload. j. Reduce load. Refer to load capacity
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chart.
4. Swing operation a. Damaged relief valve. a. Adjust, repair or replace valve.
slow in either
b. Improperly adjusted swing brake. b. Readjust.
direction.
c. Damaged hydraulic remote control c. Replace hydraulic remote control
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valve. valve.
d. Improperly lubricated swing bearing. d. Lubricate bearing per
recommendations.
e. Improper size hose and/or fittings e. Refer to the Parts Manual.
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installed.
f. Clogged or restricted hydraulic hoses f. Clean or replace damaged parts.
or fittings.
g. Worn or damaged output shaft g. Replace bearings.
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bearings
h. Worn or damaged swing motor. h. Repair or replace motor.
i. Worn or damaged hydraulic pump. i. Repair or replace pump.
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j. Crane not level. j. Level crane.

k. Damaged swing directional control k. Replace swing directional control
valve. valve.
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5. Swing operation a. Crane not level. a. Level crane.

slow in one
b. Damaged hydraulic remote control b. Replace hydraulic remote control
direction only.
valve. valve.
c. Damaged swing directional control c. Replace the swing directional control
valve. valve.
d. Clogged or restricted hose. d. Replace hose or fitting.
e. Improperly torqued turntable bearing. e. Torque turntable bearing.


6. Swing brake a. Improper brake adjustment. a. Adjust brake.
operation erratic.
b. Air in swing brake system. b. Bleed brake system.
c. Brake pedal not fully retracted. c. Check brake pedal return spring; repair
or replace spring.
d. Dirty or glazed brake disc. d. Clean or replace disc.
e. Malfunction of the glide swing power e. Repair or replace glide swing power
brake valve. brake valve.
f. Kinked or bent lines and/or hoses and f. Straighten or replace as required.
fittings.
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7. Swing brake a. Damaged swing brake release valve. a. Replace release valve.
system will not
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b. Damaged glide swing power brake b. Repair or replace glide swing power
operate.
valve. brake valve.
c. Internal damage to the swing brake c. Repair or replace affected parts.
assembly.
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d. Loose or restricted brake lines or d. Tighten or replace lines and fittings.
fittings.
8. Swing brake pedal a. Damaged glide swing power brake a. Repair or replace the glide swing
is spongy. valve. power brake valve.
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b. Loose or restricted brake lines or b. Tighten or replace brake lines and
fittings. fittings.
9. Swing brake drags. a. Damaged glide swing power brake a. Repair or replace the glide swing
valve. power brake valve.
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b. Damaged swing brake release valve. b. Replace release valve.

c. Internal damage to the swing brake c. Repair or replace affected parts.
assembly. 6
d. Loose or restricted brake lines or d. Tighten or replace brake lines and
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fittings. fittings.
10. Boom swings a. Insufficient hydraulic volume. a. Check delivery of hydraulic pump.
slowly. Ensure sufficient fluid is available to
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pump. Check pump drive speed.

b. Damaged relief valve. b. Adjust, repair, or replace valve.
c. Damaged swing motor. c. Repair or replace motor.
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11. Swing motor a. Hydraulic remote control valve sticking a. Repair or replace valve.
continues to or valve otherwise damaged.
operate when
b. Control valve sticking or valve b. Repair or replace valve.
swing control is in
otherwise damaged.
neutral.
12. Swing motor a. Improper port connections. a. Reverse port connection.
turning in wrong
direction.
13. Swing motor noisy. a. Air in system. a. Refer to Section 2 - HYDRAULIC
SYSTEM, for removal of air from the
system.
b. Motor binding. b. Repair or replace motor.

SWING MOTOR 4. Remove the two screws securing the motor and lift the
swing motor free of the flange. Remove and discard the
Description O-ring from the groove in the swing brake.
The swing motor is mounted on the swing brake housing and Installation
drives the swing gearbox through the brake assembly. The
swing motor is a hydraulic gerotor type with low speed and
high torque characteristics. It has only three moving parts,
the commutator valve, the drive, and the gerotor star. The
CAUTION
motor has two ports for connection to the hydraulic system. Use care when engaging the swing motor drive gear, do
not force the shaft to engage.
Maintenance
1. Install a new O-ring in the groove of the swing brake.
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Removal Position the swing motor on the swing brake, engaging
the shaft with the brake input shaft.
1. Ensure the swing brake and swing lock are engaged.
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2. Apply Loctite 243 to the screw threads. Install the
2. Clean the port area around the motor. Tag and screws and secure the motor to the brake housing.
disconnect the hydraulic hoses from the motor Torque the screws see Fasteners and Torque Values (pg
assembly. Cap or plug all openings. 1- 12).
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3. Connect the hydraulic lines to the swing motor as tagged
CAUTION during removal.
Oil can be hot and cause burns.
Test
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3. Remove the drain plug, loosen the filler and level plugs, 1. Test swing of superstructure in each direction. Stop and
and drain the oil. After oil is drained, replace the drain start swing several times.
plug and any other plugs that may have been removed.
2. Inspect for hydraulic leaks and repair as necessary.
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CAUTION
Pull straight up on the motor assembly to avoid damaging
the splined shaft.
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SWING GEARBOX AND BRAKE 5. Bleed all air from the brake assembly.
Description Gearbox
The swing gearbox and brake, used in conjunction with the Removal
swing motor, rotates and stops the superstructure. A pedal
1. Engage the turntable lock pin.
on the cab floor is used to activate the swing brake. The
swing gearboxes are bolted to the superstructure base plate, 2. Tag and disconnect the hydraulic lines from the swing
and its pinion gear meshes with the ring gear of the turntable motor and swing brake. Cap and/or plug all openings
bearing to rotate the turntable.
3. Unscrew the three screws securing the pinion gear
The swing gearbox utilizes double reduction planetary cover. Remove the cover.
gearing. The multi-disc swing brake assembly is an integral
4. Remove the gear from the shaft.
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part of the swing gearbox and is located between the swing
motor and the swing gearbox. The brake mechanism is a NOTE: The complete gearbox assembly with motor
disc pack that is hydraulically released and spring applied. weighs approximately 126 kg (277.7 pounds).
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Maintenance 5. Attach a suitable lifting device to the swing gearbox.
Remove the capscrews, flatwashers and bushings
NOTE: The swing brake can be removed and securing the gearbox to the mounting plate.
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disassembled independently of the swing gearbox.
NOTE: Take note of the swing motor port orientation to
ensure proper installation.
Swing Brake
6. Remove the swing gearbox.
Removal
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7. If necessary, remove the swing motor according to the
1. Engage the turntable lock pin. procedures found in this Section under SWING MOTOR
2. Tag and disconnect the hydraulic lines connected to the REMOVAL.
swing motor and the brake. Cap and/or plug all 8. If necessary, remove the swing brake according to the
openings. procedures found in this Section under SWING BRAKE
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3. Remove the swing motor from the swing brake REMOVAL.

according to the procedures found in this Section under 9. Cover the opening of the swing gearbox to ensure no
SWING MOTOR - REMOVAL. dirt, dust, etc., gets into the gearbox. 6
Installation
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CAUTION 1. If removed, install the swing brake according to the

Use care when removing the capscrews securing the procedures found in this Section under SWING BRAKE
brake, as there is tension on the bolts due to internal INSTALLATION.
brake springs.
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2. If removed, install the swing motor according to the

4. Unscrew the screws securing the brake to the gearbox. procedures found in this Section under SWING MOTOR
Lift the brake using the brake flange, then remove the O- INSTALLATION.
ring.
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3. Attach a suitable lifting device to the swing gearbox and

5. Cover the opening of the swing gearbox to ensure no lift and position the swing gearbox in place on the
dirt, dust, etc., gets into the gearbox. mounting plate.
Installation 4. Install the capscrews, flatwashers and bushings. Torque

the capscrews 85 to 93 Nm (63 to 69 lb-ft).
1. Install a new o-ring onto the brake housing.
5. Apply Loctite 243 to screws. Install the pinion gear on
2. Apply Loctite 243 to the screws. Install brake onto the output shaft. Install the cover and secure with three
gearbox and secure with the screws. Torque the screws screws. Torque screws 50 Nm (36.8 lb-ft).
50 to 60 Nm (36.8 to 44.2 pounds-foot).
6. Connect the hydraulic lines to the swing brake.
3. Install the swing motor into the swing brake according to
the procedures found in this Section under SWING 7. Connect the hydraulic lines to the swing motor.
MOTOR - INSTALLATION. 8. Service the gearbox as indicated under SERVICING.
4. Connect the hydraulic lines to the motor and brake.

Servicing NOTE: Cleaning of the gearbox with a solvent is

As with all highly stressed mechanisms, reasonable recommended to prevent an accumulation of grit
operating procedures are always required. Normal and grime. Avoid steam cleaning where moisture
maintenance should only consist of proper lubrication and a and dirt might be driven into the vent of the swing
periodic check of mounting bolt torque values. Lubrication bearing.
consists of maintaining the gearbox oil level. Oil in a new 4. To refill with oil, fill through filler plug until it begins to flow
gearbox should be drained and flushed out after out of the level plug.
approximately 250 hours of operation, and replaced with
premium quality SSGL-5 (spec 6829012964) after 5. Tighten the level and filler plugs.
approximately 500 hours of operation or each year, Checking The Oil Level
whichever occurs first. Operation in high humidity or polluted
air areas will require more frequent changes to minimize 1. Check the oil level through level plug.
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moisture or contaminate accumulation. Change the oil as
2. If no oil is visible on the level plug, add oil until the level
follows.
is between min and max on the level plug.
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1. Unscrew the drain plug. To ensure all oil has been
3. Refer to Lubrication (pg 9- 1).
removed, unscrew the filler and level plugs.
Testing
2. After oil is drained, replace the drain plug and any other
plugs that were removed to drain the oil. 1. Test swing of superstructure in each direction. Stop and
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start swing several times.
3. Flush the case with a light flushing oil.
2. Inspect for hydraulic leaks and repair as necessary.
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SWING BEARING
Description
DANGER
The swing bearing is an anti-friction roller bearing that mates
the Superstructure to the Carrier. The bearing inner race is It is mandatory that bearing attaching bolts be inspected
bolted to the Superstructure and the outer race is bolted to for lack of torque and retorqued, as required, after the first
the Carrier. The inner race contains two grease fittings for 300 hours of crane operation. The bolts may loosen in
lubrication of the bearing which are hosed to two fittings at service due to vibration, shock-loads, and temperature
the front right side of the turntable center section. changes, therefore, periodic inspection should be
accomplished every 500 hours thereafter, ensuring the
Maintenance bolts are properly torqued.
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General KNOW YOUR TORQUE WRENCH! Flexible beam type
wrenches, even though they might have a pre-set feature,
The swing bearing is the most critical maintenance point of must be pulled at right angle and the force must be applied at
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the crane. It is here, at the centerline of rotation, that the center of the handle. Force value readings must be made
stresses of loads are concentrated. In addition, the bearing while the tool is in motion. Rigid handle type, with torque
provides the only attachment between the superstructure limiting devices that can be pre-set to required values,
and carrier. Therefore, proper care of the bearing and eliminate dial readings and provide more reliable, less
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periodic maintenance of the turntable-to-bearing attach bolts variable readings.
-IS A MUST -to ensure safe and efficient operation.
NOTE: If multipliers and/or special tools are used to reach
hard to get at areas, ensure torque readings are
Torquing Turntable Bolts
accurate.
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General
Torque wrenches are precision instruments and must be
handled with care. To ensure accuracy, calibrations must be
made on a scheduled basis. Whenever there is a possibility
that a torque wrench may have been either overstressed or
DANGER
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damaged, it should immediately be removed from service

Failure to maintain proper torque of the turntable bearing until recalibrated. When using a torque wrench, any erratic or
attaching bolts will result in damage to the crane and jerking motion can result in the application of excessive or
possible injury to personnel. improper torque. ALWAYS use a slow, even movement and
STOP when the predetermined value has been reached.
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Maintaining proper torque value for bolts is extremely If it is reported by the crane operator or suspected that the
important for structural strength, performance, and reliability crane has been overloaded beyond the capacities specified
of the crane. Variations in torque can cause distortion, above the bold line on the cranes’ capacity chart, then all
binding, or complete separation of the superstructure from turntable bolts must be inspected for looseness and
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the carrier. retorqued to specifications.

Turntable bolts should be torqued according to the
CAUTION procedures outlined in this section.
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Repeated re-torquing may cause bolts to stretch. If bolts When using step wrenches, calculated wrench settings are
keep working loose, they must be replaced with new bolts valid only when the following conditions are met.
of the proper grade and size.
1. Torque wrenches must be those specified and forces
Proper identification of bolt grade is important. When marked must be applied at the handle grip. The use of handle
as a high strength bolt (grade 8 and metric grade 10.9), the extensions will change applied torque to the bolt.
serviceman must be aware of bolt classifications and that he 2. All handles must be parallel to the step wrench during
is installing a high strength heat-treated tempered final tightening. Multiplier reaction bars may be
component and the bolt must be installed according to misaligned no more than 30 degrees without causing
specifications. Special attention should be given to the serious error in torque.
existence of lubricant and plating that will cause variation
from dry torque values. When a high strength bolt is 3. Multiplier bar handles must be propped or supported
removed, or un-torqued, the bolt must be replaced with a within the outer 1/4 of the handle length, or serious
new bolt of the same classification. under or over tightening will occur.

35 36 1 2
34 3
4
33
32 5
31 6
35 36 1 2
30 34 3 7
33 4
32 5
31 6 8
29
30 7
28 29 8
9
28 9
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27 10
27 26 11 10
25
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12
26 24 13 11
23 14
22
25 21 1615 12
20 19 18 17
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24 13
23 14
22 15 6750-2
21 16 FIGURE 6-2
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20 19 18 17
The inner race of the bearing is secured to the turntable by 23, 14, and 32. Tools used are the socket, multiplier,
36, 1 inch, grade 8 bolts. The outer race of the bearing is backlash adapter, necessary extensions, and torque
secured to the carrier frame by 36, 7/8 inch, grade 8 bolts. wrench.
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Torque Values 3. Return to bolt 1 and torque all bolts sequentially in a

clockwise direction to the final torque of 1162 to 1260
Torque all inner race turntable bolts (Figure 6-2) to a final
Nm (857 to 929 lb-ft) The same tools are used as in step
torque of 1162 to 1260 Nm (857 to 929 pounds-foot).
1.
Torque all outer race turntable bolts (Figure 6-2) to a final
Outer Race Torquing
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torque of 769 to 834 Nm (567 to 615 pounds-foot).

1. Extend and set the outriggers. Fully elevate the boom.
See Fasteners and Torque Values (pg 1- 12).
2. Torque eight bolts 615 to 667 Nm (454 to 492 lb-ft) using
Tools Required
the following sequence pattern; 36, 18, 10, 28, 5, 23, 14,
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(Figure 6-3) lists the complete set of special tools required to and 32. Tools used are the socket, multiplier, backlash
torque the turntable bolts. adapter, necessary extensions, and torque wrench.
Inner Race Torquing 3. Return to bolt 1 and torque all bolts sequentially in a
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clockwise direction to the final torque of 769 to 834 Nm

1. Extend and set the outriggers. Fully elevate the boom. (567 to 615 lb-ft). The same tools are used as in step 1.
2. Torque eight bolts 930 to 1008 Nm (686 to 743 lb-ft)
using the following sequence pattern; 36, 18, 10, 28, 5,

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7 1 3
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5
Orders for special tools Description Grove Part Number Quantity Required
shall be referred to: 1. 1 1/2” Socket 3/4” Drive 9-999-100143 1
2. 4 to 1 Torque Multiplier (1/2” Input 3/4” Output) 9-999-100134 1
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Manitowoc/Grove Crane Care 3. Backlash Adapter 9-999-100141 1
1565 Buchanan Trail East 4. 1/2” Drive Torque Wrench 9-999-100136 1
Shady Grove, PA 17256-0021 5. 10” Extension 3/4” Drive 9-999-100138 A/R
Phone: (717) 597-8121 6. 13” Extension 3/4” Drive 9-999-100137 A/R
Fax: (717) 593-5929 7. Tool Box (Optional) 9-999-100146 1
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Special Turntable Bolt Torquing Tools

FIGURE 6-3
Removal 6. Remove the counterweight and auxiliary hoist following 6

procedures outlined in Section 5 - HOIST and
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1. Fully extend and set the outriggers enough to take up COUNTERWEIGHT.

the slack in the pads.
7. Tag and disconnect all water and oil lines from the
NOTE: Do not raise the machine on the outriggers. bottom of the swivel. Cap or plug all lines and openings.
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2. Ensure the boom is in the travel position and the 8. Locate the connectors and ground wire that joins the
turntable lock pin is engaged. swivel wiring harness to the receptacles and ground
3. Elevate the boom slightly and shut down the engine. stud on the carrier.
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4. Tag and disconnect the battery cables from the 9. Disconnect the swivel wiring harness connectors from
batteries. the carrier wiring receptacles. Remove the ground wire
from the ground stud.
NOTE: The boom assembly weighs approximately 5792
kg (12,769 pounds) with stowed boom extension. 10. Remove the clamp securing the swivel wiring harness to
Removal of the swingaway boom extension will the retainer plate on the bottom of the hydraulic swivel
simplify boom removal, therefore, the above weight assembly.
is for the boom without the swingaway boom 11. Coil the wiring harness and secure it to the swivel to
extension attached. The lift cylinder weighs prevent damage to the harness during turntable
approximately 578 kg (1274 pounds). removal.
5. Remove the boom and lift cylinder following the 12. On the bottom of the hydraulic swivel, bend the retainer
procedures outlined in Section 4, BOOM. tabs away from the capscrew heads. Remove the
capscrews securing the two retainer plates to the spool.

Remove the retainer plates from the spool and the lugs NOTE: The bearing weighs approximately 260 kg (573
on the carrier frame. pounds). Ensure the bearing lifting device is
capable of supporting the weight.
NOTE: The swivel assembly will be removed with the
turntable. 16. Place an adequate lifting device under the bearing and
remove the 36 bolts and washers securing the turntable
bearing to the superstructure.
17. Using the lifting device, remove the turntable bearing
DANGER from under the superstructure.
Ensure the lifting device is capable of fully supporting the
weight of the superstructure. Ensure the superstructure Inspection
will not tilt or slide during lifting and moving. Failure to do
so may result in death or injury to personnel and damage Check the bearing teeth for chipping or cracking. If any
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to equipment. evidence of these is found, replace the bearing. Ensure the
bolt holes are free of dirt, oil, or foreign material.
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NOTE: If a lifting device capable of lifting the entire
superstructure is not available, superstructure
Installation
weight may be reduced by removing various
components such as the hoist(s).
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13. Attach a suitable lifting device to the four superstructure
lifting lugs (two near the boom pivot shaft bushings and
DANGER
two near the lower lift cylinder pivot shaft bushings). Anytime a turntable bolt has been removed, it must be
Take in cable or chain to remove slack. Do not pull up on replaced with a new bolt.
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the superstructure.
NOTE: If the same bearing is to be used again, align the
marked teeth on the pinion shaft and the marked
teeth on the bearing.
DANGER NOTE: Installation is in the travel position. Ensure the
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Ensure the superstructure is fully supported before swing lock is disengaged before attempting to mate
proceeding. the bearing to the superstructure.
1. Using an appropriate lifting device, position the turntable
NOTE: It will be necessary to rotate the superstructure bearing under the superstructure. If the same bearing is
while attached to the lifting device. Outer race bolts being used, position it as marked prior to removal.
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can only be removed from the swing drive side of

the turntable. 2. Install 36 new bolts and washers securing the bearing to
the superstructure. Refer to Inner Race Torquing in this
14. Remove the 36 bolts and washers securing the turntable Sub-Section.
bearing outer race to the carrier.
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3. Using an appropriate lifting device, align the

superstructure over the carrier in the travel position and
carefully lower the superstructure, being careful not to
damage the swivel assembly, into position on the carrier
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DANGER
bearing plate.
Ensure that any blocking material used is capable of fully
supporting the weight of the superstructure and will not NOTE: It will be necessary to rotate the superstructure
allow it to tilt or shift. Failure to do so may result in death or while attached to the lifting device. Outer race bolts
injury to personnel. can only be installed from the swing drive side of
the turntable.
15. Carefully lift the superstructure, using care not to
4. Install 36 new bolts and washers. Refer to Outer Race
damage the swivel assembly, and set it on blocking that
Torquing in this Sub-Section.
will not allow the superstructure to tilt or shift, or rest on
the swivel. Leave the lifting device attached. NOTE: If a new bearing is being installed, a new pinion
gear must also be used. Align the high point
NOTE: If the same bearing is to be used again, mark the
(maximum eccentricity) on the bearing with the
position of the bearing on the superstructure so it
new pinion gear high point (Figure 6-4).
can be installed in the exact position it was before
removal.

5. Apply Loctite 271 to the capscrews. Position the two

Maximum Eccentricity Point retainer plates on the bottom of hydraulic swivel spool,
Pinion
engaging the lugs on the carrier frame, and secure them
to the spool with four capscrew retainers and bolts.
Torque the bolts 298 to 322 Nm (220 to 237 pounds-
foot). Bend all the retainer tabs to make contact with the
bolt heads.
6. Plug the swivel wiring harness connectors into the
carrier receptacles. Secure the ground wire to the
ground stud using a washer, lockwasher, and nut.
7. Install the clamp securing the swivel wiring harness to
the retainer plate on the bottom of the hydraulic swivel.
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8. Connect all water and hydraulic lines to the ports on the
bottom of the swivel as tagged during removal.
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9. Install the boom and lift cylinder following the procedures
.0.20 Thick Shim outlined in Section 4, BOOM.
By Full Width to Tooth Bearing
6750-3
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Engagement (.040) Backlash) NOTE: The counterweight structure weighs approximately
3818 kg (8417 lb).
FIGURE 6-4
10. Install the counterweight and auxiliary hoist following
Orient ring gear such that its point of max eccentricity (“high procedures outlined in Section 4 of the Operator’s
point”) is located between the swing drives. Position swing Manual.
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drives so that pinion is centered within cutout in base plate
and motor ports face towards the outboard side as shown. 11. Reconnect the batteries.
12. Check the slew potentiometer in the electrical swivel for
proper orientation. Refer to SWIVELS in this Section
CAUTION
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Do Not Clamp Over Pinion. Testing

• Using shims, set backlash by moving the swing drive Activate the crane and check for proper function.
assemblies toward the bearing in order to mesh the
NOTE: If the superstructure does not turn freely after
6
pinion with the ring gear teeth (see Figure 6-5).
bearing and pinion replacement, contact your local
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• Check tooth engagement squareness and vertical distributor.

tooth engagement.
• Remove backlash shims and recheck backlash.
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SWIVELS the spool to remain stationary with the carrier as the case
rotates with the superstructure.
Description The spool portion of the water swivel is integral with the
The swivel assembly (Figure 6-5) consists of a 10 port hydraulic swivel. The hydraulic and water swivel spools
hydraulic swivel, a 2 port water swivel, a 2 port refrigerant remain stationary with the carrier as the superstructure
swivel and a 20 conductor slip ring electrical swivel. Solid rotates. The water swivel case engages to hydraulic case by
connections cannot be used to transfer oil, heater hot water four dowel pins.
and electricity between the carrier and superstructure due to The electrical swivel center or collector ring assembly is
the continuous 360 degree swing. The use of swivels secured by setscrews to a center post which is bolted to the
efficiently accomplishes this function. spool of the hydraulic swivel. This allows the collector ring
The barrel portion of the hydraulic swivel is attached to the assembly to remain stationary with the carrier. The outer
portion or brush assembly is mounted on two studs which
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turntable base plate by four capscrews, washers and
bushings. The spool portion of the swivel rides upon a thrust are located on the mounting plate assembly which is
ring at the top of the swivel case. The spool portion is held retained to the water swivel barrel by a bolt. This allows the
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stationary with the carrier by bolts, and bolt retainer plates brush assembly to rotate with the superstructure around the
attached to the swivel retainer plate which engages the stationary collector core.
carrier frame lugs with capscrews and hex nuts. This allows
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11 1
Item Description
12, 13, 14, 15
1 Slip Ring Assembly 2, 3
2 Capscrew
3 Washer
4 Hydraulic Swivel 16, 17
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5 Retaining Plate
6 Capscrew
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7 Hex Nut
8 Adapter 4
9 Hose Nipple
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10 Adapter
11 Plate
12 Capscrew
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13 Jam Nut
5
14 Flatwasher
15 Capscrew 6, 7
16 Hose Nipple
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8, 9, 10
17 Adapter
18 Turntable Base Plate
19 Carrier Top Plate
6733-1 6
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20 Capscrew Forward 20, 21
21 Washer 22
22 Bushing
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23 Plug 18
24 Retaining Plate
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19
23 6752-2
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FIGURE 6-5

Hydraulic Swivel
Description
Each of the ports on the spool and case of the swivel is
stamped with the port number. The function of each port is
described below.
Max Test Pressure

Port # Function
kPa (bar) (psi)
1 25000 (250) (3625) Brake - Front
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2 25000 (250) (3625) Load Sense
3 25000 (250) (3625) Brake - Rear
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4 5000 (50) (725) Dual Return
5 30000 (300) (4351) Swing/Brake/Steer
6 32000 (320) (4641) Lift/Tele/Hoist
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7 25000 (250) (3625) Front Steer - Left
8 25000 (250) (3625) N/A
9 25000 (250) (3625) Front Steer-Right
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10 500 (5) (73) Case Drain
11 500 (5) (73) A/C
12 500 (5) (73) A/C
A 500 (5) (73) Heater Supply (Coolant)
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B 500 (5) (73) Heater Return (Coolant)
Theory of Operation 3. Measure the distance from the top of the lift cylinder to
the base of the boom section where the lift cylinder
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The hydraulic swivel allows oil to flow from the pumps to attaches. Cut two pieces of 10 x 10 cm (4 x 4 in) oak to
various crane functions on the superstructure. All oil is fit.
routed into the spool portion of the swivel where, through a
series of internally drilled passages, oil is transferred to NOTE: It might be necessary to raise the boom slightly to
circumferential channels on the spool exterior. These allow installation of the blocking.
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channels correspond with a mating port on the outer case of NOTE: This blocking is to add extra support for the boom.
the swivel. Each channel is separated by a series of nylon Any seepage or leakage in the holding valves or
and O-ring seals that prevent transfer of oil and pressure. internally in the cylinders will allow the boom to
Return flow from the crane superstructure is accomplished in
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settle over a period of time.

the same manner through another set of ports.
4. Use the oak blocking to block between the barrel of the
Engine coolant flows from the carrier mounted engine to the lift cylinder and the boom base section.
hot water heater in the operator’s cab through ports A and B
of the swivel. 5. Evacuate A/C system and capture refrigerant.
6. Tag and disconnect the hydraulic lines from the case of
Maintenance the hydraulic swivel. Cap or plug all lines and openings.
Removal 7. Tag and disconnect the hydraulic lines and water lines
1. Extend and set the outriggers. Ensure the crane is level from the spool of the hydraulic swivel. Cap or plug all
and the boom is over the front. lines and openings.
2. Elevate the boom and note at what boom angle you 8. Tag and disconnect the water lines from the case of the
have the most clearance between the lift cylinder and water swivel. Cap or plug all lines and openings.
the turntable side plate. Shut down the engine.

9. Disconnect the swivel wiring harness connectors from 3. Apply Loctite 271 to the capscrews. Position the two
the carrier receptacles and the yellow ground wire from retainer plates on the bottom of hydraulic swivel spool,
the connector mounting bracket on the carrier frame. If engaging the lugs on the carrier frame, and secure them
necessary, remove the electrical swivel. Refer to to the spool with four capscrew retainers and bolts.
ELECTRICAL SWIVEL in this Section. Torque the bolts 298 to 322 Nm (220 to 237 lb-ft). Bend
all the retainer tabs to make contact with the bolt heads.
NOTE: The hydraulic swivel weighs approximately 214 kg
(472 lb). The hydraulic, water, and electrical swivel 4. If removed, install the electrical swivel. Refer to
combined weigh approximately 233 kg (514 lb). ELECTRICAL SWIVEL in this Section. Connect the
swivel wiring harness connectors to the carrier
10. On the bottom of the swivel, bend the retainer tabs away
receptacles and the yellow ground wire to the mounting
from the capscrews. Remove the capscrews and
bracket on the carrier frame. Use the bolt and star
capscrew retainers securing the two retainer plates to
washers taken off at removal and refer to Grove
the spool. Remove the retainer plates from the spool
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Engineering Specification A-829-100386 for proper
and the lugs on the carrier frame.
electrical termination of grounds.
NOTE: It may be necessary to remove some drive line
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NOTE: Allow a 1/32” max gap between bolt and the
components to remove the swivel.
retaining lug on the frame. Do not tighten bolt
11. Position an adequate supporting device beneath the against lug.
swivel.
5. Install the clamp, lockwasher, flat washer and capscrew
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12. Remove the capscrews, washers, and bushings to the bottom of the swivel retainer plate securing the
securing the swivel barrel to the turntable base plate and wiring harness.
lower the swivel to the ground.
6. Connect the hydraulic lines and water lines to the spool
Installation of the hydraulic swivel as tagged during removal.
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NOTE: The hydraulic swivel weighs approximately 214 kg 7. Connect the hydraulic lines to the hydraulic swivel case
(472 lb). The hydraulic, water, and electrical swivel as tagged during removal.
combined weigh approximately 233 kg (514 lb).
8. Connect the water lines to the water swivel case as
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1. Raise the swivel into position.

2. Secure the hydraulic swivel to the turntable base plate 9. Remove the blocking material from the lift cylinder.
with the bushings, capscrews and washers. Torque the
10. Activate all systems; cycle all functions and observe for
proper operation and any leakage.
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11. Charge A/C system.

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Electrical Swivel 6. Secure the connectors and wires from each of the
numbered connectors so the harness can be withdrawn
Description through the center of the hydraulic swivel.
The swivel assembly consists of a 20 conductor slip ring and 7. Tag and disconnect the connectors from the receptacles
cover assembly. on the cab bulkhead mounting plate.
Each brush set incorporates two brushes, leads, and clips 8. Remove the setscrews and remove the cover from the
which are attached to a brush holder assembly. The brush electrical swivel.
set leads are formed into harnesses which are routed 9. Loosen the capscrews securing the electrical swivel
through the mounting plate on the swivel. The collector ring mounting tube to the center post on the water swivel.
leads are formed into one harness which is routed downward
through the center of the hydraulic swivel. Extending from 10. Remove the capscrew and jam nut securing the
electrical swivel case to the plate on the case of the
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the base of the hydraulic swivel, the collector ring leads are
also formed into connectors which plug into receptacles from water swivel.
the chassis power supply.
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The swivel cover is secured with a seal and bolts CAUTION
The electrical swivel also incorporates a slew potentiometer. When withdrawing the wiring harness through the center
The potentiometer controls functions in the load moment of the hydraulic and water swivels, ensure the wires do
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indicating, working area definition, and rear axle oscillation not get caught and damaged.
lockout systems.
11. Remove the swivel and wiring harness from the crane. If
Theory of Operation necessary, remove the spacer bushing from the center
post.
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The electrical swivel is located on top of the water swivel and
transfers electricity between the carrier and superstructure. Installation
Wiring harnesses transmit the electricity between the carrier 1. If removed, install the spacer bushing on the center post.
and superstructure. Route the collector core wiring harness through the
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center of the hydraulic and water swivels.

Maintenance
NOTE: The boom should be centered directly over the
Removal front of the crane before adjustment is made to the
1. Perform steps 1 through 4 of HYDRAULIC SWIVEL - slew potentiometer.
REMOVAL in this section.
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2. Slide the electrical swivel mounting shaft onto the center

post.
3. Ensure the threaded hole on the bottom of the electrical
swivel base is aligned with the mounting hole in the plate
CAUTION
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on the water swivel case. Install the capscrew through

D i s c on n e c t t h e b a t te r i es b e fo r e p e r f o r m i n g a n y the hole in the plate and install the jam nut. Screw the
maintenance on the electrical system. Serious burns may capscrew into the hole in the electrical swivel base until
result from accidental shorting or grounding of live the capscrew head is approximately 6.0 mm (0.23 in)
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circuits. from the bracket. Tighten the nut against the electrical
swivel (Figure 6-6).
2. Disconnect the batteries. Refer to Section 3 -
ELECTRIC SYSTEM. 4. Apply medium strength Loctite to the setscrews securing
the electrical swivel to the center post and tighten them 5
3. Locate the connectors which join the collector ring to 6 Nm (44 to 53 lb-in)
harness to the receptacles for the carrier.
5. Install the swivel cover and secure with capscrews and
4. Tag the connectors and their receptacles with numbers. washers.
Disconnect the connectors from the chassis wiring
receptacles. 6. Connect the wiring harness connectors to the
receptacles on the cab bulkhead mounting plate as
5. Remove the clamp securing the wiring harness to the tagged during removal.
retainer plate on the bottom of the hydraulic swivel
assembly.

operating hours. When this time limit is reached, perform the

4, 5, 6
following.
1. Check the collector ring and brush assembly for any
7 corrosion, pitting, arcing, and wear.
2. Check the collector ring setscrews and ensure they are
2, 3 tight.
3. Check the brush and arm assembly springs. Ensure
they are holding the brushes firmly against the collector
rings.
30° Ref 1 Slew Potentiometer Adjustment
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1. Rotate the superstructure over the front and engage the
Forward house lock pin.
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2. Remove the electrical swivel cover.
TOP OF SWIVEL FIGURE 6-6
CAUTION
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Item Description Do not attempt to rotate the slotted shaft in the center of
1 Swivel the slew potentiometer.
2 Capscrew 3. Disengage the house lock pin and swing the

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3 Hex Nut superstructure approximately 10 degrees to the right
(clockwise). Slowly swing back to the left and engage
4 Capscrew
the house lock pin.
5 Washer
NOTE: If the superstructure swings past the house lock pin
6 Bushing engaged position, step 3 must be repeated.
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7 Retaining Plate 4. Loosen the three screws that secure the slew
7. Plug the connector into the carrier wiring receptacle, potentiometer to the mounting plate.
connect the wires as tag during removal. Install the 5. Rotate the body of the slew potentiometer until the slew 6
yellow ground wire to the connector mounting bracket on angle indicates 0.6 ± 0.1 degree.
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the carrier frame using the bolt and star washers taken
of at removal and refer to Grove Engineering NOTE: The slew angle indication in step 6 may not be
Specification A-829-100386 for proper electrical obtainable due to limited wire length on the
termination of grounds. p o t e n t i o m e t e r, o r t h e e l e c t r i c a l t e r m i n a l s
interference with one of the three mounting screws.
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8. Install the clamp securing the harness to the retainer If this occurs, reposition the collar set screwed to
plate on the bottom of the hydraulic swivel assembly. the potentiometer shaft and repeat steps 3 thru 5.
9. Connect the batteries. 6. Tighten the three screws that secure the slew
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potentiometer to the mounting plate. Install the electrical

swivel cover.
CAUTION
It is imperative that the slew potentiometer be adjusted 7. Disengage the house lock pin and swing approximately
anytime work is done to the electrical swivel. 10 degrees to the left (counterclockwise). Slowly swing
back to the right and engage the house lock pin.
10. Activate all systems, cycle all functions, and observe for NOTE: If the superstructure swings past the house lock pin
proper operation. Adjust the slew potentiometer in engaged position, step 7 must be repeated.
accordance with SLEW POTENTIOMETER
ADJUSTMENT procedures in this Sub-Section. 8. If the angle indicated on the console does not exceed ±
1.0 degree, proceed to step 10. If the indicated angle
Preventive Maintenance exceeds ± 1.0 degree, return to step 3.
It is recommended that a normal inspection of the electrical 9. Disengage the house lock pin and swing approximately
swivel collector ring and brush assembly be established. An 10 degrees to the right (clockwise). Slowly swing back to
example of this could be at approximately 100 to 150 engine the left and engage the house lock pin.

NOTE: If the superstructure swings past the house lock pin NOTE: If the superstructure swings past the house lock pin
engaged position, step 10 must be repeated. engaged position, step 12 must be repeated.
10. If the angle indicated on the console does not exceed ± 12. Verify the angle indicated on the console does not
1.0 degree, proceed to step 12. If the indicated angle exceed ± 1.0 degree. If the indicated angle exceeds ±
exceeds ± 1.0 degree, return to step 3. 1.0 degree, return to step 3.
11. Disengage the house lock pin and swing approximately
10 degrees to the left (counterclockwise). Slowly swing
back to the right and engage the house lock pin.
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RT530E-2 SERVICE MANUAL POWER TRAIN
SECTION 7
POWER TRAIN
SECTION CONTENTS
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Water Cooling System . . . . . . . . . . . . . . . . . . . . . 7-17
Electronic Controls. . . . . . . . . . . . . . . . . . . . . . . . . 7-6 Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
Engine Control System Switches and Indicator Antifreeze/Coolant . . . . . . . . . . . . . . . . . . . . . . . . 7-20
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Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6 Radiator Removal and Installation. . . . . . . . . . . . 7-20
Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8 Drive Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22
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Air Intake and Exhaust System . . . . . . . . . . . . . . . 7-9 Transmission/Torque Converter . . . . . . . . . . . . . 7-22
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Air Intake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10 Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . 7-22
Charge-Air Cooler System . . . . . . . . . . . . . . . . . 7-14 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
Muffler and Diesel Oxidation Catalyst - Tier 4 Servicing the Crane After Transmission/Torque
Interim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15 Converter Overhaul . . . . . . . . . . . . . . . . . . . . . . . 7-26
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Slip Joint Exhaust Connectors . . . . . . . . . . . . . . 7-15
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ENGINE circulation. Access to the engine is gained through a door

assembly in the right side of the hood.
Description The air intake filter is mounted on the rear of the left rear
The engine is a Cummins QSB6.7L (Figure 7-1) Tier 3 or Tier fender. The muffler is mounted on the left side of the hood
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4i diesel engine. This Service Manual does not include behind the rear fender.
detailed information on the engine itself. A separate manual
as prepared in detail by the engine manufacturer, is supplied
with this Service Manual. However, a short description and
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maintenance of certain components of the fuel system, air DANGER

intake system, and water cooling system is provided in this Do not spray starting fluid into the air inlet. The spray will
section. contact the heater elements and could explode causing
personal injury.
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The engine is electronically controlled by the Electronic

Control Module (ECM), it is the control center of the system.
It processes all of the inputs and sends commands to the fuel To aid in starting the engine in cold weather, the engine is
systems as well as vehicle and engine control devices. equipped with electric air heating elements that are located
in the engine’s intake air stream to aid in cold starting and
Engine speed is controlled by the foot throttle pedal in the reduce white smoke at start-up. In the preheat mode, the
cab. It controls engine RPM which increases or decreases engine should not be cranked until the WAIT-TO-START
proportionately with the amount of foot pressure applied to lamp turns off. The WAIT-TO-START lamp is illuminated
the pedal. The foot throttle pedal is electrically connected to during the preheat time that takes place when the ignition
the superstructure control module which sends the signal to switch is in the ON position during cold weather starting. The
the engine ECM via the J1939 data link. ECM checks intake manifold temperature to determine how
The engine and its components are enclosed in a hood long to energize the air heater before extinguishing the
assembly with a grill in the rear of the hood for adequate air WAIT-TO-START lamp. Once the engine is started, the
electric air heating element will be energized again for a time
period determined by intake air temperature.

POWER TRAIN RT530E-2 SERVICE MANUAL
Maintenance engine harness and tie up excess harness so it is out of

the way. Remove the radiator. Refer to RADIATOR -
Engine Removal Removal in this Section.
1. Set the outriggers and position the boom to over the 14. Tag and disconnect all lines and tubing from the engine,
side. transmission/torque converter, and all other
components.
2. Open and remove the hood door assembly.
3. Disconnect the air filter tubing at the engine and air
cleaner. Remove and lay aside.
DANGER
4. Disconnect the exhaust tubing at the engine and muffler. The lifting device must be able to support the combined
Lay to the side. weight of the engine and transmission.
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5. Tag and disconnect the engine electrical harness
connector from the carrier harness connector and NOTE: The engine and transmission/torque converter
assembly weighs approximately 1200 kg (2646
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battery cables.
pounds).
6. Remove the start and grid heater relay panel and place
to the side of the frame. Lay the relay panel with the 15. Attach to the engine a lifting device capable of
harness on the engine. If a remote crank option is supporting the weight of the engine and transmission/
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present, disconnect the remote crank harness connector torque converter.
from the engine harness and tie up excess harness so it 16. With the lifting device supporting the weight of the
is out of the way. engine, remove the capscrews, washers and locknuts
7. Drain the engine coolant system. securing the front of the engine to the frame.
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8. Drain the engine lubrication system. 17. Remove the capscrews, washers, nuts, insulator and
mounting plate securing the rear of the engine to the
9. Drain the transmission/torque converter oil system. frame.
10. Evacuate A/C system and capture refrigerant. 18. Using the lifting device, lift the engine and transmission/
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11. Remove the engine hood assembly and pump cover torque converter as an assembly from the crane.
from the machine. 19. If a new engine is to be installed, remove all
12. Disconnect and remove the drive shaft(s) between the components, fittings, etc., from the old engine and install
transmission/torque converter and the axle(s). Refer to them on the new engine in the same locations.
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DRIVE LINES in this Section. NOTE: Ensure that the same grade hardware, torque
13. Tag and disconnect all lines from the radiator. values, and Loctite as were installed by the factory
Disconnect the coolant level sensor harness from the are used.
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1, 2
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2, 3, 4
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View Of Engine
FIGURE 7-1

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5, 6, 7
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6, 9 10
8, 12
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View Of Engine FIGURE 7-1 continued

Figure 7-1 Item Numbers 3. At the front of the engine install the capscrews, washers
and locknuts and secure the engine to the frame. Torque
Item Description the M12 grade 8.8 bolts, see Fasteners and Torque
1 Capscrew Values (pg 1- 12).
2 Washer 4. Remove the lifting device.
3 Dockwasher 5. Connect all lines and tubing to the engine, torque
4 Locknut converter, and all other components in accordance with
the identification marks made during removal.
5 Capscrew
6 Washer
CAUTION
7 Mounting Plate Do not apply sealant to the inside of the hydraulic suction
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8 Washer hoses.
9 Hex Nut
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6. Install the radiator. Refer to RADIATOR - Installation in
10 Dockwasher this Section. Connect all hoses and electrical harnesses
11 Isolator to the radiator as tagged during removal.
12 Capscrew 7. Connect the drive shafts between the transmission/
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torque converter and the axles. Refer to DRIVE LINES
Engine Installation in this Section.
8. Install the hood assembly. Install the pump cover.
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9. Position the start and grid heater relay panel on the right
DANGER side on the frame and secure with the hardware. If
equipped with a remote crank option, reconnect to the
The lifting device must be able to support the combined
engine harness.Connect the battery cables and engine
weight of the engine and transmission.
electrical harness connector in accordance with the
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identification marks made during removal.

NOTE: Use the same grade hardware, torque values, and
Loctite that were used by the factory. 10. Connect the air filter tubing at the engine and the air
filter. Connect the exhaust tubing to the engine and
NOTE: Apply medium strength sealant (Loctite 243) to muffler.
engine attaching hardware.
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11. Charge the A/C system.

1. With all components and fittings installed on the new
engine, lift the engine into the crane. 12. Install the hood top door assembly.
2. With the engine in position, install the mounting plate, 13. Service the transmission, engine lubrication system, and
insulator, nuts, washers and capscrews and secure rear engine cooling system. Refer to Section 9 - 7
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of engine (Figure 7-1). Torque M16 grade 10.9 LUBRICATION.

14. Start the engine. Check all hoses and fittings for leaks.
Recheck all fluid levels.
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OK
OK
OK
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Missing Material Traverse Cracks Longitudinal Cracks Intersecting
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with Transverse Cracks must be Replaced
FIGURE 7-2
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Engine Drive Belts areas, and glazed or shiny surfaces (Figure 7-2). A drive belt
that is glazed or shiny indicates belt slippage.
The proper operation of engine belt-driven components such
as the alternator, fan, and water pump depend on the proper Engine drive belt damage can be caused by various factors
condition and tension of the engine drive belt. such as incorrect tension, incorrect belt size, misaligned
engine pulleys, incorrectly installed belt, or by oil, grease, or
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NOTE: Belt tension is maintained with an automatic belt hydraulic fluid on the belt.
tension device.
Refer to the engine manufacturer’s manual for any special
The engine drive belt should be inspected visually on a daily tools or belt tension specifications.
basis. The drive belt should be inspected for cracks, frayed
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FUEL SYSTEM Maintenance

Description NOTE: The entire fuel system must be maintained air tight
to prevent loss of prime.
The fuel system consists of the fuel tank, strainer, lift pump,
injection fuel pump, fuel-water separator filter and the fuel Fuel Tank
injectors. All components except the fuel tank are installed
The fuel tank should be kept filled, especially overnight, to
on the engine or supplied with the engine for remote
reduce condensation to a minimum. Refer to the applicable
mounting.
engine manual for the recommended schedule for draining
Fuel Tank any water or sediment from the tank.
Removal
The fuel tank (Figure 7-3) is a steel cylinder-type tank
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located on the left side of the machine. The fuel tank has a 1. Position a suitable container under the fuel tank and
draw capacity of 220 l (58 gal). A connection on the bottom of drain all fuel from the tank.
the tank provides for fuel supply to the engine. Surplus fuel
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from the engine is provided to the bottom of the fuel tank 2. Tag and disconnect the lines from the bottom of the tank.
below the fuel level. The tank is equipped with a non-vented 3. Disconnect the electrical lead from the fuel quantity
filler cap, chain-attached to the tank, and a fuel quantity sender unit.
sender unit which provides a signal to a fuel quantity gauge
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on the instrument panel in the cab. 4. Support the weight of the tank, loosen and remove the
hardware securing the straps to the mounting brackets.
Injection Fuel Pump Remove the tank and steps.
The fuel oil is finely atomized as it is injected into the cylinder 5. If a new tank is to be installed, remove the fittings, the
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and ignited by the heat of the compression. It is metered fuel quantity sender, and steps from the tank and install
also, before injection, to meet the load requirements them in the new tank.
imposed upon the engine. Surplus fuel, returning from the Installation
injectors, is bypassed back to the fuel tank or to the inlet side
of the pump. The continuous flow of fuel through the injectors 1. Position the new tank on the mounting brackets and
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helps to cool the injectors and to purge air from the system. install the hardware on the two straps. Torque the
Fuel Filter-Water Separator 2. Connect the electrical lead to the fuel quantity sender
The fuel filter-water separator removes impurities from the unit.
fuel and also removes water from the fuel before it reaches
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3. Connect the two lines to the fittings on the bottom of the

the engine. The filter is mounted on the left side of the tank in accordance with the identification marks made
machine during removal.
The fuel mixture passes through the outer wrap of the first 4. Service the tank.
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stage of the filter paper, where large droplets of water are

formed as it is stripped from the fuel. The water falls out into Fuel Filter-Water Separator
the void between the two paper elements and goes to a
reservoir in the bottom of the housing, where it can be Draining
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drained through a drain plug at the bottom of the housing. The sump of the fuel filter-water separator should be drained
daily, 30 minutes after the engine is shut down, to remove
Electric Lift Pump any water and sediment. Adhere to the following procedure.
The ECM controls the electric lift pump located between the 1. Open the drain plug.
fuel tank and the injection pump. Whenever the keyswitch is
turned to the ON position, the lift pump will be energized for a 2. Drain until fuel appears.
few seconds to make sure the low pressure fuel lines are 3. Close the drain plug.
fully primed. The electric lift pump shuts off after the engine is
started.

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FIGURE 7-3
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Item Description
1 Fuel Tank
2 Fuel Level Sensor
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3 Fuel Supply
4 Fuel Return
5 Mounting Bracket
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6 Fuel Cooler

AIR INTAKE AND EXHAUST SYSTEM 1. Inspect the air cleaner outlet tube for damage.
2. Ensure the element gasket washer is not damaged and
Description the washer’s rubber face seals against the element.
The air intake system (Figure 7-4) controls the quality and 3. Inspect the element gasket for damage.
amount of air available for combustion. System components
are the Air Cleaner, Turbocharger, Charge Air Cooler, 4. Check for structural failures and replace damaged parts.
Cylinder Head, and Exhaust Manifold. Inlet air is pulled 5. Inspect the restriction indicator tap for leaks.
through the Air Cleaner, compressed and heated in the
compressor side of the Turbocharger. The air is pushed Check For Filter Restriction
through the Charge Air Cooler to the Air Inlet Manifold.
As a dry cleaner element becomes loaded with dust, the
Cooling the inlet air increases combustion efficiency, lowers
vacuum on the engine side of the air cleaner (at the air
fuel consumption, and increases the horsepower. The air is
cleaner outlet) increases.
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forced into the cylinder head to fill the inlet ports. Air flow
from the inlet port into the cylinder is controlled by the intake The vacuum is generally measured as restriction in
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valves. kilopascals or inches of water. The engine manufacturer
places a recommended limit on the amount of restriction the
Each cylinder has two intake valves and two exhaust valves.
engine will stand without loss in performance before the
When the intake valves open, cooled compressed air from
element must be cleaned or replaced. Cummins allows a
the inlet port is pulled into the cylinder. The intake valves
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vacuum of 6.2 kPa (25 inches of water) maximum with a dirty
close and the piston begins to move up on the compression
air cleaner at maximum governed RPM.
stroke. Fuel is injected into the cylinder and combustion
starts. The piston is forced down and is on the exhaust stroke A service indicator attached to the air cleaner housing will
when it moves up again. The exhaust valves open and indicate when the filter needs to be replaced. Reset the
exhaust is expelled through the exhaust port into the exhaust indicator each time the air cleaner is serviced. If the
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manifold. indicator’s accuracy is suspect, a water manometer is the
most accurate and dependable method of measuring
The exhaust gas from the exhaust manifold enters the
vacuum.
turbine side of the turbocharger and causes the turbine to
turn driving the compressor. Exhaust from the turbocharger To use the manometer, hold it vertically and fill both legs
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passes through the exhaust pipe and muffler into the approximately half full with water. One of the upper ends is
atmosphere. connected to the restriction tap on the outlet side of the air
cleaner by means of a flexible hose. The other end is left
The Air Cleaner is the dry-type with a replaceable element
open to the atmosphere.
and is located on the left rear fender. A service indicator,
designed to indicate red when servicing is required, is Maximum restriction in the air cleaner occurs at maximum air
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attached to the Air Cleaner. flow. On this turbocharged diesel engine, the maximum air
flow occurs only at maximum engine power.
On the Cummins QSB Engine there are electric air heating
elements that are located in the engine’s intake air stream. With the manometer held vertically and the engine drawing
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These elements heat the intake air when starting the engine maximum air, the difference in the height of the water
in cold ambient conditions. Startability and white smoke columns in the two legs, measured in inches or centimeters,
control are enhanced by the use of the intake air heater. A is the air cleaner restriction. Restriction indicators are
Wait-to-Start Lamp is located on the center front console to generally marked with the restriction at which the red signal
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indicate when to crank the engine. flag locks up.

If the initial restriction on a new or clean filter reads above the
Air Intake
maximum allowed for the engine, check the following items:
Air Cleaner Checks 1. Ensure the air cleaner inlet is not plugged.
Dust passing the air cleaner can cause rapid engine wear. All 2. Inspect the air cleaner outlet to be sure it is not plugged
connections between the air cleaner and the engine must be by paper, rags, etc.
tight and sealed. If these connections are well sealed, and
3. Ensure the correct size connections are used between
there is still evidence of dust leakage, check the following
the air cleaner and the engine.
places for possible trouble.
4. Ensure all inlet accessories are the correct size and are
NOTE: Dust that gets by the air cleaner system can often
not plugged by any foreign object.
be detected by looking for dust streaks on the air
transfer tubing or just inside the intake manifold
inlet.

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8087
Air Intake Installation - Typical
FIGURE 7-4

Figure 7-4 Item Numbers 5. Install new secondary filter (if necessary) and new
primary filter.
Item Description
1 T-bolt Clamp 6. Place the cover back on the air cleaner housing and
secure with clips (1).
2 Elbow
7. Check all connections and ducts for an air tight fit. Make
3 Air Intake Tube sure that all clamps, bolts, and connections are tight.
4 Elbow Check for holes in piping. Leaks in the air intake system
5 Filter Restriction Indicator may send dust directly to the engine.
6 Air Cleaner Assembly 8. Replace decking access plate.
7 Precleaner Element Cleaning
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8 Vacuator Valve
It is not recommended that filter elements be cleaned.
9 Air Cleaner Mounting Bracket Cummins and most other manufacturers will not warrant a
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cleaned air filter.
Filter Element Replacement
Air Cleaner Body
Before installing the filter element, remove foreign material
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CAUTION (leaves, lint or other foreign matter) that may have collected
Never service the air cleaner while the engine is running. inside the air cleaner body. Inspect the inside of the body for
dents or other damage that would interfere with air flow or
1. Lift the clips (1) (Figure 7-5) securing the cover to the air with the fins on the element or inside the body. Repair any
body dents, being careful not to damage the sealing
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cleaner body and remove the cover.
surfaces. Be sure to clean the sealing surface of the outlet
tube and the inside of the outlet tube, taking care not to
1 damage the sealing area on the tube.
Precleaner
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The precleaner (1) (Figure 7-6) prevents large debris from

entering the air cleaner and should be cleaned periodically,
especially when working in severe dust conditions. Remove
the top half of the precleaner by releasing the two latches on
the sides of the precleaner. Remove all debris from inside
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precleaner and reassemble.
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8087-1
FIGURE 7-5
2. Remove primary filter (2) (Figure 7-5) from the air

cleaner and inspect for foreign material and marks of
dust.
3. Remove secondary filter (not shown) from the air
cleaner every third primary filter change. 1
7754
4. Thoroughly clean the sealing surface and inside of the
air filter housing. Inspect all parts of the intake system 2
and air cleaner. FIGURE 7-6

Vacuator Valve Check the condition of the valve and lips frequently and keep
them clean. The valve lips should be open only when the
Vacuator valves (2, Figure 7-6), (1, Figure 7-7) are designed
engine is shut down, or running at low idle speed. If the valve
to expel loose dust and dirt from the air cleaner body
is turned outside in, check for a clogged air cleaner inlet.
automatically, thus lengthening the element service life. The
Malfunction of this valve does not reduce the air cleaner
valve lips must point straight down and be kept free from
effectiveness, but does allow the element to get dirty faster
debris to operate effectively. Mud and chaff can lodge in
and reduces serviceable life. If a valve is lost or damaged,
these lips periodically and hold them open during engine
replace it with a new valve of the same part number.
operation.
Duct Work
1. Check the intake pipe cap and screen for accumulation
of leaves, trash, and other debris that could restrict air
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flow. Repair the screen or replace the cap if any large
holes are found in the screen.
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2. Check all mounting hardware for security to eliminate
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possible vibration of intake piping. Such vibration leads
to early failure of hoses, clamps, and mounting parts,
and can cause hoses to slip off the connecting pipes,
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allowing un-filtered air into the engine air intake.
3. Check hoses for cracks, chafing, or deterioration, and
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FIGURE 7-7 replace at the first sign of probable failure.
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Charge-Air Cooler System loaded T-bolt clamps is 11.3 Nm (100 lb-in). Do not
compress the spring completely, the bellows and/or clamp
The charge-air cooler (CAC) (Figure 7-8) is used to cool may be damaged from thermal expansion of the CAC tube.
engine air after it has passed through a turbocharger, but
before it enters the engine. The charge-air cooler provides Maintenance
better horsepower, increased fuel efficiency, and reduces
engine emissions. Check the hose clamps for proper torque.
The CAC system consists of the ducting to and from the Inspect the bellows for cracks or holes.
charge-air cooler and a hydraulically driven fan. The charge- Clean the charge-air cooler, removing any dirt or debris.
air cooler system must be air-tight in order to work efficiently.
Verify the fan is operating correctly and there are no
The ducting consists of metal tubing, hose clamps and hydraulic leaks.
bellows. The recommended installation torque of the spring
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8089-1
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Charge-Air Cooler
FIGURE 7-8
Item Description
1 CAC
2 Engine Coolant Radiator
3 CAC Hot Air Inlet
4 CAC Cold Air Outlet

Muffler and Diesel Oxidation Catalyst - Tier 4 1. Install the diesel oxidation catalyst into the mounting
Interim band.
2. Connect the tube exhaust weldment/bellows assembly.
Removal
3. Install the muffler into the mounting bands.
4. Attach the elbow to the muffler using the clamp.
5. Install the exhaust tailpipe on the muffler. Secure the
CAUTION exhaust tailpipe to the muffler with clamp. Adjust the
Burn Hazard! clamp as needed.
Do not touch muffler or exhaust parts until they are at 6. Tighten all hardware and clamps.
ambient temperature. Severe burning may result.
7. Install sheet metal guard.
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1. Remove the sheet metal guard to gain access to the
muffler and diesel oxidation catalyst (Figure 7-9). Slip Joint Exhaust Connectors
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2. Remove clamp to free exhaust tailpipe from muffler. Slip joint exhaust couplers require tightening to avoid
exhaust leaks. Perform the following procedures at the
3. Remove clamps to free elbow from muffler. appropriate intervals.
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4. Loosen mounting bands and remove muffler.
After 1000 Hours, or One Year
5. Remove clamp to free exhaust tube.
Visually inspect the exhaust connector. If necessary, tighten
6. Remove clamp to free tube exhaust weldment/bellows the v-clamps by one full turn of the nuts.
assembly and remove.
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7. Loosen mounting band to free diesel oxidation catalyst 2000 Hours or 2 Years
and remove diesel oxidation catalyst.
Tighten the v-clamps by 1 ½ turns of the nuts.
8. Inspect muffler, diesel oxidation catalyst, exhaust
tailpipe, exhaust tubes, bellows, and attaching 4000 Hours or 4 Years
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hardware. Repair or replace any of these parts if

Tighten the v-clamp by 1 ½ turns of the nuts.
damaged or missing.
Installation 5000 Hours or 5 Years

Remove the v-clamps and gaskets, and replace them with
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When assembling the muffler/diesel oxidation catalyst leave

the clamps and mounting hardware loose until the assembly new gaskets and clamps. Tighten the v-clamps to 9.6 to 11.3
is together. Nm (85 to 100 lb-in) of torque.
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12
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1 13 3
14
13 12
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2
11
8
16
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10
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6
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8088
Muffler and Diesel Oxidation Catalyst - Tier 4
FIGURE 7-9
7
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1 Sheet Metal Guard 9 Diesel Oxidation Catalyst
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2 Tail Pipe 10 Muffler Clamp

3 Muffler Clamp 11 Tube Exhaust Weldment
4 Muffler 12 Clamp
5 Mounting Band 13 Gasket
6 Exhaust Tube 14 Bellows
7 Muffler Clamp 15 Tube Exhaust Weldment
8 Mounting Band 16 Elbow

WATER COOLING SYSTEM Most of these problems can be traced to overheating;

however, an engine that is running too cold can be just as
Description troublesome.
The cooling system consists of a radiator, surge tank, engine Overheating

cooling circuit, charge air cooler circuit, the connecting hoses
a nd c o n n e c ti n g t u b es . C o o l i n g s y s te m c a pa c i t y i s An engine that is overheating may lead to troubles such as
approximately 24.6 l (26 qt). The radiator consists of two the following:
sections; the top section is the charge air cooler and the 1. Burned valves.
bottom section is the engine water cooler. The temperature
is controlled by a 83°C (181°F) thermostat located between 2. Pinging or knocking.
the top of the engine and the top of the radiator. At all times, 3. Excessive fuel consumption.
the antifreeze/coolant should be properly inhibited against
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corrosion. It is recommended that a mixture of AFC-50/50 4. Poor lubrication - increased engine wear.
blended ethylene-glycol, low silicate, fully formulated, engine 5. Sticking valves.
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antifreeze/coolant concentrate and water which does not
require a pre-charge of supplemental coolant additives 6. Short injector life.
(SCA) for use in initial fill of heavy duty liquid cooled internal 7. Engine hot spots.
combustion engines be used at all times.
8. Need for higher grade fuel.
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The crane is equipped with a cab hot water heater. Hot water
is supplied by the engine coolant system through a strainer Overcooling
and two port water swivel to the cab heater. The strainer is a
cleanable type and is located on the left side of the The following engine troubles result when an engine is
transmission by the rear engine/transmission mount. Refer overcooled:
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to Section 9 - LUBRICATION for service of the strainer. 1. Excessive fuel consumption.
Maintenance 2. Sludge formation in crankcase.

3. Corrosive acids formed in crankcase.
General
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4. Excessive fuel deposits in the exhaust system.

The cooling system includes the Radiator, Surge Tank,
Thermostat, the Fan, and Water Pump. Radiator hoses are Antifreeze/Coolant
also included in this group.
Heavy duty diesel engines require a balanced mixture of
The cooling system is often neglected because the effects or
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water and antifreeze/coolant. For maximum rust, freeze, and

damage that result from an improperly maintained system boiling point protection, a 50/50 blended, fully formulated
usually occur gradually. The cooling system needs to be extended life antifreeze/coolant should be maintained at all
maintained with the same attention as other systems. times. Refer to Lubrication, page 9-1. Do not use more than
50 percent antifreeze/coolant in the mixture unless additional
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The circulation of water through the cooling system relies

entirely upon the water pump. The water pump draws water freeze protection is required. Never use more than 68
from the radiator and forces it through the water jacket and percent antifreeze/coolant under any condition. Antifreeze/
cylinder head. There it accumulates heat and flows to the coolant at 68 percent provides the maximum freeze
protection; antifreeze/coolant protection decreases above 68
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radiator tank. Then the water flows across through the

radiator core and is cooled by air from the fan. This process percent.
of removing heat from water as it circulates holds the engine
to its efficient operating temperature.
Rust Prevention
The following paragraphs point out several facts about To keep engines operating at like new efficiency, all forms of
cooling system components, the effects of cooling system rust formation must be prevented. The formation of rust in
neglect, and procedures to be followed for cooling system the cooling system is a result of the interaction of water, iron,
maintenance. and oxygen, and can only be prevented by maintaining full
strength corrosion protection at all times. Supplemental
Effects of Cooling System Neglect coolant additives (SCA) are recommended for this cooling
system. Antifreeze/coolant alone does not provide sufficient
Whenever an engine does not perform at top efficiency, a protection for heavy-duty diesel engines. Refer to Section 9
neglected cooling system may be at fault even though the for SCA specification and compatible brands.
part directly responsible is not a part of the cooling system.

Engine Antifreeze/Coolant Fill Procedure - Sulfate level greater than or equal to 1500 ppm.
(when level is low) - Chloride level greater than or equal to 200 ppm.
1. Fill the system with a 50/50 blended, fully formulated - The pH level is less than 6.5
extended life antifreeze/coolant. Fill to the bottom of the
surge tank filler neck. Fill slowly. Flow exceeding 3 gpm - Oil or fuel contamination can be identified by odor or
(11.2 l/min) can give a false reading. color.
NOTE: If the engine coolant is changed, the coolant filter If condemned, flush the system using a commercially
must also be changed. available flushing agent. Refill system with fully
formulated extended life coolant. Refer to Lubrication,
2. Wait one minute and recheck the antifreeze/coolant page 9-1.
level. Refill as necessary repeating step 1.
NOTE: Remove the radiator cap when draining the system
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3. Run the engine for 5 minutes and recheck the to ensure proper draining.
antifreeze/coolant level. Refill as necessary repeating
step 1. Refer to Lubrication, page 9-1. Cleaning
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Antifreeze/Supplemental Coolant Additives
Maintenance Summary
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Cooling System Level Check Interval CAUTION
Burn Hazard!
Daily or 10 hours
The cooling system contains very hot pressurized liquid
The cooling system level should be checked every 10 hours and injury can result when removing the radiator cap at
of operation or daily, whichever comes first. Refer to
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operating temperature. Use proper protection to remove
Lubrication, page 9-1. the radiator cap.
SCA Level Check/Coolant Filter Change Interval
1. Coolant shut-off valves to heaters and other accessories
6 months or 500 hours
should be open to allow complete circulation during
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• Check SCA Levels (use only Coolant Test Kit, Grove P/ cleaning, flushing, and draining. Run the engine with
N 9414101675, to check the coolant additive radiator covered if necessary until temperature is up to
concentration in the cooling system). operating range 160 to 180° F (71 to 82° C). Stop the
engine, remove the radiator cap, and drain the system
The Coolant Filter contains molybdate. Therefore, it is
by opening the drain cocks on the radiator and engine
important to use the Grove Coolant Test Kit, which
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block.
checks the molybdate level, regardless of whether the
SCA used to replenish the coolant system contains NOTE: Use a cleaning compound that is not corrosive to
molybdate or not. aluminum to prevent damage to the radiator.
2. Allow the engine to cool, close the drain cocks, and pour 7
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Only add coolant additive if levels are less than 1.2 units/
gal (see Standard Lubricants Package, page 9-2 for the cleaning compound into the surge tank according to
specification and recommended additives). the directions. Fill the system with water.
NOTE: An inadequate concentration of coolant additive 3. Place a clean drain pan to catch the overflow, and use it
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can result in major corrosive damage to the cooling to maintain the level in the radiator. Do not spill the
system components. Over concentration can solution on the vehicle paint.
cause formation of a “gel” that can cause restriction
4. Replace the radiator cap and run the engine at moderate
or plugging of coolant passages, and overheating.
speed, covering the radiator if necessary, so the system
• Change coolant filter. reaches a temperature of 180° F (82° C) or above, but
does not reach the boiling point. Allow the engine to run
Install charged filter if SCA levels are normal or below
at least two hours, or according to recommendations of
normal; install non-charged filter if SCA levels are above
the manufacturer of the cleaning compound, at 180° F
normal (contact Manitowoc Crane Care for filter part
(82° C) so the cleaning solution may take effect. Do not
number).
drive the vehicle or allow the liquid level in the radiator to
1 year or 1000 hours drop low enough to reduce circulation.
• Test antifreeze/coolant for contamination. 5. Stop the engine as often as necessary to prevent boiling.
Condemning limits are:

6. With the engine stopped, feel the radiator core with bare as to allow a loose fitting cap. Ensure the overflow tube
hands to check for cold spots, and then observe the is not plugged.
temperature gauge reading. When there is no change in
3. Radiator Cap - This is the pressure-setting type. Its
temperature for some time, drain the cleaning solution.
purpose is to hold the cooling system under a slight
7. If clogging of the core is relieved but not fully corrected, pressure, increasing the boiling point of the cooling
allow the engine to cool, pressure-flush the system (see solution and preventing loss of solution due to
Pressure Flushing) and repeat the cleaning operation. evaporation and overflow.
8. If problem persists, replace radiator. The cap has a spring-loaded valve, the seat of which is
below the overflow pipe in the filler neck. This prevents the
Pressure Flushing escape of air or liquid while the cap is in position. When the
cooling system pressure reaches a predetermined point, the
1. Disconnect both radiator hoses that connect the radiator
cap valve opens and will again close when the pressure falls
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to the engine.
below the predetermined point.
2. Clamp a convenient length of hose to the radiator core
When removing the pressure type cap, perform the
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outlet opening, and attach another suitable length of
operation in two steps. Loosening the cap to its first notch
hose to the radiator inlet opening to carry away the
raises the valve from the gasket and releases the pressure
flushing stream.
through the overflow pipe. In the first stage position of the
3. Connect the flushing gun to compressed air and water cap, it should be possible to depress the cap approximately
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pressure, and clamp the gun nozzle to the hose 0.13 in (3 mm). The prongs on the cap can be bent to adjust
attached to the radiator outlet opening. this condition. Care must be taken that the cap is not too
loose as this would prevent proper sealing.
4. Fill the core with water. Turn on air pressure in short
blasts to prevent core damage.
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5. Continue filling the radiator with water and applying air
pressure as above until the water comes out clear. CAUTION
6. Clamp the flushing gun nozzle firmly to a hose attached Burn Hazard!
securely to the engine water outlet opening. Fill the
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Loosen cap slowly and pause a moment to avoid possible

engine block with water, partly covering the water inlet burning by hot water or steam. Continue to turn the cap to
opening to permit complete filling. the left until it can be removed.
7. Turn on compressed air to blow out water and loose
sediment. Continue filling with water and blowing out 4. Tubes are very small and can easily become clogged by
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with air until flushing stream comes out clear. rust and scale. The general condition of the cooling
system and operating temperature are indications as to
8. When the vehicle is equipped with a water heater whether or not tubes are clean. Another good test is to
connected to the cooling system, flush the heater, feel the core for cold spots.
following the same procedure as for the radiator core.
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5. Fins are thin metal sheets that dissipate heat picked up

9. After completing the flushing operation, clean out the by the tubes. They should be kept free of bugs, leaves,
surge tank overflow pipe; inspect the water pump; clean straw etc., so as to allow the free passage of air. Bent
the thermostat and the radiator cap control valves. fins should be straightened.
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Check the thermostat for proper operation before

installation. Engine Water Jacket
10. Blow insects and dirt from the radiator core air The water jacket permits coolant to be circulated around the
passages, using water, if necessary, to soften cylinder walls, combustion chamber, and valve assemblies.
obstructions. Some of these coolant passages are small and can easily
become clogged, if the cooling system does not receive the
Component Inspection proper maintenance.
Radiator/Surge Tank 1. Core Plugs - These are sometimes mistakenly called
freeze plugs. They do not provide protection against
1. Side Tanks - Look for leaks, particularly where the tank is freezing expansion, but are only present because of
attached to the core. Vibration and pulsation from engine block casting methods. Remove and replace
pressure can fatigue soldered seams.
2. core plugs that show signs of leaking or rusting through.
2. Filler Neck - The sealing seat must be smooth and Use an installation tool for core plug replacement.
clean. Cams on filler neck must not be bent or worn so

3. Drain Plugs - The water jacket of each engine could hydrometers are not accurate enough for use with heavy
have one or more drain plugs. These should receive duty diesel cooling systems.
seasonal care and be kept free of rust and scale.
Antifreeze/Coolant
4. Gaskets - All gaskets must be in good condition to
prevent both internal and external leaks. If there are Heavy duty diesel engines require a balanced mixture of
external leaks around gaskets, there may also be water and antifreeze/coolant. Fill the system with a AFC-50/
internal leaks into the engine. Proper tightening of the 50 blended, fully formulated extended life antifreeze/coolant
head bolts with a torque wrench is essential for at all times. Refer to Section 9 - LUBRICATION. Do not use
preventing leaks around the head gasket. more than 50 percent antifreeze/coolant in the mixture
unless additional freeze protection is required. Never use
Water Pump more than 68 percent antifreeze/coolant under any
The pump should be checked carefully for leaks and proper condition. Antifreeze/coolant at 68 percent provides the
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lubrication. Replace or rebuild if leaking, cracked, or worn. maximum freeze protection; antifreeze/coolant protection
decreases above 68 percent.
Fans and Belts
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Radiator Removal and Installation
The fan should be checked for cracked or broken blades.
Refer to Engine Drive Belts, page 7-6. Removal
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1. Set the outriggers and position the boom to over the
Thermostat
side.
The thermostat is of the nonadjustable type and is
2. Open the drain cock at the end of the hose coming from
incorporated in the cooling system for the purpose of
the water pump (under the front of engine) and drain the
retarding or restricting the circulation of coolant during
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coolant into a suitable container. Dispose of in
engine warm up. Engine overheating and loss of coolant is
accordance with local and EPA regulations.
sometimes due to an inoperative thermostat. To check for
t h i s c o n d i t i o n , r e m o v e t h e t h e r m o s ta t a n d t e s t b y 3. Tag and disconnect all hoses from the top, middle, and
submerging it in hot water and noting the temperature at bottom sections of the radiator assembly.
which the thermostat opens and closes. Use an accurate
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4. Remove the hardware attaching the fan guard to the

high temperature thermometer for making this test.
shroud. The fan guard will remain with the engine.
Hoses and Clamps 5. Remove the hardware securing the support plate on
Hoses and their connections must be checked regularly each side of the radiator.
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because they are often the source of hidden trouble. Hoses NOTE: The radiator assembly weighs approximately
may often times appear in good condition on the outside 44.4 kg (97.9 lb).
while the inside will be partially deteriorated. If there are any
doubts about a hose doing its job, replacement should be 6. Attach an adequate lifting device to the radiator
assembly.
made. The clamps should be inspected to make sure they 7
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are strong enough to hold a tight connection. 7. Remove the hardware securing the radiator to the mount
bracket and remove the radiator assembly from the
Test Equipment carrier.
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The antifreeze/coolant concentration must be checked using

a refractometer. “Floating ball” type density testers or

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8089-2 FIGURE 7-10
Installation
Item Description
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1. Position the radiator assembly in the carrier using a

1 Radiator Assembly lifting device and secure the radiator to the mount
2 Drain Cock bracket with the hardware.
3 Fan Guard 2. Secure the support plates to each side of the radiator
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using a bolt.
4 Overflow Tank
3. Attach the fan guard to the shroud using the hardware.
4. Connect all hoses to the radiator assembly as tagged
during removal.
5. Ensure the drain cock is closed.
6. Service the engine coolant system, transmission oil
system, and the hydraulic system as necessary. Start
the engine, operate all systems and check for leaks.

DRIVE TRAIN Transmission/Torque Converter

Description Description
The drive train consists of the transmission/torque converter The transmission/torque converter assembly is mounted to
assembly and three drive lines. the engine and is connected to the front and rear axles by
two drive shafts. The main hydraulic pump is mounted on the
The transmission/torque converter is mounted to and driven
torque converter housing.
by the engine. The torque converter assembly provides for
mounting and driving the pumps. The transmission is a Theory of Operation
powershift with six forward speeds and six reverse speeds.
The transmission is controlled electrically by a shift lever/ The transmission and torque converter function together and
knob located on the right side of the steering column and an operate through a common hydraulic system. Therefore, it is
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axle drive mode selector rocker switch located on the left necessary to consider both units in discussing operation.
side of the front console.
With the engine running, the converter charging pump draws
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The transmission/torque converter oil is cooled by passing oil from the transmission sump through the removable oil
the oil through an externally mounted transmission cooler. suction screen and directs it through the pressure regulating
The cooler is part of the radiator. An oil filter is located on the valve and oil filter.
left side of the frame bottom rail.
The pressure regulating valve maintains pressure to the
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Three drive lines are used. Two drive lines are connected transmission control for actuating the direction and speed
between the transmission and the front axle and the other clutches. This requires a small portion of the total volume of
drive line is connected between the transmission/torque oil used in this system. The remaining volume of oil is
converter and the rear axle. directed through the torque converter circuit to the oil cooler
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and returns to the transmission for positive lubrication. This
Maintenance regulator valve consists of a hardened valve spool operating
in a closely fitted bore. The valve spool is spring loaded to
Drive Lines hold the valve in a closed position. When a specific pressure
is achieved, the valve spool works against the spring until a
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port is exposed along the side of the bore. This sequence of

CAUTION events provides the proper system pressure.
Do not disassemble drive lines when removing them from After entering the converter housing, the oil is directed
the crane. Dirt can enter the spline and cannot be purged. through the reaction member support to the converter blade
In addition, the drive lines are assembled in a specific cavity and exits in the passage between the turbine shaft and
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orientation when manufactured and can easily be reaction member support. The oil then flows out of the
incorrectly reassembled. converter to the oil cooler. After leaving the cooler, the oil is
directed to a fitting on the transmission. Then, through a
Removal series of tubes and passages, lubricates the transmission
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1. Support the drive line being removed so it does not fall bearings and clutches. The oil then gravity drains to the
when disconnected. transmission sump.
2. Remove the bolts from the bearing cap on each end of The torque converter consists basically of three elements
and their related parts to multiply engine torque. The engine
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the drive line.

power is transmitted from the engine flywheel to the impeller
3. Remove the drive line. element through the impeller cover. This element is the
Installation pump portion of the hydraulic torque converter and is the
primary component which starts the oil flowing to the other
1. Position the drive line, install the bearing cap bolts and components which results in torque multiplication. This
tighten bolts securely. element can be compared to a centrifugal pump, in that it
picks up fluid at its center and discharges at its outer
2. Torque the inboard bearing cap bolts on the drive line to
diameter.
85 to 112 Nm (63 to 83 lb-ft) and outboard bearing caps
to 122 to 149 Nm (90 to 110 lb-ft). The torque converter turbine is mounted opposite the
impeller and is connected to the output shaft of the torque
Lubrication
converter. This element receives fluid at its outer diameter
The drive line slip joints require lubrication. Refer to Section and discharges at its center. Fluid directed by the impeller
9 - Lubrication. out into the particular design of blading in the turbine and

reaction member is the means by which the hydraulic torque Maintenance

converter multiplies torque.
The reaction member of the torque converter is located General Information
between and at the center of the inner diameters of the 1. Always check the oil level with the engine idling, and the
impeller and turbine elements. Its function is to take the fluid transmission in neutral and at normal operating
which is exhausting from the inner portion of the turbine and temperature (82 to 93°C [180 to 200°F]).
change its direction to allow correct entry for recirculation
into the impeller element. 2. Change the oil filter element every 500 hours. Drain and
refill the system every 1000 hours or 6 months.
The torque converter will multiply engine torque to its
designed maximum multiplication ratio when the output shaft Troubleshooting
is at zero rpm. Therefore, as the output shaft is decreasing in
speed, the torque multiplication is increasing. The following data is presented as an aid to locating the
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source of difficulty in a malfunctioning unit. It is necessary to
The shift control valve assembly consists of a valve body consider the torque converter charging pump, transmission,
with selector valve spools. A detent ball and spring in the
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oil cooler, and connecting lines as a complete system when
selector spool provides one position for each speed range. A checking for the source of trouble, since the proper operation
detent ball and spring in the direction spool provides three of any unit therein depends greatly on the condition and
positions, one each for forward, neutral, and reverse. operation of the others. By studying the principles of
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With the engine running and the lever in the neutral position, operation together with the data in this section, it may be
oil pressure from the regulating valve is blocked at the possible to correct any malfunction which may occur in the
control valve, and the transmission is in neutral. Movement system. Troubleshooting procedures basically consist of
of the forward and reverse spool will direct oil, under hydraulic checks.
pressure, to either the forward or reverse direction clutch, as
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Hydraulic Checks
desired. When either directional clutch is selected, the
opposite clutch is relieved of pressure and vents back Before checking the transmission/torque converter and
through the direction selector spool. The same procedure is associated hydraulic system for pressures and rate of oil
used in the speed selector. flow, it is essential that the following preliminary checks be
made.
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The direction or speed clutch assembly consists of a drum

with internal splines and a bore to receive a hydraulically 1. Check oil level in transmission. This should be done with
actuated piston. The piston is oil tight by the use of sealing oil temperature at 82 to 93°C (180 to 200°F). Do not
rings. A steel disc with external splines is inserted into the attempt these checks with cold oil.
drum and rests against the piston. Next, a friction disc with 2. To bring the oil temperature to this level, it is necessary
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splines at the inner diameter is inserted. Discs are alternated to either work the machine or stall out the converter.
until the required total is achieved. A heavy back-up plate is When it is impractical to work the machine, stall out the
then inserted and secured with a snap ring. A hub with OD converter as follows.
splines is inserted into the splines of discs with teeth on the
a. Apply the parking brake.
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inner diameter. The discs and hub are free to increase in

speed or rotate in the opposite direction as long as no b. Position the shift lever to forward and high speed.
pressure is present in that specific clutch.
c. Accelerate the engine to between half and three-
To engage the clutch, the control valve is placed in the quarter throttle.
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desired position. This allows oil under pressure to flow from

the control valve, through a tube, to a chosen clutch shaft.
This shaft has a drilled passageway for oil under pressure to CAUTION
enter the shaft. Oil pressure sealing rings are located on the
Full throttle stall speeds for an excessive length of time
clutch shaft. These rings direct oil under pressure to the
will overheat the torque converter.
desired clutch. Pressure of the oil forces the piston and discs
against the heavy back-up plate. The discs, with teeth on the
d. Hold converter stalled until desired temperature is
outer diameter, clamping against discs with teeth on the
reached.
inner diameter, enables the hub and clutch shaft to be locked
together and allows them to drive as a unit. NOTE: Always make all troubleshooting checks with the
converter outlet temperature at least 82.3 to 93.3°C
There are bleed balls in the clutch piston which allow quick
(180 to 200°F).
escape for oil when the pressure to the piston is released.

Troubleshooting Procedures
SYMPTOM PROBABLE CAUSE REMEDY

1. Low clutch pressure. a. Low oil level. a. Fill to proper level. Refer to
Section 9 - LUBRICATION.
b. Clutch pressure regulating b. Clean valve spool and housing.
valve spool stuck open.
c. Faulty charging pump. c. Replace pump.
d. Broken or worn clutch shaft or d. Replace clutch shaft or sealing
piston sealing rings. rings, as applicable.
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e. Clutch piston bleed valve stuck e. Clean bleed valves thoroughly.
open.
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2. Low converter charging pump a. Low oil level. a. Fill to proper level.
pressure.
b. Suction screen plugged. b. Clean suction screen.
c. Defective oil pump. c. Replace pump.
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3. Overheating. a. Worn oil sealing rings. a. Remove, disassemble, and
rebuild converter assembly.
b. Worn oil pump. b. Replace pump.
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c. Low oil level. c. Fill to proper level.
4. Noisy converter. a. Worn oil pump. a. Replace pump.
b. Worn or damaged bearings. b. A complete disassembly will be
necessary to determine what
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bearing is faulty.
5. Lack of power. a. Low engine RPM at converter a. Tune engine and check
stall. governor.
b. See “Overheating” and make b. Make corrections as explained
same checks. in “Overheating.”
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Removal 7. Remove the hardware securing the transmission/torque

converter housing to the engine flywheel housing.
1. Extend and set the outriggers just enough to take up the
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slack in the outrigger pads. Chock the wheels. Installation

2. Position the boom over the side and stop the engine. NOTE: The transmission/torque converter assembly
3. Remove the engine and transmission/torque converter weighs approximately 374 kg (824.5 lb) dry.
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from the crane as an assembly. Refer to ENGINE in this 1. If a new transmission/torque converter is to be installed,
Section. remove all fittings and brackets from the old one and
4. Remove the hydraulic pumps from the transmission/ i n s ta l l t h e m i n t h e s a m e l o c a t i o n s o n t h e n e w
torque converter. Cover all openings. Refer to Hydraulic transmission/torque converter.
Pumps in Section 2 for removal of the pump. 2. Install the piston and single section hydraulic pumps on
NOTE: The transmission/torque converter weighs the transmission/torque converter. Refer to Hydraulic
approximately 374 kg (824.5 lb) dry. Pumps in Section 2 for installation of the hydraulic pump.
5. Attach an adequate lifting device to the transmission/ 3. Position the transmission/torque converter to the engine
torque converter and take up any slack. with the lifting device.
6. Remove the hardware securing the drive plate assembly 4. Remove all burrs from the flywheel mounting face and
to the flywheel. nose pilot bore. Clean the drive plate surface with
solvent (Figure 7-11).

MOUNT
DIAL
INDICATOR
HERE
FLYWHEEL
HOUSING
ENGINE
FLYWHEEL
PILOT
BORE
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FLYWHEEL
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CONVERTER
HOUSING
FLYWHEEL
10.2 cm
(4 in.) STUD
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6.4 cm
(2-1/2 in.)
ALIGNING
STUDS
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DRIVE
PLATE
FLYWHEEL
HOUSING SPECIAL STUD, WASHER AND
SELF-LOCK NUT FURNISHED
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BY ENGINE MANUFACTURER
FLYWHEEL
HOUSING
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IMPELLER
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COVER
(3) INTERMEDIATE
DRIVE PLATES
FIGURE 7-11

5. Check the engine flywheel and housing for conformance Servicing the Crane After Transmission/
to standard S.A.E. No. 3-S.A.E. J-927 tolerance Torque Converter Overhaul
specifications for bore size, pilot bore runout and
mounting face flatness. Measure and record engine The transmission/torque converter and its allied hydraulic
crankshaft end play. system are important links in the drive line between the
engine and the wheels. The proper operation of either the
6. Install two 63.5 mm (2.50 in) long transmission to
unit or the system depends greatly on the condition and
flywheel housing guide studs in the engine flywheel
operation of the other; therefore, whenever repair or
housing as shown in the figure titled Transmission/
overhaul of the transmission/torque converter is performed,
Torgue Converter Installation. Rotate the engine
the balance of the system must be considered before the job
flywheel to align a drive plate mounting screw hole with
can be considered completed.
the flywheel housing front access hole.
After the overhauled or repaired transmission/torque
7. Install a 101.6 mm (4.00 in) long drive plate locating stud
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converter has been installed in the crane, the oil cooler and
0.3750-24 fine thread in a drive plate nut.
connecting hydraulic system must be thoroughly cleaned.
8. Rotate the transmission/torque converter to align the This can be accomplished in several ways, and a degree of
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locating stud in the drive plate with the flywheel drive good judgement must be exercised as to the method
plate mounting screw hole positioned in step 6. Locate employed.
the transmission on the flywheel housing, aligning the
The following are considered the minimum steps to be taken:
drive plate to the flywheel and the transmission to the
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flywheel housing guide studs. Install the transmission to 1. Drain the entire system thoroughly.
flywheel housing nuts and washers. Tighten the bolts to
2. Disconnect and clean all hydraulic lines. Where feasible,
41 to 43 Nm (30 to 32 lb-ft). Remove the transmission to
hydraulic lines should be removed from the machine for
engine guide studs. Install the two remaining bolts and
cleaning.
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washers and tighten the bolts to 41 to 43 Nm (30 to 32
lb-ft). 3. Replace oil filter elements, cleaning out the filter cases
thoroughly.
9. Remove the drive plate locating stud. Install one drive
plate attaching screw and lockwasher. Snug the screw 4. The oil cooler must be thoroughly cleaned. The cooler
but do not tighten. NOTE: Some engine flywheel should be back flushed with oil and compressed air until
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housings have a hole located on the flywheel housing all foreign material has been removed. Flushing in the
circumference in line with the drive plate screw access direction of normal oil flow will not adequately clean the
hole. A screwdriver or pry bar used to hold the drive cooler. If necessary, the cooler assembly should be
plate against the flywheel will facilitate installation of the removed for cleaning, using oil, compressed air and a
drive plate screws. Rotate the engine flywheel and install steam cleaner for that purpose.
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the remaining seven flywheel to drive plate attaching

screws and lockwashers. Snug the screws but do not
tighten. After all eight screws and lockwashers have CAUTION
been installed, torque the screws to 38 to 41 Nm (28 to Do not use flushing compounds for cleaning purposes.
7
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30 lb-ft). This will require torquing each screw, then

rotating the engine flywheel until all eight screws have 5. Remove the drain plug from the transmission/torque
been torqued. converter and inspect the interior of the unit housing,
gears, etc. If the presence of considerable foreign
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10. Measure the engine crankshaft end play after the

transmission/torque converter has been completely material is noted, it will be necessary for the unit to be
installed on the engine flywheel. This value must be removed, disassembled, and cleaned thoroughly. It is
within 0.025 mm (0.001 in) of the end play recorded in realized this entails extra labor, however, such labor is a
step 5. minor cost compared to the cost of difficulties which can
result from the presence of such foreign material in the
11. Install the engine and transmission/torque converter in system.
the crane as an assembly. Refer to Section 7 - POWER
TRAIN. 6. Assemble all components and use only the type oil
recommended. Fill the transmission through the fill pipe
12. Service the crane as required in Servicing The Crane until fluid is at the top of the fill range on the dipstick. Run
After Transmission/torque Converter Overhaul in this the engine for two minutes at idle (950 rpm) to prime the
section. torque converter and hydraulic lines. Recheck the level
13. Cycle all functions and observe for proper operation. of oil in the transmission with the engine running at idle
(950 rpm). Add oil as necessary to bring the level to the
LOW mark on the dipstick. After the oil temperature

reaches 82 to 93°C (180 to 200°F), add oil to bring the contamination. For extreme conditions, judgment
level to the FULL mark on the dipstick. must be used to determine the required change
intervals.
7. Recheck all drain plugs, lines, connections, etc., for
leaks and tighten where necessary. Every 500 hours, change oil filter element. Every 1000 hours
or 6 months, drain and refill system as follows: Drain with oil
Lubrication at 66 to 93°C (150 to 200°F).
Type Of Oil NOTE: It is recommended that filter elements be changed
after 50 and 100 hours of operation on new and
Hydraulic Oil (HYDO) or equivalent. Refer to Section 9 -
rebuilt or repaired units, then at normal intervals
LUBRICATION.
thereafter.
Capacity a. Drain transmission and remove pump screen. Clean
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System Capacity (includes torque converter, lines, and screen thoroughly and replace, using a new gasket.
transmission) - Approximately 24 l (25 qt). b. Remove and discard oil filters. Clean filter housing
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and install new filters.
Check Period
c. Refill transmission to LOW mark.
Check oil level every 10 hours or DAILY with engine running
at 950 RPM and oil at 83 to 94°C (180 to 200°F). Maintain oil d. Run engine at 950 RPM to prime converter and
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level to FULL mark. lines.
Normal Drain Period e. Recheck level with engine running at 950 RPM and
add oil to bring level to LOW mark. When oil
NOTE: Normal drain periods and filter change intervals are temperature is hot (83 to 94°C [180 to 200°F]),
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f o r a v e r a g e e n v i r o n m e n ta l a n d d u t y - c y c l e make final oil level check. BRING OIL LEVEL TO
conditions. Severe or sustained high operating FULL MARK.
temperatures or very dusty atmospheric conditions
will cause accelerated deterioration and
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RT530E-2 SERVICE MANUAL UNDERCARRIAGE
SECTION 8
UNDERCARRIAGE
SECTION CONTENTS
Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 Service Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16
Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . 8-7 Corrosion Protection . . . . . . . . . . . . . . . . . . . . . . 8-20
Steering Systems . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8 Parking Brake Actuator. . . . . . . . . . . . . . . . . . . . . 8-22
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Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . 8-8 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22
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Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9 Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
Rear Steering System. . . . . . . . . . . . . . . . . . . . . 8-10 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
Hydraulic Pumps. . . . . . . . . . . . . . . . . . . . . . . . . 8-11 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
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Front Steering Control Valve. . . . . . . . . . . . . . . . 8-11 Park Brake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24
Integrated Outrigger/Rear Steer Manifold. . . . . . 8-11 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24
Steer Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12 Outriggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24
Rear Axle Oscillation Lockout System . . . . . . . . 8-13 Outrigger Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . 8-24
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
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Outrigger Beam . . . . . . . . . . . . . . . . . . . . . . . . . . 8-28
Axle Oscillation Lockout Cylinders . . . . . . . . . . . 8-13 Extension Cylinder. . . . . . . . . . . . . . . . . . . . . . . . 8-33
Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14 Outrigger Monitoring System
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14 (Optional—Standard in North America) . . . . . . . . 8-34
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . 8-14 Jack Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-34
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Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15 Outrigger Control Valves . . . . . . . . . . . . . . . . . . . 8-36

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AXLES The hypoid pinion and differential assembly of the first

reduction are supported by tapered roller bearings. The
Description pinion bearing preload is adjusted and maintained by a
hardened precision spacer between the inner and outer
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To provide maximum maneuverability, both the front and rear bearing. The differential tapered bearing preload is adjusted
axles are steerable. The rear axle (Figure 8-1) is mounted on and maintained by the positioning of the threaded adjusting
a pivoting cradle (fifth wheel) which allows the axle to rings in the carrier leg and cap bores.
oscillate while traversing uneven terrain. The front axle
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(Figure 8-2) is bolted directly to the frame. All four wheels In the planetary wheel ends, the spur teeth of the sun gear
utilize a hydraulic braking system. The axles are equipped mesh with teeth of the planet spur gears. The planet spur
with disc type brakes. A disc-type parking brake is mounted gears rotate on planet pins which are mounted in a spider.
The planet spur gear teeth in turn mesh with teeth of the
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on the front axle input shaft, at the transmission.
floating ring gear.
Each axle incorporates a single reduction carrier with hypoid
gearing mounted in the axle center. The final reduction is of Power is transmitted by the hypoid gear set in the differential
planetary design spur gearing built into the wheel hubs. carrier to the axle shafts and the sun gear of the final
reduction, through the revolving planet gears, and into the
The design of these axles permits the hypoid gearing of the planetary spider which drives the wheel hub.
differential carrier and the axle shafts to carry only a nominal
torsional load while at the same time providing the highest As an option, the front axle and rear axle may be provided
practical numerical gear reduction at the wheels. with a differential lock. When in the locked mode, the axle
shafts and the differential are locked together and there is no
differential action between the wheels.

UNDERCARRIAGE RT530E-2 SERVICE MANUAL
Maintenance 6. On the left side of the rear axle only, tag and disconnect
the electrical wires from the rear wheels not centered
NOTE: The axles do not have to be removed from the switch.
crane to remove the planetary wheel ends or the
drive units. NOTE: Each tire and wheel assembly weighs
approximately 414 kg (912 lb).
Removal 7. Remove the tire and wheel assemblies from the axle.
1. Using the outriggers, raise the wheels off the ground. NOTE: Each axle weighs approximately 1053 kg (2321 lb)
2. Install blocking under the frame at the outboard ends of with oil.
the four outrigger boxes. 8. Position jacks, which are capable of handling the weight
of the axle, under the axle for support.
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CAUTION 9. Remove the eight nuts, washers, and capscrews
Do not disassemble drive lines when removing them from securing the axle to the frame/cradle (Figure 8-1)
(Figure 8-2).
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the crane. Dirt can enter the spline and cannot be purged.
In addition, the drive lines are assembled in a specific 10. Lower the axle to the ground and remove it to a clean
orientation when manufactured and can easily be working area.
incorrectly reassembled.
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11. If a new axle is to be installed, remove the following from
3. Disconnect and remove the drive line from the the old axle and install them on the new one.
applicable axle. Do not disassemble the drive lines. a. The steer cylinders. Refer to Steer Cylinders in this
Refer to Power Train, page 7-1. section.
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4. Tag, disconnect, and cap the hydraulic brake line at b. The rear wheels not centered switch actuator
each wheel. bracket (rear axle only).
5. Tag, disconnect, and cap the hydraulic lines to the steer
cylinders.
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19
20
18
1
14
1 15
2
16 13
17 7
8
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3 21
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22 23
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6
11 10
12
9
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5
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8481 FIGURE 8-1

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1 Cotter Pin 12 Capscrew
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2 Pin 13 Washer
3 Pin 14 Hex Nut
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4 Lockout Cylinder 15 Capscrew
5 Steer Cylinder 16 Lockwasher
6 17 Flatwasher
7 Pin Weld 18 Sensor Plate
8 Pin Weld 19 Capscrew
9 Capscrew 20 Lockwasher
10 Lockwasher 21 Rear Axle
11 Flatwasher 22 Grease Fitting
23 Flatwasher

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4
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9
10
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6
7 11
8
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12
13
9
2
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14
6763
FIGURE 8-2
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1 Front Axle 8 Flatwasher
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2 Capscrew 9 Steer Cylinder

3 Hex Nut 10 Pin Weld
4 Washer 11 Grease Fitting
5 Pin Weld 12 Flatwasher
6 Capscrew 13 Lockwasher
7 Lockwasher 14 Capscrew

Cleaning 10. Remove the blocking under the outrigger beams and
retract the outriggers to lower the wheels to the ground.
Completely assembled axles may be steam cleaned on the
outside only, to facilitate initial removal and disassembly, Wheel Alignment Check Procedure
providing all openings are closed. Breathers, vented shift
units, and all other openings should be tightly covered or 1. Check the axle for wheel alignment. The wheels are to
closed to prevent the possibility of water entering the be straight ahead with no toe-in or toe-out. Adjust if
assembly. necessary by turning the tie rod ends in the direction
necessary.
Installation 2. Turn the wheels to the extreme left. Check the clearance
1. If a new axle is to be installed, remove the following from between the inside of the tire and the nearest object. If
the old axle and install them on the new one. the clearance is less than 25 mm (1.0 in) on the rear
axle or 13 mm (0.5 in) on the front axle, adjust the axle
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a. The steer cylinders. Refer to Steer Cylinders in this stop to provide clearance. Do not adjust axle stop if
section. clearance is greater than 25 mm (1.0 in).
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b. The rear wheels not centered switch actuator Check the steer cylinders to see that they are not
bracket (rear axle only). bottomed out. To check the steer cylinders, remove the
2. Position the axle under the crane on jacks which are pin at the rod end and apply pressure to move the
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capable of handling the weight of the axle. cylinder rod. The cylinder rod should travel a minimum of
3.0 mm (0.12 in).
3. Raise the axle into place and secure with the eight
attaching capscrews, washers and nuts. Torque the 3. Turn the wheels to the extreme right and repeat step 2
capscrews. Refer to Fasteners and Torque Values, page for the right side.
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1-12.
Rear Steer Indicator Adjustment Procedure
4. Install the wheels onto the axle. Refer to Wheels and
Tires in this section. 1. Ensure the wheels are straight ahead.
5. Connect the hydraulic lines to the steer cylinder as NOTE: Refer to (Figure 8-3) to perform the following
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tagged during REMOVAL. adjustments.
6. Connect the hydraulic brake line to each wheel as 2. Ensure proximity sensor switch is centered in the slot of
marked during removal. the sensor plate bolted to the top of the axle trunnion
cap. Adjust by moving the sensor mounting bracket.
7. On the left side of the rear axle only, connect the
3. Ensure a maximum gap of 5 mm (0.2 in) exists between
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electrical wires to the rear wheels not centered switch.

Refer to Rear Steer Indicator Adjustment in this sub- the sensor switch and the sensor plate. Adjust by
section and adjust the switch. loosening switch mounting bolts and moving switch up
or down on the mounting bracket. Tighten the mounting
8. Connect the drive line to the applicable axle. Refer to bolts.
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Drive Lines in Section 7 - POWER TRAIN.

4. Turn the rear wheels to verify proper operation. The
9. Refer to Brake System in this section and bleed the Rear Wheels Not Centered indicator in cab should not
hydraulic brake system. be illuminated when rear wheels are centered and the
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sensor switch is centered in the slot of the sensor plate.

3, 4
2
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5, 6, 7, 8
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6758-1
FIGURE 8-3
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Item Description
1 Sensor Plate
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2 Proxy Switch
3 Bracket
4 Rear Steer Bracket Shim
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5 Capscrew
6 Hex Nut
7 Flat Washer
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8 Lock Washer

Wheels and Tires Maintenance
Description
The standard tire size for this unit is 20.5 x 25 -24 ply. A size
DANGER
16.00 x 25 -28 ply tire is also available. Do not attempt to demount or mount tires without proper
training. The high pressures involved can cause tire and
rim parts and tools to fly with explosive force, if proper
procedures are not used, causing severe injury or death
to personnel and damage to the crane and surrounding
WARNING area.
Possible equipment damage and/or
personal injury! Mounting Wheel Assemblies
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Driving the crane with a tire under inflated at 80% or less NOTE: Do not lubricate the wheel studs or lug nuts.
of its recommended pressure can cause the wheel and/or
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tire to fail. Per OSHA Standard 1910.177(f)(2), when a tire
has been driven under inflated at 80% or less of its
recommended pressure, it must first be completely
deflated, removed from the axle, disassembled, and
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inspected before re-inflation.
1
12 5
CAUTION 9
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Do not mix tires and rims of different manufacturers. 8
3
Each wheel assembly (tire and rim) is mounted on the
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planetary hub with 12 grade 8 lug nuts.
7
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NOTE: The tire diameters, widths, and weights may vary 10

slightly depending on the tire manufacturer.
6 11
Off-highway tires are designed to operate with a certain 2
sidewall deflection or bulge. Correct air pressure ensures
prior deflection which, in turn, ensures proper traction,
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flotation, support of load, and prevents excessive flexing of

the tire. Over inflation increases rim stresses, which results
in lowered rim life. FIGURE 8-4
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Refer to and adhere to the inflation pressures in the Load NOTE: Prior to wheel installation, remove any dirt or
Chart Book in the crane cab. grease from wheel mounting surface.
1. Position the wheel assembly on the mounting studs
being careful not to damage threads. Install the lug nuts
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and tighten them to 68 Nm (50 lb-ft) in the sequence

shown in (Figure 8-4)
2. Ensure the wheel assembly is positioned properly on the
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hub.
3. Torque the lug nuts 461 to 488 Nm (340 to 360 lb-ft) in
the sequence shown in (Figure 8-4).
4. Retorque lug nuts after approximately one hour of travel.

STEERING SYSTEMS the control valve and two steer cylinders. It is activated by
the rear steer control switch located on the left armrest in the
Description cab.
To maximize maneuverability, the crane can be steered by A rear steer indicator system is provided to indicate when the
the front axle, the rear axle, or by the front and rear axles rear wheels are not centered. This system consists of an
simultaneously. The crane utilizes two separate steering indicator light located on the CCS Main Screen display in the
systems, one to control front axle steering and one for rear cab and a switch located on the right side of the rear axle.
axle steering. When the rear wheels are turned to the left or right, the
amber indicator light will illuminate.
Front Steering System
Theory of Operation
NOTE: Pump figures in following text are theoretical.
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The front steering system consists of a hydraulic pump, load Front Steering System
sense steer priority flow divider valve (part of the swing A hydraulic oil flow from pump number 2 flows through port 5
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directional control valve), load sense steering control valve, of the hydraulic swivel to the steer/swing directional control
and two steer cylinders. valve. Regulated flow from the steer priority flow divider
The hydraulic pump is driven by the engine and supplies a valve is routed to the steering control valve upon turning of
hydraulic flow of 82.9 l/min (21.9 gpm) to the load sense the steering wheel and pressurizing of the load sense line.
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steering priority flow divider. The load sense steer priority The steering control valve routes the oil to the appropriate
flow divider valve provides 26.5 l/min (7 gpm) to the load ends of the front steer cylinders to turn the wheels in the
sense steering control valve and the remainder to the swing desired direction.
system.
Rear Steering System
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When the steering wheel is turned, the load sense steering
control valve sends a load sense signal to the load sense Hydraulic flow from pump number 1 is directed through the
steer priority flow divider. As the load sense pressure integrated outrigger valve to the rear steer/outrigger
increases, the priority flow divider spool shifts to direct oil manifold. When the rear steer control switch in the cab is
from the hydraulic pump to the steering control valve, and to positioned to steer left (push top of switch) or steer right
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direct oil from the L (left) port and R (right) port of the steering (push bottom of switch), a signal is sent to the directional
control valve to the steer cylinders. control valve spool, routing the supply pressure to the
appropriate ends of the rear steer cylinders to turn the
Rear Steering System wheels in the desired direction.
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The rear steering system is controlled through a section of

the integrated outrigger/rear steer manifold and consists of
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Maintenance
Front Steering System

Troubleshooting
Table 8-1

1. Hard to steer left and right. a. Hydraulic oil low. a. Refill hydraulic reservoir.
Refer to Section 9 -
LUBRICATION
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b. Clogged or loose hydraulic b. Clean or tighten lines or
lines or fittings. fittings. (Refer to your
Manitowoc Crane Care Parts
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Manual)
c. Defective flow divider c. Repair or replace valve(s).
valve(s).
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d. Defective steering control d. Repair or replace valve.
valve.
e. Defective hydraulic pump. e. Repair or replace pump.
2. Hard to steer either left or right. a. Clogged or loose hydraulic a. Clean or tighten lines or
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lines or fittings. fittings. Refer to Section 9 -
LUBRICATION
b. Defective steer cylinder. b. Repair or replace cylinder.
3. Steering is erratic left and right. a. Hydraulic oil low. a. Refill hydraulic reservoir.
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LUBRICATION.
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c. Defective steering control c. Repair or replace valve.

valve.
d. Defective hydraulic pump. d. Repair or replace pump.
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4. Noisy hydraulic pump caused by a. Hydraulic oil low. a. Refill hydraulic reservoir.
cavitation. Refer to Section 9 -
LUBRICATION
b. Suction line plugged or too b. Clean line and check for size.
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small.
5. Hydraulic pump shaft seal
leakage.
a. Worn shaft seal. a. Replace shaft seal.
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NOTE: If replacing the shaft seal
does not stop leakage, the
pump should be
disassembled and checked
for the following:
b. Broken diaphragm seal or b. Replace seal or gasket.
backup gasket.
c. Bearing out of position. c. Replace bearing.
d. Excessive internal wear. d. Replace pump.

Functional Check a reduced oil flow to the control valve or a reduced

system relief pressure. Adequate oil flow under all
A normal periodic functional check of the entire steering
conditions can best be checked by timing the full travel
system will generally be adequate to ensure satisfactory
of the cylinder with the steered axle unloaded and
service.
loaded. If there is a great difference at low engine speed
1. Check all fittings for leakage. An accumulation of moist, and slight difference at high engine speeds this may
black dirt is a good indication of leakage. indicate a defective pump. Adequate oil pressure can
only be determined by connecting a pressure gauge (24
2. With the engine running at idle and at full throttle, and MPa/240 bar [3500 psi] full scale recommended) at the
with the machine standing still and moving, turn the accessory manifold with swing directional valve gauge
steering wheel through the full range of travel. Note any test port (GP5). With the engine running at a medium
speed irregularities and sticky sensation. This may speed, turn the steering wheel to one end of the travel
indicate dirt in the fluid. If the steering wheel continues to and hold the cylinders at the travel limit briefly, just long
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rotate when started and released, a condition known as enough to read the pressure gauge. Never hold the
Motoring exists. This may also indicate dirty fluid in the system at relief pressure for more than a few seconds at
system.
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a time. The pressure gauge should indicate 2500 psi
3. Ensure the system has adequate power. If there is an (17.3 MPa).
indication of hard steering, this can be caused by either
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Rear Steering System
Troubleshooting
Table 8-2
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1. Rear steering inoperative. a. Hydraulic oil low. a. Refill hydraulic reservoir.
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LUBRICATION.
b. Clogged, broken, or loose b. Clean, tighten, or replace
hydraulic lines or fittings. lines or fittings.
c. Steer cylinder locked. c. Repair or replace cylinders.
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d. Defective control valve. d. Repair or replace valve.

e. Defective steer cylinder(s). e. Repair or replace cylinder(s).
f. Lack of electrical signal f. Check electrical connections/
wiring
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2. Hard to steer left and right. a. Hydraulic oil low. a. Refill hydraulic reservoir.
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valve.
e. Clogged or loose hydraulic e. Clean or tighten lines or
f. Defective steer cylinder. f. Repair or replace cylinder.
g. Damaged relief. g. Replace relief valve.


3. Steering is erratic left and right. a. Hydraulic oil low. a. Refill hydraulic reservoir.
valve.
Hydraulic Pumps Installation

1. Secure the valve to the steering column and secure with
Description
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the capscrews and washers. Torque the capscrews see
Front Steer Fasteners and Torque Values (pg 1- 12).
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The hydraulic pump is mounted off of drive pads of the 2. Connect the hydraulic hoses to the ports on the valve as
torque converter and driven by the engine. Pump number 2 tagged during removal.
provides the hydraulic flow necessary to power the front 3. Connect the electrical connector to the valve as tagged
steer cylinders and swing circuit. The pump is a gear type
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during removal.
pump that provides a flow of approximately 82.9 l/min (21.9
gpm). 4. Verify proper operation of the valve.
Rear Steer 5. Check valve and hydraulic connections for leaks. Make
repairs as needed.
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The hydraulic pump is mounted off of drive pads on the
torque converter and is driven by the engine. Pump number Integrated Outrigger/Rear Steer Manifold
1 supplies oil to the integrated outrigger/rear steer valve,
boom lift, telescope, hoist and pilot function. The pump is an The integrated outrigger/rear steer manifold controls the
axial piston pump that provides a flow of approximately outrigger and rear steer circuit. The valve is mounted on the
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236.2 l/min (62.4 gpm). frame center section to the rear of the front axle.
The manifold is made up of two sections; an inlet section and
Front Steering Control Valve a working section.
Description The inlet section contains a 17,200 kPa/172 bar (2500 psi)
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relief valve and a solenoid valve. The solenoid valve is

The steering control valve is located under the dash and is normally open. It unloads the pump during cranking, and
actuated by a conventional steering wheel and steering bypasses oil from the inlet port to the tank port. Activation of
column, providing precise, full hydraulic steering. Precise either the outriggers or the rear steer circuit energizes the
steering is accomplished by a metering system within the solenoid valve to close and allow oil to flow to the selected
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valve that is directly connected to the steering column and circuit.

wheel.
The rear steer section contains a three position four way
Maintenance solenoid controlled directional valve that controls left and
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right rear steer.

Removal The outrigger section contains a three position four way
solenoid controlled directional valve, two check valves and
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two load sense valves, that controls outrigger extend and
2. Tag and disconnect the hydraulic hoses from the valve. retract.
3. Remove the capscrews and washers and remove the Maintenance
valve from the steering column.
Removal
1. Tag and disconnect the electrical connectors to the
valve.

3. Remove the capscrews and washers securing the valve Maintenance

to the frame bracket. Remove the valve.
NOTE: For Disassembly and Assembly procedures, refer
Installation to Steer Cylinders in Section 2 - HYDRAULIC and
PRESSURE SETTINGS.
1. Secure the valve to the frame bracket with the washers
and capscrews. Torque the capscrews see Fasteners Removal
and Torque Values (pg 1- 12). 1. Tag and disconnect the hydraulic lines going into the
2. Connect the hydraulic hoses to the ports on the valve as steer cylinder. Cap or plug all openings.
tagged during removal. 2. Remove the capscrews, flatwashers and spring
3. Connect the electrical connectors to the valve as tagged lockwashers securing each pin weld in the rod end and
during removal. barrel end of the cylinder.
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4. Verify operation as follows: NOTE: Steer cylinder weighs approximately 9.07 kg (19.9
lb).
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- Operate the rear steer left and right to verify smooth
operation. 3. Remove both pin welds and two thrust washers (rod end
only), and remove the cylinder from the axle.
- On outriggers, swing over the front outriggers to
ensure the oscillation cylinders lockout. Installation
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5. Check valve and hoses for leaks. Make repairs as 1. Position the cylinder onto the attachment fittings on the
needed. axle and install both pin welds.
NOTE: For further information on the Integrated Outrigger/ 2. Secure each pin weld with the capscrew, flatwashers
R e a r St e e r M a n i f o l d , r e f e r t o S e c t i o n 2 - and spring lockwashers. Torque the capscrews see
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HYDRAULIC and PRESSURE SETTINGS. Fasteners and Torque Values (pg 1- 12).
3. Connect the hydraulic lines to the cylinder as tagged
Steer Cylinders during removal.
Description 4. Operate the steering system and check the cylinder for
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proper operation and any leakage.

The steer cylinders are mounted on the axles, two cylinders
on each axle. The barrel end of each cylinder is attached to
the axle housing and the rod end is attached to the steering
lug on the axle end. The front cylinders are controlled
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hydraulically by the steering control valve. The rear cylinders

are controlled by the integrated outrigger/rear steer valve.
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REAR AXLE OSCILLATION LOCKOUT Maintenance

SYSTEM NOTE: For disassembly and assembly procedures, refer
to Axle Oscillation Lockout Cylinder in Section 2 -
Description HYDRAULIC and PRESSURE SETTINGS.
The rear axle oscillation system consists of two lockout Removal
cylinders, an axle lockout valve, an axle oscillation relay and
an area potentiometer. The lockout cylinders are mounted 1. Raise the crane up on outriggers.
between a cradle (fifth wheel) and the carrier frame. The axle 2. Rotate the turntable more than 6 degrees in either
oscillation lockout valve is located on the left inner center direction from directly over the front to lock out the
frame rail and hydraulically controls the lockout cylinders. oscillation cylinders.
The area definition potentiometer in the electrical swivel 3. Remove the wheel and tire assembly from the axle.
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energizes and deenergizes the axle oscillation relay. When
the superstructure is more than 6 degrees left or right of 4. Tag and disconnect both hydraulic hoses from the ports
directly over the front, the axle oscillati on rel ay is on the cylinder. Cap or plug both hoses and the ports on
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deenergized. the cylinder.
When the axle oscillation relay’s contacts are open, the 5. At the rod end of the cylinder, remove one of the cotter
normally closed solenoid valves are deenergized and isolate pins securing the retaining pin to the cradle attach fitting.
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the lockout cylinders from hydraulic oil supply. This keeps the
6. Tap out the retaining pin, freeing the rod end from the
cylinders from oscillating (moving up and down to damp axle
cradle.
movement) because hydraulic oil cannot leave the cylinders.
Instead, the cylinders remain full of hydraulic oil and more 7. At the barrel end of the cylinder, remove one of the cotter
rigid. pins securing the retaining pin to the frame attach fitting.
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When the axle oscillation relay’s contacts are closed, the 8. Tap out the retaining pin and remove the cylinder.
Installation
oscillate. 1. Position the barrel end of the cylinder in the frame attach
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fitting and tap in the retaining pin.

NOTE: For further information on the lockout valve, refer to
Section 2 - HYDRAULIC and PRESSURE 2. Secure the retaining pin with the cotter pin.
SETTINGS.
3. Align the rod end of the cylinder in the cradle attach
Axle Oscillation Lockout Cylinders fitting and tap in the retaining pin.
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4. Secure the retaining pin with the cotter pin.

Description
5. Remove the caps or plugs from the two hydraulic hoses
A 12.7 cm (5 inch) diameter bore lockout cylinder is installed and the cylinder ports and connect the hoses to the
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on the left and right side of the rear axle. The barrel end of appropriate cylinder ports as tagged during removal.
each cylinder is attached to each side of the carrier frame
6. Install the wheel and tire assembly on the axle. Tighten
and the rod ends are attached to each side of the cradle (fifth
the lug nuts in accordance with the procedure in Wheel
wheel).
And Tire Assemblies in this section.
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The lockout cylinders are connected hydraulically so that

7. Lubricate both ends of the cylinder using the fittings
hydraulic oil flows from the rod side of the left cylinder to the
barrel side of the right cylinder and from the rod side of the
provided. 8
right cylinder to the barrel side of the left cylinder.

BRAKE SYSTEM Hydraulic oil from hydraulic pump number 2 flows to swivel
port 5 to the accessory manifold to the dual accumulator
Description charge valve. The dual accumulator charge valve charges
the accumulators from the open center circuit upon demand
The brake system includes all the components necessary for and within its present operating charge rate and the high limit
the application of the service brakes and the parking brake. pressure setting. However, when the open center circuit
pressure reaches the brake relief setting, which is higher
Service Brakes than the high accumulator charge limit, then the
The service brakes are full power hydraulic disc brakes accumulators will be charged to the regulated maximum
which are hydraulically controlled and are used to apply the pressure setting. The dual accumulator charge valve
brake assemblies on all four wheels. The system consists of regulates flow to the hydraulic accumulators to provide fully
the tandem brake valve with treadle pedal, the dual powered independently separate, primary (front) and
secondary (rear), service brake circuits. Hydraulic pressure
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accumulator charge valve, two hydraulic accumulators, the
brake assemblies, and all the associated hoses and tubing. is constantly maintained in the brake circuits by the
The operator depresses the pedal on the tandem brake accumulators and the charging valve. The charged
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valve, located on the cab floor, and the valve modulates the accumulators supply pressurized fluid to the closed tandem
brake line pressure to the brake assemblies at each wheel. brake valve.
The full powered brake system supplies a high brake system After the accumulators are fully charged, the high limit check
pressure with relatively low reactive pedal forces, while opens and all of the pump flow is directed to the excess flow
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controlling the maximum brake line pressure. The service port and on to the front steer and swing circuits. When
brake dual accumulator charge valve regulates flow to the pressure to the steering or swing circuit becomes greater
hydraulic accumulators to provide fully powered than accumulator pressure, the main check valve opens and
independently separate, primary (front) and secondary charges the accumulator without the aid of the charging
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(rear), service brake circuits. Hydraulic pressure is valve. In this condition, the maximum accumulator pressure
c o n s ta n t l y m a i n ta i n e d i n t h e b r a k e c i r c u i ts b y t h e is the brake circuit relief valve setting of 16 MPa (2320 psi).
accumulators and the charging valve.
Once the operator depresses the brake pedal, the tandem
NOTE: For Description and Maintenance of the tandem brake valve modulates fluid out to the brakes to provide the
brake valve with treadle pedal, the accumulators, means of braking. The tandem brake valve will modulate the
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and the dual accumulator charge valve, refer to pressure in the brake system by increasing or decreasing
VA LV E S i n S e c t i o n 2 - H Y D R A U L I C a n d pressure as required in proportion to the input force from the
PRESSURE SETTINGS. operator via the brake pedal. The hydraulic force acts within
the brake assemblies to force the brake pads against the
Parking Brake brake discs, acting to slow wheel rotation. Fully powered
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separate primary (front) and secondary (rear) braking circuits

The parking brake is a hydraulic release, spring apply, disc-
are provided with independent accumulators. A low pressure
type brake, located on the transmission. The system
warning switch is used to sense the accumulator pressures
consists of a two-position switch, a three-way solenoid valve,
and warn the operator through visual brake warning indicator
actuator, one brake assembly, and all the associated
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light on the cab console in the event the pressure in the

hardware and tubing. The selector switch, located on the
accumulators drops to an unsafe operating level. In the
steering column in the cab, is used to activate the solenoid
event of engine failure, the accumulators are pre-charged
valve which controls the park brake actuator, which applies
with dry nitrogen gas and properly sized to provide power-off
and releases the park brake.
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stopping capacity for secondary braking.

Theory of Operation
Parking Brake
Service Brakes Hydraulic flow from the transmission charge pump is routed
to the parking brake control valve. When the PARK BRAKE
Braking begins when the operator depresses the brake
switch is in the ON position, the parking brake solenoid valve
pedal in the cab. Mechanical linkage transfers the force
shifts to route flow from the hydraulic parking brake actuator
created by the lever action of the brake pedal to the hydraulic
back to the transmission sump. The actuator spring pulls on
brake valve which modulates the brake line pressure to the
the lever on the brake assembly, applying the parking brake.
brake assemblies at each wheel.

Maintenance
Troubleshooting

1. Brakes are poor. a. Lining thickness less than a. Replace lining.
3mm (0.125 in).
b. Brake pedal operation. b. Free mechanical linkage.
c. Restriction or leaks in lines. c. Check all lines for leaks and
restrictions.
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d. Low hydraulic oil flow. d. Check the hydraulic oil level in
reservoir and check flow from
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the tandem brake valve.
e. Air in brake lines. e. Bleed the brakes.
f. Brake pads/linings are f. Replace pads/linings.
grease-soaked.
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g. Engine not running. g. Start engine. Due to the
operation, the engine must be
running to provide full brake
power.
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h. Brake relief valve stuck open. h. Replace the relief valve.
i. Dual accumulator charge i. Check valve operation and
valve not charging repair or replace valve.
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j. Accumulators not pre- j. Check accumulator pre-

charged. charge.
2. Hard brake pedal with engine a. Pedal travel being interfered a. Check all pedal linkage and
running. with. ensure it is free and adjusted
properly.
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3. Brakes lock up. a. Too much hydraulic flow. a. Check the flow from the flow
divider. Too much flow will
cause the brakes to be
applied by the oil trapped in
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the power boost chamber.

b. Brake pedal push rod b. Adjust the push rod linkage so
improperly adjusted, causing the brake pedal and push rod
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brakes to be always applied. fully return.

4. Uneven braking or pad wear. a. Lining thickness less than 3 a. Replace the lining.
mm (0.125 in). 8
b. Grease on the pads/linings. b. Replace the pads/linings.
General Bleeding the Brake System

A schedule for the periodic adjustment, cleaning, inspection, The brake system should be bled whenever air becomes
and lubrication of brake equipment should be established by entrapped within the brake system (usually characterized by
the operator on the basis of past experience and severity of a spongy feeling during brake pedal application), whenever
operation. any brake system line has been opened, or whenever any
brake component has been replaced.
The disc brakes are not adjustable. Brakes should be
cleaned, inspected, and linkage lubricated periodically to Always start at the point in the system that is furthest from
assure maximum performance. the tandem brake valve and work back toward the tandem

brake valve. Bleed every bleeder screw on every caliper/ 3. Repeat step 2 until a solid stream free of air bubbles is
actuator on every wheel. When you complete a bleeder obtained.
screw, go to the next closest bleeder screw on the same
caliper/actuator. When you complete a wheel, go to the 4. Repeat steps 1 thru 3 for the remaining wheel calipers/
furthest bleeder screw on the next closest wheel. actuators.
Pressure Bleeding the Brake System. SERVICE BRAKES

NOTE: Before bleeding the brake system, ensure the
hydraulic accumulators are fully charged. Description
1. Install the bleeding adapter. The brakes utilized on the axles are hydraulic disc-type
brakes. Two brake assemblies are used at each wheel end
2. Using a clean bleeding tank, fill the tank at least half full
on the front axle. One brake assembly is used at the wheel
with hydraulic oil. Position the tank so it will not have to
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end on the rear axle. The action of the brake pads riding
be moved again until all bleeding is finished.
against the brake discs acts to slow the rotation of the
wheels.
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3. Connect a 241 kPa/2.4 bar (35 psi) air source to the
bleeder tank.
Maintenance
4. Open the bleeder tank valve and bleed all air out of the NOTE: To perform maintenance on the brake caliper,
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hose to be connected to the adapter. Connect the remove the tire and wheel assembly. Refer to
bleeder hose to the adapter and open the bleeder valve. AXLES in this section.
5. Connect the end of the bleeder hose to the bleeder
screw on the caliper/actuator. Submerge the other end Removal
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in a glass jar partially filled with the proper type of clean Linings
hydraulic oil.
1. the caliper housing. Remove the end plates.
6. Open the bleeder screw and allow fluid to flow into the
2. Loosen the bleeder screws to release hydraulic
jar until it is a solid stream free of air bubbles. Close the
pressure in the caliper.
en
bleeder screw and torque to 11.3 to 13.6 Nm (100 to 120

pounds-inch).
7. Repeat steps 5 and 6 for the remaining wheel calipers/

Wood
actuators. Block
Loosen
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8. Remove the air supply from the bleeder tank. Bleeder

Screws
NOTE: Close the bleeder tank valve and disconnect the
hose and the bleeder adapter.
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9. Remove the bleeder tank and hose.
10. Remove the bleeder adapter.

Manually Bleeding the Brake System Push Wood
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Block Against
NOTE: Before bleeding the brake system, ensure the Linings to Push
hydraulic accumulators are fully charged. Pistons Into
Bores
1. Connect the end of the bleeder hose to the bleed screw
on the caliper. Submerge the other end in a jar partially FIGURE 8-5
filled with clean hydraulic oil.
2. Open the bleed screw on the caliper/actuator and allow 3. Use a piece of wood against the linings as a pry bar to
fluid to flow into the jar, while depressing the brake push the pistons completely into the housing. Tighten
pedal. Depress the brake pedal and close the bleeder the bleeder screws (Figure 8-5).
screw, then release the brake pedal. Torque the bleeder
screw to 11.3 to 13.6 Nm (100 to 120 pounds-inch). 4. Remove the linings from the caliper housing. If
necessary, discard the linings.

Caliper b. Apply compressed air to the inlet fitting to force the

pistons out of the other housing. If one piston comes
1. Disconnect the hydraulic brake line from the inlet fitting
out before the other piston, put a piece of wood in
on the caliper. Cap or plug all openings.
front of the piston that comes out first. Apply
2. Remove the linings as described previously. compressed air to force the other piston out of the
housing (Figure 8-7).
3. Remove the bolts securing the caliper housing to the
mounting bracket. Remove the caliper housing from the
mounting bracket. If shims are used mark the position of
the shims.
C-Clamp
Disassembly
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Caliper
1. Remove the inlet fitting and o-ring from the cylinder cap.
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2. Drain and discard the brake fluid.
3. Clean the outside of the housing with isopropyl alcohol. Air Gun
Dry the housing with a clean cloth. Wood
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Block Piston FIGURE 8-7
4. If installed, remove the bolts that secure the end plates
to the housing. Remove the end plates and linings. c. Remove the wood block and the C-clamp from the
housing.
5. Remove the pistons from the side of the housing
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d. Remove the pistons from the bores that are
opposite the mounting plate according to the following
opposite from the mounting plate.
procedure.
a. Use a C-clamp to hold a 12.7 mm (0.5 in) block of 6. Remove the two bleeder screws from the housing.
wood against two pistons on the mounting side of
7. Remove the cylinder caps from the housing using an
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the housing. Ensure the C-clamp is not in the area in

open end wrench. Remove and discard the O-rings
front of the piston bore (Figure 8-6).
(Figure 8-8).
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C-Clamp
Wood
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Block
O-Ring
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Cylinder
Cap
FIGURE 8-8
8
FIGURE 8-6
8. Remove the pistons from the mounting plate side of the
housing. Push on the ends of the pistons to force them
out of the disc side of the housing (Figure 8-9).
DANGER
Do not place hand in front of pistons when forcing them
out. Serious personal injury may occur.

Shoes, Linings, and End Plates
Wood Block
Remove the shoes and linings. To help prevent abnormal
lining wear, replace worn, bent, or cracked end plates and
distorted backing plates. Inspect end plate bolts for wear.
Replace the bolts if worn. Inspect the linings for:
• Lining Wear. Replace the linings when the thickness
of the lining is less than 3.2 mm (0.125 in) from the
back plate (Figure 8-11).
• Lining Wear Not Even. Replace the linings if the
thickness of the two linings is significantly different.
Check the pistons for correct operation. Replace the
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Piston piston and/or housing if a piston is cocked in the
bore. Check that the disc surface is flat and parallel
to the linings (Figure 8-11).
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FIGURE 8-9
9. Remove the dust seals from the housing.
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10. Remove and discard the O-ring and the backup rings Minimum Lining Thickness
(Figure 8-10). 3.2 mm (0.125 in) from
Backing Plate
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O-Ring
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Uneven Lining Wear

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Backup Ring FIGURE 8-10
11. Inspect the ring grooves in the housing for scratches and
rust. Remove small scratches and rust with emery cloth. FIGURE 8-11
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Replace the housing if there are large scratches or large

amounts of rust. Refer to Inspection - Caliper Parts. • Oil or Grease on Linings. Replace the linings.
12. Inspect the pistons and the bores for scratches and rust. • Cracks on Linings. Replace linings that have large
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Remove small scratches and rust with emery cloth. or deep cracks.
Replace the components if they are worn or if there are NOTE: Small, tight cracks on the surface of the lining are
large scratches or large amounts of rust. Refer to normal when the caliper is used under high
Inspection - Caliper Parts. temperature conditions.
Inspection Caliper for Leaks
Periodic On-Vehicle Inspect the following areas for fluid leaks (Figure 8-12).
Inspect the caliper, linings, and disc for any damage.

Bleeder Screw Minimum Disc

Piston Fluid
Fluid Leaks Thickness
Leaks
Maximum Disc
Inlet Wear Each Side
Cylinder
Fitting Maximum
Cap
Fluid Disc Wear
Fluid Original
Leaks
Leaks Disc Thickness
15.875 mm (0.625 in)
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Piston Fluid Typical Section Through Disc Showing
Leaks Recommended Maximum Wear Limits
FIGURE 8-12
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• Pistons. If fluid leaks at a piston, disassemble the
caliper. Inspect the piston, the bore, the o-rings, and
Lining
back-up rings. Service as necessary. Maximum
Backing Minimum Disc
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• Cylinder Cap. If fluid leaks at a cylinder cap, tighten Disc Wear
Plate Thickness
the cylinder cap, the inlet fitting, and the plug. If the Each Side
Thickness
leak continues, disassemble the caliper. Inspect the
cylinder cap threads, the housing threads, and the 7.1 mm (0.28 1.5 mm (0.06 12.7 mm (0.50
o-ring. Service as necessary. in) in) in)
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• Bleeder Screw. If fluid leaks at the bleeder screw, 8.6 mm (0.34 2.3 mm (0.09 11.2 mm (0.44
tighten the bleeder screw. If the leak continues, in) in) in)
replace the bleeder screw.
FIGURE 8-13
• Inlet Fitting. If fluid leaks at the inlet fitting, tighten
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the fitting. If the leak continues, replace the o-ring. Caliper Parts
Dust Seals 1. Inspect the pistons, housing bores, and o-ring grooves
Ensure the dust seals are soft and flexible. Disassemble the for scratches or corrosion. Remove small scratches or
caliper and replace dust seals that are hard or damaged. corrosion with fine emery cloth. Replace the
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components if they are worn beyond wear limits or if

Disc there are large scratches or large amount of corrosion.
If the disc is worn beyond the wear limits, replace the disc 2. Measure the diameter of the piston. Replace the piston if
(Figure 8-13). the outer diameter is worn less than 76.073 mm (2.995
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in) (Figure 8-14).

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8
Micrometer
Piston
Replace Piston if Outer

Diameter is Worn to Less than
76.073 mm (2.995 in)
FIGURE 8-14

3. Measure the diameter of the housing bore. Replace the • Metal parts with rough surfaces can be cleaned with
housing if the diameter is worn to more than 76.276 mm solvent cleaners or with alkaline solutions.
(3.003 in) (Figure 8-15).
• Use a wire brush to clean the threads of fasteners
and fittings.
• Use soap and water to clean parts that are not made
Replace Housing if Bore of metal.
is Worn to More than
76.276 mm (3.003 in) • Scrape away build-ups of mud and dirt on the
linings. Replace all linings contaminated with oil or
grease.
• Immediately after cleaning, dry all parts with clean
paper or rags.
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Corrosion Protection
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Apply brake system fluid to the cleaned and dried parts that
Telescoping are not damaged and are to be immediately assembled. Do
Gauge Not apply fluid to the brake linings or the disc.
FIGURE 8-15
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If parts are to be stored, apply a special material that
4. Inspect the linings as described previously. prevents corrosion to all surfaces. Do Not apply the material
to the brake linings or the disc. Store the parts inside special
5. Inspect the threads of the caliper, cylinder caps, and all paper or other material that prevents corrosion.
fittings. Replace any component that has thread
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damage that cannot be repaired. Assembly
6. Discard all back-up rings, o-rings, and dust seals. Use Caliper
new ones when assembling the caliper. CAUTION
Use only specified components when assembling the
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Cleaning calipers. Do not mix components from other calipers.

Installing the wrong components may cause the caliper not
to operate correctly and may cause damage to equipment.
Use of non manufacturer’s parts can cause damage, loss of
DANGER braking, and serious personal injury.
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Use of cleaning solvents, hot solution tanks, or alkaline NOTE: The o-rings, back-up rings, pistons, and bores
solutions incorrectly, can cause serious personal injury. To must be lubricated before installing the pistons.
prevent serious personal injury, follow the instructions
supplied by the manufacturer of these products. Do not 1. Lubricate all pistons, bores, o-rings, and back-up rings
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use gasoline to clean parts. Gasoline can explode and with silicone grease. If silicone grease is not available,
cause serious personal injury. use the same type of fluid that is used in the brake
system.
2. Install new o-ring and a new back-up ring in the groove
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CAUTION in the middle of the bore. The o-ring is installed toward

Use only solvent cleaners to clean ground or polished the outboard end of the bore. The back-up ring is
metal parts. Hot solution tanks or water and alkaline installed toward the lining side of the bore (Figure 8-16).
solutions will damage these Parts. Isopropyl alcohol,
kerosene, or diesel fuel can be used for this purpose.
CAUTION
• Use solvent cleaners to clean all metal parts that Do not use silicone grease on the dust seal.
have ground or polished surfaces. Examples of
ground or polished parts are the piston and the
3. Install a new dust seal in the top groove of the bore
piston bore in the caliper.
(Figure 8-16).

NOTE: Apply extra grease on o-ring before installing

cylinder caps. this will keep o-ring from catching on
Backup Ring - O-Ring- threads as cylinder cap is threaded into housing.
Install Toward Lining Install Toward
Side of Bore O-Ring Outboard End of Bore 6. Install the cylinder caps in the caliper housing. Tighten
the cylinder caps to 102 Nm (75 pounds-foot) minimum
O-Ring as shown in (Figure 8-18).
Cylinder Cap - -
Backup Tighten to 100 Nm 1.25 Inch
Ring (75 pounds-foot) Crow’s Foot
Minimum Wrench
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Backup Ring Dust Seal
and O-Ring Groove
Dust Seal Groove
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FIGURE 8-16
4. Install the pistons in the housing. Push the pistons in

from the lining side of the housing. Ensure the pistons
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are straight in the bores. Push each piston into the bore
until the top of the piston is even with the top of the dust Torque
seal (Figure 8-17). Wrench
FIGURE 8-18
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7. Install the bleeder screws in the housing. Tighten to 11.3
to 13.6 Nm (100 to 120 pounds-inch).
8. Install the o-ring and the inlet fitting in the cylinder cap.
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Installation
Linings
Piston - - Use CAUTION

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Equal Pressure to Always replace both linings. If only one lining is replaced,
Push Pedal into Bore
possible disc damage can occur.
1. Install the linings in the caliper housing.

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2. Position the end plates on the housing and secure with

bolts. Apply Loctite 271 or equivalent to the bolt threads.
Tighten the bolts to 224 to 285 Nm (165 to 210 pounds-
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foot).
3. Ensure the linings move freely in the housing. 8

When Correctly 4. Bleed the brake system.
Installed the End of the
Piston is Even with the 5. Apply and release the brakes three times to ensure the
Top of the Dust Seal FIGURE 8-17 caliper operates correctly. Check for fluid leaks. Ensure
the linings move freely.
5. Install a new o-ring in the groove of the cylinder cap.
Ensure the o-ring is not cut by the threads on the
cylinder cap.

Caliper Maintenance
1. Position the caliper housing on the mounting bracket. If
shims where used, place them as marker during Removal
removal. 1. Chock the wheels to prevent crane movement.
2. Secure the caliper housing with the bolts and tighten
them to 678 to 813 Nm (500 to 600 lb-ft).
CAUTION
3. Install the linings. Refer to INSTALLATION - Linings.
Do not exceed 1861.5 kPa/18.6 bar (270 psi) hydraulic
4. Ensure the housing is installed correctly on the mounting pressure to avoid damage to the brake. 1172.1kPa/11 bar
bracket. The disc must be within ± 1.5 mm (± 0.06 in) of (170 psi) is required to fully release the brake.
being centered between the lining end plates.
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2. Start the engine, ensure the transmission is in neutral,
a. To increase outboard clearance and decrease and position the Park Brake switch to Off. This will
inboard clearance, install a shim either between the pressurize the brake actuator to release the tension on
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housing and mounting bracket or between the hub the brake linkage. Engine must remain running.
and disc.
3. Remove the capscrews securing actuator to the brake
b. The shims must be steel, ground flat, and parallel
caliper. Slide the actuator off the actuator rod.
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and must cover the entire mounting surface of the
hub or housing. The linings must move freely in the 4. Position the Park Brake switch to On (press top of
housing and between the end plates (Figure 8-19). switch) and shut down the engine.
5. Disconnect the hydraulic line from the brake actuator,

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then cap or plug all openings.
Installation
NOTE: Mount brake so that the linings are parallel with the
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disc within 0.381 mm (0.015 inch). Disc is to be

located the proper distance from the mounting
surface per assembly drawing.
1. Slide brake over disc and into mounting position.
Disc Centered 2. Start hex mounting bolts into mounting surface far
er
Between Linings enough to just support the brake.
3. Remove plug, loosen the coupling nut and then tighten

FIGURE 8-19
socket setscrew until linings are clamped to the disc.
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This locates and holds the brake in the proper position to

5. Connect the hydraulic brake line to the inlet fitting. set the hex mounting bolts and hex nuts.
6. Bleed the brake system. 4. Tighten hex mounting bolts until they make contact with
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the urethane springs, then tighten 4 flats approximately

7. Apply and release the brakes three times to ensure the 1.778 mm (0.07 inch) more. This puts the proper amount
caliper operates correctly. Check for fluid leaks. Ensure of pre-load on the urethane springs.
the linings move freely.
5. Tighten jam nut/sleeves against mounting surface and
PARKING BRAKE ACTUATOR torque 271 Nm (200 lb-ft).
Description
CAUTION
The spring-applied, hydraulically-released parking brake Brake linings are susceptible to contamination. When
actuator is located on the transmission and is used to apply installing or servicing brakes, keep all oil and fluids away
and release the parking brake. from linings. Poor brake performance may result if linings
are contaminated.

6. Attach brake line to inlet port located on top of the the front console in the cab and is spring-applied and
hydraulic cylinder. hydraulically released by an actuator.
7. Apply hydraulic pressure to the brake. Maintenance

8. With plug removed, loosen coupling nut and set running
clearance to 0.5 to 0.7mm (0.020 t0 0.030 inch) total by Removal
adjusting the socket setscrew. Torque the coupling nut 1. Chock the wheels to prevent crane movement.
while holding the socket setscrew in position. Torque nut
68 to 75 Nm (50 to 55 ponds-foot).
9. replace plug. Torque plug 61 to 68 Nm (45 to 50 pounds- CAUTION
foot). Do not exceed 1861.5 kPa/18.6 bar (270 psi) hydraulic
pressure to avoid damage to the brake. 1172.1kPa/11 bar
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10. Even up running clearance to 0.25 to 0.3 mm (0.010 to (170 psi) is required to fully release the brake.
0.015 inch) each side by adjusting the socket head
capscrew.
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NOTE: Re-adjust the brake when running clearance and position the Park Brake switch to Off (press bottom
reaches a total of 2.54 mm (0.100 inch). of switch). This will pressurize the brake actuator to
release the tension on the brake linkage. Screw the
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11. Position the Park Brake switch to On (press top of caging nut up under the actuator chamber.
switch) and shut down the engine.
3. Position the Park Brake switch to On (press top of
Adjustment switch) and shut down the engine.
1. Chock the wheels to prevent crane movement. 4. Tag and disconnect the hydraulic hose from the actuator.
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Cap or plug all openings.
CAUTION 5. Unthread the two mounting bolts securing the brake

Do not exceed 1861.5 kPa/18.6 bar (270 psi) hydraulic assembly to the mounting bracket, then carefully
remove the brake assembly from the mounting bracket
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pressure to avoid damage to the brake. 1172.1kPa/11 bar

(170 psi) is required to fully release the brake. and the brake disc.
2. Start the engine, ensure the transmission is in neutral, Installation

and position the Park Brake switch to Off (press bottom 1. Position the brake over the disc and align mounting
of switch). This will pressurize the brake actuator to
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bracket holes.
release the tension on the brake linkage. Screw the
caging nut up under the actuator chamber. 2. Thread the mounting bolts into the mounting bracket
until the caliper is centered over the brake disc.
3. Install the rod ball joint until the ball joint will just connect
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to the brake linkage with the brake lever in a horizontal 3. Torque the jam nuts to 136 to 163 Nm (100 to 120 foot-
position. pounds) against the mounting bracket.
4. Lock the rod ball joint with the jam nut and back off the 4. Connect the hydraulic hose to the actuator.
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caging nut.
switch) and shut down the engine.
and position the Park Brake switch to Off (press bottom
of switch). This will pressurize the brake actuator to
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release the spring tension. Unscrew the caging nut from
PARKING BRAKE under the actuator chamber.

Description switch) and shut down the engine.
The parking brake is mounted on the transmission. The
brake is a disc-type brake that is controlled by a switch on

PARK BRAKE VALVE OUTRIGGERS

Description Outrigger Circuit
The range shift/parking brake valve controls the flow of oil to
the parking brake, hi-low range and axle disconnect
Description
actuators by the use of two solenoid valves. The valve is The outrigger circuit consists of four extension cylinders, four
located on the center of the frame. Pressure is supplied to jack cylinders, an integrated outrigger/rear steer valve, front
the valve from the transmission charge pump. and rear outrigger control manifolds, pilot operated check
valves and four Outrigger Monitoring System (OMS)
The parking brake solenoid valve is a two position three-way
( O p t i o n a l — St a n d a r d i n N o r t h A m e r i c a ) s t r i n g
valve. In its de-energized position, the inlet port is blocked
potentiometers. The front two extension cylinders are
and the parking brake actuator is drained to the reservoir.
mounted in the front outrigger beams and the rear two
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When the solenoid is energized, the reservoir port is blocked
extension cylinders are mounted in the rear outrigger beams.
and pressurized oil is directed to the actuator, engaging the
The front and rear outrigger beams are mounted in their
parking brake.
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respective outrigger boxes; in turn a jack cylinder is mounted
The range shift solenoid valve is a two position four-way on the end of each outrigger beam. The integrated outrigger/
valve. In its de-energized position, pressurized oil flows to rear steer valve is mounted on the front face of the carrier
the “B” port of the range shift actuator, while the “A” port is frame front cross member. The front and rear outrigger
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drained to the reservoir along with the axle disconnect control manifolds are mounted on the inside center of their
actuator for two wheel drive/high range. When the solenoid respective outrigger box. An OMS string potentiometer (if
is energized, pressurized oil is directed to the “A” port of the equipped) is mounted inside each outrigger box. The
range shift actuator and the axle disconnect actuator while potentiometer is connected by a cable to the outrigger beam
port “B” of the range shift actuator is drained to the reservoir to monitor the beam’s horizontal position—fully retracted,
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for four wheel drive/low range. mid-extend, or full extended.
The outrigger selector controls are located in the cab on the
Removal
CCS display or jog dial. Both the integrated outrigger valve
1. Tag and disconnect the electrical connectors to the and the manifold solenoid valves are electrically actuated
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valve. from these controls. The solenoid switches must be

depressed and held to actuate the solenoid valves. The
integrated outrigger valve switch is spring loaded to the off
position. The console is placarded with switch positions.
3. Remove the capscrews, lockwashers, flatwashers and
A sight bubble level is mounted on the right side of the cab.
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nuts securing the valve to the frame. Remove the valve.

The sight bubble level provides the operator with a visual
indication of crane level attitude.
Installation
1. Secure the valve to the frame with the nuts, flatwashers, Theory of Operation
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lockwashers and capscrews. Torque the capscrews 25

NOTE: Refer to Section 3 - OPERATING CONTROLS and
to 27 Nm (18 to 20 lb-ft).
PROCEDURES in the Operator ’s Manual for
2. Connect the hydraulic hoses to the ports on the valve as operation of the outrigger switches.
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during removal.
Functional Tests
1. Start and idle engine.
2. With units on outriggers, check for proper two/four wheel
operation.
NOTE: For further information on the park brake valve,
refer to Section 2 - HYDRAULIC and PRESSURE
SETTINGS.

Maintenance
Troubleshooting

1. Slow or erratic operation of a. Damaged relief valve. a. Remove relief valve; clean or
outrigger extension cylinders. replace.
b. Low hydraulic oil. b. Replenish oil to proper level.
LUBRICATION
c. Sticking solenoid valve spool. c. Repair or replace valve spool.
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d. Improper ground to base of d. Ground properly.
solenoid.
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e. Damaged O-rings and swivel e. Remove swivel and replace
O-rings.
f. Directional selector switch f. Clean or replace switch.
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sticking.
g. Collector ring dirty or glazed. g. Clean and deglaze collector
ring.
h. Damaged wiring to solenoid. h. Replace wiring.
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i. Weak brush springs on i. Replace brush springs.
collector ring.
j. Damaged extension cylinder j. Remove extension cylinder
(internal parts). and repair as necessary.
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k. Bent cylinder rods. k. Replace piston rods and

seals.
l. Excessive material on l. Clean outrigger beams.
outrigger beams.
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m. Binding outrigger beam. m. Repair or replace outrigger

beam.
n. Damaged outrigger valve. n. Repair or replace valve.
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o. Damaged valve coil. o. Replace coil.

p. Main hydraulic pump p. Replace or tighten hose or
cavitation. fitting.
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Slow or erratic operation of q. Partially shifted hydraulic q. Disassemble, clean, and
outrigger extension cylinders. spool in selector valve or polish spool and valve
(continued) manifolds. housing with very fine emery
cloth (water paper).
r. Insufficient voltage for r. Solenoids require a minimum
operation of solenoid valve. of 9.5 volts to energize. Check
outrigger wiring and electrical
coupling collector rings.
s. Damaged piston seals. s. Replace all cylinder seals.
t. Worn or damaged hydraulic t. Repair or replace pump
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pump section. section.
u. Scored cylinder barrel. u. Repair or replace extension
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cylinder.
v. Cracked or damaged piston. v. Replace rod weld and all
cylinder seals.
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w. Piston loose on piston rod. w. Replace all cylinder seals and
torque piston locknut.
2. Sticking spool. a. Dirt in the system. a. Change oil and flush system.
b. Distortion caused by tie bolts b. Retorque tie bolts.
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being overtorqued.
c. Flow in excess of valve rating. c. Limit flow through valve to that
recommended. Check pump
output and cylinder ratio.
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d. Pressure in excess of valve d. Check relief valve setting or

rating. pump compensation with that
recommended.
e. Electrical failure. e. Check wiring and solenoids.
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3. External leakage. a. Damaged O-ring or quad a. Check for chipped packings

rings. and replace.
b. Loose tie bolts. b. Retorque tie bolts.
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c. Damaged solenoid. c. Replace damaged parts.

4. Solenoid failure. a. No current. a. Check power source of at
least 85% of coil rating.
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b. Damaged solenoid assembly. b. Replace solenoid.

c. Short in solenoid. c. Replace coil.
d. Loss of solenoid force. d. Decrease time of solenoid
energization, decrease cycle
rate.


5. Outrigger jack cylinder slow or a. Low in hydraulic oil. a. Replenish oil to proper level.
erratic.
b. Damaged main relief valve. b. Repair or replace valve.
c. Damaged holding valve seals. c. Replace holding valve seals.
d. Bent cylinder rod. d. Replace cylinder rod and
seals.
e. Bent outrigger housing. e. Repair or replace outrigger
housing.
f. Excessive material on beams. f. Clean outrigger beams.
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g. Sticking solenoid valve spool. g. Repair or replace valve spool.
h. Damaged wiring to solenoid. h. Repair or replace wiring.
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i. Weak brush springs on i. Replace brush springs.
collector rings.
j. Collector ring dirty or glazed. j. Clean or deglaze collector
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ring.
k. Directional selector switch k. Clean or replace switch.
sticking.
l. Main hydraulic pump l. Replace or tighten hose and
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cavitation. fittings.
m. Worn or damaged hydraulic m. Repair or replace pump
pump section. section.
6. Outrigger jack cylinder retracts a. Damaged piston seals. a. Replace all cylinder seals.
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under load.
b. Damaged holding valve seals. b. Replace seals.
c. Damaged holding valve. c. Replace valve assembly.
d. Scored cylinder barrel. d. Repair or replace cylinder.
e. Cracked or damaged piston. e. Replace piston and all
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cylinder seals.
7. Outrigger jack cylinder extends a. Damaged piston seals. a. Replace all cylinder seals.
while machine is traveling.
b. Scored cylinder barrel. b. Replace jack cylinder.
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c. Cracked or damaged piston. c. Replace piston and seals.

d. Piston loose on cylinder rod. d. Replace seal and retorque.
8. Outrigger system will not activate a. Hydraulic oil low. a. Replenish system.
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(from stowed or extended and

b. Loose or broken wire on b. Repair or replace wiring.
down position).
switch. 8
c. Clogged, broken, or loose c. Clean, tighten, or replace
lines or fittings. lines or fittings.
d. Damaged relief valve or d. Repair or replace valve.
damaged control valve.


9. Outrigger system activates, but a. Clogged, broken, or loose a. Clean, tighten, or replace
selected outrigger will not stow or hydraulic lines or fittings. lines or fittings.
extend and lower as desired.
b. Loose or broken wire on b. Repair or replace wiring.
control switch or solenoid
valve.
c. Damaged solenoid valve. c. Repair or replace valve.
d. Damaged control switch. d. Replace switch.
e. Damaged hydraulic cylinder. e. Repair or replace cylinder.
10. Outriggers will not set. a. Improper sequence of a. Activate individual control
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activation. switch; then activate system
control switch.
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11. Two outriggers activate from a. Damaged solenoid valves. a. Repair or replace.
single control switch.
12. The two outriggers will not stow. a. Hydraulic lock. a. Recycle individual
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outrigger(s).
13. Individual outrigger will not set or a. Damaged piston seals. a. Replace seals.
stow.
b. Damaged check valve. b. Repair or replace valve.
c. Loosen or broken wire on c. Repair or replace wiring.
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control switch or solenoid
valve.
d. Damaged solenoid valve. d. Repair or replace valve.
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Outrigger Beam Maintenance

Removal
Description
1. On the jack cylinder end of the beam, remove the set
The outrigger beam assembly (Figure 8-20) consists of an
screw from the side adjustable wear pad and back off
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outrigger beam, a jack cylinder, an extension cylinder, an

the wear pad from the outrigger box.
Outrigger Monitoring System (OMS) (Optional—Standard in
North America), string potentiometer, and the required hoses 2. Remove the cover from the opposite end of the outrigger
and mounting hardware. box. Remove the setscrew from the side adjustable wear
pad and back off the wear pad from the beam.
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Theory of Operation 3. Remove the setscrews from the bottom adjustable wear
When the outrigger extension is activated, it extends or pads and back off the wear pads leaving approximately
retracts the outrigger beam within the outrigger box. The 6 mm (0.23 in) protruding
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outrigger beam can be extended to the mid-extend position

4. Extend the outrigger slightly to facilitate attaching a
by allowing the lock pin to ride on the top of the beam while
lifting device to the outrigger beam.
it’s extending. The lock pin will automatically drop into the
hole when the beam reaches the mid-extend position.
The stabilizer cylinder is mounted to the end of the beam and
applies force to the outrigger beam vertically. This sequence DANGER
of events provides for lifting and stabilizing the crane for Be sure any blocking material used is capable of
operation. supporting the weight of the outrigger beam. Do not allow
The jack cylinder is mounted to the end of the beam and it to tilt or slide. Failure to do so could result in death or
applies force to the outrigger beam vertically. This sequence injury to personnel.
of events provides for lifting and stabilizing the crane for
operation. 5. Place blocking material under the outrigger beam.

14, 15
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4, 5, 6
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2, 3
14, 15
17
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16
2, 3
8, 9, 10, 11, 12, 13

6759-3 18 7 FIGURE 8-20
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1 Outrigger Box Assembly 10 Capscrew
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2 Hex Nut 11 Plate

3 Capscrew 12 Wear Pad
4 Pin 13 Flatwasher
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5 Hex Nut 14 Cotter Pin

6 Capscrew 15 Clevis Pin
7 Adjusting Plate 16 Extension Cylinder
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8 Hex Nut 17 Cover

9 Setscrew 18 Jack Cylinder 8

5 4
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3
1
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7
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8
8487
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1 Jack Cylinder 5 Jack Cylinder Retract Port
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2 Extension Cylinder 6 Extension Cylinder Retract Port

3 Outrigger Beam 7 Extension Cylinder Extend Port
4 Jack Cylinder Extend Port 8 OMS Potentiometer
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NOTE: Outrigger removal and

installation similar for
both front and rear
outriggers.
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NOTE: Lifting belts or straps

should be used for lifting
purposes so as to avoid
nicking or scratching the
bottom edges of the
outrigger beam.
8486
FIGURE 8-21

6. Tag and disconnect the hydraulic lines at the cylinder 3. Install the bottom wear pads with approximately 6 mm
barrel end of the extension cylinder. Cap all lines and (0.23 in) protruding. This will prevent the beam side
fittings. plates from riding on the bottom of the box (Figure 8-22).
NOTE: Do not allow the end of the outrigger extension 4. Attach a suitable lifting device of straps or belts instead
cylinder to fall when the cylinder mounting shaft is of chains to prevent nicking the bottom edges of the
removed. Use blocking to limit the drop or an outrigger beam.
adequate soft support to cushion any distance the
5. Slide the beam into the outrigger housing and align the
rod will drop.
cylinder bushing with the mounting hole.
7. Remove the cotter pin and clevis pin securing the
6. Apply anti-seeze compound to the clevis pin. Secure the
cylinder barrel end of the extension cylinder to the
cylinder barrel to the housing with the clevis pin and
outrigger housing. Carefully extend the outrigger beam
cotter pin.
until the extension cylinder is free of the housing and
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carefully lay the end of the cylinder on the bottom of the
outrigger beam or leave on blocking.
CAUTION
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NOTE: Lifting belts or straps should be used for lifting pur- Be sure that the piston side of all outrigger cylinders are
poses so as to avoid nicking or scratching the bot- connected to the solenoid valve bank. Reversal of port
tom edges of the outrigger beam (Figure 8-21). connection of the rod and piston sides could result in
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8. After attaching a suitable lifting device of straps or belts severe damage to the cylinders as very high pressure
(Figure 8-21) instead of chains to prevent nicking the intensification will occur.
bottom edges of the outrigger beam, pull the outrigger
beam out of the outrigger box, re-adjusting the lifting
attachment to prevent the extension cylinder from sliding
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out of the outrigger beam when the beam clears the CAUTION
outrigger box. During initial start-up and checking of the outrigger
operation, each control switch must be operated before
operating the selector valve. If hydraulic lines are
reversed to one or more cylinders, this will prevent
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DANGER damage to the cylinders.

Be sure any blocking material used is capable of
7. Connect the hydraulic lines as tagged prior to removal.
supporting the weight of the outrigger beam. Do not allow
it to tilt or slide. Failure to do so could result in death or 8. Install the side adjustable wear pad in the outrigger box.
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injury to personnel.
9. Adjust the wear pads, refer to WEAR PAD
ADJUSTMENT in this Sub-Section.
NOTE: The outrigger beam assembly weighs
approximately 374 kg (824 lb). 10. Install the end cover.
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9. Position the outrigger beam on the blocking material. NOTE: At installation, be sure that the outrigger jack
cylinder hydraulic hoses are not trapped against
Inspection
the outrigger box when the beam is fully retracted.
Inspect the outrigger beams for bends, evidence of cracks,
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Wear Pad Adjustment.

or other damage. Check the outrigger beam internally for
hydraulic fluid, which may indicate a leaking cylinder, loose NOTE: When adjusting wear pads, refer to Wear Pad
connection, or damaged hydraulic line. Adjustment (Figure 8-22). 8
Installation 1. Adjust the bottom wear pads until a gap of 3 mm (0.11 in)
is obtained between the top of the beam and the top of
NOTE: Apply anti-seeze compound on clevis pins and
the outrigger box. Install and lock setscrew against wear
setscrews during installation.
pad.
1. Apply grease (EPMPG) to the bottom of the outrigger
2. Adjust outrigger box side wear pad until a gap of 2 mm
beam.
(0.07 in) is obtained between beam and shims welded in
2. If removed, install the side adjustable wear pad in the top and bottom of box. Install and lock set screw against
outrigger beam. wear pad.
3. Adjust outrigger beam side wear pad until a gap of 2 mm
(0.07 in) is obtained between shim welded on beam and
side of box. Install and lock set screw against wear pad.

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6
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Adjust for 2 mm (0.07inch)
gap with opposing shim
4
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1, 2
7, 8
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7, 8
6 mm (0.23 inch) of bottom wear pad
protruding before installing outrigger beam
8486
FIGURE 8-22
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Item Description force for the outrigger beam’s horizontal movement. The
cylinder weighs approximately 42 kg (92.5 pounds).
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1 Capscrew
2 Washer Maintenance
3 Plate NOTE: Refer to Cylinders in Section 2 - HYDRAULIC AND
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PRESSURE SETTINGS for Disassembly and

4 Wear Pad
Assembly of the cylinder.
5 Wear Pad
Removal
6 Slotted Setscrew
1. Remove the outrigger beam. Refer to OUTRIGGER
7 Setscrew BEAM - REMOVAL in this section.
8 Hex Nut 2. Remove the cotter pin and clevis pin securing the rod
end of the extension cylinder to the outrigger beam.
Extension Cylinder
3. Pull the extension cylinder from the outrigger beam until
Description the hydraulic hoses on the rod end of the cylinder can be
accessed. Tag and disconnect the hoses from the rod
Two outrigger extension cylinders are utilized within each end of the cylinder. Cap or plug all openings.
outrigger box assembly. The extension cylinders provide the
4. Remove the cylinder.

Installation Jack Cylinder

1. Place the cylinder in the beam.
Description
NOTE: Keep hydraulic fittings and hoses close to angles
shown (Figure 8-23) and as low as possible to Four jack cylinders are used on the crane, one at the end of
prevent rubbing with the beam top plate and side each outrigger beam. The jack cylinders provide the force for
plate, and for proper tracking during beam the outrigger beam’s vertical movement. The cylinder weighs
extension and retraction. approximately 64.6 kg (142.4 pounds).
Maintenance
NOTE: Refer to CYLINDERS in Section 2 - HYDRAULIC
and PRESSURE SETTINGS for Disassembly and
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Assembly of the cylinders.
Removal
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Hoses
1. Extend the outrigger beam slightly for improved access
to the jack cylinder; shut down the engine.
2. Tag and disconnect the hydraulic hoses from the jack
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cylinder. Remove the fittings from the ports. Cap or plug
all openings.
Fittings
3. Remove the nut and washer and remove the cylinder
cap.
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4. Place a jack capable of supporting the weight of the jack
cylinder at the base of the cylinder barrel. Jack up the
cylinder just enough to relieve any pressure on the
cylinder retaining pin.
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5. Remove the cotter pins securing the cylinder retaining

pin and remove the cylinder retaining pin and cylinder
cap retaining bracket.
8488 6. Jack the jack cylinder up just enough to insert the
retaining pin back into the cylinder. Insert the retaining
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FIGURE 8-23 pin into the lugs on the cylinder and secure the pin in
place with the cotter pins.
2. Position the extension cylinder so the hydraulic ports on
the rod end of the cylinder can be accessed. Connect
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the hydraulic hoses to the ports as tagged during CAUTION

removal.
Use a nylon strap to remove the cylinder. This will ensure
3. Push the cylinder into the outrigger beam. Align the the retaining pin is not damaged.
cylinder rod with the clevis in the beam. Apply anti-seeze
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to the clevis pin and secure in place with the clevis pin 7. Fasten a nylon strap onto the cylinder retaining pin and
and cotter pin. use an adequate lifting device to lift the jack cylinder out
of the tube on the beam assembly. 8
4. Install the outrigger beam. Refer to OUTRIGGER BEAM
- INSTALLATION in this section. Installation
Functional Check 1. Apply grease (EPMPG) to the ID of the jack cylinder
support tube.
1. Activate the hydraulic system; extend and retract the
outrigger. 2. If removed, install wear ring in groove in bottom of
support tube and in groove at top on jack cylinder.
2. Observe the operation of the outrigger beam.
3. Place a jack beneath the cylinder tube on the outrigger
3. Check the hydraulic connections for any evidence of
beam. Using the same method as described under
leakage.
REMOVAL, lower the jack cylinder into the cylinder tube
on the outrigger beam until the retaining pin is just above

the tube. Position the jack so that it will support the a. If oil stops flowing, the cylinder’s internal piston seal
cylinder in this position. Remove the lifting device from is sealing properly.
the cylinder.
b. If oil continues to flow out the rod port, the cylinder’s
4. Remove the retaining pin and cotter pins from the internal piston seal is leaking.
cylinder.
5. Lower the jack until the holes in the cylinder rod align
with the holes in the outrigger beam.
Piston Port
6. Apply anti-seeze compound to the retaining pin. Secure
the cylinder and cylinder cap retaining bracket to the Rod Port
support tube with the retaining pin and cotter pins.
7. Install the cylinder cap.
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8. Install the fittings in the cylinder ports and connect the
hoses as tagged during removal.
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Functional Check
1. Activate the hydraulic system.
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2. Extend and retract the jack cylinder.
3. Check for smooth operation of the cylinder.
4. Check all hydraulic connections and hoses for evidence
of leakage.
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6432
Outrigger Jack Cylinder Internal Leak Test

FIGURE 8-24
Use the following procedure to troubleshoot and diagnose an
internal leak, a leaking pilot operated check valve or a 3. After determining the condition of the cylinders internal
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thermal contraction on an outrigger jack cylinder. piston seal, let the rod side hose disconnected and
continue to test the pilot operated check valve.
Testing Pilot Operated Check Valve For Leakage
DANGER 1. Fully extend and set the outriggers.
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Perform the following procedures with the crane

positioned on a firm level surface with outriggers fully
extended and set, and the crane in the travel position CAUTION
Remove hoses from one cylinder at a time. When performing step number 2, remove hose to adapter
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connection slowly. Trapped pressure may exit between

Checking Cylinder For Internal Piston Seal Leak the outrigger cylinder and the work port pilot operated
check valves in the outrigger selector valve.
1. Fully extend and set the outriggers.
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2. Remove the piston side cylinder hose from the

suspected leaking jack cylinder (Figure 8-24). Oil will
CAUTION flow until the cavity in the cylinder port block empties.
When performing step number 2, remove hose to adapter Once the port block cavity empties, oil should stop
connection slowly. Trapped pressure may exit between flowing from the piston side port.
the outrigger cylinder and the work port pilot operated
a. If oil stops flowing, the cylinder’s pilot operated
check valves in the outrigger selector valve.
check valve is sealing properly.
2. Remove the rod side cylinder hose from the suspected b. If oil continues to flow out the piston port, the
leaking jack cylinder (Figure 8-24). Oil will flow until the cylinder’s pilot operated check valve is leaking.
cavity in the cylinder port block empties. Once the port
If oil flow is not noticed from either port, the cylinder and pilot
block cavity empties, oil should stop flowing from the rod
operated check valve are functioning properly, and any
side port.
cylinder contraction during normal operation can be
Check for the following conditions: attributed to thermal contraction of the oil.

Outrigger Control Valves first function is a holding valve, the second function provides
a thermal relief of the jack.
Description Integrated Outrigger/Rear Steer Manifold
There are four valve assemblies responsible for controlling The integrated outrigger/rear steer valve is mounted on the
the outrigger system, the integrated outrigger/rear steer frame center section to the rear of the front axle. Refer to
valve, the front and rear outrigger control manifolds, and the Section 2 - HYDRAULIC and PRESSURE SETTINGS.
pilot operated check valves.
Outrigger Control Manifold
NOTE: For a more detailed description and maintenance
of the valves, refer to Valves in Section 2 - The front and rear outrigger control manifolds are located
HYDRAULIC and PRESSURE SETTINGS. on the respective outrigger boxes. Each manifold consists of
four 2-position, 2-way solenoid valves.
Pilot Operated Check Valve
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The pilot operated check valves are located in the outrigger
jack port blocks. The check valve provides two functions; the
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RT530E-2 SERVICE MANUAL LUBRICATION
SECTION 9
LUBRICATION
SECTION CONTENTS
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 Drive Train (continued) . . . . . . . . . . . . . . . . . . . . 9-10
Lubrication Intervals . . . . . . . . . . . . . . . . . . . . . . . 9-1 Outriggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12
Arctic Conditions Below -18°C (0°F). . . . . . . . . . . 9-1 Turntable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14
Arctic Conditions Down To -40° C (-40°F) . . . . . . 9-1 Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16
Surface Protection For Cylinder Rods . . . . . . . . . 9-2 Boom (continued) . . . . . . . . . . . . . . . . . . . . . . . . 9-18
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Wire Rope Lubrication . . . . . . . . . . . . . . . . . . . . . . 9-2 Hoist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-20
Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-22
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Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
CraneLUBE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3 Carwell® Rust Inhibitor. . . . . . . . . . . . . . . . . . . . . 9-24
Protecting Cranes From Rusting . . . . . . . . . . . . . 9-24
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Cleaning Procedures . . . . . . . . . . . . . . . . . . . . . . 9-24
Steering and Suspension . . . . . . . . . . . . . . . . . . . 9-4
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Inspection and Repair . . . . . . . . . . . . . . . . . . . . . 9-25
Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-25
Drive Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
Areas of Application. . . . . . . . . . . . . . . . . . . . . . . 9-25
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GENERAL Arctic Conditions Below -18°C (0°F)
Following the designated lubrication procedures is important In general, petroleum based fluids developed especially for
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in ensuring maximum crane lifetime and utilization. The low temperature service may be used with satisfactory
procedures and lubrication charts in this section include results. However, certain fluids, such as halogenated
information on the types of lubricants used, the location of hydrocarbons, nitro hydrocarbons, and phosphate ester
the lubrication points, the frequency of lubrication, and other hydraulic fluids, might not be compatible with hydraulic
information. system seals and wear bands. If you are in doubt about the
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suitability of a specific fluid, check with your authorized

LUBRICATION INTERVALS Grove distributor or Manitowoc Crane Care.
The service intervals specified are for normal operation NOTE: All fluids and lubricants may be purchased by
contacting the Manitowoc Crane Care Parts
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where moderate temperature, humidity, and atmospheric

conditions prevail. In areas of extreme conditions, the Department.
service periods and lubrication specifications should be Regardless of temperature and oil viscosity, always use
altered to meet existing conditions. For information on suitable start-up procedures to ensure adequate lubrication
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extreme condition lubrication, contact your local Grove during system warm-up.
distributor or Manitowoc Crane Care.
Arctic Conditions Down To -40° C (-40°F)
CAUTION ALL Weather Package & Lubricants
Chassis grease lubricants must not be applied with air
Engineering recommends the following lubricants for
pressure devices as this lubricant is used on sealed
components for ambient temperatures to -40°C (-40°F).
fittings.
Special lubricants alone are not sufficient to operate at
The multipurpose grease installed during manufacture is extreme low temperatures. We also recommend the use of 9
of a lithium base. Use of a noncompatible grease could appropriately sized heaters for the hydraulic tank, engine oil
result in damage to equipment. pan, engine jacket water and batteries. The operator needs
to follow the guide lines as stated in the operator’s manual.
We assume that the customer has take steps for use of an
appropriate engine antifreeze coolant, have taken care of the

LUBRICATION RT530E-2 SERVICE MANUAL
fuel, fuel system and starting system. And has done Grease -- EP-MPG- Multipurpose Grease – Citgo Lithoplex
whatever they feel necessary to add insulation for under MP # 2; Texaco Starplex Moly # 2; Phillips 66 Philube M
hood temperatures and meet the engine manufacture's Grease; Mobil Mobilgrese XHP 222 Special, # 53055-0;
intake air temperature. Other lubricants may be used if they Chemtool Inc, Lube-A-Boom-Grease; -- Spec 6829003477
meet the specification of the lubricant that is requested.
Open Gear Lube -- (bearing / swing drive teeth -- FUCHS:
Please consult factory.
CEPLATTYN 300 SPRAY -- Spec 6829102971
Axles and Swing Box -- Petro- Canada Traxon E Synthetic
Antifreeze Coolant -- AFC – 50/50 Old World Industries,
75W-90; CITGO, Syntetic Gear Lube 75W-90; Eaton,
Inc. Fleet Charge SCA Pre-charged Antifreeze/Coolant;
Roadranger EP75W-90; Mobil, Mobilube SCH 75W-90;
Caterpillar DEAC Antifreeze/Coolant; Fleetguard Complete
Shell, Spirax S 75W-90; Sunoco Duragear EP75W-90; --
EG Antifreeze/Coolant; -- Spec 6829101130
Spec 6829014058
Supplemental Coolant Additive (SCA) – Fleetguard
Engine -- Petro-Canada Duron Synthetic CI-4- 5W-40; Mobil
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DCA4; Fleetguard DCA2; Penray Pencool 3000; Spec
Delvac 1, 5W-40; -- Spec 6829101560
6829012858
Hydraulic tank and Transmission -- Petro-Canada
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Duratran Synthetic THF; Chevron All Weather THF; Texaco Surface Protection For Cylinder Rods
TDH Oil SS; -- Spec 6829101559
Steel cylinder rods include a thin layer of chrome plating on
Hoist -- Petro-Canada ENDURATEX Synthetic EP 150; their surfaces to protect them from corroding. However,
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Mobil SHC629; -- Spec 6829103636 chrome plating inherently has cracks in its structure which
can allow moisture to corrode the underlying steel. At typical
Grease -- Petro-Canada Precision Synthetic EP1; Mobil:
ambient temperatures, hydraulic oil is too thick to penetrate
Mobilith SHC 220; -- Spec 6829104275
these cracks. Normal machine operating temperatures will
Open Gear Lube -- (bearing/swingdrive teeth) ---Vultrex.... allow hydraulic oil to warm sufficiently to penetrate these
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OGL Synthetic All Season -- No Spec cracks and if machines are operated daily, protect the rods.
Machines that are stored, transported, or used in a corrosive
Antifreeze Coolant -- Petro-Canada AFC 60/40; Old World
environment (high moisture, rain, snow, or coastline
Industries, Inc Fleet Charge SCA Pre-charged Antifreeze/
conditions) need to have the exposed rods protected more
Coolant-60/40; Fleetguard Compleat EG Antifreeze/Coolant
frequently by applying a protectant. Unless the machine is
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Premix 60/40; -- Spec 6829104212

operated daily, exposed rod surfaces will corrode. Some
Supplemental Coolant Additive (SCA) – Fleetguard cylinders will have rods exposed even when completely
DCA4; Fleetguard DCA2; Penray Pencool 3000; Spec retracted. Assume all cylinders have exposed rods, as
6829012858 corrosion on the end of the rod can ruin the cylinder.
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It is recommended that all exposed cylinder rods be

Standard Lubricants Package protected using Boeshield® T-9 Premium Metal Protectant.
Axle and Swing Box -- Century Unigear Semi-synthetic Manitowoc Crane Care has Boeshield® T-9 Premium Metal
SAE 80W-90; Texaco Multigear SS 80W-90; Chevron DELO Protectant available in 12 oz. cans that can be ordered
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80W-90; -- Spec 6829012964 through the Parts Department.
Tier 3 Engine -- CI-4 Rated 15W-40 Engine Oil Exxon XD-3; Cylinder operation and inclement weather will remove the
Conoco Fleet Supreme; -- Spec 6829003483 Boeshield® protectant; therefore, inspect machines once a
week and reapply Boeshield® to unprotected rod.
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Tier 4 Engine -- CJ-4 Rated 15W-40 Engine Oil Conoco

Fleet Supreme EC; Mobil Delvac 1300 Super; -- Spec
6829104182
WIRE ROPE LUBRICATION
Wire rope is lubricated during manufacturing so that the
Hydraulic Tank and Transmission -- To meet John Deere
strands, and individual wires in strands, may move as the
Standard JDM J20C – Hyden 052-10W-20; Exxon Torque
rope moves and bends. A wire rope cannot be lubricated
Fluid 56- 10W-20; Esso Torque Fluid 56- 10W-20; BP-
sufficiently during manufacture to last its entire life.
Eldoran UTH & Trak-Tran 9 – 10W20; BP- Blend- 7367 -
Therefore, new lubricant must be added periodically
10W20; Exxon Mobil 424- 10W-30 -- Spec 6829006444
throughout the life of a rope to replace factory lubricant which
Hoist -- AGMA No. 4 EP Extreme Pressure Gear Lube- is used or lost. For more detailed information concerning the
Mobil: Mobilfluid 629; Texaco: Meropa 150; -- Spec lubrication and inspection of wire rope, refer to WIRE ROPE
6829100213 in Section 1- INTRODUCTION in the Service Manual.

LUBRICATION POINTS lubricated with oil once a week. Motor oil, applied sparingly,
will provide the necessary lubrication and help prevent the
A regular frequency of lubrication must be established for all formation of rust. An Anti-Seize compound may be used if
lubrication points. Normally, this is based on component rust has not formed, otherwise the component must be
operating time. The most efficient method of keeping track of cleaned first.
lube requirements is to maintain a job log indicating crane
usage. The log must use the engine hourmeter to ensure Grease fittings that are worn and will not hold the grease
coverage of lube points that will receive attention based on gun, or those that have a stuck check ball, must be replaced.
their readings. Other lubrication requirements must be made Where wear pads are used, cycle the components and
on a time basis, i.e. weekly, monthly, etc. relubricate to ensure complete lubrication of the entire wear
All oil levels are to be checked with the crane parked on a area.
level surface in transport position, and while the oil is cold,
CraneLUBE
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unless otherwise specified.
On plug type check points, the oil levels are to be at the Manitowoc highly recommends the use of CraneLUBE
l u b r i c a n ts t o i n c r e a s e y o u r c r a n e ’s r e l i a b i l i t y a n d
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bottom edge of the check port.
performance. Contact your Manitowoc Distributor for
On all hoists with a check plug in the drum, the fill plug shall information about the Manitowoc’s CraneLUBE lubrication
be directly on top of the hoist, and the check plug level. program.
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All grease fittings are SAE STANDARD unless otherwise
indicated. Grease non-sealed fittings until grease is seen Safety
extruding from the fitting. One ounce(28 grams) of EP-MPG To lubricate many of the locations the engine will need to be
equals one pump on a standard one pound (0.45 kg) grease started. After positioning areas of the unit for lubrication the
gun. engine must be turned off and the moved areas stable before
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Over lubrication on non-sealed fittings will not harm the approaching.
fittings or components, but under lubrication will definitely
lead to a shorter lifetime.
On sealed U-joints, care must be exercised to prevent
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rupturing seals. Fill only until expansion of the seals first

WARNING
becomes visible. Movement of the superstructure and the boom may
create a crushing and/or pinching hazard. Failure to
Unless otherwise indicated, items not equipped with grease observe this warning could result in death or serious injury
fittings, such as linkages, pins, levers, etc., should be if the message is ignored.
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Steering and Suspension

Lube Point Figure Approved Lube
Item Lube Interval Application
Description No. Lubricant Capacity
EP-MPG
Extreme
Until
Steer Cylinder Pressure
1 Figure 9-1 grease 500 hours or 3 months 8 grease fittings
Pivot Pins Multipurpose
extrudes
Grease
A6-829-003477
EP-MPG
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Extreme
Until
Upper and Lower Pressure
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King Pins Multipurpose
extrudes
Grease
A6-829-003477
EP-MPG
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Extreme
Until
Fifth Wheel Pressure
Pivots Multipurpose
extrudes
Grease
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A6-829-003477
EP-MPG
Extreme
Until
Lockout Cylinder Pressure
Pivot Pins Multipurpose
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extrudes
Grease
A6-829-003477
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4 6818-2
1
2 1 3 6818-1
FIGURE 9-1


Axles
• Check level every
GL-5 500 hours or 3
Extended months Fill to bottom of hole
20.8 l
6 Axle Differentials Figure 9-2 Service Interval in housing on the
44 pt • Drain and fill every
Gear Lubricant steer cylinder side
A6-829-012964 4000 hours or 2
years
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NOTE: Lube level close enough to the hole to be seen or touched is not sufficient. It must be level with the hole.
When checking lube level, also check and clean housing breathers.
CAUTION: Use of non-approved lubricant may damage components and/or invalidate published lubricant intervals.
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CAUTION: If the makeup amount is substantially more than 0.23 l (0.5 pt), check for leaks.
• Check level every
GL-5 500 hours or 3 Fill to the bottom of
Axle Tech
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Extended months the level hole in the
Planetary Hubs 3.1 l
9 Figure 9-2 Service Interval housing with the fill
and Wheel 6.5 pt • Drain and fill every
Gear Lubricant plug and the oil level
Bearings 4000 hours or 2
A6-829-012964 mark horizontal.
years
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CAUTION: Use of non-approved lubricant may damage components and/or invalidate published lubricant intervals.
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6 6818-45
FIGURE 9-2


Drive Train
EO-15W/40 • Check level
Engine Oil • Check level every 10
through dipstick.
13a a. Engine SAE 15W-40 hours or daily
16.3 l • Fill engine oil
Crankcase Figure 9-3 Tier 3: • Drain, fill and replace
17.3 qt through fill cap on
13b b. Filter 6829003483 filter every 500 hours
Tier 4: engine valve
or 6 months
6829104182 cover.
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• Check level every 10
hours or daily
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• Drain and refill every
a. Transmission, 1000 hours or 6
14a HYDO Through fill pipe to
Torque 23.6 l months
Figure 9-3 Hydraulic Oil FULL mark on
Converter 25 qt
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14b A6-829-006444 • Change transmission dipstick
b. Filter filter after first 50 and
100 hours of service,
then every 500 hours
thereafter
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NOTE:
• Check fluid level with engine running at 750 rpm idle and the oil at 82 to 93° C (180 to 200° F). Do not attempt an oil level check
with cold oil. To bring the oil temperature to this range, it is necessary to either work the crane or stall the converter. Converter
stall should be accomplished by engaging shift lever in forward high range with the brakes applied and then accelerating the
engine to half or three-quarter throttle. Hold the stall until the required converter temperature is reached and stabilized.
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Do not operate the converter at stall condition for longer than 30 seconds at one time. Shift to neutral for 15 seconds and repeat
the procedure until the desired temperature is reached. Excessive temperature, i.e, 120° C (250° F) maximum will cause damage
to transmission clutches, fluid, converter and seals.
• Drain and fill with the oil at 65 to 93° C (150 to 200° F).
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• Transmission filters are located on the outside left hand frame in the area of the hydraulic oil cooler.
• To add fluid:
a. Fill to FULL mark on dipstick
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b. Run engine at 750 rpm to prime torque converter and lines

c. Check oil level with engine running at 750 rpm and oil at 82 to 93° C (180 to 200° F). Add oil to bring oil level to
FULL mark on dipstick.
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AFC 50/50 • Check coolant level • Fill surge tank to

50/50 Blended every 10 hours or center of sight
Fully Formulated daily glass. Run engine
Engine Cooling through two (2)
Antifreeze 19.8 l • Check SCA levels
15 System and SCA Figure 9-3 Coolant thermal cycles.
21 qt every 500 hours
Levels A6-829-101130
• Check coolant for • Check coolant
SCA contamination every level and refill as
6829012858 1000 hours required.
Change strainer screen
after first 100 hours and Close shutoff valves.
Coolant Strainer
16 Figure 9-3 --- --- every 2000 hours or 12 Unscrew hex plug to
(Cab Heater)
months intervals clean filter.
thereafter.

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Dipstick 13a 6818-36
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16 6813-7
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Other Side
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9
6818-40
14a 6818-29
FIGURE 9-3


Drive Train (continued)
EP-MPG
Extreme
Until
Driveline - Slip Pressure
Joints Multipurpose
extrudes
Grease
A6-829-003477
• Replace/Clean filter
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element when
indicator shows red
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(25” H20). Remove panel
52 Air Cleaner Filter Figure 9-4 --- --- • View indicator behind ladder to
through grill from rear access air filter.
of crane.
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• Refer to Service
Manual
• Change filter every • Fuel filter is
500 hours or 6 located on the
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Fuel Filter/Water months. intake manifold of
53 Figure 9-4 --- --- engine.
Separator • Drain water trap
every 10 hours or • Strainer is located
daily. near battery box.
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52 6818-38
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Other Side
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53 6818-29
17 6818-8
17 6818-43
FIGURE 9-4


Outriggers
EP-MPG
Extreme
Brush lubricant on
Pressure
18 Outrigger Beams Figure 9-5 --- 50 hours or 1 week bottom of outrigger
Multipurpose
beams
Grease
A6-829-003477
EP-MPG Brush lubricant on
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Extreme OD of jack cylinder
Jack Cylinder Pressure barrel and wear
19 Figure 9-5 --- 50 hours or 1 week
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Support Tubes Multipurpose band before
Grease installing jack
A6-829-003477 cylinders
EP-MPG Brush lubricant on
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Extreme OD of jack cylinder
Jack Cylinder Pressure support tubes (4)
51 Figure 9-5 --- 50 hours or 1 week
Barrels Multipurpose places before
Grease installing jack
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A6-829-003477 cylinders
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19
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6818-9
FIGURE 9-5


Turntable
• Check and fill every
GL-5 50 hours
Extended Use dipstick. If no
Turntable Gear 4.0 l • Drain and fill after
20 Figure 9-6 Service Interval dipstick, fill to top of
Box 4.25 qt first 250 hours and
Gear Lubricant case.
A6-829-012964 every 500 hours or
12 months thereafter.
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EP-OGL
Turntable Gear Open Gear Coat all
21 Figure 9-6 500 hours or 6 months Spray on
and Drive Pinion Lubricant teeth
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A6-829-102971
EP-OGL
Turntable Swivel Open Gear
21a Not shown Coat pin 500 hours or 6 months Spray on
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Lock Pin Lubricant
6829102971
Until
EP-MPG
grease
Extreme
extrudes 2 grease fittings at
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Turntable Pressure
22 Figure 9-6 the whole 500 hours or 6 months the front of the
Bearing Multipurpose
circumfer- turntable
Grease
ence of the
A6-829-003477
bearing
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NOTE: Rotate the turntable 90° and apply grease to fittings. Continue rotating 90° and grease the fittings until the whole
bearing is greased.
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22 6818-11
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6818-10
Dipstick ce
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21 6818-44 9
FIGURE 9-6


Boom
EP-MPG
Extreme Pressure Until
Upper Lift
25 Figure 9-7 Multipurpose grease 500 hours or 3 months 2 grease fittings
Cylinder Pin Grease extrudes
A6-829-003477
EP-MPG Extreme
Pressure Until
Hook Block
29 Figure 9-7 Multipurpose grease 250 hours or 3 months 1 grease fitting
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Swivel Bearing Grease extrudes
A6-829-003477
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EP-MPG Extreme 4 grease fittings - 35
Pressure Until
Hook Block Tons
30 Figure 9-7 Multipurpose grease 250 hours or 3 months
Sheaves Grease
3 grease fittings - 35
extrudes
Tons
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A6-829-003477
EP-MPG Extreme 2 places by brush
Telescope Pressure
Thoroughly Every boom teardown Extend boom for
31 Cylinder Wear Figure 9-7 Multipurpose
Grease coat or 125 hours/3 months access through
Pads
holes
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A6-829-003477
EP-MPG Extreme Thoroughly

Pressure coat all 12 places by brush;
32 Side Wear Pads Figure 9-7 Multipurpose areas the 250 hours or 3 months with boom in
Grease wear pad extended position
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A6-829-003477 moves on
EP-MPG Extreme Thoroughly 6 places by brush;

Boom Section Pressure coat all with boom in
33 Upper Wear Figure 9-7 Multipurpose areas the 50 hours or 1 week extended position
Pads Grease wear pad through access
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A6-829-003477 moves on holes
EP-MPG Extreme Thoroughly

Boom Section Pressure coat all 3 places by brush;
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34 Lower Wear Figure 9-7 Multipurpose areas the 50 hours or 1 week with boom in
Pads Grease wear pad extended position
A6-829-003477 moves on
EP-MPG Extreme 3 grease fittings
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Pressure Until
Extend Cable Extend boom for
35 Figure 9-7 Multipurpose grease 250 hours or 3 months
Sheaves Grease access through
extrudes
A6-829-003477 holes
EP-MPG Extreme
Pressure Until
Retract Cable
36 Figure 9-7 Multipurpose grease 250 hours or 3 months 4 grease fittings
Sheaves Grease extrudes
A6-829-003477
NOTE: Lubricate items more frequently than interval indicated in table if environmental conditions and/or operating
conditions necessitate.

33 33
32
32
34
34
34
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34
35 31
36 7181-1
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7181-2
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6818-21
29
25 6818-42 9
6818-13
6818-26
31
FIGURE 9-7


Boom (continued)
EP-MPG
Extreme
Until
Pressure
37 Boom Pivot Shaft Figure 9-8 grease 250 hours or 3 months 2 grease fittings
Multipurpose
extrudes
Grease
A6-829-003477
EP-MPG
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Extreme
Until
Boom Extension Pressure
38 Figure 9-8 grease 250 hours or 3 months 1 grease fitting
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Sheave Multipurpose
extrudes
Grease
A6-829-003477
EP-MPG
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Extreme
Until
Boom Extension Pressure
Roller Multipurpose
extrudes
Grease
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A6-829-003477
EP-MPG
Extreme
Until
Upper Boom Pressure
Nose Sheave Multipurpose
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extrudes
Grease
A6-829-003477
EP-MPG
Extreme
Until
Lower Boom Pressure
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extrudes
Grease
A6-829-003477
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EP-MPG
Extreme
Until
Auxiliary Boom Pressure
extrudes
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Grease
A6-829-003477
EP-MPG
Extreme
Until
Pressure
43 Mast Sheave Figure 9-8 grease 500 hours or 12 months 1 grease fitting
Multipurpose
extrudes
Grease
A6-829-003477

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41
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37 6818-17 6818-41
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39
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43
6818-31 9
6818-30
FIGURE 9-8


Hoist
AGMA • Check and fill every
Extreme 50 hours or weekly Oil level must be
5.2 l (5.5
45 Main Hoist Figure 9-9 Pressure Gear • Drain and fill every visible in the sight
qt)
Lubricant 1000 hours or 12 glass
A6-829-100213 months
AGMA • Check and fill every
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Extreme 50 hours or weekly Oil level must be
5.2 l (5.5
46 Auxiliary Hoist Figure 9-9 Pressure Gear • Drain and fill every visible in the sight
qt)
Lubricant glass
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1000 hours or 12
A6-829-100213 months
NOTE: Line up the Fill/Drain Plug with the upper cutout hole (A). Let hoist sit idle for 20 minutes for an accurate reading.
Ensure hoist is level and oil is within 21°C ±11°C (70°F ±20°F). If oil level is not visible in sight glass, the hoist may
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be underfilled. Oil escaping from vent plug (B) is an indication the hoist may be overfilled. If hoist is over filled,
move the Fill/Drain Plug to the lower cutout hole (C) and drain until oil level falls within the sight glass (D).
EP-MPG
Extreme
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Cable Follower Pressure Thoroughly
47 Figure 9-9 250 hours or 3 months Spray on
(Arms) Multipurpose coat
Grease
A6-829-003477
NOTE: Lubricate more frequently than interval indicated in table if environmental conditions and/or operating conditions
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necessitate.
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A B C D A C D 7114-7

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6818-17
FIGURE 9-9

Lube Point Approved Lube

Item Figure No. Lube Interval Application
Description Lubricant Capacity
Hydraulic
• Use sight gauge
on side of tank,
with boom down
HYDO and all outrigger
397.4 l Check fluid level every
48 Hydraulic Tank Figure 9-10 Hydraulic Oil cylinders
(105 gal) 10 hours or daily.
A6-829-006444 retracted.
• Drain and refill as
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necessary
NOTE: Environmental and other conditions can dramatically affect the condition of hydraulic oil and filters. Therefore,
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specific intervals for servicing/changing hydraulic oil, filters and hydraulic tank breathers cannot be set. However,
it is imperative for the continued satisfactory performance of Grove cranes that inspections be performed on the
basis of how and where each crane is used. Air borne and ingested contaminants can significantly reduce the life
of oil and the condition of hydraulic oil filters and tank breathers.
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• Under normal operating conditions, it is recommended that hydraulic oil, filters and breathers be inspected
and oils sampled at least every 3 to 6 months and more frequently for severe operating conditions. The
inspections should be for air borne and/or ingested particles and water that deteriorate and contaminate the
oil (e.g., oil appears “milky” or no longer has a transparent clear to amber color). The return filter by-pass
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indicator should be observed daily to determine if the contaminants content may be high. If the indicator
reaches the red zone or indicates a by-pass condition, the hydraulic oil must be sampled. The hydraulic tank
breather should also be inspected to assure that it is not restricting air flow into and out of the reservoir.
• To inspect hydraulic oil, fill a small glass container with a sample of reservoir oil and another glass container
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with fresh oil. Let the samples stand, undisturbed, for one to two hours and then compare the samples. If the
reservoir oil is heavily contaminated with water the sample will appear "milky" with only a small layer of
transparent oil on top. If the "milky” appearance was due to air foaming, it will dissipate and the oil should
closely match the fresh oil. Should you have any questions, please contact your local authorized Manitowoc
distributor.
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• The hydraulic oil shall meet or exceed ISO #4406 class 17/14 cleanliness level.
HYDO
Change filter when the
49 Hydraulic Filter Figure 9-10 Hydraulic Oil --- ---
indicator is red
A6-829-006444
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FIGURE 9-10
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CARWELL® RUST INHIBITOR
Protecting Cranes From Rusting While the surfaces of the crane that are easily seen have the
biggest impact on the appearance of the crane, particular
Manitowoc Crane Group's cranes are manufactured to high attention should be given to the undercarriage of the crane to
quality standards, including the type of paint finish minimize the harmful effects of corrosion.
demanded by today's industry. In partnership with our paint
supplier, we are also doing our part to help prevent Exercise special care and increase the frequency of cleaning
premature corrosion of cranes. if the crane is operated:
Grove cranes will be treated with a rust inhibitor called • on roads where large quantities of salt or calcium are
Carwell® T32-CP-90. While a rust inhibitor cannot guarantee applied to treat icy and snowy road surfaces;
that a machine will never rust, this product will help protect • in areas that use dust control chemicals;
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against corrosion on Grove cranes that are treated with this
• anywhere there are increased levels of wetness -
product.
especially near salt water;
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Carwell is a treatment, not a coating. It contains no silicones,
• during prolonged periods of exposure to damp
solvents, CFCs or anything that would be classified as
conditions (e.g., moisture held in mud), where certain
hazardous under OSHA Regulation 29CRF-19-10.1200. The
crane parts may become corroded even though other
product is a liquid blend of petroleum derivatives, rust
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parts remain dry; or
inhibitors, water-repelling and water-displacing agents.
• in high humidity, or when temperatures are just above
Special equipment is used to spray a light film onto the entire
the freezing point.
undercarriage and various other areas of each new crane
prior to shipment. When applied the product has a red tint to
Cleaning Procedures
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allow applicators to view coverage during application. This
red tint will turn clear on its own within approximately 24 To help protect against corrosion of Grove cranes,
hours after application. Manitowoc Crane Care recommends washing the crane at
least monthly to remove all foreign matter. More frequent
Once applied, treatment can appear to leave a slightly "oily"
cleaning may be needed when operating in harsh
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residue on painted surfaces and until the red tinting fades

environmental conditions. To clean the crane, follow these
could initially be mistaken for a hydraulic oil leak. While the
guidelines:
product is not harmful to painted surfaces, glass, plastic or
rubber, it must be removed using standard steam-cleaning • High pressure water or steam is effective for cleaning
techniques. the crane's undercarriage and wheel housings. Keeping
these areas clean will not only help retard the effects of
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This treatment works in various ways: (1) it eliminates the

corrosion, but will also improve the ability to identify
moisture containing salt, dirt and other pollutants by lifting
and removing them from the metal surface; (2) the film potential issues before they grow into larger problems.
creates a barrier to repel further moisture from coming in
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contact with the metal; and (3) it penetrates crevices.

In addition to the factory-applied treatment, Grove crane CAUTION
owners must provide proper maintenance and care to help High pressure water can be forced into spaces and
ensure long-term protection of their crane against corrosion. infiltrate beyond seals. Avoid pressure washing in the
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This procedure provides information and guidelines to help vicinity of electrical controls, panels, wiring, sensors,
maintain the paint finish on Grove cranes. hydraulic hoses and fittings, or anything that can be
damaged by high pressure cleaning/spraying.
The most common causes of corrosion include the following:
• Road salts, chemicals, dirt, and moisture trapped in the • Rinse the dirt and dust off before washing the crane. Dirt
hard-to-reach areas; can scratch the crane's finish during washing/cleaning.
• Chipping or wear of paint, cased by minor incidents or • Hard to clean spots caused by road tar or bugs should
moving components; be treated and cleaned after rinsing and prior to
washing. Do not use solvents or gasoline.
• Damage caused by personal abuse, such as using the
decks to transport rigging gear, tools, or cribbing; and • Wash using only soaps and detergents recommended
for automotive paint finishes.
• Exposure to harsh environmental hazards such as
alkaline, acids, or other chemicals that can attack the • Rinse all surfaces thoroughly to prevent streaking
crane's paint finish. caused by soap residue.

• Allow the crane to dry thoroughly. You can accelerate Spots should be touched up with quality paint. Primers tend
drying by using compressed air to remove excess water. to be porous; using a single coat of primer only will allow air
and water to penetrate the repair over time.
NOTE: Polishing and waxing (using an automotive-type
wax) is recommended to maintain the original paint Application
finish.
Depending upon the environment in which a crane is used
Inspection and Repair and/or stored, the initial factory application of Carwell T32-
CP-90 should help inhibit corrosion for up to approximately
• Immediately following cleaning, Manitowoc Crane Care
12 months.
recommends an inspection to detect areas that may
have become damaged by stone chips or minor It is recommended that the treatment be periodically
mishaps. A minor scratch (one that has not penetrated reapplied by the crane owner after that time to help continue
to the substrate surface) can be buffed with an to protect against corrosion of the crane and its components.
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automotive-type scratch remover. It is recommended
However, if a crane is used and/or stored in harsh
that a good coat of automotive wax be applied to this
environments (such as islands, coastal regions, industrial
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area afterwards.
areas, areas where winter road salt is regularly used, etc.),
• All identified spots and/or areas that have been reapplication of treatment is recommended sooner than 12
scratched through to the metal should be touched up months, e.g., repeat treatment in 6-9 months.
and repaired as soon as possible to prevent flash
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• Do not apply to recently primered and painted areas for
rusting. To repair a major scratch (down to bare metal) or
at least 48 hours after paint is properly dried and cured.
minor damage, follow these procedures:
For minor touch up areas a 24 hour period is needed for
NOTE: Manitowoc Crane Care recommends that a cure time before applying treatment.
qualified body repairman prepare, prime and paint
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NOTE: Unit must be completely dry before applying
any major scratch(es) or minor damage. treatment.
• Do not allow product to puddle or build-up on weather
stripping, rubber gaskets, etc. Unit should not have
CAUTION puddles or runs evident anywhere.
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To the extent any damage is structural in nature,

Manitowoc Crane Care must be contacted and consulted • To ensure proper coverage of treatment, the product
as to what repairs may be required. needs to be fogged on the unit.
• Use of pressure pots to apply the treatment to the unit
• For scratches and marks in highly visible areas: being processed is recommended.
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• Sand to remove the scratch and feather outward from • Carwell treatment is available in 16 ounce spray bottles
the mark to blend the repair into the original surface. from Manitowoc Crane Care (order part number
Body putty may be applied as necessary to hide the 8898904099).
defect; then sand smooth.
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• After application of the treatment is complete, wash or

• Cover all bare metal with a primer that is compatible with clean film residue from lights, windshield, grab handles,
the original paint finish ladders/steps and all access areas to crane, as
necessary.
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• and allow to dry thoroughly.

• Prepare the surface prior to applying the finish coat of Please contact Manitowoc Crane Care should you have any
paint. questions.
• Apply a finish coat paint using accepted blending Areas of Application

techniques. Use of original paint colors is recommended
to insure the best color match possible. Refer to Figure 9-11 and Figure 9-12
For scratches and marks in areas of low visibility: • The underside of the unit will have full coverage of the
• Consider touching up the spots with a brush technique

rust inhibitor. These are the only areas that a full coat of
the rust inhibitor is acceptable on the painted surfaces.
9
to cover the bare metal. This will retard the effects of Areas include; Valves, hose end and fittings, Swivel,
corrosion and enable you to do the repair at a later time pumps, axles, drive lines, transmission, slew ring
during a normal maintenance interval. fasteners and all interior surfaces of the frame.

• Frame application areas are; hose ends and fittings, all • Boom applications areas are; pivot pins, hose end and
unpainted fasteners and hardware, all bare metal fittings, jib pins and shafts, all bare metal surfaces,
surfaces, outrigger pads, and back up alarm hardware. headache ball pins/ hook block pins and fasteners.
• Superstructure applications are; hose end and fittings, • All hardware, clips, pins, hose connections not painted
wire rope on hoist roller tensioning springs on hoists, all will have treatment applied.
unpainted fasteners and hardware, valves, slew ring
fasteners and all bare metal surfaces.
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Figure 9-11
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8 14 21
Figure 9-12
Item Description
Item Description 7 Hose Connections inside turntable
1 Hoist Tension Springs All Hardware, Clips, Pins, Hose Connections
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2 Boom Extension Pins, Clips not painted O/R Pins, Clips
3 Boom Nose Pins, Clips 9 Turntable Bearing Fasteners
4 Hook Block\Headache Ball 10 O/R Hose Connections
5 Boom Extension Hanger Hardware 11 Hook Block Tie Down Cable
6 Pivot Shaft 12 O/R Pins, Clips

Item Description
13 O/R Beam Wear Pad Adjustment Hardware
14 Entire underside of unit
15 Valve Bank
16 Powertrain Hardware inside compartment
17 Hoist Hose Connections
18 Wire Rope
19 Counterweight Mounting Hardware
20 Counterweight Pins
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21 Hose Connections
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22 Mirror Mounting Hardware
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RT530E-2 SERVICE MANUAL
Alphabetical Index
Accessory With Swing Directional Control Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33

Air Intake and Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Axle Oscillation Lockout Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-64
Axle Oscillation Lockout Valve (Optional CE Units). . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52
Axle Oscillation Lockout Valve (Standard Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-50
Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Boom Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Boom Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Boom Extension And Retraction Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14
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Carwell® Rust Inhibitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-24
Check Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48
Counterweight Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
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Cross Axle Differential Lock Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54
Directional Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30
Drive Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
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Dual Accumulator Charge Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37
Dual Rod Telescope Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
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General Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Hoist Drum Rotation Indicator System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Hoist to Boom Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Holding Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40
Hook Block. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
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Hydraulic Accumulator Service Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39

Hydraulic Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Integrated Outrigger/Rear Steer Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Lift Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
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Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57

List of Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Lubrication Intervals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Oil Cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
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Outrigger Control Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43

Outrigger Extension Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-71
Outrigger jack Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-73
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Outriggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24
Park Brake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24
Parking Brake Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22
Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
Pilot Operated Check Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44
Piston Motor and Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Pressure Setting Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Range Shift/Parking Brake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49
Rear Axle Oscillation Lockout System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
Service Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16
Steer Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-68
Steering Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35
Steering Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
Supply Pressure and Return Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Swing Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
GROVE 1
SERVICE MANUAL RT530E-2
Swing Gearbox And Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

Swing Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Swingaway Boom Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
Swivels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Tandem Brake Valve with Treadle Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36
Telescope Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
Water Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
Wire Rope Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Wire Rope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
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Grove Service Manual RT530E 2 CTRL556 00

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Grove RT530E-2

THIS PAGE BLANK

Crane Model Number

Always furnish crane serial number when ordering parts or

An untrained operator subjects himself and others to death or

The original language of this publication is English.

See back of this manual for Alphabetical Index

Hydraulic Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Weld Studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

Wire Rope Inspection/Replacement (All Wire Rope) . . . . . . . . . . . . . . . . . . . . . . . 1-18

SECTION 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic System

Steering Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35

Hydraulic Accumulator Service Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39

SECTION 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electric System

Windshield Wiper Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Boom Alignment And Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

Telescope Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21

Lift Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25

Swingaway Boom Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29

SECTION 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . Hoist And Counterweight

Functional Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

SECTION 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Swing System

Hydraulic Swivel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16

SECTION 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Train

Service Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16

Parking Brake Actuator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22

Locks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 Seizing Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . 1-20

DESCRIPTION The superstructure is capable of 360 degree rotation in either

equipped with a four-section, full power, sequenced and

GROVE Published 4-22-15, Control # 556-00 1-1

LIST OF SPECIFICATIONS Engine

at Full Level . . . . . . . . . . . . . . . .396 l (105 gal) Length. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Axle Differentials . . . . . . . . . . . . . . . . . . 9.5 l (20 pt)

Stall Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . 2.024:1

1-2 Published 4-22-15, Control # 556-00

Hydraulic Pumps Pump #3

GROVE Published 4-22-15, Control # 556-00 1-3

CG From Rear Weight Front Axle Rear Axle

sheave) Stowed in Tray

396.24 (156.00) 193 (425) 209 (460) -16 (-35)

Storage Tray Mats 337.82 (133.00) 20 (43) 18 (40) 1 (3)

1-4 Published 4-22-15, Control # 556-00

CG From Rear Weight Front Axle Rear Axle

GROVE Published 4-22-15, Control # 556-00 1-5

1-6 Published 4-22-15, Control # 556-00

Item Description Item Description Item Description

4 Boom Pivot 9 Front Axle

FIGURE 1-2 continued

Item Description Item Description Item Description

FIGURE 1-2 continued

GROVE Published 4-22-15, Control # 556-00 1-7

is completed to see that nothing has been overlooked.

or tape each line or opening to prevent entry of foreign

Assemble tapered parts dry. Before assembling parts with

1-8 Published 4-22-15, Control # 556-00

Flat metal locks must be installed properly to be effective. Installation