RT440B ENG Rev.01 - 2007 (1) (099-248)

MAINTENANCE CHECKS
Any battery which is known to be discharged or has a BOOST CHARGE If a battery requires a boost charge,
stabilized voltage below 12.2 volts should be charged it should be charged at 45 amperes for 20 minutes.
as shown below. This cannot be used for a new battery being prepared
for installation.
12-VOLT MAINTENANCE-FREE BATTERY CHARG
ING GUIDE MODIFIED CONSTANT POTENTIAL TAPER
CHARGING It is recommended that maintenance-free
batteries be recharged on a modified constant poten
Battery Capacity
Slow Charge tial taper chargers. The total charge must not exceed
(Reserve Minutes)
the ampere-hour equivalent of the values shown in the
“Charging Guide”. It is recommended that the initial
Above 125 to 170 20 Hours @ 5 Amps
charging rate not exceed 30 amperes.
Minutes 10 Hours @ 10 Amps
NOTE: If a battery is to be charged overnight, (16

hours) a timer or voltage controlled charger is recom
mended. If the charger does not have such controls, a
3 ampere rate should be used for batteries of 80 min
utes or less capacity and 5 amperes for above 80 to
125 minutes reserve capacity batteries. Batteries over
125 minutes should be charged at the specified SLow
Charge rate.
ELECTRICAL SYSTEM
COLLECTOR RING
ELECTRICAL COLLECTOR RING When trouble MAINTENANCE CHECKS On a daily basis, inspect
shooting the electrical system, always check the collec the cylinder mounting brackets, bushings, and pins for
tor ring first to see that the spring-loaded brushes are wear, tightness and damage. If misalignment or exces
centered in the bands. Keep free of any foreign materi sive play or wear are detected, replace the defective
al. pin or bushing. Check the rod eye welds for cracks and
breaks.
Keep the set screws on the collector ring tight. Other
wise the wire harness may wrap up as the machine is Inspect the hydraulic cylinder rods for nicks, dents,
swung. and scoring as part of your WEEKLY MAINTENANCE
check. Also check the cylinders for leaks at the wiper
The cover should allow for free operation of the collec- seals. Repair or replace any damaged components.
tor ring and the brake. If linkages bind, erratic opera-
tion may result. Check for unrestricted operation. MAINTENANCE CHECK Every TWO YEARS OR
4000 HOURS disassemble and inspect the winch
COLLECTOR RING MAINTENANCE If not revolved components. These include the gearing, bearings, and
for some time, under some conditions, the ring will brake friction discs. Refer to the Service Manual for
have a tendency to collect fine silt, or salt atmosphere disassembly procedures.
will cause corrosion. If this happens, the crane should
be rotated through several revolutions if possible. The LUBRICATION Lubrication for the winch is provided
cleaning action of the brushes should clean the ring by weepage flow from the drive motor. Oil enters the
surfaces. If it does not, or it is not practical to revolve final drive end through the drive shaft tube in the drum.
the machine, it may be necessary to use a standard A drain line on the main drive end cover returns excess
non-residue solvent to clean the ring. Then lightly sand oil to the reservoir.
the brushes and rings with a fine grade of sandpaper
and dust off with compressed air.
Revised: December 2005 Page 4 - 29 RT440B

MAINTENANCE CHECKS
CABLE REEVING
CABLE REEVING When reeving the machine for any This machine incorporates a “Quick Reeving” boom
job, remember that hoisting and lowering speeds de head and block which do not require removal of the
crease as the number of parts of line increases. For wedge and socket from the rope in order to change the
the most efficient use of the machine, it is desirable to reeving. Removal of two pins in the boom head and
use the minimum number of required parts for lifting three in the hook block will allow the wedge and socket
the anticipated loads. to pass through.
Never use less than the number of parts called for by NOTE: If a socket is changed or replaced, or if you are
changing hook block weights, it is IMPORTANT to the changing hook block weights, it is IMPORTANT to use
load rating chart. The minimum required number use the correct socket.
the correct socket. of parts is determined by referring
to the load rating chart.
SPOOLING WIRE ROPE ON DRUMS
Care must be exercised when installing wire rope on

the winch drum. Improper spooling can. result in rope
damage through crushing, kinking, dog legs, abra-
sion and cutting. Poorly installed wire rope will also
adversely affect the operating characteristics of the
ma-chine by causing uneven application of force and
motion. This, in turn, can cause premature fatiguing
and failure of the rope.
Thoroughly inspect and clean the winch before pro

ceeding with the installation. Check the lagging and
drum flanges for cracks, breaks and excessive wear.
Deformed or outsized drum and excessive undercut
ting at the base of the flange also indicate that repair or
replacement of the drum is necessary.
Check the bearings for excessive wear and play. After

correcting any defects revealed by the inspection and Apply braking force to the reel flange in order to prevent
determining that the winch is in good operating condi- overrun as the rope is being drawn off. Loops formed
tion, spool the wire rope as follows: by overrun can cause kinks and doglegs in the rope,
resulting in damage and premature rope failure. A tim-
Mount the cable shipping reel vertically on jacks or a ber or block forced against the shipping reel flange can
suitable supporting structure, with a pipe or bar through be used to provide the required braking force.
the reel center. The cable should be drawn from the top
of the reel, as shown, in order to avoid reverse bend-
ing as it is spooled onto the If cable is wound from the
storage reel onto the drum, the reel should be rotated
in the same direction as the hoist.
RT440B Page 4 - 30 Revised: December 2005

MAINTENANCE CHECKS
WIRE ROPE AND REEVING
MAINTENANCE All wire ropes in active service should Replace or repair any items found to be in unsatisfacto
be inspected DAILY along with spooling, sheaves, ry condition.
wedge sockets, and any other wire rope fittings for
damage. Once WEEKLY a through wire rope inspec In addition to damage such as kinking, crushing and
tion should be made by a competent inspector. A record broken wires, factors such as corrosion, abrasion, pit
should be kept of the inspections on 4-5. ting, peening and scrubbing of the outside wires, reduc
tion of rope diameter, the condition of other compo-
Refer to Wire Rope Users Manual, section 9 and ANSI nents and proper lubrication are considered. Refer to
Standard B30.5 for guidelines covering the inspection, page 426 for wire rope lubricating procedures.
maintenance, repair, and replacement of wire rope.
Worn, kinked, birdcaged, fatigued or otherwise dam Before installing a new or replacement rope, make cer
aged wire rope must be removed immediately. Wire tain the rope to be used is the proper type and size.
rope when properly installed, lubricated and employed, The wrong rope will not function properly and may
will give many hours of satisfactory use. Whereas, a even be dangerous.
new piece of wire rope can be immediately ruined if
misused.
WIRE ROPE SPECIFICATIONS
Refer to Section 3 “OPERATING PROCEDURES”
Terex permits the use of rotation resistant wire rope,

other types are not approved. When this rope is used
the working load shall not exceed 1/5th (20%) of the
rated breaking strength. The retirement criteria shall be
as follows: two broken wires in six rope diameters or
four broken wires in thirty rope diameters.
Install cable on the winch drum in accordance with the
following procedure.
1. Position the cable over the boom tip sheave and

route back to the winch drum.
2. Position the winch drum with the cable anchor slot
on top.
3. Insert cable through slot and position around the ca
ble wedge.
4. Position the anchor wedge in the drum slot; pull
firmly on the free end of the cable to secure the
wedge.
5. Slowly rotate the drum, ensuring the first layer of
cable is evenly wound on the drum.
6. Install the remainder of the cable, as applicable.
The end of the cable should be even with the bot-
tom of the anchor wedge.
NOTE: If the wedge does not seat properly in the slot,

carefully tap the top of the wedge with a mallet.

MAINTENANCE CHECKS
Follow the procedure below when installing wedge type

WEDGE
sockets on wire rope. Be certain the correct socket and
wedge are used.
1. Lead the rope through the socket, form a large loop
and draw the rope end back through the socket. A
length of rope equal to at least one rope lay should
be drawn back through.
2. Insert the wedge and allow the rope strands to ad-

just around it.
The wrong cable wedge could permit the wire rope to

work lose and detach itself from the drum; possibly
causing property damage or personal injury.
Tension the wire rope by braking the shipping reel and

slowly operate the winch in the raise mode to wind the
cable onto the winch drum. As the spooling proceeds,
make sure the adjacent turns are tight against one an 3. Seat the wedge and loop just tightly enough to al-
other. A lead or brass hammer may be used to tap the lowhandling by attaching the socket to a strong sup-
rope over against preceding turns. Tight winding on the port and engaging the winch to take a strain on the
drum is absolutely essential. rope.
4. Final seating of the wedge is accomplished by mak-

ing lifts of gradually increasing loads. avoid impos-
ing shock loads on the rope until the wedge is firmly
Never use a steel hammer or pry bar to move the rope in place.
over on the drum. These tools can easily damage the
rope.
After the rope is wound onto the winch drum, reeve the
cable as desired.
5. After the wedge has been firmly seated, a short-

Use only factory supplied sockets, wedges and pins of length (6 inches) of the cable should be secured
the proper size; make no substitutions. to the free end of the wire rope to act as a stop as
shown. DO NOT clamp the free end to the load sup
porting end as this will weaken the rope.

MAINTENANCE CHECKS
CRANE BOOM
WEEKLY:
STRUCTURAL MEMBERS AND WELDS Visually in
spect all structural members and welds including (but
not limited to) the extended boom for straightness, roll
er (or pad) adjustment, and cracks. Pay special atten
tion to the longitudinal welds joining the top, side and If any cracks in either fillet welds or plates are noted,
bottom plates. Check the welds attaching the jib ears the particular component must be replaced before any
to the boom head and the welds attaching the boom further crane operations are performed. This is neces
head to the tip section. Inspect the cylinder attaching sary to maintain the structural strength of the boom
supports and the boom pivot area. and prevent possible catastrophic failure resulting in
injury or property damage.
On the superstructure, inspect the superstructure as
well as the welds on the hoist cylinder supports and the Field repair of boom sections is NOT recommended
welds between the bottom mounting plate and the ver because distortion may be introduced and original
tical plates. This is especially important if the machine structural strength not restored.
is being used extensively in clamshell, pile driving,
concrete pouring, headache ball, or other high duty cy Boom extension indicator decals are extremely impor
cle applications. tant and must be maintained in place at all times.
Boom section failures can occur due to overstressing
On the carrier, inspect the swing bearing weld band within rated capacities if the sections are not equally
and supporting header welds. Check the outrigger at extended within one indicator mark difference between
taching welds, outrigger box ends at the collar, jack the telescoping sections.
cylinder mounting tube, and the beam welds.
NOTE: Sections are equalized byfully extending or ful
BOOM Visually inspect all boom sections a minimum ly retracting the boom. When the boom reaches either
of weekly or every fifty (50) hours, whichever occurs full extension or retraction continuing to hold the tele-
first. Preparatory to making the inspection, set the out scope lever in the extended or retracted position will
riggers and rotate the upper to an area where the boom allow the boom sections to be proportioned equally.
can be fully lowered and extended.
If any indicator decals are missing or illegible (either tri
With the boom fully lowered and extended, visually in angle markers or boom length numbers), order the ap
spect the sides, top and bottom of each section for any plicable items through your distributor and apply them
unusual deformation, scrubbing, wear, or cracking in using the dimensions given on the following page.
either the plates or welds, particularly the fillet welds
along the bottom edge of the side plates of the tele
scoping sections. In addition, note any missing or illeg
ible indicator mark decals on the telescoping sections.

MAINTENANCE CHECKS

TROUBLESHOOTING
INDEX
SECTION 5
SUBJECT PAGE
General Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 1
Hydraulic - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 2
Operator Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 3
Front Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 4
Steering Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 6
Alternator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 10
Starter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 11
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 12
Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 13
Air Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 13
Swing Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 14
Boom Hoist Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 15
Boom Telescope Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 16
Winch Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 17
Outrigger Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 19
Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 21
Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 24
Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 25
Fluid Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 26
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 28
Cylinder Leakage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 29
Excessive Heating Of Oil In System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 30
Electrical Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 31
Propane Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 32
Maintenance Free Battery Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 35
Anti Two Block System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 37
RT700 Issued: August 2003

TROUBLESHOOTING
As the operator, it is your responsibility to detect any unusual, If you can’t answer YES to all three questions, rely on your
sounds, odors, or other signs of abnormal performance that Distributor Serviceman. He has the right tools, testing equip-
could indicate trouble ahead. ment and service knowledge to pin-point the problem in min-
utes instead of the hours consumed in hit-or-miss methods.
By detecting any problems in their early stages, you can save TIME IS MONEY! He will save it for you.
yourself unnecessary downtime and your employer a lot of
money! Therefore, it is also your responsibility to use good If you decide to attempt an adjustment yourself, follow a log-
judgment in detecting failures in quickly and repairing them. ical TROUBLE SHOOTING PROCEDURE. Don’t simply
If you don’t, one failure can lead to another. replace parts until the trouble is found.
Before attempting to make an adjustment yourself, ask your-

self if you have the RIGHT TOOLS, IF you have the PROP-
ER TEST EQUIPMENT and IF you can accurately
DIAGNOSE the cause of the problem.
GENERAL PROCEDURE
1 - KNOW THE SYSTEM Study this manual and learn 6 - TEST YOUR CONCLUSION Test your conclusions, in
what makes the machine “tick”, how it should behave, sound order of obviousness, until the source of the failure is found.
and smell. The machine can then be repaired at minimal cost and down-
time. Make the repair. Recheck to ensure that nothing has
2 - OPERATE THE MACHINE Test operate all machine been overlooked, functionally test the repaired part in the
functions. Note all abnormal sounds, odors and movements. system.
Always proceed in the most logical order to determine the
cause. 7 - REVIEW MAINTENANCE PROCEDURES Prevent
recurrences of all premature failures by regularly checking
3 - INSPECT THE MACHINE Look for leaks, listen for the the filters, temperature, adjustments and lubrication. Make
source of abnormal sounds, detect the origin of unusual daily inspections.
odors. Check the condition of the oil and filters.
NOTE: Your safety and that of others is always the number
4 - LIST THE POSSIBLE CAUSES Use your best judg- one consideration when working around cranes. Safety is a
ment in listing all possible causes of the failure. matter of thoroughly understanding the job to be done and
the application of good common sense. It is not just a matter
5 - REACH A CONCLUSION Review your list of possible of “do’s” and “don’ts”. Stay clear of all moving parts.
causes and decide which are the most likely to cause the fail-
ure. Consider the most obvious first.
RT700 Series Page 5 - 1 Issued: August 2003

TROUBLESHOOTING
HYDRAULICS - GENERAL
Before any troubleshooting is attempted, become fully ac- If, in spite of these precautions, improper operation does oc-
quainted with the following two (2) basic fundamental facts cur, the cause can generally be traced to one of the following:
of a hydraulic system:
1. Use of the wrong viscosity or type of oil.
1 - SPEED The speed of a hydraulic function is directly re-
lated to the system flow. A reduction in speed of a cylinder or 2. Insufficient fluid in the system.
motor is caused by an insufficient quantity of oil being deliv-
ered to the component. 3. Presence of air in the system.
2 - POWER The power or force of a hydraulic function is re- 4. Mechanical damage or structural failure.
lated to pressure.
5. Internal or external leakage.
If an understanding of the differences between speed and
power of a hydraulic system is under- stood correctly, then 6. Dirt, decomposed packing, water, sludge, rust, etc., in the
accurate troubleshooting can be accomplished in a minimum system.
amount of time.
7. Improper adjustments.
8. Oil cooler plugged, dirty or leaking.
Whenever hydraulic, fuel, lubricating oil lines, or air lines are

to be disconnected, clean the adjacent area as well as the point
of disconnect. As soon disconnected, cap, plug or tape each
line or opening to prevent the entry of foreign material. The
same recommendations for cleaning and covering apply when
NEVER resort to increasing the valve relief pressure in access covers or inspection plates are removed.
an attempt to cure the ills of the system. Fully diagnose
the problem. Clean and inspect all parts. Be sure all passages and holes are
open. Cover all parts to keep them clean. Be sure parts are
Hydraulic components are precision units and their continued clean when they are installed. Leave new parts in their con-
smooth operation depends on proper care. Therefore, do not tainers until ready for assembly.
neglect hydraulic systems. Keep them clean and change the
oil and oil filter at established intervals. Clean the preservative compound from all machined surfaces
of new parts before installing them.

TROUBLESHOOTING
OPERATOR - CONTROLS
NO MOVEMENT OF THE FUNCTION Check the outrigger extend-retract and function valves by
pushing the. pins in prior to activating the functions. Check to
Check to see that valve spool actuates when control is oper- see if the appropriate pin has been pushed back out as the
ated. functions are activated. If they have, the spools are shifting.
If spool shifts, refer to sections on 1) Relief Valve Trouble- If the spools do not all shift, check the electrical connections.
shooting; 2) Motor, Cylinder or Winch Troubleshooting ac- Frequently ground connection are a problem.
cording to circuit being checked; 3) Pump Troubleshooting;
4) Control Valve Troubleshooting. If no electrical power is present at the valve, check the elec-
trical wiring and correct the fault. Most controls require a
WITH THE ELECTRICALLY CONTROLLED VALVES minimum of 10 volts.
on the outriggers, three (3) spools must be checked.
If power is present, repair or replace the solenoid or valve sec-
The diverter valve should be checked by using a test gauge on tion which is not shifting.
the test port and activating the outrigger controls. If pressure
(2500 psi) is indicated, the spool is shifting. If the spools shift, see page 5-19, “Outrigger Cir- cuit”.

TROUBLESHOOTING
AXLES
RAPID OR UNEVEN TIRE WEAR
CAUSE REMEDY
Incorrect toe-setting............................................................................... Check and reset toe-in if necessary.
Improper tire inflation ........................................................................... Inflate to proper pressure.
HARD STEERING
CAUSE REMEDY
Inadequate or improper lubrication of knuckle pins ............................. Consult lubrication chart for proper lubricant,
lubrication intervals and procedures.
Overloaded Axle ...................................................................................Reduce load.
RAPID WEAR OF TIE ROD ENDS
CAUSE REMEDY
Inadequate or improper lubrication ....................................................... Consult lubrication chart for proper lubricant,
Severely contaminative environment .................................................... Clean and lubricate more often.

TROUBLESHOOTING
AXLES
BENT OR BROKEN TIE ROD, STEERING ARM,

TIE ROD ARM, OR BALL STUD
CAUSE REMEDY
Excessive power steering pressure ........................................................Check steering pump relief setting, check steering
system relief setting; adjust as required.
HEAVILY WORN STEERING ARM

BALL STUD
CAUSE REMEDY
EXCESSIVE WEAR OF KNUCKLE PINS

AND BUSHINGS
CAUSE REMEDY
lubrication intervals and procedures. Increase lubri-
cation frequency when operating in extrem condi-
tions.

TROUBLESHOOTING
STEERING CIRCUIT
Most steering problems can be corrected if the problem is properly defined. The entire steering system should be evaluated be-
fore removing any components. The steering control unit is generally not the cause of most steering problems. The following
is a list of steering problems along with possible causes and suggested corrections.
SLOW STEERING, HARD STEERING, OR LOSS OF POWER ASSIST
- -CAUSE- -REMEDY-
Worn or malfunctioning pump ................................................................................ Replace pump.
Stuck flow divider piston ........................................................................................ Replace flow divider.
Malfunctioning relief valve allowing the system

pressure to be less than specified ............................................................................ Replace the relief valve.
Overloaded steer axle .............................................................................................. Reduce load.
Leaking or kinked load sensing signal line ............................................................. Correct.
Malfunctioning priority valve.............. ...................................................................Check spring and sticking piston.

Check damping orifices in both ends
of main bore.
Check adjustment See page 5-6.
Check system pressure at SCU inlet
for proper system pressure. If not
correct replace priority valve relief
cartridge.
WANDER
VEHICLE WILL NOT STAY IN A STRAIGHT LINE
-CAUSE- -REMEDY-
Air in the system due to low level of oil,

cavitating pump, leaky fitting, pinched hose, etc ....................................................Correct.
Worn mechanical linkage........................................................................................ Repair or replace.
Bending of linkage or cylinder rod ......................................................................... Repair or replace.
Loose cylinder piston .............................................................................................. Repair or replace.
Severe wear in steering control unit........................................................................ Replace the steering control unit.

TROUBLESHOOTING
DRIFT
VEHICLE VEERS SLOWLY IN ONE DIRECTION
-CAUSE- -REMEDY-
Leaking cylinder seals ............................................................................................. Reseal cylinders.
Worn or damaged steering linkage..........................................................................Replace linkage and align front end.
SLIP
A SLOW MOVEMENT OFSTEERING WHEEL FAILS TO
CAUSE ANY MOVEMENT OF STEERED WHEELS
-CAUSE- -CAUSE-
Leakage of cylinder piston seals or accessory

valve between cylinder lines or ports...................................................................... Replace seals or accessory valve.
Worn steering control unit meter ............................................................................ Replace steering control unit.
TEMPORARY HARD STEERING OR HANG-UP
-CAUSE- -REMEDY-
Thermal Shock* ...................................................................................................... Check unit for proper operation and

cause of thermal shock.
ERRATIC STEERING
-CAUSE- -REMEDY-
Air in system due to low level of oil,

cavitating pump, leaky fitting, pinched hose, etc ....................................................Correct condition and add fluid.
Loose cylinder piston .............................................................................................. Replace cylinder.
Thermal shock damage*.......................................................................................... Replace steering control unit.
Sticking flow control spool ..................................................................................... Replace flow control valve.
“SPONGY” OR SOFT STEERING
-CAUSE- -REMEDY-
Air in hydraulic system. Most likely air

trapped in cylinders or lines ....................................................................................Bleed air out of system.
Low fluid level ........................................................................................................ Add fluid and check for leaks.

TROUBLESHOOTING
FREE WHEELING
STEERING WHEEL TURNS FREELY WITH NO FEELING OF
PRESSURE AND NO ACTION ON STEERED WHEELS
-CAUSE- -REMEDY-
Steering column upper shaft is loose or damaged ................................................... Tighten steering wheel nut.
Lower splines of column may be disengaged

or broken .................................................................................................................Repair or replace column.
Steering control unit meter has a lack of oil.

This can happen on start-up, after repair, or
long periods of non use ...........................................................................................Usually starting engine will cure
problem. If not, stop engine, discon
nect steer pump outlet hose and
pour in hydraulic oil to prime pump.
No flow to steering unit can becaused by:

1. Low fluid level ................................................................................................... Add fluid and check for leaks.
2. Ruptured hose.....................................................................................................Replace hose.
3. Internal steering control unit damage
due to thermal shock* ............................................................................................ Replace the unit.
FREE WHEELING STEERING

WHEEL TURNS WITH SLIGHT RESISTANCE BUT
RESULTS IN LITTLE OR NO STEERED WHEEL ACTION
-CAUSE- -REMEDY-
Piston seal blown out............................................................................................... Determine cause. Correct and

replace seal.
EXCESSIVE FREE PLAY AT STEERING WHEEL
-CAUSE- -REMEDY-
Loose steering wheel nut. Steering column

shaft worn or damaged. There should be very little
free play in the unit itself......................................................................................... Repair or replace steering wheel con-
nection or column.
EXCESSIVE FREE PLAY AT STEERED WHEELS
-CAUSE- REMEDY-
Broken or worn linkage between cylinder and

steered wheels ......................................................................................................... Check for loose fitting bearings and
anchor points in steering linkage
between cylinder and steered wheels.
Leaky cylinder seals ................................................................................................Replace cylinder seals.

TROUBLESHOOTING
BINDING OR POOR CENTERING OF STEERING WHEEL
-CAUSE- -REMEDY-
Binding or misalignment in steering column

or splined input connection ....................................................................................Align column pilot and spline to
steering control unit.
High back pressure in tank line can cause

slow return to center. Should not exceed 300 psi....................................................Check circuit return line for block-
age.
Large particles can cause binding between
the spool and sleeve................................................................................................Clean unit and filter oil. If another
component has failed, generating
contaminents, flush system while
bypassing steering control unit.
STEERING UNIT LOCKS UP
-CAUSE- -REMEDY-
Large particles in meter section .............................................................................. Clean the unit.
Insufficient hydraulic power (units over 15 in3) ..................................................... Check hydraulic power supply.
Severe wear and/or broken pin ................................................................................ Replace the unit.
Thermal shock* .......................................................................................................Replace the unit.
STEERING WHEEL OSCILLATES OR TURNS BY ITSELF
-CAUSE- -REMEDY-
Parts assembled wrong. Steering unit improperly timed......................................... Correct timing.
Lines connected to wrong ports .............................................................................. Reconnect lines correctly.
Leaking seal in rotary manifold .............................................................................. Reseal.
STEERED WHEELS TURN IN WRONG DIRECTION

WHEN OPERATOR ACTIVATES STEERING WHEEL
-CAUSE- -REMEDY-
Lines connected to wrong cylinder ports ................................................................ Reconnect lines correctly.
3-way steering valve malfunctioning ...................................................................... See “Operator Controls”.
Cab facing toward rear reverses response ............................................................... Be alert when operating with cab
over rear.
STEERING WHEEL KICKS AT START OF STEERING
-CAUSE- -REMEDY-
No inlet check valve on steering control unit.......................................................... Install a check valve.

TROUBLESHOOTING
ALTERNATOR
OPERATION NOISY
CAUSE REMEDY
Worn or dry bearings............................................................................. Replace worn bearings.
Alternator mounting loose..................................................................... Tighten alternator mounting.
Belt loose ...............................................................................................Replace worn belt or tighten loose belt.
Brush holders out of alignment .............................................................Replace brush holders.
Brushes not seated properly ..................................................................Reseat or replace brushes.
Armature unbalanced ............................................................................ Replace armature.
Commutator out-of-round ..................................................................... Dress commutator.
Loose windings .....................................................................................Replace defective windings.
Armature rubbing .................................................................................. Replace bearings.
EXCESSIVELY HIGH ALTERNATOR ELECTRICAL OUTPUT
CAUSE REMEDY
Alternator regulator out of adjustment .................................................. Replace regulator.
Field leads shorted................................................................................. Replace or repair alternator.
Alternator regulator shorted ..................................................................Replace regulator.
ALTERNATOR MECHANICALLY INOPERATIVE
CAUSE REMEDY
Belt loose ...............................................................................................Tighten belt.
Armature shaft sheared.......................................................................... Replace or repair alternator.

TROUBLESHOOTING
LOW OR NO ALTERNATOR ELECTRICAL OUPUT
CAUSE REMEDY
Field coil open ....................................................................................... Replace or repair alternator.
Brushes dirty, worn, pitted, or burned...................................................Replace or repair alternator.
Alternator regulator defective ............................................................... Replace regulator.
Alternator to regulator field leads

open or connections loose ..................................................................... Tighten connections or replace field leads.
ALTERNATOR OVERHEATS
CAUSE REMEDY
Loose or worn belt or pulley ................................................................. Adjust belt, or replace worn belt or pulleys.
Misalignment......................................................................................... Inspect mounting brackets and tension adjusting

arm for looseness. Tighten or replace parts as
required.
STARTER
STARTER INOPERATIVE
CAUSE REMEDY
Commutator dirty .................................................................................. Clean commutator.
Brushes worn......................................................................................... Replace brushes.
Starter relay malfunctioning..................................................................Repair or replace relay.
Pinion spring broken or weak................................................................ Replace or repair starter.
Frame housing defective ....................................................................... Replace or repair starter.

TROUBLESHOOTING
BRAKES
INSUFFICENT BRAKE ACTION
CAUSE REMEDY
Worn brake linings ................................................................................ Replace brake pads.
Blocked, bent, or broken tubing or hose ............................................... Remove obstructions in line or replace faulty tubing.
Brake valve delivery pressure below normal ........................................ Clean and replace worn parts if brake valve is defec-
tive, replace unit.
Insufficient parking brake valve delivery pressure ............................... Clean and replace worn parts, or if valve is defective,
replace unit.
BRAKES RELEASE TOO SLOWLY WITH PEDAL RELEASED
CAUSE REMEDY
Weak or broken valve diaphragm return spring.................................... Replace brake valve.
Relay or quick-release valve exhaust

ports obstructed .....................................................................................Clean or replace faulty unit.
ONE BRAKE DRAGS WITH PEDAL RELEASED
CAUSE REMEDY
Brake pad binding ................................................................................. Remove pad, clean and lubricate
Weak or broken brake shoe return springs ............................................Replace faulty spring
BRAKES ACT UNEVENLY OR GRAB WHEN PEDAL IS DEPRESSED
CAUSE REMEDY
Grease or oil on linings .........................................................................Clean linings or replace linings or pad assemblies.

Defective brake valve............................................................................ Replace faulty unit.
Brakes need relining..............................................................................Replace brake pads.
Brake chamber diaphragm leaking........................................................Tighten all fittings; if caused by broken or faulty

unit, replace the unit.

TROUBLESHOOTING
PARKING BRAKE
PARKING BRAKE WON’T APPLY
CAUSE REMEDY
Restricted hose or tube .......................................................................... Remove restriction or replace.
Defective relay valve............................................................................. Repair or replace.
Defective spring brake valve................................................................. Repair or replace.
Defective control valve .........................................................................Repair or replace.
PARKING BRAKES WON’T RELEASE
CAUSE REMEDY
Insufficient system air pressure.............................................................Allow engine to run to increase pressure to above 70

p.s.i.
Restricted hose or tube .......................................................................... Remove restriction or replace.
Insufficient hold off pressure ................................................................ Check for system (or excessive valve) leaks.
Leaking brake actuator diaphragm ........................................................Replace brake actuator (spring pot).
Defective relay valve............................................................................. Repair or replace relay valve.
Defective spring brake valve................................................................. Repair or replace spring brake valve.
Defective control valve .........................................................................Repair or replace control valve.
AIR PRESSURE
INADEQUATE AIR PRESSURE
CAUSE REMEDY
Leaks in system .....................................................................................Repair leaks.
Frozen lines ........................................................................................... Thaw out lines.
Defective compressor ............................................................................ Inspect for sticking unloader valve, replace if neces-
sary.
Reservoir leaking...................................................................................Replace.
Tank to compressor supply line damaged ............................................. Replace.

TROUBLESHOOTING
SWING CIRCUIT
SWING COMPLETELY INOPERATIVE
CAUSE REMEDY
Mechanical swing lock applied, if equipped ......................................... Disengage the swing lock.
Swing brake applied ..............................................................................Disengage the swing brake.
Spring brake stuck in applied position .................................................. Disassemble swing brake and free-up unit.
Swing valve main relief valve stuck in open position...........................See section on “Relief Valves”.
Swing motor leaks excessively internally ............................................. See section of “Fluid Motor”.
Mechanical fault in swing reducer

gear box or swing bearing ..................................................................... Repair swing reducer or replace swing bearing.
Hose plugged or liner collapsed ............................................................ Replace hose.
Rotary manifold leaking internally ....................................................... Reseal rotary manifold.
Swing pump faulty ................................................................................ See section on “Pumps”.
SWING MOTION SLUGGISH
CAUSE REMEDY
Main relief valve stuck in open position ............................................... Replace.
Faulty swing pump ................................................................................ Repair or replace swing pump.
Swing motor leaks excessively, internally ............................................Replace or reseal motor.
Excessive leakage around swing control valve spool ...........................Replace or replace control valve.
SWING MOTION ERRATIC
CAUSE REMEDY
Brake not releasing completely .............................................................Check operation of swing brake and/or swing lock.
Low hydraulic oil level .........................................................................Add oil as required.

TROUBLESHOOTING
SWING MOTION ERRATIC (CONTINUED)
CAUSE REMEDY
Swing bearing not lubricated properly .................................................. Lubricate swing bearing.
Main relief malfunctioning....................................................................See section on “Relief Valves”.
BOOM HOIST CIRCUIT
BOOM DRIFTS DOWN
CAUSE REMEDY
Hold valve not seating properly ............................................................ Replace hold valve.
Hoist cylinder by-passing...................................................................... See section on “Cylinder Leakage”.
BOOM HOIST ONLY - INOPERATIVE OR ERRATIC
CAUSE REMEDY
Boom will drift down ............................................................................ Repair or replace hold valve.
Boom won’t lower................................................................................. Repair, replace, or backflush hold valve.
Boom hoist cylinder binding ................................................................. Repair or replace.
Load is too great .................................................................................... Consult capacity chart, check RCI.
Piston packings damaged ...................................................................... Replace packings.
Low oil level..........................................................................................Add oil as required.
Air in cylinder ....................................................................................... Bleed cylinder.
BOOM DROPS SLIGHTLY AS RAISE CONTROL IS RELEASED
CAUSE REMEDY
Air in cylinder ....................................................................................... Bleed cylinder.
Boom hoist hold valve free flow check

not seating properly ............................................................................... Replace hold valve.

TROUBLESHOOTING
BOOM HOIST AND TELESCOPE INOPERATIVE OR ERRATIC
CAUSE REMEDY
Pump disconnect not engaged ............................................................... Engage pump disconnect.
Main relief valve malfunctioning .......................................................... See section on “Relief Valves”.
Rotary manifold leaking internally ....................................................... Reset rotary manifold.
Tandem pump faulty ............................................................................. See section on “Pumps”.
BOOM TELESCOPE CIRCUIT
TELESCOPE FUNCTION ONLY - WILL NOT OPERATE
CAUSE REMEDY
Load too great........................................................................................ Tilt boom pedal only halfway forward, not all the
way forward (“high speed”) . Reduce load or set
boom length before lifting load.
Both port relief valves sticking .............................................................See section on “Relief Valves”.
BOOM EXTENSION JERKY OR ERRATIC
CAUSE REMEDY
Inadequate grease on boom pad surfaces .............................................. Lubricate boom where pads contact boom.
Wear pads damaged ..............................................................................Replace wear pads.
Wear pads shimmed to boom too tight.................................................. Reshim wear pads.
Faulty counter balance valve................................................................. Replace counter balance valve.
Loose chain system ............................................................................... Adjust chains as required.

TROUBLESHOOTING
TELESCOPE CYLINDER EXTENDS BUT WILL NOT RETRACT
CAUSE REMEDY
Port relief valve sticking ....................................................................... See section on “Relief Valves”.
Hold valve malfunctioning....................................................................Repair or replace.
Internal leakage in cylinder ................................................................... See section on “Cylinder Leakage”.
Extend valve malfunctioning ................................................................ Repair or replace.
BOOM SECTIONS RETRACT UNDER LOAD
CAUSE REMEDY
“O” ring around hold valve damaged.................................................... Replace “O” rings.
Hold valve not seating properly ............................................................ Repair or replace.
Telescope cylinder by-passing .............................................................. See section on “Cylinder Leakage”.
WINCH CIRCUIT
WINCH WILL NOT DEVELOP MAXIMUM LINE PULL
CAUSE REMEDY
Main relief valve is set too low .............................................................Readjust the main relief.
Main relief valve is sticking ..................................................................See section on “Relief Valves”.
Winch motor worn excessively or damaged ......................................... See section on “Fluid Motor”.
Tandem pump worn excessively or damaged .......................................See section on “Pumps”.
Rotary manifold leaking internally ....................................................... Reseal rotary manifold.

TROUBLESHOOTING
WINCH WILL LOWER BUT WILL NOT RAISE
CAUSE REMEDY
The sprag clutch is assembled backwards............................................. Be certain that the winch is assembled properly.
Insufficient parts of line for the load being lifted..................................See the reeving diagram on the capacity chart.
WINCH WILL RAISE BUT WILL NOT LOWER
CAUSE REMEDY
The winch hold valve is mounted

on the winch motor incorrectly .............................................................Be certain that the winch is assembled properly.
The winch hold valve spool is sticking .................................................Repair or replace.
The winch brake is not releasing ........................................................... Be certain that the brake release line is open. If nec-
essary, disassemble and inspect the brake compo-
nents.
Winch brake piston “O” ring damaged .................................................Replace “O” ring.
WINCH WILL NOT HOLD LOAD

(LOAD DRIFTS DOWN)
CAUSE REMEDY
System back pressure too high .............................................................. Warm oil: check for restriction in down stream flow.
The over-running sprag on the brake is broken..................................... Inspect and replace, if necessary.
The automatic brake is not applying ..................................................... Be certain that the winch brake release line is not
plugged and no foreign objects are in the brake
assembly.
The winch brake friction plates are worn.............................................. Replace friction plates.

TROUBLESHOOTING
WINCH CHATTERS WHEN LOWERING
CAUSE REMEDY
The winch hold valve is set

wrong or is malfunctioning ................................................................... Check the hold valve setting. If the winch continues
to chatter, the holding valve is sticking. Inspect it for
worn or damaged seals or contamination.
OUTRIGGER CIRCUIT
ALL OUTRIGGERS INOPERATIVE
CAUSE REMEDY
Electrical malfunction ........................................................................... See section on “Electrical Controls”.
Outrigger relief valve malfunctioning...................................................See section on “Relief Valves”.
Outrigger diverter valve malfunctioning............................................... Repair or replace.
Line to or from steer pump

plugged or liner collapsed ..................................................................... Clear blockage or replace hose.
Steer pump worn or damaged................................................................ See section on “Pumps”.

TROUBLESHOOTING
INDIVIDUAL OUTRIGGER INOPERATIVE
CAUSE REMEDY
Electrical malfunction ........................................................................... See section on “Electrical Controls”.
Cylinder leaking internally....................................................................See section on “Cylinders”.
Hold valve on jack cylinder not operating ............................................Repair or replace.
Line plugged or collapsed between

outrigger valve and cylinder..................................................................Replace hose.
Beam wedged in extended position....................................................... Extend jack far enough to pick up end of beam and
retract. Replace slider pad block on top of outrigger
box to pick up end of beams.
OUTRIGGERS WILL NOT LIFT MACHINE
CAUSE REMEDY
Outrigger relief valve malfunctioning...................................................See section on “Relief Valves”.
Outrigger diverter valve malfunctioning............................................... Repair or replace.
Outrigger pump worn or damaged ........................................................See section on “Pumps”.
Cylinder by-passing............................................................................... See section on “Cylinders”.
JACK CYLINDER DRIFTS DOWN
CAUSE REMEDY
Hold valve on top of cylinder malfunctioning ...................................... Replace cartridge.
Thermal relief cartridge mounted in wrong end.................................... Check for proper assembly.
Cylinder by-passing............................................................................... See section on “Cylinders”.

TROUBLESHOOTING
SWING
PUMPS
CIRCUIT
FAILURE OF PUMP TO DELIVER FLUID
CAUSE REMEDY
Pumps not engaged................................................................................ Engage pumps.
Low fluid level in reservoir ................................................................... Add recommended oil and check level.
Oil intake suction filter plugged ............................................................ Clean filter.
Air leak in suction line, preventing priming or causing

noise and irregular action of control circuit .......................................... Repair leaks.
Oil viscosity too heavy to pick up prime............................................... Use lighter viscosity oil. Follow recommendation for
temperatures encountered.
Broken pump shaft or parts broken inside pump ..................................Contact your local distributor; if necessary, refer to
the manufacturer’s manual for the correct instruc-
tions in pump disassembly and repair.
NO PRESSURE IN SYSTEM
CAUSE REMEDY
Pump not delivering oil for any of

the reasons listed previously ................................................................. Follow remedies given previously.
Relief valve not functioning due to:
Valve setting not high enough............................................................... Increase pressure setting of valves.
Valve leaking......................................................................................... Check seat for score marks and reseat.
Spring in relief valve broken ................................................................. Replace spring and readjust valve.
Internal leakage in control valves or cylinders...................................... To determine location, progressively block off vari-
ous parts of circuit. When trouble is located, repair.
(Do not block between pump and relief valve).

TROUBLESHOOTING
NO PRESSURE IN SYSTEM (CONTINUED)
CAUSE REMEDY
Relief valve not functioning due to:
Cold fluid...............................................................................................Warm up system. Work with oil at recommended

operating temperature range.
(See Operation section).
Air leak or restriction at inlet line ......................................................... Repair or clean.
Internal parts of pump are worn excessively......................................... Replace pump.
PUMP MAKING NOISE
CAUSE REMEDY
Pump disconnect notengaged ................................................................ Shut engine off and engage pump disconnect.
Partially clogged intake line, intake filter

or restricted intake pipe .........................................................................Clean out intake filter screen or eliminate restric-
tion. Be sure suction line is completely open.
Air leaks:
At pump intake pipe joints ....................................................................Test by pouring oil on joints while listening for
change in sound of operation. Tighten as required.
Air drawn in through inlet opening ....................................................... Check and add oil to reservoir if necessary.
Air bubbles in oil...................................................................................Use hydraulic oil containing a foam depressant.
Too high oil viscosity ............................................................................ Work only with oil at recommended operation tem-
perature.
Oil intake suction filter plugged ............................................................ Clean filter.
Rag, paper, etc., pulled into suction line or pump................................. Remove.
Worn or broken parts............................................................................. Replace.

TROUBLESHOOTING
EXTERNAL OIL LEAKAGE AROUND PUMP
CAUSE REMEDY
Shaft seal worn causing oil to

leak into gear drive housing ..................................................................Replace.
Loose fitting on pump intake or discharge............................................Keep all joints tight.
Damaged “O” ring seals between pump sections..................................Replace.
Damaged “O” rings at fittings ............................................................... Replace.
EXCESSIVE WEAR
CAUSE REMEDY
Abrasive matter in the hydraulic oil

being circulated through the pump........................................................Clean suction filter and replace return filter. Drain
& flush system as necessary.
Viscosity of oil too low at working conditions1 ................................... Check oil recommendation.
Sustained high pressure above

maximum pump rating .......................................................................... Check relief valve setting.
Air recirculation causing chatter in system ........................................... Check for air being drawn into system. Use hydrau-
lic oil with a foam depressant.
BREAKAGE OF PARTS INSIDE PUMP HOUSING
CAUSE REMEDY
Excessive pressure above maximum pump rating ................................ Check relief valve setting.
Seizure due to lack of oil....................................................................... Check reservoir level, oil filter and possibility of
restriction in suction line more often.
Solid matter being wedged in pump...................................................... Check suction line filter, drain and flush system as
necessary.

TROUBLESHOOTING
CONTROL
SWING CIRCUIT
VALVES
STICKING PLUNGERS
CAUSE REMEDY
Excessively high oil temperature .......................................................... See section on “Excessive Heating of Oil in System”.
Dirt in oil ...............................................................................................Change oil. Clean system.
Fittings too tight .................................................................................... Check torque.
Valve warped from mounting ............................................................... Loosen valve mounting bolts and check.
Excessively high flow in valve.............................................................. Check to see if hoses from pump are not crossed or
reversed.
Plunger damaged ...................................................................................Replace valve.
Return spring damaged.......................................................................... Replace faulty parts.
Spring or detent cap binding ................................................................. Loosen cap, re-center and re-tighten.
Valve not at thermal equilibrium .......................................................... Let system warm up.
LEAKING SEALS
CAUSE REMEDY
Paint on or under seal ............................................................................ Remove and clean.
Excessive back pressure ........................................................................ Open or enlarge line to reservoir.
Dirt under seal ....................................................................................... Remove and clean.
Scored plunger....................................................................................... Replace valve.
Loose seal plates.................................................................................... Clean and tighten.
Cut or scored seal .................................................................................. Replace faulty parts.
LOAD DROPS WHEN CONTROL MOVED FROM NEUTRAL
CAUSE REMEDY
Dirt in check valve ................................................................................ Disassemble and clean.
Scored check valve poppet or seat ........................................................Replace poppet or lap poppet to seat.

TROUBLESHOOTING
POOR HYDRAULIC SYSTEM PERFORMANCE OR FAILURE
CAUSE REMEDY
Dirt in relief valve ................................................................................. Disassemble and clean.
Relief valve defective............................................................................ See section on “Relief Valves”.
Load too heavy ...................................................................................... Check line pressure.
Internal valve crack ............................................................................... Replace valve.
Plunger not at full stroke ....................................................................... Check movement of spool.
RELIEF VALVES
CAN’T GET PRESSURE
CAUSE REMEDY
Poppet stuck open or dirt under seal ..................................................... Check for foreign matter between poppets and their
mating members. Members must slide freely.
ERRATIC PRESSURE
CAUSE REMEDY
Poppet seal damaged ............................................................................. Replace damaged parts. Clean dirt and remove sur-
face marks for free movement.
PRESSURE SETTING NOT CORRECT
CAUSE REMEDY
Wear due to dirt. Lock nut adj. screw loose ......................................... See section on “Valve Adjustments”.

TROUBLESHOOTING
LEAK
CAUSE REMEDY
Damaged seats, worn “O” rings,

parts sticking due to dirt ........................................................................ Replace worn or damaged parts. Inspect for free
movement of components. Check seats for scratches,
nicks, or other marks.
FLUID MOTOR
MOTOR WILL NOT TURN
No oil ..................................................................................................... Fill reservoir to proper oil level.
Pump broken ......................................................................................... Replace pump.
Relief valve stuck open or set too low .................................................. Clean and free relief valve spool and adjust to
proper setting.
Work load jammed or stuck ..................................................................Remove obstruction from work load.
Large contaminating foreign bodies in fluid ......................................... Flush hydraulic system completely. Use new oil and
install new filters.
SLOW OPERATION
CAUSE REMEDY
Wrong oil viscosity ............................................................................... Use proper viscosity oil.
Rotary manifold leaking........................................................................ Reseal rotary manifold.
Worn pump............................................................................................ Repair or replace pump.
Extremely high fluid temperatures causing

pump and motor to slip (temperature increases
as pump and motor wear) ...................................................................... Add heat exchangers.
Relief setting too low ............................................................................ Set relief valve for proper psi.

TROUBLESHOOTING
MOTOR TURNS IN WRONG DIRECTION
CAUSE REMEDY
Hose connections wrong ....................................................................... Reverse connections.
Wrong timing ........................................................................................ Re-time motor.
ERRATIC MOTOR OPERATION
CAUSE REMEDY
Relief valve pressure set too low........................................................... Adjust relief valve setting.
Low oil level in reservoir permitting air

to enter system....................................................................................... Fill reservoir to proper level.
Air being “sucked in” on inlet side of pump......................................... Tighten fitting(s) on pump inlet side.
LEAK AT SHAFT
CAUSE REMEDY
Worn or cut shaft seal............................................................................ Replace shaft seal.
LEAK BETWEEN HOUSING AND WEAR PLATE OR

BETWEEN WEAR PLATE AND GEROLER ASSEMBLY
CAUSE REMEDY
Motor housing bolts loose ..................................................................... Clean mating surfaces and tighten nuts to appropri-
ate value.
Pinched “O” ring seal ............................................................................ Replace.
LEAK AT OIL PORTS
CAUSE REMEDY
Damaged seal or “O” ring ..................................................................... Replace “O” ring or seal.

TROUBLESHOOTING
LEAK AT OIL PORTS (CONTINUED)
CAUSE REMEDY
Poor fittings ........................................................................................... Replace fittings carefully.
Damaged threads ...................................................................................Replace housing.
CYLINDERS
CYLINDER STICKING OR BINDING
CAUSE REMEDY
Damaged parts....................................................................................... Repair or replace.
Dirt or contamination ............................................................................ Check oil condition. Check filters. Clean or replace
filter elements. Change oil if condition requires it.
Loose parts ............................................................................................ Tighten cylinder rod eyes, if loose. Check cylinder
heads and tighten, if loose.
Misalignment......................................................................................... Check mounting pins and bushings. Tighten rod

eyes.
ERRATIC ACTION OF CYLINDERS
CAUSE REMEDY
Air in system:
Oil level is too low ................................................................................ Add or change.
Air leak .................................................................................................. Locate and correct.
Foaming in reservoir ............................................................................. Use hydraulic oil containing a foam depressant.
Internal leakage .....................................................................................See “Cylinder Leakage” next page.
Main Relief pressure too low or valve sticking..................................... See section on “Relief Valve”.

TROUBLESHOOTING
CYLINDER LEAKAGE
Hydraulic cylinders may retract due to the cooling of the oil backup washers. Retest per the procedure above to deter-
in cylinder. Oil shrinks approximately 4% per 100°F of cool- mine if hold was defective.
ing, or as an example, if a cylinder is extended 100” and it
cools 100°F, it would shorten approximately 4”. An alternate method to test hold valve would be to elevate
boom and then disconnect the two hoses coming from valve
TELESCOPE CYLINDER bank. If oil continues to flow slowly from line to extend then
it is a hold problem. If oil continues to flow from retract,
If excessive leak-down is encountered, check items in the fol- then it is faulty or leaking by piston in cylinder.
lowing sequence:
IF THE HOLD VALVE IS NOT FOUND DEFECTIVE, the
1 With boom offside and horizontal, extend the boom cylinder must be removed from the boom assembly for
approximately 6 ft. per section. Mark the first telescop- repacking and checking. Prior to reassembly of the cylinder,
ing section at the end of the base section. conduct an air test on the piston rod by blocking the retract
ports on the rod near the piston end. Slip a plastic bag over
2 Elevate the boom to maximum angle and suspend a load piston end of rod and retain and seal with rubber band.
on the hook. (7 tons on a 2-part line would approximate Apply and hold a slight amount of air pressure at the retract
manufacturer’s inspection procedures.) port of the rod. (Port stamped with “R”.) Expansion of the
plastic bag indicates a defective rod weldment or seals on the
3 With engine shut off, hold or tie the telescope function port tube in the rod.
lever in the full “extend” position for approximately 15
minutes. WHEN REASSEMBLING THE CYLINDER, care should be
taken to keep the piston rod assembly parallel in all planes
4 Return the telescope lever to neutral, start engine, with the cylinder barrel as the piston enters and is pushed
ground the load, and return the boom to horizontal. Re- down the barrel prior to gland engagement.
mark the boom section as in (1). Measure the distance
between marks to determine leak-down of the cylinder. NOTE: An external leak from telescope cylinders or hydrau-
lic line within the boom assembly does not cause leak-down
The manufacturer’s allowable drift specification for produc- without also having one or more of the above conditions
tion machines is as follows: present.
With 14,300 lb. hook load, 2-part hoist line, boom extended BOOM LIFT CYLINDER
about 6 ft. per section at maximum boom angle, and 160
degree F. hydraulic oil temperature, the leak-down per cylin- The suggested procedure for identifying the specific cause of
der is not to exceed 3/4 inch in a 15-minute period. leak-down should be performed in the following sequence:
IDENTIFY A DEFECTIVE HOLD VALVE in the cylinder ELEVATE THE BOOM TO NEAR MAXIMUM ANGLE, not
which drifts excessively by interchanging the hold valve car- completely extended, with a boom length sufficient to winch
tridge with one removed from a cylinder that is not drifting, up a convenient payload approximately one (1) foot from
or by replacement with a new cartridge. Before installing ground level. Shut of engine.
the cartridge, visually inspect the external “O” rings and

TROUBLESHOOTING
BOOM LIFT CYLINDER (CONTINUED) SET THE OUTRIGGERS.
DISCONNECT THE EXTEND HOSE, PILOT DRAIN HOSE, ELEVATE THE BOOM TO NEAR MAXIMUM ANGLE, not
AND THE SMALL PILOT LINE HOSE at the holding valve completely extended, with a boom length sufficient to winch
ports and cap the pilot line hose and drain hose ends. up a convenient payload approximately one (1) foot from
ground level. Shut off engine and remove pressure from the
IF HYDRAULIC OIL CONTINUES TO RUN after the initial hydraulic reservoir by loosening the filler cap.
draining from either port of the hold valve as the hoist cylin-
der continues to leak-down, the cause is within the hold DISCONNECT THE EXTEND HOSE FROM THE HOLD
valve. VALVE. This is a hose farthest away from the port tube and
should have an “E” stamped next to it.
IF CYLINDER LEAK-DOWN OCCURS with no oil leak
from the hold valve ports, the cause is within the cylinder. IF HYDRAULIC OIL CONTINUES TO RUN after the ini-
tial draining from the port of the hold valve as the jack cylin-
OUTRIGGER JACK CYLINDER der continues to leak-down, the cause is within the hold
valve.
The suggested procedure for identifying the specific cause of
leak-down is similar to the boom lift cylinder procedure: IF CYLINDER LEAK-DOWN OCCURS with no oil leak
from the hold valve port, the cause is within the cylinder.
DO NOT START THE ENGINE UNTIL THE HOSES

HAVE BEEN RECONNECTED. The control valve spool is
open-center to reservoir in the neutral position and return
line oil would be pumped out.
EXCESSIVE HEATING OF OIL

IN SYSTEM
HEATING CAUSED BY POWER UNIT

(RESERVOIR, PUMP, RELIEF VALVE, AND COOLERS)
CAUSE REMEDY
Relief valve set at a higher or lower pressure than

specified. Excess oil dissipated through increased
slippage in various parts, or through relief valve ..................................Reset relief valve to recommended pressure.
Internal oil leakage due to wear ............................................................ Repair or replace faulty component.
Viscosity of oil too high or too low....................................................... Follow recommendations for correct viscosity grade
to be used.
Pumps assembled after overhaul may be assembled

too tightly. This reduces clearances and increases
rubbing friction...................................................................................... Follow instructions when reassembling.

TROUBLESHOOTING
HEATING CAUSED BY POWER UNIT

(RESERVOIR, PUMP, RELIEF VALVE AND COOLERS) (CONTINUED)
CAUSE REMEDY
Leaking relief valves ............................................................................. Repair.
Improper functioning of oil cooler ........................................................Inspect cooler and see that it is working properly.
Improper machine operation ................................................................. Return control to neutral when stalled, cylinder at
end of stroke, etc.
HEATING BECAUSE OF CONDITIONS IN SYSTEM
CAUSE REMEDY
Restricted lines ...................................................................................... If lines are crimped, replace; if partially plugged for
any reason, remove obstruction.
Internal leaks ......................................................................................... Locate leaks and correct.
Low oil level..........................................................................................Check oil level and fill if necessary.
ELECTRICAL CONTROLS
ELECTRICAL FAILURE
CAUSE REMEDY
Rocker switch sticking .......................................................................... Remove switch, check if hole is too tight. Cut out
decal or file hole larger.
Tripped circuit breakers ........................................................................ Reset breaker
Disconnected or broken wires ............................................................... Replace or repair.
Open circuit ........................................................................................... Check with test light. Repair or replace.
Low voltage........................................................................................... Check wires and grounds.
Poor engine solenoid connection........................................................... Clean and tighten.
Defective solenoid ................................................................................. Replace.
Solenoid failure .....................................................................................Replace.
Poor ground connections ....................................................................... Clean and tighten connections.

TROUBLESHOOTING
PROPANE
SWING CIRCUIT
HEATER
HEATER FAILS TO START

(MOTOR DOES NOT RUN)
CAUSE REMEDY
Fuse defective or burnt out....................................................................Check fuse; replace if necessary.
Electrical connection(s) defective ......................................................... Check all electrical connections, including ground;
repair any defects.
Full voltage not available at heater ....................................................... Check for power at the heater: at least 11 VDC with
heater turned on. Trace system to find any fault(s).
Motor defective .....................................................................................Check motor. Replace if necessary.
MOTOR RUNS, BUT NO COMBUSTION
CAUSE REMEDY
Fuel supply blocked ..............................................................................Check fuel supply by loosening the fitting on the out-
side of the heater and checking for propane odor. If
propane odor is present, pull off the igniter wire
completely and remove the igniter. Try to start the
heater and listen for the solenoid click. Check for
the odor of propane in the burner. If propane odor
is present at bulkhead fitting, but not the burner
head, the solenoid valve is defective or contaminated
with some foreign object. The solenoid valve can
become contaminated when a liquid take-off bottle is
used instead of the required vapor take-off bottle. If
the fuel system is contaminated, the lines and sole-
noid must be cleaned with a degreasing solvent.
Temperature control &/or microswitch

defective or out of adjustment ............................................................... Check temperature control switch and microswitch
and microswitch for adjustment. Adjust, repair, or
replace as necessary. See Section 6, “Repairs and
Adjustments”.

TROUBLESHOOTING
MOTOR RUNS, BUT NO COMBUSTION (CONTINUED)
CAUSE REMEDY
Ignition pack defective or inoperative...................................................Check for spark by holding an insulated-handle

screwdriver with the shaft grounded and the tip
approximately 1/8” away from the high tension lug
of the ignition coil. There should be a continuous
strong spark. If no spark is produced, check that
there is voltage applied to the ignition pack. If input
voltage is present and no spark or a weak spark is
produced, replace or repair the ignition pack.
Tilt switch defective, improperly

mounted or not getting power ............................................................... Check tilt switch. The switch must be secure in its
bracket and be in the vertical position with the elec-
trical leads pointing down. Check leads on both
sides of switch for power. Replace if defective.
Igniter defective or inoperative .............................................................Check the igniter. To check, shut off the fuel tank
and depress the start switch until the lines are
purged of fuel. Remove the burner head and check
the gap between the igniter and the burner tube. It
should be 1/16” to 1/8”. With the burner head
grounded, move the START-RUN-OFF switch to the
START position and check the gap for spark. If no
spark is produced, the igniter may be dirty or defec-
tive. Before removing the igniter from burner head,
check inside the burner head to determine if any car-
bon threads or chips are present which could short
the plug.
Fuel not suitable for temperatures encountered .................................... Check with your propane supplier to be sure your
fuel is suitable for the temperatures encountered.
Around -10°F, propane may not produce enough
pressure to pass through the regulator.

TROUBLESHOOTING
HEATER REMAINS ON BURNER CYCLE AFTER HEAT DEMANDS ARE MET
CAUSE REMEDY
Temperature control &/or microswitch

defective or out of adjustment ............................................................... Check temperature control switch and microswitch
and microswitch for adjustment. Adjust, repair, or
replace as necessary.
Bi-metal blade broken or linkage out of adjustment ............................. Check bi-metal blade and linkage and adjust, repair
or replace as necessary.
Dirt on fuel solenoid valve lip............................................................... Clean solenoid valve lip.
EXCESSIVE POPPING OR BACKFIRING
Ignition pack defective or inoperative...................................................Check for spark by holding an insulated-handle

screw driver with the shaft grounded and the tip
approximately 1/8” away from the high tension lug
of the ignition coil. There should be a continuous
strong spark. If no spark is produced, check that
here is voltage applied to the ignition pack. If input
voltage is present and no spark or a weak spark is
produced, replace or repair the ignition pack.
Full voltage not available at heater ....................................................... Using voltmeter, check to be sure full voltage is avail-
able for heater operation, at least 11 VDC with
heater turned on. Trace system to find fault.
Solenoid defective ................................................................................. Check solenoid. When the START-RUN-OFF

switch is in the RUN position, the solenoid should
produce an audible click and remain open until
heater cycles off.
In extremely cold weather, the regulator may

become frosted. As it thaws and freezes, the
heater will burn intermittently............................................................... No action recommended.
Clogged or restricted exhaust ................................................................ Check exhaust for blockage or restrictions. Clean
and clear as necessary.

TROUBLESHOOTING
EXCESSIVE SMOKING AT EXHAUST PORT AND BUILDUP OF CARBON IN HEAT EXCHANGER
CAUSE REMEDY
Air inlet tube blocked ............................................................................ Check for plugged or blocked air inlet tube and clear
if necessary.
Low voltage........................................................................................... Check for low voltage, at least 11 VDC.
Defective pressure regulator..................................................................Check for defective pressure regulator. There

should be 11 inches water pressure in the propane
supply line at the connector.
HEATER DOESN’T SWITCH OFF AFTER PURGE (COOL DOWN) CYCLE
CAUSE REMEDY
Flame switch will not open ................................................................... Replace.
MAINTENANCE FREE BATTERY TESTING
VISUAL INSPECTION
CAUSE REMEDY
Visible damage, terminal leakage, etc................................................... Cannot be used. Replace.
ELECTROLYTE LEVELS & STATE OF CHARGE

NOTE: PROCEED DIRECTLY TO CAUSE THAT APPLIES
CAUSE REMEDY
Level at top of plates. Water cannot be added ..................................... Replace.
If there is an indicator and it shows low level.......................................Replace.

TROUBLESHOOTING
ELECTROLYTE LEVELS & STATE OF CHARGE (CONTINUED)

NOTE: PROCEED DIRECTLY TO CAUSE THAT APPLIES
CAUSE REMEDY
Level OK, unknown, or water can be added.

Stabilized voltage below 12.4 volts*..................................................... Add water if needed (if possible). Charge, then turn
on high-beam head lamps (or 15 amp load for 15 sec-
onds). Proceed to load test.
If there is an indicator and it shows low charge .................................... Charge, then turn on high-beam head lamps (or 15
amp load for 15 seconds). Proceed to load test.
Stabilized voltage above 12.4 volts* or indicator

indicates charged ...................................................................................Perform load test.
LOAD TEST
CAUSE REMEDY
Perform load test using the following procedure:

1. Connect voltmeter and ampere load equal to 1/2
cold cranking amperes @ 0°F (-18°C) rating of battery
for 15 seconds.
2. Observe voltage at 15 seconds with load on.
3. Refer to voltage chart ........................................................................ If the voltage remains below the voltage chart levels,
replace battery. If the voltage is equal to or above
chart values, return to service.
* IF WATER CAN BE ADDED TO A BATTERY, A HYDROMETER READING OF 1.225 @ 80° F (27° C)

CAN BE USED INSTEAD OF THE 12.4 VOLTAGE READING.

TROUBLESHOOTING
ANTI-TWO
SWING
BLOCK
CIRCUIT
SYSTEM
PANEL LIGHT & HORN WILL NOT COME ON WITH BOOM SWITCH WEIGHT LIFTED
CAUSE REMEDY
Burned out fuse .....................................................................................Check and replace fuse (8 amp only).
Broken wire ........................................................................................... Check voltage in control panel between terminals #0

and #37. If 0 volts, check between ignition post of
ignition switch and ground. If 12 volts available,
wire to control panel is bad. Correct.
HORN WORKS, BUT NO LIGHT WITH SWITCH WEIGHT LIFTED
CAUSE REMEDY
Light bulb burned out............................................................................ Replace bulb.
LIGHT AND HORN ARE ON WITH HOOK BLOCK NOT CONTACTING SWITCH WEIGHT
CAUSE REMEDY
Jumper wire or jib/rooster sheave not

plugged in boom head ........................................................................... Plug in.
Boom head weight wire rope broken or hung up ..................................Check that weight is attached to wire and hanging
freely. If rope is caught up on something, correct.
Jib or auxiliary boom head switch plugged in,

but no weight ......................................................................................... Attach weight.
Broken electrical cable or bad connection ............................................Check all cable for visible damage, then remove wire
from terminals #3 and #6 in control panel and check
for continuity. If circuit is open, check the wires
inside cable reel, and wires from the reel to the boom
head switch. If the wires are OK, check the anti-two
block switch. If there is continuity between #3 and
#6 check the relay in the panel.

TROUBLESHOOTING
LIGHT AND HORN ARE ON WITH HOOK BLOCK NOT

CONTACTING SWITCH WEIGHT (CONTINUED)
CAUSE REMEDY
Defective two block switch ................................................................... Check for correct mechanical operation. If OK,
remove cover and wires from terminals #1 and #2.
With arm pulled down, there should be a closed cir-
cuit between them. With the arm up, the circuit
should be open. If all conditions are not met, replace
switch.
Defective relay in panel.........................................................................Check for 12 volts between relay pins #30 (hot) and
#86 (ground). If voltage is 0, check for voltage
between pin #87a and ground. If 12 volt, replace
relay (With no electrical power to the relay, pins #30
and #87a should show continuity. With 12 volts to
either #85 or #86 and the other grounded, there
should be continuity between pins #87 and #30.)

SERVICE AND ADJUSTMENTS
INDEX
SECTION 6
SUBJECT PAGE
VALVE ADJUSTMENTS....................................................................................................................................... 6 - 4
SWING BEARING................................................................................................................................................ 6 - 5
TORQUE WRENCH EXTENSIONS..................................................................................................................... 6 - 6
WELDING INSTRUCTIONS................................................................................................................................. 6 - 7
HYDRAULIC CYLINDERS MAINTENANCE........................................................................................................ 6 - 9
WIRE ROPE AND REEVING............................................................................................................................. 6 - 11
SPOOLING WIRE ROPE ON DRUMS............................................................................................................... 6 - 12
Revised: December 2005 Page 6 - RT440B

RT440B Page 6 - December: July 2005

As the operator, it is your responsibility to detect any un If you can’t answer YES to all three questions, rely on
usual, sounds, odors, or other signs of abnormal perfor your Distributor Serviceman. He has the right tools,
mance that could indicate trouble ahead. testing equipment and service knowledge to pin-point
the problem in minutes instead of the hours consumed
By detecting any problems in their early stages, you in hit-or-miss methods. TIME IS MONEY! He will save
can save yourself unnecessary downtime and your it for you.
employer a lot of money! Therefore, it is also your re-
sponsibility to use good judgment in detecting failures If you decide to attempt an adjustment yourself, follow
in quickly and repairing them. If you don’t, one failure a logical TROUBLE SHOOTING PROCEDURE. Don’t
can lead to another. simply replace parts until the trouble is found.
Before attempting to make an adjustment yourself, ask

yourself if you have the RIGHT TOOLS, IF you have the
PROPER TEST EQUIPMENT and IF you can accurate
ly DIAGNOSE the cause of the problem.

VALVE ADJUSTMENTS
Setting hydraulic pressure is a complex operation and

should be performed only after satisfying the following RELIEF VALVE REPAIR RECOMMENDATIONS The
conditions. cartridge type service port reliefs used in the swing
valve are of the pilot poppet type with external adjust-
1. Warm the hydraulic oil to 130°F in normal condi- ment. Any malfunctioning is usually the result of foreign
tions. matter lodging between the piston, relief valve poppet,
NOTE: If the normal hydraulic operating tempera and check valve.
ture is substantially above or below 130 F use that
value instead. To perform service, clean the surrounding area and re-
move the complete relief valve cartridge. Examine the
2. Be sure the correct engine speed is used as the seat in the main valve housing for grooves or ridges.
reliefvalve setting will vary with the flow rate. If damaged, either replace the valve or have it re-ma-
chined.
3. Be certain to calibrate the pressure gauge used.
Gaugecalibration can be lost if the gauge is sub- The design of the pilot poppet and its seat provides
jected to pulsating pressure for a few seconds. The positive seating and very seldom requires any main-
gauge must have a proper snubber to read center tenance. The pilot section can be removed from the
of pump pressure ripple or erroneous readings will cartridge housing without disturbing the setting.
result.
With it will come the check valve poppet and other in-
MAINTENANCE CHECKS All the relief valve main- ternal parts. These are easily disassembled and should
tenance checks are conducted an a SEMI-ANNUAL be examined for foreign matter. All seats and seating
BASIS. Check the relief valves and make the nec surfaces should be free of nicks, scratches, or grooves.
essary adjustments by the following procedures. Examine “O” rings and back-up washers for any dam-
age. If any parts are found to be faulty, replace the re-
The relief valves used on this hydraulic crane have a lief cartridge. All moving parts should slide freely, with
screw type adjustment. If it is determined that the valve only seal friction being present. After inspecting and
is out of adjustment, follow this general adjustment cleaning, immerse all parts in hydraulic oil and re-as-
procedure. semble. If pressure setting was not disturbed, unit can
be tested for proper functioning under normal working
NOTE: Some machines are equipped with auxiliary conditions. If operating difficulties indicate that the pilot
winch plumbing even though an auxiliary winch is not poppet is still leaking or sticking, replace the relief.
installed. on these machines you must follow the pro
cedure for setting the auxiliary winch relief valve.
Model RT440B
Max. pressure valves calib.
Winch 3045 psi
Boom up 3480 psi
THIS MACHINE USES A PRESSURIZED HYDRAULIC
Boom down 725 psi
RESERVOIR. THE PRESSURE MUST BE RELEASED
BEFORE ANY HYDRAULIC LINE OR CONNECTION Retract boom 4205 psi
IS OPENED. Failure to do so will result in substantial Extend boom 3625 psi
loss of oil and may cause personal injury. The pressure
is relieved by turning the reservoir cap counterclock- Rotation 2175 psi
wise to the first stop. DO NOT turn the cap beyond the Outriggers 2320 psi
first stop until all pressure has been released. This will
cause the cap to be blown off the reservoir with suf- Steering 2175 psi
ficient force to cause personal injury. DO NOT place Servocontrols 580 psi
any portion of your body above the reservoir cap while
relieving pressure or removing cap.

SWING BEARING
RING GEAR BOLTING SEQUENCE
MAINTENANCE CHECK RING GEAR TORQUING
It is very important to perform periodic ring gear bolt The gear and bearing assembly consists of an in-
checks. Please refer to the following chart for the slew- ner race and ring gear, an outer race, bearing rollers,
ing ring screws torque wrench setting. After the initial 40 spacer and a seal ring. The inner race is bolted to the
hours of machine operation, check and tighten the bolts. carrier; the outer race to the turntable.
If additional torque is required after the first 40 hours, then A number of causes can reduce tension in the bolts
recheck each 40 hours until all bolts are found properly when torquing and after use. These include rust on
torqued. Thereafter, checks should be performed QUAR the threads, damaged or rough threads on bolts and
TERLY. nuts, shanks of bolts which hang up on holes, etc. All
of these causes have a tendency to absorb the torque
Fixing screws type TCEI when bolts are being tightened.
Model It is important to make periodic checks of the ring rear
Crane truck M20 Class M22 Class M24 Class bolts. The bolts Must be kept torque tightened.
10.9 10.9 10.9 Torque the inner race first, then the outer race as shown
in the bolting sequence.
Model RT440B / / / / 480 ft.lb. / / / /

TORQUE WRENCH EXTENSIONS
In some applications, a standard torque wrench and FORMULA

socket cannot be fitted to the bolt (s) to be tightened be-
cause of restricted access. In other instances, the torque
(600 ft. lb.) times (“B”)
value specified cannot be obtained because sufficient
force cannot be applied to the standard length wrench. Torque wrench
= = lpq - Plw
Both of these problems may be solved by the use of ap- setting (TWS)
propriate torque wrench extensions - either commer- (“B”) plus (“A”)
cially made or fabricated by the user.
When using an extension, it must be remembered that the

wrench torque (the actual torque reading or setting of EXAMPLE
the wrench) and the wrench force (the force applied to
the wrench) must be adjusted to compensate for the A = 10.25”
added length and produce the desired bolt torque. B = 43”
Refer to the illustration and formula below when calcu- (600 ft. lb.) X 43 2580
lating the proper adjusted values for wrench torque, TWS = = = 485 ft. lb.
wrench force and bolt torque.
42 + 10.25 53.25
NOTE: If the Torque wrench setting at length “B” would
be 600 ft. lb. (813 NM) for capscrews not requiring us
of adapter, then the following shows the use of an
adapter and the calculation for that setting.

WELDING INSTRUCTIONS
When doing repair welding on your unit take precau- Always have a fire extinguisher on hand in case of
tion attaching your ground to the component being re- fire. Adequate ventilation and dry area are necessary.
paired. This will reduce the chance of arcing through a Protective clothing should be used and all persons in
bearing, cylinder, etc., damaging the component. Paint the welding area should have protection for their eyes.
should be removed from the surface to be used as the Follow instructions for welding and cutting on paint.
“ground” (earth).
AWS CLASS E7018 Low hydrogen rod for normal re-
pairs on low alloy to medium carbon steel. All position
welding, good penetration, and crack resisting up to
80,000 yield. Also suitable for repair of previous inter-
shield welds.
Use necessary precaution when welding around fuel
tanks, oil reservoir, batteries, tubing and pressure sys- AWS CLASS E11018G Low hydrogen rod for repair on
tems. high strength alloy steel such as T-1, 80,000 to 100,000
yield. All position welding, good penetration, and high
tensile strength up to 110,000.
Note: Low hydrogen rod E7018 must be used within

four (4) hours upon removal from a freshly
When welding close to glass, cylinder rods, or any pol- opened container or from a storage oven.
ished surface, provide adequate protection from splat-
ter. Low hydrogen rod E11018G must be used with
in 1/ 2 hour upon removal from its container or
from a storage oven.
Never weld when the engine is running. Always discon-

nect the battery cables and applicable grounds before
welding. All welding procedures and welding operator qualifi-
cations shall be in accordance with ANSI/AWS D14.3
when welding on load sustaining members (ANSI/
ASME B30.5)
Do not weld on wet surfaces since this will cause hy-

drogen embrittlement of the weld.

WELDING & CUTTING

ON PAINTED SURFACES
When welding or cutting steel coated with a certain paint systems, the
worker is exposed to decomposition products (metal fumes, gases or
vapors, particulate) which vary depending on the type of process being
used to weld or cut, the nature of the base metal, and the type of coating
system. The following control procedures should be utilized when one is
welding or cutting coated steel:
• Use a power brush or grinding wheel to strip the coating from the
steel in the vicinity where the cut or weld is to be made. Remove the
paint far enough from the weld to prevent any remaining paint from
becoming heated and bubbling. If this happens, continue to brush or
grind the paint away.
• A toxic dust respirator and eye protection should be used while strip-
ping the paint.
• Welder should be outfitted with a fresh air supplied respirator and

other personal protective equipment required for welding.
• Other employees should be removed from the area or told to stand

back a minimum of 10 feet from the welder. Do not be in direct line
with the weld fumes.
• Use a local exhaust hood to remove fumes during the welding or cut-
ting operation if one is available.

HYDRAULIC CYLINDERS MAINTENANCE
HYDRAULIC CYLINDER DISASSEMBLY
GENERAL
Do not disassemble a cylinder unless no other mainte-

Failure to remove the locking capscrew may result
nance procedure can correct the problem. All overhaul
in serious thread damage.
or new cylinder installations should be done in a clean,
dust-free atmosphere with all ports plugged until hose
Note: One turn off, back 1/3 turn alternately.
connections are made.
2. Remove the head gland, shaft, and piston from the
BOOM EXTEND CYLINDERS
case.
The outer case is the “moving” member of the cylinder.
3. Remove piston and gland by removing setscrews
The hollow shaft is “stationary”. The hollow shaft ports
in retaining collar removing retaining nut. Remove
the piston and case end to retract the cylinder while a
piston and gland from rod. Access to all seal units is
tube within the “shaft” ports the piston and head gland
now possible.
to extend the cylinder.
HYDRAULIC CYLINDER INSPECTION
Disassemble the boom extend cylinders by the follow-
ing procedure: Wash the cylinder bore and all the components with sol-
vent and make the following inspection:
1. Using an adjustable spanner wrench, remove head
gland of cylinder. As head gland is loosened, it may CYLINDER BORE
be necessary to begin to move rod out of cylinder
tube. For signs of scoring and deep scratches. In the event of
2. With head gland fully disengaged, remove as an any defects, reassemble the entire cylinder and contact
assembly, piston rod, head gland, and piston as- your distributor.
sembly.
3. To remove piston, remove the setscrews which se- CYLINDER SHAFT
cure the piston retaining ring to piston rod.
For dents, deep scratches, or damaged chrome plating.
Note: There are two types of cylinders used on the File any sharp edges on ends of shaft to protect the seals
machine. upon reassembly. Always protect the shaft finish when
Both cylinders have setscrews located under the clamping in a vice or when welding against weld splatter.
wear ring to retain the piston to the rod.
PISTON RINGS
Note: After removing the piston, the retainer can be
removed to reseal the inner tube. For cracks or other damage. Particularly check the
interlocking ends that they are not missing or broken.
BOOM LIFT CYLINDER
PISTON SEALS
Disassemble the boom lift cylinder by the following
procedure: For signs of severe damage. Do not remove unless
replacement is necessary.
1. Remove the locking socket head cap screw from
the draw ring. With an adjustable spanner wrench,
remove the draw ring and head gland.

PISTON & HEAD GLAND BOOM EXTENDED CYLINDERS
It is not normally necessary to replace the piston, pis- With the piston, piston rod, head gland, and retaining
ton rings, or head gland. ring assembled as a unit, slide the piston into the cylin-
der bore. Next, insert the head gland. It may be neces-
sary to tap the gland into place using a wood block and
HYDRAULIC CYLINDER REASSEMBLY hammer. In this event, cover the rod with rags or a rub-
ber tube to prevent damage from a glancing hammer
GENERAL blow. The head gland is then spun in and tightened.
As cylinder components are reassembled, be certain Note: Apply Loctite Gr. 242 to piston retaining rings at
all rings, seals, spacers, and setscrews required in one assembly. Also apply to locking setscrews.
step are in place before proceeding to the next step.
See Group 39 of the Parts Manual for a complete list-
ing of cylinder parts. HYDRAULIC CYLINDER OPERATION
A teflon ring must be installed before the piston ring As soon as the cylinder is ready to be placed in opera-
or wear ring is installed since the teflon ring must first tion, it should be slowly cycled under no load conditions
be “walked” into the piston ring groove and then into for several minutes in order to allow the entrapped air
its own groove. Warm the teflon ring until reasonably within the cylinder to escape to the reservoir and, also
flexible and oil the piston ring or wear ring to aid in the facilitate the reforming of the seals which may have
installation. temporarily deformed during shipping, storage, or re-
assembly.
Most piston ring breakage is due to careless or hasty
assembly at this point. New cylinders may show a slight “drifting” tendency
when first used. This is natural, due to one or both of
the following causes:
BOOM LIFT CYLINDERS
1. Air entrapped in the oil.
With the piston, piston rod, head gland, retaining ring,
and rod eye reassembled as a unit, slide the piston into 2. Seals not yet fully reformed or seated.
the cylinder bore. Next, insert and seat the head gland.
It may be necessary to drive the head gland into place “Drifting” should decrease with operation as piston rings
using a wood block and hammer. In this event, cover and seals “break in” to provide better sealing and the
the rod with rags or a rubber tube to prevent damage eventual escaping of the trapped air in the oil.
from a glancing hammer blow. The retaining ring is then
spun in and tightened to secure the head gland. Install
socket head cap screws. The retaining ring should be
secured with Loctite Grade 242. Coat both grooves
around the thread ring as well as the bolt heads with a
“silstic” type silicon sealant to keep moisture out.
Note: When installing the piston ring nut on the piston

rod, torque to 400 ft. lbs and then secure with
setscrew lock. Use Loctite Grade 242 on ring nut
and setscrews.
RT440B Page 6 - 10 December: July 2005

WIRE ROPE AND REEVING
MAINTENANCE If non-rotating or spin resistant rope is used on this crane,

the rope must be replaced if two or more wires are found
All wire ropes in active service should be inspected dai- broken in one lay of the rope.
ly along with spooling, sheaves, wedge sockets, and
any other wire rope fittings for damage. Once weekly CABLE REEVING
a thorough wire rope inspection should be made by a
competent inspector. A record should be kept of the When reeving the machine for any job, remember that
inspection on the form provide in section 4. hoisting and lowering speeds decrease as the number
of parts of line increases. For the most efficient use of
Refer to ANSI Standard B30.5 for guidelines covering the machine, it is desirable to use the minimum number
the inspection, maintenance, repair, and replacement of required parts for lifting the anticipated loads.
of wire rope. Worn, kinked, birdcaged, fatigued, or oth-
erwise damaged wire rope must be removed immedi-
ately. Wire rope, when properly installed, lubricated,
and employed, will give many hours of satisfactory use.
Whereas, a new piece of wire rope can be immediately
ruined if misused. Replace any wire rope found to be in
unsatisfactory condition. Never use less than the number of parts called for
by the load rating chart. The minimum required
In addition to damage such as kinking, crushing and number of parts is determined by referring to the
broken wires, factors such as corrosion, abrasion, pit- load rating chart.
ting, peening, and scrubbing of outside tires, reduction
of rope diameter, the condition of other components, This machine incorporates a “Quick Reeving” boom
and proper lubrication are considered. Refer to section head and block which do not require removal of the
4 for wire rope lubricating procedures. wedge and socket from the rope in order to change the
reeving. Removal of two pins in the boom head and
Before installing a new or replacement rope, make cer- three in the hook block will allow the wedge and socket
tain the rope to be used is the proper type and size. to pass through.
The wrong rope will not function properly and may
even be dangerous.
Refer to Section 9 for instructions on inspecting and
replacing sheaves.
If a socket is changed or replaced, or if you are

changing hook block weights; it is important to
use the correct socket.
The use of non-rotating 18 x 7 class wire rope is

not recommended in multiple reeving applications
and, if used for applications involving single part
line, must not be used with loads exceeding one
fifth (1/5) the rated break-ing strength. The inner
wires are generally the first to fail on this class of
rope making it very difficult to inspect as broken
wires cannot be seen. Refer to ANSI B30.5, Section
5-2.4 for the necessary inspection procedure and
replacement criterion.

SPOOLING WIRE ROPE ON DRUMS
Care must be exercised when installing wire rope on Apply breaking force to the reel flange in order to pre-
the winch drum. Improper spooling can result in winch vent overrun as the rope is being drawn off. Loops
damage through crushing, kinking, doglegs, abrasion, formed by overrun can cause kinks and doglegs in the
and cutting. Poorly installed wire rope will also adversly rope, resulting in damage and premature rope failure. A
affect the operating characteristics of the machine by timber or block forced against the shipping reel flange
causing uneven application of force and motion. This can be used to provide the required braking force.
can cause premature fatiguing and failure of the rope.
Install cable on the winch drum in accordance with the

Thoroughly inspect and clean the winch before pro- following procedure.
ceeding with the installation. CHeck the lagging and
drum flanges for cracks, breaks, and excessive wear. 1. Position the cable over the boom nose sheave and
Deformed or outsized drum and excessive undercut- route back to the winch drum.
ting at the base of the flange also indicate the repair or
replacement of the drum is necessary. 2. Position the winch drum with the cable anchor slot
on top.
Check the bearings for excessive wear or play.
3. Insert cable through slot and position around the
After correcting any defects revealed by the inspection cable wedge.
and determining that the winch is in good operating
condition, spool the wire rope as follows: 4. Position the anchor wedge in the drum slot; pull
firmly on the free end of the cable to secure the
Mount the cable shipping reel vertically on jacks or a wedge.
suitable supporting structure, with a pipe or bar through
the reel center. The cable should be drawn from the top 5. Slowly rotate the drum, ensuring the first layer of
of the reel, as shown, in order to avoid reverse bending cable is evenly wound onto the drum.
as it is spooled onto the winch drum.
6. Install the remainder of cable, as applicable.
If cable is wound from the storage reel onto the drum,
the reel should be rotated in the same direction as the The end of the cable should be even with the bottom of
hoist. the anchor wedge.
Note: If the wedge does not seat securely in the slot,

carefully tap the top of the wedge with a mallet.
RT440B Page 6 - 12 December: July 2005

MACHINE STORAGE
INDEX
SECTION 7
SUBJECT PAGE
SHORT TERM STORAGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 1
LONG TERM STORAGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 1
ENGINE STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 1
RESTORING ENGINE TO SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 4
TRANSMISSION STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 4
RESTORING TRANSMISSION TO SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 5
RESTORATION TO SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 5
CHROME CYLINDER ROD STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 6
Revised: May 2002

MACHINE STORAGE
Machines being placed in storage must be ade- 2. Drain and refill the swing reducer, winch(es),
quately protected from deterioration during the axle differentials, planetary hubs and the hy-
period of idleness. This will ensure that they can draulic reservoir. Refer to page 4-19 when servic-
be restored to active service with a minimum ef- ing the reservoir.
fort.
3. Distribute the new hydraulic fluid to all parts
Before removing this hydraulic crane from ser- of the system by operating all function.
vice for extended periods, it should be prepared
for storage as prescribed in the following para- 4. Clean and tape the battery cables after remov-
graphs. In general, three (3) major components ing and storing the battery.
must undergo preparation. These are the Ma-
chine Proper, the Engine and the Transmission. 5. Coat the external ring gear of the swing bearing
The specific procedure to be followed depends with oper gear lubricant.
upon the expected period of storage.
6. Fill the hydraulic reservoir to the top AFTER
THE MACHINE IS PARKED IN ITS STORAGE SPOT.
SHORT TERM STORAGE - 30 DAYS OR LESS 7. Coat wire rope with lubricant.
Short term storage requires minimal preparation.
8. Coat exposed cylinder rods with grease.
The MACHINE should be thoroughly cleaned, lu-
bricated in accordance with Section 4, and paint- The ENGINE should be prepared as prescribed
ed surfaces retouched where the paint has on page 7-2, the topic “Engine Storage”.
deteriorated. exposed portions of all hydraulic
cylinders should be coated with multipurpose The TRANSMISSION should be prepared as
grease. Coat unpainted metal surfaces with mul- prescribed on page 7-4, the topic “Transmis-
tipurpose grease after removing any rust accu- sion Storage.”
mulations.
The ENGINE should be prepared as prescribed

on page 7-2, the topic “Engine Storage”. ENGINE STORAGE
The TRANSMISSION should be prepared as pre-

scribed on page 7-4, the topic “Transmission
Storage”. PREPARING ENGINE FOR STORAGE - When an
engine is to be stored or removed from operation
for a period of time, special precautions should
be taken to protect the interior and exterior of the
LONG TERM STORAGE - 30 DAYS OR MORE engine, transmission, and other parts from rust
accumulation and corrosion. The parts requiring
Long term storage requires greater preparation attention and the recommended preparations are
than short term storage and must be undertaked given below.
with greater care.
It will be necessary to remove all rust or corrosion
The MACHINE should be prepared as follows: completely from any exposed part before applying
a rust preventive compound. Therefore, it is rec-
1. Perform the short term machine storage prep- ommended that the engine be processed for stor-
aration, making certain that All points with age as soon as possible after removal from
grease fittings are liberally lubricated. operation.
7-1 Revised: November 2000

MACHINE STORAGE
The engine should be stored in a building which EXTENDED STORAGE (30 DAYS OR MORE)
is dry and can be heated during the winter When An Engine Is To Be Removed From Opera-
months. Moisture absorbing chemicals are avail- tion For An Extended Period Of Time,prepare It
able commercially for use when excessive damp- as follows:
ness prevails in the storage area.
1. Drain and thoroughly flush the cooling sys-
temwith clean, soft water
TEMPORARY STORAGE (30 DAYS OR LESS)
To protect an engine for a temporary period of 2. Refill the cooling system with clean, soft water.
time proceed as follows:
3. Add a rust inhibitor to the cooling system (re
1. Drain the engine crankcase. fer to page 4-7, “Corrsion Inhibitor).
2. Fill the crankcase to the proper level with the 4. Remove, check and reconditon the injectors, if
recommended viscosity and grade of oil. necessary, to make sure they will be readyt to op-
erate when the engine is restored to service.
3. Fill the fuel tank with the recommended grade
of fuel oil. Operate the engine for two minutes at 5. Reinstall the injectors in the engine, time
1200 rpm and no load. them, and adjust the valve clearance.
NOTE: Do not drain the fuel system or the crank- 6. Circulate the coolant through the entire sys-
case after this run. tem by operating the engine until normal operat-
ing temperature is reached (160°F. to 185°F).
4. Check the air cleaner and service it, if neces-
sary as outlined under Air System. 7. Stop the engine.
5. If freezing weather is expected furing the stor- 8. Remove the drain plug and completely drain
age period, add a high boiling point type anti- the engine crankcase. Reinstall and tighten the
freeze solution in accordance with the drain plug. Install new lubricating oil filter ele-
manufacturer’s recommendations. Drain the ments and gaskets.
raw water system and leave the drain cocks open.
9. Fill the crankcase to the proper level with a
6. Clean the entire exterior of the engine (except 30-weight preservative lubricating oil MIL-L-
the electrical system) with fuel oil and dry it with 21260, Grade 2 (P10), or equivalent.
air.
10. Drain the engine fuel tank.
7. Seal all of the engine openings. The material
used for this purpose must be waterproof, vapor- 11. Refill the fuel tank with enough rust preven-
proof and possess sufficient physical stength to tive fuel oil such as Americal Oil Diesel Run-In
resist puncture and damage fro m the expansion Fuel (LH 4089), Mobil 4Y17, or equivalent, to en-
of entrapped air. able the engine to operate 10 minutes.
An engine prepared in this manner can be re- 12. Drain the fuel filter and strainer. Remove the
turned to service in a short time by removing the retaining bolts, shells and elements. Discard the
seals at the engine openings, checking the engine used elements and gaskets. Wash the shells in
coolant, fuel oil, lubricating oil, transmission, clean fuel oil and insert new elements. Fill the
and priming the raw water pump, if used. cavity between the element and shell about two-
thirds full of the same rust preventive compound
as used in the fuel tank and reinstall the shell.

MACHINE STORAGE
13. Operate the engine for 5 minutes to circulate 20. Remove and clean the battery and battery ca-
the rust preventive throughout the engine. bles with a baking soda solution and rinse them
with fresh water. Store the battery in a cool (nev-
14. Refer to page 4-6 and service the air cleaner. er below 32°F.) dry place. Keep the battery fully
charged .
15. With an all-purpose grease such as Shell Al-
vania No. 2, or equivalent, lubricate the clutch 21. Insert heavy paper strips between the pulleys
throwout bearing, clutch pilot bearing, drive and belts to prevent sticking.
shaft main bearing, clutch release shaft, and the
outboard bearings (if so equipped). 22. Seal all of the openings in the engine, includ-
ing the exhaust outlet, with moisture resistant
16. Remove the inspection hole cover on the tape. Use cardboard, plywood or metal covers
clutch housing and lubricate the clutch release where practical.
lever and link pins with a hand oiler. Avoid get-
ting oil on the clutch facing. 23. Clean and dry the exterior painted surfaces of
the engine. Spray the surfaces with a suitable liq-
17. Apply a non-friction rust preventive com- uid automobile body wax, a synthetic resin var-
pound, to all exposed parts. If it is convenient, nish or a rust preventive compound.
apply the rust preventive compound to the engine
flywheel. If not, disengage the clutch mechanism 24. Cover the engine with a good weather-resis-
to prevent the clutch disc from sticking to the fly- tant tarpaulin or other cover if it must be stored
wheel. outdoors. A clear plastic cover is recommended
for indoor storage.
The stored engine should be inspected periodical-

ly. If there are any indications of rust or corro-
Do not apply oil, grease or any wax base com- sion, corrective steps must be taken to prevent
pound to the flywheel. The cast iron will absorb damage to the engine parts. Perform a complete
these substances which can “sweat” out during inspection at the end of one year and apply addi-
operation and cause the clutch to slip. tional treatment as required.
18. Drain the engine cooling system (tag cap).
19. The oil may be drained from the engine

crankcase if so desired. If the oil is drained, rein-
stall and tighten the drain plug (tag cap).

MACHINE STORAGE
13. Remove the inspection hole cover and inspect

the clutch release lever and link pins and the
RESTORING ENGINE TO SERVICE bearing ends of the clutch reliease shaft. Apply
engine oil sparingly, if necessary to these areas.
1. Remove the valve rocker cover(s) and pour at 14. After all of the preparations have been com-
least one-half gallon of oil, of the same grade as pleted, start the engine. The small amount of
used in the crankcase, over the rocker arms and rust preventive compound which remains in the
push rods. fuel system will cause a smoky exhaust for a few
minutes.
2. Reinstall the valve rocker cover(s).
NOTE: Before subjecting the engine to a load or
3. Remove the covers and tape from all of the high speed, it is advisable to check the engine
openings of the engine, fuel tank, and electrical tune-up.
equipment. Do not overlook the exhaust outlet.
4. Wash the exterior of the engine with fuel oil to TRANSMISSION STORAGE
remove the rust preventive.
5. Remove the rust preventive from the flywheel.

PRESERVATIVE SELECTION When transmis-
6. Remove the paper strips from between the pul- sions are to be stored or remain inactive for ex-
leys and the belts. tended periods of time, specific preservative
methods are recommended to prevent rust and
7. Check the crankcase oil level. Fill the crank- corrosion damage. The length of storage will usu-
case to the proper level with the heavy-duty lubri- ally determine the preservative method to be
cating oil recommended under Lubricating Oil used. Various methods are described below.
Specifications.
8. Fill the fuel tank with the fuel specified under STORAGE NEW UNITS
Diesel Fuel Oil Specifications. New units contain preservative oil when shipped
for Funk and can be safely stored for 6 weeks
9. Close all of the drain cocks and fill the engine without further treatment. Refer to the Funk
cooling system with clean soft water and a rust Transmission manual for additional information.
inhibitor. If the engine is to be exposed to freezing
temperatures, add a high boiling point type anti-
freeze solution to the cooling system (the anti- STORAGE, 30 DAYS TO 1 YEAR - WITHOUT
freeze contains a rust inhibitor). OIL
10 Install and connect the battery. 1. Drain Oil.
11. Service the air cleaner as outlined under Air 2. Seal all openings and breathers, except oil
System. drain hole, with moisture-proof cover or tape.
12. Prepare the generator for starting. 3. Coat all exposed, unpainted surfaces with Nox
Rust X-110.

MACHINE STORAGE
4. Atomize or spray 4 ounces of Nox Rust VCI No.

10 oil, or equivalent, into the transmission RESTORATION TO SERVICE
through the oil drain hole. Install the drain plug.
5. If additional storage time is required, (3) and Refer to page 7-4, “Restoring Engine to Service”,
(4) above should be repeated at yearly intervals. and page 7-5 and 7-6, “Restoring Transmission
to Service”, for the procedures required to restore
these components to service.
*Nox Rust is a preservative additive manufac-
tured by the Daubert Chemical Company, Chi- Remove the MACHINE from storage via the fol-
cage, Illinois. Motorstor is covered by US lowing procedure:
Military Specifications MIL-L-46002 (ORD)
and MIL-1-23310 (WEP). 1. Remove preservative lubricants from all sur-
faces.
RESTORING TRANSMISSION TO SERVICE 2. Check all fluid levels, adding or draining as re-
quired.
1. If Nox Rust, or equivalent, was used in prepar- 3. Lubricate the machine according to Section 9,
ing the transmission for storage, use the follow- making certain that all points with grease fittings
ing procedures to restore the unit to service. are lubricated.
2. Remove the tape from openings and breather. 4. Make a thorough visual inspection of the entire
machine, placing special emphasis on the condi-
3. Wash off all the external grease with solvent. tion of all hydraulic hoses.
4. Add hydraulic transmission fluid, type C3 to

proper level.
NOTE: It is not necessary to drain C3 oil and Nox

Rust mixture from the transmission.
5. If Nox Rust or equivalent, was not used in pre-

paring the transmission for storage, use the fol-
lowing procedures to restore the unit to service.
6. Remove the tape from openings and breathers.
7. Wash off all the external grease with solvent.
8. Drain oil.
9. Install a new oil filter element(s).
10. Refill transmission with hydraulic transmis-

sion fluid, type C3 to proper level.

MACHINE STORAGE
CHROME CYLINDER ROD STORAGE 4. Inspect the cylinder rod surfaces and reapply
at three to six month intervals.
5. If the equipment is to be moved and then

Hard chrome plating is primarily applied to steel stored again for an extended period of time
cylinder rods for its wear resistant properties, al- or if the cylinder is cycled, steps 1 thru 4
though it does provide considerable corrosion re- should be repeated for all cylinder rods that
sistance as well. Once the chrome-plated rod is were exposed.
assembled into a cylinder and put into service,
the hydraulic fluid on the surface of the rod pro-
vides all the corrosion resistance required for the *Ferro-Kote 5856-BF is a product of Quaker
rod during its life cycle. As a cylinder cycles, hy- Chemical Company, Conshohocken, PA
draulic fluid is driven into any surface cracks 19428
that exist in the chrome plate. When these
cracks are filled with hydraulic fluid, moisture or For the protection of Older Equipment that is to
corrosive fluids can not penetrate the cracks. be stored, the procedure outlined above can be
However, some machining and cleaning opera- used, but greater attention to cleaning the ex-
tions can negatively impact the future corrosion posed portions of each cylinder rod is required.
resistance of chrome-plated shafting. For exam- Solvent applied with plastic or copper wool can
ple, additives such as chlorine, sulfur, and sodi- be used, but abrasives such as sandpaper
um found in Extreme Pressure (EP) coolants and should never be used to clean the exposed sur-
some washing solutions are known rust acceler- faces of the cylinder rod. If surface damage to
ates and can strip chrome plating from the base the chrome plate is discovered, the frequency of
metal. Cleaning processes, such as phosphate corrosion barrier applications should be in-
washing are also known to be detrimental to the creased.
corrosion resistance of hard chrome plated
shafting. Note: Caution must be used when cleaning
equipment in service with high pressure
If the rod is not periodically cycled and is subject washes. Soaps or chemicals containing
to a corrosive environment, moisture and oxygen chlorines or other corrosive elements
can work its way down through the chrome layer should be avoided. Cylinders should be
and begin to corrode the base metal. Brand new cleaned in a retracted position as not to
equipment may be stored outside for a consider- expose rods to the chemicals. Cylinders
able period of time at the equipment dealership should be cycled immediately following
before it is sold. During these times, a protective the wash. If rods are to be stored in the
barrier must be applied to the exposed cylinder extended position, refer to steps 1-4
rod. This protective barrier will preserve the in- above.
tegrity of the chrome plating by preventing the
elements of corrosion from getting to the metal
substrate.
Cylinders should be stored in the retracted posi-

tion, if at all possible. The steps outline below
cover the procedures to be followed for protect-
ing New Equipment from corrosion if it must be
stored in the extended position:
1. Position the equipment as it will be stored

and identify all the exposed portions of the
chrome plated cylinder rods.
2. Clean any dirt and dust from the exposed

portions of the cylinder rods using a dry
cloth or a cloth which has been dampened
with an appropriate solvent. Do not use
caustics or acids.
3. Apply a thin coating of “Ferro-Kote 5856-BF”

to the exposed surfaces of the chrome plated
cylinder rods. The ferro-Cote may be
thinned using a 40% Kerosene or no. 1 fuel
oil mixture.
7-6 Issued: May 2002

Rated Capacity Limiter Use and maintenance
Rated Capacity
Limiter
(RCL)
RCL - ed. 06-2006a page /30

Use and maintenance Rated Capacity Limiter
page /30 RCL - ed. 06-2006a

Table of contents
Introduction� �� 4
System operation description �� 6
Main features��7
System description��8
Components location on the machine � �� 9
System features�� 10
Panel description�� 11
Key function�� 13
Starting up� �� 14
How to select the operating mode�� 14
How to select the operating mode ��14
Configuration list�� 15
How to select the parts of line ��17
Disabling the fastener upstroke limit switch � �� 17
Releasing the boom upstroke limit switch lock�� 17
Panel visualizations � �� 18
How to select the limit�� 20
Diagnostic �� 22
Troubleshooting��22
Auto-diagnostic�� 24
System internal working conditions monitoring ��24
Disabling the rated capacity limiter�� 27
Warnings � �� 29
RCL - ed. 06-2006a page /30

Introduction
The information on this document could be subject to change without
notice.
The constructor is not responsible for possible content mistakes or
misprints that could be present in this manual.
Any reproduction, translation or copy of parts of this manual is forbidden
without prior written authorization by The constructor.
warnings
The rated capacity limiter, is an electronic control device, designed to help

the operator in the safe use of the machine, warning him by means of
visual and audible alarms when approaching a dangerous condition.
However, this device won’t replace the good experience of the operator in
the proper use of the crane.
The responsibility of the operations in safety conditions of the machine is
on operator care, as well as the fulfilment of all safety rules prescribed.
The operator must be able to recognize if the data transmitted by the
system is correct and coherent with the real conditions.
He also must be able to utilize the data in order to operate in safe
conditions.
The RCL is an electronic device with several components and could be
subject to failures or defects.
The operator must recognize these events and must act consequently (to
proceed to repair, if possible, or to call the constructor assistance).
Before starting the operations with the machine, user must fully read and
understand this manual and follow the instructions written in it.
IMPORTANT NOTES
● The RCL is supplied with a key for automatic shut-off over-ride.
● In the normal working condition this key must be positioned properly
not to operate the override functions.
● It is prohibited to use this key to lift loads exceeding the load table
limits provided by the manufacturer of the crane.
● The key must be used only in extreme cases: malfunctioning or
situations justifying its use.
● The use of the key is allowed only by authorized personal, who are
responsible of its use.
● The RCL has a powerful FAIL-SAFE self-diagnostics program suitable
to verify the good operation of its circuits and measuring transducers.
In case of a failure is detected, the RCL puts itself in emergency status
by blocking the manoeuvres.
● Nevertheless, the operator, before starting the operation of the
machine, must secure that the RCL functions correctly. To do this,
he must verify the accuracy of the displayed values by performing
some tests. He must also verify that there are not messages or alarm
indications, and verify the correct operation of shut down function.
page /30 RCL - ed. 06-2006a

● Generally, the RCL does not automatically change the operating

conditions of the machine (tables). The operator is responsible for
the proper setting of the operating conditions of the machine and the
correct use of the rated capacity limiter.
● About this, follow the indications given forwards in the manual and
concerning the operating modes. An incorrect setting of the tables
can cause an incorrect operation of the RCL, will create a dangerous
situation in the crane operating. For this reason it is essential to set the
correct operating mode.
● These operating conditions generally vary when:
a) outriggers are extended or retracted
b) switching, the operation from outrigger mode to on tires mode
c) shifting from operation in static conditions to translation
d) telescopic mechanical extensions are extended or not
e) further equipment (jib, ext, etc.) are installed or not
f) the number of parts of line is properly selected.
In general, it is mandatory to follow the instructions given by the crane

manufacturer.
RCL - ed. 06-2006a page /30

System operation description

The Rated Capacity Limiter is designed to aid the operator in safe functions
of the crane.
The RCL compares automatically the lifted load to the maximum one
supplied by load table providing the necessary information to the user in
order to work in safety condition.
The main readings are:

- actual lifted load
- maximum admitted load
- tilting percentage
- operating radius
- boom angle
- boom extension (length)
- working mode (Operating mode)
- warning lights (green, yellow, red) and audible alarm.
The system determines the lifted load by computing it from the relevant
sensing devices signals (pressure or load cell), and by means of the
measures of boom angle and extension operating radius is computed
too.
The lifted load is continuously compared with the maximum allowable load
obtained from the load tables.
Consequently three possible situations can occur:
1) Safety
green lamp is on, no presence of acoustic signal: lifted load is lower
than 90% of the maximum load.
2) Warning
yellow lamp is on and audible alarm intermittently sounds; this is the
warning situation.The signal occurs when the lifted load is more than
90% and less than 100% of maximum load.
3) Alarm
red lamp is on and audible alarm sound continuously inside the cab,
another audible intermittent alarm sound outside the cab. The external
alarm device is positioned on the lower part of the main boom. Lifted
load exceeds the allowable load so that the control functions shut
down is activated.
In the alarm situation, only control function operations to allow the machine
in a safe working condition are enabled.
page /30 RCL - ed. 06-2006a

Main features
Working condition Memorization of the load charts/ Visualization data

measuring table and data computing and setting
LTB1 Name Code Ballast Outrigger Jib Angl e Ji b Length Zo n e
CONTROL PANEL
C71_1: BOOM ON OUTRIGGERS 300 2,5 6,3 0
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14
1 Length 9,4 14,4 19,5 24,7 28,9 30,4
2 I 0 24 48 73 93 100
3 II 0 24 48 73 93 100
4 III 0 24 48 73 93 100
5 IV
6
7
8 Amax 79 32 79 19 79 17 79 14 79 10 79 9
9 Amin 0 8 0 4,3 0 2 0 1,05 0 0,5 18 0,8
10 2 2 2 2 2 2 2
11 3 62,4 32 71,9 20
12 3,5 58,4 27,45 69,8 20,35 75,9 18
13 4 54,1 24,4 67,4 20,75 74,5 18,45 76 14
14 4,5 49,5 21,8 65,2 21,2 73,1 18,7 75,2 14,5
15 5 45 19,4 62,8 19,3 71,7 17,3 74,6 14,3
16 6 33,4 15,5 58 14,75 68,6 13,45 72,9 12,35 77,2 10 78,2 9
17 7 19,1 11,5 53 11,7 65,2 10,9 71,2 10,1 75,2 9,55 76,4 8,85
18 8 47,7 9,4 61,7 9,05 69,2 8,5 73,2 8,05 74,5 7,9
PRESSURE
19 9 41,8 7,65 57,8 7,7 67,9 7,25 71,2 6,9 72,5 6,8
20 10 35 6,4 53,7 6,45 64,4 6,25 69 6 70,4 5,9
21 11 24,7 5,4 49,4 5,4 61,8 5,4 66,8 5,25 68,2 5,15
22 12 11 4,65 43 4,7 59 4,75 64,4 4,6 65,8 4,55
TRANSDUCERS
23 13 40,4 4,05 55, 8 4,1 62 4, 1 63,4 4,05
24 14 35,6 3,55 52, 6 3,6 59,4 3, 6 61 3,6
25 15 30,6 3,05 48,9 3,1 57 3,1 59,5 3,1
26 16 23,7 2,75 45 2,75 54,2 2,8 55,6 2,8
(lifted weight data )

27 17 12,9 2,35 40,8 2,4 51,4 2,4 53 2,4
28 18 36,2 2,15 48,6 2,2 50,1 2,2
29 19 31,4 1,95 45,8 1,95 47,2 1,95
30 20 26,4 1,7 42,8 1,7 44,2 1,7
31 21 22,6 1,5 40 1,5 43,3 1,5
32 22 12,4 1,35 36 1,35 37,8 1,35
33 23 31,2 1,2 33,8 1,2
34 24 26 1,05 29,2 1,05
35 25 19,2 0,9 24 0,9
36 26 11 0,8 18 0,8
37 27 0,5
38 28
39 29
40
Readings:
- % tilting
- Lifted Weight
- Load allowed
- Working Radius
- Boom Extension
- Boom Slope
- Operating Mode
- Attachment used
- Diagnostic
ALARM:
Lights
Green,Amber,Red
LENGTH/ANGLE
SENSOR MANUAL
(Boom’s geometrical SELECTION:
data) Activation of the emergency functions - Outrigger
External Alarm / Automatic shut off - Translation mode
- N° Rope
AUTOMATIC - Main Boom
SELECTIONS - Inclination
External attachment
Micro-switches:
- Rotation
- A2B
RCL - ed. 06-2006a page /30

System description
J1939
2
6
ENGINE
1
CAN 1 rpm
CAN 2
INPUT / OUTPUT SIGNALS

AND EXTERNAL POWER SUPPLY
HIGH CHAMBER (ROD SIDE)
HIGH CHAMBER (ROD SIDE)
3
7
EN 418
V DE 0660
AC15 6A /230V
I P 66
Ref. Description
1 Main Unit
2 Display unit Black e White
3 Cable reel 32mt
4 Cable reel 11 mt
5 Pressure transducer
6 Can Bus Cable L=10mt
7 Anti twoblock + weight 4 Kg
page /30 RCL - ed. 06-2006a

Components location on the machine
Length/Angle
sensor:
On the left side of
Main Unit and Control
the boom
Panel:
in the cab
Nr.2 Pressure
Transducers:
On the lifting cylinder.
A2B
Rod and piston side
RCL - ed. 06-2006a page /30

System features
SWITCH ON
INTERNAL Data Integrity check and warning Lamps check

CHECKING
TEREX
Logo Displayed and Software version
LOGO
WORKING Indication of the Settings, geometrical data and

PAGE operating mode of the machine
CONFIRM
OR CHANGE Selection and confirm of the operative mode and setting
DATA
OPERATION Now the system is ready to operate
page 10/30 RCL - ed. 06-2006a

Panel description
2 3 4
6 1
11
20
13
19
12
18 17 16 15 14 10
RCL - ed. 06-2006a page 11/30

Ref. Icon Description

1 Working data display
Enter
Enter
Enter
2 F1
Two
F1lights showing the safe work condition
3 F2
Light
F2showing the pre alarm condition
Sel
Sel
Sel
4 F3
Light
F3showing the shut off condition has occurred
Enter
Enter
Enter
Enter
5 F1
F1 Function
F4 key button depending of the page displayed
F4
F1
TARE
TARE
TARE
F2 F5
ESC
ESC
6 F5 key button depending of the page displayed

Function
ESC
F2
F2
Sel
Sel
Sel
Sel
7 F3
F3 Function key button depending of the page displayed
F3
8
F4
F4 Function key button depending of the page displayed
F4
TARE
TARE
TARE
TARE
F5
ESC
ESC
F5
ESC
9 Function key button depending of the page displayed

ESC
10 Enter
Enter
Enter
Enter Confirm an action ( operating mode, procedure, limit )
F1
F1F1
F1
11
F2
F2 Scroll up inside the menu
F2F2
Sel
Sel
Sel
Sel
F3
F3
F3F3
12 Scroll down inside the menu
F4
F4
F4
F413 Increase menu / list ( operating mode, number of lines, etc )
TARE
TARE
TARE
TARE
F5
ESC
F5
ESC
ESC
TARE
F5
ESC
F514
ESC
Decrease menu/list (operating mode, number of lines, etc )
15
Enter
Enter
Enter Enable/Disable the anti twoblock
F1
F1 Enter
F1 16 Disabling buzzer
F2
F2
F2 17 Sel
Sel
Sel Disable the lowering boom
F3
F3 Sel
F3 18 Changing of the pages

F4
F4
TARE
F4 TARE
TARE
TARE
F5 19 ESC
ESC
ESC Back to the main page. It also has a function of deleting the alarms once knowledged
F5
ESC
TARE
F5
ESC
Key button in order to let the operator to enter in the calibration’s menu. In order to
have access and configure the system, the user must scroll up to the operating page.
20
The function is available only if provided with the password ( to digit when the Logo is
displaying )
page 12/30 RCL - ed. 06-2006a

Key function
Enter
How to disable the buzzer:

F1
Disable: when the audible alarm

F2
is active on, by key you can disable
the audible alarm until the new alarm is detected.
Enable: after few seconds that the alarm is switch off the audible alarm
Sel
F3
will enable automatically.
F4
Enter TARE
F1 F5
ESC
Enter
F2
F1
Sel
F2
F3
Sel
F3 How to change viewing page:

F4 By pressing, the view page can be changed to indicate the:
F4
- RCL pageTARE
TARE
F5
F5 - I.S.A.A.C. page
ESC ESC
Enter
F1
F2
Sel
F3
F4
TARE
F5
ESC
RCL - ed. 06-2006a page 13/30

Starting up
When the system get started, the last operating conditions is screened on
the display, the latest setting before the machine was turned off. During
this procedure, the system performs an auto test and it put itself in shut
off condition.
How to select the operating mode
Before starting the lifting operation, the user must check that the operating
mode set corresponds to the real machine’s configuration ( boom,
outriggers, counterweight, jib’s length and angle, etc ) and the number
of lines and confirming it pressing Enter in order to change the operating
mode, please proceed as F1 follows
Enter
F2
HowF1to select the operating mode
Enter
F1 Sel
Enter
Enter F3
F2
F1
- by F1
F2 key you must change the outrigger/crawlers geometry;
Sel
F4
- by F2F3 key you must change
F2 Sel
the translation mode
TARE
F3
F5
ESC
SelSel
- by F3F4 key you must change the configuration of the boom or the
F3
F4
attachment; TARE
F5
ESC
TARE
F4
F4
- by F5 key you must change the configuration of the attachment or the
ESC
TARE
TARE
angle
F5of the jib
F5
ESC
ESC
- by Enter
key confirm the operative mode
F1
When you confirm the code line it indicates the number of the operative
F2 mode
Sel
page 14/30 F3 RCL - ed. 06-2006a
F4
TARE
Configuration list
Enter
Press the button F1 for change the outrigger configuration, like below:
F2
Enter
Sel
F1
F3
Outrigger full extended
F2F4
TARE
Sel
F3F5
ESC
Enter
F1
F4
Outrigger half extended
F2 TARE
F5
ESC
Sel
F3
Enter
F1
F4
Outrigger fully retracted
F2
TARE
F5
ESC
Sel
F3 Enter
F1
F4
On wheels
F2 TARE
F5
ESC
Sel
F3
Enter
F4F1
TARE
Press the buttonF5F2 for change the translation mode, like below:
ESC
Sel
Enter
F3
F1
F4
F2
Static Translation mode
TARE
F5
ESC
Sel
F3
Enter
F1
F4
TARE
0° F2
F5
ESC
Translation mode on front side

Sel
F3
F4
TARE
F5
ESC
RCL - ed. 06-2006a page 15/30

Enter
F1
Use and maintenance F2 Rated Capacity Limiter

Enter
F1 Sel
F3
F2
Press the button F4 for change boom Sel
or the attachment
F3 TARE
F5
ESC
Enter
F1
F4
Main boom TARE 1
F2
F5
ESC
Sel
F3
Enter
F1
F4
F2 Jib TARE
2
L
F5
ESC
Sel
F3
Enter
F4
F1 TARE
Press the button F5 for change the configuration of attachment or angle

ESC
F2
Jib is install at the moment, like below
Sel
F3
Enter
No selection
No selection
F4 1 will be
F1
TARE admitted
F5
ESC
F2
Sel
F3
F4 0 degree
Enter
inclination Jib
0° F1 TARE
F5
ESC
F2
Sel
F3 Selection is
Enter
possible only if
20 degree inclination Jib 2 “Jib” has been
20° F4
F1
TARE previously selected
F5
ESC
F2
Sel
F3
F4 40 degree inclination Jib

40° TARE
F5
ESC
Rooster sheave (it’s possible only if the main

boom icon is select.
0,5m Note: All max. load will be limited at the single
rope
By Enter
key to confirm the parts of line
F1
page 16/30 F2 RCL - ed. 06-2006a

Sel
F3
Enter
F1
How to select
F2
the parts of line
Enter
F1 Sel
Press the button F3 for change the number of rope, like below:
F2 F4
Sel
TARE
0 F3 F5 Parts of line
ESC
Enter
F1
F4
F2
TARE
F5
ESC
Sel
1 F3 Parts of line
Enter
F1
F4
F2
TARE
F5
ESC
Sel
2 F3 Parts of line
Enter
F1
F4
F2
TARE
F5
ESC
Sel
N F3 Parts of line
F4
TARE
F5
ESC
By Enter
key to confirm the parts of line
F1
F2
Sel
F3
Disabling the fastener upstroke limit
F4 switch
TARE
F5
ESC
Press and hold button

Enter
to disable fastener upstroke limit switch.
F1
F2
Sel
F3
Releasing
F4 the boom upstroke limit Enter
F1
switch lock
TARE
F5
ESC
F2
In case of boom upstroke limit switch lock, press button Sel to activate a
F3
timer releasing the boom for 10 seconds, thus allowing the operator to tilt
it to less than 75°.
F4
TARE
F5
ESC
RCL - ed. 06-2006a page 17/30

Panel visualizations
31 28 27 29 32 34
38 21
39 22
23
40
24
41 25
42 26
33 35 43 36 37 30
page 18/30 RCL - ed. 06-2006a

STOP
STOP
STOP
STOP
STOP
STOP
Ref. Icon
STOP Description
STOP
STOP
21 STOP
STOP
It indicates the RCL by pass key (if activated = black background)
STOP
STOP
STOP
STOP It indicates the winch limit switch status
22 STOP
STOP
STOP
STOP
STOPOK
STOP
(if activated = black background)
STOPOK
STOP
STOP
OK
STOP
23 STOP
STOP
OK
OK
STOP
This icon indicates the Shut Off from Isaac
OK
STOP
OK
OK
OK
OK
STOP
24 OK
OK
STOP It indicates the machine is in the normal working condition
STOP
STOP
STOP
OK
STOP
OK
25 OK
OK
STOP It indicates the machine is in the pre-alarm working condition (90%)
STOP
STOP
STOP
STOP
STOP
STOP
STOP
STOP
26 STOP
STOP It indicates the machine is in the Shut off working condition (100%)
STOP
STOP
Act
OK
STOP
STOP
Act
27 Act Indication of the Load percentage bar
Act
Act
Act
Act
Act
28 Act
MAX
Act
Indication of the actual load. Value in Ton
Act
MAX
MAX
MAX
Act
Act
MAX
Act
MAX
Act
MAX
MAX
MAX
Act
29 MAX Indication of the maximum load in that machine condition.
MAX
M1
M1
MAX
STOP
M1
M1
MAX
MAXM1
MAX
M1
MAX
M1 It indicates the Boom’s extension MOD 1 or MOD 2 status
30 M1
M1
M1
M1
R
R
R (M1 = Red Icon ; M2 = Yellow Icon)
M1
M1RR
M1
M1
M1 R
A
31 RA Indication of the main boom’s radius. Value in meters or feet
RR
Act R
A
RRA
LRRA
A
L R
LR
32 AA Indication of the main boom’s angle. Value in degrees
L AA
MAX HA
A
L A A
33 LL H 0A Indication of the main boom’s length. Value in meters or feet
A
LL
L H
L LM1H
LAlarm:
L 0 Indication of the height from the ground. Refer to the “head of the boom”.
34 L 0H
H
LCode:0 Value in meters or feet
HH
H
Alarm:
Alarm: H
R0HH
Alarm:
35 H0
0
It indicates the element extension of the main boom. Value in %
Code:H
00
Code: H
Code:
Alarm:H0
36 Alarm: 0A0 Indication of the Alarm code that its present at the moment
Alarm:
Alarm: 0
Alarm:
Code: 0
Alarm:
Code:
Code: 0
37 Alarm:
Alarm:
Code: 0 Indication of the number of operative mode
Alarm:
LCode:
Alarm:
38 Code: Crawler/outrigger configuration
Alarm:
Alarm:
Code:
Code:
Code:
Code:
39 Code: Indication of the translation mode
Code:
H
40 Indication of Parts of Line

0
41 Alarm: Configuration of the boom or the attachments

42 Code: Selection about the Jib inclination (if they are present)
43 Visualization of truck inclination (crawler crane only)
RCL - ed. 06-2006a page 19/30

Enter
F1
F2
How to select the limit Sel
F3
STOP
To enter in this page, press the key button , until this one appears
F4
STOP TARE
F5
ESC
STOP
STOP
OK
OK
STOP
STOP
Act
STOP
Act
MAX
MAX
M1
STOP
M1
R
OK
ANGLE RA
12 12.3
A
BLOCK
L VALUE: REAL VALUE:
Indication
STOP of the Indication of the actual
maximum
L
value set value
H
HEIGHT H
0
Act 4.0 4.7
Alarm:
0
BLOCK
MAX VALUE: REAL VALUE:
Indication of the Indication of the actual
Code: value set
Alarm:
maximum value
M1
Code:
RADIUS R 7.0 7.7
BLOCKA VALUE: REAL VALUE:
Indication of the Indication of the actual
maximum value set value
L
page 20/30 RCL - ed. 06-2006a

H
Enter
F1
In order to set the maximum angle, set the main boom up to the position
Enter
and press the F2 key button. F1
Sel
F3
How to set the maximum angle To delete the set value, press F2 key button.
Sel
F4 Enter
F3
F1 TARE
F5
ESC
F2 F4 Enter
F1
In order to set the maximum height,set theSel main boom to the position
TARE
F5
ESC
and then press the F3 key button. F2

Enter Sel
F4
How to set the maximum height To delete the set value,
F1 press and hold the F3 key button.
TARE
F5
ESC
Enter
F2 F4
F1
TARE
Sel
F3 F5
ESC
F2
In order to set the maximum radius, set the main boom to the position
Sel
and them press the F4 key buttom F3
TARE
F5
ESC
To delete the set value, press and hold the F4 key button.
How to set the maximum radius TARE
F5
ESC
RCL - ed. 06-2006a page 21/30

Diagnostic
An overall self test diagnostic is provided. When each of the following
alarm occurs cut-off relay is de-energized and proper alarm message
appears on alphanumeric display.
Troubleshooting
MESSAGE CAUSE SOLUTION
• potentiometer inside broken . • Check integrity of winder

ALARM 6
• Possible lack of continuity in wires carrying • Check wire continuity
BOOM LENGTH 1
the unwinding • Replace it if broken.
LOW
• Fault in main unit. • Call assistance
• Potentiometer inside broken. • Check integrity of winder

ALARM 7
BOOM LENGTH 1
HIGH
• Potentiometer inside broken . • Check integrity of winder

ALARM 11
BOOM LENGTH 2
LOW
• Lower chamber pressure transducer • Replace pressure transducer

broken • Check connection wires.
ALARM 12
• Possible lack of continuity in connection • Check insertion of connector on
PRESSL LOW
wires transducer
• Fault in main unit • Call assistance
• Lower chamber pressure transducer • Replace pressure transducer
broken • Check connection wires.
ALARM 13
• Possible lack of continuity in connection • Check insertion of connector on
PRESSH LOW
wires transducer
• Fault in main unit • Call assistance
• Angle sensing device broken. Check the • Check inclinometer
inclinometer. • Replace it if broken.
ALARM 14
• Possible lack of continuity in wires carrying • Check connection wires
ANGLE LOW
the angle signal • Call assistance
• Fault in main unit.
• Check the input status

ALARM 20 • Simultaneously Input M1 and M2 ON
• Deactivate the undesired one
FAULT M1/M2 • Fault in main unit.
• Call assistance
• Potentiometer inside broken . • Check integrity of winder

ALARM 21
BOOM LENGTH 2
HIGH
page 22/30 RCL - ed. 06-2006a

MESSAGE CAUSE SOLUTION

• Upper chamber pressure
• Replace pressure transducer
transducer broken
ALARM 22 • Check connection wires.
• Possible lack of continuity in
PRESSL HIGH • Check insertion of connector on transducer
connection wires
• Call assistance
• Fault in main unit
• Upper chamber pressure
• Replace pressure transducer
transducer broken
ALARM 23 • Check connection wires.
• Possible lack of continuity in
PRESSH HIGH • Check insertion of connector on transducer
connection wires
• Call assistance
• Fault in main unit
• Angle sensing device broken. • Check inclinometer
ALARM 25 • Possible shot circuit of • Replace it if broken.
ANGLE HIGH connection wires. • Check connection wires
• Error in EEPROM memory
ALARM 56
• The contained data are • Call assistance
EPROM KO
damaged or altered
ALARM 190 • CAN BUS cable broken; • Check of the CAN BUS cable
CANBUS HEAD KO • Internal problem • Replace unit
ALAM191 • Cable broken • Check of the cable
ASA CBO TRUCK • ASA broken • Replace ASA
ALARM 192
CANBUS
• CAN BUS cable broken; • Check of the CAN BUS cable
ENCODER
• Internal problem • Replace Encoder
TURRET
ROTATION KO
RCL - ed. 06-2006a page 23/30

Auto-diagnostic
System internal working conditions monitoring

Geometric data and load data
These readings indicate the internal status of the system when

troubleshooting a fault condition. Starting from the main working data
page press Enter button: the display will indicate the control page, giving
F1
geometric data and main cylinder pressure summary.
F2
A 1 a d c Sel A 1 a c t
F3
Enter
F4 7 0 0
F1 7 8 0
TARE
F2
TheF5displayed parameters are as follows:
ESC
• A1adc: Value (bit) reads directly from

Sel the angle sensor
F3
• A1act: Value (degree x 10) of the angle
F4
TARE
To return to the main page, press the button.

F5
ESC
S 1 a d c S 1 a c t
Enter
4 0 0
F1 1 8 7 0
F2
The displayed parameters are as follows:
• S1adc: Value (bit) reads directly fromSelthe potentiometer of the Length 1
F3
• S1act: Value (meter x 100) of the length
F4
TARE

F5
ESC
S 2 a d c S 2 a c t
Enter
4 0 0
F1 1 9 0 0
F2
• S2adc: Value (bit) reads directly fromSelthe potentiometer of the Length 2
F3
• S2act: Value (meter x 100) of the length
F4
TARE

F5
ESC
page 24/30 RCL - ed. 06-2006a

Hydraulic pressure data

Enter
F1
By pressing
F2
the the display shows the individual hydraulic pressures
summary: F3
Sel
F4
P L a d c P L a c t
TARE
F5
ESC
3 0 0 5 5 0
• PLadc: Value (bit) reads directly from the pressure sensor
• PLact:: Value of the pressure on the bottom side
P H a d c P H a c t
1 0 0 2 0 0
• PHadc: Value (bit) reads directly from the pressure sensor
• PHact: Value of the pressure on the rod side
Sensor digital inputs Enter
F1
Pressing once againF2the button the display will indicates the digital
input page;
Sel
F3
Where the asterisk is present means, that digital input is activated
F4
otherwise if is not present the asterisk the digital input is off
TARE
F5
ESC
I 0 1 2 3 4 5 6 7 8 9 0 1 2 3
* * _ _ _ _ _ _ _ _ _ _ _ _
Enter
Sensor digital outputs

F1
Pressing once againF2the button the display will indicate the digital
output page;
Sel
F3
Where the asterisk is present means, that digital output is activated
F4
otherwise if is not present the asterisk the digital output is off
TARE
F5
ESC
O 0 1 2 3 4 5 6 7 8 9 0 1 2 3
_ _ _ _ _ _ _ _ _ _ * _ _ _
RCL - ed. 06-2006a page 25/30

Diagnostic external unit Enter
F1
By pressing
F2 the the display indicates the summary of the remote
units F3
Sel
H E A D
F4
TARE
E N C O D E R
F5
ESC
1 0 0 8 1
• HEAD: counter control about Head unit: if this counter moves means
that the unit is activate
• ENCODER: counter control about Encoder: if this counter moves

means that the encoder is activate
Setting display contrast Enter
F1 Enter
F1
Press the button
F2 is possible to increase the contrast of the display
F2 Enter
Sel
F3 Sel F1
F3
Press the button
F4
is possible
F2 to decrease the contrast of the display
F4 TARE Sel
F5
ESC
TARE
F3
F5
ESC
Setting languages change

F4
TARE
F5
ESC
After the confirm the operative mode by button is possible to entry

inside the menu called “Language” where is possible to select the right
language.
D I S P L A Y
Language X
Press the button Enter
is possible to change the value of the language.
F1
F2 *
Language
F3
Enter
Sel
X
F1
F2 Enter
F4
Enter
F1
Sel
F3
F1 Press the button
F2 is possible to change the language. TARE
F5
ESC
F4 Sel
F3
F2 Press the buttonF5 Enter is possible to confirm the language.
TARE
ESC
F1
F1F1 F4
Enter
Sel
Enter
TARE
F3 0 F5 1 ESC
F2 F2
F2 Sel Sel
F3 F3
F4 Sel
F3F4
F4
Press the button is possible to exit from this menu and return on the
TARE
F5 Main Page.
TARE ESC TARE
F5 F5
ESC ESC
F4
page 26/30 TARE RCL - ed. 06-2006a
F5
ESC
Disabling the rated capacity limiter

The machine is equipped with a device for disabling the rated capacity
limiter.
To disable the limiter,

on upperstructure:
- turn clockwise and release key 44 on electric box. This operation
involves the led on button 45 inside the cabin to switch on;
44
in the cabin:
- press and hold button 45 to disable the rated capacity limiter.
45
Release button 45 to re-enable limiter.
When the rated capacity limiter is disabled a visible and audible alarm
is activated outside the cab. The external alarm device is located at the
fixing point of luffing cylinder to boom.
RCL - ed. 06-2006a page 27/30

Switch off and then back on the crane control board to reset the system
and the limiter will be operating normally again.
WARNINGS
It is forbidden to use this device to lift loads exceeding the

capacity allowed by the manufacturer.
The device shall be used only in case of system failure or
malfunction.
The device can be used only by authorised and qualified
personnel.
The key 44 should never be left on the machine; authorised
persons in charge of its use should keep it in a safe place.
page 28/30 RCL - ed. 06-2006a

Warnings
• The Rated Capacity Limiter is an electronic device with the aim to
aid the operator in the current use of the machine, warning him by
means of visual and audible alarms when approaching dangerous
conditions.
• However this device can’t replace the operator’s good experience in
the safe use of the machine.
• The responsibility of the operations in safe conditions of the machine is
the operator concern as well as the accomplishment of all prescribed
safety rules
• The Operator must be able to detect if the data given by the RCL
is correct and correspond to actual working conditions. He must be
able to utilize the data given by the RCL in order to operate in safe
conditions in any time.
• The RCL is an electronic device including several sensing components,
therefore it can be subject to failures or defects. The operator must
recognize these events and he must take action ( to proceed to repair
if possible or to call Assistance).
• Before starting the operation with the machine, the user must fully
read and understand this manual and follow the instructions at any
time.
• The RCL is supplied with a key for shut-down function by-passing.
• In normal working operations, this key must be positioned not to by-
pass shut-down.
• It’s prohibited to use the key to lift loads exceeding the loads values
allowed by the Manufacturer.
• The key can be used only when an emergency/malfunctioning occurs
or a situation justifying its use.
• Only Authorized Personnel is allowed to the use of the key; they are
also responsible for it.
• The RCL has a powerful FAIL-SAFE auto diagnosis program suitable
to verify its good operations and the one of its transducers. In case
a trouble has been detected, the RCL puts itself in a safe state by
stopping the manoeuvres (please see the AUTODIAGNOSTIC
chapter).
• In spite of this, the Operator, before starting the operation with the
machine, must take care that the RCL is working correctly. To do this,
he must verify the validity of the displayed values by doing some tests.
He must verify that there are not messages or alarm indications;
he must verify the correct operation of the manoeuvre stopping
functions.
• The operator is responsible for the correct setting of the machine
load table and therefore for the right RCL set. When switching-on
the machine the last selected Table is kept valid, to allow Operator
check.
RCL - ed. 06-2006a page 29/30

• About this, please follow the instructions given in the OPERATING

MODE SELECTION chapter. An incorrect setting of the tables, can
cause an incorrect RCL operation and therefore can provoke a
dangerous situation for the machine.
Generally, it’s compulsory to follow the Manufacturer instructions

and procedures at any time.
page 30/30 RCL - ed. 06-2006a

PMSF.72.85.0006
USE AND MAINTENANCE
December 2005
WARNING
The content of this documentation, issued exclusively to provide necessary information to the machine end user, is considered extremely
confidential and cannot be disclosed to third parties nor copied without our approval.
The manufacturing of parts or assemblies shown on this documentation, without our approval, infringes DROMOS s.r.l. industrial property
rights.
USE MANUAL
STEERING DRIVE AXLE PMSF.72.85.0006
1.0 DESCRIPTION
2.0 LUBRICATION
3.0 PUTTING IN OPERATION
4.0 OIL REFUELINGS AND CHECKS
4.1 CAPACITY
4.2 TYPE OF LUBRICATING OIL
4.3 PERIODICAL CHECK OF THE OIL LEVELS
4.4 FIRST OIL CHANGE
4.5 FURTHER OIL CHANGES
4.6 SAFETY LOCKING PRODUCTS
4.7 SEAL PRODUCTS
5.0 SPARE PARTS

1.0 DESCRIPTION
The PMSF.72.85.0006 unit consists of a reduction unit with a bevel gear pair and an epicycloidal reduction. A bevel pinion engages with a
bevel gear fixed on the train carrier of a differential gearing which transfers motion to the universal joints. Between the universal joint and the
wheel hub with drum, there is a reduction unit made of an epicycloidal reduction. At the end of the axle body there are internal half articulated
joints for the articulation of the steering equipment. The block brakes are hydraulically controlled by means of a cylinder which is fitted on the
brake plate.
2.0 LUBRICATION
Splash lubrication has been adopted for this unit and it is designed in such a way that all the gears and the bearings are sufficiently lubricated
under all operating conditions. The check of the level in the axle body and in the epicycloidal gears must be done by removing the plugs (34)
and (88).

The transmissions are delivered without oil. Before putting them in operation, they must be therefore filled with oil through the filler (34) and
(88). Use oil that is perfectly clean and of the type specified in point 4.2.
If unsuitable oil is used by accident, the guarantee conditions are no longer valid. For the levels and any necessary topping up, see point 2.0.
4.1 CAPACITY
Axle body 3.7 gal.
Epicycloidal gear on the hub 1 gal. (each one)
The product used must correspond with the following quality specifications:
AXLE BODY – EPICYCLOIDAL GEARBOXES

Type of lubricant completely synthetic PAO
SAE grade 75W-90
API GL-5
ARTICULATION PINS – BUSHINGS

Type of lubricant grease
Consistence NLGI 2

The lubricant level in the axle body and in the epicycloidal gears must not drop below the inspection plugs (34) and (88): if it does, it is
necessary to top up the level using a lubricant of the same type. If there is a large drop in the level, it is advisable you look for the cause
immediately, to avoid further damages to the mechanical parts. During every inspection, check that the breather plug (32) is working correctly,
wash it with Diesel oil and dry it with an air jet. The oil is drained by removing the plugs (34) and (88). The bushes of the articulation pins and
of the fifth wheels must be lubricated every time they are dismantled or at least every 100 working hours, by filling the grooves of the bushes
and of the fifth wheels through the lubricators (45).

The transmission oil must be replaced for the first time after 50 working hours. It is advisable you change the oil when it is still hot. It must be
drained from the plugs (34) and (88).

Every 500 working hours or at least once a year.

LOCTITE 243 “middle threadlocker” and LOCTITE 601 “locker” must be used for the screws, as prescribed in the table in this manual.
4.7 SEAL PRODUCTS
Use degreasing solvents to clean thoroughly all parts where the AREXONS Motorsil D liquid sealant for flat surfaces must be used.
N.B.: The liquid sealant must be well laied off on all surfaces where oil passes. Remove the exceeding product.
MAINTENANCE MANUAL
PMSF.72.85.0006
DISASSEMBLY OPERATIONS
1.0 PRELIMINARY OPERATIONS
2.0 DISASSEMBLY OF THE PLANETARY GEARS
3.0 DISASSEMBLY OF THE ANNULAR GEAR WITH HUB
4.0 DISASSEMBLY OF THE WHEEL HUB WITH DRUM
5.0 DISASSEMBLY OF THE SPINDLE
6.0 DISASSEMBLY OF THE EXTERNAL HALF ARTICULATED JOINT
7.0 DISASSEMBLY OF UNIVERSAL JOINT
8.0 DISASSEMBLY OF THE UNIVERSAL JOINT CARRIER BUSH
9.0 DISASSEMBLY OF THE PARKING CALIPER
10.0 DISASSEMBLY OF THE DIFFERENTIAL CARRIER
11.0 DISASSEMBLY OF THE DIFFERENTIAL
12.0 DISASSEMBLY OF THE BEVEL PINION
13.0 DISASSEMBLY OF THE CYLINDER SUPPORT
14.0 DISASSEMBLY OF THE COMPLETE BRAKE AND OF THE BRAKE JAWS
15.0 DISASSEMBLY OF THE PADS OF THE PARKING CALIPER
16.0 GENERAL NOTES
17.0 CHECKS
ASSEMBLY OPERATIONS
18.0 ASSEMBLY OF THE DIFFERENTIAL CARRIER
19.0 ASSEMBLY OF THE BEVEL PINION AND OF THE DIFFERENTIAL CARRIER ON THE DIFFERENTIAL SUMP
20.0 ASSEMBLY OF THE UNIVERSAL JOINT CARRIER BUSH
21.0 ASSEMBLY OF THE EXTERNAL HALF ARTICULATED JOINT
22.0 ASSEMBLY OF THE UNIVERSAL JOINT
23.0 ASSEMBLY OF THE SPINDLE AND OF THE COMPLETE BRAKE PLATE
24.0 ASSEMBLY OF THE WHEEL HUB WITH DRUM
25.0 ASSEMBLY OF THE SPIDER
26.0 ASSEMBLY OF THE TRACK ROD
27.0 ASSEMBLY OF THE CYLINDER SUPPORT
28.0 ASSEMBLY OF THE COMPLETE BRAKE, BRAKE JAWS AND ADJUSTMENT
29.0 ASSEMBLY OF THE PARKING CALIPER AND OF THE PADS
30.0 TORQUE WRENCH SETTING TABLE
31.0 FIGURES
PMSF.72.85.0006

1.1 Drain the lubricating oil from the axle body and/or from the epicycloidal reduction gears through the plugs (34) (88).
1.2 If necessary, remove the track rod (59) by extracting the split pins (53) and by unlooseing the nuts (52).

2.1 Unscrew the nuts for stud (90), recover the bevel washers (89) and extract the wheel.
2.2 Screw out the screws (83) and recover the complete spider (84) and the O-ring (67).
2.3 Remove the retaining ring (78) and release the planetary gear pin (85) by using a drift, if necessary.
Take care not to damage the O-ring (86) placed on the head of the planetary gear pin.
2.4 Extract the planetary gear (81) complete with its cylindric roller bearing (79) by moving it inwards in a radial direction.
2.5 Remove the retaining ring (82), the spacers (80) and the cylindric roller bearing (79) from the planetary gear (81).

3.1 Pull the universal joint with driveshafts (51) outwards, as far as possible.
3.2 Remove the retaining ring (76) and withdraw the crown wheel (75).
3.3 Before proceeding, support the hub with drum (66) by using lifting belts to avoid damaging the bevel bearings (64) (68).
3.4 Unscrew the screw (73) and recover the washer for ring nut (71), by unscrewing the ring nut (72).
3.5 Extract the annular gear with hub (70).
3.6 To extract the bevel bearing (68) from the hub of the annular gear (70), you have to push the internal ring of the bearing, by screwing the
screws on the threaded holes, placed on the annular gear with hub (70).
4.1 Take out the wheel hub with drum (66), supporting it with lifting belts; in this way, you can remove the complete bevel bearing (64) and the
ring race (63) with the oil seal ring (62).
4.2 Recover the O-ring (61).
4.3 Dismantle the external rings of the bevel bearings (64) (68).

5.1 Unscrew the screws (94) (95) (97), recover the complete brake (103) and then the spindle (60).
5.2 Extract the retaining ring (44), the oil seal rings (43) and the bushing (42) from the spindle (60).

6.1 Remove the upper articulated joint pin (47), by unscrewing the screws (46), recover the shims (48) (49) and the fifth wheel (37).
6.2 Repeat the same operations for the lower pin (47) by recovering the fifth wheel (37).
7.0 DISASSEMBLY OF THE UNIVERSAL JOINT WITH DRIVESHAFTS

7.1 You can recover the universal joint with driveshafts (51) in two different ways: the first one is by dismantling the hub with drum (66) and the
spindle (60); the second one is by dismantling the external half articulated joint, complete with spindle, brake and hub with drum.
7.2 In both cases you will have to recover the complete spider (84) by unscrewing the screws (83), the crown wheel (75) with the retaining ring
(76).
7.3 In case you choose the second system, before unscrewing the screws (46) to recover the articulation pins (47), the shims (48) (49) and the fifth
wheels (37), you will have to support the complete unit by means of lifting belts.

8.1 Unloose the nut (31), the screw (30) and extract the universal joint carrier bush (40) from the axle body (33). Then remove the retaining ring
(44), the oil seal rings (43), the bushing (42) and the O-ring (41) from the universal joint carrier bush (40).
9.0 DISASSEMBLY OF THE PARKING CALIPER
9.1 Loosen the nuts (109), recover the screws (107) and the parking caliper (113).
9.2 If necessary, unscrew the screws (106) in order to recover the caliper support (108).

10.1 Unscrew the screws (15) and extract the complete differential sump (13) from the axle body (33). The extraction of the differential sump will be
possible only after having recovered the universal joints with driveshafts (51).
10.2 By using a pin ram, extract the spring pins (19), unloose the ring nuts (18) and unscrew the screws to fasten the caps on the differential sump,
by recovering the washers.
10.3 Remove the two caps from the sump for differential and extract the complete differential carrier (23), by recovering the two external rings of
the bevel bearings (22).
10.4 By unlooseing the screws (27) (28) it will be possible to recover the ring bevel gear (25).

11.1 Before opening the two half differential carriers, check that the reference marks situated on the two half carriers can be clearly seen for the
assembly. Then separate the two halves.
11.2 Dismantle the internal parts, taking care not to separate each planetary gear or crown wheel from their spacer rings.

12.1 Tighten the bevel pinion head (24) and unloose the ring nut (1), by recovering the axial washer (2). Extract the transmission flange (3),
complete with protection for oil seal ring (5) and with the ring race (6).
12.2 Recover the O-ring (7) and the oil seal ring (5).
12.3 By striking the threaded tang of the bevel pinion with a fibre hammer, it is possible to extract the internal ring of the bevel bearing (8) and
recover the bevel pinion (24), the spacer (12) and the shims (9) (10) (11).
12.4 Then remove the external rings of the bevel bearings (8) (21).
13.1 Unscrew the screws (35) and recover the cylinder support (36).

14.1 Unscrew the nuts for stud (90), recover the bevel washers (89) and withdraw the wheel.
14.2 Unscrew the screws (83) recover the complete spider (84) and the O-ring (67).
14.3 Pull the universal joint with driveshafts (51) outwards as much as possible.
14.4 Remove the retaining ring (76) and release the crown wheel (75).
14.5 Before proceeding, support the hub with drum (66) using lifting belts to avoid damaging the bevel bearings (64) (68).
14.6 Unscrew the screw (73), recover the washer for ring nut (71) by unscrewing the ring nut (72).
14.7 Remove the annular gear with hub (70).
14.8 Release the hub with drum (66).
14.10 Unscrew the screws (94) (95) (97) and recover the complete brake (103).
14.11 By turning the two nuts opposite one to the other, you increase the opening of the two jaws (101).
14.12 Unscrew the screw (91), recover the washer (92) and the brake actuating cylinder (96).
14.13 Remove the spring (102), unscrew the screws (100), recover the washer (99) and take out the pins (98) by using an extractor fitted to the M12
threaded hole of the pin (98).
15.0 DISASSEMBLY OF THE PADS OF THE PARKING CALIPER

15.1 Unscrew the screws (112), recover the check plates (111) and take out the pad check plates.
15.2 It is now possible to take out the two pads (110) without removing the parking caliper (113) from the caliper support (108).
OVERHAUL
16.0 GENERAL NOTES

16.1 Always keep the internal and external rings of the bevel bearings paired during assembly and disassembly operations.
16.2 All screws and nuts must be tightened with a dynamometric wrench, following the torque wrench settings specified in the table of this manual.
16.3 LOCTITE 243 “middle threadlocker” and LOCTITE 601 “locker” must be used for the screws, as prescribed in the table in this manual.
16.4 Use degreasing solvents to clean carefully all the parts where the AREXONS Motorsil D liquid sealant for flat surfaces must be applied.
N.B.: The liquid sealant must be well spread over all areas coming into contact with oil. Exceeding sealant must be removed.
16.5 Wash all the moving parts (for example gears, bearings, etc.) carefully, by using Diesel oil or kerosene.
16.6 Do not wash with steam or hot water as it will then become difficult to eliminate completely all humidity from the surface.
16.7 Dry all the parts thoroughly by using an air jet or soft cloths, to avoid scratching the surface with abrasive residues.
16.8 Make sure, however, that all the surfaces are covered with a thin layer of lubricant. This will protect them from eventual oxidations.
17.0 CHECKS
17.1 Check all the roller bearings carefully, including also the external rings located in their housings: replace any bearings which are worn or
damaged.
17.2 Check that none of the gears show anomalies or are excessively worn.
17.3 Check that all the splined sections are not worn nor damaged.
17.4 Replace the damaged parts with original spare parts: in particular, if it is necessary to replace a gear of the differential, then the entire wheel
unit will have to be replaced.
17.5 After every disassembly operation, it is good practise to replace the oil seal rings and check that the O-rings are operating correctly. To make
assembly easier, lubricate all the rings with a little quantity of grease of commun type.
17.6 Check that the centering and spacer ring (74) of the crown wheel (75) is not worn: if necessary, replace it.
17.7 In the same way, check that the small block (77) is fully inserted in the spider (84).
17.8 Check the brake seals: their thickness must not be lower than 5 mm.
If they are impregnated with oil, replace them and eliminate the causes of those infiltrations of lubricant.
17.9 Check carefully that the jaws are not cracked or deformed.
17.10 Replace at the same time all the seals of the same axle: in this case, the jaws must be cleared of rust and dirt to guarantee a 70% contact with
the support surface.
17.11 Check that the return springs of the brake jaws are not yielded: if necessary, replace them.
17.12 Inspect the brake drums: if they show scorings or damages on the braking surface, or if they have an eccentricity greater than 0,016" they must
be turned (the max. enlargement of the diameter is 0,16").
17.13 Check the state of wear of the braking pads of the disc brake: replace them, if necessary.
17.14 Check the braking surface of the disc (104): it must be free from deep scratching.
17.15 Check the efficiency of the breather plug on the axle body, after having washed it with Diesel oil.
17.16 Check the oil seals on the oil drain plugs and the oil level.
ASSEMBLY OPERATIONS
PMSF.72.85.0006

18.1 Assemble the two bevel crown wheels inside the differential half carrier and the four bevel planetary gears on the cross with the respective
spacers. Couple the two half carriers together, by letting match the numbers printed on them.
18.2 Key on the ring bevel gear (25) and secure it with the screws (27) (28).
18.3 Shrink on (max 194°F) the internal rings of the bevel bearings (22).
19.1 Shrink on (max. 194°F) the bearing (21) on the bevel pinion head (24) and fit the external rings of the bevel bearings (8) (21) in the differential
sump (13).
19.2 Insert the bevel pinion (24) into the differential sump (13) so that the bevel bearing (21), attached to the pinion toothing, couples with the
external ring; insert the spacer (12) and the shims (9) (10) (11).
19.3 Insert the internal ring of the bevel bearing (8) on the side of the threaded tang of the bevel pinion, and place the oil seal ring (5) in the seat.
19.4 N.B.: Proceed as follows to establish the number of shims (9) (10) (11):
a) Position the internal ring of the bevel bearings (8) (21) as shown (see fig. 1) and place the spacer (12) between them.
b) Subject this unit to an axial load of 4496 lb. and survey the measurement A (see fig. 1).
c) Drive the external rings of the bevel bearings (8) (21) into the differential sump (13), ensuring that the contact surfaces are well clean to
avoid measurement errors.
d) Complete the assembly of the bevel bearings without placing the spacer (12) between them and subject them to an axial load of 450 lb;
survey the measurement B (see fig. 2). The difference resulting from the measurement B and the measurement A will be the thickness
measurement.
19.5 Couple the external rings of the bevel bearings (22) with their respective internal rings, those previously inserted on the differential carrier (23),
and house everything in the differential sump (13).
19.6 Place the two caps above the differential sump and tighten them with the screws using Loctite 601 on the threads, putting the washers under the
screws.
19.7 Screw the two ring nuts (18) until they touch the external ring of the bevel bearings (22).
19.8 On the transmission flange (3) fix the protection for the oil seal ring (4) paying attention to the assembly direction of the protection and shrink
on the ring race (6), controlling that the seat for the O-ring (7) is not directed towards the protection for the oil seal ring.
19.9 Cover the bevel pinion spline (24) with grease, insert the O-ring (7) in the seat for the ring race (6) and insert the transmission flange (3),
securing it with the ring nut (1), having placed the axial washer (2) under it. Wind a cable around the 5.91" machined diameter of the sump.
By holding the pinion gear still and rotating the sump, a stress of approximately 8.8÷11 lb should be registered on the torque wrench. Preload
the bearings of the differential carrier until they reach a measurement of 9.728"÷9.736". This measurement should be taken with a gauge on
the machined part of the sump caps: this part will have to be lower than the machined one situated on the seat of the caps in the axle body.
19.10 Record the play between the bevel pinion gear and the ring bevel gear (0.007874"÷0.011024") by turning the ring nuts (18) to the left and to the right.
When the correct level of play has been achieved, clamp the ring nuts (18) with the spring pins (19). To check the play (0.007874"÷0.011024"),
stop the bevel pinion rotation and, using a magnetic base comparator placed on the differential sump flange (13), measure the play between the
bevel toothing (see fig. 3).
19.11 Fix the park caliper (113) by means of the screw (107) and the nut (109).
19.12 Insert the four parallel pins (20) on the axle body (33).
Carefully clean the support surface of the axle body (33) and of the differential sump (13), apply the liquid sealant all around the whole
differential sump perimeter. Couple the two parts together and secure them with the screws (15).

20.1 Using a drift, house the bush (42) and the oil seal rings (43) in the universal joint carrier bush (40), then insert the retaining ring (44). Put the O-
ring (41) in the external housing of the universal joint carrier bush, then insert the universal joint carrier bush in the axle body, by securing it
with the screw (30) and the nut (31).

21.1 Place the two housings of the articulation pins of the external right or left half articulated joint by the two bush housings of the axle body (33).
21.2 Using a drift, insert in the bush housings of the axle body (33) the plugs with lens (39) and the bushes (38).
21.3 Insert the fifth wheel (37) in the articulated joint pin (47), paying attention that the two anti-rotation teeth do not come in contact with the
surface of the articulated joint pin.
21.4 Insert the articulated joint pin (47) in the lower part, and let match the two anti-rotation teeth of the fifth wheel (37) with the two recessings of
the axle body (33). Position the articulated joint pin (47) so that the milling on the fixing flanging is parallel to the fixing surface of the spindle,
then fix with the screws (46).
21.5 Repeat the same operation also for the upper part, by fitting the fifth wheel (37) in the articulated joint pin (47), and paying attention that the
two antirotation teeth are by the two recessings of the axle body (33); then place the shims (48) (49) between the fixing flanging of the
articulated joint pin and the surface of the half articulated joint.
21.6 Place the joint pin (47) so that the milling on the fixing flanging is parallel to the fixing surface of the spindle and fix with the screws (46). The
movement of the external half articulated joint will have to result rather bound, on the contrary add or take off the shims.
22.0 ASSEMBLY OF THE UNIVERSAL JOINT WITH DRIVESHAFTS
22.1 Clean the two splined parts of the universal joint with driveshafts (51) carefully. Insert the parallel pin (20) in the hole situated at the end of the
shortest shaft. Make sure it is well tightened, if not secure the movement of the parallel pin (20) with LOCTITE 601. Insert the longest part of
the shaft in the universal joint carrier bush (40), paying attention not to damage the oil seal rings (43).
23.0 ASSEMBLY OF THE SPINDLE AND OF THE COMPLETE BRAKE

23.1 Using a drift, insert the bushing (42) and the oil seal rings (43) in the spindle (60); then insert the retaining ring (44).
23.2 Drive the centering and spacer ring (74) in the spindle housing (60). Insert the short shaft of the universal joint with driveshafts (51) in the
spindle (60), paying attention not to damage the oil seal rings (43).
23.3 Put the spindle (60) in the centering of the external half articulated joint, then place the brake plate (93) of the complete brake (103) and secure
with the screws (94) (95) (97).

24.1 Insert the stud bolt (65) in the holes of the wheel hub with drum (66). Place the head of the stud bolt on a drift, insert the bush (69) and, using a
tube with an internal diameter equal to the external diameter of the stud bolt, push the bush with the press until the tube stops against the hub.
24.2 House the two external rings of the bevel bearings (64) (68), ensuring that the support surfaces are well clean.
24.3 Insert the oil seal ring (62) into the ring race (63).
24.4 Place the internal ring of the bevel bearing (64) against its external ring and, using a drift, place the ring race (63) complete with the oil seal
ring (62) in the external bearing housing (64).
24.5 Put the O-ring (61) on the spindle (60) and insert the wheel hub with drum (66), by holding it with a lifting belt.
24.6 Shrink on (max 194°F) the internal ring of the bearing (68) on the hub of the annular gear (70).
24.7 Insert then the annular gear with hub (70) on the spindle (60), put the washer for ring nut (71), and tighten the ring nut (72).
24.8 Rotate the hub with drum (66) continuously and, at the same time, tighten the ring nut (72) so that there is a resistance torque to the wheel hub
with drum (66) of approximately 44÷52 ft.lb. Align a threaded hole of the ring nut with one of the two splines on the spindle (60).
24.9 Screw in the screw (73).
24.10 Insert the crown wheel (75) in the splined part of the universal joint with driveshafts (51) coming out from the spindle (60), stop it with the
retaining ring (76) and make sure this one is correctly housed.
25.1 Put the O-ring (86) in the planetary gear pin (85). Take the planetary gear (81), house there the retaining ring (82), the needle spacers (80) and
the cylindric roller bearing (79). Then position the planetary gear (81) by the passage hole of the planetary gear pin (85) of the spider (84).
25.2 Strike the planetary gear pin (85) with a fibre hammer until it comes into contact with the planetary gear (81). Assemble the retaining ring (78)
in the housing of the planetary gear pin (85). Make sure that the retaining ring is correctly positioned, then give it a couple of blows with the
fibre hammer, towards the pin outlet, to ensure that the play between the planetary gear spacer and the planetary gear pin is restored.
25.3 Put the small block (77) in the housing situated in the spider.
25.4 Fix the spider (84) to the hub with drum (66) by means of the screws (83), after having put the O-ring (67) in the housing of the hub with drum
(66).

26.1 Screw the two heads (54) (58) on the track rod (56) using the respective nuts (55) (57).
26.2 Put the cone of the heads in the bevel hole of the lever of the external half articulated joint; then secure it with the nuts (52) and the split pins
(53).
26.3 Adjust the alignment by turning the track rod (56) to the right or to the left.
26.4 After that, tighten the nuts (55) (57).

27.1 Secure the support (36) with the screws (35).
28.0 ASSEMBLY OF THE COMPLETE BRAKE AND OF BRAKE JAWS AND ADJUSTMENT
28.1 Fix the complete brake (103) or the brake plate (93) by means of the screws (94) (95) (97).
28.2 House the two jaws (101) on the brake plate (93), insert the pins (98).
28.3 On the pin (98) it is radially placed a hole, which has the function to stop the movement in the axial direction. This hole will have to be placed
by the threaded hole, managed to house the screw (100).
28.4 Screw the screw (100) with the washer (99) in the hole and make sure that the cylindrical part of the screw (100) is entered the hole of the pin,
locking it axially.
28.5 Fix the brake actuating cylinder (96) by means of the screw (91) and the washer (92).
28.6 Put in contact the two brake jaws (101) against the two control pins of the brake actuating cylinder (96) and keep them in position by mounting
the spring (102), linking it in the two holes placed on the brake jaws (101).
28.7 After having mounted the hub with drum (66) and recorded the preloading of the bearings (64) (68) in order to have a resistant couple, you’ll
have to adjust the brake jaws (101).
28.8 Rotate the two adjusting screws with hexagonal head CH22 placed on the brake plate (93) so that the two jaws can be placed in contact with the
surface of the drum of the hub.
28.9 As the rotation of the hub with drum (66) in this way has been stopped, rotate a little the two adjusting screws in opposite direction comparing
to the locking operation, in order that the jaws (101) do not get in touch with the drum during the rotation of the hub with drum (66).
29.0 ASSEMBLY OF THE PARKING CALIPER AND OF THE PADS

29.1 Fix the parking caliper (113) by means of the screws (107) and the nuts (109).
29.2 Insert the pads (110), keep them in position by means of the pad check plates and lock these last ones in position with the check plates (111)
and the screws (112).
TORQUE WRENCH SETTING TABLE
APPLICATION THREADING CLASS Ft.lb NOTES
Screw (17) (112) M8x1,25 8.8 18 LOCTITE 243

Screw (30) M10x1,5 12.9 63 LOCTITE 243
Screw (100) M10x1,5 8.8 37 LOCTITE 243
Screw (105) M12x1,75 10.9 52 LOCTITE 243
Screw (73) (106) M12x1,25 12.9 114 LOCTITE 243
Screw (91) M12x1,75 12.9 108 LOCTITE 243
Screw (27) (28) M16x1,5 10.9 236 LOCTITE 243
Screw (46) M16x2 8.8 156 LOCTITE 243
Screw (115) M14x2 8.8 102 -
Screw (15) (107) M14x2 8.8 102 LOCTITE 243
Screw (83) M8x1,25 10.9 26 -
Screw (95) M16x2 12.9 264 LOCTITE 243
Screw (35) (94) (97) M18x2,5 12.9 363 LOCTITE 243
Ring nut (1) M45x1,5 - 295 LOCTITE 601
Nut (31) M10x1,5 8 37 LOCTITE 243
Nut (109) M14x2 8 102 -
Nut (52) M30x1,5 8 258 -
Nut (55) (57) M38x1,5 8 442 -
31.0 FIGURE
Fig. 1 Fig. 2 Fig. 3

PMSF.72.85.0005
USE AND MAINTENANCE
December 2005
WARNING
The content of this documentation, issued exclusively to provide necessary information to the machine end user, is considered extremely
confidential and cannot be disclosed to third parties nor copied without our approval.
The manufacturing of parts or assemblies shown on this documentation, without our approval, infringes DROMOS s.r.l. industrial property
rights.
USE MANUAL
STEERING DRIVE AXLE PMSF.72.85.0005
1.0 DESCRIPTION
2.0 LUBRICATION
4.1 CAPACITY
4.7 SEAL PRODUCTS
5.0 SPARE PARTS

1.0 DESCRIPTION
The PMSF.72.85.0005 unit consists of a reduction unit with a bevel gear pair and an epicycloidal reduction. A bevel pinion engages with a
bevel gear fixed on the train carrier of a differential gearing which transfers motion to the universal joints. Between the universal joint and the
wheel hub with drum, there is a reduction unit made of an epicycloidal reduction. At the end of the axle body there are internal half articulated
joints for the articulation of the steering equipment. The block brakes are hydraulically controlled by means of a cylinder which is fitted on the
brake plate.
2.0 LUBRICATION
Splash lubrication has been adopted for this unit and it is designed in such a way that all the gears and the bearings are sufficiently lubricated
under all operating conditions. The check of the level in the axle body and in the epicycloidal gears must be done by removing the plugs (34)
(88).

The transmissions are delivered without oil. Before putting them in operation, they must be therefore filled with oil through the filler (34) (88).
Use oil that is perfectly clean and of the type specified in point 4.2.
If unsuitable oil is used by accident, the guarantee conditions are no longer valid. For the levels and any necessary topping up, see point 2.0.
4.1 CAPACITY
Axle body 3.7 gal
Epicycloidal gear on the hub 1 gal. (each one)
The product used must correspond with the following quality specifications:
AXLE BODY – EPICYCLOIDAL GEARBOXES

Type of lubricant completely synthetic PAO
SAE grade 75W-90
API GL-5
ARTICULATION PINS – BUSHINGS

Type of lubricant grease
Consistence NLGI 2

The lubricant level in the axle body and in the epicycloidal gears must not drop below the inspection plugs (34) (88): if it does, it is necessary to
top up the level using a lubricant of the same type. If there is a large drop in the level, it is advisable you look for the cause immediately, to
avoid further damages to the mechanical parts. During every inspection, check that the breather plug (32) is working correctly, wash it with
Diesel oil and dry it with an air jet. The oil is drained by removing the plugs (34) (88). The bushes of the articulation pins and of the fifth
wheels must be lubricated every time they are dismantled or at least every 100 working hours, by filling the grooves of the bushes and of the
fifth wheels through the lubricators (45).

The transmission oil must be replaced for the first time after 50 working hours. It is advisable you change the oil when it is still hot. It must be
drained from the plugs (34) (88).

Every 500 working hours or at least once a year.

LOCTITE 243 “middle threadlocker” and LOCTITE 601 “locker” must be used for the screws, as prescribed in the table in this manual.
4.7 SEAL PRODUCTS
Use degreasing solvents to clean thoroughly all parts where the AREXONS Motorsil D liquid sealant for flat surfaces must be used.
N.B.: The liquid sealant must be well laied off on all surfaces where oil passes. Remove the exceeding product.
MAINTENANCE MANUAL
PMSF.72.85.0005
7.0 DISASSEMBLY OF UNIVERSAL JOINT
14.0 GENERAL NOTES
15.0 CHECKS
ASSEMBLY OPERATIONS
20.0 ASSEMBLY OF THE UNIVERSAL JOINT
21.0 ASSEMBLY OF THE SPINDLE AND OF THE COMPLETE BRAKE PLATE
26.0 ASSEMBLY OF THE COMPLETE BRAKE, BRAKE JAWS AND ADJUSTMENT
28.0 FIGURES
PMSF.72.85.0005

1.1 Drain the lubricating oil from the axle body and/or from the epicycloidal reduction gears through the plugs (34) (88).
1.2 If necessary, remove the track rod (59) by extracting the split pins (53) and by unlooseing the nuts (52).

2.1 Unscrew the nuts for stud (90), recover the bevel washers (89) and extract the wheel.
2.2 Screw out the screws (83) and recover the complete spider (84) and the O-ring (67).
2.3 Remove the retaining ring (78) and release the planetary gear pin (85) by using a drift, if necessary.
Take care not to damage the O-ring (86) placed on the head of the planetary gear pin.
2.4 Extract the planetary gear (81) complete with its cylindric roller bearing (79) by moving it inwards in a radial direction.
2.5 Remove the retaining ring (82), the spacers (80) and the cylindric roller bearing (79) from the planetary gear (81).

3.1 Pull the universal joint with driveshafts (51) outwards, as far as possible.
3.2 Remove the retaining ring (76) and withdraw the crown wheel (75).
3.3 Before proceeding, support the hub with drum (66) by using lifting belts to avoid damaging the bevel bearings (64) (68).
3.4 Unscrew the screw (73) and recover the washer for ring nut (71), by unscrewing the ring nut (72).
3.5 Extract the annular gear with hub (70).
3.6 To extract the bevel bearing (68) from the hub of the annular gear (70), you have to push the internal ring of the bearing, by screwing the
screws on the threaded holes, placed on the annular gear with hub (70).

4.1 Take out the wheel hub with drum (66), supporting it with lifting belts; in this way, you can remove the complete bevel bearing (64) and the
ring race (63) with the oil seal ring (62).
4.3 Dismantle the external rings of the bevel bearings (64) (68).

5.1 Unscrew the screws (94) (95) (97), recover the complete brake (103) and then the spindle (60).
5.2 Extract the retaining ring (44), the oil seal rings (43) and the bushing (42) from the spindle (60).

6.1 Remove the upper articulated joint pin (47), by unscrewing the screws (46), recover the shims (48) (49) and the fifth wheel (37).
6.2 Repeat the same operations for the lower pin (47) by recovering the fifth wheel (37).
7.0 DISASSEMBLY OF THE UNIVERSAL JOINT WITH DRIVESHAFTS

7.1 You can recover the universal joint with driveshafts (51) in two different ways: the first one is by dismantling the hub with drum (66) and the
spindle (60); the second one is by dismantling the external half articulated joint, complete with spindle, brake and hub with drum.
7.2 In both cases you will have to recover the complete spider (84) by unscrewing the screws (83), the crown wheel (75) with the retaining ring
(76).
7.3 In case you choose the second system, before unscrewing the screws (46) to recover the articulation pins (47), the shims (48) (49) and the fifth
wheels (37), you will have to support the complete unit by means of lifting belts.

8.1 Unloose the nut (31), the screw (30) and extract the universal joint carrier bush (40) from the axle body (33). Then remove the retaining ring
(44), the oil seal rings (43), the bushing (42) and the O-ring (41) from the universal joint carrier bush (40).

9.1 Unscrew the screws (15) and extract the complete differential sump (13) from the axle body (33). The extraction of the differential sump will be
possible only after having recovered the universal joints with driveshafts (51).
9.2 By using a pin ram, extract the spring pins (19), unloose the ring nuts (18) and unscrew the screws to fasten the caps on the differential sump,
by recovering the washers.
9.3 Remove the two caps from the sump for differential and extract the complete differential carrier (23), by recovering the two external rings of
the bevel bearings (22).
9.4 By unlooseing the screws (27) (28) it will be possible to recover the ring bevel gear (25).

10.1 Before opening the two half differential carriers, check that the reference marks situated on the two half carriers can be clearly seen for the
assembly. Then separate the two halves.
10.2 Dismantle the internal parts, taking care not to separate each planetary gear or crown wheel from their spacer rings.

11.1 Tighten the bevel pinion head (24) and unloose the ring nut (1), by recovering the axial washer (2). Extract the transmission flange (3),
complete with protection for oil seal ring (5) and with the ring race (6).
11.2 Recover the O-ring (7) and the oil seal ring (5).
11.3 By striking the threaded tang of the bevel pinion with a fibre hammer, it is possible to extract the internal ring of the bevel bearing (8) and
recover the bevel pinion (24), the spacer (12) and the shims (9) (10) (11).
11.4 Then remove the external rings of the bevel bearings (8) (21).

12.1 Unscrew the screws (35) and recover the cylinder support (36).

13.1 Unscrew the nuts for stud (90), recover the bevel washers (89) and withdraw the wheel.
13.2 Unscrew the screws (83) recover the complete spider (84) and the O-ring (67).
13.3 Pull the universal joint with driveshafts (51) outwards as much as possible.
13.4 Remove the retaining ring (76) and release the crown wheel (75).
13.5 Before proceeding, support the hub with drum (66) using lifting belts to avoid damaging the bevel bearings (64) (68).
13.6 Unscrew the screw (73), recover the washer for ring nut (71) by unscrewing the ring nut (72).
13.7 Remove the annular gear with hub (70).
13.8 Release the hub with drum (66).
13.10 Unscrew the screws (94) (95) (97) and recover the complete brake (103).
13.11 By turning the two nuts opposite one to the other, you increase the opening of the two jaws (101).
13.12 Unscrew the screw (91), recover the washer (92) and the brake actuating cylinder (96).
13.13 Remove the spring (102), unscrew the screws (100), recover the washer (99) and take out the pins (98) by using an extractor fitted to the M12
threaded hole of the pin (98).
OVERHAUL
14.0 GENERAL NOTES

14.1 Always keep the internal and external rings of the bevel bearings paired during assembly and disassembly operations.
14.2 All screws and nuts must be tightened with a dynamometric wrench, following the torque wrench settings specified in the table of this manual.
14.3 LOCTITE 243 “middle threadlocker” and LOCTITE 601 “locker” must be used for the screws, as prescribed in the table in this manual.
14.4 Use degreasing solvents to clean carefully all the parts where the AREXONS Motorsil D liquid sealant for flat surfaces must be applied.
N.B.: The liquid sealant must be well spread over all areas coming into contact with oil. Exceeding sealant must be removed.
14.5 Wash all the moving parts (for example gears, bearings, etc.) carefully, by using Diesel oil or kerosene.
14.6 Do not wash with steam or hot water as it will then become difficult to eliminate completely all humidity from the surface.
14.7 Dry all the parts thoroughly by using an air jet or soft cloths, to avoid scratching the surface with abrasive residues.
14.8 Make sure, however, that all the surfaces are covered with a thin layer of lubricant. This will protect them from eventual oxidations.
15.0 CHECKS
15.1 Check all the roller bearings carefully, including also the external rings located in their housings: replace any bearings which are worn or
damaged.
15.2 Check that none of the gears show anomalies or are excessively worn.
15.3 Check that all the splined sections are not worn nor damaged.
15.4 Replace the damaged parts with original spare parts: in particular, if it is necessary to replace a gear of the differential, then the entire wheel
unit will have to be replaced.
15.5 After every disassembly operation, it is good practise to replace the oil seal rings and check that the O-rings are operating correctly. To make
assembly easier, lubricate all the rings with a little quantity of grease of commun type.
15.6 Check that the centering and spacer ring (74) of the crown wheel (75) is not worn: if necessary, replace it.
15.7 In the same way, check that the small block (77) is fully inserted in the spider (84).
15.8 Check the brake seals: their thickness must not be lower than 0.197".
If they are impregnated with oil, replace them and eliminate the causes of those infiltrations of lubricant.
15.9 Check carefully that the jaws are not cracked or deformed.
15.10 Replace at the same time all the seals of the same axle: in this case, the jaws must be cleared of rust and dirt to guarantee a 70% contact with
the support surface.
15.11 Check that the return springs of the brake jaws are not yielded: if necessary, replace them.
15.12 Inspect the brake drums: if they show scorings or damages on the braking surface, or if they have an eccentricity greater than 0.016" they must
be turned (the max. enlargement of the diameter is 0.16").
15.13 Check the efficiency of the breather plug on the axle body, after having washed it with Diesel oil.
15.14 Check the oil seals on the oil drain plugs and the oil level.
ASSEMBLY OPERATIONS
PMSF.72.85.0005

16.1 Assemble the two bevel crown wheels inside the differential half carrier and the four bevel planetary gears on the cross with the respective
spacers. Couple the two half carriers together, by letting match the numbers printed on them.
16.2 Key on the ring bevel gear (25) and secure it with the screws (27) (28).
16.3 Shrink on (max 194°F) the internal rings of the bevel bearings (22).
17.1 Shrink on (max. 194°F) the bearing (21) on the bevel pinion head (24) and fit the external rings of the bevel bearings (8) (21) in the differential
sump (13).
17.2 Insert the bevel pinion (24) into the differential sump (13) so that the bevel bearing (21), attached to the pinion toothing, couples with the
external ring; insert the spacer (12) and the shims (9) (10) (11).
17.3 Insert the internal ring of the bevel bearing (8) on the side of the threaded tang of the bevel pinion, and place the oil seal ring (5) in the seat.
17.4 N.B.: Proceed as follows to establish the number of shims (9) (10) (11):
a) Position the internal ring of the bevel bearings (8) (21) as shown (see fig. 1) and place the spacer (12) between them.
b) Subject this unit to an axial load of 4496 lb. and survey the measurement A (see fig. 1).
c) Drive the external rings of the bevel bearings (8) (21) into the differential sump (13), ensuring that the contact surfaces are well clean to
avoid measurement errors.
d) Complete the assembly of the bevel bearings without placing the spacer (12) between them and subject them to an axial load of 450 lb.;
survey the measurement B (see fig. 2). The difference resulting from the measurement B and the measurement A will be the thickness
measurement.
17.5 Couple the external rings of the bevel bearings (22) with their respective internal rings, those previously inserted on the differential carrier (23),
and house everything in the differential sump (13).
17.6 Place the two caps above the differential sump and tighten them with the screws using Loctite 601 on the threads, putting the washers under the
screws.
17.7 Screw the two ring nuts (18) until they touch the external ring of the bevel bearings (22).
17.8 On the transmission flange (3) fix the protection for the oil seal ring (4) paying attention to the assembly direction of the protection and shrink
on the ring race (6), controlling that the seat for the O-ring (7) is not directed towards the protection for the oil seal ring.
17.9 Cover the bevel pinion spline (24) with grease, insert the O-ring (7) in the seat for the ring race (6) and insert the transmission flange (3),
securing it with the ring nut (1), having placed the axial washer (2) under it. Wind a cable around the 5.91" machined diameter of the sump.
By holding the pinion gear still and rotating the sump, a stress of approximately 8.8÷11 lb. should be registered on the torque wrench. Preload
the bearings of the differential carrier until they reach a measurement of 9.728"÷9.736". This measurement should be taken with a gauge on
the machined part of the sump caps: this part will have to be lower than the machined one situated on the seat of the caps in the axle body.
17.10 Record the play between the bevel pinion gear and the ring bevel gear (0.007874"÷0.011024") by turning the ring nuts (18) to the left and to the right.
When the correct level of play has been achieved, clamp the ring nuts (18) with the spring pins (19). To check the play (0.007874"÷0.011024"), stop
the bevel pinion rotation and, using a magnetic base comparator placed on the differential sump flange (13), measure the play between the bevel
toothing (see fig. 3).
17.11 Insert the four parallel pins (20) on the axle body (33).
Carefully clean the support surface of the axle body (33) and of the differential sump (13), apply the liquid sealant all around the whole
differential sump perimeter. Couple the two parts together and secure them with the screws (15).

18.1 Using a drift, house the bush (42) and the oil seal rings (43) in the universal joint carrier bush (40), then insert the retaining ring (44). Put the O-
ring (41) in the external housing of the universal joint carrier bush, then insert the universal joint carrier bush in the axle body, by securing it
with the screw (30) and the nut (31).

19.1 Place the two housings of the articulation pins of the external right or left half articulated joint by the two bush housings of the axle body (33).
19.2 Using a drift, insert in the bush housings of the axle body (33) the plugs with lens (39) and the bushes (38).
19.3 Insert the fifth wheel (37) in the articulated joint pin (47), paying attention that the two anti-rotation teeth do not come in contact with the
surface of the articulated joint pin.
19.4 Insert the articulated joint pin (47) in the lower part, and let match the two anti-rotation teeth of the fifth wheel (37) with the two recessings of
the axle body (33). Position the articulated joint pin (47) so that the milling on the fixing flanging is parallel to the fixing surface of the spindle,
then fix with the screws (46).
19.5 Repeat the same operation also for the upper part, by fitting the fifth wheel (37) in the articulated joint pin (47), and paying attention that the
two antirotation teeth are by the two recessings of the axle body (33); then place the shims (48) (49) between the fixing flanging of the
articulated joint pin and the surface of the half articulated joint.
19.6 Place the joint pin (47) so that the milling on the fixing flanging is parallel to the fixing surface of the spindle and fix with the screws (46). The
movement of the external half articulated joint will have to result rather bound, on the contrary add or take off the shims.
20.0 ASSEMBLY OF THE UNIVERSAL JOINT WITH DRIVESHAFTS

20.1 Clean the two splined parts of the universal joint with driveshafts (51) carefully. Insert the parallel pin (20) in the hole situated at the end of the
shortest shaft. Make sure it is well tightened, if not secure the movement of the parallel pin (20) with LOCTITE 601. Insert the longest part of
the shaft in the universal joint carrier bush (40), paying attention not to damage the oil seal rings (43).
21.0 ASSEMBLY OF THE SPINDLE AND OF THE COMPLETE BRAKE

21.1 Using a drift, insert the bushing (42) and the oil seal rings (43) in the spindle (60); then insert the retaining ring (44).
21.2 Drive the centering and spacer ring (74) in the spindle housing (60). Insert the short shaft of the universal joint with driveshafts (51) in the
spindle (60), paying attention not to damage the oil seal rings (43).
21.3 Put the spindle (60) in the centering of the external half articulated joint, then place the brake plate (93) of the complete brake (103) and secure
with the screws (94) (95) (97).

22.1 Insert the stud bolt (65) in the holes of the wheel hub with drum (66). Place the head of the stud bolt on a drift, insert the bush (69) and, using a
tube with an internal diameter equal to the external diameter of the stud bolt, push the bush with the press until the tube stops against the hub.
22.2 House the two external rings of the bevel bearings (64) (68), ensuring that the support surfaces are well clean.
22.3 Insert the oil seal ring (62) into the ring race (63).
22.4 Place the internal ring of the bevel bearing (64) against its external ring and, using a drift, place the ring race (63) complete with the oil seal
ring (62) in the external bearing housing (64).
22.5 Put the O-ring (61) on the spindle (60) and insert the wheel hub with drum (66), by holding it with a lifting belt.
22.6 Shrink on (max 194°F) the internal ring of the bearing (68) on the hub of the annular gear (70).
22.7 Insert then the annular gear with hub (70) on the spindle (60), put the washer for ring nut (71), and tighten the ring nut (72).
22.8 Rotate the hub with drum (66) continuously and, at the same time, tighten the ring nut (72) so that there is a resistance torque to the wheel hub
with drum (66) of approximately 44÷52 ft.lb. Align a threaded hole of the ring nut with one of the two splines on the spindle (60).
22.9 Screw in the screw (73).
22.10 Insert the crown wheel (75) in the splined part of the universal joint with driveshafts (51) coming out from the spindle (60), stop it with the
retaining ring (76) and make sure this one is correctly housed.

23.1 Put the O-ring (86) in the planetary gear pin (85). Take the planetary gear (81), house there the retaining ring (82), the needle spacers (80) and
the cylindric roller bearing (79). Then position the planetary gear (81) by the passage hole of the planetary gear pin (85) of the spider (84).
23.2 Strike the planetary gear pin (85) with a fibre hammer until it comes into contact with the planetary gear (81). Assemble the retaining ring (78)
in the housing of the planetary gear pin (85). Make sure that the retaining ring is correctly positioned, then give it a couple of blows with the
fibre hammer, towards the pin outlet, to ensure that the play between the planetary gear spacer and the planetary gear pin is restored.
23.3 Put the small block (77) in the housing situated in the spider.
23.4 Fix the spider (84) to the hub with drum (66) by means of the screws (83), after having put the O-ring (67) in the housing of the hub with drum
(66).

24.1 Screw the two heads (54) (58) on the track rod (56) using the respective nuts (55) (57).
24.2 Put the cone of the heads in the bevel hole of the lever of the external half articulated joint; then secure it with the nuts (52) and the split pins
(53).
24.3 Adjust the alignment by turning the track rod (56) to the right or to the left.
24.4 After that, tighten the nuts (55) (57).

25.1 Secure the support (36) with the screws (35).
26.0 ASSEMBLY OF THE COMPLETE BRAKE AND OF BRAKE JAWS AND ADJUSTMENT
26.1 Fix the complete brake (103) or the brake plate (93) by means of the screws (94) (95) (97).
26.2 House the two jaws (101) on the brake plate (93), insert the pins (98).
26.3 On the pin (98) it is radially placed a hole, which has the function to stop the movement in the axial direction. This hole will have to be placed
by the threaded hole, managed to house the screw (100).
26.4 Screw the screw (100) with the washer (99) in the hole and make sure that the cylindrical part of the screw (100) is entered the hole of the pin,
locking it axially.
26.5 Fix the brake actuating cylinder (96) by means of the screw (91) and the washer (92).
26.6 Put in contact the two brake jaws (101) against the two control pins of the brake actuating cylinder (96) and keep them in position by mounting
the spring (102), linking it in the two holes placed on the brake jaws (101).
26.7 After having mounted the hub with drum (66) and recorded the preloading of the bearings (64) (68) in order to have a resistant couple, you’ll
have to adjust the brake jaws (101).
26.8 Rotate the two adjusting screws with hexagonal head CH22 placed on the brake plate (93) so that the two jaws can be placed in contact with the
surface of the drum of the hub.
26.9 As the rotation of the hub with drum (66) in this way has been stopped, rotate a little the two adjusting screws in opposite direction comparing
to the locking operation, in order that the jaws (101) do not get in touch with the drum during the rotation of the hub with drum (66).
TORQUE WRENCH SETTING TABLE
APPLICATION THREADING CLASS Ft.lb NOTES
Screw (17) M8x1,25 8.8 18 LOCTITE 243

Screw (30) M10x1,5 12.9 63 LOCTITE 243
Screw (100) M10x1,5 8.8 37 LOCTITE 243
Screw (73) M12x1,25 12.9 114 LOCTITE 243
Screw (91) M12x1,75 12.9 108 LOCTITE 243
Screw (27) (28) M16x1,5 10.9 236 LOCTITE 243
Screw (46) M16x2 8.8 156 LOCTITE 243
Screw (105) M14x2 8.8 102 -
Screw (15) M14x2 8.8 102 LOCTITE 243
Screw (83) M8x1,25 10.9 26 -
Screw (95) M16x2 12.9 264 LOCTITE 243
Screw (35) (94) (97) M18x2,5 12.9 363 LOCTITE 243
Ring nut (1) M45x1,5 - 295 LOCTITE 601
Nut (31) M10x1,5 8 37 LOCTITE 243
Nut (52) M30x1,5 8 258 -
Nut (55) (57) M38x1,5 8 442 -
28.0 FIGURE
Fig. 1 Fig. 2 Fig. 3

TW 5 TEREX
(Rexroth motor)
Code : DO 050308 Edition : 11/2005

TW 5 TEREX Code DO 050308 - Ed. 11/2005
Maintenance
Changing oil
It is advisable to replace the lubricating oil of the

reduction gear mounted inside the drum every six
months or after 600 hours of use.
To replace the oil, unwind the cable until the cap found
on the drum about 2.36" from the motor side is
uncovered.
Place a container below the drum to collect the oil to
be replaced, undo the cap and rotate the drum 180°.
Empty the drum of oil, rotate it 180° and add enough

oil to fill the drum up to its horizontal axis, then replace
the cap. (Lubrication oil volume = 3.17 gal)
DINAMIC OIL S.p.A. - Via Togliatti, 15 - 41030 BOMPORTO (MO) - Italy - Tel. 059/812611 - Fax 059/812606
TW 4 TEREX
(Rexroth motor)
Code : DO 051103 Edition : 11/2005

TW 4 TEREX Code DO 051103 - Ed. 11/2005
Maintenance
Changing oil
It is advisable to replace the lubricating oil of the

reduction gear mounted inside the drum every six
months or after 600 hours of use.
To replace the oil, unwind the cable until the cap found
on the drum about 2.36" from the motor side is
uncovered.
Place a container below the drum to collect the oil to
be replaced, undo the cap and rotate the drum 180°.
Empty the drum of oil, rotate it 180° and add enough

oil to fill the drum up to its horizontal axis, then replace
the cap. (Lubrication oil volume = 3.17 gal)
DINAMIC OIL S.p.A. - Via Togliatti, 15 - 41030 BOMPORTO (MO) - Italy - Tel. 059/812611 - Fax 059/812606

RT440B ENG Rev.01 - 2007 (1) (099-248)

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MAINTENANCE CHECKS

NOTE: If a battery is to be charged overnight, (16

Revised: December 2005 Page 4 - 29 RT440B

SPOOLING WIRE ROPE ON DRUMS

Care must be exercised when installing wire rope on

Thoroughly inspect and clean the winch before pro­

Check the bearings for excessive wear and play. After

RT440B Page 4 - 30 Revised: December 2005

WIRE ROPE AND REEVING

Refer to Section 3 “OPERATING PROCEDURES”

Terex permits the use of rotation resistant wire rope,

1. Position the cable over the boom tip sheave and

NOTE: If the wedge does not seat properly in the slot,

Revised: December 2005 Page 4 - 31 RT440B

Follow the procedure below when installing wedge type

2. Insert the wedge and allow the rope strands to ad-

The wrong cable wedge could permit the wire rope to

Tension the wire rope by braking the shipping reel and

4. Final seating of the wedge is accomplished by mak-

5. After the wedge has been firmly seated, a short-

RT440B Page 4 - 32 Revised: December 2005

Revised: December 2005 Page 4 - 33 RT440B

RT440B Page 4 - 34 Revised: December 2005

Boom Hoist Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 15

Boom Telescope Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 16

Excessive Heating Of Oil In System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 30

Maintenance Free Battery Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 35

Anti Two Block System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 37

RT700 Issued: August 2003

Before attempting to make an adjustment yourself, ask your-

RT700 Series Page 5 - 1 Issued: August 2003

8. Oil cooler plugged, dirty or leaking.

Whenever hydraulic, fuel, lubricating oil lines, or air lines are

RT700 Series Page 5 - 2 Issued: August 2003

RT700 Series Page 5 - 3 Issued: August 2003

RAPID OR UNEVEN TIRE WEAR

Incorrect toe-setting............................................................................... Check and reset toe-in if necessary.

Improper tire inflation ........................................................................... Inflate to proper pressure.

Overloaded Axle ...................................................................................Reduce load.

RAPID WEAR OF TIE ROD ENDS

Severely contaminative environment .................................................... Clean and lubricate more often.

RT700 Series Page 5 - 4 Issued: August 2003

BENT OR BROKEN TIE ROD, STEERING ARM,

HEAVILY WORN STEERING ARM

EXCESSIVE WEAR OF KNUCKLE PINS

RT700 Series Page 5 - 5 Issued: August 2003

SLOW STEERING, HARD STEERING, OR LOSS OF POWER ASSIST

Worn or malfunctioning pump ................................................................................ Replace pump.

Stuck flow divider piston ........................................................................................ Replace flow divider.

Malfunctioning relief valve allowing the system

Overloaded steer axle .............................................................................................. Reduce load.

Leaking or kinked load sensing signal line ............................................................. Correct.

Malfunctioning priority valve.............. ...................................................................Check spring and sticking piston.

Air in the system due to low level of oil,

Worn mechanical linkage........................................................................................ Repair or replace.

Bending of linkage or cylinder rod ......................................................................... Repair or replace.

Loose cylinder piston .............................................................................................. Repair or replace.

RT700 Series Page 5 - 6 Issued: August 2003

Leaking cylinder seals ............................................................................................. Reseal cylinders.

Thoroughly inspect and clean the winch before pro