Rt9150e SM Ctrl659 00 Light

Grove RT9150E
Service Manual
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WARNING
California Proposition 65
Breathing diesel engine exhaust exposes you
to chemicals known to the State of California
to cause cancer and birth defects or other
reproductive harm.
• Always start and operate the engine in a
well-ventilated area.
• If in an enclosed area, vent the exhaust to
the outside.
• Do not modify or tamper with the exhaust
system.
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• Do not idle the engine except as
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For
necessary.
more information, go to
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www.P65warnings.ca.gov/diesel
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Batteries, battery posts, terminals, and

related accessories can expose you to
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chemicals, including lead and lead
compounds, which are known to the State of
California to cause cancer and birth defects or
other reproductive harm. Wash hands after
handling. F or more i n f o r m a t i o n , g o t o
www.P65warnings.ca.gov
California Spark Arrestor
Operation of this equipment may create
sparks that can start fires around dry
vegetation. A spark arrestor may be required.
The owner/operator should contact local fire
agencies for laws or regulations relating to fire
prevention requirements.
The original language of this publication is English.

SERVICE MANUAL 1
This Manual has been prepared for and is considered part of -
RT9150E
Crane Model Number
2
Crane Serial Number
This Manual is Divided into the following Sections:
SECTION 1 INTRODUCTION
SECTION 2 HYDRAULIC SYSTEM 3
SECTION 3 ELECTRICAL SYSTEM
SECTION 4 BOOM
SECTION 5 HOIST AND COUNTERWEIGHT
SECTION 6 SWING SYSTEM
SECTION 7 POWER TRAIN
SECTION 8 UNDERCARRIAGE 4
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SECTION 9 LUBRICATION
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The crane serial number is the only method your distributor or the
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factory has of providing you with correct parts and service informa-
tion.
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The crane serial number is identified on the builder’s decal
attached to the operator’s cab. Always furnish crane serial
number when ordering parts or communicating service problems
with your distributor or the factory.
6
! DANGER
An untrained operator subjects himself and others to death or
7
serious injury. Do not operate this crane unless:
• You are trained in the safe operation of this crane. Grove is not
responsible for qualifying personnel.
• You read, understand, and follow the safety and operating
8
recommendations contained in the crane manufacturer’s manuals and
load charts, your employer’s work rules, and applicable government
regulations.
• You are sure that all safety signs, guards, and other safety features are
in place and in proper condition. 9
• The Operator’s Manual and Load Chart are in the holder provided on
crane.
10
©2021 Grove U.S. L.L.C.
Published 7-12-2021 Control # 659-00
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THIS PAGE BLANK
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RT9150E SERVICE MANUAL TABLE OF CONTENTS
TABLE OF CONTENTS
SECTION 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Introduction
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Overview of Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Delivery Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Customer Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
General Crane Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Specific Crane Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Lifting Capacities (Load Chart) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Basic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 T
Axle Weight Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Serial Number Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Transportation and Lifting Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
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List Of Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 C
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
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Torque Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
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Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
nl c Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
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Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
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Swing Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Boom. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Swivel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
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Hydraulic Pumps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Hoists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
General Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
After Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Pressing Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Locking Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Wires and Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Shims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Hoses and Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Gaskets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Hydraulic Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Hydraulic Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
Fatigue of Welded Structures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
Loctite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
Fasteners and Torque Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
Weld Studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33
Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-34
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-34
Environmental Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-34
Dynamic Shock Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-34
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-34
Precautions and Recommendations During Inspection or Replacement . . . . . . . . 1-34
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TABLE OF CONTENTS RT9150E SERVICE MANUAL
Wire Rope Inspection (Running Ropes and Pendant Cables). . . . . . . . . . . . . . . . 1-35

Keeping Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-35
Frequent Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-35
Wire Rope Inspection (Boom Extension and Retraction Cables) . . . . . . . . . . . . . 1-36
Wire Rope Inspection/Replacement (All Wire Rope). . . . . . . . . . . . . . . . . . . . . . . 1-36
Seizing Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-37
Installing 35x7 Class Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-38
Procedures for Cutting and Preparing 35x7 Class Wire Rope . . . . . . . . . . . . . . . 1-38
Synthetic Hoist Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-39
SECTION 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic System

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Hydraulic System Maintenance Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Label Parts when Disassembling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Hydraulic Fluid Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Draining and Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Removing Air from the Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Parts Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
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Directional Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
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Supply Pressure And Return Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
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Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Pump Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
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Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
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Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Troubleshooting Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
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Filter Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Fill Cap Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Hydraulic Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Pressure Setting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
Connecting laptop to Crane Service Junction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
Procedure A - Checking/Setting Piston Pump Differential and
Cut-off Pressures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
Procedure B - For Checking/Setting the Outrigger/Rear Steer/Axle
Lockout Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
Procedure C - Checking/Setting Charge Air Cooler Motor Control Valve -
Tier 3 Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28
Superstructure Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28
Procedure D - Checking/Setting Main Hoist Lower Pressure . . . . . . . . . . . . . . . . 2-28
Procedure E - Checking/Setting Main Hoist Raise Pressure. . . . . . . . . . . . . . . . . 2-29
Procedure F - Checking/Setting Auxiliary Hoist Lower Pressure. . . . . . . . . . . . . . 2-29
Procedure G - Checking/Setting Auxiliary Hoist Raise Pressure. . . . . . . . . . . . . . 2-30
Procedure H - Checking/Setting Telescope Pressure . . . . . . . . . . . . . . . . . . . . . . 2-30
Procedure I - Checking/Setting Control Pressure . . . . . . . . . . . . . . . . . . . . . . . . . 2-31
Procedure J - Checking/Setting Raise Boom (Derricking) Pressure . . . . . . . . . . . 2-31
Procedure K - Checking/Setting Counterweight Raise Pressure. . . . . . . . . . . . . . 2-32
Procedure L - Checking/Setting Counterweight Lower Pressure . . . . . . . . . . . . . 2-32
Procedure M - Checking/Setting Counterweight Locking/Unlocking Pressures . . 2-32
Procedure N - Checking/Setting Cab Tilt Pressures . . . . . . . . . . . . . . . . . . . . . . . 2-32
Procedure O - Checking/Setting Luffing Jib Pressures . . . . . . . . . . . . . . . . . . . . . 2-32
TOC-2
Procedure P - Checking/Setting Counterweight Pinning Pressure . . . . . . . . . . . . . 2-33

Procedure Q - Checking/Setting Slewing Pressure . . . . . . . . . . . . . . . . . . . . . . . . 2-33
Procedure R - Checking/Setting Steering Pressure . . . . . . . . . . . . . . . . . . . . . . . . 2-33
Procedure S - Checking/Setting Service Brake Pressure. . . . . . . . . . . . . . . . . . . . 2-33
Procedure T - Checking Service Brake Accumulator Charge Pressures . . . . . . . . 2-34
Procedure U - Checking Service Brake Accumulator Pre-Charge Pressures . . . . 2-34
Procedure for Pre-Charging the Service Brake Accumulators, If Required . . . . . . 2-35
Procedure V - Checking/Setting the Differential Lock Pressure . . . . . . . . . . . . . . . 2-36
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37
Outrigger/Rear Steer/Outrigger Box Pin Removal Valve. . . . . . . . . . . . . . . . . . . . . . . . 2-40
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40
T
Outrigger Control Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44 O
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44
Park Brake/Axle Disconnect valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45
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Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45
Axle Oscillation Lockout Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46
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Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46
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Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46
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Pressure Bleed-Off Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47
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Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47
R F
Main Directional Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49
Swing Directional Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53
er
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53
Compact Block Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55
Accessory Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58
Case Drain Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60
Dual Accumulator Charge Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-61
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-61
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-61
Control Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-63
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-63
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-63
Tandem Brake Valve w/ Treadle Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-64
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-64
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-64
Hydraulic Accumulator Service Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-65
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-65
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-65
Charge Air Cooler (CAC) Motor control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-68
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-68
GROVE TOC-3
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-68
Surface Protection For Cylinder Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-68
Axle Oscillation Lockout Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-70
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-70
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-70
Steer Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-73
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-73
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-73
Outrigger Extension Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-76
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-76
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-76
Outrigger Jack Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-79
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-79
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-79
Cab Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-82
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-82
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-82
Power Pin Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-85
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-85
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-85
y e
Counterweight Pin Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-88
ef or
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-88
nl c
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lift Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-88
2-90
O en
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-90
R F
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-90
Counterweight Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-92
Proximity Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-92
er
SECTION 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical System
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Batteries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Jump Starting Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Charging the Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Fuses/Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Dielectric Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Visual Inspection and Replacement of Electrical Harnesses and Cables . . . . . . . . 3-7
General Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Tools for Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Troubleshooting Engine Starting Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Alternator/Charging System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Troubleshooting Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Troubleshooting Swivel-Caused Electrical Problems . . . . . . . . . . . . . . . . . . . . . . 3-11
Connector Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
ECOS Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Diagnostic Connector and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Troubleshooting Vehicle Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Troubleshooting Alarms, Indicators, and Emergency Components. . . . . . . . . . . . 3-14
Troubleshooting Crane Components and Accessories . . . . . . . . . . . . . . . . . . . . . 3-14
Alternator Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Starter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Battery Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
TOC-4
Relay Panel Component Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Rocker Switch Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Turn Signal Indicator Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Ignition Switch Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Turn Signal Lever and Transmission Shift Lever Replacement . . . . . . . . . . . . . . . 3-19
Windshield Wiper Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Windshield Washer Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Skylight Wiper Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
Air Conditioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
SECTION 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boom
T
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Main Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 O
Mechanical Luffing Lattice Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Optional Hydraulic Luffing Lattice Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Optional Boom Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
C
Boom Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Description and Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
y e
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
ef or
Boom Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
nl c Boom Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Assembling the Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
O en
Boom Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
R F
Boom Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35

Functional Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38
er
Boom Alignment and Servicing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38
Bi-Fold Swingaway Boom Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39
Hook Block/Overhaul ball . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39
SECTION 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hoist and Counterweight

Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Warm-up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Hoist Access Area. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Hoist Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Functional Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Changing the Hoist Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Hoist Cable (Wire Rope) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Check the Position on the Hoist Drums . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Check the Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Adjusting the Lowering Limit Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Setting the Lowering Limit Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Check the Lowering Limit Shuts Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Checking the Hoist Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
General Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Counterweight Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Counterweight Stand Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
GROVE TOC-5
Standard 39,000 lb (17,690 kg) Counterweight Installation. . . . . . . . . . . . . . . . . . . 5-7

Standard 39,000 lb (17,690 kg) Counterweight Removal . . . . . . . . . . . . . . . . . . . . 5-8
Heavy 63,000 lb (28,576 kg) Counterweight Installation . . . . . . . . . . . . . . . . . . . . . 5-9
Heavy 63,000 lb (28,576 kg) Counterweight Removal . . . . . . . . . . . . . . . . . . . . . 5-10
Counterweight Stand Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
SECTION 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Swing System

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Swing Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Swing Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Swing Box Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Swing Motor Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Swing Brake Assembly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Swing Gearbox Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Swing Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
y e
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
ef or
Swivels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
nl c
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Hydraulic Swivel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
O en
Two-Port Water Swivel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
R F
Electrical Swivel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20

Swing Lock Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
er
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
360° Swing Lock Control (Positive Lock Type). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
SECTION 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Power Train

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Engine Drive Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Electronic Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Air Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
Charge-Air Cooler System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
Exhaust. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
Tier 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
Tier 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
Water Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26
Drive Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34
TOC-6
Torque Converter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41
SECTION 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Undercarriage
Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
T
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 O
Wheel Alignment Check Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Rear Wheels Not Centered Switch Adjustment Procedure. . . . . . . . . . . . . . . . . . . . 8-3
Wheels and Tires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
C
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
y e
Steering Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
ef or
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
nl c Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
O en
Hydraulic Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
R F
Front Steering Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9

Integrated Outrigger/Rear Steer Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
Steer Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
er
Rear Axle Oscillation Lockout System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
Axle Oscillation Lockout Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
Axle Oscillation Lockout Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14
Service Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18
Park Brake Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20
Outriggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
Outrigger Monitoring System (Optional—Standard in North America) . . . . . . . . . . 8-33
SECTION 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubrication
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Environmental Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Lubrication Intervals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Standard Lubricants Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Arctic Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Below -15°C (5°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Down to –29C° (–20°F). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Surface Protection for Cylinder Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
Wire Rope Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
CraneLUBE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
GROVE TOC-7
Cummins Oil Registration List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7

Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
Steering and Suspension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10
Drive Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12
Drive Train (continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14
Outriggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16
Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-18
Turntable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-20
Cab Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-22
Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-24
Hoist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-26
Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-28
Boom (continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-30
Boom Extension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-32
Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-34
Carwell® Rust Inhibitor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-36
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-36
Cleaning Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-36
Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-37
y e
Carwell Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-37
ef or
Areas of Application. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-37
nl c
O en
R F
er
TOC-8
RT9150E SERVICE MANUAL INTRODUCTION
SECTION 1
1
INTRODUCTION
SECTION CONTENTS
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Locking Devices. . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Overview of Manuals . . . . . . . . . . . . . . . . . . . . . . 1-2 Wires and Cables . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Delivery Report . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Shims. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Customer Support. . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Hoses and Tubes. . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
General Crane Design . . . . . . . . . . . . . . . . . . . . . 1-2 Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Specific Crane Description . . . . . . . . . . . . . . . . . . 1-2 Batteries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Lifting Capacities (Load Chart) . . . . . . . . . . . . . . . 1-2 Hydraulic Systems . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Basic Components . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Hydraulic Fittings . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Axle Weight Distribution . . . . . . . . . . . . . . . . . . . . 1-2 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
Serial Number Location . . . . . . . . . . . . . . . . . . . . 1-3 Fatigue of Welded Structures . . . . . . . . . . . . . . . 1-17
Transportation and Lifting Data . . . . . . . . . . . . . . 1-4
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Loctite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
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List Of Specifications . . . . . . . . . . . . . . . . . . . . . . . 1-5 Fasteners and Torque Values . . . . . . . . . . . . . . . 1-18
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General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5
1-5
Weld Studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33
Wire Rope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-34
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Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-34
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Torque Converter . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Environmental Conditions . . . . . . . . . . . . . . . . . . 1-34

Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Dynamic Shock Loads . . . . . . . . . . . . . . . . . . . . . 1-34
Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-34
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Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Precautions and Recommendations During
Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Inspection or Replacement . . . . . . . . . . . . . . . . . 1-34
Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Wire Rope Inspection (Running Ropes and
Swing Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Pendant Cables) . . . . . . . . . . . . . . . . . . . . . . . . . 1-35
Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Keeping Records . . . . . . . . . . . . . . . . . . . . . . . . . 1-35
Swivel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Frequent Inspection . . . . . . . . . . . . . . . . . . . . . . . 1-35
Hydraulic Pumps. . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Wire Rope Inspection (Boom Extension and
Retraction Cables) . . . . . . . . . . . . . . . . . . . . . . . . 1-36
Hoists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Wire Rope Inspection/Replacement (All Wire
General Maintenance . . . . . . . . . . . . . . . . . . . . . . 1-10 Rope) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-36
Cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10 Seizing Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . 1-37
After Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10 Installing 35x7 Class Wire Rope . . . . . . . . . . . . . 1-38
Removal and Installation . . . . . . . . . . . . . . . . . . 1-10 Procedures for Cutting and Preparing 35x7
Disassembly and Assembly . . . . . . . . . . . . . . . . 1-10 Class Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . 1-38
Pressing Parts . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11 Synthetic Hoist Rope . . . . . . . . . . . . . . . . . . . . . . 1-39
GROVE Published 7-12-2021 Control # 659-00 1-1

INTRODUCTION RT9150E SERVICE MANUAL
GENERAL Go to:
http://www.manitowoccranes.com/MCG_CARE/Includes/EN
This manual provides important information concerning your /changeofownership.cfm and complete the form.
Grove Crane.
Safety Information
Overview of Manuals
A Safety CD which includes sections on operation, safety
Before servicing the crane, take time to thoroughly and maintenance for crane operators and owners is supplied
familiarize yourself with the contents of this manual. After all when the crane is purchased new. Additional copies are
sections have been read and understood, retain the manual available from your local distributor.
for future reference in a readily accessible location.
NOTE: Throughout this manual, reference is made to left, General Crane Design
right, front, and rear when describing locations. The Gro ve cran e ha s b een des ig ned for max imum
These reference locations are to be considered as performance with minimum maintenance. With proper care,
those viewed from the operator’s seat with the years of trouble-free service can be expected.
superstructure facing forward over the front of the
carrier frame. Constant improvement and engineering progress makes it
necessary that we reserve the right to make specification
Engine operating procedures and routine operation and equipment changes without notice.
procedures are supplied in separate manuals with each
crane, and should be referred to for detailed information. A Specific Crane Description
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separate safety manual is also provided with each crane.
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See the Operator’s Manual Section #2 for other safety The crane incorporates an all welded steel frame, using
related issues.
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steering is accomplished utilizing hydraulic steer cylinders.
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Delivery Report The engine is mounted at the rear of the crane and provides
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motive power through a six speed forward and reverse

A Delivery Report must be filled out by the Grove distributor, transmission. Hydraulic, double box, sliding beam outriggers
signed by the purchaser, and returned to Grove once the are removable.
crane is sold, leased or rented. This report activates the
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warranty period, assuring that your claims during the The carrier frame incorporates an integral fifth wheel, to
warranty period will be honored and processed expediently. which the rear axle is mounted, to provide axle oscillation.
To guarantee full warranty service, make sure your Grove Axle oscillation lockout is automatic when the superstructure
distributor has returned the report to Manitowoc Crane Care. rotates from the travel position.
An engine warranty form must also be filled out, signed and The superstructure is capable of 360° rotation in either
returned to the engine manufacturer for full warranty direction. All crane functions are controlled from the fully-
coverage. enclosed cab mounted on the superstructure.
Customer Support The crane is equipped with a six-section, pinned boom.

Additional reach is obtained by utilizing an optional
Grove and our distributor network want to ensure your swingaway boom extension. Lifting is provided by a main
satisfaction with our products and customer support. Your and auxiliary hoist.
local distributor is the best equipped and most
knowledgeable to assist you for parts, service and warranty Lifting Capacities (Load Chart)
issues. They have the facilities, parts, factory trained
personnel, and the information to assist you in a timely Lift Capacities are listed on the Load Chart in the cab.
manner. We request that you first contact them for
assistance. If you feel you need factory assistance, please Basic Components
ask the distributor’s service management to coordinate the For basic Crane Component locations see Figure 1-3.
contact on your behalf.
Axle Weight Distribution
New Owners
For Axle Weight Distribution see Table 1-1.
If you are the new owner of a Grove crane, please register it
with Manitowoc Crane Care so we have the ability to contact
you if the need arises.
1-2 Published 7-12-2021 Control # 659-00

Serial Number Location superstructure cab (2), and inside the cab in front of the seat
See Figure 1-1 for your crane’s serial number location;

on the right side (3). 1
stamped on left side of front frame (1), on manual holder in
2
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3
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FIGURE 1-1
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Transportation and Lifting Data

Transporting and lifting information is located on the
hydraulic tank on the right side of the crane. For
transportation and lifting data see Table 1-1.
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FIGURE 1-2

LIST OF SPECIFICATIONS Engine

1
General Cummins QSL (Tier 4)
Model . . . . . . . . . . . . . . . . . . . . . . RT9150E Series HP Rating. . . . . . . . . . . . . . . . . 320 hp @ 2200 rpm
Rated Capacity. . . . . . . . . . . See Load Chart in cab Peak Torque. . . . . . . . . . 1050 pounds @ 1400 rpm
Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 x 4 x 4 Lube Amount . . . . . . . . . . . . . . . . . . . .21 qt (19.9 l)
Gross Weight . . . . . . . . . . . . . . . . See Axle Weight Coolant System . . . . . . . . . . . . . . . . . .36 qt (34.1 l)
. . . . . . . . . . . . . . . . . . . . . . . . . . . Distribution Table
Cummins QSC (Tier 3)
Dimensions
HP Rating. . . . . . . . . . . . . . . . . 300 hp @ 2200 rpm
NOTE: Dimensions listed are for a crane with all Peak Torque. . . . . . . . . . 1000 pounds @ 1400 rpm
components fully retracted in the travel mode with Lube Amount . . . . . . . . . . . . . . . . . . . .21 qt (19.9 l)
Coolant System . . . . . . . . . . . . . . . . . .36 qt (34.1 l)
33.25 x 29 tires.
Wheelbase . . . . . . . . . . . . . . . . 16 ft 2.5 in (4.94 m) Axles
Overall Crane Length . . . . . . . . . . . 51 ft (15.545 m)
Overall Crane Width. . . . . . . . . 12 ft 5.5 in (3.80 m) Total Ratio (w/differential lock) . . . . . . . . . . . 33.43:1
Overall Crane Height . . . .13 ft 8.2 in (4.17 m) (Std) Total Ratio (standard) . . . . . . . . . . . . . . . . . 31.94:1
Tail-Swing. . . . . . . . . . . . . . . . . 15 ft 3.8 in (4.64 m) Carrier Ratio (w/differential lock) . . . . . . . . . 6.429:1
Outrigger Spread Carrier Ratio (standard) . . . . . . . . . . . . . . . . 6.143:1
Retracted. . . . . . . . . . . . . . . .11 ft 8 in (3.56 m) Planetary Ratio . . . . . . . . . . . . . . . . . . . . . . . 5.20:1
Mid Extend . . . . . . . . . . . . . 19 ft 9 in (6.02 m)
Brakes
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Fully Extended . . . . . . . . . 27 ft 10 in (8.49 m)
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Type . Hydraulic/Split system acting on all four wheels
Capacities Size . . . . . . . . . . . . . 18.5 x 1.575 in (470 x 40 mm)
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Fuel Tank . . . . . . . . . . . . . . . . . . . . . 100 gal (378 l)
Wheels and Tires
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Diesel Exhaust Fluid (DEF) . . . . . . . .10 gal (37.9 l)
Coolant System . . . . . . . . . . . . . . . . . . See Engine Lugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
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Specifications Torque . . . . . . . . . 450 to 500 lb-ft (610 to 678 Nm)

Engine Lubrication System . . . . . . . . . See Engine Tire Size
. . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications Standard . . . . . . . . . . . 33.25 x 29-38 ply rating
Hydraulic Tank (Reservoir Capacity)
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Total. . . . . . . . . . . . . . . . . . . . . . 198 gal (750 l) NOTE: For roading and lifting pressures, refer to the Load
at Full Level. . . . . . . . . . . . . . . . 173 gal (655 l) Chart Book in the cab.
at Low Level . . . . . . . . . . . . . . . 163 gal (617 l)
Expansion Space . . . . . . . . . . . . . 25 gal (95 l) Swing Gearbox
Hoists . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2 qt (4 l)
Swing Gearbox. . . . . . . . . . . . . . . . . . . . 1 qt (0.9 l) Reduction Ratio . . . . . . . . . . . . . . . . . . . . . . . . 63:1
Axle Planetary Hubs. . . . . . . . . . . . . . . 7.2 qt (6.8 l) Output Torque . . . . . . . . . . . . . . . . . . . . . 4071 lb-ft
Axle Differentials . . . . . . . . . . . . . . . 65.1 qt (61.6 l)
Transmission (Includes Torque Converter) Boom
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 qt (32 l)
Length
Retracted . . . . . . . . . . . . . . . . . . 42 ft (12.9 m)
Torque Converter Extended. . . . . . . . . . . . . . . . . . 196.8 ft (60 m)
Stall Ratio. . . . . . . . . . . . . . . . . . . . . . . . . . . .2.29:1 Power. . . . . . . . . . . . . . . . . . . 6 Section, Full Power
Charge Pump Capacity . . . . . 31 gpm (117.3 l/min) Elevation . . . . . . . . . . . . . . . . . . .-3 to +82 degrees
@ 2000 rpm Extensions
Fixed* . . . . . . . . . . . . . . . . . . . . . 36.1 ft (11 m)
Transmission Folding*. . . . . . . . . 36.1 or 59.1 ft (11 or 18 m)
*Extensions are offsettable at 0, 20, or 40
Gear Ratios: degrees.
Forward Extension Insert . . . . . . . . . . . . . . . . . . 26.2 ft (8 m)
1st . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.87 Extension Insert . . . . . . . . . . . . . . . . . . 19.7 ft (6 m)
2nd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.94
3rd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.98 Swivel Assembly
4th . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25
5th . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.95 Electrical . . . . . . . . . . . . . . . . . . . . . . 46 Slip Rings
6th . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.73 Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . 10 ports
Reverse Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ports
1st . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.87 Air Conditioning . . . . . . . . . . . . . . . . . . . . . . 2 ports
2nd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.98
3rd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.95

Hydraulic Pumps Output @ 2303 rpm . . . . . . . . . 16.9 gpm (64 l/min)
NOTE: Pump output figures are theoretical. Pump #4

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear
Pump #1 Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston Output @2486 rpm . . . . . . . . 18.3 gpm (69.3 l/min)
Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Output @ 2303 rpm . . . . . . . .64.2 gpm (243 l/min) Hoists
Drum Dimensions
Pump #2 Length . . . . . . . . . . . . . . . . . . 22.5 in (569 mm)
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston Diameter . . . . . . . . . . . . . . . . . 15 in (381 mm)
Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Cable
Output @ 2303 rpm . . . . . . 46.7 gpm (176.8 l/min) Diameter . . . . . . . . . . . . . . . . . 0.75 in (19 mm)
Length-Main. . . . . . . . . . . . . . . . 837 ft (255 m)
Length-Aux. . . . . . . . . . . . . . . . . 738 ft (225 m)
Pump #3 Max. Permissible Line Pull
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear . . . . . . . . . . . . . . . . . . . . . . . . . 15,700 lb (7121 kg)
Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Max. Single Line Speed . . . 394 fpm (120.1 m/min)
Hoist Motor Displacement
. . . . . . . . . . . . . . . . . . . . . .90 cc per revolution
Oil Capacity . . . . . . . . . . . . . . . . . . . . . . 4.2 qt (4 l)
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14
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16 21
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2 8
10 9
5
12
1
3
6
23 7473-2
4
17 7 18
FIGURE 1-3

15
1
11
22
12
13
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7473-3
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19
20
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FIGURE 1-3 continued
Item Description Item Description

1 Counterweight 13 Right Hand Valve Covers
2 Cab 14 Boom Nose Sheaves
3 Work Light 15 Swingaway
4 Outrigger Float 16 Auxiliary Boom Nose
5 Left Hand Valve Cover 17 Front Axle
6 Outrigger Jack Cylinder 18 Rear Axle
7 Steps 19 Hydraulic Tank
8 Auxiliary Hoist 20 Hydraulic Fluid Cooler
9 Main Hoist 21 Boom Assembly
10 Boom Pivot 22 Hoist Access Platform
11 Swingaway Nose 23 Fuel Tank
12 Lift Cylinder

Table 1-1: Axle Weight Distribution Table
CG To CL
Weight Front Axle Rear Axle
Description Rear Bogie
kg (lb) kg (lb) kg (lb)
cm (in)
Maximum Axle Loads Allowed at 24 km/h
40824 90000 40824 90000
(15 mph) (with no cwt installed)
Maximum Tire & Wheel Loads Allowed at
41223 90880 41223 90880
24 km/h (15 mph) (with no cwt installed)
43999 97000 43999 97000
(10 mph) (with standard cwt installed)
Maximum Tire & Wheel Loads Allowed at
16 km/h (10 mph) (with standard cwt 44829 98830 44829 98830
installed)
58968 130000 58968 130000
(2.5 mph) (with heavy cwt installed)
Maximum Tire & Wheel Loads Allowed at 4
59258 130640 59258 130640
km/h (2.5 mph) (with heavy cwt installed)
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Standard Carrier Assy (4x4) + All Fluids +
212.90 83.82 32919 72574 14187 31276 18733 41298
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Outrigger Boxes and Beams
Superstructure Assy with both hoists + 255
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m (837 ft) main cable + 225 m (738 ft) aux 52.10 20.51 7445 16414 785 1731 6660 14683
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cable
17690 kg (39000 lb) Removable
-132.51 -52.17 17705 39033 -4749 -10470 22454 49503
Counterweight on Turntable - Standard
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Main Boom 609.27 239.87 15167 33438 18705 41238 -3538 -7800
Lift Cylinder 512.85 201.91 1308 2883 1358 2993 -50 -110
Complete Basic Machine: Outrigger Boxes
Installed, 12.8 - 60.0 m (42 - 197 ft) 6-
Section Boom, Cummins QSL Tier 4 Final
Engine, 33.25x29 (38 ply) Tires, Main Hoist
200.71 79.02 74545 164342 30286 66768 44259 97574
w/255 m (837 ft) of 3/4in 35x7 cable, Aux
Hoist w/225 m (738 ft) of 3/4 in 35x7 cable,
Full Fuel and Hydraulic Oil, A/C, Standard
Counterweight
Add To Basic Machine Weight
11 - 18 m (36 - 59 ft) Manually Offsetable
Boom Extension (includes brackets on 728.78 286.92 1577 3477 2326 5129 -749 -1652
boom)
11 - 18 m (36 - 59 ft) Hydraulic Boom
Extension (includes brackets and hydraulic 775.87 305.46 1825 4023 2866 6318 -1041 -2295
components on boom)
11 - 18 m (36 - 59 ft) Heavy Duty Hydraulic
Boom Extension (includes brackets and 794.08 312.63 2063 4547 3315 7309 -1253 -2762
hydraulic components on boom)
Brackets for manual boom extension 628.17 247.31 114 251 145 319 -31 -68
Brackets and hydraulic components on
910.08 358.30 302 666 557 1227 -254 -561
boom for hydraulic boom extension
Aux Boom Nose - installed 1304.93 513.75 60 133 159 351 -99 -218
8 m (26 ft) Mechanical Boom Extension
630 1388
Insert (not included in unit weight)

Description
CG To CL
Rear Bogie
Weight
kg (lb)
Front Axle
kg (lb)
Rear Axle
kg (lb)
1
cm (in)
8 m (26 ft) Hydraulic Boom Extension
647 1426
Insert (not included in unit weight)
6 m (20 ft) Boom Extension Insert (not
446 984
included in unit weight)
9 t (10 ton) Overhaul Ball (Swivel) - tied to
787.40 310.00 330 727 526 1159 -196 -432
O/R Box
91 t (100 ton) Domestic Hookblock (7
469.90 185.00 1150 2535 1094 2411 56 124
sheave) - stowed in trough
118 t (130 ton) Domestic Hookblock (8
469.90 185.00 1148 2530 1091 2406 56 124
sheave) - stowed in trough
91 t (100 ton) CE Hookblock (7 sheave) -
469.90 185.00 1159 2555 1102 2430 57 125
stowed in trough
120 t (132 ton) CE Hookblock (7 sheave) -
469.90 185.00 1154 2544 1098 2420 56 124
stowed in trough
Rubber Mat in Front Storage Tray 454.66 179.00 26 58 24 53 2 5
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Cold Weather Package (batteries) 154.94 61.00 24 52 7 16 16 36
Driver
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Sound Package for CE - Carrier
233.68
-15.24
92.00
-6.00
113
139
250
306
54
-4
118
-9
60
143
132
315
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Sound Package for CE - Superstructure 25.40 10.00 168 370 9 19 159 351
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Substitutions, Additions, and Removals

SUB: 28577 kg (63000 lb) Removable
-132.51 -52.17 10886 24000 -2920 -6437 13806 30437
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Counterweight on Turntable - Heavy
REM: Main Hoist Cable (255m (837ft) of
-97.31 -38.31 -459 -1012 90 199 -549 -1211
3/4”” Dyform 34LR)
REM: Aux Hoist Cable (225m (738ft) of
-183.52 -72.25 -405 -893 151 332 -556 -1225
3/4”” Dyform 34LR)
REM: Titan 33.25x29 (38) tires (for travel) 247.02 97.25 -4318 -9520 -2159 -4760 -2159 -4760
REM: Air Conditioner 48.26 19.00 -30 -66 -3 -6 -27 -60
SUB: Tier 3 Engine -106.68 -42.00 -290 -640 63 138 -353 -778
ADD: Lift Cylinder Travel Support 561.34 221.00 53 117 60 133 -7 -16
ADD: Counterweight Stand (pinned to
627.38 247.00 85 187 108 237 -23 -50
carrier)
REM: Front Outrigger Box and Beam Ass’y 675.64 266.00 -4276 -9427 -5848 -12892 1572 3465
REM: Rear Outrigger Box and Beam Ass’y -208.28 -82.00 -4276 -9427 1803 3974 -6079 -13401

GENERAL MAINTENANCE compressed air on bearings. Spinning bearings without

lubricant will cause damage to the bearing, and could cause
These general suggestions should be helpful in following the the bearing to fly apart.
i ns t r u c t io n s i n th i s m a nu a l . I n a n al y z i ng a s y s te m
malfunction, use a systematic approach to locate and correct
the problem.
NOTE: Your safety and that of others is always the number CAUTION
one consideration when working around machines. Eye Injury Hazard!
Safety is a matter of thoroughly understanding the
job to be done and the application of good common When using compressed air use only low air pressure and
sense. It is not just a matter of do’s and don’ts. Stay keep air stream from direction of face.
clear of all moving parts.
Always wear eye and face protection when using
1. Determine the problem. compressed air. Injury to eyes could occur.
2. List possible causes.
Removal and Installation
3. Devise checks.
When performing maintenance, do not attempt to manually
4. Conduct checks in a logical order to determine the lift heavy parts when hoisting equipment should be used.
cause. Never locate or leave heavy parts in an unstable position.
When raising a crane or portion thereof, ensure the crane is
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5. Consider the remaining service life of components
blocked securely and the weight is supported by blocks or
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against the cost of parts and labor necessary to replace
jack stands rather than by lifting equipment.
6.
them.
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Make the necessary repair. When using hoisting equipment, follow the hoist
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manufacturers recommendations and use lifting devices that
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7. Recheck to ensure that nothing has been overlooked. will allow you to achieve the proper balance of the
assemblies being lifted and to ensure safe handling. Unless
8. Functionally test the failed part in its system.
otherwise specified, all removals requiring hoisting
equipment should be accomplished using an adjustable
er
Cleanliness
lifting attachment or straps design for that purpose. All
An important item in preserving the long life of the machine is supporting members (straps, chains and cables) should be
keeping dirt out of working parts. Enclosed compartments, parallel to each other and as near perpendicular as possible
seals, and filters have been provided to keep the supply of to the top of the object being lifted.
air, fuel, and lubricants clean. It is important that these
NOTE: The capacity of an eyebolt diminishes as the angle
enclosures be maintained.
between the supporting members and the object
Whenever hydraulic, fuel, lubricating oil lines, or air lines are becomes less than 90°. Eyebolts and brackets
disconnected, clean the adjacent area, as well as, the point should never be bent and should only have stress
of connection. As soon as the disconnection is made, cap, in tension
plug, or tape each line or opening to prevent entry of foreign
Some removals require the use of lifting fixtures to obtain
material. The same recommendations for cleaning and
proper balance. The weights of some components are given
covering apply when access covers or inspection plates are
in their respective sections of the manual.
removed.
If a part resists removal, check to be certain all nuts and bolts
Clean and inspect all parts. Be sure all passages and holes
have been removed and that an adjacent part is not
are open. Cover all parts to keep them clean. Be sure parts
interfering.
are clean when they are installed. Leave new parts in their
containers until ready for assembly.
Disassembly and Assembly
Clean the rust preventive compound from all machined
When disassembling or assembling a component or system,
surfaces of new parts before installing them.
complete each step in turn. Do not partially assemble one
After Cleaning part and start assembling another. Make all adjustments as
recommended. Always check the job after it is completed to
Remove all water or solvent from the parts immediately after see that nothing has been overlooked. Recheck the various
cleaning. Use compressed air or a clean cloth. Make sure adjustments by operating the machine before returning it to
the parts are completely dry and clean. DO NOT use service.

Pressing Parts Hoses and Tubes

When pressing one part into another, use an anti-seize
1
compound or a molybdenum disulfide base compound to ! DANGER
lubricate the mating surfaces. High Pressure/Temperature Hazard!
Assemble tapered parts dry. Before assembling parts with Exercise extreme care around pressurized hydraulic
tapered splines, be sure the splines are clean, dry, and free hoses or tubes. DO NOT work on a hydraulic system
from burrs. Position the parts together by hand to mesh the while it is in operation or until all pressure is released.
splines before applying pressure. Hydraulic fluid is hot, it can cause severe burns.
Parts which are fitted together with tapered splines are Pressurized hydraulic fluid can cause death or serious
always very tight. If they are not tight, inspect the tapered injury.
splines and discard the part if the splines are worn. Stay clear of all hydraulic fluid leaks. Relieve system
pressure and use a piece of cardboard or paper to
Locking Devices check for leaks. Do not use your hands.
Lockwashers, flat metal locks, or cotter pins are used to lock Fluid injected into skin must be surgically removed
nuts and bolts. within a few hours by a doctor familiar with this type of
Flat metal locks must be installed properly to be effective. injury or gangrene will result.
Bend one end of the lock around the edge of the part. Bend
Inspection
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the other end against one flat surface of the nut or bolt head.
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Always use new locking devices on components which have Check hoses carefully. Do not use your bare hands to check
moving parts.
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When installing lockwashers on housings made of aluminum Tighten all connections to recommended torque.
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or thin sheet metal, use a flat washer between the If the hose end connections are damaged, always replace
lockwasher and the housing. the hose or tube. Damaged, dented, crushed, or leaking
hose fittings restrict hydraulic fluid flow and the operation of
Wires and Cables
er
the parts being served. Fittings showing signs of movement
Batteries should always be disconnected prior to working on from their original position have failed and must be replaced.
the electrical system. Be sure hoses are in good condition. If in doubt, replace
When removing or disconnecting a group of wires or cables, them.
tag each one to ensure proper identification during assembly. Replace hoses if any of the following is evident (Figure 1-4):
Shims • Evidence of kinking or crushing (1)
When shims are removed, tie them together and identify • Chaffing or cuts; wire is exposed (2)
them as to location. Keep shims clean and flat until they are • Damaged or leaking fittings (3)
reinstalled.
• Localized ballooning (4)
1
2
FIGURE 1-4

Installation assembly to obtain accurate pre-loading. When installing a

bearing, spacer, or washer against a shoulder on a shaft, be
1. When installing a new hose, loosely connect each end
sure the chamfered side is toward the shoulder.
and make sure the hose takes up the designed position
before tightening the connection. Clamps should be When pressing bearings into a retainer or bore, uniformly
tightened sufficiently to hold the hose without crushing apply pressure to the outer race. If the bearing is pressed on
and to prevent chafing. the shaft, uniformly apply pressure on the inner race.
2. If a hose is replaced on a part that moves during Preload
operation, be sure it moves freely by moving the part
through its complete range of movement. Preload is an initial load placed on the bearing at the time of
assembly. Whether a tapered roller bearing should have
3. Be sure any hose which has been installed is not kinked preload could depend on any of several conditions: rigidity of
or twisted. the housings and shaft, bearing spread, speed of operation,
Free moving, unsupported hoses must never rub on each etc.
other or related work surfaces. This causes chafing and To determine whether a bearing requires preload or end
reduces hose life. c l e ar a nc e , c on s u l t t h e d i s a s s em b l y a n d a s s e m b l y
instructions pertaining to that bearing.
Bearings
Care should be exercised in applying preload. Misapplication
Antifriction Bearings while preloading bearings requiring end clearance can result
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in bearing failure.
When an antifriction bearing is removed, cover it to keep out
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dirt and abrasives. Wash bearings in non-flammable Sleeve Bearings
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cleaning solution and allow them to drain dry. The bearing
may be dried with compressed air but do not spin the Do not install sleeve bearings with a hammer. Use a press
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bearing. Discard the bearings if the races and balls or rollers and be sure to apply the pressure directly in line with the
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are pitted, scored, or show signs of heat damage. If the bore. If it is necessary to drive a bearing into place, use a
bearing is serviceable, coat it with oil and wrap it in clean bearing driver or a bar with a smooth flat end. If a sleeve
waxed paper. Do not unwrap new bearings until time of bearing has an oil hole, align it with the oil hole in the mating
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installation. The life of an antifriction bearing will be part.
shortened if not properly lubricated. Dirt in an antifriction
bearing can cause the bearing to lock resulting in the shaft Gaskets
turning in the inner race or the outer race turning within the Be sure the holes in the gaskets correspond with the
cage. passages in the mating parts. If it is necessary to make
gaskets, select material of the proper type and thickness. Be
Double Row, Tapered Roller
sure to cut holes in the right places. Blank gaskets can cause
Double row, tapered roller bearings are precision fit during serious damage.
manufacture and components are not interchangeable. The
When removed, always install new cylinder head and
cups, cones, and spacers are usually etched with the same
manifold gaskets using recommended gasket compound on
serial number and letter designator. If no letter designators
head gaskets to allow uniform sealing.
are found, wire the components together to assure correct
installation. Reusable bearing components should be Batteries
installed in their original positions.
Clean batteries by scrubbing them with a solution of baking
Heating Bearings soda and water. Rinse with clear water. After cleaning, dry
Bearings which require expansion for installation should be thoroughly and coat terminals and connections with an anti
heated in oil not to exceed 250 °F (121° C). When more than corrosion compound or grease.
one part is heated to aid in assembly, they must be allowed If the machine is to be stored or not used for an extended
to cool and then pressed together again. Parts often period of time, the batteries should be removed. Store the
separate as they cool and contract. batteries in a cool (not subfreezing), dry place, preferably on
wooden shelves. Never store on concrete. A small charge
Installation
should be introduced periodically to keep the specific gravity
Lubricate new or used bearings before installation. Bearings rating at recommended level.
that are to be preloaded must have a film of oil over the entire

Hydraulic Systems Due to manufacturing methods there is a natural curvature to

a hydraulic hose. The hose should be installed so any bend 1
is with this curvature.
! DANGER Visual Inspection of Hoses and Fittings

High Pressure/Temperature Hazard! 1. Visually inspect hoses and fittings once a month or
Exercise extreme care around pressurized hydraulic every 250 hours for the following:
systems. DO NOT work on a hydraulic system while it is in
operation or until all pressure is released. • Leaks at hose fitting or in hose
Hydraulic fluid is hot, it can cause severe burns. • Damaged, cut, or abraded cover
Pressurized hydraulic fluid can cause death or serious • Exposed reinforcement
injury.
• Kinked, crushed, flattened, or twisted hose
Stay clear of all hydraulic fluid leaks. Relieve system
pressure and use a piece of cardboard or paper to • Hard, stiff, heat cracked, or charred hose
check for leaks. Do not use your hands.
• Blistered, soft, degraded, or loose cover
Fluid injected into skin must be surgically removed
within a few hours by a doctor familiar with this type of • Cracked, damaged, or badly corroded fittings
injury or gangrene will result. • Fitting slippage on hose
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Cleanliness • Other signs of significant deterioration
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If any of the above conditions exist, evaluate hose
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Contaminants in a hydraulic system affect operation and will
result in serious damage to the system components. Dirty assemblies for correction or replacement. For replacement
of hose assemblies, refer to your Manitowoc Crane Care
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hydraulic systems are a major cause of component failures.
Parts Manual.
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Keep the System Clean

2. At the same service interval, visually inspect all other
When removing components of a hydraulic system, cover all hydraulic components and valves for the following:
openings on both the component and the crane.
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• Leaking ports.
If evidence of foreign particles is found in the hydraulic
• Leaking valve sections or manifolds and valves installed
system, flush the system.
into cylinders or onto motors.
Disassemble and assemble hydraulic components on a
• Damaged or missing hose clamps, guards, or shields.
clean surface.
• Excessive dirt and debris around the hose assemblies.
Clean all metal parts in a nonflammable cleaning fluid. Then
lubricate all components to aid in assembly. If any of these conditions exist, address them appropriately.
Sealing Elements 3. All hydraulic hose assemblies are recommended to be

replaced after 8000 hours of service life.
Inspect all sealing elements (O-rings, gaskets, etc.) when
disassembling and assembling the hydraulic system 4. Hydraulic hose assemblies operating in a temperature
components. Installation of new elements is always climate zone “C” (Table 1-2) are recommended to be
recommended. replaced after 8000 hours of service life.
Hydraulic Lines 5. Hydraulic hose assemblies operating in climate zones

“A” and “B” with high ambient temperatures, could see
When installing metal tubes, tighten all bolts finger-tight. hose service life reduced by 40 to 50%, therefore, it is
Then, in order, tighten the bolts at the rigid end, the recommended to replace these hoses after 4000 to
adjustable end, and the mounting brackets. After tubes are 5000 hours of service life.
mounted, install the hoses. Connect both ends of the hose
with all bolts finger-tight. Position the hose so it does not rub 6. Hydraulic hose assemblies operating in climate zones
on the machine or another hose and has a minimum of “D” and “E” should expect a degradation of mechanical
bending and twisting. Tighten both couplings. properties such as elasticity, therefore, it is
recommended these hoses be inspected and addressed
accordingly.

Table 1-2: Climate Zones
Zone Classification
A Tropical Moist: All months average above 18° C. Latitude 15° - 25° North and South
B Dry or Arid: Deficient precipitation most of the year. Latitude 20° - 35° North and South
C Moist Mid-Latitude: Temperature with mild winters. Latitude 30° - 50° North & South
D Moist Mid-latitude: Cold winters. Latitude 50° - 70° North & South
E Polar: Extremely cold winters and summers. Latitude 60° - 75° North & South
Hydraulic Fittings
Flats from Finger Tight (F.F.F.T.) Method
Grove recommends that the F.F.F.T. tightening method
described here be used when assembling all hydraulic
fittings. This method will minimize the risk of fitting damage
or failure due to under or overtightening.
This method will also reduce the chance of a leaky
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connection which is normally caused by combinations of
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fittings with different types of plating. This method is
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particularly useful when the type of plating on the fitting is
unknown, and during maintenance or repair when a joint
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may be oily.
a0027 FIGURE 1-5
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Follow these steps when tightening all fitting connections:

5. Tighten the joint by the number of flats as specified in
1. Make sure both threads and sealing surfaces are free of Table 1-3 and 1-4 for size and type of fitting.
burrs, nicks, scratches or any foreign particles.
er
6. Optionally for future tightening of the same connection:
2. Align tube or hose to the mating fitting and check to see extend the line from the nut at its new location onto the
that the flare seats properly on the nose of the fitting. hex of the static fitting or port (Figure 1-5).
3. Finger tighten the nut onto the fitting. If necessary, a 37° Flared Steel Fitting: Tube or Hose to Fitting
wrench should be used to seat the nut snugly against
the fitting. This is considered the “Finger Tight” Follow the F.F.F.T. method, described above.
condition.
Table 1-3: Tube and Swivel Nut/Hose Fittings
4. Using a permanent-type ink marker, make a mark on
one of the flats of the nut and continue it onto the hex of
the static fitting or port
T-2-5

Adjustable Straight Thread O-ring Fittings 6. Hold the fitting in the desired position and tighten the nut
Refer to (Figure 1-6) and (Table 1-4) for the following
(D) following the F.F.F.T. method starting with step 4. 1
procedure. Nonadjustable Straight Thread O-ring Fitting: Fitting
to Port
Table 1-4: Adjustable Straight Thread O-ring Fittings
Refer to (Table 1-5) for the following procedure.
1. Make sure both threads and sealing surfaces are free of
burrs, nicks, scratches or any foreign particles.
2. Lubricate O-ring with clean hydraulic fluid (Figure 1-7).
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Non-Adjustable Fitting to Port
FIGURE 1-7
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3. Turn fitting until finger tight.
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T-2-6
BACK OFF
4. Using the assembly torque method, tighten to given
NUT torque for size from (Table 1-5).
er
Table 1-5: Straight Thread Fittings
a0030 Adjustable Fitting to Port FIGURE 1-6

1. Inspect both mating parts for burrs, nicks, scratches, or
foreign particles.
2. Lubricate O-ring with a light coat of clean hydraulic fluid.
3. Back off locknut as far as possible (A).
4. Screw the fitting into port by hand until the backup
washer contacts the face of the port and is pushed all the T-2-7
way towards the locknut (C).
5. To orientate the fitting, unscrew the fitting the required
amount, but not more than one full turn.

Table 1-6: BSPP (Thread G) Port Assembly fitting Torque Chart
Straight Male
Straight Male O-
Tube Metric Thread Form E with ED
Series ring With Retaining
OD Size Sealing Torque (ft-
Ring Torque (ft-lbs)
lbs)
S 6 G 1/4A 41 26
S 8 G 1/4A 41 26
S 10 G 3/8A 59 52
S 12 G 3/8A 59 52
S 14 G 1/2A 85 66
S 16 G 1/2A 85 66
S 20 G 3/4A 133 133
S 25 G 1A 229 229
S 30 G 1 1/4A 332 332
S 38 G 1 1/2A 398 398
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Electrical System • Counterweight support structures.

• Chassis axle and suspension mounting structures.
1
Harnesses, Wires, and Connectors
• Hydraulic cylinder end connections.
Visually inspect all electrical harnesses, cables, and
connectors every month or 250 hours for the following: The above is provided only as a guide, and your inspection
plan should not be limited to the areas listed. A thorough
• Damaged, cut, blistered, or cracked insulation.
visual inspection of all weldments is good practice.
• Exposed bare wires.
Anyone requiring more detailed inspection instructions
• Kinked or crushed wires and cables. and/or repair procedures may request same by contacting
your local Grove distributor.
• Cracked or corroded connectors, battery terminals, and
ground connections.
Loctite
If any the above conditions exist, evaluate, clean and replace
as necessary.
! CAUTION
The climate in which the crane operates affects the service
Skin and/or Eye Hazard!
life of the electrical components. The climate zones are
defined in (Table 1-2). Recommended replacement of Loctite type adhesives contain chemicals that may be
harness and cables is as follows: harmful if misused. Read and follow the instructions on
the container.
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• Climate zone C after 10,000 hours of service.
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Always follow the directions on the Loctite container, as not
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• Climate zones A and C with high ambient temperatures
and duty cycles after 8000 hours of service.
all Loctite types are suitable for all applications.Various types
of Loctite are specified throughout the Service Manual. The
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• Climate zones D and E after 5,000 hours of service. following types of Loctite brand adhesives are available from
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the Parts Department of the local Grove distributor.

• Salt water conditions after 8,000 hours of service.
Application of Medium Strength Loctite
Fatigue of Welded Structures
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NOTE: The fastener may be re-used; the adhesive may be
Experience has shown that highly stressed welded re-applied over cured adhesive residue.
structures when repeatedly subjected to varying stresses
caused by twisting, shock, bending, and intentional and/or The following procedure covers the proper application and
unintentional overloads, often become subject to weld curing method for medium strength Loctite adhesive/sealant
cracking which may be attributed to fatigue of the welded (Loctite #243) and primer (Locquic Primer T7471).
joint. This condition is not uncommon in construction Primer Application
equipment.
NOTE: It is not necessary to bathe the threads in primer.
Equipment should be periodically inspected for evidence of
weld fatigue. The frequency of these inspections should 1. Ensure the threaded surface, both male and female, is
increase with the age of the equipment and the severity of clean and free of dirt and oil. Apply a light spray coating
the application.The following are known high stress areas of primer to both male and female parts to be joined to
applicable to Grove machines, and a visual inspection of clean and accelerate the curing process.
these areas should be made part of an owner’s planned 2. Allow the part to dry prior to adhesive/sealant
preventive maintenance program: application.
• Telescopic Boom: wear pad retaining structures, Adhesive/Sealant Application
hydraulic cylinder attaching points, boom pivot shaft
retaining structures.
Bead Application
• Outrigger pads, beams, boxes and attachment
structures.
• Main frame: generally in the area of doubler plates and
crossmembers; at the junction of front and rear frame
members on truck cranes.
4203
• Turntable bearing connection—where bearing is welded FIGURE 1-8
to the crane superstructure or chassis.

1. Apply a bead perpendicular to the thread, several When referring to the applicable torque charts, use values as
threads wide, in the approximate area of threaded close as possible to the torque values shown to allow for
engagement (see Figure 1-1). wrench calibration tolerance.
2. In a blind hole application, a bead of several drops of
adhesive should be applied into the bottom of the hole to
Torque Wrenches
be hydraulically forced up during engagement. Flexible beam type wrenches, even though they might have
a pre-set feature, must be pulled at right angle and the force
3. After application and engagement of mated threads,
must be applied at the center of the handle. Force value
fixturing will occur within five (5) minutes if primed prior
readings must be made while the tool is in motion. Rigid
to engagement. Fixturing may take up to 30 minutes on
handle type, with torque limiting devices that can be pre-set
unprimed parts.
to required values, eliminate dial readings and provide more
4. Time required to achieve full strength is 24 hours. reliable, less variable readings.
Maximum ultimate strength is achieved using no primer
NOTE: If multipliers and/or special tools are used to reach
with this specific threadlocking adhesive.
hard to get at areas, ensure torque readings are
Fasteners and Torque Values accurate.
Torque wrenches are precision instruments and must be
Use bolts of the correct length. A bolt which is too long may
handled with care. To ensure accuracy, calibrations must be
bottom before the head is tight against the part it is to hold. If
made on a scheduled basis. Whenever there is a possibility
a bolt is too short, there may not be enough threads engaged
that a torque wrench may have been either overstressed or
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to hold the part securely. Threads can be damaged. Inspect
ef or
damaged, it should immediately be removed from service
them and replace fasteners, as necessary.
until recalibrated. When using a torque wrench, any erratic or
and nuts being used. nl c

Torque values should correspond to the type bolts, studs, jerking motion can result in the application of excessive or
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improper torque. ALWAYS use a slow, even movement and
STOP when the predetermined value has been reached.
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The torque tables are provided by Grove for reference when

performing maintenance. When using step wrenches, calculated wrench settings are
valid only when the following conditions are met:
Use of proper torque values is extremely important. Improper
er
torquing can seriously affect performance and reliability. • Torque wrenches must be those specified and forces
must be applied at the handle grip. The use of handle
Identification of fastener grade is always necessary. When
extensions will change applied torque to the bolt.
marked as a high strength bolt (grade 5, 8, etc.), the
mechanic must be aware that he/she is working with a highly • All handles must be parallel to the step wrench during
stressed component and the fastener should be torqued final tightening. Multiplier reaction bars may be
accordingly. misaligned no more than 30 degrees without causing
serious error in torque.
NOTE: Some special applications require variation from
standard torque values. Reference should always • Multiplier bar handles must be propped or supported
be made to component overhaul procedures for within the outer 1/4 of the handle length, or serious
recommendations. under or over tightening will occur.
Special attention should be given to the existence of To convert pounds-foot (lb-ft) of torque to newton meters
lubricant, plating, or other factors that might require variation (Nm), multiply the pounds-foot quantity by 1.3558.
from standard torque values.
To convert pounds-inch (lb-in) of torque to newton meters
The use of lubricants on zinc-flake coated parts shall be (Nm), multiply the pounds-inch quantity by 0.11298.
prohibited since this will change the required torque value.
When maximum recommended torque values have been
Torque Values
exceeded, the fastener should be replaced. The following tables list the torque values for both ASME
Previously installed bolts and nuts of Grade 8 or Class 10.9 standard and metric fasteners. The tables list the values for
and higher may not be reused. grade 5 and grade 8 zinc-flake coated, untreated (black)
finish and stainless steel fasteners.

SAE Grade 1 SAE Grade 5 SAE Grade 7 SAE Grade 8

and Grade 2 HHCS HHCS HHCS
HHCS
Socket Head Socket Head Serrated

Capscrew Shoulder Flange Head
Screw
FIGURE 1-9
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Table 1-7 — Inch Series with Coarse Threads (UNC) – Zinc Flake Coated
Nominal Size, Threads per Torque (ft/lb)

Inch, and Series Grade
Designation Maximum Nominal Minimum
5 6.6 6.4 6.2

1/4-20 UNC
8 9.3 9.0 8.8
5 13.5 13.2 12.8
5/16-18 UNC
8 19.1 18.6 18.1
5 24.0 23.4 22.8
3/8-16 UNC
8 33.9 33.1 32.2
5 38.4 37.4 36.5
7/16-14 UNC
8 54.3 52.9 51.5
5 58.6 57.1 55.7
1/2-13 UNC
8 82.8 80.7 78.6
5 84.5 82.4 80.3
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9/16-12 UNC
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8 119.4 116.5 113.5
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5/8-11 UNC
5 116.6 113.7 110.8
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8 164.8 160.7 156.6
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5 206.8 201.7 196.5

3/4-10 UNC
8 292.3 284.9 277.6
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5 333.8 325.4 317.1
7/8-9 UNC
8 471.6 459.8 448.0
5 500.3 487.8 475.3
1-8 UNC
8 707.0 689.3 671.6
5 624.0 608.4 592.8
1 1/8-7 UNC
8 1001.4 976.4 951.4
5 880.5 858.5 836.5
1 1/4-7 UNC
8 1413.1 1377.8 1342.5
5 1154.5 1125.6 1096.7
1 3/8-6 UNC
8 1852.8 1806.5 1760.2
5 1532.0 1493.7 1455.4
1 1/2-6 UNC
8 2458.8 2397.3 2335.8

Table 1-8 — Inch Series with Fine Threads (UNF) – Zinc Flake Coated

1
5 7.5 7.3 7.1

1/4-28 UNF
8 10.6 10.4 10.1
5 15.0 14.6 14.2
5/16-24 UNF
8 21.1 20.6 20.1
5 27.2 26.5 25.8
3/8-24 UNF
8 38.4 37.5 36.5
5 42.9 41.8 40.7
7/16-20 UNF
8 60.6 59.1 57.6
5 66.0 64.4 62.7
1/2-20 UNF
8 93.3 90.9 88.6
5 94.3 91.9 89.6
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9/16-18 UNF
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8 133.2 129.9 126.6
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5/8-18 UNF
5 132.1 128.8 125.5
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8 186.7 182.0 177.3
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5 231.0 225.2 219.4

3/4-16 UNF
8 326.4 318.2 310.1
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5 367.7 358.5 349.3
7/8-14 UNF
8 519.6 506.6 493.6
5 547.4 533.7 520.0
1-12 UNF
8 773.5 754.2 734.8
5 700.0 682.5 665.0
1 1/8-12 UNF
8 1123.5 1095.4 1067.3
5 975.0 950.6 926.2
1 1/4-12 UNF
8 1564.8 1525.7 1486.5
5 1314.4 1281.5 1248.6
1 3/8-12 UNF
8 2109.5 2056.7 2004.0
5 1723.9 1680.8 1637.7
1 1/2-12 UNF
8 2766.8 2697.6 2628.4

Table 1-9 — Metric Series with Coarse Threads – Zinc Flake Coated
Nominal Size, Threads per Torque (Nm)

Property
Inch, and Series
Class Maximum Nominal Minimum
Designation
10.9 3.6 3.5 3.4
M4x0.7
12.9 4.2 4.1 4.0
10.9 7.2 7.0 6.8
M5x0.8
12.9 8.4 8.2 8.0
8.8 8.3 8.1 7.9
M6x1.0 10.9 12.2 11.9 11.6
12.9 14.3 13.9 13.6
8.8 20.2 19.7 19.2
M8x1.25 10.9 29.6 28.9 28.2
12.9 34.7 33.8 33.0
8.8 40.0 39.0 38.0
y e
ef or
M10x1.5 10.9 58.7 57.2 55.8
nl c 12.9 68.7 67.0 65.3

O en
8.8 69.7 68.0 66.2
R F
M12x1.75 10.9 102.4 99.8 97.2

12.9 119.8 116.8 113.8
er
8.8 111.4 108.6 105.8
M14x2 10.9 163.6 159.5 155.4
12.9 191.5 186.7 181.9
8.8 172.8 168.5 164.1
M16x2 10.9 253.8 247.4 241.1
12.9 296.9 289.5 282.1
8.8 246.2 240.1 233.9
M18x2.5 10.9 350.7 341.9 333.2
12.9 410.4 400.1 389.9
8.8 348.0 339.3 330.6
M20x2.5 10.9 495.6 483.2 470.8
12.9 580.0 565.5 551.0
8.8 474.4 462.6 450.7
M22x2.5 10.9 675.7 658.8 641.9
12.9 790.7 770.9 751.2
8.8 601.3 586.3 571.3
M24x3 10.9 856.4 835.0 813.6
12.9 1002.2 977.1 952.1

Nominal Size, Threads per

Inch, and Series
Property
Torque (Nm)
1
Designation
8.8 881.6 859.6 837.5
M27x3 10.9 1255.7 1224.3 1192.9
12.9 1469.4 1432.7 1395.9
8.8 1195.3 1165.5 1135.6
M30x3.5 10.9 1702.5 1659.9 1617.3
12.9 1992.3 1942.4 1892.6
8.8 2089.8 2037.6 1985.3
M36x4 10.9 2976.4 2902.0 2827.6
12.9 3483.0 3395.9 3308.9
y e
ef or
nl c
O en
R F
er

Table 1-10 — Metric Series with Fine Threads – Zinc Flake Coated

Property
Inch, and Series
Designation
8.8 21.6 21.1 20.5
M8x1.0 10.9 31.7 30.9 30.1
12.9 37.1 36.2 35.3
8.8 46.8 45.6 44.4
M10x.75 10.9 68.7 67.0 65.3
12.9 80.4 78.4 76.4
8.8 42.2 41.1 40.1
M10x1.25 10.9 62.0 60.4 58.9
12.9 72.5 70.7 68.9
8.8 79.5 77.5 75.5
M12x1.0 10.9 116.7 113.8 110.9
y e
ef or
12.9 136.6 133.2 129.8
nl c 8.8 76.2 74.2 72.3

O en
M12x1.25 10.9 111.8 109.0 106.3
R F
12.9 130.9 127.6 124.3

8.8 72.9 71.1 69.2
er
M12x1.5 10.9 107.1 104.4 101.7
12.9 125.3 122.1 119.0
8.8 120.2 117.2 114.2
M14x1.5 10.9 176.5 172.1 167.7
12.9 206.6 201.4 196.2
8.8 184.4 179.8 175.2
M16x1.5 10.9 270.9 264.1 257.3
12.9 317.0 309.1 301.2
8.8 276.6 269.7 262.8
M18x1.5 10.9 394.0 384.2 374.3
12.9 461.1 449.6 438.0
8.8 405.7 395.5 385.4
M20x1 10.9 577.8 563.3 548.9
12.9 676.1 659.2 642.3
8.8 386.0 376.3 366.7
M20x1.5 10.9 549.7 535.9 522.2
12.9 643.3 627.2 611.1
8.8 520.8 507.8 494.8
M22x1.5 10.9 741.7 723.2 704.7
12.9 868.0 846.3 824.6

Nominal Size, Threads per

Inch, and Series
Property
Torque (Nm)
1
Designation
8.8 655.8 639.4 623.0
M24x2 10.9 934.0 910.6 887.3
12.9 1092.9 1065.6 1038.3
8.8 951.4 927.6 903.8
M27x2 10.9 1355.0 1321.1 1287.2
12.9 1585.6 1546.0 1506.3
8.8 1369.2 1334.9 1300.7
M30x1.5 10.9 1950.0 1901.3 1852.5
12.9 2281.9 2224.9 2167.8
8.8 1324.6 1291.5 1258.4
M30x2 10.9 1886.6 1839.4 1792.2
12.9 2207.7 2152.5 2097.3
y e
ef or
8.8 1784.5 1739.9 1695.3
nl c
M33x2 10.9 2541.6 2478.0 2414.5
O en
12.9 2974.2 2899.8 2825.4
R F
8.8 2340.1 2281.6 2223.1

M36x2 10.9 3332.8 3249.5 3166.2
er
12.9 3900.2 3802.6 3705.1

Table 1-11 — Metric Series Screws of STAINLESS STEEL A2-70/A4-70 with Coarse Threads
Size Torque (Nm)

M2.5x0.45 0.4
M3x0.5 0.9
M4x0.7 1.5
M5x0.8 3.1
M6x1 5.3
M8x1.25 13
M10x1.5 27
Torque Values for fasteners with lubrication these torque values result in an 80% utilization of the yield strength.
Stainless steel fasteners tend to gall while being tightened. To reduce this risk, lubricate the threads and torque at low speeds
without interruptions. Do not use excessive pressure. Impact wrenches are not recommended.
Table 1-12 — Inch Series Screws of STAINLESS STEEL 300 (18-8) with Coarse Threads
Torque
y e
Size
ef or
lb-in lb-ft
#5-40 (0.125)
nl c 6.9 -
O en
#6-32 (0.138) 9 -
R F
#8-32 (0.164) 18 -
#10-24 (0.190) 21 -
er
1/4-20 68 -
5/16-18 120 10
3/8-16 210 17.5
Torque Values for fasteners with lubrication these torque and preload values result in an 80% utilization of the yield strength.
Stainless steel fasteners tend to gall while being tightened. To reduce this risk, lubricate the threads and torque at low speeds
without interruptions. Do not use excessive pressure. Impact wrenches are not recommended.

Table 1-13 — Inch Series Bearing Bolts – Untreated (black finish)

1
5/8-11 UNC 8 234 225 216

5/8-18 UNF 8 250 240 230
3/4-10 UNC 8 385 370 355
7/8-9 UNC 8 615 591 567
1-8 UNC 8 929 893 857
1 1/4-7 UNC 8 2043 1964 1885
Table 1-14 Metric Series Bearing Bolts– Untreated (black finish)

M20X2.5 12.9 756 727 698
y e
ef or
M24X3 10.9 1089 1047 1005
nl c
M24X3 12.9 1306 1256 1206
O en
M27X3 10.9 1591 1530 1469
R F
er

Table 1-15 — Inch Series with Coarse Threads (UNC) – Untreated (black finish)
Torque (ft/lb)
Size Grade
Maximum Nominal Minimum
5 9.0 8.4 7.7
1/4-20
8 12.5 12 11.5
5 19 18 17
5/16-18
8 26 25 24
5 32 31 30
3/8-16
8 48 46 44
5 52 50 48
7/16-14
8 73 70 67
5 78 75 72
1/2-13
8 120 115 110
5 114 110 106
9/16-12
y e
8 161 152 143
ef or
5/8-11
nl c 5
8
156
234
150
225
144
216
O en
5 270 259.5 249
R F
3/4-10
8 385 370 355
5 416 400 384
er
7/8-9
8 615 591 567
5 606 583 560
1-8
8 929 893 857
5 813 782 751
1 1/8-7
8 1342 1288 1234
5 1141 1097 1053
1 1/4-7
8 2043 1964 1885
5 1519 1461 1403
1 3/8-6
8 2496 2396 2296
5 2028 1946.5 1865
1 1/2-6
8 3276 3150 3024

Table 1-16 — Inch Series with Fine Threads (UNF) – Untreated (black finish)
Torque (ft/lb)
1
Size Grade
5 10 9.5 9
1/4-28
8 14.5 14 13.5
5 21 20 19
5/16-24
8 26 25 24
5 36 35 34
3/8-24
8 53 51 49
5 57 55 53
7/16-20
8 85 82 79
5 88 84.5 81
1/2-20
8 125 120 115
5 126 121 116
9/16-18
y e
8 177 170 163
ef or
nl c
5/8-18
5
8
182
250
174.5
240
167
230
O en
5 312 299.5 287
R F
3/4-16
8 425 409 393
5 458 439.5 421
er
7/8-14
8 672 646 620
5 658 632 606
1-12
8 1009 970 931
5 670 644.5 619
1-14
8 945 908.5 872
5 882 848 814
1 1/8-12
8 1500 1440 1380
5 1251 1203 1155
1 1/4-12
8 2092 2008.5 1925
5 1704 1638 1572
1 3/8-12
8 2833 2719 2605
5 2288 2196.5 2105
1 1/2-12
8 3640 3500 3360

Table 1-17 — Metric Series with Coarse Threads – Untreated (black finish)
Property Torque (Nm)

Size
8.8 3.1 2.9 2.8
M4x0.7 10.9 4.5 4.3 4.1
12.9 5.4 5.2 4.9
8.8 6.5 6.2 5.9
M5x0.8 10.9 9.2 8.9 8.5
12.9 11 10.5 10
8.8 11 10.5 10
M6x1 10.9 16 15 14
12.9 19 18 17
8.8 27 26 25
M8x1.25 10.9 38 36.5 35
y e
12.9 45 43.5 42
ef or
nl c
M10x1.5
8.8
10.9
53
75
51
72
49
69
O en
12.9 89 86 83
R F
8.8 93 89 85
M12x1.75 10.9 130 125 120
er
12.9 156 150 144
8.8 148 142 136
M14x2 10.9 212 203.5 195
12.9 248 238 228
8.8 230 221 212
M16x2 10.9 322 310 298
12.9 387 372 357
8.8 319 306.5 294
M18x2.5 10.9 455 436.5 418
12.9 532 511 490
8.8 447 430 413
M20x2.5 10.9 629 605 581
12.9 756 727 698
8.8 608 585 562
M22x2.5 10.9 856 823 790
12.9 1029 989 949
8.8 774 744 714
M24x3 10.9 1089 1047 1005
12.9 1306 1256 1206

Size
Property
Class
Torque (Nm)
1
8.8 1134 1090 1046
M27x3 10.9 1591 1530 1469
12.9 1910 1836.5 1763
8.8 1538 1479 1420
M30x3.5 10.9 2163 2080 1997
12.9 2595 2495 2395
8.8 2681 2578.5 2476
M36x4 10.9 3964 3812 3660
12.9 4639 4461 4283
y e
ef or
nl c
O en
R F
er

Table 1-18 — Metric Series with Fine Threads – Untreated (black finish)
Property Torque (Nm)

Size
8.8 29 28 27
M8x1 10.9 41 39.5 38
12.9 49 47 45
8.8 57 55 53
M10x0.75 10.9 81 78 75
12.9 96 93 90
8.8 57 55 53
M10x1.25 10.9 81 78 75
12.9 96 93 90
8.8 101 97.5 94
M12x1 10.9 150 144 138
y e
12.9 175 168 161
ef or
nl c
M12X1.25
8.8
10.9
100
147
96
141.5
92
136
O en
12.9 172 165.5 159
R F
8.8 100 96 92
M12x1.5* 10.9 140 135 130
er
12.9 168 162 156
8.8 160 153.5 147
M14x1.5 10.9 229 220 211
12.9 268 257 246
8.8 248 238.5 229
M16x1.5 10.9 348 335 322
12.9 418 402 386
8.8 345 331.5 318
M18x1.5 10.9 491 471 451
12.9 575 552 529
8.8 471 453 435
M20X1 10.9 694 667.5 641
12.9 812 781 750
8.8 483 464.5 446
M20x1.5 10.9 679 653 627
12.9 816 785 754
8.8 657 632 607
M22x1.5 10.9 924 888.5 853
12.9 1111 1068 1025

Size
Property
Class
Torque (Nm)
1
8.8 836 803.5 771
M24x2 10.9 1176 1130.5 1085
12.9 1410 1356 1302
8.8 1225 1171.5 1130
M27x2 10.9 1718 1652.5 1587
12.9 2063 1983.5 1904
8.8 1530 1471.5 1413
M30x1.5 10.9 2253 2166.5 2080
12.9 2637 2536 2435
8.8 1661 1597.5 1534
M30x2 10.9 2336 2246.5 2157
12.9 2800 2695 2590
y e
8.8 2141 2059 1977
ef or
nl c
M33x2 10.9
12.9
3155
3692
3034
3550.5
2913
3409
O en
8.8 2795 2688 2581
R F
M36x2 10.9 4118 3960 3802

12.9 4818 4634 4450
er
Weld Studs
Unless otherwise specified the following grade 2 torque
values (+/- 10%) apply.
Table 1-19: Weld Stud Torque Values
T-2-4

WIRE ROPE shall be of the type which does not hinder visual inspection.
Those sections of rope which are located over sheaves or
General otherwise hidden during inspection and maintenance
procedures require special attention when lubricating rope.
The following compendium of information is from various The object of rope lubrication is to reduce internal friction and
wire rope manufacturers and includes inspection, to prevent corrosion.
replacement, and maintenance guidelines for wire rope as
established by ANSI/ASME B30.5, federal regulations, and During fabrication, ropes receive lubrication; the kind and
Grove. The inspection interval shall be determined by a amount depends on the rope’s size, type, and anticipated
qualified person and shall be based on such factors as use. This in-process treatment will provide the finished rope
expected rope life as determined by experience on the with ample protection for a reasonable time if it is stored
particular installation or similar installations, severity of under proper conditions. But, when the rope is put into
environment, percentage of capacity lifts, frequency rates of service, the initial lubrication may be less than needed for the
operation, and exposure to shock loads. Periodic full useful life of the rope. Because of this possibility, periodic
Inspections need not be at equal calendar intervals and applications of a suitable rope lubricant are necessary.
should be performed at shorter time intervals as the wire The following are important characteristics of a good wire
rope approaches the end of its useful life. A periodic rope lubricant:
inspection shall be performed at least once a year. The
following provides inspection and maintenance procedures • It should be free from acids and alkalis.
for wire ropes used on Grove products (e.g. wire rope used • It should have sufficient adhesive strength to remain on
y e
as load lines [hoisting cables], boom extension and the rope.
ef or
retraction cables, pendant cables, tow winch cables, and
• It should be of a viscosity capable of penetrating the
nl c
hook block tie down cables).
Environmental Conditions
interstices between wires and strands.
O en
• It should not be soluble in the medium surrounding it
R F
The life expectancy of wire rope may vary due to the degree under the actual operating conditions (i.e. water).
of environmental hostility and other conditions to which these • It should have a high film strength.
mechanical devices are subjected. Variation in temperature,
er
continuous excessive moisture levels, exposure to corrosive • It should resist oxidation.
chemicals or vapors or subjecting the wire rope to abrasive
Before applying lubrication, accumulations of dirt or other
material may shorten normal wire rope life.
abrasive material should be removed from the rope.
Frequent/periodic inspections and maintenance of your wire
Cleaning can be accomplished by using a stiff wire brush and
rope is recommended for preventing premature wear and to
solvent, compressed air, or live steam. Immediately after the
insure long-term satisfactory performance.
wire rope is cleaned, it should be lubricated. Many
techniques may be used; these include bath, dripping,
Dynamic Shock Loads pouring, swabbing, painting or pressure spray methods.
Subjecting wire rope to abnormal loads beyond the Whenever possible, the lubricant should be applied at the
endurance limit will shorten the wire rope’s life expectancy. top of a bend in the rope, because at that point the strands
Examples of this type of loading are listed below. are spread by bending and are more easily penetrated.
There should be no load on the rope while it is being
1. High velocity movement e.g.; hoisting or swinging of a lubricated. It should be noted, the service life of wire rope will
load followed by abrupt stops. be directly proportional to the effectiveness of the method
2. Suspending loads while traveling over irregular surfaces used and amount of lubricant reaching the working parts of
such as railroad tracks, potholes, and rough terrain. the rope.
3. Moving a load that is beyond the rated capacity of the Precautions and Recommendations During
lifting mechanism, i.e.; overloading.
Inspection or Replacement
Lubrication 1. Always lock out equipment power when removing or
installing wire rope assemblies.
A wire rope cannot be lubricated sufficiently during
manufacture to last it’s entire life. Therefore, new lubricant 2. Always use safety glasses for eye protection.
must be added throughout the life of a rope to replace factory
lubricant which is used or lost. It is important that lubricant 3. Wear protective clothing, gloves, and safety shoes as
applied as part of a maintenance program shall be appropriate.
compatible with the original lubricant, and to this end, the 4. Use supports and clamps to prevent uncontrolled
rope manufacturer should be consulted. Lubricant applied movement of wire rope, parts, and equipment.

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

pendants) having permanently attached end fittings use
2
1
only pre-assembled lengths of wire rope as supplied
from Grove. Do not build lengths from individual 4
components.
6. Replace an entire wire rope assembly. Do not attempt to
rework damaged wire rope or wire rope ends. A925
5
7. Never electroplate wire rope assemblies.

3
8. Do not weld any wire rope assembly or component
unless welding is recommended by the wire rope FIGURE 1-11
manufacturer. Welding spatter shall never be allowed to
come in contact with the wire rope or wire rope ends. In
addition, be sure that the wire rope is not an electrical
Wire Rope Inspection (Running Ropes and
path during other welding operations. Pendant Cables)
9. Wire ropes are manufactured from special steels. If Wire rope should be inspected frequently/daily and
heating a wire rope assembly is absolutely necessary for periodically/yearly in accordance with the following
removal, the entire wire rope assembly shall be information excerpted from a National Consensus Standard
discarded. as referenced by Federal Government Agencies.
y e
Recommended inspection intervals may vary from machine
10. On systems equipped with two or more wire rope
ef or
t o m ac h in e a nd m a y v ar y ba s ed o n en v ir o n m en ta l
assemblies operating as a matched set, they shall be
nl c
replaced as an entire set.
conditions, frequency of lifts, and exposure to shock loads.
The inspection time intervals may also be predetermined by
O en
11. Do not paint or coat wire ropes with any substance state and local regulatory agencies.
R F
except approved lubricants. NOTE: Wire rope may be purchased through Manitowoc
12. Measure the rope’s diameter across crowns (1) of the Crane Care.
strands when determining if rope has become damaged Any deterioration observed in the wire rope should be noted
er
(Figure 1-10). in the equipment inspection log and an assessment
concerning wire rope replacement should be made by a
qualified person.
Keeping Records
A signed and dated report of the wire rope’s condition at
each periodic inspection must be kept on file at all times. The
report must cover all inspection points listed in this section.
The information in the records can then be used to establish
data which can be used to determine when a wire rope
1 should be replaced.
It is recommended that the wire rope inspection program
include reports on the examination of wire rope removed
A925
from service. This information can be used to establish a
FIGURE 1-10 relationship between visual inspection and the rope’s actual
internal condition at the time of removal from service.
Frequent Inspection
A frequent daily visual inspection is recommended for all
running ropes in service. This inspection should be made on
all wire rope which can be expected to be in use during the
day’s operation. This inspection should be used to monitor
progressive degradation and to discover severe damages
necessitating wire rope replacement such as:
• Distortion, kinking, crushing, un-stranding, birdcaging,
reduction of diameter, etc.

• General corrosion. following guidelines. The inspection shall cover all visible
areas of the extension and retraction cables of an assembled
• Broken or cut strands.
boom. Note that extending and/or retracting the boom may
• Number, distribution and type of broken wires. be required to access visual inspection holes.
• Evidence of core failure. The inspection shall cover the entire length of the extension
and retraction cables of a disassembled boom prior to
• End fitting wear/abrasion.
reassembly.This inspection should be used to monitor
Pay particular attention to areas of the rope where wear and progressive degradation and to discover severe damages
other damage is likely to occur: necessitating wire rope replacement or equipment repair.
Inspection criteria are as follows:
• Pick-up Points: Sections of wire rope that are repeatedly
stressed during each lift, such as those sections in 1. Inspect for reduction of rope diameter below nominal
contact with sheaves. diameter.
• End Attachments: The point where a fitting is attached to 2. Inspect for severely corroded or broken wires at end
the wire rope or the point where the wire rope is attached connections.
to the drum.
3. Inspect for severely corroded, cracked, bent, worn, or
• Abuse Points: The point where the wire rope is improperly applied end connections.
subjected to abnormal scuffing and scraping.
4. Inspect wire rope in areas subjected to rapid
deterioration such as:
y e
Periodic Inspection
ef or
Wire rope should be inspected periodically/annually or at a • Sections in contact with saddles, equalizer sheaves,
nl c
shorter time interval if necessitated by environmental or
other adverse conditions, and shall cover the entire length of •
or other sheaves where wire rope travel is limited.
Sections of wire rope at or near terminal ends where
O en
the wire rope. Only the outer surface of the wire rope need corroded or broken wires may protrude.
R F
be inspected, and no attempt should be made to open the

• Sections of wire rope in contact with stationary
rope. Periodic inspection should include all items listed
surfaces where abrasion or chafing may take place
under frequent inspection plus the following:
as a result of equipment vibration.
er
• Inspect for reduction of rope diameter below nominal
5. Inspect for damaged or wobbly boom extension and
diameter.
retraction sheaves that may cause rapid deterioration of
• Inspect for severely corroded or broken wires at end the wire rope.
connections.
6. Inspect for unusual cable sag/stretch and be sure cables
• Inspect for severely corroded, cracked, bent, worn, or used in sets all have an equal tension applied. Repeated
improperly applied end connections. need for adjustment of an individual cable is evidence of
cable stretch and indicates the need for additional and
• Inspect wire rope in areas subjected to rapid
more thorough inspection in order to determine and
deterioration such as:
correct the cause.
- Sections in contact with saddles, equalizer sheaves,
or other sheaves where wire rope travel is limited. Wire Rope Inspection/Replacement (All Wire
- Sections of wire rope at or near terminal ends where
Rope)
corroded or broken wires may protrude. No precise rules can be given for determination of the exact
• Inspect boom nose sheaves, hook block sheaves, boom time for replacement of wire rope since many variable factors
extension/jib sheaves, auxiliary boom nose sheaves, are involved. Determination regarding continued use or
and hoist drums for wear. Damaged sheaves or hoist replacement of wire rope depends largely upon the good
drums can accelerate wear and cause rapid judgement of an appointed and qualified person who
deterioration of the wire rope. evaluates the remaining strength in a used rope after
allowance for any deterioration disclosed by inspection.
Wire Rope Inspection (Boom Extension and Wire rope replacement should be determined by the
Retraction Cables) following information excerpted from a National Consensus
Standard as referenced by Federal Government Agencies
Periodic Inspection and as recommended by Grove. All wire rope will eventually
deteriorate to a point where it is no longer usable. Wire rope
It is recommended that a weekly inspection of all boom
extension and retraction cables be performed using the

shall be taken out of service when any of the following

conditions exist: 1
• Kinking, crushing, birdcaging, or any other damage
resulting in distortion of the rope structure.
• Evidence of any heat damage from any cause.
• Reductions from nominal diameter of more than:
• In running ropes, six randomly distributed broken wires
in one lay or three broken wires in one strand in one lay.
• In standing ropes, more than two broken wires in one lay
in sections beyond end connections or more than one
broken wire at an end connection.
FIGURE 1-12
• In rotation resistant rope, two randomly distributed
broken wires in six rope diameters or four randomly
Method 2
distributed broken wires in 30 rope diameters.
• Severe corrosion as evidenced by pitting.
• Grove recommends that for cable extended booms, a
y e
single damaged wire rope assembly shall require
ef or
replacement of the entire set of extension cables.
nl c
• Grove recommends for cable extended booms, that
O en
boom extension cables be replaced every seven (7)
years.
R F
Seizing Wire Rope

er
It is important to seize the ends of rotation resistant wire
ropes to prevent the displacement and unraveling of the
individual wires and strands at the ends. All preformed and
non-preformed styles of wire rope should be seized prior to
cutting. Seizings must be placed on both sides of the point
where the wire rope is to be cut.
The two preferred methods for seizing wire ropes are:
Method 1
Using a length of soft annealed wire (Figure 1-12), place one
FIGURE 1-13
end in the groove between two strands of the wire rope. Turn
the long end of the annealed wire at right angles to the wire
Wind a length of soft annealed wire (Figure 1-13) around the
and wrap it tightly over the portion in the groove.
wire rope at least seven times. The two ends should be
The two ends of the annealed wire should be twisted twisted together in the center of the seizing. Tighten the
together tightly. Cut off the excess wire and pound the twist seizing by alternately prying and twisting. Cut off both ends
flat against the wire rope. of the wire and pound the twist flat against the rope.

NOTE: Non-preformed wire rope (1) (Figure 1-14) should 5. Spool multiple layers with sufficient tension. It’s very
have three seizings (3) located on each side of the important to apply a tensioning load to the ropes during
cut (4) as compared to preformed wire rope (2). the rope breaking-in process. (If not, the lower layers
may be loose enough that the upper layers become
wedged into the lower layers under load, which can
1 4 3 seriously damage the rope.) The tensioning load should
range from 1 to 2% of the rope’s minimum breaking
force.
6. For ropes in multi-part systems: Reeve the traveling
block and boom tip sheaves so the rope spacing is
maximized and the traveling (hook) block hangs straight
and level to help assure block stability.
7. Breaking in new 35x7 Class Wire Rope—After
2 installation, properly break in the rope, which allows the
rope’s component parts to adjust themselves to the
operating conditions:
With the boom fully raised and fully extended, attach a
light load at the hook and raise it a few inches off the
ground. Allow to stand for several minutes. Then cycle
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the load between the full “up” and “down” positions
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several times. Observe the drum winding and rope travel
7204
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FIGURE 1-14 After making the lifts with a light load, increase the load
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and cycle it up and down a few times. This procedure will

Installing 35x7 Class Wire Rope train the rope and help assure smooth operation during
its useful life.
er
Ideally, you should run these loads with reeving that lets
CAUTION you place the loads on the block with all rope off the
Any cutting of this specific wire rope is not recommended. drum except the last three wraps. If this is not possible,
If 35x7 Class Wire Rope wire rope must be cut for any alternate methods must be used to assure proper
reason, it is necessary to follow the following instructions. tensioning of the rope on the drum.
Also, unlike other types of wire rope, the ends on this wire
rope must be welded to retain the rotation resistant Procedures for Cutting and Preparing 35x7
characteristics. Class Wire Rope
1. Unload properly and relieve any twists. Pull the rope off 35x7 Class Wire Rope is a special wire rope that must be
the shipping reel or unroll it from a shipping coil. (If done handled differently than any other rope manufactured. One
improperly, you may kink the rope, which will result in characteristic that makes this rope special is that the outer
permanent damage to the rope.) Then, lay the rope on strands are not preformed. It is because of this that the
the ground in direct line with the boom. This helps following procedures for cutting and preparing 35x7 Class
release any twist in the rope. Wire Rope must be followed:
2. Pull the rope over the point sheave and attach the end to 1. The welded ends prepared by the manufacturer are not
the hoist drum. Be sure not to remove the welded end. to be removed.
3. Wind rope onto drum slowly and carefully. At this point, it 2. Before cutting the rope, make three separate bands with
isn’t necessary to provide additional load other than the seizing strand on each side of where the cut is to be
weight of the rope being pulled across the ground. made (total of six bands for each cut). Each band is to
have a minimum length of one and one half times the
4. Spool first layer tightly. It is essential on smooth-faced rope diameter. The two bands closest to the cut should
drums that the first layer is spooled with wraps tight and be located at a distance equal to one rope diameter
close together since the first layer forms the foundation away from the cut. The four remaining bands should be
for succeeding layers. If need be, use a rubber, lead or evenly spaced at a distance equal to three rope
brass mallet (but never a steel hammer) to tap the rope diameters.
into place.

a. If a welder is available, the cut should be made with

an abrasive saw. Immediately after the cut, both 1
ends of the rope are to be cap welded so that all
inner and outer strands are welded together,
preventing any movement between them.
NOTE: The outer strands must not be able to move with
respect to the inner strands. The weld must not
exceed the diameter of the rope.
b. If a welder is not available, the cut is to be made with
an acetylene torch. The cut is to be made in such a
way that both ends of the rope are completely fused
so that all inner and outer strands are bonded
together, preventing any movement between
strands.
NOTE: The outer strands must not be allowed to move
with respect to the inner strands. The fused end
must not exceed the diameter of the rope.
3. Once the cuts have been completed, the seizing bands
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are to be left in place.
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FIGURE 1-15
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For detailed information concerning synthetic hoist rope,
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refer to K100 Synthetic Crane Hoist Line Manual, P/N

9828100734, available by contacting Manitowoc Crane
Care.
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THIS PAGE BLANK

RT9150E SERVICE MANUAL HYDRAULIC SYSTEM
SECTION 2
HYDRAULIC SYSTEM
SECTION CONTENTS
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Procedure J - Checking/Setting Raise Boom 2
(Derricking) Pressure. . . . . . . . . . . . . . . . . . . . . . 2-31
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Procedure K - Checking/Setting Counterweight
Raise Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32
Hydraulic System Maintenance Precautions . . . . 2-5
Procedure L - Checking/Setting Counterweight
Label Parts when Disassembling . . . . . . . . . . . . . 2-5 Lower Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32
Hydraulic Fluid Recommendations . . . . . . . . . . . . 2-5 Procedure M - Checking/Setting Counterweight
Draining and Flushing . . . . . . . . . . . . . . . . . . . . . . 2-5 Locking/Unlocking Pressures . . . . . . . . . . . . . . . 2-32
Removing Air from the Hydraulic System . . . . . . . 2-6 Procedure N - Checking/Setting Cab Tilt
Parts Replacement . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Pressures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32
Directional Control Valves. . . . . . . . . . . . . . . . . . . 2-7 Procedure O - Checking/Setting Luffing Jib
Supply Pressure And Return Circuit . . . . . . . . . . 2-9 Pressures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32
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Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Procedure P - Checking/Setting Counterweight
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Pump Distribution . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Pinning Pressure . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
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Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . .
2-12
2-12
Procedure Q - Checking/Setting Slewing
Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
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Procedure R - Checking/Setting Steering
Troubleshooting Aids . . . . . . . . . . . . . . . . . . . . . 2-13
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Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
Troubleshooting Procedures. . . . . . . . . . . . . . . . 2-13 Procedure S - Checking/Setting Service Brake
Filter Maintenance . . . . . . . . . . . . . . . . . . . . . . . 2-14 Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
Fill Cap Breather . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
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Procedure T - Checking Service Brake
Oil Cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 Accumulator Charge Pressures. . . . . . . . . . . . . . 2-34
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 Procedure U - Checking Service Brake
Accumulator Pre-Charge Pressures . . . . . . . . . . 2-34
Hydraulic Pumps . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18 Procedure for Pre-Charging the Service Brake
Accumulators, If Required . . . . . . . . . . . . . . . . . . 2-35
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Procedure V - Checking/Setting the Differential
Pressure Setting Procedures . . . . . . . . . . . . . . . 2-23 Lock Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36
Connecting laptop to Crane Service Junction. . . 2-25
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37
Procedure A - Checking/Setting Piston Pump General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37
Differential and Cut-off Pressures. . . . . . . . . . . . 2-25
Procedure B - For Checking/Setting the Outrigger/Rear Steer/Outrigger Box Pin
Outrigger/Rear Steer/Axle Lockout Pressures . . 2-25 Removal Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40
Procedure C - Checking/Setting Charge Air Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40
Cooler Motor Control Valve - Tier 3 Only . . . . . . 2-28 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40
Superstructure Hydraulic System . . . . . . . . . . . . 2-28 Outrigger Control Manifold. . . . . . . . . . . . . . . . . . 2-44
Procedure D - Checking/Setting Main Hoist Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44
Lower Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . 2-28 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44
Procedure E - Checking/Setting Main Hoist Park Brake/Axle Disconnect valve. . . . . . . . . . . . 2-45
Raise Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45
Procedure F - Checking/Setting Auxiliary Hoist Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45
Lower Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
Axle Oscillation Lockout Valve . . . . . . . . . . . . . . 2-46
Procedure G - Checking/Setting Auxiliary Hoist
Raise Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46
Procedure H - Checking/Setting Telescope Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46
Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30 Pressure Bleed-Off Valve . . . . . . . . . . . . . . . . . . . 2-47
Procedure I - Checking/Setting Control Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47
Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31

HYDRAULIC SYSTEM RT9150E SERVICE MANUAL
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47 Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-68

Main Directional Control Valve . . . . . . . . . . . . . . 2-49 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-68
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-68
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49 Surface Protection For Cylinder Rods . . . . . . . . . 2-68
Swing Directional Control Valve . . . . . . . . . . . . . 2-53 Axle Oscillation Lockout Cylinder . . . . . . . . . . . . 2-70
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-70
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-70
Compact Block Manifold . . . . . . . . . . . . . . . . . . . 2-55 Steer Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-73
Accessory Manifold . . . . . . . . . . . . . . . . . . . . . . . 2-58 Outrigger Extension Cylinder . . . . . . . . . . . . . . . . 2-76
Case Drain Manifold . . . . . . . . . . . . . . . . . . . . . . . 2-60 Outrigger Jack Cylinder . . . . . . . . . . . . . . . . . . . . 2-79
Dual Accumulator Charge Valve . . . . . . . . . . . . . 2-61 Cab Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . 2-82
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-82
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Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-61
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Control Block. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-63
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-63
Power Pin Cylinder . . . . . . . . . . . . . . . . . . . . . . . . 2-85
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-85
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Tandem Brake Valve w/ Treadle Pedal . . . . . . . . 2-64 Counterweight Pin Cylinder . . . . . . . . . . . . . . . . . 2-88
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Hydraulic Accumulator Service Brake . . . . . . . . 2-65 Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-90
Charge Air Cooler (CAC) Motor control Valve . . 2-66 Counterweight Lift Cylinder . . . . . . . . . . . . . . . . . 2-92
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66 Proximity Switches . . . . . . . . . . . . . . . . . . . . . . . . 2-92
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66
DESCRIPTION valves, and all hydraulic cylinders. Detailed descriptions and

operation of individual hydraulic circuits are discussed within
This section describes the hydraulic system, the their individual sections as applicable. A complete hydraulic
components which make up the hydraulic system, and the system schematic showing all options is at the back of this
components dependent upon the hydraulic system for their manual (Figure 2-1) and (Figure 2-2) provides A.N.S.I.
operation. This includes descriptions of the supply pressure Graphical Symbols information for this section.
and return hydraulic circuit, hydraulic pumps, all hydraulic

Description Symbol Description Symbol

Hydraulic Reservoir - Stores, cools, and
Filter - Removes contamination from
cleans machines hydraulic fluid supply.
hydraulic fluid.
1 2
Hydraulic Return Lines - Terminated at (1)
below fluid level (2) above fluid level. Filter with Bypass Valve - Bypass valve 2
allows hydraulic fluid to bypass the filter if
1 the filter becomes clogged.
Hydraulic Pump - (1) fixed displacement Accumulator - Used to either develop flow
(2) variable displacement. 2
or absorb shock.
Check Valve - Creates back pressure.

1
Power Source - Powers hydraulic pump Orifice - In-line fixed restriction.
(1) combustion engine, (2) electric motor. 2
Adjustable Orifice - In-line restriction used
for control device.
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1
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Hydraulic Fluid Cooler - Cools hydraulic
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Hydraulic Motors - (1) unidirectional,
(2) bidirectional.
fluid.
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2
Temperature Switch - Regulates the
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hydraulic fluid temperature.
Pump Disconnect - Disconnects pump

Hydraulic Pressure Switch - Senses
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from power source.
hydraulic pressure to energize electrical
Continuous Line - Supply or return lines. components.
Connecting Lines - Branch lines
Flow Switch - Illuminates indicator light to
connected to main line.
indicate a fault.
Dashed Line - Pilot pressure.
Dotted Line - Case drain or load sense. Relief Valve - Protects system from being
over pressurized.
Chain Line - Enclosure of two or more
functions contained in one unit.
Pressure Reducing Valve - Regulates

Pressure Transducer - Hydraulic/
maximum pressure.
electrical located in lift cylinder circuit for
cranes RCL circuit.
Shuttle Valve - Used to direct maximum
pressure to components.
FIGURE 2-1

Description Symbol Description Symbol
Manually Operated - Valve shifted Single Acting Cylinder - Extended

manually with check to allow flow back to hydraulically and retracted with a spring.
tank.
Double Acting Cylinder - Extended and
retracted hydraulically.
Pneumatic Operated - Valve shifted by Double Acting Telescope Cylinder - Anchored rod pushes
pneumatic device. barrel out when check valve is unseated.
Pilot Operated - Valve shifted by pilot MultiStage Telescope Cylinder - Used in multi-section
pressure. synchronized operations.
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Electric Operated - Valve shifted by Inverted Outrigger Jack - Extends the barrel down to
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electrical energy. raise the crane off the ground.
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Brake Valve - Activates swing brake.

Holding Valve - Keeps boom lift cylinder
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from collapse if hydraulic pressure failure
occurs (i.e. hose rupture).
Open Center Cylinder Spool - Directional
control valve for hydraulic cylinder
function that directs flow back to tank
through the open center when in the Pilot Operated Check Valve (with thermal
neutral position relief) - Requires pilot pressure to unseat
the one way check (nonadjustable).
Open Center Motor Spool - Directional
control valve for hydraulic motor function
that directs flow back to tank through the
open center when in the neutral position. Flow Divider Valve - Regulates flow to a
Allows flow back to tank when the crane is selected circuit.
shut down.
Closed Center Cylinder Spool - Pressure Hoist Brake - Holds load after control is
compensated directional control valve for returned to neutral (spring applied and
hydraulic cylinder which directs flow back hydraulically released).
to tank with an unloader valve cartridge.
Closed Center Motor Spool - Pressure Swing Brake - Spring applied

compensated directional control valve for hydraulically brake holds superstructure
motor with open port for flow back to tank. in place.
Allows flow back to tank when the crane is
shut down.
FIGURE 2-2

MAINTENANCE mounted, install the hoses. Connect both ends of the hose
with all bolts finger tight. Position hoses so they do not rub
Preparation the machine or another hose and has a minimum of bending
and twisting. Tighten bolts in both couplings.
Before maintenance, adjustments and repairs are started on
a crane, the following precautions shall be taken as Due to manufacturing methods, there is a natural curvature
applicable: to a hydraulic hose. The hose should be installed so any
NOTE: Maintenance, adjustments and repairs shall be

bend is with this curvature.
2
done only by designated personnel who are prop- In case of replacement hoses with angled stem reusable
erly trained. Use only Grove supplied parts to repair fittings, the hose curvature must be taken into consideration
the crane. when assembling and positioning the angled stem.
• Place a warning tag in a conspicuous location at the Label Parts when Disassembling
controls stating that the machine requires adjustment or
repair before it can be operated. When removing or disconnecting a group of wires or cables,
tag each one to ensure proper identification during re-
• Park the crane where it will cause the least interference assembly.
with other equipment or operations in the area.
When shims are removed, tie them together and identify
• Place all controls at the off position and set the brakes to them as to location. Keep shims clean and flat until they are
prevent inadvertent motion. reinstalled.
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• Disable all methods used to start the truck's engine.
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Hydraulic Fluid Recommendations
•
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Lower the boom to the ground or otherwise secure
against dropping. For the hydraulic fluid specifications, refer to Lubrication,
page 9-1.
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• Lower the hook block to ground or otherwise secure
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against dropping. Draining and Flushing

• Relieve the hydraulic pressure from all hydraulic circuits If a component has been changed because of a failure that
before loosening or removing hydraulic components.
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might allow metal or abrasive particles to enter the system,
After maintenance, adjustments and repairs have been all systems must be thoroughly checked, drained, and
made, do not return the crane to service until all guards have flushed.
been reinstalled, trapped air removed from the hydraulic NOTE: Improperly disposing of waste can threaten the
system if required, safety devices reactivated, and environment.
maintenance equipment and all warning tags removed.
Handle and dispose of waste according to local,
Hydraulic System Maintenance Precautions state, and federal environmental regulations.
Contaminants in a hydraulic system affect operation and When filling and draining crane components: Do
result in serious damage to the system components. Dirty not pour waste fluids onto the ground, down any
hydraulic systems are a major cause of component failures. drain, or into any source of water. Always drain
waste fluids into leak proof containers that are
If evidence of foreign particles is found in the hydraulic clearly marked with what they contain.
system, flush the system.
Always fill or add fluids with a funnel or a filling
Disassemble and reassemble hydraulic components on a pump. Immediately wipe up any spills.
clean surface.
1. Remove the reservoir drain plug. Allow about three
Clean all metal parts in a nonflammable cleaning fluid. Then minutes after hydraulic fluid stops flowing from the drain
lubricate all components to aid in assembly. port for the side walls to drain.
Inspect all sealing elements (O-rings, gaskets, etc.) when 2. Clean and install the reservoir plug and fill the reservoir
disassembling and assembling the hydraulic system with a 50/50 mixture of fuel oil and clean hydraulic fluid.
components. Installation of new sealing elements is always
recommended. 3. Cycle the crane through all functions several times.
Then return the crane to its stowed position and turn the
When installing metal hydraulic tubes, tighten all bolts finger front and rear wheels to the extreme left. Shut down the
tight. Then, in order, tighten the bolts at the rigid end, the engine.
adjustable end, and the mounting brackets. After tubes are

4. Remove the reservoir drain plug and drain the reservoir. 19. Disconnect the line from port A of the axle lockout valve.
Clean and install the drain plug and fill the reservoir with
20. Using a jack under the rear wheel on one side of the
clean hydraulic fluid.
crane, jack up the wheel to maximum travel.
CAUTION 21. Connect the line to port A of the axle lockout valve and
disconnect the line from Port B.
Hydraulic fluid supply lines must be connected to the
cylinders when flushing the system. 22. Repeat step 19 using the other rear wheel.
23. Connect the line to port B of the axle lockout valve.
NOTE: Draining the various components will be aided by
Energize the axle lockout valve. Replenish the reservoir
connecting a drain line in place of the disconnected
hydraulic fluid level as necessary.
return line.
24. Disconnect the return line from the main hoist motor and
5. Disconnect the return line from the lift cylinder and raise
fully hoist up the wire rope.
the boom to maximum elevation.
25. Connect the return line to the main hoist motor and hoist
6. Connect the cylinder return line and lower the boom to
down the hoist, then hoist up again. Replenish the
its stowed position. Replenish the reservoir hydraulic
reservoir hydraulic fluid level as necessary.
fluid level as required.
26. Repeat Steps 24 and 25 for the auxiliary hoist as
7. Disconnect the return line from an outrigger extension
necessary.
cylinder and fully extend the outrigger.
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27. Disconnect one of the lines from each of the swing
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8. Connect the outrigger return line and retract the
motors and drive the motors in the direction they will go.
necessary.
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outrigger. Replenish the reservoir hydraulic fluid level as
28. Connect the lines to the swing motors, then drive the
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swing motors in the opposite direction until the boom is
9. Repeat Steps 7 and 8 for the remaining outriggers.
centered and forward. Replenish the reservoir hydraulic
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fluid level as necessary.

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DANGER
When draining the outrigger cylinders, always operate DANGER
either both front or both rear cylinders together to prevent
When hydraulic fluids are changed or added, ensure that
twisting the crane.
hydraulic fluids of different manufacturers are of the same
specifications, however, discoloration (milkiness) may
10. Disconnect the return lines from a pair of outrigger jack occur. Mixing incompatible hydraulic fluids may result in
cylinders and activate the cylinders to their maximum improper operation or damage to the machine.
down positions.
11. Connect the return lines and raise the outrigger jack When hydraulic fluids are changed, recheck the reservoir
cylinders to the stowed position. Replenish the reservoir hydraulic fluid level after brief system operation and add
hydraulic fluid level as necessary. hydraulic fluid as required. Ensure the crane is level and in
the travel mode of operation when the hydraulic system is
12. Repeat Steps 10 and 11 for the remaining two outrigger being filled. The system must be filled with all cylinders
cylinders. retracted. Fill the reservoir to the full mark on the reservoir
13. Disconnect the return line from the telescope cylinder sight gauge. After the reservoir is filled, operate all circuits
and fully extend the boom. and recheck the reservoir sight gauge. Add hydraulic fluid as
required.
14. Connect the return line and retract the boom. Replenish
the reservoir hydraulic fluid level as necessary. Removing Air from the Hydraulic System
15. Disconnect the return lines from both front steer Air entering the hydraulic fluid will normally be removed
cylinders and turn the front wheels to the extreme right. automatically by passage of the hydraulic fluid over the
16. Connect the return lines and turn the front wheels to the baffles in the hydraulic reservoir. If a component has been
extreme left and then back to center. Replenish the replaced, the reservoir level is too low, or a leak develops in
reservoir hydraulic fluid level as necessary. the suction lines to the pumps, air can enter the system. If air
becomes entrapped in the hydraulic fluid, it may be
17. Repeat steps 15 and 16 for the rear steering cylinders. detectable in pumps and motor operated components such
18. Raise the crane on outriggers. as the swing mechanisms and hoist(s), because it can cause

these units to become noisy during operation. If noisy overnight. This should allow entrapped air to find its way
operation occurs, first check the level of the hydraulic to the holding valve so that telescoping the boom IN the
reservoir and replenish as necessary. Then inspect for leaks next morning should force the air back to the reservoir.
in the suction lines leading to the pumps. Ensure the boom is first telescoped IN (not OUT) in the
morning. Telescoping OUT may cause air to be forced
Minute leaks may be hard to locate. If a leak is not readily
back into a cylinder.
detectable, use the following way to check for it:
• Seal all normal openings in the hydraulic system and the 2
reservoir. Using a positive means to control the pressure
(like a regulator), pressurize the hydraulic system to 2 to DANGER
4 psi (13.8 to 27.6 kPa) and inspect all joints and fittings Do not attempt to loosen fittings in pressurized lines or
for evidence of leaks. A soap solution applied to the while the hydraulic pumps are in operation.
fittings and joints may also prove helpful in detecting
Extreme care must be used when removing any plugs or
minute leaks while the system is pressurized. Remove
restrictions from a hydraulic system suspected to have
the pressure, repair any leaks found, and reopen any
entrapped air that may be pressurized. Moderate to minor
openings (such as a vent) closed for inspection. Refill
injury may result from pressurized air in a hydraulic
the reservoir after completing any repairs or service.
system.
Operate all hydraulic circuits several times in both
directions.
• Entrapped air may be removed from cylinders having
• This action should return any entrapped air to the wet rods by cycling. On certain cylinders, a plugged port
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reservoir where it can be removed from the hydraulic
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is provided on the rod end to bleed off entrapped air.
fluid by the baffles.
nl c • In the event that air entrapment should persist, bleeding

of air by loosening various clamp and screw type fittings
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may become necessary.
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DANGER • If the above procedures fail to eliminate air entrapment,

Always locate the machine on a firm supporting surface, contact your authorized Grove Distributor.
extend the outriggers and level the machine and position
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the boom over the front to extend the boom at low angles. Parts Replacement
Injury or damage to the machine may result if this caution Parts found damaged or out of tolerance when maintenance
is not followed. is being performed should be replaced. Refer to the Grove
Parts Catalog for proper replacement parts.
• To remove entrapped air from telescope cylinders, lower
the boom to below horizontal and fully telescope the Directional Control Valves
boom in and out several times.
The control valves that control the crane functions are
• If the air is not readily removed, lower the boom to below installed on the left and right side of the turntable.
horizontal, extend the telescope cylinders as far as
practicable, and allow the boom to remain in this position

Inspection equipment should make pressure adjustments when

pressure adjustments are needed.
Inspect the control valves for visible damage, binding spools,
and evidence of leakage. If excessive internal leakage is Visual Inspection of Hoses and Fittings
suspected during operation with a spool in its center position,
it is possible that the area between the spool and working
section bore of the valve body is worn beyond serviceable CAUTION
limits. If this condition exists, the spool and body must be Ensure that hydraulic hoses are depressurized before
replaced as an assembly. loosening the connections.
Valve Leakage 1. Visually inspect hoses and fittings once a month or

Dripping hydraulic fluid indicates some type of external every 250 hours for the following:
leakage. The machine should be removed from service for a. Leaks at hose fitting or in hose
immediate repairs. External leaks sometimes develop at
fittings and seals. Spool seals are susceptible since they are b. Damaged, cut, or abraded cover
subject to wear. Seals may be damaged by temperatures c. Exposed reinforcement
that are too high, or by dirt or paint accumulation on the
spool. Damaged or torn seals must be replaced. d. Kinked, crushed, flattened, or twisted hose
A component functioning at reduced efficiency may indicate e. Hard, stiff, heat cracked, or charred hose
that the control valve for that component is leaking internally. f. Blistered, soft, degraded, or loose cover
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If preliminary check-out reveals that adequate volume is
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being supplied to the affected valve bank, relief valves are g. Cracked, damaged, or badly corroded fittings
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properly adjusted, and the component is not at fault, check
the valve for scored or worn parts. Scoring is a sign of the
h. Fitting slippage on hose
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number one problem in hydraulics - contamination (external i. Other signs of significant deterioration
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contamination by dust or internal contamination by debris If any of the above conditions exist, evaluate hose
from deteriorating components or oxidized hydraulic fluid). assemblies for correction or replacement. For replacement
Scored or severely worn valve components must be of hose assemblies, refer to your Manitowoc Crane Care
er
replaced. Parts Manual.
Check valves in the control valves are designed to permit a 2. At the same service interval, visually inspect all other
flow of hydraulic fluid in one direction only. If a piece of dirt or hydraulic components and valves for the following:
rust has worked its way into the check valve and lodges
between the poppet and seat, it will keep the valve open and a. Leaking Ports
allow a return flow of hydraulic fluid. The remedy is to clean b. Leaking valve sections or manifolds and valves
the valve, but it is also a good idea to follow through and installed into cylinders or onto motors.
ensure the hydraulic system filter is still serviceable.
c. Damaged or missing hose clamps, guard, or
Binding Spools shields.
Some of the most common causes for stiff spool movement d. Excessive dirt and debris around the hose
or jammed spool action are system overheating, excessive assemblies.
pressure, contaminated or deteriorated hydraulic fluid, or
warped mountings. When scorched, deteriorated hydraulic If any of these conditions exist, address them appropriately.
fluid or contamination is the cause, flushing the system and 3. Hydraulic hose assemblies operating in a temperature
replenishing with clean hydraulic fluid may solve the climate zone “C” (Table 2-1) are recommended to be
problem. If the spool bores are badly scored or galled, the replaced after 8000 hours of service life.
valve must be removed for servicing.
4. Hydraulic hose assemblies operating in climate zones
Warping occurs when mounting plates are not level or they “A” and “B” (Table 2-1) with high ambient temperatures,
become distorted from machine damage. As mentioned could see hose service life reduced by 40 to 50%,
previously, the valve can be shimmed level. therefore, it is recommended to replace these hoses
Also, check the valve for rust. Rust or dirt collecting on the after 4000 to 5000 hours of service life.
valves can prevent free movement of the spool, and keep it 5. Hydraulic hose assemblies operating in climate zones
from the true center position. Excessive system pressure “D” and “E” (Table 2-1) cold climates should expect a
can create both internal and external leaks in valves that are degrade of mechanical properties such as elasticity,
otherwise sound. Only qualified technicians using the correct

therefore, it is recommended these hoses be inspected Hydraulic fluid flows through four tubes at the lower rear of
and addressed accordingly. the reservoir to the four hydraulic pumps. Almost all of the
return flow goes through the filter at the top of the reservoir.
Table 2-1 The return line that goes directly into the reservoir (instead of
through the filter) is from the No. 4 port (drain) of the 10-port
Zone Classification
swivel.
Tropical Moist: All months average above 18°C.
A
Latitude: 15° - 25 ° North & South
A magnetized drain plug in the bottom of the reservoir
collects metal particles from the hydraulic fluid if it becomes 2
Dry or Arid: deficient precipitation most of the year. contaminated.
B
Latitude: 20° - 35° North & South
A sight gauge is located on the right side of the reservoir to
Most Mid-Latitude: Temperate with mild winters. indicate hydraulic fluid level.
C
Latitude: 30° - 50° North & South
A filler neck and breather on the top of the reservoir are for
Moist Mid-Latitude: Cold Winters. Latitude: 50° - filling the reservoir and for venting it. The filler neck includes
D
70° North & South a strainer for catching contaminants and gaskets to prevent
Polar: Extremely cold winters and summers. leaking. The breather, which screws onto the filler neck,
E allows air to enter or exhaust from the reservoir. It is most
Latitude: 60° - 75° North and South
important that the breather be kept clean to prevent damage
to the reservoir.
SUPPLY PRESSURE AND RETURN CIRCUIT
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Two large round access covers on the top of the reservoir
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Description provide access for cleaning. The covers are bolted to the top
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The supply pressure and return circuit is made up of several
of the reservoir and have a gasket to prevent leaking. The
access holes can also be used to fill the reservoir after it has
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circuits which route hydraulic fluid from the four hydraulic been completely drained.
pumps to the directional control valves for the individual
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operating circuits. The supply pressure and return circuit The hydraulic fluid filter is located in the reservoir. It bolts to
consists of the reservoir and integral filter, four hydraulic the top of the reservoir. The filter contains a replaceable filter
pumps, a hydraulic fluid cooler, and a ten port hydraulic element. Returning hydraulic fluid flows through the filter
er
swivel. Refer to Hydraulic Pumps in this section for element into the reservoir. Bypass fluid internal to the filter
descriptions and maintenance instructions for each hydraulic also flows to the reservoir.
pump. Refer to Swivels, page 6-16 for description and A gauge on the filter head indicates how restricted (clogged)
maintenance instructions for the ten port hydraulic swivel. the filter element is. When back pressure caused by a dirty
The supply pressure and return circuit uses Ports 2 and 3 for filter element exceeds 25 psi (172 kPa), the filter assembly’s
pump supply and the dual Port 1 for return. Each operating bypass feature functions to allow hydraulic fluid to bypass
circuit’s description and components begin with the circuit’s the filter element and flow into the reservoir through the
directional control valve. bypass valve instead. (Filter changing instructions are in
Filter Maintenance, page 2-14.)
Hydraulic Reservoir and Filter
The reservoir (Figure 2-3), attached to the right side of the
carrier frame, has a total capacity of 198.27 gal (752.2 l) or
172.92 gal (654.5 l) full level. Low level is 162.90 gal (616.6
l). The all-steel reservoir has an internally mounted full-flow
filter and integral baffles that help cool the hydraulic fluid and
prevent hydraulic fluid foaming.

6, 7, 8, 9
2 13
14 6, 7, 8, 9
10
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3, 4, 5
12
1
15
16
11
7519
FIGURE 2-3
Item Description
Item Description 12 Steps
1 Reservoir 13 Return Filter
2 Return Manifold Tube Assembly 14 Breather
3 O-ring 15 Oil Level Gauge
4 Capscrew 16 Oil Bypass Indicator Gauge
5 Lockwasher
Pump Distribution
6 Capscrew
7 Lockwasher Pump No. 1
8 Nut The torque converter drives Pump No. 1.
9 Flatwasher Pump No. 1 supplies the hoist, lift, and telescope directional
control valve. The valve sections control the main hoist,
10 Frame
boom lift, boom telescope, and, when equipped, auxiliary
11 Extension hoist functions. Hydraulic fluid flowing from this valve bank
returns to the reservoir filter.

Pump No. 1 also supplies the counterweight removal, Pump No. 3

counterweight removal pin, boom removal pin, and cab tilt
The torque converter drives Pump No. 3.
functions, and when installed, the luffing jib function.
Pump No. 3 supplies the swing directional control valve.
Pump No. 2
Pump No. 4
The torque converter drives pump No. 2.
The engine drives Pump No. 4.
Hydraulic pump No. 2 supplies the integrated outrigger/ rear
steer valve, the pressure reducing sequence valve and the Pump No. 4 priority port supplies flow to drive the oil cooler
2
steer/brake/load sense accessory manifold. motor. Pump No. 4 secondary port returns oil to the reservoir.
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MAINTENANCE
Troubleshooting
Table 2-2
Symptom Probable Cause Solution
1. No hydraulic fluid flows in a. Low hydraulic fluid level. a. Check system for leaks. Make repairs
systems. as needed. Fill reservoir.
b. Reservoir-to-pump suction b. Clean, repair, or replace lines as

lines broken or restricted. Air necessary. Check lines for security,
en tering at su ction lines . absence of cracks, and proper
Pump not priming. a t t a c h m e n t . Ti g h t e n , r e p a i r, o r
replace parts as necessary.
c. Internal contamination. c. Drain, flush with recommended oil

mixture, then drain and refill system
with recommended hydraulic fluid.
2. Slow response. a. Low hydraulic fluid level. a. Check system for leaks. Make repairs
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as needed. Fill reservoir.
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too high (watery thin oil) or too
b. If too low, warm up system. As
needed, troubleshoot cooler circuit. If
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low (thick sluggish oil). too high, troubleshoot cooler circuit.
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Likely suspects are in-line check

valve and related hydraulic circuits.
c. Faulty pump. c. Repair or replace pump.

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3. Pump noise accompanied a. Low hydraulic fluid level. a. Check system for leaks. Make repairs
by hydraulic fluid foaming as needed. Fill reservoir.
in reservoir.
b. Excessive engine speed. b. Regulate engine speed.
c. Air entering at suction lines. c. Check all lines for security and
proper repair. Tighten, repair, or
replace as needed.
4. Excessive pressure a. System relief valve(s) set too a. Using adequate pressure gauge,
buildup. high. adjust system relief valve(s) as
necessary.
b. Restricted pump-to-control b. Clean, repair, or replace line as

valve supply line. necessary.

5. Specific hydraulic system a. Leak in system. a. Check system for leaks. Make repairs
(lift, hoist, telescope, as needed. Fill reservoir.
swing) not working.
b. Faulty hydraulic remote b. Adjust or replace valve.
control valve.
c. Faulty directional control c. Replace valve.

2
valve.
d. Poorly adjusted control in d. Troubleshoot circuit with schematic.

circuit. Adjust hydraulic component per
schematic.
e. Faulty hydraulic cylinder, e. Replace faulty component.

motor, or valve.
Troubleshooting Aids collapsed or ballooned hoses, leakage around the

hydraulic components, etc.
1. Hydraulic schematics - an exact illustration of the
Second, make an analysis of symptoms. The function of
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arrangement of the system. The schematic shows all the
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components in relation to the system. The ability to each component in the system must be known before a
correct analysis can be made.
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understand the schematic is important to good
troubleshooting. Schematics can be found at the end of Remember:
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this manual.
1. If a problem is common to all circuits, the component
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2. Flowmeter - an instrument that can be connected into which is causing the problem must also be common to
the system to measure the flow of the oil in the system. all circuits. Examples are: the engine, pump, hydraulic
The flow is measured in gallons per minute (gpm) or tank and filters.
er
liters per minute (Lpm). Normally, the flowmeter is used
to check the output of the pump. The flow meter can also 2. If the problem is common to only two or three circuits,
be used to find the location of leakage or restriction in the component which is causing the problem must be
the system. Instructions for installation of the flow meter common to those two or three circuits. Examples are:
and the use of the flowmeter are normally included with pump section, relief valve, hydraulic swivel, etc.
the flowmeter. 3. If a problem is in only one circuit, then the component
3. Pressure Gauge - an instrument for measurement of which is causing the problem must be in that circuit.
the pressure in the system. This indication is normally Examples are: valve section, cylinder, motor.
given in pounds per square inch (psi) or kilo Pascals Again, use the schematic. Find which components are in the
(kPa). On this machine, quick couplers are installed in circuit or circuits. What component can cause the problem
the pressure lines from the pumps. Pressure taken at with these symptoms? Make a list of the possible causes.
these locations will give an indication of operating Start at the source of the flow in that circuit. If the problem is
pressure or relief pressure. in all circuits, start at the pump. Know the direction of oil flow
through each circuit.
Troubleshooting Procedures
Use the flowmeter and pressure gauge to check your
For good troubleshooting, a step by step analysis of the diagnosis of the problem. Start at the source of the flow and
problem and the possible cause is necessary. First, find the check each component in sequence until the exact location
symptoms. of the problem is found.
1. Check with the operator. Learn if there was a loss of If the problem is two or three circuits, check each circuit
power (machine did not move the load) or a loss of separately. After a circuit is checked, use caps or plugs to
speed (slow cycle time). remove that circuit from the system. Continue to next circuit
2. Learn if the problem is common to all circuits or is found down the line until the problem is found.
in one or two circuits. Do not remove the main relief valve from the circuit. The
3. Make a visual inspection. Look for a restriction in the relief valve must be kept in the circuit to inhibit damage to the
linkages, low level of hydraulic fluid, bent tubes, pump and other components.

Filter Maintenance Filter Element Installation
Maintenance Interval 1. Inspect all parts; replace any defective part.
Change filter when the bypass indicator gauge on the filter 2. As desired, install a new gasket around the filter bowl,
head is in the ‘red’. then secure the filter bowl to the hydraulic reservoir with
four bolts and lockwashers. Assemble the filter and
Under normal operating conditions, it is recommended that install it in the reservoir later.
hydraulic filters be inspected and oils sampled at least every
3 to 6 months, or 500 hours, and more frequently for severe 3. Install the new element around the filter tube inside the
operating conditions, refer to Lubrication, page 9-1. filter bowl.
4. Install the bypass valve in the filter tube of the filter bowl.
Filter Element Removal
5. Install a new O-ring in the groove of the head. Install the
head on the filter bowl.
6. Install a new O-ring in its groove on the cap.
CAUTION
7. Place the spring inside the circular spring guide on the
Ensure that all hydraulic systems are shut down and the
top of the bypass valve.
pressure is relieved. Moderate to minor injury may result
when working on a pressurized system. 8. Secure the cap to the filter head with four capscrews and
washers.
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1. Shut down all hydraulic systems.
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9. Screw the gauge into the filter head.
2.
3. nl c
Wipe any dirt from the filter head and cap (Figure 2-4).
Remove the capscrews and lockwashers and
10. If not done earlier, install a new gasket around the filter
bowl. Secure the filter to the hydraulic reservoir with four
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disconnect the return manifold tube from the filter. capscrews and lockwashers.
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Discard O-ring.
11. Install a new O-ring in its groove on the return manifold
4. Remove the bolts and washers and remove the filter tube. Secure the return manifold tube to the filter head
assembly from the reservoir. Discard the gasket. If with four capscrews and lockwashers.
er
necessary, the filter can be disassembled without
12. Activate the hydraulic system and check for leaks. Make
removing the entire filter from the reservoir.
repairs as needed.
5. Remove the capscrews securing the cap to the filter
head. Remove the cap and spring. Take care when Fill Cap Breather
removing the spring as it may be under pressure.
Discard O-ring. Removal and Replacement
6. Unscrew the filter gauge from the filter head.

7. Remove the filter head and discard the O-ring.
CAUTION
8. Remove the bypass valve from the filter tube on the filter
bowl. Ensure that all hydraulic systems are shut down and the
pressure is relieved. Moderate to minor injury may result
9. Remove the filter element. when working on a pressurized system.
10. Ensure the new filter element is correct by comparing Wear eye protection. Hydraulic fluid can blind or severely
their part numbers with the part numbers of the used damage eyes.
filter element.
1. Wipe any dirt from the fill cap breather (Figure 2-3).
11. Discard the used filter element.
2. Unscrew the fill cap breather from the fill neck.
12. If not done earlier, unbolt the filter bowl from the
reservoir. Remove the filter bowl. Discard gasket. 3. Screw the replacement fill cap breather into the fill neck.

8
9
12
2
11
1
6
4
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5
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10
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7518-1
FIGURE 2-4

1 Head 7 O-ring
2 Cap Assembly 8 Capscrew
3 Bowl Assembly 9 Washer
4 Spring 10 Element
5 Bypass Valve Assembly 11 Cap
6 Gauge 12 O-ring

CAUTION CAUTION
Ensure that all hydraulic systems are shut down and the Ensure that all hydraulic systems are shut down and the
pressure is relieved. Moderate to minor injury may result pressure is relieved. Moderate to minor injury may result
when working on a pressurized system. when working on a pressurized system.
Hydraulic Reservoir Removal OIL COOLER

1. Drain reservoir. Tag and disconnect lines from the
reservoir. Cover lines and reservoir fittings to prevent
Description
contamination. An air cooled hydraulic fluid cooler is the right rear portion of
2. Secure reservoir with proper lifting device. the hydraulic/transmission oil cooler (Figure 2-5). The oil
cooler is installed on the right side of the carrier beside the
3. Remove the capscrews, flatwashers, lockwashers and hydraulic reservoir.
nuts securing the reservoir to the frame. Using a suitable
lifting device, remove the reservoir. When the oil temperature reaches 120°F (48.9°C), the oil
cooler solenoid valve is de-energized, via a normally closed
4. Clean reservoir and magnetic plug. Service filter temperature switch, to allow pressurized oil from pump No. 4
assembly. Then reinstall plug and filter assembly.
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to the oil cooler motor which drives the oil cooler fan.
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Hydraulic Reservoir Installation The oil cooler fan pulls cool air through the cooling fins on the
1. nl c
Using a suitable lifting device, place the reservoir on the
cooler. Normally, most hydraulic fluid from components is
routed through the oil cooler by way of a return line and on to
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frame. Secure reservoir with the capscrews, the filter in the reservoir. When several hydraulic functions
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flatwashers, lockwashers and nuts. Torque capscrews to are being used at one time (i.e., hoisting, lifting, and
recommended torque. telescoping), more oil has to flow through this return line,
causing a pressure buildup. When this pressure reaches 65
2. Attach lines to reservoir.
er
psi (448 kPa), the normally closed check valve in the return
3. Fill reservoir; verify there is no leakage. line (in parallel with the return line through the hydraulic fluid
cooler) will open, letting some hydraulic fluid bypass the
hydraulic fluid cooler and flow directly into the reservoir filter.
When fewer functions are being used, the pressure in the
system will decrease below 45 psi (310 kPa) and the check
valve will close again.

1
2
8
5
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Air Flow
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6
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4
7308
FIGURE 2-5

1 Hydraulic Fluid Cooler 5 Finger Guard
2 Transmission Oil Cooler 6 Outlet Port
3 Fan Shroud 7 Motor
4 Fan 8 External Drain

HYDRAULIC PUMPS 1. Remove hardware as needed to gain access to the

pump. The pump is bolted to the engine’s torque
Description converter.
NOTE: Refer to (Figure 2-6) for pump locations. 2. Tag and disconnect the supply line from the pump. Cap
or plug the line and port.
Pumps No. 1, 2 and 3 are mounted on drive pads of the
torque converter. Pump No. 4 is mounted on a drive pad of 3. Tag and disconnect the pump distribution lines from the
the engine. pump. Cap or plug the lines and ports.
The purpose of these pumps is to convert mechanical

energy into fluid energy for the operation of the crane’s CAUTION
hydraulic components. Keep the pump as level as possible to avoid damaging
Pump No. 1 the input spline.
Pump no. 1 is a piston pump with a displacement of 6.71 in3/ 4. Remove the capscrews, washers and gasket attaching
rev (110 cm3/rev) and a cut-off pressure of 4640 psi (31992 the pump to the drive pad on the torque converter.
kPa). Remove the pump.
5. Clean the gasket material from the drive pad of the
Pump No. 2
torque converter and from the pump.
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Pump No. 2 is a piston pump with a displacement of 4.88 in3/ 6. Cover the drive pad’s opening to prevent dirt from
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rev (80 cm3/rev) and a cut-off pressure of 4640 psi (31992 entering.
kPa).
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Pump No. 3
1. Clean the pump and the torque converter drive pad with
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Pump No. 3 is a gear pump with a displacement of 1.77 in3/ Loctite cleaning solvent 7070 or similar non chlorinated
rev (29 cm3/rev) section with a theoretical flow of 16.9 gpm solvent.
(64 l/min) at 2512 rpm. 2. Apply a light coating of Loctite primer N7649 to pump
er
and drive pad. Allow primer to dry for one to two
Pump No. 4 minutes. Primer must be dry. Mating of parts should
Pump No. 4 is a gear pump with a displacement of 1.77 in3/ occur within five minutes.
rev (29 cm3/rev) pump with a theoretical flow of 18.3 gpm 3. Apply gasket material Loctite Master Gasket 518 to
(69.3 l/min) at 2712 rpm. pump and drive pad mounting surfaces. (This material
partially cures in 4 hours and fully cures in 48 hours.)
Maintenance
4. Install pump and gasket on drive pad with capscrews
Pump No. 1 Removal and washers. Make sure the splines mesh properly.
5. Torque capscrews to recommended torque.
CAUTION 6. Connect the distribution and supply lines to the pump as

tagged during removal. On lines that use them, discard
Absolute cleanliness is essential when working on the
any old O-ring and install a new O-ring in its place.
hydraulic pumps. The presence of dirt and foreign
materials in the system can result in serious damage or
inadequate operation.

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4 3
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1
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9090
FIGURE 2-6

1 Hydraulic Pump No. 1 4 Hydraulic Pump No. 4
2 Hydraulic Pump No. 2 5 Engine
3 Hydraulic Pump No. 3

Pump No. 2 Removal No. 3 Pump Removal
CAUTION CAUTION
Absolute cleanliness is essential when working on the Absolute cleanliness is essential when working on the
hydraulic pumps. The presence of dirt and foreign hydraulic pumps. The presence of dirt and foreign
materials in the system can result in serious damage or materials in the system can result in serious damage or
inadequate operation. inadequate operation.
1. Remove hardware as needed to gain access to the 1. Remove hardware as needed to gain access to the
pump. The pump is bolted to the engine’s torque pump. The pump is bolted to the engine’s torque
converter. converter.
2. Tag and disconnect the supply line from the pump. Cap 2. Tag and disconnect the supply line from the pump. Cap
or plug the line and port. or plug the line and port.
3. Tag and disconnect the pump distribution lines from the 3. Tag and disconnect the pump distribution lines from the
pump. Cap or plug the lines and ports. pump. Cap or plug the lines and ports.
4. Remove attaching hardware to free pump disconnect
linkage from torque converter pump disconnect shaft.
CAUTION
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Keep the pump as level as possible to avoid damaging
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the input spline. CAUTION
4. nl c
Remove the capscrews, washers and gasket attaching
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the input spline.
the pump to the drive pad on the torque converter.
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Remove the pump.

5. Remove the capscrews and washers attaching the
5. Clean the gasket material from the drive pad of the pump to the drive pad on the torque converter. Remove
drive-through charge pump and from the pump. the pump.
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6. Cover the drive pad’s opening to prevent dirt from 6. Clean the gasket material from the drive pad of the
entering. torque converter and from the pump.
Pump No. 2 Installation 7. Cover the drive pad’s opening to prevent dirt from
entering.
1. Clean the pump and the drive pad of the drive-through
charge pump with Loctite cleaning solvent 7070 or No. 3 Pump Installation
similar non chlorinated solvent.
1. Clean the pump and the torque converter drive pad with
2. Apply a light coating of Loctite primer N7649 to pump Loctite cleaning solvent 7070 or similar non chlorinated
and drive-through charge pump drive pad. Allow primer solvent.
to dry for one to two minutes. Primer must be dry. Mating
2. Apply a light coating of Loctite primer N7649 to pump
of parts should occur within five minutes.
and drive pad. Allow primer to dry for one to two
3. Apply gasket material Loctite Master Gasket 518 to minutes. Primer must be dry. Mating of parts should
pump and drive pad mounting surfaces. (This material occur within five minutes.
partially cures in 4 hours and fully cures in 48 hours.)
3. Apply gasket material Loctite Master Gasket 518 to
4. Install pump and gasket on drive pad with capscrews pump and drive pad mounting surfaces. (This material
and washers. Make sure the splines mesh properly. partially cures in 4 hours and fully cures in 48 hours.)
5. Torque capscrews to recommended torque. 4. Install pump and gasket on drive pad with capscrews
and washers. Make sure the splines mesh properly.
6. Connect the distribution and supply lines to the pump as
tagged during removal. On lines that use them, discard 5. Torque capscrews to recommended torque.
6. Connect the distribution and supply lines to the pump as
tagged during removal. On lines that use them, discard

No. 4 Pump Removal 3. Apply a light coating of Loctite Master Gasket 518 to
both surfaces of the gasket. Do not coat either side of
the rubber/steel gasket or the facing sides of the parts
CAUTION that will touch it. (This material partially cures in 4 hours
Absolute cleanliness is essential when working on the and fully cures in 48 hours.)
hydraulic pumps. The presence of dirt and foreign 4. Install pump and gasket on drive pad with capscrews
materials in the system can result in serious damage or
inadequate operation.
and washers. Make sure the splines mesh properly.
2
5. Torque capscrews to recommended torque.
1. Remove hardware as needed to gain access to the 6. Connect the distribution and supply lines to the pump as
pump. The pump is bolted to the engine. tagged during removal. On lines that use them, discard
2. Tag and disconnect the supply line from the pump. Cap any old O-ring and install a new O-ring in its place.
or plug the line and port.
3. Tag and disconnect the pump distribution lines from the CAUTION
pump. Cap or plug the lines and ports. Do not feed hot hydraulic fluid into a cold pump. This may
cause the pump to seize.
CAUTION Piston Pump Start-up Procedure
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the input spline.
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CAUTION
4.
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Remove the capscrews and washers attaching the
pump to the drive pad of the engine. Remove the pump.
Do not feed hot hydraulic fluid into a cold pump. This may
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cause the pump to seize.
R F
5. Cover the drive pad’s opening to prevent dirt from

entering. 1. Ensure the reservoir is filled with the proper hydraulic
fluid to the high level mark on the reservoir sight gauge.
No. 4 Pump Installation
er
2. Ensure no air is entering the pump inlet, and that the
1. Clean the pump and the engine drive pad with Loctite pump suction or inlet fluid is not bleeding back to the
cleaning solvent 7070 or similar non chlorinated solvent. reservoir when the engine is stopped, by making sure all
Likewise clean both surfaces of the new rubber/steel suction or inlet lines are air tight.
gasket, the spacer, and the new vellomoid gasket.
3. Remove the case drain hose and adapter from the “DR”
2. Apply a light coating of Loctite primer N7649 to Pump port (Figure 2-7) on both pumps and fill the housing with
No. 4’s mounting surface, but do not apply any to the the same hydraulic fluid that was used to fill the
engine’s drive pad. hydraulic reservoir to the bottom of the o-ring case drain
port. Re-install the case drain adapter and hose running
to the hydraulic reservoir.

Pump Case Drain

Hose to Reservoir
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FIGURE 2-7
4.
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Start the engine and idle it for two or three minutes 7. If the pump seems to be running properly, increase the
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without running any hydraulic functions. Check for leaks; RPM to 1500 to 1800 rpm for one to two minutes while
R F
as needed, stop the engine and make repairs. operating no hydraulic functions. Repeat checks in steps
4, 5, and 6.
5. Place your hand on the pump to check for excessive
heat buildup caused by binding or other problems. If the 8. Increase engine speed in steps to full RPM. Repeat
er
pump is too hot to keep a hand on, stop the engine. checks in steps 4, 5, and 6.
6. Listen for abnormal noises indicating low hydraulic fluid 9. Cycle the components the pump sections power to verify
level or internal pump problems. If the pump is making the pump sections drive them properly. Verify there is no
excessive noise, it is probably sucking air into its inlet, leaking.
keeping it from priming. In case of abnormal noise, stop
10. Check pressure settings. Refer to Pressure Setting
engine, and inspect the pump and the suction line for a
Procedures in this section.
loose connection, a leak, or a damaged or missing O-
ring.

PRESSURE SETTING PROCEDURES NOTE: When checking the directional control valve relief
settings, unless otherwise specified, start with the
The following procedures should be used to properly check, engine at idle RPM and move the controller to its
adjust and set the hydraulic system pressures. fully stroked position. Then slowly accelerate the
The following equipment is required for checking the engine to the specified RPM. Read gauge and
hydraulic pressure settings. make adjustments to specified setting.
• Three dial pressure gauge, 0-5000 psi The number after G (gauge port) corresponds to
the gauge port number on the hydraulic system 2
• Pressure check diagnostic quick disconnect - Grove P/N schematic (G1 through G3).
9999101806 and straight adapter fitting 7447040401
All valve settings can be obtained by adjusting the
• ORFS reducers as required to attach work port hoses to valve “in” to increase or “out” to decrease the
the gauge. pressure accordingly.
Table 2-3
Valve Pressure Setting Table
Pressure Gauge Port (GPX) and Adjustment

Tolerance
Valve To Be Set Setting Location (MCV - Main Control Valve)
PSI (bar)
PSI (bar) (CCV - Compact Control Valve
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NOTE: Reservoir oil temperature to be approximately 120 to 140° F (49 to 60° C)
Pressure nl c
Outrigger/Rear Steer/Axle Lockout
3000 (207) ± 50 (4)
G - Carrier mounted outrigger/rear
steer control manifold (Figure 2-11)
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Outrigger Beam Extend Pressure G - Carrier mounted outrigger/rear
R F
2000 (138) ± 50 (4)

steer control manifold (Figure 2-11)
Piston Pump # 1 Differential Pressure G1 - Carrier mounted outrigger/rear
er
(Delta P) 350 (24) ± 25 (2) steer control manifold (Figure 2-10)
and (Figure 2-11)
Piston Pump # 2 Differential Pressure G1 - Carrier mounted outrigger/rear
(Delta P) 375 (26) ± 25 (2) steer control manifold (Figure 2-10)
and (Figure 2-11)
Steer Pressure Setting GPS Superstructure mounted
2500 (172) ± 50 (4)
accessory manifold (Figure 2-26)
Control Pressure 508 (35) ± 25 (2) MSt Adjust at DM MCV (Figure 2-23)
Main Hoist Raise Pressure MA3 MCV Adjust at D3 MCV
4351 (300) ± 50 (4)
(Figure 2-16) and (Figure 2-18)
Main Hoist Lower Pressure MB3 MCV Adjust at D6
1740 (120) ± 50 (4)
MCV(Figure 2-16) and (Figure 2-18)
Auxiliary Hoist Raise Pressure MA1 on MCV control valve. Adjust at
4351 (300) +50 (4) D1 on the auxiliary hoist control valve
Auxiliary Hoist Lower Pressure MB1 on MCV Adjust at D4 on the
1740 (120) ± 50 (4) auxiliary hoist control valve
Telescope Pressure Setting MB2 MCV. Adjust at D2 on MCV
3040 (210) ± 50 (4)
(Figure 2-18)
Telescope Pinning Pressure MA6 on MCV Adjust at DBV (telescope
1450 (100) +25 (2)
locking) (Figure 2-21)
Lift Raise Pressure MA1 MCV. Adjust at D1on MCV
4351 (300) ± 50 (4)
(Figure 2-16)

Pressure Gauge Port (GPX) and Adjustment

Tolerance
Valve To Be Set Setting Location (MCV - Main Control Valve)
PSI (bar)
PSI (bar) (CCV - Compact Control Valve
Counterweight Raise Pressure MP CCV. Adjust at DBV
4351 (300) ± 50 (4) (counterweight raise) on CCV
Counterweight Lower Pressure MLs CCV. Adjust at DBV
1523 (105) ±25 (2) (counterweight lower) on CCV
Counterweight Lock Pressure MLs CCV. Adjust at DBV
2393 (165) ± 50 (4) (counterweight lock) on CCV
Counterweight Unlock Pressure MLs CCV. Adjust at DBV
2393 (165) ± 50 (4) (counterweight unlock) on CCV
Cab Lower Pressure MLs CCV. Adjust at DBV (cab lower)
798 (55) ± 25 (2) on CCV (Figure 2-20) and
(Figure 2-22)
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Cab Raise Pressure MLs CCV. Adjust at DBV (cab raise) on
1378 (95) ± 25 (2)
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Luffing Boom Extension Lower Pressure
CCV (Figure 2-20) and (Figure 2-21)
MLs CCV. Adjust at DBV (luffing jib
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4134 (285) ±50 (4) lower) on CCV (Figure 2-20) and
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(Figure 2-22)
Luffing Boom Extension Raise Pressure MLs CCV. Adjust at DBV (luffing jib
4134 (285) ±50 (4) raise) on CCV (Figure 2-20) and
er
(Figure 2-21)
Swing Pressure MP Swing control valve. Adjust at
3988 (275) +50 (4) Slewing relief on swing control valve
(Figure 2-24)
Counterweight Pin Pressure MLs CCV. Adjust at DBV
1378 (95) ± 25 (2) (counterweight un-pin) on CCV
Counterweight Un-pin Pressure MLs CCV. Adjust at DBV
1378 (95) ± 25 (2) (counterweight pin) on CCV
Service Brake Pressure GPB Superstructure mounted
3000 (207) ± 50 (4)
accessory manifold (Figure 2-26)
Service Brake High Charge Limit GPB Superstructure mounted
+72, -145
2490 (172) accessory manifold non-adjustable
(5), (10)
(Figure 2-26)
Service Brake Low Charge Limit GPB Superstructure mounted
2100 (145) ± 145 (10) accessory manifold non-adjustable
(Figure 2-26)
Service Brake Accumulator Pre-Charge
1400 (97) ± 100 (7) Accumulator (Figure 2-27)
Pressure
Differential Lock Pressure G Carrier mounted Axle Differential
100 (7) ±20 (1.5)
Lock Valve (Figure 2-28)
Charge Air Cooler Relief Pressure - Tier Carrier mounted Charge Air Cooler
1700 (117) ±50 (4)
3 engine only Motor Control Valve (Figure 2-15)

Connecting laptop to Crane Service Procedure A - Checking/Setting Piston

Junction Pump Differential and Cut-off Pressures
W h e n c o n n e c ti n g l a p t op t o th e s e r v i c e j u n c ti o n i n 1. Install pressure check diagnostic quick disconnect with
superstructure, refer to (Figure 2-8) and (Figure 2-9). gauge onto the test fitting at the G1 port of the integrated
outrigger/rear steer/axle lockout manifold (Figure 2-11).
2. Assure piston pump “cut-off” max (Figure 2-10) factory
setting is correct. Loosen the jam nut on the “cut-off” 2
max adjusting screw and turn it “in” until it softly seats or
bottoms out. Back the adjusting screw “out” 2 turns and
lock in place with jam nut. This will ensure that full
system pressure of 4351 psi (300 bar) can be obtained.
3. Assure piston pump delta P (stand-by) factory setting is
correct. With diagnostic quick disconnect still installed @
the G1 port of the integrated outrigger/rear steer/axle
lockout manifold (Figure 2-11), start engine and @ idle
RPM adjust the piston pump #1 differential setting screw
“in” to increase or out to decrease so that a gauge
reading of 375 ±25 psi (26 ±2 bar) is achieved
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(Figure 2-10).
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7490-1
4. Stop engine. Remove the diagnostic coupler.
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Connect switch box (junction RS232) and laptop
with a 9-pole cable. Set the rotary RS232 switch
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to position 3 + 4.
Pump Cut-off Max Pump Delta P (Stand-by)
FIGURE 2-8
R F
Setting Adjustment Adjustment

er
7490-3
FIGURE 2-10
7490-2
Connect switch box Connect switch Connect switch
(junction RS232) and box to the ESX- box to the ESX- Procedure B - For Checking/Setting the
D1 junction D2 junction
laptop with a 9-pole Outrigger/Rear Steer/Axle Lockout
cable. Set the rotary
RS232 switch to Pressures
position 3 + 4. FIGURE 2-9 1. Install a pressure check diagnostic quick disconnect with
gauge onto test fitting at the G port of the outrigger
NOTE: Procedures A through M in the following text
control manifold (Figure 2-11).
correlate with (Figure 2-10) through (Figure 2-27).

Pressure
Reducing
Valve
G Port
G1 Port
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7490-4
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FIGURE 2-11
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2. Start engine and select and hold the outrigger “retract” sense pressure so that a gauge pressure of 2000 ±50
R F
and an outrigger “jack” or “beam” switch on the psi (138 ±4 bar) is achieved. Increasing the l-min value
superstructure controls. Raise engine speed to full RPM. increases the pressure. The l-max value should not be
Adjust the pressure reducing valve for pressure beyond changed.
er
in the outrigger control manifold “in” to increase or “out”
4. Stop engine. Remove the diagnostic coupler.
to decrease so that the gauge pressure of 3000 ±50 psi
(207 ±4 bar) is achieved (Figure 2-11). • Once connected to the service junction, turn on the
laptop and select the RT9150E service software icon
3. Select the outrigger “extend” and an outrigger “beam”
(Figure 2-12).
switch on the superstructure controls. Fully extend and
hold. Adjust the electric relief valve using the service • Select “OK” once connected to the ESX 3.
software (Figure 2-12) through (Figure 2-14) to limit load
7490-5 FIGURE 2-12

7490-6 FIGURE 2-13
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• Under the Drive Units menu, select “Outriggers” • Adjust the “l-min” value accordingly and click “set”, then
• nl c
(Figure 2-13).
Click on the 2-stage relief solenoid symbol (956 to open •
“exit”. Repeat until the correct pressure is obtained.
Exit “outriggers” menu when finished.
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the parameters menu.
R F
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7490-7
FIGURE 2-14

Procedure C - Checking/Setting Charge Air - Brake release lines of the slewing gear brake
Cooler Motor Control Valve - Tier 3 Only - Brake release lines of the hoist brake
1. Install pressure check diagnostic quick disconnect • The following pressure values are read on the pressure
(Parker PD240) with gauge onto test nipple at the G port gauge. For measuring points indicted (M...), refer to the
(A) of the Charge Air Cooler Motor Control Valve hydraulic schematic.
(Figure 2-15).
• The hydraulic fluid temperature should be approximately
2. With engine at full RPM, remove control solenoid coil (C) 86 - 104°F (30 - 40° C) during adjustments.
from Charge Air Cooler Control Valve to turn cooler on.
Adjust relief valve (B) “in” to increase or “out” to • The following pressures do not have to be checked”
decrease so that a gauge reading of 1700 ±50 PSI
(117 ±4 bar) is obtained. 5221 psi
DBV1 Primary pressure control valve
(360 bar)
3. Stop engine, remove pressure gauge and re-install
solenoid coil. 653 psi
DV2 Control pressure
(45 bar)
A C D4 Derricking out, not in service
• The pressure values which are read at measuring point
MLs (Figure 2-20) of the compact control valve must be
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73 psi (5 bar) higher than the values indicated on the
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circuit diagram. The function speeds must be present.
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The set pressure changes with the volume adjustment.
All valve settings can be obtained by adjusting the valve
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B
“in” to increase or “out” to decrease the pressure.
R F
Procedure D - Checking/Setting Main Hoist

Lower Pressure
er
1. Install a pressure check diagnostic quick disconnect with
gauge onto test nipple @ the MB3 port of the main
directional control valve (Figure 2-16).
2. Remove solenoid coils Y1104/Y1105 from main hoist
FIGURE 2-15 brake control block (Figure 2-17). Start engine and lower
hoist at average engine speed.
Superstructure Hydraulic System 3. If necessary, adjust pressure at D6 (Figure 2-18) to 1740
• It is absolutely essential that the hydraulic system is ±50 psi (120 ±4 bar).
carefully bled to ensure that the superstructure 4. Stop engine. Reassembly solenoid coils Y1104/Y1105
hydraulics operate correctly. This applies in particular to and remove the diagnostic coupler.
the following control circuits;

D4 D1
(Aux Hoist) (Aux Hoist)
2
MA2
D1
MA1
MA3
MB3
MB2
D2 D6 D3
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MB1
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Main Directional Control Valve (Rear)
FIGURE 2-18
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Raise Pressure
R F
Main Directional Control Valve 7490-8

FIGURE 2-16 1. Install a pressure check diagnostic quick disconnect with
gauge onto test nipple @ the MA3 port of the main
er
2. Remove solenoid coils Y1104/Y1105 from main hoist
Coil Y1104 (Main Hoist) brake control block (Figure 2-17). Start engine and raise
Coil Y1204 (Aux hoist) hoist at average engine speed.
3. If necessary, adjust pressure at D3 (Figure 2-18) to 4351
±50 psi (300 ±4 bar).
4. Stop engine. Reassemble solenoid coils Y1104/Y1105
and remove the diagnostic coupler.
Procedure F - Checking/Setting Auxiliary

Hoist Lower Pressure
gauge onto test nipple @ the MB1(Aux Hoist) port of the
main directional control valve (Figure 2-19).
2. Remove solenoid coils Y1204/Y1205 from aux hoist
brake control block (Figure 2-17). Start engine and lower
3. If necessary, adjust pressure at D4 (Aux Hoist)
(Figure 2-18) to 1740 ±50 psi (120 ±4 bar).
Coil Y1105 (Main Hoist) Coil 7490-9
Coil Y1205 (Aux Hoist) Coil
Hoist Brake Control Block FIGURE 2-17

Procedure G - Checking/Setting Auxiliary 6. Adjust the pressure at D2 on the main directional control
Hoist Raise Pressure valve (Figure 2-18) to 2901 ±50 psi (200 ±4 bar).
7. Carefully extend the telescoping cylinder in the locking
pin hole.
8. Connect pressure gauge to MA6 on the compact control
valve (Figure 2-20).
9. Carefully retract the telescoping cylinder again in the
MA1 locking pin hole.
(Aux Hoist)
10. Create a pressure build-up by activating the boom
section unlocking device. This process can be repeated
by activating the boom section locking device and then
the boom section unlocking device. The pressure build-
MB1 up only occurs for a few seconds.
(Aux Hoist) 11. Adjust the pressure at DBV (telescope locking) on the
compact control valve (Figure 2-21) to 1450 ±25 psi (100
±2 bar).
12. If an adjustment has been made with the aid of
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emergency operation, turn engine off and restart. Re-
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enter the current telescope status in ECOs.
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Main Directional Control Valve (Aux Hoist) 7490-11
13. The pressurizing valve Y2115 can only be adjusted via
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FIGURE 2-19 the service software.
R F
14. If the pressure cannot be adjusted to greater than

approximately 2175 psi (150 bar), valve Y2115 is not
gauge onto test nipple @ the MA1(Aux Hoist) port of the
energized. In this case, there is an error in the control
main directional control valve (Figure 2-19).
er
system.
2. Remove solenoid coils Y1204/Y1205 from auxiliary hoist
brake control block (Figure 2-17). Start engine and raise MLs
MA6 MP
3. If necessary, adjust pressure at D1 (Aux Hoist)
(Figure 2-18) to 4351 ±50 psi (300 ±4 bar).
Procedure H - Checking/Setting Telescope

Pressure
1. A laptop with the service software is required to adjust
the pressures of the telescoping gear.
2. Connect pressure gauge to MA2 and MB2 on the main
3. Start engine and lock telescope section 1 at 50%.
4. In the service software, select the menu item to adjust
Compact Control Valve 7490-12
the pressure or go into emergency operation.
FIGURE 2-20
5. Retract telescoping gear in the locked condition.

Procedure I - Checking/Setting Control

DBV (Cab Raise DBV (Counterweight Un-Pin)
Pressure
MSt DM
DBV DBV DBV 7490-13

(Counterweight (Luffing Jib (Telescope
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Lock) Raise) Locking)
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nl cCompact Control Valve (Top)
FIGURE 2-21
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DBV (Counterweight Pin) DBV (Cab Lower)
R F
Main Directional Control Valve 7490-15
FIGURE 2-23
er
gauge onto test fitting at the MSt port of the main
2. Start engine and activate a function (pump pressure
greater then 725 psi (50 bar)) at average engine speed.
3. If necessary, adjust pressure at DM to 508 ±25 psi (35
±2 bar) (Figure 2-23).
4. Stop engine and remove the diagnostic coupler.
Procedure J - Checking/Setting Raise Boom

DBV DBV DBV 7490-14
(Derricking) Pressure
(Luffing Jib (Counterweight (Counterweight 1. Install a pressure check diagnostic quick disconnect with
Lower) Unlock) Lower) gauge onto test fitting at the MA1 port of the main
Compact Control Valve (Bottom)
FIGURE 2-22 2. Start engine and lift up (derrick in) against the stop at
average engine speed. During this, slightly move the
control lever and hold.
3. If necessary, adjust pressure at D1 to 4351 ±50 psi (300
±4 bar) (Figure 2-16).

Procedure K - Checking/Setting 3. Start engine and completely lower the counterweight

Counterweight Raise Pressure and, if necessary, lay down counterweight, ensure that
locking device is running freely.
4. Activate “Unlock Counterweight”.
gauge onto test fitting at the MP port of the compact
control valve (Figure 2-20). 5. If necessary, adjust pressure at DBV (counterweight
unlock) to 2393 ±50 psi (165 ±4 bar) (Figure 2-22).
2. Start engine and lift up (derrick in) against the stop at
average engine speed. During this, only move the 6. Activate “Lock Counterweight”.
control lever slightly and hold.
7. If necessary, adjust pressure at DBV (counterweight
3. If necessary, adjust pressure at the pressure reducing lock) to 2393 ±50 psi (165 ±4 bar) (Figure 2-21).
valve DM to 4351 ±50 psi (300 ±4 bar) (Figure 2-24).
8. Raise counterweight up against the stop.
Procedure L - Checking/Setting
Procedure N - Checking/Setting Cab Tilt
Counterweight Lower Pressure
Pressures
gauge onto test fitting at the MLs port of the compact 1. Install a pressure check diagnostic quick disconnect with
control valve (Figure 2-20). gauge onto test fitting at the MLs port of the compact
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control valve (Figure 2-20).
ef or
2. Start engine and lower the counterweight cylinders
2. Start engine and lower the cab against the stop at
3. nl c
against the stop at average engine speed and hold.
If necessary, adjust pressure at DBV (counterweight
average engine speed and hold.
O en
lower) to 1523 ±25 psi (105 ±2 bar) (Figure 2-22). 3. If necessary, adjust pressure at DBV (cab lower) to 798
R F
±25 psi (55 ±2 bar) (Figure 2-22).

4. Raise the cab against the stop at average engine speed
and hold.
er
5. If necessary, adjust pressure at DBV (cab raise) to 1378
±25 psi (95 ±2 bar) (Figure 2-21).
Procedure O - Checking/Setting Luffing Jib

Pressures
gauge onto test fitting at the MLs port of the compact
2. Start engine and lower the luffing jib against the stop at
3. If necessary, adjust pressure at DBV (luffing jib lower) to
7490-16 4134 ±50 psi (285 ±4 bar) (Figure 2-22).
DM
Compact Control Valve FIGURE 2-24 4. Raise the luffing jib against the stop at average engine
speed and hold.
Procedure M - Checking/Setting 5. If necessary, adjust pressure at DBV (luffing jib raise) to
Counterweight Locking/Unlocking 4134 ±50 psi (285 ±4 bar)(Figure 2-21).
Pressures 6. Stop engine and remove the diagnostic coupler.
1. Check the speed setting.

Procedure P - Checking/Setting Procedure R - Checking/Setting Steering

Counterweight Pinning Pressure Pressure
control valve (Figure 2-20). 3
2. Start engine and activate “Counterweight Pin” at
1 2
3. If necessary, adjust pressure at DBV (counterweight pin)
to 1378 ±25 psi (95 ±2 bar) (Figure 2-22)
4
4. Activate “Counterweight un-pin” at average engine 2
speed and hold.
5. If necessary, adjust pressure at DBV (counterweight un-
pin) to 1378 ±25 psi (95 ±2 bar) (Figure 2-21). 7490-18

Accessory Manifold FIGURE 2-26
Procedure Q - Checking/Setting Slewing
Pressure
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Item Description
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gauge onto test fitting at the MDr port of the slewing
1
2
Gauge Port B (GPB)
Gauge Port S (GPS)
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R F
2. Start engine and activate slewing gear brake, swing 3 Brake Pressure Reducing Valve
against the brake and hold.
4 Steering Relief Valve
3. If necessary, adjust pressure at DBV (slewing) to 3989
er
±50 psi (275 ±4 bar) (Figure 2-25).
gauge onto test fitting at the GPS port of the accessory
4. Stop engine and remove the diagnostic coupler. manifold (Figure 2-26).
DM (slewing) 2. Start engine, steer completely left or right at average
MDr
engine speed and hold.
3. If necessary, adjust pressure at the steering relief valve
to 2500 ±50 psi (172 ±4 bar) (Figure 2-26).
Procedure S - Checking/Setting Service

Brake Pressure
gauge onto test fitting at the GPB port of the accessory
manifold (Figure 2-26).
2. Start engine and lift up (derrick in) against the stop at
average engine speed. During this, only move the
control lever slightly and hold.
3. If necessary, adjust pressure at the brake pressure
reducing valve to 3000 ±50 psi (207 ±4 bar)
7490-17
Slewing Control Valve (Figure 2-26).
FIGURE 2-25

Procedure T - Checking Service Brake Procedure U - Checking Service Brake

Accumulator Charge Pressures Accumulator Pre-Charge Pressures
1. With engine off, discharge all of the pressurized fluid 1. With the engine off, discharge all of the pressurized oil
stored in the accumulators by depressing the service stored in the accumulators by depressing the service
brake pedal on the cab floor 8-10 times. brake pedal on the cab floor 4 – 6 times. Remove the
gas valve guard and cap on the accumulator
(Figure 2-27).
gauge onto test fitting at GPB port of the accessory
manifold (Figure 2-26). 2. Before attaching the gas charging assembly
(Figure 2-27) onto the gas valve, back out the gas chuck
3. Start engine and idle. The charging valve will
“T” handle all the way out (counterclockwise).
immediately start to charge the accumulators. Watch the
pressure gauge, the high charge limit should read 2320 3. Close the charging assembly bleed valve. Attach the
+72, -145 psi (160 +5,-10 bar)—when the pressure swivel nut onto the gas valve and tighten (10-15 lb-in).
stops rising.
4. Turn the gas chuck “T” handle all the way down
NOTE: This accumulator charge valve is non-adjustable. (clockwise) which will depress the core in the gas valve.
4. With the engine still at idle, repeatedly depress the 5. Check the pre-charge pressure. The gauge should read
service brake pedal on the cab floor until the gauge 1400 ±100 PSI (97 ±7 bar).
pressure reads approximately 2100 psi (145 bar). Once
6. If the pressure is within the specified tolerance, remove
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you have found this pressure, push the brake pedal 1-2
the charging valve assembly by turning the “T” handle all
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additional times to recharge. Watch the gauge and verify
the way out on the gas chuck and then opening the
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the low charging limit to be 1950 ±145 psi (134±10
bar)—when it starts to recharge.
bleed valve (Figure 2-27).
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7. Secure the gas valve, loosen the swivel nut and remove
NOTE: This accumulator charge valve is non-adjustable.
R F
the charging assembly. Replace the gas valve cap and

5. Stop engine and remove the diagnostic coupler. guard.
er

Procedure for Pre-Charging the Service

Brake Accumulators, If Required
Gas Valve Guard
1. With the engine off, discharge all of the pressurized oil
stored in the accumulators by depressing the service Gas Valve
brake pedal on the cab floor 4 – 6 times. Remove the
gas valve guard and cap on the accumulator
(Figure 2-27). 2
2. Ensure that the nitrogen supply bottle is shut off, then
attach the charging valve assembly to it.
3. Before attaching the charging assembly to the
accumulator gas valve, back the gas chuck “T” handle
all the way out (counterclockwise).
4. Close the charging assembly bleed valve. Without
looping or twisting the hose, attach the swivel nut to the
accumulator gas valve and tighten to 10-15 lb-in.
5. Turn the gas chuck “T” handle all the way down
(clockwise) which will depress the core in the gas valve.
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nl c 7490-19
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Accumulator Check/Charge Valve
R F
FIGURE 2-27
6. Slowly open the nitrogen bottle valve and fill the

er
accumulator. Close the valve when the pre-charge is
1400 +50, -0 psi (97 +3.5, -0 bar).
7. If the pre-charge is higher than specified in step #6,
close the nitrogen bottle and slowly open the bleed valve
on the charging assembly (Figure 2-27) until the
pressure is to specification.
8. Remove the charging valve assembly by turning the “T”
handle all the way out (counterclockwise) on the gas
chuck and then open the bleed valve.
9. Secure the gas valve, loosen the swivel nut and remove
the charging assembly. Replace the gas valve cap and
guard.

Procedure V - Checking/Setting the

Differential Lock Pressure
1. Install a pressure check diagnostic quick disconnect
(Parker PD240) with gauge onto test nipple at the G port
(1) of the accessory manifold (Figure 2-28).
2. Start engine.
3. Turn pressure reducing valve (4) “out” approximately
two (2) turns and then “in” approximately two (2) turns to
1
starting position. Adjust pressure reducing valve “in” to
increase or “out” to decrease until a gauge reading of
100 ±20 PSI (7 ±1.5 bar) is achieved.
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2
R F
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FIGURE 2-28

VALVES to Table 2-4. Refer to Figure 2-29 for location of valves

installed on the superstructure and carrier frame.
General The description of each valve given here is for the valve
This subsection provides descriptive information for itself. For information on how each valve functions in the
hydraulic valves used on this crane. For a listing of valves, individual circuits, refer to the description and operation
the circuit they are used in, and their physical location, refer procedures of that circuit.
Table 2-4: Valve Usage Table 2

Valve Name Circuit Used In Physical Location
Carrier
Outrigger/Rear Steer/Outrigger Box

Outrigger/Rear Steer Front Face of Carrier Frame Member
Pin Removal Valve
Outrigger Control Manifold Outrigger Inside of Front & Rear Outrigger Box
Park Brake Axle Disconnect Valve Park Brake/Two or Four Wheel Drive Carrier Right Hand Side Rail
Axle Oscillation Lockout Valve Rear Axle Lockout Left Rear Face of Carrier Frame
Pressure Bleed-off Valve Outrigger In Line
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Superstructure
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Main Directional Control Valve Boom Lift/Telescope(s)/Hoist(s) Superstructure Right Side Plate
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Outside Right Superstructure Side
R F
Swing Directional Valve Swing

Plate
Counterweight, Boom Extension, Cab

Compact Block Manifold Left Side Superstructure
er
Tilt and Telescope
Accessory Manifold Steer/Brake/Load Sense On Bracket Center of Superstructure
Case Drain Manifold System On Bracket Center of Superstructure
Dual Accumulator Charge Valve Service Brakes Superstructure Inside Left Side Plate
Control Block (Hoist Circuit) Hoist Beneath Hoists on Turntable
Tandem Brake Valve With Treadle

Service Brake Cab Floor
Pedal
Accumulator(s) Service Brake Outside Left Superstructure Side Plate

7492-5 4
7492-2
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9092
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7492
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Carrier
7492-4
2
7492-3 7492-6
5
1 FIGURE 2-29

CARRIER SUPERSTRUCTURE
1 Outrigger/Rear Steer Valve Main Directional Control Valve (Telescope/
8
Lift/Hoist)
2 Park Brake Axle Disconnect Valve
9 Swing Directional Control Valve
3 Manual Bleed Off Pressure Valve
10 Compact Block Manifold
4 Axle Lockout Valve
Accessory Manifold (Steer/Brake/Load
5 Differential Lock Valve (Optional) 11
Sense)
6 Outrigger Control Manifold
12 Case Drain Manifold
7 CAC Motor Control Valve (Tier 3 only)
13 Dual Accumulator Charge Valve
14 Hoist Brake Control Valve
15 Manual Bleed Off Valve
16 Pilot Operated Solenoid Valve (Optional)

15
10
7491-12
2
7491-10
13
7491-9
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7491-13
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7491-1
8 Superstructure
7491-7
7491-2
11
16
9
12
Outriggers 7513-1

OUTRIGGER/REAR STEER/OUTRIGGER The outrigger box pin removal portion of the valve contains a
BOX PIN REMOVAL VALVE three position four way solenoid controlled directional control
valve cartridge.
Description
Maintenance
The integrated outrigger/rear steer/outrigger removal valve
(Figure 2-30) directional controls the outrigger circuit, rear Removal
steer circuit, and the pin cylinders that remove the front and 1. Tag and disconnect the electrical connectors to the
rear outrigger boxes. The valve is mounted on the front face integrated outrigger/rear steer valve. Tape the lead
of the carrier frame member forward of the swivel. The ends.
manifold valve has five stations, an inlet, and four working
stations. 2. Tag and disconnect the hydraulic lines to the valve. Cap
or plug the lines and ports.
The inlet station contains a 3000 psi (20684 kPa) relief valve
and a two position two way solenoid valve that is normally 3. Remove the capscrews and washers securing the valve
open bypassing oil from the inlet port to the pressure beyond to the frame. Remove the valve as a complete assembly.
port.
Installation
Activation of either outriggers, rear steer, or removal pin
1. Install the integrated outrigger/rear steer valve to the
stations will energize the solenoid valve to close,
frame. Secure the valve with the capscrews and
pressurizing the working sections.
washers. Torque capscrews to recommended torque.
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The outrigger extend and retract section of the valve
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2. Connect the hydraulic lines to the valve as tagged during
contains a four way solenoid directional control valve
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internally connected in parallel, two pilot operated check
valves, a 2000 psi (13789 kPa) relief valve and two solenoid 3.
removal.
Connect the electrical connectors to the valve as tagged
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valves. during removal.
R F
The rear steer section of the valve contains a three position Functional Check
four way solenoid controlled directional control valve
cartridge and two pilot operated check valve cartridges. 1. Cycle an outrigger cylinder several times. Verify the
er
cylinder extends and retracts properly.
2. Rear steer the crane to the left and to the right several
times. Verify the crane steers properly in both directions.

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7
17
8 5
12 6
3
10
16
4
13 15
7484-2
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8
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5
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11
7484-1
3
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2 3 4 8 7 6 5
1
9 17
14
13
12
7484-4
16
11
15 10
FIGURE 2-30


1 Outrigger Solenoid - A Port Extend 10 Gauge Port G3
2 Outrigger Solenoid - B Port Retract
3 RSA Port to Steer Right Solenoid Valve
11 Two Stage Relief
2
12 Load Sense In Port
4 RSB Port to Steer Left Solenoid Valve 13 Tank Port
5 B1 Port to Front Outrigger Pin Extend 14 Pressure Port
6 A1 Port to Front Outrigger Pin Retract 15 Drain Port
7 B2 Port to Rear Outrigger Pin Extend 16 Load Sense Out Port
8 A2 Port to Rear outrigger Pin Retract 17 Pressure Reducing Valve
9 Gauge Port G1
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OUTRIGGER CONTROL MANIFOLD Inspection

Visually inspect the valves and hydraulic connections for any
Description evidence of leaks or other damage. Check security of the
There are two outrigger control manifolds utilized on the electrical connections. Inspect the wiring for any evidence of
crane; one for the front outriggers and one for the rear cracks or breaks.
outriggers (Figure 2-31). Each manifold consists of four
Installation
normally closed two position two way solenoid valves. They
are mounted inside the frame on their respective outrigger 1. Install the manifold and secure with the capscrews and
box. washers. Torque capscrews to recommended torque.
When energized, the solenoid shifts the spool to open 2. Connect the electrical connectors to the solenoids as
allowing extension or retraction of the outrigger cylinders. marked during removal.
Maintenance 3. Connect the hydraulic lines to the valves as marked

during removal.
Removal
Functional Check
1. Tag and disconnect the hydraulic lines to the solenoid
valves. Cap all lines and openings. Activate the hydraulic system and cycle the affected
cylinder(s) several times. Observe for proper functioning of
2. Tag and disconnect the electrical connectors. the affected cylinder(s). Ensure the solenoid valve hydraulic
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connections are secure.
3. Remove the capscrews and washers securing the
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manifold to the outrigger box. Remove the manifold.
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3 4 5
2
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7482-2 7482-1
5
4
3
2
1
FIGURE 2-31

1 In Port 4 Right Front or Rear Jack Cylinder
2 Left Front or Rear Extension Cylinder 5 Right Front or Rear Extension Cylinder
3 Left Front or Rear Jack Cylinder

PARK BRAKE/AXLE DISCONNECT VALVE 3. Remove the capscrews and washers securing the valve
to the frame. Remove the valve.
Description
Inspection
The two position three way parking brake/axle solenoid valve
Visually inspect the valves and hydraulic connections for any
(Figure 2-32) is mounted off of the carrier right hand side rail.
evidence of leaks or other damage. Check security of the
In its de-energized position, the inlet port is blocked and the
electrical connections. Inspect the wiring for any evidence of
parking brake and axle disconnect actuators are drained to
the reservoir. When the solenoid is energized, the reservoir
cracks or breaks. 2
port is blocked and pressurized oil is directed to the parking Installation
brake or axle disconnect actuators.
1. Install the valve the frame and secure with the
Maintenance c a p s c r e w s a n d w a s h e r s . To r q u e c a p s c r e w s t o
recommended torque.
Removal
2. Connect the electrical connectors to the solenoids as
1. Tag and disconnect the hydraulic lines to the solenoid marked during removal.
valves. Cap all lines and openings.
3. Connect the hydraulic lines to the valves as marked
2. Tag and disconnect the electrical connectors. during removal.
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6
3 3
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7
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1 4
7483-1 5 7483-3
5
5 4 7
4 6
2 7
1
2
7482-2
FIGURE 2-32

1 Tank Port 5 Port PB - Power Beyond
2 Pressure Port 6 Axle Disconnect Solenoid Valve
3 Pressure Switch 7 Park Brake Solenoid Valve
4 Port A - Axle Disconnect

AXLE OSCILLATION LOCKOUT VALVE Maintenance

Description Removal
The axle oscillation lockout valve (Figure 2-33) is used in the 1. Tag and disconnect the electrical connectors to the
rear axle oscillation lockout circuit. The valve is mounted on valve.
the left rear face of the carrier frame forward of the rear axle. 2. Tag and disconnect the hydraulic hoses from the valve.
It consists of a valve body and two normally-closed, two-way, Cap or plug the lines and ports.
two-position solenoid valves. It keeps the lockout cylinders
from oscillating unless the turntable is centered forward. 3. Remove the capscrews, nuts and washers securing the
valve to the frame. Remove the valve.
The area definition potentiometer in the angle sensor on the
bearing de-energizes the axle oscillation relay. When the Installation
superstructure is more than 6 degrees left or right of directly
1. Secure the valve to the frame with the capscrews, nuts
over the front, the axle oscillation relay is de-energized.
and washers. Torque capscrews to recommended
When the axle oscillation relay’s contacts are open, the torque.
normally closed solenoid valves are de-energized and
2. Connect the hydraulic hoses to the ports on the valve as
isolate the lockout cylinders from hydraulic fluid supply. This
tagged during removal.
keeps the cylinders from oscillating (moving up and down to
damp axle movement) because hydraulic fluid cannot leave 3. Connect the electrical connectors to the valve as tagged
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the cylinders. Instead, the cylinders remain full of hydraulic during removal.
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fluid and more rigid.
4. Verify proper operation. Refer to Section 3 in the
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When the axle oscillation relay’s contacts are closed, the
solenoid valves are energized and open. This allows
Operator’s Manual.
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5. Check valve and hoses for leaks. Make repairs as
hydraulic fluid in and out of the cylinders, allowing them to
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needed.
oscillate.
3 2
er
1
2
3
7481-1
7481-2
1 2
FIGURE 2-33

1 B Port - to Lockout Cylinder 3 C Port from Outrigger Rear Steer valve
2 A Port - to Lockout Cylinder

PRESSURE BLEED-OFF VALVE

Description
WARNING
The pressure bleed-off valve (Figure 2-34) is used to
manually drain to reservoir any trapped pressure from When bleeding hydraulic fluid, operate the system below
behind the outrigger box removal quick disconnects or the 500 psi. To avoid injury, ensure that all persons are clear
telescope boom removal quick disconnects. of the path of discharge. Another recommended practice
is to attach a section of hose over the bleed screw/
2
The in-line plumbed pressure bleed-off valve consists of a
knob adjustable flow control valve and a shuttle valve. The adapter to direct oil away from the area and to reduce oil
adjustable flow control valve knob can be turned spillage.
counterclockwise to open or clockwise to close. Full
adjustment is five turns of the knob. The shuttle valve acts as Maintenance
a directional selector, allowing only the pressurized circuit to
open to the flow control drain valve. Removal
Whenever possible, the bleed adapter should be mounted at 1. Tag and disconnect hydraulic lines from valve. Cap or
the highest point within the hydraulic system. The trapped plug all openings.
air can be relieved while the system is running at low 2. Remove the capscrews and washers securing the valve.
pressure. To bleed, loosen the bleed screw 1/2 turn Remove the valve.
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counterclockwise. After the hydraulic fluid begins to run
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freely from the bleed screw, the bleed screw should be re- Installation
tightened.
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removal.
er

1 1
3
5
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7501-2 3 7501
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4
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Hydraulic Schematic
2 2
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FIGURE 2-34
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1 Tank Port 4 Shuttle Valve
2 To Outrigger Extend Port “B” 5 Adjustable Flow Control Valve
3 To Outrigger Retract Port “A”

MAIN DIRECTIONAL CONTROL VALVE Removal

1. Tag and disconnect the hydraulic lines from the valve.
Description Cap or plug the lines and ports.
2. Tag and disconnect the electrical leads from the valves.
General
3. Remove the capscrews and washers securing the valve
The main directional control valves (Figure 2-35) direct and to the bracket. Remove the valve.
control hydraulic fluid flow from the pumps to the boom lift
and telescope cylinders and the hoist motors. The valve is
Installation 2
located on the outside of the right superstructure side plate. 1. Place the valve on the bracket and secure with the
The valve bank is removed and installed as an assembly. c a p s c r e w s a n d w a s h e r s . To r q u e c a p s c r e w s t o
recommended torque.
Maintenance
2. Connect the electrical connectors to the valve as tagged
during removal.
CAUTION removal.
Weight of the valve is 388 lb (176 Kg), use an appropriate NOTE: Hydraulic solenoids must be calibrated to the
lifting device to move the valve. software. This must be done by a Manitowoc Crane
Care certified technician.
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35
31
38
6 20
7
21
5
3
7486-2 2
1
FIGURE 2-35

25
29 24 26
27
22 23
28
19
17
16
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7486-3
40
32
er
39
15 18
11 30
14 12 13 34
10
33 39 30
32 19 34 18
40
20
10 37
21
36
12
15
17
11
13
7486-1 14
16 FIGURE 2-35 continued

29 7 27 26
20 21 8 28 5 6
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18
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7486-4
35 9
32 33 34
17 16 12 40 13

1 Auxiliary Hoist Up Solenoid b1 15 Port A3 - Main Hoist Raise
2 Auxiliary Hoist Down Solenoid a1 16 Port B1 - Lift Retract
3 Main Hoist Down Solenoid a3 17 Port A1 - Lift Extend
4 Main Hoist Up Solenoid b3 18 Tank Port - To Swivel Port 1
5 Telescope Out Solenoid a2 19 Pressure Port - To Swivel Port 3
6 Telescope In Solenoid b2 20 Release Lift Down
7 Lift Up Solenoid b1 21 Enable Pilot Supply
8 Lift Down Solenoid a1 22 Port X4 to Pressure Switch (Aux Hoist Raise)
9 Telescope Extend Pressure 23 Port X1 to Pressure Switch (Aux Hoist Lower)
10 Port A1 - Auxiliary Hoist Raise Port X6 to Pressure Switch (Main Hoist
24
Raise)
11 Port B1 - Auxiliary Hoist Lower
Port X3 to Pressure Switch (Main Hoist
12 Port A2 - Telescope Retract 25
Lower)
13 Port B2 - Telescope Extend
Port X5 to Pressure Switch (Telescope
14 Port B3 - Main Hoist Lower 26
Retract)

25 24 23
3 4 22
2
1
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11
38 31 30 37 7486-5
39 14 10 36
15

Port X2 to Pressure Switch (Telescope 34 Port MB2 for Test Nipple
27
Extend)
35 D2 - Pressure Check
28 Port X4 to Pressure Switch (Lift Up)
36 Port MB1 for Test Nipple
29 Port X1 to Pressure Switch (Lift Down)
30 Port MB3 for Test Nipple
39 Port MA3 for Pressure Check
32 Port MA1 for Test Nipple
40 Port MA2 for Pressure Check

SWING DIRECTIONAL CONTROL VALVE 3. Remove the capscrews and washers securing the valve
to the bracket. Remove the valve.
Description
Installation
General 1. Place the valve on the bracket and secure with the
The swing directional control valve (Figure 2-36) directs and c a p s c r e w s a n d w a s h e r s . To r q u e c a p s c r e w s t o
controls hydraulic fluid flow from the pump to each swing recommended torque.
motor. The valve is located on the outside of the right 2. Connect the electrical connectors to the valve as tagged
2
superstructure side plate. The valve bank is removed and during removal.
installed as an assembly.
Maintenance removal.
Removal NOTE: Run auto-teach in service software to calibrate

software to valve solenoids. This must be done by
1. Tag and disconnect the hydraulic lines from the valve. a Manitowoc Crane Care certified technician.
Cap or plug the lines and ports.
2. Tag and disconnect the electrical leads from the valves.
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4
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2
9
3 8
7506-1
8 5 9
7506-3
FIGURE 2-36

1 Port MP for Test Nipple 6 Swing Left Solenoid Valve
2 Port P - Pressure from Swivel Port 5 7 Swing Right Solenoid Valve
3 Port R - To Swivel Drain to Tank 8 Brake Right Solenoid Valve
4 Load Sense 9 Brake Left Solenoid Valve
Port PB - Pressure Beyond - Pressure Switch 10 Port RL - Brake Release - Drain
5
to Swing Motor

6
5
10 4
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7507 3
9 8 2
1

COMPACT BLOCK MANIFOLD Maintenance

Description Removal
The compact block manifold (Figure 2-37) directs and 1. Tag and disconnect the hydraulic lines from the valve.
controls hydraulic fluid flow for the counterweight pin lock, Cap or plug the lines and ports.
counterweight raise/lower, counterweight lock/unlock, boom 2. Remove the capscrews and washers securing the valve.
extension cylinder, cab tilt and telescope pinning lock/unlock
functions. The valve is located on the left side of the
Remove the valve bank. 2
superstructure. The valve bank is removed and installed as Installation
an assembly.
1. Install the valve and secure with the capscrews, and
2. Connect the hydraulic lines to the valves as tagged
during removal.
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13 nl c 7
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9
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23
24
25
11 7489-1
6
12
FIGURE 2-37

28 27 26 25 24 23 18 17
22 21 20 19
29
7489-4
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30
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13 12
R F
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1 Port MA6 for Pressure Gauge (Tele Locking) 16 Port A4 - Counterweight Unlock
2 Load Sense Port 17 Port MLs - for Pressure Gauge
3 Port A6 - Fill Passage Pipe 18 Load Sense Port
4 Tank Port 19 Port P - Pressure Valve
5 Telescope Pinning Lock/Unlock Solenoid 20 Port MP - for Pressure Gauge
6 Cab Tilt Lower/Raise Solenoid Valve 21 Port B3.1 Counterweight Lower
7 Boom Extension Cylinder Solenoid Valve 22 Port B3 - Counterweight Lower
8 Port B1 - Cab Tilt Lower 23 Port A3 - Counterweight Raise
9 Port A1 - Cab Tilt Raise 24 Port A3.1 - Counterweight Accumulator
10 Port B2 - Boom Extension Cylinder - Tank 25 Port S - Accumulator
11 Counterweight Lock/Unlock Solenoid Valve 26 Port MS - Pressure Transducer
12 Counterweight Raise/Lower Solenoid Valve 27 Port B8 - Counterweight Unpin
13 Counterweight Pin Lock Solenoid Valve 28 Port A8 - Counterweight Pin
14 Port A2 - Boom Extension Cylinder- Pressure 29 Port A5 - Counterweight Pin - Tank
15 Port B4 - Counterweight Lock 30 Port B5 - Counterweight Unpin - Tank

16 15 14 10 9 8 3 1 2
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11 6 4
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13 12 6
25
6 13
11 5
12
24
23
7
27
10
17
8 11 16
15
4 7
9
19 14
18
22
3 7489-3
21 7489-2
1

ACCESSORY MANIFOLD Maintenance

Description Removal
The steer/brake/load sense accessory manifold 1. Tag and disconnect the hydraulic lines from the valve.
(Figure 2-38) directs flow for the front steer and service Cap or plug the lines and ports.
brake circuits. The valve is located on a bracket in the center 2. Remove the capscrews and washers securing the valve.
of the superstructure. The valve bank is removed and Remove the valve bank.
installed as an assembly.
Installation
1. Install the valve and secure with the capscrews, and
during removal.
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10
12
13 4 5
7503-1
14
7503-2 11
9 8 7
FIGURE 2-38

1 Port DR - Drain to Swivel Port 4 to tank 9 Port GPLS - Gauge Port for Test Nipple
BRAKE Port - To Dual Accumulator Charge 10 Port GPS - Gauge Port for Test Nipple
2
Valve
11 Port P - Pressure Port
3 LS PUMP Port - to Swivel Port 8
Check Valve CV4 - Load Sense - Front Steer
12
4 RV1 - Relief Valve Valve
5 PR1 - Pressure Reducing Relieving Valve Check Valve - CV3 - Load Sense Dual
13
Accumulator Valve
6 Port STR - To Front Steer Valve
Check valve CV2 - Load Sense - to Compact
7 Port GPB - Gauge Port for Test Nipple 14
Control Valve
8 Port 1 - Load Sense

6 7 2 5 8
10
2
12
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7503-3
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9 7503-3
4
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11 1
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CASE DRAIN MANIFOLD Maintenance

Description Removal
The case drain manifold (Figure 2-39) directs drain from 1. Tag and disconnect the hydraulic lines from the
various superstructure valves and cylinders to the reservoir. manifold. Cap or plug the lines and ports.
The valve is located on a bracket in the center of the 2. Remove the capscrews, washers and nuts securing the
superstructure. The valve bank is removed and installed as manifold. Remove the manifold.
an assembly.
Installation
1. Install the manifold and secure with the capscrews,
washers and nuts. Torque capscrews to recommended
torque.
during removal.
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4
2
5
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1
1
7502
FIGURE 2-39

1 Drain to Reservoir Drain from Lift Cylinder and Main Directional
4
Control Valve
Drain from Hoist Motor, Swing Motor and
2
Main Directional Control Valve Drain from Steer/Brake/Load Sense
5
Accessory Manifold and Tandem Brake Valve
Drain from Dual Accumulator Charge Valve
3
and Compact Control Block

DUAL ACCUMULATOR CHARGE VALVE pilots the control pilot spool to open the load sense line to
tank, de-stroking the piston pump No. 1.
Description
Maintenance
The load sensing dual accumulator charging valve
( F i g u r e 2 -4 0 ) i s l o c a t e d o n t h e i n s i d e o f t h e l e f t Removal
superstructure side plate. The purpose of the valve is to
provide pressure regulation to the service brake circuit. 1. Tag and disconnect the hydraulic hoses from the valve.
Cap or plug the lines and ports.
2
The dual accumulator charge valve consists of an inlet main
check valve, a load sense control section with a pilot spool 2. Remove the capscrews, flatwashers and lockwashers
that controls the pump stroke and an inverted shuttle that securing the valve to the turntable. Remove the valve.
controls the accumulator charging (Figure 2-40).
Installation
When the valve is charging the accumulators, the load sense
control section is in neutral position, connecting the load to 1. Position the valve on the turntable and secure with the
the pump by way of the load sense line. This brings the capscrews, flatwashers, and lockwashers. Torque
piston pump No. 1 on stroke to supply fluid for charging. capscrews to recommended torque.
Fluid passes through the main check valve connecting to the
2. Connect the hydraulic hoses to the valve ports as tagged
pilot end and through the spool onward to the inverted
during removal.
shuttle that connects the accumulators.
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3. Start the engine and check for leaks. Make repairs as
When the control pilot spool bias spring senses the low limit
ef or
needed.
pressure of 2100 psi (14479 kPa), the spool shifts to the
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neutral position, allowing the pump to charge the
accumulators to a maximum of 2490 psi (17168 kPa). The
4. Depress the brake pedal several times to cause the
brake valve to charge. Make several turns with the
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inverted shuttle cartridge senses the pressure in the steering wheel, and swing the superstructure left and
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accumulators to pilot the cartridge closed when maximum right. Verify the brakes, swing, and front steering work
charge pressure is reached. Maximum charge pressure also properly.
er

5 4
3 3
1 2
1
6
6696-3
5 6
4
Valve Hydraulic Schematic
6696-2
6696-1
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FIGURE 2-40
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Item nl c Description Item Description
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Port LS - Load Sense Port - To Port 3 of Accumulator Port A1 - To Accumulator and
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1 4
Steer/Brake/Load Sense Accessory Manifold Tandem Brake Valve
Port T - Tank Port - To Compact Control Block Accumulator Port A2 - To Accumulator and
2 5
and Port 4 of Case Drain Manifold Tandem Brake Valve
er
Port P - Pressure Port - To Brake Port of 6 Pressure Switch

3
Steer/Brake/Load Sense Accessory Manifold

CONTROL BLOCK Installation

1. Install the manifold and secure with the capscrews,
Description washers and nuts. Torque capscrews to recommended
The control block (Figure 2-41) is used in the main and torque.
auxiliary hoist circuit. The valve bank is removed and 2. Connect the hydraulic lines to the valves as tagged
installed as an assembly. during removal.
Maintenance 2
Removal
1. Tag and disconnect the hydraulic lines from the
manifold. Cap or plug the lines and ports.
2. Remove the capscrews and washers securing the
manifold. Remove the manifold.
7
6
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5
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5
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2
7491-13
3 7507-2
1 8
FIGURE 2-41

TANDEM BRAKE VALVE W/ TREADLE The tandem brake valve consists of a tandem valve body, a
PEDAL closed center spool, a treadle pedal, an integral proximity
switch and a mechanical spring assembly to limit the output
Description pressure to the brake actuators to 2100 psi ±75 (14,483 kPa
±517).
The tandem brake valve with treadle pedal (Figure 2-42) is
located on the floor of the cab. The tandem brake valve Maintenance
provides split system braking for the primary (front) brakes
and the secondary (rear) brakes. The valve is a closed Removal
center spool design which modulates the output pressure 1. Tag and disconnect the electrical connector to the valve.
2100 psi ±75 (14,483 kPa ±517) to the brake actuators.
2. Tag and disconnect the hydraulic hoses from the valve.
The valve is mechanically actuated by a treadle pedal. The Cap or plug the lines and ports.
direct acting spool provides a pedal feel which accurately
represents the brake pressure, similar to automotive style 3. Remove the nuts and bolts securing the valve to the cab
pedal feedback as the brake pedal pressure increases, the floor. Remove the valve.
pedal effort increases proportionally.
Installation
As the pedal is initially actuated, the tank ports are closed off
1. Secure the valve to the cab floor with the nuts and bolts.
from the brake ports. With further application of the pedal,
the pressure ports are opened to the brake ports until the 2. Connect the hydraulic hoses to the ports on the valve as
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pedal actuation force and the hydraulic pressure force are tagged during removal.
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balanced. Also when the pedal is actuated, the integral
3. Connect the electrical connector to the valve as tagged
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proximity switch is engaged to provide an electrical signal for
brake lights. When the pedal is released, the valve and the during removal.
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pedal return to the non-applied position. In normal operation, 4. Start the engine and check valve and hoses for leaks.
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the secondary system is piloted from the primary section Make repairs as needed.
providing pressure to both systems.
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1
2 5
5 1
6
3
6
4 8441-1 8441-2
4 2
8441
FIGURE 2-42

1 P1 - Pressure port 4 T2 - Tank Port
2 T1 - Tank Port 5 Port B1 - Front Disc Brakes
3 P2 - Pressure Port 6 Port B2 - Rear Disc Brakes

HYDRAULIC ACCUMULATOR SERVICE 3. Remove the two nuts securing each clamp half. Remove
BRAKE the each clamp half and accumulator from the turntable.
Installation
Description
1. Position the accumulator in the clamps and secure with
The service brake hydraulic accumulators are located on the the removable clamp halves and nuts.
center of superstructure in the swivel area. The purpose of
each accumulator is to provide stored energy, an oil volume 2. Connect the hydraulic hose to the port on the
accumulator as tagged during removal.
2
of 231 cu in (3.8 liters) at a maximum pressure of 2320 psi
(15,996 kPa), to actuate the service brake circuits. The dual 3. Pre-charge the accumulator. Refer to Procedure for Pre-
accumulator charge valve regulates flow to the hydraulic Charging the Service Brake Accumulators, If Required,
accumulators to provide fully powered independently page 2-35.
separate, primary (front) and secondary (rear), service brake
circuits. 4. Start the engine and check accumulator and hoses for
leaks. Make repairs as needed.
Each accumulator has two chambers divided by a piston.
One side is pre-charged to 1400 psi (9655 kPa) with high 5. Depress the brake pedal several times, make several
purity nitrogen. This maintains a constant pressure in the turns with the steering wheel, and swing the
other chamber which is connected to the modulating brake superstructure left and right. Verify the brakes, swing,
valve. After the accumulators are fully charged, they will and front steering work properly.
provide the necessary brake system flow and pressure to
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actuate the brakes. Servicing
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The pre-charge nitrogen pressure should be checked every
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The accumulator consists of a tube, piston, seals, gas
charging valve, and a gas valve guard. 200 hours or once a month, whichever comes first. Refer to
Pressure Setting Procedures
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Maintenance
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Removal
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1. With the engine shutdown, deplete the hydraulic
pressure in the accumulators by depressing the service
brake pedal several times.
2. Tag and disconnect the hydraulic hose from the
accumulator. Cap or plug the line and port.

CHARGE AIR COOLER (CAC) MOTOR

CONTROL VALVE 2
1
Description 6
The CAC motor control valve (Tier 3 Only) (Figure 2-43) and
(Figure 2-44) controls hydraulic flow to the charge air cooler
(CAC) fan. It is located inside the frame behind the right side
of the turntable in front of the axle disconnect and park valve. 5
The work port is connected to the hydraulically operated
CAC fan motor. The proportional pressure control valve
modulates to allow oil flow to the circuit as the engine
4
requires (For Tier 3 ONLY: The on/off solenoid valve opens
to allow oil flow to the circuit as the engine requires). The
circuit has a relief valve to limit pressure and an orifice to limit
oil flow. The valve also has a test fitting to aid in setting the
pressure of the relief valve.
Maintenance
Removal
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3
1. Tag and disconnect the hydraulic lines to the valve.
2.
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Tag and disconnect the electrical connectors to the
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valve.
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3. Remove the bolts and washers securing the valve and

remove the valve.
Installation
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1. Install the valve and secure in place with the bolts and
washers. FIGURE 2-43
2. Connect the electrical connectors to the valve.
3. Connect the hydraulic lines to the valve. Item Description
1 Pressure Port
2 Tank Port
3 Pilot Operated Relief Valve
4 A Port
5 B Port
6 Gauge Port

2 Item Description
1 1 Pressure Port
2 Tank Port
3 Pilot Operated Relief Valve
5
4 A Port 2
5 B Port
6
6 Gauge Port
4 7 On/Off Valve
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3
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FIGURE 2-44

CYLINDERS Maintenance
General General
This subsection provides descriptive information for all the There must be a gap between the ends of each wear ring
hydraulic cylinders used on this crane. The description of the when it is installed onto the piston (as applicable) or head
cylinder given here is for the cylinder itself. For information (Table 2-5). In addition, each wear ring gap is to be located
on how the cylinder functions in the individual circuits, refer as follows: Divide 360 degrees by the number of wear rings
to the Description and Operation of that circuit. on the component. The resulting value is the number of
degrees each wear ring gap is to be located with respect to
each other.
The approximate wear ring gaps are as follows:
Table 2-5
Wear Ring Gap
Head (or Piston) Size Wear Ring Gap

Inch mm Inch mm
1 to 4.75 25.4 to 120.7 0.125 3.18
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5 to 10.0 127.0 to 254.0 0.187 4.75
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greater than 10.0 greater than 254.0 0.250 6.35
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Surface Protection For Cylinder Rods Leakage Check
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Steel cylinder rods include a thin layer of chrome plating on A hydraulic cylinder should not be disassembled unless it is
their surfaces to protect them from corroding. However, essential. The following checks will provide a means of
chrome plating inherently has cracks in its structure which determining if a cylinder has a faulty or leaking piston seal.
er
can allow moisture to corrode the underlying steel. At typical 1. Extend the rod to its maximum stroke. Remove the
ambient temperatures, hydraulic fluid is too thick to retract hose from the cylinder. Cap the retract hose.
penetrate these cracks. Normal hydraulic operating
temperatures will allow hydraulic fluid to warm sufficiently to
penetrate these cracks and if machines are operated daily,
protect the rods. Machines that are stored, transported, or
used in a corrosive environment (high moisture, rain, snow,
DANGER
or coastline conditions) need to have the exposed rods Ensure pressure is applied to the piston side of the
protected more frequently by applying a protectant. Unless cylinder only and the retract hose is capped.
the machine is operated daily, exposed rod surfaces will
corrode. Some cylinders will have rods exposed even when 2. Apply hydraulic pressure to the piston side of the
completely retracted. Assume all cylinders have exposed cylinder and observe the open cylinder port for leakage.
rods, as corrosion on the end of the rod can ruin the cylinder. If leakage is observed, the seals in the cylinder must be
replaced.
It is recommended that all exposed cylinder rods be
protected using Boeshield® T-9 Premium Metal Protectant. 3. Fully retract the cylinder rod (except the telescope
Manitowoc Crane Care has Boeshield® T-9 Premium Metal cylinder). Remove the extend hose from the cylinder.
Protectant available in 12 oz. aerosol cans by ordering part Cap the extend hose.
number 9999101803.
CAUTION DANGER
Cylinder operation and inclement weather will remove the Ensure pressure is applied to the retract (rod) side of the
Boeshield® protectant; therefore, inspect machines once cylinder only and the extend hose is capped.
a week and reapply Boeshield® to unprotected rods.
4. Apply hydraulic pressure to the retract (rod) side of the
cylinder and observe the open cylinder port for leakage.

If leakage is observed, the seals in the cylinder must be of thermal contraction of “slip stick” it is recommended that
replaced. the telescope control lever is activated periodically in the
extend position to mitigate the effects of the cooling oil.
5. Reconnect all cylinder ports.
If a load and the boom is allowed to remain stationary for a
Temperature Effects on Hydraulic Cylinders period of time and the ambient temperature is cooler than the
Hydraulic fluid expands when heated and contracts when trapped oil temperature, the trapped oil in the cylinders will
cooled. This is a natural phenomena that happens to all
liquids. The coefficient of expansion for API Group 1
cool. The load will lower as the telescope cylinder(s) retracts
allowing the boom to come in. Also, the boom angle will 2
hydraulic fluid is approximately 0.00043 cubic inches per decrease as the lift cylinder(s) retracts causing an increase
cubic inch of volume for 1°F of temperature change. in radius and a decrease in load height.
Thermal contraction will allow a cylinder to retract as the This situation will also occur in reverse. If a crane is set up in
hydraulic fluid which is trapped in the cylinder cools. the morning with cool oil and the daytime ambient
The change in the length of a cylinder is proportional to the temperature heats the oil, the cylinders will extend in similar
extended length of the cylinder and to the change in proportions.
temperature of the oil in the cylinder. For example, a cylinder
extended 25 feet in which the oil cools 60°F would retract (Table 2-6) has been prepared to assist you in determining
approximately 7 3/4 inches (see chart below). A cylinder the approximate amount of retraction/extension that may be
extended 5 feet in which the oil cools 60°F would only retract expected from a hydraulic cylinder as a result of change in
approximately 1 1/2 inches. The rate at which the oil cools the temperature of the hydraulic fluid inside the cylinder. The
chart is for dry rod cylinders. If the cylinder rod is filled with
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depends on many factors and will be more noticeable with a
hydraulic fluid, the contraction rate is somewhat greater.
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larger difference in oil temperature verses the ambient
temperature.
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Thermal contraction coupled with improper or inadequate CAUTION
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lubrication or improper wear pad adjustments and operation
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Operators and service personnel must be aware that load

at low boom angles may, under certain conditions, cause a
movement, as a result of this phenomena, can be easily
“stick-slip” condition in the boom. This “stick-slip” condition
mistaken as leaking cylinder seals or faulty holding
could result in the load not moving smoothly. Proper boom
valves. If leaking seals or faulty holding valves are
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lubrication and wear pad adjustment is important to permit
suspected to be the problem, refer to Service Bulletin 98-
the boom sections to slide freely. Slow movement, of the
036 dealing with testing telescope cylinders.
boom may be undetected by the operator unless a load is
suspended for a long period of time. To minimize the effects
Table 2-6
BOOM DRIFT CHART (Cylinder length change in inches)
3 3
Coeff. = 0.00043 (in /in / °F)
STROKE Temperature Change (°F)
(FT.) 10 20 30 40 50 60 70 80 90 100
5 0.26 0.52 0.77 1.03 1.29 1.55 1.81 2.06 2.32 2.58
10 0.52 1.03 1.55 2.06 2.58 3.10 3.61 4.13 4.64 5.16
15 0.77 1.55 2.32 3.10 3.87 4.64 5.42 6.19 6.97 7.74
20 1.03 2.06 3.10 4.13 5.16 6.19 7.22 8.26 9.29 10.32
25 1.29 2.58 3.87 5.16 6.45 7.74 9.03 10.32 11.61 12.90
30 1.55 3.10 4.64 6.19 7.74 9.29 10.84 12.38 13.93 15.48
35 1.81 3.61 5.42 7.22 9.03 10.84 12.64 14.45 16.25 18.06
40 2.06 4.13 6.19 8.26 10.32 12.38 14.45 16.51 18.58 20.64
45 2.32 4.64 6.97 9.29 11.61 13.93 16.25 18.58 20.90 23.22
50 2.58 5.16 7.74 10.32 12.90 15.48 18.06 20.64 23.22 25.80
55 2.84 5.68 8.51 11.35 14.19 17.03 19.87 22.70 25.54 28.38
60 3.10 6.19 9.29 12.38 15.48 18.58 21.67 24.77 27.86 30.96
Length change in inches = Stroke (Ft.) X Temperature Change ( °F) X Coeff. (in3/in3/ °F) X 12 in/ft
Temperature Effects on Hydraulic Cylinders

FIGURE 2-45

Table 2-7 Boom Drift Chart (Cylinder length change in millimeters)
Coeff. = 0.000774 (1/ °C)

STROKE Temperature Change (°C)
(m) 5 10 15 20 25 30 35 40 45 50 55
1.5 5.81 11.61 17.42 23.22 29.03 34.83 40.64 46.44 52.25 58.05 63.86
3 11.61 23.22 34.83 46.44 58.05 69.66 81.27 92.88 104.49 116.10 127.71
4.5 17.42 34.83 52.25 69.66 87.08 104.49 121.91 139.32 156.74 174.15 191.57
6 23.22 46.44 69.66 92.88 116.10 139.32 162.54 185.76 208.98 232.20 255.42
7.5 29.03 58.05 87.08 116.10 145.13 174.15 203.18 232.20 261.23 290.25 319.28
9 34.83 69.66 104.49 139.32 174.15 208.98 243.81 278.64 313.47 348.30 383.13
10.5 40.64 81.27 121.91 162.54 203.18 243.81 284.45 325.08 365.72 406.35 446.99
12 46.44 92.88 139.32 185.76 232.20 278.64 325.08 371.52 417.96 464.40 510.84
13.5 52.25 104.49 156.74 208.98 261.23 313.47 365.72 417.96 470.21 522.45 574.70
15 58.05 116.10 174.15 232.20 290.25 348.30 406.35 464.40 522.45 580.50 638.55
16.5 63.86 127.71 191.57 255.42 319.28 383.13 446.99 510.84 574.70 638.55 702.41
18 69.66 139.32 208.98 278.64 348.30 417.96 487.62 557.28 626.94 696.60 766.26
Length change in mm = Stroke (m) X Temperature Change ( °C) X Coeff. (1/ °C) X 1000 mm/m
AXLE OSCILLATION LOCKOUT CYLINDER
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Description CAUTION
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The two oscillation lockout cylinders (Figure 2-46) each have
Exercise extreme care when handling or setting down the
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rod. Damage to the rod surface may cause unnecessary
7.0 in (17.7 cm) diameter bores. The retracted length of each maintenance and expense.
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cylinder is 26.31 in (66.8 cm) from the center of the lug holes
to the center of the barrel bushing. The extended length of
2. Remove the rod and attached parts from the barrel.
each cylinder from the center of the lug holes to the center of
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the barrel bushing is 33.93 in (86 cm). Its stroke is 7.62 in NOTE: Cover the barrel opening to avoid contamination.
(19.3 cm). A wiper ring prevents foreign material from
entering each cylinder. O-rings and other seals prevent
internal and external leakage. CAUTION
The cylinder weighs approximately 192.0 lb (87.1 kg). When removing seals and rings, avoid scratching the
grooved and gland surfaces.
Maintenance
3. Remove the seal and wear rings from the outside of the
Disassembly piston.
NOTE: Any maintenance requiring disassembly of the 4. Remove the nut from the rod and remove the piston from
cylinder should include replacement of all cylinder the rod.
seals.
NOTE: Arranging discarded seals and rings in the order of
1. Using a chain wrench, unscrew the head from the barrel. disassembly will aid in installation of new seals and
rings. Pay attention to how each seal and ring is
installed to avoid installing replacement seals and
rings improperly.
CAUTION
Do not use air pressure to remove the rod. Use only a 5. Remove the head from the rod. Remove the O-ring and
source of controlled hydraulic fluid pressure if the rod is backup ring from the outside of the head. Remove the
hard to move. Injury may result from the cylinder rod wear rings, seal and wiper ring from the inside of the
unexpectedly exiting the cylinder barrel. head.
Inspection
1. Clean all parts with solvent and dry with compressed air.
Inspect all parts for serviceability.
2. Inspect the barrel carefully for scoring. If barrel is
scored, it must be repaired or replaced.

3. Check rod’s piston area for damage. If it is damaged, 3. Lubricate the rod with clean hydraulic fluid.
determine if it can be repaired or must be replaced.
4. Install the replacement seal and wear ring on the outside
4. Inspect rod for straightness. Determine if it can be of the piston.
straightened or must be replaced.
5. Slide the head onto the rod.
6. Lubricate freely all parts with clean hydraulic fluid.
CAUTION
Before installing new seals and rings, clean all surfaces
2
and carefully remove burrs and nicks. Parts displaying CAUTION
excessive wear or damage should be replaced. Exercise extreme care when handling the rods. Damage
to the rod surface may cause unnecessary maintenance
5. Stone out minor blemishes and polish with a fine crocus and expense. Also, take care to avoid damaging grooved
cloth. or gland surfaces, rings or seals during rod insertion.
6. Clean with solvent and dry with compressed air any
7. Remove the cover from the barrel. Insert the rod and
parts that have been stoned and polished.
attached parts into the barrel with a slight twisting
Assembly motion.
8. Clean all oil from the threads of the head. Coat the
threads with an anti-seize compound (ex: Never-Seez
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CAUTION paste lubricant or similar lubricant). Screw the head into
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When installing new seals and rings, avoid stretching place on the barrel tightly so it holds the head’s larger
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seals or scratching the grooved or gland surfaces. Make
sure parts are clean before and during assembly. Make
OD end flush with the end of the barrel.
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sure seals and rings are installed in the proper order.
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Damage to the cylinder or unexpected operation may CAUTION

result. Do not use air pressure to cycle or pressurize the cylinder.
Damage to the seals may result.
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NOTE: Lubricate seals and rings with clean hydraulic fluid.
1. Install the replacement wiper ring, wear rings and seal, 9. Pressurize and cycle the cylinder with hydraulic fluid
in the inside of the head. pressure. Test the cylinder at 3750 psi (25855.3 kPa).
Check for proper operation and any leakage. Make
2. Install the replacement O-ring on the outside of the repairs as needed.
head.

10
15 4
13 12 10
11, 14
1
5
17
7
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18
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9
9
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8 13
6
2
16
3 6705
FIGURE 2-46

1 O-ring 10 Wear Ring
2 O-ring 11 Washer
3 Backup Ring 12 Locknut
4 Seal 13 Grease Fitting
5 O-ring 14 Plug
6 Wiper Ring 15 Barrel
7 O-ring 16 Rod
8 Seal 17 Piston
9 Wear Ring 18 Head

STEER CYLINDER 4. Remove the piston seal and wear ring from the outside
of the piston.
Description NOTE: Arranging discarded seals and rings in the order of
The steer cylinders (Figure 2-47) are mounted on the axles, disassembly will aid in installation of new seals and
two cylinders on each axle. rings. Pay attention to how each seal and ring is
The steer cylinder has a 3.5 inch (8.89 cm) diameter bore.
The steer cylinder has a retracted length of 28 in (711.2 mm)
rings improperly.
2
from bushing center to bushing center. The steer cylinder 5. Loosen and remove the nut securing the piston.
has an extended length of 42.25 in (1073.2 mm) from Remove the piston from the rod.
bushing center to bushing center. Each cylinder has a stroke 6. Remove the O-ring from the inside of the piston.
of 14.25 in (362 mm).
7. Remove the spacer and head from the rod.
A wiper ring prevents foreign material from entering each
cylinder. O-rings and other seals prevent internal and 8. Remove the O-ring and backup ring from the outside of
external leakage. the head and the wiper ring and rod seal from the inside
of the head.
The cylinder weighs approximately 40 lb (20 kg).
9. Remove the O-ring from the rod.
Maintenance
Inspection
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Disassembly 1. Clean all parts with solvent and dry with compressed air.
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NOTE: Any maintenance requiring disassembly of the Inspect all parts for serviceability.
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cylinders should include replacement of all seals
and rings. A seal kit will supply the required items.
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1. Extend the rod until the piston is approximately 4 in (10.2 3. Check piston for damage. If piston is damaged,
cm) from fully extended. determine if it can be repaired or must be replaced.
2. Using a spanner wrench or chain wrench, unscrew the 4. Inspect rod for straightness. Determine if it can be
er
head from the cylinder barrel. straightened or must be replaced.
CAUTION
CAUTION Before installing new seals and rings, clean all surfaces
Do not use air pressure to remove the rod. Use only a and carefully remove burrs and nicks. Parts displaying
source of controlled hydraulic fluid pressure if the rod is excessive wear or damage should be replaced.
hard to move. Injury may result from the cylinder rod
unexpectedly exiting the cylinder barrel. 5. Stone out minor blemishes and polish with a fine crocus
cloth.
CAUTION parts that have been stoned and polished.
Exercise extreme care when handling or setting down the Assembly
maintenance and expense.
CAUTION
3. Remove rod and attached parts from the barrel.
When installing new seals and rings, avoid stretching
NOTE: Cover the barrel opening to avoid contamination. seals or scratching the grooved or gland surfaces. Make
CAUTION Damage to the cylinder or unexpected operation may
When removing seals and rings, avoid scratching the result.
NOTE: Lubricate seals and rings with clean hydraulic fluid.

1. Install the O-ring onto the rod.

2. Install the replacement wiper ring and rod seal in the
CAUTION
inside of the head. Make sure the lips of the seal face the
piston. Exercise extreme care when handling the rods. Damage
3. Install the replacement O-ring and the backup ring on and expense. Also, take care to avoid damaging grooved
the outside of the head. or gland surfaces, rings or seals during rod insertion.
4. Install the replacement O-ring in the inside of the piston.
5. Lubricate the rod with clean hydraulic fluid. attached parts into the barrel with a slight twisting
motion.
6. Slide the head, larger OD end first, onto the rod.
11. Thread the head into the barrel and using a spanner
7. Install the piston onto the rod. Secure the piston with the
wrench or chain wrench, tighten the head.
nut.
8. Install the replacement piston seal and wear ring on the
outside of the piston. CAUTION
9. Lubricate all parts freely with clean hydraulic fluid. Do not use air pressure to cycle or pressurize the cylinder.
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Pressurize and cycle the cylinder with hydraulic fluid
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pressure. Static pressure test the cylinder at 3500 psi
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Make repairs as needed.
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12
11
5
16
4
6
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9
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3
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7 2
13
14, 15
7517
FIGURE 2-47

1 Barrel 9 O-ring
2 Rod 10 Backup Ring
3 Head 11 Piston Seal
4 Piston 12 Wear Ring
5 Nut 13 O-ring
6 Spacer 14 Grease Fitting
7 Wiper Ring 15 Cap
8 Rod Seal 16 O-ring

OUTRIGGER EXTENSION CYLINDER 4. Remove the nut and piston from the rod.
5. Remove the head from the rod.
Description
6. Remove the O-ring and backup ring from the outside of
The four extension cylinders have 2.5 in (63.5 mm) diameter the head and the wear ring, rod seal and wiper ring from
bores. the inside of the head.
Each cylinder (Figure 2-48) has a retracted length of 108.88 7. Remove the O-ring from the rod.
± 0.12 in (276.5 cm) from the center of the rod bushing to the
center of the barrel bushing. Each cylinder’s extended length Inspection
is 205.9 ± 0.12 in (523 ± 0.30 cm). The stroke of each
cylinder is 97 in (246 mm).
cylinder. O-rings and other seals prevent internal and
external leakage.
3. Check rod’s piston area for damage. If it is damaged,
The cylinder weighs approximately 104.9 lb (47.6 kg).
determine if it can be repaired or must be replaced.
Maintenance 4. Inspect rod for straightness. Determine if it can be
straightened or must be replaced.
Disassembly
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NOTE: Any maintenance requiring disassembly of the
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cylinders should include replacement of all seals CAUTION
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and rings. A seal kit will supply the required items. Before installing new seals and rings, clean all surfaces
and carefully remove burrs and nicks. Parts displaying
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excessive wear or damage should be replaced.
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CAUTION
Do not use air pressure to remove the rod. Use only a 5. Stone out minor blemishes and polish with a fine crocus
source of controlled hydraulic fluid pressure if the rod is cloth.
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hard to move. Injury may result from the cylinder rod 6. Clean with solvent and dry with compressed air any
unexpectedly exiting the cylinder barrel. parts that have been stoned and polished.
rod. Damage to the rod surface may cause unnecessary Assembly
1. Using a spanner wrench or chain wrench, unscrew the CAUTION

head from the cylinder barrel. When installing new seals and rings, avoid stretching
2. Rapidly pull the rod against the head to free it. Remove sure parts are clean before and during assembly. Make
rod and attached parts from the barrel. sure seals and rings are installed in the proper order.
NOTE: Cover the barrel opening to avoid contamination. Damage to the cylinder or unexpected operation may
result.
CAUTION NOTE: Lubricate seals and rings with clean hydraulic fluid.
When removing seals and rings, avoid scratching 1. Install the O-ring on the rod.
2. Install the replacement wear ring, rod seal and wiper ring
in the inside of the head. Make sure the rod seal’s rim
3. Remove the wear rings and piston seal from the outside
groove is closer to the wear ring.
of the piston.
3. Install the replacement O-ring and the backup ring on
the outside of the head.
disassembly will aid in installation of new seals and
rings. Pay attention to how each seal and ring is 4. Lubricate the rod with clean hydraulic fluid.
rings improperly.

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8 2
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7
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5
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10
14 11
12
13
7282
4
FIGURE 2-48

1 Barrel 8 Wear Ring
2 Rod 9 O-ring
3 Piston 10 O-ring
4 Head 11 Backup Ring
5 Spacer 12 Rod Seal
6 Nut 13 Wiper Ring
7 Piston Seal 14 Wear Ring

5. Slide the head, wear ring end first, onto the rod. 8. Remove the cover from the barrel. Insert the rod and
6. Install the replacement wear rings and seal on the
motion.
outside of the piston.
9. Push the head into the barrel.Install the nut on the rod.
7. Lubricate all parts freely with clean hydraulic fluid.
CAUTION
CAUTION
Do not use air pressure to cycle or pressurize the cylinder.
Exercise extreme care when handling the rods. Damage
and expense. Also, take care to avoid damaging grooved
or gland surfaces, rings or seals during rod insertion.
10. Pressurize and cycle the cylinder with hydraulic fluid
pressure. Static pressure test the cylinder at 20684 kPa/
20.6 bar (3000 psi). Check for proper operation and any
leakage. Make repairs as needed.
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OUTRIGGER JACK CYLINDER 4. Remove a hydrolock seal from the outside of the piston
to gain access to the set screw.
Description NOTE: Arranging discarded seals and rings in the order of
The four outrigger jack cylinders each have a hollow rod for disassembly will aid in installation of new seals and
internal porting (Figure 2-49). Each cylinder has a 6.5 in rings. Pay attention to how each seal and ring is
(165.1 mm) diameter bore. A port block is welded to the rod installed to avoid installing replacement seals and
of each cylinder and a pilot operated check valve is threaded
into each port block.
rings improperly.
2
5. Remove the piston’s set screw. Unscrew the piston from
The retracted length of the cylinder from the end of the barrel the rod.
to the center of the rod’s port block rod bushing is 55.75 ± 6. Remove the other hydrolock seal from the outside of the
0.12 in (142 ± 0.30 cm). The extended length of the cylinder piston.
from the end of the barrel to the center of the rod’s port block
rod bushing is 88 ± 0.12 in (223.5 cm). Its stroke is 32.25 in 7. Remove the O-ring and the two backup rings from the
(82 cm). inside of the piston.
A wiper ring prevents foreign material from entering the 8. Remove the spacer from the rod.
cylinder. O-rings and other seals prevent internal and 9. Remove the head from the rod.
external leakage.
10. Remove the O-ring and the backup ring from the outside
The cylinder weighs approximately 331 lb (150 kg). of the head and the two wear rings, buffer seal, rod seal
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ef or
and wiper ring from the inside of the head.
Maintenance
Disassembly
nl c Inspection
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R F

and rings. A seal kit will supply the required items. 2. Inspect the barrel carefully for scoring. If barrel is
er
1. Remove the check valve from the port block.
3. Check piston for damage. If piston is damaged,
2. Using a chain wrench, unscrew the head from the barrel. determine if it can be repaired or must be replaced.
4. Inspect rod for straightness. Determine if it can be
straightened or must be replaced. Verify internal
CAUTION passages and ports are clean and undamaged.
Do not use air pressure to remove the rod. Use only a
source of controlled hydraulic fluid pressure if the rod is
CAUTION
unexpectedly exiting the cylinder barrel. Before installing new seals and rings, clean all surfaces
and carefully remove burrs and nicks. Parts displaying
Exercise extreme care when handling or setting down the excessive wear or damage should be replaced.
5. Stone out minor blemishes and polish with a fine crocus
cloth.
3. Remove the rod and attached parts from the barrel.
NOTE: Cover the barrel opening to avoid contamination. parts that have been stoned and polished.
CAUTION
When removing seals and rings, avoid scratching

17
20
7, 8 5
18
19
18
4 15
14
16
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11
R F
13
12
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2
9
10 7485 FIGURE 2-49

1 Barrel 11 Wiper Ring
2 Rod 12 Rod Seal
3 Head 13 Buffer Seal
4 Piston 14 Wear Ring
5 Spacer 15 O-ring
6 Check Valve 16 Backup Ring
7 Setscrew 17 Seal Assembly
8 Insert 18 O-ring
9 Plug 19 Backup Ring
10 Plug 20 Setscrew

Assembly 7. Slide the spacer onto the rod.

8. Screw the piston onto the rod until it can go no farther.
Hold the piston in place with the set screw.
CAUTION
When installing new seals and rings, avoid stretching 9. Install the other replacement hydrolock seal on the
seals or scratching the grooved or gland surfaces. Make outside of the piston over the setscrew. Make sure the
sure parts are clean before and during assembly. Make “vees” on the two hydrolock seals point at each other.
sure seals and rings are installed in the proper order. 10. Lubricate all parts freely with clean hydraulic fluid. 2
Damage to the cylinder or unexpected operation may
result.
CAUTION
NOTE: Lubricate seals and rings with clean hydraulic fluid. Exercise extreme care when handling the rods. Damage
NOTE: Make sure the gaps of the two wear rings are 180 to the rod surface may cause unnecessary maintenance
degrees apart. and expense. Also, take care to avoid damaging grooved
or gland surfaces, rings or seals during rod insertion.
motion.
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12. Clean all oil from the threads of the head. Coat the
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threads with an anti-seize compound (Never-Seez paste
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Buffer Seal
Wiper Ring lubricant or similar lubricant). Using a chain wrench,
screw the head into place on the barrel so its larger OD
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Deep Z Rod Seal
end is flush with the end of the barrel.
R F
FIGURE 2-50 13. Check the inside of the port block for any sharp edges or
burrs and remove as necessary with emery cloth.
1. Install the replacement wear rings, buffer seal, rod seal
er
and wiper ring in the inside of the head (Figure 2-50). 14. Install new O-rings onto the check valve.
Make sure the buffer seal’s step is away from the wear
15. Lubricate the check valve and O-rings with clean
rings. Make sure the deep Z rod seal rim groove is closer
hydraulic fluid.
to the wear rings.
2. Install the replacement O-ring and the backup ring on
the outside of the head. CAUTION
3. Install the replacement O-ring and backup rings in the Do not damage the O-rings during installation of the check
inside of the piston. valve. If the check valve turns freely then gets hard to turn,
then easy to turn, remove the check valve and check the
O-rings. They have probably been damaged by a sharp
Hydrolock Piston Seals edge of a port.
NOTE: The check valve should turn by hand until

compression of the O-rings begins.
16. Carefully install the check valve into the port block until
fully seated.
FIGURE 2-51 CAUTION

4. Install one replacement hydrolock seal on the outside of Damage to the seals may result.
the piston (Figure 2-51). Leave the other hydrolock seal
off for now so there is still access to the piston’s set
screw hole.
pressure. Test the cylinder at 4500 psi (31026 kPa).
5. Lubricate the rod with clean hydraulic fluid. Check for proper operation and any leakage. Make
repairs as needed.

CAB TILT CYLINDER 6. Rapidly pull the rod against the head to free it. Remove
rod and attached parts from the barrel. Place the rod on
Description a surface that will not damage the chrome or allow the
rod assembly to drop.
The cab tilt cylinder (Figure 2-52) installed beneath the cab
has a 2.5 in (6.3 cm) diameter bore. NOTE: Cover the barrel opening to avoid contamination.
The cylinder has a retracted length of 20.94 in (53.1 cm) and

an extended length of 29.19 in (74.1 cm) from bushing center CAUTION
to bushing center. The cylinder has a stroke of 8.25 in (20.9
When removing seals and rings, avoid scratching the
cm).
cylinder. O-rings and other seals prevent internal and 7. Remove the seal from the outside of the piston.
external leakage.
The cylinder weighs approximately 19.9 lb (9.07 kg). disassembly will aid in installation of new seals and
Maintenance installed to avoid installing replacement seals and
rings improperly.
Disassembly
8. Loosen and remove the nut securing the piston.
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Remove the piston from the rod.
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and rings. A seal kit will supply the required items. 9. Remove the O-ring from the inside of the piston.
1. nl c
Secure the cylinder in a clean work area by use of 10. Remove the head from the rod.
O en
clamps or a chain vise to prevent rolling. 11. Remove the O-ring and backup ring from the outside of
R F
2. Retract the cylinder fully to avoid damaging the rod the head. Remove the wiper ring and the rod seal from
during removal. the inside of the head.
er
NOTE: Mark or note the piston and head relationship to the Inspection
rod and barrel.
3. Clean away all dirt from the head. Place protective Inspect for damaged or worn parts and replace as
padding around the rod near the head to prevent required.
damaging the chrome during head removal.
CAUTION
CAUTION Clean all surfaces and remove all burrs and nicks before
Do not use air pressure to remove the rod. Use only a installing new seals and rings. Replace all damaged or
source of controlled hydraulic fluid pressure if the rod is worn parts.
unexpectedly exiting the cylinder barrel.
Exercise extreme care when handling or setting down the 2. Stone out minor blemishes and polish with fine crocus
rod. Damage to the rod surface may cause unnecessary cloth.
3. Clean all with solvent and dry with compressed air any
parts that have been stoned and polished.
4. Position the rod mount with the ports facing down.
4. Inspect the barrel for scoring.
5. Using a means of collecting the oil, remove the port
plugs and allow cylinder to drain.

1
2
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5 8
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6
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9
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10 11
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6722
FIGURE 2-52

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

Assembly 7. Install the piston onto the rod. Secure the piston with the
nut. Lubricate the threads and torque the nut to 130 ± 5
lb-ft (176.2 ± 6.7 Nm).
CAUTION 8. Install the seal on the outside of the piston.
When installing new seals and rings, avoid stretching
seals or scratching the grooved or gland surfaces. Make 9. Lubricate all parts freely with clean hydraulic fluid.
Damage to the cylinder or unexpected operation may CAUTION
result. Exercise extreme care when handling or setting down the
NOTE: Lubricate new seals and rings with clean hydraulic maintenance and expense.
fluid.
1. Install the replacement wiper ring into the head. attached parts into the barrel with a slight twisting
2. Install the rod seal in the inside of the head. Make sure motion.
the lips of the seal face the piston. 11. Push the head into the barrel. Torque the head to 20 lb-ft
3. Install the O-ring and backup ring onto the outside of the (27.1 Nm).
head.
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4. Install the O-ring in the inside of the piston. CAUTION
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5.
6. nl c
Lubricate the rod with clean hydraulic fluid.
Slide the head, larger outside diameter end first, onto
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the rod.
R F

(20,684 kPa). Check for proper operation and any
leakage. Make repairs as needed.
er

POWER PIN CYLINDER 6. Remove the setscrew from the flange.

7. Remove rod assembly and attached parts from the
Description barrel. Place the rod on a surface that will not damage
The power pin cylinders (Figure 2-53) are installed in the the chrome or allow the rod assembly to drop.
outrigger box assemblies have a 4.0 in (10.1 cm) diameter NOTE: Cover the barrel opening to avoid contamination.
bores.
The cylinder has a retracted length of 20.31 in (51.5 cm) and 2
an extended length of 26.43 in (67.1cm). Each cylinder has a CAUTION
stroke of 6.12 in (15.5 cm). When removing seals and rings, avoid scratching the
external leakage. 8. Unscrew the rod end from the rod.
The cylinder weighs approximately 60.1 lb (27.3 kg). 9. Remove the seal and wear rings from the outside of the
piston.
Maintenance NOTE: Arranging discarded seals and rings in the order of
Disassembly rings. Pay attention to how each seal and ring is
NOTE: Any maintenance requiring disassembly of the installed to avoid installing replacement seals and
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cylinders should include replacement of all seals rings improperly.
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and rings. A seal kit will supply the required items.
1. nl c
Secure the cylinder in a clean work area by use of
10. Loosen and remove the nut securing the piston.
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clamps or a chain vise to prevent rolling. 11. Remove the O-ring from the inside of the piston.
R F
2. Retract the cylinder fully to avoid damaging the rod 12. Remove the head from the rod.
during removal.
13. Remove the O-ring, backup ring and wire wrap from the
er
NOTE: Mark or note the piston and head relationship to the outside of the head.
rod and barrel.
14. Remove the wiper ring and rod seal from the inside of
3. Clean away all dirt from the head. Place protective the head.
padding around the rod near the head to prevent
damaging the chrome during head removal. Inspection
Inspect for damaged or worn parts and replace as
required.
CAUTION
source of controlled hydraulic fluid pressure if the rod is CAUTION
Clean all surfaces and remove all burrs and nicks before
installing new seals and rings. Replace all damaged or
Exercise extreme care when handling or setting down the worn parts.
maintenance and expense. 2. Stone out minor blemishes and polish with fine crocus
cloth.
4. Position the rod mount with the ports facing down.
3. Clean all with solvent and dry with compressed air any
5. Using a means of collecting the oil, remove the port parts that have been stoned and polished.
plugs and allow cylinder to drain.
4. Inspect the barrel for scoring.

13
8 14
5
10
11
6
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15
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12
11
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2
R F
7
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7280
FIGURE 2-53

1 Barrel 9 Setscrew
2 Flange 10 O-ring
3 Rod 11 Wear Ring
4 Rod End 12 Piston Seal
5 Piston 13 O-ring
6 Head 14 Backup RIng
7 Wire Wrap 15 Rod Seal
8 Nut 16 Wiper Ring

Assembly 8. Lubricate all parts freely with clean hydraulic fluid.

9. Apply 0.13 in (3 mm) bead of Loctite thread adhesive
#277 or equivalent across the length of the threads on
CAUTION the rod end side of the rod. Install the rod end on the rod
When installing new seals and rings, avoid stretching and torque to 375 to 450 lb-ft (508.4 to 610.1 Nm).
sure seals and rings are installed in the proper order. CAUTION 2
Exercise extreme care when handling the rod. Damage to
NOTE: Lubricate new seals and rings with clean hydraulic the rod surface may cause unnecessary maintenance
fluid. and expense. Also, take care to avoid damaging grooved
1. Install the replacement wiper ring and rod seal into the or gland surfaces, rings or seals during rod insertion.
inside of the head.
2. Install the O-ring, backup ring and wire wrap on the attached parts into the barrel with a slight twisting
outside of the head. motion.
3. Install the O-ring in the inside of the piston.
4. Lubricate the rod with clean hydraulic fluid. CAUTION
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5. Install the head onto the rod. Torque to 200 ± 20 lb-ft Do not use air pressure to cycle or pressurize the cylinder.
ef or
(271.1 ± 27.1 Nm). Damage to the seals may result.
6.
nl c
Install the piston onto the rod. Secure the piston with the
nut. Lubricate the threads and torque the nut to 245 ± 15
O en
lb-ft (332.1 ± 20.3 Nm).
R F
(20,684 kPa). Check for proper operation and any

7. Install the seal and wear rings on the outside of the leakage. Make repairs as needed.
piston.
er

COUNTERWEIGHT PIN CYLINDER NOTE: Cover the barrel opening to avoid contamination.
Description
CAUTION
The counterweight pin cylinder (Figure 2-54) has a 2.0 in
(5.08 cm) diameter bore. The cylinder has a retracted length
of 20.53 in (52.15 cm) from end to end and an extended
length of 32.53 in (82.63 cm) from end to end. Each cylinder
has a stroke of 12.0 in (30.48 cm). 8. Remove the seal from the outside of the piston.
A wiper ring prevents foreign material from entering each NOTE: Arranging discarded seals and rings in the order of
cylinder. O-rings and other seals prevent internal and disassembly will aid in installation of new seals and
external leakage. rings. Pay attention to how each seal and ring is
The cylinder weighs approximately 13.2 lb (6.0 kg). rings improperly.
Maintenance 9. Loosen and remove the nut securing the piston.

Disassembly 10. Remove the O-ring from the inside of the piston.
NOTE: Any maintenance requiring disassembly of the 11. Remove the head from the rod. Remove the O-ring and
cylinder should include replacement of all cylinder backup ring from the outside of the head. Remove the
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seals. wiper ring and the rod seal from the inside of the head.
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1. Secure the cylinder in a clean work area by use of
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clamps or a chain vise to prevent rolling. Assembly
O en
2. Retract the cylinder fully to avoid damaging the rod
R F
during removal. CAUTION

NOTE: Mark or note the piston and head relationship to the When installing new seals and rings, avoid stretching
rod and barrel. seals or scratching the grooved or gland surfaces. Make
er
3. Clean away all dirt from the head. Place protective sure seals and rings are installed in the proper order.
padding around the rod near the head to prevent
damaging the chrome during head removal. NOTE: Lubricate new seals and rings with clean hydraulic
fluid.
1. Install the replacement wiper ring into the head.
CAUTION 2. Install the rod seal in the inside of the head. Make sure
Do not use air pressure to remove the rod. Use only a the lips of the seal face the piston.
source of controlled hydraulic fluid pressure if the rod is
3. Install the O-ring and backup ring onto the outside of the
head.
Exercise extreme care when handling or setting down the 4. Install the O-ring in the inside of the piston.
rod. Damage to the rod surface may cause unnecessary 5. Lubricate the rod with clean hydraulic fluid.
4. Position the rod mount with the ports facing down. 7. Install the piston onto the rod. Secure the piston with the
5. Using a means of collecting the oil, remove the port nut. Lubricate the threads and torque the nut to 130 ± 5
plugs and allow cylinder to drain. lb-ft (176.2 ± 6.7Nm).
6. Using a chain wrench, unscrew the head from the barrel. 8. Install the seal on the outside of the piston.
7. Rapidly pull the rod against the head to free it. Remove 9. Lubricate all parts freely with clean hydraulic fluid.
rod and attached parts from the barrel. Place the rod on
a surface that will not damage the chrome or allow the
rod assembly to drop.

7
2
5
4
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2 9
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10
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R F
11
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3
6845
FIGURE 2-54
Item Description
CAUTION
1 Barrel Exercise extreme care when handling the rod. Damage to
2 Rod the rod surface may cause unnecessary maintenance
and expense. Also, take care to avoid damaging grooved
3 Rod Head or gland surfaces, rings or seals during rod insertion.
4 Piston
5 Nut
6 O-ring motion.
7 Seal Piston Ring 11. Push the head into the barrel. Torque the head to 20 lb-ft
8 O-ring (27.1 Nm).
9 Backup Ring
10 Seal Rod Ring CAUTION
11 Wiper Ring

pressure. Test the cylinder at 24,115 kPa/241.15 bar
(3500 psi). Check for proper operation and any leakage.
Make repairs as needed.

LIFT CYLINDER
Description CAUTION
The lift cylinder has a retracted length of 194.4 in (4940 mm) grooved and gland surfaces.
and an extended length of 357.8 in (9090 mm). The cylinder
has a stroke of 163.3 in (4150 mm).
7. Remove the seal and wear rings from the rod.
A wiper ring prevents foreign material from entering the
external leakage.
The cylinder weighs approximately 2764 lb (1254 kg). installed to avoid installing replacement seals and
rings improperly.
Maintenance 8. Remove the O-ring, backup ring and wear ring from the
Disassembly outside of the head.
NOTE: Any maintenance requiring disassembly of the 9. Remove the head from the rod. Remove the wiper ring,
cylinder should include replacement of all cylinder seals and wear rings from the inside of the head.
seals.
Assembly
1. Secure the cylinder in a clean work area by use of
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clamps or a chain vise to prevent rolling.
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CAUTION
2.
nl c
Retract the cylinder fully to avoid damaging the rod
during removal. When installing new seals and rings, avoid stretching
O en
3. Disconnect the tubing from the valves on the outside of sure parts are clean before and during assembly. Make
R F
the barrel. Remove the valves. sure seals and rings are installed in the proper order.
4. Disconnect the tubing from the barrel.
NOTE: Lubricate new seals and rings with clean hydraulic
er
5. Remove the cap and screw from the barrel. fluid.
1. Install the replacement wiper ring into the head.
2. Install the seals and wear rings in the inside of the head.
CAUTION 3. Install the O-ring onto the outside of the head.
source of controlled hydraulic fluid pressure if the rod is 4. Install the seals and wear rings onto the rod.
hard to move. Injury may result from the cylinder rod 5. Lubricate the rod with clean hydraulic fluid.
rod. Damage to the rod surface may cause unnecessary CAUTION
maintenance and expense. Exercise extreme care when handling the rod. Damage to
the rod surface may cause unnecessary maintenance
6. Remove rod and attached parts from the barrel. Place and expense. Also, take care to avoid damaging grooved
the rod on a surface that will not damage the chrome or or gland surfaces, rings or seals during rod insertion.
allow the rod assembly to drop.
NOTE: Cover the barrel opening to avoid contamination. 6. Remove the cover from the barrel. Insert the rod and
motion.
7. Install the screw and cap into the barrel.
8. Install the valves and tubing to the outside of the barrel.

2
4
4
2
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7512
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9 7 5
6
10, 11
12
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7511-1
14
13 16
19 23 22 26
21 25 27 28
17 20 24
18
FIGURE 2-55

1 Lift Cylinder 7 Bushing
2 Bearing 8 Head
3 Stop Brake Valve 9 Safety Cam
4 Pressure Pick-Off valve 10 Screw
5 Barrel 11 Cap
6 Rod 12 Grease Fitting

1
Item Description
13 Relief valve
14 Thread Pin
15 Lockscrew
16 Check Valve
17 Wiper Ring
18 O-ring
19 O-ring
20 Seal
21 Step Seal
22 O-ring
23 Backup Ring
24 Wear Ring
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25 Guide Ring
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26 Wear Ring
27 Seal
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28 Step Seal
R F
2 1
CAUTION
er

pressure. Test the cylinder at 3500 psi (24,115 kPa).
Check for proper operation and any leakage. Make
repairs as needed.
COUNTERWEIGHT LIFT CYLINDER

The counterweight lift cylinder seals and O-rings are not field
serviceable, the cylinder must be sent back to the factory for
service.
The counterweight lift cylinder (Figure 2-56) incorporates a
Front
rack and pinion system to rotate the rod to lock and unlock
the cylinder in the counterweight.
Proximity Switches
FIGURE 2-57
The two proximity switches are used to signal the ECOS
system, Refer to Section 3, Operating Controls and Adjustment for Switch 1
Procedures in the Operator’s Manual, that the cylinder is
locked or unlocked. The left proximity switch (1, Figure 2-56 1. Use the ECOS System to lock the cylinders.
and Figure 2-57) detects the rack in the locked position. The 2. Loosen the locknuts on the left proximity switch (1,
right proximity switch (2, Figure 2-57) detects the rack in the Figure 2-56 and Figure 2-57).
unlocked position.
3. Screw the proximity switch in until it contacts the rack.

4. Unscrew the switch ¾ turn, which equals 0.75 mm (0.03 3. Screw the proximity switch in until it contacts the rack.
in). The distance between the switch and rack should be
4. Unscrew the switch ¾ turn, which equals 0.75 mm (0.03
0.5 to 1.0 mm (.02 to .04 in) as shown in Figure 2-57.
in). The distance between the switch and rack should be
5. Tighten the locknuts. 0.5 to 1.0 mm (.02 to .04 in) as shown in Figure 2-57.
6. Use an ohmmeter to check for proper operation of the 5. Tighten the locknuts.
switch while cycling the cylinder, to locked and unlocked.
7. Repeat, as necessary, for the left proximity switch on the
6. Use an ohmmeter to check for proper operation of the
switch while cycling the cylinder, to locked and unlocked. 2
other cylinder.
7. Repeat, as necessary, for the right proximity switch on
Adjustment for Switch 2 the other cylinder.
1. Use the ECOS System to unlock the cylinders.

2. Loosen the locknuts on the right proximity switch (2,
Figure 2-57).
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THIS PAGE BLANK

RT9150E SERVICE MANUAL ELECTRICAL SYSTEM
SECTION 3
ELECTRICAL SYSTEM
SECTION CONTENTS
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Diagnostic Connector and Equipment . . . . . . . . . 3-14
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Troubleshooting Vehicle Lights . . . . . . . . . . . . . . 3-14
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Troubleshooting Alarms, Indicators, and
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Emergency Components . . . . . . . . . . . . . . . . . . . 3-14
Jump Starting Hazard . . . . . . . . . . . . . . . . . . . . . . 3-2 Troubleshooting Crane Components and
Charging the Batteries . . . . . . . . . . . . . . . . . . . . . 3-2 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Fuses/Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Alternator Replacement . . . . . . . . . . . . . . . . . . . . 3-14
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Starter Replacement . . . . . . . . . . . . . . . . . . . . . . 3-15 3
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Battery Replacement . . . . . . . . . . . . . . . . . . . . . . 3-15
Dielectric Grease . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Relay Panel Component Replacement . . . . . . . . 3-16
Visual Inspection and Replacement of Electrical Switch Replacement . . . . . . . . . . . . . . . . . . . . . . 3-16
Harnesses and Cables . . . . . . . . . . . . . . . . . . . . . 3-7 Rocker Switch Replacement . . . . . . . . . . . . . . . . 3-16
General Troubleshooting . . . . . . . . . . . . . . . . . . . 3-9 Turn Signal Indicator Replacement . . . . . . . . . . . 3-17
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Tools for Troubleshooting . . . . . . . . . . . . . . . . . . . 3-9 Ignition Switch Replacement . . . . . . . . . . . . . . . . 3-18
ef or
Troubleshooting Engine Starting Problems . . . . . 3-9 Turn Signal Lever and Transmission Shift Lever
nl c
Alternator/Charging System Troubleshooting . . . 3-10
Troubleshooting Accessories . . . . . . . . . . . . . . . 3-11
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Windshield Wiper Assembly Replacement . . . . . 3-20
O en
Troubleshooting Swivel-Caused Electrical Windshield Washer Assembly Replacement . . . . 3-22
R F
Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Skylight Wiper Assembly Replacement . . . . . . . . 3-22

Connector Troubleshooting . . . . . . . . . . . . . . . . 3-11 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
ECOS Control Panel . . . . . . . . . . . . . . . . . . . . . . 3-12 Air Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
er
DESCRIPTION Refer to the electrical schematics at the back of this manual

to aid in troubleshooting an electrical problem.
General
Alternator
The electrical system is 24-volt operation with 24-volt
starting, consisting of an alternator and four lead-acid The alternator (Figure 3-1) is mounted on the engine and is
batteries. The system is the single wire ground return type, belt driven. It is a 70 ampere alternator with an integral
using the machine’s structure as ground. transformer - rectifier unit. When the engine is running, and
the alternator is turning, the alternator’s 24-volt output
Electrical power is transferred to and from the superstructure terminal supplies the crane’s electrical circuits. The output
through the electrical swivel. For more detailed information terminal also supplies the voltage to recharge the batteries
on the electrical swivel, refer to Electrical Swivel, page 6-20. and maintains them at a full state of charge.
The superstructure control module is located behind the front
console in the cab and the carrier control module is located
near the hydraulic fluid tank.

ELECTRICAL SYSTEM RT9150E SERVICE MANUAL
CAUTION!
Possible Equipment Damage!
To avoid possible engine fault codes and undesirable
operation, ensure the keyswitch has been off two minutes
before disconnecting the batteries.
The battery disconnect switch is located to the right side of

the battery box below the air filter (Figure 3-2).To disconnect
the batteries, turn the battery disconnect switch to OFF. Turn
the switch to ON to connect the batteries.
NOTE: Disconnect the batteries if the machine will be
inactive for over 24 hours.
Jump Starting Hazard

Do not attempt to jump start the crane.
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Alternator Alternator Belt
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7621
CAUTION
nl c FIGURE 3-1 It is strongly recommended that the batteries not be

“jumped” with a different vehicle, portable power pack,
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Batteries etc. The surge of power from these sources can
R F
irreparably damage the various electronic controls and

The batteries (Figure 3-2) are located in the battery box on
computer systems. Jump starting the crane batteries with
the left side of the crane behind the fuel tank. Each battery is
a different vehicle while the engine is running can damage
the maintenance free type and is completely sealed except
er
the donor vehicle electronics as well if done improperly.
for a small vent hole in the side. The vent hole allows what
small amount of gases that are produced in the battery to
This crane has multiple computer systems (crane control,
escape. On some batteries, a test indicator located on the
RCL, engine and transmission control) that are highly
top of the battery is used to determine if the battery can be
susceptible to voltage/amperage surges in the electrical
tested in case of a starting problem.
system.
The batteries should be completely disconnected from the
crane electrical system and charged using a battery charger
of appropriate voltage level or replace the batteries with fully
charged batteries. Refer to Charging the Batteries, page 3-2.
Charging the Batteries

When charging the batteries, do not turn on the battery
charger until the charging leads have been connected to the
battery(s). Also, if the battery(s) are found to be frozen, do
not attempt to charge them. Remove the battery(s) from the
crane, allow them to thaw, and then charge the battery(s) to
full capacity.
“Slow charging” is preferred to “fast charging”. Fast charging
saves time but risks overheating the battery(s). Slow
charging at six (6) amps or less develops less heat inside the
battery and breaks up the sulfate on the battery plates more
efficiently to bring the battery up to full charge. The use of a
Batteries Battery Disconnect Switch “smart charger” that automatically adjusts the charging
amperage rate should be used.
FIGURE 3-2

Fuses/Relays Engine Compartment

Fuses protect the electrical circuits and components of the The fuses and relays are located at the front of the engine
crane from shorts and overloads. Relays are used to control compartment to the left of pumps #1 and #3, refer to
various circuits and/or components. The four main locations Figure 3-4, Table 3-2 and Table 3-3 for specific information
for the fuses and relays are: on each component.
• The battery box
F54 F55
• The engine compartment
• The cab fuse/relay panel
• The junction box fuse/relay panel.
Refer to the electrical schematics at the back of this manual
for a diagram of the electrical system. 3
Battery Box
The battery box is located to the right of the fuel tank. The
fuses are located at the rear of the battery box behind the
batteries, refer to Figure 3-3 and Table 3-1 for specific
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information on each fuse.
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F56, F57, F59 & F61 not visible F51 F52 F53
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7538-3 F58, F60 K601 K3610 FIGURE 3-4
Table 3-2: Battery Box Fuses (Figure 3-4)

er
Fuse Amp Fuse Circuit Supply
F54 125 Grid Heater Relay
B+
F55 125 Alternator Charge Circuit
F58 30 ESX-3 Power
F55
F60 15 I/O-0 Power
Table 3-3: Battery Box Relays (Figure 3-4)
Relay Function
K601 Grid Heater
K3610 Engine Starter
FIGURE 3-3
Table 3-1: Battery Box Fuses (Figure 3-3)

F51 100
F52 100 Superstructure Power
F53 100
F56 30 Engine ECM Power B+
F57 5 Diagnostic Connector Power
F59 5 CraneSTAR Power
F61 5 ESX-3 Power

Cab Relay/Fuse Panel

The panel is located behind the driver’s seat. The fuses are
easily accessible. To access the relays and other electronics
the two retaining screws must be removed and the panel
tilted forward. Refer to Figure 3-5, Figure 3-6, Figure 3-7,
Table 3-4 and Table 3-5 for specific information on each
component.
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7538-1 nl c
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Warning Buzzer FIGURE 3-5
Fuse Panel
R F
er
FIGURE 3-6

Table 3-4: Cab Fuse Panel (Figure 3-6)

K3712 K3707
ESX-2 Power, EKS5 Display,
F3-1 3 B+ K3401
ECOS Display ESX-2
K0107
F3-2 2 Cab Switches ESX2 K3706
F3-3 10 RCL Controller Power K0102 EKS-5
F3-4 10 ECOS Display K0103 K0102
F3-5 20 ESX-2, Park Brake

F3-6 5 ESX-2, EKS5 Display K3706
F3-7 5 Joysticks 3
F3-8 5 Open
K0103 K0101
F4-1 10 Open Fuse Panel Warning Buzzer
Dome Light, Aircraft Warning Fuse/Relay Panel Assembly

F4-2 10 B+ 7515-5
(Open-Tilted Forward) FIGURE 3-7
Light, 12V/24V Converter
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F4-3 7.5 Horn Table 3-5: Cab Relay Panel (Figure 3-7)
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Relay Function
F4-4
F4-5
20
5 nl c
Heater and A/C Fan
Foot Throttle Pedal, Rear Steer
K0102
K0103 K0101 Accessory #1 Position
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F4-6 5 Open K0102 Accessory #2 Position (Ignition ON)
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F4-7 20 Open K0103 Ignition ON

B+ K0107 Heater and A/C
F4-8 20 Open
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F5-1 15 Boom Lights, Work Lights K3401 Horn
Windshield Wiper, Windshield K3706 RCL Bypass

F5-2 10
Washer K3707 RCL Bypass
F5-3 15 Skylight Wiper K3712 RCL Warning (CE Option)
F5-4 10 Steer Column K0101
F5-5 5 Cab Tilt
F5-6 5 Switch LEDs
F5-7 3 RCL Warning (CE Option)
F5-8 10 Cab Circulating Fan

Junction Box Fuse/Relay Panel

The junction box fuse/relay panel is located behind the cab in F1 F2
front of the counterweight.To open the cabinet use the
special key provided. Refer to Figure 3-8, Figure 3-9,
Figure 3-10 and Table 3-6 for specific information on each
component. The relays in this panel function as interlocks.
FIGURE 3-10
Table 3-6: Junction Box Fuses (Figure 3-10)

Swing Brake Static Press. Sw.,
F1-1 20 I/O-3, Filter Feed Press. Sw.,
ESX-1 K0104
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F1-2 20 I/O-4 Power
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Junction Box FIGURE 3-8 F1-3 10 Luffing Jib Switch
K0109
K3704
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F1-4 20 Open
F1 Fuses F2 Fuses F1-5 5 Flashing Beacon Ign. Sw.
F1-6 3 Open
er
K3704
K3705 K3701
F1-7 3 I/O-3 Power, Cable Reel
F1-8 5 Open
K3406
K3704
F2-1 2 Hydraulic Boom Extension ESX-0
K0109 F2-2 20 ESX-0
K0111
F2-3 20 ESX-1
K0104
F2-4 5 Bypass Power
K3703 K0111
F2-5 15 A/C Relay
K3702
Emergency Operation Hand Held
F2-6 3 B+
Control
FIGURE 3-9
F2-7 20 Open
F2-8 20 Open

MAINTENANCE 1. Check the connection for moisture before application of

the grease. If moisture is found, clean or replace the
General connector as necessary.
Electrical system maintenance includes troubleshooting and 2. Screw a tip or trigger assembly on to the can of dielectric
replacement of damaged components. Observe standard grease if necessary.
wiring practices when replacing components. 3. Apply the grease onto socket (female) contacts.
CAUTION
Burning hazard!
Rubber
If it is necessary to perform electrical maintenance on live
or hot circuits, remove all rings, watches, and other Seal 3
jewelry before performing maintenance.
Serious burns may result from accidental grounding or
shorting circuits.
Damage to the machine or test equipment
possible!
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Make sure the batteries are disconnected before
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performing any maintenance on an electrical circuit which
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is not fused or when performing continuity checks.
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Never replace original wiring with wiring of a smaller size Terminal
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(gauge). Sockets
9746
Dielectric Grease Example. For illustration purposes FIGURE 3-11
er
Dielectric grease was applied to the following connections at only. Your connector may differ.
the factory when the crane was assembled. When servicing
4. Use a clean towel to remove excess grease from the
electrical connections, dielectric grease must be re-applied
surface of the connector, and wipe grease into the
to these connections.
terminal sockets (Figure 3-11).
• All Deutsch Connectors
5. Ensure grease is applied to each terminal socket. The
• All Valve Solenoid connections on Hydraulic valves and towel with excess grease can be used to fill empty
Transmissions terminal sockets (Figure 3-11).
• All Harness Connections 6. Ensure grease is applied to the entire surface of the
connector’s rubber seal (Figure 3-11).
• RCL Module Connections (except M12 and M8
connectors) NOTE: Do not allow grease to come in contact with any
painted surface, or any other components.
Excluded Connections 7. If clean up is necessary, contact cleaner or petroleum
Do not apply dielectric grease to the following connections: distillates can be used.
• All Connections Inside the Cab 8. Secure the connector when complete.
• M12 and M8 Connectors Visual Inspection and Replacement of
• Pin-type Contacts Electrical Harnesses and Cables
Visually inspect all electrical harness and cable assemblies
Applying Dielectric Grease to an Electrical
every month or at 250 hours of service life for the following:
Connector
• Damaged, cut or deteriorated harness loom covering.
Use the following procedure to apply dielectric grease to an
electrical connection. Grease should be applied immediately • Damaged, cut or abraded individual wires or cable
prior to securing the connector. Ensure that grease is applied insulation.
to all terminal sockets (Figure 3-11). • Exposed bare copper conductors.

• Kinked, crushed, flattened harnesses or cables. Ambient temperature, humidity and other factors affect the
life of electrical harness and cable assemblies. Use the
• Blistered, soft, degraded wires and cables.
following information for the inspection and replacement of
• Cracked, damaged, or badly corroded battery terminal these assemblies:
connections.
• Cranes operating in climate zone “C” should have the
• Inspect all machine ground connections for damaged harness and cable assemblies replaced after 10,000
terminals or excessive corrosion. hours of service life.
• Other signs of significant deterioration. • Cranes operating in climate zones “A” or “B” with high
ambient temperatures could see electrical service life
If any of these conditions exist, evaluate the harness
reduced by 25% to 40%. It is recommended to replace
assemblies for repair or replacement. For replacement of
these assemblies after 8000 hours of service life.
harness assemblies, refer to your Grove Crane Care Parts
Manual. • Cranes operating in climate zones “D” and “E”, cold
climates, should expect a degradation of mechanical
At the same service interval, visually inspect all Controller
properties, long term exposure to these cold
Area Network (CAN) nodes and electrical junction boxes for
temperatures will negatively impact service life.
the following:
Therefore, it is recommended these electrical harnesses
• Damaged or loose connectors. and cable assemblies be inspected regularly as service
life may be less than 10,000 hours.
• Damaged or missing electrical clamps or tie straps.
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• Cranes operating in salt water climates could see a
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• Excessive corrosion or dirt on the junction box significant reduction in service life. Therefore it is
•
assemblies.
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Loose junction box mounting hardware.
recommended for these electrical harnesses and cable
assemblies to be inspected regularly as service life may
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be less than 8,000 hours.
If any of these conditions exist, address them appropriately.
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Table 3-1
er
Zone Classification
A Tropical Moist: All months average above 18° C. Latitude 15° - 25° North and South
B Dry or Arid: Deficient precipitation most of the year. Latitude: 20° - 35° North and South
C Moist Mid-Latitude: Temperature with mild winters. Latitude: 30° - 50° North & South
D Moist Mid-latitude: Cold winters. Latitude 50° - 70° North & South
E Polar: Extremely cold winters and summers. Latitude: 60° - 75° North & South

General Troubleshooting these lights come on, suspect the batteries. Charge
batteries as needed, or replace the batteries if you can
Troubleshoot per the following guidelines: jump-start the crane from another crane.
3. If you hear the starter relay clicking repeatedly, power is
reaching the starter, but not enough. Suspect the
batteries. Charge batteries as needed, or replace the
CAUTION batteries if you can jump-start the crane from another
Electric Shock Hazard! crane.
Some troubleshooting procedures require testing live 4. Check Fuse 53 (100 amp) inside battery box. If fuse is
(energized) components. Perform these steps observing blown, replace it.
good safety practices to avoid electrical shock injury.
5. Turn the ignition switch to RUN (1). Check the voltmeter.
If it doesn’t move (but the head lights, tail lights, marker
NOTE: This machine incorporates a CAN-Bus Multiplex
system. In order to effectively troubleshoot the lights, dome light, work light, or gauge lights and panel 3
electrical system, contact an authorized Grove lights will come on), suspect the ignition switch and the
distributor and/or Manitowoc Crane Care. power circuit to it starting at the ignition switch fuse.
Repair or replace circuit, switch, or fuse as needed.
Make voltage checks at terminations when
components are installed and operating. Make 6. If the battery, fuses, ignition switch, and power circuit to
continuity checks (with batteries disconnected) the ignition switch check out, do one of the following:
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when components are isolated or removed. a. If you hear no noise when you try to turn the starter,
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troubleshoot the start circuit (ignition switch, electric
1.
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First, use reported symptoms to identify a problem or a
suspect component. s h i f t e r, a n d w i r i n g f r o m i g n i t i o n s w i t c h t o
superstructure control module (connector A)
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2. Test the suspect component per instructions in this through carrier control module (connector A) to
R F
section. The instructions identify the fuses and starter relay. Make repairs as needed.
components and guide you from the easiest and most
likely problems to the hardest and least likely problems. b. If the engine still won’t start, and you hear no noise
er
o r j u s t a s i n g l e c l i c k , s u s p e c t t h e s t a r t e r.
3. Using a multimeter, test the circuit for continuity if you Troubleshoot the start circuit from the starter relay
suspect a broken circuit or for voltage if you suspect a through the starter solenoid to the starter motor and
power problem. Check the electrical schematic and ground. Make repairs as needed. If the starter
wiring diagram for most accurate wiring information. solenoid or the starter motor is faulty, replace the
4. If the component proves faulty, replace it with a known starter.
working component. If wiring proves faulty, replace it c. If the starter engages but can’t turn the engine (and
with wiring of equal gauge. the lights dim, signaling power drain during start
5. After troubleshooting, test the repaired circuit. Verify the attempt), check the starter’s feed circuit from the
circuit works properly. batteries for resistance. If the resistance is high,
make repairs. If the circuit checks out, replace the
Tools for Troubleshooting starter. If the engine still won’t start, suspect a
seized engine.
This machine Incorporates a CAN bus Multiplex system. In
order to effectively troubleshoot the electrical system, you d. If the starter turns the engine, but it still won’t start,
need a Windows-based PC, CAN-link service software and a check fuses F51, F52, F53 and F56 in the battery
connection cable. The CAN-link service software and box. Replace if required. Ensure fuel system can
connection cable are available through Crane Care to those draw fuel from the tank and pump it to the engine;
service technicians who have attended the Grove New make repairs as needed.
Technology training course. 7. Refer to the engine manual for further instructions.
Troubleshooting Engine Starting Problems NOTE: If the starter won’t disengage during running, verify
the starter is mounted properly so its gear won’t
1. Verify the battery terminals are connected and clean, the mesh with the engine’s flywheel when not trying to
transmission is in neutral, and the machine is fueled. start engine. Troubleshoot the starter relay and
2. Try to turn on the head lights, tail lights, marker lights, ignition switch for closed contacts. If these
dome light, work light, or gauge lights and panel lights to components check out, replace the starter.
verify the batteries have at least some charge. If none of

Alternator/Charging System following load test. If the voltage is lower than 24.4 V,
Troubleshooting recharge the battery(s) before performing the load test.
Load Test
Anytime there is a problem with the charging system the
batteries, alternator and cables should be tested. 1. Refer to the load tester manual for instructions on
performing the load test.
Required Tools
2. Connect the load tester to one battery and test.
The following is a list of tools needed to diagnose the
3. Connect the tester to the other battery and test.
charging system:
Proceed to the next test if the batteries passed the load test.
Replace a battery if it failed the load test.
Grove
Equipment Example
Part No. Voltage at Alternator
Digital Multimeter Fluke® 177 9999101763 Measure voltage from alternator case to output terminal. The
Carbon Pile Load meter should read 24.6 V or above.
Autometer® SB5 9999101765
Tester Battery Drain
Current Clamp Meter Fluke® 336 9999101764 With a DC ammeter capable of measuring milliamps, and a
10 amp capability, perform the following test:
Visual Check
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1. Make sure the ignition key is off.
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• Belts: tight, in good condition, not frayed, cracked or
glazed
nl c 2.
3.
Set the meter to the 10 amp position.
Check for a drain by disconnecting the negative battery
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• Pulley: tight, aligned with other pulleys, not glazed
terminals and measuring between the battery post and
R F
• Alternator mounting bolts and wiring connections: clean the cable with the ammeter.
and tight, no signs of heat damage
This reading should not be more than 80 milliamps (.08 ma)
• Batteries: terminals and cables, clean and tight, no with all accessories OFF. A higher reading indicates
er
corrosion or signs of heat damage. something is draining the batteries and the system must be
troubleshot and repaired.
Engine Off Tests
Engine On Tests
Batteries
Output Voltage Test
1. Connect multimeter to negative and positive battery
terminals.
CAUTION
2. Connect ammeter clamp around output wire of
Burning hazard!
alternator to the batteries.
Do not smoke or allow sparks or open flame near
batteries, they can explode. 3. Start engine and increase speed to 2000 rpm.
When working with batteries always wear protective With fully charged batteries and no loads on the system, the
clothing, gloves and eye protection. Batteries contain multimeter should read 26V.
corrosive liquids that can burn skin and eyes and destroy
NOTE: Amperage should be 15 amps or less.
clothing.
Remove rings, watches or other jewelry before working Maximum Amperage Test
with batteries. A battery can produce a short-circuit 1. Connect an adjustable carbon pile load tester to the
current high enough to weld a ring, or the like, to metal batteries’ positive and negative cables.
causing severe burns
2. Run engine at 2000 rpm.
Disconnect the batteries and test each battery individually. 3. Adjust carbon pile to obtain maximum amperage while
Check the electrolyte level, if possible not letting voltage fall below 25 volts.
Using the multimeter, measure the voltage across the 4. Amperage should be within 10 to 15 amps of alternator
terminals. If the voltage is 24.4 V or above, perform the rating; this alternator is rated at 70A, so the meter should
read 55A to 60A.

NOTE: If the correct readings were not obtained in the lights will come on), there is an accessory circuitry
Engine On Tests, perform the following two tests. problem.
Voltage Drop Test 2. Check the primary power circuit to the accessory relays.
Make circuit repairs as needed.
Positive Side
3. If the problem remains, check the ignition switch and the
1. Set the multimeter to the 2 volt range.
accessory control circuit from the ignition switch through
2. Connect the positive (+) lead to the alternator output the coil of the accessory relays K0101 and K0103 to
terminal and the negative (–) lead to the battery positive ground. Turn the ignition switch to the ACC (3) position
terminal or post. Do not connect the meter to the battery and listen for audible click of relays K0101 and K0103. If
cable. neither relay clicks, then there is no power through the
switch when it is in the ACC (3) position. Replace
3. Run the engine at 2000 rpm. ignition switch if there is no power through it when in the
4. Load system with carbon pile load or lights and heater ACC (3) position. If one relay clicks and the other does
not, check continuity of the coil of the relay that does not
3
blower.
click. If there is no continuity through its coil, replace the
Allowable drop is 0.2 to 0.5 volts. Higher voltage indicates relay. Make circuit repairs to accessory control circuit as
loose, corroded, or broken connections. needed.
Negative Side 4. If the problem remains, check the accessory relay
contacts and the accessory power circuit. Replace relay
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1. Set the multimeter to the 2 volt range.
if its contacts stay open when the coil is energized. Make
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2. Connect the negative (–) lead to alternator case and the circuit repairs as needed.
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positive (+) lead to the battery negative terminal or post.
Troubleshooting Swivel-Caused Electrical
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Do not connect the meter to the battery cable.
Problems
R F
3. Run the engine at 2000 RPM.

Many crane component electrical troubles can be traced to
4. Load system with carbon pile load or lights and heater
the electrical swivel. Troubles common to the swivel are
blower.
er
improper mounting, foreign material between the brushes
Allowable drop is 0.1 to 0.3 volts. Higher voltage indicates and slip rings, incorrect wiring from the swivel to the
loose, corroded, or broken connections. components, incorrect wire size, worn brushes, improper
spring tension on the brush assembly, and loose setscrews
If any voltage drop is greater than the normal range,
on the slip ring assembly. Refer to the electrical schematic
troubleshoot the system and repair any problems.
and wiring diagram for slip ring connections and amperages.
After correcting any problems, perform the Engine On Tests
again. If satisfactory results are not obtained, remove the Connector Troubleshooting
alternator and bench test.
The cause of an electrical problem may be a loose or
corroded connection in the pin or socket connectors. Check
Troubleshooting Accessories the connectors to ensure that the pins and sockets are
If the crane’s engine starts and charges properly, but none of properly seated and engaged. If the pins and sockets show
its components except the horn or lights work, the accessory any signs of corrosion, use a good quality electrical contact
circuitry may be faulty. Check as follows: cleaner or fine sandpaper to clean them. When the pins or
sockets show signs of arcing or burning, it will probably be
1. Turn the ignition switch to the ACC (3) position. Try to necessary to replace them.
turn on the cab circulating fan, the heater fan, the
defroster fan, or the windshield wipers or washer. If none After cutting the pin or socket off, the wire will most likely be
of these come on (but the head lights, tail lights, marker too short. Using a wire that is too short will allow pressure to
lights, dome light, work light, or gauge lights and panel be applied to the pin or socket and wire where they are
crimped when the pin or socket is inserted in the plug or
receptacle. Add a short length of the same size wire to the
short wire by crimp splice or solder. Use heat shrinkable
tubing or other suitable material to insulate the splice.

Table 3-2
Deutsch Extraction Tool Table
Description Deutsch Part Number Grove Part Number

12 gauge wire 114010 9-999-100194
16 gauge wire 0411-204-1605 9-999-100195
8-10 gauge wire 114008 7-902-000012
4-6 gauge wire 114009 7-902-000009
20-24 gauge wire 0411-240-2005 9-999-102084
Table 3-3
Deutsch Crimping Tool Table
Description Deutsch Part Number Grove Part Number

12, 14, 16, 18, 20, 22, 24 gauge wire HDT-48-00 9-999-100808
4, 6, 8, 10 gauge wire HDT-04-08 9-999-100842
ECOS Control Panel
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The ECOS control panel is located on the right side console.
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Various menus are displayed on the ECOS display. The
individual buttons have a different function in each menu.
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The display shows various indicators about the crane; the
R F
engine, outriggers, boom, etc. All the indicators concerning

the crane’s functions are shown on the ECOS display except
for information about a lift, which is controlled and shown on
er
the RCLRCL display. Refer to Section 3 of the Operator’s
Manual for complete information on the ECOS controller.
After the ignition has been switched on, a lamp test is
conducted. Check that the lamps indicated in Figure 3-12
and Figure 3-13 light up briefly.
FIGURE 3-13
If the specified time is insufficient, switch on the ignition
again or you can perform a manual lamp test, as follows:
1. If necessary, in the ECOS display, open the main menu
and press the F4 button (1) (Figure 3-14). The Settings
submenu (Figure 3-15) opens.
FIGURE 3-12
FIGURE 3-14
2. Press the F5 button (1) (Figure 3-15).

Error Messages
If ECOS detects an error, an error message is indicated by
two flashing lamps, (Figure 3-17):
• The Warning/Error indicator lamp (1)
• The ? button lamp (2).
FIGURE 3-15
The lamps indicated in Figure 3-12 and Figure 3-13 light up

until you let go of the button.
3
Contact Crane Care if one or more lamps do not light up.
Warning Messages FIGURE 3-17
ECOS differentiates between warning messages and error When all error messages have been acknowledged, lamp (1)
messages, see Error Messages, in the following section. A and lamp (2) lights up.
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warning message indicates that certain values do not
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Both lights start to flash again as soon as a new error occurs.
correspond to a set value.
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In the event of a warning message, the following lamps flash:
To determine what the error is, you must open the Error
submenu by pressing the ? button (2) (Figure 3-18). The
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• the Warning/Error indicator (1) (Figure 3-16) button is only active when the lamp (1) flashes or lights up.
R F
• the A button lamp (2).

er
FIGURE 3-18
Each error is defined by an error code (5) and the symbols

(1) to (4).
FIGURE 3-16
Press the A button (5) next to the flashing lamp to open the
Warning submenu. Refer to Section 3, Warning Messages in
the Operator’s Manual for more information.
The warning message is acknowledged, lamp (2) lights up
FIGURE 3-19
(does not flash any longer).
When all warning messages have been acknowledged, lamp The symbols stand for:
(1) and lamp (2) lights up. (1) The faulty device
(2) The error group
Both lamps start to flash again as soon as a new warning (3) The index within the group
occurs. (4) The type of error

The error code (5) consists of 4 digits, e.g. 2332. Troubleshooting Alarms, Indicators, and
Refer to Section 3, Error Messages in the Operator’s Manual Emergency Components
for more information.
1. If an alarm or emergency component doesn’t work as
Always note down the error code before contacting Crane expected, check and replace the fuse, especially when
Care. all other components downstream from the fuse are not
working.
To exit the Error submenu, press the Esc button (1)
(Figure 3-20) once. The same menu opens that was open 2. Check the component, its sensing device, and circuit for
before the Error submenu opened. continuity, including the ground circuit. Repair or replace
any faulty component or its sensing device. Repair
wiring if faulty.
Troubleshooting Crane Components and

Accessories
FIGURE 3-20 1. If a crane component or accessory won’t work when it is
supposed to, check and replace fuse. Also check and
NOTE: All errors remain saved until you switch off the replace its relay, as needed.
ignition, even those errors of which the cause has
been eliminated in the meantime. All existing errors 2. Check the component or accessory, its control or
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are treated as new errors and displayed again after triggering component, and its circuit for continuity
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turning on the ignition. problems and other problems. Repair any faulty
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Diagnostic Connector and Equipment
component or accessory or trigger. Repair wiring if
faulty.
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The electrical diagnostic connector is located on the right Alternator Replacement
R F
side console. It can be used for troubleshooting electrical

system and engine faults and conditions. Removal
er
The connector is designed to connect a laptop computer with 1. Ensure that the key switch has been off for 2 minutes.
appropriate cable and engine or electrical system software to
the crane for diagnostic work. 2. Turn the battery disconnect switch to the OFF position.
Besides the ECOS Controller and RCL this machine 3. Remove the ECM power fuse.
inc orpo rates a CAN-b us Mu ltiplex s ys tem f or da ta 4. Remove negative battery cables.
communications.
5. Open the engine compartment.
To effectively troubleshoot the electrical CAN-bus system,
contact an authorized distributor or Manitowoc Crane Care. 6. Tag and disconnect the electrical leads from the
terminals on the alternator.
7. Turn the tensioner above the alternator clockwise to
CAUTION! remove tension from the belt. Slip the belt off of the
Possible Equipment Damage! alternator pulley, then let the tensioner return to its
normal position.
When welding on the crane, turn battery disconnect off to
prevent damage to the CAN-bus system. 8. Remove and tag all wires. Remove the alternator link
capscrew and the mounting capscrew. Remove the
Troubleshooting Vehicle Lights alternator.
1. Check the lamp first. Replace any defective lamp. Installation

2. If all lamps in a circuit do not work, check the fuse, the 1. Inspect the belt. Verify it has no cracks or other damage.
switch and ground circuit. Replace fuse if blown. Replace damaged belt as needed.
3. Check the switch and circuit for continuity, loose NOTE: Install alternator on the mounting bracket with head
connections and faulty grounds. Replace any faulty towards turbocharger.
switch or other component. Repair wiring if faulty.
2. To assemble the alternator, the mounting components
must be tightened in the following sequence.
a. Alternator-to-alternator bracket capscrew.

b. Lower brace-to-alternator capscrew. 7. Remove the bolts holding the starter to the mounting
pad. Remove the starter.
c. Lower alternator brace-to-water pump capscrew.
d. Torque fasteners to recommended torque. Installation
3. Install the belt on all engine pulleys except the alternator 1. Place the starter on its mounting pad. Secure the starter
pulley for now. with the bolts. Torque the bolts to recommended torque.
4. Turn the tensioner clockwise. Slip the belt onto the 2. Connect the electrical leads to the terminals as tagged
alternator pulley, then carefully return the tensioner to its during removal.
normal position so it puts tension on the belt. Make sure
3. Close the engine compartment. Connect the batteries.
the belt is centered on the tensioner.
5. Check belt tension at the belt’s longest span (longest Check
distance between pulleys). At the center point of the
longest span, push in on the belt with your thumb. Verify 1. Try to start the engine. Verify the starter starts the 3
you can deflect the belt no more than 3/8 to 1/2 inch (10 engine.
to 13 mm). Or, using a belt tension gauge, verify there is 2. Start engine again, and listen for starter noises. Verify
60 to 130 pounds (267 to 578 N) of tension on the belt in there is no abnormal noise indicating the starter’s gear is
the middle of its longest span. Replace belt if it is too meshing improperly with the flywheel, that the starter’s
loose (overstretched). gear hasn’t disengaged from the flywheel after the
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6. Verify tensioner bolt is torqued to recommended torque. ignition switch is in the ignition. (run) position, or some
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other problem. Install starter properly as needed.
7. Connect the electrical leads to the terminals as tagged
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during removal. Battery Replacement
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8. Close the engine compartment.
Removal
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9. Reconnect the ground cables to the battery.

10. Install the ECM power fuse.
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11. Turn the battery disconnect switch to the ON position.
Check
1. Run engine. Verify reading of voltmeter on front console
is 24 volts or greater. Make repairs as needed.
2. Continue troubleshooting charging system as needed if
replacement of alternator did not correct problem in
charging system.
Starter Replacement
Removal 7010-1
1. Ensure that the key switch has been off for 2 minutes. FIGURE 3-21
2. Turn the battery disconnect switch to the OFF position. 1. Ensure that the key switch has been off for 2 minutes.
3. Remove the ECM power fuse. 2. Turn the battery disconnect switch to the OFF position.
4. Remove negative battery cables. 3. Remove the ECM power fuse.
5. Open the engine compartment. 4. Open the battery box cover.
6. Tag and disconnect the electrical leads from the 5. Remove negative battery cables.
terminals on the starter.
6. Remove the positive battery cables.

7. Connect the electrical leads to the relay as tagged

during removal.
8. Position the console front cover on the console and
secure with the attaching hardware.
9. Turn the battery disconnect switch to ON.
10. Verify proper installation by operating all components
involved with the replacement relay verifying they all
work.
Buzzer Replacement
1. Remove the hardware securing the console front cover
and remove the cover.
2. Tag and disconnect the electrical leads from the buzzer.
3. Unscrew the plastic collar ring from under the panel and
9096 remove the buzzer from the hole in the panel.
FIGURE 3-22
7. Remove the nuts and washers from the bracket hold 4. Install replacement buzzer through the hole in panel and
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down rods. Remove the hold down bracket. secure with the plastic collar ring.
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8. Remove the batteries. 5. Connect the electrical leads to the buzzer as tagged
Installation nl c during removal.

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6. Position the console front cover on the console and
secure with the attaching hardware.
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1. Place the batteries in the battery box.

2. Install the hold down bracket so it can secure the 7. Verify proper operation by positioning the ignition switch
batteries. Secure the bracket (and batteries) to the to RUN (1). Buzzer should sound when engine is not
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bracket hold down rods with nuts and washers. running.
3. Connect leads to the battery terminals starting with the Switch Replacement
positive terminals.
4. Close the battery box cover. Rocker Switch Replacement
5. Install the ECM power fuse. Use the following procedures and refer to Figure 3-23 when
removing/installing a switch.
Removal
7. Verify replacement batteries work by starting crane’s
engine and operating various crane components. 1. Ensure that the key switch has been off for 2 minutes,
remove the ignition key.
Relay Panel Component Replacement 2. Turn the battery disconnect switch to the OFF position.
Accessory Relay 3. Pull the rubber boot (11) off the bottom of the left and
right side covers (8, 9).
1. Ensure that the key switch has been off for 2 minutes.
4. Remove the lever (12) and spacer that locks/unlocks the
2. Turn the battery disconnect switch to the OFF position. steering column tilt/telescope function.
3. Remove the hardware securing the console front cover 5. Remove the four screws (13) securing the left and right
and remove the cover. side covers (8, 9) together.
4. Tag and disconnect the electrical leads from the suspect 6. Remove the four screws (14) securing the left and right
relay. side covers (8, 9) to the switch cover (6).
5. Remove the hardware securing the suspect relay to the 7. Remove the left side cover (8) from the steering column.
relay panel assembly. Remove suspect relay.
8. Disconnect the wire harness from the back of the ignition
6. Install replacement relay on relay panel and secure it switch (10).
with attaching hardware.

9. Remove the right side cover (9) from the steering col- 12. Turn the battery disconnect switch to ON.
umn. Check
10. Disconnect the wire harness from the bottom of the 1. Operate the switch per the Operator’s Manual. Verify
switch (4) that must be replaced. Remove the switch by each of its functions works.
squeezing the retaining clips on each side of switch and
pushing upwards until switch is free of cover. 2. As needed, troubleshoot further any system or circuit
malfunction not corrected by repair or replacement of
Inspection
the switch or associated wiring.
1. Visually check the switch for evidence of cracks, dam-
aged connections, or other damage. Replace damaged Turn Signal Indicator Replacement
switch as needed.
Use the following procedures and refer to Figure 3-23 when
2. Check wiring for damaged insulation or damaged con- removing/installing a turn signal indicator.
nectors. Repair as needed. Removal 3
3. Check all connectors for corrosion. Replace corroded 1. Ensure that the key switch has been off for 2 minutes,
components as needed. remove the ignition key.
4. Perform the following check to determine switch service- 2. Turn the battery disconnect switch to the OFF position.
ability.
3. Pull the rubber boot (11) off the bottom of the left and
a. Using an ohmmeter, check for continuity between
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the switch terminals with switch at ON or activated
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position(s). Ohmmeter should register zero ohms 4. Remove the lever (12) and spacer that locks/unlocks the
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(continuity). steering column tilt/telescope function.
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b. Place switch at OFF or deactivated position. 5. Remove the four screws (13) securing the left and right
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Ohmmeter should register infinity (no continuity). side covers (8, 9) together.
c. Replace switch if it fails either part of the check. 6. Remove the four screws (14) securing the left and right
side covers (8, 9) to the switch cover (6).
Installation
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7. Remove the left side cover (8) from the steering column.
1. Remove the rocker (3) from the old switch by holding the
switch by its sides in one hand and then squeezing the 8. Disconnect the wire harness from the back of the ignition
left and right sides of the rocker with the other hand and switch (10).
pulling up.
9. Remove the right side cover (9) from the steering col-
2. Orient the rocker (3) correctly relative to the new switch umn.
(4), then install rocker in switch.
10. Disconnect the wire from the bottom of the turn signal
3. Install the switch (4) in the gauge/switch cover (6) by indicator (15) that must be replaced. Remove the indica-
pushing the switch (4) down through the top of the tor by squeezing the retaining clips on each side and
gauge/switch cover (6) until the switch’s retaining clips pushing upwards until indicator is free of cover.
click in place.
Inspection
4. Connect the wire harness to the bottom of the switch (4).
1. Check wiring for damaged insulation or damaged
5. Install the right side cover (9) on the steering column. connectors. Repair as needed.
6. Connect the wire harness to the ignition switch (10). 2. Check all connectors for corrosion. Replace corroded
components as needed.
7. Install the left side cover (8) on the steering column.
Installation
8. Secure the gauge/switch cover (6) to the left and right
side covers (8, 9) using screws (14). 1. Orient the indicator (15) correctly in the cover.
9. Secure the left and right side covers (8, 9) together using 2. Install the indicator (15) in the switch cover (6) by push-
four screws (13). ing down through the top of the switch cover (6) until the
retaining clips click in place.
10. Install the lever (12) and spacer that locks/unlocks the
steering column tilt/telescope function. 3. Connect the wire harness to the bottom of the indicator
(15).
11. Pull the rubber boot (11) up and over the bottom of the
left and right side covers (8, 9). 4. Install the right side cover (9) on the steering column.

5. Connect the wire harness to the ignition switch (10). 10. Remove the locking nut that secures the ignition switch
(10) to the right cover (9) and remove the ignition switch
(10).
7. Secure the gauge/switch cover (6) to the left and right Inspection
side covers (8, 9) using screws (14).
1. Visually check the ignition switch for evidence of cracks,
8. Secure the left and right side covers (8, 9) together using damaged connections, or other damage. Replace dam-
four screws (13). aged ignition switch as needed.
9. Install the lever (12) and spacer that locks/unlocks the 2. Check wiring for damaged insulation or damaged con-
steering column tilt/telescope function. nectors. Repair as needed.
10. Pull the rubber boot (11) up and over the bottom of the 3. Check all connectors for corrosion. Replace corroded
left and right side covers (8, 9). components as needed.
11. Turn the battery disconnect switch to ON. 4. Perform the following check to determine ignition switch
Check serviceability.
1. Operate the turn signal and emergency flashers per the a. Using an ohmmeter, check for continuity between
Operator’s Manual and verify the light illuminates. the switch terminals with switch at ON or activated
position(s). Ohmmeter should register zero ohms
2. As needed, troubleshoot further any system or circuit
(continuity).
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the indicator. b. Place switch at OFF or deactivated position.
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Ohmmeter should register infinity (no continuity).
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Ignition Switch Replacement
c. Replace switch if it fails either part of the check.
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Use the following procedures and refer to Figure 3-23 when Installation
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removing/installing the ignition switch.

1. Install the ignition switch (10) in the right side cover (9)
Removal
and secure with the locking nut.
1. Ensure that the key switch has been off for 2 minutes,
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2. Install the right side cover (9) on the steering column.
3. Connect the wire harness to the ignition switch (10).
2. Turn the battery disconnect switch to the OFF position.
right side covers (8, 9). 5. Secure the switch cover (6) to the left and right side cov-
ers (8, 9) using screws (14).
steering column tilt/telescope function. 6. Secure the left and right side covers (8, 9) together using
four screws (13).
5. Remove the four screws (13) securing the left and right
side covers (8, 9) together. 7. Install the lever (12) and spacer that locks/unlocks the
steering column tilt/telescope function.
6. Remove the screws (14) securing the left and right side
covers (8, 9) to the switch cover (6). 8. Pull the rubber boot (11) up and over the bottom of the
left and right side covers (8, 9).
7. Remove the left side cover (8) from the steering column.
8. Disconnect the wire harness from the back of the ignition
switch (10). Check
9. Remove the right side cover (9) from the steering col- 1. Operate the ignition switch per the Operator’s Manual.
umn. Verify each of its functions works.
2. As needed, troubleshoot further any system or circuit

Turn Signal Lever and Transmission Shift 14. Disconnect the wire harnesses from the bottom of the
Lever Replacement turn signal lever (5) or transmission shift lever (7).
15. Remove the two bolts (16) and nuts (17) securing the
Use the following procedures and refer to Figure 3-23 when
shift lever (7) and the turn signal lever (5) together.
removing/installing the turn signal lever or transmission shift
lever. Installation
Removal 1. Align the location pins of the turn signal and transmis-
sion shift levers (5, 7) with the holes in the steering col-
1. Ensure that the key switch has been off for 2 minutes,
umn.
2. Secure the two levers (5, 7) together using the two bolts
2. Turn the battery disconnect switch to the OFF position.
(16) and nuts (17).
3. Connect the wire harnesses to the levers.
4. Install the switch cover (6) on the steering column.
3
steering column tilt/telescope function. 5. Install the wire harnesses on the switches (4) as tagged
during removal.
5. Remove the steering wheel by doing the following:
6. Install the right side cover (9) on the steering column.
a. Remove the steering wheel cap (1) using a twisting
motion by pushing on the side of the cap closest to 7. Connect the wire harness to the ignition switch (10).
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you with your thumbs while simultaneously pulling
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on the side of the cap farthest from you with your 8. Install the left side cover (8) on the steering column.
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fingers. 9. Secure the switch cover (6) to the left and right side cov-
ers (8, 9) using screws (14).
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b. Remove the securing nut from the steering column
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shaft and remove the steering wheel (2). 10. Secure the left and right side covers (8, 9) together using
6. Remove the four screws (13) securing the left and right four screws (13).
side covers (8, 9) together. 11. Install the steering wheel (2); torque the securing nut to
er
7. Remove the screws (14) securing the left and right side 30 lb-ft ±4 (40 Nm ±5).
covers (8, 9) to the gauge/switch cover (6). 12. Install the steering wheel cap (1).
8. Remove the left side cover (8) from the steering column. 13. Install the lever (12) and spacer that locks/unlocks the
9. Disconnect the wire harness from the back of the ignition steering column tilt/telescope function.
switch (10). 14. Pull the rubber boot (11) up and over the bottom of the
10. Remove the right side cover (9) from the steering col- left and right side covers (8, 9).
umn. 15. Turn the battery disconnect switch to ON.
11. Disconnect the wire harness from the bottom of the Check
gauge cluster (5).
1. Operate the turn signal lever or transmission shift lever
12. Tag and disconnect the wire harness from the bottom of per the Operator’s Manual. Verify each of its functions
each switch (4). work.
13. Remove the switch cover (6) from the steering column. 2. As needed, troubleshoot further any system or circuit

15
1
6
7 2
14
5
8
13
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9
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10
FIGURE 3-23
Windshield Wiper Assembly Replacement washer, and tapered sleeve securing the wiper arm to
the pivot shaft kit.
Removal 6. Remove the wiper arm from the pantograph adapter kit
1. Ensure that the key switch has been off for 2 minutes, and the pivot shaft kit.
remove the ignition key. 7. Remove the flanged sleeve, nut, and two flat washers
2. Turn the battery disconnect switch to the OFF position. from the pivot shaft kit.
3. Tag and disconnect the electrical leads from the motor. 8. Remove the two capscrews and lockwashers securing
the pantograph adapter kit’s adapter to the cab exterior.
4. Disconnect the washer hose on the wiper arm (also Remove the pantograph adapter kit’s adapter and
called the pantograph arm assembly) from the washer gasket.
nozzle fitting assembly (Figure 3-24).
9. Remove attaching hardware to free the windshield wiper
NOTE: The nut and washer are part of the pantograph motor bracket from the cab interior. Remove the bracket,
adapter kit. The nut, washer and sleeve are part of with motor and pivot shaft connected, from the cab.
the pivot shaft kit.
NOTE: You may have to remove or move other parts to get
5. Remove the cap nut and washer securing the wiper arm the bracket and attached parts around the steering
to the pantograph adapter kit. Remove the cap nut, column. Take care not to damage any parts.

10. Remove the nut to free the wiper motor’s shaft from the Item Description
wiper motor kit crank. Remove the three screws and
washers to free the wiper motor from its bracket. 7 Motor
Remove the wiper motor from its bracket. Leave the 8 Gasket
other parts attached to the bracket for now.
9 Mounting Plate
Inspection 10 Serrated Collar
1. Visually check the motor housing for evidence of cracks
or other damage. Check for excessive shaft end play
Installation
indicating worn or damaged bearings. Replace motor if 1. Verify the pivot shaft and the wiper motor kit link and
damaged. crank are in place on the motor bracket. (Washers and
2. Inspect the wiper blade for serviceability. Replace wiper clip springs fasten the link to the pivot pins on the crank
blade when worn. and the pivot shaft. The pivot shaft’s pivot pin mounts in
the hole nearest the end of the pivot shaft’s lever.)
3
3. Inspect the wiper arm and parts of the linking component
kits (pantograph adapter kit, pivot shaft kit, wiper motor 2. Connect the wiper motor to the motor bracket with
kit link and crank, wiper motor bracket) for damage. screws and washers. Connect the wiper motor’s shaft to
Replace as needed. the wiper motor kit crank with the nut and washer.
Secure the adapter and the gasket of the pantograph
adapter kit to the cab exterior with capscrews and
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lockwashers.
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1
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interior with attaching hardware. Ensure the pivot shaft
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sticks through the hole in the pantograph adapter kit.
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2 NOTE: Take care not to damage any parts while moving

3 the bracket and attached parts around the steering
column.
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10
4. Secure the pivot shaft to the pantograph adapter with the
4
pivot shaft kit’s nut and washers. Install the flanged
sleeve on the pivot shaft.
9 5
5. Install the wiper arm on the shafts of the pantograph
adapter kit and the pivot shaft kit. Secure the wiper arm
8 6 to the pantograph adapter kit shaft with the kit’s own
washer and cap nut. Secure the wiper arm to the pivot
shaft with the pivot shaft kit’s own tapered sleeve,
washer, and cap nut.
7
3653 6. Connect the wiper arm’s washer hose to the washer
nozzle fitting assembly.
FIGURE 3-24
7. Connect the electrical leads to the wiper motor as
marked before removal.
Item Description
1 Windshield Wiper Arm
2 Washer Check
3 Nut 1. Squirt some cleaning fluid onto the windshield with the
4 Washer windshield washer.
5 Screw 2. Operate the windshield wiper and verify it works.

Replace wiper blade as needed if it streaks or otherwise
6 Mounting Bracket wipes poorly.

Windshield Washer Assembly Replacement 6. Fill the container with cleaning fluid.
Removal Check
1. Ensure that the key switch has been off for 2 minutes, 1. Squirt some cleaning fluid onto the windshield with the
remove the ignition key. windshield washer.
2. Turn the battery disconnect switch to the OFF position. 2. Make repairs if windshield washer doesn’t work.
3. Locate the windshield washer container and pump on Skylight Wiper Assembly Replacement
the left rear side of the cab.
4. Tag and disconnect the pump’s electrical lead and Removal
ground wire. 1. Ensure that the key switch has been off for 2 minutes,
5. Disconnect the hose from the windshield washer pump. remove the ignition key.
Point it so it won’t spill cleaning fluid. Catch cleaning fluid 2. Turn the battery disconnect switch to the OFF position.
from the windshield washer container with a suitable
container. 3. Tag and disconnect the electrical leads from the motor.
6. Remove four self tapping screws securing the 4. Remove the wiper arm from the motor shaft.
windshield washer container to the cab. Remove the 5. Remove the nut, spacer, leather washer, and nylon flat
windshield washer container and pump.
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washer from the motor shaft outside the cab roof.
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7. Remove pump and pump seal from container. 6. Remove the nut and lockwasher securing the motor
Inspection nl c bracket to the cab roof and remove the motor from the
cab roof. Remove large nylon flat washer from motor
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1. Visually check the pump for evidence of cracks, leaks, or shaft and flat washer and smaller nylon flat washer from
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other damage. Replace pump if damaged. mounting screw.
2. Inspect the container for leaking. Replace pump seal if it 7. Remove mounting screw and nylon flat washer from
outside cab roof.
er
is leaking. Replace container if it is damaged and
leaking. 8. Clean any sealing material from around holes in cab
3. Inspect spray nozzle on the wiper arm. As needed, clean roof.
the nozzle with a fine piece of wire and compressed air.
Inspection
Installation 1. Visually check the motor housing for evidence of cracks
1. Install pump and pump seal on container. or other damage. Check for excessive shaft end play
indicating worn or damaged bearings. Replace motor if
2. Install windshield washer container on the cab. Secure damaged.
the container with four self tapping screws.
2. Inspect the wiper blade for serviceability. Replace wiper
3. Attach the hose to the windshield washer pump. blade when worn.
4. Connect the pump’s electrical lead and ground wire as 3. Inspect the wiper arm and parts for damage. Replace as
tagged during removal. needed.

Installation Check
1. Install sealant material around both holes in cab roof, 1. Operate the skylight wiper and verify it works. Replace
both inside and outside. wiper blade as needed if it streaks or otherwise wipe
poorly.
2. Install screw with nylon flat washer (from outside)
through mounting hole in cab roof.
OPTIONS
3. Install flat nylon washer on motor shaft and insert motor
shaft through hole in cab roof. Position small nylon Air Conditioning
washer and flat washer on screw between mounting
bracket and cab roof. Secure with lockwasher and nut. When servicing the air conditioning system, observe the
following specifications:
4. Install nylon flat washer, leather washer, spacer, and nut
on motor shaft. Tighten nut. • Minimum Evacuation Time — 60 minutes
5. Install wiper arm and blade on motor shaft. • Refrigerant Charge Levels — 2.5 pounds 3
6. Connect the electrical leads to the wiper motor as • Additional Pag Oil Required Above the 6 ounces in
marked before removal. Compressor — 5.0 ounces
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THIS PAGE BLANK

RT9150E SERVICE MANUAL BOOM
SECTION 4
BOOM
SECTION CONTENTS
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Boom Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
Main Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Boom Installation . . . . . . . . . . . . . . . . . . . . . . . . . 4-35
Mechanical Luffing Lattice Extension . . . . . . . . . . 4-1 Functional Check . . . . . . . . . . . . . . . . . . . . . . . . . 4-37
Optional Hydraulic Luffing Lattice Extension . . . . 4-1 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38
Optional Boom Equipment . . . . . . . . . . . . . . . . . . 4-1 Boom Alignment and Servicing . . . . . . . . . . . . . . 4-38
Boom Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Bi-Fold Swingaway Boom Extension . . . . . . . . . 4-39
Description and Theory of Operation . . . . . . . . . . 4-1 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Hook Block/Overhaul ball . . . . . . . . . . . . . . . . . . . 4-39
Boom Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39
Boom Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39
Assembling the Boom . . . . . . . . . . . . . . . . . . . . . 4-16
4
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DESCRIPTION nl c Boom Controls
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Main Boom The boom is controlled by the ECOS Controller and the RCL
Controller in conjunction with the joystick controllers. Refer
A six section 42 to 196.8 ft (12.9 to 60 m) boom is installed on to Section 3 of the Operator’s Manual for more information.
er
this crane. The boom uses one telescope cylinder for
telescoping and retracting of the boom and a pinning system DESCRIPTION AND THEORY OF
for the sequenced extension and retraction of the sections. A OPERATION
single lift cylinder provides boom lift; boom elevation is from -
3 degrees to +82 degrees. NOTE: At the end of this section (Figure 4-3) is an
a n i m a t i o n t h a t s h o w s h o w t h i s Tw i n - L o c k
NOTE: The boom is comprised of the following sections:
Telescope System functions. Use Adobe Acrobat®
Base, 1, 2, 3, 4, and 5.
Reader 9 or above to view and control this
animation.
Mechanical Luffing Lattice Extension
Extension and retraction of the boom is controlled by a
The 36 to 59 ft (11 to 18 m) offsettable bifold lattice
telescope cylinder and a pinning system. The telescope
swingaway extension (mechanical luffing jib) stows
cylinder rod (1) (Figure 4-1) is secured to the rear of the
alongside the base boom section. Offsets are 0°, 20°, and
boom’s base section (2). The telescope cylinder barrel is free
40°.
to ride inside the boom sections. The pinning system
consists of a pinning block (3) that rides on the telescope
Optional Hydraulic Luffing Lattice Extension
cylinder barrel (4) and section locking pin assemblies
The 36 to 59 ft (11 to 18 m) hydraulically offsettable bifold (section pins) (5) located in the rear of each movable boom
lattice swingaway extension (hydraulic luffing jib) stows section.
alongside the base boom section. Offsets are from 0° to 40°.
The pinning block consists of two separate hydraulic circuits.
Optional Boom Equipment One circuit operates the slave cylinder (6) which actuates the
butterfly (7). The butterfly is used to retract the section pins in
The 19.7 ft (6 m) or 26.2 ft (8 m) lattice extension inserts the boom sections to allow the selected section to be moved.
install between the boom nose and bifold extension. The other circuit operates the cylinder pins (8) on the sides of
An auxiliary boom nose (rooster sheave) is available for the the pinning block. The cylinder pins are used to connect the
boom to simplify single part cable usage. cylinder to a boom section for extending or retracting that
section

BOOM RT9150E SERVICE MANUAL
All functions on the pinning block are single acting hydraulic retracts the pins to permit motion of the cylinder between
controlled, meaning the pins will return to the safe position boom sections.
using springs when pressure is released. The section pins in
Two solenoid pinning valves are located on the cylinder
the boom are spring loaded to the locked position. The
barrel forward of the pinning head. The pressure holding
butterfly pulls the pins in and the pins are held by pressure,
valve (1) (Figure 4-2) maintains or locks hydraulic pressure
when the pressure is released, the pins go back to the
in the pinning system. The cylinder pin unlock/boom section
engaged position. The same is true for the cylinder to section
pin unlock valve (2) directs fluid to either the butterfly or the
pins. The pins are spring loaded out, and the pinning block
cylinder pin functions
6
7
5
4
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7
R F
3 1
7593-48 8
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2
4
Section 2
Section 1
Base
7593-46
5 FIGURE 4-1

5
6
7593-53
7593-52
1 2 7
3
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7593-50
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R F
4
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7593-51
FIGURE 4-2
Each hydraulic circuit of the pinning block (butterfly and section. At the 50% and 100% pinning location, the pins
cylinder pins) is governed by interlocks. The interlocks carry the structural load. The base section has no pinning
function first and then the butterfly or cylinder pins function. locations, therefore the cylinder pins on the pinning block are
In each case, the interlock engages and does not allow the always engaged to Section 1 when it is not at the 0%
other option to function. The interlocks work by having location.
hydraulic pressure move a pin within the pinning block; the
Sensors in the boom and the boom control system
pin locks one component function in place and then opens a
synchronize movement of the cylinder, pinning system, and
path for oil to reach the other component.
boom sections. As a result, the boom will extend or retract
• When operating the butterfly, the interlocks for the the sections per the chosen control mode. A control module
cylinder to section pins engage to not allow the cylinder (3) atop the cylinder barrel behind the valves aids in
pins to retract, then the butterfly will function. This controlling telescope cylinder extension and retraction and
guarantees the cylinder is holding the section when the cylinder pin and section pin locking and unlocking. Sensors
section pins are retracted. feed signals to the telescope cylinder control module. The
data is then sent to the overall control system.
• When operating the cylinder pins, the interlock for the
butterfly engages to not allow the butterfly to function. • Sensors on the bottom of the pinning block (4) are used
This guarantees the sections are pinned when the to verify the position (extended or retracted) of each
cylinder is not. cylinder pin. The butterfly mechanism will not function
unless both cylinder pins are verified in the extended
The section pins are located in the rear of each moveable
position.
boom section. The section pins lock the rear of the inner
section to one of three pinning locations on the next outer • Proximity switches (5) in the butterfly mechanism sense
boom section. The pinning locations are located at the front the positions (extended or retracted) of the section pins.
(100%), middle (50%) and rest position (0%) of the boom

• Four proximity sensors (6) on the pinning head sense MAINTENANCE

the position of the pinning head in relation to the section
pins. When the pinning head is in the proper position, Boom Removal
the cylinder pins may be extended to connect the
cylinder to the individual boom section. After verifying NOTE: The boom, without any boom extension, weighs
the cylinder pins are extended, the butterfly mechanism about 33,000 lb (15,000 kg).
may be operated to retract the section pins. After a lift off 1. Extend and set the outriggers to level the crane and
sequence used to remove any load from the section ensure the boom is fully retracted and in a horizontal
pins, the cylinder may extend or retract the boom position over the front of the crane.
section.
2. Counterweight must be removed from the crane.
The boom telescope hydraulic circuit consists of the
telescope directional control valve, pinning circuit supply 3. Rotate turntable so boom is over the front of the crane
valve, holding valve, telescope cylinder, and pinning system. and engage the turntable lock pin.
The pressure and return line ports plus a holding valve are in 4. Fully retract and lock the telescopic sections.
the cylinder’s valve block. This valve block is part of the 5. If installed, remove the boom extension and auxiliary
cylinder’s rod weldment. nose.
When the pressure line applies pressure, the valve block
routes fluid through the rod weldment and piston to the ID of
the barrel. This fluid applies pressure on the cylinder barrel
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CAUTION
to extend while the seals on the OD of the piston keep fluid
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pressure from equalizing and stalling the cylinder. Injury Hazard!
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When the return line applies pressure, the valve block routes
Wear gloves when handling wire rope, metal slivers and/
or cuts may result.
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fluid through a tube in the rod weldment to the OD of the rod
R F
weldment. This fluid applies pressure on the rear of the seals

6. Remove the hook block or overhaul ball and wind all the
on the piston OD to keep the cylinder barrel from extending,
wire rope onto the hoist drum.
while the return line provides a path for fluid to leave the
er
cylinder barrel forward of the piston, and leave the inside of 7. Elevate boom to allow access to the telescope hose
the rod weldment to drain through the pressure line. These disconnects.
forces cause the cylinder barrel to retract.
8. Disconnect main telescope hydraulic lines (Figure 4-3).
The rod that slides within the ID of the rod weldment routes
fluid from the valve block through the cylinder to the solenoid
valves in front of the pinning block.
Two holding valves (7) are threaded into the port block on the
rod end of the telescope cylinder. The holding valves
function during the retraction, extension, or holding
operation. When holding the boom section at a given length,
these valves trap oil in the cylinder. A differential valve (8) is
installed to ensure the valves do not open together.
7850-1 FIGURE 4-3

9. Tag and disconnect the telescopic hydraulic lines from
the compact block, if equipped, also disconnect the
hydraulic boom extension hydraulic lines from the
compact block (Figure 4-4).

13. Using a wood block between the lift cylinder and the
bottle jack, raise the jack so it just touches the lift
cylinder barrel.
14. Tag and disconnect electrical wiring from the hydraulic
block on the left hand side of the lift cylinder (Figure 4-6).
7850-2 FIGURE 4-4

NOTE: At this point you can continue to remove the boom
or choose to remove the equipment that is attached 4
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to the boom to prevent it from being damaged. You
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can also choose to remove the attached equipment
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after the boom has been removed and is supported
on cribbing.
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10. Install lift cylinder support on carrier frame. FIGURE 4-6
R F
11. Lower the boom to zero degrees. 15. Identify and mark locations of the shims installed at the
upper lift cylinder pin.
12. Close the valve on the lift cylinder (Figure 4-5), rotate as
er
indicated.
WARNING
Crushing Hazard!
Ensure the lifting device is capable of supporting the
boom assembly.
Ensure the boom lift cylinder is properly supported before
disconnecting it from the boom.
Severe injury or death may result.
16. Attach the lifting rigging, P/N 03125617, to the boom to

provide for equal weight distribution (Figure 4-7).
7745-1 FIGURE 4-5

16.28 ft (4.96 m) 17.29 ft (5.27 m)

44.1°
B
35.1°
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A )
(6.18 m
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20.28 ft
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B
A-A
B-B
7745-1 Lifting Rigging
P/N 03125617 FIGURE 4-7

17. Attach wire rope slings to support crane. 22. Remove any hardware that would prevent the removal
of the two boom pivot pins from the boom base section.
18. Lift the boom slightly to reduce the load on the pivot
points. 23. Open pressure bleed valve on superstructure, behind
the boom pivot (1) (Figure 4-10).
19. Remove boom pivot cap plates (Figure 4-8).
1
1
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7745-2
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7745-2 FIGURE 4-10
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24. Disconnect hoses from counterweight pin cylinders
20. Remove any hardware that would prevent the removal
(Figure 4-11) and connect to boom pin cylinder. Hoses
R F
of the lift cylinder rod pin from the lift cylinder rod end
from the boom pivot cylinder are accessible at the back
and the boom base section.
of the boom (Figure 4-12).
21. Use the hand pump (1) (Figure 4-9) to pull the lift
er
cylinder rod pin free from the lift cylinder and boom.
7745-2 FIGURE 4-11
7745-2 FIGURE 4-9

WARNING
Crushing Hazard!
A secure fixture that will prevent damage to the boom is
recommended to stabilize and hold the boom from moving
during removal of any section.
Failure to properly secure a boom section may cause
serious injury or death.
NOTE: Tag parts as you remove them and note the

numbers and sizes of shims as you remove them
from each of the sections. Consult the Manitowoc
Cranes drawing or Parts Manual for each section to
verify the part number.
7745-2 FIGURE 4-12 Initial Disassembly

25. Close the pressure bleed valve on the superstructure, NOTE: The following sections describe the removal of
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behind the boom pivot (1) (Figure 4-10). equipment that may be attached to the boom base.
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It is not mandatory to remove this equipment but it
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26. Using the ECOS display, “Counterweight” menu, actuate
the locking cylinder to retract the boom pivot pins.
may make disassembly of the boom easier or
protect the equipment from damage when
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27. The weight of the boom is now held by the support disassembling the boom.
R F
crane.
Some equipment mentioned is optional and may
28. Disconnect the hydraulic hoses from the boom pivot not be installed on the boom.
cylinder and reconnect to the counterweight lock
er
1. After the boom has been removed: Tag the wires to the
cylinders.
wind speed indicator and the flight warning light before
29. Raise the boom clear of the crane and lower it to the disconnecting or removing them. Remove the wind
ground or trailer. Set cribbing to support the boom and speed indicator and the flight warning light from the
prevent tipping. boom nose on section 5. Disconnect and remove the
wires from the boom nose terminal box.
30. Remove rigging and wire rope slings from the boom.
2. Tag all wires to the boom nose terminal box before
31. Lower the lift cylinder to the lift cylinder support using the disconnecting or removing any of them. Remove boom
bottle jack. nose terminal box and related wires from the boom.
Boom Disassembly 3. Tag all wires to the boom lights before disconnecting or
removing any of them. Remove boom lights from base
NOTE: The boom assembly must be rotated 180° (upside section.
down) before performing any disassembly or
assembly procedures. 4. Tag and remove other electrical components and their
wires from the boom.
5. Tag and disconnect the hose reel hoses.
CAUTION 6. Tag the hose assemblies connected to the hose reel
Equipment Damage Hazard! hoses and remove them.
A rollover fixture with webbing is recommended to rotate
boom and sections. Chains are not recommended. If a
rollover fixture is not available, rotate sections using
adequate support with webbing.
Damage to the boom sections may result.

Boom
(top view)
Roller Holders
Holding 4
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Bracket Boom
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(left side view)
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Top Hose
R F
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P-Port Hose Reel

Bottom Hose
FIGURE 4-13
7. Remove the hardware securing the hoses to section 5. Remove attaching hardware and then remove the boom
cable length measuring unit from the base section.
8. Wrap the hoses around the hose reel.
15. Tag all wires to the boom cable reel at the bottom rear of
9. Remove the holding bracket from section 5.
the base section before disconnecting or removing any
10. Remove the hose guides from the other boom sections. of them. Provide adequate support to the boom cable
reel before removing its attaching hardware.
11. Remove the hose reel from the base section.
16. Disconnect and remove wires from the boom cable reel
12. Remove the cover assembly from the top rear of the
(2). Then remove these wires from the base section.
base section.
17. Remove attaching hardware to free and remove the
13. Tag all wires to the boom cable length measuring unit (1)
boom cable reel.
(Figure 4-14) in the top rear of the base section, then
remove the wires. 18. Remove roller holders from the sections.
14. Provide adequate support to the boom cable length
measuring unit before removing its attaching hardware.

7593-10
P1070073
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7593-9
Base Section
(shown upside-down) FIGURE 4-14

Remove Telescope Sections and Cylinder

from Base Section
1. Have fixtures in place for resting disassembled boom
sections.
CAUTION
Equipment Damage Hazard!
Apply no more than 1400 psi, seals in the butterfly can be
damaged and leak.
2. Connect hoses to the A, R, K1, and K2 ports of the rod

end valve block (Figure 4-15).
3. Connect the other end of the hoses to a hydraulic or air
pressure source.
DSC01165
2 1
3 4 1 2 4
FIGURE 4-16
5. Use the 24 VDC source to actuate the section pins and 4
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hydraulic/air pressure to actuate the cylinder pins.
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nl c 6. Engage the cylinder pins with the cutouts in section 1.
This pins the cylinder assembly to section 1.
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7. Unlock the section pins so section 1 is free from the
R F
base section.
8. Pin sections 2, 3, 4, and 5 to section 1.
er
9. Move the butterfly arms in to avoid engaging the C-
clamps of the section pins. Disconnect electrical plug.
Disconnect hydraulic/air pressure from hoses attached
to the rod end valve block.
10. Remove the four bolts (1) (Figure 4-15) and both
DSC01165 cylinder mounting plates (2) from cylinder assembly’s
A K2 K1 R
rod end valve block.
FIGURE 4-15
11. Slide the five sections away from the base section until
4. Connect a 24 VDC source (1) to the emergency/service the section pins of section 1 are well away from the
mode plug (2) of the pinning head of the cylinder cutouts in the base section.
(Figure 4-16).
12. Remove the top and bottom retainer plates from front of
base section.
13. Remove bottom corner inner wear pads and bottom
inner wear pad and related shims from between bottom
inner walls of base section and bottom outer walls of
section 1.
14. Remove the side inner wear pads and their plates from
the base section.
15. Remove side inner wear pads and shims from between
side inner walls of the base section and side outer walls
of section 1.
16. Remove the top corner inner wear pads and shims from
the base section.

17. Slide sections 2, 3, 4, and 5 out the front of the base

section.
18. Remove the two top corner outer wear pad assemblies
from the outside top corners of section 1.
19. Remove the two bottom corner outer wear pads from the
outside bottom corners of section 1.
20. Rest the pinned-together sections on an appropriate
fixture.
21. Verify the cylinder pins are not connected to any
telescope section and the butterfly arms are retracted.
22. Disconnect the 24 VDC supply and hydraulic hoses
attached to the rod end valve block.
23. Remove the capscrews (3) (Figure 4-15) securing the
hose brackets (4) to the rear of the section and route the
brackets through the cutouts in the base section so the P1060055
tele-cylinder can be removed. 1 FIGURE 4-17
24. Use appropriate lifting device to remove telescope 3. Slide section 2 and the other sections until section pins
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cylinder assembly from telescope sections. Slowly of section 2 are well away from the cutouts in section 1.
remove the cylinder from the sections; take care not to
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damage any hydraulic or electrical parts, or mechanical
4. Remove top and bottom retainer plates from front of
section 1.
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parts while removing the cylinder. Ensure proper
clearance for the pinning valve, the tubes, the wiring 5. Remove bottom corner inner wear pads and bottom
R F
harness, the pinning head, and other attached parts of inner wear pad and shims from between bottom inner
the cylinder assembly. Adjust and secure all parts as walls of section 1 and bottom outer walls of section 2.
needed to ensure clearance.
er
6. Remove the side inner wear pads and plates from
25. Place cylinder assembly on a suitable fixture. Tag and section 1. Remove side inner wear pads and shims from
remove hoses from cylinder assembly. Tag and remove between side inner walls of section 1 and side outer
wear pads from cylinder assembly as needed. walls of section 2.
Remove Sections 2, 3, 4, and 5 from Section 1 7. Remove top corner inner wear pads and shims from
section 1.
sections. 8. Slide sections 2, 3, 4, and 5 out the front of section 1.
Remove the two top corner outer wear pad assemblies
2. Unlock section 2’s section pins using set screws (1)
(Figure 4-17) to release them from the cutouts in section
1. 9. Remove the two bottom corner outer wear pads from the
10. Place boom sections on suitable fixtures for further
teardown.
Remove Sections 3, 4, and 5 from Section 2
sections.
2. Unlock section 3’s section pins using set screws to
release them from the cutouts in section 2 (Figure 4-17).
3. Slide section 3 and the other sections until section pins
of section 3 are well away from the cutouts in section 2.
4. Remove the top and bottom retainer plates from front of
section 2.

5. Remove bottom corner inner wear pads and bottom 3. Slide section 5 until section pins of section 5 are well
inner wear pad and shims from between bottom inner away from the cutouts in section 4.
walls of section 2 and bottom outer walls of section 3.
4. Remove top and bottom retainer plates from front of
6. Remove the side inner wear pads and their plates from section 4.
section 2. Remove side inner wear pads and related
shims from between side inner walls of section 2 and
inner wear pad and shims from between bottom inner
side outer walls of section 3.
walls of section 4 and bottom outer walls of section 5.
7. Remove the top corner inner wear pads from section 2.
6. Remove the side inner wear pads and shims from
Remove wear pads and shims.
between side inner walls of section 4 and side outer
8. Slide sections 3, 4, and 5 out the front of section 2. walls of section 4.
Remove the two top corner outer wear pad assemblies
7. Remove top corner inner wear pads and shims from
section 4.
8. Slide section 5 out the front of section 4.
9. Remove the two top outer wear pad assemblies from the
outside top corners of section 5.
teardown.
Remove Sections 4 and 5 from Section 3
outside bottom corners of section 5. 4
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2.
sections.
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Unlock section 4 section pins using set screws to
teardown.
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release them from the cutouts in section 3. Disassembly of Sections
R F
3. Slide section 4 and section 5 until section pins of section Section 5

4 are well away from the cutouts in section 3.
1. Place the section upside down on roller jacks or other
er
4. Remove the top and bottom retainer plates from front of appropriate supports.
section 3.
inner wear pad and related shims from between bottom 3
inner walls of section 3 and bottom outer walls of section
4.
4
6. Remove side inner wear pads and shims from between
side inner walls of section 3 and side outer walls of
1 2
section 4.
7. Remove the top corner inner wear pads and shims from
section 3.
8. Slide sections 4 and 5 out the front of section 3. 7
9. Remove the two top corner outer wear pad assemblies

from the outside top corners of section 4. 5
6
teardown.
Remove Section 5 from Section 4
1. Have fixtures in place for resting disassembled boom 7593-43
FIGURE 4-18
sections.
2. Remove the round button pads (1) (Figure 4-18) from
2. Unlock section 5 section pins using set screws to the related holes in the rear portion of the section.
release them from the cutouts in section 4.

3. Remove the four sliders (2) and shims from the upper
and lower rails in the rear portion of the section. 1
4. Remove the two bottom outer wear pads (3) and shims
from the section.
5. Remove the two side outer wear pads (4) from the
section.
6. Remove the two section pin assemblies (5):
a. Remove connecting link (C-link) (6).
b. Remove snap ring (7) in the OD groove of the guide
tube. Remove pin assembly from the outside of the
section.
c. As needed, disassemble section pin.
7593-13
FIGURE 4-20
Section 4
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1 appropriate supports.
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the related holes in the rear portion of the section.
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R F
and lower rails in the rear portion of the section.
4. Remove the two bottom outer wear pads (3) and shims
er
from the section.
7593-62 FIGURE 4-19 5. Remove the two side outer wear pads (4) from the
section.
7. Remove stop block plates (1) and shims from the stop
block mounting bosses on each side. 6. Remove the two section pin assemblies (5):
8. Remove top and bottom centering bolts and jam nuts a. Remove connecting link (C-link) (6).
from both sides. b. Remove snap ring (7) in the OD groove of the guide
9. For boom nose disassembly, refer to Boom Nose tube. Remove pin assembly from the outside of the
Disassembly, page 4-16. section.
c. As needed, disassemble section pin.
7. Remove stop block plates (1) (Figure 4-19) and shims
from the stop block mounting bosses on each side.
8. Remove cable protection strip (1) (Figure 4-20) from the
top front of the flange in the front of the section.
9. Remove top and bottom centering bolts and jam nuts
from both sides.
Section 3
appropriate supports.
2. Remove the round button pads (1) (Figure 4-18) from

4. Remove the two bottom outer wear pads and shims from 4. Remove the two bottom outer wear pads and shims from
the section. the section.
5. Remove the two side outer wear pads from the section. 5. Remove the two side outer wear pads from the section.
6. Remove the two section pin assemblies: 6. Remove the two section pin assemblies:
a. Remove connecting link (C-link). a. Remove connecting link (C-link).
b. Remove snap ring in the OD groove of the guide b. Remove snap ring in the OD groove of the guide
tube. Remove pin assembly from the outside of the tube. Remove pin assembly from the outside of the
section. section.
c. As needed, disassemble section pin. c. As needed, disassemble section pin.
7. Remove stop block plates and shims from the stop block 7. Remove stop block plates and shims from the stop block
mounting bosses on each side. mounting bosses on each side.
8. Remove cable protection strip from the top front of the 8. Remove remove cable protection strip from the top front
flange in the front of the section. of the flange in the front of the section.
9. Remove top and bottom centering bolts (1) (Figure 4-21) Remove top and bottom centering bolts and jam nuts from
and jam nuts (2) from both sides. both sides.
Section 1 4
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2. Remove the round button (1) (Figure 4-18) pads from
R F
1
er
4. Remove the two bottom outer wear pads and shims from
the section.
4 5. Remove the two side outer wear pads from the section.
2 5 6. Remove the two section pin assemblies:
3
a. Remove connecting link (C-link).
7593-56 b. Remove snap ring in the OD groove of the guide

FIGURE 4-21 tube. Remove pin assembly from the outside of the
10. Remove two snap rings (3) (Figure 4-21) and axle shaft section.
(4) and rollers (5) from the roller holder on the bottom of c. As needed, disassemble section pin.
the section.
7. Remove stop block plates and shims from the stop block
Section 2 mounting bosses on each side.
1. Place the section upside down on roller jacks or other 8. Remove remove cable protection strip from the top front
appropriate supports. of the flange in the front of the section.
2. Remove the round button pads (1) (Figure 4-18) from 9. Remove top and bottom centering bolts and jam nuts
the related holes in the rear portion of the section. from both sides.

6. Remove two linch pins and remove the lock pin from the
2 boom nose forward of the pulleys.
1
7. Remove the two axle guards from the upper axle.
Remove the axle, four spacer rings, or three and one
spacers, both rope pulleys, two spacer rings, six spacer
rings, and shim rings.
8. Remove the two axle guards from the lower axle.
Remove the axle, four spacer rings, eight pulleys and
seven spacer rings, and shim rings.
Assembling the Boom

Perform the assembly with the boom sections upside-down,
preferably on roller jacks or similar fixtures appropriate for
the buildup.
NOTE: Apply medium strength threadlocking adhesive/
sealant to the threads of all attaching hardware.
7593-62 FIGURE 4-22 Apply Mobil XHP222 lithium grease or Grove-
approved equivalent to the section pins’ springs,
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locking pins’ shafts, and insides of guide tubes.
ef or
Base Section Disassembly Apply Bec hem 9012 32920 2 Berulub PAL 1
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Removal of most parts on the outside of the base section lubricant or Grove-approved equivalent to all wear
surfaces, and to the outsides of section pins’ guide
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takes place during initial disassembly.
tubes and portions of locking pins that are outside
R F
1. Remove the linch pins and rope grab (1) (Figure 4-22) of the guide tubes.
assembly from the top front of the base section.
Use metric grade 8.8,10.9 or 12.9 torque values
2. Remove the cable protection strip (2) and two holder
er
specified in Section 1 of this manual unless
assemblies from the top front of the higher of the two otherwise specified.
flanges in the front of the base section.
The basic approach of assembling the boom is as follows:
3. Remove cable protection strip from the top rear surface
of base section—above area where boom cable length 1. Build up each of the sections. This includes installing
measuring unit mounts. sheaves and related hardware onto the nose of section
5.
Boom Nose Disassembly 2. Install each section into the next larger section—section
Refer to (Figure 4-23) for the following procedure. 5 into section 4, section 4 into section 3, section 3 into
section 2, section 2 into section 1.
1. Remove the limit switch weight from the shackle.
3. Install the telescope cylinder into the assembled
2. Remove the linch pin and shackle from the post on the sections.
bottom left hand side of the nose.
4. Install the boom sections with telescope cylinder into the
3. Remove the cover from nose. base section. Secure the telescope cylinder to the base
4. For each rope protection holder, remove securing pin section.
and pin from the holder. Then remove the rope 5. Install the remaining parts onto the assembled boom.
protection holder from the top of the nose.
NOTE: To aid in assembly contact Manitowoc Crane Care
5. Remove two linch pins and remove the lock pin from the to obtain a copy of the engineering drawings of the
boom nose above the pulleys. boom. Always consult the engineering drawings for
each section to verify part numbers and to aid in
assembly.

Boom Nose Assembly axle. Install another spacer ring on the axle so its lip will
touch the right side pulley when it is installed; make sure
Refer to Figure 4-23 for the following procedure. its flat side faces away from the right side pulley.
1. Insert the bottom axle into the right side bottom axle hole 11. Install a pulley, a spacer ring, and a spacer ring on the
in the nose of section 5. axle; the spacer ring lip touching pulley and flat side
2. Install a spacer ring (63) and a spacer ring (nylatrin facing away from the pulley. Then install the spacer ring
single lip ring) (54) on the axle so they will keep the right so it will keep the pulley from rubbing against the inside
hand pulley from rubbing against the inside right surface right surface of the nose.
of the nose. Make sure lip of spacer ring (54) touches 12. Shim the top axle as needed on the outside of spacers
the right hand pulley and its flat side faces away from the with shim rings until none of the spacers or pulleys will
pulley. be able to move side to side on the axle.
3. Install eight pulleys and seven spacer rings (double lip 13. Turn the top axle so its slots face up. Install an axle
rings) (55), one between each pair of pulleys, on the guard on each side into the slots of the axle and secure
axle. with two capscrews. Verify none of the spacers or
4. Install a single lip spacer ring (62) and a spacer ring (66) pulleys can move side to side on the axle.
on the axle so they will keep the left hand pulley (40) 14. Tighten the capscrews until there is 0.04 to 0.08 in (1 to
from rubbing against the inside left surface of the nose. 2 mm) of end play on the top axle and there is no play in
Make sure lip of spacer ring (62) touches left hand the pulleys’ bearings. 4
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pulley; make sure its flat side points away from the
15. Install a retainer pin through the holes in the bottom of
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pulleys.
the boom nose in front of the lower pulleys. (This pin
5.
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Shim the bottom axle as needed outside of spacers (63
and/or 66) with shim rings (68) until none of the spacers
helps keep the cables on the sheaves.) Secure the
retainer pin with two linch pins.
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or pulleys will be able to move side to side on the axle.
R F
16. Install a retainer pin through the holes in the bottom of

6. Turn the bottom axle so the slots face up. Install the axle the boom nose above the pulleys. (This pin helps keep
so the slots are visible on each side. Install an axle the cables on the sheaves.) Secure the lock pin with two
retainer into the slot of the axle on each side and secure
er
linch pins.
it to the nose with two capscrews. Verify none of the
spacers or pulleys can move side to side on the axle. 17. For each of the two pulleys on the top axle, secure a
rope retainer holder on the nose above the pulley. Each
7. Tighten the capscrews until there is 0.04 to 0.08 in (1 to holder goes inside a nose bracket; the nuts go on the
2 mm) of end play on the bottom axle and there is no inside surface of the holder.
play in the pulleys’ bearings.
18. Install a pin in each sleeve of the rope retainer holders
8. Insert the top axle through the left side axle hole in the above the pulleys. Secure each pin to its holder with a
boom nose. retaining clip.
9. Install three spacer rings—lip must touch pulley and flat 19. Secure cover to nose with capscrews.
side must face away from the pulley—and a pulley on
the axle. Verify the spacers prevent the pulley from 20. Install the shackle onto the post on the bottom left hand
rubbing against the inside left surface of the nose. side of the boom nose. Secure the shackle with a linch
pin.
10. Install a spacer ring next to the left side pulley on the
axle; make sure lip touches pulley and flat side faces 21. Secure the limit switch weight to the shackle with two
away from the pulley. Install five spacer rings on the nuts and capscrews.

Pulleys Spacer Ring

Spacer Ring
Axle Guard and
Spacer
Capscrews
Rings
Axle Guard and

Capscrews
Top Axle
Spacer Ring
Shim Rings
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Spacer Rings
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Spacer Ring
Shim Rings
Axle Guard and Axle Guard and

Capscrews Capscrews
Bottom Axle
Linch Pin
Spacer Ring
Shackle
Limit Switch
Pulleys and
Spacer Rings
between pulleys
Limit Switch
Weight
nose 1
FIGURE 4-23

Rope
Rope Retainer
Retainer Holder
Holder
Cover 4
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Retainer
Pin
er
Retainer
Pin
nose 2

Retainer Pin
Bottom Axle
Retainer Pin
Bottom Pulleys (8)
Cover removed
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Boom Nose (and

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Post for Limit 7593-15 Section 5) shown
Switch Shackle upside-down
Top Axle
Top Pulleys (2)
7593-16

Section 5 Assembly bottom inside of section 4 when installing section 5 into

section 4.
1. Install round button pads (1) (Figure 4-24) in the holes in
the rear portion of the section. 6. Install two side outer wear pads (5) on the sides of the
section with capscrews. Use wear pads of the proper
2. Install four sliders (2) on the upper and lower rails in the size so they just touch the inside of section 4 when
rear portion of the section, shim as needed. Note the installing section 5 into section 4.
thick end of each slider; install sliders so the thick ends
are opposite each other and the thin ends are at the rear
of the section. Use shims to attain a gap between the
3
thick ends of 6.73 to 6.74 in (171 mm).
3. Put two top corner outer wear pad assemblies
(Figure 4-25) in place on the top outside corners of the 4
section (the top outside corners are at the bottom of the
upside-down section). Secure lube hoses in lugs 2
1
provided on the rear of the section using the nuts. The
wear pads “float” in their mountings on the section;
section 4 will hold them in place.
4. Verify for each bottom corner outer wear pads (4) 5
(Figure 4-24), a capscrew holds a plate in its recess. 4
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Route two set screws through holes in the curved
ef or
surface of each wear pad and screw them into the plate.
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Put the wear pads in place on the bottom outside
corners of the section with the two slots facing down to
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clear the screws holding the sliders.
R F
5. Install two bottom wear pads (3) on the bottom of the

section with shims and countersunk screws. The wear
pads go on the top of the upside-down section. Use
er
shims as needed to make these pads just touch the 7593-43
FIGURE 4-24

Side Inner Bottom Corner

Wear Pad Inner Wear Pad
Side Outer
Wear Pads
Bottom Inner
Wear Pad
Plate for Side Inner

Wear Pad
Bottom Retainer Plates
Bottom Outer
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Wear Pad
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7593-6
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Top Retainer Bottom Corner Inner

Plates Wear Pad
Side Inner
Wear Pad
er
Bottom Corner Outer
Wear Pad
Top Corner Outer Plate and Capscrew in

Wear Pad Bottom Corner Outer
Wear Pad
Side Outer
Wear Pad
Top Corner Outer

Wear Pad and Hose
and Fittings
7593-7
Note: Parts are similar for each
section, but are of different
sizes. Consult parts list or print
as needed. 7593-8
FIGURE 4-25

7. Install the section pins as follows:

Section Shown Upside-Down
a. Install a grease fitting into the threaded hole of a
locking pin.
b. Put a spring around the shaft of the locking pin.
c. Grease the spring and the inside of a guide tube
with approved lithium grease.
d. Insert the locking pin and spring into the guide tube.
e. Install the guide tube and attached parts in the rear
of the section from the outside.
f. Place a retaining ring in the OD groove of the guide
tube to prevent it from going too far into the hole in
the section.
g. Install connecting link (C-clamp) with the triangular
end in inside the tabs on the section wall and secure
to guide tube and locking pin with a capscrew. Make
Clearance Tool between rails and
sure the C-clamp’s attached triangular flange points
forward and covers the related set screw hole in the
inside C-clamps
4
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ef or
section.Tighten the capscrew until the flange of the
guide tube touches the matching surface on the
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outside of the section, and the retaining ring around
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the guide tube touches the matching surface on the 7593-19
inside of the section.
R F
Connecting Links
er
Locking Pin (C-clamps) (note Guide
and Spring triangles for set Tube
screw adjustment)
rail to rail
6.73 - 6.74 in.
(170.9 - 171.2 mm)
button to button
14.57 - 14.58 in.
(370.1 - 370.3 mm)
7593-18 C-clamp-to C-clamp distance

(check with pins retracted, and
Retaining
extended)
Ring
FIGURE 4-26
7593-20 FIGURE 4-27

Bottom Corner Outer Wear Pad, Bottom Outer Wear Pads, Shims, and Bottom Corner Outer Wear
Plate, Capscrew, and Set Screws Countersunk Screws Pad, Plate, Capscrews, and Set
Screws
Slider, Shims,
and
Slider, Shims,
Capscrews
and
Capscrews
Buttons
Buttons
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Side Outer Wear Side Outer Wear
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Pad and Pad and
Capscrews
nl c Capscrews
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Slider, Shims,
Slider, Shims, and
R F
and Capscrews Capscrews
C-clamps
C-clamp
er
Mount for Top

Mount for Top
Corner Outer
Corner Outer
wear pad.
wear pad.
Grease fitting,
Grease fitting,
nut, pipe union,
nut, pipe union,
lube hose, angle
lube hose, angle
pipe union, and
pipe union, and
adapter shown
adapter shown
in place (except
in place (except
for end of hose
for end of hose
that connects to 7593-20
that connects to
wear pad,
wear pad,
shown tucked);
shown tucked);
wear pad not
wear pad not
shown installed
shown installed
yet.
yet.
brackets in
section walls Section Shown
Upside-Down FIGURE 4-28
8. Test clearance between C-clamps and test clearances the part installations are. The tool should slide easily
between interior wear pads with clearance tool without hanging if parts are installed properly. Refer to
CT100941. This test tool is essentially a go/no go Table 4-1 for the proper dimensions.
gauge; it lets the mechanic know roughly how accurate

Table 4-1: Assembly dimensions: Section 4 Assembly

Item Dimension 1. Install round button pads in the holes in the rear portion
C-clamps, fully extended 5.27 to 5.28 in (134 mm) of the section.
C-clamps, fully retracted 2.20 to 2.21 in (56 mm) 2. Install four sliders on the upper and lower rails in the rear
portion of the section, shim as needed. Note the thick
Button pads 14.57 to 14.58 in (370 mm) end of each slider; install sliders so the thick ends are
Thick ends of sliders 6.73 to 6.74 in (171 mm) opposite each other and the thin ends are at the rear of
the section. Use shims to attain a gap between the thick
Make adjustments as needed. ends of 6.73 to 6.74 in (171 mm).
NOTE: To fully retract the section pin assemblies, install a 3. Put two top corner outer wear pad assemblies in place
set screw in the hole provided forward of each of on the top outside corners of the section (the top outside
the two section pin assemblies. Thread set screw corners are at the bottom of the upside-down section).
into hole until it is flush with the triangular flange of Secure lube hoses in lugs provided on the rear of the
the C-clamp inside the section. Keep tightening the section using the nuts. The wear pads “float” in their
set screw against the C-clamp to retract the section mountings on the section; section 4 will hold them in
pin until the locking pin face is flush with the flange place.
of the guide tube. When done measuring, remove
4. Verify for each bottom corner outer wear pads, a
the set screw.
capscrew holds a plate in its recess. Route two set 4
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screws through holes in the curved surface of each wear
ef or
pad and screw them into the plate. Put the wear pads in
nl c place on the bottom outside corners of the section with

the two slots facing down to clear the screws holding the
O en
sliders.
R F
5. Install two bottom wear pads on the bottom of the

section with shims and countersunk screws. The wear
pads go on the top of the upside-down section. Use
er
Some pads
are shown shims as needed to make these pads just touch the
removed bottom inside of section 4 when installing section 4 into
section 3.
6. Install two side outer wear pads on the sides of the
section with capscrews. Use wear pads of the proper
size so they just touch the inside of section 4 when
installing section 4 into section 3.
7. Install the section pins as follows:
Section
a. Install a grease fitting into the threaded hole of a
Pin
locking pin.
b. Put a spring around the shaft of the locking pin.
7593-8 Set Screw
c. Grease the spring and the inside of a guide tube
FIGURE 4-29
with approved lithium grease.
9. Install stop block plates and shims on the stop block
mounting surfaces on each side of section 5 to the rear d. Insert the locking pin and spring into the guide tube.
of the nose. e. Install the guide tube and attached parts in the rear
10. Install bolts and jam nuts into place on lugs on the top of the section from the outside.
side and on the bottom side of section 5, near the rear of f. Place a retaining ring in the OD groove of the guide
the nose portion. Nominal gap for each pair of bolt heads tube to prevent it from going too far into the hole in
is 3.15 to 3.16 in (80 mm). These will need adjustment the section.
with anti-roll bars of section 4.
g. Install C-clamp with the triangular end in inside the
tabs on the section wall and secure to guide tube
and locking pin with a capscrew. Make sure the C-
clamp’s attached triangular flange points forward

and covers the related set screw hole in the is 3.15 to 3.16 in (80 mm). These will need adjustment
section.Tighten the capscrew until the flange of the with anti-roll bars of section 4.
guide tube touches the matching surface on the
outside of the section, and the retaining ring around Section 3 Assembly
the guide tube touches the matching surface on the
inside of the section. Assemble section 3 the same as section 4 plus install axle
pin and nine roller segments on the roller holder on the
8. Test clearance between C-clamps and test clearances bottom of the section. Secure axle pin with two retaining
between interior wear pads with clearance tool rings.
CT100941. This test tool is essentially a go/no go
gauge; it lets the mechanic know roughly how accurate Section 2 and 1 Assembly
the part installations are. The tool should slide easily
without hanging if parts are installed properly. Refer to Assemble section 2 and 1 the same as section 4.
Table 4-1 for the proper dimensions.
Base Section Assembly
NOTE: To fully retract the section pin assemblies, install a
set screw in the hole provided forward of each of 1. Install the cable protection strip on the top front of the
the two section pin assemblies. Thread set screw higher of the two flanges in the front of the base section.
into hole until it is flush with the triangular flange of 2. Install the two holder assemblies on the top rear of this
the C-clamp inside the section. Keep tightening the same flange.
set screw against the C-clamp to retract the section
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pin until the locking pin face is flush with the flange 3. Secure rope grab assembly to holder assemblies with
ef or
of the guide tube. When done measuring, remove linch pins.
9. nl c
the set screw.
Install stop block plates and shims on the stop block
4. Install cable protection strip to top rear surface of base
section (above area where boom cable length
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mounting surfaces on each side of section 5 to the rear measuring unit mounts).
R F
of the nose. 5. Installation of the remainder of parts on the outside of

the base section takes place during boom final
Cable Protection Strips
assembly.
er
Boom Assembly
NOTE: In the assembly procedures that follow,
“consolidate shims” to shrink a shim stack as
needed. Use fewer thicker instead of more thinner
shims to adjust distances. This shrinks the actual
distance because the more shims in the stack, the
greater the dimension due to some warping or
other abnormalities of shims.
Assemble Section 5 Into Section 4

1. Grease all section 5 sliding surfaces corresponding
7593-13 Boom sections are shown assembled. All surfaces on section 4.
but section 5 have a cable protection strip.
2. Install set screws in section 5 section pins and retract
FIGURE 4-30 the pins so they won’t lock into holes in section 4.
10. Install cable protection strip on the top front of the flange 3. Slide rear of section 5 into front of section 4. Shim the
in the front of the section (Figure 4-30). bottom wear pads (1) (Figure 4-31) to have the pads just
11. Install bolts and jam nuts into place on lugs on the top touch the section 4 inner wall. Remove and install
side and on the bottom side of section 5, near the rear of section 5, as necessary, to adjust these pads.
the nose portion. Nominal gap for each pair of bolt heads 4. Push the top corner outer wear pads (2) into place as
they go into section 4, adjust set screws in wear pads as

7593-23
2
4
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7593-22 FIGURE 4-31
R F
5. Slide section 5 into section 4 about midway.

6. Measure gap between outer side wall of section 5 and
er
inner side wall of section 4, refer to (Figure 4-32). Do this
for both sides of section 5. Note measurements. 7593-24
7. Measure gap between outer bottom wall of section 5 and FIGURE 4-32
inner bottom wall of section 4. Measure gap between
outer top wall of section 5 and inner top wall of section 4.
Note measurements.
8. Slide section 5 into section 4 until one of the set screws
of each of the bottom corner outer wear pads on section
5 is visible through the access holes of section 4
(Figure 4-32). Tighten each set screw (Figure 4-32) to
force its wear pad to touch the inside wall of section 4.
Then back off the set screw one-half turn. Repeat this for
the other set screw in each wear pad.
7593-25
FIGURE 4-33
9. Install bottom inner wear pad (1) (Figure 4-34), and

bottom corner inner wear pads (2) between walls of
section 4 and section 5.

2
1
3 4
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7593-27
nl c FIGURE 4-34
10. Install retainer plates (3) in slots behind front flange in
FIGURE 4-35
15. Tighten capscrews so the wear pads just touch section 5
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section 4 with 0.25 in (6 mm) gap between plate and outer wall. Don’t tighten capscrews any more for now.
R F
wear pads. Temporarily secure each plate with a

capscrew, flat washer, and lock nut.
er
11. Install the side inner wear pads (4) and retaining plates.
12. Install wear strips (1) (Figure 4-35) under the wear pads
to ensure bottom, corner, and side wear pads are tight
against section 5 without jamming or interfering with
normal movement. Wear strips must be same thickness
on left and right to keep boom centered during extension
and retraction.
13. Move the retainer plates tight against the wear pads and
tighten the capscrews.
14. Install top corner inner wear pads (1) (Figure 4-36)
between walls of section 4 and section 5. Shim under
wear pads as needed using shims on each side. Shims
must be same thickness on left and right.
1 FIGURE 4-36
16. Tighten side outer wear pad screws on both sides of

section 5 so the pads just touch section 4 inner walls.
This aligns section 5 during extension or retraction.
17. Move section 5 inside section 4 until the lube hoses of its
top corner outer wear pads are accessible. Lube wear
pads with proper grease.

18. Retract section 5 into section 4 until section pins of

section 5 align with cutouts in rear of section 4. Unscrew
set screws to allow section pins to extend into section 4.
Remove set screws.
19. Check each matching set of sliders in section 5 and in
section 4 with a straight edge (Figure 4-37). Shim sliders
as needed if not aligned per straightedge check.
20. Verify button pads of section 5 and section 4 are 14.57 to
14.58 in (370 mm) apart (Figure 4-38). rail to rail
6.73 - 6.74 in.
21. Verify the distance between the facing thick ends of (171 mm)
button to button
each set of sliders on the upper and lower rails of section 14.57 - 14.58 in.
5 and section 4 is 6.73 to 6.74 in (171 mm). Add or (370.2 mm)
subtract shims as needed to achieve this distance.
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7593-33
FIGURE 4-38
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22. Bring the sections together so the anti-roll bars (1)
(Figure 4-39) of section 4 are between the adjusting
bolts (2) of section 5. With section 5 centered in section
4 adjust the bolts until there is a gap of 0.125 in (3 mm)
between each bolt head and its related anti-roll bar.
Secure each bolt with its jam nut. Repeat for the other
anti-roll bar.
The purpose of the two anti-roll bars is to keep the boom
from twisting during swinging of the jib.
7593-32 FIGURE 4-37
1
2 FIGURE 4-39

23. Measure from the rear edge of each section 4 cutout to Install Telescope Cylinder Assembly into
the corresponding rear surface of the section pin on Sections
each side of section 5 (Figure 4-40). Distance must be
0.19 to 0.20 in (5 mm). Adjust by adding or subtracting 1. Inspect the telescope cylinder and assembled parts as
stop block shim(s) behind the stop block (1) follows:
(Figure 4-41) at the front of section 5.
• Verify the pinning head (the butterfly and related parts)
are installed on the pinning block on the back end of the
0.19 to 0.20 in barrel.
(5 mm)
• Verify the two-solenoid pinning valves and the control
module are in place on the barrel forward of the pinning
head.
• Verify all hoses and tubing of the cylinder assembly are
undamaged and all fittings are tight.
• Verify the top, bottom and side wear pads are secured to
the front end of the cylinder barrel.
• Verify the bottom wear pad is secure to the underside of
the pinning block of the cylinder barrel.
y e
• Verify the wiring harness, the electrical parts of the
ef or
pinning head, and other electrical parts are undamaged.
nl c Verify these parts will not hang up on other parts during

installation and normal cylinder movement.
O en
• Verify the faces of the proximity switches above the
R F
7593-34 FIGURE 4-40

target on the butterfly are 0.156 to 0.159 in (4.0 mm)
above the target.
er
• Verify the distance between the top of the top wear pad
on the front of the cylinder assembly and the bottom of
the bottom wear pad on the front of the cylinder
assembly is 25.83 to 25.84 in (656 mm) (Figure 4-42).
As needed, shim between the bottom wear pad and the
1
cylinder’s bottom wear pad mount to maintain this
dimension.
7593-12
FIGURE 4-41
Assembly of Remaining Sections 25.83 to 25.84 in

(656.2 mm)
The procedure to insert the sections into the next is the same
as the assembly of section 5 into section 4.
7593-33
FIGURE 4-42
2. Verify the top, side, and bottom pads are in place on the
barrel end of the cylinder. Verify the pad is in place on

the bottom of the pinning block. Liberally grease these

blocks attached to the cylinder assembly.
3. Turn the cylinder upside-down; the pinning head is on
the bottom.
4. Apply 24 VDC to the emergency/service mode plug with
the testing unit. Verify the LEDs on the proximity sensors
in the pinning head light to verify they are in working
order. If all the sensors do not all light, contact
Manitowoc Crane Care. Disconnect the testing unit.
CAUTION
Apply no more than 1400 psi or you will cause seals in the
butterfly to suffer damage and leak.
7593-37
FIGURE 4-44
5. Connect hydraulic/air supply hoses to the A, R, K1, and
K2 ports of the rod end valve block (Figure 4-43). 9. Slowly insert the cylinder into the sections (Figure 4-44); 4
y e
take care not to damage any hydraulic, electrical or
ef or
mechanical parts while installing the cylinder. Ensure
nl c proper clearance for the pinning valve, tubes, wiring

harness, pinning head, and other attached parts of the
O en
cylinder assembly. Verify they will all clear the interior
R F
parts of the five telescoping sections, and there will be

no damage to them during extension or retraction.
Adjust and secure them as needed to ensure clearance.
er
10. Stop when the cylinder pins in the pinning block of the
cylinder align with the mating cutouts in section 1.
DSC01165
A K2 K1 R
FIGURE 4-43
6. Use the 24 VDC control and hydraulic/air pressure to
pivot the butterfly arms in so they won’t be damaged
during installation.
7. Disconnect electrical wires and hoses.
8. Use appropriate lifting device to install telescope
cylinder assembly, barrel end first, into rear of section 1.
7593-38 2 1
FIGURE 4-45
11. Reconnect the 24 VDC testing unit’s plug to the
matching emergency/service mode plug of the pinning
head. Reconnect hoses to the rod end valve block.

12. Use electrical control and hydraulic/air pressure to 7. Measure gap between outer side wall of section 1 and
extend the cylinder pins to engage the mating cylinder inner side wall of base section. Do this for both sides of
pin holes in section 1. This pins the cylinder to section 1. section 1. Note measurements.
Keep the butterfly linkage of the cylinder assembly IN to
8. Measure gap between outer bottom wall of section 1 and
avoid engaging the C-clamps. Then disconnect
inner bottom wall of base section. Measure gap between
electrical plug and disconnect hoses from the rod end
outer top wall of section 1 and inner top wall of base
valve block.
section. Note measurements.
NOTE: The links (1) (Figure 4-45) on the ends of the
9. Slide sections into base section until one of the set
butterfly arms fit inside the C-clamps (2) without
screws of each of the bottom corner outer wear pads on
touching any sides.
section 1 is visible through the access holes in the base
section. Tighten each set screw to force its wear pad to
Assemble Telescope Assembly and Base touch the related inside wall of the base section. Then
Section back off the set screw one-half turn. Repeat this for the
1. Grease all section 1 sliding surfaces and mating base other set screw in each wear pad.
section surfaces. 10. Install bottom inner wear pad and bottom corner inner
2. Install set screws in the section 1 section pins and wear pads.
retract the pins so they won’t lock into holes in the base 11. Install retainer plates in slots behind front flange in base
section. section with 0.25 in (6 mm) gap between plate and wear
y e
3. Lube all wear pads and lube the sliders on the cylinder pads. Temporarily secure each plate with a capscrew,
ef or
rails. flat washer, and lock nut.
4.
nl c
Insert rear of section 1 into front of base section. As 12. Install the side inner wear pads and retaining plates.
O en
needed, extend out section 1 and install the right mix of 13. Install wear strips under the wear pads to ensure bottom,
R F
shims under bottom outer wear pads of section 1 so the corner, and side wear pads are tight against section 5
pads just touch the base section inner wall. without jamming or interfering with normal movement.
Wear strips must be same thickness on left and right to
er
keep boom centered during extension and retraction.
2 14. Move the retainer plates tight against the wear pads and
tighten the capscrews.
15. Install top corner inner wear pads. Adjust capscrews for
top corner inner wear pads so the wear pads are snug
against section 1 but not jammed. Shim under wear
pads as needed using shims on each side and on top.
Shims must be same thickness on left and right to keep
boom straight during extension and retraction. Divide
total shimming distance by 2 to shim properly.
16. Secure top corner inner wear pads to forward top
corners of base section inner walls with capscrews and
flat washers through holes in corners. Tighten
capscrews so the wear pads just touch section 1 outer
wall.
17. Tighten screws so side outer wear pads on both sides of
section 1 just touch base section inner walls. This
1
adjustment protects section 1 from moving left or right
during extension or retraction.
7593-39 18. Install retainer plates to hold wear pads in place.
FIGURE 4-46
5. Push the top corner outer wear pads (1) (Figure 4-46) 19. Move section 1 into the base section until the lube hoses
into place as they go into the base section. Adjust the set of its top corner outer wear pads are accessible. Lube
screws in the bottom corner outer wear pads (2) to allow wear pads with proper grease.
for assembly. 20. Move section 1 into the base section until section pins of
6. Slide section 1 into base section midway. section 1 align with cutouts in rear of base section.

Unscrew set screws to allow section pins to extend and 23. Install four anchor bolts (1) (Figure 4-47) through
lock into base section. Remove set screws. cylinder mounting bars (2) into the cylinder mounting
holes in the rear of the base section. Tighten bolts in a
21. With section 1 centered in the base section adjust the
star pattern to the proper torque.
bolts on either side of the top and bottom anti-roll bars
until there is a gap of 0.125 in (3 mm) between each bolt 24. Route the A hose (the cylinder pins lock/unlock hose
head and its related anti-roll bar. Secure each bolt with from the small “A” port on the top of the cylinder rod end)
its jam nut. Repeat for the other anti-roll bar. through the hole (outside left, looking forward) on the left
hose bar.
22. Measure from the rear edge of each base section cutout
to the corresponding rear surface of the section pin on 25. Route the R hose (the return hose from the larger “R”
each side of section 1. Distance must be 0.19 to 0.20 in port on the top of the cylinder rod end) through the
(5 mm). Adjust by adding or subtracting stop block related hole (outside right, looking forward) on the right
shim(s) at flange of section 1. Secure stop block and hose bar.
shims with capscrews.
26. Route the K2 hose (the left extend hose from the “K2”
3 1
port on the left of the cylinder rod end) through the
4 2 4
related hole (inside left, looking forward) on the left hose
bar.
27. Route the K1 hose (the right extend hose from the “K1”
port on the right of the cylinder rod end) through the 4
y e
related hole (inside left, looking forward) on the left hose
ef or
bar.
nl c 28. Secure each of the hoses to its related hose bar with
nuts on its fitting.
O en
R F
29. Grease each of the five sections’ pairs of section pins.

Their grease fittings should be accessible through the
access holes in the base section and the sections.
er
30. Verify the emergency/service mode plug is secured to
the cylinder above the cylinder control connector on the
pinning block. Roll up the cable and secure it here with a
7593-17 cable tie so it will not be damaged or interfere with
A K2 K1 R
FIGURE 4-47 cylinder operation. Verify plug is covered to protect it.

Final Assembly and Test 3. Install the boom cable length measuring unit (2) in the
top rear of the base above the cylinder rod end with
1. Install the boom cable reel mounts in the bottom rear of attaching hardware.
the base below the cylinder rod end with attaching
hardware. 4. Secure the D-ring (part of the cable reel) to the power
connector bracket on the pinning block.
2. Install the boom cable reel (1) (Figure 4-48) in its mount
with attaching hardware.
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P1070073
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1
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7593-9
Base Section
(shown upside-down) FIGURE 4-48
5. Plug wiring harness into cylinder control connector on 11. Extend the other sections, in turn, and verify the
bracket in rear of pinning block. following:
6. Secure the top rear cover plate to the top of the base • As the telescope cylinder extends, it rides on the wear
section with capscrews. pads on the bottom of the front of the barrel and on the
bottom of the pinning block. Side and top wear pads on
7. Connect the hoses and electrical connector to the crane
the front of the barrel also help guide the cylinder.
using extension hoses and electrical cable.
• The butterfly linkage works properly and locks the
8. Using the ECOS controls in the crane, verify the cylinder
section pins properly. Likewise, both section pins work
pins are retracted to allow the cylinder barrel to extend.
properly, extend, and lock section to section.
9. Lock the cylinder pins to the cutouts in the rear of section
12. Engage the telescope cylinder to retract section 1. Verify
5. Verify the cylinder extends section 5 smoothly, stop
the cylinder pins retract to allow the cylinder barrel to
section 5 when the cylinder pins align with the cutouts in
retract, then lock the cylinder pins to the cutouts in the
the front of section 4.
rear of section 1.
10. Extend the section pins of section 5 to lock it to the front
13. Retract the section pins of section 1 to unlock it from the
of section 4.
base section, then retract section 1. Verify the cylinder

retracts section 1 smoothly, then stop section 1 when the 3. Lubricate the pivot bushings in the turntable.
cylinder pins align with the cutouts in the rear of the base
4. Block the boom in place.
section. Extend the section pins of section 1 to lock it to
the rear of the base section. NOTE: The boom may need to be raised or lowered to aid
in the installation of the boom pivot shafts.
14. Retract the other sections to verify the following:
5. Apply antiseize compound to the boom pivot shafts.
• As the telescope cylinder retracts, it rides on the wear
pads on the bottom of the front of the barrel and on the 6. Open pressure bleed valve on superstructure, behind
bottom of the pinning block. Side and top wear pads on the boom pivot (1) (Figure 4-10).
the front of the barrel also help guide the cylinder.
1
• The butterfly linkage works properly and locks the
section pins properly. Likewise, both pins work properly,
extend, and lock section to section.
15. Install the rollers to the left side of the stop flanges on the
front of the sections.
16. Install the brackets and cable and connect it to its related
fitting on the nose with a snap link.
17. Install optional boom lights on boom, as required. 4
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18. Attach other removed parts, such as the flight traffic
warning indicator, the wind speed indicator, and the
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boom angle unit components, and their related wiring
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and other electrical parts, on the boom. Pay attention to
tagging done earlier when these parts and wires were
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removed.
19. Install the boom per Boom Installation procedure 7890 FIGURE 4-49
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following in this section.
7. Disconnect hoses from counterweight pin cylinders
Boom Installation (Figure 4-50) and connect to boom pin cylinder
(Figure 4-51). Hoses from the boom pivot cylinder are
NOTE: The following procedure applies to the entire boom accessible at the back of the boom.
assembly that has been totally removed from the
crane. 1
The boom, without any boom extension, weighs
about 33,000 lb (15,000 kg).
DANGER
Crushing Hazard!
Ensure blocking and lifting devices are capable of
supporting the boom assembly.
Block the boom before doing any work under the boom.
Failure to properly support the boom and/or the lift
cylinder may result in death or serious injury.
1. With the machine properly set up on outriggers, attach

an adequate lifting device to the boom and suspend the
7745-2 FIGURE 4-50
boom over the machine (Figure 4-7).
8. Close pressure bleed valve on superstructure, behind
2. Lower the boom into position. Align the boom pivot the boom pivot (1) (Figure 4-10).
mounting holes with mounting holes in the turntable.

12. Using the lifting device attached to the boom, lower the
1 boom onto the lift cylinder rod end.
The lift cylinder may be positioned by using the bottle
jack on the lift cylinder support. Use a block of wood
between the bottle jack and the lift cylinder barrel to
prevent damage to the cylinder.
Extend the lift cylinder as necessary to align the rod end
with the lugs in the base section. Using the valve on the
lift cylinder as a control valve.
NOTE: This should be carefully controlled. If the lift
cylinder rod is extended too far, it cannot be
retracted using the main directional control valve.
CAUTION
7745-2 FIGURE 4-51 If the hydraulic system must be activated to extend or
retract the lift cylinder, ensure the rod end is properly
9. Using the ECOS display, “Counterweight” menu, actuate
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aligned with the lift cylinder pivot.
the locking cylinder to extend the boom pivot pins.
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10. Install hardware removed earlier to secure the boom
pivot shafts (Figure 4-52). For the proper torque values,
13. Apply antiseize compound to the upper lift cylinder pivot
pin.
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refer to Fasteners and Torque Values, page 1-18.
14. Use the hand pump (1) (Figure 4-53) to install the upper
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1
lift cylinder pivot pin. The lift cylinder may need to be
raised or lowered to aid in the installation of the pivot pin.
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1
7745-2 FIGURE 4-52

11. Disconnect hydraulic lines from boom pivot cylinder and
connect to counterweight lock cylinders. 7745-2 FIGURE 4-53
15. Install hardware removed earlier to secure the lift
cylinder pivot pin. For the proper torque values, refer to
Fasteners and Torque Values, page 1-18.

16. Adjust the top and bottom bolts (1) (Figure 4-54) to 0.04 21. If unit is equipped with hydraulic boom extension,
in (1 mm) gap between the bolt and the lift cylinder rod connect hydraulic lines from compact block.
end pivot (2). Ensure the rod end is centered in the pivot.
22. Connect the hydraulic hoses as tagged before removal
Lock the centering bolt into place with the jam nut.
(Figure 4-56).
1 2
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FIGURE 4-56
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23. Connect electrical wires as tagged before removal
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(Figure 4-57).
FIGURE 4-54
17. Lower the bottle jack after making sure the boom is
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properly supported.
18. Remove the boom lifting device.
19. Activate the hydraulic system and remove the boom and
lift cylinder support devices.
20. Elevate boom to allow access to the telescope hose
disconnects. Connect telescope hydraulic lines from the
compact block.
FIGURE 4-57
24. Install RCL components per RCL manual.

25. Remove the lift cylinder support from the carrier and
place in the stowage tray, or remove from the crane.
Functional Check
1. Activate the hydraulic system and check for proper
operation and leaks.
7745-1 FIGURE 4-55
2. Ensure the boom will extend and retract properly.

NOTE: Cycle the boom several times to evacuate air from Boom Alignment and Servicing
the telescope cylinder.
Refer to Lubrication, page 9-1 for the proper lubricant.
3. Ensure the lift cylinder does not allow the boom to drift
down. Boom alignment is done as the boom sections are being
assembled into one another. A check and fine adjustment is
4. Ensure all electrical components disconnected during as follows.
removal are operating properly.
1. Fully extend the boom horizontally.
Inspection 2. Lubricate the bottom corners and top corners of the
Visually inspect telescoping sections for adequate lubrication outside of each inner boom section. Likewise, grease
of all wear surfaces. Observe extended sections for across the outer wall of each inner boom section at
evidence of cracks, warping, or other damage. Periodically regular intervals.
check security of boom wear pads. Check boom nose 3. Grease each section’s pair of top corner outer wear pads
sheaves for security and freedom of movement. using the grease fittings provided.
Should boom chatter or rubbing noises in the boom occur, it 4. Adjust the top corner inner wear pads such that wear
will be necessary to lubricate the telescope cylinder wear pad is just touching the next section both at the top and
pads. Refer to Lubrication, page 9-1. side surfaces of the top radius.
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CAUTION
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When extending and retrac ti ng the boom during
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alignment, stop movement if there is any restriction.
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Adjust wear pads as necessary to provide free travel of

the affected boom section(s).
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5. Retract and extend the boom. Check for the high point
where the boom has brushed the wear pads at the
widest point.
6. Retract the boom sections to align the high point on the
boom section with the adjacent wear pads.
7. Add or subtract shims under the wear pads as
necessary. Adjust screws on the top corner inner wear
pads, and adjust screws on the bottom corner outer
wear pads. Shim evenly on opposite sides.
8. Attach a weight and fully extend the boom. Check for
side to side deflection. Shim bottom wear pads as
needed; adjust screws on top corner inner wear pads as
needed. Shim evenly on opposite sides.

BI-FOLD SWINGAWAY BOOM EXTENSION For instructions on installing, removing or deployment of the
boom extension(s) refer to the Operator’s Manual.
Description
HOOK BLOCK/OVERHAUL BALL
A 59 ft (18 m) offsetable swingaway boom extension is
provided to obtain additional boom reach. The fly swingaway
section is 23 ft (7 m). The base section is 36 ft (11 m).
DANGER
The boom extension mounts directly to the boom nose
Crushing Hazard!
utilizing a four point attachment. In addition, the swingaway
can be stowed on the right side of the boom base section. Before attempting to erect or stow the boom extension,
read and strictly adhere to all warning decals installed on
The boom extension can be rotated and stowed on the right the swingaway and stowage brackets.
side of the boom base section.
To prevent uncontrolled swinging of boom extension,
The 23 ft (7m) section weighs approximately 882 lb (400 kg) always secure the extension with a guide rope on the
and the 36 ft (11 m) section weighs approximately 2205 lb main boom before removing any connections.
(1000 kg), for a combined weight of 3087 lb (1400 kg).
The serial number of the crane is also stamped on the boom Description
extensions. The extensions are aligned at the factory for use A 130 ton (118 metric ton) hook block, a 100 ton (90 metric
with this specific crane. Before installing the boom ton) hook block, and a 10 ton (9 metric ton) top swivel 4
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extensions verify that the serial numbers match that of the overhaul ball is available for the crane. The hook blocks
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crane. Figure 4-58 indicates where the serial numbers are utilizes a one-piece pivot block and the hook is equipped with
stamped.
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Maintenance
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It is recommended that the hook block and/or overhaul ball

be inspected every 50 hours. A complete disassembly
inspection of the hook, hex nut, and threaded areas, for
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corrosion and proper fit, should be conducted every quarter
or 500 hours. After assembly of the hook, a liberal coating of
multipurpose grease should be applied to the nut and
threaded areas by brush or hand to prevent corrosion.
For hook blocks and other load handling devices; follow the
FIGURE 4-58 manufacturer’s inspection and testing recommendations to
assure an adequate preventative maintenance program is
established.

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THIS PAGE BLANK

RT9150E SERVICE MANUAL HOIST AND COUNTERWEIGHT
SECTION 5
HOIST AND COUNTERWEIGHT
SECTION CONTENTS
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Setting the Lowering Limit Switch . . . . . . . . . . . . . 5-6
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Check the Lowering Limit Shuts Off . . . . . . . . . . . 5-6
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Checking the Hoist Brake . . . . . . . . . . . . . . . . . . . . 5-6
Warm-up Procedure . . . . . . . . . . . . . . . . . . . . . . . 5-1 General Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Hoist Access Area . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Counterweight Removal and Installation . . . . . . . 5-7
Hoist Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Counterweight Stand Installation . . . . . . . . . . . . . . 5-7
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Standard 39,000 lb (17,690 kg) Counterweight
Functional Check . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Changing the Hoist Oil . . . . . . . . . . . . . . . . . . . . . 5-5 Standard 39,000 lb (17,690 kg) Counterweight
Preventive Maintenance . . . . . . . . . . . . . . . . . . . . 5-5 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Hoist Cable (Wire Rope). . . . . . . . . . . . . . . . . . . . . 5-5 Heavy 63,000 lb (28,576 kg) Counterweight
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Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Check the Position on the Hoist Drums . . . . . . . . 5-5
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Heavy 63,000 lb (28,576 kg) Counterweight
Check the Rope . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
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Adjusting the Lowering Limit Switch . . . . . . . . . . 5-6
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Counterweight Stand Removal . . . . . . . . . . . . . . 5-10
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DESCRIPTION hoist controls route fluid to the hoist up or hoist down port of
the hoist motor control valve.
The hoist is installed on the superstructure and incorporates
an axial piston motor, drive unit, gearbox and lowering limit
MAINTENANCE
switch.
Warm-up Procedure
THEORY OF OPERATION
A warm-up procedure is recommended at each start-up and
Each hoist is controlled by controls in the cab. is essential at ambient temperatures below +40°F (4°C).
When the main hoist control lever in the cab is moved from The prime mover should be run at its lowest recommended
neutral, it causes the main hoist section of the directional RPM with the hydraulic hoist control valve in neutral allowing
control valve to shift the valve spool to route hydraulic flow to sufficient time to warm up the system. The hoist should then
the main hoist motor control valve. The hoist motor control be operated at low speeds, forward and reverse, several
valve routes the hydraulic flow to the hoist motor. The motor times to prime all lines with warm hydraulic fluid, and to
turns one direction to hoist up, and turns the other direction circulate gear lubricant through the planetary gear sets.
to hoist down, depending on whether the hoist controls route
fluid to the hoist up or hoist down port of the hoist motor
control valve.
When the auxiliary hoist control lever in the cab is moved WARNING
from neutral, it causes the auxiliary hoist section of the Failure to properly warm up the hoist, particularly under
directional control valve to shift the valve spool to route low ambient temperature conditions, may result in
hydraulic flow to the auxiliary hoist motor control valve. The temporary brake slippage due to high back pressures
hoist motor control valve routes the hydraulic flow to the hoist attempting to release the brake, which could result in
motor. The motor turns one direction to hoist up, and turns property damage, severe personal injury or death.
the other direction to hoist down, depending on whether the

HOIST AND COUNTERWEIGHT RT9150E SERVICE MANUAL
Hoist Access Area screws and washers securing the limit switch (Figure 5-2
continued). Remove the limit switch (1) (Figure 5-2
continued).
1 17 13, 14
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7583-2 7592-2 FIGURE 5-2
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FIGURE 5-1
in the hoist area. nl c

Use the hoist access platform (1) (Figure 5-1) when working
Item Description
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1 Lowering Limit Switch
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2 Hoist Drum
3 Axial Motor
WARNING
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4 Stop Brake
Platform must not be used for hauling passengers. No
storage of components are allowed on the platform. Only 5 Socket Head Capscrew
one person at a time is allowed on the platform. 6 Mounting Gear
7 Hex Head Capscrew
Hoist Removal
8 Spring Washers
1. Remove all cable from the hoist drum. Refer to Section
4, Set-up and Installation in the Operator’s manual. 9 Multiple Disk Brake
2. Tag and disconnect all hydraulic lines to the hoist 10 Cotter Pin
assembly. Cap or plug all lines and openings. 11 Washer
3. Drain the oil from the oil line on the hoist as follows: 12 Rod
a. Place a receptacle under the tube (3) (Figure 5-3). 13 Roll Pin
b. Unscrew the nuts (1) and (6) (Figure 5-3) and let the 14 Roller
oil drain out. 15 Oil Tube
c. If removing the oil tube, remove the capscrews (7), 16 Superstructure
flatwashers (8) and nuts (9) (Figure 5-3) and 17 Idler Roller
remove the oil tube from superstructure.
18 Socket Head Capscrew
4. Tag and disconnect the electrical wires to the lowering
limit switch (1) (Figure 5-2 continued). Remove the

10, 11, 12 16
6 7, 8
5 3
15
5 3
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2
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9
18
4
7592-1
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4
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5
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16
1
7520-13
Figure 5-2 continued

5. Attach an adequate lifting device to the hoist.

6. Ensure the hydraulic lines have been disconnected from Item Description
the hoist motor. Remove the socket head capscrews (5) 1 Breather
(Figure 5-2 continued) securing the motor to the brake.
2 Hose
Remove the motor (3).
3 Sight Gauge/Fill Tube
7. Remove the socket head capscrews (7) and spring
washers (8) (Figure 5-2 continued) securing the 4 Max Oil Fill Mark
mounting gear (6) to the hoist flange. 5 Hose
8. Using a lifting device, remove the mounting gear (6) and 6 Bolt
brake (9). Separate the brake (9) from the mounting
7 Capscrew
gear (6).
8 Flatwasher
9. Ensure the lifting device is securing the hoist drum.
Remove the cotter pins (13) (Figure 5-2 continued) and 9 Nut
remove the idler rollers (17).
Installation
10. Remove the roll pins (10), washers (11) and rods (12)
(Figure 5-2 continued) from the superstructure. 1. With the hoist supported by a suitable lifting device,
install the hoist drum.
11. Using the lifting device remove the hoist drum from the
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superstructure. 2. Install the rods (12), washers (11) and cotter pins (Figure
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5-2 continued) in the superstructure.
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4. Install the idler rollers (17) and secure with the cotter
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pins (13) (Figure 5-2 continued).

1
5. Using a lifting device, install the mounting gear (6) in the
2 hoist flange and secure with the socket head capscrews
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7, 8, 9 (7) and spring washers (8) (Figure 5-2 continued).
Torque the capscrews to recommended torque.
3
6. Remove the lifting device from the hoist.
4 7. Install the brake (9) (Figure 5-2 continued) to the

mounting gear (6) and secure with the socket head
capscrews.
8. Install the motor (3) to the brake and secure with the
7, 8, 9
socket head capscrews (5) (Figure 5-2 continued).
Torque the capscrews to recommended torque.
5
9. Install the limit switch (1) (Figure 5-2 continued) and
secure with the screws and washers. Torque the screws
6 to recommended torque. Connect the electrical wires to
the lowering limit switch.
7592-3 FIGURE 5-3
10. Connect the hydraulic lines to the hoist ensuring the
proper lines are connected to the correct ports as
marked during removal.
11. If the oil tube (3) (Figure 5-3) was removed, install and
secure with the nuts (9), flatwashers (8) and capscrews
(7). Ensure the max marking on the oil level tube is
positioned at middle of hoist.
12. Fill the oil through the oil tube (3) (Figure 5-3) up to the
max mark (4). Refer to Lubrication, page 9-1. Replace
the gaskets and secure the hoses (2) with the bolt (1)
(Figure 5-3).

13. Install the cable on the hoist following the procedures Refer to the Section 6, Preventive Maintenance in the
outlined in Section 4, Set-up and Installation in the Operator’s Manual and Lubrication, page 9-1 for more
Operator’s Manual. information.
14. Adjust the Lowering Limit Switch, refer to Setting the
Lowering Limit Switch, page 5-6. HOIST CABLE (WIRE ROPE)
Functional Check Check the Position on the Hoist Drums

1. Attach a test weight to the hook and raise and lower the
load several times.
2. Check the hoist for smooth operation of the hoist motor DANGER
and brake system. Rick of Accidents when the rope drum is turning!
3. Ensure the hydraulic connections are secure and free Keep away from the turning rope drum.
from leaks. This will prevent your limbs from being drawn in and
getting crushed.
Changing the Hoist Oil
1. Check the position of the ropes on at least one full turn of
Draining the Hoist
the rope drum for the hoist gears.
1. Place a receptacle under the tube (3) (Figure 5-3).
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2. Slowly carry out the lowering movement and check the
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2. Unscrew the nuts (1) and (6) (Figure 5-3) and let the oil rope.
drain out.
Filling the Hoistnl c • The rope needs to be evenly wound.

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• The rope turns on the drum must be evenly spaced at a
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1. Install the lower sight glass drain nut (6) (Figure 5-3). distance of 0 to 0.08 in (0 to 2 mm).
5
2. Fill the oil through the oil tube (3) (Figure 5-3) up to the • The cross-over points must be at an angle of about 180°
max mark (4). Refer to Lubrication, page 9-1. • The ropes of the top layer lie over the ropes of the
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3. Install the fill nut (1). bottom layer at the crossover points.
Preventive Maintenance Check the Rope

It is extremely important to be aware of the possibility that 1. Start the engine.
deterioration of internal critical components within the hoist 2. Unreel the rope and check that the rope is not damaged
reduction unit can occur. Hoist reduction units incorporate or improperly reeled. When five turns are left on the
planetary gears, multi-disc brake assemblies, and sprag drum, the lowering limit switch must shut off.
clutches which do not have an infinite life span. Although
these components have been designed to achieve long 3. If the lowering limit switch does not shut off or shuts off
service life, reliability can be substantially reduced by a too late it must be reset. Refer to Setting the Lowering
variety of influencing factors such as: Limit Switch, page 5-6.
• High cycle operation. 4. Check that the clamp (1) (Figure 5-4) is properly
fastened, is not damaged and is properly seated. Torque
• Operating in high ambient temperatures. the fasteners to recommended torque.
• High external contaminations, such as dusty or sandy 5. The free end of the rope must not extend out beyond the
conditions. flanged wheel.
• Level of maintenance. 6. The rope wedge must be in the pouch (2) (Figure 5-4).
7. The rope end on the rope wedge must not show any
signs of wear.

1. Remove the cover (1) (Figure 5-5).

2. Turn the bolt (2) until you hear the switch activate.
3. Screw the cover on again. Replace the gasket, if
necessary.
1 4. Check whether the lowering limit switch shuts off the
hoist correctly.
1
7592-4
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FIGURE 5-4
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8.
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Reel in the rope. Inspect the rope at the same time, the
rope may not show any signs of kinking or being
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7592-5
flattened. 1
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9. Check the end of the rope and all parts of the rope end
clamp.
2
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10. Make sure the rope is correctly fitted in the rope end and
clamp. Refer to Section 4, Installing Cable on the Hoist 1
in the Operator’s Manual.
ADJUSTING THE LOWERING LIMIT SWITCH 7592-5a

FIGURE 5-5
A lowering limit switch is mounted on the main hoist and on
the auxiliary hoist. Check the Lowering Limit Shuts Off
Setting the Lowering Limit Switch 1. Raise the hookblock until there are about 10 turns on the
hoist drum.
2. Lower the hookblock and check whether the lowering
limit switch shuts off properly.
DANGER 3. The lowering limit switch must shut off the hoisting gear
Risk of accidents due to rope end fitting being when five rope turns are still on the hoist drum. Correct
overloaded! the setting of the lowering limit switch, if necessary.
The lowering limit switch must always be reset after repair
work to the hoisting gear and after rope replacement. A CHECKING THE HOIST BRAKE
faulty lowering limit switch must always be replaced.
Check that the hoist brake is working correctly on the main
Prerequisites hoist and the auxiliary hoist.
• The hookblock is reeved 4-fold. 1. Suspend the hookblock on the singly reeved hoist rope.
• The main boom is fully raised and extended. 2. Lift a load of approximately 7.1 tons (15,653 lb) to
approximately 1.0 ft (30 cm) above the ground.
• The hookblock is lowered until only five turns of the rope
remain on the hoist drum. 3. Measure the distance from the ground when the load is
hanging completely still.

4. Turn off the engine. Standard 39,000 lb (17,690 kg)

If the load has not lowered after approximately 2 minutes, the Counterweight Installation
brake is currently in working order.
If the load lowers, contact Manitowoc Crane Care or your
authorized Grove distributor.
DANGER
GENERAL INSPECTION Read and understand the following when removing and
installing the counterweight or counterweight stands, to
• Investigate any unusual noises from the hoist. avoid serious injury or death.
• Check the hoists and the connections for leaks. • Outriggers must be fully extended and set and crane
level before installation or removal of counterweight.
• Check that hoses and fittings are tightly connected and
not damaged. • Lifting operations are not permitted with any
counterweight on the carrier deck except for the
• If any damage is found, contact Manitowoc Crane Care
removal or installation of the counterweight.
or your local Grove distributor.
• Boom is not permitted over carrier deck when the
COUNTERWEIGHT REMOVAL AND boom angle is less than 30° and any counterweight is
positioned on deck.
INSTALLATION
• Hookblock is not permitted to come in contact with
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Counterweight Stand Installation
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counterweight during removal or installation.
NOTE:
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The counterweight stands must be installed on the
front of the carrier before installing or removing the
• Travel is not permitted with any counterweight on
carrier deck.
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counterweight.
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1. Using an adequate lifting device, install the

1. Rig the crane with three parts of line. 5
counterweight stands (1) (Figure 5-6) to the front of the 2. The standard 39,000 lb (17,690 kg) counterweight may
carrier frame (2) (Figure 5-6) and secure with the hitch be lifted in one of the following boom configurations.
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pins (3) (Figure 5-6).
Boom Configuration
0-0-0-0-0
0-0-0-0-50 0-0-0-50-0
(30 ft radius)
3. Enter RCL code 1100. Refer to Section 3, Operating
Controls and Procedures in the Operator’s Manual.
4. Connect sling assembly to the standard counterweight
using the installation lifting holes (Figure 5-7 and
Figure 5-8).
5. Lift and place the counterweight onto the carrier stands.
6. Swing turntable to place the boom over the rear of the
crane.
7. Set the turntable lock pin in the down position.
8. Using the ECOS display lower the counterweight
1 3 7510-3 cylinders into the tubes on the counterweight, refer to
2
FIGURE 5-6 Section 3, Operating Controls and Procedures in the
9. Rotate the cylinders to lock into the counterweight.
DANGER 10. Raise the counterweight until the display indicates the
Adjustment of the counterweight stand (1) (Figure 5-6) counterweight is pre-tensioned.
supports is prohibited when the counterweight is resting
on them.

11. Using the ECOS display, extend the locking cylinders 4. Swing turntable to place the boom over the rear of the
until the display indicates the counterweight is locked in crane.
place.
Standard 39,000 lb (17,690 kg) 6. Using the ECOS display, retract the locking cylinders
Counterweight Removal until the display indicates the cylinders are fully
retracted.
1. Rig the crane with three parts of line (Figure 5-7 and
Figure 5-8). 7. Lower the counterweight onto the carrier stands until the
display indicates the counterweight is fully lowered.
2. The standard counterweight may be lifted in one of the
following boom configurations. 8. Rotate the cylinders to unlock from the counterweight.
9. Using the ECOS display raise the counterweight
Boom Configuration cylinders from the tubes on the counterweight.
0-0-0-0-0 10. Connect sling assembly to the standard counterweight
0-0-0-0-50 0-0-0-50-0
(30 ft radius) using the installation lifting holes (Figure 5-7 and
Figure 5-8).
Controls and Procedures in the Operator’s Manual. 11. Lift and place the counterweight onto the ground.
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Counterweight Installation
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Lifting Holes
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Counterweight
Lifting Holes
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Counterweight
Counterweight
Lifting Holes
Insert Lifting Eyes
Standard 39,000 lb (17,690 kg) Counterweight Heavy 63,000 lb (28,577 kg) Counterweight
FIGURE 5-7

Counterweight Installation
Lifting Holes
Counterweight
Lifting Lugs
Standard 39,000 lb (17,690 kg)

Cast Counterweight
Counterweight Lifting
Holes (4)
24,000 lb (10,886 kg) Cast Counterweight Insert Heavy 63,000 lb (28,577 kg) Cast Counterweight
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FIGURE 5-8
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Installation nl c
Heavy 63,000 lb (28,576 kg) Counterweight 1.
2.
Rig the crane with five parts of line.
The heavy 63,000 lb (28,576 kg) counterweight may be
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lifted in one of the following boom configurations.
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5
Boom Configuration
DANGER
er
0-0-0-0-50
Read and understand the following when removing and 0-0-0-0-0 0-0-0-50-0
(20 ft radius)
installing the counterweight or counterweight stands, to
avoid serious injury or death. 3. Enter RCL code 1100. Refer to Section 3, Operating
• Outriggers must be fully extended and set and crane Controls and Procedures in the Operator’s Manual.
level before installation or removal of counterweight. 4. Connect sling assembly to the 24,000 lb (10,886 kg)
• Lifting operations are not permitted with any counterweight insert using the lifting eyes/lugs on the
counterweight on the carrier deck except for the insert.
removal or installation of the counterweight. 5. Lift and place the counterweight insert into the standard
• Boom is not permitted over carrier deck when the counterweight.
boom angle is less than 30° and any counterweight is 6. Connect sling assembly to the heavy counterweight
positioned on deck. assembly using the installation lifting holes (Figure 5-7
• Hookblock is not permitted to come in contact with and Figure 5-8).
counterweight during removal or installation.
7. Lift and place the counterweight assembly onto the
• Travel is not permitted with any counterweight on carrier stands.
carrier deck.
8. Swing turntable to place the boom over the rear of the
crane.
CAUTION
10. Using the ECOS display lower the counterweight
Counterweight assembly must be completed on the cylinders into the tubes on the counterweight, refer to
ground; not on the carrier counterweight stand. Section 3, Operating Controls and Procedures in the
Outrigger boxes must be installed and outrigger beams Operator’s Manual.
must be fully extended.
11. Rotate the cylinders to lock into the counterweight.

12. Raise the counterweight until the display indicates the Counterweight Stand Removal
counterweight is pre-tensioned.
13. Using the ECOS display, extend the locking cylinders
until the display indicates the counterweight is locked in
place. DANGER
The main boom must not be lowered below horizontal
Heavy 63,000 lb (28,576 kg) Counterweight while swinging over the front while the counterweight
Removal supports are installed.
1. Rig the crane with five parts of line (Figure 5-7 and
Figure 5-8).
2. The 63,000 lb (28,576 kg) heavy counterweight may be
lifted in one of the following boom configurations.
Boom Configuration
0-0-0-0-50
0-0-0-0-0 0-0-0-50-0
(20 ft radius)
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Controls and Procedures in the Operators Manual.
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4.
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Swing turntable to place the counterweight over the front
of the crane.
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6. Using the ECOS display, retract the locking cylinders

until the display indicates the cylinders are fully 1 3 2 7510-3
retracted. FIGURE 5-9
er
7. Lower the counterweight until the display indicates the 1. Attach an adequate lifting device with slings to the
counterweight is fully lowered. counterweight stands (1) (Figure 5-9).
8. Rotate the cylinders to unlock from the counterweight. 2. Remove the hitch pins (3).
9. Raise the counterweight cylinders from the tubes on the

counterweight.
10. Connect sling assembly to the heavy counterweight DANGER
assembly using the installation lifting holes. Crushing Hazard
11. Lift and remove the counterweight from the carrier Death or serious injury could result from being crushed by
stands. falling counterweight.
12. Place the counterweight on the ground.
3. Using the lifting device, remove the counterweight
13. Disassemble the counterweight, if necessary. stands (1) (Figure 5-9).

RT9150E SERVICE MANUAL SWING SYSTEM
SECTION 6
SWING SYSTEM
SECTION CONTENTS
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Swing Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Swivels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Swing Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 Hydraulic Swivel . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 Two-Port Water Swivel . . . . . . . . . . . . . . . . . . . . 6-19
Swing Box Assemblies . . . . . . . . . . . . . . . . . . . . . 6-7 Electrical Swivel. . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 Swing Lock Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
Swing Motor Maintenance . . . . . . . . . . . . . . . . . . 6-7 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
Swing Brake Assembly Maintenance . . . . . . . . . . 6-8 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
Swing Gearbox Maintenance . . . . . . . . . . . . . . . . 6-8 360° Swing Lock Control (Positive Lock Type) . 6-22
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Swing Bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
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Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
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DESCRIPTION degree positive swing lock meshes with the swing gear teeth
at any point of rotation. The pin type swing lock will only lock
The purpose of the swing system is to allow the crane
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the turntable in a straight ahead position over the front or
superstructure to rotate atop the carrier frame. The rear of machine. Both swing locks are operated from the cab.
superstructure swing system provides full 360 degree
rotation in both directions and is equipped with free swing
capabilities. The term free swing means that, with the swing
THEORY OF OPERATION 6
brake switch in the off position, the superstructure will swing
Swing Drive
freely after the swing controller is released until it coasts to a
stop or the swing brake pedal is depressed. The hydraulic power for the swing drive is supplied by the
torque converter driven hydraulic Pump No. 3. Oil flows from
Swing is activated using the control lever in the cab. When
the pump to the hydraulic Port 5 swivel. Flow from the swivel
the swing lever is actuated, hydraulic pressure is routed to
is routed to the front steering flow divider valve in the swing
the swing motors to drive the swing gearboxes in the
directional control valve. Bypass flow from the flow divider
appropriate direction. As the gearboxes rotate, their pinion
valve is used to supply the swing directional control valve.
gears mesh with the teeth on the swing bearing and rotate
the superstructure. Swing speed can be controlled by the When the hydraulic remote control is positioned to select
control lever and a HIGH/LOW swing speed switch on the right or left swing, the flow through the control valve is
front console. The maximum rotation speed is 2.5 rpm in directed to the series/parallel valve, and then routed to the
HIGH speed and 1.25 rpm in LOW speed. Braking is swing motors. If the Swing Brake Selector Switch is in the
accomplished by depressing a glide swing brake pedal OFF position, the superstructure will rotate in the desired
which is a proportionate control valve that provides a direction. Shifting the control to neutral and depressing the
controlled braking of the swing motion. brake pedal will stop the swing.
The swing system consists of a hydraulic remote controller,
Swing Brake
swing speed switch, series/parallel selector valve, a
directional control valve, the swing drives, the swing brake The hydraulic power for the swing brake is supplied by the
assemblies, the brake pedal and power brake valve, and a pressure reducing/sequence valve in the swing brake and
swing brake release solenoid valve. armrest lockout manifold. With the Swing Brake Selector
Switch positioned to ON, the swing brake release valve
The crane is equipped with a pin type swing lock as standard
blocks the regulated flow to the brake release ports and
and a standard 360 degree positive swing lock. The 360
spring pressure in the swing brakes applies the brakes.

SWING SYSTEM RT9150E SERVICE MANUAL
When the Swing Brake Selector Switch is positioned to OFF, Regulated flow from the pressure reducing/sequence valve
the regulated flow is directed from the pressure reducing/ is also provided to the power brake valve where it is available
sequence valve to the brake release ports, overcoming the for the activation of the swing brake when the pedal is
brake spring pressures and releasing the swing brakes. depressed.
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3 7598-1
FIGURE 6-1
Item Description
Item Description 3 Turntable Bearing
1 Swing Drive 4 Pinion Gear
2 Axial Piston Motor

MAINTENANCE
Troubleshooting
Table 6-1

1. Boom swing a. Damaged relief valve. a. Replace relief valve.
operation erratic in
b. Swing brake dragging (not releasing b. Readjust and/or replace necessary
either direction.
properly). parts.
c. Low engine rpm. c. Increase engine rpm to obtain smooth
swing operation.
d. Low hydraulic fluid. d. Check system for leaks. Make repairs
as needed. Fill reservoir. Refer to
Lubrication, page 9-1.
e. Improper movement of control to e. Feather controls to neutral to maintain
neutral. smooth stopping action.
f. Insufficient lubricant on swing bearing. f. Lubricate bearing properly. Refer to
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g. Crane not level. g. Level crane using outriggers.
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i. Excessive overload. i. Reduce load. Refer to load capacity
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chart.
j. Restricted or partly clogged hydraulic j. Replace hose or fittings. Refer to the
hose or fittings. Manitowoc Crane Care Parts Manual.
er
k. Pump cavitation in swing section. k. Tighten suction hose or replace any
damaged fitting. Check hydraulic tank
level. 6
l. Improperly torqued turntable bolts. l. Torque turntable bolts evenly.
m. Excessive preload on upper and lower m. Adjust as necessary.
pinion shaft bearing.
n. Improperly torqued swing motor n. Torque swing motor attachment bolts.
attachment bolts.
o. Malfunction of the swing box. o. Remove swing box and make
necessary repairs.
p. Worn or damaged pump. p. Repair or replace damaged pump.
q. Damaged swing directional control q. Repair or replace swing directional
valve. control valve.
r. Damaged swing pinion. r. Replace pinion.
s. Damaged turntable bearing. s. Replace turntable bearing.
t. Controller settings. t. Check settings.
u. Electrical connection. u. Inspect wiring and connections.


2. Boom swing a. Crane not level. a. Level crane using outriggers.
operation erratic in
b. Turntable bearing binding due to b. Rotate machine 360 degrees in both
one direction only.
continuous limited swing. (Example: directions several times and lubricate
concrete pourer.) bearing.
c. Restricted hose or fitting. c. Replace hose or fitting.
Boom swing d. Damaged swing directional control d. Replace swing directional control
operation erratic in valve. valve.
one direction only.
e. Damaged swing pinion. e. Replace pinion.
f. Damaged turntable bearing. f. Replace turntable bearing.
3. Boom will not swing a. Damaged relief valve. a. Remove, clean, and repair or replace
in either direction. relief valve.
b. Damaged swing motor. b. Repair or replace swing motor.
c. Swing brake not releasing properly. c. Repair as necessary.
d. Damaged hydraulic remote control d. Replace hydraulic remote control
valve. valve.
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e. Internal damage to swing box. e. Remove swing box and repair.
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g. Damaged swing directional control g. Replace swing directional control
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valve. valve.
h. Damaged swing pinion. h. Replace pinion.
i. Damaged turntable bearing. i. Replace turntable bearing.
er
j. Excessive overload. j. Reduce load. Refer to load capacity
chart.
4. Swing operation a. Damaged relief valve. a. Adjust, repair or replace valve.
slow in either
b. Improperly adjusted swing brake. b. Readjust.
direction.
c. Damaged hydraulic remote control c. Replace hydraulic remote control
valve. valve.
d. Improperly lubricated swing bearing. d. Lubricate bearing per Lubrication, page
9-1.
e. Improper size hose and/or fittings e. Replace hose or fittings. Refer to your
installed. Manitowoc Crane Care Parts Manual.
f. Clogged or restricted hydraulic hoses f. Clean or replace damaged parts.
or fittings.
g. Worn or damaged output shaft g. Replace bearings.
bearings
h. Worn or damaged swing motor. h. Repair or replace motor.
i. Worn or damaged hydraulic pump. i. Repair or replace pump.
j. Crane not level. j. Level crane.
k. Damaged swing directional control k. Replace swing directional control
valve. valve.


5. Swing operation a. Crane not level. a. Level crane.
slow in one
b. Damaged hydraulic remote control b. Replace hydraulic remote control
direction only.
valve. valve.
c. Damaged swing directional control c. Replace the swing directional control
valve. valve.
d. Clogged or restricted hose. d. Replace hose or fitting.
e. Improperly torqued turntable bearing. e. Torque turntable bearing.
6. Swing brake a. Improper brake adjustment. a. Adjust brake.
operation erratic.
b. Air in swing brake system. b. Bleed brake system.
c. Brake pedal not fully retracted. c. Check brake pedal return spring; repair
or replace spring.
d. Dirty or glazed brake disc. d. Clean or replace disc.
e. Malfunction of the glide swing power e. Repair or replace glide swing power
brake valve. brake valve.
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f. Kinked or bent lines and/or hoses and f. Straighten or replace as required.
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fittings.
7.
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Swing brake
system will not
a. Damaged swing brake release valve. a. Replace release valve.
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b. Damaged glide swing power brake b. Repair or replace glide swing power
operate.
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valve. brake valve.

c. Internal damage to the swing brake c. Repair or replace affected parts.
assembly.
er
d. Loose or restricted brake lines or d. Tighten or replace lines and fittings.
fittings.
8. Swing brake pedal
is spongy.
a. Damaged glide swing power brake
valve.
a. Repair or replace the glide swing
power brake valve.
6
b. Loose or restricted brake lines or b. Tighten or replace brake lines and
fittings. fittings.
9. Swing brake drags. a. Damaged glide swing power brake a. Repair or replace the glide swing
valve. power brake valve.
b. Damaged swing brake release valve. b. Replace release valve.
c. Internal damage to the swing brake c. Repair or replace affected parts.
assembly.
d. Loose or restricted brake lines or d. Tighten or replace brake lines and
fittings. fittings.
10. Boom swings a. Insufficient hydraulic volume. a. Check delivery of hydraulic pump.
slowly. Ensure sufficient fluid is available to
pump. Check pump drive speed.
b. Damaged relief valve. b. Adjust, repair, or replace valve.
c. Damaged swing motor. c. Repair or replace motor.
11. Swing motor a. Hydraulic remote control valve sticking a. Repair or replace valve.
continues to or valve otherwise damaged.
operate when
b. Control valve sticking or valve b. Repair or replace valve.
swing control is in
otherwise damaged.
neutral.


12. Swing motor a. Improper port connections. a. Reverse port connection.
turning in wrong
b. Improper wiring connection b. Inspect wiring and connections. Make
direction.
repairs as needed.
13. Swing motor noisy. a. Air in system. a. Refer to Hydraulic System, page 2-1,
for removal of air from the system.
b. Motor binding. b. Repair or replace motor.
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SWING BOX ASSEMBLIES Removal

1. Engage the swing brake and the swing lock pin.
Description
There are two swing box assemblies (Figure 6-1) for turning
and stopping the turntable and superstructure. Each swing CAUTION
box assembly consists of a hydraulic motor on top, a brake Hydraulic fluid can be hot and cause burns. Always wear
assembly, and a swing gearbox on the bottom. Each swing gloves and allow the hydraulic system to cool.
motor on the swing gearbox gear pinion output shaft applies
turning force to the turntable bearing’s gear teeth to turn the 2. Clean the port area around the swing motor. Tag and
turntable. Operator-applied hydraulic power applies the disconnect the hydraulic hoses from the swing motor.
brake assemblies to stop their swing box assemblies. Cap or plug all openings.
Each swing motor runs on hydraulic power to drive its 3. Unscrew the drain plug, and drain the oil. After oil is
gearbox. Each swing motor has three ports (A, B and Tank) drained, reinstall the drain plug
for connection to the hydraulic system. .
Each swing brake assembly is between the swing motor and

CAUTION
the swing gearbox. Each brake assembly’s mechanism is a
disc pack that is hydraulically released and spring applied. Pull straight up on the motor assembly to avoid damaging
The operator steps on a pedal on the cab floor to trigger the the splined shaft.
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swing brake assemblies to stop the swing boxes from
4. Remove the fasteners securing the swing motor to the
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turning. The Swing Brake Switch prevents the swing brake
swing brake assembly housing flange. Remove and
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assemblies from releasing when ON; this prevents
inadvertent swing during travel or other situations when the discard the O-ring from the groove in the swing brake
assembly housing.
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superstructure should not turn.
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Each gearbox bolts to the superstructure base plate. Each Installation

gearbox uses double reduction planetary gearing. Each
gearbox’s pinion gear meshes with the ring gear of the
CAUTION
er
turntable bearing to rotate the turntable.
Use care when engaging the swing motor drive gear; do
A filling plug in the side of the swing brake system assembly
not force the shaft to engage. Damage to the gears may
housing allows the operator to add gear oil to the swing
gearbox and swing brake assembly. There is one drain plug
result 6
for draining gear oil from the gearbox housing.
1. Install a new O-ring in the groove of the swing brake
There are hydraulic lines to each swing brake assembly; assembly’s housing. Position the swing motor on the
these lines are in a system sealed from gear oil. The swing brake.
hydraulic lines are only for applying or releasing the brake,
not providing brake or gearbox lubrication. 2. Secure the swing motor to the swing brake assembly
housing with the capscrews. Torque the bolts according
There are hydraulic lines to the swing motor; these lines are to the specifications in Fasteners and Torque Values,
also in a system sealed from gear oil. The hydraulic lines are page 1-18.
for driving the motor in the chosen rotation. There is one
drain plug for draining hydraulic fluid from the swing motor. 3. If needed, fill the swing gear box with gear oil. Refer to
Swing Motor Maintenance 4. Connect the hydraulic lines to the swing motor as tagged
NOTE: Each swing motor can be removed and during removal.
disassembled independently of the swing brake Testing
assembly.
1. Test swing of superstructure in each direction. Stop and
start swing boxes several times.
2. Inspect for hydraulic leaks and repair as necessary.

Swing Brake Assembly Maintenance Swing Gearbox Maintenance

NOTE: Each swing brake assembly can be removed and Removal
disassembled independently of the swing gearbox.
1. Engage the swing lock pin.
Removal
1. Engage the swing lock pin. CAUTION
Hydraulic fluid can be hot and cause burns. Always wear
gloves and allow the hydraulic system to cool.
CAUTION
Hydraulic fluid can be hot and cause burns. Always wear 2. Tag and disconnect the hydraulic lines from the swing
gloves and allow the hydraulic system to cool. motor and the swing brake assembly. Cap and/or plug
all openings.
2. Tag and disconnect the hydraulic lines connected to the
swing motor and the swing brake assembly. Cap and/or 3. If necessary, remove the swing motor per instructions in
plug all openings. this section. Or, do so after removing entire swing box
assembly from superstructure.
3. Remove the swing motor from the swing brake
assembly per the procedure in this section. 4. If necessary, remove the swing brake assembly per
instructions in this section. Or, do so after removing
4. While observing tension on the bolts due to internal entire swing box assembly from superstructure.
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brake springs, unscrew socket head capscrews
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securing the swing brake assembly to the gearbox. NOTE: The swing gearbox with swing brake assembly and
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Remove the brake assembly. swing motor attached weighs about 335 pounds
(about 150 kg).
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5. Remove and discard the O-ring from the swing brake
assembly housing. 5. Attach a suitable lifting device to the swing gearbox.
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6. Cover the opening of the swing gearbox to ensure no 6. Remove the capscrews and flatwashers securing the
dirt, dust or other foreign material get into the gearbox. swing gearbox to the superstructure base plate.
er
Remove the swing gearbox.
Installation
7. Remove the bolts and bottom plate attaching the pinion
1. Install a new O-ring onto the brake assembly’s housing gear to the swing gearbox shaft. Remove the pinion
and insert the brake assembly into the gearbox. gear.
2. Secure the brake assembly with the socket head 8. Cover the opening of the swing gearbox to ensure no
capscrews. dirt, dust, or foreign material gets into the gearbox.
3. Install the swing motor on the swing brake assembly per Installation
the procedure in this section.
1. Install the pinion gear and bottom plate on the swing
4. Connect the hydraulic lines to the swing motor and gearbox splined shaft. Secure pinion gear with the bolts.
swing brake assembly.
2. Install the swing brake assembly on the swing gearbox
5. Bleed all air from the swing brake assembly. per instructions in this section.
Testing 3. Install the swing motor on the swing brake assembly per
instructions in this section.
1. With the Swing Brake Switch in the ON position, move
the swing control lever in both directions. Superstructure 4. Attach a suitable lifting device to the swing gearbox and
rotation should not occur. position the swing gearbox on the superstructure base
plate.
2. Put the Swing Brake Switch to OFF and swing the
superstructure in both directions. Use the swing brake 5. Install the capscrews and washers removed earlier to
pedal to stop rotation. secure the swing gearbox to the superstructure base
plate.
3. Check for hydraulic leaks and repair as necessary.
6. Connect the hydraulic lines to the swing brake.
7. Connect the hydraulic lines to the swing motor.
8. Service the gearbox per the following instructions.

Servicing and dirt might be driven into the vent of the swing
bearing.
Normal maintenance should only consist of proper
lubrication and a periodic check of mounting bolt torque 3. After oil is drained, reinstall the drain plug and any other
values. Lubrication consists of maintaining the gearbox oil plugs that were removed to drain the oil.
level. Oil in a new gearbox should be drained and flushed 4. To refill with oil, make sure the breather is open. Fill until
out after approximately 250 hours of operation, and proper location on dipstick.
replaced with premium quality SGL-5 after about 500
hours of operation or each year, whichever occurs first. 5. Tighten breather and dipstick.
Operation in high humidity or polluted air areas will Checking Oil Level
require more frequent changes to minimize moisture or
contaminate accumulation. 1. Check level on dipstick
Oil Changing 2. If no lubricant is visible on dipstick, add SGL-5 until

between minimum and maximum on dipstick. Refer to
Change the oil as follows: Lubrication, page 9-1.
1. Unscrew drain plug; remove breather and dipstick. 3. Reinstall the dipstick in the brake housing.
Ensure all oil has been removed.
Testing
2. Flush the case with a light flushing oil. Flushing of the
gearbox with a solvent helps prevent an accumulation of 1. Test swing of superstructure in each direction. Stop and
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grit and grime. Avoid steam cleaning where moisture start swing several times.
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2. Inspect for leaks. Make repairs as necessary.
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SWING BEARING
Description
DANGER
The swing bearing is an anti-friction roller bearing that mates
the superstructure to the carrier. The bearing inner race is It is mandatory that bearing attaching bolts be inspected
bolted to the superstructure and the outer race is bolted to for lack of torque and retorqued, as required, after the first
the carrier. The inner race contains grease fittings for 300 hours of crane operation. The bolts may loosen in
lubrication of the bearing which are hosed to two fittings at service due to vibration, shock-loads, and temperature
the front of the turntable center section. The outer race has changes, therefore, periodic inspection should be
gear teeth that mesh with the pinion gear of the swing accomplished every 500 hours thereafter, ensuring the
gearbox to provide rotation. bolts are properly torqued.
Maintenance KNOW YOUR TORQUE WRENCH! Flexible beam type

wrenches, even though they might have a pre-set feature,
General must be pulled at a right angle and the force must be applied
at the center of the handle. Force value readings must be
The swing bearing is the most critical maintenance point of made while the tool is in motion. Rigid handle type, with
the crane. It is here, at the centerline of rotation, that torque limiting devices that can be pre-set to required values,
stresses of loads are concentrated. In addition, the bearing eliminate dial readings and provide more reliable, less
provides the only attachment between the superstructure variable readings.
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and carrier. Therefore, proper care of the bearing and
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periodic maintenance of the turntable-to-bearing attach bolts NOTE: If multipliers and/or special tools are used to reach
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IS A MUST to ensure safe and efficient operation. hard to get at areas, ensure torque readings are
accurate.
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Torquing Turntable Bolts
Torque wrenches are precision instruments and must be
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General handled with care. To ensure accuracy, calibrations must be

made on a scheduled basis. Whenever there is a possibility
that a torque wrench may have been either overstressed or
er
damaged, it should immediately be removed from service
WARNING until recalibrated. When using a torque wrench, any erratic or
Failure to maintain proper torque of the turntable bearing jerking motion can result in the application of excessive or
attaching bolts will result in damage to the crane and improper torque. ALWAYS use a slow, even movement and
possible injury to personnel. STOP when the predetermined value has been reached.
If it is reported by the crane operator or suspected that the
Maintaining proper torque value for bolts is extremely crane has been overloaded beyond the capacities specified
important for structural strength, performance, and reliability above the bold line on the cranes’ capacity chart, then all
of the crane. Variations in torque can cause distortion, turntable bolts must be inspected for looseness and
binding, or complete separation of the superstructure from retorqued to specifications.
the carrier.
Turntable bolts should be torqued according to the
procedures outlined in this section.
CAUTION When using step wrenches, calculated wrench settings are
Repeated re-torquing may cause bolts to stretch. If bolts valid only when the following conditions are met.
keep working loose, they must be replaced with new bolts 1. Torque wrenches must be those specified and forces
of the proper grade and size. must be applied at the handle grip. The use of handle
extensions will change applied torque to the bolt.
Proper identification of bolt grade is important. When marked
as a high strength bolt (grade 10.9), the serviceman must be 2. All handles must be parallel to the step wrench during
aware of bolt classifications and that he is installing a high final tightening. Multiplier reaction bars may be
strength heat-treated tempered component and the bolt misaligned no more than 30 degrees without causing
must be installed according to specifications. Special serious error in torque.
attention should be given to the existence of lubricant and 3. Multiplier bar handles must be propped or supported
plating that will cause variation from dry torque values. When within the outer 1/4 of the handle length, or serious
a high strength bolt is removed, or un-torqued, the bolt must under or over tightening will occur.
be replaced with a new bolt of the same classification.

The inner race of the bearing is secured to the turntable by multiplier, backlash adapter, necessary extensions, and
71 M27x10.9 Class bolts. The outer race of the bearing is torque wrench.
secured to the carrier frame by 72 M27x10.9 Class bolts.
4. Return to bolt 1 and tighten all bolts following the same
Tools Required star pattern sequence to the final torque specification.
Special Turntable Bolt Torquing Tools (Figure 6-3) illustrates Outer Race Torquing
and lists the complete set of special tools required to torque
1. Extend and set the outriggers. Fully elevate the boom.
the turntable bolts.
2. Refer to the section Fasteners and Torque Values, page
Inner Race Torquing
1-18 for the proper torque specification for M27x10.9
1. Extend and set the outriggers. Fully elevate the boom. Class, course thread bolts.
2. Starting with bolt number 1 and following the star pattern
sequence shown in Figure 6-2, tighten all bolts to 80% of
3. Refer to the section Fasteners and Torque Values, page
the full torque specification. Tools used are the socket,
1-18 for the proper torque specification for M27x10.9
multiplier, backlash adapter, necessary extensions, and
Class, course thread bolts.
torque wrench.
Starting with bolt number 1 and following the star pattern
3. Return to bolt 1 and tighten all bolts following the same
sequence shown in Figure 6-2, tighten all bolts to 80% of
star pattern sequence to the final torque specification.
the full torque specification. Tools used are the socket,
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10172
FIGURE 6-2

1 3 6
5
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6633
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Orders for special tools Description Grove Part Number Quantity Required
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shall be referred to your
Grove distributor or
1. 1 13/16 “Socket 3/4” Drive
2. 4 to 1 Torque Multiplier (1/2” Input 3/4” Output)
9-999-101988
9-999-100134
1
1
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Manitowoc Crane Care. 3. Backlash Adapter 9-999-100141 1
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4. 1/2” Drive Torque Wrench 9-999-100136 1

5. 10” Extension 3/4” Drive 9-999-100138 A/R
6. 13“Extension 3/4” Drive 9-999-100137 A/R
7. Tool Box (Optional) 9-999-100146 1
er
FIGURE 6-3
Removal 6. Remove the counterweight following procedures

outlined in Counterweight Removal and Installation,
1. Fully extend and set the outriggers enough to take up
page 5-7.
the slack in the pads.
7. Tag and disconnect all water and oil lines from the
NOTE: Do not raise the machine on the outriggers.
bottom of the swivel. Cap or plug all lines and openings.
2. Ensure the boom is in the travel position and the
8. Locate the connectors and ground wire that joins the
turntable lock pin is engaged.
swivel wiring harness to the receptacles and ground
3. Elevate the boom slightly and shut down the engine. stud on the carrier.
4. Tag and disconnect the battery cables from the 9. Disconnect the swivel wiring harness connectors from
batteries. the carrier wiring receptacles. Remove the ground wire
from the ground stud.
NOTE: The boom assembly weighs approximately 32,758
lb (14,859 kg) without stowed boom extension. 10. Remove the clamp securing the swivel wiring harness to
Removal of the swingaway boom extension will the retainer plate on the bottom of the hydraulic swivel
simplify boom removal, therefore, the above weight assembly.
is for the boom without the swingaway boom
11. Coil the wiring harness and secure it to the swivel to
extension attached. The lift cylinder weighs
prevent damage to the harness during turntable
approximately 2765 lb (1254 kg).
removal.
5. Remove the boom and lift cylinder following the
12. On the bottom of the hydraulic swivel, bend the retainer
procedures outlined in Boom, page 4-1.
tabs away from the bolt heads. Remove the eight bolts
NOTE: The counterweight weighs approximately 63,000 lb and four bolt retainers securing the two retainer plates to
(28,576 kg). the spool. Remove the retainer plates from the spool
and the lugs on the carrier frame.

NOTE: The swivel assembly will be removed with the NOTE: The bearing weighs approximately 2030 lb
turntable. (921 kg). Ensure the bearing lifting device is
capable of supporting the weight.
16. Place an adequate lifting device under the bearing and
remove the 71 bolts and washers securing the turntable
DANGER bearing to the superstructure.
Ensure the lifting device is capable of fully supporting the
17. Using the lifting device, remove the turntable bearing
weight of the superstructure. Ensure the superstructure
from under the superstructure.
will not tilt or slide during lifting and moving. Failure to do
so may result in death or injury to personnel and damage Inspection
to equipment.
Check the bearing teeth for chipping or cracking. If any
NOTE: If a lifting device capable of lifting the entire evidence of these are found, replace the bearing. Ensure the
superstructure is not available, superstructure bolt holes are free of dirt, oil, or foreign material.
weight may be reduced by removing various
Installation
components such as the hoist(s).
13. Attach a suitable lifting device to the four superstructure
lifting lugs (two near the boom pivot shaft bushings and
two near the lower lift cylinder pivot shaft bushings). DANGER
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Take in cable or chain to remove slack. Do not pull up on Anytime a grade 10.9 turntable bolt has been removed, it
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the superstructure. must be replaced with a new grade 10.9 bolt.
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marked teeth on the pinion shaft and the marked
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DANGER teeth on the bearing.

Ensure the superstructure is fully supported before
proceeding. Installation is in the travel position. Ensure the
swing lock is disengaged before attempting to mate
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the bearing to the superstructure.
NOTE: It will be necessary to rotate the superstructure
while attached to the lifting device. Outer race bolts 1. Using an appropriate lifting device, position the turntable
can only be removed from the swing drive side of
the turntable.
bearing under the superstructure. If the same bearing is 6
being used, position it as marked prior to removal.
14. Remove the 72 bolts and washers securing the turntable 2. Install 71 new bolts and washers to secure the bearing to
bearing outer race to the carrier. the superstructure. Refer to Inner Race Torquing in this
Sub-Section.
3. Using an appropriate lifting device, align the
superstructure over the carrier in the travel position and
DANGER carefully lower the superstructure, being careful not to
Ensure that any blocking material used is capable of fully damage the swivel assembly, into position on the carrier
supporting the weight of the superstructure and will not bearing plate.
allow it to tilt or shift. Failure to do so may result in death or
injury to personnel. NOTE: It will be necessary to rotate the superstructure
while attached to the lifting device. Outer race bolts
15. Carefully lift the superstructure, using care not to can only be installed from the swing drive side of
damage the swivel assembly, and set it on blocking that the turntable.
will not allow the superstructure to tilt or shift, or rest on 4. Install 72 new bolts and washers to secure the bearing to
the swivel. Leave the lifting device attached. the carrier. Refer to Outer Race Torquing, page 6-11.
NOTE: If the same bearing is to be used again, mark the NOTE: If a new bearing is being installed, a new pinion
position of the bearing on the superstructure so it gear must also be used. Align the high point
can be installed in the exact position it was before (maximum eccentricity) on the bearing with the
removal. new pinion gear high point.

Fasteners and Torque Values, page 1-18. Bend all the

retainer tabs to make contact with the bolt heads.
4 7. Plug the swivel wiring harness connectors into the
2
carrier receptacles. Secure the ground wire to the
3 ground stud using a washer, lockwasher, and nut.
8. Install the clamp securing the swivel wiring harness to
the retainer plate on the bottom of the hydraulic swivel.
9. Connect all water and hydraulic lines to the ports on the
bottom of the swivel as tagged during removal.
1 10. Install the boom and lift cylinder following the procedures
outlined in Boom, page 4-1.
11. Install the counterweight following procedures outlined
7598-3 in Counterweight Removal and Installation, page 5-7.
FIGURE 6-4
12. Reconnect the batteries.
Item Description 13. Check the slew potentiometer mounted outside of the
bearing under the cab.
1 Bearing
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Testing
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2 Swing Gearbox
3
4 Turntable nl c
Backlash Check Point Activate the crane and check for proper function.
NOTE: If the superstructure does not turn freely after
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bearing and pinion replacement, contact your local
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5. Orient ring gear such that its point of max eccentricity distributor.
(“high point”) is located between the swing drives.
Position swing drives so that pinion is centered within Bearing Wear Check
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cutout in base plate and motor ports face towards the
Use this procedure to check whether the turntable bearing
outboard side (Figure 6-4).
wear is within specification.
Set up crane in the following configuration:
CAUTION
• Counterweight: 28.6 tonnes (63,000 lb) preferred;
Do not clamp over pinion. Damage to the gear teeth may 17.7 tonnes (39,000 lb) minimum
result.
• Outriggers: Fully extended
a. Using shims, set backlash by moving the swing • Telescope: 50-50-50-50-0
drive assemblies toward the bearing in order to
mesh the pinion with the ring gear teeth. • Load: Do not exceed 1 tonnes (2,200 lb)
b. Check tooth engagement squareness and vertical • Boom Angle: 78° to 25°
tooth engagement.
• Boom Extension: Removed from crane
c. Remove backlash shims and recheck backlash.
The base value for the turntable bearing deflection should
NOTE: Adjust the tooth engagement (3) (Figure 6-4) for a have been measured and noted when the crane was first
backlash of 0.25 in (6.4 mm). Rotate the bearing commissioned. If this value is not available, contact
(1) one revolution while checking the backlash at Manitowoc Crane Care to obtain this value.
90° increments.
The maximum allowed wear is 3.2 mm (0.126 in).
6. Position the retainer plate on the bottom of hydraulic
To calculate the maximum allowed deflection, add together
swivel spool, engaging the lugs on the carrier frame, and
the base value and the maximum allowed wear value
secure them to the spool with four bolt retainers and four
[3.2 mm (0.126 in)].
bolts. Torque the bolts according to the specifications in

1. Raise the boom to 80° and swing to 45°. 3. Zero the dial gauge.
2. Fasten a dial gauge [precision 0.01 mm (0.00039 in)] to 4. Slowly lower the boom to 25°.
the front of the turntable bearing (4) and place the switch
5. Notate the dial gauge reading as the current deflection
(1) on to the lower ring (3) as close as possible to the
for this boom swing position.
gasket (2) (see Figure 6-5).
6. Repeat steps 1 through 5 using the following swing
angles (see Figure 6-6):
- B 135°
- C -135°
- D -45°
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1
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135° -135° -45°
45° 3
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10344-2
10344 FIGURE 6-6
FIGURE 6-5
If the current turntable bearing deflection is greater than the
er
maximum allowed deflection calculated above, then the
turntable bearing must be replaced.

SWIVELS This allows the spool to remain stationary with the carrier as
the case rotates with the superstructure.
Description The spool portion of the water swivel is attached to the spool
The swivel assembly consists of a 14 port hydraulic, air of the hydraulic swivel by four bolts. The hydraulic and water
conditioning, water swivel and 46 conductor slip ring swivel spools remain stationary with the carrier as the
assembly (2) (Figure 6-7). Solid connections cannot be used superstructure rotates. The water swivel case contains a lug
to transfer oil, heater hot water and electricity between the which is keyed to a corresponding lug on the hydraulic swivel
carrier and superstructure due to the continuous 360 degree case, causing the water swivel to rotate with the
swing. The use of swivels efficiently accomplishes this superstructure.
function. The electrical swivel center or collector ring assembly is
The barrel portion of the hydraulic swivel is attached to the secured by setscrews to a center post which is bolted to the
turntable base plate by four bolts (3), washers (4) and spool of the hydraulic swivel. This allows the collector ring
bushings (6) (Figure 6-7), which connect to mounting lugs assembly to remain stationary with the carrier. The outer
(7) on the case. The spool portion of the swivel rides upon a portion or brush assembly is mounted on two studs which
thrust ring at the top of the swivel case. The spool portion is are located on the mounting plate assembly which is
held stationary with the carrier by bolts, and bolt retainer retained to the water swivel barrel by a bolt. This allows the
plates attached to the swivel retainer plate (9) which brush assembly to rotate with the superstructure around the
engages the carrier frame lugs with bolts and jam nuts (10). stationary collector core.
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3, 4, 6 10
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5
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10
7597-1 6
9
7597-2
FIGURE 6-7
Item Description
Item Description 6 Bushing
1 14 Port Hydraulic, AC, Water Swivel 7 Mounting Lug
2 46 Conductor Slip Ring Assy 8 Harness
3 Bolt 9 Swivel Retainer Plate
4 Washer 10 Screw and Jam Nut
5 45 PSI Inline Check Valve

Hydraulic Swivel 4. Use the blocking to block between the barrel of the lift
cylinder and the boom base section.
Description
5. Tag and disconnect the hydraulic lines from the case of
Each of the ports on the spool and case of the swivel is the hydraulic swivel. Cap or plug all lines and openings.
stamped with the port number. The function of each port is
6. Tag and disconnect the hydraulic lines and water lines
described below.
from the spool of the hydraulic swivel. Cap or plug all
Port # Function lines and openings.
1 Return
2 Supply - Piston Pump #1 7. Tag and disconnect the water lines from the case of the
3 Supply - Piston Pump #2 water swivel. Cap or plug all lines and openings.
4 Case Drain 8. Evacuate the air conditioning system following the time
5 Swing specification found under the section titled Air
6 Steer, Front-Left Conditioning, page 3-23, then remove the air
7 Steer, Front-Right conditioning lines.
8 Load Sense 9. Disconnect the swivel wiring harness connectors from
9 Brakes, Front the carrier receptacles and the ground wire from the
10 Brakes, Rear connector mounting bracket on the carrier frame. If
11 A/C Supply necessary, remove the electrical swivel. Refer to
12 A/C Return Electrical Swivel, page 6-20.
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A&B Heater NOTE: The hydraulic swivel weighs approximately 430 lb
Theory of Operation
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combined weigh approximately 520 lb (236 kg).
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The hydraulic swivel allows oil to flow from the pumps to
10. On the bottom of the swivel, bend the retainer tabs away
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various crane functions on the superstructure. All oil is

from the capscrew heads. Remove the eight capscrews
routed into the spool portion of the swivel where, through a
and four capscrew retainers securing the two retainer
series of internally drilled passages, oil is transferred to
plates to the spool. Remove the retainer plates from the
er
circumferential channels on the spool exterior. These
spool and the lugs on the carrier frame.
channels correspond with a mating port on the outer case of
the swivel. Each channel is separated by a series of nylon NOTE: It may be necessary to remove some drive line
and O-ring seals that prevent transfer of oil and pressure. components to remove the swivel.
Return flow from the crane superstructure is accomplished in
11. Position an adequate supporting device beneath the
the same manner through another set of ports.
swivel.
Maintenance 12. Remove the four capscrews, washers, and bushings
Removal securing the swivel barrel to the turntable base plate and
lower the swivel to the ground.
1. Extend and set the outriggers. Ensure the crane is level
and the boom is over the front. Installation
2. Elevate the boom and note at what boom angle, you NOTE: The hydraulic swivel weighs approximately 430 lb
have the most clearance between the lift cylinder and (195 kg). The hydraulic, water, and electrical swivel
the turntable side plate. Shut down the engine. combined weigh approximately 520 lb (236 kg).
3. Measure the distance from the top of the lift cylinder to 1. Raise the swivel into position.
the base of the boom section where the lift cylinder 2. Secure the hydraulic swivel to the turntable base plate
attaches. Cut two pieces of 10 x 10 cm (4 x 4 in) with the bushings, capscrews, and washers. Torque the
hardwood timbers. bolts according to the specifications in Fasteners and
NOTE: It might be necessary to raise the boom slightly to Torque Values, page 1-18.
allow installation of the blocking. 3. Position the two retainer plates on the hydraulic swivel
This blocking is to add extra support for the boom. spool ensuring they engage the lugs on the carrier
Any seepage or leakage in the holding valves or frame. Secure the retainer plates with eight capscrews
internally in the cylinders will allow the boom to and four capscrew retainers.
settle over a period of time. Apply Loctite 271 to the capscrew threads. Torque the
bolts according to the specifications in Fasteners and

Torque Values, page 1-18. Bend all the retainer tabs to Maintenance
make contact with the capscrew heads. Tighten the four
retainer plate capscrews against the lugs on the carrier Removal
frame and tighten the locking nuts. 1. Perform steps 1 thru 4 of Hydraulic Swivel, page 6-18.
4. If removed, install the electrical swivel. Refer to 2. Remove the electrical swivel. Refer to Electrical Swivel,
Electrical Swivel, page 6-20. Connect the swivel wiring page 6-20.
harness connectors to the carrier receptacles and the
ground wire to the mounting bracket on the carrier 3. Tag and disconnect the lines from the case of the water
frame. Use the bolt and star washers taken off at swivel. Cap or plug all lines and openings.
removal and refer to Grove Engineering Specification A- 4. Remove the bolt and shim(s) from the water/hydraulic
829-100386 for proper electrical termination of grounds. swivel keying lugs.
NOTE: Allow a 1/32” max gap between bolt and the 5. Remove the four capscrews and washers securing the
retaining lug on the frame. Do not tighten bolt water swivel and electrical swivel center post to the
against lug. hydraulic swivel. Remove the water swivel and center
5. Install the clamp, lockwasher, flat washer and capscrew post.
to the bottom of the swivel retainer plate securing the Disassembly
wiring harness.
6. Connect the hydraulic lines and water lines to the spool water swivel should include replacement of all
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of the hydraulic swivel as tagged during removal. seals and rings.
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7. Connect the hydraulic lines to the hydraulic swivel case
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as tagged during removal.
1.
2.
Withdraw the spool from the case.
Place the spool on a clean work surface in a dust-free
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8. Connect the water lines to the water swivel case as area and block the spool to prevent movement during
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tagged during removal. disassembly.

9. Connect the air conditioning lines, then charge the air
conditioning system following the specifications found
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under the section titled Air Conditioning, page 3-23. CAUTION
10. Remove the blocking material from the lift cylinder. grooved and gland surfaces.
11. Activate all systems; cycle all functions and observe for 6
proper operation and any leakage. NOTE: Aligning discarded seals and rings in the order of
disassembly will assist with installation of new
Two-Port Water Swivel seals and rings.
Description 3. Remove the seals and rings from the spool.
The two-port water swivel allows engine coolant to flow from Cleaning and Inspection
the carrier-mounted engine to the hot water heater in the
operator’s cab. Through an internally drilled passage in the
11 port hydraulic swivel spool, coolant is transferred to a
circumferential groove on the water spool exterior. This WARNING
groove corresponds with a mating port on the outer case of Cleaning solvents can be toxic, flammable, an irritant to
the water swivel. The spool grooves are separated by a quad the skin, or give off harmful fumes. Avoid prolonged skin
ring/telflon bronze ring seal. The lip seal prevents coolant contact, inhalation of vapors, or smoking. Failure to
from leaking externally. Return engine coolant flow from the comply can result in injury or death to personnel.
hot water heater is accomplished in the same manner
through the opposite port of the water swivel. 1. Clean the spool and case with a suitable solution and
dry with compressed air. Plug all ports with plastic caps.
2. Check the spool and inside of the case for scratches,
grooves, scoring, etc. If any grooves have developed
with a depth of 0.005 in (0.127 mm) the unit should be
replaced.

Assembly Theory of Operation

NOTE: Lubricate the interior of the swivel to prevent The electrical swivel is located on top of the water swivel and
rusting from condensation. transfers electricity between the carrier and superstructure.
Wiring harnesses transmit the electricity between the carrier
1. Lubricate the spool, seals, and rings.
and superstructure.
Maintenance
CAUTION
When installing seals and rings, avoid stretching seals or Removal
scratching grooved or gland surfaces. 1. Perform steps 1 through 4 of Hydraulic Swivel - Removal
in this section.
2. Install new seals and rings on the spool.
CAUTION CAUTION
Proper alignment when inserting the spool is required. Do D i s c o nn e c t t h e b a t t er i e s b e f or e p e r fo r m i n g a n y
not force the spool into the case. maintenance on the electrical system. Serious burns may
result from accidental shorting or grounding of live
3. Insert the spool into the barrel. circuits.
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Installation
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2. Disconnect the batteries. Refer to Batteries, page 3-10.
1. Install the water swivel on top of the hydraulic swivel
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aligning the keyed lug on the water swivel with the lug on
the hydraulic swivel. Secure the water swivel and the
3. Locate the connectors which join the collector ring
harness to the receptacles for the carrier.
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electrical swivel center post with the four bolts and
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4. Tag the connectors and their receptacles with numbers.

washers. Disconnect the connectors from the chassis wiring
2. Install the shim(s) on the keying lug to provide a snug fit receptacles.
and secure with a bolt.
er
NOTE: If the connectors are too large to go through the
3. Connect the lines to the swivel case as tagged during center of the hydraulic swivel, they must be
removal. removed. Conditional instructions will follow.
4. Install the electrical swivel. Refer to Electrical Swivel, 5. Remove the clamp securing the wiring harness to the
page 6-20. retainer plate on the bottom of the hydraulic swivel
assembly.
5. Perform steps 8 and 9 of Hydraulic Swivel - Installation
in this Section. NOTE: If connectors are too large to go through the center
of the hydraulic swivel, tag each wire on each of the
6. Activate all systems, cycle all functions, and observe for connectors. Using the appropriate pin removal
proper operation and any leakage. tools, remove the pins, with wires still attached, and
mark each wire with the pin socket number in the
Electrical Swivel connector. Collect the wires and secure into one
bundle. Mark the bundle with the connector
Description
number. For a list of the appropriate pin removal
The swivel assembly consists of a 46 conductor slip ring and tools, refer to Connector Troubleshooting, page 3-
cover assembly. 11.
Each brush set incorporates two brushes, leads, and clips 6. Secure the connectors and wires from each of the
which are attached to a brush holder assembly. The brush numbered connectors so the harness can be withdrawn
set leads are formed into harnesses which are routed through the center of the hydraulic swivel.
through the mounting plate on the swivel. The collector ring
7. Tag and disconnect the connectors from the junction box
leads are formed into one harness which is routed downward
on the turntable.
through the center of the hydraulic swivel. Extending from
the base of the hydraulic swivel, the collector ring leads are 8. Remove the nuts and washers, and remove the cover
also formed into connectors which plug into receptacles from from the electrical swivel.
the chassis power supply.
9. Loosen the setscrews securing the electrical swivel
The swivel cover is secured with a seal and bolts. mounting tube to the center post on the water swivel.

10. Remove the bolt and nut securing the electrical swivel 4. Apply Loctite to the set screws securing the electrical
case to the bracket on the case of the water swivel. swivel to the center post and tighten them to 45 to 55 in-
lb (5 to 6 Nm)
5. Install the swivel cover and two over-center latches.
CAUTION
When withdrawing the wiring harness through the center 6. Connect the wiring harness connectors to the
of the hydraulic and water swivels, ensure the wires do receptacles on the cab bulkhead mounting plate as
not get caught and damaged. tagged during removal.
7. Plug the connector into the carrier wiring receptacle,
11. Remove the swivel and wiring harness from the crane. If connect the wires as tagged during removal. Install the
necessary, remove the spacer bushing from the center ground wire to the connector mounting bracket on the
post. carrier frame using the bolt and star washers taken off at
Installation removal and refer to Grove Engineering Specification A-
829-100386 for proper electrical termination of grounds.
1. If removed, install the spacer bushing on the center post.
Route the collector core wiring harness through the 8. Install the clamp securing the harness to the retainer
center of the hydraulic and water swivels. plate on the bottom of the hydraulic swivel assembly.
2. Slide the electrical swivel mounting shaft onto the center 9. Connect the batteries.
post. 10. Activate all systems, cycle all functions, and observe for
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3. Ensure the threaded hole on the bottom of the electrical proper operation.
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swivel base is aligned with the mounting hole in the Preventive Maintenance
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bracket on the water swivel case. Install the bolt through
the hole in the bracket and install the nut. Screw the bolt It is recommended that a normal inspection of the electrical
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into the hole in the electrical swivel base until the bolt swivel collector ring and brush assembly be established. An
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head is approximately 0.25 in (6.4 mm) from the bracket. example of this could be at approximately 100 to 150 engine
Tighten the nut against the electrical swivel (Figure 6-8). operating hours. When this time limit is reached, perform the
following.
er
Bolt and Shims 1. Check the collector ring and brush assembly for any
corrosion, pitting, arcing, and wear.
2. Check the collector ring setscrews and ensure they are
tight.
6
.25
3. Check the brush and arm assembly springs. Ensure
they are holding the brushes firmly against the collector
rings.
60°
Forward
6080
Bracket
FIGURE 6-8

SWING LOCK PIN 360° SWING LOCK CONTROL (POSITIVE

LOCK TYPE)
Description
The purpose of the swing lock pin is to lock the Description
superstructure in position directly over the front or the rear of The purpose of the swing lock is to secure the superstructure
the carrier. The swing lock pin installation consists of a large in position at one of the positions in its rotation. There are
pin, a control handle in the right side of the cab, and a control roughly 247 spots about 1.45 degrees apart for the
cable and control linkage that allows the crane operator to superstructure to lock to in its 360 degree of rotation. The
set and free the pin. 360 degree swing lock control pedal is on the left side of cab.
When the superstructure is directly over the front, pushing Pushing the swing lock foot pedal engages the lock between
the control handle in inserts the swing lock pin into a socket the teeth of the swing gear. Pulling the swing lock control
on the carrier frame, locking the superstructure in place. lever up disengages the lock.
Pulling the control handle out pulls the pin out of the socket,
unlocking the superstructure. Maintenance
Verify cable is routed to avoid damage from superstructure
Maintenance rotation and is undamaged. Verify swing lock assembly is
Verify cable is routed to avoid damage from superstructure undamaged and working properly. Verify springs are
rotation and is undamaged. Verify pin, the turntable bushing undamaged and have enough strength to pull blade of swing
lock assembly completely out of the gear teeth when the
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the pin passes through, and the sockets on the frame are
control pedal is up. Verify the linkage can put the blade of the
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undamaged. Verify all attaching hardware is secure and
swing lock assembly as far as possible between the gear
undamaged.
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Ensure linkage and cable are adjusted properly. If they are,
teeth when the control pedal is down.
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the pin bottom will stick out about 4.00 inches (10.16 cm) Verify all attaching hardware is secure and undamaged.
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from the bottom of its bushing in the turntable. (If it is too far Make adjustments as needed.
in, it might not lock properly. If it is too far out, it might hang If the swing lock assembly is damaged, install a replacement.
up). Using the jam nuts on the linkage parts and cable, adjust Align the blade of the swing lock assembly so it will fall
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the linkage and cable so the pin bottom will be flush with the between gear teeth. Use the shim and the related attaching
bottom of its bushing in the turntable when not applied, and hardware (two M8x16 screws and M8 lockwashers) to
the pin will stick out about 4.00 inches (10.16 cm) from the ensure the swing lock assembly cannot move side to side,
bottom of its bushing in the turntable when applied. Verify the and can lock up the superstructure. Torque the four M24x100
superstructure can lock properly when the pin is applied and mounting bolts according to the specifications in Fasteners
the superstructure can rotate without pin hangup when the and Torque Values, page 1-18.
pin is not applied.
As needed, adjust the swing lock control and cable per
above instructions. Then operate the control lever several
times to verify the swing lock blade assembly engages and
disengages properly. Adjust cable as required.

RT9150E SERVICE MANUAL POWER TRAIN
SECTION 7
POWER TRAIN
SECTION CONTENTS
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Tier 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 Water Cooling System . . . . . . . . . . . . . . . . . . . . . 7-26
Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26
Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . 7-5 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26
Engine Drive Belts . . . . . . . . . . . . . . . . . . . . . . . . 7-6 Drive Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34
Electronic Control System. . . . . . . . . . . . . . . . . . . 7-8 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34
Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8 Torque Converter . . . . . . . . . . . . . . . . . . . . . . . . . 7-35
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35
Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . 7-35
Air Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36
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Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12 Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41
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Charge-Air Cooler System . . . . . . . . . . . . . . . . . 7-19 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41
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Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41
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Tier 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
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DESCRIPTION The engine and its components are enclosed in a hood
assembly with a grill in the rear of the hood for adequate air
The engine is either a Cummins QSC (Tier 3) or a QSL circulation. Access to the engine is gained through a door
(Tier 4) diesel engine (Figure 7-1). This Service Manual does assembly in the top of the hood that opens from both sides.
not include detailed information on the engine itself. A
separate manual as prepared in detail by the engine The air intake filter is mounted on the front of the left rear
manufacturer, is supplied with this Service Manual. However, fender. The muffler is mounted on the left side of the frame
a short description and maintenance of certain components behind the left rear fender.
of the fuel system, air intake system, and water cooling
system is provided in this section. 7
The engine is electronically controlled by the Electronic
Control Module (ECM), it is the control center of the system. WARNING
It processes all of the inputs and sends commands to the fuel Do not spray starting fluid into the air inlet. The spray will
systems as well as vehicle and engine control devices. contact the heater elements and could explode, causing
personal injury.
Engine speed is controlled by the foot throttle pedal in the
cab. It controls engine RPM which increases or decreases The engine is equipped with electric air heating elements
proportionately with the amount of foot pressure applied to that are located in the engine’s intake air stream to aid in cold
the pedal. Engine speed is also controlled by a momentary starting and reduce white smoke at start-up. In the preheat
rocker switch on the steering column. An increase in engine mode, the engine should not be cranked until the Wait-to-
rpm occurs when the top of the switch is pushed. A decrease Start Lamp turns off. The Wait-to-Start Lamp is illuminated
in engine rpm occurs when the bottom of the switch is during the preheat time that takes place when the ignition
pushed. The foot throttle pedal and Engine Increase/ switch is in the ON position during cold weather starting. The
Dec rea se Switc h ar e e l ec tric ally c o nn ec te d to t he ECM checks intake manifold temperature to determine how
superstructure control module which sends the signal to the long to energize the air heater before extinguishing the Wait-
engine ECM. to-Start Lamp. Once the engine is started, the electric air
heating element will be energized again for a time period
determined by intake air temperature.

POWER TRAIN RT9150E SERVICE MANUAL
MAINTENANCE harness. Remove the clamps holding the harness to the

engine hood.
Engine Removal 8. Remove the capscrews and washers securing the
1. Fully extend and set the outriggers and position the remote secondary fuel filter and mounting bracket to the
boom over the side to provide working clearance. engine hood. Tie strap the filter and bracket to the
engine so it is out of the way for removal of the engine.
2. Disconnect the battery.
9. Remove the engine hood assembly and pump cover
3. Open the hood top door assembly. from the machine.
4. Disconnect the air filter tubing at the engine and air 10. Drain the engine coolant system into a suitable
cleaner (Figure 7-5) and (Figure 7-6). Remove and lay container.
aside.
11. Drain the engine lubrication system into a suitable
5. Disconnect the exhaust tubing at the engine and muffler. container.
Remove and lay aside.
12. Drain the transmission/torque converter oil system into a
6. Tag and disconnect the hourmeter wiring, the engine suitable container.
electrical harness connector from the carrier harness
connector, the starter and grid heater relay harness from 13. Tag and disconnect the oil lines from the torque
the carrier harness and the battery cables from the converter. Cap or plug all openings.
batteries and the engine. 14. Remove the driveline between the torque converter and
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7. Tag and disconnect the left and right rear backup lights, the transmission. Refer to Drive Lines, page 7-34.
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stop lights and the backup alarm from the carrier
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9104-01
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FIGURE 7-1

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17. Tag and disconnect all lines from the radiator. Cap or
Item Description plug all openings. Disconnect the coolant level sensor
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1 Remote Secondary Fuel Filter harness from the engine harness and tie up excess
harness so it is out of the way.
2 Remote Coolant Filter
18. Remove the fan guard and fan ring. Refer to Radiator
3 Remote Oil Filter Removal and Installation, page 7-30.
4 Torque Converter 19. Tag and disconnect all fuel lines at the engine. Place a
5 Hydraulic Pump # 1 suitable container under the fuel line connection to catch
any spills. Cap or plug all openings. Position the fuel
6 Hydraulic Pump # 2
lines so the disconnected end is higher than the fuel
7 Hydraulic Pump # 3 tank.
8 Hydraulic Pump # 4 20. Tag and disconnect all lines and tubing from the engine.
9 Front Mount Cap or plug all openings.
10 Rear Mount 21. If equipped with optional engine block heater, tape and
stow the electrical plug to the engine so it is out of the
15. Tag and disconnect all lines from hydraulic pump No. 4 way for engine removal.
on the right side of the engine. Place a suitable container
under the hydraulic pumps to catch any oil that is spilled. 22. Remove the capscrews, flatwashers and lockwashers
Cap or plug all openings. Position the hydraulic lines so securing the remote engine oil filter bracket to the side of
the disconnected end is higher than the hydraulic tank. the frame. Tie strap the oil filter and mounting bracket to
Refer to Hydraulic Pumps, page 2-18. the side of the engine so it is out of the way for removal
of the engine.
16. Remove the capscrews and flatwashers securing the
three hydraulic pumps to the torque converter. Remove 23. Remove the three capscrews attaching the remote water
the pumps from the torque converter and position them conditioner to the left side frame rail. Tie strap the filter
so they do not interfere with removing the engine. and mounting bracket to the engine so it is out of the way
for removal of the engine.

4. Remove the lifting device.

5. Secure the remote engine oil filter and mounting bracket
to the side of the engine frame with the capscrews,
DANGER flatwashers and lockwashers. Torque the capscrews,
The lifting device must be able to support the combined refer to Fasteners and Torque Values, page 1-18.
weight of the engine and torque converter.
6. Secure the remote water conditioner filter and mounting
NOTE: The engine and torque converter assembly weighs bracket to the side of the frame with three capscrews.
approximately 2579 lb (1170 kg). Torque the capscrews, refer to Fasteners and Torque
Values, page 1-18.
24. Attach a lifting device capable of supporting the weight
of the engine, to the engine and torque converter. 7. Install the three hydraulic pumps on the torque
converter. Refer to Hydraulic Pumps, page 2-18.
25. With the lifting device supporting the weight of the
engine, remove the four capscrews, nuts and washers 8. Connect the hydraulic lines to hydraulic pump No.4 as
securing the front of the engine to the frame. Remove marked at removal. Remove all caps or plugs placed on
the capscrews, nuts, washers, shock mounts, and dock openings during removal so no blockage can occur in
washers (one set on each side) securing the rear of the the hydraulic system. Refer to Hydraulic Pumps, page 2-
engine to the frame. 18.
26. Using the lifting device, lift the engine and torque 9. Connect the fuel lines to the engine as tagged during
removal. Remove all caps or plugs placed on openings
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converter as an assembly from the crane.
during removal so no blockage can occur in the fuel
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27. Remove the torque converter from the engine. Refer to system.
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Torque Converter, page 7-35.
10. Connect all lines and tubing to the engine, torque
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28. If a new engine is to be installed, remove all converter, and all other components in accordance with
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components, fittings, etc., from the old engine and install the identification marks made during removal. Remove
them on the new engine in the same location. all caps or plugs placed on openings during removal so
no blockage can occur.
Engine Installation
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NOTE: Use the same grade hardware, torque values, and

Loctite used by the factory.
CAUTION
Do not apply sealant to the inside of the hydraulic suction
hoses.
11. Install the hydraulic hoses as tagged during removal.

DANGER
The lifting device must be able to support the combined 12. Install the radiator. Refer to Radiator Removal and
weight of the engine and torque converter. Installation, page 7-30. Connect all hoses and electrical
harnesses to the radiator as tagged during removal. 7
NOTE: The engine and torque converter assembly weighs Remove all caps or plugs placed on openings during
approximately 2579 lb (1170 kg). removal so no blockage can occur in the radiator
system.
1. Install the torque converter on the engine. Refer to
Torque Converter, page 7-35. 13. Connect the drive shaft between the torque converter
and the transmission. Refer to Drive Lines, page 7-34.
2. With all components and fittings installed on the engine,
lift the engine into the crane. 14. Install the hood assembly. Install the pump cover.
3. With the engine in position, secure the rear of the engine 15. Secure the remote secondary fuel filter to the engine
with the capscrews, nuts, washers, shock mounts, and hood with four capscrews, washers, and lockwashers.
dock washers (one set on each side). Torque the Torque the capscrews, refer to Fasteners and Torque
capscrews, refer to Fasteners and Torque Values, page Values, page 1-18.
1-18. 16. Connect the left and right rear backup lights, stop lights
At the front of the engine secure the engine mount to the and left side backup alarm at the rear of the engine
frame with the four capscrews, nuts and washers. hood. Use clamps acquired during removal to route
Torque the capscrews, refer to Fasteners and Torque harness along engine hood.
Values, page 1-18.

17. Connect the start and grid heater relay panel to the Engine Drive Belts
carrier harness.
The proper operation of engine belt-driven components such
18. Connect all electrical connections as tagged during as the alternator, fan, and water pump depend on the proper
removal. condition and tension of the engine drive belt.
19. Reconnect battery cables as tagged during removal. NOTE: Belt tension is maintained with an automatic belt
20. If equipped with engine block heater, reroute the cord for tension device.
the heater. The engine drive belt (Figure 7-2) should be inspected
21. Connect the muffler exhaust piping to the engine. visually on a daily basis. The drive belt should be inspected
for cracks, frayed areas, and glazed or shiny surfaces. A
22. Connect the air filter tubing at the engine and the air drive belt that is glazed or shiny indicates belt slippage.
filter.
Engine drive belt damage can be caused by various factors
23. Service the transmission, engine lubrication system, and such as incorrect tension, incorrect belt size, misaligned
engine cooling system. engine pulleys, incorrectly installed belt, or by oil, grease, or
24. Start the engine. Check all hoses and fittings for leaks. hydraulic fluid on the belt.
Recheck all fluid levels. Refer to Lubrication, page 9-1. Refer to the engine manufacturer’s manual for any special
tools or belt tension specification.
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OK
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Traverse Cracks Longitudinal Cracks Intersecting with Transverse

Missing Material
Cracks must be Replaced
FIGURE 7-2

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THIS PAGE BLANK

ELECTRONIC CONTROL SYSTEM Fuel Filter-Water Separator

The engine control system is an electronically operated fuel Both fuel filters have water separators that remove impurities
control system that also provides many operator and vehicle from the fuel and also remove water from the fuel before it
features as well as reducing exhaust emissions while reaches the engine. The primary fuel filter is located on the
optimizing engine performance. frame beside the fuel tank. The secondary fuel filter is
mounted on the right side of the engine hood.
The ECM performs diagnostic tests on most of its circuits
and will activate a fault code if a problem is detected in one of The fuel mixture passes through the outer wrap of the first
these circuits. Along with the fault code identifying the stage of the filter paper, where large droplets of water are
problem, a snapshot of engine operating parameters at the formed as it is stripped from the fuel. The water falls out into
time of fault activation is also stored in memory. Some fault the void between the two paper elements and goes to a
codes will cause a diagnostic lamp to activate to signal the reservoir in the bottom of the housing, where it can be
driver. The fault codes can be read using the fault lamps in drained through a drain plug at the bottom of the housing.
the cab panel or with the correct service tools. The ECM The water in fuel sensor is located in the secondary fuel filter
communicates with service tools through a SAE J1939 housing on the right side of the engine hood. Once the
datalink. storage space in the bottom of the filter housing fills with a
Engine diagnostics, warning lights and fault codes are certain amount of water, the sensor will signal the ECM.
displayed on the ECOS controller. For more information,
Electric Lift Pump
refer to Section 3 of the Operator’s Manual.
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The ECM controls the electric lift pump located between the
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FUEL SYSTEM fuel tank and the injection pump. Whenever the keyswitch is
Description nl c turned to the ON position, the lift pump will be energized for a
few seconds to make sure the low pressure fuel lines are
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fully primed. The electric lift pump shuts off after the engine is
The fuel system consists of the fuel tank, primary fuel filter
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started.
with water separator, secondary fuel filter with water
separator and water in fuel sensor, lift pump, injection fuel Maintenance
pump, fuel injectors, and return fuel cooler. All components
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except the fuel tank and primary fuel filter are installed on the NOTE: The entire fuel system must be maintained air tight
engine or supplied with the engine for remote mounting. to prevent loss of prime.
Fuel Tank Fuel Tank

The fuel tank (Figure 7-3) is a steel cylinder-type tank The fuel tank should be kept filled, especially overnight, to
located on the left side of the machine. The fuel tank has a reduce condensation to a minimum. Refer to the applicable
draw capacity of 100 gal (379 l). A connection on the bottom engine manual for the recommended schedule for draining
of the tank provides for fuel supply to the engine. Surplus fuel any water or sediment from the tank.
from the engine is routed to the bottom of the fuel tank below Removal
the fuel level. The tank is equipped with a non-vented filler
cap, chain-attached to the tank, and a fuel quantity sender 1. Position a suitable container under the fuel tank and
unit which provides a signal to a fuel gauge on the ECOS drain all fuel from the tank.
display.
2. Tag and disconnect the two lines from the bottom of the
Injection Fuel Pump tank.
The fuel oil is finely atomized as it is injected into the cylinder 3. Disconnect the electrical lead from the fuel quantity
and ignited by the heat of compression. It is also metered sender unit.
before injection, to meet the load requirements imposed 4. Support the weight of the tank, loosen and remove the
upon the engine. Surplus fuel, returning from the injectors, is nuts, washers and capscrews securing the straps to the
bypassed back to the fuel tank or to the inlet side of the mounting brackets. Remove the tank and steps.
pump. The continuous flow of fuel through the injectors helps
to cool the injectors and to purge air from the system. 5. If a new tank is to be installed, remove the two fittings,
the fuel quantity sender, and steps from the tank and
install them in the new tank.

Installation 5. Service the tank.

1. Position the new tank on the mounting brackets and Fuel Filter-Water Separator
install the nuts, washers and capscrews on the three
straps. Torque the capscrews, refer to Fasteners and Draining
Torque Values, page 1-18.
The sump of the fuel filter-water separators should be
2. Connect the electrical lead to the fuel quantity sender drained daily, 30 minutes after the engine is shut down, to
unit. remove any water and sediment. Adhere to the following
procedure:
3. Connect the two lines to the fittings on the bottom of the
tank in accordance with the identification marks made 1. Open the drain plug.
during removal.
2. Drain into suitable container until fuel appears.
4. Install the steps.
3. Close the drain plug.
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9110-1
Tier 3 Fuel System

FIGURE 7-3
Item Description
Item Description
7 Strap Assembly
1 Fuel Quantity Sending Unit
8 Fuel Cooler
2 Filler Cap
9 Line To Return Port On Tank
3 Fuel Filter
10 Bracket
4 Fuel-Water Separator
11 Line To Engine
5 Fuel Supply
6 Fuel Return

Item Description
12 Steps
13 Fuel Tank
11
3, 4
8
9
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Tier 4 Fuel System FIGURE 7-4
Item Description
Item Description
7 Strap Assembly
1 Fuel Quantity Sending Unit
8 Fuel Cooler
2 Filler Cap
9 Line To Return Port On Tank
3 Fuel Filter
10 Bracket
4 Fuel-Water Separator
11 Line To Engine
5 Fuel Supply
12 Steps
6 Fuel Return
13 Fuel Tank

AIR INTAKE NOTE: Dust that gets by the air cleaner system can often
be detected by looking for dust streaks on the air
Description transfer tubing or just inside the intake manifold
inlet.
There are two air filters available for this machine, depending
on which engine is installed, the tier 3 (Figure 7-5) for export 1. Inspect the air cleaner outlet tube for damage.
cranes and the tier 4 (Figure 7-6) for cranes in North America 2. Ensure the element gasket washer is not damaged and
and some European countries. The air intake system the washer’s rubber face seals against the element.
controls the quality and amount of air available for
combustion. System components are the Air Cleaner, 3. Inspect the element gasket for damage.
Turbocharger, Charge Air Cooler, Cylinder Head, and 4. Check for structural failures and replace damaged parts.
Exhaust Manifold. Inlet air is pulled through the Air Cleaner,
compressed and heated in the compressor side of the 5. Inspect the restriction indicator tap for leaks.
Turbocharger. The air is pushed through the Charge Air
Cooler to the Air Inlet Manifold. Cooling the inlet air Check for Filter Restriction
increases combustion efficiency, lowers fuel consumption, As a dry cleaner element becomes loaded with dust, the
and increases the horsepower. The air is forced into the vacuum on the engine side of the air cleaner (at the air
cylinder head to fill the inlet ports. Air flow from the inlet port cleaner outlet) increases.
into the cylinder is controlled by the intake valves.
The vacuum is generally measured as restriction in inches of
Each cylinder has two intake valves and two exhaust valves. water or kilopascals. The engine manufacturer places a
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When the intake valves open, cooled compressed air from recommended limit on the amount of restriction the engine
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the inlet port is pulled into the cylinder. The intake valves will stand without loss in performance before the element
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close and the piston begins to move up on the compression
stroke. Fuel is injected into the cylinder and combustion
must be replaced. Cummins allows a vacuum of 25 inches of
water (6.2 kPa) maximum with a dirty air cleaner at
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starts. The piston is forced down and is on the exhaust stroke maximum governed RPM.
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when it moves up again. The exhaust valves open and

exhaust is expelled through the exhaust port into the exhaust Air Intake Restriction Monitoring (AIRM)
manifold. Communications System - Tier 4 Only
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The exhaust gas from the exhaust manifold enters the T h e Ti e r 4 e n g i n e i n c l u d e s t h e C u m m i n s A I R M
turbine side of the turbocharger and causes the turbine to Communications System. This calculates real-time air filter
turn driving the compressor. Exhaust from the turbocharger restriction at operational flow rate using the temperature and
passes through the exhaust pipe and exhaust aftertreatment pressure input from the TBAP sensor, which is included on
system, then into the atmosphere. the Direct Flow air cleaner.
The Air Cleaner is the dry-type with a replaceable element Maintenance Fault (FC5576)
and is located on the left rear fender. An Air Intake
No light code during operation. Fault Code (FC) active for the
Restriction Monitor (AIRM) system is designed to calculate
current key cycle and displayed on operator display. At next
real-time air filter restriction at operational flow rate using the
key-on, “Check Engine” light blinks for 30 seconds. FC then
temperature and pressure input from the TBAP sensor
stays active for subsequent key cycles until delta P drops
installed on the air cleaner housing.
below clearing threshold, at which time it is cleared.
On the Cummins QSC and QSL Engines there are electric
Severe Fault (FC3341)
air heating elements that are located in the engine’s intake
air stream. These elements heat the intake air when starting If restriction goes beyond severe restriction limit for a given
the engine in cold ambient conditions. Startability and white time period, a solid amber “Check Engine” light turns on and
smoke control are enhanced by the use of the intake air stays on. FC stays active for current and subsequent key
heater. A Wait-to-Start Lamp is located on the center front cycles and is displayed on operator display. FC is cleared
console to indicate when to crank the engine. when delta P drops below clearing threshold.
Maintenance Mechanical Service Indicator - Tier 3 Only

A mechanical indicator on the air cleaner housing will
Air Cleaner Checks
indicate when the filter needs to be replaced. Reset the
Dust passing the Air Cleaner can cause rapid engine wear. indicator each time the air cleaner is serviced. If the
All connections between the Air Cleaner and the engine indicator’s accuracy is suspect, a water manometer is the
must be tight and sealed. If these connections are well most accurate and dependable method of measuring
sealed, and there is still evidence of dust leakage, check the vacuum.
following places for possible trouble.

To use the manometer, hold it vertically and fill both legs generally marked with the restriction at which the red signal
approximately half full with water. One of the upper ends is flag locks up. If the initial restriction on a new or clean filter
connected to the restriction tap on the outlet side of the air reads above the maximum allowed for the engine, check the
cleaner by means of a flexible hose. The other end is left following items.
open to the atmosphere.
1. Ensure the air cleaner inlet is not plugged.
Maximum restriction in the air cleaner occurs at maximum air
2. Inspect the air cleaner outlet to be sure it is not plugged
flow. On this turbocharged diesel engine, the maximum air
by paper, rags, etc.
flow occurs only at maximum engine power.
3. Ensure the correct size connections are used between
With the manometer held vertically and the engine drawing
the air cleaner and the engine.
maximum air, the difference in the height of the water
columns in the two legs, measured in inches or centimeters, 4. Ensure all inlet accessories are the correct size and are
is the air cleaner restriction. Restriction indicators are not plugged by any foreign object.
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1 16
Tier 3 Air Cleaner Assembly 20 6700 FIGURE 7-5

1 Air Cleaner 11 Elbow
2 Mounting Bands 12 Connector
3 Air Inlet Hood 13 Elbow
4 Elbow 14 Bulkhead Coupling
5 Intake Tube 15 Flange Screw
6 Reducer 16 Locknut
7 Restriction Indicator 17 Tubing
8 T-Bolt Clamp 18 Flex Guard
9 T-Bolt Clamp 19 Clamp
10 Muffler Clamp 20 Vacuator Valve

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Tier 4 Air Cleaner Assembly

FIGURE 7-6
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1 Air Cleaner 7 T-Bolt Clamp
2 Mounting Bracket 8 T-Bolt Clamp
3 Elbow 9 Muffler Clamp
4 Intake Tube 10 Tube Weldment
5 Reducer 11 Molded Elbow
6 T-Bolt Clamp 12 T-Bolt Clamp
7

Tier 3 Filter Element Replacement 3. Install the new element into the air cleaner body as
follows:
a. INSPECT THE FILTER FOR DAMAGE. Always
CAUTION look for filter damage, even if a new filter element is
Never service the air cleaner while the engine is running. being installed. Pay special attention to the inside of
the open end (sealing area). Do not install a
1. Unlatch the latches, open the air cleaner body and damaged filter.
withdraw the element as follows (Figure 7-7):
b. INSERT THE FILTER PROPERLY. The seal area is
a. RELEASE THE SEAL GENTLY. The filter element on the inside of the open end of the primary filter. A
fits tightly over the outlet tube, creating the critical new filter has a dry lubricant to aid installation. The
seal on the inside diameter of the filter endcap. The critical sealing area will stretch slightly, adjust itself
filter should be removed gently to reduce the and distribute the sealing pressure evenly. To
amount of dust dislodged. There will be some initial complete a tight seal, apply pressure at the outer
resistance, similar to breaking the seal on a jar. rim of the filter, not the flexible center. No cover
pressure is required to hold the seal (Figure 7-9).
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FIGURE 7-7
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FIGURE 7-9
b. AVOID DISLODGING DUST FROM THE FILTER.
Gently pull the filter off the outlet tube and out of the
housing. Avoid knocking the filter against the 4. Install the cover on the air cleaner body with the two
housing (Figure 7-8). arrows pointing up. Secure the cover with the latches.
5. Check all connections and ducts for an air tight fit. Make
sure that all clamps, bolts, and connections are tight.
Check for holes in piping. Leaks in the air intake system
may send dust directly to the engine.
Air Cleaner Body
Before installing the filter element, remove foreign material
(leaves, lint or other foreign matter) that may have collected
inside the air cleaner body. Inspect the inside of the body for
dents or other damage that would interfere with air flow or
with the fins on the element or inside the body. Repair any
FIGURE 7-8 body dents, being careful not to damage the sealing
surfaces. Be sure to clean the sealing surface of the outlet
2. Inspect all parts of the intake system and air cleaner. Be tube and the inside of the outlet tube, taking care not to
sure to clean the sealing surface of the outlet tube and damage the sealing area on the tube.
the inside of the outlet tube.

Tier 4 Filter Element Replacement damage that would interfere with air flow or with the fins on
the element or inside the body. Be sure to clean the sealing
surface of the outlet tube and the inside of the outlet tube,
CAUTION taking care not to damage the sealing area on the tube.
Never service the air cleaner while the engine is running. Precleaner
Unlatch the latches, open the air cleaner body and withdraw The Precleaner (1) (Figure 7-11) prevents large debris from
the element as follows: entering the Air Cleaner and should be cleaned periodically,
especially when working in severe dust conditions. Remove
1. Lift the clips (Figure 7-10) securing the cover to the air precleaner after first removing molded elbow (3). Remove all
cleaner body and remove the cover. debris from inside precleaner and reassemble.
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8749 FIGURE 7-10

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2. Remove Primary Filters (A) from the Air Cleaner and 8750 3 2
inspect for foreign material and marks of dust. Replace FIGURE 7-11
as necessary.
Vacuator Valve
3. Remove Secondary Filter (B) from behind the Primary
Filter from the Air Cleaner. Replace the Secondary Filter Vacuator valves (2, Figure 7-11 and Figure 7-12) are
every third time the primary filter is changed. designed to expel loose dust and dirt from the air cleaner
body automatically, thus lengthening the element service life.
4. Thoroughly clean the sealing surface and inside of the The valve lips must point straight down and be kept free from
air filter housing. Inspect all parts of the intake system
and air cleaner.
debris to operate effectively. Mud and chaff can lodge in 7
these lips periodically and hold them open during engine
5. Place the cover back on the air cleaner housing and operation.
secure with clips.
6. Check all connections and ducts for an air tight fit. Make
sure that all clamps, bolts, and connections are tight.
Check for holes in piping. Leaks in the air intake system
may send dust directly to the engine.
Element Cleaning
It is not recommended that filter elements be cleaned.

Cummins and most other manufacturers will not warrant a
cleaned air filter.
FIGURE 7-12
Air Cleaner Body
Before installing the filter element, remove foreign material Check the condition of the valve and lips frequently and keep
(leaves, lint or other foreign matter) that may have collected them clean. The valve lips should be open only when the
inside the air cleaner body. Inspect the inside of the body for engine is shut down, or running at low idle speed. If the valve

is turned outside in, check for a clogged air cleaner inlet. 2. Check all mounting hardware for security to eliminate
Malfunction of this valve does not reduce the air cleaner possible vibration of intake piping. Such vibration leads
effectiveness, but does allow the element to get dirty faster to early failure of hoses, clamps, and mounting parts,
and reduces serviceable life. If a valve is lost or damaged, and can cause hoses to slip off the connecting pipes,
replace it with a new valve of the same part number. allowing un-filtered air into the engine air intake.
Duct Work 3. Check hoses for cracks, chafing, or deterioration, and

replace at the first sign of probable failure.
1. Check the intake pipe for accumulation of leaves, trash,
and other debris that could restrict air flow.
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Charge-Air Cooler System The CAC system consists of the ducting to and from the
charge-air cooler and a hydraulically driven fan. The charge-
The charge-air cooler (CAC) (Figure 7-13) is used to cool air cooler system must be air-tight in order to work efficiently.
engine air after it has passed through a turbocharger, but
before it enters the engine. The charge-air cooler provides The ducting consists of metal tubing, hose clamps and
better horsepower, increased fuel efficiency, and reduces bellows. The recommended installation torque of the spring
engine emissions. loaded T-bolt clamps is 100 lb-in (11.3 Nm). Do not compress
the spring completely, the bellows and/or clamp may be
damaged from thermal expansion of the CAC tube.
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Tier 4 Charge-Air Cooler Assembly FIGURE 7-13
Item Description
1 Charge-air Cooler Assembly Maintenance
2 Fan Assembly Check the hose clamps for proper torque.
3 Bellows Inspect the bellows for cracks or holes.
4 Tube Clean the charge-air cooler, removing any dirt or debris.
5 Tube Verify the fan is operating correctly and there are no
6 Tube hydraulic leaks.
7 T-Bolt Clamp
8 Muffler Clamp
9 Strain Relief Cable

EXHAUST 3. Remove mounting bands to free muffler from muffler

mounting bracket.
Tier 3 4. Inspect muffler, exhaust tailpipe, exhaust tubes, bracket,
and attaching hardware. Repair or replace any of these
Removal
parts if damaged or missing.
Installation
1. Secure the muffler to the exhaust tube with a clamp.
CAUTION
Burn Hazard! 2. Install the exhaust tailpipe on the muffler. Secure the
exhaust tailpipe to the muffler with clamp. Adjust the
Do not touch any exhaust parts until they are at ambient
clamp as needed.
temperature. Severe burning may result.
3. If removed, secure the muffler mounting brackets to the
1. Remove clamp to free exhaust tailpipe from muffler mountings with capscrews and nuts as needed. Secure
(Figure 7-14). the muffler to the muffler mounting bracket with
mounting bands.
2. Remove clamp to free muffler from exhaust tube.
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7576-4
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7576-3
Tier 3 Muffler FIGURE 7-14

1 Muffler 6 Reducer Exhaust
2 Bracket 7 Seal Clamp
3 Tail Pipe 8 Clamp
4 Muffler Clamp 9 Heat Tape
5 Hose Exhaust

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THIS PAGE BLANK

Tier 4 13. Remove V-band clamp securing exhaust tube to

turbocharger and remove exhaust tube.
Removal
14. Remove hardware securing mounting bands to SCR
and remove SCR.
15. Inspect SCR, DRT and DOC, exhaust tailpipe, exhaust
CAUTION tubes, mounting bands, and attaching hardware. Repair
or replace any of these parts if damaged or missing.
Burn Hazard!
Do not touch any exhaust parts until they are at ambient Installation
temperature. Severe burning may result.
1. Install SCR and DOC into mounting bands and secure
with hardware.
1. Remove the sheet metal guard to gain access to the
exhaust system (Figure 7-15). 2. Connect the exhaust tube to the turbocharger and
secure with the V-band clamp.
2. Disconnect and tag electrical connections.
3. Install the flexible coupler and exhaust tube and secure
3. Disconnect and tag hose connections.
with muffler clamps.
4. Remove clamp to free exhaust tailpipe from selective
4. Install the flexible exhaust hose and remaining exhaust
catalytic reduction (SCR) unit.
tube and secure with V-band clamps.
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5. Remove V-band clamps to free elbows from the SCR
5. Attach the exhaust tube to the DOC and secure with the
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and the decomposition reactor tube (DRT).
clamp.
6.
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Remove V-band clamp attaching elbow to DRT and
remove DRT.
6. Wrap the thermal blanket around the exhaust tubes and
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secure with hooks and springs.
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7. Remove V-band clamp attaching elbow to diesel

7. Attach the elbow to the DOC and secure with the V-band
oxidation catalyst (DOC) and remove elbow.
clamp.
8. Remove hardware securing mounting bands to DOC.
8. Install DRT and connect it to the two elbows. Secure with
er
9. Remove clamp from DOC and exhaust tube and remove V-band clamps.
DOC.
9. Attach the last elbow to the SCR and secure with V-band
10. Remove the thermal insulation from the exhaust tubes. clamp.
11. Remove V-band clamps from flexible exhaust hose and 10. Install the exhaust tailpipe on the SCR. Secure the
remove hose. exhaust tailpipe to the SCR with clamp.
12. Remove clamps connecting flexible coupler to exhaust 11. Install sheet metal guard around exhaust system.
tubes and remove coupler.
7

20
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3 24
21
31 8
32
30 11
14
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12
17 14
25 13
16
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23
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Tier 4 Exhaust System

FIGURE 7-15


1 Bracket 17 Clamp
2 Diesel Oxidation Catalyst (DOC) 24v QSL9 18 Insulation Kit (installed on items 7, 8, and 10)
3 Selective Catalytic Reactor (SCR) 24v Prod 19 Diesel Particulate Filter Gasket
4 Decomposition Reactor Tube 20 V-Band Clamp
5 Elbow 21 Bracket
6 Mounting Band 22 Bracket
7 Exhaust Tube 23 Muffler Clamp
8 Exhaust Tube 24 Muffler Clamp
9 Flexible Exhaust Hose 25 Heat Shield
10 Exhaust Tube 26 Spacer
11 Flex Coupler 27 Elbow Fitting
12 V-Band Clamp 28 V-Band Clamp
13 Decomposition Reactor Tube Gasket 29 Elbow
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14 V-Band Clamp 30 Elbow
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Decomposition Reactor Tube Gasket 31 V-Band Clamp
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16 Tailpipe 32 Decomposition Reactor Tube Gasket
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WATER COOLING SYSTEM Most of these problems can be traced to overheating;

however, an engine that is running too cold can be just as
Description troublesome.
The cooling system consists of a Radiator, Surge Tank, Overheating

engine cooling circuit, the connecting hoses and connecting An engine that is overheating may lead to troubles such as
tubes. At all times, the antifreeze/coolant should properly the following:
inhibit corrosion. It is recommended that a mixture of 50/50
blended ethylene-glycol, low silicate, fully formulated, 1. Burned valves.
extended life engine antifreeze/coolant mixture which does 2. Pinging or knocking.
not require a pre-charge of supplemental coolant additives
(SCA) be used for fill of heavy duty liquid cooled internal 3. Excessive fuel consumption.
combustion engines.
4. Poor lubrication - increased engine wear.
Maintenance 5. Sticking valves.
General 6. Short injector life.
The cooling system includes the Radiator, Surge Tank, 7. Engine hot spots.
Thermostat, the Fan, and Water Pump. Radiator hoses are 8. Need for higher grade fuel.
also included in this group.
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Overcooling
The cooling system is often neglected because the effects or
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damage that result from an improperly maintained system The following engine troubles result when an engine is
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usually occur gradually. The cooling system needs to be
maintained with the same attention as other systems.
overcooled:
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1. Excessive fuel consumption.
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The circulation of water through the cooling system relies 2. Sludge formation in crankcase.
entirely upon the water pump. The water pump draws water
from the radiator and forces it through the water jacket and 3. Corrosive acids formed in crankcase.
cylinder head. There it accumulates heat and flows to the
er
4. Excessive fuel deposits in the exhaust system.
radiator tank. Then the water flows across through the
radiator core and is cooled by air from the fan. This process Antifreeze/Coolant
of removing heat from water as it circulates holds the engine
to its efficient operating temperature. Heavy duty diesel engines require a balanced mixture of
water and antifreeze/coolant. For maximum rust, freeze, and
The following paragraphs point out several facts about boiling point protection, a 50/50 blended, fully formulated
cooling system components, the effects of cooling system extended life antifreeze/coolant should be maintained at all
neglect, and procedures to be followed for cooling system times. Refer to Lubrication, page 9-1. Do not use more than
maintenance. 50 percent antifreeze/coolant in the mixture unless additional
freeze protection is required. Never use more than 68
Effects of Cooling System Neglect percent antifreeze/coolant under any condition. Antifreeze/
Whenever an engine does not perform at top efficiency, a coolant at 68 percent provides the maximum freeze
neglected cooling system may be at fault even though the protection; antifreeze/coolant protection decreases above 68
part directly responsible is not a part of the cooling system. percent.

Rust Prevention Engine Antifreeze/Coolant Check/Fill Procedure

To keep engines operating at like new efficiency, all forms of 1. Check for proper antifreeze/coolant level by removing
rust formation must be prevented. The formation of rust in the surge tank cap (6, Figure 7-16) and verifying that
the cooling system is a result of the interaction of water, iron, antifreeze/coolant reaches the bottom of the surge tank
and oxygen, and can only be prevented by maintaining full filler neck.
strength corrosion protection at all times. Supplemental
If necessary, fill the system with a 50/50 blended, fully
coolant additives (SCA) are recommended for this cooling
formulated extended life antifreeze/coolant. Fill to the
system. Antifreeze/coolant alone does not provide sufficient
bottom of the surge tank filler neck. Fill slowly. Flow
protection for heavy-duty diesel engines. Refer to Section 9
exceeding 3 gpm (11.2 l/min) can give a false reading.
for SCA specification and compatible brands.
NOTE: If the engine coolant is changed, the coolant filter
Engine Antifreeze/Coolant Fill Level Check must also be changed.
Procedure
2. Wait one minute and recheck the antifreeze/coolant
Due to visual access issues, this vehicle has no antifreeze/ level. Refill as necessary repeating step 1.
coolant level sight glass. To check level, remove the surge
tank cap Item #6 on Figure 7-16 and verify whether the fill 3. Run the engine for 5 minutes and recheck the
level is up to the bottom of the surge tank filler neck. If level is antifreeze/coolant level. Refill as necessary repeating
low, perform “Engine Antifreeze/Coolant Fill Procedure”. step 1. Refer to Lubrication, page 9-1.
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Antifreeze/Supplemental Coolant Additives NOTE: Remove the radiator cap when draining the system
Maintenance Summary to ensure proper draining.
Cooling System Level Check Interval Cleaning
Daily or 10 hours
The cooling system level should be checked every 10 hours
of operation or daily, whichever comes first. Refer to
CAUTION
Burn Hazard!
SCA Level Check/Coolant Filter Change Interval
The cooling system contains very hot pressurized liquid
6 months or 500 hours and injury can result when removing the radiator cap at
operating temperature. Use proper protection to remove
• Check SCA Levels (use only Coolant Test Kit, Grove P/
the radiator cap.
N 9414101675, to check the coolant additive
concentration in the cooling system).
1. Coolant shut-off valves to heaters and other accessories
The Coolant Filter contains molybdate. Therefore, it is should be open to allow complete circulation during
important to use the Grove Coolant Test Kit, which cleaning, flushing, and draining. Run the engine with
checks the molybdate level, regardless of whether the radiator covered if necessary until temperature is up to
SCA used to replenish the coolant system contains operating range 160 to 180° F (71 to 82° C). Stop the
molybdate or not. engine, remove the radiator cap, and drain the system
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by opening the drain cocks on the radiator and engine
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Only add coolant additive if levels are less than 1.2 units/
block.
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gal (see Lubrication Intervals, page 9-1 for specification
and recommended additives). NOTE: Use a cleaning compound that is not corrosive to
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aluminum to prevent damage to the radiator.
NOTE: An inadequate concentration of coolant additive
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can result in major corrosive damage to the cooling 2. Allow the engine to cool, close the drain cocks, and pour
system components. Overconcentration can cause the cleaning compound into the surge tank according to
formation of a “gel” that can cause restriction or the directions. Fill the system with water.
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plugging of coolant passages, and overheating.
3. Place a clean drain pan to catch the overflow, and use it
• Change coolant filter. to maintain the level in the radiator. Do not spill the
solution on the vehicle paint.
Install charged filter if SCA levels are normal or below
normal; install non-charged filter if SCA levels are above 4. Replace the radiator cap and run the engine at moderate
normal (contact Manitowoc Crane Care for filter part speed, covering the radiator if necessary, so the system
number). reaches a temperature of 180° F (82° C) or above, but
1 year or 1000 hours does not reach the boiling point. Allow the engine to run
at least two hours, or according to recommendations of
• Test antifreeze/coolant for contamination. the manufacturer of the cleaning compound, at 180° F
Condemning limits are: (82° C) so the cleaning solution may take effect. Do not
drive the vehicle or allow the liquid level in the radiator to
- Sulfate level greater than or equal to 1500 ppm. drop low enough to reduce circulation.
- Chloride level greater than or equal to 200 ppm. 5. Stop the engine as often as necessary to prevent boiling.
- The pH level is less than 6.5 6. With the engine stopped, feel the radiator core with bare
hands to check for cold spots, and then observe the
- Oil or fuel contamination can be identified by odor or
temperature gauge reading. When there is no change in
color.
temperature for some time, drain the cleaning solution.
If condemned, flush the system using a commercially
7. If clogging of the core is relieved but not fully corrected,
available flushing agent. Refill system with fully
allow the engine to cool, pressure-flush the system (see
formulated extended life coolant. Refer to Lubrication,
Pressure Flushing) and repeat the cleaning operation.
page 9-1.
8. If problem persists, replace radiator.

Pressure Flushing as to allow a loose fitting cap. Ensure the overflow tube
is not plugged.
1. Disconnect both radiator hoses that connect the radiator
to the engine. 3. Radiator Cap - This is the pressure-setting type. Its
purpose is to hold the cooling system under a slight
2. Clamp a convenient length of hose to the radiator core
pressure, increasing the boiling point of the cooling
outlet opening, and attach another suitable length of
solution and preventing loss of solution due to
hose to the radiator inlet opening to carry away the
evaporation and overflow.
flushing stream.
The cap has a spring-loaded valve, the seat of which is
3. Connect the flushing gun to compressed air and water
below the overflow pipe in the filler neck. This prevents the
pressure, and clamp the gun nozzle to the hose
escape of air or liquid while the cap is in position. When the
attached to the radiator outlet opening.
cooling system pressure reaches a predetermined point, the
4. Fill the core with water. Turn on air pressure in short cap valve opens and will again close when the pressure falls
blasts to prevent core damage. below the predetermined point.
5. Continue filling the radiator with water and applying air When removing the pressure type cap, perform the
pressure as above until the water comes out clear. operation in two steps. Loosening the cap to its first notch
raises the valve from the gasket and releases the pressure
6. Clamp the flushing gun nozzle firmly to a hose attached through the overflow pipe. In the first stage position of the
securely to the engine water outlet opening. Fill the cap, it should be possible to depress the cap approximately
engine block with water, partly covering the water inlet 0.13 in (3 mm). The prongs on the cap can be bent to adjust
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opening to permit complete filling. this condition. Care must be taken that the cap is not too
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loose as this would prevent proper sealing.
7.
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Turn on compressed air to blow out water and loose
sediment. Continue filling with water and blowing out
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with air until flushing stream comes out clear.
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8. When the vehicle is equipped with a water heater

connected to the cooling system, flush the heater, CAUTION
following the same procedure as for the radiator core. Burn Hazard!
er
9. After completing the flushing operation, clean out the Loosen cap slowly and pause a moment to avoid possible
surge tank overflow pipe; inspect the water pump; clean burning by hot water or steam. Continue to turn the cap to
the thermostat and the radiator cap control valves. the left until it can be removed.
Check the thermostat for proper operation before
installation. 4. Tubes are very small and can easily become clogged by
rust and scale. The general condition of the cooling
10. Blow insects and dirt from the radiator core air system and operating temperature are indications as to
passages, using water, if necessary, to soften whether or not tubes are clean. Another good test is to
obstructions. feel the core for cold spots.
Component Inspection 5. Fins are thin metal sheets that dissipate heat picked up 7
by the tubes. They should be kept free of bugs, leaves,
Radiator/Surge Tank
straw etc., so as to allow the free passage of air. Bent
1. Side Tanks - Look for leaks, particularly where the tank is fins should be straightened.
attached to the core. Vibration and pulsation from
pressure can fatigue soldered seams.
2. Filler Neck - The sealing seat must be smooth and
clean. Cams on filler neck must not be bent or worn so

Engine Water Jacket Test Equipment

The water jacket permits coolant to be circulated around the The antifreeze/coolant concentration must be checked using
cylinder walls, combustion chamber, and valve assemblies. a refractometer. “Floating ball” type density testers or
Some of these coolant passages are small and can easily hydrometers are not accurate enough for use with heavy
become clogged, if the cooling system does not receive the duty diesel cooling systems.
proper maintenance.
Antifreeze/Coolant
1. Core Plugs - These are sometimes mistakenly called
freeze plugs. They do not provide protection against Heavy duty diesel engines require a balanced mixture of
freezing expansion, but are only present because of water and antifreeze/coolant. Fill the system with a 50/50
engine block casting methods. Remove and replace blended, fully formulated extended life antifreeze/coolant at
core plugs that show signs of leaking or rusting through. all times. Refer to Lubrication, page 9-1. Do not use more
Use an installation tool for core plug replacement. than 50 percent antifreeze/coolant in the mixture unless
additional freeze protection is required. Never use more than
2. Drain Plugs - The water jacket of each engine could 68 percent antifreeze/coolant under any condition.
have one or more drain plugs (see Figure 7-16). These Antifreeze/coolant at 68 percent provides the maximum
should receive seasonal care and be kept free of rust freeze protection; antifreeze/coolant protection decreases
and scale. above 68 percent.
3. Gaskets - All gaskets must be in good condition to Radiator Removal and Installation
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prevent both internal and external leaks. If there are Removal
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external leaks around gaskets, there may also be
1. Set the outriggers and position the boom to over the
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internal leaks into the engine. Proper tightening of the
head bolts with a torque wrench is essential for side.
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preventing leaks around the head gasket.
2. Open the drain cock at the end of drain hose and drain
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Water Pump the coolant into a suitable container. If necessary,

dispose of the coolant in accordance with local and EPA
The pump should be checked carefully for leaks and proper regulations.
lubrication. Replace or rebuild if leaking, cracked, or worn.
er
3. Open the air bleed pet cock to ensure proper draining.
Fans and Belts
4. Open and remove the hood top door assembly.
The fan should be checked for cracked or broken blades.
5. Remove the hardware securing the rear engine hood
Refer to Engine Drive Belts, page 7-6. panel to the engine hood. This will gain access to the
Thermostat rear of the radiator.
The thermostat is of the nonadjustable type and is 6. Remove the engine hood assembly.
incorporated in the cooling system for the purpose of 7. Tag and disconnect the hoses from the surge tank to the
retarding or restricting the circulation of coolant during engine and from the surge tank to the radiator. Remove
engine warm up. Engine overheating and loss of coolant is surge tank assembly.
sometimes due to an inoperative thermostat. To check for
this condition, remove the thermostat and test by 8. Remove the hose clamps and radiator hose connecting
submerging it in hot water and noting the temperature at the radiator to the radiator tubes.
which the thermostat opens and closes. Use an accurate 9. Disconnect the coolant level harness from the engine
high temperature thermometer for making this test. harness.
Hoses and Clamps 10. Remove the capscrews and flatwashers attaching the
Hoses and their connections must be checked regularly fan guard to the shroud ring. Remove the fan guard.
because they are often the source of hidden trouble. Hoses 11. Remove the hardware securing the shroud ring to the
may often times appear in good condition on the outside shroud box and slide the shroud ring back onto the
while the inside will be partially deteriorated. If there are any engine fan.
doubts about a hose doing its job, replacement should be
made. The clamps should be inspected to make sure they 12. Remove the capscrews, flatwashers and lockwashers
are strong enough to hold a tight connection. that connect the plates to the middle of the radiator and
the frame rail.
NOTE: The radiator assembly weighs approximately 240
lb (109 kg).

13. Attach an adequate lifting device to the radiator 5. Position the fan guard on the shroud ring and secure
assembly. with bolts and washers.
14. Remove the capscrews and washers securing the 6. Reconnect the coolant level harness to the engine
radiator flange to the frame mounting brackets. Remove harness.
the radiator assembly from the carrier.
7. Connect the two radiator tubes to the radiator with hose
15. If a new radiator is to be installed, remove all fittings and clamps and the radiator hose.
hoses from the old one and install them in the same
8. Secure the radiator tube to the top of the engine using
locations on the new one.
nuts, washers and a muffler clamp.
Installation
9. Reinstall surge tank and connect the hoses between the
1. Ensure all fittings and hoses are installed on the radiator. surge tank and engine and the surge tank and the
radiator.
2. Position the radiator assembly in the carrier using a
lifting device. Take caution not to tear or misplace the 10. Tighten the drain cock at the bottom of the radiator drain
rubber molding around the radiator assembly. Secure hose.
the radiator flange to the frame mounting brackets using
11. Install the hood assembly.
capscrews and washers.
12. Install the hardware holding the rear engine hood panel
3. Reconnect the two plates between the middle of the
to the engine hood.
radiator and the center of the frame rail using
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capscrews, flatwashers, lockwashers and nuts. 13. Install the hood top door assembly.
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4.
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Connect the shroud ring to the shroud box using the
hardware taken off during removal.
14. Service the engine coolant system, as necessary. Refer
to Lubrication, page 9-1. Start the engine, operate all
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systems and check for leaks.
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4
1 2 3 5 6 7
Top View of
Radiator Assembly
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3 12
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Left Side View of

Radiator
Assembly
18 8456-1
15
17 16 3
14
FIGURE 7-16

Item Description
Item Description
10 Radiator
1 Air Bleed Pet Cock
11 Fan Guard
2 Upper Radiator Tube
12 Radiator Hose
3 Hose Clamp
13 Radiator Stabilizer
4 Radiator Hose
14 Radiator Hose
5 Overflow Hose
15 Lower Radiator Tube
6 Surge Tank Cap
16 Drain Cock
7 Surge Tank
17 Drain Hose
8 Fan Shroud
18 Radiator Hose, Elbow
9 Fan
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DRIVE TRAIN Removal

1. Support the drive shaft being removed so it does not fall
Description when disconnected. If removing the coupling shaft or the
T h e d r i v e t r a i n c o n s i s t s o f t h e t o r q u e c o n v e r t e r, front slip shaft, support the other shaft also.
transmission, and four drive shafts. 2. If removing the coupling shaft, free its bearing from its
The torque converter is mounted on and driven by the bracket by removing two bolts, two nuts, and four
engine. The torque converter provides for mounting and washers.
driving hydraulic pumps No. 1, No. 2, and No. 3. 3. Remove the bolts from the bearing cap on each end of
The transmission is a Spicer R36000 Series (R36626) the drive shaft. Note the lengths of the bolts and if they
powershift with six forward speeds and three reverse have lockwashers. Remove the drive shaft.
speeds. The transmission is controlled electrically by a shift
Installation
lever located on the right side of the steering column and an
axle drive mode selector rocker switch located on the 1. For any drive shaft which has mating marks (arrows),
steering column. align these mating marks to ensure proper phasing of
coupler yokes.
The torque converter and transmission oil is cooled by
passing the oil through an externally mounted transmission 2. Position the drive shaft between the couplers on the two
cooler. The cooler is mounted on the right side of the components it is joining.
machine in front of the hydraulic reservoir. An oil filter is
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located on the left side of the frame behind the fuel tank. 3. For the coupling shaft, secure its bearing to its bracket
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with two bolts, two nuts, and four washers.
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Four drive shafts are used. One drive shaft is connected
between the torque converter and the transmission. The 4. Secure the drive shaft to the coupler with bolts. For the
coupling shaft, torque the bolts connecting it to the front
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other three drive shafts are connected between the
axle installation’s differential to 110 to 120 ft-lb (149 to
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transmission and the front and rear axles.

163 Nm). For the coupling shaft’s connection to the front
Maintenance axle slip shaft, and for the other connections of the front
axle slip shaft, rear axle slip shaft, and torque converter
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Drive Lines slip shaft, torque the bolts to 90 to 100 ft-lb(122 to 136
Nm).
Lubrication
CAUTION
Do not disassemble drive lines when removing them from The drive line slip joints require lubrication. Refer to Section
the crane. Dirt can enter the spline and cannot be purged. Lubrication, page 9-1.
In addition, the drive lines are assembled in a specific
orientation when manufactured and can easily be
incorrectly reassembled.

TORQUE CONVERTER reaction member is the means by which the hydraulic torque
converter multiplies torque.
Description The reaction member of the torque converter is located
The torque converter assembly is mounted on and driven by between and at the center of the inner diameters of the
the engine. The torque converter provides for mounting and impeller and turbine elements. Its function is to take the fluid
driving hydraulic pumps No. 1, No. 2, and No. 3. which is exhausting from the inner portion of the turbine and
change its direction to allow correct entry for recirculation
Theory of Operation into the impeller element.
The transmission and torque converter function together and The torque converter will multiply engine torque to its
operate through a common hydraulic system. Therefore, it is designed maximum multiplication ratio when the output shaft
necessary to consider both units in discussing operation. is at zero rpm. Therefore, as the output shaft is decreasing in
speed, the torque multiplication is increasing.
With the engine running, the converter charging pump draws
oil from the transmission pump through the removable oil The shift control valve assembly consists of a valve body
suction screen and directs it through the pressure regulating with selector valve spools. A detent ball and spring in the
valve and oil filter. selector spool provides one position for each speed range. A
detent ball and spring in the direction spool provides three
The pressure regulating valve maintains pressure to the positions, one each for forward, neutral, and reverse.
transmission control for actuating the direction and speed
clutches. This requires a small portion of the total volume of With the engine running and the directional control lever in
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oil used in this system. The remaining volume of oil is the neutral position, oil pressure from the regulating valve is
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directed through the torque converter circuit to the oil cooler blocked at the control valve, and the transmission is in
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and returns to the transmission for positive lubrication. This
regulator valve consists of a hardened valve spool operating
neutral. Movement of the forward and reverse spool will
direct oil, under pressure, to either the forward or reverse
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in a closely fitted bore. The valve spool is spring loaded to direction clutch, as desired. When either directional clutch is
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hold the valve in a closed position. When a specific pressure selected, the opposite clutch is relieved of pressure and
is achieved, the valve spool works against the spring until a vents back through the direction selector spool. The same
port is exposed along the side of the bore. This sequence of procedure is used in the speed selector.
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events provides the proper system pressure. The direction or speed clutch assembly consists of a drum
After entering the converter housing, the oil is directed with internal splines and a bore to receive a hydraulically
through the reaction member support to the converter blade actuated piston. The piston is oil tight by the use of sealing
cavity and exits in the passage between the turbine shaft and rings. A steel disc with external splines is inserted into the
reaction member support. The oil then flows out of the drum and rests against the piston. Next, a friction disc with
converter to the oil cooler. After leaving the cooler, the oil is splines at the inner diameter is inserted. Discs are alternated
directed to a fitting on the transmission. Through a series of until the required total is achieved. A heavy back-up plate is
tubes and passages, the transmission bearings and clutches then inserted and secured with a snap ring. A hub with OD
are lubricated. The oil then drains to the transmission sump splines is inserted into the splines of discs with teeth on the
by gravity. inner diameter. The discs and hub are free to increase in
speed or rotate in the opposite direction as long as no
7
The torque converter consists basically of three elements pressure is present in that specific clutch.
and their related parts to multiply engine torque. The engine
power is transmitted from the engine flywheel to the impeller To engage the clutch, the control valve is placed in the
element through the impeller cover. This element is the desired position. This allows oil under pressure to flow from
pump portion of the hydraulic torque converter and is the the control valve, through a tube, to a chosen clutch shaft.
primary component which starts the oil flowing to the other This shaft has a drilled passageway for oil under pressure to
components which results in torque multiplication. This enter the shaft. Oil pressure sealing rings are located on the
element can be compared to a centrifugal pump, in that it clutch shaft. These rings direct oil under pressure to the
picks up fluid at its center and discharges at its outer desired clutch. Pressure of the oil forces the piston and discs
diameter. against the heavy back-up plate. The discs, with teeth on the
outer diameter, clamping against discs with teeth on the
The torque converter turbine is mounted opposite the inner diameter, enables the hub and clutch shaft to be locked
impeller and is connected to the output shaft of the torque together and allows them to drive as a unit.
converter. This element receives fluid at its outer diameter
and discharges at its center. Fluid directed by the impeller There are bleed balls in the clutch piston which allow quick
out into the particular design of blading in the turbine and escape for oil when the pressure to the piston is released.

Maintenance flow, it is essential that the following preliminary checks be

made.
General Information
1. Check oil level in transmission. This should be done with
1. Always check the oil level with the engine idling, and the oil temperature at 180 to 200 °F (82 to 93 °C). Do not
transmission in neutral and at normal operating attempt these checks with cold oil.
temperature—180 to 200°F (82 to 93°C).
2. To bring the oil temperature to this level, it is necessary
2. Change the oil filter element every 500 hours. Drain and to either work the machine or stall out the converter.
refill the system every 1000 hours or 6 months. Refer to When it is impractical to work the machine, stall out the
Lubrication, page 9-1. converter as follows.
Troubleshooting a. Apply the parking brake and service brakes.
The following data is presented as an aid to locating the b. Position the shift lever to forward and high speed.
source of difficulty in a malfunctioning unit. It is necessary to c. Accelerate the engine to between half and three-
consider the torque converter charging pump, transmission, quarter throttle.
oil cooler, and connecting lines as a complete system when
checking for the source of trouble, since the proper operation
of any unit therein depends greatly on the condition and CAUTION
operation of the others. By studying the principles of
Full throttle stall speeds for an excessive length of time
operation together with the data in this section, it may be
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will overheat the torque converter.
possible to correct any malfunction which may occur in the
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system. Troubleshooting procedures basically consist of
hydraulic checks.
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reached.
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Hydraulic Checks
NOTE: Always make all troubleshooting checks with the
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Before checking the transmission/torque converter and converter outlet temperature at least 180 to 200 °F
associated hydraulic system for pressures and rate of oil (82.3 to 93.3 °C).
Troubleshooting Procedures
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Table 7-1
SYMPTOM PROBABLE CAUSE REMEDY

1. Low clutch pressure. a. Low oil level. a. Fill to proper level. Refer to
b. Clutch pressure regulating b. Clean valve spool and housing.
valve spool stuck open.
c. Faulty charging pump. c. Replace pump. Refer to your
Manitowoc Crane Care Parts
Manual.
d. Broken or worn clutch shaft or d. Replace clutch shaft or sealing
piston sealing rings. rings, as applicable.
e. Clutch piston bleed valve stuck e. Clean bleed valves thoroughly.
open.
2. Low converter charging pump a. Low oil level. a. Fill to proper level. Refer to
pressure. Lubrication, page 9-1.
b. Suction screen plugged. b. Clean suction screen.
c. Defective oil pump. c. Replace pump. Refer to your
Manual.

SYMPTOM PROBABLE CAUSE REMEDY

3. Overheating. a. Worn oil sealing rings. a. Remove, disassemble, and
rebuild converter assembly.
b. Worn oil pump. b. Replace pump. Refer to your
Manual.
c. Low oil level. a. Fill to proper level. Refer to
Lubrication, page 9-1
4. Noisy converter. a. Worn oil pump. a. Replace pump.
b. Worn or damaged bearings. b. A complete disassembly will be
necessary to determine what
bearing is faulty.
5. Lack of power. a. Low engine RPM at converter a. Tune engine and check
stall. governor.
b. See “Overheating” and make b. Make corrections as explained
same checks. in “Overheating.”
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Removal 1. If a new torque converter is to be installed, remove all
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fittings and brackets from the original converter and
1.
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Extend and set the outriggers just enough to take up the
slack in the outrigger pads. Chock the wheels.
install them in the same locations on the new torque
converter.
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2. Position the boom over the side and stop the engine.
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2. Position the torque converter to the engine with the

3. Remove the front section of the engine hood. lifting device.
4. Refer to Drive Lines, page 7-34 in this section and 3. Remove all burrs from the flywheel mounting face and
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disconnect the drive line from the torque converter. nose pilot bore. Clean the drive plate surface with
solvent.
5. Tag and disconnect all hydraulic lines from the torque
converter to the transmission and the transmission oil NOTE: Refer to Figure 7-17 for a typical transmission/
cooler. Cap all lines and openings. torque converter installation.
6. Remove the two-section and single section hydraulic 4. Check the engine flywheel and housing for conformance
pumps from the transmission/torque converter. Cover all to standard S.A.E. No. 1-S.A.E. J-927 tolerance
openings. Refer to Hydraulic Pumps, page 2-18 for specifications for bore size, pilot bore runout and
removal of the pumps. mounting face flatness. Measure and record engine
NOTE: The torque converter weighs approximately 500 lb
crankshaft end play. 7
(225 kg) dry. 5. Rotate the engine flywheel to align a drive plate
mounting screw hole with the flywheel housing front
7. Attach an adequate lifting device to the torque converter access hole.
and take up any slack.
6. Install a 4.00 in (101.6 mm) long drive plate locating stud
8. Remove the screws and lockwashers securing the drive 7/16-20 UNF thread in a drive plate nut.
plate assembly to the flywheel.
7. Rotate the torque converter to align the locating stud in
9. Remove the bolts and washers securing the torque the drive plate with the flywheel drive plate mounting
converter housing to the engine flywheel housing. screw hole positioned in step 5. Locate the torque
Installation converter on the flywheel housing. Install the torque
converter to the flywheel housing nuts and washers.
NOTE: The torque converter assembly weighs Tighten the bolts to 29 to 32 lb-ft (39 to 43 Nm).
approximately 500 lb (225 kg) dry.

Flywheel Mount
Housing Dial
Indicator
Here
Engine
Flywheel
Pilot Bore
Flywheel
Figure 1
Converter
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Housing
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Flywheel
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(10.2 cm)
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Stud
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2.5 in
(6.4 cm)
Aligning
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Studs
Drive
Flywheel Plate
Special Stud, Washer And
Housing Self-lock Nut Furnished By
Figure 2 Engine Manufacturer
Flywheel
Housing
Impeller
Cover
(3) Intermediate
Drive Plates
Figure 3 Figure 4
FIGURE 7-17

8. Remove the drive plate locating stud. Install one drive 1. Drain the entire system thoroughly.
plate attaching bolt. Snug the bolt but do not tighten.
2. Disconnect and clean all hydraulic lines. Where feasible,
NOTE: Some engine flywheel housings have a hole hydraulic lines should be removed from the machine for
located on the flywheel housing circumference in-line cleaning.
with the drive plate bolt access hole. A screwdriver or
3. Replace oil filter elements, cleaning out the filter cases
pry bar used to hold the drive plate against the flywheel
thoroughly.
will facilitate installation of the drive plate bolts. Rotate
the engine flywheel and install the remaining seven 4. The oil cooler must be thoroughly cleaned. The cooler
flywheel to drive plate attaching bolts and washers. should be back flushed with oil and compressed air until
Snug the bolts but do not tighten. After all eight bolts all foreign material has been removed. Flushing in the
and washers have been installed, torque the bolts to 28 direction of normal oil flow will not adequately clean the
to 30 ft-lb (37 to 41 Nm). This will require torquing each cooler. If necessary, the cooler assembly should be
bolt, then rotating the engine flywheel until all eight bolts removed for cleaning, using oil, compressed air and a
have been torqued. steam cleaner for that purpose.
9. Measure the engine crankshaft end play after the torque
converter has been completely installed on the engine
flywheel. This value must be within 0.001 in (0.025 mm)
CAUTION
of the end play recorded in step 4. Do not use flushing compounds for cleaning purposes.
10. Install the two section hydraulic pumps and the single
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5. Remove the drain plug from the transmission/torque
section hydraulic pump on the torque converter. Refer to
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converter and inspect the interior of the unit housing,
Hydraulic Pumps, page 2-18 for installation of the
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hydraulic pumps.
gears, etc. If the presence of considerable foreign
material is noted, it will be necessary for the unit to be
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11. Install the hydraulic lines to the torque converter. removed, disassembled, and cleaned thoroughly. It is
realized this entails extra labor, however, such labor is a
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12. Connect the drive line to the torque converter. Refer to minor cost compared to the cost of difficulties which can
Drive Lines, page 7-34 for installation of the drive line. result from the presence of such foreign material in the
system.
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13. Install the front section of the engine hood.
14. Service the crane. Refer to Servicing The Crane After 6. Assemble all components and use only the type oil
Transmission/Torque Converter Overhaul in this section. recommended. Fill the transmission through the fill pipe
until fluid is at the top of the fill range on the dipstick. Run
15. Cycle all functions and observe for proper operation. the engine for two minutes at idle (950 rpm) to prime the
torque converter and hydraulic lines. Recheck the level
Servicing the Crane after Transmission/Torque of oil in the transmission with the engine running at idle
Converter Overhaul (950 rpm). Add oil as necessary to bring the level to the
The transmission/torque converter and its allied hydraulic LOW mark on the dipstick. After the oil temperature
system are important links in the drive line between the
engine and the wheels. The proper operation of either the
reaches 180 to 200 °F (82 to 93 °C), add oil to bring the
level to the FULL mark on the dipstick.
7
unit or the system depends greatly on the condition and 7. Recheck all drain plugs, lines, connections, etc., for
operation of the other; therefore, whenever repair or leaks and tighten where necessary.
overhaul of the transmission/torque converter is performed,
the balance of the system must be considered before the job Lubrication
can be considered completed.
Type of Oil
After the overhauled or repaired transmission/torque
converter has been installed in the crane, the oil cooler and Hydraulic Fluid (HYDO) or equivalent. Refer to Lubrication,
connecting hydraulic system must be thoroughly cleaned. page 9-1.
This can be accomplished in several ways, and a degree of Capacity
good judgement must be exercised as to the method
employed. System Capacity (includes torque converter, lines, and
transmission) - Approximately 34 qt (32 l).
The following are considered the minimum steps to be taken:

Check Period NOTE: It is recommended that filter elements be changed

after 50 and 100 hours of operation on new and
8. Check oil level every 10 hours or DAILY with engine
rebuilt or repaired units, then at normal intervals
running at 1000 RPM and oil at 150 to 200°F (82 to
thereafter.
93°C). Maintain oil level to FULL mark. Refer to
Lubrication, page 9-1. a. Drain transmission and remove pump screen. Clean
screen thoroughly and reinstall it, using a new
Normal Drain Period gasket.
NOTE: Normal drain periods and filter change intervals are b. Remove and discard both filter elements. Clean
for average environmental and duty-cycle filter housing and install new filter elements.
conditions. Severe or sustained high operating
temperatures or very dusty atmospheric conditions c. Refill transmission to LOW mark.
will cause accelerated deterioration and contam-
d. Run engine at 800 RPM to prime converter and
ination. For extreme conditions, judgment must be
lines.
used to determine the required change intervals.
e. Recheck level with engine running at 800 RPM and
9. Change oil filter element. Refer to Lubrication, page 9-1.
add oil to bring level to LOW mark. When oil
temperature is hot (150 to 200°F (82 to 93°C)),
make final oil level check. Bring oil level to full mark.
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TRANSMISSION Installation
NOTE: The transmission weighs approximately 1,303 lb
Description (591 kg) dry.
The transmission is a powershift with six forward and three 1. If a new transmission is to be installed, remove all fittings
reverse speeds. and brackets from the old transmission and install them
The transmission is controlled electrically by a shift lever in the same locations on the new transmission.
located on the right side of the steering column and an axle 2. Using a transmission jack or suitable device capable of
drive mode selector rocker switch located on the steering supporting the transmission weight, position the
column. transmission under the frame and raise it into position.
Maintenance 3. Install the capscrews, washers and nuts and secure the
transmission mount to the frame mount. Refer to
Removal Fasteners and Torque Values, page 1-18 for
1. Extend and set the outriggers just enough to take up the recommended torque.
slack in the outrigger pads. Chock the wheels. 4. Remove the supporting device from under the
2. Refer to Drive Lines, page 7-34 and disconnect the three transmission.
drive lines from the torque converter and axles. 5. Connect all the transmission oil lines to appropriate
3. Tag and disconnect the electrical leads and connectors fittings.
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from the valve body.
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6. Connect all electrical leads and connectors to the valve
4.
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Tag and disconnect all hydraulic lines
transmission. Cap all lines and openings.
to the
7.
body.
Connect the oil fill tube to the frame mount.
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5. Remove the bolt attaching the oil fill tube to the frame 8. Connect the three drive lines to the transmission. Refer
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mount. to Drive Lines, page 7-34 for installation of the drive line.
NOTE: The transmission weighs approximately 1,303 lb 9. Service the crane. Refer to Servicing The Crane After
er
(591 kg) dry. Transmission/Torque Converter Overhaul in this section.
6. Position a transmission jack or some other means of 10. Cycle all functions and observe for proper operation.
support that is capable of supporting the weight of the
transmission, under the transmission. Towing or Pushing
7. With the weight of the transmission on the supporting Before towing the crane, disconnect both front and rear drive
device, remove the capscrews, washers and nuts lines. The engine cannot be started by pushing or towing
securing the transmission mounts to the frame mounts. because of the design of the hydraulic system.
8. Using the support device, lower and remove the

transmission. 7

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THIS PAGE BLANK

RT9150E SERVICE MANUAL UNDERCARRIAGE
SECTION 8
UNDERCARRIAGE
SECTION CONTENTS
Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 Integrated Outrigger/Rear Steer Control Valve . . . 8-9
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 Steer Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 Rear Axle Oscillation Lockout System. . . . . . . . . 8-10
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 Axle Oscillation Lockout Cylinders. . . . . . . . . . . . 8-12
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 Axle Oscillation Lockout Valve. . . . . . . . . . . . . . . 8-12
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 Brake System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
Wheel Alignment Check Procedure . . . . . . . . . . . 8-3 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
Rear Wheels Not Centered Switch Adjustment Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . 8-13
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14
Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 Service Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
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Park Brake Solenoid Valve . . . . . . . . . . . . . . . . . 8-20
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Steering Systems . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 Outriggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22
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Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . .
8-5
8-5
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Theory of Operation. . . . . . . . . . . . . . . . . . . . . . .
8-22
8-22
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Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
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Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9 Outrigger Monitoring System (Optional—

Front Steering Control Valve. . . . . . . . . . . . . . . . . 8-9 Standard in North America) . . . . . . . . . . . . . . . . . 8-33
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AXLES pinion bearing preload is adjusted and maintained by a

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

UNDERCARRIAGE RT9150E SERVICE MANUAL
MAINTENANCE Cleaning
NOTE: The axles do not have to be removed from the Completely assembled axles may be steam cleaned on the
crane to remove the planetary wheel ends or the outside only, to facilitate initial removal and disassembly,
drive units. providing all openings are closed. Breathers, vented shift
units, and all other openings should be tightly covered or
Removal closed to prevent the possibility of water entering the
assembly.
1. Using the outriggers, raise the wheels off the ground.
2. Install blocking under the frame at the outboard ends of Installation
the four outrigger boxes.
1. If a new axle is to be installed, remove the following from
the old axle and install them on the new one.
CAUTION a. The steer cylinders.
Do not disassemble drive lines when removing them from b. The rear wheels not centered switch actuator
the crane. Dirt can enter the spline and cannot be purged. bracket (rear axle only).
In addition, the drive lines are assembled in a specific
orientation when manufactured and can easily be c. The parking brake actuator (front axle only). Refer
incorrectly reassembled. to Brake System, page 8-13.
2. Position the axle under the crane on jacks which are
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3. Disconnect and remove the drive line from the capable of handling the weight of the axle.
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applicable axle. Do not disassemble the drive lines.
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Refer to Drive Lines, page 7-34.
Tag, disconnect, and cap the hydraulic brake line at
3. Raise the axle into place and secure with the eight
attaching bolts, washers, and nuts. Torque the bolts
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according to the specifications in Fasteners and Torque
each wheel.
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Values, page 1-18.

5. Tag, disconnect, and cap the hydraulic lines to the steer 4. Install the wheels onto the axle. Refer to Wheels and
cylinders. Tires, page 8-4.
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6. On the front axle only, tag and disconnect the hydraulic 5. Connect the hydraulic lines to the steer cylinder as
line from the park brake actuator. tagged during removal.
7. On the right side of the rear axle only, tag and disconnect 6. Connect the hydraulic brake line to each wheel as
the electrical wires from the rear wheels not centered marked during removal.
switch.
7. On the front axle only, connect the hydraulic line to the
8. On machines equipped with cross-axle differential locks parking brake actuator.
remove hoses and wires from the differentials.
8. On the right side of the rear axle only, connect the
NOTE: Each tire and wheel assembly weighs electrical wires to the rear wheels not centered switch.
approximately 2400 lb (1089 kg). Refer to Rear Wheels Not Centered Switch Adjustment
9. Remove the wheels from the axle. Procedure in this section and adjust the switch.
NOTE: Each axle weighs approximately 6050 lb (2750 kg) 9. Connect the drive line to the applicable axle. Refer to
with oil. Refer to Wheels and Tires, page 8-4. Drive Lines, page 7-34.
10. Position jacks, which are capable of handling the weight 10. Reconnect differential lock hoses and wires if
of the axle, under the axle for support. applicable.
11. Remove the eight nuts, washers, and bolts securing the 11. Refer to Brake System, page 8-13 and bleed the
axle to the frame/cradle. hydraulic brake system.
12. Lower the axle to the ground and remove it to a clean 12. Remove the blocking under the outrigger beams and
working area. retract the outriggers to lower the wheels to the ground.

Wheel Alignment Check Procedure Rear Wheels Not Centered Switch

1. Check the axle for wheel alignment. The wheels are to Adjustment Procedure
be straight ahead with no toe-in or toe-out. Adjust if 1. Ensure the wheels are straight ahead.
necessary by turning the tie rod ends in the direction
necessary. NOTE: Refer to Figure 8-1 for rear wheels not centered
switch adjustment.
2. Check pre-set axle stop by turning the wheels to the
extreme left. Check the clearance between the inside of 2. Set the face of the proximity switch (1) 0.16 in (4 mm) to
the tire and the nearest object. If the clearance is less 0.24 in (6 mm) from the opening in the sensor plate (3).
than 25.4 mm (1.0 inch), adjust the axle stop to provide Tighten fasteners.
clearance. 3. Turn the rear wheels to verify proper operation. Rear
3. Turn the wheels to the extreme right and repeat step 2 Wheels Not Centered Lamp in cab should be out when
for the right side. rear wheels are centered and the sensor switch is
centered in the slot of the sensor plate. Adjust the
proximity switch in or out as needed.
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2
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3
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0.24 REF
(6 mm)
6128
FIGURE 8-1
Item Description 8
Item Description 2 Switch Mounting Bracket
1 Proximity Switch 3 Sensor Plate

WHEELS AND TIRES Mounting Wheel Assemblies

NOTE: Do not lubricate the wheel studs or lug nuts.
1. Raise the crane on outriggers so the wheels are off the
WARNING ground.
Possible equipment damage and/or 2. Install the wheel assembly on the mounting studs. Install
personal injury! the lug nuts and tighten them to 50 lb-ft (68 Nm) in the
sequence shown in (Figure 8-2).
Driving the crane with a tire under inflated at 80% or less
of its recommended pressure can cause the wheel and/or 3. Ensure the wheel assembly is properly on the hub.
tire to fail. Per OSHA Standard 1910.177(f)(2), when a tire
4. Torque the lug nuts to 450 to 500 lb-ft (610 to 678 Nm) in
has been driven under inflated at 80% or less of its
the sequence shown in (Figure 8-2).
recommended pressure, it must first be completely
deflated, removed from the axle, disassembled, and 5. Lower the crane onto its tires. Retract and stow the
inspected before re-inflation. outrigger assemblies and the floats.
6. Road test the tire, then retorque to 450 to 500 lb-ft (610
Description to 678 Nm). Maintain proper torque on wheel lugs and
check for proper wheel mounting. Retorque the lug nuts
after about an hour of travel after the wheels are
CAUTION removed and reinstalled. This will reseat the lug nuts.
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Do not mix tires and rims of different manufacturers.
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Check the torque every 250 hours for normal crane
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Each wheel assembly (tire and rim) is mounted on the
planetary hub with 24 grade 8 lug nuts.
operation and more frequently if the crane does a lot of
roading/travel or frequent on-rubber lifting.
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NOTE: The tire diameters, widths, and weights may vary

slightly depending on the tire manufacturer.
Off-highway tires are designed to operate with a certain
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sidewall deflection or bulge. Correct air pressure ensures
prior deflection which, in turn, ensures proper traction,
flotation, support of load, and prevents excessive flexing of
the tire. Over inflation increases rim stresses, which results
in lowered rim life.
Refer to and adhere to the inflation pressures in the Load
Chart in the crane cab.
Maintenance
DANGER 6126
Do not attempt to demount or mount tires without proper
training. The high pressures involved can cause tire and FIGURE 8-2
rim parts and tools to fly with explosive force, if proper
procedures are not used, causing severe injury or death
to personnel and damage to the crane and surrounding
area.

STEERING SYSTEMS control valve and two steer cylinders. A rear steer indicator
system is provided to indicate when the rear wheels are not
Description centered. This system consists of an indicator light in the
ECOS display and a switch located on the right side of the
To maximize maneuverability, the crane can be steered by rear axle. When the rear wheels are turned to the left or right,
the front axle, the rear axle, or by the front and rear axles the red indicator will illuminate.
simultaneously. The crane utilizes two separate steering
systems, one to control front axle steering and one for rear Theory of Operation
axle steering.
Front Steering System
Hydraulic fluid flow from pump number 2 flows through port 3
The front steering system consists of a hydraulic pump, load of the hydraulic swivel to the steer/brake accessory manifold.
sense steer priority flow divider valve, load sense steering Regulated flow from the steer priority flow divider valve is
control valve, and two steer cylinders. The hydraulic pump is routed to the front steering control valve upon turning of the
driven by the engine and supplies a hydraulic flow of 33.0 steering wheel and pressurizing of the load sense line. The
gpm (125 l/min) to the load sense steering priority flow front steering control valve routes the oil to the appropriate
divider. The load sense steer priority flow divider valve ends of the front steer cylinders to turn the wheels in the
provides 0 to 18.5 gpm (0 to 70 l/min) to the front steering desired direction.
control valve and 14.5 to 33.0 gpm (55 to 125 l/min) to the
swing system. When the steering wheel is turned, the load Rear Steering System
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sense steering control valve sends a load sense signal to the
Hydraulic flow from the second section of pump number 2 is
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load sense steer priority flow divider. As the load sense
directed to the integrated outrigger/rear steer valve. When
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pressure increases, the priority flow divider spool shifts to
direct oil from the hydraulic pump to the steering control
the Rear Steer Control Switch in the cab is positioned to left
(L) or right (R), a signal is sent to the rear steer solenoid,
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valve, and to direct oil from the L port and R port of the
shifting the control valve spool, routing the supply pressure
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steering control valve to the steer cylinders.

to the appropriate ends of the rear steer cylinders to turn the
Rear Steering System wheels in the desired direction.
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The rear steering system is controlled through a section of
the integrated outrigger/rear steer valve and consists of the

Maintenance
Table 8-1
Troubleshooting

1. Hard to steer left and right. a. Hydraulic fluid low. a. Check system for leaks. Make
repairs as needed. Fill
reservoir.
b. Clogged or loose hydraulic b. Clean or tighten lines or
lines or fittings. fittings.
c. Defective flow divider c. Repair or replace valve(s).
valve(s).
d. Defective steering control d. Repair or replace valve. Refer
valve. t o yo ur M a ni to w oc C r a ne
Care Parts Manual.
e. Defective hydraulic pump. e. Repair or replace pump.
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2. Hard to steer either left or right. a. Clogged or loose hydraulic a. Clean or tighten lines or
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lines or fittings.
Defective steer cylinder. b.
fittings.
Repair or replace cylinder.
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3. Steering is erratic left and right. a. Hydraulic fluid low. a. Refill hydraulic reservoir.
Refer to Lubrication, page 9-1.
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c. Defective steering control c. Repair or replace valve.
valve.
d. Defective hydraulic pump. d. Repair or replace pump.
4. Noisy hydraulic pump caused by a. Hydraulic fluid low. a. Check system for leaks. Make
cavitation. repairs as needed. Fill
reservoir.
b. Suction line plugged or too b. Clean line and check for size.
small.
5. Hydraulic pump shaft seal a. Worn shaft seal. a. Replace shaft seal. Refer to
leakage. your Manitowoc Crane Care
NOTE: If replacing the shaft seal
Parts Manual.
does not stop leakage, the
pump should be
disassembled and checked
for the following:
b. Broken diaphragm seal or b. Replace seal or gasket.
backup gasket.
c. Bearing out of position. c. Replace bearing.
d. Excessive internal wear. d. Replace pump.

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

system relief pressure. Adequate oil flow under all
A periodic functional check of the power steering system will
conditions can best be checked by timing the full travel
generally be adequate to ensure satisfactory service.
of the cylinder with the steered axle unloaded and
1. Check all fittings for leakage. An accumulation of moist, loaded. If there is a great difference at low engine speed
black dirt is a good indication of leakage. and slight difference at high engine speeds this may
indicate a defective pump. Adequate oil pressure can
2. Turn the steering wheel through the full range with the only be determined by connecting a pressure gauge
engine running at both idle and full throttle. Do this with (3500 psi [24 MPa] full scale recommended) at the
the machine stationary and moving. Note any speed swing control valve bank pressure gauge test port. With
irregularities and sticky sensation. This may indicate dirt the engine running at a medium speed, turn the steering
in the fluid. If the steering wheel continues to rotate wheel to one end of the travel and hold the cylinders at
when started and released, a condition known as the travel limit briefly, just long enough to read the
motoring exists. This may also indicate dirt in the pressure gauge. Never hold the system at relief
system. pressure for more than a few seconds at a time. The
3. Ensure the system has adequate power. If there is an pressure gauge should indicate 2500 psi (17.2 MPa).
indication of hard steering, this can be caused by either
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Rear Steering System
Table 8-2
Troubleshooting
1. Rear steering inoperative. a. Hydraulic fluid low. a. Check system for leaks. Make
reservoir.
b. Clogged, broken, or loose b. Clean, tighten, or replace
hydraulic lines or fittings. lines or fittings.
c. Steer cylinder locked. c. Repair or replace cylinders.
Refer to your Manitowoc
Crane Care Parts Manual.
d. Defective control valve. d. Repair or replace valve.
e. Defective steer cylinder(s). e. Repair or replace cylinder(s).
f. Lack of electrical signal f. Check electrical connections/
wiring.
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2. Hard to steer left and right. a. Hydraulic fluid low. a. Check system for leaks. Make
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reservoir.
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valve.
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e. Clogged or loose hydraulic e. Clean or tighten lines or
f. Defective steer cylinder. f. Repair or replace cylinder.
g. Damaged relief. g. Replace relief valve.
3. Steering is erratic left and right. a. Hydraulic fluid low. a. Check system for leaks. Make
reservoir.
valve.

Hydraulic Pump rear steer circuit. The valve is mounted on the rear of the
carrier frame front cross member.
Pump #2
The inlet section of the valve contains two solenoid valves
Pump #2 provides the hydraulic flow necessary to power the and two relief valves. The solenoid valve is normally open,
front and rear steer cylinders, the outrigger circuit, the front bypassing oil to the reservoir. Operation of either system
and rear pairs of outrigger box pin cylinders, and the rear energizes the solenoid valve to close it and route oil to the
axle oscillation lockout system. The pump is a piston type applicable circuit.
pump, it provides a flow of approximately 46.7 gpm (177 l/
The valve also contains four three position four-way solenoid
min).
valves that control the following:
Front Steering Control Valve • The rear steer solenoid valve is controlled by the Rear
Steer Switch in the operator’s cab through port RSA and
Description RSB of the valve.
The steering control valve is located under the dash and is • The removal pin solenoid valve for the front outrigger
actuated by a conventional steering wheel and steering box is controlled by the Pin Unlock Switch in the
column, providing precise, full hydraulic steering. Precise outrigger control box in front of the left front fender
steering is accomplished by a metering system within the through ports A1 and B1 of the valve.
valve that is directly connected to the steering column and
wheel. • The removal pin solenoid for the rear outrigger box is
controlled by the Pin Unlock Switch in the outrigger
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Maintenance control box behind the right rear fender through ports A2
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and B2 of the valve.
Removal
1. nl c
Thoroughly clean the steering control valve and the
• The outrigger section solenoid valve is controlled by the
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Extend/Retract Switch on the ECOS display through
surrounding area before removing the hydraulic hoses
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ports A and B of the valve.

from the valve.
The valve also contains double pilot operated check valves
2. Tag and disconnect the five hydraulic hoses from the
in the rear steer and outrigger lines.
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steering control valve. Cap or plug each hose and the
five ports of the valve. Maintenance
3. Remove the capscrews, lockwashers, and flat washers Removal
securing the valve to the bracket and the steering
column. Remove the control valve, leaving the steering 1. Tag and disconnect the electrical connectors to the
column in the cab. integral outrigger/rear steer valve.
Installation 2. Tag and disconnect the hydraulic lines to the integrated

outrigger/rear steer valve. Cap or plug the lines and
1. Position the control valve to the bracket and steering ports.
column and install the flat washers, lockwashers, and
c a p s c r e w s . To r q u e t h e b o l t s a c c o r d i n g t o t h e 3. Remove the capscrews, nuts and washers securing the
specifications in Fasteners and Torque Values, page integrated outrigger/rear steer valve to the carrier frame.
1-18. Remove the valve as a complete assembly.
2. Connect the five hydraulic hoses to the control valve as Installation

tagged during removal.
3. Start the engine and check for proper operation and any
1. Position the integrated outrigger/rear steer valve on the
frame. Secure the valve with the capscrews, nuts and
8
leakage. w a s h e r s . To r q u e t h e b o l t s a c c o r d i n g t o t h e
specifications in Fasteners and Torque Values, page
Integrated Outrigger/Rear Steer Control 1-18.
Valve 2. Connect the hydraulic lines to the integrated outrigger/
rear steer valve as tagged during removal.
Description
3. Connect the electrical connectors to the integrated
The integrated outrigger/rear steer valve directionally
outrigger/rear steer valve as tagged during removal.
controls the outrigger circuit, outrigger pin circuit, and the

Functional Check to the specifications in Fasteners and Torque Values,

page 1-18.
1. Cycle each outrigger cylinder several times. Verify each
cylinder extends and retracts properly. 3. Connect the hydraulic lines to the cylinder as tagged
during removal.
2. Activate the rear steer function and steer to the left and
right several times. Verify the crane steers properly in 4. Operate the steering system and check the cylinder for
both directions. proper operation and any leakage.
3. Check the valve and lines for leakage. Make repairs as Rear Axle Oscillation Lockout System
needed.
NOTE: For further information on the integrated outrigger/ Description
rear steer valve, refer to Outrigger/Rear Steer/ The rear axle oscillation system (Figure 8-3) consists of two
Outrigger Box Pin Removal Valve, page 2-40. lockout cylinders, a lockout valve, an axle oscillation relay,
and an area definition potentiometer. The lockout cylinders
Steer Cylinders are mounted between a cradle (fifth wheel) and the carrier
frame. The lockout valve is mounted on the left inner center
Description
frame rail and hydraulically controls the oscillating abilities of
The steer cylinders are mounted on the axles, two cylinders the lockout cylinders.
on each axle. The barrel end of each cylinder is attached to
the axle housing and the rod end is attached to the steering Theory of Operation
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lug on the axle end. The front steer cylinders are controlled The rear axle is mounted on a cradle (fifth wheel) allowing
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hydraulically by the front steer control valve through the steer maximum oscillation of 10 in (25 cm) total while traveling
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directional valve. The rear steer cylinders are controlled by a
solenoid valve located in the integrated outrigger /rear steer
over uneven terrain. Oscillation is provided only when the
superstructure is within 6 degrees left or right of directly over
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valve. the front. When the superstructure is within 6 degrees left or
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right of directly over the front, the area definition

Maintenance
potentiometer energizes the axle oscillation relay which in
NOTE: For Disassembly and Assembly procedures, refer turn energizes the solenoids on the lockout valve. When the
er
to Cylinders, page 2-68. solenoids are energized, the valve spools are shifted to allow
hydraulic transfer between the two lockout cylinders.
Removal
As one side of the axle is forced up by traveling over uneven
1. Tag and disconnect the hydraulic lines going into the terrain, the hydraulic fluid flows from the rod end of cylinder A
steer cylinder. Cap or plug all openings. to the barrel end of cylinder B and from the rod end of
2. Remove the capscrew, flatwasher, and lockwashers cylinder B to the barrel end of cylinder A (Figure 8-4). The
securing each pin weld in the rod end and barrel end of system is not pressurized and oil is moved from one cylinder
the cylinder. to the other by the action of the axle moving the cylinder.
NOTE: Steer cylinder weighs approximately 44 lb (20 kg). When the superstructure is more than 6 degrees left or right
of directly over the front, the area definition potentiometer
3. Remove both pin weldments and two thrust washers de-energizes the axle oscillation relay. This de-energizes the
(rod end only), and remove the cylinder from the axle. solenoids on the lockout valve and allows the springs in the
Installation valve to shift the valve spools to the closed position to
prevent hydraulic fluid flow between the cylinders. By
1. Position the cylinder onto the attachment fittings on the stopping the flow of oil, a hydraulic lock is created and the
axle and install both pin weldments. On the rod end, axle is held rigid in that position.
install a thrust washer on the top and bottom of lug.
2. Secure each pin weldment with the capscrew,
flatwasher and lockwasher. Torque the bolts according

3
3
1 1 1
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FIGURE 8-3
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Item nl c Description Item Description
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1 Carrier Frame 3 Oscillation Lockout Cylinder

2 Fifth Wheel
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Pump Supply
Axle Lockout Valve
Lockout Cylinders
REAR AXLE
FIGURE 8-4

Axle Oscillation Lockout Cylinders 6. Install the wheel and tire assembly on the axle. Tighten
the lug nuts using the procedure under Wheels and
Description Tires, page 8-4.
Two 7.0 in (17.8 cm) hydraulic lockout cylinders are installed 7. Lubricate both ends of the cylinder using the fittings
on the rear axle, one left side and one right side. The barrel provided.
end of each cylinder is attached to each side of the carrier
8. Function test the axle oscillation system. Refer to
frame and the rod ends are attached to each side of the
Section 3, Operating Controls and Procedures in the
cradle (fifth wheel).
The lockout cylinders are connected hydraulically so that
hydraulic fluid flows from the rod side of the left cylinder to Axle Oscillation Lockout Valve
the barrel side of the right cylinder and from the rod side of
the right cylinder to the barrel side of the left cylinder. Description
Each cylinder weighs approximately 192 lb (87 kg). The axle oscillation lockout valve, also called the double
solenoid valve, is used in the rear axle oscillation lockout
Maintenance circuit. The valve consists of a valve body and two solenoid
valves, which keep the lockout cylinders from oscillating
NOTE: For disassembly and assembly procedures, refer
unless the superstructure is within 6 degrees left or right of
to Axle Oscillation Lockout Cylinder, page 2-70.
directly over the front. The lockout valve is located on the left
Removal side of the frame in front of the front rear axle cross member.
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1. Raise the crane up on outriggers. When the superstructure is within 6 degrees left or right of
2.
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Rotate the turntable more than 6 degrees in either
direction from directly over the front to lock out the
directly over the front, the area definition potentiometer
energizes the axle oscillation relay which energizes the
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solenoids on the axle oscillation lockout valve. This allows
oscillation cylinders.
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hydraulic fluid to flow in and out of the lockout cylinders,

3. Remove the wheel and tire assembly from the axle. allowing the axle to oscillate.
Refer to Wheels and Tires, page 8-4.
When the superstructure is more than 6 degrees left or right
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4. Tag and disconnect both hydraulic hoses from the ports of directly over the front, the area definition potentiometer
on the cylinder. Cap or plug both hoses and the ports on deenergizes the axle oscillation relay which deenergizes the
the cylinder. solenoids on the axle oscillation lockout valve. This keeps
the axle from oscillating because hydraulic fluid cannot leave
5. At the rod end of the cylinder, remove one of the cotter the cylinders.
pins securing the retaining pin to the cradle attach fitting.
6. Tap out the retaining pin, freeing the rod end from the Maintenance
cradle. Removal
7. At the barrel end of the cylinder, remove one of the cotter 1. Tag and disconnect the electrical connector to the valve.
pins securing the retaining pin to the frame attach fitting.
2. Tag and disconnect the hydraulic hoses from the valve.
8. Tap out the retaining pin and remove the cylinder. Cap or plug the lines and ports.
Installation 3. Remove the two capscrews, nuts and washers securing
the valve to the carrier frame.
1. Position the barrel end of the cylinder in the frame attach
fitting and install the retaining pin. Installation
2. Secure the retaining pin with the cotter pin. 1. Secure the valve to the carrier frame using two
capscrews, washers and nuts. Torque the bolts
3. Align the rod end of the cylinder in the cradle attach
according to the specifications in Fasteners and Torque
fitting and install the retaining pin.
Values, page 1-18.
4. Secure the retaining pin with the cotter pin.
2. Connect the hydraulic hoses to the applicable valve
5. Remove the caps or plugs from the two hydraulic hoses ports as tagged during removal.
and the cylinder ports and connect the hoses to the
3. Connect the electrical connector to the valve as tagged
appropriate cylinder ports as tagged during removal.
during removal.

4. Function test the axle oscillation system. Refer to brake valve which modulates the brake line pressure to the
Section 3, Operating Controls and Procedures in the brake assemblies at each wheel.
Hydraulic fluid from hydraulic pump number 2 flows to swivel
5. Check the valve and hoses for signs of leakage. Tighten port 3 to the steer/brake/load sense accessory manifold and
fittings as required. then to the dual accumulator charge valve. The dual
accumulator charge valve charges the accumulators from
BRAKE SYSTEM the open center circuit upon demand and within its present
operating charge rate and the high limit pressure setting.
Description When the open center circuit pressure reaches the brake
relief setting, which is higher than the high accumulator
The brake system includes all the components necessary for charge limit, the accumulators will be charged to the
the application of the service brakes and the parking brake. regulated maximum pressure setting. The dual accumulator
charge valve regulates flow to the hydraulic accumulators to
Service Brakes
provide fully powered independently separate, primary
The service brakes are full power hydraulic disc brakes (front) and secondary (rear), service brake circuits. Hydraulic
which are hydraulically controlled and are used to apply the pressure is constantly maintained in the brake circuits by the
brake assemblies on all four wheels. The system consists of accumulators and the charging valve. The charged
the tandem brake valve with treadle pedal, the dual accumulators supply pressurized fluid to the closed tandem
accumulator charge valve, two hydraulic accumulators, the brake valve.
brake assemblies, and all the associated hoses and tubing.
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After the accumulators are fully charged, the high limit check
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The operator depresses the pedal on the tandem brake opens and all of the pump flow is directed to the excess flow
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valve, located on the cab floor, and the valve modulates the
brake line pressure to the brake assemblies at each wheel.
port and on to the front steer and swing circuits. When
pressure to the steering or swing circuit becomes greater
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The full powered brake system supplies a high brake system than accumulator pressure, the main check valve opens and
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pressure with relatively low reactive pedal forces, while charges the accumulator without the aid of the charging
controlling the maximum brake line pressure. The service valve. In this condition, the maximum accumulator pressure
brake dual accumulator charge valve regulates flow to the i s t he bra k e c ir c ui t r e l i ef v a lv e s e tt i ng of 2 4 90 ps i
(17,168 kPa).
er
hydraulic accumulators to provide fully powered
independently separate, primary (front) and secondary
Once the operator depresses the brake pedal, the tandem
(rear), service brake circuits. Hydraulic pressure is
brake valve modulates fluid out to the brakes to provide the
constantly maintained in the brake circuits by the
means of braking. The tandem brake valve will modulate the
accumulators and the charging valve.
pressure in the brake system by increasing or decreasing
NOTE: For Description and Maintenance of the tandem pressure as required in proportion to the input force from the
brake valve with treadle pedal, the accumulators, operator via the brake pedal. The hydraulic force acts within
and the dual accumulator charge valve, refer to the brake assemblies to force the brake pads against the
Valves, page 2-37. brake discs, acting to slow wheel rotation. Fully powered
separate primary (front) and secondary (rear) braking circuits
Parking Brake are provided with independent accumulators. A low pressure
The parking brake is a hydraulic release, spring apply, warning switch is used to sense the accumulator pressures
disc-type brake, located on the front axle. The system and warn the operator through visual brake warning indicator
consists of a two-position switch, a three-way solenoid valve, light on the cab console in the event the pressure in the
actuator, two brake assemblies, and all the associated accumulators drops to an unsafe operating level. In the
hardware and tubing. The selector switch, located on the event of engine failure, the accumulators are pre-charged
with dry nitrogen gas and properly sized to provide power-off
8
steering column, is used to activate the solenoid valve which
controls the park brake actuator, which applies and releases stopping capacity for secondary braking.
the park brake. There are two brake actuators on the front
Parking Brake
axle.
Hydraulic flow from the transmission charge pump is routed
Theory of Operation to the parking brake control valve. When the Park Brake
Switch is in the ON position, the parking brake solenoid valve
Service Brakes shifts to route flow from the hydraulic parking brake actuator
Braking begins when the operator depresses the brake back to the transmission sump. The actuator spring pulls on
pedal in the cab. Mechanical linkage transfers the force the lever on the brake assembly, applying the parking brake.
created by the lever action of the brake pedal to the hydraulic

Maintenance
Troubleshooting
Table 8-3

1. Brakes are poor. a. Lining thickness less than a. Replace lining.
0.125 in (3 mm).
b. Brake pedal operation. b. Free mechanical linkage.
c. Restriction or leaks in lines. c. Check all lines for leaks and
restrictions.
d. Low hydraulic fluid flow. d. Check the hydraulic fluid level
in reservoir and check flow
from the tandem brake valve.
e. Air in brake lines. e. Bleed the brakes.
f. Brake pads/linings are f. Replace pads/linings.
grease-soaked.
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g. Engine not running. g. Start engine. Due to the
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operation, the engine must be
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power.
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h. Brake relief valve stuck open. h. Replace the relief valve. Refer
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t o yo ur M a ni to w oc C r a ne
Care Parts Manual.
er
i. Dual accumulator charge i. Check valve operation and
valve not charging repair or replace valve.
j. Accumulators not j. Check accumulator
pre-charged. pre-charge.
2. Hard brake pedal with engine a. Pedal travel being interfered a. Check all pedal linkage and
running. with. ensure it is free and adjusted
properly.
3. Brakes lock up. a. Too much hydraulic flow. a. Check the flow from the flow
divider. Too much flow will
cause the brakes to be
applied by the oil trapped in
the power boost chamber.
b. Brake pedal push rod b. Adjust the push rod linkage so
improperly adjusted, causing the brake pedal and push rod
brakes to be always applied. fully return.
4. Uneven braking or pad wear. a. Lining thickness less than a. Replace the lining.
0.125 in (3 mm).
b. Grease on the pads/linings. b. Replace the pads/linings.

General Hydraulic pressure, entering the brake via a port in the

cylinder insert (6), causes the pistons (4) and, in turn, the
A schedule for the periodic adjustment, cleaning, inspection,
brake pads (2) to move toward each other until solid contact
and lubrication of brake equipment should be established by
is made with the brake disc. When braking is completed, the
the operator on the basis of past experience and severity of
elasticity of the sealing rings (5) forces the pistons back in to
operation.
the caliper, allowing the brake pads to separate from the
The disc brakes are not adjustable. Brakes should be brake disc, retracting to their neutral / starting position.
cleaned, inspected, and linkage lubricated periodically to (roll-back-effect). The exterior cylinder inserts are feeding
assure maximum performance. and bleeding over an internal connecting bore.
Bleeding the Brake System Maintenance

The brake system should be bled whenever air becomes Brake Pad Replacement
entrapped within the brake system (usually characterized by
a spongy feeling during brake pedal application), whenever
any brake system line has been opened, or whenever any Only brake pad materials recommended and approved by
brake component has been replaced. the brake or vehicle manufacturer are to be used.
Always start at the point in the system that is furthest from Brake pads must be replaced when worn to less than .088 in
the tandem brake valve and work back toward the tandem (2mm) thickness. Brake pads must not be replaced on a “per
brake valve. Bleed every bleeder screw on every caliper/ brake“, but always on a “per-axle“ basis, in order to prevent
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actuator on every wheel. When you complete a bleeder different performances. In case of pad changing you should
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screw, go to the next closest bleeder screw on the same always check the disc thickness of the brake disc and as
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caliper/actuator. When you complete a wheel, go to the
furthest bleeder screw on the next closest wheel.
soon as heavy furrows appear, or the minimum of the disc
thickness, indicated by the vehicle manufacturer fall below,
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you should replace or machine them, appropriate to the
Service Brakes machining instruction.
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Description 1. Recommended Replacement Procedure Remove cover

(3).
er
The brakes utilized are hydraulic disc-type brakes. Two
brake assemblies are used at the end of each axle. The 2. Dismantle lining pad (2). With assistance of a screw
action of the brake pads riding against the brake discs acts to driver.
slow the rotation of the wheels. 3. Check dust caps (8) for damage and watch for brake
Figure 8-5 shows a 4 piston fixed caliper hydraulic disc fluid leaks. Replace dust cap as described in the
brake. In the one piece caliper (1) (Figure 8-6), the brake following section.
pads (2) are secured by a cover (3), against coming loose. 4. Push back brake pads in to cylinder. For this open
Every piston belongs to a lining pad. Every piston (4) is bleeder valve and connect hose, drain the displaced
assembled in cylinder inserts, which have been screwed in brake fluid into a suitable container for disposal. Do not
the caliper (1) individually removable. The square sealing reuse brake fluid.
ring (5) forms a hydraulic seal around the piston whereas the
sealing ring (7) forms a hydraulic ring around the cylinder 5. Clean the brake pad cavity of the caliper (1), taking care
insert (6). The pistons are protected, from dirt entering, by not to damage the dust caps (8).
the dust cap (8). 6. Insert new brake pads (2).
7. Install cover with screws (3).
8

8. Recharge the brake actuating system with brake fluid

and bleed according to the vehicle manufacturers
recommendations and specifications. Actuate the brake
pedal after assembling several times, thus the brake pad CAUTION
can be adjusted to the disc thickness. Afterwards you 145 psi (10 bar) pressure corresponds to a piston force of
have to check the level of brake fluid in the reservoir and 1349 lbf (6000N).
to make inspection for leakages, function and brake
performance. 7. Remove seal rings (5).
8. Clean pistons (4) and the piston bores of the caliper (1)
with alcohol or other suitable, solvents, not based on
mineral oil.
9. Inspect the piston walls (4) for damage and replace if
defective DO NOT REPAIR. Repair scratches in the
piston bores of the caliper by honing the walls with
emery cloth (320 grit minimum).
10. Lubricate new piston seals (5) with silicon paste “P4 soft“
(Wacker Chemie) and install. Lubricate piston bore walls
between seals (5) and dust caps (8) with silicon paste „
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P4 soft“.
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11. Install new dust caps (8) on pistons (4).
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12. Lubricate the piston wall (4) between seal (5) and
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Seal Replacement bottom of piston, with silicon paste “P4 soft“.
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All seals must be replaced after 2 years, during the third 13. Install the pre-assembled piston (4) with dust cap (8).
brake pad change or when the dust caps (8) have become 14. Using a steel mounting ring, press in the dust caps (8).
damaged.
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In case of seal replacement exchange all seal parts of the

caliper. CAUTION
Take care not to twist the dust caps (8) during installation.
Mineral oil resistant versions contain a green colored
marking and a stamped “M“. 15. Install the cleaned cylinder insets (6) with new O-rings
Brake fluid is not allowed to be filled in to the mineral oil (7) and tighten according to the following instruction:
resistant caliper, because of the swelling of the seal parts a. Tighten all screws including an assembling torque of
and the failing of the brakes. All mineral oil resistant seal 22 lb-ft (30Nm), then tighten crossover to 37 lb-ft (50
parts have been green colored, or marked with a green spot. ±5 Nm).
Recommended Replacement Procedure
b. Lubricate the outside of the cylinder inserts with
1. Disconnect hydraulic line. silicon paste “P4 soft“, before assembling in order to
prevent corrosion.
2. Remove cover (3)
3. Remove brake pads (2).
CAUTION
4. Dismantle cylinder inserts (6) (remove the complete
Do not change position of bleeder valves.
caliper (1), if necessary).
5. Remove the dust caps (8). 16. Insert brake pads (2).
6. Remove the piston (4) out of the cylinder inserts (6), by
pressurizing the caliper with compressed air. Close the
CAUTION
vacant holes in a suitable way, at the same time.
If brake pads are worn down to thickness of nearly 0.088
in (2mm) also change them according to the previous
procedure.
17. Install cover (3).

18. Refill and charge the brake actuating system in

accordance with vehicle manufacturers specifications
Item Description
and recommended procedures.
1 Caliper
2 Brake Pads
3 Cover
4 Piston
7
5 Square Sealing Ring
6 Cylinder Insert
7 Sealing Ring
3 8 1 6
8 Dust Cap
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6 4 5 2
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FIGURE 8-6

Parking Brake journal bearing (23). A welded bracket on the cap assembly
supports the actuator (13) secured with two each nuts (11)
Description and lock washers (12).
The Series of brake head assemblies covered by this The slack adjuster (15) is attached to the splined end of the
manual consists of a caliper (7) (Figure 8-7), a manual or power screw shaft (19) which protrudes from the cap
automatic slack adjuster (15), and a hydraulic spring assembly (22). A packing (18) is seated against the journal
actuator (13). bearing (23) in the cap assembly. A flat washer (16) and a
wave spring washer (17) are installed on the power screw
The caliper (7) houses two lining and carrier assemblies (1),
shaft between the cap assembly and slack adjuster. A
a piston assembly threaded to a power screw shaft (19), and
retaining ring (14) secures the slack adjuster on the splined
a piston seal (5) installed in an ID groove in the caliper. The
end of the power screw shaft.
seal helps to align the piston assembly in the caliper and
prevents contamination of the piston bore area. A yoke (10) attaches the slack adjuster (15) to the actuator
(13) with a yoke pin (9) secured with a cotter pin (8). A boot is
A cap assembly (22), fastened to the caliper (7) with four
fitted to protect the piston rod of the actuator.
each bolts (2) and washers (3), supports the power screw
shaft (19) seated on a thrust bearing (20) and a press-fitted
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FIGURE 8-7
Operation transmitted force moves the piston assembly forward against

the lining and carrier assembly (1) until it presses against the
The hydraulic/spring caliper is actuated by dumping
disk.
(releasing) the hydraulic pressure in the actuator (13),
releasing the compressed spring in the actuator. The spring Releasing the brake allows hydraulic pressure to re-enter the
pushes the yoke (10) and slack adjuster (15) arm down, actuator (13) compressing the actuator spring and retracting
turning the attached power screw shaft (19) that is threaded the attached components discussed in the previous
into the piston assembly (6) housed in the caliper (7). This paragraph.

Maintenance h. Uncage spring actuator (13) after completing brake

clearance adjustment.
1. Inspect brake for loose or missing attaching hardware
(bolts, nuts, cotter pins, retaining rings, boot, etc.).
Tighten and replace when necessary.
2. Inspect lining and carrier assemblies (1) for worn lining CAUTION
material. Replace if lining thickness is (3.2 mm) or less.
Uncage actuator slowly to avoid injury.
See replacement below.
3. Replace lining and carrier assemblies (1) as follows: Caliper Overhaul and Seal Replacement
1. Remove caliper (7) from vehicle.
a. Support or block vehicle to prevent vehicle
WARNING movement.
Failure to replace linings when worn to limits will result in b. Apply brake pressure and mechanically cage
loss of braking and possible catastrophic failure. actuator (13) to release slack adjuster (15) tension.
Dump air- or hydraulic pressure from actuator after
a. Support or block vehicle to prevent vehicle caging.
movement.
b. Apply brake pressure and mechanically cage
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actuator (13) to release slack adjuster (15) tension.
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Dump air- or hydraulic pressure from actuator after WARNING
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caging. Do not proceed with removal procedure until actuator (13)
is securely caged as personal injury could result from
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accidental application of brake.
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WARNING c. Back-off slack adjuster (15) by rotating the

adjustment screw counterclockwise with a wrench
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Do not proceed with removal procedure until actuator (13)
until it stops turning.
is securely caged as personal injury could result from
accidental application of brake. d. Remove the caliper (7) from the vehicle support
bracket.
c. Back-off slack adjuster (15) by rotating the
2. Separate yoke (10) from slack adjuster (15) by removing
adjustment screw counterclockwise with a wrench
cotter pin (8) and yoke pin (9).
until it stops turning.
3. Dismount actuator (13) from cap assembly (22) bracket
d. Remove the caliper (7) from the vehicle support
by removing nuts (11) and washers (12) from actuator
bracket.
studs.
e. Remove worn lining and carrier assemblies (1) and
4. Remove retainer ring (14) from power screw shaft (19).
replace.
5. Slide slack adjuster (15) from power screw shaft (19).
f. Position caliper (7) over disk with a lining and carrier
assembly (1) on each side of the disk. 6. Remove and discard packing (18), flat washer (16) and
wave spring washer (17) from power screw shaft (19).
g. Perform adjustment for manual slack adjuster by
rotating adjustment screw clockwise until lining 7. Remove bolts (2) and washers (3) from cap assembly 8
assembly (1) is tight against disk assembly. Back off (22).
adjustment screw one full turn. Rotate adjustment
8. Remove as a unit the power screw shaft (19), piston
screw until a total clearance of .04 - .06 in (1.0 - 1.5
assembly (6) and cap assembly (22) with welded on
mm) is obtained between lining and disk.
bracket from caliper (7).
To adjust automatic slack adjuster, refer to section
5. 9. Slide power screw shaft (19) and piston assembly (6)
from cap assembly (22).
NOTE: Reduced running clearances caused by backing off
adjuster less than that outlined in step g may cause 10. Unscrew piston assembly (6) from power screw shaft
dragging brake which may result in significantly (19).
reduced lining life and/or brake failure.

11. Remove and discard thrust bearing (20) from power 24. Slide slack adjuster (15) on power screw shaft (19)
screw shaft (19). aligning slack adjuster arm with yoke (10).
12. Remove and discard piston seal (5) from caliper (7). NOTE: Verify adjustment screw faces away from actuator
(13). If not, remove slack adjuster (15) from power
13. Thoroughly clean all parts. Inspect journal bearing (23)
screw shaft (19) and reassemble to screw shaft
in cap assembly (22) for wear. Journal bearing ID may
with opposite face first.
not exceed 1.51" (38.35 mm). If excessively worn,
replace cap assembly. 25. Install spline washer (automatic slack adjusters only) not
shown.
14. Inspect all brake parts for damage, cracks, excessive
wear or scoring. Replace parts as required. 26. Install retainer ring (14) on power screw shaft (19).
15. Install new piston seal (5) into caliper (7). 27. Secure yoke (10) to slack adjuster (15) with yoke pin (9)
and cotter pin (8).
16. Apply grease (Lubricate Aero or equivalent) to flat face
of new thrust bearing (20). 28. Complete assembly and brake clearance adjustment:
17. Install and seat new thrust bearing (20) over splined end a. Perform adjustment for manual slack adjuster by
of power screw shaft (19) with greased side of thrust rotating adjustment screw clockwise until lining
bearing against thrust collar of power screw shaft. assembly (1) is tight against disk assembly. Back off
adjustment screw one full turn. Rotate adjustment
NOTE: Insure correct installation of thrust bearing (20) by
screw until a total clearance of .04 - .06 in (1.0 - 1.5
verifying that installation was made over the larger
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mm) is obtained between lining and disk.
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diameter end of power screw shaft (19) and that
thrust bearing l.D. lip is towards splined end of
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power screw shaft.
CAUTION
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18. Screw power screw shaft (19) into piston assembly (6) Reduced running clearances caused by backing off
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after lubricating threads with coat of Lubricate Aero adjuster less than that outlined in step a may cause
grease. dragging brake which may result in significantly reduced
lining life and/or brake failure.
19. Coat outside of piston assembly (6) with Lubricate Aero
er
grease then slide assembled power screw shaft (19) and
piston assembly into cap assembly (22), shaft end first.
20. Bolt cap assembly (22) with assembled power screw
shaft (19) and piston assembly (6) to caliper (7) using WARNING
bolts (2) and washers (3). Torque bolts to 125 - 135 ft-lbs
Uncage actuator slowly to avoid injury.
(170-185 Nm).
NOTE: Care should be taken not to push piston seal (5) b. Uncage spring actuator (13) after completing brake
out of seal groove in caliper (7) when assembling clearance adjustment.
cap assembly with piston and power screw to
caliper. Park Brake Solenoid Valve
21. Install new flat washer (16), wave spring (17) and Description
packing (18) over power screw shaft (19) with packing in
front and flat washer in middle. The park brake solenoid valve is located on the right side
frame rail in front of the rear axle. The valve is a three-way,
22. Mount brake actuator (13) on cap assembly (22) bracket two position solenoid valve. The park brake valve is used to
with nuts (11) and washers (12) and torque. See Table control the application of the crane’s spring-applied,
8-4 for torque values. hydraulically-released parking brake.
Table 8-4 Positioning the Park Brake Switch to OFF shifts the
three-way, two-position solenoid valve so hydraulic oil can
Stud Size Phosphate/Oil Cad. Plate/Wax
flow to the parking brake actuator, extending it. When the
5/8 - 11 UNG 115 - 135 Nm 75- 88 Nm actuator extends, it releases the park brake.
7/16-14 UNG 40 - 48 Nm 27- 34 Nm Positioning the Park Brake Switch to ON shifts the three-way,
two-position solenoid valve so hydraulic oil can drain from
the actuator. The parking brake actuator’s rod retracts,
23. Apply coat of Lubriplate Aero grease to mounting spline forcing hydraulic oil through the valve and the case drain
of slack adjuster (15).

manifold back to the transmission reservoir. As the actuator 3. Remove the capscrews, nuts and washers securing the
retracts, it applies the parking brake. valve to the frame. Remove the valve.
A pressure switch is installed in the line to the actuator. Installation
When the park brake is applied, a lack of hydraulic oil
1. Secure the valve to the frame and secure with the
pressure keeps the pressure switch closed, which turns on
washers, nuts and capscrews.
the red LED indicator on the switch. When the park brake is
released, pressure buildup opens the switch, which turns off 2. Connect the hydraulic lines to the valve as tagged during
the indicator. removal.
Maintenance 3. Connect the electrical connector to the valve as tagged
during removal.
Removal
4. Apply and release the park brake several times. Verify
1. Tag and disconnect the electrical connector from the the park brake holds the crane when applied. Verify the
valve. park brake doesn’t drag when released.
2. Tag and disconnect the hydraulic lines attached to the 5. Check for leaks. Make repairs as needed.
valve. Cap or plug lines and ports.
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OUTRIGGERS Theory of Operation

Description The outriggers are controlled by the ECOS display.
Activating an outrigger function causes the solenoid valve to
The outriggers, when properly extended and set, provide a open, the integrated outrigger valve spool shifts allowing flow
rigid four point platform which is capable of supporting the to either the extend or retract line as applicable. When the
crane and its maximum load capacity. The outrigger circuit extend function is activated, the flow continues through the
consists of four extension cylinders, four jack cylinders, an open solenoid valve to the piston side of the cylinder. If the
integrated outrigger/rear steer valve, front and rear outrigger jack is to be extended, the flow first unseats the cylinder
control manifolds, and pilot operated check valves. The front check valve then extends the cylinder. The oil from the rod
two extension cylinders are mounted in the front outrigger end flows through the integrated outrigger valve, and then to
beams and the rear two extension cylinders are mounted in the reservoir.
the rear outrigger beams. The front and rear outrigger beams
When the retract function is activated, the flow through the
are mounted on their respective outrigger boxes; in turn the
selector valve is directed to the rod side of the cylinder. The
jack cylinders are mounted on the end of each outrigger
oil in the piston side flows through the open solenoid back to
beam. The integrated outrigger/rear steer valve is mounted
the integrated outrigger valve. If a jack cylinder is to be
on the rear face of the carrier frame front cross member. The
retracted, then pilot pressure from the pressurized retract
front and rear outrigger control manifolds are mounted on the
line unseats the cylinder check valve allowing oil to flow from
inside center of their respective outrigger box.
the piston side through the open solenoid valve to the
The outrigger selector controls are located on the ECOS integrated outrigger valve. The integrated outrigger valve
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display. Both the integrated outrigger valve and the manifold directs the flow to the reservoir.
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solenoid valves are electrically actuated from these controls.
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The solenoid switches must be held depressed to actuate
the solenoid valve.
The integrated outrigger/rear steer valve contains three relief
valves. The main relief is set at 3000 psi (20,684 kPa).
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Thermal relief protection is provided on the extend side by a
A sight bubble level is mounted on the right side of the cab. 2000 psi (13,790 kPa) relief valve and the retract side by a
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The sight bubble level provides the operator with a visual 4000 psi (27,580 kPa) relief valve.
indication of crane level attitude.
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Maintenance
Table 8-5
Troubleshooting
1. Slow or erratic operation of a. Damaged relief valve. a. Remove relief valve; clean or
outrigger extension cylinders. replace.
b. Low hydraulic fluid level. b. Check system for leaks. Make
reservoir. Refer to Lubrication,
page 9-1.
c. Sticking solenoid valve spool. c. Repair or replace valve spool.
d. Improper ground to base of d. Ground properly.
solenoid.
e. Directional selector switch e. Clean or replace switch.
sticking.
f. Collector ring dirty or glazed. f. Clean and deglaze collector
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ring.
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h.
Damaged wiring to solenoid.
Weak brush springs on
g.
h.
Replace wiring.
Replace brush springs. Refer
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collector ring. to your Manitowoc Crane
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Care Parts Manual.

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1. Slow or erratic operation of i. Damaged extension cylinder i. Remove extension cylinder
outrigger extension cylinders. (internal parts). and repair as necessary.
(continued)
j. Bent cylinder rods. j. Replace piston rods and
seals.
k. Excessive material on k. Clean outrigger beams.
outrigger beams.
l. Binding outrigger beam. l. Repair or replace outrigger
beam.
m. Damaged outrigger valve. m. Repair or replace valve.
n. Damaged valve coil. n. Replace coil.
o. Main hydraulic pump o. Replace or tighten hose or
cavitation. fitting. Refer to your
Manual.
p. Partially shifted hydraulic p. Disassemble, clean, and
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spool in selector valve or polish spool and valve
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manifolds. housing with very fine emery
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cloth (water paper).
Solenoids require a minimum
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operation of solenoid valve. of 19 volts to energize. Check
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outrigger wiring and electrical

coupling collector rings.
r. Damaged piston seals. r. Replace all cylinder seals.
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s. Worn or damaged hydraulic s. Repair or replace pump
pump section. section.
t. Scored cylinder barrel. t. Repair or replace extension
cylinder.
u. Cracked or damaged piston. u. Replace rod weldment and all
cylinder seals.
2. Sticking spool. a. Dirt in the system. a. Change oil and flush system.
b. Distortion caused by tie bolts b. Retorque tie bolts.
being overtorqued.
c. Flow in excess of valve rating. c. Limit flow through valve to that
recommended. Check pump
output and cylinder ratio.
d. Pressure in excess of valve d. Check relief valve setting or
rating. pump compensation with that
recommended.
e. Electrical failure. e. Check wiring and solenoids.
3. External leakage. a. Damaged O-ring or quad a. Check for chipped packings
rings. and replace.
b. Loose tie bolts. b. Retorque tie bolts.
c. Damaged solenoid. c. Replace damaged parts.


4. Solenoid failure. a. No current. a. Check power source of at
least 85% of coil rating.
b. Damaged solenoid assembly. b. Replace solenoid.
c. Short in solenoid. c. Replace coil.
d. Loss of solenoid force. d. Decrease time of solenoid
energization, decrease cycle
rate.
5. Outrigger jack cylinder slow or a. Low in hydraulic fluid. a. Check system for leaks. Make
erratic. repairs as needed. Fill
reservoir.
b. Damaged main relief valve. b. Repair or replace valve.
c. Damaged holding valve seals. c. Replace holding valve seals.
d. Bent cylinder rod. d. Replace cylinder rod and
seals.
e. Bent outrigger housing. e. Repair or replace outrigger
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housing.
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g.
Excessive material on beams.
Sticking solenoid valve spool.
f.
g.
Clean outrigger beams.
Repair or replace valve spool.
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h. Damaged wiring to solenoid. h. Repair or replace wiring.
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i. Weak brush springs on i. Replace brush springs.

collector rings.
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j. Collector ring dirty or glazed. j. Clean or deglaze collector
ring.
k. Directional selector switch k. Clean or replace switch.
sticking.
a. Main hydraulic pump l. Replace or tighten hose and
cavitation. fittings.
b. Worn or damaged hydraulic m. Repair or replace pump
pump section. section.
6. Outrigger jack cylinder retracts a. Damaged piston seals. a. Replace all cylinder seals.
under load.
b. Damaged holding valve seals. b. Replace seals.
c. Damaged holding valve. c. Replace valve assembly.
d. Scored cylinder barrel. d. Repair or replace cylinder.
e. Cracked or damaged piston. e. Replace piston and all 8
cylinder seals.
7. Outrigger jack cylinder extends a. Damaged piston seals. a. Replace all cylinder seals.
while machine is traveling.
b. Scored cylinder barrel. b. Replace jack cylinder.
c. Cracked or damaged piston. c. Replace piston and seals.
d. Piston loose on cylinder rod. d. Replace seal and retorque.


8. Outrigger system will not activate a. Hydraulic fluid low. a. Check system for leaks. Make
(from stowed or extended and repairs as needed. Fill
down position). reservoir.
b. Loose or broken wire on b. Repair or replace wiring.
switch.
c. Clogged, broken, or loose c. Clean, tighten, or replace
lines or fittings. lines or fittings.
d. Damaged relief valve or d. Repair or replace valve.
damaged control valve.
9. Outrigger system activates, but a. Clogged, broken, or loose a. Clean, tighten, or replace
selected outrigger will not stow or hydraulic lines or fittings. lines or fittings.
extend and lower as desired.
b. Loose or broken wire on b. Repair or replace wiring.
control switch or solenoid
valve.
c. Damaged solenoid valve. c. Repair or replace valve.
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d. Damaged control switch. d. Replace switch.
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e. Damaged hydraulic cylinder. e. Repair or replace cylinder.
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10. Outriggers will not set. a. Improper sequence of a. Activate individual control
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activation. switch; then activate system
control switch.
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11. Two outriggers activate from a. Damaged solenoid valves. a. Repair or replace.
single control switch
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12. The two outriggers will not stow. a. Hydraulic lock. a. Recycle individual
outrigger(s).
13. Individual outrigger will not set or a. Damaged piston seals. a. Replace seals.
stow.
b. Damaged check valve. b. Repair or replace valve.
c. Loosen or broken wire on c. Repair or replace wiring.
control switch or solenoid
valve.
d. Damaged solenoid valve. d. Repair or replace valve.
14. Error codes appear during a. Outrigger electrical a. Make electrical connections
outrigger box removal.f connections unplugged. Does after outrigger box is replaced.
not influence outrigger
removal process.

Outrigger Beam of events provides for lifting and stabilizing the crane for
operation.
Description
Maintenance
The outrigger beam assembly (Figure 8-8) consists of an
outrigger beam, a jack cylinder, an extension cylinder, and Removal
the required hoses and mounting hardware. 1. On the jack cylinder end of the beam, remove the set
Theory of Operation screw from the side adjustable wear pad and back off
the wear pad from the outrigger box.
When outrigger extension is activated, it extends or retracts
the outrigger beam within the outrigger box. The outrigger 2. Remove the cover from the opposite end of the outrigger
beam can be extended to the mid-extend position by box. Remove the setscrew from the side adjustable wear
allowing the lock pin to ride on the top of the beam while it’s pad and back off the wear pad from the beam.
extending. The lock pin will automatically drop into the hole 3. Disconnect the OMS sensor, refer to OMS String
when the beam reaches the mid-extend position. Potentiometers, page 8-33.
The jack cylinder is mounted to the end of the beam and 4. Remove the setscrews from the bottom adjustable wear
applies force to the outrigger beam vertically. This sequence pads and back off the wear pads leaving approximately
0.125 in (3.2 mm) protruding.
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10
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6120
11, 12
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5, 6
11, 12
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8, 9 15, 16, 17
4
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3
1, 2
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7
3 8, 9
4
13
1, 2
13
14
7384
FIGURE 8-8


1 Retainer Pin 10 Extension Cylinder
2 Cotter Pin 11 Wear Pad
3 Extend Port 12 Setscrew
4 Retract Port 13 Jack Cylinder
5 Clevis Pin 14 Cover Plate
6 Cotter Pin 15 Nut
7 Outrigger Box 16 Cotter Pin
8 Locknut 17 Capscrew
9 Lockwasher
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NOTE: Outrigger removal and installation similar for both

front and rear outriggers.
Lifting belts or straps should be used for lifting
purposes so as to avoid nicking or scratching the
bottom edges of the outrigger beam. 6120-1
FIGURE 8-9
NOTE: Do not allow the end of the outrigger extension

cylinder to fall when the cylinder mounting shaft is
CAUTION removed. Use blocking to limit the drop or an
Be sure any blocking material used is capable of adequate soft support to cushion any distance the
supporting the weight of the outrigger beam. Do not allow rod will drop. 8
it to tilt or slide. 8. Remove the cotter pin and clevis pin securing the
cylinder barrel end of the extension cylinder to the
5. Extend the outrigger slightly to facilitate attaching a outrigger housing. Carefully extend the outrigger beam
lifting device to the outrigger beam. until the extension cylinder is free of the housing and
6. Place blocking material under the outrigger beam carefully lay the end of the cylinder on the bottom of the
(Figure 8-9). outrigger beam or leave on blocking.
7. Tag and disconnect the hydraulic lines at the cylinder 9. After attaching a suitable lifting device of straps or belts
barrel end of the extension cylinder. Cap all lines and instead of chains to prevent nicking the bottom edges of
fittings. the outrigger beam, pull the outrigger beam out of the
outrigger box, re-adjusting the lifting attachment to

prevent the extension cylinder from sliding out of the

outrigger beam when the beam clears the outrigger box.
CAUTION
Be sure that the piston side of all outrigger cylinders are
CAUTION connected to the solenoid valve bank. Reversal of port
Be sure any blocking material used is capable of connection of the rod and piston sides could result in
supporting the weight of the outrigger beam. Do not allow severe damage to the cylinders as very high pressure
it to tilt or slide. intensification will occur.
During initial start-up and checking of the outrigger
NOTE: The outrigger beam assembly weighs operation, each control switch must be operated before
approximately 2132 lb (967 kg). operating the selector valve. If hydraulic lines are
10. Position the outrigger beam on the blocking material. reversed to one or more cylinders, this will prevent
damage to the cylinders
Inspection
Inspect the outrigger beams for bends, evidence of cracks, 7. Connect the hydraulic lines as tagged prior to removal.
or other damage. Check the outrigger beam internally for 8. Install the side adjustable wear pad in the outrigger box.
hydraulic fluid, which may indicate a leaking cylinder, loose
connection, or damaged hydraulic line. 9. Adjust the wear pads, refer to Wear Pad Adjustment in
this Sub-Section.
Installation
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10. Connect the OMS sensor, refer to OMS String
1. Apply grease (EP-MPG) to the bottom of the outrigger
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Potentiometers, page 8-33.
beam.
2.
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If removed, install the side adjustable wear pad in the
11. Install the end cover.
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outrigger beam. NOTE: At installation, be sure that the outrigger jack
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cylinder hydraulic hoses are not trapped against

3. Install the bottom wear pads with approximately 0.125 in
the outrigger box when the beam is fully retracted.
(3.2 mm) protruding. This will prevent the beam side
plates from riding on the bottom of the box. Wear Pad Adjustment
er
4. Attach a suitable lifting device of straps or belts instead NOTE: When adjusting wear pads, refer to (Figure 8-10).
of chains to prevent nicking the bottom edges of the 1. Adjust each of the bottom wear pads (about 1/2 turn)
outrigger beam. until there is a gap of 0.12 to 0.18 in (3.0 to 4.5 mm)
5. Slide the beam into the outrigger housing and align the between the top of the beam and the top of the outrigger
cylinder bushing with the mounting hole. box. Install and lock set screws against wear pads.
6. Apply anti-seize compound to the clevis pin. Secure the 2. Adjust outrigger box side wear pad until there is a gap of
cylinder barrel to the housing with the clevis pin and 0.12 to 0.18 in (3.0 to 4.5 mm) between beam and shims
cotter pin. welded in top and bottom of box. Install and lock set
screw against wear pad.
3. Adjust outrigger beam side wear pad until there is a gap
of 0.12 to 0.18 in (3.0 to 4.5 mm) between shim welded
on beam and side of box. Install and lock set screw
against wear pad.

0.12 to 0.18 in
(3.0 to 4.5 mm) Gap
1 1
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2 7513-3
2
0.12 to 0.18 in
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(3.0 to 4.5 mm) Gap FIGURE 8-10
3. Pull the extension cylinder from the outrigger beam until
the hydraulic hoses on the rod end of the cylinder can be
Item Description accessed. Tag and disconnect the hoses from the rod
end of the cylinder. Cap or plug all openings.
1 Side Wear Pads and Setscrews
4. Remove the cylinder.
2 Bottom Wear Pads and Setscrews
Installation
Extension Cylinder 1. Place the cylinder in the beam.
Description NOTE: Position hydraulic fittings and hoses to prevent
Two outrigger extension cylinders are utilized within each rubbing with the beam top plate and side plate, and
outrigger box assembly. The extension cylinders provide the for proper tracking during beam extension and
force for the outrigger beam’s horizontal movement. The retraction.
cylinder weighs approximately 104.9 lb (47.6 kg). 2. Position the extension cylinder so the hydraulic ports on 8
Maintenance the rod end of the cylinder can be accessed. Connect
the hydraulic hoses to the ports as tagged during
NOTE: Refer to Cylinders, page 2-68 for disassembly and removal. Verify the piston side of the extension cylinder
assembly of the cylinder. is connected to the solenoid valve bank to prevent
Removal damage.
1. Remove the outrigger beam. Refer to Outrigger Beam, 3. Push the cylinder into the outrigger beam. Align the
page 8-27. cylinder rod with the clevis in the beam. Apply anti-seize
compound to the clevis pin and secure in place with the
2. Remove the cotter pin and clevis pin securing the rod clevis pin and cotter pin.
end of the extension cylinder to the outrigger beam.

4. Install the outrigger beam. Refer to Outrigger Beam,

page 8-27. Verify no jack cylinder hose will be trapped
by full outrigger beam retraction. CAUTION
Functional Check Use a nylon strap to remove the cylinder. This will ensure
the retaining pin is not damaged.
1. Activate the hydraulic system; extend and retract the
outrigger. 7. Fasten a nylon strap onto the cylinder retaining pin and
2. Observe the operation of the outrigger beam. use an adequate lifting device to lift the jack cylinder out
of the tube on the beam assembly.
3. Check the hydraulic connections for any evidence of
leakage. Installation
1. Apply grease (EP-MPG) to the ID of the jack cylinder
Jack Cylinder support tube.
Description 2. If removed, install wear ring in groove in bottom of
Four jack cylinders are used on the crane, one at the end of support tube and in groove at top on jack cylinder.
each outrigger beam. The jack cylinders provide the force for 3. Place a jack beneath the cylinder tube on the outrigger
the outrigger beam’s vertical movement. The cylinder weighs beam. Using the same method as described under
approximately 220.4 lb (100 kg). Removal, lower the jack cylinder into the cylinder tube
Maintenance on the outrigger beam until the retaining pin is just above
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the tube. Position the jack so that it will support the
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NOTE: Refer to Cylinders, page 2-68 for disassembly and cylinder in this position. Remove the lifting device from
Removal nl c
assembly of the cylinders. the cylinder.
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4. Remove the retaining pin and cotter pins from the
1. Extend the outrigger beam slightly for improved access cylinder.
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to the jack cylinder; shut down the engine. 5. Lower the jack until the holes in the cylinder rod align
2. Tag and disconnect the hydraulic hoses from the jack with the holes in the outrigger beam.
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cylinder. Remove the fittings from the ports. Cap or plug 6. Apply anti-seize compound to the retaining pin. Secure
all openings. the cylinder and cylinder cap retaining bracket to the
3. Remove the cylinder cap. support tube with the retaining pin and cotter pins.
4. Place a jack capable of supporting the weight of the jack 7. Install the cylinder cap.
cylinder at the base of the cylinder barrel. Jack up the 8. Install the fittings in the cylinder ports and connect the
cylinder just enough to relieve any pressure on the hoses as tagged during removal. Verify the piston side of
cylinder retaining pin. the jack cylinder is connected to the solenoid valve bank
5. Remove the cotter pins securing the cylinder retaining to prevent damage. Verify no jack cylinder hose will be
pin and remove the cylinder retaining pin and cylinder trapped by full outrigger beam retraction.
cap retaining bracket. Functional Check
6. Jack the jack cylinder up just enough to insert the 1. Activate the hydraulic system.
retaining pin back into the cylinder. Insert the retaining
pin into the lugs on the cylinder and secure the pin in 2. Observe the operation of the jack cylinder. If hydraulic
place with the cotter pins. lines are reversed, stop immediately and connect lines
properly per instructions. Verify no jack cylinder hose is
trapped by full outrigger beam retraction; if any is, stop
immediately and install lines properly to avoid trapping.
3. Check the hydraulic connections and hoses for evidence
of leakage. Make repairs as needed.

Outrigger Control Valves NOTE: Avoid free-release of cable to prevent damage to

OMS string potentiometer.
Description
3. Tag and disconnect the electrical connector and secure
There are four valve assemblies responsible for controlling to avoid damage.
the outrigger system, the integrated outrigger/rear steer
valve, the front and rear outrigger control manifolds, and the 4. Remove the mounting hardware.
pilot operated check valves.
5. Remove the OMS string potentiometer (2).
NOTE: For a more detailed description and maintenance
of the valves, refer to Valves, page 2-37.
Pilot Operated Check Valve
The pilot operated check valves are located in the outrigger
jack port blocks. The check valve provides two functions; the
first function is a holding valve, the second function provides
a thermal relief of the jack.
Integrated Outrigger/Rear Steer Valve
The integrated outrigger/rear steer valve is mounted on the
rear face of the carrier frame front cross member. The
outrigger portion of the valve consists of a 4-way three
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position solenoid valve. The inlet section contains the main
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relief valve. 2
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Outrigger Control Manifold
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The front and rear outrigger control manifolds are located 1
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on the respective outrigger boxes. Each manifold consists of

four 24 volt solenoid valves and an assembly mounting kit.
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Outrigger Monitoring System (Optional—
Standard in North America) FIGURE 8-11
Description Installation
The Outrigger Monitoring System (OMS) aids the operator 1. Install string potentiometer inside outrigger beam
by automatically identifying the position of each outrigger (Figure 8-11).
beam. The OMS uses four sensors, one per outrigger beam
to identify when an outrigger beam is positioned to one of 2. Install the mounting hardware.
three pre-defined locations, including fully retracted, 3. Attach the OMS string potentiometer spring clip (1) to
mid-extend, and fully extended. the attaching point on the outrigger beam.
If the crane is setup on outriggers and “On Outriggers” is NOTE: Avoid free-release of cable to prevent damage to
chosen when programming the RCL, then the OMS indicates the OMS string potentiometer.
to the RCL the position of each of the four outrigger beams.
The operator must confirm the outrigger positions and 4. Connect electrical connector, as tagged during removal,
to string potentiometer.
rigging code. Refer to the Operator’s Manual for more
information. 5. Install access cover plate to outrigger box.
8
OMS String Potentiometers
Removal
1. Remove the rear access cover plate from outrigger box.
2. Remove the OMS string potentiometer spring clip (1)
(Figure 8-11) from the attaching point on the outrigger
beam.

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THIS PAGE BLANK

RT9150E SERVICE MANUAL LUBRICATION
SECTION 9
LUBRICATION
SECTION CONTENTS
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 Drive Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12
Environmental Protection . . . . . . . . . . . . . . . . . . . 9-1 Outriggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16
Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-18
Lubrication Intervals . . . . . . . . . . . . . . . . . . . . . . . 9-1
Turntable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-20
Standard Lubricants Package . . . . . . . . . . . . . . . . 9-2 Cab Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-22
Arctic Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3 Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-24
Below -15°C (5°F). . . . . . . . . . . . . . . . . . . . . . . . . 9-3 Hoist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-26
Down to –29C° (–20°F). . . . . . . . . . . . . . . . . . . . . 9-3 Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-28
Surface Protection for Cylinder Rods. . . . . . . . . . 9-5 Boom Extension. . . . . . . . . . . . . . . . . . . . . . . . . . 9-32
Wire Rope Lubrication . . . . . . . . . . . . . . . . . . . . . . 9-5 Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-34
Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . 9-6 Carwell® Rust Inhibitor. . . . . . . . . . . . . . . . . . . . . 9-36
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CraneLUBE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-36
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Cummins Oil Registration List. . . . . . . . . . . . . . . . 9-7 Cleaning Procedures . . . . . . . . . . . . . . . . . . . . . . 9-36
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Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
Steering and Suspension . . . . . . . . . . . . . . . . . . . 9-8
Inspection and Repair . . . . . . . . . . . . . . . . . . . . .
Carwell Application . . . . . . . . . . . . . . . . . . . . . . .
9-37
9-37
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Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10 Areas of Application. . . . . . . . . . . . . . . . . . . . . . . 9-37
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GENERAL • Immediately clean up any spills.
Following the designated lubrication procedures is important

LUBRICATION INTERVALS
in ensuring maximum crane lifetime and utilization. The
procedures and lubrication charts in this section include Service intervals specified are for normal operation where
information on the types of lubricants used, the location of moderate temperature, humidity, and atmospheric conditions
the lubrication points, the frequency of lubrication, and other prevail. In areas of extreme conditions, the service periods
information. and lubrication specifications should be altered to meet
existing conditions. For information on extreme condition
ENVIRONMENTAL PROTECTION lubrication, contact your local Grove Distributor or Manitowoc
Crane Care.
Dispose of waste properly! Improperly disposing of waste
can threaten the environment. Lube intervals are to be used as a guideline only. Actual lube
intervals should be formulated by the operator to correspond
Potentially harmful waste used in Grove cranes includes, but accordingly to conditions such as continuous duty cycles
is not limited to; oil, fuel, grease, coolant, air conditioning and/or hazardous environments.
refrigerant, filters, batteries, and cloths which have come into
contact with these environmentally harmful substances.
CAUTION
Handle and dispose of waste following local, state, and Possible Equipment Damage Hazard!
federal environmental regulations.When filling and draining
Chassis grease lubricants must not be applied with air
crane components, observe the following:
pressure devices as this lubricant is used on sealed
• Do not pour waste fluids onto the ground, down any
drain, or into any source of water.
fittings. 9
The multipurpose grease installed during manufacture is
• Always drain waste fluids into leak proof containers that of a lithium base. Use of a incompatible grease could
are clearly marked with what they contain. result in damage to equipment.
• Always fill or add fluids with a funnel or a filling pump.
Grove Published 7-12-2021 Control # 659-00 9-1

LUBRICATION RT9150E SERVICE MANUAL
STANDARD LUBRICANTS PACKAGE Refer to Table 9-1 for a list of the recommended standard
lubricants.
The following table lists all the lubricants and coolant
recommended for this Grove crane. These standard
lubricants are effective in temperatures down to -15°C (5°F).
Table 9-1: Standard Lubricants/Fluids [Down to -9°C (15°F)]
Recommended Lubricant
Lubricant/Fluid Grove Spec.
Type Grade Classification
Axle Gear Oil Century Unigear Semi-synthetic
6829012964 Texaco Multigear SS 80W-90
Chevron DELO
Tier 3 Engine Oil Exxon XD-3 CI-4
6829003483 15W-40
Conoco Fleet Supreme
Tier 4 Engine Oil Conoco Fleet Supreme EC Cj-4
6829104182 15W-40
Mobil Delvac 1300 Super
Hydraulic/Transmission Oil Exxon Mobil 424 Must Meet John
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6829006444 ISO 46/68 Deere Std. JDM
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Phillip 66 PowerTran XP J20C
Hoist Gear Oil
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Grease, Multipurpose Citgo Lithoplex MP# 2
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Texaco Starplex Moly # 2

Phillips 66 Philube M
6829003477 NLGI 2
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Mobil Mobilgrease XHP 222
Special
Chemtool Inc, Lube-A-Boom
Open Gear Lube 6829102971 LPS Dry Force 842 Moly Lube NLGI 1-2
Swing Box Gear Oil 02313611 ARAL Synthetik API 75W-90 GL 4
Boom Telescopic Sections,
02314698 Sliding-paste
Upper and Lower Faces
Antifreeze Coolant Old World Industries, Inc. Fleet
Charge SCA
6829101130 Mix 50/50
Caterpillar DEAC
Fleetguard Complete EG
Supplemental Coolant Fleetguard DCA4
Additive (SCA) 6829012858 Fleetguard DCA2
Penray Pencool 3000
Diesel Exhaust Fluid (DEF) Fleetguard StableGuard™ Urea
32 Premix
80019225
AdBlue®
TerraCair Ultrapure® DEF
Anti-Seize Compound (ASE) Jet-Lube KOPR-KOTE
6829003689
LOCTITE C5-A compound

ARCTIC CONDITIONS Operator Manual to ensure adequate lubrication during

system warm-up and proper operation of all crane functions.
Below -15°C (5°F)
Down to –29C° (–20°F)
Regions with ambient temperatures below -15°C (5°F) are
considered arctic. In general, petroleum based fluids ALL Weather Package & Lubricants
developed especially for low temperature service may be
used with satisfactory results. However, certain fluids, such Engineering recommends the following lubricants for
as halogenated hydrocarbons, nitro hydrocarbons, and components for ambient temperatures to -20°F. Special
phosphate ester hydraulic fluids, might not be compatible lubricants alone are not sufficient to operate at extreme low
with hydraulic system seals and wear bands. If you are in temperatures. We also recommend the use of appropriately
doubt about the suitability of a specific fluid, check with your sized heaters for the hydraulic tank, engine oil pan, engine
authorized Grove distributor or Manitowoc Crane Care. water jacket and batteries. The operator needs to follow the
guide lines as stated in the operator’s manual. We assume
NOTE: All fluids and lubricants may be purchased by con- that the customer has taken steps for use of an appropriate
tacting the Manitowoc Crane Care Parts Depart- engine antifreeze coolant, have taken care of the fuel, fuel
ment. system and starting system. And has done whatever they
When operating in cold weather and regardless of the oil feel necessary to add insulation for under hood temperatures
viscosity of the crane’s lubricants, always follow the cold to meet the engine manufacturer's intake air temperature.
weather start-up and operating procedures described in the Other lubricants may be used if they meet the specification of
the lubricant that is requested. Please consult factory.
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Table 9-2 Cold Weather Lubricants/Fluids [Down to -29°C (-20°F)]
Recommended Lubricant
Lubricant/Fluid Grove Spec.
Type Grade Classification
Petro-Canada Traxon E
Synthetic
CITGO, Synthetic Gear Lube
Axle/Swing Box Gear Oil 6829014058 Eaton, Roadranger EP 75W-90 GL-5
Mobil, Mobilube SCH
Shell, Spirax S
Sunoco Duragear EP
Tier 3 Engine Oil Petro-Canada Duron Synthetic CI-4
6829101560 5W-40
Mobil Delvac 1
Tier 4 Engine Oil Citgo Citgard® Syndurance® CJ-4
6829104412 Synthetic 5W-40
Mobil Delvac 1 ESP SW-40
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Petro-Canada Duratran
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Synthetic THF Must Meet John
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Hydraulic/Transmission Oil 6829101559
Chevron All Weather THF
Deere Std. JDM
J20C
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Texaco TDH Oil SS
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Petro-Canada Precision
Grease, Multipurpose 6829104275 Synthetic EP1 NLGI 2
Mobil, Mobilith SHC 220
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Vultrex OGL Synthetic All
Open Gear Lube — NLGI 1-2
Season
Petro-Canada AFC
Old World Industries, Inc Fleet
Premix
Antifreeze Coolant 6829104212 Charge SCA
60/40
Fleetguard Compleat EG
Antifreeze/Coolant
Supplemental Coolant Fleetguard DCA4
Additive (SCA) 6829012858 Fleetguard DCA2
Penray Pencool 3000
Diesel Exhaust Fluid (DEF) Fleetguard StableGuard™ Urea
32 Premix
80019225
AdBlue®
TerraCair Ultrapure® DEF
Anti-Seize Compound (ASE) Jet-Lube KOPR-KOTE
6829003689
LOCTITE C5-A compound

SURFACE PROTECTION FOR CYLINDER It is recommended that all exposed cylinder rods be
RODS protected using Boeshield® T-9 Premium Metal Protectant.
Manitowoc Crane Care has Boeshield® T-9 Premium Metal
Steel cylinder rods include a thin layer of chrome plating on Protectant available in 12 oz. cans that can be ordered
their surfaces to protect them from corroding. However, through the Parts Department.
chrome plating inherently has cracks in its structure which
Cylinder operation and inclement weather will remove the
can allow moisture to corrode the underlying steel. At typical
Boeshield® protectant; therefore, inspect machines once a
ambient temperatures, hydraulic oil is too thick to penetrate
week and reapply Boeshield® to unprotected rods.
these cracks. Normal machine operating temperatures will
allow hydraulic oil to warm sufficiently to penetrate these
cracks and if machines are operated daily, protect the rods. WIRE ROPE LUBRICATION
Cranes that are stored, transported, or used in a corrosive Wire rope is lubricated during manufacturing so that the
environment (high moisture, rain, snow, or coastline strands, and individual wires in strands, may move as the
conditions) need to have the exposed rods protected more rope moves and bends. A wire rope cannot be lubricated
frequently by applying a protectant. Unless the crane is sufficiently during manufacture to last its entire life.
operated daily, exposed rod surfaces will corrode. Some Therefore, new lubricant must be added periodically
cylinders will have rods exposed even when completely throughout the life of a rope to replace factory lubricant which
retracted. Assume all cylinders have exposed rods, as is used or lost. For more detailed information concerning the
corrosion on the end of the rod can ruin the cylinder. lubrication and inspection of wire rope, refer to Wire Rope in
Section 1- Introduction in the Service Manual.
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LUBRICATION POINTS equals one pump on a standard one pound (0.45 kg) grease
gun.
A regular frequency of lubrication must be established for all
lubrication points. Normally, this is based on component Over lubrication on non-sealed fittings will not harm the
operating time. The most efficient method of keeping track of fittings or components, but under lubrication will definitely
lube requirements is to maintain a job log indicating crane lead to a shorter lifetime.
usage. The log must use the engine hourmeter to ensure On sealed U-joints, care must be exercised to prevent
coverage of lube points that will receive attention based on rupturing seals. Fill only until expansion of the seals first
their readings. Other lubrication requirements must be made becomes visible.
on a time basis, i.e. weekly, monthly, etc.
Unless otherwise indicated, items not equipped with grease
All oil levels are to be checked with the crane parked on a fittings, such as linkages, pins, levers, etc., should be
level surface in transport position, tires on the ground, and lubricated with oil once a week. Motor oil, applied sparingly,
the suspension set at the proper ride height. will provide the necessary lubrication and help prevent the
Lubrication checks must be performed while the oil is cool formation of rust. An Anti-Seize compound may be used if
and has not been operated within the past 30 minutes, rust has not formed, otherwise the component must be
unless otherwise specified. cleaned first.
On plug type check points, the oil levels are to be at the Grease fittings that are worn and will not hold the grease
bottom edge of the fill plug hole. The hoists have an oil level gun, or those that have a stuck check ball, must be replaced.
indicator. Where wear pads are used, cycle the components and
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All grease fittings are SAE STANDARD unless otherwise
area.
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indicated. Grease non-sealed fittings until grease is seen
extruding from the fitting. 28 grams (one ounce) of EP-MPG
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CraneLUBE Select the one that applies to your engine to view the
registered oils.
Grove highly recommends the use of CraneLUBE lubricants
to increase your crane’s reliability and performance. Contact Safety
your Grove distributor for information about the Grove’s
CraneLUBE lubrication program. To lubricate many of the locations the engine will need to be
started. After positioning areas of the crane for lubrication the
Cummins Oil Registration List engine must be turned off and the areas to be lubricated
made stable before proceeding.
Cummins has a program that lists engine oils that it has
tested to meet its engineering specifications. Listing of
recommended oils is on QuickServe® Online. Log on to
quickserve.cummins.com and login with a current username
and password or create a new account by selecting “Create DANGER
an Account” under information, choose Limited Owners Plan Crushing Hazard!
and register. Once logged in, click on the “Service” Tab in the Movement of the superstructure and the boom may
top red bar, “Service Tools” mini-tab and “Oil Registration create a crushing and/or pinching hazard. Failure to
Lists” link within the Service Tools list. This will load a list of observe this warning could result in death or serious
the different Cummins Engineering Specification numbers. injury.
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Steering and Suspension

Lube Point Figure Approved Lube
Item Lube Interval Application
Description No. Lubricant Capacity
NOTE: Standard fluids good to -15°C (5°F) - Cold weather fluids good to -29°C (-20°F)
The standard fluid part number in Approved Lubricant column in this chart appears first and cold weather part
number is listed second. If only one part number is listed, it is the standard fluid.
EP-MPG
Extreme
Pressure Until
Steer Cylinder
1 Figure 9-1 Multipurpose grease 500 hours or 3 months 8 grease fittings
Pivot Pins
Grease extrudes
6829003477
6829104275
EP-MPG
Extreme
Pressure Until
Upper and Lower
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King Pins
Grease extrudes
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6829003477
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EP-MPG
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Extreme
Pressure Until
Fifth Wheel
Pivots
Grease extrudes
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6829003477
6829104275
EP-MPG
Extreme
Pressure Until
Lockout Cylinder
Pivot Pins
Grease extrudes
6829003477
6829104275

2
1
5
1
2 7520-36
1
7520-41
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9099
7520-35
9
4
7061-13
3
FIGURE 9-1


Axles
GL-5 • Check level every
Extended 500 hours or 3 Fill to bottom of hole
Service Interval 130.2 pints months in housing on the
11 Differentials Figure 9-2
Gear Lubricant (61.6 liters) • Drain and fill every steer cylinder side (2
6829012964 4000 hours or 2 places)
6829014058 years
NOTE: Lube level close enough to the hole to be seen or touched is not sufficient. It must be level with the hole.
When checking lube level, also check and clean housing breathers.
CAUTION: Use of non semi-synthetic lubricant may damage components and/or invalidate published lubricant intervals.
CAUTION: If the makeup amount is substantially more than 0.23 liter (0.5 pint), check for leaks.
GL-5 • Check level every Fill to the bottom of
Extended 500 hours or 3 the level hole in the
Planetary Hubs months
Service Interval 14.4 pints housing with the fill
y e
12 and Wheel Figure 9-2
Gear Lubricant (6.8 liters) plug and the oil level
ef or
Bearings • Drain and fill every
6829012964 4000 hours or 2 mark horizontal (4
nl c 6829014058 years places)

O en
CAUTION: Use of non synthetic lubricant may damage components and/or invalidate published lubricant intervals.
R F
er

11
7520-36
y e
ef or
nl c
12 7117-8
O en
R F
er
9099
FIGURE 9-2


Drive Train
EO-15W/40
Engine Oil Tier 3:
SAE 15W-40 20 quarts • Through fill cap to
(19 liters) • Check level every 10
20a a. Engine FULL mark on
hours or daily
Crankcase Figure 9-3 T3 Engine: dipstick
20b b. Filter 6829003483 • Drain, fill and replace
Tier 4: • Filter located
filter every 500 hours
23 quarts under radiator
T4 Engine: (22 liters)
6829104182
• Check level every 10
hours or daily
• Drain and refill every
a. Transmission 1000 hours or 6
21a HYDO Through fill pipe to
y e
and Torque 68 quarts months
Figure 9-3 Hydraulic Oil FULL mark on
ef or
Converter (64 liters) • Change transmission
21b 6829006444 dipstick
b. Filter
nl c filter after first 50 and
100 hours of service,
O en
then every 500 hours
R F
thereafter
NOTE:
• Check fluid level with engine running at 800 rpm idle and the oil at 150° to 200°F (65° to 90°C). Do not attempt an oil level check
er
with cold oil. To bring the oil temperature to this range, it is necessary to either work the crane or stall the converter. Converter
stall should be accomplished by engaging shift lever in forward high range with the brakes applied and then accelerating the
engine to half or three-quarter throttle. Hold the stall until the required converter temperature is reached and stabilized.
Do not operate the converter at stall condition for longer than 30 seconds at one time. Shift to neutral for 15 seconds and repeat
the procedure until the desired temperature is reached. Excessive temperature, i.e, 250°F (120°C) maximum will cause damage
to transmission clutches, fluid, converter and seals.
• Drain and fill with the oil at 150° to 200°F (65° to 90°C).
• Transmission filters are located on the outside left hand frame in the area of the hydraulic oil cooler.
• Do not operate the machine in two wheel drive while the machine is up on outriggers. Serious transmission damage could result.
• To add fluid:
a. Fill to FULL mark on dipstick
b. Run engine at 800 rpm to prime torque converter and lines
c. Check oil level with engine running at 800 rpm and oil at 150° to 200°F (65° to 90°C). Add oil to bring oil level to
FULL mark on dipstick
AFC 50/50 • Check coolant level
50/50 Blended every 10 hours or
Fully daily
a. Engine Formulated • Change filter and
22a Cooling System Antifreeze 42 quarts
Figure 9-3 check SCA levels See Service Manual
22b and SCA Levels Coolant (40 liters)
every 500 hours
b. Coolant Filter A6-829-101130
• Check coolant for
SCA contamination every
6829012858 1000 hours

22a
7117-25
22b
7520-28
21a
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7520-15
ef or
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O en
R F
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9099
21b 7117-14
9
7520-12
20b 7117-19 20a
FIGURE 9-3


Drive Train (continued)
Clean strainer screen
Close shutoff valves.
Coolant Strainer after first 100 hours and
23 Figure 9-4 --- --- Unscrew hex plug to
(Cab Heater) every 2000 hours or 12
clean filter.
months thereafter.
• Replace primary filter
element when
indicator shows red
(25 in of H20).
24a Air Cleaner
Replace secondary
Filters
filter every third time Right hand side of
Figure 9-4 --- --- primary filter is engine hood.
replaced.
24b Pre-cleaner
• In severe dust
conditions the pre-
y e
cleaner may need to
ef or
be serviced.
nl c • Drain water trap Primary fuel/water

O en
every 10 hours or separator is located
Water Separator
R F
daily. beside the fuel tank.

25a Fuel Filter -
Figure 9-4 --- --- Secondary fuel filter
25b Primary and • Change filter every is located on the
Secondary 500 hours or 6 right side of the
er
months. engine
EP-MPG
Extreme
Pressure Until
26a Driveline - Slip
Figure 9-4 Multipurpose grease 500 hours or 3 months 3 grease fittings
26b Joints
Grease extrudes
6829003477
6829104275
DEF Supply
27 Module Filter --- --- --- Check filter every 4500
(Tier 4)
DEF Tank 20 quarts Check and fill every 10
28 --- DEF (AUS 32)
(Tier 4) (18.9 liters) hours or daily
CAUTION: Use caution when adding Diesel Exhaust Fluid (DEF) to avoid spills during vehicle fill-up.
CAUTION: DEF is corrosive to certain metals and paint and should be washed off with mild soap and water if spilled.
DEF Tank Filter
29 --- --- --- Check filter every 1 year
(Tier 4)

24a (Tier 3)
26a
7520-42
7520-43
26b
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ef or
25a 24b 24a (Tier 4)
nl c
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9099
23
7520-37
9
25b 7520-11
FIGURE 9-4


Outriggers
EP-MPG
Extreme
Pressure Brush lubricant on
30 Outrigger Beams Figure 9-5 Multipurpose --- 50 hours or 1 week bottom of outrigger
Grease beams
6829015304
6829104275
EP-MPG Brush lubricant on
Extreme ID of jack cylinder
Pressure support tubes and
Jack Cylinder
31 Figure 9-5 Multipurpose --- 50 hours or 1 week wear bands four (4)
Support Tubes
Grease places before
6829015304 installing jack
6829104275 cylinders
y e
Brush lubricant on
ef or
ID of jack cylinder
nl c EP-MPG
Extreme
support tubes and
wear bands four (4)
O en
Pressure
Jack Cylinder places before
R F
32 Figure 9-5 Multipurpose --- 50 hours or 1 week

Barrels installing jack
Grease
cylinders and on
6829015304
outside of support
6829104275
er
tubes at regular
intervals
Brush anti-seize
Anti-Seize
compound on all
Removable Compound
33 Figure 9-5 --- 100 hours or 1 month removable outrigger
Outrigger Box (ASC)
to frame attachment
6829003689
areas

9099
y e
ef or
nl c
O en
31
R F
er
30
32
7520-5
33 33
FIGURE 9-5

Lube Point Approved Lube

Item Figure No. Lube Interval Application
Description Lubricant Capacity
Hydraulic
• Use sight gauge on
side of tank, with
HYDO boom down and all
655 liters Check fluid level
Hydraulic Oil outrigger cylinders
40 Hydraulic Tank Figure 9-6 (173 every 10 hours or
6829006444 retracted.
gallons) daily
6829101559
• Drain and refill as
necessary
NOTE:
• Environmental and other conditions can dramatically affect the condition of hydraulic oil and filters. Therefore,
specific intervals for servicing/changing hydraulic oil, filters and hydraulic tank breathers cannot be set.
However, it is imperative for the continued satisfactory performance of Grove cranes that inspections be
performed on the basis of how and where each crane is used. Air borne and ingested contaminants can
significantly reduce the life of oil and the condition of hydraulic oil filters and tank breathers.
y e
• Under normal operating conditions, it is recommended that hydraulic oil, filters and breathers be inspected
ef or
and oils sampled at least every 3 to 6 months and more frequently for severe operating conditions. The
nl c
inspections should be for air borne and/or ingested particles and water that deteriorate and contaminate the
oil (e.g., oil appears “milky” or no longer has a transparent clear to amber color). The return filter by-pass
O en
indicator should be observed daily to determine if the contaminants content may be high. If the indicator
R F
reaches the red zone or indicates a by-pass condition, the hydraulic oil must be sampled. The hydraulic tank
breather should also be inspected to assure that it is not restricting air flow into and out of the reservoir.
• To inspect hydraulic oil, fill a small glass container with a sample of reservoir oil and another glass container
er
with fresh oil. Let the samples stand, undisturbed, for one to two hours and then compare the samples. If the
reservoir oil is heavily contaminated with water the sample will appear “milky” with only a small layer of
transparent oil on top. If the “milky” appearance was due to air foaming, it will dissipate and the oil should
closely match the fresh oil. Should you have any questions, please contact your local authorized Grove
distributor.
• The hydraulic oil shall meet or exceed ISO #4406 class 19/17/14 cleanliness level.
Fill Procedure for Hydraulic Tank (Operation below +5°F (-15 °C)
– Drain existing oil.
– Fill tank with hydraulic/transmission oil (6829101559) and cycle all cylinders
– Drain oil
– Fill tank with oil (6829101559)
Change filter when
41 Hydraulic Filter Figure 9-6 --- --- the restriction ---
indicator is in the red

7520-2
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ef or
nl c
O en
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er
41 40 7117-15
FIGURE 9-6


Turntable
SGL-5 • Check and fill every
Synthetic Gear 50 hours
1.0 quarts
Lube - API Fill to level on sight
100 Swing Drives Figure 9-7 (0.9 liters) • Drain and fill every
GL4+ gauge
SAE75W-90 1000 hours or 12
02313611 months thereafter.
CAUTION: Do not mix synthetic oil with mineral based oil.

EP-OGL
Turntable Gear Open Gear Coat all
101A Figure 9-7 500 hours or 6 months Spray on
and Drive Pinion Lubricant teeth
6829102971
EP-OGL
Turntable Swivel Open Gear Coat entire
101B Figure 9-7 500 hours or 6 months Spray on
y e
Lock Pin Lubricant pin
ef or
6829102971
nl c EP-MPG
Extreme
Until
grease
O en
Pressure extrudes 4 grease fittings at
Turntable
R F
102 Figure 9-7 Multipurpose the whole 500 hours or 6 months the front of the
Bearing
Grease circumfer- turntable.
6829003477 ence of the
er
6829104275 bearing
NOTE: Rotate the turntable 90° and apply grease to fittings. Continue rotating 90° and grease the fittings until the whole
bearing is greased.
EP-MPG
Extreme
Pressure Until
Slew Angle 5000 hours or 60
103 Figure 9-7 Multipurpose grease 1 grease fittings
Sensor months
Grease extrudes
6829003477
6829104275
NOTE: Remove plug from housing. Apply grease to fitting on bottom of sensor. Reinstall plug and tighten to 25 Nm
(18 ft-lb).
EP-MPG
Extreme
Pressure Until
104 Boom Pivot Pin Figure 9-7 Multipurpose grease 300 hours or 3 months 4 grease fittings
Grease extrudes
6829015304
6829104275

99
101
100
100
y e
7520-46
103 7520-44
ef or
nl c Other Side
O en
R F
er
7520-2
7520-20
9
102
7520-52
104
FIGURE 9-7


Cab Tilt
EP-MPG
Extreme
Pressure Until
Cab Tilt Cylinder
Pivot Pins
Grease extrudes
6829003477
6829104275
EP-MPG
Extreme
Pressure Until
Cab Tilt Pivot
Bearings
Grease extrudes
6829003477
6829104275
y e
Cab Door Track
ef or
112 --- Light Oil --- 6 months 2 places
and Rollers
nl c
O en
R F
er

111
7520-34
110 7117-17
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ef or
nl c
O en
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9099
FIGURE 9-8


Lift Cylinder
EP-MPG
Extreme
Upper Lift Pressure Until
115 Cylinder Pivot Figure 9-9 Multipurpose grease 100 hours or 1 months 1 grease fittings
Pin Grease extrudes
6829015304
6829104275
EP-MPG
Extreme
Lower Lift Pressure Until
116 Cylinder Pivot Figure 9-9 Multipurpose grease 100 hours or 1 months 1 grease fittings
Pin Grease extrudes
6829015304
6829104275
y e
ef or
nl c
O en
R F
er

7520-19
116 115
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ef or
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O en
R F
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9099
FIGURE 9-9


Hoist
Ensure hoist is level.
The oil must have
settled for 20
minutes with the
temperature in the
21°C ± 7°C (70°F ±
20°F) range. The oil
level must be
between the 'MIN'
and 'MAX' marks on
SGL Synthetic • Check and fill every
the sight gauge.
Gear Lube - 50 hours or weekly
4 quarts Variations in oil
120 Drum Figure 9-10 API GL4 + SAE • Drain and fill every temperature will
(4 liters)
75W-90 1000 hours or 12 cause oil level to
02313611 months fluctuate.
y e
ef or
To add or refill the
nl c oil, remove hose at

top of sight gauge.
O en
Fill hoist through
R F
hose until the oil

level is visible
between the 'MIN'
and 'MAX' marks on
er
the sight gauge.
CAUTION: Do not mix synthetic oil with mineral based oil.
EP-MPG
Extreme
Pressure Until
Boom Pivot 4 grease fittings, 2
121 Figure 9-10 Multipurpose grease 500 hours or 6 months
Bearing on each side
Grease extrudes
6829003477
6829104275

121
7520-13
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ef or
nl c
O en
R F
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9099
Other Side
7520-51
120 FIGURE 9-10


Boom
Telescope 5 places by brush.
Lubricant Grease Thoroughly
130 Sections - Figure 9-11 300 hours or 3 months Refer to Boom
02310394 coat
Lower Faces Lubrication Procedure.
Telescope 10 places by brush.
Lubricant Grease Thoroughly
131 Sections - Figure 9-11 300 hours or 3 months Refer to Boom
02310394 coat
Upper Faces Lubrication Procedure.
Boom Lubrication Procedure
Telescope Section 1
• Extend telescope section 1 to 100%.
• Using a brush or roller, apply grease to lower slide faces.
• Apply grease to the upper wear pads at fitting (item 131).
y e
• Lubricate locking pins at fitting (item 132).
ef or
• Lock and unlock the section to distribute the grease.
• nl c
Extend section 1 to 50%
O en
R F
Fully retract section.

er
Telescope Section 2 - 5
• Extend telescope section 5 to 100% and telescope section 4 to approximately 25%.
• Using a brush or roller, apply grease to the lower slide faces.
• Lubricate locking pins at fitting (item 132).
• Raise the main boom to 15 degrees.
• Retract telescope section 4 to 0% and telescope section 5 to approximately 50%.
• Lock and unlock telescope section 5 several times to distribute the grease.
• Lower the main boom to 0 degrees. Do not lower less than 0 degrees.
• Extend telescope section 4 to approximately 75%.
• Apply grease to the upper wear pads at fitting (item 131)
• Raise the main boom to 15 degrees.
• Retract telescope sections 4 and 5 to 0%,
• Fully extend and retract telescope section 5 to distribute the grease.
• Lower the main boom to 0 degrees.
• Lubricate telescope sections 2, 3 and 4 in the same method.

7520-22
y e
ef or
nl c
O en
R F
er
7520-2
7520-3
FIGURE 9-11


Boom (continued)
EP-MPG
Extreme
Refer to Boom
Pressure Until
300 hours or 3 Lubrication
132 Locking Pins Figure 9-12 Multipurpose grease
months Procedure on page
Grease extrudes
28.
6829003477
6829104275
EP-MPG
Extreme
Pressure Apply grease at
Boom Nose
133 Figure 9-12 Multipurpose --- assembly and/or 10 service points
Sheaves
Grease teardown
6829003477
6829104275
y e
EP-MPG
ef or
Extreme
134 nl c
Auxiliary Boom
Figure 9-12
Pressure
Multipurpose
Until
grease
250 hours or 3
1 grease fittings
O en
Nose Sheave months
Grease extrudes
R F
6829003477
6829104275
er

7520-22
134 133
y e
ef or
nl c
O en
R F
er
9099
132
9
7520-24
FIGURE 9-12


Boom Extension
EP-MPG
Extreme
Luffing Cylinder/ Pressure Until
140 Adjustment Pivot Figure 9-13 Multipurpose grease 250 hours or 3 months 2 grease fittings
Pins Grease extrudes
6829003477
6829104275
EP-MPG
Extreme
Pressure Until
Luffing Extension
Pivot Pins
Grease extrudes
6829003477
6829104275
y e
EP-MPG
ef or
Extreme
142 nl c
Mast Sheave Figure 9-13
Pressure
Multipurpose ---
Apply grease at
assembly and/or 1 place
O en
Grease teardown
R F
6829003477
6829104275
11 Meter
er
143 Extension Head --- --- 2 places
Sheave
EP-MPG
18 Meter Extreme
144 Extension Head --- Pressure --- Apply grease at 1 place
Sheave Multipurpose assembly and/or
8 Meter Insert Grease teardown
145 --- 6829003477 --- 1 place
Sheave
6829104275
3.6 Meter
146 Extension --- --- 3 places
Sheave

142
141
142
141
7567-68
140
140
142
y e
ef or
nl c
O en
7520-33
R F
7520-50
er
7520-1
142
142
7520-7
9
7520-48 FIGURE 9-13


Boom
EP-MPG
Extreme
Pressure Until
Hook Block
150 Figure 9-14 Multipurpose grease 250 hours or 3 months 1 grease fitting
Swivel Bearing
Grease extrudes
6829003477
6829104275
EP-MPG
Extreme
Pressure Until
Hook Block 1 grease fitting per
151 Figure 9-14 Multipurpose grease 250 hours or 3 months
Sheaves sheave
Grease extrudes
6829003477
6829104275
y e
EP-MPG
ef or
Extreme
153 nl c
Overhaul Ball Figure 9-14
Pressure
Multipurpose
Until
grease 250 hours or 3 months 1 grease fitting
O en
Grease extrudes
R F
6829003477
6829104275
er

153
151
7467-2
150
7520-50
y e
ef or
nl c
O en
R F
er
9099
FIGURE 9-14

CARWELL® RUST INHIBITOR • Exposure to harsh environmental hazards such as

alkaline, acids, or other chemicals that can attack the
Description crane's paint finish.
While the surfaces of the crane that are easily seen have the
Grove crane's are manufactured to the highest quality
standards, including the type of paint finish demanded by biggest impact on the appearance of the crane, particular
today's industry. In partnership with our paint supplier, Grove attention should be given to the undercarriage of the crane to
minimize the harmful effects of corrosion.
is dedicated to help prevent premature corrosion of its
cranes. Exercise special care and increase the frequency of
cleanings if the crane is operated:
Grove cranes are treated with Carwell ® T32-CP-90 rust
inhibitor. While a rust inhibitor cannot guarantee that a • on roads where large quantities of salt or calcium are
machine will never rust, this product will help protect against applied to treat icy and snowy road surfaces;
corrosion on Grove cranes when treated with this product. • in areas that use dust control chemicals;
Carwell is a treatment, not a coating. It contains no silicones, • anywhere there are increased levels of wetness—
solvents, Chlorofluorocarbons (CFCs) or anything that would especially near salt water;
be classified as hazardous under OSHA Regulation 29CFR-
19-10.1200. The product is a liquid blend of petroleum • during prolonged periods of exposure to damp
derivatives, rust inhibitors, water-repelling and water- conditions (e.g., moisture held in mud), where certain
displacing agents. crane parts may become corroded even though other
y e
parts remain dry; or
ef or
Special equipment is used to spray a light film onto the entire
• in high humidity, or when temperatures are just above
nl c
undercarriage and various other areas of each new crane
prior to shipment. When applied, the product has a red tint to the freezing point.
O en
indicate coverage during application. This red tint will turn
clear within approximately 24 hours after application. Cleaning Procedures
R F
Once applied, the treatment can appear to leave a slightly To help protect against corrosion of Grove cranes,
“oily” residue on painted surfaces, and until the red tinting Manitowoc Crane Care recommends washing the crane at
er
fades, could initially be mistaken for a hydraulic fluid leak. least monthly to remove all foreign matter. More frequent
While the product is not harmful to painted surfaces, glass, cleanings may be needed when operating in harsh
plastic or rubber, it can be removed using standard steam- environmental conditions. To clean the crane, follow these
cleaning techniques. guidelines:
This treatment works in various ways: • High pressure water or steam is effective for cleaning
the crane's undercarriage and wheel housings. Keeping
• It eliminates the moisture containing salt, dirt and other these areas clean will not only help retard the effects of
pollutants by lifting and removing them from the metal corrosion, but will also improve the ability to identify
surface;
potential issues before they grow into larger problems.
• The film creates a barrier to repel further moisture from
coming into contact with the metal; CAUTION
• It penetrates crevices. Equipment Damage Hazard!
In addition to this factory-applied treatment, Grove crane High pressure water can be forced into spaces and
owners must provide proper maintenance and care to help infiltrate beyond seals. Avoid pressure washing in the
ensure long-term protection of their crane against corrosion. vicinity of electrical controls, panels, wiring, sensors,
This procedure provides information and guidelines to help sealed bearings, hydraulic hoses and fittings, or anything
maintain the paint finish on Grove cranes. that can be damaged by high pressure cleaning/spraying.
The most common causes of corrosion include the following: • Rinse the dirt and dust off before washing the crane. Dirt
• Road salts, chemicals, dirt, and moisture trapped in can scratch the crane's finish during washing/cleaning.
hard-to-reach areas; • Hard to clean spots caused by road tar or bugs should
• Chipping or wear of paint, caused by minor incidents or be treated and cleaned after rinsing and prior to
moving components; washing. Do not use strong solvents or gasoline.
• Damage caused by personal abuse, such as using the • Wash using only soaps and detergents recommended
decks to transport rigging gear, tools, or cribbing; for automotive paint finishes.

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

• Do not allow product to puddle or build-up on weather
any major scratch(es) or minor damage. stripping, rubber gaskets, etc. Unit should not have
er
puddles or runs evident anywhere.
CAUTION
• To ensure proper coverage of treatment, the product
Structural Damage Hazard! needs to be fogged onto the crane.
To the extent any damage is structural in nature,
Manitowoc Crane Care must be contacted and consulted • Use of pressure paint pots to apply the treatment to the
as to what repairs may be required. unit being processed is recommended.
• Carwell treatment is available in 16 ounce spray bottles
For scratches and marks in highly visible areas: from Manitowoc Crane Care (order part number
8898904099).
• Sand to remove the scratch and feather outward from
the mark to blend the repair into the original surface. • After application of the treatment is complete, wash or
Body putty may be applied as necessary to hide the clean film residue from lights, windshield, grab handles,
defect; then sand smooth. ladders/steps and all access areas to crane, as
necessary.
• Cover all bare metal with a primer that is compatible with
the original paint finish and allow to dry thoroughly. Please contact Manitowoc Crane Care should you have any
questions.
• Prepare the surface prior to applying the finish coat of
paint. Areas of Application
• Apply a finish coat of paint using accepted blending
Refer to Figure 9-15.
techniques. Use of original Grove paint is recommended
to insure the best color match possible. • The underside of the crane should have full coverage of
For scratches and marks in areas of low visibility:
the rust inhibitor. These are the only areas that a full coat
of the rust inhibitor is acceptable on the painted
9
• Consider touching up the spots with a brush to cover the surfaces. Areas include; valves, hose ends and fittings,
bare metal. This will retard the effects of corrosion and swivel, pumps, axles, drivelines, transmission, slew ring
enable you to do the repair at a later time during a gear fasteners and all interior surfaces of the frame.
normal maintenance interval.

• Frame application areas are; hose ends and fittings, all • Boom applications areas are; pivot pins, hose ends and
unpainted fasteners and hardware, all bare metal fittings, jib pins and shafts, all bare metal surfaces,
surfaces, outrigger pads, and back up alarm hardware. headacheoverhaul ball pins/ hook block pins and
fasteners.
• Superstructure applications are; hose ends and fittings,
wire rope, hoist rollers, tensioning springs on hoists, all • All hardware, clips, pins, and hose connections not
unpainted fasteners and hardware, valves, slew ring painted should have treatment applied.
gear fasteners and all bare metal surfaces.
3
5 7
2 8 10 8 12
21 6 9
y e
ef or
nl c 11
O en
R F
13
er
19 1
4
20
22
16
14 15
15
7473-2
1 18 17 19
FIGURE 9-15

Item Description
Item Description 12 Boom Nose Pins, Clips
1 O/R Hose Connections 13 O/R Pins, Clips
2 Counterweight Removal Hoses 14 Hook block Tiedown Cable
3 Hoist Tension Springs 15 O/R Beam Wear Pad Adjustment Hardware
4 Mirror Mounting Hardware 16 Hook Block\Overhaul Ball
5 Hoist Hose Connections 17 Entire underside of unit
6 Powertrain Hardware (Inside Compartment) 18 Turntable Bearing Fasteners
7 Valve Bank All Hardware, Clips, Pins, Hose Connections
19
not painted, O/R Pins, Clips
8 Boom Extension Pins, Clips
20 Wire Rope
9 Hose Connections inside turntable
21 Counterweight Mounting Hardware
10 Lift Cylinder Pivot Shafts
22 Hose Connections
11 Boom Extension Hanger Hardware
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THIS PAGE BLANK

Alphabetical Index
360° Swing Lock Control (Positive Lock Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22

Accessory Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58
Adjusting the Lowering Limit Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Air Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
Arctic Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Axle Oscillation Lockout Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-70
Axle Oscillation Lockout Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46
Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Bi-Fold Swingaway Boom Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39
Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
Cab Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-82
Carwell® Rust Inhibitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-36
Case Drain Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60
Charge Air Cooler (CAC) Motor control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66
Checking the Hoist Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Compact Block Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55
Control Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-63
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Counterweight Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-92
ef or
Counterweight Pin Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-88
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Counterweight Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-68
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Description and Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
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Drive Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34

Dual Accumulator Charge Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-61
Electronic Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
er
Environmental Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
General Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
General Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Hoist Cable (Wire Rope) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Hook Block/Overhaul ball . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39
Hydraulic Accumulator Service Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-65
Hydraulic Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-90
List Of Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Lubrication Intervals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
Main Directional Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49
Oil Cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
Outrigger Control Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44
Outrigger Extension Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-76
Outrigger Jack Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-79
Outrigger/Rear Steer/Outrigger Box Pin Removal Valve. . . . . . . . . . . . . . . . . . . . . . . . 2-40
Outriggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22
Park Brake/Axle Disconnect valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45
Power Pin Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-85
Pressure Bleed-Off Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47
Pressure Setting Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
Standard Lubricants Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Steer Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-73
Steering Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Supply Pressure And Return Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Surface Protection for Cylinder Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
Swing Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Swing Box Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Swing Directional Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53
Swing Lock Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
Swivels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Synthetic Hoist Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-39
Tandem Brake Valve w/ Treadle Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-64
Torque Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41
Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37
Water Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26
Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Wire Rope Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
Wire Rope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-34
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Rt9150e SM Ctrl659 00 Light

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Grove RT9150E

Batteries, battery posts, terminals, and

The original language of this publication is English.

Swing Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Wire Rope Inspection (Running Ropes and Pendant Cables). . . . . . . . . . . . . . . . 1-35

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

Procedure P - Checking/Setting Counterweight Pinning Pressure . . . . . . . . . . . . . 2-33

Main Directional Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49

Relay Panel Component Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

nl c Boom Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Boom Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35

SECTION 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hoist and Counterweight

Standard 39,000 lb (17,690 kg) Counterweight Installation. . . . . . . . . . . . . . . . . . . 5-7

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

Electrical Swivel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20

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

Torque Converter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35

nl c Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5

Front Steering Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9

Cummins Oil Registration List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7

Torque Converter . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Environmental Conditions . . . . . . . . . . . . . . . . . . 1-34

GROVE Published 7-12-2021 Control # 659-00 1-1

motive power through a six speed forward and reverse

Customer Support The crane is equipped with a six-section, pinned boom.

1-2 Published 7-12-2021 Control # 659-00

See Figure 1-1 for your crane’s serial number location;

GROVE Published 7-12-2021 Control # 659-00 1-3

Transportation and Lifting Data

1-4 Published 7-12-2021 Control # 659-00

LIST OF SPECIFICATIONS Engine

Specifications Torque . . . . . . . . . 450 to 500 lb-ft (610 to 678 Nm)

GROVE Published 7-12-2021 Control # 659-00 1-5

Hydraulic Pumps Output @ 2303 rpm . . . . . . . . . 16.9 gpm (64 l/min)

NOTE: Pump output figures are theoretical. Pump #4

1-6 Published 7-12-2021 Control # 659-00

FIGURE 1-3 continued

Item Description Item Description

GROVE Published 7-12-2021 Control # 659-00 1-7

Table 1-1: Axle Weight Distribution Table

1-8 Published 7-12-2021 Control # 659-00

Substitutions, Additions, and Removals

GROVE Published 7-12-2021 Control # 659-00 1-9

GENERAL MAINTENANCE compressed air on bearings. Spinning bearings without

1-10 Published 7-12-2021 Control # 659-00

Pressing Parts Hoses and Tubes

GROVE Published 7-12-2021 Control # 659-00 1-11

Installation assembly to obtain accurate pre-loading. When installing a

1-12 Published 7-12-2021 Control # 659-00

Hydraulic Systems Due to manufacturing methods there is a natural curvature to

! DANGER Visual Inspection of Hoses and Fittings

Keep the System Clean

Sealing Elements 3. All hydraulic hose assemblies are recommended to be

Hydraulic Lines 5. Hydraulic hose assemblies operating in climate zones

GROVE Published 7-12-2021 Control # 659-00 1-13

Table 1-2: Climate Zones

Follow these steps when tightening all fitting connections:

1-14 Published 7-12-2021 Control # 659-00

a0030 Adjustable Fitting to Port FIGURE 1-6

GROVE Published 7-12-2021 Control # 659-00 1-15