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Manitowoc CD25 Service Manual Download Page 7

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CD25

TABLE OF CONTENTS

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Telescope Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
Oil Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
Holding Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Port Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Hydraulic Swivel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28

Hoist Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
Oil Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
Brake Holding Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29

Swing Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
Oil Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32

Anti-Double Block System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
System Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33

Outrigger and Axle Lock Out Circuits  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34

Outrigger Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
Axle Oscillation Circuit  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
Oil Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
Outrigger Control Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35
Load Holding Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37
Vertical Outrigger Cylinder Leakage Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37

Hydraulic Pump Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37
Main Control Valve  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38

Main Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39
Outrigger Control Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-49
Swing Motor  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-50
Hoist Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-55
Hydraulic Swivel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-56
Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-58

SECTION 5 . . . . . . . . . . . . . . . . . . . . . . . . . . .  Preventative Maintenance

Introduction  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Spark Arresting Mufflers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  . 5-2

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Environmental Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Dynamic Shock Loads  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Lubrication  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Precautions and Recommendations During Inspection or Replacement . . . . . . . . . 5-3
Wire Rope Inspection—Running Ropes and Pendant Cables . . . . . . . . . . . . . . . . . 5-5
Wire Rope Inspection—Boom Extension and Retraction Cables . . . . . . . . . . . . . . . 5-5
Wire Rope Inspection/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Seizing Wire Rope  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

Lubricants  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Maintenance Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Special Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

After First 50 Hours of Operation (New Cranes). . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
After First 100 Hours of Operation (New Cranes). . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Cranes Not in Regular Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

Preventive Maintenance  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

Maintenance Schedule and Checklist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

Lubricant symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Lubrication Points  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Lubrication Points  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

Reference Only

Summary of Contents for CD25

Page 1: ...CD25 Service Manual R e f e r e n c e O n l y ...

Page 2: ...This Page Blank R e f e r e n c e O n l y ...

Page 3: ...ber 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 An untrained operator subjects himself and others to death or serious injury Do not operate this crane unless You are trained in the safe operation of this crane Manitowoc is not responsible for qualify...

Page 4: ...e State of California to cause cancer birth defects and other reproductive harm CALIFORNIA PROPOSITION 65 WARNING Battery posts terminals and related accessories contain chemical lead and lead compounds chemicals known to the State of California to cause cancer birth defects or other reproductive harm Wash hands after handling R e f e r e n c e O n l y ...

Page 5: ...T Method 1 7 Hydraulic Pressure Testing 1 8 Fasteners 1 8 Loctite 1 8 Fasteners and Torque Values 1 9 Weld Studs 1 12 SECTION 2 Safety Practices Introduction 2 1 Signal Words 2 1 Signal Word 2 1 Personal Considerations 2 2 Equipment Considerations 2 2 General Considerations 2 3 Operational Considerations 2 3 Environmental Protection 2 4 Final Word 2 4 SECTION 3 Electric System General 3 1 Comparin...

Page 6: ...eneral Hydraulic System Troubleshooting 4 4 Lift Circuit Troubleshooting 4 6 Telescope Crowd Circuit Troubleshooting 4 6 Outrigger Circuit Troubleshooting 4 7 Hoist Circuit Troubleshooting 4 8 Swing Circuit Troubleshooting 4 8 Hydraulic System 4 9 General Maintenance 4 9 Preparation 4 9 Hydraulic System Maintenance Precautions 4 9 Label Parts when Disassembling 4 9 Hydraulic Oil Recommendations 4 ...

Page 7: ...Motor 4 50 Hoist Motor 4 55 Hydraulic Swivel 4 56 Hydraulic Cylinders 4 58 SECTION 5 Preventative Maintenance Introduction 5 2 Spark Arresting Mufflers 5 2 Wire Rope 5 2 General 5 2 Environmental Conditions 5 2 Dynamic Shock Loads 5 3 Lubrication 5 3 Precautions and Recommendations During Inspection or Replacement 5 3 Wire Rope Inspection Running Ropes and Pendant Cables 5 5 Wire Rope Inspection B...

Page 8: ...f Operation Three Months 5 29 Inspect the Tires 5 29 Inspect the Parking Brake Pads 5 29 Replace Fuel Filter Water Separator 5 29 Replace the Secondary Fuel Element 5 29 Replace Air Cleaner Element 5 30 Add Rust Inhibitor to Engine Cooling System 5 30 Lubricate the Outrigger Slides 5 30 Check the Axle Housing Lubricant Level 5 31 Check the Wheel Hub Lubricant Level 5 31 Check Swing Gearbox Lubrica...

Page 9: ... System Assembly 6 7 Removal and Installation 6 10 Removal 6 10 Installation 6 11 SECTION 7 Transmission and Torque Converter Towing or Pushing 7 1 4 Speed Powershift transmission 7 1 Technical Specifications 7 2 Identification of the Unit 7 2 Weight Dimensions Oil Capacity 7 2 Pressure and Temperature Specifications 7 2 Electrical Specifications 7 3 Hydraulic Cooler and Filter Line Specifications...

Page 10: ...rake Adjustment 9 5 Accumulator Charging 9 5 Residual Brake System Pressure 9 5 Service Brake Repair 9 6 Disassembly 9 6 Assembly 9 8 Parking Brake Repair 9 9 Brake Modulating Valve Repair 9 12 Troubleshooting 9 14 Service Brakes 9 14 SECTION 10 Steering System Technical Data 10 1 Description 10 1 General 10 1 Steering Modes 10 1 Two Wheel Steering 10 3 Four Wheel Steering 10 4 Crab Steering 10 5 ...

Page 11: ...Installation 11 15 Hoist 11 17 Theory of Operation 11 17 Hoist Operation 11 17 Repair 11 19 Troubleshooting 11 37 Bearing Mast and Related Parts 11 39 General 11 39 Mast Bearing 11 39 Mast Bearing Bolts 11 39 Inspection for Bearing Wear 11 40 Replacing the Mast Bearing 11 40 Swing Gearbox and Pinion 11 41 Swing Gearbox Repair 11 44 Brake Cylinder Service 11 48 Planet Assembly Service 11 50 Outrigg...

Page 12: ...TABLE OF CONTENTS CD25 TOC 8 This Page Blank R e f e r e n c e O n l y ...

Page 13: ... 8 Loctite 1 8 Fasteners and Torque Values 1 9 Weld Studs 1 12 This manual contains information on maintenance service and repair of the Model CD25 cranes Major components and systems are included except service on the engine This information will be found in the engine manufacturer s service manual DIRECTIONAL REFERENCE All directional references in this manual unless otherwise noted are viewed f...

Page 14: ... VDC Alternator 130 amps Batteries 730 cold cranking amps each FUEL TANK Capacity 50 gal 189 L HYDRAULIC SYSTEM Pump Variable displacement piston pump Main Control Valves Four way closed center pilot operated hoist lift telescope Four way open center pilot operated swing Swing Motor Single section gerotor type Hoist Motor Fixed displacement axial piston Hydraulic Filters One 10 micron filter in li...

Page 15: ...r Drive Head REAR AXLE DRIVE Type International Transmissions Limited Model SD80 Center Drive Head OUTRIGGERS Type Hydraulic Construction 1 stage hydraulic telescoping beam with vertical jack Item Description Item Description 1 Boom Four Section 13 Counterweight 2 Pivot Head 14 Engine Compartment 3 Anti Two Block Device 15 Batteries FIGURE 1 2 1 13 14 2 12 15 10 7 6 4 3 11 5 8 9 16 17 20 19 18 R e...

Page 16: ...5 Hydraulic Valve Location Below Deck 17 Fuel Tank 6 Mast w Swing Gear 18 Folding Boom Extension 7 Hoist 19 Hook Block 8 Drive Steer Axles 20 Storage Compartments 9 Cab 10 Lift Cylinder 2 11 Hydraulic Tank 12 Air Cleaner Item Description Item Description R e f e r e n c e O n l y ...

Page 17: ...ly cleaned and heated Flush the parts thoroughly after cleaning to remove all residue of the alkali solution Rubber Parts Use brake fluid to clean rubber parts To inhibit damage to the part do not use mineral base solvents for example acetone or paint thinner NOTE Use brake fluid to clean rubber parts Acetone paint thinner or other mineral base solvents must not be used on rubber parts Mineral bas...

Page 18: ...ARINGS Removal 1 Bearings should never be removed unless absolutely necessary Always use the appropriate puller to reduce the risk of bearing or related component damage 2 When bearings or bushings are removed check that the bearing is free from discoloration nicks scuffing and signs of overheating If in doubt replace the bearing or bushing Cleaning Bearings acceptable for service should be cleane...

Page 19: ...he mating fitting and check to see that the flare seats properly on the nose of the fitting 3 Finger tighten the nut onto the fitting If necessary a wrench should be used to seat the nut snugly against the fitting This is considered the Finger Tight condition 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 5 ...

Page 20: ...size from Table 1 3 Table 1 3 Straight Thread Fittings HYDRAULIC PRESSURE TESTING Prior to pressure testing be sure all hoses are in good condition and all fittings are tight Use a pressure gauge with a range that is high enough to measure the specific pressure Comply with the correct procedure to inhibit damage to the system or the equipment and eliminate the possibility of injury FASTENERS Locti...

Page 21: ...sed component and the fastener should be torqued accordingly NOTE Some special applications require variation from standard torque values Reference should always be made to component overhaul procedures for recommendations Special attention should be given to the existence of lubricant plating or other factors that might require variation from standard torque values When maximum recommended torque...

Page 22: ... 1 1 4 1 1 2 Zinc Flake 5 7 14 25 40 61 88 121 213 342 512 636 884 1532 8 10 20 36 57 86 124 171 301 483 723 1032 1433 2488 Untreated 5 9 0 7 7 19 17 32 30 52 48 78 72 114 106 156 144 270 249 416 384 606 560 813 751 1141 1053 2028 1865 8 12 5 11 5 26 24 48 44 73 67 120 110 161 143 234 216 385 355 615 567 929 857 1342 1234 2043 1885 3276 3024 Bolt Diameter Inches Torque Values Pounds Foot Maximum M...

Page 23: ...046 1538 1420 10 9 4 5 4 1 9 2 8 5 16 14 26 24 38 35 75 69 130 120 212 195 322 298 455 418 629 581 856 790 1089 1005 1591 1469 2163 1997 12 9 5 4 4 9 11 10 19 17 31 28 45 42 89 83 156 144 248 228 387 357 532 490 756 698 1029 949 1306 1206 1910 1763 2595 2395 Bolt Diameter Metric Torque Values Nm Class M8x1 M10x1 M10x1 25 M12x1 5 M14x1 5 M16x1 5 M18x1 5 M20x1 5 M22x1 5 M24x2 M27x2 M30x2 M33x2 M36x3...

Page 24: ...nless steel fasteners tend to gall while being tightened To reduce this risk lubricate the threads with oil or molybdenum disulfide and torque at low speeds without interruptions Do not use excessive pressure Impact wrenches are not recommended Weld Studs Unless otherwise specified the following grade 2 torque values 10 apply Table 1 12 Weld Stud Torque Values 10 0 190 21 1 4 68 5 16 120 10 3 8 21...

Page 25: ...to the existence and relative degree of the hazard Important The information in this manual does not replace any safety rules and laws used in your area Before operating the crane learn the rules and laws for your area Make sure the crane has the correct equipment according to these rules and laws Your safety and the safety of others in the work area depend significantly upon your knowledge and un...

Page 26: ...ure you are capable of lifting the object If in doubt get help Avoids injury through incorrect handling of components What to do Why Operator s Cab Before using the crane be sure there are no loose items in operator s cab Inhibits operator injury from parts of operator s body or clothing being caught on objects when leaving the cab Lifting Equipment Ensure that lifting equipment chains brackets ho...

Page 27: ...g any service Inhibits serious injury and or death Place a warning sign in cab to warn others that service is being performed on the crane Disconnect the battery leads if leaving the crane unattended Inhibits serious injury and or death Do not attempt to start the engine while standing beside it Inhibits serious injury and or death Hoists Do not remove any hoist component unless the drop block or ...

Page 28: ...rked with what they contain Always fill or add fluids with a funnel or a filling pump Immediately clean up any spills FINAL WORD Safety precautions are very seldom the figment of someone s imagination They are the result of sad experiences most likely personal injury Heed these precautions and you will protect yourself and others accordingly Disregard them and you may duplicate the sad experiences...

Page 29: ...ge called protons until an electrical imbalance occurs Amperage rate of flow of electrons CURRENT measured in amperes Voltage the electromotive force EMF which causes electrons to move through an electrical circuit measured in volts Resistance any resistance to flow of electrons in an electrical circuit measured in Ohms Ohm s Law Electric current increases in direct relation to the voltage and dec...

Page 30: ...l system These components will be covered further in the discussion of the electrical system MAIN ELECTRICAL SYSTEM General The electrical system used on this machine is a 12 volt direct current DC system with a negative ground The power is supplied by two 12 volt batteries An alternator supplies the necessary current amps for system operation and charging of the batteries when the engine is runni...

Page 31: ...auge FU2 15 amp Windshield Wipers FU3 15 amp Cold Start Switch Horn Switch FU4 15 amp Winch Control Switch Outrigger Disable Relay FU5 15 amp Brake Light Pressure Switch Oil Pressure Switch FU6 20 amp LSI Relay LSI LI LSI RCL Hirsch Wylie Power Connector FU7 20 amp Drum Rotation Indicator Driver Board Drum Rotation Indicator Indicator Lamp Panel Hoist Speed Switch Turn Signal Emergency Flasher Axl...

Page 32: ... are five fuses in the battery compartment Refer to TABLE 3 3 for identification of the fuses The relay is the starter lockout relay TABLE 3 2 LSI Fuse Relay Panel Fuse Identification Fuse Rating Function FU1 5 amp RCL Power FU2 5 amp Seat Switch FIGURE 3 3 7508 74 RCL Relay 7508 74a FIGURE 3 4 TABLE 3 3 Engine Compartment Fuse Identification Fuse Rating Function 1 30 amp Ignition Power Relay 2 Li...

Page 33: ...ator using the mounting bolts and washers Torque bolts refer to Fasteners and Torque Values page 1 9 for the proper torque value 3 Install the belt on all engine pulleys except the alternator pulley for now 4 Turn the tensioner clockwise Slip the belt onto the alternator pulley then carefully return the tensioner to its normal position so it puts tension on the belt Make sure the belt is centered ...

Page 34: ...ive terminal to positive terminal negative terminal to negative terminal Never use a battery charger as a booster for battery output Heat can cause damage to the diodes Keep all sources of heat away from the alternator Battery Maintenance and Charging Batteries Maintenance free batteries are used on this machine A limited amount of maintenance is required on the batteries See Preventive Maintenanc...

Page 35: ...ads from the suspect relay 4 Remove the hardware securing the suspect relay to the relay panel assembly Remove suspect relay 5 Install replacement relay on relay panel and secure it with attaching hardware 6 Connect the electrical leads to the relay as tagged during removal 7 Position the cover on the panel and secure with the attaching hardware 8 Connect the batteries 9 Turn the battery disconnec...

Page 36: ...nectors 3 Inspect wiring for worn insulation or other damage Replace bad wiring Inspect all connections at the starter motor starter solenoid starter relay neutral start relay starter lock out relay and wire harness plugs Clean and tighten all connections and replace any bad wiring 4 If the starter still does not operate after correcting the circuit remove the starter and perform a bench test 5 If...

Page 37: ...esponding indication on the fuel gauge representing fuel level Engine Oil Pressure Gauge This gauge connects to a sending unit in the engine lubrication system The sending unit causes a variable resistance which gives a corresponding indication on the gauge indicating engine oil pressure Engine Temperature Gauge This gauge is connected to a sending unit in the engine cooling system The variable re...

Page 38: ... instrument panel wire harness supplies electrical current to the gauges lights and switches in the instrument panel It connects to the main frame wire harness Cab Wire Harness The cab harness supplies power to the strobe light dome light seat switch and heater AC unit It connects to the main frame harness Table 3 2 Voltage Level Conditions Voltage Measured Engine Speed Condition of Charging Syste...

Page 39: ...onent Normally the best method is to start at the furthest component in the circuit and move backwards toward the power supply An ohmmeter can be used to measure the resistance in any component Remember to disconnect the component from the power supply before you connect the ohmmeter Problem Possible Cause Solution Alternator does not charge 1 Alternator belt loose or broken 1 Replace and or tight...

Page 40: ...ter Check wiring and connections between ignition switch and starter solenoid 2 Bad starter relay 2 Replace starter relay 3 Bad ignition switch 3 Replace switch 4 Worn starter motor bad starter solenoid or internal problem in engine 4 Repair or replace starter replace solenoid or see engine manual 5 Dead battery s 5 Recharge or replace battery s 6 Parking brake not engaged 6 Engage parking brake 7...

Page 41: ...ation 4 11 Suction Return and Pump Pressure Circuits 4 14 General 4 14 Hydraulic Pump 4 16 Hydraulic Swivel 4 17 System Pressure Relief Valves 4 17 Four Section Main Control Valve 4 18 Checking and Adjusting Hydraulic Pressure Settings 4 20 Lift Circuit 4 24 General 4 24 Oil Flow 4 24 Counterbalance Valve 4 25 Lift Cylinder Leakage Test 4 25 Telescope Circuit 4 26 General 4 26 Oil Flow 4 26 Holdin...

Page 42: ...h the system It is important to remember that the pump causes the flow not the pressure in the system Pressure is caused by resistance to the flow This resistance can be external for example a load on a cylinder or motor or internal the resistance of the components of the system Pressure increases as the resistance to the flow increases The pump will continue to push more oil into the system until...

Page 43: ...inimum loss of time use the following aids and procedures Troubleshooting Aids 1 Hydraulic schematics an exact illustration of the arrangement of the system The schematic shows all the components in relation to the system The ability to understand the schematic is important to good troubleshooting The schematic can be found in Schematics Wiring Diagrams page 12 1 2 Flowmeter an instrument that can...

Page 44: ...remove that circuit from the system Continue to next circuit down the line until the problem is found NOTE Do not remove the main relief valve from the circuit The relief valve must be kept in the circuit to inhibit damage to the pump and other components TROUBLESHOOTING GUIDES General Hydraulic System Troubleshooting Table 4 1 Symptom Possible Cause Remedy Noise above normal Air in system Low oil...

Page 45: ...eriods Dirty filters Oil too light Low oil level Dirty oil Change procedure of operation Change filter See SECTION 5 Use correct oil Check and add oil Change oil and filters See SECTION 5 Foam in hydraulic tank Leak in system Wrong type of oil Low oil level Bad seal in pump motor or cylinder Check O ring on pump inlet Check for leak in system and correct Use correct oil Check and add oil Overhaul ...

Page 46: ...l leakage in cylinder Leakage in holding valve Faulty controller Broken centering spring in control valve section Replace piston seals Replace holding valve DO NOT ADJUST Repair or replace Replace broken spring Symptom Possible Cause Remedy Cylinder will not extend the boom under load Restriction in boom sections Load too heavy Faulty pump Leakage in hydraulic swivel Load sense relief valve malfun...

Page 47: ...valve Increase engine speed Clean or replace the dump valve Slow movement one outrigger Solenoid valve on outrigger valve section not fully actuating the valve spool Internal leakage in cylinder Check for restriction or binding in the solenoid valve Replace the piston seals Outrigger extends but does not retract or vice versa Problem in electrical circuit See Section 3 Outrigger lowers but will no...

Page 48: ...ion Brake not holding Faulty brake valve cartridge Decrease the load Repair or replace the brake See Brake Holding Valve page 4 29 Replace the brake valve cartridge Hoist drum does not move Restriction in brake valve cartridge Brake not releasing Clean or replace the brake valve cartridge Check condition of the brake line Repair as necessary Check condition of brake Repair as necessary Hook block ...

Page 49: ...ic tubes tighten all bolts finger tight Then in order tighten the bolts at the rigid end the adjustable end and the mounting brackets After tubes are mounted install the hoses Connect both ends of the hose with all bolts finger tight Position the hose so it does not rub the machine or another hose and has a minimum of bending and twisting Tighten bolts in both couplings Due to manufacturing method...

Page 50: ...ng filled The system must be filled with all cylinders retracted Fill the reservoir to the full mark on the reservoir sight gauge After the reservoir is filled operate all circuits and recheck the reservoir sight gauge Add hydraulic oil as required Removing Air From the Hydraulic System Air entering the hydraulic oil will normally be removed automatically by passage of the hydraulic oil over the b...

Page 51: ...ion 10 For information on the outrigger system see page 4 33 For information on the brake system see Section 9 Description of Operation The hydraulic system is a closed center hydraulic system Which means that hydraulic oil is blocked from returning to tank when the valve spools are in the neutral position The control valve sections used in the hydraulic system of the main control valve are pressu...

Page 52: ...of the inlet outlet section and then to tank Load Sensing Valve Section The load sensing valve section Figure 4 2 has a load sense relief valve installed in its housing The load sense relief valve is a direct acting design It limits the pressure sent to the variable displacement load sensing pump Using the load sense relief valve to limit system pressure versus a main relief valve maintains flow t...

Page 53: ...RE 4 2 8557 Inlet Priority Steer Section Inlet Port Lift Working Section Hoist Working Section Telescope Extend Relief Valve Load Sense Relief Valve Load Sense Port Load Sense Section Telescope Working Section Outlet Port Swing Working Section R e f e r e n c e O n l y ...

Page 54: ...e 4 3 is a variable displacement axial piston pressure compensated pump This pump moves hydraulic oil to the inlet section of the three section main control valve Here the oil is available to operate the lift telescope and hoist functions Hydraulic oil is also available from this pump to operate the pilot control system Hydraulic oil returns to the hydraulic oil tank through the return filter FIGU...

Page 55: ...4 15 CD25 HYDRAULIC SYSTEM 4 Published 5 24 2017 Control 587 01 FIGURE 4 4 8572 R e f e r e n c e O n l y ...

Page 56: ... forcing oil into the pressure port and out to the hydraulic system Pressure Regulation System pressure is working on the pressure compensator against a setting spring When system pressure overcomes the spring force the spool shifts allowing system pressure into the control piston This causes the pump to stroke to a regulating point sufficient to maintain the increased compensator setting system p...

Page 57: ... flows through this port back to tank Port No 5 Hydraulic oil under pressure flows through this port when the boom is being raised When lowering the boom low pressure hydraulic fluid flows through this port back to tank Port No 6 Hydraulic oil under pressure flows through this port when the boom is being lowered When raising the boom low pressure hydraulic oil returns through this port back to tan...

Page 58: ...Valve See Figure 4 7 Load Sensing Relief Valve See Figure 4 7 Port pressurized Spool in A Port Spool out B Port Valve Identification FIGURE 4 7 8557 Inlet Priority Steer Section Inlet Port Lift Working Section Hoist Working Section Telescope Extend Relief Valve Load Sense Relief Valve Load Sense Port Load Sense Section Telescope Working Section Outlet Port Swing Working Section R e f e r e n c e O...

Page 59: ...em will not be operating The most important benefit of this principle is that in multifunction operation when total demand exceeds pump output capacity all functions can still be operated but will slow down proportionally Load Sensing and Port Relief Valves The load sensing relief valve is located in the load sensing section of the valve assembly The purpose of the load sensing relief valve is to ...

Page 60: ...sconnect Parker PD240 with gauge onto test nipple at the G1 port 1 Figure 4 13 2 Start engine and read the pressure gauge while at engine idle A reading of 350 25 psi 24 1 7 bar should be observed 3 If pressure reading is correct shut off the engine and disconnect the pressure gauge 4 If pressure is incorrect loosen the pump margin stand by set screw from the pump compensator valve Figure 4 14 5 A...

Page 61: ...nstall pressure check diagnostic quick disconnect Parker PD240 with gauge onto test nipple at the G1 gauge port 1 Figure 4 16 located on the brake steering manifold 2 With the park brake on start the engine Set crane up on a level surface with outrigger jacks fully extended 3 With the engine at full RPM turn steering wheel all the way to one side until the steer cylinder bottoms out while another ...

Page 62: ... gauge clockwise increases pressure counterclockwise reduces the pressure 5 Tighten the jam nut against the relief valve body 6 Shut down the engine and remove the pressure gauge Procedure for checking Supply Pilot Pressure 1 Testing System Pressure a With the engine shutdown and the parking brake set install pressure diagnostic quick disconnect Parker PD240 with gauge onto pilot supply test port ...

Page 63: ... install pressure check diagnostic quick disconnect Parker PD240 with gauge onto test nipple at the gauge port Figure 4 17 disconnect both the hydraulic hoses from the under the deck winch motor Cap the hydraulic adapters and plug the hydraulic hoses 2 Start engine and accelerate the engine to full RPM 3 Watching the pressure gauge actuate the under the deck winch until the winch relief valve open...

Page 64: ...aulic swivel and enters the base end of the lift cylinders through the counterbalance valves The oil flows freely through the counterbalance valves and into the base end of the cylinders The cylinder rods extend pushing oil ahead of the piston out the rod end ports The oil returns through Port 6 of the hydraulic swivel to the control valve The oil is routed to the outlet port of the control valve ...

Page 65: ...ion Engine speed is important for proper lowering of the boom At low engine speed normally there is not enough oil from the pump to keep the cylinder filled As a result the boom will lower in an irregular movement NOTE Do not adjust the counterbalance valve setting The valve is adjusted at the factory If the valve is suspected of being faulty replace the valve Lift Cylinder Leakage Test If interna...

Page 66: ...e pressure opens the holding valve oil enters the telescope cylinder extending the boom oil returns through swivel port 3 then the control valve and is routed to the outlet port of the valve and returns to the hydraulic tank through the in line return filter Boom Retract Actuating the telescope lever to retract the boom routes oil under pressure to pilot port B of the control valve engaging the va...

Page 67: ...4 27 CD25 HYDRAULIC SYSTEM 4 Published 5 24 2017 Control 587 01 FIGURE 4 21 Port 3 Out Front of Crane Port 4 Out Port 4 In Extend Retract Port 3 In Retract Extend R e f e r e n c e O n l y ...

Page 68: ... there is a failure of the pump or the hydraulic lines the holding valve will hold the boom in position Engine speed is important for good retracting of the boom At low engine speed normally there is not enough oil from the pump to keep the cylinder filled As a result the boom will retract in a movement that is not smooth NOTE Do not adjust the holding valve setting The valve is adjusted at the fa...

Page 69: ... the supply from the pump through the port relief valve routing the oil to port 2 of the swivel and to the hoist assembly the pressure causes the motor to turn and begins releasing the brake pushing the control lever farther increases the hoist speed and fully releases the brake as the hoist is slowed the brake is applied When the hoist high speed switch is ON the high speed valve routes oil to th...

Page 70: ...CD25 4 30 Published 5 24 2017 Control 587 01 FIGURE 4 22 Pressure Tank Anti Two Block Load Sense Swivel Pressure Tank Main Control Valve Hoist Controller Hoist Third Wrap Lockout Optional Tank R e f e r e n c e O n l y ...

Page 71: ...4 31 CD25 HYDRAULIC SYSTEM 4 Published 5 24 2017 Control 587 01 Up Down FIGURE 4 23 R e f e r e n c e O n l y ...

Page 72: ...om the deck causing the mast and boom to rotate right oil from the downstream side of the motor returns to work port B of the control valve From there the oil is routed to the outlet port of the valve and through the in line return filter to the hydraulic tank Swing Left Actuating the swing lever to rotate the mast boom left routes oil under pressure to pilot port B of the control valve sending oi...

Page 73: ...locked fluid under pressure passes through a restriction in the valve section to the check valve The check valve is held closed by a combination of the check valve spring and oil pressure from the closed solenoid valve In combination the oil pressure and spring pressure is greater than the return oil pressure and the check valve is kept closed Return oil is then directed through the valve spool to...

Page 74: ...ludes the fifth solenoid valve of the rear outrigger control manifold and two oscillation lock out cylinders Oil Flow Oil from the pump flows to the rear outrigger control manifold and then the front outrigger control manifold Both valves are located in the distribution manifold Depending upon which outrigger function or axle lockout function is activated solenoid valve energized the oil flows thr...

Page 75: ... passage blocking oil at the valve and preventing oil from returning to tank unless the spool is shifted Oil from the manifold inlet flows directly to each valve where it stops When a solenoid is activated the spool moves allowing oil to flow through the solenoid valve and manifold to the outrigger cylinder Return oil from the cylinder flows through the valve back to tank A relief valve set at 17 ...

Page 76: ...ft Rear In I Right Front Down J Right Front Up K Right Front Out L Right Front In M Left Front Down N Left Front Up O Left Front Out P Left Front In Q To Filter R Port BR Control Manifolds S To Axle Lock T Front Outrigger Return U To Axle Unlock A B C D E F G H M N O P L K I J Rear Outrigger Selector Control Manifold A C G E H F D B C R Q S T U Return Manifold Return Manifold Front Outrigger Contr...

Page 77: ...he engine and actuate the control switch in the direction to lower the outrigger Check the amount of leakage from the open port If the leakage is more than a couple of drops per minute replacement of the piston seals is recommended HYDRAULIC PUMP REPAIR Removal 1 Drain the hydraulic tank 2 Disconnect the suction line and pressure line from the pump Disconnect the load sense and drain lines from th...

Page 78: ...ls to wear and result in internal leakage sticking spools or both A thorough cleaning of the valve and replacement of seals will generally remedy a leaking problem Extreme care must be taken to prevent nicks or scratches in machined surfaces All spools must be installed in their original bores If a spool or valve bore is damaged the entire valve section must be replaced Removal 1 Shut off the engi...

Page 79: ...uts 8 from the tie rods 7 at the outlet section 1 4 Slowly lift the outlet section from the tie rods NOTE Be careful when separating the valve sections The working sections have spring loaded check valve assemblies The spring could fly out of the valve section when the section is removed 5 Slowly lift the four working valve sections 2 3 4 and 5 from the tie rods 6 Remove the tie rods 7 from inlet ...

Page 80: ... Assembly Inlet Section 1 Install poppet 11 spring 12 and screw 13 and secure with nuts 15 and 16 2 Install relief valve 3 Install poppet 7 spring 8 and plug 10 Item Description 1 Inlet Section 2 Hoist Section 3 Lift Section 4 Telescope Section 5 Swing Section 6 Outlet Section 7 Tie Rod 3 8 Nut 6 9 Drain Regulator Assy 10 Plug Assy 11 Shut Off Plug Assy 12 Relief Valve Assy 13 Relief Valve Assy 14...

Page 81: ...st Section Disassembly 1 Remove screws 11 Figure 4 30 and valves 10 2 Remove plugs 6 springs 4 and spring seats 3 Item Description 1 Housing Inlet 2 Spool 3 Spring 4 Spring 5 O Ring 6 Plug Assy 7 Poppet C V 8 Spring 9 O Ring 10 Plug Assy 11 Poppet R V 12 Spring 13 Screw Adjust 14 O Ring 15 Nut Special 16 Nut Special 17 O Ring 18 O Ring 19 O Ring FIGURE 4 29 R e f e r e n c e O n l y ...

Page 82: ...s 6 3 Install valves 10 and secure with screws 11 4 Install and hold in place with petroleum jelly poppet 12 and spring 17 5 Install O rings and other plugs as necessary Item Description 1 Housing Spool Hoist 2 Spool 3 Spring Seat 4 Spring 5 O Ring 6 Plug Assy 7 Spool Compensator 8 O Ring 9 Plug Assy 10 Solenoid Cartridge Valve 11 Cap Screw 12 Poppet C V 13 Spring 14 O Ring 15 O Ring 16 O Ring 17 ...

Page 83: ...ng seats 3 3 Remove plugs 9 and spool compensator 7 4 Remove other plugs and O rings as necessary Item Description 1 Housing Spool Lift 2 Spool 3 Spring Seat 4 Spring 5 O Ring 6 Plug Assy 7 Spool Compensator 8 O Ring 9 Plug Assy 10 Solenoid Cartridge Valve 11 Cap Screw 12 Poppet C V 13 Spring 14 O Ring 15 O Ring 16 O Ring 17 Spring FIGURE 4 31 R e f e r e n c e O n l y ...

Page 84: ... with screws 11 4 Install and hold in place with petroleum jelly poppet 12 and spring 17 5 Install O rings and other plugs as necessary Telescope Section Disassembly 1 Remove screws 11 Figure 4 32 and valves 10 2 Remove plugs 6 springs 4 and spring seats 3 3 Remove plugs 9 and spool compensator 7 4 Remove relief valve 5 Remove other plugs and O rings as necessary R e f e r e n c e O n l y ...

Page 85: ...all and hold in place with petroleum jelly poppet 12 and spring 17 5 Install relief valve 6 Install O rings and other plugs as necessary Item Description 1 Housing Spool Telescope 2 Spool 3 Spring Seat 4 Spring 5 O Ring 6 Plug Assy 7 Spool Compensator 8 O Ring 9 Plug Assy 10 Solenoid Cartridge Valve 11 Cap Screw 12 Poppet C V 13 Spring 14 O Ring 15 O Ring 16 O Ring 17 Spring FIGURE 4 32 R e f e r ...

Page 86: ...e plug 10 spring 8 and spool assy compensator 7 4 Remove other plugs and O rings as necessary Item Description 1 Housing Spool Swing 2 Spool 3 Spring Seat 4 Spring 5 O Ring 6 Plug Assy 7 Spool Assy Compensator 8 Spring 9 O Ring 10 Plug Assy 11 O Ring 12 Plug Assy 13 Solenoid Cartridge Valve 14 Cap Screw 15 Poppet C V 16 Spring 17 O Ring 18 O Ring 19 O Ring FIGURE 4 33 R e f e r e n c e O n l y ...

Page 87: ...t Section Disassembly 1 Remove screws and valve 2 Figure 4 34 2 Remove plug 3 Assembly 1 Install plug 3 2 Install valve 2 and secure with screws Complete Valve Assembly 1 Lay the valve components on a clean flat work surface 2 Assemble nuts 7 and 9 Figure 4 29 to one end of each tie rod 6 and 8 Insert the tie rods through the stud holes in the inlet valve section 10 Lay the inlet section on the wo...

Page 88: ... provides positive seating and very seldom requires any maintenance Therefore the pilot section can be removed from the cartridge housing without disturbing the pressure setting With it will come the check valve poppet and other internal parts These are easily disassembled and should be examined for foreign material All seats and seating surfaces should be smooth and free of nicks scratches or gro...

Page 89: ... each hydraulic function several times in both directions 5 Check for leaks and fill the reservoir if required Outrigger Control Valves The outrigger control valves are on separate valve blocks front and rear Figure 4 37 The valve blocks are mounted between and below the frame rails on the inside of the front and rear outrigger boxes Removal 1 Stop the engine and engage the parking brake Place cho...

Page 90: ...f the engine Even then disconnect the hose or line slowly to release any pressure that still might be in the circuit NOTE The swing motor can only be reached from under the machine Shut off the engine set the parking brake and remove the ignition key Block all tires 2 Before disconnecting the hydraulic lines clean the port area of the swing motor thoroughly Disconnect the hydraulic lines from the ...

Page 91: ... to break the capscrews loose apply heat according to the following When heated Loctite partially melts This reduces the torque required to remove screw Use a small flame propane torch to heat a small area of the housing where the screws enter See Figure 4 41 Be careful not to overheat the housing and damage the motor Gradually apply torque to the capscrew with a socket wrench as heat is applied f...

Page 92: ...n be applied the parts should be cleaned as follows NOTE Fully cured Loctite resists most solvents oils gasoline and kerosene and is not affected by cleaning operations It is not necessary to remove cured Loctite that is securely bonded in tapped holes however any loose particles of cured Loctite should be removed 1 Wash the housing with a suitable solvent to remove oil grease and debris Pay parti...

Page 93: ...n tapped holes of housing 10 Allow the primer to air dry for at least 1 minute Do not force dry with air jet the primer will blow away Use of primer is optional With primer Loctite curing time is approximately 15 minutes Without the primer the curing time is approximately 6 hours 9 Apply 3 or 4 drops of Loctite sealant at the top of the threads for each of the four holes in the housing see Figure ...

Page 94: ...Timing Procedure 15 Install drive shaft 14 Figure 4 39 Use a felt tip pen to mark one drive tooth Align this mark with the timing dot on the output shaft Figure 4 48 NOTE If drive shaft 14 is not symmetrical install larger splined end into output shaft 9 16 Install spacer plate 15 17 Install seal 13 in gerotor seal groove Carefully place gerotor on spacer plate seal side toward the spacer plate Al...

Page 95: ...tor to the hoist Remove the hoist motor and gasket Discard the gasket 4 Remove the adapter flanges spacer block and line mount body Figure 4 50 from the pump Discard all O rings Disassembly The hoist motor is not field serviceable It must either be replaced or returned to your distributor for repair Installation 1 Install the line mount body Figure 4 50 spacer and adapter flanges to the hoist moto...

Page 96: ...d discard seals 10 seals 11 wear ring 12 and O rings 13 Inspection Wash the housing and shaft in a suitable solvent Check the housing for damage If there is scoring or deep grooves the housing must be replaced Use compressed air to remove foreign materials from the passages in the swivel shaft Check the shaft for rough edges that could cause damage to the seals during installation Assembly 1 Lubri...

Page 97: ... a4140 FIGURE 4 51 Item Description 1 O ring Plug 2 2 Plug 3 Plug 4 4 Swivel Stem 5 O ring 2 6 Thrust Washer 2 7 Swivel Housing 8 Retainer 9 Retainer Ring 10 End Seal 2 11 Piston Seal Assembly 8 12 Wear Ring 13 O ring Included in Seal Kit R e f e r e n c e O n l y ...

Page 98: ... the hydraulic swivel using three bolts and lockwashers 3 Connect the hydraulic lines to the lower ports of the hydraulic swivel 4 Fill the lower hydraulic system by adding recommended hydraulic oil through the upper ports of the hydraulic swivel 5 Connect the hydraulic lines to the upper ports 6 Start the engine and move the hydraulic oil through the swivel by actuating all functions Visually che...

Page 99: ...ble the rings and seals on the piston 4 Be sure O ring is installed between the piston and the rod Fasten the piston to the rod with locking nut and tighten to the specified torque On pistons with internal threads apply Loctite coarse to the threads and screw piston onto cylinder rod and torque in place 5 Apply hydraulic oil to the bore of cylinder and the rings on the piston Carefully slide the p...

Page 100: ...rdware 2 Connect the hydraulic lines 3 Lubricate the cylinder pivot grease fittings with recommended grease 4 Check hydraulic oil level in the hydraulic oil reservoir Add oil if necessary Item Description 1 Cylinder Tube 2 Nut 3 Wear Ring 4 O ring 5 Piston Seal 6 Piston 7 O ring 8 O ring 9 Back Up Ring 10 Head 11 Rod Seal 12 Wiper 13 Rod Included In Seal Kit a4146 FIGURE 4 53 Rear Axle Lockout Cyl...

Page 101: ... 54 Item Description 1 Cylinder Tube 2 Nut 3 Wear Ring 2 4 Seal 5 Loader 6 Piston 7 O ring 8 O ring 9 Back Up Ring 10 Wiper Ring 11 Gland 12 Seal 13 Wiper 14 Rod 15 Bushing 4 16 Grease Fitting 4 17 Counterbalance Valve Included In Seal Kit Lift Cylinder R e f e r e n c e O n l y ...

Page 102: ...rew 15 Retaining Ring 16 Rod Wiper 17 Rod Seal 18 Back up Ring 19 O Ring 20 Wear Ring 21 Retaining Ring Telescope Cylinder Item Description 22 Rod Wiper 23 Rod Seal 24 Back Up Ring 25 O Ring 26 Wear Ring 27 Piston Seal 28 O Ring 29 Wear Ring 30 Piston Seal 31 O Ring 32 Wear Ring 33 Lock Washer 3 8 4 34 Cap Screw 3 8 4 35 Locknut 36 Holding Valve Assy Item Description 37 90 Elbow Assy 38 90 Elbow A...

Page 103: ...em Description 1 Cylinder Tube 2 Nut 3 Wear Ring 2 4 Poly Ring 5 O ring 6 Piston 7 O ring 8 Spacer 9 O ring 10 Backup Ring 11 Head 12 Wear Ring 13 U Cup 14 Rod Wiper 15 Rod Included In Seal Kit a4144 FIGURE 4 56 Horizontal Outrigger Cylinder R e f e r e n c e O n l y ...

Page 104: ... Description 1 Cylinder Tube 2 Nut 3 Wear Ring 2 4 O ring 5 Piston Seal 6 Piston 7 O ring 8 O ring 9 Back Up Ring 10 Gland 11 Rod Seal 12 Wiper 13 Rod 14 Counterbalance Valve Included In Seal Kit a4145 FIGURE 4 57 Vertical Outrigger Cylinder R e f e r e n c e O n l y ...

Page 105: ...pect the Fan Belts 5 25 Check the Wheel Nut Torque 5 26 250 Hours of Operation Monthly 5 26 Inspect the Hydraulic Hoses 5 26 Clean the Batteries and Cables 5 26 Lubricate the Wire Rope 5 27 Lubricate the Swing Gear and Pinion 5 27 Torque Critical Bolts 5 27 Replace the Crankcase Oil 5 28 Replace the Engine Oil Filter 5 29 Clean the Radiator 5 29 500 Hours of Operation Three Months 5 29 Inspect the...

Page 106: ...re rope as established by ANSI ASME B30 5 federal regulations and Manitowoc The inspection interval shall be determined by a qualified person and shall be based on such factors as expected rope life as determined by experience on the particular installation or similar installations severity of environment percentage of capacity lifts frequency rates of operation and exposure to shock loads Periodi...

Page 107: ... finished rope with ample protection for a reasonable time if it is stored under proper conditions But when the rope is put into service the initial lubrication may be less than needed for the full useful life of the rope Because of this possibility periodic applications of a suitable rope lubricant are necessary The following are important characteristics of a good wire rope lubricant It should b...

Page 108: ...er 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 path during other welding operations Wire ropes are manufactured from special steels If heating a wire rope assembly is absolutely necessary for removal the entire wire rope assembly shall be discarded On systems equipped with two or more wire rope assemblies operating ...

Page 109: ...f core failure End fitting wear abrasion Pay particular attention to areas of the rope where wear and other damage is likely to occur Pick up Points Sections of wire rope that are repeatedly stressed during each lift such as those sections in contact with sheaves End Attachments The point where a fitting is attached to the wire rope or the point where the wire rope is attached to the drum Abuse Po...

Page 110: ...by inspection Wire rope replacement should be determined by the following information excerpted from a National Consensus Standard as referenced by Federal Government Agencies and as recommended by Manitowoc All wire rope will eventually deteriorate to a point where it is no longer usable Wire rope shall be taken out of service when any of the following conditions exist Kinking crushing bird cagin...

Page 111: ...d lubricants or guarantee lubricant performance The responsibly for the quality rests completely with the distributor or manufacturer of the lubricant In various paragraphs in this maintenance section statements may be found use lubricant brand name or equivalent This statement does not constitute an unconditional guarantee of performance of the brand of lubricant mentioned It is intended only as ...

Page 112: ...case Fill if level is low Remove water from fuel filters Cooling System Check coolant level Fill if level is low Hydraulic Tank Check oil level Fill if level is low Drive Axles Check axle housing lubricant level and wheel hub lubricant level Fill if levels are low Hoist Gearbox Check lubricant level Fill if level is low Tires Check tires for correct air pressure Wire Rope Cable Clamps and Connecti...

Page 113: ...ing the 250 Hour Monthly maintenance interval perform all the tasks required for Daily 50 Hour and 100 Hour maintenance Service Check Interval Daily Before Operation 50 Hours Weekly 100 Hours Two Weeks 250 Hours Monthly 500 Hours Three Months 1000 Hours Six Months 2000 Hours Yearly Inspect the Anti Double Blocking System X Inspect the Wire Rope X Inspect the Reeving Clamps and Connectors X Inspect...

Page 114: ... Engine Crankcase Oil1 X Replace the Engine Oil Filter1 X Clean Radiator Fins and Core X Clean Battery and Connections X Torque Critical Fasteners X Check Axle Wheel Hub Lubricant Level 4 places X Check Axle Housing Lubricant Level 2 places X Check Swing Gearbox Lubricant Level X Lubricate the Outrigger Slides X Replace Fuel Filter Water Separator Elements X Replace the In line Fuel Filter X Repla...

Page 115: ...ity Limiter Option X 1 Under extremely dusty conditions the engine oil and filter as well as the air cleaner element may require replacement more frequently Service Check Interval Daily Before Operation 50 Hours Weekly 100 Hours Two Weeks 250 Hours Monthly 500 Hours Three Months 1000 Hours Six Months 2000 Hours Yearly Lube Symbol Description Specification EP MPG EP MPG Multipurpose Grease A6 829 0...

Page 116: ...er Axle 1 Differential 4 8 Gal 18 0 Liters HYDO 2 Planetary Hub Gears 2 1 Qts 2 0 Liters HYDO 3 Kingpin Bearings EP MPG 4 Steer Cylinder Bearing EP MPG 5 Universal Joints EP MPG 6 Brake Caliper EP MPG Rear Drive Steer Axle 7 Differential 4 8 Gal 18 0 Liters HYDO 8 Planetary Hub Gears 2 1 Qts 2 0 Liters HYDO FIGURE 5 8 8534 R e f e r e n c e O n l y ...

Page 117: ...PG 17 T T Gear Pinion EP OGL 18 T T Bearing EP MPG Cylinders 19 Outrigger Cylinder ASC 20 Lift Cylinder EP MPG Boom 21 Boom Nose Sheaves EP MPG 22 Jib Boom Sheave EP MPG 23 Boom Sections EP MPG See Note 6 24 Tele Cylinder Wear Pads EP MPG 25 Boom Extension Sheave EP MPG 26 Boom Ret Sheave EP MPG 27 Hook Block Swivel Bearing EP MPG 28 Boom Pivot Shaft EP MPG 29 Hook Block Sheaves EP MPG Outriggers ...

Page 118: ...gure 5 10 1 Boom Head Sheaves and Pivot See Figure 5 11 2 Lift Cylinder 2 Pivots See Figure 5 12 4 Location Qty Steering Knuckles Front and Rear Axles See Figure 5 13 8 Steering Cylinder Pivot Ends Front and Rear Axles See Figure 5 14 4 Drive Shaft Front Axle See Figure 5 15 No routine lubrication is required Lubricate only after major axle overhaul 2 Drive Shaft Rear Axle See Figure 5 16 No routi...

Page 119: ...eaves and Pivot Grease Points both sides 7407 43 FIGURE 5 12 Lift Cylinder Pivot Grease Points 7407 41 7407 42 p0489 FIGURE 5 13 Steering Knuckle Grease Points Front and Rear Axles Both sides p0488 FIGURE 5 14 Steering Cylinder Pivot Grease Points Front and Rear Axles Both sides R e f e r e n c e O n l y ...

Page 120: ...7 Control 587 01 p0490 FIGURE 5 15 Front Axle Drive Shaft Grease Points Three Lube Fittings p0491 FIGURE 5 16 Rear Axle Drive Shaft Grease Points Three Lube Fittings p0492 FIGURE 5 17 Axle Pivot Grease Points Front and Rear Axles R e f e r e n c e O n l y ...

Page 121: ...NTENANCE 5 Published 5 24 2017 Control 587 01 p0528 FIGURE 5 18 Drop Block Grease Point Both sides p0315 FIGURE 5 19 Jib Head Sheave Grease Point p0316 FIGURE 5 20 Jib Boom Deflector Sheave Grease Point R e f e r e n c e O n l y ...

Page 122: ... Do not operate the crane if any of the above is found Only after correcting the problem should the crane be put back in service Inspect the Lifting Hook Daily before beginning operation inspect the lifting hook for damage cracks deformation loose retaining hardware etc If any damage is found DO NOT operate the crane until the damage is repaired Inspect All Safety Devices Daily before beginning op...

Page 123: ...al operating temperature 82 to 93 C 180 to 200 F 2 Level the crane engage the parking brake and let the engine run at idle speed 3 Remove the transmission dipstick Figure 5 21 and check the oil level Oil should be at the FULL mark on the dipstick 4 Install the dipstick 5 If the oil is low add recommended oil to bring the level up to the full mark on the dipstick 6 Shut off the engine Check the Eng...

Page 124: ...the outriggers are retracted and up 2 With the crane on level ground engage the parking brake and shut off the engine 3 Visually check the oil level in the sight glass Figure 5 22 The hydraulic oil should be visible in the sight gauge on the side of the tank If low fill the tank with pre filtered recommended hydraulic oil NOTE The pump used on this crane requires clean hydraulic oil for proper ope...

Page 125: ...sing could cause damage to the engine Use a clean water dampened cloth to wipe every surface clean Check it visually to make sure it is clean before installing a new element 5 Always clean the gasket sealing surfaces of the housing An improper gasket seal is one of the most common causes of engine contamination Make sure that all hardened ridges are completely removed Inspecting the Element 1 Don ...

Page 126: ...quivalent to the inner boom surface in front of and behind the slide block Only use a small amount of lubricant for best results Extend and retract the booms to distribute the lubricant along the slide path Check the Hoist Gearbox and Brake Lubricant Levels 1 Lower the boom to its lowest position 2 Engage the parking brake and shut off the engine 3 Check the lubricant level Oil should be visible i...

Page 127: ...rate 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 or coastline conditions need to have the exposed rods protected more frequently by applying a protectant Unless the machine is operated daily exposed rod surfaces will corrode Some cylinders will have rods exposed even when completely...

Page 128: ...the grease 9 Repeat steps 3 5 Fully extend and retract the boom to spread the grease Side and Bottom Boom Wear Pad Lubrication 1 Fully extend and set the outriggers NOTE A fully extended boom at horizontal needs to have an assist from a crane or forklift to retract Lift the front of the boom enough to relieve pressure on the bottom wear pads This should be sufficient for the boom to retract 2 Lowe...

Page 129: ... safety rules found in Section 2 Safety Practices before performing any operation or maintenance procedures For additional engine maintenance guidelines see the engine manual furnished with this crane Inspect the Fan Belts Keep the engine and accessory belts properly tensioned for maximum engine performance and fuel economy Proper belt tension minimizes slippage and increases belt life Belts that ...

Page 130: ...d fittings and worn exterior Do not use your hands to check for hydraulic leaks Hydraulic oil under pressure can cause serious injury or possible death Use a piece of cardboard or other material as a deflector to detect leaks Replace any problem hose before beginning work Clean the Batteries and Cables 1 Open the battery compartment cover to gain access to the batteries 1 Figure 5 29 2 Tighten all...

Page 131: ...rope Lubricate the Swing Gear and Pinion 1 Engage the parking brake and shut off the engine 2 Remove the guard covering the swing pinion 3 Using a brush apply open gear lube to the pinion and swing gear teeth 1 Figure 5 30 Rotating gears can cause injury Keep hands clear of rotating pinion and gear while the mast is rotating 4 Start the engine and rotate the mast until a non lubricated portion of ...

Page 132: ...ighten them Rotate the mast through a complete cycle tightening all bolts Mast to Swing Bearing Mounting Bolts Tighten the twenty six 26 7 8 mast mounting bolts 1 Figure 5 34 to 619 Nm 455 lb ft Tighten each bolt in a crisscross pattern Replace the Crankcase Oil Change the engine oil more frequently if operating under difficult conditions for example in high or low temperatures or frequent startin...

Page 133: ...materials are not removed the engine may overheat due to blocked air through the radiator fins and core 500 HOURS OF OPERATION THREE MONTHS NOTE You must read and understand the warnings and basic safety rules found in Section 2 Safety Practices of this manual before performing any operation or maintenance procedures For additional engine maintenance guidelines see the engine manual furnished with...

Page 134: ...ay NOTE The secondary element must be replaced after two primary element replacements 7 Install the new element in the housing and slide it all the way in 8 Make sure the gasket is seating evenly If the gasket isn t seating evenly for a perfect seal you won t have protection Recheck to see if the sealing surface in the housing is clean or if the element is not the right model number If may be too ...

Page 135: ...ich should be even with the bottom of the fill check hole 3 If necessary add Mobil Fluid 424 or equivalent to fill the housings until the oil is level with the bottom of the fill check hole Check the Wheel Hub Lubricant Level 1 Position the fill check plug so it is horizontal with the ground at the 3 o clock position 1 Figure 5 40 2 Clean around the plug and then remove it 3 Check the lubricant le...

Page 136: ...e grease fitting 2 Figure 5 41 on the gear box 1000 HOURS OF OPERATION SIX MONTHS NOTE You must read and understand the warnings and basic safety rules found in Section 2 Safety Practices of this manual before performing any operation or maintenance procedures For additional engine maintenance guidelines see the engine manual furnished with this crane Replacing the Transmission Oil and Filter 1 En...

Page 137: ...fill all lines 10 With the engine running at idle speed check the transmission oil level and fill to the LOW mark on the dipstick 11 When the transmission is at normal operating temperature 82 to 93 C 180 to 200 F make a final check of the oil level Add oil to the FULL mark on the dipstick Replace the Axle Housing Lubricant NOTE It is necessary to climb under the crane to drain the axle housing oi...

Page 138: ...he crane until one of the front axle wheel hub drain plugs is located at the bottom of the wheel hub Figure 5 47 2 Clean around the drain plug and then remove it Drain the wheel hub oil into a suitable container 3 Drive the crane until the drain hole is horizontal Figure 5 48 4 Fill the wheel hub with approximately 2 0 l 2 1 qt of Mobil Fluid 424 through the exposed hole until the oil reaches the ...

Page 139: ...ean around the swing gear box drain check and fill plugs Figure 5 50 2 Remove the fill check and drain plugs and catch draining lubricant in a suitable container Properly dispose of the lubricant 3 Install the drain plug 4 Fill the swing gearbox with EP 90 weight oil until the oil reaches the bottom of the check plug hole 5 Install the check plug 6 Clean the fill plug vent in a suitable solvent an...

Page 140: ...fill strainer suction strainer suction hose return hose and drain plug to the hydraulic tank 11 Replace the hydraulic oil filter See Replacing the Hydraulic Oil Filter below 12 Fill the hydraulic tank with Mobil Fluid 424 hydraulic oil to the bottom of fill strainer 13 After the tank is filled start the engine and operate each function until all the cylinders and lines are filled 14 Fully retract ...

Page 141: ...ion The high point is punch marked on the edge of the mast base plate Figure 5 53 Rotating gears can cause injury Keep hands clear of rotating pinion and gear while the mast is rotating 3 Using a feeler gauge check the backlash between the gear and pinion 1 Figure 5 53 There should be no clearance between the swing gear tooth and the pinion tooth If there is any clearance adjust the backlash See t...

Page 142: ...ystem NOTE Lead acid batteries produce flammable and explosive gases To avoid personal injury when checking testing or charging batteries DO NOT use smoking materials near batteries Keep arcs sparks and flames away from batteries Provide ventilation and wear safety glasses Never check battery charge by placing a metal object across the posts The sparks could explode battery gases and cause injury ...

Page 143: ...d period causes accumulation of sediment dirt water and other foreign materials in the fuel Many engine problems are caused by dirty fuel and long storage periods Keep fuel in an outside location Use a shelter to keep the fuel as cool as possible The water from condensation must be removed at regular intervals from the storage tank Fuses and Relays Fuse Block 1 Fuse Relay Panel Fuse block 1 fuse r...

Page 144: ...he battery compartment fuse block 3 1 Figure 5 57 and fuse block 4 2 Refer to TABLE 5 1 and TABLE 5 2 for identification of the fuses FIGURE 5 55 8543 25A 7 5A AXLE OSC SWITCH FIGURE 5 56 8543 1 10A K9 HORN K10 SHIFT TABLE 5 1 Fuse Block 3 Fuse Function Size F1 Fuse Block FB 1 F10 FB 2 F3 20 F2 FB 1 F1 FB 1 F2 FB 2 F6 30 F3 ECM B 30 F4 FB 1 F7 FB 1 F8 FB 1 F9 FB 2 F1 FB 2 F4 FB 2 F8 30 F5 FB 1 F3 ...

Page 145: ...ure 5 58 incorporates a fluid level sending unit and a heating element to keep the DEF from freezing When the indicator in the dash illuminates TABLE 5 2 Fuse Block 4 Fuse Function Size F1 DEF Pressure Line DEF Return Line DEF Suction Line 15 F2 DEF Line Relay Coil 5 F3 DEF Supply Module Relay Coil DEF Module 15 F4 Aftertreatment Sensors 10 F5 Aftertreatment Sensor Relay Coil High Exhaust Temp Rel...

Page 146: ...tes the moisture containing salt dirt and other pollutants by lifting and removing them from the metal surface The film creates a barrier to repel further moisture from coming into contact with the metal It penetrates crevices In addition to this factory applied treatment Manitowoc crane owners must provide proper maintenance and care to help ensure long term protection of their crane against corr...

Page 147: ...rea afterwards All identified spots and or areas that have been scratched through to the metal should be touched up and repaired as soon as possible to prevent flash rusting To repair a major scratch down to bare metal or minor damage follow these procedures NOTE Manitowoc Crane Care recommends that a qualified body repairman prepare prime and paint any major scratch es or minor damage For scratch...

Page 148: ... paint pots to apply the treatment to the unit being processed is recommended Carwell treatment is available in 16 ounce spray bottles from Manitowoc Crane Care order part number 8898904099 After application of the treatment is complete wash or clean film residue from lights windshield grab handles ladders steps and all access areas to crane as necessary Please contact Manitowoc Crane Care should ...

Page 149: ...artments 7 Boom Extension Pins Clips 8 Hose Connections inside turntable 9 Lift Cylinder Pivot Shafts 10 Boom Extension Hanger Hardware 11 Boom Nose Pins Clips 12 Hook block Tiedown Cable 13 O R Beam Wear Pad Adjustment Hardware 14 Hook Block Headache Ball 15 Entire underside of unit 16 Turntable Bearing Fasteners 17 All Hardware Clips Pins Hose Connections not painted O R Pins Clips 18 Wire Rope ...

Page 150: ...PREVENTATIVE MAINTENANCE CD25 5 46 Published 5 24 2017 Control 587 01 This Page Blank R e f e r e n c e O n l y ...

Page 151: ...hydraulic pump which supplies power to operate the work functions of the crane For maximum power the engine must be kept in good working condition ENGINE RPM To check the engine speed follow the instructions in the engine operator s manual Maximum and minimum speeds are controlled by a governor installed on the engine The throttle gives variable control of the engine speed within the limits set by...

Page 152: ... consistently below 23 C 10 F use a lubricating oil that meets the following requirements ENGINE COOLING SYSTEM The engine cooling system consists of the coolant passages in the engine a thermostat water pump hoses and radiator The engine is cooled by the circulation of coolant through the passages in the engine block and head Circulation is by a thermo siphon action assisted by a water pump drive...

Page 153: ...l rust through allowing coolant leakage An incorrect or malfunctioning radiator cap can result in the loss of coolant and engine running hot Any sudden loss of coolant from a heavily loaded engine can result in severe damage to the pistons and cylinder bore Some corrosion inhibitor mixtures contain soluble oil which can have an adverse effect on some types of water hoses Radiator Cap The cooling s...

Page 154: ...e loosened or lines are replaced Initial start up or start up after an extended period of time The fuel tank has run empty Refer to the diesel operator s manual furnished with this crane for bleeding procedures Fuel Filter The filter is used to collect contaminants and water that has accumulated in the fuel and is not picked up by the sediment bowl It must be serviced at regular intervals See Sect...

Page 155: ...static scale Figure 6 3 Correct diesel fuel grade A B is shown next to the scale NOTE If engine is operating at temperatures of 40 to 57 C 40 to 70 F Grade DF A arctic fuel is recommended Also consult the engine distributor for special lubricants and starting aids Cetane number should be a minimum of 40 to assure satisfactory starting and overall performance At low temperatures and or high altitud...

Page 156: ...ducting consists of metal tubing hose clamps and bellows The recommended installation torque of the spring loaded T bolt clamps is 6 8 8 5 Nm 60 75 lb in Do not compress the spring completely the bellows and or clamp may be damaged from thermal expansion of the CAC tube Maintenance Check the hose clamps for proper torque Inspect the bellows for cracks or holes Clean the charge air cooler removing ...

Page 157: ...diesel oxidation catalyst DOC decomposition reactor tube a selective catalytic reduction SCR unit and various tubes elbows and clamps Removal NOTE The down pipe insulation is an emissions compo nent and must be replaced if removed for service or if damaged The exhaust aftertreatment components are bolted to a single weldment that can be removed by a properly rated lifting device The subassembly we...

Page 158: ...ENGINE AND ENGINE SYSTEMS CD25 6 8 Published 5 24 2017 Control 587 01 8573 FIGURE 6 6 1 2 3 4 5 6 7 6 8 9 9 9 9 10 8 11 9 12 13 14 15 16 17 18 R e f e r e n c e O n l y ...

Page 159: ...n Reactor Tube 11 Elbow 12 Tail Pipe 13 Clamp 14 Selective Catalytic Reduction SCR Unit 15 Diesel Oxidation Catalyst DOC Unit 16 Mounting Band 17 Mounting Band 18 Muffler Clamp Table 6 2 Engine Troubleshooting Chart Problem Probable Cause Action Engine hard to start or will not start 1 Improper starting procedure 2 No fuel 3 Air in fuel line 4 Crankcase oil too heavy 5 Improper type of fuel 6 Wate...

Page 160: ...ne 15 Drain the oil from the hydraulic tank Lack of power 1 Engine overload 2 Intake air restriction 3 Clogged fuel filters 4 Overheated engine 5 Below normal engine temperature 6 Faulty engine 1 Reduce the load 2 Service air cleaner 3 Replace fuel filters 4 Refer to Engine Operator s Manual Check for plugged radiator oil cooler fins 5 Remove and check thermostat 6 Refer to Engine Operator s Manua...

Page 161: ...s until the rear mounting bolts washers rubber mounts and nuts can be installed and tightened 4 Install the rear axle a Locate the rear axle under its mounting location Raise the axle and mounting bracket into position and install the eight mounting bolts and flat washers b Install the front engine mounting hardware c Connect the brake lines to the axle d Connect the hydraulic hoses to the steerin...

Page 162: ...ENGINE AND ENGINE SYSTEMS CD25 6 12 Published 5 24 2017 Control 587 01 This Page Blank R e f e r e n c e O n l y ...

Page 163: ...cifications 7 3 Maintenance 7 4 Oil Specification 7 4 Maintenance Intervals 7 5 Servicing Machine After Components Overhaul 7 5 Removal 7 6 Installation 7 6 TOWING OR PUSHING Before towing the vehicle be sure to lift the rear wheels off the ground or disconnect the driveline to avoid damage to the transmission during towing If the transmission has 4 wheel drive disconnect both front and rear drive...

Page 164: ... and hydraulic lines Consult operator s manual on applicable machine for system capacity Pressure and Temperature Specifications Normal operating temperature 70 120 C 158 248 F measured at temperature check port converter out Maximum allowed transmission temperature 120 C 248 F Transmission regulator pressure neutral At 600 rpm min 16 5 bar 240 psi minimum At 2200 rpm 19 3 bar 280 psi maximum Pump...

Page 165: ... Sensor signal generates a square current with a fixed amplitude changing between 7 and 14 mA Hydraulic Cooler and Filter Line Specifications Minimum 19 mm 75 in internal diameter for lines and fittings Operation Suitable for operation from ambient to 120 C 248 F continuous operating temperature Pressure Must withstand 20 bar 290 psi continuous pressure and with 40 bar 580 psi intermittent surges ...

Page 166: ...erature for the oil viscosity used before engine start up Normal Oil Change Interval Drain and refill system every 1000 hours for average environmental and duty cycle conditions Severe or sustained high operating temperature or very dusty atmospheric conditions will result in accelerated deterioration or contamination Judgement must be used to determine the required change intervals for extreme co...

Page 167: ...en the engine and the wheels The proper operation of either unit depends greatly on the condition and operation of the other Therefore whenever repair or overhaul of one unit is performed the balance of the system must be considered before the job can be considered complete After the overhauled or repaired transmission has been installed in the machine the oil cooler and connecting hydraulic syste...

Page 168: ...ut and lockwasher from the locating stud 7 Carefully remove the transmission and move to a clean work area INSTALLATION 1 Use a hoist and chains to support the weight of the transmission 2 Position the transmission on the engine flywheel housing aligning one mounting hole with the locating stud 3 Install lockwasher and bolt on locating stud 4 Install eleven 11 lockwashers and bolts securing the tr...

Page 169: ...tallation 8 17 Lubrication Procedure 8 18 Wheels and Tires 8 19 Tire Inflation 8 19 Wheel Stud Nuts 8 19 DESCRIPTION Front Axle and Rear Axle The front axle and rear axle Figure 8 1 are the same except for the means of attachment to the crane frame The axles include a 3 piece spiral bevel input with epicyclic hub reduction The brakes are on either side of the drive head The front axle is a rigid m...

Page 170: ...eering cylinders and without wheels 540 kg 1191 lb approximate Hub brakes 5 plate either side of drive head positive retraction type Input type 1480 half yoke Oscillation Both Directions Rear Axle only 4 degrees Oscillation lockouts not engaged Toe in 0 degrees Caster angle 0 degrees Camber angle 1 degrees King pin inclination 0 degrees Hub reduction 5 4 1 Overall ratio 24 975 1 Crownwheel and pin...

Page 171: ...ngs on both ends of the pin 5 Connect the brake line or hose to the axle 6 Connect the hydraulic hoses to the steering cylinder 7 Connect the front drive shaft to the axle using four bolts and lockwashers 8 Bleed the air from the service brake system See Brake System page 9 1 9 Bleed the air from the steering circuit See Steering System page 10 1 10 Install the wheels to the axle Lower the machine...

Page 172: ...inion Bearing Cone Spacer Pinion Bearing Pre load 17 mm A F x 3 4 in square drive Impulse Extractor Set for Hub Bearing Seals Adapter Steer Drive Axle Pinion Bearing Cone Bearing Pad Driver Measuring Cup Pinion Head Bearing Adapter Impulse Extractor Small 17 to 25 mm Medium 25 to 45 mm Large 45 to 80 mm Driver Pinion Head Bearing Cup Drive Coupling Spanner for Axle Yoke Couplings a4069 Annulus Rem...

Page 173: ...in the oil 2 Support the axle arm and remove bolts A Figure 8 4 3 Separate the axle arm from the drive head Figure 8 5 by tapping the flange with a soft faced hammer Remove all traces of gasket material from the mating faces 4 Position the drive head as shown in Figure 8 6 with the crownwheel at the top Remove coupling yoke using Annulus Removal Tool and removing stake nuts together Remove capscre...

Page 174: ...ion 8 Using a soft faced hammer hit the pinion end shaft until the pinion is free from its front bearing then withdraw the pinion Figure 8 9 9 Withdraw the pinion seal and outer bearing cone 10 If necessary drive out the pinion inner bearing cup and shims Discard the shims Repeat for the outer bearing cup if required Note that there are no shims for the outer bearing cup 11 Remove and discard the ...

Page 175: ...ral guidance on crownwheel and pinion adjustment 1 Assemble the pinion inner bearing and its cup on a flat surface 2 Place Measuring Cup Pinion Head Bearing Figure 8 2 over the bearing assembly Measure gap A Figure 8 12 Add tool depth 30 01 mm to gap A to give bearing depth 3 Note the mounting distance B Figure 8 13 etched on the pinion and the deviation C Figure 8 14 on the drive head housing Bot...

Page 176: ...rotating the pinion The marking will then be transferred to the crown wheel teeth 1 Figure 8 15 shows correct tooth marking 2 Figure 8 16 shows pinion too deeply in mesh Decrease the shim thickness between the pinion inner bearing cup and the axle casing Move the crown wheel towards the pinion to correct the backlash 3 Figure 8 17 shows pinion too far out of mesh Increase the shim thickness betwee...

Page 177: ... rotation 3 Fit the pinion inner bearing cup Figure 8 19 together with the required thickness of shims to give correct pinion depth see Pinion Depth To ensure the cup is fitted square use a suitable puller assembly Do not use a hammer Fit the outer bearing cup 4 Fit the pinion inner bearing cone Figure 8 20 and a new collapsible spacer 5 Insert the pinion into its bore Figure 8 21 NOTE Before inse...

Page 178: ... opposite end to the crownwheel using the procedure in Step 8 Then install the crownwheel differential assembly into the drive head 10 Apply Loctite 275 sealant to the drive head mating face then fit the brake piston housing Figure 8 21 Ensure that the match marks made during disassembly are aligned Fit capscrews A see Note and torque to 56 Nm 42 lb ft Applies to both piston and housings NOTE When...

Page 179: ...ify crownwheel pinion and preload are set correctly see Crownwheel and Pinion Adjustment NOTE To measure the backlash use a magnet drilled and tapped 6 mm to accept a length of threaded 6 mm on one end Position the magnet in between the crown wheel locking bolts as shown in Figure 8 26 13 Apply Loctite 275 to the mating face of the drive head Locate the axle arm onto the drive head Figure 8 27 wit...

Page 180: ...r 9 Combination Seal 10 Outer wheel bearing Cup 11 Outer wheel bearing 12 Annulus ring 13 Annulus carrier 14 Circlip 15 Retaining Plate 16 Verbus Ripp bolts 17 Driveshaft Thrust Pad 18 Planet gear carrier 19 Circlip 20 Sun gear 21 Half Shaft 22 Circlip 23 O ring 24 Screws 25 Planet gear 26 Bolt 27 Trunnion 28 Shim Not Required 29 Trunnion seals 30 Trunnion Bearing 31 Inner Seal 32 Circlip 33 Beari...

Page 181: ...les remove and discard combination seal 9 13 Disconnect the track rod and steering cylinder from the axle steer knuckles If the track rod is removed completely identify R H and L H ends to ensure correct assembly NOTE The top and bottom trunnions are very similar bottom trunnion not illustrated the only difference being that shims 28 are fitted to the top trunnion only Trunnions may be removed eas...

Page 182: ...ly into carrier 19 until flush as shown at X NOTE After assembling the bearing carrier to the swivel hub make sure that there is sufficient clearance between the hub and seal 14 Install the cup of outer wheel bearing 10 into the bearing carrier 8 Grease the bore of the seal and the surface of the stub 15 Fit the bearing carrier 8 onto the hub swivel 3 16 Lightly oil the bearing race of outer wheel...

Page 183: ...ng carrier 8 turning it slightly to engage the gear teeth and aligning the two tapped holes A Figure 8 28 in the bearing carrier The tapped holes are diametrically opposite one another Ensure the planet gear carrier butts fully against the bearing carrier NOTE Do not strike the centre of the planet gear carrier 18 when fitting as this may dislodge the half shaft thrust pad 17 23 Fit screws 24 and ...

Page 184: ...ive shaft in the direction of the bearings to push the bearings out of the flange yoke When the bearings are removed tilt the journal cross to permit removal of the universal joint 3 Disassemble the journal crosses 2 from the drive shaft using the procedure in step 2 After the snap rings are removed use a soft drift with a flat face slightly smaller than the diameter of the bearing to remove the b...

Page 185: ...n the bearing retainers If they are damaged in any way replace the complete journal and bearing assembly 2 Install the journal cross into the yoke of the sleeve yoke The relief must be towards the sleeve yoke 3 Apply a small amount of SAE 140 oil to the trunnions on the journal cross Press the bearings and cap assemblies into place Use care not to cause damage to the bearings or caps Install the s...

Page 186: ...ermediate angle as at Z 3 Apply grease with a grease gun to the fittings on the journal crosses and on the slip joint Apply grease until it exits through the seals See Lubrication Procedure 4 Check the drive shaft for correct balance before the machine is put into operation Lower the outriggers to lift the wheels off the ground Operate the drive train and check for vibration If vibration is found ...

Page 187: ...eekly or after every 50 hours of operation whichever occurs first Wheel stud torque is 502 Nm 370 lb ft WARNING Never try to disassemble the wheel until all air is released from the tire The retaining ring and rim of the wheel and tire can come off with explosive force and can cause serious injury or death Be extremely careful when working with them Always use a tire and rim cage guard when inflat...

Page 188: ...AXLES DRIVE SHAFTS WHEELS AND TIRES CD25 8 20 Published 5 24 2017 Control 587 01 This Page Blank R e f e r e n c e O n l y ...

Page 189: ...ulating Valve Repair 9 12 Troubleshooting 9 14 Service Brakes 9 14 TECHNICAL DATA Axle Brakes Type Oil immersed multi plate disc Actuation Hydraulic Location Inboard Drive Head Friction Plates 4 per set Outside Diameter 220 mm 8 66 in Inside Diameter 180 mm 7 09 in Nominal facing area plate 12 616 mm 19 5 in Hydraulic Piston Diameter 216 mm 8 5 in Piston Operation Standard retraction Accumulator T...

Page 190: ...alve a low pressure warning switch an accumulator a needle valve a manifold valve a brake modulating valve a brake light switch and the front and rear axle service brakes Description of Operation Hydraulic Pump The pump supplies hydraulic oil flow to the priority flow control valve Figure 9 1 FIGURE 9 1 Front Park Brake Low Pressure Warning Switch Service Brakes Accumulator Needle Valve Brake Ligh...

Page 191: ...ake Modulating Valve The brake modulating valve is a closed center spool design When the valve is in no applied position brake port A Figure 9 1 is open to tank port T As the valve is initially actuated tank port T is closed off from brake port T Additional actuation opens pressure port P to brake port A More input force will increase the pressure to brake port A until actuation effort and hydraul...

Page 192: ...re not sure the accumulator is charged engage the parking brake start the engine and let it run for several minutes 1 Engage the parking brake and shut off the engine Block the rear wheels on both sides 2 Attach a hose to the right hand bleed screw ensuring that the free end of the hose is immersed in fluid contained in a suitable container 3 Open the brake bleeder screw and apply full pedal strok...

Page 193: ...ng apparatus Charge the accumulator to 5171 275 kPa 750 40 psi Residual Brake System Pressure If residual pressure is greater than the pressure required to overcome the brake retraction springs in the axle brake piston retraction will not occur resulting in excessive heat and wear on the brake components If the residual pressure in the braking system is above 0 35 bar 5 psi in the hot condition th...

Page 194: ...ck the axle arm off the drive head using drive head securing bolts 1 Figure 9 7 Remove all traces of gasket from the mating surfaces 3 There are two counterplates B Figure 9 8 one at each end of the brake pack which are not secured to the plate carrier C If the plates are to be reused note their position and which direction they are installed then remove the brake pack FIGURE 9 5 p0088 12 13 9 11 ...

Page 195: ...f the counterplates is normal Completely replace the brake pack if worn or damaged Do not replace individual plates 6 Remove the three reaction pins D Figure 9 11 Inspect for damage and scoring 7 Position the drive head as shown in Figure 9 12 with the crownwheel at the top For coupling removal see Drive Head Disassembly page 8 5 Remove capscrews A 8 Match mark the brake piston housing B and drive...

Page 196: ... sealant to the drive head mating face then fit the brake piston housing Ensure that the match marks made during dismantling are aligned Fit capscrews A Figure 9 12 see Note and torque to 56 Nm 42 Ib ft Applies to both piston housings NOTE When refitting the cap screws clean the threads with a wire brush and coat the threads with Loctite 243 Some new capscrews come pre coated and do not require cl...

Page 197: ... tighten to a torque of 400 Nm 295 lb ft 10 Fill the axle with recommended lubricant See Replace the Axle Housing Lubricant page 5 33 Install the axle to the crane s frame Refer to Axles Drive Shafts Wheels and Tires page 8 1 PARKING BRAKE REPAIR Operation Ten disc springs 8 Figure 9 17 are used to hold the park brake in the actuated state The springs 8 push the pistons 9 12 into the lining and ca...

Page 198: ...ssure from the brake and remove lining and carrier assemblies 19 4 Using a press compress springs 8 to reduce the force on the spring housing 4 5 Use a spanner wrench to remove the spring housing 4 counter clockwise direction 6 The springs 8 will be accessible when the spring housing is removed NOTE The spring housing 4 may be removed without compressing the springs 8 however it is not recommended...

Page 199: ...ce the shim 7 so it will be in the bottom of the spring housing 4 when it is installed See Figure 9 18 for a graphical representation NOTE Springs are matched and pretested If new springs are being installed add a shim only if the new springs are shipped with one 10 Thread spring housing 4 into torque plate 1 about 3 turns or until it makes contact with the springs 8 11 Using a press compress spri...

Page 200: ...and housing 12 3 Remove piston 2 springs 3 4 and 5 shims 6 and retainer assembly 7 from housing 12 NOTE Observe and take note of the number of shims 6 being removed from the housing 4 Carefully remove cup 14 and seal 15 from housing 12 bore Be careful not to scratch or mar the bore 5 Remove end plug 8 and spring 10 from housing 12 Remove O ring 9 from plug 8 6 Carefully remove spool 11 from end pl...

Page 201: ... bore 6 Assemble springs 3 4 and 5 shims 6 and retainer assembly 7 into piston 2 7 Carefully install piston 2 assembly into bore of housing 12 8 Install new boot 1 on housing 12 and piston 2 9 Install the valve assembly onto the pedal assembly with new capscrews 13 Tighten to a torque of 24 4 29 8 Nm 18 22 lb ft 10 After final assembly the valve must develop a pressure of 3792 345 kPa 550 50 psi I...

Page 202: ...pedal 1 Air in system 2 High pressure leaks external 1 Bleed brake system 2 Apply full brake pressure inspect for leakage in lines hoses and fittings Charging valve actuates every time foot pedal is pressed 1 Accumulator needle valve closed 2 Loss of nitrogen in accumulator 3 Insufficient hydraulic pressure in accumulator 1 Open needle valve 2 Charge accumulator 3 Faulty accumulator charging valve...

Page 203: ...load sensing steering orbitrol hydraulic tank one front steering cylinder one rear steering cylinder and the steering select valve When the steering wheel is turned a pressure demand is sensed by the priority flow control valve through load sensing line between the priority flow control valve and the flow sensing steering orbitrol Oil from the pump is then distributed through the priority flow con...

Page 204: ...STEERING SYSTEM CD25 10 2 Published 5 24 2017 Control 587 01 FIGURE 10 1 a2095 Steering System MANIFOLD LS R e f e r e n c e O n l y ...

Page 205: ...R of the steering orbitrol to port P of the steering select valve The steering select valve has four solenoid valves These valves are activated by the steering select switch in the operators compartment When the steering select switch is placed in the two wheel steering mode solenoid A is actuated Oil passes through the porting of the valve block to the base end of the front axle steering cylinder...

Page 206: ...ering select valve has four solenoid valves These valves are activated by the steering select switch in the operator s compartment When the steering select switch is placed in the four wheel steering mode solenoids C and D are actuated Oil passes through the porting of the valve block and out port A to the rear axle steering cylinder Oil is directed to the rod end of the left steering cylinder and...

Page 207: ...vated by the steering select switch in the operator s compartment When the steering select switch is placed in the crab steering mode solenoids B and C are actuated Oil passes through the porting of the valve block and out port B to the rear axle steering cylinders Oil is directed to the base end of the left steering cylinder and rod end of the right cylinder causing the rear wheels to turn to the...

Page 208: ...em electrical circuit includes two sensors Figure 10 8 one selector switch one relay box and two solenoid valves The selector switch is controlled by the operator in the cab to select the steering modes The relay box located under the instrument panel contains relays that control the steering mode solenoid valves The system is used to select one of the three steering modes When the selector switch...

Page 209: ...10 7 CD25 STEERING SYSTEM 10 Published 5 24 2017 Control 587 01 FIGURE 10 8 a2096 Steering Wiring Diagram R e f e r e n c e O n l y ...

Page 210: ...sensor A yellow light Figure 10 9 will illuminate indicating that the sensor is functioning 4 If the sensor is working properly check the spacing between the sensor and sensor bracket Adjust if necessary 5 If the sensor is malfunctioning replace it and adjust the sensor spacing Sensor Spacing Check 1 Align the sensor bracket on the axle steering knuckle with the sensor on the axle Figure 10 10 2 M...

Page 211: ...teering actuator position of rotor to shaft slot incorrect 1 Clean and inspect unit 2 Check orbitrol Repair or replace 3 See page 10 11 Correct if required Machine will not turn when the steering wheel is turned 1 Insufficient oil level 2 Leaks in relevant hoses or component connections 3 Air in the hydraulic system 4 Low pump flow 5 Malfunctioning relief valve 6 Worn or damaged parts in the steer...

Page 212: ...ing 1 Air in system due to low level of hydraulic oil cavitating pump leaky fitting pinched hose etc 2 Loose steering cylinder piston 3 Sticking check valve 4 Turning steering wheel too rapidly 1 Correct condition and add fluid Bleed system and load sense line 2 Repair or replace cylinder 3 Clean or replace 4 Slow movement Spongy or soft steering 1 Air in hydraulic system Most likely air trapped i...

Page 213: ...ht turn flow from the pump enters port P Figure 10 12 The gerotor takes this flow and meters to port R right turn Return flow from the steering cylinders enters port L and is returned to tank through port T Emergency Manual Steering The gerotor Figure 10 12 in the orbitrol permits steering with difficulty when power is lost A check valve between the IN and OUT ports allows for recirculation of the...

Page 214: ...STEERING SYSTEM CD25 10 12 Published 5 24 2017 Control 587 01 FIGURE 10 12 a0671 Steering Orbitrol R e f e r e n c e O n l y ...

Page 215: ...nliness is extremely important when repairing a steering orbitrol Work in a clean area Use a wire brush to remove foreign materials and debris from around exterior joints of the unit NOTE Although not all illustrations show the unit in a vice we recommend that you keep the unit in a vice during disassembly Follow the clamping procedures explained throughout the instructions FIGURE 10 13 a0327 Stee...

Page 216: ...ect the surface finish Use a thin bladed screwdriver Figure 10 15 to pry retaining ring 2 Figure 10 13 from housing 8 6 Rotate spool 12 and sleeve 9 until pin 11 is horizontal Push the spool and sleeve assembly forward with your thumbs just far enough to free gland bushing 3 from the housing Remove gland bushing 3 7 Remove quad seal 5 from gland bushing 3 8 Use a thin bladed screwdriver to pry dus...

Page 217: ...ce all seals when assembling the unit Lubricate all seals with clean petroleum jelly before assembling DO NOT use excessive lubricant on seals for the meter section Assembly 1 Use a needle nose pliers to lower check ball retainer 20 Figure 10 13 into the check valve hole in housing 8 2 Install check ball 21 into housing 8 3 Lubricate seals 22 and 24 and install them on check ball seat 23 4 Lubrica...

Page 218: ...f the housing Do not pull the spool and meter assembly beyond this point to prevent the cross pin from dropping into the discharge groove of the housing With the spool assembly in this flush position check for free rotation within the housing by turning with a light finger tip force at the splined end 12 Place the housing on a clean lint free cloth Install seal 4 Figure 10 13 into housing 8 13 Ins...

Page 219: ...n bolt holes without disengaging the gerotor from the drive 23 Install drive spacer 17 Figure 10 13 into the gerotor 24 Install seal 13 into end cap 18 Install end cap 18 onto gerotor 16 Align the bolt holes 25 Install the seven 6 pt Torx Drive screws with new seal washers in the end cap Tighten each screw to 17 Nm 150 lb in then tighten each screw in sequence Figure 10 25 to a torque of 31 Nm 275...

Page 220: ...ure 10 27 and pivot pins B Swing the track rod clear of the steering joints 5 Remove screws C and washers D 4 of each from the cylinder mounting flange 6 Mark the cylinder flange and housing for relocation 7 Using a soft faced hammer tap the closed end of the cylinder and carefully withdraw the cylinder and track rod from the housing FIGURE 10 26 a0341 Hexagon Spanners for Cylinder Pistons and End...

Page 221: ...10 19 CD25 STEERING SYSTEM 10 Published 5 24 2017 Control 587 01 FIGURE 10 27 a275490 R e f e r e n c e O n l y ...

Page 222: ...ed 5 24 2017 Control 587 01 FIGURE 10 28 JS07951 Item Description 1 Screw 2 Cylinder Cover 3 Cylinder Flange 4 Housing Flange 5 Piston Rod Assembly 6 Seal 7 Guide Ring 8 Seal 2 9 Seal 2 10 Backup Ring 2 11 Seal R e f e r e n c e O n l y ...

Page 223: ...ully tap the closed end of cylinder 3 and withdraw the cylinder from its housing 4 Remove and discard seals 8 and 9 with back up washer 10 Inspection 1 Clean all parts in a suitable solvent Dry with compressed air Make sure threads of piston rod piston end cap and cylinder are thoroughly cleaned using a wire brush to remove grease hydraulic oil and Loctite 2 Inspect cylinder rod for rust distortio...

Page 224: ...Loctite 574 to cylinder flange face 3 Locate cover piston guide 2 onto the piston rod and slide into position against cylinder flange 3 aligning the location mark made during dismantling 8 Insert four screws 1 and torque them to 166 Nm 122 lb ft 9 Coat the first three external threads of track rod end ball joint D with Loctite 243 and screw into the end of the steering piston rod Torque to 400 Nm ...

Page 225: ...ing Steering System Whenever any hydraulic steering component is disconnected or removed the system must be bled as follows With the engine running this procedure must be carried out in the correct order that is laid down You must not alter the order of selections and operations 1 Select 2 Wheel Steer a Turn steering wheel to left until front wheels are fully locked to the left b Turn steering whe...

Page 226: ...STEERING SYSTEM CD25 10 24 Published 5 24 2017 Control 587 01 This Page Blank R e f e r e n c e O n l y ...

Page 227: ...the boom is used to raise and lower the boom The telescope cylinder is a two stage double acting type It is attached to the 1st or base section The cylinder extends the 2nd and 3rd sections Extend cables are used to extend the 4th section The telescope cylinder retracts the 2nd section Retract cables are used to retract the 3rd and 4th sections The extend cables for the 4th section are attached to...

Page 228: ...ury death or equipment damage may result 9 8 4 5 7 1 6 7632 31 FIGURE 11 2 8 A2B Switch Assembly 9 Lower Sheave 10 Cable Retaining Pin 11 Boom Nose 12 Upper Sheave Item Component 10 2 3 1 3 11 12 10 Item Component 1 Grease Fitting 2 Upper Pin 3 Capscrew 4 Pivot Locking Pin 5 Lynch Pin 6 Lower Pin 7 A2B Switch Connector FIGURE 11 3 1 3 2 5 6 25 23 1 11 13 15 19 3 12 6 Item Component 1 Spacer 2 Shea...

Page 229: ...ift cylinder boom pivot pin retainer and pivot pin from the base section Figure 11 4 8 Lower the lift cylinder to a suitable support 9 Repeat the procedure to remove the boom pivot pin on the other lift cylinder 10 Tag and disconnect the hydraulic lines from the boom telescope cylinder Cap all lines and ports 11 With the lifting device attached to the boom raise the boom until the weight is remove...

Page 230: ...1 Raise the 2nd 3rd and 4th boom assembly inside the base section remove and tag bottom wear pads 12 Slide the 2nd 3rd and 4th assembly out of the base section and place on a suitable work surface Disassembly of Boom Sections Refer to Figure 11 5 1 Remove adjustment nuts for the 4th section extend cables 9 2 Remove the cable anchor assembly 9 3 Remove two cylinder locking retainers 6 4 Remove and ...

Page 231: ...n s retract cables 12 Rear anchor point of 3rd section for 3rd section retract cables 13 Extend sheaves at front of telescope cylinder 14 Front attach point of 1st section for 3rd section retract cables 15 Front attach point of 2nd section for 4th section retract cables 16 Retract sheaves at rear of 3rd section for 4th section retract cables 17 Retract sheaves at rear of 2nd section for 3rd sectio...

Page 232: ...ace as required Sheave bearings for excessive wear or damage replace as necessary If the bearing diameter is 0 38 mm 0 015 inch larger than the pin diameter the bearing must be replaced Clean and inspect all cable assemblies and replace as required Lubricate all cable assemblies before reinstalling in boom Inspect all sheave pins for wear or damage replace as necessary Inspect all grease fittings ...

Page 233: ...the wear pads pivot the wear pads and plates independently of each other 10 Slide boom sections completely together Extend Retract Cable installation 1 Uncoil 3rd section retract cable assemblies 1 and insert the button end into the slot in the anchor plate 10 inside the rear of the section Install the keeper plate 2 over the cable end Figure 11 8 2 Coat the surfaces of the bearings and keeper pla...

Page 234: ...able 1 Figure 11 10 around the cable sheave 2 and place it on top of the 3rd section Tie the cable together as shown this assembly is attached to the 2nd section later NOTE The cable sheave must be towards the front The threaded end of the cable should be on the left side and button end should be on the right side 11 Slide the 4th 3rd section assembly into the 2nd section routing the 3rd section r...

Page 235: ...955045 19 Install the cable retainer 21 cable guide 24 and wear pad 25 with capscrews and washers to the top plate of the 2nd section 20 Install the cable sheave 2 onto anchor plate 8 with the sheave retainer 3 Figure 11 12 NOTE Grease hole must align with hole in keeper plate retainer and the lube hole in the boom section 21 Reeve the 3rd section retract cable 1 around the cable sheave 2 22 Route...

Page 236: ...to the base end of the 4th section Figure 11 14 8 Insert the telescope cylinder the rest of the way into the boom assembly 9 Insert cylinder lugs into notches in rear 2nd and 3rd sections Figure 11 15 10 Install the cylinder lock bar and retainer plates Figure 11 16 11 Insert the extend cable anchor assembly into the base end of the 2nd section Figure 11 17 12 Install the extend cable through the ...

Page 237: ...n install the upper wear pad and plate Figure 11 19 NOTE The section should slide with a slight amount of resistance and be centered in the other section The holes in the wear pads are offset 0 8 mm 0 03 in and the holes in the adjusting plate are offset 1 5 mm 0 06 in To adjust the wear pads pivot the wear pads and plates independently of each other 7 Install the spacers and capscrews through the...

Page 238: ...d section should be bottomed on the anchor plates at the back of the 2nd section c The 4th section should be bottomed on the anchor plates at the back of the 3rd section NOTE It is important that all the sections are bottomed out before proceeding If the boom sections do not bottom out as specified the boom is out of sequence Adjust the cables to achieve proper section positioning After the proper...

Page 239: ... on the bottom of the 1st section Use the flats at the front of the cable ends to keep the cables from turning while torquing retainer nuts Figure 11 23 8 Torque the proportioning cable to 12 2 N m 9 ft lb The cable adjustment point is located at rear of boom Figure 11 24 NOTE Clearance must be maintained between proportioning cable and the rear edge of the 2nd section at full boom retraction 9 Fu...

Page 240: ...carrier deck under the boom 3 Line up the lift cylinder with the attach point on the turret and install the pivot pin Figure 11 4 4 Raise the rod end of the lift cylinder to the attach point under the boom and install the pivot pin WARNING Falling Hazard Do not under any circumstances work at an elevated height without using proper fall protection as required by local state or federal regulations ...

Page 241: ...e end of the wire rope and insert it through the small opening on the anchor pocket Loop the wire rope and push the free end about 3 4 of the way through the pocket Install the wedge then pull the slack out of the wire rope The wedge will slip into the pocket and secure the wire rope into the drum The anchor is designed to fit several different sizes of wire rope Make sure the anchor is installed ...

Page 242: ...wly to move the wire rope directly from the reel to the hoist Make sure the wire rope winds correctly on the drum Loose windings will increase wear on the wire rope and cause bad performance 4 After installation operate the hoist with a minimum load until you see the wire rope is moving easily over the sheaves and winding correctly on the hoist drum 5 Gradually increase the speed and load until th...

Page 243: ...orted by the brake cylinder The other end of the drum rotates on a ball bearing on the support bolted to the base The ring gear for both planetary sets is machined into the drum s inside surface Hoist Operation The hydraulic motor drives the sun gear of the primary planetary gear set through the spline inner race of the brake clutch When driven by the sun gear the primary planet gears walk around ...

Page 244: ...ction See Figure 11 32 When the control valve is placed in the lowering position the spring loaded pilot operated spool valve remains closed Figure 11 33 until sufficient pilot pressure is applied to the end of the spool valve to shift it against spring pressure opening a flow passage Figure 11 34 After the pilot operated spool valve cracks open the pilot pressure becomes flow dependent and modula...

Page 245: ...ressure lower than that required to open the brake valve The extent to which the brake valve opens will determine the amount of oil that can flow through it and the speed at which the load will be lowered Increasing the flow of oil to the hoist motor will cause the pressure to rise and the opening in the brake valve to enlarge speeding up the decent of the load Decreasing this flow causes the pres...

Page 246: ...STRUCTURALS CD25 11 20 Published 5 24 2017 Control 587 01 FIGURE 11 37 a2204 Hoist Exploded View R e f e r e n c e O n l y ...

Page 247: ...e oil install a short piece of 1 inch threaded pipe in the larger threads of the drain hole Figure 11 38 If necessary insert a bar in the wedge socket anchor pocket and manually rotate the drum in the direction to hoist a load until the drain holes align 2 Use a 5 16 inch Allen wrench to remove the drain plug through the pipe Figure 11 39 Item Description Item Description Item Description Item Des...

Page 248: ...stalled on the pilot of the motor 5 Tag and remove the hoses and fittings from the brake cylinder release port Figure 11 41 6 Remove the brake clutch Figure 11 42 assembly from the motor support Refer to Brake Clutch Service page 11 33 for additional information 7 Remove the motor support capscrews and install two 2 capscrews and a short piece of chain Figure 11 43 into the motor mounting bolt hol...

Page 249: ...igure 11 44 placed between the primary planet carrier and the drum closure pry upward to remove the drum closure Remove and discard the O ring from the outside of the drum closure 10 Remove the seal and bearing from inside of closure 11 Remove the primary sun gear and thrust washer Figure 11 45 from the primary planet carrier 12 Remove the primary planet carrier from the drum Figure 11 46 Refer to...

Page 250: ...ve wear Replace if wear is greater than 0 4 mm 0 015 in when compared to unworn area of teeth Assembly NOTE Hoists with a three piece fabricated base use special shoulder capscrews to fasten the side plates to the base plate DO NOT use standard capscrews in their place 1 Place hoist base on side with bearing supported up Figure 11 49 2 Install a new bearing in the drum if replacement is necessary ...

Page 251: ...ge may occur if vent is positioned incorrectly 5 Install and tighten the bearing support capscrews to the recommended torque 6 Stand hoist on bearing support end Install the output sun gear and thrust washer into output planet carrier Figure 11 52 7 Install the output planet carrier Figure 11 53 into the drum while meshing the planet gears with the ring gear and the planet housing with the bearing...

Page 252: ...ended torque 13 Install the brake clutch assembly Figure 11 57 with the short end of the inner race toward motor When installed correctly the inner race should turn freely in the opposite direction the drum turns to pull wire rope in An easy way to check the rotation is to hold the outer race in one hand and rotate the inner race If the clutch free wheels in the wrong direction disassemble the clu...

Page 253: ...ween the planet gears and the planet carrier If the hoist is operated with the primary thrust plate wedged between primary gears and the planet carrier or with a thrust washer out of position severe damage to internal hoist components could result 17 Measure the distance from the motor mounting surface to the inner brake race Figure 11 60 With all components properly installed this distance should...

Page 254: ... the planet shafts bearings spacer thrust washers and gears Thoroughly clean all parts and inspect for damage and wear The bearing rollers should not exhibit any irregularities If the rollers show any sign of spalling corrosion discoloration material displacement or abnormal wear the bearing should be replaced Likewise the cage should be inspected for unusual wear or deformation particularly the c...

Page 255: ...he planet gear shaft Figure 11 68 and drive the roll pin into place Always use NEW roll pins When properly positioned 50 of the roll pin will engage the planet gear shaft and 50 will remain in the planet carrier 4 Note that the roll pin is slightly recessed in the carrier when properly installed With a center punch Figure 11 69 stake the carrier next to the pin hole as shown This will distort the ...

Page 256: ...ackup ring and pressure plate Figure 11 72 3 Remove brake springs Figure 11 73 and the spring spacer Clean and Inspect 1 Thoroughly clean and inspect all parts at this time Check brake piston sealing surfaces on the brake cylinder and motor support Be sure brake release port is free of contamination Figure 11 74 2 Check oil seal and bearing surfaces on the brake cylinder for damage and wear Figure...

Page 257: ...r failure If a brake spring must be replaced then all brake springs must be replaced NOTE Failure to replace brake springs as a set may result in uneven brake application pressure and repeated brake spring failure Assembly 1 Begin assembly by placing the motor support on the workbench with motor mounting surface down Install new O ring and brake spring Figure 11 78 2 Insert first a steel brake dis...

Page 258: ...al to the motor support with the lip seal down Figure 11 82 6 Install the spring spacer and then the brake springs Figure 11 83 7 Install the pressure plate into the brake cylinder followed by the piston backup ring Figure 11 84 The close fitting piston backup ring may be depressed slightly to one side to lodge the backup ring in the brake cylinder bore Temporarily hold the pressure plate and spri...

Page 259: ...ressure gauge and shut off valve to this fitting Figure 11 86 2 WHILE PRESSURE IS APPLIED AND THE BRAKE RELEASED install the brake clutch assembly in the brake pack short end of the inner race toward the motor Turn the clutch back and forth as you align the outer race splines with the brake disc splines 3 Release the pressure on the cylinder and then remove the brake clutch assembly The brake cyli...

Page 260: ...cted before assembly Assembly 1 Press a sprag bushing into the outer race using a suitable press A flat plate of approximately the same diameter as the bushing flange outside diameter should be placed between the press and bushing This will protect the bushing from damage Be certain the bushing flange is against the shoulder in the outer race Figure 11 91 2 Turn the assembly over and install the s...

Page 261: ...eplaced 6 Turn the assembly over with the snap ring down Install the second retainer and snap ring Figure 11 95 Make sure the snap ring is properly seated in the groove 7 Figure 11 96 shows a completed clutch assembly FIGURE 11 93 a2268 FIGURE 11 94 a2260 WARNING Load Control Hazard Be certain the snap ring Figure 11 58 is seated in the groove in the splined bore of the inner race This snap ring w...

Page 262: ...ebolt 9 to the dimension shown in Figure 11 97 3 Apply grease to shaft and I D of rollers Rollers must turn freely FIGURE 11 97 a2270 Hoist Tension Roller Subassembly Cut Away View Item Description 1 Tension roller arm 2 Tension spring 2 3 Tension roller shaft 4 Tension arm shaft 5 Set screw 2 6 Washer 6 7 Roller bushing 2 8 Spring anchor 2 9 Roller rod end 2 10 Nut 4 Item Description 11 Lockwashe...

Page 263: ...y 6895 kPa 1000 psi to the brake Close the shutoff valve and let stand for five 5 minutes c If there is any loss of pressure in five 5 minutes the brake cylinder should be disassembled for inspection of sealing surfaces and replacement of the seals Refer to Motor Support Brake Cylinder Service page 11 30 2 Disassemble the brake to inspect brake discs Check stack up height as described in Motor Sup...

Page 264: ...t and refill hoist with recommended planetary oil See Preventative Maintenance page 5 1 D The hoist runs hot 1 Excessively worn or damaged internal hoist parts 1 Disassemble hoist to inspect replace worn parts E Hoist chatters while raising rated load 1 Hydraulic oil flow to motor may be too low 2 Hoist control being operated too quickly 1 Hydraulic pump not operating efficiently 2 Conduct operato...

Page 265: ... through several rotations and then repeat the procedure with the other grease fitting The excess grease will extrude out of the bearing seal Mast Bearing Bolts Very high stress is put on the mast bolts during crane operation It is important that these bolts be checked at regular intervals Check the torque on the bolts after the first week or 50 hours of operation whichever occurs first and then e...

Page 266: ...al indicator 5 Lower the boom and then rotate it 180 Repeat steps 2 through 4 6 Average the two readings The maximum allowable movement is 1 52 mm 0 060 in The mast bearing must be replaced if the movement is greater than the stated measurement Replacing the Mast Bearing Removal 1 Refer to Boom Removal page 11 3 and remove the boom from the mast 2 Remove swivel torque arm 29 Figure 11 103 from the...

Page 267: ...1 103 to hydraulic swivel 31 9 Connect the hydraulic lines to the hydraulic swivel 10 Install counterweights 3 and 4 into the mast 11 Install the hoist assembly to the mast 12 Install the boom assembly Swing Gearbox and Pinion Maintenance Gearbox The swing gearbox has a worm gear set which rotates on tapered roller bearings The gears and bearings are given lubrication by the grease in the gearbox ...

Page 268: ...lt 6 9 Washer 16 10 Hex bolt 4 11 Hex bolt 4 12 Hex bolt 26 13 Washer 56 14 Mast bearing 15 Hex bolt 30 16 Swing gearbox 17 Hex bolt 2 18 Nut 2 19 Connector 2 20 Hex bolt 4 21 Washer 4 22 Tubing 23 Grease fitting 24 Eccentric ring 25 Swing pinion cover 26 Washer 8 27 Lockwasher 8 28 Hex bolt 4 29 Swivel torque arm 30 Hex bolt 7 31 Hydraulic swivel 32 Chock 2 33 Lockwasher 4 34 Hex bolt 4 35 Washer...

Page 269: ... ring 9 Split ring retainer 10 Ring gear 11 Primary sun gear 12 Lockwasher 8 13 Brake housing 14 Spring 4 15 Spring locator 16 Spring plate 17 U cup seal 18 Brake plate spacer 19 Friction disc 5 20 Brake disc 7 21 O ring 22 Motor adapter 23 Capscrew 8 24 Hydraulic motor 25 O ring 2 26 Brake valve 27 Capscrew 4 28 Elbow fitting 2 29 Hose assembly 30 Thrust plug 31 Thrust washer 32 Brake coupling 33...

Page 270: ...r box and eccentric ring from beneath the machine Disassembly 1 Drain the oil and clean the outside surfaces of the gearbox Set the gearbox with the input motor side up on a work bench and use wood blocks under the flange of the bearing carrier 2 Figure 11 104 to stabilize it on the workbench 2 Disconnect the brake release hose at the gearbox Unbolt and remove the hydraulic motor from the gearbox ...

Page 271: ...ing gear See Brake Cylinder Service page 11 48 for procedure to disassemble the brake cylinder assembly 4 Remove the primary sun gear 11 and the thrust washer 31 5 Remove the primary planet carrier assembly and thrust plug 30 6 Remove the secondary planet carrier assembly 39 31 FIGURE 11 108 a4151 11 FIGURE 11 109 a4152 30 FIGURE 11 110 a4153 FIGURE 11 111 a4154 R e f e r e n c e O n l y ...

Page 272: ...and discard the ring gear O rings 37 8 Remove the split ring retainer 9 9 Take care not to damage the ground surface of the split ring halves Use a hammer and punch to remove the split ring halves 8 from the output pinion 1 10 Remove output pinion from bearing carrier 2 37 38 10 1 FIGURE 11 112 a4155 9 FIGURE 11 113 a4156 8 1 FIGURE 11 114 a4157 1 2 FIGURE 11 115 a4158 R e f e r e n c e O n l y ...

Page 273: ...e primary planet carrier assembly into the ring gear The output sun gear is retained on the primary planet carrier and engages with the output carrier assembly planet gears 10 Install the thrust plug 30 and then the primary sun gear 11 into the primary planet carrier assembly Install the thrust washer 31 onto the primary sun gear 11 11 Install O ring 37 into groove on brake housing 13 and lubricat...

Page 274: ...a time alternating across the gearbox until the spring force is released Remove the motor adapter and discard O ring 21 2 Continue disassembly removing spacer 18 friction discs 19 brake discs 20 U cup seal 17 pressure plate 16 springs 14 and spring locator 15 22 23 FIGURE 11 117 a4160 FIGURE 11 118 a4161 18 16 14 15 FIGURE 11 119 a4162 20 19 FIGURE 11 120 a4163 FIGURE 11 121 a4164 R e f e r e n c ...

Page 275: ...housing 13 on the workbench and place the spring locator in the housing Refer to the unit material list for the required number of springs 14 Space the required number of springs evenly around the outside diameter of the spring locator 5 Install the spring pressure plate 16 on top of the springs in the brake housing The close fitting spring pressure plate may be depressed at a slight angle to lodg...

Page 276: ...llers should be examined for any signs of spalling corrosion discoloration material displacement or abnormal wear Gears should be inspected for abnormal wear or pitting and replaced as necessary Inspect machined surfaces and bearing bores for signs of damage or excessive wear Assembly 1 Liberally coat the bore of a planet gear with general purpose oil soluble grease 2 Set a thrust washer on a clea...

Page 277: ...sing a sling and hoist raise the beam so the sliding jack weldment 3 can be removed from the beam 8 As necessary tag disconnect and remove hydraulic hoses tubes and fittings from the outrigger horizontal beam Assembly 1 If removed install and connect the hydraulic hoses tubes and fittings in the outrigger horizontal beam 5 Figure 11 124 as tagged during disassembly 2 Lubricate the inside of the ou...

Page 278: ...Horizontal Beam Lower 2 Outrigger Horizontal Beam Upper 3 Jack Tube 4 Vertical Cylinder 5 Horizontal Cylinder 6 Cover 7 Cover 8 Pin Upper 9 Pin 10 Snap Ring 11 Pin Lower 12 Snap Ring 13 Pin 14 Snap Ring Item Component 1 2 3 3 4 5 6 7 8 9 10 11 12 13 14 5 14 13 4 8 11 12 10 9 R e f e r e n c e O n l y ...

Page 279: ...e switch mounting bracket 2 3 Remove jam nuts 3 and thread switch 4 out of the mounting bracket Installation 1 Feed cable through the mounting bracket and jam nuts 2 Thread switch through mounting bracket 3 Thread nuts on switch 4 Thread switch up until it touches tab of mounting bracket and LED is pointed away from the bracket 5 Tighten jam nuts against mounting bracket 6 Install bracket with swi...

Page 280: ...STRUCTURALS CD25 11 54 Published 5 24 2017 Control 587 01 This Page Blank R e f e r e n c e O n l y ...

Page 281: ...2 1 CD25 SCHEMATICS WIRING DIAGRAMS 12 Published 5 24 2017 Control 587 01 SECTION 12 SCHEMATICS WIRING DIAGRAMS Included in this Section Electrical Schematic Hydraulic Schematic R e f e r e n c e O n l y ...

Page 282: ...SCHEMATICS WIRING DIAGRAMS CD25 12 2 Published 5 24 2017 Control 587 01 This Page Blank R e f e r e n c e O n l y ...

Page 283: ...5 Engine Air Intake System 6 5 Engine Cooling System 6 2 Engine Crankcase System 6 1 Engine Electrical System 6 3 Engine Exhaust System 6 7 Engine Fuel System 6 3 Engine Performance 6 1 Engine RPM 6 1 Environmental Protection 2 4 Fasteners 1 8 Final Word 2 4 Front and Rear Drive Axle Repair 8 3 General Description 4 2 General Service Information 1 5 Governor 6 1 Hoist Circuit 4 29 Hoist 11 17 Hose...

Page 284: ... 8 Specifications 1 2 Starting Circuit 3 7 Steering Cylinder 10 18 Steering Orbitrol 10 11 Steering Proximity Switches 10 6 Suction Return and Pump Pressure Circuits 4 14 Swing Circuit 4 32 Technical Data 4 2 Technical Data 8 2 Technical Data 9 1 Technical Data 10 1 Technical Specifications 7 2 Telescope Circuit 4 26 Towing or Pushing 7 1 Troubleshooting Guides 4 4 Troubleshooting 3 11 Troubleshoo...

Page 285: ...CD25 SERVICE MANUAL Published 05 24 2017 Control 587 01 13 iii This Page Blank R e f e r e n c e O n l y ...

Page 286: ...SERVICE MANUAL CD25 13 iv Published 05 24 2017 Control 587 01 This Page Blank R e f e r e n c e O n l y ...

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