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Manitowoc Grove YB5515-2, Service And Maintenance Manual

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Manitowoc Grove YB5515-2 Service And Maintenance Manual Download Page 165

TRANSMISSION AND TORQUE CONVERTER

CD5515-2/YB5515-2 SERVICE MANUAL

7-18

Published 1-20-2017, Control# 483-02

TESTING

Solenoid Identification

When testing individual clutch pressures page 7-19, it is
necessary to isolate the clutch being tested. For instance, to
check the layshaft clutch, you could select 1st gear forward.
This would energize the layshaft and forward low clutches.
Because we only want to check the layshaft clutch pressure
and not the forward low clutch pressure, remove the
electrical connector to the forward low clutch BEFORE
selecting 1st gear.

Use the tables below to determine which solenoid electrical
connectors should be removed when pressure-testing
individual clutches. Table 7-3 identifies the solenoid
connectors and Table 7-4 and Figure 7-14 identifies which
clutches are engaged when the various gears are selected.

NOTE:

Travel directions as described are the actual travel
directions of the crane.

Test for Clutch Leakage

Isolating A Suspect Clutch

Stop the engine, connect a 0-20 bar (0-300 psi) pressure
gauge to the test connector A Figure 7-15 (mainline pressure
test point).

Make sure that both sides of all four wheels are chocked.
Apply the foot brake and the parking brake.

Start the engine and run at 1000 rpm. Engage 1st gear
forward. Record the pressure reading. Repeat the test for all
rear ratios in forward drive and record the pressure readings
as shown below.

Table 7-3: Solenoid Descriptions

Item

Solenoid Description

SV1

Reverse Low

SV2

Reverse High

SV3

Layshaft

SV4

Mainshaft

SV5

Forward High

SV6

Forward Low

FIGURE 7-14

a0248

SV2 SV4 SV6

SV1

SV3

SV5

Table 7-4: Solenoid Valve Energizing Sequence

Gear

Direction

Clutches Engaged 

Solenoids

First

Forward

Forward Low & Layshaft 
SV6 and SV3

Second

Forward

Forward High & Layshaft 
SV5 and SV3

Third

Forward

Forward Low & Mainshaft 
SV6 and SV4 (SV4 only 
used on six solenoid 
transmissions)

Fourth

Forward

Forward High & Mainshaft 
SV5 and SV4 (SV4 only 
used on six solenoid 
transmissions)

First Reverse

Reverse Low & Layshaft 
SV3 and SV1

Second Reverse

Reverse High & Layshaft 
SV3 and SV2

Third

Reverse

Reverse Low & Mainshaft 
SV4 and SV1

Fourth

Reverse

Reverse High & Mainshaft 
SV4 and SV2

WARNING

DO NOT

 go under the crane with the engine running. Turn

off the engine, apply the parking brake, chock the wheels
and remove the ignition key before going underneath the
crane.

Reference Only

Summary of Contents for Grove YB5515-2

Page 1: ...Shuttlelift CD5515 2 Grove YB5515 2 Service Maintenance 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: ...ial number is identified on the builder s decal attached to the operator s cab Always furnish crane serial number when ordering parts or communicating service problems with your Grove distributor or Crane Care Customer Service at Grove 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 Ma...

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: ...teries 1 9 Hydraulic Systems 1 9 Electrical System 1 11 Fatigue of Welded Structures 1 11 Loctite 1 12 Fasteners and Torque Values 1 12 Weld Studs Table 1 10 1 16 Hydraulic Fitting 1 16 Wire Rope 1 18 General 1 18 Environmental Conditions 1 18 Dynamic Shock Loads 1 18 Lubrication 1 18 Precautions and Recommendations During Inspection or Replacement 1 18 Wire Rope Inspection Running Ropes and Penda...

Page 6: ...eneral Inspections 3 6 Starting Circuit Check 3 6 Instrument and Light Circuits 3 7 General 3 7 Light Bulbs 3 7 Gauges and Indicators 3 7 ECM Display Toggle Switch 3 7 Wire Harnesses 3 8 Engine Wire Harness 3 8 Main Frame Wire Harness 3 8 Dash Wire Harness 3 8 Cab Wire Harness 3 8 Boom Wire Harness 3 8 Accessory Circuits 3 17 Anti Double Blocking System 3 17 Rated Capacity Limiter RCL System 3 17 ...

Page 7: ...4 15 Checking and Adjusting Hydraulic Pressure Settings 4 15 Anti Double Blocking System 4 19 General 4 19 System Function 4 19 Outrigger and Axle Lock Out Circuits 4 19 Independently Controlled Outrigger Hydraulic System 4 19 Oil Flow 4 19 Outrigger Valves 4 19 Load Holding Valves 4 22 Vertical Outrigger Cylinder Leakage Check 4 22 Component Repair 4 22 Hydraulic Pump Repair 4 22 Outrigger Contro...

Page 8: ...Fuel System 5 33 Carwell Rust Inhibitor 5 33 Protecting Cranes From Rusting 5 33 Cleaning Procedures 5 34 Inspection and Repair 5 34 Application 5 34 Areas of Application 5 35 SECTION 6 Engine and Engine Systems General 6 1 Engine Types 6 1 Engine Performance 6 1 Engine RPM 6 1 Governor 6 1 Engine Crankcase System 6 1 Crankcase Oil Data 6 1 Engine Cooling System 6 2 Coolant Requirements 6 2 Radiat...

Page 9: ...iption 8 1 Front Axle 8 1 Rear Axle 8 1 Technical Data 8 2 Front Drive Axle 8 2 Rear Drive Axle 8 2 Rear Non Drive Axle 8 3 Front Drive Axle Repair 8 4 Removal 8 4 Installation 8 4 Special Tools 8 4 Replacing the Pinion Oil Seal 8 6 Axle Hub Repair 8 7 Drive Head Repair 8 11 Rear Axles Repair 8 19 Removal 8 19 Installation 8 19 Service Tools 8 19 Replacing the Pinion Oil Seal 8 19 Axle Hub Repair ...

Page 10: ...8 Removal 9 18 Disassembly 9 18 Assembly 9 19 Installation 9 19 Troubleshooting 9 20 Service Brakes 9 20 SECTION 10 Steering System Description 10 1 General 10 1 Steering Modes 10 1 Two Wheel Steering 10 1 Four Wheel Steering 10 4 Crab Steering 10 4 Steering Proximity Switches 10 7 General 10 7 Principle Of Operation 10 7 Sensor Operation and Spacing Checks 10 9 Steering Orbitrol 10 12 Description...

Page 11: ...eshooting 11 23 Bearing Mast And Related Parts 11 24 General 11 24 Mast Bearing 11 24 Mast Bearing Bolts 11 25 Inspection for Bearing Wear 11 25 Replacing the Mast Bearing 11 26 Swing Gearbox and Pinion 11 26 Swing Gearbox Repair 11 29 Outriggers 11 31 Outrigger Monitoring System OMS Optional Standard in North America 11 31 Removal 11 32 Disassembly 11 32 Assembly 11 32 Installation 11 32 SECTION ...

Page 12: ...TABLE OF CONTENTS CD5515 2 YB5515 2 SERVICE MANUAL TOC 8 This Page Blank R e f e r e n c e O n l y ...

Page 13: ...brication 1 18 Precautions and Recommendations During Inspection or Replacement 1 18 Wire Rope Inspection Running Ropes and Pendant Cables 1 19 Keeping Records 1 19 Frequent Inspection 1 19 Wire Rope Inspection Boom Extension and Retraction Cables 1 20 Wire Rope Inspection Replacement All Wire Rope 1 20 Seizing Wire Rope 1 21 O ring Seal and Elastic Nut Replacement 1 22 Hydraulic Pressure Testing ...

Page 14: ...blished 1 20 2017 Control 483 02 FIGURE 1 1 Crane S N Location FIGURE 1 2 Engine S N Location p1878 FIGURE 1 3 Transmission S N Location p0076 FIGURE 1 4 Front Drive Steer Axle p0074 FIGURE 1 5 Rear Drive Axle S N Location p0073 R e f e r e n c e O n l y ...

Page 15: ...er and type of batteries Standard Battery One maintenance free Battery Two with cold weather start 150 amp hr each Battery rating 150 amp hr Alternator 120 amps FUEL TANK Capacity 151 L 40 gal HYDRAULIC SYSTEM Primary Pump Piston 60 cc CCW Swing Motor Single section gerotor type Hoist Motor Gear Hydraulic Filters One 3 micron filter in line from valves One 30 mesh suction filter inside hydraulic t...

Page 16: ...Optional Below Deck Winch Diameter 11 1 mm 7 16 in Length 35 1 m 115 ft Hydraulic System Filters 10 micron return line filter 30 mesh suction filter in tank Weight Crane Gross Vehicle Weight 13 488 kg 29 735 lb Travel Speeds Two Wheel Steer 1st gear 6 4 km hr 4 mph 2nd gear 11 3 km hr 7 mph 3rd gear 21 km hr 13 mph 4th gear 34 km hr 21 mph Crane Gross Vehicle Weight 13 488 kg 29 735 lb FRONT AXLE ...

Page 17: ...er line outside tires 6 09 m 19 10 5 Outside turning radius end of boom extension 41 boom 7 75 m 25 5 end of boom extension 50 boom 7 66 m 25 2 Four Wheel Steer Outside turning radius center line outside tires 3 84 m 12 7 Outside turning radius end of boom extension 41 boom 5 57 m 18 3 end of boom extension 50 boom 5 48 m 18 0 Boom Angle Maximum 69 Minimum 0 OUTRIGGERS Type Hydraulic Construction ...

Page 18: ...erstanding the job to be done and the application of good common sense It is not just a matter of do s and don ts Stay clear of all moving parts 1 Determine the problem 2 List possible causes 3 Devise checks 4 Conduct checks in a logical order to determine the cause FIGURE 1 6 a1841 Item Description Item Description 1 Hook Block 11 Rear Axle 2 Boom Nose 12 Operator s Cab 3 Boom Extension 13 Operat...

Page 19: ...alance of the assemblies being lifted and to ensure safe handling Unless otherwise specified all removals requiring hoisting equipment should be accomplished using an adjustable lifting attachment or straps designed for that purpose All supporting members straps chains and cables should be parallel to each other and as near perpendicular as possible to the top of the object being lifted NOTE The c...

Page 20: ...ng and to prevent chafing 2 If a hose is replaced on a part that moves during operation be sure it moves freely by moving the part through its complete range of movement 3 Be sure any hose which has been installed is not kinked or twisted Free moving unsupported hoses must never rub on each other or related work surfaces This causes chafing and reduces hose life Bearings Antifriction Bearings When...

Page 21: ...h flat end If a sleeve bearing has an oil hole align it with the oil hole in the mating part Gaskets Be sure the holes in the gaskets correspond with the passages in the mating parts If it is necessary to make gaskets select material of the proper type and thickness Be sure to cut holes in the right places Blank gaskets can cause serious damage When removed always install new cylinder head and man...

Page 22: ...ly inspect hoses and fittings once a month or every 250 hours for the following Leaks at hose fitting or in hose Damaged cut or abraded cover Exposed reinforcement Kinked crushed flattened or twisted hose Hard stiff heat cracked or charred hose Blistered soft degraded or loose cover Cracked damaged or badly corroded fittings Fitting slippage on hose Other signs of significant deterioration If any ...

Page 23: ...rying stresses caused by twisting shock bending and intentional and or unintentional overloads often become subject to weld cracking which may be attributed to fatigue of the welded joint This condition is not uncommon in construction equipment Equipment should be periodically inspected for evidence of weld fatigue The frequency of these inspections should increase with the age of the equipment an...

Page 24: ... part it is to hold If a bolt is too short there may not be enough threads engaged to hold the part securely Threads can be damaged Inspect them and replace fasteners as necessary Torque values should correspond to the type bolts studs and nuts being used The torque tables are provided by Manitowoc for reference when performing maintenance Use of proper torque values is extremely important Imprope...

Page 25: ...bar handles must be propped or supported within the outer 1 4 of the handle length or serious under or over tightening will occur To convert pounds foot lb ft of torque to newton meters Nm multiply the pounds foot quantity by 1 3558 To convert pounds inch lb in of torque to newton meters Nm multiply the pounds inch quantity by 0 11298 Torque Values The following tables list the torque values for b...

Page 26: ... M4 M5 M6 M8 M10 M12 M14 M16 M18 M20 M22 M24 M27 M30 M33 M36 8 8 2 6 5 2 9 0 21 6 42 4 73 1 116 178 250 349 467 600 877 1195 1608 2072 10 9 3 7 7 5 12 5 31 5 62 0 110 170 265 365 520 700 900 1325 1800 2450 3150 12 9 4 3 9 0 15 0 36 0 75 0 128 205 315 435 615 830 1060 1550 2125 2850 3700 Bolt Diameter Metric Torque Values Nm Maximum Minimum Grade M4 M5 M6 M7 M8 M10 M12 M14 M16 M18 M20 M22 M24 M27 M...

Page 27: ...threads with oil or molybdenum disulfide and torque at low speeds without interruptions Do not use excessive pressure Impact wrenches are not recommended Bolt Diameter Metric Torque Values Nm Maximum Minimum Grade M8x1 M10x1 M10x1 25 M12x1 5 M14x1 5 M16x1 5 M18x1 5 M20x1 5 M22x1 5 M24x2 M27x2 M30x2 M33x2 M36x3 8 8 29 27 57 53 57 53 100 92 160 147 248 229 345 318 483 446 657 607 836 771 1225 1130 1...

Page 28: ...g connections 1 Make sure both threads and sealing surfaces are free of burrs nicks scratches or any foreign particles 2 Align tube or hose to the 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 condit...

Page 29: ...itting unscrew the fitting the required amount but not more than one full turn Figure 1 11C 6 Hold the fitting in the desired position and tighten the nut Figure 1 11D following the F F F T method See F F F T METHOD Flats from Finger Tight starting with step 4 Nonadjustable Straight Thread O ring Fitting Fitting to Port Table 1 13 1 Make sure both threads and sealing surfaces are free of burrs nic...

Page 30: ...d or lost It is important that lubricant applied as part of a maintenance program shall be compatible with the original lubricant and to this end the rope manufacturer should be consulted Lubricant applied shall be of the type which does not hinder visual inspection Those sections of rope which are located over sheaves or otherwise hidden during inspection and maintenance procedures require specia...

Page 31: ...s and Pendant Cables Wire rope should be inspected frequently daily and periodically yearly in accordance with the following information excerpted from a National Consensus Standard as referenced by Federal Government Agencies Recommended inspection intervals may vary from crane to crane and may vary based on environmental conditions frequency of lifts and exposure to shock loads The inspection ti...

Page 32: ...over the entire length of the extension and retraction cables This inspection should be used to monitor progressive degradation and to discover severe damages necessitating wire rope replacement or equipment repair Inspection criteria are as follows Inspect for reduction of rope diameter below nominal diameter Inspect for severely corroded or broken wires at end connections Inspect for severely co...

Page 33: ... and unraveling of the individual wires and strands at the ends All preformed and non preformed styles of wire rope should be seized prior to cutting Seizings must be placed on both sides of the point where the wire rope is to be cut The two preferred methods for seizing wire ropes are Method 1 Using a length of soft annealed wire Figure 1 15 place one end in the groove between two strands of the ...

Page 34: ...s unless stated otherwise with 10W30 oil or petroleum jelly before installation Replace all used elastic locknuts with new parts 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 syste...

Page 35: ...alerts the viewer 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 you...

Page 36: ...Lifting Make sure 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 chai...

Page 37: ...e before performing 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 ...

Page 38: ...are clearly marked 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 s...

Page 39: ...rical Energy power which comes from the movement of electrons Electrons are particles with a negative charge Electrons will collect around particles with a positive charge 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 volt...

Page 40: ...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 one two with diesel engine cold start 12 volt battery An alternator supplies the necessary current amps for system operation and charging of the batteries when the engine is...

Page 41: ...hifter TCU Trans Oil Cooler Back Up Alarm FU4 5 Outrigger Monitoring FU5 5 Park Brake Brake Light Switch FU6 20 Outriggers Winch FU7 25 RCL DRI Crane Functions FU8 5 Gauge Cluster Switch LEDs FU9 10 Steering Select FU10 15 Head Tail Lts Worklights Turn Signals 4 Way Flashers Fuse Amps Circuit FU1 5 Hoist Down Solenoid FU2 5 1195 ECM Power E Stop FU3 Diode Buzzer FU4 5 Diagnostic Connector FU5 Diod...

Page 42: ...ery Relay Compartment FIGURE 3 2 Battery Disconnect Switch Fuse Amps Circuit FU1 30 ACC Power Relay FU2 30 IGN Power Relay FU3 30 ECM Power FU4 30 Headlights FU5 30 IGN Power Relay 2 FU6 5 Starter Lockout Signal from Engine ECM FU7 Empty FU8 15 Module Power FU9 5 Swing Valves 360 Swing Lock Opt FU10 Diode Fuse Amps Circuit R e f e r e n c e O n l y ...

Page 43: ...FF position 3 Remove the ECM power fuse 4 Remove the negative battery cables 5 Remove the positive battery cables Use the following procedure when connecting the battery 1 Connect leads to the battery terminals starting with the positive terminals 2 Install the ECM power fuse 3 Turn the battery disconnect switch to ON Battery Disconnect Switch The battery disconnect switch Figure 3 2 is located in...

Page 44: ...er operates the starter and solenoid are good The problem is somewhere between the solenoid and the ignition switch Go to step 3 b If the starter does not operate connect the jumper cable to the B and M terminals on the starter solenoid If the starter operates correctly the problem is in the starter solenoid Replace the solenoid If the starter still does not operate the starter is bad and must be ...

Page 45: ...it in the engine cooling system The variable resistance caused by the sending unit gives a corresponding indication of the temperature of the engine coolant Voltmeter Display The voltmeter is connected in parallel with the charging circuit The voltmeter gives an indication of electrical charging system problems that can not be seen with an ammeter Normally when the engine is stopped ignition switc...

Page 46: ... The cab wire harness Figure 3 8 supplies electrical current to the components in the cab not connected to the dash wire harness Boom Wire Harness The boom wire harness Figure 3 9 supplies electrical current to the components mounted on the boom NOTE For wire harness wiring diagrams see Schematics Wiring Diagrams at the end of this manual Table 3 3 Voltage Level Conditions Voltage Measured Engine ...

Page 47: ...TEM 3 FIGURE 3 4 Tier 3 Engine Wire Harness Alternator Coolant Sensor ECM Ground To Carrier WIF Connector on Fuel Filter AC Compressor Engine ECM Connector Engine Power Connector WIF Connector on Engine J1939 Terminating Resistor Engine Ground Foot Pedal Connectors R e f e r e n c e O n l y ...

Page 48: ...er 4 Engine Wire Harness Alternator Coolant Sensor ECM Ground To Carrier WIF Connector on Fuel Filter AC Compressor Engine ECM Connector J1939 Terminating Resistor Engine Ground Foot Pedal Connectors MAF Sensor Air Cleaner OEM Breakout Connector ECM MAF Sensor WIF Sensor Engine R e f e r e n c e O n l y ...

Page 49: ...Control 483 02 3 11 CD5515 2 YB5515 2 SERVICE MANUAL ELECTRIC SYSTEM 3 FIGURE 3 6 Main Frame Harness Sheet 1 16 13 14 15 12 17 11 10 8 7 6 1 2 3 4 5 9 5 18 19 20 21 22 23 24 25 26 27 28 29 15 To Sheet 2 R e f e r e n c e O n l y ...

Page 50: ...t Jack 10 Right Front Outrigger Beam 11 Winch 12 Left Front OMS 13 Left Front Headlight 14 Left Front Turn Indicator 15 Ground Splice 16 Transmission Cooler Temperature Switch 17 Horn 18 Transmission Temperature Switch 19 Front Steering Proximity Switch 20 Main Control Valve 21 Hoist Down 22 Ground Splice 23 Outrigger Alarm Option 24 Brake Light Pressure Switch 25 Transmission Gear Shifter 26 Tran...

Page 51: ...83 02 3 13 CD5515 2 YB5515 2 SERVICE MANUAL ELECTRIC SYSTEM 3 FIGURE 3 6 continued Main Frame Harness Sheet 2 44 40 39 15 33 43 38 37 35 30 31 34 32 36 42 19 20 48 49 23 45 47 46 41 To Sheet 3 From Sheet 1 50 51 R e f e r e n c e O n l y ...

Page 52: ...ice 33 360 Swing Lock 34 360 Swing Lock 35 To Cab 36 To Cab 37 Frame Grounds 38 To Dash Harness 39 To Dash Harness 40 To Dash Harness 41 PC1 42 Slew Proximity 43 Swivel 44 Ground Splice 45 Hydraulic Oil Temperature 46 Unloader Valve 47 2WD 4WD Solenoid 48 Fuel Level Sending Unit 49 Ground Splice 50 To Engine 51 Rear Steer Proximity Switch R e f e r e n c e O n l y ...

Page 53: ...rol 483 02 3 15 CD5515 2 YB5515 2 SERVICE MANUAL ELECTRIC SYSTEM 3 FIGURE 3 6 continued Main Frame Harness Sheet 3 44 60 39 15 33 58 56 37 54 52 59 53 55 63 62 67 61 65 72 66 64 69 70 57 From Sheet 2 68 71 R e f e r e n c e O n l y ...

Page 54: ...ion 56 Relays 57 Power Post B 58 Power Post A 59 Right Rear Turn Signal 60 Right Rear Work Light 61 Right Rear Stop Tail Light 62 Right Rear OMS 63 Left Rear Turn Signal 64 Left Rear Work Light 65 Left Rear OMS 66 Left Rear Stop Tail Light 67 A C Binary Switch 68 Left Rear Outrigger Beam 69 Left Rear Outrigger Jack 70 Right Rear Outrigger Jack 71 Right Rear Outrigger Beam 72 Backup Alarm R e f e r...

Page 55: ... CD5515 2 YB5515 2 SERVICE MANUAL ELECTRIC SYSTEM 3 FIGURE 3 7 Dash Wire Harness 13 21 11 12 2 10 7 5 4 1 8 3 14 6 23 35 38 33 36 15 9 16 17 18 19 20 22 24 25 26 27 28 29 30 31 32 34 37 39 40 41 42 43 44 45 46 47 48 49 50 R e f e r e n c e O n l y ...

Page 56: ...9 Crane Power 20 Hazard Switch 21 Locked Indicator 22 RCL Override 23 LSI Display 24 Winch Switch 25 71 Splice 26 Swing Lock Switch 27 Diagnostic 28 J1939 Blue 29 J1939 Orange 30 Fuse Box 2 31 Shift Turn Right B 32 Shift Turn Left A 33 Flasher 34 Transmission Pressure Alarm 35 Steering Select Switch 36 2WD 4WD Select Switch 37 Work Headlights 38 Screen Toggle Switch 39 Defroster Fan 40 Cluster Gau...

Page 57: ...ater Air Conditioning 3 Seat Switch 4 RCL A 5 RCL B 6 RCL C 7 Dome Light 8 Strobe Light Item Description 1 To Swivel 2 Hoist High Speed 3 Hoist Rotation Indicator 4 Left Hand Boom Lights 5 Right Hand Boom Lights 6 RCL Warning Light CE Option 7 RCL Warning Alarm CE Option FIGURE 3 9 Boom Wire Harness 3 4 2 6 1 5 7 R e f e r e n c e O n l y ...

Page 58: ...ngle length or height For more information on the RCL system see the Owner s Manual furnished with the crane See wiring diagram in Schematics Wiring Diagrams Optional Engine Shutdown General Description Cranes can be furnished with an automatic engine shutdown to protect the engine when the engine oil pressure is too low or the engine water temperature is too high The electrical circuit includes a...

Page 59: ...ohmmeter Table 3 4 Charging System Troubleshooting Problem Possible Cause Solution Alternator does not charge 1 Alternator belt loose or broken 1 Replace and or tighten to specification 2 Worn brushes or open brush leads or connections 2 Replace or repair alternator 3 Open circuit short circuit or ground stator winding 3 Replace alternator 4 Fault in voltage regulator 4 Replace voltage regulator 5...

Page 60: ...gage parking brake 7 Bad neutral start relay 7 Replace relay Winch motor runs in only one direction 1 Defective solenoid or stuck solenoid 1 Jar solenoid to free contacts Check by applying 12 volts to coil terminal should hear an audible click when energized Replace solenoid 2 Defective control switch 2 Check and replace if necessary Winch motor runs extremely hot 1 Long period of operation 1 Cool...

Page 61: ...Check by applying 12 volts to coil terminal should hear an audible click when energized Replace solenoid 2 Defective control switch 2 Check and replace if necessary 3 Defective motor 3 If solenoids operate check voltage at armature post Replace motor if defective 4 Loose connections 4 Tighten connections on bottom side of hood and on motor Problem Possible Cause Solution R e f e r e n c e O n l y ...

Page 62: ...ntrolled Outrigger Hydraulic System 4 19 Oil Flow 4 19 Outrigger Valves 4 19 Load Holding Valves 4 22 Vertical Outrigger Cylinder Leakage Check 4 22 Component Repair 4 22 Hydraulic Pump Repair 4 22 Outrigger Control Valve 4 23 Swing Motor 4 23 Hydraulic Swivel 4 30 Hydraulic Cylinders 4 33 Under Deck Winch 4 40 GENERAL DESCRIPTION General A hydraulic system uses liquid to make a transfer of force ...

Page 63: ...tem for the transmission brakes and steering is found in Sections 7 9 and 10 respectively Only the main hydraulic system is included in this section The main hydraulic system gives hydraulic power to The swing motor The boom cylinders lift and telescope The front and rear outrigger cylinders The main hoist motor The hydraulic components on the boom and mast are connected to the hydraulic component...

Page 64: ...low through each circuit Use the flowmeter and pressure gauge to check your diagnosis of the problem Start at the source of the flow and check each component in sequence until the exact location of the problem is found If the problem is in two or three circuits check each circuit separately After a circuit is checked use caps or plugs to remove that circuit from the system Continue to next circuit...

Page 65: ...w normal warming procedure Loss of movement during operation Low oil level Check and add oil Vacuum in hydraulic tank Clean tank filler breather cap Restriction or leakage in the relief valve Clean or replace the relief valve Broken hydraulic line Replace Bad seal in hydraulic swivel Replace seals Broken gear or shaft in pump Overhaul or replace Overheating of hydraulic oil Wrong operation running...

Page 66: ...linder retracts but does not extend Malfunction in anti double blocking electrical system See Electric System Bad cartridge in anti double blocking solenoid valve Replace cartridge Restriction in pilot control line to control valve Locate and repair Faulty controller Repair or replace Boom moves slowly downward when control valve is in NEUTRAL position Internal leakage in cylinder Replace piston s...

Page 67: ...setting Faulty pump section Overhaul or replace the pump Slow movement all outriggers Low engine rpm Increase engine speed Solenoid valve on outrigger valve section not fully actuating the valve spool Check for restriction or binding in the solenoid valve Leakage in relief valve Clean or replace the relief valve Slow movement one cylinder Internal leakage in the cylinder Replace piston seals Outri...

Page 68: ...lve Motor will not hold the load when the control lever is in neutral load drifts down slowly Overload condition Decrease the load Faulty counterbalance valve Replace the counterbalance valve Hoist does not move Restriction in holding valve cartridge Clean or replace the holding valve cartridge Brake not releasing Check condition of the brake Repair as necessary Low pilot pressure Check and adjust...

Page 69: ...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 pressure and the lubrication fluid flow required When the system pressure setting is reac...

Page 70: ... to the pressure side of the variable displacement load sense pump by a hydraulic hose There is a load sense relief valve installed in the inlet section Working Valve Sections There are four working sections Figure 4 2 of the main control valve that receive hydraulic oil from the variable displacement load sense pump These sections control the hoist telescope lift and swing functions They are clos...

Page 71: ...il under low pressure flows through this port Port No 5 Hydraulic oil under pressure flows through this port when the boom is being retracted When extending the boom the hydraulic oil under low pressure flows through this port Port No 6 Hydraulic oil under pressure flows through this port when the boom is being extended When retracting the boom the hydraulic oil under low pressure flows through th...

Page 72: ...valve lets the cylinder retract only if there is oil under pressure available to the rod port of the cylinder See Holding Valve Holding Valve The holding valve has three functions 1 Inhibit cavitation of the cylinder 2 Give full control of the lowering of the boom 3 Hold the load in event of a hydraulic failure Pilot pressure from the rod side of the piston opens the holding valve If the cylinder ...

Page 73: ...HYDRAULIC SYSTEM CD5515 2 YB5515 2 SERVICE MANUAL 4 12 Published 1 20 2017 Control 483 02 FIGURE 4 4 Hoist Lift Telescope Swing R e f e r e n c e O n l y ...

Page 74: ...rt or 193 05 bar 2800 psi to the piston port the relief valve will open and return oil to tank stopping any movement of the telescope cylinder and its cable mechanism Oil from the rod end of the cylinder returns through port 6 of the hydraulic swivel to the control valve From here the oil is routed through the return filter to the hydraulic tank Holding Valve The holding valve has three functions ...

Page 75: ... Oil Flow When the valve spool is in the neutral position both A and B ports are closed Oil is held in the hoist circuit inhibiting movement of the hoist motor Hoist Up Pulling the joystick towards the operator routes oil from the pump to cylinder port A of the control valve Figure 4 4 From here the oil is routed through the anti double block solenoid valve and swivel port 2 to the brake holding v...

Page 76: ...e of the motor returns through the B port and sent back to tank through the return filter Swing Left Pulling the joystick towards the operator sends oil through motor port B of the valve section to the swing motor The motor rotates counter clockwise and causes the mast to rotate to the left Oil from downstream side of the motor returns through the A port and is sent back to the tank through the re...

Page 77: ...ned on the gauge clockwise increases pressure counterclockwise reduces the pressure A 6 mm hex wrench is required for the adjusting screw 6 Tighten the margin set screw 7 Shut off the engine and disconnect the pressure gauge Pump Compensator Pressure Setting The pump compensator pressure is the main hydraulic system pressure It is regulated by a pressure compensating valve located on the main hydr...

Page 78: ...re 4 6 located on the front outrigger manifold 2 Start the engine 3 Loosen the jam nut on the relief valve 1 Figure 4 8 A 19 mm open end wrench is required for the jam nut 4 Ensure the boom is all the way down Activate the boom down function at full engine throttle adjust the load sense relief setting by turning the relief valve adjusting screw 1 Figure 4 8 until 258 55 3 45 bar 3750 50 psi pressu...

Page 79: ...ure A 3mm hex wrench is required for the adjusting screw 3 Retract the boom and outriggers 4 Shut the engine off 5 Remove the gauge Outrigger Circuit Pressure Setting 1 Shut off the engine Install a 0 344 73 bar 0 5000 psi pressure gauge to the front outrigger manifold test point 4 Figure 4 6 2 Start and accelerate the engine to maximum rpm 3 Actuate the outrigger enable switch to the extend posit...

Page 80: ... flow to the lift cylinder telescopic cylinder or hoist motor through port A of the valve section is returned through the check valve to the outlet of the control valve or through the open solenoid valve back to tank Lowering the hoist block will deactivate the switch to close the solenoid valves and return flow through port A to the function OUTRIGGER AND AXLE LOCK OUT CIRCUITS Independently Cont...

Page 81: ...r Valve Ports For easy identification the ports of the outrigger valve are stamped on the valve manifold Table 4 7 Port Identification Figure 4 11 Port Function 1 Under Deck Winch 2 Left Front Jack Cylinder 3 Left Front Beam Cylinder 4 Right Front Beam Cylinder 5 Right Front Jack Cylinder A1 Front Outrigger Beam and Jack Return A2 Not Used A3 Rear Outrigger Manifold Return A4 Under Deck Winch Retu...

Page 82: ...GROVE Published 1 20 2017 Control 483 02 4 21 CD5515 2 YB5515 2 SERVICE MANUAL HYDRAULIC SYSTEM 4 FIGURE 4 11 7948 1 A1 7948 2 A2 1 A3 2 A4 T P 3 4 5 7948 3 R e f e r e n c e O n l y ...

Page 83: ...ne 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 COMPONENT REPAIR Hydraulic Pump Repair Removal 1 Drain the hydraulic tank 2 Remove the secondary pump from the primary pump See removal instructions 3 Disconnect the suction l...

Page 84: ...ve Solenoid Replacement 1 The solenoids on the valve section can be removed without removing the valve section from the manifold block 2 Stop the engine and engage the parking brake Place chocks under the wheels 3 Disconnect the battery using the battery disconnect switch 4 Open the access cover over the control valves and remove the cover plate 5 Disconnect the wire leads from the solenoid valve ...

Page 85: ...scard seal 13 from the gerotor 5 Remove drive spacer if applicable 6 Remove drive shaft 14 7 Remove spacer plate 15 8 Remove seal 13 from housing 10 9 Remove output shaft 9 from housing 10 10 Remove needle thrust bearing 8 from shaft or housing 11 Reposition the motor in the vice Clamp across ports Figure 4 14 DO NOT clamp on housing Excessive clamping pressure on side of housing causes distortion...

Page 86: ...y apply torque to the capscrew with a socket wrench as heat is applied for 8 to 10 seconds As soon as the screw breaks loose remove the heat from the housing Continue turning the screw until it is completely removed Repeat for other capscrews 13 Carefully remove flange 3 Figure 4 13 from housing 10 NOTE Important Some motors may have a quad seal and back up ring in place of the pressure seal The q...

Page 87: ...motor DO NOT stretch the seals before installing them Cleanliness is extremely important in the successful application of Loctite Before Loctite can 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 ...

Page 88: ...ge examine the seal condition If damaged or improperly installed replace the seal before continuing with assembly 7 Install O ring 6 Figure 4 13 into groove in flange 3 8 It is recommended to apply a light coat of Loctite Primer NF in 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 p...

Page 89: ... not stretch the seals before installing them in a groove 13 Pour approximately 30 cc 1 ounce of clean hydraulic oil in the output shaft cavity 14 Install O ring 13 Figure 4 13 in the housing groove Avoid twisting the seal Timing Procedure 15 Install drive shaft 14 Figure 4 13 Use a felt tip pen to mark one drive tooth Align this mark with the timing dot on the output shaft Figure 4 22 NOTE If dri...

Page 90: ...cuit Check for leaks Hoist Motor Removal 1 Shut off the engine set the parking brake 2 Before disconnecting the hydraulic lines clean the port area of the hoist motor thoroughly Disconnect the hydraulic lines from the hoist motor Put caps and plugs on the hoses and ports to keep dirt out 3 Loosen and remove the two capscrews and lockwashers securing the motor to the hoist Remove the hoist motor an...

Page 91: ...s on the hydraulic lines with the number of the hydraulic port to which the line connects 3 Disconnect the hydraulic lines from the upper and lower swivel ports Be prepared to collect the hydraulic oil in the lines Put caps or plugs on the fittings and hydraulic lines 4 Remove the stop from the bottom of the swivel 5 Put a support under the swivel Remove the three bolts and lockwashers securing th...

Page 92: ...AL HYDRAULIC SYSTEM 4 FIGURE 4 25 1 Housing Assembly 2 Washer Ring 3 Retainer Ring 4 Piston Seal 7 5 Wiper Ring 6 Energizer Square Seal 7 7 U cup Seal 2 8 Wear Ring 2 9 Wiper Ring 10 Thrust Washer 11 Spool Assembly 12 Thrust Washer Included In Seal Kit R e f e r e n c e O n l y ...

Page 93: ...ll one heated square seal 6 over each piston seal 5 Install the two wear rings 8 into their appropriate grooves 6 Install wiper ring 9 into its groove 7 Place the swivel housing 1 on the work bench with the bottom of housing facing up Lubricate the lower 1 4 of the swivel bore with hydraulic fluid 8 Place seal 7 on the end of the swivel housing 1 and then insert the assembled spool into the housin...

Page 94: ...ch to loosen and remove the piston b On pistons which are fastened with a locking nut use a socket wrench and extension to loosen the nut 7 Remove and discard the seals and wear rings from the piston 8 Remove and discard all seals backup rings wear rings etc from the head gland Inspection Wash the parts in a suitable solvent Use compressed air to remove all residue Check the bore of the cylinder t...

Page 95: ...lly check for internal and external leakage No internal or external leakage is permitted 5 Fully extend the cylinder rod Keep the rod port open Apply test pressure in Table 4 8 to the base port Hold this pressure for a minimum of 10 seconds Visually check for internal and external leakage No internal or external leakage is permitted 6 Put plugs in the cylinder ports to keep out dirt during install...

Page 96: ... 26 5 Not Used 6 O Ring Plug 7 Metal Plug 2 8 Not Used 9 Screw 10 Locknut 11 Grease Fitting 12 Counterbalance Valve 13 Piston Seal 14 Wear Ring 2 15 O Ring 16 Rod Seal 17 Buffer Seal 18 Wear Ring 2 19 Wiper Ring 20 O Ring 21 Backup Ring 22 O Ring 23 Bushing 4 24 Not used 25 Seal Kit Piston 26 Seal Kit Head Repair Kit Lift Cylinder Sheet 1 See Detail See Sheet 2 See Sheet 2 Detail R e f e r e n c e...

Page 97: ...HYDRAULIC SYSTEM CD5515 2 YB5515 2 SERVICE MANUAL 4 36 Published 1 20 2017 Control 483 02 a0432 FIGURE4 26continued Lift Cylinder Sheet 2 Detail Item 25 Detail Item 26 R e f e r e n c e O n l y ...

Page 98: ...13 Round Nut 14 Screw 15 Retaining Ring 16 Rod Wiper 17 Rod Seal 18 Backup Ring 19 O ring 20 Wear Ring 21 Retaining Ring 22 Rod Wiper 23 Rod Seal 24 Backup 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 Lockwasher 34 Capscrew 35 45 Degree Elbow 36 Locknut 37 Holding Valve Assembly 38 Piston Seal 40 90 Degree Elbow 41 Piston Seal 42 Strait...

Page 99: ...rol 483 02 a0440 FIGURE 4 28 1 Cylinder Tube 2 Piston Nut 3 Piston 4 Wiper 5 O Ring 6 Seal 7 O Ring 8 O Ring 9 Back Up Ring 10 Gland Head 11 Seal 12 Rod Wiper 13 Cylinder Rod Seal Kit Tighten nut to a torque of 25 lb ft 34 Nm Horizontal Outrigger Cylinder R e f e r e n c e O n l y ...

Page 100: ...TEM 4 a0437 FIGURE 4 29 1 Cylinder Tube 2 Piston 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 Head 11 Rod Seal 12 Seal Wiper 13 Cylinder Rod Seal Kit Tighten nut to a torque of 175 lb ft 238 Nm Vertical Outrigger Cylinder R e f e r e n c e O n l y ...

Page 101: ...NDER DECK WINCH The under deck winch is connected to the front outrigger control manifold Hydraulic oil flows through an electrically activated three position directional control valve to provide directional control and a two position control valve to supply oil flow R e f e r e n c e O n l y ...

Page 102: ... eye protection when performing service or maintenance tasks Propelled and or dropped items can cause eye injury If maintenance or adjustments must be performed with the engine running have a person at the controls while another person performs the work to prevent accidental movement which could cause injury or death Preventive maintenance is necessary to keep the crane in good condition as long a...

Page 103: ...l be taken as applicable Place a warning tag in a conspicuous location at the controls stating that the machine requires adjustment or repair before it can be operated Park the crane where it will cause the least interference with other equipment or operations in the area Place all controls at the off position and set the brakes to prevent inadvertent motion Disable all methods used to start the c...

Page 104: ... the reservoir hydraulic oil level as necessary 9 Repeat Steps 7 and 8 for the remaining outriggers 10 Disconnect the return lines from a pair of outrigger jack cylinders and activate the cylinders to their maximum down positions 11 Connect the return lines and raise the outrigger jack cylinders to the stowed position Replenish the reservoir hydraulic oil level as necessary 12 Repeat Steps 10 and ...

Page 105: ...air is not readily removed lower the boom to below horizontal extend the telescope cylinders as far as practicable and allow the boom to remain in this position overnight This should allow entrapped air to find its way to the holding valve so that telescoping the boom IN the next morning should force the air back to the reservoir Ensure the boom is first telescoped IN not OUT in the morning Telesc...

Page 106: ...ualified person Standby cranes must be inspected using the daily through monthly inspection by a qualified person PREVENTIVE MAINTENANCE Maintenance Schedule and Checklist NOTE Hour intervals in each maintenance chart show the correct time for service The hourmeter located in the operator s cab indicates the total hours the crane has been running In addition to the following scheduled maintenance ...

Page 107: ...leaner duct cup x Lubricate parking brake fitting x Inspect engine fan belts x Check wheel nut torque x Lubricate the swing gear and pinion x Lubricate the wire rope x Inspect the boom sheaves x Inspect all hydraulic hoses x Replace engine crankcase oil x Replace engine oil filter x Clean radiator fins and core x Clean battery and connections x Torque critical bolts x Service Check Daily before op...

Page 108: ...s x Inspect the parking brake pads x Inspect tires for damage x Add rust inhibitor to engine cooling system x Replace the air cleaner element x Check swing gear to pinion backlash x Replace the transmission oil and filter x Replace the axle wheel hub lubricant x Replace the axle housing lubricant x Replace the hoist gearbox lubricant x Replace the hydraulic oil x Replace the hydraulic oil filter x...

Page 109: ...2 Boom Pivot see Figure 5 2 2 Boom Head Sheaves and Pivot see Figure 5 3 2 Lift Cylinder Pivots see Figure 5 5 2 Drive Train Location QTY Steering Knuckles front axle see Figure 5 6 4 Steering Knuckles rear axle see Figure 5 7 4 Steering Link front axle see Figure 5 8 2 Steering Link rear axle see Figure 5 9 2 Steering Cylinder Pivot Ends front axle see Figure 5 10 2 Steering Cylinder Pivot Ends r...

Page 110: ...ngs Located On Inside Surface or Bearing Ring FIGURE 5 1 p1663 Boom Pivot Lubrication Points FIGURE 5 2 Boom Head Sheaves and Pivot Lube Points FIGURE 5 3 p1639 Lift Cylinder Pivots Lube Points Base End FIGURE 5 4 p1664 Lift Cylinder Pivots Lube Point Rod End FIGURE 5 5 p0417 Steering Knuckle Lube Points Front Axle FIGURE 5 6 R e f e r e n c e O n l y ...

Page 111: ... Knuckle Lube Points Rear Axle FIGURE 5 7 p0419 Steering Link Lube Points Front Axle FIGURE 5 8 p0422 Steering Link Lube Points Rear Axle FIGURE 5 9 p0418 Steering Cylinder Pivot Ends Lube Points Front Axle FIGURE 5 10 p0420 Steering Cylinder Pivots Ends Lube Points Rear Axle FIGURE 5 11 R e f e r e n c e O n l y ...

Page 112: ...Shaft Lube Points Front Axle FIGURE 5 12 p0401 Drive Shaft Lube Points Rear Axle Typical FIGURE 5 13 p0423 Rear Axle Pivot Lube Point FIGURE 5 14 p0391 Drop Block Lube Point FIGURE 5 15 p0315 Jib Head Sheave Lube Point Typical FIGURE 5 16 p0392 Jib Boom Deflector Sheave Lube Point FIGURE 5 17 R e f e r e n c e O n l y ...

Page 113: ...recting 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 operation check all safety devices for proper operation Examples of saf...

Page 114: ... cold 3 If oil is low add recommended oil to bring the level between the marks DO NOT OVERFILL Install the dipstick Close the cover Check Engine Coolant Level NEVER remove the radiator cap while the cooling system is hot Check coolant level only when the coolant temperature is below 50 C 120 F The system is under pressure and the coolant can cause severe burns or eye injury Wear protective clothin...

Page 115: ...uctions Check Hydraulic Oil Level If the hydraulic oil is consistently low check for leaks in the hydraulic system 1 Be sure the boom is fully retracted and lowered and the outriggers are retracted and up 2 Level the crane engage the parking brake and shut off the engine 3 Visually check the oil level on the hydraulic oil level sight gauge Figure 5 21 The hydraulic oil should be visible in the sig...

Page 116: ...ipe every surface clean Check it visually to make sure it is clean before installing a cleaned or 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 both on the bottom and top of the housing Inspect the Element 1 Don t be fooled by the appear...

Page 117: ...striction indicator by pushing in the reset button Figure 5 33 6 If a cleaned air cleaner element was installed start the engine and run at high idle If the air cleaner restriction indicator s colored piston pops out and is visible again shut down the engine and replace the air cleaner element with a new element Check Tire Pressure Check the air pressure in the crane s four tires Correct pressure ...

Page 118: ...riteria for each application inspected If you are not familiar with wire rope inspection information on how to inspect wire rope sheaves and drums is available from your distributor Order Wireco Report No 107 General Inspection NOTE Always wear gloves when working with wire rope to prevent hand injuries 1 Wire Rope Inspect for damage rust or wear to the wire rope Keep a record of each inspection R...

Page 119: ... access to the telescope cylinder rod end slide pad 6 Apply extreme pressure multipurpose grease or equivalent 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 p1643 Parking Brake Lube Fitting FIGURE 5 24 Boom Slide Lubrication FIGURE 5 25 Extend booms...

Page 120: ...essive vibration and increased wear A belt that is too tight produces wear on the belt and the bearings of the pulleys it travels around Check ribbed belts for intersecting cracks Cracks across the belt are acceptable Cracks along the length of a ribbed belt are not acceptable Ribbed belts with cracks along their length should be replaced See Figure 5 26 Any ribbed belt showing signs of wear or th...

Page 121: ...uidelines see the engine manual furnished with this crane Inspect the Hydraulic Hoses Inspect hydraulic hose assemblies for leaks damaged 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 beginn...

Page 122: ...and old lubricant NOTE To prevent personal injury from compressed air always wear safety glasses when using compressed air for cleaning 3 After cleaning the wire rope apply a good grade of wire rope lubricant to the entire length of the wire rope Or apply a light weight oil that has been preheated to a temperature between 18 to 36 C 60 to 100 F Use a brush or cloth to apply the oil NOTE Be sure th...

Page 123: ... the gasket makes contact Then tighten the filter 1 2 to 3 4 turn to get correct seal 8 Fill the engine crankcase with clean recommended lubricating oil 9 Operate the engine at idle and inspect for leaks at the filter and drain plug Torque Critical Bolts NOTE Maintain correct torque on all bolts Failure to do so may result in severe damage to the crane Hoist Gearbox Mounting Bolts Torque the M16 m...

Page 124: ...e Replace Fuel Filter See the engine operator s manual furnished with the crane and follow the replacement procedures NOTE If the filter is not filled with fuel prior to installation the engine will not start due to air in the fuel system The fuel system will have to be bled as instructed in the engine operator s manual furnished with the crane Replace Air Cleaner Element NOTE Service the air clea...

Page 125: ...bitor in the radiator reservoir following manufacturer s instructions Lubricate the Outrigger Slides 1 Lower the outriggers 2 Clean the tops of the outriggers with a suitable solvent 3 Apply Mobil EP grease or equivalent to the areas shown in Figure 5 34 Do not over lubricate Raise and lower the outriggers several times to spread the grease Add Grease to the Swing Gearbox NOTE It is necessary to c...

Page 126: ...lug Figure 5 36 and Figure 5 37 and remove the plug 2 Check the lubricant level which should be even with the bottom of the fill check hole 3 If necessary add Mobil Fluid 424 to fill the housings until oil is level with the bottom of the fill check hole Check Wheel Hub Lubricant Level 1 Using the outriggers raise the tires slightly off of the ground 2 Place the transmission in neutral and release ...

Page 127: ...hed with this crane Replace the Transmission Oil and Filter 1 Engage the parking brake and shut off the engine Remove the ignition key NOTE It is necessary to climb under the crane to drain the transmission oil Be sure engine is shut off the ignition key is removed parking brake is engaged and chock blocks are in place before climbing under the crane When the strainer is loosened removed oil will ...

Page 128: ...oil to fill the transmission filter torque converter and hoses 11 Stop the engine wait approximately one minute and then check oil level If low add oil to the upper mark on the transmission dipstick DO NOT OVERFILL Replace the Axle Housing Lubricant NOTE It is necessary to climb under the crane to drain the axle housing lube Be sure engine is shut off the ignition key is removed and chock blocks a...

Page 129: ...g is located at the bottom of the wheel hub Figure 5 47 4 Clean around the drain plug and then remove it Drain the wheel hub oil into a suitable container 5 Turn the wheel hub until the drain hole is horizontal Figure 5 48 6 Fill the wheel hub with the recommended lubricant through the fill hole until the oil reaches the bottom of the hole 7 Install the plug p0429 Axle Housing Drain and Fill Plugs...

Page 130: ...ipple 8 Fill the gearbox through the fill hole until the fluid is even with the bottom of the fill hole Fill with SAE 90 EP gear lube 9 Install the fill check plug Replace the Hydraulic Oil NOTE ISO International Standards Organization 46 68 Hydraulic Oil Mobil Fluid 424 is recommend for year round use in the hydraulic system In very cold temperatures SAE 5W or SAE 5W 20 oils can be used if the vi...

Page 131: ...lass Add hydraulic oil if necessary 13 Visually check for leaks Replace the Hydraulic Oil Filter 1 Engage the parking brake and shut off the engine NOTE It is necessary to climb under the crane to replace the hydraulic oil filter Be sure engine is shut off the ignition key is removed and chock blocks are in place before climbing under the crane 2 Locate the hydraulic oil filter under the machine F...

Page 132: ...ion If there is any other clearance adjust the backlash See Swing Gearbox and Pinion page 11 26 2000 Hours of Operation Yearly NOTE You must read and understand the warnings and basic safety rules found in Section 2 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 Engi...

Page 133: ...a low battery charge A reading of less than 14 volts with the engine speed above low idle indicates a problem in the charging system The system should be checked out by a qualified service technician Charging the Battery Under normal conditions the engine s alternator will have no problem keeping a charge on the batteries The only condition in which the battery s may cause a problem is when they h...

Page 134: ...n approximately 24 hours after application Once applied treatment can appear to leave a slightly oily residue on painted surfaces and until the red tinting fades could initially be mistaken for a hydraulic oil leak While the product is not harmful to painted surfaces glass plastic or rubber it must be removed using standard steam cleaning techniques This treatment works in various ways 1 it elimin...

Page 135: ...e 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 scratches and marks in highly visible areas Sand to remove the scratch and feather outward from the mark to blend the repair into the original surface Body putty may be applied as necessary to hide the defect then sand...

Page 136: ...s ladders steps and all access areas to crane as necessary Please contact Manitowoc Crane Care should you have any questions Areas of Application Refer to Figure 5 54 The underside of the unit will have full coverage of the rust inhibitor These are the only areas that a full coat of the rust inhibitor is acceptable on the painted surfaces Areas include valves hose end and fittings swivel pumps axl...

Page 137: ...PREVENTATIVE MAINTENANCE CD5515 2 YB5515 2 SERVICE MANUAL 5 36 Published 1 20 2017 Control 483 02 1 3 10 12 2 6 3 11 4 8 9 5 13 12 14 7 6 R e f e r e n c e O n l y ...

Page 138: ...e 5 Hose Connections inside turntable 6 All Hardware Clips Pins Hose Connections not painted O R Pins Clips 7 Boom Nose Pins Clips 8 Headache Ball Hook Block 9 Turntable Bearing Fasteners 10 O R Pins Clips 11 Hook block Tiedown Cable 12 O R Hose Connections 13 Entire underside of unit 14 Powertrain Hardware inside compartment 15 Boom Extension Pins Clips Option 16 Boom Extension Hanger Hardware Op...

Page 139: ...PREVENTATIVE MAINTENANCE CD5515 2 YB5515 2 SERVICE MANUAL 5 38 Published 1 20 2017 Control 483 02 This Page Blank R e f e r e n c e O n l y ...

Page 140: ...our wheel drive units use a Cummins 4B3 3 turbo charged diesel engine ENGINE PERFORMANCE Engine performance is very important to the operation of the crane The engine is the drive for the 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 t...

Page 141: ...ant through the passages in the engine block and head Circulation is by a thermo siphon action assisted by a water pump driven by a belt from the crankshaft pulley The water pump bearings are packed with a special grease during assembly and do not require attention in maintenance Coolant Requirements The quality of coolant will determine the efficiency and life of the cooling system 1 Check the an...

Page 142: ...allows coolant to be expelled into the overflow bottle and as soon as the engine cools the overflow fluid is sucked back into the radiator An incorrect radiator cap can result in a great loss of coolant and the engine running hot Keep the overflow bottle at least half full of coolant at all times Thermostat A malfunctioning thermostat can result in the engine running hot or cold If it becomes nece...

Page 143: ...ting fuels contain harmful chemicals which can seriously affect engine efficiency and performance Due to precise tolerances of diesel fuel injection systems it is extremely important that the fuel be kept clean and free of dirt and water Dirt or water in the system can cause severe damage to both the injection pump and the injection nozzles Use either a Grade No 1 or a Grade No 2 ultra low sulfur ...

Page 144: ...rts that would be adversely affected by heat When installing an exhaust system allow for expansion when the system is hot Periodic maintenance of the exhaust system is not required However it is advisable to check the condition of the system when performing other maintenance on the crane Check the complete exhaust system for broken damaged missing or mispositioned parts open seams holes loose conn...

Page 145: ...e filter elements Below normal engine temperature 1 Defective thermostat 2 Defective temperature gauge 1 Remove and check thermostat 2 Check gauge sender and all connections 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 En...

Page 146: ...e engine ground cable from the engine or the engine flywheel 21 Remove the rear axle a Attach a chain to the front engine lifting lug and attach to a hoist Use the hoist to support the engine while the rear axle is removed b Loosen and remove the wheel lug nuts and remove both rear wheels c Disconnect and plug the hydraulic hoses at the steering cylinders d Disconnect and cap and plug the brake ho...

Page 147: ...gasket 12 Connect the drive shaft s to the engine See Axles Drive Shafts Wheels and Tires Section 8 13 Connect the fuel lines to the fuel tank NOTE The diesel fuel supply fuel line must be bled of air before engine can be started Refer to the engine operator s manual furnished with this crane for bleeding procedure 14 Install the air cleaner and intake hose 15 Install the radiator in place on the ...

Page 148: ...ission Repair 7 24 Special Service Tools 7 24 Servicing the Torque Converter 7 26 TECHNICAL DATA General Technical Data Description Two Wheel Drive Full electrohydraulic transmission unit with input reverse and mainshaft clutch packs Torque converter is integral Four Wheel Drive Full electrohydraulic transmission unit with input reverse four wheel drive and mainshaft clutch packs Torque converter ...

Page 149: ...m 11 0 15 0 bar 2 9 4 0 psi Pump 2000 rpm 22 5 29 5 bar 6 0 7 8 psi The following clutch pressures should be the same as the Mainline Pressure to within 7 bar 10 psi Input Clutch Pressure high and low ratio Forward Clutch Pressure high and low ratio Layshaft Clutch Pressure Mainshaft Clutch Pressure Clutch Solenoid Technical Data Type 4 way 3 position directional control Operating Flow 40 L min 9 ...

Page 150: ...he steering column actuates both gear ratio and direction solenoids The Powershift transmission consists of a torque converter A Figure 7 2 input clutch assembly B forward clutch C layshaft assembly E and a mainshaft assembly D The torque converter is a fluid coupling bolted to a drive plate which is bolted to the engine flywheel As the engine crankshaft begins to rotate the torque converter gives...

Page 151: ...elected therefore the two engaged clutches will be reverse low ratio clutch B and layshaft drive clutch E For purpose of this description clutches not used when 1st gear reverse is selected are not shown Oil from the pump Q is fed through an internal passage by way of the filter Y to pressure the maintaining valve R which maintains a constant pressure to the solenoid valve adapter block S The sole...

Page 152: ...ocked at the solenoid valves Restrictor orifice X in the feed lines to the solenoid valves modulates the pressure to the clutches This ensures a smooth clutch engagement Pressure from the clutches not engaged will vent back to the sump by way of internal passages and the solenoid spools When 1st gear forward is selected valves G and M are energized The energized valves cause internal spools to mov...

Page 153: ...e transmission from four wheel drive mode to two wheel drive mode In four wheel drive mode the solenoid valve is not actuated and the clutch pack J is spring applied In two wheel drive mode the solenoid is actuated and hydraulic oil is directed to the clutch pack releasing the clutch Although the solenoid is furnished with the cranes with four wheel drive the two wheel drive option is not availabl...

Page 154: ...zed diverts pressurized oil by way of the shaft to the appropriate clutch in the unit Pressure from the other clutch is vented to the sump by way of the solenoid valve spool NOTE The forward high and forward low clutch unit operates in a similar manner The mainshaft and layshaft assemblies each have a single clutch The principle of operation similar to the forward reverse high low clutch assemblie...

Page 155: ...ch B2 Reverse High Ratio Clutch C1 Forward Low Ratio Clutch C2 Forward High Ratio Clutch D Mainshaft Clutch E Layshaft Clutch F 4WD Clutch a2278 Solenoid Identification SV1 Reverse Low Solenoid SV2 Reverse High Solenoid SV6 Forward Low Solenoid SV5 Forward High Solenoid SV4 Mainshaft Layshaft Solenoid SV3 2 4WD Solenoid Not functional FIGURE 7 7 R e f e r e n c e O n l y ...

Page 156: ...Stall Speeds on all clutches 10 See fault Overheating Low Mainline Pressure 1 Worn pump 2 Blocked suction strainer 3 Pressure maintaining valve sticking or leaking 4 Foaming oil 1 Check repair or replace the pump 2 Clean suction strainer 3 Free sticking valve or replace valve 4 Internal leakage cored passages inspect transmission Dirty suction strainer clean strainer High oil level drain to proper...

Page 157: ...ce the relief valve Overheating 1 Low oil level 2 High oil level 3 Trapped or kinked hoses in cooler system 4 Low converter out pressure relief valve 5 Oil cooler blockage 6 Operating in wrong gear ranges 7 Engine cooling system overheating 8 Foaming oil 9 Clutch pistons sticking on return stroke 10 Passages on front housing pump mounting face are the wrong depth indicated with an excessively low ...

Page 158: ... harness Table 7 1 shows which solenoid valves are energized for the four speeds and two directions of travel Electronic Control Unit ECU The Electronic Control Unit ECU is designed to do two things Figure 7 10 To control the selection of gears and direction of travel To protect the gearbox from damage due to incorrect use of the controls It is a microprocessor controlled unit which is mounted in ...

Page 159: ...sing gears 1 Faulty solenoid s 2 Faulty shift control 3 Low oil pressures 1 Check solenoid s and wiring 2 Check control and wiring 3 Check clutch pack and mainline pressures No 4th gear 1 Faulty speed signal 1 Check speed sensor and wiring 2 Check speed sensor installation i e distance from transfer case Down speed protection does not seem to be working 1 Faulty speed signal 1 Check speed sensor a...

Page 160: ...ion 1 Slow crane with brakes Deselect reversal Sporadic gear changes 1 Moisture in ECU connectors 1 Check that connector seals are installed and are in good condition Problem Possible Cause Remedy CAUTION Never check for voltage directly across any pins on the ECU Internal damage can result from shorting pins Gear Selection Solenoids Forward 1st Forward Low SV6 and Layshaft SV3 Forward 2nd Forward...

Page 161: ... check the wire harness for proper connections 9 If the solenoids are being energized correctly and the problem persists the problem may be in the transmission itself or a stuck spool in the solenoid If the problem seems to be intermittent e g transmission dropping to neutral select a gear and place a small washer on the ends of the energized solenoids The washers will be held in place by the magn...

Page 162: ...1 NC 22 NC 23 12V 24 12V 25 GRN Pison Factory Use Only 26 RX Pison Factory Use Only 27 TX Pison Factory Use Only 28 CTS Pison Factory Use Only 29 NC 30 NC 31 NC 32 NC 33 NC 34 NC 35 NC 36 NC 1 ECU operation The application of the parking brake de energizes all solenoids except when in 4th gear to enable stall testing 2 ECU Operation Pressing the kickdown button places the transmission in the next ...

Page 163: ...the instrument panel wire harness connector 5 Turn the ignition switch to the ON position Do not set the parking brake as this dumps the transmission to a neutral state 6 Test the voltages on the pins in the harness connector DO NOT check the ECU pins using a test lamp or voltmeter Refer to Table 7 2 for pin identification 7 If the lamp illuminates or the voltmeter shows full battery charge where ...

Page 164: ...amount to problem free operation It has been noticed that water entry into the shift control assembly can occur if the control is damaged replace the control This is particularly important on open cab cranes It is possible that the water can short internal switches providing false signals to the ECU If water is trapped in the control it can corrode internal switch contacts making them stick on or ...

Page 165: ...ne pressure test point Make sure that both sides of all four wheels are chocked Apply the foot brake and the parking brake Start the engine and run at 1000 rpm Engage 1st gear forward Record the pressure reading Repeat the test for all rear ratios in forward drive and record the pressure readings as shown below Table 7 3 Solenoid Descriptions Item Solenoid Description SV1 Reverse Low SV2 Reverse H...

Page 166: ...ly 1st and 3rd gear selection shown normal operating pressures So it can be assumed that the forward high clutch is leaking We can now confirm the forward reverse clutch is leaking by completing an Individual Clutch Leakage Test NOTE Repeat the above procedure using reverse ratios if necessary Individual Clutch Leakage Test In the following procedures the forward high clutch is tested therefore in...

Page 167: ...ressure D Mainshaft clutch pressure E Layshaft clutch pressure F Pump flow remove filter and fit adapters G Reverse high ratio clutch pressure H Reverse low ratio clutch pressure J Lubrication Pressure K Cooler flow flowmeter in line from cooler to transmission L Forward high ratio clutch pressure M Forward low ratio clutch pressure N 5 wheel drive clutch pressure P Load valve TEST POINTS R e f e ...

Page 168: ...meter One must be installed to perform this test Before completing the following test remove the transmission dipstick If there is any sign of smoke emitting from the dipstick tube STOP THE TEST IMMEDIATELY and service the transmission 1 Ensure that the engine and transmission are at normal working temperatures Run the engine at maximum speed and check the No Load Speed High Idle Specs See Engine ...

Page 169: ...uge reading with engine running at 2000 rpm Stop the engine and remove the test gauge Converter Out Pressure Oil Cooler Flow Rate Stop the engine and connect a 0 20 bar 0 300 psi pressure gauge and flowmeter into the converter out line as shown at C and K respectively Figure 7 15 Run the engine at 1000 rpm with the transmission in neutral The pressure gauge indicates the converter out pressure and...

Page 170: ... reading which should rise to the converter relief valve setting specified on page 7 1 4 If the reading is higher than specified the converter relief valve is faulty A low reading indicates a leaking pump seal or faulty converter relief valve 5 Stop the engine and remove the test gauges and install hoses to original position Lubricating Pressure 1 Stop the engine and connect a suitable pressure ga...

Page 171: ...22 a1411 Mainshaft Air Line Adapter FIGURE 7 23 a1386 Seal Stake Nut Setting Tool Kit Torque Wrench Spacer Kit Includes spacers listed below Setting Tool Kit Spacer 12 75 mm Spacer 13 80mm Spacer 13 85 mm Spacer 13 90 mm Spacer 13 95 mm Spacer 13 00 mm Spacer 13 05 mm Spacer 13 10 mm Spacer 13 15 mm Spacer 13 20 mm Spacer 13 25 mm Spacer 13 30 mm Spacer 13 35 mm Spacer 13 40 mm Spacer 13 45 mm Spa...

Page 172: ... Pillar 20 75 mm 6 Pillar 45 75 mm 7 Setting Body 54 mm 8 Setting Body 64 mm 9 Setting Tool 12 mm 10 Setting Tool 10 mm 11 Setting Wrench 0 74 lb ft 0 100 Nm 12 Pillar Input Shaft 13 Setting Body If these items are not in your kit they may be ordered separately but base plate 2 will have to be drilled to secure item 12 see A and B Dimensions in mm End Play Checking Kit Torque Converter Removal Ins...

Page 173: ...ashers 9 securing torque converter 5 to drive plate 7 and remove the drive plate and its reinforcement 8 7 Replace the complete torque converter The parts are not serviced separately Replace drive plate if there is distortion or damage NOTE It is recommended that the torque converter be replaced any time system contamination occurs It is not possible to completely clean the torque converter by flu...

Page 174: ...ive shaft and rotate it 180 on the torque converter and repeat step 3 4 Apply Loctite 243 to drive plate mounting bolts 6 and tighten to a torque of 19 Nm 14 lb ft 5 Clean and lubricate the splines of the transmission input shaft 6 Align the transmission input shaft splines with the splines of the torque converter impeller and assemble the transmission torque converter housing to engine flywheel h...

Page 175: ...TRANSMISSION AND TORQUE CONVERTER CD5515 2 YB5515 2 SERVICE MANUAL 7 28 Published 1 20 2017 Control 483 02 This Page Blank R e f e r e n c e O n l y ...

Page 176: ...bly 8 27 Inspection 8 28 Assembly 8 28 Installation 8 29 Lubrication Procedure 8 30 Wheel Tires 8 30 Tire Inflation 8 30 Wheel Stud Nuts 8 30 DESCRIPTION Front Axle The front axle Figure 8 1 is a rigid mounted drive axle attached to the frame of the crane by eight bolts washers and nuts The axle includes a 3 piece spiral bevel input two reduction drive hubs and inboard brakes Rear Axle The crane m...

Page 177: ...raking type 5 plate each half shaft Standard retraction type Input type 1480 half yoke Toe in 0 Caster angle 0 Camber angle 1 King pin inclination 0 Hub reduction 5 4 1 Overall ratio 13 7 1 Crownwheel and pinion ratio 2 538 1 Number of teeth Crownwheel 33 Pinion 13 Rear Drive Axle Type Spiral bevel input with epicyclic hub reduction Installation Pin mount Number of steering cylinders 2 Weight dry ...

Page 178: ...o 4 625 1 Number of teeth Crownwheel 37 Pinion 8 Rear Non Drive Axle Type Spiral bevel input with epicyclic hub reduction Installation Pin mount Number of steering cylinders 2 Weight dry with no steering cylinders and without wheels 424 kg 931 lb approximate Hub brakes 3 plate each hub standard retraction type Input type 1480 half yoke Oscillation Both Directions 1 1 2 Oscillation lockouts engaged...

Page 179: ...ers and Torque Values on page 1 12 4 Connect the brake line or hose to the axle 5 Connect the hydraulic hoses to the steering cylinder 6 Connect the hydraulic line to the parking brake 7 Connect the front drive shaft to the parking brake disc plate using eight bolts lockwashers and nuts 8 Bleed the air from both service and parking brake system See Section 9 9 Bleed the air from the steering circu...

Page 180: ...Cones Adapter Steer Drive Axle Pinion 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 ...

Page 181: ...when removing the old oil seal 4 Align the locating marks on the yoke and the splined shaft Install the coupling yoke and a new combined stake nut and washer 5 Using the drive coupling spanner Figure 8 10 tighten the nut to a torque of 250 Nm 184 lb ft 6 Measure the rolling axle torque Figure 8 9 The reading should be the 0 5 to 1 Nm 0 37 to 0 74 lb ft more than that recorded in Step 1 If necessar...

Page 182: ...ating surfaces might be evident This condition is normal do not attempt to repair If the hub swivel and annulus carrier are to be replaced they must be replaced as a pair not individually 9 Remove internal retaining ring 14 to separate the annulus ring 12 from the annulus carrier 13 10 Pull off bearing carrier 8 together with the outer wheel bearing cone 10 and cup 11 Remove combination seal 9 Rem...

Page 183: ...arrier 9 Combination Seal 10 Wheel Bearing Cone 11 Wheel Bearing Cup 12 Annulus Ring 13 Brake Carrier 14 Retaining Ring 15 Retainer Plate 16 Verbus Ripp Bolts 4 17 Thrust Pad 18 Planetary Gear Carrier 19 Planet Gear Assembly 3 20 Sun Gear 21 Drive Shaft 22 Snap Ring 3 23 O Ring 24 Capscrew 2 26 Trunnion Bolts 8 27 Trunnion 2 28 Shim 29 Seal 2 30 Bearing 2 31 Oil Seal 32 Retaining Ring 33 Bearing R...

Page 184: ...26 and then tighten to a torque of 56 Nm 42 lb ft Install top trunnion 27 with normal 0 25 mm 0 10 in shim 28 and leave top trunnion bolts 26 finger tight 8 Attach a spring balance Figure 8 9 to track rod swivel and turn the swivel Tighten the top trunnion bolts 26 to eliminate end float but without bearing pre load that is no increase in spring balance reading 9 Measure the gap at the top trunnio...

Page 185: ... 19 and 19A and record the reading d To get the rolling force subtract the seal drag rolling force Step 19 A from reading obtained at step 19C The result should be 1 4 to 15 3 kg 3 to 34 lb If the resulting force is outside these limits check that seal 19 is installed correctly and or replace bearings 6 and 11 NOTE A high rolling force reading may indicate that the oil seal was damaged during inst...

Page 186: ...tched case halves and gears Disassembly 1 Before disassembling the axle drain the oil from the axle into a suitable container 2 Remove the steering cylinders and track rod 3 Remove both axle arms a Support the axle arm and remove bolts A Figure 8 12 b Jack the axle arm off of the drive head using the drive head securing bolts Figure 8 13 Remove all traces of gasket material from the mating surface...

Page 187: ...gure 8 17 NOTE If both brake piston housings are removed put a mark on the crownwheel end of the drive head casing to ensure that the assembly is returned to its original position 9 Using a soft hammer hit the pinion end shaft until the pinion is free from its front bearing Remove the pinion Figure 8 18 CAUTION METAL SPLINTERS You can be injured by flying metal splinters when driving metal pins in...

Page 188: ...s Figure 8 20 Discard the shims Repeat for the outer bearing cup if required There are no shims for the outer bearing cup 12 Remove and discard the pinion collapsible spacer Figure 8 21 Pull off the bearing cone 13 To dismantle the differential assembly a Remove bolts D Figure 8 22 b Lift off the top half housing Figure 8 23 FIGURE 8 19 a0194 FIGURE 8 20 a0195 FIGURE 8 21 a0196 FIGURE 8 22 a0197 F...

Page 189: ...30 1 mm 1 18 in to gap A to give bearing depth 3 Find the mounting distance value B Figure 8 26 on the pinion and deviation C Figure 8 27 on the drive head housing Both units are in millimeters To convert millimeters to inches multiply millimeters by 0 03937 4 If dimension B is positive add it to the bearing depth If dimension B is negative subtract it from the bearing depth See example Crownwheel...

Page 190: ...ars should be checked by marking three of the pinion teeth with engineers marking compound and rotating the pinion The marking will then be transferred to the crown wheel teeth Correct teeth marking Figure 8 28 Pinion too deeply in mesh Figure 8 29 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 Pi...

Page 191: ... Nm 122 lb ft Assemble the differential gears and their spherical washers into the bottom half housing Figure 8 31 Install the differential bearing cones 2 Position the top half housing onto the differential aligning the match mark letters Apply Loctite 243 to the threads of bolts D Figure 8 32 Install the bolts and tighten to a torque of 56 Nm 42 lb ft Check the gears for free rotation 3 Install ...

Page 192: ...e nut until end float is almost zero then check the seal drag torque It should be between 0 40 to 1 0 Nm 3 5 to 8 9 lb in Continue to tighten the stake nut to achieve the correct rolling torque as described in Step 8 If the nut is overtightened the collapsible spacer must be replaced 8 Measure the rolling torque Figure 8 38 which should be 1 7 to 2 8 Nm 1 3 to 2 1 lb ft excluding seal drag When th...

Page 193: ... do not require cleaning or manually coating with sealant 11 Adjust differential side nuts B Figure 8 42 to give a bearing pre load of 1 36 to 2 5 Nm 1 0 to 1 84 lb ft Measure the pre load by taking another rolling torque reading and subtracting the torque value measured at Step 8 The difference is the bearing pre load 12 Measure the crownwheel backlash which should be 0 13 to 0 2 mm 0 005 to 0 00...

Page 194: ... axle special tools are required Unless you have the tools illustrated Figure 8 3 DO NOT service the axle Replacing the Pinion Oil Seal The procedure for replacing the pinion or seal on the rear drive axle is the same as the front drive axle Refer to page 8 6 for replacement procedures Axle Hub Repair Disassembly Figure 8 45 1 Disconnect the track rod and steering cylinders NOTE If the track rod i...

Page 195: ...friction plates is to the depth of the crosshatching Figure 8 44 Check all plates for flatness and damage Some scoring of the counter plates is normal Completely replace the brake pack if it is worn or damaged Do not replace individual plates NOTE Excessive wear of the brake and counterplates can indicate sticking brakes or possible residual pressure in the braking system See Section 9 Brakes 12 R...

Page 196: ... Seal 15 Brake Piston 16 Brake Carrier 17 Annulus Ring 18 Retaining Ring 19 Brake Seal 20 Retainer Plate 21 Verbus Ripp Bolts 4 22 Friction Plate 3 23 Counter Plate 4 24 Pressure Plate 25 Retaining Ring 26 Thrust Pad 27 Planet Gear Carrier 28 Planet Gear Assembly 3 29 Snap Ring 3 30 Sun Gear 31 Snap Ring 32 O ring 33 Bolt 2 34 Trunnion 2 35 Bolt 8 NOTE Items 39 40 and 41 are used on drive axles on...

Page 197: ...e magnetic drain plug Assembly NOTE The top and bottom trunnions are very similar bottom trunnion is not illustrated in Figure 8 45 the only difference being that shims 36 are installed to the top trunnion NOTE Steps 1 through 3 are for drive axles only 1 Tap the drive shaft inner bearing 41 into position in the axle casing 2 Install retaining ring 40 3 Install new oil seal 39 Pack grease between ...

Page 198: ...stalled Apply Loctite 243 to threads 22 Install the annulus assembly onto the splined hub Check that the relationship marks align Push the annulus assembly into the splined hub until the splines of the annulus assembly are flush with the end of the splined hub Fit brake seal 19 onto the hub swivel 23 Install retainer plate 20 making sure the breather hole and brake galleries align Secure using Ver...

Page 199: ... Disassembly Figure 8 49 NOTE The axle need not be removed to disassemble the drive head 1 Drain the oil from the axle center casing Remove the rear drive shaft from the axle 2 Remove both hub assemblies with drive shafts see page 8 7 3 Mark the installation position of the drive head carrier 2 Figure 8 49 4 Remove bolts 1 and remove drive head carrier 2 from the axle casing 5 Clean the drive head...

Page 200: ...Roller Bearing Cone 10 Differential Assembly 11 Retaining Bolts 8 12 Case Half 13 Case Half 14 Differential Side Gears 2 15 Thrust Washers 2 16 Planet Gears 4 17 Thrust Washers 4 18 Taper Roller Bearing Cone 19 Verbus Ripp Bolts 12 20 Crownwheel 21 Pinion Nut 22 Washer 23 Drive Yoke 24 Pinion 25 Pinion Oil Seal 26 Taper Roller Bearing Cone 27 Bearing Outer Race 28 Bearing Outer Race 29 Shims 30 Co...

Page 201: ...torque of 166 Nm 122 lb ft 8 Assemble the four planet gears 16 and thrust washers 17 onto the trunnion pins Install the planet gear assembly and two differential side gears 14 and thrust washers 15 into case half 13 9 Position top case half 12 onto bottom half assembly 13 aligning the match mark letters see Note on page 8 7 Apply Loctite 243 to the threads of bolts 11 then install them and tighten...

Page 202: ...move bolts lockwashers and mounting straps 2 from rear axle Disassembly Front Axle Drive Shaft 1 Put the flange yoke 5 Figure 8 50 in a vice Using pliers remove two snap rings from the bearing caps in the flange yoke 2 Apply force on the drive 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...

Page 203: ...h and compressed air Apply a small amount of SAE 140 oil into each bearing cap and rotate the bearing on the trunnion to check for wear If there is any indication of wear or damage to the needle bearings bearing cap or journal crosses replace the journal and bearings as an assembly Check for damage to the splines of the sleeve yoke Make sure the splines are clean and smooth Look for damage or dist...

Page 204: ...ide the sleeve yoke into the slip yoke 4 Make sure both ends of the drive shaft are in the same plane Tighten the dust cap assembly Installation Front Axle Drive Shaft 1 Fasten the flange yoke 5 Figure 8 50 to the parking brake disc on the front axle with eight bolts lockwashers and nuts NOTE The drive shaft must have both ends exactly on the same plane as shown in X Figure 8 52 The yokes must not...

Page 205: ...he slip joint apply grease to the fitting until the grease comes through the hole in the end off the shaft Put your finger over the hole Figure 8 53 and continue to apply grease until the grease shows at the seal on slip joint At each lubrication check the drive shaft for side movement As wear in the bearings increases the side movement will increase Movement must be to minimum to prevent vibratio...

Page 206: ...ake Repair 9 14 Lining Kit Replacement 9 14 Repair Kit Installation 9 15 Seal Kit Installation 9 17 Brake Modulating Valve Repair 9 18 Removal 9 18 Disassembly 9 18 Assembly 9 19 Installation 9 19 Troubleshooting 9 20 Service Brakes 9 20 TECHNICAL DATA Front Axle Brakes Type Oil immersed multi plate disc Actuation Hydraulic Location Inboard Axle center casing 2 brake sets Friction Plates 5 per set...

Page 207: ... 63 cu in Nitrogen Recharge Pressure 51 71 2 75 bar 750 40 psi Accumulator Charging Valve Nominal Accumulator Charge Rate 10 2 1 9 L min 2 7 0 5 gpm Nominal High Limit 137 90 3 45 bar 2000 50 psi Nominal Low Limit 113 76 3 45 bar 1650 50 psi Priority Flow Control Valve Priority Flow Set At 12 3 L min 3 25 gpm Control Pressure 7 58 bar 110 psi Relief Valve Setting 172 37 bar 2500 psi R e f e r e n ...

Page 208: ...or charging valve If oil is required for the steering operation the priority flow control valve shifts to furnish flow to the steering system See Steering System Section 10 The priority flow control valve also includes the relief valve used to protect the steering and brake systems Accumulator Charging Valve The accumulator charging valve supplies oil to the accumulator on demand This is accomplis...

Page 209: ... 2017 Control 483 02 FIGURE 9 1 Variable Displacement Piston Pump Hydraulic Tank Brake Steering Manifold Priority Flow Control Valve Brake Modulating Valve Foot Pedal Service Brakes Park Brake Secondary Brake Brake Light Switch R e f e r e n c e O n l y ...

Page 210: ...m brake port A 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 hydraulic reaction forces are balanced When actuation is released the valve returns to its non applied position Brake Light Switch The brake light switch illuminates the brake lights when the brake modulating valve builds system pressure t...

Page 211: ...pool in the valve to open the circuit to the parking brake The hydraulic fluid under pressure disengages the brake pads from the brake disc Even though the parking brake switch may be in the DISENGAGE position in the event of a loss of pressure in the accumulator below what it takes to apply the service brakes the parking brake will engage MAINTENANCE AND ADJUSTMENTS Service Brake Bleeding When ev...

Page 212: ...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 all wheels on both sides 2 Attach a tube to the bleed screw on the parking brake Figure 9 8 and place the other end in a suitable container 3 Open the bleed screw then disengage the parking brake 4 Observe the fluid exiting the hose When there is no air o...

Page 213: ...essure The following should be done with the engine running and the hydraulic oil at working temperature 1 Apply and release the brakes Check that the brakes release immediately 2 If the brakes do not release immediately place a container under the axle hub to collect any spilled oil Unscrew the bleed nipple on the axle to release any residual pressure NOTE The same effort should be needed to rota...

Page 214: ...the following test a Install an adapter fitted with a piece of clear tube approximately 120 mm 4 75 in long to the brake piston port B Figure 9 11 NOTE The tube must be kept vertical during the test Use tape to attach the tube to the side of machine b Fill the tube until it is approximately three quarters full with Mobil fluid 424 or equivalent hydraulic oil c Using a suitable pen mark the level l...

Page 215: ...on and which way round they are then remove the brake pack 4 Remove the retaining ring Figure 9 15 If the brake pack is to be reused note the position of the plates before removing them NOTE The planet carrier has an internal chamber at the end which faces away from the drive head 5 Wear limit of friction plates is to the depth of the circumferential grooves X Figure 9 16 Check all plates for flat...

Page 216: ...orce the piston out of the housing 8 Remove and discard seals F and G Figure 9 19 Inspect the housing for damage and scoring Nicks or cuts in the seals may be responsible for loss of brake fluid Assembly 1 Install new seals F and G Figure 9 20 Make sure they seat squarely in their grooves 2 Carefully press piston E Figure 9 21 all the way into its housing FIGURE 9 16 a0228 FIGURE 9 17 p0092 FIGURE...

Page 217: ...ecuring them with grease Push the pins fully into their location holes in the housing 5 Install one counterplate B Figure 9 24 into the housing then the brake pack then the other counterplate Ensure that the chamfered end of the brake carrier C faces away from the drive head Return reused counterplates to their original positions Push the brake pack fully home 6 Apply Loctite 275 to the mating fac...

Page 218: ... should be tightened to a torque of 400 Nm 295 lb ft 8 Fill the axle with recommended lubricant See Preventative Maintenance on page 5 1 9 Install the axle to the crane s frame Refer to Axles Drive Shafts Wheels and Tires on page 8 1 Rear Axle Brakes Refer to Axles Drive Shafts Wheels and Tires on page 8 1 for Axle Hub Assembly Service The service instructions include disassembly replacement and a...

Page 219: ...t 9 Rotate lining assembly 22 until screws 21 are aligned with the access holes in housing 26 Remove the two flat head screws 21 Pry lining 20 from piston 19 and remove the lining through the disc clearance slot 10 Install new lining 20 into piston 19 through the disc clearance slot Install new flat head screws 21 and tighten to a torque of 3 4 4 5 Nm 30 40 lb in 11 Insert new bushings 24 into new...

Page 220: ...and then remove the hydraulic hose 3 Cap the hydraulic hose to prevent contamination from entering the hydraulic system 4 Loosen lock nut 8 Figure 9 26 and back off adjusting bolt 7 FIGURE 9 26 a0779 1 Capscrew 4 2 Lockwasher 4 3 Cover 4 Seal 5 Belleville Springs 5 6 Washer 7 Adjusting Bolt 8 Lock Nut 9 Piston 10 Backup Ring 11 O Ring 12 Push Rod 13 O Ring 14 Backup Ring 15 Piston 16 O Ring 17 Bac...

Page 221: ...ponents NOT THE BRAKE LININGS in clean hydraulic oil Use the same type as used in the hydraulic system 18 Clean all parts EXCEPT LININGS and housing bore thoroughly with a suitable solvent and then coat them with clean hydraulic oil of the same type used in the hydraulic system Keep all parts free of contaminants dirt and debris NOTE Coat the surfaces indicated Figure 9 26 with a Lithium Base E P ...

Page 222: ...ome pressure may still be present in the hydraulic hose Let the pressure escape and then remove the hydraulic hose 3 Cap the hydraulic hose to prevent contamination from entering the hydraulic system 4 Loosen lock nut 8 Figure 9 26 and back off adjusting bolt 7 5 Remove the bolts and nuts used to fasten the brake mounting bracket to the crane Remove the parking brake assembly 6 Separate the mounti...

Page 223: ...ch screw to a torque of 29 8 36 6 Nm 22 27 lb ft 26 Assemble the brake assembly onto the mounting bracket 31 27 Install the parking brake assembly onto the frame of the crane 28 Attach the hydraulic hose 29 Adjust the lining clearance as described on page 9 7 30 Open the accumulator needle valve and then bleed air from the system as described on page 9 6 NOTE The needle valve must be in the open p...

Page 224: ...refully install new cup 14 and new seal 15 into bore of housing 12 Make sure they are installed in the proper order and direction Take care when installing not to scratch or mar the housing 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 ...

Page 225: ...t brake 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 chargi...

Page 226: ...r and brake circuits through the priority flow control valve Maximum steering system pressure is controlled by a relief valve in the priority flow control valve Steering Modes The crane can be operated in three steering modes These modes are selected using the steering selector switch located to the left of the operator on the instrument panel The three modes are Two wheel steering Four wheel stee...

Page 227: ... Control 483 02 FIGURE 10 1 a2095 Steering System Variable Displacement Piston Pump Hydraulic Tank Brake Steering Manifold Priority Flow Control Valve Load Sense Dump Valve Engine Transmission Steering Orbitrol Rear Front Steering Selector Manifold R e f e r e n c e O n l y ...

Page 228: ...GROVE Published 1 20 2017 Control 483 02 10 3 CD5515 2 YB5515 2 SERVICE MANUAL STEERING SYSTEM 10 FIGURE 10 2 a2098 Right Turn in 2 Wheel Steer Mode R e f e r e n c e O n l y ...

Page 229: ...inder extends and the right rod retracts turning the front wheels to the right Return oil from the front steering cylinders flows into port L and out of port T of the steering orbitrol and back to tank Crab Steering During crab steering all the wheels steer in the same direction This mode allows the operator to move the crane sideways for short distances This is especially helpful in tight areas o...

Page 230: ...GROVE Published 1 20 2017 Control 483 02 10 5 CD5515 2 YB5515 2 SERVICE MANUAL STEERING SYSTEM 10 FIGURE 10 3 a2097 Right Turn in 4 Wheel Steer Mode R e f e r e n c e O n l y ...

Page 231: ...STEERING SYSTEM CD5515 2 YB5515 2 SERVICE MANUAL 10 6 Published 1 20 2017 Control 483 02 FIGURE 10 4 a2099 Right Side Ways in Crab Steer Mode R e f e r e n c e O n l y ...

Page 232: ...ves The system is used to select one of the three steering modes When the selector switch in the cab is placed in either two wheel steer four wheel steer or crab steer that particular mode of steering is used to steer the crane The system however will not activate unless the front and rear wheels are in or pass over the forward position For example when the front wheels are not aligned forward in ...

Page 233: ...STEERING SYSTEM CD5515 2 YB5515 2 SERVICE MANUAL 10 8 Published 1 20 2017 Control 483 02 FIGURE 10 7 a2096 Steering Electrical Wiring Diagram R e f e r e n c e O n l y ...

Page 234: ...nch in front of the sensor A yellow light Figure 10 8 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 a...

Page 235: ... or broken 3 Steering actuator position of rotor to shaft slot incorrect 1 Clean and inspect unit 2 Check orbitrol Repair or replace 3 See page 10 13 Correct if required Crane 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 ...

Page 236: ...rbitrol Erratic steering 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...

Page 237: ... available supply from the pump is returned to tank Steering Left When making a left turn flow from the pump enters port P Figure 10 10 The gerotor takes this flow and meters it to port L left turn Return flow from the steering cylinders enters port R and is returned to tank through port T Steering Right When making a right turn flow from the pump enters port P Figure 10 10 The gerotor takes this ...

Page 238: ...OUT ports allows for recirculation of the oil to prevent cavitation when steering without power Orbitrol Repair Special Tools The following special tools are required to assemble the orbitrol Holding tool Guide Ring Assembly tool for O ring and Kin ring Roto Glyd Assembly tool for lip seal Assembly tool for cardan shaft Assembly tool for dust seal FIGURE 10 11 FIGURE 10 12 FIGURE 10 13 FIGURE 10 1...

Page 239: ... amount in each direction several times then release to get a balance of pressure in the steering circuit Slowly loosen the hydraulics lines at ports L and R to release any remaining pressure Disconnect the hydraulic lines from IN and OUT ports Put plugs and caps in the ports and hydraulic lines 5 Remove the four bolts which fasten the steering column and orbitrol to the mounting bracket Be sure t...

Page 240: ... 4 Threaded Bushing 5 O Ring Kin ring 6 Bearing Assembly 7 Kin ring 8 Cross Pin 9 Neutral Position Springs 10 Cardan Shaft 11 O ring 12 Distributor Plate 13 Gearwheel Set 14 End Cover 15 Washer 16 Special Screw 17 Screw 18 Name Plate 21 Relief Valve 22 Spring 23 Shock Valve 31 Ball Spring 33 Suction Valve Pins 34 Gearwheel Set 35 O ring 36 Kin ring 37 Bushing R e f e r e n c e O n l y ...

Page 241: ...r plate 12 6 Remove the threaded bushing 4 over the check valve 7 Remove the O ring 11 8 Shake out the check valve ball and suction valve pins and balls Figure 10 21 9 Take care to keep the cross pin in the sleeve and spool horizontal The pin can be seen through the open end of the spool Press the spool inwards and the sleeve ring bearing races and needle bearing will be pushed out of the housing ...

Page 242: ...the spool out of the sleeve 2 Figure 10 18 14 Press the neutral position springs 9 out of their slots in the spool 15 Remove dust seal and O ring Kin ring Roto Glyd Figure 10 27 16 Remove plugs from shock valves using a 6 mm Allen wrench Figure 10 27 17 Remove seal washers Figure 10 28 18 Unscrew the setting screws using a 6 mm Allen wrench Figure 10 29 19 Shake out the two springs and two valve b...

Page 243: ...t use a coarse grit emery cloth or try to file or grind any parts Replace 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 Place the two flat neutral position springs in the slot Place the curved springs between the flat ones and press them into place Center the springs in th...

Page 244: ...e 10 39 8 Grease O ring and kin ring roto Glyd with hydraulic oil and place them on the tool Figure 10 40 9 Hold the outer part of the assembly tool in the bottom of the steering unit housing and guide the inner part of the tool right to the bottom Figure 10 41 FIGURE 10 35 FIGURE 10 36 FIGURE 10 37 1 Outer bearing race 2 Needle bearing 3 Inner bearing race 4 Spool 5 Sleeve FIGURE 10 38 1 Washer f...

Page 245: ...Insert the assembly tool fully to the bottom Press and turn the lip seal into place in the housing Figure 10 44 14 With a light turning movement guide the spool and sleeve into the bore Fit the spool assembly holding the cross pin horizontal Figure 10 45 15 The spool assembly will push out the assembly tool guide The O ring and kin ring roto Glyd are now in position Figure 10 46 16 Turn the steeri...

Page 246: ...20 Lubricate an O ring 11 Figure 10 18 with petroleum jelly and install in groove 21 Place the distributor plate so that the channel holes match the holes in the housing 22 Guide the cardan shaft down into the bore so that the slot is parallel with the connection flange 23 Place the cardan shaft as shown so that it is held in position by the mounting fork 24 Grease the two O rings with petroleum j...

Page 247: ...6 Fit the spacer if any 27 Place the end cover in position 28 Fit the special screw with washer and place it in the hole shown 29 Fit the six screws with washers and insert them Cross tighten all the screws with a torque of 30 6 Nm 265 5 53 lb in 30 Install the piston and spring Figure 10 58 31 Screw in the setting screw with an 8 mm Allen wrench Make the pressure setting on a panel or the vehicle...

Page 248: ...em with a torque of 30 10 Nm 265 5 88 5 lb in using a 6 mm Allen wrench 37 Fit the dust seal ring in the housing using special tool and a plastic hammer Installation 1 Locate the steering orbitrol and steering column in position on the mounting bracket under the instrument panel Secure in place with four bolts and numerous flat washers 2 Connect the hydraulic lines to the steering orbitrol 3 Check...

Page 249: ...der 5 Remove the steering cylinder from the axle Disassembly 1 Remove the caps from the cylinder ports and drain remaining oil from the cylinder 2 Secure the cylinder If a vice is used clamp only on the base end of the cylinder DO NOT clamp across the cylinder tube 3 Loosen end cap 13 Figure 10 65 using a special spanner wrench See Special Tools above and remove the piston rod assembly 16 from the...

Page 250: ...are thoroughly cleaned using a wire brush to remove grease hydraulic oil and Loctite 2 Inspect cylinder rod for rust distortion pitting or damage to the chrome If there is damage to the cylinder rod replace it Do not try to straighten a bent cylinder rod 3 Inspect inside of the cylinder barrel for grooves distortion or other damage Use a light to illuminate the cylinder bore for careful inspection...

Page 251: ... of the wiper seal must be facing out 3 Apply Loctite Activator T to threads of the end cap and cylinder barrel Allow the activator to dry for 15 minutes before bringing in contact with Loctite NOTE Be sure that lubricants used during assembly do not come in contact with Loctite 4 Cover the threads on the cylinder rod to prevent lubricant from contacting the Loctite 5 Apply petroleum jelly to the ...

Page 252: ...932 to the first three threads of the end cap Slide the end cap into the cylinder barrel and engage the threads Tighten the end cap with the spanner wrench to a torque of 678 Nm 500 lb ft NOTE If hydraulic oil contacts uncured Loctite a weakening of the bond will result Cure times vary according to the ambient temperature and the type of activator used The curing time for Loctite 932 and Activator...

Page 253: ...STEERING SYSTEM CD5515 2 YB5515 2 SERVICE MANUAL 10 28 Published 1 20 2017 Control 483 02 This Page Blank R e f e r e n c e O n l y ...

Page 254: ...nstalled 4 Raise the boom until the pin in the rod end of the lift cylinder can be seen NOTE Use at least a 1 8 Metric Ton 2 ton overhead crane when lifting the boom assembly Be sure slings and or chains are capable of handling a 1 8 Metric Ton 2 ton load 5 Connect a hoist to the boom that will lift more than 1812 kg 4000 lb 6 Release the hydraulic pressure in the hoist and telescope circuits Disc...

Page 255: ...rol 483 02 4 Connect electrical wiring as necessary Refer to Electric System page 3 1 5 Install the wire rope and hook block 6 Start the engine and operate all boom functions in both directions to remove air from the hydraulic system Check for leaks R e f e r e n c e O n l y ...

Page 256: ...Grove Published 1 20 2017 Control 483 02 11 3 CD5515 2 YB5515 2 SERVICE MANUAL STRUCTURALS 11 FIGURE 11 1 Boom Assembly Section 1 R e f e r e n c e O n l y ...

Page 257: ...STRUCTURALS CD5515 2 YB5515 2 SERVICE MANUAL 11 4 Published 1 20 2017 Control 483 02 FIGURE 11 1 continued Boom Assembly Section 2 R e f e r e n c e O n l y ...

Page 258: ...Grove Published 1 20 2017 Control 483 02 11 5 CD5515 2 YB5515 2 SERVICE MANUAL STRUCTURALS 11 FIGURE 11 1 continued Boom Assembly Section 3 R e f e r e n c e O n l y ...

Page 259: ...STRUCTURALS CD5515 2 YB5515 2 SERVICE MANUAL 11 6 Published 1 20 2017 Control 483 02 FIGURE 11 1 continued Boom Assembly Section 4 R e f e r e n c e O n l y ...

Page 260: ...ened Washer 27 Flat Washer 28 Bearing 29 Pendulum 30 Locknut 31 Grease Fitting 32 Washer 33 Spacer 34 Capscrew 35 Capscrew 36 Hex Nut 37 Capscrew 38 Pin 39 Sheave Wheel 40 Capscrew 41 Wear Pad 42 Shim 43 Capscrew 44 Plate 45 Wear Pad 46 Anchor Plate 47 Capscrew 48 Cable Keeper 49 Not used 50 Wear Pad 51 Plate 52 Capscrew 53 Hardened Washer 54 Anchor Plate 55 Anchor Plate 56 Wear Pad 57 Spacer 58 W...

Page 261: ...7 Sheave Wheel 88 Sheave Pin 89 Jam Nut 90 Capscrew 91 Anchor 92 Anchor Plate 93 Capscrew 94 Capscrew 95 Lock Bar 96 Plate 97 Capscrew Item Description 98 Cable Protector 99 Plate 100 Capscrew 101 Spacer 102 Capscrew 103 Snap Ring 104 Shim 105 Guide 106 Short Cable Guide 107 Cable Protector 108 Shim 109 Not used 110 Anti Two Block Switch Assembly 111 Clamp 112 Washer 113 Cotter Pin 114 Retainer Pl...

Page 262: ...tems from boom section 2 a Remove the bolts and lockwashers securing the lower rear wear pads remove the wear pads b Remove the front top and bottom side wear pads plugs and set screws 19 Remove the top rear wear pads from boom section 3 20 Remove hardware securing sheave wheels to side of boom section 3 21 Raise up on boom section 4 assembly and remove the bolts and lockwashers securing the front...

Page 263: ...nd Nut 14 Screw 15 Retaining Ring 16 Rod Wiper 17 Rod Seal 18 Back up Ring 19 O ring 20 Wear Ring 21 Retaining Ring 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 34 Capscrew 35 90 Degree Elbow Fitting 36 Lock Nut 37 Holding Valve Assembly 38 Piston Seal 39 Piston Seal 40 Not used 41 Straigh...

Page 264: ...tom wear pads in boom section 3 Install the bolts and lockwashers securing the wear pads 7 Install the top rear wear pads on boom section 3 8 As necessary install the following items on boom section 2 a Install the lower rear wear pads and secure with the bolts and lockwashers b Install the front top and bottom side wear pads plugs and set screws Do not tighten the set screw at this time 9 Slide t...

Page 265: ...ades are Traction Steel TS Plow Steel PS Improved Plow Steel IPS Extra Improved Plow Steel EIPS and Extra Extra Improved Plow Steel EEIPS The wire rope used on this crane is an EIPS Grade One cannot determine the grade of wire rope by its feel or appearance To be sure you are using the proper rope always obtain the wire rope from your distributor Wire Rope Safety The following information is not a...

Page 266: ...maged by knots Wire rope with knots must never be used Environmental factors such as corrosive conditions and heat can damage a wire rope Lack of lubrication can significantly shorten the useful life of a wire rope Contact with electrical wires and resulting arcing will damage a wire rope Inspecting Wire Rope Inspect entire length of wire rope for any conditions listed in Figure 11 4 If any of the...

Page 267: ... wedge is fully engaged with the socket Install cable clamp on the loose end of the wire rope as shown in Figure 11 5 To properly seat the wedge lift a load equal to the rated capacity of the crane Wire Rope Inspection FIGURE 11 4 a1298 REDUCTION FROM NORMAL 9 16 14 3 MM DIAMETER OF MORE THAN 1 32 0 8 MM CAUTION To prevent personal injury from compressed air always wear safety glasses when using c...

Page 268: ...drum Use care to prevent twists or sharp bends 3 Operate the hoist slowly to move the wire rope directly from the reel to the hoist drum Keep the wire rope under tension and 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 ...

Page 269: ...the hoist drum 7 Tag and disconnect the hoist hydraulic lines Cap and plug all hydraulic openings 8 Attach a lifting device to the hoist and take up the slack 9 Remove the mounting bolts from the hoist 10 Remove the hoist from the crane with the lifting device Hydraulic Hoses Inspect the hydraulic hoses and replace as required Hoist Installation 1 Attach a lifting device to the hoist 2 Lift the ho...

Page 270: ...st cover from the center of the drum To install the DRI use the following procedure 1 Insert the DRI into the drum Rotate the DRI so that the DRI shaft engages the drive inside the drum 2 Push the DRI into the drum so that the notch is lined up with the breather refer to Figure 11 11 DRI Cable Retaining Screws FIGURE 11 9 DRI Sensor Dust Cover DRI Shaft FIGURE 11 10 Retaining Screws Breather FIGUR...

Page 271: ...w seconds 8 Replace the LLI programming screw NOTE Failure to replace the programming screw could effect the operation of the LLI Hoist Repair Disassembly The following steps describe how to disassemble the hoist Inspect and replace all worn parts 1 Stand the hoist on its end with the motor pointing up Place blocking under the side plate so the hoist is not sitting on the shaft Figure 11 14 NOTE S...

Page 272: ... the shaft 32 5 Lay the unit down with the rods 2 pointing up Support the side plate 29 with blocking Figure 11 14 so that the hoist is not setting on shaft 32 6 Set cable drum 5 onto shaft 32 and seat drum on bearing 28 Be careful not to damage seal 306 7 Install the output planet set 4 8 Install the output sun gear 16 into the output planet set 9 Install the thrust washer 6 into the output plane...

Page 273: ...g sure that the clutch is installed properly 12 Install a new seal into the brake housing If the brake housing is removed from the hoist temporarily install the input sun gear into the brake housing and slide the driver clutch assembly onto the sun gear spline 13 Install the stator plates 19 and friction discs 18 into the brake housing starting with a stator and alternating friction discs and stat...

Page 274: ... 77 49 72 55 73 52 45 45 9 305 11 20 40 77 35 75 45 35 70 30 303 24 310 302 10 308 309 19 17 14 15 18 38 9 39 15 17 13 307 28 32 2 21 34 14 63 62 50 5 8 33 3 306 6 36 4 6 16 43 306 28 304 26 12 105 101 108 102 106 2 1 103 108 106 107 104 207 205 201 207 204 203 206 202 69 42 301 301 35 44 30 31 7155 R e f e r e n c e O n l y ...

Page 275: ...ock 43 2 Support Rod 44 1 Motor Assy 45 4 Fitting Adapter 49 1 Fitting Tee 50 1 Plate Side 52 4 Lockwasher 1 2 ID 55 4 Capscrew 58 4 Counterbalance Valve 61 4 NCC Label 62 6 Capscrew 63 2 Screw Buttonhead 64 1 Cord Set 65 1 Fitting Tee 66 1 Fitting Straight Adapter 69 1 Fitting Reducer 70 1 Hose Assy 72 1 Fitting Tee Adapter 73 1 Manifold Block 74 1 Valve Cart Solenoid 75 1 Hose Assy 77 3 Hose Ass...

Page 276: ...d cartridge valves are not serviceable in the field Return them to an authorized distributor for service CAUTION Possible Equipment Damage If the pins are not lined up properly the thrust washers can be shattered during the pressing operation FIGURE 11 17 2 3 1 Metering Hole 7148 7147 TROUBLESHOOTING Problem Cause Solution Hoist does not hold load Excessive back pressure in the system Check the sy...

Page 277: ...ng A slotted hole in the mast plate allows access to the inner race and the grease fittings Mast Bearing The bearing is a ball thrust bearing The outer race rotates outside of the inner race on a row of steel balls Apply grease weekly or every 50 hours of operation whichever occurs first Use a Lithium based E P No 2 bearing grease or equivalent There are two grease fittings to grease the bearing a...

Page 278: ...e the bolt on each side of the broken bolt The proper torque will not be obtained without the hardened steel washers under the bolt heads on the outer mast bolt circle Inspection for Bearing Wear Because of conservative design parameters static loading and slow intermittent rotation there are very few mast bearings that ever see their full design use However the mast bearing does have moving inter...

Page 279: ...ring plate 3 Install the bolts 18 and flat washers 17 to fasten the mast bearing to the bearing plate 4 Figure 11 20 shows order of tightening the bolts Each bolt must first be tightened to a torque of 754 to 816 Nm 556 to 602 lb ft and then loosened slightly After which each bolt must again be torqued to 754 to 816 Nm 556 to 602 lb ft NOTE For ease of lubrication when turntable mast is removed ap...

Page 280: ...m 0 005 in feeler gauge check the backlash between the gear and pinion There should be 0 013 mm 0 005 in clearance between the swing gear tooth and the pinion tooth If there is any other clearance adjust the backlash Backlash Adjustment NOTE Be sure the swing gear and pinion are aligned at the high spot of the swing gear 1 Slightly loosen the four bolts securing the gearbox Figure 11 22 2 Use a 0 ...

Page 281: ...Lock Washer 14 Washer 15 Hydraulic Swivel 16 Bolt 17 Washer 18 Bolt 19 Swing Bearing 20 Bolt 21 Washer 22 Bolt 23 Lock Washer 24 Washer 25 Pinion Gear Cover 26 Bolt 27 Washer 28 Swing Motor 29 Gasket 30 Swing Gear Box 31 Nut 32 Washer 33 Bolt 34 Lock Washer 35 Washer 36 Stop Assembly 37 Bar 38 Eccentric Ring 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 ...

Page 282: ...her to prevent any shim from being lost 4 Remove shims 19 through 21 from the gear case Be careful not to damage or lose any of the shims 5 Remove O ring 18 and cover 22 6 Remove socket head capscrews 13 Remove end motor cap 12 7 If shims 9 though 11 are located between cover 12 and housing 25 remove the shims Be sure not to damage or lose any of the shims 8 Remove and discard O ring 7 and seal 8 ...

Page 283: ...l 4 Pipe Plug 2 5 Bearing Cup 2 6 Bearing Cone 2 7 O Ring 2 8 Seal 2 9 Shim 2 10 Shim 2 11 Shim 2 12 End Motor Cap 13 Socket Head Capscrew 14 Bearing Cup 2 15 Bearing Cone 2 16 Spacer 2 17 Worm Gear 18 O Ring 19 Shim 20 Shim Item Description 21 Shim 22 Cover 23 Capscrew 8 24 Grease Fitting 25 Housing 26 Worm 27 End Cap 28 Capscrew 4 29 Breather Item Description R e f e r e n c e O n l y ...

Page 284: ... were installed proper bearing pre load must be determined before final installation of the end cap 27 a Install end cap 27 without shims installed b Using a dial indicator measure the amount of axial movement of the worm Proper axial movement must be between 0 025 to 0 05 mm 0 001 to 0 002 in Determine the amount of shims required to acquire the proper axial movement Then install the shims betwee...

Page 285: ...ulic hoses from the vertical cylinder 13 Remove the hoses 4 Remove retaining ring 1 from either side of mounting pin 2 Hold the cylinder in position and drive out the mounting pin Assembly 1 Completely clean the outrigger beam and outrigger jack Use steam or a suitable solvent Also clean the slide contact surfaces of the main frame 2 Install outrigger jack 6 Figure 11 26 over the vertical cylinder...

Page 286: ...rigger Assembly Item Description 1 Retaining Ring 4 2 Mounting Pin 3 Mounting Pin 4 Retaining Ring 2 5 Mounting Pin 6 Jack Outrigger 7 Outrigger Beam 8 Cylinder Mounting Bracket 2 9 Hex Bolt 4 10 Flat Washer 4 11 Counterbalance Valve 12 Horizontal Cylinder 13 Vertical Cylinder 14 Lockwasher 8 R e f e r e n c e O n l y ...

Page 287: ...STRUCTURALS CD5515 2 YB5515 2 SERVICE MANUAL 11 34 Published 1 20 2017 Control 483 02 This Page Blank R e f e r e n c e O n l y ...

Page 288: ...Grove Published 1 20 2017 Control 483 02 12 1 CD5515 2 YB5515 2 SERVICE MANUAL SCHEMATICS WIRING DIAGRAMS 12 SECTION 12 SCHEMATICS WIRING DIAGRAMS This Page Blank R e f e r e n c e O n l y ...

Page 289: ...SCHEMATICS WIRING DIAGRAMS CD5515 2 YB5515 2 SERVICE MANUAL 12 2 Published 1 20 2017 Control 483 02 This Page Blank R e f e r e n c e O n l y ...

Page 290: ... 6 1 Engine RPM 6 1 Engine Types 6 1 Environmental Protection 2 4 Final Word 2 4 Front Drive Axle Repair 8 4 General Description 4 1 General Maintenance 1 6 General Specifications 1 3 General 3 1 General 6 1 Governor 6 1 Hoist Circuit 4 14 Hydraulic Pressure Testing 1 22 Hydraulic Swivel 4 9 Hydraulic System 4 8 Identification Plates 1 1 Instrument and Light Circuits 3 7 Introduction 2 1 Introduct...

Page 291: ...trol 10 12 Steering Proximity Switches 10 7 Swing Circuit 4 15 Technical Data 7 1 Technical Data 8 2 Technical Data 9 1 Telescope Circuit 4 13 Testing 7 18 Tests 9 8 Transmission Repair 7 24 Troubleshooting Guides 4 3 Troubleshooting 11 23 Troubleshooting 3 18 Troubleshooting 4 2 Troubleshooting 9 20 Under Deck Winch 4 40 Weld Studs Table 1 10 1 16 Wheel Tires 8 30 Wire Harnesses 3 8 Wire Rope 1 1...

Page 292: ...R e f e r e n c e O n l y ...

Page 293: ...R e f e r e n c e O n l y ...

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