1

SERVICE MANUAL
This Manual has been prepared for and is considered part of -

RT890E3 2
Crane Model Number

This Manual is divided into the following Sections:

3
SECTION 1 INTRODUCTION
SECTION 2 HYDRAULIC SYSTEM
SECTION 3 ELECTRIC SYSTEM
SECTION 4
SECTION 5
BOOM
HOIST AND COUNTERWEIGHT 4
SECTION 6 SWING SYSTEM
SECTION 7 POWER TRAIN
SECTION 8 UNDERCARRIAGE
SECTION 9 LUBRICATION

NOTICE 5
The crane serial number is the only method your Manitowoc Cranes
distributor or the factory has of providing you with correct parts and
service information.

The crane serial number is stamped on the top of the outrigger box. 6
Always furnish crane serial number when ordering parts or
communicating service problems with your Manitowoc Cranes
distributor or the factory.

7
! DANGER
An untrained operator subjects himself and others to death or
serious injury. Do not operate this crane unless:
8
• You are trained in the safe operation of this crane. Manitowoc is not
responsible for qualifying personnel.
• You read, understand, and follow the safety and operating
recommendations contained in the crane manufacturer’s manuals and
load charts, your employer’s work rules, and applicable government
regulations.
9
• You are sure that all safety signs, guards, and other safety features are
in place and in proper condition.
• The Operator’s Manual and Load Chart are in the holder provided on
crane.

© 2013 Manitowoc
Published 07-24-2013 Control # 069-12
 CALIFORNIA
PROPOSITION 65 WARNING
Diesel engine exhaust and some of its constituents are
known to the 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.

The original language of this publication is English.

 TABLE OF CONTENTS
RT890E3 SERVICE MANUAL
SECTION 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Introduction
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
List of Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Torque Converter/Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Swing Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Boom. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Swivel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Hydraulic Pumps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
General Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Pressing Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Locks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Wires and Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Shims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Gaskets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Hydraulic Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Fatigue of Welded Structures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Loctite®. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Fasteners and Torque Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Environmental Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Dynamic Shock Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Precautions and Recommendations During Inspection or Replacement . . . . . . . . 1-14
Wire Rope Inspection (Running Ropes and Pendant Cables) . . . . . . . . . . . . . . . . 1-15
Wire Rope Inspection (Boom Extension and Retraction Cables) . . . . . . . . . . . . . . 1-16
Wire Rope Inspection/Replacement (All Wire Rope) . . . . . . . . . . . . . . . . . . . . . . . 1-16
Seizing Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
Installing 35x7 Class Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
Procedures for Cutting and Preparing FLEX-X 35 . . . . . . . . . . . . . . . . . . . . . . . . . 1-18

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

Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Theory Of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Hydraulic Oil Recommendations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Draining and Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Removing Air from the Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Parts Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Directional Control Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Supply Pressure and Return Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

GROVE TOC-1
TABLE OF CONTENTS RT890E3

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Hydraulic Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Pressure Setting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Procedure A - For Checking/Setting The Main Control Valve For Hoists(s),
Boom Lift and Telescope(s) Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
Procedure B - For Setting the Outrigger Pressures. . . . . . . . . . . . . . . . . . . . . . . . 2-21
Procedure C - For Setting the Oil Cooler Motor Pressure . . . . . . . . . . . . . . . . . . . 2-21
Procedure D - For Checking/Setting the Load Sense Reduction Manifold . . . . . . 2-21
Procedure E - For Checking/Setting the Service Brake
Accumulator Charging Valve Charging Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Procedure F - For Checking Accumulator Pre-Charge Pressure . . . . . . . . . . . . . 2-22
Procedure G - For Pre-Charging the Accumulator . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Procedure H - For Checking/Setting the Front Steer Pressure . . . . . . . . . . . . . . . 2-22
Procedure I - For Checking/Setting the Swing Work Port Pressure . . . . . . . . . . . 2-22
Procedure J - For Checking/Setting the Swing Brake Release Pressure . . . . . . . 2-23
Procedure K - For Checking/Setting the Controller Supply Pressure . . . . . . . . . . 2-23
Procedure L - For Checking/Setting the Hose Reel Brake and Motor Supply . . . . 2-23
Procedure M - For Checking the Counterweight Removal Cylinder Extend
Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
Procedure N - For Checking the Counterweight Pin Cylinder Pressure . . . . . . . . 2-23
Procedure O - For Checking the Cab Tilt Cylinder Extend/Retract Pressure . . . . 2-23
Procedure P - For Checking the Luffing Jib Lower Pressure. . . . . . . . . . . . . . . . . 2-24
Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31
Directional Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35
Front Steer, Swing/Brake Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41
Steering Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45
Hydraulic Remote Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46
Swing Power Brake Valve With Treadle Pedal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-50
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-50
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-50
2 Speed Swing Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51
Cab Tilt Double Pilot Operated Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52
Tandem Brake Valve with Treadle Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53
Dual Accumulator Charge Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54
Hydraulic Accumulator Service Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56

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RT890E3 TABLE OF CONTENTS

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56
Holding Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57
Cross Axle Differential Lock Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58
Outrigger Control Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-59
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-59
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-59
Pilot Operated Check Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62
Axle Lockout, Rear Steer and Oil Cooler Fan Motor Control Manifold . . . . . . . . . . . . . 2-63
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-63
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-63
Check Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66
Range Shift/Parking Brake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-67
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-67
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-67
Load Sense Reduction Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-68
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-68
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-68
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-70
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-70
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-70
Surface Protection for Cylinder Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-70
Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-72
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-72
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-72
Dual Rod Telescope Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-75
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-75
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-75
Upper Telescope Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-79
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-79
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-79
Axle Oscillation Lockout Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-82
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-82
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-82
Axle Oscillation Lockout Cylinder (CE Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-85
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-85
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-85
Steer Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-88
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-88
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-88
Outrigger Extension Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-91
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-91
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-91
Outrigger Stabilizer Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-94
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-94
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-94
Cab Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-97
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-97
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-97
Counterweight Removal Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-100

GROVE TOC-3
TABLE OF CONTENTS RT890E3

Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-100
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-100
Counterweight Pin Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-103
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-103
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-103
Park Brake Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-106
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-106

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

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Batteries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Relay Panel and Fuse Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
General Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Troubleshooting Swivel-Caused Electrical Problems . . . . . . . . . . . . . . . . . . . . . . . 3-6
Connector Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Control Module Diagnostic Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Alternator/Charging System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Alternator Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Starter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Battery Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Relay Panel Component Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Instrument Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Windshield Wiper Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Windshield Washer Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Skylight Wiper Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Strobe Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Spotlight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Boom Mounted Floodlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Rear View Mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Air Conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

SECTION 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boom
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Lattice Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Optional Hydraulic Luffing Extension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Optional Lattice Extension Inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Boom Control Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Boom Extension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Boom Retraction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
RCL System with Boom Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Telescoping Control System Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Extension Sequence for the Main Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Extension Sequence for the Main Boom with Boom Extensions or Offset Jibs. . . . 4-4
Electronic Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

TOC-4
RT890E3 TABLE OF CONTENTS

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Boom Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Boom Nose Sheaves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Boom Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Functional Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Boom Alignment and Servicing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Cam Operated Check Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Guide Block Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Boom Extension and Retraction Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Telescope Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Hose Reel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Lift Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Auxiliary Boom Nose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
Counterweight with Auxiliary Hoist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
Counterweight without Auxiliary Hoist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
Installing the Bi-fold Manual Boom Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36
Checking the Transport Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38
Boom Extensions/Components Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38
Transportation on a Separate Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38
Boom Extension (Additional Equipment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39
Identification and Slinging Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39
Monthly Maintenance Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40

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

Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Warm-up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Routine Maintenance and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Functional Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Fluid Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Hoist to Boom Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Piston Motor and Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Idler Drum and Cable Follower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Hoist Drum Rotation Indicator System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

GROVE TOC-5
TABLE OF CONTENTS RT890E3

Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Counterweight Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Removal of Standard Counterweight and Auxiliary Hoist . . . . . . . . . . . . . . . . . . . 5-13
Installation of Standard Counterweight and Auxiliary Hoist Mounting Structure . . 5-13
Removal of Counterweight Without Auxiliary Hoist . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Installation of Counterweight Without Auxiliary Hoist . . . . . . . . . . . . . . . . . . . . . . 5-15
Third Wrap Indicator (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15

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

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Swing Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Swing Gearbox And Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Swing Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Swivels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Hydraulic Swivel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Two Port Water Swivel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Electrical Swivel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17

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

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Electronic Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Engine Control System Switches and Indicator Lights . . . . . . . . . . . . . . . . . . . . . . 7-6
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Air Intake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Water Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
Antifreeze/Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
Radiator Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
Drive Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
Transmission/torque Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20

TOC-6
RT890E3 TABLE OF CONTENTS

Towing or Pushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22

Servicing the Crane After Transmission/Torque Converter Overhaul. . . . . . . . . . . 7-24
Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25
Engine Block Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25

SECTION 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Undercarriage
Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Steering Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Rear Steering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
Hydraulic Pumps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
Front Steering Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
Rear Steer/ Axle Lockout/Fan Drive Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
Steer Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
Rear Axle Oscillation Lockout System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
Axle Oscillation Lockout Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
Axle Oscillation Lockout Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
Service Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14
Corrosion Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18
Parking Brake Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20
Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21
Park Brake Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21
Outriggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22
Outrigger Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22
Outrigger Beam. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-26
Extension Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-30
Stabilizer Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-30
Outrigger Control Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-32
Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-32
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-32
Pintle Hook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-32
Secondary Front Steer (CE Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-32

SECTION 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubrication
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

GROVE TOC-7
TABLE OF CONTENTS RT890E3

Lubrication Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

Arctic Conditions - Below -18°C (0°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Arctic Conditions Down To -40°F. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Surface Protection for Cylinder Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Wire Rope Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
CraneLUBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Steering and Suspension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
Drive Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
Drive Train (continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10
Turntable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12
Cab Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14
Outriggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16
Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-18
Boom (continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-20
Boom (continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-22
Hoist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-24
Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-26
Instructions for Accessing Lubrication Points on Boom. . . . . . . . . . . . . . . . . . . . . 9-28
Carwell® Rust Inhibitor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-29
Protecting Cranes From Rusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-29
Cleaning Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-29
Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-30
Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-30
Areas of Application. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-30

TOC-8
RT890E3 SERVICE MANUAL INTRODUCTION

SECTION 1
1
INTRODUCTION

SECTION CONTENTS
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
List of Specifications . . . . . . . . . . . . . . . . . . . . . . . 1-2 Batteries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Hydraulic Systems . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Fatigue of Welded Structures . . . . . . . . . . . . . . . . 1-9
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Loctite® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Torque Converter/Transmission . . . . . . . . . . . . . . 1-2 Fasteners and Torque Values . . . . . . . . . . . . . . . 1-10
Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Weld Studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Wire Rope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Environmental Conditions . . . . . . . . . . . . . . . . . . 1-14
Swing Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Dynamic Shock Loads . . . . . . . . . . . . . . . . . . . . . 1-14
Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
Swivel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Precautions and Recommendations During
Hydraulic Pumps. . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Inspection or Replacement . . . . . . . . . . . . . . . . . 1-15
Wire Rope Inspection (Running Ropes and
General Maintenance . . . . . . . . . . . . . . . . . . . . . . . 1-6
Pendant Cables) . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
Cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Wire Rope Inspection (Boom Extension and
Removal and Installation . . . . . . . . . . . . . . . . . . . 1-7 Retraction Cables) . . . . . . . . . . . . . . . . . . . . . . . . 1-17
Disassembly and Assembly . . . . . . . . . . . . . . . . . 1-8 Wire Rope Inspection/Replacement
Pressing Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 (All Wire Rope) . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
Locks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 Seizing Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . 1-18
Wires and Cables . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 Installing 35x7 Class Wire Rope . . . . . . . . . . . . . 1-19
Shims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 Procedures for Cutting and Preparing 35x7 Class
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19

DESCRIPTION Axle oscillation lockout is automatic when the superstructure

rotates from the travel position.
This Manual provides information for the maintenance of the
Model RT890E3 Series Manitowoc Crane. The superstructure is capable of 360 degree rotation in either
direction. All crane functions are controlled from the fully-
The lift capacities are listed on the Load Chart in the cab. enclosed cab mounted on the superstructure. The crane is
The crane incorporates an all welded parallel box construc- equipped with a five-section, full power, sequenced and syn-
tion steel frame, using planetary drive axles to provide four- chronized boom. Additional reach is obtained by utilizing an
wheel drive. Axle steering is accomplished utilizing hydraulic optional swingaway boom extension. Lifting is provided by a
steer cylinders. The engine is mounted at the rear of the main hoist and an optional auxiliary hoist.
crane carrier and provides motive power through a six speed NOTE: Throughout this manual, reference is made to left,
forward and reverse transmission. right, front, and rear when describing locations.
The carrier frame incorporates an integral fifth wheel, to When operating the crane, these reference loca-
which the rear axle is mounted, to provide axle oscillation. tions are to be considered as those viewed from
the operator’s seat with the superstructure facing
forward over the front of the carrier frame.

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INTRODUCTION RT890E3 SERVICE MANUAL

LIST OF SPECIFICATIONS Hi 2nd . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.08

Hi 3rd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.76
General Engine
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . .RT890E3
Rated Capacity . . . . . . . . . . See Load Chart in cab
Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 x 4 Cummins QSB6.7
Gross Weight . . . . . . . . . . . . . . . . See Axle Weight Displacement . . . . . . . . . . . . . .6.7 liters (409 cu in)
Distribution Table Firing Order. . . . . . . . . . . . . . . . . . . . . . 1-5-3-6-2-4
Lube Amount . . . . . . . . . . . . . . 17.5 liters (18.5 qt)
Dimensions Coolant System . . . . . . . . . . . . . . . 36 liters (38 qt)

NOTE: Dimensions listed are for a crane with all compo- Axles
nents fully retracted in the travel mode with 29.5 x Total Ratio. . . . . . . . . . . . . . . . . . . . . . . . . . 25.35:1
25-34 bias ply tires. Carrier Ratio . . . . . . . . . . . . . . . . . . . . . . . . . 6.43:1
Wheelbase . . . . . . . . . . . . . . . . . 5318 mm (209 in) Wheel End Ratio. . . . . . . . . . . . . . . . . . . . . . 5.20:1
Overall Crane Length . . . . . . . .14,427 mm (568 in)
Overall Crane Width . . . . . . . . . . 3340 mm (131 in) Brakes
Overall Crane Height . . . . . . . . . 3758 mm (147 in) Type . . . . . . . . .Hydraulic/Split system acting on all
Tail-Swing . . . . . . . . . . . . . . . . . . 4420 mm (174 in) four wheels
Outrigger Spread
Retracted . . . . . . . . . . . . . 3150 mm (10 ft 4 in)
Mid Extend . . . . . . . . . . . . .5283 mm(17 ft 4 in) Wheels and Tires
Fully Extended . . . . . . . . . . . . 7315 mm (24 ft) Lugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Torque. . . . . . . . . . . 461 to 488 Nm (340 - 359 ft lb)
Capacities Tire Size
Standard . . . . . . . . . . . 29.5 x 25, 34 ply rating
Fuel Tank . . . . . . . . . . . . . . . . . . 280 liters (74 gal) For roading and lifting pressures, refer to the Load
Coolant System. . . . . . . . . . . . . . . . . . . See Engine Chart Book in the cab.
Specifications
Engine Lubrication System . . . . . . . . . . See Engine
Specifications Swing Gearbox
Hydraulic Tank (Reservoir Capacity) Reduction Ratio . . . . . . . . . . . . . . . . . . . . . . 33.6:1
Total . . . . . . . . . . . . . . . . . . 959 liters (253 gal) Output Torque . . . . . . . . . . . . . . . . . . . . 72,222 in lb
at Full Level . . . . . . . . . . . . 864 liters (228 gal)
at Low Level. . . . . . . . . . . . 808 liters (213 gal) Boom
Expansion Space . . . . . . . . . . 95 liters (25 gal)
Hoists . . . . . . . . . . . . . . . . . . . . .14.7 liters (15.5qt) Length. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Swing Gearbox . . . . . . . . . . . . . . . 5.4 liters (5.7 qt) Retracted . . . . . . . . . . . . . . . . . . . 11.6 m (38 ft)
Axle Planetary Hubs . . . . . . . . . . 5.2 liters (11.0 pt) Extended . . . . . . . . . . . . . . . . . .43.3 m (142 ft)
Axle Differentials . . . . . . . . . . . . 24.6 liters (51.9 pt) Power . . . . . . . . . . . . . . . . . . 5 Section, Full Power
Transmission (includes Torque Converter) Elevation . . . . . . . . . . . . . . . . . . . -3 to +78 degrees
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 liters (30 qt) Extensions
Fixed* . . . . . . . . . . . . . . . . .10.1 meters (33 ft)
Torque Converter/Transmission Folding* . . . . . . 10.1 or 17 meters (33 or 56 ft)
*Extensions are offsettable at 0, 20, or 40
Stall Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.82:1 degrees.
Charge Pump Capacity . . . . . . . 106 l/min (28 gpm) Extension Insert . . . . . . . . . . . . . . . . . .4.8 m (16 ft)
@ 2000 rpm
Gear Ratios Swivel Assembly
Forward/Reverse
Lo 1st . . . . . . . . . . . . . . . . . . . . . . . . . . . .12.59 Electrical . . . . . . . . . . . . . . . . . . . . . . . 15 Slip Rings
Lo 2nd . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.06 Hydraulic. . . . . . . . . . . . . . . . . . . . . . . . . . . 12 ports
Lo 3rd. . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.22 Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ports
Hi 1st . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.33

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RT890E3 SERVICE MANUAL INTRODUCTION

Hydraulic Pumps Hoists

Drum Dimensions 1
Pump #1 Diameter . . . . . . . . . . . . . . . . . .381 mm (15 in)
Length (Standard) . . . . . . . . 467 mm (18.38 in)
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Piston Cable
Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 Diameter . . . . . . . . . . . . . . . . . . 19 mm (3/4 in)
Output - @ 2700 rpm w/no load Length-Main . . . . . . . . . . . . . . . .182 m (600 ft)
Section 1 . . . . . . . . . . . . . 373 l/min (98.7 gpm) Length-Aux. . . . . . . . . . . . . . . . .185 m (607 ft)
Max. Permissible Line Pull (6x36)
. . . . . . . . . . . . . . . . . . . . . . . . . 9,185 kg (20,250 lb)
Pump #2 Max. Single Line Speed . . . .156.7 m/min (514 fpm)
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Gear Hoist Motor Displacement
Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 Low . . . . . . . . 107 cm3 (6.53 in3) per revolution
Output - @ 2700 rpm w/no load High . . . . . . . . 61 cm3 (3,72 in3) per revolution
Section 1 . . . . . . . . . . . . . 147 l/min (38.9 gpm)

FIGURE 1-1

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INTRODUCTION RT890E3 SERVICE MANUAL

Table 1-1: AXLE WEIGHT DISTRIBUTION TABLE

CG From Rear Weight Front Axle Rear Axle

Description
Axle cm (in) kg (lb) kg (lb) kg (lb)
Basic Unit
Maximum Axle Loads Allowed 27215 (60000) 27215 (60000)
Maximum Tire Loads Allowed 27215 (60000) 27215 (60000)
Carrier 4 x 4; All Fluids 184.8 (72.78) 21369 (47111) 9369 (20655) 12000 (26456)
Superstructure w/cab plus w/main hoist plus
67.9 (26.74) 5721 (12612) 922 (2032) 4799 (10580)
600 ft cable
Removable Counterweight (Includes
-198.5 (-78.18) 9980 (22003) -4700 (-10363) 14681 (32366)
cylinders, aux. hoist and cable)
Boom Assembly; w/RCL, 2/5 Nose Sheaves,
547.8 (215.67) 12207 (26912) 15860 (34965) -3653 (-8053)
Pivot Pins
Lift Cylinder & Lower Shaft 432.8 (170.42) 1193 (2630) 1225 (2700) -32 (-70)
Complete Basic Machine
4 x 4 chassis; Cummins QSB6.7 engine w/
transmission; front and rear axles; 29.5 x 25 189.4 (74.58) 50470 (111268) 22675 (49989) 27796 (61279)
tires; main hoist
w/183 m (600 ft) of 3/4 in. cable; full fuel and
hydraulic oil; RCL; plus all the above.
Add To Basic Unit Weight
10.1 to 17.1 m (33 to 56 ft)
653.8 (257.42) 1142 (2517) 1770 (3903) -629 (-1386)
Bi-Fold Boom Extension
10.1 meter (33 ft) Fixed Boom Extension 740.2 (291.42) 796 (1754) 1397 (3079) -601 (-1325)
10.1 to 17.1 m (33 to 56 ft) Hydraulic Bi-Fold
666.5 (262.42) 1311 (2891) 2073 (4570) -762 (-1679)
Boom Extension
Components for hydraulic boom extension
583.0 (229.52) 148 (327) 205 (452) -57 (-125)
(installed on boom)
Boom Ext. Carrier Brackets (Bolt On) 488.6 (192.39) 114 (251) 132 (291) -18 (-40)
Auxiliary Boom Nose - Installed 1138.7 (448.32) 68 (150) 184 (405) -116 (-255)
72 mt (80 Ton), Stowed in tray 421.9 (166.14) 730 (1610) 731 (1611) -0.45 (-1)
82 mt (90 Ton), Stowed in tray 421.9 (166.14) 590 (1300) 590 (1301) -0.45 (-1)
9.0 mt (10 Ton), Headache Ball (Swivel)-
688.4 (271.06) 258 (568) 420 (927) -133 (-359)
Attached to O/R Box
Remove: Auxiliary Hoist Cable (607 ft) -200.6 (-79) -358 (-789) 170 (375) -434 (-1164)
Air Conditioning - Carrier and superstructure
0.38 (-0.15) 36 (80) 0 36 (80)
components
Driver 205 (80.71) 113 (250) 55 (122) 58 (128)
Rear Mounted Pintle Hook -212 (-83.46) 14 (30) -6.8 (-15) 20 (45)
16 ft (4.8 m) Boom Ext. Insert w/RCL (CG
461.6 (181.74) 439 (968) 481 (1060) -41.7 (-92)
relative to CL pins)
Drive controlled differential locks 210.8 (83.0) 14 (30) 6.8 (15) 6.8 (15)
Substitute: Removable counterweight
-211.3 (-83.18) -175 (-387) 88 (194) -263 (-581)
(includes cylinder, IPO counterweight)

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RT890E3 SERVICE MANUAL INTRODUCTION

1
1

7 2

6263-1

4 4
5
3

Item Description
1 Cab
2. Work Light
3. Outrigger Float
4. Outrigger Jack Cylinder
5. Steps
6. Valve Cover
7. Counterweight

FIGURE 1-2

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INTRODUCTION RT890E3 SERVICE MANUAL

1 2 3 6
4 7
5

9
13 12
8 11
10 10
6263-2

Item Description Item Description Item Description

1 Counterweight 6 Mast Assembly 11 Front Axle
2 Auxiliary Hoist 7 Boom Nose Sheaves 12 Hydraulic Tank
3 Main Hoist 8 Air Cleaner 13 Rear Axle
4 Boom Pivot 9 Swingaway
5 Lift Cylinder 10 Outrigger Jack Cylinder

FIGURE 1-2 continued

GENERAL MAINTENANCE 7. Recheck to ensure that nothing has been overlooked.

These general suggestions should be helpful in following the 8. Functionally test the failed part in its system.
instructions in this manual. In analyzing a system malfunc- NOTE: Your safety and that of others is always the number
tion, use a systematic procedure to locate and correct the one consideration when working around machines.
problem. Safety is a matter of thoroughly understanding the
1. Determine the problem. job to be done and the application of good common
sense. It is not just a matter of do’s and don’ts. Stay
2. List possible causes. clear of all moving parts.
3. Devise checks.
Cleanliness
4. Conduct checks in a logical order to determine the
cause. An important item in preserving the long life of the machine is
keeping dirt out of working parts. Enclosed compartments,
5. Consider the remaining service life of components seals, and filters have been provided to keep the supply of
against the cost of parts and labor necessary to replace air, fuel, and lubricants clean. It is important that these enclo-
them. sures be maintained.
6. Make the necessary repair.

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RT890E3 SERVICE MANUAL INTRODUCTION

1
3 6
2 4 5 7
1

6263-3

11 9
13 12 10
Item Description 8
1 Swingaway
2 Boom
3 Swingaway Extension Item Description
4 Hydraulic Tank 9 Air Conditioning Components
5 Main Hoist 10 Windshield Washer Fluid Container
6 Auxiliary Hoist 11 Cab
7 Counterweight 12 Work Light
8 Muffler 13 Spotlight

FIGURE 1-2 continued

Whenever hydraulic, fuel, lubricating oil lines, or air lines are When using hoisting equipment, follow the hoist manufactur-
disconnected, clean the adjacent area as well as the point of ers recommendations and use lifting devices that will allow
disconnect. As soon as the disconnection is made, cap, plug, you to achieve the proper balance of the assemblies being
or tape each line or opening to prevent entry of foreign mate- lifted and to ensure safe handling. Unless otherwise speci-
rial. The same recommendations for cleaning and covering fied, all removals requiring hoisting equipment should be
apply when access covers or inspection plates are removed. accomplished using an adjustable lifting attachment. All sup-
porting members (chains and cables) should be parallel to
Clean and inspect all parts. Be sure all passages and holes
each other and as near perpendicular as possible to the top
are open. Cover all parts to keep them clean. Be sure parts
of the object being lifted.
are clean when they are installed. Leave new parts in their
containers until ready for assembly.
Clean the rust preventive compound from all machined sur- CAUTION
faces of new parts before installing them. The capacity of an eyebolt diminishes as the angle
between the supporting members and the object
Removal and Installation becomes less than 90. Eyebolts and brackets should
When performing maintenance, do not attempt to manually never be bent and should only have stress in tension.
lift heavy parts when hoisting equipment should be used.
Never locate or leave heavy parts in an unstable position. Some removals require the use of lifting fixtures to obtain
When raising a portion of a crane or a complete crane, proper balance. The weights of some components are given
ensure the crane is blocked securely and the weight is sup- in their respective sections of the manual.
ported by blocks rather than by lifting equipment.

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INTRODUCTION RT890E3 SERVICE MANUAL

If a part resists removal, check to be certain all nuts and bolts Bearings
have been removed and that an adjacent part is not interfer-
ing. Antifriction Bearings
Disassembly and Assembly When an antifriction bearing is removed, cover it to keep out
dirt and abrasives. Wash bearings in non-flammable clean-
When assembling or disassembling a component or system, ing solution and allow them to drain dry. The bearing may be
complete each step in turn. Do not partially assemble one dried with compressed air BUT do not spin the bearing. Dis-
part and start assembling some other part. Make all adjust- card the bearings if the races and balls or rollers are pitted,
ments as recommended. Always check the job after it is scored, or burned. If the bearing is serviceable, coat it with oil
completed to see that nothing has been overlooked. and wrap it in clean waxed paper. Do not unwrap new bear-
Recheck the various adjustments by operating the machine ings until time of installation. The life of an antifriction bearing
before returning it to the job. will be shortened if not properly lubricated. Dirt in an antifric-
tion bearing can cause the bearing to lock resulting in the
Pressing Parts shaft turning in the inner race or the outer race turning within
When pressing one part into another, use an anti-seize com- the cage.
pound or a molybdenum disulfide base compound to lubri-
cate the mating surfaces. Double Row, Tapered Roller
Assemble tapered parts dry. Before assembling parts with Double row, tapered roller bearings are precision fit during
tapered splines, be sure the splines are clean, dry, and free manufacture and components are not interchangeable. The
from burrs. Position the parts together by hand to mesh the cups, cones, and spacers are usually etched with the same
splines before applying pressure. serial number and letter designator. If no letter designators
are found, wire the components together to assure correct
Parts which are fitted together with tapered splines are installation. Reusable bearing components should be
always very tight. If they are not tight, inspect the tapered installed in their original positions.
splines and discard the part if the splines are worn.
Heating Bearings
Locks
Bearings which require expansion for installation should be
Lockwashers, flat metal locks, or cotter pins are used to lock
heated in oil not to exceed 121 °C (250 °F). When more than
nuts and bolts.
one part is heated to aid in assembly, they must be allowed
Flat metal locks must be installed properly to be effective. to cool and then pressed together again. Parts often sepa-
Bend one end of the lock around the edge of the part. Bend rate as they cool and contract.
the other end against one flat surface of the nut or bolt head.
Installation
Always use new locking devices on components which have
moving parts. Lubricate new or used bearings before installation. Bearings
that are to be preloaded must have a film of oil over the entire
When installing lockwashers on housings made of alumi-
assembly to obtain accurate pre-loading. When installing a
num, use a flat washer between the lockwasher and the
bearing, spacer, or washer against a shoulder on a shaft, be
housing.
sure the chamfered side is toward the shoulder.
Wires and Cables When pressing bearings into a retainer or bore, uniformly
apply pressure to the outer race. If the bearing is pressed on
Batteries should always be disconnected prior to working on
the shaft, uniformly apply pressure on the inner race.
the electrical system.
When removing or disconnecting a group of wires or cables, Preload
tag each one to ensure proper identification during assembly.
Preload is an initial load placed on the bearing at the time of
Shims assembly. Whether a tapered roller bearing should have pre-
load could depend on any of several conditions: rigidity of the
When shims are removed, tie them together and identify housings and shaft, bearing spread, speed of operation, etc.
them as to location. Keep shims clean and flat until they are
To determine whether a bearing requires preload or end
reinstalled.
clearance, consult the disassembly and assembly instruc-
tions pertaining to that bearing.

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RT890E3 SERVICE MANUAL INTRODUCTION

Care should be exercised in applying preload. Misapplication Disassemble and assemble hydraulic components on a
of preload to bearings requiring end clearance can result in clean surface. 1
bearing failure.
Clean all metal parts in a nonflammable cleaning fluid. Then
lubricate all components to aid in assembly.
Sleeve Bearings
Do not install sleeve bearings with a hammer. Use a press Sealing Elements
and be sure to apply the pressure directly in line with the
Inspect all sealing elements (O-ring, gaskets, etc.) when dis-
bore. If it is necessary to drive on a bearing, use a bearing
assembling and assembling the hydraulic system compo-
driver or a bar with a smooth flat end. If a sleeve bearing has
nents. Installation of new elements is always recommended.
an oil hole, align it with the oil hole in the mating part.

Gaskets Hydraulic Lines

Be sure the holes in the gaskets correspond with the lubri- When installing metal tubes, tighten all bolts finger-tight.
cant passages in the mating parts. If it is necessary to make Then, in order, tighten the bolts at the rigid end, the adjust-
gaskets, select material of the proper type and thickness. Be able end, and the mounting brackets. After tubes are
sure to cut holes in the right places. Blank gaskets can cause mounted, install the hoses. Connect both ends of the hose
serious damage. with all bolts finger-tight. Position the hose so it does not rub
the machine or another hose and has a minimum of bending
When removed, always install new cylinder head and mani- and twisting. Tighten bolts in both couplings.
fold gaskets using recommended gasket compound on head
gaskets to allow uniform sealing. Due to manufacturing methods there is a natural curvature to
a hydraulic hose. The hose should be installed so any bend
Batteries is with this curvature.

Clean batteries by scrubbing them with a solution of baking Fatigue of Welded Structures
soda and water. Rinse with clear water. After cleaning, dry
thoroughly and coat terminals and connections with an anti Experience has shown that highly stressed welded struc-
corrosion compound or grease. tures when repeatedly subjected to varying stresses caused
by twisting, shock, bending, and intentional and/or uninten-
If the machine is to be stored or not used for an extended tional overloads, often become subject to weld cracking
period of time, the batteries should be removed. Store the which may be attributed to fatigue of the welded joint. This
batteries in a cool (not subfreezing), dry place, preferably on condition is not uncommon in construction equipment.
wooden shelves. Never store on concrete. A small charge
should be introduced periodically to keep the specific gravity Equipment should be periodically inspected for evidence of
rating at recommended level. weld fatigue. The frequency of these inspections should be
commensurate with the age of the equipment, the severity of
Hydraulic Systems the application, and the experience of the operators and
maintenance personnel.The following are known high stress
areas applicable to Manitowoc machines, and a visual
inspection of these areas should be made part of an owner’s
planned preventive maintenance program:
DANGER
Exercise extreme care around pressurized hydraulic 1. Power Telescope Boom - wear pad retaining structures,
systems. Do not work on a hydraulic system while it is in hydraulic cylinder attaching points, boom pivot shaft
operation or until all pressure is released. retaining structures.
2. Outrigger pads, beams, boxes and attachment struc-
Cleanliness tures.
Contaminants in a hydraulic system affect operation and will 3. Main frames - generally in the area of doubler plates and
result in serious damage to the system components. Dirty crossmembers; at the junction of front and rear frame
hydraulic systems are a major cause of component failures. members on truck cranes.
4. Turntable bearing connection (where bearing is welded
Keep the System Clean to the crane superstructure or chassis).
When removing components of a hydraulic system, cover all 5. Counterweight support structures.
openings on both the component and the crane.
6. Chassis axle and suspension mounting structures.
If evidence of foreign particles is found in the hydraulic sys-
tem, flush the system. 7. Hydraulic cylinder end connections.

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INTRODUCTION RT890E3 SERVICE MANUAL

The above is provided only as a guide, and your inspection 1. Apply a bead perpendicular to the thread, several
plan should not be limited to the areas listed. A thorough threads wide, in the approximate area of threaded
visual inspection of all weldments is good practice. engagement (Figure 1-3).
Anyone requiring more detailed inspection instructions and/ 2. In a blind hole application, a bead of several drops of
or repair procedures may request them by contacting the adhesive should be applied into the bottom of the hole to
local Manitowoc Cranes distributor. be hydraulically forced up during engagement.
3. After application and engagement of mated threads, fix-
Loctite® turing will occur within five (5) minutes if primed prior to
engagement. Fixturing may take up to 30 minutes on
unprimed parts.
4. Time required to achieve full strength is 24 hours. Maxi-
DANGER
mum ultimate strength is achieved using no primer with
Loctite type adhesives contain chemicals that may be this specific threadlocking adhesive.
harmful if misused. Read and follow the instructions on
the container. Fasteners and Torque Values
Always follow the directions on the Loctite container as not Use bolts of the correct length. A bolt which is too long may
all Loctite types are suitable for all applications.Various types bottom before the head is tight against the part it is to hold. If
of Loctite are specified throughout the Service Manual.The a bolt is too short, there may not be enough threads engaged
following types of Loctite brand adhesives are available from to hold the part securely. Threads can be damaged. Inspect
the Parts Department of the local Manitowoc Cranes distribu- them and replace fasteners, as necessary.
tor. Torque values should correspond to the type bolts, studs,
and nuts being used.
Application of Medium Strength Loctite
The torque tables are provided by Manitowoc for reference
NOTE: The fastener may be re-used; the adhesive may be when performing maintenance.
re-applied over cured adhesive residue.
Use of proper torque values is extremely important. Improper
The following procedure covers the proper application and torquing can seriously affect performance and reliability.
curing method for medium strength Loctite adhesive/sealant
(Loctite® #243) and primer (Locquic® Primer T7471). Identification of fastener grade is always necessary. When
marked as a high strength bolt (grade 5, 8, etc.), the
Primer Application mechanic must be aware that he/she is working with a highly
NOTE: It is not necessary to bathe the threads in primer. stressed component and the fastener should be torqued
accordingly.
1. Ensure the threaded surface, both male and female, is
clean and free of dirt and oil. Apply a light spray coating NOTE: Some special applications require variation from
of primer to both male and female parts to be joined to standard torque values. Reference should always
clean and accelerate the curing process. be made to component overhaul procedures for
recommendations.
2. Allow the part to dry prior to adhesive/sealant applica-
tion. Special attention should be given to the existence of
lubricant, plating, or other factors that might require variation
Adhesive/Sealant Application from standard torque values.
The use of lubricants on zinc-flake coated parts shall be
BEAD APPLICATION prohibited since this will change the required torque value.
When maximum recommended torque values have been
exceeded, the fastener should be replaced.
Previously installed bolts and nuts of Grade 8 or Class 10.9
and higher may not be reused.
4203

FIGURE 1-3 When referring to the applicable torque charts, use values as
close as possible to the torque values shown to allow for
wrench calibration tolerance.

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RT890E3 SERVICE MANUAL INTRODUCTION

Torque Wrenches • Torque wrenches must be those specified and forces

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

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

and Grade 2 HHCS HHCS HHCS
HHCS

Socket Head Socket Head Serrated

Capscrew Shoulder Flange Head
Screw

FIGURE 1-4

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INTRODUCTION RT890E3 SERVICE MANUAL

Table 1-2: UNC (Course) Thread: Torque Values for Zinc-Flake Coated and Untreated Fasteners

Bolt Diameter - Inches

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

NOTE: Studs shall be torqued using capscrew values when grade is known.

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

Bolt Diameter - Inches

Torque Values (Pounds-Foot, Maximum/Minimum)
SAE Grade 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1 1-1/8 1-1/4 1-1/2
5 8 15 28 44 66 95 132 229 364 543 785 944 1654
Zinc-Flake
8 11 22 39 61 94 134 186 323 514 766 1109 1530 2682
10 21 36 57 88 126 182 312 458 658 882 1251 2288
5
9 19 34 53 81 116 167 287 421 606 814 1155 2105
Untreated
14.5 26 53 85 125 177 250 425 672 1009 1500 2092 3640
8
13.5 24 49 79 115 163 230 393 620 931 1380 1925 3360

NOTE: Studs shall be torqued using capscrew values when grade is known.

Table 1-4: Metric Fasteners, Coarse Thread, Zinc-Flake Coating

Bolt Diameter - Metric

Torque Values (Nm)
M4 M5 M6 M8 M10 M12 M14 M16 M18 M20 M22 M24 M27 M30 M33 M36
Grade
0.157 0.197 0.236 0.315 0.394 0.472 0.551 0.630 0.709 0.787 0.866 0.945 1.06 1.18 1.18 1.18
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

Table 1-5: Metric Fasteners, Coarse Thread, Untreated

Bolt Diameter - Metric

Torque Values (Nm, Maximum/Minimum)
M4 M5 M6 M7 M8 M10 M12 M14 M16 M18 M20 M22 M24 M27 M30
Grade
0.157 0.197 0.236 0.276 0.315 0.394 0.472 0.551 0.630 0.709 0.787 0.866 0.945 1.06 1.18
3.1 6.5 11 19 27 53 93 148 230 319 447 608 774 1134 1538
8.8
2.8 5.9 10 17 25 49 85 136 212 294 413 562 714 1046 1420
4.5 9.2 16 26 38 75 130 212 322 455 629 856 1089 1591 2163
10.9
4.1 8.5 14 24 35 69 120 195 298 418 581 790 1005 1469 1997
5.4 11 19 31 45 89 156 248 387 532 756 1029 1306 1910 2595
12.9
4.9 10 17 28 42 83 144 228 357 490 698 949 1206 1763 2395

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RT890E3 SERVICE MANUAL INTRODUCTION

Table 1-6: Metric Fasteners, Fine Thread, Zinc-Flake Coating

Bolt Diameter - Metric

1
Torque Values (Nm)
M8x1 M10x1 M10x1.25 M12x1.5 M14x1.5 M16x1.5 M18x1.5 M20x1.5 M22x1.5 M24x2 M27x2 M30x2 M33x2 M36x3
Grade
0.157 0.197 0.236 0.315 0.394 0.472 0.551 0.630 0.709 0.787 0.866 0.945 1.06 1.18
8.8 23 46 44 75 123 185 270 374 496 635 922 1279 1707 2299
10.9 34 71 66 113 188 285 415 575 770 980 1425 2025 2500 3590
12.9 41 84 79 135 220 335 485 675 900 1145 1675 2375 2900 4200

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

Bolt Diameter - Metric

Torque Values (Nm, Maximum/Minimum)
M8x1 M10x1 M10x1.25 M12x1.5 M14x1.5 M16x1.5 M18x1.5 M20x1.5 M22x1.5 M24x2 M27x2 M30x2 M33x2 M36x3
Grade
0.157 0.197 0.236 0.315 0.394 0.472 0.551 0.630 0.709 0.787 0.866 0.945 1.06 1.18
29 57 57 100 160 248 345 483 657 836 1225 1661 — —
8.8
27 53 53 92 147 229 318 446 607 771 1130 1534 — —
41 81 81 1140 229 348 491 679 924 1176 1718 2336 — —
10.9
38 75 75 130 211 322 451 627 853 1085 1587 2157 — —
49 96 96 168 268 418 575 816 1111 1410 2063 2800 — —
12.9
45 90 90 156 246 386 529 754 1025 1302 1904 2590 — —

Table 1-8: UNC (Course) Thread: Torque Values for Table 1-9: Metric Course Thread: Torque Values for
Stainless Steel Fasteners with Oil Lubrication Stainless Steel Fasteners with Oil Lubrication

Torque Value Torque

Size Value
lb-in lb-ft Size
#5 (0.125) 6.9 —
Nm

#8 (0.164) 18 — M2.5 0.4

#10 (0.190) 21 — M3 0.9

1/4 68 — M4 1.5

5/16 120 10 M5 3.1

3/8 210 17.5 M6 5.3

7/16 340 28 M8 13.0

1/2 — 39 M10 27.0

5/8 — 74 M12 45.0

3/4 — 114 M14 71.1

M16 109
NOTE: Stainless steel fasteners tend to gall while being
M18 157
tightened. To reduce this risk, lubricate the threads
with oil or molybdenum disulfide and torque at low M20 220
speeds without interruptions. Do not use excessive
pressure. Impact wrenches are not recommended. NOTE: Stainless steel fasteners tend to gall while being
tightened. To reduce this risk, lubricate the threads
with oil or molybdenum disulfide and torque at low
speeds without interruptions. Do not use excessive
pressure. Impact wrenches are not recommended.

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INTRODUCTION RT890E3 SERVICE MANUAL

Weld Studs Torque wrenches are precision instruments and must be

handled with care. To ensure accuracy, calibrations must be
Unless otherwise specified the following grade 2 torque made on a scheduled basis. Whenever there is a possibility
values (+/- 10%) apply. that a torque wrench may have been either overstressed or
damaged, it should immediately be removed from service
Table 1-10: Weld Stud Torque Values until recalibrated. When using a torque wrench, any erratic or
jerking motion can result in the application of excessive or
improper torque. ALWAYS use a slow, even movement and
STOP when the predetermined value has been reached.
When using step wrenches, calculated wrench settings are
valid only when the following conditions are met:
T-2-4
1. Torque wrenches must be those specified and forces
must be applied at the handle grip. The use of handle
Torque Wrenches extensions will change applied torque to the bolt.
Flexible beam type wrenches, even though they might have 2. All handles must be parallel to the step wrench during
a pre-set feature, must be pulled at right angle and the force final tightening. Multiplier reaction bars may be mis-
must be applied at the center of the handle. Force value aligned no more than 30 degrees without causing seri-
readings must be made while the tool is in motion. Rigid ous error in torque.
handle type, with torque limiting devices that can be pre-set
3. Multiplier bar handles must be propped or supported
to required values, eliminate dial readings and provide more
within the outer 1/4 of the handle length, or serious
reliable, less variable readings.
under or over tightening will occur.
NOTE: If multipliers and/or special tools are used to reach
To convert pounds-foot of torque to newton meters (Nm),
hard to get at areas, ensure torque readings are
multiply the pounds-foot quantity by 1.3558.
accurate.
To convert pounds-inch of torque to newton meters (Nm),
multiply the pounds-inch quantity by 0.11298.

WIRE ROPE Environmental Conditions

General The life expectancy of wire rope may vary due to the degree
of environmental hostility and other conditions to which these
The following information is a compendium of information mechanical devices are subjected. Variation in temperature,
from various wire rope manufacturers and includes inspec- continuous excessive moisture levels, exposure to corrosive
tion, replacement, and maintenance guidelines for wire rope chemicals or vapors or subjecting the wire rope to abrasive
as established by ANSI/ASME B30.5, federal regulations, material may shorten normal wire rope life. Frequent/peri-
and Manitowoc. The inspection interval shall be determined odic inspections and maintenance of your wire rope is rec-
by a qualified person and shall be based on such factors as ommended for preventing premature wear and to insure
expected rope life as determined by experience on the par- long-term satisfactory performance.
ticular installation or similar installations, severity of environ-
ment, percentage of capacity lifts, frequency rates of Dynamic Shock Loads
operation, and exposure to shock loads. Periodic Inspec-
Subjecting wire rope to abnormal loads beyond the endur-
tions need not be at equal calendar intervals and should be
ance limit will shorten the wire ropes, life expectancy. Exam-
performed at shorter time intervals as the wire rope
ples of this type of loading are listed below.
approaches the end of its useful life. A periodic inspection
shall be performed at least once a year. The following pro- 1. High velocity movement e.g.; hoisting or swinging of a
vides inspection and maintenance procedures for wire ropes load followed by abrupt stops.
used on Manitowoc products (e.g. wire rope used as load
2. Suspending loads while traveling over irregular surfaces
lines [hoisting cables], boom extension and retraction
such as railroad tracks, potholes, and rough terrain.
cables, pendant cables, tow winch cables, and hook block tie
down cables). 3. Moving a load that is beyond the rated capacity of the lift-
ing mechanism, i.e.; overloading.

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RT890E3 SERVICE MANUAL INTRODUCTION

Lubrication bending and are more easily penetrated. There should be no

A wire rope cannot be lubricated sufficiently during manufac-

load on the rope while it is being lubricated. It should be 1
noted, the service life of wire rope will be directly proportional
ture to last it’s entire life. Therefore, new lubricant must be to the effectiveness of the method used and amount of lubri-
added throughout the life of a rope to replace factory lubri- cant reaching the working parts of the rope.
cant which is used or lost. It is important that lubricant
applied as part of a maintenance program shall be compati- Precautions and Recommendations During
ble with the original lubricant, and to this end, the rope manu- Inspection or Replacement
facturer should be consulted. Lubricant applied shall be of
the type which does not hinder visual inspection. Those sec- 1. Always lock out equipment power when removing or
tions of rope which are located over sheaves or otherwise installing wire rope assemblies.
hidden during inspection and maintenance procedures
2. Always use safety glasses for eye protection.
require special attention when lubricating rope. The object of
rope lubrication is to reduce internal friction and to prevent 3. Wear protective clothing, gloves, and safety shoes as
corrosion. appropriate.
During fabrication, ropes receive lubrication; the kind and 4. Use supports and clamps to prevent uncontrolled move-
amount depends on the rope’s size, type, and anticipated ment of wire rope, parts, and equipment.
use. This in-process treatment will provide the finished rope
5. When replacing fixed length cable assemblies (e.g. pen-
with ample protection for a reasonable time if it is stored
dants) having permanently attached end fittings use only
under proper conditions. But, when the rope is put into ser-
pre-assembled lengths of wire rope as supplied from
vice, the initial lubrication may be less than needed for the
Manitowoc. Do not build lengths from individual compo-
full useful life of the rope. Because of this possibility, periodic
nents.
applications of a suitable rope lubricant are necessary.
6. Replace an entire wire rope assembly. Do not attempt to
The following are important characteristics of a good wire
rework damaged wire rope or wire rope ends.
rope lubricant:
7. Never electroplate wire rope assemblies.
1. It should be free from acids and alkalis.
8. Do not weld any wire rope assembly or component
2. It should have sufficient adhesive strength to remain on
unless welding is recommended by the wire rope manu-
the ropes.
facturer. Welding spatter shall never be allowed to come
3. It should be of a viscosity capable of penetrating the in contact with the wire rope or wire rope ends. In addi-
interstices between wires and strands. tion, be sure that the wire rope is not an electrical path
during other welding operations.
4. It should not be soluble in the medium surrounding it
under the actual operating conditions (i.e. water). 9. Wire ropes are manufactured from special steels. If
heating a wire rope assembly is absolutely necessary for
5. It should have a high film strength.
removal, the entire wire rope assembly shall be dis-
6. It should resist oxidation. carded.
Before applying lubrication, accumulations of dirt or other 10. On systems equipped with two or more wire rope
abrasive material should be removed from the rope. Clean- assemblies operating as a matched set, they shall be
ing can be accomplished by using a stiff wire brush and sol- replaced as an entire set.
vent, compressed air, or live steam. Immediately after the
11. Do not paint or coat wire ropes with any substance
wire rope is cleaned, it should be lubricated. Many tech-
except approved lubricants.
niques may be used; these include bath, dripping, pouring,
swabbing, painting or pressure spray methods. Whenever 12. Measure the rope’s diameter across crowns (1) of the
possible, the lubricant should be applied at the top of a bend strands when determining if rope has become damaged
in the rope, because at that point the strands are spread by Figure 1-5.

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INTRODUCTION RT890E3 SERVICE MANUAL

Keeping Records
A signed and dated report of the wire rope’s condition at
each periodic inspection must be kept on file at all times. The
report must cover all inspection points listed in this section.
The information in the records can then be used to establish
data which can be used to determine when a wire rope
should be replaced.
It is recommended that the wire rope inspection program
include reports on the examination of wire rope removed
1 from service. This information can be used to establish a
relationship between visual inspection and the rope’s actual
internal condition at the time of removal from service.

FIGURE 1-5 Frequent Inspection

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

4 3. Broken or cut strands.

4. Number, distribution and type of broken wires.
5. Evidence of core failure.
5
A925
6. End fitting wear/abrasion.
3 Pay particular attention to areas of the rope where wear and
other damage is likely to occur:
FIGURE 1-6 7. Pick-up Points: Sections of wire rope that are
repeatedly stressed during each lift, such as those
Wire Rope Inspection (Running Ropes and sections in contact with sheaves.
Pendant Cables) 8. End Attachments: The point where a fitting is
Wire rope should be inspected frequently/daily and periodi- attached to the wire rope or the point where the wire
cally/yearly in accordance with the following information rope is attached to the drum.
excerpted from a National Consensus Standard as refer- 9. Abuse Points: The point where the wire rope is
enced by Federal Government Agencies. Recommended subjected to abnormal scuffing and scraping.
inspection intervals may vary from machine to machine and
may vary based on environmental conditions, frequency of Periodic Inspection
lifts, and exposure to shock loads. The inspection time inter-
vals may also be predetermined by state and local regulatory Wire rope should be inspected periodically/annually or at a
agencies. shorter time interval if necessitated by environmental or
other adverse conditions, and shall cover the entire length of
NOTE: Wire rope may be purchased through Manitowoc the wire rope. Only the outer surface of the wire rope need
Crane Care. be inspected, and no attempt should be made to open the
Any deterioration observed in the wire rope should be noted rope. Periodic inspection should include all items listed
in the equipment inspection log and an assessment concern- under frequent inspection plus the following:
ing wire rope replacement should be made by a qualified
person.

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RT890E3 SERVICE MANUAL INTRODUCTION

1. Inspect for reduction of rope diameter below nominal 6. Inspect for unusual cable sag/stretch and be sure cables
diameter. used in sets all have an equal tension applied. Repeated 1
need for adjustment of an individual cable is evidence of
2. Inspect for severely corroded or broken wires at end
cable stretch and indicates the need for additional and
connections.
more thorough inspection in order to determine and cor-
3. Inspect for severely corroded, cracked, bent, worn, or rect the cause.
improperly applied end connections.
Wire Rope Inspection/Replacement (All Wire
4. Inspect wire rope in areas subjected to rapid deteriora-
tion such as:
Rope)
• Sections in contact with saddles, equalizer sheaves, No precise rules can be given for determination of the exact
or other sheaves where wire rope travel is limited. time for replacement of wire rope since many variable factors
are involved. Determination regarding continued use or
• Sections of wire rope at or near terminal ends where replacement of wire rope depends largely upon the good
corroded or broken wires may protrude. judgement of an appointed and qualified person who evalu-
5. Inspect boom nose sheaves, hook block sheaves, boom ates the remaining strength in a used rope after allowance
extension/jib sheaves, auxiliary boom nose sheaves, for any deterioration disclosed by inspection.
and hoist drums for wear. Damaged sheaves or hoist Wire rope replacement should be determined by the follow-
drums can accelerate wear and cause rapid deteriora- ing information excerpted from a National Consensus Stan-
tion of the wire rope. dard as referenced by Federal Government Agencies and as
recommended by Manitowoc. All wire rope will eventually
Wire Rope Inspection (Boom Extension and deteriorate to a point where it is no longer usable. Wire rope
Retraction Cables) shall be taken out of service when any of the following condi-
tions exist:
Periodic Inspection
1. In running ropes, six randomly distributed broken wires
It is recommended that a periodic inspection of all boom in one lay or three broken wires in one strand in one lay.
extension and retraction cables be performed using the fol-
2. Wear of one-third the original diameter of outside individ-
lowing guidelines. This inspection shall cover the entire
ual wires. Kinking, crushing, bird caging, or any other
length of the extension and retraction cables. This inspection
damage resulting in distortion of the rope structure.
should be used to monitor progressive degradation and to
discover severe damages necessitating wire rope replace- 3. Evidence of any heat damage from any cause.
ment or equipment repair. Inspection criteria are as follows:
4. Reductions from nominal diameter of more than:
1. Inspect for reduction of rope diameter below nominal
• 1/64 inch for diameters up to and including 5/16
diameter.
inch.
2. Inspect for severely corroded or broken wires at end • 1/32 inch for diameters 3/8 and 1/2 inch inclusive.
connections.
• 3/64 inch for diameters 9/16 to 3/4 inch inclusive.
3. Inspect for severely corroded, cracked, bent, worn, or
improperly applied end connections. • 1/16 inch for diameters 7/8 to 1 1/8 inches inclusive.

4. Inspect wire rope in areas subjected to rapid deteriora- • 3/32 inch for diameters 1/14 to 1 1/2 inches inclu-
tion such as: sive.

• Sections in contact with saddles, equalizer sheaves, 5. In running rope, six randomly distributed broken wires in
or other sheaves where wire rope travel is limited. one lay or three broken wires in one strand in one lay.

• Sections of wire rope at or near terminal ends where 6. In standing ropes, more than two broken wires in one lay
corroded or broken wires may protrude. in sections beyond end connections or more than one
broken wire at an end connection.
• Sections of wire rope in contact with stationary sur-
faces where abrasion or chafing may take place as 7. In rotation resistant rope, two randomly distributed bro-
a result of equipment vibration. ken wires in six rope diameters or four randomly distrib-
uted broken wires in 30 rope diameters.
5. Inspect for damaged or wobbly boom extension and
retraction sheaves that may cause rapid deterioration of 8. Severe corrosion as evidenced by pitting.
the wire rope.
9. Manitowoc recommends that for cable extended booms,
a single damaged wire rope assembly shall require
replacement of the entire set of extension cables.

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INTRODUCTION RT890E3 SERVICE MANUAL

10. Manitowoc recommends for cable extended booms, that Method 2

boom extension cables be replaced every seven (7)
years.

Seizing Wire Rope

It is important to seize the ends of rotation resistant wire
ropes to prevent the displacement and unraveling of the indi-
vidual wires and strands at the ends. All preformed and non-
preformed styles of wire rope should be seized prior to cut-
ting. 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 1-7, place one
end in the groove between two strands of the wire rope. Turn
the long end of the annealed wire at right angles to the wire
and wrap it tightly over the portion in the groove.
The two ends of the annealed wire should be twisted
together tightly. Cut off the excess wire and pound the twist
flat against the wire rope.
FIGURE 1-8

Wind a length of soft annealed wire Figure 1-8 around the

wire rope at least seven times. The two ends should be
twisted together in the center of the seizing. Tighten the seiz-
ing by alternately prying and twisting. Cut off both ends of the
wire and pound the twist flat against the rope.
NOTE: Non-preformed wire rope (1) Figure 1-9 should
have three seizings (3) located on each side of the
cut (4) as compared to performed wire rope (2).

1 4 3
FIGURE 1-7

7204

FIGURE 1-9

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RT890E3 SERVICE MANUAL INTRODUCTION

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

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INTRODUCTION RT890E3 SERVICE MANUAL

NOTE: The outer strands must not be allowed to move

with respect to the inner strands. The fused end
must not exceed the diameter of the rope.
4. Once the cuts have been completed, the seizing bands
are to be left in place for shipment of the rope.
5. Attach a “Do not remove welded ends” tag on each reel
flange.

FIGURE 1-10

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RT890E3 SERVICE MANUAL HYDRAULIC SYSTEM

SECTION 2
HYDRAULIC SYSTEM

SECTION CONTENTS
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Pin Cylinder Pressure . . . . . . . . . . . . . . . . . . . . . 2-23 2
Theory Of Operation. . . . . . . . . . . . . . . . . . . . . . . . 2-2 Procedure O - For Checking the Cab Tilt Cylinder
Extend/Retract Pressure . . . . . . . . . . . . . . . . . . . 2-23
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Procedure P - For Checking the Luffing Jib Lower
Hydraulic Oil Recommendations. . . . . . . . . . . . . . 2-6 Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
Draining and Flushing . . . . . . . . . . . . . . . . . . . . . . 2-6
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31
Removing Air from the Hydraulic System . . . . . . . 2-7 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31
Parts Replacement . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Directional Control Valves . . . . . . . . . . . . . . . . . . 2-35
Directional Control Valves. . . . . . . . . . . . . . . . . . . 2-7
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35
Supply Pressure and Return Circuit . . . . . . . . . . . 2-9 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Front Steer, Swing/Brake Manifold . . . . . . . . . . . 2-41
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41
Oil Cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Steering Control Valve . . . . . . . . . . . . . . . . . . . . . 2-45
Hydraulic Pumps . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Hydraulic Remote Control Valve . . . . . . . . . . . . . 2-46
Pressure Setting Procedures . . . . . . . . . . . . . . . 2-19 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46
Procedure A - For Checking/Setting The Main Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46
Control Valve For Hoists(s), Boom Lift and
Telescope(s) Pressures . . . . . . . . . . . . . . . . . . . 2-20 Swing Power Brake Valve With Treadle Pedal . . 2-50
Procedure B - For Setting the Outrigger Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-50
Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-50
Procedure C - For Setting the Oil Cooler Motor 2 Speed Swing Valve. . . . . . . . . . . . . . . . . . . . . . . 2-51
Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51
Procedure D - For Checking/Setting the Load Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51
Sense Reduction Manifold . . . . . . . . . . . . . . . . . 2-21
Cab Tilt Double Pilot Operated Check Valve . . . 2-52
Procedure E - For Checking/Setting the Service Brake Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52
Accumulator Charging Valve Charging Limits . . 2-21
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52
Procedure F - For Checking Accumulator Pre-Charge
Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22 Tandem Brake Valve with Treadle Pedal. . . . . . . 2-53
Procedure G - For Pre-Charging the Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53
Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53
Procedure H - For Checking/Setting the Front Dual Accumulator Charge Valve . . . . . . . . . . . . . 2-54
Steer Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54
Procedure I - For Checking/Setting the Swing Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54
Work Port Pressure. . . . . . . . . . . . . . . . . . . . . . . 2-22
Hydraulic Accumulator Service Brake . . . . . . . . 2-56
Procedure J - For Checking/Setting the Swing
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56
Brake Release Pressure . . . . . . . . . . . . . . . . . . . 2-23
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56
Procedure K - For Checking/Setting the Controller
Supply Pressure . . . . . . . . . . . . . . . . . . . . . . . . . 2-23 Holding Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57
Procedure L - For Checking/Setting the Hose Reel Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57
Brake and Motor Supply . . . . . . . . . . . . . . . . . . . 2-23 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57
Procedure M - For Checking the Counterweight Cross Axle Differential Lock Valve . . . . . . . . . . . 2-58
Removal Cylinder Extend Pressure . . . . . . . . . . 2-23 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58
Procedure N - For Checking the Counterweight Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58

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HYDRAULIC SYSTEM RT890E3 SERVICE MANUAL

Outrigger Control Manifold . . . . . . . . . . . . . . . . . 2-59 Axle Oscillation Lockout Cylinder . . . . . . . . . . . . 2-83

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-59 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-83
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-59 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-83
Pilot Operated Check Valve . . . . . . . . . . . . . . . . . 2-62 Axle Oscillation Lockout Cylinder (CE Option). . 2-86
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-86
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-86
Axle Lockout, Rear Steer and Oil Cooler Fan Motor Telescope Cylinder Charge Valve Manifold
Control Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . 2-63 (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-89
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-63 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-89
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-63 Checking/Setting the Charge Valve Manifold. . . . 2-89
Check Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-89
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66 Steer Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-92
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-92
Range Shift/Parking Brake Valve. . . . . . . . . . . . . 2-67 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-92
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-67 Outrigger Extension Cylinder . . . . . . . . . . . . . . . . 2-95
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-67 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-95
Load Sense Reduction Manifold . . . . . . . . . . . . . 2-68 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-95
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-68 Outrigger Stabilizer Cylinder . . . . . . . . . . . . . . . . 2-98
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-68 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-98
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-70 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-98
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-70 Cab Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . 2-101
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-70 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-101
Surface Protection for Cylinder Rods . . . . . . . . . 2-70 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-101
Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-73 Counterweight Removal Cylinder. . . . . . . . . . . . 2-104
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-73 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-104
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-73 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-104
Dual Rod Telescope Cylinder . . . . . . . . . . . . . . . 2-76 Counterweight Pin Cylinder . . . . . . . . . . . . . . . . 2-107
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-76 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-107
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-76 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-107
Upper Telescope Cylinder . . . . . . . . . . . . . . . . . . 2-80 Park Brake Cylinder . . . . . . . . . . . . . . . . . . . . . . . 2-110
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-80 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-110
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-80

DESCRIPTION THEORY OF OPERATION

This section describes the hydraulic system, the Three different control systems are used in the hydraulic
components which make up the hydraulic system, and the system; load sense (LS), constant pressure unloaded
components dependent upon the hydraulic system for their (CPU), and open center (OC).
operation. This includes descriptions of the supply pressure
Hoist, lift, telescope, cab tilt, and counterweight removal are
and return hydraulic circuit, hydraulic pumps, all hydraulic
constant pressure unloaded (CPU) functions. They are
valves, and all hydraulic cylinders. Detailed descriptions and
supplied oil flow via a variable displacement supercharged
operation of individual hydraulic circuits are discussed within
piston pump. CPU functions have directional spools that
their individual sections as applicable. A complete hydraulic
meter the required flow and pressure to the function. The
system schematic showing all options is at the back of this
pump delivers only the required flow at the pumps
manual, Figure 2-1 and Figure 2-2 shows A.N.S.I. hydraulic
compensator setting.
symbol information for this section.
Outriggers, rear steer, service brakes, oil cooler motor,
telescope hose reel motor/brake controller supply and swing
brake release are load sense (LS) functions.They are

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RT890E3 SERVICE MANUAL HYDRAULIC SYSTEM

supplied oil flow by the same pump as the CPU functions. common to the pump by the shuttle valves. When using a LS
The LS functions are in parallel with the CPU valves. LS function, the highest signal PSI up to the pumps
signal shuttle valves send the highest load signal of all the compensator setting is sent to the variable displacement
functions that are activated. The function’s spools or orifices piston pump. When a CPU function is activated, the signal
meter the required flow to the function. The pump will deliver line being drained across the directional control valve spool
only the required flow up to the compensator setting. When a is blocked, causing the pump to rise in pressure to its
load sense function is operated at the same time as a compensated pressure setting.
constant pressure unloaded function, the pump stays at it’s
A load signal drain valve in the variable displacement pump 2
compensated setting.
prevents the pump from coming on stroke during engine
The swing function is the only open center (OC) function. start. It is activated by the ignition key switch during the
Swing is supplied with oil from a single section gear pump. starting mode. The ensures the engine does not start against
Front steer is also supplied with oil from this gear pump and a load in the event the accumulators are charging or the fan
is prioritized to take any required flow before swing. Front motor is activated.
steer acts like a load sense function because of the priority
An integrated circuit (manifold) limits the output pressure of
valve.
the variable displacement pump at low engine speeds. This
Both load sense and constant pressure unloaded functions circuit allows for multi-function operation at engine idle
utilize a signal control line that loops through all valves without stalling the engine by reducing the horsepower draw.

GROVE Published 07-24-2013, Control # 069-12 2-3

HYDRAULIC SYSTEM RT890E3 SERVICE MANUAL

FIGURE 2-1

2-4 Published 07-24-2013, Control # 069-12

RT890E3 SERVICE MANUAL HYDRAULIC SYSTEM

FIGURE 2-2

GROVE Published 07-24-2013, Control # 069-12 2-5

HYDRAULIC SYSTEM RT890E3 SERVICE MANUAL

MAINTENANCE 10. Disconnect the return lines from a pair of outrigger

stabilizer cylinders and activate the cylinders to their
Hydraulic Oil Recommendations. maximum down positions.

For the hydraulic oil specifications, refer to Section 9 - 11. Connect the return lines and raise the outrigger
LUBRICATION. stabilizer cylinders to the stowed position. Replenish the
reservoir hydraulic oil level as necessary.
Draining and Flushing 12. Repeat Steps 10 and 11 for the remaining two outrigger
If a component has been changed because of a failure that cylinders.
might allow metal or abrasive particles to enter the system, 13. Disconnect the return line from the telescope cylinder
all systems must be thoroughly checked, drained, and and fully extend the boom.
flushed.
14. Connect the return line and retract the boom. Replenish
1. Remove the reservoir drain plug. Allow about three the reservoir hydraulic oil level as necessary.
minutes after hydraulic oil stops flowing from the drain
port for the side walls to drain. 15. Disconnect the return lines from both front steer
cylinders and turn the front wheels to the extreme right.
2. Clean and install the reservoir plug and fill the reservoir
with a 50/50 mixture of fuel oil and clean hydraulic oil. 16. Connect the return lines and turn the front wheels to the
extreme left and then back to center. Replenish the
3. Cycle the crane through all functions several times. reservoir hydraulic oil level as necessary.
Then return the crane to its stowed position and turn the
front and rear wheels to the extreme left. Shut down the 17. Repeat Steps 15 and 16 for the rear steering cylinders.
engine. 18. Raise the crane on outriggers.
4. Remove the reservoir drain plug and drain the reservoir. 19. Disconnect the line from port A of the axle lockout valve.
Clean and install the drain plug and fill the reservoir with
clean hydraulic oil. 20. Using a jack under the rear wheel on one side of the
crane, jack up the wheel to maximum travel.
21. Connect the line to port A of the axle lockout valve and
CAUTION disconnect the line from Port B.
Hydraulic oil supply lines must be connected to the
cylinders when flushing the system. 22. Repeat step 19 using the other rear wheel.
23. Connect the line to port B of the axle lockout valve.
NOTE: Draining the various components will be aided by Energize the axle lockout valve. Replenish the reservoir
connecting a drain line in place of the disconnected hydraulic oil level as necessary.
return line.
24. Disconnect the return line from the main hoist motor and
5. Disconnect the return line from the lift cylinder and raise fully hoist up the hoist.
the boom to maximum elevation.
25. Connect the return line to the main hoist motor and fully
6. Connect the cylinder return line and lower the boom to hoist down the hoist, then hoist up again. Replenish the
its stowed position. Replenish the reservoir hydraulic oil reservoir hydraulic oil level as necessary.
level as required.
26. Repeat Steps 24 and 25 for the auxiliary hoist as
7. Disconnect the return line from an outrigger extension necessary.
cylinder and fully extend the outrigger.
27. Disconnect one of the lines from the swing motor and
8. Connect the outrigger return line and retract the drive the motor in the direction it will go.
outrigger. Replenish the reservoir hydraulic oil level as
necessary. 28. Connect the line to the swing motor, then drive the swing
motor in the opposite direction until the boom is centered
9. Repeat Steps 7 and 8 for the remaining outriggers. and forward. Replenish the reservoir hydraulic oil level
as necessary.

CAUTION
When draining the outrigger cylinders, always operate CAUTION
either both front or both rear cylinders together to prevent When hydraulic oils are changed or added, ensure that
twisting the crane. hydraulic oils of different manufacturers are of the same
specifications. However, discoloration may occur.

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RT890E3 SERVICE MANUAL HYDRAULIC SYSTEM

When hydraulic oils are changed, recheck the reservoir If the air is not readily removed, lower the boom to below
hydraulic oil level after brief system operation and add horizontal, extend the telescope cylinders as far as
hydraulic oil as required. Working reservoir capacity practicable, and allow the boom to remain in this position
(capacity to full mark) is 894 liters (236 U.S. gallons). Ensure overnight. This should allow entrapped air to find its way
the crane is level and in the travel mode of operation when to the holding valve so that telescoping the boom IN the
the hydraulic system is being filled. The system must be filled next morning should force the air back to the reservoir.
with all cylinders retracted. Fill the reservoir to the full mark Ensure the boom is first telescoped IN (not OUT) in the
on the reservoir sight gauge. After the reservoir is filled, morning. Telescoping OUT may cause air to be forced 2
operate all circuits and recheck the reservoir sight gauge. back into a cylinder.
Add hydraulic oil as required.

Removing Air from the Hydraulic System

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

Seal all normal openings in the hydraulic system and the In the event that air entrapment should persist, bleeding
reservoir. Using a positive means to control the pressure of air by loosening various clamp and screw type fittings
(like a regulator), pressurize the hydraulic system to may become necessary.
13.8 to 27.6 kPa (0.14 to 0.28 bar) (2 to 4 psi) and
inspect all joints and fittings for evidence of leaks. A If the above procedures fail to eliminate air entrapment,
soap solution applied to the fittings and joints may also contact your authorized Grove Distributor.
prove helpful in detecting minute leaks while the system
is pressurized. Remove the pressure, repair any leaks Parts Replacement
found, and reopen any openings (such as a vent) closed Parts found damaged or out of tolerance when maintenance
for inspection. Refill the reservoir after completing any is being performed should be replaced. Refer to the
repairs or service. Operate all hydraulic circuits several Manitowoc Crane Care Parts Catalog for proper replacement
times in both directions. parts.
This action should return any entrapped air to the
reservoir where it can be removed from the hydraulic oil Directional Control Valves
by the baffles. The control valves that control the crane functions are
installed on the right side on the outside of the superstructure
side plate, and between the left and right superstructure side
plates under the main hoist.
DANGER
Locate the machine on a firm supporting surface and Inspection
position the boom over the front on outriggers when Inspect the control valves for visible damage, binding spools,
extending the boom at low angles. and evidence of leakage. If excessive internal leakage is
suspected during operation with a spool in its center position,
To remove entrapped air from telescope cylinders, lower it is possible that the area between the spool and working
the boom to below horizontal and fully telescope the section bore of the valve body is worn beyond serviceable
boom in and out several times. limits. If this condition exists, the spool and body must be
replaced as an assembly.

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HYDRAULIC SYSTEM RT890E3 SERVICE MANUAL

Valve Leakage Visual Inspection of Hoses and Fittings

Dripping hydraulic oil indicates some type of external
leakage. The machine should be removed from service for
immediate repairs. External leaks sometimes develop at
CAUTION
fittings and seals. Spool seals are susceptible since they are Ensure that the hydraulic hose is depressurized before
subject to wear. Seals may be damaged by temperatures loosening the connections.
that are too high, or by dirt or paint accumulation on the
spool. Damaged or torn seals must be replaced. Visually inspect hoses and fittings once a month or every 250
hours for the following:
A component functioning at reduced efficiency may indicate
that the control valve for that component is leaking internally. • Leaks at hose fitting or in hose
If preliminary check-out reveals that adequate volume is • Damaged, cut, or abraded cover
being supplied to the affected valve bank, relief valves are
properly adjusted, and the component is not at fault, check • Exposed reinforcement
the valve for scored or worn parts. Scoring is a sign of the • Kinked, crushed, flattened, or twisted hose
number one problem in hydraulics - contamination (external
contamination by dust or internal contamination by debris • Hard, stiff, heat cracked, or charred hose
from deteriorating components or oxidized hydraulic oil). • Blistered, soft, degraded, or loose cover
Scored or severely worn valve components must be
replaced. • Cracked, damaged, or badly corroded fittings

Check valves in the control valves are designed to permit a • Fitting slippage on hose
flow of hydraulic oil in one direction only. If a piece of dirt or • Other signs of significant deterioration
rust has worked its way into the check valve and lodges
between the poppet and seat, it will keep the valve open and If any of the above conditions exist, evaluate hose
allow a return flow of hydraulic oil. The remedy is to clean the assemblies for correction or replacement. For replacement
valve, but it is also a good idea to follow through and ensure of hose assemblies, refer to your Manitowoc Crane Care
the hydraulic system filter is still serviceable. Parts Manual.

Binding Spools At the same service interval, visually inspect all other
hydraulic components and valves for the following:
Some of the most common causes for stiff spool movement
or jammed spool action are system overheating, excessive • Leaking ports
pressure, contaminated or deteriorated hydraulic oil, or • Leaking valve sections or manifolds and valves installed
warped mountings. When scorched, deteriorated hydraulic into cylinders or onto motors.
oil or contamination is the cause, flushing the system and
replenishing with clean hydraulic oil may solve the problem. • Damaged or missing hose clamps, guard, or shields.
If the spool bores are badly scored or galled, the valve must • Excessive dirt and debris around the hose assemblies.
be removed for servicing.
If any of these conditions exist, address them appropriately.
Warping occurs when mounting plates are not level or they
become distorted from machine damage. As mentioned All hydraulic hose assemblies are recommended to be
previously, the valve can be shimmed level. replaced after 8000 hours of service life. Working conditions,
ambient temperatures and high duty circuits can affect
Also, check the valve for rust. Rust or dirt collecting on the service life of hose assemblies and must be taken into
valves can prevent free movement of the spool, and keep it account when inspecting and replacing hoses. High duty
from the true center position. Excessive system pressure circuits can include, but are not limited to, outriggers,
can create both internal and external leaks in valves that are hoist(s), boom lift, swing, pump suction and discharge to
otherwise sound. Only qualified technicians using the correct directional valves and directional valve return to the
equipment should make pressure adjustments when reservoir.
pressure adjustments are needed.

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RT890E3 SERVICE MANUAL HYDRAULIC SYSTEM

Table 2-1

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

Hydraulic hose assemblies operating in a temperature Hydraulic oil flows through two tubes at the lower rear of the
climate zone “C” (Table 2-1) are recommended to be reservoir to the two hydraulic pumps. Almost all of the return
replaced after 8000 hours of service life. flow goes through the filter at the top of the reservoir. The
return line that goes directly into the reservoir (instead of
Hydraulic hose assemblies operating in climate zones “A”
through the filter) is from the No. 10 port (drain) of the 11-port
and “B” (Table 2-1) with high ambient temperatures, could
swivel.
see hose service life reduced by 40 to 50%, therefore, it is
recommended to replace these hoses after 4000 to 5000 A magnetized drain plug in the bottom of the reservoir
hours of service life. collects metal particles from the hydraulic oil if it becomes
contaminated.
Hydraulic hose assemblies operating in climate zones “D”
and “E” (Table 2-1), cold climates, should expect a degrade A sight gauge is located on the front of the reservoir to
of mechanical properties, long term exposure to these cold indicate hydraulic oil level.
temperatures will negatively impact service life. Therefore it
A filler neck and breather on the top of the reservoir are for
is recommended for these hoses to be inspected thoroughly
filling the reservoir and for venting it. The filler neck includes
as service life may be less than 8000 hours.
a strainer for catching contaminants and gaskets to prevent
leaking. The breather -- which screws onto the filler neck --
SUPPLY PRESSURE AND RETURN CIRCUIT allows air to enter or exhaust from the reservoir. It is most
important that the breather be kept clean to prevent damage
Description to the reservoir. A breather guard protects the breather and
The supply pressure and return circuit is made up of several filler neck.
circuits which route hydraulic oil from the hydraulic pumps to Two large round access covers on the top of the reservoir
the directional control valves for the individual operating provide access for cleaning. The covers are bolted to the top
circuits. The supply pressure and return circuit consists of of the reservoir and have a gasket to prevent leaking. The
the reservoir and integral filter, two hydraulic pumps, a access holes can also be used to fill the reservoir after it has
hydraulic oil cooler, and a 11-port hydraulic swivel. Refer to been completely drained.
HYDRAULIC PUMPS in this section for descriptions and
maintenance instructions for each hydraulic pump. Refer to The hydraulic oil filter (see Figure 2-3 and Figure 2-4) is
Section 6 - SWING for description and maintenance located in the reservoir. It bolts to the top of the reservoir, and
instructions for the 11-port hydraulic swivel. its bypass outlet fits into a tube welded in the reservoir. The
filter housing contains two replaceable filter elements.
The supply pressure and return circuit uses Ports 6 and 7 for Returning hydraulic oil flows through the filter head, through
pump supply and the dual Port 4 for return. Each operating the filter element, and into the reservoir.
circuit’s description and components begin with the circuit’s
directional control valve. An element condition indicator on the filter head indicates
when to change the filter element. When back pressure
Hydraulic Reservoir and Filter caused by a dirty filter element exceeds 172.3 kPa/1.72 bar
(25 psid), the filter head’s bypass feature functions to allow
The reservoir (see Figure 2-3), attached to the right side of
the hydraulic oil to bypass the filter element and flow into the
the carrier frame, has a capacity of 958.7 liters (253.3
reservoir through the bypass outlet instead. A bypass filter
gallons) total, 863.8 liters (228 gallons) to the full mark. The
screen prevents gross contamination from passing through
all-steel reservoir has an internally mounted full-flow filter
the filter even during bypass. (Filter changing instructions
and integral baffles that help cool the hydraulic oil and
are in Return Hydraulic Filter Assembly, page 2-12.)
prevent hydraulic oil foaming.

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HYDRAULIC SYSTEM RT890E3 SERVICE MANUAL

Pump Distribution pressure. The pump differential or standby pressure is 1896

kPa/19 bar (275 psi). Pump No. 1 supplies oil to the
Pump No. 1 and 2 are mounted off drive pads of the torque
outrigger, rear steer, axle lockout, boom lift, telescope, hoist,
converter.
hose reel and pilot functions.
Pump No. 1
Pump No. 2
Pump No. 1 is a variable displacement, pressure
Pump No. 2 is a single positive displacement gear pump @
compensated load sense piston pump @ 145 cm3/rev. (8.85
57 cm3/rev. (3.48 in3/rev.) delivering a theoretic flow of 144
in3/rev.) delivering a theoretic flow of 363 lpm (96 gpm) @ lpm (38 gpm). Pump No. 2 supplies oil to the front steer and
2500 engine rpm. It has an integral inlet impeller to insure swing circuits.
proper self-priming and soft start valve that unloads the load
sense signal so that the engine starts only against standby

Item Description 1
2 3
1 Return Filter 4
6 8
2 Filter Indicator
3 Sight Gauge 7
4 Return Line
5 Suction Line
6 Access Cover
7 Filler Neck and Breather
8 Step Assembly
9 Magnetic Plug
6
10 Capscrew
11 Flatwasher
12 Spring Lockwasher
13 Hex Nut

11
10
13
6644
11
12

FIGURE 2-3

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RT890E3 SERVICE MANUAL HYDRAULIC SYSTEM

Maintenance
Troubleshooting

Symptom Probable Cause Solution

1. No hydraulic oil a. Low hydraulic oil level. a. Fill reservoir.
flows in systems.
b. Reservoir-to-pump suction lines b. Clean, repair, or replace lines as 2
broken or restricted. Air entering at necessary. Check lines for security,
suction lines. Pump not priming. absence of cracks, and proper
a t ta c h m e n t . Ti g h t e n , r e pa i r, o r
replace parts as necessary.
c. Pump shaft sheared or disengaged. c. If drive shaft is damaged or sheared,
remove and repair or replace as
necessary
d. Internal contamination. d. Drain, flush with recommended oil
mixture, then drain and refill system
with recommended hydraulic oil.
2. Slow response. a. Low hydraulic oil level. a. Fill reservoir.
b. Hydraulic oil temperature too high b. If too low, warm up system. As
(watery thin oil) or too low (thick needed, troubleshoot cooler circuit. If
sluggish oil). too high, troubleshoot cooler circuit.
Likely suspects are in-line check
valve and related hydraulic circuits.
c. Faulty pump section(s). c. Repair or replace pump section(s) or
entire pump.
3. Pump noise a. Low hydraulic oil level. a. Fill reservoir.
accompanied by
b. Excessive engine speed. b. Regulate engine speed.
hydraulic oil
foaming in c. Air entering at suction lines. c. Check all lines for security and proper
reservoir. repair. Tighten, repair, or replace as
needed.
4. Excessive a. System relief valve set too high. a. Using adequate pressure gauge,
pressure buildup. adjust system relief valve as
necessary.
b. Restricted pump-to-control b. Clean, repair, or replace line as
valve supply line. necessary.
5. Specific hydraulic a. Leak in system. a. Repair leak.
system (lift, hoist,
b. Faulty hydraulic remote control valve. b. Adjust or replace valve.
telescope, swing)
not working. c. Faulty directional control valve. c. Replace valve.
d. Poorly adjusted control in circuit. d. Troubleshoot circuit with schematic.
Adjust hydraulic component per
schematic.
e. Faulty hydraulic cylinder, motor, or e. Replace faulty component.
valve.

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HYDRAULIC SYSTEM RT890E3 SERVICE MANUAL

Return Hydraulic Filter Assembly 7. Unscrew the “T” handle from the bypass assembly (with
mesh screen) and remove the bypass assembly.
Element Removal
8. Lift the element over the exposed rod assembly and
discard.
Element Installation
DANGER
1. Place a new element over the rod and seat on the
Ensure that all hydraulic systems are shut down and the
bottom.
pressure is relieved.
2. Install the bypass assembly to the top of the element.
1. Shut down all hydraulic systems.
3. Install the “T” handle and hand-tighten.
2. Remove the nuts and flatwashers securing the mounting
4. Firmly place the entire cartridge assembly back into the
plate over the return filter.
filter housing.
3. Wipe any dirt from the filter head and cap assembly.
5. Set the cover back on the housing, and install the clamp
4. Loosen the clamp handle counter clockwise and remove assembly. Hand tighten the handle.
the clamp assembly.
6. Install the mounting plate over the return filter and
5. Remove the filter cover by lifting upward. secure with the flatwashers and nuts.
6. Pull the entire cartridge assembly out by grabbing onto
the “T” handle.

Item Description
1 Head 9
10 8
2 Cover
16, 17 3
3 Bypass Mount 7
4 Drivescrew 11 2
2
5 Bypass Valve
1 5
6 Screen
6
7 Screen Retaining Ring 18
12
8 T-Handle Assembly
9 Clamp
19
10 Clamp Handle 15
11 Cover O-ring
12 Element
13 Cartridge Rod Assembly
14 Diffuser Tube Assembly
15 Gasket
16 Nameplate
17 Drivescrew
18 Pressure Gauge
14
19 Indicators 13
6384

FIGURE 2-4

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RT890E3 SERVICE MANUAL HYDRAULIC SYSTEM

OIL COOLER the filter in the reservoir. When several hydraulic functions
are being used at one time (i.e., hoisting, lifting, and
Description telescoping), more oil has to flow through this return line,
causing a pressure buildup. When this pressure reaches
An air cooled hydraulic oil cooler (see Figure 2-5) is the right 103.4 kPa/1.0 bar (15 psi), the normally closed check valve
rear portion of the hydraulic/transmission oil cooler. When in the return line (in parallel with the return line through the
the oil temperature reaches 48.8° C (120°F), the oil cooler hydraulic oil cooler) will open, letting some hydraulic oil
solenoid valve is de-energized, via a NC pressure switch, to
allow pressurized oil from pump No. 1 to the oil cooler motor
bypass the hydraulic oil cooler and flow directly into the 2
reservoir filter.
which drives the oil cooler fan.
When fewer functions are being used, the pressure in the
The oil cooler fan pulls cool air through the cooling fins on the system will decrease below 103.4 kPa/1.0 bar (15 psi) and
cooler. Normally, most hydraulic oil from components is the check valve will close again.
routed through the oil cooler by way of a return line and on to

7
4

1
3 5

Item Description 6629

1 Transmission Oil Cooler

2 External Drain Port
3 Fan
4 Hydraulic Oil Cooler
5 Inlet Port
6 Motor
7 Shroud
8 Outlet Port

FIGURE 2-5

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HYDRAULIC SYSTEM RT890E3 SERVICE MANUAL

HYDRAULIC PUMPS in3/rev) delivering a theoretic flow of 363 lpm (96 gpm) @
2500 engine RPM. IT has an integral inlet impeller to ensure
Description proper self-priming and soft start valve that unloads the load
sense signal so that the engine starts only against standby
Pumps No. 1 and No. 2 are mounted on drive pads of the
pressure. The pump differential or standby pressure is 1896
torque converter (see Figure 2-7).
kPa (19 bar) (275 psi). Pump No. 1 supplies oil to the
The purpose of these pumps is to convert mechanical outrigger, rear steer, axle lockout, boom lift, telescope, hoist,
energy into fluid energy for the operation of the crane’s hose reel and pilot functions. Pump No. 2 is a single section
hydraulic components. positive displacement gear pump @ 56.3 cm3/rev (3.44 in3/
Pump No.1 is a variable displacement, pressure rev) delivering a theoretic flow of 144 lpm (38 gpm). Pump
No. 2 supplies oil to the front steer and swing circuits.
compensated load sense piston pump @ 145 cm3/rev (8.85

Maintenance
Pump No. 1 Troubleshooting

Symptom Probable Cause Solution

1. Oil Leakage a. Hose fittings loose, worn or damaged a. Check and replace damaged fittings
or O-rings.
b. Oil seal rings deteriorated by excess b. Replace oil seals by disassembling
heat. pump. Contact Manitowoc Crane
Care for instructions

c. Bolt loose or its sealing area c. Loosen bolt, then torque, or replace
deteriorated by excess heat. bolt.
d. Shaft seal worn or damaged. d.
NOTE: Check fluid leaking from housing
weep hole to better determine which
seal has failed. If pump is leaking
hydraulic fluid, the inboard seal has
failed. If the pump is leaking
transmission fluid, the outboard seal
has failed.
- Remove seal carrier from pump
- Remove damaged seal
- If shaft is worn, install new seal
- Reinstall seal carrier
2. No flow from a. Pump not installed correctly. a. Check proper drive rotation. Make
pump (if pump sure pump shaft is turning (i.e. drive
does not prime in coupling is engaged). Check for
30 seconds, sources of suction leaks. Check that
STOP) inlet flange is tight. Check for pinched
O-rings.
b. Pump not getting oil. b. Make sure reservoir is at proper level.
3. Pump does not a. Flow has an unrestricted path a. Check for open circuit to reservoir.
build pressure.

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RT890E3 SERVICE MANUAL HYDRAULIC SYSTEM

Symptom Probable Cause Solution

4. Pump only builds a. Pump control settings too low a.
a few hundred PSI
- Check if compensator is backed out
20 to 30 bar (290
to 435 psi) - Check for load sense pressure signal
- Check that system relief valve is
vented 2
b. Control is malfunctioning b. Make sure orifices are not plugged
and that control spools/springs are
assembled correctly.
c. Internal leakage in cylinders, valves, c. Repair component
motors, or pumps.
5. Pump won’t a. Control is malfunctioning. a. Clean orifices in control of
compensate contamination. Confirm orifice and
plugs are properly assembled.

No. 1 Pump Removal No. 1 Pump Installation

1. Install new gasket material to the pump mounting flange
as follows.
CAUTION
Absolute cleanliness is essential when working on the a. Clean the drive pad and the pump with Loctite
hydraulic pumps. Always work in a clean area. The cleaning solvent 7070 or similar non chlorinated
presence of dirt and foreign materials in the system can solvent.
result in serious damage or inadequate operation. b. Apply a light coating of Loctite primer N7649 to both
surfaces. Allow primer to dry for one to two minutes.
1. Remove the pump cover to gain access to the pump. Primer must be dry. Mating of parts should occur
The pump is bolted to the engine’s torque converter. within five minutes.
2. Tag and disconnect the supply line from the pump. Cap c. Apply gasket material Loctite Master Gasket 518 to
or plug the line and port. one surface. Partial cure is obtained in four hours,
3. Tag and disconnect the pump distribution lines from the with full cure in 48 hours.
pump. Cap or plug the lines and ports. 2. Install pump on torque converter drive pad with bolts and
washers. Make sure the splines mesh properly. Torque
bolts to 203 Nm (150 foot-pounds).
CAUTION
When removing the pump, keep the pump as level as 3. Replace the charge pump and studs.
possible to avoid damaging the input spline. 4. Connect the distribution and supply lines as tagged
during removal.
NOTE: Charge pump and two studs must be removed for
wrench access to piston pump mounting bolts. No. 2 Pump Removal
4. Remove the bolts and washers attaching the pump to
the drive pad on the torque converter. Remove the
CAUTION
pump.
Absolute cleanliness is essential when working on the
5. Clean the gasket material from the drive pad on the hydraulic pumps. Always work in a clean area. The
torque converter. presence of dirt and foreign materials in the system can
result in serious damage or inadequate operation.
6. Cover the drive pad’s opening to prevent dirt from
entering.
1. Tag and disconnect the supply line from the pump. Cap
or plug the line and port.
2. Tag and disconnect the pump distribution line(s) from
the pump. Cap or plug the line(s) and port.

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HYDRAULIC SYSTEM RT890E3 SERVICE MANUAL

Pump No. 1 Start-up Procedure

CAUTION
When removing the pump, keep the pump as level as CAUTION
possible to avoid damaging the input spline. Failure to follow this procedure can cause the pump to fail

3. Remove the bolts and washers attaching the No. 2 pump 1. Ensure the reservoir is filled with the proper hydraulic
to the drive pad on the torque converter. Remove the fluid to the high level mark on the reservoir sight gauge.
pump.
2. Ensure no air is entering the pump inlet, and that the
4. Remove the gasket material from the drive pad on the pump suction or inlet fluid is not bleeding back to the
torque converter. reservoir when the engine is stopped, by making sure all
suction or inlet lines are air tight.
5. Cover the drive pad’s opening to prevent dirt from
entering. 3. Remove plug (see Figure 2-6), and add a cup of
hydraulic fluid to the pump case to help lubricate parts
No. 2 Pump Installation during start-up priming.
1. Install new gasket material to the pump mounting flange 4. Start the engine.
as follows.
a. Idle engine for two to three minutes with no
a. Clean the drive pad and the pump with Loctite functions actuated. Check for leaks and repair if
cleaning solvent 7070 or similar non chlorinated required. Lay hand on pump to check for excessive
solvent. heat build-up. If the pump section is too hot to keep
b. Apply a light coating of Loctite primer N7649 to both your hand on, stop immediately. If the pump makes
surfaces. Allow primer to dry for one to two minutes. excessive noise it is probably sucking air. Keep the
Primer must be dry. Mating of parts should occur pump from priming. If this occurs, stop engine, and
within five minutes. inspect all connections of the suction hose/tube for
a loose connection, or a missing or damaged o-ring.
c. Apply gasket material Loctite Master Gasket 518 to Re-start the engine and run until the pump takes
one surface. Partial cure is obtained in four hours, prime for a maximum of 30 seconds. If the pump
with full cure in 48 hours. does not prime in 30 seconds, stop the engine and
2. Install pump on torque converter drive pad with bolts and repeat until the pump primes.
washers. Make sure gear teeth mesh properly. Torque b. Increase the RPM to 1500-1800 for 1 to 2 minutes
bolts to 97.6 to 105.7 Nm (72 to 78 foot-pounds). with no functions actuated and make checks again
3. Connect the distribution and supply lines as tagged as outlined in step a. Incrementally increase throttle
during removal. to full RPM and then cycle the functions that the
pump supples to verify proper speed. Verify pump
flow.
CAUTION 5. Check pressure settings. Refer to PRESSURE
Do not feed hot hydraulic oil into a cold pump. This may SETTING PROCEDURES in this section.
cause the pump to seize.

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RT890E3 SERVICE MANUAL HYDRAULIC SYSTEM

Remove Plug

6444-1

6483
FIGURE 2-6

Pump No. 2 Start-up Procedure does not prime in 30 seconds, stop the engine and
repeat until the pump primes.
1. Ensure the reservoir is filled with the proper hydraulic
fluid to the high level mark on the reservoir sight gauge. b. Increase the RPM to 1500-1800 for 1 to 2 minutes
with no functions actuated and make checks again
2. Ensure no air is entering the pump inlet, and that the
as outlined in step a. Incrementally increase throttle
pump suction or inlet fluid is not bleeding back to the
to full RPM and then cycle the functions that the
reservoir when the engine is stopped, by making sure all
pump supples to verify proper speed. Verify pump
suction or inlet lines are air tight.
flow.
NOTE: The following step can be done before the pump is
5. Check pressure settings. Refer to PRESSURE
installed by removing the plug from “T1” port, and
SETTING PROCEDURES in this section.
checking to ensure “T2” port on the opposite side of
the pump is plugged. Fill housing full of hydraulic oil Testing After Rebuild or Replacement
through “T1” port. Re-install the plug and then
install the pump. 1. Operate the pump for at least two minutes at zero
pressure and moderate speed (not over 1500 rpm).
3. Remove adapter and hose from “T1” port, and check to
ensure “T2” port on the opposite side of the pump is
plugged. Fill housing full of hydraulic oil through “T1” CAUTION
port. Re-install the adapter and hose into the “T1” port. If the pump becomes hot to the touch, it is binding and
4. Start the engine. may seize. Stop engine, disassemble pump, and repair it
so it will not bind.
a. Idle engine for two to three minutes with no
functions actuated. Check for leaks and repair if 2. Touch pump to verify it has not become hot from binding.
required. Lay hand on pump to check for excessive Listen for abnormal noises indicating low hydraulic oil
heat build-up. If the pump section is too hot to keep level or internal pump problems. If the pump appears to
your hand on, stop immediately. If the pump makes be operating satisfactorily, increase the rpm by steps,
excessive noise it is probably sucking air. Keep the until reaching governed rpm. Operate pump about five
pump from priming. If this occurs, stop engine, and minutes while checking for proper operation and
inspect all connections of the suction hose/tube for leakage. Fix leaks; make repairs as needed.
a loose connection, or a missing or damaged o-ring.
Re-start the engine and run until the pump takes 3. Cycle the components the pump powers to verify the
prime for a maximum of 30 seconds. If the pump pump drives them all properly.

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HYDRAULIC SYSTEM RT890E3 SERVICE MANUAL

FRONT OF CRANE

2 3 4

Pump Location

Item Description
1 No. 1 Pump
2 No. 2 Pump
3 Transmission
4 Engine

6631

FIGURE 2-7

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RT890E3 SERVICE MANUAL HYDRAULIC SYSTEM

PRESSURE SETTING PROCEDURES NOTE: When checking the directional control valve relief
settings, unless otherwise specified, start with the
The following procedures should be used to properly check, engine at idle RPM and move the controller to its
adjust and set the hydraulic system pressures. fully stroked position. Then slowly accelerate the
The following equipment is required for checking the engine to the specified RPM. Read gauge and
hydraulic pressure settings. make adjustments to specified setting.

• Three dial gauge 0-34.5 MPa (0-5000 psi) When checking the outrigger relief valve setting,
start with the engine at idle RPM and activate and 2
• Pressure check diagnostic quick disconnect—Grove P/ hold the extend switch. Then slowly accelerate the
N 99 99 10 18 06 an d st raig ht ad ap te r f it ting P/ N engine to the specified RPM. Read gauge and
7447040401 make adjustment as required.
• ORFS reducers as required to attach work port hoses to
the gauge.

Table 2-2
Valve Pressure Setting Table

Pressure
Tolerance
Valve To Be Set Setting PSI Adjustment Location
PSI (MPa)
(MPa)
Hoist (s), Lift & Telescope Inner Mid 4000 (27.6) ± 50 (0.4) Pump No. 1: Piston Pump (see figure
Retract 2-9)
Telescope Inner Mid Extend 3060 (21.1) ± 50 (0.4) Main Directional Control Valve Port
Relief (see figure 2-10)
*Telescope Inner Mid Retract 4300 (29.7) ± 50 (0.4) Main Directional Control Valve Port
Relief (see figure 2-10) Thermal Relief
Telescope Center Mid Extend 2540 (17.6) ± 50 (0.4) Main Directional Control Valve Port
Two Stage Relief (see figure 2-11)
Telescope Outer Mid Extend 3140 (21.7) ± 50 (0.4) Main Directional Control Valve Port
Two Stage Relief (see figure 2-11)
Telescope Center/Outer Mid Retract 3461 (23.8) ± 50 (0.4) Main Valve Tele Center Mid Extend
Port (see figure 2-10)
Outrigger Extend & Retract 2000 (13.8) ± 50 (0.4) Outrigger Control Manifold
(see figure 2-12)
Hyd/Trans. Oil Cooler Motor 3000 (20.7) ± 50 (0.4) Front Steer, Swing & Accessory
Manifold (see figure 2-8)
Load Sense Reduction Manifold 3000 (20.7) ± 50 (0.4) Pump No. 1 (see figure 2-9 and 2-13)
Service Brake High Charge Limit 2900 (20.0) +50/-0 (+0.4/-0) Dual Accumulator Charge Valve (see
figure 2-14)
Service Brake Low Charge Limit 2400-2550 See Range Dual Accumulator Charge Valve (see
(16.6-17.6) figure 2-14)
Accumulator Pre-charge 1700 - 1750 See Range Accumulator (see figure 2-15)
(11.7 - 12.1)
Front Steer 2600 (18.0) ± 50 (0.4) Front Steer, Swing & Accessory
Manifold (see figure 2-8)
Swing "Left" Relief 2400 - 2550 See Range Front Steer, Swing & Accessory
(16.6 - 17.6) Manifold (see figure 2-8)
Swing "Right" Relief 2400 - 2550 See Range Front Steer, Swing & Accessory
(16.6 - 17.6) Manifold (see figure 2-8)

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HYDRAULIC SYSTEM RT890E3 SERVICE MANUAL

Pressure
Tolerance
Valve To Be Set Setting PSI Adjustment Location
PSI (MPa)
(MPa)
Hose Reel Motor Supply & Brake Front Steer, Swing & Accessory
1200 (8.3) ± 50 (0.4)
Release Manifold (see figure 2-8)
Swing Brake Supply 250- 300 Front Steer, Swing & Accessory
See Range
(1.7- 2.1) Manifold (see figure 2-8)
Controller Supply 350- 400 Front Steer, Swing & Accessory
See Range
(2.4- 2.8) Manifold (see figure 2-8)
*Counterweight Removal Extend 1000 (6.91) ± 100 (0.8) Counterweight Removal Valve
*Luffing Jib Extend 1450 (10.0) ± 100 (0.8) Luffing Jib & Cab Tilt Valve
*Cab Tilt Up/down 2500 (17.2) ± 100 (0.8) Luffing Jib & Cab Tilt Valve
*Counterweight Removal Pin 2500 (17.2) ± 100 (0.8) Counterweight Removal Valve
* Non-Adjustable

NOTE: Procedures A through P in the following text 7. Set the boom mode switches on the cab right hand
correlate with Figures 2-8 through 2-16. armrest to "Manual" and "IM". Start engine and throttle
up to full RPM. Attempt to telescope the inner mid OUT
Procedure A - For Checking/Setting The by feathering into the controller to full controller stroke.
Main Control Valve For Hoists(s), Boom Lift Adjust the work port relief valve "in" to increase or "out"
and Telescope(s) Pressures to decrease so that a gauge pressure reading of 3060
±50 PSI is achieved (see figure 2-10).
Set hoist(s) boom lift and telescope inner mid retract as
8. Stop engine and remove pressure gauge and re-connect
follows:
plumbing.
1. Install pressure check diagnostic quick disconnect with
gauge onto test nipple @ the Outlet Gauge Port of the Center Mid Extend
P1 piston pump (see figure 2-9). 9. Disconnect the extend hose (the larger of the two)
2. If the lift cylinder is not installed, plug the extend hose running from port B, center mid/outer mid telescope
(the larger of the two). If lift cylinder is installed, omit this section of the VG35 directional control valve to the hose
step. reel at the hose reel. Cap hose reel adapter.

3. Start engine and throttle up to full RPM. Feather into the 10. Install a pressure gauge into the disconnected hose
boom lift controller to full controller stroke (Up or down) running to the VG35 directional control valve.
and hold. Adjust the maximum pressure adjusting screw 11. Set the boom mode switches on the cab right hand
on the main piston pump "in" to increase or "out" to armrest to "Manual" and "CM". Start engine and throttle
decrease so that a gauge pressure reading of 4000 ±50 up to full RPM. Attempt to telescope the center mid OUT
PSI (see figure 2-9). by feathering into the controller to full controller stroke.
4. Stop engine and remove the diagnostic couplers from Adjust the two stage relief to 2540 ±50 PSI by loosening
the test nipples. the low pressure jam nut and turning "in" on the
adjustment nut to increase or "out" to decrease the
Set the telescope inner mid extend and outer mid extend and pressure (see figure 2-11). Stop Engine, with the hose
retract as follows: still capped, continue to Outer Mid Extend.
Inner Mid Extend Outer Mid Extend
5. If the boom is installed, completely retract all sections 12. With the boom installed, fully extend the telescope
and boom lift down to below a horizontal boom angle center mid section. If the boom is not installed, remove
and disconnect the extend hose (the larger of the two) the Deutsch electrical connectors from the telescope
running from port B, inner mid telescope section of the two stage relief solenoid valve and the hose reel brake
VG35 directional control valve to the cylinder port block solenoid both integral to the steer, swing and accessory
at the back of the base section and cap adapter. manifold (see figure 2-8).
6. Install a pressure gauge into the disconnected hose
running to the directional control valve.

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RT890E3 SERVICE MANUAL HYDRAULIC SYSTEM

13. Supply power to the telescope two stage relief solenoid of the front steer, swing and accessory manifold (see
valve by connecting the hose reel brake solenoid figure 2-8).
Deutsch electrical connector to it.
2. Start engine, throttle up to full RPM. Stroke lift, hoist or
14. Start engine and throttle up to full RPM. Telescope (with telescope controller by feathering into the controller to
boom installed) or attempt to telescope (without boom full stroke. Adjust the pressure reducing valve integrated
installed) the outer mid section OUT by feathering into in the outrigger control manifold "in" to increase or "out"
the controller to full stroke. Adjust the two stage relief
valve to 3140 ±50 PSI by loosening the high pressure
to decrease so that a gauge pressure of 3000 ±50 PSI is
achieved (see figure 2-12). 2
jam nut and turning "in" on the adjusting nut to increase
3. Stop engine. Remove diagnostic couplers and re-
or "out" to decrease the pressure (see figure 2-11).
connect plumbing.
15. Stop engine, remove the pressure gauge and re-connect
the plumbing to the hose reel and all electrical Procedure D - For Checking/Setting the Load
connectors to their proper solenoids. Sense Reduction Manifold
Center and Outer Mid Retract 1. With engine off, install a pressure check diagnostic quick
disconnect with gauge onto test nipple at the Outlet
16. With the boom installed, fully retract the boom or if the
Gauge Port of the P1 piston pump (see (1) figure 2-9).
boom is not installed, disconnect the retract hose (the
smaller of the two) running from the port A, center mid 2. Start engine, throttle up to 1400 RPM. Fully stroke lift,
and outer mid telescope section of the VG35 directional hoist or telescope controller. Adjust the pressure
control valve to the hose reel at the hose reel. reducing valve in the LS reduction manifold (see figure
2-13) "in" to increase or "out" to decrease so that a
17. Install a pressure gauge into the disconnected hose
gauge pressure of 3000 ±50 PSI is achieved.
running to the VG35 directional control valve.
3. Throttle up over 1500 RPM. Fully stroke lift, hoist or
18. Set the boom mode switches on the cab right hand
telescope controller. A maximum of 4000 ±50 PSI
armrest to "manual" and "CM". Start engine and throttle
should be read on the gauge. If not refer to Procedure
up to full RPM. Attempt to retract the telescope by
For Checking/Setting the Main Directional Control Valve
feathering into the controller to full controller stroke.
for Hoist(s), Boom Lift and Telescope(s) pressures, step
Adjust the work port relief valve "in" to increase or "out"
No. 3 or check electrical.
to decrease so that a gauge pressure reading of 3060
±50 PSI is achieved (see figure 2-10). 4. Stop engine. Remove diagnostic couplers and
reconnect plumbing.
19. Stop engine. Remove the pressure gauge and re-
connect the plumbing to the hose reel. Procedure E - For Checking/Setting the
Procedure B - For Setting the Outrigger Service Brake Accumulator Charging Valve
Pressures Charging Limits
1. Install a pressure check diagnostic quick disconnect with 1. With the engine off, discharge all of the pressurized oil
gauge onto test nipple at GP1 port of the outrigger stored in the accumulators by depressing the service
control manifold (see figure 2-12). brake pedal on the cab floor 4-6 times or until the pedal
has no back pressure.
2. Start engine and throttle up to full RPM. Select and
activate the outrigger "extend or retract" switch on the 2. Remove the cap from the tee at port 1A of the dual
cab dash. Adjust the pressure reducing valve integrated accumulator charging valve (see figure 2-14) and install
in the outrigger control manifold "in" to increase or "out" a pressure gauge onto the uncapped tee port.
to decrease so that a gauge pressure of 2000 ±50 PSI is 3. Start engine and idle. The charging valve will
achieved (see figure 2-12). immediately start to charge the accumulators. Watch the
3. Stop engine. Remove the diagnostic coupler. pressure gauge. The high charge limit pressure should
read 2900 +50, -0 PSI when the pressure gauge stops
Procedure C - For Setting the Oil Cooler rising.
Motor Pressure 4. With the engine still running at idle, repeatedly depress
service brake pedal on the cab floor until the gauge
1. With engine off, Install a pressure check diagnostic
pressure reads 2400 PSI and the dual accumulator
coupler with gauge onto the diagnostic nipple at G8 port
charging valve starts to recharge. Once you have found
this, push the brake pedal again to recharge. Watch the
pressure gauge. The low charging limit should be 2400 -

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HYDRAULIC SYSTEM RT890E3 SERVICE MANUAL

2550 PSI when it starts to recharge. Replace the valve if 5. Turn the gas chuck "T" handle all the way down
the pressures are not within the specified range. (clockwise) which will depress the core in the gas valve.
5. Stop engine. Remove diagnostic couplers and 6. Crack the nitrogen bottle valve and slowly fill the
reconnect plumbing. accumulator. Shut off the valve when the pre-charge is
1700 +50, -0 PSI.
Procedure F - For Checking Accumulator
7. If the pre-charge pressure is higher than specified in
Pre-Charge Pressure step #6, close the nitrogen bottle valve and slowly open
1. With the engine off, discharge all of the pressurized oil the bleed valve on the charging assembly (see figure 2-
stored in the accumulators by depressing the service 15) until the pressure is to specification.
brake pedal on the cab floor 4-6 times or until the pedal 8. Remove the charging assembly by turning the "T"
has no back pressure. Remove the gas valve guard and handle all the way out (counterclockwise) on the gas
cap on the accumulator (see figure 2-15). chuck and then open the bleed valve.
2. Before attaching the gas charging assembly onto the 9. Secure the gas valve, loosen the swivel nut and remove
gas valve, back the gas chuck "T" handle all the way out the charging assembly. Replace the gas valve cap and
(counterclockwise). guard.
3. Close the charging assembly bleed valve. Attach the
swivel nut onto the gas valve and tighten (10-15 pounds- Procedure H - For Checking/Setting the
inch). Front Steer Pressure
4. Turn the gas chuck "T" handle all the way down 1. Install pressure check diagnostic quick disconnect with
(clockwise) which will depress the core in the gas valve. gauge onto test nipple @ GP7 port of the front steer,
swing and accessory manifold (see figure 2-8).
5. Check the pre-charge pressure. It should be 1700 +50, -
0 PSI. 2. Start engine and throttle up to full RPM. Fully turn the
steering wheel to left or right against the axle stop.
6. If the pressure is 1700 +50, -0 PSI, remove the charging
Adjust the priority flow control relief valve in the front
valve assembly by turning the "T" handle all the way out
steer, swing and accessory manifold (see figure 2-8) by
on the gas chuck and then opening the bleed valve (see
removing the adapter and hose in the end of the
figure 2-15).
cartridge to access the hex adjustment screw and adjust
7. Secure the gas valve, loosen the swivel nut and remove "in" to increase or "out" to decrease so that a gauge
the charging assembly. Replace the gas valve cap and pressure of 2600 ±50 PSI is achieved.
guard.
3. Stop engine. Remove diagnostic couplers.
Procedure G - For Pre-Charging the Procedure I - For Checking/Setting the
Accumulator Swing Work Port Pressure
1. With the engine off, discharge all of the pressurized oil
1. Install pressure check diagnostic quick disconnect with
stored in the accumulators by depressing the service
gauge onto test nipple @ GP5 port of the front steer,
brake pedal on the cab floor 4-6 times or until the pedal
swing and accessory manifold (see figure 2-8).
has no back pressure. Remove the gas valve guard and
cap on the accumulator (see figure 2-15). 2. Start engine and throttle up to full RPM. With the swing
house lock engaged, swing right and hold. Adjust the
2. Ensure that the nitrogen supply bottle is shut off, then
work port relief “in” to increase or “out” to decrease so
attach the charging valve assembly to it.
that a gauge pressure reading of 2500 ± 50 PSI is
3. Before attaching the charging assembly to the achieved (see figure 2-8).
accumulator gas valve, back the gas chuck "T" handle
3. With house lock still engaged, swing left and hold. Adjust
all the way out (counterclockwise).
the work port relief “in” to increase or “out” to decrease
4. Close the charging assembly bleed valve. Without so that a gauge pressure reading of 2500 ± 50 PSI is
looping or twisting the hose, attach the swivel nut to the achieved (see figure 2-8).
accumulator gas valve and tighten (10-15 pounds-inch).
4. Stop engine. Remove diagnostic couplers.

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RT890E3 SERVICE MANUAL HYDRAULIC SYSTEM

Procedure J - For Checking/Setting the 3. Start engine idle. Attempt to lower the left counterweight
Swing Brake Release Pressure cylinder. Gauge should read 1000 ±100 PSI. If not,
replace the relief valve as they are non-adjustable (see
1. Install pressure check diagnostic quick disconnect with figure 2-16).
gauge onto test nipple @ GP3 port of the front steer,
4. Repeat for right hand counterweight removal cylinder.
swing and accessory manifold (see figure 2-8).
5. Stop engine. Remove the pressure gauge and
2. Start engine and idle, adjust the swing brake release
pressure reducing valve "in" to increase or "out" to
reconnect the plumbing. 2
decrease so that the gauge pressure of 325-350 PSI is
achieved (see figure 2-8).
Procedure N - For Checking the
Counterweight Pin Cylinder Pressure
3. Stop engine. Remove diagnostic couplers.
1. With the engine off, remove the hose running from the
Procedure K - For Checking/Setting the pin cylinder piston port to port "A" of the directional
Controller Supply Pressure control valve at the pin cylinder and cap or plug the
adapter in the cylinder port.
1. Install pressure check diagnostic quick disconnect with
2. Install a pressure gauge onto the disconnected hose.
gauge onto test nipple @ GP4 port of the front steer,
swing and accessory manifold (see figure 2-8). 3. Start engine idle. Attempt to extend pin. Gauge should
read 2500 ± 100 PSI. If not, replace the relief valve as
2. Start engine and idle, lower left armrest, stroke the
they are non-adjustable.
joystick of any crane function enough to start movement
of that function and adjust the controller pressure 4. Stop engine. Remove the pressure gauge and
reducing valve of the front steer, swing and accessory reconnect the plumbing.
manifold "in" to increase or "out" to decrease so that the
gauge pressure of 350-400 PSI is achieved (see figure 5. With the engine off, disconnect the hose running from
2-8). the pin cylinder rod tee adapter to port "B" of the
directional control valve at the cylinder tee.
3. Stop engine. Remove diagnostic couplers.
6. Start engine idle. Attempt to retract the pin. Gauge
Procedure L - For Checking/Setting the Hose should read 2500 ± 100 PSI. If not, replace the relief
valve as they are non-adjustable (see figure 2-16).
Reel Brake and Motor Supply
7. Stop engine. Remove the pressure gauge and
1. Remove pressure switch from port PS1 of the front reconnect the plumbing.
steer, swing and accessory manifold (see figure 2-8) and
install a pressure gauge into the port. Procedure O - For Checking the Cab Tilt
2. Start engine and idle, while telescoping, adjust the hose Cylinder Extend/Retract Pressure
reel pressure reducing valve "in" to increase or "out" to
decrease so that the gauge pressure of 1200 ±50 PSI is 1. With the engine off, remove the hose running from the
achieved (see figure 2-8). cab tilt dual PO check valve "CA" port to the cylinder rod
port at the cylinder and cap or plug the adapter in the
3. Stop engine. Remove gauge and re-connect plumbing. cylinder.

Procedure M - For Checking the 2. Install a pressure gauge onto the disconnected hose.
Counterweight Removal Cylinder Extend 3. Start engine and idle. Attempt to lower the cab. Gauge
Pressure should read 2500 ± 100 PSI. If not, replace the relief
valve as they are non-adjustable.
1. With the engine off, and counterweight pinned,
disconnect the extend hoses from port "A" of the 4. Stop engine. Remove the pressure gauge and
counterweight removal directional control valve for both reconnect the plumbing.
left and right removal cylinders and cap or plug the
adapter in the cylinder port.
2. Remove the quick disconnect coupler body from the
hose and install a pressure gauge onto the hose.

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HYDRAULIC SYSTEM RT890E3 SERVICE MANUAL

5. With the engine off, disconnect the hose running from Procedure P - For Checking the Luffing Jib
the cab tilt dual PO check valve "CB" port to the cylinder Lower Pressure
piston port at the cylinder and cap or plug the adapter in
the cylinder. 1. With the engine off, disconnect the hose running from
the directional control valve "B" port to the boom quick
6. Install a pressure gauge onto the disconnected hose.
disconnect at the disconnect and cap or plug the
7. Start engine and idle. Attempt to raise the cab. Gauge adapter.
should read 2500 ± 100 PSI. If not, replace the relief
2. Install a pressure gauge onto the disconnected hose.
valve as they are non-adjustable.
3. Start engine and idle. Attempt to raise the cab. Gauge
8. Stop engine. Remove the pressure gauge and
should read 1450 ± 50 PSI. If not, replace the relief valve
reconnect the plumbing.
as they are non-adjustable (see figure 2-16).
4. Stop engine. Remove the pressure gauge and re-
connect the plumbing.

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RT890E3 SERVICE MANUAL HYDRAULIC SYSTEM

Item Description
1 Procedure L - Check/Set Hose Reel Brake and Motor Supply Pressure - Step No. 1
2 Procedure L - Check/Set Hose Reel Brake and Motor Supply Pressure - Step No. 2
3 Procedure K - Check/Set the Controller Supply Pressure - Steps No. 1 and No. 2
2
4 Procedure C - Check/Set the Oil Cooler Motor Pressure - Step No. 1
5 Procedure J - Check/Set the Swing Brake Release Pressure - Step No. 1
6 Procedure I - Check/Set the Swing Work Port - Step No. 1, No. 2 & No. 3
7 Procedure H - Check/Set the Front Steer Pressure - Step No. 1 & No. 2
8 Procedure I -Check/Set the Swing Work Port - Swing WP Relief Valve

5
2 6 8

4
6431
7
Front View As Facing T/T Side Plate - Front Steer, Swing and Accessory Manifold

FIGURE 2-8

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HYDRAULIC SYSTEM RT890E3 SERVICE MANUAL

Item Description
1 Procedure A -Check/Set the Main Directional Control
Valve, Hoist(s), Lift and Telescope(s) - Step No. 3
(Maximum Pressure)
2 Procedure J -Check/Set the Swing Brake Release
Pressure- Step No. 3 (Differential Pressure)
3 Procedure A -Check/Set the Main Directional Control
Valve, Hoist(s), Lift and Telescope(s)- Steps No. 1 and
No. 3

6385-2

P1 Piston Pump

FIGURE 2-9

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RT890E3 SERVICE MANUAL HYDRAULIC SYSTEM

Item Description
1 Procedure A - Check/Set the Main Directional Control Valve,
Hoist(s), Lift and Telescope(s) - Step No. 18
2 Center/Outer Mid Extend Two Stage Port Relief - See Figure 2-11 2
3 Procedure A - Check/Set the Main Directional Control Valve,
Hoist(s), Lift and Telescope(s)- Step No. 7
4 Lift Retract Thermal Relief valve - Do Not Set/Adjust
5 Telescope Inner Mid Retract Thermal Relief Valve - Do Not Set/
Adjust

5
1
6385-3

Main Crane Function Directional Control Valve

FIGURE 2-10

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HYDRAULIC SYSTEM RT890E3 SERVICE MANUAL

1
Item Description
1 Procedure A - Check/Set Main Directional
Control Valve, Hoist(s), Lift and
Telescope(s) - Step No. 14
2 Procedure A - Check/Set Main Directional
Control Valve, Hoist(s), Lift and
Telescope(s) - Step No. 11
2

6385-4

Detail Showing Adjustment to Two-Stage Relief Valve

FIGURE 2-11

Item Description
3 Procedure B -Check/Set the Outrigger Circuit - Step
No. 1 and No. 3
4 Procedure B - Check/Set the Outrigger Circuit - Step
No. 2
3
5 Procedure C -Check/Set the Oil Cooler Motor Pressure
- Step No. 2

6385-5

Outrigger Control Manifold

FIGURE 2-12

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RT890E3 SERVICE MANUAL HYDRAULIC SYSTEM

Item Description
1 Procedure D - Check/Set the Load Sense
Reduction Manifold - Step No. 2
1
2

6385-6

Load Sense Reduction Manifold

FIGURE 2-13

Item Description
1 Procedure E - Check/Set the Service Brake
Accumulator Charging Valve - Step No. 2

6385-7

Service Brake Dual Accumulator Charge Valve

FIGURE 2-14

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HYDRAULIC SYSTEM RT890E3 SERVICE MANUAL

Item Description
2
1 Gas Valve Guard
2 Gas Valve

6385-8

Use For Checking and Pre-Charging The Accumulator

FIGURE 2-15

Item Description
1 Non-Adjustable Port Relief Location

6385-9

FIGURE 2-16

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RT890E3 SERVICE MANUAL HYDRAULIC SYSTEM

VALVES locations. The description of each valve given here is for the
valve itself. For information on how each valve functions in
General the individual circuits, refer to the description and operation
procedures of that circuit.
This subsection provides descriptive information for all the
hydraulic valves used on this crane. For a listing of all valves, NOTE: On each valve illustration in this section, each item
the circuit they are used in, and their physical location, refer number in table correlates to location on the valve,
to the Valve Usage Table. Refer to figure 2-17 for valve and to the valve hydraulic schematic.
2
Table 2-3
Valve Usage Table

Valve Name Circuit Used In Physical Location

Directional Control Valves Boom Lift/Telescope(s)/Hoist(s) Superstructure (Right Side Plate)
Counterweight Removal Between Superstructure Side Plates
Cab Tilt /Luffing Jib Between Superstructure Side Plates
Steering Control Valve Front Axle Steer Control Cab Steering Column
Front Steer/Swing/Accessory Manifold Front Axle Steer Supply Superstructure Right Side Plate
Swing Directional Control
Telescope Relief Control
Swing Brake Pressure
Controller Supply
Hose Reel Brake Control
Hose Reel Motor Supply
Steering Control Unit Front Axle Steer Cab Steering Column
Hydraulic Remote Controllers Boom Lift Cab Seat Arm Rests (2)
(HRC) Telescope (Floor) Cab Floor for Telescope with Optional
Main Hoist Aux Hoist
Auxiliary Hoist
Swing
Swing Power Brake Valve w/Treadle Swing Cab Floor
Pedal
Double PO Check Valve Cab Tilt Between Superstructure Side Plates
Tandem Brake Valve with Treadle Service Brakes Cab Floor
Dual Accumulator Charging Valve Service Brakes Superstructure inside Left Side Plate
Accumulator(s) Service Brake Superstructure Left Side
Holding Valves Boom Lift Lift Cylinder (Bolt on Manifold)
Telescope (3) Cylinder Port Blocks (Cartridge style)
Counterweight Removal (2) Cylinder Port Blocks (Cartridge style)
Axle Lockout, Rear Steer and Oil Axle Lockout Control Left Hand Carrier Frame Rail
Cooler Fan Motor Control Manifold Rear Steer Control
Oil Cooler Motor Control
Solenoid Valves:
Cross Axle Differential Lock Differential Lock (Optional) Carrier Inside Right Side Rail

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HYDRAULIC SYSTEM RT890E3 SERVICE MANUAL

Valve Name Circuit Used In Physical Location

Hoist Motor Control Valve Hoist(s) Both Hoists (see Hoist section)
Check Valves Return Circuit One in Parallel With Oil Cooler
Outrigger Control Manifold Outrigger On Rear Face of Carrier Frame Front
Cross Member
Load Sense Reduction Manifold Load Sense or CPU line to Pump No. 1 Left Hand Carrier Frame Rail Fwd of
Engine
Pilot Operated Check Valve Outrigger Port Block of each Stabilizer Cylinder
(4)
Telescope Rod Drain Solenoid Telescope Horizontal Plate Between The
Manifold Superstructure Side Plates
Cross Axle Differential Lock Valve Differential Lock (Optional) Carrier Bulkhead Plate Forward Of
The Engine
Hi-Low Range Shift, Axle Disconnect Parking Brake Axle Disconnect Front Side Of The Rear Frame
And Parking Brake Valve Bulkhead In The Swivel Area.

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RT890E3 SERVICE MANUAL HYDRAULIC SYSTEM

3 1

14
2

15

5
2

4
7
6

13

6339

SUPERSTRUCTURE

FIGURE 2-17

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HYDRAULIC SYSTEM RT890E3 SERVICE MANUAL

9 10

12
8 11
6338

CARRIER
FIGURE 2-17 continued

Item Description Item Description

1 Luffing Jib Cab Tilt Directional Valve 9 Rear Steer, Axle Lockout, Fan Drive Valve
2 Cab Tilt Check Valve 10 Range Shift/Park Brake Manifold
3 Counterweight Removal Directional Valve 11 Differential Lock Valve
4 Telescope Rod Manifold Drain 12 Selectable Pressure Reducing Manifold
5 Accumulator Brake Charge Valve 13 Two Speed Swing Valve
6 Directional Valve (Boom/Lift/Telescope(s), 14 Emergency Steer Accumulators (CE
Hoist(s), Counterweight Removal, Cab Tilt/ Machines)
Luffing Jib)
15 Brake Accumulator
7 Swing/Steer Brake Valve
8 Outrigger Manifold

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RT890E3 SERVICE MANUAL HYDRAULIC SYSTEM

DIRECTIONAL CONTROL VALVES 1034.2 kPa/10.3 bar (150 psi) resistance check valve located
in the front steer and accessory manifold providing make-up
Description oil to the swing motor for motor over-run when the valve is
centered. It receives oil from the fixed displacement gear
The directional control valves direct and control hydraulic oil pump No. 2 internally through the front steer and accessory
flow from the pumps to the boom lift and telescope cylinders, manifold and also returns oil internally through the front steer
each hoist motor, the swing motor, the counterweight and accessory manifold.
removal/cab tilt cylinders, and the front steer cylinders from
the steer control valve. The swing, front steer and accessory The counterweight removal directional control valve is a 2
directional control valve/manifold (see Figure 2-21), and the three section, manually actuated three position four way,
boom lift/telescope/hoist directional control valve (see Figure pressure compensated, closed center directional valve. It is
2-19) are located on the outside of the right superstructure plumbed in parallel with the boom lift/telescope/hoist
side plate. The counterweight removal (see Figure 2-18) and directional control valve and the luffing jib/cab directional
the luffing jib/cab tilt directional control valve (see Figure 2- control valve. The first and second sections control the left
20) are located between the left and right superstructure side and right removal cylinders, while the third section controls
plates under the main hoist. Each valve bank is removed and the counterweight pin cylinder. The removal cylinder
installed as an assembly. sections have an integral port relief for retract and the pin
cylinder has integral port relief valves for both raise and
The boom lift/telescope/hoist and counterweight removal/ lower functions.
cab tilt directional control valve is a five section, hydraulic
remote pilot actuated with three position four way spools that The luffing jib/cab tilt directional control valve is a two
are pressure and flow compensated. It receives pump flow section, solenoid controlled three position four way, pressure
from hydraulic swivel port 6 and pump No. 1. compensated, closed center directional valve. It is plumbed
in parallel with the boom lift/telescope/hoist directional
The inlet section contains of the boom lift/telescope/hoist control valve and the counterweight removal directional
directional control valve contains a 0.055 Ø orifice controlling control valve. The first working section raises and lowers the
the piston pump No. 1 differential or standby pressure at luffing jib, while the second working section controls the cab
1896 kPa/19 bar (275 psi) and a 29647 kPa/296 bar 4300 psi tilt. The luffing jib section has an integral port relief valve for
clipper relief valve that protects the piston pump (No. 1 raising the luffing jib.
pump) from transient pressure spikes. The telescope inner
mid section has integral port relief valves protecting extend Maintenance
and retract. The center mid/outer mid telescope section has
a two-stage port relief. When not pressurized, it is set to Boom Lift/Telescope/Hoist Valve Bank Removal
protect the center mid cylinder while extending. When
1. Tag and disconnect all of the electrical connectors or
pressurized, it is set to protect the outer mid cylinder. There
manual control levers.
is an integral port relief valve for both the center and outer
mid sections protecting cylinder retract. The boom lift section 2. Tag and disconnect the hydraulic lines from the valves.
has an integral port relief that thermally protects the retract Cap or plug the lines and ports.
side of the cylinder. All working sections have a two position
NOTE: The lift/telescope/hoist valve bank weighs
three-way solenoid RCL lockout valve in their pilot end cap
approximately 82.41 kg (181.6 pounds).
except the boom lift up. Both telescope sections are solenoid
proportionally controlled and disabled by the RCL system’s 3. Remove the capscrews and washers securing the valve
lockout solenoid valves. When the hoist(s), boom lift or bank and remove the valve bank.
telescope spool is actuated, the signal line (load sense)
connecting the load to the pump is blocked by the shifting Boom Lift/Telescope/Hoist Valve Bank Installation
spool causing the pump to go to its full compensating setting. 1. Place the valve bank on the superstructure side plate
The individual working sections meter only the required flow and secure it with the capscrews and washers. Torque
of oil to the function @ full pump compensator setting. the capscrews refer to SECTION 1-Fasteners and
The swing directional control valve is a single cast iron Torque Values.
section bolted onto the front steer and accessory manifold. 2. Connect the hydraulic lines to the valves as tagged
Refer to Front Steer, Swing and Accessory Manifold. It is during removal.
located on the outside of the right turntable side plate. The
valve contains a three position four way open center design 3. Connect the electrical connectors and manual control
that is remote pilot operated. Both working ports have port levers as tagged during removal.
relief valves and anti-void check valves that are flooded by a

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HYDRAULIC SYSTEM RT890E3 SERVICE MANUAL

Counterweight Removal Valve Bank Removal Luffing Jib/Cab Valve Bank Installation
1. Tag and disconnect all of the electrical connectors or 1. Place the valve bank on the superstructure side plate
manual control levers. and fasten it with the capscrews and lockwashers.
Torque the capscrews refer to SECTION 1-Fasteners
2. Tag and disconnect the hydraulic lines from the valves.
and Torque Values.
Cap or plug the lines and ports.
2. Connect the hydraulic lines to the valves as tagged
NOTE: The counterweight removal valve bank weighs
during removal.
approximately 16.4 kg (43.9 pounds).
3. Connect the electrical connectors to the valve as tagged
3. Remove the capscrews, lockwashers, flatwashers, and
during removal.
hex nuts securing the valve bank and remove the valve
bank. Functional Check (All Valve Banks)
Counterweight Removal Valve Bank Installation 1. Start the engine and run it at normal speed.
1. Place the valve bank on the superstructure side plate 2. Operate the control levers of the valve bank(s). Check
and secure it with the capscrews, lockwashers, for smooth operation of cylinders and motors.
flatwashers, and nuts. Torque the capscrews refer to
3. Check the valve bank(s) and lines for leakage. Make
SECTION 1-Fasteners and Torque Values.
repairs as needed.
2. Connect the hydraulic lines to the valves as tagged
during removal. Function Check - RCL Lockout Valves

3. Connect the electrical connectors and manual control 1. Remove fuse F16 from the power panel in the cab. This
levers as tagged during removal. cuts off power to the RCL.
2. Start the engine.
Luffing Jib/Cab Valve Bank Removal
3. Try to telescope the boom out, lower the boom, hoist up
1. Tag and disconnect all of the electrical connectors or
the main hoist, and hoist the auxiliary hoist up (if
manual control levers.
installed). Verify none of these functions work.
2. Tag and disconnect the hydraulic lines from the valves.
4. Shut down the engine. Reinstall fuse F16.
Cap or plug the lines and ports.
5. Telescope the boom out, lower the boom, hoist up the
NOTE: The luffing jib/cab valve bank weighs
main hoist, and hoist the auxiliary hoist up (if installed).
approximately 11.78 kg (25.9 pounds).
Verify all of these functions work.
3. Remove the capscrews and lockwashers securing the
6. Check for leaks. Make repairs as needed.
valve bank and remove the valve bank.

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RT890E3 SERVICE MANUAL HYDRAULIC SYSTEM

Item Description
1 Port P1
2 Port P2
3 Port P3 2
4 Port T1
6 5 Port T2
6387-3
6 Port T3
7 L.H. Cylinder - Rod Port
8 L.H. Cylinder - Piston Port
9 R.H. Cylinder - Rod Port
10 R.H. Cylinder - Piston Port
11 Pin Cylinder - Rod Port
12 12 Pin Cylinder - Piston Port
11
9

10

6387-2

12
8 9 10
11
7

3
2
4
1
5 6

1000 psi 1000 psi 2500 psi

6387-4
CWT Removal CWT Removal Pin

Valve Hydraulic Schematic

FIGURE 2-18

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HYDRAULIC SYSTEM RT890E3 SERVICE MANUAL

13
16 9 11 8
5
20 10
2 12
27
1
23

25
19

26

14

17
15

22 21
3, 31
6
18 24 6365-1
4

Item Description Item Description

1 Port T1 15 Port LS
2 Port T3 16 Lift Port PB - RCL Extend
3 Port P1 17 Lift Port PA - Lift Retract
4 Aux Hoist - Down - Port A 18 Main Hoist Port PA - Hoist
Down
5 Aux Hoist - Up - Port B
19 Main Hoist Port PB - Hoist Up
6 Main Hoist - Down - Port A
20 Tele Inner Mid Port PB - RCL
7 Main Hoist - Up - Port B
Extend
8 Telescope Outer Mid -
21 Tele Inner Mid Port PA - RCL
Retract - Port A
Retract
9 Telescope Outer Mid -
22 Tele Outer Mid Port PA - RCL
Extend - Port B
Retract
10 Telescope Inner Mid - Retract
23 Tele Outer Mid Port PB 0
- Port A
RCL Extend
11 Telescope Inner Mid - Extend
24 Aux Hoist Port PA - Down
- Port B
25 Aux Hoist Port PB - Up
12 Lift Retract - Port A
26 Port TP
13 Lift Extend - Port B
27 Pilot
14 Port T2
FIGURE 2-19

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RT890E3 SERVICE MANUAL HYDRAULIC SYSTEM

8 12
6 10
19 4 20
7
25
5
23
9 11 16 13
2
3

1
15
2
14

18
22 21 17 26
24 27 6365-3

Boom Lift/Telescope/Hoist Main Valve Hydraulic Schematic

FIGURE 2-19 continued

GROVE Published 07-24-2013, Control # 069-12 2-39

HYDRAULIC SYSTEM RT890E3 SERVICE MANUAL

Item Description
1 Port P2
2 Port T2
3 Port P1
4 Port A Cab Tilt Cylinder - Rod Side
5 Port B Cab Tilt Cylinder - Piston SIde
6 Port A Luff Jib
6386-2
7 Port B Luff Jib

2 1

5 4

6
6385-9

6386-1 3

6
7 5 4

Luffing Jib Cab Tilt 6386-3

Valve Hydraulic Schematic

FIGURE 2-20

2-40 Published 07-24-2013, Control # 069-12

RT890E3 SERVICE MANUAL HYDRAULIC SYSTEM

FRONT STEER, SWING/BRAKE MANIFOLD functions. It has a separate connection, before the 100 mesh
screen that supplies the service brake charge valve.
Description One pressure reducing valve and solenoid are used for the
The front steer, swing and brake manifold Figure 2-21 swing brake and brake release, one pressure reducing valve
houses cartridge components that control the front steer, feeds solenoids for the controllers and telescope two stage
pilot functions, swing brake release and the telescope hose relief, and one pressure reducing valve is used for the hose
r e e l . I t i s l o c a t e d o n t h e o u ts i d e o f t h e r i g h t h a n d
superstructure side plate under the removable valve cover.
reel motor and hose reel brake. The pump load sense and
(4) load sense shuttle checks are required to bring the pump 2
The manifold has two inlets, one for the piston pump No. 1 on and off stroke when the hose reel or telescope two stage
and one for the gear pump No. 2. The end opposite the bolt relief valve is selected and located in this manifold. All other
on swing directional valve houses the low pressure case pilot functions use the pump standby pressure to fully
drain that manifolds low pressure oil from swivel port 10, and operate at engine idle.
returns it to the tank. It is located on the outside of the right
hand superstructure side plate under the removable valve Maintenance
cover.
Removal
Oil from pump No. 2 enters the P2 inlet port from port 5 of the
1. Tag and disconnect all of the electrical connectors or
hydraulic swivel. The oil flows to the front steer flow control
manual control levers.
valve to a second flow control valve for the swing directional
valve which is bolted onto the front steer, swing and 2. Tag and disconnect the hydraulic lines from the valves.
accessory manifold. A main inlet relief protects pump No. 2. Cap or plug the lines and ports.
The front steer flow control valve is a load sense priority type
NOTE: The swing/steer/brake valve bank weighs
flow control valve. On a load sense signal from the cab
approximately 31.6 kg (69.6 pounds).
steering control valve, the spool shifts, directing controlled
flow to the cab steering control unit. The load sense port 3. Remove the bolts and lockwashers securing the valve
maintains a constant 861.8 kPa/8.6 bar (125 psi) standby bank and remove the valve bank.
pressure. Any excess flow is directed to the swing section.
The circuit is protected by a load sense relief valve Installation
incorporated in this section. The second flow control valve is 1. Place the valve bank on the superstructure side plate
unloaded when the swing directional valve is in neutral. and fasten it with the capscrews and washers. the
When the swing is actuated, the valve delivers a maximum of capscrews 49 to 53 Nm (36 to 39 pounds-foot)
95 lpm (25 gpm).
2. Connect the hydraulic lines to the valves as tagged
Pump No. 1 enters the P1 inlet through swivel port 7. The oil during removal.
flows first through a 100 mesh screen bad then supplies
three pressure reducing valves and five two position three 3. Connect the electrical connectors to the valve as tagged
way solenoid valves in parallel for the pilot and hose reel during removal.

48

46 62
40

49

41

Top View 7392-4 47

50 51 9
10
6366-3
Left View FIGURE 2-21

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HYDRAULIC SYSTEM RT890E3 SERVICE MANUAL

53 26

54
32 56
55
38 6
31
52

30
45

44

5
57

11 23
34 15 29 33 4
28 27
7392-1

25

7 36 24
17 35
12

42 1
22
43

39

7392-2
13
21 16 20 18 19 37 2 3

FIGURE 2-21 continued

2-42 Published 07-24-2013, Control # 069-12

RT890E3 SERVICE MANUAL HYDRAULIC SYSTEM

12 13
35 36 37 20
14 15 8 27 3 28
29 38 21 31 22 4
48 51 32
30
59 39 26 2
6

11
5

56
58

53 50 52 45
9 54 55 73923
16 10 17 18
19 40 23 46 42 44 7 34 1
2 33 24 41 43
60

Valve Hydraulic Schematic

FIGURE 2-21 continued

Item Description Item Description

1 Cooler Port - Return Swivel Port #4 12 D2 - Drain
2 Pump P2 Inlet 13 D3 - Drain
3 STR - Front Steer Control valve 14 D4 - Drain
4 STR-R - Steer Relief 15 D5 - Drain
5 A Port - Swing Right 16 D8 - Drain
6 B Port - Swing Left 17 D10 - Drain
7 P1 - Pump P1 Inlet 18 D11 - Drain
8 D6 - Drain 19 D12 - Drain
9 D7 - Drain 20 JS - Joystick Supply
10 D9 - Drain 21 HRS - Hose Reel Supply
11 D1 - Drain 22 HRR - Hose Reel Relief

GROVE Published 07-24-2013, Control # 069-12 2-43

HYDRAULIC SYSTEM RT890E3 SERVICE MANUAL

Item Description Item Description

23 SB - Swing Brake 43 LS-SWV - Load Sense Swing Valve
24 Drain - Front Steer Control Valve 44 LS-Aux - Auxiliary Load Sense
25 PA - Swing Pilot 45 OR2 - Orifice (ø.147) - Hose Reel Supply
26 PB - Swing Pilot 46 SH2 - Shuttle Valve - Hose Reel/Telescope
Relief Circuit
27 GP1 - Gauge Port 1 - Steer Inlet Pressure
47 SH3 - Shuttle Valve - Hose Reel/Telescope
28 GP2 - Gauge Port 2 - Steer Load Sense
Relief Circuit
Pressure
48 SV1 - Solenoid Valve - Telescope Two Stage
29 GP3- Gauge Port 3 - Swing Brake Foot Pedal
Relief
Inlet Pressure
49 SH1 - Shuttle Valve - Hose Reel/Telescope
30 GP4 - Gauge Port 4 - Joystick Supply
Relief Circuit
31 GP5 - Swing Valve Inlet Pressure
50 SV3 - Solenoid Valve - Joystick Supply
32 GP6 - Gauge Port 6 - Return Pressure from
51 SV2 - Solenoid Valve - Swing Brake Release
Gear Pump to cooler
52 PR3 - Pressure Reducing Valve (1200 psi) -
33 GP7 - Gauge Port 7 - Gear Pump Outlet to Steer/
Hose Reel Brake Release
Swing Valve
53 PR2 - Pressure Reducing Valve (350 psi) -
34 GP8 - Gauge Port 8 - Pressure From Stabilizer
Joystick Supply
Manifold
54 PR1 - Pressure Reducing Valve (250 psi) -
35 LS-STR - Front Steer Control Load Sense
Swing Brake Release
36 SWV - Swing Valve
55 RV1 - Relief Valve (3000 psi) - Pump #2 - Inlet
37 BS - Brake Supply Relief
38 SWB - Swing Brake Release 56 CV1 - Check Valve - Swing
39 HBR - Hose Reel Brake Release 57 SH4 - Shuttle Valve - Hose Reel/Telescope
40 LS-B - Hose Reel Brake Load Sense Relief

41 Tele - Telescope Two Stage Relief 58 OR1 - Orifice (ø.156)- Swing

42 LS - Load Sense Hoist/Telescope Lift Direction 59 CMP1 (2750 psi) - Front Steer Control Valve
Valve

2-44 Published 07-24-2013, Control # 069-12

RT890E3 SERVICE MANUAL HYDRAULIC SYSTEM

STEERING CONTROL VALVE 3. Remove the four mounting bolts and remove the valve
from the steering column.
Description
Installation
The load sense steering control unit (see Figure 2-22)
1. Secure the valve to the steering column and secure with
controls hydraulic flow to the front steering cylinders. It is
the four mounting bolts. Torque the bolts refer to
located in the steering column of the cab.
SECTION 1-Fasteners and Torque Values.
Both work ports are connected to the rod side of one steer
2. Connect the hydraulic hoses to the ports on the valve as
2
cylinder and to the piston side of the other steer cylinder.
tagged during removal.
Displacement of the valve is 588.2 cm³ (35.9 in³).
3. Connect the electrical connector to the valve as tagged
Maintenance during removal.
4. Verify proper operation of the valve.
Removal
5. Check valve and hydraulic connections for leaks. Make
1. Tag and disconnect the electrical connector to the valve. repairs as needed.
2. Tag and disconnect the hydraulic hoses from the valve.
Cap or plug the lines and ports.

1 2 1 3

5
4
3 5 4
Valve Hydraulic Schematic

Item Description
1 Pressure Port
2 Tank Port
3 Load Sense Port
4 Steer Right Port
5 Steer Left Port
FIGURE 2-22

GROVE Published 07-24-2013, Control # 069-12 2-45

HYDRAULIC SYSTEM RT890E3 SERVICE MANUAL

HYDRAULIC REMOTE CONTROL VALVE 3. Remove the bolts securing the control valve to the
armrest. Remove the control valve.
Description
Armrest Control Valve Installation
Single Axis Controller 1. Place the valve on the armrest. Secure the valve to the
The crane has four single axis hydraulic remote control armrest with the attaching bolts.
valves Figure 2-23. Each crane function has a control lever 2. Connect the hydraulic lines to the valve as tagged during
for the operator’s use. removal.
The four hydraulic remote control valves are single function 3. Install the plastic cover on the bottom of the armrest.
type valves. Moving the control lever forward or back Secure it with screws, washers and nuts.
operates the selected function. Two valves are located in
each armrest. The valves in the right armrest control the Armrest Control Valve Functional Check
main hoist and boom lift. The valves in the left armrest
1. Start the engine and run it at normal speed.
control swing and auxiliary hoist.
2. Move each control lever to operate the function
If the crane has an optional auxiliary hoist, the auxiliary hoist
controlled by the corresponding control valve. Verify
function replaces the telescope function on the control lever
proper operation of the hoist motor, swing motor, lift
on the left armrest. Instead, the telescope function is
cylinder, and telescope cylinder.
controlled by a pedal operated single function control valve.
The pedal is on the cab floor Figure 2-25. The control valve 3. Check valve and lines for leakage. Make repairs as
is mounted on the left rear underside of the cab and is needed.
connected to the pedal by linkage.
Telescope Pedal Control Valve Removal
When the armrests are up, the crane function switch is off, or
the operator leaves his seat, the controller lockout valve is 1. Disconnect the pedal linkage from the control valve by
de-energized and the functions are disabled. removing the pin and cotter pin.

Dual Axis Controllers 2. Tag and disconnect the hydraulic lines from the control
valve. Cap or plug the lines and ports.
The two hydraulic remote control valves Figure 2-24 are dual
function joystick type valves. One valve is located in each 3. Remove the four bolts and washers securing the control
armrest. The valve in the right armrest controls the main valve to the mounting bracket. Remove the valve.
hoist and boom lift. The valve in the left armrest controls Telescope Pedal Control Valve Installation
swing and telescope.
1. Place the valve on the mounting bracket and secure in
If the crane is equipped with an optional auxiliary hoist, the place with the bolts and washers.
auxiliary hoist function replaces the telescope function on the
control lever of the left armrest and the telescope function is 2. Connect the hydraulic lines to the valve as tagged during
controlled by a pedal operated single function control valve. removal.
The pedal is located on the left side of the cab floor. The 3. Connect the pedal linkage to the control valve with the
control valve is mounted beneath the cab and is connected pin and cotter pin.
to the pedal by linkage.
Telescope Pedal Control Valve Functional Check
Maintenance
1. Start the engine and run it at normal speed.
Armrest Control Valve Removal
2. Telescope the boom the whole way out and then the
1. Gain access to the base of the control valve by raising whole way back in. Verify proper telescoping.
the armrest and removing the plastic cover screwed
3. Check valve and lines for leakage. Make repairs as
onto the bottom of the armrest.
needed.
2. Tag and disconnect the hydraulic lines to the control
valve. Cap or plug the lines and ports.

2-46 Published 07-24-2013, Control # 069-12

RT890E3 SERVICE MANUAL HYDRAULIC SYSTEM

NOTE: R.H. and L.H. controllers oriented from seated operator.

Ports of control lever seen facing aft looking at seat with armrest in up position.

Single Axis

4, 8, 12

7393-2

3, 7, 11 7393-1

2 5, 9
6, 10

AUX HOIST/
TELESCOPE
SWING BOOM HOIST

Left Right In Out 1 Ext Retract Up Down 6403-3

10 9 8, 12 7, 11 2 6 5 4
3

FIGURE 2-23

Item Description Item Description

1 P Port - Pressure 7 B Port - Telescope Out
2 T Port - Tank 8 A Port - Telescope In
3 A Port - Hoist Down 9 A Port - Swing Right
4 B Port - Hoist Up 10 B Port - Swing Left
5 A Port - Boom Retract 11 A Port - Aux Hoist Up
6 B Port - Boom Extend 12 B Port - Aux Hoist Down

GROVE Published 07-24-2013, Control # 069-12 2-47

HYDRAULIC SYSTEM RT890E3 SERVICE MANUAL

Dual Axis

Forward Back Left Right

P
T 7, 8
5, 6, 11
1 3 4 2 6403-7

5, 6, 11
1

7, 8
6403-4

3, 4

2
9, 10, 12
6403-2b

FIGURE 2-24

Item Description Item Description

1 Port 1 - Tank Port 7 Port 3 - Hoist Down
2 Port 2 - Pump Port 8 Port 3 - Telescope Out
3 Port 1 - Hoist Up 9 Port 4 - Boom Up
4 Port 1 - Telescope In 10 Port 4 - Aux Hoist Up
5 Port 2 - Boom Retract 11 Port 2 - Swing Right
6 Port 2 - Aux Hoist Down 12 Port 4 - Swing Left

2-48 Published 07-24-2013, Control # 069-12

RT890E3 SERVICE MANUAL HYDRAULIC SYSTEM

3 1

2
6402-1
4 2
2
4

Telescope Foot Controller

6402-2
1
3

FIGURE 2-25

Item Description Item Description

1 Telescope In 3 Telescope Out
2 Pressure Port 4 Port To Tank

GROVE Published 07-24-2013, Control # 069-12 2-49

HYDRAULIC SYSTEM RT890E3 SERVICE MANUAL

SWING POWER BRAKE VALVE WITH 1. Engage the swing lock.

TREADLE PEDAL 2. Install the brake valve and secure in place with the three
bolts, flat washers, spring lockwashers, and nuts. Torque
Description the bolts refer to SECTION 1-Fasteners and Torque
Values.
The swing power brake valve is used to provide hydraulic
pressure to the piston of the swing brake to apply the brake. 3. Attach the hydraulic lines to the brake valve as tagged
The valve receives its supply of oil from the front steer and during removal.
accessory manifold. Depressing the brake pedal causes
hydraulic oil to flow to the top of the brake piston where, Function Check
combined with spring tension, the total force overcomes the 1. Start the engine and let it idle.
brake release pressure and applies the brake. When the
valve is released, excess hydraulic oil flows from the valve to 2. Disengage the swing lock.
the case drain manifold and back to the reservoir (see 3. Slowly swing the turntable.
Figure 2-26).

Maintenance
Removal DANGER
Engage the swing lock before adjusting the swing brake
1. Tag and disconnect hydraulic lines attached to the brake
valve.
valve. Cap or plug the lines and ports.
2. Remove the three bolts, spring lockwashers, flat 4. Test the valve by engaging the swing brake control valve
washers, and nuts which secure the brake valve to the and operating the swing brake. Verify the swing brake
cab floor. Remove the brake valve. works when the pedal is pressed. Verify the brake is off
when the pedal is not pressed. Engage the swing lock
Installation and make adjustments to the pedal as needed.
5. Check for leaks. Make repairs as needed.

DANGER
Engage the swing lock before installing the swing brake
valve.

Item Description
1 A Port - To Swing Drive
2 T Port - To Reservoir
3 P Port - Pressure From Swing, Steer and
Accessory Manifold

3 2 3
1 2 FIGURE 2-26

2-50 Published 07-24-2013, Control # 069-12

RT890E3 SERVICE MANUAL HYDRAULIC SYSTEM

2 SPEED SWING VALVE Swing speed is selected in the cab via the dashboard
SWING HIGH/LOW SPEED switch. In the deenergized
Description position or LOW SPEED switch position, the two solenoid
actuated two position two-way valves allow oil to pass across
The 2-speed swing valve (see Figure 2-27) is used to select the adjustable flow control to the opposite side of the motor
the swing motor speed. The valve is bolted directly to the thus reducing the flow available to the motor. When selecting
swing motor. It consists of two solenoid actuated two position the HIGH SPEED switch position, the two solenoid actuated
two-way valves and an adjustable flow control. two position two-way valves are energized thus not allowing 2
oil to pass across the adjustable flow control and forcing all
available flow to the motor.

1 2
3, 4
NV1 V1
SV2

NV1

SV1

3, 4 SV2
5 SV1
2
6392-1 V2

Item Description
6392-2
1 Needle Valve
2 Adapter
3 2-Way Valve
4 Coil
5 Plug
FIGURE 2-27

Maintenance Installation

Removal 1. Secure the valve to the swing motor using the two
retaining screws.
1. Tag and disconnect the electrical connector to the valve.
2. Connect the hydraulic hoses to the ports on the valve as
2. Tag and disconnect the hydraulic hoses from the valve. tagged during removal.
Cap or plug the lines and ports.
3. Connect the electrical connector to the valve as tagged
3. Remove the two retaining screws securing the valve to during removal.
the swing motor.
4. Verify proper operation of the valve. Refer to the SWING
4. Remove valve. SPEED in the Operator’s and Safety Handbook.
5. Check valve and hydraulic connections for leaks. Make
repairs as needed.

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HYDRAULIC SYSTEM RT890E3 SERVICE MANUAL

CAB TILT DOUBLE PILOT OPERATED 1. Tag and disconnect the hydraulic lines running to the
CHECK VALVE valve. Cap or plug all openings.
2. Remove the capscrews and lockwashers securing the
Description valve to the plate and remove the valve.
The cab tilt double pilot operated (PO) check valve is located Installation
on the horizontal plate between the superstructure side
plates, forward of the telescope hose reel. It is used to hold 1. Install the valve to the plate and secure with the
or lock the cab tilt cylinder in place. Oil flow is directed from capscrews and lockwashers. Torque the capscrews 25
the “V” ports to the “C” ports, while blocking flow in the to 27 Nm (18 to 20 pounds-foot).
opposite direction. Flow is reversed from “C” to “V” when 2. Connect the hydraulic lines to the valve as tagged during
pressure pilot oil is applied to the opposite side “V” port (see removal.
Figure 2-28).
3. Operate the applicable function and check the valve for
Maintenance proper operation and any leaks.

Removal 4. Test the check valve by operating the cab tilt cylinder.
Verify it extends and retracts without problems; verify
there is no leaking. Make repairs as needed.
CAUTION
Completely lower the cab before disconnecting valve
plumbing.

Item Description 1 5 3

1 Port CA - To Cab Tilt Cylinder

2 Port CB - To Cab Tilt Cylinder
3 Port VA - Cab Tilt Valve
4 Port VB - Cab Tilt valve
5 CV1 - Check Valve A ports
6 CV2 - Check Valve B ports

2
1

5
6
3 6389-1
4
2 6 4
6389-2
Valve Hydraulic Schematic FIGURE 2-28

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RT890E3 SERVICE MANUAL HYDRAULIC SYSTEM

TANDEM BRAKE VALVE WITH TREADLE The tandem brake valve consists of a tandem valve body, a
PEDAL closed center spool, a treadle pedal, an integral proximity
switch and a mechanical spring assembly to limit the output
Description pressure to the brake actuators to 14,479 ± 517 kPa (145 ±
5.2 bar) (2100 ± 75 psi).
The tandem brake valve with treadle pedal is located on the
floor of the cab. The tandem brake valve provides split Maintenance
system braking for the primary (front) brakes and the
Removal
2
secondary (rear) brakes.
The valve is a closed center spool design which modulates 1. Tag and disconnect the electrical connector to the valve.
the output pressure [14,479 ± 517 kPa (145 ± 5.2 bar) (2100 2. Tag and disconnect the hydraulic hoses from the valve.
± 75 psi)] to the brake actuators. The valve is mechanically Cap or plug the lines and ports.
actuated by a treadle pedal (see Figure 2-29). The direct
acting spool provides a pedal feel which accurately 3. Remove the nuts and bolts securing the valve to the cab
represents the brake pressure, similar to automotive style Floor. Remove the valve.
pedal feedback as the brake pedal pressure increases, the
Installation
pedal effort increases proportionally. As the pedal is initially
actuated, the tank ports are closed off from the brake ports. 1. Secure the valve to the cab floor with the nuts and bolts.
With further application of the pedal, the pressure ports are
opened to the brake ports until the pedal actuation force and 2. Connect the hydraulic hoses to the ports on the valve as
the hydraulic pressure force are balanced. tagged during removal.

Also when the pedal is actuated, the integral proximity switch 3. Connect the electrical connector to the valve as tagged
is engaged to provide an electrical signal for brake lights. during removal.
When the pedal is released, the valve and the pedal return to 4. Start the engine and check valve and hoses for leaks.
the non-applied position. In normal operation, the secondary Make repairs as needed.
system is piloted from the primary section providing pressure
to both systems.

Item Description
1 Port B1
2 Port B2
3 Pressure Port P1
4 Tank
5 Pressure Port P2
3
1
4

2 5

4
Valve Hydraulic Schematic

FIGURE 2-29

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HYDRAULIC SYSTEM RT890E3 SERVICE MANUAL

DUAL ACCUMULATOR CHARGE VALVE pressure also pilots the control pilot spool to open the load
sense line to tank, destroking the piston pump No. 1.
Description
Maintenance
The load sensing dual accumulator charging valve is located
on the inside of the left superstructure side plate. The Removal
purpose of the valve is to provide pressure regulation to the
1. Tag and disconnect the hydraulic hoses from the valve.
service brake circuit.
Cap or plug the lines and ports.
The dual accumulator charge valve consists of an inlet main
2. Remove the two bolts, washers, and lockwashers
check valve, a load sense control section with a pilot spool
securing the valve to the turntable. Remove the valve.
that controls the pump stroke and an inverted shuttle that
controls the accumulator charging (see Figure 2-30). Installation
When the valve is charging the accumulators, the load sense 1. Position the valve on the turntable and secure with two
control section is in neutral position, connecting the load to bolts, washers, and lockwashers. Torque bolts refer to
the pump by way of the load sense line. This brings the SECTION 1-Fasteners and Torque Values.
piston pump No. 1 on stroke to supply fluid for charging.
Fluid passes through the main check valve connecting to the 2. Connect the hydraulic hoses to the valve ports as tagged
pilot end and through the spool onward to the inverted during removal.
shuttle that connects the accumulators. 3. Start the engine and check for leaks. Make repairs as
When the control pilot spool bias spring senses the low limit needed.
pressure of 15,514 kPa/155 bar (2250 psi), the spool shifts to 4. Depress the brake pedal several times to cause the
the neutral position, allowing the pump to charge the brake valve to charge. Make several turns with the
accumulators to a maximum of 19,995 kPa/200 bar (2900 steering wheel, and swing the superstructure left and
psi). The inverted shuttle cartridge senses the pressure in right. Verify the brakes, swing, and front steering work
the accumulators to pilot the cartridge closed when properly.
maximum charge pressure is reached. Maximum charge

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RT890E3 SERVICE MANUAL HYDRAULIC SYSTEM

6
Item Description
1 Load Sense Port 3

2 Tank Port
3 Pressure Port 2
4 Accumulator Port 1A
5 Accumulator Port 2A
6 Pressure Switch

4 5
4

5
6
2

6343-1
3 6343-2
Valve Hydraulic Schematic
FIGURE 2-30

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HYDRAULIC SYSTEM RT890E3 SERVICE MANUAL

HYDRAULIC ACCUMULATOR SERVICE 3. Remove the two nuts securing each clamp half. Remove
BRAKE the each clamp half and accumulator from the turntable.

Installation
Description
1. Position the accumulator in the clamps and secure with
The service brake hydraulic accumulators are located on the the removable clamp halves and nuts.
outside of the left superstructure side plate behind the cab.
The purpose of each accumulator is to provide stored 2. Connect the hydraulic hose to the port on the
energy, an oil volume of 3.0 liters (173 cu in) at a maximum accumulator as tagged during removal.
pressure of 19,995 kPa/200 bar (2900 psi), to actuate the 3. Pre-charge the accumulator. Refer to paragraph titled
service brake circuits. The dual accumulator charge valve Pre-Charging Accumulator in Sub-Section titled
regulates flow to the hydraulic accumulators to provide fully Pressure Setting Procedures.
powered independently separate, primary (front) and
secondary (rear), service brake circuits. 4. Start the engine and check accumulator and hoses for
leaks. Make repairs as needed.
Each accumulator has two chambers divided by a piston.
One side is pre-charged to 11,722 kPa/117 bar (1700 psi) 5. Depress the brake pedal several times, make several
with high purity nitrogen. This maintains a constant pressure turns with the steering wheel, and swing the
in the other chamber which is connected to the modulating superstructure left and right. Verify the brakes, swing,
brake valve. After the accumulators are fully charged, they and front steering work properly.
will provide the necessary brake system flow and pressure to
actuate the brakes. Servicing

The accumulator consists of a tube, piston, seals, gas The pre-charge nitrogen pressure should be checked every
charging valve, and a gas valve guard. 200 hours or once a month, whichever comes first. Refer to
Pressure Setting Procedures in this section.
Maintenance
Removal
1. With the engine shutdown, deplete the hydraulic
pressure in the accumulators by depressing the service
brake pedal several times.
2. Tag and disconnect the hydraulic hose from the
accumulator. Cap or plug the line and port.

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RT890E3 SERVICE MANUAL HYDRAULIC SYSTEM

HOLDING VALVES Removal

1. Unscrew holding valve from its port block or manifold.
Description
Installation
A bolt-on manifold style holding valve is installed on the
boom lift and luffing jib cylinders. A cartridge style holding 1. Check the inside of the port block or manifold for any
valve is used on each telescope cylinder installed in the sharp edges or burrs and remove as necessary with
piston side of the cylinder. The counterweight removal
cylinders have two cartridge style holding valves installed in
emery cloth. 2
rod side of each cylinder. 2. Install new o-rings onto the holding valve.

The holding valve provides meter out control, will lock the 3. Lubricate the holding valve and o-rings with clean
cylinder in place, prevent a load from running ahead of the oil hydraulic oil.
supply, and will relieve excess pressure caused by thermal
expansion.
CAUTION
Maintenance Do not damage the o-rings during installation of the
holding valve. If the holding valve turns freely then gets
hard to turn, then easy to turn, remove the holding valve
and check the o-rings. They have probably been
damaged by a sharp edge of a port.
DANGER
Boom must be fully lowered and fully retracted before NOTE: The holding valve should turn by hand until
removing lift cylinder and telescope cylinder holding compression of the o-rings begins.
valves. The counterweight must be removed or pinned
before removing counterweight removal cylinder holding 4. Carefully install the holding valve into the port block or
valves. manifold until fully seated.
5. Test the holding valve and port block or manifold by
operating the lift cylinder and/or the telescope cylinder,
as applicable. Verify lift cylinder and/or telescope
cylinder works without problems; verify there is no
leaking. Make repairs as needed.

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HYDRAULIC SYSTEM RT890E3 SERVICE MANUAL

CROSS AXLE DIFFERENTIAL LOCK VALVE Maintenance

Description Removal

The cross axle differential lock valve Figure 2-31 is mounted 1. Tag and disconnect the electrical connector from the
off the carrier bulkhead plate forward of the engine. The valve.
valve is a four-way, two position solenoid valve. The valve is 2. Tag and disconnect the hydraulic lines attached to the
used to control the application of the crane’s hydraulically valve. Cap or plug lines and ports.
applied and released cross axle differential lock actuators.
3. Remove the two bolts and washers securing the valve to
Positioning the cab AXLE DIFF switch to LOCK shifts the the frame. Remove the valve.
four-way, two-position solenoid valve so hydraulic oil can
flow to the engage port of the cross axle differential lock Installation
actuators, extending them. When the actuators extend, they
1. Secure the valve to the frame with the two bolts and
engage the splines on the differential case and the axle
washers. Torque the bolts refer to SECTION 1-
shafts to lock the differential assemblies together.
Fasteners and Torque Values.
Positioning the cab AXLE DIFF switch to UNLOCK shifts the
2. Connect the hydraulic lines to the valve as tagged during
three-way, two-position solenoid valve so hydraulic oil can
removal.
flow to the disengage port of the actuators, retracting them.
As the actuators retract, they unlock the axles. 3. Connect the electrical connector to the valve as tagged
during removal.
4. Apply and release the cross axle differential lock several
times. Verify the cross axle differential lock holds the
axle from moving when applied so there is no differential
action between the wheels.
5. Check for leaks. Make repairs as needed.

3
1

2 2
3

7395-1
7395-2 1 FIGURE 2-31

Item Description Item Description

1 To Front and Rear Axle 3 Port P - To Port P Of Park Brake Range Shift
Valve
2 Port T - To Port T Of Park Brake Range Shift
Valve

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RT890E3 SERVICE MANUAL HYDRAULIC SYSTEM

OUTRIGGER CONTROL MANIFOLD 3. Remove the bolts, flatwashers and spring lockwashers
securing the manifold to the bracket and remove the
Description manifold.

The outrigger control manifold reduces the pressure Inspection

supplied to the front steer accessories manifold and
Visually inspect the valves and hydraulic connections for any
directionally controls the outrigger circuit. The valve is
evidence of leaks or other damage. Check security of the
mounted from the bottom of the frame rail in front of the oil
cooler.
electrical connections. Inspect the wiring for any evidence of 2
cracks or breaks.
The inlet of the manifold has a bolt on block that houses two
pressure reducing valves. One reduces the internal outrigger Installation
pressure to 13,789 kPa/137.8 bar (2000 psi) and the other 1. Position the manifold on the mounting bracket and
reduces the system pressure to 20,684 kPa/206.8 bar (3000 secure with the bolts, flatwashers and spring
psi) for an external port feeding the front steer accessories lockwashers. Torque the bolts refer to SECTION 1-
manifold and the rear steer/fan drive axle lockout manifold. Fasteners and Torque Values.
The outrigger control consists of four (two for extend and two 2. Connect the electrical connectors to the solenoids as
for retract), two position two-way solenoid control valves, marked during removal.
internally connected in parallel and two pilot operated check
valves with integral thermal relief valves set at 20,684 kPa/ 3. Connect the hydraulic lines to the valves as marked
206.84 bar (3000 psi) (see Figure 2-32). The manifold also during removal.
includes eight (four front and four rear) normally closed two
Functional Check
position two-way solenoid valves. When energized, the
solenoid shifts the spool to open allowing extension or 1. Start engine and run at medium speed.
retraction of the outrigger cylinders.
2. Operate the outriggers and check for smooth operation
Maintenance of the cylinder(s).

Removal
1. Tag and disconnect the electrical connectors or manual
control levers.
2. Tag and disconnect the hydraulic lines to the solenoid
valves; cap all lines and openings.

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HYDRAULIC SYSTEM RT890E3 SERVICE MANUAL

27 5
32 24 4

23
31 3
30

29 17 15
18 16
22 1

14

13
12 3

11
28
10 36
35

9
2 20
8 19
7 34
33 6373-1
13 29 30 31
5 32 6
3 12 11 10

26

25
27 28
24 21

23 22

20
2 36
4 33 34 35
16 3
6 9 17 18
7 8
19
Hydraulic Schematic 6373-2
14 1 15
FIGURE 2-32

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RT890E3 SERVICE MANUAL HYDRAULIC SYSTEM

Item Description Item Description

1 Pump Port 19 Pressure Reducing Valve PR2
2 Tank Port 20 Pressure Reducing Valve PR1
3 RET Port 21 Solenoid Valve SV12
4 P STAB Port 22 Solenoid Valve SV11 2
5 T STAB Port 23 Solenoid Valve SV10
6 Left Rear Extension Cylinder Port 24 Solenoid Valve SV9
7 Left Rear Stabilizer Cylinder Port 25 Pilot Operated Check Valve POCV2
8 Right Rear Stabilizer Cylinder Port 26 Pilot Operated Check Valve POCV1
9 Right Rear Extension Cylinder Port 27 Thermal Relief Valve RV1
10 Right Front Extension Cylinder Port 28 Thermal Relief Valve RV2
11 Right Front Stabilizer Cylinder Port 29 Solenoid Valve SV1 - Left Front Extension
12 Left Front Stabilizer Cylinder Port 30 Solenoid Valve SV2 - Left Front Stabilizer
13 Left Front Extension Cylinder Port 31 Solenoid Valve SV3 - Right Front Stabilizer
14 Turret Port 32 Solenoid Valve SV4 - Right Front Extension
15 Drain Port 33 Solenoid Valve SV5 - Left Rear Extension
16 Gauge Port 1 34 Solenoid Valve SV6 - Left Rear Stabilizer
17 Gauge Port 2 35 Solenoid Valve SV7 - Right Rear Stabilizer
18 Gauge Port 3 36 Solenoid Valve SV8 - Right Rear Extension

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HYDRAULIC SYSTEM RT890E3 SERVICE MANUAL

PILOT OPERATED CHECK VALVE 3. Lubricate the check valve and o-rings with clean
hydraulic oil.
Description
A pilot operated (PO) check valve is located in each CAUTION
outrigger stabilizer cylinder port block. The check valve Do not damage the o-rings during installation of the check
functions as a holding valve for the stabilizer cylinder. Oil valve. If the check valve turns freely then gets hard to turn,
flow is directed from the “V” port to the “C” ports, while then easy to turn, remove the check valve and check the
blocking flow in the opposite direction. Flow is reversed from o-rings. They have probably been damaged by a sharp
“C” to “V” when pressure pilot oil is applied to the opposite edge of a port.
side “V” port (see Figure 2-33).
NOTE: The check valve should turn by hand until
Maintenance compression of the o-rings begins.
Removal 4. Carefully install the check valve into the port block until
1. Unscrew the check valve from the stabilizer cylinder port fully seated.
block. 5. Test the check valve and port block by operating the
affected outrigger’s stabilizer cylinder. Verify it extends
Installation
and retracts without problems; verify there is no leaking.
1. Check the inside of the port block for any sharp edges or Make repairs as needed.
burrs and remove as necessary with emery cloth.
2. Install new o-rings onto the check valve.

Item Description
1 Port C - Cylinder
2 Port P - Pilot 1

3 Port V - Valve

6155 FIGURE 2-33

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RT890E3 SERVICE MANUAL HYDRAULIC SYSTEM

AXLE LOCKOUT, REAR STEER AND OIL The rear steer is controlled by a three position four-way
COOLER FAN MOTOR CONTROL solenoid actuated directional control valve. The valve shifts
in one direction for right turn and the other direction for left
MANIFOLD turn. To ensure the steering cylinders do not drift out of a
locked position, a double pilot operated check valve is
Description installed between the directional valve and the cylinder work
The manifold cartridge components controls the axle lockout ports.
and supplies flow for the oil cooler fan motor. It is located on
Maintenance
2
the inside of the left hand carrier frame rail, forward of the
hydraulic swivel.
Removal
The pump “P” and tank “T” ports are connected by hoses in
1. Tag and disconnect the electrical connectors to the
parallel to the outrigger control manifold. The load sense/
valve.
CPU control line from the superstructure passes through the
manifold and is connected onward to the pump by two load 2. Tag and disconnect the hydraulic hoses from the valve.
sense shuttle valves. One shuttle valve senses oil cooler Cap or plug the lines and ports.
pressure and the other senses rear steer and outrigger
pressure. A two position three-way solenoid valve connects 3. Remove the capscrews and washers securing the valve
the fan drive to the pump load sense. to the frame bracket. Remove the valve.

The oil cooler motor is controlled by two position three-way Installation

solenoid cartridge valves and is limited to 19 lpm (5 gpm) by 1. Secure the valve to the frame bracket with the washers
a pressure compensated flow control valve located between a nd c aps c r e w s . To r q u e t h e c a ps c r e w s r e f er t o
the two position three-way solenoid and the port to the cooler SECTION 1-Fasteners and Torque Values.
motor (see Figure 2-34).
2. Connect the hydraulic hoses to the ports on the valve as
The rear axle lockout circuit consists of two normally closed, tagged during removal.
two position, two-way cartridge solenoid valves. Pump No. 2
enters the P2 inlet port from port No. 5 of the hydraulic 3. Connect the electrical connectors to the valve as tagged
swivel. It keeps the lockout cylinders from oscillating unless during removal.
the turntable is centered forward. The area definition 4. Verify operation as follows:
potentiometer in the electrical swivel energizes and de-
energizes the axle lockout relay. When the superstructure is • Operate the rear steer left and right to verify smooth
more than six degrees left or right of front center, the axle operation.
oscillation relay is de-energized. When the relays are open,
• On outriggers, swing over the front outriggers to ensure
the normally closed solenoid valves are de-energized and
the oscillation cylinders lockout.
isolate the lockout cylinders from oil supply. This keeps the
lockout cylinders from oscillating because oil is trapped in • Remove the electrical connection from the oil cooler
the cylinders. When the axle oscillation relays are closed, the motor two position three-way solenoid valve to verify
solenoid valves are energized and open. This allows that it operation.
hydraulic oil in and out of the cylinders allowing them to
5. Check valve and hoses for leaks. Make repairs as
oscillate.
needed.

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HYDRAULIC SYSTEM RT890E3 SERVICE MANUAL

NOTE: Models without axle lockout do not have solenoid

SV1 and SV2 installed on the manifold

19

16

14

13

17

12
10 6371-1

11

9
15 7

3
18

2
4

20 6371-3

5 8
FIGURE 2-34

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RT890E3 SERVICE MANUAL HYDRAULIC SYSTEM

13 19
14 18
2

17 12

6371-2

2 10 11
8 3
1 9 6 4
7 5
15 16
20

FIGURE 2-34 continued

Item Description Item Description

1 P STAB Port - Pressure to Stabilizers 12 Solenoid Valve SV3 - Rear Steer
2 T STAB Port - To Tank 13 Solenoid Valve SV1 - Axle Lockout - Right
3 STEER A Port - Rear Steer Cylinder 14 Solenoid Valve SV2 - Axle Lockout - Left
4 STEER B Port - Rear Steer Cylinder 15 SH1 Shuttle Valve - Load Sense/CPU To Pump
5 FAN DRIVE Port - Hydraulic Oil Cooler 16 SH2 Shuttle Valve - Load Sense/CPU To Pump
6 ALO A Port - Right Axle Lockout Cylinder 17 Pressure Reducing Valve - Axle Lockout
7 ALO B Port - Left Axle Lockout Cylinder 18 Check Valve CV1 - Rear Steer
8 LS PUMP Port - Load Sense 19 Check Valve CV2 - Rear Steer
9 LS TURRET Port - Load Sense 20 FR1 - Flow Restrictor - Oil Cooler/Fan Drive
10 Solenoid Valve SV4 - Pump On Stroke Valve
11 Solenoid Valve SV5 - Fan Drive

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HYDRAULIC SYSTEM RT890E3 SERVICE MANUAL

CHECK VALVES if the steer cylinder pressure rises above the inlet port
pressure.
Description
Maintenance
There are two check valves utilized in the crane hydraulic
system. The check valves are used to block flow in one Removal
direction and allow free flow in the opposite direction.
1. Tag and disconnect hydraulic lines from the valve and
The crane’s hydraulic dual return circuit has an in-line check cap or plug all openings and remove valve.
valve plumbed in one of the two return lines. It is used to
force hot return oil through the second return line and into the Installation
oil cooler. 1. Connect the hydraulic lines as tagged during removal.
The second check valve is plumbed in-line at the inlet of the 2. Check valve and hydraulic connections for leaks. Make
front steer control valve. It prevents steering wheel kick-back repairs as needed.

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RT890E3 SERVICE MANUAL HYDRAULIC SYSTEM

RANGE SHIFT/PARKING BRAKE VALVE Maintenance

Description Removal
The range shift/parking brake valve Figure 2-35 controls the 1. Tag and disconnect the electrical connectors to the
flow of oil to the parking brake, hi-low range and axle valve.
disconnect actuators by the use of two solenoid valves. The
2. Tag and disconnect the hydraulic hoses from the valve.
valve is located on the center of the frame. Pressure is
supplied to the valve from the transmission charge pump. Cap or plug the lines and ports. 2
The parking brake solenoid valve is a two position three-way 3. Remove the capscrews, lockwashers and nuts securing
valve. In its de-energized position, the inlet port is blocked the valve to the frame. Remove the valve.
and the parking brake actuator is drained to the reservoir.
When the solenoid is energized, the reservoir port is blocked Installation
and pressurized oil is directed to the actuator, engaging the 1. Secure the valve to the frame with the nuts, flatwashers,
parking brake. lockwashers and capscrews. Torque the capscrews
The range shift solenoid valve is a two position four-way refer to SECTION 1-Fasteners and Torque Values.
valve. In its de-energized position, pressurized oil flows to 2. Connect the hydraulic hoses to the ports on the valve as
the “A” port of the range shift actuator, while the “B” port is tagged during removal.
drained to the reservoir along with the axle disconnect
actuator for two wheel drive/high range. When the solenoid 3. Connect the electrical connectors to the valve as tagged
is energized, pressurized oil is directed to the “B” port of the during removal.
range shift actuator and the axle disconnect actuator while
port “A” of the range shift actuator is drained to the reservoir Functional Tests
for four wheel drive/low range. 1. Start and idle engine.
2. With units on outriggers, check for proper two/four wheel
operation.

7
8 5 3 4
7 6 6

1
2
6697-2

2 6697-1

5
1
3

4 FIGURE 2-35

Item Description Item Description

1 Port P - Pressure 5 Port PB - To Park Brake
2 Port T - Tank 6 Solenoid Valve - Range Shift
3 Port A - Range Shift Actuator 7 Solenoid Valve - park Brake
4 Port B - Range Shift Actuator 8 Pressure Switch

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HYDRAULIC SYSTEM RT890E3 SERVICE MANUAL

LOAD SENSE REDUCTION MANIFOLD 3. Remove the capscrews, spring washers, washers and
nuts securing the valve to the frame rail. Remove the
Description valve.

The load sense reduction manifold limits the CPU or load Installation
sense pressure to the piston pump (pump No. 1) to 20,684
1. Secure the valve to the frame rail with the nuts, washers,
kPa/206.8 bar (3000 psi) when the engine is at 1500 rpm or
spring washers and capscrews. Torque the capscrews
lower. The valve is mounted on the left hand carrier frame rail
refer to SECTION 1-Fasteners and Torque Values.
beside the transmission.
2. Connect the hydraulic hoses to the ports on the valve as
The CPU or load sense flow enters the manifold through a
tagged during removal.
0.030 Ø orifice. When the engine is over 1500 rpm, a
normally open two position two-way solenoid valve is de- 3. Connect the electrical connectors or manual control
energized allowing a pressure signal to pass through the levers to the valve as tagged during removal.
manifold to the piston pump (pump No. 1) (see Figure 2-36)
When energized, the normally open two position two-way Functional Tests
valve closes directing the pressure signal to a pressure 1. Start engine and set rpm below 1500.
reducing valve and then to the pump. There is a check valve
between the pressure reducing valve and the outlet keeping 2. Install an accurate capable 5000 psi gauge at the outlet.
the pump signal from leaking off through the pressure operate hoist or boom lift function. The gauge should
reducing valve when the solenoid valve is in the normally read 27,579 kPa/275.7 bar (3000 psi).
open position. 3. Set engine speed above 1500 rpm. The pressure gauge
should read 4000 psi.
Maintenance
Removal
1. Tag and disconnect the electrical connectors or manual
control levers to the valve.
2. Tag and disconnect the hydraulic hoses from the valve.
Cap or plug the lines and ports.

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RT890E3 SERVICE MANUAL HYDRAULIC SYSTEM

4 1

6340-1

3 5

2
1

Item Description
6
1 GP Port - Gauge Port
2 PR1 Valve - Pressure Reducing Valve
3
3 LS-PUMP Port - To Pump No. 1 5
4 DRAIN Port - To Reservoir
5 LS-IN Port - Load Sense In To Manifold
6 SV1 Solenoid Valve - To Pump No.1
Hydraulic Schematic 6340-2

FIGURE 2-36

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HYDRAULIC SYSTEM RT890E3 SERVICE MANUAL

CYLINDERS Maintenance
General General

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

Table 2-4
Wear Ring Gap

Head (or Piston) Size Wear Ring Gap

Inch mm Inch mm
1 to 4.75 25.4 to 120.7 0.125 3.18
5 to 10.0 127.0 to 254.0 0.187 4.75
greater than 10.0 greater than 254.0 0.250 6.35

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

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RT890E3 SERVICE MANUAL HYDRAULIC SYSTEM

Temperature Effects on Hydraulic Cylinders the telescope control lever is activated periodically in the
extend position to mitigate the effects of the cooling oil.
Hydraulic oil expands when heated and contracts when
cooled. This is a natural phenomena that happens to all If a load and the boom is allowed to remain stationary for a
liquids. The coefficient of expansion for API Group 1 period of time and the ambient temperature is cooler than the
hydraulic oil is approximately 0.00043 cubic inches per cubic trapped oil temperature, the trapped oil in the cylinders will
inch of volume for 1°F of temperature change. Thermal cool. The load will lower as the telescope cylinder(s) retracts
contraction will allow a cylinder to retract as the
hydraulic fluid which is trapped in the cylinder cools.
allowing the boom to come in. Also, the boom angle will
decrease as the lift cylinder(s) retracts causing an increase 2
The change in the length of a cylinder is proportional to the in radius and a decrease in load height.
extended length of the cylinder and to the change in
This situation will also occur in reverse. If a crane is set up in
temperature of the oil in the cylinder. For example, a cylinder
the morning with cool oil and the daytime ambient
extended 25 feet in which the oil cools 60°F would retract
temperature heats the oil, the cylinders will extend in similar
approximately 7 3/4 inches (see chart below). A cylinder
proportions.
extended 5 feet in which the oil cools 60°F would only retract
approximately 1 1/2 inches. The rate at which the oil cools The chart below has been prepared to assist you in
depends on many factors and will be more noticeable with a determining the approximate amount of retraction/extension
larger difference in oil temperature verses the ambient that may be expected from a hydraulic cylinder as a result of
temperature. change in the temperature of the hydraulic oil inside the
cylinder. The chart is for dry rod cylinders. If the cylinder rod
Thermal contraction coupled with improper or inadequate
is filled with hydraulic oil, the contraction rate is somewhat
lubrication or improper wear pad adjustments and operation
greater.
at low boom angles may, under certain conditions, cause a
“stick-slip” condition in the boom. This “stick-slip” condition NOTE: Operators and service personnel must be aware
could result in the load not moving smoothly. Proper boom that load movement, as a result of this phenomena,
lubrication and wear pad adjustment is important to permit can be easily mistaken as leaking cylinder seals or
the boom sections to slide freely. Slow movement, of the faulty holding valves. If leaking seals or faulty
boom may be undetected by the operator unless a load is holding valves are suspected to be the problem,
suspended for a long period of time. To minimize the effects refer to Service Bulletin 98-036 dealing with testing
of thermal contraction or “slip stick”, it is recommended that telescope cylinders.

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HYDRAULIC SYSTEM RT890E3 SERVICE MANUAL

BOOM DRIFT CHART (Cylinder length change in inches)

3 3
Coeff. = 0.00043 (in /in / °F)
STROKE Temperature Change (°F)
(FT.) 10 20 30 40 50 60 70 80 90 100
5 0.26 0.52 0.77 1.03 1.29 1.55 1.81 2.06 2.32 2.58
10 0.52 1.03 1.55 2.06 2.58 3.10 3.61 4.13 4.64 5.16
15 0.77 1.55 2.32 3.10 3.87 4.64 5.42 6.19 6.97 7.74
20 1.03 2.06 3.10 4.13 5.16 6.19 7.22 8.26 9.29 10.32
25 1.29 2.58 3.87 5.16 6.45 7.74 9.03 10.32 11.61 12.90
30 1.55 3.10 4.64 6.19 7.74 9.29 10.84 12.38 13.93 15.48
35 1.81 3.61 5.42 7.22 9.03 10.84 12.64 14.45 16.25 18.06
40 2.06 4.13 6.19 8.26 10.32 12.38 14.45 16.51 18.58 20.64
45 2.32 4.64 6.97 9.29 11.61 13.93 16.25 18.58 20.90 23.22
50 2.58 5.16 7.74 10.32 12.90 15.48 18.06 20.64 23.22 25.80
55 2.84 5.68 8.51 11.35 14.19 17.03 19.87 22.70 25.54 28.38
60 3.10 6.19 9.29 12.38 15.48 18.58 21.67 24.77 27.86 30.96

Length change in inches = Stroke (Ft.) X Temperature Change ( °F) X Coeff. (in3/in3/ °F) X 12 in/ft

Temperature Effects on Hydraulic Cylinders

FIGURE 2-37

Table 2-5 Boom Drift Chart (Cylinder length change in millimeters)

Coeff. = 0.000774 (1/ °C)

STROKE Temperature Change (°C)
(m) 5 10 15 20 25 30 35 40 45 50 55
1.5 5.81 11.61 17.42 23.22 29.03 34.83 40.64 46.44 52.25 58.05 63.86
3 11.61 23.22 34.83 46.44 58.05 69.66 81.27 92.88 104.49 116.10 127.71
4.5 17.42 34.83 52.25 69.66 87.08 104.49 121.91 139.32 156.74 174.15 191.57
6 23.22 46.44 69.66 92.88 116.10 139.32 162.54 185.76 208.98 232.20 255.42
7.5 29.03 58.05 87.08 116.10 145.13 174.15 203.18 232.20 261.23 290.25 319.28
9 34.83 69.66 104.49 139.32 174.15 208.98 243.81 278.64 313.47 348.30 383.13
10.5 40.64 81.27 121.91 162.54 203.18 243.81 284.45 325.08 365.72 406.35 446.99
12 46.44 92.88 139.32 185.76 232.20 278.64 325.08 371.52 417.96 464.40 510.84
13.5 52.25 104.49 156.74 208.98 261.23 313.47 365.72 417.96 470.21 522.45 574.70
15 58.05 116.10 174.15 232.20 290.25 348.30 406.35 464.40 522.45 580.50 638.55
16.5 63.86 127.71 191.57 255.42 319.28 383.13 446.99 510.84 574.70 638.55 702.41
18 69.66 139.32 208.98 278.64 348.30 417.96 487.62 557.28 626.94 696.60 766.26

Length change in mm = Stroke (m) X Temperature Change ( °C) X Coeff. (1/ °C) X 1000 mm/m

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RT890E3 SERVICE MANUAL HYDRAULIC SYSTEM

LIFT CYLINDER NOTE: Arranging discarded seals and rings in the order of
disassembly will aid in installation of new seals and
Description rings. Pay attention to how each seal and ring is
installed to avoid installing replacement seals and
The lift cylinder Figure 2-38 has a bore of 30.48 cm (12.0 rings improperly.
inches). The retracted length of the cylinder from the center
of the barrel bushing to the center of the rod bushing is 438.7 7. Remove the setscrew securing the piston to the rod.
cm (172.75 inches). The extended length of the cylinder from
the center of the barrel bushing to the center of the rod
8. Unscrew the piston from the rod. 2
bushing is 786.7 (309.75 inches). Its stroke is 347.9 cm (137 9. Remove the T-seal from the inside of the piston.
inches). A wiper ring prevents foreign material from entering 10. Remove the head from the rod. Remove the o-ring and
the cylinder. O-rings and other seals prevent internal and the backup ring from the outside of the head.
external leakage.
11. Remove the wear ring, buffer seal, deep Z rod seal,
The cylinder weighs approximately 1274 kg (2809 pounds). backup ring, and wiper ring from the inside of the head.
Maintenance 12. Remove and discard the two threaded inserts from the
head.
Disassembly
13. Remove the head retainer ring from the rod.
NOTE: Any maintenance requiring disassembly of the
cylinders should include replacement of all seals Inspection
and rings. A seal kit will supply the required items. 1. Clean all parts with solvent and dry with compressed air.
1. Disconnect the tube assembly from the holding valve. Inspect all parts for serviceability.

2. Remove the capscrews and washers securing the 2. Inspect the barrel carefully for scoring. If barrel is
holding valve and remove the holding valve from the scored, it must be repaired or replaced.
cylinder barrel. 3. Check piston for damage. If piston is damaged,
3. Remove the two socket head cap screws securing the determine if it can be repaired or must be replaced.
head retainer ring to the head. 4. Inspect rod for straightness. Determine if it can be
4. Using a spanner wrench or chain wrench, unscrew the straightened or must be replaced.
head retainer ring from the barrel.

CAUTION
Before installing new seals and rings, clean all surfaces
DANGER and carefully remove burrs and nicks. Parts displaying
Do not use air pressure to remove the rod. Use only a excessive wear or damage should be replaced.
source of controlled hydraulic oil pressure if the rod is
hard to move. 5. Stone out minor blemishes and polish with a fine crocus
cloth.
CAUTION
Exercise extreme care when handling or setting down the 6. Clean with solvent and dry with compressed air any
rod. Damage to the rod surface may cause unnecessary parts that have been stoned and polished.
maintenance and expense.
Assembly
5. Remove the rod and attached parts from the barrel.
NOTE: Cover the barrel opening to avoid contamination. CAUTION
When installing new seals and rings, avoid stretching
seals or scratching the grooved or gland surfaces. Make
CAUTION sure parts are clean before and during assembly. Make
When removing seals and rings, avoid scratching the sure seals and rings are installed in the proper order.
grooved and gland surfaces.
NOTE: Lubricate seals and rings with clean hydraulic oil.
6. Remove the two hydrolock seals from the outside of the
piston.

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HYDRAULIC SYSTEM RT890E3 SERVICE MANUAL

18
27, 28
19
5 26, 27
24
21
25

20

1 25 23
24

9
10
8
3
13 22
14

6 11
4
15
12 17

16

7397 FIGURE 2-38

Item Description Item Description

1 Barrel 12 Buffer Seal
2 Rod 13 Rod Seal
3 Piston 14 Backup Ring
4 Head 15 Wiper Ring
5 Holding Valve 16 Socket Head Capscrew
6 Retaining Ring 17 Insert
7 Seal Assembly 18 Capscrew
8 T-Seal 19 Flatwasher
9 O-ring 20 Plug
10 Backup Ring 21 Plug
11 Wear Ring 22 Socket Setscrew

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RT890E3 SERVICE MANUAL HYDRAULIC SYSTEM

Item Description
23 Tube Assembly CAUTION
24 Adapter Exercise extreme care when handling the rod. Damage to
the rod surface may cause unnecessary maintenance
25 Plug
and expense. Also, take care to avoid damaging grooved
26 Elbow or gland surfaces or rings or seals during rod insertion.
27 Cap Assembly 2
11. Remove the cover from the barrel. Insert the rod and
28 Adapter attached parts into the barrel with a slight twisting
1. Install head retainer ring on rod. motion.

2. Install two new threaded inserts into head. 12. Install new gasket material to the cylinder head retainer
ring flange as follows.
3. Install the replacement wear ring, buffer seal, deep Z rod
seal, backup ring, and wiper ring in the inside of the a. Clean the barrel and retainer ring with Loctite
head. Make sure the buffer seal’s step is closer to the cleaning solvent 7070 or similar non-chlorinated
deep Z rod seal. Make sure the deep Z rod seal’s rim solvent.
groove is closer to the buffer seal. b. Apply a light coating of Loctite primer N7649 to both
4. Install the replacement o-ring and the backup ring on the surfaces. Allow primer to dry for one to two minutes.
outside of the head. Primer must be dry. Mating of parts should occur
within five minutes.
5. Install the replacement T-Seal in the inside of the piston.
c. Apply gasket material Loctite Master Gasket 518 to
6. Lubricate the rod with clean hydraulic oil. one surface. Partial cure is obtained in four hours,
with full cure in 48 hours.
7. Slide the head, wiper ring end first, onto the rod.
13. Screw the head retainer ring into the barrel and align
8. Screw the piston onto the rod tightly. Secure the piston
holes in retainer ring with holes in head. Install two
with the setscrew.
socket head capscrews. Torque the capscrews 59.6 to
65.0 Nm (44 to 48 pounds-foot).
Hydrolock Piston Seals
14. Using a spanner wrench or chain wrench, continue to
screw the retainer ring/head into place in the barrel.

CAUTION
Do not use air pressure to cycle or pressurize the cylinder.

15. Position the holding valve on the cylinder barrel and

secure with four capscrews and washers. Connect
FIGURE 2-39
tubing to holding valve.
9. Install the replacement hydrolock seals on the outside of 16. Pressurize and cycle the cylinder with hydraulic oil
the piston. Make sure the “vees” on the two hydrolock pressure. Test the cylinder at 41,368.5 kPa/413.6 bar
seals point at each other Figure 2-39. (6000 psi). Check for proper operation and any leakage.
Make repairs as needed.
10. Lubricate all parts freely with clean hydraulic oil.

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HYDRAULIC SYSTEM RT890E3 SERVICE MANUAL

DUAL ROD TELESCOPE CYLINDER

Description CAUTION
When removing seals and rings, avoid scratching
The boom dual rod telescope cylinder (upper telescope grooved and gland surfaces.
cylinder) Figure 2-40 has a 20.9 cm (8.25 inch) bore. The
cylinder is internally ported (rod ported). Oil from the
NOTE: Aligning discarded seals and rings in the order of
telescope control valve is routed to the cylinder by external
disassembly will facilitate installation of new seals
lines. Foreign material is prevented from entering the
and rings.
cylinder rod during retraction by a wiper seal in the head. O-
ring seals prevent internal and external leakage. 3. Remove the hydrolock piston seal to gain access to the
setscrew securing the piston to the outer cylinder rod.
The retracted length of the telescope cylinder is 989.6 cm
(389.64 inch). The cylinder incorporates two cylinder rods 4. Remove the setscrew and unscrew the piston from the
therefore each rod has a separate stroke. One rod has a cylinder rod.
stroke of 795.5 cm (313.19 inches), and one rod has a stroke
5. Remove the remaining hydrolock seal and guide lock
of 804.2 cm (316.62 inches), which provides a combined
seal from the outside of the piston and the o-ring and two
overall stroke of 1599.7 cm (629.81 inches). This gives the
backup rings from the inside of the piston.
cylinder an overall extended length of 2589.4 cm (1019.45
inches) from the end of the cylinder barrel to the center of the 6. Remove the spacer from the rod and remove the wear
attachment fittings on the cylinder rod. ring from the spacer.
7. Remove the cylinder head from the outer rod.
CAUTION 8. Remove the o-ring and backup ring from the outside of
Do not retract the cylinder completely if it is not attached the head and the wear ring, buffer seal, deep Z rod seal,
to the boom. Maintain a spacer that is split or hinged 6.88” backup ring and the wiper ring from the inside of the
long to prevent cylinder from retracting completely. head.
9. Using a spanner wrench, unscrew the inner cylinder
The cylinder weighs approximately 1616 kg (3562 pounds) head from the outer cylinder rod.
wet.

Maintenance CAUTION
Disassembly Do not use air pressure to remove the cylinder rod
assembly. Use only a source of controlled hydraulic oil
NOTE: Any maintenance requiring disassembly of the pressure if the rod is hard to remove.
cylinder should include replacement of all cylinder CAUTION
seals and o-rings.
Exercise extreme care when handling or setting down the
1. Using a spanner wrench, unscrew the outer cylinder cylinder rod. Do not damage the chrome surface.
head from the cylinder barrel.
10. Remove the inner cylinder rod assembly from the outer
cylinder rod and cover the opening to avoid
contamination.
DANGER 11. Remove the hydrolock piston seal to gain access to the
Do not use air pressure to remove the cylinder rod setscrew securing the piston to the inner cylinder rod.
assembly. Use only a source of controlled hydraulic oil
pressure if the rod is hard to remove. 12. Remove the setscrew and unscrew the piston from the
cylinder rod.
CAUTION
Exercise extreme care when handling or setting down the 13. Remove the remaining hydrolock seal from the outside
cylinder rod. Do not damage the chrome surface. of the piston and the o-ring and two backup rings from
the cylinder rod
2. Remove the cylinder rod assembly from the cylinder 14. Remove the spacer from the rod.
barrel and cover the barrel to avoid contamination.
15. Remove the cylinder head from the inner rod.

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RT890E3 SERVICE MANUAL HYDRAULIC SYSTEM

29
30 31

32
33
36 35
34
2
17 28
22
40
39 20 26
21
27
19
37

16
37
38 41
41

10

11 38
10 13
12
13
9 1
14
15 3

4
5
24 4
2
6
25 6 7
8

7398
23
18
FIGURE 2-40

Item Description Item Description

1 Barrel 10 Seal
2 Piston 11 Guidelock Ring
3 Setscrew 12 O-ring
4 Seal 13 Backup Ring
5 Wear Ring 14 Spacer
6 Backup Ring 15 Wear Ring
7 O-ring 16 Rod
8 Spacer 17 Rod
9 Piston 18 Head

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HYDRAULIC SYSTEM RT890E3 SERVICE MANUAL

Item Description 3. Clean all with solvent and dry with compressed air any
parts that have been stoned and polished.
19 Rod Wiper
4. Inspect the barrel for scoring.
20 Rod Seal
21 Backup Ring Assembly

22 Buffer Seal 1. If removed, install the holding valves. Refer to HOLDING

VALVES in this section.
23 Wear Ring
24 O-ring
CAUTION
25 Backup Ring
When installing new seals and rings, clean all surfaces
26 Backup Ring and carefully remove burrs and nicks. Parts displaying
27 Retaining Ring excessive wear or damage should be replaced.

28 Head NOTE: Lubricate new seals and rings with clean hydraulic
29 O-ring oil.
30 Backup Ring NOTE: Locate the gap of wear ring 180 degrees with
respect to each other.
31 Wear Ring
2. Install the wiper ring into the cylinder head.
32 Buffer Seal
33 Rod Seal 3. Install the wear ring into the head.

34 Wiper Ring
35 Backup Ring
36 Retaining Ring
37 Counterbalance Valve
38 Plug
39 Seal
40 Capscrew
41 Adapter 6294

16. Remove the o-ring and backup ring from the outside of Wiper Ring
Backup Ring Buffer Seal
the head and the wear rings, buffer seal, deep Z rod Deep Z Rod Seal
seal, backup ring and the wiper ring from the inside of FIGURE 2-41
the head.
17. If necessary, remove the holding valve from the inner
CAUTION
cylinder rod and from the cylinder barrel.
Improper seal installation can cause faulty cylinder
Inspection operation.

1. Clean all parts with solvent and dry with compressed air. 4. Install the buffer seal, rod seal and backup ring inside
Inspect for damaged or worn parts and replace as the head ensuring the seals are assembled properly and
required. installed in the correct direction (see Figure 2-41).
5. Install the o-ring and backup ring onto the outside of the
CAUTION head.
Clean all surfaces and remove all burrs and nicks before 6. Install the inner cylinder head onto the inner cylinder rod.
installing new seals and rings. Replace all damaged or
worn parts. 7. Install the wear ring onto the spacer and install the
spacer onto the rod.
2. Stone out minor blemishes and polish with fine crocus 8. Install the o-ring and backup rings onto the rod and
cloth. install the piston onto the inner cylinder rod. Secure the
piston in place with the setscrew.

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RT890E3 SERVICE MANUAL HYDRAULIC SYSTEM

14. Install the buffer seal, backup ring, deep Z rod seal and
backup ring inside the head ensuring the seals are
Hydrolock Piston Seals
assembled properly and installed in the correct direction
Figure 2-43.
15. Install the o-ring and backup ring onto the outside of the
outer cylinder head.
16. Install the outer cylinder head onto the outer cylinder 2
rod.
17. Install the wear ring onto the spacer and install the
spacer onto the rod.
FIGURE 2-42
18. Install the o-ring and backup rings into the piston and
9. Install the hydrolock seals onto the piston Figure 2-42. install the piston onto the outer cylinder rod. Secure the
piston in place with the setscrew.

CAUTION Hydrolock Piston Seals

Avoid scratching or damaging the grooved and gland
surfaces or the seals and rings.

10. Lubricate the inner cylinder rod assembly with clean

hydraulic oil and install the rod assembly into the outer
cylinder rod with a slight twisting motion.
11. Using a spanner wrench, secure the inner cylinder head
to the outer cylinder rod.
12. Install the wiper ring into the outer cylinder head.
FIGURE 2-44
13. Install the wear rings into the head.
19. Install the hydrolock seals onto the piston Figure 2-44.

CAUTION
Avoid scratching or damaging the grooved or gland
surfaces or the ring and seals.

20. Lubricate the outer cylinder rod assembly with clean

6293
hydraulic oil and install the rod assembly into the
cylinder barrel with a slight twisting motion.
Wiper Ring Deep Z Seal Buffer Seal
Back-Up Ring 21. Using a spanner wrench, secure the outer cylinder head
Back-Up Seal to the cylinder barrel.

FIGURE 2-43

DANGER
CAUTION Do not use air pressure to cycle or pressurize the cylinder.
Improper installation of seals could cause faulty cylinder
operation. 22. Pressurize and cycle the cylinder with hydraulic oil
pressure. Test the cylinder at 25,855 kPa/258.5 bar
(3750 psi) retracted (rod side) and 25,855 kPa/258.5 bar
(3750 psi) extended (piston side). Check for proper
operation and any leakage.

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HYDRAULIC SYSTEM RT890E3 SERVICE MANUAL

UPPER TELESCOPE CYLINDER 3. Remove the guide lock ring at the top of the piston to
gain access to the setscrew securing the piston to the
Description cylinder rod.

The upper boom telescope cylinder Figure 2-45 has a 16.51 4. Remove the set screw and discard.
cm (5.50 inch) bore and is internally ported (rod ported). Oil 5. Unscrew the piston from the rod.
from the telescope control valve is routed to the cylinder by
external lines. 6. Remove the remaining guide lock ring and the hydrolock
seal assemblies from the outside of the piston.
Foreign material is prevented from entering the cylinder
during rod retraction by a wiper ring in the head and o-ring 7. Remove the o-ring and backup rings from the inside of
seals prevent internal and external leakage. The retracted the piston.
length of the telescope cylinder is 945.8 cm (372.38 inches) 8. Remove the spacer from the rod and the wear ring from
and the extended length is 1738.1cm (684.3 inches) from the the spacer.
end of the barrel to the end of the port block on the rod.
9. Remove the cylinder head from the rod.
10. Remove the o-ring and backup ring from the outside of
CAUTION the cylinder head.
Do not retract the cylinder completely if it is not attached
to the boom. Maintain a spacer that is split or hinged 6.88” 11. Remove the wear ring, buffer seal, backup ring, deep Z
long to prevent cylinder from retracting completely. rod seal and wiper ring from the inside of the head.

Inspection
The cylinder weighs 803 kg (1770 pounds).
1. Clean all parts with solvent and dry with compressed air.
Maintenance Inspect all parts for serviceability.

Disassembly
NOTE: Replace all cylinder seals and o-rings with new
CAUTION
ones anytime the cylinder is disassembled. Clean all surfaces and remove all burrs and nicks.
Replace all damaged or worn parts.
1. Using a chain wrench, unscrew the retaining ring and
head from the cylinder barrel. 2. Stone out minor blemishes and polish with fine crocus
cloth.
3. Clean with solvent and dry with compressed air parts
that have been stoned and polished.
DANGER
Do not use air pressure to remove the cylinder rod. Use 4. Inspect the barrel for scoring.
only controlled hydraulic pressure.
Assembly
CAUTION
Do not damage the cylinder rod chrome surface. 1. If removed, install the holding valve. Refer to VALVES in
this section.
2. Remove the cylinder rod assembly from the cylinder
barrel and cover the barrel to avoid contamination.
CAUTION
Do not scratch the grooved and gland surfaces or
CAUTION damage the seals and o-rings.
Do not scratch the grooved and gland surfaces.
NOTE: Lubricate new seals and rings with clean hydraulic
NOTE: Align old seals in order of removal to facilitate oil. Orient wear ring gaps 180° apart.
installation of new seals. 2. Install the wiper ring, wear ring, buffer seal, backup ring
and rod seal on the inside of the head.

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RT890E3 SERVICE MANUAL HYDRAULIC SYSTEM

12
13

17 14
15
18
20
16 2
11

10
22

21

24
19
4
5
4

23
3 1

8 2

7387
FIGURE 2-45

Item Description Item Description

1 Barrel 13 Backup Ring
2 Piston 14 Wear Ring
3 Setscrew 15 Buffer Seal
4 Seal 16 Rod Seal
5 Guidelock Ring 17 Retaining Ring
6 O-ring 18 Wiper Ring
7 Backup Ring 19 Counterbalance Valve
8 Spacer 20 Backup Ring
9 Wear Ring 21 Seal
10 Rod 22 Capscrew
11 Head 23 Plug
12 O-ring 24 Adapter

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HYDRAULIC SYSTEM RT890E3 SERVICE MANUAL

Hydrolock Piston Seals

6294
Guidelock RIng
Wiper Ring Rod Seal FIGURE 2-47
Buffer Seal
Backup Ring
9. Install the wear ring on the outside of the spacer.
FIGURE 2-46

3. Install the o-ring and backup ring onto the outside of the CAUTION
head. Do not scratch the grooved and gland surfaces or
4. Install the cylinder head onto the cylinder rod. damage the seals and o-rings.
5. Install the spacer onto the cylinder rod. 10. Clean all oil from the threads of the cylinder head and
apply Loctite #290 to the threads.
CAUTION 11. Lubricate the piston seals and cylinder head o-ring with
Improper seal installation could cause faulty cylinder clean hydraulic oil and install the rod assembly into the
operation. cylinder barrel with a slight twisting motion.
12. Using a chain wrench, secure the cylinder head to the
6. Install the o-ring and backup rings into the inside of the cylinder barrel.
piston.
NOTE: Use a new self-locking soft-tip setscrew.
7. Screw the piston onto cylinder rod and secure with a DANGER
new setscrew.
Do not use air pressure to cycle the cylinder. Use only
8. Install the guide lock rings and hydrolock seals onto the controlled hydraulic pressure.
outside of the piston.
13. Pressurize and cycle the cylinder with hydraulic oil
pressure. Test the cylinder at 36,199 kPa/362 bar (5250
psi). Check for proper operation and any leakage. Make
repairs as needed.

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RT890E3 SERVICE MANUAL HYDRAULIC SYSTEM

AXLE OSCILLATION LOCKOUT CYLINDER 7. Using a hoist, extend the rod assembly slowly until the
piston is free of the barrel.
Description 8. Remove the rod and attached parts from the barrel.
The two oscillation lockout cylinders Figure 2-48 each have NOTE: Cover the barrel opening to avoid contamination.
12.7 cm (5 inch) diameter bores. The retracted length of
each cylinder is 48.8 cm (19.25 inches) from the center of the
lug holes to the center of the barrel bushing. The extended
length of each cylinder from the center of the lug holes to the
CAUTION 2
center of the barrel bushing is 65.5 cm (25.8 inches). Its When removing seals and rings, avoid scratching the
stroke is 16.8 cm (6.62 inches). grooved and gland surfaces.

A wiper ring prevents foreign material from entering each 9. Remove the lip seals and wear rings from the outside of
cylinder. O-rings and other seals prevent internal and the piston.
external leakage.
NOTE: Arranging discarded seals and rings in the order of
The cylinder weighs approximately 38.8 kg (85.5 pounds). disassembly will aid in installation of new seals and
rings. Pay attention to how each seal and ring is
Maintenance installed to avoid installing replacement seals and
rings improperly.
Disassembly
10. Remove the head from the rod. Remove the o-ring and
NOTE: Any maintenance requiring disassembly of the backup ring from the outside of the head. Remove the
cylinder should include replacement of all cylinder wear ring, buffer seal, lip seal and wiper ring from the
seals. inside of the head.
1. Clean away all dirt from the head. Place protective
padding around the rod near the head to prevent
Inspection
damaging the chrome. Using a spanner wrench, 1. Inspect the rod. There should be no scratches or pits
unscrew the head from the barrel. deep enough to catch the fingernail. Pits that go to the
base metal are unacceptable. Chrome should be
present over the entire surface of the rod. If lack of
DANGER chrome on rod, the rod should be replaced.
Do not use air pressure to remove the rod. Use only a
2. Inspect rod for straightness. Determine if it can be
source of controlled hydraulic oil pressure if the rod is
straightened or must be replaced.
hard to remove.
CAUTION 3. Inspect the head. Visually inspect the inside bore for
scratching or polishing. Deep scratches are
Exercise extreme care when handling or setting down the
unacceptable. Polishing indicates uneven loading, and
rod. Do not damage the chrome surface.
the bore should be checked for out-of-roundness.
2. Open both ports on the side of the cylinder barrel and 4. Inspect the piston. Visually inspect the outside surface
drain the oil from the cylinder. for scratches or polishing, Deep scratches are
unacceptable. Polishing indicates uneven loading, and
3. Secure cylinder barrel in a chain vise without putting
the diameter should be checked for out-of roundness.
pressure on the side feeder tube preferably in the
vertical position with the rod assembly up. 5. Inspect the barrel carefully for scoring. If barrel is
scored, it must be repaired or replaced.
4. Using a screwdriver, or 1/4 inch wrench, remove the
screw from the head. 6. Thoroughly rinse parts, allow to drain, and wipe with a
lint-free rag. Inspect all parts for serviceability.
5. Remove the grease fitting from the rod
6. Turn the head counterclockwise with a fitted spanner
wrench until the threads disengage. CAUTION
NOTE: Residual oil will spill over the end of the barrel Before installing new seals and rings, clean all surfaces
wh en th e rod as se mbly is ex te nde d. Mak e and carefully remove burrs and nicks. Parts displaying
provisions to contain the oil. excessive wear or damage should be replaced.

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14
17

17
13

4
1 5
2

15
6

12
9
10
11

6731
3
16

FIGURE 2-48

Item Description Item Description

1 Barrel 10 Lip Seal
2 Rod 11 Wiper Ring
3 Head 12 Retainer Ring
4 Lip Seal 13 Bleeder Plug
5 Wear Ring 14 Grease Fitting
6 O-ring 15 Grease Fitting
7 Backup Ring 16 Screw
8 Wear Ring 17 O-ring
9 Buffer Seal

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

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

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HYDRAULIC SYSTEM RT890E3 SERVICE MANUAL

AXLE OSCILLATION LOCKOUT CYLINDER NOTE: Cover the barrel opening to avoid contamination.
(CE OPTION)
Description CAUTION
When removing seals and rings, avoid scratching the
The lockout cylinders Figure 2-49 have 12.7 cm (5 inch) grooved and gland surfaces.
diameter bores. The retracted length of each cylinder is 48.8
cm (19.25 inches) from the center of the lug holes to the NOTE: Arranging discarded seals and rings in the order of
center of the barrel bushing. The extended length of each disassembly will aid in installation of new seals and
cylinder from the center of the lug holes to the center of the rings. Pay attention to how each seal and ring is
barrel bushing is 65.5 cm (25.8 inches). Its stroke is 16.8 cm installed to avoid installing replacement seals and
(6.62 inches). A wiper ring prevents foreign material from rings improperly.
entering each cylinder. O-rings and other seals prevent
internal and external leakage. 8. Remove the hydrolock seals and guidelock ring from the
outside of the piston.
The cylinder weighs approximately 45.3 kg (102 pounds).
9. Remove the head from the rod.
Maintenance 10. Remove the o-ring and backup ring from the outside of
Disassembly the head.

NOTE: Any maintenance requiring disassembly of the 11. Remove the wear ring, buffer seal, rod seal and wiper
cylinder should include replacement of all cylinder ring from the inside of the head.
seals.
Inspection
1. Clean away all dirt from the head. Place protective
1. Inspect the rod. There should be no scratches or pits
padding around the rod near the head to prevent
deep enough to catch the fingernail. Pits that go to the
damaging the chrome. Using a spanner wrench,
base metal are unacceptable. Chrome should be
unscrew the head from the barrel.
present over the entire surface of the rod. If lack of
chrome on rod, the rod should be replaced.
2. Inspect rod for straightness. Determine if it can be
DANGER straightened or must be replaced.
Do not use air pressure to remove the rod. Use only a 3. Inspect the head. Visually inspect the inside bore for
source of controlled hydraulic oil pressure if the rod is scratching or polishing. Deep scratches are
hard to remove. unacceptable. Polishing indicates uneven loading, and
CAUTION the bore should be checked for out-of-roundness.
Exercise extreme care when handling or setting down the 4. Inspect the piston. Visually inspect the outside surface
rod. Do not damage the chrome surface. for scratches or polishing, Deep scratches are
unacceptable. Polishing indicates uneven loading, and
2. Drain the oil from the cylinder. the diameter should be checked for out-of roundness.
3. Secure cylinder barrel in a vise. 5. Inspect the barrel carefully for scoring. If barrel is
4. Remove the grease fitting from the rod scored, it must be repaired or replaced.

5. Turn the head counterclockwise with a fitted spanner 6. Thoroughly rinse parts, allow to drain, and wipe with a
wrench until the threads disengage. lint-free rag. Inspect all parts for serviceability.

NOTE: Residual oil will spill over the end of the barrel
wh en th e r od as se mbly is ex te nde d. Mak e CAUTION
provisions to contain the oil. Before installing new seals and rings, clean all surfaces
6. Using a hoist, extend the rod assembly slowly until the and carefully remove burrs and nicks. Parts displaying
piston is free of the barrel. excessive wear or damage should be replaced.

7. Remove the rod and attached parts from the barrel.

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7
6

3 2
11

5
10
9
8

12
4
14

13

15 1

16 7097 13

14
FIGURE 2-49

Item Description
Item Description 15 Grease Fitting
1 Barrel 16 Plug
2 Piston Rod
7. Stone out minor blemishes and polish with a fine crocus
3 Hydrolock Seal cloth.
4 Guidelock Ring 8. Clean with solvent and dry with compressed air any
5 Head parts that have been stoned and polished.

6 O-ring Assembly
7 Backup Ring
8 Wear Ring CAUTION
9 Buffer Seal When installing new seals and rings, avoid stretching
seals or scratching the grooved or gland surfaces. Make
10 Rod Seal
sure parts are clean before and during assembly. Make
11 Wiper Ring sure seals and rings are installed in the proper order.
12 Grease Fitting
NOTE: Lubricate seals and rings with clean hydraulic oil.
13 Cap
1. Install the replacement wiper ring, rod seal, buffer seal
14 Solenoid Valve and wear ring in the inside of the head.
2. Install the replacement o-ring and backup ring on the
outside of the head.

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HYDRAULIC SYSTEM RT890E3 SERVICE MANUAL

3. Install the hydrolock seals and guidelock ring onto the 8. Lubricate the OD seals on the piston and head with
outside of the piston. clean light oil and lower the assembly into the barrel.
Stop just before the head enters the barrel.
4. Lubricate the rod with clean hydraulic oil.
9. Place a spanner wrench on the head and turn
5. Slide the head, onto the rod. Tap the head with a rubber
counterclockwise until the thread clicks, then reverse
mallet to engage the seals. Push the head about half
direction to clockwise and thread in until there is no gap
way down the length of the rod assembly.
between the head shoulder and top of barrel.
6. Remove the cover from the barrel.

CAUTION
CAUTION Do not use air pressure to cycle or pressurize the cylinder.
Exercise extreme care when handling the rod. Damage to
the rod surface may cause unnecessary maintenance 10. Pressurize and cycle the cylinder with hydraulic oil
and expense. Also, take care to avoid damaging grooved pressure. Test the cylinder at 25,856 kPa/259 bar (3750
or gland surfaces or rings or seals during rod insertion. psi). Check for proper operation and any leakage. Make
repairs as needed.
7. With a hoist, raise the rod assembly back into a vertical
position taking care not to damage the OD seals on the
head and piston.

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TELESCOPE CYLINDER CHARGE VALVE Checking/Setting the Charge Valve Manifold

MANIFOLD (IF EQUIPPED) 1. Install pressure check diagnostic quick disconnect
(Parker PD240) with gauge onto test nipple @ GPA or
Description GPB on the charge valve manifold.
The telescope cylinder charge valve manifold is used in the 2. Boom lift up to achieve a boom angle greater than 35°
telescope cylinder charge system. The charge valve (Boom Telescope cylinder must be fully retracted).
manifold is mounted to the stiffener bracket, which is located
3. With the engine at idle rpm, check to ensure pressure is
2
behind the swivel, that connects the two vertical sections of
the turret together (1, Figure 2-50). 200 psi. If the pressure is low, adjust the pressure
reducing valve (3, Figure 2-51) adjusting stem clockwise
The charge valve manifold (Figure 2-51) consists of a (in). If pressure is higher than specification, adjust the
manifold (1); a spring offset, solenoid controlled, two-way adjustment stem Counter Clockwise (out).
control valve with integral check valve (2); a pressure
reducing valve (3) set to 13.8 bar (200 psi); two check valves 4. Once pressure is set move pressure transducer to the
(4); and a normally-closed pressure switch (5). other (GPA or GPB) diagnostic coupler on the make-up
oil manifold check to ensure the pressure reads the
The telescope cylinder charge valve manifold prevents the same as set in step #3.
boom from retracting due to thermal contraction of the oil in
the telescope cylinders under certain circumstances (refer to 5. Stop engine and remove transducer
Telescope Circuit, page 4-24 for more detailed information).
The charge valve manifold does this by supplying oil to the Maintenance
telescope cylinder extend circuits when the boom is elevated
above 35 degrees. The solenoid valve (2) is energized by the Removal
RCL when the boom angle is greater than 35 degrees, 1. Tag and disconnect the electrical connectors to the
allowing oil to flow through the pressure reducing valve (3) valve.
and on to the telescope extend circuits. Pressure in the
telescope extend circuits is maintained by the two check 2. Tag and disconnect the hydraulic hoses from the valve.
valves (4). The normally-closed pressure switch (5) is Cap or plug the lines and ports.
plumbed into the charge valve manifold and is used to alert 3. Remove the capscrews, nuts and washers securing the
the operator by way of a buzzer and warning indicator if the valve to the turret bracket. Remove the valve.
pressure in the telescope cylinder charge system is less than
approximately 6.9 bar (100 psi). For a schematic of the Installation
telescope cylinder charge system, refer to Figure 2-52.
1. Secure the valve to the crane with the capscrews, nuts
and washers.
2. Connect the hydraulic hoses to the ports on the valve as
tagged during removal.
3. Connect the electrical connectors to the valve as tagged
during removal.
4. Elevate boom above 35 degrees and ensure buzzer
does not sound and telescope cylinder charge indicator
does not illuminate.
5. Check valve and hoses for leaks. Make repairs as
needed.
1

8020-1

FIGURE 2-50

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HYDRAULIC SYSTEM RT890E3 SERVICE MANUAL

5
4

1
4

1
8017
2 3
8017-2

6 7

Item Description
1 Manifold
2 Solenoid Valve
3 Pressure Reducing Valve
4 Check Valves
5 Pressure Switch
6 Gauge Port A
7 Gauge Port B

8017-3

FIGURE 2-51

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RT890E3 SERVICE MANUAL HYDRAULIC SYSTEM

2
2
3
4

8020-2

Item Description
1 Main Directional Control Valve
2 Center Mid/Outer Mid Tele Extend Circuit
3 Inner Mid Tele Extend Circuit
4 Case Drain Manifold
5 Tele Cyl Charge Valve Manifold
6 Swivel
7 Pressure Reducing Sequence Valve

FIGURE 2-52

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HYDRAULIC SYSTEM RT890E3 SERVICE MANUAL

STEER CYLINDER installed to avoid installing replacement seals and

rings improperly.
Description 4. Remove the nut from the rod.
The steer cylinders Figure 2-53 are mounted on the axles, 5. Unscrew the piston from the rod.
two cylinders on each axle. The front and rear steer cylinders
each have 8.89 cm (3.5 inch) diameter bores. The front and 6. Remove the o-ring from the inside of the piston.
rear steer cylinders each have a retracted length of 66.0 cm 7. Remove the head and spacer from the rod.
(26 inches) from bushing center to bushing center. The front
and rear steer cylinders each have an extended length of 8. Remove the o-ring and the backup ring from the outside
95.25 cm (37.5 inches) from bushing center to bushing of the head.
center. Each cylinder has a stroke of 29.21 cm (11.50 9. Remove the wiper ring and rod seal from the inside of
inches). the head.
A wiper ring prevents foreign material from entering each
cylinder. O-rings and other seals prevent internal and Inspection
external leakage.
1. Clean all parts with solvent and dry with compressed air.
The cylinder weighs approximately 20 kg (44 pounds). Inspect all parts for serviceability.
2. Inspect the barrel carefully for scoring. If barrel is
Maintenance
scored, it must be repaired or replaced.
Disassembly 3. Check piston for damage. If piston is damaged,
determine if it can be repaired or must be replaced.
NOTE: Any maintenance requiring disassembly of the
cylinders should include replacement of all seals 4. Inspect rod for straightness. Determine if it can be
and rings. A seal kit will supply the required items. straightened or must be replaced.
1. Using a spanner wrench, unscrew the cylinder head.
CAUTION
Before installing new seals and rings, clean all surfaces
and carefully remove burrs and nicks. Parts displaying
DANGER excessive wear or damage should be replaced.
To prevent serious injury, do not use air pressure to
remove the rod. Use only a source of controlled hydraulic 5. Stone out minor blemishes and polish with a fine crocus
oil pressure if the rod is hard to move. cloth.
6. Clean with solvent and dry with compressed air any
parts that have been stoned and polished.
CAUTION
Exercise extreme care when handling or setting down the Assembly
rod. Damage to the rod surface may cause unnecessary
maintenance and expense.
CAUTION
2. Remove rod and attached parts from the barrel. When installing new seals and rings, avoid stretching
seals or scratching the grooved or gland surfaces. Make
NOTE: Cover the barrel opening to avoid contamination. sure parts are clean before and during assembly. Make
sure seals and rings are installed in the proper order.
CAUTION
When removing seals and rings, avoid scratching NOTE: Lubricate seals and rings with clean hydraulic oil.
grooved and gland surfaces. 1. Install the replacement wiper ring in the head.

3. Remove the wear ring and piston seal from the outside 2. Install the rod seal in the inside of the head.
of the piston. 3. Install the replacement o-ring and the backup ring on the
NOTE: Arranging discarded seals and rings in the order of outside of the head.
disassembly will aid in installation of new seals and 4. Install the cylinder head and spacer onto the rod.
rings. Pay attention to how each seal and ring is
5. Install the replacement o-ring in the inside of the piston.

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4
6
10
7
11
5
8

12
13

14, 15

7405

FIGURE 2-53

Item Description Item Description

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

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HYDRAULIC SYSTEM RT890E3 SERVICE MANUAL

6. Screw the piston onto the rod. NOTE: Lubricate seals and rings with clean hydraulic oil.
7. Install the nut on the rod. 1. Install the replacement wiper ring in the head.
8. Install the seal and wear ring on outside of the piston. 2. Install the rod seal in the inside of the head.
9. Lubricate all parts freely with clean hydraulic oil. 3. Install the replacement o-ring and the backup ring on the
outside of the head.
Inspection
4. Install the cylinder head and spacer onto the rod.
1. Inspect the rod. There should be no scratches or pits
deep enough to catch the fingernail. Pits that go to the 5. Install the replacement o-ring in the inside of the piston.
base metal are unacceptable. Chrome should be 6. Screw the piston onto the rod.
present over the entire surface of the rod. If lack of
chrome on rod, the rod should be replaced. 7. Install the nut on the rod.

2. Inspect rod for straightness. Determine if it can be 8. Install the seal and wear ring on outside of the piston.
straightened or must be replaced. 9. Lubricate all parts freely with clean hydraulic oil.
3. Inspect the head. Visually inspect the inside bore for
scratching or polishing. Deep scratches are CAUTION
unacceptable. Polishing indicates uneven loading, and
Exercise extreme care when handling the rod. Damage to
the bore should be checked for out-of-roundness.
the rod surface may cause unnecessary maintenance
4. Inspect the piston. Visually inspect the outside surface and expense. Also, take care to avoid damaging grooved
for scratches or polishing, Deep scratches are or gland surfaces or rings or seals during rod insertion.
unacceptable. Polishing indicates uneven loading, and
the diameter should be checked for out-of roundness. 10. Remove the cover from the barrel. Insert the rod and
attached parts into the barrel with a slight twisting
5. Inspect the barrel carefully for scoring, scratches and
motion.
pits. There should be no scratches or pits deep enough
to catch the fingernail. If barrel is scored, it must be 11. Using a spanner wrench, tighten the head into the
repaired or replaced. barrel.
6. Thoroughly rinse parts, allow to drain, and wipe with a
lint-free rag. Inspect all parts for serviceability. CAUTION
Do not use air pressure to cycle or pressurize the cylinder.
Assembly
12. Pressurize and cycle the cylinder with hydraulic oil
pressure. Static test the cylinder at 27,579 kPa (275.7
CAUTION bar) (4000 psi). Check for proper operation and any
When installing new seals and rings, avoid stretching leakage. Make repairs as needed.
seals or scratching the grooved or gland surfaces. Make
sure parts are clean before and during assembly. Make
sure seals and rings are installed in the proper order.

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RT890E3 SERVICE MANUAL HYDRAULIC SYSTEM

OUTRIGGER EXTENSION CYLINDER 5. Remove the nut from the rod.

6. Remove the piston, spacer and head from the rod.
Description
7. Remove the o-ring and the backup ring from the outside
The four extension cylinders Figure 2-54 have 63.5 mm (2.5 of the head.
inch) diameter bores. Each cylinder has a retracted length of
238.4 cm ± 30.4 (93.88±12 inches) from the center of the rod 8. Remove the rod seal, wear ring and wiper ring from the
bushing to the center of the barrel bushing. Each cylinder’s
extended length is 446.7 cm (175.88 inches). The stroke of
inside of the head.
2
9. Remove the o-ring from the rod.
each cylinder is 208.2 cm (82 inches).
A wiper ring prevents foreign material from entering each Inspection
cylinder. O-rings and other seals prevent internal and
1. Clean all parts with solvent and dry with compressed air.
external leakage.
Inspect all parts for serviceability.
The cylinder weighs approximately 45.5 kg (100.3 pounds).
2. Inspect the barrel carefully for scoring. If barrel is
scored, it must be repaired or replaced.
Maintenance
3. Check rod’s piston area for damage. If it is damaged,
Disassembly determine if it can be repaired or must be replaced.
NOTE: Any maintenance requiring disassembly of the 4. Inspect rod for straightness. Determine if it can be
cylinders should include replacement of all seals straightened or must be replaced.
and rings. A seal kit will supply the required items.
1. Remove all dirt, grease and other contaminants from
around the ports and the head CAUTION
Before installing new seals and rings, clean all surfaces
and carefully remove burrs and nicks. Parts displaying
excessive wear or damage should be replaced.
DANGER
5. Stone out minor blemishes and polish with a fine crocus
Do not use air pressure to remove the rod. Use only a
cloth.
source of controlled hydraulic oil pressure if the rod is
hard to move. 6. Clean with solvent and dry with compressed air any
CAUTION parts that have been stoned and polished.
Exercise extreme care when handling or setting down the Assembly
rod. Damage to the rod surface may cause unnecessary
maintenance and expense.
CAUTION
2. Using a spanner wrench, unscrew the cylinder head.
When installing new seals and rings, avoid stretching
3. Remove rod and attached parts from the barrel. seals or scratching the grooved or gland surfaces. Make
sure parts are clean before and during assembly. Make
NOTE: Cover the barrel opening to avoid contamination.
sure seals and rings are installed in the proper order.

NOTE: Lubricate seals and rings with clean hydraulic oil.

CAUTION
When removing the seals and rings, avoid scratching the 1. Install the replacement wear ring, rod seal and wiper ring
grooved and gland surfaces. in the inside of the head.
2. Install the replacement o-ring and the backup ring on the
4. Remove the wear rings and piston seal from the outside outside of the head.
of the piston.
3. Install the o-ring onto the rod.
NOTE: Arranging discarded seals and rings in the order of
disassembly will aid in installation of new seals and 4. Lubricate the rod with clean hydraulic oil.
rings. Pay attention to how each seal and ring is 5. Slide the head onto the rod.
installed to avoid installing replacement seals and
rings improperly. 6. Install the spacer and piston on the rod.
7. Install the locknut onto the rod.

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15

6 1

8 5

10

14
11
12

13
7073

4
FIGURE 2-54

Item Description Item Description

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

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8. Install the replacement piston seal and wear rings on the 10. Remove the cover from the barrel. Insert the rod and
outside of the piston. attached parts into the barrel with a slight twisting
motion.
9. Lubricate all parts freely with clean hydraulic oil.
11. Push the head into the barrel.

CAUTION
CAUTION
Exercise extreme care when handling the rod. Damage to
the rod surface may cause unnecessary maintenance Do not use air pressure to cycle or pressurize the cylinder.
2
and expense. Also, take care to avoid damaging grooved
or gland surfaces, rings or seals during rod insertion. 12. Pressurize and cycle the cylinder with hydraulic oil
pressure. Test the cylinder at 24,131.6 kPa (241.3 bar)
(3500 psi). Check for proper operation and any leakage.
Make repairs as needed.

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HYDRAULIC SYSTEM RT890E3 SERVICE MANUAL

OUTRIGGER STABILIZER CYLINDER on a workbench taking care not to damage the surface
of the rod.
Description 6. Cover the open end of the barrel.
The four outrigger stabilizer cylinders Figure 2-55 each have 7. Secure the rod assembly using the pinholes. Do not use
a hollow rod for internal porting. Each cylinder has a 13.9 cm a clamp on the rod working surface.
(5.5 inch) diameter bore. A port block is welded to the rod of
each cylinder and a pilot operated check valve is threaded 8. Using an Allen wrench, remove the setscrew from the
into each port block. The retracted length of the cylinder from piston. The piston seal must be removed to access the
the end of the barrel to the center of the rod’s port block rod setscrew.
bushing is 128.5± 30.8 cm (50.62±.12 inches). The extended
length of the cylinder from the end of the barrel to the center 9. Turn the piston counterclockwise with a fitted spanner
of the rod’s port block rod bushing is 199.6 cm (78.62 ±.12 wrench to remove.
inches). Its stroke is 71.1 cm (28 inches). 10. Remove the spacer and head from the rod by hand.
A wiper ring prevents foreign material from entering the
cylinder. O-rings and other seals prevent internal and
external leakage. CAUTION
When removing seals and rings, avoid scratching the
The cylinder weighs approximately 103.8 kg (228.8 pounds). grooved and gland surfaces.
Maintenance
NOTE: Arranging discarded seals and rings in the order of
Disassembly disassembly will aid in installation of new seals and
rings. Pay attention to how each seal and ring is
NOTE: Any maintenance requiring disassembly of the installed to avoid installing replacement seals and
cylinders should include replacement of all seals rings improperly.
and rings. A seal kit will supply the required items.
11. Remove the o-ring and backup rings from the inside of
1. Open ports and drain the oil from the cylinder. the piston and the seals from the outside of the piston.
12. Remove the o-ring and backup ring from the outside of
the head and the wear rings, seals and wiper ring from
DANGER the inside of the head.
Do not use air pressure to remove the rod. Use only a Inspection
source of controlled hydraulic oil pressure if the rod is
hard to move. 1. Inspect the rod. There should be no scratches or pits
deep enough to catch the fingernail. Pits that go to the
CAUTION base metal are unacceptable. Chrome should be
Exercise extreme care when handling or setting down the present over the entire surface of the rod. If lack of
rod. Damage to the rod surface may cause unnecessary chrome on rod, the rod should be replaced.
maintenance and expense.
2. Inspect rod for straightness. Determine if it can be
2. Secure cylinder barrel in a chain vise preferably in the straightened or must be replaced.
vertical position with the rod assembly at chest level. 3. Inspect the head. Visually inspect the inside bore for
NOTE: Oil or oil/air mixture may rapidly exit out of the ports scratching or polishing. Deep scratches are
during extension. Shield the work area from the unacceptable. Polishing indicates uneven loading, and
exiting oil. the bore should be checked for out-of-roundness.

3. With the ports open, extend the rod assembly with a 4. Inspect the piston. Visually inspect the outside surface
hoist enough to access the top of the head with a for scratches or polishing, Deep scratches are
spanner wrench. Do not extend completely. unacceptable. Polishing indicates uneven loading, and
the diameter should be checked for out-of roundness.
4. Turn the head counterclockwise with a fitted spanner
wrench until the threads disengage. 5. Inspect the barrel carefully for scoring. If barrel is
scored, it must be repaired or replaced.
5. Extend the rod assembly slowly until the piston is free of
the barrel assembly. Place the rod assembly horizontally

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RT890E3 SERVICE MANUAL HYDRAULIC SYSTEM

19
18
19
4
17
17
5
8

15
14

16

3
13
12
11

2
9
6
10 7389 FIGURE 2-55

Item Description Item Description

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

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HYDRAULIC SYSTEM RT890E3 SERVICE MANUAL

6. Thoroughly rinse parts, allow to drain, and wipe with a 11. Lubricate the ID of the head seals with clean light oil and
lint-free rag. Inspect all parts for serviceability. slide the head onto the rod. The head will need to be
tapped on with a rubber mallet to engage the seals.
7. Flush the barrel and fluid tube. Drain and wipe dry with a
Push the head about hal way down the length of the rod.
lint-free cloth. Compressed air may be used to blow out
barrel port. 12. Install the spacer onto the rod with the ID lip at the piston
end.
8. Inspect the bore of barrel for nicks, gouges or scratches.
Replace barrel assembly if any of these conditions exist. 13. Lubricate the ID piston seals with clean light oil and
thread the piston clockwise onto the rod assembly with
the spanner wrench until it bottoms out.
CAUTION
14. Install the setscrew with an Allen wrench until hand tight.
Before installing new seals and rings, clean all surfaces Seat the piston seal bottom ring into the groove.
and carefully remove burrs and nicks. Parts displaying
excessive wear or damage should be replaced. 15. With the hoist, raise the rod assembly into a vertical
position taking care not to damage the OD seals on the
Assembly head and piston.
16. Lubricate the OD seals on the piston and head with
clean light oil and lower the assembly into the barrel.
CAUTION Stop just before the head enters the barrel.
When installing new seals and rings, avoid stretching
seals or scratching the grooved or gland surfaces. Make 17. Place the spanner wrench on the head and turn
sure parts are clean before and during assembly. Make counterclockwise while applying light downward force
sure seals and rings are installed in the proper order. until threads engage. Continue turning counterclockwise
until the thread clicks, the reverse direction to clockwise
NOTE: Lubricate seals and rings with clean hydraulic oil. and thread in until there is no gap between the head
shoulder and the top of the barrel.
NOTE: Leave access to the setscrew hole on the piston by
only partially installing the bottom ring of the piston 18. Instal the setscrew with an Allen wrench until hand tight.
seal into the groove leaving the gap in the ring at 19. Slowly lower the rod down to the fully retracted position.
the hole location.
NOTE: Oil or oil/air mixture may rapidly exit out of the ports
9. Install the wear rings, seals and wiper ring in the inside during extension. Shield the work area from the
of the head and the o-ring and backup ring on the exiting oil.
outside of the head.
20. Pressurize and cycle the cylinder with hydraulic oil
10. Install the o-ring and backup rings in the inside of the pressure. Static pressure test the cylinder at 31,026.4
piston and the seals on the outside of the piston. kPa/310.2 bar (4500 psi) in both directions. Check for
proper operation and any leakage. Make repairs as
needed.

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RT890E3 SERVICE MANUAL HYDRAULIC SYSTEM

CAB TILT CYLINDER NOTE: Cover the barrel opening to avoid contamination.

Description
CAUTION
The cab tilt cylinder Figure 2-56 has a 6.35 cm (2.50 inch)
When removing seals and rings, avoid scratching the
diameter bores. The retracted length of each cylinder is
grooved and gland surfaces.
53.1cm (20.94 inches) from the center of the rod bushing to
the center of the barrel bushing. The extended length of each
cylinder from the center of the rod bushing to the center of 7. Remove the seal from the outside of the piston. 2
the barrel bushing is 73.9 cm (29.1 inches). Its stroke is 20.9 NOTE: Arranging discarded seals and rings in the order of
cm (8.25 inches). disassembly will aid in installation of new seals and
A wiper ring prevents foreign material from entering each rings. Pay attention to how each seal and ring is
cylinder. O-rings and other seals prevent internal and installed to avoid installing replacement seals and
external leakage. rings improperly.

The cylinder weighs approximately 9.07 kg (19.9 pounds- 8. Loosen and remove the nut securing the piston.
foot). Remove the piston from the rod.
9. Remove the o-ring from the inside of the piston.
Maintenance
10. Remove the head from the rod. Remove the o-ring and
Disassembly backup ring from the outside of the head.
NOTE: Any maintenance requiring disassembly of the 11. Remove the wiper ring and the rod seal from the inside
cylinders should include replacement of all seals of the head.
and rings. A seal kit will supply the required items.
Inspection
1. Secure the cylinder in a clean work area by use of
clamps or a chain vise to prevent rolling. 1. Clean all parts with solvent and dry with compressed air.
Inspect for damaged or worn parts and replace as
2. Retract the cylinder fully to avoid damaging the rod required.
during removal.
NOTE: Mark or note the piston and head relationship to the
rod and barrel.
CAUTION
Clean all surfaces and remove all burrs and nicks before
3. Clean away all dirt from the head. Place protective installing new seals and rings. Replace all damaged or
padding around the rod near the head to prevent worn parts.
damaging the chrome during head removal.
2. Stone out minor blemishes and polish with fine crocus
cloth.

DANGER 3. Clean all with solvent and dry with compressed air any
parts that have been stoned and polished.
Do not use air pressure to remove the rod. Use only a
source of controlled hydraulic oil pressure if the rod is 4. Inspect the barrel for scoring.
hard to move.
Assembly
CAUTION
Exercise extreme care when handling or setting down the
rod. Damage to the rod surface may cause unnecessary CAUTION
maintenance and expense.
When installing new seals and rings, clean all surfaces
and carefully remove burrs and nicks. Parts displaying
4. Position the rod mount with the ports facing down. excessive wear or damage should be replaced.
5. Using a means of collecting the oil, remove the port
plugs and allow cylinder to drain. NOTE: Lubricate new seals and rings with clean hydraulic
oil.
6. Rapidly pull the rod against the head to free it. Remove
rod and attached parts from the barrel. Place the rod on 1. Install the replacement wiper ring into the head.
a surface that will not damage the chrome or allow the
2. Install the rod seal in the inside of the head. Make sure
rod assembly to drop.
the lips of the seal face the piston.

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HYDRAULIC SYSTEM RT890E3 SERVICE MANUAL

8
6 9
5
4
3

11

10

6722

FIGURE 2-56

Item Description Item Description

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

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RT890E3 SERVICE MANUAL HYDRAULIC SYSTEM

3. Install the o-ring and backup ring onto the outside of the 10. Remove the cover from the barrel. Insert the rod and
head. attached parts into the barrel with a slight twisting
motion.
4. Install the o-ring in the inside of the piston.
11. Push the head into the barrel. Torque the head 27.1 Nm
5. Lubricate the rod with clean hydraulic oil.
(20 pounds-foot).
6. Slide the head, larger OD end first, onto the rod.
7. Install the piston onto the rod. Secure the piston with the CAUTION 2
nut. Lubricate the threads and torque the nut to 176.2 ±
Do not use air pressure to cycle or pressurize the cylinder.
6.7 Nm (130 ± 5 pounds-foot).
8. Install the seal on the outside of the piston. 12. Pressurize and cycle the cylinder with hydraulic oil
pressure. Test the cylinder at 20,684 kPa/206.8 bar
9. Lubricate all parts freely with clean hydraulic oil.
(3000 psi). Check for proper operation and any leakage.
Make repairs as needed.
CAUTION
Exercise extreme care when handling the rod. Damage to
the rod surface may cause unnecessary maintenance
and expense. Also, take care to avoid damaging grooved
or gland surfaces or rings or seals during rod insertion.

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HYDRAULIC SYSTEM RT890E3 SERVICE MANUAL

COUNTERWEIGHT REMOVAL CYLINDER 5. Remove the wear ring from the outside of the piston to
gain access to the setscrew.
Description NOTE: Arranging discarded seals and rings in the order of
The counterweight removal cylinder Figure 2-57 7.62 cm disassembly will aid in installation of new seals and
(3.0 inch) diameter bore. The retracted length of the cylinder rings. Pay attention to how each seal and ring is
is 23.4 cm (9.25 inches) from the center of the rod bushing to installed to avoid installing replacement seals and
the center of the barrel bushing. The extended length of the rings improperly.
cylinder is 86.9 cm (34.25 inches). The stroke of the cylinder 6. Loosen the piston’s setscrew. Remove the piston from
is 63.5 cm (25 inches). the rod.
A wiper ring prevents foreign material from entering each 7. Remove the other wear ring and seal from the outside of
cylinder. O-rings and other seals prevent internal and the piston.
external leakage.
8. Remove the o-ring from the inside of the piston.
The cylinder weighs approximately 42.63 kg (93.9 pounds).
9. Remove the head and spacer from the rod.
Maintenance 10. Remove the o-ring and backup ring from the outside of
Disassembly the head. Remove the o-ring, seal and wiper ring from
the inside of the head.
1. Remove the capscrews and washers securing the
cylinder in the cylinder assembly tube. Inspection
NOTE: Any maintenance requiring disassembly of the 1. Inspect the rod. There should be no scratches or pits
cylinders should include replacement of all seals deep enough to catch the fingernail. Pits that go to the
and rings. A seal kit will supply the required items. base metal are unacceptable. Chrome should be
present over the entire surface of the rod. If lack of
2. Remove the counterbalance valves from the port block. chrome on rod, the rod should be replaced.
3. Clean away all dirt from the head. Place protective 2. Inspect rod for straightness. Determine if it can be
padding around the rod near the head to prevent straightened or must be replaced.
damaging the chrome during head removal. Using a
spanner wrench, unscrew the head from the barrel. 3. Inspect the head. Visually inspect the inside bore for
scratching or polishing. Deep scratches are
unacceptable. Polishing indicates uneven loading, and
the bore should be checked for out-of-roundness.
DANGER 4. Inspect the piston. Visually inspect the outside surface
Do not use air pressure to remove the rod. Use only a for scratches or polishing, Deep scratches are
source of controlled hydraulic oil pressure if the rod is unacceptable. Polishing indicates uneven loading, and
hard to move. the diameter should be checked for out-of roundness.
CAUTION 5. Inspect the barrel carefully for scoring. If barrel is
Exercise extreme care when handling or setting down the scored, it must be repaired or replaced.
rod. Damage to the rod surface may cause unnecessary
6. Thoroughly rinse parts, allow to drain, and wipe with a
maintenance and expense.
lint-free rag. Inspect all parts for serviceability.
4. Rapidly pull the rod against the head to free it. Remove
rod and attached parts from the barrel.
CAUTION
NOTE: Cover the barrel opening to avoid contamination. Before installing new seals and rings, clean all surfaces
and carefully remove burrs and nicks. Parts displaying
excessive wear or damage should be replaced.
CAUTION
When removing seals and rings, avoid scratching the 7. Stone out minor blemishes and polish with a fine crocus
grooved and gland surfaces. cloth.
8. Clean with solvent and dry with compressed air any
parts that have been stoned and polished.

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RT890E3 SERVICE MANUAL HYDRAULIC SYSTEM

1
2

16

7 3
5
8
4 12
7
11 15
9

10

14

13

7063

FIGURE 2-57

Item Description Item Description

1 Barrel 9 O-ring
2 Rod 10 Backup Ring
3 Piston 11 Seal
4 Spacer 12 Wiper Ring
5 Head 13 Counterbalance Valve
6 O-ring 14 Plug
7 Wear Ring 15 O-ring
8 Seal 16 Setscrew

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HYDRAULIC SYSTEM RT890E3 SERVICE MANUAL

Assembly

CAUTION
CAUTION Exercise extreme care when handling the rod. Damage to
When installing new seals and rings, avoid stretching the rod surface may cause unnecessary maintenance
seals or scratching the grooved or gland surfaces. Make and expense. Also, take care to avoid damaging grooved
sure parts are clean before and during assembly. Make or gland surfaces or rings or seals during rod insertion.
sure seals and rings are installed in the proper order.
11. Remove the cover from the barrel. Insert the rod and
NOTE: Lubricate seals and rings with clean hydraulic oil. attached parts into the barrel with a slight twisting
motion.
1. Install the replacement o-ring, seal and wiper ring in the
inside of the head. 12. Clean all oil from the threads of the head. Coat the
threads with an anti-seize compound (Never-Seez paste
2. Install the replacement o-ring and backup ring on the lubricant or similar lubricant). Using a chain wrench,
outside of the head. screw the head into place on the barrel so its larger
3. Install the replacement o-ring in the inside of the piston. outside diameter end is flush with the end of the barrel.

4. Install one replacement wear ring on the outside of the 13. Check the inside of the port block for any sharp edges or
piston. Leave the other wear ring off for now so there is burrs and remove as necessary with emery cloth.
still access to the piston’s setscrew hole. 14. Lubricate the counterbalance valves with clean
5. Lubricate the rod with clean hydraulic oil. hydraulic oil.

6. Slide the head, larger outside diameter end first, onto 15. Carefully install the counterbalance valves into the
the rod. cylinder port block until fully seated.

7. Slide the spacer onto the rod.

8. Screw the piston onto the rod until it can go no further. CAUTION
Hold the piston in place with the setscrew. Do not use air pressure to cycle or pressurize the cylinder.
9. Install the other replacement wear ring on the outside of 16. Pressurize and cycle the cylinder with hydraulic oil
the piston over the setscrew. pressure. Static test the cylinder at 20,684 kPa/206.8
10. Lubricate all parts freely with clean hydraulic oil. bar (3000 psi). Check for proper operation and any
leakage. Make repairs as needed.
17. Install the cylinder into the cylinder assembly tube and
secure with the washers and capscrews. Torque the
capscrews 120 to 130 Nm (88 to 96 pounds-foot).

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RT890E3 SERVICE MANUAL HYDRAULIC SYSTEM

COUNTERWEIGHT PIN CYLINDER 5. Remove the wear ring and seal from the outside of the
piston and o-ring from the inside of the piston.
Description 6. Remove the head and spacer from the rod.
The counterweight pin removal cylinder Figure 2-58 has a 7. Remove the o-ring and the backup ring from the outside
bore of 7.62 cm (3.0 inches). The retracted length of the of the head. Remove the spacer, seal and wiper ring
cylinder is 96.5 cm (38 inches). The extended length of the from the inside of the head.
cylinder is 127 cm (50 inches). Its stroke is 30.4 cm (12
inches). 8. Repeat steps 1 through 7 for the remaining rod 2
assembly.
A wiper ring prevents foreign material from entering the
cylinder. O-rings and other seals prevent internal and Inspection
external leakage.
1. Inspect the rod. There should be no scratches or pits
The cylinder weighs approximately 31.75 kg (69.9 pounds). deep enough to catch the fingernail. Pits that go to the
base metal are unacceptable. Chrome should be
Maintenance present over the entire surface of the rod. If lack of
chrome on rod, the rod should be replaced.
Disassembly
2. Inspect rod for straightness. Determine if it can be
NOTE: Any maintenance requiring disassembly of the straightened or must be replaced.
cylinders should include replacement of all seals
and rings. A seal kit will supply the required items. 3. Inspect the head. Visually inspect the inside bore for
scratching or polishing. Deep scratches are
1. Using a spanner wrench, unscrew the rod end from the unacceptable. Polishing indicates uneven loading, and
rod. the bore should be checked for out-of-roundness.
4. Inspect the piston. Visually inspect the outside surface
for scratches or polishing, Deep scratches are
DANGER unacceptable. Polishing indicates uneven loading, and
the diameter should be checked for out-of roundness.
Do not use air pressure to remove the rod. Use only a
source of controlled hydraulic oil pressure if the rod is 5. Inspect the barrel carefully for scoring. If barrel is
hard to move. scored, it must be repaired or replaced.
CAUTION 6. Thoroughly rinse parts, allow to drain, and wipe with a
Exercise extreme care when handling or setting down the lint-free rag. Inspect all parts for serviceability.
rod. Damage to the rod surface may cause unnecessary
maintenance and expense.
CAUTION
2. Using a spanner wrench, unscrew the head from the Before installing new seals and rings, clean all surfaces
barrel. and carefully remove burrs and nicks. Parts displaying
3. Remove the rod and attached parts from the barrel. excessive wear or damage should be replaced.

NOTE: Cover the barrel opening to avoid contamination. 7. Stone out minor blemishes and polish with a fine crocus
cloth.
8. Clean with solvent and dry with compressed air any
CAUTION parts that have been stoned and polished.
When removing seals and rings, avoid scratching the
grooved and gland surfaces. Assembly

NOTE: Arranging discarded seals and rings in the order of

disassembly will aid in installation of new seals and CAUTION
rings. Pay attention to how each seal and ring is When installing new seals and rings, avoid stretching
installed to avoid installing replacement seals and seals or scratching the grooved or gland surfaces. Make
rings improperly. sure parts are clean before and during assembly. Make
4. Remove the locknut and unscrew the piston from the sure seals and rings are installed in the proper order.
rod.
NOTE: Lubricate seals and rings with clean hydraulic oil.

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HYDRAULIC SYSTEM RT890E3 SERVICE MANUAL

2
15
14 6 12
11

10 5
8
4
7
13

10

11 9
1

7
12

5
14
8
13

2
6
4

3
15

7062

FIGURE 2-58

1 Barrel 9 Piston Seal

2 Rod 10 Wear Ring
3 Rod End 11 O-ring
4 Piston 12 Backup Ring
5 Spacer 13 Rod Seal
6 Head 14 Wiper Ring
7 Nut 15 O-ring
8 O-ring

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RT890E3 SERVICE MANUAL HYDRAULIC SYSTEM

1. Install the replacement spacer, seal and wiper ring in the 10. Remove the cover from the barrel. Insert the rod and
inside of the head. attached parts into the barrel with a slight twisting
motion.
2. Install the replacement o-rings and the backup ring on
the outside of the head. 11. Install new gasket material to the cylinder head retainer
ring flange as follows.
3. Install the replacement o-ring in the inside of the piston.
12. Screw the head into the barrel.
4. Install the wear ring and piston seal on the outside of the
piston. 13. Using a spanner wrench, continue to screw the head 2
into place in the barrel.
5. Lubricate the rod with clean hydraulic oil.
14. Repeat steps 1 through 13 for the remaining rod
6. Slide the head, wiper ring end first, onto the rod.
assembly.
7. Install the spacer on the rod.
8. Screw the piston onto the rod tightly. CAUTION
9. Lubricate all parts freely with clean hydraulic oil. Do not use air pressure to cycle or pressurize the cylinder.

15. Pressurize and cycle the cylinder with hydraulic oil

CAUTION pressure. Static test the cylinder at 20,685 kPa/206.8
Exercise extreme care when handling the rod. Damage to bar (3000 psi). Check for proper operation and any
the rod surface may cause unnecessary maintenance leakage. Make repairs as needed.
and expense. Also, take care to avoid damaging grooved
or gland surfaces or rings or seals during rod insertion.

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HYDRAULIC SYSTEM RT890E3 SERVICE MANUAL

PARK BRAKE CYLINDER cylinder’s spring to extend, retracting the cylinder lever, and
applying the park brake to hold the crane in place. When the
Description operator positions the PARK BRAKE switch to OFF, the park
brake solenoid valve energizes and opens the valve to apply
The park brake cylinder, mounted on the front axle, releases hydraulic force to the cylinder’s piston. This allows the piston
and applies the park brake. The park brake cylinder consists to compress the spring, extend the cylinder lever, and
of a hydraulic cylinder and a lever. When the operator release the park brake.
positions the PARK BRAKE switch to ON, the park brake
solenoid valve de-energizes and closes the valve, removing
hydraulic force from the cylinder’s piston. This allows the

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RT890E3 SERVICE MANUAL ELECTRIC SYSTEM

SECTION 3
ELECTRIC SYSTEM

SECTION CONTENTS
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Battery Replacement . . . . . . . . . . . . . . . . . . . . . . 3-12
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Relay Panel Component Replacement . . . . . . . . 3-12
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Instrument Replacement . . . . . . . . . . . . . . . . . . . 3-13
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Switch Replacement . . . . . . . . . . . . . . . . . . . . . . 3-13
Relay Panel and Fuse Panel . . . . . . . . . . . . . . . . 3-1 Windshield Wiper Assembly Replacement . . . . . 3-14
Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Windshield Washer Assembly Replacement . . . . 3-15
Skylight Wiper Assembly Replacement . . . . . . . . 3-16
3
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
General Troubleshooting . . . . . . . . . . . . . . . . . . . 3-6 Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . 3-16
Troubleshooting Swivel-Caused Electrical Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Strobe Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Connector Troubleshooting . . . . . . . . . . . . . . . . . 3-6 Spotlight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Control Module Diagnostic Light . . . . . . . . . . . . . . 3-9 Boom Mounted Floodlights . . . . . . . . . . . . . . . . . 3-17
Alternator/Charging System Troubleshooting . . . 3-10 Rear View Mirror . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Alternator Replacement . . . . . . . . . . . . . . . . . . . 3-11 Air Conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Starter Replacement . . . . . . . . . . . . . . . . . . . . . . 3-11

DESCRIPTION Batteries
General The batteries are located in a box on the left side of the crane
behind the hydraulic oil cooler. The batteries are the
The electrical system is 12-volt operation with 12-volt maintenance free type and completely sealed except for a
starting, consisting of an alternator and two lead-acid small vent hole in the side. The vent hole allows what small
batteries. The system is single wire negative ground return amount of gases that are produced in the battery to escape.
type, using the machine’s structure as ground. On some batteries, a test indicator located on the top of the
battery is used to determine if the battery can be tested in
Electrical power is transferred to and from the carrier and
case of a starting problem.
superstructure through the electrical swivel via CANbus
system. The superstructure control module is located behind Relay Panel and Fuse Panel
the front console in the cab and the carrier control module is
located behind the hydraulic oil cooler on left side of the Most electrical circuits are protected by the components of
machine. For more detailed information on the electrical the relay panel assembly and the fuse panel.
swivel, refer to SECTION 6.
The relay panel assembly contains 2 relays, a terminal block
Alternator with 3 diodes, and a buzzer. It is located in front of the front
console in the cab. Access is gained by removing the front
The alternator is mounted on the engine and is belt driven. It console cover.
is a 130 ampere alternator with an integral transformer -
The fuse panel is located in front of the swing lock control
rectifier unit. When the engine is running, and the alternator
handle and contains 20 fuses. To gain access to the fuses,
is turning, the alternator’s 12-volt output terminal supplies
remove the snap on cover. A decal in the cover identities
the crane’s electrical circuits. The output terminal also
each fuse and the function. Fuses 1, 2, 3, 4, 5, 6, 7 and 8 are
supplies the voltage to recharge the batteries and maintains
energized when the battery is connected. When the battery
them at a full state of charge.
is connected and the ignition switch is in the ignition (run) or
accessory power position, fuses 9-12 and 20 are energized
through ACC relay #1 and 13-19 are energized through ACC
relay #2.

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ELECTRIC SYSTEM RT890E3 SERVICE MANUAL

• Fuse 9 protects the beacon lights, drive select switch,

park brake and differential lock.
• Fuse 10 - not used.
• Fuse 11 protects the cab circulating fan and skylight
wiper.
• Fuse 12 protects the defroster fan.
• Fuse 13 protects the crane function switch, seat switch,
armrest switch, swing brake switch, swing brake release
solenoid, and swing hi speed solenoid.
• Fuse 14 protects the indicator lights, gauge circuits,
outrigger controls, engine switches, throttle switch,
buzzer, and cab tilt/drive enable switch.
• Fuse 15 protects the ACC outlet, electrical loads shall
not exceed 8 amps.
• Fuse 16 protects the RCL circuit, the RCL lockout
circuits, and inner mid and outer mid extend and retract
solenoids when in manual mode.
• Fuse 17 protects the optional RCL 3rd wrap indicator
lamp, RCL relay box, boom telescope switches, auxiliary
hoist hi speed and down solenoids, and main hoist hi
speed and down solenoid.

6633 • Fuse 18 protects the main and auxiliary hoist rotation

FIGURE 3-1
indicators and thumb thumpers.
The following fuse assignments apply: • Fuse 19 protects the heater and optional A/C fan
• Fuse 1 protects the work light circuit. motors.
• Fuse 2 is provided for customer additions with an 8 amp • Fuse 20 protects the optional A/C condenser fans.
max load • Fuses 51, 52 and 53 are inside the battery box
• Fuse 3 protects dome/spot light. compartment located behind the oil cooler on the left
side of the crane. These fuses protect the superstructure
• Fuse 4 protects the turn signal, panel lights, brake and electrical power system.
switch lights.
• Fuses 54 and 55 are under the engine hood on the right
• Fuse 5 protects the spare. side of engine on frame rail. These protect the engine
• Fuse 6 protects the ECM power. grid heaters.

• Fuse 7 protects the boom flood lights. • Fuses 56, 57, 58, 59, 60, and 61 are located inside the
battery box compartment located behind the oil cooler
• Fuse 8 protects the ignition, start, transmission shifter on the left side of crane. These fuses protect the
and accessories. Cummins ECM and carrier control module.

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RT890E3 SERVICE MANUAL ELECTRIC SYSTEM

3
2

6312-3
6635-2
1
FIGURE 3-2

the engine hood on the right side of machine on the frame

rail.
Item Description
1 Battery Box For the start relay coil to energize, the battery must be
connected. The coil of the start relay (K301) is energized
2 Battery Disconnect Switch when the transmission is in neutral and the ignition switch is
3 Fuse Mounting Bracket at START (2) position.
The coil of the accessory relays (K1 and K2) are energized
Relays when the ignition switch is at the RUN (1) or ACC (3)
The crane has 5 relays which control many of its functions. position.
Relays K1 and K2, the accessory power relays, are located For the grid heater relay coils to energize, the battery must
in the cab under the front console cover on the relay panel be connected and signals from the engine ECM must be
assembly. Relays K601, K602, and K301 are located under sent.

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ELECTRIC SYSTEM RT890E3 SERVICE MANUAL

Engine Relay Panel

Engine Relay Panel

6121-1

6635-1

Grid Heater Positive

Connection

Carrier Harness Assembly Diagnostic

Connector

Hourmeter
6312-1

Note Diode
Polarity
D6 D5
D7 D4

Cab
ACC Relay #2
(K2)

Buzzer
ACC Relay #1
Relay
(K1)
Panel

Buss Bar
6636
FIGURE 3-3

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RT890E3 SERVICE MANUAL ELECTRIC SYSTEM

MAINTENANCE • Cracked, damaged, or badly corroded battery terminal

connections.
General • Inspect all machine ground connections for damaged
Electrical system maintenance includes troubleshooting and terminals or excessive corrosion.
replacement of damaged components. Observe standard • Other signs of significant deterioration.
wiring practices when replacing components.
If any of these conditions exist, evaluate the harness
assemblies for repair or replacement. For replacement of
harness assemblies, refer to your Manitowoc Crane Care
Parts Manual.
DANGER
When possible, ensure the battery is disconnected At the same service interval, visually inspect all Controller
before performing any maintenance on an electrical Area Network (CAN) nodes and electrical junction boxes for
circuit which is not fused. the following: 3
If it is necessary to perform electrical maintenance on • Damaged or loose connectors.
live or hot circuits, remove all rings, watches, and other
• Damaged or missing electrical clamps or tie straps.
jewelry before performing maintenance as serious
burns may result from accidental grounding or shorting • Excessive corrosion or dirt on the junction box
circuits. assemblies.
• Loose junction box mounting hardware.
If any of these conditions exist, address them appropriately.
CAUTION Ambient temperature, humidity and other factors affect the
Never replace original wiring with wiring of a smaller life of electrical harness and cable assemblies. Use the
size (gauge). Fire or other damage to the machine may following information for the inspection and replacement of
result. these assemblies:
• Cranes operating in climate zone “C” should have the
Visual Inspection and Replacement of Electrical harness and cable assemblies replaced after 10,000
Harnesses and Cables hours of service life.
• Cranes operating in climate zones “A” or “B” with high
ambient temperatures could see electrical service life
CAUTION reduced by 25% to 40%. It is recommended to replace
Ensure that the battery cables are disconnected from these assemblies after 8000 hours of service life.
the batteries before loosening any electrical
connections. • Cranes operating in climate zones “D” and “E”, cold
climates, should expect a degradation of mechanical
Visually inspect all electrical harness and cable assemblies properties, long term exposure to these cold
every month or at 250 hours of service life for the following: temperatures will negatively impact service life.
Therefore, it is recommended these electrical harnesses
• Damaged, cut or deteriorated harness loom covering. and cable assemblies be inspected regularly as service
• Damaged, cut or abraded individual wires or cable life may be less than 10,000 hours.
insulation. • Cranes operating in salt water climates could see a
• Exposed bare copper conductors. significant reduction in service life. Therefore it is
recommended for these electrical harnesses and cable
• Kinked, crushed, flattened harnesses or cables. assemblies to be inspected regularly as service life may
• Blistered, soft, degraded wires and cables. be less than 8,000 hours.

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ELECTRIC SYSTEM RT890E3 SERVICE MANUAL

Table 3-1

Zone Classification
A Tropical Moist: All months average above 18° C. Latitude 15° - 25° North and South
B Dry or Arid: Deficient precipitation most of the year. Latitude: 20° - 35° North and South
C Moist Mid-Latitude: Temperature with mild winters. Latitude: 30° - 50° North & South
D Moist Mid-latitude: Cold winters. Latitude 50° - 70° North & South
E Polar: Extremely cold winters and summers. Latitude: 60° - 75° North & South

General Troubleshooting and slip rings, incorrect wiring from the swivel to the
components, incorrect wire size, worn brushes, improper
NOTE: Make voltage checks at terminations when spring tension on the brush assembly, and loose setscrews
components are installed and operating. Make on the slip ring assembly. Refer to the electrical schematic
continuity checks (with batteries disconnected) and wiring diagram for slip ring connections and amperages.
when components are isolated or removed.
Troubleshoot per the following guidelines: Connector Troubleshooting
1. First, use reported symptoms to identify a problem or a The cause of an electrical problem may be a loose or
suspect component. corroded connection in the pin or socket connectors. Check
2. Test the suspect component per instructions in this the connectors to ensure that the pins and sockets are
section. The instructions identify the circuit breakers and properly seated and engaged. If the pins and sockets show
components and guide you from the easiest and most any signs of corrosion, use a good quality electrical contact
likely problems to the hardest and least likely problems. cleaner or fine sandpaper to clean them. When the pins or
sockets show signs of arcing or burning, it will probably be
3. Using a multimeter, test the circuit for continuity if you necessary to replace them.
suspect a broken circuit or for voltage if you suspect a
power problem. Check the electrical schematic and Refer to the following tables listing tools necessary for
wiring diagram for most accurate wiring information. connector maintenance.

4. If the component proves faulty, replace it with a known Because the pins and sockets are crimped to the wires, it is
working component. If wiring proves faulty, replace it not possible to remove them. Using the proper extraction
with wiring of equal gauge. tool, remove the pin(s) or socket(s) from the plug or
receptacle. Cut the wire as close to the pin or socket as
5. After troubleshooting, test the repaired circuit. Verify the possible. After cutting the pin or socket off, the wire will most
circuit works properly. likely be too short. Using a wire that is too short will allow
pressure to be applied to the pin or socket and wire where
Troubleshooting Swivel-Caused Electrical they are crimped when the pin or socket is inserted in the
Problems plug or receptacle. Add a short length of the same size wire
to the short wire by crimp splice or solder. Use heat
Many crane component electrical troubles can be traced to
shrinkable tubing or other suitable material to insulate the
the electrical swivel. Troubles common to the swivel are
splice.
improper mounting, foreign material between the brushes

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RT890E3 SERVICE MANUAL ELECTRIC SYSTEM

Front Console Superstructure Control

Harness Module

Superstructure
Control Module

Control Module
Mounting Panel
3
Cab Relay
6073-1
Panel
Cab Relay Panel

View A See View A

Superstructure Control
Module Connection

Vehicle Data Link Connection

With Dust Cover
Service Connector
Located Under Panel
12 V Accessory Outlet

S/S
Harness

Swivel
Harness
Console
Harness

Console
Harness
Harness Ground Wires

Seat to Console Harness Connection

S/S Console Module Cab Mounting Bracket
Location Connection
S/S, Swivel and Console
Circuit Breaker and
Harness Ground Wires
Fuse Location
6314 FIGURE 3-4

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ELECTRIC SYSTEM RT890E3 SERVICE MANUAL

Swivel Harness Hydraulic Tank

Swivel

Carrier
Harness
Carrier
Frame

6 Pass
Sockets

6312-5 6312-4

Ground Battery Box

FIGURE 3-5

Table 3-2: AMP Extraction Tool Table

Description AMP Part Number Manitowoc Part Number

14 gauge wire (connectors) 305183 9-999-100176
12 to 8 gauge wire (connectors) 91019-3 9-999-100175
4 to 9 circuit (in-line connectors) 453300-1 N/A
15 circuit (in-line connectors) 458944-1 N/A

Table 3-3:AMP Crimping Tool Table

Description AMP Part Number Manitowoc Part Number

Tool Die Tool Die
14 to 12 gauge wire 69710-1 90145-1 9-999-100177 N/A
10 to 8 gauge wire 69710-1 90140-1 9-999-100177 9-999-100178
4 to 9 circuit
69710-1 90306-1 9-999-100177 N/A
(in-line connectors)
15 circuit
90299-1 -- N/A --
(in-line connectors)

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RT890E3 SERVICE MANUAL ELECTRIC SYSTEM

Table 3-4
Deutsch Extraction Tool Table

Description Deutsch Part Number Manitowoc Part Number

12 gauge wire 114010 9-999-100194
16 gauge wire 0411-204-1605 9-999-100195
8-10 gauge wire 114008 7-902-000012
4-6 gauge wire 114009 7-902-000009
20-24 gauge wire 0411-240-2005 9-999-102084

Table 3-5
Deutsch Crimping Tool Table 3
Description Deutsch Part Number Manitowoc Part Number
12, 14, 16, 18, 20, 22, 24 gauge wire HDT-48-00 9-999-100808
4, 6, 8, 10 gauge wire HDT04-08 9-999-100842

Control Module Diagnostic Light The Electrical System Diagnostic lamp is located in the cab
in the center of the front console. The lamp used in
The front console indicator lights are located in the cab on conjunction with the turnsignal indicator lamps are used for
the center of the front console (see Figure 3-6). The lights troubleshooting the superstructure and carrier control
are linked to various parts of the crane by the control module modules. A red indicator light illuminates giving the operator
and notify the operator when a certain condition occurs a signal that there is a problem with the crane’s operation
during the operation of the crane. When the ignition key is which must be corrected. The Electrical System Diagnostic
turned to the ACC or RUN position the indicator lights go lamp can have four symptoms.
through all operations check to see if the lights are working.
This operation check takes about two seconds in which all of 1. Only the Electrical System Diagnostic lamp is flashing
the lights except for the Hoist Third Wrap, Boom Not Sync, (ignition switch may be in the on or off position) - crane
Low Steer Pressure, and Hose Reel Brake On lights turn on electrical system output diagnostic error, possible open
and off allowing the operator to know that the lights are load, short to battery or short to ground. Use service
working. software to locate error.
2. The Electrical System Diagnostic lamp is on solid and
the turnsignal indicators are flashing (ignition switch may
be in the on or off position) - no communications from
the carrier control module.
3. The Electrical System Diagnostic lamp is not on but the
turnsignal indicators are flashing and the ignition switch
is on - no communication from the engine’s ECM.
4. The Electrical System Diagnostic lamp is not on but the
turnsignal indicators are flashing and the ignition switch
is off - there is communication from the carrier control
module to the superstructure control module but no
communications from the superstructure control module
to the carrier control module.

CAUTION
6234-1 When welding on the crane, disconnect battery cables
to prevent damage to the CANbus system.
FIGURE 3-6

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ELECTRIC SYSTEM RT890E3 SERVICE MANUAL

Alternator/Charging System Load Test

Troubleshooting 1. Refer to the load tester manual for instructions on
performing the load test.
Anytime there is a problem with the charging system the
batteries, alternator and cables should be tested. 2. Connect the load tester to one battery and test.
Required Tools 3. Connect the tester to the other battery and test.

The following is a list of tools needed to diagnose the Proceed to the next test if the batteries passed the load test.
charging system: Replace a battery if it failed the load test.
Voltage at Alternator
Grove Measure voltage from alternator case to output terminal. The
Equipment Example
Part No. meter should read 12.6V or above.
Digital Multimeter Fluke® 177 9999101763
Battery Drain
Carbon Pile Load
Autometer® SB5 9999101765 With a DC ammeter capable of measuring milliamps, and a
Tester
10 amp capability, perform the following test:
Current Clamp Meter Fluke® 336 9999101764
1. Make sure the ignition key is off.
Visual Check 2. Set the meter to the 10 amp position.
• Belts: tight, in good condition, not frayed, cracked or 3. Check for a drain by disconnecting the negative battery
glazed terminals and measuring between the battery post and
• Pulley: tight, aligned with other pulleys, not glazed the cable with the ammeter.

• Alternator mounting bolts and wiring connections: clean This reading should not be more than 80 milliamps (.08 ma)
and tight, no signs of heat damage with all accessories OFF. A higher reading indicates
something is draining the batteries and the system must be
• Batteries: terminals and cables, clean and tight, no troubleshot and repaired.
corrosion or signs of heat damage.
Engine On Tests
Engine Off Tests
Output Voltage Test
Batteries
1. Connect multimeter to negative and positive battery
terminals.
2. Connect ammeter clamp around output wire of
DANGER alternator to the batteries.
Do not smoke or allow sparks or open flame near 3. Start engine and increase speed to 2000 rpm.
batteries, they can explode.
With fully charged batteries and no loads on the system, the
When working with batteries always wear protective
multimeter should read 14V.
clothing, gloves and eye protection. Batteries contain
corrosive liquids that can burn skin and eyes and NOTE: Amperage should be 15 amps or less.
destroy clothing.
Maximum Amperage Test
Remove rings, watches or other jewelry before working
with batteries. A battery can produce a short-circuit 1. Connect an adjustable carbon pile load tester to the
current high enough to weld a ring, or the like, to metal batteries’ positive and negative cables.
causing severe burns 2. Run engine at 2000 rpm.

Disconnect the batteries and test each battery individually. 3. Adjust carbon pile to obtain maximum amperage while
not letting voltage fall below 13 volts.
Check the electrolyte level, if possible
4. Amperage should be within 10 to 15 amps of alternator
Using the multimeter, measure the voltage across the rating; this alternator is rated at 130A, so the meter
terminals. If the voltage is 12.4 V or above, perform the should read 115A to 120A.
following load test. If the voltage is lower than 12.4 V,
recharge the battery(s) before performing the load test. NOTE: If the correct readings were not obtained in the
Engine On Tests, perform the following two tests.

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RT890E3 SERVICE MANUAL ELECTRIC SYSTEM

Voltage Drop Test Installation

Positive Side 1. Inspect the belt. Verify it has no cracks or other damage.
Replace damaged belt as needed.
1. Set the multimeter to the 2 volt range.
2. To install the alternator, the mounting components must
2. Connect the positive (+) lead to the alternator output be tightened in the following sequence.
terminal and the negative (–) lead to the battery positive
terminal or post. Do not connect the meter to the battery a. Alternator-to-alternator bracket capscrew.
cable. b. Lower brace-to-alternator capscrew.
3. Run the engine at 2000 rpm. c. Lower alternator brace-to-water pump capscrew.
4. Load system with carbon pile load or lights and heater d. Torque brace-to-alternator bolt to refer to SECTION
blower. 1-Fasteners and Torque Values.
Allowable drop is.2 to.5 volts. Higher voltage indicates loose, 3. Install the belt on all engine pulleys except the alternator 3
corroded, or broken connections. pulley for now.
Negative Side 4. Turn the tensioner clockwise. Slip the belt onto the
1. Set the multimeter to the 2 volt range. alternator pulley, then carefully return the tensioner to its
normal position so it puts tension on the belt. Make sure
2. Connect the negative (–) lead to alternator case and the the belt is centered on the tensioner.
positive (+) lead to the battery negative terminal or post.
5. Check belt tension at the belt’s longest span (longest
Do not connect the meter to the battery cable.
distance between pulleys). At the center point of the
3. Run the engine at 2000 RPM. longest span, push in on the belt with your thumb. Verify
you can deflect the belt no more than 10 to 13 mm (3/8
4. Load system with carbon pile load or lights and heater
to 1/2 inch) with your thumb. (Or, using a belt tension
blower.
gauge, verify there is 267 to 578 N (60 to 130 lb) of
Allowable drop is.1 to.3 volts. Higher voltage indicates loose, tension on the belt in the middle of its longest span.)
corroded, or broken connections. Replace belt if it is too loose (overstretched).
If any voltage drop is greater than the normal range, 6. Verify tensioner bolt is torqued to 43 Nm (32 ft lb).
troubleshoot the system and repair any problems.
7. Connect the electrical leads to the terminals as tagged
After correcting any problems, perform the Engine On Tests during removal.
again. If satisfactory results are not obtained, remove the
8. Close the engine compartment.
alternator and bench test.
9. Install the ECM power fuse.
Alternator Replacement
10. Turn the battery disconnect switch to the ON position.
Removal
Check
1. Ensure that the key switch has been off for 2 minutes.
1. Run engine. Verify reading of voltmeter on front console
2. Turn the battery disconnect switch to the OFF position. is 12 volts or greater. Make repairs as needed.
3. Remove the ECM power fuse. 2. Continue troubleshooting charging system as needed if
replacement of alternator did not correct problem in
4. Remove negative battery cables.
charging system.
5. Open the engine compartment.
Starter Replacement
6. Tag and disconnect the electrical leads from the
terminals on the alternator. Removal
7. Turn the tensioner above the alternator clockwise to 1. Ensure that the key switch has been off for 2 minutes.
remove tension from the belt. Slip the belt off of the
alternator pulley, then let the tensioner return to its 2. Turn the battery disconnect switch to the OFF position.
normal position. 3. Remove the ECM power fuse.
8. Remove and tag all wires. Remove the alternator link 4. Remove negative battery cables.
capscrew and the mounting capscrew. Remove the
alternator. 5. Open the engine compartment.

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ELECTRIC SYSTEM RT890E3 SERVICE MANUAL

6. Tag and disconnect the electrical leads from the 1. Ensure that the key switch has been off for 2 minutes.
terminals on the starter.
2. Turn the battery disconnect switch to the OFF position.
7. Remove the bolts holding the starter to the mounting
3. Remove the ECM power fuse.
pad. Remove the starter.
4. Remove negative battery cables.
Installation
5. Remove positive battery cables.
1. Place the starter on its mounting pad. Secure the starter
with the bolts. Torque the bolts to 43 Nm (32 ft lb). 6. Tag and disconnect leads from the battery terminals
starting with the negative terminals.
2. Connect the electrical leads to the terminals as tagged
during removal. 7. Remove the nuts and washers from the bracket hold
down rods. Remove the hold down bracket.
3. Close the engine compartment.
8. Remove the batteries.
4. Install the ECM power fuse.
Installation
5. Turn the battery disconnect switch to the ON position.
1. Place the batteries in the battery box.
Check
2. Install the hold down bracket so it can hold down the
1. Try to start the engine. Verify the starter starts the batteries. Secure the bracket (and batteries) to the
engine. bracket hold down rods with nuts and washers.
2. Start engine again, and listen for starter noises. Verify 3. Connect leads to the battery terminals starting with the
there is no abnormal noise indicating the starter’s gear is positive terminals.
meshing properly with the flywheel, that the starter’s
gear hasn’t remained engaged to the flywheel after the 4. Close the battery box cover.
ignition switch is in the ignition (run) position, or some 5. Install the ECM power fuse.
other problem. Install starter properly as needed.
6. Turn the battery disconnect switch to the ON position.
Battery Replacement
Relay Panel Component Replacement
Removal
Accessory Relay
1. Turn the ignition switch to the OFF position.
CAUTION 2. Wait two minutes.
To avoid possible engine fault codes and undesirable
operation, ensure the keyswitch has been off 2 minutes 3. Turn the battery disconnect switch to the OFF position.
before disconnecting batteries. 4. Remove the hardware securing the panel cover and
Disconnect batteries, if machine will be inactive for remove the cover.
over 24 hours.
5. Tag and disconnect the electrical leads from the suspect
relay.
6. Remove the hardware securing the suspect relay to the
relay panel assembly.
7. Install replacement relay on relay panel and secure it
with attaching hardware.
8. Connect the electrical leads to the relay as tagged
during removal.
9. Position the console front cover on the console and
secure with the attaching hardware.
10. Turn the battery disconnect switch to the ON position.
11. Verify proper installation by operating all components
involved with the replacement relay verifying they all
work.
FIGURE 3-7

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RT890E3 SERVICE MANUAL ELECTRIC SYSTEM

Buzzer Replacement 4. Turn the battery disconnect switch to the ON position.

1. Remove the hardware securing the console front cover Check
and remove the cover.
1. Start the engine and verify that the instrument works.
2. Tag and disconnect the electrical leads from the buzzer. (Refer to Operator’s and Safety Handbook.)
3. Unscrew the plastic collar ring from under the panel and 2. As needed, troubleshoot further any system malfunction
remove the buzzer from the hole in the panel. not corrected by repair or replacement of the instrument
4. Install replacement buzzer through the hole in panel and or associated wiring.
secure with the plastic collar ring.
Switch Replacement
5. Connect the electrical leads to the buzzer as tagged
during removal. Rocker Switch
6. Position the console front cover on the console and Removal 3
secure with the attaching hardware.
1. Turn the ignition switch to the OFF position and remove
7. Verify proper operation by positioning the ignition switch the ignition key.
to RUN (1). Buzzer should sound when engine is not
2. Wait two minutes.
running.
3. Turn the battery disconnect switch to the OFF position.
Instrument Replacement
4. Remove the hardware securing the console front cover
Removal and remove the cover.

1. Turn the ignition switch to the OFF position and remove 5. Disconnect the electrical connector or tag and
the ignition key. disconnect the electrical wiring from the switch.

2. Wait two minutes. 6. Depress the plastic tabs on top and bottom of switch and
pull the switch through the front of the console panel to
3. Turn the battery disconnect switch to the OFF position. remove it.
4. Remove the hardware securing the console front cover Inspection
and remove the cover.
1. Visually check the switch for evidence of cracks,
5. Tag and disconnect the electrical wiring from the damaged connections, or other damage. Replace
instrument. damaged switch as needed.
6. Remove the hardware securing the instrument to the 2. Check wiring for damaged insulation or damaged
console panel. (Typically, remove nuts and lockwashers, connectors. Repair as needed.
and then a bracket or clamp.) Pull the instrument
through the front of the console panel and remove it. 3. Perform the following check to determine switch
serviceability.
Inspection
a. Using an ohmmeter, check for continuity between
1. Examine the instrument for cracked and broken lenses. the switch terminals with switch at ON or activated
Check instrument terminals, bracket or clamp, and position(s). Ohmmeter should register zero ohms
mounting studs for damage. Replace damaged (continuity).
instrument; repair or replace damaged connecting
b. Place switch at OFF or deactivated position.
hardware.
Ohmmeter should register infinity (no continuity).
2. Check wiring for damaged insulation or damaged
c. Replace switch if it fails either part of the check.
connectors. Make repairs as needed.
Installation
Installation
1. Place the switch on the front console panel and secure it
1. Put the instrument in place on the console panel and by pushing the switch into the panel, until it snaps into
secure it with the attaching hardware. place.)
2. Connect the electrical wiring to the instrument as 2. Connect the electrical connector or wires to the switch.
marked during removal.
3. Position the console front cover on the console and
3. Position the console front cover on the console and secure with the attaching hardware.
secure with the attaching hardware.

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ELECTRIC SYSTEM RT890E3 SERVICE MANUAL

4. Turn the battery disconnect switch to the ON position. Check

Check 1. Operate the switch per the Operator’s and Safety
Handbook. Verify each of its functions works.
1. Operate the switch per the Operator’s and Safety
Handbook. Verify each of its functions works. 2. As needed, troubleshoot further any system or circuit
malfunction not corrected by repair or replacement of
2. As needed, troubleshoot further any system or circuit
the switch or associated wiring.
malfunction not corrected by repair or replacement of
the switch or associated wiring. Windshield Wiper Assembly Replacement
Ignition and Fan Switch
Removal
Removal
1. Turn the ignition switch to the OFF position and remove
1. Turn the ignition switch to the OFF position and remove the ignition key.
the ignition key.
2. Wait two minutes.
2. Wait two minutes.
3. Turn the battery disconnect switch to the OFF position.
3. Turn the battery disconnect switch to the OFF position.
4. Tag and disconnect the electrical leads from the motor.
4. Remove the hardware securing the console front cover
5. Disconnect the washer hose on the wiper arm (also
and remove the cover.
called the pantograph arm assembly) from the washer
5. Tag and disconnect the electrical leads from the switch. nozzle fitting assembly.
6. On the front of the console panel, remove the nut 6. Remove the cap nut and washer securing the wiper arm
securing the switch to the panel. If removing the fan to the pantograph adapter kit. (The nut and washer are
switch, remove the knob from the switch first. part of the pantograph adapter kit.) Remove the cap nut,
washer, and tapered sleeve securing the wiper arm to
7. Remove the switch from the hole in the panel. the pivot shaft kit. (The nut, washer, and sleeve are part
Inspection of the pivot shaft kit.)

1. Visually check the switch for evidence of cracks, 7. Remove the wiper arm from the pantograph adapter kit
damaged connections, or other damage. Replace and the pivot shaft kit.
damaged switch as needed. 8. Remove the flanged sleeve, nut, and two flat washers
2. Check wiring for damaged insulation or damaged from the pivot shaft kit. (The sleeve, nut, and washers
connectors. Repair as needed. are part of the pivot shaft kit.)

3. Perform the following check to determine switch 9. Remove the two capscrews and lockwashers securing
serviceability. the pantograph adapter kit’s adapter to the cab exterior.
Remove the pantograph adapter kit’s adapter and
a. Using an ohmmeter, check for continuity between gasket.
the switch terminals with switch at ON or activated
position(s). Ohmmeter should register zero ohms 10. Remove attaching hardware to free the windshield wiper
(continuity). motor bracket from the cab interior. Remove the bracket,
with motor and pivot shaft connected, from the cab.
b. Place switch at OFF or deactivated position.
Ohmmeter should register infinity (no continuity). NOTE: You may have to remove or move other parts to get
the bracket and attached parts around the steering
c. Replace switch if it fails either part of the column. Take care not to damage any parts.
check.Installation.
11. Remove the nut to free the wiper motor’s shaft from the
4. Place the switch through the hole in the front console wiper motor kit crank. Remove the three screws and
panel and secure to the front of the panel with the nut. washers to free the wiper motor from its bracket.
Install the knob on the fan switch. Remove the wiper motor from its bracket. Leave the
5. Connect the electrical leads to the switch as tagged other parts attached to the bracket for now.
during removal.
Inspection
6. Position the console front cover on the console and
1. Visually check the motor housing for evidence of cracks
secure with the attaching hardware.
or other damage. Check for excessive shaft end play
7. Turn the battery disconnect switch to the ON position.

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RT890E3 SERVICE MANUAL ELECTRIC SYSTEM

indicating worn or damaged bearings. Replace motor if 5. Secure the pivot shaft to the pantograph adapter with the
damaged. pivot shaft kit’s nut and washers. Install the flanged
sleeve on the pivot shaft.
2. Inspect the wiper blade for serviceability. Replace wiper
blade when worn. 6. Install the wiper arm on the shafts of the pantograph
adapter kit and the pivot shaft kit. Secure the wiper arm
3. Inspect the wiper arm and parts of the linking component
to the pantograph adapter kit shaft with the kit’s own
kits (pantograph adapter kit, pivot shaft kit, wiper motor
washer and cap nut. Secure the wiper arm to the pivot
kit link and crank, wiper motor bracket) for damage.
shaft with the pivot shaft kit’s own tapered sleeve,
Replace as needed.
washer, and cap nut.
Installation 7. Connect the wiper arm’s washer hose to the washer
1. Verify the pivot shaft and the wiper motor kit link and nozzle fitting assembly.
crank are in place on the motor bracket. (Washers and 8. Connect the electrical leads to the wiper motor as
clip springs fasten the link to the pivot pins on the crank marked before removal. 3
and the pivot shaft. The pivot shaft’s pivot pin mounts in
the hole nearest the end of the pivot shaft’s lever.) 9. Turn the battery disconnect switch to the ON position.

2. Connect the wiper motor to the motor bracket with Check

screws and washers (see Figure 3-8). Connect the
1. Squirt some cleaning fluid onto the windshield with the
wiper motor’s shaft to the wiper motor kit crank with the
windshield washer.
nut and washer.
2. Operate the windshield wiper. Verify it works. (Replace
3. Secure the adapter and the gasket of the pantograph
wiper blade as needed if it streaks or otherwise wipes
adapter kit to the cab exterior with capscrews and
poorly.)
lockwashers.
4. Install the motor bracket and attached parts in the cab Windshield Washer Assembly Replacement
interior with attaching hardware. Ensure the pivot shaft
sticks through the hole in the pantograph adapter kit. Removal
NOTE: Take care not to damage any parts while moving 1. Turn the ignition switch to the OFF position and remove
the bracket and attached parts around the steering the ignition key.
column.
2. Wait two minutes.
3. Turn the battery disconnect switch to the OFF position.
4. Locate the windshield washer container and pump on
Windshield Wiper Arm
the left rear side of the cab.
Serrated Collar
5. Tag and disconnect the pump’s electrical lead and
ground wire.

Mounting Plate Washer 6. Disconnect the hose from the windshield washer pump.
Point it so it won’t spill cleaning fluid. Catch cleaning fluid
Nuts
from the windshield washer container with a suitable
container.
Washer 7. Remove four self tapping screws securing the
windshield washer container to the cab. Remove the
Screws
windshield washer container and pump.
8. Remove pump and pump seal from container.
Gasket
Mounting Bracket Inspection
1. Visually check the pump for evidence of cracks, leaks, or
other damage. Replace pump if damaged.
Motor

3653
2. Inspect the container for leaking. Replace pump seal if it
FIGURE 3-8 is leaking. Replace container if it is damaged and
leaking.

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ELECTRIC SYSTEM RT890E3 SERVICE MANUAL

3. Inspect spray nozzle on the wiper arm. As needed, clean Installation

the nozzle with a fine piece of wire and compressed air.
1. Install sealant material around both holes in cab roof,
Installation both inside and outside.

1. Install pump and pump seal on container. 2. Install screw with nylon flat washer (from outside)
through mounting hole in cab roof.
2. Install windshield washer container on the cab. Secure
the container with four self tapping screws. 3. Install flat nylon washer on motor shaft and insert motor
shaft through hole in cab roof. Position small nylon
3. Attach the hose to the windshield washer pump. washer and flat washer on screw between mounting
4. Connect the pump’s electrical lead and ground wire as bracket and cab roof. Secure with lockwasher and nut.
tagged during removal. 4. Install nylon flat washer, leather washer, spacer, and nut
5. Turn the battery disconnect switch to the ON position. on motor shaft. Tighten nut.

6. Fill the container with cleaning fluid. 5. Install wiper arm and blade on motor shaft.
6. Connect the electrical leads to the wiper motor as
Check
marked before removal.
1. Squirt some cleaning fluid onto the windshield with the
7. Turn the battery disconnect switch to the ON position.
windshield washer.
2. Make repairs if windshield washer doesn’t work. Check
1. Operate the skylight wiper. Verify it works. (Replace
Skylight Wiper Assembly Replacement wiper blade as needed if it streaks or otherwise wipes
poorly.)
Removal
1. Turn the ignition switch to the OFF position. Troubleshooting
2. Wait two minutes. NOTE: This machine Incorporates a CANbus Multiplex
system. In order to effectively troubleshoot the
3. Turn the battery disconnect switch to the OFF position.
electrical system, you need a Windows-based PC,
4. Tag and disconnect the electrical leads from the motor. CAN-link service software and a connection cable.
The CAN-link software and connection cable may
5. Remove the wiper arm from the motor shaft.
be ordered from Manitowoc Crane Care. These
6. Remove the nut, spacer, leather washer, and nylon flat items can only be purchased by technicians that
washer from the motor shaft outside the cab roof. have attended the Grove New Technology training
course.
7. Remove the nut and lockwasher securing the motor
bracket to the cab roof and remove the motor from the
cab roof. Remove large nylon flat washer from motor OPTIONAL EQUIPMENT
shaft and flat washer and smaller nylon flat washer from
mounting screw. Description
8. Remove mounting screw and nylon flat washer from This section is provided to give a brief description of the
outside cab roof. optional equipment available for the crane which is not
discussed elsewhere within this service manual.
9. Clean any sealing material from around holes in cab
roof. Strobe Light
Inspection The strobe light is installed on the outside of the cab on the
left rear corner. The light is illuminated anytime the ignition
1. Visually check the motor housing for evidence of cracks
switch is in the on position.
or other damage. Check for excessive shaft end play
indicating worn or damaged bearings. Replace motor if Spotlight
damaged.
The spotlight is installed on the right side of the cab. It can be
2. Inspect the wiper blade for serviceability. Replace wiper
rotated 360 degrees and is illuminated by an on-off switch
blade when worn.
located on the spotlight handle.
3. Inspect the wiper arm and parts for damage. Replace as
needed.

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RT890E3 SERVICE MANUAL ELECTRIC SYSTEM

Boom Mounted Floodlights Air Conditioner

The boom light (WORK LIGHT) switch is located on the A hydraulic air conditioner is installed on the left side of the
lower left side of the front console. The switch is an ON/OFF turntable. It consists of a compressor motor, a condenser
toggle switch that illuminates the light located on the unit, and a cab unit mounted under the operators seat. It is
underside of the boom. turned on and off by a rocker switch mounted on the front
console, refer to Air Conditioner Control Switch (Optional) in
Rear View Mirror the Operator’s Handbook in Section 3 -Operating Controls
and Procedures. The air conditioning compressor motor is
The rear view mirror installation consists of a rear view mirror
driven by the No. 2 hydraulic pump. The dual accumulator
mounted on the right side of the turntable. The mirror can be
charge valve insures the brake circuit gets the priority flow
adjusted as required for optimum view from the cab while the
and the air conditioner circuit receives the excess flow.
boom is over the front of the crane.

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ELECTRIC SYSTEM RT890E3 SERVICE MANUAL

THIS PAGE BLANK

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RT890E3 SERVICE MANUAL BOOM

SECTION 4
BOOM

SECTION CONTENTS
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Boom Extension and Retraction Cable . . . . . . . . 4-21
Lattice Extension . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Optional Hydraulic Luffing Extension . . . . . . . . . . 4-1 Telescope Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Optional Lattice Extension Inserts . . . . . . . . . . . . 4-1 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Boom Control Switches. . . . . . . . . . . . . . . . . . . . . 4-2 Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . 4-23
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Boom Extension . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Hose Reel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Boom Retraction . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
RCL System with Boom Control System . . . . . . . 4-3 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Lift Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Telescoping Control System Description . . . . . . . 4-3
Extension Sequence for the Main Boom. . . . . . . . 4-4
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Theory of Operation. . . . . . . . . . . . . . . . . . . . . . .
4-28
4-28
4
Extension Sequence for the Main Boom with Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Boom Extensions or Offset Jibs . . . . . . . . . . . . . . 4-4
Auxiliary Boom Nose . . . . . . . . . . . . . . . . . . . . . . 4-32
Electronic Control System. . . . . . . . . . . . . . . . . . . 4-6 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 Counterweight with Auxiliary Hoist . . . . . . . . . . . 4-33
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Counterweight without Auxiliary Hoist . . . . . . . . 4-33
Boom Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Boom Nose Sheaves . . . . . . . . . . . . . . . . . . . . . 4-15 Installing the Bi-fold Manual Boom Extension . . 4-36
Boom Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 Checking the Transport Condition . . . . . . . . . . . . 4-38
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 Boom Extensions/Components Procedures . . . 4-38
Functional Check . . . . . . . . . . . . . . . . . . . . . . . . 4-20 Transportation on a Separate Vehicle . . . . . . . . . 4-38
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20 Boom Extension (Additional Equipment) . . . . . . 4-39
Boom Alignment and Servicing. . . . . . . . . . . . . . 4-20 Identification and Slinging Points. . . . . . . . . . . . . 4-39
Cam Operated Check Valve Adjustment . . . . . . 4-21 Monthly Maintenance Work . . . . . . . . . . . . . . . . . 4-40
Guide Block Adjustment . . . . . . . . . . . . . . . . . . . 4-21

DESCRIPTION Optional Hydraulic Luffing Extension

One boom Figure 4-4 is available on the crane; a five 10.1 - 17.1 m (33 - 56 ft) hydraulically offsettable bifold luffing
section, full power, sequenced and synchronized, 11.6 to swing away extension. Offsets from 0° to 40°. Stows
43.3 m (38 to 142 ft) boom. The boom assembly utilizes a alongside base boom section.
mega form design. The five section boom utilizes two
sequenced telescope cylinders for telescoping and retracting Optional Lattice Extension Inserts
of the boom plus cable synchronization for the extension and
4.9m (2 x 16.0 ft) lattice extension inserts. Installs between
retraction of the fly section. Boom lift is provided by a single
the boom nose and bifold extension, non-stowable. A
lift cylinder and boom elevation is from - 3 degrees to +78
standard auxiliary boom nose (rooster sheave) is available
degrees.
for the boom to simplify single part cable usage. The rooster
Lattice Extension sheave is installed on the main boom nose and is secured by
pins that pass through the rooster sheave and main boom
10.1 - 17.1 m (33 - 56 ft) offsettable bifold lattice swing away nose.
extension (jib). Offsets 0°, 20°, and 40°. Stows alongside
base boom section.

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BOOM RT890E3 SERVICE MANUAL

Boom Control Switches THEORY OF OPERATION

The following switches and indicators are located in the Boom Extension
crane’s superstructure cab and are used together to control
the boom telescope function. Boom extension and retraction is accomplished with two
telescope cylinders, five extension cables, and two retraction
Boom Auto/Manual Telescope Mode Switches cables. The lower telescope cylinder is a two stage cylinder.
The boom auto/manual telescope mode switch is located on The rod for the first stage is secured to the rear of the boom
the right armrest. The switch is a two-position rocker switch base section and the barrel of the first stage is secured to the
placarded auto and manual. This switch has a lock to inner mid boom section by a trunnion. The second stage of
prevent accidental activation. the first telescope cylinder barrel is secured to the rear of the
center mid boom section by a trunnion. The rod end of the
When the switch is in the AUTO mode, the boom sections upper telescope cylinder is attached to the rear of the center
extend in a predetermined sequence when telescoping the mid and the barrel is secured to the outer mid boom section
boom; the inner mid extends 75% and stops, then the center by a trunnion. The extension cables are secured to the back
mid extends to 75% and stops, then the inner mid extends to of the fly section and run around extension sheaves on the
100%, the center mid extends to 100%, and then the outer front of the upper telescope cylinder to the front of the
mid and fly section extend in a synchronized fashion. The second stage barrel of the lower telescope cylinder.
sections retract in the same manner in reverse order.
The hydraulic fluid for the first stage of the lower cylinder is
When in the manual mode, the red LED square in the switch supplied by hoses from the turntable. The hydraulic fluid for
will illuminate. The boom telescope section select switch is the second stage of the lower cylinder and the upper cylinder
positioned to either the center mid or inner mid position in is routed through the hose reel that is mounted in the
order to extend or retract the selected section until it is turntable into a manifold that is attached at the rear of the
returned to the proper position for normal boom center mid section. There are two cam operated check
synchronization to occur. valves mounted at the rear of the center mid which control
The manual mode operation is primarily used for boom flow to the second stage of the lower cylinder and the upper
maintenance and function the boom in an unlikely event of a telescope cylinder. With both cylinders retracted, the check
BCS failure. In manual mode, the boom is controlled by the valve for the second stage of the lower telescope cylinder is
section selector switch in the right hand arm rest in the cab. open and the check valve for the upper cylinder is closed
When IM is selected, crane electric provides full power to the allowing the second stage of the lower cylinder to extend.
extend and retract proportional solenoids on the IM pilot When the lower cylinder is fully extended, the check valve for
operated 4-way directional control valve. This means the the upper cylinder opens allowing the upper cylinder to
telescoping action is controlled directly by moving the extend. The check valve for the lower cylinder closes after
joystick or foot operated treadle valve. The BCS does not the upper cylinder starts to extend and shuts off the flow to
control movement. Likewise when CM is selected, crane the lower cylinder. As the upper telescope cylinder barrel
electric provides full power to the extend and retract extends, the extend cables around the extend sheaves on
proportional solenoids on the CM pilot operated 4-way the end of the cylinder barrel push on the extend cables to
directional control valve. pull the fly section out at the same time the outer mid is
extending.
Center Mid/Inner Mid Boom Telescope Sections
Select Switch Boom Retraction
The center mid/inner mid boom telescope section select The upper telescope cylinder retracts the outer-mid and two
switch is located on the right armrest. This switch is a three retract cables pull the fly section in at the same time. When
position rocker switch that is used in conjunction with the the upper cylinder is fully retracted, the check valve for the
boom auto/manual telescope mode switch. When the boom lower telescope cylinder is opened and the lower cylinder
mode switch is positioned to manual, the boom telescope starts to retract. The check valve for the upper cylinder is
section select switch is positioned to either of the two closed as the lower cylinder starts to retract. The outer mid
positions. When placed in the upper position, the center mid and fly retract first and then the center mid and lastly the
can be extended. When the center mid is fully extended, the inner mid.
outer mid and fly can be controlled. The red LED square will
illuminate when the switch is positioned in either the inner
mid or center mid position.

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RT890E3 SERVICE MANUAL BOOM

RCL SYSTEM WITH BOOM CONTROL b. In Manual (MANUAL) mode, the operator has the
SYSTEM selective capability to adjust the extension of the
inner mid and center mid sections independently.
General Manual mode adjustment is utilized on ly to
reconfigure the boom sections into a synchronized
The crane has a 5-section sequence synchronized boom relationship according to the programmed criteria
assembly. The electronic control system interfaces with the for automatic mode operation (if the boom has for
actuating systems, and provides the necessary controls, any rea son bec ome unsy nchronize d during
according to the following system standards. operation in the Automatic mode), or to extend the
boom intentionally in non-synchronized mode, so
Telescoping Control System Description that access holes in the boom sections align, and
serviceable internal components of the boom are
Boom Configuration made accessible for maintenance. To prevent
The boom is a five section configuration (i.e. one fixed overloading of the boom while the sections are
section and four telescoping sections). The fully retracted unsynchronized, when the Manual mode has been
length of the boom is 11.4 mm (38 ft) and the fully extended selected, the RCL electronic controller limits the
length is 43.2 mm (142.0 ft). allowable gross load to 10,000 kg (22,046 lb), or
50% of the load chart allowable capacity at the
Extension/Retraction Modes applicable measured boom length, whichever figure
The boom telescoping system operates in either of two
is less. In the Manual mode, the smoothness of the
changeover from section to section is entirely under
4
modes selected by the operator, Automatic or Manual.
the control of the operator.
a. In Automatic (AUTO) mode, a single telescope
controller extends or retracts the boom at the Extension/Retraction Sequence (Automatic Mode)
correct speeds, in the correct sequence of section Boom extension in the Automatic mode does not follow the
movements, with no action by the operator other customary sequence whereby all the boom sections are
than to actuate the controller and to cease actuating extended by the same proportion for any given boom length.
it when the desired boom length is achieved. The Instead, in order to optimize the crane structural and/or
system also automatically enforces a “soft” stability limitations, the sections extend in particular
transition at each section changeover point in the proportions according to the following sequences (as
sequence, resulting in smooth changes from section directed by the particular load chart/crane configuration
to section without the need for the operator to selected by the operator; i.e. these sequences reside in the
“feather” the telescope control. system data software, not in the control software):

GROVE Published 07-24-2013, Control # 069-12 4-3

BOOM RT890E3 SERVICE MANUAL

6 6081

FIGURE 4-1

Extension Sequence for the Main Boom Extension Sequence for the Main Boom with
Item (1) in Figure 4-1 shows the boom fully retracted. The Boom Extensions or Offset Jibs
following describes the extension process: There are no discrete boom extension or jib capacity charts
a. The inner mid section(2) alone extends to 75% of its for boom lengths less than 100% extension of the center mid
maximum, all other sections remain retracted. section. Therefore, to reduce telescoping time, the following
automatic mode extension sequence is activated whenever
b. The center mid section(3) alone extends to 75% of an offset jib load chart is selected by the operator:
its maximum, the inner mid section remaining at
75% of its maximum, the outer mid and fly sections a. The inner mid section alone extends to its full
remain retracted. extension, all other sections remaining retracted.

c. The inner mid section(4) alone extends to its full b. The center mid section alone extends to its full
extension, the center mid section remaining at 75% extension, the outer mid and fly sections remaining
of its maximum, and the outer mid and fly sections retracted.
remain retracted. c. The outer mid and fly sections extend
d. The center mid section(5) alone extends to its full simultaneously, synchronized, to their full extension.
extension, the outer mid and fly sections remain The boom retraction sequences are the reverse of the above
retracted. extension sequences.
e. The outer mid and fly sections (6) extend
Rated Boom Lengths
simultaneously, synchronized, to their full extension.
The boom carries capacity ratings according to the boom
section extension proportions shown in Table 1 (again,
shown as a percentage of extension of each section).

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RT890E3 SERVICE MANUAL BOOM

Capacities at Intermediate Boom Lengths inner mid, center mid, and outer mid section
telescope cylinders. Thus, when so directed by
It is not mandatory that only the specified discrete boom
electrical signal, the pressure reducing valves
lengths are utilized for lifting, and intermediate boom lengths
effectively override the pilot pressure signal being
will be usable. The allowable capacities at intermediate
transmitted from the operator’s pilot controller to the
lengths behave in accordance with customary practice, in
telescope control valves, automatically opening,
that they reduce to the figure applicable to that adjacent
feathering and closing so as to initiate, control and
boom length having lower capacities (either the next longer
halt motion of the respective sections according to
or shorter rated boom length, according to the particular load
the predetermined sequence.
chart in use), whenever the actual boom length differs from
the rated length by more than 500 mm (19.7 in). (For any c. Mechanically actuated valves sensing the status of
given boom length, the capacities vary steplessly with load the center mid and outer mid sections (i.e. outer mid
radius according to the particular calibration curves). section fully retracted, and center mid section fully
extended) and diverting the flow of oil, when
Hydraulic Actuation and Control System extending, from the center mid section cylinder to
Extension of the inner mid, center mid, and outer mid the outer mid cylinder when the center mid section
sections occurs by way of three hydraulic cylinders (one 2- (and therefore also the inner mid section) is fully
stage cylinder moving the inner mid and center mid sections, extended, and vice versa during boom retraction.
and one single-stage cylinder, moving the outer mid section). Thus the outer mid section is not able to receive any
oil to extend until the center mid section is already
The fly section is cable extended and retracted by the
movement of the outer mid section and center mid sections, fully extended; and similarly, no “retract” oil will flow 4
and thus is mechanically synchronized with the outer mid to the center mid section until the outer mid section
section, but the other sections are electro hydraulically is fully retracted.
sequenced/synchronized by the boom telescoping control d. A normally closed, solenoid operated 2-way, 2-
system. position control valve, which bleeds off residual rod
Controlling the telescope cylinders, the boom telescoping side pressure from the telescope cylinders (as
hydraulic actuating system consists of the following selected by a double check valve, according to the
elements: cylinder being telescoped, and an orifice to prevent
significant loss of oil to tank that would compromise
a. A single pilot pressure joystick or foot pedal cylinder retraction speed). The purpose of this valve
controller, which actuates two pilot operated 4-way, is to allow residual pressure trapped in the rod side
3-position, pressure compensated proportional of the cylinders to escape, preventing subsequent
control valves controlling the flow and pressure of unseating of the holding valve and transfer of the
hydraulic oil respectively to the inner mid and center trapped oil to the piston side, which can cause a
mid/outer mid section telescope circuits. slight spontaneous and unwanted extension of the
b. The propositional control valve(s) noted in a. above, boom sections
in which are incorporated solenoid operated e. Unless overridden by the pilot signal pressure
proportional pressure reducing valves in both of the reducing valves in paragraph b. (above), the oil flow
valves’ pilot pressure spool actuator sections (i.e. and pressure applied to the telescoping cylinders is
both “extend” and “retract” directions), acting to vary under the direct control of the joystick pilot
the pilot pressure being applied to shift the valve controller.
spool, and thereby controlling the flow of oil to the

Table 1: Boom Section Extension Proportions

Boom Length (ft) 37.3 50.5 63.6 76.7 89.8 102.8 115.8 128.8 141.7
Inner-mid (%) 0 50 75 75 100 100 100 100 100
Center-mid (%) 0 0 25 75 100 100 100 100 100
Outer-mid (%) 0 0 0 0 0 25 50 75 100
Fly (%) 0 0 0 0 0 25 50 75 100

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BOOM RT890E3 SERVICE MANUAL

Electronic Control System value, giving a smooth acceleration of that section. This
system prevents out of sequence conditions occurring as a
As mentioned previously, the electro hydraulic sequencing result of overshoot of the section that is coming to a halt, and
and synchronization of the inner mid and center mid section also enforces a smooth transition from section to section.
telescope cylinders are controlled through a combination
RCL/boom control system electronic processor/controller, An additional benefit occurs in situations in which the
since both systems need to sense the various section operator is simultaneously operating the hoist, in order to
extensions (i.e. to determine the boom length and its keep the load at a constant height while telescoping the
configuration [sectional extension relationships] in order to boom. Since telescoping speed inevitably varies from
compute allowable load moment and the corresponding section to section according to the bore of the cylinder, and
allowable hook load for RCL purposes, and to close the also whether a section is indirectly moved by a cable
telescope sequencing/synchronization system feedback extension system, the compensating speed of the hoist has
control loop). to be varied by the operator as each successive section
change occurs, so that the load does not immediately rise or
System Interfaces and Logic fall. The smooth changeover effect enforced by the
telescope control system allows the operator a wider band in
The electronic system is supplied with electrical power at
which to adjust compensatory speed of the hoist so that the
12 VDC.
load can be more easily kept at a constant height.
The electronic system collects electrical inputs from boom
The inner mid and center mid sections are extended by a 2-
length sensors that separately measure overall boom length,
stage cylinder, the larger diameter cylinder being the center
and extension of the inner mid section. Since the outer mid
mid section stage. Therefore this stage has the capability to
and fly sections are mechanically [cable-] synchronized, and
exert higher load than the inner mid section stage, for a given
change over of hydraulic oil supply to or from the outer mid/
hydraulic pressure. Such loads would exceed the buckling
fly section telescope cylinder is mechanically effected by trip
resistance of the smaller inner mid section stage, which in
valves upon full extension of the center mid section, or full
Automatic mode is already at 75% extension before the
retraction of the outer mid section, it is assumed that these
center mid section cylinder is actuated. For this reason, the
sections cannot become unsynchronized. Therefore, on this
system provides an additional electrical output to a dual
basis the computed difference between the measured boom
pressure relief valve integrated in the telescope control valve
extension value and the measured inner mid section
block, causing it to reduce the maximum pressure that can
extension value allows the system to infer the extension of
be applied to the center mid section telescope cylinder, so
the center mid section.
that the cylinder is protected from such excessive buckling
The system also collects electrical inputs of boundary loads. The system programming always ensures that the
conditions (operator selection, by switch, of “Automatic” or lower pressure is selected before the center mid section
Manual mode, electrical sensing, by proximity switches, of cylinder is pressurized, and that the center mid section
retracted condition of the inner mid section relative to the cylinder is isolated or fully extended, before the higher
base section, and of the center mid section relative to the pressure is selected and applied to the other cylinders.
inner mid section, and of telescope extend or retract pilot
The system also provides a control signal to the solenoid
pressure being applied). The system then produces current
operated telescope cylinder rod drain valve, opening the
controlled electrical outputs to the appropriate pilot system
valve whenever either the inner mid or center mid section is
proportional pressure reducing valves, allowing the pilot
not fully retracted (i.e. either of the section “retracted”
pressure to shift the telescoping control valve spools
switches is open), and closing the valve whenever both the
appropriately to direct oil to the inner mid or to the center mid
switches are closed, indicating complete boom retraction
section telescope cylinder, according to prevailing boom
condition.
length and to the direction of motion selected.
If for any reason loss of synchronization of the inner mid/
In Automatic mode, the control system output current being
center mid section telescoping system is detected by the
applied to the applicable valve is automatically reduced as
boom length sensing and computing system, the system
each section approaches a position at which the selected
inhibits all telescoping control signals to all four of the pilot
telescope sequence would require it to stop and the next
system proportional control valves, preventing any further
section to begin to move. This causes the pilot oil pressure
telescoping motion. To correct the condition, manual
being applied to the control valve spool to be proportionately
switches are incorporated, which, when actuated, change
reduced according to the current, (overriding the operator’s
the system from Automatic to Manual mode, and select
pilot control valve), so that the section telescoping speed
either the inner mid or center mid section for correction in
reduces smoothly before the section finally comes to rest. In
Manual mode. The selected section can then be telescoped
the same way the current supply to the valve controlling the
individually, by passing the automatic synchronization
following section is initiated just before the previous section
system, until it is brought into correct synchronization (the
finally comes to a halt, and rises smoothly to its regulated
system constantly displays the prevailing percentage of

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RT890E3 SERVICE MANUAL BOOM

extension of the sections, an indicator light on the console

remains illuminated as long as the unsynchronized condition
persists, and the inner mid or center mid section telescope
cylinder selection is indicated by respective lights on the arm CAUTION
rest, thereby allowing the operator to telescope the section[s] Wear gloves when handling wire rope. Injury to your
appropriately). As long as the system continues to detect the hands is possible.
unsynchronized condition, and/or the manual mode is
selected, the load moment monitoring/lockout system also 3. Remove the hook block or headache ball and wind all
limits the allowable load moment to 10,000 kg (22,046 lb) or the wire rope onto the hoist drum.
50% of the rated capacity at the particular prevailing boom
length, the intent being that, while the sections are 4. Position the boom to make sure that the lift cylinder is
unsynchronized, any hook load will be deposited, only the resting securely in the lift cylinder support.
hook block remaining suspended while the necessary
adjustment of the boom sections occurs: only when
synchronization has been achieved will the system reset and
normalize the load monitoring system when switched back to DANGER
Automatic mode. Ensure the lifting device is capable of supporting the
The standard used by the system to define an boom assembly.
unsynchronized condition is an error or +/-3% of the full
extension value of one section. Since the inner mid, center 5. Attach a lifting device to the boom to provide for equal 4
mid, and the outer mid/fly combination all extend individually, weight distribution.
compliance with the criterion can only be assessed at 6. Shut down the crane and turn the battery disconnect
s e c t i o n e x t e n s i o n s c o r r e s p o n d i n g t o t h e p o i n ts o f switch to OFF.
changeover of movement from section to section. Therefore,
the system reviews the extension of each section prior to 7. Tag and disconnect any electrical wiring from the boom.
permitting the changeover, and unless all section extension 8. Tag and disconnect the hydraulic lines to the lower tele-
values are within 3% of their programmed changeover scope cylinder and plug. Remove the base cover from
length, the system defaults to the out-of-synchronization the top of the boom base section near the pivot shaft.
condition described above. The same default occurs if, in the
course of operation, any boom section moves out of 9. Secure the hose reel in the turntable using an S-hook as
synchronization to a length corresponding to one of its own shown in (Figure 4-2) to prevent the reel from rotating
changeover lengths (since it then invokes the +/-3% criterion before proceeding to the next step.
against the other sections), or moves away from such a
changeover length by more than the 3% margin. S-Hook

MAINTENANCE
Removal
NOTE: The boom weighs approximately 12,045 kg
(26,554 lb). Removal of the swingaway boom
extension will simplify boom removal, therefore, the
above weight is for the boom without the swinga-
way boom extension attached.
1. Extend and set the outriggers to level the crane and
ensure the boom is fully retracted and in a horizontal
position over the front of the crane.
2. If equipped, remove the swingaway boom extension and 7119 FIGURE 4-2
auxiliary nose according to the removal procedures in
this section. 10. Reach through the hole in the top of the base section
and disconnect the hose reel line from the hydraulic
manifold (Figure 4-3) that is mounted on the rear of the
center mid. Cap all lines and openings. Feed the hoses
through the rollers at the rear of the base.

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BOOM RT890E3 SERVICE MANUAL

Hose Reel Line

DANGER
The boom assembly must be rotated 180° (upside down)
before performing any assembly or disassembly
procedures.
A rollover fixture with webbing is recommended to rotate
boom and sections. Chains are not recommended. If a
rollover fixture is not available, rotate sections using
adequate support with webbing.
A secure fixture that will prevent damage to the boom is
recommended to stabilize and hold the boom from moving
during removal of section or sections.

3. On the top front of the base section, remove bolts, wash-

FIGURE 4-3 ers, and three cable pads.
7119-1
4. Repeat step 3 on the inner mid, removing two cable
pads.
5. Repeat step 3 on the center mid, removing two cable
pads.
DANGER
Ensure the boom lift cylinder is properly supported before 6. Repeat step 3 on outer mid, removing two cable pads.
disconnecting it from the boom. 7. Remove eight bolts, washers and the telescope mount
plates from the lower telescope cylinder.
11. Block the lift cylinder.
NOTE: The combined weight of the boom inner mid, center
12. Remove the bolt and washer securing the upper lift cyl- mid, outer mid, and fly sections, including the tele-
inder shaft to the side of the attach fitting on the boom. scope cylinders, is approximately 8,691 kg (15,185
13. Remove upper lift cylinder shaft. lb).

14. Take up the slack on the boom lifting device. 8. Slide the assembly out of the base part way.

15. Remove clip pin and cross pin securing boom point pin 9. Remove the bolts and washers and the two set screws
to base section. and locknuts securing each front top wear pad to base
section. Remove two bolts and washers securing each
16. Remove boom pivot pin. adjusting plate to top of base section. Remove two
17. Raise the boom clear of the crane and lower to ground adjusting plates. Remove upper wear pad assembly. If
and set cribbing to support the boom and prevent tip- necessary, remove four bolts securing front upper wear
ping. pad to pad plate.
10. Remove the 18 bolts and washers securing the bottom
Boom Disassembly and side wear pad keeper plates to the base section.
1. Remove the boom in accordance with the REMOVAL Remove the keeper plates.
procedures outlined in this section. 11. Lift up on the front of the base and remove the bottom
2. If necessary, on the left side of the boom remove the two and side wear pads and shims from the base section,
bolts and washers securing the RCL cable angle brack- noting quantity, size, and location of shims.
ets to the base, inner mid, center mid, and outer mid. 12. Continue to pull the assembly from the base section
NOTE: The boom weighs approximately 12,045 kg removing the top rear wear pads from the inner mid sec-
(26,554 lb). The above weight is for the boom with- tion as they clear the base section.
out the swingaway boom extension attached. 13. Remove the two bolts, washers, shims, and lower wear
pad from the inner mid, noting the quantity and size of
shims.
14. Remove the cotter pins, shaft, and roller from the rear of
the inner mid.

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RT890E3 SERVICE MANUAL BOOM

15. Remove the four bolts and hardened washers securing 20. Remove the 18 bolts and washers securing the bottom
each trunnion mounting plate from the lower cylinder and side wear pad keeper plates to the inner mid.
barrel. Remove the keeper plates.
16. If necessary, remove both grease fitting connectors and 21. Lift up on the front of the center mid and remove the bot-
grease lines from the rear of the inner mid. tom and side wear pads and shims from the inner mid,
noting quantity, size, and location of shims.
17. Remove the bolts, washers, and trigger plate from the
front left side of the inner mid. 22. Continue to pull the assembly from the inner mid, remov-
ing the top rear wear pads from the center mid as they
NOTE: Together the boom center mid, outer mid and fly
clear the center mid.
sections, and telescope cylinders weigh approxi-
mately 6851 kg (15,104 lb). 23. Remove the two bolts, washers, shims, and lower wear
pad from the inner mid, noting the quantity and size of
18. Slide the assembly out of the inner mid part way.
shims.
19. Remove the bolts and washers and the two set screws
24. If necessary, remove both grease fittings, connectors,
and locknuts securing each front top wear pad to base
and grease lines from the rear of the inner mid.
section. Remove two bolts and washers securing each
adjusting plate to top of base section. Remove two 25. Remove the mounting plates from the lugs on the lower
adjusting plates. Remove upper wear pad assembly. If cylinder barrel.
necessary, remove four bolts securing front upper wear
pad to pad plate.
26. Tag and disconnect the hydraulic hoses and tubes from
the telescope cylinders, the two cam valves and the
4
hydraulic manifold. Cap and plug all openings.

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BOOM RT890E3 SERVICE MANUAL

42 41
24
36

See View A

38
43 1
23

6315-3
44

36

4
6315-1
39
40
37
23

2 21
5
6
27 3
16
30
7

2 10

17

45
20
14 18
31 34 19
8 13 22 33
11 35
28
29 26
15 12
9 32

1 46

48

6641 47
View A FIGURE 4-4

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RT890E3 SERVICE MANUAL BOOM

Item Description Item Description

1 Base Section 26 Lower Sheave Shaft
2 Inner Mid Section 27 Upper Boom Nose Sheaves
3 Center Mid Section 28 Lower Boom Nose Sheaves
4 Outer Mid Section 29 Cable Retainer Pins
5 Fly Section Upper Sheave Shaft/Boom Extension Anchor
30
Lugs
6 Upper Telescope Cylinder
31 Anti-two Block Plate
7 Lower Telescope Cylinder
32 Cable Retainer
8 Extend Sheave Mounting Sheave
33 Bolt
9 Upper Cylinder Support Foot
34 Sled Weld
10 Wear Pads
35 Plate Cover
11 Extend Sheave Assembly
36 Stop Block Plates
12 Extend Sheave Shaft w/Grease Fitting
37 Lower/Side Keeper Plates
4
13 Extend Sheave Shaft Plate
38 Wear Pad Assembly
14 Cable Retainer
39 Screw
15 Cable Guide
40 Washer
16 Extend Cables
41 Pad Support
17 Retract Cables
42 Screw, Flatwasher
18 Skid Pad
43 Bracket
19 Lower Cylinder Mount
44 Screw, Washer, Lockwasher, Hex Nut
20 Lower Cylinder Mount Shaft
45 Lower Boom Extension Anchor Lugs
21 Upper Cylinder Support
46 Cable Guide Assembly
22 Wear Pad Support
47 Hitch Pin Clip
23 Shims
48 Washer
24 Cable Pads
25 RCL Cable Mounting Angles

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BOOM RT890E3 SERVICE MANUAL

1
56 60
2

51 60

3 49
4
60

52

60
5
10
6 16
58
61
10
57

59

53

10

50
58 55
54

59
58

17 7

6315-2
FIGURE4-4continued

Item Description Item Description

49 Cam Operated Check Valve 56 Upper Cylinder Rod Mounting Plate
50 Retract Cable Sheave 57 Lower Cylinder Rod Mounting Plate
51 Pusher Rod 58 Bottom Wear Pads
52 Upper Cylinder Mounting Plate 59 Rear Side Wear Pads
53 Lower Cylinder Mounting Plate 60 Top Rear Wear Pads
54 Retract Cable Sheave Mounting Plate 61 Manifold Block
55 Retract Cable Sheave Shaft

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RT890E3 SERVICE MANUAL BOOM

65

60

49

63

64
4
61

62

6315-4 58
FIGURE4-4continued

31. Place blocking under the lower second stage cylinder

barrel.
Item Description
32. Remove the four bolts and hardened washer securing
62 Adapters each lower cylinder barrel mounting plate to the center
63 Valve Actuator mid.
64 Valve Actuator Arm 33. Remove five bolts and hardened washers securing each
65 Grease Fitting upper cylinder rod mounting plate to the center mid.
NOTE: Together the boom outer mid, fly section, and tele-
27. Remove the three bolts, washers, and nuts securing scope cylinders weigh approximately 5217 kg
each cam valve to its mounting plate and remove the (11,501 lb).
valves.
34. Slide the assembly out of the center mid part way.
28. Remove the four bolts and washers securing the
hydraulic manifold to the mounting plate and remove the 35. Remove the bolts and washers and the two set screws
hydraulic manifold. and locknuts securing each front top wear pad to base
section. Remove two bolts and washers securing each
29. On the right side of the center mid, remove the valve adjusting plate to top of base section. Remove two
pusher rod. adjusting plates. Remove upper wear pad assembly. If
30. On the left side of the center mid, remove spring and the necessary, remove four bolts securing front upper wear
valve pusher weld. Disassemble as necessary. pad to pad plate.

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BOOM RT890E3 SERVICE MANUAL

36. Remove the 18 bolts and washers securing the bottom

and side wear pad keeper plates to the center mid.
Remove the keeper plates.
37. Lift up on the front of the outer mid section and remove DANGER
the bottom and side wear pads and shims from the cen- Ensure the telescope cylinders are securely blocked and
ter mid, noting quantity, size, and location of shims. some means used to hold them together to prevent any
accidental movement. Severe injury can occur if the
38. Continue to pull the assembly from the center mid, cylinders drop.
removing the top rear wear pads from the outer mid sec-
tion as they clear the center mid. NOTE: The telescope cylinder assembly weighs approxi-
39. Remove the two bolts, washers, shims, and lower wear mately 1616 kg (3,563 lb).
pad from the outer mid, noting the quantity and size of 52. Slide the telescope cylinder assembly part way out
shims. (approximately ten feet) of the rear of the fly. Support the
40. If necessary, remove both grease fittings, connectors, end of the telescope cylinders with adequate blocking.
and grease lines from the rear of the outer mid. NOTE: The lower telescope cylinder assembly weighs
41. Remove the retract cable sheave mounts from the rear approximately 803 kg (1,770 lb).
of the outer mid section, remove retract sheaves. 53. Slide the lower two stage cylinder farther out of the fly
42. Remove the mounting plates from the second stage of until the end of the cylinder is out of the fly.
the lower cylinder barrel mounting lugs and upper cylin- 54. Remove the four bolts and washers holding the top plate
der mounting lugs. cover to the cylinder mount. Remove the two bolts
43. Place blocking under the upper telescope cylinder bar- securing each wear pad if necessary.
rel. 55. Remove the two nuts and swivel nuts that attach the sled
44. Remove the four bolts and hardened washers securing weld to the two adjusting bolts at the end of the lower
each trunnion mounting plate from the upper cylinder cylinder.
barrel mounting plate to the outer mid. 56. Slide the sled weld off the two adjusting bolts and
NOTE: Together the boom fly section, and telescope cylin- remove the adjusting bolts from the shaft on the lower
ders weigh approximately 3853 kg (8,494 lb). cylinder.

45. Slide the assembly out of the outer mid part way. 57. Remove the four nuts that attach the retract cable ends
to the sled weld. Remove the retract cables from the cyl-
46. Remove the bolts and washers and the two set screws inder mount.
and locknuts securing each front top wear pad to base
section. Remove two bolts and washers securing each 58. Remove the lower cylinder assembly and place on ade-
adjusting plate to top of base section. Remove two quate support.
adjusting plates. Remove upper wear pad assembly. If 59. If necessary, remove one cotter pin from the shaft that
necessary, remove four bolts securing front upper wear holds the cylinder mount to the lower cylinder.
pad to pad plate.
NOTE: The telescope cylinder assembly weighs approxi-
47. Remove the 18 bolts and washers securing the bottom mately 803 kg (1,770 lb).
and side wear pad keeper plates to the outer mid.
Remove the keeper plates. 60. Remove the shaft and cylinder mount from the lower cyl-
inder. If necessary, remove the bolts securing each pad
48. Lift up on the front of the fly section and remove the bot- to the cylinder mount.
tom and side wear pads and shims from the outer mid,
noting quantity, size, and location of shims. 61. Remove the two bolts and hardened washers securing
the extend cable keeper plate to the rear of the fly.
49. Continue to pull the assembly from the outer mid, Remove the keeper plate and remove the four extend
removing the top rear wear pads from the fly section as cable ends from the slots in the fly.
they clear the outer mid.
62. Continue to slide the upper cylinder out of the fly making
50. Remove the two bolts, washers, shims, and lower wear sure that the cables are moving with the cylinder. Slide
pad from the fly, noting the quantity and size of shims. the telescope cylinder outward until the foot weld at the
51. If necessary, remove both grease fittings, connectors, end of the upper telescope cylinder is approximately two
and grease lines from the rear of the fly section. feet from the rear of the fly.

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RT890E3 SERVICE MANUAL BOOM

63. Remove the two bolts and washers from each side of the 4. Remove the bolt, washer, and nut securing the upper
foot weld and remove both wear pad supports. If neces- boom nose sheave shaft. Remove the collar.
sary, remove two flat head screws and pad from each
NOTE: The upper boom nose sheave shaft weighs
support.
approximately 66 kg (146 lb). The boom nose
64. Continue to slide the telescope cylinder assembly out of sheaves weigh approximately 10 kg (22 lb) apiece.
the fly section. Raising the rear of the fly section and
5. Carefully pull the upper boom nose sheave shaft from
lowering the rod end of the cylinder will aid in removal.
the boom nose, removing the spacers, shims, and boom
65. On the front of the fly section, remove the two nuts and nose sheaves.
hardened washers from the end of each retract cable
6. Repeat steps 2 and 3.
and remove the retract cables from the fly section.
7. Remove bolts and washers securing shaft end plate to
66. Remove the two bolts and washers on both sides of the
lower boom nose shaft. Remove end plate.
sheave mount on the end of the upper cylinder that
holds the cable guide and shaft plates. Remove the 8. Carefully pull the lower boom nose shaft from the boom
cable guide and shaft plates. nose, removing spacers, shims, and sheaves.
67. Remove the two bolts and washers securing the extend 9. Remove the shim, keyed washer and locknut from both
cable retainer plate to the front of the sheave mount. sheave shafts.
Remove the retainer plate.
68. Remove the five extend cables from the sheave assem-
Installation
4
bly.
69. Remove the grease fitting from the shaft. Remove the CAUTION
sheave shaft and the sheave assembly from the mount- Do not install the boom nose sheaves over the threaded
ing assembly. end of the boom nose sheave shaft.
70. Remove the four bolts and hardened washers securing
NOTE: The lower boom nose sheave shaft weighs approx-
the sheave mounting assembly and the support foot to
imately 20 kg (44 lb). The boom nose sheaves
the front of the telescope cylinder. Remove the two bolts
weigh approximately 11.5 kg (25 lb) and 9 kg (20
and washers holding the cylinder support foot to the
lb) respectively.
sheave mount. Remove the sheave mounting assembly
and the support foot. 1. Install the spacers and sheaves onto the sheave shaft
while installing the sheave shafts into the boom nose.
71. If necessary, remove the two bolts securing each wear
pad to the support foot and remove the wear pads. NOTE: The lockwasher can be used more than once but
must be replaced if not in good condition.
72. Remove the two bolts and washers that retain the plate
cover to the sled weld. Remove the plate cover and NOTE: Install the lockwasher onto the sheave shaft with
remove the five extension cables. the tabs facing out.
73. If removal of the boom nose sheaves are required, refer 2. Install the locknut, washer, keyed washer, and shims (if
to BOOM NOSE SHEAVES - Removal in this section. necessary) onto the boom nose sheave shaft with the
chamfer side out. Install the collar onto the opposite end
74. Refer to BOOM EXTENSION AND RETRACTION
of the upper shaft and secure in place with the bolt,
CABLE MAINTENANCE in this section for cable inspec-
washer, and nut. Install end plate onto opposite end of
tion.
lower shaft and secure in place with bolts and washers.
Boom Nose Sheaves NOTE: If more than one shim is required, install an equal
amount on each side of the boom nose.
Removal
3. Tighten the locknut until the play in the entire assembly
1. Remove the clip pins from the cable retainer pins and is within 1 to 2 mm (0.03 to 0.06 in) total. Install shims as
remove the cable retainer pins from the upper and lower necessary to achieve the correct dimension. Bend the
part of the boom nose. lockwasher tabs to secure the locknut in place.
2. Flatten out the tab on the lockwasher. 4. Install the cable retainer pins into the upper and lower
3. Backoff locknut until there is no pressure on the lock- part of the boom nose and secure in place with the clip
washer. pins.

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BOOM RT890E3 SERVICE MANUAL

Boom Assembly 6. If removed, install the two wear pads on the top of the
cable guide by using two flathead screws.
7. Install the other ends of the extension cables into the
CAUTION sled weld, making sure the extension cables are not
When adjusting cables, hold the cable end and turn the crossed and twisted.
nut. Install cables in their natural untwisted condition. Do
8. Install the plate cover on the sled weld and secure with
not turn or twist the cable. Turning/twisting cable while
two bolts and washers.
adjusting will result in damage or failure of cable.
9. At the rear of the fly section, install the upper wear pad
NOTE: Apply Loctite 243 to the threads of all attaching grease line, connector and grease fitting on each side.
hardware except cable ends and cable lock nuts.
10. Install the lower rear wear pad and shims on the fly sec-
Apply multipurpose grease (MPG) to all wear tion with two flat head screws.
surfaces.
11. Route the two retract cables (threaded ends) through
Use standard Grade 5 and/or 8 torque values the fly section to the front. Insert the threaded ends
specified in Section 1 of this Manual unless through the holes on the front of the fly section and
otherwise specified. install a hardened washer and two nuts on each cable
end.
12. Using an adequate lifting device, position the upper tele-
scope cylinder into the rear of the fly section.
DANGER
13. Slide the telescope cylinder assembly into the rear of the
The boom assembly must be rotated 180° (upside down)
fly section until foot support clears the gussets at the
before performing any assembly or disassembly
rear of the fly section. Raising the rear of the fly and low-
procedures.
ering the rod end of the cylinders will aid in sliding these
A secure fixture that will prevent damage to the boom is together.
recommended to stabilize and hold the boom from moving
during insertion of section or sections. 14. Place the five extend cable lug ends in the slots at the
top of the fly section and secure them with the keeper
1. Install wear pads on the bottom of the upper telescope plate and two bolts and hardened washers.
cylinder support foot using two screws each. 15. Install a wear pad on the two upper telescope cylinder
2. Install the support foot and the sheave mounting assem- wear pad holders using two flat head screws.
bly on the front of the upper telescope cylinder assem- 16. Position the wear pad holders on each side of the upper
bly, with four bolts and hardened washers. Attach the telescope cylinder support foot and secure each with
support foot and the sheave mounting assembly two bolts and hardened washers.
together using two bolts and hardened washers.
17. Slide the upper telescope cylinder assembly part way in
NOTE: The sheave shaft should be installed with grease (approximately ten feet). Place blocking under the rear
fitting hole to the left side. of the telescope cylinder to aid in assembly.
3. Using the sheave shaft, install the sheave assembly in 18. Using the cylinder mount shaft attach the lower cylinder
the sheave mounting assembly, making sure the grease mount to the end of the lower cylinder. Attach cotter pins
fitting hole is toward the left of the assembly. Secure the to secure shaft.
shaft and the cable guide with a cable guide weld and
two bolts and washers on each side of the sheave 19. Install the wear pad and skid pad with bolts to the lower
mounting assembly. Install grease fitting in the shaft and cylinder mount.
apply grease. 20. Lift lower telescope cylinder assembly and place on
4. Route the end of the five extension cables up and upper telescope cylinder.
around the upper telescope cylinder sheaves about one 21. Install the wear pads with bolts to the top plate cover.
foot onto the cylinder. To aid in assembly, secure the
cables to the end of the cylinder by wrapping tape 22. Install the top plate cover assembly with four bolts and
around the cylinder. washes to the lower cylinder mount, to attach the upper
and lower cylinders together.
5. Position the cable retainer plate on the front of the
sheave mounting assembly and secure with two bolts 23. Install both ends of the retract cables to the appropriate
and lockwashers. holes in the lower cylinder mount, making sure that the

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RT890E3 SERVICE MANUAL BOOM

cables are not crossed or twisted. Install a hardened 35. Install center mid front top wear pads and shims as
washer and two nuts on each cable end. noted during disassembly. Secure each with four bolts
and washers.
24. Install the adjusting bolts through the holes in the lower
mount shaft. 36. Install outer mid front top wear pads as noted during dis-
assembly. Secure each with a bolt and washer. Install
25. Install the sled assembly onto the adjusting bolts and
two adjusting blocks and secure each with two bolts and
install both swivel nuts and regular nuts, making sure
washers. Install adjusting screws and lock nuts. (Two
that the extension cables are not crossed and twisted.
each on top and two each on side.)
NOTE: Use adjusting screws as necessary to adjust wear
pad so that the wear pad is just touching or is within
DANGER 2 mm (0.078 in) of the fly section side plate at both
Ensure the telescope cylinders are securely blocked and the top and side surfaces of the top radius.
some means used to hold them together to prevent any 37. Install bottom and side wear pad keeper plate on each
accidental movement. Severe injury can occur if the side of the outer mid and secure with 16 bolts and wash-
cylinders drop. ers each.

26. Slide the telescope cylinders into the fly section until the 38. Continue to completely slide together.
trunnion on the upper cylinder is three feet from the back 39. Lift up on end of the upper cylinder to align barrel mount-
of the fly. ing plate holes with holes in outer mid. Secure each with 4
27. Block up the telescope cylinders at the rear of the fly four bolts and hardened washers.
section to aid in installing the fly section assembly into 40. Remove any blocking under the upper cylinder.
the outer mid.
41. Detach the retract cables from the upper telescope cylin-
28. At the rear of the outer mid section, install the upper der, place the cables around each retract sheave, place
wear pad grease line, connector and grease fitting on the sheave onto the shaft weld and use four bolts and
each side. washers to secure each shaft weld assembly into the
29. Install the bottom rear wear pad on the outer mid section rear of the outer mid, making sure that the retract cables
with two bolts and hardened washers. are not crossed and twisted.

30. Position the front end of the outer mid at the rear of the 42. Install and adjust guide bolts to the correct clearance
fly/telescope cylinder assembly. with respect to the guide plate on next section. Lock in
place with lock nuts.
31. Place the mounting plates on the upper telescope cylin-
der barrel mounting lugs. 43. Place the mounting plates on the second stage lower
cylinder barrel mounting lugs and on mounting lugs of
32. Slide the fly/telescope cylinder assembly into the outer the rod of upper cylinder.
mid section installing top rear wear pads in the pockets
of the fly section (cutout should align with grease line). 44. At the rear of the outer mid install the fittings and hoses
Stop and check rear wear pad clearance and shim if to both retract sheaves, then grease sheaves.
needed. 45. At the rear of the center mid section, install the upper
NOTE: Use shims as they are necessary to adjust wear wear pad grease line, connector and grease fitting on
pads within 2 mm (0.078 in) of the outer mid sec- each side.
tion side plate. Use equal number of shims on side 46. Install the lower wear pad and shims on the rear of the
pads. center mid with two bolts and washers.
33. Continue to slide together being careful not to damage 47. Position the front end of the center mid at the rear of the
cables. outer mid/fly/telescope cylinder assembly.
34. Install bottom and side front wear pads in outer mid. Lift 48. Slide the outer mid/fly/telescope cylinder assembly into
up in the front of the fly section assembly, check clear- the center mid section installing top rear wear pads in
ance between the pads and the pad box weldment on pockets of outer mid section (cutout should align with
the outer mid section. Install shims as necessary so grease line). Stop and install rear side wear pads and
there is no more than 1 mm (0.03 in) clearance between shims on outer mid section with two bolts each.
the wear pads and the fly section.
NOTE: Use shims as they are necessary to adjust wear
If necessary, attach front upper wear pad to wear pad pads within 2 mm (0.078 in) of the center mid sec-
plate using four bolts.

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BOOM RT890E3 SERVICE MANUAL

tion side plate. Use equal number of shims on each 63. At the rear of the inner mid section, install the upper
side. wear pad grease line, connector, and fitting on each
side.
49. Install bottom and side front wear pads in center mid. Lift
up in the front of the outer mid section assembly, check 64. Install the bottom rear wear pad on the inner mid section
clearance between the pads and the pad box weldment with two bolts and washers.
on the center mid section. Install shims as necessary so
65. Position the front end of the inner mid at the rear of the
there is no more than 1 mm (0.03 in) clearance between
center mid/outer mid/fly/telescope cylinder assembly.
the wear pads and the outer mid section.
66. Slide the center mid/outer mid/fly/telescope cylinder
If necessary, attach front upper wear pad to wear pad
assembly into the inner mid section installing top rear
plate using four bolts.
wear pads in pockets of the center mid section (cutout
50. Install center mid front top wear pads and shims as should align with grease line). Stop and install rear side
noted during disassembly. Secure with four bolts and wear pads and shims on center mid section with two
washers each. bolts each.
NOTE: Use adjusting screws as necessary to adjust wear NOTE: Use shims as necessary to adjust wear pad so it is
pad so that the wear pad is just touching or is within within 2 mm (0.078 in) of the inner mid section side
2 mm (0.078 in) of the outer mid section side plate plate. Use equal number of shims on each side.
at both the top and side surfaces of the top radius.
67. Continue to slide together.
51. Install bottom and side wear pad keeper plate on each
68. Install bottom and side front wear pads in the inner mid.
side of the center mid and secure with six bolts and
Lift up in the front of the center mid section assembly,
washers each.
check clearance between the pads and the pad box
52. Continue to slide together aligning the upper cylinder rod weldment on the inner mid section. Install shims as nec-
end mounting plate holes with holes in center mid. essary so there is no more than 1 mm (0.03 in) clear-
Secure each with four bolts and washers. Slide com- ance between the wear pads and the center mid section.
pletely together.
If necessary, attach front upper wear pad to wear pad
53. Install tapped pusher rod, bolt, nut, and washer in right plate using four bolts.
side of center mid.
69. Install center mid front top wear pads and shims as
54. Install left side valve pusher weld assembly in guides on noted during disassembly. Secure each with four bolts
left side of center mid, then attach return spring. and washers.
55. Lift up on end of the lower cylinder to align barrel mount- NOTE: Use adjusting screws as necessary to adjust wear
ing plate holes with holes in inner mid. Secure each with pad so that the wear pad is just touching or is within
four bolts and hardened washers. 2 mm (0.078 in) of the outer mid section side plate
at both the top and side surfaces of the top radius.
56. Remove any blocking under cylinder.
70. Install bottom and side wear pad keeper plate on each
57. Install the cam valves on the mounting plates on each
side of the inner mid and secure with six bolts and wash-
side of the inner mid using three bolts, hardened wash-
ers each.
ers, and nuts each.
71. Continue to completely slide together.
58. Install hydraulic manifold on the mount plate at the rear
of the center mid with four bolts and washers. 72. Lift up on end of the lower cylinder to align barrel mount-
ing plate holes with holes in inner mid. Secure each with
59. If removed, install hydraulic fittings in the ports of the
four bolts and hardened washers.
valves, hydraulic manifold, and the cylinders as tagged
during disassembly. 73. Remove any blocking under cylinder.
60. Connect the hydraulic hoses and tubing to the valves, 74. Install the trigger plate at the front of the inner mid.
hydraulic manifold, and cylinders as tagged during dis-
75. Install and adjust guide bolts to the correct clearance
assembly.
with respect to the guide plate on next section. Lock in
61. Place the mounting plates on the lower cylinder barrel place with lock nuts.
mounting lugs.
76. If removed, install the roller shaft and cotter pins at the
62. Install and adjust guide bolts to the correct clearance rear of the inner mid. Place the mounting plates on the
with respect to the guide plate on the next section. Lock lower cylinder rod mounting lugs.
in place with lock nuts.

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RT890E3 SERVICE MANUAL BOOM

77. Position the front end of the base at the rear of the inner 90. Repeat step 88 on the center mid, installing two cable
mid/center mid/outer mid/fly/telescope cylinder assem- pads.
bly.
91. Repeat step 88 on outer mid, installing two cable pads.
78. Slide the inner mid/center mid/outer mid/fly/telescope
cylinder assembly into the base section installing top
rear wear pads in pockets of inner mid section (cutout
should align with grease line). Stop and install rear side DANGER
wear pads and shims on inner mid section with two bolts The boom assembly must be rotated 180° right side up to
each. install on crane.
NOTE: Use shims as necessary to adjust wear pad so it is A rollover fixture with webbing is recommended to rotate
within 2 mm (0.078 in) of the base section side boom and sections. Chains are not recommended. If a
plate. Use equal number of shims on each side. rollover fixture is not available, rotate sections using
adequate support with webbing.
79. Continue to slide together.
80. Install bottom and side front wear pads in base. Lift up in NOTE: The boom weighs approximately 12033 kg
the front of the inner mid section assembly, check clear- (26,528 lb). The above weight is for the boom with-
ance between the pads and the pad box weldment on out the swingaway boom extension attached.
the base section. Install shims as necessary so there is
92. Lower the boom to ground level and secure with cribbing
no more than 1 mm (0.03 in) clearance between the
wear pads and the inner mid section. to prevent tipping. 4
If necessary, attach front upper wear pad to wear pad 93. On the left side only, install a RCL cable angle bracket
plate using four bolts. on the base, inner mid, and outer mid using two bolts
and washers each.
81. Install center mid front top wear pads and shims as
noted during disassembly. Secure with four bolts and 94. Install the boom in accordance with the INSTALLATION
washers each. procedures outlined in this section.

NOTE: Use adjusting screws as necessary to adjust wear Installation

pad so that the wear pad is just touching or is within
2mm (0.078 in) of the inner mid section side plate NOTE: The following procedure applies to a boom totally
at both the top and side surfaces of the top radius. removed from the crane.

82. Install bottom and side wear pad keeper plate on each
side of the base section and secure with six bolts and
washers each.
DANGER
83. Continue to completely slide together. Block the boom before doing any work under the boom.
84. Continue to slide together aligning the lower cylinder rod Ensure blocking and lifting devices are capable of
end mounting plate holes with holes in base section. supporting the boom assembly.
Secure each with four bolts and hardened washer.
1. Attach an adequate lifting device to the boom and sus-
85. Install hydraulic fittings if removed from lower telescope pend the boom over the machine.
cylinder rod.
2. Lower the boom into position and align the boom pivot
86. If removed, install the four rollers, spindle roller, and cot- shaft mounting holes for installation of the pivot shaft to
ter pins to the rear of the base section. the superstructure assembly.
87. Install and adjust guide bolts to the correct clearance 3. Lubricate the pivot shaft bushings in the superstructure
with respect to the guide plate on next section. Lock in assembly.
place with lock nuts.
4. Block the boom in place.
88. On the top front of the base section, install bolts, wash-
ers, and three cable pads. 5. The boom may need to be raised or lowered to aid in the
installation of the pivot shaft. Install pivot shaft.
89. Repeat step 88 on the inner mid, installing two cable
pads. 6. Install anti-rotation pin and lock in place with clip pin.

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BOOM RT890E3 SERVICE MANUAL

18. Install the base cover on top of the boom base section,
then secure with four bolts and washers.
19. Connect any electrical wires as tagged prior to removal.
DANGER
Failure to properly support the boom lift cylinder may 20. Refer to BOOM EXTENSION AND RETRACTION
result in death or injury to personnel. CABLE ADJUSTMENT in this section for cable adjust-
ments.
7. Using the lifting device attached to the boom, lower the 21. Refer to CAM OPERATED CHECK VALVE ADJUST-
boom onto the lift cylinder rod end and extend the lift cyl- MENT in this section for valve adjustment.
inder as necessary to align rod with attach fitting on
boom. Functional Check
1. Activate the hydraulic system and check for proper oper-
ation and any leaks.
DANGER 2. Ensure the boom will extend and retract properly.
If the hydraulic system must be activated to extend or 3. Ensure the lift cylinder will not allow the boom to drift
retract the lift cylinder, ensure the rod end is properly down until the operator lowers it.
aligned with the lift cylinder attach fitting.
4. Ensure all electrical components disconnected during
8. Lubricate the upper lift cylinder pin. Install upper lift cylin- removal are operating properly.
der pin. The lift cylinder may need to be raised or low-
ered to aid in the installation of the lift cylinder pin into Inspection
the lift box, this can be done by using the jack on the lift Visually inspect telescoping sections for adequate lubrication
cylinder support. Return pump handle to cab. of all wear surfaces. Observe extended sections for
9. Secure the upper lift cylinder pin with the bolt and evidence of cracks, warping, or other damage. Periodically
washer to the attached fitting on the boom. check security of boom wear pads. Check boom nose
sheaves for security and freedom of movement.
10. Lower the jack on the lift cylinder support.
Should boom chatter or rubbing noises in the boom occur, it
11. Remove the boom lifting device. will be necessary to lubricate the telescope cylinder wear
12. Activate the hydraulic system and remove the boom and pads. Refer to SECTION 9.
lift cylinder blocking devices. Lower the boom to horizon-
tal. Shut down the crane. Boom Alignment and Servicing
13. Connect the hydraulic lines to the lower telescope cylin- Refer to SECTION 9 for the proper lubricant.
der as tagged prior to removal and connect the PAT lines Boom alignment is done as the boom sections are being
(RCL). assembled into one another. A check and fine adjustment is
14. Run the boom in or out to get the inner mid to the access as follows.
hole in the base. Connect the lines from the hose reel to 1. Fully extend the boom horizontally.
the boom.
2. Lubricate the boom bottom channels and top corners.
15. After the bi-line is connected you should be able to pull
the bi-line hoses by hand to remove the S-hook. 3. Adjust the front top wear pads such that wear pad is just
touching or is no more than 2 mm (0.078 in) from con-
NOTE: Be sure to hold tension on the hose and allow them tacting the next section both at the top and side surfaces
to wrap up on the reel. of the top radius.
16. Tele the boom out to take up a majority of the slack in the
hoses. Leave a little slack to be sure you do not put too
much pressure on the hoses. Be careful not to pinch or CAUTION
damage the lines. When extending and retrac ti ng the boom during
alignment, movement should be stopped if a restriction is
17. With the crane off, connect the hydraulic line that feeds
encountered, and wear pads adjusted as necessary to
the hose reel. Note: Do not hit the tele control. The
provide free travel of the affected boom section(s).
hydraulic system will finish wrapping the hoses as soon
as the crane starts. It is suggested the someone watch
the hoses to make sure they wrap correctly.

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RT890E3 SERVICE MANUAL BOOM

4. Retract and extend the boom; check for the high point Guide Block Adjustment
where the boom has brushed the wear pads at the wid-
est point. 1. Align and service the boom by following the instructions
in Boom Alignment and Servicing page 4-20.
5. Retract the boom sections to align the high point on the
boom section with the adjacent wear pads. 2. Adjust the bolts at the top and bottom of the inner/center/
outer/ and fly section so that the bolt is within 0 to 2 mm
6. Add or subtract shims as necessary. of the guide plate on the top and bottom of the next sec-
7. Attach a weight and extend the boom full length. Check tion.
for side deflection. 3. After obtaining proper clearance, tighten the four lock-
nuts.
Example: If the boom deflects to the left, the top left wear pad
would have shims added and the top right wear pad would
have shims removed. BOOM EXTENSION AND RETRACTION
CABLE
Cam Operated Check Valve Adjustment
Maintenance
There are two cam operated valves mounted on the back of
the center mid section. When the boom is fully retracted or NOTE: For more detailed information concerning mainte-
the center mid is fully extended and the outer mid is fully nance of the extension and retraction cables, refer
retracted, the valve on the right side of the boom is held open
to supply flow to the second stage of the lower cylinder.
to WIRE ROPE in SECTION 1.
4
When the center mid is fully extended, the valve on the left Inspection
side of the boom opens to supply flow to the upper telescope
cylinder. For a short period of time, both valves are open
because the booms second stage lower cylinder is fully
extended before the upper cylinder starts to extend. As the CAUTION
outer mid starts to extend, the valve on the right side closes Never handle wire rope with bare hands.
to shut off the flow to the second stage of the lower cylinder.
1. Ensure the extend and retract cables are adjusted. The following information is tak en from a National
Consensus standard as referenced by Federal Government
2. Extend the inner mid section out of the base section until Agencies.
the front access holes on the inner mid section are
accessible. The inner mid section can be extended com- All wire rope will eventually deteriorate to a point where it is
pletely if needed. Extend the center mid section com- no longer usable. Wire rope shall be taken out of service
pletely making sure that the outer mid section is against when any of the following conditions exist.
the stop blocks on the center mid section. 1. In running ropes, six randomly distributed broken wires
3. Access the check valves through the front access holes in one lay or three broken wires in one strand in one lay.
on each side of the inner mid section. 2. Wear of one-third the original diameter of outside individ-
4. Left side valve: on the left side of the inner mid section, ual wires. Kinking, crushing, bird caging, or any other
adjust the trigger plate to move the pusher weld causing damage resulting in distortion of the rope structure.
the pusher to just contact the valve stem. Continue to 3. Evidence of any heat damage from any cause.
adjust the trigger plate until the pusher depresses the
valve stem approximately 10 mm (0.39 in). Tighten the 4. Reductions from nominal diameter of more than:
nuts. - 0.4 mm (0.016 in) for diameters up to and including
5. Right side valve: through the access hole in the inner 8 mm (0.3125 in).
mid section on the right rear of the center mid, loosen - 0.79 mm (0.031 in) for diameters 10 and 13 mm
the lock nut and adjust the bolt until it just contacts the (0.375 and 0.5 in) inclusive.
valve stem. Continue to adjust the bolt until it depresses
the valve stem approximately 10 mm (0.39 in). Tighten - 1.19 mm (0.047 in) for diameters 14 to 19 mm
the lock nut. (0.5625 to 0.7 in) inclusive.
- 1.59 mm (0.063 in) for diameters 22 to 29 mm
(0.875 to 1.125 in) inclusive.
- 2.38 mm (0.094 in) for diameters 32 to 38 mm (1.25
to 1.5 in) inclusive.

GROVE Published 07-24-2013, Control # 069-12 4-21

BOOM RT890E3 SERVICE MANUAL

5. In standing ropes, more than two broken wires in one lay 6. Lock the adjustments with the jam nuts.
in sections beyond end connections or more than one
7. Extend the boom until the outer mid/fly extends several
broken wire at an end connection.
cm (in).
Adjustment 8. Retract the boom until either the fly section just contacts
At near fully extended boom length, during sudden extension the outer mid stop block or the outer mid section just
after retracting the boom some distance, and with high contacts the inner mid stop block.
telescoping speeds, the extension cables may slap the 9. Check the gap between the stop blocks and the boom
inside of the boom section. This will make a somewhat sections. If there is a gap between the center mid sec-
audible noise, however this will not cause any damage and is tion’s stop block and the outer mid of more than 3 mm
acceptable. If the cables do not make a slapping noise under (0.125 in), loosen the retract cable. If there is gap
these conditions, it is an indication that the extension cables between the outer mid section’s stop block and the fly
may be too tight and should be readjusted. Be aware that section, tighten the retract cable slightly.
there may also be a similar noise made by the telescope
cylinder rod mount at the rear of the base section and center
mid section and confusion between the two could be CAUTION
experienced.
Overtightening of the retract cable will damage the cable.
Take care when retracting the boom fully, while adjusting
the cable, to avoid full boom retraction if the fly section
CAUTION contacts its stop block more than 3 mm (0.125 in) before
When adjusting cables, hold the cable end and turn the the outer mid section contacts its stop block on the center
nut. Do not turn cable. Turning cable while adjusting will mid.
result in damage or failure of cable.
10. Extend the boom approximately 1.5 cm (6 in). Retract
NOTE: The extension cables must be adjusted properly the boom again until one of the stop blocks just contacts
before the retract cables can be adjusted. its boom section.
1. Extend and set the outriggers, ensuring the crane is 11. Again check the gap as in step 9 and if necessary, make
level. further adjustments.
2. Ensure the boom is over the front and at a horizontal 12. Repeat steps 10 and 11 until there is a 3 mm (0.125 in)
position (boom angle elevation 0 degrees or lower). gap at the outer mid section’s stop block when the fly
3. With the inner mid section completely retracted, extend section’s stop block has just made contact.
the center mid section until the large access hole at the 13. Lock the retract cable adjustments with the jam nuts.
front of the center mid is lined up with the large access
hole in the outer mid section. NOTE: If grease zerks are not fully accessible at full boom
extension, make the following adjustments.
4. With the front of the boom in the above position, extend
the boom approximately 25 mm (1 in) to relieve the ten- 14. Retract boom approximately one foot and tighten extend
sion in the retract cables. Access the retract cables from cables one full turn each.
the front of the boom nose and view the slack of the 15. Extend boom to make sure grease zerks line up with
retract cables through the hole in the back of the boom hole. If not lined up with hole, retract boom slightly and
nose. Using the nuts on the retract cables, remove slack add one additional turn on each of the extend cables.
evenly, until both retract cables are at least 25 mm (1 in)
above the lower leg of the cable retainer bars on the cyl- 16. Once grease zerk lines up with boom at full extension,
inder foot support on the upper telescope cylinder. fully retract boom at Hi speed. When boom initially
begins to retract, extension cables should become slack
5. Retract the boom approximately 25 mm (1 in) to relieve enough to hit the boom section. If this does not happen,
tension on the extension cables. Shut down the crane. reduce tension on retract cables until they do become
Access the extension cable adjusting bolts through the slack.
access hole in front of the center mid section. Evenly
tighten the swivel nuts on the adjusting bolts, until the 17. Just as the boom begins to bottom out, observe that the
extension cables are up 150 mm (6 in) off the top of the fly still bottoms out before the outer mid. If so, all adjust-
bottom pad plate at the back of the fly section. Look ments are correct.
through the access hole on the center mid section.

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RT890E3 SERVICE MANUAL BOOM

TELESCOPE CIRCUIT the lower telescope cylinder. The holding valve for the
second stage of the lower telescope cylinder is mounted into
Description the port block on the barrel end of the second stage barrel.
The holding valves function during the retraction, extension,
The boom telescope circuit consists of the telescope or holding operation. When holding the boom section at a
hydraulic remote controller, telescope directional control given length, oil is trapped in the cylinder by the holding
valve, holding valve, hose reel, and the upper and lower valve. Refer to VALVES in SECTION 2 for a complete
telescope cylinders. description of the holding valve.
The telescope control valve is the closed spool type and is
described under VALVES in SECTION 2 along with a Theory of Operation
complete description of the hydraulic remote controller. Flow from the pump travels to the telescope directional
The boom telescope system has a lower and an upper control valve. Movement of the foot pedal for telescope
telescope cylinder. The lower telescope cylinder is a two functions from neutral sends a pilot pressure signal to the
stage cylinder. The first stage is 6.50 inch bore and the directional control valve to shift the spool in the directional
second stage is a 8.25 inch bore. The upper has a 6.50 inch control valve. This aligns the appropriate passages in the
bore. Foreign material is prevented from entering the control valve to route oil to the telescope cylinders.
cylinder by a wiper seal during rod retraction. O-ring seals Also refer to BOOM - THEORY OF OPERATION in this
prevent internal and external leakage. Refer to CYLINDERS Section.
in SECTION 2 for a complete description of the telescope
cylinder. Maintenance
4
A holding valve is threaded into a port block on the rod end of
Troubleshooting
the upper telescope cylinder and the first stage rod end on

SYMPTOM PROBABLE CAUSE SOLUTION

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

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BOOM RT890E3 SERVICE MANUAL

SYMPTOM PROBABLE CAUSE SOLUTION

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

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RT890E3 SERVICE MANUAL BOOM

SYMPTOM PROBABLE CAUSE SOLUTION

4. Telescope cylinder a. Low hydraulic oil level. a. Replenish oil to proper level.
will not retract.
b. Relief valve damaged. b. Repair or replace relief valve.
c. Excessive load. c. Reduce load. (Refer to load chart).
d. Inoperative check valve. d. Replace check valve.
e. Clogged hose and fittings. e. Replace hose or fittings. (Refer to Parts
Manual).
f. Broken valve spool. f. Replace valve section.
g. Broken piston(s). g. Replace piston(s) and all cylinder
seals.
h. Damaged piston seals. h. Replace all cylinder seals.
i. Bent boom section(s). i. Replace damaged boom section(s).
j. Broken hydraulic pump coupling. j. Replace broken hydraulic pump
coupling.
k. Worn or damaged hydraulic pump. k. Repair or replace pump. 4
l. Broken hydraulic pump shaft. l. Replace pump shaft.
5. Center mid will not a. Right side check valve blocked. a. Readjust, repair, or replace valve.
extend.
6. Center mid will not a. Right side check valve closed. a. Readjust valve.
retract.
7. Outer mid will not a. Left side check valve is closed. a. Readjust valve.
extend.
8. Center mid retracts a. Right side check valve is open or a. Install hoses properly.
before outer mid. hosed backwards.
9. Outer mid extends a. Left check valve is open or hosed a. Install hoses properly.
only a short dis- backwards.
tance then stops.

Removal and Installation The hose reel is spring return. The spring return provides
drag on the hoses so that no slack develops when the
Removal and installation of the telescope cylinder from the
telescope cylinders are being extended or the boom is being
boom is described under disassembly and assembly of the
lowered, and retrieves the hoses as the telescope cylinders
boom. Refer to BOOM MAINTENANCE in this Section.
are being retracted or when the boom is raised.
Disassembly and Assembly
Maintenance
Disassembly and assembly procedures of the telescope
cylinder and control valve are provided in SECTION 2 under Service
CYLINDERS and VALVES respectively.
Lubricate the hose reel spring with engine oil through the
drain access holes located around the circumference of the
HOSE REEL spring cover. Lubricate every 50 operating hours.

Description With the boom fully retracted, spray motor oil, under
pressure, into the hose reel spring housing. The spring
The quadruple plus one hydraulic hose reel Figure 4-5 should be saturated with oil. If air pressure lubricating
supplies the boom manifold for the upper telescope cylinder. equipment is not available, use a pump oil can, but ensure
The hose reel is mounted in the turntable center section, the spring is completely saturated with oil.
under the boom.

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BOOM RT890E3 SERVICE MANUAL

Removal NOTE: Ensure there is enough hose unwound from the

hose reel to attach the hoses to the telescope cylin-
ders.

DANGER
Before disconnecting the hoses from the outer mid
telescoping cylinders, secure the hoses from rotating by DANGER
using the hose reel retaining bolt and drum locking Ensure the retaining bolt remains installed until the hoses
brackets. are attached to the telescope cylinders.

1. Secure the rotation of the hose reel by using the retain- 3. Connect the hydraulic hoses to the manifold block
ing bolt and drum locking bracket. assembly located at the rear of the boom inner mid
section.
2. Tag and disconnect the hydraulic supply hoses for the
hose reel assembly; cap hoses and openings. 4. Remove the retaining bolt from the hose reel to allow
tension to be applied to the hoses.
3. Tag and disconnect the hose reel hydraulic hoses from
the manifold block assembly; cap hoses and openings. 5. Secure the retaining bolt to the hose reel so the hose
reel is allowed to rotate.
4. Remove the capscrews and washers securing the hose
reel to the turntable, remove the hose reel. 6. Adjust and secure the hose retainer.
Installation Hose Reel Alignment
NOTE: The drum must have a minimum of two pre- tension After hose reel is installed and the attaching bolts properly
turns. torqued, check hose reel to hose guide roller alignment
1. Position the hose reel assembly on the turntable and Figure 4-5.
secure with the washer and capscrews. Torque the cap- 1. Check measurements between the hose reel’s hose
screws refer to SECTION 1-Fasteners and Torque Val- flanges and its guide roller Figure 4-5.
ues.
2. Add shims as required to align the hose reel assembly to
2. Connect the hydraulic supply hoses to the hose reel the roller within 2 mm (0.07 inches).
assembly.

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RT890E3 SERVICE MANUAL BOOM

6 12
4 13
5
3
8 7 10
15

6434-2

12
1
2 11 13

6434-3

12 14
9
4
2 mm (0.07 in)

2 mm
(0.07 in)

Shims 6434-1

Hose Reel To Hose Guide Roller Alignment FIGURE 4-5

Item Description Item Description

1 Sprocket 9 Bearing
2 Bearing 10 Swivel Joint
3 Brake 11 Hose Reel
4 Clevis Pin 12 Chain
5 Brake Mount 13 Orbit Motor
6 Cotter Pin 14 Disk
7 Boot 15 Motor Mount
8 Housing

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BOOM RT890E3 SERVICE MANUAL

LIFT CIRCUIT
Description The holding valve is a balanced poppet type hydraulic valve.
It is threaded into the port block which is an integral portion of
The boom lift circuit consists of the lift hydraulic remote the lift cylinder barrel. The holding valve functions when
controller, lift directional control valve, holding valve, and the booming up (cylinder rod extended), booming down (cylinder
lift cylinder. These components enable the boom to be raised rod retracted), or holding (cylinder rod stationary).
or lowered to various degrees of elevation ranging from -3 to
+78 degrees from horizontal. Theory of Operation
The lift directional control valve is the closed spool type and The directional control valve bank housing the lift control
is described under VALVES in Section 2 - HYDRAULIC valve is supplied by flow from the hydraulic pump.
SYSTEM.
When booming up, oil unseats the poppet (check) valve in
Refer to VALVES in Section 2 for a complete description of the holding valve, letting oil flow to the piston side of the
the hydraulic remote controller. cylinder. Pressure is applied to the piston, forcing the rod to
The RT890E3 lift cylinder has a 30.48 cm (12.0 in) bore. The extend, raising the boom.
cylinder is a double acting type. Dirt and other foreign When booming down, oil enters the retract port of the port
material is prevented from entering the cylinder and causing block and flows to the cylinder rod side. When pilot pressure
internal damage by a wiper seal during rod retraction. Oil reaches a pre-determined value, the main poppet unseats
seals on both the piston and cylinder head prevent internal and oil flows from the piston side of the cylinder to the
and external hydraulic oil leakage. Refer to CYLINDERS in reservoir.
Section 2 for a complete description of the lift cylinder.
All return flow from the control valve goes to the reservoir.

Maintenance
Troubleshooting

Symptom Probable Cause Solution

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

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RT890E3 SERVICE MANUAL BOOM

Symptom Probable Cause Solution

3. Boom raises a. Low hydraulic oil level. a. Replenish hydraulic oil to proper level.
slowly.
b. Low engine rpm. b. Increase and maintain engine rpm.
c. Damaged relief valve. c. Repair or replace relief valve.
d. Extremely cold hydraulic oil. d. Operate unit to bring oil to operating
temperature.
e. Improper hose or fittings, installed. e. Replace hose or fittings. (Refer to Parts
Manual).
f. Operating two functions with in the same f. Feather controls to obtain desired speed
control valve bank assembly. of both functions.
g. Restriction in return hose. g. Replace return hose.
h. Cylinder piston seals leaking. h. Replace all cylinder seals.
i. Scored cylinder barrel. i. Hone or replace barrel.
j. Worn hydraulic pump section. j. Repair or replace pump section.
4. Boom lowers
slowly.
a. Low hydraulic oil level. a. Replenish hydraulic oil to proper level. 4
b. Low engine rpm. b. Increase rpm to recommended level.
c. Damaged relief valve. c. Repair or replace relief valve.
d. Operating two functions within the same d. Feather controls to obtain desired speed
control valve bank assembly. of both functions.
e. Extremely cold hydraulic oil. e. Operate unit to bring oil to operating
temperature.
f. Improper hose or fittings installed. f. Replace hose or fittings. (Refer to Parts
Manual).
g. Restriction in return hose. g. Replace return hose.
h. Cylinder piston seals worn. h. Replace all cylinder seals.
i. Scored cylinder barrel. i. Hone or replace barrel.
j. Worn hydraulic pump section. j. Repair or replace pump section.
k. Piston rod broken (loose from piston). k. Replace piston rod and all cylinder seals.
5. Boom will not raise. a. Low hydraulic oil. a. Replenish hydraulic oil to proper level.
b. Main relief valve or circuit relief valve b. Repair or replace relief valve.
damaged.
c. Excessive load. c. Reduce load as required.
d. Worn or damaged hydraulic pump d. Repair or replace pump section.
section.
e. Broken pump shaft. e. Replace pump shaft and seals.
f. Broken pump drive coupling. f. Replace drive coupling.
g. Broken control valve spool. g. Replace control valve.

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BOOM RT890E3 SERVICE MANUAL

Symptom Probable Cause Solution

6. Boom will not a. Low hydraulic oil. a. Replenish hydraulic oil to proper level.
lower.
b. Main relief valve or circuit relief valve b. Repair or replace relief valve.
damaged.
c. Worn or damaged hydraulic pump c. Repair or replace pump section.
section.
d. Broken pump shaft. d. Replace pump shaft and seals.
e. Broken pump drive coupling. e. Replace drive coupling.
f. Broken control valve spool. f. Replace control valve.
NOTE: Refer to SECTION 2 for Lift Cylinder Disassembly the shaft is clear of the lift box, activate the hydraulic sys-
and Assembly procedures. Maintenance not requir- tem and retract the lift cylinder enough to clear the upper
ing removal of the cylinder barrels, such as packing, attach point.
may be performed without removing the cylinders 8. Tag and disconnect all the hydraulic lines to the cylinder.
from the turntable. However, all disassembly and Cap or plug all openings with high pressure fittings.
assembly should be conducted in a clean dust-free
9. Pull the lower lift cylinder pivot shaft out far enough to
area.
remove the cylinder.
Removal
10. Move the lift cylinder to a clean work area.
1. Extend and set the outriggers and level the crane.
Disassembly and Assembly
2. Elevate the boom slightly so that the lift cylinder is
Disassembly and assembly procedures of the lift cylinder
extended approximately 0.3 m (1 ft).
holding valve, and control valve are provided in SECTION 2
under CYLINDERS and VALVES respectively.
Installation
DANGER 1. Attach an adequate lifting device to the lift cylinder and
position the cylinder over the attach fitting on the turnta-
Ensure any blocking or cribbing used is capable of ble.
supporting the boom.
2. Lower the lift cylinder into the attach fittings on the turnta-
ble and align the lift cylinder bushing with the attach fitting
3. Ensure the boom is fully supported by placing blocking or holes.
cribbing under the boom. Rest the boom on the blocking
NOTE: Install pivot shaft with tapped hole on the right side,
or cribbing.
side opposite the cab.
4. Remove the bolt and washer securing the lift cylinder
3. Install the lift cylinder lower pivot shaft and secure with the
upper pivot shaft to the boom.
bolt and locknut.
5. Remove the bolt and locknut securing the lift cylinder
4. Connect the extend and retract hoses to the lift cylinder.
lower pivot shaft to the turntable.
5. Activate the crane’s hydraulic system and align the lift cyl-
inder rod end with the attach point on the boom. Using the
hand pump located on the left side of the boom, insert the
pump lever (found in cab) into the hand pump. Turn the
DANGER pump flow control lever counterclockwise and pump the
Ensure the lifting/supporting device is capable of pump lever until the upper lift cylinder pivot shaft is
supporting the lift cylinder. engaged and completely against the side plate of the
boom lift box. The lift cylinder may need to be raised or
lowered to aid in the installation of the lift cylinder pivot
6. Attach an adequate lifting/supporting device to the lift cyl-
shaft into the lift box. This can be done by using the jack
inder.
on the lift cylinder support. Shut down the engine.
7. Remove the upper lift cylinder pivot shaft by inserting the
pump lever (found in cab) into the hand pump located on 6. Secure the upper pivot shaft to the boom with the bolt and
the left side of the boom. Turn the pump flow control lever washer.
clockwise and pump the lever until the upper lift cylinder 7. Remove the lifting and supporting devices from the boom
pivot shaft is clear of the boom lift box. The lift cylinder and lift cylinders. Activate the hydraulic system and check
may need to be raised or lowered to aid in the release of the lift cylinders for proper operation and any leaks. Lubri-
the lift cylinder pivot shaft from the lift box. This can be cate the pivot shafts using grease fittings. Refer to
done by using the jack on the lift cylinder support. Once Figure 4-6.

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RT890E3 SERVICE MANUAL BOOM

Item Description
1 Lift Cylinder 1

2 Shaft
3 Bolt and Nut
4 Grease Fitting

4
Cutaway For Clarity

6266-1

2 1
6317-5

6317-4
FIGURE 4-6

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BOOM RT890E3 SERVICE MANUAL

AUXILIARY BOOM NOSE part cable usage. The rooster sheave is installed on the main
boom nose and is secured by attach pins that pass through
Description the rooster sheave and the main boom nose.

The auxiliary boom nose Figure 4-7 (rooster sheave) is

available for the boom to simplify single part and maximum

AUXILIARY BOOM NOSE

ATTACH PINS

MAIN BOOM NOSE

6435

FIGURE 4-7

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RT890E3 SERVICE MANUAL BOOM

COUNTERWEIGHT WITH AUXILIARY HOIST 3. Properly attach chains with clevis to the counterweight
lifting holes Figure 4-9 and use a crane to carefully
Removal transfer the counterweight and auxiliary hoist to the
1. Position the crane on a firm, level surface. Fully extend frame counterweight supports over the rear outrigger
and set the outriggers. Level the crane. box.

2. Position the superstructure over the front of the machine 4. Attach the counterweight removal cylinder hydraulic
and engage the turntable lock. lines.

3. Remove any load and handling device from the auxiliary 5. Using the control levers (left and right), extend the
hoist cable and retract all cable onto the hoist drum. counterweight removal cylinders, one at a time, guiding
Secure the cable. them into the turntable wing/support brackets and pin
securely.
4. Disconnect the auxiliary hoist hydraulic lines and
electrical harness and secure. Do not disconnect the 6. Using the control levers (left and right), simultaneously
counterweight removal cylinder hydraulic lines. retract (raise) the counterweight removal cylinders until
the counterweight round bar engages the lugs on the
5. Remove the ball detent pins which secure the turntable and the counterweight pinning holes are
counterweight mounting pins. aligned with the counterweight mounting pins. Feather
individual controls as required to raise the counterweight
6. Ensure that the counterweight removal cylinder support
pins are securely attaching the counterweight to the
in a level position. 4
turntable wing-support brackets. Disengage the 7. Engage the counterweight mounting pins using the
counterweight mounting pins using the pinning control control lever (center).
lever (center).
8. Attach the ball detent pins securing the counterweight
NOTE: It may be necessary to retract the counterweight
mounting pins.
removal cylinders Figure 4-8 and Figure 4-9 to
relieve weight from the counterweight mounting 9. Relieve pressure on the counterweight removal cylinder
pins. so that weight is fully supported by the counterweight
mounting pins.
7. Using the control levers (left and right), simultaneously
extend (lower) the counterweight onto the frame 10. Attach the auxiliary hoist hydraulic lines and electrical
counterweight supports. Feather individual controls as harness.
required to lower the counterweight in a level position.
COUNTERWEIGHT WITHOUT AUXILIARY
8. Remove the counterweight removal support pins from
turntable wing-support brackets and using the control
HOIST
levers (left and right), retract the counterweight removal Removal
cylinders fully.
1. Position the crane on a firm, level surface. Fully extend
9. Disconnect and secure the counterweight removal and set the outriggers.
cylinder hydraulic lines and replace the counterweight
removal cylinder support pins on the turntable wing- 2. Position the superstructure over the front of the machine
support brackets. and engage the turntable lock.
3. Remove the ball detent pins which secure the counter-
10. Properly attach chains with clevis to the counterweight weight mounting pins.
lifting holes Figure 4-9 and use a crane to carefully
transfer the counterweight and auxiliary hoist to the 4. Ensure that the counterweight removal cylinder support
ground or a suitable transport vehicle. pins are securely attaching the counterweight to the
Installation turntable wing/support brackets. Disengage the
counterweight mounting pins using the pinning control
1. Position the crane on a firm, level surface. Fully extend lever (center).
and set the outriggers. Level the crane.
NOTE: It may be necessary to retract the counterweight
2. Position the superstructure over the front of the machine removal cylinders to relieve weight from the coun-
and engage the turntable lock. terweight mounting pins.

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BOOM RT890E3 SERVICE MANUAL

8, 9, 10, 11

12
3

6, 7 2

4
5

FIGURE 4-8

Item Description Item Description

1 Counterweight 7 Washer
2 Counterweight Pin Cylinder 8 Capscrew
3 Counterweight Removal Cylinder 9 Flatwasher
4 Cylinder Support Weld 10 Lockwasher
5 Ball Detent Pin 11 Hex Nut
6 Screw 12 IPO Counterweight

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RT890E3 SERVICE MANUAL BOOM

Counterweight
2
2 Lifting Points

4
1

2
2

6326

Item Description
1 Counterweight
2 Counterweight Cylinder Assembly

FIGURE 4-9

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BOOM RT890E3 SERVICE MANUAL

5. Using the control levers (left and right), simultaneously 9. Relieve pressure on the counterweight removal cylinder
extend (lower) the counterweight onto the frame so that weight is fully supported by the counterweight
counterweight supports. Feather individual controls as mounting pins.
required to lower the counterweight in a level position.
INSTALLING THE BI-FOLD MANUAL BOOM
6. Remove the counterweight removal cylinder support
pins from turntable wing/support brackets and using the EXTENSION
control levers (left and right), retract the counterweight
removal cylinders fully.

7. Disconnect and secure the counterweight removal DANGER

cylinder hydraulic lines and replace the counterweight
To prevent serious injury or death, always wear personal
removal cylinder support pins on the turntable wing/
protective equipment; i.e., a hard hat, eye protection,
support brackets.
gloves and metatarsal boots.
8. If applicable, properly attach chains with clevis to the
counterweight lifting holes Figure 4-9 and use a crane to 1. Before installing the boom extension make sure the
carefully transfer the counterweight to the ground or a crane is set up on outriggers using normal setup proce-
suitable transport vehicle. dures. Refer to SECTION 3 - OPERATING CONTROLS
and PROCEDURES in the Operator’s Manual.
Installation
NOTE: An auxiliary crane with sling is required to install
1. Position the crane on a firm, level surface. Fully extend the bi-fold boom extension.
and set the outriggers. Level the crane.
2. Check the transport condition of the bi-fold extension.
2. Position the superstructure over the front of the machine
3. Using an auxiliary crane, attach sling to the bi-fold exten-
and engage the turntable lock.
sion.
3. If applicable, properly attach chains with clevis to the 4. Lift the bi-fold extension in front of the main boom with
counterweight lifting holes Figure 4-9 and use a crane to the auxiliary crane and lock the 33 ft (10.1 m) section to
carefully transfer the counterweight to the frame the right of the main boom head Figure 4-10.
counterweight supports over the rear outrigger box.

4. Attach the counterweight removal cylinder hydraulic

lines.

5. Using the control levers (left and right) extend the

counterweight removal cylinders, one at a time, guiding
them into the turntable wing/support brackets and pin
securely.

6. Using the control levers (left and right) simultaneously

retract (raise) the counterweight removal cylinders until FIGURE 4-10
the counterweight round bar engages the lugs on the
turntable and the counterweight pinning holes are 5. Pin the left side to the boom nose.
aligned with the counterweight mounting pins. Feather
6. Establish electrical connection between the extension
individual controls as required to raise the counterweight
and the main boom.
in a level position.
7. For units equipped with hydraulic luffing boom exten-
7. Engage the counterweight mounting pins using the sion, establish hydraulic connections between the
control lever (center). extension and the main boom.
8. Attach the ball detent pins securing the counterweight NOTE: You can also install the bi-fold swingaway boom
mounting pins. extension in front of a 16 ft (4.9 m) section when
you are changing directly from the 56 ft (17.1 m) bi-
fold swingaway extension to a boom extension.

4-36 Published 07-24-2013, Control # 069-12

RT890E3 SERVICE MANUAL BOOM

1
Item Description
1 Front Support
2 Horizontal Pin
2
3 Boom
4 Pin
5 Pin
6 Bracket
7 Holding Plate

3 6510-2

4
7 6510-8

7 6510-7

6 5
4
6624
3

4
5
6

6510-5

6510-3

6510-1
6 6510-4
FIGURE 4-11

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BOOM RT890E3 SERVICE MANUAL

Checking the Transport Condition - The connection (5) between 23 ft (7 m) section and
m a i n b o o m i n t h e r e a r a r e a i s e s ta b l i s h e d
For transportation you must establish certain connections Figure 4-11 (control # 6510-7).
between both parts of the lattice extension. The connections
which need to be established depend on whether the lattice If the 23 ft (7 m) Section Only is Folded at the Side:
extension: - The connection (7) in the middle area is between
- is folded up at the side of the main boom for the 23 ft (7 m) section and the main boom (3)
transportation or Figure 4-11 (control # 6510-8).

- is completely removed for transportation. - The connection (5) between the 23 ft (7 m) section
and the main boom in the rear area is established.

BOOM EXTENSIONS/COMPONENTS
DANGER PROCEDURES
Be careful not to damage the lattice extension and the
For instructions on erecting and stowing the boom
main boom. Always put the lattice extension into transport
extension(s) and/or using additional equipment refer to
condition when folded at the side or working with the main
SECTION 4 in the Operator’s Manual.
boom. Only then is the lattice extension secured against
slipping. This way you prevent the partly fastened lattice
extension hitting the main boom or the individual
components of the lattice extension hitting each other and Transportation on a Separate Vehicle
becoming damaged.

You must check transport condition:

- After stowing the lattice extension, before you drive DANGER
the crane with the lattice extension folded at the side Risk of accidents from a falling lattice extension.
or work with the main boom. Only attach the lattice extension in such a way that it is
- Before installation and before erecting the lattice positioned in the center of gravity and always use lifting
extension. gear with sufficient lifting capacity. This prevents the
lattice extension from falling and injuring people while
Transport Condition with Lattice Extension Folded at loading.
the Side
• Check if all the required connections for transport
The transport condition with the lattice extension folded at
condition are established.
the side is created when all of the following connections are
established. • For transportation, place the lattice extension on the skid
• Check the connections and establish them if at the front and onto the lower cross strut at the rear of
necessary, see Figure 4-11. the 33 ft (10.1 m) section.
• Always secure the lattice extension on the separate
If 23 ft (7 m) Section and 33 ft (10.1 m) Section are
vehicle with belts as well as to prevent slipping and
Folded at the Side:
overturning.
- The 33 ft (10.1 m) section is locked at the front
support (1) on the main boom and is secured with
the horizontal retaining pin (2) CAUTION
- The pins (4) are inserted on the pivot point between Risk of damaging the lattice extension.
the 23 ft (7 m) section and the 33 ft (10.1 m) section. Always secure the lattice extension by tying it down with
suitable belts when it is transported on the separate
- The connection (7) in the middle area is between vehicle. This prevents the two-stage swingaway lattice
the 23 ft (7 m) section/33 ft (10.1 m) section. extension tipping and becoming damaged during
transportation.

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RT890E3 SERVICE MANUAL BOOM

BOOM EXTENSION (ADDITIONAL NOTE: For technical reasons a crane may only be set with
EQUIPMENT) one boom extension.
If you wish to use the boom extension on several Manitowoc
Identification and Slinging Points cranes, the parts of the boom extension must be adjusted for
these cranes and labeled with all of the respective serial
Identification
numbers.
The boom extension consists of the 56 ft (17.1 m) bi-fold
swingaway lattice extension and two boom extension
sections. The boom extension is designed for the crane it CAUTION
was delivered with. The parts which belong to the crane have Have the adjustment of the boom extension only carried
the same serial number as the crane. out on site by Manitowoc Crane Care!
The following sections are identified by the serial number:
Serial numbers on the 16 ft (4.9 m) sections
- All parts of the 56 ft (17.1 m) bi-fold swingaway
lattice extension. The serial number is on a plate at the front of the 16 ft
sections.
- Both sections of the boom extension 16 ft (4.9 m)
sections) Slinging Points
.

CAUTION CAUTION
4
Operate the crane only with those sections of the boom This section shows the slinging points of the 16 ft (4.9 m)
extension which have the same serial number as the sections. Attach the sections only to these slinging points
crane. This prevents malfunctions and damage. because they will then automatically have the correct
center of gravity. Use only lifting gear with sufficient load
bearing capacity.

w3351a FIGURE 4-12

The 16 ft (4.9 m) sections have two slinging points (one slightly offset on each side).

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BOOM RT890E3 SERVICE MANUAL

MONTHLY MAINTENANCE WORK The joints are lubricated via lubricating nipples.

Pins On either side of 33 ft (10.1 m) section, there is a lubricating

nipple at the pivot point Figure 4-13.
Lubricate all attach, securing and retaining pins, in other
words: • Clean the lubricating nipple and lubricate it with a grease
gun.
- the pins for the pin connection on the lattice
extension, • Also lubricate the joint on the other side.

- the retaining pins on the return pulleys, Lubricate the derricking cylinder in 33 ft (10.1 m)
section
- the retaining pins used for fastening the lattice
extension sections for transport,
- the spring latch on the run-up rail.
NOTE: The maintenance interval applies to average oper-
ation. Also, lubricate the pins after high-pressure
cleaning and generally at an interval that will pre-
vent them getting dry.
Lubricating Joint on 33 ft (10.1 m) Section

1
1 1 w2427a
FIGURE 4-14

The derricking cylinder is lubricated via a lubricating nipple.

On head and foot axle there is one lubricating nipple each
Figure 4-14.
• Clean the lubricating nipples and insert grease into the
lubricating nipple with a grease gun.

w3300a
FIGURE 4-13

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RT890E3 SERVICE MANUAL HOIST AND COUNTERWEIGHT

SECTION 5
HOIST AND COUNTERWEIGHT

SECTION CONTENTS
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Idler Drum and Cable Follower. . . . . . . . . . . . . . . . 5-7
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Warm-up Procedure . . . . . . . . . . . . . . . . . . . . . . . 5-2 Hoist Drum Rotation Indicator System . . . . . . . . 5-10
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Routine Maintenance and Inspection . . . . . . . . . . 5-2
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Counterweight Removal . . . . . . . . . . . . . . . . . . . . 5-13
Functional Check . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Removal of Standard Counterweight and
Auxiliary Hoist . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Fluid Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Installation of Standard Counterweight and
Hoist to Boom Alignment. . . . . . . . . . . . . . . . . . . . 5-5 Auxiliary Hoist Mounting Structure. . . . . . . . . . . . 5-13
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 Removal of Counterweight Without Auxiliary
Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 Hoist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 Installation of Counterweight Without Auxiliary
Piston Motor and Control Valve . . . . . . . . . . . . . . 5-7 Hoist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Third Wrap Indicator (Optional) . . . . . . . . . . . . . . 5-15
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
5

DESCRIPTION THEORY OF OPERATION

One hoist is available, the HP30-18G (Figure 5-1). The hoist The hoist assembly is controlled by hydraulic remote
incorporates one dual displacement piston motor which controllers located in the cab. When the control lever in the
drives a reduction unit within the hoist. The hoist utilizes cab is moved from neutral, it causes the main hoist section of
planetary reduction gear assemblies with a multi-disc the directional control valve to shift the valve spool to route
automatic brake that is spring applied and hydraulically hydraulic flow to the hoist motor control valve. The hoist
released. An overrunning clutch allows the hoist to be raised motor control valve is used to stop or slow the hoist when the
without releasing the brake while at the same time holding load is trying to drive the hoist down too quickly. The motor
the load until there is sufficient pressure to release the brake control valve is piloted open by the hoist down pressure. If
when hoisting down. The hoist motor controls both speed the load lowers faster than the flow of oil in the hoist down
and torque of the hoist. line, the pilot pressure decreases and the motor control valve
partially closes to restrict the oil leaving the motor until a
There are two modes in which the hoist operates. One mode
balance occurs. This results in the load lowering at a uniform
is high speed. The pilot solenoid valve shifts the selector
speed based on the position of the hoist control lever.
spool on the motor to provide minimum motor displacement.
This gives high line speed and low torque. During stopping, when the hoist down flow ceases, the pilot
pressure holding the motor control valve open decays to
The second mode is low speed. The pilot solenoid valve
zero and the motor control valve spool closes, thus blocking
shifts the selector spool on the motor to provide maximum
all flow of oil out of the hoist motor. This same pressure
motor displacement. This gives low line speeds and high
decay allows the spring applied pressure released hoist
torque.
brake to apply when the load is fully stopped. This brake acts
as a “parking brake” and holds the load in the stopped
position.

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HOIST AND COUNTERWEIGHT RT890E3 SERVICE MANUAL

MAINTENANCE mal contamination should be treated seriously, with an

examination of the internal components of the hoist con-
Warm-up Procedure ducted at the earliest opportunity.

A warm-up procedure is recommended at each start-up and 2. Check for correct function of the hoist brake by carrying
is essential at ambient temperatures below +40°F (4°C). out a high line pull load test, see Functional Check page
5-4. Ensure the brake holds without creeping and that
The engine should be run at its lowest recommended RPM the hoist control is correct.
with the hydraulic hoist control valve in neutral allowing
sufficient time to warm up the system. The hoist should then NOTE: The function of the hoist brake should be checked
be operated at low speeds, forward and reverse, several more often under extreme or abnormal operating
times to prime all lines with warm hydraulic oil, and to conditions.
circulate gear lubricant through the planetary gear sets.
Every Ten Years or 10,000 Hours (whichever comes
first)
As part of a preventative maintenance program, we
DANGER recommend that hoist assemblies be opened in a properly
controlled workshop environment. The major internal
Failure to properly warm up the hoist, particularly under
components (gears, spline couplings, shafts, etc.) should be
low ambient temperature conditions, may result in
examined for damage and/or wear. New components should
temporary brake slippage due to high back pressures
be installed if any are found to be worn or if there is evidence
attempting to release the brake, which could result in
of heat or other damage. Reassemble the hoist using all new
property damage, severe personal injury or death.
seals, bearings, fasteners, washers, brake discs, brake
stators, sprag clutch, and springs.
Routine Maintenance and Inspection
A comprehensive hoist line pull and load holding test must
Hoisting gear assemblies must receive proper maintenance be carried out following any such repair work.
and inspection in order to provide satisfactory long term
operation. It is extremely important that maintenance Manitowoc Crane Care offers prepackaged kits that include
personnel recognize that deterioration of critical internal all the seals, bearings, fasteners, washers, brake disks,
components within the hoist reduction unit can occur. The brake stators, sprag clutch, and springs that are required for
service life and reliability of the hoist can be substantially reassembling the hoist after inspection. During the
reduced by such factors as the following: inspection, if components not included in the kit are found to
be worn or damaged, contact your Manitowoc Cranes
• High cycle operation distributor or Manitowoc Crane Care to order replacement
• Operating in high ambient temperatures
• High external contamination, such as dusty or sandy
conditions
DANGER
• Level of maintenance Failure to implement and adhere to a hoist inspection and
maintenance program may result in damage to the crane,
Weekly or at 40 Hours of Operation (whichever comes
other property damage, and/or serious injury or death to
first)
persons working on or near the crane.
1. Check the hoist oil level. Use only the manufacturer’s
recommended oil when filling. Removal
2. Inspect for any oil leaks from the hoist gearbox. 1. Remove all cable from the hoist drum.
Every Three Months or 300 Hours of Operation 2. Tag and disconnect the hydraulic lines to the hoist. Cap
(whichever comes first) or plug all lines and openings.
Lubricate the hoist cable follower and idler arm bearings. 3. Tag and disconnect the electrical wires to the hoist
Refer to Hoist page 9-24 for recommended grease. rotation indicator sensor box.
Annually 4. Tag and disconnect the electrical wires to the hoist hi-
1. Replace the oil in the hoist gearbox, refer to Hoist page speed solenoid valve.
9-24. We recommend having the used hoist oil tested by
5. Remove the hoist mounting nuts, capscrews, washers,
a hydraulic oil analysis provider, which can give advance
and shims (if shims are used, mark their location).
warning of developing wear patterns. Any sign of abnor-

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RT890E3 SERVICE MANUAL HOIST AND COUNTERWEIGHT

NOTE: The HP30-18G hoist assembly, less the cable, 6. Using an adequate lifting device, remove the hoist from
weighs approximately 674 kg (1485.9 pounds). the crane.

2
1
3 4
5

11
12
3

11

DETAIL A
6, 7, 8, 9

DETAIL A
5

6319, 6319-2

Item Description
1 Main Hoist
2 Auxiliary Hoist
3 Counterweight Cylinder
4 Cable Follower
5 Idler Drum
6 Shims
7 Capscrew
8 Nut
9 Washer
10 Counterweight
11 Ball Detent Pin
12 Counterweight Cylinder Pin

FIGURE 5-1

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HOIST AND COUNTERWEIGHT RT890E3 SERVICE MANUAL

Installation Functional Check

1. Ensure the mounting plate and hoist pads are clean and 1. Attach a test weight to the hook and raise and lower the
free from debris and the hoist has not been damaged load several times.
during handling.
2. Check the hoist for smooth operation of the hoist motor
2. With the hoist supported by a suitable lifting device, posi- and brake system.
tion the hoist on the mount.
3. Ensure the hydraulic connections are secure and free
3. Check the hoist to boom alignment according to the from leaks.
HOIST TO BOOM ALIGNMENT procedure in this sec-
tion. Fluid Level
4. Place a level between the boom pivot shaft bushings. NOTE: Failure to align the fill/drain plug (1) with the upper
access hole (2) as shown in Figure 5-2 prior to
5. Place a level across the top of the hoist drum and deter-
checking the oil level will result in an inaccurate
mine if the hoist is sitting in the same plane in relation to
reading.
the level positioned between the boom pivot shaft bush-
ings. 1. Rotate the hoist drum until the fill/Drain plug (1) appears
in the upper access hole (2) shown in Figure 5-2.
6. With the hoist level, check to determine if all the hoist
mounting pads are in contact with the mounting plate by This will ensure that the planetary gears are in proper
rocking the hoist. alignment and will permit an accurate reading of the oil
level in the hoist.
7. Keeping the hoist level, use a feeler gauge to determine
the amount of gap existing between the pads and the 2. Allow the hoist to stand idle for 20 minutes before check-
mounting plate. ing the oil.
8. Add shims to satisfy any existing gaps. Altering the shim 3. The oil level should be visible in the sight glass (3).
thickness to fit a tapering gap is acceptable. Install the
Compare your reading with Table 5-1 below and take the
capscrews, washers and nuts and torque. Refer to SEC-
required action.
TION 1-Fasteners and Torque Values.
9. Remove the lifting device from the hoist.
10. Connect the hydraulic lines to the hoist ensuring the
proper lines are connected to the correct ports as 1 4
marked during removal.
11. Connect the electrical wires to the hoist hi speed sole-
noid valve as marked during removal. 3

12. Connect the electrical wires to the hoist rotation indicator

sensor box as tagged during removal.
13. Install the cable, following the procedures outlined under
INSTALLING CABLE ON THE HOIST, in the Operator’s 2
Manual.

FIGURE 5-2

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RT890E3 SERVICE MANUAL HOIST AND COUNTERWEIGHT

Table 5-1

Reading Diagnosis Action Required

Fill the hoist with oil from the upper access hole until the
The hoist is under oil level rises within the sight glass. Do not fill above 1/8”
Oil is not visible in the sight glass. (3 mm) from the top of the site glass.
filled.
Refer to Hoist page 9-24 for the correct type of oil.
Oil is visible in the sight glass and the
The oil level is
level is no more than 1/8” (3 mm) from No action is required.
correct.
the top of the sight glass.
Oil level is more than 1/8” (3 mm) Drain the hoist drum from the upper access hole until the
from the top of the sight glass or the The hoist is overfilled. oil level falls to within 1/8” (3 mm) from the top of the sight
oil is escaping from the vent plug (4). glass.

HOIST TO BOOM ALIGNMENT Procedure

Preparation The hoist mounting location will determine the alignment
procedure used. Shift one side of the hoist back or forward to
Boom alignment must be completed before attempting hoist align the hoist with the boom sheave for cranes that have the
alignment. If the hoist is not properly aligned, the cable can hoist mounted either directly to the boom or on a mount
be damaged or fine control could be affected. attached to the boom. It may be necessary to shim under
one side of the hoist to make it level.
The crane must be set on outriggers fully extended and the
crane must be leveled. The boom must be over the rear on The hoist must be checked in two directions, one at 0 degree
TM/TMS models and over the front on RT/Industrial models. and the other is above 45 degrees boom angle on any crane
that the hoist is not mounted directly to the boom, stationary 5
Tools Required mounted.
• two foot square Check the hoist at 0 degree to see if the hoist is aligned to
the boom nose sheave. The main hoist is aligned to the right
• Mason cord or cat gut fishing line
hand sheave and the auxiliary hoist is aligned to the center
• chalk sheave (see Figure 5-2).
• protractor NOTE: The hoist cable will have gaps in it during spooling
if the alignment is not correct.
NOTE: The hoist is not level if the cable is piling up on one
side of the drum.

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HOIST AND COUNTERWEIGHT RT890E3 SERVICE MANUAL

MAIN HOIST IS ALIGNED TO THE RIGHT HAND

SHEAVE

LOCATING CENTERLINE WITH

SQUARE

AUXILIARY HOIST IS ALIGNED TO THE CENTER

SHEAVE
6019
FIGURE 5-3

1. The boom must be extended one half of full extension on check from both flanges indicates that the resultant
all hoist alignments. This length is used because when line is straight.
the main hoist cable is positioned on the top right hand
3. Tie the line around the hoist drum so that the line is very
boom nose sheave, the cable must leave the center of
tight and the line is crossing the absolute center of the
the drum at a 90 degree angle. The boom has the ability
drum at the centerline mark you put on the drum.
to extend, retract, and change the angle of departure
from the drum. Extend the boom half way to provide a 4. Using a protractor, lay it on the vertical line on the hoist
center point of adjustment to check the fleet angle of the drum so the string line is in the center of the protractor.
cable. The string line will be at the 90 degree mark on the pro-
tractor if the hoist is straight with the boom nose sheave.
2. All the cable must be removed from the hoist drum to
If it is not at the 90 degree mark, the hoist mounting bolts
check the fleet angle. Using mason cord or cat gut fish-
will have to be loosened and the hoist moved so it is.
ing line you will be able to pull the line tight to make an
accurate measurement of the fleet angle. Find the cen- NOTE: This test is for cable leaving gaps while spooling.
terline of the hoist drum by using a square and drawing a
line horizontal on the drum. Put a line vertical to the hori-
zontal line in the absolute center of the drum by using a CAUTION
tape measure. With the boom at 0 degree, tie the line Do not alter holes or stop blocks on the crane mounting
tight to the boom nose and have it in the center of the plate, as very small adjustments result in large angular
right hand boom nose sheave. changes. Extreme care should be taken to avoid over-
NOTE: If this special equipment is not available, sufficient correction.
accuracy in locating a centerline may be obtained
by using a steel square against the machine’s inner 5. Elevate the boom above 45 degrees boom angle to
surfaces of both flanges. It is advisable to avoid check if the hoist is level. Reposition the hoist drum and
using any cast surfaces in this procedure unless a tighten the cord so you can have the cord in the center of
the protractor at the 90 degree mark. If the cord is not at

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RT890E3 SERVICE MANUAL HOIST AND COUNTERWEIGHT

the 90 degree mark, the hoist will have to be shimmed auxiliary hoist, the idler drum on the auxiliary hoist is used to
until the cord is at the 90 degree mark. keep the hoist cable from coming in contact with the main
hoist. The cable follower is mounted on the rear side of it’s
NOTE: This test is for cable piling up on one side of the
respective hoist. The cable follower applies a downward
hoist drum.
spring pressure against the cable onto the hoist drum, to
ensure that the cable will be uniformly wound onto the hoist
PISTON MOTOR AND CONTROL VALVE drum, and also prevent cable from jumping under abnormal
line conditions.
Description
The piston motor is a bent axis, bidirectional, variable Maintenance
displacement heavy-duty motor. The motor is bolted to the
Idler Drum
hoist and is geared directly to the hoist planetary.
Removal and Disassembly
The motor control valve is bolted to the motor.
1. Remove the bolt, washer, and lockwasher from the right
Maintenance side of the idler roller (see Figure 5-3).

Removal 2. Support the idler roller and withdraw the shaft from the
left side. Take care not to lose the dowel pin on the end.
1. Thoroughly clean the external surfaces of the drum and
motor with steam or clean solvent and blow dry. 3. Remove the roller from between the side plates.

2. Tag and disconnect the hydraulic lines connected to the Cleaning and Inspection
hoist motor and the motor control valve. 1. Clean all rust and dirt from the shaft.
3. Remove the capscrews and lockwashers that secures 2. Inspect the shaft and roller for cracks, scoring, or groov-
the motor and motor control valve to the hoist. ing. Replace if necessary.
4. Place the motor and motor control valve in a clean, dry Assembly and Installation
5
suitable work area.
1. Position the roller between the side plates
Installation
2. Install the shaft through the left side plate and the roller.
NOTE: Care must be taken to assure the primary thrust Ensure the flat on the shaft end aligns with the stop
plate remains properly located in its counterbore welded on the side plate, align the dowel pin.
when the motor is re-installed. If the winch is oper-
ated with the primary thrust plate wedged between 3. Secure the shaft to the right side plate with a bolt,
the primary gears and the planet carrier, or with a washer and lockwasher. Apply Loctite 243 to the bolt
thrust washer out of position severe damage to threads.
internal winch components could result.
Cable Follower
1. Install a new O-ring on the motor pilot then lubricate with
Removal and Disassembly
petroleum jelly or gear oil. Engage the motor shaft with
the brake clutch inner race and lower into place. 1. Loosen the adjusting nuts and remove the tension
spring and adjusting rod from both sides of the hoist (see
2. Apply Loctite No. 243 to the mounting bolts, and install
Figure 5-3).
the bolts and lockwashers. Torque the bolts to 102 Nm
(75 lb-ft). 2. Remove the tack welds from the bolt heads securing the
arm to the cable follower roller.
3. Connect the hydraulic lines as tagged during removal.
3. Support the cable follower roller and remove the bolts
4. Fill the drum with oil. Refer to Section 9 - LUBRICATION
and washers securing the arms to the angles on each
in this manual.
end of the roller. Remove the cable follower roller.

IDLER DRUM AND CABLE FOLLOWER 4. Disassemble the cable follower roller as follows.
a. Remove the two bolts and washers securing the
Description angle to the right side of the shaft.
The main and auxiliary hoists are equipped with an idler b. Remove the shims and roller from the shaft.
drum on the forward side of the hoist. The main hoist idler
drum is used to keep the hoist cable from coming in contact c. If necessary, remove the bearing and bearing
with the boom. When the crane is also equipped with an housing from both ends of the roller.

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HOIST AND COUNTERWEIGHT RT890E3 SERVICE MANUAL

5. Remove the bolt and locknut securing the arm to the each side plate and connect to the other end of the
spring attaching lever on each side of the hoist. Remove spring. Install the adjusting nuts on each rod and tighten
arms and levers from the side plates. enough to take the slack out of the springs.
NOTE: Be sure to mark each arm and lever as to what side 6. Using a grease gun, apply grease to the fittings on each
(left or right) they were removed from. This will be side plate bushing.
helpful during installation.
7. Adjust the roller as follows.
Cleaning and Inspection
a. With one layer of cable on the hoist drum, adjust the
1. Clean all grease from the shaft, bearing, and roller. bolts on the front of each side plate (that push
against each arm) so the roller applies pressure on
2. Check the shaft, roller, and bearings for cracks, scoring,
the layer of cable, and does not interfere with filler/
or grooving. Replace if necessary.
riser protrusions on the hoist drum flanges. Tighten
3. Check the spring tension. If the springs will not provide jam nuts to secure setting.
sufficient tension when adjusted, replace them.
b. With a full drum of cable, the adjusting spring length
Assembly and Installation from eye to eye should not exceed 25.7 cm (10.12
in). Adjust rods as necessary and tighten jam nuts to
1. Install the left arm through the bushing on the left side secure this setting.
plate. Install left spring attaching lever on the arm and
secure with a bolt and locknut. Apply Loctite 243 to the Complete Assembly
bolt threads.
Removal
2. Repeat step 2 on the right side.
1. Remove all tension from the springs on each side by
3. Assemble the cable follower roller as follows. loosening the nuts and jam nuts.
a. Apply high strength retaining compound Loctite 680 2. Support the weight of the assembly and remove the two
to the bearing housings and the bearings. Install bolts and washers securing each side plate to the hoist.
them in both ends of the roller. Remove the idler drum and cable follower assembly
b. Install the shaft into the roller with a least one shim from the hoist.
on each end. 3. If necessary to completely disassemble or remove any
c. Position the angle on the right side of the shaft and part of the assembly, refer to the applicable paragraphs
secure with two bolts and washers. Apply Loctite in this Sub-section.
243 to the bolt threads. Installation
4. Position the cable follower roller on the arms and secure 1. Position the idler drum and cable roller assembly on the
with four bolts and washers. Center the roller between hoist and secure each side plate to the hoist with two
the hoist drum flanges and tighten the bolts. Tack weld bolts and washers.
the bolt heads.
2. Adjust the tension on the cable follower. Refer to instruc-
5. Attach one end of the tension springs to the levers on tions in paragraph titled CABLE FOLLOWER - Assem-
each side. Install the adjusting rod through the lug on bly and Installation in this Sub-Section.

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RT890E3 SERVICE MANUAL HOIST AND COUNTERWEIGHT

1.0 cm (.42 inch)

1
8

12
3
Item Description
1 Pivot Bracket
2 Drum
6637-2 3 Follower Roller
4 Arm
5 Spring 5
8 2 6 Spring Adjusting Rod
10
7 Lever
8 Idler Roller
9 Nut
6 1 10 Bracket
11 Rotation Sensor
12 Hydraulic Motor

5
11

6637-1

FIGURE 5-4

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HOIST AND COUNTERWEIGHT RT890E3 SERVICE MANUAL

HOIST DRUM ROTATION INDICATOR Thumb Thumper Solenoid

SYSTEM The thumb thumper solenoid provides feedback proportional
to the hoist line speed by pulsing the rubber button on top of
Description the hoist control lever.
The hoist drum rotation indicator system is an electrically Troubleshooting
operated system that provides the operator with a touch
indication of drum rotation so he will know if and at what To troubleshoot the system, use the three diagnostic LED’s
speed the hoist drum is rotating, even under the most located on the control module (CPU). Under normal
distracting conditions. operating conditions (hoist drum rotating) the diagnostic
LED’s function as shown in the Table below.
The rotation indicator system consists of three separate
electrical components; the rotation indicator sensor, drum Table 5-2
rotation indicator control module (CPU), and thumb thumper
solenoid. The rotation sensor and control module (CPU) are LED Operation Definition
located on the hoist. The pulsing thumb thumper solenoid is Green On continuously Current applied to sensor
located in the applicable hoist control lever handle (Figure 5-
4). Pulses on, varies
Red Sensor signal received
with speed
Maintenance Pulses on, varies
Yellow Solenoid pulse working
with speed
General
NOTE: The following paragraphs troubleshoot the system
using the diagnostic LED’s. The hoist drum must
be rotating during all troubleshooting.
DANGER Green LED
D i s c on n e c t t h e b a t te r i es b e fo r e p e r f o r m i n g a n y
maintenance on this system. Serious burns may result Turn the ignition switch on. Verify that the green LED is on.
from accidental shorting or grounding of live circuits. The LED should stay on as long as accessory power is on. If
the green LED is not on, either the voltage did not arrive at
Proper circuit operation can be checked for each individual the CPU, or the CPU is defective and needs to be replaced.
electrical component. If a malfunction occurs within the If the green LED repeatedly flashes once with the red and
system, repairs should be limited to finding and replacing the yellow LED’s off, the solenoid circuit is shorted. If the green
faulty component(s). To determine which component is at LED repeatedly flashes two times with the red and yellow
fault, use the self diagnostic LED’s on the CPU. If difficulty LED’s off, the CPU is defective. If the green LED repeatedly
persists, contact your local distributor for additional flashes three times with the red and yellow LED’s off, the
troubleshooting aid. CPU needs to be reprogrammed. The following should be
used only after using the diagnostic LED’s.
Rotation Sensor
1. Use a digital voltmeter or multimeter to measure if volt-
The rotation sensor is screwed into the hoist housing and age is present on wire 27 at circuit breaker or fuse feed.
senses the rotation of the primary drive. (See figure titled Replace fuse, circuit breaker or wire if necessary.
Hoist Rotation Indicator System). The initial sensor
adjustment should be 30.7mm (1.21 in) from sensing end of 2. Make sure 12 volts are measured across terminals A
sensor to first lock nut. If sensor does not function properly, (red wire) and B (black wire) of connector DT3S. If there
loosen locking nuts and turn counter clockwise is no voltage present, check wiring and circuit breaker
approximately one turn. If results are not achieved, try up to (fuse).
one turn clockwise. 3. If voltage is present but green LED does not light,
Drum Rotation Indicator Control Module (CPU) replace the CPU.

The control module (CPU) is bracket mounted to the upper Red LED
hoist motor attaching bolt. It provides LED’s for checking With the green LED on, and the hoist rotating, the red LED
proper circuit operation, as well as providing power to the should be pulsing on and off and should stop pulsing when
rotation sensor. It also sends a signal to the thumper the hoist stops rotating. If the red LED does not pulse on and
solenoid proportional to the sensor. off, then either the CPU is defective or the sensor is
defective. The following should be used only after using the
diagnostic LED’s.

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RT890E3 SERVICE MANUAL HOIST AND COUNTERWEIGHT

1. Measure the sensor input voltage from +10V terminal 1 following should be used only after using the diagnostic
to ground terminal 3 on the DTM3S connector. Measure LED’s.
the pulsating return signal from +5V terminal 2 to ground
1. Using a digital voltmeter check to see if the CPU is
terminal 3 on the DTM3S connector. If the +10V is
receiving 12 volts between terminals A (red wire) and B
applied to the sensor input and the +5V pulsating signal
(black wire) of connector DT3S. If no voltage is present,
is applied to the DTM3S connector terminal 2 and the
check wiring and circuit breaker (fuse).
red LED still does not pulsate, the CPU is defective and
should be replaced. 2. Using a digital ohmmeter check to see if the thumper
solenoid resistance is 12 ± 2 ohm. If the resistance does
2. If the +5V signal on terminal 2 does not oscillate, the
not measure correctly the solenoid is defective and
sensor is defective or the sensor adjustment air gap
should be replaced.
from the gear teeth is to wide. Adjust the sensor position
and retest. If oscillation does not occur, the sensor 3. Using a digital voltmeter, measure the voltage on sole-
should be replaced. noid white feed wire 27. The voltage should measure
12V. If voltage is not within ± 10 percent, check the volt-
Yellow LED
age at the fuse or circuit breaker. If the voltage does not
With the green LED on continuously, and the red LED measure within ± 10 percent, trace the hi or low volts
pulsating (hoist is rotating), the yellow LED should also be back to the source and repair the defect. If the voltage
pulsating. If the yellow LED does not pulse on and off, a does measure within ± 10 percent the solenoid white
defective CPU could be the problem. If the yellow LED feed wire 27 is pinched and should be replaced.
pulsates, but the thumb thumper solenoid does not, then the
4. After disconnecting both ends of wire 508/509, measure
thumper solenoid is defective and should be replaced or
the resistance of wire 508/509. If the resistance mea-
there are broken or pinched wires in the system. The
sures more than 0.5 ohm, the wire is defective and
should be replaced.

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HOIST AND COUNTERWEIGHT RT890E3 SERVICE MANUAL

Control Module - CPU

Control Module - CPU

Hi Speed
Solenoid

Sensor
Sensor
To Thumb Thumper

Green LED Button

Control Lever Thumb Thumper

Handle Rotation
Yellow LED
Indicator
Solenoid 12±2
OHMS
Red LED
Manitowoc CPU
Part Number

Control Module - CPU

Single Axis
Controller
FIGURE 5-5

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RT890E3 SERVICE MANUAL HOIST AND COUNTERWEIGHT

COUNTERWEIGHT REMOVAL
Removal of Standard Counterweight and
Auxiliary Hoist DANGER
Assemble the counterweight and auxiliary hoist structure
1. Position the crane on a firm, level surface. Fully extend on the ground or on a suitable transport vehicle. Do not
and set the outriggers. Level the crane. attempt to assemble on the counterweight stand. the
2. Position the superstructure over the front of the machine auxiliary hoist structure may hit the counterweight and
and engage the turntable lock. knock it off the stand.

3. Remove any load and handling device from the auxiliary 3. Properly attach the supplied slings to the counterweight
hoist cable and retract all cable onto the hoist drum. lifting holes and use a crane to carefully transfer the
Secure the cable. counterweight and auxiliary hoist to the frame counter-
4. Disconnect and secure the auxiliary hoist hydraulic lines weight supports over the rear outrigger box.
and electrical harness. 4. Attach the counterweight removal cylinder hydraulic
5. Remove the ball detent pins which secure the counter- lines.
weight mounting pins. 5. Using the control levers (left and right) extend the coun-
NOTE: It may be necessary to retract the counterweight terweight removal cylinders, one at a time, guiding them
removal cylinders to relieve weight from the coun- into the turntable wing/support brackets and pin
terweight mounting pins. securely.

6. Ensure the counterweight removal cylinder support pins 6. Using the control levers (left and right) simultaneously
are securely attaching the counterweight to the turntable retract (raise) the counterweight removal cylinders until
wing/support brackets. Disengage the counterweight the counterweight round bar engages the lugs on the
mounting pins using the pinning control lever (center). turntable and the counterweight pinning holes are
aligned with the counterweight mounting pins. Feather 5
7. Using the control levers (left and right), simultaneously individual controls as required to raise the counterweight
extend (lower) the counterweight onto the frame coun- in a level position.
terweight supports. Feather individual controls as
required to lower the counterweight in a level position. 7. Engage the counterweight mounting pins using the con-
trol lever (center).
8. Remove the counterweight removal cylinder support
pins from turntable wing/support brackets and using the 8. Attach the ball detent pins securing the counterweight
control levers (left and right) retract the counterweight mounting pins.
removal cylinders fully. 9. Relieve pressure on the counterweight removal cylinder
9. Disconnect and secure the counterweight removal cylin- so that weight is fully supported by the counterweight
der hydraulic lines and replace the counterweight mounting pins.
removal cylinder support pins on the turntable wing/sup- 10. Attach the auxiliary hoist hydraulic lines and electrical
port brackets. harness.
10. Properly attach the supplied slings to the counterweight
lifting holes and use a crane to carefully transfer the Removal of Counterweight Without Auxiliary
counterweight and auxiliary hoist to the ground or a suit- Hoist
able transport vehicle.
1. Position the crane on a firm, level surface. Fully extend
Installation of Standard Counterweight and and set the outriggers. Level the crane.
Auxiliary Hoist Mounting Structure 2. Position the superstructure over the front of the machine
and engage the turntable lock.
1. Position the crane on a firm, level surface. Fully extend
and set the outriggers. Level the crane. 3. Remove the ball detent pins which secure the counter-
weight mounting pins.
2. Position the superstructure over the front of the machine
and engage the turntable lock. NOTE: It may be necessary to retract the counterweight
removal cylinders to relieve weight from the coun-
terweight mounting pins.

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HOIST AND COUNTERWEIGHT RT890E3 SERVICE MANUAL

10, 11, 12 13

9
2

6, 7

4
3

Item Description Item Description

1 Counterweight 8 Ball Detent Pin
2 Counterweight Cylinder Assembly 9 Shim
3 Cylinder Support 10 Capscrew
4 Pin Removal Cylinder 11 Washer
5 Capscrew 12 Nut
6 Washer 13 Hoist
7 Capscrew

FIGURE 5-6

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RT890E3 SERVICE MANUAL HOIST AND COUNTERWEIGHT

4. Ensure that the counterweight removal cylinder support 10. mounting pins.
pins are securely attaching the counterweight to the
turntable wing/support brackets. Disengage the counter- THIRD WRAP INDICATOR (OPTIONAL)
weight mounting pins using the pinning control lever
(center). Description
5. Using the control levers (left and right), simultaneously The third wrap indicator (Figure 5-7) is installed to give the
extend (lower) the counterweight onto the frame coun- operator an indication that the wire rope is down to the last
terweight supports. Feather individual controls as three wraps on the hoist drum and no more rope should be
required to lower the counterweight in a level position. reeled out. In addition to the warning light in the cab, a
6. Remove the counterweight removal cylinder support lockout valve is actuated to stop hoist down operation.
pins from turntable wing/support brackets and using the
control levers (left and right), fully retract the counter- Maintenance
weight removal cylinders.
Removal
7. Disconnect and secure the counterweight removal cylin-
1. Turn the ignition key to off and remove the key.
der hydraulic lines and replace the counterweight
removal cylinder support pins on the turntable wing/sup- 2. Remove the wire at the limit switch (1).
port brackets.
3. Loosen and remove the outside nut (7) and washer (8)
8. Properly attach the supplied slings to the counterweight securing the threaded rod (9) to the hoist.
lifting holes and use a crane to carefully transfer the
4. Loosen and back off the inside nut (10) on the threaded
counterweight to the ground or a suitable transport vehi-
rod.
cle.
5. Loosen and back off the nut (11) holding the sensor shaft
Installation of Counterweight Without (12) in place against the side plate.
Auxiliary Hoist 6. Loosen the setscrews securing the limit switch bracket 5
1. Position the crane on a firm, level surface. Fully extend (2), actuating cam (3), and spring holder collar (5) from
and set the outriggers. Level the crane. the sensor shaft.

2. Position the superstructure over the front of the machine 7. Unscrew the threaded rod from the sensor shaft.
and engage the turntable lock. 8. After removing the nuts and washer from the inside end
3. Properly attach the supplied slings to the counterweight of the threaded rod, pull the threaded rod out through the
lifting holes and use a crane to carefully transfer the hoist housing.
counterweight to the frame counterweight supports over 9. Remove the capscrew (13) and washer (14) securing
the rear outrigger box. the sensor shaft to the hoist housing.
4. Attach the counterweight removal cylinder hydraulic
Installation
lines.
NOTE: All fasteners must be treated with Loctite® 243
5. Using the control levers (left and right), extend the coun-
adhesive and primer.
terweight removal cylinders, one at a time, guiding them
into the turntable wing/support brackets. Pin securely. 1. Install the capscrew and washer to secure the sensor
shaft to the hoist housing. Torque the capscrew 117 to
6. Using the control levers (left and right) simultaneously
127 Nm (86 to 94 foot-pounds).
retract (raise) the counterweight removal cylinders until
the counterweight round bar engages the lugs on the 2. Apply anti seize grease to inside of roller assembly.
turntable and the counterweight pinning holes are
aligned with the counterweight mounting pins. Feather 3. Slide limit switch bracket with limit switch, actuating
individual controls as required to raise the counterweight cam, roller assembly, spring, and spring holder collar
in a level position. onto the sensor shaft.

7. Engage the counterweight mounting pins using the con- 4. Position center of roller approximately 7.6 cm (3 in) from
trol lever (center). the inside flange of the hoist drum.

8. Attach the ball detent pins securing the counterweight 5. Install the threaded rod through the opening in the hoist
mounting pins. housing and thread the washer and two nuts onto the
rod.
9. Relieve pressure on the counterweight removal cylinder
so that weight is fully supported by the counterweight 6. Screw the threaded rod into the sensor shaft.

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HOIST AND COUNTERWEIGHT RT890E3 SERVICE MANUAL

7. Tighten the nut to hold the sensor shaft to the side plate. screws in the limit switch bracket to 1.1 to 1.5 Nm (10-13
lb-in).
8. Tighten the nut securing the threaded rod to the hoist
housing. 12. Adjust spring holder collar such that spring applies
ample pressure to arm. Torque the set screws to 1.1 to
9. Install the remaining washer and nut onto the outside
1.5 Nm (10-13 lb-in).
end of the threaded rod.
13. Adjust actuating cam such that switch plunger drops into
10. Torque the three nuts 117 to 127 Nm (86 to 94 lb-ft).
notch when roller drops to bare hoist drum. Torque the
11. Adjust the roller assembly so the centerline of the roller set screws to 1.1 to 1.5 Nm (10-13 lb-in).
is 3.0 inches (7.6 cm) from the inside face of the nearby
14. Reconnect the wire to the limit switch.
side plate such that the roller drops to the drum after the
fourth wrap is unwound from the drum. Torque the set

5
7131 6

2 7, 8

10
9
11
12
1

6928-1

13, 14

FIGURE 5-7

Item Description Item Description

1 Limit Switch 4 Roller Assembly
2 Limit Switch Bracket 5 Spring Holder Collar
3 Actuating Cam 6 Spring

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RT890E3 SERVICE MANUAL SWING SYSTEM

SECTION 6
SWING SYSTEM

SECTION CONTENTS
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Swing Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . 6-1 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 Swivels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Swing Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Hydraulic Swivel . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Two Port Water Swivel . . . . . . . . . . . . . . . . . . . . 6-16
Swing Gearbox And Brake. . . . . . . . . . . . . . . . . . . 6-6 Electrical Swivel. . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

INTRODUCTION teeth at any point of rotation. The pin type turntable lock will
only lock the turntable in a straight ahead position over the
Description front of machine. Both swing locks are operated from the
cab.
The purpose of the swing system is to allow the crane
superstructure to rotate atop the carrier frame. The Theory of Operation
superstructure swing system provides full 360 degree
rotation in both directions and is equipped with free swing Swing Drive
capabilities. The term free swing means that, with the
The hydraulic power for the swing drive is supplied by the
SWING BRAKE switch in the OFF position, the
superstructure will swing freely after the SWING control lever
engine driven hydraulic Pump No. 1, Section 2 mounted on 6
the torque converter. Oil flows from the pump to the hydraulic
is released until it coasts to a stop or the glide swing brake
Port 5 swivel. Flow from the swivel is routed to the front
pedal is depressed.
steering flow divider valve in the swing directional control
Swing is activated using the control lever in the cab. When valve. Bypass flow from the flow divider valve is used to
the swing lever is actuated, hydraulic pressure is routed to supply the swing directional control valve.
the swing motor to drive the gearbox in the appropriate
When the hydraulic remote control is positioned to select
direction. As the gearbox rotates, the pinion gear meshes
right or left swing, the flow through the control valve is
with the teeth on the swing bearing and rotates the
directed to the series/parallel valve, and then routed to the
superstructure. Swing speed can be controlled by the control
swing motors. If the SWING BRAKE selector switch is in the
lever and a HIGH/LOW swing speed switch on the front
OFF position, the superstructure will rotate in the desired
console. The maximum rotation speed is 2.5 rpm in HIGH
direction. Shifting the control to neutral and depressing the
speed and 1.25 rpm in LOW speed. Braking is accomplished
brake pedal will stop the swing.
by depressing a glide swing brake pedal which is a
proportionate control valve that provides a controlled braking Swing Brake
of the swing motion.
The hydraulic power for the swing brake is supplied by the
The swing system consists of a hydraulic remote controller, pressure reducing/sequence valve in the swing brake and
swing speed switch, series/parallel selector valve, a armrest lockout manifold. With the SWING BRAKE selector
directional control valve, the swing drives, the swing brake switch positioned to ON, the swing brake release valve
assemblies, the brake pedal and power brake valve, and a blocks the regulated flow to the brake release port and spring
swing brake release solenoid valve. pressure in the swing brake applies the brake. When the
The crane is equipped with a pin type turntable lock as SWING BRAKE selector switch is positioned to OFF, the
standard and a standard 360 degree positive swing lock. The regulated flow is directed from the pressure reducing/
360 degree positive swing lock meshes with the swing gear sequence valve to the brake release port, overcoming the

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SWING SYSTEM RT890E3 SERVICE MANUAL

brake spring pressure and releasing the swing brake. for the activation of the swing brake when the pedal is
Regulated flow from the pressure reducing/sequence valve depressed.
is also provided to the power brake valve where it is available

8
11

9
7

10
6

13
5

3
12

14

6493-1 FIGURE 6-1

Item Description Item Description

1 Plug 9 Breather
2 Plug 10 Plug
3 Plug 11 Motor
4 Elbow 12 Gearbox and Brake
5 Pipe 13 Plug
6 Breather 14 Pinion
7 Plug
8 Dipstick

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RT890E3 SERVICE MANUAL SWING SYSTEM

Maintenance
Troubleshooting

Symptom Probable Cause Solution

1. Boom swing opera- a. Damaged relief valve. a. Replace relief valve.
tion erratic in either
b. Swing brake dragging (not releasing b. Readjust and/or replace necessary
direction.
properly). parts.
c. Low engine rpm. c. Increase engine rpm to obtain smooth
swing operation.
d. Low hydraulic oil. d. Replenish hydraulic oil to proper level.
e. Improper movement of control to e. Feather controls to neutral to maintain
neutral. smooth stopping action.
f. Insufficient lubricant on swing bearing. f. Lubricate bearing properly. Refer to
Turntable, page 9-12.
g. Crane not level. g. Level crane using outriggers.
h. Damaged swing motor. h. Repair or replace swing motor.
i. Excessive overload. i. Reduce load. Refer to load capacity
chart.
j. Restricted or partly clogged hydraulic j. Replace hose or fittings.
hose or fittings.
k. Pump cavitation in swing section. k. Tighten suction hose or replace any
damaged fitting. Check hydraulic tank
level.
l. Improperly torqued turntable bolts. l. Torque turntable bolts evenly.
m. Excessive preload on upper and lower m. Adjust as necessary. 6
pinion shaft bearing.
n. Improperly torqued swing motor n. Torque swing motor attachment bolts.
attachment bolts.
o. Malfunction of the swing box. o. Remove swing box and make
necessary repairs.
p. Worn or damaged pump. p. Repair or replace damaged pump.
q. Damaged swing directional control q. Repair or replace swing directional
valve. control valve.
r. Damaged swing pinion. r. Replace pinion.
s. Damaged turntable bearing. s. Replace turntable bearing.
2. Boom swing opera- a. Crane not level. a. Level crane using outriggers.
tion erratic in one
b. Turntable bearing binding due to b. Rotate machine 360 degrees in both
direction only.
continuous limited swing. (Example: directions several times and lubricate
concrete pourer.) bearing.
c. Restricted hose or fitting. c. Replace hose or fitting.
d. Damaged swing directional control d. Replace swing directional control
valve. valve.
e. Damaged swing pinion. e. Replace pinion.
f. Damaged turntable bearing. f. Replace turntable bearing.

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SWING SYSTEM RT890E3 SERVICE MANUAL

Symptom Probable Cause Solution

3. Boom will not swing a. Damaged relief valve. a. Remove, clean, and repair or replace
in either direction. relief valve.
b. Damaged swing motor. b. Repair or replace swing motor.
c. Swing brake not releasing properly. c. Repair as necessary.
d. Damaged hydraulic remote control d. Replace hydraulic remote control
valve. valve.
e. Internal damage to swing box. e. Remove swing box and repair.
f. Worn or damaged hydraulic pump. f. Replace pump section.
g. Damaged swing directional control g. Replace swing directional control
valve. valve.
h. Damaged swing pinion. h. Replace pinion.
i. Damaged turntable bearing. i. Replace turntable bearing.
j. Excessive overload. j. Reduce load. Refer to load capacity
chart.
4. Swing operation a. Damaged relief valve. a. Adjust, repair or replace valve.
slow in either direc-
b. Improperly adjusted swing brake. b. Readjust.
tion.
c. Damaged hydraulic remote control c. Replace hydraulic remote control
valve. valve.
d. Improperly lubricated swing bearing. d. Lubricate bearing per
recommendations in Turntable, page 9-
12.
e. Improper size hose and/or fittings e. Refer to the Parts Manual.
installed.
f. Clogged or restricted hydraulic hoses f. Clean or replace damaged parts.
or fittings.
g. Worn or damaged output shaft g. Replace bearings.
bearings
h. Worn or damaged swing motor. h. Repair or replace motor.
i. Worn or damaged hydraulic pump. i. Repair or replace pump.
j. Crane not level. j. Level crane.
k. Damaged swing directional control k. Replace swing directional control
valve. valve.
5. Swing operation a. Crane not level. a. Level crane.
slow in one direc-
b. Damaged hydraulic remote control b. Replace hydraulic remote control
tion only.
valve. valve.
c. Damaged swing directional control c. Replace the swing directional control
valve. valve.
d. Clogged or restricted hose. d. Replace hose or fitting.
e. Improperly torqued turntable bearing. e. Torque turntable bearing.

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RT890E3 SERVICE MANUAL SWING SYSTEM

Symptom Probable Cause Solution

6. Swing brake opera- a. Improper brake adjustment. a. Adjust brake.
tion erratic.
b. Air in swing brake system. b. Bleed brake system.
c. Brake pedal not fully retracted. c. Check brake pedal return spring; repair
or replace spring.
d. Dirty or glazed brake disc. d. Clean or replace disc.
e. Malfunction of the glide swing power e. Repair or replace glide swing power
brake valve. brake valve.
f. Kinked or bent lines and/or hoses and f. Straighten or replace as required.
fittings.
7. Swing brake sys- a. Damaged swing brake release valve. a. Replace release valve.
tem will not oper-
b. Damaged glide swing power brake b. Repair or replace glide swing power
ate.
valve. brake valve.
c. Internal damage to the swing brake c. Repair or replace affected parts.
assembly.
d. Loose or restricted brake lines or d. Tighten or replace lines and fittings.
fittings.
8. Swing brake pedal a. Damaged glide swing power brake a. Repair or replace the glide swing
is spongy. valve. power brake valve.
b. Loose or restricted brake lines or b. Tighten or replace brake lines and
fittings. fittings.
9. Swing brake drags. a. Damaged glide swing power brake a. Repair or replace the glide swing
valve. power brake valve.
b. Damaged swing brake release valve. b. Replace release valve.
c. Internal damage to the swing brake c. Repair or replace affected parts.
assembly. 6
d. Loose or restricted brake lines or d. Tighten or replace brake lines and
fittings. fittings.
10. Boom swings a. Insufficient hydraulic volume. a. Check delivery of hydraulic pump.
slowly. Ensure sufficient fluid is available to
pump. Check pump drive speed.
b. Damaged relief valve. b. Adjust, repair, or replace valve.
c. Damaged swing motor. c. Repair or replace motor.
11. Swing motor con- a. Hydraulic remote control valve sticking a. Repair or replace valve.
tinues to operate or valve otherwise damaged.
when swing control
b. Control valve sticking or valve b. Repair or replace valve.
is in neutral.
otherwise damaged.
12. Swing motor turn- a. Improper port connections. a. Reverse port connection.
ing in wrong direc-
tion.
13. Swing motor noisy. a. Air in system. a. Refer to Removing Air from the
H y d r a u l i c S y s t e m , pa g e 2 - 7, f o r
removal of air from the system.
b. Motor binding. b. Repair or replace motor.

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SWING SYSTEM RT890E3 SERVICE MANUAL

SWING MOTOR Test

1. Test swing of superstructure in each direction. Stop and
Description start swing several times.
The swing motor is mounted on the swing brake housing and 2. Inspect for hydraulic leaks and repair as necessary.
drives the swing gearbox through the brake assembly. The
swing motor is a hydraulic gerotor type with low speed and
high torque characteristics. It has only three moving parts,
SWING GEARBOX AND BRAKE
the commutator valve, the drive, and the gerotor star. The
motor has two ports for connection to the hydraulic system.
Description
The swing gearbox and brake, used in conjunction with the
Maintenance swing motor, rotates and stops the superstructure. A pedal
on the cab floor is used to activate the swing brake. The
Removal swing gearboxes are bolted to the superstructure base plate,
1. Ensure the swing brake and swing lock are engaged. and its pinion gear meshes with the ring gear of the turntable
bearing to rotate the turntable.
2. Clean the port area around the motor. Tag and discon-
nect the hydraulic hoses from the motor assembly. Cap The swing gearbox utilizes double reduction planetary
or plug all openings. gearing. The multi-disc swing brake assembly is an integral
part of the swing gearbox and is located between the swing
motor and the swing gearbox. The brake mechanism is a
CAUTION disc pack that is hydraulically released and spring applied.
Oil can be hot and cause burns.
Maintenance
3. Unscrew the drain plug, remove the breather and dip- NOTE: The swing brake can be removed and disassem-
stick to ensure that all oil has been removed. After the oil bled independently of the swing gearbox.
has been drained, replace the drain plug and any other
plugs that may have been removed. Swing Brake
Removal
CAUTION 1. Engage the turntable lock pin.
Pull straight up on the motor assembly to avoid damaging
2. Tag and disconnect the hydraulic lines connected to the
the splined shaft.
swing motor and the brake. Cap and/or plug all open-
ings.
4. Remove the capscrews securing the motor and lift the
swing motor free of the motor support plate. Remove 3. Remove the swing motor from the swing brake accord-
and discard the O-ring from the groove in the swing ing to the procedures found in this Section under
brake. SWING MOTOR - REMOVAL.

Installation
CAUTION
Use care when removing the capscrews securing the
CAUTION brake, as there is tension on the bolts due to internal
Use care when engaging the swing motor drive gear, do brake springs.
not force the shaft to engage.
4. While observing tension on the bolts, unscrew the
1. Install a new O-ring in the groove of the swing brake. socket head capscrews securing the brake to the gear-
Position the swing motor on the swing brake, engaging box. Remove the brake assembly in one piece with the
the shaft with the brake input shaft. motor support plate.
2. Apply Loctite 243 to the capscrew threads. Install the 5. Remove the bolts and washers securing the brake to the
capscrews and secure the motor to the brake housing. gearbox. Remove the brake assembly.
Torque the capscrews 85 to 103.2 Nm (44 to 72.2 lb-ft).
6. Remove and discard the O-ring from the brake housing.
3. Connect the hydraulic lines to the swing motor as tagged
during removal. 7. Cover the opening of the swing gearbox to ensure no
dirt, dust, etc., gets into the gearbox.

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RT890E3 SERVICE MANUAL SWING SYSTEM

Installation 9. Cover the opening of the swing gearbox to ensure no

dirt, dust, etc., gets into the gearbox.
1. Install a new o-ring onto the brake housing.
Installation
2. Place motor support plate on brake housing.
1. If removed, install the swing brake according to the pro-
3. Apply Loctite 270 to socket capscrews. Install motor
cedures found in this Section under SWING BRAKE
support and brake onto gearbox and secure with the
INSTALLATION.
socket capscrews. Torque the capscrews 49.9 to 60.6
Nm (34.9 to 42.4 lb-ft). 2. If removed, install the swing motor according to the pro-
cedures found in this Section under SWING MOTOR
4. Install the swing motor into the swing brake according to
INSTALLATION.
the procedures found in this Section under SWING
MOTOR - INSTALLATION. 3. Attach a suitable lifting device to the swing gearbox and
lift and position the swing gearbox in place on the
5. Connect the hydraulic lines to the motor and brake.
mounting plate.
6. Bleed all air from the brake assembly.
4. Install the capscrews, washers and spacers. Torque the
Testing capscrews 298 to 322 Nm (220 to 237 lb-ft).
1. With the SWING BRAKE switch in the ON position, posi- 5. Install the pinion gear on the output shaft and secure
tion the swing control lever in both directions. Super- with three bolts. Torque 49 to 60.6 Nm (34.9 to 42.4 lb-
structure rotation should not occur. ft).
2. Position the SWING BRAKE switch to OFF and swing 6. Connect the hydraulic lines to the swing brake.
the superstructure in both directions. Use the swing
7. Connect the hydraulic lines to the swing motor.
brake pedal to stop rotation.
8. Service the gearbox as indicated under SERVICING.
3. Check for hydraulic leaks and repair as necessary.
Servicing
Gearbox
As with all highly stressed mechanisms, reasonable
Removal operating procedures are always required. Normal
1. Engage the turntable lock pin. maintenance should only consist of proper lubrication and a
periodic check of mounting bolt torque values. Lubrication
2. Tag and disconnect the hydraulic lines from the swing consists of maintaining the gearbox oil level. Oil in a new
motor and swing brake. Cap and/or plug all openings gearbox should be drained and flushed out after 6
3. Remove the capscrews and lockwashers securing the approximately 250 hours of operation, and replaced with
pinion guard. Remove the guard. premium quality SSGL-5 after approximately 500 hours of
operation or each year, whichever occurs first. Operation in
4. Remove the three bolts and plate attaching the pinion high humidity or polluted air areas will require more frequent
gear to the output shaft and remove the pinion gear. changes to minimize moisture or contaminate accumulation.
NOTE: The complete gearbox assembly with motor Change the oil as follows.
weighs approximately 170 kg (375 pounds). 1. Unscrew the drain plug; remove the breather and dip-
5. Attach a suitable lifting device to the swing gearbox. stick to ensure all oil has been removed.
Remove the capscrews, washers and spacers securing 2. After oil is drained, replace the drain plug and any other
the gearbox to the mounting plate. plugs that were removed to drain the oil.
NOTE: Take note of the swing motor port orientation to 3. Flush the case with a light flushing oil.
ensure proper installation.
NOTE: Cleaning of the gearbox with a solvent is recom-
6. Remove the swing gearbox. mended to prevent an accumulation of grit and
7. If necessary, remove the swing motor according to the grime. Avoid steam cleaning where moisture and
procedures found in this Section under SWING MOTOR dirt might be driven into the vent of the swing bear-
REMOVAL. ing.

8. If necessary, remove the swing brake according to the 4. To refill with oil (see Figure 6-2), make sure the breather
procedures found in this Section under SWING BRAKE is open. Insert oil through breather oil fill until it reaches
REMOVAL. proper location on dipstick.
5. Tighten the breather and dipstick.

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SWING SYSTEM RT890E3 SERVICE MANUAL

provides the only attachment between the superstructure

and carrier. Therefore, proper care of the bearing and
Dipstick Oil periodic maintenance of the turntable-to-bearing attach bolts
Level -IS A MUST -to ensure safe and efficient operation.
Breather Oil Torquing Turntable Bolts
Fill
General

DANGER
Failure to maintain proper torque of the turntable bearing
Oil Drain attaching bolts will result in damage to the crane and
possible injury to personnel.

Maintaining proper torque value for bolts is extremely

important for structural strength, performance, and reliability
of the crane. Variations in torque can cause distortion,
binding, or complete separation of the superstructure from
the carrier. Refer to Fasteners and Torque Values, page 1-10
for information on the use of a torque wrench and torque
values or fasteners.

FIGURE 6-2
CAUTION
Checking the Oil Level Repeated re-torquing may cause bolts to stretch. If bolts
keep working loose, they must be replaced with new bolts
1. Check the level on the dipstick on the swing gearbox.
of the proper grade and size.
2. If no oil is visible on the dipstick, add SSGL-5 weight oil
until the level is between min and max on the dipstick. Proper identification of bolt grade is important. When marked
as a high strength bolt (grade 8 and metric grade 10.9), the
3. Replace the dipstick in the brake housing.
serviceman must be aware of bolt classifications and that he
Testing is installing a high strength heat-treated tempered
component and the bolt must be installed according to
1. Test swing of superstructure in each direction. Stop and specifications. Special attention should be given to the
start swing several times. existence of lubricant and plating that will cause variation
2. Inspect for hydraulic leaks and repair as necessary. from dry torque values. When a high strength bolt is
removed, or un-torqued, the bolt must be replaced with a
SWING BEARING new bolt of the same classification.

Description
The swing bearing is an anti-friction roller bearing that mates DANGER
the Superstructure to the Carrier. The bearing inner race is
It is mandatory that bearing attaching bolts be inspected
bolted to the Superstructure and the outer race is bolted to
for lack of torque and retorqued, as required, after the first
the Carrier. The inner race contains two grease fittings for
300 hours of crane operation. The bolts may loosen in
lubrication of the bearing which are hosed to two fittings at
service due to vibration, shock-loads, and temperature
the front right side of the turntable center section.
changes, therefore, periodic inspection should be
Maintenance accomplished every 500 hours thereafter, ensuring the
bolts are properly torqued.
General
If it is reported by the crane operator or suspected that the
The swing bearing is the most critical maintenance point of crane has been overloaded beyond the capacities specified
the crane. It is here, at the centerline of rotation, that above the bold line on the cranes’ capacity chart, then all
stresses of loads are concentrated. In addition, the bearing

6-8 Published 07-24-2013, Control # 069-12

RT890E3 SERVICE MANUAL SWING SYSTEM

turntable bolts must be inspected for looseness and Inner Race Torquing
retorqued to specifications.
1. Extend and set the outriggers. Fully elevate the boom.
The inner race of the bearing is secured to the turntable by
2. Torque eight bolts to 804 to 870 Nm (593 to 642 lb-ft)
72, M24 Grade 10.9 bolts. The outer race of the bearing is
using the following sequence pattern; 1, 40, 22, 58, 16,
secured to the carrier frame by 72, M24 Grade 10.9 bolts.
52, 34, and 70. Tools used are the socket, multiplier,
Torque Values backlash adapter, necessary extensions, and torque
wrench.
Torque all turntable bolts (Figure 6-3) to a final torque of 1005
to 1089 Nm (741 to 803 ft-lb). 3. Return to bolt 1 and torque all bolts sequentially in a
clockwise direction to the final torque of 1005 to 1089
Tools Required
Nm (741 to 803 ft-lb). The same tools are used as in step
Figure 6-4 lists the complete set of special tools required to 1.
torque the turntable bolts.
Outer Race Torquing
Same as inner race.

18 19 20 21
NOTE: Bolt pattern 16 17 22
23 24
15
numbering 14 25
13
is the same 12 26
11 27
for the inner 28
and outer 10
9 29
race 30
8
7 31
6 32
5 33
4 34

3 35
2 36
37
1
REAR 6
72
38
71
39
70
40
69
41
68
42
67
43
66
65 44
64 45
63 46
62 47
61 48
60 49
59 50
58
57 56 52 51 FIGURE 6-3
55 54 53

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SWING SYSTEM RT890E3 SERVICE MANUAL

7 1
3 6
5 6633

Orders for special tools Description Manitowoc Part Number Quantity Required
shall be referred to: 1. M24 Socket 3/4” Drive 9-999-101798 1
2. 4 to 1 Torque Multiplier (1/2” Input 3/4” Output) 9-999-100134 1
Manitowoc Crane Care 3. Backlash Adapter 9-999-100141 1
Customer Support 4. 1/2” Drive Torque Wrench 9-999-100136 1
1565 Buchanan Trail East 5. 10” Extension 3/4” Drive 9-999-100138 A/R
Shady Manitowoc, PA 17256 6. 13” Extension 3/4” Drive 9-999-100137 A/R
Phone: (717) 597-8121 7. Tool Box (Optional) 9-999-100146 1
Fax: (717) 593-5929

Special Turntable Bolt Torquing Tools FIGURE 6-4

Removal 6. Remove the counterweight and auxiliary hoist following

procedures outlined in Section 6 of the Operator and
1. Fully extend and set the outriggers enough to take up
Safety Handbook.
the slack in the pads.
7. Tag and disconnect all water and oil lines from the bot-
NOTE: Do not raise the machine on the outriggers.
tom of the swivel. Cap or plug all lines and openings.
2. Ensure the boom is in the travel position and the turnta-
8. Locate the connectors and ground wire that joins the
ble lock pin is engaged.
swivel wiring harness to the receptacles and ground
3. Elevate the boom slightly and shut down the engine. stud on the carrier.
4. Tag and disconnect the battery cables from the batter- 9. Disconnect the swivel wiring harness connectors from
ies. the carrier wiring receptacles. Remove the ground wire
from the ground stud.
NOTE: The boom assembly weighs approximately 16606
kg (36,610 lb) with stowed boom extension. 10. Remove the clamp securing the swivel wiring harness to
Removal of the swingaway boom extension will the retainer plate on the bottom of the hydraulic swivel
simplify boom removal, therefore, the above weight assembly.
is for the boom without the swingaway boom exten-
11. Coil the wiring harness and secure it to the swivel to pre-
sion attached. The lift cylinder weighs approxi-
vent damage to the harness during turntable removal.
mately 1769 kg (3900 lb).
12. On the bottom of the hydraulic swivel, bend the retainer
5. Remove the boom and lift cylinder following the proce-
tabs away from the bolt heads. Remove the eight bolts
dures outlined in Section 4, BOOM.
and four bolt retainers securing the two retainer plates to
NOTE: The counterweight/auxiliary hoist and structure the spool. Remove the retainer plates from the spool
weighs approximately 11067 kg (24,398 lb). and the lugs on the carrier frame.

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RT890E3 SERVICE MANUAL SWING SYSTEM

NOTE: The swivel assembly will be removed with the turn- NOTE: The bearing weighs approximately 703 kg (1550
table. lb). Ensure the bearing lifting device is capable of
supporting the weight.
16. Place an adequate lifting device under the bearing and
remove the 72 bolts and washers securing the turntable
DANGER bearing to the superstructure.
Ensure the lifting device is capable of fully supporting the
17. Using the lifting device, remove the turntable bearing
weight of the superstructure. Ensure the superstructure
from under the superstructure.
will not tilt or slide during lifting and moving. Failure to do
so may result in death or injury to personnel and damage Inspection
to equipment.
Check the bearing teeth for chipping or cracking. If any
NOTE: If a lifting device capable of lifting the entire super- evidence of these is found, replace the bearing. Ensure the
structure is not available, superstructure weight bolt holes are free of dirt, oil, or foreign material.
may be reduced by removing various components
Installation
such as the hoist(s).
13. Attach a suitable lifting device to the four superstructure
lifting lugs (two near the boom pivot shaft bushings and
two near the lower lift cylinder pivot shaft bushings). DANGER
Take in cable or chain to remove slack. Do not pull up on Anytime a turntable bolt has been removed, it must be
the superstructure. replaced with a new bolt.

NOTE: If the same bearing is to be used again, align the

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

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SWING SYSTEM RT890E3 SERVICE MANUAL

6. Position the two retainer plates on the bottom of hydrau-

Maximum Eccentricity Point lic swivel spool, engaging the lugs on the carrier frame,
Pinion
and secure them to the spool with four bolt retainers and
eight bolts. Torque the bolts to 122 Nm (90 ft-lb). Bend
all the retainer tabs to make contact with the bolt heads.
7. Plug the swivel wiring harness connectors into the car-
rier receptacles. Secure the ground wire to the ground
stud using a washer, lockwasher, and nut.
8. Install the clamp securing the swivel wiring harness to
the retainer plate on the bottom of the hydraulic swivel.
9. Connect all water and hydraulic lines to the ports on the
bottom of the swivel as tagged during removal.
10. Install the boom and lift cylinder following the procedures
outlined in Section 4, BOOM.
Bearing
NOTE: The counterweight/auxiliary hoist and structure
6492
weighs approximately 11067 kg (24,398 lb).
.008 Thick Shim By Full Width to
Tooth Engagement (.016) 11. Install the counterweight and auxiliary hoist following
Backlash) FIGURE 6-5 procedures outlined in Section 4 of the Operator’s Man-
ual.
5. Orient ring gear such that its point of max eccentricity
(“high point”) is located between the swing drives. Posi- 12. Reconnect the batteries.
tion swing drives so that pinion is centered within cutout 13. Check the slew potentiometer in the electrical swivel for
in base plate and motor ports face towards the outboard proper orientation. Refer to SWIVELS in this Section
side as shown.
Testing
Activate the crane and check for proper function.
CAUTION
Do Not Clamp Over Pinion. NOTE: If the superstructure does not turn freely after bear-
ing and pinion replacement, contact your local dis-
• Using shims, set backlash by moving the swing drive tributor.
assemblies toward the bearing in order to mesh the
pinion with the ring gear teeth (see Figure 6-5).
• Check tooth engagement squareness and vertical
tooth engagement.
• Remove backlash shims and recheck backlash.

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RT890E3 SERVICE MANUAL SWING SYSTEM

SWIVELS stationary with the carrier as the case rotates with the
superstructure.
Description The spool portion of the water swivel is integral with the
The swivel assembly (Figure 6-6) consists of a 12 port hydraulic swivel. The hydraulic and water swivel spools
hydraulic swivel, a 2 port water swivel, and a 15 conductor remain stationary with the carrier as the superstructure
slip ring electrical swivel. Solid connections cannot be used rotates. The water swivel case engages to hydraulic case by
to transfer oil, heater hot water and electricity between the four dowel pins.
carrier and superstructure due to the continuous 360 degree The electrical swivel center or collector ring assembly is
swing. The use of swivels efficiently accomplishes this secured by setscrews to a center post which is bolted to the
function. spool of the hydraulic swivel. This allows the collector ring
The barrel portion of the hydraulic swivel is attached to the assembly to remain stationary with the carrier. The outer
turntable base plate by four bolts, washers and bushings. portion or brush assembly is mounted on two studs which
The spool portion of the swivel rides upon a thrust ring at the are located on the mounting plate assembly which is
top of the swivel case. The spool portion is held stationary retained to the water swivel barrel by a bolt. This allows the
with the carrier by bolts, and bolt retainer plates attached to brush assembly to rotate with the superstructure around the
the swivel retainer plate which engages the carrier frame stationary collector core.
lugs with bolts and jam nuts. This allows the spool to remain

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SWING SYSTEM RT890E3 SERVICE MANUAL

1
2

Item Description 9
3
1 Nut and Washer
2 Electric Swivel 8
4
3 Capscrew and Washer
4 Spacer Bushing
5 Frame Mounting Lugs
Hex Head Screw and Jam
6
Nut
7 Retainer Plate 10

8 Hydraulic Swivel
9 Mounting Bolts
Water and Hydraulic
10
Case
11 Turntable Base Plate
6
12 Carrier Top Plate
Bolt and Bolt Retainer
13
Plate
Tubing Clamp, Bolt,
14 7
Lockwasher, Flatwasher
15 Electric Swivel Harness

11

12

13

6490-1, 6490-2
14
15

FIGURE 6-6

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RT890E3 SERVICE MANUAL SWING SYSTEM

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

Standard Working Pressure

Port # Function
kPa (bar) (psi)
1 20000 (200) (2901) Brake - Front
2 20000 (200) (2901) Brake - Rear
3 20000 (200) (2901) Load Sense
4 3500 (35) (508) Dual Return
5 20000 (245) (3553) Swing/Steer
6 24500 (245) (3553) Lift/Tele/Hoist
7 20000 (200) (2901) Pilot/Accessory
8 20000 (200) (2901) Front Steer-Left
9 20000 (200) (2901) Front Steer-Right
10 3500 (35) (508) Drain
11 200 (2) (29) A/C
12 200 (2) (29) A/C
A 200 (2) (29) Heater Supply (Coolant)
B 200 (2) (29) Heater Return (Coolant)

Theory of Operation NOTE: It might be necessary to raise the boom slightly to

allow installation of the blocking.
6
The hydraulic swivel allows oil to flow from the pumps to
various crane functions on the superstructure. All oil is NOTE: This blocking is to add extra support for the boom.
routed into the spool portion of the swivel where, through a Any seepage or leakage in the holding valves or
series of internally drilled passages, oil is transferred to internally in the cylinders will allow the boom to set-
circumferential channels on the spool exterior. These tle over a period of time.
channels correspond with a mating port on the outer case of
4. Use the oak blocking to block between the barrel of the
the swivel. Each channel is separated by a series of nylon
lift cylinder and the boom base section.
and O-ring seals that prevent transfer of oil and pressure.
Return flow from the crane superstructure is accomplished in 5. Tag and disconnect the hydraulic lines from the case of
the same manner through another set of ports. the hydraulic swivel. Cap or plug all lines and openings.

Maintenance 6. Tag and disconnect the hydraulic lines and water lines
from the spool of the hydraulic swivel. Cap or plug all
Removal lines and openings.
1. Extend and set the outriggers. Ensure the crane is level 7. Tag and disconnect the water lines from the case of the
and the boom is over the front. water swivel. Cap or plug all lines and openings.
2. Elevate the boom and note at what boom angle, you 8. Disconnect the swivel wiring harness connectors from
have the most clearance between the lift cylinder and the carrier receptacles and the yellow ground wire from
the turntable side plate. Shut down the engine. the connector mounting bracket on the carrier frame. If
3. Measure the distance from the top of the lift cylinder to necessary, remove the electrical swivel. Refer to Electri-
the base of the boom section where the lift cylinder cal Swivel, page 6-17.
attaches. Cut two pieces of 10 x 10 cm (4 x 4 in) oak to
fit.

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SWING SYSTEM RT890E3 SERVICE MANUAL

NOTE: The hydraulic swivel weighs approximately 97 kg 7. Connect the hydraulic lines to the hydraulic swivel case
(213 lb). The hydraulic, water, and electrical swivel as tagged during removal.
combined weigh approximately 108 kg (239 lb).
8. Connect the water lines to the water swivel case as
9. On the bottom of the swivel, bend the retainer tabs away tagged during removal.
from the bolt heads. Remove the capscrews and cap-
9. Remove the blocking material from the lift cylinder.
screw retainers securing the two retainer plates to the
spool. Remove the retainer plates from the spool and 10. Activate all systems; cycle all functions and observe for
the lugs on the carrier frame. proper operation and any leakage.
NOTE: It may be necessary to remove some drive line
Two Port Water Swivel
components to remove the swivel.
10. Position an adequate supporting device beneath the Description
swivel. The two port water swivel allows engine coolant to flow from
11. Remove the capscrews, washers, and bushings secur- the carrier-mounted engine to the hot water heater in the
ing the swivel barrel to the turntable base plate and operator’s cab. Through an internally drilled passage in the
lower the swivel to the ground. 12 port hydraulic swivel spool, coolant is transferred to a
circumferential groove on the water spool exterior. This
Installation groove corresponds with a mating port on the outer case of
NOTE: The hydraulic swivel weighs approximately 97 kg the water swivel. The spool grooves are separated by a quad
(213 lb). The hydraulic, water, and electrical swivel ring/telflon bronze ring seal. The lip seal prevents coolant
combined weigh approximately 106 kg (234 lb). from leaking externally. Return engine coolant flow from the
hot water heater is accomplished in the same manner
1. Raise the swivel into position. through the opposite port of the water swivel.
2. Secure the hydraulic swivel to the turntable base plate Maintenance
with the bushings, capscrews and washers. Torque the
capscrews 713 to 743 Nm (526 to 548 lb-ft). Removal
3. Position the two retainer plates on the hydraulic swivel 1. Perform steps 1 thru 4 of HYDRAULIC SWIVEL -
spool ensuring they engage the lugs on the carrier REMOVAL in this section.
frame. Secure the retainer plates with the capscrews
2. Remove the electrical swivel. Refer to ELECTRICAL
and capscrew retainers. Apply Loctite 271 to the bolt
SWIVEL - REMOVAL in this section.
threads. Torque the bolts 270 Nm (199 lb-ft). Bolt head
flats must align with retainer tabs. Bend all the retainer 3. Tag and disconnect the lines from the case of the water
tabs to make contact with the bolt heads. Snug the swivel. Cap or plug all lines and openings.
retainer plate capscrews against the lugs on the carrier
4. Remove the four bolts and washers securing the water
frame and tighten the locking nuts.
swivel and electrical swivel center post to the hydraulic
4. If removed, install the electrical swivel. Refer to ELEC- swivel. Remove the water swivel case and center post.
TRICAL SWIVEL in this Section. Connect the swivel wir-
Disassembly
ing harness connectors to the carrier receptacles and
the ground wire to the mounting bracket on the carrier NOTE: Any maintenance requiring disassembly of the
frame. Use the bolt and star washers taken off at water swivel should include replacement of all
removal. Make sure the ground connection is clean and seals and rings.
has good metal to metal contact. Spray the connection
with a battery terminal protectant such as Deka Battery
Terminal Protection spray, Grove P/N 9999102423. CAUTION
5. Install the clamp, lockwasher, flat washer and capscrew When removing seals and rings, avoid scratching
to the bottom of the swivel retainer plate securing the grooved and gland surfaces.
wiring harness.
NOTE: Aligning discarded seals and rings in the order of
6. Connect the hydraulic lines and water lines to the spool disassembly will assist with installation of new
of the hydraulic swivel as tagged during removal. seals and rings.

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RT890E3 SERVICE MANUAL SWING SYSTEM

1. Remove the seals and rings from the spool. Electrical Swivel
Cleaning and Inspection Description
The swivel assembly consists of a 15 conductor slip ring and
cover assembly.
DANGER Each brush set incorporates two brushes, leads, and clips
Cleaning solvents can be toxic, flammable, an irritant to which are attached to a brush holder assembly. The brush
the skin, or give off harmful fumes. Avoid prolonged skin set leads are formed into harnesses which are routed
contact, inhalation of vapors, or smoking. Failure to through the mounting plate on the swivel. The collector ring
comply can result in injury or death to personnel. leads are formed into one harness which is routed downward
through the center of the hydraulic swivel. Extending from
1. Clean the spool and case with a suitable solution and the base of the hydraulic swivel, the collector ring leads are
dry with compressed air. Plug all ports with plastic caps. also formed into connectors which plug into receptacles from
the chassis power supply.
2. Check the spool and inside of the case for scratches,
grooves, scoring, etc. If any grooves have developed The swivel cover is secured with a seal and bolts
with a depth of 0.127 mm (0.005 in) the unit should be The electrical swivel also incorporates a slew potentiometer.
replaced. The potentiometer controls functions in the load moment
Assembly indicating, working area definition, and rear axle oscillation
lockout systems.
NOTE: Lubricate the interior of the swivel to prevent rust-
ing from condensation. Theory of Operation
1. Lubricate the spool, seals, and rings. The electrical swivel is located on top of the water swivel and
transfers electricity between the carrier and superstructure.
Wiring harnesses transmit the electricity between the carrier
CAUTION and superstructure.
When installing seals and rings, avoid stretching seals or
scratching grooved or gland surfaces. Maintenance
Removal
2. Install new seals and rings on the spool.
1. Perform steps 1 through 4 of HYDRAULIC SWIVEL -
REMOVAL in this section.
6
CAUTION
Proper alignment when installing the case is required. Do
not force the spool into the case.
DANGER
3. Insert the spool into the barrel. D i s c o nn e c t t h e ba t t er i e s b e f or e pe r fo r m i n g a n y
maintenance on the electrical system. Serious burns may
Installation result from accidental shorting or grounding of live
1. Install the water swivel on top of the hydraulic swivel. circuits.
Secure the water swivel and the electrical swivel center
post with the capscrews and washers. 2. Disconnect the batteries. (Refer to Batteries, page 3-1.

2. Connect the lines to the swivel case as tagged during 3. Locate the connectors which join the collector ring har-
removal. ness to the receptacles for the carrier.

3. Install the electrical swivel. Refer to ELECTRICAL 4. Tag the connectors and their receptacles with numbers.
SWIVEL - INSTALLATION in this Section. Disconnect the connectors from the chassis wiring
receptacles.
4. Perform steps 8 and 9 of HYDRAULIC SWIVEL -
INSTALLATION in this Section. 5. Remove the clamp securing the wiring harness to the
retainer plate on the bottom of the hydraulic swivel
5. Activate all systems, cycle all functions, and observe for assembly.
proper operation and any leakage.
6. Secure the connectors and wires from each of the num-
bered connectors so the harness can be withdrawn
through the center of the hydraulic swivel.

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SWING SYSTEM RT890E3 SERVICE MANUAL

7. Tag and disconnect the connectors from the receptacles

on the cab bulkhead mounting plate.
8. Remove the capscrews and washers, and remove the 1, 2
cover from the electrical swivel. 3, 4

9. Loosen the setscrews securing the electrical swivel

mounting tube to the center post on the water swivel.
10. Remove the capscrew and jam nut securing the electri-
cal swivel case to the plate on the case of the water
swivel.
7, 8
5, 6
CAUTION
When withdrawing the wiring harness through the center
of the hydraulic and water swivels, ensure the wires do 6490-4
not get caught and damaged. TOP OF SWIVEL
FIGURE 6-7
11. Remove the swivel and wiring harness from the crane. If
necessary, remove the spacer bushing from the center
Item Description
post.
1 Hex Nut
Installation
2 Capscrew
1. If removed, install the spacer bushing on the center post.
Route the collector core wiring harness through the cen- 3 Capscrew
ter of the hydraulic and water swivels. 4 Flatwasher
NOTE: The boom should be centered directly over the 5 Capscrew
front of the crane before adjustment is made to the 6 Jam Nut
slew potentiometer.
7 Nipple
2. Slide the electrical swivel mounting shaft onto the center
8 Adapter
post.
3. Ensure the threaded hole on the bottom of the electrical 7. Plug the connector into the carrier wiring receptacle,
swivel base is aligned with the mounting hole in the plate connect the wires as tagged during removal. Install the
on the water swivel case. Install the capscrew through yellow ground wire to the connector mounting bracket on
the hole in the plate and install the jam nut. Screw the the carrier frame using the bolt and star washers taken
capscrew into the hole in the electrical swivel base until off at removal. Make sure the ground connection is clean
the capscrew head is approximately 6.0 mm (0.23 in) and has good metal to metal contact. Spray the connec-
from the bracket. Tighten the nut against the electrical tion with a battery terminal protectant such as Deka Bat-
swivel (Figure 6-7). tery Terminal Protection spray, Grove P/N 9999102423.

4. Apply medium strength Loctite to the setscrews securing 8. Install the clamp securing the harness to the retainer
the electrical swivel to the center post and tighten them 5 plate on the bottom of the hydraulic swivel assembly.
to 6 Nm (44 to 53 lb-in) 9. Connect the batteries.
5. Install the swivel cover and secure with capscrews and
washers.
CAUTION
6. Connect the wiring harness connectors to the recepta- It is imperative that the slew potentiometer be adjusted
cles on the cab bulkhead mounting plate as tagged dur- anytime work is done to the electrical swivel.
ing removal.
10. Activate all systems, cycle all functions, and observe for
proper operation. Adjust the slew potentiometer in
accordance with SLEW POTENTIOMETER ADJUST-
MENT procedures in this Sub-Section.

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RT890E3 SERVICE MANUAL SWING SYSTEM

Preventive Maintenance 5. Loosen the three screws that secure the slew potentiom-
eter to the mounting plate.
It is recommended that a normal inspection of the electrical
swivel collector ring and brush assembly be established. An 6. Rotate the body of the slew potentiometer until the slew
example of this could be at approximately 100 to 150 engine angle indicates 0.6 ± 0.1 degree.
operating hours. When this time limit is reached, perform the
NOTE: The slew angle indication in step 6 may not be
following.
obtainable due to limited wire length on the potenti-
1. Check the collector ring and brush assembly for any cor- ometer, or the electrical terminals interference with
rosion, pitting, arcing, and wear. one of the three mounting screws. If this occurs,
reposition the collar set screwed to the potentiome-
2. Check the collector ring setscrews and ensure they are
ter shaft and repeat steps 4 thru 6.
tight.
7. Tighten the three screws that secure the slew potentiom-
3. Check the brush and arm assembly springs. Ensure
eter to the mounting plate. Install the electrical swivel
they are holding the brushes firmly against the collector
cover.
rings.
8. Disengage the house lock pin and swing approximately
Slew Potentiometer Adjustment 10 degrees to the left (counterclockwise). Slowly swing
1. Rotate the superstructure over the front and engage the back to the right and engage the house lock pin.
house lock pin. NOTE: If the superstructure swings past the house lock pin
2. Set the RCL console to read slewing angle as follows: engaged position, step 8 must be repeated.
NOTE: Refer to the PAT Load Moment Indicator BCS 9. If the angle indicated on the console does not exceed ±
Operator’s Handbook for detailed instructions. 1.0 degree, proceed to step 10. If the indicated angle
exceeds ± 1.0 degree, return to step 4.
• Complete the RCL console setup according to the
crane’s current operating configuration. 10. Disengage the house lock pin and swing approximately
10 degrees to the right (clockwise). Slowly swing back to
• Press limits LIM.
the left and engage the house lock pin.
• Press 4 for slew angle/work area definition limits.
NOTE: If the superstructure swings past the house lock pin
• Press 1 for slew angle. engaged position, step 10 must be repeated.
• Press 2 or 3 to display slewing angle. 11. If the angle indicated on the console does not exceed ±
3. Remove the electrical swivel cover. 1.0 degree, proceed to step 12. If the indicated angle 6
exceeds ± 1.0 degree, return to step 3.
12. Disengage the house lock pin and swing approximately
CAUTION 10 degrees to the left (counterclockwise). Slowly swing
Do not attempt to rotate the slotted shaft in the center of back to the right and engage the house lock pin.
the slew potentiometer.
NOTE: If the superstructure swings past the house lock pin
4. Disengage the house lock pin and swing the superstruc- engaged position, step 12 must be repeated.
ture approximately 10 degrees to the right (clockwise). 13. Verify the angle indicated on the console does not
Slowly swing back to the left and engage the house lock exceed ± 1.0 degree. If the indicated angle exceeds ±
pin. 1.0 degree, return to step 3.
NOTE: If the superstructure swings past the house lock pin
engaged position, step 4 must be repeated.

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SWING SYSTEM RT890E3 SERVICE MANUAL

THIS PAGE BLANK

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RT890E SERVICE MANUAL POWER TRAIN

SECTION 7
POWER TRAIN

SECTION CONTENTS
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Antifreeze/Coolant . . . . . . . . . . . . . . . . . . . . . . . . 7-16
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Radiator Removal and Installation. . . . . . . . . . . . 7-16
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 Drive Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
Electronic Control System. . . . . . . . . . . . . . . . . . . 7-6 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
Engine Control System Switches and Indicator Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Transmission/torque Converter . . . . . . . . . . . . . . 7-19
Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7 Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . 7-19
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
Air Intake System . . . . . . . . . . . . . . . . . . . . . . . . . 7-10 Towing or Pushing . . . . . . . . . . . . . . . . . . . . . . . . 7-22
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10 Servicing the Crane After Transmission/Torque
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10 Converter Overhaul . . . . . . . . . . . . . . . . . . . . . . . 7-24
Water Cooling System . . . . . . . . . . . . . . . . . . . . . 7-13 Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . 7-25
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13 Engine Block Heater . . . . . . . . . . . . . . . . . . . . . . 7-25

ENGINE the superstructure control module which sends the signal to

the engine ECM via the data link.
Description The engine and its components are enclosed in a hood
The engine is a Cummins QSB6.7 (Figure 7-1) diesel assembly with a grill in the rear of the hood for adequate air
engine. This Service Manual does not include detailed circulation. Access to the engine is gained through a door
information on the engine itself. A separate manual as assembly in the top of the hood that opens from both sides.
prepared in detail by the engine manufacturer, is supplied The air intake filter is mounted on the rear of the right rear
with this Service Manual. However, a short description and fender. The muffler is mounted on the left side of the frame
maintenance of certain components of the fuel system, air
intake system, and water cooling system is provided in this
behind the rear fender.
7
section.
The engine is electronically controlled by the Electronic
Control Module (ECM), it is the control center of the system. DANGER
It processes all of the inputs and sends commands to the fuel Do not spray starting fluid into the air inlet. The spray will
systems as well as vehicle and engine control devices. contact the heater elements and could explode causing
Engine speed is controlled by the foot throttle pedal in the personal injury.
cab. It controls engine RPM which increases or decreases
proportionately with the amount of foot pressure applied to To aid in starting the engine in cold weather, the engine is
the pedal. Engine speed is also controlled by a hand equipped with electric air heating elements that are located
controlled knob located to the right of the ignition switch. A in the engine’s intake air stream to aid in cold starting and
rocker switch located beside the ignition switch is used to reduce white smoke at start-up. In the preheat mode, the
choose between HAND or FOOT control. An increase in engine should not be cranked until the WAIT-TO-START
engine rpm occurs when the hand throttle is turned lamp turns off. The WAIT-TO-START lamp is illuminated
clockwise. A decrease in engine rpm occurs when the hand during the preheat time that takes place when the ignition
throttle is turned counter clockwise. The foot throttle pedal switch is in the ON position during cold weather starting. The
and hand throttle control knob are electrically connected to ECM checks intake manifold temperature to determine how
long to energize the air heater before extinguishing the

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WAIT-TO-START lamp. Once the engine is started, the engine. If a remote crank option is present, disconnect
electric air heating element will be energized again for a time the remote crank harness connector from the engine
period determined by intake air temperature. harness and tie up excess harness so it is out of the way.

Maintenance 7. Drain the engine coolant system.

8. Drain the engine lubrication system.
Engine Removal
9. Drain the transmission/torque converter oil system.
1. Set the outriggers and position the boom to over the
side. 10. Remove the engine hood assembly and pump cover
from the machine.
2. Open and remove the hood top door assembly.
11. Disconnect and remove the drive shaft(s) between the
3. Disconnect the air filter tubing at the engine and air transmission/torque converter and the axle(s). Refer to
cleaner. Remove and lay aside. DRIVE LINES in this Section.
4. Disconnect the exhaust tubing at the engine and muffler. 12. Tag and disconnect all lines from the radiator. Discon-
Lay to the side. nect the coolant level sensor harness from the engine
5. Tag and disconnect the engine electrical harness con- harness and tie up excess harness so it is out of the way.
nector from the carrier harness connector and battery Remove the radiator. Refer to RADIATOR - Removal in
cables. this Section.

6. Remove the bolts, washers, lockwashers, and nuts 13. Tag and disconnect all lines and tubing from the engine,
securing the start and grid heater relay panel to the side transmission/torque converter, and all other compo-
of the frame. Lay the relay panel with the harness on the nents.

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Transmission
Regulated 6
8 9, 10
Return From Filter Pressure 12

Supply To Filter

Air Flow

Route To Swivel

1, 2, 3, 4, 5
6631-2a
11
Converter Out To
Transmission Cooler

14
13
Fuel FIlter

15, 16

7
17

22
Fuel
Supply
18, 19

Return From 20, 21

Transmission Cooler
6631-3a
Range Shift Valve

FIGURE 7-1

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NOTE: Fan must be centered

between frame rails.
Return From
Transmission Filter
26

To Transmission Filter

7
32

33

27, 28
25 23

6631-4
29, 30, 31

Filter Out Port

24
6631-5
Return From Transmission Cooler
Filter In Port

FIGURE 7-1 continued

Item Description Item Description

1 Clamp 18 Capscrew
2 Capscrew 19 Washer
3 Flatwasher 20 Locknut
4 Lockwasher 21 Washer
5 Hex Nut 22 Bracket
6 Gear Pump 23 Dipstick
7 Temperature Sender 24 Tube Assembly - Dipstick
8 Pressure Switch 25 Transmission Mounting Bracket
9 Capscrew 26 Hot Oil Hose
10 Washer 27 Flatwasher
11 Transmission Dipstick Bracket 28 Hex Nut
12 Alternator 29 Capscrew
13 Intake 30 Flatwasher
14 Dipstick 31 Lockwasher
15 Capscrew 32 Fan
16 Washer 33 Hot Oil Hose
17 Hot Oil Hose

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CAUTION
DANGER Do not apply sealant to the inside of the hydraulic suction
The lifting device must be able to support the combined hoses.
weight of the engine and transmission.
5. Apply a moderate coat of Permatex® Type No. 2 to the
NOTE: The engine and transmission/torque converter male hose adapter and install the hydraulic hoses. Do
assembly weighs approximately 1100 kg (2400 lb). not apply sealant to the inside of the hydraulic hose, and
push it onto the male adapter. This can result in excess
14. Attach to the engine a lifting device capable of support- sealant being pushed ahead of the male adapter and
ing the weight of the engine and transmission/torque being exposed to the hydraulic oil.
converter.
6. Install the radiator. Refer to Radiator Removal and
15. With the lifting device supporting the weight of the Installation., page 7-16. Connect all hoses and electrical
engine, remove the four sets of bolts, washers, and nuts harnesses to the radiator as tagged during REMOVAL.
securing the front of the engine to the frame. Remove
the four sets of capscrews, locknuts, and washers (two 7. Connect the drive shafts between the transmission/
sets on each side) securing the transmission/torque torque converter and the axles. Refer to Drive Lines,
converter to the frame. page 7-19.

16. Using the lifting device, lift the engine and transmission/ 8. Install the hood assembly. Install the pump cover.
torque converter as an assembly from the crane. 9. Position the start and grid heater relay panel on the right
17. If a new engine is to be installed, remove all compo- side on the frame and secure with the bolts, washers,
nents, fittings, etc., from the old engine and install them lockwashers, and nuts. If equipped with a remote crank
on the new engine in the same locations. option, reconnect to the engine harness

Ensure that the same grade hardware, torque values, and 10. Connect the battery cables and engine electrical har-
Loctite as were installed by the factory are used. ness connector in accordance with the identification
marks made during removal.
Engine Installation
11. Connect the electrical wiring to the hourmeter as tagged
NOTE: Use the same grade Hardware, torque values, and during removal.
Loctite that were used by the factory.
12. Connect the air filter tubing at the engine and the air fil-
ter. Connect the exhaust tubing to the engine and muf-
fler.

DANGER 13. Install the hood top door assembly.

The lifting device must be able to support the combined 14. Service the transmission, engine lubrication system, and
weight of the engine and transmission. engine cooling system. 7
15. Start the engine. Check all hoses and fittings for leaks.
1. With all components and fittings installed on the new
Recheck all fluid levels.
engine, lift the engine into the crane.
2. With the engine in position, secure each side of the Engine Drive Belts
transmission/torque converter with four sets of cap- The proper operation of engine belt-driven components such
screws, nuts and washers (two sets on each side). At the as the alternator, fan, and water pump depend on the proper
front of the engine secure the engine mount to the frame condition and tension of the engine drive belt.
with the four sets of bolts, washers, and nuts.
NOTE: Belt tension is maintained with an automatic belt
3. Remove the lifting device. tension device.
4. Connect all lines and tubing to the engine, torque con- The engine drive belt should be inspected visually on a daily
verter, and all other components in accordance with the basis. The drive belt should be inspected for cracks, frayed
identification marks made during removal. areas, and glazed or shiny surfaces (see Figure 7-2). A drive
belt that is glazed or shiny indicates belt slippage.

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OK
OK
OK

Missing Material Traverse Cracks Longitudinal Cracks Intersecting

with Transverse Cracks must be Replaced
FIGURE 7-2

Engine drive belt damage can be caused by various factors It is a two position (ON-OFF) switch used to activate the
such as incorrect tension, incorrect belt size, misaligned testing mode.
engine pulleys, incorrectly installed belt, or by oil, grease, or
hydraulic fluid on the belt. Engine Diagnostic Idle Switch

Refer to the engine manufacturer’s manual for any special The ENGINE DIAGNOSTIC IDLE switch is located at the
tools or belt tension specifications. center of the front console panel. The switch is to be used
when servicing the engine’s electronic control system. It is a
two position momentary switch that provides idle-control
ELECTRONIC CONTROL SYSTEM
inputs or diagnostic-mode inputs, depending upon operating
The engine control system is an electronically operated fuel conditions at the time it is activated.
control system that also provides many operator and vehicle
features, as well as, reducing emissions while optimizing Engine Service Light
engine performance. The ENGINE SERVICE light is located at the center of the
The ECM performs diagnostic tests on most of its circuits front console panel. It is an amber indicator light that is a part
and will activate a fault code if a problem is detected in one of of the engine’s electronic control system and will illuminate
these circuits. Along with the fault code identifying the when an engine protection fault code is active. When
problem, a snapshot of engine operating parameters at the illuminated, there is a engine fluid (coolant or lubricant) level
time of fault activation is also stored in memory. Some fault problem which must be corrected.
codes will cause a diagnostic lamp to activate to signal the
Engine Stop Light
driver. The fault codes can be read using the fault lamps in
the cab panel or with the correct service tools. The ECM The ENGINE STOP light is located at the center of the front
communicates with service tools supplied by Cummins console panel. It is a red indicator light that illuminates to
through a SAE data link. signify a serious engine problem that requires the vehicle
and the engine to be stopped as soon as safely possible.
Engine Control System Switches and The engine should remain shut down until the fault can be
Indicator Lights repaired.
In addition to alerting the operator of system faults, the
Engine Diagnostic Test Mode Switch
ENGINE STOP light, in conjunction with the ENGINE
The ENGINE DIAGNOSTIC TEST MODE switch is located WARNING light, is used in the diagnostic operation of the
at the center of the front console panel. The switch is to be engine control system.
used when servicing the engine’s electronic control system.

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NOTE: When not using the diagnostic system, turn the manufacturers service manual for explanation and correction
ENGINE DIAGNOSTIC TEST MODE switch to the of the fault codes.
OFF position.
To check for active fault codes, turn the keyswitch to the OFF FUEL SYSTEM
position, and move the ENGINE DIAGNOSTIC TEST MODE
switch to the ON position. Turn the vehicle keyswitch to the Description
ON position. If no active fault codes are recorded, both The fuel system consists of the fuel tank, strainer, lift pump,
lamps stay off. If active fault codes are recorded, both lamps injection fuel pump, fuel-water separator filter and the fuel
will come on momentarily, then begin to flash one code of the injectors. All components except the fuel tank are installed
recorded faults. on the engine or supplied with the engine for remote
mounting.
Engine Warning Light
The ENGINE WARNING light is located at the top of the front Fuel Tank
console. It is an yellow indicator light that is a part of the The fuel tank (Figure 7-3) is a steel cylinder-type tank
engine’s electronic control system and when illuminated, located on the left side of the machine. The fuel tank has a
gives the operator a signal that there is a engine problem draw capacity of 280 liters (74 gallons). A connection on the
which must be corrected. bottom of the tank provides for fuel supply to the engine.
In addition to alerting the operator of system faults, the Surplus fuel from the engine is provided to the bottom of the
ENGINE WARNING light, in conjunction with the ENGINE fuel tank below the fuel level. The tank is equipped with a
STOP light, is used in the diagnostic operation of the engine non-vented filler cap, chain-attached to the tank, and a fuel
control system. quantity sender unit which provides a signal to a fuel quantity
gauge on the instrument panel in the cab. The fuel tank for
NOTE: When not using the diagnostic system, turn the the CE units has a lockable filler cap.
ENGINE DIAGNOSTIC TEST MODE switch to the
OFF position. Injection Fuel Pump
To check for active fault codes, the keyswitch must be in the The fuel oil is finely atomized as it is injected into the cylinder
OFF position, and move the ENGINE DIAGNOSTIC TEST and ignited by the heat of the compression. It is metered
MODE switch to the ON position. Turn the vehicle keyswitch also, before injection, to meet the load requirements
to the ON position. If no active fault codes are recorded, both imposed upon the engine. Surplus fuel, returning from the
lamps stay off. If active fault codes are recorded, both lamps injectors, is bypassed back to the fuel tank or to the inlet side
will come on momentarily, then begin to flash one code of the of the pump. The continuous flow of fuel through the injectors
recorded faults. helps to cool the injectors and to purge air from the system.

Fault Code Flashing Sequence Fuel Filter-Water Separator

The ENGINE WARNING light (yellow) flashes at the The fuel filter-water separator removes impurities from the
beginning of a fault code sequence. There will be a short 1- fuel and also removes water from the fuel before it reaches
or 2-second pause after which the number of the recorded
fault code will flash in the ENGINE STOP light (red). To
the engine. The filter is mounted on the right side of the
engine.
7
interpret the flash code, count the first sequence of red
The fuel mixture passes through the outer wrap of the first
flashes for the first digit and after a two second delay, count
stage of the filter paper, where large droplets of water are
the second sequence of red flashes for the second digit.
formed as it is stripped from the fuel. The water falls out into
When the number has finished flashing in red, the ENGINE
the void between the two paper elements and goes to a
WARNING light (yellow) flashes again. The lamps flash each
reservoir in the bottom of the housing, where it can be
fault code 3 times before advancing to the next code. To skip
drained through a drain plug at the bottom of the housing.
to the next fault code, move the ENGINE DIAGNOSTIC
IDLE switch in either position (+/-) to see other fault codes. If The water in fuel sensor is located in the fuel filter housing on
only one active fault is recorded, the control system will the right side of the engine. Once the storage space in the
continuously display the same fault code when pressing the bottom of the filter housing fills with a certain amount of
ENGINE DIAGNOSTIC IDLE switch. Reference the engine water, the sensor will signal the ECM. The WATER IN FUEL
lamp will illuminate at the operator controls, indicating that
the water should be drained from the fuel filter assembly.

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3 4
1 5
6632
2
2

FIGURE 7-3

Maintenance
Item Description
NOTE: The entire fuel system must be maintained air tight
1 Fuel Tank to prevent loss of prime.
2 Steps Fuel Tank
3 Fuel Supply
The fuel tank should be kept filled, especially overnight, to
4 Fuel Return reduce condensation to a minimum. Refer to the applicable
5 Oil Cooler Mounting Bracket engine manual for the recommended schedule for draining
any water or sediment from the tank.
6 Oil Cooler
Removal
Electric Lift Pump
1. Position a suitable container under the fuel tank and
The ECM controls the electric lift pump located between the drain all fuel from the tank.
fuel tank and the injection pump. Whenever the keyswitch is
turned to the ON position, the lift pump will be energized for a 2. Tag and disconnect the two lines from the bottom of the
few seconds to make sure the low pressure fuel lines are tank.
fully primed. The electric lift pump shuts off after the engine is 3. Disconnect the electrical lead from the fuel quantity
started. sender unit.
4. Support the weight of the tank, loosen and remove the
capscrews and washers securing the straps to the
mounting brackets. Remove the tank and steps.

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5. If a new tank is to be installed, remove the two fittings, 4. Service the tank.
the fuel quantity sender, and steps from the tank and
install them in the new tank. Fuel Filter-Water Separator

Installation Draining

1. Position the new tank on the mounting brackets and The sump of the fuel filter-water separator should be drained
install the capscrews and washers on the two straps. daily, 30 minutes after the engine is shut down, to remove
Torque the capscrews refer to SECTION 1, Fasteners any water and sediment. Adhere to the following procedure.
and Torque Values. 1. Open the drain plug.
2. Connect the electrical lead to the fuel quantity sender 2. Drain until fuel appears.
unit.
3. Close the drain plug.
3. Connect the two lines to the fittings on the bottom of the
tank in accordance with the identification marks made
during removal.

3
1
6
2
4

8
7

5
7
9

11
10 12
13
6644 11
FIGURE 7-4

Item Description Item Description

1 Return Filter 6 Access Cover
2 Filter Indicator 7 Filler Neck and Breather
3 Sight Gauge 8 Step Assembly
4 Return Line 9 Magnetic Plug
5 Suction Line 10 Capscrew

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5. Inspect the restriction indicator tap for leaks.

Item Description Check For Filter Restriction
11 Flatwasher As a dry cleaner element becomes loaded with dust, the
12 Spring Lockwasher vacuum on the engine side of the air cleaner (at the air
13 Hex Nut cleaner outlet) increases.
The vacuum is generally measured as restriction in
AIR INTAKE SYSTEM kilopascals or inches of water. The engine manufacturer
places a recommended limit on the amount of restriction the
Description engine will stand without loss in performance before the
element must be cleaned or replaced. Cummins allows a
The engine air intake system consists of an air cleaner and vacuum of 6.2 kPa (25 inches of water) maximum with a dirty
associated piping Figure 7-5 for channelling the air from the air cleaner at maximum governed RPM.
atmosphere to the engine turbocharger intake.
A service indicator on the air cleaner housing will indicate
The air cleaner is the dry-type with a replaceable element when the filter needs to be cleaned or replaced. Reset the
and is located on the right rear fender assembly. A service indicator each time the air cleaner is serviced. If the
indicator, designed to indicate red when servicing is indicator’s accuracy is suspect, a water manometer is the
required, is installed at the air cleaner outlet. most accurate and dependable method of measuring
On the Cummins QSB6.7 engine there are electric air vacuum.
heating elements that are located in the engine’s intake air To use the manometer, hold it vertically and fill both legs
stream. These elements heat the intake air when starting the approximately half full with water. One of the upper ends is
engine in cold ambient conditions. Startability and white connected to the restriction tap on the outlet side of the air
smoke control are enhanced by the use of an intake air cleaner by means of a flexible hose. The other end is left
heater. A WAIT-TO-START lamp is located on the center open to the atmosphere.
front console to indicate when to crank the engine.
Maximum restriction in the air cleaner occurs at maximum air
Maintenance flow. On this turbocharged diesel engine, the maximum air
flow occurs only at maximum engine power.
Air Cleaner Checks
With the manometer held vertically and the engine drawing
Dust passing the air cleaner can cause rapid engine wear. All maximum air, the difference in the height of the water
connections between the air cleaner and the engine must be columns in the two legs, measured in inches or centimeters,
tight and sealed. If these connections are well sealed, and is the air cleaner restriction. Restriction indicators are
there is still evidence of dust leakage, check the following generally marked with the restriction at which the red signal
places for possible trouble. flag locks up.
NOTE: Dust that gets by the air cleaner system can often If the initial restriction on a new or clean filter reads above the
be detected by looking for dust streaks on the air maximum allowed for the engine, check the following items.:
transfer tubing or just inside the intake manifold
inlet. 1. Ensure the air cleaner inlet is not plugged.

1. Inspect the air cleaner outlet tube for damage. 2. Inspect the air cleaner outlet to be sure it is not plugged
by paper, rags, etc.
2. Ensure the element gasket washer is not damaged and
the washer’s rubber face seals against the element. 3. Ensure the correct size connections are used between
the air cleaner and the engine.
3. Inspect the element gasket for damage.
4. Ensure all inlet accessories are the correct size and are
4. Check for structural failures and replace damaged parts. not plugged by any foreign object.

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8 5
7
6
3 2
4

11

10

6640

FIGURE 7-5

Filter Element Replacement

Item Description
1 Air Cleaner CAUTION
2 Mounting Band Never service the air cleaner while the engine is running.
3 Inlet Hood
Remove decking access plate behind steps. Unlatch the
4 Clamp
latches, open the air cleaner body and withdraw the element
5 Rubber Elbow as follows:
6 Intake Tube 1. Lift the lever, securing the cover to the air cleaner body.
7 Intake Tube 2. Twist the cover to the left (counter-clockwise) to the
7
8 Muffler Clamp open position.
9 Support Intake Bracket 3. Remove the filter cover.
10 Service Indicator 4. RELEASE THE SEAL GENTLY. The filter element fits
11 Vacuator Valve tightly over the outlet tube, creating the critical seal on
the inside diameter of the filter end cap. The filter should
be removed gently to reduce the amount of dust dis-
lodged. There will be some initial resistance, similar to
breaking the seal on a jar. Gently twist the filter left and
right while pulling the element from the filter body.
The inner filter (secondary element) is replaced every
third time the outer filter (primary element) is replaced.
When replacing the inner filter follow the same
procedure as above.
5. Inspect the filter for foreign material on the sealing sur-
face and potential marks of dust at the clean air side.

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6. Thoroughly clean the sealing surface and inside of the Air Cleaner Body
air filter housing. Inspect all parts of the intake system
Before installing the filter element, remove foreign material
and air cleaner.
(leaves, lint or other foreign matter) that may have collected
7. Install both the inner, if necessary, and outer filters in the inside the air cleaner body. Inspect the inside of the body for
same manner, as follows: dents or other damage that would interfere with air flow or
with the fins on the element or inside the body. Repair any
a. INSPECT THE FILTER FOR DAMAGE. Always
body dents, being careful not to damage the sealing
look for filter damage, even if a new filter element is
surfaces. Be sure to clean the sealing surface of the outlet
being installed. Pay special attention to the inside of
tube and the inside of the outlet tube, taking care not to
the open end (sealing area). Do not install a
damage the sealing area on the tube.
damaged filter.
Vacuator Valve
b. INSERT THE FILTER PROPERLY. The seal area is
on the inside of the open end of the filter. A new filter Vacuator valves are designed to expel loose dust and dirt
has a dry lubricant to aid installation. The critical from the air cleaner body automatically, thus lengthening the
sealing area will stretch slightly, adjust itself and element service life. The valve lips must point straight down
distribute the sealing pressure evenly. To complete and be kept free from debris to operate effectively. Mud and
a tight seal, apply pressure at the outer rim of the chaff can lodge in these lips periodically and hold them open
filter, not the flexible center. No cover pressure is during engine operation.
required to hold the seal Figure 7-6.

FIGURE 7-7
FIGURE 7-6
Check the condition of the valve and lips frequently and keep
8. Place the cover back on the housing with the dust ejec- them clean. The valve lips should be open only when the
tion valve near the bottom. engine is shut down, or running at low idle speed. If the valve
is turned outside in, check for a clogged air cleaner inlet.
9. Twist the cover to the right (clockwise) into the closed
Malfunction of this valve does not reduce the air cleaner
position.
effectiveness, but does allow the element to get dirty faster
10. Secure the cover with the lever. and reduces serviceable life. If a valve is lost or damaged,
replace it with a new valve of the same part number.
11. Check all connections and ducts for an air tight fit. Make
sure that all clamps, bolts, and connections are tight. Duct Work
Check for holes in piping. Leaks in the air intake system
may send dust directly to the engine. 1. Check the intake pipe cap and screen for accumulation
of leaves, trash, and other debris that could restrict air
12. Replace decking access plate. flow. Repair the screen or replace the cap if any large
holes are found in the screen.
Element Cleaning
It is not recommended that filter elements be cleaned and 2. Check all mounting hardware for security to eliminate
that inner (secondary) elements should never be cleaned. If possible vibration of intake piping. Such vibration leads
you want to clean the outer element is should only be done to early failure of hoses, clamps, and mounting parts,
by a commercial air filter cleaning service. It is also and can cause hoses to slip off the connecting pipes,
recommended that the cleaning service provide a warranty, allowing un-filtered air into the engine air intake.
Cummins and most other manufacturers will not warrant a 3. Check hoses for cracks, chafing, or deterioration, and
cleaned air filter. replace at the first sign of probable failure.

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RT890E SERVICE MANUAL POWER TRAIN

WATER COOLING SYSTEM part directly responsible is not a part of the cooling system.
Most of these problems can be traced to overheating;
Description however, an engine that is running too cold can be just as
troublesome.
The cooling system consists of a radiator Figure 7-8, surge
tank, engine cooling circuit, charge air cooler circuit, the Overheating
connecting hoses and connecting tubes. Cooling system An engine that is overheating may lead to troubles such as
capacity is approximately 36 liters (38 quarts). The radiator the following:
consists of two sections; the top section is the charge air
cooler, the bottom section is the engine water cooler. The • Burned valves.
temperature is controlled by a 83°C (181°F) thermostat • Pinging or knocking.
located between the top of the engine and the top of the
radiator. At all times, the antifreeze/coolant should be • Excessive fuel consumption.
properly inhibited against corrosion. It is recommended that
• Poor lubrication - increased engine wear.
a mixture of AFC-50/50 blended ethylene-glycol, low silicate,
fully formulated, engine antifreeze/coolant concentrate and • Sticking valves.
water which does not require a pre-charge of supplemental
• Short injector life.
coolant additives (SCA) for use in initial fill of heavy duty
liquid cooled internal combustion engines be used at all • Engine hot spots.
times.
• Need for higher grade fuel.
The crane is equipped with a cab hot water heater. Hot water
Overcooling
is supplied by the engine coolant system through a strainer
and two port water swivel to the cab heater. The strainer is a The following engine troubles result when an engine is
cleanable type and is located on the left side of the overcooled:
transmission by the rear engine/transmission mount. Refer
to SECTION 9, for service of the strainer. • Excessive fuel consumption.
• Sludge formation in crankcase.
Maintenance
• Corrosive acids formed in crankcase.
General
• Excessive fuel deposits in the exhaust system.
The cooling system includes the radiator, surge tank,
thermostat, the fan, and water pump. Radiator hoses are Rust Prevention
also included in this group. To keep engines operating at newness efficiency, all forms of
The cooling system is often neglected because the effects or rust formation must be prevented. The formation of rust in
damage that result from an improperly maintained system the cooling system is a result of the interaction of water, iron,
usually occur gradually. The cooling system needs to be and oxygen, and can only be prevented by maintaining full
maintained with the same attention as other systems. strength corrosion protection at all times.

The circulation of water through the cooling system relies For maximum rust, freeze, and boiling point protection, an 7
entirely upon the water pump. The water pump draws water AFC-50/50 blended, f ully formu lated e xtended life
from the radiator and forces it through the water jacket and antifreeze/coolant should be maintained at all times.
cylinder head. There it accumulates heat and flows to the Test Equipment
right radiator tank. Then the water flows across through the
radiator core and is cooled by air from the fan. This process The antifreeze/coolant concentration must be checked using
of removing heat from water as it circulates holds the engine a refractometer. “Floating ball” type density testers or
to its efficient operating temperature. hydrometers are not accurate enough for use with heavy
duty diesel cooling systems.
The following paragraphs point out several facts about
cooling system components, the effects of cooling system Engine Antifreeze/Coolant Fill Procedure
neglect, and procedures to be followed for cooling system
maintenance. This procedure is for when the cooling system has been
drained or most of the coolant has been removed. For daily
Effects of Cooling System Neglect maintenance procedures refer to Drive Train, page 9-8.
Whenever an engine does not perform at top efficiency, a NOTE: If the engine coolant is changed, the coolant filter
neglected cooling system may be at fault even though the must also be changed.

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POWER TRAIN RT890E SERVICE MANUAL

1. Open air bleed valve or remove plug on radiator inlet If condemned, flush the system using a mixture of sodium
tube, to allow trapped air to bleed. carbonate and water or an equivalent commercially available
flushing agent. Refill system with fully formulated extended
2. Slowly fill the system with an AFC-50/50 blended, fully
life coolant. Refer to Drive Train, page 9-8.
formulated extended life antifreeze/coolant. Fill to the
bottom of the surge tank filler neck. NOTE: Remove the radiator cap and open the air bleed
valve when draining the system to ensure proper
NOTE: A fill rate exceeding 12 l/min (3 gpm) can give a
draining.
false reading.
3. Close the air bleed valve or secure the plug, as Cleaning
equipped.
4. Wait one minute and recheck the antifreeze/coolant
level. Refill as necessary repeating step 2.
DANGER
5. Run the engine through two (2) thermal cycles and The cooling system is pressurized and injury can result
recheck the antifreeze/coolant level. Refill as necessary when removing the radiator cap at operating temperature.
repeating step 2. Use proper protection to remove the radiator cap.
SCA Level Check/Coolant Filter Change Interval
1. Coolant shut-off valves to heaters and other accessories
The cooling system level should be checked every 10 hours should be open to allow complete circulation during
of operation or daily, whichever comes first. cleaning, flushing, and draining. Run the engine with
radiator covered if necessary until temperature is up to
6 Months or 500 Hours
operating range 71 to 82 °C (160 to 180 °F). Stop the
• Check SCA (Supplemental Coolant Additives) Levels engine, remove the radiator cap, and drain the system
(use Fleetguard kit # CC2626). by opening the drain cocks on the radiator and engine
block.
The Coolant Filter contains molybdate. Therefore, it is
important to use the Grove Coolant Test Kit, which 2. Allow the engine to cool, close the drain cocks, and pour
checks the molybdate level, regardless of whether the the cleaning compound into the surge tank according to
SCA used to replenish the coolant system contains the directions. Fill the system with water.
molybdate or not.
3. Place a clean drain pan to catch the overflow, and use it
If SCA levels are less than 1.2 Units/Gal, add cummins DCA- to maintain the level in the radiator. Do not spill the solu-
4 to maintain desired level. tion on the vehicle paint.
NOTE: An inadequate concentration of coolant additive 4. Replace the radiator cap and run the engine at moderate
can result in major corrosive damage to the cooling speed, covering the radiator if necessary, so the system
system components. Overconcentration can cause reaches a temperature of 82 °C (180 °F) or above, but
formation of a “gel” that can cause restriction or does not reach the boiling point. Allow the engine to run
plugging of coolant passages, and overheating. at least two hours, or according to recommendations of
the manufacturer of the cleaning compound, at 82 °C
• Change coolant filter.
(180 °F) so the cleaning solution may take effect. Do not
Install charged filter if SCA levels are normal or below drive the vehicle or allow the liquid level in the radiator to
normal; install non-charged filter if SCA levels are above drop low enough to reduce circulation.
normal (contact Manitowoc Crane Care for filter part
5. Stop the engine as often as necessary to prevent boiling.
number).
6. With the engine stopped, feel the radiator core with bare
1 Year or 1000 Hours hands to check for cold spots, and then observe the tem-
• Test coolant for contamination condemning. perature gauge reading. When there is no change in
temperature for some time, drain the cleaning solution.
Condemning limits are:
7. If clogging of the core is relieved but not fully corrected,
Sulfate level greater than or equal to 1500 ppm. allow the engine to cool, pressure-flush the system (see
Chloride level greater than or equal to 200 ppm. Pressure Flushing) and repeat the cleaning operation.

The ph level is less than 6.5 8. If clogging of the core, indicated by low temperature
spots on core, is not relieved, the radiator core must be
Oil or fuel contamination can be identified by odor or color. removed for mechanical cleaning. Mechanical cleaning
requires removal of the upper and lower tanks, and rod-

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RT890E SERVICE MANUAL POWER TRAIN

ding out the accumulated rust and scale from the water 3. Radiator Cap - This is the pressure-setting type. Its pur-
passages of the core. pose is to hold the cooling system under a slight pres-
sure, increasing the boiling point of the cooling solution
Pressure Flushing and preventing loss of solution due to evaporation and
1. Disconnect both radiator hoses that connect the radiator overflow.
to the engine. The cap has a spring-loaded valve, the seat of which is
2. Clamp a convenient length of hose to the radiator core below the overflow pipe in the filler neck. This prevents the
outlet opening, and attach another suitable length of escape of air or liquid while the cap is in position. When the
hose to the radiator inlet opening to carry away the flush- cooling system pressure reaches a predetermined point, the
ing stream. cap valve opens and will again close when the pressure falls
below the predetermined point.
3. Connect the flushing gun to compressed air and water
pressure, and clamp the gun nozzle to the hose When removing the pressure type cap, perform the
attached to the radiator outlet opening. operation in two steps. Loosening the cap to its first notch
raises the valve from the gasket and releases the pressure
4. Fill the core with water. Turn on air pressure in short through the overflow pipe. In the first stage position of the
blasts to prevent core damage. cap, it should be possible to depress the cap approximately 3
5. Continue filling the radiator with water and applying air mm (0.13 in). The prongs on the cap can be bent to adjust
pressure as above until the water comes out clear. this condition. Care must be taken that the cap is not too
loose as this would prevent proper sealing.
6. Clamp the flushing gun nozzle firmly to a hose attached
securely to the engine water outlet opening. Fill the
engine block with water, partly covering the water inlet
opening to permit complete filling.
DANGER
7. Turn on compressed air to blow out water and loose sed- Loosen cap slowly and pause a moment to avoid possible
iment. Continue filling with water and blowing out with air burning by hot water or steam. Continue to turn the cap to
until flushing stream comes out clear. the left until it can be removed.
8. For badly clogged water jackets that do not respond to
regular pressure flushing, remove the engine cylinder 4. Tubes are very small and can become easily clogged by
head and core hole plugs, and with a suitable length of rust and scale. The general condition of the cooling sys-
small copper tubing attached to the flushing gun nozzle, tem and operating temperature are indications as to
flush the water jackets through the openings. whether or not tubes are clean. Another good test is to
feel the core for cold spots.
9. When the vehicle is equipped with a water heater con-
nected to the cooling system, flush the heater, following 5. Fins are thin metal sheets that dissipate heat picked up
the same procedure as for the radiator core. by the tubes. They should be kept free of bugs, leaves,
straw etc., so as to allow the free passage of air. Bent
10. After completing the flushing operation, clean out the fins should be straightened.
surge tank overflow pipe; inspect the water pump; clean 7
the thermostat and the radiator cap control valves. Engine Water Jacket
Check the thermostat for proper operation before instal-
The water jacket permits coolant to be circulated around the
lation.
cylinder walls, combustion chamber, and valve assemblies.
11. Blow insects and dirt from the radiator core air pas- Some of these coolant passages are small and can easily
sages, using water, if necessary, to soften obstructions. become clogged, if the cooling system does not receive the
proper maintenance.
Component Inspection
1. Core Plugs - These are sometimes mistakenly called
Radiator/Surge Tank freeze plugs. They do not provide protection against
1. Side Tanks - Look for leaks, particularly where the tank is freezing expansion, but are only present because of
soldered to the core. Vibration and pulsation from pres- engine block casting methods. Remove and replace
sure can fatigue soldered seams. core plugs that show signs of leaking or rusting through.
Use an installation tool for core plug replacement.
2. Filler Neck - The sealing seat must be smooth and
clean. Cams on filler neck must not be bent or worn so 2. Drain Plugs - The water jacket of each engine has one or
as to allow a loose fitting cap. Ensure the overflow tube more drain plugs. These should receive seasonal care
is not plugged. and be kept free of rust and scale.

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POWER TRAIN RT890E SERVICE MANUAL

3. Gaskets - Gaskets must be in good condition to prevent Radiator Removal and Installation.
both internal and external leaks. If there are external
leaks around gaskets, there may also be internal leaks Removal
into the engine. Proper tightening of the head bolts with
1. Set the outriggers and position the boom to over the
a torque wrench is essential for preventing leaks around
side.
the head gasket.
2. Open the drain cock at the bottom of the radiator and
Water Pump drain the coolant into a suitable container. Dispose of the
The pump should be checked carefully for leaks and proper coolant in accordance with local and EPA regulations.
lubrication. Replace or rebuild if leaking, cracked, or worn. NOTE: Remove the radiator cap when draining the system
to ensure proper draining.
Fans and Belts
3. Open and remove the hood top door assembly.
The fan should be checked for cracked or broken blades.
4. Remove the bolts and nuts holding the rear engine hood
Refer to Engine Drive Belts, page 7-5.
panel to the engine hood. This will gain access to the
Thermostat rear of the radiator and the surge tank mounting hard-
ware.
The thermostat is of the nonadjustable type and is
incorporated in the cooling system for the purpose of 5. Tag and disconnect the hoses from the surge tank to the
retarding or restricting the circulation of coolant during engine and from the surge tank to the radiator.
engine warm up. Engine overheating and loss of coolant is 6. Remove the four bolts, washers, lockwashers and nuts
sometimes due to an inoperative thermostat. To check for holding the surge tank to the frame.
t h i s c o n d i t i o n , r e m o v e t h e t h e r m o s ta t a n d t e s t b y
submerging it in hot water and noting the temperature at 7. Remove the nuts, washers and muffler clamps securing
which the thermostat opens and closes. Use an accurate the right charge air cooler tube to the frame.
high temperature thermometer for making this test. 8. Remove the baffles on the rear side of the radiator
Hoses and Clamps assembly.

Hoses and their connections must be checked regularly 9. Remove the hose clamps and bellows connecting the
because they are often the source of hidden trouble. Hoses radiator to the charge air cooler tubes.
may often times appear in good condition on the outside 10. Remove the hose clamps and radiator hose connecting
while the inside will be partially deteriorated. If there are any the radiator to the radiator tubes.
doubts about a hose doing its job, replacement should be
made. The clamps should be inspected to make sure they 11. Disconnect the coolant level harness from the engine
are strong enough to hold a tight connection. harness.
12. Remove the bolts and washers attaching the fan guard
Antifreeze/Coolant to the shroud ring. Remove the fan guard.
Heavy duty diesel engines require a balanced mixture of 13. Remove the bolts, washers and lockwashers that con-
water and antifreeze/coolant. Fill the system with a AFC-50/ nect the plates to the top of the radiator and the top of
50 blended, fully formulated extended life antifreeze/coolant the frame rail.
at all times. Refer to SECTION 9. Do not use more than 50
percent antifreeze/coolant in the mixture unless additional NOTE: The radiator assembly weighs approximately 123
freeze protection is required. Never use more than 68 kg (271 pounds).
percent antifreeze/coolant under any condition. Antifreeze/ 14. Attach an adequate lifting device to the radiator assem-
coolant at 68 percent provides the maximum freeze bly.
protection; antifreeze/coolant protection decreases above 68
percent. 15. Remove the two bolts, washers, lockwashers, nuts and
mounting bushings securing the radiator flange to the
frame mounting brackets. Remove the radiator assem-
bly from the carrier.
16. Remove the six bolts, washers, lockwashers and six
bushings securing the shroud ring to the radiator.
17. If a new radiator is to be installed, remove all fittings and
hoses from the old one and install them in the same
locations on the new one.

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RT890E SERVICE MANUAL POWER TRAIN

10
6 14
3
25
2

4 19

20
22
11

9 18, 23
18, 24
8 17
6 3
2

6289-1
1

5
21

14
13
19
25
14 22 7

7 8

6289-2 1
9
12 15
16

FIGURE 7-8

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POWER TRAIN RT890E SERVICE MANUAL

6. Reconnect the coolant level harness to the engine har-

ness.
Item Description
1 Radiator 7. Connect the two radiator tubes to the radiator with hose
clamps and the radiator hose. Install baffles to rear side
2 Surge Tank of the radiator assembly.
3 Radiator Cap 8. Secure the radiator return tube to the top of the engine
4 Window Gauge using nuts, washers and a muffler clamp.
5 Mounting Bracket 9. Reconnect the charge air cooler tubes to the radiator
using hose clamps and bellows. The recommended
6 Overflow Hose
installation torque of the spring loaded hose clamp is
7 Engine Block Vent Hose Connection 11.3 Nm (100 lb-in). Do not compress spring completely,
8 Shroud clamp may be damaged from thermal expansion of CAC
tube.
9 Hose Clamps
10. Secure the charge air cooler tube with nuts, washers
10 Vent Hose and muffler clamps to the right side of the frame.
11 Coolant Fill Hose 11. Tighten the drain cock at the bottom of the radiator.
12 Radiator Out
12. Install the hood assembly.
13 Radiator In
13. Mount the surge tank to the frame using the four bolts,
14 Bellows washers, lockwashers and nuts.
15 Radiator Hose 14. Connect the hoses between the surge tank and engine
16 Drain Cock and the surge tank and the radiator.

17 Muffler Clamp 15. Fill the engine coolant system, refer to Engine Anti-
freeze/Coolant Fill Procedure, page 7-13. Start the
18 Charge Air Cooler Tube engine, operate all systems and check for leaks.
19 Plate
16. Install the bolts and nuts holding the rear engine hood
20 Radiator Coolant Level Switch panel to the engine hood.
21 Mounting Bushings 17. Install the hood top door assembly.
22 Rubber Molding
DRIVE TRAIN
23 Charge Air Cooler In
24 Charge Air Cooler Out Description
25 Air Bleed Valve The drive train consists of the transmission/torque converter
assembly (Figure 7-1) and three drive lines.
Installation
The transmission/torque converter is mounted on and driven
1. Ensure all fittings and hoses are installed on the radiator. by the engine. The torque converter assembly provides for
2. Position the radiator assembly in the carrier using a lift- mounting and driving the piston and single section hydraulic
ing device. Secure the radiator flange to the frame pumps. The transmission is a powershift with six forward
mounting brackets using two bolts, washers, lockwash- speeds and six reverse speeds. The transmission is
ers, nuts and mounting bushings. controlled electrically by a shift lever/knob located on the
right side of the steering column and an axle drive mode
3. Reconnect the two plates between the top of the radiator selector rocker switch located on the left side of the front
and the top of the frame rail using bolts, washers, lock- console.
washers and nuts.
The transmission/torque converter oil is cooled by passing
4. Adjust the shroud face to have equal clearance between the oil through an externally mounted transmission cooler.
fan and face opening on opposite sides. The cooler is located beside the fuel tank. An oil filter is
5. Position the fan guard on the shroud ring and secure located on the left side of the frame bottom rail.
with bolts and washers. Three drive lines are used. Two drive lines are connected
between the transmission/torque converter and the front axle

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RT890E SERVICE MANUAL POWER TRAIN

an d t h e o th e r dr iv e li n e i s c o n ne c te d b e tw e en th e oil used in this system. The remaining volume of oil is

transmission/torque converter and the rear axle. directed through the torque converter circuit to the oil cooler
and returns to the transmission for positive lubrication. This
Maintenance regulator valve consists of a hardened valve spool operating
in a closely fitted bore. The valve spool is spring loaded to
Drive Lines hold the valve in a closed position. When a specific pressure
is achieved, the valve spool works against the spring until a
port is exposed along the side of the bore. This sequence of
CAUTION events provides the proper system pressure.
Do not disassemble drive lines when removing them from
After entering the converter housing, the oil is directed
the crane. Dirt can enter the spline and cannot be purged.
through the reaction member support to the converter blade
In addition, the drive lines are assembled in a specific
cavity and exits in the passage between the turbine shaft and
orientation when manufactured and can easily be
reaction member support. The oil then flows out of the
incorrectly reassembled.
converter to the oil cooler. After leaving the cooler, the oil is
directed to a fitting on the transmission. Then, through a
Removal
series of tubes and passages, lubricates the transmission
1. Support the drive line being removed so it does not fall bearings and clutches. The oil then gravity drains to the
when disconnected. transmission sump.
2. Remove the bolts from the bearing cap on each end of The torque converter consists basically of three elements
the drive line. and their related parts to multiply engine torque. The engine
power is transmitted from the engine flywheel to the impeller
3. Remove the drive line.
element through the impeller cover. This element is the
Installation pump portion of the hydraulic torque converter and is the
primary component which starts the oil flowing to the other
1. Position the drive line, install the bearing cap bolts and components which results in torque multiplication. This
tighten bolts securely. element can be compared to a centrifugal pump, in that it
2. Torque the inboard bearing cap bolts on the drive line to picks up fluid at its center and discharges at its outer
85 to 112 Nm (63 to 83 lb-ft) and outboard bearing caps diameter.
to 122 to 149 Nm (90 to 110 lb-ft). The torque converter turbine is mounted opposite the
Lubrication impeller and is connected to the output shaft of the torque
converter. This element receives fluid at its outer diameter
The drive line slip joints require lubrication. Refer to and discharges at its center. Fluid directed by the impeller
SECTION 9. out into the particular design of blading in the turbine and
reaction member is the means by which the hydraulic torque
TRANSMISSION/TORQUE CONVERTER converter multiplies torque.
The reaction member of the torque converter is located
Description
between and at the center of the inner diameters of the 7
The transmission/torque converter assembly is mounted to impeller and turbine elements. Its function is to take the fluid
the engine and is connected to the front and rear axles by which is exhausting from the inner portion of the turbine and
three drive shafts. The main hydraulic pump and hydraulic change its direction to allow correct entry for recirculation
pump number two are mounted on the torque converter. into the impeller element.

Theory of Operation The torque converter will multiply engine torque to its
designed maximum multiplication ratio when the output shaft
The transmission and torque converter function together and is at zero rpm. Therefore, as the output shaft is decreasing in
operate through a common hydraulic system. Therefore, it is speed, the torque multiplication is increasing.
necessary to consider both units in discussing operation.
The shift control valve is mounted on the side of the
With the engine running, the converter charging pump draws converter housing. Its function is to direct pressurized oil to
oil from the transmission sump through the removable oil the appropriate direction and speed clutches to achieve the
suction screen and directs it through the pressure regulating desired gear ratio. The valve consists of solenoid operated
valve and oil filter. valves which direct oil to operate the larger spool valves that
pass or block oil flow to a specific clutch.
The pressure regulating valve maintains pressure to the
transmission control for actuating the direction and speed NOTE: On this machine, the reverse clutch is energized for
clutches. This requires a small portion of the total volume of forward motion of the crane.

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POWER TRAIN RT890E SERVICE MANUAL

With the engine running and the directional control lever in Troubleshooting
the neutral position, oil pressure from the regulating valve is
The following data is presented as an aid to locating the
blocked at the control valve, and the transmission is in
source of difficulty in a malfunctioning unit. It is necessary to
neutral. Movement of the forward and reverse spool will
consider the torque converter charging pump, transmission,
direct oil, under pressure, to either the forward or reverse
oil cooler, and connecting lines as a complete system when
direction clutch, as desired. When either directional clutch is
checking for the source of trouble, since the proper operation
selected, the opposite clutch is relieved of pressure and
of any unit therein depends greatly on the condition and
vents back through the direction selector spool. The same
operation of the others. By studying the principles of
procedure is used in the speed selector.
operation together with the data in this section, it may be
The direction or speed clutch assembly consists of a drum possible to correct any malfunction which may occur in the
with internal splines and a bore to receive a hydraulically system. Troubleshooting procedures basically consist of
actuated piston. The piston is oil tight by the use of sealing hydraulic checks.
rings. A steel disc with external splines is inserted into the
drum and rests against the piston. Next, a friction disc with Hydraulic Checks
splines at the inner diameter is inserted. Discs are alternated Before checking the transmission/torque converter and
until the required total is achieved. A heavy back-up plate is associated hydraulic system for pressures and rate of oil
then inserted and secured with a snap ring. A hub with OD flow, it is essential that the following preliminary checks be
splines is inserted into the splines of discs with teeth on the made.
inner diameter. The discs and hub are free to increase in
speed or rotate in the opposite direction as long as no 1. Check oil level in transmission. This should be done with
pressure is present in that specific clutch. oil temperature at 82 to 93 °C (180 to 200 °F). Do not
attempt these checks with cold oil.
To engage the clutch, the control valve is placed in the
desired position. This allows oil under pressure to flow from 2. To bring the oil temperature to this level, it is necessary
the control valve, through a tube, to a chosen clutch shaft. to either work the machine or stall out the converter.
This shaft has a drilled passageway for oil under pressure to When it is impractical to work the machine, stall out the
enter the shaft. Oil pressure sealing rings are located on the converter as follows.
clutch shaft. These rings direct oil under pressure to the a. Apply the parking brake and service brakes.
desired clutch. Pressure of the oil forces the piston and discs
against the heavy back-up plate. The discs, with teeth on the b. Position the shift lever to forward and high speed.
outer diameter, clamping against discs with teeth on the c. Accelerate the engine to between half and three-
inner diameter, enables the hub and clutch shaft to be locked quarter throttle.
together and allows them to drive as a unit.
There are bleed balls in the clutch piston which allow quick
escape for oil when the pressure to the piston is released. CAUTION
Full throttle stall speeds for an excessive length of time
Maintenance will overheat the torque converter.

General Information d. Hold converter stalled until desired temperature is

1. Always check the oil level with the engine idling, and the reached.
transmission in neutral and at normal operating temper- NOTE: Always make all troubleshooting checks with the
ature (82 to 93 °C [180 to 200 °F]). converter outlet temperature at least 82.3 to 93.3
2. Change the oil filter element every 500 hours. Drain and °C (180 to 200 °F).
refill the system every 1000 hours or 6 months.

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RT890E SERVICE MANUAL POWER TRAIN

Troubleshooting Procedures

SYMPTOM PROBABLE CAUSE REMEDY

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

Removal 7. Remove the nuts and washers securing the transmis-

sion/torque converter housing to the engine flywheel
1. Extend and set the outriggers just enough to take up the
housing.
slack in the outrigger pads. Chock the wheels.
2. Position the boom over the side and stop the engine. Installation 7
3. Remove the engine and transmission/torque converter NOTE: The transmission/torque converter assembly
from the crane as an assembly. Refer to ENGINE in this weighs approximately 450 kg (990 pounds) dry.
Section. 1. If a new transmission/torque converter is to be installed,
4. Remove the piston and single section hydraulic pumps remove all fittings and brackets from the old one and
from the transmission/torque converter. Cover all open- install them in the same locations on the new transmis-
ings. Refer to Hydraulic Pumps, page 2-14 for removal sion/torque converter.
of the pump. 2. Install the piston and single section hydraulic pumps on
NOTE: The transmission/torque converter weighs approxi- the transmission/torque converter. Refer to Hydraulic
mately 450 kg (990 pounds) dry. Pumps, page 2-14 for installation of the hydraulic pump.

5. Attach an adequate lifting device to the transmission/ 3. Position the transmission/torque converter to the engine
torque converter and take up any slack. with the lifting device.

6. Remove the screws and lockwashers securing the drive 4. Remove all burrs from the flywheel mounting face and
plate assembly to the flywheel. nose pilot bore. Clean the drive plate surface with sol-
vent.

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POWER TRAIN RT890E SERVICE MANUAL

5. Check the engine flywheel and housing for conformance plate screws. Rotate the engine flywheel and install the
to standard S.A.E. No. 3-S.A.E. J-927 tolerance specifi- remaining seven flywheel to drive plate attaching screws
cations for bore size, pilot bore runout and mounting and lockwashers. Snug the screws but do not tighten.
face flatness. Measure and record engine crankshaft After all eight screws and lockwashers have been
end play. installed, torque the screws to 46 to 49 Nm (34 to 36 lb-
ft). This will require torquing each screw, then rotating
6. Install the 12 studs in the engine flywheel housing.
the engine flywheel until all eight screws have been
Rotate the engine flywheel to align a drive plate mount-
torqued.
ing screw hole with the flywheel housing front access
hole. 10. Measure the engine crankshaft end play after the trans-
mission/torque converter has been completely installed
7. Install a 101.6 mm (4.00 inch) long drive plate locating
on the engine flywheel. This value must be within 0.025
stud 0.3750-24 fine thread in a drive plate nut.
mm (0.001 inch) of the end play recorded in step 5.
8. Rotate the transmission/torque converter to align the
11. Install the engine and transmission/torque converter in
locating stud in the drive plate with the flywheel drive
the crane as an assembly. Refer to Section 7 - POWER
plate mounting screw hole positioned in step 6. Locate
TRAIN.
the transmission on the flywheel housing, aligning the
drive plate to the flywheel and the transmission on the 12. Service the crane as required in Servicing the Crane
flywheel housing mounting studs. Install the transmis- After Transmission/Torque Converter Overhaul, page 7-
sion to flywheel housing nuts and washers. Tighten the 24.
nuts to 49 to 53 Nm (36 to 39 lb-ft).
13. Cycle all functions and observe for proper operation.
9. Remove the drive plate locating stud. Install one drive
plate attaching screw and lockwasher. Snug the screw Towing or Pushing
but do not tighten. NOTE: Some engine flywheel hous-
Before towing the crane, disconnect both front and rear drive
ings have a hole located on the flywheel housing circum-
lines. The engine can not be started by pushing or towing
ference in line with the drive plate screw access hole. A
because of the design of the hydraulic system.
screwdriver or pry bar used to hold the drive plate
against the flywheel will facilitate installation of the drive

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RT890E SERVICE MANUAL POWER TRAIN

Mount
Dial
Indicator
Here
Flywheel
Housing

Engine

Flywheel
Pilot
Bore

Flywheel

Converter
Housing

Flywheel
10.2 cm
(4 in.) Stud

6.4 cm
(2-1/2 in.)
Aligning
Studs

Drive
Plate
Flywheel
Housing Special Stud, Washer and
Self-lock Nut Furnished
by Engine Manufacturer

Flywheel
Housing

Impeller
Cover

(3) Intermediate
Drive Plates

FIGURE 7-9

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POWER TRAIN RT890E SERVICE MANUAL

Servicing the Crane After Transmission/ level of oil in the transmission with the engine running at
Torque Converter Overhaul idle (1000 rpm). Add oil as necessary to bring the level to
the LOW mark on the dipstick. After the oil temperature
The transmission/torque converter and its allied hydraulic reaches 82 to 93 °C (180 to 200 °F), add oil to bring the
system are important links in the drive line between the level to the FULL mark on the dipstick.
engine and the wheels. The proper operation of either the
7. Recheck all drain plugs, lines, connections, etc., for
unit or the system depends greatly on the condition and
leaks and tighten where necessary.
operation of the other; therefore, whenever repair or
overhaul of the transmission/torque converter is performed, Lubrication
the balance of the system must be considered before the job
can be considered completed. Type of Oil
After the overhauled or repaired transmission/torque Hydraulic Oil (HYDO) or equivalent. Refer to SECTION 9.
converter has been installed in the crane, the oil cooler and
Capacity
connecting hydraulic system must be thoroughly cleaned.
This can be accomplished in several ways, and a degree of System Capacity (includes torque converter, lines, and
good judgement must be exercised as to the method transmission) - Approximately 37.9 liters (40 quarts).
employed.
Check Period
The following are considered the minimum steps to be taken:
Check oil level every 10 hours or DAILY with engine running
1. Drain the entire system thoroughly. at 1000 rpm and oil at 83 to 94 °C (180 to 200 °F). Maintain
2. Disconnect and clean all hydraulic lines. Where feasible, oil level to FULL mark.
hydraulic lines should be removed from the machine for Normal Drain Period
cleaning.
NOTE: Normal drain periods and filter change intervals are
3. Replace oil filter elements, cleaning out the filter cases for average environmental and duty-cycle condi-
thoroughly. tions. Severe or sustained high operating tempera-
4. The oil cooler must be thoroughly cleaned. The cooler tures or very dusty atmospheric conditions will
should be back flushed with oil and compressed air until cause accelerated deterioration and contamina-
all foreign material has been removed. Flushing in the tion. For extreme conditions, judgment must be
direction of normal oil flow will not adequately clean the used to determine the required change intervals.
cooler. If necessary, the cooler assembly should be Every 500 hours, change oil filter element. Every 1000 hours
removed for cleaning, using oil, compressed air and a or 6 months, drain and refill system as follows: Drain with oil
steam cleaner for that purpose. at 66 to 93 °C (150 to 200 °F).
NOTE: It is recommended that filter elements be changed
CAUTION after 50 and 100 hours of operation on new and
Do not use flushing compounds for cleaning purposes. rebuilt or repaired units, then at normal intervals
thereafter.
5. Remove the drain plug from the transmission/torque a. Drain transmission and remove pump screen. Clean
converter and inspect the interior of the unit housing, screen thoroughly and replace, using a new gasket.
gears, etc. If the presence of considerable foreign mate-
rial is noted, it will be necessary for the unit to be b. Remove and discard oil filters. Clean filter housing
removed, disassembled, and cleaned thoroughly. It is and install new filters.
realized this entails extra labor, however, such labor is a c. Refill transmission to LOW mark.
minor cost compared to the cost of difficulties which can
result from the presence of such foreign material in the d. Run engine at 1000 rpm to prime converter and
system. lines.

6. Assemble all components and use only the type oil rec- e. Recheck level with engine running at 1000 rpm and
ommended. Fill the transmission through the fill pipe add oil to bring level to LOW mark. When oil
until fluid is at the top of the fill range on the dipstick. Run temperature is hot (83 to 94 °C [180 to 200 °F]),
the engine for two minutes at idle (1000 rpm) to prime make final oil level check. BRING OIL LEVEL TO
the torque converter and hydraulic lines. Recheck the FULL MARK.

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RT890E SERVICE MANUAL POWER TRAIN

OPTIONAL EQUIPMENT Engine Block Heater

Description The pre-heater is an 120 volt immersion type heater. The
immersion heater is installed in the engine block to preheat
This section is provided to give a brief description of the the coolant water. The immersion heater is provided with a
optional equipment available for the crane which is not short power cord equipped with a three prong ground plug.
discussed elsewhere within this service manual. The heater is 1500 watts.

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POWER TRAIN RT890E SERVICE MANUAL

THIS PAGE BLANK

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RT890E3 SERVICE MANUAL UNDERCARRIAGE

SECTION 8
UNDERCARRIAGE

SECTION CONTENTS
Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 Service Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14
Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 Corrosion Protection . . . . . . . . . . . . . . . . . . . . . . 8-18
Steering Systems . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 Parking Brake Actuator. . . . . . . . . . . . . . . . . . . . . 8-20
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . 8-5 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6 Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21
Rear Steering System. . . . . . . . . . . . . . . . . . . . . . . 8-7 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21
Hydraulic Pumps. . . . . . . . . . . . . . . . . . . . . . . . . . 8-7 Park Brake Solenoid Valve . . . . . . . . . . . . . . . . . . 8-21
Front Steering Control Valve. . . . . . . . . . . . . . . . . 8-8 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21
Rear Steer/ Axle Lockout/Fan Drive Valve . . . . . . 8-8 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21
Steer Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9 Outriggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22
Rear Axle Oscillation Lockout System . . . . . . . . . 8-9 Outrigger Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . 8-22
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9 Outrigger Beam . . . . . . . . . . . . . . . . . . . . . . . . . . 8-26
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . 8-9 Extension Cylinder. . . . . . . . . . . . . . . . . . . . . . . . 8-30
Axle Oscillation Lockout Cylinders . . . . . . . . . . . 8-11 Stabilizer Cylinder . . . . . . . . . . . . . . . . . . . . . . . . 8-30
Axle Oscillation Lockout Valve . . . . . . . . . . . . . . 8-11 Outrigger Control Valves . . . . . . . . . . . . . . . . . . . 8-32
Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12 Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . 8-32
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-32
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . 8-12 Pintle Hook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-32
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13 Secondary Front Steer (CE Option). . . . . . . . . . . 8-32

AXLES The hypoid pinion and differential assembly of the first

reduction are supported by tapered roller bearings. The
Description pinion bearing preload is adjusted and maintained by a
hardened precision spacer between the inner and outer
To provide maximum maneuverability, both the front and rear bearing. The differential tapered bearing preload is adjusted
axles are steerable. The rear axle is mounted on a pivoting and maintained by the positioning of the threaded adjusting
cradle (fifth wheel) which allows the axle to oscillate while
traversing uneven terrain. The front axle is bolted directly to
rings in the carrier leg and cap bores. 8
the frame. All four wheels utilize a hydraulic braking system. In the planetary wheel ends, the spur teeth of the sun gear
The axles are equipped with disc type brakes. A disc-type mesh with teeth of the planet spur gears. The planet spur
parking brake is mounted of the front axle input shaft. gears rotate on planet pins which are mounted in a spider.
The planet spur gear teeth in turn mesh with teeth of the
Each axle incorporates a single reduction carrier with hypoid floating ring gear.
gearing mounted in the axle center. The final reduction is of
planetary design spur gearing built into the wheel hubs. Power is transmitted by the hypoid gear set in the differential
carrier to the axle shafts and the sun gear of the final
The design of these axles permits the hypoid gearing of the reduction, through the revolving planet gears, and into the
differential carrier and the axle shafts to carry only a nominal planetary spider which drives the wheel hub.
torsional load while at the same time providing the highest
practical numerical gear reduction at the wheels.

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UNDERCARRIAGE RT890E3 SERVICE MANUAL

As an option, the front axle and rear axle may be provided a. The steer cylinders.
with a differential lock. When in the locked mode, the axle
b. The rear wheels not centered switch actuator
shafts and the differential are locked together and there is no
bracket (rear axle only).
differential action between the wheels.
c. The parking brake actuator (front axle only). Refer
Maintenance to Brake System, page 8-12.
NOTE: The axles do not have to be removed from the Cleaning
crane to remove the planetary wheel ends or the
drive units. Completely assembled axles may be steam cleaned on the
outside only, to facilitate initial removal and disassembly,
Removal providing all openings are closed. Breathers, vented shift
units, and all other openings should be tightly covered or
1. Using the outriggers, raise the wheels off the ground.
closed to prevent the possibility of water entering the
2. Install blocking under the frame at the outboard ends of assembly.
the four outrigger boxes.
Installation
1. If a new axle is to be installed, remove the following from
CAUTION the old axle and install them on the new one.
Do not disassemble drive lines when removing them from
the crane. Dirt can enter the spline and cannot be purged. a. The steer cylinders.
In addition, the drive lines are assembled in a specific b. The rear wheels not centered switch actuator
orientation when manufactured and can easily be bracket (rear axle only).
incorrectly reassembled.
c. The parking brake actuator (front axle only). Refer
3. Disconnect and remove the drive line from the applica- to Brake System, page 8-12.
ble axle. Do not disassemble the drive lines. Refer to 2. Position the axle under the crane on jacks which are
SECTION 7. capable of handling the weight of the axle.
4. Tag, disconnect, and cap the hydraulic brake line at 3. Raise the axle into place and secure with the eight
each wheel. attaching bolts, washers and nuts. The front axle has
5. Tag, disconnect, and cap the hydraulic lines to the steer washers and nuts and the rear axle has tapped holes in
cylinders. the fifth wheel. Torque the bolts.Refer to SECTION 1,
Fasteners and Torque Values.
6. On the front axle only, tag and disconnect the hydraulic
line from the park brake actuator. 4. Install the wheels onto the axle. Refer to Mounting
Wheel Assemblies, page 8-4.
7. On the left side of the rear axle only, tag and disconnect
the electrical wires from the rear wheels not centered 5. Connect the hydraulic lines to the steer cylinder as
switch. tagged during removal.

NOTE: Each tire and wheel assembly weighs approxi- 6. Connect the hydraulic brake line to each wheel as
mately 2991 kg (6594 pounds). marked during removal.

8. Remove the wheels from the axle. 7. On the front axle only, connect the hydraulic line to the
parking brake actuator.
NOTE: Each axle weighs approximately 1735 kg (3825
pounds) with oil. 8. On the left side of the rear axle only, connect the electri-
cal wires to the rear wheels not centered switch. Adjust
9. Position jacks, which are capable of handling the weight the switch in accordance with REAR WHEELS NOT
of the axle, under the axle for support. CENTERED SWITCH ADJUSTMENT PROCEDURE.
10. Remove the eight nuts, washers, and bolts securing the 9. Connect the drive line to the applicable axle. Refer to
axle to the frame/cradle. DRIVE LINES in SECTION 7.
11. Lower the axle to the ground and remove it to a clean 10. Refer to Bleeding the Brake System, page 8-13 in this
working area. section and bleed the hydraulic brake system.
12. If a new axle is to be installed, remove the following from 11. Remove the blocking under the outrigger beams and
the old axle and install them on the new one. retract the outriggers to lower the wheels to the ground.

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RT890E3 SERVICE MANUAL UNDERCARRIAGE

Wheel Alignment Check Procedure Rear Wheels Not Centered Switch Adjustment
Procedure
1. Check the axle for wheel alignment. The wheels are to
be straight ahead with no toe-in or toe-out. Adjust if nec- 1. Ensure the wheels are straight ahead.
essary by turning the tie rod ends in the direction neces-
NOTE: Refer to (Figure 8-1) to perform the following
sary.
adjustments.
2. Turn the wheels to the extreme left. Check the clearance
2. Ensure proximity sensor switch is centered in the slot of
between the inside of the tire and the nearest object. If
the sensor plate bolted to the top of the axle trunnion
the clearance is less than 25 mm (1.0 inch), adjust the
cap. Adjust by moving the sensor mounting bracket.
axle stop to provide clearance. Do not adjust axle stop if
clearance is greater than 25 mm. With the axles set at a 3. Ensure a maximum gap of 5 mm (0.2 in) exists between
25 mm (1.0 inch) clearance, check the steer cylinders to the sensor switch and the sensor plate. Adjust by loos-
see that they are not bottomed out. To check the steer ening switch mounting bolts and moving switch up or
cylinders, remove the pin at the rod end and apply pres- down on the mounting bracket. Tighten the mounting
sure to move the cylinder rod. The cylinder rod should bolts.
travel a minimum of 3.0 mm (0.12 inch).
4. Turn the rear wheels to verify proper operation. REAR
3. Turn the wheels to the extreme right and repeat step 2 WHEELS NOT CENTERED light in cab should be out
for the right side. when rear wheels are centered and the sensor switch is
centered in the slot of the sensor plate.

Mounting Bracket

Sensor Plate

Sensor Switch 8
6393-1

FIGURE 8-1

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UNDERCARRIAGE RT890E3 SERVICE MANUAL

Wheels and Tires

Wheel End Horizontal Oil Fill Level and Drain Plug
Description
24 1 5
The standard tire size for this unit is 29.5 x 25-34 ply. 20 9
16 13
17
12
CAUTION
Do not mix tires and rims of different manufacturers. 21
8

Each wheel assembly (tire and rim) is mounted on the 4 3

planetary hub with 24 grade 8 lug nuts.
22 7
NOTE: The tire diameters, widths, and weights may vary
slightly depending on the tire manufacturer. 18 11
14 15
10 19
6 2 23
FIGURE 8-2
WARNING
Possible equipment damage and/or Maintenance
personal injury!
Driving the crane with a tire under inflated at 80% or less
of its recommended pressure can cause the wheel and/or
DANGER
tire to fail. Per OSHA Standard 1910.177(f)(2), when a tire Do not attempt to demount or mount tires without proper
has been driven under inflated at 80% or less of its training. The high pressures involved can cause tire and
recommended pressure, it must first be completely rim parts and tools to fly with explosive force, if proper
deflated, removed from the axle, disassembled, and procedures are not used, causing severe injury or death
inspected before re-inflation. to personnel and damage to the crane and surrounding
area.
Off-highway tires are designed to operate with a certain
sidewall deflection or bulge. Correct air pressure ensures Mounting Wheel Assemblies
prior deflection which, in turn, ensures proper traction, NOTE: Do not lubricate the wheel studs or lug nuts.
flotation, support of load, and prevents excessive flexing of
the tire. Over inflation increases rim stresses, which results
in lowered rim life. 1. Position the wheel assembly on the mounting studs.
Install the lug nuts and tighten them to 68 Nm (50 lb-ft) in
Refer to and adhere to the inflation pressures in the Load the sequence shown in (Figure 8-2).
Chart Book in the crane cab.
2. Ensure the wheel assembly is positioned properly on the
hub.
3. Torque the lug nuts 461 to 488 Nm (340 to 359 lb-ft) in
the sequence shown in Figure 8-2.
4. Retorque lug nuts after approximately one hour of travel.

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RT890E3 SERVICE MANUAL UNDERCARRIAGE

STEERING SYSTEMS control valve and two steer cylinders. A rear steer indicator
system is provided to indicate when the rear wheels are not
Description centered. This system consists of an indicator light located
on the front console in the cab and a switch located on the
To maximize maneuverability, the crane can be steered by right side of the rear axle. When the rear wheels are turned
the front axle, the rear axle, or by the front and rear axles to the left or right, the amber indicator light will illuminate.
simultaneously. The crane utilizes two separate steering
systems, one to control front axle steering and one for rear Theory of Operation
axle steering.
Front Steering System
Front Steering System
A hydraulic oil flow from pump number 2 flows through port 5
The front steering system consists of a hydraulic pump, load of the hydraulic swivel to the steer/swing directional control
sense steer priority flow divider valve (part of the swing valve. Regulated flow from the steer priority flow divider
directional control valve), load sense steering control valve, valve is routed to the steering control valve upon turning of
and two steer cylinders. The hydraulic pump is driven by the the steering wheel and pressurizing of the load sense line.
engine and supplies a hydraulic flow of 147 l/min (38.9 gpm) The steering control valve routes the oil to the appropriate
to the load sense steering priority flow divider. The load ends of the front steer cylinders to turn the wheels in the
sense steer priority flow divider valve provides 45 l/min (12 desired direction.
gpm) to the load sense steering control valve and the
remainder to the swing system. When the steering wheel is Rear Steering System
turned, the load sense steering control valve sends a load
Hydraulic flow from pump number 1 is directed through the
sense signal to the load sense steer priority flow divider. As
integrated outrigger valve to the rear steer/fan drive valve.
the load sense pressure increases, the priority flow divider
When the REAR STEER control switch in the cab is
spool shifts to direct oil from the hydraulic pump to the
positioned to left (L) or right (R), a signal is sent to the rear
steering control valve, and to direct oil from the L port and R
steer solenoid, shifting the control valve spool, routing the
port of the steering control valve to the steer cylinders.
supply pressure to the appropriate ends of the rear steer
Rear Steering System cylinders to turn the wheels in the desired direction.

The rear steering system is controlled through a section of

the integrated outrigger/rear steer valve and consists of the

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UNDERCARRIAGE RT890E3 SERVICE MANUAL

Maintenance
Front Steering System
Troubleshooting

Symptom Probable Cause Solution

1. Hard to steer left and right. a. Hydraulic oil low. a. Refill hydraulic reservoir.
b. Clogged or loose hydraulic b. Clean or tighten lines or
lines or fittings. fittings.
c. Defective flow divider c. Repair or replace valve(s).
valve(s).
d. Defective steering control d. Repair or replace valve.
valve.
e. Defective hydraulic pump. e. Repair or replace pump.
2. Hard to steer either left or right. a. Clogged or loose hydraulic a. Clean or tighten lines or
lines or fittings. fittings.
b. Defective steer cylinder. b. Repair or replace cylinder.
3. Steering is erratic left and right. a. Hydraulic oil low. a. Refill hydraulic reservoir.
b. Clogged or loose hydraulic b. Clean or tighten lines or
lines or fittings. fittings.
c. Defective steering control c. Repair or replace valve.
valve.
d. Defective hydraulic pump. d. Repair or replace pump.
4. Noisy hydraulic pump caused by a. Hydraulic oil low. a. Refill hydraulic reservoir.
cavitation.
b. Suction line plugged or too b. Clean line and check for size.
small.
5. Hydraulic pump shaft seal a. Worn shaft seal. a. Replace shaft seal.
leakage.
NOTE: If replacing the shaft seal
does not stop leakage, the
pump should be disassem-
bled and checked for the fol-
lowing:
b. Broken diaphragm seal or b. Replace seal or gasket.
backup gasket.
c. Bearing out of position. c. Replace bearing.
d. Excessive internal wear. d. Replace pump.

Functional Check speed irregularities and sticky sensation. This may indi-
cate dirt in the fluid. If the steering wheel continues to
A normal periodic functional check of the entire steering
rotate when started and released, a condition known as
system will generally be adequate to ensure satisfactory
Motoring exists. This may also indicate dirty fluid in the
service.
system.
1. Check all fittings for leakage. An accumulation of moist,
3. Ensure the system has adequate power. If there is an
black dirt is a good indication of leakage.
indication of hard steering, this can be caused by either
2. With the engine running at idle and at full throttle, and a reduced oil flow to the control valve or a reduced sys-
with the machine standing still and moving, turn the tem relief pressure. Adequate oil flow under all condi-
steering wheel through the full range of travel. Note any tions can best be checked by timing the full travel of the

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RT890E3 SERVICE MANUAL UNDERCARRIAGE

cylinder with the steered axle unloaded and loaded. If running at a medium speed, turn the steering wheel to
there is a great difference at low engine speed and slight one end of the travel and hold the cylinders at the travel
difference at high engine speeds this may indicate a limit briefly, just long enough to read the pressure gauge.
defective pump. Adequate oil pressure can only be Never hold the system at relief pressure for more than a
determined by connecting a pressure gauge (24 MPa/ few seconds at a time. The pressure gauge should indi-
240 bar [3500 psi] full scale recommended) at the swing/ cate 17.9 MPa/179 bar (2600 psi).
steer/pressure gauge test port (GP2). With the engine

REAR STEERING SYSTEM

Troubleshooting

Symptom Probable Cause Solution

1. Rear steering inoperative. a. Hydraulic oil low. a. Refill hydraulic reservoir.
b. Clogged, broken, or loose b. Clean, tighten, or replace
hydraulic lines or fittings. lines or fittings.
c. Steer cylinder locked. c. Repair or replace cylinders.
d. Defective control valve. d. Repair or replace valve.
e. Defective steer cylinder(s). e. Repair or replace cylinder(s).
f. Lack of electrical signal f. Check electrical connections/
wiring
2. Hard to steer left and right. a. Hydraulic oil low. a. Refill hydraulic reservoir.
b. Clogged or loose hydraulic b. Clean or tighten lines or
lines or fittings. fittings.
c. Defective steering control c. Repair or replace valve.
valve.
d. Defective hydraulic pump. d. Repair or replace pump.
e. Clogged or loose hydraulic e. Clean or tighten lines or
lines or fittings. fittings.
f. Defective steer cylinder. f. Repair or replace cylinder.
g. Damaged relief. g. Replace relief valve.
3. Steering is erratic left and right. a. Hydraulic oil low. a. Refill hydraulic reservoir.
b. Clogged or loose hydraulic b. Clean or tighten lines or
lines or fittings. fittings.
c. Defective steering control c. Repair or replace valve.
valve.
d. Defective hydraulic pump. d. Repair or replace pump. 8
Hydraulic Pumps gear type pump that provides a flow of approximately 147 l/
min (38.9 gpm).
Description
Rear Steer
Front Steer
The hydraulic pump is mounted to the torque converter and
The hydraulic pump is mounted off of drive pads of the is driven by the engine. Pump number 1 provides the
torque converter and driven by the engine. Pump number 2 hydraulic flow necessary to power all crane function except
provides the hydraulic flow necessary to power the front front steer and swing. The pump is a piston type pump that
steer cylinders and the swing drive system. The pump is a provides a flow of approximately 373 l/min (98.7 gpm).

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UNDERCARRIAGE RT890E3 SERVICE MANUAL

Front Steering Control Valve The third section is the removal pin section for the front
outrigger box and contains a three position four-way
Description solenoid valve. The solenoid valve is controlled by the pin
unlock switch in the outrigger control box in front of the left
The steering control valve is located under the dash and is
front fender.
actuated by a conventional steering wheel and steering
column, providing precise, full hydraulic steering. Precise The fourth section is the removal pin section for the rear
steering is accomplished by a metering system within the outrigger box and contains a three position four way solenoid
valve that is directly connected to the steering column and valve. The solenoid valve is controlled by the pin unlock
wheel. switch in the outrigger control box behind the right rear
fender.
Maintenance
The fifth section is the outrigger section and contains two
Removal bolt-on three position four-way solenoid valves, a bolt on
1. Thoroughly clean the steering control valve and the sur- manifold that contains work port double pilot operated check
rounding area before removing the hydraulic hoses from valves with integral 2.1 MPa/21.0 bar (300 psi) rod side and
the valve. 20 MPa/210 bar (3000 psi) piston side thermal relief valves.
The solenoid valve is controlled by the extend/retract switch
2. Tag and disconnect the five hydraulic hoses from the in the operator’s cab.
steering control valve. Cap or plug each hose and the
five ports of the valve. The second and fifth sections both contain a double pilot
operated check valve.
3. Remove the four bolts, lockwashers, and flat washers
securing the valve to the bracket and the steering col- Maintenance
umn. Remove the control valve, leaving the steering col-
Removal
umn in the cab.
1. Tag and disconnect the electrical connectors to the rear
Installation
steer/axle lockout/fan drive valve.
1. Position the control valve to the bracket and steering col-
2. Tag and disconnect the hydraulic lines to the rear steer/
umn and install the four flat washers, lockwashers, and
axle lockout/fan drive valve. Cap or plug the lines and
bolts. Torque the bolts.Refer to SECTION 1, Fasteners
ports.
and Torque Values.
3. Remove the four bolts and nuts securing the rear steer/
2. Connect the five hydraulic hoses to the control valve as
axle lockout/fan drive valve to the crane. Remove the
tagged during removal.
valve as a complete assembly.
3. Start the engine and check for proper operation and any
Installation
leakage.
1. Position the rear steer/axle lockout/fan drive valve on its
Rear Steer/ Axle Lockout/Fan Drive Valve mount. Secure the valve with the four nuts and bolts.

Description 2. Connect the hydraulic lines to the rear steer axle lock-
out/fan drive valve as tagged during removal.
The rear steer valve/axle lockout/fan drive directionally
controls the outrigger circuit, outrigger pin circuit, and the 3. Connect the electrical connectors to the rear steer/axle
rear steer circuit. The valve is mounted on the front face of lockout/fan drive valve as tagged during removal.
the carrier frame member forward of the swivel. Functional Check
The valve is made up of five sections. The inlet section 1. Cycle each outrigger cylinder several times. Verify each
contains a solenoid valve and a 13.8 MPa/138 bar (2000 psi) cylinder extends and retracts properly.
relief valve. The relief valve is the main relief for both
systems. The solenoid valve is normally open, bypassing oil 2. Rear steer the crane to the left and to the right several
to the reservoir. Operation of either system energizes the times. Verify the crane steers properly in both directions.
solenoid valve to close it and route oil to the applicable
3. Check the valve and lines for leakage. Make repairs as
circuit.
needed.
The second section is the rear steer section and contains a
NOTE: For further information on the rear steer/axle lock-
three position four-way solenoid valve. The solenoid valve is
out/fan drive valve, refer to Axle Lockout, Rear
controlled by the rear steer switch in the operator’s cab. A
Steer and Oil Cooler Fan Motor Control Manifold,
bolt on manifold that contains work port double pilot operated
page 2-63.
check valves.

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RT890E3 SERVICE MANUAL UNDERCARRIAGE

Steer Cylinders REAR AXLE OSCILLATION LOCKOUT

SYSTEM
Description
The steer cylinders are mounted on the axles, two cylinders Description
on each axle. The barrel end of each cylinder is attached to
The rear axle oscillation system consists of two lockout
the axle housing and the rod end is attached to the steering
cylinders, a lockout valve, an axle oscillation relay, and an
lug on the axle end. The cylinders are controlled
area definition potentiometer (see Figure 8-3 and 8-48-4).
hydraulically by the steering control valve.
The lockout cylinders are mounted between a cradle (fifth
Maintenance wheel) and the carrier frame. The lockout valve is mounted
on the left inner center frame rail and hydraulically controls
NOTE: For Disassembly and Assembly procedures, refer the oscillating abilities of the lockout cylinders. The axle
to Steer Cylinders, page 8-9. oscillation relay is located on the relay panel under the front
Removal console cover in the cab and the area definition
potentiometer is located in the electrical swivel assembly.
1. Tag and disconnect the hydraulic lines going into the
steer cylinder. Cap or plug all openings. Theory of Operation
2. Remove the bolt, washer, and lockwasher securing each The rear axle is mounted on a cradle (fifth wheel) allowing
pin weld in the rod end and barrel end of the cylinder. maximum oscillation of 25 cm (10 inches) total while
NOTE: Steer cylinder weighs approximately 20 kg (44 traveling over uneven terrain. Oscillation is provided only
pounds). when the superstructure is within 6 degrees left or right of
directly over the front. When the superstructure is within 6
3. Remove both pin welds and two thrust washers (rod end degrees left or right of directly over the front, the area
only), and remove the cylinder from the axle. definition potentiometer energizes the axle oscillation relay
which in turn energizes the solenoids on the lockout valve.
Installation
When the solenoids are energized, the valve spools are
1. Position the cylinder onto the attachment fittings on the shifted to allow hydraulic transfer between the two lockout
axle and install both pin welds. On the rod end, install a cylinders. As one side of the axle is forced up by traveling
thrust washer on the top and bottom of lug. over uneven terrain, the hydraulic oil flows from the rod end
of cylinder A to the barrel end of cylinder B and from the rod
2. Secure each pin weld with the bolt, washer, and lock-
end of cylinder B to the barrel end of cylinder A. The system
washer.
is not pressurized and oil is moved from one cylinder to the
3. Connect the hydraulic lines to the cylinder as tagged other by the action of the axle moving the cylinder.
during removal.
When the superstructure is more than 6 degrees left or right
4. Operate the steering system and check the cylinder for of directly over the front, the area definition potentiometer
proper operation and any leakage. deenergizes the axle oscillation relay. This deenergizes the
solenoids on the lockout valve and allows the springs in the
valve to shift the valve spools to the closed position to
prevent hydraulic oil flow between the cylinders. By stopping
the flow of oil, a hydraulic lock is created and the axle is held
rigid in that position.

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UNDERCARRIAGE RT890E3 SERVICE MANUAL

Oscillation
Carrier Frame Lockout Cylinder

A B

Pivot Point

Fifth Wheel Pivot Point

FIGURE 8-3

Axle Lockout
Valve

Axle Lockout Cylinders

B A

Supply from Pump

FIGURE 8-4

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RT890E3 SERVICE MANUAL UNDERCARRIAGE

Axle Oscillation Lockout Cylinders 7. Lubricate both ends of the cylinder using the fittings pro-
vided.
Description
8. Function test the axle oscillation system in accordance
Two 12.7 cm (5.0 inch) hydraulic lockout cylinders are with the Operator’s and Safety Handbook to ensure
installed on the rear axle, one left side and one right side. proper operation.
The barrel end of each cylinder is attached to each side of
the carrier frame and the rod ends are attached to each side Axle Oscillation Lockout Valve
of the cradle (fifth wheel). The lockout cylinders are
connected hydraulically so that hydraulic oil flows from the Description
rod side of the left cylinder to the barrel side of the right The axle oscillation lockout valve, also called the double
cylinder and from the rod side of the right cylinder to the solenoid valve, is used in the rear axle oscillation lockout
barrel side of the left cylinder. circuit. The valve consists of a valve body and two solenoid
Each cylinder weighs approximately 40 kg (88 pounds). valves, which keep the lockout cylinders from oscillating
unless the superstructure is within 6 degrees left or right of
Maintenance directly over the front. The lockout valve is located on the left
side of the frame in front of the front rear axle cross member.
NOTE: For disassembly and assembly procedures, refer
to Axle Oscillation Lockout Cylinder, page 2-83. When the superstructure is within 6 degrees left or right of
directly over the front, the area definition potentiometer
Removal
energizes the axle oscillation relay which energizes the
1. Raise the crane up on outriggers. solenoids on the axle oscillation lockout valve. This allows
hydraulic oil to flow in and out of the lockout cylinders,
2. Rotate the turntable more than 6 degrees in either direc-
allowing the axle to oscillate.
tion from directly over the front to lock out the oscillation
cylinders. When the superstructure is more than 6 degrees left or right
of directly over the front, the area definition potentiometer
3. Remove the wheel and tire assembly from the axle.
deenergizes the axle oscillation relay which deenergizes the
4. Tag and disconnect both hydraulic hoses from the ports solenoids on the axle oscillation lockout valve. This keeps
on the cylinder. Cap or plug both hoses and the ports on the axle from oscillating because hydraulic oil cannot leave
the cylinder. the cylinders.
5. At the rod end of the cylinder, remove one of the cotter Maintenance
pins securing the retaining pin to the cradle attach fitting.
Removal
6. Tap out the retaining pin, freeing the rod end from the
cradle. 1. Tag and disconnect the electrical connector to the valve.

7. At the barrel end of the cylinder, remove one of the cotter 2. Tag and disconnect the hydraulic hoses from the valve.
pins securing the retaining pin to the frame attach fitting. Cap or plug the lines and ports.

8. Tap out the retaining pin and remove the cylinder. 3. Remove the two screws and nuts securing the valve to
the carrier frame.
Installation
Installation
1. Position the barrel end of the cylinder in the frame attach
fitting and tap in the retaining pin. 1. Secure the valve to the carrier frame using two screws
and nuts.
2. Secure the retaining pin with the cotter pin.
2. Connect the hydraulic hoses to the applicable valve 8
3. Align the rod end of the cylinder in the cradle attach fit- ports as tagged during removal.
ting and tap in the retaining pin.
3. Connect the electrical connector to the valve as tagged
4. Secure the retaining pin with the cotter pin. during removal.
5. Remove the caps or plugs from the two hydraulic hoses 4. Function test the axle oscillation system in accordance
and the cylinder ports and connect the hoses to the with the Operator’s and Safety Handbook to ensure
appropriate cylinder ports as tagged during removal. proper operation.
6. Install the wheel and tire assembly on the axle. Tighten 5. Check the valve and hoses for signs of leakage. Tighten
the lug nuts in accordance with the procedure in Wheels fittings as required.
and Tires, page 8-4.

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UNDERCARRIAGE RT890E3 SERVICE MANUAL

BRAKE SYSTEM Hydraulic oil from hydraulic pump number 2 flows to swivel
port 9 to the dual accumulator charge valve. The dual
Description accumulator charge valve charges the accumulators from
the open center circuit upon demand and within its present
The brake system includes all the components necessary for operating charge rate and the high limit pressure setting.
the application of the service brakes and the parking brake. However, when the open center circuit pressure reaches the
brake relief setting, which is higher than the high
Service Brakes
accumulator charge limit, then the accumulators will be
The service brakes are full power hydraulic disc brakes charged to the regulated maximum pressure setting. The
which are hydraulically controlled and are used to apply the dual accumulator charge valve regulates flow to the
brake assemblies on all four wheels. The system consists of hydraulic accumulators to provide fully powered
the tandem brake valve with treadle pedal, the dual independently separate, primary (front) and secondary
accumulator charge valve, two hydraulic accumulators, the (rear), service brake circuits. Hydraulic pressure is
brake assemblies, and all the associated hoses and tubing. c o n s ta n t l y m a i n ta i n e d i n t h e b r a k e c i r c u i ts b y t h e
The operator depresses the pedal on the tandem brake accumulators and the charging valve. The charged
valve, located on the cab floor, and the valve modulates the accumulators supply pressurized fluid to the closed tandem
brake line pressure to the brake assemblies at each wheel. brake valve.
The full powered brake system supplies a high brake system
After the accumulators are fully charged, the high limit check
pressure with relatively low reactive pedal forces, while
opens and all of the pump flow is directed to the excess flow
controlling the maximum brake line pressure. The service
port and on to the front steer and swing circuits. When
brake dual accumulator charge valve regulates flow to the
pressure to the steering or swing circuit becomes greater
hydraulic accumulators to provide fully powered
than accumulator pressure, the main check valve opens and
independently separate, primary (front) and secondary
charges the accumulator without the aid of the charging
(rear), service brake circuits. Hydraulic pressure is
valve. In this condition, the maximum accumulator pressure
c o n s ta n t l y m a i n ta i n e d i n t h e b r a k e c i r c u i ts b y t h e
is the brake circuit relief valve setting of 20 MPa (2900 psi).
accumulators and the charging valve.
Once the operator depresses the brake pedal, the tandem
Parking Brake brake valve modulates fluid out to the brakes to provide the
The parking brake is a hydraulic release, spring apply, disc- means of braking. The tandem brake valve will modulate the
type brake, located on the front axle. The system consists of pressure in the brake system by increasing or decreasing
a two-position switch, a three-way solenoid valve, actuator, pressure as required in proportion to the input force from the
two brake assemblies, and all the associated hardware and operator via the brake pedal. The hydraulic force acts within
tubing. The selector switch, located on the front console in the brake assemblies to force the brake pads against the
the cab, is used to activate the solenoid valve which controls brake discs, acting to slow wheel rotation. Fully powered
the park brake actuator, which applies and releases the park separate primary (front) and secondary (rear) braking circuits
brake. There are two brake actuators on the front axle. are provided with independent accumulators. A low pressure
warning switch is used to sense the accumulator pressures
NOTE: For Description and Maintenance of the tandem and warn the operator through visual brake warning indicator
brake valve with treadle pedal, the accumulators, light on the cab console in the event the pressure in the
and the dual accumulator charge valve, refer to accumulators drops to an unsafe operating level. In the
SECTION 2. event of engine failure, the accumulators are pre-charged
with dry nitrogen gas and properly sized to provide power-off
Theory of Operation stopping capacity for secondary braking.
Service Brakes Parking Brake
Braking begins when the operator depresses the brake Hydraulic flow from the transmission charge pump is routed
pedal in the cab. Mechanical linkage transfers the force to the parking brake control valve. When the PARK BRAKE
created by the lever action of the brake pedal to the hydraulic switch is in the ON position, the parking brake solenoid valve
brake valve which modulates the brake line pressure to the shifts to route flow from the hydraulic parking brake actuator
brake assemblies at each wheel. back to the transmission sump. The actuator spring pulls on
the lever on the brake assembly, applying the parking brake.

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RT890E3 SERVICE MANUAL UNDERCARRIAGE

Maintenance
Troubleshooting

Symptom Probable Cause Solution

1. Brakes are poor. a. Lining thickness less than a. Replace lining.
3mm (0.125 in).
b. Brake pedal operation. b. Free mechanical linkage.
c. Restriction or leaks in lines. c. Check all lines for leaks and
restrictions.
d. Low hydraulic oil flow. d. Check the hydraulic oil level in
reservoir and check flow from
the tandem brake valve.
e. Air in brake lines. e. Bleed the brakes.
f. Brake pads/linings are f. Replace pads/linings.
grease-soaked.
g. Engine not running. g. Start engine. Due to the
operation, the engine must be
running to provide full brake
power.
h. Brake relief valve stuck open. h. Replace the relief valve.
i. Dual accumulator charge i. Check valve operation and
valve not charging repair or replace valve.
j. Accumulators not pre- j. Check accumulator pre-
charged. charge.
2. Hard brake pedal with engine run- a. Pedal travel being interfered a. Check all pedal linkage and
ning. with. ensure it is free and adjusted
properly.
3. Brakes lock up. a. Too much hydraulic flow. a. Check the flow from the flow
divider. Too much flow will
cause the brakes to be
applied by the oil trapped in
the power boost chamber.
b. Brake pedal push rod b. Adjust the push rod linkage so
improperly adjusted, causing the brake pedal and push rod
brakes to be always applied. fully return.
4. Uneven braking or pad wear. a. Lining thickness less than 3 a. Replace the lining.
mm (0.125 in). 8
b. Grease on the pads/linings. b. Replace the pads/linings.

General Bleeding the Brake System

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

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UNDERCARRIAGE RT890E3 SERVICE MANUAL

actuator on every wheel. When you complete a bleeder 3. Repeat step 2 until a solid stream free of air bubbles is
screw, go to the next closest bleeder screw on the same obtained.
caliper/actuator. When you complete a wheel, go to the
furthest bleeder screw on the next closest wheel. 4. Repeat steps 1 thru 3 for the remaining wheel calipers/
actuators.
Pressure Bleeding the Brake System.
NOTE: Before bleeding the brake system, ensure the SERVICE BRAKES
hydraulic accumulators are fully charged.
Description
1. Install the bleeding adapter.
The brakes utilized on the axles are hydraulic disc-type
2. Using a clean bleeding tank, fill the tank at least half full
brakes. Two brake assemblies are used at each wheel end
with hydraulic oil. Position the tank so it will not have to
on the front axle. One brake assembly is used at the wheel
be moved again until all bleeding is finished.
end on the rear axle. The action of the brake pads riding
3. Connect a 241 kPa/2.4 bar (35 psi) air source to the against the brake discs acts to slow the rotation of the
bleeder tank. wheels.

4. Open the bleeder tank valve and bleed all air out of the Maintenance
hose to be connected to the adapter. Connect the NOTE: To perform maintenance on the brake caliper,
bleeder hose to the adapter and open the bleeder valve. remove the tire and wheel assembly. Refer to Sec-
5. Connect the end of the bleeder hose to the bleeder tion Contents, page 8-1.
screw on the caliper/actuator. Submerge the other end Removal
in a glass jar partially filled with the proper type of clean
hydraulic oil. Linings

6. Open the bleeder screw and allow fluid to flow into the 1. the caliper housing. Remove the end plates.
jar until it is a solid stream free of air bubbles. Close the 2. Loosen the bleeder screws to release hydraulic pres-
bleeder screw and torque to 11.3 to 13.6 Nm (100 to 120 sure in the caliper.
lb-in).

7. Repeat steps 5 and 6 for the remaining wheel calipers/

actuators. Wood
Loosen Block
8. Remove the air supply from the bleeder tank. Bleeder
NOTE: Close the bleeder tank valve and disconnect the Screws
hose and the bleeder adapter.

9. Remove the bleeder tank and hose.

10. Remove the bleeder adapter.

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

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RT890E3 SERVICE MANUAL UNDERCARRIAGE

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

pistons out of the other housing. If one piston comes
1. Disconnect the hydraulic brake line from the inlet fitting
out before the other piston, put a piece of wood in
on the caliper. Cap or plug all openings.
front of the piston that comes out first. Apply
2. Remove the linings as described previously. compressed air to force the other piston out of the
housing (Figure 8-7).
3. Remove the bolts securing the caliper housing to the
mounting bracket. Remove the caliper housing from the
mounting bracket. If shims are used mark the position of
the shims.
C-Clamp
Disassembly
Caliper
1. Remove the inlet fitting and o-ring from the cylinder cap.
2. Drain and discard the brake fluid.

3. Clean the outside of the housing with isopropyl alcohol.

Air Gun
Dry the housing with a clean cloth. Wood
Block Piston FIGURE 8-7
4. If installed, remove the bolts that secure the end plates
to the housing. Remove the end plates and linings. c. Remove the wood block and the C-clamp from the
housing.
5. Remove the pistons from the side of the housing
opposite the mounting plate according to the following d. Remove the pistons from the bores that are
procedure. opposite from the mounting plate.

a. Use a C-clamp to hold a 12.7 mm (0.5 in) block of 6. Remove the cylinder caps from the housing using an
wood against two pistons on the mounting side of open end wrench. Remove and discard the O-rings
the housing. Ensure the C-clamp is not in the area in (Figure 8-8).
front of the piston bore (Figure 8-6).

C-Clamp

Wood
Block
O-Ring
Cylinder
Cap

FIGURE 8-8
8
FIGURE 8-6 7. Remove the pistons from the mounting plate side of the
housing. Push on the ends of the pistons to force them
out of the disc side of the housing (Figure 8-9).

DANGER
Do not place hand in front of pistons when forcing them
out. Serious personal injury may occur.

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UNDERCARRIAGE RT890E3 SERVICE MANUAL

• Lining Wear. Replace the linings when the thickness

of the lining is less than 3.2 mm (0.125 in) from the
Wood Block back plate (Figure 8-11).
• Lining Wear Not Even. Replace the linings if the
thickness of the two linings is significantly different.
Check the pistons for correct operation. Replace the
piston and/or housing if a piston is cocked in the
bore. Check that the disc surface is flat and parallel
to the linings (Figure 8-11).

Minimum Lining Thickness

3.2 mm (0.125 in) from
Piston Backing Plate

FIGURE 8-9

8. Remove the dust seals from the housing.

9. Remove and discard the O-ring and the backup rings

(Figure 8-10).

Uneven Lining Wear

O-Ring

FIGURE 8-11

• Oil or Grease on Linings. Replace the linings.

• Cracks on Linings. Replace linings that have large
Backup Ring
or deep cracks.
FIGURE 8-10
NOTE: Small, tight cracks on the surface of the lining are
10. Inspect the ring grooves in the housing for scratches and normal when the caliper is used under high temper-
rust. Remove small scratches and rust with emery cloth. ature conditions.
Replace the housing if there are large scratches or large Caliper for Leaks
amounts of rust. Refer to Inspection - Caliper Parts.
Inspect the following areas for fluid leaks (Figure 8-12).
11. Inspect the pistons and the bores for scratches and rust.
Remove small scratches and rust with emery cloth.
Replace the components if they are worn or if there are Piston Fluid Bleeder Screw
large scratches or large amounts of rust. Refer to Leaks Fluid Leaks
Inspection - Caliper Parts.

Inspection Inlet
Cylinder
Periodic On-Vehicle Fitting
Cap
Fluid
Fluid
Inspect the caliper, linings, and disc for any damage. Leaks
Leaks
Shoes, Linings, and End Plates
Remove the shoes and linings. To help prevent abnormal
lining wear, replace worn, bent, or cracked end plates and Piston Fluid
distorted backing plates. Inspect end plate bolts for wear. Leaks
FIGURE 8-12
Replace the bolts if worn. Inspect the linings for:

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RT890E3 SERVICE MANUAL UNDERCARRIAGE

• Pistons. If fluid leaks at a piston, disassemble the Caliper Parts

caliper. Inspect the piston, the bore, the o-rings, and
1. Inspect the pistons, housing bores, and o-ring grooves
back-up rings. Service as necessary.
for scratches or corrosion. Remove small scratches or
• Cylinder Cap. If fluid leaks at a cylinder cap, tighten corrosion with fine emery cloth. Replace the compo-
the cylinder cap, the inlet fitting, and the plug. If the nents if they are worn beyond wear limits or if there are
leak continues, disassemble the caliper. Inspect the large scratches or large amount of corrosion.
cylinder cap threads, the housing threads, and the
o-ring. Service as necessary. 2. Measure the diameter of the piston. Replace the piston if
the outer diameter is worn less than 76.073 mm (2.995
• Bleeder Screw. If fluid leaks at the bleeder screw, in) (Figure 8-14).
tighten the bleeder screw. If the leak continued,
replace the bleeder screw.
• Inlet Fitting. If fluid leaks at the inlet fitting, tighten
the fitting. If the leak continues, replace the o-ring.
Dust Seals
Ensure the dust seals are soft and flexible. Disassemble the
caliper and replace dust seals that are hard or damaged. Micrometer
Piston
Disc
If the disc is worn beyond the wear limits, replace the disc
(Figure 8-13). Replace Piston if Outer
Diameter is Worn to Less than
76.073 mm (2.995 in)
Minimum Disc FIGURE 8-14
Thickness
3. Measure the diameter of the housing bore. Replace the
housing if the diameter is worn to more than 76.276 mm
Maximum Disc
Wear Each Side (3.003 in) (Figure 8-15).
Maximum
Disc Wear
Original
Disc Thickness Replace Housing if Bore
15.875 mm (0.625 in) is Worn to More than
76.276 mm (3.003 in)

Typical Section Through Disc Showing

Recommended Maximum Wear Limits

Lining
Maximum
Backing Minimum Disc
Disc Wear
Plate Thickness
Each Side Telescoping
Thickness

7.1 mm (0.28 1.5 mm (0.06 12.7 mm (0.50

Gauge
FIGURE 8-15 8
in) in) in)
4. Inspect the linings as described previously.
8.6 mm (0.34 2.3 mm (0.09 11.2 mm (0.44
5. Inspect the threads of the caliper, cylinder caps, and all
in) in) in)
fittings. Replace any component that has thread
FIGURE 8-13 damage that cannot be repaired.

6. Discard all back-up rings, o-rings, and dust seals. Use

new ones when assembling the caliper.

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UNDERCARRIAGE RT890E3 SERVICE MANUAL

Cleaning Assembly
Caliper

DANGER CAUTION
Use of cleaning solvents, hot solution tanks, or alkaline
Use only specified components when assembling the
solutions incorrectly, can cause serious personal injury. To
calipers. Do not mix components from other calipers.
prevent serious personal injury, follow the instructions
Installing the wrong components may cause the caliper
supplied by the manufacturer of these products. Do not
not to operate correctly and may cause damage to
use gasoline to clean parts. Gasoline can explode and
equipment. Use of non manufacturer’s parts can cause
cause serious personal injury.
damage, loss of braking, and serious personal injury.

CAUTION NOTE: The o-rings, back-up rings, pistons, and bores

must be lubricated before installing the pistons.
Use only solvent cleaners to clean ground or polished
metal parts. Hot solution tanks or water and alkaline 1. Lubricate all pistons, bores, o-rings, and back-up rings
solutions will damage these Parts. Isopropyl alcohol, with silicone grease. If silicone grease is not available,
kerosene, or diesel fuel can be used for this purpose. use the same type of fluid that is used in the brake sys-
tem.
• Use solvent cleaners to clean all metal parts that
2. Install new o-ring and a new back-up ring in the groove
have ground or polished surfaces. Examples of
in the middle of the bore. The o-ring is installed toward
ground or polished parts are the piston and the
the outboard end of the bore. The back-up ring is
piston bore in the caliper.
installed toward the lining side of the bore (Figure 8-16).
• Metal parts with rough surfaces can be cleaned with
solvent cleaners or with alkaline solutions.
• Use a wire brush to clean the threads of fasteners CAUTION
and fittings. Do not use silicone grease on the dust seal.
• Use soap and water to clean parts that are not made 3. Install a new dust seal in the top groove of the bore
of metal. (Figure 8-16).
• Scrape away build-ups of mud and dirt on the
linings. Replace all linings contaminated with oil or
grease.
Backup Ring - O-Ring-
• Immediately after cleaning, dry all parts with clean Install Toward Lining Install Toward
paper or rags. Side of Bore O-Ring Outboard End of Bore
O-Ring
Corrosion Protection
Apply brake system fluid to the cleaned and dried parts that
are not damaged and are to be immediately assembled. Do
Backup
Not apply fluid to the brake linings or the disc. Ring
If parts are to be stored, apply a special material that
prevents corrosion to all surfaces. Do Not apply the material Backup Ring Dust Seal
and O-Ring Groove
to the brake linings or the disc. Store the parts inside special Dust Seal Groove
paper or other material that prevents corrosion.
FIGURE 8-16

4. Install the pistons in the housing. Push the pistons in

from the lining side of the housing. Ensure the pistons
are straight in the bores. Push each piston into the bore
until the top of the piston is even with the top of the dust
seal (Figure 8-17).

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RT890E3 SERVICE MANUAL UNDERCARRIAGE

7. Install the bleeder screws in the housing. Tighten to 11.3

to 13.6 Nm (100 to 120 lb-in).

8. Install the o-ring and the inlet fitting in the cylinder cap.

Installation
Linings

CAUTION
Always replace both linings. If only one lining is replaced,
Piston - - Use possible disc damage can occur.
Equal Pressure to
Push Pedal into Bore 1. Install the linings in the caliper housing.
2. Position the end plates on the housing and secure with
bolts. Apply Loctite 271 or equivalent to the bolt threads.
Tighten the bolts to 224 to 285 Nm (165 to 210 lb-ft).

3. Ensure the linings move freely in the housing.

4. Bleed the brake system.

5. Apply and release the brakes three times to ensure the

caliper operates correctly. Check for fluid leaks. Ensure
When Correctly
Installed the End of the the linings move freely.
Piston is Even with the Caliper
Top of the Dust Seal FIGURE 8-17
1. Position the caliper housing on the mounting bracket. If
5. Install a new o-ring in the groove of the cylinder cap. shims where used, place them as marker during
Ensure the o-ring is not cut by the threads on the removal.
cylinder cap. 2. Secure the caliper housing with the bolts and tighten
NOTE: Apply extra grease on o-ring before installing cylin- them to 678 to 813 Nm (500 to 600 lb-ft).
der caps. this will keep o-ring from catching on 3. Install the linings. Refer INSTALLATION - Linings.
threads as cylinder cap is threaded into housing.
4. Ensure the housing is installed correctly on the mounting
6. Install the cylinder caps in the caliper housing. Tighten bracket. The disc must be within ± 1.5 mm (± 0.06 in) of
the cylinder caps to 102 Nm (75 lb-ft) minimum as shown being centered between the lining end plates.
in (Figure 8-18).
a. To increase outboard clearance and decrease
inboard clearance, install a shim either between the
Cylinder Cap - - housing and mounting bracket or between the hub
Tighten to 100 Nm 1.25 Inch and disc.
(75 lb-ft) Minimum Crow’s Foot
Wrench b. The shims must be steel, ground flat, and parallel
and must cover the entire mounting surface of the
8
hub or housing. The linings must move freely in the
housing and between the end plates (Figure 8-19).

Torque
Wrench
FIGURE 8-18

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UNDERCARRIAGE RT890E3 SERVICE MANUAL

sure of 1862 kPa/18.6 bar (270 psi) may be used to

pressurize the actuator.

3. Remove the capscrews holding actuator to the brake

caliper, and slide the actuator off the actuator rod.

4. Position the PARK BRAKE switch to ON and shut down

the engine.

5. Disconnect the hydraulic line from the brake actuator,

then cap or plug all openings.

Installation
Disc Centered
Between Linings 1. Connect the hydraulic line to the brake actuator.
2. Start the engine, ensure the transmission is in neutral,
FIGURE 8-19 and position the PARK BRAKE switch to OFF. This will
pressurize brake the brake actuator to release the ten-
sion on the brake linkage. Engine must remain running.
5. Connect the hydraulic brake line to the inlet fitting. Air pressure of 1862 kPa/18.6 bar (270 psi) may be used
to pressurize the actuator.
6. Bleed the brake system.
3. Slide the actuator over the actuator rod and install the
7. Apply and release the brakes three times to ensure the
capscrews to attach the actuator to the caliper.
caliper operates correctly. Check for fluid leaks. Ensure
the linings move freely. 4. Position the PARK BRAKE switch to ON and shut down
the engine.
PARKING BRAKE ACTUATOR
Adjustment
Description 1. Chock the wheels to prevent crane movement.
The spring-applied, hydraulically-released parking brake 2. Start the engine, ensure the transmission is in neutral,
actuator is located on the front axle and is used to apply and and position the PARK BRAKE switch to OFF. This will
release the parking brake. Depending on the crane model pressurize the brake actuator to release the tension on
there will be either one or two parking brakes per crane. the brake linkage. Air pressure of 1862 kPa/18.6 bar
(270 psi) may be used to pressurize the actuator. Screw
Maintenance the caging nut up under the actuator chamber.
Removal 3. Install the rod ball joint until the ball joint will just connect
1. Chock the wheels to prevent crane movement. to the brake linkage with the brake lever in a horizontal
position.
2. Start the engine, ensure the transmission is in neutral,
and position the PARK BRAKE switch to OFF. This will 4. Lock the rod ball joint with the jam nut and back off the
pressurize the brake actuator to release the tension on caging nut.
the brake linkage. Engine must remain running. Air pres-
5. Position the PARK BRAKE switch to ON and shut down
the engine.

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RT890E3 SERVICE MANUAL UNDERCARRIAGE

PARKING BRAKE 3. Torque the jam nuts to 136 to 163 Nm (100 to 120 foot-
pounds) against the mounting bracket (Figure 8-20).
Description
4. Connect the hydraulic hose to the actuator.
The parking brake is mounted on the front axle input shaft, or
transmission output (depending on crane model) in line 5. Start the engine, ensure the transmission is in neutral,
between the front axle and the driveline from the and position the PARK BRAKE switch to OFF. This will
transmission. The brake is a disc-type brake that is pressurize the brake actuator to release the spring
controlled by a switch on the front console in the cab and is tension. Air pressure of 1862 kPa/18.6 bar (270 psi) may
spring-applied and hydraulically released by an actuator. be used to pressurize the actuator. Unscrew the caging
nut from under the actuator chamber.
Maintenance
6. Position the PARK BRAKE switch to ON and shut down
Removal the engine.

1. Chock the wheels to prevent crane movement.

PARK BRAKE SOLENOID VALVE
2. Start the engine, ensure the transmission is in neutral,
and position the PARK BRAKE switch to OFF. This will Description
pressurize the brake actuator to release the tension on
the brake linkage. Air pressure of 1862 kPa/18.6 bar The park brake solenoid valve (Figure 8-21) is located on the
(270 psi) may be used to pressurize the actuator. Screw front side of the carrier aft center frame cross member. The
the caging nut up under the actuator chamber. valve is a three-way two position solenoid valve. The park
brake valve is used to control the application of the crane’s
3. Position the PARK BRAKE switch to ON and shut down spring-applied, hydraulically-released parking brake.
the engine. Positioning the PARK BRAKE switch to OFF shifts the three-
way, two-position solenoid valve so hydraulic oil can flow to
4. Tag and disconnect the hydraulic hose from the actuator.
the parking brake actuator, extending it. When the actuator
Cap or plug all openings.
extends, it releases the park brake.
5. Unthread the two mounting bolts securing the brake Positioning the PARK BRAKE switch to ON shifts the three-
assembly to the mounting bracket, then carefully way, two-position solenoid valve so hydraulic oil can drain
remove the brake assembly from the mounting bracket from the actuator. The parking brake actuator’s rod retracts,
and the brake disc. forcing hydraulic oil through the valve and the case drain
manifold back to the transmission reservoir. As the actuator
Installation
retracts, it applies the parking brake.
1. Position the brake over the disc and align mounting
A pressure switch is installed in the line to the actuator.
bracket holes.
When the park brake is applied, a lack of hydraulic oil
2. Thread the mounting bolts into the mounting bracket pressure keeps the pressure switch closed, which turns on
until the caliper is centered over the brake disc. the red LED indicator on the switch.When the park brake is
released, pressure buildup opens the switch, which turns off
the indicator.
Mounting
Bracket Sleeve
Maintenance
Brake
Assembly Removal
8
1. Tag and disconnect the hydraulic lines attached to the
valve. Cap or plug lines and ports. Remove the valve.

Installation
1. Position the valve and connect the hydraulic lines to the
valve as tagged during removal.
2. Connect the electrical connector to the valve as tagged
Jam Nut FIGURE 8-20 during removal.

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UNDERCARRIAGE RT890E3 SERVICE MANUAL

3. Apply and release the park brake several times. Verify frame front cross member. The front and rear outrigger
the park brake holds the crane when applied. Verify the control manifolds are mounted on the inside center of their
park brake doesn’t drag when released. respective outrigger box.

4. Check for leaks. Make repairs as needed. The outrigger selector controls are located in the cab on the
front console. Both the integrated outrigger valve and the
manifold solenoid valves are electrically actuated from these
controls. The solenoid switches must be held depressed to
actuate the solenoid valve. The integrated outrigger valve
switch is spring loaded to the off position. The console is
placarded with switch positions.
2 A sight bubble level is mounted on the left side of the cab by
1
3 the door latch plate. The sight bubble level provides the
operator with a visual indication of crane level attitude.

Theory of Operation
The appropriate EXTENSION/STABILIZER switch must be
depressed before the OUTRIGGER EXTEND/RETRACT
Port (3) switch is depressed. Depressing one of the outrigger
Port (2) selector switches causes that solenoid valve to open. As the
OUTRIGGER switch is moved, the integrated outrigger valve
spool shifts allowing flow to either the extend or retract line
as applicable. If the OUTRIGGER switch is in the EXTEND
position, the flow continues through the open solenoid valve
Port (1) to the piston side of the cylinder. If the stabilizer is to be
extended, the flow first unseats the cylinder check valve then
FIGURE 8-21
extends the cylinder. The oil from the rod end flows through
the integrated outrigger valve, and then to the reservoir.
OUTRIGGERS When the OUTRIGGER switch is in the RETRACT position,
the flow through the selector valve is directed to the rod side
Outrigger Circuit of the cylinder. The oil in the piston side flows through the
Description open solenoid back to the integrated outrigger valve. If a
stabilizer cylinder is to be retracted, then pilot pressure from
The outrigger circuit consists of four extension cylinders, four the pressurized retract line unseats the cylinder check valve
stabilizer cylinders, an integrated outrigger/rear steer valve, allowing oil to flow from the piston side through the open
front and rear outrigger control manifolds, and pilot operated solenoid valve to the integrated outrigger valve. The
check valves. The front two extension cylinders are mounted integrated outrigger valve directs the flow to the reservoir.
in the front outrigger beams and the rear two extension
cylinders are mounted in the rear outrigger beams. The front The integrated outrigger/rear steer valve contains three relief
and rear outrigger beams are mounted on their respective valves. The main relief is set at 24,132/241.3 kPa (3500 psi).
outrigger boxes; in turn the stabilizer cylinders are mounted Thermal relief protection is provided on the extend side by a
on the end of each outrigger beam. The integrated outrigger/ 27,580/275.8 bar kPa (4000 psi) relief valve and the retract
rear steer valve is mounted on the rear face of the carrier side by a 27,580 kPa/275.8 bar (4000 psi) relief valve.

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RT890E3 SERVICE MANUAL UNDERCARRIAGE

Maintenance
Troubleshooting

Symptom Probable Cause Solution

1. Slow or erratic operation of outrig- a. Damaged relief valve. a. Remove relief valve; clean or
ger extension cylinders. replace.
b. Low hydraulic oil. b. Replenish oil to proper level.
c. Sticking solenoid valve spool. c. Repair or replace valve spool.
d. Improper ground to base of d. Ground properly.
solenoid.
2. Slow or erratic operation of outrig- a. Directional selector switch a. Clean or replace switch.
ger extension cylinders (contin- sticking.
ued).
b. Collector ring dirty or glazed. b. Clean and deglaze collector
ring.
c. Damaged wiring to solenoid. c. Replace wiring.
d. Weak brush springs on d. Replace brush springs.
collector ring.
e. Damaged extension cylinder e. Remove extension cylinder
(internal parts). and repair as necessary.
f. Bent cylinder rods. f. Replace piston rods and
seals.
g. Excessive material on g. Clean outrigger beams.
outrigger beams.
h. Binding outrigger beam. h. Repair or replace outrigger
beam.
i. Damaged outrigger valve. i. Repair or replace valve.
j. Damaged valve coil. j. Replace coil.
k. Main hydraulic pump k. Replace or tighten hose or
cavitation. fitting.
l. Partially shifted hydraulic l. Disassemble, clean, and
spool in selector valve or polish spool and valve
manifolds. housing with very fine emery
cloth (water paper).
m. Insufficient voltage for m. Solenoids require a minimum
operation of solenoid valve. of 9.5 volts to energize. Check
outrigger wiring and electrical
coupling collector rings.
8
n. Damaged piston seals. n. Replace all cylinder seals.
o. Worn or damaged hydraulic o. Repair or replace pump
pump section. section.
p. Scored cylinder barrel. p. Repair or replace extension
cylinder.
q. Cracked or damaged piston. q. Replace rod weld and all
cylinder seals.

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UNDERCARRIAGE RT890E3 SERVICE MANUAL

Symptom Probable Cause Solution

3. Sticking spool. a. Dirt in the system. a. Change oil and flush system.
Sticking spool. b. Distortion caused by tie bolts b. Retorque tie bolts.
being overtorqued.
c. Flow in excess of valve rating. c. Limit flow through valve to that
recommended. Check pump
output and cylinder ratio.
4. Sticking spool (continued). a. Pressure in excess of valve a. Check relief valve setting or
rating. pump compensation with that
recommended.
b. Electrical failure. b. Check wiring and solenoids.
5. External leakage. a. Damaged O-ring or quad a. Check for chipped packings
rings. and replace.
b. Loose tie bolts. b. Retorque tie bolts.
c. Damaged solenoid. c. Replace damaged parts.
6. Solenoid failure. a. No current. a. Check power source of at
least 85% of coil rating.
b. Damaged solenoid assembly. b. Replace solenoid.
c. Short in solenoid. c. Replace coil.
d. Loss of solenoid force. d. Decrease time of solenoid
energization, decrease cycle
rate.
7. Outrigger stabilizer cylinder slow a. Low in hydraulic oil. a. Replenish oil to proper level.
or erratic.
b. Damaged main relief valve. b. Repair or replace valve.
c. Damaged holding valve seals. c. Replace holding valve seals.
d. Bent cylinder rod. d. Replace cylinder rod and
seals.
e. Bent outrigger housing. e. Repair or replace outrigger
housing.
f. Excessive material on beams. f. Clean outrigger beams.
g. Sticking solenoid valve spool. g. Repair or replace valve spool.
h. Damaged wiring to solenoid. h. Repair or replace wiring.
i. Weak brush springs on i. Replace brush springs.
collector rings.
j. Collector ring dirty or glazed. j. Clean or deglaze collector
ring.
k. Directional selector switch k. Clean or replace switch.
sticking.
l. Main hydraulic pump l. Replace or tighten hose and
cavitation. fittings.
m. Worn or damaged hydraulic m. Repair or replace pump
pump section. section.

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RT890E3 SERVICE MANUAL UNDERCARRIAGE

Symptom Probable Cause Solution

8. Outrigger stabilizer cylinder a. Damaged piston seals. a. Replace all cylinder seals.
retracts under load.
b. Damaged holding valve seals. b. Replace seals.
c. Damaged holding valve. c. Replace valve assembly.
d. Scored cylinder barrel. d. Repair or replace cylinder.
e. Cracked or damaged piston. e. Replace piston and all
cylinder seals.
9. Outrigger stabilizer cylinder a. Damaged piston seals. a. Replace all cylinder seals.
extends while machine is travel-
b. Scored cylinder barrel. b. Replace jack cylinder.
ing.
c. Cracked or damaged piston. c. Replace piston and seals.
d. Piston loose on cylinder rod. d. Replace seal and retorque.
10. Outrigger system will not activate a. Hydraulic oil low. a. Replenish system.
(from stowed or extended and
b. Loose or broken wire on b. Repair or replace wiring.
down position).
switch.
c. Clogged, broken, or loose c. Clean, tighten, or replace
lines or fittings. lines or fittings.
d. Damaged relief valve or d. Repair or replace valve.
damaged control valve.
11. Outrigger system activates, but a. Clogged, broken, or loose a. Clean, tighten, or replace
selected outrigger will not stow or hydraulic lines or fittings. lines or fittings.
extend and lower as desired.
b. Loose or broken wire on b. Repair or replace wiring.
control switch or solenoid
valve.
c. Damaged solenoid valve. c. Repair or replace valve.
d. Damaged control switch. d. Replace switch.
e. Damaged hydraulic cylinder. e. Repair or replace cylinder.
12. Outriggers will not set. a. Improper sequence of a. Activate individual control
activation. switch; then activate system
control switch.
13. Two outriggers activate from sin- a. Damaged solenoid valves. a. Repair or replace.
gle control switch.
14. The two outriggers will not stow. a. Hydraulic lock. a. Recycle individual
outrigger(s).
15. Individual outrigger will not set or a. Damaged piston seals. a. Replace seals.
stow.
b. Damaged check valve. b. Repair or replace valve. 8
c. Loosen or broken wire on c. Repair or replace wiring.
control switch or solenoid
valve.
d. Damaged solenoid valve. d. Repair or replace valve.

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UNDERCARRIAGE RT890E3 SERVICE MANUAL

Outrigger Beam quate soft support to cushion any distance the rod
will drop,
Description
7. Remove the cotter pin and clevis pin securing the cylin-
The outrigger beam assembly consists of an outrigger beam, der barrel end of the extension cylinder to the outrigger
a stabilizer cylinder, a extension cylinder, and the required housing. Carefully extend the outrigger beam until the
hoses and mounting hardware. extension cylinder is free of the housing and carefully lay
the end of the cylinder on the bottom of the outrigger
Theory of Operation beam or leave on blocking.
When the outrigger extension is activated, it extends or 8. After attaching a suitable lifting device of straps or belts
retracts the outrigger beam within the outrigger box. The instead of chains to prevent nicking the bottom edges of
outrigger beam can be extended to the mid-extend position the outrigger beam, pull the outrigger beam out of the
by allowing the lock pin to ride on the top of the beam while outrigger box, re-adjusting the lifting attachment to pre-
it’s extending. The lock pin will automatically drop into the vent the extension cylinder from sliding out of the outrig-
hole when the beam reaches the mid-extend position. ger beam when the beam clears the outrigger box.
The stabilizer cylinder is mounted to the end of the beam and
applies force to the outrigger beam vertically. This sequence
of events provides for lifting and stabilizing the crane for
operation. DANGER
Be sure any blocking material used is capable of
Maintenance supporting the weight of the outrigger beam. Do not allow
Removal it to tilt or slide.

1. On the stabilizer cylinder end of the beam, remove the NOTE: The outrigger beam assembly weighs approxi-
set screw from the side adjustable wear pad and back off mately 669 kg (1474 pounds).
the wear pad from the outrigger box.
9. Position the outrigger beam on the blocking material.
2. Remove the cover from the opposite end of the outrigger
box. Remove the setscrew from the side adjustable wear Inspection
pad and back off the wear pad from the beam.
Inspect the outrigger beams for bends, evidence of cracks,
3. Remove the setscrews from the bottom adjustable wear or other damage. Check the outrigger beam internally for
pads and back off the wear pads leaving approximately hydraulic fluid, which may indicate a leaking cylinder, loose
3.2 mm (0.125 in) protruding connection, or damaged hydraulic line.
4. Extend the outrigger slightly to facilitate attaching a lift- Installation
ing device to the outrigger beam.
1. Apply grease (EPMPG) to the bottom of the outrigger
beam.
2. If removed, install the side adjustable wear pad in the
DANGER outrigger beam.
be sure any blocking material used is capable of 3. Install the bottom wear pads with approximately 3.2 mm
supporting the weight of the outrigger beam. Do not allow (0.125 in) protruding. This will prevent the beam side
it to tilt or slide. plates from riding on the bottom of the box.

5. Place blocking material under the outrigger beam. 4. Attach a suitable lifting device of straps or belts instead
of chains to prevent nicking the bottom edges of the out-
6. Tag and disconnect the hydraulic lines at the cylinder rigger beam.
barrel end of the extension cylinder. Cap all lines and fit-
tings. 5. Slide the beam into the outrigger housing and align the
cylinder bushing with the mounting hole.
NOTE: Do not allow the end of the outrigger extension cyl-
inder to fall when the cylinder mounting shaft is 6. Apply anti-seeze compound to the clevis pin. Secure the
removed. Use blocking to limit the drop or an ade- cylinder barrel to the housing with the clevis pin and cot-
ter pin.

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RT890E3 SERVICE MANUAL UNDERCARRIAGE

NOTE: At installation, be sure that the outrigger stabilizer

cylinder hydraulic hoses are not trapped against
CAUTION the outrigger box when the beam is fully retracted.
Be sure that the piston side of all outrigger cylinders are
Wear Pad Adjustment.
connected to the solenoid valve bank. Reversal of port
connection of the rod and piston sides could result in NOTE: When adjusting wear pads, refer to Wear Pad
severe damage to the cylinders as very high pressure Adjustment (Figure 8-24).
intensification will occur.
1. Adjust the bottom wear pads (approximately 1/4 turn)
During initial start-up and checking of the outrigger until a gap of 1.5 mm (0.06 in) is obtained between the
operation, each control switch must be operated before top of the beam and the top of the outrigger box. Install
operating the selector valve. If hydraulic lines are and lock set screw against wear pad.
reversed to one or more cylinders, this will prevent
damage to the cylinders. 2. Adjust outrigger box side wear pad until a gap of 1.5 mm
(0.06 in) is obtained between beam and shims welded in
7. Connect the hydraulic lines as tagged prior to removal. top and bottom of box. Install and lock set screw against
wear pad.
8. Install the side adjustable wear pad in the outrigger box.
3. Adjust outrigger beam side wear pad until a gap of 1.5
9. Adjust the wear pads, refer to WEAR PAD ADJUST- mm (0.06 in) is obtained between shim welded on beam
MENT in this Sub-Section. and side of box. Install and lock set screw against wear
10. Install the end cover. pad.

6, 7

13 2, 3
10, 11, 12

4, 5

9
8
2, 3

2, 3
1 FIGURE 8-22

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UNDERCARRIAGE RT890E3 SERVICE MANUAL

Item Description Item Description

1 Outrigger Beam Assembly 8 Pin
2 Wear Pad 9 Cover Plate
3 Setscrew 10 Screw
4 Clevis Pin 11 Lockwasher
5 Cotter Pin 12 Retaining Nut
6 Capscrew 13 Extension Cylinder
7 Hex Nut

NOTE: Outrigger removal and

installation similar for
both front and rear out-
riggers.
NOTE: Lifting belts or straps
should be used for lifting
purposes so as to avoid
nicking or scratching the
bottom edges of the out-
rigger beam.

6120-1

FIGURE 8-23

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RT890E3 SERVICE MANUAL UNDERCARRIAGE

Item Description
1 1 Outrigger Beam Assembly
1 2 Wear Pad
3 Setscrew
4 Clevis Pin
5 Cotter Pin
2, 3

2, 3

4, 5

2, 3

2, 3 2, 3
FIGURE 8-24

Extension Cylinder Extend Port Jack Cylinder Extend Port

Jack Cylinder and Extension Cylinder Retract Port

Jack Cylinder Extend Port

Jack Cylinder and Extension Cylinder 8
Retract Port

Extension Cylinder Extend Port

FIGURE 8-25

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UNDERCARRIAGE RT890E3 SERVICE MANUAL

Extension Cylinder the clevis pin and secure in place with the clevis pin and
cotter pin.
Description
4. Install the outrigger beam. Refer to OUTRIGGER BEAM
Two outrigger extension cylinders are utilized within each - INSTALLATION in this section.
outrigger box assembly. The extension cylinders provide the
force for the outrigger beam’s horizontal movement. The Functional Check
cylinder weighs approximately 45.3 kg (100 pounds). 1. Activate the hydraulic system; extend and retract the
outrigger.
Maintenance
2. Observe the operation of the outrigger beam.
NOTE: Refer to Outrigger Extension Cylinder, page 2-95
for Disassembly and Assembly of the cylinder. 3. Check the hydraulic connections for any evidence of
leakage.
Removal
1. Remove the outrigger beam. Refer to OUTRIGGER Stabilizer Cylinder
BEAM - REMOVAL in this section.
Description
2. Remove the cotter pin and clevis pin securing the rod
Four stabilizer cylinders are used on the crane, one at the
end of the extension cylinder to the outrigger beam.
end of each outrigger beam. The stabilizer cylinders provide
3. Pull the extension cylinder from the outrigger beam until the force for the outrigger beam’s vertical movement. The
the hydraulic hoses on the rod end of the cylinder can be cylinder weighs approximately 104 kg (229 pounds).
accessed. Tag and disconnect the hoses from the rod
end of the cylinder. Cap or plug all openings. Maintenance

4. Remove the cylinder. NOTE: Refer to Outrigger Stabilizer Cylinder, page 2-98 for
Disassembly and Assembly of the cylinders.
Installation
Removal
1. Place the cylinder in the beam.
1. Extend the outrigger beam slightly for improved access
NOTE: Keep hydraulic fittings and hoses close to angles to the stabilizer cylinder; shut down the engine.
shown and as low as possible to prevent rubbing
with the beam top plate and side plate, and for 2. Tag and disconnect the hydraulic hoses from the stabi-
proper tracking during beam extension and retrac- lizer cylinder. Remove the fittings from the ports. Cap or
tion. plug all openings.
3. Remove the cylinder cap.
4. Place a jack capable of supporting the weight of the sta-
bilizer cylinder at the base of the cylinder barrel. Jack up
the cylinder just enough to relieve any pressure on the
cylinder retaining pin.
17.5° 5. Remove the cotter pins securing the cylinder retaining
10° pin and remove the cylinder retaining pin and cylinder
cap retaining bracket.

NOTE: Keep hydraulic fittings and hoses close to 6. Jack the stabilizer cylinder up just enough to insert the
angles shown and as low as possible to pre- retaining pin back into the cylinder. Insert the retaining
vent rubbing with the beam top plate and pin into the lugs on the cylinder and secure the pin in
side plate, and for proper tracking during place with the cotter pins.
beam extension and retraction.
FIGURE 8-26 CAUTION
2. Position the extension cylinder so the hydraulic ports on Use a nylon strap to remove the cylinder. This will ensure
the rod end of the cylinder can be accessed. Connect the retaining pin is not damaged.
the hydraulic hoses to the ports as tagged during
removal. 7. Fasten a nylon strap onto the cylinder retaining pin and
use an adequate lifting device to lift the stabilizer cylin-
3. Push the cylinder into the outrigger beam. Align the cyl- der out of the tube on the beam assembly.
inder rod with the clevis in the beam. Apply anti-seeze to

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RT890E3 SERVICE MANUAL UNDERCARRIAGE

Installation Checking Cylinder for Internal Piston Seal Leak

1. Apply grease (EPMPG) to the ID of the stabilizer cylin- 1. Fully extend and set the outriggers.
der support tube.
2. If removed, install wear ring in groove in bottom of sup-
port tube and in groove at top on stabilizer cylinder.
Piston Port
3. Place a jack beneath the cylinder tube on the outrigger
beam. Using the same method as described under Rod Port
REMOVAL, lower the stabilizer cylinder into the cylinder
tube on the outrigger beam until the retaining pin is just
above the tube. Position the jack so that it will support
the cylinder in this position. Remove the lifting device
from the cylinder.
4. Remove the retaining pin and cotter pins from the cylin-
der.
5. Lower the jack until the holes in the cylinder rod align
with the holes in the outrigger beam.
6. Apply anti-seeze compound to the retaining pin. Secure
the cylinder and cylinder cap retaining bracket to the
support tube with the retaining pin and cotter pins. 6432

7. Install the cylinder cap.

8. Install the fittings in the cylinder ports and connect the FIGURE 8-27
hoses as tagged during removal.
Functional Check CAUTION
1. Activate the hydraulic system. When performing step number 2, remove hose to adapter
connection slowly. Trapped pressure may exit between
2. Extend and retract the stabilizer cylinder.
the outrigger cylinder and the work port pilot operated
3. Check for smooth operation of the cylinder. check valves in the outrigger selector valve.
4. Check all hydraulic connections and hoses for evidence
2. Remove the rod side cylinder hose from the suspected
of leakage.
leaking stabilizer cylinder (see Figure 8-27). Oil will flow
Outrigger Stabilizer Cylinder Internal Leak Test until the cavity in the cylinder port block empties. Once
the port block cavity empties, oil should stop flowing
Use the following procedure to troubleshoot and diagnose an
from the rod side port.
internal leak, a leaking pilot operated check valve or a
thermal contraction on an outrigger stabilizer cylinder. Check for the following conditions:
a. If oil stops flowing, the cylinder’s internal piston seal
is sealing properly.

DANGER b. If oil continues to flow out the rod port, the cylinder’s
Perform the following procedures with the crane
internal piston seal is leaking. 8
positioned on a firm level surface with outriggers fully 3. After determining the condition of the cylinders internal
extended and set, and the crane in the travel position piston seal, let the rod side hose disconnected and con-
Remove hoses from one cylinder at a time. tinue to test the pilot operated check valve.

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UNDERCARRIAGE RT890E3 SERVICE MANUAL

Testing Pilot Operated Check Valve For Leakage outrigger portion of the valve consists of a 4-way two position
solenoid valve. The inlet section contains the main relief
1. Fully extend and set the outriggers.
valve.
Outrigger Control Manifold
CAUTION
The front and rear outrigger control manifolds are located
When performing step number 2, remove hose to adapter on the respective outrigger boxes. Each manifold consists of
connection slowly. Trapped pressure may exit between four 12 volt solenoid valves and an assembly mounting kit.
the outrigger cylinder and the work port pilot operated
check valves in the outrigger selector valve.
OPTIONAL EQUIPMENT
2. Remove the piston side cylinder hose from the sus-
pected leaking stabilizer cylinder (see Figure 8-27). Oil Description
will flow until the cavity in the cylinder port block empties. This section is provided to give a brief description of the
Once the port block cavity empties, oil should stop flow- optional equipment available for the crane which is not
ing from the piston side port. discussed elsewhere within this service manual.
a. If oil stops flowing, the cylinder’s pilot operated
check valve is sealing properly. Pintle Hook
b. If oil continues to flow out the piston port, the A conventional pintle hook with safety pinned latch can be
cylinder’s pilot operated check valve is leaking. installed on the front and/or back of the crane. It is bolted
onto a plate which is welded onto the front or rear outrigger
If oil flow is not noticed from either port, the cylinder and pilot boxes of the crane.
operated check valve are functioning properly, and any
cylinder contraction during normal operation can be Secondary Front Steer (CE Option)
attributed to thermal contraction of the oil.
A secondary front steering system for the CE option consists
Outrigger Control Valves of a hydraulic pump, load sense steer priority flow divider
valve (part of the swing directional control valve), load sense
Description steering control valve, two steer cylinders, dual accumulator
charge valve, pressure switches, pilot operated valve and
There are four valve assemblies responsible for controlling
two accumulators.
the outrigger system, the integrated outrigger/rear steer
valve, the front and rear outrigger control manifolds, and the The hydraulic pump is driven by the engine and supplies
pilot operated check valves. hydraulic flow to the load sense steering priority flow divider.
The load sense steer priority flow divider valve provides flow
NOTE: For a more detailed DESCRIPTION and MAINTE-
to the load sense steering control valve. When the steering
NANCE of the valves, refer to Valves, page 2-31.
wheel is turned, the load sense steering control valve sends
Pilot Operated Check Valve a load sense signal to the load sense steer priority flow
divider. As the load sense pressure increases, the priority
The pilot operated check valves are located in the outrigger flow divider spool shifts to direct oil from the hydraulic pump
stabilizer port blocks. The check valve provides two to the steering control valve, and to direct oil from the L port
functions; the first function is a holding valve, the second and R port of the steering control valve to the front steer
function provides a thermal relief of the stabilizer. cylinders.
Integrated Outrigger/Rear Steer Valve The two accumulators allow for emergency steering should
The integrated outrigger/rear steer valve is mounted on the there be a loss of hydraulic pressure.
rear face of the carrier frame front cross member. The

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RT890E3 SERVICE MANUAL LUBRICATION

SECTION 9
LUBRICATION

SECTION CONTENTS
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 Cab Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14
Environmental Protection . . . . . . . . . . . . . . . . . . . 9-1 Outriggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16
Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-18
Lubrication Intervals . . . . . . . . . . . . . . . . . . . . . . . 9-1
Boom (continued) . . . . . . . . . . . . . . . . . . . . . . . . 9-20
Arctic Conditions - Below -18°C (0°F). . . . . . . . . . 9-2
Boom (continued) . . . . . . . . . . . . . . . . . . . . . . . . 9-22
Arctic Conditions Down To -40°F.. . . . . . . . . . . . . 9-2
Hoist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-24
Surface Protection for Cylinder Rods . . . . . . . . . . 9-2
Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-26
Wire Rope Lubrication . . . . . . . . . . . . . . . . . . . . . . 9-3
Instructions for Accessing Lubrication Points
Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . 9-3 on Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-28
CraneLUBE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3 Carwell® Rust Inhibitor. . . . . . . . . . . . . . . . . . . . . 9-29
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3 Protecting Cranes From Rusting . . . . . . . . . . . . . 9-29
Steering and Suspension . . . . . . . . . . . . . . . . . . . 9-4 Cleaning Procedures . . . . . . . . . . . . . . . . . . . . . . 9-29
Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6 Inspection and Repair . . . . . . . . . . . . . . . . . . . . . 9-30
Drive Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8 Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-30
Drive Train (continued) . . . . . . . . . . . . . . . . . . . . 9-10 Areas of Application. . . . . . . . . . . . . . . . . . . . . . . 9-30
Turntable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12

GENERAL • Always fill or add fluids with a funnel or a filling pump.

Following the designated lubrication procedures is important • Immediately clean up any spills.
in ensuring maximum crane lifetime and utilization. The
procedures and lubrication charts in this section include LUBRICATION INTERVALS
information on the types of lubricants used, the location of
The service intervals specified are for normal operation
the lubrication points, the frequency of lubrication, and other
where moderate temperature, humidity, and atmospheric
information.
conditions prevail. In areas of extreme conditions, the
service periods and lubrication specifications should be
ENVIRONMENTAL PROTECTION altered to meet existing conditions. For information on
Dispose of waste properly! Improperly disposing of waste extreme condition lubrication, contract your local Manitowoc
can threaten the environment. distributor or Manitowoc Crane Care.

Potentially harmful waste used in Manitowoc cranes includes

— but is not limited to — oil, fuel, grease, coolant, air CAUTION
conditioning refrigerant, filters, batteries, and cloths which
Chassis grease lubricants must not be applied with air
have come into contact with these environmentally harmful
pressure devices as this lubricant is used on sealed
substances.
fittings.
Handle and dispose of waste according to local, state, and
federal environmental regulations.
When filling and draining crane components, observe the
CAUTION
9
following:
The multipurpose grease installed during manufacture is
• Do not pour waste fluids onto the ground, down any of a lithium base. Use of a noncompatible grease could
drain, or into any source of water. result in damage to equipment.
• Always drain waste fluids into leak proof containers that
are clearly marked with what they contain.

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LUBRICATION RT890E3 SERVICE MANUAL

Arctic Conditions - Below -18°C (0°F) Coolant-60/40; Fleetguard Compleat EG Antifreeze/Coolant

Premix 60/40; -- Spec 6829104212
In general, petroleum based fluids developed especially for
low temperature service may be used with satisfactory Supplemental Coolant Additive (SCA) – Fleetguard
results. However, certain fluids, such as halogenated DCA4; Fleetguard DCA2; Penray Pencool 3000; -- Spec
hydrocarbons, nitro hydrocarbons, and phosphate ester 6829012858
hydraulic fluids, might not be compatible with hydraulic
system seals and wear bands. If you are in doubt about the Standard Lubricants Package
suitability of a specific fluid, check with your authorized Axle and Swing Box -- Century Unigear Semi-synthetic
distributor or Manitowoc Crane Care. SAE 80W-90; Texaco Multigear SS 80W-90; Chevron DELO
NOTE: All fluids and lubricants may be purchased by 80W-90; -- Spec 6829012964
contacting the Manitowoc Crane Care Parts Engine -- CI-4 Rated 15W-40 Engine Oil Exxon XD-3;
Department. Conoco Fleet Supreme; -- Spec 6829003483
Regardless of temperature and oil viscosity, always use Hydraulic Tank and Transmission -- To meet John Deere
suitable start-up procedures to ensure adequate lubrication Standard JDM J20C – Hyden 052-10W-20; Exxon Torque
during system warm-up. Fluid 56- 10W-20; Esso Torque Fluid 56- 10W-20; BP-
Eldoran UTH & Trak-Tran 9 – 10W20; BP- Blend- 7367 -
Arctic Conditions Down To -40°F. 10W20; Exxon Mobil 424- 10W-30 -- Spec 6829006444
All Weather Package & Lubricants Hoist -- AGMA No. 4 EP Extreme Pressure Gear Lube-
Mobil: Mobilfluid 629; Texaco: Meropa 150; -- Spec
Engineering recommends the following lubricants for 6829100213
components for ambient temperatures to -40F. Special
lubricants alone are not sufficient to operate at extreme low Grease -- EP-MPG- Multipurpose Grease – Citgo Lithoplex
temperatures. We also re commend the use of appropriately MP # 2; Texaco Starplex Moly # 2; Phillips 66 Philube M
sized heaters for the hydraulic tank, engine oil pan, engine Grease; Mobil Mobilgrese XHP 222 Special, # 53055-0;
jacket water and batteries. The operator needs to follow the Chemtool Inc, Lube-A-Boom-Grease; -- Spec 6829003477
guide lines as stated in the operator’s manual. We assume Open Gear Lube -- (bearing / swingdrive teeth -- FUCHS:
that the customer has take steps for use of an appropriate CEPLATTYN 300 SPRAY -- Spec 6829102971
engine antifreeze coolant, have taken care of the fuel, fuel
system and starting system. And has done whatever they Antifreeze Coolant -- AFC – 50/50 Old World Industries,
feel necessary to add insulation for under hood temperatures Inc. Fleet Charge SCA Pre-charged Antifreeze/Coolant;
and meet the engine manufacture's intake air temperature. Caterpillar DEAC Antifreeze/Coolant; Fleetguard Complete
Other lubricants may be used if they meet the specification of EG Antifreeze/Coolant; -- Spec 6829101130
the lubricant that is requested. Please consult factory. Supplemental Coolant Additive (SCA) – Fleetguard
Axles and Swing Box -- Petro- Canada Traxon E Synthetic DCA4; Fleetguard DCA2; Penray Pencool 3000; -- Spec
75W-90; CITGO, Synthetic Gear Lube 75W-90; Eaton, 6829012858
Roadranger EP75W-90; Mobil, Mobilube SCH 75W-90;
Shell, Spirax S 75W-90; Sunoco Duragear EP75W-90; -- Surface Protection for Cylinder Rods
Spec 6829014058 Steel cylinder rods include a thin layer of chrome plating on
Engine -- Petro-Canada Duron Synthetic CI-4- 5W-40; Mobil their surfaces to protect them from corroding. However,
Delvac 1, 5W-40; -- Spec 6829101560 chrome plating inherently has cracks in its structure which
can allow moisture to corrode the underlying steel. At typical
Hydraulic tank and Transmission -- Petro-Canada ambient temperatures, hydraulic oil is too thick to penetrate
Duratran Synthetic THF; Chevron All Weather THF; Texaco these cracks. Normal machine operating temperatures will
TDH Oil SS; -- Spec 6829101559 allow hydraulic oil to warm sufficiently to penetrate these
Hoist -- Petro-Canada ENDURATEX Synthetic EP 150; cracks and if machines are operated daily, protect the rods.
Mobil SHC629; -- Spec 6829103636 Machines that are stored, transported, or used in a corrosive
environment (high moisture, rain, snow, or coastline
Grease -- Petro-Canada Precision Synthetic EP1; Mobil: conditions) need to have the exposed rods protected more
Mobilith SHC 220; -- Spec 6829104275 frequently by applying a protectant. Unless the machine is
Open Gear Lube -- (bearing/swingdrive teeth) ---Vultrex.... operated daily, exposed rod surfaces will corrode. Some
OGL Synthetic All Season -- No Spec cylinders will have rods exposed even when completely
retracted. Assume all cylinders have exposed rods, as
Antifreeze Coolant -- Petro-Canada AFC 60/40; Old World corrosion on the end of the rod can ruin the cylinder.
Industries, Inc Fleet Charge SCA Pre-charged Antifreeze/

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RT890E3 SERVICE MANUAL LUBRICATION

It is recommended that all exposed cylinder rods be extruding from the fitting. One ounce(28 grams) of EP-MPG
protected using Boeshield® T-9 Premium Metal Protectant. equals one pump on a standard one pound (0.45 kg) grease
Manitowoc Crane Care has Boeshield® T-9 Premium Metal gun.
Protectant available in 12 oz. cans by ordering part number
Over lubrication on non-sealed fittings will not harm the
9999101803 through the Manitowoc Crane Care Parts
fittings or components, but under lubrication will definitely
Department.
lead to a shorter lifetime.
NOTE: Cylinder operation and inclement weather will
On sealed U-joints, care must be exercised to prevent
remove the Boeshield® protectant; therefore,
rupturing seals. Fill only until expansion of the seals first
inspect machines once a week and reapply
becomes visible.
Boeshield® to unprotected rods.
Unless otherwise indicated, items not equipped with grease
WIRE ROPE LUBRICATION fittings, such as linkages, pins, levers, etc., should be
lubricated with oil once a week. Motor oil, applied sparingly,
Wire rope is lubricated during manufacturing so that the will provide the necessary lubrication and help prevent the
strands, and individual wires in strands, may move as the formation of rust. An Anti-Seize compound may be used if
rope moves and bends. A wire rope cannot be lubricated rust has not formed, otherwise the component must be
sufficiently during manufacture to last its entire life. cleaned first.
Therefore, new lubricant must be added periodically
throughout the life of a rope to replace factory lubricant which Grease fittings that are worn and will not hold the grease
is used or lost. For more detailed information concerning the gun, or those that have a stuck check ball, must be replaced.
lubrication and inspection of wire rope, refer to WIRE ROPE Where wear pads are used, cycle the components and
in Section 1- INTRODUCTION in the Service Manual. relubricate to ensure complete lubrication of the entire wear
area.
LUBRICATION POINTS
CraneLUBE
A regular frequency of lubrication must be established for all
lubrication points. Normally, this is based on component Manitowoc highly recommends the use of CraneLUBE
operating time. The most efficient method of keeping track of l u b r i c a n ts t o i n c r e a s e y o u r c r a n e ’s r e l i a b i l i t y a n d
lube requirements is to maintain a job log indicating crane performance. Contact your Manitowoc Distributor for
usage. The log must use the engine hourmeter to ensure information about the Manitowoc’s CraneLUBE lubrication
coverage of lube points that will receive attention based on program.
their readings. Other lubrication requirements must be made
on a time basis, i.e. weekly, monthly, etc. Safety
All oil levels are to be checked with the crane parked on a To lubricate many of the locations the engine will need to be
level surface in transport position, tires on the ground, and started. After positioning areas of the unit for lubrication the
the suspension set at the proper ride height. engine must be turned off and the moved areas stable before
approaching.
Lubrication checks must be performed while the oil is cool
and has not been operated within the past 30 minutes,
unless otherwise specified.
On plug type check points, the oil levels are to be at the WARNING
bottom edge of the fill plug hole.
Movement of the superstructure and the boom may
On all hoists with a check plug in the drum, the fill plug shall create a crushing and/or pinching hazard. Failure to
be directly on top of the hoist, and the check plug level. observe this warning could result in death or serious injury
if the message is ignored.
All grease fittings are SAE STANDARD unless otherwise
indicated. Grease non-sealed fittings until grease is seen

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LUBRICATION RT890E3 SERVICE MANUAL

Steering and Suspension

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

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RT890E3 SERVICE MANUAL LUBRICATION

1
5 7061-4
2
7061-22

6265-1

1 7061-7
9
7061-10
3

FIGURE 9-1

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LUBRICATION RT890E3 SERVICE MANUAL

Lube Point Figure Approved Lube

Item Lube Interval Application
Description No. Lubricant Capacity
Axles
• Check level every
GL-5 500 hours or 3
Extended months Fill to bottom of hole
29.8 liters
11 Differentials Figure 9-2 Service Interval in housing on the
62.9 pints • Drain and fill every
Gear Lubricant steer cylinder side
A6-829-012964 4000 hours or 2
years
NOTE: Lube level close enough to the hole to be seen or touched is not sufficient. It must be level with the hole.
When checking lube level, also check and clean housing breathers.
CAUTION: Use of non-approved lubricant may damage components and/or invalidate published lubricant intervals.
CAUTION: If the makeup amount is substantially more than 0.23 liter (0.5 pint), check for leaks.
• Check level every
GL-5 500 hours or 3 Fill to the bottom of
Planetary Hubs Extended months the level hole in the
5.2 liters
12 and Wheel Figure 9-2 Service Interval housing with the fill
10.9 pints • Drain and fill every
Bearings Gear Lubricant plug and the oil level
A6-829-012964 4000 hours or 2 mark horizontal.
years
CAUTION: Use of non-approved lubricant may damage components and/or invalidate published lubricant intervals.

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RT890E3 SERVICE MANUAL LUBRICATION

11
7061-7

12 7061-22

6265-1

FIGURE 9-2

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LUBRICATION RT890E3 SERVICE MANUAL

Lube Point Figure Approved Lube

Item Lube Interval Application
Description No. Lubricant Capacity
Drive Train
• Through fill pipe
EO-15W/40 • Check level every 10
20a a. Engine to FULL mark on
Engine Oil 20 liters hours or daily
Crankcase Figure 9-3 dipstick
SAE 15W-40 21.1 quarts • Drain, fill and replace
20b b. Filter • Filter located
A6-829-003483 filter every 250 hours
under radiator
• Check level every 10
hours or daily
• Drain and refill every
a. Transmission, 1000 hours or 6
21a HYDO Through fill pipe to
Torque 37.9 liters months
Figure 9-3 Hydraulic Oil FULL mark on
Converter 40 quarts • Change transmission
21b A6-829-006444 dipstick
b. Filter filter after first 50 and
100 hours of service,
then every 500 hours
thereafter
NOTE:
• Check fluid level with engine running at 1000 rpm idle and the oil at 82 to 93° C (150 to 200 ° F). Do not attempt an oil level check
with cold oil. To bring the oil temperature to this range, it is necessary to either work the crane or stall the converter. Converter
stall should be accomplished by engaging shift lever in forward high range with the brakes applied and then accelerating the
engine to half or three-quarter throttle. Hold the stall until the required converter temperature is reached and stabilized.
Do not operate the converter at stall condition for longer than 30 seconds at one time. Shift to neutral for 15 seconds and repeat
the procedure until the desired temperature is reached. Excessive temperature, i.e, 120° C (250° F) maximum will cause damage
to transmission clutches, fluid, converter and seals.
• Drain and fill with the oil at 65 to 93° C (150 to 200° F).
• Transmission filters are located on the outside left hand frame in the area of the hydraulic oil cooler.
• Do not operate the machine in two wheel drive while the machine is up on outriggers. Serious transmission damage could result.
• To add fluid:
a. Fill to FULL mark on dipstick
b. Run engine at 1000 rpm to prime torque converter and lines
c. Check oil level with engine running at 1000 rpm and oil at 82 to 93° C (180 to 200° F). Add oil to bring oil level to
FULL mark on dipstick.
AFC 50/50 • Fill surge tank to
• Check coolant level
50/50 Blended bottom of filler
every 10 hours or
Fully neck.
a. Engine daily
22a Formulated • Run engine
Cooling System Antifreeze 36 liters • Change filter every
Figure 9-3 through two (2)
and SCA Levels Coolant 38 quarts 500 hours
22b thermal cycles.
b. Coolant Filter A6-829-101130 • Check coolant for
• Check coolant
SCA contamination every
level and refill as
6829012858 1000 hours
required.

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RT890E3 SERVICE MANUAL LUBRICATION

21b 7116-5

22 7061-45

6265-1

21a 7061-36

20b
7116-4
9

20a 7061-27

FIGURE 9-3

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LUBRICATION RT890E3 SERVICE MANUAL

Lube Point Figure Approved Lube

Item Lube Interval Application
Description No. Lubricant Capacity
Drive Train (continued)
Clean strainer screen
Close shutoff valves.
Coolant Strainer after first 100 hours and
23 Figure 9-4 --- --- Unscrew hex plug to
(Cab Heater) every 2000 hours or 12
clean filter.
months thereafter.
• Replace filter
Remove panel
element when
behind ladder to
indicator shows red
access air filter.
24 Air Cleaner Filter Figure 9-4 --- --- (25” H20).
• View indicator
Refer to Service
through grill from rear
Manual
of crane.
• Drain water trap
every 10 hours or
daily. Fuel filter is located
25 Fuel Filter Figure 9-4 --- --- on the intake
• Change filter every manifold of engine.
500 hours or 6
months.
Fuel Water Drain water trap every
25a Figure 9-4 --- --- Beside the fuel tank
Separator 10 hours or daily
EP-MPG
Extreme
Until
Driveline - Slip Pressure
26 Figure 9-4 grease 500 hours or 3 months 2 grease fittings
Joints Multipurpose
extrudes
Grease
A6-829-003477

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RT890E3 SERVICE MANUAL LUBRICATION

23

7061-37 7116-7
26 24

Other Side
26
7116-9

6265-1

25a 7116-5

9
25 7061-27

FIGURE 9-4

GROVE Published 07-24-2013, Control # 069-12 9-11

LUBRICATION RT890E3 SERVICE MANUAL

Lube Point Figure Approved Lube

Item Lube Interval Application
Description No. Lubricant Capacity
Turntable
• Check and fill every
GL-5 50 hours
Extended
Turntable Gear 5.4 liters • Drain and fill after
30 Figure 9-5 Service Interval Full mark on dipstick
Box 5.7 quarts first 250 hours and
Gear Lubricant
A6-829-012964 every 500 hours or
12 months thereafter.
EP-OGL
Turntable Gear Open Gear Coat all
31 Figure 9-5 500 hours or 6 months Spray on
and Drive Pinion Lubricant teeth
A6-829-102971
Until
EP-MPG
grease
Extreme
extrudes 2 grease fittings at
Turntable Pressure
32 Figure 9-5 the whole 500 hours or 6 months the side of the
Bearing Multipurpose
circumfer- turntable.
Grease
ence of the
A6-829-003477
bearing
EP-OGL 500 hours or 6 months,
Not Open Gear whichever interval
32a Swivel Lock Pin Coat pin Spray on
Shown Lubricant occurs first
6829102971
NOTE: Rotate the turntable 90° and apply grease to fittings. Continue rotating 90° and grease the fittings until the whole
bearing is greased.
EP-MPG
Extreme
Until
Pressure
34 Hose Rollers Figure 9-5 grease 250 hours or 3months 2 grease fittings
Multipurpose
extrudes
Grease
A6-829-003477

9-12 Published 07-24-2013, Control # 069-12

RT890E3 SERVICE MANUAL LUBRICATION

30

32 7061-25

7061-24
31

6265-2

34

9
7116-3

FIGURE 9-5

GROVE Published 07-24-2013, Control # 069-12 9-13

LUBRICATION RT890E3 SERVICE MANUAL

Lube Point Figure Approved Lube

Item Lube Interval Application
Description No. Lubricant Capacity
Cab Tilt
EP-MPG
Extreme
Until
Cab Tilt Cylinder Pressure
40 Figure 9-6 Grease 500 hours or 3 months 2 grease fittings
Pivot Pins Multipurpose
extrudes
Grease
A6-829-003477
EP-MPG
Extreme
Until
Pressure
41 Pillow Block Figure 9-6 grease 500 hours or 3 months 2 grease fittings
Multipurpose
extrude
Grease
A6-829-003477

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RT890E3 SERVICE MANUAL LUBRICATION

40 7061-18

41 7061-47

6265-1

FIGURE 9-6

GROVE Published 07-24-2013, Control # 069-12 9-15

LUBRICATION RT890E3 SERVICE MANUAL

Lube Point Figure Approved Lube

Item Lube Interval Application
Description No. Lubricant Capacity
Outriggers
EP-MPG
Extreme
Brush lubricant on
Pressure
50 Outrigger Beams Figure 9-7 --- 50 hours or 1 week bottom of outrigger
Multipurpose
beams
Grease
A6-829-003477
EP-MPG Brush lubricant on
Extreme ID of jack cylinder
Jack Cylinder Pressure support tubes (4)
51 Figure 9-7 --- 50 hours or 1 week
Support Tubes Multipurpose places before
Grease installing jack
A6-829-003477 cylinders
EP-MPG Brush lubricant on
Extreme ID of jack cylinder
Jack Cylinder Pressure support tubes (4)
52 Figure 9-7 --- 50 hours or 1 week
Barrels Multipurpose places before
Grease installing jack
A6-829-003477 cylinders

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RT890E3 SERVICE MANUAL LUBRICATION

6265-1

51

50

52

9
7061-57

FIGURE 9-7

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LUBRICATION RT890E3 SERVICE MANUAL

Lube Point Figure Approved Lube

Item Lube Interval Application
Description No. Lubricant Capacity
Boom
EP-MPG
Extreme Pressure Until
Hook Block
70 Figure 9-8 Multipurpose grease 250 hours or 3 months 1 grease fitting
Swivel Bearing Grease extrudes
A6-829-003477
EP-MPG
Extreme Pressure Until 1 grease fitting per
Hook Block
71 Figure 9-8 Multipurpose grease 250 hours or 3 months sheave (5 fittings
Sheaves Grease extrudes total)
A6-829-003477
EP-MPG
Extreme Pressure Until
72 Headache Ball Figure 9-8 Multipurpose grease 250 hours or 3 months 1 grease fitting
Grease extrudes
A6-829-003477
EP-MPG
Telescope Extreme Pressure 5 places by brush.
Thoroughly
73 Cylinder Wear Figure 9-8 Multipurpose Every boom teardown Extend boom for
Grease coat
Pads access through holes.
A6-829-003477

! WARNING
Crane Setup for Items 74 - 78: Crane to be set up on firm level surface with fully extended outriggers and 22,000 lbs
counterweight installed. Ensure crane is level. Boom must be directly over the front and the house lock engaged. Set boom
angle at zero degrees. Do not exceed 115 foot boom length in auto mode A. Do not exceed 90 Foot boom length in auto
mode B. All lubrication points can be accessed by operating the crane in the 0001 RCL operating mode by using both A & B
boom configurations. Do NOT operate the crane in the RCL bypass to lubricate the boom.

EP-MPG Thoroughly
Internal Side and 14 places by brush;
Extreme Pressure coat all
Bottom Wear with boom in
74 Figure 9-8 Multipurpose areas the 250 hours or 3 months
Pads (Inner Grease
extended position
wear pad
Sections) A6-829-003477 through access holes
moves on
NOTE:

! WARNING
See Table 9-1, page 9-28 at the end of this sections for how to access lubrication points 74 - 78
EP-MPG 8 grease fittings; with
Boom Section Extreme Pressure Until
boom in extended
75 Upper Wear Figure 9-8 Multipurpose grease 50 hours or 1 week
Grease
position through
Pads extrudes
A6-829-003477 access holes

EP-MPG Thoroughly
Boom Section Extreme Pressure coat all 12 places by brush;
76 Upper and Lower Figure 9-8 Multipurpose areas the 50 hours or 1 week with boom in
Wear Pads Grease wear pad extended position
A6-829-003477 moves on

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RT890E3 SERVICE MANUAL LUBRICATION

73
72
73
75 74
75

7061-66

73
73
77
71

74 7136-3

70

7116-6

7136-1

6265-1

75
76
75

75

75

74

74

74
9
7061-43 74 7136-2

FIGURE 9-8

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LUBRICATION RT890E3 SERVICE MANUAL

Lube Point Figure Approved Lube

Item Lube Interval Application
Description No. Lubricant Capacity
Boom (continued)
EP-MPG
Extreme Pressure Until 1 grease fitting. See
Extend Cable
77 Figure 9-8 Multipurpose grease 250 hours or 3 months “Warnings” on
Sheaves Grease extrudes previous page
A6-829-003477
EP-MPG 2 grease fittings
Extreme Pressure Until
Retract Cable (1) on each side.
78 Figure 9-9 Multipurpose grease 250 hours or 3 months
Sheaves Grease
See “Warnings” on
extrudes
A6-829-003477 previous page
EP-MPG
Extreme Pressure Until
2 grease fittings
79 Boom Pivot Shaft Figure 9-9 Multipurpose grease 250 hours or 3 months
Grease
(1) on each side
extrudes
A6-829-003477
EP-MPG
Extreme Pressure Until
Upper Boom 2 grease fittings
80 Figure 9-9 Multipurpose grease 250 hours or 3 months
Nose Sheave Grease (1) per sheave
extrudes
A6-829-003477

EP-MPG
Extreme
Until 1 grease fitting per
Lower Boom Pressure
81 Figure 9-9 grease 250 hours or 3 months sheave (5 sheaves)
Nose Sheave Multipurpose
extrudes total
Grease
A6-829-003477
EP-MPG
Extreme
Until
Pressure
82 Hose Rollers Figure 9-9 grease 250 hours or 3 months 4 grease fittings
Multipurpose
extrudes
Grease
A6-829-003477
EP-MPG
Extreme
Until
Auxiliary Boom Pressure
83 Figure 9-9 grease 250 hours or 3 months 1 grease fitting
Nose Sheave Multipurpose
extrudes
Grease
A6-829-003477
EP-MPG
Extreme
Until
Pressure 500 hours or 12
84 Mast Sheave Figure 9-9 grease 1 grease fitting
Multipurpose months
extrudes
Grease
A6-829-003477
EP-MPG
Extreme
Until
Boom Extension Pressure
85 Figure 9-9 grease 250 hours or 3 months 2 grease fittings
Sheaves Multipurpose
extrudes
Grease
A6-829-003477

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RT890E3 SERVICE MANUAL LUBRICATION

80

7116-1

81
83

79 7061-49

7061-1

78
7136-2
9
82 7116-2

FIGURE 9-9

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LUBRICATION RT890E3 SERVICE MANUAL

Lube Point Approved Lube

Item Figure No. Lube Interval Application
Description Lubricant Capacity
Boom (continued)
EP-MPG
Extreme
Until
Pressure 500 hours or 12
84 Mast Sheave Figure 9-10 grease 1 grease fitting
Multipurpose months
extrudes
Grease
A6-829-003477
EP-MPG
Extreme
Until
Boom Extension Pressure 250 hours or 3
85 Figure 9-10 grease 2 grease fittings
Sheaves Multipurpose months
extrudes
Grease
A6-829-003477

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RT890E3 SERVICE MANUAL LUBRICATION

6265-2

6265-3

85

84

85

9
7061-61 7116-8

FIGURE 9-10

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LUBRICATION RT890E3 SERVICE MANUAL

Lube Point Approved Lube

Item Figure No. Lube Interval Application
Description Lubricant Capacity
Hoist
NOTE: Proper positioning of rotating drum ensures that the cable pocket is above the oil level. If the cable
pocket is below the oil fill level it will cause the oil level to rise, causing an inaccurate reading.
AGMA • Check and fill every Oil level must be
Extreme 14.7 liters 50 hours or weekly visible in the sight
90 Main Hoist Figure 9-11 Pressure Gear (15.5 • Drain and fill every glass. (See note)
Lubricant quarts) 1000 hours or 12 Remove hose at top
A6-829-100213 months of sight gauge. Fill
hoist through hose
AGMA • Check and fill every until fluid is at full
Extreme 14.7 liters 50 hours or weekly mark on sight
91 Auxiliary Hoist Figure 9-11 Pressure Gear (15.5 • Drain and fill every gauge.Variations in
Lubricant quarts) 1000 hours or 12 oil temperature will
A6-829-100213 months cause oil level to
fluctuate.
NOTE: To check hoist oil, ensure hoist is level and the fill plug is horizontal and centered in access hole at the 9:00
position. The oil must have settled for 20 minutes with the temperature in 70°F +/- 20°F range.
If oil level is not visible in sight glass, the hoist may be underfilled. Oil escaping from vent plug is an indication the
hoist may be overfilled.
EP-MPG
Extreme
Cable Follower Pressure Thoroughly
92 Figure 9-11 250 hours or 3 months Spray on
(Arms) Multipurpose coat
Grease
A6-829-003477
NOTE: Lubricate more frequently than interval indicated in table if environmental conditions and/or operating conditions
necessitate.

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RT890E3 SERVICE MANUAL LUBRICATION

91 92 90 92

A B A B 7116-10

6265-1

FIGURE 9-11

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LUBRICATION RT890E3 SERVICE MANUAL

Lube Point Approved Lube

Item Figure No. Lube Interval Application
Description Lubricant Capacity
Hydraulic
• Use sight gauge
on side of tank,
HYDO 894 liters Check fluid level with boom down
100 Hydraulic Tank Figure 9-12 Hydraulic Oil (236 every 10 hours or and all outrigger
A6-829-006444 gallons) daily. cylinders retracted.
• Drain and refill as
necessary
NOTE:
• Environmental and other conditions can dramatically affect the condition of hydraulic oil and filters. Therefore,
specific intervals for servicing/changing hydraulic oil, filters and hydraulic tank breathers cannot be set.
However, it is imperative for the continued satisfactory performance of cranes that inspections be performed
on the basis of how and where each crane is used. Air borne and ingested contaminants can significantly
reduce the life of oil and the condition of hydraulic oil filters and tank breathers.
• Under normal operating conditions, it is recommended that hydraulic oil, filters and breathers be inspected
and oils sampled at least every 3 to 6 months and more frequently for severe operating conditions. The
inspections should be for air borne and/or ingested particles and water that deteriorate and contaminate the
oil (e.g., oil appears “milky” or no longer has a transparent clear to amber color). The return filter by-pass
indicator should be observed daily to determine if the contaminants content may be high. If the indicator
reaches the red zone or indicates a by-pass condition, the hydraulic oil must be sampled. The hydraulic tank
breather should also be inspected to assure that it is not restricting air flow into and out of the reservoir.
• To inspect hydraulic oil, fill a small glass container with a sample of reservoir oil and another glass container
with fresh oil. Let the samples stand, undisturbed, for one to two hours and then compare the samples. If the
reservoir oil is heavily contaminated with water the sample will appear "milky" with only a small layer of
transparent oil on top. If the "milky” appearance was due to air foaming, it will dissipate and the oil should
closely match the fresh oil. Should you have any questions, please contact your local authorized Manitowoc
distibutor.
• The hydraulic oil shall meet of exceed ISO #4406 class 17/14 cleanliness level.
HYDO
Change filter when
101 Hydraulic Filter Figure 9-12 Hydraulic Oil --- ---
the indicator is red
A6-829-006444
EP-MPG
Extreme
Until
Hose Reel Pressure 500 hours or 6
102 Figure 9-12 grease 3 Grease fittings
Swivel Joint Multipurpose months
extrudes
Grease
A6-829-003477

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RT890E3 SERVICE MANUAL LUBRICATION

102

102 7117-41

6265-2

101

100 7061-29 FIGURE 9-12

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LUBRICATION RT890E3 SERVICE MANUAL

Table 9-1Accessing Lubrication Points on Boom

Boom
Boom
Item Boom Section Access Location Length (ft)
Mode
(+/-.2 ft)
74 Inner Large hole in center & outer mid A 94.6
74 Inner Large hole in inner mid B 81.2
Multiple
75 Outer mid & fly Small holes on the sides A
Lengths
Multiple
75 Inner mid Small holes on the sides B
Lengths
Multiple
75 Center mid Small holes on the sides B
Lengths
76 Center, outer mid & fly External on the boom A 114
76 Inner mid External on the boom B 83.3
77 Extend cable sheaves Small hole left side on the front of the outer mid A 79.7
78 Retract cable sheaves Small holes at the middle of the center mid A 98.3

Instructions for Accessing Lubrication

Points on Boom
1. Use the above Table and the information on the pages
that contain the items noted.

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RT890E3 SERVICE MANUAL LUBRICATION

CARWELL® RUST INHIBITOR

Protecting Cranes From Rusting While the surfaces of the crane that are easily seen have the
biggest impact on the appearance of the crane, particular
Manitowoc Crane Group's cranes are manufactured to high attention should be given to the undercarriage of the crane to
quality standards, including the type of paint finish minimize the harmful effects of corrosion.
demanded by today's industry. In partnership with our paint
supplier, we are also doing our part to help prevent Exercise special care and increase the frequency of cleaning
premature corrosion of cranes. if the crane is operated:

Grove cranes will be treated with a rust inhibitor called • on roads where large quantities of salt or calcium are
Carwell® T32-CP-90. While a rust inhibitor cannot guarantee applied to treat icy and snowy road surfaces;
that a machine will never rust, this product will help protect • in areas that use dust control chemicals;
against corrosion on Grove cranes that are treated with this
• anywhere there are increased levels of wetness -
product.
especially near salt water;
Carwell is a treatment, not a coating. It contains no silicones,
• during prolonged periods of exposure to damp
solvents, CFCs or anything that would be classified as
conditions (e.g., moisture held in mud), where certain
hazardous under OSHA Regulation 29CRF-19-10.1200. The
crane parts may become corroded even though other
product is a liquid blend of petroleum derivatives, rust
parts remain dry; or
inhibitors, water-repelling and water-displacing agents.
• in high humidity, or when temperatures are just above
Special equipment is used to spray a light film onto the entire
the freezing point.
undercarriage and various other areas of each new crane
prior to shipment. When applied the product has a red tint to
Cleaning Procedures
allow applicators to view coverage during application. This
red tint will turn clear on its own within approximately 24 To help protect against corrosion of Grove cranes,
hours after application. Manitowoc Crane Care recommends washing the crane at
least monthly to remove all foreign matter. More frequent
Once applied, treatment can appear to leave a slightly "oily"
changeling may be needed when operating in harsh
residue on painted surfaces and until the red tinting fades
environmental conditions. To clean the crane, follow these
could initially be mistaken for a hydraulic oil leak. While the
guidelines:
product is not harmful to painted surfaces, glass, plastic or
rubber, it must be removed using standard steam-cleaning • High pressure water or steam is effective for cleaning
techniques. the crane's undercarriage and wheel housings. Keeping
these areas clean will not only help retard the effects of
This treatment works in various ways: (1) it eliminates the
corrosion, but will also improve the ability to identify
moisture containing salt, dirt and other pollutants by lifting
and removing them from the metal surface; (2) the film potential issues before they grow into larger problems.
creates a barrier to repel further moisture from coming in
contact with the metal; and (3) it penetrates crevices.
In addition to the factory-applied treatment, Grove crane CAUTION
owners must provide proper maintenance and care to help High pressure water can be forced into spaces and
ensure long-term protection of their crane against corrosion. infiltrate beyond seals. Avoid pressure washing in the
This procedure provides information and guidelines to help vicinity of electrical controls, panels, wiring, sensors,
maintain the paint finish on Grove cranes. hydraulic hoses and fittings, or anything that can be
damaged by high pressure cleaning/spraying.
The most common causes of corrosion include the following:
• Road salts, chemicals, dirt, and moisture trapped in the • Rinse the dirt and dust off before washing the crane. Dirt
hard-to-reach areas; can scratch the crane's finish during washing/cleaning.

• Chipping or wear of paint, cased by minor incidents or • Hard to clean spots caused by road tar or bugs should
moving components; be treated and cleaned after rinsing and prior to
washing. Do not use solvents or gasoline.
9
• Damage caused by personal abuse, such as using the
decks to transport rigging gear, tools, or cribbing; and • Wash using only soaps and detergents recommended
for automotive paint finishes.
• Exposure to harsh environmental hazards such as
alkaline, acids, or other chemicals that can attack the • Rinse all surfaces thoroughly to prevent streaking
crane's paint finish. caused by soap residue.

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LUBRICATION RT890E3 SERVICE MANUAL

• Allow the crane to dry thoroughly. You can accelerate Spots should be touched up with quality paint. Primers tend
drying by using compressed air to remove excess water. to be porous; using a single coat of primer only will allow air
and water to penetrate the repair over time.
NOTE: Polishing and waxing (using an automotive-type
wax) is recommended to maintain the original paint Application
finish.
Depending upon the environment in which a crane is used
Inspection and Repair and/or stored, the initial factory application of Carwell T32-
CP-90 should help inhibit corrosion for up to approximately
• Immediately following cleaning, Manitowoc Crane Care
12 months.
recommends an inspection to detect areas that may
have become damaged by stone chips or minor It is recommended that the treatment be periodically
mishaps. A minor scratch (one that has not penetrated reapplied by the crane owner after that time to help continue
to the substrate surface) can be buffed with an to protect against corrosion of the crane and its components.
automotive-type scratch remover. It is recommended
However, if a crane is used and/or stored in harsh
that a good coat of automotive wax be applied to this
environments (such as islands, coastal regions, industrial
area afterwards.
areas, areas where winter road salt is regularly used, etc.),
• All identified spots and/or areas that have been reapplication of treatment is recommended sooner than 12
scratched through to the metal should be touched up months, e.g., repeat treatment in 6-9 months.
and repaired as soon as possible to prevent flash
• Do not apply to recently primered and painted areas for
rusting. To repair a major scratch (down to bare metal) or
at least 48 hours after paint is properly dried and cured.
minor damage, follow these procedures:
For minor touch up areas a 24 hour period is needed for
NOTE: Manitowoc Crane Care recommends that a cure time before applying treatment.
qualified body repairman prepare, prime and paint
NOTE: Unit must be completely dry before applying
any major scratch(es) or minor damage. treatment.
• Do not allow product to puddle or build-up on weather
stripping, rubber gaskets, etc. Unit should not have
CAUTION puddles or runs evident anywhere.
To the extent any damage is structural in nature,
Manitowoc Crane Care must be contacted and consulted • To ensure proper coverage of treatment, the product
as to what repairs may be required. needs to be fogged on the unit.
• Use of pressure pots to apply the treatment to the unit
• For scratches and marks in highly visible areas: being processed is recommended.
• Sand to remove the scratch and feather outward from • Carwell treatment is available in 16 ounce spray bottles
the mark to blend the repair into the original surface. from Manitowoc Crane Care (order part number
Body putty may be applied as necessary to hide the 8898904099).
defect; then sand smooth.
• After application of the treatment is complete, wash or
• Cover all bare metal with a primer that is compatible with clean film residue from lights, windshield, grab handles,
the original paint finish ladders/steps and all access areas to crane, as
• and allow to dry thoroughly. necessary.

• Prepare the surface prior to applying the finish coat of Please contact Manitowoc Crane Care should you have any
paint. questions.

• Apply a finish coat paint using accepted blending Areas of Application

techniques. Use of original paint colors is recommended
to insure the best color match possible. Refer to Figure 9-13 and Figure 9-14.

For scratches and marks in areas of low visibility: • The underside of the unit will have full coverage of the
rust inhibitor. These are the only areas that a full coat of
• Consider touching up the spots with a brush technique the rust inhibitor is acceptable on the painted surfaces.
to cover the bare metal. This will retard the effects of Areas include; Valves, hose end and fittings, Swivel,
corrosion and enable you to do the repair at a later time pumps, axles, drive lines, transmission, slew ring
during a normal maintenance interval. fasteners and all interior surfaces of the frame.

9-30 Published 07-24-2013, Control # 069-12

RT890E3 SERVICE MANUAL LUBRICATION

• Frame application areas are; hose ends and fittings, all • Boom applications areas are; pivot pins, hose end and
unpainted fasteners and hardware, all bare metal fittings, jib pins and shafts, all bare metal surfaces,
surfaces, outrigger pads, and back up alarm hardware. headache ball pins/ hook block pins and fasteners.
• Superstructure applications are; hose end and fittings, • All hardware, clips, pins, hose connections not painted
wire rope on hoist roller tensioning springs on hoists, all will have treatment applied.
unpainted fasteners and hardware, valves, slew ring
fasteners and all bare metal surfaces.

1
4

8
16

15
9
8

7650-15 14 13 12 11 10 Figure 9-13

GROVE Published 07-24-2013, Control # 069-12 9-31

LUBRICATION RT890E3 SERVICE MANUAL

17

1
18

19

20

12

10

5 22 13 21 5 11

7650-16
Figure 9-14

9-32 Published 07-24-2013, Control # 069-12

RT890E3 SERVICE MANUAL LUBRICATION

Item Description
Item Description 12 Mirror Mounting Hardware
1 Pivot Shaft 13 Entire underside of unit
2 Boom Extension Pins, Clips 14 Valve Bank
3 Boom Nose Pins, Clips 15 Counterweight Mounting Hardware
4 Boom Extension Hanger Hardware 16 Hoist Hose Connections
All Hardware, Clips, Pins, Hose Connections 17 Counterweight Cylinder Pins
5
not painted O/R Pins, Clips 18 Counterweight Cylinder Hose Connections
6 Hose Connections inside turntable 19 Tension Spring
7 Turntable Bearing Fasteners 20 Wire Rope
8 O/R Hose Connections 21 Powertrain Hardware Inside Compartment
9 Hook Block Tiedown Cable 22 Hose Connections
10 O/R Pins, Clips 23 Hook Block/Headache Ball (Not Shown)
11 O/R Beam Wear Pad Adjustment Hardware

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LUBRICATION RT890E3 SERVICE MANUAL

THIS PAGE BLANK

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RT890E3 SERVICE MANUAL

ALPHABETICAL INDEX
2 Speed Swing Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51
Air Intake System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Auxiliary Boom Nose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
Axle Lockout, Rear Steer and Oil Cooler Fan Motor Control Manifold . . . . . . . . . . . . . 2-63
Axle Oscillation Lockout Cylinder (CE Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-86
Axle Oscillation Lockout Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-83
Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Boom Extension (Additional Equipment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39
Boom Extension and Retraction Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Boom Extensions/Components Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38
Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
Cab Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-101
Cab Tilt Double Pilot Operated Check Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52
Carwell® Rust Inhibitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-29
Check Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66
Counterweight Pin Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-107
Counterweight Removal Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-104
Counterweight Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Counterweight with Auxiliary Hoist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
Counterweight without Auxiliary Hoist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
Cross Axle Differential Lock Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-70
Directional Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35
Drive Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
Dual Accumulator Charge Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54
Dual Rod Telescope Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-76
Electronic Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Environmental Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Front Steer, Swing/Brake Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41
Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
General Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Hoist Drum Rotation Indicator System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Hoist to Boom Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Holding Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57
Hose Reel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Hydraulic Accumulator Service Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56
Hydraulic Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Hydraulic Remote Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46
Idler Drum and Cable Follower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Installing the Bi-fold Manual Boom Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Lift Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-73
List of Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Load Sense Reduction Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-68
Lubrication Intervals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Monthly Maintenance Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40
Oil Cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Outrigger Control Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-59
Outrigger Extension Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-95
Outrigger Stabilizer Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-98
Outriggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22

GROVE APL-1
SERVICE MANUAL RT890E3

Park Brake Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-110

Park Brake Solenoid Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21
Parking Brake Actuator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20
Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21
Pilot Operated Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62
Piston Motor and Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Pressure Setting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Range Shift/Parking Brake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-67
RCL System with Boom Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Rear Axle Oscillation Lockout System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
Rear Steering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
Service Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14
Steer Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-92
Steering Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45
Steering Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Supply Pressure and Return Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Swing Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Swing Gearbox And Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Swing Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Swing Power Brake Valve With Treadle Pedal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-50
Swivels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Tandem Brake Valve with Treadle Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53
Telescope Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Telescope Cylinder Charge Valve Manifold (If Equipped) . . . . . . . . . . . . . . . . . . . . . . 2-89
Third Wrap Indicator (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Transmission/torque Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
Upper Telescope Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-80
Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31
Water Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
Wire Rope Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Wire Rope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

APL-2