Manitowoc CD25 User manual

CD25
Service Manual
Reference Only

This Page Blank
Reference Only

SERVICE MANUAL
This Manual has been prepared for and is considered part of -
CD25
Crane Model Number
This Manual is Divided into the following Sections:
SECTION 1 INTRODUCTION
SECTION 2 SAFETY PRACTICES
SECTION 3 ELECTRIC SYSTEM
SECTION 4 HYDRAULIC SYSTEM
SECTION 5 PREVENTATIVE MAINTENANCE
SECTION 6 ENGINE AND ENGINE SYSTEMS
SECTION 7 TRANSMISSION AND TORQUE CONVERTER
SECTION 8 AXLES/DRIVE SHAFTS/WHEELS AND TIRES
SECTION 9 BRAKE SYSTEM
SECTION 10 STEERING SYSTEM
SECTION 11 STRUCTURALS
SECTION 12 SCHEMATICS/WIRING DIAGRAMS
NOTICE
The crane serial number is the only method your distributor or the factory
has of providing you with correct parts and service information.
The crane serial number is identified on the builder’s decal attached to the
operator’s cab. Always furnish crane serial number when ordering
parts or communicating service problems with your distributor or the
factory.
An untrained operator subjects himself and others to death or
serious injury. Do not operate this crane unless:
•You are trained in the safe operation of this crane. Manitowoc is not
responsible for 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.
•You are sure that all safety signs, guards, and other safety features are
in place and in proper condition.
•The Operator Manual and Load Chart are in the holder provided on
crane.
DANGER
!
© 2017 Manitowoc
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Published 5-25-2017, Control# 587-01
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The original language of this publication is English.
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.
Reference Only

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CD25 TABLE OF CONTENTS
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TABLE OF CONTENTS
SECTION 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Introduction
Directional Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Identification Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
General Service Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Cleaning Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Complete Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Parts with Machined Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Rough Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Rubber Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
After Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
To Prevent Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
O-ring, Seal and Elastic Nut Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Hoses and Tubes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Hydraulic Fittings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Flats from Finger Tight (F.F.F.T.) Method. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Hydraulic Pressure Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Fasteners. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Loctite®. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Fasteners and Torque Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Weld Studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
SECTION 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Safety Practices
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Signal Words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Signal Word . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
Personal Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Equipment Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
General Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Operational Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Environmental Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Final Word . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4
SECTION 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electric System
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Comparing Electrical System to a Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Magnetism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Main Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Wire Harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
Fuses and Relays. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Charging System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Alternator and Voltage Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Alternator Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5
Starter Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Voltmeter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Special Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
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TABLE OF CONTENTS CD25
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Battery Maintenance and Charging. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Battery Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Relay Panel Component Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Starting Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
General Inspections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Instrument and Light Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Light Bulbs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Gauge Cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Wire Harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Engine Wire Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Main Frame Wire Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Instrument Panel Wire Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Cab Wire Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
SECTION 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hydraulic System
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Hydraulic Pressures: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Rated Pump Output at 2500 RPM: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Troubleshooting Aids. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Troubleshooting Guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
General Hydraulic System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Lift Circuit Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Telescope (Crowd) Circuit Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Outrigger Circuit Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Hoist Circuit Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Swing Circuit Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
General Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Hydraulic System Maintenance Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Label Parts when Disassembling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Hydraulic Oil Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Draining and Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Removing Air From the Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Description of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Suction, Return and Pump Pressure Circuits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Hydraulic Swivel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
System Pressure Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Four Section Main Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Checking and Adjusting Hydraulic Pressure Settings . . . . . . . . . . . . . . . . . . . . . . 4-20
Lift Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
Oil Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
Counterbalance Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Lift Cylinder Leakage Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
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Telescope Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
Oil Flow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
Holding Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Port Relief Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Hydraulic Swivel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Hoist Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-29
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
Oil Flow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
Brake Holding Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
Swing Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
Oil Flow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
Anti-Double Block System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
System Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
Outrigger and Axle Lock Out Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
Outrigger Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
Axle Oscillation Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
Oil Flow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
Outrigger Control Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35
Load Holding Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37
Vertical Outrigger Cylinder Leakage Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37
Hydraulic Pump Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37
Main Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38
Main Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39
Outrigger Control Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-49
Swing Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-50
Hoist Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-55
Hydraulic Swivel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-56
Hydraulic Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-58
SECTION 5. . . . . . . . . . . . . . . . . . . . . . . . . . . Preventative Maintenance
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Spark Arresting Mufflers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Environmental Conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Dynamic Shock Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Precautions and Recommendations During Inspection or Replacement . . . . . . . . . 5-3
Wire Rope Inspection—Running Ropes and Pendant Cables . . . . . . . . . . . . . . . . . 5-5
Wire Rope Inspection—Boom Extension and Retraction Cables. . . . . . . . . . . . . . . 5-5
Wire Rope Inspection/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Seizing Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Maintenance Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Special Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
After First 50 Hours of Operation (New Cranes). . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
After First 100 Hours of Operation (New Cranes). . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Cranes Not in Regular Use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Maintenance Schedule and Checklist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Lubricant symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
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Booms and Main Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Drive Train. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Optional Equipment and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Daily Walk-Around Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Inspections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Component/System Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
50 Hours of Operation (Weekly). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
Grease Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
Lubricate the Boom Slides. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
Check the Hoist Gearbox and Brake Lubricant Levels . . . . . . . . . . . . . . . . . . . . . 5-22
Clean the Air Cleaner Vacuator Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
Surface Protection for Cylinder Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
Inner Boom Wear Pad Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
Side and Bottom Boom Wear Pad Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
Internal Cable Sheave Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
100 Hours of Operation (Two Weeks) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
Inspect the Fan Belts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
Check the Wheel Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
250 Hours of Operation (Monthly) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
Inspect the Hydraulic Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
Clean the Batteries and Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
Lubricate the Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
Lubricate the Swing Gear and Pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
Torque Critical Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
Replace the Crankcase Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
Replace the Engine Oil Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
Clean the Radiator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
500 Hours of Operation (Three Months). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
Inspect the Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
Inspect the Parking Brake Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
Replace Fuel Filter/Water Separator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
Replace the Secondary Fuel Element. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
Replace Air Cleaner Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
Add Rust Inhibitor to Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
Lubricate the Outrigger Slides. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
Check the Axle Housing Lubricant Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31
Check the Wheel Hub Lubricant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31
Check Swing Gearbox Lubricant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32
1000 Hours Of Operation (Six Months) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32
Replacing the Transmission Oil and Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32
Replace the Axle Housing Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33
Replace the Axle Wheel Hub Lubricant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34
Replace the Hoist Gearbox and Brake Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . 5-35
Replace Swing Gearbox Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35
Replace the Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35
Replace the Hydraulic Oil Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36
Check the Swing Gear/Pinion Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37
2000 Hours Of Operation (Yearly) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38
Replace the Engine Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38
Inspect the Crane Structure and Booms for Damage . . . . . . . . . . . . . . . . . . . . . . 5-38
Test the Rated Capacity Limiter (RCL) (Optional). . . . . . . . . . . . . . . . . . . . . . . . . 5-38
Miscellaneous Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38
Batteries/Charging System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38
Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39
Fuses and Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39
Diesel Exhaust Fluid (DEF) Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41
Carwell® Rust Inhibitor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42
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Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42
Cleaning Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-43
Inspection and Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43
Carwell Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44
Areas of Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44
SECTION 6. . . . . . . . . . . . . . . . . . . . . . . . . Engine and Engine Systems
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Engine Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Engine RPM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Engine Crankcase System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Crankcase Oil Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Cummins Oil Registration List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Coolant Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Radiator Cap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3
Engine Electrical System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Engine Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
QSB Engine Electronic Controlled Fuel System Units . . . . . . . . . . . . . . . . . . . . . . . 6-5
Types of Fuel to Use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Engine Air Intake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5
Charge-Air Cooler System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Engine Exhaust System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Exhaust System Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
SECTION 7. . . . . . . . . . . . . . . . . . .Transmission and Torque Converter
Towing or Pushing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
4-Speed Powershift transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Identification of the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2
Weight, Dimensions, Oil Capacity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Pressure and Temperature Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Electrical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Hydraulic Cooler and Filter Line Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-4
Oil Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-4
Maintenance Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Servicing Machine After Components Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
SECTION 8. . . . . . . . . . . . . . . . . . Axles/Drive Shafts/Wheels and Tires
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Front Axle and Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Technical Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-2
Front and Rear Drive Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Front and Rear Drive Axle Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Drive Head - Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Drive Head - Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
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Axle Hub and Axle Half Shaft Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
Axle Hub and Axle Half Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
Drive Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17
Lubrication Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18
Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19
Tire Inflation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19
Wheel Stud Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19
SECTION 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brake System
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Axle Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Accumulator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Accumulator Charging Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Service Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Parking Brake System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Maintenance and Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
Service Brake Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
Parking Brake Bleeding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
Parking Brake Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
Accumulator Charging. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
Residual Brake System Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
Service Brake Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
Parking Brake Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
Brake Modulating Valve Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14
Service Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14
SECTION 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Steering System
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Steering Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Two-Wheel Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
Four-Wheel Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
Crab Steering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
Relief Valve Pressure Check and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6
Pressure Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6
Steering Proximity Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6
Principle of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6
Sensor Operation and Spacing Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8
Steering Orbitrol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11
Orbitrol Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11
Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-18
Technical Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-18
Special Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-18
Cylinder/Power Track Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-18
Reference Only

TOC-7
CD25 TABLE OF CONTENTS
T
O
C
Bleeding Steering System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-23
SECTION 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Structurals
Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-1
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
Boom Nose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2
Boom Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3
Lift Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3
Boom Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-4
Boom Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6
Cable Tensioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-12
Boom Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-14
Lift Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-14
Wire Rope, Sheave and Hoist Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-15
Inspecting Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-15
Inspection of Sheaves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-15
Wire Rope Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-15
Hoist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-17
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-17
Hoist Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-17
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-19
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-37
Bearing, Mast and Related Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-39
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-39
Mast Bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-39
Mast Bearing Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-39
Inspection for Bearing Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-40
Replacing the Mast Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-40
Swing Gearbox and Pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-41
Swing Gearbox Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-44
Brake Cylinder Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-48
Planet Assembly Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-50
Outriggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-51
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-51
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-51
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-51
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-51
Outrigger Monitoring System (OMS) (Optional—Standard in North America) . . . 11-53
SECTION 12. . . . . . . . . . . . . . . . . . . . . . . .Schematics/Wiring Diagrams
Reference Only

TABLE OF CONTENTS CD25
TOC-8
This Page Blank
Reference Only

1-1
CD25 INTRODUCTION
1
Published 5-24-2017, Control# 587-01
SECTION 1
INTRODUCTION
SECTION CONTENTS
Directional Reference. . . . . . . . . . . . . . . . . . . . . . . 1-1
Identification Decal. . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
General Service Information . . . . . . . . . . . . . . . . . 1-5
Cleaning Instructions. . . . . . . . . . . . . . . . . . . . . . . 1-5
Complete Assemblies. . . . . . . . . . . . . . . . . . . . . . 1-5
Parts with Machined Surfaces . . . . . . . . . . . . . . . 1-5
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Rough Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Rubber Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
After Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
To Prevent Corrosion . . . . . . . . . . . . . . . . . . . . . . 1-5
O-ring, Seal and Elastic Nut Replacement . . . . . . 1-5
Hoses and Tubes. . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Hydraulic Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Flats from Finger Tight (F.F.F.T.) Method . . . . . . . 1-7
Hydraulic Pressure Testing . . . . . . . . . . . . . . . . . . 1-8
Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Loctite® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Fasteners and Torque Values . . . . . . . . . . . . . . . . 1-9
Weld Studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
This manual contains information on maintenance, service
and repair of the Model CD25 cranes. Major components
and systems are included, except service on the engine.
This information will be found in the engine manufacturer’s
service manual.
DIRECTIONAL REFERENCE
All directional references in this manual, unless otherwise
noted, are viewed from the normal operator’s working
position at the main controls. “LEFT” is the operator’s left and
“RIGHT” is the operator’s right.
IDENTIFICATION DECAL
When assistance is required for parts and service, be sure to
include the model number and serial number of the crane in
the correspondence. Location of serial number decal is
shown in Figure 1-1.
FIGURE 1-1
Serial Number Decal
8538
Reference Only

INTRODUCTION CD25
1-2 Published 5-24-2017, Control# 587-01
SPECIFICATIONS
ENGINE
Diesel Engine
Make and Model.........................................................................................Cummins QSB4.5L diesel
Type of Aspiration ......................................................................................Turbocharged
Horsepower................................................................................................130 hp @ 2500 rpm
Low Engine Idle Speed...............................................................................800 rpm
Intermediate Speed Control (ISC) Idle Speed ............................................1200 rpm - Coolant Temperature is less than
71° C (160° F)
Maximum Engine Speed............................................................................2500 rpm
BOOM
Construction...............................................................................................Telescopic, welded box sections
Number of Sections....................................................................................Four
Reach.........................................................................................................23 ft. 8 in. to 71 ft. (7.21 m to 21.6 m)
MAST ROTATION - 360°
Mast Bearing (Diameter)............................................................................40.00 inches (1016 mm)
Swing Drive Mechanism.............................................................................Hydraulic motor driven gearbox
Swing Speed..............................................................................................2.5 rpm
ELECTRICAL
Type ...........................................................................................................12 VDC
Alternator ...................................................................................................130 amps
Batteries.....................................................................................................730 cold cranking amps each
FUEL TANK
Capacity.....................................................................................................50 gal. (189 L)
HYDRAULIC SYSTEM
Pump..........................................................................................................Variable displacement piston pump
Main Control Valves ...................................................................................Four-way, closed center, pilot operated (hoist,
lift, telescope)
Four-way, open center, pilot operated (swing)
Swing Motor...............................................................................................Single section, gerotor-type
Hoist Motor.................................................................................................Fixed displacement, axial piston
Hydraulic Filters .........................................................................................One 10-micron filter in line from valves, One
100-mesh suction filter inside hydraulic tank
Hydraulic Cylinders....................................................................................Double-acting cylinders for lift, telescope,
steering and outriggers
Hydraulic Tank............................................................................................60 gal. (227 L) capacity, steel construction
with internal baffles
WIRE ROPE
Wire Rope, Hoist:
Diameter ................................................................................................5/8 in. (16 mm)
Type.......................................................................................................XXIPS
Length....................................................................................................390 ft. (118.9 m)
Wire Rope, Optional Below Deck Winch:
Diameter ................................................................................................1/4 in. (6 mm)
Length....................................................................................................100 ft (30.5 m)
Reference Only

1-3
CD25 INTRODUCTION
1
Published 5-24-2017, Control# 587-01
TORQUE CONVERTER/TRANSMISSION
Manufacturer..............................................................................................Dana Transmission
Type ...........................................................................................................Hydraulic Powershift
FRONT AXLE DRIVE
Type ...........................................................................................................International Transmissions Limited
Model .........................................................................................................SD80 - Center Drive Head
REAR AXLE DRIVE
Type ...........................................................................................................International Transmissions Limited
Model .........................................................................................................SD80 - Center Drive Head
OUTRIGGERS
Type ...........................................................................................................Hydraulic
Construction...............................................................................................1-stage hydraulic telescoping beam
with vertical jack
Item Description Item Description
1 Boom, Four Section 13 Counterweight
2 Pivot Head 14 Engine Compartment
3 Anti Two-Block Device 15 Batteries
FIGURE 1-2
1
13
14
2
12
15
10
7
6
4
3
11
5
8
9
16
17
20 19
18
Reference Only

INTRODUCTION CD25
1-4 Published 5-24-2017, Control# 587-01
4Winch 16Outriggers
5 Hydraulic Valve Location (Below Deck) 17 Fuel Tank
6 Mast w/ Swing Gear 18 Folding Boom Extension
7 Hoist 19 Hook Block
8 Drive/Steer Axles 20 Storage Compartments
9Cab
10 Lift Cylinder (2)
11 Hydraulic Tank
12 Air Cleaner
Item Description Item Description
Reference Only

1-5
CD25 INTRODUCTION
1
Published 5-24-2017, Control# 587-01
GENERAL SERVICE INFORMATION
Appropriate service methods and proper repair procedures
are essential for safe, reliable operation of the crane and
safety of the individual doing the work. This Service Manual
provides general directions for accomplishing service and
repair with effective techniques. Following them will assure
reliability.
There are many variations in procedures, techniques, tools
and parts for servicing machines as well as work skills. This
manual cannot possibly anticipate all such variations and
provide advice or cautions for each one. Accordingly, anyone
who intends to depart from the instructions in this manual
must first consider personal safety and the machine’s
integrity.
CLEANING INSTRUCTIONS
Complete Assemblies
Before removal or disassembly, clean the outside of the
component as necessary. Steam can be used if all openings
are closed to prevent water from entering the component.
Parts with Machined Surfaces
Gears, bearings, shafts, or other parts which have machined
surfaces can be cleaned with a solvent that is notflammable.
DO NOT clean these parts in hot solution tanks or with warm
water and alkaline solutions (for example; hydroxide,
othosilicates and phosphates).
Bearings
See Cleaning for bearing cleaning instructions.
Rough Parts
Housings and case parts can be cleaned in hot solution
tanks with a mild alkali if these parts do not have machined
surfaces. Keep the parts in the solution long enough to be
thoroughly cleaned and heated. Flush the parts thoroughly
after cleaning to remove all residue of the alkali solution.
Rubber Parts
Use brake fluid to clean rubber parts. To inhibit damage to
the part, do not use mineral base solvents (for example;
acetone or paint thinner).
NOTE: Use brake fluid to clean rubber parts. Acetone,
paint thinner or other mineral base solvents must
not be used on rubber parts. Mineral base solvents
will cause damage and possible failure of the part.
After Cleaning
Remove all water or solvent from the parts immediately after
cleaning. Use compressed air or a clean cloth. Make sure
the parts are completely dry and clean. DO NOT use
compressed air on bearings. Spinning bearings without
lubricant will cause damage to the bearing.
To Prevent Corrosion
Apply a light weight oil to those parts which normally use
lubrication and are assembled immediately. If the parts will
be put into storage for any length of time, apply a rust
preventative lubricant and put a protective paper on the
parts.
O-RING, SEAL AND ELASTIC NUT
REPLACEMENT
Replace O-rings and gaskets whenever they are disturbed.
Never mix new and old seals or O-rings regardless of
condition. Always lubricate new seals and O-rings (unless
stated otherwise) with 10W30 oil or petroleum jelly before
installation. Replace all used elastic locknuts with new parts.
WARNING
Burn Hazard!
To prevent injury from burns, always use a solvent that is
not flammable for cleaning component parts. DO NOT
use gasoline or other flammable substances.
WARNING
Possible Eye Injury Hazard!
When using compressed air use only low air pressure
nozzles and safety glasses; keep air stream from direction
of face. Injury to eyes could occur.
Reference Only

INTRODUCTION CD25
1-6 Published 5-24-2017, Control# 587-01
HOSES AND TUBES
Inspection
Check hoses carefully. Do not use your bare hands to check
for leaks.
Tighten all connections to recommended torque.
If the hose end connections are damaged, always replace
the hose or tube. Damaged, dented, crushed, or leaking
hose fittings restrict oil flow and the operation of the parts
being served. Fittings showing signs of movement from their
original position have failed and must be replaced.
Be sure hoses are in good condition. If in doubt, replace
them.
Replace hoses if any of the following is evident Figure 1-3:
•Evidence of kinking or crushing (1)
•Chaffing or cuts; wire is exposed (2)
•Damaged or leaking fittings (3)
•Localized ballooning (4)
Installation
1. When installing a new hose, loosely connect each end
and make sure the hose takes up the designed position
before tightening the connection. Clamps should be
tightened sufficiently to hold the hose without crushing
and to prevent chafing.
2. If a hose is replaced on a part that moves during
operation, be sure it moves freely by moving the part
through its complete range of movement.
3. Be sure any hose which has been installed is not kinked
or twisted.
Free moving, unsupported hoses must never rub on each
other or related work surfaces. This causes chafing and
reduces hose life.
BEARINGS
Removal
1. Bearings should never be removed unless absolutely
necessary. Always use the appropriate puller to reduce
the risk of bearing or related component damage.
2. When bearings or bushings are removed, check that the
bearing is free from discoloration, nicks, scuffing, and
signs of overheating. If in doubt, replace the bearing or
bushing.
Cleaning
Bearings acceptable for service should be cleaned in a
suitable solvent and immersed in clean lubricating oil until
needed.
Installation
1. Be sure bearings are installed with care during servicing,
maintenance and repair.
2. Whenever possible, always install the bearing on the
rotating part first.
3. Use proper tools or a press when installing a bearing or
bushing.
4. In the absence of the proper tools or press, when
installing press fit bearings and bushings, heat the
bearing and/or the casing in hot oil to assist in the
installation.
DANGER
High Pressure/Temperature Hazard!
Exercise extreme care around pressurized hydraulic
hoses or tubes. DO NOT work on a hydraulic system
while it is in operation or until all pressure is released.
Hydraulic oil is hot, it can cause severe burns.
Pressurized hydraulic oil can cause death or serious
injury.
Stay clear of all hydraulic oil leaks. Relieve system
pressure and use a piece of cardboard or paper to
check for leaks. Do not use your hands.
Fluid injected into skin must be surgically removed
within a few hours by a doctor familiar with this type of
injury or gangrene will result.
!
FIGURE 1-3
1
2
3
4
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1-7
CD25 INTRODUCTION
1
Published 5-24-2017, Control# 587-01
HYDRAULIC FITTINGS
Flats from Finger Tight (F.F.F.T.) Method
Manitowoc recommends that the F.F.F.T. tightening method
described here be used when assembling all hydraulic
fittings. This method will minimize the risk of fitting damage
or failure due to under or overtightening.
This method will also reduce the chance of a leaky
connection which is normally caused by combinations of
fittings with different types of plating. This method is
particularly useful when the type of plating on the fitting is
unknown, and during maintenance or repair when a joint
may be oily.
Follow these steps when tightening all fitting connections:
1. Make sure both threads and sealing surfaces are free of
burrs, nicks, scratches or any foreign particles.
2. Align tube or hose to the mating fitting and check to see
that the flare seats properly on the nose of the fitting.
3. Finger tighten the nut onto the fitting. If necessary, a
wrench should be used to seat the nut snugly against
the fitting. This is considered the “Finger Tight”
condition.
4. Using a permanent-type ink marker, make a mark on
one of the flats of the nut and continue it onto the hex of
the static fitting or port
5. Tighten the joint by the number of flats as specified in
Table 1-1 and 1-2 for size and type of fitting.
6. Optionally for future tightening of the same connection:
extend the line from the nut at its new location onto the
hex of the static fitting or port (Figure 1-4).
37° Flared Steel Fitting: Tube or Hose to Fitting
Follow the F.F.F.T. method, described above.
Table 1-1: Tube and Swivel Nut/Hose Fittings
Adjustable Straight Thread O-ring Fittings
Refer to Figure 1-5 and Table 1-2 for the following
procedure.
Table 1-2: Adjustable Straight Thread O-ring Fittings
FIGURE 1-4
a0027
T-2-5
T-2-6
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INTRODUCTION CD25
1-8 Published 5-24-2017, Control# 587-01
1. Inspect both mating parts for burrs, nicks, scratches, or
foreign particles.
2. Lubricate O-ring with a light coat of clean oil.
3. Back off locknut as far as possible (A).
4. Screw the fitting into port by hand until the backup
washer contacts the face of the port and is pushed all the
way towards the locknut (C).
5. To orientate the fitting, unscrew the fitting the required
amount, but not more than one full turn.
6. Hold the fitting in the desired position and tighten the nut
(D) following the F.F.F.T. method starting with step 4.
Nonadjustable Straight Thread O-ring Fitting: Fitting
to Port
Refer to Table 1-3 for the following procedure.
1. Make sure both threads and sealing surfaces are free of
burrs, nicks, scratches or any foreign particles.
2. Lubricate O-ring with clean oil (Figure 1-6).
3. Turn fitting until finger tight.
4. Using the assembly torque method, tighten to given
torque for size from Table 1-3.
Table 1-3: Straight Thread Fittings
HYDRAULIC PRESSURE TESTING
Prior to pressure testing, be sure all hoses are in good
condition and all fittings are tight.
Use a pressure gauge with a range that is high enough to
measure the specific pressure.
Comply with the correct procedure to inhibit damage to the
system or the equipment and eliminate the possibility of
injury.
FASTENERS
Loctite®
Always follow the directions on the Loctite container, as not
all Loctite types are suitable for all applications. Various
types of Loctite are specified throughout the Service Manual.
The following types of Loctite brand adhesives are available
from the Parts Department of the local Manitowoc distributor.
Application of Medium Strength Loctite
NOTE: The fastener may be re-used; the adhesive may be
re-applied over cured adhesive residue.
FIGURE 1-5
Adjustable Fitting to Port
a0030
BACK OFF
NUT
FIGURE 1-6
Non-Adjustable Fitting to Port
a0032
CAUTION
Possible Eye and Skin Hazard!
Loctite type adhesives contain chemicals that may be
harmful if misused. Read and follow the instructions on
the container.
T-2-7
Reference Only