1. Manuals
  2. Brands
  3. Manitowoc Manuals
  4. Construction Equipment
  5. Shuttlelift CD5515-2
  6. Service and maintenance manual

Manitowoc Shuttlelift CD5515-2 Service And Maintenance Manual

Hide thumbs Also See for Shuttlelift CD5515-2:
Table of Contents

Advertisement

Quick Links

Shuttlelift CD5515-2
Grove YB5515-2
Service/Maintenance Manual

Advertisement

Table of Contents
loading

Related Manuals for Manitowoc Shuttlelift CD5515-2

Summary of Contents for Manitowoc Shuttlelift CD5515-2

  • Page 1 Shuttlelift CD5515-2 Grove YB5515-2 Service/Maintenance Manual...
  • Page 2 This Page Blank...
  • Page 3 Grove distributor or Crane Care Customer Service at Grove. DANGER An untrained operator subjects himself and others to death or serious injury. Do not operate this crane unless: Manitowoc is not • You are trained in the safe operation of this crane. responsible for qualifying personnel. •...
  • Page 4 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.

  • Page 5: Table Of Contents

    CD5515-2/YB5515-2 SERVICE MANUAL TABLE OF CONTENTS SECTION 1 ........Introduction Directional Reference .
  • Page 6 TABLE OF CONTENTS CD5515-2/YB5515-2 SERVICE MANUAL Equipment Considerations..........2-2 General Considerations .
  • Page 7 CD5515-2/YB5515-2 SERVICE MANUAL TABLE OF CONTENTS Functions ............4-10 Troubleshooting .
  • Page 8 TABLE OF CONTENTS CD5515-2/YB5515-2 SERVICE MANUAL Draining and Flushing ..........5-3 Removing Air From the Hydraulic System.
  • Page 9 CD5515-2/YB5515-2 SERVICE MANUAL TABLE OF CONTENTS Clutch Solenoid Technical Data ........7-2 Description of Operation .
  • Page 10 TABLE OF CONTENTS CD5515-2/YB5515-2 SERVICE MANUAL Description ............9-3 Service Brake System .
  • Page 11 CD5515-2/YB5515-2 SERVICE MANUAL TABLE OF CONTENTS Wire Rope Lubrication ..........11-13 Wire Rope Installation.
  • Page 12 TABLE OF CONTENTS CD5515-2/YB5515-2 SERVICE MANUAL This Page Blank TOC-8...

  • Page 13: Directional Reference

    CD5515-2/YB5515-2 SERVICE MANUAL INTRODUCTION SECTION 1 INTRODUCTION SECTION CONTENTS Directional Reference..... . . 1-1 Gaskets ....... . . 1-9 Batteries.
  • Page 14 INTRODUCTION CD5515-2/YB5515-2 SERVICE MANUAL p0076 Crane S/N Location FIGURE 1-1 p1878 Transmission S/N Location FIGURE 1-3 p0074 Engine S/N Location FIGURE 1-2 Front Drive/Steer Axle FIGURE 1-4 p0073 Rear Drive Axle S/N Location FIGURE 1-5 Published 1-20-2017, Control# 483-02...

  • Page 15: General Specifications

    CD5515-2/YB5515-2 SERVICE MANUAL INTRODUCTION GENERAL SPECIFICATIONS Engine Make and model....................Cummins QSB3.3L -4 Cyl. Diesel Tier 4i Type of Aspiration .....................Turbocharged Horsepower.......................100 hp @ 2600 rpm Low idle speed ....................900 rpm Intermediate Speed Control (ISC) Idle Speed ..........1200 rpm - Coolant Temperature is less than ..........................71°...

  • Page 16: Mast Rotation - 360

    INTRODUCTION CD5515-2/YB5515-2 SERVICE MANUAL Boom Elevation....................0° to 69° MAST ROTATION - 360° Mast Bearing (Diameter) ................860.6 mm (33.884 in) Swing Drive Mechanism................Hydraulic motor driven gearbox Swing Speed ....................2.1 rpm Wire Rope Wire Rope (Main Hoist): Domestic Size......................

  • Page 17: Operating Dimensions

    CD5515-2/YB5515-2 SERVICE MANUAL INTRODUCTION Type .......................International Transmissions Limited Model.....................SD80 - Offset with No Drive Head Operating Dimensions Two-Wheel Steer • Outside turning radius (center line outside tires) ................6.09 m (19' 10.5“) • Outside turning radius (end of boom extension, 41’ boom) ............7.75 m (25' 5") (end of boom extension, 50’...

  • Page 18: General Maintenance

    INTRODUCTION CD5515-2/YB5515-2 SERVICE MANUAL FIGURE 1-6 a1841 Item Description Item Description Hook Block Rear Axle Boom Nose Operator’s Cab Boom Extension Operator Controls Lift Cylinders (2) Front Axle Boom Swing Motor and Gearbox Engine Location Second Boom Section Main Hoist Third Boom Section Mast and Counterweights Chassis...

  • Page 19: Cleanliness

    CD5515-2/YB5515-2 SERVICE MANUAL INTRODUCTION Consider the remaining service life of components blocked securely and the weight is supported by blocks or against the cost of parts and labor necessary to replace jack stands rather than by lifting equipment. them. W h e n u s i n g h o i s t i n g e q u i p m e n t , f o l l o w t h e h o i s t Make the necessary repair.

  • Page 20: Wires And Cables

    INTRODUCTION CD5515-2/YB5515-2 SERVICE MANUAL Always use new locking devices on components which have • Chaffing or cuts; wire is exposed (2) moving parts. • Damaged or leaking fittings (3) When installing lockwashers on housings made of aluminum • Localized ballooning (4) or th in s h e et me tal, us e a f l at was h e r be t w ee n th e lockwasher and the housing.

  • Page 21: Gaskets

    CD5515-2/YB5515-2 SERVICE MANUAL INTRODUCTION Double Row, Tapered Roller sure to cut holes in the right places. Blank gaskets can cause serious damage. Double row, tapered roller bearings are precision fit during When removed, always install new cylinder head and manufacture and components are not interchangeable. The cups, cones, and spacers are usually etched with the same manifold gaskets using recommended gasket compound on head gaskets to allow uniform sealing.
  • Page 22 For replacement mounted, install the hoses. Connect both ends of the hose of hose assemblies, refer to your Manitowoc Crane Care with all bolts finger-tight. Position the hose so it does not rub Parts Manual.

  • Page 23: Electrical System

    8000 hours of service. or repair procedures may request same by contacting your local Manitowoc distributor. • Climate zones D and E after 5,000 hours of service. • Salt water conditions after 8,000 hours of service.

  • Page 24: Loctite

    Torque values should correspond to the type bolts, studs, following types of Loctite brand adhesives are available from and nuts being used. the Parts Department of the local Manitowoc distributor. The torque tables are provided by Manitowoc for reference Application of Medium Strength Loctite when performing maintenance. NOTE: The fastener may be re-used;...
  • Page 25 CD5515-2/YB5515-2 SERVICE MANUAL INTRODUCTION NOTE: If multipliers and/or special tools are used to reach • All handles must be parallel to the step wrench during hard to get at areas, ensure torque readings are final tightening. Multiplier reaction bars may be misaligned no more than 30 degrees without causing accurate.
  • Page 26 INTRODUCTION CD5515-2/YB5515-2 SERVICE MANUAL 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 5/16 7/16 9/16 1-1/8 1-1/4 1-1/2 1654 Zinc-Flake 1109 1530 2682 1251 2288 1155 2105 Untreated...
  • Page 27 CD5515-2/YB5515-2 SERVICE MANUAL INTRODUCTION Table 1-7: Metric Fasteners, Fine Thread, Untreated Bolt Diameter - Metric Torque Values (Nm, Maximum/Minimum) Grade M8x1 M10x1 M10x1.25 M12x1.5 M14x1.5 M16x1.5 M18x1.5 M20x1.5 M22x1.5 M24x2 M27x2 M30x2 M33x2 M36x3 1225 1661 — — 1130 1534 —...

  • Page 28: Weld Studs (Table 1-10)

    F.F.F.T. METHOD (Flats from Finger Tight) Extend the line from the nut at its new location onto the Manitowoc Cranes, Inc. recommends that the F.F.F.T. hex of the static fitting or port (Figure 1-10). tightening method described here be used when assembling 37°...
  • Page 29 CD5515-2/YB5515-2 SERVICE MANUAL INTRODUCTION Adjustable Straight Using the assembly torque method, tighten to given torque for size from Table 1-13. Table 1-12 a0030 Adjustable Straight Thread O-ring BACK OFF T-2-6 FIGURE 1-11 Adjustable Fitting to Port Table 1-13 T-2-7 Thread O-ring Fitting - Fitting to Port (Table 1-12) Inspect both mating parts for burrs, nicks, scratches, or foreign particles.

  • Page 30: Wire Rope

    ANSI/ASME B30.5, federal regulations, and amount depends on the rope’s size, type, and anticipated Manitowoc. The inspection interval shall be determined by a use. This in-process treatment will provide the finished rope qualified person and shall be based on such factors as...

  • Page 31: Wire Rope Inspection (Running Ropes And Pendant Cables)

    When replacing fixed length cable assemblies (for example, pendants) having permanently attached end fittings use only pre-assembled lengths of wire rope as supplied from Manitowoc. Do not build lengths from individual components. A925 Replace an entire wire rope assembly. Do not attempt to rework damaged wire rope or wire rope ends.

  • Page 32: Wire Rope Inspection (Boom Extension And Retraction Cables)

    Standard as referenced by Federal Government Agencies deterioration of the wire rope. and as recommended by Manitowoc. All wire rope will Wire Rope Inspection (Boom Extension and eventually deteriorate to a point where it is no longer usable.

  • Page 33: Seizing Wire Rope

    30 rope diameters. • Severe corrosion as evidenced by pitting. • Manitowoc recommends that for cable extended booms, a single damaged wire rope assembly shall require replacement of the entire set of extension cables.

  • Page 34: O-Ring, Seal And Elastic Nut Replacement

    INTRODUCTION CD5515-2/YB5515-2 SERVICE MANUAL O-RING, SEAL AND ELASTIC NUT HYDRAULIC PRESSURE TESTING REPLACEMENT Prior to pressure testing, be sure all hoses are in good condition and all fittings are tight. Replace O-rings and gaskets whenever they are disturbed. Never mix new and old seals or O-rings regardless of Use a pressure gauge with a range that is high enough to condition.

  • Page 35: Section 2

    CD5515-2/YB5515-2 SERVICE MANUAL SAFETY PRACTICES SECTION 2 SAFETY PRACTICES SECTION CONTENTS Introduction....... 2-1 General Considerations .

  • Page 36: Personal Considerations

    SAFETY PRACTICES CD5515-2/YB5515-2 SERVICE MANUAL Personal Considerations What to do Clothing Check to see that you are suitably The wrong cloths or carelessness in clothed. For certain work it may be dress can cause accidents and injury. ne c es sa ry t o wea r flam e or a cid resistant clothing.

  • Page 37: General Considerations

    CD5515-2/YB5515-2 SERVICE MANUAL SAFETY PRACTICES General Considerations What to Do Solvents Use only cleaning fluids and solvents Certain types of fluids cause damage that are known to be safe. to components and can cause skin irritations. Housekeeping Clean and remove all hazards from the Improves surroundings and daily area.

  • Page 38: Environmental Protection

    Always drain waste fluids into leak proof containers that can threaten the environment. are clearly marked with what they contain. Potentially harmful waste used in Manitowoc cranes includes • Always fill or add fluids with a funnel or a filling pump.

  • Page 39: Section 3

    CD5515-2/YB5515-2 SERVICE MANUAL ELECTRIC SYSTEM SECTION 3 ELECTRIC SYSTEM SECTION CONTENTS General ........3-1 Starting Circuit Check .

  • Page 40: Comparing Electrical System To A Hydraulic System

    ELECTRIC SYSTEM CD5515-2/YB5515-2 SERVICE MANUAL In series circuit arrangements, the voltage is completely the electrical system. These components will be covered used in the circuit when the current is flowing. In parallel further in the discussion of the electrical system. circuit arrangements, the voltage is constant.
  • Page 41 CD5515-2/YB5515-2 SERVICE MANUAL ELECTRIC SYSTEM Fuse Block Location & Relay Identification FIGURE 3-1 Fuse Box #1 Circuit Identification Fuse Box #2 Circuit Identification Fuse Amps Circuit Fuse Amps Circuit Defroster, Heater, Dome/Strobe Lts. Hoist Down Solenoid Wipers, Washer, Swing Lock 1195, ECM Power, E-Stop Shifter, TCU, Trans Oil Cooler, Back Diode...
  • Page 42 ELECTRIC SYSTEM CD5515-2/YB5515-2 SERVICE MANUAL Battery Disconnect Switch Fuse Block Location in Battery/ Relay Compartment FIGURE 3-2 Fuse Box #3 Circuit Identification Fuse Amps Circuit Fuse Amps Circuit Starter Lockout Signal from Engine ACC Power Relay Empty IGN Power Relay Module Power ECM Power Swing Valves (360°...

  • Page 43: Charging System

    CD5515-2/YB5515-2 SERVICE MANUAL ELECTRIC SYSTEM CHARGING SYSTEM Turn the battery disconnect switch to ON. The purpose of the charging system is to give power for Battery Disconnect Switch operation of the lights, instruments, electrical accessories The battery disconnect switch, Figure 3-2, is located in the and controls, and to keep a full charge on the batteries.

  • Page 44: Starting Circuit

    ELECTRIC SYSTEM CD5515-2/YB5515-2 SERVICE MANUAL Charging the Battery CAUTION The ignition switch must be in the OFF position when WARNING performing steps 1 and 2. If the switch is in the ON position, the engine may start if the parking brake is Batteries produce explosive gases.

  • Page 45: Instrument And Light Circuits

    CD5515-2/YB5515-2 SERVICE MANUAL ELECTRIC SYSTEM INSTRUMENT AND LIGHT CIRCUITS Voltmeter Display The voltmeter is connected in parallel with the charging General circuit. The voltmeter gives an indication of electrical charging system problems that can not be seen with an Power is available to the light switch from a 20 amp fuse on ammeter.

  • Page 46: Wire Harnesses

    ELECTRIC SYSTEM CD5515-2/YB5515-2 SERVICE MANUAL Table 3-3: Voltage Level Conditions Voltage Measured Engine Speed Condition of Charging System 0-10 volts Stopped or low idle Battery discharged. Low battery charge. 11-12 volts Above low idle. Problem in charging system. See Troubleshooting - Charging System. Stopped or low idle.
  • Page 47 CD5515-2/YB5515-2 SERVICE MANUAL ELECTRIC SYSTEM Engine Ground J1939 Terminating Resistor WIF Connector on Engine Engine Power Connector Foot Pedal Engine ECM Connectors Connector Compressor WIF Connector on Fuel Filter Carrier Coolant Sensor Ground Tier 3 Engine Wire Harness FIGURE 3-4 Alternator GROVE Published 1-20-2017, Control# 483-02...
  • Page 48 ELECTRIC SYSTEM CD5515-2/YB5515-2 SERVICE MANUAL J1939 ECM MAF Engine Ground Terminating Sensor Resistor WIF Sensor Engine Foot Pedal Connectors Engine ECM Connector WIF Connector OEM Breakout on Fuel Filter Connector Compressor Carrier Coolant Sensor Ground Alternator Tier 4 Engine Wire Harness MAF Sensor FIGURE 3-5 Air Cleaner...
  • Page 49 CD5515-2/YB5515-2 SERVICE MANUAL ELECTRIC SYSTEM To Sheet 2 FIGURE 3-6 Main Frame Harness Sheet 1 GROVE 3-11 Published 1-20-2017, Control# 483-02...
  • Page 50 ELECTRIC SYSTEM CD5515-2/YB5515-2 SERVICE MANUAL Item Description Sheet 1 Right Front OMS Right Front Turn Indicator Right Front Headlight Steer Solenoids Outrigger Return Outrigger Extend Left Front Outrigger Beam Left Front Jack Right Front Jack Right Front Outrigger Beam Winch Left Front OMS Left Front Headlight Left Front Turn Indicator...
  • Page 51 CD5515-2/YB5515-2 SERVICE MANUAL ELECTRIC SYSTEM To Sheet 3 From Sheet 1 Main Frame Harness Sheet 2 FIGURE 3-6 continued GROVE 3-13 Published 1-20-2017, Control# 483-02...
  • Page 52 ELECTRIC SYSTEM CD5515-2/YB5515-2 SERVICE MANUAL Item Description Sheet 2 To Dash Harness To Dash Harness Ground Splice 360° Swing Lock 360° Swing Lock To Cab To Cab Frame Grounds To Dash Harness To Dash Harness To Dash Harness Slew Proximity Swivel Ground Splice Hydraulic Oil Temperature...
  • Page 53 CD5515-2/YB5515-2 SERVICE MANUAL ELECTRIC SYSTEM From Sheet 2 Main Frame Harness Sheet 3 FIGURE 3-6 continued GROVE 3-15 Published 1-20-2017, Control# 483-02...
  • Page 54 ELECTRIC SYSTEM CD5515-2/YB5515-2 SERVICE MANUAL Item Description Sheet 3 Fuse/Relay Box Transmission Temperature Switch, Tier 3 Module Connector 360° Swing Lock Option Relays Power Post (B) Power Post (A) Right Rear Turn Signal Right Rear Work Light Right Rear Stop/Tail Light Right Rear OMS Left Rear Turn Signal Left Rear Work Light...
  • Page 55 CD5515-2/YB5515-2 SERVICE MANUAL ELECTRIC SYSTEM 43 44 Dash Wire Harness FIGURE 3-7 GROVE 3-17 Published 1-20-2017, Control# 483-02...
  • Page 56 ELECTRIC SYSTEM CD5515-2/YB5515-2 SERVICE MANUAL Item Description Skylight Wiper Carrier P6 Carrier P1 Carrier P2 Carrier P3 Carrier P5 Steering Return to Center 46 Splice Ignition Switch Outrigger Left Front Outrigger Right Rear Outrigger Right Front Outrigger Left Rear Ground Splice 2 Ground Splice 1 Ground Splice 3 Thumb Thumper...
  • Page 57 CD5515-2/YB5515-2 SERVICE MANUAL ELECTRIC SYSTEM Item Description To Carrier Harness Heater/Air Conditioning Seat Switch RCL A RCL B RCL C Dome Light Strobe Light Boom Wire Harness FIGURE 3-9 Item Description To Swivel Hoist High Speed Hoist Rotation Indicator Left Hand Boom Lights Right Hand Boom Lights RCL Warning Light (CE Option) RCL Warning Alarm (CE Option)

  • Page 58: Accessory Circuits

    ELECTRIC SYSTEM CD5515-2/YB5515-2 SERVICE MANUAL ACCESSORY CIRCUITS Rated Capacity Limiter (RCL) System Description Anti-Double Blocking System The rated capacity limiter (RCL) is a length, load, angle, General radius, lifting capacity and anti-double block indicator. A This mechanism (Figure 3-10) prevents the hook block from display in the cab provides information to assist the operator being pulled into the boom head during extension of the in operating the crane.

  • Page 59: Troubleshooting

    CD5515-2/YB5515-2 SERVICE MANUAL ELECTRIC SYSTEM TROUBLESHOOTING Each circuit in the system has a fuse for protection against overloads. Remember that a burnt fuse is an indication of an Finding a problem in the electrical system is not difficult if you overload or SHORT circuit, not an OPEN circuit.
  • Page 60 ELECTRIC SYSTEM CD5515-2/YB5515-2 SERVICE MANUAL Problem Possible Cause Solution Alternator Noise. Badly worn belt. Replace belt and adjust. Pulleys out of alignment. Align fan and alternator pulleys. Loose pulley. Check for broken key or worn keyway, if used. Tighten pulley nut.
  • Page 61 CD5515-2/YB5515-2 SERVICE MANUAL ELECTRIC SYSTEM Problem Possible Cause Solution Winch motor will not operate. Defective solenoid stuck Jar solenoid to free contacts solenoid. Check by applying 12 volts to coil terminal (should hear an audible click when energized). Replace solenoid. Defective control switch Check and replace if necessary.

  • Page 62: Section 4

    CD5515-2/YB5515-2 SERVICE MANUAL HYDRAULIC SYSTEM SECTION 4 HYDRAULIC SYSTEM SECTION CONTENTS General Description ......4-1 Brake Holding Valve ..... . 4-15 General .

  • Page 63: Troubleshooting

    HYDRAULIC SYSTEM CD5515-2/YB5515-2 SERVICE MANUAL Valves are used to control the flow, pressure, direction, and • The front and rear outrigger cylinders volume of the oil in the system. There are many different • The main hoist motor types of valves. An explanation of the different valves used on this machine is given in the description of each circuit.

  • Page 64: Troubleshooting Guides

    CD5515-2/YB5515-2 SERVICE MANUAL HYDRAULIC SYSTEM Second, make an analysis of symptoms. The function of with these symptoms? Make a list of the possible causes. each component in the system must be known before a Start at the source of the flow in that circuit. If the problem is in all circuits, start at the pump.

  • Page 65: Hydraulic System

    HYDRAULIC SYSTEM CD5515-2/YB5515-2 SERVICE MANUAL Problem Possible Cause Remedy Slow operating speeds (All functions). Low engine rpm. Increase engine rpm. Air leak in pump inlet line. Tighten pump inlet line. Replace O-ring in inlet flange. Air in oil (foam in tank). Check oil level, look for leaks in the system.
  • Page 66 CD5515-2/YB5515-2 SERVICE MANUAL HYDRAULIC SYSTEM Problem Possible Cause Remedy Difficult to engage valve spools. Dirt or foreign material between spool Remove and clean valve spool and and valve bore. bore. Broken spring (spool return). Replace spring. Distortion or damage to valve spool. Replace valve section.
  • Page 67 HYDRAULIC SYSTEM CD5515-2/YB5515-2 SERVICE MANUAL Problem Possible Cause Remedy Boom retracts but will not extend Malfunction in anti-double blocking See Electric System. electrical system. Bad cartridge in anti-double blocking Replace the cartridge solenoid valve. Restriction in pilot control line to control Check and correct.
  • Page 68 CD5515-2/YB5515-2 SERVICE MANUAL HYDRAULIC SYSTEM Table 4-5 Main Hoist Circuit Troubleshooting Problem Possible Cause Remedy Hoist will not lift maximum (rated) load, Faulty load sense relief valve. Replace the relief valve. considerable reduction in line speed. Dirt in load sense relief valve, keeping Remove and clean the relief valve.

  • Page 69: System Description

    HYDRAULIC SYSTEM CD5515-2/YB5515-2 SERVICE MANUAL HYDRAULIC SYSTEM cylinder bore, forcing oil into the pressure port and out to the hydraulic system. System Description Test - Pump Output The hydraulic system is a closed-center hydraulic system The hydraulic pump output can not be checked using a with pressure compensated load sensing characteristics flowmeter.

  • Page 70: Hydraulic Swivel

    CD5515-2/YB5515-2 SERVICE MANUAL HYDRAULIC SYSTEM function regardless of differences in their load and (i.e. 76, 114, 151 Lpm [20, 30, 40 gpm]) at a predetermined regardless of the pump flow. The flow relationships specified pres sure d iffe rentia l at spoo l (3). It is the work ing combination of the components that sets up the flow dividing between functions are maintained over the full range of the pump.

  • Page 71: Functions

    HYDRAULIC SYSTEM CD5515-2/YB5515-2 SERVICE MANUAL housing. The housing rotates with the mast and the shaft is Port No. 4 stationary. Hydraulic oil under pressure flows through this port when the boom is being raised. When lowering the boom the hydraulic Functions oil under low pressure flows through this port.

  • Page 72: Oil Flow

    CD5515-2/YB5515-2 SERVICE MANUAL HYDRAULIC SYSTEM block cutout solenoid valve, a valve section of the four-spool Holding Valve control valve (Figure 4-4), and the hydraulic lines. The holding valve has three functions: Oil Flow Inhibit cavitation of the cylinder, When the valve spool is in the neutral position, both A and B Give full control of the lowering of the boom, ports are closed and oil is held in the circuit to prevent Hold the load in event of a hydraulic failure.
  • Page 73 HYDRAULIC SYSTEM CD5515-2/YB5515-2 SERVICE MANUAL Swing Telescope Lift Hoist FIGURE 4-4 4-12 Published 1-20-2017, Control# 483-02...

  • Page 74: Telescope Circuit

    CD5515-2/YB5515-2 SERVICE MANUAL HYDRAULIC SYSTEM TELESCOPE CIRCUIT Holding Valve Use the hydraulic schematic in Section 12 along with the The holding valve has three functions: following text to understand how the telescope circuit Inhibit cavitation of the cylinder. functions. Give full control of the lowering of the boom. General Hold the load in event of a hydraulic failure.

  • Page 75: Telescope Cylinder Leakage Test

    HYDRAULIC SYSTEM CD5515-2/YB5515-2 SERVICE MANUAL If the pressure readings are correct, stop the engine and Oil Flow remove the pressure gauge. When the valve spool is in the neutral position, both A and B If the pressure readings are incorrect, adjust the ports are closed.

  • Page 76: Brake Holding Valve

    CD5515-2/YB5515-2 SERVICE MANUAL HYDRAULIC SYSTEM Brake Holding Valve through the B port and sent back to tank through the return filter. The holding valve has three functions: Swing Left Inhibit cavitation of the motor. Pulling the joystick towards the operator sends oil through Give full control of the lowering of the load.
  • Page 77 HYDRAULIC SYSTEM CD5515-2/YB5515-2 SERVICE MANUAL FIGURE 4-5 FIGURE 4-6 Pump Margin Pressure Setting With the engine shut off, install a 0 - 344.73 bar (0-5000 psi) pressure gauge on the test port G1 (1, Figure 4-6). Start engine and read the pressure gauge while at engine idle.
  • Page 78 CD5515-2/YB5515-2 SERVICE MANUAL HYDRAULIC SYSTEM Start the engine. Set the pressure on the load sense relief valve, refer to Load Sense Relief Valve Pressure Setting Ensure the boom is all the way down. Activate the boom down function at full engine throttle. The pressure gauge Load Sense Relief Valve Pressure Setting should read 289.57 +/- 3.45 bar (4200 +/- 50 psi).
  • Page 79 HYDRAULIC SYSTEM CD5515-2/YB5515-2 SERVICE MANUAL If the pressure is incorrect, adjust the extend work Shut down the engine and remove the pressure gauge. port relief valve (3, Figure 4-8) on the control valve Install a 0 - 344.73 bar (0-5000 psi) pressure gauge on until the pressure reads 193.05 +3.45/-0 bar (2800 the G2 port (3, Figure 4-9) located on the brake/steering + 5 0 / - 0 ps i ) ;...

  • Page 80: Anti-Double Blocking System

    CD5515-2/YB5515-2 SERVICE MANUAL HYDRAULIC SYSTEM ANTI-DOUBLE BLOCKING SYSTEM alone is not enough to hold the check valve closed, therefore, the check valve opens. With the check valve open, General hydraulic oil which would normally flow to the lift cylinder, telescopic cylinder or hoist motor through port A of the valve The anti-double block circuit protects the hoist, telescope section is returned through the check valve to the outlet of and lift circuits from damage in the event that the hoist block...
  • Page 81 HYDRAULIC SYSTEM CD5515-2/YB5515-2 SERVICE MANUAL A relief valve set at 144.79 ± 3.45 bar (2100 ± 50 psi) is installed in the inlet of the manifold, protects the outrigger Table 4-7: Port Identification Figure 4-11 circuits from high pressure buildup. Port Function Outrigger Valve Ports...
  • Page 82 CD5515-2/YB5515-2 SERVICE MANUAL HYDRAULIC SYSTEM 7948-1 7948-2 7948-3 FIGURE 4-11 GROVE 4-21 Published 1-20-2017, Control# 483-02...

  • Page 83: Load Holding Valves

    HYDRAULIC SYSTEM CD5515-2/YB5515-2 SERVICE MANUAL Load Holding Valves COMPONENT REPAIR The vertical (jack) cylinders have load holding valves Hydraulic Pump Repair installed in the cylinder base. The purpose of these valves is to inhibit the cylinder from retracting if a hydraulic line or Removal hose breaks.

  • Page 84: Outrigger Control Valve

    CD5515-2/YB5515-2 SERVICE MANUAL HYDRAULIC SYSTEM Pump Start-up Open the access cover over the control valves and remove the cover plate. Start the engine and let it idle. Do not allow the engine to Disconnect the wire leads from the solenoid valve. surge or run excessively fast during the initial start-up.
  • Page 85 HYDRAULIC SYSTEM CD5515-2/YB5515-2 SERVICE MANUAL Disassembly CAUTION Cleanliness is extremely important when repairing the swing motor. Work in a clean area. Plug the ports then use a wire brush to remove foreign material and debris from around the external joints of the motor. Check the shaft and key slot, remove all nicks, burrs or sharp edges that might damage seals during installation.
  • Page 86 CD5515-2/YB5515-2 SERVICE MANUAL HYDRAULIC SYSTEM 1. Screw (4) 2. Exclusion Seal 3. Mounting Flange 4. Backup Ring * 5. Shaft Pressure Seal * 6. Seal * 7. Bearing Race 8. Thrust Needle Bearing 9. Output Shaft 10. Housing 11. O-Ring 12.
  • Page 87 HYDRAULIC SYSTEM CD5515-2/YB5515-2 SERVICE MANUAL occurs around the plug. To remove the plug, insert a 5 mm (0.187 in) hex key through the port opening and push it out. The model 009 plug is not interchangeable with the 007 and 008 plugs. Inspection/Cleaning Check all mating surfaces.
  • Page 88 CD5515-2/YB5515-2 SERVICE MANUAL HYDRAULIC SYSTEM CAUTION Do not permit oil to get into the four tapped holes of housing (10). Shaft Pressure Seal Seal Driver Output Shaft Needle Thrust Bearing Seal Lubricate Exclusion Tube these areas Seal Bearing Race Back-up Ring (008 and 009 motors...
  • Page 89 HYDRAULIC SYSTEM CD5515-2/YB5515-2 SERVICE MANUAL than 15 minutes, repeat application. No additional Gerotor End cleaning or removal of previously applied Loctite is 12. Reposition the motor in the vise with gerotor end up. necessary. Clamp across the ports. Do not clamp on side of housing.
  • Page 90 CD5515-2/YB5515-2 SERVICE MANUAL HYDRAULIC SYSTEM 21. Install capscrews (19) and seal washers (18) in end cap Install the swing motor to the gearbox with two socket (17). Tighten the capscrews to 7.4 Nm (40 lb-in). Make head capscrews and lockwashers. sure the seal washers are properly seated.

  • Page 91: Hydraulic Swivel

    HYDRAULIC SYSTEM CD5515-2/YB5515-2 SERVICE MANUAL Hydraulic Swivel CAUTION Removal To inhibit cavitation and damage to the motor due to lack of lubricating hydraulic oil, DO NOT start the motor CAUTION without first filling the motor with hydraulic oil. The area around the swivel and the swivel must be Fill the hoist motor with clean hydraulic fluid through the completely cleaned before removing the swivel from the case drain port Figure 4-24 to the bottom of the fill plug.
  • Page 92 CD5515-2/YB5515-2 SERVICE MANUAL HYDRAULIC SYSTEM 1. Housing Assembly 2. Washer Ring 3. Retainer Ring 4. Piston Seal (7)* 5. Wiper Ring * 6. Energizer Square Seal (7)* 7. U-cup Seal (2)* 8. Wear Ring (2)* 9. Wiper Ring * 10. Thrust Washer * 11.
  • Page 93 HYDRAULIC SYSTEM CD5515-2/YB5515-2 SERVICE MANUAL Disassembly Install one heated square seal (6) over each piston seal. Install the two wear rings (8) into their appropriate Remove retaining ring (3) Figure 4-25 and washer ring grooves. (2). Remove and discard thrust washer (10) and wiper ring (5).

  • Page 94: Hydraulic Cylinders

    CD5515-2/YB5515-2 SERVICE MANUAL HYDRAULIC SYSTEM Hydraulic Cylinders b. On pistons which are fastened with a locking nut, use a socket wrench and extension to loosen the Removal nut. NOTE: The following removal instructions are general and Remove and discard the seals and wear rings from the should be modified to suit the cylinder being piston.
  • Page 95 HYDRAULIC SYSTEM CD5515-2/YB5515-2 SERVICE MANUAL Table 4-8 in both directions as directed in steps 2 pressure for a minimum of 10 seconds. Visually check through 5. for internal and external leakage. No internal or external leakage is permitted. Table 4-8: Cylinder Test Pressures Fully extend the cylinder rod.
  • Page 96 CD5515-2/YB5515-2 SERVICE MANUAL HYDRAULIC SYSTEM See Detail 1. Barrel Assembly 2. Rod Assembly 3. Piston Assembly includes item 25 4. Head Assembly includes item 26 See Sheet 2 5. Not Used 6. O-Ring Plug 7. Metal Plug (2) 8. Not Used 9.
  • Page 97 HYDRAULIC SYSTEM CD5515-2/YB5515-2 SERVICE MANUAL Detail Item 26 Detail Item 25 Lift Cylinder Sheet 2 FIGURE 4-26 continued a0432 4-36 Published 1-20-2017, Control# 483-02...
  • Page 98 CD5515-2/YB5515-2 SERVICE MANUAL HYDRAULIC SYSTEM 1. Barrel Assembly 2. Outer Shaft Assembly 3. Inner Shaft Assembly 4. Packing Gland 5. Packing Gland 6. Stop Tube 7. Mandrel 8. Piston 9. Mandrel 10. Stop Tube 11. Mandrel 12. Piston 13. Round Nut 14.
  • Page 99 HYDRAULIC SYSTEM CD5515-2/YB5515-2 SERVICE MANUAL 1. Cylinder Tube 2. Piston Nut 3. Piston 4. Wiper* 5. O-Ring* 6. Seal* 7. O-Ring* 8. O-Ring* 9. Back-Up Ring 10. Gland Head 11. Seal* 12. Rod Wiper 13. Cylinder Rod *= Seal Kit Tighten nut to a torque of 25 lb-ft.
  • Page 100 CD5515-2/YB5515-2 SERVICE MANUAL HYDRAULIC SYSTEM 1. Cylinder Tube 2. Piston Nut 3. Wear Ring (2)* 4. O-Ring* 5. Piston Seal* 6. Piston 7. O-Ring* 8. O-Ring* 9. Back-Up Ring* 10. Gland Head 11. Rod Seal* 12. Seal Wiper* 13. Cylinder Rod *= Seal Kit Tighten nut to a torque of 175 lb-ft.

  • Page 101: Under Deck Winch

    HYDRAULIC SYSTEM CD5515-2/YB5515-2 SERVICE MANUAL UNDER DECK WINCH directional control and a two-position control valve to supply oil flow. The under deck winch is connected to the front outrigger control manifold. Hydraulic oil flows through an electrically activated three position directional control valve to provide 4-40 Published 1-20-2017, Control# 483-02...
  • Page 102 CD5515-2/YB5515-2 SERVICE MANUAL PREVENTATIVE MAINTENANCE SECTION 5 PREVENTATIVE MAINTENANCE SECTION CONTENTS Introduction....... 5-1 Maintenance Schedule and Checklist .

  • Page 103: Lubricants

    Select the one that applies to your engine to view the registered oils. Hydraulic System Maintenance Precautions It is not the policy of Manitowoc Cranes, Inc. to publish lists Contaminants in a hydraulic system affect operation and of approved lubricants or guarantee lubricant performance.

  • Page 104: Label Parts When Disassembling

    CD5515-2/YB5515-2 SERVICE MANUAL PREVENTATIVE MAINTENANCE In case of replacement hoses with angled stem reusable fittings, the hose curvature must be taken into consideration CAUTION when assembling and positioning the angled stem. When draining the outrigger cylinders, always operate Label Parts when Disassembling either both front or both rear cylinders together to prevent twisting the crane.

  • Page 105: Removing Air From The Hydraulic System

    • If the above procedures fail to eliminate air entrapment, 0.138 to 0.276 bar (2 to 4 psi) and inspect all joints and contact your authorized Manitowoc distributor. fittings for evidence of leaks. A soap solution applied to Parts Replacement the fittings and joints may also prove helpful in detecting minute leaks while the system is pressurized.

  • Page 106: After First 50 Hours Of Operation (New Cranes)

    CD5515-2/YB5515-2 SERVICE MANUAL PREVENTATIVE MAINTENANCE Wire rope cable clamps and connections Cranes Not In Regular Use • Check for loose or missing parts. A crane which has been idle for a period of one month or more, but less than six months, must be given an inspection Anti-Double Blocking System by a qualified person.
  • Page 107 PREVENTATIVE MAINTENANCE CD5515-2/YB5515-2 SERVICE MANUAL 1000 Daily 2000 Hours Hours Hours Service Check before Hours Hours Hours Three operation Weekly Monthly Yearly Weeks Months Months Drain water from engine fuel filter Check air cleaner restriction indicator Check hydraulic oil level Inspect wire rope and sheaves Apply grease to all lubrication fittings Lubricate the boom slides...
  • Page 108 CD5515-2/YB5515-2 SERVICE MANUAL PREVENTATIVE MAINTENANCE 1000 Daily 2000 Hours Hours Hours Service Check before Hours Hours Hours Three operation Weekly Monthly Yearly Weeks Months Months Check axle wheel hub lubricant level (4) Check axle housing lubricant level (2) Check hoist gearbox and brake lubricant level Lubricate the outrigger slides Add grease to swing gearbox...

  • Page 109: Lubrication Points

    PREVENTATIVE MAINTENANCE CD5515-2/YB5515-2 SERVICE MANUAL Lubrication Points bearing grease or equivalent. Apply enough grease to remove the old grease. Apply grease to the following fittings after the first 20 hours of NOTE: *Drive shaft u-joints do not require routine operation, thereafter every 50 hours of operation or weekly, lubrication.
  • Page 110 CD5515-2/YB5515-2 SERVICE MANUAL PREVENTATIVE MAINTENANCE p1639 p1638 Lift Cylinder Pivots Lube Points (Base End) FIGURE 5-4 Two Fittings Located On Inside Surface or Bearing Ring p1664 Mast Bearing Lubrication Point FIGURE 5-1 p1663 Lift Cylinder Pivots Lube Point (Rod End) FIGURE 5-5 Boom Pivot Lubrication Points FIGURE 5-2...
  • Page 111 PREVENTATIVE MAINTENANCE CD5515-2/YB5515-2 SERVICE MANUAL p0421 p0418 Steering Cylinder Pivot Ends Lube Points (Front Axle) Steering Knuckle Lube Points (Rear Axle) FIGURE 5-7 FIGURE 5-10 p0419 p0420 Steering Link Lube Points (Front Axle) FIGURE 5-8 Steering Cylinder Pivots Ends Lube Points (Rear Axle) p0422 FIGURE 5-11 Steering Link Lube Points (Rear Axle)
  • Page 112 CD5515-2/YB5515-2 SERVICE MANUAL PREVENTATIVE MAINTENANCE p1643 p0391 Drive Shaft Lube Points (Front Axle) Drop Block Lube Point FIGURE 5-12 FIGURE 5-15 p0401 p0315 Jib Head Sheave Lube Point (Typical) FIGURE 5-16 Drive Shaft Lube Points (Rear Axle-Typical) p0392 FIGURE 5-13 p0423 Jib Boom Deflector Sheave Lube Point FIGURE 5-17...

  • Page 113: Scheduled Maintenance

    PREVENTATIVE MAINTENANCE CD5515-2/YB5515-2 SERVICE MANUAL SCHEDULED MAINTENANCE Daily before beginning operation, inspect the lifting hook for damage; cracks, deformation, loose retaining hardware, etc. Daily (Walk-around) Inspection If any damage is found, DO NOT operate the crane until the damage is repaired. NOTE: You must read and understand the warnings and Inspect All Safety Devices...
  • Page 114 CD5515-2/YB5515-2 SERVICE MANUAL PREVENTATIVE MAINTENANCE DO NOT fill the fuel tank to capacity. Allow room for fuel expansion. Tighten the fuel cap securely. If the cap is lost, replace only with original equipment. Transmission Level Dipstick FIGURE 5-18 Check the Engine Crankcase Oil Level Check Engine Coolant Level Level the crane, engage the parking brake and shut off the engine.
  • Page 115 PREVENTATIVE MAINTENANCE CD5515-2/YB5515-2 SERVICE MANUAL NOTE: For more details on proper radiator checking and maintenance procedures, see the engine manual furnished with the crane. Overflow Bottle FIGURE 5-19 Drain Water from Engine Fuel Filter Be sure the boom is fully retracted and lowered and the outriggers are retracted and up.
  • Page 116 CD5515-2/YB5515-2 SERVICE MANUAL PREVENTATIVE MAINTENANCE Check the Air Cleaner Restriction Indicator cause damage if the engine is operated with the air cleaner element removed. The air cleaner is equipped with a filter restriction indicator Remove the housing cover. (Figure 5-22). The air cleaner element needs cleaning or replacing if the indicator’s colored piston has popped out and Remove the element as gently as possible until you get is visible when the engine is running at high idle.
  • Page 117 PREVENTATIVE MAINTENANCE CD5515-2/YB5515-2 SERVICE MANUAL have protection. Recheck to see if the sealing surface in indicator’s colored piston pops out and is visible again, the housing is clean, or if the element is the right model shut down the engine and replace the air cleaner number.

  • Page 118: Hours Of Operation (Weekly)

    CD5515-2/YB5515-2 SERVICE MANUAL PREVENTATIVE MAINTENANCE 50 Hours of Operation (Weekly) Inspection Inspections should be carried out by a person who has NOTE: You must read and understand the warnings and learned through special training or practical experience what basic safety rules, found in Section 2 of this to look for, and who knows how to judge the importance of manual, before performing any operation or any abnormal conditions they may discover.
  • Page 119 PREVENTATIVE MAINTENANCE CD5515-2/YB5515-2 SERVICE MANUAL Lubricate the Boom Slides p1643 Extend the outriggers. Lower the boom and then extend it to its maximum out position. Engage the parking brake and shut off the engine. Clean the old lubricant from the booms. Apply extreme pressure multipurpose grease, or equivalent, to the boom sliding surfaces (Figure 5-25) on the boom sections.

  • Page 120: Hours Of Operation (Two Weeks)

    CD5515-2/YB5515-2 SERVICE MANUAL PREVENTATIVE MAINTENANCE 100 Hours of Operation (Two Weeks) A belt that is too loose will see excessive vibration and increased wear. A belt that is too tight produces wear on the NOTE: You must read and understand the warnings and belt and the bearings of the pulleys it travels around.

  • Page 121: Hours Of Operation (Monthly)

    PREVENTATIVE MAINTENANCE CD5515-2/YB5515-2 SERVICE MANUAL 250 Hours of Operation (Monthly) NOTE: You must read and understand the warnings and basic safety rules, found in Section 2 of this manual, before performing any operation or maintenance procedures. For additional engine maintenance guidelines, see the engine manual furnished with this crane.
  • Page 122 CD5515-2/YB5515-2 SERVICE MANUAL PREVENTATIVE MAINTENANCE Tighten all battery hardware to keep the battery securely in place. w0022 Disconnect the battery cables. Sprinkle the battery with baking soda to neutralize the acid. Rinse with water. Be careful not to get water inside the battery.
  • Page 123 PREVENTATIVE MAINTENANCE CD5515-2/YB5515-2 SERVICE MANUAL Replace the Crankcase Oil and Filter p1644 Change the engine oil more frequently if operating under difficult conditions, for example in high or low temperatures, dusty surroundings or frequent starting and stopping. NOTE: If it is necessary to climb under the crane to change the engine oil and replace the engine oil filter, be sure engine is shut off, the ignition key is removed and chock blocks are in place before climbing...

  • Page 124: Hours Of Operation (3 Months)

    CD5515-2/YB5515-2 SERVICE MANUAL PREVENTATIVE MAINTENANCE If a broken bolt is found, replace the bolt and also p0329 replace the bolt on each side of the broken bolt. The proper bolt torque will not be obtained without the hardened steel washers under the bolt heads on the outer (mast) bolt circle.
  • Page 125 PREVENTATIVE MAINTENANCE CD5515-2/YB5515-2 SERVICE MANUAL Install the new element over the opening in the housing Add Rust Inhibitor to Engine Cooling System and slide it all the way in. Make sure the gasket is seating evenly. If you don’t feel the gasket is seating evenly for a perfect seal, you won’t have protection.
  • Page 126 CD5515-2/YB5515-2 SERVICE MANUAL PREVENTATIVE MAINTENANCE p0430 p0438 Check Plug Location Fill/CHeck Plug- Rear Axle Housing Swing Gearbox Grease Fitting FIGURE 5-37 FIGURE 5-35 Check the lubricant level, which should be even with the Engage the parking brake and shut off the engine. bottom of the fill/check hole.

  • Page 127: 1000 Hours Of Operation (6 Months)

    PREVENTATIVE MAINTENANCE CD5515-2/YB5515-2 SERVICE MANUAL If necessary, add Mobil Fluid 424 to fill the hub to the Check the lubricant level which should be level with the recommended level. bottom of the check plug hole. Repeat Steps 1 through 6 for the other wheel hubs. Check Hoist Gearbox and Brake Lubricant Levels WARNING Lower the boom to its lowest position.
  • Page 128 CD5515-2/YB5515-2 SERVICE MANUAL PREVENTATIVE MAINTENANCE p1655 p1653 Transmission Oil Filter Transmission Strainer FIGURE 5-43 FIGURE 5-41 Fill the transmission with Mobil ATF 210, or equivalent, p1654 transmission fluid to the upper mark on the dipstick (approximately 13 liters [3.43 gallons]). 10.
  • Page 129 PREVENTATIVE MAINTENANCE CD5515-2/YB5515-2 SERVICE MANUAL Replace Axle Wheel Hub Lubricant p0429 Fill Plug Drain Plug Axle Housing Drain and Fill Plugs (Front Axle) FIGURE 5-44 Drain Plug Location FIGURE 5-47 p0430 Using the outriggers, raise the tires slightly off of the ground.
  • Page 130 CD5515-2/YB5515-2 SERVICE MANUAL PREVENTATIVE MAINTENANCE Repeat the above procedure for the other three wheel Fill the gearbox through the fill hole until the fluid is even hubs. with the bottom of the fill hole. Fill with SAE 90 EP gear lube.
  • Page 131 PREVENTATIVE MAINTENANCE CD5515-2/YB5515-2 SERVICE MANUAL Replace the Hydraulic Oil Filter p0426 Tank Hoses and Suction Strainer FIGURE 5-51 When the tank is empty, disconnect the two hydraulic lines from the rear of the hydraulic oil tank (Figure 5-51). Remove the suction strainer from the suction port and clean it in a suitable solvent.

  • Page 132: 2000 Hours Of Operation (Yearly)

    CD5515-2/YB5515-2 SERVICE MANUAL PREVENTATIVE MAINTENANCE Check Swing Gear/Pinion Backlash a0097 Remove the cover to expose the swing pinion and ring gear. High Point Swing Gear Backlash Check FIGURE 5-53 2000 Hours of Operation (Yearly) NOTE: You must read and understand the warnings and basic safety rules, found in Section 2 of this manual, before performing any operation or maintenance procedures.

  • Page 133: Miscellaneous Maintenance

    A reading of less than 10 volts with the engine at low idle crane if a critical weld is cracked or broken until the weld indicates a low battery charge. is repaired. Contact your Grove distributor or Manitowoc Crane Care. A reading of less than 14 volts with the engine speed above low idle indicates a problem in the charging •...

  • Page 134: Fuel System

    Manitowoc Crane Group's cranes are manufactured to high quality standards, including the type of paint finish Exercise special care and increase the frequency of demanded by today's industry.

  • Page 135: Cleaning Procedures

    To help protect against corrosion of Grove cranes, any major scratch(es) or minor damage. Manitowoc Crane Care recommends washing the crane at least monthly to remove all foreign matter. More frequent cleanings may be needed when operating in harsh CAUTION environmental conditions.

  • Page 136: Areas Of Application

    • All hardware, clips, pins, hose connections not painted necessary. will have treatment applied. Please contact Manitowoc Crane Care should you have any questions. GROVE 5-35 Published 1-20-2017, Control# 483-02...
  • Page 137 PREVENTATIVE MAINTENANCE CD5515-2/YB5515-2 SERVICE MANUAL 5-36 Published 1-20-2017, Control# 483-02...
  • Page 138 CD5515-2/YB5515-2 SERVICE MANUAL PREVENTATIVE MAINTENANCE 7650-65 FIGURE 5-54 Item Description Turntable Bearing Fasteners Item Description O/R Pins, Clips Hoist Tension Spring Hook block Tiedown Cable Hoist Hose Connections O/R Hose Connections Pivot Shaft Entire underside of unit Wire Rope Powertrain Hardware inside compartment Hose Connections inside turntable Boom Extension Pins, Clips - Option All Hardware, Clips, Pins, Hose Connections...
  • Page 139 PREVENTATIVE MAINTENANCE CD5515-2/YB5515-2 SERVICE MANUAL This Page Blank 5-38 Published 1-20-2017, Control# 483-02...
  • Page 140 CD5515-2/YB5515-2 SERVICE MANUAL ENGINE AND ENGINE SYSTEMS SECTION 6 ENGINE AND ENGINE SYSTEMS SECTION CONTENTS General ........6-1 Engine Fuel System .

  • Page 141: Engine Cooling System

    ENGINE AND ENGINE SYSTEMS CD5515-2/YB5515-2 SERVICE MANUAL Oil Performance Recommendations Oil Viscosity Recommendations CC/SF for use in naturally aspirated engines and in engines The use of a multigrade lubricating oil improves oil that operate in light duty service including standby and consumption control and improves engine cranking in cold emergency operation (equivalent to MIL-L-2104B).

  • Page 142: Radiator Cap And Overflow Bottle

    CD5515-2/YB5515-2 SERVICE MANUAL ENGINE AND ENGINE SYSTEMS protection will never be required, use a non-chromate ENGINE FUEL SYSTEM corrosion inhibitor and clean soft water. Change the Diesel Engine Fuel System Description water/corrosion inhibitor every 12 months, or 500 hours, or to manufacturer’s recommendation. The diesel engine fuel system is a closed-loop fuel system Do not use hard water in the cooling system.

  • Page 143: Qsb Engine Electronic Controlled Fuel System Units

    ENGINE AND ENGINE SYSTEMS CD5515-2/YB5515-2 SERVICE MANUAL • High pressure fuel line connections are loosened or the system can cause severe damage to both the lines are replaced. injection pump and the injection nozzles. • Initial start up or start up after an extended period of Use either a Grade No.

  • Page 144: Engine Air Intake System

    CD5515-2/YB5515-2 SERVICE MANUAL ENGINE AND ENGINE SYSTEMS ENGINE AIR INTAKE SYSTEM Check the complete exhaust system for broken, damaged, missing or mispositioned parts, open seams, holes, loose Air for combustion is pulled through an air filter by the connections and other deterioration which could cause engine.
  • Page 145 ENGINE AND ENGINE SYSTEMS CD5515-2/YB5515-2 SERVICE MANUAL Table 6-2: Engine Troubleshooting Chart Problem Probable Cause Action Engine hard to start or Improper starting procedure. Review starting procedure Engine will not start. Operator’s Manual. No fuel. Check fuel gauge. Air in fuel line. Bleed the fuel line.

  • Page 146: Removal And Installation

    CD5515-2/YB5515-2 SERVICE MANUAL ENGINE AND ENGINE SYSTEMS REMOVAL AND INSTALLATION 16. Disconnect the hydraulic hoses from the four sections of the hydraulic pump. Removal 17. Disconnect the suction hose from the hydraulic tank and the hydraulic pump suction manifold. 18. Disconnect the throttle linkage from the engine. WARNING 19.

  • Page 147: Installation

    ENGINE AND ENGINE SYSTEMS CD5515-2/YB5515-2 SERVICE MANUAL Installation 13. Connect the fuel lines to the fuel tank. NOTE: The diesel fuel supply fuel line must be bled of air Attach a hoist to the engine the same way removal was before engine can be started.
  • Page 148 CD5515-2/YB5515-2 SERVICE MANUAL TRANSMISSION AND TORQUE CONVERTER SECTION 7 TRANSMISSION AND TORQUE CONVERTER SECTION CONTENTS Technical Data ......7-1 Electrical Troubleshooting .
  • Page 149 TRANSMISSION AND TORQUE CONVERTER CD5515-2/YB5515-2 SERVICE MANUAL Minimum Engine RPM at Converter Stall: Gear ......... . . 2075 rpm Gear .

  • Page 150: Description Of Operation

    CD5515-2/YB5515-2 SERVICE MANUAL TRANSMISSION AND TORQUE CONVERTER DESCRIPTION OF OPERATION CAUTION Torque Converter Normal operating temperature is 82° - 88°C (180° - The torque converter Figure 7-1 is the hydraulic link between 190°F). High temperatures will cause damage and the engine and the drive train. There are three main leakage in the seals and gaskets of the torque converter.
  • Page 151 TRANSMISSION AND TORQUE CONVERTER CD5515-2/YB5515-2 SERVICE MANUAL NOTE: The filter is not used on this transmission. A remote filter installation is used. A - Torque Converter K - Spined Output Shaft B - Input Shaft Assembly L - 3 Position Solenoid Valve (Forward) C - Forward Clutch Assembly M - 3- Position Solenoid Valve (Mainshaft/Layshaft D - Main Shaft Assembly...
  • Page 152 CD5515-2/YB5515-2 SERVICE MANUAL TRANSMISSION AND TORQUE CONVERTER Two-Wheel Drive Transmission Hydraulic Circuits a2276 FIGURE 7-3 Oil from the torque converter flows out of the transmission smooth clutch engagement. Pressure from the clutches not unit to the external oil cooler V. From the cooler, the oil flows engaged will vent back to the sump by way of internal to pipe cluster W (the pipe cluster is only used on earlier passages and the solenoid spools.
  • Page 153 TRANSMISSION AND TORQUE CONVERTER CD5515-2/YB5515-2 SERVICE MANUAL Four-Wheel Drive Transmission Hydraulic Circuits - Typical a0233 FIGURE 7-4 Hydraulic Operation - Four- Wheel Drive J is spring applied. In two-wheel drive mode the solenoid is actuated and hydraulic oil is directed to the clutch pack The solenoid adapter block also houses a solenoid valve K releasing the clutch.
  • Page 154 CD5515-2/YB5515-2 SERVICE MANUAL TRANSMISSION AND TORQUE CONVERTER Forward High and Low Clutch Operation - Typical a2277 FIGURE 7-5 Clutch Operation clutch is vented to the sump by way of the solenoid valve spool. The transmission reverse high and reverse low clutch NOTE: The forward high and forward low clutch unit assemblies (Figure 7-5) are operated by the double solenoid...
  • Page 155 TRANSMISSION AND TORQUE CONVERTER CD5515-2/YB5515-2 SERVICE MANUAL B1 Reverse Low Ration Clutch B2 Reverse High Ratio Clutch C1 Forward Low Ratio Clutch C2 Forward High Ratio Clutch Mainshaft Clutch Layshaft Clutch 4WD Clutch Clutch Identification a1363 FIGURE 7-6 SV1 Reverse Low Solenoid SV2 Reverse High Solenoid SV6 Forward Low Solenoid SV5 Forward High Solenoid...
  • Page 156 CD5515-2/YB5515-2 SERVICE MANUAL TRANSMISSION AND TORQUE CONVERTER Troubleshooting Problem Possible Cause Remedy Lack of Power. Poor engine condition. Check and if necessary repair the engine. Low oil level. Add oil to transmission. Worn pump. Check, repair or replace the pump. Torque converter damaged.
  • Page 157 TRANSMISSION AND TORQUE CONVERTER CD5515-2/YB5515-2 SERVICE MANUAL Problem Possible Cause Remedy Low Converter Out Pressure. Low mainline pressure. See fault “Low Mainline Pressure.” Converter internal leakage. Check and replace the torque converter. Converter relief valve faulty. Check and replace the relief valve. Low Pump Flow.
  • Page 158 CD5515-2/YB5515-2 SERVICE MANUAL TRANSMISSION AND TORQUE CONVERTER Electrical Troubleshooting Table 7-1 shows which solenoid valves are energized for the four speeds and two directions of travel. System Operation Table 7-1: Solenoid Valve Energizing Sequence Each powershift transmission is provided with electrical safety locks which inhibit inadvertent operation of the crane GEAR DIRECTION...
  • Page 159 TRANSMISSION AND TORQUE CONVERTER CD5515-2/YB5515-2 SERVICE MANUAL FIGURE 7-10 Electrical Troubleshooting Chart Problem Possible Cause Remedy No drive at engine start up Blown ECU fuse. Check ECU fuse (also check fuse to shift lever). ECU connector loose. Check that connector is mating correctly with ECU.
  • Page 160 CD5515-2/YB5515-2 SERVICE MANUAL TRANSMISSION AND TORQUE CONVERTER Problem Possible Cause Remedy Machine will not perform a reversal of Speed too high for reversal of Slow crane with brakes. Deselect direction and repeating double beep direction. reversal. sounded. Sporadic gear changes. Moisture in ECU connectors.
  • Page 161 TRANSMISSION AND TORQUE CONVERTER CD5515-2/YB5515-2 SERVICE MANUAL Turn the ignition switch to the ON position. Do not set the If the solenoids are being energized correctly and the parking brake as this dumps the transmission to a problem persists, the problem may be in the neutral state.
  • Page 162 CD5515-2/YB5515-2 SERVICE MANUAL TRANSMISSION AND TORQUE CONVERTER Table 7-2: Instrument Panel Wire Harness Check  Full Battery Charge No voltage measured with key ON – Pin not connected Forward Gears Reverse Gears Pin No. Function Jumps To 1 – – –...
  • Page 163 TRANSMISSION AND TORQUE CONVERTER CD5515-2/YB5515-2 SERVICE MANUAL Checking for (+ V) Supply to Solenoids integrity of the harness and power supply to the ECU is verified. Chock all four tires, or lower all outriggers. Checking Parking Brake Switch Disable the machine neutral start protection to prevent the engine from starting.
  • Page 164 CD5515-2/YB5515-2 SERVICE MANUAL TRANSMISSION AND TORQUE CONVERTER (+) meter lead to the pin for the RED wire and the It has been noticed that water entry into the shift control negative (-) meter lead to the pin for the BLUE wire. assembly can occur if the control is damaged (replace the control).
  • Page 165 TRANSMISSION AND TORQUE CONVERTER CD5515-2/YB5515-2 SERVICE MANUAL TESTING Table 7-4: Solenoid Valve Energizing Sequence Solenoid Identification Clutches Engaged Gear Direction Solenoids When testing individual clutch pressures page 7-19, it is necessary to isolate the clutch being tested. For instance, to Forward Low &...
  • Page 166 CD5515-2/YB5515-2 SERVICE MANUAL TRANSMISSION AND TORQUE CONVERTER Example Only: From the example you can see that the forward clutch high is used for selection of both 2nd and 4th gear forward. We know from the table that the mainshaft and layshaft clutches Mainshaft are working normally (1st and 3rd gear selection shown Gear...
  • Page 167 TRANSMISSION AND TORQUE CONVERTER CD5515-2/YB5515-2 SERVICE MANUAL TEST POINTS A - Mainline Pressure J - Lubrication Pressure B - Converter inlet/converter relief valve pressure K - Cooler flow (flowmeter in line from cooler to C - Converter outlet pressure transmission) D - Mainshaft clutch pressure L - Forward high ratio clutch pressure E - Layshaft clutch pressure...
  • Page 168 CD5515-2/YB5515-2 SERVICE MANUAL TRANSMISSION AND TORQUE CONVERTER When testing other suspect clutches, connect a gauge to the If after interchanging the gauges, the readings are relevant suspect clutch pressure test point. See Figure 7-15 different than in step 4, have the gauges calibrated and repeat the test procedure.
  • Page 169 NOTE: Special adapters are required to perform the transmission in neutral the pressure gauge will show following test. Contact Manitowoc Crane Care. “Converter In Pressure”. Compare the gauge reading with the figures listed in the General Technical Data on 7-22...
  • Page 170 CD5515-2/YB5515-2 SERVICE MANUAL TRANSMISSION AND TORQUE CONVERTER page 7-1. A high or low reading could indicate a faulty valve P while observing the gauge reading which should converter relief valve. rise to the converter relief valve setting specified on page 7-1. Remove the pressure test gauge.
  • Page 171 TRANSMISSION AND TORQUE CONVERTER CD5515-2/YB5515-2 SERVICE MANUAL TRANSMISSION REPAIR Special Service Tools 4WD Pressure Test Kit FIGURE 7-21 a1518 FIGURE 7-17 a0254 End Float Setting Tool Mainshaft Air Line Adapter FIGURE 7-22 a1411 Reverse Clutch End Float Setting Tool FIGURE 7-18 a0249 Seal Stake Nut...
  • Page 172 CD5515-2/YB5515-2 SERVICE MANUAL TRANSMISSION AND TORQUE CONVERTER 1. End Play Checking Kit (Includes Items 2 - 13) 2. Base Plate and Bolts 3. Yoke 4. Mainshaft Adapter 5. Pillar (20,75 mm) 6. Pillar (45,75 mm) 7. Setting Body (54 mm) 8.
  • Page 173 TRANSMISSION AND TORQUE CONVERTER CD5515-2/YB5515-2 SERVICE MANUAL Transmission Hex Bolt (12) Lockwasher (12) Drive Plate Kit Torque Converter Screw (6) Drive Plate Reinforcement Lockwasher 10. Bolt (6) 11. Engine FIGURE 7-25 a0257 Servicing the Torque Converter six drive plate mounting screws 6 to remove the torque converter and drive plate.
  • Page 174 CD5515-2/YB5515-2 SERVICE MANUAL TRANSMISSION AND TORQUE CONVERTER dial indicator held in position against the converter hub Figure 7-26. The torque converter must be centered on the flywheel within 0.15 mm (0.006 in). NOTE: If the alignment should exceed 0.15 mm (0.006 in), remove the torque converter and check the spline shaft for burrs, remove the drive shaft and rotate it 180°...
  • Page 175 TRANSMISSION AND TORQUE CONVERTER CD5515-2/YB5515-2 SERVICE MANUAL This Page Blank 7-28 Published 1-20-2017, Control# 483-02...
  • Page 176 CD5515-2/YB5515-2 SERVICE MANUAL AXLES/DRIVE SHAFTS/WHEELS AND TIRES SECTION 8 AXLES/DRIVE SHAFTS/WHEELS AND TIRES Removal....... . 8-19 Description .
  • Page 177 AXLES/DRIVE SHAFTS/WHEELS AND TIRES CD5515-2/YB5515-2 SERVICE MANUAL Rear Drive Axle FIGURE 8-2 a0166 TECHNICAL DATA Front Drive Axle Type ..........3 piece spiral bevel input with epicyclic hub reduction and inboard braking Installation .
  • Page 178 CD5515-2/YB5515-2 SERVICE MANUAL AXLES/DRIVE SHAFTS/WHEELS AND TIRES Input type ..........1480 half yoke Oscillation (Both Directions) .

  • Page 179: Axles/Drive Shafts/Wheels And Tires

    AXLES/DRIVE SHAFTS/WHEELS AND TIRES CD5515-2/YB5515-2 SERVICE MANUAL FRONT DRIVE AXLE REPAIR Loosen and remove the eight mounting bolts and nuts. Remove the axle from the machine. Removal Installation Place the axle on a trolly jack. WARNING Position the axle and trolly jack under the crane frame. A raised and badly supported crane can fall on you Install the eight bolts and nuts with the nuts on top of the causing severe injury or death.
  • Page 180 CD5515-2/YB5515-2 SERVICE MANUAL AXLES/DRIVE SHAFTS/WHEELS AND TIRES a0174 a0167 Driver - Crownwheel Bearing Bearing Pad Driver and Differential Bearing Cones a0168 a0171 Measuring Cup - Pinion Head Adapter - Steer/Drive Axle Adapter - Steer/Drive Axle Bearing Pinion Bearing Cone Pinion Bearing Cone a0169 Spacer - Pinion Bearing Pre-load a0172...

  • Page 181: Replacing The Pinion Oil Seal

    AXLES/DRIVE SHAFTS/WHEELS AND TIRES CD5515-2/YB5515-2 SERVICE MANUAL Replacing the Pinion Oil Seal WARNING A raised and badly supported crane can fall on you causing severe injury or death. Position the crane on a firm, level surface before raising one end. Ensure that the other end is securely chocked.

  • Page 182: Axle Hub Repair

    CD5515-2/YB5515-2 SERVICE MANUAL AXLES/DRIVE SHAFTS/WHEELS AND TIRES Remove the external retaining ring 22 and sun gear 20. Remove the Verbus Ripp bolts 16. These bolts are very tight and care must be taken not to distort the bolt heads. Use as short of an extension as possible. Discard the Verbus Ripp bolts.
  • Page 183 AXLES/DRIVE SHAFTS/WHEELS AND TIRES CD5515-2/YB5515-2 SERVICE MANUAL Bearing Oil Seal Hub Swivel Snap Ring Wheel Bearing Cone Wheel Bearing Cup Bearing Carrier Combination Seal 10. Wheel Bearing Cone 11. Wheel Bearing Cup 12. Annulus Ring 13. Brake Carrier 14. Retaining Ring 15.
  • Page 184 CD5515-2/YB5515-2 SERVICE MANUAL AXLES/DRIVE SHAFTS/WHEELS AND TIRES 16. Remove drive shaft 21 from the axle casing. 17. Pry out drive shaft inner oil seal 2. 18. Using a bearing puller, remove bearing 1. 19. Pry out drive shaft inner seal 31B. 20.
  • Page 185 AXLES/DRIVE SHAFTS/WHEELS AND TIRES CD5515-2/YB5515-2 SERVICE MANUAL FIGURE 8-11 a0186 FIGURE 8-10 a0496 Repeat steps 19 and 19A and record the reading. NOTE: After assembling the bearing carrier to the swivel d. To get the rolling force, subtract the seal drag rolling hub, make sure that there is sufficient clearance force (Step 19 A) from reading obtained at step 19C.

  • Page 186: Drive Head Repair

    CD5515-2/YB5515-2 SERVICE MANUAL AXLES/DRIVE SHAFTS/WHEELS AND TIRES Drive Head Repair The following procedures can only be carried out with the axle removed from the crane. See “Removal”, on page 8-4. It will be necessary to provide a suitable stand to support the axle after removal.
  • Page 187 AXLES/DRIVE SHAFTS/WHEELS AND TIRES CD5515-2/YB5515-2 SERVICE MANUAL Lift crownwheel/differential assembly Figure 8-17. NOTE: If both brake piston housings are removed, put a mark on the crownwheel end of the drive head casing to ensure that the assembly is returned to its original position.
  • Page 188 CD5515-2/YB5515-2 SERVICE MANUAL AXLES/DRIVE SHAFTS/WHEELS AND TIRES 10. Remove the pinion seal and outer bearing cone Figure 8-19. a0196 FIGURE 8-21 13. To dismantle the differential assembly: FIGURE 8-19 a0194 Remove bolts D Figure 8-22. 11. If necessary, drive out the pinion inner bearing cup and shims Figure 8-20.
  • Page 189 AXLES/DRIVE SHAFTS/WHEELS AND TIRES CD5515-2/YB5515-2 SERVICE MANUAL Remove the differential gears and spherical washers Figure 8-24. Pull off both differential bearing cones. If required, remove the crownwheel to differential c a s e h a l f r e t a i n i n g b o l t s a n d r e m o v e t h e crownwheel.
  • Page 190 CD5515-2/YB5515-2 SERVICE MANUAL AXLES/DRIVE SHAFTS/WHEELS AND TIRES Example: Pinion too deeply in mesh Figure 8-29 Dimensions in Millimeters Decrease the shim thickness between the pinion inner bearing cup and the axle casing. Move the crown wheel Dimension A 0.25 towards the pinion to correct the backlash. Add to depth +30.01 Total...
  • Page 191 AXLES/DRIVE SHAFTS/WHEELS AND TIRES CD5515-2/YB5515-2 SERVICE MANUAL Assembly Procedures Install the pinion bearing cup Figure 8-33, together with the required thickness of shims to give correct pinion NOTE: The crownwheel and pinion are matched and depth (see Pinion Depth on page 8-14). To ensure that should be replaced as a set, if either one is cup is installed square, use a suitable puller assembly.
  • Page 192 CD5515-2/YB5515-2 SERVICE MANUAL AXLES/DRIVE SHAFTS/WHEELS AND TIRES Insert the pinion into its bore Figure 8-35. Before zero, then check the seal drag torque. It should be inserting, ensure that pinion matches between 0,40 to 1,0 Nm (3.5 to 8.9 lb-in). crownwheel.
  • Page 193 AXLES/DRIVE SHAFTS/WHEELS AND TIRES CD5515-2/YB5515-2 SERVICE MANUAL 11. Adjust differential side nuts B Figure 8-42 to give a bearing pre-load of 1,36 to 2,5 Nm (1.0 to 1.84 lb-ft). Measure the pre-load by taking another rolling torque reading and subtracting the torque value measured at Step 8.

  • Page 194: Rear Axles Repair

    CD5515-2/YB5515-2 SERVICE MANUAL AXLES/DRIVE SHAFTS/WHEELS AND TIRES REAR AXLES REPAIR Installation Place the axle on a trolley jack and position it under the Removal crane frame. Raise axle and position it in the mounting frame. Install the axle pivot pin. WARNING Coat the threads of the pin retaining bolt with Loctite®...
  • Page 195 AXLES/DRIVE SHAFTS/WHEELS AND TIRES CD5515-2/YB5515-2 SERVICE MANUAL Remove planet gears 28 only if defective. Note that gears can only be removed as assemblies, which consist of the gear, the bearing and two “L” shaped retaining rings. To remove the planet gear, remove the external retaining ring 29.
  • Page 196 CD5515-2/YB5515-2 SERVICE MANUAL AXLES/DRIVE SHAFTS/WHEELS AND TIRES Bearing Oil Seal Hub Swivel Wheel Bearing Cone Wheel Bearing Cup Bearing Carrier Combination Seal 10. Wheel Bearing Cone 11. Wheel Bearing Cup 12. Brake Seal 13. Seal 14. Seal 15. Brake Piston 16.
  • Page 197 AXLES/DRIVE SHAFTS/WHEELS AND TIRES CD5515-2/YB5515-2 SERVICE MANUAL 15. If removal is necessary, carefully remove the brake Install new oil seal 39. Pack grease between the lips of piston 15 from its housing. A hydraulic hand pump can the seal. be used to force the piston out of the housing. Tap drive shaft inner bearing 1 into position in hub swivel 16.
  • Page 198 CD5515-2/YB5515-2 SERVICE MANUAL AXLES/DRIVE SHAFTS/WHEELS AND TIRES 13. Connect the track rod and steering cylinder to the axle 22. Install the annulus assembly onto the splined hub. steering knuckle. Tighten the track rod nut to a torque of Check that the relationship marks align. Push the annulus assembly into the splined hub until the splines 135 Nm (100 lb-ft), then continue to tighten to next castellation and insert the pin.

  • Page 199: Drive Head Repair (Drive Axles Only)

    AXLES/DRIVE SHAFTS/WHEELS AND TIRES CD5515-2/YB5515-2 SERVICE MANUAL activates and retracts correctly and does not stick in the Remove bolts 1 and remove drive head carrier 2 from applied position before installing planet gear carrier 27. the axle casing. If the brake piston has not retracted, the brake seal or Clean the drive head carrier and axle casing mating piston assembly may have been assembled incorrectly.
  • Page 200 CD5515-2/YB5515-2 SERVICE MANUAL AXLES/DRIVE SHAFTS/WHEELS AND TIRES Bolts (16) Drive Head Carrier Tension Pin Tension Pin Castellated Nut Castellated Nut Outer Bearing Race Outer Bearing Race Taper Roller Bearing Cone 10. Differential Assembly 11. Retaining Bolts (8) 12. Case Half 13.
  • Page 201 AXLES/DRIVE SHAFTS/WHEELS AND TIRES CD5515-2/YB5515-2 SERVICE MANUAL Assembly Position top case half 12 onto bottom half assembly 13 aligning the match mark letters (see Note on page 8-7). NOTE: The crownwheel 20 Figure 8-49 and pinion 24 are Apply Loctite® 243 to the threads of bolts 11, then install matched and should be replaced as a pair if either them and tighten to a torque of 56 Nm (32 lb-ft).

  • Page 202: Drive Shafts

    CD5515-2/YB5515-2 SERVICE MANUAL AXLES/DRIVE SHAFTS/WHEELS AND TIRES The retaining straps 2 Figure 8-50 and Figure 8-51 stretch with use, therefore these straps must always be replaced with new ones. CAUTION Front Axle Drive Shaft Verbus Ripp bolts must NOT be reused. Remove bolts, lockwashers and mounting straps 2 Figure 8-50 from transmission.

  • Page 203: Inspection

    AXLES/DRIVE SHAFTS/WHEELS AND TIRES CD5515-2/YB5515-2 SERVICE MANUAL cap is free, pull the sleeve yoke and dust cap free of the Repeat steps 1 and 2 to the sleeve yoke end. slip yoke. To disassemble the sleeve yoke 3 from the slip yoke 4, turn the dust cap assembly counterclockwise.

  • Page 204: Installation

    CD5515-2/YB5515-2 SERVICE MANUAL AXLES/DRIVE SHAFTS/WHEELS AND TIRES assemblies into place. Use care not to cause damage to the bearings or caps. Install the snap rings. Make sure the snap rings are engaged fully in the groove. Repeat steps 1 through 3 on opposite end of drive shaft. Repeat steps 1 through 3 to install the flange yoke to the drive shaft.

  • Page 205: Lubrication Procedure

    AXLES/DRIVE SHAFTS/WHEELS AND TIRES CD5515-2/YB5515-2 SERVICE MANUAL Apply grease with a grease gun to the fittings on the WHEEL & TIRES journal crosses and on the slip joint. Apply grease until it exists through the seals. See Lubrication Procedure on this page.
  • Page 206 CD5515-2/YB5515-2 SERVICE MANUAL SECTION 9 BRAKE SYSTEM SECTION CONTENTS Technical Data ......9-1 Brake Piston Seal Leakage Test (Front Axle Only) .

  • Page 207: Accumulator

    CD5515-2/YB5515-2 SERVICE MANUAL Hydraulic Piston Diameter ....... . . 216 mm (8.5 in) Piston Operation .

  • Page 208: Description

    CD5515-2/YB5515-2 SERVICE MANUAL DESCRIPTION steering operation the priority flow control valve shifts to furnish flow to the steering system. (See Steering System, There are two brake systems used on the crane; the service Section 10) The priority flow control valve also includes the brake system and the parking brake system.
  • Page 209 CD5515-2/YB5515-2 SERVICE MANUAL Park Brake/ Secondary Brake Service Brakes Brake Light Switch Brake Modulating Valve (Foot Pedal) Brake/Steering Manifold Priority Flow Control Valve Variable Displacement Piston Pump Hydraulic Tank FIGURE 9-1 Published 1-20-2017, Control# 483-02...
  • Page 210 CD5515-2/YB5515-2 SERVICE MANUAL Low Pressure Warning Switch The low pressure warning switch illuminates a red light on the dash when the brake pressure goes below 58.61 bar (850 psi). When the red light illuminates, there still is enough pressure for brake application to stop the crane. After which, the brake system must be checked and repaired.

  • Page 211: Parking Brake System

    CD5515-2/YB5515-2 SERVICE MANUAL Parking Brake System Description Of Operation The parking brake system consists of a two-way switch in the instrument panel, a solenoid valve and a parking brake. The system connects into the service brake system and uses the accumulator for system pressure.

  • Page 212: Parking Brake Bleeding

    CD5515-2/YB5515-2 SERVICE MANUAL Parking Brake Bleeding NOTE: Before working on the brake system, make sure the crane is on level ground and that all four wheels are chocked. The accumulator must be charged before this operation can be performed. If you are not sure the accumulator is charged, engage the parking brake, start the engine and let it run for several minutes.

  • Page 213: Accumulator Charging

    CD5515-2/YB5515-2 SERVICE MANUAL Shut off the engine and place chock blocks in front and Checking For Residual Pressure behind all four wheels. Release the parking brake. The following should be done with the engine running and Check that the brake moves freely on the guide/slide the hydraulic oil at working temperature.

  • Page 214: Service Brake Repair

    CD5515-2/YB5515-2 SERVICE MANUAL FIGURE 9-10 a0222 FIGURE 9-11 a0223 To check for severe piston seal damage: NOTE: The tube must be kept vertical during the test. Use Fill the housing of hand pump with Mobil fluid 424, tape to attach the tube to the side of machine. or equivalent hydraulic oil.
  • Page 215 CD5515-2/YB5515-2 SERVICE MANUAL Disassembly Support the axle arm Figure 9-12 and remove bolts A. FIGURE 9-14 p0090 Remove the retaining ring Figure 9-15. If the brake pack is to be reused, note the position of the plates before FIGURE 9-12 p0088 removing them.
  • Page 216 CD5515-2/YB5515-2 SERVICE MANUAL Remove and discard seals F and G Figure 9-19. Inspect the housing for damage and scoring. Nicks or cuts in the seals may be responsible for loss of brake fluid. FIGURE 9-16 a0228 Remove the three reaction pins D Figure 9-17. Inspect for damage.
  • Page 217 CD5515-2/YB5515-2 SERVICE MANUAL p0092 FIGURE 9-23 p0093 FIGURE 9-21 Install one counterplate B Figure 9-24 into the housing, Assemble the friction plates and counterplates onto the then the brake pack, then the other counterplate. Ensure carrier. If the original brake pack is being reused, return that the chamfered end of the brake carrier C faces the plates to their original positions (see Disassembly away from the drive head.

  • Page 218: Rear Axle Brakes

    CD5515-2/YB5515-2 SERVICE MANUAL Install bolts A Figure 9-25 and tighten to a torque of 244 Nm (178 lb-ft). NOTE: Check the grade of bolts installed. Grade 8.8 should be tightened to a torque of 244 Nm (178 lb- ft). Grade 12.9 bolts should be tightened to a torque of 400 Nm (295 lb-ft).

  • Page 219: Parking Brake Repair

    CD5515-2/YB5515-2 SERVICE MANUAL PARKING BRAKE REPAIR Clamp the brake in a vice with soft jaws with the clearance slot facing straight up. Lining Kit Replacement NOTE: Clamping should be done on sides of the brake, not on machined surfaces. Remove two screws 27 through access holes in housing 26.

  • Page 220: Repair Kit Installation

    CD5515-2/YB5515-2 SERVICE MANUAL Capscrew (4) Lockwasher (4) Cover Seal Belleville Springs (5) Washer Adjusting Bolt Lock Nut Piston 10. Backup Ring 11. O-Ring 12. Push Rod 13. O-Ring 14. Backup Ring 15. Piston 25. Lining 16. O-Ring 26. Housing 17. Backup Ring 27.
  • Page 221 CD5515-2/YB5515-2 SERVICE MANUAL Remove the bolts and nuts used to fasten the brake 14. Remove piston 15 from housing 26 bore. Remove O- mounting bracket assembly to the crane. Remove the rings 13 and 16 and backup rings 14 and 17 from piston parking brake assembly.

  • Page 222: Seal Kit Installation

    CD5515-2/YB5515-2 SERVICE MANUAL The linings must be kept free of grease, oil, etc. This will shut off hydraulic pressure to the parking brake. Release system pressure by actuating the service brake pedal until no resistance is felt. Then, engage and disengage the parking brake to release its pressure.

  • Page 223: Brake Modulating Valve Repair

    CD5515-2/YB5515-2 SERVICE MANUAL 14. Remove lining and piston assembly 22 from housing 26 30. Open the accumulator needle valve and then bleed air bore. Remove O-rings 18 from the lining and piston from the system as described on page 9-6. assembly.

  • Page 224: Assembly

    CD5515-2/YB5515-2 SERVICE MANUAL Remove end plug 8 and spring 10 from housing 12. Carefully install new cup 14 and new seal 15 into bore of Remove O-ring 9 from plug 8. housing 12. Make sure they are installed in the proper order and direction.

  • Page 225: Troubleshooting

    CD5515-2/YB5515-2 SERVICE MANUAL TROUBLESHOOTING Service Brakes PROBLEM POSSIBLE CAUSE REMEDY Warning light on instrument panel Loss of brake pressure. Any cause under NO BRAKES. illuminates. No brakes. Faulty brake modulating valve. Repair or replace. Faulty priority flow control valve. Replace. Loss of fluid from broken line, Check all circuit lines, hoses and loose fitting of hose.
  • Page 226 CD5515-2/YB5515-2 SERVICE MANUAL STEERING SYSTEM SECTION 10 STEERING SYSTEM Sensor Operation and Spacing Checks..10-9 Description ......10-1 General .
  • Page 227 STEERING SYSTEM CD5515-2/YB5515-2 SERVICE MANUAL Steering Selector Manifold Front Rear Steering Orbitrol Brake/Steering Manifold Load Sense Dump Valve Priority Flow Control Valve Variable Displacement Engine Piston Pump Transmission Hydraulic Tank Steering System a2095 FIGURE 10-1 10-2 Published 1-20-2017, Control# 483-02...
  • Page 228 CD5515-2/YB5515-2 SERVICE MANUAL STEERING SYSTEM Right Turn in 2 Wheel Steer Mode a2098 FIGURE 10-2 GROVE 10-3 Published 1-20-2017, Control# 483-02...

  • Page 229: Crab Steering

    STEERING SYSTEM CD5515-2/YB5515-2 SERVICE MANUAL Four-Wheel Steering steering cylinders flows into port L and out of port T of the steering orbitrol and back to tank. During four-wheel steering, the front wheels steer in the direction that the steering wheel is turned, while the rear Crab Steering wheels turn in the opposite direction.
  • Page 230 CD5515-2/YB5515-2 SERVICE MANUAL STEERING SYSTEM Right Turn in 4 Wheel Steer Mode a2097 FIGURE 10-3 GROVE 10-5 Published 1-20-2017, Control# 483-02...
  • Page 231 STEERING SYSTEM CD5515-2/YB5515-2 SERVICE MANUAL Right Side Ways in Crab Steer Mode a2099 FIGURE 10-4 10-6 Published 1-20-2017, Control# 483-02...

  • Page 232: Steering Proximity Switches

    CD5515-2/YB5515-2 SERVICE MANUAL STEERING SYSTEM STEERING PROXIMITY SWITCHES The system is used to select one of the three steering modes. When the selector switch in the cab is placed in General either two-wheel steer, four-wheel steer or crab steer, that particular mode of steering is used to steer the crane.
  • Page 233 STEERING SYSTEM CD5515-2/YB5515-2 SERVICE MANUAL Steering Electrical Wiring Diagram a2096 FIGURE 10-7 10-8 Published 1-20-2017, Control# 483-02...

  • Page 234: Steering System

    CD5515-2/YB5515-2 SERVICE MANUAL STEERING SYSTEM Sensor Operation and Spacing Checks If the sensor is working properly, check the spacing between the sensor and sensor bracket. Adjust if Checking Alignment and Operation necessary. Both sensors must be working and spaced properly for the If the sensor is malfunctioning, replace it and adjust the steering mode selection to function properly.
  • Page 235 STEERING SYSTEM CD5515-2/YB5515-2 SERVICE MANUAL Symptom Probable Cause Action Slow steering, hard steering, or loss of Worn or malfunctioning pump. Repair or replace the pump. power assist. Priority valve not operating Check for stuck spool. Repair or correctly. replace. Check load sense line for leaks or poor connection.
  • Page 236 CD5515-2/YB5515-2 SERVICE MANUAL STEERING SYSTEM Symptom Probable Cause Action Steering fails to respond to selected Selector switch faulty. Replace switch. mode. Proximity switches not operating Check setting of proximity switch. IMPORTANT: The wheels must pass correctly. Reset or replace switches. the proximity sensor to actuate relays Steering mode...

  • Page 237: Steering Orbitrol

    STEERING SYSTEM CD5515-2/YB5515-2 SERVICE MANUAL Symptom Probable Cause Action Binding or poor centering of steering Large dirt particles can cause Clean the orbitrol. Repair or wheel. binding between orbitrol spool and replace if necessary. If another sleeve. component has failed, generating contaminants, flush the hydraulic s y s t e m w h i l e b y p a s s i n g t h e orbitrol.
  • Page 238 CD5515-2/YB5515-2 SERVICE MANUAL STEERING SYSTEM Emergency Manual Steering The gerotor Figure 10-10 in the orbitrol permits steering, with difficulty, when power is lost. A check valve between the IN and OUT ports allows for recirculation of the oil to prevent cavitation when steering without power.
  • Page 239 STEERING SYSTEM CD5515-2/YB5515-2 SERVICE MANUAL Removal Completely clean around the area of the steering orbitrol. Remove the outside cover plate Figure 10-17 in front of Put tags on the lines to the steering orbitrol for the operator’s compartment. identification at installation. Rotate the steering wheel a small amount in each direction several times, then release to get a balance of pressure in the steering circuit.
  • Page 240 CD5515-2/YB5515-2 SERVICE MANUAL STEERING SYSTEM Dust Seal Ring 15. Washer Housing, Spool and Sleeve 16. Special Screw Ball 17. Screw Threaded Bushing 18. Name Plate O-Ring & Kin-ring 21. Relief Valve Bearing Assembly 22. Spring Kin-ring 23. Shock Valve Cross Pin 31.
  • Page 241 STEERING SYSTEM CD5515-2/YB5515-2 SERVICE MANUAL Disassembly Cleanliness is extremely important when repairing a steering orbitrol. Work in a clean area. Use a wire brush to remove foreign materials and debris from around exterior joints of the unit. Place the steering unit in the holding tool. Screw out the screws in the end cover (6 standard plus one special screw).
  • Page 242 CD5515-2/YB5515-2 SERVICE MANUAL STEERING SYSTEM 16. Remove plugs from shock valves using a 6 mm Allen wrench (Figure 10-27). FIGURE 10-24 FIGURE 10-27 12. A small mark has been made with a pumice stone on both spool and sleeve close to one of the slots for the 17.
  • Page 243 STEERING SYSTEM CD5515-2/YB5515-2 SERVICE MANUAL FIGURE 10-30 FIGURE 10-33 20. Remove the plug using and 8 mm Allen wrench. Inspection Remove seal washers (Figure 10-31). Check all mating surfaces. Replace any parts that have scratches or burrs that could cause leakage or binding. Clean all metal parts in a clean solvent.
  • Page 244 CD5515-2/YB5515-2 SERVICE MANUAL STEERING SYSTEM 1. Washer for axial bearing 2. Outer needle bearing 3. Outer bearing race 4. Spool 5. Sleeve 6. Inner needle bearing 7. Inner bearing race FIGURE 10-35 FIGURE 10-38 Fit the cross pin into the spool/sleeve (Figure 10-36). Turn the steering unit until the bore is horizontal.
  • Page 245 STEERING SYSTEM CD5515-2/YB5515-2 SERVICE MANUAL FIGURE 10-41 FIGURE 10-44 10. Press and turn the O-ring/kin-ring into position in the 14. With a light turning movement, guide the spool and housing. sleeve into the bore. Fit the spool assembly holding the cross pin horizontal (Figure 10-45).
  • Page 246 CD5515-2/YB5515-2 SERVICE MANUAL STEERING SYSTEM 21. Place the distributor plate so that the channel holes match the holes in the housing. FIGURE 10-47 17. Screw the threaded bushing lightly into the check valve FIGURE 10-50 bore. The top of the bushing must lie just below the surface of the housing.
  • Page 247 STEERING SYSTEM CD5515-2/YB5515-2 SERVICE MANUAL FIGURE 10-53 FIGURE 10-56 25. Fit the gearwheel (rotor) and cardan shaft so that a tooth 28. Fit the special screw with washer and place it in the hole base in the rotor is positioned in relation to the shaft slot shown.
  • Page 248 CD5515-2/YB5515-2 SERVICE MANUAL STEERING SYSTEM 34. Place springs and valve cones over the two balls. NOTE: The blue spring applies to setting range 90-180 bar (1305-2610 psi). The untreated spring applies to setting range 170-260 bar (2465-3770 psi). 35. Screw in the two setting screws using a 6 mm Allen wrench.

  • Page 249: Steering Cylinder

    STEERING SYSTEM CD5515-2/YB5515-2 SERVICE MANUAL STEERING CYLINDER Technical Data Cylinder Bore ........60 mm (2.36 inches) Stroke .
  • Page 250 CD5515-2/YB5515-2 SERVICE MANUAL STEERING SYSTEM Grease Fitting (2) Piston Seal Cylinder Barrel 10. Wear Ring Left Side Pipe 11. O-Ring Right Side Pipe 12. O-Ring Oil Seal (4) 13. End Cap Bushing (2) 14. Gland Seal Dowel 15. Wiper Seal Piston 16.
  • Page 251 STEERING SYSTEM CD5515-2/YB5515-2 SERVICE MANUAL Assembly Install new gland seal 14 Figure 10-65 using the special installation tool as follows: NOTE: The size (diameter) and position of pins is determined by the diameter and radial width of the gland seal being installed. The pins are screwed into threaded holes in the tool body, the spacing of the holes is designed to fit small and large diameter gland seals.
  • Page 252 CD5515-2/YB5515-2 SERVICE MANUAL STEERING SYSTEM 12. Carefully insert the assembled cylinder rod into the cylinder barrel. Use care to prevent damage to the piston seal and wear ring during installation. Work the piston rod straight into the cylinder barrel. 13. Apply Loctite 932 to the first three threads of the end cap.
  • Page 253 STEERING SYSTEM CD5515-2/YB5515-2 SERVICE MANUAL This Page Blank 10-28 Published 1-20-2017, Control# 483-02...
  • Page 254 CD5515-2/YB5515-2 SERVICE MANUAL STRUCTURALS SECTION 11 STRUCTURALS SECTION CONTENTS Booms ........11-1 Hoist Service .
  • Page 255 STRUCTURALS CD5515-2/YB5515-2 SERVICE MANUAL Connect electrical wiring as necessary. Refer to Electric Start the engine and operate all boom functions in both System, page 3-1. directions to remove air from the hydraulic system. Check for leaks. Install the wire rope and hook block. 11-2 Published 1-20-2017, Control# 483-02...
  • Page 256 CD5515-2/YB5515-2 SERVICE MANUAL STRUCTURALS Boom Assembly - Section 1 FIGURE 11-1 Grove 11-3 Published 1-20-2017, Control# 483-02...
  • Page 257 STRUCTURALS CD5515-2/YB5515-2 SERVICE MANUAL Boom Assembly - Section 2 FIGURE 11-1 continued 11-4 Published 1-20-2017, Control# 483-02...
  • Page 258 CD5515-2/YB5515-2 SERVICE MANUAL STRUCTURALS Boom Assembly - Section 3 FIGURE 11-1 continued Grove 11-5 Published 1-20-2017, Control# 483-02...
  • Page 259 STRUCTURALS CD5515-2/YB5515-2 SERVICE MANUAL Boom Assembly - Section 4 FIGURE 11-1 continued 11-6 Published 1-20-2017, Control# 483-02...
  • Page 260 CD5515-2/YB5515-2 SERVICE MANUAL STRUCTURALS Item Description Item Description Sheave Wheel 1st Boom Section Capscrew 2nd Boom Section Wear Pad 3rd Boom Section Shim 4th Boom Section Capscrew Retract Cable Plate Extend Cable Wear Pad Retract Cable Anchor Plate Extend Cable Capscrew Telescope Cylinder Cable Keeper...
  • Page 261 STRUCTURALS CD5515-2/YB5515-2 SERVICE MANUAL Item Description Item Description Cable Protector Pivot Boom Head Hanger Plate Anti-Two Block Assembly Upper Pivot Capscrew Lower Anti-Two Block Assembly Spacer Capscrew Capscrew Capscrew Snap Ring Spacer Shim Hardened Washer Guide Clamp Short Cable Guide Plate Cable Protector Hex Nut...

  • Page 262: Disassembly

    CD5515-2/YB5515-2 SERVICE MANUAL STRUCTURALS Disassembly 18. As necessary, remove the following items from boom section 2: At the rear of the assembly, remove the hoses and Remove the bolts and lockwashers securing the fittings from the telescope cylinder. Cap or plug all lower rear wear pads, remove the wear pads.
  • Page 263 STRUCTURALS CD5515-2/YB5515-2 SERVICE MANUAL Barrel Cylinder 22. Rod Wiper Cylinder Shaft 23. Rod Seal Inner Shaft Assembly 24. Back-up Ring Packing Gland 25. O-ring Packing Gland 26. Wear Ring Stop Tube 27. Piston Seal Mandrel 28. O-ring Piston 29. Wear Ring Mandrel 30.
  • Page 264 CD5515-2/YB5515-2 SERVICE MANUAL STRUCTURALS Assembly Install the top rear wear pads on boom section 3. As necessary, install the following items on boom NOTE: During assembly, use Loctite® 243 (blue) on all section 2: fastener threads. Apply lubricant (bronze anti- seize) to all wear pads.

  • Page 265: Wire Rope, Sheaves And Hoist Blocks

    STRUCTURALS CD5515-2/YB5515-2 SERVICE MANUAL WIRE ROPE, SHEAVES AND HOIST a0358 BLOCKS Wire Rope Wire Rope Description A wire rope is a machine, by definition: “An assemblage of parts that transmit forces, motion and energy from one to another in some predetermined manner and to some desired end.”...

  • Page 266: Inspecting Wire Rope

    CD5515-2/YB5515-2 SERVICE MANUAL STRUCTURALS In the U.S.A., regular INSPECTIONS of the wire rope • Wire ropes are damaged by knots. Wire rope with and keeping of PERMANENT RECORDS SIGNED BY knots must never be used. A QUALIFIED PERSON ARE REQUIRED BY OSHA •...

  • Page 267: Wire Rope Installation

    STRUCTURALS CD5515-2/YB5515-2 SERVICE MANUAL a1298 Wire Rope Inspection REDUCTION FROM NORMAL 9/16” (14.3 MM) DIAMETER OF MORE THAN 1/32” (0.8 MM) FIGURE 11-4 Wire Rope Installation a0025 Installation of Socket and Wedge Always connect the socket so that the load is pulled on the same line as the socket (See Figure 11-5).
  • Page 268 CD5515-2/YB5515-2 SERVICE MANUAL STRUCTURALS Installation of a New Wire Rope After installation, operate the hoist with a minimum load until you see the wire rope is moving easily over the The wire rope is given a natural bend or winding from the sheaves and is winding correctly on the hoist drum.

  • Page 269: Main Hoist

    STRUCTURALS CD5515-2/YB5515-2 SERVICE MANUAL MAIN HOIST Warm-up Procedure A warm-up procedure is recommended at each start-up and Description is essential if ambient temperature is below +40°F (4°C). Run the crane at idle with the hoist control lever in neutral The hoist is composed of motor control valve, a fixed and allow sufficient time for the hydraulic system to warm up.
  • Page 270 CD5515-2/YB5515-2 SERVICE MANUAL STRUCTURALS • Remove the DRI unit from the hoist. Installation The DRI is installed on the left side of the drum. For initial installations, remove the dust cover from the center of the Retaining Screws drum. DRI Cable FIGURE 11-9 DRI Shaft DRI Sensor...

  • Page 271: Hoist Repair

    STRUCTURALS CD5515-2/YB5515-2 SERVICE MANUAL Secure the DRI with the retaining screws. Loosen the set screw on the bottom of the DRI flange (Figure 11-12). LLI Learn Button Use a spanner wrench and rotate the DRI so that the connector is pointed down. Tighten the set screw after the DRI is positioned.

  • Page 272: Hoist Service

    CD5515-2/YB5515-2 SERVICE MANUAL STRUCTURALS Attach the shaft (32) to the side plate (29) using the six capscrews (3). Make sure the vent (30) is oriented properly. Torque the capscrews to recommended values, refer to Fasteners and Torque Values, page 1- Install retaining ring (48) onto the shaft (32) Lay the unit down with the rods (2) pointing up.
  • Page 273 STRUCTURALS CD5515-2/YB5515-2 SERVICE MANUAL cover up as the capscrews are loosened. Remove the plate than friction disc so the last item installed is a stator cover from the brake housing. plate. Remove the springs (24) from the piston and check the 14.
  • Page 274 CD5515-2/YB5515-2 SERVICE MANUAL STRUCTURALS 302 10 308 303 24 7155 FIGURE 11-16 Grove 11-21 Published 1-20-2017, Control# 483-02...
  • Page 275 STRUCTURALS CD5515-2/YB5515-2 SERVICE MANUAL Item Quantity Description Item Quantity Description Plate, Side NCC Label Capscrew Capscrew Snap Ring Screw, Buttonhead Cord Set Gear Set Drum Housing Fitting, Tee Race, Bearing Fitting, Straight Adapter Gear, Input Sun Fitting, Reducer Capscrew Hose Assy Brake Piston Fitting, Tee Adapter Screw...

  • Page 276: Troubleshooting

    CD5515-2/YB5515-2 SERVICE MANUAL STRUCTURALS Planetary Set Motor NOTE: See Figure 11-16 for item number identification. Remove the hose and the counterbalance block (42) from the motor assembly. Remove the spiral retaining rings from the planet pins. To remove the counterbalance block (42), loosen and Remove the pins from the carrier by carefully tapping remove the 4 capscrews (55).

  • Page 277: Bearing, Mast And Related Parts

    STRUCTURALS CD5515-2/YB5515-2 SERVICE MANUAL BEARING, MAST AND RELATED PARTS The rotation of the mast is done by a gearbox which is mounted below the frame deck. A hydraulic motor connected General to the gearbox provides power for rotation of the mast. The bearing is filled with grease through two grease fittings The mast is fastened to the main frame of the crane through on the inner race of the bearing.

  • Page 278: Mast Bearing Bolts

    CD5515-2/YB5515-2 SERVICE MANUAL STRUCTURALS a0495 FIGURE 11-20 Swing Mechanism Access Hole FIGURE 11-19 p0220 Inspection for Bearing Wear Because of conservative design parameters, static loading Mast Bearing Bolts and slow intermittent rotation, there are very few mast bearings that ever see their full design use. Very high stress is put on the mast bolts during crane However, the mast bearing does have moving internal parts operation.

  • Page 279: Replacing The Mast Bearing

    STRUCTURALS CD5515-2/YB5515-2 SERVICE MANUAL Installation Using a suitable solvent, clean the holes in the bearing plate on the main frame. Remove the residue with compressed air. Clean all dirt from the bearing plate. Locate the mast bearing (19, Figure 11-23) in place on the bearing plate.
  • Page 280 CD5515-2/YB5515-2 SERVICE MANUAL STRUCTURALS Adjustment With a spanner wrench, turn the eccentric ring to move the pinion until it contacts the feeler gauge (0.013 mm Checking Backlash (0.005 in) backlash). Check the backlash between the swing gear and the swing Tighten the four bolts to appropriate torque.

  • Page 281: Hydraulic Swivel

    STRUCTURALS CD5515-2/YB5515-2 SERVICE MANUAL Item Description Mast Counterweight Hoist Bolt Washer Washer Washer Bolt Washer Bolt Lock Washer Washer Hydraulic Swivel Bolt Washer Bolt Swing Bearing Bolt Washer Bolt Lock Washer Washer Pinion Gear Cover Bolt Washer Swing Motor Gasket Swing Gear Box Washer Bolt...

  • Page 282: Swing Gearbox Repair

    CD5515-2/YB5515-2 SERVICE MANUAL STRUCTURALS Swing Gearbox Repair Removal Use a hoist and blocks to hold the boom in position and Remove socket head capscrews (13). Remove end prevent the mast from rotating motor cap (12). Remove the swing motor from the gearbox. If shims (9) though (11) are located between cover (12) and housing (25) remove the shims.
  • Page 283 STRUCTURALS CD5515-2/YB5515-2 SERVICE MANUAL Item Description Item Description Item Description Shim (2) Shim Pinion Shaft End Motor Cap Cover Key (2) Socket Head Capscrew Capscrew (8) Oil Seal Bearing Cup (2) Grease Fitting Pipe Plug (2) Bearing Cone (2) Housing Bearing Cup (2) Spacer (2) Worm...

  • Page 284: Outriggers

    CD5515-2/YB5515-2 SERVICE MANUAL STRUCTURALS 18. Using a suitable puller, remove bearing cup (14) from Install end cap (27) without shims installed. housing (25). b. Using a dial indicator, measure the amount of axial 19. Using a suitable puller, remove bearing cup (14) from movement of the worm.

  • Page 285: Removal

    STRUCTURALS CD5515-2/YB5515-2 SERVICE MANUAL Use a hoist to remove the outrigger assembly from the frame. Disassembly Remove retaining ring (1, Figure 11-26) from either side of mounting pin (5). Drive the pin out. Pull outrigger jack (6) from outrigger beam (7). Disconnect the hydraulic hoses from the vertical cylinder (13).
  • Page 286 CD5515-2/YB5515-2 SERVICE MANUAL STRUCTURALS Item Description Retaining Ring (4) Mounting Pin Mounting Pin Retaining Ring (2) Mounting Pin Jack Outrigger Outrigger Beam Cylinder Mounting Bracket (2) Hex Bolt (4) Flat Washer (4) Counterbalance Valve Horizontal Cylinder Vertical Cylinder Lockwasher (8) Outrigger Assembly a0491 FIGURE 11-26...
  • Page 287 STRUCTURALS CD5515-2/YB5515-2 SERVICE MANUAL This Page Blank 11-34 Published 1-20-2017, Control# 483-02...
  • Page 288 CD5515-2/YB5515-2 SERVICE MANUAL SCHEMATICS/WIRING DIAGRAMS SECTION 12 SCHEMATICS/WIRING DIAGRAMS This Page Blank Grove 12-1 Published 1-20-2017, Control# 483-02...
  • Page 289 SCHEMATICS/WIRING DIAGRAMS CD5515-2/YB5515-2 SERVICE MANUAL This Page Blank 12-2 Published 1-20-2017, Control# 483-02...
  • Page 290 CD5515-2/YB5515-2 SERVICE MANUAL ALPHABETICAL INDEX Accessory Circuits ........... . . 3-17 Anti-Double Blocking System .
  • Page 291 CD5515-2/YB5515-2 SERVICE MANUAL Preventive Maintenance ..........5-5 Rear Axles Repair .

This manual is also suitable for:

Grove yb5515-2

Table of Contents