Page 1 An untrained operator subjects himself and others to death or serious injury. Do not operate this crane unless: • You are trained in the safe operation of this crane. Manitowoc is not responsible for qualifying personnel. • You read, understand, and follow the safety and operating recommendations contained in the crane manufacturer’s manuals and...
Page 2 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. ...
Page 3: Table Of Contents
5540F/YB5515 SERVICE MANUAL TABLE OF CONTENTS SECTION 1 ........Introduction Directional Reference .
Page 4 TABLE OF CONTENTS 5540F/YB5515 SERVICE MANUAL Magnetism ............3-1 ...
Page 5 5540F/YB5515 SERVICE MANUAL TABLE OF CONTENTS Main Winch Circuit........... . . 4-26 General .
Page 6 TABLE OF CONTENTS 5540F/YB5515 SERVICE MANUAL Areas of Application..........5-33 ...
Page 7 5540F/YB5515 SERVICE MANUAL TABLE OF CONTENTS Clutch Solenoid Technical Data ........7-2 Description of Operation .
Page 8 TABLE OF CONTENTS 5540F/YB5515 SERVICE MANUAL Wheel & Tires ............8-30 ...
Page 9 5540F/YB5515 SERVICE MANUAL TABLE OF CONTENTS Principle Of Operation..........10-12 Sensor Operation And Spacing Checks .
Page 10 TABLE OF CONTENTS 5540F/YB5515 SERVICE MANUAL TOC-8 ...
Page 11 SECTION 1 INTRODUCTION TABLE OF CONTENTS Directional Reference ........... 1-1 Identification Plates .
Page 12 INTRODUCTION 5540F/ YB5515 SERVICE MANUAL THIS PAGE BLANK 1-ii ...
Page 13: Directional Reference
5540F/YB5515 SERVICE MANUAL INTRODUCTION SECTION 1 INTRODUCTION This manual contains information on maintenance, service and repair of the Models 5540F & YB5515 cranes. Major p1878 components and systems are included, except service on the engine. This information will be found in the engine manufacturer’s service manual.
Page 14: Specifications
INTRODUCTION 5540F/YB5515 SERVICE MANUAL p0073 Rear Drive Axle S/N Location FIGURE 1-6 SPECIFICATIONS ENGINE Diesel Engine Make and Model..................Cummins 4B3T.3 – 85 diesel, Tier II Type of Aspiration ..................Turbocharged Horsepower....................
Page 15 5540F/YB5515 SERVICE MANUAL INTRODUCTION Primary Pump.....................4 Section, gear pump Main Control ValvesFour-way, open center, pilot operated Swing Motor ....................Single section, gerotor-type Winch Motor ....................Fixed displacement, axial piston Hydraulic Filters..................One 10-micron filter in line from valves One 30- mesh suction filter inside hydraulic tank Hydraulic Cylinders ..................Double-acting cylinders lift,...
Page 16 INTRODUCTION 5540F/YB5515 SERVICE MANUAL FIGURE 1-7 a1841 Published 10-21-2010, Control# 198-04 ...
Page 17: General Maintenance
5540F/YB5515 SERVICE MANUAL Item Description Item Description Drop Block Outrigger (4) 3rd Boom Section (3 Section Boom) Rear Drive Axle (Steerable & Non-Steerable) 4th Boom Section (4 Section Boom) Enclosed Operator’s Cab (Shown) Optional Boom Extension Optional Cab Guard (Not Shown) Lift Cylinder Main Control Valve Location 1st Boom Section...
Page 18: Disassembly And Assembly
5540F/YB5515 SERVICE MANUAL supporting members (straps, chains and cables) should be Wires and Cables parallel to each other and as near perpendicular as possible Batteries should always be disconnected prior to working on to the top of the object being lifted. the electrical system.
Page 19: Bearings
5540F/YB5515 SERVICE MANUAL serial number and letter designator. If no letter designators are found, wire the components together to assure correct installation. Reusable bearing components should be installed in their original positions. Heating Bearings Bearings which require expansion for installation should be heated in oil not to exceed 250 °F (121°...
Page 20: Batteries
If any of the above conditions exist, evaluate hose assemblies for correction or replacement. For replacement Contaminants in a hydraulic system affect operation and will of hose assemblies, refer to your Manitowoc Crane Care result in serious damage to the system components. Dirty Parts Manual.
Page 21: 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 22: Loctite
Loctite types are suitable for all applications.Various types and nuts being used. of Loctite are specified throughout the Service Manual. The The torque tables are provided by Manitowoc for reference following types of Loctite brand adhesives are available from when performing maintenance.
Page 23 5540F/YB5515 SERVICE MANUAL Torque wrenches are precision instruments and must be misaligned no more than 30 degrees without causing handled with care. To ensure accuracy, calibrations must be serious error in torque. made on a scheduled basis. Whenever there is a possibility •...
Page 24 5540F/YB5515 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 ...
Page 25 5540F/YB5515 SERVICE MANUAL Table 1-7: Metric Fasteners, Fine Thread, Untreated Bolt Diameter - Metric Torque Values (Nm, Maximum/Minimum) M8x1 M10x1 M10x1.25 M12x1.5 M14x1.5 M16x1.5 M18x1.5 M20x1.5 M22x1.5 M24x2 M27x2 M30x2 M33x2 M36x3 Grade 0.157 0.197 0.236 0.315 0.394 0.472 0.551 0.630 0.709 0.787...
Page 26: Weld Studs (Table 1-10)
Optional for future tightening of the same connection.) 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 1-11). ...
Page 27 5540F/YB5515 SERVICE MANUAL 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 1-12 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 28: 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 29: Wire Rope Inspection (Running Ropes And Pendant Cables)
When replacing fixed length cable assemblies (e.g. 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. Replace an entire wire rope assembly. Do not attempt to rework damaged wire rope or wire rope ends.
Page 30: 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 31: 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 32: Installing Flex-X 35 Wire Rope
5540F/YB5515 SERVICE MANUAL wedged into the lower layers under load, which can seriously damage the rope.) The tensioning load should range from 1 to 2% of the rope’s minimum breaking force. For ropes in multi-part systems: Reeve the traveling ...
Page 33: O-Ring, Seal And Elastic Nut Replacement
5540F/YB5515 SERVICE MANUAL NOTE: The outer strands must not be able to move with respect to the inner strands. The weld must not exceed the diameter of the rope. O-RING, SEAL AND ELASTIC NUT REPLACEMENT b. If a welder is not available, the cut is to be made with an acetylene torch.
Page 34 5540F/YB5515 SERVICE MANUAL THIS PAGE BLANK 1-22 Published 10-21-2010, Control# 198-04 ...
Page 35: Section 2
SECTION 2 SAFETY PRACTICES TABLE OF CONTENTS Introduction ............2-1 Signal Words .
Page 36 5540F/YB5515 SERVICE MANUAL THIS PAGE BLANK 2-ii ...
Page 37: Introduction
5540F/YB5515 SERVICE MANUAL SAFETY PRACTICES SECTION 2 SAFETY PRACTICES INTRODUCTION Some of the Service work involves the need to drive the crane. The operator’s manual supplied with each crane DANGER contains the detailed safety practices relating to driving and The signal word “DANGER” denotes that an extremely operating.
Page 38: Personal Considerations
SAFETY PRACTICES 5540F/YB5515 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 39: General Considerations
5540F/YB5515 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 40: Final Word
SAFETY PRACTICES 5540F/YB5515 SERVICE MANUAL What to do Pressure Testing Make sure all test equipment is in good condition. Use only specified gauges. Comply with test procedures specified. Inhibits damage to the system or the equipment and inhibits the possibility ...
Page 41: Section 3
SECTION 3 ELECTRIC SYSTEM TABLE OF CONTENTS General ............. . 3-1 Comparing Electrical System to a Hydraulic System .
Page 42 5540F/YB5515 SERVICE MANUAL THIS PAGE BLANK 3-ii ...
Page 43: General
5540F/YB5515 SERVICE MANUAL ELECTRIC SYSTEM SECTION 3 ELECTRIC SYSTEM GENERAL Comparing Electrical System to a Hydraulic System To aid in the understanding and troubleshooting of an electrical system, review the terms and information that The electrical system is in many ways similar to a hydraulic follows.
Page 44: Wire Harnesses
ELECTRIC SYSTEM 5540F/YB5515 SERVICE MANUAL Wire Harnesses Identification of the fuse ratings and the circuits protected is shown in Table 3-2. Always replace the fuse with one of the Four wire harnesses connect the electrical system same rating. components: ...
Page 45: Charging System
5540F/YB5515 SERVICE MANUAL ELECTRIC SYSTEM CHARGING SYSTEM Always connect the positive (+) cable from the starter to the positive (+) terminal of the battery. Connect the The purpose of the charging system is to give power for ground cable from the engine to the negative (-) terminal operation of the lights, instruments, electrical accessories of the battery.
Page 46: Starting Circuit
ELECTRIC SYSTEM 5540F/YB5515 SERVICE MANUAL batteries and leaving the other at low charge can solenoid. If the starter operates correctly, the cause damage to the fully charged battery. A weak problem is in the starter solenoid. Replace the battery in the system puts an overload on the solenoid.
Page 47: Instrument And Light Circuits
5540F/YB5515 SERVICE MANUAL ELECTRIC SYSTEM and the ignition switch. If voltage was indicated, go to Gauges step 4. The gauges are 12 volt components. Power is available to Turn the ignition switch to the START position and check the gauges through a 15 amp fuse when the ignition switch is voltage at the start terminal.
Page 48: Wire Harnesses
ELECTRIC SYSTEM 5540F/YB5515 SERVICE MANUAL Hour Meter Power is available through the oil pressure switch on the engine. The hour meter operates only when the engine is running. Table 3-4: Voltage Level Conditions Voltage Measured Engine Speed Condition of Charging System ...
Page 49 5540F/YB5515 SERVICE MANUAL ELECTRIC SYSTEM To main wire harness FIGURE 3-2 Engine Wire Harness - Diesel Engine a1634 GROVE Published 10-21-2010, Control# 198-04...
Page 50 ELECTRIC SYSTEM 5540F/YB5515 SERVICE MANUAL Water Temp Sender Transmission Oil Pressure Switch Engine Wire Harness - Gasoline/Dual Fuel a1633 FIGURE 3-3 ...
Page 51 5540F/YB5515 SERVICE MANUAL ELECTRIC SYSTEM RIGHT REAR WORK LIGHT RIGHT REAR INDICATOR LIGHT LEFT REAR WORK LIGHT LEFT REAR INDICATOR LIGHT RIGHT FRONT TO ENGINE WORK LIGHT HARNESS TO INSTRUMENT PANEL RIGHT FRONT LEFT FRONT INDICATOR LIGHT INDICATOR LIGHT LEFT FRONT WORK LIGHT Main Frame Harness FIGURE 3-4...
Page 52 ELECTRIC SYSTEM 5540F/YB5515 SERVICE MANUAL To Main Frame Harness Turn Signal Switch To LMI System Duel Fuel Turn Signal Enging Flashers Malfunction ...
Page 53: Accessory Circuits
5540F/YB5515 SERVICE MANUAL ELECTRIC SYSTEM ACCESSORY CIRCUITS Circuit Description See the wiring diagrams in Schematics/Wiring Diagrams. Anti-Double Blocking System (Figure 3-6) Power is made available through a 20 amp fuse to the circuit relay under the console in the cab and to the limit switch on General the boom head.
Page 54 ELECTRIC SYSTEM 5540F/YB5515 SERVICE MANUAL Trip Arm Cable Reel Limit Switch Relay Anti-Double Blocking Solenoid Valves Swivel ...
Page 55: Load Moment Indicator (Lmi) System (Figure 3-1)
5540F/YB5515 SERVICE MANUAL ELECTRIC SYSTEM Load Moment Indicator (LMI) System (Figure 3-1) Description The load moment indicator (LMI) is a length, load, angle, radius, lifting capacity and anti-double block indicator. A display in the cab provides information to assist the operator in operating the crane.
Page 56 ELECTRIC SYSTEM 5540F/YB5515 SERVICE MANUAL Load Transmitter Cable Reel Load Assembly Angle / Lenght Transmitter Anti-Double Block Transmiiter ...
Page 57: Optional Engine Shutdown
5540F/YB5515 SERVICE MANUAL ELECTRIC SYSTEM Optional Engine Shutdown Circuit Function When the engine oil pressure drops below a safe operating General Description pressure or the water temperature rises above a safe Units with a diesel engine can be furnished with an automatic operating temperature, the sending unit sends a signal to the engine shutdown, to protect the engine when the engine oil indicator light though either wire 142 or 143, illuminating the...
Page 58: Heater
ELECTRIC SYSTEM 5540F/YB5515 SERVICE MANUAL Heater See the electrical wiring diagrams in Schematics/Wiring Diagrams. Power is available through a 15 amp fuse to the The heater is a hot water heater and is connected into the heater/defroster switch in the instrument panel when the cooling system of the engine.
Page 59 5540F/YB5515 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 5540F/YB5515 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. Worn bearings.
Page 61 5540F/YB5515 SERVICE MANUAL ELECTRIC SYSTEM Problem Possible Cause Solution 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 ELECTRIC SYSTEM 5540F/YB5515 SERVICE MANUAL THIS PAGE BLANK 3-20 Published 10-21-2010, Control# 198-04 ...
Page 63: Section 4
SECTION 4 HYDRAULIC SYSTEM TABLE OF CONTENTS Technical Data............4-1 General Description .
Page 64 5540F/YB5515 SERVICE MANUAL THIS PAGE BLANK 4-ii ...
Page 65: Technical Data
5540F/YB5515 SERVICE MANUAL HYDRAULIC SYSTEM SECTION 4 HYDRAULIC SYSTEM TECHNICAL DATA Hydraulic Pressures: Hoist and Boom (Lift) Circuits ..............3500 ±50 psi (24,132 ±345 kPa) Telescope and Outrigger Circuits ...............3500 ±50 psi (24,132 ±345 kPa) Swing Circuit ....................2000 ±50 psi (13,790 ±345 kPa) Steering Circuit ...................2500 ±50 psi (17,237 ±345 kPa) Rated Pump Output at 2600 rpm: Section 1 ....................24 gpm (91 lpm)
Page 66: Troubleshooting
HYDRAULIC SYSTEM 5540F/YB5515 SERVICE MANUAL this section. The main hydraulic system gives hydraulic • Check with the operator. Learn if there was a loss of power to: power (machine did not move the load) or a loss of speed (slow cycle time). •...
Page 67: Troubleshooting Guides
5540F/YB5515 SERVICE MANUAL HYDRAULIC SYSTEM TROUBLESHOOTING GUIDES Table 4-1 General Hydraulic System Troubleshooting Problem Possible Cause Remedy Noise (above normal). Air in system. With engine at low rpm, operate all control functions several times to return the air to atmosphere through the tank breather.
Page 68 HYDRAULIC SYSTEM 5540F/YB5515 SERVICE MANUAL Problem Possible Cause Remedy Overheating of hydraulic oil. Wrong operation (running over the Change procedure of operation. load sense relief pressure setting for long periods). Dirty filters. Change filter. See Preventative Maintenance, Chapter 5. Oil too light.
Page 69 5540F/YB5515 SERVICE MANUAL HYDRAULIC SYSTEM Problem Possible Cause Remedy Boom moves slowly downward when Internal leakage in cylinder. Replace piston seals. control valve is in NEUTRAL position. Leakage in holding valve. Replace holding valve. DO NOT ADJUST. Faulty controller. Repair or replace. Broken centering spring in control Replace broken spring.
Page 70 HYDRAULIC SYSTEM 5540F/YB5515 SERVICE MANUAL Table 4-4 Outrigger Circuit Troubleshooting Problem Possible Cause Remedy No movement all cylinders Dirt in relief valve keeping the valve off Clean the relief valve. the valve seat. Relief valve setting too low. Check and adjust the relief valve setting.
Page 71: Suction, Pressure And Return Circuits
5540F/YB5515 SERVICE MANUAL HYDRAULIC SYSTEM Problem Possible Cause Remedy Hook block lowers, but will not raise. Malfunction in anti-double blocking See Electric System, Chapter 3. electrical system. Bad cartridge in anti-double blocking Faulty controller. solenoid valve. Faulty controller. Repair or replace. Restriction in pilot control line to control Locate and correct.
Page 72 HYDRAULIC SYSTEM 5540F/YB5515 SERVICE MANUAL Lubrication of internal components is provided through passages in the hydraulic pump body and grooves in the pressure plates. A lip seal on the shaft and o-rings between the sections prevent external leakage in the pump. ...
Page 73 5540F/YB5515 SERVICE MANUAL HYDRAULIC SYSTEM Fill Spout Suction Circuits a1564 FIGURE 4-3 GROVE Published 10-21-2010, Control# 198-04...
Page 74 HYDRAULIC SYSTEM 5540F/YB5515 SERVICE MANUAL Hydraulic Tank Main Hydraulic Control Return Valve Filter Hydraulic Manifold Valve Accumlator Charge Valve ...
Page 75 5540F/YB5515 SERVICE MANUAL HYDRAULIC SYSTEM Test - Pump Output Slowly close the needle valve of the flowmeter until the pressure for the circuit being supplied by the pump To check the output of the hydraulic pump, use a 100 gpm section being tested.
Page 76: Main Relief Valves
HYDRAULIC SYSTEM 5540F/YB5515 SERVICE MANUAL Main Relief Valves Each pump section has a main relief valve to protect the hydraulic circuits fed by the section. Pump sections 1, 2 and 3 are in the inlet and mid-inlet sections of the main control valve.
Page 77: Main Control Valve
5540F/YB5515 SERVICE MANUAL HYDRAULIC SYSTEM Main Control Valve Technical Data Spool type Sliding, double action, cylinder Hoist, Crowd and Lift Circuits and outriggers Main Relief Valves See Figure 4-9 Swing Circuit Main Relief Valve See Figure 4-9 Spool travel (from neutral) 5/16 inch (7,87 mm) Port pressurized (3-Spool Control Valve): Handle In - Spool out...
Page 78 HYDRAULIC SYSTEM 5540F/YB5515 SERVICE MANUAL Parallel Valve Spool Description A parallel spool is a solid-core spool designed to route oil from the work circuit back to tank. In a valve assembly that has all parallel valve spools, if two are shifted at the same time, the spool closest to the valve ...
Page 79 5540F/YB5515 SERVICE MANUAL HYDRAULIC SYSTEM Actuate the swing control and observe the pressure If the pressure reading is correct, stop the engine and gauge attached to the pump outlet. The relief valve remove the pressure gauge. should open at 2000 ± 50 psi (138 ± 3.5 bar). Release If the pressure reading is incorrect, adjust the pressure the control lever after the reading is obtained.
Page 80: Adjusting Main Relief Valve Pressure Settings
HYDRAULIC SYSTEM 5540F/YB5515 SERVICE MANUAL If the pressure reading is correct, stop the engine and remove the pressure gauge. p1636 If the pressure reading is incorrect, the priority flow control valve must be replaced. The relief valve portion of the valve is nonadjustable.
Page 81 5540F/YB5515 SERVICE MANUAL HYDRAULIC SYSTEM Swing Circuit Main Relief Valve Adjusting Procedure Boom Lift/Telescope/Outrigger Circuit Main Relief Valve Adjusting Procedure With the engine shut off and parking brake engaged, install a 0 - 5000 psi (0 - 345 bar) pressure gauge to the With the engine shut off and the parking brake engaged, test connection on the pressure side of the swing section connect a 0 - 5000 psi (0 - 345 bar) to the test...
Page 82: Lift Circuit
HYDRAULIC SYSTEM 5540F/YB5515 SERVICE MANUAL Winch Hoist/Circuit Main Relief Valve Adjusting Release the control lever. Tighten the jam nut on the relief valve. Actuate the lever again and check the Procedure pressure reading. If correct stop the engine and remove With the engine shut off and the parking brake engaged, the pressure gauge.
Page 83: Holding Valve
5540F/YB5515 SERVICE MANUAL HYDRAULIC SYSTEM Holding Valve The holding valve has three functions: Inhibit cavitation of the cylinder,. WARNING Give full control of the lowering of the boom,. Do not adjust the holding valve setting. The valve is adjusted by the manufacturer. Hold the load in event of a hydraulic failure.
Page 84 HYDRAULIC SYSTEM 5540F/YB5515 SERVICE MANUAL FIGURE 4-21 a1620 Oil Flow - Rasing the Boom FIGURE 4-22 a1621 Oil Flow - Lowering the Boom ...
Page 85 5540F/YB5515 SERVICE MANUAL HYDRAULIC SYSTEM Lift Circuit Hydraulic Lines FIGURE 4-23 a1622 GROVE 4-21 Published 10-21-2010, Control# 198-04...
Page 86: Hydraulic Swivel
HYDRAULIC SYSTEM 5540F/YB5515 SERVICE MANUAL Hydraulic Swivel Port No. 3 Hydraulic oil under pressure flows through this port when the General boom is being raised. When lowering the boom the hydraulic The hydraulic swivel is at the center of rotation of the mast. oil under low pressure flows through this port.
Page 87: Crowd Circuit
5540F/YB5515 SERVICE MANUAL HYDRAULIC SYSTEM CROWD CIRCUIT in pressure as the pump continues to push more oil into the rod port of the cylinders. When the pressure is high enough General to open the holding valve, the cylinder retracts. See Holding Valve.
Page 88 HYDRAULIC SYSTEM 5540F/YB5515 SERVICE MANUAL Pilot Pressure Oil Flow - Crowd Out FIGURE 4-25 a1624 Oil Flow - Crowd Out FIGURE 4-26 a1623...
Page 89 5540F/YB5515 SERVICE MANUAL HYDRAULIC SYSTEM FIGURE 4-27 a1623 GROVE 4-25 Published 10-21-2010, Control# 198-04...
Page 90: Crowd Cylinders Leakage Test
HYDRAULIC SYSTEM 5540F/YB5515 SERVICE MANUAL Crowd Cylinders Leakage Test Winch Up Pulling the handle spool IN routes oil from the front pump to If the cylinders does not hold the load, the problem is port B of the spool in the control valve Figure 4-28. From normally internal leakage in the cylinders.
Page 91: Brake Holding Valve
5540F/YB5515 SERVICE MANUAL HYDRAULIC SYSTEM Brake Holding Valve Engine speed is important for smooth operation. At low engine speed, normally there will not be enough oil from the The holding valve has three functions: pump to keep the motor turning. As a result, the load will move down in a movement that is not regular.
Page 92 HYDRAULIC SYSTEM 5540F/YB5515 SERVICE MANUAL Pilot Pressure Oil Flow - Winch Up FIGURE 4-28 a1626 Pilot Pressure ...
Page 93 5540F/YB5515 SERVICE MANUAL HYDRAULIC SYSTEM Winch Circuit Hydraulic Lines FIGURE 4-30 a1628 GROVE 4-29 Published 10-21-2010, Control# 198-04...
Page 94: Swing Circuit
HYDRAULIC SYSTEM 5540F/YB5515 SERVICE MANUAL SWING CIRCUIT clockwise and causes the mast to rotate to the right. Oil from downstream side of the motor returns through the A port and General sent back to tank through the return filter. ...
Page 95: System Function
5540F/YB5515 SERVICE MANUAL HYDRAULIC SYSTEM System Function p1622 The main control valve sections for the hoist, telescope and lift functions each have a check valve installed internally. This check valve is connected to the return passage in the valve section and to port A (boom lift and telescope) or port B (Winch) of the valve section.
Page 96 HYDRAULIC SYSTEM 5540F/YB5515 SERVICE MANUAL Telescope Cylinders Hoist Lift Anti-Double Block Circuit - Closed FIGURE 4-34 a1589 ...
Page 97 5540F/YB5515 SERVICE MANUAL HYDRAULIC SYSTEM Anti-Double Block Circuit - Open FIGURE 4-35 a1590 GROVE 4-33 Published 10-21-2010, Control# 198-04...
Page 98: Outrigger Circuit
HYDRAULIC SYSTEM 5540F/YB5515 SERVICE MANUAL OUTRIGGER CIRCUIT Oil Flow Outrigger Down General Pushing the handle (pushing the valve spool IN), routes oil Two outrigger hydraulic systems are available on the crane: out of the valve port A (Figure 4-38 and Figure 4-39) to the •...
Page 99 5540F/YB5515 SERVICE MANUAL HYDRAULIC SYSTEM Oil Flow - Vertical Outrigger Extend and Retract FIGURE 4-36 a0404 (Standard Outriggers) GROVE 4-35 Published 10-21-2010, Control# 198-04...
Page 100 HYDRAULIC SYSTEM 5540F/YB5515 SERVICE MANUAL Left Rear M & N Left Front Right Front Right Rear Q & R ...
Page 101: Load Holding Valves
5540F/YB5515 SERVICE MANUAL HYDRAULIC SYSTEM Load Holding Valves Start the engine and engage the parking brake. Fully lower the outrigger. The outrigger cylinders have load holding valves installed in the cylinder base. The purpose of these valves is to inhibit Shut off the engine.
Page 102 HYDRAULIC SYSTEM 5540F/YB5515 SERVICE MANUAL Outrigger Hydraulic Lines (Standard Outriggers) FIGURE 4-38 a0412 4-38 Published 10-21-2010, Control# 198-04 ...
Page 103 5540F/YB5515 SERVICE MANUAL HYDRAULIC SYSTEM Outrigger and Hydraulic Lines (Optional Independent Outriggers) FIGURE 4-39 a0411 GROVE 4-39 Published 10-21-2010, Control# 198-04...
Page 104 HYDRAULIC SYSTEM 5540F/YB5515 SERVICE MANUAL To Reservoir Axle Lockout Solenoid Valve Show Accumlator Charge Valve Show Oil Flow - Axle Oscillation Lockout (Axle Locked) a0407 FIGURE 4-40 ...
Page 105: Component Repair
5540F/YB5515 SERVICE MANUAL HYDRAULIC SYSTEM COMPONENT REPAIR Remove port end cover 57. Remove gear housing 52. Tap the housing with a soft Hydraulic Pump Repair hammer, if necessary. Removal Since the metal components are not replaceable there is no need to disassemble the gear housings 52, 38, and Drain the oil from the hydraulic tank.
Page 106 HYDRAULIC SYSTEM 5540F/YB5515 SERVICE MANUAL 1. Lip Seal 17. Plastic Seal 32. Rubber Sea 44. Spacer Plate 54. Thrust Block 2. End Cover 18. Rubber Seal 33. Thrust Block 45. Plastic Seal 55. Rubber Seal 3. Dowel (2) 19. Thrust Block 34.
Page 107 5540F/YB5515 SERVICE MANUAL HYDRAULIC SYSTEM Assembly 14. Install spacer plate 30. 15. Install connecting shaft 34 into gear 21. Push lip seal 1 Figure 4-41 squarely into the recess of shaft end cover 2. Lip seal garter spring faces in toward 16.
Page 108: Main Control Valves
HYDRAULIC SYSTEM 5540F/YB5515 SERVICE MANUAL Main Control Valves Lift off boom lift spool section 8. Lift off mid-inlet section 15. General Lift off winch spool section 8. The main control valves are designed with very close tolerances between the spools and the valve bores. Dirt, Lift off mid-inlet sections 14 and 13.
Page 109 5540F/YB5515 SERVICE MANUAL HYDRAULIC SYSTEM 1. Main Relief Valve 2. Inlet Valve Section 3. O-Ring 4. Shut Off Plug 5. Swing Valve Spool Section 6. Mid-Inlet Section 7. Anti-Void Assembly 8. Telescope, Winch and Boom Lift Valve Spool Sections 9. Outrigger Valve Spool Sections 10.
Page 110 HYDRAULIC SYSTEM 5540F/YB5515 SERVICE MANUAL 1. Spool and Housing 2. O-Ring 3. Load Check Poppet 4. Load Check Spring 5. O-Ring 6. Wiper Seal 7. Seal Plate 8. End Mechanism Kit 9. O-Ring 10. Wiper Seal 11.
Page 111 5540F/YB5515 SERVICE MANUAL HYDRAULIC SYSTEM Complete Valve Assembly Layout the valve components on a clean, flat working surface. Assemble tie rod nuts and washers to one end of each tie rod 17 Figure 4-42. Insert the tie rods through the tie rod holes of inlet section 2.
Page 112 HYDRAULIC SYSTEM 5540F/YB5515 SERVICE MANUAL main relief housing and if grooves and ridges are evident, the With it will come the check valve poppet and other internal valve must be replaced. parts. These are easily disassembled and should be examined for foreign material.
Page 113: Swing Motor
5540F/YB5515 SERVICE MANUAL HYDRAULIC SYSTEM Installation Place the motor in a vice and clamp across the edges of the flange Figure 4-48 with the output shaft facing down. Position the valve assembly on the mounting plate and When clamping use protective devices on the jaws, such secure with three bolts, washers and nuts.
Page 114 HYDRAULIC SYSTEM 5540F/YB5515 SERVICE MANUAL 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 ...
Page 115 5540F/YB5515 SERVICE MANUAL HYDRAULIC SYSTEM Inspection/Cleaning Check all mating surfaces. Replace any parts with scratches or burrs that could cause leakage or damage. Clean all metal parts in a suitable solvent. Blow dry with air. Do not wipe parts with a cloth or paper towels, because lint or other matter could get into the hydraulic system and cause damage.
Page 116 HYDRAULIC SYSTEM 5540F/YB5515 SERVICE MANUAL Output Shaft Needle Thrust Shaft Bearing Pressure Seal Seal Driver Lubricate these areas Bearing Race Seal Exclusion Tube Seal FIGURE 4-54 a0768 Mounting Install needle thrust bearing 8, then bearing race 7 on Flange shaft 9.
Page 117 5540F/YB5515 SERVICE MANUAL HYDRAULIC SYSTEM NOTE: To aid installation of seals, apply a light coat of clean petroleum jelly to seals. Do not stretch the Place tip of seals before installing them in a groove. applicator at top of threaded portion 13.
Page 118 HYDRAULIC SYSTEM 5540F/YB5515 SERVICE MANUAL Connect the hydraulic lines and fittings to the swing motor. Start the engine and slowly rotate the mast to remove any air in the swing hydraulic circuit. Check for leaks. Winch Motor Removal ...
Page 119: Hydraulic Swivel
5540F/YB5515 SERVICE MANUAL HYDRAULIC SYSTEM Fill the winch motor with hydraulic fluid through the case Hydraulic Swivel drain port Figure 4-60 to the bottom of the fill plug with Removal clean hydraulic oil. Connect all the hydraulic hoses and fittings to the motor. CAUTION Start the engine and slowly run the boom winch through several cycles to remove any air in the system.
Page 120 HYDRAULIC SYSTEM 5540F/YB5515 SERVICE MANUAL 1. Retaining Ring 2. Retainer 3. Thrust Washer * 4. O Ring * 5. Housing 6. O Ring * 7. O Ring * 8. Seal (2) * 9. Wear Ring (2)* 10.
Page 121 5540F/YB5515 SERVICE MANUAL HYDRAULIC SYSTEM Disassembly Install the two wear rings 9 into their appropriate grooves. Remove retaining ring 1 Figure 4-61 and retainer 2. Install o-ring 7 into its groove. Remove and discard thrust washer 3 and o-ring 4. Place the swivel housing 5 on the work bench with the Carefully pull the swivel spool 10 from swivel housing 5.
Page 122: Hydraulic Cylinders
HYDRAULIC SYSTEM 5540F/YB5515 SERVICE MANUAL 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 123 5540F/YB5515 SERVICE MANUAL HYDRAULIC SYSTEM cylinder has hit bottom. Test to pressure indicated Table pressure for a minimum of 10 seconds. Visually check 4-7 in both directions as directed in steps 2 through 5. for internal and external leakage. No internal or external leakage is permitted.
Page 124 HYDRAULIC SYSTEM 5540F/YB5515 SERVICE MANUAL 1. Bushing (4) 2. Grease Fitting 3. Cylinder Tube 4. Piston Nut 5. Wear Ring (2) * 6. Piston Seal * ...
Page 125 5540F/YB5515 SERVICE MANUAL HYDRAULIC SYSTEM 1. Cylinder Tube 2. Piston Nut 3. Piston Wear Ring (2) * 4. Piston Seal * 5. O-Ring * 6. Piston 7. O-Ring * 8. Tube Stop 9. O-Ring * 10. Ring * 11. Gland 12.
Page 126 HYDRAULIC SYSTEM 5540F/YB5515 SERVICE MANUAL 1. Cylinder Tube 2. Piston Nut 3. Piston Wear Ring (2) * 4. Piston Seal * 5. O-Ring * 6. Piston 7. O-Ring * 8. Tube Stop 9. O-Ring * 10. Ring * 11.
Page 127 5540F/YB5515 SERVICE MANUAL HYDRAULIC SYSTEM 1. Cylinder Tube 2. Piston Nut 3. Piston Wear Ring (2) * 4. Piston Seal * 5. O-Ring * 6. Piston 7. O-Ring * 8. O-Ring * 9. Back-up Ring * 10. Gland 11. Rod Seal * 12.
Page 128 HYDRAULIC SYSTEM 5540F/YB5515 SERVICE MANUAL 1. Cylinder Tube 2. Piston Nut 3. Piston Assembly 4. Wear Ring* 5. O-Ring* 6. Piston Seal* 7. Piston 8. O-Ring* 9. Gland Head Assembly 10. O-Ring* 11. Back-Up Ring* 12.
Page 129 SECTION 5 PREVENTATIVE MAINTENANCE TABLE OF CONTENTS Introduction ............5-1 Spark Arresting Mufflers .
Page 130 5540F/YB5515 SERVICE MANUAL Replace the Hydraulic Oil Filter ........5-26 ...
Page 131: Introduction
NOTE: If maintenance or adjustments must be performed It is not the policy of Manitowoc Cranes, Inc. to publish lists with the engine running, have a person at the of approved lubricants or guarantee lubricant performance.
Page 132: After First 50 Hours Of Operation (New Cranes)
PREVENTATIVE MAINTENANCE 5540F/YB5515 SERVICE MANUAL Winch Gearbox Cranes Not In Regular Use • Check oil level. Fill if level is low. A crane which has been idle for a period of one month or more, but less than six months, it must be given an Tires ...
Page 133 5540F/YB5515 SERVICE MANUAL PREVENTATIVE MAINTENANCE 1000 Daily 2000 Hours Hours Hours Service Check before Hours Hours Hours Three operation Weekly Monthly Yearly Weeks Months Months Inspect the anti-double blocking system Inspect the wire rope Inspect reeving, clamps and connections Inspect the lifting hook Inspect safety devices Check controls operation Check engine crankcase oil level...
Page 134 PREVENTATIVE MAINTENANCE 5540F/YB5515 SERVICE MANUAL 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) ...
Page 135: Lubrication Points
5540F/YB5515 SERVICE MANUAL PREVENTATIVE MAINTENANCE Lubrication Points NOTE: *Drive shaft u-joints do not require routine lubrication. Lubricate only after major overhaul. Apply grease to the following fitting after the first 20 hours of operation, thereafter every 50 hours of operation, whichever occurs first.
Page 136 PREVENTATIVE MAINTENANCE 5540F/YB5515 SERVICE MANUAL 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 ...
Page 137 5540F/YB5515 SERVICE MANUAL PREVENTATIVE MAINTENANCE 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 138 PREVENTATIVE MAINTENANCE 5540F/YB5515 SERVICE MANUAL 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 ...
Page 139: Scheduled Maintenance
5540F/YB5515 SERVICE MANUAL PREVENTATIVE MAINTENANCE 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 140 PREVENTATIVE MAINTENANCE 5540F/YB5515 SERVICE MANUAL p1650 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...
Page 141 5540F/YB5515 SERVICE MANUAL PREVENTATIVE MAINTENANCE NOTE: For more details on proper radiator checking and Be sure the boom is fully retracted and lowered and the maintenance procedures, see the engine manual outriggers are retracted and up. furnished with the crane. Level the crane, engage the parking brake and shut off p1651 the engine.
Page 142 PREVENTATIVE MAINTENANCE 5540F/YB5515 SERVICE MANUAL sealing problems. A dust trail or pattern on the element p0409 clean side is a sign that the element was not firmly sealed or that a dust leak exists. Make sure the cause of the leak is identified and rectified before replacing the ...
Page 143: Hours Of Operation (Weekly)
5540F/YB5515 SERVICE MANUAL PREVENTATIVE MAINTENANCE 50 Hours of Operation (Weekly) • It indicates if you are using the most suitable type of rope. NOTE: You must read and understand the warnings and • It makes possible the discovery and correction of faults basic safety rules, found in Section 1 of this in equipment or operation that can cause costly manual, before performing any operation or...
Page 144: Grease Fittings
PREVENTATIVE MAINTENANCE 5540F/YB5515 SERVICE MANUAL Reduction from normal diameter of 9/16” (14 mm) of more than 1/32” (0.8mm). Evidence of heat damage from any cause. Kinking, crushing, or distortion of rope structure 6 broken wires in any one lay or 3 broken wires ...
Page 145 5540F/YB5515 SERVICE MANUAL PREVENTATIVE MAINTENANCE a1876 FIGURE 5-25 Boom Slide Lubrication GROVE 5-15 Published 10-21-2010, Control# 198-04...
Page 146: Hours Of Operation (Two Weeks)
PREVENTATIVE MAINTENANCE 5540F/YB5515 SERVICE MANUAL 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 147: Hours Of Operation (Monthly)
5540F/YB5515 SERVICE MANUAL PREVENTATIVE MAINTENANCE 250 Hours of Operation (Monthly) Inspect the Hydraulic Hoses Inspect hydraulic hose assemblies for leaks, damaged fittings and worn exterior. Do not use your hands to check for hydraulic leaks. Hydraulic oil under pressure can cause serious injury or possible death.
Page 148: Clean The Radiator
PREVENTATIVE MAINTENANCE 5540F/YB5515 SERVICE MANUAL Tighten all battery hardware to keep the battery securely in place. w0022 Disconnect the battery cables. Sprinkle the batteries with baking soda to neutralize the acid. Rinse with water. Be careful not to get water inside ...
Page 149: Replace The Crankcase Oil And Filter
5540F/YB5515 SERVICE MANUAL PREVENTATIVE MAINTENANCE 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 150: Hours Of Operation (3 Months)
PREVENTATIVE MAINTENANCE 5540F/YB5515 SERVICE MANUAL NOTE: If a broken bolt is found, replace the bolt and also p0329 replace the bolt on each side of the broken bolt. NOTE: The proper bolt torque will not be obtained without the hardened steel washers under the bolt heads on the outer (mast) bolt circle.
Page 151: Spark Plug Gap (Gasoline Engine)
5540F/YB5515 SERVICE MANUAL PREVENTATIVE MAINTENANCE NOTE: The safety element must be replaced after two For maximum protection of the engine cooling system, add a main element replacements. corrosive inhibitor to the radiator. When the engine is cold, remove the radiator cap and pour the inhibitor in the radiator Install the new element over the stud in the housing and reservoir, following manufacturer’s instructions.
Page 152: Check Axle Housing Lubricant Level
PREVENTATIVE MAINTENANCE 5540F/YB5515 SERVICE MANUAL 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.
Page 153: 1000 Hours Of Operation (6 Months)
5540F/YB5515 SERVICE MANUAL PREVENTATIVE MAINTENANCE 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 4 for the other wheel hubs. Check Winch Gearbox and Brake Lubricant Levels WARNING Lower the boom to its lowest position.
Page 154: Replace The Axle Housing Lubricant
PREVENTATIVE MAINTENANCE 5540F/YB5515 SERVICE MANUAL 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 ...
Page 155: Replace Axle Wheel Hub Lubricant
5540F/YB5515 SERVICE MANUAL PREVENTATIVE MAINTENANCE Replace Axle Wheel Hub Lubricant p0429 p1385 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 156: Replace The Winch Gearbox And Brake Lubricant
PREVENTATIVE MAINTENANCE 5540F/YB5515 SERVICE MANUAL Replace the Winch Gearbox and Brake Lubricant In very cold temperatures, SAE 5W or SAE 5W-20 oils can be used if the viscosity of the oil will not be Winch Gearbox less than 60 SUS (Saybolt Universal Seconds) at maximum operating temperature.
Page 157: Replace The Hydraulic Oil Filter
5540F/YB5515 SERVICE MANUAL PREVENTATIVE MAINTENANCE When the tank is empty, disconnect the two hydraulic Locate the hydraulic oil filter under the machine lines from the rear of the hydraulic oil tank (Figure 5-51). (Figure 5-52). Remove the suction strainer from the suction port and Remove the filter: clean it in a suitable solvent.
Page 158: 2000 Hours Of Operation (Yearly)
PREVENTATIVE MAINTENANCE 5540F/YB5515 SERVICE MANUAL Check Swing Gear/Pinion Backlash Replace the Spark Plugs (Gasoline Engine) Remove the cover to expose the swing pinion and ring Disconnect one spark plug wire at a time and then replace gear. the old spark plug with a new plug. Correct spark plug as AC ...
Page 159: Miscellaneous Maintenance
Engine stopped - 10 to 14 volts crane if a critical weld is cracked or broken until the weld is repaired. Contact your Grove distributor or Manitowoc A reading of less than 10 volts with the engine at low Crane Care.
Page 160: Fuel System
PREVENTATIVE MAINTENANCE 5540F/YB5515 SERVICE MANUAL • Internal - Drink large quantities of water. Follow with Fuel Storage milk of magnesia, beaten egg or vegetable oil. Get Storage of fuel for an extended period causes accumulation immediate medical attention. of sediment, dirt, water and other foreign materials in the ...
Page 161 5540F/YB5515 SERVICE MANUAL PREVENTATIVE MAINTENANCE p1645 Fuse Cover Location FIGURE 5-54 GROVE 5-31 Published 10-21-2010, Control# 198-04...
Page 162: Carwell® Rust Inhibitor
While the surfaces of the crane that are easily seen have the biggest impact on the appearance of the crane, particular Manitowoc Crane Group's cranes are manufactured to high attention should be given to the undercarriage of the crane to quality standards, including the type of paint finish minimize the harmful effects of corrosion.
Page 163: Inspection And Repair
• Cover all bare metal with a primer that is compatible with the original paint finish Please contact Manitowoc Crane Care should you have any questions. • and allow to dry thoroughly. Areas of Application •...
Page 164 PREVENTATIVE MAINTENANCE 5540F/YB5515 SERVICE MANUAL • Frame application areas are; hose ends and fittings, all • Boom applications areas are; pivot pins, hose end and unpainted fasteners and hardware, all bare metal fittings, jib pins and shafts, all bare metal surfaces, surfaces, outrigger pads, and back up alarm hardware.
Page 165 5540F/YB5515 SERVICE MANUAL PREVENTATIVE MAINTENANCE 7650-65 FIGURE 5-55 GROVE 5-35 Published 10-21-2010, Control# 198-04...
Page 166 PREVENTATIVE MAINTENANCE 5540F/YB5515 SERVICE MANUAL 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 ...
Page 167 SECTION 6 ENGINE AND ENGINE SYSTEMS TABLE OF CONTENTS General ............. . 6-1 Engine Types.
Page 168 5540F/YB5515 SERVICE MANUAL THIS PAGE BLANK 6-ii ...
Page 169: General
5540F/YB5515 SERVICE MANUAL ENGINE AND ENGINE SYSTEMS SECTION 6 ENGINE AND ENGINE SYSTEMS GENERAL linkage moves the engine throttle lever through a full stroke. If necessary, disconnect the throttle These instructions are written for worldwide use. In territories linkage and move the throttle by hand. Check the where legal requirements govern engine smoke emissions, engine speed with the throttle linkage disconnected noise, safety factors, etc., then all instructions, data and...
Page 170: Engine Cooling System
ENGINE AND ENGINE SYSTEMS 5540F/YB5515 SERVICE MANUAL FIGURE 6-1 a0103 Oil Viscosity Recommendations - Diesel Engine Arctic Operation Check the antifreeze concentration several weeks before the beginning of the cold season or hot season. NOTE: SAE 5W viscosity grade synthetic oil may be used T h e a n t i f r e e z e m u s t h a v e a n e t h y l e n e g l y c o l...
Page 171: Radiator Cap And Overflow Bottle
5540F/YB5515 SERVICE MANUAL ENGINE AND ENGINE SYSTEMS An incorrect or malfunctioning radiator cap can result in the loss of coolant and engine running hot. Any sudden loss of coolant from a heavily loaded engine can result in severe damage to the pistons and cylinder bore.
Page 172: Qsb Engine Electronic Controlled Fuel System Units
ENGINE AND ENGINE SYSTEMS 5540F/YB5515 SERVICE MANUAL Fuel Injectors Fuel injectors should be taken out and examined at regular intervals. Refer to the engine operator’s manual. QSB Engine Electronic Controlled Fuel System Units Refer to the Engine Manual Furnished with this unit for a ...
Page 173: Engine Air Intake System
5540F/YB5515 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 174 ENGINE AND ENGINE SYSTEMS 5540F/YB5515 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. ...
Page 175: Removal And Installation
5540F/YB5515 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 176: Installation
ENGINE AND ENGINE SYSTEMS 5540F/YB5515 SERVICE MANUAL Installation 19. Connect the transmission wire harness to the instrument panel wire harness. Attach a hoist to the engine the same way removal was 20. Connect the transmission high temperature switch lead accomplished.
Page 177: Engine Rpm
5540F/YB5515 SERVICE MANUAL ENGINE AND ENGINE SYSTEMS Engine RPM The engine is cooled by the circulation of coolant through the passages in the engine block and head. Circulation is by a To check the engine speed, follow the instructions in the thermo-siphon action assisted by a V-belt from the engine operator’s manual.
Page 178: Radiator Cap And Overflow Bottle
ENGINE AND ENGINE SYSTEMS 5540F/YB5515 SERVICE MANUAL a corrosion inhibitor for even a short period, the cup plugs will rust through, allowing coolant leakage. An incorrect or malfunctioning radiator cap can result in the loss of coolant and engine running hot. ...
Page 179: Engine Fuel Systems
5540F/YB5515 SERVICE MANUAL ENGINE AND ENGINE SYSTEMS ENGINE FUEL SYSTEMS Fuel Injected Dual Fuel System LPG Tank FIGURE 6-6 a0959 Gasoline Portion Liquid Propane Gas (LPG) Portion The gasoline fuel portion of this dual fuel system Figure 6-7 The LPG portion of the dual fuel system includes an LPG is a closed-loop system which includes a fuel tank, an in-line tank, a bulkhead connection, a hydrostatic relief valve, an in- fuel pump, a filter installed between the fuel pump and the...
Page 180: Fuel Tank
ENGINE AND ENGINE SYSTEMS 5540F/YB5515 SERVICE MANUAL Mixer Unit Vapor/Regulator Unit Throttle Body LPG Shutoff Solenoid Valve FIGURE 6-9 p3028 Mixer Unit Hydrostatic Relief Valve and In-Line Filter The mixer unit Figure 6-9 adjusts the correct amount of fuel ...
Page 181: Engine Air Intake System
5540F/YB5515 SERVICE MANUAL ENGINE AND ENGINE SYSTEMS The exhaust system is installed under the frame to minimize the transfer of noise and vibration into the operator ’s CAUTION compartment. The use of gasoline with a lower octane than 87 AKI (91 Annoying rattles and noise vibrations in the exhaust system RON) octane will result in serious damage to the engine.
Page 182 ENGINE AND ENGINE SYSTEMS 5540F/YB5515 SERVICE MANUAL Control Unit change the air/fuel ratio (mixture) to compensate for different ambient air temperatures. The Electronic Control Unit (ECU) Figure 6-11 is a simple programmable computer that controls air/fuel mixtures, spark advance curves and provides electronic governor control based upon engine and environment ...
Page 183: Fuel Injection Components
5540F/YB5515 SERVICE MANUAL ENGINE AND ENGINE SYSTEMS Fuel Injection Components Coarse Fuel Filter Figure 6-17 Located between the fuel tank and the fuel pump, this 4 0 m i c r o n f i l t e r p r o t e c t s t h e f u e l p u m p f r o m contaminants in the fuel supply.
Page 184 ENGINE AND ENGINE SYSTEMS 5540F/YB5515 SERVICE MANUAL Table 6-3: Error Codes Error Codes Error Description Diagnostic mode indicator Oxygen sensor error Engine coolant tempera -- high Engine coolant temperature -- low Throttle position sensor error Throttle body actuator not responding ...
Page 185 5540F/YB5515 SERVICE MANUAL ENGINE AND ENGINE SYSTEMS NOTE: For electrical connections, pin numbers, etc., refer to wiring diagrams. Error Code Diagnostics Code 12: Code 12 is special code signifying the beginning or end of the error codes. Code 13: Code 13 indicates the oxygen (O2) sensor has not warmed up or is stuck rich, lean or neutral for a period of time. Other fuel system issues can cause this;...
Page 186 ENGINE AND ENGINE SYSTEMS 5540F/YB5515 SERVICE MANUAL Code 15: The engine coolant reads too low. This may occur if the temperature is below 30° F (-1° C), or if the coolant tem- perature sensor is unplugged. To verify coolant temperature wiring: ...
Page 187 5540F/YB5515 SERVICE MANUAL ENGINE AND ENGINE SYSTEMS and drive-by-wire pot (if it is used and easy to disconnect). Perform the measurements below: TPS Wiring Troubleshooting Meter Mode From Desired Result If Defective Ohms ECM Harness 10 TPS A < 1 Ohm Ground wire is open Ohms ECM Harness 40...
Page 188 ENGINE AND ENGINE SYSTEMS 5540F/YB5515 SERVICE MANUAL Turn ignition power OFF. Disconnect the ECM from the wire harness. Disconnect the MAP sensor and TPS. Perform the following measurements: DBW Wiring Troubleshooting Meter Mode From Desired Result If Defective DBW GND ...
Page 189 5540F/YB5515 SERVICE MANUAL ENGINE AND ENGINE SYSTEMS 3.2 Turn ignition power OFF. Disconnect the ECM from the wire harness. Disconnect the TPS sensor and drive-by-wire pot. Perform the following measurements. MAP Wiring Troubleshooting Meter Mode From Desired Result If Defective Ohms ECM Harness 10 MAP A...
Page 190 ENGINE AND ENGINE SYSTEMS 5540F/YB5515 SERVICE MANUAL Basic Dual Fuel System Troubleshooting Guide NOTE: The following figures show items referenced in the dual fuel troubleshooting guide. LPG Mixer Gasoline Inlet Maximum LPG Air Inlet Flow Adjustment ...
Page 191 5540F/YB5515 SERVICE MANUAL ENGINE AND ENGINE SYSTEMS LPG Mixer Engine Vacuum Line Propane Vapor Hose LPG Shut-Off Solenoid LPG Vaporizer Regulator LPG Fuel System p3033 FIGURE 6-21 Vacuum Solenoid LPG Vaporizer Valve Regulator Electronic Control Unit (ECM) LPG Vaporizer Regulator LPG Vaporizer Regulator LPG Fuel System...
Page 192 ENGINE AND ENGINE SYSTEMS 5540F/YB5515 SERVICE MANUAL The following is a guide to the most common engine CONDITION: Engine runs lean or misfires on gasoline performance complaints. The guide is to be used to Verify each item below: Remedy for each item: diagnose problems that are due to worn out components and/or basic adjustments in the fueling system.
Page 193: Checks And Adjustments
5540F/YB5515 SERVICE MANUAL ENGINE AND ENGINE SYSTEMS CONDITION: Engine runs too rich on LPG Thoroughly, clean the spark plugs, including the threads. Check the electrode gap with a feeler gauge. There will be a Verify each item below: Remedy for each item: small amount of friction as you move the feeler gauge between the electrodes, if adjusted correctly.
Page 194: Troubleshooting
ENGINE AND ENGINE SYSTEMS 5540F/YB5515 SERVICE MANUAL TROUBLESHOOTING Problem Possible Cause Solution Engine will not start. Improper starting procedure. Review starting procedure Operator’s Manual. No fuel. Check fuel gauge. Switch to LPG or gasoline. Crankcase oil too heavy (cold Use oil with proper viscosity.
Page 195: Removal And Installation
5540F/YB5515 SERVICE MANUAL ENGINE AND ENGINE SYSTEMS Problem Possible Cause Solution Engine knocking. Incorrect engine timing. Check engine timing and adjust. Fuel contamination or low octane Drain and replace fuel (minimum fuel. 87 octane). Engine overheating. Check thermostat. Replace necessary. Check for low coolant level.
Page 196 ENGINE AND ENGINE SYSTEMS 5540F/YB5515 SERVICE MANUAL 11. Remove the air cleaner and intake hose(s). d. Disconnect and cap and plug the brake hoses from the axle. NOTE: Have a fire extinguisher handy and know how to use it before performing the next step. Support the axle on a trolley jack.
Page 197 5540F/YB5515 SERVICE MANUAL ENGINE AND ENGINE SYSTEMS Connect the hydraulic hoses to the four sections of the 19. Connect the transmission wire harness to the instrument hydraulic pump. panel wire harness. Fill the hydraulic tank. 20. Connect the transmission high temperature switch lead to the switch.
Page 198 ENGINE AND ENGINE SYSTEMS 5540F/YB5515 SERVICE MANUAL THIS PAGE BLANK 6-30 Published 10-21-2010, Control# 198-04 ...
Page 199 SECTION 7 TRANSMISSION AND TORQUE CONVERTER TABLE OF CONTENTS Technical Data............7-1 General Technical Data .
Page 200 5540F/YB5515 SERVICE MANUAL 7-ii ...
Page 201: Technical Data
5540F/YB5515 SERVICE MANUAL TRANSMISSION AND TORQUE CONVERTER SECTION 7 TRANSMISSION AND TORQUE CONVERTER TECHNICAL DATA General Technical Data Description ......................Combined torque converter, reverser, and gearbox unit with synchromesh manual gear selection Designation.......................SS720 (2 wheel drive) SS740 (4 wheel drive) Weight (dry)....................... (375 Ib)170 kg (441 Ib) 200 kg Number of Teeth Transfer Gear .....................19 17...
Page 202: Clutch Solenoid Technical Data
TRANSMISSION AND TORQUE CONVERTER 5540F/YB5515 SERVICE MANUAL Converter Inlet Relief Valve Pressure (Max.) ............ 95 Lubrication Pressures (in neutral) ..............PSI At 122° F (50° C) 1000 rpm/min..................4.0-13 28-90 2000 rpm/min..................26 – 35 172-241 At 212° F (100° C) ...
Page 203: Description Of Operation
5540F/YB5515 SERVICE MANUAL TRANSMISSION AND TORQUE CONVERTER DESCRIPTION OF OPERATION NOTE: Normal operating temperature is 180° - 190° F (82° - 88° C). High temperatures will cause damage and General leakage in the seals and gaskets of the torque converter. Do not continue operation if the The transmission consists of a torque converter, hydraulic temperature increases above 180°...
Page 204 TRANSMISSION AND TORQUE CONVERTER 5540F/YB5515 SERVICE MANUAL transmission unit to pass through the centre of the input shaft Reverse: A3 for clutch lubrication. Oil then returns to the sump. When reverse is selected electrical solenoid E2 is energized Lubrication oil is also provided via a pump drain line to the and pressurised oil is diverted to the reverse clutch A2.
Page 205 5540F/YB5515 SERVICE MANUAL TRANSMISSION AND TORQUE CONVERTER A388431 FIGURE 7-2 GROVE Published 10-21-2010, Control# 198-04...
Page 206 TRANSMISSION AND TORQUE CONVERTER 5540F/YB5515 SERVICE MANUAL A396520 FIGURE 7-3 Published 10-21-2010, Control# 198-04 ...
Page 207 5540F/YB5515 SERVICE MANUAL TRANSMISSION AND TORQUE CONVERTER Synchromesh Unit d. SPLIT ENERGIZER PINS (D). These pins take the initial axial load of the synchro hub on the shoulder Description of the split energizer pin neck. As the axial load reaches approximately 90 lb. (40.8 kg) the internal T h e t r a n s m i s s i o n i s e q u i p p e d w i t h “...
Page 208 TRANSMISSION AND TORQUE CONVERTER 5540F/YB5515 SERVICE MANUAL a1234 a1235 FIGURE 7-6 FIGURE 7-7 As the axial load on the synchro hub increases, the split As the speeds are synchronized the radial load on the energizer pin “collapses”...
Page 209: Reverser Clutch
5540F/YB5515 SERVICE MANUAL TRANSMISSION AND TORQUE CONVERTER Reverser Clutch shaft to the gear G1. Clutch A2 is disengaged and no drive is transmitted to gear/plate carrier G2. The gear is also free to The reverser clutch unit 1(See Figure 7-9) transfers drive rotate on the input shaft assembly.
Page 210: Hydraulic 2/4 Wheel Drive Unit - Spring On/Pressure Off
TRANSMISSION AND TORQUE CONVERTER 5540F/YB5515 SERVICE MANUAL Hydraulic 2/4-Wheel Drive Unit When the switch is in the 4-wheel drive position, solenoid valve A is de-energized. With the solenoid A1 de-energized, - Spring ON/Pressure OFF the valve spool moves under the force of the spring A2. The oil supply to the piston C is blocked, (shown at port 3).
Page 211 5540F/YB5515 SERVICE MANUAL TRANSMISSION AND TORQUE CONVERTER 2 Wheel Drive Operation (See Figure 7-11) Pressurised oil is directed to piston C via ports 3 and 2. The piston moves actuating sleeve F and then pressure plate G When the switch is in the 2-wheel drive position, solenoid against the force of springs D, thus releasing the spring force valve A is energized.
Page 212: Hydraulic 2/4 Wheel Drive Unit - Pressure On/Spring Off
TRANSMISSION AND TORQUE CONVERTER 5540F/YB5515 SERVICE MANUAL Hydraulic 2/4-Wheel Drive Unit - Pressure ON/Spring OFF 4-Wheel Drive Operation (See Figure 7-12) This clutch is of the 'Pressure-ON (4WD)/Spring-OFF (2WD)' type. The clutch is engaged and disengaged by introducing or dumping pressurised oil behind piston C via a solenoid valve A.
Page 213: Hydraulic 2/4 Wheel Drive Unit - Pressure On/Spring Off (Cont'd)
5540F/YB5515 SERVICE MANUAL TRANSMISSION AND TORQUE CONVERTER Hydraulic 2/4-Wheel Drive Unit - Pressure ON/Spring OFF (cont'd) 2-Wheel Drive Operation (See Figure 7-13) When the switch is in the 2-wheel drive position, solenoid valve A is de-energized. With the solenoid A1 de-energized, the valve spool moves under the force of the spring A2.
Page 214: Troubleshooting
TRANSMISSION AND TORQUE CONVERTER 5540F/YB5515 SERVICE MANUAL TROUBLESHOOTING b. If the transmission is overheating, start at check 4. If the transmission will not pull, start at check 12. General Troubleshooting d. If there is no drive in one or both directions, start at ...
Page 215 5540F/YB5515 SERVICE MANUAL TRANSMISSION AND TORQUE CONVERTER CHECK ACTION Is there noise when selecting direction? Check 3. Check 2. Is there noise when running with direction selector in neutral Check 9. and ratio selector is in first? Check 19. Is there air in the hydraulic system? Continue running to expel air.
Page 216 TRANSMISSION AND TORQUE CONVERTER 5540F/YB5515 SERVICE MANUAL CHECK ACTION 16. Are clutch sealing rings damaged? Install pressure gauge into clutch feed lines to monitor pressure. Check clutch plates for damage. 17. Is there drive is one direction only? Check 19.
Page 217 5540F/YB5515 SERVICE MANUAL TRANSMISSION AND TORQUE CONVERTER CHECK ACTION 34. Are the selector fork pads out of position? Reposition or replace (check interlock). Check 35 35. Is there excessive end float in gears or shafts? Adjust. Check thrust washers and mating surfaces.
Page 218: Hydraulic 2/4 Wheel Drive Unit (Spring On/Pressure Off)
TRANSMISSION AND TORQUE CONVERTER 5540F/YB5515 SERVICE MANUAL Hydraulic 2/4-Wheel Drive Unit (Spring ON/ Check that the 4-wheel drive external pipework is not damaged. Pressure OFF) Check that all the electrical connections are clean and 2wd Cannot Be Engaged secure.
Page 219: Hydraulic 2/4 Wheel Drive Unit (Pressure On/Spring Off)
5540F/YB5515 SERVICE MANUAL TRANSMISSION AND TORQUE CONVERTER Hydraulic 2/4-Wheel Drive Unit (Pressure Check that the 4-wheel drive external pipework is not damaged and that the drive train is intact. ON/Spring OFF) Check that all the electrical connections are clean and 4wd Cannot Be Engaged secure.
Page 220: Water Contamination
TRANSMISSION AND TORQUE CONVERTER 5540F/YB5515 SERVICE MANUAL Possible Cause Remedy 11. Non-return valve faulty. 11. Check the non-return valve 12. 2/4WD solenoid permanently energized 12. Check the 2/4WD relay and select switch, replace as necessary. Water Contamination dipstick or inside the filler tube.
Page 221: Inspection
5540F/YB5515 SERVICE MANUAL TRANSMISSION AND TORQUE CONVERTER Flushing Procedure Reconnect the hoses to the cooler. Ensure the joints are CAUTION clean and leakproof. The oil could be hot, avoid contact with the skin to prevent Renew the oil filter. scalds. Refill the transmission circuit with the recommended Inspection grade of oil.
Page 222 TRANSMISSION AND TORQUE CONVERTER 5540F/YB5515 SERVICE MANUAL A396911 FIGURE 7-14 7-22 Published 10-21-2010, Control# 198-04 ...
Page 223: Pressure And Flow Tests
5540F/YB5515 SERVICE MANUAL TRANSMISSION AND TORQUE CONVERTER Pressure and Flow Tests Pressure which should be as shown in Technical Data, page 7-1. Before completing any of the transmission pressure/flow Repeat step 2 and note gauge readings with engine tests, make sure that the oil level is correct and at normal operating temperature.
Page 224: Converter Out Pressure/Oil Cooler Flow Rate
TRANSMISSION AND TORQUE CONVERTER 5540F/YB5515 SERVICE MANUAL Converter Out Pressure/Oil Cooler Flow Rate If the reading is higher than specified then the converter relief valve is faulty. A low reading indicates a leaking Stop engine, connect a 0-145 psi (0-1000 kPa) pressure pump seal or a faulty converter relief valve.
Page 225 5540F/YB5515 SERVICE MANUAL TRANSMISSION AND TORQUE CONVERTER NOTE 2: Maximum Governed Speed is a datum figure The transmission should be overfilled for initial start-up. only. It cannot be adjusted or checked with the Disconnect the oil cooler feeder pipe at E and run the engine installed in the machine.
Page 226 TRANSMISSION AND TORQUE CONVERTER 5540F/YB5515 SERVICE MANUAL a1231 FIGURE 7-15 Component Key: Suction strainer (892/00970) Gasket Pressure Filter Hot Oil ...
Page 227: Transmission Repair
5540F/YB5515 SERVICE MANUAL TRANSMISSION AND TORQUE CONVERTER TRANSMISSION REPAIR Remove the transmission and place it in a clean work area where the torque converter can be removed. It is Servicing the Torque Converter recommended that the transmission be mounted in a service fixture.
Page 228: Installation
used. The alignment tool is available from your Ensure that the flywheel face, drive plate and hardware are Grove distributor or Manitowoc Crane Care under clean and free from burrs or other surface imperfections. part number 1902662. If the tool can not be ...
Page 229 5540F/YB5515 SERVICE MANUAL TRANSMISSION AND TORQUE CONVERTER Place the drive plate and reinforcing plate a1239 (1 Figure 7-17) onto the torque converter. a1240 FIGURE 7-19 Tighten the drive plate mounting bolts 3 to a torque of 14 lb-ft (10 Nm). Installing without Alignment Tool (Optional) Assemble the drive plate and reinforcing plate (1, Figure 7-17) to the torque converter using bolts 2.
Page 230: Servicing The Transmission
TRANSMISSION AND TORQUE CONVERTER 5540F/YB5515 SERVICE MANUAL Installing Transmission Transmission Gearbox Repair Clean and lubricate the splines of the transmission input shaft. Install the transmission to the converter, ensuring that the dogs on the converter oil seal shaft engage with WARNING the recesses on the transmission input.
Page 231 5540F/YB5515 SERVICE MANUAL TRANSMISSION AND TORQUE CONVERTER If not already removed, remove hydraulic pump from gear box. Remove the circlip (1, Figure 7-21) and then withdraw the pump driveshaft 1a together with its bearing 1b. Remove and discard the shaft sealing ring. A395360 FIGURE 7-23 Unscrew bolts (Figure 7-24) and withdraw pump 7.
Page 232 TRANSMISSION AND TORQUE CONVERTER 5540F/YB5515 SERVICE MANUAL 10. On 4-wheel drive transmissions remove the 4-wheel drive hydraulic pipe and control valve 10a. 11. Undo the 4 bolts and remove the gear lever turret. Remove the baffle plate beneath if fitted. If necessary the turret assembly can be disassembled as follows: ...
Page 233 5540F/YB5515 SERVICE MANUAL TRANSMISSION AND TORQUE CONVERTER 14. Remove the torque converter pressure relief valve ball and spring assembly 14a (Figure 7-28). Remove the torque converter pressure regulating valve spool and spring assembly 14b. 15. Unscrew bolts 15 and lift off output end casing 15a. Be sure to retrieve bearing outer cups from inside the casing.
Page 234 TRANSMISSION AND TORQUE CONVERTER 5540F/YB5515 SERVICE MANUAL 25. Remove idler gear lower thrust washers and bearing 25. washer 30a beneath. Support output shaft from beneath Keep the thrust washers and bearing together. and lift off the yoke 30b. 26. Lift off idler gear spacer 26. 31.
Page 235 5540F/YB5515 SERVICE MANUAL TRANSMISSION AND TORQUE CONVERTER 36. Remove bearing 36 from converter end of mainshaft using press a suitable. A395470 FIGURE 7-34 S388160 FIGURE 7-33 Setting Ring Removal Layshaft The mainshaft and layshaft end float is controlled by a threaded 'setting ring' screwed into the casing.
Page 236 TRANSMISSION AND TORQUE CONVERTER 5540F/YB5515 SERVICE MANUAL although a failed component may be easy to identify, the cause of that failure may be less easy to trace. It is also possible that a failed component may have caused damage to other areas of the gearbox.
Page 237: Assembly
5540F/YB5515 SERVICE MANUAL TRANSMISSION AND TORQUE CONVERTER Inspect the teeth on all cones and rings for excessive wear or damage. If wear or damage is evident the unit must be renewed. S396100 FIGURE 7-38 FIGURE 7-40 S401260 Assembly Bearing Setting Rings FIGURE 7-39 S161651 If the bearing outer cups and setting rings have been...
Page 238 TRANSMISSION AND TORQUE CONVERTER 5540F/YB5515 SERVICE MANUAL FIGURE 7-41 A388250 FIGURE 7-43 A388420 Layshaft Smear bearing surface of shaft with Mobil HP222 Grease and fit needle roller bearings 1a (wider bearing first), followed by 2nd gear 1b.
Page 239 5540F/YB5515 SERVICE MANUAL TRANSMISSION AND TORQUE CONVERTER (Figure 7-45). Assemble 3rd gear 6c and synchro-cup 6d. Fit synchro gear 6e. Install spacer washer 7a and oil retention washer 7b with bevel towards bearings. Press bearing 7c onto shaft and smear with Mobil HP222 Grease. Press bearing 8 onto assembled mainshaft and coat bearing with Mobil HP222 Grease.
Page 240 TRANSMISSION AND TORQUE CONVERTER 5540F/YB5515 SERVICE MANUAL d. Install sleeve A and initially tighten nut B to 36.9 lb ft (50 Nm). Check there is no end float and rolling torque less than 1.0 Ib ft (1.5 Nm). If the rolling torque exceeds 1.0 Ib ft (1.5 Nm) check that the ...
Page 241 5540F/YB5515 SERVICE MANUAL TRANSMISSION AND TORQUE CONVERTER 16. Install idler gear spacer 16. 17. Install thrust washers and bearing assembly 17. Lubricate and fit the needle roller bearing 17a. 18. Install synchro cone to 3rd gear 18 (mainshaft L). Fit the idler gear 18a to the spindle while tilting mainshaft L to one side.
Page 242 TRANSMISSION AND TORQUE CONVERTER 5540F/YB5515 SERVICE MANUAL FIGURE 7-53 FIGURE 7-52 S395500 221090 29. Apply a bead of Loctite 574 Multi gasket (Figure 7-54) to 23. Install selector forks 23 (Figure 7-53) into position. mating face of casing.
Page 243 5540F/YB5515 SERVICE MANUAL TRANSMISSION AND TORQUE CONVERTER first, followed by 3rd/4th gear selector rod. To ensure 33. End Float Checking - Reverser Unit (Figure 7-57) that the mainshaft locates with the output shaft it will be Measure end float of forward/reverse shaft which should be necessary to push on tool T to keep the shaft correctly 0.0004 to 0.006 in (0.01 to 0.16 mm).
Page 244 TRANSMISSION AND TORQUE CONVERTER 5540F/YB5515 SERVICE MANUAL d. When the correct setting has been obtained, stake If the layshaft and/or its bearings have been renewed, the the setting ring to the casing as shown at Y (see the shaft end float must be reset. note below).
Page 245 5540F/YB5515 SERVICE MANUAL TRANSMISSION AND TORQUE CONVERTER Install the torque converter housing. Apply Loctite 242 to the 12 bolts and tighten to 42 Ib ft (56 Nm). FIGURE 7-63 a388020 FIGURE 7-61 a396630 36. Place new pump sealing ring 36 (Figure 7-62) in position.
Page 246 TRANSMISSION AND TORQUE CONVERTER 5540F/YB5515 SERVICE MANUAL 41. Assemble pressure maintenance valve spool 41 and spring into adaptor block. Apply Loctite 242 to plug, fit and tighten. Do not overtighten as damage to the aluminium housing could result. ...
Page 247 5540F/YB5515 SERVICE MANUAL TRANSMISSION AND TORQUE CONVERTER 45. Locate a new gasket (not shown) on the casing followed Remove the service strainer and fit a production by the gear lever turret baffle plate (Figure 7-68). Make strainer after the first 100 hours operation. Renew sure the plate is the correct way round.
Page 248: Solenoid Valve Disassembly And Assembly
TRANSMISSION AND TORQUE CONVERTER 5540F/YB5515 SERVICE MANUAL For clarity, only one solenoid has been numbered in the dismantling sequence. FIGURE 7-71 a388040 Solenoid Valve Disassembly and Assembly The numerical sequence shown on the illustration is intended as a guide to dismantling.
Page 249 5540F/YB5515 SERVICE MANUAL TRANSMISSION AND TORQUE CONVERTER Apply a small quantity of Loctite 242 to the threads in the Remove the thrust bearing and thrust washers knurled nut 2 before fitting. (3, Figure 7-75). Torque Settings Withdraw the gear and splined hub assembly 4 with the needle roller bearing and spacer.
Page 250: Assembly
TRANSMISSION AND TORQUE CONVERTER 5540F/YB5515 SERVICE MANUAL NOTE: If the piston does not loosen when the clutch shaft is knocked on aluminum, then hand pump air down the shaft oil inlet hole. 15. Remove and discard piston and shaft O-rings (Figure 7-80) ...
Page 251 5540F/YB5515 SERVICE MANUAL TRANSMISSION AND TORQUE CONVERTER s407190 FIGURE 7-82 FIGURE 7-84 A402700 Install the disc spring assembly. (5, Figure 7-83). Install 11. Using a dial test indicator, as shown (Figure 7-85), the assembly so that the outer diameter curves away measure the end float of the pressure (end) plate, which from the clutch piston.
Page 252 TRANSMISSION AND TORQUE CONVERTER 5540F/YB5515 SERVICE MANUAL NOTE: Prior to fitting gear, align teeth of clutch plates Piston Ring Seals - Fitting Procedure using a thin rod (screwdriver). Wind the PTFE piston ring seal around your finger as 14. Install the spacer 14 followed by the needle roller shown (Figure 7-89), so that the seal forms a 'coil'.
Page 253: Hydraulic 2/4 Wheel Drive Unit Disassembly And Assembly (Pressure On/Spring Off Type)7-53
5540F/YB5515 SERVICE MANUAL TRANSMISSION AND TORQUE CONVERTER Hydraulic 2/4-Wheel Drive Unit Disassembly Two different suppliers of the thinner friction plates 0.062 to 0.067 in (1.6 to 1.7 mm) approximately have been used and Assembly (Pressure ON/Spring OFF (identified as brown or green), do not mix the different plates Type) in the same clutch pack.
Page 254 TRANSMISSION AND TORQUE CONVERTER 5540F/YB5515 SERVICE MANUAL 14. Fit a new oil seal M, fit the output yoke E, and flanged bolt F. Torque the bolt to 291 Ib ft (395 Nm). ...
Page 255: Hydraulic 2/4 Wheel Drive Unit Disassembly And Assembly (Spring On/Pressure Off Type)7-55
5540F/YB5515 SERVICE MANUAL TRANSMISSION AND TORQUE CONVERTER Hydraulic 2/4-Wheel Drive Unit Disassembly Friction plates - the cross hatching should be clearly visible, plates that are not flat, have friction material damage or and Assembly (Spring ON/Pressure OFF scoring must be replaced with a new set. Type) Do not mix old, new and worn plates.
Page 256 TRANSMISSION AND TORQUE CONVERTER 5540F/YB5515 SERVICE MANUAL 12. Install thrust washer 4 and bearing 3. components have been assembled correctly, the shaft end float will be 0.0004 to 0.006 in (0.01 to 0.16 mm). 13. Fit sealing ring 2 and bearing 1. Rotate the shaft by hand and ensure that it runs smoothly.
Page 257 5540F/YB5515 SERVICE MANUAL TRANSMISSION AND TORQUE CONVERTER Hydraulic 2/4-Wheel Drive Unit Pressure Testing (Spring ON/Pressure OFF Type) Assemble the 2/4-wheel drive unit, as described in Assembly, see Figure 7-93. Check the clutch pack end float and adjust as required, see Assembly. Using special tool 993/59300, insert the adaptor A into the oil gallery in the end of the 2/4-wheel drive unit shaft as shown.
Page 258 TRANSMISSION AND TORQUE CONVERTER 5540F/YB5515 SERVICE MANUAL 7-58 Published 10-21-2010, Control# 198-04 ...
Page 259 5540F/YB5515 SERVICE MANUAL SECTION 8 AXLES/DRIVE SHAFTS/WHEELS AND TIRES TABLE OF CONTENTS Description............8-1 Front Axle .
Page 260 5540F/YB5515 SERVICE MANUAL THIS PAGE BLANK 8-ii ...
Page 261: Description
5540F/YB5515 SERVICE MANUAL AXLES/DRIVE SHAFTS/WHEELS AND TIRES SECTION 8 AXLES/DRIVE SHAFTS/WHEELS AND TIRES DESCRIPTION The axle is pin mounted to the frame of crane, allowing it to pivot in both directions. When the axle is equipped with axle Front Axle lockouts, the axle will pivot 4°...
Page 262: Technical Data
AXLES/DRIVE SHAFTS/WHEELS AND TIRES 5540F/YB5515 SERVICE MANUAL TECHNICAL DATA Front Drive Axle Type ..........3 piece spiral bevel input with epicyclic hub reduction and inboard braking ...
Page 263: Rear Non-Drive Axle
5540F/YB5515 SERVICE MANUAL AXLES/DRIVE SHAFTS/WHEELS AND TIRES Rear Non-Drive Axle Type ..........Spiral bevel input with epicyclic hub reduction Installation.
Page 264: Front Drive Axle Repair
AXLES/DRIVE SHAFTS/WHEELS AND TIRES 5540F/YB5515 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 machine ...
Page 265 5540F/YB5515 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 266: Replacing The Pinion Oil Seal
AXLES/DRIVE SHAFTS/WHEELS AND TIRES 5540F/YB5515 SERVICE MANUAL Replacing The Pinion Oil Seal WARNING A raised and badly supported machine can fall on you causing severe injury or death. Position the machine on a firm, level surface before raising one end. Ensure that the other end is securely chocked.
Page 267: Axle Hub Repair
5540F/YB5515 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 268 AXLES/DRIVE SHAFTS/WHEELS AND TIRES 5540F/YB5515 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 ...
Page 269 5540F/YB5515 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 270 AXLES/DRIVE SHAFTS/WHEELS AND TIRES 5540F/YB5515 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.
Page 271: Drive Head Repair
5540F/YB5515 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 machine. See “Removal”, on page 8-4. It will be necessary to provide a suitable stand to support the axle after removal.
Page 272 AXLES/DRIVE SHAFTS/WHEELS AND TIRES 5540F/YB5515 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 ...
Page 273 5540F/YB5515 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 274 AXLES/DRIVE SHAFTS/WHEELS AND TIRES 5540F/YB5515 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 ...
Page 275 5540F/YB5515 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 276 AXLES/DRIVE SHAFTS/WHEELS AND TIRES 5540F/YB5515 SERVICE MANUAL Install the pinion bearing cup Figure 8-33, together with Assembly Procedures 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 277 5540F/YB5515 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 3.5 to 8.9 lb-in. (0,40 to 1,0 Nm). crownwheel.
Page 278 AXLES/DRIVE SHAFTS/WHEELS AND TIRES 5540F/YB5515 SERVICE MANUAL 11. Adjust differential side nuts B Figure 8-42 to give a bearing pre-load of 1.0 to 1.84 lb-ft (1,36 to 2,5 Nm). Measure the pre-load by taking another rolling torque reading and subtracting the torque value measured at Step 8.
Page 279: Rear Axles Repair
5540F/YB5515 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 machine 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 242 A raised and badly supported machine can fall on you...
Page 280 AXLES/DRIVE SHAFTS/WHEELS AND TIRES 5540F/YB5515 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 ...
Page 281 5540F/YB5515 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 282 AXLES/DRIVE SHAFTS/WHEELS AND TIRES 5540F/YB5515 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.
Page 283 5540F/YB5515 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 100 lb-ft (135 Nm), then continue to tighten to next castellation and insert the pin.
Page 284: Drive Head Repair (Drive Axles Only)
AXLES/DRIVE SHAFTS/WHEELS AND TIRES 5540F/YB5515 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 ...
Page 285 5540F/YB5515 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 286: Drive Shafts
AXLES/DRIVE SHAFTS/WHEELS AND TIRES 5540F/YB5515 SERVICE MANUAL Assembly assembly and two differential side gears 14 and thrust washers 15 into case half 13. NOTE: The crownwheel 20 Figure 8-49 and pinion 24 are Position top case half 12 onto bottom half assembly 13 matched and should be replaced as a pair if either ...
Page 287: Drive Shafts
5540F/YB5515 SERVICE MANUAL AXLES/DRIVE SHAFTS/WHEELS AND TIRES NOTE: 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 288: Inspection
AXLES/DRIVE SHAFTS/WHEELS AND TIRES 5540F/YB5515 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 289: Installation
5540F/YB5515 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 290: Lubrication Procedure
AXLES/DRIVE SHAFTS/WHEELS AND TIRES 5540F/YB5515 SERVICE MANUAL must not be at right angles as at Y or at an WHEEL & TIRES intermediate angle as at Z. Apply grease with a grease gun to the fittings on the journal crosses and on the slip joint.
Page 291 SECTION 9 BRAKE SYSTEM TABLE OF CONTENTS Technical Data............9-1 Front Axle Brakes .
Page 292 5540F/YB5515 SERVICE MANUAL THIS PAGE BLANK 9-ii ...
Page 293: Technical Data
5540F/YB5515 SERVICE MANUAL SECTION 9 BRAKE SYSTEM TECHNICAL DATA Front Axle Brakes Type ..........Oil-immersed multi-plate disc Actuation .
Page 294: Description
5540F/YB5515 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 8) The priority flow control valve also includes the brake system and the parking brake system.
Page 295 5540F/YB5515 SERVICE MANUAL a1663 FIGURE 9-2 GROVE Published 10-21-2010, Control# 198-04...
Page 296 5540F/YB5515 SERVICE MANUAL Low Pressure Warning Switch The low pressure warning switch illuminates a red light on the dash when the brake pressure goes below 850 psi (5861 kPa). When the red light illuminates, there still is enough pressure for brake application to stop the crane. ...
Page 297: Parking Brake System
5540F/YB5515 SERVICE MANUAL Parking Brake System Description Of Operation The parking brake system consists of 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. Parking Brake The parking brake is a disc-type brake Figure 9-5.
Page 298: Parking Brake Bleeding
5540F/YB5515 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. NOTE: The accumulator must be charged before this operation can be performed. If you are not sure the accumulator is charged, engage the parking brake, ...
Page 299: Accumulator Charging
5540F/YB5515 SERVICE MANUAL Shut off the engine and place chock blocks in front and NOTE: Pressure cannot build up in the hydraulic tank until behind all four wheels. Release the parking brake. the oil is hot, or if the pressure is vented by removing the tank cap/breather.
Page 300 5540F/YB5515 SERVICE MANUAL With the engine shut off and the parking brake engaged, To check for severe piston seal damage: close the accumulator needle valve Figure 9-11 to shut Fill the housing of hand pump with Mobil fluid 424, off hydraulic pressure to the service brakes.
Page 301: Service Brake Repair
5540F/YB5515 SERVICE MANUAL Using a suitable pen, mark the level line (C) of the fluid in the tube. d. After approximately 1/2 hour, check if the level has dropped below the original marked line. If it has then check the brake piston seals for slight nicks, cuts or general wear.
Page 302 5540F/YB5515 SERVICE MANUAL FIGURE 9-19 FIGURE 9-17 p0091 p0092 Wear limit of friction plates is to the depth of the Carefully remove brake piston E Figure 9-20 from its circumferential grooves X Figure 9-18. Check all plates housing, if removal is necessary.
Page 303 5540F/YB5515 SERVICE MANUAL Remove and discard seals F and G Figure 9-21. Inspect Carefully press piston E Figure 9-23 all the way into its the housing for damage and scoring. Nicks or cuts in the housing. seals may be responsible for loss of brake fluid. p0093 FIGURE 9-23 FIGURE 9-21...
Page 304: Rear Axle Brakes
5540F/YB5515 SERVICE MANUAL Locate the three reaction pins D Figure 9-25 into their Apply Loctite 275 to the mating face of the drive head. grooves, securing them with grease. Push the pins fully Locate the axle arm onto the drivehead, with the into their location holes in the housing.
Page 305: Parking Brake Repair
5540F/YB5515 SERVICE MANUAL PARKING BRAKE REPAIR Separate the mounting bracket assembly 31 from the brake assembly. Lining Kit Replacement Clamp the brake in a vice with soft jaws with the clearance slot facing straight up. NOTE: Clamping should be done on sides of the brake, not on machined surfaces.
Page 306 5540F/YB5515 SERVICE MANUAL FIGURE 9-28 a0779 Item Description Item Description Capscrew O-ring Lockwasher Piston Cover Lining Seal Screw Belleville Springs Lining Assembly ...
Page 307: Repair Kit Installation
5540F/YB5515 SERVICE MANUAL Repair Kit Installation The parking brake has a repair kit available. It includes all the parts necessary to rebuild the brake. These parts are WARNING indicated in Figure 9-28 with a symbol. Cap (3) is under spring pressure. Use care when removing the cap to prevent personal injury.
Page 308: Seal Kit Installation
5540F/YB5515 SERVICE MANUAL hydraulic system. Keep all parts free of contaminants, A, B, C and D Figure 9-29. When installed, tighten each dirt and debris. screw to a torque of 22-27 lb-ft (29,8 - 36,6 Nm). NOTE: Coat the surfaces indicated Figure 9-28 with a 30.
Page 309 5540F/YB5515 SERVICE MANUAL Remove the bolts and nuts used to fasten the brake NOTE: Coat the surfaces Figure 9-28 with a Lithium Base, mounting bracket to the crane. Remove the parking E.P. No. 2 bearing grease or equivalent. brake assembly. 17.
Page 310: Brake Modulating Valve Repair
5540F/YB5515 SERVICE MANUAL BRAKE MODULATING VALVE REPAIR NOTE: Be careful not to damage the spool or housing bore as they are a matched set and not sold separately. Removal Assembly A seal kit is available for repair of the valve. It consists of the ...
Page 311: Troubleshooting
5540F/YB5515 SERVICE MANUAL Boot Piston Assembly Spring Spring Spring Shim Retainer Assembly End Plug O-ring 10. Spring 11. Spool 12. Housing 13. Screw 14. Cup 15. Seal Brake Modulating Valve FIGURE 9-31 a0780 TROUBLESHOOTING Service Brakes PROBLEM POSSIBLE CAUSE REMEDY Warning light on instrument panel Loss of brake pressure.
Page 312 5540F/YB5515 SERVICE MANUAL PROBLEM POSSIBLE CAUSE REMEDY Charging valve actuates every time Accumulator needle valve closed. Open needle valve. foot pedal is pressed. Loss of nitrogen in accumulator. Charge accumulator. Insufficient hydraulic pressure in Faulty accumulator charging accumulator.
Page 313: Section 10
SECTION 10 STEERING SYSTEM TABLE OF CONTENTS Units Without Return-To-Center Steering ........10-1 Technical Data.
Page 314 5540F/YB5515 SERVICE MANUAL THIS PAGE BLANK 10-ii ...
Page 315: Units Without Return-To-Center Steering
5540F/YB5515 SERVICE MANUAL STEERING SYSTEM SECTION 10 STEERING SYSTEM UNITS WITHOUT RETURN-TO-CENTER STEERING TECHNICAL DATA Rated pump output ....... . 16 gpm at 2500 rpm (20,8 l/min at 2500 rpm) Relief valve setting .
Page 316 STEERING SYSTEM 5540F/YB5515 SERVICE MANUAL Right Turn in 2 Wheel Steer Mode a0323 FIGURE 10-1 ...
Page 317 5540F/YB5515 SERVICE MANUAL STEERING SYSTEM Right Turn in 4 Wheel Steer Mode a0324 FIGURE 10-2 GROVE 10-3 Published 10-21-2010, Control# 198-04...
Page 318 STEERING SYSTEM 5540F/YB5515 SERVICE MANUAL Right Side Ways in Crab Steer Mode a0325 FIGURE 10-3 ...
Page 319: Relief Valve Pressure Check And Adjustment
5540F/YB5515 SERVICE MANUAL STEERING SYSTEM When moving side ways to the right Figure 10-3, hydraulic oil Start the engine allowing the hydraulic oil to reach under pressure from the steering pump flows to the steering operating temperature. Increase the engine speed to full rpm.
Page 320: Units With Return-To-Center Steering
STEERING SYSTEM 5540F/YB5515 SERVICE MANUAL UNITS WITH RETURN-TO-CENTER STEERING TECHNICAL DATA Rated pump output ....... .9.8 gpm at 2500 rpm (37,1 L/min at 2500 rpm) ...
Page 321 5540F/YB5515 SERVICE MANUAL STEERING SYSTEM Steering System a2095 FIGURE 10-6 GROVE 10-7 Published 10-21-2010, Control# 198-04...
Page 322 STEERING SYSTEM 5540F/YB5515 SERVICE MANUAL Right Turn in 2 Wheel Steer Mode a2098 FIGURE 10-7 ...
Page 323: Four-Wheel Steering
5540F/YB5515 SERVICE MANUAL STEERING SYSTEM Four-Wheel Steering Crab Steering During four-wheel steering, the front wheels steer in the During crab steering all the wheels steer in the same direction that the steering wheel is turned, while the rear direction. This mode allows the operator to move the wheels turn in the opposite direction.
Page 324 STEERING SYSTEM 5540F/YB5515 SERVICE MANUAL Right Turn in 4 Wheel Steer Mode a2097 FIGURE 10-8 ...
Page 325 5540F/YB5515 SERVICE MANUAL STEERING SYSTEM Right Side Ways in Crab Steer Mode a2099 FIGURE 10-9 GROVE 10-11 Published 10-21-2010, Control# 198-04...
Page 326: Relief Valve Pressure Check And Adjustment
STEERING SYSTEM 5540F/YB5515 SERVICE MANUAL RELIEF VALVE PRESSURE CHECK AND operator in the cab to select the steering modes. The relay box, located under the instrument panel, contains relays that ADJUSTMENT control the steering mode solenoid valves. Refer to page 10-5 for pressure check and pressure ...
Page 327 5540F/YB5515 SERVICE MANUAL STEERING SYSTEM Steering Electrical Wiring Diagram a2096 FIGURE 10-12 GROVE 10-13 Published 10-21-2010, Control# 198-04...
Page 328: Sensor Operation And Spacing Checks
STEERING SYSTEM 5540F/YB5515 SERVICE MANUAL 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 329 5540F/YB5515 SERVICE MANUAL STEERING SYSTEM 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 stick spool. Repair or correctly. replace. Check load sense line for leaks or poor connection.
Page 330 STEERING SYSTEM 5540F/YB5515 SERVICE MANUAL 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 ...
Page 331: Steering Orbitrol
5540F/YB5515 SERVICE MANUAL STEERING SYSTEM 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 332 STEERING SYSTEM 5540F/YB5515 SERVICE MANUAL Steering Orbitrol FIGURE 10-16 a0671 10-18 Published 10-21-2010, Control# 198-04 ...
Page 333 5540F/YB5515 SERVICE MANUAL STEERING SYSTEM Seal 14. Spacer Plate Retaining Ring 15. Drive Seal Gland Bushing 16. Gerotor Seal 17. Spacer Quad Ring Seal 18. End Cap Needle Bearing Kit 19. Capscrew (7) Control Part Assembly 20. Check Ball Retainer Housing 21.
Page 334 STEERING SYSTEM 5540F/YB5515 SERVICE MANUAL protective material on the vise jaws. Housing distortion Rotate spool (12) and sleeve (9) until pin (11) is could result if the vise jaws are overtightened. horizontal. Push the spool and sleeve assembly forward with your thumbs just far enough to free gland bushing (3) from the housing.
Page 335 5540F/YB5515 SERVICE MANUAL STEERING SYSTEM 13. Push spool (12) back through and out of sleeve (9). Lubricate the check ball seat and seals thoroughly Rotate spool slowly when removing from the sleeve before installing into the housing. When installing the Figure 10-22.
Page 336 STEERING SYSTEM 5540F/YB5515 SERVICE MANUAL Compress the extended end of the centering spring set and push into the spool and sleeve assembly, Screwdriver Screwdriver withdrawing the installation tool at the same time. Dust Seal Center the spring set in the parts so they push down evenly and flush with the outer surface of the sleeve.
Page 337 5540F/YB5515 SERVICE MANUAL STEERING SYSTEM 22. With seal side of the gerotor toward spacer plate (14), align star valleys Figure 10-28 Ref. A) on drive (Ref. B). Note the parallel relationship of reference lines A, B, C Port Face Drive and D.
Page 338: Steering Cylinder
STEERING SYSTEM 5540F/YB5515 SERVICE MANUAL STEERING CYLINDER Technical Data Cylinder Bore ........2.36 inches (60 mm) Stroke .
Page 339 5540F/YB5515 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 340 STEERING SYSTEM 5540F/YB5515 SERVICE MANUAL Assembly Install new gland seal 14 Figure 10-32 using the special and installation tool as follows: NOTE: The size (diameter) and position of pins is determined by the diameter and radial width of the ...
Page 341 5540F/YB5515 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 342 STEERING SYSTEM 5540F/YB5515 SERVICE MANUAL THIS PAGE BLANK 10-28 Published 10-21-2010, Control# 198-04 ...
Page 343: Section 11
SECTION 11 STRUCTURALS TABLE OF CONTENTS Booms ............. . 11-1 General .
Page 344 5540F/YB5515 SERVICE MANUAL Disassembly ..........11-56 ...
Page 345: Booms
5540F/YB5515 SERVICE MANUAL STRUCTURALS SECTION 11 STRUCTURALS BOOMS Install pin “A” into holes “D” and “E” (Figure 11-3). Install the snapper pin to retain pin “A”. General a1850 The three section boom as well as the four section boom is hydraulically extended and retracted by a dual telescope cylinder inside the boom.
Page 346 STRUCTURALS 5540F/YB5515 SERVICE MANUAL a1852 FIGURE 11-3 11-2 ...
Page 347: Retracting The Fourth Boom Section
5540F/YB5515 SERVICE MANUAL STRUCTURALS Retracting the Fourth Boom Section Fully extend the telescope cylinder by actuating the telescope lever in the cab (Figure 11-3). Extend the outriggers. Install pin “A” into holes “C” and “F”. Lower the boom to its horizontal position. Completely retract fourth...
Page 348: Removal Of Boom Assembly
STRUCTURALS 5540F/YB5515 SERVICE MANUAL FIGURE 11-6 Removal of Boom Assembly Installation of the Boom Assembly Remove the hook block and wire rope. NOTE: Use at least a 2 ton (1.8 Metric Ton) overhead ...
Page 349: Disassembly
5540F/YB5515 SERVICE MANUAL STRUCTURALS Disassembly Raise up on the boom section 2 assembly and remove the wear pads from the boom section 1. NOTE: Refer to Figure 11-7 for steps 1 thru 7. Slide the assembly out of the boom section 1. At the rear of the assembly, remove the hoses and As necessary, remove the following items from the boom fittings from the telescope cylinder.
Page 350 STRUCTURALS 5540F/YB5515 SERVICE MANUAL NOTE: Refer to Figure 11-8 for steps 8 thru 14. 12. Raise up on the boom section 3 assembly and remove the wear pads from the boom section 2. Remove the top rear wear pads from boom section 2. 13.
Page 351 5540F/YB5515 SERVICE MANUAL STRUCTURALS NOTE: Refer to Figure 11-9 For steps 15 thru 18. Remove the bolts and lockwashers securing the lower rear wear pad, remove the wear pad. Steps 15 thru 18 pertain only to the disassembly of boom section 3 of the four section boom. b.
Page 352 STRUCTURALS 5540F/YB5515 SERVICE MANUAL NOTE: Refer Figure 11-10 For steps 19 thru 22. On the three section boom only, remove the bolts and lockwashers securing the rear bottom wear pad Steps 19 thru 22 pertain to the disassembly of and remove the wear pad.
Page 353 5540F/YB5515 SERVICE MANUAL STRUCTURALS NOTE: Refer to Figure 11-11 For steps 23 thru 31. Steps 23 thru 31 pertain to disassembly (as necessary) of the telescope cylinder assembly. 23. On the four section boom, remove the bolts, washers, lockwashers and nuts securing the guide pad and pad support bar to the piston end of the lower telescope cylinder.
Page 354 STRUCTURALS 5540F/YB5515 SERVICE MANUAL Upper Telescope Cylinder Counterbalance Valve Washer Cotter Pin Lockwasher Lower Telescope Cylinder 10. Cotter pin 11. Bolt 12. Lockwasher 13. Washer 14. Bolt 15. Wear Pad 16. Bolt 17. Pin 18.
Page 355: Assembly
5540F/YB5515 SERVICE MANUAL STRUCTURALS Assembly On the four section boom, install the retract adjuster using two nuts. NOTE: During assembly, use Loctite 242 (blue) on all d. Replace the bearings in the sheaves as necessary. fastener threads. Apply lubricant (bronze anti- seize) to all wear pads.
Page 356: Wire Rope, Sheaves And Hoist Blocks
STRUCTURALS 5540F/YB5515 SERVICE MANUAL 22. Install the pin and cotter pin securing the telescope another in some predetermined manner and to some desired cylinder bracket to the rear of boom section 2. (Refer to end." figure 9-11) A typical wire rope may contain dozens, even hundreds, of ...
Page 357: Wire Rope Safety
5540F/YB5515 SERVICE MANUAL STRUCTURALS Wire Rope Safety • Broken wires; number and location. • Reduction in diameter. The following information is not a complete discussion of wire rope. What follows is a brief outline of the basic • Rope stretch (elongation). information required to safely use wire rope.
Page 358: Wire Rope Lubrication
STRUCTURALS 5540F/YB5515 SERVICE MANUAL As wear in the sheaves increases, the groove for the wire rope gets smaller, NOT larger. Tracks in the sheaves are caused by the wire rope, and the wire rope will continue to engage the tracks (for example; like a chain engaging a sprocket). A twist in the wire rope or a small change of lay will prevent the wire rope from engaging the track in the sheave.
Page 359: Installation Of A New Wire Rope
5540F/YB5515 SERVICE MANUAL STRUCTURALS Installation of a New Wire Rope After installation, operate the winch 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 winch drum.
Page 360: Main Winch (Tulsa Model)
STRUCTURALS 5540F/YB5515 SERVICE MANUAL MAIN WINCH (TULSA MODEL) When the load comes to a stop, the cam clutch locks up and the load is inhibited from moving by the brake. During payout Theory Of Operation (Figure 11-19), a counterbalance valve is used to inhibit the load from moving faster than desired.
Page 361 5540F/YB5515 SERVICE MANUAL STRUCTURALS a0481 FIGURE 11-18 a0482 FIGURE 11-19 a0485 Winch Exploded View FIGURE 11-20 11-17...
Page 362: Repair
STRUCTURALS 5540F/YB5515 SERVICE MANUAL Repair Removal Remove the wire rope from the winch drum. With the engine shut off, move the winch control level back and forth several times to release any hydraulic pressure in the winch hydraulic circuit. ...
Page 363 5540F/YB5515 SERVICE MANUAL STRUCTURALS approximately the middle of one of planet gear Assembly teeth. Thoroughly clean all parts. Replace those which show b. Using a screwdriver or your finger, rotate the planet wear. gear back and forth, reading the movement on the After inspecting the drum for excessive wear in the gear dial indicator.
Page 364: Motor Group
STRUCTURALS 5540F/YB5515 SERVICE MANUAL planet set and insert the output sun gear 16 into the that the bolts for the motor are aligned properly. Install output planet set. the mounting capscrews and tighten to a torque of 100 to110 lb-ft. (130 to 143 Nm). Also, make sure that the Install the input planet set into the drum.
Page 365: Brake Section
5540F/YB5515 SERVICE MANUAL STRUCTURALS make sure it is not obstructed. Also, check the o-rings to The motor and cartridge valve are not serviceable in the ensure that they are not cut or flattened. Replace if field. necessary. Brake Section Disassembly Remove the capscrews (Figure 11-34) holding the motor cover in place.
Page 366 STRUCTURALS 5540F/YB5515 SERVICE MANUAL p0202 p0200 FIGURE 11-36 FIGURE 11-34 If one or both of the square seals (8, Figure 11-33) remain in the bore of the brake housing, remove them. ...
Page 367 5540F/YB5515 SERVICE MANUAL STRUCTURALS p0203 FIGURE 11-38 Remove the spacer (Figure 11-39) from the brake FIGURE 11-40 p0206 housing. With a hook (Figure 11-40) or pry bar, remove the seal. .Examine the bushing (Figure 11-41) in the brake housing for wear and if found replace it. FIGURE 11-41 p0207 p0205...
Page 368 STRUCTURALS 5540F/YB5515 SERVICE MANUAL p0208 FIGURE 11-42 Carefully disassemble the brake driver clutch assembly noting the direction of lockup on the clutch. The clutch p0210 FIGURE 11-43 assembly must be assembled with the arrow pointing in the proper direction for the winch to operate properly.
Page 369 5540F/YB5515 SERVICE MANUAL STRUCTURALS a0479 FIGURE 11-45 Inspect each new seal (8, Figure 11-33) to make sure it has an o-ring (Figure 11-46) in the groove. p0201 FIGURE 11-47 Coat a new o-ring (Figure 11-48) with light oil and install the o-ring into the groove on the brake cover.
Page 370 STRUCTURALS 5540F/YB5515 SERVICE MANUAL brake port and adapting a torque wrench to input shaft. Planet Sets The torque here in the payout direction should be 95 to Remove spiral ring from planet pins 115 lb. (10.6 to 12.9 Nm). (Figure 11-50).
Page 371 5540F/YB5515 SERVICE MANUAL STRUCTURALS Remove the planet gears, thrust washers and bearings from the carrier (Figure 11-52). Inspect the pins, bearings and gear bores for evidence of wear and replace if necessary. On the output planet sets, note that two bearings with a spacer between them are used.
Page 372: Troubleshooting
STRUCTURALS 5540F/YB5515 SERVICE MANUAL Troubleshooting Trouble Possible Cause Remedy Excessive back pressure in the Check the circuit or restrictions winch circuit. reduce the back pressure. Winch won’t hold load. Brake discs are worn out. Replace the brake discs. ...
Page 373: Main Winch (Braden Model)
5540F/YB5515 SERVICE MANUAL STRUCTURALS MAIN WINCH (BRADEN MODEL) Primary planetary gear set. The hydraulic motor is bolted to the motor support which in Theory Of Operation turn is bolted to the brake cylinder and the base. The motor end of the drum, rotating on a ball bearing, is supported by Description Of Winch ( Figure 11-54 ) the brake cylinder.The other end of the drum is rotates on a The winch has five basic component parts:...
Page 374 STRUCTURALS 5540F/YB5515 SERVICE MANUAL oil, under pressure, from the pump is sent through the main control valve to the counterbalance valve; opening the check valve. Oil flows through the check valve to the motor, rotating in the hoisting direction. See Figure 11-55. ...
Page 375 5540F/YB5515 SERVICE MANUAL STRUCTURALS braking takes place in the brake valve and that little, if any, heat is absorbed by the friction brake. The friction brake is load holding brake only, and has nothing to do with dynamic braking or rate of descent of a load. The brake clutch is splined to the primary sun gearshaft between the motor and the primary sun gear.It will allow this shaft to turn freely in the direction to raise a load and lock up...
Page 376: Repair
STRUCTURALS 5540F/YB5515 SERVICE MANUAL When lowering a load very slowly for precise positioning, no Repair oil flow actually occurs through the winch motor. The Removal pressure will build up to a point when the brake will release sufficiently to allow the load to rotate the motor through its ...
Page 377 5540F/YB5515 SERVICE MANUAL STRUCTURALS Winch Exploded View a2204 FIGURE 11-60 11-33...
Page 378: Winch Assembly
STRUCTURALS 5540F/YB5515 SERVICE MANUAL Service Precautions manually rotate the drum in the direction to hoist a load until the drain holes align. • Before any part is removed from the winch, all service instructions should be read and understood. ...
Page 379 5540F/YB5515 SERVICE MANUAL STRUCTURALS Begin disassembly by removing the oil level plug and standing the winch on the bearing support end. Tag and remove the hydraulic hoses that connect the brake valve and manifold to the brake cylinder (Figure 11-63). FIGURE 11-65 a2215 Remove the motor support capscrews and install two (2)
Page 380 STRUCTURALS 5540F/YB5515 SERVICE MANUAL Remove and discard the O-ring from the outside of the 12. Remove the primary planet carrier from the drum drum closure. (Figure 11-69). Refer to “Planet Carrier Service,” for additional information. ...
Page 381 5540F/YB5515 SERVICE MANUAL STRUCTURALS Place winch base on side with bearing supported up (Figure 11-72). FIGURE 11-71 a2221 15. Stand winch on motor end with bearing support up. Then FIGURE 11-72 a2222 remove eight (8) bearing support capscrews and bearing support being careful to avoid damaging the Install a new bearing in the drum if replacement is sealing or bearing surfaces.
Page 382 STRUCTURALS 5540F/YB5515 SERVICE MANUAL Center the drum in the opening of the base (Figure 11-74). Lubricate the bearing support with petroleum jelly or gear oil and install in base and drum. NOTE: Be sure the vent plug is located above the h o r i z o n t a l c e n t e r l i n e f o r t h e i n t e n d e d ...
Page 383 5540F/YB5515 SERVICE MANUAL STRUCTURALS rope in. An easy way to check the rotation is to hold the outer race in one hand, and rotate the inner race. If the clutch free wheels in the wrong direction, disassembly the clutch and reverse the inner race. Refer to “Brake Clutch Service”, for additional information.
Page 384 STRUCTURALS 5540F/YB5515 SERVICE MANUAL 15. Install the hoses and fittings to the brake cylinder release port (Figure 11-82). FIGURE 11-83 a2233 a2232 FIGURE 11-82 16. Install a new O-ring on the motor pilot then lubricate with petroleum jelly or gear oil.
Page 385: Planet Carrier Service
5540F/YB5515 SERVICE MANUAL STRUCTURALS a2237 FIGURE 11-87 a2235 FIGURE 11-85 20. After the winch assembly is complete, check all Now you can remove the planet shafts, bearings, capscrews and fittings to make certain they have been spacer, thrust washers and gears.Thoroughly clean all tightened correctly.
Page 386: Motor Support-Brake Cylinder Service
STRUCTURALS 5540F/YB5515 SERVICE MANUAL Assembly Place the output planet carrier on workbench with splined coupling side down. Install output thrust plate in center of carrier (Figure 11-89). a2239 FIGURE 11-89 a2241 FIGURE 11-91 ...
Page 387 5540F/YB5515 SERVICE MANUAL STRUCTURALS FIGURE 11-93 a2243 Disassembly a2246 FIGURE 11-96 Remove spacers, friction brake discs and steel brake discs (Figure 11-94). Clean and Inspect Thoroughly clean and inspect all parts at this time. Check brake piston sealing surfaces on the brake cylinder and motor support.
Page 388 STRUCTURALS 5540F/YB5515 SERVICE MANUAL pattern visible. Replace the friction disc if the splines are Assembly worn to a point, disc is distorted, friction material is worn Begin assembly by placing the motor support on the unevenly, or the groove pattern is worn away. workbench with motor mounting surface down.
Page 389 5540F/YB5515 SERVICE MANUAL STRUCTURALS To check brake stack height, place a pressure plate on top of brake spacer. Hold pressure plate down firmly by hand and measure the clearance in three places between the motor support and the pressure plate WARNING (Figure 11-104).
Page 390: Brake Clutch Service
STRUCTURALS 5540F/YB5515 SERVICE MANUAL Release the pressure on the cylinder, and then remove the brake clutch assembly. The brake cylinder assembly is now compete and ready to install in the winch. Brake Clutch Service Disassembly Remove the snap ring and sprag bushing retainer from ...
Page 391 5540F/YB5515 SERVICE MANUAL STRUCTURALS be placed between the press and bushing. This will protect the busing from damage. Be certain the bushing flange is against the shoulder in the outer race (Figure 11-114). a2264 FIGURE 11-112 Next, slide the sprag clutch out. Inspect the sprag clutch FIGURE 11-114 a2267 closely for abnormal war, cracks, pitting, or corrosion.
Page 392: Winch Tension Roller Subassembly Service
STRUCTURALS 5540F/YB5515 SERVICE MANUAL freewheeling direction to start it through the sprag clutch. If the inner race will not go through the bushings, the bushings have probably been damaged and should be replaced. a2272 FIGURE 11-119 ...
Page 393 5540F/YB5515 SERVICE MANUAL STRUCTURALS Winch Tension Roller Subassembly Cut-Away View a2270 FIGURE 11-120 Item Description Item Description Tension Roller Arm Lockwasher (8) Tension Spring (2) Capscrew (4) Tension Roller Shaft Roll Pin (2) Tension Arm Shaft Snap Ring (2) Set Screw (2) Thrust Race (2) Washer (6) Roller...
Page 394: Troubleshooting
STRUCTURALS 5540F/YB5515 SERVICE MANUAL Troubleshooting Trouble Possible Cause Remedy The friction brake may not be 1.Check brake cylinder seal as releasing as a result of a defective follows: brake cylinder seal. Disconnect the swivel tee NOTE: If the brake cylinder seal is f r o m t h e b r a k e r e l e a s e defective leaking will occur...
Page 395: Bearing, Mast And Related Parts
5540F/YB5515 SERVICE MANUAL STRUCTURALS Trouble Possible Cause Remedy Excessive system back pressure Same as Remedy 2 of possible act in on the brake release port. cause B2. Friction brake will not hold due to Same as Remedy 3 of Possible worn or damaged brake discs.
Page 396: Mast Bearing
STRUCTURALS 5540F/YB5515 SERVICE MANUAL Cross Section of Mast Bearing a0490 FIGURE 11-121 Mast Bearing The bearing is a ball thrust bearing. The inner race rotates inside the outer race on a row of steel balls.
Page 397: Mast Bearing Bolts
5540F/YB5515 SERVICE MANUAL STRUCTURALS Mast Bearing Bolts b. Increased drive power required. Noisy rotation. Very high stress is put on the mast bolts during crane operation. It is important that these bolts be checked at d. Rough rotation. regular intervals. If one or more of the above symptoms are present, the Check the torque on the bolts after the first week or 50 hours following procedure should be used to test the bearing for...
Page 398: Swing Gearbox And Pinion
STRUCTURALS 5540F/YB5515 SERVICE MANUAL Disconnect the hydraulic lines from the lower swivel 10. Install counterweights 2 and 4 into the mast. ports. Put caps or plugs on the fittings and hydraulic 11. Install the winch assembly to the mast. lines.
Page 399 5540F/YB5515 SERVICE MANUAL STRUCTURALS Item Description Mast Right Counterweight Winch Left Counterweight Washer Bolt Washer Bolt Washer Swing Bearing Lock Washer Bolt Swing Motor Tulsa Swing Gear Box Bolt Eccentric Ring Pinion Gear Cover Bolt Lock Washer Washer Bolt Bolt Stop Assembly Hydraulic Swivel Bolt...
Page 400: Swing Gearbox Repair (Tulsa Gearbox)
STRUCTURALS 5540F/YB5515 SERVICE MANUAL With a spanner wrench, turn the eccentric ring to move the pinion until it contacts the swing gear tooth (zero backlash). Tighten the four bolts to appropriate torque. Install the swing pinion cover. ...
Page 401 5540F/YB5515 SERVICE MANUAL STRUCTURALS 13. Using a suitable puller, remove bearing cone 15 from 15. Using a suitable puller, remove bearing cone 15 from pinion shaft 1. Remove spacer 16. pinion shaft 1. 14. Using a suitable puller, remove worm gear 17from pinion 16.
Page 402 STRUCTURALS 5540F/YB5515 SERVICE MANUAL Item Description Item Description Item Description Shim (2) Shim Pinion Shaft End Motor Cap Cover Key (2) Socket Head Capscrew Capscrew (8) ...
Page 403: Swing Gearbox Repair (Braden Gearbox)
5540F/YB5515 SERVICE MANUAL STRUCTURALS 18. Using a suitable puller, remove bearing cup14 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 404 STRUCTURALS 5540F/YB5515 SERVICE MANUAL a2273 Item Description Item Description Item Description Item Description Bearing Retainer Gasket - 0.031” Capscrew (4) Worm Housing Motor Adapter Cover Gasket Motor Gasket Bushing Retaining Ring (2) Capscrew (4)
Page 405: Outriggers
5540F/YB5515 SERVICE MANUAL STRUCTURALS Assembly Installation If removed, install bushing 2 and 4 into worm housing 1 Install the gearbox in reverse order of removal. and worm housing cover 3. Align the pinion gear with the swing gear following the Install bearing cups 8 and bearing cones 9 onto worm instructions.
Page 406: Cylinder Removal
STRUCTURALS 5540F/YB5515 SERVICE MANUAL Cylinder Removal Remove the cylinder rod end pin and remove the cylinder. Position the crane so that the outrigger is over some sort of a pit. If a pit is not available, an overhead crane of Cylinder Installation ...
Page 407 5540F/YB5515 SERVICE MANUAL STRUCTURALS Item Outrigger Assembly a0490 FIGURE 11-130 Item Description Retaining Ring Cylinder Outrigger Boom Retaining Ring 11-63...
Page 408 STRUCTURALS 5540F/YB5515 SERVICE MANUAL 11-64 ...
Page 409 SECTION 12 SCHEMATICS/WIRING DIAGRAMS GROVE 12-i...
Page 410 5540F/YB5515 SERVICE MANUAL THIS PAGE BLANK 12-ii ...
Page 411 5540F/ YB5515 SERVICE MANUAL ALPHABETICAL INDEX Accessory Circuits ........... . . 3-11 Anti-Double Blocking System .
Page 412 5540F/ YB5515 SERVICE MANUAL Special Maintenance ........... 5-1 ...

This manual is also suitable for:

Grove yb5515

Manitowoc Grove 5540F Service Manual

Table of Contents

Section 2 Safety Practices

Section 3 Electric System

Section 4 Hydraulic System

Section 5 Preventative Maintenance

Section 6 Engine and Engine Systems

Section 7 Transmission and Torque Converter

Quick Links

Chapters

Troubleshooting

Related Manuals for Manitowoc Grove 5540F

Summary of Contents for Manitowoc Grove 5540F