Disassembly And Assembly; Pressing Parts; Locking Devices; Wires And Cables - Manitowoc Grove 5540F Service Manual

supporting members (straps, chains and cables) should be
parallel to each other and as near perpendicular as possible
to the top of the object being lifted.
NOTE: The capacity of an eyebolt diminishes as the angle
between the supporting members and the object
becomes less than 90°. Eyebolts and brackets
should never be bent and should only have stress
in tension
Some removals require the use of lifting fixtures to obtain
proper balance. The weights of some components are given
in their respective sections of the manual.
If a part resists removal, check to be certain all nuts and bolts
have been removed and that an adjacent part is not
interfering.

Disassembly and Assembly

When disassembling or assembling a component or system,
complete each step in turn. Do not partially assemble one
part and start assembling another. Make all adjustments as
recommended. Always check the job after it is completed to
see that nothing has been overlooked. Recheck the various
adjustments by operating the machine before returning it to
service.

Pressing Parts

When pressing one part into another, use an anti-seize
compound or a molybdenum disulfide base compound to
lubricate the mating surfaces.
Assemble tapered parts dry. Before assembling parts with
tapered splines, be sure the splines are clean, dry, and free
from burrs. Position the parts together by hand to mesh the
splines before applying pressure.
Parts which are fitted together with tapered splines are
always very tight. If they are not tight, inspect the tapered
splines and discard the part if the splines are worn.

Locking Devices

Lockwashers, flat metal locks, or cotter pins are used to lock
nuts and bolts.
Flat metal locks must be installed properly to be effective.
Bend one end of the lock around the edge of the part. Bend
the other end against one flat surface of the nut or bolt head.
Always use new locking devices on components which have
moving parts.
When installing lockwashers on housings made of aluminum
or th in s h e et me tal, us e a f l at was h e r be t w ee n th e
lockwasher and the housing.
1-6

Wires and Cables

Batteries should always be disconnected prior to working on
the electrical system.
When removing or disconnecting a group of wires or cables,
tag each one to ensure proper identification during assembly.

Shims

When shims are removed, tie them together and identify
them as to location. Keep shims clean and flat until they are
reinstalled.

Hoses and Tubes

Exercise extreme care around pressurized hydraulic
hoses or tubes. DO NOT work on a hydraulic system
while it is in operation or until all pressure is released.
Hydraulic oil is hot, it can cause severe burns.
Pressurized hydraulic oil can cause death or serious
injury.
Stay clear of all hydraulic oil leaks. Relieve system
pressure and use a piece of cardboard or paper to
check for leaks. Do not use your hands.
Fluid injected into skin must be surgically removed
within a few hours by a doctor familiar with this type of
injury or gangrene will result.
Inspection
Check hoses carefully. Do not use your bare hands to check
for leaks.
Tighten all connections to recommended torque.
If the hose end connections are damaged, always replace
the hose or tube. Damaged, dented, crushed, or leaking
hose fittings restrict oil flow and the operation of the parts
being served. Fittings showing signs of movement from their
original position have failed and must be replaced.
Be sure hoses are in good condition. If in doubt, replace
them.
Replace hoses if any of the following is evident Figure 1-8:
• Evidence of kinking or crushing (1)
• Chaffing or cuts; wire is exposed (2)
• Damaged or leaking fittings (3)
• Localized ballooning (4)
Published 10-21-2010, Control# 198-04
5540F/YB5515 SERVICE MANUAL
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DANGER
High Pressure/Temperature Hazard!