Grove RT890E

Service/Maintenance Manual

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THIS PAGE BLANK
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 1
SERVICE MANUAL
This Manual has been prepared for and is considered part of -

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RT890E
Crane Model Number

This Manual is divided into the following Sections:

SECTION 1 INTRODUCTION
SECTION 2 HYDRAULIC SYSTEM 3
SECTION 3 ELECTRIC SYSTEM
SECTION 4 BOOM
SECTION 5 HOIST AND COUNTERWEIGHT
SECTION 6 SWING SYSTEM
SECTION 7 POWER TRAIN
SECTION 8 UNDERCARRIAGE
SECTION 9 LUBRICATION
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NOTICE 5
The crane serial number is the only method your Manitowoc Cranes
distributor or the factory has of providing you with correct parts and
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service information.
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The crane serial number is stamped on the top of the outrigger box.
Always furnish crane serial number when ordering parts or 6
communicating service problems with your Manitowoc Cranes
distributor or the factory.

! DANGER
An untrained operator subjects himself and others to death or
7

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. 8
• You read, understand, and follow the safety and operating
recommendations contained in the crane manufacturer’s manuals and
load charts, your employer’s work rules, and applicable government
regulations.
• You are sure that all safety signs, guards, and other safety features are 9
in place and in proper condition.
• The Operator Manual and Load Chart are in the holder provided on
crane.

© 2014 Manitowoc
Published 09-18-2014, Control # 308-06
 CALIFORNIA
PROPOSITION 65 WARNING
Diesel engine exhaust and some of its constituents are
known to the State of California to cause cancer, birth
defects, and other reproductive harm.

CALIFORNIA
PROPOSITION 65 WARNING
Battery posts, terminals, and related accessories contain
chemical lead and lead compounds, chemicals known to
the State of California to cause cancer, birth defects or

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other reproductive harm. Wash hands after handling.
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The original language of this publication is English.
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RT890E TABLE OF CONTENTS

See end of this manual for Alphabetical Index

See end of this manual for Alphabetical Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

SECTION 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Introduction
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
List of Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Torque Converter/Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Swing Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Boom. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Swivel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Hydraulic Pumps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
General Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Pressing Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

8
Locks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Wires and Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
27
Shims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Hoses and Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
2
Gaskets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
23

Hydraulic Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Hydraulic Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Fatigue of Welded Structures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Loctite®. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Fasteners and Torque Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Weld Studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
Environmental Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
Dynamic Shock Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
Precautions and Recommendations During Inspection or Replacement . . . . . . . . 1-19
Wire Rope Inspection (Running Ropes and Pendant Cables) . . . . . . . . . . . . . . . . 1-20
Wire Rope Inspection (Boom Extension and Retraction Cables) . . . . . . . . . . . . . . 1-21
Wire Rope Inspection/Replacement (All Wire Rope) . . . . . . . . . . . . . . . . . . . . . . . 1-21
Seizing Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
Installing 35x7 Class Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
Procedures for Cutting and Preparing 35x7 Class Wire Rope . . . . . . . . . . . . . . . . 1-23

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

Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Theory Of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Hydraulic Oil Recommendations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Draining and Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

GROVE TOC-1
TABLE OF CONTENTS RT890E

Removing Air from the Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Parts Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Directional Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Supply Pressure and Return Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Hydraulic Oil Return Filter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Oil Cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Hydraulic Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Pressure Setting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
Procedure A - Main Control Valve Pressure For Hoists, Boom Lift,
Telescope(s) - Check/Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Procedure B - Outrigger Pressures - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Procedure C - Oil Cooler Motor Pressure - Adjust. . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Procedure D - Set Service Brake Accumulator Charge Valve Limits -
Check/Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Procedure E - Accumulator Pre-Charge Pressure - Check . . . . . . . . . . . . . . . . . . 2-22
Procedure F - Pre-Charging the Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
Procedure G - Front Steer Pressure - Check/Adjust . . . . . . . . . . . . . . . . . . . . . . . 2-23
Procedure H - Swing Work Port Pressure - Check/Adjust. . . . . . . . . . . . . . . . . . . 2-23
Procedure I - Swing Brake Release Pressure - Check/Adjust. . . . . . . . . . . . . . . . 2-23
Procedure J - Controller Supply Pressure - Check/Adjust. . . . . . . . . . . . . . . . . . . 2-23
Procedure K - Hose Reel Brake and Motor Supply Pressure - Check/Adjust . . . . 2-23
Procedure L - Counterweight Removal Cylinder Extend Pressure - Check . . . . . 2-24

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Procedure M - Counterweight Pin Cylinder Pressure - Check. . . . . . . . . . . . . . . . 2-24
27
Procedure N - Cab Tilt Cylinder Extend/Retract Pressure - Check . . . . . . . . . . . . 2-24
Procedure O - Luffing Jib Lower Pressure - Check . . . . . . . . . . . . . . . . . . . . . . . . 2-24
Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31
2

Directional Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35

Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35
23

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35
Front Steer/Swing/Brake Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41
Steering Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45
Hydraulic Remote Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46
Swing Power Brake Valve With Treadle Pedal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-50
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-50
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-50
2 Speed Swing Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51
Cab Tilt Double Pilot Operated Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52
Tandem Brake Valve with Treadle Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53
Dual Accumulator Charge Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54
Hydraulic Accumulator Service Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56

TOC-2
RT890E TABLE OF CONTENTS

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56
Holding Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57
Cross Axle Differential Lock Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58
Outrigger Control Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-59
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-59
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-59
Pilot Operated Check Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62
Axle Lockout, Rear Steer and Oil Cooler Fan Motor Control Manifold . . . . . . . . . . . . . 2-63
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-63
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-63
Check Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66
Range Shift/Parking Brake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-67
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-67
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-67
Load Sense Dump Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-68

8
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-68
27
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-68
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-70
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-70
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-70
2

Surface Protection for Cylinder Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-70

Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-73
23

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-73
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-73
Dual Rod Telescope Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-76
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-76
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-76
Upper Telescope Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-80
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-80
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-80
Axle Oscillation Lockout Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-83
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-83
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-83
Axle Oscillation Lockout Cylinder (CE Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-86
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-86
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-86
Steer Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-89
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-89
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-89
Outrigger Extension Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-92
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-92
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-92
Outrigger Jack Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-95
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-95
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-95
Cab Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-98
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-98
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-98

GROVE TOC-3
TABLE OF CONTENTS RT890E

Counterweight Removal Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-101

Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-101
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-101
Counterweight Pin Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-104
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-104
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-104
Park Brake Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-106
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-106

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

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Batteries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Cab Electrical Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Carrier Electrical Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
General Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Troubleshooting Swivel-Caused Electrical Problems . . . . . . . . . . . . . . . . . . . . . . . 3-8
Connector Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Alternator/Charging System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Alternator Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

8
Starter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Battery Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
27
Relay Panel Component Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Gauge Cluster Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Rocker Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Ignition Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
2

Turn Signal Lever and Transmission Shift Lever Replacement. . . . . . . . . . . . . . . 3-15

Windshield Wiper Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
23

Windshield Washer Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

Skylight Wiper Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Telescope Cylinder Charge System - Electrical Schematic (If Equipped) . . . . . . . 3-20
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Beacon Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Boom Mounted Floodlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Rear View Mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Air Conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Cold Weather Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

SECTION 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boom
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Lattice Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Optional Hydraulic Luffing Extension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Optional Lattice Extension Inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Boom Control Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Boom Extension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Boom Retraction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
RCL System with Boom Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Telescoping Control System Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Extension Sequence for the Main Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

TOC-4
RT890E TABLE OF CONTENTS

Extension Sequence for the Main Boom with Boom Extensions or Offset Jibs . . . . 4-4
Electronic Control System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Boom Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Boom Nose Sheaves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Boom Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Functional Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Boom Alignment and Servicing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Cam Operated Check Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Guide Block Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Boom Extension and Retraction Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Telescope Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Hose Reel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
Lift Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29

8
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
27
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
Auxiliary Boom Nose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
Counterweight with Auxiliary Hoist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
2

Counterweight without Auxiliary Hoist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34

Installing the Bi-fold Manual Boom Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37
23

Checking the Transport Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39

Boom Extensions/Components Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39
Transportation on a Separate Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39
Boom Extension (Additional Equipment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39
Identification and Slinging Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39
Monthly Maintenance Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41

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

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

GROVE TOC-5
TABLE OF CONTENTS RT890E

Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Hoist Drum Rotation Indicator System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Counterweight Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Removal of Standard Counterweight and Auxiliary Hoist . . . . . . . . . . . . . . . . . . . 5-12
Installation of Standard Counterweight and Auxiliary Hoist Mounting Structure . . 5-12
Removal of Counterweight Without Auxiliary Hoist . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Installation of Counterweight Without Auxiliary Hoist . . . . . . . . . . . . . . . . . . . . . . 5-14
Third Wrap Indicator (Optional—Standard on CE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15

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

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Swing Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

8
Swing Gearbox And Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
27
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Swing Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
2

Swivels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
23

Hydraulic Swivel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15

Two Port Water Swivel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Electrical Swivel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17

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

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Electronic Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Engine Control System Switches and Indicator Lights . . . . . . . . . . . . . . . . . . . . . . 7-4
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Air Intake and Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Air Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Charge-Air Cooler System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
Water Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
Antifreeze/Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
Radiator Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
Radiator Fill and Servicing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22
Drive Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23

TOC-6
RT890E TABLE OF CONTENTS

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
Transmission/torque Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26
Troubleshooting Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26
Towing or Pushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28
Servicing the Crane After Transmission/Torque Converter Overhaul. . . . . . . . . . . 7-30
Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31
Engine Block Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31

SECTION 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Undercarriage
Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Typical Wear Patterns. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Steering Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8

8
Rear Steering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
27
Hydraulic Pumps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
Front Steering Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
Rear Steer/ Axle Lockout/Fan Drive Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
Steer Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
2

Rear Axle Oscillation Lockout System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
23

Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11

Axle Oscillation Lockout Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
Axle Oscillation Lockout Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
Service Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16
Corrosion Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20
Parking Brake Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22
Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
Park Brake Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-26
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-26
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-26
Outriggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27
Outrigger Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27
Outrigger Beam. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-31
Extension Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-35
Outrigger Monitoring System (Optional—Standard in North America) . . . . . . . . . . 8-36

GROVE TOC-7
TABLE OF CONTENTS RT890E

Jack Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-36

Outrigger Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-38
Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-38
Pintle Hook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-38
Secondary Front Steer (CE Option). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-38

SECTION 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubrication
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Environmental Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Lubricants and Lubrication Intervals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Standard Lubricants. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Arctic Lubricants and Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Surface Protection for Cylinder Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
Wire Rope Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
CraneLUBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
Steering and Suspension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10
Drive Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12
Drive Train (continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14
Turntable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16
Cab Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-18

8
Outriggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-20
Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-22
27
Hoist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-28
Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-30
Accessing Boom Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-32
Carwell® Rust Inhibitor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-33
2

Protecting Cranes From Rusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-33

Cleaning Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-33
23

Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-34

Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-34
Areas of Application. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-34

TOC-8
RT890E SERVICE MANUAL INTRODUCTION

SECTION 1
1
INTRODUCTION

SECTION CONTENTS
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Batteries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
List of Specifications . . . . . . . . . . . . . . . . . . . . . . . 1-2 Hydraulic Systems . . . . . . . . . . . . . . . . . . . . . . . . 1-10
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Hydraulic Fittings . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Fatigue of Welded Structures . . . . . . . . . . . . . . . 1-13
Torque Converter/Transmission . . . . . . . . . . . . . . 1-2 Loctite® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Fasteners and Torque Values . . . . . . . . . . . . . . . 1-14
Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Weld Studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Wire Rope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
Swing Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Environmental Conditions . . . . . . . . . . . . . . . . . . 1-19
Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Dynamic Shock Loads . . . . . . . . . . . . . . . . . . . . . 1-19
Swivel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
Hydraulic Pumps. . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Precautions and Recommendations During

8
Inspection or Replacement . . . . . . . . . . . . . . . 1-19
General Maintenance . . . . . . . . . . . . . . . . . . . . . . . 1-8
Cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 Wire Rope Inspection (Running Ropes and
27
Pendant Cables) . . . . . . . . . . . . . . . . . . . . . . . 1-20
Removal and Installation . . . . . . . . . . . . . . . . . . . 1-8
Wire Rope Inspection (Boom Extension and
Disassembly and Assembly . . . . . . . . . . . . . . . . . 1-8 Retraction Cables) . . . . . . . . . . . . . . . . . . . . . . 1-21
Pressing Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Wire Rope Inspection/Replacement (All Wire
2

Locks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 Rope) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21

Wires and Cables . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
23

Seizing Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . 1-22

Shims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 Installing 35x7 Class Wire Rope . . . . . . . . . . . . . 1-23
Hoses and Tubes . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 Procedures for Cutting and Preparing 35x7
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 Class Wire Rope . . . . . . . . . . . . . . . . . . . . . . . 1-23
Gaskets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

DESCRIPTION Axle oscillation lockout is automatic when the superstructure

rotates from the travel position.
This Manual provides information for the maintenance of the
Model RT890E Grove Crane. The superstructure is capable of 360 degree rotation in either
direction. All crane functions are controlled from the fully-
The lift capacities are listed on the Load Chart in the cab. enclosed cab mounted on the superstructure. The crane is
T h e c r an e i n c o r p or at e s a n al l w el d e d par al l e l b o x equipped with a five-section, full power, sequenced and
construction steel frame, using planetary drive axles to synchronized boom. Additional reach is obtained by utilizing
provide four-wheel drive. Axle steering is accomplished an optional swingaway boom extension. Lifting is provided
utilizing hydraulic steer cylinders. The engine is mounted at by a main hoist and an optional auxiliary hoist.
the rear of the crane carrier and provides motive power NOTE: Throughout this manual, reference is made to left,
through a six speed forward and reverse transmission. right, front, and rear when describing locations.
The carrier frame incorporates an integral fifth wheel, to When operating the crane, these reference
which the rear axle is mounted, to provide axle oscillation. locations are to be considered as those viewed
from the operator seat with the superstructure
facing forward over the front of the carrier frame.

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INTRODUCTION RT890E SERVICE MANUAL

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

Hi 3rd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.76
General Engine
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . .RT890E4
Rated Capacity . . . . . . . . . . See Load Chart in cab Cummins QSB6.7
Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 x 4
Gross Weight . . . . . . . . . . . . . . . . See Axle Weight Displacement . . . . . . . . . . . . . . . . . 409 cu in (6.7 l)
Distribution Table Firing Order. . . . . . . . . . . . . . . . . . . . . . 1-5-3-6-2-4
Lube Amount . . . . . . . . . . . . . . . . . . 18.5 qt (17.5 l)
Coolant System . . . . . . . . . . . . . . . . . . . 38 qt (36 l)
Dimensions Radiator . . . . . . . . . . . . . . . . . . . . . . . 2.5 gal (9.5 l)
CAC . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2 gal (8.2 l)
NOTE: Dimensions listed are for a crane with all
components fully retracted in the travel mode with Axles
29.5 x 25-34 bias ply tires.
Total Ratio. . . . . . . . . . . . . . . . . . . . . . . . . . 25.35:1
Wheelbase . . . . . . . . . . . . . . . . . 209 in (5318 mm) Carrier Ratio . . . . . . . . . . . . . . . . . . . . . . . . . 6.43:1
Overall Crane Length . . . . . . . .544 in (13,817 mm) Wheel End Ratio. . . . . . . . . . . . . . . . . . . . . . 5.20:1
Overall Crane Width . . . . . . . . . . 131 in (3340 mm)
Overall Crane Height . . . . . . . . . 147 in (3758 mm) Brakes
Tail-Swing . . . . . . . . . . . . . . . . . . 174 in (4420 mm)
Outrigger Spread Type . . . . . . . . .Hydraulic/Split system acting on all
Retracted . . . . . . . . . . . . . 10 ft 4 in (3150 mm) four wheels
Mid Extend . . . . . . . . . . . . 17 ft 4 in (5283 mm)
Fully Extended . . . . . . . . . . . . 24 ft (7315 mm) Wheels and Tires
Lugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Capacities Torque. . . . . . . . . . . 340 - 360 lb-ft (461 to 488 Nm)
Fuel Tank . . . . . . . . . . . . . . . . . . . . . .74 gal (280 l) Tire Size

8
Coolant System. . . . . . . . . . . . . . . . . . . See Engine Standard . . . . . . . . . . . 29.5 x 25, 34 ply rating
Specifications For roading and lifting pressures, refer to the Load
27
Engine Lubrication System . . . . . . . . . . See Engine Chart Book in the cab.
Specifications
Hydraulic Tank (Reservoir Capacity) Swing Gearbox
Total . . . . . . . . . . . . . . . . . . . . . .253 gal (959 l)
Reduction Ratio . . . . . . . . . . . . . . . . . . . . . . 33.6:1
2
at Full Level . . . . . . . . . . . . . . . .228 gal (864 l)
at Low Level. . . . . . . . . . . . . . . .213 gal (808 l) Output Torque . . . . . . . . . . . . . . . . . . . . 72,222 in lb
Expansion Space . . . . . . . . . . . . . .25 gal (95 l)
23

Hoists . . . . . . . . . . . . . . . . . . . . . . . .15.5 qt (14.7 l) Boom

Swing Gearbox . . . . . . . . . . . . . . . . . . .5.7 qt (5.4 l) Length. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Axle Planetary Hubs . . . . . . . . . . . . . . 11.0 pt (5.2 l) Retracted . . . . . . . . . . . . . . . . . . . 38 ft (11.6 m)
Axle Differentials . . . . . . . . . . . . . . . .51.9 pt (24.6 l) Extended . . . . . . . . . . . . . . . . . .142 ft (43.3 m)
Transmission (includes Torque Converter) Power . . . . . . . . . . . . . . . . . . 5 Section, Full Power
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 qt (37.9 l) Elevation . . . . . . . . . . . . . . . . . . . -3 to +78 degrees
Extensions
Torque Converter/Transmission Fixed* . . . . . . . . . . . . . . . . . . . . .33 ft (10.1 m)
Stall Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.82:1 Folding* . . . . . . . . . . 33 or 56 ft (10.1 or 17 m)
Charge Pump Capacity . . . . . . . 28 gpm (106 l/min) *Extensions are offsettable at 0, 20, or 40
@ 2000 rpm degrees.
Gear Ratios Extension Insert . . . . . . . . . . . . . . . . . .16 ft (4.8 m)
Forward/Reverse
Lo 1st . . . . . . . . . . . . . . . . . . . . . . . . . . . .12.59 Swivel Assembly
Lo 2nd . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.06 Electrical . . . . . . . . . . . . . . . . . . . . . . . 20 Slip Rings
Lo 3rd. . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.22 Hydraulic. . . . . . . . . . . . . . . . . . . . . . . . . . .12 Ports
Hi 1st . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.33 Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 Ports

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RT890E SERVICE MANUAL INTRODUCTION

Hydraulic Pumps Hoists

Drum Dimensions 1
Pump #1 Diameter . . . . . . . . . . . . . . . . . .15 in (381 mm)
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Piston Length (Standard) . . . . . . . . 18.38 in (467 mm)
Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 Cable
Output - @ 2700 rpm w/no load Diameter . . . . . . . . . . . . . . . . . . 3/4 in (19 mm)
Section 1 . . . . . . . . . . . . . 98.7 gpm (373 l/min) Length-Main . . . . . . . . . . . . . . . .600 ft (182 m)
Length-Aux. . . . . . . . . . . . . . . . .607 ft (185 m)
Max. Permissible Line Pull (6x36)
Pump #2 . . . . . . . . . . . . . . . . . . . . . . . . . 20,250 lb (9,185 kg)
Max. Single Line Speed . . . .514 fpm (156.7 m/min)
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Gear Hoist Motor Displacement
Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Output - @ 2700 rpm w/no load Low . . . . . . . . 6.53 in3 (107 cm3) per revolution
Section 1 . . . . . . . . . . . . . 38.9 gpm (147 l/min) High . . . . . . . . 3.72 in3 (61 cm3) per revolution

8
2 27
23

FIGURE 1-1

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INTRODUCTION RT890E SERVICE MANUAL

Table 1-1: AXLE WEIGHT DISTRIBUTION TABLE

CG From Rear Weight Front Axle Rear Axle

Description
Axle cm (in) kg (lb) kg (lb) kg (lb)
Basic Unit
Maximum Axle Loads Allowed 29484 (65000) 29484 (65000)
Maximum Axle Loads while Towing 27216 (60000) 27216 (60000)
Maximum Tire Loads Allowed 28885 (63680) 28885 (63680)
Standard Carrier 4 x 4, plus all Fluids 184.38 (72.59) 21683 (47803) 9482 (20904) 12201 (26899)
Superstructure w/Cab; w/Main Hoist, plus 55.35 (21.79) 5929 (13071) 778 (1716) 5151 (11355)
600 ft Cable
Removable Counterweight (Includes -201.47 (-79.32) 9728 (21447) -4648 (-10248) 14377 (31695)
Cylinders, Aux. Hoist and Cable)
Boom Assembly; w/RCL, 2/5 Nose Sheaves, 544.55 (214.39) 12361 (27250) 15964 (35194) -3603 (-7944)
Lift Cyl, Pivot Pins
Lift Cylinder & Lower Shaft 435.64 (171.51) 1204 (2654) 1244 (2742) -40 (-88)
Basic Machine: 5-Sect Boom, Tier 4 Engine, 189.00 (74.41) 50905 (112225) 22819 (50307) 28086 (61918)
Tires, Main Hoist plus 600 ft Cable, all Fluids
Add To Basic Unit Weight

8
10.0 - 17.0 m (33 - 56 ft) Bi-fold Manual 643.69 (253.42) 1183 (2609) 1807 (3983) -623 (-1374)
Boom Extension
27
33 to 56 ft (10.0 to 17.0 m) Bi-Fold Boom 724.97 (285.42) 812 (1791) 1397 (3079) -584 (-1288)
Extension
2
10.0 - 17.0 m (33 - 56 ft) Bi-fold Hydraulic 653.85 (257.42) 1341 (2956) 2079 (4584) -738 (-1628)
Boom Extension
23

10.0 m (33 ft) Fixed Hydraulic Boom 722.43 (284.42) 1046 (2306) 1792 (3951) -746 (-1645)
Extension
Boom Extension Carrier Brackets (Bolt On) 511.53 (201.39) 120 (265) 146 (321) -25 (-56)
Components for Hydraulic Boom Extension 539.47 (212.39) 161 (355) 206 (454) -45 (-99)
(Installed on Boom)
Auxiliary Boom Nose - Installed 1156.77 (455.42) 60 (133) 166 (365) -105 (-232)
5.0 m (16 ft) Boom Extension Insert, manual 434 (956) -
(not included in weight)
10.9 t (12 ton) Overhaul Ball (Swivel) - tied to 688.49 (271.06) 258 (568) 420 (927) -163 (-359)
O/R Box
81.5 t (90 ton) Hookblock (5 sheave) - 422.00 (166.14) 590 (1300) 590 (1301) 0 (-1)
stowed in tray
Rubber mat in front Stowage Tray 421.64 (166.00) 27 (60) 27 (60) 0 (0)
Air Conditioning - Carrier 17.78 (7.00) 12 (26) 0 (1) 11 (25)
Air Conditioning - Superstructure 43.18 (17.00) 32 (71) 3 (7) 29 (64)
360 Degree Swing Lock 152.40 (60.00) 29 (64) 10 (23) 19 (41)
Driver 189.76 (74.71) 113 (250) 51 (113) 62 (137)
Sound Package for CE - Carrier 91.44 (36.00) 108 (238) 24 (52) 84 (186)
Sound Package for CE - S/S - Main Hoist -20.32 (-8.00) 230 (508) -11 (-24) 241 (532)

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RT890E SERVICE MANUAL INTRODUCTION

Description
CG From Rear
Axle cm (in)
Weight
kg (lb)
Front Axle
kg (lb)
Rear Axle
kg (lb) 1
Sound Package for CE - S/S - Main and Aux -71.12 (-28.00) 303 (667) -51 (-113) 354 (780)
Hoist
Substitutions, Deletions, and Removals from Basic Unit Weight
Sub: Removable Ctwt (includes Cylinders & -201.47 (-79.32) -115 (-254) 55 (121) -170 (-375)
IPO Ctwt)
Sub: Aux Hoist additional weight (not part of 35.56 (14.00) 16 (36) 0 (3) 15 (33)
Ctwt)
Sub: Tier 3 Engine -104.14 (-41.00) -107 (-235) 26 (58) -133 (-293)
REM: Main Hoist cable (185 m (607 ft) of 19 -113.79 (-44.80) -336 (-741) 91 (200) -427 (-941)
mm (3/4 in) 35x7
REM: Aux Hoist cable (185 m (607 ft) of 19 -200.66 (-79.00) -336 (-741) 160 (353) -496 (-1094)
mm(3/4 in) 35x7

8
2 27
23

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INTRODUCTION RT890E SERVICE MANUAL

7 5
8 4 2
3
18

16
17
6

7693-1

10
11 13 14
10 12 15

Item Description

8
1 Counterweight
27
2 Auxiliary Hoist
3 Main Hoist
4 Boom Pivot
2
5 Cab
6 Lift Cylinder
23

7 Boom
8 Boom Nose Sheaves
9 Auxiliary Boom Nose
10 Outrigger Jack Cylinder
11 Front Axle
12 Fuel Tank
13 Oil Cooler
14 Rear Axle
15 Outrigger Float
16 Work Lights
17 Muffler
18 Windshield Washer Fluid

FIGURE 1-2

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RT890E SERVICE MANUAL INTRODUCTION

6 5 4
2 1 1
7

15

3 14

7693

11 12
9 9
10 13

8
27
Item Description
1 Boom Nose Sheaves
2

2 Boom Extension Mast Sheave

23

3 Lift Cylinder
4 Swingaway Nose
5 Boom Pivot
6 Main Hoist
7 Auxiliary Hoist
8 Counterweight
9 Outrigger Jack Cylinder
10 Rear Axle
11 Hydraulic Tank
12 Hydraulic Filter
13 Front Axle
14 Swingaway Extension
15 Air Cleaner

FIGURE 1-3

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INTRODUCTION RT890E SERVICE MANUAL

GENERAL MAINTENANCE When raising a portion of a crane or a complete crane,

ensure the crane is blocked securely and the weight is
These general suggestions should be helpful in following the supported by blocks rather than by lifting equipment.
i ns t r u c t io n s i n th i s m a nu a l . I n a n al y z i ng a s y s te m
malfunction, use a systematic procedure to locate and When using hoisting equipment, follow the hoist
correct the problem. manufacturers recommendations and use lifting devices that
will allow you to achieve the proper balance of the
1. Determine the problem. assemblies being lifted and to ensure safe handling. Unless
2. List possible causes. otherwise specified, all removals requiring hoisting
equipment should be accomplished using an adjustable
3. Devise checks. lifting attachment. All supporting members (chains and
4. Conduct checks in a logical order to determine the cables) should be parallel to each other and as near
cause. perpendicular as possible to the top of the object being lifted.

5. Consider the remaining service life of components

against the cost of parts and labor necessary to replace CAUTION
them.
The capacity of an eyebolt diminishes as the angle
6. Make the necessary repair. between the supporting members and the object
becomes less than 90°. Eyebolts and brackets should
7. Recheck to ensure that nothing has been overlooked.
never be bent and should only have stress in tension.
8. Functionally test the replaced part in its system.
Some removals require the use of lifting fixtures to obtain
NOTE: Your safety and that of others is always the number
proper balance. The weights of some components are given
one consideration when working around machines.
in their respective sections of the manual.

8
Safety is a matter of thoroughly understanding the
job to be done and the application of good common If a part resists removal, check to be certain all nuts and bolts
27
sense. It is not just a matter of do’s and don’ts. Stay have been removed and that an adjacent part is not
clear of all moving parts. interfering.

Cleanliness Disassembly and Assembly

2

An important item in preserving the long life of the machine is When assembling or disassembling a component or system,
23

keeping dirt out of working parts. Enclosed compartments, complete each step in turn. Do not partially assemble one
seals, and filters have been provided to keep the supply of part and start assembling some other part. Make all
air, fuel, and lubricants clean. It is important that these adjustments as recommended. Always check the job after it
enclosures be maintained. is completed to see that nothing has been overlooked.
Recheck the various adjustments by operating the machine
Whenever hydraulic, fuel, lubricating oil lines, or air lines are
before returning it to the job.
disconnected, clean the adjacent area as well as the point of
disconnect. As soon as the disconnection is made, cap, plug, Pressing Parts
or tape each line or opening to prevent entry of foreign
material. The same recommendations for cleaning and When pressing one part into another, use an anti-seize
covering apply when access covers or inspection plates are compound or a molybdenum disulfide base compound to
removed. lubricate the mating surfaces.
Clean and inspect all parts. Be sure all passages and holes Assemble tapered parts dry. Before assembling parts with
are open. Cover all parts to keep them clean. Be sure parts tapered splines, be sure the splines are clean, dry, and free
are clean when they are installed. Leave new parts in their from burrs. Position the parts together by hand to mesh the
containers until ready for assembly. splines before applying pressure.
Clean the rust preventive compound from all machined Parts which are fitted together with tapered splines are
surfaces of new parts before installing them. always very tight. If they are not tight, inspect the tapered
splines and discard the part if the splines are worn.
Removal and Installation
Locks
When performing maintenance, do not attempt to manually
lift heavy parts when hoisting equipment should be used. Lockwashers, flat metal locks, or cotter pins are used to lock
Never locate or leave heavy parts in an unstable position. nuts and bolts.

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RT890E SERVICE MANUAL INTRODUCTION

Flat metal locks must be installed properly to be effective. • Evidence of kinking or crushing (1)
Bend one end of the lock around the edge of the part. Bend
• Chaffing or cuts; wire is exposed (2)
1
the other end against one flat surface of the nut or bolt head.
• Damaged or leaking fittings (3)
Always use new locking devices on components which have
moving parts. • Localized ballooning (4)
Wh en insta lling loc kwashe rs o n ho usings made of
aluminum, use a flat washer between the lockwasher and 1
the housing. 2

Wires and Cables

Batteries should always be disconnected prior to working on 3
the electrical system.
When removing or disconnecting a group of wires or cables,
tag each one to ensure proper identification during assembly.

Shims
4
When shims are removed, tie them together and identify
them as to location. Keep shims clean and flat until they are
reinstalled.
FIGURE 1-4
Hoses and Tubes Installation

8
1. When installing a new hose, loosely connect each end
27
! DANGER and make sure the hose takes up the designed position
High Pressure/Temperature Hazard! before tightening the connection. Clamps should be
Exercise extreme care around pressurized hydraulic tightened sufficiently to hold the hose without crushing
and to prevent chafing.
2
hoses or tubes. DO NOT work on a hydraulic system
while it is in operation or until all pressure is released. 2. If a hose is replaced on a part that moves during
23

Hydraulic oil is hot, it can cause severe burns. operation, be sure it moves freely by moving the part
Pressurized hydraulic oil can cause death or serious through its complete range of movement.
injury. 3. Be sure any hose which has been installed is not kinked
Stay clear of all hydraulic oil leaks. Relieve system or twisted.
pressure and use a piece of cardboard or paper to
Free moving, unsupported hoses must never rub on each
check for leaks. Do not use your hands.
other or related work surfaces. This causes chafing and
Fluid injected into skin must be surgically removed reduces hose life.
within a few hours by a doctor familiar with this type of
injury or gangrene will result. Bearings

Inspection Antifriction Bearings

Check hoses carefully. Do not use your bare hands to check When an anti friction bearing is removed, cover it to keep out
for leaks. dirt and abrasives. Wash bearings in non-flammable
cleaning solution and allow them to drain dry. The bearing
Tighten all connections to recommended torque. may be dried with compressed air BUT do not spin the
If the hose end connections are damaged, always replace bearing. Discard the bearings if the races and balls or rollers
the hose or tube. Damaged, dented, crushed, or leaking are pitted, scored, or burned. If the bearing is serviceable,
hose fittings restrict oil flow and the operation of the parts coat it with oil and wrap it in clean waxed paper. Do not
being served. Fittings showing signs of movement from their unwrap new bearings until time of installation. The life of an
original position have failed and must be replaced. anti friction bearing will be shortened if not properly
lubricated. Dirt in an anti friction bearing can cause the
Be sure hoses are in good condition. If in doubt, replace bearing to lock resulting in the shaft turning in the inner race
them. or the outer race turning within the cage.
Replace hoses if any of the following is evident Figure 1-4:

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INTRODUCTION RT890E SERVICE MANUAL

Double Row, Tapered Roller When removed, always install new cylinder head and
manifold gaskets using recommended gasket compound on
Double row, tapered roller bearings are precision fit during
head gaskets to allow uniform sealing.
manufacture and components are not interchangeable. The
cups, cones, and spacers are usually etched with the same Batteries
serial number and letter designator. If no letter designators
are found, wire the components together to assure correct Clean batteries by scrubbing them with a solution of baking
installation. Reusable bearing components should be soda and water. Rinse with clear water. After cleaning, dry
installed in their original positions. thoroughly and coat terminals and connections with an anti
corrosion compound or grease.
Heating Bearings
If the machine is to be stored or not used for an extended
Bearings which require expansion for installation should be period of time, the batteries should be removed. Store the
heated in oil not to exceed 121 °C (250 °F). When more than batteries in a cool (not subfreezing), dry place, preferably on
one part is heated to aid in assembly, they must be allowed wooden shelves. Never store on concrete. A small charge
to cool and then pressed together again. Parts often should be introduced periodically to keep the specific gravity
separate as they cool and contract. rating at recommended level.
Installation Hydraulic Systems
Lubricate new or used bearings before installation. Bearings
that are to be preloaded must have a film of oil over the entire
assembly to obtain accurate pre-loading. When installing a ! DANGER
bearing, spacer, or washer against a shoulder on a shaft, be
sure the chamfered side is toward the shoulder. High Pressure/Temperature Hazard!
Exercise extreme care around pressurized hydraulic

8
When pressing bearings into a retainer or bore, uniformly systems. DO NOT work on a hydraulic system while it is in
apply pressure to the outer race. If the bearing is pressed on
27
operation or until all pressure is released.
the shaft, uniformly apply pressure on the inner race.
Hydraulic oil is hot, it can cause severe burns.
Preload Pressurized hydraulic oil can cause death or serious
injury.
2
Preload is an initial load placed on the bearing at the time of
assembly. Whether a tapered roller bearing should have Stay clear of all hydraulic oil leaks. Relieve system
23

preload could depend on any of several conditions: rigidity of pressure and use a piece of cardboard or paper to
the housings and shaft, bearing spread, speed of operation, check for leaks. Do not use your hands.
etc. Fluid injected into skin must be surgically removed
To determine whether a bearing requires preload or end
within a few hours by a doctor familiar with this type of
c l ea r an c e , c o n s u lt t h e d i s a ss e m bl y a n d a s s e m b l y injury or gangrene will result.
instructions pertaining to that bearing.
Cleanliness
Care should be exercised in applying preload. Misapplication
of preload to bearings requiring end clearance can result in Contaminants in a hydraulic system affect operation and will
bearing failure. result in serious damage to the system components. Dirty
hydraulic systems are a major cause of component failures.
Sleeve Bearings
Keep the System Clean
Do not install sleeve bearings with a hammer. Use a press
and be sure to apply the pressure directly in line with the When removing components of a hydraulic system, cover all
bore. If it is necessary to drive on a bearing, use a bearing openings on both the component and the crane.
driver or a bar with a smooth flat end. If a sleeve bearing has If evidence of foreign particles is found in the hydraulic
an oil hole, align it with the oil hole in the mating part. system, flush the system.

Gaskets Disassemble and assemble hydraulic components on a

clean surface.
Be sure the holes in the gaskets correspond with the
lubricant passages in the mating parts. If it is necessary to Clean all metal parts in a nonflammable cleaning fluid. Then
make gaskets, select material of the proper type and lubricate all components to aid in assembly.
thickness. Be sure to cut holes in the right places. Blank
gaskets can cause serious damage.

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RT890E SERVICE MANUAL INTRODUCTION

Sealing Elements • Other signs of significant deterioration

Inspect all sealing elements (O-ring, gaskets, etc.) when If any of the above conditions exist, evaluate hose
1
disassembling and assembling the hydraulic system assemblies for correction or replacement. For replacement
components. Installation of new elements is always of hose assemblies, refer to your Manitowoc Crane Care
recommended. Parts Manual.

Hydraulic Lines 2. At the same service interval, visually inspect all other
hydraulic components and valves for the following:
When installing metal tubes, tighten all bolts finger-tight.
Then, in order, tighten the bolts at the rigid end, the • Leaking ports.
adjustable end, and the mounting brackets. After tubes are • Leaking valve sections or manifolds and valves
mounted, install the hoses. Connect both ends of the hose installed into cylinders or onto motors.
with all bolts finger-tight. Position the hose so it does not rub
• Damaged or missing hose clamps, guards, or
the machine or another hose and has a minimum of bending
shields.
and twisting. Tighten bolts in both couplings.
• Excessive dirt and debris around the hose
Due to manufacturing methods there is a natural curvature to
assemblies.
a hydraulic hose. The hose should be installed so any bend
is with this curvature. If any of these conditions exist, address them appropriately.

Visual Inspection of Hoses and Fittings 3. All hydraulic hose assemblies are recommended to be
replaced after 8000 hours of service life.
1. Visually inspect hoses and fittings once a month or
every 250 hours for the following: 4. Hydraulic hose assemblies operating in a temperature
climate zone “C” Table 1-2 are recommended to be

8
• Leaks at hose fitting or in hose replaced after 8000 hours of service life.
• Damaged, cut, or abraded cover 5. Hydraulic hose assemblies operating in climate zones
27
• Exposed reinforcement “A” and “B” with high ambient temperatures, could see
hose service life reduced by 40 to 50%, therefore, it is
• Kinked, crushed, flattened, or twisted hose
recommended to replace these hoses after 4000 to
2
• Hard, stiff, heat cracked, or charred hose 5000 hours of service life.
• Blistered, soft, degraded, or loose cover 6. Hydraulic hose assemblies operating in climate zones
23

• Cracked, damaged, or badly corroded fittings “D” and “E” should expect a degradation of mechanical
properties such as elasticity, therefore, it is
• Fitting slippage on hose recommended these hoses be inspected and addressed
accordingly.

Table 1-2: Climate Zones

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

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INTRODUCTION RT890E SERVICE MANUAL

Hydraulic Fittings 37° Flared Steel Fitting: Tube or Hose to Fitting

Flats from Finger Tight (F.F.F.T.) Method Follow the F.F.F.T. method, described above.

Manitowoc recommends that the F.F.F.T. tightening method Table 1-3: Tube and Swivel Nut/Hose Fittings
described here be used when assembling all hydraulic
fittings. This method will minimize the risk of fitting damage
or failure due to under or overtightening.
This method will also reduce the chance of a leaky
connection which is normally caused by combinations of
fittings with different types of plating. This method is
particularly useful when the type of plating on the fitting is
unknown, and during maintenance or repair when a joint
may be oily.
Follow these steps when tightening all fitting connections:
1. Make sure both threads and sealing surfaces are free of
burrs, nicks, scratches or any foreign particles.
2. Align tube or hose to the mating fitting and check to see
that the flare seats properly on the nose of the fitting.
T-2-5
3. Finger tighten the nut onto the fitting. If necessary, a
wrench should be used to seat the nut snugly against Adjustable Straight Thread O-ring Fittings

8
the fitting. This is considered the “Finger Tight”
condition. Refer to Figure 1-6 and Table 1-4 for the following
27
procedure.
4. Using a permanent-type ink marker, make a mark on
one of the flats of the nut and continue it onto the hex of Table 1-4: Adjustable Straight Thread O-ring Fittings
the static fitting or port
2
23

a0027 FIGURE 1-5

5. Tighten the joint by the number of flats as specified in
Table 1-3 and 1-4 for size and type of fitting.
6. Optionally for future tightening of the same connection:
extend the line from the nut at its new location onto the T-2-6

hex of the static fitting or port (Figure 1-5).

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RT890E SERVICE MANUAL INTRODUCTION

Table 1-5: Straight Thread Fittings

BACK OFF
NUT
1

a0030 Adjustable Fitting to Port FIGURE 1-6

1. Inspect both mating parts for burrs, nicks, scratches, or
foreign particles.
2. Lubricate O-ring with a light coat of clean oil.
T-2-7
3. Back off locknut as far as possible (A).
4. Screw the fitting into port by hand until the backup
washer contacts the face of the port and is pushed all the Electrical System
way towards the locknut (C).

8
Harnesses, Wires, and Connectors
5. To orientate the fitting, unscrew the fitting the required
Visually inspect all electrical harnesses, cables, and
27
amount, but not more than one full turn.
connectors every month or 250 hours for the following:
6. Hold the fitting in the desired position and tighten the nut
• Damaged, cut, blistered, or cracked insulation.
(D) following the F.F.F.T. method starting with step 4.
2
• Exposed bare wires.
Nonadjustable Straight Thread O-ring Fitting: Fitting
• Kinked or crushed wires and cables.
23

to Port
Refer to Table 1-5 for the following procedure. • Cracked or corroded connectors, battery terminals, and
ground connections.
1. Make sure both threads and sealing surfaces are free of
burrs, nicks, scratches or any foreign particles. If any the above conditions exist, evaluate, clean and replace
as necessary.
2. Lubricate O-ring with clean oil (Figure 1-7).
The climate in which the crane operates affects the service
life of the electrical components. The climate zones are
defined in Table 1-2. Recommended replacement of harness
and cables is as follows:
• Climate zone C after 10,000 hours of service.
• Climate zones A and C with high ambient temperatures
and duty cycles after 8000 hours of service.
• Climate zones D and E after 5,000 hours of service.
• Salt water conditions after 8,000 hours of service.

Fatigue of Welded Structures

Non-Adjustable Fitting to Port
a0032 FIGURE 1-7 Experience has shown that highly stressed welded
3. Turn fitting until finger tight. structures when repeatedly subjected to varying stresses
caused by twisting, shock, bending, and intentional and/or
4. Using the assembly torque method, tighten to given unintentional overloads, often become subject to weld
torque for size from Table 1-5. cracking which may be attributed to fatigue of the welded

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INTRODUCTION RT890E SERVICE MANUAL

joint. This condition is not uncommon in construction The following procedure covers the proper application and
equipment. curing method for medium strength Loctite adhesive/sealant
(Loctite® #243) and primer (Locquic® Primer T7471).
Equipment should be periodically inspected for evidence of
weld fatigue. The frequency of these inspections should be Primer Application
commensurate with the age of the equipment, the severity of
NOTE: It is not necessary to bathe the threads in primer.
the application, and the experience of the operators and
maintenance personnel.The following are known high stress 1. Ensure the threaded surface, both male and female, is
areas applicable to Manitowoc machines, and a visual clean and free of dirt and oil. Apply a light spray coating
inspection of these areas should be made part of an owner’s of primer to both male and female parts to be joined to
planned preventive maintenance program: clean and accelerate the curing process.
1. Power Telescope Boom - wear pad retaining structures, 2. Allow the part to dry prior to adhesive/sealant
hydraulic cylinder attaching points, boom pivot shaft application.
retaining structures.
Adhesive/Sealant Application
2. Outrigger pads, beams, boxes and attachment
structures.
BEAD APPLICATION
3. Main frames - generally in the area of doubler plates and
crossmembers; at the junction of front and rear frame
members on truck cranes.
4. Turntable bearing connection (where bearing is welded
to the crane superstructure or chassis). 4203

8
5. Counterweight support structures. FIGURE 1-8
6. Chassis axle and suspension mounting structures.
27
1. Apply a bead perpendicular to the thread, several
7. Hydraulic cylinder end connections. threads wide, in the approximate area of threaded
The above is provided only as a guide, and your inspection engagement (Figure 1-8).
2
plan should not be limited to the areas listed. A thorough 2. In a blind hole application, a bead of several drops of
visual inspection of all weldments is good practice. adhesive should be applied into the bottom of the hole to
23

Anyone requiring more detailed inspection instructions and/ be hydraulically forced up during engagement.
or repair procedures may request them by contacting the 3. After application and engagement of mated threads,
local Manitowoc Cranes distributor. fixturing will occur within five (5) minutes if primed prior
to engagement. Fixturing may take up to 30 minutes on
Loctite® unprimed parts.
4. Time required to achieve full strength is 24 hours.
Maximum ultimate strength is achieved using no primer
with this specific threadlocking adhesive.
DANGER
Loctite type adhesives contain chemicals that may be Fasteners and Torque Values
harmful if misused. Read and follow the instructions on
the container. Use bolts of the correct length. A bolt which is too long may
bottom before the head is tight against the part it is to hold. If
a bolt is too short, there may not be enough threads engaged
Always follow the directions on the Loctite container as not
to hold the part securely. Threads can be damaged. Inspect
all Loctite types are suitable for all applications.Various types
them and replace fasteners, as necessary.
of Loctite are specified throughout the Service Manual.The
following types of Loctite brand adhesives are available from Torque values should correspond to the type bolts, studs,
the Parts Department of the local Manitowoc Cranes and nuts being used.
distributor.
The torque tables are provided by Manitowoc for reference
Application of Medium Strength Loctite when performing maintenance.

NOTE: The fastener may be re-used; the adhesive may be Use of proper torque values is extremely important. Improper
re-applied over cured adhesive residue. torquing can seriously affect performance and reliability.

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RT890E SERVICE MANUAL INTRODUCTION

Identification of fastener grade is always necessary. When Torque wrenches are precision instruments and must be
marked as a high strength bolt (grade 5, 8, etc.), the handled with care. To ensure accuracy, calibrations must be 1
mechanic must be aware that he/she is working with a highly made on a scheduled basis. Whenever there is a possibility
stressed component and the fastener should be torqued that a torque wrench may have been either overstressed or
accordingly. damaged, it should immediately be removed from service
until recalibrated. When using a torque wrench, any erratic or
NOTE: Some special applications require variation from
jerking motion can result in the application of excessive or
standard torque values. Reference should always
improper torque. ALWAYS use a slow, even movement and
be made to component overhaul procedures for
STOP when the predetermined value has been reached.
recommendations.
When using step wrenches, calculated wrench settings are
Special attention should be given to the existence of
valid only when the following conditions are met:
lubricant, plating, or other factors that might require variation
from standard torque values. • Torque wrenches must be those specified and forces
must be applied at the handle grip. The use of handle
The use of lubricants on zinc-flake coated parts shall be
extensions will change applied torque to the bolt.
prohibited since this will change the required torque value.
• All handles must be parallel to the step wrench during
When maximum recommended torque values have been
final tightening. Multiplier reaction bars may be
exceeded, the fastener should be replaced.
misaligned no more than 30 degrees without causing
Previously installed bolts and nuts of Grade 8 or Class 10.9 serious error in torque.
and higher may not be reused.
• Multiplier bar handles must be propped or supported
When referring to the applicable torque charts, use values as within the outer 1/4 of the handle length, or serious
close as possible to the torque values shown to allow for under or over tightening will occur.

8
wrench calibration tolerance.
To convert pounds-foot (lb-ft) of torque to newton meters
Torque Wrenches (Nm), multiply the pounds-foot quantity by 1.3558.
27
Flexible beam type wrenches, even though they might have To convert pounds-inch (lb-in) of torque to newton meters
a pre-set feature, must be pulled at right angle and the force (Nm), multiply the pounds-inch quantity by 0.11298.
must be applied at the center of the handle. Force value
2
Torque Values
readings must be made while the tool is in motion. Rigid
handle type, with torque limiting devices that can be pre-set The following tables list the torque values for both ASME
23

to required values, eliminate dial readings and provide more standard and metric fasteners. The tables list the values for
reliable, less variable readings. grade 5 and grade 8 zinc-flake coated, untreated (black)
finish and stainless steel fasteners.
NOTE: If multipliers and/or special tools are used to reach
hard to get at areas, ensure torque readings are
accurate.

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

and Grade 2 HHCS HHCS HHCS
HHCS

Socket Head Socket Head Serrated

Capscrew Shoulder Flange Head
Screw

FIGURE 1-9

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INTRODUCTION RT890E SERVICE MANUAL

Table 1-6: UNC (Coarse) Thread: Torque Values for Zinc-Flake Coated and Untreated Fasteners

Bolt Diameter - Inches

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

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

Table 1-7: UNF (Fine) Thread: Torque Values for Zinc-Flake Coated and Untreated Fasteners

Bolt Diameter - Inches

Torque Values (Pounds-Foot, Maximum/Minimum)
SAE Grade 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1 1-1/8 1-1/4 1-1/2
Zinc-Flake 5 8 15 28 44 66 95 132 229 364 543 785 944 1654

8
8 11 22 39 61 94 134 186 323 514 766 1109 1530 2682
Untreated 5 10 21 36 57 88 126 182 312 458 658 882 1251 2288
27
9 19 34 53 81 116 167 287 421 606 814 1155 2105
8 14.5 26 53 85 125 177 250 425 672 1009 1500 2092 3640
13.5 24 49 79 115 163 230 393 620 931 1380 1925 3360
2

NOTE: Studs shall be torqued using capscrew values when grade is known.
23

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RT890E SERVICE MANUAL INTRODUCTION

Table 1-8: Metric Fasteners, Coarse Thread, Zinc-Flake Coating

Bolt Diameter - Metric

1
Torque Values (Nm)
Class M4 M5 M6 M8 M10 M12 M14 M16 M18 M20 M22 M24 M27 M30 M33 M36
8.8 2.6 5.2 9.0 21.6 42.4 73.1 116 178 250 349 467 600 877 1195 1608 2072
10.9 3.7 7.5 12.5 31.5 62.0 110 170 265 365 520 700 900 1325 1800 2450 3150
12.9 4.3 9.0 15.0 36.0 75.0 128 205 315 435 615 830 1060 1550 2125 2850 3700

Table 1-9: Metric Fasteners, Coarse Thread, Untreated

Bolt Diameter - Metric

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

Table 1-10: Metric Fasteners, Fine Thread, Zinc-Flake Coating

8
27
Bolt Diameter - Metric
Torque Values (Nm)
2

Class M8x1 M10x1 M10x1.25 M12x1.5 M14x1.5 M16x1.5 M18x1.5 M20x1.5 M22x1.5 M24x2 M27x2 M30x2 M33x2 M36x3
23

8.8 23 46 44 75 123 185 270 374 496 635 922 1279 1707 2299
10.9 34 71 66 113 188 285 415 575 770 980 1425 2025 2500 3590
12.9 41 84 79 135 220 335 485 675 900 1145 1675 2375 2900 4200

Table 1-11: Metric Fasteners, Fine Thread, Untreated

Bolt Diameter - Metric

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

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INTRODUCTION RT890E SERVICE MANUAL

Table 1-12: UNC (Coarse) Thread: Torque Values for Table 1-13: Metric Coarse Thread: Torque Values for
Stainless Steel Fasteners with Oil Lubrication Stainless Steel Fasteners with Oil Lubrication

Torque Value Torque

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

#8 (0.164) 18 — M2.5 0.4

#10 (0.190) 21 — M3 0.9

1/4 68 — M4 1.5

5/16 120 10 M5 3.1

3/8 210 17.5 M6 5.3

7/16 340 28 M8 13.0

1/2 — 39 M10 27.0

5/8 — 74 M12 45.0

3/4 — 114 M14 71.1

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

8
pressure. Impact wrenches are not recommended. NOTE: Stainless steel fasteners tend to gall while being
tightened. To reduce this risk, lubricate the threads
27
with oil or molybdenum disulfide and torque at low
speeds without interruptions. Do not use excessive
pressure. Impact wrenches are not recommended.
2

Weld Studs
23

Unless otherwise specified the following grade 2 torque

values (+/- 10%) apply.

Table 1-14: Weld Stud Torque Values

T-2-4

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RT890E SERVICE MANUAL INTRODUCTION

WIRE ROPE shall be of the type which does not hinder visual inspection.
Those sections of rope which are located over sheaves or 1
General otherwise hidden during inspection and maintenance
procedures require special attention when lubricating rope.
The following information is a compendium of information The object of rope lubrication is to reduce internal friction and
from various wire rope manufacturers and includes to prevent corrosion.
inspection, replacement, and maintenance guidelines for
wire rope as established by ANSI/ASME B30.5, federal During fabrication, ropes receive lubrication; the kind and
regulations, and Manitowoc. The inspection interval shall be amount depends on the rope’s size, type, and anticipated
determined by a qualified person and shall be based on such use. This in-process treatment will provide the finished rope
factors as expected rope life as determined by experience on with ample protection for a reasonable time if it is stored
the particular installation or similar installations, severity of under proper conditions. But, when the rope is put into
environment, percentage of capacity lifts, frequency rates of service, the initial lubrication may be less than needed for the
operation, and exposure to shock loads. Periodic full useful life of the rope. Because of this possibility, periodic
Inspections need not be at equal calendar intervals and applications of a suitable rope lubricant are necessary.
should be performed at shorter time intervals as the wire The following are important characteristics of a good wire
rope approaches the end of its useful life. A periodic rope lubricant:
inspection shall be performed at least once a year. The
following provides inspection and maintenance procedures • It should be free from acids and alkalis.
for wire ropes used on Manitowoc products (e.g. wire rope • It should have sufficient adhesive strength to remain on
used as load lines [hoisting cables], boom extension and the ropes.
retraction cables, pendant cables, tow winch cables, and
hook block tie down cables). • It should be of a viscosity capable of penetrating the
interstices between wires and strands.

8
Environmental Conditions • It should not be soluble in the medium surrounding it
27
The life expectancy of wire rope may vary due to the degree under the actual operating conditions (i.e. water).
of environmental hostility and other conditions to which these • It should have a high film strength.
mechanical devices are subjected. Variation in temperature,
continuous excessive moisture levels, exposure to corrosive • It should resist oxidation.
2

chemicals or vapors or subjecting the wire rope to abrasive

Before applying lubrication, accumulations of dirt or other
material may shorten normal wire rope life. Frequent/
23

abrasive material should be removed from the rope.

periodic inspections and maintenance of your wire rope is
Cleaning can be accomplished by using a stiff wire brush and
recommended for preventing premature wear and to insure
solvent, compressed air, or live steam. Immediately after the
long-term satisfactory performance.
wire rope is cleaned, it should be lubricated. Many
techniques may be used; these include bath, dripping,
Dynamic Shock Loads pouring, swabbing, painting or pressure spray methods.
Subjecting wire rope to abnormal loads beyond the Whenever possible, the lubricant should be applied at the
endurance limit will shorten the wire rope’s life expectancy. top of a bend in the rope, because at that point the strands
Examples of this type of loading are listed below. are spread by bending and are more easily penetrated.
There should be no load on the rope while it is being
1. High velocity movement e.g.; hoisting or swinging of a lubricated. It should be noted, the service life of wire rope will
load followed by abrupt stops. be directly proportional to the effectiveness of the method
2. Suspending loads while traveling over irregular surfaces used and amount of lubricant reaching the working parts of
such as railroad tracks, potholes, and rough terrain. the rope.
3. Moving a load that is beyond the rated capacity of the Precautions and Recommendations During
lifting mechanism, i.e.; overloading.
Inspection or Replacement
Lubrication 1. Always lock out equipment power when removing or
installing wire rope assemblies.
A wire rope cannot be lubricated sufficiently during
manufacture to last it’s entire life. Therefore, new lubricant 2. Always use safety glasses for eye protection.
must be added throughout the life of a rope to replace factory
lubricant which is used or lost. It is important that lubricant 3. Wear protective clothing, gloves, and safety shoes as
applied as part of a maintenance program shall be appropriate.
compatible with the original lubricant, and to this end, the 4. Use supports and clamps to prevent uncontrolled
rope manufacturer should be consulted. Lubricant applied movement of wire rope, parts, and equipment.

GROVE Published 9-18-2014, Control # 308-06 1-19

INTRODUCTION RT890E SERVICE MANUAL

5. When replacing fixed length cable assemblies (e.g.

pendants) having permanently attached end fittings use
2
only pre-assembled lengths of wire rope as supplied
from Manitowoc. Do not build lengths from individual 4
components.
6. Replace an entire wire rope assembly. Do not attempt to
rework damaged wire rope or wire rope ends. A925
5

7. Never electroplate wire rope assemblies.

3
8. Do not weld any wire rope assembly or component
unless welding is recommended by the wire rope FIGURE 1-11
manufacturer. Welding spatter shall never be allowed to
come in contact with the wire rope or wire rope ends. In
addition, be sure that the wire rope is not an electrical
Wire Rope Inspection (Running Ropes and
path during other welding operations. Pendant Cables)
9. Wire ropes are manufactured from special steels. If Wire rope should be inspected frequently/daily and
heating a wire rope assembly is absolutely necessary for periodically/yearly in accordance with the following
removal, the entire wire rope assembly shall be information excerpted from a National Consensus Standard
discarded. as referenced by Federal Government Agencies.
Recommended inspection intervals may vary from machine
10. On systems equipped with two or more wire rope t o m a ch i ne an d m a y v ar y b as ed on e n vi r o nm en ta l
assemblies operating as a matched set, they shall be conditions, frequency of lifts, and exposure to shock loads.
replaced as an entire set. The inspection time intervals may also be predetermined by

8
11. Do not paint or coat wire ropes with any substance state and local regulatory agencies.
27
except approved lubricants. NOTE: Wire rope may be purchased through Manitowoc
12. Measure the rope’s diameter across crowns (1) of the Crane Care.
strands when determining if rope has become damaged Any deterioration observed in the wire rope should be noted
2
Figure 1-10. in the equipment inspection log and an assessment
concerning wire rope replacement should be made by a
23

qualified person.

Keeping Records
A signed and dated report of the wire rope’s condition at
each periodic inspection must be kept on file at all times. The
report must cover all inspection points listed in this section.
The information in the records can then be used to establish
data which can be used to determine when a wire rope
should be replaced.
1
It is recommended that the wire rope inspection program
include reports on the examination of wire rope removed
from service. This information can be used to establish a
FIGURE 1-10 relationship between visual inspection and the rope’s actual
internal condition at the time of removal from service.
13. When checking for broken wires (5) Figure 1-11 relax
the rope, move it off “pick-up points”, and flex it as much Frequent Inspection
as possible. Use a sharp awl to pick and probe between A frequent daily visual inspection is recommended for all
wires and strands, lifting any wire which appears loose running ropes in service. This inspection should be made on
or moves excessively. Defect in the rope is spoke of in all wire rope which can be expected to be in use during the
relations to “Lay Length” (2) which is the distance day’s operation. This inspection should be used to monitor
measured along rope in which one strand (3) makes one
progressive degradation and to discover severe damages
complete revolution around core (4).
necessitating wire rope replacement such as:
• Distortion, Kinking, Crushing, Un-stranding, Bird caging,
Reduction of diameter, etc.

1-20 Published 9-18-2014, Control # 308-06

RT890E SERVICE MANUAL INTRODUCTION

• General corrosion. following guidelines. This inspection shall cover the entire
• Broken or cut strands.
length of the extension and retraction cables. This inspection 1
should be used to monitor progressive degradation and to
• Number, distribution and type of broken wires. d i s c o v e r s e v e r e d a m a g e s n e c e s s i ta t i n g w i r e r o p e
replacement or equipment repair. Inspection criteria are as
• Evidence of core failure.
follows:
• End fitting wear/abrasion.
• Inspect for reduction of rope diameter below nominal
Pay particular attention to areas of the rope where wear and diameter.
other damage is likely to occur:
• Inspect for severely corroded or broken wires at end
• Pick-up Points: Sections of wire rope that are repeatedly connections.
stressed during each lift, such as those sections in
• Inspect for severely corroded, cracked, bent, worn, or
contact with sheaves.
improperly applied end connections.
• End Attachments: The point where a fitting is attached to
• Inspect wire rope in areas subjected to rapid
the wire rope or the point where the wire rope is attached
deterioration such as:
to the drum.
• Sections in contact with saddles, equalizer sheaves,
• Abuse Points: The point where the wire rope is or other sheaves where wire rope travel is limited.
subjected to abnormal scuffing and scraping.
• Sections of wire rope at or near terminal ends where
Periodic Inspection corroded or broken wires may protrude.
Wire rope should be inspected periodically/annually or at a • Sections of wire rope in contact with stationary
shorter time interval if necessitated by environmental or surfaces where abrasion or chafing may take place

8
other adverse conditions, and shall cover the entire length of as a result of equipment vibration.
the wire rope. Only the outer surface of the wire rope need
27 • Inspect for damaged or wobbly boom extension and
be inspected, and no attempt should be made to open the
retraction sheaves that may cause rapid deterioration of
rope. Periodic inspection should include all items listed
the wire rope.
under frequent inspection plus the following:
• Inspect for unusual cable sag/stretch and be sure cables
2
• Inspect for reduction of rope diameter below nominal
used in sets all have an equal tension applied. Repeated
diameter.
23

need for adjustment of an individual cable is evidence of

• Inspect for severely corroded or broken wires at end cable stretch and indicates the need for additional and
connections. more thorough inspection in order to determine and
correct the cause.
• Inspect for severely corroded, cracked, bent, worn, or
improperly applied end connections. Wire Rope Inspection/Replacement (All Wire
• Inspect wire rope in areas subjected to rapid Rope)
deterioration such as:
No precise rules can be given for determination of the exact
• Sections in contact with saddles, equalizer sheaves, time for replacement of wire rope since many variable factors
or other sheaves where wire rope travel is limited. are involved. Determination regarding continued use or
• Sections of wire rope at or near terminal ends where replacement of wire rope depends largely upon the good
corroded or broken wires may protrude. judgement of an appointed and qualified person who
evaluates the remaining strength in a used rope after
• Inspect boom nose sheaves, hook block sheaves, boom allowance for any deterioration disclosed by inspection.
extension/jib sheaves, auxiliary boom nose sheaves,
and hoist drums for wear. Damaged sheaves or hoist Wire rope replacement should be determined by the
drums can accelerate wear and cause rapid following information excerpted from a National Consensus
deterioration of the wire rope. Standard as referenced by Federal Government Agencies
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.
Retraction Cables) Wire rope shall be taken out of service when any of the
following conditions exist:
Periodic Inspection • Kinking, crushing, birdcaging, or any other damage
It is recommended that a periodic inspection of all boom resulting in distortion of the rope structure.
extension and retraction cables be performed using the • Evidence of any heat damage from any cause.

GROVE Published 9-18-2014, Control # 308-06 1-21

INTRODUCTION RT890E SERVICE MANUAL

• Reductions from nominal diameter of more than: 5% Method 2

• In running ropes, six randomly distributed broken wires
in one lay or three broken wires in one strand in one lay.
• In standing ropes, more than two broken wires in one lay
in sections beyond end connections or more than one
broken wire at an end connection.
• In rotation resistant rope, two randomly distributed
broken wires in six rope diameters or four randomly
distributed broken wires in 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.
• Manitowoc recommends for cable extended booms, that
boom extension cables be replaced every seven (7)
years.

Seizing Wire Rope

It is important to seize the ends of rotation resistant wire
ropes to prevent the displacement and unraveling of the FIGURE 1-13

8
individual wires and strands at the ends. All preformed and
non-preformed styles of wire rope should be seized prior to
27
Wind a length of soft annealed wire Figure 1-13 around the
cutting. Seizings must be placed on both sides of the point wire rope at least seven times. The two ends should be
where the wire rope is to be cut. twisted together in the center of the seizing. Tighten the
The two preferred methods for seizing wire ropes are: seizing by alternately prying and twisting. Cut off both ends
2
of the wire and pound the twist flat against the rope.
Method 1
23

NOTE: Non-preformed wire rope (1) Figure 1-14 should

Using a length of soft annealed wire Figure 1-12, place one have three seizings (3) located on each side of the
end in the groove between two strands of the wire rope. Turn cut (4) as compared to performed wire rope (2).
the long end of the annealed wire at right angles to the wire
and wrap it tightly over the portion in the groove.
1 4 3
The two ends of the annealed wire should be twisted
together tightly. Cut off the excess wire and pound the twist
flat against the wire rope.

7204
FIGURE 1-12
FIGURE 1-14

1-22 Published 9-18-2014, Control # 308-06

RT890E SERVICE MANUAL INTRODUCTION

Installing 35x7 Class Wire Rope train the rope and help assure smooth operation during
its useful life. 1
Ideally, you should run these loads with reeving that lets
CAUTION you place the loads on the block with all rope off the
Any cutting of this specific wire rope is not recommended. drum except the last three wraps. If this is not possible,
If 35x7 class wire rope must be cut for any reason, it is alternate methods must be used to assure proper
necessary to follow the attached instructions. Also, unlike tensioning of the rope on the drum.
other types of wire rope, the ends on this wire rope must
be welded to retain the rotation resistant characteristics. Procedures for Cutting and Preparing 35x7
Class Wire Rope
1. Unload properly and relieve any twists. Pull the rope off
the shipping reel or unroll it from a shipping coil. (If done 35x7 class rope is a special wire rope that must be handled
improperly, you may kink the rope, which will result in differently than any other rope we manufacture. One
permanent damage to the rope.) Then lay the rope on characteristic that makes this rope special is that the outer
the ground in direct line with the boom. This helps strands are not preformed. It is because of this that the
release any twist in the rope. following procedures for cutting and preparing 35x7 class
rope must be followed:
2. Attach rope’s end to drum. Pull the rope over the point
sheave and attach the end to the drum. Be sure not to 1. The welded ends prepared by the manufacturer are not
remove the welded end. to be removed.

3. Wind rope onto drum slowly and carefully. At this point, it 2. Before cutting the rope, make three separate bands with
isn’t necessary to provide additional load other than the seizing strand on each side of where the cut is to be
weight of the rope being pulled across the ground. made (total of six bands for each cut). Each band is to

8
have a minimum length of one and one half times the
4. Spool first layer tightly. It is essential on smooth-faced rope diameter. The two bands closest to the cut should
27
drums that the first layer is spooled with wraps tight and be located at a distance equal to one rope diameter
close together since the first layer forms the foundation away from the cut. The four remaining bands should be
for succeeding layers. If need be, use a rubber, lead or evenly spaced at a distance equal to three rope
brass mallet (but never a steel hammer) to tap the rope diameters.
2

in place.
a. If a welder is available, the cut should be made with
23

5. Spool multiple layers with sufficient tension. It’s very an abrasive saw. Immediately after the cut, both
important to apply a tensioning load to the ropes during ends of the rope are to be cap welded so that all
the rope breaking-in process. (If not, the lower layers inner and outer strands are welded together,
may be loose enough that the upper layers become preventing any movement between them.
wedged into the lower layers under load, which can
seriously damage the rope.) The tensioning load should NOTE: The outer strands must not be able to move with
range from 1 to 2% of the rope’s minimum breaking respect to the inner strands. The weld must not
force. exceed the diameter of the rope.

6. For ropes in multi-part systems: Reeve the traveling b. If a welder is not available, the cut is to be made with
block and boom tip sheaves so the rope spacing is an acetylene torch. The cut is to be made in such a
maximized and the traveling (hook) block hangs straight way that both ends of the rope are completely fused
and level to help assure block stability. so that all inner and outer strands are bonded
together, preventing any movement between
7. Breaking in your new 35x7 class rope—After installation, strands.
you should properly break in your rope, which allows the
rope’s component parts to adjust themselves to your NOTE: The outer strands must not be allowed to move
operating conditions. with respect to the inner strands. The fused end
must not exceed the diameter of the rope.
With the boom fully raised and fully extended, attach a
light load at the hook and raise it a few inches off the 3. Once the cuts have been completed, the seizing bands
ground. Allow to stand for several minutes. Then cycle are to be left in place for shipment of the rope.
the load between the full “up” and “down” positions 4. Attach a “Do not remove welded ends” tag on each reel
several times. Stand back and watch the drum winding flange.
and rope travel for any potential problems.
After making the lifts with a light load, increase the load
and cycle it up and down a few times. This procedure will

GROVE Published 9-18-2014, Control # 308-06 1-23

INTRODUCTION RT890E SERVICE MANUAL

FIGURE 1-15

8
2 27
23

1-24 Published 9-18-2014, Control # 308-06

RT890E SERVICE MANUAL HYDRAULIC SYSTEM

SECTION 2
HYDRAULIC SYSTEM

SECTION CONTENTS
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31 2
Theory Of Operation. . . . . . . . . . . . . . . . . . . . . . . . 2-5 Directional Control Valves . . . . . . . . . . . . . . . . . . 2-35
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Hydraulic Oil Recommendations. . . . . . . . . . . . . . 2-5 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35
Draining and Flushing . . . . . . . . . . . . . . . . . . . . . . 2-5 Front Steer/Swing/Brake Manifold . . . . . . . . . . . . 2-41
Removing Air from the Hydraulic System . . . . . . . 2-6 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41
Parts Replacement . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41
Directional Control Valves. . . . . . . . . . . . . . . . . . . 2-7 Steering Control Valve . . . . . . . . . . . . . . . . . . . . . 2-45
Supply Pressure and Return Circuit . . . . . . . . . . . 2-9 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45
Hydraulic Reservoir. . . . . . . . . . . . . . . . . . . . . . . . 2-9 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45
Hydraulic Oil Return Filter Assembly . . . . . . . . . 2-10 Hydraulic Remote Control Valve . . . . . . . . . . . . . 2-46
Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46
Hydraulic Pumps. . . . . . . . . . . . . . . . . . . . . . . . . 2-13 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . 2-19 Swing Power Brake Valve With Treadle Pedal . . 2-50

8
Pressure Setting Procedures . . . . . . . . . . . . . . . 2-20 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-50
Procedure A - Main Control Valve Pressure Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-50
27
For Hoists, Boom Lift, Telescope(s) - 2 Speed Swing Valve. . . . . . . . . . . . . . . . . . . . . . . 2-51
Check/Adjust. . . . . . . . . . . . . . . . . . . . . . . . . . 2-21 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51
Procedure B - Outrigger Pressures - Adjust . . . . 2-22 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51
2

Procedure C - Oil Cooler Motor Pressure - Cab Tilt Double Pilot Operated Check Valve . . . 2-52
Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
23

Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52
Procedure D - Set Service Brake Accumulator
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52
Charge Valve Limits - Check/Adjust . . . . . . . . 2-22
Procedure E - Accumulator Pre-Charge Tandem Brake Valve with Treadle Pedal. . . . . . . 2-53
Pressure - Check . . . . . . . . . . . . . . . . . . . . . . 2-22 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53
Procedure F - Pre-Charging the Accumulator. . . 2-23 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53
Procedure G - Front Steer Pressure - Dual Accumulator Charge Valve . . . . . . . . . . . . . 2-54
Check/Adjust. . . . . . . . . . . . . . . . . . . . . . . . . . 2-23 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54
Procedure H - Swing Work Port Pressure - Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54
Check/Adjust. . . . . . . . . . . . . . . . . . . . . . . . . . 2-23 Hydraulic Accumulator Service Brake . . . . . . . . 2-56
Procedure I - Swing Brake Release Pressure - Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56
Check/Adjust. . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56
Procedure J - Controller Supply Pressure -
Check/Adjust. . . . . . . . . . . . . . . . . . . . . . . . . . 2-23 Holding Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57
Procedure K - Hose Reel Brake and Motor Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57
Supply Pressure - Check/Adjust . . . . . . . . . . . 2-23 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57
Procedure L - Counterweight Removal Cross Axle Differential Lock Valve . . . . . . . . . . . 2-58
Cylinder Extend Pressure - Check . . . . . . . . . 2-24 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58
Procedure M - Counterweight Pin Cylinder Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58
Pressure - Check . . . . . . . . . . . . . . . . . . . . . . 2-24
Outrigger Control Manifold. . . . . . . . . . . . . . . . . . 2-59
Procedure N - Cab Tilt Cylinder Extend/Retract Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-59
Pressure - Check . . . . . . . . . . . . . . . . . . . . . . 2-24
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-59
Procedure O - Luffing Jib Lower Pressure -
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24 Pilot Operated Check Valve . . . . . . . . . . . . . . . . . 2-62
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62

GROVE Published 9-18-2014, Control # 308-06 2-1

HYDRAULIC SYSTEM RT890E SERVICE MANUAL

Axle Lockout, Rear Steer and Oil Cooler Axle Oscillation Lockout Cylinder . . . . . . . . . . . . 2-83
Fan Motor Control Manifold . . . . . . . . . . . . . . . . . 2-63 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-83
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-63 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-83
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-63 Axle Oscillation Lockout Cylinder (CE Option). . 2-86
Check Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-86
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-86
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66 Steer Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-89
Range Shift/Parking Brake Valve. . . . . . . . . . . . . 2-67 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-89
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-67 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-89
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-67 Outrigger Extension Cylinder . . . . . . . . . . . . . . . . 2-92
Load Sense Dump Valve . . . . . . . . . . . . . . . . . . . 2-68 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-92
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-68 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-92
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-68 Outrigger Jack Cylinder . . . . . . . . . . . . . . . . . . . . 2-95
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-70 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-95
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-70 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-95
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-70 Cab Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . 2-98
Surface Protection for Cylinder Rods . . . . . . . . . 2-70 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-98
Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-73 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-98
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-73 Counterweight Removal Cylinder. . . . . . . . . . . . 2-101
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-73 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-101

8
Dual Rod Telescope Cylinder . . . . . . . . . . . . . . . 2-76 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-101
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-76 Counterweight Pin Cylinder . . . . . . . . . . . . . . . . 2-104
27
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-76 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-104
Upper Telescope Cylinder . . . . . . . . . . . . . . . . . . 2-80 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-104
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-80 Park Brake Cylinder . . . . . . . . . . . . . . . . . . . . . . . 2-106
2
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-80 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-106
23

DESCRIPTION valves, and all hydraulic cylinders. Detailed descriptions and

operation of individual hydraulic circuits are discussed within
This section describes the hydraulic system, the their individual sections as applicable. A complete hydraulic
components which make up the hydraulic system, and the system schematic showing all options is at the back of this
components dependent upon the hydraulic system for their manual, Figure 2-1 and Figure 2-2 shows A.N.S.I. hydraulic
operation. This includes descriptions of the supply pressure symbol information for this section.
and return hydraulic circuit, hydraulic pumps, all hydraulic

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RT890E SERVICE MANUAL HYDRAULIC SYSTEM

8
2 27
23

FIGURE 2-1

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HYDRAULIC SYSTEM RT890E SERVICE MANUAL

8
2 27
23

FIGURE 2-2

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RT890E SERVICE MANUAL HYDRAULIC SYSTEM

THEORY OF OPERATION Draining and Flushing

Three different control systems are used in the hydraulic If a component has been changed because of a failure that
system; load sense (LS), constant pressure unloaded might allow metal or abrasive particles to enter the system,
(CPU), and open center (OC). all systems must be thoroughly checked, drained, and
flushed.
Hoist, lift, telescope, cab tilt, and counterweight removal are
constant pressure unloaded (CPU) functions. They are 1. Remove the reservoir drain plug. Allow about three
supplied oil flow via a variable displacement supercharged minutes after hydraulic oil stops flowing from the drain 2
piston pump. CPU functions have directional spools that port for the side walls to drain.
meter the required flow and pressure to the function. The
2. Clean and install the reservoir plug and fill the reservoir
pump delivers only the required flow at the pumps
with a 50/50 mixture of fuel oil and clean hydraulic oil.
compensator setting.
3. Cycle the crane through all functions several times.
Outriggers, rear steer, service brakes, oil cooler motor,
Then return the crane to its stowed position and turn the
telescope hose reel motor/brake controller supply and swing
front and rear wheels to the extreme left. Shut down the
brake release are load sense (LS) functions.They are
engine.
supplied oil flow by the same pump as the CPU functions.
The LS functions are in parallel with the CPU valves. LS 4. Remove the reservoir drain plug and drain the reservoir.
signal shuttle valves send the highest load signal of all the Clean and install the drain plug and fill the reservoir with
functions that are activated. The function’s spools or orifices clean hydraulic oil.
meter the required flow to the function. The pump will deliver
only the required flow up to the compensator setting. When a
load sense function is operated at the same time as a CAUTION
constant pressure unloaded function, the pump stays at it’s Hydraulic oil supply lines must be connected to the

8
compensated setting. cylinders when flushing the system.
27
The swing function is the only open center (OC) function.
Swing is supplied with oil from a single section gear pump. NOTE: Draining the various components will be aided by
Front steer is also supplied with oil from this gear pump and connecting a drain line in place of the disconnected
is prioritized to take any required flow before swing. Front return line.
2

steer acts like a load sense function because of the priority 5. Disconnect the return line from the lift cylinder and raise
valve.
23

the boom to maximum elevation.

Both load sense and constant pressure unloaded functions 6. Connect the cylinder return line and lower the boom to
utilize a signal control line that loops through all valves its stowed position. Replenish the reservoir hydraulic oil
common to the pump by the shuttle valves. When using a LS level as required.
function, the highest signal PSI up to the pumps
compensator setting is sent to the variable displacement 7. Disconnect the return line from an outrigger extension
piston pump. When a CPU function is activated, the signal cylinder and fully extend the outrigger.
line being drained across the directional control valve spool 8. Connect the outrigger return line and retract the
is blocked, causing the pump to rise in pressure to its outrigger. Replenish the reservoir hydraulic oil level as
compensated pressure setting. necessary.
A load signal dump valve prevents the pump from coming on 9. Repeat Steps 7 and 8 for the remaining outriggers.
stroke during engine start. It is activated by the ignition key
switch during the starting mode. This ensures the engine
does not start against a load in the event the accumulators CAUTION
are charging or the fan motor is activated. When draining the outrigger cylinders, always operate
either both front or both rear cylinders together to prevent
twisting the crane.
MAINTENANCE
10. Disconnect the return lines from a pair of outrigger jack
Hydraulic Oil Recommendations. cylinders and activate the cylinders to their maximum
down positions.
For the hydraulic oil specifications, refer to Lubrication, page
9-1. 11. Connect the return lines and raise the outrigger jack
cylinders to the stowed position. Replenish the reservoir
hydraulic oil level as necessary.

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HYDRAULIC SYSTEM RT890E SERVICE MANUAL

12. Repeat Steps 10 and 11 for the remaining two outrigger with all cylinders retracted. Fill the reservoir to the full mark
cylinders. on the reservoir sight gauge. After the reservoir is filled,
operate all circuits and recheck the reservoir sight gauge.
13. Disconnect the return line from the telescope cylinder
Add hydraulic oil as required.
and fully extend the boom.
14. Connect the return line and retract the boom. Replenish Removing Air from the Hydraulic System
the reservoir hydraulic oil level as necessary.
Air entering the hydraulic oil will normally be removed
15. Disconnect the return lines from both front steer automatically by passage of the hydraulic oil over the baffles
cylinders and turn the front wheels to the extreme right. in the hydraulic reservoir. If a component has been replaced,
the reservoir level is too low, or a leak develops in the suction
16. Connect the return lines and turn the front wheels to the
lines to the pumps, air can enter the system. If air becomes
extreme left and then back to center. Replenish the
entrapped in the hydraulic oil, it may be detectable in pumps
reservoir hydraulic oil level as necessary.
and motor operated components such as the swing
17. Repeat Steps 15 and 16 for the rear steering cylinders. mechanism and hoist(s), because it can cause these units to
become noisy during operation. If noisy operation occurs,
18. Raise the crane on outriggers. first check the level of the hydraulic reservoir and replenish
19. Disconnect the line from port A of the axle lockout valve. as necessary. Then inspect for leaks in the suction lines
leading to the pumps.
20. Using a jack under the rear wheel on one side of the
crane, jack up the wheel to maximum travel. Minute leaks may be hard to locate. If a leak is not readily
detectable, use the following way to check for it:
21. Connect the line to port A of the axle lockout valve and
disconnect the line from Port B. Seal all normal openings in the hydraulic system and the
reservoir. Using a positive means to control the pressure

8
22. Repeat step 19 using the other rear wheel. (like a regulator), pressurize the hydraulic system to 2 to
23. Connect the line to port B of the axle lockout valve. 4 psi (13.8 to 27.6 kPa/0.14 to 0.28 bar) and inspect all
27
Energize the axle lockout valve. Replenish the reservoir joints and fittings for evidence of leaks. A soap solution
hydraulic oil level as necessary. applied to the fittings and joints may also prove helpful in
detecting minute leaks while the system is pressurized.
24. Disconnect the return line from the main hoist motor and
2
Remove the pressure, repair any leaks found, and
fully hoist up the hoist. reopen any openings (such as a vent) closed for
23

25. Connect the return line to the main hoist motor and fully inspection. Refill the reservoir after completing any
hoist down the hoist, then hoist up again. Replenish the repairs or service. Operate all hydraulic circuits several
reservoir hydraulic oil level as necessary. times in both directions.

26. Repeat Steps 24 and 25 for the auxiliary hoist as This action should return any entrapped air to the
necessary. reservoir where it can be removed from the hydraulic oil
by the baffles.
27. Disconnect one of the lines from the swing motor and
drive the motor in the direction it will go.
28. Connect the line to the swing motor, then drive the swing
motor in the opposite direction until the boom is centered DANGER
and forward. Replenish the reservoir hydraulic oil level Locate the machine on a firm supporting surface and
as necessary. position the boom over the front on outriggers when
extending the boom at low angles.

CAUTION To remove entrapped air from telescope cylinders, lower

When hydraulic oils are changed or added, ensure that the boom to below horizontal and fully telescope the
hydraulic oils of different manufacturers are of the same boom in and out several times.
specifications. However, discoloration may occur.
If the air is not readily removed, lower the boom to below
horizontal, extend the telescope cylinders as far as
When hydraulic oils are changed, recheck the reservoir
practicable, and allow the boom to remain in this position
hydraulic oil level after brief system operation and add
overnight. This should allow entrapped air to find its way
hydraulic oil as required. Working reservoir capacity
to the holding valve so that telescoping the boom IN the
(capacity to full mark) is 236 U.S. gal (894 l). Ensure the
next morning should force the air back to the reservoir.
crane is level and in the travel mode of operation when the
Ensure the boom is first telescoped IN (not OUT) in the
hydraulic system is being filled. The system must be filled

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RT890E SERVICE MANUAL HYDRAULIC SYSTEM

morning. Telescoping OUT may cause air to be forced that are too high, or by dirt or paint accumulation on the
back into a cylinder. spool. Damaged or torn seals must be replaced.
A component functioning at reduced efficiency may indicate
that the control valve for that component is leaking internally.
If preliminary check-out reveals that adequate volume is
DANGER being supplied to the affected valve bank, relief valves are
Extreme care must be used when removing any plugs or
restrictions from a hydraulic system suspected to have
properly adjusted, and the component is not at fault, check
the valve for scored or worn parts. Scoring is a sign of the 2
entrapped air that may be pressurized. number one problem in hydraulics - contamination (external
contamination by dust or internal contamination by debris
Entrapped air may be removed from cylinders having from deteriorating components or oxidized hydraulic oil).
wet rods by cycling. On certain cylinders, a plugged port Scored or severely worn valve components must be
is provided on the rod end to bleed off entrapped air. replaced.
Check valves in the control valves are designed to permit a
flow of hydraulic oil in one direction only. If a piece of dirt or
rust has worked its way into the check valve and lodges
DANGER between the poppet and seat, it will keep the valve open and
Do not attempt to loosen fittings in pressurized lines or allow a return flow of hydraulic oil. The remedy is to clean the
while the hydraulic pumps are in operation. valve, but it is also a good idea to follow through and ensure
the hydraulic system filter is still serviceable.
In the event that air entrapment should persist, bleeding
of air by loosening various clamp and screw type fittings Binding Spools
may become necessary.

8
Some of the most common causes for stiff spool movement
If the above procedures fail to eliminate air entrapment, or jammed spool action are system overheating, excessive
27
contact your authorized Grove Distributor. pressure, contaminated or deteriorated hydraulic oil, or
warped mountings. When scorched, deteriorated hydraulic
Parts Replacement oil or contamination is the cause, flushing the system and
replenishing with clean hydraulic oil may solve the problem.
2
Parts found damaged or out of tolerance when maintenance
If the spool bores are badly scored or galled, the valve must
is being performed should be replaced. Refer to the
be removed for servicing.
23

Manitowoc Crane Care Parts Catalog for proper replacement

parts. Warping occurs when mounting plates are not level or they
become distorted from machine damage. As mentioned
Directional Control Valves previously, the valve can be shimmed level.
The control valves that control the crane functions are Also, check the valve for rust. Rust or dirt collecting on the
installed on the right side on the outside of the superstructure valves can prevent free movement of the spool, and keep it
side plate, and between the left and right superstructure side from the true center position. Excessive system pressure
plates under the main hoist. can create both internal and external leaks in valves that are
otherwise sound. Only qualified technicians using the correct
Inspection equipment should make pressure adjustments when
Inspect the control valves for visible damage, binding spools, pressure adjustments are needed.
and evidence of leakage. If excessive internal leakage is
Visual Inspection of Hoses and Fittings
suspected during operation with a spool in its center position,
it is possible that the area between the spool and working
section bore of the valve body is worn beyond serviceable
limits. If this condition exists, the spool and body must be
CAUTION
replaced as an assembly. Ensure that the hydraulic hose is depressurized before
loosening the connections.
Valve Leakage
Visually inspect hoses and fittings once a month or every 250
Dripping hydraulic oil indicates some type of external hours for the following:
leakage. The machine should be removed from service for
immediate repairs. External leaks sometimes develop at • Leaks at hose fitting or in hose
fittings and seals. Spool seals are susceptible since they are
• Damaged, cut, or abraded cover
subject to wear. Seals may be damaged by temperatures
• Exposed reinforcement

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HYDRAULIC SYSTEM RT890E SERVICE MANUAL

• Kinked, crushed, flattened, or twisted hose All hydraulic hose assemblies are recommended to be
replaced after 8000 hours of service life. Working conditions,
• Hard, stiff, heat cracked, or charred hose
ambient temperatures and high duty circuits can affect
• Blistered, soft, degraded, or loose cover service life of hose assemblies and must be taken into
account when inspecting and replacing hoses. High duty
• Cracked, damaged, or badly corroded fittings
circuits can include, but are not limited to, outriggers,
• Fitting slippage on hose hoist(s), boom lift, swing, pump suction and discharge to
directional valves and directional valve return to the
• Other signs of significant deterioration reservoir.
If any of the above conditions exist, evaluate hose Hydraulic hose assemblies operating in a temperature
assemblies for correction or replacement. For replacement climate zone “C” (Table 2-1) are recommended to be
of hose assemblies, refer to your Manitowoc Crane Care replaced after 8000 hours of service life.
Parts Manual.
Hydraulic hose assemblies operating in climate zones “A”
At the same service interval, visually inspect all other and “B” (Table 2-1) with high ambient temperatures, could
hydraulic components and valves for the following: see hose service life reduced by 40 to 50%, therefore, it is
• Leaking ports recommended to replace these hoses after 4000 to 5000
hours of service life.
• Leaking valve sections or manifolds and valves installed
into cylinders or onto motors. Hydraulic hose assemblies operating in climate zones “D”
and “E” (Table 2-1), cold climates, should expect a degrade
• Damaged or missing hose clamps, guard, or shields. of mechanical properties, long term exposure to these cold
• Excessive dirt and debris around the hose assemblies. temperatures will negatively impact service life. Therefore it
is recommended for these hoses to be inspected thoroughly

8
If any of these conditions exist, address them appropriately. as service life may be less than 8000 hours.
27
Table 2-1

Zone Classification
2
A Tropical Moist: All months average above 18° C. Latitude 15° - 25° North and South
B Dry or Arid: Deficient precipitation most of the year. Latitude: 20° - 35° North and South
23

C Moist Mid-Latitude: Temperature with mild winters. Latitude: 30° - 50° North & South
D Moist Mid-latitude: Cold winters. Latitude 50° - 70° North & South
E Polar: Extremely cold winters and summers. Latitude: 60° - 75° North & South

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RT890E SERVICE MANUAL HYDRAULIC SYSTEM

SUPPLY PRESSURE AND RETURN CIRCUIT Hydraulic Reservoir

The supply pressure and return circuit is made up of several The reservoir (see Figure 2-3), attached to the right side of
circuits which route hydraulic oil from the hydraulic pumps to the carrier frame, has a capacity of 253.3 gallons (958.7 l)
the directional control valves for the individual operating total, 228 gal (863.8 l) to the full mark. The all-steel reservoir
circuits. The supply pressure and return circuit consists of has an internally mounted full-flow filter and integral baffles
the reservoir and integral filter, two hydraulic pumps, a that help cool the hydraulic oil and prevent hydraulic oil
hydraulic oil cooler, and a 14-port hydraulic swivel. Refer to
H y d r a u l i c P u m ps , pa g e 2 - 1 3 f o r d e s c r i p t i o n s a n d
foaming.
2
Hydraulic oil flows through two tubes at the lower rear of the
maintenance instructions for each hydraulic pump. Refer to
reservoir to the two hydraulic pumps. Almost all of the return
Swing System, page 6-1 for description and maintenance
flow goes through the filter at the top of the reservoir. The
instructions for the 14-port hydraulic swivel.
return line that goes directly into the reservoir (instead of
The supply pressure and return circuit uses Ports 6 and 7 for through the filter) is from the No. 10 port (drain) of the 14-port
pump supply and the dual Port 4 for return. Each operating swivel.
circuit’s description and components begin with the circuit’s
A magnetized drain plug in the bottom of the reservoir
directional control valve.
collects metal particles from the hydraulic oil if it becomes
contaminated.
A sight gauge is located on the front of the reservoir to
indicate hydraulic oil level.

8
Item Description 1
2 3
1 Return Filter
27
4
6 8
2 Filter Indicator
3 Sight Gauge 7
2

4 Return Line
23

5 Suction Line
6 Access Cover
7 Filler Neck and Breather
8 Step Assembly
9 Magnetic Plug
15 6
10 Capscrew
11 Flatwasher
12 Spring Lockwasher 14
13 Hex Nut
14 Temperature Switch (High
Hydraulic Oil Temperature) 5

15 Temperature Switch (Oil Cooler

9
Fan Motor Speed)
11
10
13
6644-1
11
12

FIGURE 2-3

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HYDRAULIC SYSTEM RT890E SERVICE MANUAL

A temperature switch (15), located in the tube that routes screen prevents gross contamination from passing through
return oil to the hydraulic oil return filter in the reservoir, is the filter even during bypass.
part of a circuit that controls the oil cooler fan motor speed;
Refer to the following procedures and Figure 2-4 when
refer to Oil Cooler, page 2-12 for more detailed information
removing or installing the hydraulic oil return filter element.
on its operation.
A second temperature switch in the hydraulic reservoir is part
of a circuit that will alert the operator to a high hydraulic oil CAUTION
temperature condition. The switch is normally closed and will
Ensure that all hydraulic systems are shut down and the
open and cause the circuit to lose ground when the hydraulic
pressure is relieved. Moderate to minor injury may result
oil temperature exceeds 190°F (88°C). When the circuit
when working on a pressurized system.
loses ground, the CAN bus system will turn on power to
illuminate the Hydraulic Oil High Temperature Indicator in the Wear eye protection. Hydraulic fluid can blind or severely
gauge display in the operator cab. See Section 3 -Operating damage eyes.
Controls and Procedures, in the Operator Manual for details
of the Hydraulic Oil High Temperature Indicator. Element Removal
A filler neck and breather on the top of the reservoir are for
filling the reservoir and for venting it. The filler neck includes 1. Shut down all hydraulic systems.
a strainer for catching contaminants and gaskets to prevent 2. Wipe any dirt from the cap on top of the return filter
leaking. The breather -- which screws onto the filler neck -- head.
allows air to enter or exhaust from the reservoir. It is most
important that the breather be kept clean to prevent damage 3. Remove the four bolts securing the cap to the return
to the reservoir. A breather guard protects the breather and filter head; remove cap.

8
filler neck. 4. Remove the spring and bypass valve and inspect for any
Two large round access covers on the top of the reservoir damage; replace if necessary.
27
provide access for cleaning. The covers are bolted to the top 5. Remove and discard the O-ring between the cap and the
of the reservoir and have a gasket to prevent leaking. The return filter head.
access holes can also be used to fill the reservoir after it has
6. Remove the element from through the return filter head.
2
been completely drained.

Hydraulic Oil Return Filter Assembly Element Installation

23

The hydraulic oil filter (see Figure 2-3 and Figure 2-4) is 1. Replace the filter with one having the same part number
located in the reservoir. It bolts to the top of the reservoir, and as the one removed.
its bypass outlet fits into a tube welded in the reservoir. The 2. Install the bypass valve and spring.
filter housing contains two replaceable filter elements.
Returning hydraulic oil flows through the filter head, through 3. Install the cap on top of the return filter head making
the filter element, and into the reservoir. sure that the new O-ring between the cap and filter head
is installed correctly.
An element condition indicator on the filter head indicates
when to change the filter element. When back pressure 4. Secure the cap to the filter head using the bolts and lock
caused by a dirty filter element exceeds 25 psi (172.3 kPa/ washers; torque bolts to their specified value.
1.72 bar), the filter head’s bypass feature functions to allow 5. Activate the hydraulic system and check for leaks. Make
the hydraulic oil to bypass the filter element and flow into the repairs as needed.
reservoir through the bypass outlet instead. A bypass filter

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RT890E SERVICE MANUAL HYDRAULIC SYSTEM

13

14
5

11
12
2
8

7
9

8
27 4

2
2
23

10

7820
FIGURE 2-4

Item Description Item Description

1 Filter Head 8 Plug
2 Bowl Assembly 9 O-ring
3 Compression Spring 10 Element
4 Bypass Valve Assembly 11 Cap
5 I.D. Plate 12 O-ring
6 Gasket 13 Screw
7 Gauge Assembly 14 Washer

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HYDRAULIC SYSTEM RT890E SERVICE MANUAL

Oil Cooler A temperature switch (15, Figure 2-3), located in the tube
that routes return oil to the hydraulic oil return filter in the
An air cooled oil cooler (see Figure 2-5) is located on the left reservoir, is part of a circuit that controls the oil cooler fan
side of the crane and consists of a transmission oil cooler motor. The switch is normally closed and will open and cause
and a hydraulic oil cooler. the circuit to lose ground when the hydraulic oil temperature
The fan pulls cool air through the cooling fins on the coolers. exceeds 120°F (48.8°C). When the circuit loses ground, the
Normally, most hydraulic oil from components is routed CAN bus system will de-energize the oil cooler solenoid
through the oil cooler by way of a return line and on to the valve, allowing pressurized oil from Pump No. 1 to flow to the
filter in the reservoir. When several hydraulic functions are oil cooler fan motor.
b e i n g u s e d a t o n e t i m e ( i . e . , h o i s t i n g , l i ft i n g , a n d A second temperature switch located in the inlet tube of the
telescoping), more oil has to flow through this return line, transmission oil cooler, is part of a circuit that will alert the
causing a pressure buildup. When this pressure reaches operator to a high transmission oil temperature condition.
15 psi (103.4 kPa), the normally closed check valve in the The switch is normally closed and will open and cause the
return line (in parallel with the return line through the circuit to lose ground when the transmission oil temperature
hydraulic oil cooler) will open, letting some hydraulic oil exceeds 200°F (93°C). When the circuit loses ground, the
bypass the hydraulic oil cooler and flow directly into the CAN bus system will turn on power to illuminate the
reservoir filter. Transmission Warning Indicator in the gauge display in the
When fewer functions are being used, the pressure in the operator cab. See Section 3 - Operating Controls and
system will decrease below 15 psi (103.4 kPa) and the Procedures, in the Operator Manual for details of the
check valve will close again. Transmission Warning Indicator.

8
7
1
27
4

3
2
5
23

Item Description
1 Transmission Oil Cooler
2 External Drain Port
3 Fan
4 Hydraulic Oil Cooler
5 Inlet Port
6 Motor
7 Shroud
6 8 Outlet Port
7697

2 FIGURE 2-5

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RT890E SERVICE MANUAL HYDRAULIC SYSTEM

Hydraulic Pumps cm3/rev) delivering a theoretic flow of 96 gpm (363 lpm) @

2500 engine rpm. It has an integral inlet impeller to insure
Pump No. 1 and 2 are mounted off drive pads of the torque
proper self-priming. The pump differential or standby
converter (Figure 2-6).
pressure is 275 psi (1896 kPa/19 bar). Pump No. 1 supplies
The purpose of these pumps is to convert mechanical oil to the outrigger, rear steer, axle lockout, boom lift,
energy into fluid energy for the operation of the crane’s telescope, hoist, hose reel and pilot functions.
hydraulic components.
Pump No. 1 is a variable displacement, pressure
Pump No. 2 is a single positive displacement gear pump @
2
3.48 in3 /rev (57 cm3 /rev) delivering a theoretic flow of 38
compensated load sense piston pump @ 8.85 in3/rev (145 gpm (144 lpm). Pump No. 2 supplies oil to the front steer and
swing circuits.

Front of Crane

8
2 27
23

7401 2 3 Pump Location 4

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

FIGURE 2-6

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HYDRAULIC SYSTEM RT890E SERVICE MANUAL

Pump No. 1 Troubleshooting

Symptom Probable Cause Solution

1. Oil Leakage a. Hose fittings loose, worn or damaged a. Check and replace damaged fittings
or O-rings.
b. Oil seal rings deteriorated by excess b. Replace oil seals by disassembling
heat. pump. Contact Manitowoc Crane
Care for instructions, or refer to
Volume 2 of the Service Maintenance
Manual
c. Bolt loose or its sealing area c. Loosen bolt, then torque, or replace
deteriorated by excess heat. bolt.
d. Shaft seal worn or damaged. d.
NOTE: Check fluid leaking from housing
weep hole to better determine which
seal has failed. If pump is leaking
hydraulic fluid, the inboard seal has
failed. If the pump is leaking
transmission fluid, the outboard seal
has failed.

8
27 - Remove seal carrier from pump
- Remove damaged seal
- If shaft is worn, install new seal
- Reinstall seal carrier
2

2. No flow from a. Pump not installed correctly. a. Check proper drive rotation. Make
pump (if pump sure pump shaft is turning (i.e. drive
23

does not prime in coupling is engaged). Check for

30 seconds, sources of suction leaks. Check that
STOP) inlet flange is tight. Check for pinched
O-rings.
b. Pump not getting oil. b. Make sure reservoir is at proper level.
3. Pump does not a. Flow has an unrestricted path a. Check for open circuit to reservoir.
build pressure.
4. Pump only builds a. Pump control settings too low a.
a few hundred PSI
- Check if compensator is backed out
290 to 435 psi (20
to 30 bar) - Check for load sense pressure signal
- Check that system relief valve is
vented
b. Control is malfunctioning b. Make sure orifices are not plugged
and that control spools/springs are
assembled correctly.
c. Internal leakage in cylinders, valves, c. Repair component
motors, or pumps.
5. Pump won’t a. Control is malfunctioning. a. Clean orifices in control of
compensate contamination. Confirm orifice and
plugs are properly assembled.

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RT890E SERVICE MANUAL HYDRAULIC SYSTEM

Pump No. 1 Removal Pump No. 2 Removal

CAUTION CAUTION
Absolute cleanliness is essential when working on the Absolute cleanliness is essential when working on the
hydraulic pumps. Always work in a clean area. The hydraulic pumps. Always work in a clean area. The
presence of dirt and foreign materials in the system can presence of dirt and foreign materials in the system can
result in serious damage or inadequate operation. result in serious damage or inadequate operation. 2
1. Remove the pump cover to gain access to the pump. 1. Tag and disconnect the supply line from the pump. Cap
The pump is bolted to the engine’s torque converter. or plug the line and port.
2. Tag and disconnect the supply line from the pump. Cap 2. Tag and disconnect the pump distribution line(s) from
or plug the line and port. the pump. Cap or plug the line(s) and port.
3. Tag and disconnect the pump distribution lines from the
pump. Cap or plug the lines and ports.
CAUTION
When removing the pump, keep the pump as level as
CAUTION possible to avoid damaging the input spline.
When removing the pump, keep the pump as level as
3. Remove the bolts and washers attaching the No. 2 pump
possible to avoid damaging the input spline.
to the drive pad on the torque converter. Remove the
pump.
NOTE: Charge pump and two studs must be removed for

8
wrench access to piston pump mounting bolts. 4. Remove the gasket material from the drive pad on the
torque converter.
27
4. Remove the bolts and washers attaching the pump to
the drive pad on the torque converter. Remove the 5. Cover the drive pad’s opening to prevent dirt from
pump. entering.
2
5. Clean the gasket material from the drive pad on the Pump No. 2 Installation
torque converter.
1. Install new gasket material to the pump mounting flange
23

6. Cover the drive pad’s opening to prevent dirt from as follows.

entering.
a. Clean the drive pad and the pump with Loctite
Pump No. 1 Installation cleaning solvent 7070 or similar non chlorinated
solvent.
1. Install new gasket material to the pump mounting flange
as follows. b. Apply a light coating of Loctite primer N7649 to both
surfaces. Allow primer to dry for one to two minutes.
a. Clean the drive pad and the pump with Loctite
Primer must be dry. Mating of parts should occur
cleaning solvent 7070 or similar non chlorinated
within five minutes.
solvent.
c. Apply gasket material Loctite Master Gasket 518 to
b. Apply a light coating of Loctite primer N7649 to both
one surface. Partial cure is obtained in four hours,
surfaces. Allow primer to dry for one to two minutes.
with full cure in 48 hours.
Primer must be dry. Mating of parts should occur
within five minutes. 2. Install pump on torque converter drive pad with bolts and
washers. Make sure gear teeth mesh properly. Torque
c. Apply gasket material Loctite Master Gasket 518 to
bolts; refer to Fasteners and Torque Values, page 1-14
one surface. Partial cure is obtained in four hours,
for the proper torque value.
with full cure in 48 hours.
3. Connect the distribution and supply lines as tagged
2. Install pump on torque converter drive pad with bolts and
during removal.
washers. Make sure the splines mesh properly. Torque
bolts to 150 lb-ft (203 Nm).
3. Replace the charge pump and studs. CAUTION
Do not feed hot hydraulic oil into a cold pump. This may
4. Connect the distribution and supply lines as tagged
cause the pump to seize.
during removal.

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HYDRAULIC SYSTEM RT890E SERVICE MANUAL

Pump No. 1 Bleeding and Start-up to full RPM and then cycle the functions that the
pump supplies to verify proper speed. Verify pump
flow.
CAUTION 8. Check pressure settings; refer to Pressure Setting
Failure to follow this procedure can cause the pump to fail Procedures, page 2-20.

Pump No. 2 Bleeding and Start-up

CAUTION
The Pump Priming Tool is set to 1-2 psi to prevent the
reservoir from being over-pressurized and damaged. Do CAUTION
not adjust the Pump Priming Tool. Always monitor the Failure to follow this procedure can cause the pump to fail
pressure gauge of the Pump Priming Tool to ensure that 2
psi is not exceeded during the air bleeding process.
CAUTION
1. Ensure reservoir is filled with the proper hydraulic fluid to Do not retract hydraulic cylinders with the pump priming
the high level mark on the reservoir sight gauge. If tool connected to the reservoir. Damage to the reservoir
hydraulic oil is aerated (oil has a foamy white tint with may occur due to the priming tool’s inability to properly
bubbles), allow crane to sit until the air has escaped and vent the reservoir of air.
the fluid is a dark solid color.
2. Remove the plug from the Dr port of the pump
(Figure 2-7). Fill the pump casing with hydraulic oil, then
CAUTION
re-install plug; torque plug to 123 lb-ft. The pump priming tool is set to 1-2 psi to prevent the
reservoir from being over-pressurized and damaged. Do

8
3. Place an adequate container under Pump No. 1 to catch not adjust the pump priming tool. Always monitor the
the hydraulic oil. Remove the plug from the pump’s Tair pressure gauge of the pump priming tool to ensure that 2
27
port (Figure 2-7). psi is not exceeded during air bleeding.
4. Remove the breather from the Hydraulic Oil Reservoir,
then install the Pump Priming Tool (Figure 2-8) (Grove 1. Ensure reservoir is filled with the proper hydraulic fluid to
the high level mark on the reservoir sight gauge. If
2
P/N 80030367) onto the reservoir in place of the
breather, Connect a compressed air supply (nominal hydraulic oil is aerated (oil has a foamy white tint with
bubbles), allow crane to sit until the air has escaped and
23

100 psi, maximum 300 psi) to the Pump Priming Tool.

the fluid is a dark solid color.
5. Wait for a solid stream of fluid, free of air bubbles, to exit
the Tair port, then re-install the plug in the Tair port while 2. If gear pump is equipped with 7/16-20 UN-2B port(s) in
oil is still coming out; torque plug to 9 lb-ft. the inlet side of the pump housing, place an adequate
container under Pump No. 2 to catch the hydraulic oil
6. Remove the air supply from the Pump Priming Tool. and then remove the plug from this port (if the pump has
more than one gear section, remove the plug that is
7. Start the engine and do the following.
most convenient as they are common to the inlet).
a. Idle engine for two to three minutes with no
If gear pump is not equipped with 7/16-20 UN-2B ports
functions actuated. Check for leaks and repair if
in the inlet side of the pump housing, place an adequate
required. Lay hand on pump to check for excessive
container under Pump No. 2 to catch the hydraulic oil
heat build-up. If the pump section is too hot to keep
and then slightly loosen the inlet port hose.
your hand on, stop immediately. If the pump makes
excessive noise it is probably sucking air, which 3. Remove the breather from the Hydraulic Oil Reservoir,
prevents the pump from priming. If this occurs, stop then install the Pump Priming Tool (Figure 2-8) (Grove
engine, and inspect all connections of the suction P/N 80030367) onto the reservoir in place of the
hose/tube for a loose connection, or a missing or breather, Connect a compressed air supply (nominal
damaged O-ring. Re-start the engine and run until 100 psi, maximum 300 psi) to the Pump Priming Tool.
the pump take s prime f or a ma xim um of 30
seconds. If the pump does not prime in 30 seconds, 4. If gear pump is equipped with 7/16-20 UN-2B port(s),
stop the engine and repeat procedure until the wait for a solid stream of fluid, free of air bubbles, to exit
pump primes. the port, then re-install the plug while oil is still coming
out; torque plug to 10 lb-ft.
b. Increase the RPM to 1500-1800 for 1 to 2 minutes
with no functions actuated and make checks again If gear pump is not equipped with 7/16-20 UN-2B port(s),
as outlined in step a. Incrementally increase throttle wait for a solid stream of fluid, free of air bubbles, to exit
the loose hose connection, then re-tighten the hose

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RT890E SERVICE MANUAL HYDRAULIC SYSTEM

fitting while oil is still coming out; refer to Hydraulic minutes with NO crane functions actuated. Check for
Fittings, page 1-12 for proper tightening procedure. leaks and repair if required.
5. Perform this step on gear pumps that start up against If the pump outlet becomes too hot to keep your hand on
high pressure, such as service brake charging or it comfortably, stop the engine immediately.
sequence valve circuits.
8. Stop the engine and remove the Pump Priming Tool and
With the compressed air supply (nominal 100 psi, re-install the breather.
maximum 300 psi) still attached to the Pump Priming
9. Start the engine. Slowly increase the engine speed to 2
Tool, slightly loosen the outlet port hose of the pump.
approximately 1500 rpm and hold for approximately 1
Jog the engine starter until a solid stream of fluid, free of
minute while making sure the hydraulic reservoir is filled
air bubbles, exits the loose hose connection, then re-
to the proper level and the fluid is not aerated.
tighten the hose fitting while oil is still coming out; refer to
Hydraulic Fittings, page 1-12 for proper tightening 10. Slowly increase the engine speed to full rpm and hold for
procedure. 1 minute while making sure the hydraulic reservoir is
filled to the proper level and the fluid is not aerated.
6. If the pump’s hydraulic circuit includes an air
conditioning compressor motor, ensure this function is 11. At full engine rpm, cycle all functions without fully
turned off. extending or retracting the cylinders to their stops to
verify operation and that the pump(s) stay quiet and do
7. With the compressed air supply (nominal 100 psi,
not become excessively hot.
maximum 300 psi) still attached to the Pump Priming
Tool, start the engine and let it idle for two to three 12. Check pressure settings. Refer to Pressure Setting
Procedures, page 2-20.

8
27
7748-02
7748-01
2
23

7748-03

Item Description
1 Dr Port
2 Tair Port

FIGURE 2-7

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HYDRAULIC SYSTEM RT890E SERVICE MANUAL

8
2 27
23

Pump Priming Tool (Grove P/N 80030367)

FIGURE 2-8

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RT890E SERVICE MANUAL HYDRAULIC SYSTEM

Troubleshooting

Symptom Probable Cause Solution

1. No hydraulic oil a. Low hydraulic oil level. a. Fill reservoir.
flows in systems.
b. Reservoir-to-pump suction lines b. Clean, repair, or replace lines as
broken or restricted. Air entering at
suction lines. Pump not priming.
necessary. Check lines for security,
absence of cracks, and proper
2
a t ta c h m e n t . Ti g h t e n , r e pa i r, o r
replace parts as necessary.
c. Pump shaft sheared or disengaged. c. If drive shaft is damaged or sheared,
remove and repair or replace as
necessary
d. Internal contamination. d. Drain, flush with recommended oil
mixture, then drain and refill system
with recommended hydraulic oil.
2. Slow response. a. Low hydraulic oil level. a. Fill reservoir.
b. Hydraulic oil temperature too high b. If too low, warm up system. As
(watery thin oil) or too low (thick needed, troubleshoot cooler circuit. If
sluggish oil). too high, troubleshoot cooler circuit.
Likely suspects are in-line check

8
valve and related hydraulic circuits.
c. Faulty pump section(s).
27 c. Repair or replace pump section(s) or
entire pump.
3. Pump noise a. Low hydraulic oil level. a. Fill reservoir.
accompanied by
2
b. Excessive engine speed. b. Regulate engine speed.
hydraulic oil
foaming in c. Air entering at suction lines. c. Check all lines for security and proper
23

reservoir. repair. Tighten, repair, or replace as

needed.
4. Excessive a. System relief valve set too high. a. Using adequate pressure gauge,
pressure buildup. adjust system relief valve as
necessary.
b. Restricted pump-to-control b. Clean, repair, or replace line as
valve supply line. necessary.

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HYDRAULIC SYSTEM RT890E SERVICE MANUAL

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

• Three dial gauge 0-5000 psi (0-34.5 MPa) When checking the outrigger relief valve setting,
start with the engine at idle RPM and activate and
• Pressure check diagnostic quick disconnect—Grove hold the extend switch. Then slowly accelerate the
P/N 9999101806 and straight adapter fitting P/N engine to the specified RPM. Read gauge and
7447040401 make adjustment as required.
• ORFS reducers as required to attach work port hoses to
the gauge.

Table 2-2
Valve Pressure Setting Table

Pressure
Tolerance
Valve To Be Set Setting PSI Adjustment Location
PSI (MPa)
(MPa)
Hoist (s), Lift & Telescope Inner Mid 4000 (27.6) ± 50 (0.4) Pump No. 1: Piston Pump (see
Retract Figure 2-10)

8
Telescope Inner Mid Extend 3060 (21.1) ± 50 (0.4) Main Directional Control Valve Port
27
Relief (see Figure 2-11)
*Telescope Inner Mid Retract 4300 (29.7) ± 50 (0.4) Main Directional Control Valve Port
Relief (see Figure 2-11) Thermal Relief
2
Telescope Center Mid Extend 2540 (17.6) ± 50 (0.4) Main Directional Control Valve Port
Two Stage Relief (see Figure 2-12)
23

Telescope Outer Mid Extend 3140 (21.7) ± 50 (0.4) Main Directional Control Valve Port
Two Stage Relief (see Figure 2-12)
Telescope Center/Outer Mid Retract 3461 (23.8) ± 50 (0.4) Main Valve Tele Center Mid Extend
Port (see Figure 2-11)
Outrigger Extend & Retract 2000 (13.8) ± 50 (0.4) Outrigger Control Manifold
(see Figure 2-13)
Hyd/Trans. Oil Cooler Motor 3000 (20.7) ± 50 (0.4) Front Steer, Swing & Accessory
Manifold (see Figure 2-13)
Service Brake High Charge Limit 2320 (17.4) +72/-145 (+0.5/- Dual Accumulator Charge Valve (see
1.00) Figure 2-14)
Service Brake Low Charge Limit 1950 (13.5) ±145 (±1.00) Dual Accumulator Charge Valve (see
Figure 2-14)
Accumulator Pre-charge 1500 - 1550 See Range Accumulator (see Figure 2-15)
(10.3 - 10.7)
Front Steer 2600 (18.0) ± 50 (0.4) Front Steer, Swing & Accessory
Manifold (see Figure 2-9)
Swing "Left" Relief 2400 - 2550 See Range Front Steer, Swing & Accessory
(16.6 - 17.6) Manifold (see Figure 2-9)
Swing "Right" Relief 2400 - 2550 See Range Front Steer, Swing & Accessory
(16.6 - 17.6) Manifold (see Figure 2-9)

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RT890E SERVICE MANUAL HYDRAULIC SYSTEM

Pressure
Tolerance
Valve To Be Set Setting PSI Adjustment Location
PSI (MPa)
(MPa)
Hose Reel Motor Supply & Brake Front Steer, Swing & Accessory
1425 (9.8) ± 25(0.17)
Release Manifold (see Figure 2-9)
Swing Brake Release Pressure 250- 300 Front Steer, Swing & Accessory
(1.7- 2.1)
See Range
Manifold (see Figure 2-9) 2
Controller Supply 350- 400 Front Steer, Swing & Accessory
See Range
(2.4- 2.8) Manifold (see Figure 2-9)
*Counterweight Removal Extend 1000 (6.91) ± 100 (0.8) Counterweight Removal Valve
*Luffing Jib Extend 1450 (10.0) ± 100 (0.8) Luffing Jib & Cab Tilt Valve
*Cab Tilt Up/down 2500 (17.2) ± 100 (0.8) Luffing Jib & Cab Tilt Valve
*Counterweight Removal Pin 2500 (17.2) ± 100 (0.8) Counterweight Removal Valve
* Non-Adjustable

Procedure A - Main Control Valve Pressure up to full RPM. Attempt to telescope the inner mid OUT
For Hoists, Boom Lift, Telescope(s) - Check/ by feathering into the controller to full controller stroke.
Adjust the work port relief valve “in” to increase or “out”
Adjust to decrease so that a gauge pressure reading of
3060 psi ±50 is achieved (see Figure 2-11).

8
Set hoist(s) boom lift and telescope inner mid retract as
follows: 8. Stop engine and remove pressure gauge and re-connect
27
1. Install pressure check diagnostic quick disconnect with plumbing.
gauge onto test port at the inlet tube of the Boom Lift/
Center Mid Extend
Telescope/Hoist Valve Bank (see Figure 2-11).
2
9. Disconnect the extend hose (the larger of the two)
2. If the lift cylinder is not installed, plug the extend hose
running from port B, center mid/outer mid telescope
(the larger of the two). If lift cylinder is installed, omit this
23

section of the VG35 directional control valve to the hose

step.
reel at the hose reel. Cap hose reel adapter.
3. Start engine and throttle up to full RPM. Feather into the
10. Install a pressure gauge into the disconnected hose
boom lift controller to full controller stroke (Up or down)
running to the VG35 directional control valve.
and hold. Adjust the maximum pressure adjusting screw
on the main piston pump “in” to increase or “out” to 11. Set the boom mode switches on the cab right hand
decrease so that a gauge pressure reading of 4000 psi armrest to “Manual” and “CM”. Start engine and throttle
±50 (see Figure 2-10). up to full RPM. Attempt to telescope the center mid OUT
by feathering into the controller to full controller stroke.
4. Stop engine and remove the diagnostic couplers from
Adjust the two stage relief to 2540 psi ±50 by loosening
the test nipples.
the low pressure jam nut and turning “in” on the
Set the telescope inner mid extend and outer mid extend and adjustment nut to increase or “out” to decrease the
retract as follows: pressure (see Figure 2-12). Stop Engine, with the hose
still capped, continue to Outer Mid Extend.
Inner Mid Extend
Outer Mid Extend
5. If the boom is installed, completely retract all sections
and boom lift down to below a horizontal boom angle 12. With the boom installed, fully extend the telescope
and disconnect the extend hose (the larger of the two) center mid section. If the boom is not installed, remove
running from port B, inner mid telescope section of the the Deutsch electrical connectors from the telescope
VG35 directional control valve to the cylinder port block two stage relief solenoid valve and the hose reel brake
at the back of the base section and cap adapter. solenoid both integral to the steer, swing and accessory
manifold (see Figure 2-9).
6. Install a pressure gauge into the disconnected hose
running to the directional control valve. 13. Supply power to the telescope two stage relief solenoid
valve by connecting the hose reel brake solenoid
7. Set the boom mode switches on the cab right hand
Deutsch electrical connector to it.
armrest to “Manual” and “IM”. Start engine and throttle

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HYDRAULIC SYSTEM RT890E SERVICE MANUAL

14. Start engine and throttle up to full RPM. Telescope (with to decrease so that a gauge pressure of 3000 psi ±50 is
boom installed) or attempt to telescope (without boom achieved (see Figure 2-13).
installed) the outer mid section OUT by feathering into
3. Stop engine. Remove diagnostic couplers and re-
the controller to full stroke. Adjust the two stage relief
valve to 3140 psi ±50 by loosening the high pressure connect plumbing.
jam nut and turning “in” on the adjusting nut to increase
or “out” to decrease the pressure (see Figure 2-12). Procedure D - Set Service Brake
Accumulator Charge Valve Limits - Check/
15. Stop engine, remove the pressure gauge and re-connect
the plumbing to the hose reel and all electrical
Adjust
connectors to their proper solenoids. 1. With the engine off, discharge all of the pressurized oil
stored in the accumulators by depressing the service
Center and Outer Mid Retract
brake pedal on the cab floor 4-6 times or until the pedal
16. With the boom installed, fully retract the boom or if the has no back pressure.
boom is not installed, disconnect the retract hose (the
2. Remove the cap from the tee at port A1 of the dual
smaller of the two) running from the port A, center mid
accumulator charging valve (see Figure 2-14) and install
and outer mid telescope section of the VG35 directional
a pressure gauge onto the uncapped tee port.
control valve to the hose reel at the hose reel.
3. Start engine and idle. The charging valve will
17. Install a pressure gauge into the disconnected hose
immediately start to charge the accumulators. Watch the
running to the VG35 directional control valve.
pressure gauge. The high charge limit pressure should
18. Set the boom mode switches on the cab right hand read 2320 psi +72, -145 when the pressure gauge stops
armrest to “manual” and “CM”. Start engine and throttle rising.
up to full RPM. Attempt to retract the telescope by

8
4. With the engine still running at idle, repeatedly depress
feathering into the controller to full controller stroke.
service brake pedal on the cab floor until the gauge
Adjust the work port relief valve “in” to increase or “out”
27
pressure reads 1950 psi ±145 and the dual accumulator
to decrease so that a gauge pressure reading of
charging valve starts to recharge. Once you have found
3461 psi ±50 is achieved (see Figure 2-11).
this, push the brake pedal again to recharge. Watch the
19. Stop engine. Remove the pressure gauge and re- pressure gauge. The low charging limit should be
2

connect the plumbing to the hose reel. 1950 psi ±145 when it starts to recharge. Replace the
valve if the pressures are not within the specified range.
23

Procedure B - Outrigger Pressures - Adjust 5. Stop engine. Remove diagnostic couplers and
1. Install a pressure check diagnostic quick disconnect with reconnect plumbing.
gauge onto test nipple at GP1 port of the outrigger
control manifold (see Figure 2-13). Procedure E - Accumulator Pre-Charge
2. Start engine and throttle up to full RPM. Select and
Pressure - Check
activate the outrigger “extend or retract” switch on the 1. With the engine off, discharge all of the pressurized oil
cab dash. Adjust the pressure reducing valve integrated stored in the accumulators by depressing the service
in the outrigger control manifold “in” to increase or “out” brake pedal on the cab floor 4-6 times or until the pedal
to decrease so that a gauge pressure of 2000 psi ±50 is has no back pressure. Remove the gas valve guard and
achieved (see Figure 2-13). cap on the accumulator (see Figure 2-15).
3. Stop engine. Remove the diagnostic coupler. 2. Before attaching the gas charging assembly onto the
gas valve, back the gas chuck “T” handle all the way out
Procedure C - Oil Cooler Motor Pressure - (counterclockwise).
Adjust 3. Close the charging assembly bleed valve. Attach the
1. With engine off, Install a pressure check diagnostic swivel nut onto the gas valve and tighten (10-15 lb-in).
coupler with gauge onto the diagnostic nipple at G8 port
4. Turn the gas chuck "T" handle all the way down
of the front steer, swing and accessory manifold (see
(clockwise) which will depress the core in the gas valve.
Figure 2-9).
5. Check the pre-charge pressure. It should be 1500 -
2. Start engine, throttle up to full RPM. Stroke lift, hoist or
1550 psi.
telescope controller by feathering into the controller to
full stroke. Adjust the pressure reducing valve integrated 6. If the pressure is 1500 - 1550 psi, remove the charging
in the outrigger control manifold “in” to increase or “out” valve assembly by turning the “T” handle all the way out

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RT890E SERVICE MANUAL HYDRAULIC SYSTEM

on the gas chuck and then opening the bleed valve (see Procedure H - Swing Work Port Pressure -
Figure 2-15). Check/Adjust
7. Secure the gas valve, loosen the swivel nut and remove
1. Install pressure check diagnostic quick disconnect with
the charging assembly. Replace the gas valve cap and
gauge onto test port at GP5 port of the front steer, swing
guard.
and accessory manifold (see Figure 2-9).
Procedure F - Pre-Charging the Accumulator 2. Start engine and throttle up to full RPM. With the swing
house lock engaged, swing right and hold. Adjust the 2
1. With the engine off, discharge all of the pressurized oil
work port relief “in” to increase or “out” to decrease so
stored in the accumulators by depressing the service
that a gauge pressure reading of 2400 - 2550 psi is
brake pedal on the cab floor 4-6 times or until the pedal
achieved (see Figure 2-9).
has no back pressure. Remove the gas valve guard and
cap on the accumulator (see Figure 2-15). 3. With house lock still engaged, swing left and hold. Adjust
the work port relief “in” to increase or “out” to decrease
2. Ensure that the nitrogen supply bottle is shut off, then
so that a gauge pressure reading of 2400 - 2550 psi is
attach the charging valve assembly to it.
achieved (see Figure 2-9).
3. Before attaching the charging assembly to the
4. Stop engine. Remove diagnostic couplers.
accumulator gas valve, back the gas chuck "T" handle
all the way out (counterclockwise). Procedure I - Swing Brake Release Pressure
4. Close the charging assembly bleed valve. Without - Check/Adjust
looping or twisting the hose, attach the swivel nut to the
accumulator gas valve and tighten (10-15 lb-in). 1. Install pressure check diagnostic quick disconnect with
gauge onto test port at GP3 port of the front steer, swing

8
5. Turn the gas chuck "T" handle all the way down and accessory manifold (see figure 2-8).
(clockwise) which will depress the core in the gas valve.
2. Start engine and idle, adjust the swing brake release
27
6. Crack the nitrogen bottle valve and slowly fill the pressure reducing valve “in” to increase or “out” to
accumulator. Shut off the valve when the pre-charge is decrease so that the gauge pressure of 250 - 300 psi is
1500 - 1550 psi. achieved (see Figure 2-9).
2

7. If the pre-charge pressure is higher than specified in 3. Stop engine. Remove diagnostic couplers.
step #6, close the nitrogen bottle valve and slowly open
23

the bleed valve on the charging assembly (see Procedure J - Controller Supply Pressure -
Figure 2-15) until the pressure is to specification. Check/Adjust
8. Remove the charging assembly by turning the "T" 1. Install pressure check diagnostic quick disconnect with
handle all the way out (counterclockwise) on the gas gauge onto test port at GP4 port of the front steer, swing
chuck and then open the bleed valve. and accessory manifold (see Figure 2-9).
9. Secure the gas valve, loosen the swivel nut and remove 2. Start engine and idle, lower left armrest, stroke the
the charging assembly. Replace the gas valve cap and joystick of any crane function enough to start movement
guard. of that function and adjust the controller pressure
reducing valve of the front steer, swing and accessory
Procedure G - Front Steer Pressure - Check/ manifold “in” to increase or “out” to decrease so that the
Adjust gauge pressure of 350 - 400 psi is achieved (see
1. Install pressure check diagnostic quick disconnect with Figure 2-9).
gauge onto test port at GP7 port of the front steer, swing 3. Stop engine. Remove diagnostic couplers.
and accessory manifold (see Figure 2-9).
2. Start engine and throttle up to full RPM. Fully turn the
Procedure K - Hose Reel Brake and Motor
steering wheel to left or right against the axle stop. Supply Pressure - Check/Adjust
Adjust the priority flow control relief valve in the front 1. Remove pressure switch from port PS1 of the front
steer, swing and accessory manifold (see Figure 2-9) by steer, swing and accessory manifold (see Figure 2-9)
removing the adapter and hose in the end of the and install a pressure gauge into the port.
cartridge to access the hex adjustment screw and adjust
“in” to increase or “out” to decrease so that a gauge 2. Start engine and idle, while telescoping, adjust the hose
pressure of 2600 psi ±50 is achieved. reel pressure reducing valve “in” to increase or “out” to

3. Stop engine. Remove diagnostic couplers.

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HYDRAULIC SYSTEM RT890E SERVICE MANUAL

decrease so that the gauge pressure of 1425 psi ±25 is 7. Stop engine. Remove the pressure gauge and
achieved (see Figure 2-9). reconnect the plumbing.
3. Stop engine. Remove gauge and re-connect plumbing. Procedure N - Cab Tilt Cylinder Extend/
Procedure L - Counterweight Removal Retract Pressure - Check
Cylinder Extend Pressure - Check 1. With the engine off, remove the hose running from the
cab tilt dual PO check valve "CA" port to the cylinder rod
1. With the engine off, and counterweight pinned,
port at the cylinder and cap or plug the adapter in the
disconnect the extend hoses from port "A" of the
cylinder.
counterweight removal directional control valve for both
left and right removal cylinders and cap or plug the 2. Install a pressure gauge onto the disconnected hose.
adapter in the cylinder port.
3. Start engine and idle. Attempt to lower the cab. Gauge
2. Remove the quick disconnect coupler body from the should read 2500 psi ±100. If not, replace the relief valve
hose and install a pressure gauge onto the hose. as they are non-adjustable.
3. Start engine idle. Attempt to lower the left counterweight 4. Stop engine. Remove the pressure gauge and
cylinder. Gauge should read 1000 psi ±100. If not, reconnect the plumbing.
replace the relief valve as they are non-adjustable (see
5. With the engine off, disconnect the hose running from
Figure 2-16).
the cab tilt dual PO check valve "CB" port to the cylinder
4. Repeat for right hand counterweight removal cylinder. piston port at the cylinder and cap or plug the adapter in
the cylinder.
5. Stop engine. Remove the pressure gauge and
reconnect the plumbing. 6. Install a pressure gauge onto the disconnected hose.

8
Procedure M - Counterweight Pin Cylinder 7. Start engine and idle. Attempt to raise the cab. Gauge
should read 2500 psi ±100. If not, replace the relief valve
27
Pressure - Check as they are non-adjustable.
1. With the engine off, remove the hose running from the 8. Stop engine. Remove the pressure gauge and
pin cylinder piston port to port "A" of the directional reconnect the plumbing.
2

control valve at the pin cylinder and cap or plug the

adapter in the cylinder port. Procedure O - Luffing Jib Lower Pressure -
23

2. Install a pressure gauge onto the disconnected hose. Check

3. Start engine idle. Attempt to extend pin. Gauge should 1. With the engine off, disconnect the hose running from
read 2500 psi ±100. If not, replace the relief valve as the directional control valve "B" port to the boom quick
they are non-adjustable. disconnect at the disconnect and cap or plug the
adapter.
4. Stop engine. Remove the pressure gauge and
reconnect the plumbing. 2. Install a pressure gauge onto the disconnected hose.
5. With the engine off, disconnect the hose running from 3. Start engine and idle. Attempt to raise the cab. Gauge
the pin cylinder rod tee adapter to port "B" of the should read 1450 psi ±100. If not, replace the relief valve
directional control valve at the cylinder tee. as they are non-adjustable (see Figure 2-16).
6. Start engine idle. Attempt to retract the pin. Gauge 4. Stop engine. Remove the pressure gauge and re-
should read 2500 psi ±100. If not, replace the relief valve connect the plumbing.
as they are non-adjustable (see Figure 2-16).

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RT890E SERVICE MANUAL HYDRAULIC SYSTEM

Front Steer, Swing and Accessory Manifold

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

8
5 6
3
27
2
8
2
23

PS1 GP4 SWB GP5

GP6
GP7
LS-AUX GP8

GP1

D5 STR-R
GP2

D1 SB GP3

4
7
7750

Front View As Facing T/T Side Plate

FIGURE 2-9

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HYDRAULIC SYSTEM RT890E SERVICE MANUAL

P1 Piston Pump

Item Description
1 Procedure A - Main Control Valve Pressure For Hoists, Boom Lift,
Telescope(s) - Check/Adjust - Step No. 3 (Maximum Pressure)

8
2 27
23

7748-02

FIGURE 2-10

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RT890E SERVICE MANUAL HYDRAULIC SYSTEM

Main Crane Function Manifold Valve

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

8
27
3
2
23

7402-3
6

FIGURE 2-11

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HYDRAULIC SYSTEM RT890E SERVICE MANUAL

Two-Stage Relief Valve Adjustment

1
Item Description
1 Procedure A - Main Control Valve Pressure
For Hoists, Boom Lift, Telescope(s) - Check/
Adjust - Step No. 14
2 Procedure A - Main Control Valve Pressure
For Hoists, Boom Lift, Telescope(s) - Check/
Adjust - Step No. 11
2

6385-4

FIGURE 2-12

Outrigger Control Manifold Valve

8
Item Description
27
3 Procedure B - Outrigger Pressures - Adjust - Step No. 1
& No. 3
4 Procedure B - Outrigger Pressures - Adjust - Step No. 2
2

5 Procedure C - Oil Cooler Motor Pressure - Adjust - Step

3
23

No. 2

6385-5

FIGURE 2-13

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RT890E SERVICE MANUAL HYDRAULIC SYSTEM

Service Brake Dual Accumulator Charge Valve

Item Description
1 Procedure D - Set Service Brake
Accumulator Charge Valve Limits - Check/
Adjust - Step No. 2
2
1

7752-02

FIGURE 2-14

8
Checking and Pre-Charging The Accumulator
27
1
Item Description
1 Gas Valve Guard 2
2

2 Gas Valve
23

6385-8

FIGURE 2-15

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HYDRAULIC SYSTEM RT890E SERVICE MANUAL

Counterweight Removal Valve Bank

Item Description
1 Non-Adjustable Port Relief Location

8
27 7776

1 1
FIGURE 2-16
2
23

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RT890E SERVICE MANUAL HYDRAULIC SYSTEM

VALVES locations pictorial. The description of each valve given here

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

Valve Name Circuit Used In Physical Location

Directional Control Valves Boom Lift/Telescope(s)/Hoist(s) Superstructure (Right Side Plate)
Counterweight Removal Between Superstructure Side Plates
Cab Tilt /Luffing Jib Between Superstructure Side Plates
Steering Control Valve Front Axle Steer Control Cab Steering Column
Front Steer/Swing/Accessory Manifold Front Axle Steer Supply Superstructure Right Side Plate
Swing Directional Control
Telescope Relief Control

8
Swing Brake Pressure
Controller Supply
27
Hose Reel Brake Control
Hose Reel Motor Supply
2
Steering Control Unit Front Axle Steer Cab Steering Column
Hydraulic Remote Controllers Boom Lift Cab Seat Arm Rests (2)
23

(HRC) Telescope (Floor) Cab Floor for Telescope with Optional

Main Hoist Aux Hoist
Auxiliary Hoist
Swing
Swing Power Brake Valve w/Treadle Swing Cab Floor
Pedal
Double PO Check Valve Cab Tilt Between Superstructure Side Plates
Tandem Brake Valve with Treadle Service Brakes Cab Floor
Dual Accumulator Charging Valve Service Brakes Superstructure inside Left Side Plate
Accumulator(s) Service Brake Superstructure Left Side
Holding Valves Boom Lift Lift Cylinder (Bolt on Manifold)
Telescope (3) Cylinder Port Blocks (Cartridge style)
Counterweight Removal (2) Cylinder Port Blocks (Cartridge style)
Axle Lockout, Rear Steer and Oil Axle Lockout Control Left Hand Carrier Frame Rail
Cooler Fan Motor Control Manifold Rear Steer Control
Oil Cooler Motor Control
Solenoid Valves:
Cross Axle Differential Lock Differential Lock (Optional) Carrier Inside Right Side Rail

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HYDRAULIC SYSTEM RT890E SERVICE MANUAL

Valve Name Circuit Used In Physical Location

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

8
2 27
23

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RT890E SERVICE MANUAL HYDRAULIC SYSTEM

Valve Installation

3 1

2
14

15

8
5
2
2 27
4
23

7
6

13

6339-01

SUPERSTRUCTURE

FIGURE 2-17

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HYDRAULIC SYSTEM RT890E SERVICE MANUAL

9 10

12
8 11
6338

CARRIER
FIGURE 2-17 continued

Item Description Item Description

1 Luffing Jib/Cab Tilt Directional Valve

8
9 Rear Steer/Axle Lockout/Fan Drive Valve
2 Cab Tilt Check Valve 10 Range Shift/Park Brake Manifold
27
3 Counterweight Removal Directional Valve 11 Differential Lock Valve
4 Telescope Rod Manifold Drain 12 Load Sense Dump Valve
2
5 Accumulator Brake Charge Valve 13 Two Speed Swing Valve
6 Directional Valve (Boom/Lift/Telescope(s)/ 14 Emergency Steer Accumulators (CE
23

Hoist(s)/Counterweight Removal/Cab Tilt/ Machines)

Luffing Jib)
15 Brake Accumulator
7 Swing/Steer/Brake Valve
8 Outrigger Manifold

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RT890E SERVICE MANUAL HYDRAULIC SYSTEM

DIRECTIONAL CONTROL VALVES 150 psi (1034.2 kPa/10.3 bar) resistance check valve located
in the front steer and accessory manifold providing make-up
Description oil to the swing motor for motor over-run when the valve is
centered. It receives oil from the fixed displacement gear
The directional control valves direct and control hydraulic oil pump No. 2 internally through the front steer and accessory
flow from the pumps to the boom lift and telescope cylinders, manifold and also returns oil internally through the front steer
each hoist motor, the swing motor, the counterweight and accessory manifold.
removal/cab tilt cylinders, and the front steer cylinders from
the steer control valve. The swing, front steer and accessory The counterweight removal directional control valve is a 2
directional control valve/manifold (see Figure 2-21), and the three section, manually actuated three position four way,
boom lift/telescope/hoist directional control valve (see pressure compensated, closed center directional valve. It is
Figure 2-19) are located on the outside of the right plumbed in parallel with the boom lift/telescope/hoist
superstructure side plate. The counterweight removal (see directional control valve and the luffing jib/cab directional
Figure 2-18) and the luffing jib/cab tilt directional control control valve. The first and second sections control the left
valve (see Figure 2-20) are located between the left and right and right removal cylinders, while the third section controls
superstructure side plates under the main hoist. Each valve the counterweight pin cylinder. The removal cylinder
bank is removed and installed as an assembly. sections have an integral port relief for retract and the pin
cylinder has integral port relief valves for both raise and
The boom lift/telescope/hoist and counterweight removal/ lower functions.
cab tilt directional control valve is a five section, hydraulic
remote pilot actuated with three position four way spools that The luffing jib/cab tilt directional control valve is a two
are pressure and flow compensated. It receives pump flow section, solenoid controlled three position four way, pressure
from hydraulic swivel port 6 and pump No. 1. compensated, closed center directional valve. It is plumbed
in parallel with the boom lift/telescope/hoist directional
The inlet section of the boom lift/telescope/hoist directional

8
control valve and the counterweight removal directional
control valve contains a 0.055 Ø orifice controlling the piston control valve. The first working section raises and lowers the
pump No. 1 differential or standby pressure at 275 psi (1896
27
luffing jib, while the second working section controls the cab
kPa/19 bar) and a 4300 psi (29647 kPa/296 bar) clipper relief tilt. The luffing jib section has an integral port relief valve for
valve that protects the piston pump (No. 1 pump) from raising the luffing jib.
transient pressure spikes. The telescope inner mid section
2
has integral port relief valves protecting extend and retract. Maintenance
The center mid/outer mid telescope section has a two-stage
23

port relief. When not pressurized, it is set to protect the Boom Lift/Telescope/Hoist Valve Bank Removal
center mid cylinder while extending. When pressurized, it is
1. Tag and disconnect all of the electrical connectors or
set to protect the outer mid cylinder. There is an integral port
manual control levers.
relief valve for both the center and outer mid sections
protecting cylinder retract. The boom lift section has an 2. Tag and disconnect the hydraulic lines from the valves.
integral port relief that thermally protects the retract side of Cap or plug the lines and ports.
the cylinder. All working sections have a two position three-
NOTE: The lift/telescope/hoist valve bank weighs
way solenoid RCL lockout valve in their pilot end cap except
approximately 181.6 lb (82.41 kg).
the boom lift up. Both telescope sections are solenoid
proportionally controlled and disabled by the RCL system’s 3. Remove the capscrews and washers securing the valve
lockout solenoid valves. When the hoist(s), boom lift or bank and remove the valve bank.
telescope spool is actuated, the signal line (load sense)
connecting the load to the pump is blocked by the shifting Boom Lift/Telescope/Hoist Valve Bank Installation
spool causing the pump to go to its full compensating setting. 1. Place the valve bank on the superstructure side plate
The individual working sections meter only the required flow and secure it with the capscrews and washers. Torque
of oil to the function @ full pump compensator setting. capscrews; refer to Fasteners and Torque Values, page
The swing directional control valve is a single cast iron 1-14 for proper torque value.
section bolted onto the front steer and accessory manifold. 2. Connect the hydraulic lines to the valves as tagged
Refer to Front Steer, Swing and Accessory Manifold. It is during removal.
located on the outside of the right turntable side plate. The
valve contains a three position four way open center design 3. Connect the electrical connectors and manual control
that is remote pilot operated. Both working ports have port levers as tagged during removal.
relief valves and anti-void check valves that are flooded by a

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HYDRAULIC SYSTEM RT890E SERVICE MANUAL

Counterweight Removal Valve Bank Removal Luffing Jib/Cab Tilt Valve Bank Installation
1. Tag and disconnect all of the electrical connectors or 1. Place the valve bank on the superstructure side plate
manual control levers. and fasten it with the capscrews and lockwashers.
Torque capscrews; refer to Fasteners and Torque
2. Tag and disconnect the hydraulic lines from the valves.
Values, page 1-14 for proper torque value.
Cap or plug the lines and ports.
2. Connect the hydraulic lines to the valves as tagged
NOTE: The counterweight removal valve bank weighs
during removal.
approximately 43.9 lb (16.4 kg).
3. Connect the electrical connectors to the valve as tagged
3. Remove the capscrews, lockwashers, flatwashers, and
during removal.
hex nuts securing the valve bank and remove the valve
bank. Functional Check (All Valve Banks)
Counterweight Removal Valve Bank Installation 1. Start the engine and run it at normal speed.
1. Place the valve bank on the superstructure side plate 2. Operate the control levers of the valve bank(s). Check
and secure it with the capscrews, lockwashers, for smooth operation of cylinders and motors.
flatwashers, and nuts. Torque capscrews; refer to
3. Check the valve bank(s) and lines for leakage. Make
Fasteners and Torque Values, page 1-14 for the proper
repairs as needed.
torque value.
2. Connect the hydraulic lines to the valves as tagged Function Check - RCL Lockout Valves
during removal. 1. Remove fuse F13 from the power panel in the cab. This
3. Connect the electrical connectors and manual control cuts off power to the RCL.

8
levers as tagged during removal. 2. Start the engine.
27
Luffing Jib/Cab Valve Bank Removal 3. Try to telescope the boom out, lower the boom, hoist up
the main hoist, and hoist the auxiliary hoist up (if
1. Tag and disconnect all of the electrical connectors or
installed). Verify none of these functions work.
manual control levers.
2
4. Shut down the engine. Reinstall fuse F13.
2. Tag and disconnect the hydraulic lines from the valves.
Cap or plug the lines and ports. 5. Telescope the boom out, lower the boom, hoist up the
23

main hoist, and hoist the auxiliary hoist up (if installed).

NOTE: The luffing jib/cab valve bank weighs
Verify all of these functions work.
approximately 25.9 lb (11.78 kg).
6. Check for leaks. Make repairs as needed.
3. Remove the capscrews and lockwashers securing the
valve bank and remove the valve bank.

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RT890E SERVICE MANUAL HYDRAULIC SYSTEM

Counterweight Removal Valve Bank

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

8
27
7

10
2
23

6387-2

12
8 9 10
11
7

3
2
4
1
5 6

1000 psi 1000 psi 2500 psi

6387-4
CWT Removal CWT Removal Pin

Valve Hydraulic Schematic

FIGURE 2-18

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HYDRAULIC SYSTEM RT890E SERVICE MANUAL

Boom Lift/Telescope/Hoist Valve Bank

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

25
19

26

14

8
17
15
27
22 21
3, 31
6
18 24 6365-1
4
2

Item Description Item Description

23

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

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RT890E SERVICE MANUAL HYDRAULIC SYSTEM

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

1
15
2
14

18

8
22 21 17 26
24 27 6365-3
27
Boom Lift/Telescope/Hoist Main Valve Hydraulic Schematic
2
23

FIGURE 2-19 continued

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HYDRAULIC SYSTEM RT890E SERVICE MANUAL

Luffing Jib/Cab Tilt Valve Bank

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

2 1

5 4

8
2 27
23

6
6385-9

6386-1 3

6
7 5 4

Luffing Jib Cab Tilt 6386-3

Valve Hydraulic Schematic

FIGURE 2-20

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RT890E SERVICE MANUAL HYDRAULIC SYSTEM

FRONT STEER/SWING/BRAKE MANIFOLD functions. It has a separate connection, before the 100 mesh
screen that supplies the service brake charge valve.
Description One pressure reducing valve and solenoid are used for the
The front steer, swing and brake manifold Figure 2-21 swing brake and brake release, one pressure reducing valve
houses cartridge components that control the front steer, feeds solenoids for the controllers and telescope two stage
pilot functions, swing brake release and the telescope hose relief, and one pressure reducing valve is used for the hose
r e e l . I t i s l o c a t e d o n t h e o u ts i d e o f t h e r i g h t h a n d
superstructure side plate under the removable valve cover.
reel motor and hose reel brake. The pump load sense and
(4) load sense shuttle checks are required to bring the pump 2
The manifold has two inlets, one for the piston pump No. 1 on and off stroke when the hose reel or telescope two stage
and one for the gear pump No. 2. The end opposite the bolt relief valve is selected and located in this manifold. All other
on swing directional valve houses the low pressure case pilot functions use the pump standby pressure to fully
drain that manifolds low pressure oil from swivel port 10, and operate at engine idle.
returns it to the tank. It is located on the outside of the right
hand superstructure side plate under the removable valve Maintenance
cover.
Removal
Oil from pump No. 2 enters the P2 inlet port from port 5 of the
1. Tag and disconnect all of the electrical connectors or
hydraulic swivel. The oil flows to the front steer flow control
manual control levers.
valve to a second flow control valve for the swing directional
valve which is bolted onto the front steer, swing and 2. Tag and disconnect the hydraulic lines from the valves.
accessory manifold. A main inlet relief protects pump No. 2. Cap or plug the lines and ports.
The front steer flow control valve is a load sense priority type
NOTE: The swing/steer/brake valve bank weighs
flow control valve. On a load sense signal from the cab
approximately 69.6 lb (31.6 kg).

8
steering control valve, the spool shifts, directing controlled
flow to the cab steering control unit. The load sense port 3. Remove the bolts and lockwashers securing the valve
27
maintains a constant 861.8 kPa/8.6 bar (125 psi) standby bank and remove the valve bank.
pressure. Any excess flow is directed to the swing section.
The circuit is protected by a load sense relief valve Installation
incorporated in this section. The second flow control valve is
2
1. Place the valve bank on the superstructure side plate
unloaded when the swing directional valve is in neutral. and fasten it with the capscrews and washers. Torque
When the swing is actuated, the valve delivers a maximum of
23

capscrews; refer to Fasteners and Torque Values, page

95 lpm (25 gpm). 1-14 for the proper torque value.
Pump No. 1 enters the P1 inlet through swivel port 7. The oil 2. Connect the hydraulic lines to the valves as tagged
flows first through a 100 mesh screen bad then supplies during removal.
three pressure reducing valves and five two position three
way solenoid valves in parallel for the pilot and hose reel 3. Connect the electrical connectors to the valve as tagged
during removal.

48

46 62
40

49

41

Top View 7392-4 47

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

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HYDRAULIC SYSTEM RT890E SERVICE MANUAL

53 26

54
32 56
55
38 6
31
52

30
45

44

5
57

8
11 23
34 15 29 33 4
28
27
27
7392-1

25
2
23

7 36 24
17 35
12

42 1
22
43

39

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

FIGURE 2-21 continued

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RT890E SERVICE MANUAL HYDRAULIC SYSTEM

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

11
5

56
58

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

8
41
60 27
2
23

Valve Hydraulic Schematic

FIGURE 2-21 continued

Item Description Item Description

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

GROVE Published 9-18-2014, Control # 308-06 2-43

HYDRAULIC SYSTEM RT890E SERVICE MANUAL

Item Description Item Description

23 SB - Swing Brake 43 LS-SWV - Load Sense Swing Valve
24 Drain - Front Steer Control Valve 44 LS-Aux - Auxiliary Load Sense
25 PA - Swing Pilot 45 OR2 - Orifice (ø.147) - Hose Reel Supply
26 PB - Swing Pilot 46 SH2 - Shuttle Valve - Hose Reel/Telescope
Relief Circuit
27 GP1 - Gauge Port 1 - Steer Inlet Pressure
47 SH3 - Shuttle Valve - Hose Reel/Telescope
28 GP2 - Gauge Port 2 - Steer Load Sense
Relief Circuit
Pressure
48 SV1 - Solenoid Valve - Telescope Two Stage
29 GP3- Gauge Port 3 - Swing Brake Foot Pedal
Relief
Inlet Pressure
49 SH1 - Shuttle Valve - Hose Reel/Telescope
30 GP4 - Gauge Port 4 - Joystick Supply
Relief Circuit
31 GP5 - Swing Valve Inlet Pressure
50 SV3 - Solenoid Valve - Joystick Supply
32 GP6 - Gauge Port 6 - Return Pressure from
51 SV2 - Solenoid Valve - Swing Brake Release
Gear Pump to cooler
52 PR3 - Pressure Reducing Valve (1200 psi) -
33 GP7 - Gauge Port 7 - Gear Pump Outlet to Steer/
Hose Reel Brake Release
Swing Valve
53 PR2 - Pressure Reducing Valve (350 psi) -
34 GP8 - Gauge Port 8 - Pressure From Jack

8
Joystick Supply
Manifold
54 PR1 - Pressure Reducing Valve (250 psi) -
27
35 LS-STR - Front Steer Control Load Sense
Swing Brake Release
36 SWV - Swing Valve
55 RV1 - Relief Valve (3000 psi) - Pump #2 - Inlet
37 BS - Brake Supply Relief
2

38 SWB - Swing Brake Release 56 CV1 - Check Valve - Swing

23

39 HBR - Hose Reel Brake Release 57 SH4 - Shuttle Valve - Hose Reel/Telescope
40 LS-B - Hose Reel Brake Load Sense Relief

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

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

2-44 Published 9-18-2014, Control # 308-06

RT890E SERVICE MANUAL HYDRAULIC SYSTEM

STEERING CONTROL VALVE 3. Remove the four mounting bolts and remove the valve
from the steering column.
Description
Installation
The load sense steering control unit (see Figure 2-22)
1. Secure the valve to the steering column and secure with
controls hydraulic flow to the front steering cylinders. It is
the four mounting bolts. Torque bolts; refer to Fasteners
located in the steering column of the cab.
and Torque Values, page 1-14 for proper torque value.
Both work ports are connected to the rod side of one steer
2. Connect the hydraulic hoses to the ports on the valve as
2
cylinder and to the piston side of the other steer cylinder.
tagged during removal.
Displacement of the valve is 35.9 in³ (588.2 cm³).
3. Connect the electrical connector to the valve as tagged
Maintenance during removal.
4. Verify proper operation of the valve.
Removal
5. Check valve and hydraulic connections for leaks. Make
1. Tag and disconnect the electrical connector to the valve. repairs as needed.
2. Tag and disconnect the hydraulic hoses from the valve.
Cap or plug the lines and ports.

1 2 1 3

8
2 27
23

5
4
3 5 4
Valve Hydraulic Schematic

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

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HYDRAULIC SYSTEM RT890E SERVICE MANUAL

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

8
When the armrests are up, the crane function switch is off, or
the operator leaves his seat, the controller lockout valve is 1. Disconnect the pedal linkage from the control valve by
removing the pin and cotter pin.
27
de-energized and the functions are disabled.

Dual Axis Controller 2. Tag and disconnect the hydraulic lines from the control
valve. Cap or plug the lines and ports.
The two hydraulic remote control valves Figure 2-24 are dual
2

function joystick type valves. One valve is located in each 3. Remove the four bolts and washers securing the control
armrest. The valve in the right armrest controls the main valve to the mounting bracket. Remove the valve.
23

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

2-46 Published 9-18-2014, Control # 308-06

RT890E SERVICE MANUAL HYDRAULIC SYSTEM

Single Axis Controller

NOTE: R.H. and L.H. controllers oriented from seated operator.
Ports of control lever seen facing aft looking at seat with armrest in up position.

4, 8, 12
1

7393-2

3, 7, 11 7393-1
5, 9

8
6, 10 2 27
AUX HOIST/
TELESCOPE
BOOM
2
SWING HOIST
23

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

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

FIGURE 2-23

Item Description Item Description

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

GROVE Published 9-18-2014, Control # 308-06 2-47

HYDRAULIC SYSTEM RT890E SERVICE MANUAL

Dual Axis Controller

Left Right Back Forward

2
1
6 4 5 3 6403-7

8
27 6403-4
1

4
6
2
23

6403-2
5

Item Description
1 Tank Port
2 Pump Port
3 Tele Out, Hoist Down, Aux Hoist Down
4 Swing Right, Boom Down
5 Tele In, Hoist Up, Aux Hoist Up
6 Swing Left, Boom Up

FIGURE 2-24

2-48 Published 9-18-2014, Control # 308-06

RT890E SERVICE MANUAL HYDRAULIC SYSTEM

Telescope Foot Controller

4 3 4 2

7766-01
1 2

7766-02
1 3

FIGURE 2-25

Item Description Item Description

1 Telescope In 3 Telescope Out

8
2 Pressure Port 27 4 Port To Tank
2
23

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HYDRAULIC SYSTEM RT890E SERVICE MANUAL

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

TREADLE PEDAL 2. Install the brake valve and secure in place with the three
bolts, flat washers, spring lockwashers, and nuts. Torque
Description bolts; refer to Fasteners and Torque Values, page 1-14
for proper torque value.
The swing power brake valve is used to provide hydraulic
pressure to the piston of the swing brake to apply the brake. 3. Attach the hydraulic lines to the brake valve as tagged
The valve receives its supply of oil from the front steer and during removal.
accessory manifold. Depressing the brake pedal causes
hydraulic oil to flow to the top of the brake piston where, Function Check
combined with spring tension, the total force overcomes the 1. Start the engine and let it idle.
brake release pressure and applies the brake. When the
valve is released, excess hydraulic oil flows from the valve to 2. Disengage the swing lock.
the case drain manifold and back to the reservoir (see 3. Slowly swing the turntable.
Figure 2-26).

Maintenance
Removal DANGER
Engage the swing lock before adjusting the swing brake
1. Tag and disconnect hydraulic lines attached to the brake
valve.
valve. Cap or plug the lines and ports.
2. Remove the three bolts, spring lockwashers, flat 4. Test the valve by engaging the swing brake control valve
washers, and nuts which secure the brake valve to the and operating the swing brake. Verify the swing brake

8
cab floor. Remove the brake valve. works when the pedal is pressed. Verify the brake is off
when the pedal is not pressed. Engage the swing lock
27
Installation and make adjustments to the pedal as needed.
5. Check for leaks. Make repairs as needed.
2

DANGER
23

Engage the swing lock before installing the swing brake

valve.

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

3 2 3
1 2 FIGURE 2-26

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RT890E SERVICE MANUAL HYDRAULIC SYSTEM

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

1 2
3, 4
NV1 V1
SV2

NV1

SV1

8
27
3, 4 SV2
5 SV1
2
6392-1 V2
2
23

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

Maintenance Installation

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

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HYDRAULIC SYSTEM RT890E SERVICE MANUAL

CAB TILT DOUBLE PILOT OPERATED 1. Tag and disconnect the hydraulic lines running to the
CHECK VALVE valve. Cap or plug all openings.
2. Remove the capscrews and lockwashers securing the
Description valve to the plate and remove the valve.
The cab tilt double pilot operated (PO) check valve is located Installation
on the horizontal plate between the superstructure side
plates, forward of the telescope hose reel. It is used to hold 1. Install the valve to the plate and secure with the
or lock the cab tilt cylinder in place. Oil flow is directed from capscrews and lockwashers. Torque capscrews; refer to
the “V” ports to the “C” ports, while blocking flow in the Fasteners and Torque Values, page 1-14 for the proper
opposite direction. Flow is reversed from “C” to “V” when torque value.
pressure pilot oil is applied to the opposite side “V” port (see 2. Connect the hydraulic lines to the valve as tagged during
Figure 2-28). removal.
Maintenance 3. Operate the applicable function and check the valve for
proper operation and any leaks.
Removal
4. Test the check valve by operating the cab tilt cylinder.
Verify it extends and retracts without problems; verify
CAUTION there is no leaking. Make repairs as needed.
Completely lower the cab before disconnecting valve
plumbing.

8
27
Item Description 1 5 3

1 Port CA - To Cab Tilt Cylinder

2 Port CB - To Cab Tilt Cylinder
2

3 Port VA - Cab Tilt Valve

23

4 Port VB - Cab Tilt valve

5 CV1 - Check Valve A ports
6 CV2 - Check Valve B ports

2
1

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

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RT890E SERVICE MANUAL HYDRAULIC SYSTEM

TANDEM BRAKE VALVE WITH TREADLE The tandem brake valve consists of a tandem valve body, a
PEDAL closed center spool, a treadle pedal, an integral proximity
switch and a mechanical spring assembly to limit the output
Description pressure to the brake actuators to [1500 psi ±75 (10,342 kPa
±517)].
The tandem brake valve with treadle pedal is located on the
floor of the cab. The tandem brake valve provides split Maintenance
system braking for the primary (front) brakes and the
Removal
2
secondary (rear) brakes.
The valve is a closed center spool design which modulates 1. Tag and disconnect the electrical connector to the valve.
the output pressure [1500 psi ±75 (10,342 kPa ±517)] to the 2. Tag and disconnect the hydraulic hoses from the valve.
brake actuators. The valve is mechanically actuated by a Cap or plug the lines and ports.
treadle pedal (see Figure 2-29). The direct acting spool
provides a pedal feel which accurately represents the brake 3. Remove the nuts and bolts securing the valve to the cab
pressure, similar to automotive style pedal feedback as the Floor. Remove the valve.
brake pedal pressure increases, the pedal effort increases
Installation
proportionally. As the pedal is initially actuated, the tank ports
are closed off from the brake ports. With further application of 1. Secure the valve to the cab floor with the nuts and bolts.
the pedal, the pressure ports are opened to the brake ports
until the pedal actuation force and the hydraulic pressure 2. Connect the hydraulic hoses to the ports on the valve as
force are balanced. tagged during removal.

Also when the pedal is actuated, the integral proximity switch 3. Connect the electrical connector to the valve as tagged
is engaged to provide an electrical signal for brake lights. during removal.

8
When the pedal is released, the valve and the pedal return to 4. Start the engine and check valve and hoses for leaks.
27
the non-applied position. Make repairs as needed.
2
23

3 5

1 2

Valve Hydraulic Schematic

4
Item Description 2
5
1 Port B1
2 Port B2
3 Pressure Port P1 3 1 7716-03

4 Tank
5 Pressure Port P2
FIGURE 2-29

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HYDRAULIC SYSTEM RT890E SERVICE MANUAL

DUAL ACCUMULATOR CHARGE VALVE Maintenance

Description Removal

The load sensing dual accumulator charging valve is located 1. Tag and disconnect the hydraulic hoses from the valve.
on the inside of the left superstructure side plate. The Cap or plug the lines and ports.
purpose of the valve is to provide pressure regulation to the 2. Remove the three bolts, washers, and lockwashers
service brake circuit. securing the valve to the turntable. Remove the valve.
The dual accumulator charge valve consists of a flow divider
Installation
spool, cut-in/cut-out spool, check valve and two sequence
valves (see Figure 2-30). 1. Position the valve on the superstructure with ports A1,
A2, and B3 facing up and secure with three bolts,
When used with a fixed displacement pump, the flow divider
washers, and lockwashers. Torque bolts.
spool shifts to ensure priority flow to the accumulators until
the cut-out pressure is obtained. The balance of the flow 2. Connect the hydraulic hoses to the valve ports as tagged
exits the valve through the auxiliary port (A) to tank. When during removal.
used with a LS piston pump, the LS port is connected to the
3. Start the engine and check for leaks. Make repairs as
pump when the accumulator pressure reaches the cut-in
needed.
setting [1950 psi (13.4 MPa)]. The pump will deliver the
required charge flow to charge the accumulators. When the 4. Depress the brake pedal several times to cause the
cut-out setting [2320 psi (16.0 MPa)] is reached, the cut-in/ brake valve to charge. Make several turns with the
cut-out spool shifts to vent the LS line to tank. The sequence steering wheel, and swing the superstructure left and
valves isolate the two accumulators. If one of the right. Verify the brakes, swing, and front steering work
accumulator loses pressure, the other accumulator will properly.

8
continue to charge and provide flow to the brake circuit when
required.
2 27
23

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RT890E SERVICE MANUAL HYDRAULIC SYSTEM

3
2
4

8
7752-02
27
7752-01
2
23

These ports plugged

6 Item Description
1
1 Load Sense Port
2 Tank Port
3 Pressure Port
2
4 Accumulator Port 1A
5 Accumulator Port 2A
6 Pressure Switch
7752-03

5 4

Valve Hydraulic Schematic

FIGURE 2-30

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HYDRAULIC SYSTEM RT890E SERVICE MANUAL

HYDRAULIC ACCUMULATOR SERVICE Maintenance

BRAKE
Removal
Description 1. With the engine shutdown, deplete the hydraulic
pressure in the accumulators by depressing the service
The service brake hydraulic accumulators are located on the
brake pedal several times.
outside of the left superstructure side plate behind the cab.
The purpose of each accumulator is to provide stored 2. Tag and disconnect the hydraulic hose from the
energy, an oil volume of 2.8 l (.75 gal) at a maximum accumulator. Cap or plug the line and port.
pressure of 2320 psi (15,996 kPa/159.9 bar), to actuate the
3. Remove the two nuts securing each clamp half. Remove
service brake circuits. The dual accumulator charge valve
each clamp half and accumulator from the turntable.
regulates flow to the hydraulic accumulators to provide fully
powered independently separate, primary (front) and Installation
secondary (rear), service brake circuits.
1. Position the accumulator in the clamps and secure with
Each accumulator has two chambers divided by a piston. the removable clamp halves and nuts.
One side is pre-charged to 1500 psi (10,342 kPa) with high
purity nitrogen. This maintains a constant pressure in the 2. Connect the hydraulic hose to the port on the
other chamber which is connected to the modulating brake accumulator as tagged during removal.
valve. After the accumulators are fully charged, they will 3. Pre-charge the accumulator. Refer to Procedure F - Pre-
provide the necessary brake system flow and pressure to Charging the Accumulator, page 2-23.
actuate the brakes.
4. Start the engine and check accumulator and hoses for
The accumulator consists of a tube, piston, seals, gas leaks. Make repairs as needed.
charging valve, and a gas valve guard.

8
5. Depress the brake pedal several times, make several
turns with the steering wheel, and swing the
27
superstructure left and right. Verify the brakes, swing,
and front steering work properly.

Servicing
2

The pre-charge nitrogen pressure should be checked every

23

200 hours or once a month, whichever comes first. Refer to

Pressure Setting Procedures in this section.

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RT890E SERVICE MANUAL HYDRAULIC SYSTEM

HOLDING VALVES Removal

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

The holding valve provides meter out control, will lock the 3. Lubricate the holding valve and o-rings with clean
cylinder in place, prevent a load from running ahead of the oil hydraulic oil.
supply, and will relieve excess pressure caused by thermal
expansion.
CAUTION
Maintenance Do not damage the o-rings during installation of the
holding valve. If the holding valve turns freely then gets
hard to turn, then easy to turn, remove the holding valve
and check the o-rings. They have probably been
damaged by a sharp edge of a port.
DANGER
Boom must be fully lowered and fully retracted before NOTE: The holding valve should turn by hand until
removing lift cylinder and telescope cylinder holding compression of the o-rings begins.
valves. The counterweight must be removed or pinned

8
before removing counterweight removal cylinder holding 4. Carefully install the holding valve into the port block or
valves. manifold until fully seated.
27
5. Test the holding valve and port block or manifold by
operating the lift cylinder and/or the telescope cylinder,
as applicable. Verify lift cylinder and/or telescope
2

cylinder works without problems; verify there is no

leaking. Make repairs as needed.
23

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HYDRAULIC SYSTEM RT890E SERVICE MANUAL

CROSS AXLE DIFFERENTIAL LOCK VALVE Maintenance

Description Removal

The cross axle differential lock valve (Figure 2-31) is 1. Tag and disconnect the electrical connector from the
mounted off the carrier bulkhead plate forward of the engine. valve.
The valve is a four-way, two position solenoid valve. The 2. Tag and disconnect the hydraulic lines attached to the
valve is used to control the application of the crane’s valve. Cap or plug lines and ports.
hydraulically applied and released cross axle differential lock
actuators. 3. Remove the two bolts and washers securing the valve to
the frame. Remove the valve.
The axle differential lock switch is a spring loaded, two-
position momentary switch. Positioning the cab Axle Diff Installation
Switch to LOCK shifts the four-way, two-position solenoid
1. Secure the valve to the frame with the two bolts and
valve so hydraulic oil can flow to the engage port of the cross
washers. Torque bolts; refer to Fasteners and Torque
axle differential lock actuators, extending them. When the
Values, page 1-14 for proper torque value.
actuators extend, they engage the splines on the differential
case and the axle shafts to lock the differential assemblies 2. Connect the hydraulic lines to the valve as tagged during
together. removal.
Positioning the cab Axle Diff Switch to UNLOCK shifts the 3. Connect the electrical connector to the valve as tagged
three-way, two-position solenoid valve so hydraulic oil can during removal.
flow to the disengage port of the actuators, retracting them.
4. Apply and release the cross axle differential lock several
As the actuators retract, they unlock the axles.
times. Verify the cross axle differential lock holds the

8
axle from moving when applied so there is no differential
action between the wheels.
27
5. Check for leaks. Make repairs as needed.
2
23

3
1

2 2
3

7395-1
7395-2 1 FIGURE 2-31

Item Description Item Description

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

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RT890E SERVICE MANUAL HYDRAULIC SYSTEM

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

The outrigger control manifold reduces the pressure Inspection

supplied to the front steer accessories manifold and
Visually inspect the valves and hydraulic connections for any
directionally controls the outrigger circuit. The valve is
evidence of leaks or other damage. Check security of the
mounted from the bottom of the frame rail in front of the oil
cooler.
electrical connections. Inspect the wiring for any evidence of 2
cracks or breaks.
The inlet of the manifold has a bolt on block that houses two
pressure reducing valves. One reduces the internal outrigger Installation
pressure to 2000 psi (13,789 kPa) and the other reduces the 1. Position the manifold on the mounting bracket and
system pressure to 3000 psi (20,684 kPa) for an external secure with the bolts, flatwashers and spring
port feeding the front steer accessories manifold and the rear lockwashers. Torque bolts; refer to Fasteners and
steer/fan drive axle lockout manifold. Torque Values, page 1-14 for proper torque value.
The outrigger control consists of four (two for extend and two 2. Connect the electrical connectors to the solenoids as
for retract), two position two-way solenoid control valves, marked during removal.
internally connected in parallel and two pilot operated check
valves with integral thermal relief valves set at 300 psi 3. Connect the hydraulic lines to the valves as marked
(2068 kPa) for the retract circuit and 3000 psi (20,684 kPa) during removal.
for the extend circuit (see Figure 2-32). The manifold also
Functional Check
includes eight (four front and four rear) normally closed two
position two-way solenoid valves. When energized, the 1. Start engine and run at medium speed.

8
solenoid shifts the spool to open allowing extension or
2. Operate the outriggers and check for smooth operation
retraction of the outrigger cylinders.
27
of the cylinder(s).
Maintenance
Removal
2

1. Tag and disconnect the electrical connectors or manual

23

control levers.
2. Tag and disconnect the hydraulic lines to the solenoid
valves; cap all lines and openings.

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HYDRAULIC SYSTEM RT890E SERVICE MANUAL

34
33
32
31

21
22

27
28

6 29 4 22
30 21
33
7 34
35 36
8
24
9
23 16
17 3 15 14
18
1 19 20 5
S80029392-1 20 19
10
11
12
13

8
2 27
5 30 32 S80029392-3
3 13 29 12 31
11 10
23

25

26
24 21

23 22

20
35 36
2 33 34 17 3
4 6 7 8 9 16 18
19

80029392-1
Hydraulic Schematic
14 1 15

FIGURE 2-32

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RT890E SERVICE MANUAL HYDRAULIC SYSTEM

Item Description Item Description

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

8
16 Gauge Port 1 34 Solenoid Valve SV8 - Right Rear Extension
27
17 Gauge Port 2
18 Gauge Port 3
2
23

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HYDRAULIC SYSTEM RT890E SERVICE MANUAL

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

8
27
Item Description
1 Port C - Cylinder
2

2 Port P - Pilot 1
23

3 Port V - Valve

6155 FIGURE 2-33

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RT890E SERVICE MANUAL HYDRAULIC SYSTEM

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

The oil cooler motor is controlled by two position three-way 3. Remove the capscrews and washers securing the valve
solenoid cartridge valves and is limited to 3.5 gpm (13.3 lpm) to the frame bracket. Remove the valve.
by a pressure compensated flow control valve located Installation
between the two position three-way solenoid and the port to

8
the cooler motor (see Figure 2-34). 1. Secure the valve to the frame bracket with the washers
and capscrews. Torque capscrews; refer to Fasteners
The rear axle lockout hydraulic circuit consists of a pressure
27
and Torque Values, page 1-14 for proper torque value.
reducing valve, set to 500 psi (3447 kPa), that supplies oil to
two normally closed, two position, two-way cartridge 2. Connect the hydraulic hoses to the ports on the valve as
solenoid valves. The two solenoid valves keep the lockout tagged during removal.
2
cylinders from oscillating unless the turntable is centered 3. Connect the electrical connectors to the valve as tagged
forward. Included in the rear axle lockout system is an angle during removal.
23

encoder located in the top of the electrical slip ring assembly.

The encoder sends a message to the RCL, which converts 4. Verify operation as follows:
the message to a positional angle of the superstructure
• Operate the rear steer left and right to verify smooth
relative to the carrier (slew angle). If the slew angle is within
operation.
±2° of directly over the front, the RCL sends a CAN bus
message to the Crane Control System to allow axle • On outriggers, swing over the front outriggers to ensure
oscillation. Upon receiving this message, the Crane Control the oscillation cylinders lockout.
System will switch on a digital output, thus energizing and
• Remove the electrical connection from the oil cooler
opening the rear axle lockout solenoids. This allows
motor two position three-way solenoid valve to verify
hydraulic oil in and out of the cylinders allowing them to
that it operation.
oscillate. If the slew angle is greater that 2° left or right of
directly over front, the Crane Control system switches off the 5. Check valve and hoses for leaks. Make repairs as
digital output, thus de-energizing and closing the rear axle needed.
lockout solenoids. This isolates the lockout cylinders from oil

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HYDRAULIC SYSTEM RT890E SERVICE MANUAL

NOTE: Models without axle lockout do not have solenoid

SV1 and SV2 installed on the manifold

19

16

14

13

17

8
12
27
10 6371-1

11
2
23

9
15 7

3
18

2
4

20 6371-3

5 8
FIGURE 2-34

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RT890E SERVICE MANUAL HYDRAULIC SYSTEM

13 19
14 18
2

17 12

8
27 6371-2

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

FIGURE 2-34 continued

23

Item Description Item Description

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

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HYDRAULIC SYSTEM RT890E SERVICE MANUAL

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

8
2 27
23

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RT890E SERVICE MANUAL HYDRAULIC SYSTEM

RANGE SHIFT/PARKING BRAKE VALVE Maintenance

Description Removal
The range shift/parking brake valve Figure 2-35 controls the 1. Tag and disconnect the electrical connectors to the
flow of oil to the parking brake, hi-low range and axle valve.
disconnect actuators by the use of two solenoid valves. The
2. Tag and disconnect the hydraulic hoses from the valve.
valve is located on the center of the frame. Pressure is
supplied to the valve from the transmission charge pump. Cap or plug the lines and ports. 2
The parking brake solenoid valve is a two position three-way 3. Remove the capscrews, lockwashers and nuts securing
valve. In its de-energized position, the inlet port is blocked the valve to the frame. Remove the valve.
and the parking brake actuator is drained to the reservoir.
When the solenoid is energized, the reservoir port is blocked Installation
and pressurized oil is directed to the actuator, engaging the 1. Secure the valve to the frame with the nuts, flatwashers,
parking brake. lockwashers and capscrews. Torque capscrews; refer to
The range shift solenoid valve is a two position four-way Fasteners and Torque Values, page 1-14 for proper
valve. In its de-energized position, pressurized oil flows to torque value.
the “A” port of the range shift actuator, while the “B” port is 2. Connect the hydraulic hoses to the ports on the valve as
drained to the reservoir along with the axle disconnect tagged during removal.
actuator for two wheel drive/high range. When the solenoid
is energized, pressurized oil is directed to the “B” port of the 3. Connect the electrical connectors to the valve as tagged
range shift actuator and the axle disconnect actuator while during removal.
port “A” of the range shift actuator is drained to the reservoir

8
for four wheel drive/low range. Functional Tests
27
1. Start and idle engine.
2. With units on outriggers, check for proper two/four wheel
operation.
2

7
8 5 3 4
23

7 6 6

1
2
6697-2

Item Description
2 6697-1
1 Port P - Pressure
5
1
2 Port T - Tank 3

3 Port A - Range Shift Actuator

4
4 Port B - Range Shift Actuator
5 Port PB - To Park Brake
6 Solenoid Valve - Range Shift
7 Solenoid Valve - Park Brake
8 Pressure Switch
FIGURE 2-35

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HYDRAULIC SYSTEM RT890E SERVICE MANUAL

LOAD SENSE DUMP VALVE Installation

1. Secure the valve to the frame rail with the washers,
Description spring washers and capscrews. Torque capscrews; refer
The Load Sense Dump Valve prevents Pump No. 1 from to Fasteners and Torque Values, page 1-14 for proper
coming on stroke during engine start. It is activated by the torque value.
Ignition Key Switch during the starting mode. This ensures 2. Connect the hydraulic hoses to the ports on the valve as
the engine does not attempt to start against a load in the tagged during removal.
event the accumulators are charging or the fan motor is
activated. 3. Connect the electrical connectors to the valve as tagged
during removal.
The Load Sense Dump Valve consists of a solenoid actuated
two position two-way valve that is normally open and Functional Tests
deenergized during normal crane operation (Figure 2-36). In
this valve position the load sense circuit to the pump is 1. Remove the electrical connector from the solenoid on
complete, allowing any load sense signal (pressure) from an the Load Sense Dump Valve. Using a multimeter set to
actuated function to stroke the pump to its full compensating measure voltage, probe the connector.
pressure of 4000 psi (27.6 MPa). Only during engine 2. Turn the Ignition Switch to START and crank the engine;
cranking (ignition switch in the START position) does the verify 12 V is measured only when engine is cranking
solenoid become energized, shifting the valve to a closed (Ignition Switch in the START position).
position and directing any load sense signal (pressure) to the
reservoir, thereby preventing the pump from stroking and 3. Turn off engine.
building pressure over its standby pressure of 4. Install the electrical connector onto the solenoid.
350 (2.41 MPa).
5. Install a pressure check diagnostic quick disconnect with

8
Maintenance gauge onto the test port at the inlet tube of the Boom Lift/
27 Telescope/Hoist Valve Bank (see Figure 2-11).
Removal
6. With the engine off, discharge all of the pressurized oil
1. Tag and disconnect the electrical connectors to the stored in the accumulators by depressing the Service
valve. Brake Pedal on the cab floor 4-6 times or until the pedal
2

has no back pressure.

2. Tag and disconnect the hydraulic hoses from the valve.
23

Cap or plug all openings. 7. Turn the Ignition Switch to START and crank the engine
while observing the pressure gauge; during engine
3. Remove the capscrews, spring washers, and washers
cranking (ignition switch in the START position), a
securing the valve to the frame rail. Remove the valve.
pressure reading of 350 psi (2.41 MPa) should be
observed.
8. Turn off engine. Remove the diagnostic coupler.

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2
1 3
1

2 2

7768-01
7768-02

Hydraulic Schematic

8
Item Description
27
1 LS-PUMP Port - To Pump No. 1
2 DRAIN Port - To Reservoir
3 LS-IN Port - Load Sense In To Manifold
2

FIGURE 2-36
23

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HYDRAULIC SYSTEM RT890E SERVICE MANUAL

CYLINDERS Maintenance
General General

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

Table 2-4
Wear Ring Gap

Head (or Piston) Size Wear Ring Gap

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

8
Surface Protection for Cylinder Rods 1. Extend the rod to its maximum stroke. Remove the
27
retract hose from the cylinder. Cap the retract hose.
Steel cylinder rods include a thin layer of chrome plating on
their surfaces to protect them from corroding. However,
chrome plating inherently has cracks in its structure which
2
can allow moisture to corrode the underlying steel. At typical
DANGER
ambient temperatures, hydraulic oil is too thick to penetrate
23

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

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RT890E SERVICE MANUAL HYDRAULIC SYSTEM

Temperature Effects on Hydraulic Cylinders of thermal contraction or “slip stick”, it is recommended that
the telescope control lever is activated periodically in the
Hydraulic oil expands when heated and contracts when
extend position to mitigate the effects of the cooling oil.
cooled. This is a natural phenomena that happens to all
liquids. The coefficient of expansion for API Group 1 If a load and the boom is allowed to remain stationary for a
hydraulic oil is approximately 0.00043 cubic inches per cubic period of time and the ambient temperature is cooler than the
inch of volume for 1°F of temperature change. Thermal trapped oil temperature, the trapped oil in the cylinders will
contraction will allow a cylinder to retract as the
hydraulic fluid which is trapped in the cylinder cools.
cool. The load will lower as the telescope cylinder(s) retracts
allowing the boom to come in. Also, the boom angle will 2
The change in the length of a cylinder is proportional to the decrease as the lift cylinder(s) retracts causing an increase
extended length of the cylinder and to the change in in radius and a decrease in load height.
temperature of the oil in the cylinder. For example, a cylinder
This situation will also occur in reverse. If a crane is set up in
extended 25 feet in which the oil cools 60°F would retract
the morning with cool oil and the daytime ambient
approximately 7 3/4 inches (see chart below). A cylinder
temperature heats the oil, the cylinders will extend in similar
extended 5 feet in which the oil cools 60°F would only retract
proportions.
approximately 1 1/2 inches. The rate at which the oil cools
depends on many factors and will be more noticeable with a The charts below (Table 2-5 and Table 2-6) have been
larger difference in oil temperature verses the ambient prepared to assist you in determining the approximate
temperature. amount of retraction/extension that may be expected from a
hydraulic cylinder as a result of change in the temperature of
NOTE: Boom telescope cylinder must be fully retracted
the hydraulic oil inside the cylinder. The charts are for dry rod
before lifting boom angle to 35° and checking oil
cylinders. If the cylinder rod is filled with hydraulic oil, the
and pressure.
contraction rate is somewhat greater.
Thermal contraction coupled with improper or inadequate

8
NOTE: Operators and service personnel must be aware
lubrication or improper wear pad adjustments and operation
that load movement, as a result of this phenomena,
at low boom angles may, under certain conditions, cause a
27
can be easily mistaken as leaking cylinder seals or
“stick-slip” condition in the boom. This “stick-slip” condition
faulty holding valves. If leaking seals or faulty
could result in the load not moving smoothly. Proper boom
holding valves are suspected to be the problem,
lubrication and wear pad adjustment is important to permit
refer to Service Bulletin 98-036 dealing with testing
2
the boom sections to slide freely. Slow movement, of the
telescope cylinders.
boom may be undetected by the operator unless a load is
23

suspended for a long period of time. To minimize the effects

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HYDRAULIC SYSTEM RT890E SERVICE MANUAL

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

BOOM DRIFT CHART (Cylinder length change in inches)

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

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

Temperature Effects on Hydraulic Cylinders

8
27 FIGURE 2-37

Table 2-6
Boom Drift Chart (Cylinder length change in millimeters)
2
Coeff. = 0.000774 (1/ °C)
STROKE Temperature Change (°C)
23

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

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

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RT890E SERVICE MANUAL HYDRAULIC SYSTEM

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

8
holding valve and remove the holding valve from the 2. Inspect the barrel carefully for scoring. If barrel is
cylinder barrel. scored, it must be repaired or replaced.
27
3. Remove the two socket head cap screws securing the 3. Check piston for damage. If piston is damaged,
head retainer ring to the head. determine if it can be repaired or must be replaced.
4. Inspect rod for straightness. Determine if it can be
2
4. Using a spanner wrench or chain wrench, unscrew the
head retainer ring from the barrel. straightened or must be replaced.
23

CAUTION
DANGER Before installing new seals and rings, clean all surfaces
Do not use air pressure to remove the rod. Use only a and carefully remove burrs and nicks. Parts displaying
source of controlled hydraulic oil pressure if the rod is excessive wear or damage should be replaced.
hard to move.
5. Stone out minor blemishes and polish with a fine crocus
CAUTION cloth.
Exercise extreme care when handling or setting down the
rod. Damage to the rod surface may cause unnecessary 6. Clean with solvent and dry with compressed air any
maintenance and expense. parts that have been stoned and polished.

Assembly
5. Remove the rod and attached parts from the barrel.
NOTE: Cover the barrel opening to avoid contamination.
CAUTION
When installing new seals and rings, avoid stretching
CAUTION seals or scratching the grooved or gland surfaces. Make
When removing seals and rings, avoid scratching the sure parts are clean before and during assembly. Make
grooved and gland surfaces. sure seals and rings are installed in the proper order.

6. Remove the two hydrolock seals from the outside of the NOTE: Lubricate seals and rings with clean hydraulic oil.
piston.

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HYDRAULIC SYSTEM RT890E SERVICE MANUAL

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

20

1 25 23
24

9
10
8
3
22

8
13
14
11
27
6
4
15
12 17
2
23

16

7397 FIGURE 2-38

Item Description Item Description

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

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

2. Install two new threaded inserts into head. 12. Install new gasket material to the cylinder head retainer
ring flange as follows.
3. Install the replacement wear ring, buffer seal, deep Z rod
seal, backup ring, and wiper ring in the inside of the a. Clean the barrel and retainer ring with Loctite
head. Make sure the buffer seal’s step is closer to the cleaning solvent 7070 or similar non-chlorinated
deep Z rod seal. Make sure the deep Z rod seal’s rim solvent.
groove is closer to the buffer seal. b. Apply a light coating of Loctite primer N7649 to both
4. Install the replacement o-ring and the backup ring on the surfaces. Allow primer to dry for one to two minutes.
outside of the head. Primer must be dry. Mating of parts should occur
within five minutes.
5. Install the replacement T-Seal in the inside of the piston.
c. Apply gasket material Loctite Master Gasket 518 to

8
6. Lubricate the rod with clean hydraulic oil. one surface. Partial cure is obtained in four hours,
with full cure in 48 hours.
7. Slide the head, wiper ring end first, onto the rod.
27
13. Screw the head retainer ring into the barrel and align
8. Screw the piston onto the rod tightly. Secure the piston
holes in retainer ring with holes in head. Install two
with the setscrew.
socket head capscrews. Torque the capscrews 44 to 48
2
lb-ft (59.6 to 65.0 Nm).
Hydrolock Piston Seals
14. Using a spanner wrench or chain wrench, continue to
23

screw the retainer ring/head into place in the barrel.

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

15. Position the holding valve on the cylinder barrel and

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

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HYDRAULIC SYSTEM RT890E SERVICE MANUAL

DUAL ROD TELESCOPE CYLINDER

Description CAUTION
When removing seals and rings, avoid scratching
The boom dual rod telescope cylinder (upper telescope grooved and gland surfaces.
cylinder) Figure 2-40 has a 8.25 in (20.9 cm) bore. The
cylinder is internally ported (rod ported). Oil from the
NOTE: Aligning discarded seals and rings in the order of
telescope control valve is routed to the cylinder by external
disassembly will facilitate installation of new seals
lines. Foreign material is prevented from entering the
and rings.
cylinder rod during retraction by a wiper seal in the head. O-
ring seals prevent internal and external leakage. 3. Remove the hydrolock piston seal to gain access to the
setscrew securing the piston to the outer cylinder rod.
The retracted length of the telescope cylinder is 389.64 in
(989.6 cm). The cylinder incorporates two cylinder rods 4. Remove the setscrew and unscrew the piston from the
therefore each rod has a separate stroke. One rod has a cylinder rod.
stroke of 313.19 in (795.5 cm), and one rod has a stroke of
5. Remove the remaining hydrolock seal and guide lock
316.62 in (804.2 cm), which provides a combined overall
seal from the outside of the piston and the o-ring and two
stroke of 629.81 in (1599.7 cm). This gives the cylinder an
backup rings from the inside of the piston.
overall extended length of 1019.45 in (2589.4 cm) from the
end of the cylinder barrel to the center of the attachment 6. Remove the spacer from the rod and remove the wear
fittings on the cylinder rod. ring from the spacer.
7. Remove the cylinder head from the outer rod.
CAUTION 8. Remove the o-ring and backup ring from the outside of

8
Do not retract the cylinder completely if it is not attached the head and the wear ring, buffer seal, deep Z rod seal,
to the boom. Maintain a spacer that is split or hinged 6.88” backup ring and the wiper ring from the inside of the
27
long to prevent cylinder from retracting completely. head.
9. Using a spanner wrench, unscrew the inner cylinder
The cylinder weighs approximately 3562 pounds (1616 kg) head from the outer cylinder rod.
2
wet.

Maintenance
23

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

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29
30 31

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

16
37
38 41
41

10

11 38
13

8
10
12
13
27
9 1
14
15 3
2

4
23

5
24 4
2
6
25 6 7
8

7398
23
18
FIGURE 2-40

Item Description Item Description

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

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HYDRAULIC SYSTEM RT890E SERVICE MANUAL

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

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

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

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

8
34 Wiper Ring
35 Backup Ring
27
36 Retaining Ring
37 Counterbalance Valve
2

38 Plug
23

39 Seal
40 Capscrew
41 Adapter 6294

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

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

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

CAUTION Hydrolock Piston Seals

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

10. Lubricate the inner cylinder rod assembly with clean

hydraulic oil and install the rod assembly into the outer
cylinder rod with a slight twisting motion.

8
11. Using a spanner wrench, secure the inner cylinder head
27
to the outer cylinder rod.
12. Install the wiper ring into the outer cylinder head.
FIGURE 2-44
13. Install the wear rings into the head.
2

19. Install the hydrolock seals onto the piston Figure 2-44.
23

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

20. Lubricate the outer cylinder rod assembly with clean

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

FIGURE 2-43

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

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HYDRAULIC SYSTEM RT890E SERVICE MANUAL

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

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

Inspection
The cylinder weighs 1770 lb (803 kg).
1. Clean all parts with solvent and dry with compressed air.

8
Maintenance Inspect all parts for serviceability.
27
Disassembly
NOTE: Replace all cylinder seals and o-rings with new
CAUTION
ones anytime the cylinder is disassembled. Clean all surfaces and remove all burrs and nicks.
2
Replace all damaged or worn parts.
1. Using a chain wrench, unscrew the retaining ring and
head from the cylinder barrel.
23

2. Stone out minor blemishes and polish with fine crocus

cloth.
3. Clean with solvent and dry with compressed air parts
that have been stoned and polished.
DANGER
Do not use air pressure to remove the cylinder rod. Use 4. Inspect the barrel for scoring.
only controlled hydraulic pressure.
Assembly
Do not damage the cylinder rod chrome surface.
1. If removed, install the holding valve. Refer to VALVES in
2. Remove the cylinder rod assembly from the cylinder this section.
barrel and cover the barrel to avoid contamination.

CAUTION
CAUTION Do not scratch the grooved and gland surfaces or
Do not scratch the grooved and gland surfaces. damage the seals and o-rings.

NOTE: Align old seals in order of removal to facilitate NOTE: Lubricate new seals and rings with clean hydraulic
installation of new seals. oil. Orient wear ring gaps 180° apart.
2. Install the wiper ring, wear ring, buffer seal, backup ring
and rod seal on the inside of the head.

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12
13

17 14
15
18
20
16 2
11

10
22

21

24
19
4
5
4

8
23 27 3 1

9
2
8 2
23

7387
FIGURE 2-45

Item Description Item Description

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

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HYDRAULIC SYSTEM RT890E SERVICE MANUAL

Hydrolock Piston Seals

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

3. Install the o-ring and backup ring onto the outside of the CAUTION
head. Do not scratch the grooved and gland surfaces or
4. Install the cylinder head onto the cylinder rod. damage the seals and o-rings.
5. Install the spacer onto the cylinder rod. 10. Clean all oil from the threads of the cylinder head and
apply Loctite #290 to the threads.
CAUTION 11. Lubricate the piston seals and cylinder head o-ring with
clean hydraulic oil and install the rod assembly into the

8
Improper seal installation could cause faulty cylinder
operation. cylinder barrel with a slight twisting motion.
27
12. Using a chain wrench, secure the cylinder head to the
6. Install the o-ring and backup rings into the inside of the cylinder barrel.
piston.
2
NOTE: Use a new self-locking soft-tip setscrew.
7. Screw the piston onto cylinder rod and secure with a DANGER
23

new setscrew.
Do not use air pressure to cycle the cylinder. Use only
8. Install the guide lock rings and hydrolock seals onto the controlled hydraulic pressure.
outside of the piston.
13. Pressurize and cycle the cylinder with hydraulic oil
pressure. Test the cylinder at 5250 psi (36,199 kPa/362
bar). Check for proper operation and any leakage. Make
repairs as needed.

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

A wiper ring prevents foreign material from entering each 9. Remove the lip seals and wear rings from the outside of
cylinder. O-rings and other seals prevent internal and the piston.
external leakage.
NOTE: Arranging discarded seals and rings in the order of
The cylinder weighs approximately 85.5 lb (38.8 kg). disassembly will aid in installation of new seals and
rings. Pay attention to how each seal and ring is
Maintenance installed to avoid installing replacement seals and
rings improperly.
Disassembly
10. Remove the head from the rod. Remove the o-ring and
NOTE: Any maintenance requiring disassembly of the backup ring from the outside of the head. Remove the
cylinder should include replacement of all cylinder wear ring, buffer seal, lip seal and wiper ring from the
seals. inside of the head.

8
1. Clean away all dirt from the head. Place protective
Inspection
padding around the rod near the head to prevent
27
damaging the chrome. Using a spanner wrench, 1. Inspect the rod. There should be no scratches or pits
unscrew the head from the barrel. deep enough to catch the fingernail. Pits that go to the
base metal are unacceptable. Chrome should be
2

present over the entire surface of the rod. If lack of

DANGER chrome on rod, the rod should be replaced.
23

Do not use air pressure to remove the rod. Use only a

2. Inspect rod for straightness. Determine if it can be
source of controlled hydraulic oil pressure if the rod is
straightened or must be replaced.
hard to remove.
CAUTION 3. Inspect the head. Visually inspect the inside bore for
scratching or polishing. Deep scratches are
Exercise extreme care when handling or setting down the
unacceptable. Polishing indicates uneven loading, and
rod. Do not damage the chrome surface.
the bore should be checked for out-of-roundness.
2. Open both ports on the side of the cylinder barrel and 4. Inspect the piston. Visually inspect the outside surface
drain the oil from the cylinder. for scratches or polishing, Deep scratches are
unacceptable. Polishing indicates uneven loading, and
3. Secure cylinder barrel in a chain vise without putting
the diameter should be checked for out-of roundness.
pressure on the side feeder tube preferably in the
vertical position with the rod assembly up. 5. Inspect the barrel carefully for scoring. If barrel is
scored, it must be repaired or replaced.
4. Using a screwdriver, or 1/4 inch wrench, remove the
screw from the head. 6. Thoroughly rinse parts, allow to drain, and wipe with a
lint-free rag. Inspect all parts for serviceability.
5. Remove the grease fitting from the rod
6. Turn the head counterclockwise with a fitted spanner
wrench until the threads disengage. CAUTION
NOTE: Residual oil will spill over the end of the barrel Before installing new seals and rings, clean all surfaces
wh en th e rod as se mbly is ex te nde d. Mak e and carefully remove burrs and nicks. Parts displaying
provisions to contain the oil. excessive wear or damage should be replaced.

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HYDRAULIC SYSTEM RT890E SERVICE MANUAL

14
17

17
13

4
1 5
2

15
6

8
2 27
8
23

12
9
10
11

6731
3
16

FIGURE 2-48

Item Description Item Description

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

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RT890E SERVICE MANUAL HYDRAULIC SYSTEM

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

cloth.
CAUTION
8. Clean with solvent and dry with compressed air any
parts that have been stoned and polished. Exercise extreme care when handling the rod. Damage to
the rod surface may cause unnecessary maintenance
Assembly and expense. Also, take care to avoid damaging grooved
or gland surfaces or rings or seals during rod insertion.
2
CAUTION 7. With a hoist, raise the rod assembly back into a vertical
When installing new seals and rings, avoid stretching position taking care not to damage the OD seals on the
seals or scratching the grooved or gland surfaces. Make head and piston.
sure parts are clean before and during assembly. Make 8. Lubricate the OD seals on the piston and head with
sure seals and rings are installed in the proper order. clean light oil and lower the assembly into the barrel.
Stop just before the head enters the barrel.
NOTE: Lubricate seals and rings with clean hydraulic oil.
9. Place a spanner wrench on the head and turn
1. Install the replacement wiper ring, lip seal, buffer seal counterclockwise until the thread clicks, then reverse
and wear ring in the inside of the head. direction to clockwise and thread in until there is no gap
2. Install the replacement O-rings and backup ring on the between the head shoulder and top of barrel.
outside of the head. 10. Install the setscrew into the head.
3. Install the lip seals and wear rings onto the outside of the
piston.
CAUTION

8
4. Lubricate the rod with clean hydraulic oil. Do not use air pressure to cycle or pressurize the cylinder.
27
5. Slide the head, onto the rod. Tap the head with a rubber
mallet to engage the seals. Push the head about half 11. Pressurize and cycle the cylinder with hydraulic oil
way down the length of the rod assembly. pressure. Test the cylinder at 3750 psi (25,856 kPa/259
bar). Check for proper operation and any leakage. Make
2
6. Remove the cover from the barrel. repairs as needed.
23

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HYDRAULIC SYSTEM RT890E SERVICE MANUAL

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

NOTE: Any maintenance requiring disassembly of the 11. Remove the wear ring, buffer seal, rod seal and wiper
cylinder should include replacement of all cylinder ring from the inside of the head.
seals.
Inspection

8
1. Clean away all dirt from the head. Place protective
1. Inspect the rod. There should be no scratches or pits
padding around the rod near the head to prevent
deep enough to catch the fingernail. Pits that go to the
27
damaging the chrome. Using a spanner wrench,
base metal are unacceptable. Chrome should be
unscrew the head from the barrel.
present over the entire surface of the rod. If lack of
chrome on rod, the rod should be replaced.
2

2. Inspect rod for straightness. Determine if it can be

DANGER straightened or must be replaced.
23

Do not use air pressure to remove the rod. Use only a 3. Inspect the head. Visually inspect the inside bore for
source of controlled hydraulic oil pressure if the rod is scratching or polishing. Deep scratches are
hard to remove. unacceptable. Polishing indicates uneven loading, and
CAUTION the bore should be checked for out-of-roundness.
Exercise extreme care when handling or setting down the 4. Inspect the piston. Visually inspect the outside surface
rod. Do not damage the chrome surface. for scratches or polishing, Deep scratches are
unacceptable. Polishing indicates uneven loading, and
2. Drain the oil from the cylinder. the diameter should be checked for out-of roundness.
3. Secure cylinder barrel in a vise. 5. Inspect the barrel carefully for scoring. If barrel is
4. Remove the grease fitting from the rod scored, it must be repaired or replaced.

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

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

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

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RT890E SERVICE MANUAL HYDRAULIC SYSTEM

7
6

3 2
11

5
10
9
8

12
4
14

13

8
15 1
27
16 7097 13
2

14
FIGURE 2-49
23

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

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

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HYDRAULIC SYSTEM RT890E SERVICE MANUAL

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

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

8
2 27
23

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RT890E SERVICE MANUAL HYDRAULIC SYSTEM

STEER CYLINDER installed to avoid installing replacement seals and

rings improperly.
Description 4. Remove the nut from the rod.
The steer cylinders Figure 2-50 are mounted on the axles, 5. Unscrew the piston from the rod.
two cylinders on each axle. The front and rear steer cylinders
each have 3.5 in (8.89 cm) diameter bores. The front and 6. Remove the o-ring from the inside of the piston.
rear steer cylinders each have a retracted length of 26 in
(66.0 cm) from bushing center to bushing center. The front
7. Remove the head and spacer from the rod. 2
and rear steer cylinders each have an extended length of 8. Remove the o-ring and the backup ring from the outside
37.5 in (95.25 cm) from bushing center to bushing center. of the head.
Each cylinder has a stroke of 11.50 in (29.21 cm). 9. Remove the wiper ring and rod seal from the inside of
A wiper ring prevents foreign material from entering each the head.
cylinder. O-rings and other seals prevent internal and
external leakage. Inspection
The cylinder weighs approximately 44 lb (20 kg). 1. Clean all parts with solvent and dry with compressed air.
Inspect all parts for serviceability.
Maintenance
2. Inspect the barrel carefully for scoring. If barrel is
scored, it must be repaired or replaced.
Disassembly
3. Check piston for damage. If piston is damaged,
NOTE: Any maintenance requiring disassembly of the determine if it can be repaired or must be replaced.
cylinders should include replacement of all seals

8
and rings. A seal kit will supply the required items. 4. Inspect rod for straightness. Determine if it can be
straightened or must be replaced.
1. Using a spanner wrench, unscrew the cylinder head.
27
CAUTION
Before installing new seals and rings, clean all surfaces
DANGER
2
and carefully remove burrs and nicks. Parts displaying
To prevent serious injury, do not use air pressure to excessive wear or damage should be replaced.
23

remove the rod. Use only a source of controlled hydraulic

oil pressure if the rod is hard to move. 5. Stone out minor blemishes and polish with a fine crocus
cloth.
6. Clean with solvent and dry with compressed air any
CAUTION parts that have been stoned and polished.
Exercise extreme care when handling or setting down the
rod. Damage to the rod surface may cause unnecessary Assembly
maintenance and expense.

2. Remove rod and attached parts from the barrel. CAUTION

When installing new seals and rings, avoid stretching
NOTE: Cover the barrel opening to avoid contamination. seals or scratching the grooved or gland surfaces. Make
sure parts are clean before and during assembly. Make
CAUTION sure seals and rings are installed in the proper order.
When removing seals and rings, avoid scratching
grooved and gland surfaces. NOTE: Lubricate seals and rings with clean hydraulic oil.
1. Install the replacement wiper ring in the head.
3. Remove the wear ring and piston seal from the outside
of the piston. 2. Install the rod seal in the inside of the head.

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

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HYDRAULIC SYSTEM RT890E SERVICE MANUAL

4
6
10
7
11
5
8

8
27
12
13

3
2
23

14, 15

7405

FIGURE 2-50

Item Description Item Description

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

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RT890E SERVICE MANUAL HYDRAULIC SYSTEM

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

2. Inspect rod for straightness. Determine if it can be 8. Install the seal and wear ring on outside of the piston.
straightened or must be replaced. 9. Lubricate all parts freely with clean hydraulic oil.
3. Inspect the head. Visually inspect the inside bore for
scratching or polishing. Deep scratches are CAUTION
unacceptable. Polishing indicates uneven loading, and
Exercise extreme care when handling the rod. Damage to
the bore should be checked for out-of-roundness.
the rod surface may cause unnecessary maintenance
4. Inspect the piston. Visually inspect the outside surface and expense. Also, take care to avoid damaging grooved
for scratches or polishing, Deep scratches are or gland surfaces or rings or seals during rod insertion.
unacceptable. Polishing indicates uneven loading, and

8
the diameter should be checked for out-of roundness. 10. Remove the cover from the barrel. Insert the rod and
attached parts into the barrel with a slight twisting
5. Inspect the barrel carefully for scoring, scratches and
27
motion.
pits. There should be no scratches or pits deep enough
to catch the fingernail. If barrel is scored, it must be 11. Using a spanner wrench, tighten the head into the
repaired or replaced. barrel.
2

6. Thoroughly rinse parts, allow to drain, and wipe with a

CAUTION
23

lint-free rag. Inspect all parts for serviceability.

Do not use air pressure to cycle or pressurize the cylinder.
Assembly
12. Pressurize and cycle the cylinder with hydraulic oil
pressure. Static test the cylinder at 4000 psi (27,579
CAUTION kPa/275.7 bar). Check for proper operation and any
When installing new seals and rings, avoid stretching leakage. Make repairs as needed.
seals or scratching the grooved or gland surfaces. Make
sure parts are clean before and during assembly. Make
sure seals and rings are installed in the proper order.

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HYDRAULIC SYSTEM RT890E SERVICE MANUAL

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

6. Remove the piston, spacer and head from the rod.
Description
7. Remove the o-ring and the backup ring from the outside
The four extension cylinders Figure 2-51 have 2.5 in (63.5 of the head.
mm) diameter bores. Each cylinder has a retracted length of
93.88±12 in (238.4 cm ± 30.4) from the center of the rod 8. Remove the rod seal, wear ring and wiper ring from the
bushing to the center of the barrel bushing. Each cylinder’s inside of the head.
extended length is 175.88 in (446.7 cm). The stroke of each 9. Remove the o-ring from the rod.
cylinder is 82 in (208.2 cm).
A wiper ring prevents foreign material from entering each Inspection
cylinder. O-rings and other seals prevent internal and
1. Clean all parts with solvent and dry with compressed air.
external leakage.
Inspect all parts for serviceability.
The cylinder weighs approximately 100.3 lb (45.5 kg).
2. Inspect the barrel carefully for scoring. If barrel is
scored, it must be repaired or replaced.
Maintenance
3. Check rod’s piston area for damage. If it is damaged,
Disassembly determine if it can be repaired or must be replaced.
NOTE: Any maintenance requiring disassembly of the 4. Inspect rod for straightness. Determine if it can be
cylinders should include replacement of all seals straightened or must be replaced.
and rings. A seal kit will supply the required items.
1. Remove all dirt, grease and other contaminants from

8
around the ports and the head CAUTION
Before installing new seals and rings, clean all surfaces
27
and carefully remove burrs and nicks. Parts displaying
excessive wear or damage should be replaced.
DANGER
5. Stone out minor blemishes and polish with a fine crocus
2
Do not use air pressure to remove the rod. Use only a
cloth.
source of controlled hydraulic oil pressure if the rod is
23

hard to move. 6. Clean with solvent and dry with compressed air any
CAUTION parts that have been stoned and polished.
Exercise extreme care when handling or setting down the Assembly
rod. Damage to the rod surface may cause unnecessary
maintenance and expense.
CAUTION
2. Using a spanner wrench, unscrew the cylinder head.
When installing new seals and rings, avoid stretching
3. Remove rod and attached parts from the barrel. seals or scratching the grooved or gland surfaces. Make
sure parts are clean before and during assembly. Make
NOTE: Cover the barrel opening to avoid contamination.
sure seals and rings are installed in the proper order.

NOTE: Lubricate seals and rings with clean hydraulic oil.

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

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15

6 1

8
8 5
2 27
10
23

14
11
12

13
7073

4
FIGURE 2-51

Item Description Item Description

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

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HYDRAULIC SYSTEM RT890E SERVICE MANUAL

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

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

8
2 27
23

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RT890E SERVICE MANUAL HYDRAULIC SYSTEM

OUTRIGGER JACK CYLINDER on a workbench taking care not to damage the surface
of the rod.
Description 6. Cover the open end of the barrel.
The four outrigger jack cylinders Figure 2-52 each have a 7. Secure the rod assembly using the pinholes. Do not use
hollow rod for internal porting. Each cylinder has a 5.5 in a clamp on the rod working surface.
(13.9 cm) diameter bore. A port block is welded to the rod of
each cylinder and a pilot operated check valve is threaded
into each port block. The retracted length of the cylinder from
8. Using an Allen wrench, remove the setscrew from the
piston. The piston seal must be removed to access the 2
the end of the barrel to the center of the rod’s port block rod setscrew.
bushing is 50.62 ±12 in (128.5 ±30.8 cm). The extended
length of the cylinder from the end of the barrel to the center 9. Turn the piston counterclockwise with a fitted spanner
of the rod’s port block rod bushing is 78.62 ±12 in (199.6 cm). wrench to remove.
Its stroke is 28 in (71.1 cm). 10. Remove the spacer and head from the rod by hand.
A wiper ring prevents foreign material from entering the
cylinder. O-rings and other seals prevent internal and
external leakage. CAUTION
When removing seals and rings, avoid scratching the
The cylinder weighs approximately 228.8 lb (103.8 kg). grooved and gland surfaces.
Maintenance
NOTE: Arranging discarded seals and rings in the order of
Disassembly disassembly will aid in installation of new seals and
rings. Pay attention to how each seal and ring is
NOTE: Any maintenance requiring disassembly of the installed to avoid installing replacement seals and

8
cylinders should include replacement of all seals rings improperly.
and rings. A seal kit will supply the required items.
27
11. Remove the o-ring and backup rings from the inside of
1. Open ports and drain the oil from the cylinder. the piston and the seals from the outside of the piston.
12. Remove the o-ring and backup ring from the outside of
2
the head and the wear rings, seals and wiper ring from
DANGER the inside of the head.
23

Do not use air pressure to remove the rod. Use only a Inspection
source of controlled hydraulic oil pressure if the rod is
hard to move. 1. Inspect the rod. There should be no scratches or pits
deep enough to catch the fingernail. Pits that go to the
CAUTION base metal are unacceptable. Chrome should be
Exercise extreme care when handling or setting down the present over the entire surface of the rod. If lack of
rod. Damage to the rod surface may cause unnecessary chrome on rod, the rod should be replaced.
maintenance and expense.
2. Inspect rod for straightness. Determine if it can be
2. Secure cylinder barrel in a chain vise preferably in the straightened or must be replaced.
vertical position with the rod assembly at chest level. 3. Inspect the head. Visually inspect the inside bore for
NOTE: Oil or oil/air mixture may rapidly exit out of the ports scratching or polishing. Deep scratches are
during extension. Shield the work area from the unacceptable. Polishing indicates uneven loading, and
exiting oil. the bore should be checked for out-of-roundness.

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

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HYDRAULIC SYSTEM RT890E SERVICE MANUAL

19
18
19
4
17
17
5
8

15
14

8
27 16

3
13
2

12
11
23

2
9
6
10 7389 FIGURE 2-52

Item Description Item Description

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

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RT890E SERVICE MANUAL HYDRAULIC SYSTEM

6. Thoroughly rinse parts, allow to drain, and wipe with a 11. Lubricate the ID of the head seals with clean light oil and
lint-free rag. Inspect all parts for serviceability. slide the head onto the rod. The head will need to be
tapped on with a rubber mallet to engage the seals.
7. Flush the barrel and fluid tube. Drain and wipe dry with a
Push the head about hal way down the length of the rod.
lint-free cloth. Compressed air may be used to blow out
barrel port. 12. Install the spacer onto the rod with the ID lip at the piston
end.
8. Inspect the bore of barrel for nicks, gouges or scratches.
Replace barrel assembly if any of these conditions exist. 13. Lubricate the ID piston seals with clean light oil and 2
thread the piston clockwise onto the rod assembly with
the spanner wrench until it bottoms out.
CAUTION
14. Install the setscrew with an Allen wrench until hand tight.
Before installing new seals and rings, clean all surfaces Seat the piston seal bottom ring into the groove.
and carefully remove burrs and nicks. Parts displaying
excessive wear or damage should be replaced. 15. With the hoist, raise the rod assembly into a vertical
position taking care not to damage the OD seals on the
Assembly head and piston.
16. Lubricate the OD seals on the piston and head with
clean light oil and lower the assembly into the barrel.
CAUTION Stop just before the head enters the barrel.
When installing new seals and rings, avoid stretching
seals or scratching the grooved or gland surfaces. Make 17. Place the spanner wrench on the head and turn
sure parts are clean before and during assembly. Make counterclockwise while applying light downward force
sure seals and rings are installed in the proper order. until threads engage. Continue turning counterclockwise

8
until the thread clicks, the reverse direction to clockwise
NOTE: Lubricate seals and rings with clean hydraulic oil. and thread in until there is no gap between the head
27
shoulder and the top of the barrel.
NOTE: Leave access to the setscrew hole on the piston by
only partially installing the bottom ring of the piston 18. Instal the setscrew with an Allen wrench until hand tight.
seal into the groove leaving the gap in the ring at 19. Slowly lower the rod down to the fully retracted position.
2

the hole location.

NOTE: Oil or oil/air mixture may rapidly exit out of the ports
23

9. Install the wear rings, seals and wiper ring in the inside during extension. Shield the work area from the
of the head and the o-ring and backup ring on the exiting oil.
outside of the head.
20. Pressurize and cycle the cylinder with hydraulic oil
10. Install the o-ring and backup rings in the inside of the pressure. Static pressure test the cylinder at 4500 psi
piston and the seals on the outside of the piston. (31,026.4 kPa/310.2 bar) in both directions. Check for
proper operation and any leakage. Make repairs as
needed.

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HYDRAULIC SYSTEM RT890E SERVICE MANUAL

CAB TILT CYLINDER

Description CAUTION
When removing seals and rings, avoid scratching the
The cab tilt cylinder Figure 2-53 has a 2.50 in (6.35 cm) grooved and gland surfaces.
diameter bores. The retracted length of each cylinder is
20.94 in (53.1cm) from the center of the rod bushing to the
7. Remove the seal from the outside of the piston.
center of the barrel bushing. The extended length of each
cylinder from the center of the rod bushing to the center of NOTE: Arranging discarded seals and rings in the order of
the barrel bushing is 29.1 in (73.9 cm). Its stroke is 8.25 in disassembly will aid in installation of new seals and
(20.9 cm). rings. Pay attention to how each seal and ring is
installed to avoid installing replacement seals and
A wiper ring prevents foreign material from entering each
rings improperly.
cylinder. O-rings and other seals prevent internal and
external leakage. 8. Loosen and remove the nut securing the piston.
Remove the piston from the rod.
The cylinder weighs approximately 19.9 lb-ft (9.07 kg).
9. Remove the o-ring from the inside of the piston.
Maintenance
10. Remove the head from the rod. Remove the o-ring and
Disassembly backup ring from the outside of the head.

NOTE: Any maintenance requiring disassembly of the 11. Remove the wiper ring and the rod seal from the inside
cylinders should include replacement of all seals of the head.
and rings. A seal kit will supply the required items.
Inspection

8
1. Secure the cylinder in a clean work area by use of
1. Clean all parts with solvent and dry with compressed air.
clamps or a chain vise to prevent rolling.
27
Inspect for damaged or worn parts and replace as
2. Retract the cylinder fully to avoid damaging the rod required.
during removal.
2
NOTE: Mark or note the piston and head relationship to the CAUTION
rod and barrel.
Clean all surfaces and remove all burrs and nicks before
23

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

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8
6 9
5
4
3

8
11
27
10
2
23

6722

FIGURE 2-53

Item Description Item Description

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

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HYDRAULIC SYSTEM RT890E SERVICE MANUAL

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

8
2 27
23

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RT890E SERVICE MANUAL HYDRAULIC SYSTEM

COUNTERWEIGHT REMOVAL CYLINDER 5. Remove the wear ring from the outside of the piston to
gain access to the setscrew.
Description NOTE: Arranging discarded seals and rings in the order of
The counterweight removal cylinder (Figure 2-54) 3.0 in disassembly will aid in installation of new seals and
(7.62 cm) diameter bore. The retracted length of the cylinder rings. Pay attention to how each seal and ring is
is 9.25 in (23.4 cm) from the center of the rod bushing to the installed to avoid installing replacement seals and
center of the barrel bushing. The extended length of the
cylinder is 34.25 in (86.9 cm). The stroke of the cylinder is 25
rings improperly.
2
6. Loosen the piston’s setscrew. Remove the piston from
in (63.5 cm). the rod.
A wiper ring prevents foreign material from entering each 7. Remove the other wear ring and seal from the outside of
cylinder. O-rings and other seals prevent internal and the piston.
external leakage.
8. Remove the o-ring from the inside of the piston.
The cylinder weighs approximately 93.9 lb (42.63 kg).
9. Remove the head and spacer from the rod.
Maintenance 10. Remove the o-ring and backup ring from the outside of
Disassembly the head. Remove the o-ring, seal and wiper ring from
the inside of the head.
1. Remove the capscrews and washers securing the
cylinder in the cylinder assembly tube. Inspection
NOTE: Any maintenance requiring disassembly of the 1. Inspect the rod. There should be no scratches or pits
cylinders should include replacement of all seals deep enough to catch the fingernail. Pits that go to the

8
and rings. A seal kit will supply the required items. base metal are unacceptable. Chrome should be
present over the entire surface of the rod. If lack of
27
2. Remove the counterbalance valves from the port block. chrome on rod, the rod should be replaced.
3. Clean away all dirt from the head. Place protective 2. Inspect rod for straightness. Determine if it can be
padding around the rod near the head to prevent straightened or must be replaced.
2
damaging the chrome during head removal. Using a
spanner wrench, unscrew the head from the barrel. 3. Inspect the head. Visually inspect the inside bore for
23

scratching or polishing. Deep scratches are

unacceptable. Polishing indicates uneven loading, and
the bore should be checked for out-of-roundness.
DANGER 4. Inspect the piston. Visually inspect the outside surface
Do not use air pressure to remove the rod. Use only a for scratches or polishing, Deep scratches are
source of controlled hydraulic oil pressure if the rod is unacceptable. Polishing indicates uneven loading, and
hard to move. the diameter should be checked for out-of roundness.
CAUTION 5. Inspect the barrel carefully for scoring. If barrel is
Exercise extreme care when handling or setting down the scored, it must be repaired or replaced.
rod. Damage to the rod surface may cause unnecessary
6. Thoroughly rinse parts, allow to drain, and wipe with a
maintenance and expense.
lint-free rag. Inspect all parts for serviceability.
4. Rapidly pull the rod against the head to free it. Remove
rod and attached parts from the barrel.
CAUTION
NOTE: Cover the barrel opening to avoid contamination. Before installing new seals and rings, clean all surfaces
and carefully remove burrs and nicks. Parts displaying
excessive wear or damage should be replaced.
CAUTION
When removing seals and rings, avoid scratching the 7. Stone out minor blemishes and polish with a fine crocus
grooved and gland surfaces. cloth.
8. Clean with solvent and dry with compressed air any
parts that have been stoned and polished.

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HYDRAULIC SYSTEM RT890E SERVICE MANUAL

16

7 3
5
8
4 12
7
11 15

8
9 27
10
2

6
23

14

13

7063

FIGURE 2-54

Item Description Item Description

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

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RT890E SERVICE MANUAL HYDRAULIC SYSTEM

Assembly

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

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

6. Slide the head, larger outside diameter end first, onto 15. Carefully install the counterbalance valves into the

8
the rod.
27 cylinder port block until fully seated.

7. Slide the spacer onto the rod.

8. Screw the piston onto the rod until it can go no further. CAUTION
Hold the piston in place with the setscrew. Do not use air pressure to cycle or pressurize the cylinder.
2

9. Install the other replacement wear ring on the outside of 16. Pressurize and cycle the cylinder with hydraulic oil
the piston over the setscrew. pressure. Static test the cylinder at 3000 psi (20,684
23

10. Lubricate all parts freely with clean hydraulic oil. kPa/206.8 bar). Check for proper operation and any
leakage. Make repairs as needed.
17. Install the cylinder into the cylinder assembly tube and
secure with the washers and capscrews. Torque the
capscrews 88 to 96 lb-ft (120 to 130 Nm).

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HYDRAULIC SYSTEM RT890E SERVICE MANUAL

COUNTERWEIGHT PIN CYLINDER 5. Remove the wear ring and seal from the outside of the
piston and o-ring from the inside of the piston.
Description 6. Remove the head and spacer from the rod.
The counterweight pin removal cylinder (Figure 2-55) has a 7. Remove the o-ring and the backup ring from the outside
bore of 3.0 in (7.62 cm). The retracted length of the cylinder of the head. Remove the spacer, seal and wiper ring
is 38 in (96.5 cm). The extended length of the cylinder is 50 from the inside of the head.
in (127 cm). Its stroke is 12 in (30.4 cm).
8. Repeat steps 1 through 7 for the remaining rod
A wiper ring prevents foreign material from entering the assembly.
cylinder. O-rings and other seals prevent internal and
external leakage. Inspection
The cylinder weighs approximately 69.9 lb (31.75 kg). 1. Inspect the rod. There should be no scratches or pits
deep enough to catch the fingernail. Pits that go to the
Maintenance base metal are unacceptable. Chrome should be
present over the entire surface of the rod. If lack of
Disassembly chrome on rod, the rod should be replaced.
NOTE: Any maintenance requiring disassembly of the 2. Inspect rod for straightness. Determine if it can be
cylinders should include replacement of all seals straightened or must be replaced.
and rings. A seal kit will supply the required items.
3. Inspect the head. Visually inspect the inside bore for
1. Using a spanner wrench, unscrew the rod end from the scratching or polishing. Deep scratches are
rod. unacceptable. Polishing indicates uneven loading, and
the bore should be checked for out-of-roundness.

8
4. Inspect the piston. Visually inspect the outside surface
27
DANGER for scratches or polishing, Deep scratches are
unacceptable. Polishing indicates uneven loading, and
Do not use air pressure to remove the rod. Use only a
the diameter should be checked for out-of roundness.
source of controlled hydraulic oil pressure if the rod is
2
hard to move. 5. Inspect the barrel carefully for scoring. If barrel is
CAUTION scored, it must be repaired or replaced.
23

Exercise extreme care when handling or setting down the 6. Thoroughly rinse parts, allow to drain, and wipe with a
rod. Damage to the rod surface may cause unnecessary lint-free rag. Inspect all parts for serviceability.
maintenance and expense.

2. Using a spanner wrench, unscrew the head from the CAUTION

barrel. Before installing new seals and rings, clean all surfaces
3. Remove the rod and attached parts from the barrel. and carefully remove burrs and nicks. Parts displaying
excessive wear or damage should be replaced.
NOTE: Cover the barrel opening to avoid contamination.
7. Stone out minor blemishes and polish with a fine crocus
cloth.
CAUTION 8. Clean with solvent and dry with compressed air any
When removing seals and rings, avoid scratching the parts that have been stoned and polished.
grooved and gland surfaces.
Assembly
NOTE: Arranging discarded seals and rings in the order of
disassembly will aid in installation of new seals and
rings. Pay attention to how each seal and ring is CAUTION
installed to avoid installing replacement seals and When installing new seals and rings, avoid stretching
rings improperly. seals or scratching the grooved or gland surfaces. Make
4. Remove the locknut and unscrew the piston from the sure parts are clean before and during assembly. Make
rod. sure seals and rings are installed in the proper order.

NOTE: Lubricate seals and rings with clean hydraulic oil.

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RT890E SERVICE MANUAL HYDRAULIC SYSTEM

2 2
15
14 6 12
11

10 5
8
4
7
13

10

11

8
27 1 9

7
12

5
2
14
8
13
23

2
6
4

3
15

7062

FIGURE 2-55

1 Barrel 9 Piston Seal

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

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HYDRAULIC SYSTEM RT890E SERVICE MANUAL

1. Install the replacement spacer, seal and wiper ring in the 13. Using a spanner wrench, continue to screw the head
inside of the head. into place in the barrel.
2. Install the replacement o-rings and the backup ring on 14. Repeat steps 1 through 13 for the remaining rod
the outside of the head. assembly.
3. Install the replacement o-ring in the inside of the piston.
4. Install the wear ring and piston seal on the outside of the CAUTION
piston. Do not use air pressure to cycle or pressurize the cylinder.
5. Lubricate the rod with clean hydraulic oil.
15. Pressurize and cycle the cylinder with hydraulic oil
6. Slide the head, wiper ring end first, onto the rod. pressure. Static test the cylinder at 3000 psi (20,685
kPa/206.8 bar). Check for proper operation and any
7. Install the spacer on the rod.
leakage. Make repairs as needed.
8. Screw the piston onto the rod tightly.
9. Lubricate all parts freely with clean hydraulic oil. PARK BRAKE CYLINDER
Description
CAUTION The park brake cylinder, mounted on the front axle, releases
Exercise extreme care when handling the rod. Damage to and applies the park brake. The park brake cylinder consists
the rod surface may cause unnecessary maintenance of a hydraulic cylinder and a lever. When the operator
and expense. Also, take care to avoid damaging grooved positions the PARK BRAKE switch to ON, the park brake
or gland surfaces or rings or seals during rod insertion. solenoid valve de-energizes and closes the valve, removing

8
hydraulic force from the cylinder’s piston. This allows the
10. Remove the cover from the barrel. Insert the rod and cylinder’s spring to extend, retracting the cylinder lever, and
27
attached parts into the barrel with a slight twisting applying the park brake to hold the crane in place. When the
motion. operator positions the PARK BRAKE switch to OFF, the park
11. Install new gasket material to the cylinder head retainer brake solenoid valve energizes and opens the valve to apply
hydraulic force to the cylinder’s piston. This allows the piston
2
ring flange as follows.
to compress the spring, extend the cylinder lever, and
12. Screw the head into the barrel.
23

release the park brake.

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RT890E SERVICE MANUAL ELECTRIC SYSTEM

SECTION 3
ELECTRIC SYSTEM

SECTION CONTENTS
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Rocker Switch Replacement . . . . . . . . . . . . . . . . 3-14
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Ignition Switch Replacement . . . . . . . . . . . . . . . . 3-14
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Turn Signal Lever and Transmission Shift
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Lever Replacement . . . . . . . . . . . . . . . . . . . . . 3-15
Cab Electrical Panel . . . . . . . . . . . . . . . . . . . . . . . 3-3 Windshield Wiper Assembly Replacement . . . . . 3-18
Carrier Electrical Panel . . . . . . . . . . . . . . . . . . . . . 3-6 Windshield Washer Assembly Replacement . . . . 3-19
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Skylight Wiper Assembly Replacement . . . . . . . . 3-19 3
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Telescope Cylinder Charge System - Electrical
General Troubleshooting . . . . . . . . . . . . . . . . . . . 3-8 Schematic (If Equipped) . . . . . . . . . . . . . . . . . 3-20
Troubleshooting Swivel-Caused Electrical Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . 3-22
Connector Troubleshooting . . . . . . . . . . . . . . . . . 3-8 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Alternator/Charging System Troubleshooting . . . 3-10 Beacon Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Alternator Replacement . . . . . . . . . . . . . . . . . . . 3-11 Boom Mounted Floodlights . . . . . . . . . . . . . . . . . 3-22
Starter Replacement . . . . . . . . . . . . . . . . . . . . . . 3-11 Rear View Mirror . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

8
Battery Replacement . . . . . . . . . . . . . . . . . . . . . 3-12 Air Conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Cold Weather Operation . . . . . . . . . . . . . . . . . . . 3-22
27
Relay Panel Component Replacement. . . . . . . . 3-12
Gauge Cluster Replacement. . . . . . . . . . . . . . . . 3-13
2
23

DESCRIPTION Electrical power is transferred to and from the carrier and

superstructure through the electrical swivel via CANbus
General system. The CANbus system consists of many control
modules which are located on the carrier, superstructure,
The electrical system is 12-volt operation with 12-volt and operator cab. Refer to Figure 3-1 for a list of the different
starting, consisting of an alternator and three lead-acid control modules and their locations. For more detailed
batteries. The system is single wire negative ground return information on the electrical swivel, refer to SECTION 6.
type, using the machine’s structure as ground.

GROVE Published 9-18-2014, Control # 308-06 3-1

3-2
Superstructure
Cab
ELECTRIC SYSTEM

Slave Module
T/T Slave Slave Slave
Slave Module Module Module
I/O & Valve RCL Module
T/T Crane S/S Cab S/S Cab
Driver Control S/S Cab
PWR Mod Star (Steering (Behind Seat
(Right side T/T Module (Front of
(Left side T/T) Column) on PWR
Boom Pivot Cab)
Area) Panel)

23
Swivel Swivel
2 Swivel
27 Swivel

Published 9-18-2014, Control # 308-06

8
Carrier

7747
Engine

Master Slave Slave

Module Module Module
Engine
(Battery Frame Frame
ECM
Box) (Front (Rear
Frame) Frame)

FIGURE 3-1
RT890E SERVICE MANUAL
RT890E SERVICE MANUAL ELECTRIC SYSTEM

Alternator
The alternator (Figure 3-2) is mounted on the engine and is
belt driven. It is a 145 ampere alternator with an integral
transformer - rectifier unit. When the engine is running, and
the alternator is turning, the alternator’s 12-volt output
terminal supplies the crane’s electrical circuits. The output
terminal also supplies the voltage to recharge the batteries
and maintain them at a full state of charge.

8
2 27
Batteries Battery Disconnect Switch FIGURE 3-3
23

Alternator Alternator Belt 7333-5 Cab Electrical Panel

FIGURE 3-2 The cab electrical panel (7, Figure 3-4) contains the cab and
superstructure relays, fuse box, wiring harness connector
Batteries bulkhead, RCL module, RCL Override switch, and the fast
The batteries are located in a box on the left side of the crane pulse buzzer alarm. It is located inside the crane cab, behind
behind the hydraulic oil cooler. The batteries are the the operator seat. Access is gained to the back of the panel
maintenance free type and completely sealed except for a by removing the two screws (4) (Figure 3-4) securing the
small vent hole in the side. The vent hole allows what small panel cover.
amount of gases that are produced in the battery to escape. The two accessory relays (10, 11) (Figure 3-4) behind the
On some batteries, a test indicator located on the top of the cab electrical panel control power to fuses 9 - 20 in the fuse
battery is used to determine if the battery can be tested in box. The coils of the accessory relays are energized when
case of a starting problem. the ignition switch is at the RUN or ACC position.
A Battery Disconnect Switch is located on the right side of The fuse box (3) (Figure 3-4) in the cab electrical panel
the battery box (Figure 3-3). To disconnect the batteries, turn contains twenty fuses. Fuses 1 - 5 are energized when the
the Battery Disconnect Switch to OFF. Turn the switch to ON battery is connected. When the battery is connected and the
to connect the batteries. ignition switch is at the RUN or ACC position, fuses 6 - 8 are
energized, fuses 9-12 are energized through ACC relay #1,
and 13-20 are energized through ACC relay #2.
NOTE: The cab control modules and RCL module are not
serviceable; contact Crane Care Customer Service
with any service or repair questions about the
modules.

GROVE Published 9-18-2014, Control # 308-06 3-3

ELECTRIC SYSTEM RT890E SERVICE MANUAL

1 2

10 11

4
7

5
6

7893 8 9
1

8
27
13

14 12
2

15
23

16

17 5
27
26
25
18

19 24 7693-6

23
20
22
21

7693-8 FIGURE 3-4

Figure 3-4 Item Numbers Item Component

Item Component 6 Electrical Panel
1 Diode Box 7 RCL Controller
2 Fuse Box (see Figure 3-5) 8 ACC Relay, Cab Modules & T/T Modules Power
3 Panel Screw 9 ACC Relay, Jib Stow, RCL, Jib Option
4 Fast Pulse Buzzer Alarm 10 Relay, Windshield Wiper Low Speed
5 RCL Override Switch 11 Relay, Windshield Wiper High Speed

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RT890E SERVICE MANUAL ELECTRIC SYSTEM

Item Component The following fuse assignments apply:

12 Connector Bulkhead • Fuse 1 - Ignition Power in circuit
13 Cab Interior Harness • Fuse 2 - Steering Column Power circuit
14 Swivel Harness
• Fuse 3 - Dome Light and Working Lights
15 Seat Harness
• Fuse 4 - Spare
16 Seat Harness
17 Superstructure Harness • Fuse 5 - ACC power and Diagnostic Connector circuit
18 Overhead Harness • Fuse 6 - Ignition power out
19 Overhead Harness • Fuse 7 - Engine ECM Ignition Signal and Emergency
20 Cab Interior Harness Stop
21 Cab Interior Harness • Fuse 8 - Key Switch Accessory Power 3
22 Cab Interior Harness
• Fuse 9 - Cab Control Modules Power
23 Cab Interior Harness
24 Superstructure Harness • Fuse 10 - Turntable I/O Module

25 Superstructure Harness • Fuse 11 - Turntable Power Module (Horn, Fan Motor)

26 CAN Junction Box (125K) • Fuse 12 - Turntable Power Module (AC Condenser
27 Cab Module Motor, Boom Lights, Counterweight Removal - Option)
• Fuse 13 - RCL CPU

8
• Fuse 14 - Luffing Jib Option
• Fuse 15 - Jib Stowage Power Option
27
• Fuse 16 - Spare - 5A Max
• Fuse 17 - Spare - 5A Max
2

• Fuse 18 - Windshield Wiper

23

• Fuse 19 - Skylight Wiper

• Fuse 20 - Circulating Fan

7693-9 FIGURE 3-5

GROVE Published 9-18-2014, Control # 308-06 3-5

ELECTRIC SYSTEM RT890E SERVICE MANUAL

Carrier Electrical Panel equipped with a Tier 4 engine, the starter lockout signal from
engine ECM must be present.
The carrier electrical panel contains the battery disconnect
switch, main power relay, and fuses that control power to the The coil of the grid heater relay (8) (Figure 3-6) is energized
crane’s entire electrical system. The panel (3) (Figure 3-6) is when the batteries are connected, the ignition switch is in the
located on the fuel tank side of the crane, under the battery RUN position, and the output from the engine ECM to the
box assembly. grid heater coil must be energized.

The coil of the main power relay (6) (Figure 3-6) is energized The 250A fuse (10) (Figure 3-6) protects the batteries, the
when the ignition switch is in the RUN or ACC position, or alternator, and the battery/alternator charge line. The 100A
while the crane’s control system Master Module commands it fuse (9) (Figure 3-6) protects those circuits that receive
to be on, or when the head light, tail lights, hazard lights or power when the battery disconnect switch is closed. The
brake lights are activated. 250A fuse (12) (Figure 3-6) and the three 100A fuses (13,
14, 15) (Figure 3-6) receive power when the main power
The coil of the start relay (7) (Figure 3-6) is energized when relay is energized. The 250A (12) protects the grid heater
the batteries are connected, the start message from the circuit and the three 100A fuses (13, 14, 15) protect the main
steering column is present, the emergency stop switch is not feeds to all other circuits.
activated, the engine is not running, and if the crane is

5
2

8
27
4
2
23

7693-4 3

2
1
3

11
10
9
7693-10

12
7
13
14
15
6

7693-12

FIGURE 3-6

3-6 Published 9-18-2014, Control # 308-06

RT890E SERVICE MANUAL ELECTRIC SYSTEM

Figure 3-3 Item Numbers

Item Description
1 Battery Disconnect Switch DANGER
2 Battery Fuse Box (See Table) When possible, ensure the battery is disconnected
3 Fuse Panel Assembly before performing any maintenance on an electrical
circuit.
4 Battery Box
If it is necessary to perform electrical maintenance on
5 Power Control Relay (KC1) live or hot circuits, remove all rings, watches, and other
6 Power Relay (K301) jewelry before performing maintenance as serious
burns may result from accidental grounding or shorting
7 Starter Relay (K303)
circuits.
8 Grid Heater Relay (K302)
3
100 Amp Fuse, Starter Relay/
9
Engine
10 250 Amp Fuse, Alternator
CAUTION
Never replace original wiring with wiring of a smaller
11 Power Distribution Post
size (gauge). Fire or other damage to the machine may
12 250 Amp Fuse, Grid Heater result.
13 100 Amp Fuse, Cab KS1 Relay
Visual Inspection and Replacement of Electrical
14 100 Amp Fuse, Cab KS2 Relay
Harnesses and Cables

8
100 Amp Fuse, Battery Fuse
15
Box
27
CAUTION
Ensure that the battery cables are disconnected from
Fuse Box (Figure 3-3)
the batteries before loosening any electrical
2

Fuse connections.
Description
Number
23

Visually inspect all electrical harness and cable assemblies

F1 30 Amp, Engine EMC every month or at 250 hours of service life for the following:
F2 5 Amp, Crane Star
• Damaged, cut or deteriorated harness loom covering.
F3 25 Amp, Carrier Rear Module
• Damaged, cut or abraded individual wires or cable
F4 30 Amp, Carrier Rear Module insulation.
F5 30 Amp, Carrier Front Module • Exposed bare copper conductors.
F6 5 Amp, Diagnostic Connector • Kinked, crushed, flattened harnesses or cables.
F7 5 Amp, Power Relay • Blistered, soft, degraded wires and cables.
5 Power Relay (KC1)
• Cracked, damaged, or badly corroded battery terminal
connections.
MAINTENANCE • Inspect all machine ground connections for damaged
terminals or excessive corrosion.
General
• Other signs of significant deterioration.
Electrical system maintenance includes troubleshooting and
replacement of damaged components. Observe standard If any of these conditions exist, evaluate the harness
wiring practices when replacing components. assemblies for repair or replacement. For replacement of
harness assemblies, refer to your Manitowoc Crane Care
Parts Manual.
At the same service interval, visually inspect all Controller
Area Network (CAN) nodes and electrical junction boxes for
the following:

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ELECTRIC SYSTEM RT890E SERVICE MANUAL

• Damaged or loose connectors. • Cranes operating in climate zones “A” or “B” with high
ambient temperatures could see electrical service life
• Damaged or missing electrical clamps or tie straps.
reduced by 25% to 40%. It is recommended to replace
• Excessive corrosion or dirt on the junction box these assemblies after 8000 hours of service life.
assemblies.
• Cranes operating in climate zones “D” and “E”, cold
• Loose junction box mounting hardware. climates, should expect a degradation of mechanical
properties, long term exposure to these cold
If any of these conditions exist, address them appropriately.
temperatures will negatively impact service life.
Ambient temperature, humidity and other factors affect the Therefore, it is recommended these electrical harnesses
life of electrical harness and cable assemblies. Use the and cable assemblies be inspected regularly as service
following information for the inspection and replacement of life may be less than 10,000 hours.
these assemblies:
• Cranes operating in salt water climates could see a
• Cranes operating in climate zone “C” should have the significant reduction in service life. Therefore it is
harness and cable assemblies replaced after 10,000 recommended for these electrical harnesses and cable
hours of service life. assemblies to be inspected regularly as service life may
be less than 8,000 hours.

Table 3-1

Zone Classification
A Tropical Moist: All months average above 18° C. Latitude 15° - 25° North and South
B Dry or Arid: Deficient precipitation most of the year. Latitude: 20° - 35° North and South

8
C Moist Mid-Latitude: Temperature with mild winters. Latitude: 30° - 50° North & South
27
D Moist Mid-latitude: Cold winters. Latitude 50° - 70° North & South
E Polar: Extremely cold winters and summers. Latitude: 60° - 75° North & South
2
General Troubleshooting Troubleshooting Swivel-Caused Electrical
Problems
23

NOTE: Make voltage checks at terminations when

components are installed and operating. Make Many crane component electrical troubles can be traced to
continuity checks (with batteries disconnected) the electrical swivel. Troubles common to the swivel are
when components are isolated or removed. improper mounting, foreign material between the brushes
Troubleshoot per the following guidelines: and slip rings, worn brushes, improper spring tension on the
1. First, use reported symptoms to identify a problem or a brush assembly, and loose setscrews on the slip ring
suspect component. assembly. Refer to the electrical schematic and wiring
diagram for slip ring connections and amperages.
2. Test the suspect component per instructions in this
section. The instructions identify the fuses and Connector Troubleshooting
components and guide you from the easiest and most
likely problems to the hardest and least likely problems. The cause of an electrical problem may be a loose or
corroded connection in the pin or socket connectors. Check
3. Using a multimeter, test the circuit for continuity if you the connectors to ensure that the pins and sockets are
suspect a broken circuit or for voltage if you suspect a properly seated and engaged. If the pins and sockets show
power problem. Check the electrical schematic and any signs of corrosion, use a good quality electrical contact
wiring diagram for most accurate wiring information. cleaner or fine sandpaper to clean them. When the pins or
4. If the component proves faulty, replace it with a known sockets show signs of arcing or burning, it will probably be
working component. If wiring proves faulty, replace it necessary to replace them.
with wiring of equal gauge. Refer to the following tables listing tools necessary for
5. After troubleshooting, test the repaired circuit. Verify the connector maintenance.
circuit works properly. Because the pins and sockets are crimped to the wires, it is
not possible to remove them. Using the proper extraction
tool, remove the pin(s) or socket(s) from the plug or
receptacle. Cut the wire as close to the pin or socket as

3-8 Published 9-18-2014, Control # 308-06

RT890E SERVICE MANUAL ELECTRIC SYSTEM

possible. After cutting the pin or socket off, the wire will most plug or receptacle. Add a short length of the same size wire
likely be too short. Using a wire that is too short will allow to the short wire by crimp splice or solder. Use heat
pressure to be applied to the pin or socket and wire where shrinkable tubing or other suitable material to insulate the
they are crimped when the pin or socket is inserted in the splice.

Table 3-2
AMP Extraction Tool Table

Description AMP Part Number Manitowoc Part Number

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

Table 3-3
AMP Crimping Tool Table

Description AMP Part Number Manitowoc Part Number

Tool Die Tool Die
14 to 12 gauge wire 69710-1 90145-1 9-999-100177 N/A

8
10 to 8 gauge wire 69710-1 90140-1 9-999-100177 9-999-100178
27
4 to 9 circuit
69710-1 90306-1 9-999-100177 N/A
(in-line connectors)
15 circuit
2

90299-1 -- N/A --
(in-line connectors)
23

Table 3-4
Deutsch Extraction Tool Table

Description Deutsch Part Number Manitowoc Part Number

12 gauge wire 114010 9999100194
16 gauge wire 0411-204-1605 9999100195
8-10 gauge wire 114008 7902000012
4-6 gauge wire 114009 7902000009

Table 3-5
Deutsch Crimping Tool Table

Description Deutsch Part Number Manitowoc Part Number

12, 14, 16, 18, 20, 22, 24 gauge wire HDT-48-00 9999100808
4, 6, 8, 10 gauge wire HDT04-08 9999100842

GROVE Published 9-18-2014, Control # 308-06 3-9

ELECTRIC SYSTEM RT890E SERVICE MANUAL

Alternator/Charging System Using the multimeter, measure the voltage across the
Troubleshooting terminals. If the voltage is 12.4 V or above, perform the
following load test. If the voltage is lower than 12.4 V,
Anytime there is a problem with the charging system the recharge the battery(s) before performing the load test.
batteries, alternator and cables should be tested.
Load Test
Required Tools 1. Refer to the load tester manual for instructions on
The following is a list of tools needed to diagnose the performing the load test.
charging system: 2. Connect the load tester to one battery and test.
3. Connect the tester to the second battery and test.
Grove
Equipment Example 4. Connect the tester to the third battery and test.
Part No.
Digital Multimeter Fluke® 177 9999101763 Proceed to the next test if the batteries passed the load test.
Replace a battery if it failed the load test.
Carbon Pile Load
Autometer® SB5 9999101765
Tester Voltage at Alternator
Current Clamp Meter Fluke® 336 9999101764 Measure voltage from alternator case to output terminal. The
meter should read 12.6V or above.
Visual Check
Battery Drain
• Belts: tight, in good condition, not frayed, cracked or
glazed With a DC ammeter capable of measuring milliamps, and a
10 amp capability, perform the following test:

8
• Pulley: tight, aligned with other pulleys, not glazed
1. Make sure the ignition key is off.
• Alternator mounting bolts and wiring connections: clean
27
and tight, no signs of heat damage 2. Set the meter to the 10 amp position.

• Batteries: terminals and cables, clean and tight, no 3. Check for a drain by disconnecting the negative battery
corrosion or signs of heat damage. terminals and measuring between the battery post and
2
the cable with the ammeter.
• If alternator charge lamp is illuminated on steering
23

column display while engine is running, check alternator This reading should not be more than 80 milliamps (.08 ma)
fuse. with all accessories OFF. A higher reading indicates
something is draining the batteries and the system must be
Engine Off Tests troubleshot and repaired.
Batteries Engine On Tests
Output Voltage Test
1. Connect multimeter to negative and positive battery
DANGER terminals.
Do not smoke or allow sparks or open flame near 2. Connect ammeter clamp around output wire of
batteries, they can explode. alternator to the batteries.
When working with batteries always wear protective
3. Start engine and increase speed to 2000 rpm.
clothing, gloves and eye protection. Batteries contain
corrosive liquids that can burn skin and eyes and With fully charged batteries and no loads on the system, the
destroy clothing. multimeter should read 14V.
Remove rings, watches or other jewelry before working Maximum Amperage Test
with batteries. A battery can produce a short-circuit
current high enough to weld a ring, or the like, to metal 1. Connect an adjustable carbon pile load tester to the
causing severe burns batteries’ positive and negative cables.
2. Run engine at 2000 rpm.
Disconnect the batteries and test each battery individually.
3. Adjust carbon pile to obtain maximum amperage while
Check the electrolyte level, if possible not letting voltage fall below 13 volts.

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RT890E SERVICE MANUAL ELECTRIC SYSTEM

4. Amperage should be within 10 to 15 amps of alternator 7. Using a 1/2 in drive bar/ratchet, turn the tensioner, below
rating; this alternator is rated at 145A, so the meter the alternator, clockwise to remove tension from the belt.
should read 130A to 135A. Slip the belt off of the alternator pulley, then let the
tensioner return to its normal position.
NOTE: If the correct readings were not obtained in the
Engine On Tests, perform the following two tests. 8. Remove the alternator mounting capscrews. Remove
the alternator.
Voltage Drop Test
Positive Side Installation

1. Set the multimeter to the 2 volt range. 1. Inspect the belt. Verify it has no cracks or other damage.
Replace damaged belt as needed.
2. Connect the positive (+) lead to the alternator output
2. Install the alternator using the mounting bolts and
terminal and the negative (–) lead to the battery positive washers. Torque bolts; refer to Fasteners and Torque
terminal or post. Do not connect the meter to the battery
cable.
Values, page 1-14 for the proper torque value. 3
3. Install the belt on all engine pulleys except the alternator
3. Run the engine at 2000 rpm. pulley for now.
4. Load system with carbon pile load or lights and heater 4. Turn the tensioner clockwise. Slip the belt onto the
blower. alternator pulley, then carefully return the tensioner to its
Allowable drop is 0.2 to 0.5 volts. Higher voltage indicates normal position so it puts tension on the belt. Make sure
loose, corroded, or broken connections. the belt is centered on the tensioner.

Negative Side 5. Check belt tension at the belt’s longest span (longest
distance between pulleys). At the center point of the

8
1. Set the multimeter to the 2 volt range. longest span, push in on the belt with your thumb. Verify
you can deflect the belt no more than 10 to 13 mm (3/8
27
2. Connect the negative (–) lead to alternator case and the
positive (+) lead to the battery negative terminal or post. to 1/2 inch) with your thumb. (Or, using a belt tension
gauge, verify there is 267 to 578 N (60 to 130 lb) of
Do not connect the meter to the battery cable.
tension on the belt in the middle of its longest span.)
2
3. Run the engine at 2000 RPM. Replace belt if it is too loose (overstretched).
4. Load system with carbon pile load or lights and heater 6. Verify tensioner bolt is torqued to 32 lb-ft (43 Nm).
23

blower.
7. Connect the electrical leads to the terminals as tagged
Allowable drop is 0.1 to 0.3 volts. Higher voltage indicates during removal.
loose, corroded, or broken connections.
8. Close the engine compartment.
If any voltage drop is greater than the normal range,
9. Reconnect the ground cables to the battery.
troubleshoot the system and repair any problems.
10. Install the ECM power fuse.
After correcting any problems, perform the Engine On Tests
again. If satisfactory results are not obtained, remove the 11. Turn the battery disconnect switch to the ON position.
alternator and bench test.
Check
Alternator Replacement 1. Run engine. Verify reading of voltmeter on front console
Removal is 12 volts or greater. Make repairs as needed.

1. Ensure that the key switch has been in the OFF position 2. Continue troubleshooting charging system as needed if
for 2 minutes. replacement of alternator did not correct problem in
charging system.
2. Turn the battery disconnect switch to the OFF position.
3. Remove the ECM power fuse.
Starter Replacement
4. Remove the negative battery cables. Removal

5. Open the engine compartment. 1. Ensure that the key switch has been in the OFF position
for 2 minutes.
6. Tag and disconnect the electrical leads from the
terminals on the alternator. 2. Turn the battery disconnect switch to the OFF position.
3. Remove the ECM power fuse.

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ELECTRIC SYSTEM RT890E SERVICE MANUAL

4. Remove the negative battery cables.

5. Open the engine compartment.
6. Tag and disconnect the electrical leads from the
terminals on the starter.
7. Remove the bolts holding the starter to the mounting
pad. Remove the starter.

Installation
1. Place the starter on its mounting pad. Secure the starter
with the bolts. Torque the bolts to 32 lb-ft (43 Nm).
2. Connect the electrical leads to the terminals as tagged
during removal.
3. Connect the batteries.
FIGURE 3-7
4. Install the ECM power fuse.
1. Ensure that the key switch has been in the OFF position
5. Turn the battery disconnect switch to the ON position. for 2 minutes.
6. Close the engine compartment. 2. Turn the battery disconnect switch to the OFF position.
Check 3. Remove the ECM power fuse.
1. Try to start the engine. Verify the starter starts the 4. Remove the negative battery cables.

8
engine.
5. Remove the positive battery cables.
27
2. Start engine again, and listen for starter noises. Verify
there is no abnormal noise indicating the starter’s gear is 6. Tag and disconnect leads from the battery terminals
meshing properly with the flywheel, that the starter’s starting with the positive terminals.
gear hasn’t remained engaged to the flywheel after the 7. Remove the nuts and washers from the bracket hold
2

ignition switch is in the ignition (run) position, or some down rods. Remove the hold down bracket.
other problem. Install starter properly as needed.
23

8. Remove the batteries.

Battery Replacement Installation
Removal 1. Place the batteries in the battery box.
2. Install the hold down bracket so it can hold down the
batteries. Secure the bracket (and batteries) to the
CAUTION bracket hold down rods with nuts and washers.
To avoid possible engine fault codes and undesirable
operation, ensure the keyswitch has been off 2 minutes 3. Connect leads to the battery terminals starting with the
before disconnecting batteries. positive terminals.
Disconnect batteries if machine will be inactive for over 4. Close the battery box cover.
24 hours. 5. Install the ECM power fuse.
6. Turn the battery disconnect switch to ON.
7. Verify replacement batteries work by starting crane’s
engine and operating various crane components.

Relay Panel Component Replacement

Accessory Relay
1. Ensure that the key switch has been in the OFF position
for 2 minutes.
2. Turn the battery disconnect switch to the OFF position.

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RT890E SERVICE MANUAL ELECTRIC SYSTEM

3. Working behind the operator’s seat, remove the 5. Remove the steering wheel by doing the following:
hardware securing the panel cover and remove the
a. Remove the steering wheel cap (1) using a twisting
cover.
motion by pushing on the side of the cap closest to
4. Tag and disconnect the electrical leads from the suspect you with your thumbs while simultaneously pulling
relay. on the side of the cap farthest from you with your
fingers.
5. Remove the hardware securing the suspect relay to the
relay panel assembly. Remove suspect relay. b. Remove the securing nut from the steering column
shaft and remove the steering wheel (2).
6. Install replacement relay on relay panel and secure it
with attaching hardware. 6. Remove the four screws (13) securing the left and right
side covers (8, 9) together.
7. Connect the electrical leads to the relay as tagged
during removal. 7. Remove the six screws (14) securing the left and right
8. Position the cover on the panel and secure with the
side covers (8, 9) to the gauge/switch cover (6). 3
attaching hardware. 8. Remove the left side cover (8) from the steering column.
9. Connect the batteries. 9. Disconnect the wire harness from the back of the ignition
switch (10).
10. Turn the battery disconnect switch to the ON position.
10. Remove the right side cover (9) from the steering
11. Verify proper installation by operating all components
column.
involved with the replacement relay verifying they all
work. 11. Disconnect the wire harness from the bottom of the
gauge cluster (5).
Buzzer Replacement

8
12. Remove the gauge cluster (5) from the gauge/switch
1. Working behind the operator seat, remove the hardware cover (6) by pushing in on the left and right sides of the
27
securing the panel cover and remove the cover. gauge cluster (5), then pushing the gauge cluster (5) up
2. Tag and disconnect the electrical leads from the buzzer. through the gauge/switch cover (6).

3. Unscrew the plastic collar ring from under the panel and Installation
2

remove the buzzer from the hole in the panel.

1. Install the gauge cluster (5) in the top of the gauge/
23

4. Install replacement buzzer through the hole in panel and switch cover (6) by pushing the gauge cluster (5) down
secure with the plastic collar ring. through the top of the gauge/switch cover (6) until the
gauge cluster’s retaining clips click in place.
5. Connect the electrical leads to the buzzer as tagged
during removal. 2. Connect the wire harness to the bottom of the gauge
cluster (5).
6. Position the console front cover on the console and
secure with the attaching hardware. 3. Install the right side cover (9) on the steering column.
7. Verify proper operation by positioning the ignition switch 4. Connect the wire harness to the ignition switch (10).
to RUN (1). Buzzer should sound when engine is not
5. Install the left side cover (8) on the steering column.
running.
6. Secure the gauge/switch cover (6) to the left and right
Gauge Cluster Replacement side covers (8, 9) using six screws (14).
Use the following procedures and refer to Figure 3-8 when 7. Secure the left and right side covers (8, 9) together using
removing/installing the gauge cluster. four screws (13).

Removal 8. Install the steering wheel (2); torque the securing nut to
30 lb-ft ±4 (40 Nm ±5).
1. Ensure that the key switch has been in the OFF position
for 2 minutes. 9. Install the steering wheel cap (1).

2. Turn the battery disconnect switch to the OFF position. 10. Install the lever (12) and spacer that locks/unlocks the
steering column tilt/telescope function.
3. Pull the rubber boot (11) off the bottom of the left and
right side covers (8, 9). 11. Pull the rubber boot (11) up and over the bottom of the
left and right side covers (8, 9).
4. Remove the lever (12) and spacer that locks/unlocks the
steering column tilt/telescope function. 12. Turn the battery disconnect switch to the ON position.

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ELECTRIC SYSTEM RT890E SERVICE MANUAL

Check b. Place switch at OFF or deactivated position.

Ohmmeter should register infinity (no continuity).
1. Start the engine and verify that the instruments work.
c. Replace switch if it fails either part of the check.
2. As needed, troubleshoot further any system malfunction
not corrected by repair or replacement of the gauge Installation
cluster or associated wiring.
1. Remove the rocker (3) from the old switch by holding the
Rocker Switch Replacement switch by its sides in one hand and then squeezing the
left and right sides of the rocker with the other hand and
Use the following procedures and refer to Figure 3-8 when pulling up.
removing/installing a switch.
2. Orient the rocker (3) correctly relative to the new switch
Removal (4), then install rocker in switch.
1. Ensure that the key switch has been in the OFF position 3. Install the switch (4) in the gauge/switch cover (6) by
for 2 minutes. pushing the switch (4) down through the top of the
gauge/switch cover (6) until the switch’s retaining clips
2. Turn the battery disconnect switch to the OFF position.
click in place.
3. Pull the rubber boot (11) off the bottom of the left and
4. Connect the wire harness to the bottom of the switch (4).
right side covers (8, 9).
5. Install the right side cover (9) on the steering column.
4. Remove the lever (12) and spacer that locks/unlocks the
steering column tilt/telescope function. 6. Connect the wire harness to the ignition switch (10).
5. Remove the four screws (13) securing the left and right 7. Install the left side cover (8) on the steering column.
side covers (8, 9) together.

8
8. Secure the gauge/switch cover (6) to the left and right
6. Remove the six screws (14) securing the left and right side covers (8, 9) using six screws (14).
27
side covers (8, 9) to the gauge/switch cover (6).
9. Secure the left and right side covers (8, 9) together using
7. Remove the left side cover (8) from the steering column. four screws (13).
8. Disconnect the wire harness from the back of the ignition 10. Install the lever (12) and spacer that locks/unlocks the
2

switch (10). steering column tilt/telescope function.

23

9. Remove the right side cover (9) from the steering 11. Pull the rubber boot (11) up and over the bottom of the
column. left and right side covers (8, 9).
10. Disconnect the wire harness from the bottom of the 12. Turn the battery disconnect switch to the ON position.
switch (4) that must be replaced. Remove the switch by
squeezing the retaining clips on each side of switch and Check
pushing upwards until switch is free of cover. 1. Operate the switch per the Operator Manual. Verify each
of its functions works.
Inspection
2. As needed, troubleshoot further any system or circuit
1. Visually check the switch for evidence of cracks,
malfunction not corrected by repair or replacement of
damaged connections, or other damage. Replace
the switch or associated wiring.
damaged switch as needed.
2. Check wiring for damaged insulation or damaged Ignition Switch Replacement
connectors. Repair as needed.
Use the following procedures and refer to Figure 3-8 when
3. Check all connectors for corrosion. Replace corroded removing/installing the ignition switch.
components as needed.
Removal
4. Perform the following check to determine switch
serviceability. 1. Ensure that the key switch has been in the OFF position
for 2 minutes.
a. Using an ohmmeter, check for continuity between
the switch terminals with switch at ON or activated 2. Turn the battery disconnect switch to the OFF position.
position(s). Ohmmeter should register zero ohms 3. Pull the rubber boot (11) off the bottom of the left and
(continuity). right side covers (8, 9).

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4. Remove the lever (12) and spacer that locks/unlocks the 8. Pull the rubber boot (11) up and over the bottom of the
steering column tilt/telescope function. left and right side covers (8, 9).
5. Remove the four screws (13) securing the left and right 9. Turn the battery disconnect switch to the ON position.
side covers (8, 9) together.
Check
6. Remove the six screws (14) securing the left and right
side covers (8, 9) to the gauge/switch cover (6). 1. Operate the ignition switch per the Operator Manual.
Verify each of its functions works.
7. Remove the left side cover (8) from the steering column.
2. As needed, troubleshoot further any system or circuit
8. Disconnect the wire harness from the back of the ignition malfunction not corrected by repair or replacement of
switch (10). the switch or associated wiring.
9. Remove the right side cover (9) from the steering
column. Turn Signal Lever and Transmission Shift
Lever Replacement 3
10. Remove the locking nut that secures the ignition switch
(10) to the right cover (9) and remove the ignition switch Use the following procedures and refer to Figure 3-8 when
(10). removing/installing the turn signal lever or transmission shift
lever.
Inspection
Removal
1. Visually check the ignition switch for evidence of cracks,
damaged connections, or other damage. Replace 1. Ensure that the key switch has been in the OFF position
damaged ignition switch as needed. for 2 minutes.
2. Check wiring for damaged insulation or damaged 2. Turn the battery disconnect switch to the OFF position.

8
connectors. Repair as needed.
3. Pull the rubber boot (11) off the bottom of the left and
27
3. Check all connectors for corrosion. Replace corroded right side covers (8, 9).
components as needed.
4. Remove the lever (12) and spacer that locks/unlocks the
4. Perform the following check to determine ignition switch steering column tilt/telescope function.
2
serviceability.
5. Remove the steering wheel by doing the following:
23

a. Using an ohmmeter, check for continuity between

a. Remove the steering wheel cap (1) using a twisting
the switch terminals with switch at ON or activated
motion by pushing on the side of the cap closest to
position(s). Ohmmeter should register zero ohms
you with your thumbs while simultaneously pulling
(continuity).
on the side of the cap farthest from you with your
b. Place switch at OFF or deactivated position. fingers.
Ohmmeter should register infinity (no continuity).
b. Remove the securing nut from the steering column
c. Replace switch if it fails either part of the check. shaft and remove the steering wheel (2).

Installation 6. Remove the four screws (13) securing the left and right
side covers (8, 9) together.
1. Install the ignition switch (10) in the right side cover (9)
and secure with the locking nut. 7. Remove the six screws (14) securing the left and right
side covers (8, 9) to the gauge/switch cover (6).
2. Install the right side cover (9) on the steering column.
8. Remove the left side cover (8) from the steering column.
3. Connect the wire harness to the ignition switch (10).
9. Disconnect the wire harness from the back of the ignition
4. Install the left side cover (8) on the steering column. switch (10).
5. Secure the gauge/switch cover (6) to the left and right 10. Remove the right side cover (9) from the steering
side covers (8, 9) using six screws (14). column.
6. Secure the left and right side covers (8, 9) together using 11. Disconnect the wire harness from the bottom of the
four screws (13). gauge cluster (5).
7. Install the lever (12) and spacer that locks/unlocks the 12. Tag and disconnect the wire harness from the bottom of
steering column tilt/telescope function. each switch (4).

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 ELECTRIC SYSTEM RT890E SERVICE MANUAL
13. Remove the gauge/switch cover (6) from the steering 9. Install the left side cover (8) on the steering column.
column.
10. Secure the gauge/switch cover (6) to the left and right
14. Disconnect the wire harnesses from the bottom of the side covers (8, 9) using six screws (14).
turn signal and transmission shift levers (7).
11. Secure the left and right side covers (8, 9) together using
15. Remove the two bolts and nuts securing the two levers four screws (13).
(7) together.
12. Install the steering wheel (2); torque the securing nut to
Installation 30 lb-ft ±4 (40 Nm ±5).

1. Align the location pins of the turn signal and 13. Install the steering wheel cap (1).
transmission shift levers (7) with the holes in the steering 14. Install the lever (12) and spacer that locks/unlocks the
column. steering column tilt/telescope function.
2. Secure the two levers (7) together using the two bolts 15. Pull the rubber boot (11) up and over the bottom of the
and nuts. left and right side covers (8, 9).
3. Connect the wire harnesses to the levers (7). 16. Turn the battery disconnect switch to the ON position.
4. Install the gauge/switch cover (6) on the steering
Check
column.
1. Operate the turn signal lever or transmission shift lever
5. Connect the wire harness to the bottom of the gauge
per the Operator Manual. Verify each of its functions
cluster (5).
work.
6. Install the wire harnesses on the switches (4) as tagged
2. As needed, troubleshoot further any system or circuit
during removal.
malfunction not corrected by repair or replacement of

8
7. Install the right side cover (9) on the steering column. the switch or associated wiring.
8. Connect the wire harness to the ignition switch (10).
2 27
23

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RT890E SERVICE MANUAL ELECTRIC SYSTEM

5
1

3
6

4 3
4
7

14

8
8
13
27
14 12

9
2

14
13
23

11

14
10

7794-1

FIGURE 3-8

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ELECTRIC SYSTEM RT890E SERVICE MANUAL

Windshield Wiper Assembly Replacement Installation

Removal 1. Verify the pivot shaft and the wiper motor kit link and
crank are in place on the motor bracket. (Washers and
1. Ensure that the key switch has been in the OFF position clip springs fasten the link to the pivot pins on the crank
for 2 minutes. and the pivot shaft. The pivot shaft’s pivot pin mounts in
the hole nearest the end of the pivot shaft’s lever.)
2. Turn the battery disconnect switch to the OFF position.
2. Connect the wiper motor to the motor bracket with
3. Tag and disconnect the electrical leads from the motor.
screws and washers (see Figure 3-9). Connect the
4. Disconnect the washer hose on the wiper arm (also wiper motor’s shaft to the wiper motor kit crank with the
called the pantograph arm assembly) from the washer nut and washer.
nozzle fitting assembly.
3. Secure the adapter and the gasket of the pantograph
5. Remove the cap nut and washer securing the wiper arm adapter kit to the cab exterior with capscrews and
to the pantograph adapter kit. (The nut and washer are lockwashers.
part of the pantograph adapter kit.) Remove the cap nut,
4. Install the motor bracket and attached parts in the cab
washer, and tapered sleeve securing the wiper arm to
interior with attaching hardware. Ensure the pivot shaft
the pivot shaft kit. (The nut, washer, and sleeve are part
sticks through the hole in the pantograph adapter kit.
of the pivot shaft kit.)
NOTE: Take care not to damage any parts while moving
6. Remove the wiper arm from the pantograph adapter kit the bracket and attached parts around the steering
and the pivot shaft kit. column.
7. Remove the flanged sleeve, nut, and two flat washers
from the pivot shaft kit. (The sleeve, nut, and washers

8
are part of the pivot shaft kit.)
27
8. Remove the two capscrews and lockwashers securing Windshield Wiper Arm
Serrated Collar
the pantograph adapter kit’s adapter to the cab exterior.
Remove the pantograph adapter kit’s adapter and
gasket.
2

Mounting Plate Washer

9. Remove attaching hardware to free the windshield wiper
23

motor bracket from the cab interior. Remove the bracket, Nuts
with motor and pivot shaft connected, from the cab.
NOTE: You may have to remove or move other parts to get Washer
the bracket and attached parts around the steering
column. Take care not to damage any parts. Screws

10. Remove the nut to free the wiper motor’s shaft from the
wiper motor kit crank. Remove the three screws and Gasket
washers to free the wiper motor from its bracket. Mounting Bracket
Remove the wiper motor from its bracket. Leave the
other parts attached to the bracket for now.
Motor
Inspection
3653
1. Visually check the motor housing for evidence of cracks FIGURE 3-9
or other damage. Check for excessive shaft end play
indicating worn or damaged bearings. Replace motor if 5. Secure the pivot shaft to the pantograph adapter with the
damaged. pivot shaft kit’s nut and washers. Install the flanged
sleeve on the pivot shaft.
2. Inspect the wiper blade for serviceability. Replace wiper
blade when worn. 6. Install the wiper arm on the shafts of the pantograph
adapter kit and the pivot shaft kit. Secure the wiper arm
3. Inspect the wiper arm and parts of the linking component to the pantograph adapter kit shaft with the kit’s own
kits (pantograph adapter kit, pivot shaft kit, wiper motor washer and cap nut. Secure the wiper arm to the pivot
kit link and crank, wiper motor bracket) for damage. shaft with the pivot shaft kit’s own tapered sleeve,
Replace as needed. washer, and cap nut.

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RT890E SERVICE MANUAL ELECTRIC SYSTEM

7. Connect the wiper arm’s washer hose to the washer 3. Attach the hose to the windshield washer pump.
nozzle fitting assembly.
4. Connect the pump’s electrical lead and ground wire as
8. Connect the electrical leads to the wiper motor as tagged during removal.
marked before removal.
5. Turn the battery disconnect switch to the ON position.
9. Turn the battery disconnect switch to the ON position.
6. Fill the container with cleaning fluid.
Check
Check
1. Squirt some cleaning fluid onto the windshield with the
1. Squirt some cleaning fluid onto the windshield with the
windshield washer.
windshield washer.
2. Operate the windshield wiper. Verify it works. (Replace
2. Make repairs if windshield washer doesn’t work.
wiper blade as needed if it streaks or otherwise wipes
poorly.)
Skylight Wiper Assembly Replacement 3
Windshield Washer Assembly Replacement Removal
Removal 1. Ensure that the key switch has been in the OFF position
for 2 minutes.
1. Ensure that the key switch has been in the OFF position
for 2 minutes. 2. Turn the battery disconnect switch to the OFF position.
2. Turn the battery disconnect switch to the OFF position. 3. Tag and disconnect the electrical leads from the motor.
3. Locate the windshield washer container and pump on 4. Remove the wiper arm from the motor shaft.

8
the left rear side of the cab.
5. Remove the nut, spacer, leather washer, and nylon flat
4. Tag and disconnect the pump’s electrical lead and washer from the motor shaft outside the cab roof.
27
ground wire.
6. Remove the nut and lockwasher securing the motor
5. Disconnect the hose from the windshield washer pump. bracket to the cab roof and remove the motor from the
Point it so it won’t spill cleaning fluid. Catch cleaning fluid cab roof. Remove large nylon flat washer from motor
2

from the windshield washer container with a suitable shaft and flat washer and smaller nylon flat washer from
container. mounting screw.
23

6. Remove four self tapping screws securing the 7. Remove mounting screw and nylon flat washer from
windshield washer container to the cab. Remove the outside cab roof.
windshield washer container and pump.
8. Clean any sealing material from around holes in cab
7. Remove pump and pump seal from container. roof.

Inspection Inspection
1. Visually check the pump for evidence of cracks, leaks, or 1. Visually check the motor housing for evidence of cracks
other damage. Replace pump if damaged. or other damage. Check for excessive shaft end play
indicating worn or damaged bearings. Replace motor if
2. Inspect the container for leaking. Replace pump seal if it
damaged.
is leaking. Replace container if it is damaged and
leaking. 2. Inspect the wiper blade for serviceability. Replace wiper
blade when worn.
3. Inspect spray nozzle on the wiper arm. As needed, clean
the nozzle with a fine piece of wire and compressed air. 3. Inspect the wiper arm and parts for damage. Replace as
needed.
Installation
1. Install pump and pump seal on container.
2. Install windshield washer container on the cab. Secure
the container with four self tapping screws.

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ELECTRIC SYSTEM RT890E SERVICE MANUAL

Installation 7. Turn the battery disconnect switch to the ON position.

1. Install sealant material around both holes in cab roof, Check
both inside and outside.
1. Operate the skylight wiper. Verify it works. (Replace
2. Install screw with nylon flat washer (from outside) wiper blade as needed if it streaks or otherwise wipes
through mounting hole in cab roof. poorly.)
3. Install flat nylon washer on motor shaft and insert motor
shaft through hole in cab roof. Position small nylon
Telescope Cylinder Charge System -
washer and flat washer on screw between mounting Electrical Schematic (If Equipped)
bracket and cab roof. Secure with lockwasher and nut. The telescope cylinder charge system prevents boom
4. Install nylon flat washer, leather washer, spacer, and nut retraction due to thermal contraction under certain operating
on motor shaft. Tighten nut. conditions. Refer to the sub-section titled Telescope Circuit,
page 4-24 for detailed information of this system’s operation.
5. Install wiper arm and blade on motor shaft. Refer to Figure 3-10 for an electrical schematic of the
6. Connect the electrical leads to the wiper motor as telescope cylinder charge system.
marked before removal.

8
2 27
23

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RT890E SERVICE MANUAL ELECTRIC SYSTEM

5 7

3 4

3
2

8
10

8
27
11
2

12
23

13

Item Description Item Description

1 O/R Extend/Retract Switch 8 Tele Cyl Charge Indicator
2 Fuses 17, 18, 19 9 Tele Cyl Charge Pressure Switch
3 ACC #2 Relay 10 Tele Cyl Pressure Buzzer Relay
4 Rear Steer Switch 11 Power Panel Module
5 Tele Cyl Charge Relay #2 12 Buzzer
6 Tele Cyl Charge Relay #1 13 Crane Buzzer Relay
7 Rated Capacity Limiter (RCL)

FIGURE 3-10

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ELECTRIC SYSTEM RT890E SERVICE MANUAL

Troubleshooting Cold Weather Operation

This machine incorporates a CAN bus Multiplex system. Regions with ambient temperatures below -9°C (15°F) are
considered arctic. The following recommendations are for
To effectively troubleshoot the electrical system, you need a
operating Grove cranes in very low (i.e., sub-zero)
Windows-based personal computer, CAN-Link service
temperatures.
software (Part No. 9999102587), and a connection cable
(Part No. 80026376). Use particular care to ensure that cranes being operated in
very cold temperatures are operated and maintained in
Manitowoc Crane Care requests you have, as part of your
accordance with the procedures as provided by Manitowoc.
service tool kit inventory, the CAN-Link service tool kit for the
Therefore, always ensure adequate lubrication during
RT890E4. The software will allow you to see in real time the
system warm-up and proper operation of all crane functions
status of all inputs and outputs on the system, and it will allow
when operating in cold weather and regardless of the oil
you to detect any errors on input or output. The CAN-Link
viscosity of the crane’s lubricants, always follow the cold
service software and connection cable are available through
weather start-up and operating procedures described in the
Crane Care to those service technicians who have attended
Operator Manual. To ensure adequate lubrication during
the Grove New Technology training course.
system warm-up and proper operation of all crane functions,
(Refer to Arctic Lubricants and Conditions, page 9-3.)
OPTIONAL EQUIPMENT
Individual crane functions should be operated to ensure they
Description are sufficiently warmed prior to performing a lift.

This section is provided to give a brief description of the Operation of cranes at full rated capacities in ambient
optional equipment available for the crane which is not temperatures between -9°C and -40°C (15°F and -40°F) or
discussed elsewhere within this service manual. lower should be accomplished only by competent operators

8
who possess the skill, experience, and dexterity to ensure
Beacon Light smooth operation.
27
The beacon light is installed on the right side of the turntable Component Coolant Heater
in front of the main hoist. The light is illuminated anytime the
A diesel fueled coolant heater circulates warm coolant
ignition switch is in the on position.
2
through engine and crane components when operating
during arctic temperatures. The coolant heater should be
Boom Mounted Floodlights
23

activated 2 hours before starting the crane to allow sufficient

The boom lights switch is located in the cab overhead time to preheat fluids and assist with easy start-up
console panel. The switch is an On/Off rocker switch that will conditions.
illuminate the lamps located on the underside of the boom.

Rear View Mirror WARNING

The rear view mirror installation consists of a rear view mirror Explosion Hazard!
mounted on the right side of the turntable. The mirror can be Before switching on, check if the heater can be operated
adjusted as required for optimum view from the cab while the at the current site of the crane. There is a danger of
boom is over the front of the crane. explosion when using the heater around combustible
objects! Do not park the vehicle near objects that are
Air Conditioner flammable.
A hydraulic driven air conditioner is installed on the left side Use caution near the exhaust tailpipe as it will also
of the turntable. It consists of a compressor motor, a become very hot.
condenser unit, and a cab unit mounted under the operators
seat. It is turned on and off by a rotary switch mounted on the To activate the heater, ensure the fuel supply valve from the
overhead console, refer to Air Conditioner Control Switch heater fuel reservoir is turned to the ON position. Ensure the
(Optional) in the Operator Manual in Section 3 -Operating battery disconnect switch is turned to the ON position and
Controls and Procedures. The air conditioning compressor push the activation button at the heater control panel. A
motor is driven by the No. 2 hydraulic pump. The dual green light will illuminate indicating the system is activated.
accumulator charge valve ensures the brake circuit gets the The start-up and shutdown cycles may take approximately 2
priority flow and the air conditioner circuit receives the minutes for initialization. Ensure the coolant, transmission
excess flow. heater, swivel, battery heater, in-line fuel pump, in-line fuel
heater, and hydraulic reservoir heater are heating properly.

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RT890E SERVICE MANUAL ELECTRIC SYSTEM

To de-activate the heater, push the button at the heater - Anything is clogging the combustion air supply or
control panel. The green light will turn off indicating the exhaust system?
system is de-activated. The shutdown cycle may take
• Check the openings of the combustion air supply and
approximately 2 minutes.
exhaust system after longer standstill periods, clean if
NOTE: Accelerated discharging of battery will occur when necessary!
the crane engine is switched off. If you run the
• If the heater remains faulty even after these points have
heater while the crane engine is stopped, the
been checked, or another malfunction occurs in your
batteries voltage will need to be recharged after
heater, contact an authorized Manitowoc distributor or
short periods of time.
Manitowoc Crane Care.
Troubleshooting
Maintenance Instructions
In case of faults, please check the following points:
• Switch the heater on once a month for about 10 minutes,
• If the heater does not start after being switched on: even outside the heating period. 3
- switch the heater off and on again. • Before the heating period starts, the heater should
undergo a trial run. If persistent extreme smoke
• If the heater still does not start, check whether:
develops, unusual burning noise or a clear fuel smell
- There is fuel in the tank? can be perceived or if electric / electronic parts heat up,
the heater must be switched off and put out of service by
- The fuses are OK?
removing the fuse. In this case, the heater should not be
- The electrical cables, connections etc. are OK? started up again until it has been checked by qualified
staff who have been properly trained.

8
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23

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ELECTRIC SYSTEM RT890E SERVICE MANUAL

8
27
THIS PAGE BLANK
2
23

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RT890E SERVICE MANUAL BOOM

SECTION 4
BOOM

SECTION CONTENTS
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Boom Extension and Retraction Cable . . . . . . . . 4-22
Lattice Extension . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Optional Hydraulic Luffing Extension . . . . . . . . . . 4-1 Telescope Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
Optional Lattice Extension Inserts . . . . . . . . . . . . 4-1 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
Boom Control Switches. . . . . . . . . . . . . . . . . . . . . 4-2 Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . 4-24
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Boom Extension . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Hose Reel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
Boom Retraction . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
RCL System with Boom Control System . . . . . . . 4-3 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Lift Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
Telescoping Control System Description . . . . . . . 4-3
Extension Sequence for the Main Boom. . . . . . . . 4-4
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Theory of Operation. . . . . . . . . . . . . . . . . . . . . . .
4-29
4-29
4
Extension Sequence for the Main Boom with Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
Boom Extensions or Offset Jibs . . . . . . . . . . . . 4-4
Auxiliary Boom Nose . . . . . . . . . . . . . . . . . . . . . . 4-33

8
Electronic Control System. . . . . . . . . . . . . . . . . . . 4-6 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 Counterweight with Auxiliary Hoist . . . . . . . . . . . 4-34
27
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Counterweight without Auxiliary Hoist . . . . . . . . 4-34
Boom Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Boom Nose Sheaves . . . . . . . . . . . . . . . . . . . . . 4-15 Installing the Bi-fold Manual Boom Extension . . 4-37
Checking the Transport Condition . . . . . . . . . . . . 4-39
2
Boom Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 Boom Extensions/Components Procedures . . . 4-39
23

Functional Check . . . . . . . . . . . . . . . . . . . . . . . . 4-21 Transportation on a Separate Vehicle . . . . . . . . . 4-39

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21 Boom Extension (Additional Equipment) . . . . . . 4-39
Boom Alignment and Servicing. . . . . . . . . . . . . . 4-21 Identification and Slinging Points. . . . . . . . . . . . . 4-39
Cam Operated Check Valve Adjustment . . . . . . 4-21 Monthly Maintenance Work . . . . . . . . . . . . . . . . . 4-41
Guide Block Adjustment . . . . . . . . . . . . . . . . . . . 4-22

DESCRIPTION Optional Hydraulic Luffing Extension

One boom Figure 4-7 is available on the crane; a five 33 - 56 ft (10.1 - 17.1 m) hydraulically offsettable bifold luffing
section, full power, sequenced and synchronized, 38 to swingaway extension. Offsets from 0° to 40°. Stows
142 ft (11.6 to 43.3 m) boom. The boom assembly utilizes a alongside base boom section.
mega form design. The five section boom utilizes two
sequenced telescope cylinders for telescoping and retracting Optional Lattice Extension Inserts
of the boom plus cable synchronization for the extension and
2 x 16.0 ft (4.9 m) lattice extension inserts. Installs between
retraction of the fly section. Boom lift is provided by a single
the boom nose and bifold extension, non-stowable. A
lift cylinder and boom elevation is from - 3 degrees to +78
standard auxiliary boom nose (rooster sheave) is available
degrees.
for the boom to simplify single part cable usage. The rooster
Lattice Extension sheave is installed on the main boom nose and is secured by
pins that pass through the rooster sheave and main boom
33 - 56 ft (10.1 - 17.1 m) offsettable bifold lattice swingaway nose.
extension (jib). Offsets 0°, 20°, and 40°. Stows alongside
base boom section.

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BOOM RT890E SERVICE MANUAL

Boom Control Switches THEORY OF OPERATION

The following switches and indicators are located in the Boom Extension
crane’s superstructure cab and are used together to control
the boom telescope function. Boom extension and retraction is accomplished with two
telescope cylinders, five extension cables, and two retraction
Boom Auto/Manual Telescope Mode Switches cables. The lower telescope cylinder is a two stage cylinder.
The boom auto/manual telescope mode switch is located on The rod for the first stage is secured to the rear of the boom
the right armrest. The switch is a two-position rocker switch base section and the barrel of the first stage is secured to the
placarded auto and manual. This switch has a lock to inner mid boom section by a trunnion. The second stage of
prevent accidental activation. the first telescope cylinder barrel is secured to the rear of the
center mid boom section by a trunnion. The rod end of the
When the switch is in the AUTO mode, the boom sections upper telescope cylinder is attached to the rear of the center
extend in a predetermined sequence when telescoping the mid and the barrel is secured to the outer mid boom section
boom; the inner mid extends 75% and stops, then the center by a trunnion. The extension cables are secured to the back
mid extends to 75% and stops, then the inner mid extends to of the fly section and run around extension sheaves on the
100%, the center mid extends to 100%, and then the outer front of the upper telescope cylinder to the front of the
mid and fly section extend in a synchronized fashion. The second stage barrel of the lower telescope cylinder.
sections retract in the same manner in reverse order.
The hydraulic fluid for the first stage of the lower cylinder is
When in the manual mode, the red LED square in the switch supplied by hoses from the turntable. The hydraulic fluid for
will illuminate. The boom telescope section select switch is the second stage of the lower cylinder and the upper cylinder
positioned to either the center mid or inner mid position in is routed through the hose reel that is mounted in the
order to extend or retract the selected section until it is turntable into a manifold that is attached at the rear of the

8
returned to the proper position for normal boom center mid section. There are two cam operated check
synchronization to occur. valves mounted at the rear of the center mid which control
27
The manual mode operation is primarily used for boom flow to the second stage of the lower cylinder and the upper
maintenance and function the boom in an unlikely event of a telescope cylinder. With both cylinders retracted, the check
BCS failure. In manual mode, the boom is controlled by the valve for the second stage of the lower telescope cylinder is
open and the check valve for the upper cylinder is closed
2
section selector switch in the right hand arm rest in the cab.
When IM is selected, crane electric provides full power to the allowing the second stage of the lower cylinder to extend.
When the lower cylinder is fully extended, the check valve for
23

extend and retract proportional solenoids on the IM pilot

operated 4-way directional control valve. This means the the upper cylinder opens allowing the upper cylinder to
telescoping action is controlled directly by moving the extend. The check valve for the lower cylinder closes after
joystick or foot operated treadle valve. The BCS does not the upper cylinder starts to extend and shuts off the flow to
control movement. Likewise when CM is selected, crane the lower cylinder. As the upper telescope cylinder barrel
electric provides full power to the extend and retract extends, the extend cables around the extend sheaves on
proportional solenoids on the CM pilot operated 4-way the end of the cylinder barrel push on the extend cables to
directional control valve. pull the fly section out at the same time the outer mid is
extending.
Center Mid/Inner Mid Boom Telescope Sections
Select Switch Boom Retraction
The center mid/inner mid boom telescope section select The upper telescope cylinder retracts the outer-mid and two
switch is located on the right armrest. This switch is a three retract cables pull the fly section in at the same time. When
position rocker switch that is used in conjunction with the the upper cylinder is fully retracted, the check valve for the
boom auto/manual telescope mode switch. When the boom lower telescope cylinder is opened and the lower cylinder
mode switch is positioned to manual, the boom telescope starts to retract. The check valve for the upper cylinder is
section select switch is positioned to either of the two closed as the lower cylinder starts to retract. The outer mid
positions. When placed in the upper position, the center mid and fly retract first and then the center mid and lastly the
can be extended. When the center mid is fully extended, the inner mid.
outer mid and fly can be controlled. The red LED square will
illuminate when the switch is positioned in either the inner
mid or center mid position.

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RT890E SERVICE MANUAL BOOM

RCL SYSTEM WITH BOOM CONTROL b. In Manual (MANUAL) mode, the operator has the
SYSTEM selective capability to adjust the extension of the
inner mid and center mid sections independently.
General Manual mode adjustment is utilized on ly to
reconfigure the boom sections into a synchronized
The crane has a 5-section sequence synchronized boom relationship according to the programmed criteria
assembly. The electronic control system interfaces with the for automatic mode operation (if the boom has for
actuating systems, and provides the necessary controls, any rea son bec ome unsy nchronize d during
according to the following system standards. operation in the Automatic mode), or to extend the
boom intentionally in non-synchronized mode, so
Telescoping Control System Description that access holes in the boom sections align, and
serviceable internal components of the boom are
Boom Configuration made accessible for maintenance. To prevent
The boom is a five section configuration (i.e. one fixed overloading of the boom while the sections are
section and four telescoping sections). The fully retracted unsynchronized, when the Manual mode has been
length of the boom is 11.4 mm (38 ft) and the fully extended selected, the RCL electronic controller limits the
length is 43.2 mm (142.0 ft). allowable gross load to 10,000 kg (22,046 lb), or
50% of the load chart allowable capacity at the
Extension/Retraction Modes applicable measured boom length, whichever figure
The boom telescoping system operates in either of two
is less. In the Manual mode, the smoothness of the
changeover from section to section is entirely under
4
modes selected by the operator, Automatic or Manual.
the control of the operator.
a. In Automatic (AUTO) mode, a single telescope
controller extends or retracts the boom at the Extension/Retraction Sequence (Automatic Mode)

8
correct speeds, in the correct sequence of section Boom extension in the Automatic mode does not follow the
27
movements, with no action by the operator other customary sequence whereby all the boom sections are
than to actuate the controller and to cease actuating extended by the same proportion for any given boom length.
it when the desired boom length is achieved. The Instead, in order to optimize the crane structural and/or
system also automatically enforces a “soft” stability limitations, the sections extend in particular
2

transition at each section changeover point in the proportions according to the following sequences (as
sequence, resulting in smooth changes from section directed by the particular load chart/crane configuration
23

to section without the need for the operator to selected by the operator; i.e. these sequences reside in the
“feather” the telescope control. system data software, not in the control software):

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BOOM RT890E SERVICE MANUAL

8
27
6 6081

FIGURE 4-1
2
23

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

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

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RT890E SERVICE MANUAL BOOM

Capacities at Intermediate Boom Lengths inner mid, center mid, and outer mid section
telescope cylinders. Thus, when so directed by
It is not mandatory that only the specified discrete boom
electrical signal, the pressure reducing valves
lengths are utilized for lifting, and intermediate boom lengths
effectively override the pilot pressure signal being
will be usable. The allowable capacities at intermediate
transmitted from the operator’s pilot controller to the
lengths behave in accordance with customary practice, in
telescope control valves, automatically opening,
that they reduce to the figure applicable to that adjacent
feathering and closing so as to initiate, control and
boom length having lower capacities (either the next longer
halt motion of the respective sections according to
or shorter rated boom length, according to the particular load
the predetermined sequence.
chart in use), whenever the actual boom length differs from
the rated length by more than 500 mm (19.7 in). (For any c. Mechanically actuated valves sensing the status of
given boom length, the capacities vary steplessly with load the center mid and outer mid sections (i.e. outer mid
radius according to the particular calibration curves). section fully retracted, and center mid section fully
extended) and diverting the flow of oil, when
Hydraulic Actuation and Control System extending, from the center mid section cylinder to
Extension of the inner mid, center mid, and outer mid the outer mid cylinder when the center mid section
sections occurs by way of three hydraulic cylinders (one 2- (and therefore also the inner mid section) is fully
stage cylinder moving the inner mid and center mid sections, extended, and vice versa during boom retraction.
and one single-stage cylinder, moving the outer mid section). Thus the outer mid section is not able to receive any
oil to extend until the center mid section is already
The fly section is cable extended and retracted by the
movement of the outer mid section and center mid sections, fully extended; and similarly, no “retract” oil will flow 4
and thus is mechanically synchronized with the outer mid to the center mid section until the outer mid section
section, but the other sections are electro hydraulically is fully retracted.
sequenced/synchronized by the boom telescoping control

8
d. A normally closed, solenoid operated 2-way, 2-
system. position control valve, which bleeds off residual rod
27
Controlling the telescope cylinders, the boom telescoping side pressure from the telescope cylinders (as
hydraulic actuating system consists of the following selected by a double check valve, according to the
elements: cylinder being telescoped, and an orifice to prevent
significant loss of oil to tank that would compromise
2
a. A single pilot pressure joystick or foot pedal cylinder retraction speed). The purpose of this valve
controller, which actuates two pilot operated 4-way, is to allow residual pressure trapped in the rod side
23

3-position, pressure compensated proportional of the cylinders to escape, preventing subsequent

control valves controlling the flow and pressure of unseating of the holding valve and transfer of the
hydraulic oil respectively to the inner mid and center trapped oil to the piston side, which can cause a
mid/outer mid section telescope circuits. slight spontaneous and unwanted extension of the
b. The propositional control valve(s) noted in a. above, boom sections
in which are incorporated solenoid operated e. Unless overridden by the pilot signal pressure
proportional pressure reducing valves in both of the reducing valves in paragraph b. (above), the oil flow
valves’ pilot pressure spool actuator sections (i.e. and pressure applied to the telescoping cylinders is
both “extend” and “retract” directions), acting to vary under the direct control of the joystick pilot
the pilot pressure being applied to shift the valve controller.
spool, and thereby controlling the flow of oil to the

Table 1: Boom Section Extension Proportions

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

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BOOM RT890E SERVICE MANUAL

Electronic Control System value, giving a smooth acceleration of that section. This
system prevents out of sequence conditions occurring as a
As mentioned previously, the electro hydraulic sequencing result of overshoot of the section that is coming to a halt, and
and synchronization of the inner mid and center mid section also enforces a smooth transition from section to section.
telescope cylinders are controlled through a combination
RCL/boom control system electronic processor/controller, An additional benefit occurs in situations in which the
since both systems need to sense the various section operator is simultaneously operating the hoist, in order to
extensions (i.e. to determine the boom length and its keep the load at a constant height while telescoping the
configuration [sectional extension relationships] in order to boom. Since telescoping speed inevitably varies from
compute allowable load moment and the corresponding section to section according to the bore of the cylinder, and
allowable hook load for RCL purposes, and to close the also whether a section is indirectly moved by a cable
telescope sequencing/synchronization system feedback extension system, the compensating speed of the hoist has
control loop). to be varied by the operator as each successive section
change occurs, so that the load does not immediately rise or
System Interfaces and Logic fall. The smooth changeover effect enforced by the
telescope control system allows the operator a wider band in
The electronic system is supplied with electrical power at
which to adjust compensatory speed of the hoist so that the
12 VDC.
load can be more easily kept at a constant height.
The electronic system collects electrical inputs from boom
The inner mid and center mid sections are extended by a 2-
length sensors that separately measure overall boom length,
stage cylinder, the larger diameter cylinder being the center
and extension of the inner mid section. Since the outer mid
mid section stage. Therefore this stage has the capability to
and fly sections are mechanically [cable-] synchronized, and
exert higher load than the inner mid section stage, for a given
change over of hydraulic oil supply to or from the outer mid/
hydraulic pressure. Such loads would exceed the buckling
fly section telescope cylinder is mechanically effected by trip

8
resistance of the smaller inner mid section stage, which in
valves upon full extension of the center mid section, or full
Automatic mode is already at 75% extension before the
retraction of the outer mid section, it is assumed that these
27
center mid section cylinder is actuated. For this reason, the
sections cannot become unsynchronized. Therefore, on this
system provides an additional electrical output to a dual
basis the computed difference between the measured boom
pressure relief valve integrated in the telescope control valve
extension value and the measured inner mid section
block, causing it to reduce the maximum pressure that can
extension value allows the system to infer the extension of
2

be applied to the center mid section telescope cylinder, so

the center mid section.
that the cylinder is protected from such excessive buckling
23

The system also collects electrical inputs of boundary loads. The system programming always ensures that the
conditions (operator selection, by switch, of “Automatic” or lower pressure is selected before the center mid section
Manual mode, electrical sensing, by proximity switches, of cylinder is pressurized, and that the center mid section
retracted condition of the inner mid section relative to the cylinder is isolated or fully extended, before the higher
base section, and of the center mid section relative to the pressure is selected and applied to the other cylinders.
inner mid section, and of telescope extend or retract pilot
The system also provides a control signal to the solenoid
pressure being applied). The system then produces current
operated telescope cylinder rod drain valve, opening the
controlled electrical outputs to the appropriate pilot system
valve whenever either the inner mid or center mid section is
proportional pressure reducing valves, allowing the pilot
not fully retracted (i.e. either of the section “retracted”
pressure to shift the telescoping control valve spools
switches is open), and closing the valve whenever both the
appropriately to direct oil to the inner mid or to the center mid
switches are closed, indicating complete boom retraction
section telescope cylinder, according to prevailing boom
condition.
length and to the direction of motion selected.
If for any reason loss of synchronization of the inner mid/
In Automatic mode, the control system output current being
center mid section telescoping system is detected by the
applied to the applicable valve is automatically reduced as
boom length sensing and computing system, the system
each section approaches a position at which the selected
inhibits all telescoping control signals to all four of the pilot
telescope sequence would require it to stop and the next
system proportional control valves, preventing any further
section to begin to move. This causes the pilot oil pressure
telescoping motion. To correct the condition, manual
being applied to the control valve spool to be proportionately
switches are incorporated, which, when actuated, change
reduced according to the current, (overriding the operator’s
the system from Automatic to Manual mode, and select
pilot control valve), so that the section telescoping speed
either the inner mid or center mid section for correction in
reduces smoothly before the section finally comes to rest. In
Manual mode. The selected section can then be telescoped
the same way the current supply to the valve controlling the
individually, by passing the automatic synchronization
following section is initiated just before the previous section
system, until it is brought into correct synchronization (the
finally comes to a halt, and rises smoothly to its regulated
system constantly displays the prevailing percentage of

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RT890E SERVICE MANUAL BOOM

extension of the sections, an indicator light on the console 3. If equipped, remove the swingaway boom extension and
remains illuminated as long as the unsynchronized condition auxiliary nose according to the removal procedures in
persists, and the inner mid or center mid section telescope this section.
cylinder selection is indicated by respective lights on the arm
4. Ensure the boom is in a horizontal position over the front
rest, thereby allowing the operator to telescope the section[s]
of the crane and the inner mid is extended 9%.
appropriately). As long as the system continues to detect the
unsynchronized condition, and/or the manual mode is 5. Position the boom to make sure that the lift cylinder is
selected, the load moment monitoring/lockout system also resting securely in the lift cylinder support.
limits the allowable load moment to 10,000 kg (22,046 lb) or
6. Shut down the crane and turn the battery disconnect
50% of the rated capacity at the particular prevailing boom
switch to OFF.
length, the intent being that, while the sections are
unsynchronized, any hook load will be deposited, only the
hook block remaining suspended while the necessary
adjustment of the boom sections occurs: only when
synchronization has been achieved will the system reset and DANGER
normalize the load monitoring system when switched back to Ensure the lifting device is capable of supporting the
Automatic mode. boom assembly.
The standard used by the system to define an
7. Attach a lifting device to the boom to provide for equal
unsynchronized condition is an error or +/-3% of the full
extension value of one section. Since the inner mid, center
weight distribution.
4
mid, and the outer mid/fly combination all extend individually, 8. Disconnect the PAT lines (RCL).
compliance with the criterion can only be assessed at
9. Tag and disconnect the three hydraulic lines from the
s e c t i o n e x t e n s i o n s c o r r e s p o n d i n g t o t h e p o i n ts o f
hose reel drive motor; cap or plug all lines and ports.

8
changeover of movement from section to section. Therefore,
the system reviews the extension of each section prior to NOTE: Hydraulic lines may be previously marked from fac-
27
permitting the changeover, and unless all section extension tory (“A” = this hose comes from the hose reel sup-
values are within 3% of their programmed changeover ply (HRS) port on the front steer/swing/brake valve
length, the system defaults to the out-of-synchronization manifold, “B” = this hose comes from the hose reel
condition described above. The same default occurs if, in the return (HRR) port on the front steer/swing/brake
2

course of operation, any boom section moves out of valve manifold) (Figure 4-2 and Figure 4-3).
23

synchronization to a length corresponding to one of its own

changeover lengths (since it then invokes the +/-3% criterion
against the other sections), or moves away from such a
changeover length by more than the 3% margin.

MAINTENANCE
Removal
NOTE: The boom weighs approximately 12,045 kg
(26,554 lb). Removal of the swingaway boom
extension will simplify boom removal, therefore, the
above weight is for the boom without the swinga-
way boom extension attached.
1. Extend and set the outriggers to level the crane.

CAUTION
Wear gloves when handling wire rope. Injury to your
hands is possible.
8071 FIGURE 4-2
2. Remove the hook block or headache ball and wind all
the wire rope onto the hoist drum.

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BOOM RT890E SERVICE MANUAL

8072-1
FIGURE 4-5
13. Remove the top hose roller at rear of boom, then pull out
8071-1 FIGURE 4-3 the two tri-lines and one bi-line from rear of boom
(Figure 4-6).
10. Remove the base cover from the top of the boom base
section near the pivot shaft.

8
11. Install S-hook on cab side of hose reel as shown in
27
(Figure 4-4) to prevent the reel from rotating once hoses
are disconnected.
2
S-Hook
23

8072-2
FIGURE 4-6

7119
FIGURE 4-4
DANGER
Ensure the boom lift cylinder is properly supported before
12. Tag and disconnect the hydraulic lines from the lower disconnecting it from the boom.
telescope cylinder; cap and plug all lines and ports
(Figure 4-5). 14. Block the lift cylinder.
15. Remove the bolt and washer securing the upper lift cyl-
inder shaft to the side of the attach fitting on the boom.
16. Remove upper lift cylinder shaft.
17. Take up the slack on the boom lifting device.
18. Remove clip pin and cross pin securing boom point pin
to base section.

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RT890E SERVICE MANUAL BOOM

19. Remove boom pivot pin. 10. Remove the 18 bolts and washers securing the bottom
and side wear pad keeper plates to the base section.
20. Raise the boom clear of the crane and lower to ground
Remove the keeper plates.
and set cribbing to support the boom and prevent tip-
ping. 11. Lift up on the front of the base and remove the bottom
and side wear pads and shims from the base section,
Boom Disassembly noting quantity, size, and location of shims.
1. Remove the boom in accordance with the REMOVAL 12. Continue to pull the assembly from the base section
procedures outlined in this section. removing the top rear wear pads from the inner mid sec-
tion as they clear the base section.
2. If necessary, on the left side of the boom remove the two
bolts and washers securing the RCL cable angle brack- 13. Remove the two bolts, washers, shims, and lower wear
ets to the base, inner mid, center mid, and outer mid. pad from the inner mid, noting the quantity and size of
shims.
NOTE: The boom weighs approximately 12,045 kg
(26,554 lb). The above weight is for the boom with- 14. Remove the cotter pins, shaft, and roller from the rear of
out the swingaway boom extension attached. the inner mid.
15. Remove the four bolts and hardened washers securing
each trunnion mounting plate from the lower cylinder
barrel.
DANGER
16. If necessary, remove both grease fitting connectors and
4
The boom assembly must be rotated 180° (upside down)
grease lines from the rear of the inner mid.
before performing any assembly or disassembly
procedures. 17. Remove the bolts, washers, and trigger plate from the

8
A rollover fixture with webbing is recommended to rotate front left side of the inner mid.
boom and sections. Chains are not recommended. If a
27
NOTE: Together the boom center mid, outer mid and fly
rollover fixture is not available, rotate sections using sections, and telescope cylinders weigh approxi-
adequate support with webbing. mately 6851 kg (15,104 lb).
A secure fixture that will prevent damage to the boom is
2
18. Slide the assembly out of the inner mid part way.
recommended to stabilize and hold the boom from moving
during removal of section or sections. 19. Remove the bolts and washers and the two set screws
23

and locknuts securing each front top wear pad to base

3. On the top front of the base section, remove bolts, wash- section. Remove two bolts and washers securing each
ers, and three cable pads. adjusting plate to top of base section. Remove two
adjusting plates. Remove upper wear pad assembly. If
4. Repeat step 3 on the inner mid, removing two cable
necessary, remove four bolts securing front upper wear
pads.
pad to pad plate.
5. Repeat step 3 on the center mid, removing two cable
20. Remove the 18 bolts and washers securing the bottom
pads.
and side wear pad keeper plates to the inner mid.
6. Repeat step 3 on outer mid, removing two cable pads. Remove the keeper plates.
7. Remove eight bolts, washers and the telescope mount 21. Lift up on the front of the center mid and remove the bot-
plates from the lower telescope cylinder. tom and side wear pads and shims from the inner mid,
noting quantity, size, and location of shims.
NOTE: The combined weight of the boom inner mid, center
mid, outer mid, and fly sections, including the tele- 22. Continue to pull the assembly from the inner mid, remov-
scope cylinders, is approximately 8,691 kg (15,185 ing the top rear wear pads from the center mid as they
lb). clear the center mid.
8. Slide the assembly out of the base part way. 23. Remove the two bolts, washers, shims, and lower wear
pad from the inner mid, noting the quantity and size of
9. Remove the bolts and washers and the two set screws
shims.
and locknuts securing each front top wear pad to base
section. Remove two bolts and washers securing each 24. If necessary, remove both grease fittings, connectors,
adjusting plate to top of base section. Remove two and grease lines from the rear of the inner mid.
adjusting plates. Remove upper wear pad assembly. If
25. Remove the mounting plates from the lugs on the lower
necessary, remove four bolts securing front upper wear
cylinder barrel.
pad to pad plate.

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BOOM RT890E SERVICE MANUAL

42 41
24
36

See View A

38
43 1
23

6315-3
44

36

4
6315-1
39
40
37
23

2 21
5

8
6
27 3
27 16
30
7
2
23

2 10

17

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

1 46

48

6641 47
View A FIGURE 4-7

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RT890E SERVICE MANUAL BOOM

Item Description Item Description

1 Base Section 26 Lower Sheave Shaft
2 Inner Mid Section 27 Upper Boom Nose Sheaves
3 Center Mid Section 28 Lower Boom Nose Sheaves
4 Outer Mid Section 29 Cable Retainer Pins
5 Fly Section Upper Sheave Shaft/Boom Extension Anchor
30
Lugs
6 Upper Telescope Cylinder
31 Anti-two Block Plate
7 Lower Telescope Cylinder
32 Cable Retainer
8 Extend Sheave Mounting Sheave
33 Bolt
9 Upper Cylinder Support Foot
34 Sled Weld
10 Wear Pads
35 Plate Cover
11 Extend Sheave Assembly
36 Stop Block Plates
12 Extend Sheave Shaft w/Grease Fitting
37 Lower/Side Keeper Plates
4
13 Extend Sheave Shaft Plate
38 Wear Pad Assembly
14 Cable Retainer
39 Screw

8
15 Cable Guide
40 Washer
16 Extend Cables
27
41 Pad Support
17 Retract Cables
42 Screw, Flatwasher
18 Skid Pad
43 Bracket
2
19 Lower Cylinder Mount
44 Screw, Washer, Lockwasher, Hex Nut
20 Lower Cylinder Mount Shaft
23

45 Lower Boom Extension Anchor Lugs

21 Upper Cylinder Support
46 Cable Guide Assembly
22 Wear Pad Support
47 Hitch Pin Clip
23 Shims
48 Washer
24 Cable Pads
25 RCL Cable Mounting Angles

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BOOM RT890E SERVICE MANUAL

1
56 60
2

51 60

3 49
4
60

52

60
5
10
6 16
58
61
10
57

8
27 59

53

10
2
50
58 55
23

54

59
58

17 7

6315-2
FIGURE4-7continued

Item Description Item Description

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

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RT890E SERVICE MANUAL BOOM

65

60

49

63

64
4
61

8
27
62
2
23

6315-4 58
FIGURE4-7continued

30. On the left side of the center mid, remove spring and the
valve pusher weld. Disassemble as necessary.
Item Description
62 Adapters 31. Place blocking under the lower second stage cylinder
barrel.
63 Valve Actuator
32. Remove the four bolts and hardened washer securing
64 Valve Actuator Arm each lower cylinder barrel mounting plate to the center
65 Grease Fitting mid.

26. Tag and disconnect the hydraulic hoses and tubes from 33. Remove five bolts and hardened washers securing each
the telescope cylinders, the two cam valves and the upper cylinder rod mounting plate to the center mid.
hydraulic manifold. Cap and plug all openings. NOTE: Together the boom outer mid, fly section, and tele-
27. Remove the three bolts, washers, and nuts securing scope cylinders weigh approximately 5217 kg
each cam valve to its mounting plate and remove the (11,501 lb).
valves. 34. Slide the assembly out of the center mid part way.
28. Remove the four bolts and washers securing the 35. Remove the bolts and washers and the two set screws
hydraulic manifold to the mounting plate and remove the and locknuts securing each front top wear pad to base
hydraulic manifold. section. Remove two bolts and washers securing each
29. On the right side of the center mid, remove the valve adjusting plate to top of base section. Remove two
pusher rod. adjusting plates. Remove upper wear pad assembly. If

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BOOM RT890E SERVICE MANUAL

necessary, remove four bolts securing front upper wear 51. If necessary, remove both grease fittings, connectors,
pad to pad plate. and grease lines from the rear of the fly section.
36. Remove the 18 bolts and washers securing the bottom
and side wear pad keeper plates to the center mid.
Remove the keeper plates.
DANGER
37. Lift up on the front of the outer mid section and remove Ensure the telescope cylinders are securely blocked and
the bottom and side wear pads and shims from the cen- some means used to hold them together to prevent any
ter mid, noting quantity, size, and location of shims. accidental movement. Severe injury can occur if the
38. Continue to pull the assembly from the center mid, cylinders drop.
removing the top rear wear pads from the outer mid sec-
tion as they clear the center mid. NOTE: The telescope cylinder assembly weighs approxi-
mately 1616 kg (3,563 lb).
39. Remove the two bolts, washers, shims, and lower wear
pad from the outer mid, noting the quantity and size of 52. Slide the telescope cylinder assembly part way out
shims. (approximately ten feet) of the rear of the fly. Support the
end of the telescope cylinders with adequate blocking.
40. If necessary, remove both grease fittings, connectors,
and grease lines from the rear of the outer mid. NOTE: The lower telescope cylinder assembly weighs
approximately 803 kg (1,770 lb).
41. Remove the retract cable sheave mounts from the rear
of the outer mid section, remove retract sheaves. 53. Slide the lower two stage cylinder farther out of the fly
until the end of the cylinder is out of the fly.
42. Remove the mounting plates from the second stage of
the lower cylinder barrel mounting lugs and upper cylin- 54. Remove the four bolts and washers holding the top plate

8
der mounting lugs. cover to the cylinder mount. Remove the two bolts
securing each wear pad if necessary.
27
43. Place blocking under the upper telescope cylinder bar-
rel. 55. Remove the two nuts and swivel nuts that attach the sled
weld to the two adjusting bolts at the end of the lower
44. Remove the four bolts and hardened washers securing cylinder.
2
each trunnion mounting plate from the upper cylinder
barrel mounting plate to the outer mid. 56. Slide the sled weld off the two adjusting bolts and
23

remove the adjusting bolts from the shaft on the lower

NOTE: Together the boom fly section, and telescope cylin- cylinder.
ders weigh approximately 3853 kg (8,494 lb).
57. Remove the four nuts that attach the retract cable ends
45. Slide the assembly out of the outer mid part way. to the sled weld. Remove the retract cables from the cyl-
46. Remove the bolts and washers and the two set screws inder mount.
and locknuts securing each front top wear pad to base 58. Remove the lower cylinder assembly and place on ade-
section. Remove two bolts and washers securing each quate support.
adjusting plate to top of base section. Remove two
adjusting plates. Remove upper wear pad assembly. If 59. If necessary, remove one cotter pin from the shaft that
necessary, remove four bolts securing front upper wear holds the cylinder mount to the lower cylinder.
pad to pad plate. NOTE: The telescope cylinder assembly weighs approxi-
47. Remove the 18 bolts and washers securing the bottom mately 803 kg (1,770 lb).
and side wear pad keeper plates to the outer mid. 60. Remove the shaft and cylinder mount from the lower cyl-
Remove the keeper plates. inder. If necessary, remove the bolts securing each pad
48. Lift up on the front of the fly section and remove the bot- to the cylinder mount.
tom and side wear pads and shims from the outer mid, 61. Remove the two bolts and hardened washers securing
noting quantity, size, and location of shims. the extend cable keeper plate to the rear of the fly.
49. Continue to pull the assembly from the outer mid, Remove the keeper plate and remove the four extend
removing the top rear wear pads from the fly section as cable ends from the slots in the fly.
they clear the outer mid. 62. Continue to slide the upper cylinder out of the fly making
50. Remove the two bolts, washers, shims, and lower wear sure that the cables are moving with the cylinder. Slide
pad from the fly, noting the quantity and size of shims. the telescope cylinder outward until the foot weld at the
end of the upper telescope cylinder is approximately two
feet from the rear of the fly.

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RT890E SERVICE MANUAL BOOM

63. Remove the two bolts and washers from each side of the 4. Remove the bolt, washer, and nut securing the upper
foot weld and remove both wear pad supports. If neces- boom nose sheave shaft. Remove the collar.
sary, remove two flat head screws and pad from each
NOTE: The upper boom nose sheave shaft weighs
support.
approximately 66 kg (146 lb). The boom nose
64. Continue to slide the telescope cylinder assembly out of sheaves weigh approximately 10 kg (22 lb) apiece.
the fly section. Raising the rear of the fly section and
5. Carefully pull the upper boom nose sheave shaft from
lowering the rod end of the cylinder will aid in removal.
the boom nose, removing the spacers, shims, and boom
65. On the front of the fly section, remove the two nuts and nose sheaves.
hardened washers from the end of each retract cable
6. Repeat steps 2 and 3.
and remove the retract cables from the fly section.
7. Remove bolts and washers securing shaft end plate to
66. Remove the two bolts and washers on both sides of the
lower boom nose shaft. Remove end plate.
sheave mount on the end of the upper cylinder that
holds the cable guide and shaft plates. Remove the 8. Carefully pull the lower boom nose shaft from the boom
cable guide and shaft plates. nose, removing spacers, shims, and sheaves.
67. Remove the two bolts and washers securing the extend 9. Remove the shim, keyed washer and locknut from both
cable retainer plate to the front of the sheave mount. sheave shafts.
Remove the retainer plate.
68. Remove the five extend cables from the sheave assem-
Installation
4
bly.
69. Remove the grease fitting from the shaft. Remove the CAUTION

8
sheave shaft and the sheave assembly from the mount- Do not install the boom nose sheaves over the threaded
ing assembly. end of the boom nose sheave shaft.
27
70. Remove the four bolts and hardened washers securing
NOTE: The lower boom nose sheave shaft weighs approx-
the sheave mounting assembly and the support foot to
imately 20 kg (44 lb). The boom nose sheaves
the front of the telescope cylinder. Remove the two bolts
weigh approximately 11.5 kg (25 lb) and 9 kg (20
2
and washers holding the cylinder support foot to the
lb) respectively.
sheave mount. Remove the sheave mounting assembly
23

and the support foot. 1. Install the spacers and sheaves onto the sheave shaft
while installing the sheave shafts into the boom nose.
71. If necessary, remove the two bolts securing each wear
pad to the support foot and remove the wear pads. NOTE: The lockwasher can be used more than once but
must be replaced if not in good condition.
72. Remove the two bolts and washers that retain the plate
cover to the sled weld. Remove the plate cover and NOTE: Install the lockwasher onto the sheave shaft with
remove the five extension cables. the tabs facing out.
73. If removal of the boom nose sheaves are required, refer 2. Install the locknut, washer, keyed washer, and shims (if
to BOOM NOSE SHEAVES - Removal in this section. necessary) onto the boom nose sheave shaft with the
chamfer side out. Install the collar onto the opposite end
74. Refer to BOOM EXTENSION AND RETRACTION
of the upper shaft and secure in place with the bolt,
CABLE MAINTENANCE in this section for cable inspec-
washer, and nut. Install end plate onto opposite end of
tion.
lower shaft and secure in place with bolts and washers.
Boom Nose Sheaves NOTE: If more than one shim is required, install an equal
amount on each side of the boom nose.
Removal
3. Tighten the locknut until the play in the entire assembly
1. Remove the clip pins from the cable retainer pins and is within 1 to 2 mm (0.03 to 0.06 in) total. Install shims as
remove the cable retainer pins from the upper and lower necessary to achieve the correct dimension. Bend the
part of the boom nose. lockwasher tabs to secure the locknut in place.
2. Flatten out the tab on the lockwasher. 4. Install the cable retainer pins into the upper and lower
3. Backoff locknut until there is no pressure on the lock- part of the boom nose and secure in place with the clip
washer. pins.

GROVE Published 9-18-2014, Control # 308-06 4-15

BOOM RT890E SERVICE MANUAL

Boom Assembly 6. If removed, install the two wear pads on the top of the
cable guide by using two flathead screws.
7. Install the other ends of the extension cables into the
CAUTION sled weld, making sure the extension cables are not
When adjusting cables, hold the cable end and turn the crossed and twisted.
nut. Install cables in their natural untwisted condition. Do
8. Install the plate cover on the sled weld and secure with
not turn or twist the cable. Turning/twisting cable while
two bolts and washers.
adjusting will result in damage or failure of cable.
9. At the rear of the fly section, install the upper wear pad
NOTE: Apply Loctite 243 to the threads of all attaching grease line, connector and grease fitting on each side.
hardware except cable ends and cable lock nuts.
10. Install the lower rear wear pad and shims on the fly sec-
Apply multipurpose grease (MPG) to all wear tion with two flat head screws.
surfaces.
11. Route the two retract cables (threaded ends) through
Use standard Grade 5 and/or 8 torque values the fly section to the front. Insert the threaded ends
specified in Section 1 of this Manual unless through the holes on the front of the fly section and
otherwise specified. install a hardened washer and two nuts on each cable
end.
12. Using an adequate lifting device, position the upper tele-
scope cylinder into the rear of the fly section.
DANGER
13. Slide the telescope cylinder assembly into the rear of the
The boom assembly must be rotated 180° (upside down)
fly section until foot support clears the gussets at the

8
before performing any assembly or disassembly
rear of the fly section. Raising the rear of the fly and low-
procedures.
ering the rod end of the cylinders will aid in sliding these
27
A secure fixture that will prevent damage to the boom is together.
recommended to stabilize and hold the boom from moving
during insertion of section or sections. 14. Place the five extend cable lug ends in the slots at the
top of the fly section and secure them with the keeper
2

1. Install wear pads on the bottom of the upper telescope plate and two bolts and hardened washers.
23

cylinder support foot using two screws each. 15. Install a wear pad on the two upper telescope cylinder
2. Install the support foot and the sheave mounting assem- wear pad holders using two flat head screws.
bly on the front of the upper telescope cylinder assem- 16. Position the wear pad holders on each side of the upper
bly, with four bolts and hardened washers. Attach the telescope cylinder support foot and secure each with
support foot and the sheave mounting assembly two bolts and hardened washers.
together using two bolts and hardened washers.
17. Slide the upper telescope cylinder assembly part way in
NOTE: The sheave shaft should be installed with grease (approximately ten feet). Place blocking under the rear
fitting hole to the left side. of the telescope cylinder to aid in assembly.
3. Using the sheave shaft, install the sheave assembly in 18. Using the cylinder mount shaft attach the lower cylinder
the sheave mounting assembly, making sure the grease mount to the end of the lower cylinder. Attach cotter pins
fitting hole is toward the left of the assembly. Secure the to secure shaft.
shaft and the cable guide with a cable guide weld and
two bolts and washers on each side of the sheave 19. Install the wear pad and skid pad with bolts to the lower
mounting assembly. Install grease fitting in the shaft and cylinder mount.
apply grease. 20. Lift lower telescope cylinder assembly and place on
4. Route the end of the five extension cables up and upper telescope cylinder.
around the upper telescope cylinder sheaves about one 21. Install the wear pads with bolts to the top plate cover.
foot onto the cylinder. To aid in assembly, secure the
cables to the end of the cylinder by wrapping tape 22. Install the top plate cover assembly with four bolts and
around the cylinder. washes to the lower cylinder mount, to attach the upper
and lower cylinders together.
5. Position the cable retainer plate on the front of the
sheave mounting assembly and secure with two bolts 23. Install both ends of the retract cables to the appropriate
and lockwashers. holes in the lower cylinder mount, making sure that the

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RT890E SERVICE MANUAL BOOM

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

26. Slide the telescope cylinders into the fly section until the 38. Continue to completely slide together.
trunnion on the upper cylinder is three feet from the back 39. Lift up on end of the upper cylinder to align barrel mount-
of the fly. ing plate holes with holes in outer mid. Secure each with 4
27. Block up the telescope cylinders at the rear of the fly four bolts and hardened washers.
section to aid in installing the fly section assembly into 40. Remove any blocking under the upper cylinder.
the outer mid.

8
41. Detach the retract cables from the upper telescope cylin-
28. At the rear of the outer mid section, install the upper der, place the cables around each retract sheave, place
27
wear pad grease line, connector and grease fitting on the sheave onto the shaft weld and use four bolts and
each side. washers to secure each shaft weld assembly into the
29. Install the bottom rear wear pad on the outer mid section rear of the outer mid, making sure that the retract cables
2

with two bolts and hardened washers. are not crossed and twisted.
42. Install and adjust guide bolts to the correct clearance
23

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

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BOOM RT890E SERVICE MANUAL

tion side plate. Use equal number of shims on each 63. At the rear of the inner mid section, install the upper
side. wear pad grease line, connector, and fitting on each
side.
49. Install bottom and side front wear pads in center mid. Lift
up in the front of the outer mid section assembly, check 64. Install the bottom rear wear pad on the inner mid section
clearance between the pads and the pad box weldment with two bolts and washers.
on the center mid section. Install shims as necessary so
65. Position the front end of the inner mid at the rear of the
there is no more than 1 mm (0.03 in) clearance between
center mid/outer mid/fly/telescope cylinder assembly.
the wear pads and the outer mid section.
66. Slide the center mid/outer mid/fly/telescope cylinder
If necessary, attach front upper wear pad to wear pad
assembly into the inner mid section installing top rear
plate using four bolts.
wear pads in pockets of the center mid section (cutout
50. Install center mid front top wear pads and shims as should align with grease line). Stop and install rear side
noted during disassembly. Secure with four bolts and wear pads and shims on center mid section with two
washers each. bolts each.
NOTE: Use adjusting screws as necessary to adjust wear NOTE: Use shims as necessary to adjust wear pad so it is
pad so that the wear pad is just touching or is within within 2 mm (0.078 in) of the inner mid section side
2 mm (0.078 in) of the outer mid section side plate plate. Use equal number of shims on each side.
at both the top and side surfaces of the top radius.
67. Continue to slide together.
51. Install bottom and side wear pad keeper plate on each
68. Install bottom and side front wear pads in the inner mid.
side of the center mid and secure with six bolts and
Lift up in the front of the center mid section assembly,
washers each.
check clearance between the pads and the pad box

8
52. Continue to slide together aligning the upper cylinder rod weldment on the inner mid section. Install shims as nec-
end mounting plate holes with holes in center mid. essary so there is no more than 1 mm (0.03 in) clear-
27
Secure each with four bolts and washers. Slide com- ance between the wear pads and the center mid section.
pletely together.
If necessary, attach front upper wear pad to wear pad
53. Install tapped pusher rod, bolt, nut, and washer in right plate using four bolts.
2
side of center mid.
69. Install center mid front top wear pads and shims as
54. Install left side valve pusher weld assembly in guides on noted during disassembly. Secure each with four bolts
23

left side of center mid, then attach return spring. and washers.
55. Lift up on end of the lower cylinder to align barrel mount- NOTE: Use adjusting screws as necessary to adjust wear
ing plate holes with holes in inner mid. Secure each with pad so that the wear pad is just touching or is within
four bolts and hardened washers. 2 mm (0.078 in) of the outer mid section side plate
at both the top and side surfaces of the top radius.
56. Remove any blocking under cylinder.
70. Install bottom and side wear pad keeper plate on each
57. Install the cam valves on the mounting plates on each
side of the inner mid and secure with six bolts and wash-
side of the inner mid using three bolts, hardened wash-
ers each.
ers, and nuts each.
71. Continue to completely slide together.
58. Install hydraulic manifold on the mount plate at the rear
of the center mid with four bolts and washers. 72. Lift up on end of the lower cylinder to align barrel mount-
ing plate holes with holes in inner mid. Secure each with
59. If removed, install hydraulic fittings in the ports of the
four bolts and hardened washers.
valves, hydraulic manifold, and the cylinders as tagged
during disassembly. 73. Remove any blocking under cylinder.
60. Connect the hydraulic hoses and tubing to the valves, 74. Install the trigger plate at the front of the inner mid.
hydraulic manifold, and cylinders as tagged during dis-
75. Install and adjust guide bolts to the correct clearance
assembly.
with respect to the guide plate on next section. Lock in
61. Place the mounting plates on the lower cylinder barrel place with lock nuts.
mounting lugs.
76. If removed, install the roller shaft and cotter pins at the
62. Install and adjust guide bolts to the correct clearance rear of the inner mid. Place the mounting plates on the
with respect to the guide plate on the next section. Lock lower cylinder rod mounting lugs.
in place with lock nuts.

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RT890E SERVICE MANUAL BOOM

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

8
and washers each.
81. Install center mid front top wear pads and shims as
94. Install the boom in accordance with the INSTALLATION
27
noted during disassembly. Secure with four bolts and
washers each. procedures outlined in this section.

NOTE: Use adjusting screws as necessary to adjust wear Installation

2
pad so that the wear pad is just touching or is within
2mm (0.078 in) of the inner mid section side plate NOTE: The following procedure applies to a boom totally
removed from the crane.
23

at both the top and side surfaces of the top radius.

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

GROVE Published 9-18-2014, Control # 308-06 4-19

BOOM RT890E SERVICE MANUAL

DANGER
Failure to properly support the boom lift cylinder may
result in death or injury to personnel.

7. Using the lifting device attached to the boom, lower the

boom onto the lift cylinder rod end and extend the lift cyl-
inder as necessary to align rod with attach fitting on
boom.

DANGER
If the hydraulic system must be activated to extend or
retract the lift cylinder, ensure the rod end is properly 8072-3
FIGURE 4-8
aligned with the lift cylinder attach fitting.
17. After the bi-line is connected, pull the bi-line hoses by
8. Lubricate the upper lift cylinder pin. Install upper lift cylin- hand to remove the S-hook.
der pin.
NOTE: Be sure to hold tension on the hose and allow them
NOTE: The lift cylinder may need to be raised or lowered to wrap up on the reel.

8
to aid in the installation of the lift cylinder pin into
18. Connect the three hydraulic lines to the hose reel drive
the lift box, this can be done by using the jack on
motor as tagged prior to removal.
27
the lift cylinder support. Return pump handle to
cab. NOTE: Hydraulic lines may be previously marked from fac-
tory (“A” = this hose comes from the hose reel sup-
9. Secure the upper lift cylinder pin with the bolt and
ply (HRS) port on the front steer/swing/brake valve
2
washer to the attached fitting on the boom.
manifold, “B” = this hose comes from the hose reel
10. Lower the jack on the lift cylinder support. return (HRR) port on the front steer/swing/brake
23

valve manifold) (Figure 4-9).

11. Remove the boom lifting device.
12. Activate the hydraulic system and remove the boom and
lift cylinder blocking devices. Lower the boom to horizon-
tal. Shut down the crane.
13. Connect the PAT lines (RCL).
14. Connect the hydraulic lines to the lower telescope cylin-
der as tagged prior to removal
15. Extend the inner mid until its end is accessible through
the access hole in the top of the boom base section.
16. Connect the hose reel’s two tri-lines and one bi-line to
the lower telescope cylinder as tagged prior to removal
(Figure 4-8).

8071-1 FIGURE 4-9

19. With someone watching the hose reel to ensure the

hydraulic lines wrap up properly, start the engine.

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RT890E SERVICE MANUAL BOOM

Ensure hoses lay flat and there are no hydraulic leaks. Boom alignment is done as the boom sections are being
Shut off engine. assembled into one another. A check and fine adjustment is
as follows.
20. Install the top hose roller using the clips (Figure 4-10).
1. Fully extend the boom horizontally.
2. Lubricate the boom bottom channels and top corners.
3. Adjust the front top wear pads such that wear pad is just
touching or is no more than 2 mm (0.078 in) from con-
tacting the next section both at the top and side surfaces
of the top radius.

CAUTION
When extending and retrac ting the boom during
alignment, movement should be stopped if a restriction is
encountered, and wear pads adjusted as necessary to
provide free travel of the affected boom section(s).

4. Retract and extend the boom; check for the high point
where the boom has brushed the wear pads at the wid- 4
8072-4
FIGURE 4-10 est point.

21. Install the base cover at the top of the boom base sec- 5. Retract the boom sections to align the high point on the

8
tion near the pivot shaft. boom section with the adjacent wear pads.
6. Add or subtract shims as necessary.
27
22. Refer to BOOM EXTENSION AND RETRACTION
CABLE ADJUSTMENT in this section for cable adjust- 7. Attach a weight and extend the boom full length. Check
ments. for side deflection.
23. Refer to CAM OPERATED CHECK VALVE ADJUST-
2

MENT in this section for valve adjustment. Example: If the boom deflects to the left, the top left wear pad
would have shims added and the top right wear pad would
23

Functional Check have shims removed.

1. Activate the hydraulic system and check for proper oper- Cam Operated Check Valve Adjustment
ation and any leaks.
There are two cam operated valves mounted on the back of
2. Ensure the boom will extend and retract properly. the center mid section. When the boom is fully retracted or
the center mid is fully extended and the outer mid is fully
3. Ensure the lift cylinder will not allow the boom to drift
retracted, the valve on the right side of the boom is held open
down until the operator lowers it.
to supply flow to the second stage of the lower cylinder.
4. Ensure all electrical components disconnected during When the center mid is fully extended, the valve on the left
removal are operating properly. side of the boom opens to supply flow to the upper telescope
cylinder. For a short period of time, both valves are open
Inspection because the booms second stage lower cylinder is fully
extended before the upper cylinder starts to extend. As the
Visually inspect telescoping sections for adequate lubrication
outer mid starts to extend, the valve on the right side closes
of all wear surfaces. Observe extended sections for
to shut off the flow to the second stage of the lower cylinder.
evidence of cracks, warping, or other damage. Periodically
check security of boom wear pads. Check boom nose 1. Ensure the extend and retract cables are adjusted.
sheaves for security and freedom of movement.
2. Extend the inner mid section out of the base section until
Should boom chatter or rubbing noises in the boom occur, it the front access holes on the inner mid section are
will be necessary to lubricate the telescope cylinder wear accessible. The inner mid section can be extended com-
pads. Refer to SECTION 9. pletely if needed. Extend the center mid section com-
pletely making sure that the outer mid section is against
Boom Alignment and Servicing the stop blocks on the center mid section.
Refer to SECTION 9 for the proper lubricant. 3. Access the check valves through the front access holes
on each side of the inner mid section.

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BOOM RT890E SERVICE MANUAL

4. Left side valve: on the left side of the inner mid section, 5. In standing ropes, more than two broken wires in one lay
adjust the trigger plate to move the pusher weld causing in sections beyond end connections or more than one
the pusher to just contact the valve stem. Continue to broken wire at an end connection.
adjust the trigger plate until the pusher depresses the
6. In rotation resistant rope, two randomly distributed bro-
valve stem approximately 10 mm (0.39 in). Tighten the
ken wires in six rope diameters or four randomly distrib-
nuts.
uted broken wires in 30 rope diameters.
5. Right side valve: through the access hole in the inner
7. Severe corrosion as evidenced by pitting.
mid section on the right rear of the center mid, loosen
the lock nut and adjust the bolt until it just contacts the 8. Manitowoc recommends that for cable extended booms,
valve stem. Continue to adjust the bolt until it depresses a single damaged wire rope assembly shall require
the valve stem approximately 10 mm (0.39 in). Tighten replacement of the entire set of extension cables.
the lock nut.
9. Manitowoc recommends for cable extended booms, that
Guide Block Adjustment boom extension cables be replaced every seven (7)
years.
1. Align and service the boom by following the instructions
in Boom Alignment and Servicing, page 4-21.
CAUTION
2. Adjust the bolts at the top and bottom of the inner/center/ Any cutting of this specific wire rope is not recommended.
outer/ and fly section so that the bolt is within 0 to 2 mm If 35x7class wire rope must be cut for any reason, it is
of the guide plate on the top and bottom of the next sec- necessary to follow the following instructions. Also, unlike
tion. other types of wire rope, the ends on this wire rope must
be welded to retain the rotation resistant characteristics.
3. After obtaining proper clearance, tighten the four lock-

8
nuts.
Adjustment
27
BOOM EXTENSION AND RETRACTION At near fully extended boom length, during sudden extension
CABLE after retracting the boom some distance, and with high
telescoping speeds, the extension cables may slap the
Maintenance inside of the boom section. This will make a somewhat
2

audible noise, however this will not cause any damage and is
NOTE: For more detailed information concerning mainte- acceptable. If the cables do not make a slapping noise under
23

nance of the extension and retraction cables, refer these conditions, it is an indication that the extension cables
to WIRE ROPE in SECTION 1. may be too tight and should be readjusted. Be aware that
there may also be a similar noise made by the telescope
Inspection
cylinder rod mount at the rear of the base section and center
mid section and confusion between the two could be
experienced.

CAUTION
Never handle wire rope with bare hands. CAUTION
When adjusting cables, hold the cable end and turn the
Th e following information is taken from a Na tional nut. Do not turn cable. Turning cable while adjusting will
Consensus standard as referenced by Federal Government result in damage or failure of cable.
Agencies.
All wire rope will eventually deteriorate to a point where it is NOTE: The extension cables must be adjusted properly
no longer usable. Wire rope shall be taken out of service before the retract cables can be adjusted.
when any of the following conditions exist. 1. Extend and set the outriggers, ensuring the crane is
1. Kinking, crushing, bird caging, or any other damage level.
resulting in distortion of the rope structure. 2. Ensure the boom is over the front and at a horizontal
2. Evidence of any heat damage from any cause. position (boom angle elevation 0 degrees or lower).
3. Reductions from nominal diameter of more than: 5% 3. With the inner mid section completely retracted, extend
the center mid section until the large access hole at the
4. In running ropes, six randomly distributed broken wires front of the center mid is lined up with the large access
in one lay or three broken wires in one strand in one lay. hole in the outer mid section.

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RT890E SERVICE MANUAL BOOM

4. With the front of the boom in the above position, extend 10. Extend the boom approximately 1.5 cm (0.6 in). Retract
the boom approximately 25 mm (1 in) to relieve the ten- the boom again until one of the stop blocks just contacts
sion in the retract cables. Access the retract cables from its boom section.
the front of the boom nose and view the slack of the
11. Again check the gap as in step 9 and if necessary, make
retract cables through the hole in the back of the boom
further adjustments.
nose. Using the nuts on the retract cables, remove slack
evenly, until both retract cables are at least 25 mm (1 in) 12. Repeat steps 10 and 11 until there is a 3 mm (0.125 in)
above the lower leg of the cable retainer bars on the cyl- gap at the outer mid section’s stop block when the fly
inder foot support on the upper telescope cylinder. section’s stop block has just made contact.
5. Retract the boom approximately 25 mm (1 in) to relieve 13. Lock the retract cable adjustments with the jam nuts.
tension on the extension cables. Shut down the crane.
NOTE: If grease zerks are not fully accessible at full boom
Access the extension cable adjusting bolts through the
extension, make the following adjustments.
access hole in front of the center mid section. Evenly
tighten the swivel nuts on the adjusting bolts, until the 14. Retract boom approximately one foot and tighten extend
extension cables are up 150 mm (6 in) off the top of the cables one full turn each.
bottom pad plate at the back of the fly section. Look
through the access hole on the center mid section. 15. Extend boom to make sure grease zerks line up with
hole. If not lined up with hole, retract boom slightly and
6. Lock the adjustments with the jam nuts. add one additional turn on each of the extend cables.
7. Extend the boom until the outer mid/fly extends several 16. Once grease zerk lines up with boom at full extension, 4
cm (in). fully retract boom at Hi speed. When boom initially
begins to retract, extension cables should become slack
8. Retract the boom until either the fly section just contacts
enough to hit the boom section. If this does not happen,

8
the outer mid stop block or the outer mid section just
reduce tension on retract cables until they do become
contacts the inner mid stop block.
slack.
27
9. Check the gap between the stop blocks and the boom
17. Just as the boom begins to bottom out, observe that the
sections. If there is a gap between the center mid sec-
fly still bottoms out before the outer mid. If so, all adjust-
tion’s stop block and the outer mid of more than 3 mm
ments are correct.
2
(0.125 in), loosen the retract cable. If there is gap
between the outer mid section’s stop block and the fly
23

section, tighten the retract cable slightly.

CAUTION
Overtightening of the retract cable will damage the cable.
Take care when retracting the boom fully, while adjusting
the cable, to avoid full boom retraction if the fly section
contacts its stop block more than 3 mm (0.125 in) before
the outer mid section contacts its stop block on the center
mid.

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BOOM RT890E SERVICE MANUAL

TELESCOPE CIRCUIT with a long boom length and low boom angle, and the
hydraulic oil in the telescope cylinders cools and contracts,
Description the friction forces in the extended boom will prevent the
boom from retracting. Then, if the operator begins to elevate
The boom telescope circuit consists of the telescope the boom without telescoping out slightly, the crane may
hydraulic remote controller, telescope directional control reach a boom elevation angle where the weight of the boom
valve, holding valve, hose reel, and the upper and lower sections and load overcomes the friction forces in the boom
telescope cylinders. sections, causing the boom to retract until the column of oil
The telescope control valve is the closed spool type and is inside the cylinders once again supports the boom sections.
described under VALVES in SECTION 2 along with a The telescope cylinder charge system will prevent the boom
complete description of the hydraulic remote controller. from retracting under these conditions by automatically
replenishing the volume of hydraulic oil lost in the telescope
The boom telescope system has a lower and an upper cylinders due to thermal contraction.
telescope cylinder. The lower telescope cylinder is a two
stage cylinder. The first stage is 6.50 inch bore and the Additionally, the system utilizes a pressure switch plumbed
second stage is a 8.25 inch bore. The upper has a 6.50 inch into the telescope extend circuit, which will turn on the
bore. Foreign material is prevented from entering the telescope cylinder charge indicator and sound the warning
cylinder by a wiper seal during rod retraction. O-ring seals buzzer in the operator’s cab if the charge system is not
prevent internal and external leakage. Refer to CYLINDERS functioning properly (see Telescope Cylinder Charge
in SECTION 2 for a complete description of the telescope Indicator in Section 3 of the applicable Operator’s Manual).
cylinder. Refer to Valves, page 2-31 for a complete description of the
telescope cylinder charge valve manifold. Refer to the sub-
A holding valve is threaded into a port block on the rod end of section titled Telescope Cylinder Charge System - Electrical
the upper telescope cylinder and the first stage rod end on Schematic (If Equipped), page 3-20 for an electrical

8
the lower telescope cylinder. The holding valve for the schematic of this system.
second stage of the lower telescope cylinder is mounted into
27
the port block on the barrel end of the second stage barrel. Theory of Operation
The holding valves function during the retraction, extension,
or holding operation. When holding the boom section at a Flow from the pump travels to the telescope directional
given length, oil is trapped in the cylinder by the holding control valve. Movement of the foot pedal for telescope
2

valve. Refer to VALVES in SECTION 2 for a complete functions from neutral sends a pilot pressure signal to the
description of the holding valve. directional control valve to shift the spool in the directional
23

control valve. This aligns the appropriate passages in the

Cranes equipped with a telescope cylinder charge system control valve to route oil to the telescope cylinders.
will have an additional valve manifold in the telescope circuit
to prevent boom retraction due to thermal contraction under Also refer to BOOM - THEORY OF OPERATION in this
the following operating conditions: If the crane is operated Section.

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RT890E SERVICE MANUAL BOOM

Maintenance
Table 4-1Troubleshooting

SYMPTOM PROBABLE CAUSE SOLUTION

1. Erratic operation of a. Low hydraulic oil level. a. Replenish hydraulic oil to proper level.
extending telescop-
b. Damaged relief valves. b. Repair or replace relief valves.
ing cylinder.
c. Air in telescope cylinder. c. Bleed by lowering telescope cylinder
below horizontal.
d. Low engine rpm. d. Increase engine rpm to recommended
setting.
e. Lack of lubrication on boom sections. e. Properly lubricate all boom sections.
f. Extremely tight boom extension f. Inspect and properly lubricate boom
sheaves. extension sheaves.
g. Improper boom alignment caused from g. Reduce and properly hoist load.
side loading.
h. Worn boom wear pads. h. Replace wear pads and properly 4
lubricate.
i. Distorted boom section. i. Replace distorted section.

8
j. Damaged telescope cylinder. j. Repair or replace cylinder.
k. Clogged, broken, or loose hydraulic k. Clean, tighten, or replace lines or
27
lines or fittings. fittings.
l. Damaged control valve. l. Repair or replace control valve.
2. Erratic operation of a. Low hydraulic oil level. a. Replenish hydraulic oil to proper level.
2

retracting telescop-
b. Damaged relief valve. b. Repair or replace relief valve.
23

ing cylinder.
c. Air in cylinder. c. Bleed by lowering telescoping cylinder
below horizontal and cycle telescope
cylinder.
d. Low engine rpm. d. Increase engine rpm to recommended
setting.
e. Lack of lubrication. e. Properly lubricate all boom sections.
f. Check valve malfunctioning. f. Repair or replace check valve.
g. Improper boom alignment caused from g. Reduce and properly hoist load.
side loading.
h. Extremely tight boom retraction h. Inspect and properly lubricate.
sheave.
i. Distorted boom section. i. Replace distorted section.
j. Worn boom wear pads. j. Replace wear pads and properly
lubricate.
k. Bent cylinder rod(s). k. Replace cylinder rod(s) and all cylinder
seals.
l. Scored cylinder barrel. l. Repair or replace cylinder barrel.
m. Damaged piston seals. m. Replace all cylinder seals.
n. Loose or damaged piston(s). n. Replace all seals and re-torque or
replace piston(s).

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BOOM RT890E SERVICE MANUAL

SYMPTOM PROBABLE CAUSE SOLUTION

3. Telescope cylinder a. Low hydraulic oil level. a. Replenish oil to proper level.
will not extend.
b. Relief valve malfunctioning. b. Repair or replace relief valve.
c. Excessive load. c. Reduce load.
d. Clogged hose and fittings. d. Replace hose or fittings. (Refer to Parts
Manual).
e. Broken valve spool. e. Replace valve.
f. Damaged piston seals. f. Replace all cylinder seals.
g. Damaged piston(s). g. Replace piston(s) and all cylinder
seals.
h. Bent boom section(s). h. Replace damaged boom section(s).
i. Broken hydraulic pump coupling. i. Replace broken hydraulic pump
coupling.
j. Worn or damaged hydraulic pump j. Repair or replace pump section.
section.
4. Telescope cylinder a. Low hydraulic oil level. a. Replenish oil to proper level.
will not retract.
b. Relief valve damaged. b. Repair or replace relief valve.
c. Excessive load. c. Reduce load. (Refer to load chart).

8
d. Inoperative check valve. d. Replace check valve.
27
e. Clogged hose and fittings. e. Replace hose or fittings. (Refer to Parts
Manual).
f. Broken valve spool. f. Replace valve section.
2

g. Broken piston(s). g. Replace piston(s) and all cylinder

23

seals.
h. Damaged piston seals. h. Replace all cylinder seals.
i. Bent boom section(s). i. Replace damaged boom section(s).
j. Broken hydraulic pump coupling. j. Replace broken hydraulic pump
coupling.
k. Worn or damaged hydraulic pump. k. Repair or replace pump.
l. Broken hydraulic pump shaft. l. Replace pump shaft.
5. Center mid will not a. Right side check valve blocked. a. Readjust, repair, or replace valve.
extend.
6. Center mid will not a. Right side check valve closed. a. Readjust valve.
retract.
7. Outer mid will not a. Left side check valve is closed. a. Readjust valve.
extend.
8. Center mid retracts a. Right side check valve is open or a. Install hoses properly.
before outer mid. hosed backwards.
9. Outer mid extends a. Left check valve is open or hosed a. Install hoses properly.
only a short dis- backwards.
tance then stops.

Removal and Installation boom is described under disassembly and assembly of the
boom. Refer to BOOM MAINTENANCE in this Section.
Removal and installation of the telescope cylinder from the

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RT890E SERVICE MANUAL BOOM

Disassembly and Assembly 3. Tag and disconnect the hose reel hydraulic hoses from
the manifold block assembly; cap hoses and openings.
Disassembly and assembly procedures of the telescope
cylinder and control valve are provided in SECTION 2 under 4. Remove the capscrews and washers securing the hose
CYLINDERS and VALVES respectively. reel to the turntable, remove the hose reel.

HOSE REEL Installation

NOTE: The drum must have a minimum of two pre- tension
Description turns.
The quadruple plus one hydraulic hose reel Figure 4-11 1. Position the hose reel assembly on the turntable and
supplies the boom manifold for the upper telescope cylinder. secure with the washer and capscrews. Torque cap-
The hose reel is mounted in the turntable center section, screws; refer to Fasteners and Torque Values, page 1-
under the boom. 14 for proper torque value.
The hose reel is spring return. The spring return provides 2. Connect the hydraulic supply hoses to the hose reel
drag on the hoses so that no slack develops when the assembly.
telescope cylinders are being extended or the boom is being
lowered, and retrieves the hoses as the telescope cylinders NOTE: Ensure there is enough hose unwound from the
are being retracted or when the boom is raised. hose reel to attach the hoses to the telescope cylin-
ders.
Maintenance 4
Service
DANGER

8
Lubricate the hose reel spring with engine oil through the
drain access holes located around the circumference of the Ensure the retaining bolt remains installed until the hoses
27
spring cover. Lubricate every 50 operating hours. are attached to the telescope cylinders.
With the boom fully retracted, spray motor oil, under
3. Connect the hydraulic hoses to the manifold block
pressure, into the hose reel spring housing. The spring
assembly located at the rear of the boom inner mid
2
should be saturated with oil. If air pressure lubricating
section.
equipment is not available, use a pump oil can, but ensure
23

the spring is completely saturated with oil. 4. Remove the retaining bolt from the hose reel to allow
tension to be applied to the hoses.
Removal
5. Secure the retaining bolt to the hose reel so the hose
reel is allowed to rotate.

DANGER 6. Adjust and secure the hose retainer.

Before disconnecting the hoses from the outer mid
Hose Reel Alignment
telescoping cylinders, secure the hoses from rotating by
using the hose reel retaining bolt and drum locking After hose reel is installed and the attaching bolts properly
brackets. torqued, check hose reel to hose guide roller alignment
Figure 4-11.
1. Secure the rotation of the hose reel by using the retain-
1. Check measurements between the hose reel’s hose
ing bolt and drum locking bracket.
flanges and its guide roller Figure 4-11.
2. Tag and disconnect the hydraulic supply hoses for the
2. Add shims as required to align the hose reel assembly to
hose reel assembly; cap hoses and openings.
the roller within 2 mm (0.07 inches).

GROVE Published 9-18-2014, Control # 308-06 4-27

BOOM RT890E SERVICE MANUAL

6 12
4 13
5
3
8 7 10
15

6434-2

12
1
2 11 13

6434-3

12 14
9

2 mm (0.07 in)

8
27
2 mm
(0.07 in)
2

Shims
23

6434-1

Hose Reel To Hose Guide Roller Alignment FIGURE 4-11

Item Description Item Description

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

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RT890E SERVICE MANUAL BOOM

LIFT CIRCUIT
Description The holding valve is a balanced poppet type hydraulic valve.
It is threaded into the port block which is an integral portion of
The boom lift circuit consists of the lift hydraulic remote the lift cylinder barrel. The holding valve functions when
controller, lift directional control valve, holding valve, and the booming up (cylinder rod extended), booming down (cylinder
lift cylinder. These components enable the boom to be raised rod retracted), or holding (cylinder rod stationary).
or lowered to various degrees of elevation ranging from -3 to
+78 degrees from horizontal. Theory of Operation
The lift directional control valve is the closed spool type and The directional control valve bank housing the lift control
is described under VALVES in Section 2 - HYDRAULIC valve is supplied by flow from the hydraulic pump.
SYSTEM.
When booming up, oil unseats the poppet (check) valve in
Refer to VALVES in Section 2 for a complete description of the holding valve, letting oil flow to the piston side of the
the hydraulic remote controller. cylinder. Pressure is applied to the piston, forcing the rod to
The RT890E lift cylinder has a 30.48 cm (12.0 in) bore. The extend, raising the boom.
cylinder is a double acting type. Dirt and other foreign When booming down, oil enters the retract port of the port
material is prevented from entering the cylinder and causing block and flows to the cylinder rod side. When pilot pressure
internal damage by a wiper seal during rod retraction. Oil reaches a pre-determined value, the main poppet unseats
seals on both the piston and cylinder head prevent internal and oil flows from the piston side of the cylinder to the 4
and external hydraulic oil leakage. Refer to CYLINDERS in reservoir.
Section 2 for a complete description of the lift cylinder.
All return flow from the control valve goes to the reservoir.

8
Maintenance
27
Troubleshooting

Symptom Probable Cause Solution

2

1. Boom raises errati- a. Low hydraulic oil. a. Replenish hydraulic oil to proper level.
23

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

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BOOM RT890E SERVICE MANUAL

Symptom Probable Cause Solution

3. Boom raises a. Low hydraulic oil level. a. Replenish hydraulic oil to proper level.
slowly.
b. Low engine rpm. b. Increase and maintain engine rpm.
c. Damaged relief valve. c. Repair or replace relief valve.
d. Extremely cold hydraulic oil. d. Operate unit to bring oil to operating
temperature.
e. Improper hose or fittings, installed. e. Replace hose or fittings. (Refer to Parts
Manual).
f. Operating two functions with in the same f. Feather controls to obtain desired speed
control valve bank assembly. of both functions.
g. Restriction in return hose. g. Replace return hose.
h. Cylinder piston seals leaking. h. Replace all cylinder seals.
i. Scored cylinder barrel. i. Hone or replace barrel.
j. Worn hydraulic pump section. j. Repair or replace pump section.
4. Boom lowers a. Low hydraulic oil level. a. Replenish hydraulic oil to proper level.
slowly.
b. Low engine rpm. b. Increase rpm to recommended level.
c. Damaged relief valve. c. Repair or replace relief valve.

8
d. Operating two functions within the same d. Feather controls to obtain desired speed
control valve bank assembly. of both functions.
27
e. Extremely cold hydraulic oil. e. Operate unit to bring oil to operating
temperature.
f. Improper hose or fittings installed. f. Replace hose or fittings. (Refer to Parts
2

Manual).
23

g. Restriction in return hose. g. Replace return hose.

h. Cylinder piston seals worn. h. Replace all cylinder seals.
i. Scored cylinder barrel. i. Hone or replace barrel.
j. Worn hydraulic pump section. j. Repair or replace pump section.
k. Piston rod broken (loose from piston). k. Replace piston rod and all cylinder seals.
5. Boom will not raise. a. Low hydraulic oil. a. Replenish hydraulic oil to proper level.
b. Main relief valve or circuit relief valve b. Repair or replace relief valve.
damaged.
c. Excessive load. c. Reduce load as required.
d. Worn or damaged hydraulic pump d. Repair or replace pump section.
section.
e. Broken pump shaft. e. Replace pump shaft and seals.
f. Broken pump drive coupling. f. Replace drive coupling.
g. Broken control valve spool. g. Replace control valve.

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RT890E SERVICE MANUAL BOOM

Symptom Probable Cause Solution

6. Boom will not a. Low hydraulic oil. a. Replenish hydraulic oil to proper level.
lower.
b. Main relief valve or circuit relief valve b. Repair or replace relief valve.
damaged.
c. Worn or damaged hydraulic pump c. Repair or replace pump section.
section.
d. Broken pump shaft. d. Replace pump shaft and seals.
e. Broken pump drive coupling. e. Replace drive coupling.
f. Broken control valve spool. f. Replace control valve.
NOTE: Refer to SECTION 2 for Lift Cylinder Disassembly the shaft is clear of the lift box, activate the hydraulic sys-
and Assembly procedures. Maintenance not requir- tem and retract the lift cylinder enough to clear the upper
ing removal of the cylinder barrels, such as packing, attach point.
may be performed without removing the cylinders 8. Tag and disconnect all the hydraulic lines to the cylinder.
from the turntable. However, all disassembly and Cap or plug all openings with high pressure fittings.
assembly should be conducted in a clean dust-free
9. Pull the lower lift cylinder pivot shaft out far enough to
area.
remove the cylinder.
Removal
10. Move the lift cylinder to a clean work area.
4
1. Extend and set the outriggers and level the crane.
Disassembly and Assembly
2. Elevate the boom slightly so that the lift cylinder is
Disassembly and assembly procedures of the lift cylinder
extended approximately 0.3 m (1 ft).

8
holding valve, and control valve are provided in SECTION 2
under CYLINDERS and VALVES respectively.
27
Installation
DANGER 1. Attach an adequate lifting device to the lift cylinder and
position the cylinder over the attach fitting on the turnta-
Ensure any blocking or cribbing used is capable of
2
ble.
supporting the boom.
2. Lower the lift cylinder into the attach fittings on the turnta-
23

ble and align the lift cylinder bushing with the attach fitting
3. Ensure the boom is fully supported by placing blocking or holes.
cribbing under the boom. Rest the boom on the blocking
NOTE: Install pivot shaft with tapped hole on the right side,
or cribbing.
side opposite the cab.
4. Remove the bolt and washer securing the lift cylinder
3. Install the lift cylinder lower pivot shaft and secure with the
upper pivot shaft to the boom.
bolt and locknut.
5. Remove the bolt and locknut securing the lift cylinder
4. Connect the extend and retract hoses to the lift cylinder.
lower pivot shaft to the turntable.
5. Activate the crane’s hydraulic system and align the lift cyl-
inder rod end with the attach point on the boom. Using the
hand pump located on the left side of the boom, insert the
pump lever (found in cab) into the hand pump. Turn the
DANGER pump flow control lever counterclockwise and pump the
Ensure the lifting/supporting device is capable of pump lever until the upper lift cylinder pivot shaft is
supporting the lift cylinder. engaged and completely against the side plate of the
boom lift box. The lift cylinder may need to be raised or
lowered to aid in the installation of the lift cylinder pivot
6. Attach an adequate lifting/supporting device to the lift cyl-
shaft into the lift box. This can be done by using the jack
inder.
on the lift cylinder support. Shut down the engine.
7. Remove the upper lift cylinder pivot shaft by inserting the
pump lever (found in cab) into the hand pump located on 6. Secure the upper pivot shaft to the boom with the bolt and
the left side of the boom. Turn the pump flow control lever washer.
clockwise and pump the lever until the upper lift cylinder 7. Remove the lifting and supporting devices from the boom
pivot shaft is clear of the boom lift box. The lift cylinder and lift cylinders. Activate the hydraulic system and check
may need to be raised or lowered to aid in the release of the lift cylinders for proper operation and any leaks. Lubri-
the lift cylinder pivot shaft from the lift box. This can be cate the pivot shafts using grease fittings. Refer to
done by using the jack on the lift cylinder support. Once Figure 4-12.

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BOOM RT890E SERVICE MANUAL

Item Description
1 Lift Cylinder 1

2 Shaft
3 Bolt and Nut
4 Grease Fitting

8
4
Cutaway For Clarity
2 27
23

7649-18

2 1
6317-5

6317-4
FIGURE 4-12

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RT890E SERVICE MANUAL BOOM

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

The auxiliary boom nose Figure 4-13 (rooster sheave) is

available for the boom to simplify single part and maximum

AUXILIARY BOOM NOSE

8
27
ATTACH PINS
2
23

MAIN BOOM NOSE

6435

FIGURE 4-13

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BOOM RT890E SERVICE MANUAL

COUNTERWEIGHT WITH AUXILIARY HOIST 3. Properly attach chains with clevis to the counterweight
lifting holes Figure 4-15 and use a crane to carefully
Removal transfer the counterweight and auxiliary hoist to the
1. Position the crane on a firm, level surface. Fully extend frame counterweight supports over the rear outrigger
and set the outriggers. Level the crane. box.

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

3. Remove any load and handling device from the auxiliary 5. Using the control levers (left and right), extend the
hoist cable and retract all cable onto the hoist drum. counterweight removal cylinders, one at a time, guiding
Secure the cable. them into the turntable wing/support brackets and pin
securely.
4. Disconnect the auxiliary hoist hydraulic lines and
electrical harness and secure. Do not disconnect the 6. Using the control levers (left and right), simultaneously
counterweight removal cylinder hydraulic lines. retract (raise) the counterweight removal cylinders until
the counterweight round bar engages the lugs on the
5. Remove the ball detent pins which secure the turntable and the counterweight pinning holes are
counterweight mounting pins. aligned with the counterweight mounting pins. Feather
individual controls as required to raise the counterweight
6. Ensure that the counterweight removal cylinder support in a level position.
pins are securely attaching the counterweight to the
turntable wing-support brackets. Disengage the 7. Engage the counterweight mounting pins using the
counterweight mounting pins using the pinning control control lever (center).
lever (center).

8
8. Attach the ball detent pins securing the counterweight
NOTE: It may be necessary to retract the counterweight
27 mounting pins.
removal cylinders Figure 4-14 and Figure 4-15 to
relieve weight from the counterweight mounting 9. Relieve pressure on the counterweight removal cylinder
pins. so that weight is fully supported by the counterweight
2
mounting pins.
7. Using the control levers (left and right), simultaneously
extend (lower) the counterweight onto the frame 10. Attach the auxiliary hoist hydraulic lines and electrical
23

counterweight supports. Feather individual controls as harness.

required to lower the counterweight in a level position.
COUNTERWEIGHT WITHOUT AUXILIARY
8. Remove the counterweight removal support pins from
turntable wing-support brackets and using the control
HOIST
levers (left and right), retract the counterweight removal Removal
cylinders fully.
1. Position the crane on a firm, level surface. Fully extend
9. Disconnect and secure the counterweight removal and set the outriggers.
cylinder hydraulic lines and replace the counterweight
removal cylinder support pins on the turntable wing- 2. Position the superstructure over the front of the machine
support brackets. and engage the turntable lock.
3. Remove the ball detent pins which secure the counter-
10. Properly attach chains with clevis to the counterweight weight mounting pins.
lifting holes Figure 4-15 and use a crane to carefully
transfer the counterweight and auxiliary hoist to the 4. Ensure that the counterweight removal cylinder support
ground or a suitable transport vehicle. pins are securely attaching the counterweight to the
Installation turntable wing/support brackets. Disengage the
counterweight mounting pins using the pinning control
1. Position the crane on a firm, level surface. Fully extend lever (center).
and set the outriggers. Level the crane.
NOTE: It may be necessary to retract the counterweight
2. Position the superstructure over the front of the machine removal cylinders to relieve weight from the coun-
and engage the turntable lock. terweight mounting pins.

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RT890E SERVICE MANUAL BOOM

8, 9, 10, 11

12
3

8
27
5
2
23

6, 7 2

4
5

FIGURE 4-14

Item Description Item Description

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

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BOOM RT890E SERVICE MANUAL

Counterweight
2
2 Lifting Points

8
2 27
23

2
2

6326

Item Description
1 Counterweight
2 Counterweight Cylinder Assembly

FIGURE 4-15

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RT890E SERVICE MANUAL BOOM

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

7. Disconnect and secure the counterweight removal DANGER

cylinder hydraulic lines and replace the counterweight
To prevent serious injury or death, always wear personal
removal cylinder support pins on the turntable wing/
protective equipment; i.e., a hard hat, eye protection,
support brackets.
gloves and metatarsal boots.
8. If applicable, properly attach chains with clevis to the
counterweight lifting holes Figure 4-15 and use a crane 1. Before installing the boom extension make sure the
to carefully transfer the counterweight to the ground or a crane is set up on outriggers using normal setup proce-
suitable transport vehicle. dures. Refer to SECTION 3 - OPERATING CONTROLS
and PROCEDURES in the Operator Manual.
Installation
NOTE: An auxiliary crane with sling is required to install 4
1. Position the crane on a firm, level surface. Fully extend the bi-fold boom extension.
and set the outriggers. Level the crane.
2. Check the transport condition of the bi-fold extension.

8
2. Position the superstructure over the front of the machine
3. Using an auxiliary crane, attach sling to the bi-fold exten-
and engage the turntable lock.
sion.
27
3. If applicable, properly attach chains with clevis to the 4. Lift the bi-fold extension in front of the main boom with
counterweight lifting holes Figure 4-15 and use a crane the auxiliary crane and lock the 33 ft (10.1 m) section to
to carefully transfer the counterweight to the frame the right of the main boom head Figure 4-16.
2
counterweight supports over the rear outrigger box.
23

4. Attach the counterweight removal cylinder hydraulic

lines.

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

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

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

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

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BOOM RT890E SERVICE MANUAL

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

3 6510-2

7 6510-8

8
2 27
6510-7
23

7
6 5
4
6624
3

4
5
6

6510-5

6510-3

6510-1
6 6510-4
FIGURE 4-17

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RT890E SERVICE MANUAL BOOM

Checking the Transport Condition If the 23 ft (7 m) Section Only is Folded at the Side:
For transportation you must establish certain connections - The connection (7) in the middle area is between
between both parts of the lattice extension. The connections the 23 ft (7 m) section and the main boom (3)
which need to be established depend on whether the lattice Figure 4-17 (control # 6510-8).
extension: - The connection (5) between the 23 ft (7 m) section
- is folded up at the side of the main boom for and the main boom in the rear area is established.
transportation or
- is completely removed for transportation.
BOOM EXTENSIONS/COMPONENTS
PROCEDURES
For instructions on erecting and stowing the boom
extension(s) and/or using additional equipment refer to
DANGER SECTION 4 in the Operator Manual.
Be careful not to damage the lattice extension and the
main boom. Always put the lattice extension into transport Transportation on a Separate Vehicle
condition when folded at the side or working with the main
boom. Only then is the lattice extension secured against
slipping. This way you prevent the partly fastened lattice
extension hitting the main boom or the individual
components of the lattice extension hitting each other and
DANGER 4
Risk of accidents from a falling lattice extension.
becoming damaged.
Only attach the lattice extension in such a way that it is
positioned in the center of gravity and always use lifting

8
You must check transport condition:
gear with sufficient lifting capacity. This prevents the
- After stowing the lattice extension, before you drive lattice extension from falling and injuring people while
27
the crane with the lattice extension folded at the side loading.
or work with the main boom.
- Before installation and before erecting the lattice • Check if all the required connections for transport
2

extension. condition are established.

23

• For transportation, place the lattice extension on the skid

Transport Condition with Lattice Extension Folded at
at the front and onto the lower cross strut at the rear of
the Side
the 33 ft (10.1 m) section.
The transport condition with the lattice extension folded at
• Always secure the lattice extension on the separate
the side is created when all of the following connections are
vehicle with belts as well as to prevent slipping and
established.
overturning.
• Check the connections and establish them if
necessary, see Figure 4-17.
If 23 ft (7 m) Section and 33 ft (10.1 m) Section are
CAUTION
Folded at the Side: Risk of damaging the lattice extension.
Always secure the lattice extension by tying it down with
- The 33 ft (10.1 m) section is locked at the front suitable belts when it is transported on the separate
support (1) on the main boom and is secured with vehicle. This prevents the two-stage swingaway lattice
the horizontal retaining pin (2) extension tipping and becoming damaged during
- The pins (4) are inserted on the pivot point between transportation.
the 23 ft (7 m) section and the 33 ft (10.1 m) section.
- The connection (7) in the middle area is between BOOM EXTENSION (ADDITIONAL
the 23 ft (7 m) section/33 ft (10.1 m) section. EQUIPMENT)
- The connection (5) between 23 ft (7 m) section and Identification and Slinging Points
m a i n b o o m i n t h e r e a r a r e a i s e s ta b l i s h e d
Figure 4-17 (control # 6510-7). Identification
The boom extension consists of the 56 ft (17.1 m) bi-fold
swingaway lattice extension and two boom extension
sections. The boom extension is designed for the crane it

GROVE Published 9-18-2014, Control # 308-06 4-39

BOOM RT890E SERVICE MANUAL

was delivered with. The parts which belong to the crane have these cranes and labeled with all of the respective serial
the same serial number as the crane. numbers.
The following sections are identified by the serial number:
- All parts of the 56 ft (17.1 m) bi-fold swingaway CAUTION
lattice extension. Have the adjustment of the boom extension only carried
- Both sections of the boom extension 16 ft (4.9 m) out on site by Manitowoc Crane Care!
sections)
. Serial numbers on the 16 ft (4.9 m) sections
The serial number is on a plate at the front of the 16 ft
CAUTION sections.
Operate the crane only with those sections of the boom
extension which have the same serial number as the Slinging Points
crane. This prevents malfunctions and damage.

NOTE: For technical reasons a crane may only be set with CAUTION
one boom extension. This section shows the slinging points of the 16 ft (4.9 m)
sections. Attach the sections only to these slinging points
If you wish to use the boom extension on several Manitowoc
because they will then automatically have the correct
cranes, the parts of the boom extension must be adjusted for
center of gravity. Use only lifting gear with sufficient load
bearing capacity.

8
2 27
23

w3351a FIGURE 4-18

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

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RT890E SERVICE MANUAL BOOM

MONTHLY MAINTENANCE WORK The joints are lubricated via lubricating nipples.

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

nipple at the pivot point Figure 4-19.
Lubricate all attach, securing and retaining pins, in other
words: • Clean the lubricating nipple and lubricate it with a grease
gun.
- the pins for the pin connection on the lattice
extension, • Also lubricate the joint on the other side.

- the retaining pins on the return pulleys, Lubricate the derricking cylinder in 33 ft (10.1 m)
section
- the retaining pins used for fastening the lattice
extension sections for transport,
- the spring latch on the run-up rail.
NOTE: The maintenance interval applies to average oper-
ation. Also, lubricate the pins after high-pressure
cleaning and generally at an interval that will pre-
vent them getting dry.
Lubricating Joint on 33 ft (10.1 m) Section
4
1
1 1 w2427a
FIGURE 4-20

8
The derricking cylinder is lubricated via a lubricating nipple.
27
On head and foot axle there is one lubricating nipple each
Figure 4-20.
• Clean the lubricating nipples and insert grease into the
2

lubricating nipple with a grease gun.

23

w3300a
FIGURE 4-19

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BOOM RT890E SERVICE MANUAL

8
27
THIS PAGE BLANK
2
23

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RT890E SERVICE MANUAL HOIST AND COUNTERWEIGHT

SECTION 5
HOIST AND COUNTERWEIGHT

SECTION CONTENTS
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Hoist Drum Rotation Indicator System . . . . . . . . 5-10
Warm-up Procedure . . . . . . . . . . . . . . . . . . . . . . . 5-2 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Routine Maintenance and Inspection . . . . . . . . . . 5-2 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Counterweight Removal . . . . . . . . . . . . . . . . . . . . 5-12
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Removal of Standard Counterweight and
Auxiliary Hoist . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Functional Check . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Installation of Standard Counterweight and
Fluid Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Auxiliary Hoist Mounting Structure. . . . . . . . . . 5-12
Hoist to Boom Alignment. . . . . . . . . . . . . . . . . . . . 5-5 Removal of Counterweight Without Auxiliary
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 Hoist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 Installation of Counterweight Without Auxiliary
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 Hoist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Piston Motor and Control Valve . . . . . . . . . . . . . . 5-7 Third Wrap Indicator

8
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 (Optional—Standard on CE) . . . . . . . . . . . . . . . . . 5-15
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
27
Idler Drum and Cable Follower . . . . . . . . . . . . . . . 5-7 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
5
2
23

DESCRIPTION THEORY OF OPERATION

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

GROVE Published 9-18-2014, Control # 308-06 5-1

HOIST AND COUNTERWEIGHT RT890E SERVICE MANUAL

MAINTENANCE mal contamination should be treated seriously, with an

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

A warm-up procedure is recommended at each start-up and 2. Check for correct function of the hoist brake by carrying
is essential at ambient temperatures below +40°F (4°C). out a high line pull load test, see Functional Check, page
5-4. Ensure the brake holds without creeping and that
The engine should be run at its lowest recommended RPM the hoist control is correct.
with the hydraulic hoist control valve in neutral allowing
sufficient time to warm up the system. The hoist should then NOTE: The function of the hoist brake should be checked
be operated at low speeds, forward and reverse, several more often under extreme or abnormal operating
times to prime all lines with warm hydraulic oil, and to conditions.
circulate gear lubricant through the planetary gear sets.
Every Ten Years or 10,000 Hours (whichever comes
first)
As part of a preventative maintenance program, we
DANGER recommend that hoist assemblies be opened in a properly
controlled workshop environment. The major internal
Failure to properly warm up the hoist, particularly under
components (gears, spline couplings, shafts, etc.) should be
low ambient temperature conditions, may result in
examined for damage and/or wear. New components should
temporary brake slippage due to high back pressures
be installed if any are found to be worn or if there is evidence
attempting to release the brake, which could result in
of heat or other damage. Reassemble the hoist using all new
property damage, severe personal injury or death.
seals, bearings, fasteners, washers, brake discs, brake
stators, sprag clutch, and springs.
Routine Maintenance and Inspection

8
A comprehensive hoist line pull and load holding test must
Hoisting gear assemblies must receive proper maintenance be carried out following any such repair work.
27
and inspection in order to provide satisfactory long term
operation. It is extremely important that maintenance Manitowoc Crane Care offers prepackaged kits that include
personnel recognize that deterioration of critical internal all the seals, bearings, fasteners, washers, brake disks,
components within the hoist reduction unit can occur. The brake stators, sprag clutch, and springs that are required for
2

service life and reliability of the hoist can be substantially reassembling the hoist after inspection. During the
inspection, if components not included in the kit are found to
23

reduced by such factors as the following:

be worn or damaged, contact your Manitowoc Cranes
• High cycle operation Distributor or Manitowoc Crane Care to order replacement
• Operating in high ambient temperatures
• High external contamination, such as dusty or sandy
conditions
DANGER
• Level of maintenance Failure to implement and adhere to a hoist inspection and
maintenance program may result in damage to the crane,
Weekly or at 40 Hours of Operation (whichever comes
other property damage, and/or serious injury or death to
first)
persons working on or near the crane.
1. Check the hoist oil level. Use only the manufacturer’s
recommended oil when filling. Removal
2. Inspect for any oil leaks from the hoist gearbox. 1. Remove all cable from the hoist drum.
Every Three Months or 300 Hours of Operation 2. Tag and disconnect the hydraulic lines to the hoist. Cap
(whichever comes first) or plug all lines and openings.
Lubricate the hoist cable follower and idler arm bearings. 3. Tag and disconnect the electrical wires to the hoist
Refer to Hoist, page 9-26 for recommended grease. rotation indicator sensor box.
Annually 4. Tag and disconnect the electrical wires to the hoist hi-
1. Replace the oil in the hoist gearbox, refer to Hoist, page speed solenoid valve.
9-28. We recommend having the used hoist oil tested by
5. Remove the hoist mounting nuts, capscrews, washers,
a hydraulic oil analysis provider, which can give advance
and shims (if shims are used, mark their location).
warning of developing wear patterns. Any sign of abnor-

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RT890E SERVICE MANUAL HOIST AND COUNTERWEIGHT

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

2
1
3 4
5

11
12
3

11

DETAIL A
6, 7, 8, 9

8
27
DETAIL A
5
2
23

6319, 6319-2

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

FIGURE 5-1

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HOIST AND COUNTERWEIGHT RT890E SERVICE MANUAL

Installation Functional Check

1. Ensure the mounting plate and hoist pads are clean and 1. Attach a test weight to the hook and raise and lower the
free from debris and the hoist has not been damaged load several times.
during handling.
2. Check the hoist for smooth operation of the hoist motor
2. With the hoist supported by a suitable lifting device, posi- and brake system.
tion the hoist on the mount.
3. Ensure the hydraulic connections are secure and free
3. Check the hoist to boom alignment; refer to Hoist to from leaks.
Boom Alignment, page 5-5.
Fluid Level
4. Place a level between the boom pivot shaft bushings.
NOTE: Failure to align the fill/drain plug (1) with the upper
5. Place a level across the top of the hoist drum and deter-
access hole (2) as shown in Figure 5-2 prior to
mine if the hoist is sitting in the same plane in relation to
checking the oil level will result in an inaccurate
the level positioned between the boom pivot shaft bush-
reading.
ings.
1. Rotate the hoist drum until the fill/drain plug (1) appears
6. With the hoist level, check to determine if all the hoist
in the upper access hole (2) shown in Figure 5-2.
mounting pads are in contact with the mounting plate by
rocking the hoist. This will ensure that the planetary gears are in proper
alignment and will permit an accurate reading of the oil
7. Keeping the hoist level, use a feeler gauge to determine
level in the hoist.
the amount of gap existing between the pads and the
mounting plate. 2. Allow the hoist to stand idle for 20 minutes before check-
ing the oil.

8
8. Add shims to satisfy any existing gaps. Altering the shim
thickness to fit a tapering gap is acceptable. Install the 3. The oil level should be visible in the sight glass (3).
27
capscrews, washers and nuts. Torque capscrews; refer
Compare your reading with Table 5-1 below and take the
to Fasteners and Torque Values, page 1-14 for proper
required action.
torque value.
2
9. Remove the lifting device from the hoist.
23

10. Connect the hydraulic lines to the hoist ensuring the

proper lines are connected to the correct ports as 1 4
marked during removal.
11. Connect the electrical wires to the hoist hi speed sole-
noid valve as marked during removal. 3

12. Connect the electrical wires to the hoist rotation indicator

sensor box as tagged during removal.
13. Install the cable, following the procedures outlined under
Installing Cable On The Hoist, in the Operator’s Manual. 2

FIGURE 5-2

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RT890E SERVICE MANUAL HOIST AND COUNTERWEIGHT

Table 5-1

Reading Diagnosis Action Required

Fill the hoist with oil from the upper access hole until the
The hoist is under oil level rises within the sight glass. Do not fill above 1/8”
Oil is not visible in the sight glass. (3 mm) from the top of the site glass.
filled.
Refer to Hoist, page 9-28 for the correct type of oil.
Oil is visible in the sight glass and the
The oil level is
level is no more than 1/8” (3 mm) from No action is required.
correct.
the top of the sight glass.
Oil level is more than 1/8” (3 mm) Drain the hoist drum from the upper access hole until the
from the top of the sight glass or the The hoist is overfilled. oil level falls to within 1/8” (3 mm) from the top of the sight
oil is escaping from the vent plug (4). glass.

HOIST TO BOOM ALIGNMENT Procedure

Preparation The hoist mounting location will determine the alignment
procedure used. Shift one side of the hoist back or forward to
Boom alignment must be completed before attempting hoist align the hoist with the boom sheave for cranes that have the
alignment. If the hoist is not properly aligned, the cable can hoist mounted either directly to the boom or on a mount
be damaged or fine control could be affected. attached to the boom. It may be necessary to shim under
one side of the hoist to make it level.
The crane must be set on outriggers fully extended and the

8
crane must be leveled. The boom must be over the rear on The hoist must be checked in two directions, one at 0 degree
27
TM/TMS models and over the front on RT/Industrial models. and the other is above 45 degrees boom angle on any crane
that the hoist is not mounted directly to the boom, stationary 5
Tools Required mounted.
• two foot square Check the hoist at 0 degree to see if the hoist is aligned to
2

the boom nose sheave. The main hoist is aligned to the right
• Mason cord or cat gut fishing line
23

hand sheave and the auxiliary hoist is aligned to the center

• chalk sheave (see Figure 5-2).
• protractor NOTE: The hoist cable will have gaps in it during spooling
if the alignment is not correct.
NOTE: The hoist is not level if the cable is piling up on one
side of the drum.

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HOIST AND COUNTERWEIGHT RT890E SERVICE MANUAL

MAIN HOIST IS ALIGNED TO THE RIGHT HAND

SHEAVE

LOCATING CENTERLINE WITH

SQUARE

8
27
AUXILIARY HOIST IS ALIGNED TO THE CENTER
SHEAVE
6019
FIGURE 5-3
2

1. The boom must be extended one half of full extension on check from both flanges indicates that the resultant
23

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

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RT890E SERVICE MANUAL HOIST AND COUNTERWEIGHT

the 90 degree mark, the hoist will have to be shimmed keep the hoist cable from coming in contact with the main
until the cord is at the 90 degree mark. hoist. The cable follower is mounted on the rear side of it’s
respective hoist. The cable follower applies a downward
NOTE: This test is for cable piling up on one side of the
spring pressure against the cable onto the hoist drum, to
hoist drum.
ensure that the cable will be uniformly wound onto the hoist
drum, and also prevent cable from jumping under abnormal
PISTON MOTOR AND CONTROL VALVE line conditions.

Description Maintenance
The piston motor is a bent axis, bidirectional, variable
Idler Drum
displacement heavy-duty motor. The motor is bolted to the
hoist and is geared directly to the hoist planetary. Removal and Disassembly
The motor control valve is bolted to the motor. 1. Remove the bolt, washer, and lockwasher from the right
side of the idler roller (see Figure 5-3).
Maintenance
2. Support the idler roller and withdraw the shaft from the
Removal left side. Take care not to lose the dowel pin on the end.

1. Thoroughly clean the external surfaces of the drum and 3. Remove the roller from between the side plates.
motor with steam or clean solvent and blow dry. Cleaning and Inspection
2. Tag and disconnect the hydraulic lines connected to the 1. Clean all rust and dirt from the shaft.
hoist motor and the motor control valve.
2. Inspect the shaft and roller for cracks, scoring, or groov-

8
3. Remove the capscrews and lockwashers that secures ing. Replace if necessary.
the motor and motor control valve to the hoist.
27
4. Place the motor and motor control valve in a clean, dry
Assembly and Installation
5
suitable work area. 1. Position the roller between the side plates

Installation 2. Install the shaft through the left side plate and the roller.
2

Ensure the flat on the shaft end aligns with the stop
NOTE: Care must be taken to assure the primary thrust welded on the side plate, align the dowel pin.
23

plate remains properly located in its counterbore

when the motor is re-installed. If the winch is oper- 3. Secure the shaft to the right side plate with a bolt,
ated with the primary thrust plate wedged between washer and lockwasher. Apply Loctite 243 to the bolt
the primary gears and the planet carrier, or with a threads.
thrust washer out of position severe damage to
Cable Follower
internal winch components could result.
Removal and Disassembly
1. Install a new O-ring on the motor pilot then lubricate with
petroleum jelly or gear oil. Engage the motor shaft with 1. Loosen the adjusting nuts and remove the tension
the brake clutch inner race and lower into place. spring and adjusting rod from both sides of the hoist (see
Figure 5-3).
2. Apply Loctite No. 243 to the mounting bolts, and install
the bolts and lockwashers. Torque bolts to 282 lb-ft 2. Remove the tack welds from the bolt heads securing the
(383 Nm). arm to the cable follower roller.
3. Connect the hydraulic lines as tagged during removal. 3. Support the cable follower roller and remove the bolts
and washers securing the arms to the angles on each
4. Fill the drum with oil. Refer to Lubrication, page 9-1.
end of the roller. Remove the cable follower roller.

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

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HOIST AND COUNTERWEIGHT RT890E SERVICE MANUAL

5. Remove the bolt and locknut securing the arm to the each side plate and connect to the other end of the
spring attaching lever on each side of the hoist. Remove spring. Install the adjusting nuts on each rod and tighten
arms and levers from the side plates. enough to take the slack out of the springs.
NOTE: Be sure to mark each arm and lever as to what side 6. Using a grease gun, apply grease to the fittings on each
(left or right) they were removed from. This will be side plate bushing.
helpful during installation.
7. Adjust the roller as follows.
Cleaning and Inspection
a. With one layer of cable on the hoist drum, adjust the
1. Clean all grease from the shaft, bearing, and roller. bolts on the front of each side plate (that push
against each arm) so the roller applies pressure on
2. Check the shaft, roller, and bearings for cracks, scoring,
the layer of cable, and does not interfere with filler/
or grooving. Replace if necessary.
riser protrusions on the hoist drum flanges. Tighten
3. Check the spring tension. If the springs will not provide jam nuts to secure setting.
sufficient tension when adjusted, replace them.
b. With a full drum of cable, the adjusting spring length
Assembly and Installation from eye to eye should not exceed 25.7 cm (10.12
in). Adjust rods as necessary and tighten jam nuts to
1. Install the left arm through the bushing on the left side secure this setting.
plate. Install left spring attaching lever on the arm and
secure with a bolt and locknut. Apply Loctite 243 to the Complete Assembly
bolt threads.
Removal
2. Repeat step 2 on the right side.
1. Remove all tension from the springs on each side by
3. Assemble the cable follower roller as follows. loosening the nuts and jam nuts.

8
a. Apply high strength retaining compound Loctite 680 2. Support the weight of the assembly and remove the two
27
to the bearing housings and the bearings. Install bolts and washers securing each side plate to the hoist.
them in both ends of the roller. Remove the idler drum and cable follower assembly
b. Install the shaft into the roller with a least one shim from the hoist.
2
on each end. 3. If necessary to completely disassemble or remove any
c. Position the angle on the right side of the shaft and part of the assembly, refer to the applicable paragraphs
23

secure with two bolts and washers. Apply Loctite in this Sub-section.
243 to the bolt threads. Installation
4. Position the cable follower roller on the arms and secure 1. Position the idler drum and cable roller assembly on the
with four bolts and washers. Center the roller between hoist and secure each side plate to the hoist with two
the hoist drum flanges and tighten the bolts. Tack weld bolts and washers.
the bolt heads.
2. Adjust the tension on the cable follower. Refer to instruc-
5. Attach one end of the tension springs to the levers on tions in paragraph titled CABLE FOLLOWER - Assem-
each side. Install the adjusting rod through the lug on bly and Installation in this Sub-Section.

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RT890E SERVICE MANUAL HOIST AND COUNTERWEIGHT

1.0 cm (.42 inch)

1
8

12
3
Item Description
1 Pivot Bracket
2 Drum

8
6637-2 3 Follower Roller
4 Arm
27
5 Spring 5
8 2 6 Spring Adjusting Rod
10
2
7 Lever
8 Idler Roller
23

9 Nut
6 1 10 Bracket
11 Rotation Sensor
12 Hydraulic Motor

5
11

6637-1

FIGURE 5-4

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HOIST AND COUNTERWEIGHT RT890E SERVICE MANUAL

HOIST DRUM ROTATION INDICATOR Troubleshooting

SYSTEM NOTE: This machine incorporates a CAN-Bus Multiplex
system. In order to effectively troubleshoot the
Description electrical system, you will need a Windows-based
The hoist drum rotation indicator system (Figure 5-6) is an PC, CAN-link service software (9999102409), and
electrically operated system that provides the operator with a a connection cable (9999102296). The CAN-Link
touch indication of drum rotation so the operator will know if service software and connection cable are avail-
and at what speed the hoist drum is rotating, even under the able through Manitowoc Crane Care to those ser-
most distracting conditions. vice technicians who have attended the Grove New
Technology training course.
The drum rotation indicator system consists of the drum
rotation sensor and thumb thumper solenoid. The drum Removal
rotation sensor is located on the hoist (Figure 5-6) and 1. Disconnect the wire at the drum rotation sensor.
senses the rotation of the primary drive end driven gear. The
pulsing thumb thumper solenoid is located in the applicable 2. Loosen the jam nut securing the drum rotation sensor
hoist control lever handle (Figure 5-6). Actuation of the and then remove the sensor.
thumb thumper is controlled by the Can-Bus system from
input supplied by the drum rotation sensor. The thumb Installation
thumper solenoid provides feedback proportional to the hoist 1. Turn the two jam nuts on the drum rotation sensor to pro-
line speed by pulsing the rubber button on top of the hoist duce 1.25 in. (31 mm) installed length of threads mea-
controller. The thumb thumper will cease operation at high sured from the bottom of the sensor to the bottom jam
line speeds to prevent damage to the solenoid. nut (Figure 5-5).

8
Maintenance 27
General 7792-1
2

DANGER
23

D i s c on n e c t t h e b a t te r i es b e fo r e p e r f o r m i n g a n y
maintenance on this system. Serious burns may result FIGURE 5-5
from accidental shorting or grounding of live circuits.
2. Hold the bottom jam nut with a wrench and tighten the
Proper circuit operation can be checked for each individual top jam nut against it. Check the length of threads to be
electrical component. If a malfunction occurs within the sure the installed length did not change.
system, repairs should be limited to finding and replacing the 3. Apply a small amount of general purpose grease to the
faulty component(s). To determine which component is at threads and install the drum rotation sensor into the
fault, refer to the troubleshooting section of your CAN-Bus motor end-plate.
CD.
4. Using the outer jam nut, tighten the sensor until just
snug to avoid damage to the sensor.
5. Connect the wire to the drum rotation sensor.

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RT890E SERVICE MANUAL HOIST AND COUNTERWEIGHT

8
27
5
7792-2

Drum Rotation
2
Sensor
23

7792-3

Button

Control Lever Thumb Thumper

Handle Rotation
Indicator
Solenoid

Single Axis
Controller
FIGURE 5-6

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HOIST AND COUNTERWEIGHT RT890E SERVICE MANUAL

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

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

6. Ensure the counterweight removal cylinder support pins 6. Using the control levers (left and right) simultaneously
retract (raise) the counterweight removal cylinders until

8
are securely attaching the counterweight to the turntable
wing/support brackets. Disengage the counterweight the counterweight round bar engages the lugs on the
27 turntable and the counterweight pinning holes are
mounting pins using the pinning control lever (center).
aligned with the counterweight mounting pins. Feather
7. Using the control levers (left and right), simultaneously individual controls as required to raise the counterweight
extend (lower) the counterweight onto the frame coun- in a level position.
2
terweight supports. Feather individual controls as
required to lower the counterweight in a level position. 7. Engage the counterweight mounting pins using the con-
23

trol lever (center).

8. Remove the counterweight removal cylinder support
pins from turntable wing/support brackets and using the 8. Attach the ball detent pins securing the counterweight
control levers (left and right) retract the counterweight mounting pins.
removal cylinders fully. 9. Relieve pressure on the counterweight removal cylinder
9. Disconnect and secure the counterweight removal cylin- so that weight is fully supported by the counterweight
der hydraulic lines and replace the counterweight mounting pins.
removal cylinder support pins on the turntable wing/sup- 10. Attach the auxiliary hoist hydraulic lines and electrical
port brackets. harness.
10. Properly attach the supplied slings to the counterweight
lifting holes and use a crane to carefully transfer the Removal of Counterweight Without Auxiliary
counterweight and auxiliary hoist to the ground or a suit- Hoist
able transport vehicle.
1. Position the crane on a firm, level surface. Fully extend
Installation of Standard Counterweight and and set the outriggers. Level the crane.
Auxiliary Hoist Mounting Structure 2. Position the superstructure over the front of the machine
and engage the turntable lock.
1. Position the crane on a firm, level surface. Fully extend
and set the outriggers. Level the crane. 3. Remove the ball detent pins which secure the counter-
weight mounting pins.
2. Position the superstructure over the front of the machine
and engage the turntable lock. NOTE: It may be necessary to retract the counterweight
removal cylinders to relieve weight from the coun-
terweight mounting pins.

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RT890E SERVICE MANUAL HOIST AND COUNTERWEIGHT

10, 11, 12 13

9
2

6, 7

8
8 27
5
3

4
2

3
23

Item Description Item Description

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

FIGURE 5-7

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HOIST AND COUNTERWEIGHT RT890E SERVICE MANUAL

4. Ensure that the counterweight removal cylinder support 3. Properly attach the supplied slings to the counterweight
pins are securely attaching the counterweight to the lifting holes and use a crane to carefully transfer the
turntable wing/support brackets. Disengage the counter- counterweight to the frame counterweight supports over
weight mounting pins using the pinning control lever the rear outrigger box.
(center).
4. Attach the counterweight removal cylinder hydraulic
5. Using the control levers (left and right), simultaneously lines.
extend (lower) the counterweight onto the frame coun-
5. Using the control levers (left and right), extend the coun-
terweight supports. Feather individual controls as
terweight removal cylinders, one at a time, guiding them
required to lower the counterweight in a level position.
into the turntable wing/support brackets. Pin securely.
6. Remove the counterweight removal cylinder support
6. Using the control levers (left and right) simultaneously
pins from turntable wing/support brackets and using the
retract (raise) the counterweight removal cylinders until
control levers (left and right), fully retract the counter-
the counterweight round bar engages the lugs on the
weight removal cylinders.
turntable and the counterweight pinning holes are
7. Disconnect and secure the counterweight removal cylin- aligned with the counterweight mounting pins. Feather
der hydraulic lines and replace the counterweight individual controls as required to raise the counterweight
removal cylinder support pins on the turntable wing/sup- in a level position.
port brackets.
7. Engage the counterweight mounting pins using the con-
8. Properly attach the supplied slings to the counterweight trol lever (center).
lifting holes and use a crane to carefully transfer the
8. Attach the ball detent pins securing the counterweight
counterweight to the ground or a suitable transport vehi-
mounting pins.
cle.

8
9. Relieve pressure on the counterweight removal cylinder
Installation of Counterweight Without so that weight is fully supported by the counterweight
27
Auxiliary Hoist mounting pins.

1. Position the crane on a firm, level surface. Fully extend

and set the outriggers. Level the crane.
2

2. Position the superstructure over the front of the machine

and engage the turntable lock.
23

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RT890E SERVICE MANUAL HOIST AND COUNTERWEIGHT

THIRD WRAP INDICATOR (OPTIONAL— illuminating when down to the third wrap, a lockout valve is
STANDARD ON CE) actuated to stop hoist down operation.

Description Maintenance
The third wrap indicator switch mechanism must be adjusted
The third wrap indicator (Figure 5-8) is installed to give the
such that only when the hoist has three wraps of cable
operator an indication that the wire rope is down to the last
remaining on the drum, the switch is actuated. Once
three wraps on the hoist drum and no more rope should be
adjusted properly, ensure there is no continuity through the
reeled out. In addition to the warning light in the cab
switch when actuated and continuity through the switch
when not actuated.

8
27
5
2
23

7833-01

7833-02
FIGURE 5-8

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HOIST AND COUNTERWEIGHT RT890E SERVICE MANUAL

8
27
THIS PAGE BLANK
2
23

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RT890E SERVICE MANUAL SWING SYSTEM

SECTION 6
SWING SYSTEM

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

INTRODUCTION only lock the turntable in a straight ahead position over the

8
front of machine. Both swing locks are operated from the
Description cab.
27
The purpose of the swing system is to allow the crane Theory of Operation
superstructure to rotate atop the carrier frame. The
superstructure swing system provides full 360 degree Swing Drive
2

rotation in both directions and is equipped with free swing

The hydraulic power for the swing drive is supplied by the
23

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

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SWING SYSTEM RT890E SERVICE MANUAL

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

8
11

9
7

10
6

13
5

3
12

8
2
2 27
23

14

6493-1 FIGURE 6-1

Item Description Item Description

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

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RT890E SERVICE MANUAL SWING SYSTEM

Maintenance
Troubleshooting

Symptom Probable Cause Solution

1. Boom swing opera- a. Damaged relief valve. a. Replace relief valve.
tion erratic in either
b. Swing brake dragging (not releasing b. Readjust and/or replace necessary
direction.
properly). parts.
c. Low engine rpm. c. Increase engine rpm to obtain smooth
swing operation.
d. Low hydraulic oil. d. Replenish hydraulic oil to proper level.
e. Improper movement of control to e. Feather controls to neutral to maintain
neutral. smooth stopping action.
f. Insufficient lubricant on swing bearing. f. Lubricate bearing properly. Refer to
Turntable, page 9-16.
g. Crane not level. g. Level crane using outriggers.
h. Damaged swing motor. h. Repair or replace swing motor.
i. Excessive overload. i. Reduce load. Refer to load capacity
chart.

8
j. Restricted or partly clogged hydraulic j. Replace hose or fittings.
27
hose or fittings.
k. Pump cavitation in swing section. k. Tighten suction hose or replace any
damaged fitting. Check hydraulic tank
2
level.
l. Improperly torqued turntable bolts. l. Torque turntable bolts evenly.
23

m. Excessive preload on upper and lower m. Adjust as necessary. 6

pinion shaft bearing.
n. Improperly torqued swing motor n. Torque swing motor attachment bolts.
attachment bolts.
o. Malfunction of the swing box. o. Remove swing box and make
necessary repairs.
p. Worn or damaged pump. p. Repair or replace damaged pump.
q. Damaged swing directional control q. Repair or replace swing directional
valve. control valve.
r. Damaged swing pinion. r. Replace pinion.
s. Damaged turntable bearing. s. Replace turntable bearing.
2. Boom swing opera- a. Crane not level. a. Level crane using outriggers.
tion erratic in one
b. Turntable bearing binding due to b. Rotate machine 360 degrees in both
direction only.
continuous limited swing. (Example: directions several times and lubricate
concrete pourer.) bearing.
c. Restricted hose or fitting. c. Replace hose or fitting.
d. Damaged swing directional control d. Replace swing directional control
valve. valve.
e. Damaged swing pinion. e. Replace pinion.
f. Damaged turntable bearing. f. Replace turntable bearing.

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SWING SYSTEM RT890E SERVICE MANUAL

Symptom Probable Cause Solution

3. Boom will not swing a. Damaged relief valve. a. Remove, clean, and repair or replace
in either direction. relief valve.
b. Damaged swing motor. b. Repair or replace swing motor.
c. Swing brake not releasing properly. c. Repair as necessary.
d. Damaged hydraulic remote control d. Replace hydraulic remote control
valve. valve.
e. Internal damage to swing box. e. Remove swing box and repair.
f. Worn or damaged hydraulic pump. f. Replace pump section.
g. Damaged swing directional control g. Replace swing directional control
valve. valve.
h. Damaged swing pinion. h. Replace pinion.
i. Damaged turntable bearing. i. Replace turntable bearing.
j. Excessive overload. j. Reduce load. Refer to load capacity
chart.
4. Swing operation a. Damaged relief valve. a. Adjust, repair or replace valve.
slow in either direc-
b. Improperly adjusted swing brake. b. Readjust.
tion.
c. Damaged hydraulic remote control c. Replace hydraulic remote control

8
valve. valve.
27
d. Improperly lubricated swing bearing. d. Lubricate bearing per
r e c o m m e n d a t i o n s i n Tu r n t a b l e ,
page 9-16.
2
e. Improper size hose and/or fittings e. Refer to the Parts Manual.
installed.
23

f. Clogged or restricted hydraulic hoses f. Clean or replace damaged parts.

or fittings.
g. Worn or damaged output shaft g. Replace bearings.
bearings
h. Worn or damaged swing motor. h. Repair or replace motor.
i. Worn or damaged hydraulic pump. i. Repair or replace pump.
j. Crane not level. j. Level crane.
k. Damaged swing directional control k. Replace swing directional control
valve. valve.
5. Swing operation a. Crane not level. a. Level crane.
slow in one direc-
b. Damaged hydraulic remote control b. Replace hydraulic remote control
tion only.
valve. valve.
c. Damaged swing directional control c. Replace the swing directional control
valve. valve.
d. Clogged or restricted hose. d. Replace hose or fitting.
e. Improperly torqued turntable bearing. e. Torque turntable bearing.

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RT890E SERVICE MANUAL SWING SYSTEM

Symptom Probable Cause Solution

6. Swing brake opera- a. Improper brake adjustment. a. Adjust brake.
tion erratic.
b. Air in swing brake system. b. Bleed brake system.
c. Brake pedal not fully retracted. c. Check brake pedal return spring; repair
or replace spring.
d. Dirty or glazed brake disc. d. Clean or replace disc.
e. Malfunction of the glide swing power e. Repair or replace glide swing power
brake valve. brake valve.
f. Kinked or bent lines and/or hoses and f. Straighten or replace as required.
fittings.
7. Swing brake sys- a. Damaged swing brake release valve. a. Replace release valve.
tem will not oper-
b. Damaged glide swing power brake b. Repair or replace glide swing power
ate.
valve. brake valve.
c. Internal damage to the swing brake c. Repair or replace affected parts.
assembly.
d. Loose or restricted brake lines or d. Tighten or replace lines and fittings.
fittings.
8. Swing brake pedal a. Damaged glide swing power brake a. Repair or replace the glide swing

8
is spongy. valve. power brake valve.
b. Loose or restricted brake lines or b. Tighten or replace brake lines and
27
fittings. fittings.
9. Swing brake drags. a. Damaged glide swing power brake a. Repair or replace the glide swing
valve. power brake valve.
2

b. Damaged swing brake release valve. b. Replace release valve.

23

c. Internal damage to the swing brake c. Repair or replace affected parts.

assembly. 6
d. Loose or restricted brake lines or d. Tighten or replace brake lines and
fittings. fittings.
10. Boom swings a. Insufficient hydraulic volume. a. Check delivery of hydraulic pump.
slowly. Ensure sufficient fluid is available to
pump. Check pump drive speed.
b. Damaged relief valve. b. Adjust, repair, or replace valve.
c. Damaged swing motor. c. Repair or replace motor.
11. Swing motor con- a. Hydraulic remote control valve sticking a. Repair or replace valve.
tinues to operate or valve otherwise damaged.
when swing control
b. Control valve sticking or valve b. Repair or replace valve.
is in neutral.
otherwise damaged.
12. Swing motor turn- a. Improper port connections. a. Reverse port connection.
ing in wrong direc-
tion.
13. Swing motor noisy. a. Air in system. a. Refer to Removing Air from the
H y d r a u l i c S y s t e m , pa g e 2 - 6 , f o r
removal of air from the system.
b. Motor binding. b. Repair or replace motor.

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SWING SYSTEM RT890E SERVICE MANUAL

SWING MOTOR Test

1. Test swing of superstructure in each direction. Stop and
Description start swing several times.
The swing motor is mounted on the swing brake housing and 2. Inspect for hydraulic leaks and repair as necessary.
drives the swing gearbox through the brake assembly. The
swing motor is a hydraulic gerotor type with low speed and
high torque characteristics. It has only three moving parts,
SWING GEARBOX AND BRAKE
the commutator valve, the drive, and the gerotor star. The
motor has two ports for connection to the hydraulic system.
Description
The swing gearbox and brake, used in conjunction with the
Maintenance swing motor, rotates and stops the superstructure. A pedal
on the cab floor is used to activate the swing brake. The
Removal swing gearboxes are bolted to the superstructure base plate,
1. Ensure the swing brake and swing lock are engaged. and its pinion gear meshes with the ring gear of the turntable
bearing to rotate the turntable.
2. Clean the port area around the motor. Tag and discon-
nect the hydraulic hoses from the motor assembly. Cap The swing gearbox utilizes double reduction planetary
or plug all openings. gearing. The multi-disc swing brake assembly is an integral
part of the swing gearbox and is located between the swing
motor and the swing gearbox. The brake mechanism is a
CAUTION disc pack that is hydraulically released and spring applied.
Oil can be hot and cause burns.
Maintenance

8
3. Unscrew the drain plug, remove the breather and dip- NOTE: The swing brake can be removed and disassem-
stick to ensure that all oil has been removed. After the oil
27 bled independently of the swing gearbox.
has been drained, replace the drain plug and any other
plugs that may have been removed. Swing Brake
Removal
2

CAUTION 1. Engage the turntable lock pin.

23

Pull straight up on the motor assembly to avoid damaging

2. Tag and disconnect the hydraulic lines connected to the
the splined shaft.
swing motor and the brake. Cap and/or plug all open-
ings.
4. Remove the capscrews securing the motor and lift the
swing motor free of the motor support plate. Remove 3. Remove the swing motor from the swing brake accord-
and discard the O-ring from the groove in the swing ing to the removal procedures found under Swing Motor,
brake. page 6-6.

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

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RT890E SERVICE MANUAL SWING SYSTEM

Installation Installation
1. Install a new o-ring onto the brake housing. 1. If removed, install the swing brake according to the
installation procedures found under Swing Gearbox And
2. Place motor support plate on brake housing.
Brake, page 6-6.
3. Apply Loctite 270 to socket capscrews. Install motor
2. If removed, install the swing motor according to the
support and brake onto gearbox and secure with the
installation procedures found under Swing Motor, page
socket capscrews. Torque the capscrews 34.9 to
6-6.
42.4 lb-ft (49.9 to 60.6 Nm).
3. Attach a suitable lifting device to the swing gearbox and
4. Install the swing motor into the swing brake according to
lift and position the swing gearbox in place on the
the installation procedures found under Swing Motor,
mounting plate.
page 6-6.
4. Install the capscrews, washers and spacers. Torque
5. Connect the hydraulic lines to the motor and brake.
capscrews; refer to Fasteners and Torque Values, page
6. Bleed all air from the brake assembly. 1-14 for proper torque value.
Testing 5. Install the pinion gear on the output shaft and secure
with three bolts. Torque 34.9 to 42.4 lb-ft (49 to
1. With the Swing Brake Switch in the ON position, position 60.6 Nm).
the swing control lever in both directions. Superstructure
rotation should not occur. 6. Connect the hydraulic lines to the swing brake.
2. Position the Swing Brake Switch to OFF and swing the 7. Connect the hydraulic lines to the swing motor.
superstructure in both directions. Use the swing brake
8. Service the gearbox as indicated under Servicing, page
pedal to stop rotation.

8
6-7.
3. Check for hydraulic leaks and repair as necessary.
Servicing
27
Gearbox As with all highly stressed mechanisms, reasonable
Removal operating procedures are always required. Normal
maintenance should only consist of proper lubrication and a
2

1. Engage the turntable lock pin. periodic check of mounting bolt torque values. Lubrication
consists of maintaining the gearbox oil level. Oil in a new
23

2. Tag and disconnect the hydraulic lines from the swing

motor and swing brake. Cap and/or plug all openings gearbox should be drained and flushed out after
approximately 250 hours of operation, and replaced with
6
3. Remove the capscrews and lockwashers securing the premium quality SSGL-5 after approximately 500 hours of
pinion guard. Remove the guard. operation or each year, whichever occurs first. Operation in
4. Remove the three bolts and plate attaching the pinion high humidity or polluted air areas will require more frequent
gear to the output shaft and remove the pinion gear. changes to minimize moisture or contaminate accumulation.
Change the oil as follows.
NOTE: The complete gearbox assembly with motor
weighs approximately 375 lb (170 kg). 1. Unscrew the drain plug; remove the breather and dip-
stick to ensure all oil has been removed.
5. Attach a suitable lifting device to the swing gearbox.
Remove the capscrews, washers and spacers securing 2. After oil is drained, replace the drain plug and any other
the gearbox to the mounting plate. plugs that were removed to drain the oil.

NOTE: Take note of the swing motor port orientation to 3. Flush the case with a light flushing oil.
ensure proper installation. NOTE: Cleaning of the gearbox with a solvent is recom-
6. Remove the swing gearbox. mended to prevent an accumulation of grit and
grime. Avoid steam cleaning where moisture and
7. If necessary, remove the swing motor according to the dirt might be driven into the vent of the swing bear-
removal procedures found under Swing Motor, page 6-6. ing.
8. If necessary, remove the swing brake according to the 4. To refill with oil (see Figure 6-2), make sure the breather
removal procedures found under Swing Gearbox And is open. Insert oil through breather oil fill until it reaches
Brake, page 6-6. proper location on dipstick.
9. Cover the opening of the swing gearbox to ensure no 5. Tighten the breather and dipstick.
dirt, dust, etc., gets into the gearbox.

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SWING SYSTEM RT890E SERVICE MANUAL

provides the only attachment between the superstructure

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

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

Maintaining proper torque value for bolts is extremely

important for structural strength, performance, and reliability
of the crane. Variations in torque can cause distortion,
binding, or complete separation of the superstructure from
the carrier. Refer to Fasteners and Torque Values, page 1-14
for information on the use of a torque wrench and torque
values or fasteners.

8
FIGURE 6-2
CAUTION
27
Checking the Oil Level Repeated re-torquing may cause bolts to stretch. If bolts
keep working loose, they must be replaced with new bolts
1. Check the level on the dipstick on the swing gearbox.
of the proper grade and size.
2

2. If no oil is visible on the dipstick, add SSGL-5 weight oil

until the level is between min and max on the dipstick. Proper identification of bolt grade is important. When marked
23

as a high strength bolt (grade 8 and metric grade 10.9), the

3. Replace the dipstick in the brake housing.
serviceman must be aware of bolt classifications and that he
Testing is installing a high strength heat-treated tempered
component and the bolt must be installed according to
1. Test swing of superstructure in each direction. Stop and specifications. Special attention should be given to the
start swing several times. existence of lubricant and plating that will cause variation
2. Inspect for hydraulic leaks and repair as necessary. from dry torque values. When a high strength bolt is
removed, or un-torqued, the bolt must be replaced with a
SWING BEARING new bolt of the same classification.

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

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RT890E SERVICE MANUAL SWING SYSTEM

turntable bolts must be inspected for looseness and Inner Race Torquing
retorqued to specifications.
1. Extend and set the outriggers. Fully elevate the boom.
Before March 29, 2011 the inner race of the bearing is
2. Torque eight bolts to 80% of their specified torque value
secured to the turntable by 72, M24 Grade 10.9 bolts. After
using the following sequence pattern: 1, 40, 22, 58, 16,
March 29, 2011 the inner race of the bearing is secured to
52, 34, and 70; refer to Fasteners and Torque Values,
the turntable by 71, M24 Grade 10.9 bolts.
page 1-14 for proper torque value. Tools used are the
The outer race of the bearing is secured to the carrier frame socket, multiplier, backlash adapter, necessary exten-
by 72, M24 Grade 10.9 bolts. sions, and torque wrench.
Tools Required 3. Return to bolt 1 and torque all bolts sequentially in a
clockwise direction to their final torque value specified.
Figure 6-4 lists the complete set of special tools required to
The same tools are used as in Step 1.
torque the turntable bolts.
Outer Race Torquing
Same as inner race.

18 19 20 21
NOTE: Bolt pattern 16 17 22
23 24
15
numbering 14 25
13
is the same 12 26
11 27
for the inner 28
and outer 10
9 29
race

8
8 30
7 31
27
6 32
5 33
4 34
35
2
3
2 36
37
23

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

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SWING SYSTEM RT890E SERVICE MANUAL

7 1
3 6
5 6633

Orders for special tools Description Manitowoc Part Number Quantity Required
shall be referred to: 1. M24 Socket 3/4” Drive 9-999-101798 1
1

8
2. 4 to 1 Torque Multiplier (1/2” Input 3/4” Output) 9-999-100134
Manitowoc Crane Care 3. Backlash Adapter 9-999-100141 1
Customer Support 4. 1/2” Drive Torque Wrench 9-999-100136 1
27
1565 Buchanan Trail East 5. 10” Extension 3/4” Drive 9-999-100138 A/R
Shady Manitowoc, PA 17256 6. 13” Extension 3/4” Drive 9-999-100137 A/R
Phone: (717) 597-8121 7. Tool Box (Optional) 9-999-100146 1
Fax: (717) 593-5929
2

Special Turntable Bolt Torquing Tools FIGURE 6-4

23

Removal 6. Remove the counterweight and auxiliary hoist following

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

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RT890E SERVICE MANUAL SWING SYSTEM

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

8
NOTE: If the same bearing is to be used again, align the
marked teeth on the pinion shaft and the marked
27
DANGER teeth on the bearing.
Ensure the superstructure is fully supported before
proceeding. NOTE: Installation is in the travel position. Ensure the
swing lock is disengaged before attempting to mate
2

the bearing to the superstructure.

NOTE: It will be necessary to rotate the superstructure
23

while attached to the lifting device. Outer race bolts 1. Using an appropriate lifting device, position the turntable
can only be removed from the swing drive side of
the turntable.
bearing under the superstructure. If the same bearing is 6
being used, position it as marked prior to removal.
14. Remove the 72 bolts and washers securing the turntable 2. Install 72 new bolts and washers securing the bearing to
bearing outer race to the carrier. the superstructure. Refer to Inner Race Torquing, page
6-9.
3. Using an appropriate lifting device, align the superstruc-
ture over the carrier in the travel position and carefully
DANGER lower the superstructure, being careful not to damage
Ensure that any blocking material used is capable of fully the swivel assembly, into position on the carrier bearing
supporting the weight of the superstructure and will not plate.
allow it to tilt or shift. Failure to do so may result in death or
injury to personnel. NOTE: It will be necessary to rotate the superstructure
while attached to the lifting device. Outer race bolts
15. Carefully lift the superstructure, using care not to dam- can only be installed from the swing drive side of
age the swivel assembly, and set it on blocking that will the turntable.
not allow the superstructure to tilt or shift, or rest on the 4. Install 72 new bolts and washers. Refer to Outer Race
swivel. Leave the lifting device attached. Torquing, page 6-9.
NOTE: If the same bearing is to be used again, mark the NOTE: If a new bearing is being installed, a new pinion
position of the bearing on the superstructure so it gear must also be used. Align the high point (maxi-
can be installed in the exact position it was before mum eccentricity) on the bearing with the new pin-
removal. ion gear high point.

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SWING SYSTEM RT890E SERVICE MANUAL

6. Position the retainer plate on the bottom of hydraulic

Maximum Eccentricity Point swivel spool, engaging the lugs on the carrier frame, and
Pinion
secure it to the spool with two bolt retainers and four
bolts. Torque the bolts to 199 ft-lb (270 Nm). Bend all the
retainer tabs to make contact with the bolt heads.
7. Plug the swivel wiring harness connectors into the car-
rier receptacles. Secure the ground wire to the ground
stud using a washer, lockwasher, and nut.
8. Install the clamp securing the swivel wiring harness to
the retainer plate on the bottom of the hydraulic swivel.
9. Connect all water and hydraulic lines to the ports on the
bottom of the swivel as tagged during removal.
10. Install the boom and lift cylinder following the procedures
outlined in the section titled Boom, page 4-1.
Bearing
NOTE: The counterweight/auxiliary hoist and structure
6492
weighs approximately 24,398 lb (11067 kg).
.008 Thick Shim By Full Width to
Tooth Engagement (.016) 11. Install the counterweight and auxiliary hoist following
Backlash) FIGURE 6-5 procedures outlined in Section 4 of the Operator Man-
ual.
5. Orient ring gear such that its point of max eccentricity
(“high point”) is located between the swing drives. Posi- 12. Reconnect the batteries.

8
tion swing drives so that pinion is centered within cutout 13. Check the slew potentiometer in the electrical swivel for
in base plate and motor ports face towards the outboard
27
proper orientation. Refer to Swivels, page 6-13.
side as shown.
Testing
Activate the crane and check for proper function.
2
CAUTION
Do Not Clamp Over Pinion. NOTE: If the superstructure does not turn freely after bear-
23

ing and pinion replacement, contact your local dis-

• Using shims, set backlash by moving the swing drive tributor.
assemblies toward the bearing in order to mesh the
pinion with the ring gear teeth (see Figure 6-5).
• Check tooth engagement squareness and vertical
tooth engagement.
• Remove backlash shims and recheck backlash.

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RT890E SERVICE MANUAL SWING SYSTEM

SWIVELS stationary with the carrier as the case rotates with the
superstructure.
Description The spool portion of the water swivel is integral with the
The swivel assembly (Figure 6-6) consists of a 12 port hydraulic swivel. The hydraulic and water swivel spools
hydraulic swivel, a 2 port water swivel, and a 20 conductor remain stationary with the carrier as the superstructure
slip ring electrical swivel. Solid connections cannot be used rotates. The water swivel case engages to hydraulic case by
to transfer oil, heater hot water and electricity between the four dowel pins.
carrier and superstructure due to the continuous 360 degree The electrical swivel center or collector ring assembly is
swing. The use of swivels efficiently accomplishes this secured by setscrews to a center post which is bolted to the
function. spool of the hydraulic swivel. This allows the collector ring
The barrel portion of the hydraulic swivel is attached to the assembly to remain stationary with the carrier. The outer
turntable base plate by four bolts, washers and bushings. portion or brush assembly is mounted on two studs which
The spool portion of the swivel rides upon a thrust ring at the are located on the mounting plate assembly which is
top of the swivel case. The spool portion is held stationary retained to the water swivel barrel by a bolt. This allows the
with the carrier by bolts, and bolt retainer plates attached to brush assembly to rotate with the superstructure around the
the swivel retainer plate which engages the carrier frame stationary collector core.
lugs with bolts and jam nuts. This allows the spool to remain

8
2 27
23

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SWING SYSTEM RT890E SERVICE MANUAL

1
2

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

8 Hydraulic Swivel
9 Mounting Bolts
Water and Hydraulic
10
Case

8
11 Turntable Base Plate
6
12 Carrier Top Plate
27
Bolt and Bolt Retainer
13
Plate
Tubing Clamp, Bolt,
2

14 7
Lockwasher, Flatwasher
23

15 Electric Swivel Harness

11

12

13

6490-1, 6490-2
14
15

FIGURE 6-6

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RT890E SERVICE MANUAL SWING SYSTEM

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

Standard Working Pressure

Port # Function
psi (kPa)
1 2901 (20000) Brake - Front
2 2901 (20000) Brake - Rear
3 2901 (20000) Load Sense
4 508 (3500) Dual Return
5 3553 (24500) Swing/Steer
6 3553 (24500) Lift/Tele/Hoist
7 2901 (20000) Pilot/Accessory
8 2901 (20000) Front Steer-Left
9 2901 (20000) Front Steer-Right

8
10 508 (3500) Drain
11 29 (200)
27 A/C
12 29 (200) A/C
A 29 (200) Heater Supply (Coolant)
2

B 29 (200) Heater Return (Coolant)

23

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

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

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

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SWING SYSTEM RT890E SERVICE MANUAL

NOTE: The hydraulic swivel weighs approximately 213 lb 7. Connect the hydraulic lines to the hydraulic swivel case
(97 kg). The hydraulic, water, and electrical swivel as tagged during removal.
combined weigh approximately 239 lb (108 kg).
8. Connect the water lines to the water swivel case as
9. On the bottom of the swivel, bend the retainer tabs away tagged during removal.
from the bolt heads. Remove the capscrews and cap-
9. Remove the blocking material from the lift cylinder.
screw retainers securing the two retainer plates to the
spool. Remove the retainer plates from the spool and 10. Activate all systems; cycle all functions and observe for
the lugs on the carrier frame. proper operation and any leakage.
NOTE: It may be necessary to remove some drive line
Two Port Water Swivel
components to remove the swivel.
10. Position an adequate supporting device beneath the Description
swivel. The two port water swivel allows engine coolant to flow from
11. Remove the capscrews, washers, and bushings secur- the carrier-mounted engine to the hot water heater in the
ing the swivel barrel to the turntable base plate and operator cab. Through an internally drilled passage in the 14
lower the swivel to the ground. port hydraulic swivel spool, coolant is transferred to a
circumferential groove on the water spool exterior. This
Installation groove corresponds with a mating port on the outer case of
NOTE: The hydraulic swivel weighs approximately 213 lb the water swivel. The spool grooves are separated by a quad
(97 kg). The hydraulic, water, and electrical swivel ring/telflon bronze ring seal. The lip seal prevents coolant
combined weigh approximately 234 lb (106 kg). from leaking externally. Return engine coolant flow from the
hot water heater is accomplished in the same manner
1. Raise the swivel into position. through the opposite port of the water swivel.

8
2. Secure the hydraulic swivel to the turntable base plate Maintenance
27
with the bushings, capscrews and washers. Torque cap-
screws; refer to Fasteners and Torque Values, page 1- Removal
14 for proper torque value.
1. Perform steps 1 thru 4 of the removal procedure under
2
3. Position the retainer plate on the hydraulic swivel spool Hydraulic Swivel, page 6-15.
ensuring it engage the lugs on the carrier frame. Secure
2. Remove the electrical swivel. Refer to removal proce-
23

the retainer plate with the capscrews and capscrew

dure under Electrical Swivel, page 6-17.
retainers. Apply Loctite 271 to the bolt threads. Torque
the bolts 199 lb-ft (270 Nm). Bolt head flats must align 3. Tag and disconnect the lines from the case of the water
with retainer tabs. Bend all the retainer tabs to make swivel. Cap or plug all lines and openings.
contact with the bolt heads. Snug the retainer plate cap-
4. Remove the four bolts and washers securing the water
screws against the lugs on the carrier frame and tighten
swivel and electrical swivel center post to the hydraulic
the locking nuts.
swivel. Remove the water swivel case and center post.
4. If removed, install the electrical swivel. Refer to Electri-
Disassembly
cal Swivel, page 6-17. Connect the swivel wiring har-
ness connectors to the carrier receptacles and the NOTE: Any maintenance requiring disassembly of the
ground wire to the mounting bracket on the carrier water swivel should include replacement of all
frame. Use the bolt and star washers taken off at seals and rings.
removal. Make sure the ground connection is clean and
has good metal to metal contact. Spray the connection
with a battery terminal protectant such as Deka Battery CAUTION
Terminal Protection spray, Grove P/N 9999102423. When removing seals and rings, avoid scratching
5. Install the clamp, lockwasher, flat washer and capscrew grooved and gland surfaces.
to the bottom of the swivel retainer plate securing the
wiring harness. NOTE: Aligning discarded seals and rings in the order of
disassembly will assist with installation of new
6. Connect the hydraulic lines and water lines to the spool seals and rings.
of the hydraulic swivel as tagged during removal.

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RT890E SERVICE MANUAL SWING SYSTEM

1. Remove the seals and rings from the spool. Electrical Swivel
Cleaning and Inspection Description
The swivel assembly consists of a 20 conductor slip ring and
cover assembly.
DANGER Each brush set incorporates two brushes, leads, and clips
Cleaning solvents can be toxic, flammable, an irritant to which are attached to a brush holder assembly. The brush
the skin, or give off harmful fumes. Avoid prolonged skin set leads are formed into harnesses which are routed
contact, inhalation of vapors, or smoking. Failure to through the mounting plate on the swivel. The collector ring
comply can result in injury or death to personnel. leads are formed into one harness which is routed downward
through the center of the hydraulic swivel. Extending from
1. Clean the spool and case with a suitable solution and the base of the hydraulic swivel, the collector ring leads are
dry with compressed air. Plug all ports with plastic caps. also formed into connectors which plug into receptacles from
the chassis power supply.
2. Check the spool and inside of the case for scratches,
grooves, scoring, etc. If any grooves have developed The swivel cover is secured with a seal and bolts
with a depth of 0.005 in (0.127 mm) the unit should be The electrical swivel also incorporates a slew potentiometer.
replaced. The potentiometer controls functions in the load moment
Assembly indicating, working area definition, and rear axle oscillation
lockout systems.
NOTE: Lubricate the interior of the swivel to prevent rust-
ing from condensation. Theory of Operation

8
1. Lubricate the spool, seals, and rings. The electrical swivel is located on top of the water swivel and
transfers electricity between the carrier and superstructure.
27
Wiring harnesses transmit the electricity between the carrier
CAUTION and superstructure.
When installing seals and rings, avoid stretching seals or
scratching grooved or gland surfaces. Maintenance
2

Removal
23

2. Install new seals and rings on the spool.

1. Perform steps 1 through 4 of the removal procedure
under Hydraulic Swivel, page 6-15.
6
CAUTION
Proper alignment when installing the case is required. Do
not force the spool into the case.
DANGER
3. Insert the spool into the barrel. D i s c o nn e c t t h e ba t t er i e s b e f or e pe r fo r m i n g a n y
maintenance on the electrical system. Serious burns may
Installation result from accidental shorting or grounding of live
1. Install the water swivel on top of the hydraulic swivel. circuits.
Secure the water swivel and the electrical swivel center
post with the capscrews and washers. 2. Disconnect the batteries. (Refer to Batteries, page 3-3.)

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

3. Install the electrical swivel. Refer to the installation pro- 4. Tag the connectors and their receptacles with numbers.
cedure under Electrical Swivel, page 6-17. Disconnect the connectors from the chassis wiring
receptacles.
4. Perform steps 8 and 9 of the installation procedure
under Hydraulic Swivel, page 6-15. 5. Remove the clamp securing the wiring harness to the
retainer plate on the bottom of the hydraulic swivel
5. Activate all systems, cycle all functions, and observe for assembly.
proper operation and any leakage.
6. Secure the connectors and wires from each of the num-
bered connectors so the harness can be withdrawn
through the center of the hydraulic swivel.

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SWING SYSTEM RT890E SERVICE MANUAL

7. Tag and disconnect the connectors from the receptacles

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

9. Loosen the setscrews securing the electrical swivel

mounting tube to the center post on the water swivel.
10. Remove the capscrew and jam nut securing the electri-
cal swivel case to the plate on the case of the water
swivel.
7, 8
5, 6
CAUTION
When withdrawing the wiring harness through the center
of the hydraulic and water swivels, ensure the wires do 6490-4
not get caught and damaged. TOP OF SWIVEL
FIGURE 6-7
11. Remove the swivel and wiring harness from the crane. If
necessary, remove the spacer bushing from the center
Item Description
post.
1 Hex Nut
Installation
2 Capscrew
1. If removed, install the spacer bushing on the center post.

8
Route the collector core wiring harness through the cen- 3 Capscrew
ter of the hydraulic and water swivels.
274 Flatwasher
NOTE: The boom should be centered directly over the 5 Capscrew
front of the crane before adjustment is made to the 6 Jam Nut
slew potentiometer.
2

7 Nipple
2. Slide the electrical swivel mounting shaft onto the center
23

8 Adapter
post.
3. Ensure the threaded hole on the bottom of the electrical 7. Plug the connector into the carrier wiring receptacle,
swivel base is aligned with the mounting hole in the plate connect the wires as tagged during removal. Install the
on the water swivel case. Install the capscrew through yellow ground wire to the connector mounting bracket on
the hole in the plate and install the jam nut. Screw the the carrier frame using the bolt and star washers taken
capscrew into the hole in the electrical swivel base until off at removal. Make sure the ground connection is clean
the capscrew head is approximately 0.23 in (6.0 mm) and has good metal to metal contact. Spray the connec-
from the bracket. Tighten the nut against the electrical tion with a battery terminal protectant such as Deka Bat-
swivel (Figure 6-7). tery Terminal Protection spray, Grove P/N 9999102423.

4. Apply medium strength Loctite to the setscrews securing 8. Install the clamp securing the harness to the retainer
the electrical swivel to the center post and tighten them plate on the bottom of the hydraulic swivel assembly.
44 to 53 lb-in (5 to 6 Nm). 9. Connect the batteries.
5. Install the swivel cover and secure with capscrews and
washers.
CAUTION
6. Connect the wiring harness connectors to the recepta- It is imperative that the slew potentiometer be adjusted
cles on the cab bulkhead mounting plate as tagged dur- anytime work is done to the electrical swivel.
ing removal.
10. Activate all systems, cycle all functions, and observe for
proper operation. Adjust the slew potentiometer in
accordance with the procedures under Slew Potentiom-
eter Adjustment, page 6-19.

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RT890E SERVICE MANUAL SWING SYSTEM

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

8
exceeds ± 1.0 degree, return to step 4.
• Complete the RCL console setup according to the
crane’s current operating configuration. 10. Disengage the house lock pin and swing approximately
27
10 degrees to the right (clockwise). Slowly swing back to
• Press limits LIM.
the left and engage the house lock pin.
• Press 4 for slew angle/work area definition limits.
NOTE: If the superstructure swings past the house lock pin
2

• Press 1 for slew angle. engaged position, step 10 must be repeated.

23

• Press 2 or 3 to display slewing angle. 11. If the angle indicated on the console does not exceed ±
3. Remove the electrical swivel cover. 1.0 degree, proceed to step 12. If the indicated angle 6
exceeds ± 1.0 degree, return to step 3.
12. Disengage the house lock pin and swing approximately
CAUTION 10 degrees to the left (counterclockwise). Slowly swing
Do not attempt to rotate the slotted shaft in the center of back to the right and engage the house lock pin.
the slew potentiometer.
NOTE: If the superstructure swings past the house lock pin
4. Disengage the house lock pin and swing the superstruc- engaged position, step 12 must be repeated.
ture approximately 10 degrees to the right (clockwise). 13. Verify the angle indicated on the console does not
Slowly swing back to the left and engage the house lock exceed ± 1.0 degree. If the indicated angle exceeds ±
pin. 1.0 degree, return to step 3.
NOTE: If the superstructure swings past the house lock pin
engaged position, step 4 must be repeated.

GROVE Published 9-18-2014, Control # 308-06 6-19

SWING SYSTEM RT890E SERVICE MANUAL

8
27
THIS PAGE BLANK
2
23

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RT890E SERVICE MANUAL POWER TRAIN

SECTION 7
POWER TRAIN

SECTION CONTENTS
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Antifreeze/Coolant . . . . . . . . . . . . . . . . . . . . . . . . 7-20
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Radiator Removal and Installation. . . . . . . . . . . . 7-20
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 Radiator Fill and Servicing. . . . . . . . . . . . . . . . . . 7-22
Electronic Control System. . . . . . . . . . . . . . . . . . . 7-4 Drive Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
Engine Control System Switches and Indicator Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7 Transmission/torque Converter . . . . . . . . . . . . . . 7-25
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8 Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . 7-25
Air Intake and Exhaust System . . . . . . . . . . . . . . . 7-8 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8 Troubleshooting Procedures . . . . . . . . . . . . . . . . 7-26
Air Intake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9 Towing or Pushing . . . . . . . . . . . . . . . . . . . . . . . . 7-28
Charge-Air Cooler System . . . . . . . . . . . . . . . . . 7-13 Servicing the Crane After Transmission/Torque
Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14 Converter Overhaul . . . . . . . . . . . . . . . . . . . . . 7-30

8
Water Cooling System . . . . . . . . . . . . . . . . . . . . . 7-17 Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . 7-31
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31
27
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17 Engine Block Heater . . . . . . . . . . . . . . . . . . . . . . 7-31
2
23

ENGINE the idle switch). The foot throttle pedal and idle switch are
electrically connected to the superstructure control module
Description which sends the signal to the engine ECM via the data link.

The engine is a Cummins QSB6.7 diesel engine. This The engine and its components are enclosed in a hood
Service Manual does not include detailed information on the assembly with a grill in the rear of the hood for adequate air
engine itself. A separate manual as prepared in detail by the circulation. Access to the engine is gained through a door
assembly in the top of the hood that opens from both sides.
engine manufacturer, is supplied with this Service Manual.
However, a short description and maintenance of certain
7
The air intake filter is mounted on the rear of the right rear
components of the fuel system, air intake system, and water fender. The muffler is mounted on the left side of the frame
cooling system is provided in this section. behind the rear fender.
The engine is electronically controlled by the Electronic
Control Module (ECM), it is the control center of the system.
It processes all of the inputs and sends commands to the fuel
systems as well as vehicle and engine control devices. DANGER
Engine speed is controlled by the foot throttle pedal in the Do not spray starting fluid into the air inlet. The spray will
cab. It controls engine RPM which increases or decreases contact the heater elements and could explode causing
proportionately with the amount of foot pressure applied to personal injury.
the pedal. Engine speed is also controlled by the idle switch,
which is a three position rocker switch located on the front of To aid in starting the engine in cold weather, the engine is
the steering column. The idle switch allows the operator to equipped with electric air heating elements that are located
infinitely vary and hold the engine speed between the in the engine’s intake air stream to aid in cold starting and
engine’s minimum and maximum idle settings (refer to reduce white smoke at start-up. In the preheat mode, the
Section 3, Operating Controls and Procedures in the engine should not be cranked until the Wait-To-Start Lamp
applicable Operation Manual for details on the operation of turns off. The Wait-To-Start Lamp is illuminated during the

GROVE Published 9-18-2014, Control # 308-06 7-1

POWER TRAIN RT890E SERVICE MANUAL

preheat time that takes place when the ignition switch is in 14. Attach to the engine a lifting device capable of support-
the ON position during cold weather starting. The ECM ing the weight of the engine and transmission/torque
checks information it receives from various sensors on the converter.
engine to determine how long to energize the air heater
15. With the lifting device supporting the weight of the
before extinguishing the Wait-To-Start Lamp. Once the
engine, remove the four sets of bolts, washers, and nuts
engine is started, the electric air heating element will be
securing the front of the engine to the frame. Remove
energized again for a time period determined by intake air
the four sets of capscrews, locknuts, and washers (two
temperature.
sets on each side) securing the transmission/torque
Maintenance converter to the frame.
16. Using the lifting device, lift the engine and transmission/
Engine Removal torque converter as an assembly from the crane.
1. Set the outriggers and position the boom to over the 17. If a new engine is to be installed, remove all compo-
side. nents, fittings, etc., from the old engine and install them
2. Open and remove the hood top door assembly. on the new engine in the same locations.

3. Disconnect the air filter tubing at the engine and air Ensure that the same grade hardware, torque values, and
cleaner. Remove and lay aside. Loctite as were installed by the factory are used.

4. Disconnect the exhaust tubing at the engine and muffler. Engine Installation
Lay to the side.
NOTE: Use the same grade Hardware, torque values, and
5. Tag and disconnect the engine electrical harness con- Loctite that were used by the factory.
nector from the carrier harness connector and battery

8
cables.
6. Unbolt the fuel filter and engine lubrication filter from the
27
frame and lay on the engine. DANGER
The lifting device must be able to support the combined
7. Drain the engine coolant system.
weight of the engine and transmission.
2
8. Drain the engine lubrication system.
1. With all components and fittings installed on the new
23

9. Drain the transmission/torque converter oil system.

engine, lift the engine into the crane.
10. Remove the engine hood assembly and pump cover
2. With the engine in position, secure each side of the
from the machine.
transmission/torque converter with four sets of cap-
11. Disconnect and remove the drive shaft(s) between the screws, nuts and washers (two sets on each side). At the
transmission/torque converter and the axle(s). Refer to front of the engine secure the engine mount to the frame
DRIVE LINES in this Section. with the four sets of bolts, washers, and nuts.
12. Tag and disconnect all lines from the radiator. Discon- 3. Remove the lifting device.
nect the coolant level sensor harness from the engine
4. Connect all lines and tubing to the engine, torque con-
harness and tie up excess harness so it is out of the way.
verter, and all other components in accordance with the
Remove the radiator. Refer to RADIATOR - Removal in
identification marks made during removal.
this Section.
13. Tag and disconnect all lines and tubing from the engine,
transmission/torque converter, and all other compo- CAUTION
nents. Do not apply sealant to the inside of the hydraulic suction
hoses.

5. Apply a moderate coat of Permatex® Type No. 2 to the

DANGER male hose adapter and install the hydraulic hoses. Do
The lifting device must be able to support the combined not apply sealant to the inside of the hydraulic hose, and
weight of the engine and transmission. push it onto the male adapter. This can result in excess
sealant being pushed ahead of the male adapter and
NOTE: The engine and transmission/torque converter being exposed to the hydraulic oil.
assembly weighs approximately 2400 lb (1100 kg).

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6. Install the radiator. Refer to Radiator Removal and 14. Start the engine. Check all hoses and fittings for leaks.
Installation, page 7-20. Connect all hoses and electrical Recheck all fluid levels.
harnesses to the radiator as tagged during removal.
Engine Drive Belts
7. Connect the drive shafts between the transmission/
torque converter and the axles. Refer to Drive Lines, The proper operation of engine belt-driven components such
page 7-23. as the alternator, fan, and water pump depend on the proper
condition and tension of the engine drive belt.
8. Install the hood assembly. Install the pump cover.
NOTE: Belt tension is maintained with an automatic belt
9. Attach the fuel filter and engine lubrication filter to the tension device.
frame.Connect the battery cables and engine electrical
harness connector in accordance with the identification The engine drive belt should be inspected visually on a daily
marks made during removal. basis. The drive belt should be inspected for cracks, frayed
areas, and glazed or shiny surfaces (see Figure 7-1). A drive
10. Connect the electrical wiring to the hourmeter as tagged belt that is glazed or shiny indicates belt slippage.
during removal.
Engine drive belt damage can be caused by various factors
11. Connect the air filter tubing at the engine and the air fil- such as incorrect tension, incorrect belt size, misaligned
ter. Connect the exhaust tubing to the engine and muf- engine pulleys, incorrectly installed belt, or by oil, grease, or
fler. On Tier IV engines, replace the exhaust tube hydraulic fluid on the belt.
gaskets with new
Refer to the engine manufacturer’s manual for any special
12. Install the hood top door assembly. tools or belt tension specifications.
13. Service the transmission, engine lubrication system, and
engine cooling system.

8
27
OK
OK
OK
2
23

Missing Material Traverse Cracks Longitudinal Cracks Intersecting

with Transverse Cracks must be Replaced

FIGURE 7-1

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ELECTRONIC CONTROL SYSTEM Diagnostic function — With the Ignition Switch in the RUN
position, the engine off, and the top of the Engine Diagnostic/
The engine control system is an electronically operated fuel Speed Control Switch pressed, press the top or bottom of the
control system that also provides many operator and vehicle Increment/Decrement Switch to toggle forward and
features, as well as, reducing emissions while optimizing backward through the engine fault codes shown on the
engine performance. steering column display. If there are no engine fault codes,
The ECM performs diagnostic tests on most of its circuits zeroes will be shown in the steering column display.
and will activate a fault code if a problem is detected in one of Engine low idle function — With the engine running and the
these circuits. Along with the fault code identifying the top of the Engine Diagnostic/Speed Control Switch pressed,
problem, a snapshot of engine operating parameters at the press the top or bottom of the Increment/Decrement Switch
time of fault activation is also stored in memory. Some fault to increase or decrease the low engine idle.
codes will cause a diagnostic lamp to activate to signal the
driver. The fault codes can be read using the fault lamps in Engine rpm function — With the engine running and the
the cab panel or with the correct service tools. The ECM bottom of the Engine Diagnostic/Speed Control Switch
communicates with service tools supplied by Cummins pressed, the Increment/Decrement Switch is used to adjust
through a SAE data link. engine rpm. Quickly press the top of the switch once to go to
full engine rpm; quickly press the bottom of the switch once
The ECM also monitors the condition of the diesel particulate to return to low engine idle. If the engine speed is below the
filter and will alert the operator by way of an indicator in the maximum rpm setting, pressing and holding the top of the
cab if the filter becomes clogged with carbon. When the filter switch will cause the engine rpm to slowly increase; release
becomes clogged, the ECM will control the regeneration the switch when the desired rpm is attained. If the engine
process to clean the filter of particulate matter. speed is above the minimum rpm setting, pressing and
holding the bottom of the switch will cause the engine rpm to
Engine Control System Switches and

8
slowly decrease; release the switch when the desired rpm is
Indicator Lights attained.
27
Engine Diagnostic/Speed Control Switch Engine Stop Light
The Engine Diagnostic/Speed Control Switch is a two The Engine Stop Light is located in the steering column
position maintained on/off rocker switch used to access the gauge display. It is a red indicator light that illuminates to
2

engine fault codes or enable the control of the low engine signify a serious engine problem that requires the vehicle
idle and engine rpm functions. and the engine to be stopped as soon as safely possible.
23

The engine should remain shut down until the fault can be
Diagnostic function — With the Ignition Switch in the RUN
repaired.
position and the engine off, press the top of the Engine
Diagnostic/Speed Control Switch to view the engine fault In addition to alerting the operator of system faults, the
codes on the steering column display. If there is more than Engine Stop Light, in conjunction with the Engine Warning
one active engine fault code, use the Increment/Decrement Light, is used in the diagnostic operation of the engine
Switch to toggle forward and backward through the fault control system.
codes. If there are no engine fault codes, zeroes will be
NOTE: When not using the diagnostic system, turn the
shown in the steering column display.
Engine Diagnostic Test Mode Switch to the OFF
Engine low idle function — With the engine running and the position.
top of the Engine Diagnostic/Speed Control Switch pressed,
To check for active fault codes, turn the keyswitch to the OFF
the engine low idle is adjusted using the Increment/
position, and move the Engine Diagnostic Test Mode Switch
Decrement Switch.
to the ON position. Turn the vehicle keyswitch to the ON
Engine rpm function — With the engine running and the position. If no active fault codes are recorded, both lamps
bottom of the Engine Diagnostic/Speed Control Switch stay off. If active fault codes are recorded, both lamps will
pressed, the engine rpm is adjusted using the Increment/ come on momentarily, then begin to flash one code of the
Decrement Switch. recorded faults.

Increment/Decrement Switch Engine Warning Light

The Increment/Decrement Switch is a three position The Engine Warning Light is located in the steering column
momentary rocker switch with center maintained position gauge display. It is an amber indicator light that is a part of
being off. Use this switch to toggle backward and forward the engine’s electronic control system and when illuminated,
through active engine fault codes or adjust engine speed. gives the operator a signal that there is a engine problem
which must be corrected.

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In addition to alerting the operator of system faults, the If even more clogging occurs, the engine warning light will
Engine Warning Light, in conjunction with the Engine Stop illuminate in addition to the DPF indicator and severe engine
Light, is used in the diagnostic operation of the engine derate will occur.
control system.
NOTE: When not using the diagnostic system, turn the
Engine Diagnostic/Speed Control Switch to the WARNING
speed control position. Fire or Burn Hazard!
To check for active fault codes, the keyswitch must be in the During the regeneration process the exhaust becomes
OFF position, and move the Engine Diagnostic/Speed very hot. Do not park the vehicle near flammable objects.
Control Switch to the engine diagnostic position. Turn the Use caution near the exhaust tailpipe during regeneration
vehicle keyswitch to the ON position. If no active fault codes as it will become very hot.
are recorded, both lamps stay off. If active fault codes are
recorded, both lamps will come on momentarily, then begin The regeneration process can take place in three different
to flash one code of the recorded faults. modes:
Fault Code Flashing Sequence Passive: The exhaust is hot enough during normal working
operation to burn off any hydrocarbon (soot) accumulation.
The Engine Warning Light (amber) flashes at the beginning
of a fault code sequence. There will be a short 1- or 2-second Active: Active self-regeneration occurs when there is not
pause after which the number of the recorded fault code will sufficient heat in the exhaust to convert all the hydrocarbon
flash in the Engine Stop Light (red). To interpret the flash being collected in the DPF. Exhaust temperatures are raised
code, count the first sequence of red flashes for the first digit by injecting a small amount of fuel. The resulting chemical
and after a two second delay, count the second sequence of reaction raises exhaust gas temperatures high enough to

8
red flashes for the second digit. When the number has oxidize the hydrocarbon from the filter. This is all done
finished flashing in red, the Engine Warning Light (yellow) without any operator intervention.
27
flashes again. The lamps flash each fault code 3 times
Manual: Manual or stationary, regeneration is the same as
before advancing to the next code. To skip to the next fault
active regeneration but takes place while the equipment is
code, move the Increment/Decrement Switch in either
not being operated. It offers the equipment operator the
position (+/-) to see other fault codes. If only one active fault
2
option, if needed, of performing regeneration outside the
is recorded, the control system will continuously display the normal duty cycle.
23

same fault code when pressing the Increment/Decrement

Switch. Reference the engine manufacturers service manual Diesel Particulate Filter Regeneration Switch (Tier 4
for explanation and correction of the fault codes. Engines Only)

Diesel Particulate Filter Indicator (Tier 4 Engines

Only)
WARNING
The Diesel Particulate Filter (DPF) indicator is located in the
steering column gauge display. This indicator illuminates
Fire or Burn Hazard!
7
amber when the diesel particulate filter is getting filled with During the regeneration process the exhaust becomes
soot and needs to be cleaned out. very hot. Do not park the vehicle near flammable objects.
Use caution near the exhaust tailpipe during regeneration
When the DPF indicator illuminates or flashes, start as it will become very hot.
regeneration process.
The indicator will be lit continuously during the early stages The Engine Diesel Particulate Filter (DPF) switch is located
of clogging. If the system continues to clog, the lamp will on the right side of the overhead control panel. This switch is
begin to flash and slight engine derate will occur. a three position switch, Inhibit Regen/Permit Regen/Start
Regen. Press this switch to start engine regeneration or to
disable regeneration:

• Start Regeneration (7649-10)

• Inhibit Regeneration (7649-11)

To regenerate, set the crane parking brake, the crane

transmission must be in neutral and have all pedals
released.

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Set up a safe exhaust area around the crane; remove tools, Inhibit Regeneration Indicator
rags, grease or any debris from the engine exhaust area.
The Inhibit Regeneration indicator is located in the steering
With the engine idling push the DPF Regen Switch to initiate column gauge display. When the Diesel Particulate Filter
regeneration. Regeneration switch is in the inhibit regeneration position,
this amber indicator is illuminated and active and manual
Within 5 seconds the engine should rev up to 1000 to 1400
regeneration is prevented.
rpm. The engine will continue to run at this speed for up to 45
minutes. High Exhaust System Temperature
Pressing any pedals during regeneration or activating the The High Exhaust System Temperature (HEST) indicator is
Inhibit Regen switch will interrupt the regeneration process. located in the steering column gauge display.
Make sure the crane and surrounding area are monitored During regeneration it is possible for the engine exhaust to
during manual regeneration. If any unsafe condition occurs, reach temperatures exceeding 1200° F. The HEST indicator
shut off the engine immediately. will illuminate red to warn the operator of when temperatures
During this period the sound of the engine may change. reach 1247° F (675° C) and will stay on until the
When regeneration is complete the engine will return to its temperatures falls below 1157° F (625° C).
idle speed. Warning lights near the tailpipe will flash during regeneration
when high exhaust temperatures exist.

8
2 27
23

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FUEL SYSTEM Fuel Tank

The fuel tank (Figure 7-2) is a steel cylinder-type tank
Description located on the left side of the machine. The fuel tank has a
The fuel system consists of the fuel tank, fuel-water draw capacity of 74 gal (280 l). A connection on the bottom
separator, secondary filter, lift pump, high-pressure pump, of the tank provides for fuel supply to the engine. Surplus fuel
high-pressure common fuel rail (Tier 4 only) and the fuel from the engine is provided to the bottom of the fuel tank
injectors. All components except the fuel tank are installed below the fuel level. The tank is equipped with a non-vented
on the engine or supplied with the engine for remote filler cap, chain-attached to the tank, and a fuel quantity
mounting. sender unit which provides a signal to a fuel quantity gauge
on the instrument panel in the cab. The fuel tank for the CE
units has a lockable vented filler cap.

8
27
7753-02
2
23

1 4

1
7
7753-01
2
2

FIGURE 7-2

Item Description
1 Fuel Tank
2 Steps
3 Fuel Supply
4 Fuel Return
5 Oil Cooler

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Injection Fuel Pump 4. Support the weight of the tank, loosen and remove the
capscrews and washers securing the straps to the
The fuel oil is finely atomized as it is injected into the cylinder
mounting brackets. Remove the tank and steps.
and ignited by the heat of the compression. It is metered
during injection, to meet the load requirements imposed 5. If a new tank is to be installed, remove the two fittings,
upon the engine. Surplus fuel, returning from the injectors, is the fuel quantity sender, and steps from the tank and
bypassed back to the fuel tank or to the inlet side of the install them in the new tank.
pump. The continuous flow of fuel through the injectors helps
Installation
to cool the injectors and to purge air from the system.
1. Position the new tank on the mounting brackets and
Fuel Filter-Water Separator install the capscrews and washers on the two straps.
The fuel filter-water separator removes impurities from the Torque capscrews; refer to Fasteners and Torque Val-
fuel and also removes water from the fuel before it reaches ues, page 1-14 for proper torque value.
the engine. The filter is mounted to the hydraulic oil cooler 2. Connect the electrical lead to the fuel quantity sender
bracket on the right side of the crane. unit.
The fuel mixture passes through the outer wrap of the first 3. Connect the two lines to the fittings on the bottom of the
stage of the filter paper, where large droplets of water are tank in accordance with the identification marks made
formed as it is stripped from the fuel. The water falls out into during removal.
the void between the two paper elements and goes to a
reservoir in the bottom of the housing, where it can be 4. Service the tank.
drained through a drain plug at the bottom of the housing.
Fuel Filter-Water Separator
The water in fuel sensor is located in the fuel filter housing on
the right side of the crane. Once the storage space in the Draining

8
bottom of the filter housing fills with a certain amount of The sump of the fuel filter-water separator should be drained
water, the sensor will signal the ECM. The Engine Warning
27
daily, 30 minutes after the engine is shut down, to remove
light will illuminate at the operator controls, indicating that the any water and sediment. Adhere to the following procedure.
water should be drained from the fuel filter assembly.
1. Open the drain plug.
Electric Lift Pump
2

2. Drain until fuel appears.

The ECM controls the electric lift pump located between the
23

3. Close the drain plug.

fuel tank and the injection pump. Whenever the keyswitch is
turned to the ON position, the lift pump will be energized for a
few seconds to make sure the low pressure fuel lines are AIR INTAKE AND EXHAUST SYSTEM
fully primed. The electric lift pump shuts off after the engine is
started. Description
The air intake system (Figure 7-3) controls the quality and
Maintenance amount of air available for combustion. System components
NOTE: The entire fuel system must be maintained air tight are the Air Cleaner, Turbocharger, Charge Air Cooler,
to prevent loss of prime. Cylinder Head, and Exhaust Manifold. Inlet air is pulled
through the Air Cleaner, compressed and heated in the
Fuel Tank compressor side of the Turbocharger. The air is pushed
through the Charge Air Cooler to the Air Inlet Manifold.
The fuel tank should be kept filled, especially overnight, to
Cooling the inlet air increases combustion efficiency, lowers
reduce condensation to a minimum. Refer to the applicable
fuel consumption, and increases the horsepower. The air is
engine manual for the recommended schedule for draining
forced into the cylinder head to fill the inlet ports. Air flow
any water or sediment from the tank.
from the inlet port into the cylinder is controlled by the intake
Removal valves.
1. Position a suitable container under the fuel tank and Each cylinder has two intake valves and two exhaust valves.
drain all fuel from the tank. When the intake valves open, cooled compressed air from
the inlet port is pulled into the cylinder. The intake valves
2. Tag and disconnect the two lines from the bottom of the close and the piston begins to move up on the compression
tank. stroke. Fuel is injected into the cylinder and combustion
3. Disconnect the electrical lead from the fuel quantity starts. The piston is forced down and is on the exhaust stroke
sender unit. when it moves up again. The exhaust valves open and

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exhaust is expelled through the exhaust port into the exhaust Check For Filter Restriction
manifold.
As a dry cleaner element becomes loaded with dust, the
The exhaust gas from the exhaust manifold enters the vacuum on the engine side of the air cleaner (at the air
turbine side of the turbocharger and causes the turbine to cleaner outlet) increases.
turn driving the compressor. Exhaust from the turbocharger
The vacuum is generally measured as restriction in
passes through the exhaust pipe and muffler/diesel
kilopascals or inches of water. The engine manufacturer
particulate filter into the atmosphere.
places a recommended limit on the amount of restriction the
The Air Cleaner is the dry-type with a replaceable element engine will stand without loss in performance before the
and is located on the left rear fender. A service indicator, element must be cleaned or replaced. Cummins allows a
designed to indicate red when servicing is required, is vacuum of 6.2 kPa (25 inches of water) maximum with a dirty
installed in the left center deck and is connected to the Air air cleaner at maximum governed RPM.
Cleaner by plastic air line.
A service indicator attached to the air cleaner housing will
On the Cummins QSC Engine there are electric air heating indicate when the filter needs to be cleaned or replaced.
elements that are located in the engine’s intake air stream. Reset the indicator each time the air cleaner is serviced. If
These elements heat the intake air when starting the engine the indicator’s accuracy is suspect, a water manometer is the
in cold ambient conditions. Startability and white smoke most accurate and dependable method of measuring
control are enhanced by the use of the intake air heater. A vacuum.
Wait-to-Start Lamp is located on the center front console to
To use the manometer, hold it vertically and fill both legs
indicate when to crank the engine.
approximately half full with water. One of the upper ends is
Air Intake connected to the restriction tap on the outlet side of the air
cleaner by means of a flexible hose. The other end is left

8
Air Cleaner Checks open to the atmosphere.

Dust passing the air cleaner can cause rapid engine wear. All Maximum restriction in the air cleaner occurs at maximum air
27
connections between the air cleaner and the engine must be flow. On this turbocharged diesel engine, the maximum air
tight and sealed. If these connections are well sealed, and flow occurs only at maximum engine power.
there is still evidence of dust leakage, check the following With the manometer held vertically and the engine drawing
2
places for possible trouble. maximum air, the difference in the height of the water
NOTE: Dust that gets by the air cleaner system can often columns in the two legs, measured in inches or centimeters,
23

be detected by looking for dust streaks on the air is the air cleaner restriction. Restriction indicators are
transfer tubing or just inside the intake manifold generally marked with the restriction at which the red signal
inlet. flag locks up.

1. Inspect the air cleaner outlet tube for damage. If the initial restriction on a new or clean filter reads above the
maximum allowed for the engine, check the following items.:
2. Ensure the element gasket washer is not damaged and
the washer’s rubber face seals against the element. 1. Ensure the air cleaner inlet is not plugged.
7
3. Inspect the element gasket for damage. 2. Inspect the air cleaner outlet to be sure it is not plugged
by paper, rags, etc.
4. Check for structural failures and replace damaged parts.
3. Ensure the correct size connections are used between
5. Inspect the restriction indicator tap for leaks. the air cleaner and the engine.
4. Ensure all inlet accessories are the correct size and are
not plugged by any foreign object.

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15
14

Detail A

16

5 6 7
13
4 8
See Detail A
12

3
11

8
10
1 9
27
2
2
23

2
16

17
1

18
B
21

3
B-B
20

7693-13

14
20
19
FIGURE 7-3

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Figure 7-4 Item Numbers

Item Description 1
1 Air Cleaner
2 Service Indicator
3 Nylon Tube
4 Clamp, T-Bolt 6.25-6.66 2

5 Elbow, Reducing 6” - 5”
6 Clamp 5.75”
7 Clamp Hardware
8 Intake Tube
9 Support Intake Bracket
10 Intake Tube
11 Elbow 5” - 4”
12 Muffler Clamp 4”
13 Exhaust Wrap 7832-01
FIGURE 7-4
14 Elbow 4”
3. Remove primary filter (2) from the air cleaner and
15 Elbow, 90° inspect for foreign material and marks of dust.

8
16 Male Connector 4. Replace secondary filter (not shown) from the air
27
17 Coupling, 1/8” cleaner every third primary filter change.
18 Elbow, 90° 5. Thoroughly clean the sealing surface and inside of the
19 Bracket air filter housing. Inspect all parts of the intake system
and air cleaner.
2

20 Bracket Hardware
6. Place the cover back on the air cleaner housing and
23

21 Clamp 5” secure with clips (1).

Filter Element Replacement 7. Check all connections and ducts for an air tight fit. Make
sure that all clamps, bolts, and connections are tight.
Check for holes in piping. Leaks in the air intake system
CAUTION may send dust directly to the engine.
Never service the air cleaner while the engine is running. 8. Replace decking access plate.
7
1. Remove upper step/access plate from side of crane. Element Cleaning
2. Lift the clips (1) (Figure 7-4) securing the cover to the air It is not recommended that filter elements be cleaned.
cleaner body and remove the cover. Cummins and most other manufacturers will not warrant a
cleaned air filter.
Air Cleaner Body
Before installing the filter element, remove foreign material
(leaves, lint or other foreign matter) that may have collected
inside the air cleaner body. Inspect the inside of the body for
dents or other damage that would interfere with air flow or
with the fins on the element or inside the body. Repair any
body dents, being careful not to damage the sealing
surfaces. Be sure to clean the sealing surface of the outlet
tube and the inside of the outlet tube, taking care not to
damage the sealing area on the tube.

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Precleaner these lips periodically and hold them open during engine
operation.
The precleaner (1) (Figure 7-5) prevents large debris from
entering the air cleaner and should be cleaned periodically,
especially when working in severe dust conditions. Remove
the top half of the precleaner by releasing the two latches on
the sides of the precleaner. Remove all debris from inside
precleaner and reassemble.

FIGURE 7-6

Check the condition of the valve and lips frequently and keep
them clean. The valve lips should be open only when the
engine is shut down, or running at low idle speed. If the valve
is turned outside in, check for a clogged air cleaner inlet.
Malfunction of this valve does not reduce the air cleaner
effectiveness, but does allow the element to get dirty faster
and reduces serviceable life. If a valve is lost or damaged,
replace it with a new valve of the same part number.

8
1 Duct Work
7754
27
1. Check the intake pipe cap and screen for accumulation
2 of leaves, trash, and other debris that could restrict air
FIGURE 7-5 flow. Repair the screen or replace the cap if any large
holes are found in the screen.
2

Vacuator Valve
2. Check all mounting hardware for security to eliminate
23

Vacuator valves (2, Figure 7-5) (Figure 7-6) are designed to possible vibration of intake piping. Such vibration leads
expel loose dust and dirt from the air cleaner body to early failure of hoses, clamps, and mounting parts,
automatically, thus lengthening the element service life. The and can cause hoses to slip off the connecting pipes,
valve lips must point straight down and be kept free from allowing un-filtered air into the engine air intake.
debris to operate effectively. Mud and chaff can lodge in
3. Check hoses for cracks, chafing, or deterioration, and
replace at the first sign of probable failure.

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Charge-Air Cooler System

The charge-air cooler (CAC) (Figure 7-7) is used to cool
engine air after it has passed through a turbocharger, but 3
before it enters the engine. The charge-air cooler provides
better horsepower, increased fuel efficiency, and reduces 1
engine emissions.
The CAC system consists of the ducting to and from the
charge-air cooler and a hydraulically driven fan. The charge-
air cooler system must be air-tight in order to work efficiently.
The ducting consists of metal tubing, hose clamps and
bellows. The recommended installation torque of the spring
loaded T-bolt clamps is 75 lb-in (8.5 Nm). Do not compress
the spring completely, the bellows and/or clamp may be
damaged from thermal expansion of the CAC tube.
2
Maintenance
Check the hose clamps for proper torque.
Inspect the bellows for cracks or holes.
Clean the charge-air cooler, removing any dirt or debris.
Verify the fan is operating correctly and there are no

8
hydraulic leaks.
7878-2
27
Charge-Air Cooler Assembly
2

FIGURE 7-7
23

Item Description
1 CAC
2 Engine Coolant Radiator
3 CAC Hot Tube
7

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Muffler 3. Remove clamp to free muffler from exhaust tube.

NOTE: Tier 3 muffler (Figure 7-8) and Tier 4 muffler 4. Tier 4 only—tag and disconnect electrical connections.
(Figure 7-9) are similar in removal and installation 5. Remove mounting bands to free muffler from muffler
despite the differences in the two mufflers, the mounting bracket.
exhaust tailpipes, and the mounting bracket weld-
ments. 6. Inspect muffler, exhaust tailpipe, exhaust tubes, bracket,
and attaching hardware. Repair or replace any of these
The Tier 4 muffler (diesel particulate filter) is parts if damaged or missing.
different in that it has sensors and electrical
connections. Installation
Removal 1. Secure the muffler to the exhaust tube with a clamp.
2. Install the exhaust tailpipe on the muffler. Secure the
exhaust tailpipe to the muffler with clamp. Adjust the
clamp as needed.
CAUTION
3. If removed, secure the muffler mounting brackets to the
Burn Hazard! mountings with capscrews and nuts as needed. Secure
Do not touch muffler or exhaust parts until they are at the muffler to the muffler mounting bracket with mount-
ambient temperature. Severe burning may result. ing bands.
4. Tier 4 only—connect electrical connections as tagged
1. Remove the sheet metal guard to gain access to the
during disassembly.
muffler.
5. Install sheet metal guard.

8
2. Remove clamp to free exhaust tailpipe from muffler. 27
2
23

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6
3 9

1 5

4
7

8
2 27
23

Tier 3 Muffler
FIGURE 7-8

Item Description Item Description

1 Exhaust Tube 6 Elbow 7
2 Muffler Clamp 4’’ 7 Mounting Band
3 V-Band Clamp 8 Muffler
4 Bellows 9 Tailpipe
5 Muffler Clamp 5’’

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11
12

10

7
6
5

9 2

8
1
2 27
3
23

3
7843

Tier 4 Diesel Particulate Filter/Muffler

FIGURE 7-9

Item Description Item Description

1 Elbow 7 Gasket
2 Wire Tie Bar 8 V-Band Clamp
3 Mounting Band Clamp 9 Bellows
4 Diesel Particulate Filter 10 Exhaust Tube
5 Muffler Clamp 11 Gasket
6 Exhaust Tube 12 V-Band Clamp

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RT890E SERVICE MANUAL POWER TRAIN

WATER COOLING SYSTEM 4. Poor lubrication - increased engine wear.

5. Sticking valves.
Description
6. Short injector life.
The cooling system consists of a Radiator, Surge Tank,
engine cooling circuit, the connecting hoses and connecting 7. Engine hot spots.
tubes. At all times, the antifreeze/coolant should properly 8. Need for higher grade fuel.
inhibit corrosion. It is recommended that a mixture of 50/50
blended ethylene-glycol, low silicate, fully formulated, Overcooling
extended life engine antifreeze/coolant mixture which does
The following engine troubles result when an engine is
not require a pre-charge of supplemental coolant additives
overcooled:
(SCA) be used for fill of heavy duty liquid cooled internal
combustion engines. 1. Excessive fuel consumption.
2. Sludge formation in crankcase.
Maintenance
3. Corrosive acids formed in crankcase.
General
4. Excessive fuel deposits in the exhaust system.
The cooling system includes the Radiator, Surge Tank,
Thermostat, the Fan, and Water Pump. Radiator hoses are Antifreeze/Coolant
also included in this group.
Heavy duty diesel engines require a balanced mixture of
The cooling system is often neglected because the effects or water and antifreeze/coolant. For maximum rust, freeze, and
damage that result from an improperly maintained system boiling point protection, a 50/50 blended, fully formulated
usually occur gradually. The cooling system needs to be extended life antifreeze/coolant should be maintained at all

8
maintained with the same attention as other systems. times. Refer to Lubrication, page 9-1. Do not use more than
50 percent antifreeze/coolant in the mixture unless additional
27
The circulation of water through the cooling system relies
freeze protection is required. Never use more than 68
entirely upon the water pump. The water pump draws water
percent antifreeze/coolant under any condition. Antifreeze/
from the radiator and forces it through the water jacket and
coolant at 68 percent provides the maximum freeze
cylinder head. There it accumulates heat and flows to the
protection; antifreeze/coolant protection decreases above 68
2

radiator tank. Then the water flows across through the

percent.
radiator core and is cooled by air from the fan. This process
23

of removing heat from water as it circulates holds the engine Rust Prevention
to its efficient operating temperature.
To keep engines operating at like new efficiency, all forms of
The following paragraphs point out several facts about rust formation must be prevented. The formation of rust in
cooling system components, the effects of cooling system the cooling system is a result of the interaction of water, iron,
neglect, and procedures to be followed for cooling system and oxygen, and can only be prevented by maintaining full
maintenance. strength corrosion protection at all times. Supplemental
Effects of Cooling System Neglect
coolant additives (SCA) are recommended for this cooling 7
system. Antifreeze/coolant alone does not provide sufficient
Whenever an engine does not perform at top efficiency, a protection for heavy-duty diesel engines. Refer to Section 9
neglected cooling system may be at fault even though the for SCA specification and compatible brands.
part directly responsible is not a part of the cooling system.
Most of these problems can be traced to overheating; Engine Antifreeze/Coolant Fill Procedure (when level
however, an engine that is running too cold can be just as is low)
troublesome. 1. Fill the system with a 50/50 blended, fully formulated
Overheating extended life antifreeze/coolant. Fill to the bottom of the
surge tank filler neck. Fill slowly. Flow exceeding 3 gpm
An engine that is overheating may lead to troubles such as (11.2 l/min) can give a false reading.
the following:
2. Wait one minute and recheck the antifreeze/coolant
1. Burned valves. level. Refill as necessary repeating step 1.
2. Pinging or knocking. 3. Run the engine for 5 minutes and recheck the anti-
3. Excessive fuel consumption. freeze/coolant level. Refill as necessary repeating step
1. Refer to Lubrication, page 9-1.

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POWER TRAIN RT890E SERVICE MANUAL

Antifreeze/Supplemental Coolant Additives 1. Coolant shut-off valves to heaters and other accessories
Maintenance Summary should be open to allow complete circulation during
cleaning, flushing, and draining. Run the engine with
Cooling System Level Check Interval radiator covered if necessary until temperature is up to
Daily or 10 hours operating range 160 to 180°F (71 to 82°C). Stop the
engine, remove the radiator cap, and drain the system
The cooling system level should be checked every 10 hours
by opening the drain cocks on the radiator and engine
of operation or daily, whichever comes first. Refer to
block.
Lubrication, page 9-1.
NOTE: Use a cleaning compound that is not corrosive to
SCA Level Check Interval aluminum to prevent damage to the radiator.
6 months or 500 hours
2. Allow the engine to cool, close the drain cocks, and pour
• Check SCA Levels (use only Coolant Test Kit, Grove P/ the cleaning compound into the surge tank according to
N 9414101675, to check the coolant additive the directions. Fill the system with water.
concentration in the cooling system).
3. Place a clean drain pan to catch the overflow, and use it
Only add coolant additive if levels are less than 1.2 units/ to maintain the level in the radiator. Do not spill the solu-
gal (see Lubricants and Lubrication Intervals, page 9-1 tion on the vehicle paint.
for specification and recommended additives).
4. Replace the radiator cap and run the engine at moderate
NOTE: An inadequate concentration of coolant additive speed, covering the radiator if necessary, so the system
can result in major corrosive damage to the cooling reaches a temperature of 180°F (82°C) or above, but
system components. Overconcentration can cause does not reach the boiling point. Allow the engine to run
formation of a “gel” that can cause restriction or at least two hours, or according to recommendations of

8
plugging of coolant passages, and overheating. the manufacturer of the cleaning compound, at 180°F
1 year or 1000 hours
(82°C) so the cleaning solution may take effect. Do not
27
drive the vehicle or allow the liquid level in the radiator to
• Test antifreeze/coolant for contamination. drop low enough to reduce circulation.
Condemning limits are: 5. Stop the engine as often as necessary to prevent boiling.
2

- Sulfate level greater than or equal to 1500 ppm. 6. With the engine stopped, feel the radiator core with bare
hands to check for cold spots, and then observe the tem-
23

- Chloride level greater than or equal to 200 ppm.

perature gauge reading. When there is no change in
- The ph level is less than 6.5 temperature for some time, drain the cleaning solution.
- Oil or fuel contamination can be identified by odor or 7. If clogging of the core is relieved but not fully corrected,
color. allow the engine to cool, pressure-flush the system (see
Pressure Flushing) and repeat the cleaning operation.
If condemned, flush the system using a commercially
available flushing agent. Refill system with fully 8. If problem persists, replace radiator.
formulated extended life coolant. Refer to Lubrication,
page 9-1. Pressure Flushing

NOTE: Remove the radiator cap when draining the system 1. Disconnect both radiator hoses that connect the radiator
to ensure proper draining. to the engine.
2. Clamp a convenient length of hose to the radiator core
Cleaning
outlet opening, and attach another suitable length of
hose to the radiator inlet opening to carry away the flush-
ing stream.

CAUTION 3. Connect the flushing gun to compressed air and water

pressure, and clamp the gun nozzle to the hose
Burn Hazard!
attached to the radiator outlet opening.
The cooling system contains very hot pressurized liquid
and injury can result when removing the radiator cap at 4. Fill the core with water. Turn on air pressure in short
operating temperature. Use proper protection to remove blasts to prevent core damage.
the radiator cap. 5. Continue filling the radiator with water and applying air
pressure as above until the water comes out clear.

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6. Clamp the flushing gun nozzle firmly to a hose attached

securely to the engine water outlet opening. Fill the
engine block with water, partly covering the water inlet
opening to permit complete filling. CAUTION
7. Turn on compressed air to blow out water and loose sed- Burn Hazard!
iment. Continue filling with water and blowing out with air Loosen cap slowly and pause a moment to avoid possible
until flushing stream comes out clear. burning by hot water or steam. Continue to turn the cap to
8. When the vehicle is equipped with a water heater con- the left until it can be removed.
nected to the cooling system, flush the heater, following
the same procedure as for the radiator core. 4. Tubes are very small and can easily become clogged by
rust and scale. The general condition of the cooling sys-
9. After completing the flushing operation, clean out the tem and operating temperature are indications as to
surge tank overflow pipe; inspect the water pump; clean whether or not tubes are clean. Another good test is to
the thermostat and the radiator cap control valves. feel the core for cold spots.
Check the thermostat for proper operation before instal-
lation. 5. Fins are thin metal sheets that dissipate heat picked up
by the tubes. They should be kept free of bugs, leaves,
10. Blow insects and dirt from the radiator core air pas- straw etc., so as to allow the free passage of air. Bent
sages, using water, if necessary, to soften obstructions. fins should be straightened.
Component Inspection Engine Water Jacket
Radiator/Surge Tank The water jacket permits coolant to be circulated around the
cylinder walls, combustion chamber, and valve assemblies.
1. Side Tanks - Look for leaks, particularly where the tank is

8
Some of these coolant passages are small and can easily
attached to the core. Vibration and pulsation from pres-
become clogged, if the cooling system does not receive the
sure can fatigue soldered seams.
27
proper maintenance.
2. Filler Neck - The sealing seat must be smooth and
1. Core Plugs - These are sometimes mistakenly called
clean. Cams on filler neck must not be bent or worn so
freeze plugs. They do not provide protection against
as to allow a loose fitting cap. Ensure the overflow tube
2
freezing expansion, but are only present because of
is not plugged.
engine block casting methods. Remove and replace
23

3. Radiator Cap - This is the pressure-setting type. Its pur- core plugs that show signs of leaking or rusting through.
pose is to hold the cooling system under a slight pres- Use an installation tool for core plug replacement.
sure, increasing the boiling point of the cooling solution
2. Drain Plugs - The water jacket of each engine could
and preventing loss of solution due to evaporation and
have one or more drain plugs. These should receive
overflow.
seasonal care and be kept free of rust and scale.
The cap has a spring-loaded valve, the seat of which is
3. Gaskets - All gaskets must be in good condition to pre-
below the overflow pipe in the filler neck. This prevents
the escape of air or liquid while the cap is in position.
vent both internal and external leaks. If there are exter- 7
nal leaks around gaskets, there may also be internal
When the cooling system pressure reaches a
leaks into the engine. Proper tightening of the head bolts
predetermined point, the cap valve opens and will again
with a torque wrench is essential for preventing leaks
close when the pressure falls below the predetermined
around the head gasket.
point.
Water Pump
When removing the pressure type cap, perform the
operation in two steps. Loosening the cap to its first The pump should be checked carefully for leaks and proper
notch raises the valve from the gasket and releases the lubrication. Replace or rebuild if leaking, cracked, or worn.
pressure through the overflow pipe. In the first stage
position of the cap, it should be possible to depress the
Fans and Belts
cap approximately 3 mm (0.13 in). The prongs on the The fan should be checked for cracked or broken blades.
cap can be bent to adjust this condition. Care must be
taken that the cap is not too loose as this would prevent Refer to Engine Drive Belts, page 7-3.
proper sealing. Thermostat
The thermostat is of the nonadjustable type and is
incorporated in the cooling system for the purpose of
retarding or restricting the circulation of coolant during

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POWER TRAIN RT890E SERVICE MANUAL

engine warm up. Engine overheating and loss of coolant is 4. Remove the bolts and nuts holding the rear engine hood
sometimes due to an inoperative thermostat. To check for panel to the engine hood. This will gain access to the
t h i s c o n d i t i o n , r e m o v e t h e t h e r m o s ta t a n d t e s t b y rear of the radiator and the surge tank mounting hard-
submerging it in hot water and noting the temperature at ware.
which the thermostat opens and closes. Use an accurate
5. Tag and disconnect the hoses from the surge tank to the
high temperature thermometer for making this test.
engine and from the surge tank to the radiator.
Hoses and Clamps
6. Remove the four bolts, washers, lockwashers and nuts
Hoses and their connections must be checked regularly holding the surge tank to the frame.
because they are often the source of hidden trouble. Hoses
7. Remove the nuts, washers and muffler clamps securing
may often times appear in good condition on the outside
the right charge air cooler tube to the frame.Remove the
while the inside will be partially deteriorated. If there are any
baffles on the rear side of the radiator assembly.
doubts about a hose doing its job, replacement should be
made. The clamps should be inspected to make sure they 8. Remove the hose clamps and bellows connecting the
are strong enough to hold a tight connection. radiator to the charge air cooler tubes.Remove the hose
clamps and radiator hose connecting the radiator to the
Antifreeze/Coolant radiator tubes.
Heavy duty diesel engines require a balanced mixture of 9. Disconnect the coolant level harness from the engine
water and antifreeze/coolant. Fill the system with a AFC-50/ harness.
50 blended, fully formulated extended life antifreeze/coolant
10. Remove the bolts and washers attaching the fan guard
at all times. Refer to Lubrication, page 9-1. Do not use more
to the shroud ring. Remove the fan guard.
than 50 percent antifreeze/coolant in the mixture unless
additional freeze protection is required. Never use more than 11. Remove the bolts, washers and lockwashers that con-

8
68 percent antifreeze/coolant under any condition. nect the plates to the top of the radiator and the top of
Antifreeze/coolant at 68 percent provides the maximum the frame rail.
27
freeze protection; antifreeze/coolant protection decreases
NOTE: The radiator weighs approximately 114 lb
above 68 percent.
(51.7 kg).
Radiator Removal and Installation
2
12. Attach an adequate lifting device to the radiator assem-
bly.
Removal
23

13. Remove the two bolts, washers, lockwashers, nuts and

1. Set the outriggers and position the boom to over the mounting bushings securing the radiator flange to the
side. frame mounting brackets. Remove the radiator assem-
2. Open the drain cock at the bottom of the radiator and bly from the carrier.
drain the coolant into a suitable container. Dispose of the 14. Remove the six bolts, washers, lockwashers and six
coolant in accordance with local and EPA regulations. bushings securing the shroud ring to the radiator.
NOTE: Remove the radiator cap when draining the system 15. If a new radiator is to be installed, remove all fittings and
to ensure proper draining. hoses from the old one and install them in the same
3. Open and remove the hood top door assembly. locations on the new one.

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RT890E SERVICE MANUAL POWER TRAIN

10
6 14
3
25
2

4 19

20
22
11

8
9 18, 23
18, 24
8 17
6 3
27
2

6289-1
1
2
5
21
23

14
13
19
25
14 22 7

7 8

6289-2 1
9
12 15
16

FIGURE 7-10

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POWER TRAIN RT890E SERVICE MANUAL

3. Reconnect the two plates between the top of the radiator

and the top of the frame rail using bolts, washers, lock-
Item Description
washers and nuts.
1 Radiator
4. Adjust the shroud face to have equal clearance between
2 Surge Tank fan and face opening on opposite sides.
3 Radiator Cap 5. Position the fan guard on the shroud ring and secure
4 Window Gauge with bolts and washers.
5 Mounting Bracket 6. Reconnect the coolant level harness to the engine har-
ness.
6 Overflow Hose
7. Connect the two radiator tubes to the radiator with hose
7 Engine Block Vent Hose Connection
clamps and the radiator hose. Install baffles to rear side
8 Shroud of the radiator assembly.
9 Hose Clamps 8. Secure the radiator return tube to the top of the engine
10 Vent Hose using nuts, washers and a muffler clamp.

11 Coolant Fill Hose 9. Reconnect the charge air cooler tubes to the radiator
using hose clamps and bellows. The recommended
12 Radiator Out
installation torque of the spring loaded hose clamp is
13 Radiator In 100 lb-in (11.3 Nm). Do not compress spring completely,
clamp may be damaged from thermal expansion of CAC
14 Bellows
tube.
15 Radiator Hose

8
10. Secure the charge air cooler tube with nuts, washers
16 Drain Cock and muffler clamps to the right side of the frame.
27
17 Muffler Clamp 11. Tighten the drain cock at the bottom of the radiator.
18 Charge Air Cooler Tube 12. Install the hood assembly.
2
19 Plate
13. Mount the surge tank to the frame using the four bolts,
20 Radiator Coolant Level Switch washers, lockwashers and nuts.
23

21 Mounting Bushings 14. Connect the hoses between the surge tank and engine
22 Rubber Molding and the surge tank and the radiator.

23 Charge Air Cooler In 15. Fill the engine coolant system, refer to Engine Anti-
freeze/Coolant Fill Procedure (when level is low),
24 Charge Air Cooler Out page 7-17. Start the engine, operate all systems and
25 Air Bleed Valve check for leaks.

Installation 16. Install the bolts and nuts holding the rear engine hood
panel to the engine hood.
1. Ensure all fittings and hoses are installed on the radiator.
17. Install the hood top door assembly.
2. Position the radiator assembly in the carrier using a lift-
ing device. Secure the radiator flange to the frame Radiator Fill and Servicing
mounting brackets using two bolts, washers, lockwash- Refer to Lubrication, page 9-1 for complete fill and service
ers, nuts and mounting bushings. procedures.

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RT890E SERVICE MANUAL POWER TRAIN

DRIVE TRAIN Maintenance

Description Drive Lines

The drive train consists of the transmission/torque converter

assembly and three drive lines (Figure 7-11). CAUTION
The transmission/torque converter is mounted on and driven Do not disassemble drive lines when removing them from
by the engine. The torque converter assembly provides for the crane. Dirt can enter the spline and cannot be purged.
mounting and driving the piston and single section hydraulic In addition, the drive lines are assembled in a specific
pumps. The transmission is a range shift with six forward orientation when manufactured and can easily be
speeds and six reverse speeds. The transmission is incorrectly reassembled.
controlled electrically by a shift lever/knob located on the
right side of the steering column and an axle drive mode Removal
selector rocker switch located on the left side of the front
1. Support the drive line being removed so it does not fall
console.
when disconnected.
The transmission/torque converter oil is cooled by passing
2. Remove the bolts from the bearing cap on each end of
the oil through an externally mounted transmission cooler.
the drive line.
The cooler is located beside the fuel tank. An oil filter is
located on the left side of the frame bottom rail. 3. Remove the drive line.
Three drive lines are used. Two drive lines are connected Installation
between the transmission/torque converter and the front axle
an d t h e o th e r dr iv e li n e i s c o n ne c te d b e tw e en th e 1. Position the drive line, install the bearing cap bolts and
tighten bolts securely.

8
transmission/torque converter and the rear axle.
2. Torque the bearing cap bolts 110 to 121 lb-ft (149 to
27
164 Nm).
Lubrication
The drive line slip joints require lubrication. Refer to
2

Lubrication, page 9-1.

23

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POWER TRAIN RT890E SERVICE MANUAL

Transmission

Rear Slip Shaft

8
27
7058

Front Slip Shaft

2
23

Bearing
Coupling Shaft

FIGURE 7-11

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RT890E SERVICE MANUAL POWER TRAIN

TRANSMISSION/TORQUE CONVERTER reaction member is the means by which the hydraulic torque
converter multiplies torque.
Description The reaction member of the torque converter is located
The transmission/torque converter assembly is mounted to between and at the center of the inner diameters of the
the engine and is connected to the front and rear axles by impeller and turbine elements. Its function is to take the fluid
three drive shafts. The main hydraulic pump and hydraulic which is exhausting from the inner portion of the turbine and
pump number two are mounted on the torque converter. change its direction to allow correct entry for recirculation
into the impeller element.
Theory of Operation The torque converter will multiply engine torque to its
The transmission and torque converter function together and designed maximum multiplication ratio when the output shaft
operate through a common hydraulic system. Therefore, it is is at zero rpm. Therefore, as the output shaft is decreasing in
necessary to consider both units in discussing operation. speed, the torque multiplication is increasing.

With the engine running, the converter charging pump draws The shift control valve is mounted on the side of the
oil from the transmission sump through the removable oil converter housing. Its function is to direct pressurized oil to
suction screen and directs it through the pressure regulating the appropriate direction and speed clutches to achieve the
valve and oil filter. desired gear ratio. The valve consists of solenoid operated
valves which direct oil to operate the larger spool valves that
The pressure regulating valve maintains pressure to the pass or block oil flow to a specific clutch.
transmission control for actuating the direction and speed
clutches. This requires a small portion of the total volume of NOTE: On this machine, the reverse clutch is energized for
oil used in this system. The remaining volume of oil is forward motion of the crane.
directed through the torque converter circuit to the oil cooler With the engine running and the directional control lever in

8
and returns to the transmission for positive lubrication. This the neutral position, oil pressure from the regulating valve is
regulator valve consists of a hardened valve spool operating blocked at the control valve, and the transmission is in
27
in a closely fitted bore. The valve spool is spring loaded to neutral. Movement of the forward and reverse spool will
hold the valve in a closed position. When a specific pressure direct oil, under pressure, to either the forward or reverse
is achieved, the valve spool works against the spring until a direction clutch, as desired. When either directional clutch is
port is exposed along the side of the bore. This sequence of
2
selected, the opposite clutch is relieved of pressure and
events provides the proper system pressure. vents back through the direction selector spool. The same
23

After entering the converter housing, the oil is directed procedure is used in the speed selector.
through the reaction member support to the converter blade The direction or speed clutch assembly consists of a drum
cavity and exits in the passage between the turbine shaft and with internal splines and a bore to receive a hydraulically
reaction member support. The oil then flows out of the actuated piston. The piston is oil tight by the use of sealing
converter to the oil cooler. After leaving the cooler, the oil is rings. A steel disc with external splines is inserted into the
directed to a fitting on the transmission. Then, through a drum and rests against the piston. Next, a friction disc with
series of tubes and passages, lubricates the transmission splines at the inner diameter is inserted. Discs are alternated
bearings and clutches. The oil then gravity drains to the until the required total is achieved. A heavy back-up plate is 7
transmission sump. then inserted and secured with a snap ring. A hub with OD
The torque converter consists basically of three elements splines is inserted into the splines of discs with teeth on the
and their related parts to multiply engine torque. The engine inner diameter. The discs and hub are free to increase in
power is transmitted from the engine flywheel to the impeller speed or rotate in the opposite direction as long as no
element through the impeller cover. This element is the pressure is present in that specific clutch.
pump portion of the hydraulic torque converter and is the To engage the clutch, the control valve is placed in the
primary component which starts the oil flowing to the other desired position. This allows oil under pressure to flow from
components which results in torque multiplication. This the control valve, through a tube, to a chosen clutch shaft.
element can be compared to a centrifugal pump, in that it This shaft has a drilled passageway for oil under pressure to
picks up fluid at its center and discharges at its outer enter the shaft. Oil pressure sealing rings are located on the
diameter. clutch shaft. These rings direct oil under pressure to the
The torque converter turbine is mounted opposite the desired clutch. Pressure of the oil forces the piston and discs
impeller and is connected to the output shaft of the torque against the heavy back-up plate. The discs, with teeth on the
converter. This element receives fluid at its outer diameter outer diameter, clamping against discs with teeth on the
and discharges at its center. Fluid directed by the impeller inner diameter, enables the hub and clutch shaft to be locked
out into the particular design of blading in the turbine and together and allows them to drive as a unit.

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POWER TRAIN RT890E SERVICE MANUAL

There are bleed balls in the clutch piston which allow quick Troubleshooting
escape for oil when the pressure to the piston is released.
The following data is presented as an aid to locating the
Maintenance source of difficulty in a malfunctioning unit. It is necessary to
consider the torque converter charging pump, transmission,
General Information oil cooler, and connecting lines as a complete system when
checking for the source of trouble, since the proper operation
1. Always check the oil level with the engine idling, and the of any unit therein depends greatly on the condition and
transmission in neutral and at normal operating temper- operation of the others. By studying the principles of
ature 180 to 200°F (82 to 93°C). operation together with the data in this section, it may be
2. Change the oil filter element every 500 hours. Drain and possible to correct any malfunction which may occur in the
refill the system every 1000 hours or 6 months. system. Troubleshooting procedures basically consist of
hydraulic checks.

Troubleshooting Procedures

SYMPTOM PROBABLE CAUSE REMEDY

1. Low clutch pressure. a. Low oil level. a. Fill to proper level.
b. Clutch pressure regulating b. Clean valve spool and housing.
valve spool stuck open.
c. Faulty charging pump. c. Replace pump.
d. Broken or worn clutch shaft or d. Replace clutch shaft or sealing

8
piston sealing rings. rings, as applicable.
27
e. Clutch piston bleed valve stuck e. Clean bleed valves thoroughly.
open.
2. Low converter charging pump pres- a. Low oil level. a. Fill to proper level.
2
sure.
b. Suction screen plugged. b. Clean suction screen.
23

c. Defective oil pump. c. Replace pump.

3. Overheating. a. Worn oil sealing rings. a. Remove, disassemble, and
rebuild converter assembly.
b. Worn oil pump. b. Replace pump.
c. Low oil level. c. Fill to proper level.
4. Noisy converter. a. Worn oil pump. a. Replace pump.
b. Worn or damaged bearings. b. A complete disassembly will be
necessary to determine what
bearing is faulty.
5. Lack of power. a. Low engine RPM at converter a. Tune engine and check
stall. governor.
b. See “Overheating” and make b. Make corrections as explained
same checks. in “Overheating.”

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RT890E SERVICE MANUAL POWER TRAIN

Hydraulic Checks NOTE: Always make all troubleshooting checks with the
converter outlet temperature at least 180 to 200°F
Before checking the transmission/torque converter and
(82.3 to 93.3°C).
associated hydraulic system for pressures and rate of oil
flow, it is essential that the following preliminary checks be Removal
made.
1. Extend and set the outriggers just enough to take up the
1. Check oil level in transmission. This should be done with slack in the outrigger pads. Chock the wheels.
oil temperature at 180 to 200°F (82 to 93°C). Do not
attempt these checks with cold oil. 2. Position the boom over the side and stop the engine.

2. To bring the oil temperature to this level, it is necessary 3. Remove the engine and transmission/torque converter
to either work the machine or stall out the converter. from the crane as an assembly. Refer to Engine
When it is impractical to work the machine, stall out the Removal, page 7-2.
converter as follows. 4. Remove the piston and single section hydraulic pumps
a. Apply the parking brake and service brakes. from the transmission/torque converter. Cover all open-
ings. Refer to Hydraulic Pumps, page 2-13 for removal
b. Position the shift lever to forward and high speed. of the pump.
c. Accelerate the engine to between half and three- NOTE: The transmission/torque converter weighs approxi-
quarter throttle. mately 990 lb (450 kg) dry.
5. Attach an adequate lifting device to the transmission/
CAUTION torque converter and take up any slack.
Full throttle stall speeds for an excessive length of time 6. Remove the screws and hardened lockwashers secur-

8
will overheat the torque converter. 27 ing the drive plate assembly to the flywheel.
7. Remove the nuts and washers securing the transmis-
d. Hold converter stalled until desired temperature is
sion/torque converter housing to the engine flywheel
reached.
housing.
2
23

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POWER TRAIN RT890E SERVICE MANUAL

Installation sion to flywheel housing nuts and hardened flatwashers.

Tighten the nuts to 30 lb-ft (40.7 Nm).
NOTE: The transmission/torque converter assembly
weighs approximately 990 lb (450 kg) dry. 9. Remove the drive plate locating stud. Install one drive
plate attaching screw and hardened flatwasher. Snug
1. If a new transmission/torque converter is to be installed,
the screw but do not tighten. NOTE: Some engine fly-
remove all fittings and brackets from the old one and
wheel housings have a hole located on the flywheel
install them in the same locations on the new transmis-
housing circumference in line with the drive plate screw
sion/torque converter.
access hole. A screwdriver or pry bar used to hold the
2. Install the piston and single section hydraulic pumps on drive plate against the flywheel will facilitate installation
the transmission/torque converter. Refer to Hydraulic of the drive plate screws. Rotate the engine flywheel and
Pumps, page 2-13 for installation of the hydraulic pump. install the remaining seven flywheel to drive plate attach-
ing screws and hardened flatwashers. Snug the screws
3. Position the transmission/torque converter to the engine but do not tighten. After all eight screws and lockwash-
with the lifting device. ers have been installed, torque the screws to 28 lb-ft
4. Remove all burrs from the flywheel mounting face and (38 Nm). This will require torquing each screw, then
nose pilot bore. Clean the drive plate surface with sol- rotating the engine flywheel until all eight screws have
vent. been torqued.

5. Check the engine flywheel and housing for conformance 10. Measure the engine crankshaft end play after the trans-
to standard S.A.E. No. 3-S.A.E. J-927 tolerance specifi- mission/torque converter has been completely installed
cations for bore size, pilot bore runout and mounting on the engine flywheel. This value must be within
face flatness. Measure and record engine crankshaft 0.001 in (0.025 mm) of the end play recorded in step 5.
end play. 11. Install the engine and transmission/torque converter in

8
6. Install the 12 studs in the engine flywheel housing. the crane as an assembly. Refer to Power Train, page 7-
Rotate the engine flywheel to align a drive plate mount- 1.
27
ing screw hole with the flywheel housing front access 12. Service the crane as required in Servicing the Crane
hole. After Transmission/Torque Converter Overhaul, page 7-
7. Install a 4.00 in (101.6 mm) long drive plate locating stud 30.
2

0.3750-24 fine thread in a drive plate nut. 13. Cycle all functions and observe for proper operation.
23

8. Rotate the transmission/torque converter to align the

locating stud in the drive plate with the flywheel drive Towing or Pushing
plate mounting screw hole positioned in step 6. Locate Before towing the crane, disconnect both front and rear drive
the transmission on the flywheel housing, aligning the lines. The engine can not be started by pushing or towing
drive plate to the flywheel and the transmission on the because of the design of the hydraulic system.
flywheel housing mounting studs. Install the transmis-

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RT890E SERVICE MANUAL POWER TRAIN

Mount
Dial
Indicator
Here
Flywheel
Housing

Engine

Flywheel
Pilot
Bore

Flywheel

Converter
Housing

Flywheel
4 in

8
27 (10.2 cm) Stud

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

Drive
23

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

Flywheel
Housing

Impeller
Cover

(3) Intermediate
Drive Plates

FIGURE 7-12

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POWER TRAIN RT890E SERVICE MANUAL

Servicing the Crane After Transmission/ idle (1000 rpm). Add oil as necessary to bring the level to
Torque Converter Overhaul the LOW mark on the dipstick. After the oil temperature
reaches 180 to 200° F (82 to 93° C), add oil to bring the
The transmission/torque converter and its allied hydraulic level to the FULL mark on the dipstick.
system are important links in the drive line between the
7. Recheck all drain plugs, lines, connections, etc., for
engine and the wheels. The proper operation of either the
leaks and tighten where necessary.
unit or the system depends greatly on the condition and
operation of the other; therefore, whenever repair or Lubrication
overhaul of the transmission/torque converter is performed,
the balance of the system must be considered before the job Type of Oil
can be considered completed. Hydraulic Oil (HYDO) or equivalent. Refer to Lubrication,
After the overhauled or repaired transmission/torque page 9-1.
converter has been installed in the crane, the oil cooler and
Capacity
connecting hydraulic system must be thoroughly cleaned.
This can be accomplished in several ways, and a degree of System Capacity (includes torque converter, lines, and
good judgement must be exercised as to the method transmission) - Approximately 40 qt (37.9 l).
employed.
Check Period
The following are considered the minimum steps to be taken:
Check oil level every 10 hours or DAILY with engine running
1. Drain the entire system thoroughly. at 1000 rpm and oil at 180 to 200° F (83 to 94° C). Maintain
2. Disconnect and clean all hydraulic lines. Where feasible, oil level to FULL mark.
hydraulic lines should be removed from the machine for Normal Drain Period

8
cleaning.
NOTE: Normal drain periods and filter change intervals are
3. Replace oil filter elements, cleaning out the filter cases for average environmental and duty-cycle condi-
27
thoroughly. tions. Severe or sustained high operating tempera-
4. The oil cooler must be thoroughly cleaned. The cooler tures or very dusty atmospheric conditions will
should be back flushed with oil and compressed air until cause accelerated deterioration and contamina-
2

all foreign material has been removed. Flushing in the tion. For extreme conditions, judgment must be
direction of normal oil flow will not adequately clean the used to determine the required change intervals.
23

cooler. If necessary, the cooler assembly should be Every 500 hours, change oil filter element. Every 1000 hours
removed for cleaning, using oil, compressed air and a or 6 months, drain and refill system as follows: Drain with oil
steam cleaner for that purpose. at 150 to 200° F) (66 to 93° C).
NOTE: It is recommended that filter elements be changed
CAUTION after 50 and 100 hours of operation on new and
Do not use flushing compounds for cleaning purposes. rebuilt or repaired units, then at normal intervals
thereafter.
5. Remove the drain plug from the transmission/torque a. Drain transmission and remove pump screen. Clean
converter and inspect the interior of the unit housing, screen thoroughly and replace, using a new gasket.
gears, etc. If the presence of considerable foreign mate-
rial is noted, it will be necessary for the unit to be b. Remove and discard oil filters. Clean filter housing
removed, disassembled, and cleaned thoroughly. It is and install new filters.
realized this entails extra labor, however, such labor is a c. Refill transmission to LOW mark.
minor cost compared to the cost of difficulties which can
result from the presence of such foreign material in the d. Run engine at 1000 rpm to prime converter and
system. lines.

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

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RT890E SERVICE MANUAL POWER TRAIN

OPTIONAL EQUIPMENT Engine Block Heater

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

8
2 27
23

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THIS PAGE BLANK

8
2 27
23

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RT890E SERVICE MANUAL UNDERCARRIAGE

SECTION 8
UNDERCARRIAGE

SECTION CONTENTS
Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 Service Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16
Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 Corrosion Protection . . . . . . . . . . . . . . . . . . . . . . 8-20
Typical Wear Patterns. . . . . . . . . . . . . . . . . . . . . . 8-5 Parking Brake Actuator. . . . . . . . . . . . . . . . . . . . . 8-22
Steering Systems . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . 8-7 Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
Rear Steering System. . . . . . . . . . . . . . . . . . . . . . . 8-9 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9 Park Brake Solenoid Valve . . . . . . . . . . . . . . . . . . 8-26
Hydraulic Pumps. . . . . . . . . . . . . . . . . . . . . . . . . 8-10 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-26
Front Steering Control Valve. . . . . . . . . . . . . . . . 8-10 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-26
Rear Steer/ Axle Lockout/Fan Drive Valve . . . . . 8-10 Outriggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27

8
Steer Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11 Outrigger Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . 8-27
Rear Axle Oscillation Lockout System . . . . . . . . 8-11 Outrigger Beam . . . . . . . . . . . . . . . . . . . . . . . . . . 8-31
27
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11 Extension Cylinder. . . . . . . . . . . . . . . . . . . . . . . . 8-35
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . 8-11 Outrigger Monitoring System (Optional—
Axle Oscillation Lockout Cylinders . . . . . . . . . . . 8-13 Standard in North America) . . . . . . . . . . . . . . . 8-36
2

Axle Oscillation Lockout Valve . . . . . . . . . . . . . . 8-13 Jack Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-36

Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14 Outrigger Control Valves . . . . . . . . . . . . . . . . . . . 8-38
23

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14 Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . 8-38

Theory of Operation . . . . . . . . . . . . . . . . . . . . . . 8-14 Pintle Hook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-38
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15 Secondary Front Steer (CE Option). . . . . . . . . . . 8-38

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

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UNDERCARRIAGE RT890E SERVICE MANUAL

reduction, through the revolving planet gears, and into the 12. If a new axle is to be installed, remove the following from
planetary spider which drives the wheel hub. the old axle and install them on the new one.
As an option, the front axle and rear axle may be provided a. The steer cylinders.
with a differential lock. When in the locked mode, the axle
b. The rear wheels not centered switch actuator
shafts and the differential are locked together and there is no
bracket (rear axle only).
differential action between the wheels.
c. The parking brake actuator (front axle only). Refer
Maintenance to Brake System, page 8-14.
NOTE: The axles do not have to be removed from the Cleaning
crane to remove the planetary wheel ends or the
drive units. Completely assembled axles may be steam cleaned on the
outside only, to facilitate initial removal and disassembly,
Removal providing all openings are closed. Breathers, vented shift
units, and all other openings should be tightly covered or
1. Using the outriggers, raise the wheels off the ground.
closed to prevent the possibility of water entering the
2. Install blocking under the frame at the outboard ends of assembly.
the four outrigger boxes.
Installation
1. If a new axle is to be installed, remove the following from
CAUTION the old axle and install them on the new one.
Do not disassemble drive lines when removing them from
the crane. Dirt can enter the spline and cannot be purged. a. The steer cylinders.
In addition, the drive lines are assembled in a specific

8
b. The rear wheels not centered switch actuator
orientation when manufactured and can easily be bracket (rear axle only).
incorrectly reassembled.
27
c. The parking brake actuator (front axle only). Refer
3. Disconnect and remove the drive line from the applica- to Brake System, page 8-14.
ble axle. Do not disassemble the drive lines. Refer to 2. Position the axle under the crane on jacks which are
2

Drive Lines, page 7-23. capable of handling the weight of the axle.
23

4. Tag, disconnect, and cap the hydraulic brake line at 3. Raise the axle into place and secure with the eight
each wheel. attaching bolts, washers and nuts. The front axle has
5. Tag, disconnect, and cap the hydraulic lines to the steer washers and nuts and the rear axle has tapped holes in
cylinders. the fifth wheel. Torque bolts; refer to Fasteners and
Torque Values, page 1-14 for proper torque value.
6. On the front axle only, tag and disconnect the hydraulic
line from the park brake actuator. 4. Install the wheels onto the axle. Refer to Mounting
Wheel Assemblies, page 8-4.
7. On the left side of the rear axle only, tag and disconnect
the electrical wires from the rear wheels not centered 5. Connect the hydraulic lines to the steer cylinder as
switch. tagged during removal.

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

8. Remove the wheels from the axle. 7. On the front axle only, connect the hydraulic line to the
parking brake actuator.
NOTE: Each axle weighs approximately 3825 lb (1735 kg)
with oil. 8. On the left side of the rear axle only, connect the electri-
cal wires to the rear wheels not centered switch. Adjust
9. Position jacks, which are capable of handling the weight the switch in accordance with Rear Wheels Not Cen-
of the axle, under the axle for support. tered Switch Adjustment Procedure, page 8-3.
10. Remove the eight nuts, washers, and bolts securing the 9. Connect the drive line to the applicable axle. Refer to
axle to the frame/cradle. Drive Lines, page 7-23.
11. Lower the axle to the ground and move it to a clean 10. Refer to Bleeding the Brake System, page 8-15 in this
working area. section and bleed the hydraulic brake system.

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RT890E SERVICE MANUAL UNDERCARRIAGE

11. Remove the blocking under the outrigger beams and Rear Wheels Not Centered Switch Adjustment
retract the outriggers to lower the wheels to the ground. Procedure
Wheel Alignment Check Procedure 1. Ensure the wheels are straight ahead.

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

Mounting Bracket

8
27
Sensor Plate
2
23

8
Sensor Switch
6393-1

FIGURE 8-1

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UNDERCARRIAGE RT890E SERVICE MANUAL

Wheels and Tires

Wheel End Horizontal Oil Fill Level and Drain Plug
Description
24 1 5
The standard tire size for this unit is 29.5 x 25-34 ply. 20 9
16 13
17
12
CAUTION
Do not mix tires and rims of different manufacturers. 21
8
Vehicle stability can be affected.
4 3
Each wheel assembly (tire and rim) is mounted on the
planetary hub with 24 grade 8 lug nuts. 22 7

NOTE: The tire diameters, widths, and weights may vary 18 11

slightly depending on the tire manufacturer.
14 15
Off-highway tires are designed to operate with a certain 10 19
sidewall deflection or bulge. Correct air pressure ensures 6 2 23
FIGURE 8-2
prior deflection which, in turn, ensures proper traction,
flotation, support of load, and prevents excessive flexing of Mounting Wheel Assemblies
the tire. Over inflation increases rim stresses, which results
in lowered rim life. NOTE: Do not lubricate the wheel studs or lug nuts.

Refer to and adhere to the inflation pressures in the Load

1. Position the wheel assembly on the mounting studs.

8
Chart Book in the crane cab.
Install the lug nuts and tighten them to 50 lb-ft (70 Nm) in
27 the sequence shown in (Figure 8-2).
Maintenance
2. Ensure the wheel assembly is positioned properly on the
hub.
2
3. Torque the lug nuts 340 to 360 lb-ft (461 to 488 Nm) in
DANGER
the sequence shown in Figure 8-2.
23

Do not attempt to demount or mount tires without proper

training. The high pressures involved can cause tire and 4. Retorque lug nuts after approximately one hour of travel.
rim parts and tools to fly with explosive force, if proper
procedures are not used, causing severe injury or death
to personnel and damage to the crane and surrounding
area.

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RT890E SERVICE MANUAL UNDERCARRIAGE

Typical Wear Patterns

Incorrect Tire Pressure
Too high air pressure Figure 8-3, View 1) gives rapid wear in
the middle of the tire. Too low air pressure (Figure 8-3, View
2) gives rapid shoulder wear.

FIGURE 8-5

Item Description
1 Incorrect Toe-In

8
2 Incorrect Toe-Out
27
3 Out-of-line Axles
FIGURE 8-3 4 Steering Arm Defect

Incorrect Camber
2
Incorrect Caster and Wheel Imbalance
Incorrect camber gives abnormal wear on one half of the tire.
Incorrect caster or wheel imbalance shows as spot wear that
23

is either in the middle of the tire or extends to the shoulder.

This rapidly wears the mechanical parts of steering linkage,
kingpin and wheel bearing.

FIGURE 8-4

Incorrect Toe and Axle Alignment

Incorrect toe has a “scrubbing” effect on the front wheels that
shows in rapid shoulder wear or across the tire.
FIGURE 8-6
Incorrect axle alignment has a “scrubbing” effect on all
wheels.

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UNDERCARRIAGE RT890E SERVICE MANUAL

Cuts in the Tire Tread Feathered Edges

Cuts are due to poor roads, air pressure too high or incorrect Normal occurrence on non-driving wheels on good roads
tire type for the application. and high mileage.

FIGURE 8-7

Item Description
1 Cuts
2 Flaking Cuts

8
3 Rubber Flaking
FIGURE 8-9
27
Spot Wear
Sudden braking, locking brakes or out-of-round brake drums Cupping
give spot wear. Cupping is a normal occurrence that depends on the tread
2
pattern - the higher the load, the greater the wear.
23

FIGURE 8-10

FIGURE 8-8

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RT890E SERVICE MANUAL UNDERCARRIAGE

STEERING SYSTEMS Theory of Operation

Description Front Steering System

To maximize maneuverability, the crane can be steered by A hydraulic oil flow from pump number 2 flows through port 5
the front axle, the rear axle, or by the front and rear axles of the hydraulic swivel to the steer/swing directional control
simultaneously. The crane utilizes two separate steering valve. Regulated flow from the steer priority flow divider
systems, one to control front axle steering and one for rear valve is routed to the steering control valve upon turning of
axle steering. the steering wheel and pressurizing of the load sense line.
The steering control valve routes the oil to the appropriate
Front Steering System ends of the front steer cylinders to turn the wheels in the
desired direction.
The front steering system consists of a hydraulic pump, load
sense steer priority flow divider valve (part of the swing Rear Steering System
directional control valve), load sense steering control valve,
and two steer cylinders. The hydraulic pump is driven by the Hydraulic flow from pump number 1 is directed through the
engine and supplies a hydraulic flow of 38.9 gpm (147 l/min) integrated outrigger valve to the rear steer/fan drive valve.
to the load sense steering priority flow divider. The load When the Rear Steer Control Switch in the cab is positioned
sense steer priority flow divider valve provides 12 gpm (45 l/ to left (L) or right (R), a signal is sent to the rear steer
min) to the load sense steering control valve and the solenoid, shifting the control valve spool, routing the supply
remainder to the swing system. When the steering wheel is pressure to the appropriate ends of the rear steer cylinders
turned, the load sense steering control valve sends a load to turn the wheels in the desired direction.
sense signal to the load sense steer priority flow divider. As
Secondary Steering System (CE Units)
the load sense pressure increases, the priority flow divider
spool shifts to direct oil from the hydraulic pump to the When the engine is running, the load sense steering priority

8
steering control valve, and to direct oil from the L port and R flow divider valve maintains a constant 125 psi (862 kPa)
27
port of the steering control valve to the steer cylinders. standby pressure in the steering load sense line. When a
minimum 125 psi (862 kPa) load sense pressure is
Rear Steering System maintained in the pilot circuit, the pilot operated, 2 position,
The rear steering system is controlled through a section of 3-way valve ports are aligned to charge the secondary
2

the integrated outrigger/rear steer valve and consists of the steering hydraulic accumulator. The hydraulic accumulator is
control valve and two steer cylinders. A rear steer indicator charged from the switch (SW) port on the service brake dual
23

system is provided to indicate when the rear wheels are not accumulator charge valve when the engine is running, A
centered. This system consists of an indicator light located check valve is installed in the pressure line to prevent back
on the front console in the cab and a switch located on the flow from the secondary steering hydraulic accumulator to
right side of the rear axle. When the rear wheels are turned the service brake dual accumulator charge valve and the
to the left or right, the amber indicator light will illuminate. service brake pressure switch.
Secondary Steering System (CE Units) When flow from the steer pump stops for any reason, the
load sense pressure will drop to zero. When the load sense
The secondary steering system is provided to back up the pressure drops below 125 psi (862 kPa), the pilot ports so
normal front steering system if loss of hydraulic flow occurs. hydraulic fluid stored in the secondary steering hydraulic
The system consists of an hydraulic accumulator, two check accumulator will flow to the load sense steering control
valves, a pressure switch, and a pilot operated, 2 position 3- valve. The secondary steering hydraulic accumulator charge
way valve used in conjunction with the service brake dual will allow the operator to safely steer the crane to a safe stop.
accumulator charge valve and the load sense steering
control valve.
When the load sense pressure drops below 100 psi
(689 kPa), the secondary steer pressure switch will close its
8
contacts and energize the red Engine Distress Indicator and
sound the warning buzzer.

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UNDERCARRIAGE RT890E SERVICE MANUAL

Maintenance
Front Steering System
Troubleshooting

Symptom Probable Cause Solution

1. Hard to steer left and right. a. Hydraulic oil low. a. Refill hydraulic reservoir.
b. Clogged or loose hydraulic b. Clean or tighten lines or
lines or fittings. fittings.
c. Defective flow divider c. Repair or replace valve(s).
valve(s).
d. Defective steering control d. Repair or replace valve.
valve.
e. Defective hydraulic pump. e. Repair or replace pump.
2. Hard to steer either left or right. a. Clogged or loose hydraulic a. Clean or tighten lines or
lines or fittings. fittings.
b. Defective steer cylinder. b. Repair or replace cylinder.
3. Steering is erratic left and right. a. Hydraulic oil low. a. Refill hydraulic reservoir.

8
b. Clogged or loose hydraulic b. Clean or tighten lines or
lines or fittings. fittings.
27
c. Defective steering control c. Repair or replace valve.
valve.
d. Defective hydraulic pump. d. Repair or replace pump.
2

4. Noisy hydraulic pump caused by a. Hydraulic oil low. a. Refill hydraulic reservoir.
cavitation.
23

b. Suction line plugged or too b. Clean line and check for size.
small.
5. Hydraulic pump shaft seal a. Worn shaft seal. a. Replace shaft seal.
leakage.
NOTE: If replacing the shaft seal
does not stop leakage, the
pump should be disassem-
bled and checked for the fol-
lowing:
b. Broken diaphragm seal or b. Replace seal or gasket.
backup gasket.
c. Bearing out of position. c. Replace bearing.
d. Excessive internal wear. d. Replace pump.

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RT890E SERVICE MANUAL UNDERCARRIAGE

Functional Check 3. Ensure the system has adequate power. If there is an

indication of hard steering, this can be caused by either
A normal periodic functional check of the entire steering
a reduced oil flow to the control valve or a reduced sys-
system will generally be adequate to ensure satisfactory
tem relief pressure. Adequate oil flow under all condi-
service.
tions can best be checked by timing the full travel of the
1. Check all fittings for leakage. An accumulation of moist, cylinder with the steered axle unloaded and loaded. If
black dirt is a good indication of leakage. there is a great difference at low engine speed and slight
difference at high engine speeds this may indicate a
2. With the engine running at idle and at full throttle, and defective pump. Adequate oil pressure can only be
with the machine standing still and moving, turn the determined by connecting a pressure gauge [3500 psi
steering wheel through the full range of travel. Note any (24 MPa) full scale recommended) at the swing/steer/
speed irregularities and sticky sensation. This may indi- pressure gauge test port (GP2). With the engine running
cate dirt in the fluid. If the steering wheel continues to at a medium speed, turn the steering wheel to one end
rotate when started and released, a condition known as of the travel and hold the cylinders at the travel limit
Motoring exists. This may also indicate dirty fluid in the briefly, just long enough to read the pressure gauge.
system. Never hold the system at relief pressure for more than a
few seconds at a time. The pressure gauge should indi-
cate 2600 psi (17.9 MPa).

REAR STEERING SYSTEM

Troubleshooting

8
Symptom Probable Cause Solution
27
1. Rear steering inoperative. a. Hydraulic oil low. a. Refill hydraulic reservoir.
b. Clogged, broken, or loose b. Clean, tighten, or replace
hydraulic lines or fittings. lines or fittings.
2

c. Steer cylinder locked. c. Repair or replace cylinders.

23

d. Defective control valve. d. Repair or replace valve.

e. Defective steer cylinder(s). e. Repair or replace cylinder(s).
f. Lack of electrical signal f. Check electrical connections/
wiring
2. Hard to steer left and right. a. Hydraulic oil low. a. Refill hydraulic reservoir.
b. Clogged or loose hydraulic b. Clean or tighten lines or
lines or fittings. fittings.
c. Defective steering control c. Repair or replace valve.
valve.
d. Defective hydraulic pump. d. Repair or replace pump.
e. Clogged or loose hydraulic
lines or fittings.
e. Clean or tighten lines or
fittings.
8
f. Defective steer cylinder. f. Repair or replace cylinder.
g. Damaged relief. g. Replace relief valve.
3. Steering is erratic left and right. a. Hydraulic oil low. a. Refill hydraulic reservoir.
b. Clogged or loose hydraulic b. Clean or tighten lines or
lines or fittings. fittings.
c. Defective steering control c. Repair or replace valve.
valve.
d. Defective hydraulic pump. d. Repair or replace pump.

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UNDERCARRIAGE RT890E SERVICE MANUAL

Hydraulic Pumps Rear Steer/ Axle Lockout/Fan Drive Valve

Description Description
Front Steer The rear steer valve/axle lockout/fan drive directionally
controls the outrigger circuit, outrigger pin circuit, and the
The hydraulic pump is mounted off of drive pads of the
rear steer circuit. The valve is mounted on the front face of
torque converter and driven by the engine. Pump number 2
the carrier frame member forward of the swivel.
provides the hydraulic flow necessary to power the front
steer cylinders and the swing drive system. The pump is a The valve is made up of five sections. The inlet section
gear type pump that provides a flow of approximately contains a solenoid valve and a 2000 psi (13.8 MPa) relief
38.9 gpm (147 l/min). valve. The relief valve is the main relief for both systems. The
solenoid valve is normally open, bypassing oil to the
Rear Steer reservoir. Operation of either system energizes the solenoid
The hydraulic pump is mounted to the torque converter and valve to close it and route oil to the applicable circuit.
is driven by the engine. Pump number 1 provides the The second section is the rear steer section and contains a
hydraulic flow necessary to power all crane function except three position four-way solenoid valve. The solenoid valve is
front steer and swing. The pump is a piston type pump that controlled by the rear steer switch in the operator cab. A bolt
provides a flow of approximately 98.7 gpm (373 l/min). on manifold that contains work port double pilot operated
check valves.
Front Steering Control Valve
The third section is the removal pin section for the front
Description outrigger box and contains a three position four-way
The steering control valve is located under the dash and is solenoid valve. The solenoid valve is controlled by the pin

8
actuated by a conventional steering wheel and steering unlock switch in the outrigger control box in front of the left
column, providing precise, full hydraulic steering. Precise front fender.
27
steering is accomplished by a metering system within the The fourth section is the removal pin section for the rear
valve that is directly connected to the steering column and outrigger box and contains a three position four way solenoid
wheel. valve. The solenoid valve is controlled by the pin unlock
2
switch in the outrigger control box behind the right rear
Maintenance
fender.
23

Removal The fifth section is the outrigger section and contains two
1. Thoroughly clean the steering control valve and the sur- bolt-on three position four-way solenoid valves, a bolt on
rounding area before removing the hydraulic hoses from manifold that contains work port double pilot operated check
the valve. valves with integral 300 psi (2.1 MPa) rod side and 3000 psi
(20 MPa) piston side thermal relief valves. The solenoid
2. Tag and disconnect the five hydraulic hoses from the valve is controlled by the extend/retract switch in the
steering control valve. Cap or plug each hose and the operator cab.
five ports of the valve.
The second and fifth sections both contain a double pilot
3. Remove the four bolts, lockwashers, and flat washers operated check valve.
securing the valve to the bracket and the steering col-
umn. Remove the control valve, leaving the steering col- Maintenance
umn in the cab.
Removal
Installation
1. Tag and disconnect the electrical connectors to the rear
1. Position the control valve to the bracket and steering col- steer/axle lockout/fan drive valve.
umn and install the four flat washers, lockwashers, and
bolts. Torque bolts; refer to Fasteners and Torque Val- 2. Tag and disconnect the hydraulic lines to the rear steer/
ues, page 1-14 for proper torque value. axle lockout/fan drive valve. Cap or plug the lines and
ports.
2. Connect the five hydraulic hoses to the control valve as
tagged during removal. 3. Remove the four bolts and nuts securing the rear steer/
axle lockout/fan drive valve to the crane. Remove the
3. Start the engine and check for proper operation and any valve as a complete assembly.
leakage.

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RT890E SERVICE MANUAL UNDERCARRIAGE

Installation 3. Connect the hydraulic lines to the cylinder as tagged

during removal.
1. Position the rear steer/axle lockout/fan drive valve on its
mount. Secure the valve with the four nuts and bolts. 4. Operate the steering system and check the cylinder for
proper operation and any leakage.
2. Connect the hydraulic lines to the rear steer axle lock-
out/fan drive valve as tagged during removal.
REAR AXLE OSCILLATION LOCKOUT
3. Connect the electrical connectors to the rear steer/axle SYSTEM
lockout/fan drive valve as tagged during removal.
Functional Check Description
1. Cycle each outrigger cylinder several times. Verify each The rear axle oscillation system consists of two lockout
cylinder extends and retracts properly. cylinders, a lockout valve, an axle oscillation relay, and an
area definition potentiometer (see Figure 8-11 and 8-12).
2. Rear steer the crane to the left and to the right several The lockout cylinders are mounted between a cradle (fifth
times. Verify the crane steers properly in both directions. wheel) and the carrier frame. The lockout valve is mounted
3. Check the valve and lines for leakage. Make repairs as on the left inner center frame rail and hydraulically controls
needed. the oscillating abilities of the lockout cylinders. The axle
oscillation relay is located on the relay panel under the front
NOTE: For further information on the rear steer/axle lock- console cover in the cab and the area definition
out/fan drive valve, refer to Axle Lockout, Rear potentiometer is located in the electrical swivel assembly.
Steer and Oil Cooler Fan Motor Control Manifold,
page 2-63. Theory of Operation
Steer Cylinders

8
The rear axle is mounted on a cradle (fifth wheel) allowing
maximum oscillation of 10 in (25 cm) total while traveling
27
Description over uneven terrain. Oscillation is provided only when the
superstructure is within 6 degrees left or right of directly over
The steer cylinders are mounted on the axles, two cylinders
the front. When the superstructure is within 6 degrees left or
on each axle. The barrel end of each cylinder is attached to
right of directly over the front, the area definition
the axle housing and the rod end is attached to the steering
2

potentiometer energizes the axle oscillation relay which in

lug on the axle end. The cylinders are controlled
turn energizes the solenoids on the lockout valve. When the
23

hydraulically by the steering control valve.

solenoids are energized, the valve spools are shifted to allow
Maintenance hydraulic transfer between the two lockout cylinders. As one
side of the axle is forced up by traveling over uneven terrain,
NOTE: For Disassembly and Assembly procedures, refer the hydraulic oil flows from the rod end of cylinder A to the
to Steer Cylinders, page 8-11. barrel end of cylinder B and from the rod end of cylinder B to
Removal the barrel end of cylinder A. The system is not pressurized
and oil is moved from one cylinder to the other by the action
1. Tag and disconnect the hydraulic lines going into the of the axle moving the cylinder.
steer cylinder. Cap or plug all openings.
When the superstructure is more than 6 degrees left or right
2. Remove the bolt, washer, and lockwasher securing each of directly over the front, the area definition potentiometer
pin weld in the rod end and barrel end of the cylinder. deenergizes the axle oscillation relay. This deenergizes the
NOTE: Steer cylinder weighs approximately 44 lb (20 kg). solenoids on the lockout valve and allows the springs in the

3. Remove both pin welds and two thrust washers (rod end
valve to shift the valve spools to the closed position to
prevent hydraulic oil flow between the cylinders. By stopping
8
only), and remove the cylinder from the axle. the flow of oil, a hydraulic lock is created and the axle is held
rigid in that position.
Installation
1. Position the cylinder onto the attachment fittings on the
axle and install both pin welds. On the rod end, install a
thrust washer on the top and bottom of lug.
2. Secure each pin weld with the bolt, washer, and lock-
washer.

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UNDERCARRIAGE RT890E SERVICE MANUAL

Oscillation
Carrier Frame Lockout Cylinder

A B

Pivot Point

Fifth Wheel Pivot Point

FIGURE 8-11

8
27
Axle Lockout
Valve
2
23

Axle Lockout Cylinders

B A

Supply from Pump

FIGURE 8-12

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RT890E SERVICE MANUAL UNDERCARRIAGE

Axle Oscillation Lockout Cylinders 7. Lubricate both ends of the cylinder using the fittings pro-
vided.
Description
8. Function test the axle oscillation system in accordance
Two 5.0 in (12.7 cm) hydraulic lockout cylinders are installed with the Operator and Safety Handbook to ensure
on the rear axle, one left side and one right side. The barrel proper operation.
end of each cylinder is attached to each side of the carrier
frame and the rod ends are attached to each side of the Axle Oscillation Lockout Valve
cradle (fifth wheel). The lockout cylinders are connected
hydraulically so that hydraulic oil flows from the rod side of Description
the left cylinder to the barrel side of the right cylinder and The axle oscillation lockout valve, also called the double
from the rod side of the right cylinder to the barrel side of the solenoid valve, is used in the rear axle oscillation lockout
left cylinder. circuit. The valve consists of a valve body and two solenoid
Each cylinder weighs approximately 88 lb (40 kg). valves, which keep the lockout cylinders from oscillating
unless the superstructure is within 6 degrees left or right of
Maintenance directly over the front. The lockout valve is located on the left
side of the frame in front of the front rear axle cross member.
NOTE: For disassembly and assembly procedures, refer
to Axle Oscillation Lockout Cylinder, page 2-83. When the superstructure is within 6 degrees left or right of
directly over the front, the area definition potentiometer
Removal
energizes the axle oscillation relay which energizes the
1. Raise the crane up on outriggers. solenoids on the axle oscillation lockout valve. This allows
hydraulic oil to flow in and out of the lockout cylinders,
2. Rotate the turntable more than 6 degrees in either direc-
allowing the axle to oscillate.
tion from directly over the front to lock out the oscillation

8
cylinders. When the superstructure is more than 6 degrees left or right
of directly over the front, the area definition potentiometer
27
3. Remove the wheel and tire assembly from the axle.
deenergizes the axle oscillation relay which deenergizes the
4. Tag and disconnect both hydraulic hoses from the ports solenoids on the axle oscillation lockout valve. This keeps
on the cylinder. Cap or plug both hoses and the ports on the axle from oscillating because hydraulic oil cannot leave
2
the cylinder. the cylinders.
23

5. At the rod end of the cylinder, remove one of the cotter Maintenance
pins securing the retaining pin to the cradle attach fitting.
Removal
6. Tap out the retaining pin, freeing the rod end from the
cradle. 1. Tag and disconnect the electrical connector to the valve.

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

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

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UNDERCARRIAGE RT890E SERVICE MANUAL

BRAKE SYSTEM created by the lever action of the brake pedal to the hydraulic
brake valve which modulates the brake line pressure to the
Description brake assemblies at each wheel.

The brake system includes all the components necessary for Hydraulic oil from Pump No. 1 flows to swivel port 7 to the
the application of the service brakes and the parking brake. dual accumulator charge valve. The dual accumulator
charge valve charges the accumulators from the open center
Service Brakes circuit upon demand and within its present operating charge
rate and the high limit pressure setting. However, when the
The service brakes are full power hydraulic disc brakes
open center circuit pressure reaches the brake relief setting,
which are hydraulically controlled and are used to apply the
which is higher than the high accumulator charge limit, then
brake assemblies on all four wheels. The system consists of
the accumulators will be charged to the regulated maximum
the tandem brake valve with treadle pedal, the dual
pressure setting. The dual accumulator charge valve
accumulator charge valve, two hydraulic accumulators, the
regulates flow to the hydraulic accumulators to provide fully
brake assemblies, and all the associated hoses and tubing.
powered independently separate, primary (front) and
The operator depresses the pedal on the tandem brake
secondary (rear), service brake circuits. Hydraulic pressure
valve, located on the cab floor, and the valve modulates the
is constantly maintained in the brake circuits by the
brake line pressure to the brake assemblies at each wheel.
accumulators and the charging valve. The charged
The full powered brake system supplies a high brake system
accumulators supply pressurized fluid to the closed tandem
pressure with relatively low reactive pedal forces, while
brake valve.
controlling the maximum brake line pressure. The service
brake dual accumulator charge valve regulates flow to the Once the operator depresses the brake pedal, the tandem
hydraulic accumulators to provide fully powered brake valve modulates fluid out to the brakes to provide the
independently separate, primary (front) and secondary means of braking. The tandem brake valve will modulate the
(rear), service brake circuits. Hydraulic pressure is

8
pressure in the brake system by increasing or decreasing
c o n s ta n t l y m a i n ta i n e d i n t h e b r a k e c i r c u i ts b y t h e pressure as required in proportion to the input force from the
27
accumulators and the charging valve. operator via the brake pedal. The hydraulic force acts within
the brake assemblies to force the brake pads against the
Parking Brake brake discs, acting to slow wheel rotation. Fully powered
The parking brake is a hydraulic release, spring apply, disc- separate primary (front) and secondary (rear) braking circuits
2

type brake, located on the front axle. The system consists of are provided with independent accumulators. A low pressure
a two-position switch, a three-way solenoid valve, actuator, warning switch is used to sense the accumulator pressures
23

two brake assemblies, and all the associated hardware and and warn the operator through visual brake warning indicator
tubing. The selector switch, located on the front console in light on the cab console in the event the pressure in the
the cab, is used to activate the solenoid valve which controls accumulators drops to an unsafe operating level. In the
the park brake actuator, which applies and releases the park event of engine failure, the accumulators are pre-charged
brake. There are two brake actuators on the front axle. with dry nitrogen gas and properly sized to provide power-off
stopping capacity for secondary braking.
NOTE: For Description and Maintenance of the tandem
brake valve with treadle pedal, the accumulators, Parking Brake
and the dual accumulator charge valve, refer to
Hydraulic flow from the transmission charge pump is routed
Hydraulic System, page 2-1.
to the parking brake control valve. When the Park Brake
Theory of Operation Switch is in the ON position, the parking brake solenoid valve
shifts to route flow from the hydraulic parking brake actuator
Service Brakes back to the transmission sump. The actuator spring pulls on
the lever on the brake assembly, applying the parking brake.
Braking begins when the operator depresses the brake
pedal in the cab. Mechanical linkage transfers the force

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RT890E SERVICE MANUAL UNDERCARRIAGE

Maintenance
Troubleshooting

Symptom Probable Cause Solution

1. Brakes are poor. a. Lining thickness less than a. Replace lining.
0.125 in (3mm).
b. Brake pedal operation. b. Free mechanical linkage.
c. Restriction or leaks in lines. c. Check all lines for leaks and
restrictions.
d. Low hydraulic oil flow. d. Check the hydraulic oil level in
reservoir and check flow from
the tandem brake valve.
e. Air in brake lines. e. Bleed the brakes.
f. Brake pads/linings are f. Replace pads/linings.
grease-soaked.
g. Engine not running. g. Start engine. Due to the
operation, the engine must be
running to provide full brake
power.

8
h. Brake relief valve stuck open. h. Replace the relief valve.
27
i. Dual accumulator charge i. Check valve operation and
valve not charging repair or replace valve.
j. Accumulators not pre- j. Check accumulator pre-
2
charged. charge.
2. Hard brake pedal with engine run- a. Pedal travel being interfered a. Check all pedal linkage and
23

ning. with. ensure it is free and adjusted

properly.
3. Brakes lock up. a. Too much hydraulic flow. a. Check the flow from the flow
divider. Too much flow will
cause the brakes to be
applied by the oil trapped in
the power boost chamber.
b. Brake pedal push rod b. Adjust the push rod linkage so
improperly adjusted, causing the brake pedal and push rod
brakes to be always applied. fully return.
4. Uneven braking or pad wear. a. Lining thickness less than a. Replace the lining.
0.125 in (3 mm). 8
b. Grease on the pads/linings. b. Replace the pads/linings.

General Bleeding the Brake System

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

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UNDERCARRIAGE RT890E SERVICE MANUAL

actuator on every wheel. When you complete a bleeder SERVICE BRAKES

screw, go to the next closest bleeder screw on the same
caliper/actuator. When you complete a wheel, go to the Description
furthest bleeder screw on the next closest wheel.
The brakes utilized on the axles are hydraulic disc-type
Pressure Bleeding the Brake System. brakes. Two brake assemblies are used at each wheel end
NOTE: Before bleeding the brake system, ensure the on the front axle. One brake assembly is used at the wheel
hydraulic accumulators are fully charged. end on the rear axle. The action of the brake pads riding
against the brake discs acts to slow the rotation of the
1. Install the bleeding adapter. wheels.
2. Using a clean bleeding tank, fill the tank at least half full
with hydraulic oil. Position the tank so it will not have to
Maintenance
be moved again until all bleeding is finished. NOTE: To perform maintenance on the brake caliper,
3. Connect a 35 psi (241 kPa) air source to the bleeder remove the tire and wheel assembly. Refer to
tank. Wheels and Tires, page 8-4.

4. Open the bleeder tank valve and bleed all air out of the Removal
hose to be connected to the adapter. Connect the Linings
bleeder hose to the adapter and open the bleeder valve.
1. Remove the bolts securing the end plates to one side of
5. Connect the end of the bleeder hose to the bleeder the caliper housing. Remove the end plates.
screw on the caliper/actuator. Submerge the other end
in a glass jar partially filled with the proper type of clean 2. Loosen the bleeder screws to release hydraulic pres-
hydraulic oil. sure in the caliper.

8
6. Open the bleeder screw and allow fluid to flow into the
27
jar until it is a solid stream free of air bubbles. Close the
bleeder screw and torque to 100 to 120 lb-in (11.3 to Wood
13.6 Nm). Loosen Block
Bleeder
2
7. Repeat steps 5 and 6 for the remaining wheel calipers/
Screws
actuators.
23

8. Remove the air supply from the bleeder tank.

NOTE: Close the bleeder tank valve and disconnect the
hose and the bleeder adapter.
9. Remove the bleeder tank and hose.
Push Wood
10. Remove the bleeder adapter. Block Against
Linings to Push
Manually Bleeding the Brake System Pistons Into
NOTE: Before bleeding the brake system, ensure the Bores
hydraulic accumulators are fully charged. FIGURE 8-13
1. Connect the end of the bleeder hose to the bleed screw
on the caliper. Submerge the other end in a jar partially 3. Use a piece of wood against the linings as a pry bar to
filled with clean hydraulic oil. push the pistons completely into the housing. Tighten
the bleeder screws (Figure 8-13).
2. Open the bleed screw on the caliper/actuator and allow
fluid to flow into the jar, while depressing the brake 4. Remove the linings from the caliper housing. If neces-
pedal. Depress the brake pedal and close the bleeder sary, discard the linings.
screw, then release the brake pedal. Torque the bleeder
screw to 100 to 120 lb-in (11.3 to 13.6 Nm). Caliper

3. Repeat step 2 until a solid stream free of air bubbles is 1. Disconnect the hydraulic brake line from the inlet fitting
obtained. on the caliper. Cap or plug all openings.

4. Repeat steps 1 thru 3 for the remaining wheel calipers/ 2. Remove the linings as described previously.
actuators. 3. Remove the bolts securing the caliper housing to the
mounting bracket. Remove the caliper housing from the

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RT890E SERVICE MANUAL UNDERCARRIAGE

mounting bracket. If shims are used mark the position of out before the other piston, put a piece of wood in
the shims. front of the piston that comes out first. Apply
compressed air to force the other piston out of the
Disassembly housing (Figure 8-15).
Caliper
1. Remove the inlet fitting and O-ring from the cylinder cap.
2. Drain and discard the brake fluid. C-Clamp

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

Dry the housing with a clean cloth.
4. If installed, remove the bolts that secure the end plates
to the housing. Remove the end plates and linings.
5. Remove the pistons from the side of the housing oppo-
site the mounting plate according to the following proce-
Air Gun
dure. Wood
Block Piston FIGURE 8-15
a. Use a C-clamp to hold a 0.5 in (12.7 mm) block of
wood against two pistons on the mounting side of c. Remove the wood block and the C-clamp from the
the housing. Ensure the C-clamp is not in the area in housing.
front of the piston bore (Figure 8-14).
d. Remove the pistons from the bores that are
opposite from the mounting plate.

8
6. Remove the cylinder caps from the housing using an
open end wrench. Remove and discard the O-rings
C-Clamp
27
(Figure 8-16).

Wood
2

Block
23

FIGURE 8-14 O-Ring

Cylinder
Cap

DANGER FIGURE 8-16

Do not place hand in front of pistons when forcing them 7. Remove the pistons from the mounting plate side of the
out. Serious personal injury may occur. housing. Push on the ends of the pistons to force them
out of the disc side of the housing (Figure 8-17).
8
b. Apply compressed air to the inlet fitting to force the
pistons out of the other housing. If one piston comes

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UNDERCARRIAGE RT890E SERVICE MANUAL

• Lining Wear. Replace the linings when the thickness

of the lining is less than 0.125 in (3.2 mm) from the
Wood Block back plate (Figure 8-19).
• Lining Wear Not Even. Replace the linings if the
thickness of the two linings is significantly different.
Check the pistons for correct operation. Replace the
piston and/or housing if a piston is cocked in the
bore. Check that the disc surface is flat and parallel
to the linings (Figure 8-19).

Minimum Lining Thickness

0.125 in (3.2 mm) from
Piston Backing Plate

FIGURE 8-17

8. Remove the dust seals from the housing.

9. Remove and discard the O-ring and the backup rings
(Figure 8-18).

Uneven Lining Wear

8
O-Ring
2 27
FIGURE 8-19
23

• Oil or Grease on Linings. Replace the linings.

• Cracks on Linings. Replace linings that have large
Backup Ring FIGURE 8-18 or deep cracks.

10. Inspect the ring grooves in the housing for scratches and NOTE: Small, tight cracks on the surface of the lining are
rust. Remove small scratches and rust with emery cloth. normal when the caliper is used under high temper-
Replace the housing if there are large scratches or large ature conditions.
amounts of rust. Refer to Inspection - Caliper Parts. Caliper for Leaks
11. Inspect the pistons and the bores for scratches and rust. Inspect the following areas for fluid leaks (Figure 8-20).
Remove small scratches and rust with emery cloth.
Replace the components if they are worn or if there are
large scratches or large amounts of rust. Refer to Cali- Piston Fluid Bleeder Screw
per Parts, page 8-19. Leaks Fluid Leaks

Inspection
Periodic On-Vehicle Inlet
Cylinder
Fitting
Inspect the caliper, linings, and disc for any damage. Cap
Fluid
Fluid
Leaks
Shoes, Linings, and End Plates Leaks

Remove the shoes and linings. To help prevent abnormal

lining wear, replace worn, bent, or cracked end plates and
distorted backing plates. Inspect end plate bolts for wear. Piston Fluid
Replace the bolts if worn. Inspect the linings for: Leaks
FIGURE 8-20

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RT890E SERVICE MANUAL UNDERCARRIAGE

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

caliper. Inspect the piston, the bore, the O-rings,
1. Inspect the pistons, housing bores, and O-ring grooves
and back-up rings. Service as necessary.
for scratches or corrosion. Remove small scratches or
• Cylinder Cap. If fluid leaks at a cylinder cap, tighten corrosion with fine emery cloth. Replace the compo-
the cylinder cap, the inlet fitting, and the plug. If the nents if they are worn beyond wear limits or if there are
leak continues, disassemble the caliper. Inspect the large scratches or large amount of corrosion.
cylinder cap threads, the housing threads, and the
O-ring. Service as necessary. 2. Measure the diameter of the piston. Replace the piston if
the outer diameter is worn less than 2.995 in
• Bleeder Screw. If fluid leaks at the bleeder screw, (76.073 mm) (Figure 8-22).
tighten the bleeder screw. If the leak continued,
replace the bleeder screw.
• Inlet Fitting. If fluid leaks at the inlet fitting, tighten
the fitting. If the leak continues, replace the O-ring.
Dust Seals
Ensure the dust seals are soft and flexible. Disassemble the
caliper and replace dust seals that are hard or damaged. Micrometer
Piston
Disc
If the disc is worn beyond the wear limits, replace the disc
(Figure 8-21). Replace Piston if Outer
Diameter is Worn to Less than

8
2.995 in (76.073 mm)
Minimum Disc FIGURE 8-22
Thickness
27
3. Measure the diameter of the housing bore. Replace the
housing if the diameter is worn to more than 3.003 in
Maximum Disc (76.276 mm) (Figure 8-23).
Wear Each Side
2

Maximum
23

Disc Wear
Original
Replace Housing if Bore
Disc Thickness
is Worn to More than
0.625 in (15.875 mm)
3.003 in (76.276 mm)

Typical Section Through Disc Showing

Recommended Maximum Wear Limits

Lining
Maximum
Backing Minimum Disc
Disc Wear
Plate Thickness
Each Side Telescoping
Thickness Gauge
0.28 in (7.1 0.06 in (1.5 0.50 in (12.7
FIGURE 8-23 8
mm) mm) mm) 4. Inspect the linings as described previously.

0.34 in (8.6 0.09 in (2.3 0.44 in (11.2 5. Inspect the threads of the caliper, cylinder caps, and all
mm) mm) mm) fittings. Replace any component that has thread dam-
age that cannot be repaired.
FIGURE 8-21
6. Discard all back-up rings, O-rings, and dust seals. Use
new ones when assembling the caliper.

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UNDERCARRIAGE RT890E SERVICE MANUAL

Cleaning Assembly
Caliper

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

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

must be lubricated before installing the pistons.
Use only solvent cleaners to clean ground or polished
metal parts. Hot solution tanks or water and alkaline 1. Lubricate all pistons, bores, O-rings, and back-up rings
solutions will damage these Parts. Isopropyl alcohol, with silicone grease. If silicone grease is not available,
kerosene, or diesel fuel can be used for this purpose. use the same type of fluid that is used in the brake sys-
tem.
• Use solvent cleaners to clean all metal parts that
2. Install new O-ring and a new back-up ring in the groove
have ground or polished surfaces. Examples of
in the middle of the bore. The O-ring is installed toward
ground or polished parts are the piston and the
the outboard end of the bore. The back-up ring is
piston bore in the caliper.
installed toward the lining side of the bore (Figure 8-24).

8
• Metal parts with rough surfaces can be cleaned with
solvent cleaners or with alkaline solutions.
27
• Use a wire brush to clean the threads of fasteners CAUTION
and fittings. Do not use silicone grease on the dust seal.
2
• Use soap and water to clean parts that are not made 3. Install a new dust seal in the top groove of the bore
of metal. (Figure 8-24).
23

• Scrape away build-ups of mud and dirt on the

linings. Replace all linings contaminated with oil or
grease.
Backup Ring - O-Ring-
• Immediately after cleaning, dry all parts with clean Install Toward Lining Install Toward
paper or rags. Side of Bore O-Ring Outboard End of Bore
O-Ring
Corrosion Protection
Apply brake system fluid to the cleaned and dried parts that
are not damaged and are to be immediately assembled. Do
Backup
Not apply fluid to the brake linings or the disc. Ring
If parts are to be stored, apply a special material that
prevents corrosion to all surfaces. Do Not apply the material Backup Ring Dust Seal
and O-Ring Groove
to the brake linings or the disc. Store the parts inside special Dust Seal Groove
paper or other material that prevents corrosion.
FIGURE 8-24

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

from the lining side of the housing. Ensure the pistons
are straight in the bores. Push each piston into the bore
until the top of the piston is even with the top of the dust
seal (Figure 8-25).

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RT890E SERVICE MANUAL UNDERCARRIAGE

7. Install the bleeder screws in the housing. Tighten to 100

to 120 lb-in (11.3 to 13.6 Nm).
8. Install the O-ring and the inlet fitting in the cylinder cap.

Installation
Linings

CAUTION
Always replace both linings. If only one lining is replaced,
Piston - - Use possible disc damage can occur.
Equal Pressure to
Push Pedal into Bore 1. Install the linings in the caliper housing.
2. Position the end plates on the housing and secure with
bolts. Apply Loctite 271 or equivalent to the bolt threads.
Tighten the bolts to 165 to 210 lb-ft (224 to 285 Nm).
3. Ensure the linings move freely in the housing.
4. Bleed the brake system.
5. Apply and release the brakes three times to ensure the
caliper operates correctly. Check for fluid leaks. Ensure

8
the linings move freely.
When Correctly
Installed the End of the Caliper
27
Piston is Even with the
Top of the Dust Seal FIGURE 8-25 1. Position the caliper housing on the mounting bracket. If
shims where used, place them as marked during
5. Install a new O-ring in the groove of the cylinder cap. removal.
2

Ensure the O-ring is not cut by the threads on the cylin- 2. Secure the caliper housing with the bolts and tighten
23

der cap. them to 500 to 600 lb-ft (678 to 813 Nm).

NOTE: Apply extra grease on O-ring before installing cylin- 3. Install the linings. Refer to Linings, page 8-21.
der caps. this will keep O-ring from catching on
threads as cylinder cap is threaded into housing. 4. Ensure the housing is installed correctly on the mounting
bracket. The disc must be within ±0.06 in (±1.5 mm) of
6. Install the cylinder caps in the caliper housing. Tighten being centered between the lining end plates.
the cylinder caps to 75 lb-ft (102 Nm) minimum as shown
in (Figure 8-26). a. To increase outboard clearance and decrease
inboard clearance, install a shim either between the
housing and mounting bracket or between the hub
Cylinder Cap - - and disc.
Tighten to 75 lb-ft (100 1.25 Inch
Nm) Minimum Crow’s Foot b. The shims must be steel, ground flat, and parallel
Wrench and must cover the entire mounting surface of the
hub or housing. The linings must move freely in the 8
housing and between the end plates (Figure 8-27).

Torque
Wrench
FIGURE 8-26

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UNDERCARRIAGE RT890E SERVICE MANUAL

sure of 270 psi (1862 kPa) may be used to pressurize

the actuator.
3. Remove the capscrews holding actuator to the brake
caliper, and slide the actuator off the actuator rod.
4. Position the Park Brake Switch to ON and shut down the
engine.
5. Disconnect the hydraulic line from the brake actuator,
then cap or plug all openings.

Installation
Disc Centered
1. Connect the hydraulic line to the brake actuator.
Between Linings
2. Start the engine, ensure the transmission is in neutral,
and position the Park Brake Switch to OFF. This will
FIGURE 8-27
pressurize brake the brake actuator to release the ten-
sion on the brake linkage. Engine must remain running.
5. Connect the hydraulic brake line to the inlet fitting.
Air pressure of 270 psi (1862 kPa) may be used to pres-
6. Bleed the brake system. surize the actuator.
7. Apply and release the brakes three times to ensure the 3. Slide the actuator over the actuator rod and install the
caliper operates correctly. Check for fluid leaks. Ensure capscrews to attach the actuator to the caliper.
the linings move freely.
4. Position the Park Brake Switch to ON and shut down the

8
engine.
PARKING BRAKE ACTUATOR
27
Adjustment
Description
1. Chock the wheels to prevent crane movement.
The spring-applied, hydraulically-released parking brake
2. Start the engine, ensure the transmission is in neutral,
2
actuator is located on the front axle and is used to apply and
and position the Park Brake Switch to OFF. This will
release the parking brake. Depending on the crane model
pressurize the brake actuator to release the tension on
23

there will be either one or two parking brakes per crane.

the brake linkage. Air pressure of 270 psi (1862 kPa/
Maintenance 18.6 bar) may be used to pressurize the actuator. Screw
the caging nut up under the actuator chamber.
Removal 3. Install the rod ball joint until the ball joint will just connect
1. Chock the wheels to prevent crane movement. to the brake linkage with the brake lever in a horizontal
position.
2. Start the engine, ensure the transmission is in neutral,
and position the Park Brake Switch to OFF. This will 4. Lock the rod ball joint with the jam nut and back off the
pressurize the brake actuator to release the tension on caging nut.
the brake linkage. Engine must remain running. Air pres- 5. Position the Park Brake Switch to ON and shut down the
engine.

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RT890E SERVICE MANUAL UNDERCARRIAGE

PARKING BRAKE 4. Tighten hex mounting bolts (36) until they make contact
with the urethane springs (33), then tighten 4 flats
Description approximately 0.07 in (1.778 mm) more. This puts the
proper amount of pre-load on the urethane springs.
The parking brake is mounted on the front axle input shaft, or
transmission output (depending on crane model) in line 5. Tighten jam nut/sleeves (35) against mounting surface
between the front axle and the driveline from the and torque 200 lb-ft (271.1 Nm).
transmission. The brake is a disc-type brake that is
controlled by a switch on the front console in the cab and is
spring-applied and hydraulically released by an actuator. CAUTION
Brake linings are susceptible to contamination. When
Maintenance installing or servicing brakes, keep all oil and fluids away
from the linings. Poor brake performance may result if the
Removal linings are contaminated.
Use the following procedure and refer to Figure 8-28 when
removing the brake. 6. Attach brake line to inlet port located on the top of the
hydraulic cylinder (26).
1. Chock the wheels to prevent crane movement.

CAUTION
CAUTION Do not exceed 270 psi (1861.5 kPa) hydraulic pressure to
Do not exceed 270 psi (1861.5 kPa) hydraulic pressure to avoid damage to the brake; 170 psi (1172.1 kPa) is
avoid damage to the brake; 170 psi (1172.1 kPa) is required to fully release the brake.
required to fully release the brake.

8
7. Apply hydraulic pressure to the brake.
2. Start the engine, ensure the transmission is in neutral,
27
and position the Park Brake Switch to OFF. This will 8. Set the running clearance by doing the following:
pressurize the brake actuator to release the tension on a. Remove the plug(16).
the brake linkage.
b. Loosen coupling nut (13).
2

3. Remove plug (16), back off both jam nuts (39), loosen
socket head cap screw (38) and socket set screw (12). c. Rotate the socket set screw (12) until the brake is
23

clamped onto the disc.

4. Position the Park Brake Switch to ON and turn off
engine. d. Loosen the outer hex nut (39) and rotate socket
head cap screw (38) until it makes contact with the
5. Loosen the brake line and cap inlet port. bump stop on the mounting bracket, then back it off
6. Loosen jam nut/sleeves (35), remove hex mounting 1/4 turn (0.016 in/0.406 mm).
bolts from the bracket and remove brake. e. Hold the socket head cap screw (38) in place while
tightening the outer hex nut (39) against the inner
Installation
hex nut (39) to 30 to 35 lb-ft (40.7 to 47.5 Nm).
Use the following procedure and refer to Figure 8-28 when
f. Back off the socket set screw (12) 1/2 turn (0.028 in/
installing the brake.
0.711 mm).
NOTE: Mount brake so that the linings are parallel with the
g. Hold the socket set screw (12) in place and torque
disc within 0.015 in (0.381 mm).
coupling nut (13) to 50 to 55 lb-ft (67.8 to 74.6 Nm). 8
1. Slide brake over disc and into the mounting position.
h. Replace plug. Torque plug 45 to 50 lb-ft (61.0 to
2. Start hex mounting bolts (36) into mounting surface far 67.7 Nm).
enough to just support the brake.
NOTE: Re-adjust the brake when running clearance
3. Remove plug (16), loosen the coupling nut (13) and then reaches a total of 0.10 in (2.54 mm).
tighten socket setscrew (12) until linings (37) are
9. Position the Park Brake Switch to ON and shut down the
clamped to the disc. This locates and holds the brake in
engine.
the proper position to set the hex mounting bolts.

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UNDERCARRIAGE RT890E SERVICE MANUAL

8
2 27
23

FIGURE 8-28

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RT890E SERVICE MANUAL UNDERCARRIAGE

Item Description Item Description

1 Torque Plate 20 Clevis Pin
2 O-ring Seal 21 Cotter Pin
3 Washer 22 Jam nut
4 Bearing 23 Rod
5 Thrust Cam 24 Excluder Rod
6 O-ring Seal 25 Retainer Ring
7 Piston Assembly 26 Cylinder Housing
8 Magnet 27 Piston
9 Ball Bearing 28 Seal
10 Cam 29 Ring
11 Dowel Pin 30 Capscrew
12 Setscrew 31 Flatwasher
13 Nut 32 Spring
14 Disc Spring 33 O-ring Seal
15 Housing 34 Jam Nut

8
16 Plug 35 Capscrew
27
17 Lever 36 Lining and Carrier Assembly
18 Retainer Ring 37 Capscrew
2
19 Clevis 38 Nut
23

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UNDERCARRIAGE RT890E SERVICE MANUAL

PARK BRAKE SOLENOID VALVE 3. Apply and release the park brake several times. Verify
the park brake holds the crane when applied. Verify the
Description park brake doesn’t drag when released.

The park brake solenoid valve (Figure 8-29) is located on the 4. Check for leaks. Make repairs as needed.
front side of the carrier aft center frame cross member. The
valve is a three-way two position solenoid valve. The park
brake valve is used to control the application of the crane’s
spring-applied, hydraulically-released parking brake.
Positioning the Park Brake switch to OFF shifts the three-
way, two-position solenoid valve so hydraulic oil can flow to
2
the parking brake actuator, extending it. When the actuator 1
3
extends, it releases the park brake.
Positioning the Park Brake switch to ON shifts the three-way,
two-position solenoid valve so hydraulic oil can drain from
the actuator. The parking brake actuator’s rod retracts,
forcing hydraulic oil through the valve and the case drain
manifold back to the transmission reservoir. As the actuator Port (3)
retracts, it applies the parking brake. Port (2)

A pressure switch is installed in the line to the actuator.

When the park brake is applied, a lack of hydraulic oil
pressure keeps the pressure switch closed, which turns on

8
the red LED indicator on the switch.When the park brake is Port (1)
released, pressure buildup opens the switch, which turns off
27
the indicator. FIGURE 8-29

Maintenance
2
Removal
1. Tag and disconnect the hydraulic lines attached to the
23

valve. Cap or plug lines and ports. Remove the valve.

Installation
1. Position the valve and connect the hydraulic lines to the
valve as tagged during removal.
2. Connect the electrical connector to the valve as tagged
during removal.

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RT890E SERVICE MANUAL UNDERCARRIAGE

OUTRIGGERS A sight bubble level is mounted on the left side of the cab by
the door latch plate. The sight bubble level provides the
Outrigger Circuit operator with a visual indication of crane level attitude.

Description Theory of Operation

The outrigger circuit consists of four extension cylinders, four The appropriate Extension/Jack Switch must be depressed
jack cylinders, an integrated outrigger/rear steer valve, front before the Outrigger Extend/Retract Switch is depressed.
and rear outrigger control manifolds, pilot operated check Depressing one of the outrigger selector switches causes
valves and four Outrigger Monitoring System (OMS) that solenoid valve to open. As the Outrigger Switch is
( O p t i o n a l — St a n d a r d i n N o r t h A m e r i c a ) s t r i n g moved, the integrated outrigger valve spool shifts allowing
potentiometers. The front two extension cylinders are flow to either the extend or retract line as applicable. If the
mounted in the front outrigger beams and the rear two Outrigger Switch is in the EXTEND position, the flow
extension cylinders are mounted in the rear outrigger beams. continues through the open solenoid valve to the piston side
The front and rear outrigger beams are mounted in their of the cylinder. If the jack is to be extended, the flow first
respective outrigger boxes; in turn a jack cylinder is mounted unseats the cylinder check valve then extends the cylinder.
on the end of each outrigger beam. The integrated outrigger/ The oil from the rod end flows through the integrated
rear steer valve is mounted on the front face of the carrier outrigger valve, and then to the reservoir.
frame front cross member. The front and rear outrigger When the Outrigger Switch is in the RETRACT position, the
control manifolds are mounted on the inside center of their flow through the selector valve is directed to the rod side of
respective outrigger box. An OMS string potentiometer (if the cylinder. The oil in the piston side flows through the open
equipped) is mounted inside each outrigger box. The solenoid back to the integrated outrigger valve. If a jack
potentiometer is connected by a cable to the outrigger beam cylinder is to be retracted, then pilot pressure from the
to monitor the beam’s position—fully retracted, mid-extend, pressurized retract line unseats the cylinder check valve

8
or full extended. allowing oil to flow from the piston side through the open
solenoid valve to the integrated outrigger valve. The
27
The outrigger selector controls are located in the cab on the
front console. Both the integrated outrigger valve and the integrated outrigger valve directs the flow to the reservoir.
manifold solenoid valves are electrically actuated from these The integrated outrigger/rear steer valve contains three relief
controls. The solenoid switches must be held depressed to valves. The main relief is set at 2000 psi (13,789 kPa).
2

actuate the solenoid valve. The integrated outrigger valve Thermal relief protection is provided on the extend side by a
switch is spring loaded to the off position. The console is 3000 psi (20,684 kPa) relief valve and the retract side by a
23

placarded with switch positions. 300 psi (2068 kPa) relief valve.

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UNDERCARRIAGE RT890E SERVICE MANUAL

Maintenance
Troubleshooting

Symptom Probable Cause Solution

1. Slow or erratic operation of outrig- a. Damaged relief valve. a. Remove relief valve; clean or
ger extension cylinders. replace.
b. Low hydraulic oil. b. Replenish oil to proper level.
c. Sticking solenoid valve spool. c. Repair or replace valve spool.
d. Improper ground to base of d. Ground properly.
solenoid.
2. Slow or erratic operation of outrig- a. Directional selector switch a. Clean or replace switch.
ger extension cylinders (contin- sticking.
ued).
b. Collector ring dirty or glazed. b. Clean and deglaze collector
ring.
c. Damaged wiring to solenoid. c. Replace wiring.
d. Weak brush springs on d. Replace brush springs.
collector ring.
e. Damaged extension cylinder e. Remove extension cylinder

8
(internal parts). and repair as necessary.
f. Bent cylinder rods. f. Replace piston rods and
27
seals.
g. Excessive material on g. Clean outrigger beams.
outrigger beams.
2

h. Binding outrigger beam. h. Repair or replace outrigger

23

beam.
i. Damaged outrigger valve. i. Repair or replace valve.
j. Damaged valve coil. j. Replace coil.
k. Main hydraulic pump k. Replace or tighten hose or
cavitation. fitting.
l. Partially shifted hydraulic l. Disassemble, clean, and
spool in selector valve or polish spool and valve
manifolds. housing with very fine emery
cloth (water paper).
m. Insufficient voltage for m. Solenoids require a minimum
operation of solenoid valve. of 9.5 volts to energize. Check
outrigger wiring and electrical
coupling collector rings.
n. Damaged piston seals. n. Replace all cylinder seals.
o. Worn or damaged hydraulic o. Repair or replace pump
pump section. section.
p. Scored cylinder barrel. p. Repair or replace extension
cylinder.
q. Cracked or damaged piston. q. Replace rod weld and all
cylinder seals.

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RT890E SERVICE MANUAL UNDERCARRIAGE

Symptom Probable Cause Solution

Sticking spool. a. Dirt in the system. a. Change oil and flush system.
b. Distortion caused by tie bolts b. Retorque tie bolts.
being overtorqued.
c. Flow in excess of valve rating. c. Limit flow through valve to that
recommended. Check pump
output and cylinder ratio.
3. Sticking spool (continued). a. Pressure in excess of valve a. Check relief valve setting or
rating. pump compensation with that
recommended.
b. Electrical failure. b. Check wiring and solenoids.
4. External leakage. a. Damaged O-ring or quad a. Check for chipped packings
rings. and replace.
b. Loose tie bolts. b. Retorque tie bolts.
c. Damaged solenoid. c. Replace damaged parts.
5. Solenoid failure. a. No current. a. Check power source of at
least 85% of coil rating.
b. Damaged solenoid assembly. b. Replace solenoid.

8
c. Short in solenoid. c. Replace coil.
d. Loss of solenoid force. d. Decrease time of solenoid
27
energization, decrease cycle
rate.
6. Outrigger jack cylinder slow or a. Low in hydraulic oil. a. Replenish oil to proper level.
2

erratic.
b. Damaged main relief valve. b. Repair or replace valve.
23

c. Damaged holding valve seals. c. Replace holding valve seals.

d. Bent cylinder rod. d. Replace cylinder rod and
seals.
e. Bent outrigger housing. e. Repair or replace outrigger
housing.
f. Excessive material on beams. f. Clean outrigger beams.
g. Sticking solenoid valve spool. g. Repair or replace valve spool.
h. Damaged wiring to solenoid. h. Repair or replace wiring.
i. Weak brush springs on i. Replace brush springs.
collector rings.
j. Collector ring dirty or glazed. j. Clean or deglaze collector 8
ring.
k. Directional selector switch k. Clean or replace switch.
sticking.
l. Main hydraulic pump l. Replace or tighten hose and
cavitation. fittings.
m. Worn or damaged hydraulic m. Repair or replace pump
pump section. section.

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UNDERCARRIAGE RT890E SERVICE MANUAL

Symptom Probable Cause Solution

7. Outrigger jack cylinder retracts a. Damaged piston seals. a. Replace all cylinder seals.
under load.
b. Damaged holding valve seals. b. Replace seals.
c. Damaged holding valve. c. Replace valve assembly.
d. Scored cylinder barrel. d. Repair or replace cylinder.
e. Cracked or damaged piston. e. Replace piston and all
cylinder seals.
8. Outrigger jack cylinder extends a. Damaged piston seals. a. Replace all cylinder seals.
while machine is traveling.
b. Scored cylinder barrel. b. Replace jack cylinder.
c. Cracked or damaged piston. c. Replace piston and seals.
d. Piston loose on cylinder rod. d. Replace seal and retorque.
9. Outrigger system will not activate a. Hydraulic oil low. a. Replenish system.
(from stowed or extended and
b. Loose or broken wire on b. Repair or replace wiring.
down position).
switch.
c. Clogged, broken, or loose c. Clean, tighten, or replace
lines or fittings. lines or fittings.
d. Damaged relief valve or d. Repair or replace valve.
damaged control valve.

8
10. Outrigger system activates, but a. Clogged, broken, or loose a. Clean, tighten, or replace
27
selected outrigger will not stow or hydraulic lines or fittings. lines or fittings.
extend and lower as desired.
b. Loose or broken wire on b. Repair or replace wiring.
control switch or solenoid
2
valve.
c. Damaged solenoid valve. c. Repair or replace valve.
23

d. Damaged control switch. d. Replace switch.

e. Damaged hydraulic cylinder. e. Repair or replace cylinder.
11. Outriggers will not set. a. Improper sequence of a. Activate individual control
activation. switch; then activate system
control switch.
12. Two outriggers activate from sin- a. Damaged solenoid valves. a. Repair or replace.
gle control switch.
13. The two outriggers will not stow. a. Hydraulic lock. a. Recycle individual
outrigger(s).
14. Individual outrigger will not set or a. Damaged piston seals. a. Replace seals.
stow.
b. Damaged check valve. b. Repair or replace valve.
c. Loosen or broken wire on c. Repair or replace wiring.
control switch or solenoid
valve.
d. Damaged solenoid valve. d. Repair or replace valve.

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RT890E SERVICE MANUAL UNDERCARRIAGE

Outrigger Beam NOTE: Do not allow the end of the outrigger extension cyl-
inder to fall when the cylinder mounting shaft is
Description removed. Use blocking to limit the drop or an ade-
quate soft support to cushion any distance the rod
The outrigger beam assembly consists of an outrigger beam,
will drop,
a jack cylinder, a extension cylinder, an Outrigger Monitoring
System (OMS) (Optional—Standard in North America), and 7. Remove the OMS string potentiometer cable (if
the required hoses and mounting hardware. equipped) from the attaching point on the outrigger
beam.
Theory of Operation
NOTE: Avoid free-release of cable to prevent damage to
When the outrigger extension is activated, it extends or OMS string potentiometer caused by over-range of
retracts the outrigger beam within the outrigger box. The cable.
outrigger beam can be extended to the mid-extend position
by allowing the lock pin to ride on the top of the beam while 8. Remove the cotter pin and clevis pin securing the cylin-
it’s extending. The lock pin will automatically drop into the der barrel end of the extension cylinder to the outrigger
hole when the beam reaches the mid-extend position. housing. Carefully extend the outrigger beam until the
extension cylinder is free of the housing and carefully lay
The Outrigger Monitoring System (OMS) (if equipped) has a the end of the cylinder on the bottom of the outrigger
string potentiometer mounted inside each outrigger box beam or leave on blocking.
connected to the outrigger beam by a cable to monitor
position of the extension beam (full, half or retracted). NOTE: Do not allow the end of the outrigger extension cyl-
inder to fall when the cylinder mounting shaft is
The jack cylinder is mounted to the end of the beam and removed. Use blocking to limit the drop to prevent
applies force to the outrigger beam vertically. This sequence damage to the OMS string potentiometer.
of events provides for lifting and stabilizing the crane for

8
operation. OMS string potentiometer may be easily removed
to avoid damage during extension cylinder pin
27
Maintenance removal. Refer to Outrigger Monitoring System
(Optional—Standard in North America), page 8-36.
Removal
NOTE: Lifting belts or straps should be used for lifting pur-
2
NOTE: Outrigger removal and installation is similar for
poses so as to avoid nicking or scratching the bot-
both the front and rear outriggers.
tom edges of the outrigger beam Figure 8-31.
23

1. On the jack cylinder end of the beam, remove the set

9. After attaching a suitable lifting device of straps or belts
screw from the side adjustable wear pad and back off
instead of chains to prevent nicking the bottom edges of
the wear pad from the outrigger box.
the outrigger beam, pull the outrigger beam out of the
2. Remove the cover from the opposite end of the outrigger outrigger box, re-adjusting the lifting attachment to pre-
box. Remove the setscrew from the side adjustable wear vent the extension cylinder from sliding out of the outrig-
pad and back off the wear pad from the beam. ger beam when the beam clears the outrigger box.
3. Remove the setscrews from the bottom adjustable wear
pads and back off the wear pads leaving approximately
0.125 in (3.2 mm) protruding
DANGER
4. Extend the outrigger slightly to facilitate attaching a lift- Be sure any blocking material used is capable of
ing device to the outrigger beam. supporting the weight of the outrigger beam. Do not allow
it to tilt or slide. 8
NOTE: The outrigger beam assembly weighs approxi-
DANGER mately 1474 lb (669 kg).
Be sure any blocking material used is capable of
10. Position the outrigger beam on the blocking material.
supporting the weight of the outrigger beam. Do not allow
it to tilt or slide. Inspection
Inspect the outrigger beams for bends, evidence of cracks,
5. Place blocking material under the outrigger beam.
or other damage. Check the outrigger beam internally for
6. Tag and disconnect the hydraulic lines at the cylinder hydraulic fluid, which may indicate a leaking cylinder, loose
barrel end of the extension cylinder. Cap all lines and fit- connection, or damaged hydraulic line.
tings.

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UNDERCARRIAGE RT890E SERVICE MANUAL

Installation
1. Apply grease (EPMPG) to the bottom of the outrigger CAUTION
beam.
Be sure that the piston side of all outrigger cylinders are
2. If removed, install the side adjustable wear pad in the connected to the solenoid valve bank. Reversal of port
outrigger beam. connection of the rod and piston sides could result in
severe damage to the cylinders as very high pressure
3. Install the bottom wear pads with approximately 0.125 in
intensification will occur.
(3.2 mm) protruding. This will prevent the beam side
plates from riding on the bottom of the box. During initial start-up and checking of the outrigger
operation, each control switch must be operated before
4. Attach a suitable lifting device of straps or belts instead operating the selector valve. If hydraulic lines are
of chains to prevent nicking the bottom edges of the out- reversed to one or more cylinders, this will prevent
rigger beam. damage to the cylinders.
5. Slide the beam into the outrigger housing and align the
cylinder bushing with the mounting hole. 8. Connect the hydraulic lines as tagged prior to removal.

6. Apply anti-seeze compound to the clevis pin. Secure the 9. Install the side adjustable wear pad in the outrigger box.
cylinder barrel to the housing with the clevis pin and cot- 10. Adjust the wear pads, refer to Wear Pad Adjustment,
ter pin. page 8-32.
7. Attach the OMS string potentiometer cable (if equipped) 11. Install the end cover.
to the attaching point on the outrigger beam.
NOTE: At installation, be sure that the outrigger jack cylin-
If the OMS string potentiometer was removed, install the der hydraulic hoses are not trapped against the

8
potentiometer at this time. Refer to Outrigger Monitoring outrigger box when the beam is fully retracted.
System (Optional—Standard in North America), page 8-
27
36. Wear Pad Adjustment
NOTE: Avoid free-release of cable to prevent damage to NOTE: When adjusting wear pads, refer to Wear Pad
OMS string potentiometer caused by over-range of Adjustment (Figure 8-32).
2
cable. 1. Adjust the bottom wear pads (approximately 1/4 turn)
until a gap of 0.06 in (1.5 mm) is obtained between the
23

top of the beam and the top of the outrigger box. Install
and lock set screw against wear pad.
2. Adjust outrigger box side wear pad until a gap of 0.06 in
(1.5 mm) is obtained between beam and shims welded
in top and bottom of box. Install and lock set screw
against wear pad.
3. Adjust outrigger beam side wear pad until a gap of
0.06 in (1.5 mm) is obtained between shim welded on
beam and side of box. Install and lock set screw against
wear pad.

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RT890E SERVICE MANUAL UNDERCARRIAGE

6, 7

13 2, 3
10, 11, 12

4, 5

8
9
2, 3
27
2, 3
1 FIGURE 8-30
2
23

Item Description Item Description

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

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UNDERCARRIAGE RT890E SERVICE MANUAL

NOTE: Outrigger removal and

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

6120-1

8
FIGURE 8-31
27
Item Description
1 1 Outrigger Beam Assembly
2
1 2 Wear Pad
23

3 Setscrew
4 Clevis Pin
5 Cotter Pin
2, 3

2, 3

4, 5

2, 3

2, 3 2, 3
FIGURE 8-32

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RT890E SERVICE MANUAL UNDERCARRIAGE

Extension Cylinder Extend Port Jack Cylinder Extend Port

Jack Cylinder and Extension Cylinder Retract Port

Jack Cylinder and Extension Cylinder

Jack Cylinder Extend Port
Retract Port

Extension Cylinder Extend Port

8
FIGURE 8-33
27
Extension Cylinder vent rubbing with the beam top plate and side
plate, and for proper tracking during beam exten-
Description sion and retraction.
2

Two outrigger extension cylinders are utilized within each

23

outrigger box assembly. The extension cylinders provide the

force for the outrigger beam’s horizontal movement. The
cylinder weighs approximately 100 lb (45.3 kg).

Maintenance
17.5°
NOTE: Refer to Outrigger Extension Cylinder, page 2-92
for Disassembly and Assembly of the cylinder. 10°
FIGURE 8-34
Removal
1. Remove the outrigger beam. Refer to Outrigger Beam, 2. Position the extension cylinder so the hydraulic ports on
page 8-31. the rod end of the cylinder can be accessed. Connect
the hydraulic hoses to the ports as tagged during
2. Remove the cotter pin and clevis pin securing the rod removal.
end of the extension cylinder to the outrigger beam.
3. Push the cylinder into the outrigger beam. Align the cyl- 8
3. Pull the extension cylinder from the outrigger beam until inder rod with the clevis in the beam. Apply anti-seeze to
the hydraulic hoses on the rod end of the cylinder can be the clevis pin and secure in place with the clevis pin and
accessed. Tag and disconnect the hoses from the rod cotter pin.
end of the cylinder. Cap or plug all openings.
4. Install the outrigger beam. Refer to Outrigger Beam,
4. Remove the cylinder. page 8-31.
Installation Functional Check
1. Place the cylinder in the beam. 1. Activate the hydraulic system; extend and retract the
NOTE: Keep hydraulic fittings and hoses close to angles outrigger.
shown (Figure 8-34) and as low as possible to pre- 2. Observe the operation of the outrigger beam.

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UNDERCARRIAGE RT890E SERVICE MANUAL

3. Check the hydraulic connections for any evidence of Installation

leakage.
1. Install string potentiometer inside outrigger beam.
Outrigger Monitoring System (Optional— 2. Install the OMS string potentiometer enough to engage
Standard in North America) slotted hole with mounting hardware Figure 8-35.

Description 3. Install the other mounting hardware.

The Outrigger Monitoring System (OMS) utilizes a string 4. Attach the OMS string potentiometer connector to the
potentiometer to monitor outrigger extension beam position. attaching point on the outrigger beam.
Four monitoring string potentiometers are used on the crane; NOTE: Avoid free-release of cable to prevent damage to
one at the fixed end of each outrigger extension beam. Each the OMS string potentiometer.
potentiometer sensor monitors if the corresponding beam is
at full, half or retracted position. 5. Connect electrical harness connector to string potenti-
ometer.
Removal
6. Install access cover plate to outrigger box.
1. Extend the outrigger beam slightly for improved access
and shut down the engine. Jack Cylinder
2. Remove the outer access cover plate from outrigger Description
box.
Four jack cylinders are used on the crane, one at the end of
3. Remove the OMS string potentiometer connector (1, each outrigger beam. The jack cylinders provide the force for
Figure 8-35) from the attaching point on the outrigger the outrigger beam’s vertical movement. The cylinder weighs
beam. approximately 229 lb (104 kg).

8
NOTE: Avoid free-release of cable to prevent damage to
Maintenance
27
OMS string potentiometer.
NOTE: Refer to Outrigger Jack Cylinder, page 2-95 for dis-
4. Disconnect electrical harness connector and secure to
assembly and assembly of the cylinders.
avoid damage.
2

5. Loosen mounting hardware enough to disengage OMS Removal

string potentiometer from the slotted mounting hole. 1. Extend the outrigger beam slightly for improved access
23

6. Completely remove the other mounting hardware. to the jack cylinder; shut down the engine.

7. Remove OMS string potentiometer from inside outrigger 2. Tag and disconnect the hydraulic hoses from the jack
beam. cylinder. Remove the fittings from the ports. Cap or plug
all openings.
3. Remove the cylinder cap.
4. Place a jack capable of supporting the weight of the jack
cylinder at the base of the cylinder barrel. Jack up the
cylinder just enough to relieve any pressure on the cylin-
der retaining pin.
5. Remove the cotter pins securing the cylinder retaining
pin and remove the cylinder retaining pin and cylinder
cap retaining bracket.
6. Jack the jack cylinder up just enough to insert the retain-
ing pin back into the cylinder. Insert the retaining pin into
the lugs on the cylinder and secure the pin in place with
1
the cotter pins.

CAUTION
Use a nylon strap to remove the cylinder. This will ensure
7554-2 the retaining pin is not damaged.
FIGURE 8-35

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RT890E SERVICE MANUAL UNDERCARRIAGE

7. Fasten a nylon strap onto the cylinder retaining pin and Checking Cylinder for Internal Piston Seal Leak
use an adequate lifting device to lift the jack cylinder out
1. Fully extend and set the outriggers.
of the tube on the beam assembly.
Installation
1. Apply grease (EPMPG) to the ID of the jack cylinder
support tube. Piston Port

2. If removed, install wear ring in groove in bottom of sup- Rod Port

port tube and in groove at top on jack cylinder.
3. Place a jack beneath the cylinder tube on the outrigger
beam. Using the same method as described under
Removal, lower the jack cylinder into the cylinder tube
on the outrigger beam until the retaining pin is just above
the tube. Position the jack so that it will support the cylin-
der in this position. Remove the lifting device from the
cylinder.
4. Remove the retaining pin and cotter pins from the cylin-
der.
5. Lower the jack until the holes in the cylinder rod align
with the holes in the outrigger beam. 6432

6. Apply anti-seeze compound to the retaining pin. Secure

8
the cylinder and cylinder cap retaining bracket to the FIGURE 8-36
support tube with the retaining pin and cotter pins.
27
7. Install the cylinder cap.
CAUTION
8. Install the fittings in the cylinder ports and connect the
When performing step number 2, remove hose to adapter
2
hoses as tagged during removal.
connection slowly. Trapped pressure may exit between
Functional Check the outrigger cylinder and the work port pilot operated
23

check valves in the outrigger selector valve.

1. Activate the hydraulic system.
2. Extend and retract the jack cylinder. 2. Remove the rod side cylinder hose from the suspected
leaking jack cylinder (see Figure 8-36). Oil will flow until
3. Check for smooth operation of the cylinder.
the cavity in the cylinder port block empties. Once the
4. Check all hydraulic connections and hoses for evidence port block cavity empties, oil should stop flowing from
of leakage. the rod side port.
Outrigger Jack Cylinder Internal Leak Test Check for the following conditions:
Use the following procedure to troubleshoot and diagnose an a. If oil stops flowing, the cylinder’s internal piston seal
internal leak, a leaking pilot operated check valve or a is sealing properly.
thermal contraction on an outrigger jack cylinder.
b. If oil continues to flow out the rod port, the cylinder’s
internal piston seal is leaking. 8
3. After determining the condition of the cylinders internal
DANGER piston seal, leave the rod side hose disconnected and
continue to test the pilot operated check valve.
Perform the following procedures with the crane
positioned on a firm level surface with outriggers fully
extended and set, and the crane in the travel position
Remove hoses from one cylinder at a time.

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UNDERCARRIAGE RT890E SERVICE MANUAL

Testing Pilot Operated Check Valve For Leakage outrigger portion of the valve consists of a 4-way two position
solenoid valve. The inlet section contains the main relief
1. Fully extend and set the outriggers.
valve.
Outrigger Control Manifold
CAUTION
The front and rear outrigger control manifolds are located
When performing step number 2, remove hose to adapter on the respective outrigger boxes. Each manifold consists of
connection slowly. Trapped pressure may exit between four 12 volt solenoid valves and an assembly mounting kit.
the outrigger cylinder and the work port pilot operated
check valves in the outrigger selector valve.
OPTIONAL EQUIPMENT
2. Remove the piston side cylinder hose from the sus- This section is provided to give a brief description of the
pected leaking jack cylinder (see Figure 8-27). Oil will optional equipment available for the crane which is not
flow until the cavity in the cylinder port block empties. discussed elsewhere within this service manual.
Once the port block cavity empties, oil should stop flow-
ing from the piston side port. Pintle Hook
a. If oil stops flowing, the cylinder’s pilot operated A conventional pintle hook with safety pinned latch can be
check valve is sealing properly. installed on the front and/or back of the crane. It is bolted
b. If oil continues to flow out the piston port, the onto a plate which is welded onto the front or rear outrigger
cylinder’s pilot operated check valve is leaking. boxes of the crane.

If oil flow is not noticed from either port, the cylinder and pilot Secondary Front Steer (CE Option)
operated check valve are functioning properly, and any
A secondary front steering system for the CE option consists

8
cylinder contraction during normal operation can be
attributed to thermal contraction of the oil. of a hydraulic pump, load sense steer priority flow divider
27
valve (part of the swing directional control valve), load sense
Outrigger Control Valves steering control valve, two steer cylinders, dual accumulator
charge valve, pressure switches, pilot operated valve and
Description two accumulators.
2

There are four valve assemblies responsible for controlling The hydraulic pump is driven by the engine and supplies
23

the outrigger system, the integrated outrigger/rear steer hydraulic flow to the load sense steering priority flow divider.
valve, the front and rear outrigger control manifolds, and the The load sense steer priority flow divider valve provides flow
pilot operated check valves. to the load sense steering control valve. When the steering
wheel is turned, the load sense steering control valve sends
NOTE: For a more detailed description and maintenance
a load sense signal to the load sense steer priority flow
of the valves, refer to Valves, page 2-31.
divider. As the load sense pressure increases, the priority
Pilot Operated Check Valve flow divider spool shifts to direct oil from the hydraulic pump
to the steering control valve, and to direct oil from the L port
The pilot operated check valves are located in the outrigger and R port of the steering control valve to the front steer
jack port blocks. The check valve provides two functions; the cylinders.
first function is a holding valve, the second function provides
a thermal relief of the jack. The two accumulators allow for emergency steering should
there be a loss of hydraulic pressure.
Integrated Outrigger/Rear Steer Valve
The integrated outrigger/rear steer valve is mounted on the
rear face of the carrier frame front cross member. The

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RT890E SERVICE MANUAL LUBRICATION

SECTION 9
LUBRICATION

SECTION CONTENTS
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 Turntable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16
Environmental Protection . . . . . . . . . . . . . . . . . . . 9-1 Cab Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-18
Outriggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-20
Lubricants and Lubrication Intervals . . . . . . . . . . 9-1
Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-22
Standard Lubricants . . . . . . . . . . . . . . . . . . . . . . . 9-2
Boom (continued) . . . . . . . . . . . . . . . . . . . . . . . . 9-24
Arctic Lubricants and Conditions . . . . . . . . . . . . . 9-3
Boom (continued) . . . . . . . . . . . . . . . . . . . . . . . . 9-26
Surface Protection for Cylinder Rods . . . . . . . . . . 9-5
Hoist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-28
Wire Rope Lubrication . . . . . . . . . . . . . . . . . . . . . . 9-6
Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-30
Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . 9-7 Accessing Boom Lubrication Points . . . . . . . . . . 9-32
CraneLUBE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
Carwell® Rust Inhibitor. . . . . . . . . . . . . . . . . . . . . 9-33
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
Protecting Cranes From Rusting . . . . . . . . . . . . . 9-33
Steering and Suspension . . . . . . . . . . . . . . . . . . . 9-8 Cleaning Procedures . . . . . . . . . . . . . . . . . . . . . . 9-33
Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10 Inspection and Repair . . . . . . . . . . . . . . . . . . . . . 9-34
Drive Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12
Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-34
Drive Train (continued) . . . . . . . . . . . . . . . . . . . . 9-14

8
27 Areas of Application. . . . . . . . . . . . . . . . . . . . . . . 9-34

GENERAL • Do not pour waste fluids onto the ground, down any
2

drain, or into any source of water.

Following the designated lubrication procedures is important
23

in ensuring maximum crane lifetime and utilization. The • Always drain waste fluids into leak proof containers that
procedures and lubrication charts in this section include are clearly marked with what they contain.
information on the types of lubricants used, the location of • Always fill or add fluids with a funnel or a filling pump.
the lubrication points, the frequency of lubrication, and other
information. • Immediately clean up any spills.

ENVIRONMENTAL PROTECTION LUBRICANTS AND LUBRICATION

INTERVALS
Dispose of waste properly! Improperly disposing of waste
can threaten the environment. The service intervals specified are for normal operation
where moderate temperature, humidity, and atmospheric
Potentially harmful waste used in Manitowoc cranes includes
conditions prevail. In areas of extreme conditions, the
— but is not limited to — oil, fuel, grease, coolant, air
service periods and lubrication specifications should be
conditioning refrigerant, filters, batteries, and cloths which
altered to meet existing conditions.
have come into contact with these environmentally harmful
substances. For information on extreme condition lubrication, contact
your local Manitowoc Cranes distributor or Manitowoc Crane
Handle and dispose of waste according to local, state, and
Care.
federal environmental regulations.
NOTE: All fluids and lubricants may be purchased by
When filling and draining crane components, observe the
following:
contacting an authorized Manitowoc distributor or 9
Manitowoc Crane Care Parts Department.

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LUBRICATION RT890E SERVICE MANUAL

Standard Lubricants
CAUTION Standard lubricants are used on all Manitowoc cranes unless
the crane is ordered with a cold weather package. These
Possible Equipment Damage!
standard lubricants are effective in temperatures down to
Chassis grease lubricants must not be applied with air -9°C (15°F). Refer to Table 9-1 for a list of the recommended
pressure devices as this lubricant is used on sealed standard lubricants.
fittings.
The multipurpose grease applied during manufacturing is
of a lithium base. Use of a noncompatible grease could
result in damage to equipment.

Table 9-1: Standard Lubricants [Down to -9°C (15°F)]

Recommended Lubricant
Lubricant/Fluid Grove Spec.
Type Grade Classification
Axle Gear Oil Century Unigear Semi-synthetic
6829012964 Texaco Multigear SS 80W-90
Chevron DELO
Tier 3 Engine Oil Exxon XD-3 CI-4
6829003483 15W-40
Conoco Fleet Supreme

8
Tier 4 Engine Oil Conoco Fleet Supreme EC CJ-4
6829104182 15W-40
Mobil Delvac 1300 Super
27
Hydraulic/Transmission Oil Kendall Hyken 052 Must Meet John
Exxon Torque Fluid 56 Deere Std. JDM
Esso Torque Fluid 56 10W-20 J20c
6829006444
2
BP-Eldoran UTH & Trak-Tran 9
BP- Blend- 7367
23

Exxon Mobil 424 10W-30

Hoist Gear/Swing Drive Oil Mobil: Mobilfluid 629 AGMA No. 4 EP
6829100213
Texaco: Meropa 150
Grease, Multipurpose Citgo Lithoplex MP# 2
Texaco Starplex Moly # 2
Phillips 66 Philube M
6829003477 NLGI 2
Mobil Mobilgrese XHP 222 Spe-
cial
Chemtool Inc, Lube-A-Boom
Open Gear Lube 6829102971 Fuchs Ceplattyn 300 Spray NLGI 1-2
Antifreeze Coolant Old World Industries, Inc. Fleet
Charge SCA
6829101130 Mix 50/50
Caterpillar DEAC
Fleetguard Complete EG
Supplemental Coolant Fleetguard DCA4
Additive (SCA) 6829012858 Fleetguard DCA2
Penray Pencool 3000

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RT890E SERVICE MANUAL LUBRICATION

Arctic Lubricants and Conditions • Fan clutch

• Radiator air shutters
Temperatures Below -9°C (15°F)
• Air diverter
Regions with ambient temperatures below -9°C (15°F) are
considered arctic. In general, petroleum based fluids • Diesel fired cab heater
developed especially for low temperature service may be
used with satisfactory results in these temperatures. • Cold weather alternator
However, certain fluids, such as halogenated hydrocarbons, • Fluids suitable to -29°C (-20°F)
nitro hydrocarbons, and phosphate ester hydraulic fluids,
may not be compatible with hydraulic system seals and wear - Arctic windshield washer fluid
bands. Therefore, always check with an authorized - Arctic fuel
Manitowoc distributor or Manitowoc Crane Care if in doubt of
the suitability of a specific fluid or lubricant. -40°C (-40°F) Package

When operating in cold weather and regardless of the oil • Coolant heater (to circulate warm coolant through
viscosity of the crane’s lubricants, always follow the cold heaters and engine)
weather start-up and operating procedures described in the • Transmission heater
Operator Manual to ensure adequate lubrication during
system warm-up and proper operation of all crane functions. • Swivel heater
• Battery heater
Cold Weather Package and Lubricants
• Fuel heater
Manitowoc recommends the following cold weather
lubricants for use with ambient temperatures down to -29°C • Hydraulic reservoir heater

8
(-20°F) (Table 9-2) and -40°C (-40°F) (Table 9-3). But, these
• Engine hood insulation
cold weather lubricants alone are not sufficient to operate the
27
crane in extreme low temperatures. Therefore, it is also • Fan clutch
recommended that the crane be equipped with the following
accessories: • Radiator shutters
• Air diverter
2
--29°C (-20°F) Package
• Transmission heater • Diesel fired cab heater
23

• Swivel heater • Cold weather alternator

• Battery heater • Super-capacitor starting system

• Fuel heater • Fluids suitable to -40°C (-40°F):

• Engine hood insulation - Arctic windshield washer fluid

- Arctic fuel

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LUBRICATION RT890E SERVICE MANUAL

Table 9-2: Cold Weather Lubricants [Down to -29°C (-20°F)]

Recommended Lubricant
Lubricant/Fluid Grove Spec.
Type Grade Classification
Axle Gear Oil Petro-Canada Traxon E Syn-
thetic
CITGO, Syntetic Gear Lube
6829014058 Eaton, Roadranger EP 75W-90
Mobil, Mobilube SCH
Shell, Spirax S
Sunoco Duragear EP
Tier 3/Tier 4 Engine Oil Shell Rotella® T6 CJ-4
Mobil Delvac 1 ESP
80056036 0W-40
Caterpillar Cat DE0-ULS Cold
Weather
Transmission Oil Petro-Canada Duratran Syn- Must Meet John
thetic THF Deere Std. JDM
6829101559 J20c & J20d
Chevron All Weather THF

8
Texaco TDH Oil SS
Hoist Gear/Swing Drive Oil Petro-Canada ENDURATEX AGMA No. 4 EP
27
6829103636 Synthetic EP 150
Mobil SHC629
2
Grease, Multipurpose Petro-Canada Precision Syn-
6829104275 thetic EP1 NLGI 2
23

Mobil, Mobilith SHC 220

Open Gear Lube 6829102971 Fuchs Ceplattyn 300 Spray NLGI 1-2
Antifreeze Coolant Old World Industries, Inc. Fleet
Charge SCA Mix
6829101130
Caterpillar DEAC 50/50
Fleetguard Complete EG
Supplemental Coolant Fleetguard DCA4
Additive (SCA) 6829012858 Fleetguard DCA2
Penray Pencool 3000
Hydraulic Oil 6829006993 Exxon Mobil Univis HVI 26
Windshield Washer fluid 90037773 Splash De-icer
Diesel Fuel NOCO Kerosene, 3, UN1223, III NLOCK08
80069407 #1
Product #1

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RT890E SERVICE MANUAL LUBRICATION

Table 9-3: Cold Weather Lubricants [Down to -40°C (-40°f)]

Recommended Lubricant
Lubricant/Fluid Grove Spec.
Type Grade Classification
Axle Gear Oil Petro-Canada Traxon E Syn-
thetic
CITGO, Syntetic Gear Lube
6829014058 Eaton, Roadranger EP 75W-90
Mobil, Mobilube SCH
Shell, Spirax S
Sunoco Duragear EP
Tier 3/Tier 4 Engine Oil Shell Rotella® T6 CJ-4
Mobil Delvac 1 ESP
80056036 0W-40
Caterpillar Cat DE0-ULS Cold
Weather
Transmission Oil Petro-Canada Duratran Syn- Must Meet John
thetic THF Deere Std. JDM
6829101559 J20c & J20d
Chevron All Weather THF

8
Texaco TDH Oil SS
Hoist Gear/Swing Drive Oil Petro-Canada ENDURATEX AGMA No. 4 EP
27
6829103636 Synthetic EP 150
Mobil SHC629
2
Grease, Multipurpose Petro-Canada Precision Syn-
6829104275 thetic EP1 NLGI 2
23

Mobil, Mobilith SHC 220

Open Gear Lube 6829102971 Fuchs Ceplattyn 300 Spray NLGI 1-2
Antifreeze Coolant Old World Industries, Inc. Fleet
Charge SCA Pre-charged Mix
6829104212
Fleetguard Compleat EG 60/40
Petro-Canada
Supplemental Coolant Fleetguard DCA4
Additive (SCA) 6829012858 Fleetguard DCA2
Penray Pencool 3000
Hydraulic Oil 6829006993 Exxon Mobil Univis HVI 26
Windshield Washer fluid 90037773 Splash De-icer
Diesel Fuel 80069407 NOCO Kerosene, 3, UN1223, III #1 NLOCK08

Surface Protection for Cylinder Rods cracks and if machines are operated daily, protect the rods.
Machines that are stored, transported, or used in a corrosive
Steel cylinder rods include a thin layer of chrome plating on
their surfaces to protect them from corroding. However,
environment (high moisture, rain, snow, or coastline 9
conditions) need to have the exposed rods protected more
chrome plating inherently has cracks in its structure which frequently by applying a protectant. Unless the machine is
can allow moisture to corrode the underlying steel. At typical operated daily, exposed rod surfaces will corrode. Some
ambient temperatures, hydraulic oil is too thick to penetrate cylinders will have rods exposed even when completely
these cracks. Normal machine operating temperatures will retracted. Assume all cylinders have exposed rods, as
allow hydraulic oil to warm sufficiently to penetrate these corrosion on the end of the rod can ruin the cylinder.

GROVE Published 9-18-2014, Control # 308-06 9-5

LUBRICATION RT890E SERVICE MANUAL

It is recommended that all exposed cylinder rods be WIRE ROPE LUBRICATION

protected using Boeshield® T-9 Premium Metal Protectant.
Manitowoc Crane Care has Boeshield® T-9 Premium Metal Wire rope is lubricated during manufacturing so that the
Protectant available in 12 oz. cans by ordering part number strands, and individual wires in strands, may move as the
9999101803 through the Manitowoc Crane Care Parts rope moves and bends. A wire rope cannot be lubricated
Department. sufficiently during manufacture to last its entire life.
Therefore, new lubricant must be added periodically
NOTE: Cylinder operation and inclement weather will throughout the life of a rope to replace factory lubricant which
remove the Boeshield® protectant; therefore, is used or lost. For more detailed information concerning the
inspect machines once a week and reapply lubrication and inspection of wire rope, refer to WIRE ROPE
Boeshield® to unprotected rods. in Section 1- INTRODUCTION in the Service Manual.

8
2 27
23

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RT890E SERVICE MANUAL LUBRICATION

LUBRICATION POINTS Unless otherwise indicated, items not equipped with grease
fittings, such as linkages, pins, levers, etc., should be
A regular frequency of lubrication must be established for all lubricated with oil once a week. Motor oil, applied sparingly,
lubrication points. Normally, this is based on component will provide the necessary lubrication and help prevent the
operating time. The most efficient method of keeping track of formation of rust. An Anti-Seize compound may be used if
lube requirements is to maintain a job log indicating crane rust has not formed, otherwise the component must be
usage. The log must use the engine hourmeter to ensure cleaned first.
coverage of lube points that will receive attention based on
their readings. Other lubrication requirements must be made Grease fittings that are worn and will not hold the grease
on a time basis, i.e. weekly, monthly, etc. gun, or those that have a stuck check ball, must be replaced.

All oil levels are to be checked with the crane parked on a Where wear pads are used, cycle the components and
level surface in transport position, tires on the ground, and relubricate to ensure complete lubrication of the entire wear
the suspension set at the proper ride height. area.

Lubrication checks must be performed while the oil is cool CraneLUBE

and has not been operated within the past 30 minutes,
unless otherwise specified. Manitowoc highly recommends the use of CraneLUBE
l u b r i c a n ts t o i n c r e a s e y o u r c r a n e ’s r e l i a b i l i t y a n d
On plug type check points, the oil levels are to be at the performance. Contact your Manitowoc Distributor for
bottom edge of the fill plug hole. information about the Manitowoc’s CraneLUBE lubrication
On all hoists with a check plug in the drum, the fill plug shall program.
be directly on top of the hoist, and the check plug level.
Safety
All grease fittings are SAE STANDARD unless otherwise

8
indicated. Grease non-sealed fittings until grease is seen To lubricate many of the locations the engine will need to be
extruding from the fitting. One ounce(28 grams) of EP-MPG started. After positioning areas of the unit for lubrication the
27
equals one pump on a standard one pound (0.45 kg) grease engine must be turned off and the moved areas stable before
gun. approaching.

Over lubrication on non-sealed fittings will not harm the

2
fittings or components, but under lubrication will definitely
lead to a shorter lifetime.
WARNING
23

On sealed U-joints, care must be exercised to prevent Movement of the superstructure and the boom may
rupturing seals. Fill only until expansion of the seals first create a crushing and/or pinching hazard. Failure to
becomes visible. observe this warning could result in death or serious injury
if the message is ignored.

GROVE Published 9-18-2014, Control # 308-06 9-7

LUBRICATION RT890E SERVICE MANUAL

Steering and Suspension

Lube Point Figure Approved Lube
Item Lube Interval Application
Description No. Lubricant Capacity
EP-MPG
Extreme
Until
Steer Cylinder Pressure
1 Figure 9-1 grease 500 hours or 3 months 8 grease fittings
Pivot Pins Multipurpose
extrudes
Grease
6829003477
EP-MPG
Extreme
Until
Upper and Lower Pressure
2 Figure 9-1 grease 500 hours or 3 months 8 grease fittings
King Pins Multipurpose
extrudes
Grease
6829003477
EP-MPG
Extreme
Until
Fifth Wheel Pressure
3 Figure 9-1 grease 500 hours or 3 months 2 grease fittings
Pivots Multipurpose
extrudes
Grease

8
6829003477
EP-MPG
27
Extreme
Until
Lockout Cylinder Pressure
4 Figure 9-1 grease 500 hours or 3 months 4 grease fittings
Pivot Pins Multipurpose
extrudes
2
Grease
6829003477
23

EP-MPG
Extreme
Until
Tie Rod Pivot Pressure 4 grease fittings per
5 Figure 9-1 grease 500 hours or 3 months
Pins Multipurpose wheel
extrudes
Grease
6829003477

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RT890E SERVICE MANUAL LUBRICATION

1
5 7061-4
2
7061-22

8
2 27
23

7693-1

1 7061-7
9
7061-10
3

FIGURE 9-1

GROVE Published 9-18-2014, Control # 308-06 9-9

LUBRICATION RT890E SERVICE MANUAL

Lube Point Figure Approved Lube

Item Lube Interval Application
Description No. Lubricant Capacity
Axles
• Check level every
GL-5 500 hours or 3
Extended months Fill to bottom of hole
52.0 pt
11 Differentials Figure 9-2 Service Interval in housing on the
(24.6 l) • Drain and fill every
Gear Lubricant steer cylinder side
6829012964 4000 hours or 2
years
NOTE: Lube level close enough to the hole to be seen or touched is not sufficient. It must be level with the hole.
When checking lube level, also check and clean housing breathers.
CAUTION: Use of non-approved lubricant may damage components and/or invalidate published lubricant intervals.
CAUTION: If the makeup amount is substantially more than 0.23 liter (0.5 pint), check for leaks.
• Check level every
GL-5 500 hours or 3 Fill to the bottom of
Planetary Hubs Extended months the level hole in the
13.9 pt
12 and Wheel Figure 9-2 Service Interval housing with the fill
(6.6 l) • Drain and fill every
Bearings Gear Lubricant plug and the oil level
6829012964 4000 hours or 2 mark horizontal.
years

8
CAUTION: Use of non-approved lubricant may damage components and/or invalidate published lubricant intervals.
2 27
23

9-10 Published 9-18-2014, Control # 308-06

RT890E SERVICE MANUAL LUBRICATION

11
7061-7

12 7061-22

8
2 27
23

7693-1
7693-1

FIGURE 9-2

GROVE Published 9-18-2014, Control # 308-06 9-11

LUBRICATION RT890E SERVICE MANUAL

Lube Point Figure Approved Lube

Item Lube Interval Application
Description No. Lubricant Capacity
Drive Train
EO-15W/40 • Check level every 10
Engine Oil • Through valve
20a a. Engine hours or daily
SAE 15W-40 cover to FULL
Crankcase 21.1 qt • Drain, fill and replace mark on dipstick
Figure 9-3 Tier 3 Engine -
20 l filter every 250 hours
6829003483 • Filter located
20b b. Filter (500 hours for Tier 4
Tier 4 Engine - under radiator
6829104182 engine)

• Check level every 10

hours or daily
• Drain and refill every
21a a. Transmission,
1000 hours or 6
Torque HYDO Through fill pipe to
40 qt months
Converter Figure 9-3 Hydraulic Oil FULL mark on
37.9 l • Change transmission
Dipstick 6829006444 dipstick
21b b. Filter filter after first 50 and
100 hours of service,
then every 500 hours
thereafter

8
NOTE:
27
• Check fluid level with engine running at 1000 rpm idle and the oil at 150 to 200°F (82 to 93°C). Do not attempt an oil level check
with cold oil. To bring the oil temperature to this range, it is necessary to either work the crane or stall the converter. Converter
stall should be accomplished by engaging shift lever in forward high range with the brakes applied and then accelerating the
engine to half or three-quarter throttle. Hold the stall until the required converter temperature is reached and stabilized.
2

Do not operate the converter at stall condition for longer than 30 seconds at one time. Shift to neutral for 15 seconds and repeat
the procedure until the desired temperature is reached. Excessive temperature, i.e, 250°F (120°C) maximum will cause damage
23

to transmission clutches, fluid, converter and seals.

• Drain and fill with the oil at 150 to 200°F (65 to 93°C).
• Transmission filters are located on the outside left hand frame in the area of the hydraulic oil cooler.
• Do not operate the machine in two wheel drive while the machine is up on outriggers. Serious transmission damage could result.
• To add fluid:
a. Fill to FULL mark on dipstick
b. Run engine at 1000 rpm to prime torque converter and lines
c. Check oil level with engine running at 1000 rpm and oil at 180 to 200°F (82 to 93°C). Add oil to bring oil level to
FULL mark on dipstick.
AFC 50/50 • Check coolant level
50/50 Blended in sight glass (22a)
Fully every 10 hours or
a. Engine daily
22 Formulated
Cooling System 37 qt See Water Cooling
Figure 9-3 Antifreeze • Check SCA levels
and SCA Levels 35 l System, page 7-17
22a Coolant every 500 hours
b. Sight Glass 6829101130
• Check coolant for
SCA contamination every
6829012858 1000 hours

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RT890E SERVICE MANUAL LUBRICATION

22

7695
21b 22a 7061-45

8
2 27
23

7693-1

21a 7061-36

7856
20b 20a

FIGURE 9-3

GROVE Published 9-18-2014, Control # 308-06 9-13

LUBRICATION RT890E SERVICE MANUAL

Lube Point Figure Approved Lube

Item Lube Interval Application
Description No. Lubricant Capacity
Drive Train (continued)
Clean strainer screen
Close shutoff valves.
Coolant Strainer after first 100 hours and
23 Figure 9-4 --- --- Unscrew hex plug to
(Cab Heater) every 2000 hours or 12
clean filter.
months thereafter.
• Replace filter
Remove panel
element when
behind ladder to
indicator shows red
access air filter.
24 Air Cleaner Filter Figure 9-4 --- --- (25” H20).
• View indicator
Refer to Service
through grill from rear
Manual
of crane.
• Drain water trap
every 10 hours or
daily. Fuel filter is located
25 Fuel Filter Figure 9-4 --- --- on the top right
• Change filter every frame rail.
500 hours or 6
months.

8
Fuel Water Drain water trap every
25a Figure 9-4 --- --- Beside the fuel tank
Separator 10 hours or daily
27
EP-MPG
Extreme
Until
Driveline - Slip Pressure
26 Figure 9-4 grease 500 hours or 3 months 2 grease fittings
2
Joints Multipurpose
extrudes
Grease
23

6829003477

9-14 Published 9-18-2014, Control # 308-06

RT890E SERVICE MANUAL LUBRICATION

23

7061-37
26 24
Step-Cover Removed

Other Side
26
7116-9

8
2 27
23

6265-1

7693-1

7695-1
25a

9
25 7856

FIGURE 9-4

GROVE Published 9-18-2014, Control # 308-06 9-15

LUBRICATION RT890E SERVICE MANUAL

Lube Point Figure Approved Lube

Item Lube Interval Application
Description No. Lubricant Capacity
Turntable
• Check and fill every
GL-5 50 hours
Extended
Turntable Gear 5.7 qt • Drain and fill after
30 Figure 9-5 Service Interval Full mark on dipstick
Box (5.4 l) first 250 hours and
Gear Lubricant
6829012964 every 500 hours or
12 months thereafter.
EP-OGL
Turntable Gear Open Gear Coat all
31 Figure 9-5 500 hours or 6 months Spray on
and Drive Pinion Lubricant teeth
6829102971
Until
EP-MPG
grease
Extreme
extrudes 2 grease fittings at
Turntable Pressure
32 Figure 9-5 the whole 500 hours or 6 months the side of the
Bearing Multipurpose
circumfer- turntable.
Grease
ence of the
6829003477
bearing

8
NOTE: Rotate the turntable 90° and apply grease to fittings. Continue rotating 90° and grease the fittings until the whole
27
bearing is greased.
EP-MPG
Extreme
Until
2
Pressure
34 Hose Rollers Figure 9-5 grease 250 hours or 3months 2 grease fittings
Multipurpose
extrudes
23

Grease
6829003477

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RT890E SERVICE MANUAL LUBRICATION

30

31 7061-24

32 7061-25

8
2 27
23

7693

34

7116-3
FIGURE 9-5

GROVE Published 9-18-2014, Control # 308-06 9-17

LUBRICATION RT890E SERVICE MANUAL

Lube Point Figure Approved Lube

Item Lube Interval Application
Description No. Lubricant Capacity
Cab Tilt
EP-MPG
Extreme
Until
Cab Tilt Cylinder Pressure
40 Figure 9-6 Grease 500 hours or 3 months 2 grease fittings
Pivot Pins Multipurpose
extrudes
Grease
6829003477
EP-MPG
Extreme
Until
Pressure
41 Pillow Block Figure 9-6 grease 500 hours or 3 months 2 grease fittings
Multipurpose
extrude
Grease
6829003477

8
2 27
23

9-18 Published 9-18-2014, Control # 308-06

RT890E SERVICE MANUAL LUBRICATION

40 7061-18

41 7061-47

8
2 27
23

7693-1

FIGURE 9-6

GROVE Published 9-18-2014, Control # 308-06 9-19

LUBRICATION RT890E SERVICE MANUAL

Lube Point Figure Approved Lube

Item Lube Interval Application
Description No. Lubricant Capacity
Outriggers
EP-MPG
Extreme
Brush lubricant on
Pressure
50 Outrigger Beams Figure 9-7 --- 50 hours or 1 week bottom of outrigger
Multipurpose
beams
Grease
6829003477
EP-MPG Brush lubricant on
Extreme ID of jack cylinder
Jack Cylinder Pressure support tubes (4)
51 Figure 9-7 --- 50 hours or 1 week
Support Tubes Multipurpose places before
Grease installing jack
6829003477 cylinders
EP-MPG Brush lubricant on
Extreme ID of jack cylinder
Jack Cylinder Pressure support tubes (4)
52 Figure 9-7 --- 50 hours or 1 week
Barrels Multipurpose places before
Grease installing jack

8
6829003477 cylinders
2 27
23

9-20 Published 9-18-2014, Control # 308-06

RT890E SERVICE MANUAL LUBRICATION

7693-1

8
2 27
23

51

50

52

9
7061-57

FIGURE 9-7

GROVE Published 9-18-2014, Control # 308-06 9-21

LUBRICATION RT890E SERVICE MANUAL

Lube Point Figure Approved Lube

Item Lube Interval Application
Description No. Lubricant Capacity
Boom
EP-MPG
Extreme Pressure Until
Hook Block
70 Figure 9-8 Multipurpose grease 250 hours or 3 months 1 grease fitting
Swivel Bearing Grease extrudes
6829003477
EP-MPG
Extreme Pressure Until 1 grease fitting per
Hook Block
71 Figure 9-8 Multipurpose grease 250 hours or 3 months sheave (5 fittings
Sheaves Grease extrudes total)
6829003477
EP-MPG
Extreme Pressure Until
72 Headache Ball Figure 9-8 Multipurpose grease 250 hours or 3 months 1 grease fitting
Grease extrudes
6829003477
EP-MPG
Telescope Extreme Pressure 5 places by brush.
Thoroughly
73 Cylinder Wear Figure 9-8 Multipurpose Every boom teardown Extend boom for
Grease coat
Pads access through holes.

8
6829003477 27
! WARNING
Crane Setup for Items 74 - 78: Crane to be set up on firm level surface with fully extended outriggers and 22,000 lb
counterweight installed. Ensure crane is level. Boom must be directly over the front and the swing lock engaged. Set boom
2

angle at zero degrees. Do not exceed 115 ft boom length in auto mode A. Do not exceed 90 ft boom length in auto mode B.
23

All lubrication points can be accessed by operating the crane in the 0001 RCL operating mode by using both A & B boom
configurations. Do NOT operate the crane in the RCL bypass to lubricate the boom.

EP-MPG Thoroughly
Internal Side and 14 places by brush;
Extreme Pressure coat all
Bottom Wear with boom in
74 Figure 9-8 Multipurpose areas the 250 hours or 3 months
Pads (Inner Grease extended position
wear pad
Sections) 6829003477 through access holes
moves on
NOTE: See Table 9-4, page 9-32 at the end of this section for how to access lubrication points 74 - 78
EP-MPG 8 grease fittings; with
Boom Section Extreme Pressure Until
boom in extended
75 Upper Wear Figure 9-8 Multipurpose grease 50 hours or 1 week
Grease position through
Pads extrudes
6829003477 access holes

EP-MPG Thoroughly
Boom Section Extreme Pressure coat all 12 places by brush;
76 Upper and Lower Figure 9-8 Multipurpose areas the 50 hours or 1 week with boom in
Wear Pads Grease wear pad extended position
6829003477 moves on

9-22 Published 9-18-2014, Control # 308-06

RT890E SERVICE MANUAL LUBRICATION

73
72
73
75 74
75

7061-66

73
73
77
71

74 7136-3

70

7116-6

7136-1

8
2 27
23

7693-1

75
76
75

75

75

74

74

74
9
7061-43 74 7136-2

FIGURE 9-8

GROVE Published 9-18-2014, Control # 308-06 9-23

LUBRICATION RT890E SERVICE MANUAL

Lube Point Figure Approved Lube

Item Lube Interval Application
Description No. Lubricant Capacity
Boom (continued)
EP-MPG
Extreme Pressure Until 1 grease fitting. See
Extend Cable
77 Figure 9-8 Multipurpose grease 250 hours or 3 months “Warnings” on
Sheaves Grease extrudes previous page
6829003477
EP-MPG 2 grease fittings
Extreme Pressure Until
Retract Cable (1) on each side.
78 Figure 9-9 Multipurpose grease 250 hours or 3 months
Sheaves Grease
See “Warnings” on
extrudes
6829003477 previous page
EP-MPG
Extreme Pressure Until
2 grease fittings
79 Boom Pivot Shaft Figure 9-9 Multipurpose grease 250 hours or 3 months
Grease
(1) on each side
extrudes
6829003477
EP-MPG
Extreme Pressure Until
Upper Boom 2 grease fittings
80 Figure 9-9 Multipurpose grease 250 hours or 3 months
Nose Sheave Grease (1) per sheave
extrudes

8
6829003477

EP-MPG
27
Extreme
Until 1 grease fitting per
Lower Boom Pressure
81 Figure 9-9 grease 250 hours or 3 months sheave (5 sheaves)
Nose Sheave Multipurpose
extrudes total
2
Grease
6829003477
23

EP-MPG
Extreme
Until
Pressure
82 Hose Rollers Figure 9-9 grease 250 hours or 3 months 4 grease fittings
Multipurpose
extrudes
Grease
6829003477
EP-MPG
Extreme
Until
Auxiliary Boom Pressure
83 Figure 9-9 grease 250 hours or 3 months 1 grease fitting
Nose Sheave Multipurpose
extrudes
Grease
6829003477
EP-MPG
Extreme
Until
Pressure 500 hours or 12
84 Mast Sheave Figure 9-9 grease 1 grease fitting
Multipurpose months
extrudes
Grease
6829003477
EP-MPG
Extreme
Until
Boom Extension Pressure
85 Figure 9-9 grease 250 hours or 3 months 2 grease fittings
Sheaves Multipurpose
extrudes
Grease
6829003477

9-24 Published 9-18-2014, Control # 308-06

RT890E SERVICE MANUAL LUBRICATION

80

7116-1

81
83

79 7061-49

8
2 27
23

7693-1

78
7136-2
9
82 7116-2

FIGURE 9-9

GROVE Published 9-18-2014, Control # 308-06 9-25

LUBRICATION RT890E SERVICE MANUAL

Lube Point Approved Lube

Item Figure No. Lube Interval Application
Description Lubricant Capacity
Boom (continued)
EP-MPG
Extreme
Until
Pressure 500 hours or 12
84 Mast Sheave Figure 9-10 grease 1 grease fitting
Multipurpose months
extrudes
Grease
6829003477
EP-MPG
Extreme
Until
Boom Extension Pressure 250 hours or 3
85 Figure 9-10 grease 2 grease fittings
Sheaves Multipurpose months
extrudes
Grease
6829003477

8
2 27
23

9-26 Published 9-18-2014, Control # 308-06

RT890E SERVICE MANUAL LUBRICATION

7693-1

8
2 27
23

6265-3

85

84

85

9
7061-61 7116-8

FIGURE 9-10

GROVE Published 9-18-2014, Control # 308-06 9-27

LUBRICATION RT890E SERVICE MANUAL

Lube Point Approved Lube

Item Figure No. Lube Interval Application
Description Lubricant Capacity
Hoist
AGMA • Check and fill every
Extreme 50 hours or weekly Oil level must be
15.5 qt
90 Main Hoist Figure 9-11 Pressure Gear • Drain and fill every visible in the sight
(14.7 l)
Lubricant 1000 hours or 12 glass
6829100213 months
AGMA • Check and fill every
Extreme 50 hours or weekly Oil level must be
15.5 qt
91 Auxiliary Hoist Figure 9-11 Pressure Gear • Drain and fill every visible in the sight
(14.7 l)
Lubricant 1000 hours or 12 glass
6829100213 months
NOTE: Line up the Fill/Drain Plug with the upper cutout hole (A). Let hoist sit idle for 20 minutes for an accurate reading.
Ensure hoist is level and oil is within 21°C ±11°C (70°F ±20°F). If oil level is not visible in sight glass, the hoist may
be underfilled. Oil escaping from vent plug is an indication the hoist may be overfilled. If hoist is over filled move
the Fill/Drain Plug to the lower cutout hole (B) and drain until oil level falls within the sight glass.
EP-MPG
Extreme

8
Cable Follower Pressure Thoroughly
92 Figure 9-11 250 hours or 3 months Spray on
(Arms) Multipurpose coat
27
Grease
6829003477
NOTE: Lubricate more frequently than interval indicated in table if environmental conditions and/or operating conditions
2

necessitate.
23

9-28 Published 9-18-2014, Control # 308-06

RT890E SERVICE MANUAL LUBRICATION

91 92 90 92

8
A
2
B
27 A B 7116-10
23

7693-1

FIGURE 9-11

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LUBRICATION RT890E SERVICE MANUAL

Lube Point Approved Lube

Item Figure No. Lube Interval Application
Description Lubricant Capacity
Hydraulic
• Use sight gauge
on side of tank,
HYDO Check fluid level with boom down
236 gal and all outrigger
100 Hydraulic Tank Figure 9-12 Hydraulic Oil every 10 hours or
(894 l) cylinders retracted.
6829006444 daily.
• Drain and refill as
necessary
NOTE:
• Environmental and other conditions can dramatically affect the condition of hydraulic oil and filters. Therefore,
specific intervals for servicing/changing hydraulic oil, filters and hydraulic tank breathers cannot be set.
However, it is imperative for the continued satisfactory performance of cranes that inspections be performed
on the basis of how and where each crane is used. Air borne and ingested contaminants can significantly
reduce the life of oil and the condition of hydraulic oil filters and tank breathers.
• Under normal operating conditions, it is recommended that hydraulic oil, filters and breathers be inspected
and oils sampled at least every 3 to 6 months and more frequently for severe operating conditions. The
inspections should be for air borne and/or ingested particles and water that deteriorate and contaminate the

8
oil (e.g., oil appears “milky” or no longer has a transparent clear to amber color). The return filter by-pass
indicator should be observed daily to determine if the contaminants content may be high. If the indicator
27
reaches the red zone or indicates a by-pass condition, the hydraulic oil must be sampled. The hydraulic tank
breather should also be inspected to assure that it is not restricting air flow into and out of the reservoir.
• To inspect hydraulic oil, fill a small glass container with a sample of reservoir oil and another glass container
2
with fresh oil. Let the samples stand, undisturbed, for one to two hours and then compare the samples. If the
reservoir oil is heavily contaminated with water the sample will appear “milky” with only a small layer of
23

transparent oil on top. If the “milky” appearance was due to air foaming, it will dissipate and the oil should
closely match the fresh oil. Should you have any questions, please contact your local authorized Manitowoc
distributor.
• The hydraulic oil shall meet of exceed ISO #4406 class 17/14 cleanliness level.
HYDO
Change filter when
101 Hydraulic Filter Figure 9-12 Hydraulic Oil --- ---
the indicator is red
6829006444
EP-MPG
Extreme
Until
Hose Reel Pressure 500 hours or 6
102 Figure 9-12 grease 3 Grease fittings
Swivel Joint Multipurpose months
extrudes
Grease
6829003477

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RT890E SERVICE MANUAL LUBRICATION

102

102 7117-41

8
2 27
23

7693-

101

100 7061-29 FIGURE 9-12

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LUBRICATION RT890E SERVICE MANUAL

Accessing Boom Lubrication Points

Refer to the information in Table 9-4 and next to item
numbers 74 - 78 in the lubrication table, which begins on
page 9-22, to lubricate the boom.

Table 9-4Accessing Lubrication Points on Boom

Boom
Boom
Item Boom Section Access Location Length (ft)
Mode
(+/- 0.2 ft)
74 Inner Large hole in center & outer mid A 94.6
74 Inner Large hole in inner mid B 81.2
Multiple
75 Outer mid & fly Small holes on the sides A
Lengths
Multiple
75 Inner mid Small holes on the sides B
Lengths
Multiple
75 Center mid Small holes on the sides B
Lengths
76 Center, outer mid & fly External on the boom A 114

8
76 Inner mid External on the boom B 83.3
77 Extend cable sheaves Small hole left side on the front of the outer mid A 79.7
27
78 Retract cable sheaves Small holes at the middle of the center mid A 98.3
2
23

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RT890E SERVICE MANUAL LUBRICATION

CARWELL® RUST INHIBITOR

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

Grove cranes will be treated with a rust inhibitor called • on roads where large quantities of salt or calcium are
Carwell® T32-CP-90. While a rust inhibitor cannot guarantee applied to treat icy and snowy road surfaces;
that a machine will never rust, this product will help protect • in areas that use dust control chemicals;
against corrosion on Grove cranes that are treated with this
• anywhere there are increased levels of wetness -
product.
especially near salt water;
Carwell is a treatment, not a coating. It contains no silicones,
• during prolonged periods of exposure to damp
solvents, CFCs or anything that would be classified as
conditions (e.g., moisture held in mud), where certain
hazardous under OSHA Regulation 29CRF-19-10.1200. The
crane parts may become corroded even though other
product is a liquid blend of petroleum derivatives, rust
parts remain dry; or
inhibitors, water-repelling and water-displacing agents.
• in high humidity, or when temperatures are just above
Special equipment is used to spray a light film onto the entire
the freezing point.
undercarriage and various other areas of each new crane
prior to shipment. When applied the product has a red tint to

8
Cleaning Procedures
allow applicators to view coverage during application. This
red tint will turn clear on its own within approximately 24 To help protect against corrosion of Grove cranes,
27
hours after application. Manitowoc Crane Care recommends washing the crane at
least monthly to remove all foreign matter. More frequent
Once applied, treatment can appear to leave a slightly “oily”
changeling may be needed when operating in harsh
residue on painted surfaces and until the red tinting fades
2
environmental conditions. To clean the crane, follow these
could initially be mistaken for a hydraulic oil leak. While the
guidelines:
product is not harmful to painted surfaces, glass, plastic or
23

rubber, it must be removed using standard steam-cleaning • High pressure water or steam is effective for cleaning
techniques. the crane's undercarriage and wheel housings. Keeping
these areas clean will not only help retard the effects of
This treatment works in various ways: (1) it eliminates the
corrosion, but will also improve the ability to identify
moisture containing salt, dirt and other pollutants by lifting
and removing them from the metal surface; (2) the film potential issues before they grow into larger problems.
creates a barrier to repel further moisture from coming in
contact with the metal; and (3) it penetrates crevices.
In addition to the factory-applied treatment, Grove crane CAUTION
owners must provide proper maintenance and care to help High pressure water can be forced into spaces and
ensure long-term protection of their crane against corrosion. infiltrate beyond seals. Avoid pressure washing in the
This procedure provides information and guidelines to help vicinity of electrical controls, panels, wiring, sensors,
maintain the paint finish on Grove cranes. hydraulic hoses and fittings, or anything that can be
damaged by high pressure cleaning/spraying.
The most common causes of corrosion include the following:
• Road salts, chemicals, dirt, and moisture trapped in the • Rinse the dirt and dust off before washing the crane. Dirt
hard-to-reach areas; can scratch the crane's finish during washing/cleaning.

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

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LUBRICATION RT890E SERVICE MANUAL

• Allow the crane to dry thoroughly. You can accelerate Spots should be touched up with quality paint. Primers tend
drying by using compressed air to remove excess water. to be porous; using a single coat of primer only will allow air
and water to penetrate the repair over time.
NOTE: Polishing and waxing (using an automotive-type
wax) is recommended to maintain the original paint Application
finish.
Depending upon the environment in which a crane is used
Inspection and Repair and/or stored, the initial factory application of Carwell T32-
CP-90 should help inhibit corrosion for up to approximately
• Immediately following cleaning, Manitowoc Crane Care
12 months.
recommends an inspection to detect areas that may
have become damaged by stone chips or minor It is recommended that the treatment be periodically
mishaps. A minor scratch (one that has not penetrated reapplied by the crane owner after that time to help continue
to the substrate surface) can be buffed with an to protect against corrosion of the crane and its components.
automotive-type scratch remover. It is recommended
However, if a crane is used and/or stored in harsh
that a good coat of automotive wax be applied to this
environments (such as islands, coastal regions, industrial
area afterwards.
areas, areas where winter road salt is regularly used, etc.),
• All identified spots and/or areas that have been reapplication of treatment is recommended sooner than 12
scratched through to the metal should be touched up months, e.g., repeat treatment in 6-9 months.
and repaired as soon as possible to prevent flash
• Do not apply to recently primered and painted areas for
rusting. To repair a major scratch (down to bare metal) or
at least 48 hours after paint is properly dried and cured.
minor damage, follow these procedures:
For minor touch up areas a 24 hour period is needed for
NOTE: Manitowoc Crane Care recommends that a cure time before applying treatment.
qualified body repairman prepare, prime and paint

8
NOTE: Unit must be completely dry before applying
any major scratch(es) or minor damage. treatment.
27
• Do not allow product to puddle or build-up on weather
stripping, rubber gaskets, etc. Unit should not have
CAUTION puddles or runs evident anywhere.
To the extent any damage is structural in nature,
2

Manitowoc Crane Care must be contacted and consulted • To ensure proper coverage of treatment, the product
as to what repairs may be required. needs to be fogged on the unit.
23

• Use of pressure pots to apply the treatment to the unit

• For scratches and marks in highly visible areas: being processed is recommended.
• Sand to remove the scratch and feather outward from • Carwell treatment is available in 16 ounce spray bottles
the mark to blend the repair into the original surface. from Manitowoc Crane Care (order part number
Body putty may be applied as necessary to hide the 8898904099).
defect; then sand smooth.
• After application of the treatment is complete, wash or
• Cover all bare metal with a primer that is compatible with clean film residue from lights, windshield, grab handles,
the original paint finish ladders/steps and all access areas to crane, as
• and allow to dry thoroughly. necessary.

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

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

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

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

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RT890E SERVICE MANUAL LUBRICATION

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

8
27
1
4
2

5
23

8
16

15
9
8

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

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LUBRICATION RT890E SERVICE MANUAL

17

8
THIS PAGE BLANK 18
27
19

20
2

12
23

10

5 22 13 21 5 11

7650-16
Figure 9-14

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RT890E SERVICE MANUAL LUBRICATION

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

8
2 27
23

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LUBRICATION RT890E SERVICE MANUAL

8
27
THIS PAGE BLANK
2
23

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RT890E SERVICE MANUAL

Alphabetical Index

2 Speed Swing Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51

Air Intake and Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Auxiliary Boom Nose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
Axle Lockout, Rear Steer and Oil Cooler Fan Motor Control Manifold . . . . . . . . . . . . . 2-63
Axle Oscillation Lockout Cylinder (CE Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-86
Axle Oscillation Lockout Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-83
Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Boom Extension (Additional Equipment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39
Boom Extension and Retraction Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Boom Extensions/Components Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39
Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14
Cab Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-98
Cab Tilt Double Pilot Operated Check Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52
Carwell® Rust Inhibitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-33
Check Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66
Counterweight Pin Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-104
Counterweight Removal Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-101
Counterweight Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Counterweight with Auxiliary Hoist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
Counterweight without Auxiliary Hoist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34

8
Cross Axle Differential Lock Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-70
27
Directional Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35
Drive Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
Dual Accumulator Charge Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54
Dual Rod Telescope Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-76
2

Electronic Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

23

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Environmental Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Front Steer/Swing/Brake Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41
Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
General Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Hoist Drum Rotation Indicator System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Hoist to Boom Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Holding Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57
Hose Reel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
Hydraulic Accumulator Service Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56
Hydraulic Remote Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46
Idler Drum and Cable Follower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Installing the Bi-fold Manual Boom Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Lift Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-73
List of Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Load Sense Dump Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-68
Lubricants and Lubrication Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
Monthly Maintenance Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41
Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31
Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-38
Outrigger Control Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-59

GROVE APL-1
SERVICE MANUAL RT890E

Outrigger Extension Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-92

Outrigger Jack Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-95
Outriggers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27
Park Brake Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-106
Park Brake Solenoid Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-26
Parking Brake Actuator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22
Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
Pilot Operated Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62
Piston Motor and Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Pressure Setting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
Range Shift/Parking Brake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-67
RCL System with Boom Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Rear Axle Oscillation Lockout System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
Rear Steering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
See end of this manual for Alphabetical Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Service Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16
Steer Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-89
Steering Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45
Steering Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
Supply Pressure and Return Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Swing Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Swing Gearbox And Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Swing Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Swing Power Brake Valve With Treadle Pedal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-50

8
Swivels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
27
Tandem Brake Valve with Treadle Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53
Telescope Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
Theory Of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
2

Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Third Wrap Indicator (Optional—Standard on CE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
23

Transmission/torque Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25

Upper Telescope Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-80
Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31
Water Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
Wire Rope Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
Wire Rope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19

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