Manitowoc Boom Trucks, Inc
SECTION 8
MAINTENANCE AND REPAIR
IMPORTANT This section does not contain maintenance
and repair instructions for the truck. Refer to the truck man-
ufacturer’s manual for instructions pertaining to the truck.
SAFETY
Prevent injury to personnel or
damage to crane and property.
Take following precautions when
making maintenance checks, adjustments, or re-
pairs to crane:
–Apply truck parking brakes.
–Lower all loads to ground so wire rope is slack.
–Move all controls to off.
–Disengage power takeoff and turn off engine.
–Attach CAUTION sign to start controls warning per-
sonnel that crane is being serviced and must not be
started.
–Do not stick hands or tools into any hole in boom
sections while power is on or boom sections are
moving.
–Do not perform maintenance, adjustment, or repair
procedures unless authorized to do so. Make sure
all applicable instructions have been read and are
thoroughly understood.
–Do not check for hydraulic leaks with hands. Oil un-
der pressure can penatrate human skin causing se-
rious injury. Oil under pressure can be nearly
invisible; therefore, check for hydraulic leaks with a
piece of cardboard or wood.
–Hydraulic oil is flammible; do not check inside hy-
draulic tank with open flame.
–Do not alter specified flow and pressure settings.
Higher than specified flow and pressure can cause
damage to crane and hydraulic components. Lower
than specified flows and pressures can result in
loss of control.
–Do not weld or burn close to hydraulic lines and
components without first placing a protective cover
over them.
–Do not remove cylinders until working parts are
resting on ground or are securely blocked from
movement.
–Components are heavy. Do not attempt to lift them
by hand; use a chain hoist, jacks, or blocking.
–Do not place crane back into service until all guards
and covers have been securely reinstalled and all
service equipment has been removed.
–This crane has a step and two grab handles for
climbing onto and off pedestal on either side of
crane. Crane owner/user shall provide sturdy lad-
ders for personnel to gain access to components
which cannot be reached either from platform or
from top of flatbed. Do not allow personnel to climb
A Manitowoc Company
onto turret, winch, or top of boom; use a sturdy lad-
der to gain access to these locations.
STORING COMPONENTS
1. Store new components (valves, pumps, motors, cylin-
ders, hoses, tubes, fittings) in a clean, dry indoor location.
2. Do not unpack components or remove port plugs until
the components are needed.
3. Once unpacked, carefully inspect each component for
damage that may have occured during shipping
4. Fittings, hoses, and tubes that are not equipped with
shipping caps or plugs must be carefully cleaned before
they are used. Flush the fittings, hoses, and tubes with
clean hydraulic oil. Then seal all openings until use at as-
sembly.
IMPORTANT Do not use rags to plug openings. Use clean
plastic shipping plugs and caps.
LABELING COMPONENTS AT DISASSEMBLY
1. Before disconnecting wires, hoses, or tubes, tag them
for proper identification at reassembly.
2. Before removing a component (pump, motor, valve,
etc.), match mark its mounting position with relation to the
adja- cent component.
3. Before disassembling any multiple section component
(pump, motor, valve), matchmark the position of each sec-
tion with relation to each other. Do not mix parts from one
section with those from another; keep parts segregated.
4. Before removing shims, tie them together and identify
their location.
CLEANLINESS
1. Before removing a component from the crane, thor-
oughly clean the area around it to prevent dirt from enter-
ing the mating component or the hydraulic system. Cover
all openings with plastic to prevent dirt and water from en-
tering.
2. Carefully clean the area around fittings before discon-
necting hoses and tubes. Install plastic plugs or caps on
the ends of hoses and tubes and the mating ports of all
components to prevent dirt and water from entering.
3. Disassemble components on a clean work bench (free
from dust, dirt, and metal particles).
4. Use tools that are clean and in proper working order.
5. Clean metal parts in nonflammable safety solvent.
Clean rubber parts in warm soap and water lubricate all
parts with clean oil at assembly.
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Manitowoc Boom Trucks, Inc

TORQUE VALUES MAINTENANCE CHECKS

The torque values for fasteners which must be torqued to a
specific value are identified in Table 8-1 and shown in Fig-
ure 8-2.
Loose or improperly torqued
subframe mounting studs and
slewing ring mounting bolts will
cause studs or bolts to fail, possibly allowing crane
to come off truck.
IMPORTANT Observe following precautions when install-
ing fasteners; failing to do so will seriously weaken attach-
ment.
– Make sure each fastener is of correct size, length, and
grade; if in doubt, refer to parts pages for specifications.
– Do not interchange grade 5 fasteners with grade 8 fasten-
ers and vice versa (see Figure 8-1 for identification).
– Use grade 8 nuts (see Figure 8-1) with grade 8 bolts.
– Use hardened flat washers under head of screws and un-
der each nut of bolts and studs.
– Make sure threads are clean and free of burrs.
– Torque fasteners to proper torque values; semiannually
check items 1 through 5, Table 8-1.
– Use a torque wrench which is properly calibrated. Check
calibration of torque wrench on a regular basis.
NOTE Use grade 2 nuts with grade 5 bolts. Grade 2 nuts
do not have any grade marking.
GENERAL
Following is a list of preventive maintenance checks which
should be made to maintain the safety, dependability, and
productivity built into this crane.
INTERVALS
The intervals given are provided as a guide only. Follow
these intervals until adequate experience is gained to es-
tablish intervals which meet your operating conditions.
Any increase or decrease in the intervals shall be pre-
ceded by a complete analysis of how the crane is perform-
ing. Carefully study previous maintenance and repair
records before making any changes in the intervals.
RECORDS
Dated and signed records of all defects and repairs shall
be kept on file so future maintenance needs can be fore-
casted.
REPAIRS
Any hazardous or abnormal conditions found while making
the maintenance checks shall be corrected before the
crane is placed back into service. All adjustments and
repairs shall be made by authorized personnel only.
NOTE Maintenance checks which require the engine to
be running and the power takeoff to be engaged
are identified with a bold dot (•). Take every pre-
caution to prevent injury from moving parts
when power is on

Table 8-1 Torque Values

Item Torque
Figure 8-2 Identification Size Grade (ft-lbs)
1 Pedestal Mounting Studs 1 - 8 UNC 5 440
2 Stabilizer Mounting Studs 1 - 8 UNC 5 440
3 Slewing Ring Mounting Bolts ¾ - 10 UNC 5 250
4 Swing Reducer Mounting Bolts ¾ - 10 UNC 5 280
5 Swing Motor Mounting Studs ½ - 13 UNC 5 55
6 Winch Mounting Bolts ¾ - 10 UNC 5 200
7 Telescope Manifold Mounting Bolts ½ - 13 UNC 5 78
8 Winch Motor Mounting Bolts ½ - 13 UNC 5 55
9 Pump Mounting Screws ½ - 13 UNC 5 55

Figure 8-1 Grade Markings

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1
4
5 9
6
Figure 8-2 Fasteners
DAILY CHECKS
1. Perform the daily lube services.
2. Clean all debris and dirt from the crane.
3. Check for oil leaks.
4. Check that all guards, covers, stairs, and platforms are
securely in place.
5. Check the entire crane for obvious signs of damage.
6. Check the wire rope for obvious signs of wear and dam-
age.
7. Check the wire rope for proper spooling on the winch
drum and proper reeving through all sheaves. Check that
all sheaves turn freely.
8. Make sure the load line is properly fastened to the load
block or the overhaul ball.
9. Check that all slings and other loose gear that will be
used to make lifts are safe for operation.
10. Check the load block or the overhaul ball (whichever is
being used) for loose or missing nuts, screws, and cotter
pins.
11. Check that the hook has a hook latch and that the hook
latch operates properly.
12. Check that the Capacity Chart is present at the control
station.
· 13. Test the anti-two block/overload warning horn as fol-
lows:
a) Start the truck engine and engage the power takeoff.
A Manitowoc Company
Manitowoc Boom Trucks, Inc
3-Outer Ring
3-Inner Ring
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b) Lift the anti-two block weight by hand so the chain is
slack.
c) The warning horn should sound (beep) and the
WINCH UP and TELESCOPE OUT functions should
be inoperable.
d) Release the weight so it hangs freely. The warning
horn should go off and the WINCH UP and TELE-
SCOPE OUT functions should be operable.
· 14. Test the overload warning horn and, if equipped, the
shutdown device, as follows:
a) Slowly raise the boom to its maximum angle (80°).
The warning horn should sound.
b) If equipped with overload shutdown, the BOOM
DOWN, WINCH UP, and TELESCOPE OUT func-
tions should be inoperable.
c) If equipped with overload shutdown, hold in the boom
down bypass button. Try to lower the boom; it should
lower and the warning horn should shut off. Release
the button once the boom starts to lower. The boom
should continue to lower.
· 15. Test the Load Moment Indicator.
See Pre-Operation Inspections section in separate
Operator’s Manual for daily routine to be performed.
· 16. Check for proper operation of the engine and power
takeoff controls.
· 17. Check for proper operation of all accessory devices
(horn, gauges, lighting systems, etc.).
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 Manitowoc Boom Trucks, Inc
· 18. Check for proper operation of each crane function in re-
sponse to control lever movement.
When any control lever is returned to off, the correspond-
ing function must come to a complete stop and remain in
position.
· 19. Check that all boom sections extend and retract
equally.
20. Check the condition of the truck tires and make sure
they are inflated to the proper pressure.
21. Check for proper operation of the truck parking brake.
22. Remove all rust, corrosion and dirt from the oil cooler
core (if equipped) to ensure proper heat transfer. If neces-
sary, steam clean the core.
NOTE The oil cooler fan comes on only when the temper-
ature of the hydraulic oil rises to 160°F.
WEEKLY CHECKS
1. Perform the daily and weekly lube services.
2. Perform the daily maintenance checks.
3. Check all mechanical control linkage for excessive wear
and binding; oil the linkage as required.
4. Clean the vent plug on the winch.
5. Check for missing bolts, pins, keeper plates, retaining
rings, and cotter pins.
6. Check the winch drum and all sheaves for excessive
wear, cracks, or other damage.
7. Check the boom angle indicators for accuracy over their
full range of operation.
8. Check Load Moment Indicator. See separate owner’s
handbook under Service and Maintenance for weekly
check routine to be performed
MONTHLY CHECKS
1. Perform the daily, weekly, and monthly lube services.
2. Perform the daily and weekly maintenance checks.
3. Check the boom and all structural components of the
crane for deformed, cracked or corroded members. Pay
close attention to all welds.
4. Clean, prime, and paint any rusted surfaces.
5. Thoroughly inspect the wire rope for damage.
6. Check that the hook and hook housing on the load block
and the swivel on the overhaul ball rotate freely without ex-
cessive play. Faulty operation indicates faulty bearings or
inadequate lubrication.
7. Check the load block or the overhaul ball for signs of
overloading: spread side plates, elongated holes, bent or
elongated tie bolts, and cracks.
8. Check the gap between the shank and the barrel of the
swivel on the overhaul ball. The gap must not exceed 1/16
inch.
9. Carefully check the hook on the load block or the over-
haul ball for signs of distortion or cracks.
IMPORTANT Hooks shall be discarded if cracks exist or if
throat opening is 15% more than original throat opening.
8-4 A Manitowoc Company
Hook shall also be discarded if bent or twisted more than
10° from plane of normal configuration.
10. Check that the wire rope clip is tight at the dead end
wedge socket.
11. Retighten the fasteners for the subframe, the slewing
ring, the swing reducer, and the winch to the specified
torque values.This is an initial service only (see Semian-
nual Checks).
12. Inspect all electric wiring and devices for malfunctioning,
signs of deterioration, and dirt or moisture accumulation.
13. Inspect all hydraulic hoses and tubes for the following:
– Evidence of excessive scrubbing or abrasion on the outer
surface of hoses, tubing, and fittings.
– Dented, kinked or cracked tubing.
– Evidence of leakage at the surface of hoses caused by
blistering or abnormal deformation of the outer cover.
– Leakage at threaded, clamped, or welded connections.
14. Check the hydraulic pumps and motors for the following:
– Loose bolts or fasteners.
– Leaks at joints between sections.
– Shaft seal leaks.
– Unusual noise and vibrations.
– Loss of operating speed or pressure.
– Excessive heating of the oil.
15. Check the hydraulic valves for the following:
– Cracks in the valve housings.
– Leaks at the spools or between the sections.
– Sticking spools.
16. Check the hydraulic cylinders for the following:
– Drift caused by internal leakage.
– Rod seal leakage.
– Leaks at welded joints.
– Scored, nicked, or dented cylinder rods.
– Dented case (barrel).
– Loose or deformed rod eyes or connecting joints.
· 17. Check the adjustment of the crowd rope system in the
boom. This is an initial service only; see Semiannual
Checks.
18. Check that all nameplates and decals are readable and
securely attached at the proper locations on the crane.
19. Check the levers at each control station for proper ad-
justment.
SEMIANNUAL CHECKS
1. Perform the daily, weekly, and monthly lube services.
2. Perform the daily, weekly, and monthly maintenance
checks.
3. Tighten all fasteners on the crane. Tighten those fasten-
ers which require torquing to the specified value (including
slewing ring bolts).
 Manitowoc Boom Trucks, Inc

· 4. Check the adjustment of the crowd rope system in the filled with lubricant to provide a complete seal. Use one of
boom. the methods shown in Figure 8-3 to lubricate the wire rope.
For maximum penetration, the lubricant should be applied
5. Check the boom slider pads for wear and proper adjust- where the wire rope “opens up” as it travels around a
ment. sheave or winds onto the drum.
· 6. Check relief valve settings for all crane functions. The wire rope must be clean and dry before applying the lu-
ANNUAL CHECKS bricant; an air jet, steam, and a wire brush are some clean-
ing methods.
1. Perform the daily, weekly, monthly, and semiannual
lube services. INSPECTION
2. Perform the daily, weekly, monthly, and semiannual How Often
maintenance checks. It is impossible to predict when a wire rope will break; how-
3. Check each hook for cracks using a nondestructive test. ever, regular careful inspection will indicate when the po-
tential for breakage exists.
WIRE ROPE MAINTENANCE The wire rope shall be visually inspected by a qualified per-
son for obvious signs of gross damage once each work
LUBRICATION shift.
New wire rope is lubricated during manufacturing, but this The entire length of wire rope shall be thoroughly and care-
lubrication is only adequate for initial storage and the early fully inspected by a qualified person once each month.
stages of operation. To prevent the damaging effects of This interval also applies to any rope being placed into ser-
corrosion and to reduce wear, the wire rope must be lubri- vice which has been idle for one month or longer.
cated at regular intervals.
A dated and signed report of the wire rope’s condition at
The lubrication interval and the type of lubricant to be used each inspection interval shall be kept on file at all times.
depend on the type of wire rope, the severity of duty, and The data on these reports can then be used to determine
the type of corrosive elements the wire rope is subjected when the wire rope needs to be replaced.
to; therefore, contact the nearest wire rope dealer for lubri-
cation recommendations. When inspecting the wire rope, pay particular attention to
the condition of the wire rope in the following areas:
The wire rope must be properly protected at all times;
therefore, the gaps between the strands and wires must be 1. PICK-UP POINTS – sections of wire rope that are re-
peatedly stressed during each lift, such as those sections
in contact with sheaves.
2. END ATTACHMENTS – the point where a fitting is at-
tached to the wire rope, or the point where the wire rope is
attached to the drum.
Bathing 3. ABUSE POINTS – points where the wire rope is sub-
jected to abnormal scuffing and scraping.
Replacement
No precise rules can be given for determining when to re-
place a wire rope. Wire rope replacement depends upon
the good judgement of the qualified person making the in-
Casing
Filled with spection and upon comparison of the data recorded on
Swab and Pouring previous inspection reports. Any deterioration resulting in
Lubricant onto Slow an appreciable loss of wire rope strength, such as listed
Moving
Sheave below, shall be sufficient cause for removing the wire rope
from service:
1. Six randomly distributed broken outer wires in one rope
lay length or three broken outside wires in one strand of
Hand one rope lay length (see Figure 8-4).
Swabing
Brushing

ONE ROPE LAY is distance measured along

a rope in which one strand makes one
complete revolution around rope core.

Core

One Wire
Take every precaution to
protect hands from injury One Strand

Figure 8-3 Lubricating Wire rope Figure 8-4 Rope Lay Length

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Manitowoc Boom Trucks, Inc
2. One broken outside wire at the point the wire contacts
the core. The broken wire will have worked its way out of
the rope structure and either protrude or loop out from the
rope structure. Additional inspection of this area of the wire
rope is required to determine if there is core damage.
3. Wear of one-third the original diameter of outside wires.
4. Kinking, crushing, birdcaging, core protrusion, or any
other damage resulting in distortion of the rope structure.
5. Evidence of heat damage from any cause.
6. Reductions from the nominal diameter of more than:
1/64" for rope diameters through 5/16"
1/32" for rope diameters 3/8" through 1/2"
3/64" for rope diameters 9/16" through 3/4"
1/16" for rope diameters 7/8" through 1-1/8"
3/32" for rope diameters 1-1/4" through 1-1/2"
Figure 8-5 Measuring Wire Rope diameter
Measure the wire rope diameter across the crowns of the
strands only so the true diameter is measured as shown in
Figure 8-5.
7. Core failure. This type of damage is usually indicated by
a reduction in the nominal diameter or by an increase in
rope lay length. When a reduction in diameter or an in-
crease in rope lay length is noted, “open up” the wire rope
as shown in Figure 8-6 and carefully inspect the core. The
wire rope should be replaced if any wires in the core are
broken.
8. Severe corrosion
Figure 8-6
SHEAVE AND DRUM INSPECTION
Proper operation of the sheaves and the winch drum has a
direct affect on wire rope wear; therefore, the sheaves and
winch drum must be inspected monthly for the following
defects:
1. Check the depth, width, and contour of each sheave us-
ing a groove gauge as shown in Figure 8-7. Replace
sheaves that have over or under-size grooves.
2. Replace the winch drum or any sheave that has broken
or cracked flanges.
8-6 A Manitowoc Company
3. Check that the winch drum and all sheaves turn true on
the shafts. If the drum or any sheave has a wobble to it, re-
place the bearings.
DISTRIBUTING WIRE ROPE WEAR
Wire rope wear at the “critical wear points” can be reduced
and the life of the wire rope extended by moving the rope at
regular intervals so different sections of the rope are sub-
jected to the wear points. This practice can also help cor-
rect spooling problems and rope vibration.
To move the wire rope, cut off a piece of wire rope at the
drum and refasten it. The piece cut off should be long
enough to move the wire rope at least one full drum wrap.
If the wire rope is too short to allow cutting off a piece, re-
verse the wire rope end for end and refasten it.
Figure 8-7 Measuring Sheave Groove
HYDRAULIC SYSTEM MAINTENANCE
INSPECTING SYSTEM
The damaging effects of dirt, heat, air, and water in the hy-
draulic system can only be prevented by regular, thorough
inspection of the system. The frequency of inspection de-
pends on operating conditions and experience with the
system; however, the more often the system is inspected
and deficiencies corrected, the less likely the system will
malfunction.
A good inspection program will include the following
checks:
1. Keep accurate records so future maintenance needs
can be projected.
2. Only use approved hydraulic oil in the system (see Lubri-
cation Section).

3. Check the level of the oil in the tank daily. Carefully
clean the area around the fill cap before removing it to add
oil to the tank.
IMPORTANT When adding oil to tank, filter oil through a
10-micron filter.
4. Clean the exterior of the system often; do not let dirt ac-
cumulate on or around any part of the system.
5. Check for external leaks. Leaks are not only unsafe,
they also attract dirt and in some cases allow air and water
to enter the system.
Remember! Do not to use your hands to check for
leaks.
– Look for oil leaking from fittings and from between parts
that are bolted together. Tighten loose fittings and attach-
ing bolts to the proper torque; do not overtighten.
If leakage persists at these points, replace the seals or
gaskets.
– Look for oil leaking from pump and motor shaft ends, from
valve spool ends, and from cylinder shaft ends. Replace
the seal(s) if leakage is found at any of these points.
– Replace tubes that are cracked, kinked, or bent.
– Replace hoses that are cracked, split, or abraded.
– Listen to pumps and motors for unusual noises; a high
pitched whine or scream can indicate that air is being
drawn in.
An air leak can be pinpointed by flooding the inlet fitting,
hose, or tube with oil. If there is an air leak, the oil will
cause a noticeable reduction in the noise. Correct the
cause for any air leak, or the pump or motor will be ruined.
IMPORTANT Do not return leakage oil back to hydraulic
tank.
NOTE A high pitched whine or scream from the pump can
also indicate cavitation (pump being starved of oil).
This condition is caused by the following problems:
–Collapsed or plugged suction line.
–Plugged/Clogged Suction Screen
–Wrong oil (viscosity too high).
6. Look for signs of overheating: heat peeled parts, burned
and scorched oil odor, and darkening or thickening of the
oil. The maximum temperature of the oil in the tank must
not exceed 200° F.
7. Have the hydraulic oil analyzed at regular intervals to
determine the condition of the oil and the extent of system
contamination.
By having the oil analyzed on a regular basis, an oil change
interval that meets your operating conditions can be estab-
lished.
NOTE Contact your oil supplier for the availability of oil
analysis services and the steps that should be
taken to obtain these services.
REPLACING HYDRAULIC FILTER ELEMENT (Figure 8-8)
Replace the filter element when the pressure gauge on the
head reads 25 psi with the engine at high idle and the oil
warm from operation.
A Manitowoc Company
Manitowoc Boom Trucks, Inc
NOTE The filter has a 25 psi bypass which opens when
the element is plugged with dirt.
IMPORTANT Do not operate crane when filter is bypass-
ing oil (gauge reads 25 psi); otherwise, unfiltered oil will be
drawn into system and faulty operation or damage to parts
will result.
1. Stop engine.
2. Remove and discard the old element.
3. Wipe clean the base of the filter head.
4. Apply clean oil to the gasket on the new element.
5. Thread the new element onto the head until the gasket
contacts the head. Then hand tighten the element an addi-
tional 3/8 to 1/2 turn. Do not use a wrench to tighten ele-
ment.
6. Check the element for leaks during operation. If neces-
sary, tighten the element until the leak stops.
REPLACING HYDRAULIC TANK BREATHER
(Figure 8-8)
If equipped with a spin-on breather, replace it every 3
months. Do not attempt to clean and reuse the breather.
Gauge Breather Fill Cap
Level Gauge
Filter Element Drain Plug (at bottom)
Figure 8-8 Hydraulic Tank & Level Gauge
1. Remove and discard the old breather.
2. It is not necessary to apply thread sealant to the threads
of the breather. Install the new breather hand tight; do not
tighten with a wrench.
CHANGING OIL
Drain and refill the hydraulic system every 6 months unless
an alternate interval has been established by an oil analy-
sis program.
1. Operate the crane until the oil is at its normal operating
temperature. This step will help prevent impurities from
settling in the system.
2. Move all controls to off and stop engine.
3. Remove the drain plug from the bottom of the tank to
drain the oil (see Figure 8-8).
NOTE Crack open one of the hydraulic fittings in a line at
the high point of the system. This step will vent the
system so that all of the oil drains out. Tightly
close fitting once oil has drained.
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4. Thoroughly clean all dirt from the access cover on the
tank and remove the access cover.
5. Clean out any sediment from inside the tank.
6. If equipped, remove and clean the suction strainer. Soak
in solvent and blow out with compressed air. Then securely
reinstall the strainer.
7. Reinstall the cover on the hydraulic tank. Install a new
gasket if necessary.
8. Replace the filter element
9. Replace the spin-on breather, if equipped; otherwise,
soak the fill cap breather in solvent and blow it clean with
compressed air.
10. Clean any metal particles from the drain plug. Install
and securely tighten the drain plug.
NOTE If a new pump or motor has been installed, fill all
ports with clean oil before connecting any lines.
This step will provide initial lubrication of the unit.
11. Fill the hydraulic tank to the proper level with approved
hydraulic oil (see Lubrication Section).
IMPORTANT Filter new oil through a 10-micron element
when filling tank.
12. Connect and securely tighten any hydraulic lines that
are disconnected.
IMPORTANT If equipped with optional suction line shut-off
valve, open valve before starting engine or engaging
P.T.O.; otherwise, the pump will cavitate and be ruined.
13. Start the engine, engage the power takeoff, and oper-
ate the pump for at least two minutes with no load at low-
est possible rpm. During this priming period, the pump
should run smoothly and not develop excessive heat.
14. Gradually increase speed and operate all functions
(cylinders and motors) to purge all air from the system. Op-
eration will be sluggish or erratic until all air is purged.
15. Once the functions are operating smoothly, speed and
loading can be increased to normal.
16. Stop the engine. Fill the hydraulic tank to the proper
level.
IMPORTANT If hydraulic system is extremely dirty (gum or
lacquer formation on parts indicated by jerky, sluggish, or
erratic operation) repeat Changing Oil procedure after
next 48 hours of operation.
BLEEDING OVERLOAD PILOT LINE
Before operating the crane after the pilot lines between the
boom hoist cylinder and the transducers for the load mo-
ment indicator have been disconnected, all air must be
bled from the pilot line on the extend side of the hoist cylin-
der, as follows:
Load moment indicator may not
operate properly if air is not bled
from the overload pilot line.
1. Securely connect all of the pilot lines between the boom
hoist cylinder and the transducers inside the pedestal of
the crane.
2. Start and run the engine at low idle.
3. Locate hose attached to port labeled “TE” on the base
end of the boom hoist cylinder. Identify transducer inside
crane pedestal to which pilot hose is attached (Figure 8-9).
Hoses
Transducers
View inside
Pedestals
Figure 8-9 Transducers
4. Crack open the pilot line fitting at the transducer.
5. Raise the boom as slow as possible.
NOTE If the boom is raised too fast, the flow meter in the
pilot line to the transducer will close, and no oil will
flow to the transducer.
6. Securely tighten the pilot line fitting when a steady
stream of oil appears.
7. Wipe up any spilled oil and inspect for leaks.
TIGHTENING HYDRAULIC CONNECTIONS
General
1. Make sure the fittings and O-rings being used are the
proper size and style.
2. Flush sealing surfaces with clean hydraulic oil to remove
any dirt.
3. Carefully inspect threads and sealing surfaces for nicks,
gouges, and other damage. Do not use damaged parts,
because they will leak.
4. Carefully inspect O-rings for cuts and other damage. Do
not use damaged O-rings, because they will leak.
5. Always lubricate O-rings with clean hydraulic oil at as-
sembly.
6. Be careful not to cut O-rings when assembling them to
fittings. Use a thimble as shown in Figure 8-10 when as-
sembling an O-ring over threads.
O-Ring
Plastic or Metal Thimble
Covering Threads
Figure 8-10 O-Ring Installation

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 Manitowoc Boom Trucks, Inc

Pipe Thread Connection washer will be tight against the spot face as shown in View
B, Figure 8-12.
1. Apply sealant (Loctite 92 or equivalent) to the male
threads, never to the female threads. Do not apply seal- Washer will not seat properly on spot face. Compressed
ant to the first two male threads. rubber between washer and spot face will cold flow out of
compression. Causing fitting to loosen and leak.
IMPORTANT Do not use TFE-flourocarbon tape to seal
threads; pices of tape will enter hydraulic system and Jam Nut
cause damage.
Washer O-ring
2. Tighten the fittings about 4-1/2 turns by hand and then 3
additional turns with a wrench.

Table 8-2 Pipe Thread Leakage View A View B

Causes Cures
1. Fitting loose. Tighten When jam nut and washer are not backed up, there is not
enough room for O-ring when squeeze takes place
2. Fitting too tight causing thread Replace damaged parts.
distortion.
Figure 8-11 Improper Assembly of
3. Thread on fitting or in port Use proper size threads. SAE Straight Thread Fitting
wrong size.
4. Thread dirty, galled or nicked. Clean or replace parts.
5. Straight thread used instead of Use proper type and size
tapered thread. thread. Spot Face
Jam Nut
6. Female threads expanded from Tighten when hot.
heat.
Washer O-ring
7. Fitting loosened by vibration. Retighten.

SAE Straight Thread Connection

This type connection leaks most often because the jam nut View A View B
and washer are not backed up before assembly
Nut and washer backed up to
When the jam nut and washer are not backed up, there is end of smooth portion on fitting
not enough room for the O-ring when the squeeze takes
place and the washer will not seat properly as shown in Figure 8-12 Proper Assembly of
View A, Figure 8-11. The compressed rubber between the
SAE Straight Thread Fitting
washer and the spot face will cold flow out of compression,
causing the fitting to loosen and leak shown in View B, Fig- Split Flange Connection
ure 8-11.
1. Lubricate and install the O-ring in the groove of the
shoulder (see Figure 8-13).
Table 8-3 Straight Thread Leakage
Causes Cures
2. Align the shoulder with the port and assemble the
flanges over the shoulder.
1. Jam nut and washer not backed Replace O-ring and tighten fit-
up at assembly, causing O-ring ting properly. IMPORTANT Bolts used must be grade-5 or better.
to be pinched. Grade-5 bolt has three dashes in head.
2. O-ring cut. Replace.
3. Snug the bolts in a diagonal manner (see Figure 8-13) to
3. O-ring wrong size. Replace with proper size.
1/3 of the torque given in Table 8-4.
4. Sealing surfaces gouged or Repair if possible or replace
scratched. damaged parts. 4. Repeat step 3 to 2/3 of the final torque. Repeat step 3 to
5. Sealing surfaces dirty Clean and lubricate. the final torque.

Tighten the SAE straight thread connection, as follows: Flange

Tube

1. Back up the jam nut and washer to the end of the smooth
portion on the fitting as shown in View A, Figure 8-12.
2. Lubricate the O-ring with clean oil; this is very impor-
tant.
3. Thread the fitting into the port until the washer bottoms
against the spot face as shown in View B, Figure 8-12.

NOTE If an elbow is being used, back it out as necessary Shoulder

to align it with the hose. O-ring Port
4. Tighten the jam nut. When the fitting is properly in-
stalled, the O-ring will completely fill the seal cavity and the Figure 8-13 Split Flange Connection

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Manitowoc Boom Trucks, Inc

Table 8-4 Split Flange Assembly Torque Table 8-7 SAE 37° Flare Tightening
“A” Dimension Flange Torque Connector Nut Size Fitting Adapter Flats to
inch Size in-lbs. N-m inch across flats Size Rotate
Standard Pressure Series 9/16 -04 2-1/2
1-1/2 -08 175-225 20-25 5/8 -05 2-1/2
1-7/8 -12 225-350 25-40 11/16 -06 2
2-1/16 -16 325-425 37-48 7/8 -08 2
2-5/16 -20 425-550 48-62 1 -10 1-1/2 to 2
2-3/4 -24 550-700 62-79 1-1/4 -12 1
3-1/16 -32 650-800 73-90 1-1/2 -16 3/4 to 1
2 -20 3/4 to 1
High Pressure Series 2-1/4 -24 1/2 to 3/4
1-9/16 -08 175-225 20-25
2 -12 300-400 34-45
2-1/4 -16 500-600 57-68
2-5/8 -20 750-900 85-102
3-1/8 -24 1400-1600 158-181
3-13/16 -32 2400-2600 271-294
View A

Connector Nut Adapter

A
Turn connector nut
required number of
View B flats (Table 8-7)
Table 8-5 Split Flange Leakage
Causes Cures
Figure 8-14 SAE 37° Flare Connection
1. Flanges not tight. Tighten bolts evenly to proper
torque.
2. Flanges tightened unevenly Replace O-rings. Tighten bolts SAE Face Seal Connection
causing extrusion of O-ring. evenly to proper torque.
1. Lubricate and install the O-ring in the groove in the
3. O-ring cut. Replace.
adapter (see Figure 8-15).
4. O-ring wrong size. Replace with proper size.
2. Lubricate the threads.
5. Sealing surfaces not smooth; Repair if possible or replace
scratched or gouged. parts. 3. Tighten the nut to the torque value given in Table 8-8.
6. Sealing surfaces dirty. Clean.
Table 8-8 SAE Face Seal Assembly Torque
7. Flanges keep getting loose in Use SAE grade 5 bolts or
service. better. Retighten bolts after sys- Nut Size Fitting Torque
tem is hot. inch across flats Size in-lbs. N.m
5/8 -04 120-145 14-16
13/16 -06 203-245 23-28
SAE 37° Flare Connection 15/16 -08 380-470 43-53
1-1/8 -10 550-680 62-77
1. Tighten the nut finger tight until the sealing surfaces 1-3/8 -12 763-945 86-107
touch. 1-5/8 -16 1110-1260 125-142
1-7/8 -20 1500-1680 170-190
2. Mark a line (use a felt pen or marker) on the adapter and
extend in onto the connector nut (see View A, Figure 8-14).
3. Using wrenches, tighten the connector nut the number Table 8-9 SAE Face Seal Leakage
of flats shown in Table 8-7 (see View B, Figure 8-14). Causes Cures
4. The misalignment of the marks will show how much the 1. Nut Loose Tighten to proper torque.
nut has been tightened, and best of all that it has been 2 O-ring Cut Replace.
tightened. 3. O-ring wrong size. Replace with proper size.
4. Sealing surfaces gouged or Repair if possible or replace
Table 8-6 SAE 37° Flare Leakage scratched. damaged parts.
Causes Cures 5. Sealing surfaces dirty. Clean and lubricate.
1. Joint loose. Tighten properly.
2. Sealing surfaces dirty. Clean. O-ring

3. Sealing surfaces not smooth; Replace faulty parts.

scratched or gouged.
4. Sealing surfaces cracked. Replace faulty parts.
5. SAE 45° parts used with SAE Only use SAE 37° parts. Adapter
37° parts. Nut

Figure 8-15 SAE Face Seal

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 Manitowoc Boom Trucks, Inc

7-Section Main Swing

Control Valve Relief Valve Relief Valve

Winch
Relief Valve

Acorn
Nut
Adjusting
Screw
Valve Arrangement Mid-Inlet Winch
Control Valve Locknut
for Triple Pump Section

7-Section Swing Left Main

Control Valve Relief Valve Relief Valve

Relief Valve
Winch
Relief Valve

Valve Arrangement Swing Right Winch

for Tandem Pump Relief Valve Control Valve

Figure 8-16 Relief Valve Identification

ADJUSTING RELIEF VALVES

General
The relief valves are factory set and should not be tam-
pered with unless poor performance is experienced.
Pressure Gauge on
Any relief valve which has been removed for inspection, Driver Side Control
cleaning, or replacement must be adjusted after installa- Console
tion.

NOTE Refer to Figure 8-16 for identification of the relief

valves. The cover on the control console must be
removed to gain access to the relief valves.
Main Relief Valve for 7-Section Valve
1. Operate the hydraulic system until the oil is warm from Figure 8-17 System Pressure Gauge
operation.
2. Move all of the control levers to off. 6. If the proper pressure is not obtained, proceed as fol-
lows:
3. Increase engine speed to full throttle.
a) Remove the acorn nut from the adjusting screw
4. Fully retract the boom to stall the hydraulic system by
(seeFigure 8-16).
slowly moving the telescope control lever in the IN
direcation. Leave all other control levers in off. b) Hold the adjusting screw with a screwdriver and
loosen the locknut.
5. Observe the system pressure gauge on the right side
console (see Figure 8-17); the gauge should read 2,500 c) Turn the adjusting screw IN to INCREASE pressure
psi. or OUT to DECREASE pressure.
IMPORTANT Move telescope control lever to off as soon d) Repeat “Main Relief Valve” steps 3 through 5 and 6c
as pressure reading is obtained; otherwise, hydraulic until the specified pressure is obtained.
compoanents may be damaged from overheating.

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Manitowoc Boom Trucks, Inc
e) Hold the adjusting screw with a screwdriver and
tighten the locknut. Reinstall the acorn nut on the ad-
justing screw. Torque both nuts to 10 ft-lbs.
Swing Relief Valves (with Tandem Pump)
1. Check that the main relief valve is set for the specified
pressure.
2. Operate the hydraulic system until the oil is warm from
normal operation.
3. STOP ENGINE. Do not perform step 4 until the engine is
off.
Elbow
Disconnect hose here
Brake Release Hose
Swing Brake
Figure 8-18 Swing Drive
4. Disconnect the brake release hose from the elbow on
the swing brake (see Figure 8-18).
5. Connect an accurate 0-3,000 psi hydraulic pressure
gauge to the end of the brake release hose. The hose has a
1/4 inch SAE face seal fitting.
6. Start and run the engine at full throttle.
7. Slowly move the swing control lever in the SWING LEFT
direction. The applied swing brake will stall the hydraulic
system.
8. Observe the pressure gauge; the gauge should read
1,500 psi.
IMPORTANT Move swing control lever to off as soon as
pressure reading is obtained; otherwise, hydraulic
compoanents may be damaged from overheating.
9. If the specified pressure is not obtained, proceed as fol-
lows:
a) Remove the acorn nut from the adjusting screw on
the SWING LEFT relief valve (see Figure 8-16).
b) Hold the adjusting screw with a screwdriver and
loosen the locknut.
c) Turn the adjusting screw IN to INCREASE pressure
or OUT to DECREASE pressure.
d) Repeat “Swing Relief Valves” steps 6 through 8 and
9c until the specified presure is obtained.
e) Hold the adjusting screw with a screwdriver and
tighten the locknut. Reinstall the acorn nut on the ad-
justing screw. Torque both nuts to 10 ft-lbs.
8-12 A Manitowoc Company
10. Repeat “Swing Relief Valves” steps 6 through 9e for
the SWING RIGHT relief valve. Operate the swing control
lever in the SWING RIGHT direction.
11. STOP ENGINE. Disconnect the hydraulic gauge from
the brake release hose and reconnect the hose to the fit-
ting at the swing break.
Swing Relief Valve (with Triple Pump)
1. Operate the hydraulic system until the oil is warm from
normal operation.
2. STOP ENGINE. Do not perform step 3 until the engine is
off.
3. Disconnect the brake release hose from the elbow on
the swing brake (see Figure 8-18).
4. Connect an accurate 0-3,000 psi hydraulic pressure
gauge to the end of the brake release hose. The hose has a
1/4 inch SAE face seal fitting.
5. Start and run the engine at full throttle.
6. Slowly move the swing control lever in either direction.
The applied swing brake will stall the hydraulic system.
7. Observe the pressure gauge; the gauge should read
1,500 psi.
IMPORTANT Move swing control lever to off as soon as
pressure reading is obtained; otherwise, hydraulic compo-
nents may be damaged from overheating.
8. If the specified pressure is not obtained, proceed as fol-
lows:
a) Remove the acorn nut from the adjusting screw on
the SWING relief valve (see Figure 8-16).
b) Hold the adjusting screw with a screwdriver and
loosen the locknut.
c) Turn the adjusting screw IN to INCREASE pressure
or OUT to DECREASE pressure.
d) Repeat Swing Relief Valve steps 5 through 7 and 8c
until the specified presure is obtained.
e) Hold the adjusting screw with a screwdriver and
tighten the locknut. Reinstall the acorn nut on the ad-
justing screw. Torque both nuts to 10 ft-lbs.
9. STOP ENGINE. Disconnect the hydraulic gauge from
the brake release hose and reconnect the hose to the fit-
ting at the swing brake.
Winch Relief Valve
1. Operate the hydraulic system until the oil is warm from
operation.
2. Reeve the boom point for one part of hoist line.
3. Retract the boom to its shortest length.
4. Increase engine speed to full throttle.
5. To stall the hydraulic system, slowly lift against a
10,000 pounds at a 20 foot radius or less.
Do not exceed load or radius in
step 5; structural damage or tip-
ping will occur.
6. Observe the system pressure gauge on the right side
console (see Figure 8-17); the gauge should read 2,800
psi.

IMPORTANT Move winch control lever to off as soon as
pressure reading is obtained; otherwise, hydraulic compo-
nents may be damaged from overheating.
7. If the proper pressure is not obtained, proceed as fol-
lows to adjust the winch relief valve:
a) Remove the acorn nut from the adjusting screw (see
Figure 8-16).
b) Hold the adjusting screw with a screwdriver and
loosen the locknut.
c) Turn the adjusting screw IN to INCREASE pressure
or OUT to DECREASE pressure.
d) Repeat Winch Relief Valve steps 4 through 6 and 7c
until the specified presure is obtained.
e) Hold the adjusting screw with a screwdriver and
tighten the locknut. Reinstall the acorn nut on the ad-
justing screw. Torque both nuts to 10 ft-lbs.
Stabilizer Out Relief Valve
NOTE The stabilizer OUT relief valve is mounted inside
the rear of the subframe.
Because it is dificult to gain acces to the relief
valve, it is recommended that the hydraulic lines be
connected to the relief valve and the relief valve be
adjusted before it is fastened to the subframe.
1. Operate the hydraulic system until the oil is warm from
normal operation.
2. Move all control levers to off.
3. Increase engine speed to full throttle.
4. Move the stabilizer IN/OUT control lever to the OUT po-
sition and hold. Leave all other control levers in off.
Access Hole in
Bottom of Subframe
View
inside
Rear of
Subframe
Locknut
Relief Valve
Adjusting Cartridge
Screw
Figure 8-19 Stabilizer OUT Relief Valve
5. Once the stabilizer boxes are fully extended and stalled,
observe the sytem pressure gauge at the right side control
station (see Figure 8-17); the gauge should read 1000 psi.
IMPORTANT Return stabilizer IN/OUT control lever to off
as soon as pressure reading is obtained; otherwise, hy-
draulic components may be damaged from overheating.
6. If the proper pressure is not obtained, proceed as fol-
lows to adjust the relief valve (see Figure 8-19):
A Manitowoc Company
Manitowoc Boom Trucks, Inc
a) Hold the adjusting screw with a wrench and loosen
the locknut.
b) Turn the adjusting screw IN to INCREASE pressure
or OUT to DECREASE pressure.
c) Repeat “Stabilizer OUT Relief Valve” steps 3 through
6b until the specified presure is obtained.
d) Hold the adjusting screw with a wrench and tighten
the locknut.
PUMP INSTALLATION
IMPORTANT Rotation of pumps must match rotation of
power takeoff (P.T.O.). If pumps are rotated in wrong di-
rection, they will be damaged.
Perform the following steps before installing a new or re-
paired pump on the P.T.O.:
1. Start and run the engine at low idle.
2. Observe the P.T.O.’s output shaft.
3. If the P.T.O.’s output shaft turns CLOCKWISE (viewed
from shaft end), the pump must be assembled for COUN-
TERCLOCKWISE rotation.
If the P.T.O.’s output shaft turns COUNTERCLOCKWISE
(viewed from shaft end), the pump must be assembled for
CLOCKWISE rotation.
NOTE If it is necessary to change the rotation of the
pumps, refer to the pump manufacturer’s overhaul
manual for instructions.
Be sure to change rotation of cartridge in each
pump section.
ADJUSTING LEVELS
Check the adjustment of the levels on the control consoles
every month using the following procedure:
1. Extend the outriggers and the stabilizers so the crane is
level according to the level on either control console.
2. Raise the boom to the maximum angle (80) and fully re-
tract the boom.
Do not swing boom over either
side of truck until Adjusting
Levels step 2 has been per-
formed; otherwise, crane may tip over.
Turret
Carpenter’s
Level
Figure 8-20 Positioning the carpenter’s Level
8-13
Manitowoc Boom Trucks, Inc

3. Place an accurate carpenters level on either side of the Loading Plug

turret (Figure 8-20). Do not lay the level across the top of (approximately 90° to left of swing pinion position) Pedestal
the bolts.
4. Adjust the outriggers and stabilizers so the crane is level
from front to rear according to the carpenter’s level.
5. Swing the boom 90° over either side of the truck and ad-
just the outriggers and stabilizers so the crane is level from
side to side according to the carpenters level.
6. Repeat “Adjusting Levels” steps 4 and 5 until the crane
is level with all tires off the ground.
7. Check the bubble in the level on each control console. If
necessary, adjust the levels as follows:
a) Loosen adjusting screws (Figure 8-21) until spring Swing
under level is no longer compressed. Limiting
Device Swing
b) Preload spring by tightening adjusting screws evenly. Pinion
Do not overtighten as this will cause loss of adjust-
ment range. Turret
c) Turn adjusting screws until the bubble is centered in
the glass. Figure 8-22 Slewing Ring Orientation
5. Lift the turret and slewing ring into position over the ped-
estal.
6. Rotate the inner ring so the loading plug (Figure 8-22) is
positioned approximately 90° to the left of the swing pinion
centerline (viewed from top).
7. Install the bolts, hardened flat washers and nuts to fas-
ten the inner ring to the pedestal (see Figure 8-23). Do not
tighten the nuts.
Adjusting Scew
(3 each)
Level NOTE Access holes are provided in the turret for installing
the bolts in the inner ring.
Figure 8-21 Level on Control Console Install three 4 inch long bolts in the tapped holes
nearest the front of the pedestal.
INSTALLING SLEWING RING/ADJUSTING GEAR 8. Temporarily assemble the swing reducer with the ec-
BACKLASH centric plate to the pedestal.
NOTE The following instructions assume that the boom NOTE When performing step 8, position the eccentric
has been removed from the turret. plate so it is in the middle of its adjustment as
1. Thoroughly clean any dirt, grease, or oil from all mount- shown in Figure 8-24.
ing surfaces and remove any burrs.
¾-10 UNC Socket ¾-10 UNC
2. Remove the swing reducer from its mounting position Head Bolt Grade 8 Nut
and lay it on the control console. It is not necessary to dis-
Hardened
connect the hydraulic lines when performing this step. Flat Washer Acces Hole
3. Lift the turret onto the slewing ring so the high spot of the
gear (marked with paint or punch marked) is centered as Turret
close as possible between the boom hoist cylinder mount- Outer Ring
ing lugs on the turret (see Figure 8-22).
Guard Outer
Ring
NOTE The high spot of the ring gear teeth should be ei- Pedestal
ther painted or punch marked for identification. If
the teeth are not painted or punch marked, locate
the high spot with a dial indicator.
Install the bolts, hardened flat washers, and nuts to fasten Acces Hole Hardened
the slewing ring to the turret as shown in Figure 8-23. Flat Washer
Tighten the nuts to 100 ft-lbs. Then retighten the nuts to
250 ft-lbs. ¾-10 UNC Socket ¾-10 UNC
Head Bolt Grade 8 Nut
4. If it was removed, install the swing limiting device at this
time.
Figure 8-23 Slewing Ring Installation

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 Manitowoc Boom Trucks, Inc

BOOM SERVICE
NOTE The item numbers used for the “Boom Service” in-
structions correspond to the item numbers on the
Drivers Side “Boom Assembly” drawing in the parts section of
of Truck this manual.
SLIDER PAD REPLACEMENT AND ADJUSTMENT
High Side of Low Side of Rear Top Slider Pads (see Figure 8-28)
Eccentric Plate Eccentric Plate
1. Remove the access cover from the rear of the boom
base.
Console Side of Pedestal
2. Fully retract the boom so rear top slider pads (57) on the
Figure 8-24 Eccentric Plate Orientation 3rd section line up with the access holes in the rear of the
boom as shown in Figure 8-26.
9. Push the turret and slewing ring toward the swing re-
ducer so there is no backlash between the ring gear and
the swing pinion.
Rear Top
10. Remove the swing reducer from its mounting position. Slider Pads
(57)
11. Tighten the nuts for the inner ring to 100 ft-lbs. Then
tighten the nuts to 250 ft-lbs.

NOTE It will be necessary to rotate the turret to gain ac-

cess to all of the bolts through the access holes.
One person must hold the heads of the bolts with a Shims
hex socket wrench while another person tightens (58,59,60)
the nuts from inside the turret.
12. Reinstall the swing reducer so the mounting screws are
loose
13. Rotate the outer ring so the high spot of the ring gear
teeth is in mesh with the swing pinion. Access
Holes
Turret

Outer Ring Figure 8-26 Rear Top Slider Pads

3. Stop engine.
Eccentric
Plate NEVER reach into any boom sec-
tion unless all sections are an-
Pedestal chored together, the PTO is
disengaged and engine is OFF. Serious injury will
occur if boom is telescoped.
Swing
Pinion 4. Measure the thickness of slider pads (57). Replace both
slider pads if either has worn to the dimension given in Ta-
ble 8-10.
Figure 8-25 Eccentric Plate Installation
Table 8-10 Slider Pad Replacement
14. Rotate the eccentric plate (see Figure 8-25) with a Item Location New Replace
hammer and punch until there is no backlash between the (Figure 8-27) (Section) Thickness Thickness
swing gear and the swing pinion. 51 Rear Side (1st, 2nd, 3rd)* 1/2" 3/8"
and Extend Sheave Bracket*
IMPORTANT Backlash must be adjusted any time slewing
ring or swing reducer is removed; otherwise, gears may 55 Front Bottom (Crowd)* 3/8" 1/4"
bind when swinging. 56 Front Side (Crowd)* 3/8" 1/4"

15. Tighten the swing reducer mounting screws to 280 57 Rear Top (2nd, 3rd) 1/2" 3/8"
and Front Bottom (Base, 1st)
ft-lbs.
61 Front Bottom (2nd Section) 1/2" 3/8"
16. Reconnect any hydraulic lines that may have been dis- 62 Front Side (Base, 1st, 2nd) 3/8" 1/4"
connected from the swing reducer or the swing motor. and Rear Side (Inside 3rd)*
* Can only be checked or replaced when boom is disassembled. All other
slider pads can be checked or replaced when boom is assembled.

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Manitowoc Boom Trucks, Inc
5. Measure the clearance between rear top slider pads
(57) and the adjacent section.
6. If necessary, loosen the mounting screws and add
shims (58, 59, or 60) under the slider pads to provide the
clearance given in Figure 8-28.
NOTE The shims come in three thicknesses: 3/64 inch,
5/64 inch, and 9/64 inch.
7. Securely tighten the mounting screws after the shims
are installed.
8. Extend the boom so rear top slider pads (57) on the 2nd
section line up with the access holes in the boom as shown
in Figure 8-28.
9. Repeat “Rear Top Slider Pads” steps 3 through 7 for the
2nd section.
10. Extend the boom so rear top slider pads (57) on the 1st
section line up with the access holes in the boom as shown
in Figure 8-26.
11. Repeat “Rear Top Slider Pads” steps 3 through 7 for
the 1st section.
Front Side Slider Pads (see Figure 8-28)
NOTE Rear side slider pads (51 & 62) can only be re-
placed and adjusted when the boom is disassem-
bled.
NEVER reach into any boom sec-
tion unless all sections are an-
chored together, the PTO is
disengaged and engine is OFF. Serious injury will
occur if boom is telescoped.
1. Extend the boom approximately 6 inches.
2. Stop engine.
3. Measure the thickness of front side slider pads (62)
shown in Figure 8-27. Replace all of the front side slider
pads for the respective section if any front side slider pad
has worn down to the thickness given in Table 8-10.
4. Fully extend the boom and stop engine.
5. Adjust the sections from side to side so the boom is as
straight as possible.
Front Bottom
Front Side Slider Pad
Slider Pad (57 or 61)
(62)
Figure 8-27 Front Side & Bottom Pads
8-16 A Manitowoc Company
6. If necessary, add shims (63, 64, or 65) behind the front
side slider pads to keep the boom straight (see Figure 8-28
for clearance specifications).
NOTE The shims come in three thicknesses: 3/64 inch,
5/64 inch, and 9/64 inch.
It is possible to have more shims on one side of the
boom than on the other side, as long as the boom is
straight.
7. Securely tighten the mounting screws after the shims
are installed.
IMPORTANT End of mounting screws for front side slider
pads must not rub against adjacent section. If necessary,
install washers under head of mounting screws so screws
fully engage nuts in slider pads, but do not rub against sec-
tion.
Front Bottom Slider Pads (see Figure 8-28)
1. Extend the boom approximately 8 inches.
2. Stop engine.
NEVER reach into any boom sec-
tion unless all sections are an-
chored together, the PTO is
disengaged and engine is OFF. Serious injury will
occur if boom is telescoped.
3. Measure the thickness of front bottom slider pads (57 or
61) shown in Figure 8-27. Replace both front slider pads
for the respective section if either slider pad has worn
down to the dimension given in Table 8-10.
NOTE It will be necessary to lift the ends of the sections
with a hoist to remove and adjust the front bottom
slider pads.
Front bottom slider pads (57) are fastened to
mounting pads; therefore, the mounting pads must
be removed to gain access to the slider pads.
Be sure to readjust retract ropes after reinstalling
the mounting pads between the 1st and 2nd sec-
tions.
4. Measure the clearance between the sections.
5. If necessary, add shims (58, 59 & 60) under the front bot-
tom slider pads to provide the clearance given in Figure
8-28.
NOTE The shims come in three thicknesses: 3/64 inch,
5/64 inch, and 9/64 inch.
6. Securely tighten the mounting screws after the shims
are installed.
 Manitowoc Boom Trucks, Inc

Figure 8-28 Slider Pad and Shim Identification

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Manitowoc Boom Trucks, Inc
BOOM REMOVAL
1. If equipped, remove the jib.
2. Fully retract and lower the boom onto the boom rest.
3. Remove the load block or the overhaul ball and spool the
load line onto the winch.
4. Disengage the PTO and stop engine.
5. Tag and disconnect the telescope hydraulic lines from
the valve manifold on the end of the telescope cylinder.
6. Lift against the rod end of the boom hoist cylinder and re-
move the rod end pin (at boom).
7. Lower the boom hoist cylinder onto blocking on the flat-
bed.
8. Lift against the boom at the center of gravity with another
crane. The center of gravity is approximately 14 feet 10
inches forward of the boom hinge pin.
9. Remove the boom hinge pin.
10. Lift the boom onto stands or blocking. Stands or
blocking must be installed close to both ends of boom
base to provide a sturdy support.
BOOM DISASSEMBLY AND ASSEMBLY
NOTE Refer to “Boom Assembly Drawing” found in the
parts section of this manual for assembly and dis-
assembly procedure.
NOTE Some of the adjustment procedures wil require a
hydraulic power source to be available. The source
shall be capable of providing 2500 psi of hydraulic
pressure.
The rear end of the boom base
must be chained an d
counterweighted when boom
service is performed on stands or blocking. The
boom will tip off stands or blocking when extended
if it is not properly secured.
IMPORTANT To avoid confusion when reassembling
boom, keep slider pads and shims in matched sets as they
are removed. Also, keep bolts, capscrews, lockwashers,
and nuts with parts they retain.
BOOM INSPECTION
1. Inspect all slider pads for wear or damage. Replace the
slider pads if they have worn down to the “Replace Thick-
ness” given in Table 8-10.
2. Inspect all bearings for wear. The sheaves must turn
true on the shafts without any wobble.
3. Inspect the extend and retract ropes for wear and
damaage; see “Wire Rope Maintenance” for wire rope re-
placement criteria.
4. Inspect the sheaves for wear and damage; see “Sheave
and Drum Inspection.”
BOOM INSTALLATION
1. Lift the boom into position at the turret and install the
boom hinge pins.
2. Lower the boom onto the boom rest.
3. Lift the rod end of the boom hoist cylinder into position at
the lugs on the boom and install the rod-end pin.
8-18 A Manitowoc Company
4. Connect the hydraulic lines to the proper ports at the
manifold on the telescope cylinder.
5. Adjust the crowd rope system.
6. Assemble cover (71) to the top of the base section.
7. Install the load line over the sheaves on the boom point.
8. If equipped, assemble the jib to the side of the boom.
9. Check anti-two block system for proper operation.
IMPORTANT If ATB/LMI cable from cable reel to the limit
switch on the boom point has been disconnected, then the
potentiometer in the length transducer must be reset. Oth-
erwise, boom length sensor may malfunction, and cause
possible damage to crane and property due to an overload.
10. Check length display in the load moment system’s cen-
tral microprocessor unit. Refer to the PAT troubleshooting
manual under “3 Broken Length Cable”, for instructions
when replacing cable and checking or resetting potentiom-
eter in length transducer.
11. Operate the telescope cylinder in both directions until
all air is bled from the system. Fill the hydraualic tank to the
proper level.
CROWD ROPE ADJUSTMENT
THREE-SECTION BOOM
(Refer To Figure 8-29)
1. Check that the jam nuts and the locking nuts are loose
on the extend (28 and 29) and retract ropes (32).
2. Fully retract the boom. Ensure the second section has
stopped against the first. If necessary, push against
the end of the second section to further ensure the
boom is fully retracted.
3. Put match-marks (A and B) on the side of the first and
second sections, the mark should be flush with the end
of the adjacent section, refer to Figure 8-29.
4. Fully extend the boom and stop engine.
5. Tighten the adjusting nut on each extend rope (28 and
29) until the distance from the end of each extend rope
to the edge of each nut is 3/4-inch.
Do not place hands or tools into
any opening in boom sections
while power is on or boom sec-
tions are moving.
6. Visually inspect the extend rope tension through the
sight hole in the side of the first section. Tighten the ad-
justing nut on the loosest rope until all extend ropes
are tensioned equally.
NOTE All extend ropes have wrench flats to hold the
ropes stationary while tightening the nuts.
7. Torque the adjusting nut on both retract ropes (32) to
30-35 ft-lb.
NOTE All retract ropes have wrench flats to hold the ropes
stationary while tightening the nuts.
8. Fully retract the boom while watching the end of the
sections; note which section stops first.

Stop for
3/4-inch Starting Point for Second
Base
Extend Ropes Section
Locking Section
Nut
A B
Extend Ropes Adjusting
(28 and 29) Nut
Figure 8-29 Three Section Boom Crowd Ropes
9. Extend the boom approximately six inches and repeat
previous step as slowly as possible. Release the
telescope control lever to off as soon as the corre-
sponding sections stops.
10. Determine the remaining stroke to fully retract the
boom as follows.
A. If the second section stopped first, measure the
remaining stroke between mark A on the first sec-
tion and the end of the base section.
B. If the first section stopped first, measure the re-
maining stroke between mark B on the second sec-
tion and the end of the first section.
11. If the remaining stroke is greater than 1/8-inch, pro-
ceed as follows.
A. If the second section stopped first:
Loosen the adjusting nut on the retract ropes (32)
three turns for each 1/8-inch of remaining stroke.
Tighten the adjusting nut on the extend ropes (28
and 29) four turns for each 1/8-inch of remaining
stroke.
B. If the first section stopped first:
Loosen the adjusting nut on the extend ropes (28
and 29) four turns for each 1/8-inch of remaining
stroke.
Tighten the adjusting nut on the retract ropes (32)
three turns for each 1/8-inch of remaining stroke.
12. Repeat previous steps until the remaining stroke is
1/8-inch or less.
13. Re-check the torque of retract ropes (32).
14. Install and tighten locking nuts (90 and 91).
FOUR-SECTION BOOM
(Refer to Figure 8-30)
1. Remove the access cover from the top of the base
section at rear.
A Manitowoc Company
Manitowoc Boom Trucks, Inc
Adjusting Nut Retract
Rope (32)
First Second
Section Section
Locking Nut
1-inch Starting Point
for Retract Ropes
Do not place hands or tools into
any opening in boom sections
while power is on or boom sec-
tions are moving.
2. Loosen the adjusting nut and the lock nut on each ex-
tend rope (28 and 29) and on retract ropes (33) so the
ropes are slack.
3. Visually inspect the extend rope tension (30 and 31)
through the sight hole in the side of the first section.
Tighten the adjusting nut on the loosest rope until both
ropes are tensioned equally.
IMPORTANT If lock nuts are not removed in this step,
damage to nuts or base section will result when boom is re-
tracted later.
4. Tighten the adjusting nut on each retract rope (32) until
the distance from the end of each rope to the outside
edge of the adjusting nut is one inch.
5. Fully retract the boom.
6. Put a match-mark on the side of the first section flush
with the end of the base section A, refer to Figure 8-30.
Put a match-mark on the side of the second section
flush with the end of the first section B.
7. Extend the boom approximately eight feet and stop
engine. Tighten the adjusting nut on each extend rope
(28 through 31) until the distance from the end of each
rope to the outside edge of the adjusting nut is
3/4-inch.
8. Fully extend the boom and stop engine.
9. Visually inspect the extend rope tension (30 and 31)
through the sight hole in the side of the first section.
Tighten the adjusting nut on the loosest rope until both
ropes are tensioned equally.
NOTE Both extend ropes have wrench flats to hold the
ropes stationary while tightening the nuts.
10. Torque the adjusting nut on both retract ropes (33) to
30-35 ft-lb.
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Manitowoc Boom Trucks, Inc

NOTE Both retract ropes have wrench flats to hold the telescope control lever to OFF as soon as the corre-
ropes stationary while tightening the nuts. sponding section stops.
11. Fully retract the boom while watching the third and
second sections, note whether the third section stops
before match-mark B aligns itself with the end of the
first section.
12. Extend the boom approximately six inches and repeat
previous step as slowly as possible. Release the
telescope lever to OFF as soon as the third section
stops or as soon as match-mark B is aligned, which-
ever occurs first.
13. Determine the remaining stroke to fully retract the
boom, as follows.
A. If the third section stopped first, measure the re-
maining stroke between match mark B on the sec- Extend Ropes First Section
ond section and the end of the first section. (30 and 31)

B. If match-mark B aligned itself first, measure the View at Top of Boom Base - Cover Removed
remaining stroke between the third and second
sections at location C.
14. If the remaining stroke is greater than 1/8-inch, pro- Starting Point for
ceed as follows. all Extend Ropes 3/4”

A. Extend the boom approximately eight feet and stop

engine.
B. If the third section stopped first:
Loosen the adjusting nut on each retract rope (33)
three turns for each 1/8-inch of remaining stroke.
Extend Ropes
Tighten the adjusting nut on each extend rope (30 (28 and 29)
and 31) four turns for each 1/8-inch of remaining
stroke.
C. If match-mark B aligned first:
Loosen the adjusting nut on each extend rope (30
and 31) four turns for each 1/8-inch of remaining
stroke. Locking Nut
Adjusting Nut
Tighten the adjusting nut on each retract rope (33)
View at Top Rear of Base
three turns for each 1/8-inch of remaining stroke.
15. Repeat previous steps until the remaining stroke is
1/8-inch or less.
16. Recheck the torque of the adjusting nut for retract
ropes (33). 1st 2nd 3rd
Base Section Section Section
17. Extend the boom approximately eight-and-one-half Section
B
feet and stop engine. Looking through the access A
holes in the base section, visually check the tension of
extend ropes (28 and 29). Tighten the adjusting nut on
the loosest ropes until all four ropes are tensioned
C
equally.
Retract
NOTE All four extend ropes have wrench flats to hold the Ropes (33)
ropes stationary while tightening the nuts.
Adjusting
18. Torque the adjusting nut on each retract rope (32) to Nut
1”
30-35 ft-lb. Adjusting Starting Point for Retract
Nut All Retract Ropes Ropes (32)
NOTE All four retract ropes have wrench flats to hold the
ropes stationary while tightening the nuts.
View at Front of Boom
19. Fully retract the boom while watching the second and (shows locknuts removed)
first sections, note which section stops first.
20. Extend the boom approximately six inches and repeat
Figure 8-30 Four Section Boom Crowd Ropes
previous step as slowly as possible. Release the

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 Manitowoc Boom Trucks, Inc

21. Determine the remaining stroke to fully retract the

boom as follows:
A. If the second section stopped first, measure the
remaining stroke between match-mark A on the
first section and the end of the base section.
B. If the first section stopped first, measure the re-
maining stroke between match-mark B on the sec-
ond section and the end of the first section.
22. If the remaining stroke is greater than l/8-inch, proceed
as follows:
A. Extend the boom approximately eight feet and stop
engine.
B. If the second section stopped first:
Loosen the adjusting nut on each retract rope (32)
three turns for each 1/8-inch of remaining stroke.
Tighten the adjusting nut on each extend rope (28
and 29) four turns for each 1/8-inch of remaining
stroke.
C. If the first section stopped first:
Loosen the adjusting nut on each extend rope (28
and 29) four turns for each 1/8-inch of remaining
stroke.
Tighten The adjusting nut on each retract rope (32)
three turns for each 1/8-inch of remaining stroke.
23. Repeat previous steps until the remaining stroke is
1/8-inch or less.
24. Recheck the torque of the adjusting nut for retract
ropes (32).
25. Install all of the lock nuts and securely tighten them.
26. Cycle the boom two or three more times and check
that all boom sections are properly synchronized per
the above instructions. If not, check which sections re-
quire readjustment and perform the proper adjustment
procedure for those sections.
27. Repeat until the boom is properly synchronized.
28. Recheck the torque of the adjusting nut for each re-
tract rope (32 and 33).
29. Install the access cover on the base section.

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