RT500E SERIES LUBRICATION
SECTION 5
LUBRICATION
GENERAL the suitability of a specific fluid, check with your autho-
rized Manitowoc/Grove distributor or Manitowoc/Grove
Following the designated lubrication procedures is Crane Care.
important in ensuring maximum crane lifetime and utili-
zation. The procedures and lubrication charts in this sec- Regardless of temperature and oil viscosity, always use
tion include information on the types of lubricants used, suitable start-up procedures to ensure adequate lubrica-
the location of the lubrication points, the frequency of tion during system warm-up.
lubrication, and other information.
LUBRICATION POINTS
The service intervals specified are for normal operation
where moderate temperature, humidity, and atmospheric
conditions prevail. In areas of extreme conditions, the A regular frequency of lubrication must be established
service periods and lubrication specifications should be for all lubrication points. Normally, this is based on com-
altered to meet existing conditions. For information on ponent operating time. The most efficient method of
extreme condition lubrication, contact your local service keeping track of lubrication requirements is to maintain a
representative or Manitowoc/Grove Crane Care, Shady job log indicating crane usage. The log must use the read-
Grove, Pennsylvania. ings from the engine hourmeter to ensure coverage of
lubrication points that will receive attention based on the
hourmeter readings. Other lubrication requirements must
CAUTION be made on a time basis, i.e. weekly, monthly, etc.
CHASSIS GREASE LUBRICANTS MUST
NOT BE APPLIED WITHAIR PRESSURE All oil levels are to be checked with the crane parked on a
DEVICES AS THIS LUBRICANT IS USED level surface in the transport position, and while the oil is
ON SEALED FITTINGS. cold, unless otherwise specified.
CAUTION
On plug type check points, the oil levels are to be at the
bottom edge of the check port.
THE MULTIPURPOSE GREASE
INSTALLED DURING MANUFACTURE IS
OF A LITHIUM BASE. USE OF A NON- On all cranes with a sight glass on the left side of the
COMPATIBLE GREASE COULD RESULT hoist, the fill level should be to the center of the sight
IN DAMAGE TO EQUIPMENT. glass.
Specific recommendations of brand and grade of lubri-
cants are not made here due to regional availability, oper- All grease fittings are SAE STANDARD unless other-
ating conditions, and the continual development of wise indicated. Grease non-sealed fittings until grease is
improved products. Where questions arise, refer to the seen extruding from the fitting. One pump on a standard
component manufacturers manual and a reliable supplier. 0.45 kg (1 lb) grease gun equals 28 grams (1 oz) of EP-
MPG.
Arctic Conditions Below -18 °C (0°F)
Over lubrication on non-sealed fittings will not harm the
fittings or components, but under lubrication will defi-
In general, petroleum based fluids developed especially
nitely lead to a shorter lifetime.
for low temperature service may be used with satisfac-
tory results. However, certain fluids, such as halogenated
hydrocarbons, nitro hydrocarbons, and phosphate ester On sealed U-joints, care must be exercised to prevent
hydraulic fluids, might not be compatible with hydraulic rupturing the seals. Fill only until expansion of the seals
system seals and wear bands. If you are in doubt about first becomes visible.
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LUBRICATION RT500E SERIES
Unless otherwise indicated, items not equipped with replaced. Where wear pads are used, cycle the compo-
grease fittings, such as linkage, pins, levers, etc. should nents and lubricate to ensure coverage of the entire wear
be lubricated with oil once a week. Motor oil, applied area.
sparingly, will provide the necessary lubrication and help
prevent the formation of rust. An Anti-Seize compound
may be used if rust has not formed, otherwise the compo- Each lubrication point on the crane is numbered, which
nent must be cleaned first. corresponds to the index number shown on the Lubrica-
tion Diagram. The descriptions of the lubrication points
Grease fittings that are worn and will not hold the grease give the lube type, lube interval, lube amount, and appli-
gun, or those that have a stuck check ball, must be cation.
LUBE SYMBOL CHART
Symbol Description Lube
Specification
AFC Antifreeze/Coolant - 50/50 Blended Fully Formulated, Low Silicate, Ethylene-Glycol A6-829-101130
Type, SAE J1941
EO-15W-40 Engine Oil - SAE 15W-40, API Service Classification CI-4. A6-829-003483
AGMA EP-4 Extreme Pressure Gear Lubricant - AGMA No. 4 EP rating. A6-829-100213
EP-MPG Extreme Pressure Multipurpose Grease - Lithium Soap Base, NLGI Grade 2. A6-829-003477
EP-OGL Open Gear Lubricant - Fuchs CEPLATTYN 300 Spray. Service temperature -30°C to A6-829-102971
+250°C
HYDO Hydraulic Oil - Must meet John Deere Standard JDM-J20C (Antibrake chatter) and ISO A6-829-006444
4406 level 17/14 upon delivery.
SBF Silicone Brake Fluid - MIL-B-46176. A6-829-006952
SSGL-5 Semi-Synthetic Gear Lubricant - SAE Grade 80W-90, API Service Designation GL-5. A6-829-102964
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RT500E SERIES LUBRICATION
10 11 21 20
5 7 7
17 9 8 19 37 4 12
18 15 3
13
6
14
16
27
25 38 6
31 1 2
30 24 36 22
34 35 29 23 33 32 31 30
32 23 33 34 29
6398
22 26
28
1. Hook Block Swivel Bearing 15. Upper Lift Cylinder Pivot Pin 27. Engine Cooling System
2. Hook Block Sheaves 16. Lower Lift Cylinder Pivot Pins 28. Coolant Strainer
3. Telescope Cylinder Wear Pads 17. Main Hoist 29. Drive Line - Slip and U-Joints
4. Side Wear Pads 18. Auxiliary Hoist (Optional) 30. Outrigger Beams
5. Boom Section Upper Wear Pads 19. Turntable Gearbox 31. Jack Cylinder Support Tubes
6. Boom Section Lower Wear Pads 20. Turntable Gear and Drive Pinion 32. Steer Cylinder Pivot Pins
7. Extend Cable Sheaves 21. Turntable Bearing 33. Upper and Lower King Pins
8. Retract Cable Sheave 22. Differentials 34. Fifth Wheel Pivots
9. Boom Pivot Shaft 23. Planetary Hubs and Wheel 35. Lockout Cylinder pivot Pins
10. Boom Extension Sheave Bearings 36. Hydraulic Reservoir
11. Boom Extension Roller 24. Brake Master Cylinder (Far Side) 37. Hydraulic Filter
12. Upper Boom Nose Sheave 25. Engine Crankcase 38. Mast Sheave
13. Lower Boom Nose Sheave 26. Transmission, Torque Converter
14. Auxiliary Boom Nose Sheave and Filter
Lubrication Chart
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LUBRICATION RT500E SERIES
1. Hook Block Swivel Bearing 7. Extend Cable Sheaves
Lube Type - EP-MPG Lube Type - EP-MPG
Lube Interval - 250 hours or 3 months Lube Interval - 250 hours or 3 months
Lube Amount - Until grease extrudes Lube Amount - Until grease extrudes
Application - 1 grease fitting Application - 3 grease fittings (RT530E); 1 grease
fitting (RT525E); extend boom for entry
2. Hook Block Sheaves through access holes at front top of inner mid
section.
Lube Type - EP-MPG
Lube Interval - 250 hours or 3 months 8. Retract Cable Sheaves
Lube Amount - Until grease extrudes
Application - 1 grease fitting per sheave Lube Type - EP-MPG
(3 fittings total - 30 ton) Lube Interval - 250 hours or 3 months
(2 fittings total - 15 ton) Lube Amount - Until grease extrudes
Application - 4 grease fittings (RT530E); 2 grease
3. Telescope Cylinder Wear Pads fittings (RT525E); extend boom for entry
through access holes
Lube Type - EP-MPG
Lube Interval -125 hours or 3 months 9. Boom Pivot Shaft
Lube Amount - Thoroughly coat the area the wear
pad moves on. Lube Type - EP-MPG
Application - By brush: 2 places; extend boom for Lube Interval - 250 hours or 3 months
entry through access holes in fly section Lube Amount - Until grease extrudes
Application - 2 grease fittings, one on each side
4. Side Wear Pads
10. Boom Extension Sheave
Lube Type - EP-MPG
Lube Interval - 250 hours or 3 months Lube Type - EP-MPG
Lube Amount - Thoroughly coat the area the wear Lube Interval - 250 hours or 3 months
pad moves on. Lube Amount - Until grease extrudes
Application - By brush: 12 places (RT530E) - 8 Application - 1 grease fitting
places (RT525E); with boom in extended posi-
11. Boom Extension Roller (RT530)
tion.
Lube Type - EP-MPG
5. Boom Section Upper Wear Pads Lube Interval - 250 hours or 3 months
Lube Amount - Until grease extrudes
Lube Type - EP-MPG
Application - 1 grease fitting
Lube Interval - 50 hours or 1 week
Lube Amount - Thoroughly coat the area the wear 12. Upper Boom Nose Sheave
pad moves on.
Application - By brush: 6 places; with boom in Lube Type - EP-MPG
extended position. Lube Interval - 250 hours or 3 months
Lube Amount - Until grease extrudes
6. Boom Section Lower Wear Pads Application - 1 grease fitting per sheave
Lube Type - EP-MPG 13. Lower Boom Nose Sheave
Lube Interval - 50 hours or 1 week
Lube Amount - Thoroughly coat the area the wear Lube Type - EP-MPG
pad moves on. Lube Interval - 250 hours or 3 months
Application - By brush; 3 places; extend boom for Lube Amount - Until grease extrudes
entry through access holes Application - 1 grease fitting per sheave
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14. Auxiliary Boom Nose Sheave Lube Interval - Check and fill every 50 hours. Drain
and fill after first 250 hours and every 500 hours
Lube Type - EP-MPG or 12 months thereafter.
Lube Interval - 250 hours or 3 months
Lube Amount - Until grease extrudes CAUTION
Application - 1 grease fitting
USE OF NON-SEMI-SYNTHETIC LUBRI-
15. Upper Lift Cylinder Pivot Pin CANT MAY DAMAGE COMPONENTS AND/
OR INVALIDATE PUBLISHED LUBRICA-
Lube Type - EP-MPG TION INTERVALS.
Lube Interval - 500 hours or every 3 months
Lube Amount - Until grease extrudes Lube Amount -
Application - 1 grease fitting Tulsa Gearbox - Capacity - 1.6 liters (1.75 quarts)
Application - Fill until oil appears in sight gauge.
16. Lower Lift Cylinder Pivot Pins SOM Gearbox - Capacity - 4.0 liters (4.25 quarts)
Application - Fill mark on dipstick
Lube Type - EP-MPG
Lube Interval - 500 hours or 3 months 20. Turntable Gear and Drive Pinion
Lube Amount - Until grease extrudes
Application - 2 grease fittings Lube Type - EP-OGL
Lube Interval - 500 hours or 6 months
17. Main Hoist Lube Amount - Coat all teeth
Application - Spray on
Lube Type - AGMA EP-4
Lube Interval - Every 1000 hours or 12 months 21. Turntable Bearing
Lube Amount - Capacity - 5.2 liters (5.5 quarts)
Application - Fill until level with the check plug Lube Type - EP-MPG
opening. Lube Interval - 500 hours or 6 months
Lube Amount - Until grease extrudes the whole
18. Auxiliary Hoist (Optional) circumference of the bearing.
Application - 2 grease fittings at the front of the
Lube Type - AGMA EP-4 turntable. Rotate the turntable 90° and apply
Lube Interval - Every 1000 hours or 12 months grease to fittings. Continue rotating 90° and
Lube Amount - Capacity - 5.2 liters (5.5 quarts) grease the fittings until the whole bearing is
Application - Fill until level with the check plug greased.
opening.
22. Differentials
19. Turntable Gear Box
Lube Type - SSGL-5
Lube Type - SSGL-5 Lube Interval - Check lubricant level every 500
hours or 3 months and refill as necessary. Drain
NOTE
and refill every 4000 hours or 2 years.
Remove one valve to equalize the pres-
CAUTION
sure before checking the swing gearbox
oil level. This will keep the oil from push-
ing out. IF THE MAKEUP AMOUNT IS SUBSTAN-
TIALLY MORE THAN 0.5 PINT (0.23 LITER)
CHECK FOR LEAKS.
CAUTION
WHEN CHECKING THE SWING GEAR CAUTION
BOX OIL LEVEL, PLACE THE DIPSTICK
INTO THE SLEEVE UNTIL THE CAP IS USE OF NON-SEMI-SYNTHETIC LUBRI-
FLUSH WITH THE END OF THE SLEEVE. CANT MAY DAMAGE COMPONENTS AND/
DO NOT SCREW THE CAP ONTO THE OR INVALIDATE PUBLISHED LUBRICA-
SLEEVE TO CHECK THE LEVEL. TION INTERVALS.
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LUBRICATION RT500E SERIES
Lube Amount - Capacity - 9.5 liters (20 pints) Nor- 2. Run engine at 800 rpm to prime torque con-
mal makeup - less than 0.23 liter (0.5 pint) verter and lines.
Application - Fill to bottom of hole in the housing 3. Check oil level with engine running at 800
on the steer cylinder side. rpm and oil at 82 to 93 °C (180 to 200 °F). Add
oil to bring oil level to FULL mark on dipstick.
23. Planetary Hubs and Wheel Bearings
NOTE
Lube Type - SSGL-5
Lube Interval - Check fluid level every 500 hours or When checking the oil level, the oil tem-
3 months and refill as necessary. Drain and refill perature must be stabilized at 82 to 93 °C
every 4000 hours or 2 years. (180 to 200 °F) to properly check the oil
level. Do not attempt an oil level check
CAUTION with cold oil. To bring the oil temperature
to this range, it is necessary to either
USE OF NON-SEMI-SYNTHETIC LUBRI- work the crane or stall the converter. Con-
CANT MAY DAMAGE COMPONENTS AND/ verter stall should be accomplished by
OR INVALIDATE PUBLISHED LUBRICA- engaging the shift lever in forward high
TION INTERVALS. range with the brakes applied and then
accelerating the engine to half or three-
Lube Amount - 1.6 liters (3.5 pints) quarter throttle. Hold the stall until the
desired converter temperature is reached
Application - Fill to the bottom of the level hole in
and stabilized.
the housing with the fill plug and the oil level
mark horizontal. CAUTION
24. Brake Master Cylinder FULL THROTTLE STALL SPEEDS FOR AN
EXCESSIVE LENGTH OF TIME WILL
Lube Type - SBF OVERHEAT THE CONVERTER AND
Lube Interval - Check fluid level every 500 hours or CAUSE SERIOUS DAMAGE.
3 months and fill as required
Lube Amount - Capacity - 1.9 liters (4 pints) Lube Amount - Capacity - Torque converter, lines,
Application - Fill cap on top of master cylinder and transmission as a system - Approximately
23.7 liters (25 quarts).
25. Engine Crankcase Application - Through fill pipe to FULL mark on
dipstick.
Lube Type - EO-15W-40
Lube Interval - Check fluid level every 10 hours or 27. Engine Cooling System
daily; drain and fill filter every 250 hours.
Drain, fill and replace filter every 500 hours. Lube Type - AFC
Lube Amount - Capacity - 16.4 liters (17.3 quarts) Lube Interval - Check coolant level every 10 hours
or daily; drain and refill cooling system in
Application - Fill to full mark on dipstick. accordance with Engine Service Manual.
Lube Amount - Capacity - 32.2 liters (34 quarts)
26. Transmission, Torque Converter and Transmis- Application - Fill radiator with mixture of 50% AFC
sion Filter and 50% water to bottom of the surge tank filler
Lube Type -HYDO neck. Run engine through two (2) thermal
cycles. Check coolant level and refill as
Lube Interval - Check fluid level every 10 hours or required.
daily with the engine running at 800 rpm and the
oil at 82 to 93 °C (180 to 200 °F); Drain and 28. Coolant Strainer (Cab Heater Supply)
refill every 1000 hours or 6 months with the oil
at 65 to 93 °C (150 to 200 °F); change transmis- Lube Type - Not applicable
sion filter after the first 50 and 100 hours of ser- Lube Interval - Change strainer element at first 100
vice, then every 500 hours thereafter. hour interval and thereafter every 2000 hours or
12 months or when cab heater performance
To add fluid: becomes poor.
Lube Amount - Not applicable
1. Fill to FULL mark on dipstick. Application - Not applicable
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RT500E SERIES LUBRICATION
29. Drive Line - Slip and U-Joints Lube Interval - 500 hours or 3 months
Lube Amount - Until grease extrudes
Lube Type - EP-MPG
Lube Interval - 500 hours or every 3 months Application - 4 fittings
Lube Amount - Until grease extrudes
36. Hydraulic Reservoir
Application - 6 grease fittings
Lube Type - HYDO
30. Outrigger Beams
Lube Interval - Check fluid level every 10 hours or
Lube Type - EP-OGL daily, using sight gauge on side of tank, with
Lube Interval - 500 hours or 6 months boom down and all outrigger cylinders
retracted; drain and refill as necessary.
Lube Amount - Spray lubricant on bottom of outrig-
ger beams. Lube Amount - 371 liters (98.0 gal.), to FULL mark
Application - Spray on on sight gauge.
Application - Fill through breather/fill cap on top of
31. Jack Cylinder Support Tubes tank. When tank is drained, clean the magnetic
pipe plug.
Lube Type - EP-OGL
Lube Interval - 500 hours or 6 months 37. Hydraulic Filter
Lube Amount - Spray lubricant on ID of jack cylin-
der support tubes before installing jack cylin- Lube Type - Not applicable
ders. Lube Interval - Change the filter when the restric-
Application - Spray on tion indicator gauge on the filter head is in the
red.
32. Steering Cylinder Pivot Pins
Lube Amount - Not applicable
Lube Type - EP-MPG Application - Not applicable
Lube Interval - 500 hours or 3 months
Lube Amount - Until grease extrudes 38. Mast Sheave
Application - 8 grease fittings
Lube Type - EP-MPG
33. Upper and Lower King Pins Lube Interval - 500 hours or 12 months
Lube Amount - As Necessary
Lube Type - EP-MPG
Lube Interval - 500 hours or 3 months Application - Disassemble sheave and repack bear-
ing.
Lube Amount - Until grease extrudes
Application - 8 grease fittings
WIRE ROPE LUBRICATION
34. Fifth Wheel Pivots
Wire rope is lubricated during manufacturing so that the
Lube Type - EP-MPG strands, and individual wires in strands, may move as the
Lube Interval - 500 hours or 3 months rope moves and bends. A wire rope cannot be lubricated
sufficiently during manufacture to last its entire life.
Lube Amount - Until grease extrudes
Therefore, new lubricant must be added periodically
Application - 2 grease fittings throughout the life of a rope to replace factory lubricant
which is used or lost. For more detailed information con-
35. Lockout Cylinder Pivot Pins cerning the lubrication and inspection of wire rope, refer
to WIRE ROPE in Chapter 1, Section 2 - GENERAL
Lube Type - EP-MPG MAINTENANCE in the Service Manual.
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