Manitowoc Grove RT530E-2

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HOIST AND COUNTERWEIGHT RT530E-2 SERVICE MANUAL

5-16 Published 4-22-15, Control # 556-00

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Table of Contents5
Section 113
List of Specifications14
General14
Dimensions14
Capacities14
Torque Converter/Transmission14
Engine14
Axles14
Brakes14
Wheels and Tires14
Swing Gearbox14
Hydraulic Pumps15
General Maintenance20
Cleanliness20
Removal and Installation20
Disassembly and Assembly20
Pressing Parts20
Locks20
Wires and Cables21
Shims21
Bearings21
Gaskets21
Batteries21
Hydraulic Systems22
Electrical System23
Fatigue of Welded Structures23
Loctite24
Fasteners and Torque Values24
Weld Studs28
Wire Rope29
General29
Environmental Conditions29
Dynamic Shock Loads29
Lubrication29
Precautions and Recommendations During Inspection or Replacement29
Wire Rope Inspection (Running Ropes and pendant Cables)30
Wire Rope Inspection (Boom Extension and Retraction Cables)31
Wire Rope Inspection/Replacement (All Wire Rope)31
Seizing Wire Rope32
Installing 35X7 Class Wire Rope33
Procedures for Cutting and Preparing 35X7 Class Wire Rope33
Section 235
Description36
Maintenance39
Hydraulic Oil Recommendations39
Draining and Flushing39
Removing Air from the Hydraulic System40
Parts Replacement40
Directional Control Valves40
Supply Pressure and Return Circuit42
Description42
Maintenance43
Oil Cooler47
Description47
Hydraulic Pumps48
Description48
Maintenance48
Pressure Setting Procedures51
Procedure a - for Checking/Setting the Main Control Valve for Hoists(S), Boom Lift and Piston Pump53
Procedure B - for Setting the Outrigger/Rear Steer/Oil Cooler Motor Pressures53
Procedure C - for Checking/Setting the Swing Directional Control Valve Work Port Relief Valves54
Procedure C - for Checking/Setting the Swing Direc- Tional Control Valve Work Port Relief Valves54
Procedure D - for Checking/Setting the Service Brake Dual Accumulator Charge Valve Charging Limits54
Procedure E - for Checking/Pre-Charging the Service Brake Accumulators54
Procedure F - for Checking/Setting the Front Steer Pressure55
Procedure G - for Checking/Setting the Pilot Supply Pressure55
Procedure H - for Checking/Setting the Swing Brake Release Pressure55
Procedure J - for Setting Threshold on Electronic Controllers55
Procedure K - Setting Threshold and Max on Swing Brake Pedal56
Valves61
General61
Directional Control Valves64
Description64
Maintenance64
Accessory with Swing Directional Control Manifold67
Description67
Maintenance67
Steering Control Valve69
Description69
Maintenance69
Tandem Brake Valve with Treadle Pedal70
Description70
Maintenance70
Dual Accumulator Charge Valve71
Description71
Maintenance71
Hydraulic Accumulator Service Brake73
Description73
Maintenance73
Holding Valves74
Description74
Maintenance74
Cross Axle Differential Lock Valve75
Description75
Maintenance75
Outrigger Control Manifold77
Description77
Maintenance77
Pilot Operated Check Valve78
Description78
Maintenance78
Integrated Outrigger/Rear Steer Manifold79
Description79
Maintenance79
Check Valves82
Description82
Maintenance82
Range Shift/Parking Brake Valve83
Description83
Maintenance83
Axle Oscillation Lockout Valve (Standard Units)84
Description84
Maintenance84
Axle Oscillation Lockout Valve (Optional CE Units)86
Description86
Maintenance86
Cylinders88
General88
Maintenance88
Surface Protection for Cylinder Rods88
Lift Cylinder91
Description91
Maintenance91
Dual Rod Telescope Cylinder94
Description94
Maintenance94
Axle Oscillation Lockout Cylinder98
Description98
Maintenance98
Steer Cylinder102
Description102
Maintenance102
Outrigger Extension Cylinder105
Description105
Maintenance105
Outrigger Jack Cylinder107
Description107
Maintenance107
Description111
General111
Batteries111
Fuse Panel112
Relays113
Maintenance114
General114
General Troubleshooting114
Troubleshooting Swivel-Caused Electrical Problems114
Connector Troubleshooting114
Troubleshooting Engine Starting Problems115
Troubleshooting Engine Charging Problems115
Troubleshooting Accessories116
Electric System116
Alternator Replacement117
Starter Replacement117
Battery Replacement118
Relay Panel Component Replacement118
Rocker Switch Replacement118
Ignition Switch Replacement119
Turn Signal Lever and Transmission Shift Lever Replacement120
Windshield Wiper Assembly Replacement122
Windshield Washer Assembly Replacement123
Skylight Wiper Assembly Replacement123
Appendix A: Crane Control System (CCS) Fault Codes126
Section 4149
Description149
Theory of Operation149
Boom Extension149
Boom Retraction150
Maintenance154
Removal154
Boom Disassembly154
Remove the Base Section154
Disconnect Inner MID Section156
Remove the Inner MID Section157
Remove Outer MID Section158
Remove Telescope Cylinder160
Boom Nose Sheaves161
Boom Assembly161
Install Telescope Cylinder161
Install Outer MID Section162
Install Inner MID Section164
Connect Inner MID Section165
Install Base Section166
Boom Installation167
Functional Check167
Inspection167
Boom Alignment and Servicing167
Boom Extension and Retraction Cable168
Maintenance168
Inspection168
Extension Cable Adjustment168
Retract Cable Adjustment169
Telescope Circuit169
Description169
Theory of Operation169
Maintenance170
Lift Circuit173
Description173
Theory of Operation173
Maintenance173
Swingaway Boom Extension177
Description177
Maintenance177
Hook Block182
Description183
Warm-Up Procedure183
Removal184
Installation185
Functional Check185
Servicing185
Fluid Level185
Usage and Inspection186
Preventative Maintenance186
Oil Sampling188
Brake Test Procedure188
Hoist to Boom Alignment189
Preparation189
Tools Required189
Procedure190
Piston Motor and Control Valve191
Description191
Maintenance191
Hoist Drum Rotation Indicator System194
Description194
Maintenance194
Counterweight Removal196
Description196
Theory of Operation199
Description200
Maintenance201
Troubleshooting201
Swing Motor204
Description204
Maintenance204
Swing Gearbox and Brake205
Description205
Maintenance205
Swing Bearing207
Description207
Maintenance207
Swivels212
Description212
Hydraulic Swivel214
Description214
Electrical Swivel216
Section 7219
Engine219
Description219
Maintenance220
Description223
Fuel System225
Description225
Maintenance225
Description226
Air Intake and Exhaust System227
Description227
Air Intake227
Charge-Air Cooler System231
Muffler and Diesel Oxidation Catalyst - Tier 4 Interim232
Slip Joint Exhaust Connectors232
Water Cooling System234
Description234
Maintenance234
Test Equipment237
Antifreeze/Coolant237
Radiator Removal and Installation237
Drive Train239
Description239
Maintenance239
Transmission/Torque Converter239
Theory of Operation239
Maintenance240
Servicing the Crane after Transmission/Torque Converter Overhaul243
Axles245
Description245
Maintenance246
Wheels and Tires251
Description251
Maintenance251
Steering Systems252
Description252
Theory of Operation252
Rear Steering System252
Hydraulic Pumps255
Front Steering Control Valve255
Integrated Outrigger/Rear Steer Manifold255
Steer Cylinders256
Rear Axle Oscillation Lockout System257
Description257
Axle Oscillation Lockout Cylinders257
Brake System258
Description258
Theory of Operation258
Maintenance259
Service Brakes260
Description260
Maintenance260
Corrosion Protection264
Parking Brake Actuator266
Description266
Maintenance266
Parking Brake267
Description267
Maintenance267
Park Brake Valve268
Description268
Outriggers268
Outrigger Circuit268
Outrigger Beam272
Extension Cylinder276
Jack Cylinder277
Outrigger Control Valves279
Section 9281
General281
Lubrication Intervals281
Arctic Conditions below -18°C (0°F)281
Arctic Conditions down to -40° C (-40°F)281
Surface Protection for Cylinder Rods282
Wire Rope Lubrication282
Lubrication Points283
Cranelube283
Safety283
Steering and Suspension284
Axles286
Drive Train288
Drive Train (Continued)290
Outriggers292
Turntable294
Boom296
Boom (Continued)296
Boom (Continued)298
Hoist300
Hydraulic302
Carwell® Rust Inhibitor304
Protecting Cranes from Rusting304
Cleaning Procedures304
Inspection and Repair305
Application305
Areas of Application305

Manitowoc Grove RT530E-2 - Page 198

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