Manitowoc Grove RT540E

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TABLE OF CONTENTS RT540E SERVICE MANUAL

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Table of Contents5
Section 113
Description13
List of Specifications14
General14
Dimensions14
Capacities14
Torque Converter/Transmission14
Engine14
Axles14
Brakes14
Wheels and Tires14
Swing Gearbox14
General Maintenance19
Cleanliness19
Removal and Installation19
Disassembly and Assembly19
Pressing Parts19
Locks19
Wires and Cables20
Shims20
Bearings20
Gaskets20
Batteries20
Hydraulic Systems21
Electrical System22
Fatigue of Welded Structures22
Loctite22
Fasteners and Torque Values23
Weld Studs26
Wire Rope27
General27
Environmental Conditions27
Dynamic Shock Loads27
Lubrication27
Precautions and Recommendations During Inspection or Replacement27
Wire Rope Inspection (Running Ropes and pendant Cables)28
Wire Rope Inspection (Boom Extension and Retraction Cables)29
Wire Rope Inspection/Replacement (All Wire Rope)29
Seizing Wire Rope30
Installing 35X7 Class Wire Rope31
Procedures for Cutting and Preparing 35X7 Class Wire Rope31
Section 233
Description34
Maintenance37
Hydraulic Oil Recommendations37
Draining and Flushing37
Removing Air from the Hydraulic System38
Parts Replacement38
Directional Control Valves38
Supply Pressure and Return Circuit40
Description40
Maintenance41
Oil Cooler45
Description45
Hydraulic Pumps46
Description46
Maintenance46
Pressure Setting Procedures49
Procedure a - Checking/Setting the Main Control Valve for Hoist(S), Boom Lift and Piston Pump51
Procedure B - Setting the Outrigger/Rear Steer/Oil Cooler Motor Pressures51
Procedure C - Checking/Setting the Swing Directional Control Valve Work Port Relief Valves52
Procedure D - Checking/Setting the Service Brake Dual Accumulator Charge Valve Charging Limits52
Procedure E - Checking/Pre-Charging the Service Brake Accumulators52
Procedure F - Checking/Setting the Front Steer Pressure53
Procedure G - Checking/Setting the Pilot Supply Pressure53
Procedure H - Checking/Setting the Swing Brake Release Pressure53
Procedure J - Setting Threshold on Electronic Controllers53
Procedure K - Setting Threshold and Max on Swing Brake Pedal54
Valves59
General59
Directional Control Valves62
Description62
Maintenance62
Accessory with Swing Directional Control Manifold65
Description65
Maintenance65
Steering Control Valve67
Description67
Maintenance67
Tandem Brake Valve with Treadle Pedal68
Description68
Maintenance68
Dual Accumulator Charge Valve69
Description69
Maintenance69
Hydraulic Accumulator Service Brake71
Description71
Maintenance71
Holding Valves72
Description72
Maintenance72
Cross Axle Differential Lock Valve73
Description73
Maintenance73
Outrigger Control Manifold75
Description75
Maintenance75
Pilot Operated Check Valve76
Description76
Maintenance76
Integrated Outrigger/Rear Steer Manifold77
Description77
Maintenance77
Check Valves80
Description80
Maintenance80
Range Shift/Parking Brake Valve81
Description81
Maintenance81
Axle Oscillation Lockout Valve (Standard Units)82
Description82
Maintenance82
Axle Oscillation Lockout Valve (Optional CE Units)84
Description84
Maintenance84
Cylinders86
General86
Maintenance86
Surface Protection for Cylinder Rods86
Lift Cylinder89
Description89
Maintenance89
Dual Rod Telescope Cylinder92
Description92
Maintenance92
Axle Oscillation Lockout Cylinder96
Description96
Maintenance96
Steer Cylinder100
Description100
Maintenance100
Outrigger Extension Cylinder103
Description103
Maintenance103
Outrigger Jack Cylinder105
Description105
Maintenance105
Description109
General109
Batteries109
Fuse Panel110
Relays111
Maintenance112
General112
General Troubleshooting112
Troubleshooting Swivel-Caused Electrical Problems112
Connector Troubleshooting112
Troubleshooting Engine Starting Problems113
Troubleshooting Engine Charging Problems113
Troubleshooting Accessories114
Electric System114
Alternator Replacement115
Starter Replacement115
Battery Replacement116
Relay Panel Component Replacement116
Rocker Switch Replacement116
Ignition Switch Replacement117
Turn Signal Lever and Transmission Shift Lever Replacement118
Windshield Wiper Assembly Replacement120
Windshield Washer Assembly Replacement121
Skylight Wiper Assembly Replacement121
Appendix A: Crane Control System (CCS) Fault Codes124
Section 4147
Description147
Safety147
Boom System Components148
Telescope Cylinder148
Fly Section Extension Cables148
Extend Synchronizing Cable148
Fly Retraction Cables148
Outer MID Retract Cables148
Boom Extension Sequence148
Boom Retract Sequence150
Telescope Circuit150
Description150
Theory of Operation150
Lift Circuit150
General Maintenance Notes151
Swingaway Extension Removable151
Boom Removal152
Disconnect the Base Section153
Remove the Base Section154
Disconnect the Inner MID Section156
Remove the Inner MID Section156
Remove the Outer MID Section159
Remove the Tele Cylinder160
Boom Nose Sheaves161
Boom Nose Sheaves Removal162
Boom Nose Sheaves Installation162
Boom Assembly Procedure163
Install Tele Cylinder163
Install the Outer MID Section166
Install the Inner MID Section170
Install the Base Section175
Final Boom Assembly177
Swingaway Extension Installation178
Tensioning the Boom Extend and Retract Cables180
Boom Maintenance182
Functional Test of the Boom182
Boom Inspection182
Boom Alignment and Servicing182
Extension and Retraction Cable Maintenance183
Inspection183
Telescope Circuit Troubleshooting184
Lift Circuit Troubleshooting186
Lift Cylinder Maintenance188
Lift Cylinder Removal188
Lift Cylinder Disassembly and Assembly188
Lift Cylinder Installation188
Description191
Theory of Operation191
Maintenance192
Warm-Up Procedure192
Removal192
Installation193
Functional Check193
Servicing193
Hoist Maintenance and Inspection194
Usage and Inspection194
Pre-Use or Daily Inspection195
Quarterly Inspection (Every Three Months)195
Semi-Annual Inspections (Every Six Months)195
Annual Inspection195
Preventive Maintenance and Oil Sampling195
Oil Change195
Gear Oil Sampling and Analysis195
Brake Test Procedure (to be Performed with no Load on the Hoist)196
Brake Test Procedure for Hp15C-17G196
17G, Ho30A-19G, Hp35-26G Hoists196
Hoist to Boom Alignment197
Preparation197
Tools Required197
Procedure197
Piston Motor and Control Valve198
Description198
Maintenance198
Idler Drum and Cable Follower199
Description199
Maintenance199
Hoist Drum Rotation Indicator System201
Description201
Maintenance201
Counterweight Removal203
Introduction205
Description205
Theory of Operation205
Description206
Maintenance207
Troubleshooting207
Swing Motor210
Description210
Maintenance210
Swing Gearbox and Brake211
Description211
Maintenance211
Swing Bearing213
Description213
Maintenance213
Swivels218
Description218
Hydraulic Swivel220
Description220
Electrical Swivel222
Section 7225
Engine225
Description225
Maintenance226
Description229
Fuel System231
Description231
Maintenance231
Description232
Air Intake and Exhaust System233
Description233
Air Intake233
Charge-Air Cooler System237
Muffler and Diesel Oxidation Catalyst - Tier 4 Interim238
Slip Joint Exhaust Connectors238
Water Cooling System240
Description240
Maintenance240
Test Equipment243
Antifreeze/Coolant243
Radiator Removal and Installation243
Drive Train245
Description245
Maintenance245
Transmission/Torque Converter245
Theory of Operation245
Maintenance246
Servicing the Crane after Transmission/Torque Converter Overhaul249
Axles251
Description251
Maintenance252
Wheels and Tires257
Description257
Maintenance257
Steering Systems260
Description260
Theory of Operation260
Rear Steering System260
Hydraulic Pumps263
Front Steering Control Valve263
Integrated Outrigger/Rear Steer Manifold263
Steer Cylinders264
Rear Axle Oscillation Lockout System265
Description265
Axle Oscillation Lockout Cylinders265
Brake System266
Description266
Theory of Operation266
Maintenance267
Service Brakes268
Description268
Maintenance268
Corrosion Protection272
Parking Brake Actuator274
Description274
Maintenance274
Parking Brake275
Description275
Maintenance275
Park Brake Valve277
Description277
Outriggers277
Outrigger Circuit277
Outrigger Beam281
Extension Cylinder285
Jack Cylinder286
Outrigger Control Valves288
General289
Environmental Protection289
Lubrication Intervals289
Arctic Conditions below -18°C (0°F)289
Arctic Conditions down to -40°F290
Surface Protection for Cylinder Rods290
Wire Rope Lubrication291
Lubrication Points292
Cranelube292
Safety292
Steering and Suspension293
Axles295
Drive Train297
Drive Train (Continued)299
Outriggers301
Turntable303
Boom305
Boom (Continued)307
Hoist309
Hydraulic311
Carwell® Rust Inhibitor313
Protecting Cranes from Rusting313
Cleaning Procedures313
Inspection and Repair314
Application314
Areas of Application314

Manitowoc Grove RT540E - Page 12

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