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Grove RT540E
Manitowoc Grove RT540E Service Maintenance Manual
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Published 4-20-2015, Control # 502-01
4-43
RT540E SERVICE MANUAL
BOOM
4
GROVE
.
UPPER
PIVOT SHAFT
FIGURE
4-
100
RET
AINING BOL
T
LOWER PI
VOT SHAFT
DET
AIL B
DET
AIL A
A
B
Reference
Only
188
190
Table of Contents
Table of Contents
5
Section 1
13
Description
13
List of Specifications
14
General
14
Dimensions
14
Capacities
14
Torque Converter/Transmission
14
Engine
14
Axles
14
Brakes
14
Wheels and Tires
14
Swing Gearbox
14
General Maintenance
19
Cleanliness
19
Removal and Installation
19
Disassembly and Assembly
19
Pressing Parts
19
Locks
19
Wires and Cables
20
Shims
20
Bearings
20
Gaskets
20
Batteries
20
Hydraulic Systems
21
Electrical System
22
Fatigue of Welded Structures
22
Loctite
22
Fasteners and Torque Values
23
Weld Studs
26
Wire Rope
27
General
27
Environmental Conditions
27
Dynamic Shock Loads
27
Lubrication
27
Precautions and Recommendations During Inspection or Replacement
27
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 Rope
30
Installing 35X7 Class Wire Rope
31
Procedures for Cutting and Preparing 35X7 Class Wire Rope
31
Section 2
33
Description
34
Maintenance
37
Hydraulic Oil Recommendations
37
Draining and Flushing
37
Removing Air from the Hydraulic System
38
Parts Replacement
38
Directional Control Valves
38
Supply Pressure and Return Circuit
40
Description
40
Maintenance
41
Oil Cooler
45
Description
45
Hydraulic Pumps
46
Description
46
Maintenance
46
Pressure Setting Procedures
49
Procedure a - Checking/Setting the Main Control Valve for Hoist(S), Boom Lift and Piston Pump
51
Procedure B - Setting the Outrigger/Rear Steer/Oil Cooler Motor Pressures
51
Procedure C - Checking/Setting the Swing Directional Control Valve Work Port Relief Valves
52
Procedure D - Checking/Setting the Service Brake Dual Accumulator Charge Valve Charging Limits
52
Procedure E - Checking/Pre-Charging the Service Brake Accumulators
52
Procedure F - Checking/Setting the Front Steer Pressure
53
Procedure G - Checking/Setting the Pilot Supply Pressure
53
Procedure H - Checking/Setting the Swing Brake Release Pressure
53
Procedure J - Setting Threshold on Electronic Controllers
53
Procedure K - Setting Threshold and Max on Swing Brake Pedal
54
Valves
59
General
59
Directional Control Valves
62
Description
62
Maintenance
62
Accessory with Swing Directional Control Manifold
65
Description
65
Maintenance
65
Steering Control Valve
67
Description
67
Maintenance
67
Tandem Brake Valve with Treadle Pedal
68
Description
68
Maintenance
68
Dual Accumulator Charge Valve
69
Description
69
Maintenance
69
Hydraulic Accumulator Service Brake
71
Description
71
Maintenance
71
Holding Valves
72
Description
72
Maintenance
72
Cross Axle Differential Lock Valve
73
Description
73
Maintenance
73
Outrigger Control Manifold
75
Description
75
Maintenance
75
Pilot Operated Check Valve
76
Description
76
Maintenance
76
Integrated Outrigger/Rear Steer Manifold
77
Description
77
Maintenance
77
Check Valves
80
Description
80
Maintenance
80
Range Shift/Parking Brake Valve
81
Description
81
Maintenance
81
Axle Oscillation Lockout Valve (Standard Units)
82
Description
82
Maintenance
82
Axle Oscillation Lockout Valve (Optional CE Units)
84
Description
84
Maintenance
84
Cylinders
86
General
86
Maintenance
86
Surface Protection for Cylinder Rods
86
Lift Cylinder
89
Description
89
Maintenance
89
Dual Rod Telescope Cylinder
92
Description
92
Maintenance
92
Axle Oscillation Lockout Cylinder
96
Description
96
Maintenance
96
Steer Cylinder
100
Description
100
Maintenance
100
Outrigger Extension Cylinder
103
Description
103
Maintenance
103
Outrigger Jack Cylinder
105
Description
105
Maintenance
105
Description
109
General
109
Batteries
109
Fuse Panel
110
Relays
111
Maintenance
112
General
112
General Troubleshooting
112
Troubleshooting Swivel-Caused Electrical Problems
112
Connector Troubleshooting
112
Troubleshooting Engine Starting Problems
113
Troubleshooting Engine Charging Problems
113
Troubleshooting Accessories
114
Electric System
114
Alternator Replacement
115
Starter Replacement
115
Battery Replacement
116
Relay Panel Component Replacement
116
Rocker Switch Replacement
116
Ignition Switch Replacement
117
Turn Signal Lever and Transmission Shift Lever Replacement
118
Windshield Wiper Assembly Replacement
120
Windshield Washer Assembly Replacement
121
Skylight Wiper Assembly Replacement
121
Appendix A: Crane Control System (CCS) Fault Codes
124
Section 4
147
Description
147
Safety
147
Boom System Components
148
Telescope Cylinder
148
Fly Section Extension Cables
148
Extend Synchronizing Cable
148
Fly Retraction Cables
148
Outer MID Retract Cables
148
Boom Extension Sequence
148
Boom Retract Sequence
150
Telescope Circuit
150
Description
150
Theory of Operation
150
Lift Circuit
150
General Maintenance Notes
151
Swingaway Extension Removable
151
Boom Removal
152
Disconnect the Base Section
153
Remove the Base Section
154
Disconnect the Inner MID Section
156
Remove the Inner MID Section
156
Remove the Outer MID Section
159
Remove the Tele Cylinder
160
Boom Nose Sheaves
161
Boom Nose Sheaves Removal
162
Boom Nose Sheaves Installation
162
Boom Assembly Procedure
163
Install Tele Cylinder
163
Install the Outer MID Section
166
Install the Inner MID Section
170
Install the Base Section
175
Final Boom Assembly
177
Swingaway Extension Installation
178
Tensioning the Boom Extend and Retract Cables
180
Boom Maintenance
182
Functional Test of the Boom
182
Boom Inspection
182
Boom Alignment and Servicing
182
Extension and Retraction Cable Maintenance
183
Inspection
183
Telescope Circuit Troubleshooting
184
Lift Circuit Troubleshooting
186
Lift Cylinder Maintenance
188
Lift Cylinder Removal
188
Lift Cylinder Disassembly and Assembly
188
Lift Cylinder Installation
188
Description
191
Theory of Operation
191
Maintenance
192
Warm-Up Procedure
192
Removal
192
Installation
193
Functional Check
193
Servicing
193
Hoist Maintenance and Inspection
194
Usage and Inspection
194
Pre-Use or Daily Inspection
195
Quarterly Inspection (Every Three Months)
195
Semi-Annual Inspections (Every Six Months)
195
Annual Inspection
195
Preventive Maintenance and Oil Sampling
195
Oil Change
195
Gear Oil Sampling and Analysis
195
Brake Test Procedure (to be Performed with no Load on the Hoist)
196
Brake Test Procedure for Hp15C-17G
196
17G, Ho30A-19G, Hp35-26G Hoists
196
Hoist to Boom Alignment
197
Preparation
197
Tools Required
197
Procedure
197
Piston Motor and Control Valve
198
Description
198
Maintenance
198
Idler Drum and Cable Follower
199
Description
199
Maintenance
199
Hoist Drum Rotation Indicator System
201
Description
201
Maintenance
201
Counterweight Removal
203
Introduction
205
Description
205
Theory of Operation
205
Description
206
Maintenance
207
Troubleshooting
207
Swing Motor
210
Description
210
Maintenance
210
Swing Gearbox and Brake
211
Description
211
Maintenance
211
Swing Bearing
213
Description
213
Maintenance
213
Swivels
218
Description
218
Hydraulic Swivel
220
Description
220
Electrical Swivel
222
Section 7
225
Engine
225
Description
225
Maintenance
226
Description
229
Fuel System
231
Description
231
Maintenance
231
Description
232
Air Intake and Exhaust System
233
Description
233
Air Intake
233
Charge-Air Cooler System
237
Muffler and Diesel Oxidation Catalyst - Tier 4 Interim
238
Slip Joint Exhaust Connectors
238
Water Cooling System
240
Description
240
Maintenance
240
Test Equipment
243
Antifreeze/Coolant
243
Radiator Removal and Installation
243
Drive Train
245
Description
245
Maintenance
245
Transmission/Torque Converter
245
Theory of Operation
245
Maintenance
246
Servicing the Crane after Transmission/Torque Converter Overhaul
249
Axles
251
Description
251
Maintenance
252
Wheels and Tires
257
Description
257
Maintenance
257
Steering Systems
260
Description
260
Theory of Operation
260
Rear Steering System
260
Hydraulic Pumps
263
Front Steering Control Valve
263
Integrated Outrigger/Rear Steer Manifold
263
Steer Cylinders
264
Rear Axle Oscillation Lockout System
265
Description
265
Axle Oscillation Lockout Cylinders
265
Brake System
266
Description
266
Theory of Operation
266
Maintenance
267
Service Brakes
268
Description
268
Maintenance
268
Corrosion Protection
272
Parking Brake Actuator
274
Description
274
Maintenance
274
Parking Brake
275
Description
275
Maintenance
275
Park Brake Valve
277
Description
277
Outriggers
277
Outrigger Circuit
277
Outrigger Beam
281
Extension Cylinder
285
Jack Cylinder
286
Outrigger Control Valves
288
General
289
Environmental Protection
289
Lubrication Intervals
289
Arctic Conditions below -18°C (0°F)
289
Arctic Conditions down to -40°F
290
Surface Protection for Cylinder Rods
290
Wire Rope Lubrication
291
Lubrication Points
292
Cranelube
292
Safety
292
Steering and Suspension
293
Axles
295
Drive Train
297
Drive Train (Continued)
299
Outriggers
301
Turntable
303
Boom
305
Boom (Continued)
307
Hoist
309
Hydraulic
311
Carwell® Rust Inhibitor
313
Protecting Cranes from Rusting
313
Cleaning Procedures
313
Inspection and Repair
314
Application
314
Areas of Application
314
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Manitowoc Grove RT540E Specifications
General
Brand
Manitowoc
Model
Grove RT540E
Category
Construction Equipment
Language
English
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