Published 4-20-2015, Control # 502-01 5-5
RT540E SERVICE MANUAL HOIST AND COUNTERWEIGHT
Pre-Use or Daily Inspection
Must include but is not limited to the following inspections
that will be performed prior to placing the crane into service
and then as necessary during extended operation. This
inspection must be performed by a qualified crane operator
or qualified crane technician.
1. Check for external oil leaks and repair as necessary.
This is extremely important due to the accelerated wear
that will result from insufficient lubricating oil in the hoist.
Hoists with a sight glass; check oil level daily. Hoists
without a sight glass; check oil level monthly if no
external oil leaks are detected. Lubricant level must be
maintained between the minimum and maximum levels;
midway up sight glass or at bottom of level plug port as
equipped. Use ONLY the recommended type of
lubricant. Refer to the machine’s lubrication chart.
2. Check hydraulic fittings and hoses for chaffing,
deterioration or corrosion and repair as necessary.
3. 3. Visually inspect for corroded, loose or missing bolts,
pins or other fasteners and replace or tighten as
necessary.
4. 4. Visually inspect rotation indicator transmitters, anti-
two-blocking switches and other safety equipment and
repair as necessary.
Quarterly Inspection (every three months)
Must include but is not limited to the following inspections
that must be performed by a qualified crane operator or
qualified crane technician.
1. Perform the pre-use inspection.
2. Inspect for corrosion of fasteners, hoist base, drum, etc.
and repair/replace as required to maintain the structural
integrity of the hoist.
Semi-Annual Inspections (every six months)
1. Perform the pre-use and quarterly inspections.
2. Take a sample of the lubricant from the hoist gear cavity
as described on this page and analyze it for wear metals
content, correct viscosity, lubricant deterioration,
moisture and other contaminants. If the oil sample
contains a high amount of metallic particles, the hoist
must be taken out of service to undergo a tear down
inspection.
NOTE: Oil analysis alone cannot detect nor warn against a
fatigue failure.
Annual Inspection
This inspection must be carried out by a qualified crane
technician. The annual inspection MUST include, but not be
limited, to the following:
1. Perform the pre-use/daily, quarterly and semi-annual
inspections.
2. Change the lubricating oil in the hoist gear cavity after an
oil sample has been taken as described on this page.
Refill the hoist to the proper level with recommended
lubricant. Refer to the machine’s lubrication chart.
PREVENTIVE MAINTENANCE AND OIL
SAMPLING
Oil Change
The hoist gear oil must be changed after the first 100
operating hours then on an annual basis, at a minimum
thereafter. In severe duty applications, the gear oil should be
changed every six months. Use the recommended
lubricants. Refer to the machine’s lubrication chart.
Gear Oil Sampling and Analysis
Proper gear oil sampling and analysis is a vital part of a
comprehensive preventive maintenance program.
Information obtained from the oil analysis allows the
maintenance technician to substitute preventive
maintenance for more costly unscheduled down time or a far
WARNING
Possible equipment damage and/or
personal injury!
Failure to use the proper type and viscosity of planetary
gear oil may contribute to intermittent brake clutch
slippage which could result in property damage, severe
personal injury or death. Some gear lubricants contain
large amounts of EP (extreme pressure) and anti-friction
additives which may contribute to brake clutch slippage or
damage to brake friction discs or seals. Oil viscosity with
regard to ambient temperature is also critical to reliable
brake clutch operation. Our tests indicate that excessively
heavy or thick gear oil may contribute to intermittent brake
clutch slippage. Make certain that the gear oil viscosity
used in your hoist is correct for your prevailing ambient
temperature.
WARNING
Risk of personal injury!
Hot oil may cause personal injury and/or burns to
unprotected skin. Make certain the oil has cooled to a
safe temperature (typically less than 43°C or 110°F)
before taking an oil sample, changing oil or servicing the
hoist.
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