Manitowoc Grove RT530E-2 Service Manual – PDF DOWNLOAD

Manitowoc Grove RT530E-2 Service Manual – PDF DOWNLOAD

FILE DETAILS:

Manitowoc Grove RT530E-2 Service Manual – PDF DOWNLOAD

Language : English
Pages :314
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Manitowoc Grove RT530E-2 Service Manual – PDF DOWNLOAD

See back of this manual for Alphabetical Index 5
SECTION 1 13
Introduction 13
Description 13
List of Specifications 14
General 14
Dimensions 14
Capacities 14
Torque Converter/Transmission 14
Engine 14
Cummins QSB67 14
Axles 14
Brakes 14
Wheels and Tires 14
Swing Gearbox 14
Boom 14
Swivel Assembly 14
Hydraulic Pumps 15
Pump #1 15
Pump #2 15
Pump #3 15
Hoists 15
General Maintenance 20
Cleanliness 20
Removal and Installation 20
Disassembly and Assembly 20
Pressing Parts 20
Locks 20
Wires and Cables 21
Shims 21
Bearings 21
Antifriction Bearings 21
Double Row, Tapered Roller 21
Heating Bearings 21
Installation 21
Preload 21
Sleeve Bearings 21
Gaskets 21
Batteries 21
Hydraulic Systems 22
Cleanliness 22
Keep the System Clean 22
Sealing Elements 22
Hydraulic Lines 22
Visual Inspection of Hoses and Fittings 22
Electrical System 23
Connectors, Harnesses, Wires, and Connectors 23
Fatigue of Welded Structures 23
Loctite 24
Application of Medium Strength Loctite 24
Primer Application 24
Adhesive/Sealant Application 24
Fasteners and Torque Values 24
Torque Wrenches 24
Torque Values 25
Weld Studs 28
Wire Rope 29
General 29
Environmental Conditions 29
Dynamic Shock Loads 29
Lubrication 29
Precautions and Recommendations During Inspection or Replacement 29
Wire Rope Inspection (Running Ropes and Pendant Cables) 30
Keeping Records 30
Frequent Inspection 30
Periodic Inspection 31
Wire Rope Inspection (Boom Extension and Retraction Cables) 31
Periodic Inspection 31
Wire Rope Inspection/Replacement (All Wire Rope) 31
Seizing Wire Rope 32
Method 1 32
Method 2 32
Installing 35×7 Class Wire Rope 33
Procedures for Cutting and Preparing 35×7 Class Wire Rope 33
SECTION 2 35
Hydraulic System 35
Description 36
Maintenance 39
Hydraulic Oil Recommendations 39
Draining and Flushing 39
Removing Air from the Hydraulic System 40
Parts Replacement 40
Directional Control Valves 40
Inspection 40
Valve Leakage 41
Binding Spools 41
Supply Pressure and Return Circuit 42
Description 42
Hydraulic Reservoir and Filter 42
Pump Distribution 42
Pump No 1 42
Pump No 2 42
Pump No 3 42
Maintenance 43
Troubleshooting 43
Return Hydraulic Filter Assembly 46
Element Removal 46
Element Installation 46
Hydraulic Reservoir Removal 46
Hydraulic Reservoir Installation 46
Oil Cooler 47
Description 47
Hydraulic Pumps 48
Description 48
Pump No 1 48
Pump No 2 48
Pump No 3 48
Maintenance 48
No 1 Pump Removal 48
No 1 Pump Installation 48
No 2 Pump Removal 48
No 2 Pump Installation 49
No 3 Pump Removal 49
No 3 Pump Installation 49
Testing After Rebuild or Replacement 49
Hydraulic Gear Pump Start-up Procedure 49
Piston Pump Start-up Procedure 50
Pressure Setting Procedures 51
Procedure A – For Checking/Setting The Main Control Valve For Hoists(s), Boom Lift and Piston Pump 53
Procedure B – For Setting The Outrigger/ Rear Steer/Oil Cooler Motor Pressures 53
Procedure C – For Checking/Setting The Swing Directional Control Valve Work Port Relief Valves 54
Procedure D – For Checking/Setting The Service Brake Dual Accumulator Charge Valve Charging Limits 54
Procedure E – For Checking/Pre-Charging The Service Brake Accumulators 54
Procedure F – For Checking/Setting the Front Steer Pressure 55
Procedure G – For Checking/Setting the Pilot Supply Pressure 55
Procedure H – For Checking/Setting The Swing Brake Release Pressure 55
Procedure J – For Setting Threshold on Electronic Controllers 55
Procedure K – Setting Threshold and Max on Swing Brake Pedal 56
Valves 61
General 61
Directional Control Valves 64
Description 64
Maintenance 64
Boom Lift/Telescope/Hoist Valve Bank Removal 64
Boom Lift/Telescope/Hoist Valve Bank Installation 64
Functional Check (All Valve Banks) 64
Function Check – RCL Lockout Valves 64
Accessory With Swing Directional Control Manifold 67
Description 67
Maintenance 67
Removal 67
Installation 67
Steering Control Valve 69
Description 69
Maintenance 69
Removal 69
Installation 69
Tandem Brake Valve with Treadle Pedal 70
Description 70
Maintenance 70
Removal 70
Installation 70
Dual Accumulator Charge Valve 71
Description 71
Maintenance 71
Removal 71
Installation 71
Hydraulic Accumulator Service Brake 73
Description 73
Maintenance 73
Removal 73
Installation 73
Servicing 73
Holding Valves 74
Description 74
Maintenance 74
Removal 74
Installation 74
Cross Axle Differential Lock Valve 75
Description 75
Maintenance 75
Removal 75
Installation 75
Outrigger Control Manifold 77
Description 77
Maintenance 77
Removal 77
Inspection 77
Installation 77
Functional Check 77
Pilot Operated Check Valve 78
Description 78
Maintenance 78
Removal 78
Installation 78
Integrated Outrigger/Rear Steer Manifold 79
Description 79
Maintenance 79
Removal 79
Installation 79
Check Valves 82
Description 82
Maintenance 82
Removal 82
Installation 82
Range Shift/Parking Brake Valve 83
Description 83
Maintenance 83
Removal 83
Installation 83
Functional Tests 83
Axle Oscillation Lockout Valve (Standard Units) 84
Description 84
Maintenance 84
Removal 84
Installation 84
Axle Oscillation Lockout Valve (Optional CE Units) 86
Description 86
Maintenance 86
Removal 86
Installation 86
Cylinders 88
General 88
Maintenance 88
General 88
Surface Protection for Cylinder Rods 88
Leakage Check 88
Temperature Effects on Hydraulic Cylinders 89
Lift Cylinder 91
Description 91
Maintenance 91
Disassembly 91
Inspection 91
Assembly 91
Dual Rod Telescope Cylinder 94
Description 94
Maintenance 94
Disassembly 94
Inspection 96
Assembly 96
Axle Oscillation Lockout Cylinder 98
Description 98
Maintenance 98
Disassembly 98
Inspection 98
Assembly101
Steer Cylinder102
Description102
Maintenance102
Disassembly102
Inspection102
Assembly102
Outrigger Extension Cylinder105
Description105
Maintenance105
Disassembly105
Inspection105
Assembly105
Outrigger jack Cylinder107
Description107
Maintenance107
Disassembly107
Inspection109
Assembly109
SECTION 3111
Electric System111
Description111
General111
Alternator111
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
Alternator Replacement117
Removal117
Installation117
Check117
Starter Replacement117
Removal117
Installation117
Check117
Battery Replacement118
Removal118
Installation118
Relay Panel Component Replacement118
Accessory Relay118
Rocker Switch Replacement118
Removal118
Inspection119
Installation119
Check119
Ignition Switch Replacement119
Removal119
Inspection120
Installation120
Check120
Turn Signal Lever and Transmission Shift Lever Replacement120
Removal120
Installation120
Check121
Windshield Wiper Assembly Replacement122
Removal122
Inspection122
Installation122
Check123
Windshield Washer Assembly Replacement123
Removal123
Inspection123
Installation123
Check123
Skylight Wiper Assembly Replacement123
Removal123
Inspection123
Installation123
Check124
Appendix A: Crane Control System (CCS) Fault Codes125
Component Codes125
Condition Codes142
Device Codes145
Index Codes146
SECTION 4147
Boom147
Description147
Theory Of Operation147
Boom Extension147
Boom Retraction148
Maintenance152
Removal152
Boom Disassembly152
Remove the Base Section152
Disconnect Inner Mid Section154
Remove the Inner Mid Section155
Remove Outer Mid Section156
Remove Telescope Cylinder158
Boom Nose Sheaves159
Boom Assembly159
Install Telescope Cylinder159
Install Outer Mid Section160
Install Inner Mid Section162
Connect Inner Mid Section163
Install Base Section164
Boom Installation165
Functional Check165
Inspection165
Boom Alignment And Servicing165
Boom Extension And Retraction Cable166
Maintenance166
Inspection166
Extension Cable Adjustment166
Retract Cable Adjustment167
Telescope Circuit167
Description167
Theory Of Operation167
Maintenance168
Telescope Circuit Troubleshooting168
Removal And Installation170
Disassembly And Assembly170
Lift Circuit171
Description171
Theory Of Operation171
Maintenance171
Lift Circuit Troubleshooting171
Removal173
Disassembly And Assembly173
Installation173
Swingaway Boom Extension175
Description175
Maintenance175
Removal175
Installation179
Hook Block180
Description180
Maintenance180
Periodic Maintenance180
SECTION 5181
Hoist And Counterweight181
Description181
Theory of Operation181
Maintenance181
Warm-up Procedure181
Removal182
Installation183
Functional Check183
Servicing183
Fluid Level183
Usage and Inspection184
Preventative Maintenance184
Oil Sampling186
Oil Change186
Gear Oil Sampling and Analysis186
General Guidelines for Iron Contaminant Level186
Brake Test Procedure186
Hoist to Boom Alignment187
Preparation187
Tools Required187
Procedure188
Piston Motor and Control Valve189
Description189
Maintenance189
Removal189
Installation189
Description189
Maintenance189
Idler Drum189
Removal and Disassembly189
Cleaning and Inspection189
Assembly and Installation189
Cable Follower190
Removal and Disassembly190
Cleaning and Inspection190
Assembly and Installation190
Complete Assembly192
Removal192
Installation192
Hoist Drum Rotation Indicator System192
Description192
Maintenance192
General192
Rotation Sensor in Hydraulic Motor192
Thumb Thumper Solenoid192
Counterweight Removal194
Fixed Counterweight Description194
Fixed Counterweight Removal194
Fixed Counterweight Installation194
SECTION 6197
Swing System197
Introduction197
Description197
Theory of Operation197
Swing Drive197
Maintenance199
Troubleshooting199
Swing Motor202
Description202
Maintenance202
Removal202
Installation202
Test202
Swing Gearbox And Brake203
Description203
Maintenance203
Swing Brake203
Removal203
Installation203
Gearbox203
Removal203
Installation203
Servicing204
Checking The Oil Level204
Testing204
Swing Bearing205
Description205
Maintenance205
General205
Torquing Turntable Bolts205
General205
Torque Values206
Tools Required206
Inner Race Torquing206
Outer Race Torquing206
Removal207
Inspection208
Installation208
Testing209
Swivels210
Description210
Hydraulic Swivel212
Description212
Theory of Operation212
Maintenance212
Removal212
Installation213
Electrical Swivel214
Description214
Theory of Operation214
Maintenance214
Removal214
Installation214
Preventive Maintenance215
Slew Potentiometer Adjustment215
SECTION 7217
Power Train217
Engine217
Description217
Maintenance218
Engine Removal218
Engine Installation221
Engine Drive Belts222
Fuel System223
Description223
Fuel Tank223
Injection Fuel Pump223
Fuel Filter-Water Separator223
Maintenance223
Fuel Tank223
Removal223
Installation223
Fuel Filter-Water Separator223
Draining223
Air Intake System225
Description225
Air Intake225
Air Cleaner Checks225
Filter Restriction Check225
Filter Element Replacement226
Element Cleaning226
Air Cleaner Body227
Precleaner227
Vacuator Valve227
Duct Work227
Charge-Air Cooler System (CAC)228
Maintenance228
Exhaust System229
Removal229
Installation229
Slip Joint Exhaust Connectors229
After 1000 Hours, or One Year229
2000 Hours or 2 Years229
4000 Hours or 4 Years229
5000 Hours or 5 Years229
Water Cooling System231
Description231
Maintenance231
General231
Effects of Cooling System Neglect231
Overheating231
Overcooling231
Antifreeze/Coolant231
Rust Prevention231
Engine Antifreeze/Coolant Fill Procedure (when level is low)232
Antifreeze/Supplemental Coolant Additives Maintenance Summary232
Cooling System Level Check Interval232
SCA Level Check/Coolant Filter Change Interval232
Cleaning232
Pressure Flushing233
Component Inspection233
Radiator/Surge Tank233
Engine Water Jacket233
Water Pump234
Fans and Belts234
Thermostat234
Hoses and Clamps234
Test Equipment234
Antifreeze/Coolant234
Radiator Removal and Installation234
Removal234
Installation235
Drive Train236
Description236
Maintenance236
Drive Lines236
Removal236
Installation236
Lubrication236
Transmission/Torque Converter236
Description236
Theory of Operation236
Maintenance237
General Information237
Troubleshooting237
Hydraulic Checks237
Troubleshooting Procedures238
Removal238
Installation238
Servicing Crane After Transmission/Torque Converter Overhaul240
Lubrication241
Type Of Oil241
Capacity241
Check Period241
Normal Drain Period241
SECTION 8243
Undercarriage243
Axles243
Description243
Maintenance244
Removal244
Cleaning247
Installation247
Wheel Alignment Check Procedure247
Rear Steer Indicator Adjustment Procedure247
Wheels and Tires249
Description249
Maintenance249
Mounting Wheel Assemblies249
Steering Systems250
Description250
Front Steering System250
Rear Steering System250
Theory of Operation250
Front Steering System250
Rear Steering System250
Maintenance251
Front Steering System251
Troubleshooting251
Functional Check252
Rear Steering System252
Troubleshooting252
Hydraulic Pumps253
Description253
Front Steer253
Rear Steer253
Front Steering Control Valve253
Description253
Maintenance253
Removal253
Installation253
Integrated Outrigger/Rear Steer Manifold253
Maintenance253
Removal253
Installation254
Steer Cylinders254
Description254
Maintenance254
Removal254
Installation254
Rear Axle Oscillation Lockout System255
Description255
Axle Oscillation Lockout Cylinders255
Description255
Maintenance255
Removal255
Installation255
Brake System256
Description256
Service Brakes256
Parking Brake256
Theory of Operation256
Service Brakes256
Parking Brake256
Maintenance257
Troubleshooting257
General257
Bleeding the Brake System257
Pressure Bleeding the Brake System258
Manually Bleeding the Brake System258
Service Brakes258
Description258
Maintenance258
Removal258
Linings258
Caliper259
Disassembly259
Caliper259
Inspection260
Periodic On-Vehicle260
Shoes, Linings, and End Plates260
Caliper for Leaks260
Dust Seals261
Disc261
Caliper Parts261
Cleaning262
Corrosion Protection262
Assembly262
Caliper262
Installation263
Linings263
Caliper264
Parking Brake Actuator264
Description264
Maintenance264
Removal264
Installation264
Adjustment265
Parking Brake265
Description265
Maintenance265
Removal265
Installation265
Park Brake Valve266
Description266
Removal266
Installation266
Functional Tests266
Outriggers266
Outrigger Circuit266
Description266
Theory of Operation266
Maintenance267
Troubleshooting267
Outrigger Beam270
Description270
Theory of Operation270
Maintenance270
Removal270
Inspection273
Installation273
Wear Pad Adjustment273
Extension Cylinder274
Description274
Maintenance274
Removal274
Installation275
Functional Check275
Jack Cylinder275
Description275
Maintenance275
Removal275
Installation275
Functional Check276
Outrigger Jack Cylinder Internal Leak Test276
Checking Cylinder For Internal Piston Seal Leak276
Testing Pilot Operated Check Valve For Leakage276
Outrigger Control Valves277
Description277
Pilot Operated Check Valve277
Integrated Outrigger/Rear Steer Manifold277
Outrigger Control Manifold277
SECTION 9279
Lubrication279
General279
Environmental Protection279
Lubrication Intervals279
Standard Lubricants280
Arctic Conditions Below -9°C (15°F)281
Arctic Conditions Down To -40°C (-40°F)281
All Weather Package and Lubricants281
Surface Protection For Cylinder Rods283
Wire Rope Lubrication283
Lubrication Points283
CraneLUBE283
Cummins Oil Registration List283
Safety283
Steering and Suspension284
Axles286
Drive Train288
Drive Train (continued)291
Outriggers293
Turntable295
Boom297
Boom (continued)299
Hoist301
Hydraulic303
Diesel Exhaust Fluid (DEF) Tank305
Carwell® Rust Inhibitor306
Protecting Cranes From Rusting306
Cleaning Procedures306
Inspection and Repair307
Application307
Areas of Application307

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