Manitowoc Grove RT540E SERVICE Manual – PDF DOWNLOAD

Manitowoc Grove RT540E SERVICE Manual – PDF DOWNLOAD

FILE DETAILS:

Manitowoc Grove RT540E SERVICE Manual – PDF DOWNLOAD

Language : English
Pages :322
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Manitowoc Grove RT540E SERVICE Manual – PDF DOWNLOAD

See end 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 14
Pump #1 14
Pump #2 14
Pump #3 14
Hoists 15
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
Antifriction Bearings 20
Double Row, Tapered Roller 20
Heating Bearings 20
Installation 20
Preload 20
Sleeve Bearings 20
Gaskets 20
Batteries 20
Hydraulic Systems 21
Cleanliness 21
Keep the System Clean 21
Sealing Elements 21
Hydraulic Lines 21
Visual Inspection of Hoses and Fittings 21
Electrical System 22
Connectors, Harnesses, Wires, and Connectors 22
Fatigue of Welded Structures 22
Loctite 22
Application of Medium Strength Loctite 22
Primer Application 22
Adhesive/Sealant Application 23
Fasteners and Torque Values 23
Torque Wrenches 23
Torque Values 24
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
Keeping Records 28
Frequent Inspection 28
Periodic Inspection 29
Wire Rope Inspection (Boom Extension and Retraction Cables) 29
Periodic Inspection 29
Wire Rope Inspection/Replacement (All Wire Rope) 29
Seizing Wire Rope 30
Method 1 30
Method 2 30
Installing 35×7 Class Wire Rope 31
Procedures for Cutting and Preparing 35×7 Class Wire Rope 31
SECTION 2 33
HYDRAULIC SYSTEM 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
Inspection 38
Valve Leakage 39
Binding Spools 39
Supply Pressure and Return Circuit 40
Description 40
Hydraulic Reservoir and Filter 40
Pump Distribution 40
Pump No 1 40
Pump No 2 40
Pump No 3 40
Maintenance 41
Troubleshooting 41
Return Hydraulic Filter Assembly 44
Element Removal 44
Element Installation 44
Hydraulic Reservoir Removal 44
Hydraulic Reservoir Installation 44
Oil Cooler 45
Description 45
Hydraulic Pumps 46
Description 46
Pump No 1 46
Pump No 2 46
Pump No 3 46
Maintenance 46
No 1 Pump Removal 46
No 1 Pump Installation 46
No 2 Pump Removal 46
No 2 Pump Installation 47
No 3 Pump Removal 47
No 3 Pump Installation 47
Testing After Rebuild or Replacement 47
Hydraulic Gear Pump Start-up Procedure 47
Piston Pump Start-up Procedure 48
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
Boom Lift/Telescope/Hoist Valve Bank Removal 62
Boom Lift/Telescope/Hoist Valve Bank Installation 62
Functional Check (All Valve Banks) 62
Function Check – RCL Lockout Valves 62
Accessory With Swing Directional Control Manifold 65
Description 65
Maintenance 65
Removal 65
Installation 65
Steering Control Valve 67
Description 67
Maintenance 67
Removal 67
Installation 67
Tandem Brake Valve with Treadle Pedal 68
Description 68
Maintenance 68
Removal 68
Installation 68
Dual Accumulator Charge Valve 69
Description 69
Maintenance 69
Removal 69
Installation 69
Hydraulic Accumulator Service Brake 71
Description 71
Maintenance 71
Removal 71
Installation 71
Servicing 71
Holding Valves 72
Description 72
Maintenance 72
Removal 72
Installation 72
Cross Axle Differential Lock Valve 73
Description 73
Maintenance 73
Removal 73
Installation 73
Outrigger Control Manifold 75
Description 75
Maintenance 75
Removal 75
Inspection 75
Installation 75
Functional Check 75
Pilot Operated Check Valve 76
Description 76
Maintenance 76
Removal 76
Installation 76
Integrated Outrigger/Rear Steer Manifold 77
Description 77
Maintenance 77
Removal 77
Installation 77
Check Valves 80
Description 80
Maintenance 80
Removal 80
Installation 80
Range Shift/Parking Brake Valve 81
Description 81
Maintenance 81
Removal 81
Installation 81
Functional Tests 81
Axle Oscillation Lockout Valve (Standard Units) 82
Description 82
Maintenance 82
Removal 82
Installation 82
Axle Oscillation Lockout Valve (Optional CE Units) 84
Description 84
Maintenance 84
Removal 84
Installation 84
Cylinders 86
General 86
Maintenance 86
General 86
Surface Protection for Cylinder Rods 86
Leakage Check 86
Temperature Effects on Hydraulic Cylinders 87
Lift Cylinder 89
Description 89
Maintenance 89
Disassembly 89
Inspection 89
Assembly 89
Dual Rod Telescope Cylinder 92
Description 92
Maintenance 92
Disassembly 92
Inspection 93
Assembly 93
Axle Oscillation Lockout Cylinder 96
Description 96
Maintenance 96
Disassembly 96
Inspection 96
Assembly 99
Steer Cylinder100
Description100
Maintenance100
Disassembly100
Inspection100
Assembly100
Outrigger Extension Cylinder103
Description103
Maintenance103
Disassembly103
Inspection103
Assembly103
Outrigger jack Cylinder105
Description105
Maintenance105
Disassembly105
Inspection106
Assembly107
SECTION 3109
ELECTRIC SYSTEM109
Description109
General109
Alternator109
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
Alternator Replacement115
Removal115
Installation115
Check115
Starter Replacement115
Removal115
Installation115
Check115
Battery Replacement116
Removal116
Installation116
Relay Panel Component Replacement116
Accessory Relay116
Rocker Switch Replacement116
Removal116
Inspection117
Installation117
Check117
Ignition Switch Replacement117
Removal117
Inspection118
Installation118
Check118
Turn Signal Lever and Transmission Shift Lever Replacement118
Removal118
Installation118
Check119
Windshield Wiper Assembly Replacement120
Removal120
Inspection120
Installation120
Check121
Windshield Washer Assembly Replacement121
Removal121
Inspection121
Installation121
Check121
Skylight Wiper Assembly Replacement121
Removal121
Inspection121
Installation121
Check122
Appendix A: Crane Control System (CCS) Fault Codes124
Component Codes124
Condition Codes141
Device Codes144
Index Codes145
SECTION 4147
BOOM147
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
Description150
Theory Of Operation150
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
Extend Cable Sheave Removal161
Boom Nose Sheaves161
Boom Nose Sheaves Removal162
Boom Nose Sheaves Installation162
Boom Assembly Procedure163
Extend Cable Sheave Installation163
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
SECTION 5191
HOIST AND COUNTERWEIGHT191
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 for HP15C- 17G, HO30A-19G, HP35-26G Hoists196
Brake Test Procedure (To be performed with no load on the hoist)196
Hoist to Boom Alignment197
Preparation197
Tools Required197
Procedure197
Piston Motor and Control Valve198
Description198
Maintenance198
Removal198
Installation198
Idler Drum and Cable Follower199
Description199
Maintenance199
Idler Drum199
Removal and Disassembly199
Cleaning and Inspection199
Assembly and Installation199
Cable Follower199
Removal and Disassembly199
Cleaning and Inspection199
Assembly and Installation199
Complete Assembly201
Removal201
Installation201
Hoist Drum Rotation Indicator System201
Description201
Maintenance201
General201
Rotation Sensor201
Thumb Thumper Solenoid201
Counterweight Removal203
Fixed Counterweight Description203
Fixed Counterweight Removal203
Fixed Counterweight Installation203
SECTION 6205
SWING SYSTEM205
Introduction205
Description205
Theory of Operation205
Swing Drive205
Maintenance207
Troubleshooting207
Swing Motor210
Description210
Maintenance210
Removal210
Installation210
Test210
Swing Gearbox And Brake211
Description211
Maintenance211
Swing Brake211
Removal211
Installation211
Gearbox211
Removal211
Installation211
Servicing212
Checking The Oil Level212
Testing212
Swing Bearing213
Description213
Maintenance213
General213
Torquing Turntable Bolts213
General213
Torque Values214
Tools Required214
Inner Race Torquing214
Outer Race Torquing214
Removal215
Inspection216
Installation216
Testing217
Swivels218
Description218
Hydraulic Swivel220
Description220
Theory of Operation220
Maintenance220
Removal220
Installation221
Electrical Swivel222
Description222
Theory of Operation222
Maintenance222
Removal222
Installation222
Preventive Maintenance223
Slew Potentiometer Adjustment223
SECTION 7225
POWER TRAIN225
Engine225
Description225
Maintenance226
Engine Removal226
Engine Installation229
Engine Drive Belts230
Fuel System231
Description231
Fuel Tank231
Injection Fuel Pump231
Fuel Filter-Water Separator231
Electric Lift Pump231
Maintenance231
Fuel Tank231
Removal231
Installation231
Fuel Filter-Water Separator231
Draining231
Air Intake and Exhaust System233
Description233
Air Intake233
Air Cleaner Checks233
Check For Filter Restriction233
Filter Element Replacement235
Element Cleaning235
Air Cleaner Body235
Precleaner235
Vacuator Valve236
Duct Work236
Charge-Air Cooler System237
Maintenance237
Muffler and Diesel Oxidation Catalyst – Tier 4 Interim238
Removal238
Installation238
Slip Joint Exhaust Connectors238
After 1000 Hours, or One Year238
2000 Hours or 2 Years238
4000 Hours or 4 Years238
5000 Hours or 5 Years238
Water Cooling System240
Description240
Maintenance240
General240
Effects of Cooling System Neglect240
Overheating240
Overcooling240
Antifreeze/Coolant240
Rust Prevention240
Engine Antifreeze/Coolant Fill Procedure (when level is low)241
Antifreeze/Supplemental Coolant Additives Maintenance Summary241
Cooling System Level Check Interval241
SCA Level Check/Coolant Filter Change Interval241
Cleaning241
Pressure Flushing242
Component Inspection242
Radiator/Surge Tank242
Engine Water Jacket242
Water Pump243
Fans and Belts243
Thermostat243
Hoses and Clamps243
Test Equipment243
Antifreeze/Coolant243
Radiator Removal and Installation243
Removal243
Installation244
Drive Train245
Description245
Maintenance245
Drive Lines245
Removal245
Installation245
Lubrication245
Transmission/Torque Converter245
Description245
Theory of Operation245
Maintenance246
General Information246
Troubleshooting246
Hydraulic Checks246
Troubleshooting Procedures247
Removal247
Installation247
Servicing the Crane After Transmission/ Torque Converter Overhaul249
Lubrication250
Type Of Oil250
Capacity250
Check Period250
Normal Drain Period250
SECTION 8251
UNDERCARRIAGE251
Axles251
Description251
Maintenance252
Removal252
Cleaning255
Installation255
Wheel Alignment Check Procedure255
Rear Steer Indicator Adjustment Procedure255
Wheels and Tires257
Description257
Maintenance257
Mounting Wheel Assemblies257
Typical Wear Patterns257
Incorrect Tire Pressure257
Incorrect Camber258
Incorrect Toe and Axle Alignment258
Incorrect Caster and Wheel Imbalance258
Cuts in the Tire Tread259
Spot Wear259
Feathered Edges259
Cupping259
Steering Systems260
Description260
Front Steering System260
Rear Steering System260
Theory of Operation260
Front Steering System260
Rear Steering System260
Maintenance261
Front Steering System261
Troubleshooting261
Functional Check262
Rear Steering System262
Troubleshooting262
Hydraulic Pumps263
Description263
Front Steer263
Rear Steer263
Front Steering Control Valve263
Description263
Maintenance263
Removal263
Installation263
Integrated Outrigger/Rear Steer Manifold263
Maintenance263
Removal263
Installation264
Steer Cylinders264
Description264
Maintenance264
Removal264
Installation264
Rear Axle Oscillation Lockout System265
Description265
Axle Oscillation Lockout Cylinders265
Description265
Maintenance265
Removal265
Installation265
Brake System266
Description266
Service Brakes266
Parking Brake266
Theory of Operation266
Service Brakes266
Parking Brake266
Maintenance267
Troubleshooting267
General267
Bleeding the Brake System267
Pressure Bleeding the Brake System268
Manually Bleeding the Brake System268
Service Brakes268
Description268
Maintenance268
Removal268
Linings268
Caliper269
Disassembly269
Caliper269
Inspection270
Periodic On-Vehicle270
Shoes, Linings, and End Plates270
Caliper for Leaks270
Dust Seals271
Disc271
Caliper Parts271
Cleaning272
Corrosion Protection272
Assembly272
Caliper272
Installation273
Linings273
Caliper274
Parking Brake Actuator274
Description274
Maintenance274
Removal274
Installation274
Adjustment275
Parking Brake275
Description275
Maintenance275
Removal275
Installation275
Procedure for Manually Releasing the Parking Brake276
Park Brake Valve277
Description277
Removal277
Installation277
Functional Tests277
Outriggers277
Outrigger Circuit277
Theory of Operation277
Maintenance278
Troubleshooting278
Outrigger Beam281
Description281
Theory of Operation281
Maintenance281
Removal281
Inspection284
Installation284
Wear Pad Adjustment284
Extension Cylinder285
Description285
Maintenance285
Removal285
Installation286
Functional Check286
Jack Cylinder286
Description286
Maintenance286
Removal286
Installation286
Functional Check287
Outrigger Jack Cylinder Internal Leak Test287
Checking Cylinder For Internal Piston Seal Leak287
Testing Pilot Operated Check Valve For Leakage287
Outrigger Control Valves288
Description288
Pilot Operated Check Valve288
Integrated Outrigger/Rear Steer Manifold288
Outrigger Control Manifold288
SECTION 9289
LUBRICATION289
General289
Environmental Protection289
Lubrication Intervals289
Arctic Conditions Below -18°C (0°F)289
Arctic Conditions Down To -40°F290
ALL Weather Package & Lubricants290
Standard Lubricants Package290
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

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