Manitowoc Grove RT540E Operator's Manual
  1. Manuals
  2. Brands
  3. Manitowoc Manuals
  4. Construction Equipment
  5. Grove RT540E
  6. Operator's manual

Manitowoc Grove RT540E Operator's Manual

Hide thumbs Also See for Grove RT540E:
Table of Contents

Advertisement

Quick Links

Download this manual
© 2017 Manitowoc
Published 3-30-2017, Control # 516-04
OPERATOR MANUAL
Supplement
Crane Warm-up Procedures
!
An untrained operator subjects himself and others to death or
serious injury. Do not operate this crane unless:
•
You are trained in the safe operation of this crane.
responsible for qualifying personnel.
•
You read, understand, and follow the safety and operating
recommendations contained in the crane manufacturer's manuals and
load charts, your employer's work rules, and applicable government
regulations.
•
You are sure that all safety signs, guards, and other safety features are
in place and in proper condition.
•
The Operator Manual and Load Chart are in the holder provided on
crane.
DANGER
Manitowoc is not

Advertisement

Table of Contents
loading

Related Manuals for Manitowoc Grove RT540E

Summary of Contents for Manitowoc Grove RT540E

  • Page 1 An untrained operator subjects himself and others to death or serious injury. Do not operate this crane unless: • You are trained in the safe operation of this crane. Manitowoc is not responsible for qualifying personnel. • You read, understand, and follow the safety and operating recommendations contained in the crane manufacturer’s manuals and...
  • Page 2 SECTION CONTENTS Crane Warm-up Procedures......... . . 1 Engine.
  • Page 3 Lubrication section of your crane’s Operator Manual, operating temperature. by contacting your local Manitowoc distributor, or by contacting Manitowoc Crane Care directly). NOTE: Warm-up operation of 4-wheel drive transmission engaged in 2-wheel drive only could cause transmission damage.
  • Page 4 Rotate the superstructure at a speed of less than one- and engine immediately and contact a Manitowoc half RPM for at least two complete revolutions in one distributor.
  • Page 5 Grove RT540E Operator Manual...
  • Page 6 THIS PAGE BLANK...
  • Page 7 You must read and understand the Operator's Manual and the Load Chart before operating your new crane. You must also view and understand the supplied safety video. The Operator's Manual supplied with and considered part of your crane must be read and completely understood by each person responsible for assembly, disassembly, operation and maintenance of the crane.
  • Page 11 DANGER An untrained operator subjects himself and others to death or serious injury. Do not operate this crane unless: Manitowoc is not • You are trained in the safe operation of this crane. responsible for qualifying personnel.
  • Page 12 CALIFORNIA PROPOSITION 65 WARNING Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. CALIFORNIA PROPOSITION 65 WARNING Battery posts, terminals, and related accessories contain chemical lead and lead compounds, chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.

  • Page 13: Table Of Contents

    RT540E OPERATOR MANUAL TABLE OF CONTENTS See end of this manual for Alphabetical Index SECTION 1 ........Introduction General .
  • Page 14 TABLE OF CONTENTS RT540E OPERATOR MANUAL Lubrication ............2-15 Tires.
  • Page 15 RT540E OPERATOR MANUAL TABLE OF CONTENTS Swing/Telescope or Swing/Auxiliary Hoist Control Lever (Dual Axis)... . 3-7 Main Hoist Enable Switch ..........3-7 Boom Up Bypass Switch (Optional) .
  • Page 16 TABLE OF CONTENTS RT540E OPERATOR MANUAL Buzzer ............3-38 RCL Emergency Override Switch (Non-CE Certified Cranes).

  • Page 17: Section 1

    The superstructure is capable of 360° rotation in either direction. All crane functions are controlled from the fully- Manitowoc and our Distributor Network want to ensure your enclosed cab mounted on the superstructure. The crane is satisfaction with our products and customer support. Your...
  • Page 18 Includes/EN/changeOfOwnership.cfm and complete the If you are the new owner of a Grove crane, please register it form. with Manitowoc Crane Care so we have the ability to contact you if the need arises. Published 04-20-2015, Control # 501-02...

  • Page 19: List Of Specifications

    RT540E OPERATOR MANUAL INTRODUCTION LIST OF SPECIFICATIONS Axles Total Ratio ......20.06:1 General Carrier Ratio ......5.57:1 Wheel End Ratio .
  • Page 20 INTRODUCTION RT540E OPERATOR MANUAL Hoists Length-Aux....137 m (450 ft) Max. Permissible Line Pull (6x36) Drum Dimensions ......52.4 kN (11,770 lb) Diameter .

  • Page 21: Serial Number Location

    RT540E OPERATOR MANUAL INTRODUCTION SERIAL NUMBER LOCATION Refer to Figure 1-2 for the locations of the crane serial number. Frame - Left Front Manual Cover 8041 FIGURE 1-2 Inside Cab - Lower Right GROVE Published 04-20-2015, Control # 501-02...
  • Page 22 INTRODUCTION RT540E OPERATOR MANUAL 8047-1 Top View of Crane 8046-2 Left Side View of Crane FIGURE 1-3 Item Description Item Description Boom Extension Outrigger Float Boom Extension Nose Outrigger Stabilizer Cylinder Boom Pivot Steps Hydraulic Tank Counterweight Hydraulic Filter Lift Cylinder Main Hoist Boom Auxiliary Hoist...
  • Page 23 RT540E OPERATOR MANUAL INTRODUCTION 8046-1 Right Side View of Crane Front View of Crane Rear View of Crane 8047-3 8047-2 FIGURE 1-3 continued GROVE Published 04-20-2015, Control # 501-02...
  • Page 24 INTRODUCTION RT540E OPERATOR MANUAL 7275-1A Left Side View - Cast Counterweight Units THIS PAGE BLANK 7275-2 Rear View - Cast Counterweight Units FIGURE 1-3 continued Published 04-20-2015, Control # 501-02...

  • Page 25: Section 2

    RT540E OPERATOR MANUAL SAFETY INFORMATION SECTION 2 SAFETY INFORMATION SECTION CONTENTS Safety Messages......2-1 Environmental Protection.

  • Page 26: General

    ACCIDENTS Following any accident or damage to equipment, the WARNING Manitowoc dealer must be immediately advised of the Identifies hazards that may result in death or serious incident and consulted on necessary inspections and injury if the message is ignored.

  • Page 27: Operator Qualifications

    RT540E OPERATOR MANUAL SAFETY INFORMATION No personnel shall be allowed to climb onto the crane or Refer to the Parts Manual for this crane for the locations of all enter the crane cab or operator’s station unless performance safety decals. of their duties require them to do so, and then only with You must be familiar with the regulations and standards knowledge of the operator or other qualified person.

  • Page 28: Operational Aids

    (HCAS), a safe load indicator (SLI), or the designated person responsible for supervising the an EKS5; Manitowoc refers to these systems as a rated lifting operations shall establish procedures for capacity limiter (RCL) throughout its Operator and Service determining load weights and shall ascertain that the Manuals.

  • Page 29: Working Area Limiter (If Equipped)

    RT540E OPERATOR MANUAL SAFETY INFORMATION Two-blocking is more likely to occur when both the main and intended to assist the operator in preventing dangerous two- auxiliary hoist lines are reeved over the main boom nose and block conditions. It is not a replacement for operator awareness and competence.

  • Page 30: Load Charts

    SAFETY INFORMATION RT540E OPERATOR MANUAL outriggers must also be pinned when operating from the mid- extend position. Use adequate cribbing under outrigger floats to distribute weight over a greater area. Check frequently for settling. Read and follow the following safety decal for cranes with center front stabilizers.

  • Page 31: Lifting Operations

    SAFETY INFORMATION upon the direction from which the wind is blowing (e.g., wind a loss of control in handling the load. Manitowoc on the rear of the boom can result in decreased forward recommends that, if the wind speed (velocity) is between...

  • Page 32: Counterweight

    The crane is improperly operated. reached instability. The “balance point” for stability testing according to SAE and Manitowoc criteria is a condition of Do not rely on the crane’s tipping to determine your lifting loading wherein the load moment acting to overturn the capacity.

  • Page 33: Pile Driving And Extracting

    • All hoist hooks shall be equipped with a positive locking It is not the intention of Manitowoc to recommend specific latch. types or makes of pile driving and pile extraction equipment, but rather to advise of the operational requirements to help...
  • Page 34 Electrocution Hazard! Manitowoc cranes are not equipped with all features Electrocution can occur even without direct contact with the required to operate within OSHA 29CFR1926.1408, Table crane.

  • Page 35: Set-Up And Operation

    RT540E OPERATOR MANUAL SAFETY INFORMATION Set-Up and Operation not assure that electrical contact will not occur. Even if codes or regulations require the use of such devices, failure to During crane use, assume that every line is energized (“hot” follow the rules listed here may result in serious injury or or “live”) and take the necessary precautions.

  • Page 36: Electrical Contact

    If taglines are used, they must be non-conductive. 29CFRI926.1431 for Construction. • Every precaution must be taken to dissipate induced Use of a Manitowoc crane to handle personnel is acceptable voltages. Consult a qualified RF (radio frequency) provided: 2-12 Published 04-20-2015, Control # 501-02...

  • Page 37: Environmental Protection

    Manitowoc reminds crane owners to ensure that all safety requirements of applicable national, state and local decals are in place and legible. Manitowoc continues to urge regulations and safety codes are met. crane owners to upgrade their cranes with rated capacity limiter and control lever lockout systems for all lifting •...

  • Page 38: Service And Repairs

    • Stop the engine and disconnect the battery. affects its original design and is not authorized and approved by Manitowoc is strictly prohibited. All replacement parts • Controls should be properly tagged. Never operate the must be Manitowoc approved. Such action invalidates all...

  • Page 39: Lubrication

    The nominal strength of a wire rope Wire Rope should never be used as its working load. Use only the wire rope specified by Manitowoc as indicated • Each type of fitting attached to a wire rope has a specific on the crane’s Load Chart.

  • Page 40: Sheaves

    SAFETY INFORMATION RT540E OPERATOR MANUAL • Never “shock load” a wire rope. A sudden application of Evidence of abuse or contact with another object. force or load can cause both visible external and internal Heat damage. damage. There is no practical way to estimate the force applied by shock loading a rope.

  • Page 41: Batteries

    RT540E OPERATOR MANUAL SAFETY INFORMATION Ensure sheaves carrying ropes that can be momentarily • If applicable, maintain battery electrolyte at the proper unloaded are equipped with close fitting guards or other level. Check the electrolyte with a flashlight. devices to guide the rope back into the groove when the load •...

  • Page 42: Travel Operation

    SAFETY INFORMATION RT540E OPERATOR MANUAL Stunt driving and horse-play are strictly prohibited. Never allow anyone to hitch a ride or get on or off a moving crane. Follow the instructions in this manual when preparing the crane for travel. If using a boom dolly/trailer, thoroughly read and understand all the steps and safety precautions in this manual for setup and travel.

  • Page 43: Work Practices

    Operator Manual when extending or retracting the system that have not been evaluated and approved by outriggers. Death or serious injury could result from improper Manitowoc Crane Care. crane set up on outriggers. Do not step on surfaces on the crane that are not approved Be familiar with surface conditions and the presence of or suitable for walking and working.

  • Page 44: Lifting

    SAFETY INFORMATION RT540E OPERATOR MANUAL Sparks from the crane’s electrical system and/or engine exhaust can cause an explosion. Do not operate this crane in an area with flammable dust or vapors, unless good ventilation has removed the hazard. Carbon monoxide fumes from the engine exhaust can cause suffocation in an enclosed area.

  • Page 45: Hand Signals

    RT540E OPERATOR MANUAL SAFETY INFORMATION Check the hoist brake by raising the load a few inches, If the boom should contact an object, stop immediately and stopping the hoist and holding the load. Be sure the hoist inspect the boom. Remove the crane from service if the boom is damaged.
  • Page 46 SAFETY INFORMATION RT540E OPERATOR MANUAL 2-22 Published 04-20-2015, Control # 501-02...

  • Page 47: Boom Extension

    However, Manitowoc recognizes that certain jobsite conditions may not permit the If applicable to your crane, frequently check all air tanks for boom and boom extension of a crane to be fully lowered to water in freezing weather.

  • Page 48: Temperature Effects On Hook Blocks

    SAFETY INFORMATION RT540E OPERATOR MANUAL If applicable to your crane, always handle propane tanks extended 7.6 m (25 ft) in which the oil cools 15.5°C (60°F) according to the supplier’s instructions. would retract approximately 196 mm (7 3/4 in) [see Table 2- 2].
  • Page 49 RT540E OPERATOR MANUAL SAFETY INFORMATION Table 2-2: Boom Drift Chart (Cylinder length change in inches) Coeff. = 0.00043 (in / °F) STROKE Temperature Change (°F) (FT.) 0.26 0.52 0.77 1.03 1.29 1.55 1.81 2.06 2.32 2.58 0.52 1.03 1.55 2.06 2.58 3.10 3.61...

  • Page 50: Crane Specific Information

    50%. (RCL) manual supplied with each Grove crane. • Stop operating the crane and contact Manitowoc When the RCL system has acknowledged an overload on Crane Care immediately for overloads of 50% and your crane, you must carry out specified inspections on the higher.

  • Page 51: Boom Inspection

    RT540E OPERATOR MANUAL SAFETY INFORMATION Boom Inspection 9, 10 3, 4 9, 10 GROVE 2-27 Published 04-20-2015, Control # 501-02...
  • Page 52 SAFETY INFORMATION RT540E OPERATOR MANUAL Overload less than 25% Sheaves Inspect all for damage. Luffing Mechanism/ Inspect for damage/leaks. Cylinder Collar-wear Inspect all for damage. pads Overload from 25% to 49% Sheaves Inspect all for damage. Luffing Mechanism/ Inspect for damage/leaks. Cylinder Collar-wear Inspect all for damage.

  • Page 53: Superstructure Inspection

    RT540E OPERATOR MANUAL SAFETY INFORMATION Superstructure Inspection 9, 10 GROVE 2-29 Published 04-20-2015, Control # 501-02...
  • Page 54 SAFETY INFORMATION RT540E OPERATOR MANUAL Overload less than 25% Lift Cylinder Inspect for leaking. Turntable See topic in Swing section of Check bolts for proper torque. Bearing Service Manual. See topic in Introduction section Wire Rope Inspect all for damage. of Service Manual.

  • Page 55: Carrier Inspection

    RT540E OPERATOR MANUAL SAFETY INFORMATION Carrier Inspection 5, 6 GROVE 2-31 Published 04-20-2015, Control # 501-02...
  • Page 56 SAFETY INFORMATION RT540E OPERATOR MANUAL Overload less than 25% Stabilizer Inspect for leaking. Cylinders Outrigger Inspect for deformation and cracked welds. Pads Overload from 25% to 49% Stabilizer Inspect for leaking. Cylinders Outrigger Inspect for deformation and cracked welds. Pads Outrigger Inspect for deformation and cracked welds.

  • Page 57: Section 3

    RT540E OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES SECTION 3 OPERATING CONTROLS AND PROCEDURES SECTION CONTENTS Controls and Indicators ..... 3-2 Armrest Adjustment Knobs .

  • Page 58: Controls And Indicators

    OPERATING CONTROLS AND PROCEDURES RT540E OPERATOR MANUAL Buzzer ....... . . 3-38 Strobe Light or Beacon (Optional) (Not Shown).

  • Page 59: Turn Signal Lever And Windshield Wiper/Washer/Horn Controls

    RT540E OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES Turn Signal Lever and Windshield Wiper/ display turns yellow when the crane is in four-wheel drive mode. This icon will flash if, while the engine is running, the Washer/Horn Controls switch position is changed when the transmission is not in The Turn Signal Lever, Horn and Windshield Wiper/Washer Neutral and the brake pedal is not pressed.

  • Page 60: Transmission Shift Lever

    OPERATING CONTROLS AND PROCEDURES RT540E OPERATOR MANUAL Transmission Shift Lever Skylight Window Latch The Skylight Window Latch (1) (Figure 3-3) is at the front of the window. Squeeze the latch and slide the window to the CAUTION rear to open. To close slide the window forward until the latch Transmission Damage! engages.

  • Page 61: Overhead Control Panel

    RT540E OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES Overhead Control Panel Heater Control Switch The Heater Control Switch (3) (Figure 3-4) controls intensity of heating temperature. Turn the switch to the right (clockwise) to open the valve for heat. (Heat comes from heated fluid going through the heater coil.) Turn the switch to the left (counterclockwise) to close the valve to stop fluid flow and minimize heat.

  • Page 62: Control Seat Assembly

    OPERATING CONTROLS AND PROCEDURES RT540E OPERATOR MANUAL CONTROL SEAT ASSEMBLY 8044-2 FIGURE 3-5 Figure 3-5 Item Numbers Item Description Item Description Seat Height Adjustment Lever Boom Lift/Main Hoist Control Lever RCL Bypass Switch Swing/Telescope or Swing/Auxiliary Hoist Emergency Stop Switch Control Lever Level Indicator Main Hoist Enable Switch...

  • Page 63: Swing/Telescope Or Swing/Auxiliary Hoist Control Lever (Dual Axis)

    RT540E OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES Swing/Telescope or Swing/Auxiliary Hoist Outrigger Function Enable Switch Control Lever (Dual Axis) The Outrigger Function Enable Switch (7) (Figure 3-5) allows the operator to switch between extension/retraction of the outriggers and raising/lowering of the jacks. Press and hold this switch to force the lower screen display to change DANGER to the outrigger page.

  • Page 64: Air Conditioner/Heater Climate Unit

    OPERATING CONTROLS AND PROCEDURES RT540E OPERATOR MANUAL Air Conditioner/Heater Climate Unit provides the operator with a visual aid in determining the levelness of the crane. The crane cab Air Conditioner/Heater Climate Unit (14) (Figure 3-5) is located in the cab under the driver’s seat. The Deadman Switches (Optional) (Dual Axis vents (15) are part of the climate unit and can be adjusted to Joysticks only)

  • Page 65: Operating Procedures

    RT540E OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES OPERATING PROCEDURES Hook Block and Headache Ball Inspect for nicks, gouges, cracks, and evidence of any other Pre-Starting Checks damage. Replace a hook that has cracks or shows evidence of excessive deformation of the hook opening (including A complete walk-around visual inspection of the crane twist).

  • Page 66: Cold Weather Operation

    Manitowoc down to the required temperature. This will prevent clogging Crane Care. Cranes should have appropriate hydraulic oil, of filters and small passages by wax crystals.

  • Page 67: Crane Travel Operation

    RT540E OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES NOTE: The engine “wait to start” indicator located on the Battery Disconnect top left side of the front console illuminates amber for a period of time when the ignition is turned to the on position. The engine should not be cranked until the indicator turns off.
  • Page 68 OPERATING CONTROLS AND PROCEDURES RT540E OPERATOR MANUAL Traveling — General Use four-wheel drive only when greater traction is necessary. (Refer to Four-Wheel Drive Operation, page 3-15 for operating instructions.) WARNING CAUTION Inadvertent Operation Hazard! Machine Damage Hazard! Before traveling, ensure that the crane functions are fully On open ground, tow or pull only on the tow/tie-down lugs disabled.
  • Page 69 • Limit boom angle to a maximum of 20°. models are in compliance with The Manitowoc Company, Inc. recommendations. The operator of the crane assumes • Do not support any load from the boom (see Pick and responsibility for determining the suitability of traveling on a Carry Load chart for limitations for this application).
  • Page 70 OPERATING CONTROLS AND PROCEDURES RT540E OPERATOR MANUAL • Headache ball may be reeved over boom extension, Disengage the parking brake. hanging 0.9 m (3 ft) below sheave. Position the Drive Axle Switch to either two-wheel high 13.7 m (45 ft) Boom Extension or four-wheel low.
  • Page 71 RT540E OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES Four-Wheel Drive Operation WARNING CAUTION Unexpected Operation Hazard! Machine Damage Hazard! Operate the rear steer ONLY at slow speeds for added job Do not tow or pull in 1st gear with the Drive Axle Selector site maneuverability.
  • Page 72 OPERATING CONTROLS AND PROCEDURES RT540E OPERATOR MANUAL Differential Lock Operation (Optional) Lock the differentials only when maximum traction is needed on poor road or highway surfaces. CAUTION CAUTION Unexpected Operation! Possible Loss of Vehicle Stability! When using the differential lock, steering characteristics Do not lock the differentials when the vehicle is traveling may be affected.

  • Page 73: General Crane Operation

    RT540E OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES Ensure the tires are inflated to the recommended NOTE: Always operate the control levers with slow, even pressure. Refer to the Load Chart Book in the crane cab pressure. for proper inflation pressures. Preload Check With the hook unloaded, the boom fully retracted and After the crane has been readied for service, an operational...
  • Page 74 (7940 lb) on outriggers over-front and 4970 lb on outriggers 360 degrees. We subtract the load handling weight of 632 lb The load chart also gives weight reductions for Manitowoc/ from the load capacity of 3601 kg (7940 lb) and 2254 kg Grove load handling devices such as hookblocks, overhaul (4970 lb).

  • Page 75: Crane Functions

    RT540E OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES crane is level to within 1% of grade. The bubble level that is provided on the crane is calibrated to be accurate within 1% of grade. WARNING To properly level the crane, the boom must be positioned Be sure the outriggers are properly extended and set, and over the front of the crane, fully lowered to horizontal and the crane is level for operation on outriggers.
  • Page 76 OPERATING CONTROLS AND PROCEDURES RT540E OPERATOR MANUAL appropriate outrigger beam will extend. Refer to Engaging the Mid Extend Lock Pin, page 3-20 if the crane is to be operated with any outrigger at the mid- extend position. WARNING Tipping Hazard! The mid-extend outrigger beam lock pin must be engaged before operating on any beam from the mid-extend WARNING...
  • Page 77 RT540E OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES Use the screen buttons or jog dial with the Outrigger Function Enable Switch to select the left or right rear outrigger on the CCS screen. Retract until the rear jacks have retracted several inches. DANGER Keep feet and hands clear of floats when unlocking the Use the screen buttons or jog dial with the Outrigger...
  • Page 78 OPERATING CONTROLS AND PROCEDURES RT540E OPERATOR MANUAL Stowing the Mid-Extend Lock Pin NOTE: If the lock pin is wedged in the hole in the outrigger beam, it may be necessary to jog the outrigger extend/retract switch slightly while pulling upward on the pin.
  • Page 79 RT540E OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES Extending the Boom Lowering and Raising the Hoist Cable DANGER WARNING Crushing Hazard! When extending the boom, simultaneously let out the hoist cable to prevent two-blocking the boom nose and Keep the area beneath the load clear of all obstructions hookblock.

  • Page 80: Stowing And Parking

    OPERATING CONTROLS AND PROCEDURES RT540E OPERATOR MANUAL Stowing and Parking Unattended Crane When parking the crane, do the following: WARNING DANGER Tipping Hazard! Never park crane near holes, on rocky surfaces, or on soft Changing weather conditions including, but not limited to, spots.

  • Page 81: Crane Control System (Ccs)

    RT540E OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES CRANE CONTROL SYSTEM (CCS) Item Description The RT540E is equipped with the electronic CCS (Crane Anti Two-Block Indicator Control System). CCS includes a control unit in the cab and Swing Brake Engaged Indicator several control units (MWSCM and MWCCM) distributed over the superstructure and carrier.

  • Page 82: Turntable Lock Control (Pin Type)

    OPERATING CONTROLS AND PROCEDURES RT540E OPERATOR MANUAL Turntable Lock Control (Pin Type) superstructure in place. When the control handle is pulled up, the pin is pulled out of the socket, unlocking the The Swing Lock Pin Control Handle (13) (Figure 3-11) is superstructure.

  • Page 83: Ccs Main Screen Symbols And Icons

    RT540E OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES CCS Main Screen Symbols and Icons FIGURE 3-13 GROVE 3-27 Published 04-20-2015, Control # 501-02...
  • Page 84 OPERATING CONTROLS AND PROCEDURES RT540E OPERATOR MANUAL Figure 3-13 Item Numbers Item Description Transmission Temperature Fuel Level Battery Voltage Engine Speed (Tachometer) Engine Coolant Temperature Diesel Exhaust Fluid (Optional) Direction/Gear Number Engine Warm-up Indicator (Wait-to-start) Park Brake Emergency Stop Marker/Position/Side Light Rear Wheels Not Centered Four-Wheel Drive Indicator Differential Lock Indicator (Optional)

  • Page 85: Ccs Menu Screen

    RT540E OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES CCS Menu Screen FIGURE 3-14 GROVE 3-29 Published 04-20-2015, Control # 501-02...
  • Page 86 OPERATING CONTROLS AND PROCEDURES RT540E OPERATOR MANUAL Figure 3-14 Item Numbers Item Description Menu Screen Indicator Status Indicator Bar Outrigger Group Outrigger Button WRL Swing Group WRL Height Limit Reached WRL Boom Angle Limit Reached WRL Swing Angle Limit Reached WRL Radius Limit Reached WRL Virtual Wall Limit Reached Tools Group...

  • Page 87: Ccs Operation Display

    RT540E OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES CCS Operation Display Menu Screen When the menu button on the jog dial (3) (Figure 3-12) or There are three different levels: The Main Screen, the Menu control panel of the CCS is pressed, the overview of the Screen and the Sub Level menus.

  • Page 88: Rated Capacity Limiter (Rcl) System

    OPERATING CONTROLS AND PROCEDURES RT540E OPERATOR MANUAL RATED CAPACITY LIMITER (RCL) SYSTEM The Rated Capacity Limiter (RCL) is an electro-mechanical sensing system designed to alert the crane operator of DANGER impending capacity when the system has been properly preset by the operator. The control panel is mounted in the Electronic equipment on this crane is intended as an aid front console of the operator cab.

  • Page 89: Outrigger Operation Menu

    RT540E OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES Outrigger Operation Menu Raising the Jacks Spin the jog dial clockwise and press OK button to select and For choosing options during rigging. This is the only function choose jack operation. Press the lower side of the Outrigger w h e r e t h e m e n u b u t t o n ( 3 ) ( F i g u r e 3 -1 2 ) w i l l n o t Function Enable Switch on the left armrest to enable jack automatically navigate directly to the menu screen.
  • Page 90 OPERATING CONTROLS AND PROCEDURES RT540E OPERATOR MANUAL Toggle counterclockwise and select the menu icon to exit this Press OK/enter button on display or jog dial (6) (Figure 3-12) group. to exit the outrigger screen. Press escape button (1) (Figure 3-12) to leave menu and CAUTION return to CCS main screen.

  • Page 91: Rcl Setup Wizard

    CCS screen will be illuminated in red. NOTE: If the RCL is not working correctly, do not start work with the crane but notify Manitowoc Crane Care. NOTE: When the RCL override icon (above, the third icon...
  • Page 92 OPERATING CONTROLS AND PROCEDURES RT540E OPERATOR MANUAL Set the Boom Set the Jib Angle (if installed) Turn jog dial clockwise to set boom, including aux nose and Turn jog dial clockwise to program the jib angle after the reeving options. length is selected.

  • Page 93: Switch To Rcl Home Screen Display

    RT540E OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES Reeving Selection Switch to RCL Home Screen Display Turn jog dial clockwise to select the icon for reeving options. Press Screen Toggle button (4) (Figure 3-12) on the Jog Dial Press ENTER a second time and turn dial to change reeving menu control to switch to the RCL main menu screen.

  • Page 94: Foot Pedal Controls

    OPERATING CONTROLS AND PROCEDURES RT540E OPERATOR MANUAL FOOT PEDAL CONTROLS spring pressure to overcome the hydraulic pressure being applied to the brake release circuit and applies the spring brake according to the pressure from the swing power brake valve. Telescope Control Pedal (Optional) The Telescope Control Pedal (4) (Figure 3-15) is supplied when the crane is equipped with an auxiliary hoist, is located in the middle of the cab floor.

  • Page 95: Rcl Emergency Override Switch (Non-Ce Certified Cranes)

    RT540E OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES RCL Emergency Override Switch (Non-CE RCL Emergency Override Switch and Certified Cranes) Indicator (CE Certified Cranes) WARNING WARNING Loss of RCL Monitoring Hazard! Loss of RCL Monitoring Hazard! The RCL Emergency Override switch is to be used in The RCL Emergency Override Switch is to be used in emergency situations only.

  • Page 96: Rcl Internal Light Bar (Optional)

    OPERATING CONTROLS AND PROCEDURES RT540E OPERATOR MANUAL Strobe Light or Beacon (Optional) (Not Shown) The strobe light or beacon is on the right side of the superstructure. It is on when the ignition switch is on. Backup Alarm (Not Shown) The backup alarm is an audio system used to warn personnel outside the crane when the crane is backing up.

  • Page 97: Appendix A: Crane Control System (Ccs) Symbols And Icons

    RT540E OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES Appendix A: Crane Control System (CCS) Symbols and Icons Symbol Description 3rd Wrap Warning 4-Wheel Drive Auxiliary Hoist Status Auxiliary Hoist Disabled Auxiliary Hoist Enabled Auxiliary Hoist Raise Auxiliary Hoist Not In Use Auxiliary Hoist Lower Battery Voltage Boom Lift Status...
  • Page 98 OPERATING CONTROLS AND PROCEDURES RT540E OPERATOR MANUAL Symbol Description Bypass 3 Pressed Coolant Temp Differential Lock Engine Preheat Engine Speed (RPM) Engine Warning (Error) Emergency Stop Fuel Level Hoist Limit Switch Shutdown Hydraulic Oil Temp Information Group Jib Angle Difference Jib Angle Too High Jib Angle Too Low Jib Load Too High...
  • Page 99 RT540E OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES Symbol Description Low Brake Pressure Low Steering Fluid Pressure Main Hoist Status Main Hoist Disabled Main Hoist Enabled Main Hoist Raise Main Hoist Not In Use Main Hoist Lower Marker/Position/Side Light Rear Wheels Not Centered Oil Feed Filter Contaminated Outrigger Button Outrigger Front Left...
  • Page 100 OPERATING CONTROLS AND PROCEDURES RT540E OPERATOR MANUAL Symbol Description RCL Override Status Light Bar Error Swing Status Swing Brake Swing Group SLI Early Warning SLI Shutdown Swing Brake Telescope Status Tools Group Transmission Temperature Warning Transmission Status WRL Area Limit WRL Height Limit WRL Radius Limit WRL Swing Angle Limit...

  • Page 101: General

    RT540E OPERATOR MANUAL SET-UP AND INSTALLATION PROCEDURES SECTION 4 SET-UP AND INSTALLATION PROCEDURES SECTION CONTENTS General ........4-1 Erecting .

  • Page 102: Cable Reeving

    SET-UP AND INSTALLATION PROCEDURES RT540E OPERATOR MANUAL CABLE REEVING NOTE: The type of cable (wire rope) available on this crane is 35 x 7 (non-rotating). Within the limits of the load and range charts and permissible line pull, multi-part lines allow the operator to raise a greater load than can be raised with a single part line.
  • Page 103 RT540E OPERATOR MANUAL SET-UP AND INSTALLATION PROCEDURES Upper Boom Upper Boom Nose Sheaves To Main Hoist Nose Sheaves To Hoist To Aux Hoist Bottom Boom Nose Sheaves Aux. Nose Boom Nose Dead End Bottom Boom Nose Sheaves Ball Ball Hookblock Single Part Line Sheaves 4-Sheave Hookblock...
  • Page 104 SET-UP AND INSTALLATION PROCEDURES RT540E OPERATOR MANUAL Mast On Boom To Hoist Extension 6710-2 One Part Line Using Fixed Boom Extension Ball To Hoist To Hoist 6710-8 6710-9 One Part Line One Part Line Using Fixed Boom Extension Using Fixed Boom Extension Shown at 30°Offset Shown at 15°Offset FIGURE 4-3 continued...
  • Page 105 RT540E OPERATOR MANUAL SET-UP AND INSTALLATION PROCEDURES Upper Boom Upper Boom Nose Sheaves Nose Sheaves To Main Hoist To Main Hoist Bottom Boom Nose Sheaves Bottom Boom Nose Sheaves Hookblock Sheaves Hookblock Sheaves Hookblock Dead End Hookblock Dead End Four Parts Line Five Parts Line 4-Sheave Hookblock 3-Sheave Hookblock...

  • Page 106: Dead-End Rigging/Wedge Sockets

    Refer to SECTION 1 - regulations in force. If there are any questions, contact your Introduction in the Service Manual for wire rope Manitowoc distributor or Manitowoc Crane Care. procedures. Do not mix components from different manufacturers. The...

  • Page 107: Dead-End Rigging

    Table 4-1 block system and other components during use of the crane. Wire Rope Clip Torque Values Of the methods shown below, Manitowoc prefers that Clip Sizes Torque method A or F be used, i.e., clipping a short piece of wire...

  • Page 108: Erecting And Stowing The Boom Extension

    SET-UP AND INSTALLATION PROCEDURES RT540E OPERATOR MANUAL ERECTING AND STOWING THE BOOM The extension may swing out on its own accord when you remove the last connection that held the extension at the EXTENSION side of the main boom. General Warnings You must therefore secure the extension before you begin the erection procedure.
  • Page 109 RT540E OPERATOR MANUAL SET-UP AND INSTALLATION PROCEDURES Raise the boom to horizontal and extend the boom approximately 51 to 64 cm (20 to 25”). Make certain that the boom extension stowage lugs clear the guide pins (Figure 4-10) (3) and ramp (Figure 4-8) (4) on the front and rear stowage brackets.

  • Page 110: Stowing

    SET-UP AND INSTALLATION PROCEDURES RT540E OPERATOR MANUAL Disconnect RCL cable: Remove connector from junction box on boom nose. b. Install dummy plug in junction box. Route cable to and attach to boom extension Raise the boom to horizontal. Extend the boom approximately 51 to 64 cm (20 to 25”). Make certain that the boom extension stowage lugs will line up in front of the guide pins (3) (Figure 4-10) and ramp (4) (Figure 4-8) on the stowage brackets when the...

  • Page 111: Setting The Offset

    RT540E OPERATOR MANUAL SET-UP AND INSTALLATION PROCEDURES handle (10) Figure 4-12 to push the swingaway against the rear of the boom and disengage the swingaway anchor fittings from the boom nose attachment lugs (9) Figure 4-7. Install the retainer pin (11) Figure 4-12 securing the sliding support in the “IN”...

  • Page 112: Setting The Telescoping Extension Length

    SET-UP AND INSTALLATION PROCEDURES RT540E OPERATOR MANUAL Connect the anti-two block cable connector to the Loop the anti-two block cable over the spool on the side junction box. of the base section. Setting The Telescoping Extension Length COUNTERWEIGHTS Extending Counterweight Description Position the boom to over the front.
  • Page 113 RT540E OPERATOR MANUAL SET-UP AND INSTALLATION PROCEDURES 6711 Fabricated Counterweight FIGURE 4-14 Shut down crane. Item Description Remove and cap hydraulic lines from auxiliary hoist (if installed) Counterweight Attach an adequate lifting device to the counterweight. Primary Retainer Pin Assembly Leveling Capscrew For cast counterweight;...
  • Page 114 SET-UP AND INSTALLATION PROCEDURES RT540E OPERATOR MANUAL 14. Replace pin assembly in turntable counterweight NOTE: The counterweight weighs approximately 4300 kg mounting lugs. (9490 lb). 15. Move counterweight far enough from crane to allow the NOTE: Use of a forklift to remove/install the fixed turntable/superstructure to clear during repositioning.

  • Page 115: Section 5

    Dispose of waste properly! Improperly disposing of waste distributor or Manitowoc Crane Care. can threaten the environment. Potentially harmful waste used in Manitowoc cranes includes — but is not limited to — oil, fuel, grease, coolant, air CAUTION conditioning refrigerant, filters, batteries, and cloths which...

  • Page 116: Standard Lubricants

    ALL Weather Package and Lubricants system seals and wear bands. If you are in doubt about the suitability of a specific fluid, check with your Manitowoc Engineering recommends the following lubricants for distributor or Manitowoc Crane Care.
  • Page 117 RT540E OPERATOR MANUAL LUBRICATION temperatures. We also recommend the use of appropriately system and starting system. And has done whatever they sized heaters for the hydraulic tank, engine oil pan, engine feel necessary to add insulation for under hood temperatures and meet the engine manufacture's intake air temperature.

  • Page 118: Surface Protection For Cylinder Rods

    An Anti-Seize compound may be used if protected using Boeshield® T-9 Premium Metal Protectant. rust has not formed, otherwise the component must be Manitowoc Crane Care has Boeshield® T-9 Premium Metal cleaned first. Protectant available in 12 oz cans that can be ordered through Manitowoc Crane Care (request P/N 9999101803).

  • Page 119: Steering And Suspension

    RT540E OPERATOR MANUAL LUBRICATION Steering and Suspension Lube Point Figure Approved Lube Item Lube Interval Application Description Lubricant Capacity EP-MPG Extreme Until Steer Cylinder Pressure Figure 5-1 grease 500 hours or 3 months 8 grease fittings Pivot Pins Multipurpose extrudes Grease 6829003477 EP-MPG...
  • Page 120 LUBRICATION RT540E OPERATOR MANUAL 8046-1 6818-2 6818-1 FIGURE 5-1 Published 04-20-2015, Control # 501-02...

  • Page 121: Axles

    RT540E OPERATOR MANUAL LUBRICATION Lube Point Figure Approved Lube Item Lube Interval Application Description Lubricant Capacity Axles • Check level every GL-5 500 hours or 3 Extended Fill to bottom of hole months Axle Tech 20.8 l Figure 5-2 Service Interval in housing on the Differentials (44 pt)
  • Page 122 LUBRICATION RT540E OPERATOR MANUAL 8046-1 6818-3 6818-45 FIGURE 5-2 Published 04-20-2015, Control # 501-02...

  • Page 123: Drive Train

    RT540E OPERATOR MANUAL LUBRICATION Lube Point Figure Approved Lube Item Lube Interval Application Description Lubricant Capacity Drive Train EO-15W/40 • Check level • Check level every 10 Engine Oil through dipstick. hours or daily Engine SAE 15W-40 17.5 l • Fill engine oil Crankcase Figure 5-3 T3 Engine -...
  • Page 124 LUBRICATION RT540E OPERATOR MANUAL 8054 Dipstick 6818-36 6813-7 8046-1 Opposite Side 6818-37 8048 8045 FIGURE 5-3 5-10 Published 04-20-2015, Control # 501-02...

  • Page 125: Drive Train (Continued)

    RT540E OPERATOR MANUAL LUBRICATION Lube Point Figure Approved Lube Item Lube Interval Application Description Lubricant Capacity Drive Train (continued) EP-MPG Extreme Until Driveline - Slip Pressure Figure 5-4 grease 500 hours or 3 months 2 grease fittings Joints Multipurpose extrudes Grease 6829003477 •...
  • Page 126 LUBRICATION RT540E OPERATOR MANUAL Fuel Cap Access 8053 6818-36 Opposite Side 8046-1 Opposite Side 8052 6818-8 6818-43 FIGURE 5-4 5-12 Published 04-20-2015, Control # 501-02...

  • Page 127: Outriggers

    RT540E OPERATOR MANUAL LUBRICATION Lube Point Figure Approved Lube Item Lube Interval Application Description Lubricant Capacity Outriggers EP-MPG Extreme Brush lubricant on Outrigger Beams Pressure Figure 5-5 50 hours or 1 week bottom of outrigger (Outside) Multipurpose beams Grease 6829003477 EP-MPG Brush lubricant on Extreme...
  • Page 128 LUBRICATION RT540E OPERATOR MANUAL 8046-1 7961 6818-9 FIGURE 5-5 5-14 Published 04-20-2015, Control # 501-02...

  • Page 129: Turntable

    RT540E OPERATOR MANUAL LUBRICATION Lube Point Figure Approved Lube Item Lube Interval Application Description Lubricant Capacity Turntable • Check and fill every GL-5 50 hours Extended Use dipstick. If no Turntable Gear 4.0 l • Drain and fill after Figure 5-6 Service Interval dipstick, fill to top of (4.25 qt)
  • Page 130 LUBRICATION RT540E OPERATOR MANUAL 6818-11 6818-10 Dipstick 8046-1 6818-44 FIGURE 5-6 5-16 Published 04-20-2015, Control # 501-02...

  • Page 131: Boom

    RT540E OPERATOR MANUAL LUBRICATION Lube Point Figure Approved Lube Item Lube Interval Application Description Lubricant Capacity Boom EP-MPG Until Extreme Pressure Upper Lift Figure 5-7 grease 500 hours or 3 months 1 grease fittings Multipurpose Cylinder Pin Grease extrudes 6829003477 EP-MPG Until Extreme Pressure...
  • Page 132 LUBRICATION RT540E OPERATOR MANUAL 6818-14 6818-15 6818-27 8046-1 6818-21 6818-12 6818-13 6818-26 FIGURE 5-7 5-18 Published 04-20-2015, Control # 501-02...

  • Page 133: Boom (Continued)

    RT540E OPERATOR MANUAL LUBRICATION Lube Point Figure Approved Lube Item Lube Interval Application Description Lubricant Capacity Boom (continued) EP-MPG Extreme Until Pressure Boom Pivot Shaft Figure 5-8 grease 250 hours or 3 months 2 grease fittings Multipurpose extrudes Grease 6829003477 EP-MPG Extreme Until...
  • Page 134 LUBRICATION RT540E OPERATOR MANUAL 6818-14 6818-17 8046-1 6818-25 6818-22 6818-35 FIGURE 5-8 5-20 Published 04-20-2015, Control # 501-02...

  • Page 135: Hoist

    RT540E OPERATOR MANUAL LUBRICATION Lube Point Figure Approved Lube Item Lube Interval Application Description Lubricant Capacity Hoist • Check and fill every AGMA 50 hours or weekly Extreme Oil level must be 5.2 l Main Hoist Figure 5-9 Pressure Gear visible in the sight •...
  • Page 136 LUBRICATION RT540E OPERATOR MANUAL 8046-1 6818-17 FIGURE 5-9 5-22 Published 04-20-2015, Control # 501-02...

  • Page 137: Hydraulic

    "milky" with only a small layer of transparent oil on top. If the "milky” appearance was due to air foaming, it will dissipate and the oil should closely match the fresh oil. Should you have any questions, please contact your local authorized Manitowoc distributor.
  • Page 138 LUBRICATION RT540E OPERATOR MANUAL 8046-1 Sight Gauge 6818-19 8055 FIGURE 5-10 5-24 Published 04-20-2015, Control # 501-02...

  • Page 139: General

    RT540E OPERATOR MANUAL MAINTENANCE CHECKLIST SECTION 6 MAINTENANCE CHECKLIST SECTION CONTENTS General ........6-1 Daily or 10 Hour Check List .

  • Page 140: Weekly Or 50 Hour Check List

    MAINTENANCE CHECKLIST RT540E OPERATOR MANUAL Fuel/Water Separator: Drain moisture. Air Cleaner: Check for proper service/level. Check for cracks or leaks. Hook Block and Headache Ball Safety Latch: Check for proper working order. Check for cracks and leaks. Check for excessive wear. Lock-out Cylinder and Swing Potentiometer: Check for proper operation while operating machine.
  • Page 141 RT540E OPERATOR MANUAL Alphabetical Index Accidents ............. 2-2 Arctic Conditions .
  • Page 142 OPERATOR MANUAL RT540E THIS PAGE BLANK APL 2...

Table of Contents