Page 1 Grove RT540E Service/Maintenance Manual...
Page 2 THIS PAGE BLANK...
Page 3 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. © 2015 Manitowoc Crane Group Published 4-20-2015, Control # 502-01...
Page 4 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 5: Table Of Contents
RT540E SERVICE MANUAL TABLE OF CONTENTS See end of this Manual for Alphabetical Index SECTION 1 ........INTRODUCTION Description.
Page 6 TABLE OF CONTENTS RT540E SERVICE MANUAL Description............2-8 Maintenance .
Page 7 RT540E SERVICE MANUAL TABLE OF CONTENTS Description ............2-48 Maintenance .
Page 8 TABLE OF CONTENTS RT540E SERVICE MANUAL Windshield Wiper Assembly Replacement ......3-12 Windshield Washer Assembly Replacement .
Page 9 RT540E SERVICE MANUAL TABLE OF CONTENTS SECTION 5 ..... . . HOIST AND COUNTERWEIGHT Description............5-1 Theory of Operation.
Page 10 TABLE OF CONTENTS RT540E SERVICE MANUAL SECTION 7........POWER TRAIN Engine .
Page 11 RT540E SERVICE MANUAL TABLE OF CONTENTS Parking Brake ............8-25 Description .
Page 12 TABLE OF CONTENTS RT540E SERVICE MANUAL THIS PAGE BLANK TOC-8...
Page 13: Section 1
RT540E SERVICE MANUAL INTRODUCTION SECTION 1 INTRODUCTION SECTION CONTENTS Description ....... 1-1 Batteries.
Page 14: List Of Specifications
INTRODUCTION RT540E SERVICE MANUAL LIST OF SPECIFICATIONS Axles Total Ratio......20.06:1 General Carrier Ratio ......5.57:1 Wheel End Ratio.
Page 15 RT540E SERVICE MANUAL INTRODUCTION Hoists Length-Aux....137 m (450 ft) Max. Permissible Line Pull (6x36) Drum Dimensions ......51.7 kN (11,640 lb) Diameter .
Page 16 INTRODUCTION RT540E SERVICE MANUAL CG From Rear Weight Front Axle Rear Axle Description Axle cm (in) kg (lb) kg (lb) kg (lb) Lift Cylinder & Lower Shaft 218.0 (85.85) 638 (1407) 381 (839) 258 (568) Complete Basic Machine 4 x 4 chassis; Cummins QSB 6.7 Tier 4 engine w/ transmission;...
Page 17 RT540E SERVICE MANUAL INTRODUCTION 8047-2 Item Description Outrigger Float Outrigger Jack Cylinder Steps Valve Cover Counterweight FIGURE 1-2 GROVE Published 4-20-2015, Control # 502-01...
Page 18 INTRODUCTION RT540E SERVICE MANUAL 8046-1 FIGURE 1-2 continued Item Description Item Description Counterweight Swingaway Auxiliary Hoist Outrigger Jack Cylinder Main Hoist Front Axle Boom Pivot Hydraulic Tank Lift Cylinder Rear Axle Boom Nose Sheaves 6812-2 FIGURE 1-2 continued Item Description Item Description Swingaway...
Page 19: General Maintenance
RT540E SERVICE MANUAL INTRODUCTION GENERAL MAINTENANCE When raising a portion of a crane or a complete crane, ensure the crane is blocked securely and the weight is These general suggestions should be helpful in following the supported by blocks rather than by lifting equipment. i ns t r u c t io n s i n th i s m a nu a l .
Page 20: Wires And Cables
INTRODUCTION RT540E SERVICE MANUAL Flat metal locks must be installed properly to be effective. Installation Bend one end of the lock around the edge of the part. Bend Lubricate new or used bearings before installation. Bearings the other end against one flat surface of the nut or bolt head. that are to be preloaded must have a film of oil over the entire Always use new locking devices on components which have assembly to obtain accurate pre-loading.
Page 21: Hydraulic Systems
Moist Mid-latitude: Cold winters. Latitude 50° - 70° North & South Polar: Extremely cold winters and summers. Latitude: 60° - 75° North & South Visually inspect hoses and fittings once a month or of hose assemblies, refer to your Manitowoc Crane Care every 250 hours for the following: Parts Manual.
Page 22: Electrical System
8000 hours of service life. areas applicable to Manitowoc/Grove machines, and a visual inspection of these areas should be made part of an owner’s Hydraulic hose assemblies operating in climate zones planned preventive maintenance program: “A”...
Page 23: Fasteners And Torque Values
• Torque wrenches must be those specified and forces and nuts being used. must be applied at the handle grip. The use of handle The torque tables are provided by Manitowoc for reference extensions will change applied torque to the bolt. when performing maintenance.
Page 24 INTRODUCTION RT540E SERVICE MANUAL To convert pounds-inch (lb-in) of torque to Newton meters Torque Values (Nm), multiply the pounds-inch quantity by 0.11298. The following tables list the torque values for both ASME standard and metric fasteners. The tables list the values for grade 5 and grade 8 zinc-flake coated, untreated (black) finish and stainless steel fasteners.
Page 25 RT540E SERVICE MANUAL INTRODUCTION Table 1-5: Metric Fasteners, Coarse Thread, Zinc-Flake Coating Bolt Diameter - Metric Torque Values (Nm) Class 21.6 42.4 73.1 1195 1608 2072 10.9 12.5 31.5 62.0 1325 1800 2450 3150 12.9 15.0 36.0 75.0 1060 1550 2125 2850 3700...
Page 26: Weld Studs
INTRODUCTION RT540E SERVICE MANUAL Table 1-9: UNC (Coarse) Thread: Torque Values for Table 1-10: Metric Coarse Thread: Torque Values for Stainless Steel Fasteners with Oil Lubrication Stainless Steel Fasteners with Oil Lubrication Torque Value Torque Size Value Size lb-in lb-ft #5 (0.125) —...
Page 27: Wire Rope
ANSI/ASME B30.5, federal amount depends on the rope’s size, type, and anticipated regulations, and Manitowoc. The inspection interval shall be use. This in-process treatment will provide the finished rope determined by a qualified person and shall be based on such...
Page 28: Wire Rope Inspection (Running Ropes And Pendant Cables)
When replacing fixed length cable assemblies (e.g. pendants) having permanently attached end fittings use only pre-assembled lengths of wire rope as supplied from Manitowoc. Do not build lengths from individual components. Replace an entire wire rope assembly. Do not attempt to rework damaged wire rope or wire rope ends.
Page 29: Wire Rope Inspection (Boom Extension And Retraction Cables)
RT540E SERVICE MANUAL INTRODUCTION Distortion, Kinking, Crushing, Un-stranding, Bird caging, Wire Rope Inspection (Boom Extension and Reduction of diameter, etc. Retraction Cables) General corrosion. Periodic Inspection. Broken or cut strands. It is recommended that a periodic inspection of all boom Number, distribution and type of broken wires.
Page 30: Seizing Wire Rope
30 rope diameters. • Severe corrosion as evidenced by pitting. • Manitowoc recommends that for cable extended booms, a single damaged wire rope assembly shall require replacement of the entire set of extension cables. • Manitowoc recommends for cable extended booms, that boom extension cables be replaced every seven (7) years.
Page 31: Installing 35X7 Class Wire Rope
RT540E SERVICE MANUAL INTRODUCTION wedged into the lower layers under load, which can seriously damage the rope.) The tensioning load should range from 1 to 2% of the rope’s minimum breaking force. For ropes in multi-part systems: Reeve the traveling block and boom tip sheaves so the rope spacing is maximized and the traveling (hook) block hangs straight and level to help assure block stability.
Page 32 INTRODUCTION RT540E SERVICE MANUAL NOTE: The outer strands must not be able to move with respect to the inner strands. The weld must not exceed the diameter of the rope. b. If a welder is not available, the cut is to be made with an acetylene torch.
Page 33: Section 2
RT540E SERVICE MANUAL HYDRAULIC SYSTEM SECTION 2 HYDRAULIC SYSTEM SECTION CONTENTS Description ....... 2-2 Description.
Page 34: Description
HYDRAULIC SYSTEM RT540E SERVICE MANUAL Cylinders ....... . 2-54 Description ......2-64 General .
Page 35 RT540E SERVICE MANUAL HYDRAULIC SYSTEM FIGURE 2-1 GROVE Published 4-20-2015, Control # 502-01...
Page 36 HYDRAULIC SYSTEM RT540E SERVICE MANUAL FIGURE 2-2 Published 4-20-2015, Control # 502-01...
Page 37: Maintenance
RT540E SERVICE MANUAL HYDRAULIC SYSTEM MAINTENANCE 10. Disconnect the return lines from a pair of outrigger jack cylinders and activate the cylinders to their maximum Hydraulic Oil Recommendations. down positions. 11. Connect the return lines and raise the outrigger jack For the hydraulic oil specifications, refer to Section 9 - cylinders to the stowed position.
Page 38: Removing Air From The Hydraulic System
Parts found damaged or out of tolerance when maintenance times in both directions. is being performed should be replaced. Refer to the Manitowoc Crane Care Parts Catalog for proper replacement This action should return any entrapped air to the parts.
Page 39 RT540E SERVICE MANUAL HYDRAULIC SYSTEM limits. If this condition exists, the spool and body must be between the poppet and seat, it will keep the valve open and replaced as an assembly. allow a return flow of hydraulic oil. The remedy is to clean the valve, but it is also a good idea to follow through and ensure Valve Leakage the hydraulic system filter is still serviceable.
Page 40: Supply Pressure And Return Circuit
HYDRAULIC SYSTEM RT540E SERVICE MANUAL SUPPLY PRESSURE AND RETURN CIRCUIT An oil temperature gauge is located on the lower front of the reservoir to indicate oil temperature. Description The hydraulic oil filter (Figure 2-4) is located in the top of the reservoir.
Page 41: Maintenance
RT540E SERVICE MANUAL HYDRAULIC SYSTEM Maintenance Troubleshooting Symptom Probable Cause Solution No hydraulic oil Low hydraulic oil level. Fill reservoir. flows in systems. b. Reservoir-to-pump suction lines b. Clean, repair, or replace lines as broken or restricted. Air entering at necessary.
Page 42 HYDRAULIC SYSTEM RT540E SERVICE MANUAL 6727 6, 7, 8 FIGURE 2-3 Item Description Item Description Access Cover Hex Locknut Breather/Fill Cap Flatwasher Return Line Filter Thermometer (Temperature Gauge) Reservoir Ladder Sight Gauge Magnetic Plug Capscrew 2-10 Published 4-20-2015, Control # 502-01...
Page 43 RT540E SERVICE MANUAL HYDRAULIC SYSTEM 5, 6 6728 FIGURE 2-4 Item Description Item Description Capscrew Filter Head Washer Gauge O-ring O-ring Element Bypass Valve Bowl Spacer Gasket Capscrew GROVE 2-11 Published 4-20-2015, Control # 502-01...
Page 44 HYDRAULIC SYSTEM RT540E SERVICE MANUAL Return Hydraulic Filter Assembly Element Installation Place a new element into the filter bowl (housing). Element Removal Install new O-ring in the cap assembly. If by-pass valve was removed from cap, install by-pass capscrews to cap. DANGER Install cap assembly on filter head and secure with the Ensure that all hydraulic systems are shut down and the...
Page 45: Oil Cooler
RT540E SERVICE MANUAL HYDRAULIC SYSTEM OIL COOLER the filter in the reservoir. When several hydraulic functions are being used at one time (i.e., hoisting, lifting, and Description telescoping), more oil has to flow through this return line, causing a pressure buildup. When this pressure reaches An air cooled hydraulic oil cooler (Figure 2-5) is installed on 206.8 kPa/2.0 bar (30 psi), the normally closed check valve the rear of the superstructure behind the hoists.
Page 46: Hydraulic Pumps
HYDRAULIC SYSTEM RT540E SERVICE MANUAL HYDRAULIC PUMPS NOTE: Charge pump and two studs must be removed for wrench access to piston pump mounting bolts. Description Remove the capscrews and washers attaching the pump to the drive pad on the torque converter. Remove Pump No.
Page 47 RT540E SERVICE MANUAL HYDRAULIC SYSTEM No. 2 Pump Installation Connect the distribution and supply lines as tagged during removal. Install new gasket material to the pump mounting flange. Install pump on to left front of engine with capscrews and CAUTION washers.
Page 48 HYDRAULIC SYSTEM RT540E SERVICE MANUAL from priming. If this occurs, stop engine, and inspect hydraulic oil that was used to fill the hydraulic reservoir all connections of the suction hose/tube for a loose to the bottom of the O-ring case drain port. Install the connection, or a missing or damaged O-ring.
Page 49: Pressure Setting Procedures
NOTE: A Digital Pressure Gauge and accessories may be make adjustments to specified setting. purchased through Manitowoc Crane Care. When checking the outrigger relief valve setting, The following equipment is required for checking the start with the engine at idle RPM and activate and hydraulic pressure settings.
Page 50 HYDRAULIC SYSTEM RT540E SERVICE MANUAL Table 2-1 Valve Pressure Setting Table Pressure Tolerance Valve To Be Set Setting Adjustment Location PSI (MPa) PSI (MPa) 4000 (27.6) ± 50 (0.4) GP2 - Superstructure mounted main Hoist (s), and Lift Pressure Setting directional control valve load sense relief valve (Figure 2-9) Telescope Extend Pressure Setting...
Page 51: Procedure A - Checking/Setting The Main Control Valve For Hoist(S), Boom Lift And Piston Pump
RT540E SERVICE MANUAL HYDRAULIC SYSTEM NOTE: Procedures A through H in the following text Cap hose (the larger of the two) running from port A, correlate with Figures 2-6 through 2-10. telescope section of the main directional control valve to the cylinder port block at the back of the base section.
Page 52: Procedure C - Checking/Setting The Swing Directional Control Valve Work Port Relief Valves
HYDRAULIC SYSTEM RT540E SERVICE MANUAL Procedure C - Checking/Setting the Swing Close the charging assembly bleed valve. Attach the swivel nut onto the gas valve and tighten 1.1 - 1.6 Nm Directional Control Valve Work Port Relief (10-15 lb-in). Valves Turn the gas chuck “T”...
Page 53: Procedure F - Checking/Setting The Front Steer Pressure
RT540E SERVICE MANUAL HYDRAULIC SYSTEM Procedure F - Checking/Setting the Front detection procedure should detect RT->RT540i/RT530i- >Superstructure. Steer Pressure Start engine and run at @ idle rpm's, make sure to lower Install pressure check diagnostic quick disconnect with left armrest. gauge onto test nipple @ GP5 port of the accessory m a n i f o l d w i t h s w i n g d i r e c t i o n a l c o n t r o l v a l v e For each function, attach a test fitting and pressure...
Page 54: Procedure K - Setting Threshold And Max On Swing Brake Pedal
HYDRAULIC SYSTEM RT540E SERVICE MANUAL FIGURE 2-8 Procedure K - Setting Threshold and Max on pressure of 1.7-1.9 MPa (250-275 PSI) is achieved (Figure 2-9). Swing Brake Pedal If adjustment can’t obtain the setting in step #2, stop Install pressure check diagnostic quick disconnect engine and install a pressure check diagnostic quick (Parker PD240) with gauge onto test nipple @ GP6 port disconnect (Parker PD240) with gauge onto the test...
Page 55 RT540E SERVICE MANUAL HYDRAULIC SYSTEM Item Description Procedure G- Pilot Supply PSI Reducing Valve Procedure H - Swing Brake PSI Reducing Valve Procedure C - Swing Left Port Relief Valve Procedure F - Front Steer Load Sense Relief Valve Procedure C - Swing Right Port Relief Valve Gauge Port 2 Gauge Port 3 Gauge Port 6...
Page 56 HYDRAULIC SYSTEM RT540E SERVICE MANUAL Item Description Procedure A - Telescope Extend Port Relief Procedure A - Load Sense Relief Valve Procedure A - Telescope Retract Port Relief Gauge Port 7 Pilot End Cap GPD Lift Down Pilot End Cap GPC Telescope Retract Pilot End Cap GPA Main Hoist Up Pilot End Cap GPB Aux Hoist Up FIGURE 2-10...
Page 57 RT540E SERVICE MANUAL HYDRAULIC SYSTEM Procedure B - Outrigger PSI Reducing Valve 6739-3 FIGURE 2-11 Item Description Gas Valve Guard Gas Valve 6739-4 FIGURE 2-12 GROVE 2-25 Published 4-20-2015, Control # 502-01...
Page 58 HYDRAULIC SYSTEM RT540E SERVICE MANUAL Item Description Procedure A -Pump Cut-Off Max Setting Adjustment  Procedure A - Pump P (Stand-by) Adjustment 6739-5 FIGURE 2-13 2-26 Published 4-20-2015, Control # 502-01...
Page 59: Valves
RT540E SERVICE MANUAL HYDRAULIC SYSTEM VALVES description of each valve given here is for the valve itself. For information on how each valve functions in the individual General circuits, refer to the description and operation procedures of that circuit. This subsection provides descriptive information for all the NOTE: On each valve illustration in this section, each item hydraulic valves used on this crane.
Page 60 HYDRAULIC SYSTEM RT540E SERVICE MANUAL 6726 SUPERSTRUCTURE FIGURE 2-14 Item Description Item Description Hoist/Telescope/Lift Directional Valve Secondary Steer Valve (CE Option) Swing/Steer Directional Valve Accumulator Service Brake Dual Accumulator Charge Valve Superstructure 2-28 Published 4-20-2015, Control # 502-01...
Page 61 RT540E SERVICE MANUAL HYDRAULIC SYSTEM 6725 CARRIER FIGURE 2-14 continued Item Description Item Description Front Outrigger Control Manifold Axle Lockout Valve Outrigger/Rear Steer Valve Rear Outrigger Control manifold Differential Lock Valve Frame Park Brake Range Shift Valve GROVE 2-29 Published 4-20-2015, Control # 502-01...
Page 62: Directional Control Valves
HYDRAULIC SYSTEM RT540E SERVICE MANUAL DIRECTIONAL CONTROL VALVES NOTE: lift/telescope/hoist valve bank weighs approximately 81.30 kg (179.2 pounds). Description Remove the capscrews, washers and nuts securing the valve bank and remove the valve bank. The directional control valves direct and control hydraulic oil flow from the pumps to the boom lift and telescope cylinders, Boom Lift/Telescope/Hoist Valve Bank each hoist motor, the swing motor, and the front steer...
Page 63 RT540E SERVICE MANUAL HYDRAULIC SYSTEM FIGURE 2-15 Item Description Item Description Port 1A -Main Hoist Up Load Sense - Inlet Port Port 1B - Main Hoist Down Port PS - Pilot Supply Port 2A - Aux Hoist Up Gauge Port Port 2B - Aux Hoist Down Relief Valve - Telescope Extend Port 3A - Telescope Extend...
Page 64 HYDRAULIC SYSTEM RT540E SERVICE MANUAL Hoist Inlet Auxiliary Hoist Lift Outlet Telescope Boom Lift/Telescope/Hoist Main Valve Hydraulic Schematic FIGURE 2-15 continued 2-32 Published 4-20-2015, Control # 502-01...
Page 65: Accessory With Swing Directional Control Manifold
RT540E SERVICE MANUAL HYDRAULIC SYSTEM ACCESSORY WITH SWING DIRECTIONAL resistance check valve providing make-up oil to the swing motor for motor over-run when the valve is centered. It CONTROL MANIFOLD receives oil from pump #1 through swivel port 5. This section is controlled by two proportional two position, three way Description solenoid valves.
Page 66 HYDRAULIC SYSTEM RT540E SERVICE MANUAL 8492 FIGURE 2-16 continued Item Description Item Description Pilot Supply Relief Valve Drain Port - D7 (Swing Brake/Lift Cylinder Pilot) Gauge Port- GP4 Drain Port - D3 (Plugged) Swing Brake Relief Valve Gauge Port - GP2 Solenoid Valve - Swing Brake Gauge Port - GP5 Solenoid Valve - Swing Brake Release...
Page 67: Steering Control Valve
RT540E SERVICE MANUAL HYDRAULIC SYSTEM STEERING CONTROL VALVE Remove the capscrews and washers and remove the valve from the steering column. Description Installation The steering control unit (Figure 2-17) controls hydraulic flow Secure the valve to the steering column and secure with to the front steering cylinders.
Page 68: Tandem Brake Valve With Treadle Pedal
HYDRAULIC SYSTEM RT540E SERVICE MANUAL TANDEM BRAKE VALVE WITH TREADLE The tandem brake valve consists of a tandem valve body, a closed center spool, a treadle pedal and a mechanical spring PEDAL assembly to limit the output pressure to the brake actuators to 10,342 kPa/103.4 bar (1500 psi).
Page 69: Dual Accumulator Charge Valve
RT540E SERVICE MANUAL HYDRAULIC SYSTEM DUAL ACCUMULATOR CHARGE VALVE pressure also pilots the control pilot spool to open the load sense line to tank, destroking the piston pump No. 1. Description Maintenance The load sensing dual accumulator charging valve is located on the inside of the left superstructure side plate.
Page 70 HYDRAULIC SYSTEM RT540E SERVICE MANUAL Item Description Port LS - Load Sense Port Port T - Tank Port Port P - Pressure Port Accumulator Port A1 Accumulator Port A2 Pressure Switch 6696-2 6696-1 6696-3 Valve Hydraulic Schematic FIGURE 2-19 2-38 Published 4-20-2015, Control # 502-01...
Page 71: Hydraulic Accumulator Service Brake
RT540E SERVICE MANUAL HYDRAULIC SYSTEM HYDRAULIC ACCUMULATOR SERVICE Remove the two nuts securing each clamp half. Remove the each clamp half and accumulator from the turntable. BRAKE Installation Description Position the accumulator in the clamps and secure with The service brake hydraulic accumulators are located on the the removable clamp halves and nuts.
Page 72: Holding Valves
HYDRAULIC SYSTEM RT540E SERVICE MANUAL HOLDING VALVES Removal Unscrew holding valve from its port block or manifold. Description Installation A bolt-on manifold style holding valve is installed on the boom lift cylinder. A cartridge style holding valve is used on Check the inside of the port block or manifold for any the telescope cylinder installed in the piston side of the sharp edges or burrs and remove as necessary with...
Page 73: Cross Axle Differential Lock Valve
RT540E SERVICE MANUAL HYDRAULIC SYSTEM CROSS AXLE DIFFERENTIAL LOCK VALVE Maintenance Description Removal The optional cross axle differential lock valve is mounted on Tag and disconnect the electrical connector from the the right side of the aft center frame cross member. The valve.
Page 74 HYDRAULIC SYSTEM RT540E SERVICE MANUAL Item Description Three-Way Solenoid Valve Pressure Reducing Valve Port P - From Pressure Port On Transmission Port C - To Differential Lock Actuator On Axles Port T - To Tank Port On Transmission Port G - Gauge Port 100 Mesh Screen 6718-2 Hydraulic Schematic...
Page 75: Outrigger Control Manifold
RT540E SERVICE MANUAL HYDRAULIC SYSTEM OUTRIGGER CONTROL MANIFOLD Inspection Visually inspect the valves and hydraulic connections for any Description evidence of leaks or other damage. Check security of the There are two outrigger control manifolds utilized on the electrical connections. Inspect the wiring for any evidence of crane, one for the front outriggers and one for the rear cracks or breaks.
Page 76: Pilot Operated Check Valve
HYDRAULIC SYSTEM RT540E SERVICE MANUAL PILOT OPERATED CHECK VALVE Lubricate the check valve and O-rings with clean hydraulic oil. Description A pilot operated (PO) check valve is located in each CAUTION outrigger jack cylinder port block. The check valve functions Do not damage the O-rings during installation of the check as a holding valve for the jack cylinder.
Page 77: Integrated Outrigger/Rear Steer Manifold
RT540E SERVICE MANUAL HYDRAULIC SYSTEM INTEGRATED OUTRIGGER/REAR STEER Maintenance MANIFOLD Removal Description Tag and disconnect the electrical connectors to the valve. The integrated outrigger/rear steer manifold (Figure 2-24) controls the outrigger and rear steer circuit. The valve is Tag and disconnect the hydraulic hoses from the valve. mounted on the frame center section to the rear of the front Cap or plug the lines and ports.
Page 78 HYDRAULIC SYSTEM RT540E SERVICE MANUAL 6751-3 View A See View A for this side 8, 9 6751-1 FIGURE 2-24 2-46 Published 4-20-2015, Control # 502-01...
Page 79 RT540E SERVICE MANUAL HYDRAULIC SYSTEM 8467 FIGURE 2-24 continued Item Description Item Description Pressure Reducing Valve - PR1 Load Sense - LS0 Check Valve - CV1 Load Sense - LS1 Orifice - ORF1 Port ALO - To Axle Lockout Valve Solenoid Valve - Rear Steer S1 Port T - Tank Solenoid Valve - Rear Steer S2...
Page 80: Check Valves
HYDRAULIC SYSTEM RT540E SERVICE MANUAL CHECK VALVES Maintenance Description Removal Check valves are used in the crane hydraulic system to block Tag and disconnect hydraulic lines from the valve and flow in one direction and allow free flow in the opposite cap or plug all openings and remove valve.
Page 81: Range Shift/Parking Brake Valve
RT540E SERVICE MANUAL HYDRAULIC SYSTEM RANGE SHIFT/PARKING BRAKE VALVE Maintenance Description Removal The range shift/parking brake valve controls the flow of oil to Tag and disconnect the electrical connectors to the the parking brake, hi-low range and axle disconnect valve. actuators by the use of two solenoid valves (Figure 2-25).
Page 82: Axle Oscillation Lockout Valve (Standard Units)
HYDRAULIC SYSTEM RT540E SERVICE MANUAL AXLE OSCILLATION LOCKOUT VALVE Maintenance (STANDARD UNITS) Removal Description Tag and disconnect the electrical connectors to the valve. The axle oscillation lockout valve is used in the rear axle oscillation lockout circuit. The valve is located on the left Tag and disconnect the hydraulic hoses from the valve.
Page 83 RT540E SERVICE MANUAL HYDRAULIC SYSTEM Hydraulic Schematic 6694-2 6694-1 FIGURE 2-26 Item Description Port C- Pressure From Axle Lockout Port On Port B - To Left Hand Lockout Cylinder Outrigger Selector Valve Port A - To Right Hand Lockout Cylinder Solenoid Valve GROVE 2-51...
Page 84: Axle Oscillation Lockout Valve (Optional Ce Units)
HYDRAULIC SYSTEM RT540E SERVICE MANUAL AXLE OSCILLATION LOCKOUT VALVE Maintenance (OPTIONAL CE UNITS) Removal Description Tag and disconnect the electrical connectors to the valve. The axle oscillation lockout valve is used in the rear axle oscillation lockout circuit. The valve is located on the left Tag and disconnect the hydraulic hoses from the valve.
Page 85 RT540E SERVICE MANUAL HYDRAULIC SYSTEM 6719-1 6719-2 Hydraulic Schematic FIGURE 2-27 Item Description Item Description Port P - Pressure From Axle Lockout Port On Solenoid Valve Outrigger Selector Valve Port B - To Lockout Cylinder Pilot Port T - Tank Port P1 - To Lockout Cylinder Pressure Reducing Valve GROVE...
Page 86: Cylinders
Fully retract the cylinder rod (except the telescope protected using Boeshield® T-9 Premium Metal Protectant. cylinder). Remove the extend hose from the cylinder. Manitowoc Crane Care has Boeshield® T-9 Premium Metal Cap the extend hose. Protectant available in 12 oz. cans that can be ordered through the Parts Department.
Page 87 RT540E SERVICE MANUAL HYDRAULIC SYSTEM If leakage is observed, the seals in the cylinder must be minimize the effects of thermal contraction or “Stick-slip” it is replaced. recommended that the telescope control lever is activated periodically in the extend position to mitigate the effects of Reconnect all cylinder ports.
Page 88 HYDRAULIC SYSTEM RT540E SERVICE MANUAL Table 2-4 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 89: Lift Cylinder
RT540E SERVICE MANUAL HYDRAULIC SYSTEM LIFT CYLINDER Remove the two hydrolock seals and guidelock ring from the outside of the piston. Description NOTE: Arranging discarded seals and rings in the order of disassembly will aid in installation of new seals and The lift cylinder (Figure 2-28) has a bore of 22.8 cm (9.0 rings.
Page 90 HYDRAULIC SYSTEM RT540E SERVICE MANUAL 22, 23, 24 Item Description Item Description Grease Fitting Wear Ring Buffer Seal Setscrew Rod Seal Piston Wiper Ring Seal Assembly Barrel Guidelock Ring Washer Capscrew Plug Backup Ring Holding Valve O-ring Tube Assembly Head Backup Ring Capscrew O-ring...
Page 91 RT540E SERVICE MANUAL HYDRAULIC SYSTEM Install the replacement wear ring, buffer seal, rod seal, Lubricate all parts freely with clean hydraulic oil. backup ring and wiper ring in the inside of the head. Make sure the buffer seal’s step is closer to the rod seal. CAUTION Make sure the rod seal’s rim groove is closer to the buffer seal (Figure 2-29).
Page 92: Dual Rod Telescope Cylinder
HYDRAULIC SYSTEM RT540E SERVICE MANUAL DUAL ROD TELESCOPE CYLINDER NOTE: Aligning discarded seals and rings in the order of disassembly will facilitate installation of new seals Description and rings. Remove the hydrolock piston seal to gain access to the The boom dual rod telescope cylinder (upper telescope setscrew securing the piston to the outer cylinder rod.
Page 93 RT540E SERVICE MANUAL HYDRAULIC SYSTEM Inspection Clean all parts with solvent and dry with compressed air. CAUTION Inspect for damaged or worn parts and replace as Improper seal installation can cause faulty cylinder required. operation. Install the buffer seal, rod seal and backup ring inside CAUTION the head ensuring the seals are assembled properly and Clean all surfaces and remove all burrs and nicks before...
Page 94 HYDRAULIC SYSTEM RT540E SERVICE MANUAL 6714 FIGURE 2-33 Item Description Item Description Barrel O-ring Piston Backup Ring Seal Spacer Wear Ring Piston Setscrew Spacer O-ring Backup Ring Hydrolock Seal Head Wear Ring Wear Ring 2-62 Published 4-20-2015, Control # 502-01...
Page 95 RT540E SERVICE MANUAL HYDRAULIC SYSTEM 15. Install the O-ring and backup ring onto the outside of the Item Description outer cylinder head. O-ring 16. Install the outer cylinder head onto the outer cylinder Backup Ring rod. Buffer Seal 17. Install the spacer onto the rod. Backup Ring 18.
Page 96: Axle Oscillation Lockout Cylinder
HYDRAULIC SYSTEM RT540E SERVICE MANUAL AXLE OSCILLATION LOCKOUT CYLINDER Using a hoist, extend the rod assembly slowly until the piston is free of the barrel. Description Remove the rod and attached parts from the barrel. The two oscillation lockout cylinders (Figure 2-36) standard NOTE: Cover the barrel opening to avoid contamination.
Page 97 RT540E SERVICE MANUAL HYDRAULIC SYSTEM 6731 FIGURE 2-36 Item Description Item Description Barrel Lip Seal Ring Wiper Ring Head Retainer Ring Lip Seal Ring Bleeder Plug Wear Ring Grease Fitting O-ring Grease Fitting Backup Ring Screw Buffer Ring O-ring Wear Ring Cap Assembly GROVE 2-65...
Page 98 HYDRAULIC SYSTEM RT540E SERVICE MANUAL 6732 FIGURE 2-37 Item Description Item Description Barrel Backup Ring Piston Spacer Head Piston Wear Ring Spacer Setscrew O-ring Backup Ring Head Hydrolock Seal Wear Ring Wear Ring Plug O-ring Check Valve 2-66 Published 4-20-2015, Control # 502-01...
Page 99 RT540E SERVICE MANUAL HYDRAULIC SYSTEM Stone out minor blemishes and polish with a fine crocus cloth. CAUTION Clean with solvent and dry with compressed air any Exercise extreme care when handling the rod. Damage to parts that have been stoned and polished. the rod surface may cause unnecessary maintenance and expense.
Page 100: Steer Cylinder
HYDRAULIC SYSTEM RT540E SERVICE MANUAL STEER CYLINDER NOTE: Cover the barrel opening to avoid contamination. Description CAUTION The steer cylinders (Figure 2-38) are mounted on the axles, When removing seals and rings, avoid scratching the two cylinders on each axle. The front and rear steer cylinders grooved and gland surfaces.
Page 101 RT540E SERVICE MANUAL HYDRAULIC SYSTEM 6722 FIGURE 2-38 Item Description Item Description Barrel Piston Ring Seal Piston O-ring Head Backup Ring Wear Ring Seal Rod Ring Setscrew Wiper Ring O-ring Install the O-ring and backup ring onto the outside of the head.
Page 102 HYDRAULIC SYSTEM RT540E SERVICE MANUAL Install the O-ring in the inside of the piston. 10. Remove the cover from the barrel. Insert the rod and attached parts into the barrel with a slight twisting Lubricate the rod with clean hydraulic oil. motion.
Page 103: Outrigger Extension Cylinder
RT540E SERVICE MANUAL HYDRAULIC SYSTEM OUTRIGGER EXTENSION CYLINDER Remove the piston and spacer from the rod. Remove the O-ring and the backup ring from the outside Description of the head. The four extension cylinders (Figure 2-1) have 6.4 cm (2.5- Remove the rod seal, wear ring and wiper ring from the inch) diameter bores.
Page 104 HYDRAULIC SYSTEM RT540E SERVICE MANUAL 6815 Item Description Item Description Barrel Wear Ring O-ring Piston O-ring Head Backup Ring Spacer Seal Wiper Piston Seal Wear Ring 2-72 Published 4-20-2015, Control # 502-01...
Page 105: Outrigger Jack Cylinder
RT540E SERVICE MANUAL HYDRAULIC SYSTEM Install the replacement piston seal and wear rings on the damaging the chrome. Using a spanner wrench, outside of the piston. unscrew the head from the barrel. Lubricate all parts freely with clean hydraulic oil. DANGER CAUTION Do not use air pressure to remove the rod.
Page 106 HYDRAULIC SYSTEM RT540E SERVICE MANUAL rings. Pay attention to how each seal and ring is present over the entire surface of the rod. If lack of installed to avoid installing replacement seals and chrome on rod, the rod should be replaced. rings improperly.
Page 107 RT540E SERVICE MANUAL HYDRAULIC SYSTEM NOTE: Lubricate seals and rings with clean hydraulic oil. Item Description Install the replacement wiper ring, rod seal, buffer seal and wear rings in the inside of the head. Barrel Install the replacement O-ring and backup ring on the outside of the head.
Page 108 HYDRAULIC SYSTEM RT540E SERVICE MANUAL THIS PAGE BLANK 2-76 Published 4-20-2015, Control # 502-01...
Page 109: Description
RT540E SERVICE MANUAL ELECTRIC SYSTEM SECTION 3 ELECTRIC SYSTEM SECTION CONTENTS Description ....... 3-1 Troubleshooting Accessories.
Page 110: Fuse Panel
ELECTRIC SYSTEM RT540E SERVICE MANUAL The following fuse assignments apply: Table 3-1: Superstructure Cab Power Panel Fuse Protects Amps Location Dome Light (Figure 3-3) ACC Power Outlet/ (Figure 3-3) Heater Motor Work Lights (Figure 3-3) Steering Column Power (Figure 3-3) Key Switch Power (Figure 3-3) Turntable Module...
Page 111: Relays
RT540E SERVICE MANUAL ELECTRIC SYSTEM Table 3-2 Superstructure Cab Fuse Box Table 3-4 Carrier Fuses and Relays Fuse Protects Amps Location Fuse Protects Amps Location Keyswitch Ignition Relay (Figure 3-3) Alternator (Figure 3-4) Open (Figure 3-3) Swivel (Figure 3-4) Ignition On Signal (Figure 3-3) Swivel (Figure 3-4)
Page 112: Maintenance
Electrical system maintenance includes troubleshooting and Proceed to make appropriate wiring fault repair. Wiring replacement of damaged components. Observe standard repairs must be made using Manitowoc approved wiring practices when replacing components. materials. Splicing sections of broken wire must have terminations that meet minimum pull test requirements listed in table 3-5.
Page 113: Troubleshooting Engine Starting Problems
These tables list common tools; however, relay). Make repairs as needed. contact Manitowoc CraneCare to ensure the proper crimp b. If the engine still won’t start, and you hear no noise tool is available.
Page 114: Troubleshooting Accessories
ELECTRIC SYSTEM RT540E SERVICE MANUAL NOTE: If the alternator overcharges (voltmeter reads high, If the problem remains, check the ignition switch and the light bulbs burn out quickly), look for a ground accessory control circuit from the ignition switch through where one shouldn’t exist.
Page 115: Alternator Replacement
RT540E SERVICE MANUAL ELECTRIC SYSTEM Alternator Replacement Connect the electrical leads to the terminals as tagged during removal. Removal Close the engine compartment. Ensure that the key switch has been in the OFF position Reconnect the ground cables to the battery. for 2 minutes.
Page 116: Battery Replacement
ELECTRIC SYSTEM RT540E SERVICE MANUAL Battery Replacement Installation Place the batteries in the battery box. Removal Install the hold down brackets so they can hold down the batteries. Secure the brackets (and batteries) to the bracket hold down rods with nuts and washers. CAUTION Connect leads to the battery terminals starting with the To avoid possible engine fault codes and undesirable...
Page 117: Ignition Switch Replacement
RT540E SERVICE MANUAL ELECTRIC SYSTEM Pull the rubber boot (11) off the bottom of the left and Connect the wire harness to the bottom of the switch (4). right side covers (8, 9). Install the right side cover (9) on the steering column. Remove the lever (12) and spacer that locks/unlocks the Connect the wire harness to the ignition switch (10).
Page 118: Turn Signal Lever And Transmission Shift Lever Replacement
ELECTRIC SYSTEM RT540E SERVICE MANUAL Inspection Removal Visually check the ignition switch for evidence of cracks, Ensure that the key switch has been in the OFF position damaged connections, or other damage. Replace for 2 minutes. damaged ignition switch as needed. Turn the battery disconnect switch to the OFF position.
Page 119 RT540E SERVICE MANUAL ELECTRIC SYSTEM Connect the wire harness to the bottom of the gauge 13. Install the steering wheel cap (1). cluster (5). 14. Install the lever (12) and spacer that locks/unlocks the Install the wire harnesses on the switches (4) as tagged steering column tilt/telescope function.
Page 120: Windshield Wiper Assembly Replacement
ELECTRIC SYSTEM RT540E SERVICE MANUAL Windshield Wiper Assembly Replacement Installation Removal Ensure that the key switch has been in the OFF position Windshield Wiper Arm Serrated Collar for 2 minutes. Turn the battery disconnect switch to the OFF position. Tag and disconnect the electrical leads from the motor. Washer Mounting Plate Disconnect the washer hose on the wiper arm (also...
Page 121: Windshield Washer Assembly Replacement
RT540E SERVICE MANUAL ELECTRIC SYSTEM Connect the electrical leads to the wiper motor as Turn the battery disconnect switch to the ON position. marked before removal. Fill the container with cleaning fluid. Turn the battery disconnect switch to the ON position. Check Check Squirt some cleaning fluid onto the windshield with the...
Page 122 ELECTRIC SYSTEM RT540E SERVICE MANUAL Install nylon flat washer, leather washer, spacer, and nut Check on motor shaft. Tighten nut. Operate the skylight wiper. Verify it works. (Replace Install wiper arm and blade on motor shaft. wiper blade as needed if it streaks or otherwise wipes poorly.) Connect the electrical leads to the wiper motor as marked before removal.
Page 123 RT540E SERVICE MANUAL ELECTRIC SYSTEM Table 3-6 Amp Extraction Tool Table Description Amp Part Number Grove Part Number 14 gauge wire (connectors) 305183 9-999-100176 12 to 8 gauge wire (connectors) 91019-3 9-999-100175 4 to 9 circuit (in-line connectors) 453300-1 15 circuit (in-line connectors) 458944-1 Table 3-7 Amp Crimping Tool Table...
Page 124: Appendix A: Crane Control System (Ccs) Fault Codes
ELECTRIC SYSTEM RT540E SERVICE MANUAL Appendix A: Crane Control System (CCS) Fault Codes There are four codes for every fault in the Crane Control Index Code reveals the type of fault. For example, a code System (CCS) diagnostic. The Component Code number reading “7111.
Page 125 RT540E SERVICE MANUAL ELECTRIC SYSTEM Fault Code Component Description 5033 Rear steer right switch input 5034 Park brake release switch input 5035 2 wheel drive switch input 5036 Differential lock switch input 5037 Brake pedal switch input 5038 Retarder / Thelma brake switch 5040 Outrigger extend switch input 5041...
Page 126 ELECTRIC SYSTEM RT540E SERVICE MANUAL Fault Code Component Description 5152 Seat Switch deadman input 5153 Armrest deadman switch input 5154 Both Deadman switches input 5160 Carrier Emergency Off Switch 5161 Carrier Emergency Off Relay input 5162 Carrier Emergency Operation input 5163 AMOT active input 5170...
Page 127 RT540E SERVICE MANUAL ELECTRIC SYSTEM Fault Code Component Description 5526 Long Diff Lock switch input Axle 6 5527 Long Diff Lock switch input Axle 7 5528 Long Diff Lock switch input Axle 8 5529 Long Diff Lock switch input Axle 9 5530 Drag link unlocked 5531...
Page 128 ELECTRIC SYSTEM RT540E SERVICE MANUAL Fault Code Component Description 5814 Angle sensor axle 4 5815 Angle sensor axle 5 5816 Angle sensor axle 6 5817 Angle sensor axle 7 5818 Angle sensor axle 8 5819 Angle sensor axle 9 5820 Fuel Level analog input 5821 Sensor Supply Voltage analog input...
Page 129 RT540E SERVICE MANUAL ELECTRIC SYSTEM Fault Code Component Description 5912 Derricking Down pressure switch 5913 Derricking Up pressure switch 5914 Telescoping Extend pressure switch 5915 Telescoping Retract pressure switch 5916 Hydraulic Oil Temp switch 5917 Brake Pressure switch 5918 AC Clutch Required switch 5919 Swing Right pressure switch 5920...
Page 130 ELECTRIC SYSTEM RT540E SERVICE MANUAL Fault Code Component Description 5950 Auxiliary Hoist Indenitifier input 5951 New York House Lock Pin Bolted input 5952 New York House Lock Locked input 5953 New York House Lock Unlocked input 5954 Counterweight Left Unlock input 5955 Counterweight Right Unlock input 5956...
Page 131 RT540E SERVICE MANUAL ELECTRIC SYSTEM Fault Code Component Description 6002 Gearshift power supply output 6003 SCM0 ignition to CCM10 output 6004 SCM0 ignition to CCM11 output 6005 Oil Cooler Off relay output 6006 SCM0 ignition to IOS modules output 6007 SCM0 ignition to displays output 6008 Accessory output...
Page 132 ELECTRIC SYSTEM RT540E SERVICE MANUAL Fault Code Component Description 6065 Windshield Wash front Wiper high speed 6066 Windshield Wash front Wiper park 6100 Headlight Low Beam Left output 6101 Headlight Low Beam Right output 6102 Brake Lights output 6103 Engine Start output 6104 AC Clutch output 6105...
Page 133 RT540E SERVICE MANUAL ELECTRIC SYSTEM Fault Code Component Description 6137 Outrigger Light Front Left Output 6138 Outrigger Light Front Right Output 6139 Outrigger Light Rear Left Output 6140 Outrigger Light Rear Right Output 6200 Four Wheel Drive output 6201 Rear Axle Oscillation output 6202 Rear Steer Right output 6203...
Page 134 ELECTRIC SYSTEM RT540E SERVICE MANUAL Fault Code Component Description 6252 Steer Left solenoid Axle 2 6253 Steer Left solenoid Axle 3 6254 Steer Left solenoid Axle 4 6255 Steer Left solenoid Axle 5 6256 Steer Left solenoid Axle 6 6257 Steer Left solenoid Axle 7 6258 Steer Left solenoid Axle 8...
Page 135 RT540E SERVICE MANUAL ELECTRIC SYSTEM Fault Code Component Description 6291 Axle Lifting Front Right solenoid 6292 Axle Lifting Rear Left solenoid 6293 Axle Lifting Rear Right solenoid 6294 Pressure Axle Lifting Front Left solenoid 6295 Pressure Axle Lifting Front Right solenoid 6296 Pressure Axle Lifting Rear Left solenoid 6297...
Page 136 ELECTRIC SYSTEM RT540E SERVICE MANUAL Fault Code Component Description 6429 Counterweight Raise solenoid 6430 Counterweight Unlock solenoid 6431 Counterweight Lock solenoid 6432 Aux hoist carrier raise 6433 Aux hoist carrier lower 6434 Aux hoist lock 6435 Aux hoist unlock 6436 Main hoist Fast Moving 6437 Aux hoist Fast Moving...
Page 137 RT540E SERVICE MANUAL ELECTRIC SYSTEM Fault Code Component Description 7025 CCM10 7026 CCM11 7027 CCM12 7028 CCM13 7032 IOL30 7033 IOL31 7034 IOL32 7035 IOL33 7036 IOL34 7037 IOL35 7038 IOL36 7039 IOL37 7040 IOL38 7041 IOL39 7042 IOL40 7043 IOL41 7044 IOL42...
Page 138 ELECTRIC SYSTEM RT540E SERVICE MANUAL Fault Code Component Description 7090 Simulated Joystick 7091 Left joystick 7092 Right joystick 7093 Left joystick 7100 Remote Control -or- Slew Angle Sensor (default node ID) 7101 MMI Left 7102 MI Right 7106 External Light Tower 7108 Service Software 7109...
Page 139 RT540E SERVICE MANUAL ELECTRIC SYSTEM Fault Code Component Description 8400 Eeprom 8401 CPU watchdog 8402 Data Flash 8600 RCL Boom Length 8601 RCL Slewing Range 8602 RCL Outrigger 8603 RCL Jib 8700 Telescoping Length Sensor Comparison 8701 Pinning Proxy Switches Left 8702 Pinning Proxy Switches Right 8900...
Page 140 ELECTRIC SYSTEM RT540E SERVICE MANUAL Fault Code Component Description 10132 Proximity Sensor Output (V+) Drum 2 10133 Proximity Sensor Output (V+) Drum 3 10134 Proximity Sensor Output (V+) Drum 4 10135 Proximity Sensor Output (V+) Drum 5 10136 Proximity Sensor Output (V+) Drum 6 10137 Proximity Sensor Output (V+) Drum 7 10138...
Page 141 RT540E SERVICE MANUAL ELECTRIC SYSTEM Condition Codes Fault Code Condition Description No Error Over Current Cable Break Short to Battery Short to Ground Resistor Low Resistor High Below minimum level Above maximum level Undefined Area Initialization failed System Function Error Logic Fuse PWM Signal...
Page 142 ELECTRIC SYSTEM RT540E SERVICE MANUAL Fault Code Condition Description The internal supply voltage UC2 is too low Analog Input error Digital Input error Digital Output error PWM Output error Task Time too long Data is not valid Device is not operational Could not get semaphore Data does not match required data The counter from a connected CAN device is no longer...
Page 143 RT540E SERVICE MANUAL ELECTRIC SYSTEM Fault Code Condition Description The last reset was because the watchdog detected a configuration error Unexpected NULL pointer Command not zero. The joystick or tele pedal command must be zero to enable a function. Pressure negative and positive Pressure negative at positive Pressure positive at negative Pressure positive at stop...
Page 144 ELECTRIC SYSTEM RT540E SERVICE MANUAL Device Codes Fault Code Device Description SCM0 SCM1 SCM2 SCM3 CCM10 CCM11 CCM12 CCM13 IOS20 IOS21 IOS22 IOS23 IOS24 IOS25 IOS26 IOS27 IOL30 IOL31 IOL32 IOL33 IOL34 IOL35 IOL36 IOL37 IOL38 IOL39 IOL40 IOL41 IOL42 IOL43 IOL44 IOL45...
Page 145 RT540E SERVICE MANUAL ELECTRIC SYSTEM Index Codes Fault Code Index Description 0-29 Digital Inputs 48-95 Digital Outputs 96-110 Analog Inputs Internal measurement CAN bus 1 CAN bus 2 CAN bus 3 CAN bus 4 Eeprom Read - backup area Eeprom Read - customer area Eeprom Write - backup area Eeprom Write - customer area Not Applicable...
Page 146 ELECTRIC SYSTEM RT540E SERVICE MANUAL THIS PAGE BLANK 3-38 Published 4-20-2015, Control # 502-01...
Page 147: Section 4
RT540E SERVICE MANUAL BOOM SECTION 4 BOOM SECTION CONTENTS Description ....... 4-1 Boom Nose Sheaves .
Page 148: Boom System Components
BOOM RT540E SERVICE MANUAL outer mid section (6) and is routed around two sheaves (11) on the top front of the inner mid (4), and secured to the rear of the base section (13). DANGER Fly Retraction Cables To prevent serious injury or death, always wear personal protective equipment;...
Page 149 RT540E SERVICE MANUAL BOOM 6838-1 6838-2 FIGURE 4-1 GROVE Published 4-20-2015, Control # 502-01...
Page 150: Boom Retract Sequence
BOOM RT540E SERVICE MANUAL BOOM RETRACT SEQUENCE During retraction, oil enters the retract port and flows to the rod sides of the cylinder. When pilot pressure reaches a pre- Refer to Figure 4-1 for item location. As the telescope determined value, the main poppet unseats, and oil flows cylinder is retracted, the outer mid section (6) (attached to from the piston sides of the cylinder to the reservoir causing the cylinder barrel) and the inner mid section (4) (attached to...
Page 151: General Maintenance Notes
RT540E SERVICE MANUAL BOOM GENERAL MAINTENANCE NOTES • Apply medium strength thread locking adhesive/sealant and primer to all hardware except items Mid Syncro DANGER Cable threads, Fly Retract Cable threads, and Outer Mid Before attempting to remove the boom extension; read Retract Cable threads.
Page 152: Boom Removal
BOOM RT540E SERVICE MANUAL Place the now free swingaway extension in a safe secure location. BOOM REMOVAL Do not attempt to work on the boom without experienced supervision. DANGER To prevent serious injury or death, always wear personal protective equipment; i.e., a hard hat, eye protection, gloves and metatarsal boots.
Page 153: Disconnect The Base Section
RT540E SERVICE MANUAL BOOM Attach a lifting device to the boom to provide for equal 15. Remove the grease fittings from the pivot shaft to weight distribution. prevent damage. Remove the boom pivot shaft. Disconnect any electrical wiring from the boom. Tag and disconnect the hydraulic lines to the telescope cylinder.
Page 154: Remove The Base Section
BOOM RT540E SERVICE MANUAL FIGURE 4-9 Remove the bolts and washers securing the telescope cylinder outer rod (Figure 4-10, 1) to the rear of the base section. CAUTION 6837 FIGURE 4-7 Use extreme caution during piston and rod tube assembly removal.
Page 155 RT540E SERVICE MANUAL BOOM DANGER The combined weight of the boom inner mid, outer mid, and fly sections, including the telescope cylinder, is approximately 3680 kg (8110 lb). Ensure that adequate and properly tested lifting devices are used to remove these sections DANGER To prevent serious injury or death, always wear personal...
Page 156: Disconnect The Inner Mid Section
BOOM RT540E SERVICE MANUAL and thrust washers.If necessary, remove the grease fitting from the shaft weldments. 6818-15 6748-25 FIGURE 4-15 FIGURE 4-14 Remove the two bolts and bushings securing the cylinder inner rod (Figure 4-16, 1) to the rear of the inner Attach a suitable lifting device to the Fly/Outer/Inner Mid mid (Figure 4-16, 2).
Page 157 RT540E SERVICE MANUAL BOOM DANGER The combined weight of the boom outer mid, and fly s e c t i o n s , i n c l u d i n g t h e t e l e s c o p e c y l i n d e r, i s approximately 2550 kg (5610 lb).
Page 158 BOOM RT540E SERVICE MANUAL the extend cable in the proper sequence for re- assembly. 6748-29 FIGURE 4-22 6748-25 11. Continue to pull the assembly from the inner mid section FIGURE 4-20 until access to the rear of the outer mid is gained to disconnect the four retract cables (Figure 4-23, 1).
Page 159: Remove The Outer Mid Section
RT540E SERVICE MANUAL BOOM Remove the Outer Mid Section Do not attempt to work on the boom without experienced supervision. DANGER To prevent serious injury or death, always wear personal protective equipment; i.e., a hard hat, eye protection, gloves and metatarsal boots. DANGER The combined weight of the boom fly section including the FIGURE 4-25...
Page 160: Remove The Tele Cylinder
BOOM RT540E SERVICE MANUAL 10. Lift up on the front of the fly assembly and remove the wear pads (4) from the pockets in the bottom of the outer mid. 11. Continue to pull the assembly from the outer mid section until access to the rear of the fly is gained to disconnect the two retract cables.
Page 161: Boom Nose Sheaves
RT540E SERVICE MANUAL BOOM NOTE: Pull the extend cable along with the telescope Remove bottom and lower rear side wear pads and cylinder (Figure 4-31). Failure to do so will cause shims if they are to be replaced. Note location of shims binding and jamming of the cables in the fly for installation.
Page 162: Boom Nose Sheaves Removal
BOOM RT540E SERVICE MANUAL Boom Nose Sheaves Removal nose sheaves weigh approximately 17.4 kg (38 lb) each. Remove the clip pins from the cable retainer pins Carefully pull the upper boom nose sheave shaft (Figure 4-35, 7) and remove the cable retainer pins (Figure 4-35, 6) from the boom nose, removing the (Figure 4-35, 3) from the upper and lower part of the spacers, and boom nose sheaves (Figure 4-35, 4).
Page 163: Boom Assembly Procedure
RT540E SERVICE MANUAL BOOM BOOM ASSEMBLY PROCEDURE Do not attempt to work on the boom without experienced supervision. DANGER To prevent serious injury or death, always wear personal protective equipment; i.e., a hard hat, eye protection, gloves and metatarsal boots. Extend Cable Sheave Installation CAUTION The extend cable sheave weighs approximately 17.3 kg...
Page 164 BOOM RT540E SERVICE MANUAL Measure and mark the center line of the Fly Section. Attach a suitable lifting device to the Tele Cylinder. Raise This mark will be used to set the adjustable wear pads the Tele Cylinder. after the section is installed in the Outer Mid Section. Position the sheave end of the Tele Cylinder at the rear Install the lower rear side wear pads (Figure 4-37, 1) and of the fly section, with port block turned as shown...
Page 165 RT540E SERVICE MANUAL BOOM with extend cable keeper plate (Figure 4-42, 2) and two bolts. FIGURE 4-42 14. Turn cylinder rod mounting lug ends (Figure 4-43) so they are aligned vertically to clear mounting brackets in the outer mid section. FIGURE 4-41 CAUTION When adjusting cables, hold the cable end and turn the...
Page 166: Install The Outer Mid Section
BOOM RT540E SERVICE MANUAL adjustment weldment). The tools should extend past the wear pad adjustments (Figure 4-45). Align On This Edge FIGURE 4-44 18. Temporary tie extend cables to the Tele Cylinder to maintain proper cable alignment during assembly (Figure 4-43). FIGURE 4-45 Install the Outer Mid Section Measure and note the total width of the boom...
Page 167 RT540E SERVICE MANUAL BOOM CAUTION Do not allow the cables to become entangled or overlap. cable or boom failure could result. Attach the fly retract cables to the cable anchors (Figure 4-49, 1) on the base end of the fly section on both sides.
Page 168 BOOM RT540E SERVICE MANUAL 13. Align cylinder mounting holes with mounting bracket holes in rear of Outer Mid section and secure with two bolts and bushings on each side. (Figure 4-52) NOTE: It is important that the cylinder mount bolts be properly torqued.
Page 169 RT540E SERVICE MANUAL BOOM FIGURE 4-54 19. Rotate cylinder mounting to facilitate mounting in to the Inner Mid section. (Figure 4-55) FIGURE 4-57 21. Install adjusting (Figure 4-58) bolt to the anchor assembly. 6748-31 FIGURE 4-55 Permanent Anchor Bolt 20. Install Extend Cables in to the round keeper plate (Figure 4-56 and Figure 4-57).
Page 170: Install The Inner Mid Section
BOOM RT540E SERVICE MANUAL FIGURE 4-59 Install the Inner Mid Section Do not attempt to work on the boom without experienced supervision. 6748-26 FIGURE 4-61 DANGER To prevent serious injury or death, always wear personal Assemble the mid syncro cable sheave assembly protective equipment;...
Page 171 RT540E SERVICE MANUAL BOOM Assemble the Fly retract sheave assembly as shown in Figure 4-63 and Figure 4-64. Note that the pin has one thrust washer to the inside of the boom and two thrust washers to the outside of the boom. Lubricate both sheave assemblies FIGURE 4-65 NOTE:...
Page 172 BOOM RT540E SERVICE MANUAL FIGURE 4-68 FIGURE 4-70 14. Install the brass wear pad (Figure 4-69, 1) at the nose 18. Align the Outer Mid section with the Inner Mid section. end of the Inner Mid section. Slide sections together (Figure 4-71) until side wear pads on the Outer Mid section engage with the Inner Mid section.
Page 173 RT540E SERVICE MANUAL BOOM 20. Attach fly retract cable anchors to the nose of the inner mid section (Figure 4-72, 1). FIGURE 4-72 21. Continue inserting the Outer Mid section in the Inner Mid section. Stop when the upper rear adjustable wear pads on the Inner Mid section are accessible.
Page 174 BOOM RT540E SERVICE MANUAL 27. Carefully clamp the anchor assembly to the Inner Mid 30. Assemble the mid retract sheave assembly as shown in anchor weldment (Figure 4-76). Figure 4-78 and Figure 4-79. Note that the pin has one thrust washer to the inside of the boom and two thrust Remove the installation bolt and replace with the washers to the outside of the boom.
Page 175: Install The Base Section
RT540E SERVICE MANUAL BOOM 34. Attach two cables to each anchor adjust each cable to Insert Inner Mid section into the Base section until the 1.75 inches and install locknuts (Figure 4-80). Inner Mid section is past the side wear pad access and stop.
Page 176 BOOM RT540E SERVICE MANUAL FIGURE 4-84 FIGURE 4-86 Connect Mid Syncro Cables to rear of Base section. CAUTION 10. Adjust cable until there is 76mm (3 inch) of threads Ensure the Tele Cylinder Port Block is correctly positioned showing past adjustment nut (Figure 4-87). before proceeding.
Page 177: Final Boom Assembly
RT540E SERVICE MANUAL BOOM 12. Disconnect RCL, A2B/Cable that was attached to the FINAL BOOM ASSEMBLY Base section cable guide (Figure 4-89, 1) in the removal Do not attempt to work on the boom without experienced of the boom and feed cable through the Inner and Outer supervision.
Page 178: Swingaway Extension Installation
BOOM RT540E SERVICE MANUAL Connect all electrical wiring to the boom. Elevate the boom slightly with the lifting device so that the lift cylinder can be extended approximately 30.48 cm DANGER (12 in) to allow for insertion of the lift cylinder rod end to Boom angles are used to control speed at which the lift cylinder lift box on the bottom of the boom.
Page 179 RT540E SERVICE MANUAL BOOM 6821-1 FIGURE 4-95 6814-4 DANGER FIGURE 4-93 When stowing the boom extension, ensure that all personnel and equipment are kept clear of the swing path. 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 (Figure 4-94, 1) and ramp (Figure 4-95, 2) on the stowage brackets when the...
Page 180: Tensioning The Boom Extend And Retract Cables
BOOM RT540E SERVICE MANUAL 20. Perform all adjustments and maintenance for the boom. TENSIONING THE BOOM EXTEND AND RETRACT CABLES The boom extend and retract cables must be tensioned after the boom has been rebuilt and any time the cables appear to be loose.
Page 181 RT540E SERVICE MANUAL BOOM Position the boom to horizontal before making retract simultaneously and that they do not drift out when adjustments. the hydraulic valve is in neutral. Slightly tighten all cables. If the 2 stage is fully retracting late, loosen the 3/2/1 retract cables and tighten the 1/2/3 extend Fully retract the boom.
Page 182: Boom Maintenance
BOOM RT540E SERVICE MANUAL BOOM MAINTENANCE Boom alignment is achieved by adjustment of the wear pads located at various points in the boom assembly. Adjustment Functional Test Of The Boom of the wear pads is as follows: Fully extend the boom horizontally. Activate the hydraulic system and check for proper operation and any leaks.
Page 183: Extension And Retraction Cable Maintenance
RT540E SERVICE MANUAL BOOM NOTE: DEFLECTION EXAGGERATED FOR ILLUSTRATION PURPOSES Boom Alignment FIGURE 4-99 EXTENSION AND RETRACTION CABLE The following information is tak en from a National Consensus standard as referenced by Federal Government MAINTENANCE Agencies. Do not attempt to work on the boom without experienced All wire rope will eventually deteriorate to a point where it is supervision.
Page 184: Telescope Circuit Troubleshooting
BOOM RT540E SERVICE MANUAL TELESCOPE CIRCUIT TROUBLESHOOTING Table 4-3 SYMPTOM PROBABLE CAUSE SOLUTION Erratic operation of Low hydraulic oil level. Replenish hydraulic oil to proper level. e x t e n d i n g b. Damaged relief valves. b. Repair or replace relief valves. t e l e s c o p i n g Air in telescope cylinder.
Page 185 Repair or replace relief valve. Excessive load. Reduce load. d. Clogged hose and fittings. d. Replace hose or fittings. (Refer to Manitowoc Crane Care Parts Manual). Broken valve spool. Replace valve. Damaged piston seals. Replace all cylinder seals. g. Damaged piston(s).
Page 186: Lift Circuit Troubleshooting
Operate unit to bring oil to operating temperature. Improper hose or fittings, installed. Replace hose or fittings. (Refer to Manitowoc Crane Care Parts Manual). Operating two functions with in the Feather controls to obtain desired same control valve bank assembly.
Page 187 RT540E SERVICE MANUAL BOOM Symptom Probable Cause Solution B o o m l o w e r s Worn hydraulic pump section. Repair or replace pump section. slowly. (Continued) Piston rod broken (loose from piston). Replace piston rod and all cylinder seals.
Page 188: Lift Cylinder Maintenance
BOOM RT540E SERVICE MANUAL LIFT CYLINDER MAINTENANCE Pull the lower lift cylinder pivot shaft out far enough to remove the cylinder. Lift Cylinder Removal 10. Move the lift cylinder to a clean work area. NOTE: Refer to HYDRAULIC SYSTEM (pg 2-1) for lift Lift Cylinder Disassembly And Assembly cylinder disassembly and assembly procedures.
Page 189 RT540E SERVICE MANUAL BOOM RETAINING BOLT UPPER PIVOT SHAFT LOWER PIVOT SHAFT DETAIL B DETAIL A FIGURE 4-100 4-43 GROVE Published 4-20-2015, Control # 502-01...
Page 190 BOOM RT540E SERVICE MANUAL THIS PAGE BLANK 4-44 Published 4-20-2015, Control # 502-01...
Page 191: Description
RT540E SERVICE MANUAL HOIST AND COUNTERWEIGHT SECTION 5 HOIST AND COUNTERWEIGHT SECTION CONTENTS Description ....... 5-1 BRAKE TEST PROCEDURE FOR HP15C-17G, HO30A-19G, HP35-26G HOISTS .
Page 192: Maintenance
HOIST AND COUNTERWEIGHT RT540E SERVICE MANUAL MAINTENANCE Removal If the CE option is provided, remove the hoist covers. Warm-up Procedure Remove all cable from the hoist drum. A warm-up procedure is recommended at each start-up and is essential at ambient temperatures below 4°C (+40°F). Tag and disconnect the hydraulic lines to the hoist.
Page 193: Installation
RT540E SERVICE MANUAL HOIST AND COUNTERWEIGHT relation to the level positioned between the boom pivot shaft bushings. Item Description With the hoist level, check to determine if all the hoist Auxiliary Hoist mounting pads are in contact with the mounting plate by Main Hoist rocking the hoist.
Page 194: Hoist Maintenance And Inspection
HOIST AND COUNTERWEIGHT RT540E SERVICE MANUAL HOIST MAINTENANCE AND INSPECTION categories based upon their usage or duty cycle, which in turn determines appropriate intervals for inspections. The t is extremely important that maintenance staff involved with usage categories must be assigned by the crane user on a the crane inspections be made aware of the possibility that consistent crane-by-crane basis.
Page 195: Pre-Use Or Daily Inspection
RT540E SERVICE MANUAL HOIST AND COUNTERWEIGHT Pre-Use or Daily Inspection Perform the pre-use/daily, quarterly and semi-annual inspections. Must include but is not limited to the following inspections Change the lubricating oil in the hoist gear cavity after an that will be performed prior to placing the crane into service oil sample has been taken as described on this page.
Page 196: Brake Test Procedure (To Be Performed With No Load On The Hoist)
HOIST AND COUNTERWEIGHT RT540E SERVICE MANUAL more dangerous failure. Early detection of accelerated from the midstream flow of the oil to obtain an accurate component wear allows the scheduling of corrective representation of the oil condition. After taking the oil sample maintenance.
Page 197: Hoist To Boom Alignment
RT540E SERVICE MANUAL HOIST AND COUNTERWEIGHT HOIST TO BOOM ALIGNMENT center point of adjustment to check the fleet angle of the cable. Preparation All the cable must be removed from the hoist drum to check the fleet angle. Using mason cord or cat gut Boom alignment must be completed before attempting hoist fishing line you will be able to pull the line tight to make alignment.
Page 198: Piston Motor And Control Valve
HOIST AND COUNTERWEIGHT RT540E SERVICE MANUAL MAIN HOIST IS ALIGNED TO THE RIGHT HAND SHEAVE LOCATING CENTERLINE WITH SQUARE AUXILIARY HOIST IS ALIGNED TO THE CENTER SHEAVE 6019 FIGURE 5-2 PISTON MOTOR AND CONTROL VALVE Place the motor and motor control valve in a clean, dry suitable work area.
Page 199: Idler Drum And Cable Follower
RT540E SERVICE MANUAL HOIST AND COUNTERWEIGHT IDLER DRUM AND CABLE FOLLOWER Disassemble the cable follower roller as follows. Remove the two bolts and washers securing the Description angle to the right side of the shaft. The main and auxiliary hoists are equipped with an idler b.
Page 200 HOIST AND COUNTERWEIGHT RT540E SERVICE MANUAL Item Description Pivot Bracket Drum Follower Roller 6957-1 Spring Spring Adjusting Rod Lever Idler Roller Bracket Hydraulic Motor 6957-2 FIGURE 5-3 5-10 Published 4-20-2015, Control # 502-01...
Page 201: Hoist Drum Rotation Indicator System
RT540E SERVICE MANUAL HOIST AND COUNTERWEIGHT With one layer of cable on the hoist drum, adjust the illuminate a hoist up or hoist down indicator light to show the direction of hoist motion. bolts on the front of each side plate (that push against each arm) so the roller applies pressure on The rotation indicator system consists of the rotation the layer of cable, and does not interfere with filler/...
Page 202 HOIST AND COUNTERWEIGHT RT540E SERVICE MANUAL 8479 Hoist 8478-1 Controller FIGURE 5-4 Item Description Thumb Thumper Controller Rotation Sensor Connection Two Speed Solenoid Connection 5-12 Published 4-20-2015, Control # 502-01...
Page 203: Counterweight Removal
RT540E SERVICE MANUAL HOIST AND COUNTERWEIGHT COUNTERWEIGHT REMOVAL Lower counterweight until attaching lugs are clear of the turntable. Fixed Counterweight Description 10. Back counterweight away from turntable until it is clear of crane. The counterweight is pinned to the rear of the turntable and weighs 4300 kg (9480 lb).
Page 204 HOIST AND COUNTERWEIGHT RT540E SERVICE MANUAL 2, 11 2, 11 7, 8, 9, 10 6826 FIGURE 5-5 Item Description Counterweight Pin Assembly Capscrew Hex Nut Jam Nut Grill Retaining Nut Flat Washer Lock Washer Capscrew Lock Pin 5-14 Published 4-20-2015, Control # 502-01...
Page 205: Introduction
RT540E SERVICE MANUAL SWING SYSTEM SECTION 6 SWING SYSTEM SECTION CONTENTS Introduction....... 6-1 Description.
Page 206: Description
SWING SYSTEM RT540E SERVICE MANUAL 6713 FIGURE 6-1 Item Description Item Description Plug Dipstick Plug Breather Plug Plug Elbow Motor Pipe Gearbox and Brake Breather Pinion Plug Published 4-20-2015, Control # 502-01...
Page 207: Maintenance
RT540E SERVICE MANUAL SWING SYSTEM Maintenance Troubleshooting Symptom Probable Cause Solution Boom swing Damaged relief valve. Replace relief valve. operation erratic in b. Swing brake dragging (not releasing b. Readjust and/or replace necessary either direction. properly). parts. Low engine rpm. Increase engine rpm to obtain smooth swing operation.
Page 208 SWING SYSTEM RT540E SERVICE MANUAL Symptom Probable Cause Solution Boom will not swing Damaged relief valve. Remove, clean, and repair or replace in either direction. relief valve. b. Damaged swing motor. b. Repair or replace swing motor. Swing brake not releasing properly. Repair as necessary.
Page 209 RT540E SERVICE MANUAL SWING SYSTEM Symptom Probable Cause Solution Swing brake Improper brake adjustment. Adjust brake. operation erratic. b. Air in swing brake system. b. Bleed brake system. Brake pedal not fully retracted. Check brake pedal return spring; repair or replace spring. d.
Page 210: Swing Motor
SWING SYSTEM RT540E SERVICE MANUAL SWING MOTOR Remove the two screws securing the motor and lift the swing motor free of the flange. Remove and discard the Description O-ring from the groove in the swing brake. The swing motor is mounted on the swing brake housing and Installation drives the swing gearbox through the brake assembly.
Page 211: Swing Gearbox And Brake
RT540E SERVICE MANUAL SWING SYSTEM SWING GEARBOX AND BRAKE Bleed all air from the brake assembly. Gearbox Description Removal The swing gearbox and brake, used in conjunction with the swing motor, rotates and stops the superstructure. A pedal Engage the turntable lock pin. on the cab floor is used to activate the swing brake.
Page 212 SWING SYSTEM RT540E SERVICE MANUAL Servicing NOTE: Cleaning of the gearbox with a solvent is recommended to prevent an accumulation of grit As with all highly stressed mechanisms, reasonable and grime. Avoid steam cleaning where moisture operating procedures are always required. Normal and dirt might be driven into the vent of the swing maintenance should only consist of proper lubrication and a bearing.
Page 213: Swing Bearing
RT540E SERVICE MANUAL SWING SYSTEM SWING BEARING Description DANGER The swing bearing is an anti-friction roller bearing that mates It is mandatory that bearing attaching bolts be inspected the Superstructure to the Carrier. The bearing inner race is for lack of torque and retorqued, as required, after the first bolted to the Superstructure and the outer race is bolted to 300 hours of crane operation.
Page 214 SWING SYSTEM RT540E SERVICE MANUAL 6750-2 FIGURE 6-2 The inner race of the bearing is secured to the turntable by 23, 14, and 32. Tools used are the socket, multiplier, 36, 1 inch, grade 8 bolts. The outer race of the bearing is backlash adapter, necessary extensions, and torque secured to the carrier frame by 36, 7/8 inch, grade 8 bolts.
Page 215 Orders for special tools 1. 1 1/2” Socket 3/4” Drive 9-999-100143 shall be referred to: 2. 4 to 1 Torque Multiplier (1/2” Input 3/4” Output) 9-999-100134 Manitowoc/Grove Crane Care 3. Backlash Adapter 9-999-100141 1565 Buchanan Trail East 4. 1/2” Drive Torque Wrench 9-999-100136 Shady Grove, PA 17256-0021 5.
Page 216 SWING SYSTEM RT540E SERVICE MANUAL Remove the retainer plates from the spool and the lugs NOTE: The bearing weighs approximately 260 kg (573 lb). on the carrier frame. Ensure the bearing lifting device is capable of supporting the weight. NOTE: The swivel assembly will be removed with the turntable.
Page 217 RT540E SERVICE MANUAL SWING SYSTEM Apply Loctite 271 to the capscrews. Position the two retainer plates on the bottom of hydraulic swivel spool, Maximum Eccentricity Point Pinion engaging the lugs on the carrier frame, and secure them to the spool with four capscrew retainers and bolts. Torque the bolts 298 to 322 Nm (220 to 237 lb-ft).
Page 218: Swivels
SWING SYSTEM RT540E SERVICE MANUAL SWIVELS the spool to remain stationary with the carrier as the case rotates with the superstructure. Description The spool portion of the water swivel is integral with the hydraulic swivel. The hydraulic and water swivel spools The swivel assembly (Figure 6-5) consists of a 10 port remain stationary with the carrier as the superstructure hydraulic swivel, a 2 port water swivel, a 2 port refrigerant...
Page 219 RT540E SERVICE MANUAL SWING SYSTEM Item Description 12, 13, 14, 15 2, 3 Slip Ring Assembly Capscrew Washer 16, 17 Hydraulic Swivel Retaining Plate Capscrew Hex Nut Adapter Hose Nipple Adapter Plate Capscrew Jam Nut Flatwasher 6, 7 Capscrew Hose Nipple 8, 9, 10 Adapter Turntable Base Plate...
Page 220: Hydraulic Swivel
SWING SYSTEM RT540E SERVICE MANUAL Hydraulic Swivel Description Each of the ports on the spool and case of the swivel is stamped with the port number. The function of each port is described below. Max Test Pressure Port # Function bar (psi) 25000 (250) (3625) Brake - Front...
Page 221 RT540E SERVICE MANUAL SWING SYSTEM Disconnect the swivel wiring harness connectors from Apply Loctite 271 to the capscrews. Position the two the carrier receptacles and the yellow ground wire from retainer plates on the bottom of hydraulic swivel spool, engaging the lugs on the carrier frame, and secure them the connector mounting bracket on the carrier frame.
Page 222: Electrical Swivel
SWING SYSTEM RT540E SERVICE MANUAL Electrical Swivel Secure the connectors and wires from each of the numbered connectors so the harness can be withdrawn through the center of the hydraulic swivel. Description Tag and disconnect the connectors from the receptacles The swivel assembly consists of a 20 conductor slip ring and on the cab bulkhead mounting plate.
Page 223 RT540E SERVICE MANUAL SWING SYSTEM operating hours. When this time limit is reached, perform the following. 4, 5, 6 Check the collector ring and brush assembly for any corrosion, pitting, arcing, and wear. Check the collector ring setscrews and ensure they are tight.
Page 224 SWING SYSTEM RT540E SERVICE MANUAL NOTE: If the superstructure swings past the house lock pin NOTE: If the superstructure swings past the house lock pin engaged position, step 10 must be repeated. engaged position, step 12 must be repeated. 10. If the angle indicated on the console does not exceed ± 12.
Page 225: Section 7
RT540E SERVICE MANUAL POWER TRAIN SECTION 7 POWER TRAIN SECTION CONTENTS Engine ........7-1 Description.
Page 226: Maintenance
POWER TRAIN RT540E SERVICE MANUAL Maintenance engine harness and tie up excess harness so it is out of the way. Remove the radiator. Refer to Radiator Removal and Installation (pg 7-19) l in this Section. Engine Removal 14. Tag and disconnect all lines and tubing from the engine, Set the outriggers and position the boom to over the transmission/torque converter,...
Page 227 RT540E SERVICE MANUAL POWER TRAIN 1, 2 2, 3, 4 View Of Engine FIGURE 7-1 GROVE Published 4-20-2015, Control # 502-01...
Page 228 POWER TRAIN RT540E SERVICE MANUAL 5, 6, 7 6, 9 8, 12 View Of Engine FIGURE 7-1 continued Published 4-20-2015, Control # 502-01...
Page 229: Description
RT540E SERVICE MANUAL POWER TRAIN Figure 7-1 Item Numbers At the front of the engine install the capscrews, washers and locknuts and secure the engine to the frame. Torque Item Description the M12 grade 8.8 bolts see Fasteners and Torque Capscrew Values (pg 1-11).
Page 230 POWER TRAIN RT540E SERVICE MANUAL Traverse Cracks Missing Material Longitudinal Cracks Intersecting with Transverse Cracks must be Replaced FIGURE 7-2 Engine Drive Belts areas, and glazed or shiny surfaces (Figure 7-2). A drive belt that is glazed or shiny indicates belt slippage. The proper operation of engine belt-driven components such Engine drive belt damage can be caused by various factors as the alternator, fan, and water pump depend on the proper...
Page 231: Fuel System
RT540E SERVICE MANUAL POWER TRAIN FUEL SYSTEM Maintenance NOTE: The entire fuel system must be maintained air tight Description to prevent loss of prime. The fuel system consists of the fuel tank, strainer, lift pump, Fuel Tank injection fuel pump, fuel-water separator filter and the fuel injectors.
Page 232: Description
POWER TRAIN RT540E SERVICE MANUAL FIGURE 7-3 Item Description Fuel Tank Fuel Level Sensor Fuel Supply Fuel Return Mounting Bracket Fuel Cooler Published 4-20-2015, Control # 502-01...
Page 233: Air Intake And Exhaust System
RT540E SERVICE MANUAL POWER TRAIN AIR INTAKE AND EXHAUST SYSTEM Inspect the air cleaner outlet tube for damage. Ensure the element gasket washer is not damaged and Description the washer’s rubber face seals against the element. The air intake system (Figure 7-4) controls the quality and Inspect the element gasket for damage.
Page 234 POWER TRAIN RT540E SERVICE MANUAL 8087 Air Intake Installation - Typical FIGURE 7-4 7-10 Published 4-20-2015, Control # 502-01...
Page 235 RT540E SERVICE MANUAL POWER TRAIN Figure 7-4 Item Numbers Install new secondary filter (if necessary) and new primary filter. Item Description Place the cover back on the air cleaner housing and T-bolt Clamp secure with clips (1). Elbow Check all connections and ducts for an air tight fit. Make Air Intake Tube sure that all clamps, bolts, and connections are tight.
Page 236 POWER TRAIN RT540E SERVICE MANUAL Vacuator Valve Check the condition of the valve and lips frequently and keep them clean. The valve lips should be open only when the Vacuator valves (2, Figure 7-6) (Figure 7-7) are designed to engine is shut down, or running at low idle speed. If the valve expel loose dust and dirt from the air cleaner body is turned outside in, check for a clogged air cleaner inlet.
Page 237: Charge-Air Cooler System
RT540E SERVICE MANUAL POWER TRAIN Charge-Air Cooler System loaded T-bolt clamps is 11.3 Nm (100 lb-in). Do not compress the spring completely, the bellows and/or clamp The charge-air cooler (CAC) (Figure 7-8) is used to cool may be damaged from thermal expansion of the CAC tube. engine air after it has passed through a turbocharger, but before it enters the engine.
Page 238: Muffler And Diesel Oxidation Catalyst - Tier 4 Interim
POWER TRAIN RT540E SERVICE MANUAL Muffler and Diesel Oxidation Catalyst - Tier 4 Install the diesel oxidation catalyst into the mounting band. Interim Connect the tube exhaust weldment/bellows assembly. Removal Install the muffler into the mounting bands. Attach the elbow to the muffler using the clamp. Install the exhaust tailpipe on the muffler.
Page 239 RT540E SERVICE MANUAL POWER TRAIN 8088 Muffler and Diesel Oxidation Catalyst - Tier 4 FIGURE 7-9 Item Description Item Description Sheet Metal Guard Diesel Oxidation Catalyst Tail Pipe Muffler Clamp Muffler Clamp Tube Exhaust Weldment Muffler Clamp Mounting Band Gasket Exhaust Tube Bellows Muffler Clamp...
Page 240: Water Cooling System
POWER TRAIN RT540E SERVICE MANUAL WATER COOLING SYSTEM part directly responsible is not a part of the cooling system. Most of these problems can be traced to overheating; Description however, an engine that is running too cold can be just as troublesome.
Page 241 RT540E SERVICE MANUAL POWER TRAIN Engine Antifreeze/Coolant Fill Procedure f o r m u l a t e d e x t e n d e d l i f e c o o l a n t . R e f e r t o LUBRICATION, page 9-1.
Page 242 POWER TRAIN RT540E SERVICE MANUAL Pressure Flushing The cap has a spring-loaded valve, the seat of which is below the overflow pipe in the filler neck. This prevents the Disconnect both radiator hoses that connect the radiator escape of air or liquid while the cap is in position. When the to the engine.
Page 243: Test Equipment
RT540E SERVICE MANUAL POWER TRAIN head bolts with a torque wrench is essential for Antifreeze/Coolant preventing leaks around the head gasket. Heavy duty diesel engines require a balanced mixture of Water Pump water and antifreeze/coolant. Fill the system with a AFC-50/ 50 blended, fully formulated extended life antifreeze/coolant The pump should be checked carefully for leaks and proper at all times.
Page 244 POWER TRAIN RT540E SERVICE MANUAL 8089-2 FIGURE 7-10 Installation Item Description Position the radiator assembly in the carrier using a Radiator Assembly lifting device and secure the radiator to the mount bracket with the hardware. Drain Cock Fan Guard Secure the support plates to each side of the radiator using a bolt.
Page 245: Drive Train
RT540E SERVICE MANUAL POWER TRAIN DRIVE TRAIN Transmission/Torque Converter Description Description The drive train consists of the transmission/torque converter The transmission/torque converter assembly is mounted to assembly and three drive lines. the engine and is connected to the front and rear axles by two drive shafts.
Page 246: Maintenance
POWER TRAIN RT540E SERVICE MANUAL reaction member is the means by which the hydraulic torque Maintenance converter multiplies torque. General Information The reaction member of the torque converter is located between and at the center of the inner diameters of the Always check the oil level with the engine idling, and the impeller and turbine elements.
Page 247 RT540E SERVICE MANUAL POWER TRAIN Troubleshooting Procedures SYMPTOM PROBABLE CAUSE REMEDY Low clutch pressure. Low oil level. Fill to proper level. Refer to LUBRICATION (pg 9-1). b. Clutch pressure regulating b. Clean valve spool and housing. valve spool stuck open. Faulty charging pump.
Page 248 POWER TRAIN RT540E SERVICE MANUAL MOUNT DIAL INDICATOR HERE FLYWHEEL HOUSING ENGINE FLYWHEEL PILOT BORE FLYWHEEL CONVERTER HOUSING FLYWHEEL 10.2 cm (4 in.) STUD 6.4 cm (2-1/2 in.) ALIGNING STUDS DRIVE PLATE FLYWHEEL HOUSING SPECIAL STUD, WASHER AND SELF-LOCK NUT FURNISHED BY ENGINE MANUFACTURER FLYWHEEL HOUSING...
Page 249: Servicing The Crane After Transmission/Torque Converter Overhaul
RT540E SERVICE MANUAL POWER TRAIN Check the engine flywheel and housing for conformance Servicing the Crane After Transmission/ to standard S.A.E. No. 3-S.A.E. J-927 tolerance Torque Converter Overhaul specifications for bore size, pilot bore runout and mounting face flatness. Measure and record engine The transmission/torque converter and its allied hydraulic system are important links in the drive line between the crankshaft end play.
Page 250 POWER TRAIN RT540E SERVICE MANUAL reaches 82 to 93 °C (180 to 200 °F), add oil to bring the w i l l c a u s e a c c e l e r a t e d d e t e r i o r a t i o n a n d level to the FULL mark on the dipstick.
Page 251: Axles
RT540E SERVICE MANUAL UNDERCARRIAGE SECTION 8 UNDERCARRIAGE SECTION CONTENTS Axles ........8-1 Maintenance .
Page 252: Maintenance
UNDERCARRIAGE RT540E SERVICE MANUAL Maintenance On the left side of the rear axle only, tag and disconnect the electrical wires from the rear wheels not centered NOTE: The axles do not have to be removed from the switch. crane to remove the planetary wheel ends or the NOTE: Each tire...
Page 253 RT540E SERVICE MANUAL UNDERCARRIAGE FIGURE 8-1 Item Description Item Description Cotter Pin Capscrew Washer Hex Nut Lockout Cylinder Capscrew Steer Cylinder Lockwasher Grease Fitting Flatwasher Pin Weld Sensor Plate Pin Weld Capscrew Capscrew Lockwasher Lockwasher Rear Axle Flatwasher GROVE Published 4-20-2015, Control # 502-01...
Page 254 UNDERCARRIAGE RT540E SERVICE MANUAL FIGURE 8-2 Item Description Item Description Front Axle Flatwasher Capscrew Steer Cylinder Hex Nut Pin Weld Washer Grease Fitting Pin Weld Flatwasher Capscrew Lockwasher Lockwasher Capscrew Published 4-20-2015, Control # 502-01...
Page 255 RT540E SERVICE MANUAL UNDERCARRIAGE Cleaning 10. Remove the blocking under the outrigger beams and retract the outriggers to lower the wheels to the ground. Completely assembled axles may be steam cleaned on the outside only, to facilitate initial removal and disassembly, Wheel Alignment Check Procedure providing all openings are closed.
Page 256 UNDERCARRIAGE RT540E SERVICE MANUAL 3, 4 5, 6, 7, 8 6758-1 FIGURE 8-3 Item Description Sensor Plate Proxy Switch Bracket Rear Steer Bracket Shim Capscrew Hex Nut Flat Washer Lock Washer Published 4-20-2015, Control # 502-01...
Page 257: Wheels And Tires
RT540E SERVICE MANUAL UNDERCARRIAGE Wheels and Tires Mounting Wheel Assemblies NOTE: Do not lubricate the wheel studs or lug nuts. Description The standard tire size for this unit is 20.5 x 25 -24 ply. A size 16.00 x 25 -28 ply tire is also available. WARNING Possible equipment damage and/or personal injury!
Page 258 UNDERCARRIAGE RT540E SERVICE MANUAL FIGURE 8-7 FIGURE 8-5 Item Description Incorrect Camber Incorrect Toe-In Incorrect camber gives abnormal wear on one half of the tire. Incorrect Toe-Out Out-of-line Axles Steering Arm Defect Incorrect Caster and Wheel Imbalance Incorrect caster or wheel imbalance shows as spot wear that is either in the middle of the tire or extends to the shoulder.
Page 259 RT540E SERVICE MANUAL UNDERCARRIAGE Cuts in the Tire Tread Feathered Edges Cuts are due to poor roads, air pressure too high or incorrect Normal occurrence on non-driving wheels on good roads tire type for the application. and high mileage. FIGURE 8-9 Item Description Cuts...
Page 260: Steering Systems
UNDERCARRIAGE RT540E SERVICE MANUAL STEERING SYSTEMS the control valve and two steer cylinders. It is activated by the rear steer control switch located on the left armrest in the Description cab. A rear steer indicator system is provided to indicate when the To maximize maneuverability, the crane can be steered by rear wheels are not centered.
Page 261 Clogged or loose hydraulic b. Clean or tighten lines or lines or fittings. f i t t i n g s . ( R e f e r t o y o u r Manitowoc Crane Care Parts Manual) Defective flow divider Repair or replace valve(s).
Page 262 UNDERCARRIAGE RT540E SERVICE MANUAL Functional Check a reduced oil flow to the control valve or a reduced system relief pressure. Adequate oil flow under all A normal periodic functional check of the entire steering conditions can best be checked by timing the full travel system will generally be adequate to ensure satisfactory of the cylinder with the steered axle unloaded and service.
Page 263: Hydraulic Pumps
RT540E SERVICE MANUAL UNDERCARRIAGE Symptom Probable Cause Solution Steering is erratic left and right. Hydraulic oil low. Refill hydraulic reservoir. b. Clogged or loose hydraulic b. Clean or tighten lines or lines or fittings. fittings. Defective steering control Repair or replace valve. valve.
Page 264: Steer Cylinders
UNDERCARRIAGE RT540E SERVICE MANUAL Remove the capscrews and washers securing the valve Maintenance to the frame bracket. Remove the valve. NOTE: For Disassembly and Assembly procedures, refer to Steer Cylinders in Section 2 - HYDRAULIC and Installation PRESSURE SETTINGS. Secure the valve to the frame bracket with the washers Removal and capscrews.
Page 265: Rear Axle Oscillation Lockout System
RT540E SERVICE MANUAL UNDERCARRIAGE REAR AXLE OSCILLATION LOCKOUT Maintenance SYSTEM NOTE: For disassembly and assembly procedures, refer to Axle Oscillation Lockout Cylinder in Section 2 - Description HYDRAULIC and PRESSURE SETTINGS. The rear axle oscillation system consists of two lockout Removal cylinders, an axle lockout valve, an axle oscillation relay and Raise the crane up on outriggers.
Page 266: Brake System
UNDERCARRIAGE RT540E SERVICE MANUAL BRAKE SYSTEM Hydraulic oil from hydraulic pump number 2 flows to swivel port 5 to the accessory manifold to the dual accumulator Description charge valve. The dual accumulator charge valve charges the accumulators from the open center circuit upon demand The brake system includes all the components necessary for and within its present operating charge rate and the high limit the application of the service brakes and the parking brake.
Page 267: Maintenance
RT540E SERVICE MANUAL UNDERCARRIAGE Maintenance Troubleshooting Symptom Probable Cause Solution Brakes are poor. Lining thickness less than Replace lining. 3mm (0.125 in). b. Brake pedal operation. b. Free mechanical linkage. Restriction or leaks in lines. Check all lines for leaks and restrictions.
Page 268: Service Brakes
UNDERCARRIAGE RT540E SERVICE MANUAL brake valve. Bleed every bleeder screw on every caliper/ Repeat steps 1 thru 3 for the remaining wheel calipers/ actuator on every wheel. When you complete a bleeder actuators. screw, go to the next closest bleeder screw on the same caliper/actuator.
Page 269 RT540E SERVICE MANUAL UNDERCARRIAGE Caliper b. Apply compressed air to the inlet fitting to force the pistons out of the other housing. If one piston comes Disconnect the hydraulic brake line from the inlet fitting out before the other piston, put a piece of wood in on the caliper.
Page 270 UNDERCARRIAGE RT540E SERVICE MANUAL Shoes, Linings, and End Plates Remove the shoes and linings. To help prevent abnormal Wood Block lining wear, replace worn, bent, or cracked end plates and distorted backing plates. Inspect end plate bolts for wear. Replace the bolts if worn. Inspect the linings for: •...
Page 271 RT540E SERVICE MANUAL UNDERCARRIAGE Minimum Disc Bleeder Screw Piston Fluid Thickness Fluid Leaks Leaks Maximum Disc Wear Each Side Inlet Cylinder Fitting Maximum Fluid Disc Wear Fluid Original Leaks Leaks Disc Thickness 15.875 mm (0.625 in) Typical Section Through Disc Showing Piston Fluid Recommended Maximum Wear Limits Leaks...
Page 272: Corrosion Protection
UNDERCARRIAGE RT540E SERVICE MANUAL Measure the diameter of the housing bore. Replace the • Use a wire brush to clean the threads of fasteners housing if the diameter is worn to more than 76.276 mm and fittings. (3.003 in) (Figure 8-23). •...
Page 273 RT540E SERVICE MANUAL UNDERCARRIAGE Install a new o-ring in the groove of the cylinder cap. Ensure the o-ring is not cut by the threads on the cylinder cap. O-Ring- Backup Ring - Install Toward Install Toward Lining NOTE: Apply extra grease on o-ring before installing Outboard End of Bore Side of Bore O-Ring cylinder caps.
Page 274: Parking Brake Actuator
UNDERCARRIAGE RT540E SERVICE MANUAL Caliper Maintenance Position the caliper housing on the mounting bracket. If Removal shims where used, place them as marker during removal. Chock the wheels to prevent crane movement. Secure the caliper housing with the bolts and tighten CAUTION them to 678 to 813 Nm (500 to 600 lb-ft).
Page 275: Parking Brake
RT540E SERVICE MANUAL UNDERCARRIAGE Attach brake line to inlet port located on top of the the front console in the cab and is spring-applied and hydraulic cylinder. hydraulically released by an actuator. Apply hydraulic pressure to the brake. Maintenance With plug removed, loosen coupling nut and set running Removal clearance to 0.5 to 0.7 mm (0.020 to 0.030 in) total by adjusting the socket setscrew.
Page 276 UNDERCARRIAGE RT540E SERVICE MANUAL Procedure for Manually Releasing the Parking Brake NOTE: Refer to (Figure 8-28) and (Figure 8-30) during parking brake adjustment procedure. Block wheels to prevent crane from moving. Remove the screw-in plug (1). Loosen coupling nut (3). Back out socket setscrew (2) until brake is released.
Page 277: Park Brake Valve
RT540E SERVICE MANUAL UNDERCARRIAGE PARK BRAKE VALVE Functional Tests Start and idle engine. Description With units on outriggers, check for proper two/four wheel The range shift/parking brake valve controls the flow of oil to operation. the parking brake, hi-low range and axle disconnect actuators by the use of two solenoid valves.
Page 278 UNDERCARRIAGE RT540E SERVICE MANUAL Maintenance Troubleshooting Symptom Probable Cause Solution Slow erratic operation Damaged relief valve. Remove relief valve; clean or outrigger extension cylinders. replace. b. Low hydraulic oil. b. Replenish oil to proper level. Refer to LUBRICATION (pg 9- Sticking solenoid valve spool.
Page 279 RT540E SERVICE MANUAL UNDERCARRIAGE Symptom Probable Cause Solution S l o w o r e r r a t i c o p e r a t i o n o f q. Partially shifted hydraulic q. Disassemble, clean, outrigger extension cylinders. spool in selector valve or p o l i s h s p o o l a n d v a l v e (continued)
Page 280 UNDERCARRIAGE RT540E SERVICE MANUAL Symptom Probable Cause Solution Outrigger jack cylinder slow or Low in hydraulic oil. Replenish oil to proper level. erratic. b. Damaged main relief valve. b. Repair or replace valve. Damaged holding valve seals. Replace holding valve seals. d.
Page 281: Outrigger Beam
RT540E SERVICE MANUAL UNDERCARRIAGE Symptom Probable Cause Solution Outrigger system activates, but Clogged, broken, or loose Clean, tighten, or replace selected outrigger will not stow or hydraulic lines or fittings. lines or fittings. extend and lower as desired. b. Loose or broken wire on b.
Page 282 UNDERCARRIAGE RT540E SERVICE MANUAL 14, 15 4, 5, 6 2, 3 14, 15 6759-3 2, 3 8, 9, 10, 11, 12, 13 FIGURE 8-30 Item Description Item Description Outrigger Box Assembly Capscrew Hex Nut Plate Capscrew Wear Pad Flatwasher Hex Nut Cotter Pin Capscrew Clevis Pin...
Page 283 RT540E SERVICE MANUAL UNDERCARRIAGE 8487 FIGURE 8-30 continued Item Description Item Description Jack Cylinder Jack Cylinder Retract Port Extension Cylinder Extension Cylinder Retract Port Outrigger Beam Extension Cylinder Extend Port Jack Cylinder Extend Port OMS Potentiometer NOTE: Outrigger removal and installation similar for b o t h f r o n t a n d r e a r outriggers.
Page 284 UNDERCARRIAGE RT540E SERVICE MANUAL Tag and disconnect the hydraulic lines at the cylinder Attach a suitable lifting device of straps or belts instead barrel end of the extension cylinder. Cap all lines and of chains to prevent nicking the bottom edges of the fittings.
Page 285: Extension Cylinder
RT540E SERVICE MANUAL UNDERCARRIAGE Adjust for 2 mm (0.07inch) gap with opposing shim 1, 2 7, 8 7, 8 6 mm (0.23 inch) of bottom wear pad protruding before installing outrigger beam FIGURE 8-32 force for the outrigger beam’s horizontal movement. The cylinder weighs approximately 42 kg (92.5 lb).
Page 286: Jack Cylinder
UNDERCARRIAGE RT540E SERVICE MANUAL Installation Jack Cylinder Place the cylinder in the beam. Description NOTE: Keep hydraulic fittings and hoses close to angles Four jack cylinders are used on the crane, one at the end of shown (Figure 8-33) and as low as possible to each outrigger beam.
Page 287 RT540E SERVICE MANUAL UNDERCARRIAGE the tube. Position the jack so that it will support the If oil stops flowing, the cylinder’s internal piston seal cylinder in this position. Remove the lifting device from is sealing properly. the cylinder. b. If oil continues to flow out the rod port, the cylinder’s Remove the retaining pin and cotter pins from the internal piston seal is leaking.
Page 288: Outrigger Control Valves
UNDERCARRIAGE RT540E SERVICE MANUAL Outrigger Control Valves first function is a holding valve, the second function provides a thermal relief of the jack. Description Integrated Outrigger/Rear Steer Manifold There are four valve assemblies responsible for controlling The integrated outrigger/rear steer valve is mounted on the the outrigger system, the integrated outrigger/rear steer frame center section to the rear of the front axle.
Page 289: General
Dispose of waste properly! Improperly disposing of waste can threaten the environment. CAUTION Potentially harmful waste used in Manitowoc cranes includes — but is not limited to — oil, fuel, grease, coolant, air Chassis grease lubricants must not be applied with air...
Page 290: Arctic Conditions Down To -40°F
Industries, Inc Fleet Charge SCA Pre-charged Antifreeze/ protected using Boeshield® T-9 Premium Metal Protectant. Coolant-60/40; Fleetguard Compleat EG Antifreeze/Coolant Manitowoc Crane Care has Boeshield® T-9 Premium Metal Premix 60/40; -- Spec 6829104212 Protectant available in 12 oz. cans that can be ordered through the Parts Department.
Page 291: Wire Rope Lubrication
RT540E SERVICE MANUAL LUBRICATION Cylinder operation and inclement weather will remove the rope moves and bends. A wire rope cannot be lubricated Boeshield® protectant; therefore, inspect machines once a sufficiently during manufacture to last its entire life. week and reapply Boeshield® to unprotected rod Therefore, new lubricant must be added periodically throughout the life of a rope to replace factory lubricant which is used or lost.
Page 292: Lubrication Points
The oil must have settled for 20 minutes, with the temperature in the 21°C ± 7°C (70°F ±20°F) range. Manitowoc highly recommends the use of CraneLUBE Variations in oil temperature will cause oil level to fluctuate. l u b r i c a n ts t o i n c r e a s e y o u r c r a n e ’s r e l i a b i l i t y a n d performance.
Page 293: Steering And Suspension
RT540E SERVICE 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 9-1 grease 500 hours or 3 months 8 grease fittings Pivot Pins Multipurpose extrudes Grease A6-829-003477 EP-MPG...
Page 294 LUBRICATION RT540E SERVICE MANUAL 6818-2 6818-1 FIGURE 9-1 Published 4-20-2015, Control # 502-01...
Page 295: Axles
RT540E SERVICE 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 9-2 Service Interval in housing on the Differentials 44 pt...
Page 296 LUBRICATION RT540E SERVICE MANUAL 9, 11 6, 7 6818-45 FIGURE 9-2 Published 4-20-2015, Control # 502-01...
Page 297: Drive Train
RT540E SERVICE 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 a. Engine SAE 15W-40 16.3 l •...
Page 298 LUBRICATION RT540E SERVICE MANUAL Dipstick 6818-36 6813-7 Other Side Other Side 6818-29 6818-40 FIGURE 9-3 9-10 Published 4-20-2015, Control # 502-01...
Page 299: Drive Train (Continued)
RT540E SERVICE 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 9-4 grease 500 hours or 3 months 3 grease fittings Joints Multipurpose extrudes Grease A6-829-003477 •...
Page 300 LUBRICATION RT540E SERVICE MANUAL 6818-38 Other Side Other Side 6818-29 6818-8 6818-43 FIGURE 9-4 9-12 Published 4-20-2015, Control # 502-01...
Page 301: Outriggers
RT540E SERVICE MANUAL LUBRICATION Lube Point Figure Approved Lube Item Lube Interval Application Description Lubricant Capacity Outriggers EP-MPG Extreme Brush lubricant on Pressure Outrigger Beams Figure 9-5 50 hours or 1 week bottom of outrigger Multipurpose beams Grease A6-829-003477 EP-MPG Brush lubricant on Extreme OD of jack cylinder...
Page 302 LUBRICATION RT540E SERVICE MANUAL 6818-9 FIGURE 9-5 9-14 Published 4-20-2015, Control # 502-01...
Page 303: Turntable
RT540E SERVICE 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 9-6 Service Interval dipstick, fill to top of 4.25 qt...
Page 304 LUBRICATION RT540E SERVICE MANUAL 6818-11 6818-10 Dipstick 6818-44 FIGURE 9-6 9-16 Published 4-20-2015, Control # 502-01...
Page 305: Boom
RT540E SERVICE MANUAL LUBRICATION Lube Point Figure Approved Lube Item Lube Interval Application Description Lubricant Capacity Boom EP-MPG Until Extreme Pressure Upper Lift Figure 9-7 grease 500 hours or 3 months 2 grease fittings Multipurpose Cylinder Pin Grease extrudes A6-829-003477 EP-MPG Extreme Until Pressure...
Page 306 LUBRICATION RT540E SERVICE MANUAL 7181-1 7181-2 6818-21 6818-42 6818-13 6818-26 FIGURE 9-7 9-18 Published 4-20-2015, Control # 502-01...
Page 307: Boom (Continued)
RT540E SERVICE 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 9-8 grease 250 hours or 3 months 2 grease fittings Multipurpose extrudes Grease A6-829-003477 EP-MPG Extreme Until...
Page 308 LUBRICATION RT540E SERVICE MANUAL 6818-17 6818-41 6818-31 6818-30 FIGURE 9-8 9-20 Published 4-20-2015, Control # 502-01...
Page 309: Hoist
RT540E SERVICE MANUAL LUBRICATION Lube Point Figure Approved Lube Item Lube Interval Application Description Lubricant Capacity Hoist • Check and fill every AGMA Oil level must be 50 hours or weekly Extreme 5.2 l (5.5 visible in the sight Main Hoist Figure 9-9 Pressure Gear •...
Page 310 LUBRICATION RT540E SERVICE MANUAL 6818-17 FIGURE 9-9 9-22 Published 4-20-2015, Control # 502-01...
Page 311: 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 312 LUBRICATION RT540E SERVICE MANUAL FIGURE 9-10 9-24 Published 4-20-2015, Control # 502-01...
Page 313: Carwell® Rust Inhibitor
While the surfaces of the crane that are easily seen have the biggest impact on the appearance of the crane, particular Manitowoc Crane Group's cranes are manufactured to high attention should be given to the undercarriage of the crane to quality standards, including the type of paint finish minimize the harmful effects of corrosion.
Page 314: Inspection And Repair
• and allow to dry thoroughly. Please contact Manitowoc Crane Care should you have any • Prepare the surface prior to applying the finish coat of questions. paint.
Page 315 RT540E SERVICE MANUAL LUBRICATION • Frame application areas are; hose ends and fittings, all • Boom applications areas are; pivot pins, hose end and unpainted fasteners and hardware, all bare metal fittings, jib pins and shafts, all bare metal surfaces, surfaces, outrigger pads, and back up alarm hardware.
Page 316 LUBRICATION RT540E SERVICE MANUAL 7650-7 FIGURE 9-11 9-28 Published 4-20-2015, Control # 502-01...
Page 317 RT540E SERVICE MANUAL LUBRICATION FIGURE 9-12 Item Description O/R Hose Connections Item Description Hookblock Tie Down Cable Hoist Tension Springs O/R Pins, Clips Boom Extension Pins, Clips O/R Beam Wear Pad Adjustment Hardware Boom Nose Pins, Clips Turntable Bearing Fasteners Hook Block/ Headache Ball Entire underside of unit Boom Extension Hanger Hardware...
Page 318 LUBRICATION RT540E SERVICE MANUAL Item Description Counterweight Mounting Hardware Counterweight Pins Hose Connections Mirror Mounting Hardware 9-30 Published 4-20-2015, Control # 502-01...
Page 319 RT540E SERVICE MANUAL Alphabetical Index Accessory With Swing Directional Control Manifold ......2-33 Air Intake and Exhaust System ..........7-9 Axle Oscillation Lockout Cylinder .
Page 320 SERVICE MANUAL RT540E Parking Brake Actuator..........8-24 Parking Brake .

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