Manitowoc Grove 5540F Manuals

Manitowoc Grove 5540F Manuals

Manuals and User Guides for Manitowoc Grove 5540F. We have 2 Manitowoc Grove 5540F manuals available for free PDF download: Service Manual, Operator's Manual

Manitowoc Grove 5540F Service Manual

Manitowoc Grove 5540F Service Manual (412 pages)

Brand: Manitowoc | Category: Construction Equipment | Size: 24.02 MB

Table of Contents

Table of Contents

3
- Directional Reference
  13
- Identification Plates
  13
- Specifications
  14
- General Maintenance
  17
  - Cleanliness
    17
  - After Cleaning
    17
  - Removal and Installation
    17
  - Disassembly and Assembly
    18
  - Pressing Parts
    18
  - Locking Devices
    18
  - Wires and Cables
    18
  - Shims
    18
  - Hoses and Tubes
    18
  - Bearings
    19
  - Gaskets
    19
  - Batteries
    20
  - Hydraulic Systems
    20
  - Electrical System
    21
  - Fatigue of Welded Structures
    21
  - Loctite
    22
  - Fasteners and Torque Values
    22
  - Weld Studs (Table 1-10)
    26
  - Hydraulic Fitting
    26
- Wire Rope
  28
- Hydraulic Pressure Testing
  33
- O-Ring, Seal and Elastic Nut Replacement
  33
Section 2 Safety Practices

35
- Section 2
  35
  - Introduction
    37
  - Signal Words
    37
    
    Equipment Considerations
    38
    
    Personal Considerations
    38
    
    General Considerations
    39
    
    Operational Considerations
    39
  - Final Word
    40
Section 3 Electric System

41
- Section 3
  41
  - General
    43
    
    Comparing Electrical System to a Hydraulic System
    43
    
    Magnetism
    43
  - Main Electrical System
    43
    
    Fuses
    44
    
    Wire Harnesses
    44
  - Charging System
    45
    
    Alternator and Voltage Regulator
    45
    
    Batteries
    45
    
    Battery Maintenance and Charging
    45
    
    Pressure Switch
    45
    
    Special Precautions
    45
    
    Voltmeter
    45
  - Starting Circuit
    46
    
    General Inspections
    46
    
    Starting Circuit Check
    46
  - Instrument and Light Circuits
    47
    
    Gauges
    47
    
    General
    47
    
    Light Bulbs
    47
  - Wire Harnesses
    48
    
    Engine Wire Harness
    48
    
    Instrument Panel Wire Harness
    48
  - Accessory Circuits
    53
  - Anti-Double Blocking System (Figure 3-6)
    53
  - Load Moment Indicator (LMI) System (Figure 3-1)
    55
    
    Optional Engine Shutdown
    57
    
    Heater
    58
Section 4 Hydraulic System

63
- Section 4
  63
  - Technical Data
    65
  - General Description
    65
    
    General
    65
    
    Hydraulic System
    65
  - Troubleshooting
    66
    
    Troubleshooting Aids
    66
    
    Troubleshooting Procedures
    66
  - Troubleshooting Guides
    67
  - Suction, Pressure and Return Circuits
    71
    
    General
    71
    
    Hydraulic Pump
    71
    
    Main Relief Valves
    76
    
    Main Control Valve
    77
    
    Adjusting Main Relief Valve Pressure Settings
    80
  - Lift Circuit
    82
    
    General
    82
    
    Oil Flow
    82
    
    Holding Valve
    83
    
    Lift Cylinder Leakage Check
    83
    
    Hydraulic Swivel
    86
  - Crowd Circuit
    87
    
    General
    87
    
    Holding Valve
    87
    
    Oil Flow
    87
    
    Crowd Cylinders Leakage Test
    90
    
    Hydraulic Swivel
    90
  - Main Winch Circuit
    90
    
    General
    90
    
    Oil Flow
    90
    
    Brake Holding Valve
    91
    
    Hydraulic Swivel
    91
  - Swing Circuit
    94
    
    General
    94
    
    Oil Flow
    94
  - Anti-Double Blocking System
    94
    
    System Function
    95
  - Outrigger Circuit
    98
    
    General
    98
    
    Oil Flow
    98
    
    Load Holding Valves
    101
    
    Outrigger Cylinder Leakage Check
    101
  - Axle Lockout Circuit
    101
    
    General
    101
    
    Oil Flow
    101
  - Component Repair
    105
    
    Hydraulic Pump Repair
    105
    
    Main Control Valves
    108
    
    Swing Motor
    113
    
    Hydraulic Swivel
    119
    
    Hydraulic Cylinders
    122
Section 5 Preventative Maintenance

129
- Introduction
  131
  - Spark Arresting Mufflers
    131
  - Safety List
    131
- Lubricants
  131
- Maintenance Records
  131
- Special Maintenance
  131
  - Delivery Inspection
    131
  - After First 50 Hours of Operation (New Cranes)
    132
  - Cranes Not in Regular Use
    132
- Preventive Maintenance
  132
  - Maintenance Schedule and Checklist
    132
  - Lubrication Points
    135
- Scheduled Maintenance
  139
  - Daily (Walk-Around) Inspection
    139
    
    Component/System Checks
    139
    
    Inspections
    139
  - Hours of Operation (Weekly)
    143
    
    Clean the Air Cleaner Dust Cup
    143
    
    Wire Rope Inspection
    143
    
    Grease Fittings
    144
    
    Lubricate Parking Brake
    144
    
    Lubricate the Boom Slides
    144
  - Hours of Operation (Two Weeks)
    146
    
    Check Wheel Nut Torque
    146
    
    Inspect the Fan Belts
    146
  - Hours of Operation (Monthly)
    147
    
    Clean Battery and Cables
    147
    
    Inspect the Hydraulic Hoses
    147
    
    Clean the Radiator
    148
    
    Lubricate the Swing Gear and Pinion
    148
    
    Lubricate the Wire Rope
    148
    
    Replace the Crankcase Oil and Filter
    149
    
    Torque Critical Bolts
    149
  - Hours of Operation (3 Months)
    150
    
    Inspect Parking Brake Pads
    150
    
    Inspect the Tires
    150
    
    Replace Air Cleaner Element
    150
    
    Replace Fuel Filter (Diesel Engine)
    150
    
    Add Grease to the Swing Gearbox
    151
    
    Add Rust Inhibitor to Engine Cooling System
    151
    
    Lubricate the Outrigger Slides
    151
    
    Spark Plug Gap (Gasoline Engine)
    151
    
    Check Axle Housing Lubricant Level
    152
    
    Check Wheel Hub Lubricant Level
    152
  - 1000 Hours of Operation (6 Months)
    153
    
    Check Winch Gearbox and Brake Lubricant Levels
    153
    
    Replace the Transmission Oil and Filter
    153
    
    Replace the Axle Housing Lubricant
    154
    
    Replace Axle Wheel Hub Lubricant
    155
    
    Replace the Hydraulic Oil
    156
    
    Replace the Winch Gearbox and Brake Lubricant
    156
  - Replace the Hydraulic Oil Filter
    157
  - Replace L.P.G. Inline Filter
    157
  - 2000 Hours of Operation (Yearly)
    158
  - Check Swing Gear/Pinion Backlash
    158
  - Replace the Spark Plugs (Gasoline Engine)
    158
  - Replacing the In-Line Fuel Filter (Dual Fuel Engine)
    158
  - Replacing the Engine Coolant
    158
- Miscellaneous Maintenance
  159
  - Batteries/Charging System
    159
  - Inspect the Crane Structure and Booms for Damage
    159
  - Testing the Load Moment Indicator (Optional)
    159
  - Checking the Charging System
    159
  - Charging the Battery
    159
  - Replacing the Battery
    159
  - Fuel System
    160
  - Fuse Replacement
    160
  - Fuel Storage
    160
- Carwell® Rust Inhibitor
  162
  - Protecting Cranes from Rusting
    162
  - Cleaning Procedures
    162
  - Inspection and Repair
    163
  - Application
    163
- Areas of Application
  163
Section 6 Engine and Engine Systems

167
- Engine Crankcase System
  169
  - Crankcase Oil Data
    169
- Engine Performance
  169
- Engine RPM
  169
- Engine Types
  169
- General
  169
- Governor
  169
- Engine Cooling System
  170
  - Coolant Requirements
    170
  - Radiator Cap and Overflow Bottle
    171
  - Thermostat
    171
- Engine Electrical System
  171
- Engine Fuel System
  171
- Checks and Adjustments
  173
  - Throttle Linkage Adjustment
    173
- Engine Air Intake System
  173
- Engine Exhaust System
  173
- Removal and Installation
  175
  - Removal
    175
  - Installation
    176
- Dual Fuel Engine and Engine Systems
  176
  - General
    176
  - Engine Types
    176
  - Engine Performance
    176
  - Engine RPM
    177
  - Governor
    177
  - Crankcase System
    177
  - Crankcase Oil Data
    177
  - Engine Cooling System
    177
  - Coolant Requirements
    177
  - Radiator Cap and Overflow Bottle
    178
  - Thermostat
    178
  - Engine Electrical System
    178
- Engine Fuel Systems
  179
  - Fuel Injected Dual Fuel System
    179
  - Fuel Tank
    180
  - Fuel Level Sender and Gauge
    180
  - Fuel Pump
    180
  - Types of Fuel to Use
    180
  - Engine Air Intake System
    181
- Engine Exhaust System
  181
  - Electronic Fuel Injection System
    181
  - Fuel Injection Components
    183
  - Checks and Adjustments
    193
  - Troubleshooting
    194
    
    Removal and Installation
    195
Section 7 Transmission and Torque Converter

199
- Technical Data
  201
  - General Technical Data
    201
    
    Clutch Solenoid Technical Data
    202
  - Description of Operation
    203
    
    General
    203
    
    Torque Converter
    203
    
    Transmission
    203
    
    Reverser Clutch
    209
    
    Hydraulic 2/4 Wheel Drive Unit - Spring On/Pressure off
    210
    
    Hydraulic 2/4 Wheel Drive Unit - Pressure On/Spring off
    212
    
    Hydraulic 2/4 Wheel Drive Unit - Pressure On/Spring off (Cont'D)
    213
  - Troubleshooting
    214
    
    General Troubleshooting
    214
    
    Hydraulic 2/4 Wheel Drive Unit (Spring On/Pressure OFF)
    218
    
    Hydraulic 2/4 Wheel Drive Unit (Pressure On/Spring OFF)
    219
    
    Troubleshooting
    220
    
    Water Contamination
    220
    
    Cooler Test Procedure
    221
    
    Flushing Procedure
    221
    
    General Procedure
    221
    
    Inspection
    221
    
    Stalling the Torque Converter
    221
    
    Clutch Pressure (Forward Clutch Given in Example)
    223
    
    Mainline Pressure
    223
    
    Pressure and Flow Tests
    223
    
    Pump Flow
    223
    
    Converter in Pressure
    224
    
    Converter out Pressure/Oil Cooler Flow Rate
    224
    
    Lubrication Pressure
    224
  - Transmission Repair
    227
    
    Removal
    227
    
    Servicing the Torque Converter
    227
    
    Installation
    228
    
    Removal
    230
    
    Servicing the Transmission
    230
    
    Transmission Gearbox Repair
    230
    
    Assembly
    237
    
    Assembly
    248
    
    Solenoid Valve Disassembly and Assembly
    248
    
    Assembly
    250
    
    Hydraulic 2/4 Wheel Drive Unit Disassembly and Assembly (Pressure On/Spring off Type)
    253
    
    Hydraulic 2/4 Wheel Drive Unit Disassembly and Assembly (Pressure On/Spring off Type)7-53
    253
    
    Hydraulic 2/4 Wheel Drive Unit Disassembly and Assembly (Spring On/Pressure off Type)
    255
    
    Hydraulic 2/4 Wheel Drive Unit Disassembly and Assembly (Spring On/Pressure off Type)7-55
    255
Section 8 Axles/Drive Shafts/Wheels and Tires

259
- Description
  261
  - Front Axle
    261
  - Rear Axle
    261
  - Front Drive Axle
    261
- Technical Data
  262
  - Rear Drive Axle
    262
  - Rear Non-Drive Axle
    263
- Front Drive Axle Repair
  264
  - Removal
    264
  - Installation
    264
  - Special Tools
    264
  - Replacing the Pinion Oil Seal
    266
  - Axle Hub Repair
    267
  - Drive Head Repair
    271
- Rear Axles Repair
  279
  - Removal
    279
  - Installation
    279
  - Service Tools
    279
  - Replacing the Pinion Oil Seal
    279
  - Axle Hub Repair
    279
  - Drive Head Repair (Drive Axles Only)
    284
- Drive Shafts
  286
- Drive Shafts
  287
  - Removal
    287
  - Disassembly
    287
  - Inspection
    288
  - Assembly
    288
  - Installation
    289
  - Lubrication Procedure
    290
- Wheel & Tires
  290
  - Tire Inflation
    290
  - Wheel Stud Nuts
    290
Grove

291
- Technical Data
  293
  - Front Axle Brakes
    293
  - Rear Axle Brakes
    293
  - Accumulator
    293
  - Accumulator Charging Valve
    293
  - Priority Flow Control Valve
    293
- Description
  294
  - Service Brake System
    294
  - Parking Brake System
    297
- Maintenance and Adjustments
  297
  - Service Brake Bleeding
    297
  - Parking Brake Bleeding
    298
  - Parking Brake Adjustment
    298
  - Accumulator Charging
    299
  - Residual Brake System Pressure
    299
- Tests
  299
  - Brake Piston Seal Leakage Test (Front Axle Only)
    299
- Service Brake Repair
  301
  - Front Axle Brakes
    301
  - Rear Axle Brakes
    304
- Parking Brake Repair
  305
  - Lining Kit Replacement
    305
  - Repair Kit Installation
    307
  - Seal Kit Installation
    308
- Brake Modulating Valve Repair
  310
  - Removal
    310
  - Disassembly
    310
  - Assembly
    310
  - Installation
    310
- Troubleshooting
  311
  - Service Brakes
    311
Grove

313
- Section 10
  313
  - Units Without Return-To-Center Steering
    315
  - Technical Data
    315
  - Description
    315
    
    Crab Steering
    315
    
    Four-Wheel Steering
    315
    
    Two-Wheel Steering
    315
  - Relief Valve Pressure Check and Adjustment
    319
    
    Pressure Adjustment
    319
    
    Pressure Check
    319
  - Units with Return-To-Center Steering
    320
  - Technical Data
    320
  - Description
    320
    
    General
    320
    
    Steering Modes
    320
    
    Two-Wheel Steering
    320
    
    Crab Steering
    323
    
    Four-Wheel Steering
    323
  - Relief Valve Pressure Check and Adjustment
    326
  - Steering Proximity Switches
    326
    
    General
    326
    
    Principle of Operation
    326
    
    Sensor Operation and Spacing Checks
    328
  - Steering Orbitrol
    331
    
    Description
    331
    
    Orbitrol Repair
    331
  - Steering Cylinder
    338
    
    Cylinder Repair
    338
    
    Special Tools
    338
    
    Technical Data
    338
Section 11 11

343
- Booms
  345
  - General
    345
    
    Extending the Fourth Boom Section
    345
  - Retracting the Fourth Boom Section
    347
  - Removal of Boom Assembly
    348
  - Installation of the Boom Assembly
    348
  - Disassembly
    349
  - Assembly
    355
- Wire Rope, Sheaves and Hoist Blocks
  356
  - Wire Rope Description
    356
  - Wire Rope Safety
    357
  - Inspecting Wire Rope
    357
  - Inspection of Sheaves
    357
  - Wire Rope Lubrication
    358
  - Wire Rope Installation
    358
    
    Installation of Socket and Wedge
    358
  - Installation of a New Wire Rope
    359
- Main Winch (Tulsa Model)
  360
  - Theory of Operation
    360
  - Repair
    362
    
    Removal
    362
    
    Winch Assembly
    362
  - Motor Group
    364
  - Brake Section
    365
  - Troubleshooting
    372
- Main Winch (Braden Model)
  373
  - Theory of Operation
    373
  - Winch Operation
    373
  - Description of Winch (Figure 11-54)
    373
  - Repair
    376
    
    Removal
    376
  - Winch Assembly
    378
  - Planet Carrier Service
    385
  - Motor Support-Brake Cylinder Service
    386
  - Brake Clutch Service
    390
  - Winch Tension Roller Subassembly Service
    392
  - Troubleshooting
    394
- Bearing, Mast and Related Parts
  395
  - General
    395
  - Mast Bearing
    396
  - Mast Bearing Bolts
    397
  - Inspection for Bearing Wear
    397
  - Replacing the Mast Bearing
    397
    
    Removal
    397
  - Swing Gearbox and Pinion
    398
    
    Adjustment
    398
    
    Installation
    398
    
    Maintenance
    398
  - Swing Gearbox Repair (Tulsa Gearbox)
    400
    
    Removal
    400
  - Disassembly
    400
  - Swing Gearbox Repair (Braden Gearbox)
    403
  - Inspection
    403
  - Installation
    403
  - Removal
    403
  - Disassembly
    403
  - Assembly
    403
- Outriggers
  405
  - Outrigger Monitoring System (OMS)(Optional-Standard in North America)
    405
  - Installation
    405
  - Removal
    405
  - Cylinder Removal
    406
  - Cylinder Installation
    406

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Manitowoc Grove 5540F Operator's Manual

Manitowoc Grove 5540F Operator's Manual (134 pages)

Brand: Manitowoc | Category: Construction Equipment | Size: 6.02 MB

Table of Contents

Table of Contents
7
Section 1

11
- The Manual
  11
- Directional Reference
  11
- Serial Number Plate
  11
- Reports
  11
- Disclaimer
  12
- Customer Support
  12
  - New Owners
    12
- Nomenclature
  13
Section 2

15
- Safety Messages
  15
  - General
    15
  - Safety Alert Symbol
    15
- General
  16
  - Signal Words
    16
- Accidents
  16
- Operator's Information
  16
- Operator's Qualifications
  17
- Operational Aids
  17
- Crane Stability/Structural Strength
  19
  - Load Charts
    20
  - Work Site
    20
  - Wind Forces
    20
  - Lifting Operations
    21
  - Counterweight
    22
  - Outrigger Lift off
    22
  - Multiple Crane Lifts
    22
- Electrocution Hazard
  22
- Personnel Handling
  25
- Environmental Protection
  26
- Maintenance
  26
  - Service and Repairs
    27
  - Lubrication
    27
  - Tires
    28
  - Wire Rope
    28
  - Sheaves
    29
  - Batteries
    30
  - Engine
    30
- Transporting the Crane
  30
- Travel Operation
  30
- Work Practices
  32
  - Personal Considerations
    32
  - Crane Access
    32
  - Job Preparation
    32
  - Working
    32
  - Lifting
    33
  - Hand Signals
    34
- Boom Extension
  36
- Parking and Securing
  36
- Shut-Down
  36
- Cold Weather Operation
  36
- Temperature Effects on Hydraulic Cylinders
  37
- Overload Inspection
  38
  - Boom Inspection
    38
  - Superstructure Inspection
    40
  - Carrier Inspection
    42
Section 3

45
- Controls, Switches, and Gauges
  46
  - Cab Controls
    46
  - Panel Switches
    47
  - Gauges and Indicators
    50
- Operator's Cab
  55
  - Seat Belt
    55
  - Seat Adjustment
    55
- Machine Operation
  57
- Operating the Outrigger Controls
  64
- Operating Practices
  74
  - Handling a Load
    74
  - Attaching the Load
    75
  - Holding the Load
    75
  - Moving the Load
    75
  - Traveling with a Load (Pick and Carry)
    75
  - Turning Clearances
    75
  - Machine Shutdown
    75
  - Unattended Crane
    76
  - Towing a Disabled Machine
    76
Section 4

77
- Using the Capacity Chart
  77
Section 5

81
- Hoist Block
  81
  - Removing the Hoist Block
    81
  - Installing the Hoist Block
    82
- Fourth Boom Section
  82
- Boom Extension
  85
  - Installing the Boom Extension
    85
  - Stowing the Boom Extension
    85
- Down Haul Weight
  87
  - Installing the down Haul Weight
    87
  - Removing the down Haul Weight
    88
- Installing Cable on the Hoist
  88
- Wire Rope Wedge Socket
  89
- Part Wire Rope Reeving
  91
Section 6

93
- Introduction
  93
  - Spark Arresting Mufflers
    93
  - Safety List
    93
- Lubricants
  94
- Maintenance Records
  94
- Special Maintenance
  94
- Preventive Maintenance
  95
  - Maintenance Schedule and Checklist
    95
  - Lubrication Points
    98
- Scheduled Maintenance
  101
  - Daily (Walk-Around) Inspection
    101
  - Hours of Operation (Weekly)
    106
  - Hours of Operation (Two Weeks)
    109
  - Hours of Operation (Monthly)
    110
  - Hours of Operation (3 Months)
    113
  - 1000 Hours of Operation (6 Months)
    116
  - 2000 Hours of Operation (Yearly)
    121
- Miscellaneous Maintenance
  122
  - Batteries/Charging System
    122
  - Fuel System
    123
  - Fuse Replacement
    123
Section 7

125
- All Adjustments Must be Performed by a Qualified Mechanic
  125
  - Refer to the Service Manual for the Proper Procedures
    125
Section 8

127
- Lubricants and Capacities
  127
  - Engine Oil Specifications
    128
- Fuel Types
  129
  - Diesel Fuel
    129
- Gasoline
  129
  - Relief Valve Settings
    130
  - General Specifications
    130
    
    Engine
    130
    
    Tires
    130
    
    Electrical System
    130
    
    Boom
    130
    
    Wire Rope
    131
    
    Hydraulic System
    131
    
    Weight
    131
    
    Travel Speeds
    131
    
    Operating Dimensions
    131
  - Dimensions
    132

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