Sign In
Upload
Manuals
Brands
Manitowoc Manuals
Construction Equipment
Grove RT540E
Manitowoc Grove RT540E Manuals
Manuals and User Guides for Manitowoc Grove RT540E. We have
3
Manitowoc Grove RT540E manuals available for free PDF download: Service Maintenance Manual, Operator's Manual
Manitowoc Grove RT540E Service Maintenance Manual (322 pages)
Brand:
Manitowoc
| Category:
Construction Equipment
| Size: 15.5 MB
Table of Contents
Table of Contents
5
Section 1
13
Description
13
List of Specifications
14
General
14
Dimensions
14
Capacities
14
Torque Converter/Transmission
14
Engine
14
Axles
14
Brakes
14
Wheels and Tires
14
Swing Gearbox
14
General Maintenance
19
Cleanliness
19
Removal and Installation
19
Disassembly and Assembly
19
Pressing Parts
19
Locks
19
Wires and Cables
20
Shims
20
Bearings
20
Gaskets
20
Batteries
20
Hydraulic Systems
21
Electrical System
22
Fatigue of Welded Structures
22
Loctite
22
Fasteners and Torque Values
23
Weld Studs
26
Wire Rope
27
General
27
Environmental Conditions
27
Dynamic Shock Loads
27
Lubrication
27
Precautions and Recommendations During Inspection or Replacement
27
Wire Rope Inspection (Running Ropes and pendant Cables)
28
Wire Rope Inspection (Boom Extension and Retraction Cables)
29
Wire Rope Inspection/Replacement (All Wire Rope)
29
Seizing Wire Rope
30
Installing 35X7 Class Wire Rope
31
Procedures for Cutting and Preparing 35X7 Class Wire Rope
31
Section 2
33
Description
34
Maintenance
37
Hydraulic Oil Recommendations
37
Draining and Flushing
37
Removing Air from the Hydraulic System
38
Parts Replacement
38
Directional Control Valves
38
Supply Pressure and Return Circuit
40
Description
40
Maintenance
41
Oil Cooler
45
Description
45
Hydraulic Pumps
46
Description
46
Maintenance
46
Pressure Setting Procedures
49
Procedure a - Checking/Setting the Main Control Valve for Hoist(S), Boom Lift and Piston Pump
51
Procedure B - Setting the Outrigger/Rear Steer/Oil Cooler Motor Pressures
51
Procedure C - Checking/Setting the Swing Directional Control Valve Work Port Relief Valves
52
Procedure D - Checking/Setting the Service Brake Dual Accumulator Charge Valve Charging Limits
52
Procedure E - Checking/Pre-Charging the Service Brake Accumulators
52
Procedure F - Checking/Setting the Front Steer Pressure
53
Procedure G - Checking/Setting the Pilot Supply Pressure
53
Procedure H - Checking/Setting the Swing Brake Release Pressure
53
Procedure J - Setting Threshold on Electronic Controllers
53
Procedure K - Setting Threshold and Max on Swing Brake Pedal
54
Valves
59
General
59
Directional Control Valves
62
Description
62
Maintenance
62
Accessory with Swing Directional Control Manifold
65
Description
65
Maintenance
65
Steering Control Valve
67
Description
67
Maintenance
67
Tandem Brake Valve with Treadle Pedal
68
Description
68
Maintenance
68
Dual Accumulator Charge Valve
69
Description
69
Maintenance
69
Hydraulic Accumulator Service Brake
71
Description
71
Maintenance
71
Holding Valves
72
Description
72
Maintenance
72
Cross Axle Differential Lock Valve
73
Description
73
Maintenance
73
Outrigger Control Manifold
75
Description
75
Maintenance
75
Pilot Operated Check Valve
76
Description
76
Maintenance
76
Integrated Outrigger/Rear Steer Manifold
77
Description
77
Maintenance
77
Check Valves
80
Description
80
Maintenance
80
Range Shift/Parking Brake Valve
81
Description
81
Maintenance
81
Axle Oscillation Lockout Valve (Standard Units)
82
Description
82
Maintenance
82
Axle Oscillation Lockout Valve (Optional CE Units)
84
Description
84
Maintenance
84
Cylinders
86
General
86
Maintenance
86
Surface Protection for Cylinder Rods
86
Lift Cylinder
89
Description
89
Maintenance
89
Dual Rod Telescope Cylinder
92
Description
92
Maintenance
92
Axle Oscillation Lockout Cylinder
96
Description
96
Maintenance
96
Steer Cylinder
100
Description
100
Maintenance
100
Outrigger Extension Cylinder
103
Description
103
Maintenance
103
Outrigger Jack Cylinder
105
Description
105
Maintenance
105
Description
109
General
109
Batteries
109
Fuse Panel
110
Relays
111
Maintenance
112
General
112
General Troubleshooting
112
Troubleshooting Swivel-Caused Electrical Problems
112
Connector Troubleshooting
112
Troubleshooting Engine Starting Problems
113
Troubleshooting Engine Charging Problems
113
Troubleshooting Accessories
114
Electric System
114
Alternator Replacement
115
Starter Replacement
115
Battery Replacement
116
Relay Panel Component Replacement
116
Rocker Switch Replacement
116
Ignition Switch Replacement
117
Turn Signal Lever and Transmission Shift Lever Replacement
118
Windshield Wiper Assembly Replacement
120
Windshield Washer Assembly Replacement
121
Skylight Wiper Assembly Replacement
121
Appendix A: Crane Control System (CCS) Fault Codes
124
Section 4
147
Description
147
Safety
147
Boom System Components
148
Telescope Cylinder
148
Fly Section Extension Cables
148
Extend Synchronizing Cable
148
Fly Retraction Cables
148
Outer MID Retract Cables
148
Boom Extension Sequence
148
Boom Retract Sequence
150
Telescope Circuit
150
Description
150
Theory of Operation
150
Lift Circuit
150
General Maintenance Notes
151
Swingaway Extension Removable
151
Boom Removal
152
Disconnect the Base Section
153
Remove the Base Section
154
Disconnect the Inner MID Section
156
Remove the Inner MID Section
156
Remove the Outer MID Section
159
Remove the Tele Cylinder
160
Boom Nose Sheaves
161
Boom Nose Sheaves Removal
162
Boom Nose Sheaves Installation
162
Boom Assembly Procedure
163
Install Tele Cylinder
163
Install the Outer MID Section
166
Install the Inner MID Section
170
Install the Base Section
175
Final Boom Assembly
177
Swingaway Extension Installation
178
Tensioning the Boom Extend and Retract Cables
180
Boom Maintenance
182
Functional Test of the Boom
182
Boom Inspection
182
Boom Alignment and Servicing
182
Extension and Retraction Cable Maintenance
183
Inspection
183
Telescope Circuit Troubleshooting
184
Lift Circuit Troubleshooting
186
Lift Cylinder Maintenance
188
Lift Cylinder Removal
188
Lift Cylinder Disassembly and Assembly
188
Lift Cylinder Installation
188
Description
191
Theory of Operation
191
Maintenance
192
Warm-Up Procedure
192
Removal
192
Installation
193
Functional Check
193
Servicing
193
Hoist Maintenance and Inspection
194
Usage and Inspection
194
Pre-Use or Daily Inspection
195
Quarterly Inspection (Every Three Months)
195
Semi-Annual Inspections (Every Six Months)
195
Annual Inspection
195
Preventive Maintenance and Oil Sampling
195
Oil Change
195
Gear Oil Sampling and Analysis
195
Brake Test Procedure (to be Performed with no Load on the Hoist)
196
Brake Test Procedure for Hp15C-17G
196
17G, Ho30A-19G, Hp35-26G Hoists
196
Hoist to Boom Alignment
197
Preparation
197
Tools Required
197
Procedure
197
Piston Motor and Control Valve
198
Description
198
Maintenance
198
Idler Drum and Cable Follower
199
Description
199
Maintenance
199
Hoist Drum Rotation Indicator System
201
Description
201
Maintenance
201
Counterweight Removal
203
Introduction
205
Description
205
Theory of Operation
205
Description
206
Maintenance
207
Troubleshooting
207
Swing Motor
210
Description
210
Maintenance
210
Swing Gearbox and Brake
211
Description
211
Maintenance
211
Swing Bearing
213
Description
213
Maintenance
213
Swivels
218
Description
218
Hydraulic Swivel
220
Description
220
Electrical Swivel
222
Section 7
225
Engine
225
Description
225
Maintenance
226
Description
229
Fuel System
231
Description
231
Maintenance
231
Description
232
Air Intake and Exhaust System
233
Description
233
Air Intake
233
Charge-Air Cooler System
237
Muffler and Diesel Oxidation Catalyst - Tier 4 Interim
238
Slip Joint Exhaust Connectors
238
Water Cooling System
240
Description
240
Maintenance
240
Test Equipment
243
Antifreeze/Coolant
243
Radiator Removal and Installation
243
Drive Train
245
Description
245
Maintenance
245
Transmission/Torque Converter
245
Theory of Operation
245
Maintenance
246
Servicing the Crane after Transmission/Torque Converter Overhaul
249
Axles
251
Description
251
Maintenance
252
Wheels and Tires
257
Description
257
Maintenance
257
Steering Systems
260
Description
260
Theory of Operation
260
Rear Steering System
260
Hydraulic Pumps
263
Front Steering Control Valve
263
Integrated Outrigger/Rear Steer Manifold
263
Steer Cylinders
264
Rear Axle Oscillation Lockout System
265
Description
265
Axle Oscillation Lockout Cylinders
265
Brake System
266
Description
266
Theory of Operation
266
Maintenance
267
Service Brakes
268
Description
268
Maintenance
268
Corrosion Protection
272
Parking Brake Actuator
274
Description
274
Maintenance
274
Parking Brake
275
Description
275
Maintenance
275
Park Brake Valve
277
Description
277
Outriggers
277
Outrigger Circuit
277
Outrigger Beam
281
Extension Cylinder
285
Jack Cylinder
286
Outrigger Control Valves
288
General
289
Environmental Protection
289
Lubrication Intervals
289
Arctic Conditions below -18°C (0°F)
289
Arctic Conditions down to -40°F
290
Surface Protection for Cylinder Rods
290
Wire Rope Lubrication
291
Lubrication Points
292
Cranelube
292
Safety
292
Steering and Suspension
293
Axles
295
Drive Train
297
Drive Train (Continued)
299
Outriggers
301
Turntable
303
Boom
305
Boom (Continued)
307
Hoist
309
Hydraulic
311
Carwell® Rust Inhibitor
313
Protecting Cranes from Rusting
313
Cleaning Procedures
313
Inspection and Repair
314
Application
314
Areas of Application
314
Advertisement
Manitowoc Grove RT540E Operator's Manual (160 pages)
Brand:
Manitowoc
| Category:
Construction Equipment
| Size: 4.31 MB
Table of Contents
Table of Contents
13
Section 1
17
Noise/Vibration Test Results
17
Noise Level Test Results
17
Vibration Level Test Results
17
Customer Support
17
List of Specifications
18
General
18
Dimensions
18
Capacities
18
Torque Converter/Transmission
18
Engine
18
Axles
18
Brakes
18
Wheels and Tires
18
Swing Gearbox
18
Serial Number Location
20
Section 2
23
Safety Messages
23
General
24
Safety Alert Symbol
24
Signal Words
24
Accidents
24
Operator Information
24
Warning Signs
24
Operator Qualifications
25
Operational Aids
26
Rated Capacity Limiter (RCL) Systems (if Equipped)
26
Anti-Two-Blocking Device
26
Rated Capacity Limiter (RCL) Systems (if
26
Working Area Limiter (if Equipped)
27
Crane Stability/Structural Strength
27
Working Area Limiter
27
Load Charts
28
Work Site
28
Wind Forces
29
Wind Speeds
29
Lifting Operations
42
Counterweight
43
Outrigger Lift off
43
Multiple Crane Lifts
43
Tilt-Up Panel Lifting
43
Pile Driving and Extracting
44
Crane Equipment
44
Crane Inspection
44
Electrocution Hazard
45
Set-Up and Operation
46
Electrocution Hazard Devices
46
Electrical Contact
47
Special Operating Conditions and Equipment
47
Personnel Handling
47
Environmental Protection
48
Maintenance
49
Service and Repairs
49
Lubrication
50
Tires
50
Wire Rope
50
Hoist Rope
50
Sheaves
52
Batteries
52
Synthetic Hoist Rope
52
Engine
53
Transporting the Crane
53
Travel Operation
53
Work Practices
54
Personal Considerations
54
Crane Access
54
Job Preparation
55
Working
55
Lifting
56
Hand Signals
57
Boom Extension
59
Parking and Securing
59
Shut-Down
59
Cold Weather Operation
59
Jib
59
Temperature Effects on Hook Blocks
60
Temperature Effects on Hydraulic Cylinders
60
Crane Specific Information
62
Overload Inspection
62
Boom Inspection
63
Superstructure Inspection
65
Carrier Inspection
67
Controls and Indicators
70
Steering Column
70
Turn Signal Lever and Windshield Wiper/Washer/Horn Controls
71
Steering Column Tilt Lever
71
Park Brake Control Switch
71
Headlights Switch
71
Drive Axle Selector Switch
71
Hazard Lights Switch
71
Increment/Decrement Switch
71
Ignition Switch
71
Transmission Shift Lever
72
Cab Overhead Controls
72
Skylight Window Latch
72
Skylight Wiper and Wiper Motor
72
Skylight Sunscreen
72
Dome Light
72
Cab Circulating Fan
72
Right Side Window Latch
72
Overhead Control Panel
73
Skylight Wiper Switch
73
Heater/Air Conditioner Fan Speed Switch
73
Heater Control Switch
73
Air Conditioner Switch
73
Work Lights Switch
73
Crane Function Power Switch
73
Exhaust System Cleaning Switch
74
Diesel Particulate Filter
75
Inhibit Regeneration
75
Diesel Exhaust Fluid (Tier 4 Engines-2014 and Later Only)
75
High Exhaust System Temperature
75
Diesel Exhaust Fluid
75
Control Seat Assembly
76
Boom Lift/Main Hoist Control Lever (Dual Axis)
76
Swing/Telescope or Swing/Auxiliary Hoist Control Lever (Dual Axis)
77
Main Hoist Enable Switch
77
Boom up Bypass Switch (Optional)
77
Lift Function Enable Switch
77
Jog Dial
77
Outrigger Function Enable Switch
77
Differential Lock On/Off Switch (Optional)
77
Rear Steer Switch
77
Auxiliary Hoist Enable Switch (Optional)
77
Boom Telescope Enable Switch
77
Seat Slide Lever
78
Air Conditioner/Heater Climate Unit
78
Armrest Adjustment Knobs
78
Seat Height Adjustment Lever
78
Rated Capacity Limiter (RCL) Bypass Switch
78
Emergency Stop Switch
78
Level Indicator
78
Deadman Switches (Optional) (Dual Axis Joysticks Only)
78
Hoist High Speed Toggle Switches
78
Horn Button
78
Operating Procedures
79
Pre-Starting Checks
79
Cold Weather Operation
80
Engine Operation
81
Crane Travel Operation
82
General Crane Operation
88
Crane Functions
90
Stowing and Parking
95
Unattended Crane
95
Crane Control System (CCS)
96
Crane Control System (CCS) Display
96
Menu Control
96
Turntable Lock Control (Pin Type)
97
Sensors
97
CCS Main Screen Symbols and Icons
97
CCS Menu Screen
99
CCS Operation Display
101
Menu Screen
101
Rated Capacity Limiter (RCL) System
102
Mode of Operation
102
Outrigger Operation Menu
103
RCL Setup Wizard
105
Switch to RCL Home Screen Display
107
Foot Pedal Controls
108
360° Swing Lock Pedal
108
Swing Brake Pedal
108
Telescope Control Pedal (Optional)
108
Service Brake Pedal
108
Foot Throttle Pedal
108
Miscellaneous Controls and Indicators
108
Fuse Panel
108
Buzzer
108
RCL Emergency Override Switch (Non-CE Certified Cranes)
109
RCL Emergency Override Switch and Indicator (CE Certified Cranes)
109
RCL Internal Light Bar (Optional)
110
Strobe Light or Beacon (Optional) (Not
110
Backup Alarm
110
Emergency Exit
110
Appendix A: Crane Control System (CCS) Symbols and Icons
111
General
115
Installing Cable on the Hoist
115
Anti Two Block (A2B) Switch
116
Lock
116
Unlock
116
Before Operation
116
Cable Reeving
118
Dead-End Rigging/Wedge Sockets
122
Installing Wedge and Socket
122
Dead-End Rigging
123
Erecting and Stowing the Boom Extension
124
General Warnings
124
Erecting
124
Stowing
126
Setting the Offset
127
Changing Boom Extension from Telescoping Type to Fixed Type
127
Setting the Telescoping Extension Length
128
Counterweights
128
Section 5
131
General
131
Environmental Protection
131
Lubrication Intervals
131
Standard Lubricants
132
Arctic Conditions
133
Below -18°C (0°F)
133
Arctic Conditions down to -40°C (-40°F)
133
Surface Protection for Cylinder Rods
135
Wire Rope Lubrication
135
Lubrication Points
135
Cranelube
135
Safety
135
Steering and Suspension
136
Axles
138
Drive Train
140
Drive Train (Continued)
142
Outriggers
144
Turntable
146
Boom
148
Boom (Continued)
150
Hoist
152
Hydraulic
154
General
157
Instructions
157
Daily or 10 Hour Check List
157
Weekly or 50 Hour Check List
158
Manitowoc Grove RT540E Operator's Manual (144 pages)
Brand:
Manitowoc
| Category:
Construction Equipment
| Size: 6.53 MB
Table of Contents
Table of Contents
13
Section 1
17
Noise/Vibration Test Results
17
Noise Level Test Results
17
Vibration Level Test Results
17
Customer Support
17
List of Specifications
19
General
19
Dimensions
19
Capacities
19
Torque Converter/Transmission
19
Engine
19
Axles
19
Brakes
19
Wheels and Tires
19
Swing Gearbox
19
Serial Number Location
21
Section 2
25
Safety Messages
25
General
26
Safety Alert Symbol
26
Signal Words
26
Accidents
26
Operator Information
26
Operator Qualifications
27
Operational Aids
28
Rated Capacity Limiter (RCL) Systems (if Equipped)
28
Anti-Two-Blocking Device
28
Working Area Limiter (if Equipped)
29
Crane Stability/Structural Strength
29
Load Charts
30
Work Site
30
Wind Forces
30
Lifting Operations
31
Counterweight
32
Outrigger Lift off
32
Multiple Crane Lifts
32
Pile Driving and Extracting
33
Crane Equipment
33
Crane Inspection
33
Electrocution Hazard
33
Set-Up and Operation
35
Electrocution Hazard Devices
35
Electrical Contact
36
Special Operating Conditions and Equipment
36
Personnel Handling
36
Environmental Protection
37
Maintenance
37
Service and Repairs
38
Lubrication
39
Tires
39
Wire Rope
39
Sheaves
40
Batteries
41
Engine
41
Transporting the Crane
41
Travel Operation
42
Work Practices
43
Personal Considerations
43
Crane Access
43
Job Preparation
43
Working
43
Lifting
44
Hand Signals
45
Boom Extension
47
Parking and Securing
47
Shut-Down
47
Cold Weather Operation
47
Temperature Effects on Hook Blocks
48
Temperature Effects on Hydraulic Cylinders
48
Crane Specific Information
50
Overload Inspection
50
Boom Inspection
51
Superstructure Inspection
53
Carrier Inspection
55
Section 3
57
Controls and Indicators
58
Steering Column
58
Turn Signal Lever and Windshield Wiper/Washer/Horn Controls
59
Steering Column Tilt Lever
59
Park Brake Control Switch
59
Headlights Switch
59
Drive Axle Selector Switch
59
Hazard Lights Switch
59
Increment/Decrement Switch
59
Ignition Switch
59
Transmission Shift Lever
60
Cab Overhead Controls
60
Skylight Window Latch
60
Skylight Wiper and Wiper Motor
60
Skylight Sunscreen
60
Dome Light
60
Cab Circulating Fan
60
Right Side Window Latch
60
Overhead Control Panel
61
Skylight Wiper Switch
61
Heater/Air Conditioner Fan Speed Switch
61
Heater Control Switch
61
Air Conditioner Switch
61
Work Lights Switch
61
Boom Lights Switch (Optional)
61
Crane Function Power Switch
61
Control Seat Assembly
62
Boom Lift/Main Hoist Control Lever (Dual Axis)
62
Swing/Telescope or Swing/Auxiliary Hoist Control Lever (Dual Axis)
63
Main Hoist Enable Switch
63
Boom up Bypass Switch (Optional)
63
Lift Function Enable Switch
63
Jog Dial
63
Outrigger Function Enable Switch
63
Differential Lock On/Off Switch (Optional)
63
Rear Steer Switch
63
Auxiliary Hoist Enable Switch (Optional)
63
Boom Telescope Enable Switch
63
Air Conditioner/Heater Climate Unit
64
Seat Slide Lever
64
Armrest Adjustment Knobs
64
Seat Height Adjustment Lever
64
Rated Capacity Limiter (RCL) Bypass Switch
64
Emergency Stop Switch
64
Level Indicator
64
Deadman Switches (Optional) (Dual Axis Joysticks Only)
64
Hoist High Speed Toggle Switches
64
Horn Button
64
Operating Procedures
65
Pre-Starting Checks
65
Cold Weather Operation
66
Engine Operation
66
Crane Travel Operation
67
General Crane Operation
73
Crane Functions
75
Stowing and Parking
80
Unattended Crane
80
Crane Control System (CCS)
81
Crane Control System (CCS) Display
81
Menu Control
81
Turntable Lock Control (Pin Type)
82
Sensors
82
CCS Main Screen Symbols and Icons
83
CCS Menu Screen
85
CCS Operation Display
87
Menu Screen
87
Rated Capacity Limiter (RCL) System
88
Mode of Operation
88
Outrigger Operation Menu
89
RCL Setup Wizard
91
Switch to RCL Home Screen Display
93
Foot Pedal Controls
94
360° Swing Lock Pedal
94
Swing Brake Pedal
94
Telescope Control Pedal (Optional)
94
Service Brake Pedal
94
Foot Throttle Pedal
94
Miscellaneous Controls and Indicators
94
Fuse Panel
94
Buzzer
94
RCL Emergency Override Switch (Non-CE Certified Cranes)
95
RCL Emergency Override Switch and Indicator (CE Certified Cranes)
95
RCL Internal Light Bar (Optional)
96
Strobe Light or Beacon (Optional) (Not Shown)
96
Backup Alarm (Not Shown)
96
Emergency Exit
96
Appendix A: Crane Control System (CCS) Symbols and Icons
97
General
101
Installing Cable on the Hoist
101
Cable Reeving
102
Dead-End Rigging/Wedge Sockets
106
Installing Wedge and Socket
106
Dead-End Rigging
107
Erecting and Stowing the Boom Extension
108
General Warnings
108
Erecting
108
Stowing
110
Setting the Offset
111
Changing Boom Extension from Telescoping Type to Fixed Type
111
Setting the Telescoping Extension Length
112
Counterweights
112
Section 5
115
Environmental Protection
115
Lubrication Intervals
115
Standard Lubricants
116
Arctic Conditions
116
Below -18°C (0°F)
116
Arctic Conditions down to -40°C (-40°F)
116
Surface Protection for Cylinder Rods
118
Wire Rope Lubrication
118
Lubrication Points
118
Cranelube
118
Safety
118
Steering and Suspension
119
Axles
121
Drive Train
123
Drive Train (Continued)
125
Outriggers
127
Turntable
129
Boom
131
Boom (Continued)
133
Hoist
135
Hydraulic
137
General
139
Instructions
139
Daily or 10 Hour Check List
139
Weekly or 50 Hour Check List
140
Advertisement
Advertisement
Related Products
Manitowoc Grove RT530E-2
Manitowoc Grove RT9150E
Manitowoc Grove RT890E
Manitowoc Grove RT9130E
Manitowoc GROVE RT650E
Manitowoc Grove RT9130E-2
Manitowoc Grove RT880E
Manitowoc Grove RT765E-2
Manitowoc Grove RT770E
Manitowoc Grove GMK4070E
Manitowoc Categories
Construction Equipment
Ice Maker
Accessories
Dispenser
Kitchen Appliances
More Manitowoc Manuals
Login
Sign In
OR
Sign in with Facebook
Sign in with Google
Upload manual
Upload from disk
Upload from URL