Grove Crane RT540E Service Manual 101-00 – PDF DOWNLOAD

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Grove Crane RT540E Service Manual 101-00 – PDF DOWNLOAD

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Grove Crane RT540E Service Manual 101-00 – PDF DOWNLOAD

Language : English
Pages : 280
Downloadable : Yes
File Type : PDF

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DESCRIPTION:

Grove Crane RT540E Service Manual 101-00 – PDF DOWNLOAD

INTRODUCTION:
DESCRIPTION:

• This Manual provides information for the maintenance of the Model RT540E Series Grove Crane.
  The lift capacities are listed on the Load Chart in the cab.
• The crane incorporates an all welded parallel box construction steel frame, using planetary
  drive axles to provide four-wheel drive. Axle steering is accomplished utilizing hydraulic steer
  cylinders. The engine is mounted at the rear of the crane carrier and provides motive power through
  a six speed forward and reverse transmission.
• The carrier frame incorporates an integral fifth wheel, to which the rear axle is mounted, to
  provide axle oscillation. Axle oscillation lockout is automatic when the superstructure rotates
  from the travel position.
• The superstructure is capable of 360 degree rotation in either direction. All crane functions are
  controlled from the fully- enclosed cab mounted on the superstructure. The crane is equipped with a
  four-section, full power, sequenced and synchronized boom. Additional reach is obtained by
  utilizing an optional swingaway boom extension. Lifting is provided
  by a main hoist and an optional auxiliary hoist.

TABLE OF CONTENTS:

Grove Crane RT540E Service Manual 101-00 – PDF DOWNLOAD

SECTION 1 INTRODUCTION
SECTION 2 HYDRAULIC SYSTEM
SECTION 3 ELECTRIC SYSTEM
SECTION 4 BOOM
SECTION 5 HOIST AND COUNTERWEIGHT
SECTION 6 SWING SYSTEM
SECTION 7 POWER TRAIN
SECTION 8 UNDERCARRIAGE
SECTION 9 LUBRICATION

SECTION 1 Introduction 1
Description 1-1
List of Specifications 1-1
General 1-1
Dimensions 1-1
Capacities 1-1
Torque Converter/Transmission 1-1
Engine 1-1
Axles 1-1
Brakes 1-1
Wheels and Tires 1-1
Swing Gearbox 1-2
Boom 1-2
Swivel Assembly 1-2
Hydraulic Pumps 1-2
General Maintenance 1-6
Cleanliness 1-6
Removal and Installation 1-6
Disassembly and Assembly 1-7
Pressing Parts 1-7
Locks 1-7
Wires and Cables 1-7
Shims 1-7
Bearings 1-7
Gaskets 1-8
Batteries 1-8
Hydraulic Systems 1-8
Electrical System 1-9
Fatigue of Welded Structures 1-9
Loctite 1-10
Fasteners and Torque Values 1-10
Dynamic Shock Loads 1-11
Wire Rope 1-14
General 1-14
Environmental Conditions 1-14
Lubrication 1-14
Precautions and Recommendations During Inspection or Replacement 1-15
Wire Rope Inspection (Running Ropes and Pendant Cables) 1-15
Wire Rope Inspection (Boom Extension and Retraction Cables) 1-16
Wire Rope Replacement (All Wire Rope) 1-16
Seizing Wire Rope 1-17
Installing FLEX-X 35 Wire Rope 1-17
Procedures for Cutting and Preparing FLEX-X 35 1-18
SECTION 2 Hydraulic System 1
Description 2-1
Maintenance 2-4
Hydraulic Oil Recommendations 2-4
Draining and Flushing 2-4
Removing Air from the Hydraulic System 2-5
Parts Replacement 2-5
Directional Control Valves 2-5
Supply Pressure and Return Circuit 2-7
Description 2-7
Maintenance 2-8
Oil Cooler 2-12
TABLE OF CONTENTS RT540E
TOC-2 Published 2-20-2007, Control # 101-00
Description 2-12
Hydraulic Pumps 2-13
Description 2-13
Maintenance 2-13
Pressure Setting Procedures 2-16
Procedure A – For Checking/Setting The Main Control Valve For Hoists(s), Boom Lift and Piston Pump
2-17
Procedure B – For Setting The Outrigger/Rear Steer/Oil Cooler Motor Pressures 2-18
Procedure C – For Checking/Setting The Swing Directional Control Valve Work Port Relief Valves2-18
Procedure D – For Checking/Setting The Service Brake Dual Accumulator Charge Valve Charging Limits
2-18
Procedure E – For Checking/Pre-Charging The Service Brake Accumulators 2-18
Procedure F – For Checking/Setting the Front Steer Pressure 2-19
Procedure G – For Checking/Setting the Pilot Supply Pressure 2-19
Procedure H – For Checking/Setting the Swing Brake Release Pressure 2-19
Valves 2-24
General 2-24
Directional Control Valves 2-27
Description 2-27
Maintenance 2-27
Accessory With Swing Directional Control Manifold 2-30
Description 2-30
Maintenance 2-30
Steering Control Valve 2-32
Description 2-32
Maintenance 2-32
Tandem Brake Valve with Treadle Pedal 2-33
Description 2-33
Maintenance 2-33
Dual Accumulator Charge Valve 2-35
Description 2-35
Maintenance 2-35
Hydraulic Accumulator Service Brake 2-37
Description 2-37
Maintenance 2-37
Holding Valves 2-38
Description 2-38
Maintenance 2-38
Cross Axle Differential Lock Valve 2-39
Description 2-39
Maintenance 2-39
Outrigger Control Manifold 2-40
Description 2-40
Maintenance 2-40
Pilot Operated Check Valve 2-42
Description 2-42
Maintenance 2-42
Integrated Outrigger/Rear Steer Manifold 2-43
Description 2-43
Maintenance 2-43
Check Valves 2-46
Description 2-46
Maintenance 2-46
Range Shift/Parking Brake Valve 2-47
Description 2-47
Maintenance 2-47
Axle Oscillation Lockout Valve (Standard Units) 2-48
Description 2-48
Maintenance 2-48
Axle Oscillation Lockout Valve (Optional CE Units) 2-50
Description 2-50
Maintenance 2-50
Cylinders 2-52
General 2-52
Maintenance 2-52
Surface Protection for Cylinder Rods 2-52
Lift Cylinder 2-54
Description 2-54
Maintenance 2-54
Dual Rod Telescope Cylinder 2-57
Description 2-57
Maintenance 2-57
Axle Oscillation Lockout Cylinder 2-61
Description 2-61
Maintenance 2-61
Steer Cylinder 2-65
Description 2-65
Maintenance 2-65
Outrigger Extension Cylinder 2-68
Description 2-68
Maintenance 2-68
Outrigger Stabilizer Cylinder 2-71
Description 2-71
Maintenance 2-71
SECTION 3 Electric System 1
Description 3-1
General 3-1
Alternator 3-1
Batteries 3-1
Fuse Panel 3-2
Relays 3-2
Maintenance 3-3
General 3-3
General Troubleshooting 3-3
Troubleshooting Swivel-Caused Electrical Problems 3-3
Connector Troubleshooting 3-3
Troubleshooting Engine Starting Problems 3-3
Troubleshooting Engine Charging Problems 3-4
Troubleshooting Accessories 3-4
Alternator Replacement 3-5
Starter Replacement 3-6
Battery Replacement 3-6
Relay Panel Component Replacement 3-6
Instrument Replacement 3-7
Switch Replacement 3-7
Windshield Wiper Assembly Replacement 3-8
Windshield Washer Assembly Replacement 3-9
Skylight Wiper Assembly Replacement 3-9
SECTION 4 Boom 1
Description 4-1
Safety 4-1
TABLE OF CONTENTS RT540E
TOC-4 Published 2-20-2007, Control # 101-00
Telescope Cylinder 4-1
Fly Section Extension Cables 4-1
Extend Synchronizing Cable 4-1
Fly Retraction Cables 4-1
Outer Mid Retract Cables 4-1
Boom Extension Sequence 4-1
Boom Retract Sequence 4-1
Swingaway Extension Removable 4-3
Boom Removal 4-4
Disconnect the Base Section 4-5
Remove the Base Section 4-6
Disconnect the Inner Mid Section 4-7
Remove the Inner Mid Section 4-8
Remove the Outer Mid Section 4-10
Remove the Tele Cylinder 4-12
Boom Nose Sheaves 4-13
Boom Nose Sheaves Removal 4-13
Boom Nose Sheaves Installation 4-13
Boom Assembly Procedure 4-14
Install Tele Cylinder 4-15
Install the Outer Mid Section 4-17
Install the Inner Mid Section 4-21
Install the Base Section 4-27
Boom Cable Adjustment 4-29
Extend Cable Adjustment 4-29
Retract Cable Adjustment 4-30
Check cables to insure that they are tightened equally 4-30
Functional Test Of The Boom 4-30
Boom Inspection 4-31
Boom Alignment And Servicing 4-31
Extension And Retraction Cable Maintenance 4-31
Inspection 4-31
Telescope Circuit 4-33
Description 4-33
Theory Of Operation 4-33
General Maintenance Notes 4-33
Telescope Circuit Troubleshooting 4-34
Lift Circuit 4-36
Description 4-36
Theory Of Operation 4-36
Lift Circuit Troubleshooting 4-36
Lift Cylinder Removal 4-38
Lift Cylinder Disassembly And Assembly 4-38
Lift Cylinder Installation 4-38
SECTION 5 Hoist And Counterweight 1
Description 5-1
Theory of Operation 5-1
Maintenance 5-1
Warm-up Procedure 5-1
Removal 5-1
Installation 5-2
Functional Check 5-3
Servicing 5-3
Hoist to Boom Alignment 5-3
Preparation 5-3
Tools Required 5-3
Procedure 5-3
Piston Motor and Control Valve 5-5
Description 5-5
Maintenance 5-5
Idler Drum and Cable Follower 5-6
Description 5-6
Maintenance 5-6
Hoist Drum Rotation Indicator System 5-9
Description 5-9
Maintenance 5-9
Counterweight Removal 5-11
SECTION 6 Swing System 1
Introduction 6-1
Description 6-1
Theory of Operation 6-1
Maintenance 6-3
Troubleshooting 6-3
Swing Motor 6-6
Description 6-6
Maintenance 6-6
Swing Gearbox And Brake 6-7
Description 6-7
Maintenance 6-7
Swing Bearing 6-9
Description 6-9
Maintenance 6-9
Swivels 6-14
Description 6-14
Hydraulic Swivel 6-16
Electrical Swivel 6-18
SECTION 7 Power Train 1
Engine 7-1
Description 7-1
Maintenance 7-1
Electronic Controls 7-6
Engine Wait To Start Indicator/Transmission Service Indicator (XMSN) 7-6
Engine Warning/Electrical System Diagnostic Indicator 7-6
Engine Stop/Module Off Line Indicator 7-6
Fuel System 7-7
Description 7-7
Maintenance 7-7
Air Intake System 7-9
Description 7-9
Maintenance 7-9
Water Cooling System 7-14
Description 7-14
Maintenance 7-14
Test Equipment 7-17
Antifreeze/Coolant 7-18
Radiator Removal and Installation 7-18
Drive Train 7-19
Description 7-19
Maintenance 7-19
TABLE OF CONTENTS RT540E
TOC-6 Published 2-20-2007, Control # 101-00
Transmission/Torque Converter 7-19
Description 7-19
Theory of Operation 7-19
Maintenance 7-20
Servicing the Crane After Transmission/Torque Converter Overhaul 7-23
SECTION 8 Undercarriage 1
Axles 8-1
Description 8-1
Maintenance 8-1
Wheels and Tires 8-5
Steering Systems 8-7
Description 8-7
Theory of Operation 8-7
Maintenance 8-8
Rear Steering System 8-9
Hydraulic Pumps 8-10
Front Steering Control Valve 8-10
Integrated Outrigger/Rear Steer Manifold 8-10
Steer Cylinders 8-11
Rear Axle Oscillation Lockout System 8-12
Description 8-12
Axle Oscillation Lockout Cylinders 8-12
Brake System 8-13
Description 8-13
Theory of Operation 8-13
Maintenance 8-14
Service Brakes 8-15
Description 8-15
Maintenance 8-15
Corrosion Protection 8-19
Parking Brake Actuator 8-21
Description 8-21
Maintenance 8-21
Parking Brake 8-22
Description 8-22
Maintenance 8-22
Park Brake Valve 8-23
Description 8-23
Outriggers 8-25
Outrigger Circuit 8-25
Outrigger Beam 8-28
Extension Cylinder 8-32
Stabilizer Cylinder 8-33
Outrigger Control Valves 8-35
Table of Contents 9-i
SECTION 9 Lubrication 1
General 9-1
Arctic Conditions Below -18°C (0°F) 9-1
Lubrication Points 9-1
Surface Protection For Cylinder Rods 9-1
Safety 9-2
Steering & Suspension Lubrication 9-3
Axle Lubrication 9-3
Drive Train Lubrication 9-8
Published 2-20-2007, Control # 101-00 TOC-7
Outrigger Lubrication 9-8
Turntable Lubrication 9-9
Lift Cylinder Lubrication 9-9
Boom Lubrication 9-9
Hoist Lubrication 9-11
Hydraulic Lubrication 9-11
Fuel Filter 9-11
Air Cleaner Filter 9-11
Wire Rope Lubrication 9-11

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