Manitowoc/Grove RT530E-2 Rough Terrain Cranes Service/Maintenance Manual (Ver. April 2015)

Manitowoc/Grove RT530E-2 Rough Terrain Cranes Service/Maintenance Manual

Type of machine: Rough Terrain Cranes
Print No: April 2015
Language and Format: English/PDF
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The Service/Maintenance Manual will give you complete information on repair, servicing and preventative maintenance, for your Manitowoc/Grove RT530E-2 Rough Terrain Cranes.

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Table of contents:
SECTION 1 – INTRODUCTION
Description
– List of Specifications
General
Dimensions
Capacities
Torque Converter/Transmission
Engine
Axles
Brakes
Wheels and Tires
Swing Gearbox
Boom
Swivel Assembly
Hydraulic Pumps
– General Maintenance
Cleanliness
Removal and Installation
Disassembly and Assembly
Pressing Parts
Locks
Wires and Cables
Shims
Bearings
Gaskets
Batteries
Hydraulic Systems
Electrical System
Fatigue of Welded Structures
Loctite
Fasteners and Torque Values
Weld Studs
– Wire Rope
General
Environmental Conditions
Dynamic Shock Loads
Lubrication
Precautions and Recommendations During
Inspection or Replacement
Wire Rope Inspection
(Running Ropes and Pendant Cables)
Wire Rope Inspection (Boom Extension and
Retraction Cables)
Wire Rope Inspection/Replacement
(All Wire Rope)
Seizing Wire Rope
Installing 35×7 Class Wire Rope
Procedures for Cutting and Preparing 35×7 Class
Wire Rope

SECTION 2 – HYDRAULIC SYSTEM
Description
– Maintenance
Hydraulic Oil Recommendations
Draining and Flushing
Removing Air from the Hydraulic System
Parts Replacement
Directional Control Valves
– Supply Pressure and Return Circuit
Description
Maintenance
– Oil Cooler
Description
– Hydraulic Pumps
Description
Maintenance
– Pressure Setting Procedures
Procedure A – For Checking/Setting The Main Control
Valve For Hoists(s), Boom Lift and Piston Pump
Procedure B – For Setting The Outrigger/Rear Steer/
Oil Cooler Motor Pressures
Procedure C – For Checking/Setting The Swing Directional
Control Valve Work Port Relief Valves
Procedure D – For Checking/Setting The Service
Brake Dual Accumulator Charge Valve Charging Limits
Procedure E – For Checking/Pre-Charging The
Service Brake Accumulators
Procedure F – For Checking/Setting the Front Steer Pressure
Procedure G – For Checking/Setting the Pilot Supply Pressure
Procedure H – For Checking/Setting The Swing Brake
Release Pressure
Procedure J – For Setting Threshold on Electronic Controllers
Procedure K – Setting Threshold and Max on Swing
Brake Pedal
Valves
General
– Directional Control Valves
Description
Maintenance
– Accessory With Swing Directional Control
Manifold
Description
Maintenance
– Steering Control Valve
Description
Maintenance
– Tandem Brake Valve with Treadle Pedal
Description
Maintenance
– Dual Accumulator Charge Valve
Description
Maintenance
– Hydraulic Accumulator Service Brake
Description
Maintenance
– Holding Valves
Description
Maintenance
– Cross Axle Differential Lock Valve
Description
Maintenance
– Outrigger Control Manifold
Description
Maintenance
– Pilot Operated Check Valve
Description
Maintenance
– Integrated Outrigger/Rear Steer Manifold
Description
Maintenance
– Check Valves
Description
Maintenance
– Range Shift/Parking Brake Valve
Description
Maintenance
– Axle Oscillation Lockout Valve (Standard Units)
Description
Maintenance
– Axle Oscillation Lockout Valve (Optional CE Units)
Description
Maintenance
– Cylinders
General
Maintenance
Surface Protection for Cylinder Rods
– Lift Cylinder
Description
Maintenance
– Dual Rod Telescope Cylinder
Description
Maintenance
– Axle Oscillation Lockout Cylinder
Description
Maintenance
– Steer Cylinder
Description
Maintenance
– Outrigger Extension Cylinder
Description
Maintenance
– Outrigger jack Cylinder
Description
Maintenance

SECTION 3 – ELECTRIC SYSTEM
– Description
General
Alternator
Batteries
Fuse Panel
Relays
– Maintenance
General
General Troubleshooting
Troubleshooting Swivel-Caused Electrical
Problems
Connector Troubleshooting
Troubleshooting Engine Starting Problems
Troubleshooting Engine Charging Problems
Troubleshooting Accessories
Alternator Replacement
Starter Replacement
Battery Replacement
Relay Panel Component Replacement
Rocker Switch Replacement
Ignition Switch Replacement
Turn Signal Lever and Transmission Shift Lever
Replacement
Windshield Wiper Assembly Replacement
Windshield Washer Assembly Replacement
Skylight Wiper Assembly Replacement
Appendix A: Crane Control System (CCS)
Fault Codes

SECTION 4 – BOOM
– Description
Theory Of Operation
Boom Extension
Boom Retraction
– Maintenance
Removal
– Boom Disassembly
Remove the Base Section
Disconnect Inner Mid Section
Remove the Inner Mid Section
Remove Outer Mid Section
Remove Telescope Cylinder
Boom Nose Sheaves
– Boom Assembly
Install Telescope Cylinder
Install Outer Mid Section
Install Inner Mid Section
Connect Inner Mid Section
Install Base Section
– Boom Installation
Functional Check
Inspection
Boom Alignment And Servicing
Boom Extension And Retraction Cable
Maintenance
Inspection
Extension Cable Adjustment
Retract Cable Adjustment
– Telescope Circuit
Description
Theory Of Operation
Maintenance
– Lift Circuit
Description
Theory Of Operation
Maintenance
– Swingaway Boom Extension
Description
Maintenance
– Hook Block
Description
Maintenance

SECTION 5 – HOIST AND COUNTERWEIGHT
– Description
Theory of Operation
– Maintenance
Warm-up Procedure
Removal
Installation
Functional Check
Servicing
Fluid Level
Usage and Inspection
Preventative Maintenance
Oil Sampling
Brake Test Procedure
Hoist to Boom Alignment
Preparation
Tools Required
Procedure
– Piston Motor and Control Valve
Description
Maintenance
Description
Maintenance
– Hoist Drum Rotation Indicator System
Description
Maintenance
– Counterweight Removal

SECTION 6 – SWING SYSTEM
– Introduction
Description
Theory of Operation
Maintenance
Troubleshooting
– Swing Motor
Description
Maintenance
– Swing Gearbox And Brake
Description
Maintenance
– Swing Bearing
Description
Maintenance
– Swivels
Description
Hydraulic Swivel
Electrical Swivel

SECTION 7 – POWER TRAIN
– Engine
Description
Maintenance
– Electronic Controls
Engine Control System Switches and Indicator
Lights
Fuel System
Description
Maintenance
– Air Intake and Exhaust System
Description
Air Intake
Charge-Air Cooler System
Muffler and Diesel Oxidation Catalyst – Tier 4
Interim
Slip Joint Exhaust Connectors
– Water Cooling System
Description
Maintenance
Test Equipment
Antifreeze/Coolant
Radiator Removal and Installation
– Drive Train
Description
Maintenance
Transmission/Torque Converter
Description
Theory of Operation
Maintenance
Servicing the Crane After Transmission/Torque
Converter Overhaul

SECTION 8 – UNDERCARRIAGE
– Axles
Description
Maintenance
Wheels and Tires
– Steering Systems
Description
Theory of Operation
Maintenance
Rear Steering System
Hydraulic Pumps
Front Steering Control Valve
Integrated Outrigger/Rear Steer Manifold
Steer Cylinders
– Rear Axle Oscillation Lockout System
Description
Axle Oscillation Lockout Cylinders
– Brake System
Description
Theory of Operation
Maintenance
– Service Brakes
Description
Maintenance
Corrosion Protection
– Parking Brake Actuator
Description
Maintenance
– Parking Brake
Description
Maintenance
– Park Brake Valve
Description
– Outriggers
Outrigger Circuit
Outrigger Beam
Extension Cylinder
Outrigger Monitoring System (Optional-Standard in North America)
Jack Cylinder
Outrigger Control Valves

SECTION 9 – LUBRICATION
– General
– Lubrication Intervals
Arctic Conditions Below -18°C (0°F)
Arctic Conditions Down To -40° C (-40°F)
Surface Protection For Cylinder Rods
– Wire Rope Lubrication
– Lubrication Points
CraneLUBE
Safety
Steering and Suspension
Axles
Drive Train
Drive Train (continued)
Outriggers
Turntable
Boom
Boom (continued)
Hoist
Hydraulic
– Carwell® Rust Inhibitor
Protecting Cranes From Rusting
Cleaning Procedures
Inspection and Repair
Application
Areas of Application