Grove RT540E

Service/Maintenance Manual

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345
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 1
SERVICE MANUAL
This Manual has been prepared for and is considered part of -

RT540E 2
Crane Model Number

This Manual is divided into the following Sections:

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

7
SECTION 9 LUBRICATION
45
NOTICE 5
The crane serial number is the only method your distributor or the factory
3
has of providing you with correct parts and service information.
23

The crane serial number is stamped on the top of the outrigger box.
Always furnish crane serial number when ordering parts or 6
communicating service problems with your distributor or the factory.

! DANGER
An untrained operator subjects himself and others to death or
7

serious injury. Do not operate this crane unless:

• You are trained in the safe operation of this crane. Manitowoc is not
responsible for qualifying personnel. 8
• You read, understand, and follow the safety and operating
recommendations contained in the crane manufacturer’s manuals and
load charts, your employer’s work rules, and applicable government
regulations.
• You are sure that all safety signs, guards, and other safety features are 9
in place and in proper condition.
• The Operator Manual and Load Chart are in the holder provided on
crane.

© 2014 Manitowoc Crane Group

Published 2-26-2014, Control # 414-03
 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.

7
45
CALIFORNIA
3

PROPOSITION 65 WARNING
Battery posts, terminals, and related accessories contain
23

chemical lead and lead compounds, chemicals known to

the State of California to cause cancer, birth defects or
other reproductive harm. Wash hands after handling.

The original language of this publication is English.

RT540E SERVICE MANUAL TABLE OF CONTENTS

See end of this Manual for Alphabetical Index

SECTION 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INTRODUCTION
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
List of Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Torque Converter/Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 T
Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Swing Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Boom. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
O
Swivel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Hydraulic Pumps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 C
General Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Pressing Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Locks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

7
Wires and Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Shims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
45
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Gaskets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Hydraulic Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
3

Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

23

Fatigue of Welded Structures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Loctite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Fasteners and Torque Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Weld Studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
Environmental Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
Dynamic Shock Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
Precautions and Recommendations During Inspection or Replacement . . . . . . . . 1-15
Wire Rope Inspection (Running Ropes and Pendant Cables) . . . . . . . . . . . . . . . . 1-16
Wire Rope Inspection (Boom Extension and Retraction Cables) . . . . . . . . . . . . . . 1-17
Wire Rope Inspection/Replacement (All Wire Rope) . . . . . . . . . . . . . . . . . . . . . . . 1-17
Seizing Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
Installing 35x7 Class Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
Procedures for Cutting and Preparing 35x7 Class Wire Rope . . . . . . . . . . . . . . . . 1-19

SECTION 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HYDRAULIC SYSTEM

Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Hydraulic Oil Recommendations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Draining and Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Removing Air from the Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Parts Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Directional Control Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Supply Pressure and Return Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

GROVE TOC-1
TABLE OF CONTENTS RT540E SERVICE MANUAL

Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Hydraulic Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Pressure Setting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Procedure A - Checking/Setting the Main Control Valve for Hoist(s), Boom Lift
and Piston Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Procedure B - Setting The Outrigger/Rear Steer/Oil Cooler Motor Pressures . . . 2-20
Procedure C - Checking/Setting the Swing Directional Control Valve Work Port
Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
Procedure D - Checking/Setting the Service Brake Dual Accumulator Charge
Valve Charging Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
Procedure E - Checking/Pre-Charging the Service Brake Accumulators . . . . . . . 2-21
Procedure F - Checking/Setting the Front Steer Pressure . . . . . . . . . . . . . . . . . . 2-21
Procedure G - Checking/Setting the Pilot Supply Pressure. . . . . . . . . . . . . . . . . . 2-21
Procedure H - Checking/Setting the Swing Brake Release Pressure . . . . . . . . . . 2-21
Procedure J - Setting Threshold on Electronic Controllers . . . . . . . . . . . . . . . . . . 2-22
Procedure K - Setting Threshold and Max on Swing Brake Pedal . . . . . . . . . . . . 2-23
Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28
Directional Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31

7
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31
45
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31
Accessory With Swing Directional Control Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34
3

Steering Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37

Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37
23

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37
Tandem Brake Valve with Treadle Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38
Dual Accumulator Charge Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40
Hydraulic Accumulator Service Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42
Holding Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43
Cross Axle Differential Lock Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44
Outrigger Control Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46
Pilot Operated Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47
Integrated Outrigger/Rear Steer Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48
Check Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51

TOC-2
RT540E SERVICE MANUAL TABLE OF CONTENTS

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51
Range Shift/Parking Brake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52
Axle Oscillation Lockout Valve (Standard Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53
Axle Oscillation Lockout Valve (Optional CE Units). . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56
T
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56
Surface Protection for Cylinder Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56 O
Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-59
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-59
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-59
C
Dual Rod Telescope Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62
Axle Oscillation Lockout Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66

7
Steer Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-70
45
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-70
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-70
Outrigger Extension Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-73
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-73
3

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-73
Outrigger Stabilizer Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-75
23

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-75
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-75

SECTION 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ELECTRIC SYSTEM

Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Fuse Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
General Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Troubleshooting Swivel-Caused Electrical Problems . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Connector Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Troubleshooting Engine Starting Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Troubleshooting Engine Charging Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Troubleshooting Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Alternator Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Starter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Battery Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Relay Panel Component Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Gauge Cluster Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Rocker Switch Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Ignition Switch Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

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TABLE OF CONTENTS RT540E SERVICE MANUAL

Turn Signal Lever and Transmission Shift Lever Replacement. . . . . . . . . . . . . . . 3-11

Windshield Wiper Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Windshield Washer Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Skylight Wiper Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

SECTION 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BOOM
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Boom System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Telescope Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Fly Section Extension Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Extend Synchronizing Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Fly Retraction Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Outer Mid Retract Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Boom Extension Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Boom Retract Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Telescope Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Theory Of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Lift Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Theory Of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

7
General Maintenance Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Swingaway Extension Removable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
45
Boom Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Disconnect the Base Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Remove the Base Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Disconnect the Inner Mid Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
3

Remove the Inner Mid Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Remove the Outer Mid Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
23

Remove the Tele Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

Boom Nose Sheaves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Boom Nose Sheaves Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Boom Nose Sheaves Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Boom Assembly Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Install Tele Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Install the Outer Mid Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Install the Inner Mid Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
Install the Base Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
Final Boom Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31
Swingaway Extension Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
Tensioning the Boom Extend and Retract Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
Boom Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36
Functional Test Of The Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36
Boom Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36
Boom Alignment And Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36
Extension And Retraction Cable Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37
Telescope Circuit Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38
Lift Circuit Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40
Lift Cylinder Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42
Lift Cylinder Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42
Lift Cylinder Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42
Lift Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42

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RT540E SERVICE MANUAL TABLE OF CONTENTS

SECTION 5 . . . . . . . . . . . . . . . . . . . . . . . HOIST AND COUNTERWEIGHT

Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Warm-up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Functional Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
hoist maintenance and inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Usage and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Pre-Use or Daily Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Quarterly Inspection (every three months) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
T
Semi-Annual Inspections (every six months) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Annual Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 O
Preventive Maintenance And Oil Sampling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Gear Oil Sampling and Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
C
Brake Test Procedure For Hp15c-17g, Ho30a-19g, Hp35-26g Hoists . . . . . . . . . . . . . . 5-7
Brake Test Procedure (To be performed with no load on the hoist) . . . . . . . . . . . . . 5-7
Hoist to Boom Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

7
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Piston Motor and Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
45
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Idler Drum and Cable Follower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
3

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Hoist Drum Rotation Indicator System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
23

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Counterweight Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15

SECTION 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SWING SYSTEM

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

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TABLE OF CONTENTS RT540E SERVICE MANUAL

SECTION 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . POWER TRAIN

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Electronic Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Engine Control System Switches and Indicator Lights . . . . . . . . . . . . . . . . . . . . . . 7-7
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Air Intake and Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
Air Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
Charge-Air Cooler System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
Muffler and Diesel Oxidation Catalyst - Tier 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
Slip Joint Exhaust Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
Water Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
Antifreeze/Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
Radiator Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
Drive Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23

7
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
Transmission/Torque Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
45
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24
Servicing the Crane After Transmission/Torque Converter Overhaul . . . . . . . . . . 7-27
3

SECTION 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UNDERCARRIAGE
23

Axles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Wheels and Tires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
Steering Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
Rear Steering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
Hydraulic Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
Front Steering Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
Integrated Outrigger/Rear Steer Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
Steer Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14
Rear Axle Oscillation Lockout System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
Axle Oscillation Lockout Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16
Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17
Service Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18
Corrosion Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22
Parking Brake Actuator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24

TOC-6
RT540E SERVICE MANUAL TABLE OF CONTENTS

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24
Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-25
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-25
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-25
Park Brake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27
Outriggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27
Outrigger Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27
Outrigger Beam. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-31
Extension Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-35
Stabilizer Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-36
Outrigger Control Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-38
T
SECTION 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LUBRICATION O
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Environmental Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Lubrication Intervals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
C
Arctic Conditions Below -18°C (0°F). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Arctic Conditions Down To -40°F.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Surface Protection for Cylinder Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Wire Rope Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4

7
CraneLUBE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
45
Steering and Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
Drive Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
Drive Train (continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11
3

Outriggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13
Turntable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15
23

Boom. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-17
Boom (continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-19
Hoist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-21
Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-23
Carwell® Rust Inhibitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-25
Protecting Cranes From Rusting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-25
Cleaning Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-25
Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-26
Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-26
Areas of Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-26

GROVE TOC-7
TABLE OF CONTENTS RT540E SERVICE MANUAL

7
45
THIS PAGE BLANK
3
23

TOC-8
RT540E SERVICE MANUAL INTRODUCTION

SECTION 1
1
INTRODUCTION

SECTION CONTENTS
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Batteries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
List of Specifications . . . . . . . . . . . . . . . . . . . . . . . 1-2 Hydraulic Systems . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Fatigue of Welded Structures . . . . . . . . . . . . . . . 1-10
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Loctite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Torque Converter/Transmission . . . . . . . . . . . . . . 1-2 Fasteners and Torque Values . . . . . . . . . . . . . . . 1-11
Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Weld Studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Wire Rope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Environmental Conditions . . . . . . . . . . . . . . . . . . 1-15
Swing Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Dynamic Shock Loads . . . . . . . . . . . . . . . . . . . . . 1-15
Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
Swivel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Precautions and Recommendations During
Hydraulic Pumps. . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Inspection or Replacement . . . . . . . . . . . . . . . . . 1-15

7
Wire Rope Inspection (Running Ropes and
General Maintenance . . . . . . . . . . . . . . . . . . . . . . . 1-7
Pendant Cables) . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
Cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
45
Wire Rope Inspection (Boom Extension and
Removal and Installation . . . . . . . . . . . . . . . . . . . 1-7 Retraction Cables) . . . . . . . . . . . . . . . . . . . . . . . . 1-17
Disassembly and Assembly . . . . . . . . . . . . . . . . . 1-7 Wire Rope Inspection/Replacement
Pressing Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 (All Wire Rope) . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
3

Locks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 Seizing Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . 1-18

Wires and Cables . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
23

Installing 35x7 Class Wire Rope . . . . . . . . . . . . . 1-19

Shims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 Procedures for Cutting and Preparing 35x7 Class
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
Gaskets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

DESCRIPTION The superstructure is capable of 360 degree rotation in either

direction. All crane functions are controlled from the fully-
This Manual provides information for the maintenance of the enclosed cab mounted on the superstructure. The crane is
Model RT540E Series Grove Crane. equipped with a four-section, full power, sequenced and
The lift capacities are listed on the Load Chart in the cab. synchronized boom. Additional reach is obtained by utilizing
an optional swingaway boom extension. Lifting is provided
T h e c r an e i n c o r p or at e s a n al l w el d e d par al l e l b o x by a main hoist and an optional auxiliary hoist.
construction steel frame, using planetary drive axles to
provide four-wheel drive. Axle steering is accomplished NOTE: Throughout this manual, reference is made to left,
utilizing hydraulic steer cylinders. The engine is mounted at right, front, and rear when describing locations.
the rear of the crane carrier and provides motive power When operating the crane, these reference
through a six speed forward and reverse transmission. locations are to be considered as those viewed
from the operator seat with the superstructure
The carrier frame incorporates an integral fifth wheel, to facing forward over the front of the carrier frame.
which the rear axle is mounted, to provide axle oscillation.
Axle oscillation lockout is automatic when the superstructure NOTE: Transportation and Lifting Decal is shown in
rotates from the travel position. (Figure 1-1).

GROVE Published 2-26-2014, Control # 414-03 1-1

INTRODUCTION RT540E SERVICE MANUAL

LIST OF SPECIFICATIONS Axles

Total Ratio. . . . . . . . . . . . . . . . . . . . . . . . . . 20.06:1
General Carrier Ratio . . . . . . . . . . . . . . . . . . . . . . . . . 5.57:1
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . .RT540E Wheel End Ratio. . . . . . . . . . . . . . . . . . . . . . 3.60:1
Rated Capacity . . . . . . . . . . See Load Chart in cab
Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 x 4 Brakes
Gross Weight . . . . . . . . . . . . . . . . See Axle Weight Type . . . . . . . . .Hydraulic/Split system acting on all
Distribution Table four wheels
Dimensions Wheels and Tires
NOTE: Dimensions listed are for a crane with all Lugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
components fully retracted in the travel mode with Torque. . . . . . . . . . . 461 to 488 Nm (340 - 360 lb-ft)
Tire Size
20.5 x 25-24 earthmover bias ply tires. Standard . . . . . . . . . . . .20.5 x 25-20 ply rating
Wheelbase . . . . . . . . . . . . . . . . . . . 3.66 m (144 in) For roading and lifting pressures, refer to the Load
Overall Crane Length . . . . . . . . .12.29 m (483.7 in) Chart Book in the cab.
Overall Crane Width . . . . . . . . . . . . 2.54 m (100 in)
Overall Crane Height . . . . . . . . . . . 3.24 m (127 in) Swing Gearbox
Tail-Swing . . . . . . . . . . . . . . . . . . . . 3.66 m (144 in)
Outrigger Spread Reduction Ratio . . . . . . . . . . . . . . . . . . . . . . . . 36:1
Retracted . . . . . . . . . . . . . . . 2.39 m (7 ft 10 in) Output Torque . . . . . . . . . . . . . . . . . . . . . 6680 lb-in
Mid Extend . . . . . . . . . . . . . . . . . 4.27 m (14 ft)
Fully Extended . . . . . . . . . . . . . . 6.10 m (20 ft) Boom
Length. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Capacities Retracted . . . . . . . . . . . . . . . . . . 9.8 m (32.2 ft)
Fuel Tank . . . . . . . . . . . . . . . . . . . . . .220 l (58 gal) Extended . . . . . . . . . . . . . . . . 31.0 m (101.7 ft)

7
Coolant System. . . . . . . . . . . . . . . . . . . See Engine Power . . . . . . . . . . . . . . . . . . 4 Section, Full Power
Specifications Elevation . . . . . . . . . . . . . . . . . . . -3 to +76 degrees
45 Extensions
Engine Lubrication System . . . . . . . . . . See Engine
Specifications Fixed Offsettable . . . . . . . . . . . . . .7.9 m (26 ft)
Hydraulic Tank (Reservoir Capacity) Folding* . . . . . . . . . . . . 7.6 - 13.7 m (25 - 45 ft)
Total . . . . . . . . . . . . . . . . . . . . . . 442 l (117 gal) *Extensions are offsettable at 0, 15, or 30
degrees.
3
at Full Level . . . . . . . . . . . . . . . .396 l (105 gal)
at Low Level. . . . . . . . . . . . . . . . .369 l (97 gal)
Expansion Space . . . . . . . . . . . . . .46 l (12 gal) Swivel Assembly
23

Hoists . . . . . . . . . . . . . . . . . . . . . . . . . .5.2 l (5.5 qt) Electrical . . . . . . . . . . . . . . . . . . . . . . . 20 Slip Rings

Swing Gearbox . . . . . . . . . . . . . . . . . . . 4 l (4.25 qt) Hydraulic. . . . . . . . . . . . . . . . . . . . . . . . . . . 14 ports
Axle Planetary Hubs . . . . . . . . . . . . . . .1.7 l (3.5 pt) Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ports
Axle Differentials . . . . . . . . . . . . . . . . . . 9.5 l (20 pt)
Transmission (includes Torque Converter) Hydraulic Pumps
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 l (25 qt)

Torque Converter/Transmission Pump #1

Stall Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . 2.024:1 NOTE: Pump output is theoretical @ no-load engine
Charge Pump Capacity . . . . . . .70 l/min (14.5 gpm) speed.
@ 2000 rpm
Gear Ratios Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston
Forward/Reverse Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Lo 1st . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.07 Output - @ 275.8 bar (4,000 psi) w/no load
Lo 2nd . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.64 Section 1 . . . . . . . . . . . 283.7 l/min (62.4 gpm)
Lo 3rd. . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.00
Hi 1st . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.05 Pump #2
Hi 2nd. . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.86
Hi 3rd . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.80 Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear
Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Output - @ 172.4 bar (2,500 psi) w/no load
Engine Section 1 . . . . . . . . . . . . 86.5 l/min (22.9 gpm)

Cummins QSB6.7 Pump #3

Displacement . . . . . . . . . . . . . . . . . 6.7 l (409 cu in) Type . . . . . . . . . . . . . Gear with priority flow divider
Firing Order. . . . . . . . . . . . . . . . . . . . . . 1-5-3-6-2-4 Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Lube Amount. . . . . . . . . . . . . . . . . . .17.5 l (18.5 qt) Output - @ 199.9 bar (2,900 psi) w/no load
Coolant System. . . . . . . . . . . . . . . . . . 28.5 l (30 qt) Section 1 . . . . . . . . . . . . 57.2 l/min (15.1 gpm)

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RT540E SERVICE MANUAL INTRODUCTION

Hoists Length-Aux. . . . . . . . . . . . . . . . .137 m (450 ft)

Drum Dimensions
Max. Permissible Line Pull (6x36)
. . . . . . . . . . . . . . . . . . . . . . . . . .52.4 kN (11,770 lb)
1
Diameter . . . . . . . . . . . . . . . 270 mm (10.63 in) Max. Single Line Speed . . . .156.7 m/min (514 fpm)
Length (Standard) . . . . . . . . 415 mm (16.34 in) Hoist Motor Displacement
Cable
Diameter . . . . . . . . . . . . . . . . . . . . mm (5/8 in) Low . . . . . . . . 107 cm3 (6.53 in3) per revolution
Length-Main . . . . . . . . . . . . . . . 137 m (450 ft) High . . . . . . . . 61 cm3 (3,72 in3) per revolution

7
3 45
23

FIGURE 1-1

Table 1-1
Axle Weight Distribution Table

CG From Rear Weight Front Axle Rear Axle

Description
Axle cm (in) kg (lb) kg (lb) kg (lb)
Basic Unit
Maximum Axle Loads Allowed 16783 (37000) 16783 (37000)
Maximum Axle Loads Allowed while Towing 14969 (33000) 14969 (33000)
Maximum Tire Loads Allowed 15604 (34400) 15604 (34400)
Standard Carrier Assy. 4 x 4; Plus all Fluids 158.83 (62.53) 12451 (27449) 5406 (11919) 7044 (15530)
Superstructure w/Cab Plus w/Main Hoist 68.66 (27.03) 3862 (8514) 725 (1598) 3137 (6916)
Pinned on Counterweight -119.38 (-47.00) 4305 (9490) -1405 (-3097) 5709 (12587)
Boom Assembly; w/(2/4) Sheaves, RCL,
464.82 (183.00) 5954 (13126) 7566 (16681) -1613 (-3555)
Pivot Pins

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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; front and rear axles; 170.36 (67.07) 27209 (59986) 12674 (27940) 14536 (32046)
20.5 x 25 tires; main hoist
w/137 m (450 ft) of 5/8 in. 6 X 37 cable; full
fuel and hydraulic oil
Add To Basic Unit Weight
7.9 to 13.7 m (26 to 45 ft) Tele Boom
616.36 (242.66) 745 (1642) 1255 (2767) -510 (-1125)
Extension
Boom Ext. Carrier Brackets (Bolt On) 543.56 (214.00) 116 (256) 172 (380) -56 (-124)
1018.95
Auxiliary Boom Nose - Installed 48 (105) 133 (293) -85 (-188)
(401.16)
36 metric ton (40 ton) CE Hookblock (4 - 14
396.24 (156.00) 351 (774) 381 (839) -29 (-65)
in sheaves) Stowed in Tray
36 metric ton (40 ton) Hookblock (3 - 14 in
396.24 (156.00) 283 (623) 306 (675) -24 (-52)
sheaves) Stowed in Tray

7
36 metric ton (40 ton) Hookblock (3 -12 in
396.24 (156.00) 272 (599) 294 (649) -23 (-50)
sheaves) Stowed in Tray
45
7 metric ton (7.5 Ton) Headache Ball
581.66 (229.00) 167 (369) 266 (587) -99 (-218)
(Swivel) - Attached to Front O/R Box
Storage Tray Mats 337.82 (133.00) 20 (43) 18 (40) 1 (3)
3

Rear Mounted Pintle Hook -162.56 (-64.00) 5 (11) -2 (-5) 7 (16)

23

Driver Controlled Differential Locks 177.80 (70.00) 19 (41) 9 (20) 10 (21)

Russian Certification Package 127.00 (50.00) 28 (61) 10 (21) 18 (40)
Air Conditioning - Carrier and superstructure
38.10 (15.00) 44 (98) 5 (10) 40 (88)
components
360 Degree Swing Lock 205.74 (81.00) 29 (64) 16 (36) 13 (28)
Driver 187.96 (74.00) 113 (250) 58 (128) 55 (122)
CE Components - w Main Hoist 10.16 (4.00) 285 (628) 8 (17) 277 (611)
CE Components - w Main & Aux Hoists 15.24 (6.00) 274 (603) 11 (25) 262 (578)
Remove: Auxiliary Hoist Cable (453 ft) of 5/8
-121.92 (-48.00) -179 (-394) 59 (131) -238 (-525)
35 x 7
Remove: Main Hoist Cable (450 ft) of 5/8 6 X
-60.96 (-24.00) -174 (-383) 29 (64) -203 (-447)
37
Add: Aux Hoist (Replace IPO Cwt With Aux
-109.22 (-43.00) 174 (383) -52 (-114) 225 (497)
Hoist and Cable)
Sub: Optional Cable on Main Hoist (453 ft of
-60.96 (-24.00) 5 (11) -1 (-2) 6 (13)
5/8 inch 35 X 7)
Sub: Tier 3 Engine -157.48 (-62.00) -17 (-37) 7 (16) -24 (-53)
Sub: Kessler Axles 175.26 (69.00) -86 (-190) -41 (-91) -45 (-99)
Sub: 16.00 X 25 Titan Tires 182.88 (72.00) -64 (-140) -32 (-70) -32 (-70)

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RT540E SERVICE MANUAL INTRODUCTION

1
1

7
3 45 3

2
3

2
23

4 8047-2

Item Description
1 Cab
2 Outrigger Float
3 Outrigger Jack Cylinder
4 Steps
5 Valve Cover
6 Counterweight

FIGURE 1-2

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INTRODUCTION RT540E SERVICE MANUAL

3
1 2 6
4
5

7
8046-1

11 10
8
9 8 FIGURE 1-2 continued

Item Description Item Description

1 Counterweight 7 Swingaway
2 Auxiliary Hoist 8 Outrigger Jack Cylinder

7
3 Main Hoist 9 Front Axle
4 Boom Pivot 10 Hydraulic Tank
45
5 Lift Cylinder 11 Rear Axle
6 Boom Nose Sheaves
3

4
23

1 3 5
2

6
9 7
8 6812-2
4
FIGURE 1-2 continued

Item Description Item Description

1 Swingaway 6 Auxiliary Hoist
2 Boom 7 Main Hoist
3 Stinger 8 Cab
4 Outrigger Stabilizer 9 Boom Nose
5 Counterweight

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RT540E SERVICE MANUAL INTRODUCTION

GENERAL MAINTENANCE 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. 1
i ns t r u c t io n s i n th i s m a nu a l . I n a n al y z i ng a s y s te m When using hoisting equipment, follow the hoist
malfunction, use a systematic procedure to locate and manufacturers recommendations and use lifting devices that
correct the problem. will allow you to achieve the proper balance of the
assemblies being lifted and to ensure safe handling. Unless
1. Determine the problem. otherwise specified, all removals requiring hoisting
2. List possible causes. equipment should be accomplished using an adjustable
lifting attachment. All supporting members (chains and
3. Devise checks.
cables) should be parallel to each other and as near
4. Conduct checks in a logical order to determine the perpendicular as possible to the top of the object being lifted.
cause.
5. Consider the remaining service life of components
against the cost of parts and labor necessary to replace CAUTION
them. The capacity of an eyebolt diminishes as the angle
between the supporting members and the object
6. Make the necessary repair.
becomes less than 90. Eyebolts and brackets should
7. Recheck to ensure that nothing has been overlooked. never be bent and should only have stress in tension.
8. Functionally test the failed part in its system.
Some removals require the use of lifting fixtures to obtain
NOTE: Your safety and that of others is always the number proper balance. The weights of some components are given
one consideration when working around machines. in their respective sections of the manual.

7
Safety is a matter of thoroughly understanding the
If a part resists removal, check to be certain all nuts and bolts
job to be done and the application of good common
45 have been removed and that an adjacent part is not
sense. It is not just a matter of do’s and don’ts. Stay
interfering.
clear of all moving parts.
Disassembly and Assembly
Cleanliness
3

When assembling or disassembling a component or system,

An important item in preserving the long life of the machine is
23

complete each step in turn. Do not partially assemble one

keeping dirt out of working parts. Enclosed compartments,
part and start assembling some other part. Make all
seals, and filters have been provided to keep the supply of
adjustments as recommended. Always check the job after it
air, fuel, and lubricants clean. It is important that these
is completed to see that nothing has been overlooked.
enclosures be maintained.
Recheck the various adjustments by operating the machine
Whenever hydraulic, fuel, lubricating oil lines, or air lines are before returning it to the job.
disconnected, clean the adjacent area as well as the point of
disconnect. As soon as the disconnection is made, cap, plug, Pressing Parts
or tape each line or opening to prevent entry of foreign
When pressing one part into another, use an anti-seize
material. The same recommendations for cleaning and
compound or a molybdenum disulfide base compound to
covering apply when access covers or inspection plates are
lubricate the mating surfaces.
removed.
Assemble tapered parts dry. Before assembling parts with
Clean and inspect all parts. Be sure all passages and holes
tapered splines, be sure the splines are clean, dry, and free
are open. Cover all parts to keep them clean. Be sure parts
from burrs. Position the parts together by hand to mesh the
are clean when they are installed. Leave new parts in their
splines before applying pressure.
containers until ready for assembly.
Parts which are fitted together with tapered splines are
Clean the rust preventive compound from all machined
always very tight. If they are not tight, inspect the tapered
surfaces of new parts before installing them.
splines and discard the part if the splines are worn.
Removal and Installation Locks
When performing maintenance, do not attempt to manually
Lockwashers, flat metal locks, or cotter pins are used to lock
lift heavy parts when hoisting equipment should be used.
nuts and bolts.
Never locate or leave heavy parts in an unstable position.
When raising a portion of a crane or a complete crane,

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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
the other end against one flat surface of the nut or bolt head. Lubricate new or used bearings before installation. Bearings
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. When installing a
moving parts. bearing, spacer, or washer against a shoulder on a shaft, be
Wh en insta lling loc kwashe rs o n ho usings made of sure the chamfered side is toward the shoulder.
aluminum, use a flat washer between the lockwasher and When pressing bearings into a retainer or bore, uniformly
the housing. apply pressure to the outer race. If the bearing is pressed on
the shaft, uniformly apply pressure on the inner race.
Wires and Cables
Batteries should always be disconnected prior to working on Preload
the electrical system. Preload is an initial load placed on the bearing at the time of
When removing or disconnecting a group of wires or cables, assembly. Whether a tapered roller bearing should have
tag each one to ensure proper identification during assembly. preload could depend on any of several conditions: rigidity of
the housings and shaft, bearing spread, speed of operation,
Shims etc.

When shims are removed, tie them together and identify To determine whether a bearing requires preload or end
them as to location. Keep shims clean and flat until they are c l e ar a nc e , c on s u l t t h e d i s a s s em b l y a n d a s s e m b l y
reinstalled. instructions pertaining to that bearing.
Care should be exercised in applying preload. Misapplication
Bearings of preload to bearings requiring end clearance can result in

7
bearing failure.
Antifriction Bearings
45
When an anti friction bearing is removed, cover it to keep out Sleeve Bearings
dirt and abrasives. Wash bearings in non-flammable Do not install sleeve bearings with a hammer. Use a press
cleaning solution and allow them to drain dry. The bearing and be sure to apply the pressure directly in line with the
3

may be dried with compressed air BUT do not spin the bore. If it is necessary to drive on a bearing, use a bearing
bearing. Discard the bearings if the races and balls or rollers
23

driver or a bar with a smooth flat end. If a sleeve bearing has

are pitted, scored, or burned. If the bearing is serviceable, an oil hole, align it with the oil hole in the mating part.
coat it with oil and wrap it in clean waxed paper. Do not
unwrap new bearings until time of installation. The life of an Gaskets
anti friction bearing will be shortened if not properly
lubricated. Dirt in an anti friction bearing can cause the Be sure the holes in the gaskets correspond with the
bearing to lock resulting in the shaft turning in the inner race lubricant passages in the mating parts. If it is necessary to
or the outer race turning within the cage. make gaskets, select material of the proper type and
thickness. Be sure to cut holes in the right places. Blank
Double Row, Tapered Roller gaskets can cause serious damage.

Double row, tapered roller bearings are precision fit during When removed, always install new cylinder head and
manufacture and components are not interchangeable. The manifold gaskets using recommended gasket compound on
cups, cones, and spacers are usually etched with the same head gaskets to allow uniform sealing.
serial number and letter designator. If no letter designators
are found, wire the components together to assure correct Batteries
installation. Reusable bearing components should be Clean batteries by scrubbing them with a solution of baking
installed in their original positions. soda and water. Rinse with clear water. After cleaning, dry
thoroughly and coat terminals and connections with an anti
Heating Bearings corrosion compound or grease.
Bearings which require expansion for installation should be If the machine is to be stored or not used for an extended
heated in oil not to exceed 121 °C (250 °F). When more than period of time, the batteries should be removed. Store the
one part is heated to aid in assembly, they must be allowed batteries in a cool (not subfreezing), dry place, preferably on
to cool and then pressed together again. Parts often wooden shelves. Never store on concrete. A small charge
separate as they cool and contract. should be introduced periodically to keep the specific gravity
rating at recommended level.

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RT540E SERVICE MANUAL INTRODUCTION

Hydraulic Systems Sealing Elements

Inspect all sealing elements (O-ring, gaskets, etc.) when
1
disassembling and assembling the hydraulic system
components. Installation of new elements is always
DANGER recommended.
Exercise extreme care around pressurized hydraulic
systems. Do not work on a hydraulic system while it is in Hydraulic Lines
operation or until all pressure is released.
When installing metal tubes, tighten all bolts finger-tight.
Then, in order, tighten the bolts at the rigid end, the
Cleanliness adjustable end, and the mounting brackets. After tubes are
Contaminants in a hydraulic system affect operation and will mounted, install the hoses. Connect both ends of the hose
result in serious damage to the system components. Dirty with all bolts finger-tight. Position the hose so it does not rub
hydraulic systems are a major cause of component failures. the machine or another hose and has a minimum of bending
and twisting. Tighten bolts in both couplings.
Keep the System Clean Due to manufacturing methods there is a natural curvature to
When removing components of a hydraulic system, cover all a hydraulic hose. The hose should be installed so any bend
openings on both the component and the crane. is with this curvature.

If evidence of foreign particles is found in the hydraulic Visual Inspection of Hoses and Fittings
system, flush the system.
Disassemble and assemble hydraulic components on a
CAUTION

7
clean surface.
Ensure that the hydraulic hose is depressurized before
Clean all metal parts in a nonflammable cleaning fluid. Then
45
loosening the connections.
lubricate all components to aid in assembly.
Table 1-2
3

Zone Classification
23

A Tropical Moist: All months average above 18°C. Latitude 15° - 25° North and South
B Dry or Arid: Deficient precipitation most of the year. Latitude: 20° - 35° North and South
C Moist Mid-Latitude: Temperature with mild winters. Latitude: 30° - 50° North & South
D Moist Mid-latitude: Cold winters. Latitude 50° - 70° North & South
E Polar: Extremely cold winters and summers. Latitude: 60° - 75° North & South

1. 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.
a. Leaks at hose fitting or in hose 2. At the same service interval, visually inspect all other
hydraulic components and valves for the following:
b. Damaged, cut, or abraded cover
a. Leaking Ports
c. Exposed reinforcement
b. Leaking valve sections or manifolds and valves
d. Kinked, crushed, flattened, or twisted hose
installed into cylinders or onto motors.
e. Hard, stiff, heat cracked, or charred hose
c. Damaged or missing hose clamps, guard, or
f. Blistered, soft, degraded, or loose cover shields.
g. Cracked, damaged, or badly corroded fittings d. Excessive dirt and debris around the hose
assemblies.
h. Fitting slippage on hose
If any of these conditions exist, address them appropriately.
i. Other signs of significant deterioration
3. All hydraulic hose assemblies are recommended to be
If any of the above conditions exist, evaluate hose
replaced after 8000 hours of service life.
assemblies for correction or replacement. For replacement

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INTRODUCTION RT540E SERVICE MANUAL

4. Hydraulic hose assemblies operating in a temperature the application, and the experience of the operators and
climate zone “C” (Table 1-2) are recommended to be maintenance personnel.The following are known high stress
replaced after 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
5. Hydraulic hose assemblies operating in climate zones
planned preventive maintenance program:
“A” and “B” (Table 1-2) with high ambient temperatures,
could see hose service life reduced by 40 to 50%, 1. Power Telescope Boom - wear pad retaining structures,
therefore, it is recommended to replace these hoses hydraulic cylinder attaching points, boom pivot shaft
after 4000 to 5000 hours of service life. retaining structures.
6. Hydraulic hose assemblies operating in climate zones 2. Outrigger pads, beams, boxes and attachment
“D” and “E” (Table 1-2) cold climates should expect a structures.
degrade of mechanical properties such as elasticity,
3. Main frames - generally in the area of doubler plates and
therefore, it is recommended these hoses be inspected
crossmembers; at the junction of front and rear frame
and addressed accordingly.
members on truck cranes.
Electrical System 4. Turntable bearing connection (where bearing is welded
to the crane superstructure or chassis).
Connectors, Harnesses, Wires, and
5. Counterweight support structures.
Connectors
6. Chassis axle and suspension mounting structures.
Visually inspect all electrical harnesses, cables, and
connectors every month or 250 hours for the following: 7. Hydraulic cylinder end connections.

• Damaged, cut, blistered, or cracked insulation. The above is provided only as a guide, and your inspection

7
plan should not be limited to the areas listed. A thorough
• Exposed bare wires. visual inspection of all weldments is good practice.
45
• Kinked or crushed wires and cables. Anyone requiring more detailed inspection instructions and/
• Cracked or corroded connectors, battery terminals, and or repair procedures may request them by contacting the
ground connections. local Manitowoc/Grove distributor.
3

If any the above conditions exist, evaluate and replace as Loctite

23

necessary.
The climate in which the crane operates affects the service
life of the electrical components. The climate zones are
defined in (Table 1-2). Recommended replacement of DANGER
harness and cables is as follows: Loctite type adhesives contain chemicals that may be
harmful if misused. Read and follow the instructions on
• Climate zone C after 10,000 hours of service.
the container.
• Climate zones A and C with high ambient temperatures
and duty cycles after 8000 hours of service. Always follow the directions on the Loctite container as not
all Loctite types are suitable for all applications.Various types
• Climate zones D and E after 10,000 hours of service.
of Loctite are specified throughout the Service Manual.The
• Salt water conditions after 8,000 hours of service. following types of Loctite brand adhesives are available from
the Parts Department of the local Manitowoc/Grove
Fatigue of Welded Structures distributor.
Experience has shown that highly stressed welded Application of Medium Strength Loctite
structures when repeatedly subjected to varying stresses
caused by twisting, shock, bending, and intentional and/or NOTE: The fastener may be re-used; the adhesive may be
unintentional overloads, often become subject to weld re-applied over cured adhesive residue.
cracking which may be attributed to fatigue of the welded
The following procedure covers the proper application and
joint. This condition is not uncommon in construction
curing method for medium strength Loctite adhesive/sealant
equipment.
(Loctite #243) and primer (Locquic Primer T7471).
Equipment should be periodically inspected for evidence of
Primer Application
weld fatigue. The frequency of these inspections should be
commensurate with the age of the equipment, the severity of NOTE: It is not necessary to bathe the threads in primer.

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RT540E SERVICE MANUAL INTRODUCTION

1. Ensure the threaded surface, both male and female, is be made to component overhaul procedures for
clean and free of dirt and oil. Apply a light spray coating recommendations. 1
of primer to both male and female parts to be joined to
Special attention should be given to the existence of
clean and accelerate the curing process.
lubricant, plating, or other factors that might require variation
2. Allow the part to dry prior to adhesive/sealant from standard torque values.
application.
The use of lubricants on zinc-flake coated parts shall be
Adhesive/Sealant Application prohibited since this will change the required torque value.
When maximum recommended torque values have been
Bead Application exceeded, the fastener should be replaced.
Previously installed bolts and nuts of Grade 8 or Class 10.9
and higher may not be reused.
When referring to the applicable torque charts, use values as
close as possible to the torque values shown to allow for
4203
wrench calibration tolerance.
FIGURE 1-3
Torque Wrenches
1. Apply a bead perpendicular to the thread, several Flexible beam type wrenches, even though they might have
threads wide, in the approximate area of threaded a pre-set feature, must be pulled at right angle and the force
engagement (Figure 1-3). must be applied at the center of the handle. Force value
2. In a blind hole application, a bead of several drops of readings must be made while the tool is in motion. Rigid
handle type, with torque limiting devices that can be pre-set

7
adhesive should be applied into the bottom of the hole to
be hydraulically forced up during engagement. to required values, eliminate dial readings and provide more
reliable, less variable readings.
45
3. After application and engagement of mated threads,
fixturing will occur within five (5) minutes if primed prior NOTE: If multipliers and/or special tools are used to reach
to engagement. Fixturing may take up to 30 minutes on hard to get at areas, ensure torque readings are
accurate.
3
unprimed parts.
4. Time required to achieve full strength is 24 hours. Torque wrenches are precision instruments and must be
23

Maximum ultimate strength is achieved using no primer handled with care. To ensure accuracy, calibrations must be
with this specific threadlocking adhesive. made on a scheduled basis. Whenever there is a possibility
that a torque wrench may have been either overstressed or
Fasteners and Torque Values damaged, it should immediately be removed from service
until recalibrated. When using a torque wrench, any erratic or
Use bolts of the correct length. A bolt which is too long may jerking motion can result in the application of excessive or
bottom before the head is tight against the part it is to hold. If improper torque. ALWAYS use a slow, even movement and
a bolt is too short, there may not be enough threads engaged STOP when the predetermined value has been reached.
to hold the part securely. Threads can be damaged. Inspect
them and replace fasteners, as necessary. When using step wrenches, calculated wrench settings are
valid only when the following conditions are met:
Torque values should correspond to the type bolts, studs,
and nuts being used. • Torque wrenches must be those specified and forces
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.
• All handles must be parallel to the step wrench during
Use of proper torque values is extremely important. Improper final tightening. Multiplier reaction bars may be
torquing can seriously affect performance and reliability. misaligned no more than 30 degrees without causing
serious error in torque.
Identification of fastener grade is always necessary. When
marked as a high strength bolt (grade 5, 8, etc.), the • Multiplier bar handles must be propped or supported
mechanic must be aware that he/she is working with a highly within the outer 1/4 of the handle length, or serious
stressed component and the fastener should be torqued under or over tightening will occur.
accordingly.
To convert pounds-foot (lb-ft) of torque to newton meters
NOTE: Some special applications require variation from (Nm), multiply the pounds-foot quantity by 1.3558.
standard torque values. Reference should always

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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.

SAE Grade 1 SAE Grade 5 SAE Grade 7 SAE Grade 8

and Grade 2 HHCS HHCS HHCS
HHCS

Socket Head Socket Head Serrated

Capscrew Shoulder Flange Head
Screw

7
FIGURE 1-4
45
Table 1-3: UNC (Coarse) Thread: Torque Values for Zinc-Flake Coated and Untreated Fasteners

Bolt Diameter - Inches

3

Torque Values (Pounds-Foot, Maximum/Minimum)

23

SAE Grade 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1 1-1/8 1-1/4 1-1/2
5 7 14 25 40 61 88 121 213 342 512 636 884 1532
Zinc-Flake
8 10 20 36 57 86 124 171 301 483 723 1032 1433 2488
9.0 19 32 52 78 114 156 270 416 606 813 1141 2028
5
7.7 17 30 48 72 106 144 249 384 560 751 1053 1865
Untreated
12.5 26 48 73 120 161 234 385 615 929 1342 2043 3276
8
11.5 24 44 67 110 143 216 355 567 857 1234 1885 3024

NOTE: Studs shall be torqued using capscrew values when grade is known.

Table 1-4: UNF (Fine) Thread: Torque Values for Zinc-Flake Coated and Untreated Fasteners

Bolt Diameter - Inches

Torque Values (Pounds-Foot, Maximum/Minimum)
SAE Grade 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1 1-1/8 1-1/4 1-1/2
5 8 15 28 44 66 95 132 229 364 543 785 944 1654
Zinc-Flake
8 11 22 39 61 94 134 186 323 514 766 1109 1530 2682
10 21 36 57 88 126 182 312 458 658 882 1251 2288
5
9 19 34 53 81 116 167 287 421 606 814 1155 2105
Untreated
14.5 26 53 85 125 177 250 425 672 1009 1500 2092 3640
8
13.5 24 49 79 115 163 230 393 620 931 1380 1925 3360

NOTE: Studs shall be torqued using capscrew values when grade is known.

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RT540E SERVICE MANUAL INTRODUCTION

Table 1-5: Metric Fasteners, Coarse Thread, Zinc-Flake Coating

Bolt Diameter - Metric

1
Torque Values (Nm)
Class M4 M5 M6 M8 M10 M12 M14 M16 M18 M20 M22 M24 M27 M30 M33 M36
8.8 2.6 5.2 9.0 21.6 42.4 73.1 116 178 250 349 467 600 877 1195 1608 2072
10.9 3.7 7.5 12.5 31.5 62.0 110 170 265 365 520 700 900 1325 1800 2450 3150
12.9 4.3 9.0 15.0 36.0 75.0 128 205 315 435 615 830 1060 1550 2125 2850 3700

Table 1-6: Metric Fasteners, Coarse Thread, Untreated

Bolt Diameter - Metric

Torque Values (Nm, Maximum/Minimum)
Class M4 M5 M6 M7 M8 M10 M12 M14 M16 M18 M20 M22 M24 M27 M30
3.1 6.5 11 19 27 53 93 148 230 319 447 608 774 1134 1538
8.8
2.8 5.9 10 17 25 49 85 136 212 294 413 562 714 1046 1420
4.5 9.2 16 26 38 75 130 212 322 455 629 856 1089 1591 2163
10.9
4.1 8.5 14 24 35 69 120 195 298 418 581 790 1005 1469 1997
5.4 11 19 31 45 89 156 248 387 532 756 1029 1306 1910 2595
12.9
4.9 10 17 28 42 83 144 228 357 490 698 949 1206 1763 2395

Table 1-7: Metric Fasteners, Fine Thread, Zinc-Flake Coating

7
45
Bolt Diameter - Metric
Torque Values (Nm)
3

Class M8x1 M10x1 M10x1.25 M12x1.5 M14x1.5 M16x1.5 M18x1.5 M20x1.5 M22x1.5 M24x2 M27x2 M30x2 M33x2 M36x3
23

8.8 23 46 44 75 123 185 270 374 496 635 922 1279 1707 2299
10.9 34 71 66 113 188 285 415 575 770 980 1425 2025 2500 3590
12.9 41 84 79 135 220 335 485 675 900 1145 1675 2375 2900 4200

Table 1-8: Metric Fasteners, Fine Thread, Untreated

Bolt Diameter - Metric

Torque Values (Nm, Maximum/Minimum)
Class M8x1 M10x1 M10x1.25 M12x1.5 M14x1.5 M16x1.5 M18x1.5 M20x1.5 M22x1.5 M24x2 M27x2 M30x2 M33x2 M36x3
29 57 57 100 160 248 345 483 657 836 1225 1661 — —
8.8
27 53 53 92 147 229 318 446 607 771 1130 1534 — —
41 81 81 1140 229 348 491 679 924 1176 1718 2336 — —
10.9
38 75 75 130 211 322 451 627 853 1085 1587 2157 — —
49 96 96 168 268 418 575 816 1111 1410 2063 2800 — —
12.9
45 90 90 156 246 386 529 754 1025 1302 1904 2590 — —

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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
lb-in lb-ft Size
#5 (0.125) 6.9 —
Nm

#8 (0.164) 18 — M2.5 0.4

#10 (0.190) 21 — M3 0.9

1/4 68 — M4 1.5

5/16 120 10 M5 3.1

3/8 210 17.5 M6 5.3

7/16 340 28 M8 13.0

1/2 — 39 M10 27.0

5/8 — 74 M12 45.0

3/4 — 114 M14 71.1

M16 109
NOTE: Stainless steel fasteners tend to gall while being
M18 157
tightened. To reduce this risk, lubricate the threads
with oil or molybdenum disulfide and torque at low M20 220
speeds without interruptions. Do not use excessive

7
pressure. Impact wrenches are not recommended. NOTE: Stainless steel fasteners tend to gall while being
tightened. To reduce this risk, lubricate the threads
45
with oil or molybdenum disulfide and torque at low
speeds without interruptions. Do not use excessive
pressure. Impact wrenches are not recommended.
3

Weld Studs
23

Unless otherwise specified the following grade 2 torque

values (± 10%) apply.

Table 1-11: Weld Stud Torque Values

T-2-4

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RT540E SERVICE MANUAL INTRODUCTION

WIRE ROPE shall be of the type which does not hinder visual inspection.
Those sections of rope which are located over sheaves or 1
General otherwise hidden during inspection and maintenance
procedures require special attention when lubricating rope.
The following information is a compendium of information The object of rope lubrication is to reduce internal friction and
from various wire rope manufacturers and includes to prevent corrosion.
inspection, replacement, and maintenance guidelines for
wire rope as established by ANSI/ASME B30.5, federal During fabrication, ropes receive lubrication; the kind and
regulations, and Manitowoc. The inspection interval shall be amount depends on the rope’s size, type, and anticipated
determined by a qualified person and shall be based on such use. This in-process treatment will provide the finished rope
factors as expected rope life as determined by experience on with ample protection for a reasonable time if it is stored
the particular installation or similar installations, severity of under proper conditions. But, when the rope is put into
environment, percentage of capacity lifts, frequency rates of service, the initial lubrication may be less than needed for the
operation, and exposure to shock loads. Periodic full useful life of the rope. Because of this possibility, periodic
Inspections need not be at equal calendar intervals and applications of a suitable rope lubricant are necessary.
should be performed at shorter time intervals as the wire The following are important characteristics of a good wire
rope approaches the end of its useful life. A periodic rope lubricant:
inspection shall be performed at least once a year. The
following provides inspection and maintenance procedures 1. It should be free from acids and alkalis.
for wire ropes used on Grove products (e.g. wire rope used 2. It should have sufficient adhesive strength to remain on
as load lines [hoisting cables], boom extension and the ropes.
retraction cables, pendant cables, tow winch cables, and
hook block tie down cables). 3. It should be of a viscosity capable of penetrating the
interstices between wires and strands.

7
Environmental Conditions 4. It should not be soluble in the medium surrounding it
45
The life expectancy of wire rope may vary due to the degree under the actual operating conditions (i.e. water).
of environmental hostility and other conditions to which these 5. It should have a high film strength.
mechanical devices are subjected. Variation in temperature,
continuous excessive moisture levels, exposure to corrosive 6. It should resist oxidation.
3

chemicals or vapors or subjecting the wire rope to abrasive

Before applying lubrication, accumulations of dirt or other
material may shorten normal wire rope life. Frequent/
23

abrasive material should be removed from the rope.

periodic inspections and maintenance of your wire rope is
Cleaning can be accomplished by using a stiff wire brush and
recommended for preventing premature wear and to insure
solvent, compressed air, or live steam. Immediately after the
long-term satisfactory performance.
wire rope is cleaned, it should be lubricated. Many
techniques may be used; these include bath, dripping,
Dynamic Shock Loads pouring, swabbing, painting or pressure spray methods.
Subjecting wire rope to abnormal loads beyond the Whenever possible, the lubricant should be applied at the
endurance limit will shorten the wire ropes, life expectancy. top of a bend in the rope, because at that point the strands
Examples of this type of loading are listed below. are spread by bending and are more easily penetrated.
There should be no load on the rope while it is being
1. High velocity movement e.g.; hoisting or swinging of a lubricated. It should be noted, the service life of wire rope will
load followed by abrupt stops. be directly proportional to the effectiveness of the method
2. Suspending loads while traveling over irregular surfaces used and amount of lubricant reaching the working parts of
such as railroad tracks, potholes, and rough terrain. the rope.
3. Moving a load that is beyond the rated capacity of the Precautions and Recommendations During
lifting mechanism, i.e.; overloading.
Inspection or Replacement
Lubrication 1. Always lock out equipment power when removing or
installing wire rope assemblies.
A wire rope cannot be lubricated sufficiently during
manufacture to last it’s entire life. Therefore, new lubricant 2. Always use safety glasses for eye protection.
must be added throughout the life of a rope to replace factory
lubricant which is used or lost. It is important that lubricant 3. Wear protective clothing, gloves, and safety shoes as
applied as part of a maintenance program shall be appropriate.
compatible with the original lubricant, and to this end, the 4. Use supports and clamps to prevent uncontrolled
rope manufacturer should be consulted. Lubricant applied movement of wire rope, parts, and equipment.

GROVE Published 2-26-2014, Control # 414-03 1-15

INTRODUCTION RT540E SERVICE MANUAL

5. When replacing fixed length cable assemblies (e.g.

pendants) having permanently attached end fittings use
2
only pre-assembled lengths of wire rope as supplied
from Manitowoc. Do not build lengths from individual 4
components.
6. Replace an entire wire rope assembly. Do not attempt to
rework damaged wire rope or wire rope ends. A925
5

7. Never electroplate wire rope assemblies.

3
8. Do not weld any wire rope assembly or component
unless welding is recommended by the wire rope FIGURE 1-6
manufacturer. Welding spatter shall never be allowed to
come in contact with the wire rope or wire rope ends. In
addition, be sure that the wire rope is not an electrical
Wire Rope Inspection (Running Ropes and
path during other welding operations. Pendant Cables)
9. Wire ropes are manufactured from special steels. If Wire rope should be inspected frequently/dally and
heating a wire rope assembly is absolutely necessary for periodically/yearly in accordance with the following
removal, the entire wire rope assembly shall be information excerpted from a National Consensus Standard
discarded. as referenced by Federal Government Agencies.
Recommended inspection intervals may vary from machine
10. On systems equipped with two or more wire rope t o m a ch i ne an d m a y v ar y b as ed on e n vi r o nm en ta l
assemblies operating as a matched set, they shall be conditions, frequency of lifts, and exposure to shock loads.
replaced as an entire set. The inspection time intervals may also be predetermined by

7
11. Do not paint or coat wire ropes with any substance state and local regulatory agencies.
45
except approved lubricants. NOTE: Wire rope may be purchased through Manitowoc
12. Measure the rope’s diameter across crowns (1) of the Crane Care.
strands when determining if rope has become damaged Any deterioration observed in the wire rope should be noted
3
(Figure 1-5). in the equipment inspection log and an assessment
concerning wire rope replacement should be made by a
23

qualified person.

Keeping Records
A signed and dated report of the wire rope’s condition at
each periodic inspection must be kept on file at all times. The
report must cover all inspection points listed in this section.
The information in the records can then be used to establish
data which can be used to determine when a wire rope
should be replaced.
1
It is recommended that the wire rope inspection program
include reports on the examination of wire rope removed
from service. This information can be used to establish a
FIGURE 1-5 relationship between visual inspection and the rope’s actual
internal condition at the time of removal from service.
13. When checking for broken wires (5) (Figure 1-6) relax
the rope, move it off “pick-up points”, and flex it as much Frequent Inspection
as possible. Use a sharp awl to pick and probe between A frequent daily visual inspection is recommended for all
wires and strands, lifting any wire which appears loose running ropes in service. This inspection should be made on
or moves excessively. Defect in the rope is spoke of in all wire rope which can be expected to be in use during the
relations to “Lay Length” (2) which is the distance day’s operation. This inspection should be used to monitor
measured along rope in which one strand (3) makes one
progressive degradation and to discover severe damages
complete revolution around core (4).
necessitating wire rope replacement such as:

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RT540E SERVICE MANUAL INTRODUCTION

1. Distortion, Kinking, Crushing, Un-stranding, Bird caging, Wire Rope Inspection (Boom Extension and
Reduction of diameter, etc. Retraction Cables) 1
2. General corrosion.
Periodic Inspection.
3. Broken or cut strands.
It is recommended that a periodic inspection of all boom
4. Number, distribution and type of broken wires. extension and retraction cables be performed using the
5. Evidence of core failure. following guidelines. This inspection shall cover the entire
length of the extension and retraction cables. This inspection
6. End fitting wear/abrasion. should be used to monitor progressive degradation and to
d i s c o v e r s e v e r e d a m a g e s n e c e s s i ta t i n g w i r e r o p e
Pay particular attention to areas of the rope where wear and
replacement or equipment repair. Inspection criteria are as
other damage is likely to occur:
follows:
7. Pick-up Points: Sections of wire rope that are
1. Inspect for reduction of rope diameter below nominal
repeatedly stressed during each lift, such as those
diameter.
sections in contact with sheaves.
2. Inspect for severely corroded or broken wires at end
8. End Attachments: The point where a fitting is
connections.
attached to the wire rope or the point where the wire
rope is attached to the drum. 3. Inspect for severely corroded, cracked, bent, worn, or
improperly applied end connections.
9. Abuse Points: The point where the wire rope is
subjected to abnormal scuffing and scraping. 4. Inspect wire rope in areas subjected to rapid
deterioration such as:
Periodic Inspection

7
• Sections in contact with saddles, equalizer sheaves,
Wire rope should be inspected periodically/annually or at a or other sheaves where wire rope travel is limited.
shorter time interval if necessitated by environmental or
45
other adverse conditions, and shall cover the entire length of • Sections of wire rope at or near terminal ends where
the wire rope. Only the outer surface of the wire rope need corroded or broken wires may protrude.
be inspected, and no attempt should be made to open the • Sections of wire rope in contact with stationary
3
rope. Periodic inspection should include all items listed surfaces where abrasion or chafing may take place
under frequent inspection plus the following: as a result of equipment vibration.
23

1. Inspect for reduction of rope diameter below nominal 5. Inspect for damaged or wobbly boom extension and
diameter. retraction sheaves that may cause rapid deterioration of
2. Inspect for severely corroded or broken wires at end the wire rope.
connections. 6. Inspect for unusual cable sag/stretch and be sure cables
3. Inspect for severely corroded, cracked, bent, worn, or used in sets all have an equal tension applied. Repeated
improperly applied end connections. need for adjustment of an individual cable is evidence of
cable stretch and indicates the need for additional and
4. Inspect wire rope in areas subjected to rapid more thorough inspection in order to determine and
deterioration such as: correct the cause.
• Sections in contact with saddles, equalizer sheaves,
or other sheaves where wire rope travel is limited.
Wire Rope Inspection/Replacement (All Wire
Rope)
• Sections of wire rope at or near terminal ends where
corroded or broken wires may protrude. No precise rules can be given for determination of the exact
time for replacement of wire rope since many variable factors
5. Inspect boom nose sheaves, hook block sheaves, boom
are involved. Determination regarding continued use or
extension/jib sheaves, auxiliary boom nose sheaves,
replacement of wire rope depends largely upon the good
and hoist drums for wear. Damaged sheaves or hoist
judgement of an appointed and qualified person who
drums can accelerate wear and cause rapid
evaluates the remaining strength in a used rope after
deterioration of the wire rope.
allowance for any deterioration disclosed by inspection.
Wire rope replacement should be determined by the
following information excerpted from a National Consensus
Standard as referenced by Federal Government Agencies
and as recommended by Grove Worldwide. All wire rope will

GROVE Published 2-26-2014, Control # 414-03 1-17

INTRODUCTION RT540E SERVICE MANUAL

eventually deteriorate to a point where it is no longer usable.

Wire rope shall be taken out of service when any of the
following conditions exist:
• Kinking, crushing, birdcaging, or any other damage
resulting in distortion of the rope structure.
• Evidence of any heat damage from any cause.
• Reductions from nominal diameter of more than 5%.
• In running ropes, six randomly distributed broken wires
in one lay or three broken wires in one strand in one lay.
• In standing ropes, more than two broken wires in one lay
in sections beyond end connections or more than one
broken wire at an end connection. FIGURE 1-7
• In rotation resistant rope, two randomly distributed
Method 2
broken wires in six rope diameters or four randomly
distributed broken wires in 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.

7
• Manitowoc recommends for cable extended booms, that
boom extension cables be replaced every seven (7)
45
years.

Seizing Wire Rope

3

It is important to seize the ends of rotation resistant wire

ropes to prevent the displacement and unraveling of the
23

individual wires and strands at the ends. All preformed and

non-preformed styles of wire rope should be seized prior to
cutting. Seizings must be placed on both sides of the point
where the wire rope is to be cut.
The two preferred methods for seizing wire ropes are:

Method 1
FIGURE 1-8
Using a length of soft annealed wire (Figure 1-7), place one
end in the groove between two strands of the wire rope. Turn
Wind a length of soft annealed wire (Figure 1-8) around the
the long end of the annealed wire at right angles to the wire
wire rope at least seven times. The two ends should be
and wrap it tightly over the portion in the groove.
twisted together in the center of the seizing. Tighten the
The two ends of the annealed wire should be twisted seizing by alternately prying and twisting. Cut off both ends
together tightly. Cut off the excess wire and pound the twist of the wire and pound the twist flat against the rope.
flat against the wire rope.
NOTE: Non-preformed wire rope (1) (Figure 1-9) should
have three seizings (3) located on each side of the
cut (4) as compared to performed wire rope (2).

1-18 Published 2-26-2014, Control # 414-03

RT540E SERVICE MANUAL INTRODUCTION

wedged into the lower layers under load, which can

1 4 3 seriously damage the rope.) The tensioning load should 1
range from 1 to 2% of the rope’s minimum breaking
force.
6. 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.
7. Breaking in your new 35x7 class rope: After installation,
2 you should properly break in your rope, which allows the
rope’s component parts to adjust themselves to your
operating conditions.
With the boom fully raised and fully extended, attach a
light load at the hook and raise it a few inches off the
ground. Allow to stand for several minutes. Then cycle
the load between the full “up” and “down” positions
several times. Stand back and watch the drum winding
7204
and rope travel for any potential problems.
FIGURE 1-9 After making the lifts with a light load, increase the load
and cycle it up and down a few times. This procedure will
Installing 35x7 Class Wire Rope train the rope and help assure smooth operation during

7
its useful life.
Ideally, you should run these loads with reeving that lets
45
CAUTION you place the loads on the block with all rope off the
Any cutting of this specific wire rope is not recommended. drum except the last three wraps. If this is not possible,
If 35x7 class wire rope must be cut for any reason, it is alternate methods must be used to assure proper
3
necessary to follow the attached instructions. Also, unlike tensioning of the rope on the drum.
other types of wire rope, the ends on this wire rope must
Procedures for Cutting and Preparing 35x7
23

be welded to retain the rotation resistant characteristics.

Class Wire Rope
1. Unload properly and relieve any twists. Pull the rope off
35x7 class wire rope is a special wire rope that must be
the shipping reel or unroll it from a shipping coil. (If done
handled differently than any other rope we manufacture. One
improperly, you may kink the rope, which will result in
characteristic that makes this rope special is that the outer
permanent damage to the rope.) Then lay the rope on
strands are not preformed. It is because of this that the
the ground in direct line with the boom. This helps
following procedures for cutting and preparing 35x7 class
release any twist in the rope.
rope must be followed:
2. Attach rope’s end to drum. Pull the rope over the point
1. The welded ends prepared by the manufacturer are not
sheave and attach the end to the drum. Be sure not to
to be removed.
remove the welded end.
2. Before cutting the rope, make three separate bands with
3. Wind rope onto drum slowly and carefully. At this point, it
seizing strand on each side of where the cut is to be
isn’t necessary to provide additional load other than the
made (total of six bands for each cut). Each band is to
weight of the rope being pulled across the ground.
have a minimum length of one and one half times the
4. Spool first layer tightly. It is essential on smooth-faced rope diameter. The two bands closest to the cut should
drums that the first layer is spooled with wraps tight and be located at a distance equal to one rope diameter
close together since the first layer forms the foundation away from the cut. The four remaining bands should be
for succeeding layers. If need be, use a rubber, lead or evenly spaced at a distance equal to three rope
brass mallet (but never a steel hammer) to tap the rope diameters.
in place.
a. If a welder is available, the cut should be made with
5. Spool multiple layers with sufficient tension. It’s very an abrasive saw. Immediately after the cut, both
important to apply a tensioning load to the ropes during ends of the rope are to be cap welded so that all
the rope breaking-in process. (If not, the lower layers inner and outer strands are welded together,
may be loose enough that the upper layers become preventing any movement between them.

GROVE Published 2-26-2014, Control # 414-03 1-19

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. The cut is to be made in such a
way that both ends of the rope are completely fused
so that all inner and outer strands are bonded
together, preventing any movement between
strands.
NOTE: The outer strands must not be allowed to move
with respect to the inner strands. The fused end
must not exceed the diameter of the rope.
3. Once the cuts have been completed, the seizing bands
are to be left in place for shipment of the rope.
4. Attach a “Do not remove welded ends” tag on each reel
flange.

FIGURE 1-10

7
3 45
23

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RT540E SERVICE MANUAL HYDRAULIC SYSTEM

SECTION 2
HYDRAULIC SYSTEM

SECTION CONTENTS
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Steering Control Valve . . . . . . . . . . . . . . . . . . . . . 2-37 2
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37
Hydraulic Oil Recommendations. . . . . . . . . . . . . . 2-5 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37
Draining and Flushing . . . . . . . . . . . . . . . . . . . . . . 2-5 Tandem Brake Valve with Treadle Pedal. . . . . . . 2-38
Removing Air from the Hydraulic System . . . . . . . 2-6 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38
Parts Replacement . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38
Directional Control Valves. . . . . . . . . . . . . . . . . . . 2-6 Dual Accumulator Charge Valve . . . . . . . . . . . . . 2-40
Supply Pressure and Return Circuit . . . . . . . . . . . 2-8 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Hydraulic Accumulator Service Brake . . . . . . . . 2-42
Oil Cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42
Hydraulic Pumps . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 Holding Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43

7
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43
Pressure Setting Procedures . . . . . . . . . . . . . . . 2-18 Cross Axle Differential Lock Valve . . . . . . . . . . . 2-44
45
Procedure A - Checking/Setting the Main Control Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44
Valve for Hoist(s), Boom Lift and Piston Pump. . 2-19 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44
Procedure B - Setting The Outrigger/Rear Steer/Oil Outrigger Control Manifold. . . . . . . . . . . . . . . . . . 2-46
3

Cooler Motor Pressures . . . . . . . . . . . . . . . . . . . 2-20 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46

Procedure C - Checking/Setting the Swing Directional Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46
23

Control Valve Work Port Relief Valves . . . . . . . . 2-20

Pilot Operated Check Valve . . . . . . . . . . . . . . . . . 2-47
Procedure D - Checking/Setting the Service Brake
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47
Dual Accumulator Charge Valve Charging Limits 2-20
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47
Procedure E - Checking/Pre-Charging the Service
Brake Accumulators . . . . . . . . . . . . . . . . . . . . . . 2-21 Integrated Outrigger/Rear Steer Manifold . . . . . . 2-48
Procedure F - Checking/Setting the Front Steer Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48
Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48
Procedure G - Checking/Setting the Pilot Supply Check Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51
Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51
Procedure H - Checking/Setting the Swing Brake Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51
Release Pressure . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Range Shift/Parking Brake Valve . . . . . . . . . . . . . 2-52
Procedure J - Setting Threshold on Electronic
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52
Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52
Procedure K - Setting Threshold and Max on
Swing Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . 2-23 Axle Oscillation Lockout Valve
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28 (Standard Units). . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53
Directional Control Valves . . . . . . . . . . . . . . . . . . 2-31
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31 Axle Oscillation Lockout Valve
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31 (Optional CE Units) . . . . . . . . . . . . . . . . . . . . . . . . 2-54
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54
Accessory With Swing Directional Control
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54
Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34 Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56

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Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66

Surface Protection for Cylinder Rods . . . . . . . . . 2-56 Steer Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-70
Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-59 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-70
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-59 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-70
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-59 Outrigger Extension Cylinder . . . . . . . . . . . . . . . . 2-73
Dual Rod Telescope Cylinder . . . . . . . . . . . . . . . 2-62 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-73
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-73
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62 Outrigger Stabilizer Cylinder . . . . . . . . . . . . . . . . 2-75
Axle Oscillation Lockout Cylinder . . . . . . . . . . . . 2-66 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-75
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-75

DESCRIPTION operation of individual hydraulic circuits are discussed within

their individual sections as applicable. A complete hydraulic
This section describes the hydraulic system, the system schematic showing all options is at the back of this
components which make up the hydraulic system, and the manual and a figure titled A.N.S.I. Graphical Symbols
components dependent upon the hydraulic system for their provides hydraulic symbol information for this section
operation. This includes descriptions of the supply pressure (Figure 2-1) and (Figure 2-2).
and return hydraulic circuit, hydraulic pumps, all hydraulic
valves, and all hydraulic cylinders. Detailed descriptions and

7
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RT540E SERVICE MANUAL HYDRAULIC SYSTEM

7
3 45
23

FIGURE 2-1

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HYDRAULIC SYSTEM RT540E SERVICE MANUAL

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FIGURE 2-2

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RT540E SERVICE MANUAL HYDRAULIC SYSTEM

MAINTENANCE 10. Disconnect the return lines from a pair of outrigger

stabilizer cylinders and activate the cylinders to their
Hydraulic Oil Recommendations. maximum down positions.

For the hydraulic oil specifications, refer to Section 9 - 11. Connect the return lines and raise the outrigger
LUBRICATION. stabilizer cylinders to the stowed position. Replenish the
reservoir hydraulic oil level as necessary.
Draining and Flushing 12. Repeat Steps 10 and 11 for the remaining two outrigger 2
If a component has been changed because of a failure that cylinders.
might allow metal or abrasive particles to enter the system, 13. Disconnect the return line from the telescope cylinder
all systems must be thoroughly checked, drained, and and fully extend the boom.
flushed.
14. Connect the return line and retract the boom. Replenish
1. Remove the reservoir drain plug. Allow about three the reservoir hydraulic oil level as necessary.
minutes after hydraulic oil stops flowing from the drain
port for the side walls to drain. 15. Disconnect the return lines from both front steer
cylinders and turn the front wheels to the extreme right.
2. Clean and install the reservoir plug and fill the reservoir
with a 50/50 mixture of fuel oil and clean hydraulic oil. 16. Connect the return lines and turn the front wheels to the
extreme left and then back to center. Replenish the
3. Cycle the crane through all functions several times. reservoir hydraulic oil level as necessary.
Then return the crane to its stowed position and turn the
front and rear wheels to the extreme left. Shut down the 17. Repeat Steps 15 and 16 for the rear steering cylinders.
engine. 18. Raise the crane on outriggers.

7
4. Remove the reservoir drain plug and drain the reservoir. 19. Disconnect the line from port A of the axle lockout valve.
Clean and install the drain plug and fill the reservoir with
45
clean hydraulic oil. 20. Using a jack under the rear wheel on one side of the
crane, jack up the wheel to maximum travel.
21. Connect the line to port A of the axle lockout valve and
CAUTION
3
disconnect the line from Port B.
Hydraulic oil supply lines must be connected to the
22. Repeat step 19 using the other rear wheel.
23

cylinders when flushing the system.

23. Connect the line to port B of the axle lockout valve.
NOTE: Draining the various components will be aided by Energize the axle lockout valve. Replenish the reservoir
connecting a drain line in place of the disconnected hydraulic oil level as necessary.
return line.
24. Disconnect the return line from the main hoist motor and
5. Disconnect the return line from the lift cylinder and raise fully hoist up the hoist.
the boom to maximum elevation.
25. Connect the return line to the main hoist motor and fully
6. Connect the cylinder return line and lower the boom to hoist down the hoist, then hoist up again. Replenish the
its stowed position. Replenish the reservoir hydraulic oil reservoir hydraulic oil level as necessary.
level as required.
26. Repeat Steps 24 and 25 for the auxiliary hoist as
7. Disconnect the return line from an outrigger extension necessary.
cylinder and fully extend the outrigger.
27. Disconnect one of the lines from the swing motor and
8. Connect the outrigger return line and retract the drive the motor in the direction it will go.
outrigger. Replenish the reservoir hydraulic oil level as
necessary. 28. Connect the line to the swing motor, then drive the swing
motor in the opposite direction until the boom is centered
9. Repeat Steps 7 and 8 for the remaining outriggers. and forward. Replenish the reservoir hydraulic oil level
as necessary.

CAUTION
When draining the outrigger cylinders, always operate CAUTION
either both front or both rear cylinders together to prevent When hydraulic oils are changed or added, ensure that
twisting the crane. hydraulic oils of different manufacturers are of the same
specifications. Discoloration may occur.

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HYDRAULIC SYSTEM RT540E SERVICE MANUAL

When hydraulic oils are changed, recheck the reservoir If the air is not readily removed, lower the boom to below
hydraulic oil level after brief system operation and add horizontal, extend the telescope cylinders as far as
hydraulic oil as required. Working reservoir capacity practicable, and allow the boom to remain in this position
(capacity to full mark) is 395.99 l (104.6 U.S. gal). Ensure the overnight. This should allow entrapped air to find its way
crane is level and in the travel mode of operation when the to the holding valve so that telescoping the boom IN the
hydraulic system is being filled. The system must be filled next morning should force the air back to the reservoir.
with all cylinders retracted. Fill the reservoir to the full mark Ensure the boom is first telescoped IN (not OUT) in the
on the reservoir sight gauge. After the reservoir is filled, morning. Telescoping OUT may cause air to be forced
operate all circuits and recheck the reservoir sight gauge. back into a cylinder.
Add hydraulic oil as required.

Removing Air from the Hydraulic System

Air entering the hydraulic oil will normally be removed DANGER
automatically by passage of the hydraulic oil over the baffles Pressurized fluid can cause serious injury or death.
in the hydraulic reservoir. If a component has been replaced, Extreme care must be used when removing any plugs or
the reservoir level is too low, or a leak develops in the suction restrictions from a hydraulic system suspected to have
lines to the pumps, air can enter the system. If air becomes entrapped air that may be pressurized.
entrapped in the hydraulic oil, it may be detectable in pumps
and motor operated components such as the swing Entrapped air may be removed from cylinders having
mechanism and hoist(s), because it can cause these units to wet rods by cycling. On certain cylinders, a plugged port
become noisy during operation. If noisy operation occurs, is provided on the rod end to bleed off entrapped air.
first check the level of the hydraulic reservoir and replenish
as necessary. Then inspect for leaks in the suction lines

7
leading to the pumps.
DANGER
45
Minute leaks may be hard to locate. If a leak is not readily
detectable, use the following way to check for it: Pressurized fluid can cause serious injury or death. Do
not attempt to loosen fittings in pressurized lines or while
Seal all normal openings in the hydraulic system and the the hydraulic pumps are in operation.
3
reservoir. Using a positive means to control the pressure
(like a regulator), pressurize the hydraulic system to In the event that air entrapment should persist, bleeding
23

13.8 to 27.6 kPa (0.14 to 0.28 bar) (2 to 4 psi) and of air by loosening various clamp and screw type fittings
inspect all joints and fittings for evidence of leaks. A may become necessary.
soap solution applied to the fittings and joints may also
prove helpful in detecting minute leaks while the system If the above procedures fail to eliminate air entrapment,
is pressurized. Remove the pressure, repair any leaks contact your authorized Grove Distributor.
found, and reopen any openings (such as a vent) closed
for inspection. Refill the reservoir after completing any Parts Replacement
repairs or service. Operate all hydraulic circuits several Parts found damaged or out of tolerance when maintenance
times in both directions. is being performed should be replaced. Refer to the
This action should return any entrapped air to the Manitowoc Crane Care Parts Catalog for proper replacement
reservoir where it can be removed from the hydraulic oil parts.
by the baffles.
Directional Control Valves
The control valves that control the crane functions are
installed on the right side on the outside of the superstructure
DANGER side plate, and between the left and right superstructure side
Tipping Hazard plates under the main hoist.
To avoid death or serious injury, locate the machine on a
firm supporting surface and position the boom over the
Inspection
front on outriggers when extending the boom at low Inspect the control valves for visible damage, binding spools,
angles. and evidence of leakage. If excessive internal leakage is
suspected during operation with a spool in its center position,
To remove entrapped air from telescope cylinders, lower it is possible that the area between the spool and working
the boom to below horizontal and fully telescope the section bore of the valve body is worn beyond serviceable
boom in and out several times.

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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.
Dripping hydraulic oil indicates some type of external Binding Spools
leakage. The machine should be removed from service for
immediate repairs. External leaks sometimes develop at
fittings and seals. Seals may be damaged by temperatures
Some of the most common causes for stiff spool movement
or jammed spool action are system overheating, excessive
2
that are too high, or by dirt or paint accumulation on the pressure, contaminated or deteriorated hydraulic oil, or
spool. Damaged or torn seals must be replaced. warped mountings. When scorched, deteriorated hydraulic
oil or contamination is the cause, flushing the system and
A component functioning at reduced efficiency may indicate
replenishing with clean hydraulic oil may solve the problem.
that the control valve for that component is leaking internally.
If the spool bores are badly scored or galled, the valve must
If preliminary check-out reveals that adequate volume is
be removed for servicing.
being supplied to the affected valve bank, relief valves are
properly adjusted, and the component is not at fault, check Warping occurs when mounting plates are not level or they
the valve for scored or worn parts. Scoring is a sign of the become distorted from machine damage. As mentioned
number one problem in hydraulics - contamination (external previously, the valve can be shimmed level.
contamination by dust or internal contamination by debris
Also, check the valve for rust. Rust or dirt collecting on the
from deteriorating components or oxidized hydraulic oil).
valves can prevent free movement of the spool, and keep it
Scored or severely worn valve components must be
from the true center position. Excessive system pressure
replaced.
can create both internal and external leaks in valves that are
Check valves in the control valves are designed to permit a otherwise sound. Only qualified technicians using the correct

7
flow of hydraulic oil in one direction only. If a piece of dirt or equipment should make pressure adjustments when
rust has worked its way into the check valve and lodges pressure adjustments are needed.
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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
The supply pressure and return circuit is made up of several reservoir. The filter housing contains a replaceable filter
circuits which route hydraulic oil from the hydraulic pumps to element. Returning hydraulic oil flows through the filter head,
the directional control valves for the individual operating through the filter element and into the reservoir.
circuits. The supply pressure and return circuit consists of An element condition indicator on the filter head indicates
the reservoir and integral filter, two hydraulic pumps, a when to change the filter element. When back pressure
hydraulic oil cooler, and a 12-port hydraulic swivel. Refer to caused by a dirty filter element exceeds 172.3 kPa/1.72 bar
HYDRAULIC PUMPS in this section for descriptions and (25 psid), the filter head’s bypass feature functions to allow
maintenance instructions for each hydraulic pump. Refer to the hydraulic oil to bypass the filter element and flow into the
Section 6 - SWING for description and maintenance reservoir through the bypass outlet instead. A bypass filter
instructions for the 12-port hydraulic swivel. screen prevents gross contamination from passing through
The supply pressure and return circuit uses Ports 5 and 6 for the filter even during bypass. Refer to Return Hydraulic Filter
pump supply and the dual Port 4 for return. Each operating for filter changing instructions.
circuit’s description and components begin with the circuit’s
directional control valve. Pump Distribution
Pump No. 1 is mounted off drive pads of the torque
Hydraulic Reservoir and Filter converter. Pump No. 2 is mounted on the left front side of the
The reservoir (Figure 2-3), attached to the right side of the engine.
carrier frame, has a capacity of 442.3 l (116.8 gal) total, Pump No. 1
395.9 l (104.6 gal) to the full mark. The all-steel reservoir has

7
an internally mounted full-flow filter and integral baffles that Pump No. 1 is a variable displacement axial piston pump
help cool the hydraulic oil and prevent hydraulic oil foaming. with a maximum displacement of 112 cm3/rev. (6.83 in3/rev).
45
The pump differential or standby pressure is 2413 kPa/24
Hydraulic oil flows through three tubes at the rear of the
bar (350 psi). Pump No. 1 supplies oil to the integrated
reservoir to the three hydraulic pumps. Almost all of the
outrigger/rear steer valve, boom lift, telescope, hoist, brakes
return flow goes through the filter at the top of the reservoir.
3
and pilot functions.
The return line that goes directly into the reservoir (instead of
through the filter) is from the No. 10 port (drain) of the 12-port
23

Pump No. 2
swivel.
Pump No. 2 is a single positive displacement gear pump with
A magnetized drain plug in the bottom of the reservoir a displacement of 39 cm 3 /rev. (2.40 in 3 /rev) delivering a
collects metal particles from the hydraulic oil if it becomes theoretic flow of 84 lpm (22.2 gpm). Pump No. 2 supplies oil
contaminated. to the front steer and swing circuits.
A sight gauge is located on the front of the reservoir to Pump No. 3
indicate hydraulic oil level.
Pump No. 3 is a single positive displacement gear pump with
1. A breather/fill cap located on the top of the reservoir
allows air to enter or exhaust the reservoir. It consists of a displacement of 19 cm 3 /rev. (1.16 in 3 /rev) delivering a
a breather, fill neck, gaskets and strainer. It is important theoretic flow of 57.2 lpm (15.1 gpm). Pump No. 3 supplies
that the breather be kept clean to prevent damage to the oil to the transmission oil cooler fan motor.
reservoir. The breather/fill cap also provides for filling the
reservoir.
A large access cover on top of the reservoir provides for
cleaning. The access cover can also be used to fill the
reservoir after it has been completely drained.

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RT540E SERVICE MANUAL HYDRAULIC SYSTEM

Maintenance

Troubleshooting

Symptom Probable Cause Solution

1. No hydraulic oil a. Low hydraulic oil level. a. Fill reservoir.
flows in systems.
b. Reservoir-to-pump suction lines b. Clean, repair, or replace lines as
2
broken or restricted. Air entering at necessary. Check lines for security,
suction lines. Pump not priming. absence of cracks, and proper
a t ta c h m e n t . Ti g h t e n , r e pa i r, o r
replace parts as necessary.
c. Pump shaft sheared or disengaged. c. If drive shaft is damaged or sheared,
remove and repair or replace as
necessary
d. Internal contamination. d. Drain, flush with recommended oil
mixture, then drain and refill system
with recommended hydraulic oil.
2. Slow response. a. Low hydraulic oil level. a. Fill reservoir.
b. Hydraulic oil temperature too high b. If too low, warm up system. As
(watery thin oil) or too low (thick needed, troubleshoot cooler circuit. If

7
sluggish oil). too high, troubleshoot cooler circuit.
Likely suspects are in-line check
45
valve and related hydraulic circuits.
c. Faulty pump section(s). c. Repair or replace pump section(s) or
entire pump.
3

3. Pump noise a. Low hydraulic oil level. a. Fill reservoir.

23

accompanied by
b. Excessive engine speed. b. Regulate engine speed.
hydraulic oil
foaming in c. Air entering at suction lines. c. Check all lines for security and proper
reservoir. repair. Tighten, repair, or replace as
needed.
4. Excessive a. System relief valve set too high. a. Using adequate pressure gauge,
pressure buildup. adjust system relief valve as
necessary.
b. Restricted pump-to-control b. Clean, repair, or replace line as
valve supply line. necessary.
5. Specific hydraulic a. Leak in system. a. Repair leak.
system (lift, hoist,
b. Faulty electric controls/signals. b. Adjust or replace controls signals.
telescope, swing)
not working. c. Faulty directional control valve. c. Replace valve.
d. Poorly adjusted control in circuit. d. Troubleshoot circuit with schematic.
Adjust hydraulic component per
schematic.
e. Faulty hydraulic cylinder, motor, or e. Replace faulty component.
valve.

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1 2 3

7
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11 6727

10 9
6, 7, 8
FIGURE 2-3

Item Description Item Description

1 Access Cover 7 Hex Locknut
2 Breather/Fill Cap 8 Flatwasher
3 Return Line Filter 9 Thermometer
4 Reservoir 10 Ladder
5 Sight Gauge 11 Magnetic Plug
6 Capscrew

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2
3
11
2
4

5, 6

12

7
9
45
10
3
23

13

6728

FIGURE 2-4

Item Description Item Description

1 Capscrew 8 Filter Head
2 Washer 9 Gauge
3 Cap 10 O-ring
4 O-ring 11 Element
5 Bypass Valve 12 Bowl
6 Spacer 13 Gasket
7 Capscrew

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HYDRAULIC SYSTEM RT540E SERVICE MANUAL

Return Hydraulic Filter Assembly Element Installation

Element Removal 1. Place a new element into the filter bowl (housing).
2. Install new O-ring in the cap assembly.
3. If by-pass valve was removed from cap, install by-pass
capscrews to cap.
DANGER
Ensure that all hydraulic systems are shut down and the 4. Install cap assembly on filter head and secure with the
pressure is relieved. four bolts. Torque bolts 14.9 ±2.7 Nm (11.00 ±2.00 lb-ft)
until the gasket starts to bulge slightly. Do not over
1. Shut down all hydraulic systems. torque. Torque bolt in a criss-cross pattern.

2. Wipe any dirt from the filter head and cap assembly. 5. Activate the hydraulic system and check for leaks. make
repairs as necessary.
NOTE: The bypass valve assembly is installed to the cap
and is removed with the cap. Hydraulic Reservoir Removal
3. Remove the four bolts securing the cap assembly to the 1. Remove the capscrews, flatwashers, lockwashers and
filter head. Remove the cap and bypass valve assembly. hex nuts securing the reservoir to the fame. Using a
4. Remove the filter element from the filter bowl (housing). suitable lifting device, remove the reservoir.

5. Ensure the new filter element is correct by comparing Hydraulic Reservoir Installation
their part numbers with the part numbers of the used
element. 1. Using a suitable lifting device, install the reservoir to the
frame and secure with the capscrews, flatwashers,

7
6. Discard the element. lockwashers and hex nuts. Torque the capscrews see
Fasteners and Torque Values, page 1-11.
3 45
23

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RT540E SERVICE MANUAL HYDRAULIC SYSTEM

OIL COOLER telescoping), more oil has to flow through this return line,
causing a pressure buildup. When this pressure reaches
Description 206.8 kPa/2.0 bar (30 psi), the normally closed check valve
in the return line (in parallel with the return line through the
An air cooled hydraulic oil cooler (Figure 2-5) is installed on hydraulic oil cooler) will open, letting some hydraulic oil
the rear of the superstructure behind the hoists. bypass the hydraulic oil cooler and flow directly into the
When the oil temperature reaches 48.8°C (120°F), the reservoir filter.
normally closed temperature switch opens to turn on the oil When fewer functions are being used, the pressure in the 2
cooler electric motor which drives the oil cooler fan. system will decrease below 206.8 kPa/2.0 bar (30 psi) and
The oil cooler fan pulls cool air through the cooling fins on the the check valve will close again.
cooler. Normally, most hydraulic oil from components is NOTE: Refer to POWER TRAIN, page 7-1 for more
routed through the oil cooler by way of a return line and on to information and illustration.
the filter in the reservoir. When several hydraulic functions
are being used at one time (i.e., hoisting, lifting, and

7
3 45
23

5
6 7

1, 2, 3, 4

1, 2, 3, 4 6770
8

FIGURE 2-5

Item Description Item Description

1 Flatwasher 5 Mounting Bracket
2 Lockwasher 6 Mounting Bracket
3 Capscrew 7 Shield Plate
4 Hex Nut 8 Oil Cooler

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HYDRAULIC SYSTEM RT540E SERVICE MANUAL

HYDRAULIC PUMPS The pump differential or standby pressure is 2413 kPa/24

bar (350 psi). Pump No. 1 supplies oil to the integrated
Description outrigger/rear steer valve, boom lift, telescope, hoist, brakes
and pilot functions.
Pump No. 1 is mounted off drive pads of the torque
converter. Pump No. 2 is mounted on the left front side of the Pump No. 2
engine (Figure 2-6). Pump No. 2 is a single positive displacement gear pump with
Pump No. 1 a displacement of 39 cm 3 /rev. (2.40 in 3 /rev) delivering a
theoretic flow of 84 lpm (22.2 gpm). Pump No. 2 supplies oil
Pump No. 1 is a variable displacement axial piston pump
to the front steer and swing circuits.
with a maximum displacement of 112 cm3/rev. (6.83 in3/rev).

Maintenance

No. 1 Pump Removal 3. Replace the charge pump and studs.

4. Connect the distribution and supply lines as tagged
during removal.
CAUTION
Absolute cleanliness is essential when working on the No. 2 Pump Removal
hydraulic pumps. Always work in a clean area. The
presence of dirt and foreign materials in the system can
result in serious damage or inadequate operation. CAUTION
Absolute cleanliness is essential when working on the

7
1. For ease of removal, gain access to the pump by hydraulic pumps. Always work in a clean area. The
removing the engine hood. The pump is bolted to the presence of dirt and foreign materials in the system can
45
engine’s torque converter. result in serious damage or inadequate operation.
2. Tag and disconnect the supply line from the pump. Cap
or plug the line and port. 1. For ease of removal, gain access to the pump by
3
removing the engine hood.
3. Tag and disconnect the pump distribution lines from the
2. Tag and disconnect the supply line from the pump. Cap
23

pump. Cap or plug the lines and ports.

or plug the line and port.
3. Tag and disconnect the pump distribution line(s) from
CAUTION the pump. Cap or plug the line(s) and port.
When removing the pump, keep the pump as level as
possible to avoid damaging the input spline.
CAUTION
NOTE: Charge pump and two studs must be removed for When removing the pump, keep the pump as level as
wrench access to piston pump mounting bolts. possible to avoid damaging the input spline.
4. Remove the capscrews and washers attaching the
pump to the drive pad on the torque converter. Remove 4. Remove the capscrews and washers attaching the No. 2
the pump. pump to the drive pad on the torque converter. Remove
the pump.
5. Clean the gasket material from the drive pad on the
torque converter. 5. Remove the gasket material from the drive pad on the
torque converter.
6. Cover the drive pad’s opening to prevent dirt from
entering. 6. Cover the drive pad’s opening to prevent dirt from
entering.
No. 1 Pump Installation
No. 2 Pump Installation
1. Install new gasket material to the pump mounting flange.
1. Install new gasket material to the pump mounting flange.
2. Install pump on torque converter drive pad with
capscrews and washers. Make sure the splines mesh 2. Install pump on to left front of engine with capscrews and
properly. Torque capscrews 292 to 317.2 Nm (216 to 234 washers. Make sure gear teeth mesh properly. Torque
foot-pounds). capscrews to 85 to 93 Nm (63 to 69 lb-ft).

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RT540E SERVICE MANUAL HYDRAULIC SYSTEM

3. Connect the distribution and supply lines as tagged Testing After Rebuild or Replacement
during removal.
1. Operate the pump for at least two minutes at zero
pressure and moderate speed (not over 1500 rpm).
CAUTION
Do not feed hot hydraulic oil into a cold pump. This may
cause the pump to seize.
CAUTION
If the pump becomes hot to the touch, it is binding and
may seize. Stop engine, disassemble pump, and repair it
2
No. 3 Pump Removal
so it will not bind.

2. Touch pump to verify it has not become hot from binding.

CAUTION Listen for abnormal noises indicating low hydraulic oil
Absolute cleanliness is essential when working on the level or internal pump problems. If the pump appears to
hydraulic pumps. Always work in a clean area. The be operating satisfactorily, increase the rpm by steps,
presence of dirt and foreign materials in the system can until reaching governed rpm. Operate pump about five
result in serious damage or inadequate operation. minutes while checking for proper operation and
leakage. Fix leaks; make repairs as needed.
1. For ease of removal, gain access to the pump by
removing the engine hood. 3. Cycle the components the pump powers to verify the
pump drives them all properly.
2. Tag and disconnect the supply line from the pump. Cap
or plug the line and port. Hydraulic Gear Pump Start-up Procedure
3. Tag and disconnect the pump distribution line(s) from

7
1. Ensure the reservoir is filled with the proper hydraulic
the pump. Cap or plug the line(s) and port. fluid to the high level mark on the reservoir sight gauge.
45
2. Ensure no air is entering the pump inlet, and that the
CAUTION pump suction or inlet fluid is not bleeding back to the
When removing the pump, keep the pump as level as reservoir when the engine is stopped, by making sure all
3
possible to avoid damaging the input spline. suction or inlet lines are air tight.
NOTE: The following step can be done before the pump is
23

4. Remove the capscrews and washers attaching the No. 3 installed by removing the plastic cap from “T1” port,
pump to the No. 1 pump. Remove the pump. and checking to ensure “T2” port on the opposite
5. Remove the gasket material from the drive pad on the side of the pump is plugged. Fill housing full of
No. 1 pump. hydraulic oil through “T1” port. Re-install the plastic
cap and then install the pump.
6. Cover the drive pad’s opening to prevent dirt from
entering. 3. Remove adapter and hose from “T1” port, and check to
ensure “T2” port on the opposite side of the pump is
No. 3 Pump Installation plugged. Fill housing full of hydraulic oil through “T1”
port. Re-install the adapter and hose into the “T1” port.
1. Clean and prime the mounting surfaces with Loctite
4. Start the engine.
7649 primer.
a. Idle engine for two to three minutes with no
2. Apply Loctite 518 sealant to the pump mounting flange.
functions actuated. Check for leaks and repair if
3. Install pump on to pump No. 1 with capscrews and required. Lay hand on pump to check for excessive
washers. Make sure gear teeth mesh properly. Torque heat build-up. If the pump section is too hot to keep
capscrews to spec listed in Fasteners and Torque your hand on, stop immediately. If the pump makes
Values, page 1-11. excessive noise, air is probably entering the pump
keeping it from priming. If this occurs, stop engine,
4. Connect the distribution and supply lines as tagged
and inspect all connections of the suction hose/tube
during removal.
for a loose connection, or a missing or damaged O-
ring. Re-start the engine and run until the pump
takes prime for a maximum of 30 seconds. If the
CAUTION pump does not prime in 30 seconds, stop the engine
Do not feed hot hydraulic oil into a cold pump. This may and repeat until the pump primes.
cause the pump to seize.

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HYDRAULIC SYSTEM RT540E SERVICE MANUAL

b. Increase the RPM to 1500-1800 for 1 to 2 minutes 4. Start the engine.

with no functions actuated and make checks again
a. Idle engine for two to three minutes with no
as outlined in step a. Incrementally increase throttle
functions actuated. Check for leaks and repair if
to full RPM and then cycle the functions that the
required. Lay hand on pump to check for excessive
pump supples to verify proper speed. Verify pump
heat build-up. If the pump section is too hot to keep
flow.
your hand on, stop immediately. If the pump makes
5. Check pressure settings. Refer to PRESSURE excessive noise, air is probably entering the pump
SETTING PROCEDURES in this section. keeping it from priming. If this occurs, stop engine,
and inspect all connections of the suction hose/tube
Piston Pump Start-up Procedure for a loose connection, or a missing or damaged O-
ring. Re-start the engine and run until the pump
1. Ensure the reservoir is filled with the proper hydraulic takes prime for a maximum of 30 seconds. If the
fluid to the high level mark on the reservoir sight gauge. pump does not prime in 30 seconds, stop the engine
2. Ensure no air is entering the pump inlet, and that the and repeat until the pump primes.
pump suction or inlet fluid is not bleeding back to the b. Increase the RPM to 1500-1800 for 1 to 2 minutes
reservoir when the engine is stopped, by making sure all with no functions actuated and make checks again
suction or inlet lines are air tight. as outlined in step a. Incrementally increase throttle
3. Remove the case drain hose and adapter from port DR to full RPM and then cycle the functions that the
on the pump (Figure 2-7), and fill housing with the same pump supples to verify proper speed. Verify pump
hydraulic oil that was used to fill the hydraulic reservoir flow.
to the bottom of the O-ring case drain port. Install the 5. Check pressure settings. Refer to PRESSURE
case drain adapter and hose. SETTING PROCEDURES in this section.

7
45
5
3

2
23

1
3

Pump Location On Engine

FIGURE 2-6

Item Description Item Description

1 No. 1 - Piston Pump 4 Transmission
2 No. 2 - Gear Pump 5 Engine
3 No. 3 - Gear Pump

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RT540E SERVICE MANUAL HYDRAULIC SYSTEM

Pump Case Drain

Hose To Reservoir

FIGURE 2-7

7
3 45
23

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HYDRAULIC SYSTEM RT540E SERVICE MANUAL

PRESSURE SETTING PROCEDURES NOTE: When checking the directional control valve relief
settings, unless otherwise specified, start with the
The following procedures should be used to properly check, engine at idle RPM and move the controller to its
adjust and set the hydraulic system pressures. fully stroked position. Then slowly accelerate the
NOTE: A Digital Pressure Gauge and accessories may be engine to the specified RPM. Read gauge and
purchased through Manitowoc Crane Care. make adjustments to specified setting.

The following equipment is required for checking the When checking the outrigger relief valve setting,
hydraulic pressure settings. start with the engine at idle RPM and activate and
hold the extend switch. Then slowly accelerate the
• Pressure Gauge engine to the specified RPM. Read gauge and
• Three dial gauge 0-34.5 MPa (0-5000 psi) make adjustment as required.

• Pressure check diagnostic quick disconnect - Grove P/N GP (gauge Port) and number corresponds to
9999101806 and straight adapter fitting 7447040401 gauge ports on the valve and on the hydraulic
schematic.
• ORFS reducers as required to attach work port hoses to
the gauge.

Table 2-1
Valve Pressure Setting Table

Pressure
Tolerance
Valve To Be Set Setting Adjustment Location
PSI (MPa)

7
PSI (MPa)
4000 (27.6) ± 50 (0.4) GP2 - Superstructure mounted main
45
Hoist (s), and Lift Pressure Setting directional control valve load sense
relief valve (Figure 2-9)
Telescope Extend Pressure Setting 3500 (24.2) ± 50 (0.4) GP7 - Superstructure mounted main
3

directional control valve port relief

valve (Figure 2-10)
23

Telescope Retract Pressure Setting 3250 (22.5) ± 50 (0.4) GP7 - Superstructure mounted main
directional control valve port relief
valve (Figure 2-10)
Outrigger Extend/Retract/Rear Steer/Oil 2500 (17.3) ± 50 (0.4) GP2 - Carrier mounted outrigger
Cooler Motor Pressure control manifold (Figure 2-11)
Swing Left and Right Work Port Relief 1800 - 1900 See Range GP1 - Superstructure mounted
Pressures (12.4 - 13.1) accessory manifold with swing
directional control valve (Figure 2-9)
Front Steer Pressure Setting 2500 (17.3) ± 50 (0.4) GP5 - Superstructure mounted
accessory manifold with swing
directional control valve (Figure 2-9)
Swing Brake Supply Pressure Setting 250 - 275 See Range GP4 - Superstructure mounted
(1.7 - 2.1) accessory manifold with swing
directional control valve (Figure 2-9)
Pilot Supply Pressure Setting 2500 - 2550 See Range GP3 - Superstructure mounted
(17.3 - 17.6) accessory manifold with swing
directional control valve (Figure 2-9)

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RT540E SERVICE MANUAL HYDRAULIC SYSTEM

Pressure
Tolerance
Valve To Be Set Setting Adjustment Location
PSI (MPa)
PSI (MPa)
Non-CE Cranes 325 - 400 See Range GP2 - Carrier mounted piston pump
Piston Pump P Pressure Setting (2.2 - 2.8) (Figure 2-13)

CE Cranes 525 - 550 2

Piston Pump P Pressure Setting (3.6 - 3.8)

Service Brake High Charge Limit 2320 (17.4) +72, -145 GP7 (Figure 2-10) Non-adjustable
(0.5) (1.00)
Service Brake Low Charge Limit 1950 (13.5) ±145 PSI (1.00) GP7 - (Figure 2-10) Non-adjustable
Service Brake Accumulator Pre-charge 800 - 850 See Range Accumulator (Figure 2-12)
(5.5 - 5.8)

NOTE: Procedures A through H in the following text the GP2 port of the accessory manifold with swing
correlate with Figures 2-6 through 2-10. directional control valve (Figure 2-9), start engine and @
idle RPM adjust the piston pump differential setting
Procedure A - Checking/Setting the Main screw “in” to increase or “out” to decrease so that a
Control Valve for Hoist(s), Boom Lift and gauge reading of 2.2 - 2.8 MPa (325 - 400 psi)
Piston Pump (Figure 2-13).

7
4. If the lift cylinder is not installed, plug the extend hose
NOTE: Procedure A for max. and  P settings.
(the larger of the two). If lift cylinder is installed, omit this
45
Set hoist(s) and boom lift as follows: step and continue to step #5.
1. Install pressure check diagnostic quick disconnect with 5. With diagnostic quick disconnect still installed @ the
gauge onto test nipple @ the GP2 Port of the accessory GP2 port of the accessory manifold with swing
3

manifold with swing directional control valve directional control valve (Figure 2-9), start engine and
(Figure 2-9). throttle up to full RPM. Feather into the boom lift
23

controller to full controller stroke (up or down) and hold.

2. Assure piston pump cut-off max.(Figure 2-13) factory
If the boom is installed, boom up to max elevation and
setting is correct. Loosen the jam nut on the cut-off max
hold or boom down to minimum elevation and hold.
adjusting screw and turn it in until it softly seats or
Adjust the load sense relief valve “in” to increase or “out”
bottoms out. Then back the adjusting screw out 1/4 to 1/
to decrease so that a gauge pressure reading of 27.6±
2 turn and lock in place with jam nut. This will ensure that
0.4 MPa (4000 ± 50 psi) is achieved (Figure 2-10).
full system pressure of 27.6 MPa (4000 psi) can be
obtained in step #4. 6. Stop engine and remove the diagnostic couplers from
the test nipples
3. Assure piston pump ΔP (stand-by) factory setting is
correct. With diagnostic quick disconnect still installed @

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HYDRAULIC SYSTEM RT540E SERVICE MANUAL

Set telescope extend and retract as follows: Procedure B - Setting The Outrigger/Rear
Extend Steer/Oil Cooler Motor Pressures
7. If boom is not installed, install a pressure check 1. Install a pressure check diagnostic quick disconnect with
diagnostic quick disconnect with gauge onto test nipple gauge onto test nipple at G2 port of the outrigger control
@ the GP7 port of the main directional control valve manifold (Figure 2-11).
(Figure 2-10).
2. Start engine and throttle up to full RPM. Select and
8. Cap hose (the larger of the two) running from port A, activate the outrigger “extend or retract” switch on the
telescope section of the main directional control valve to cab dash. Adjust the pressure reducing valve integrated
the cylinder port block at the back of the base section. in the outrigger control manifold “in” to increase or “out”
to decrease so that a gauge pressure of 17.3 MPa ± 0.4
9. Start engine and throttle up to full RPM. Attempt to (2500 ±50 PSI) is achieved (Figure 2-11).
telescope OUT by feathering into the controller to full
controller stroke. Adjust the work port relief “in” to 3. Stop engine. Remove the diagnostic coupler.
increase or “out” to decrease so that a gauge pressure
of 24.2 ±0.4 MPa (3500 ±50 psi) is achieved Procedure C - Checking/Setting the Swing
(Figure 2-10). Directional Control Valve Work Port Relief
10. If the boom is installed, start engine and throttle up to full Valves
RPM. Telescope out to fully extend the boom and hold. 1. With engine off, Install a pressure check diagnostic
Adjust the work port relief valve “in” to increase or “out” coupler with gauge onto test nipple at GP1 port of the
to decrease so that a gauge pressure reading of 24.2 accessory manifold with swing directional control valve
±0.4 MPa (3500 ±50 psi) is achieved (Figure 2-10). (Figure 2-9).

7
11. Stop engine and remove pressure gauge and re-connect 2. Start engine, throttle up to full RPM. With the swing
plumbing. house lock engaged, swing full right and hold controller.
45
Retract Adjust the “B” port work port relief “in” to increase or
“out” to decrease so that a gauge pressure reading of
12. If the boom is not installed, install a pressure check 12.4 - 13.1MPa (1800 - 1900 psi) is achieved.
diagnostic quick disconnect with gauge onto test nipple
3

@ the GP7 port of the main directional control valve 3. Repeat step #2 for swing left adjusting the “A” port relief.
(Figure 2-10).
23

Procedure D - Checking/Setting the Service

13. Cap hose (the smaller of the two) running from port B,
Brake Dual Accumulator Charge Valve
telescope section of the main directional control valve to
the cylinder port block at the back of the base section. Charging Limits
14. Start engine and throttle up to full RPM. Attempt to 1. With engine off, discharge all of the pressurized fluid
telescope IN by feathering into the controller to full stored in the accumulators by depressing the service
controller stroke. Adjust the work port relief valve “in” to brake pedal on the cab floor 8 - 10 times.
increase or “out” to decrease so that a gauge pressure 2. Install a pressure check diagnostic quick disconnects
reading of 22.5 ±0.4 MPa (3250 ±50 psi) is achieved with gauge onto test nipple at GP7 port of the main
(Figure 2-10). directional control valve (Figure 2-10).
15. If the boom is installed, start engine and throttle up to full 3. Start engine and idle. The charging valve will
RPM. Telescope in to fully retract the boom and hold. immediately start to charge the accumulators. Watch the
Adjust the work port relief valve “in” to increase or “out” pressure gauge. The high charge limit should read 17.4
to decrease so that a gauge pressure reading of 22.5 MPa +0.5- 1.00 (2320 +72, -145 psi) when the pressure
±0.4 MPa (3250 ±50 psi) is achieved (Figure 2-10). stops rising. This accumulator charge valve is non-
16. Stop the engine and remove pressure gauge and re- adjustable.
connect plumbing. 4. With the engine still at idle, repeatedly depress the
service brake pedal on the cab floor until the gauge
pressure reads approximately 13.5 ± 1.00 MPa (1950 ±
145 psi) when it starts to recharge. Once you have found
this pressure, push the brake pedal again to recharge.
Watch the gauge and verify the low charging limit to be
13.5 ± 1.00 MPa (1950 ± 145 psi) (when it starts to

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RT540E SERVICE MANUAL HYDRAULIC SYSTEM

recharge). This accumulator charge valve is non- the charging assembly (Figure 2-12) until the pressure is
adjustable. to specification.
5. Stop engine. Remove pressure gauge. 8. Remove the charging valve assembly by turning the “T”
handle all the way out (counterclockwise) on the gas
Procedure E - Checking/Pre-Charging the check and then open the bleed valve.
Service Brake Accumulators 9. Secure the gas valve, loosen the swivel nut and remove
1. With the engine off, discharge all of the pressurized oil the charging assembly. Replace the gas valve cap and 2
stored in the accumulators by depressing the service guard.
brake pedal on the cab floor 4-6 times. Remove the gas
valve guard and cap on the accumulator (Figure 2-13) Procedure F - Checking/Setting the Front
Steer Pressure
2. Before attaching the gas charging assembly
(Figure 2-13) onto the gas valve, back out the gas chuck 1. Install pressure check diagnostic quick disconnect with
“T” handle all the way out (counterclockwise). gauge onto test nipple @ GP5 port of the accessory
manifold with swing directional control valve
3. Close the charging assembly bleed valve. Attach the
(Figure 2-9).
swivel nut onto the gas valve and tighten 1.1 - 1.6 Nm
(10-15 lb-in). 2. Start engine and throttle up to full RPM. Fully turn the
steering wheel left or right against the axle stop. Adjust
4. Turn the gas chuck “T” handle all the way down
the steering load sense relief valve in the accessory
(clockwise) which will depress the core in the gas valve
manifold with swing directional control “in” to increase or
5. Check the pre-charge pressure. The gauge should read “out” to decrease so that a gauge pressure of 17.3 MPa
5.5 +0.4, -0 MPa (800 +50, -0 psi). (2500 psi) is achieved (Figure 2-9).

7
6. If the pressure is 5.5 +0.4, -0 MPa (800 +50, -0 psi), 3. Stop engine. Remove diagnostic couplers.
remove the charging valve assembly by turning the “T”
45
handle all the way out on the gas chuck and then Procedure G - Checking/Setting the Pilot
opening the bleed valve (Figure 2-13). Supply Pressure
7. Secure the gas valve, loosen the swivel nut and remove
3
1. Install pressure check diagnostic quick disconnect with
the charging assembly. Replace the gas valve cap and gauge onto test nipple @ GP3 port of the accessory
guard.
23

manifold with swing directional control valve

Procedure For Pre-charging the Accumulator, If required (Figure 2-9).

1. With the engine off, discharge all of the pressurized oil 2. Start engine and @ idle RPM, lower left armrest, fully
stored in the accumulators by depressing the service stroke and hold the boom lift raise or lower joystick.
brake pedal on the cab floor 4 - 6 times. Remove the gas Adjust the pilot pressure reducing valve of the accessory
valve and cap on the accumulator (Figure 2-12). manifold with swing directional control valve “in” to
increase or “out” to decrease so that the gauge pressure
2. Ensure the nitrogen supply bottle is shut off, then attach of 17.3 - 17.6 MPa (2500 - 2550 psi) is achieved
the charging valve assembly to it. (Figure 2-9).
3. Before attaching the charging assembly to the 3. Stop engine. remove diagnostic couplers.
accumulator gas valve, back the gas chuck “T” handle
all the way out (counterclockwise). Procedure H - Checking/Setting the Swing
4. Close the charging assembly bleed valve. Without Brake Release Pressure
looping or twisting the hose, attach the swivel nut to the 1. Install pressure check diagnostic quick disconnect with
accumulator gas valve and tighten 1.1 - 1.6 Nm (10-15 gauge onto test nipple @ GP4 port of the accessory
lb-in). manifold with swing directional control valve
5. Turn the gas check “T” handle al the way down (Figure 2-9). Unplug connectors containing wires 50
(clockwise) which will depress the core in the gas valve. with 1475. Plug connector containing wire 50 into
solenoid where wire 1475 was.
6. Slowly open the nitrogen bottle valve and fill the
accumulator. Close the valve when the pre-charge is 5.5 2. Start engine and idle, select and depress the swing
+0.4, -0 MPa (800 +50, -0 psi). brake release switch and adjust the swing brake
pressure reducing valve “in” to increase or “out” to
7. If the precharge is higher than specified in step #6, close decrease so that a gauge pressure of 1.7 - 2.1 MPa (250
the nitrogen bottle and slowly open the bleed valve on

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HYDRAULIC SYSTEM RT540E SERVICE MANUAL

- 275 psi) (Figure 2-9) is achieved. Place connectors 1. Attach test fitting and pressure gage in the Pilot End
back to their original positions. Caps one at a time at GPA for Main Hoist Up, GPB for
Aux Hoist Up, GPC Tele Retract, GPD Lift Down
3. If adjustment can not obtain the setting in step #2, stop
(Figure 2-10), GP8 and GP9 Swing Left and Right
engine and install a pressure check diagnostic quick
(Figure 2-9).
disconnect (Parker PD240) with gauge onto test nipple
at GP2 at the accessory manifold valve. Follow 2. Attach laptop to diagnostic connector in cab and bring
procedure A to set and then repeat this step. up the eprom settings (Figure 2-8). Arrange windows so
you can view the eprom window & Output Window
4. Stop engine. Remove diagnostic couplers.
values.
Procedure J - Setting Threshold on
Electronic Controllers

Eprom Window

Set

7
45
Value Window
Output Window

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3

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23

FIGURE 2-8

3. Start engine and run at @ idle rpm's, make sure to lower reaches approx 0.7 MPa (100 psi) hold it there and look
left armrest. at the value for Main Hoist up in the Output Window. If
the pressure goes over 0.7 MPa (100 psi) back the value
4. End caps for function ports GPA, GPB, GPC and GPD
down. To change the value double click the value you
(Figure 2-10) move joystick to full on for the function,
want to change in the Eprom Window and the value
monitor the pressure gage and adjust the Max down
window will turn blue.
counts to reach 2.0 MPa (295 psi) then adjust to 2.1
Enter the value for the Main hoist up and select “Set”
(300psi) ±0.4 MPa (50psi). Match the counts for the
and change the Main Hoist down with the same settings.
opposite side for Main hoist down and Aux hoist down,
Repeat again and make sure that it does not exceed 0.7
Lift up and Tele ext. (No test Fittings)
MPa (100 psi). Repeat this process for ports GPB, GPC,
5. End caps for function ports GP8 and GP9 (Figure 2-9) GPD (Figure 2-10) and GP8, GP9 (Figure 2-9) and enter
move joystick to full on for the function, monitor the values to respected function. Make sure to select SAVE
pressure gage and adjust the Max up or down on the ALL after completing the entered value settings.
counts to reach 1.9 MPa (275psi) ± 0.4 MPa (50psi).
7. After setting all of the functions and selecting save all,
6. Setting the starting threshold for each function. Start with select the File Down-Load button. Save the file in a
GPA Main Hoist Up (Figure 2-10). Monitor the pressure folder under the model designation (RT535E). Name the
gage and move the joystick just off center for Main Hoist file as follows: (Sales order number_Date). Sample:
in the up position. Watch the pressure gage, move until it (123456_2006aug17.

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RT540E SERVICE MANUAL HYDRAULIC SYSTEM

Procedure K - Setting Threshold and Max on #1) port with engine running at idle. Fully depress swing
Swing Brake Pedal brake pedal. Monitor the press gage and adjust the
swing brake solenoid Max counts to reach 1.68 MPa
1. Attach laptop to diagnostic connector in cab and bring (245 psi). Then raise the counts up to reach 1.7 MPa 250
up the eprom settings (shown in the Figure in section J.). psi.To set swing brake solenoid threshold. Slowly
Arrange windows so you can view the eprom window & depress swing brake pedal down until you reach).17
Output Window values MPa (25 psi) on the gage. Then looking at the swing
2. Set swing brake center percentage X & Y counts to 500.
brake output value, set the swing brake solenoid 2
threshold counts to that output value.
Attach test fitting and pressure gage GP4 (see in figure

7
3 45
23

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HYDRAULIC SYSTEM RT540E SERVICE MANUAL

Item Description
1 Procedure G- Pilot Supply PSI Reducing Valve
2 Procedure H - Swing Brake PSI Reducing Valve
3 Procedure C - Swing Left Port Relief Valve
4 Procedure F - Front Steer Load Sense Relief Valve
5 Procedure C - Swing Right Port Relief Valve
6 Gauge Port 2
7 Gauge Port 3
8 Gauge Port 6
9 Gauge Port 9
10 Gauge Port 8
11 Wire 1475
12 Gauge Port 4
13 Wire 50

7
3
1 2 8
45
13 9
3
23

12

7
11 10

4 5

6739-1

FIGURE 2-9

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RT540E SERVICE MANUAL HYDRAULIC SYSTEM

Item Description
1 Procedure A - Telescope Extend Port Relief
2 Procedure A - Load Sense Relief Valve
3 Procedure A - Telescope Retract Port Relief
2
4 Gauge Port 7

7
3 45
4
23

6739-2

3
FIGURE 2-10

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HYDRAULIC SYSTEM RT540E SERVICE MANUAL

Procedure B - Outrigger PSI Reducing Valve

7
45
6739-3
3

FIGURE 2-11
23

1
2

Item Description
1 Gas Valve Guard
2 Gas Valve

6739-4

FIGURE 2-12

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RT540E SERVICE MANUAL HYDRAULIC SYSTEM

Item Description
1 Procedure A -Pump Cut-Off Max Setting Adjustment
2 Procedure A - Pump P (Stand-by) Adjustment
2
1

7
3 45
23

6739-5

FIGURE 2-13

1
Item Description
1 Pump No. 3 Priority Flow Relief Adj.-80 bar (1160 psi)

FIGURE 2-14

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HYDRAULIC SYSTEM RT540E SERVICE MANUAL

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
hydraulic valves used on this crane. For a listing of all valves, NOTE: On each valve illustration in this section, each item
the circuit they are used in, and their physical location, refer number in table correlates to location on the valve,
to (Table 2-2). Refer to (Figure 2-15) for valve locations. The and to the valve hydraulic schematic.

Table 2-2
Valve Usage Table

Valve Name Circuit Used In Physical Location

Directional Control Valves Boom Lift/Telescope(s)/Hoist(s) Superstructure Right Side Plate
Swing/Steer Superstructure Right Side Plate
Steering Control Valve Front Axle Steer Control Cab Steering Column
Front Steer/Swing/Accessory Manifold Front Axle Steer Supply Superstructure Right Side Plate
Swing Directional Control
Swing Brake Release
Pilot Supply

7
Tandem Brake Valve with Treadle Service Brakes Cab Floor
Dual Accumulator Charging Valve Service Brakes Superstructure Left Side Plate
45
Accumulator(s) Service Brake Rear Superstructure
Holding Valves Boom Lift Lift Cylinder (Bolt on Manifold)
3
Telescope (3) Cylinder Port Blocks (Cartridge style)
Counterweight Removal (2) Cylinder Port Blocks (Cartridge style)
23

Axle Lockout, Rear Steer and Oil Axle Lockout Control Left Hand Carrier Frame Rail
Cooler Fan Motor Control Manifold Rear Steer Control
Oil Cooler Motor Control
Solenoid Valves:
Cross Axle Differential Lock Differential Lock (Optional) Carrier Inside Right Side Rail
1
Hoist Motor Control Valve Hoist(s) Both Hoists (see Hoist section)
Check Valves Return Circuit One in Parallel With Oil Cooler
Outrigger Control Manifold Outrigger On Front and Rear Face of Carrier
Frame Front and Rear Cross Member
Pilot Operated Check Valve Outrigger Port Block of each Stabilizer Cylinder
(4)
Cross Axle Differential Lock Valve Differential Lock (Optional) Carrier Bulkhead Plate Forward Of
The Engine
Range Shift and Parking Brake Valve Parking Brake Axle Disconnect Center of Rear Frame

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RT540E SERVICE MANUAL HYDRAULIC SYSTEM

3
5

7
3 45
1
23

6726

SUPERSTRUCTURE

FIGURE 2-15

Item Description Item Description

1 Hoist/Telescope/Lift Directional Valve 4 Secondary Steer Valve (CE Option)
2 Swing/Steer Directional Valve 5 Accumulator
3 Service Brake Dual Accumulator Charge Valve 6 Superstructure

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HYDRAULIC SYSTEM RT540E SERVICE MANUAL

4
6

7
45
6725
3
23

CARRIER
FIGURE 2-15 continued

Item Description Item Description

1 Front Outrigger Control Manifold 5 Axle Lockout Valve
2 Outrigger/Rear Steer Valve 6 Rear Outrigger Control manifold
3 Differential Lock Valve 7 Frame
4 Park Brake Range Shift Valve

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RT540E SERVICE MANUAL HYDRAULIC SYSTEM

DIRECTIONAL CONTROL VALVES NOTE: The lift/telescope/hoist valve bank weighs

approximately 81.30 kg (179.2 pounds).
Description 3. Remove the capscrews, washers and nuts securing the
The directional control valves direct and control hydraulic oil valve bank and remove the valve bank.
flow from the pumps to the boom lift and telescope cylinders,
each hoist motor, the swing motor, and the front steer Boom Lift/Telescope/Hoist Valve Bank
cylinders from the front steer control valve. The boom lift/
telescope/hoist directional control valve (Figure 2-16) is
Installation 2
located on the outside of the right superstructure side plate. 1. Place the valve bank on the superstructure side plate
The valve bank is removed and installed as an assembly. and secure it with the capscrews, washers and nuts.
Torque the capscrews see Fasteners and Torque
The boom lift/telescope/hoist control valve is a three position Values, page 1-11.
four way pressure compensated, closed center directional
valve. It receives pump flow from hydraulic swivel port 6 and 2. Connect the hydraulic lines to the valves as tagged
pump No. 1. Lift, telescope and hoist (s) functions are during removal.
controlled by proportional two position two way solenoid 3. Connect the electrical connectors as tagged during
cartridges installed into the valve’s casting under each spool. removal.
These valves receive an electrical signal from the controllers
on the cab armrest. Functional Check (All Valve Banks)
RCL lockout is achieved by de-energizing the proportional 1. Start the engine and run it at normal speed.
solenoids.
2. Operate the control levers of the valve bank(s). Check
The inlet section of the boom lift/telescope/hoist directional for smooth operation of cylinders and motors.

7
control valve contains a load sense relief valve set at 27,579
kPa/275.7 bar (4000 psi) protecting the main and auxiliary 3. Check the valve bank(s) and lines for leakage. Make
45
hoist and boom lift sections. The boom lift retract has a repairs as needed.
thermal port relief set of 29,647.4kPa/296.4 bar (4300 psi).
The telescope section has port reliefs set at 22,407.9 kPa/ Function Check - RCL Lockout Valves
224.0 bar (3250 psi) and 24,131.6 kPa/241.3 bar (3500 psi).
3
1. Remove circuit breaker F12 from the power panel in the
The swing directional control valve is installed on the outside cab. This cuts off power to the RCL.
23

of the right superstructure side plate. Refer to Accessory 2. Start the engine.
Manifold with Swing Directional Control Valve.
3. Try to telescope the boom out, lower the boom, hoist up
Maintenance the main hoist, and hoist the auxiliary hoist up (if
installed). Verify none of these functions work.
Boom Lift/Telescope/Hoist Valve Bank 4. Shut down the engine. Reinstall F12.
Removal
5. Telescope the boom out, lower the boom, hoist up the
1. Tag and disconnect all of the electrical connectors from main hoist, and hoist the auxiliary hoist up (if installed).
the valve. Verify all of these functions work.
2. Tag and disconnect the hydraulic lines from the valves. 6. Check for leaks. Make repairs as needed.
Cap or plug the lines and ports.

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HYDRAULIC SYSTEM RT540E SERVICE MANUAL

NOTE: Four section directional valve shown in illustration.

Three section directional valve is identical except it
contains no auxiliary hoist section. 17

11

14 7
2 5

3
1

6 16

7
45
13
15
9
3
12
23

10

18
4 FIGURE 2-16

Item Description Item Description

1 Port 1A -Main Hoist Up 11 Load Sense - Input Port
2 Port 1B - Main Hoist Down 12 Port PS - Pilot Supply
3 Port 2A - Aux Hoist Up 13 Gauge Port
4 Port 2B - Aux Hoist Down 14 Relief Valve - Telescope Extend
5 Port 3A - Telescope Extend 15 Relief Valve - Telescope Retract
6 Port 3B - Telescope Retract 16 Relief Valve - Lift
7 Port 4A - Lift Up 17 Relief Valve - Load Sense
8 Port 4B - Lift Down Proportional Two Position Two Way Solenoid
18
9 Load Sense - Outlet Port Cartridge

10 Port P1 - From Swivel Port 5

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RT540E SERVICE MANUAL HYDRAULIC SYSTEM

NOTE: Four section directional valve shown in illustration.

Three section directional valve is identical except it
contains no auxiliary hoist section.

3 4 2 14 5 6 7 8 16
12 1 15
11 2

17
10

13

Inlet Auxiliary Hoist Hoist Telescope Lift Outlet

7
45 18
3

Boom Lift/Telescope/Hoist Main Valve Hydraulic Schematic

23

FIGURE 2-16 continued

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HYDRAULIC SYSTEM RT540E SERVICE MANUAL

ACCESSORY WITH SWING DIRECTIONAL resistance check valve providing make-up oil to the swing
CONTROL MANIFOLD motor for motor over-run when the valve is centered. It
receives oil from pump #1 through swivel port 6. This section
Description is controlled by two proportional two position, three way
solenoid valves. These valves receive an electrical signal
The accessory manifold with swing directional valve from the cab armrest controllers.
(Figure 2-17) or (Figure 2-18) is located on the right side of
the turntable. The manifold contains two adjustable pressure Maintenance
reducing valves, five 3-way two position solenoid valves, 3-
way four position swing directional valve, and a check valve. Removal
One pressure reducing valve provides 1.72 mPa (250 psi) for 1. Tag and disconnect all of the electrical connectors or
operation of the swing brake. The other provides 17.2 mPa manual control levers.
(2500 psi) for the pilot circuit.
2. Tag and disconnect the hydraulic lines from the valves.
Each solenoid valve is held in its normally closed position by Cap or plug the lines and ports.
a spring. When the solenoid is energized, the plunger
assembly forces the spool to shift, causing the valve to shift. NOTE: The swing/steer/brake valve manifold weighs
De-energizing the solenoid causes spring pressure to shift approximately 10.0 kg (22.0 lb).
the spool to its normally closed position. 3. Remove the capscrews, lockwashers and flatwashers
One two position, three way solenoid valve serves as the securing the manifold. Remove the manifold.
swing brake release valve. This normally closed valve, when
de-energized, prevents hydraulic oil pressure from releasing Installation
the swing brake. When the swing brake switch is off, this 1. Place the manifold on the superstructure side plate and

7
valve opens to allow hydraulic oil pressure to release the secure with the capscrews, lockwashers and
swing brake. flatwashers. Torque the capscrews see Fasteners and
45
One proportional two position, three way solenoid valve Torque Values, page 1-11.
actuated by the cab swing foot brake proportionally supplies 2. Connect the hydraulic lines to the valves as tagged
pressurized oil to the swing drive brake. during removal.
3

The three position four-way swing directional valve is 3. Connect the electrical connectors to the valve as tagged
23

installed onto the manifold. Both swing working ports have during removal.
check valves that are flooded by a.41 mPa (60 psi)

9 4 23 2 21 20 8
19 16 25 5 6
27

12

3 7
13 22 18 26
11
14 15 28 24
10

7158-2
1
17 FIGURE 2-17

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RT540E SERVICE MANUAL HYDRAULIC SYSTEM

19 9 16 4 23 2 25 21 5 20 8 6 27

12

6753-2
15 3 28
13 22 7 11 24
14 10 26
18

FIGURE 2-18

7
17

23 11
45 21 20

See View A
3
for this side

10 11
23

12
18 8

View A
13 22
24
14
16
15 27
19
9

7
27
2

28
17 6
29
5
6753-4
3
4
1
FIGURE 2-18 continued

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HYDRAULIC SYSTEM RT540E SERVICE MANUAL

Item Description Item Description

1 Pilot Supply Relief Valve 15 Drain Port - D7 (Swing Brake/Lift Cylinder Pilot)
2 Gauge Port- GP4 16 Drain Port - D3 (Plugged)
3 Swing Brake Relief Valve 17 Gauge Port - GP2
4 Solenoid Valve - Swing Brake 18 Gauge Port - GP5
5 Solenoid Valve - Swing Brake Release 19 Drain Port - D1
6 Solenoid Valve - Pilot Supply 20 Gauge Port - GP3
7 Gauge Port - GP1 21 Swing Brake Release Port - SBR
8 Pilot Supply Port - PS 22 Drain Port - D5
9 Drain - D2 23 Swing Brake Supply Port -SBS
10 Port 2B - Swing Left 24 Tank Port
11 Port 2A - Swing Right 25 Gauge Port - GP6 (Plugged)
12 Swing Directional Valve 26 Gauge Port - GP8 (Plugged)
13 Drain Port - D4 (Swing Motor Pilot Supply) 27 Proportional Two Position Two Way Solenoid
14 Drain Port - D6 (Hoist/Tele/Lift valve Pilot Supply) 28 Steering Priority Valve
29 Steer Circuit Load Sense Relief

7
3 45
23

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RT540E SERVICE MANUAL HYDRAULIC SYSTEM

STEERING CONTROL VALVE 3. Remove the capscrews and washers and remove the
valve from the steering column.
Description
Installation
The steering control unit (Figure 2-19) controls hydraulic flow
to the front steering cylinders. It is located on the steering 1. Secure the valve to the steering column and secure with
column of the cab. the capscrews and washers. Torque the capscrews see

Both work ports are connected to the rod side of one steer
Fasteners and Torque Values, page 1-11.
2
cylinder and to the piston side of the other steer cylinder. A 2. Connect the hydraulic hoses to the ports on the valve as
steering wheel input will connect the load sense port #5 to tagged during removal.
the steering cylinder load demand by way of the steer priority 3. Connect the electrical connector to the valve as tagged
valve located in the swing/steer manifold. during removal.
Displacement of the valve is 315 cm³ (19.22 in³). 4. Verify proper operation of the valve.
Maintenance 5. Check valve and hydraulic connections for leaks. Make
repairs as needed.
Removal
1. Tag and disconnect the electrical connector to the valve.
2. Tag and disconnect the hydraulic hoses from the valve.
Cap or plug the lines and ports.

7
2 5
1
5
3 45
23

2
6747-2

3
4 4
Valve Hydraulic Schematic 1
6747

Item Description
1 Port T - Tank Port - To Swivel Port 4
2 Port P - Pressure From Port 1B- Accessory Manifold
3 Port R - To Right Front Steer Cylinder
4 Port L - To Left Front Steer Cylinder
5 Port LS - From Port 1A - Accessory Manifold
FIGURE 2-19

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HYDRAULIC SYSTEM RT540E SERVICE MANUAL

TANDEM BRAKE VALVE WITH TREADLE switch and a mechanical spring assembly to limit the output
PEDAL pressure to the brake actuators to 10,342 kPa/10.3 bar
(1500 psi).
Description
Maintenance
The tandem brake valve with treadle pedal (Figure 2-20) is
located on the floor of the cab. The tandem brake valve Removal
provides split system braking for the primary (front) brakes
and the secondary (rear) brakes. 1. Tag and disconnect the electrical connector to the valve.

The valve modulates the output pressure 10,342 kPa/10.3 2. Tag and disconnect the hydraulic hoses from the valve.
bar (1500 psi) to the brake actuators. The valve is Cap or plug the lines and ports.
mechanically actuated by a treadle pedal (Figure 2-20). The 3. Remove the capscrews, lockwashers, flatwashers and
direct acting spool provides a pedal feel which accurately nuts securing the valve to the cab Floor. Remove the
represents the brake pressure, similar to automotive style valve.
pedal feedback as the brake pedal pressure increases, the
pedal effort increases proportionally. As the pedal is initially Installation
actuated, the tank ports are closed off from the brake ports.
With further application of the pedal, the pressure ports are 1. Secure the valve to the cab floor with the capscrews,
opened to the brake ports until the pedal actuation force and lockwashers, fl atwas hers and nuts. Torque the
the hydraulic pressure force are balanced. capscrews see Fasteners and Torque Values, page 1-
11.
Also when the pedal is actuated, a pressure switch located
off a tee in port P2 provides an electrical signal for brake 2. Connect the hydraulic hoses to the ports on the valve as
lights. When the pedal is released, the valve and the pedal tagged during removal.

7
return to the non-applied position. In normal operation, the 3. Connect the electrical connector to the valve as tagged
45
secondary system is piloted from the primary section during removal.
providing pressure to both systems.
4. Start the engine and check valve and hoses for leaks.
The tandem brake valve consists of a tandem valve body, a Make repairs as needed.
closed center spool, a treadle pedal, an integral proximity
3
23

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RT540E SERVICE MANUAL HYDRAULIC SYSTEM

1
5
2
2

3 4

Valve Hydraulic Schematic

6745-2
Item Description
1 Pressure Port P1 2 6745-1
2 Pressure Port P2
3 Port F1- Front Brakes

7
1 5
4 Port F2 - Rear Brakes 4
45
5 Port T - Tank 3 FIGURE 2-20
3
23

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HYDRAULIC SYSTEM RT540E SERVICE MANUAL

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. The Removal
purpose of the valve is to provide pressure regulation to the
service brake circuit. 1. Tag and disconnect the hydraulic hoses from the valve.
Cap or plug the lines and ports.
The dual accumulator charge valve consists of an inlet main
check valve, a load sense control section with a pilot spool 2. Remove the capscrews, flatwashers and lockwashers
that controls the pump stroke and an inverted shuttle that securing the valve to the turntable. Remove the valve.
controls the accumulator charging (Figure 2-21).
Installation
When the valve is charging the accumulators, the load sense
control section is in neutral position, connecting the load to 1. Position the valve on the turntable and secure with the
the pump by way of the load sense line. This brings the capscrews, flatwashers, and lockwashers. Torque
piston pump No. 1 on stroke to supply fluid for charging. capscrews see Fasteners and Torque Values, page 1-11
Fluid passes through the main check valve connecting to the
2. Connect the hydraulic hoses to the valve ports as tagged
pilot end and through the spool onward to the inverted
during removal.
shuttle that connects the accumulators.
3. Start the engine and check for leaks. Make repairs as
When the control pilot spool bias spring senses the low limit
needed.
pressure of 13,445 kPa/134 bar (1950 psi), the spool shifts to
the neutral position, allowing the pump to charge the 4. Depress the brake pedal several times to cause the

7
accumulators to a maximum of 16,202 kPa/162 bar (2350 brake valve to charge. Make several turns with the
psi). The inverted shuttle cartridge senses the pressure in steering wheel, and swing the superstructure left and
45
the accumulators to pilot the cartridge closed when right. Verify the brakes, swing, and front steering work
maximum charge pressure is reached. Maximum charge properly.
3
23

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RT540E SERVICE MANUAL HYDRAULIC SYSTEM

2
Item Description
5 4
1 Port LS - Load Sense Port
2 Port T - Tank Port
3 Port P - Pressure Port
3 2
4 Accumulator Port 1A
5 Accumulator Port 2A
6 Pressure Switch

1
6 6
6

1
6696-2
6696-1
2

7
45
6696-3
5 4
3
Valve Hydraulic Schematic
FIGURE 2-21
23

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HYDRAULIC SYSTEM RT540E SERVICE MANUAL

HYDRAULIC ACCUMULATOR SERVICE 3. Remove the two nuts securing each clamp half. Remove
BRAKE the each clamp half and accumulator from the turntable.

Description Installation
The service brake hydraulic accumulators are located on the 1. Position the accumulator in the clamps and secure with
outside of the left superstructure side plate behind the cab. the removable clamp halves and nuts.
The purpose of each accumulator is to provide stored 2. Connect the hydraulic hose to the port on the
energy, an oil volume of 1.23 l (75.1 cu in) at a maximum accumulator as tagged during removal.
pressure of 27,579 kPa/275 bar (4000 psi), to actuate the
service brake circuits. The dual accumulator charge valve 3. Pre-charge the accumulator. Refer to paragraph titled
regulates flow to the hydraulic accumulators to provide fully Pre-Charging Accumulator in Sub-Section titled
powered independently separate, primary (front) and Pressure Setting Procedures.
secondary (rear), service brake circuits. 4. Start the engine and check accumulator and hoses for
Each accumulator has two chambers divided by a piston. leaks. Make repairs as needed.
One side is pre-charged to 5,515.8 kPa/55.1 bar (800 psi) 5. Depress the brake pedal several times, make several
with high purity nitrogen. This maintains a constant pressure turns with the steering wheel, and swing the
in the other chamber which is connected to the modulating superstructure left and right. Verify the brakes, swing,
brake valve. After the accumulators are fully charged, they and front steering work properly.
will provide the necessary brake system flow and pressure to
actuate the brakes. Servicing
The accumulator consists of a tube, piston, seals, gas The pre-charge nitrogen pressure should be checked every
charging valve, and a gas valve guard.

7
200 hours or once a month, whichever comes first. Refer to
Pressure Setting Procedures in this section.
Maintenance
45
Removal
3
1. With the engine shutdown, deplete the hydraulic
pressure in the accumulators by depressing the service
23

brake pedal several times.

2. Tag and disconnect the hydraulic hose from the
accumulator. Cap or plug the line and port.

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RT540E SERVICE MANUAL HYDRAULIC SYSTEM

HOLDING VALVES Removal

Description 1. Unscrew holding valve from its port block or manifold.

A bolt-on manifold style holding valve is installed on the Installation

boom lift cylinder. A cartridge style holding valve is used on
the telescope cylinder installed in the piston side of the 1. Check the inside of the port block or manifold for any
sharp edges or burrs and remove as necessary with
cylinder.
emery cloth. 2
The holding valve provides meter out control, will lock the
cylinder in place, prevent a load from running ahead of the oil 2. Install new O-rings onto the holding valve.
supply, and will relieve excess pressure caused by thermal 3. Lubricate the holding valve and O-rings with clean
expansion. hydraulic oil.

Maintenance
CAUTION
Do not damage the O-rings during installation of the
holding valve. If the holding valve turns freely then gets
DANGER hard to turn, then easy to turn, remove the holding valve
Boom must be fully lowered and fully retracted before and check the O-rings. They have probably been
removing lift cylinder and telescope cylinder holding damaged by a sharp edge of a port.
valves. The counterweight must be removed or pinned
before removing counterweight removal cylinder holding NOTE: The holding valve should turn by hand until
valves. compression of the O-rings begins.

7
4. Carefully install the holding valve into the port block or
45
manifold until fully seated.
5. Test the holding valve and port block or manifold by
operating the lift cylinder and/or the telescope cylinder,
3
as applicable. Verify lift cylinder and/or telescope
cylinder works without problems; verify there is no
23

leaking. Make repairs as needed.

GROVE Published 2-26-2014, Control # 414-03 2-43

HYDRAULIC SYSTEM RT540E SERVICE MANUAL

CROSS AXLE DIFFERENTIAL LOCK VALVE Maintenance

Description Removal
The optional cross axle differential lock valve is mounted on 1. Tag and disconnect the electrical connector from the
the right side of the aft center frame cross member. The valve.
valve consists of a three way, two position solenoid valve and
a pressure reducing valve (Figure 2-22) and (Figure 2-23) or 2. Tag and disconnect the hydraulic lines attached to the
a three-way, two position valve without a reducing valve.The valve. Cap or plug lines and ports.
valve is used to control the application of the crane’s 3. Remove the capscrews, flatwashers, lockwashers and
hydraulically applied and released cross axle differential lock nuts securing the valve to the frame. Remove the valve.
actuators.
Pressing the top of the cross axle differential lock switch on Installation
the front console shifts the three-way, two-position solenoid 1. Secure the valve to the frame with the capscrews
valve so hydraulic oil can flow to the engage port of the cross flatwashers, lockwas hers and nuts. Torque the
axle differential lock actuators, extending them. When the capscrews see Fasteners and Torque Values, page 1-
actuators extend, they engage the splines on the differential 11.
case and the axle shafts to lock the differential assemblies
together. 2. Connect the hydraulic lines to the valve as tagged during
removal.
Releasing the cross axle differential lock switch unlocks the
three-way, two-position solenoid valve so hydraulic oil can 3. Connect the electrical connector to the valve as tagged
flow to the disengage port of the actuators, retracting them. during removal.
As the actuators retract, they unlock the axles.

7
4. Apply and release the cross axle differential lock several
times. Verify the cross axle differential lock holds the
45
axle from moving when applied so there is no differential
action between the wheels.
5. Check for leaks. Make repairs as needed.
3
23

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RT540E SERVICE MANUAL HYDRAULIC SYSTEM

1
Item Description
1 Three-Way Solenoid Valve
2 Pressure Reducing Valve

3
Port P - From Pressure Port On 6 2
Transmission
4 Port C - To Cylinders On Axles
5 Port T - To Tank Port On Transmission
6 Port G - Gauge Port
4
1
5
6

3
2
4

7
2
45
5
6718-2 6718-1
Hydraulic Schematic
3
FIGURE 2-22
23

Item Description
1 Port 1 to Front and Rear Axle
2 Port 2 to Park Brake/Shift Valve Port P
3 Port 3 to Park Brake/Shift Valve Port T
4
4 Solenoid Valve (Connector not shown)

1
2

3 7011-1
1
Hydraulic Schematic
7011-2 FIGURE 2-23

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HYDRAULIC SYSTEM RT540E SERVICE MANUAL

OUTRIGGER CONTROL MANIFOLD Inspection

Description Visually inspect the valves and hydraulic connections for any
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.
outriggers. The manifold consists of four normally closed two
position two way solenoid valves (Figure 2-24). They are Installation
mounted inside the frame of their respective outrigger box.
1. Position the manifold on the mounting and secure with
When energized, the solenoid shifts the spool to open the lockwashers, flatwashers, nuts and capscrews.
allowing extension or retraction of the outrigger cylinders. Torque capscrews see Fasteners and Torque Values,
page 1-11.
Maintenance
2. Connect the electrical connectors to the solenoids as
Removal marked during removal.
3. Connect the hydraulic lines to the valves as marked
1. Tag and disconnect the hydraulic lines to the solenoid
during removal.
valves; cap all lines and openings.
2. Tag and disconnect the electrical connectors. Functional Check
3. Remove the capscrews, nuts, lockwashers and Activate the hydraulic system and cycle the affected
flatwashers securing the manifold to the outrigger box; cylinder(s) several times. Observe for proper functioning of
remove the manifold. the affected cylinder(s). Ensure the solenoid valve hydraulic
connections are secure.

7
45
4
3

1 2
3
5
6 7 8
23

6544-2 8
7
1 2 3 4
6
9
5
6544-1

FIGURE 2-24

Item Description Item Description

1 Solenoid Valve - Left Front or Rear Extension Cyl 6 Outlet Port Left Front or Rear Stabilizer Cyl
2 Solenoid Valve - Left Front or Rear Stabilizer Cyl 7 Outlet Port Right Front or Rear Stabilizer Cyl
3 Solenoid Valve Right Front or Rear Stabilizer Cyl 8 Outlet Port Right Front or Rear Extension Cyl
4 Solenoid Valve Right Front or Rear Extension Cyl In Port (Far Side) - From Port B of Outrigger
9
Selector Valve
5 Outlet Port - Left Front or Rear Extension Cyl

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RT540E SERVICE MANUAL HYDRAULIC SYSTEM

PILOT OPERATED CHECK VALVE 3. Lubricate the check valve and O-rings with clean
hydraulic oil.
Description
A pilot operated (PO) check valve is located in each CAUTION
outrigger stabilizer cylinder port block. The check valve Do not damage the O-rings during installation of the check
functions as a holding valve for the stabilizer cylinder. Oil valve. If the check valve turns freely then gets hard to turn,
flow is directed from the “V” port to the “C” ports, while
blocking flow in the opposite direction. Flow is reversed from
then easy to turn, remove the check valve and check the 2
O-rings. They have probably been damaged by a sharp
“C” to “V” when pressure pilot oil is applied to the opposite edge of a port.
side “V” port (Figure 2-25)
NOTE: The check valve should turn by hand until
Maintenance compression of the O-rings begins.
Removal 4. Carefully install the check valve into the port block until
fully seated.
1. Unscrew the check valve from the stabilizer cylinder port
block. 5. Test the check valve and port block by operating the
affected outrigger’s stabilizer cylinder. Verify it extends
Installation and retracts without problems; verify there is no leaking.
Make repairs as needed.
1. Check the inside of the port block for any sharp edges or
burrs and remove as necessary with emery cloth.
2. Install new O-rings onto the check valve.

7
45
Item Description
1 Port C - Cylinder
3

2 Port P - Pilot 1
23

3 Port V - Valve

6155

6155-2 3

3 FIGURE 2-25

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HYDRAULIC SYSTEM RT540E SERVICE MANUAL

INTEGRATED OUTRIGGER/REAR STEER Maintenance

MANIFOLD
Removal
Description 1. Tag and disconnect the electrical connectors to the
The integrated outrigger/rear steer manifold (Figure 2-26) valve.
controls the outrigger and rear steer circuit. The valve is 2. 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.
axle.
3. Remove the capscrews and washers securing the valve
The manifold is made up of two sections; an inlet section and to the frame bracket. Remove the valve.
a working section.
The inlet section contains a 17,200 kPa/172 bar (2500 psi) Installation
pressure reducing valve and a load sense shuttle valve. The
1. Secure the valve to the frame bracket with the washers
solenoid valve is a normally closed two position two way
and capscrews. Torque the capscrews see Fasteners
valve. It unloads the load sense line to the pump to ensure
and Torque Values, page 1-11.
the pump is de-stroked during engine start.
2. Connect the hydraulic hoses to the ports on the valve as
The rear steer section contains a three position four way
tagged during removal.
solenoid controlled directional valve that controls left and
right rear steer. The rear steer cylinders are positive locked 3. Connect the electrical connectors to the valve as tagged
by the double pilot operated check valves integral to the work during removal.
ports.
4. Verify operation as follows:

7
The outrigger section contains a three position four way pilot
• Operate the rear steer left and right to verify smooth
controlled directional valve, two check valves, two load
operation.
45
sense shuttle valves, and two, two position three way
solenoids for pilot control of the outrigger extend and retract • On outriggers, swing over the front outriggers to ensure
function. the oscillation cylinders lockout.
3
• Remove the electrical connection from the oil cooler
motor two position three-way solenoid valve to verify
23

that it operation.
5. Check valve and hoses for leaks. Make repairs as
needed.

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RT540E SERVICE MANUAL HYDRAULIC SYSTEM

18 19
17

16

21

6751-3

View A

7
1 7 6
45
10
5
3
23

15
See View A
for this side

12

13

14
20 11

8, 9 6751-1

FIGURE 2-26

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HYDRAULIC SYSTEM RT540E SERVICE MANUAL

18 19 5 21
2 22 6 20

22
11

3 22

7
16
1
4

17

15 14

13

12

7
45
10
3
22 6751-2
23

FIGURE 2-26 continued

Item Description Item Description

1 Pressure Reducing Valve - PR1 12 Load Sense - LS0
2 Check Valve - CV1 13 Load Sense - LS1
3 Orifice - ORF1 14 Port ALO - To Axle Lockout Valve
4 Solenoid Valve - Rear Steer S1 15 Port T - Tank
5 Solenoid Valve - Rear Steer S2 16 Port G1 - Gauge Port
6 Solenoid Valve - SV2 17 Port P - Pressure From Pump #1
7 Solenoid Valve - SV1 18 Port A - Outrigger Retract
8 Gauge Port - G2 19 Port B - Outrigger Extend
9 Orifice - ORF2 20 Port RSA - Left Rear Steer
10 Solenoid - SF1 21 Port RSB - Right Rear Steer
11 Check Valve - CV4 22 Load Sense Shuttle valve

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RT540E SERVICE MANUAL HYDRAULIC SYSTEM

CHECK VALVES Maintenance

Description Removal
Check valves are used in the crane hydraulic system to block 1. 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.
direction.
A check valve is plumbed in-line at the inlet of the front steer
Installation 2
control valve. It prevents steering wheel kick-back if the steer 1. Connect the hydraulic lines as tagged during removal.
cylinder pressure rises above the inlet port pressure.
2. Check valve and hydraulic connections for leaks. Make
repairs as needed.

7
3 45
23

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HYDRAULIC SYSTEM RT540E SERVICE MANUAL

RANGE SHIFT/PARKING BRAKE VALVE Maintenance

Description Removal
The range shift/parking brake valve controls the flow of oil to 1. 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 2-27).
The valve is located on the center of the frame. Pressure is 2. Tag and disconnect the hydraulic hoses from the valve.
supplied to the valve from the transmission charge pump. Cap or plug the lines and ports.

The parking brake solenoid valve is a two position three-way 3. Remove the capscrews, lockwashers, flatwashers and
valve. In its de-energized position, the inlet port is blocked nuts securing the valve to the frame. Remove the valve.
and the parking brake actuator is drained to the reservoir.
When the solenoid is energized, the reservoir port is blocked Installation
and pressurized oil is directed to the actuator, engaging the 1. Secure the valve to the frame with the nuts, flatwashers,
parking brake. lockwashers and capscrews. Torque the capscrews see
The range shift solenoid valve is a two position four-way Fasteners and Torque Values, page 1-11.
valve. In its de-energized position, pressurized oil flows to 2. Connect the hydraulic hoses to the ports on the valve as
the “A” port of the range shift actuator, while the “B” port is tagged during removal.
drained to the reservoir along with the axle disconnect
actuator for two wheel drive/high range. When the solenoid 3. Connect the electrical connectors to the valve as tagged
is energized, pressurized oil is directed to the “B” port of the during removal.
range shift actuator and the axle disconnect actuator while
port “A” of the range shift actuator is drained to the reservoir Functional Tests

7
for four wheel drive/low range. 1. Start and idle engine.
45
2. With units on outriggers, check for proper two/four wheel
operation.
3

Item Description
23

7
1 Port P - Pressure 6

2 Port T - Tank
3 Port A - Range Shift Actuator
4 Port B - Range Shift Actuator
5 Port PB - To Park Brake
6 Solenoid Valve - Range Shift 8

7 Solenoid Valve - park Brake

8 Pressure Switch

8 5 3 4
7 6

2
5
1
3

1 4 6697-1
2

6697-2
Hydraulic Schematic
FIGURE 2-27

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RT540E SERVICE MANUAL HYDRAULIC SYSTEM

AXLE OSCILLATION LOCKOUT VALVE Maintenance

(STANDARD UNITS)
Removal
Description 1. Tag and disconnect the electrical connectors to the
The axle oscillation lockout valve is used in the rear axle valve.
oscillation lockout circuit. The valve is located on the left 2. Tag and disconnect the hydraulic hoses from the valve.
inner center frame rail. It consists of a valve body and two Cap or plug the lines and ports. 2
normally-closed, two way, two position solenoid valves. It
keeps the lockout cylinders from oscillating unless the 3. Remove the capscrews, hex nuts, flatwashers and
turntable is centered forward. lockwashers securing the valve to the frame. Remove
the valve.
The area definition potentiometer in the electrical swivel
energizes and deenergizes the axle oscillation relay. When Installation
the superstructure is more than 6 degrees left or right of
directly over the front, the axle oscillati on rel ay is 1. Secure the valve to the crane with the capscrews, hex
deenergized. nuts, flatwashers and loc kwashers. Torque the
capscrews see Fasteners and Torque Values, page 1-
When the axle oscillation relay’s contacts are open, the
11.
normally closed solenoid valves are deenergized and isolate
the lockout cylinders from hydraulic oil supply. This keeps the 2. Connect the hydraulic hoses to the ports on the valve as
cylinders from oscillating (moving up and down) because tagged during removal.
hydraulic oil cannot leave the cylinders. Instead, the
3. Connect the electrical connectors to the valve as tagged
cylinders remain full of hydraulic oil and rigid.
during removal.

7
When the axle oscillation relay’s contacts are closed, the
4. Check valve and hoses for leaks. Make repairs as
solenoid valves are energized and open. This allows
45
needed.
hydraulic oil in and out of the cylinders, allowing them to
oscillate.
3
23

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HYDRAULIC SYSTEM RT540E SERVICE MANUAL

4
1
4
4

2
3
3

Hydraulic Schematic 6694-2

6694-1

7
FIGURE 2-28
45
Item Description
3

Port C- Pressure From Axle Lockout Port On

1 3 Port B - To Left Hand Lockout Cylinder
Outrigger Selector Valve
23

2 Port A - To Right Hand Lockout Cylinder 4 Solenoid Valve

AXLE OSCILLATION LOCKOUT VALVE cylinders from oscillating (moving up and down) because
(OPTIONAL CE UNITS) hydraulic oil cannot leave the cylinders. Instead, the
cylinders remain full of hydraulic oil and rigid.
Description When the axle oscillation relay’s contacts are closed, the
solenoid valves are energized and open. This allows
The axle oscillation lockout valve is used in the rear axle
hydraulic oil in and out of the cylinders, allowing them to
oscillation lockout circuit. The valve is located on the left
oscillate.
inner center frame rail. It consists of a valve body, a normally-
closed two way, two position solenoid valve and a pressure
reducing valve. It keeps the lockout cylinders from oscillating
Maintenance
unless the turntable is centered forward.
Removal
The area definition potentiometer in the electrical swivel
energizes and deenergizes the axle oscillation relay. When 1. Tag and disconnect the electrical connectors to the
the superstructure is more than 6 degrees left or right of valve.
directly over the front, the axle oscillati on relay is 2. Tag and disconnect the hydraulic hoses from the valve.
deenergized. Cap or plug the lines and ports.
When the axle oscillation relay’s contacts are open, the 3. Remove the capscrews, hex nuts, flatwashers and
normally closed solenoid valves are deenergized and isolate lockwashers securing the valve to the frame. Remove
the lockout cylinders from hydraulic oil supply. This keeps the the valve.

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RT540E SERVICE MANUAL HYDRAULIC SYSTEM

Installation 3. Connect the electrical connectors to the valve as tagged

during removal.
1. Secure the valve to the crane with the capscrews, hex
nuts, flatwashers and lockwas hers. Torque the 4. Check valve and hoses for leaks. Make repairs as
capscrews see Fasteners and Torque Values, page 1- needed.
11.
2. Connect the hydraulic hoses to the ports on the valve as
tagged during removal. 2
5 4

2
6

7
1 1
45
5
3
2 6719-1
23

3
6719-2
Hydraulic Schematic
6
FIGURE 2-29

Item Description Item Description

Port P - Pressure From Axle Lockout Port On 4 Solenoid Valve
1
Outrigger Selector Valve
5 Port B - To Load Sense Line
2 Port T - Tank
7 Port P1 - To Lockout Cylinder
3 Pressure Reducing Valve

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HYDRAULIC SYSTEM RT540E SERVICE MANUAL

CYLINDERS Maintenance
General General
This subsection provides descriptive information for all the There must be a gap between the ends of each wear ring
hydraulic cylinders used on this crane. The description of the when it is installed onto the piston (as applicable) or head. In
cylinder given here is for the cylinder itself. For information addition, each wear ring gap is to be located as follows:
on how the cylinder functions in the individual circuits, refer Divide 360 degrees by the number of wear rings on the
to the Description and Operation of that circuit. component. The resulting value is the number of degrees
each wear ring gap is to be located with respect to each
other.
The approximate wear ring gaps are as follows:

Table 2-3
Wear Ring Gap

Head (or Piston) Size Wear Ring Gap

Inch mm Inch mm
1 to 4.75 25.4 to 120.7 0.125 3.18
5 to 10.0 127.0 to 254.0 0.187 4.75
greater than 10.0 greater than 254.0 0.250 6.35

7
Surface Protection for Cylinder Rods Leakage Check
45
Steel cylinder rods include a thin layer of chrome plating on A hydraulic cylinder should not be disassembled unless it is
their surfaces to protect them from corroding. However, essential. The following checks will provide a means of
chrome plating inherently has cracks in its structure which determining if a cylinder has a faulty or leaking piston seal.
3

can allow moisture to corrode the underlying steel. At typical

1. Extend the rod to its maximum stroke. Remove the
ambient temperatures, hydraulic oil is too thick to penetrate
23

retract hose from the cylinder. Cap the retract hose.

these cracks. Normal machine operating temperatures will
allow hydraulic oil to warm sufficiently to penetrate these
cracks and if machines are operated daily, protect the rods.
Machines that are stored, transported, or used in a corrosive
environment (high moisture, rain, snow, or coastline DANGER
conditions) need to have the exposed rods protected more Ensure pressure is applied to the piston side of the
frequently by applying a protectant. Unless the machine is cylinder only and the retract hose is capped.
operated daily, exposed rod surfaces will corrode. Some
cylinders will have rods exposed even when completely 2. Apply hydraulic pressure to the piston side of the
retracted. Assume all cylinders have exposed rods, as cylinder and observe the open cylinder port for leakage.
corrosion on the end of the rod can ruin the cylinder. If leakage is observed, the seals in the cylinder must be
replaced.
It is recommended that all exposed cylinder rods be
protected using Boeshield® T-9 Premium Metal Protectant. 3. Fully retract the cylinder rod (except the telescope
Manitowoc Crane Care has Boeshield® T-9 Premium Metal cylinder). Remove the extend hose from the cylinder.
Protectant available in 12 oz. cans that can be ordered Cap the extend hose.
through the Parts Department.
NOTE: Cylinder operation and inclement weather will
remove the Boeshield® protectant; therefore,
inspect machines once a week and reapply
DANGER
Boeshield® to unprotected rods. Ensure pressure is applied to the retract (rod) side of the
cylinder only and that the extend hose is capped.

4. Apply hydraulic pressure to the retract (rod) side of the

cylinder and observe the open cylinder port for leakage.

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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
5. Reconnect all cylinder ports.
cooling oil.
Temperature Effects on Hydraulic Cylinders If a load and the boom is allowed to remain stationary for a
period of time and the ambient temperature is cooler than the
Hydraulic oil expands when heated and contracts when
cooled. This is a natural phenomena that happens to all
trapped oil temperature, the trapped oil in the cylinders will
cool. The load will lower as the telescope cylinder(s) retracts 2
liquids. The coefficient of expansion for API Group 1 allowing the boom to come in. Also, the boom angle will
hydraulic oil is approximately 0.00043 cubic inches per cubic decrease as the lift cylinder(s) retracts causing an increase
inch of volume for 1°F of temperature change. Thermal in radius and a decrease in load height.
contraction will allow a cylinder to retract as the
hydraulic fluid which is trapped in the cylinder cools. This situation will also occur in reverse. If a crane is set up in
The change in the length of a cylinder is proportional to the the morning with cool oil and the daytime ambient
extended length of the cylinder and to the change in temperature heats the oil, the cylinders will extend in similar
temperature of the oil in the cylinder. For example, a cylinder proportions.
extended 25 feet in which the oil cools 60°F would retract
The charts below have been prepared to assist you in
approximately 7 3/4 inches (see chart below). A cylinder
determining the approximate amount of retraction/extension
extended 5 feet in which the oil cools 60°F would only retract
that may be expected from a hydraulic cylinder as a result of
approximately 1 1/2 inches. The rate at which the oil cools
change in the temperature of the hydraulic oil inside the
depends on many factors and will be more noticeable with a
cylinder. The chart is for dry rod cylinders. If the cylinder rod
larger difference in oil temperature verses the ambient
is filled with hydraulic oil, the contraction rate is somewhat
temperature.
greater.

7
Thermal contraction coupled with improper lubrication or
NOTE: Operators and service personnel must be aware
improper wear pad adjustments may, under certain
45
that load movement, as a result of this phenomena,
conditions, cause a “stick-slip” condition in the boom. This
can be easily mistaken as leaking cylinder seals or
“stick-slip” condition could result in the load not moving
faulty holding valves. If leaking seals or faulty
smoothly. Proper boom lubrication and wear pad adjustment
holding valves are suspected to be the problem,
3
is important to permit the boom sections to slide freely. Slow
refer to Service Bulletin 98-036 dealing with testing
movement, of the boom may be undetected by the operator
telescope cylinders.
23

unless a load is suspended for a long period of time. To

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HYDRAULIC SYSTEM RT540E SERVICE MANUAL

Table 2-4 Boom Drift Chart (Cylinder length change in inches)

3 3
Coeff. = 0.00043 (in /in / °F)
STROKE Temperature Change (°F)
(FT.) 10 20 30 40 50 60 70 80 90 100
5 0.26 0.52 0.77 1.03 1.29 1.55 1.81 2.06 2.32 2.58
10 0.52 1.03 1.55 2.06 2.58 3.10 3.61 4.13 4.64 5.16
15 0.77 1.55 2.32 3.10 3.87 4.64 5.42 6.19 6.97 7.74
20 1.03 2.06 3.10 4.13 5.16 6.19 7.22 8.26 9.29 10.32
25 1.29 2.58 3.87 5.16 6.45 7.74 9.03 10.32 11.61 12.90
30 1.55 3.10 4.64 6.19 7.74 9.29 10.84 12.38 13.93 15.48
35 1.81 3.61 5.42 7.22 9.03 10.84 12.64 14.45 16.25 18.06
40 2.06 4.13 6.19 8.26 10.32 12.38 14.45 16.51 18.58 20.64
45 2.32 4.64 6.97 9.29 11.61 13.93 16.25 18.58 20.90 23.22
50 2.58 5.16 7.74 10.32 12.90 15.48 18.06 20.64 23.22 25.80
55 2.84 5.68 8.51 11.35 14.19 17.03 19.87 22.70 25.54 28.38
60 3.10 6.19 9.29 12.38 15.48 18.58 21.67 24.77 27.86 30.96

3 3
Length change in inches = Stroke (Ft.) X Temperature Change ( °F) X Coeff. (in /in / °F) X 12 in/ft

Table 2-5 Boom Drift Chart (Cylinder length change in millimeters)

7
Coeff. = 0.000774 (1/ °C)
STROKE Temperature Change (°C)
45
(m) 5 10 15 20 25 30 35 40 45 50 55
1.5 5.81 11.61 17.42 23.22 29.03 34.83 40.64 46.44 52.25 58.05 63.86
3 11.61 23.22 34.83 46.44 58.05 69.66 81.27 92.88 104.49 116.10 127.71
4.5 17.42 34.83 52.25 69.66 87.08 104.49 121.91 139.32 156.74 174.15 191.57
3

6 23.22 46.44 69.66 92.88 116.10 139.32 162.54 185.76 208.98 232.20 255.42
7.5 29.03 58.05 87.08 116.10 145.13 174.15 203.18 232.20 261.23 290.25 319.28
23

9 34.83 69.66 104.49 139.32 174.15 208.98 243.81 278.64 313.47 348.30 383.13
10.5 40.64 81.27 121.91 162.54 203.18 243.81 284.45 325.08 365.72 406.35 446.99
12 46.44 92.88 139.32 185.76 232.20 278.64 325.08 371.52 417.96 464.40 510.84
13.5 52.25 104.49 156.74 208.98 261.23 313.47 365.72 417.96 470.21 522.45 574.70
15 58.05 116.10 174.15 232.20 290.25 348.30 406.35 464.40 522.45 580.50 638.55
16.5 63.86 127.71 191.57 255.42 319.28 383.13 446.99 510.84 574.70 638.55 702.41
18 69.66 139.32 208.98 278.64 348.30 417.96 487.62 557.28 626.94 696.60 766.26

Length change in mm = Stroke (m) X Temperature Change ( °C) X Coeff. (1/ °C) X 1000 mm/m

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RT540E SERVICE MANUAL HYDRAULIC SYSTEM

LIFT CYLINDER 6. 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
The lift cylinder (Figure 2-30) has a bore of 22.8 cm (9.0 disassembly will aid in installation of new seals and
inches). The retracted length of the cylinder from the center rings. Pay attention to how each seal and ring is
of the barrel bushing to the center of the rod bushing is installed to avoid installing replacement seals and
265.1cm (104.4 inches). The extended length of the cylinder
from the center of the barrel bushing to the center of the rod
rings improperly.
2
7. Remove the set screw securing the piston to the rod.
bushing is 464.5 cm (182.9 inches). Its stroke is 199.3 cm
(78.5 inches). A wiper ring prevents foreign material from 8. Unscrew the piston from the rod.
entering the cylinder. O-rings and other seals prevent 9. Remove the O-ring and two backup rings from the inside
internal and external leakage. of the piston.
The cylinder weighs approximately 578 kg (1274.2 lb). 10. Remove the head from the rod.
Maintenance 11. Remove the O-ring and the backup ring from the outside
of the head and the wear ring, buffer seal, deep Z rod
Disassembly seal, and wiper ring from the inside of the head.

NOTE: Any maintenance requiring disassembly of the Inspection

cylinders should include replacement of all seals
and rings. A seal kit will supply the required items. 1. Clean all parts with solvent and dry with compressed air.
Inspect all parts for serviceability.
1. Disconnect the tube assembly from the holding valve.

7
2. Inspect the barrel carefully for scoring. If barrel is
2. Remove the capscrews and washers securing the scored, it must be repaired or replaced.
holding valve and remove the holding valve from the
45
cylinder barrel. 3. Check piston for damage. If piston is damaged,
determine if it can be repaired or must be replaced.
3. Break the tack weld and remove the pin and retaining
plate. 4. Inspect rod for straightness. Determine if it can be
3

straightened or must be replaced.

4. Using a spanner wrench or chain wrench, unscrew the
23

head from the barrel.

CAUTION
Before installing new seals and rings, clean all surfaces
and carefully remove burrs and nicks. Parts displaying
DANGER excessive wear or damage should be replaced.
Do not use air pressure to remove the rod. Use only a
source of controlled hydraulic oil pressure if the rod is 5. Stone out minor blemishes and polish with a fine crocus
hard to move. cloth.
CAUTION 6. Clean with solvent and dry with compressed air any
Exercise extreme care when handling or setting down the parts that have been stoned and polished.
rod. Damage to the rod surface may cause unnecessary
maintenance and expense. Assembly
5. Remove the rod and attached parts from the barrel.
NOTE: Cover the barrel opening to avoid contamination. CAUTION
When installing new seals and rings, avoid stretching
seals or scratching the grooved or gland surfaces. Make
CAUTION sure parts are clean before and during assembly. Make
When removing seals and rings, avoid scratching the sure seals and rings are installed in the proper order.
grooved and gland surfaces.
NOTE: Lubricate seals and rings with clean hydraulic oil.

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HYDRAULIC SYSTEM RT540E SERVICE MANUAL

5
6

1 3

5
11 8
9
12
8 4

13
7
14
15 18
10
19

7
45 20

16
21
3
23

22, 23, 24
17

6721

FIGURE 2-30

Item Description Item Description

1 Grease Fitting 10 Head
2 Rod 11 Backup Ring
3 Setscrew 12 O-ring
4 Piston 13 Wear Ring
5 Seal Assembly 14 Buffer Seal
6 Guidelock Ring 15 Rod Seal
7 Capscrew 16 Wiper Ring
8 Backup Ring 17 Barrel
9 O-ring 18 Washer

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Item Description 7. Install the replacement hydrolock seals on the outside of

the piston. Make sure the “vees” on the two hydrolock
19 Plug seals point at each other (Figure 2-32).
20 Holding Valve 8. Lubricate all parts freely with clean hydraulic oil.
21 Tube Assembly
22 Nut CAUTION
23 Capscrew Exercise extreme care when handling the rod. Damage to
2
24 Pipe Clamp the rod surface may cause unnecessary maintenance
and expense. Also, take care to avoid damaging grooved
1. Install the replacement wear ring, buffer seal, rod seal, or gland surfaces or rings or seals during rod insertion.
backup ring and wiper ring in the inside of the head.
Make sure the buffer seal’s step is closer to the rod seal. 9. Remove the cover from the barrel. Insert the rod and
Make sure the rod seal’s rim groove is closer to the attached parts into the barrel with a slight twisting
buffer seal (Figure 2-31). motion.

Buffer Seal Rod Seal 10. Install new gasket material to the cylinder head retainer
Wear Ring Wiper Ring
ring flange as follows.
a. Clean the barrel and retainer ring with Loctite
cleaning solvent 7070 or similar non-chlorinated
solvent.
b. Apply a light coating of Loctite primer N7649 to both

7
surfaces. Allow primer to dry for one to two minutes.
6749 Primer must be dry. Mating of parts should occur
45
within five minutes.
FIGURE 2-31
c. Apply gasket material Loctite Master Gasket 518 to
2. Install the replacement O-ring and the backup ring on one surface. Partial cure is obtained in four hours,
3
the outside of the head. with full cure in 48 hours.
3. Install the replacement O-ring and backup rings in the 11. Using a spanner wrench or chain wrench, screw the
23

inside of the piston. head into place in the barrel.

4. Lubricate the rod with clean hydraulic oil.
5. Slide the head, wiper ring end first, onto the rod. CAUTION
6. Screw the piston onto the rod tightly. Secure the piston Do not use air pressure to cycle or pressurize the cylinder.
with the set screw.
12. Install the retainer plate and pin to the barrel. Tack weld
the plate to the barrel.
Hydrolock Piston Seals
13. Position the holding valve on the cylinder barrel and
secure with four capscrews and washers. Connect
tubing to holding valve.
14. Pressurize and cycle the cylinder with hydraulic oil
pressure. Test the cylinder at 41,368 kPa/413.6 bar
(6000 psi). Check for proper operation and any leakage.
Make repairs as needed.

FIGURE 2-32

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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.

The boom dual rod telescope cylinder (upper telescope 3. Remove the hydrolock piston seal to gain access to the
cylinder) has a 17.7 cm (7.0 inch) bore. The cylinder is setscrew securing the piston to the outer cylinder rod.
internally ported (rod ported). Oil from the telescope control 4. Remove the setscrew and unscrew the piston from the
valve is routed to the cylinder by external lines. Foreign cylinder rod.
material is prevented from entering the cylinder rod during
retraction by a wiper seal in the head. O-ring seals prevent 5. Remove the remaining hydrolock seal and wear rings
internal and external leakage (Figure 2-35). from the outside of the piston and the O-ring and two
backup rings from the inside of the piston.
The cylinder incorporates two cylinder rods with separate
strokes. One rod has a stroke of 736.0 cm (289.8 inches), 6. Remove the spacer from the rod.
and one rod has a stroke of 743.7 cm (292.8 inches), which 7. Remove the cylinder head from the outer rod.
provides a combined overall stroke of 1479.7 cm (582.6
inches). 8. Remove the O-ring and backup ring from the outside of
the head and the wear rings, buffer seal, rod seal,
backup ring and the wiper ring from the inside of the
CAUTION head.
Do not retract the cylinder completely if it is not attached 9. Using a spanner wrench, unscrew the inner cylinder
to the boom. Maintain a spacer that is split or hinged 6.88” head from the outer cylinder rod.
long to prevent cylinder from retracting completely.

7
The cylinder weighs approximately 1249 kg (2753.5 lb) wet. CAUTION
Do not use air pressure to remove the cylinder rod
45
Maintenance assembly. Use only a source of controlled hydraulic oil
pressure if the rod is hard to remove.
Disassembly CAUTION
3

NOTE: Any maintenance requiring disassembly of the Exercise extreme care when handling or setting down the
cylinder should include replacement of all cylinder cylinder rod. Do not damage the chrome surface.
23

seals and O-rings.

10. Remove the inner cylinder rod assembly from the outer
1. Using a spanner wrench, unscrew the outer cylinder
cylinder rod and cover the opening to avoid
head from the cylinder barrel.
contamination.
11. Remove the hydrolock piston seal to gain access to the
setscrew securing the piston to the inner cylinder rod.
DANGER 12. Remove the setscrew and unscrew the piston from the
Do not use air pressure to remove the cylinder rod cylinder rod.
assembly. Use only a source of controlled hydraulic oil
pressure if the rod is hard to remove. 13. Remove the remaining hydrolock seal and wear ring
from the outside of the piston and the O-ring and two
CAUTION backup rings from the cylinder rod
Exercise extreme care when handling or setting down the
cylinder rod. Do not damage the chrome surface. 14. Remove the spacer from the rod and remove the wear
ring from the spacer.
2. Remove the cylinder rod assembly from the cylinder 15. Remove the cylinder head from the inner rod.
barrel and cover the barrel to avoid contamination.
16. Remove the O-ring and backup ring from the outside of
the head and the wear rings, buffer seal, deep Z rod
CAUTION seal, backup ring and the wiper ring from the inside of
When removing seals and rings, avoid scratching the head.
grooved and gland surfaces. 17. If necessary, remove the holding valve from the inner
cylinder rod and from the cylinder barrel.

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Inspection
1. 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.

4. Install the buffer seal, rod seal and backup ring inside
CAUTION
Clean all surfaces and remove all burrs and nicks before
the head ensuring the seals are assembled properly and 2
installed in the correct direction (Figure 2-33).
installing new seals and rings. Replace all damaged or
worn parts. 5. Install the O-ring and backup ring onto the outside of the
head.
2. Stone out minor blemishes and polish with fine crocus 6. Install the inner cylinder head onto the inner cylinder rod.
cloth.
7. Install the wear ring onto the spacer and install the
3. Clean all with solvent and dry with compressed air any spacer onto the rod.
parts that have been stoned and polished.
8. Install the O-ring and backup rings onto the rod and
4. Inspect the barrel for scoring. install the piston onto the inner cylinder rod. Secure the
piston in place with the setscrew.
Assembly
1. If removed, install the holding valves. Refer to HOLDING Hydrolock Piston Seals
VALVES in this section.

7
CAUTION
45
When installing new seals and rings, clean all surfaces
and carefully remove burrs and nicks. Parts displaying
excessive wear or damage should be replaced.
3

NOTE: Lubricate new seals and rings with clean hydraulic

23

oil. FIGURE 2-34

NOTE: Locate the gap of wear ring 180 degrees with 9. Install the hydrolock seals onto the piston (Figure 2-34).
respect to each other.
2. Install the wiper ring into the cylinder head.
CAUTION
3. Install the wear rings into the head (Figure 2-33). Avoid scratching or damaging the grooved and gland
surfaces or the seals and rings.

10. Lubricate the inner cylinder rod assembly with clean

Backup Ring hydraulic oil and install the rod assembly into the outer
cylinder rod with a slight twisting motion.
11. Using a spanner wrench, secure the inner cylinder head
to the outer cylinder rod.
12. Install the wiper ring into the outer cylinder head.
13. Install the wear rings into the head.
Wear Ring Wiper Ring
Buffer Seal Rod Seal
6488-2

FIGURE 2-33

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HYDRAULIC SYSTEM RT540E SERVICE MANUAL

3
4

3
1
19
20
12
5
2
7

17 6
7

5
8
9
18
8
21
22 9
24 15
23

7
25
13
45 11
10
11
14
28
3
23

29

16
26

34
27 6714
32 31 30
35 33 FIGURE 2-35

Item Description Item Description

1 Barrel 10 O-ring
2 Piston 11 Backup Ring
3 Seal 12 Spacer
4 Wear Ring 13 Piston
5 Setscrew 14 Spacer
6 O-ring 15 Rod
7 Backup Ring 16 Rod
8 Hydrolock Seal 17 Head
9 Wear Ring 18 Wear Ring

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RT540E SERVICE MANUAL HYDRAULIC SYSTEM

Item Description 15. Install the O-ring and backup ring onto the outside of the
outer cylinder head.
19 O-ring
16. Install the outer cylinder head onto the outer cylinder
20 Backup Ring rod.
21 Buffer Seal 17. Install the spacer onto the rod.
22 Backup Ring
23 Rod Seal
18. Install the O-ring and backup rings into the inside of the
piston and install the piston onto the outer cylinder rod. 2
24 Backup Ring Secure the piston in place with the setscrew.

25 Wiper Ring
Hydrolock Piston Seals
26 Head
27 Wear Ring
28 O-ring
29 Backup Ring
30 Seal
31 Seal
32 Backup Ring
33 Wiper Ring FIGURE 2-37

7
34 Holding Valve
19. Install the hydrolock seals and wear rings onto the piston
35 Plug (Figure 2-37).
45
CAUTION CAUTION
3
Avoid scratching or damaging the grooved or gland
Improper installation of seals could cause faulty cylinder
surfaces or the ring and seals.
operation.
23

20. Lubricate the outer cylinder rod assembly with clean

14. Install the buffer seal, backup rings and rod seal into the
hydraulic oil and install the rod assembly into the
head ensuring the seals are assembled properly and
cylinder barrel with a slight twisting motion.
installed in the correct direction (Figure 2-36).
21. Using a spanner wrench, secure the outer cylinder head
Backup Ring to the cylinder barrel.
Backup Ring

DANGER
Do not use air pressure to cycle or pressurize the cylinder.

Wiper Ring 22. Pressurize and cycle the cylinder with hydraulic oil
Wear Ring
Buffer Seal Rod Seal pressure. Test the cylinder at 32,750 kPa/327.5 bar
6488-1 (4750 psi). Check for proper operation and any leakage.
FIGURE 2-36

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HYDRAULIC SYSTEM RT540E SERVICE MANUAL

AXLE OSCILLATION LOCKOUT CYLINDER 7. Using a hoist, extend the rod assembly slowly until the
piston is free of the barrel.
Description 8. Remove the rod and attached parts from the barrel.
The two oscillation lockout cylinders (Figure 2-38) standard NOTE: Cover the barrel opening to avoid contamination.
or (Figure 2-39) CE Option, each have 12.7 cm (5 inch)
diameter bores. The retracted length of each cylinder is 48.8
cm (19.25 inches) from the center of the lug holes to the
CAUTION
center of the barrel bushing. The extended length of each
cylinder from the center of the lug holes to the center of the When removing seals and rings, avoid scratching the
barrel bushing is 65.5 cm (25.8 inches). Its stroke is 16.8 cm grooved and gland surfaces.
(6.62 inches). A wiper ring prevents foreign material from
entering each cylinder. O-rings and other seals prevent 9. Remove the lip seals and wear ring from the outside of
internal and external leakage. the piston.

The cylinder weighs approximately 38.8 kg (85.5 lb). NOTE: Arranging discarded seals and rings in the order of
disassembly will aid in installation of new seals and
Maintenance rings. Pay attention to how each seal and ring is
installed to avoid installing replacement seals and
Disassembly rings improperly.
10. Remove the retaining ring from the rod.
NOTE: Any maintenance requiring disassembly of the
cylinder should include replacement of all cylinder 11. Remove the head from the rod. Remove the O-ring and
seals. backup ring from the outside of the head. Remove the
wear ring, buffer seal, lip seal and wiper ring from the

7
1. Clean away all dirt from the head. Place protective
inside of the head.
padding around the rod near the head to prevent
45
damaging the chrome. Using a spanner wrench,
unscrew the head from the barrel.
Inspection
1. Inspect the rod. There should be no scratches or pits
3
deep enough to catch the fingernail. Pits that go to the
base metal are unacceptable. Chrome should be
DANGER
23

present over the entire surface of the rod. If lack of

Do not use air pressure to remove the rod. Use only a chrome on rod, the rod should be replaced.
source of controlled hydraulic oil pressure if the rod is 2. Inspect rod for straightness. Determine if it can be
hard to remove. straightened or must be replaced.
CAUTION
3. Inspect the head. Visually inspect the inside bore for
Exercise extreme care when handling or setting down the scratching or polishing. Deep scratches are
rod. Do not damage the chrome surface. unacceptable. Polishing indicates uneven loading, and
the bore should be checked for out-of-roundness.
2. Open both ports on the side of the cylinder barrel and
drain the oil from the cylinder. 4. Inspect the piston. Visually inspect the outside surface
for scratches or polishing, Deep scratches are
3. Secure cylinder barrel in a chain vise without putting unacceptable. Polishing indicates uneven loading, and
pressure on the side feeder tube preferably in the the diameter should be checked for out-of roundness.
vertical position with the rod assembly up.
5. Inspect the barrel carefully for scoring. If barrel is
4. Using a screwdriver, or 1/4 inch wrench, remove the scored, it must be repaired or replaced.
screw from the head.
6. Thoroughly rinse parts, allow to drain, and wipe with a
5. Remove the grease fitting from the rod lint-free rag. Inspect all parts for serviceability.
6. Turn the head counterclockwise with a fitted spanner
wrench until the threads disengage.
CAUTION
NOTE: Residual oil will spill over the end of the barrel
Before installing new seals and rings, clean all surfaces
wh en th e r od as se mbly is ex te nde d. Mak e
and carefully remove burrs and nicks. Parts displaying
provisions to contain the oil.
excessive wear or damage should be replaced.

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RT540E SERVICE MANUAL HYDRAULIC SYSTEM

18
14
17
18

17
13 2
5

4
1 5
2

15
6

7
3 45
8
23

12
9
10
11

6731
3
16
FIGURE 2-38

Item Description Item Description

1 Barrel 10 Lip Seal Ring
2 Rod 11 Wiper Ring
3 Seal 12 Retainer Ring
4 Lip Seal Ring 13 Bleeder Plug
5 Wear Ring 14 Grease Fitting
6 O-ring 15 Grease Fitting
7 Backup Ring 16 Screw
8 Buffer Ring 17 O-ring
9 Wear Ring 18 Cap Assembly

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HYDRAULIC SYSTEM RT540E SERVICE MANUAL

18 19

17 17
13

14
1

20
5

2 15

7
45 6

8
3
9
7
23

10
16
11

12

3
6732

FIGURE 2-39

Item Description Item Description

1 Barrel 11 Backup Ring
2 Piston 12 Spacer
3 Seal 13 Piston
4 Wear Ring 14 Spacer
5 Setscrew 15 Rod
6 O-ring 16 Rod
7 Backup Ring 17 Head
8 Hydrolock Seal 18 Wear Ring
9 Wear Ring 19 Plug
10 O-ring 20 Check Valve

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RT540E SERVICE MANUAL HYDRAULIC SYSTEM

7. Stone out minor blemishes and polish with a fine crocus

cloth.
CAUTION
8. Clean with solvent and dry with compressed air any
parts that have been stoned and polished. Exercise extreme care when handling the rod. Damage to
the rod surface may cause unnecessary maintenance
Assembly and expense. Also, take care to avoid damaging grooved
or gland surfaces or rings or seals during rod insertion.
2
7. With a hoist, raise the rod assembly back into a vertical
CAUTION position taking care not to damage the OD seals on the
When installing new seals and rings, avoid stretching head and piston.
seals or scratching the grooved or gland surfaces. Make
sure parts are clean before and during assembly. Make 8. Lubricate the OD seals on the piston and head with
sure seals and rings are installed in the proper order. clean light oil and lower the assembly into the barrel.
Stop just before the head enters the barrel.
NOTE: Lubricate seals and rings with clean hydraulic oil. 9. Place a spanner wrench on the head and turn
1. Install the replacement wiper ring, lip seal, buffer seal counterclockwise until the thread clicks, then reverse
and wear ring in the inside of the head. direction to clockwise and thread in until there is no gap
between the head shoulder and top of barrel.
2. Install the replacement O-rings and backup ring on the
outside of the head. 10. Install the retaining ring onto the rod.

3. Install the lip seals and wear ring onto the outside of the 11. Install the setscrew into the head.
piston.

7
4. Lubricate the rod with clean hydraulic oil. CAUTION
45
5. Slide the head, onto the rod. Tap the head with a rubber Do not use air pressure to cycle or pressurize the cylinder.
mallet to engage the seals. Push the head about half
way down the length of the rod assembly. 12. Pressurize and cycle the cylinder with hydraulic oil
pressure. Test the cylinder at 25,856 kPa/259 bar (3750
3

6. Remove the cover from the barrel. psi). Check for proper operation and any leakage. Make
23

repairs as needed.

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HYDRAULIC SYSTEM RT540E SERVICE MANUAL

STEER CYLINDER NOTE: Cover the barrel opening to avoid contamination.

Description
CAUTION
The steer cylinders (Figure 2-40) 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.
each have 6.3 cm (2.5 inch) diameter bores. The front and
rear steer cylinders each have a retracted length of 53.1cm
(20.94 inches) from bushing center to bushing center. The 7. Remove the seal from the outside of the piston.
front and rear steer cylinders each have an extended length NOTE: Arranging discarded seals and rings in the order of
of 74.1cm (29.19 inches) from bushing center to bushing disassembly will aid in installation of new seals and
center. Each cylinder has a stroke of 20.9 cm (8.25 inches). rings. Pay attention to how each seal and ring is
A wiper ring prevents foreign material from entering each installed to avoid installing replacement seals and
cylinder. O-rings and other seals prevent internal and rings improperly.
external leakage.
8. Loosen and remove the nut securing the piston.
The cylinder weighs approximately 9.07 kg (19.9 lb). Remove the piston from the rod.

Maintenance 9. Remove the O-ring from the inside of the piston.

10. Remove the head from the rod. Remove the O-ring and
Disassembly backup ring from the outside of the head. Remove the
wiper ring and the rod seal from the inside of the head.
NOTE: Any maintenance requiring disassembly of the
cylinders should include replacement of all seals
and rings. A seal kit will supply the required items.
Inspection

7
1. Secure the cylinder in a clean work area by use of 1. Clean all parts with solvent and dry with compressed air.
45
clamps or a chain vise to prevent rolling. Inspect for damaged or worn parts and replace as
required.
2. Retract the cylinder fully to avoid damaging the rod
during removal.
3

NOTE: Mark or note the piston and head relationship to the

CAUTION
Clean all surfaces and remove all burrs and nicks before
23

rod and barrel.

installing new seals and rings. Replace all damaged or
3. Clean away all dirt from the head. Place protective worn parts.
padding around the rod near the head to prevent
damaging the chrome during head removal. 2. Stone out minor blemishes and polish with fine crocus
cloth.
3. Clean all with solvent and dry with compressed air any
DANGER parts that have been stoned and polished.
Do not use air pressure to remove the rod. Use only a 4. Inspect the barrel for scoring.
source of controlled hydraulic oil pressure if the rod is
hard to move. Assembly
CAUTION
Exercise extreme care when handling or setting down the
rod. Damage to the rod surface may cause unnecessary CAUTION
maintenance and expense. When installing new seals and rings, clean all surfaces
and carefully remove burrs and nicks. Parts displaying
4. Position the rod mount with the ports facing down. excessive wear or damage should be replaced.

5. Using a means of collecting the oil, remove the port NOTE: Lubricate new seals and rings with clean hydraulic
plugs and allow cylinder to drain. oil.
6. Rapidly pull the rod against the head to free it. Remove 1. Install the replacement wiper ring into the head.
rod and attached parts from the barrel. Place the rod on
a surface that will not damage the chrome or allow the 2. Install the rod seal in the inside of the head. Make sure
rod assembly to drop. the lips of the seal face the piston.

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RT540E SERVICE MANUAL HYDRAULIC SYSTEM

5 6 8

7
4
45
10 11
3

3
23

6722

FIGURE 2-40

Item Description Item Description

1 Barrel 7 Piston Ring Seal
2 Piston 8 O-ring
3 Seal 9 Backup Ring
4 Wear Ring 10 Seal Rod Ring
5 Setscrew 11 Wiper Ring
6 O-ring

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HYDRAULIC SYSTEM RT540E SERVICE MANUAL

3. Install the O-ring and backup ring onto the outside of the 10. Remove the cover from the barrel. Insert the rod and
head. attached parts into the barrel with a slight twisting
motion.
4. Install the O-ring in the inside of the piston.
11. Push the head into the barrel. Torque the head 27.1 Nm
5. Lubricate the rod with clean hydraulic oil.
(20 lb-ft).
6. Slide the head, larger OD end first, onto the rod.
7. Install the piston onto the rod. Secure the piston with the CAUTION
nut. Lubricate the threads and torque the nut to 176.2 ±
Do not use air pressure to cycle or pressurize the cylinder.
6.7 Nm (130 ± 5 lb-ft).
8. Install the seal on the outside of the piston. 12. Pressurize and cycle the cylinder with hydraulic oil
pressure. Test the cylinder at 20,684 kPa/206.8 bar
9. Lubricate all parts freely with clean hydraulic oil.
(3000 psi). Check for proper operation and any leakage.
Make repairs as needed.
CAUTION
Exercise extreme care when handling the rod. Damage to
the rod surface may cause unnecessary maintenance
and expense. Also, take care to avoid damaging grooved
or gland surfaces or rings or seals during rod insertion.

7
3 45
23

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RT540E SERVICE MANUAL HYDRAULIC SYSTEM

OUTRIGGER EXTENSION CYLINDER 6. Remove the piston and spacer from the rod.
7. 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- 8. Remove the rod seal, wear ring and wiper ring from the
inch) diameter bores. Each cylinder has a retracted length of inside of the head.
218.1 ± 0.30 cm (85.88 ± 0.12 inches) from the center of the
rod bushing to the center of the barrel bushing. Each
cylinder’s extended length is 403.5 cm (157.87 inches). The
9. Remove the O-ring from the rod.
2
stroke of each cylinder is 185.4 cm (73.0 inches). A wiper Inspection
ring prevents foreign material from entering each cylinder. O-
1. Clean all parts with solvent and dry with compressed air.
rings and other seals prevent internal and external leakage.
Inspect all parts for serviceability.
The cylinder weighs approximately 42 kg (112.5 lb).
2. Inspect the barrel carefully for scoring. If barrel is
scored, it must be repaired or replaced.
Maintenance
3. Check rod’s piston area for damage. If it is damaged,
Disassembly determine if it can be repaired or must be replaced.
NOTE: Any maintenance requiring disassembly of the 4. Inspect rod for straightness. Determine if it can be
cylinders should include replacement of all seals straightened or must be replaced.
and rings. A seal kit will supply the required items.
1. Remove all dirt, grease and other contaminants from CAUTION
around the ports and the head
Before installing new seals and rings, clean all surfaces

7
and carefully remove burrs and nicks. Parts displaying
excessive wear or damage should be replaced.
45
DANGER 5. Stone out minor blemishes and polish with a fine crocus
Do not use air pressure to remove the rod. Use only a cloth.
3
source of controlled hydraulic oil pressure if the rod is
hard to move. 6. Clean with solvent and dry with compressed air any
23

parts that have been stoned and polished.

CAUTION
Exercise extreme care when handling or setting down the Assembly
rod. Damage to the rod surface may cause unnecessary
maintenance and expense.
CAUTION
2. Using a spanner wrench, unscrew the cylinder head.
When installing new seals and rings, avoid stretching
3. Remove rod and attached parts from the barrel. seals or scratching the grooved or gland surfaces. Make
sure parts are clean before and during assembly. Make
NOTE: Cover the barrel opening to avoid contamination.
sure seals and rings are installed in the proper order.

NOTE: Lubricate seals and rings with clean hydraulic oil.

CAUTION
When removing the seals and rings, avoid scratching the 1. Install the replacement wear ring, rod seal and wiper ring
grooved and gland surfaces. in the inside of the head.
2. Install the replacement O-ring and the backup ring on
4. Remove the wear rings and piston seal from the outside the outside of the head.
of the piston.
3. Install the O-ring onto the rod.
NOTE: Arranging discarded seals and rings in the order of
disassembly will aid in installation of new seals and 4. Lubricate the rod with clean hydraulic oil.
rings. Pay attention to how each seal and ring is 5. Slide the head onto the rod.
installed to avoid installing replacement seals and
rings improperly. 6. Install the spacer and piston on the rod.

5. Remove the nut from the rod. 7. Install the locknut onto the rod.

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HYDRAULIC SYSTEM RT540E SERVICE MANUAL

1
3
2

8
7 9
2
8
5

7
45
14
12
13
3
23

10 4

6815

11

Item Description Item Description

1 Barrel 8 Wear Ring
2 Rod 9 O-ring
3 Piston 10 O-ring
4 Head 11 Backup Ring
5 Spacer 12 Seal
6 Nut 13 Wiper
7 Piston Seal 14 Wear Ring

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RT540E SERVICE MANUAL HYDRAULIC SYSTEM

8. 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.
9. Lubricate all parts freely with clean hydraulic oil.

CAUTION DANGER
Do not use air pressure to remove the rod. Use only a
Exercise extreme care when handling the rod. Damage to
the rod surface may cause unnecessary maintenance source of controlled hydraulic oil pressure if the rod is 2
and expense. Also, take care to avoid damaging grooved hard to remove.
or gland surfaces, rings or seals during rod insertion. CAUTION
Exercise extreme care when handling or setting down the
10. Remove the cover from the barrel. Insert the rod and rod. Do not damage the chrome surface.
attached parts into the barrel with a slight twisting
motion. 2. Open ports on the side of the cylinder barrel and drain
11. Push the head into the barrel. the oil from the cylinder.
3. Secure cylinder barrel in a chain vise without putting
pressure on the side feeder tube in the vertical position
CAUTION with the rod assembly up.
Do not use air pressure to cycle or pressurize the cylinder.
4. Using a 5/32 inch Allen wrench, remove the setscrew on
the barrel OD at the head.
12. Pressurize and cycle the cylinder with hydraulic oil
pressure. Test the cylinder at 20,700 kPa (270 bar) NOTE: Oil or oil/air mixture may rapidly exit out of the ports

7
(3000 psi). Check for proper operation and any leakage. during rod extension. Shield the work area from the
Make repairs as needed. exiting oil.
45
5. With the ports open, extend the rod assembly with a
OUTRIGGER STABILIZER CYLINDER hoist enough to access the top of the head with spanner
wrench. Do not extend completely.
Description
3

6. Turn the head counterclockwise with a fitted spanner

The four outrigger stabilizer cylinders (Figure 2-41) each
23

wrench until the threads disengage.

have a hollow rod for internal porting. Each cylinder has a
10.1 cm (4.0 inch) diameter bore. A port block is welded to 7. Extend the rod assembly slowly until the piston is free of
the rod of each cylinder and a pilot operated check valve is the barrel assembly. Place the rod assembly horizontally
threaded into each port block. The retracted length of the on a workbench taking care not to damage the surface
cylinder from the end of the barrel to the center of the rod’s of the rod.
port block rod bushing is 122.2 ± 30.8 cm (48.12 ±.12
inches). The extended length of the cylinder from the end of NOTE: Cover the barrel opening to avoid contamination.
the barrel to the center of the rod’s port block rod bushing is 8. Remove the piston seal to gain access to the piston
185.7 cm (73.12 inches). Its stroke is 63.5cm (25 inches). A setscrew Using a 3/16 inch Allen wrench, remove the
wiper ring prevents foreign material from entering the setscrew from the piston.
cylinder. O-rings and other seals prevent internal and
external leakage 9. Remove the piston by turning counterclockwise with a
fitted spanner wrench.
The cylinder weighs approximately 64.6 kg (142.52 lb).
10. Remove the spacer and head from the rod.
Maintenance

Disassembly CAUTION
When removing seals and rings, avoid scratching the
NOTE: Any maintenance requiring disassembly of the
grooved and gland surfaces.
cylinder should include replacement of all cylinder
seals.
11. Remove the seal assembly from the outside of the
1. Clean away all dirt from the head. Place protective piston and the O-ring and backup rings from he inside of
padding around the rod near the head to prevent the piston.
NOTE: Arranging discarded seals and rings in the order of
disassembly will aid in installation of new seals and

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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.
2. Inspect rod for straightness. Determine if it can be
12. Remove the O-ring and backup ring from the outside of straightened or must be replaced.
the head. Remove the wear rings, buffer seal, rod seal
3. Inspect the head. Visually inspect the inside bore for
and wiper ring from the inside of the head.
scratching or polishing. Deep scratches are
unacceptable. Polishing indicates uneven loading, and
Inspection the bore should be checked for out-of-roundness.
1. Inspect the rod. There should be no scratches or pits
4. Inspect the piston. Visually inspect the outside surface
deep enough to catch the fingernail. Pits that go to the
for scratches or polishing, Deep scratches are
base metal are unacceptable. Chrome should be
unacceptable. Polishing indicates uneven loading, and
the diameter should be checked for out-of roundness.
5. Inspect the barrel carefully for scoring. If barrel is
scored, it must be repaired or replaced.

11

7
45
1

20 10
19
3

12
23

13
3

15
14

5
18 17
17
4
6
7, 8

16

6744

FIGURE 2-41

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NOTE: Lubricate seals and rings with clean hydraulic oil.

Item Description 1. Install the replacement wiper ring, rod seal, buffer seal
1 Barrel and wear rings in the inside of the head.

2 Rod 2. Install the replacement O-ring and backup ring on the

outside of the head.
3 Head
4 Piston
3. Lubricate the rod with clean hydraulic oil.
2
4. Slide the head, onto the rod. Tap the head with a rubber
5 Spacer
mallet to engage the seals. Push the head about half
6 Check Valve way down the length of the rod assembly.
7 Setscrew 5. Install the spacer onto the rod with the ID lip at the piston
8 Insert end.

9 Plug 6. Install the setscrew in the piston with a 3/16 inch Allen
wrench until hand tight. Install the seal assemblies onto
10 Wiper Ring the piston.
11 Rod Seal 7. Remove the cover from the barrel.
12 Buffer Seal
13 Wear Ring
CAUTION
14 O-ring Exercise extreme care when handling the rod. Damage to
15 Backup Ring the rod surface may cause unnecessary maintenance

7
and expense. Also, take care to avoid damaging grooved
16 Seal Assembly or gland surfaces or rings or seals during rod insertion.
45
17 Backup Ring
8. With a hoist, raise the rod assembly back into a vertical
18 O-ring
position taking care not to damage the OD seals on the
3
19 Setscrew head and piston.
20 Insert 9. Lubricate the OD seals on the piston and head with
23

clean light oil and lower the assembly into the barrel.
6. Thoroughly rinse parts, allow to drain, and wipe with a
Stop just before the head enters the barrel.
lint-free rag. Inspect all parts for serviceability.
10. Place a spanner wrench on the head and turn
counterclockwise until the thread clicks, then reverse
CAUTION direction to clockwise and thread in until there is no gap
Before installing new seals and rings, clean all surfaces between the head shoulder and top of barrel.
and carefully remove burrs and nicks. Parts displaying
11. Using a 5/32 inch Allen wrench install the setscrew into
excessive wear or damage should be replaced.
the head until hand tight.
7. Stone out minor blemishes and polish with a fine crocus 12. Slowly lower the rod down to the fully retracted position.
cloth.
8. Clean with solvent and dry with compressed air any CAUTION
parts that have been stoned and polished.
Do not use air pressure to cycle or pressurize the cylinder.
Assembly
13. Pressurize and cycle the cylinder with hydraulic oil
pressure. Test the cylinder at 31,026 kPa/310.2 bar
(4500 psi). Check for proper operation and any leakage.
CAUTION Make repairs as needed.
When installing new seals and rings, avoid stretching
seals or scratching the grooved or gland surfaces. Make
sure parts are clean before and during assembly. Make
sure seals and rings are installed in the proper order.

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45
THIS PAGE BLANK
3
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RT540E SERVICE MANUAL ELECTRIC SYSTEM

SECTION 3
ELECTRIC SYSTEM

SECTION CONTENTS
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Troubleshooting Accessories. . . . . . . . . . . . . . . . . 3-5
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Alternator Replacement . . . . . . . . . . . . . . . . . . . . . 3-7
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Starter Replacement . . . . . . . . . . . . . . . . . . . . . . . 3-7
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Battery Replacement . . . . . . . . . . . . . . . . . . . . . . . 3-8
Fuse Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Relay Panel Component Replacement . . . . . . . . . 3-8
Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Gauge Cluster Replacement . . . . . . . . . . . . . . . . . 3-9 3
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Rocker Switch Replacement . . . . . . . . . . . . . . . . . 3-9
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Ignition Switch Replacement . . . . . . . . . . . . . . . . 3-10
General Troubleshooting . . . . . . . . . . . . . . . . . . . 3-4 Turn Signal Lever and Transmission Shift Lever
Troubleshooting Swivel-Caused Electrical Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Windshield Wiper Assembly Replacement . . . . . 3-12
Connector Troubleshooting . . . . . . . . . . . . . . . . . 3-4 Windshield Washer Assembly Replacement . . . . 3-13
Troubleshooting Engine Starting Problems . . . . . 3-4 Skylight Wiper Assembly Replacement . . . . . . . . 3-14
Troubleshooting Engine Charging Problems . . . . 3-5 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

7
45
DESCRIPTION test indicator located on the top of the battery is used to
determine if the battery can be tested in case of a starting
3

General problem.
23

The electrical system is 24-volt operation with 24-volt There is a battery disconnect switch off to the right of the
starting, consisting of an alternator and two lead-acid battery. battery (1) (Figure 3-2).
The system is the single wire ground return type, using the
machine’s structure as ground

Alternator
The alternator is mounted on the engine and is belt driven. It
is a 70 ampere alternator with an integral transformer -
rectifier unit. When the engine is running, and the alternator
is turning, the alternator’s 24-volt output terminal supplies
the crane’s electrical circuits. The output terminal also
supplies the voltage to recharge the batteries and maintains
them at a full state of charge.

Batteries
The batteries are located in a box on the left side of the crane
(1) (Figure 3-1). The batteries are the maintenance free type
and completely sealed except for a small vent hole in the
side. The vent hole allows what small amount of gases that
are produced in the battery to escape. On some batteries, a 1 FIGURE 3-1

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ELECTRIC SYSTEM RT540E SERVICE MANUAL

Table 3-1: Cab Fuse Panel

1 Fuse Protects Amps Location
F1 Ignition, start 5 (Figure 3-3)
F2 Steering Column Power 5 (Figure 3-3)
F3 Dome Light, Work Lights 15 (Figure 3-3)
F4 Spare (5 amp Maximum) 7.5 (Figure 3-3)
F5 ACC Power Outlet 7.5 (Figure 3-3)
F6 Ignition Power Out 5 (Figure 3-3)
Engine ECM Ignition
F7 5 (Figure 3-3)
Signal
Key Switch Accessory
F8 5 (Figure 3-3)
Power
F9 Cab Control Modules 10 (Figure 3-3)
F10 Turntable I/O Module 25 (Figure 3-3)
Turntable Power Module
F11 25 (Figure 3-3)
(Horn, Fan Motor)
FIGURE 3-2
Turntable Power Module
F12 (AC Condenser Motor, 25 (Figure 3-3)

7
Fuse Panel
Boom Lights)
Fuses are located behind the seat in the cab (Figure 3-3). In
45
F13 RCL CPU 15 (Figure 3-3)
the battery box fuse panel (4) (Figure 3-4) and in the battery
box (5). Spare (5 amp Maximum)
F14 5 (Figure 3-3)
(Luffing Jib Option)
3

F15 Spare (5 amp Maximum) 7.5 (Figure 3-3)

23

F16 Spare (5 amp Maximum) 7.5 (Figure 3-3)

F17 Spare (5 amp Maximum) 7.5 (Figure 3-3)
F18 Windshield Wiper 10 (Figure 3-3)
F19 Skylight Wiper 10 (Figure 3-3)
F20 Circulating Fan 5 (Figure 3-3)

Table 3-2: Battery Box Fuse Panel

Fuse Protects Amps Location

12VDC Battery Input,
F1 30 (Figure 3-4)
ECM
12VDC Battery Input,
F2 5 (Figure 3-4)
Swivel
FIGURE 3-3 Power Outputs, Carrier
F3 25 (Figure 3-4)
Rear Module
The following fuse assignments apply:
Power Outputs, Carrier
F4 30 (Figure 3-4)
Rear Module
Power Outputs, Carrier
F5 30 (Figure 3-4)
Front Module
F6 Diagnostic Connector 5 (Figure 3-4)

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RT540E SERVICE MANUAL ELECTRIC SYSTEM

Table 3-3: Battery Box Fuses

5
Fuse Protects Amps Location
F51 Alternator 250 (Figure 3-4)
Main Power Relay,
Swivel
F52 Power Control Relay, 100 (Figure 3-4)
Battery Box Fuse and
Relay Panel
F53 Grid Heater 250 (Figure 3-4)
F54 Engine ECM Ignition 100 (Figure 3-4)
F55 Relay KS2 100 (Figure 3-4) 3
Fuses F3,F4, F5 F6
F56 100 (Figure 3-4)
Battery Box Fuse Panel

Relays
The relays are located at the back of the battery box 1 5 3 2 4
(Figure 3-4): relay K-301 power relay (1), relay K-302 grid FIGURE 3-4
heater relay (2) and relay K-303 start relay(3).

7
3 45
23

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ELECTRIC SYSTEM RT540E SERVICE MANUAL

MAINTENANCE 5. After troubleshooting, test the repaired circuit. Verify the

circuit works properly.
General
Troubleshooting Swivel-Caused Electrical
Electrical system maintenance includes troubleshooting and Problems
replacement of damaged components. Observe standard
wiring practices when replacing components. Many crane component electrical troubles can be traced to
the electrical swivel. Troubles common to the swivel are
improper mounting, foreign material between the brushes
and slip rings, incorrect wiring from the swivel to the
CAUTION components, incorrect wire size, worn brushes, improper
spring tension on the brush assembly, and loose setscrews
If it is necessary to perform electrical maintenance on live
on the slip ring assembly. Refer to the electrical schematic
or hot circuits, remove all rings, watches, and other
and wiring diagram for slip ring connections and amperages.
jewelry before performing maintenance as serious burns
result from accidental grounding or shorting circuits. Connector Troubleshooting
The cause of an electrical problem may be a loose or
corroded connection in the pin or socket connectors. Check
CAUTION the connectors to ensure that the pins and sockets are
Ensure the batteries are disconnected before performing properly seated and engaged. If the pins and sockets show
any maintenance on an electrical circuit which is not fused any signs of corrosion, use a good quality electrical contact
or when performing continuity checks. cleaner or fine sandpaper to clean them. When the pins or
sockets show signs of arcing or burning, it will probably be
Never replace original wiring with wiring of a smaller size

7
necessary to replace them.
(gauge).
Refer to the following tables listing tools necessary for
45
General Troubleshooting connector maintenance.
Because the pins and sockets are crimped to the wires, it is
not possible to remove them. Using the proper extraction
3

tool, remove the pin(s) or socket(s) from the plug or

CAUTION receptacle. Cut the wire as close to the pin or socket as
23

Many steps in the troubleshooting procedures require possible. After cutting the pin or socket off, the wire will most
testing live (energized) components. Perform these steps likely be too short. Using a wire that is too short will allow
observing good safety practices to avoid electrical shock pressure to be applied to the pin or socket and wire where
injury. they are crimped when the pin or socket is inserted in the
plug or receptacle. Add a short length of the same size wire
NOTE: Make voltage checks at terminations when to the short wire by crimp splice or solder. Use heat
components are installed and operating. Make shrinkable tubing or other suitable material to insulate the
continuity checks (with batteries disconnected) splice.
when components are isolated or removed.
Troubleshoot per the following guidelines: Troubleshooting Engine Starting Problems
1. First, use reported symptoms to identify a problem or a 1. Verify the battery terminals are connected and clean,
suspect component. fuses 51, 52, and 53 are not blown, the transmission is in
neutral, and the machine is fueled.
2. Test the suspect component per instructions in this
section. The instructions identify the circuit breakers and 2. Try to turn on the head lights, tails lights, marker lights,
components and guide you from the easiest and most dome light, work light, or gauge lights and panel lights to
likely problems to the hardest and least likely problems. verify the battery has at least some charge. If none of
these lights comes on, suspect the battery. Charge
3. Using a multimeter, test the circuit for continuity if you battery as needed, or replace the battery if you can
suspect a broken circuit or for voltage if you suspect a jump-start the crane from another crane.
power problem. Check the electrical schematic and
wiring diagram for most accurate wiring information. 3. If you hear the starter relay clicking repeatedly, power is
reaching the starter, but not enough. Suspect the
4. If the component proves faulty, replace it with a known battery. Charge battery as needed, or replace the
working component. If wiring proves faulty, replace it battery if you can jump-start the crane from another
with wiring of equal diameter. crane.

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RT540E SERVICE MANUAL ELECTRIC SYSTEM

4. If the problem remains, suspect Fuse 53 and the mesh with the engine’s flywheel when not trying to
secondary power circuit (wiring from Fuse 52 to circuit start engine. Troubleshoot the starter relay and
breaker 10). Replace Fuse 52 and make repairs to the ignition switch for closed contacts. If these
circuit. components check out, replace the starter.
5. Turn the ignition (run) (Position 1). Check the voltmeter. Troubleshooting Engine Charging Problems
If it doesn’t move (but the head lights, tail lights, marker
lights, dome lights, work light, or gauge lights and panel 1. Verify battery terminals are connected and clean and all
lights will come on), suspect the ignition switch fuse wires in the charging system are in good repair and are
(F6). Repair of replace circuit or switch or circuit breaker connected properly.
as needed.
2. Verify the alternator belt is properly installed and is
6. If the battery, fuses, secondary circuit, ignition switch, under proper tension.
and power circuit to the ignition switch check out, do one
3. Verify the battery puts out 24 volts minimum. Charge
of the following:
battery as needed so the battery can supply a minimum 3
a. If you hear no noise when you try to turn the starter, excitation voltage to the engine’s charging system.
troubleshoot the start circuit (ignition switch, electric
4. Verify when the crane is running that the alternator is
shifter, and wiring from ignition switch to starter
putting out a minimum of 24 volts DC on the voltmeter.
relay). Make repairs as needed.
5. Replace the alternator if the other conditions check out.
b. If the engine still won’t start, and you hear no noise
o r j u s t a s i n g l e c l i c k , s u s p e c t t h e s t a r t e r. 6. Refer to the engine manual for further instructions.
Troubleshoot the starter circuit from the starter relay
NOTE: If the alternator runs noisily, check belt tension. If
through the starter solenoid to the starter motor and
problem persists, replace alternators.

7
ground. Make repairs as needed. If the starter
solenoid or the starter motor is faulty, replace the NOTE: If the alternator overcharges (voltmeter reads high,
45
starter. light bulbs turn out quickly), look for a ground
where one shouldn’t exist. If external wiring checks
c. If the starter engages but can’t turn the engine (and
out, replace alternator. (The alternator probably
the lights dim, signaling power drain during start
has an internal ground or a faulty internal voltage
3
attempt), check the starter’s feed circuit from the
regulator.)
batteries for resistance. If the resistance is high,
23

make repairs. If the circuit checks out, replace the

starter. If the engine still won’t start, suspect a
Troubleshooting Accessories
seized engine. If the crane’s engine starts and charges properly, but none of
its components except the horn or lights work, the accessory
d. If the starter turns the engine, but it still won’t start,
circuitry may be faulty. Check as follows:
suspect a fuel problem. Troubleshoot the start fuel
circuit from the ignition switch through the fuel relay 1. Turn the ignition switch to accessory power (Position 3).
(K302) coil to ground; also check the start fuel circuit Try to turn on the cab circulating fan, the heater fan, the
from the starter relay (K301) through the fuel relay defroster fan, or the windshield wipers or washer. If none
contacts through the fuel solenoid valve’s pull of these come on (but the head lights, tail lights, marker
solenoid to ground. Replace fuel solenoid valve or lights, dome light, work light, or gauge lights and panel
fuel relay or wiring as needed; make needed lights will come on), there is accessory circuitry problem.
repairs. Ensure fuel system can draw fuel from the
tank and pump it to the engine; make repairs as 2. Check the primary power circuit to the accessory relays
needed. KS1 and KS2. Make circuit repairs as needed.

e. If the engine starts, then shuts down, suspect a fuel 3. If the problem remains, check the ignition switch and the
problem. Troubleshooting the start fuel circuit from accessory control circuit from the ignition switch through
the ignition switch through the fuel solenoid valve’s the coil of the accessory relay (KS1) to ground. Turn the
hold solenoid to ground. Replace fuel solenoid ignition switch to accessory power (Position 3) and shift
value or wiring as needed; make needed repairs. the electric shifter to reverse; if the backup lights and
Ensure fuel system can draw fuel from the tank and backup alarm do not turn on, then there is no power
pump it to the engine; make repairs as needed. through the switch when it is at accessory power
(Position 3). Replace ignition switch if there is no power
7. Refer to the engine manual for further instructions. through it when at accessory power (Position 3).
Replace accessory relay if there is no continuity through
NOTE: If the starter won’t disengage during running, verify
the starter is mounted properly so its gear won’t

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ELECTRIC SYSTEM RT540E SERVICE MANUAL

it’s coil. Make circuit repairs to accessory control circuit 4. If the problem remains, check the accessory relay
as needed. (K101) contacts and the accessory power circuit.
Replace relay if its contacts stay open when the coil is
energized. Make circuit repairs as needed.

Table 3-4
Amp Extraction Tool Table

Description Deutsch 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 N/A
15 circuit (in-line connectors) 458944-1 N/A

Table 3-5
Amp Crimping Tool Table

Description Amp Part Number Grove Part Number

Tool Die Tool Die
14 to 12 gauge wire 69710-1 90145-1 9-999-100177 N/A
10 to 8 gauge wire 69710-1 90140-1 9-999-100177 9-999-100178

7
4 to 9 circuit
69710-1 90306-1 9-999-100177 N/A
45
(in-line connectors
15 circuit
90299-1 -- N/A --
(in-line connectors
3

Table 3-6
23

Deutsch Extraction Tool Table

Description Deutsch Part Number Grove Part Number

12 gauge wire 114010 9-999-100194
16 gauge wire 0411-204-1605 9-999-100195
8-10 gauge wire 114008 7-902-000012
4-6 gauge wire 114009 7-902-000009

Table 3-7
Deutsch Crimping Tool Table

Description Deutsch Part Number Grove Part Number

12, 14, 16, 18, 20 gauge wire HDT-48-00 9-999-100808
4, 6, 8, 10 gauge wire HDT04-08 9-999-100842

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RT540E SERVICE MANUAL ELECTRIC SYSTEM

Alternator Replacement 7. Connect the electrical leads to the terminals as tagged

during removal.
Removal 8. Close the engine compartment.
1. Ensure that the key switch has been in the OFF position 9. Reconnect the ground cables to the battery.
for 2 minutes.
10. Install the ECM power fuse.
2. Turn the battery disconnect switch to the OFF position.
11. Turn the battery disconnect switch to the ON position.
3. Remove the ECM power fuse.
4. Remove the negative battery cables. Check
5. Open the engine compartment. 1. Run engine. Verify reading of voltmeter on front console
is 24 volts or greater. Make repairs as needed.
6. Tag and disconnect the electrical leads from the
terminals on the alternator. 2. Continue troubleshooting charging system as needed if 3
replacement of alternator did not correct problem in
7. Turn the tensioner above the alternator clockwise to charging system.
remove tension from the belt. Slip the belt off of the
alternator pulley, then let the tensioner return to its Starter Replacement
normal position.
8. Remove and tag all wires. Remove the alternator link Removal
capscrew and the mounting capscrew. Remove the 1. Ensure that the key switch has been in the OFF position
alternator. for 2 minutes.

7
Installation 2. Turn the battery disconnect switch to the OFF position.
3. Remove the ECM power fuse.
45
1. Inspect the belt. Verify it has no cracks or other damage.
Replace damaged belt as needed. 4. Remove the negative battery cables.
2. To assemble the alternator, the mounting components 5. Open the engine compartment.
3
must be tightened in the following sequence.
6. Tag and disconnect the electrical leads from the
a. Alternator-to-alternator bracket capscrew.
23

terminals on the starter.

b. Lower brace-to-alternator capscrew. 7. Remove the bolts holding the starter to the mounting
c. Lower alternator brace-to-water pump capscrew. pad. Remove the starter.

d. Torque brace-to-alternator bolt see Fasteners and Installation

Torque Values (pg 1-11). Torque alternator-to-
alternator bracket see Fasteners and Torque Values 1. Place the starter on its mounting pad. Secure the starter
(pg 1-11). with the bolts. Torque the bolts to 43 Nm (32 lb-ft).

3. Install the belt on all engine pulleys except the alternator 2. Connect the electrical leads to the terminals as tagged
pulley for now. during removal.

4. Turn the tensioner clockwise. Slip the belt onto the 3. Connect the batteries.
alternator pulley, then carefully return the tensioner to its 4. Install the ECM power fuse.
normal position so it puts tension on the belt. Make sure
the belt is centered on the tensioner. 5. Turn the battery disconnect switch to the ON position.
5. Check belt tension at the belt’s longest span (longest 6. Close the engine compartment.
distance between pulleys). At the center point of the
longest span, push in on the belt with your thumb. Verify Check
you can deflect the belt no more than 10 to 13 mm (3/8
1. Try to start the engine. Verify the starter starts the
to 1/2 inch) with your thumb. (Or, using a belt tension
engine.
gauge, verify there is 267 to 578 N (60 to 130 lb) of
tension on the belt in the middle of its longest span.) 2. Start engine again, and listen for starter noises. Verify
Replace belt if it is too loose (overstretched). there is no abnormal noise indicating the starter’s gear is
meshing improperly with the flywheel, that the starter’s
6. Verify tensioner bolt is torqued to 43 Nm (32 lb-ft).
gear hasn’t disengaged from the flywheel after the

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ELECTRIC SYSTEM RT540E SERVICE MANUAL

ignition switch is in the ignition (run) position, or some 3. Connect leads to the battery terminals starting with the
other problem. Install starter properly as needed. negative terminals (Figure 3-5)

Battery Replacement 4. Close the battery box cover.

5. Install the ECM power fuse.
Removal
6. Turn the battery disconnect switch to ON.
7. Verify replacement batteries work by starting crane’s
engine and operating various crane components.
CAUTION
To avoid possible engine fault codes and undesirable Relay Panel Component Replacement
operation, ensure the keyswitch has been off 2 minutes
before disconnecting batteries. Accessory Relay
Disconnect batteries, if machine will be inactive for over
24 hours. 1. Ensure that the key switch has been in the OFF position
for 2 minutes.
2. Turn the battery disconnect switch to the OFF position.
3. Remove the hardware securing the console front cover
and remove the cover.
4. Tag and disconnect the electrical leads from the suspect
relay.
5. Remove the hardware securing the suspect relay to the

7
relay panel assembly. Remove suspect relay.
45
6. Install replacement relay on relay panel and secure it
with attaching hardware.
7. Connect the electrical leads to the relay as tagged
3
during removal.
8. Position the console front cover on the console and
23

secure with the attaching hardware.

FIGURE 3-5
9. Connect the batteries.
1. Ensure that the key switch has been in the OFF position
for 2 minutes. 10. Turn the battery disconnect switch to the ON position.
2. Turn the battery disconnect switch to the OFF position. 11. Verify proper installation by operating all components
involved with the replacement relay verifying they all
3. Remove the ECM power fuse.
work.
4. Remove the negative battery cables.
Buzzer Replacement
5. Remove the positive battery cables.
1. Remove the hardware securing the rear cover and fold
6. Tag and disconnect leads from the battery terminals
cover out.
starting with the positive terminals.
2. Tag and disconnect the electrical leads from the buzzer.
7. Remove the nuts and washers from the bracket hold
down rods. Remove the hold down bracket. 3. Unscrew the plastic collar ring from under the panel and
remove the buzzer from the hole in the panel.
8. Remove the batteries.
4. Install replacement buzzer through the hole in panel and
Installation secure with the plastic collar ring.
1. Place the batteries in the battery box. 5. Connect the electrical leads to the buzzer as tagged
during removal.
2. Install the hold down brackets so they can hold down the
batteries. Secure the brackets (and batteries) to the 6. Position the rear cover to the back panel and secure with
bracket hold down rods with nuts and washers. the attaching hardware.

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RT540E SERVICE MANUAL ELECTRIC SYSTEM

7. Verify proper operation by positioning the ignition switch 4. Connect the wire harness to the ignition switch (10).
to RUN (1). Buzzer should sound when engine is not
5. Install the left side cover (8) on the steering column.
running.
6. Secure the gauge/switch cover (6) to the left and right
Gauge Cluster Replacement side covers (8, 9) using six screws (14).
Use the following procedures and refer to Figure 3-6 when 7. Secure the left and right side covers (8, 9) together using
removing/installing the gauge cluster. four screws (13).

Removal 8. Install the steering wheel (2); torque the securing nut to
40 Nm ±5 (30 lb-ft ±4).
1. Ensure that the key switch has been in the OFF position
for 2 minutes. 9. Install the steering wheel cap (1).

2. Turn the battery disconnect switch to the OFF position. 10. Install the lever (12) and spacer that locks/unlocks the

3. Pull the rubber boot (11) off the bottom of the left and
steering column tilt/telescope function. 3
right side covers (8, 9). 11. Pull the rubber boot (11) up and over the bottom of the
left and right side covers (8, 9).
4. Remove the lever (12) and spacer that locks/unlocks the
steering column tilt/telescope function. 12. Turn the battery disconnect switch to the ON position.

5. Remove the steering wheel by doing the following: Check

a. Remove the steering wheel cap (1) using a twisting 1. Start the engine and verify that the instruments work.
motion by pushing on the side of the cap closest to
2. As needed, troubleshoot further any system malfunction
you with your thumbs while simultaneously pulling
not corrected by repair or replacement of the gauge

7
on the side of the cap farthest from you with your
cluster or associated wiring.
fingers.
45
b. Remove the securing nut from the steering column Rocker Switch Replacement
shaft and remove the steering wheel (2).
Use the following procedures and refer to Figure 3-6 when
6. Remove the four screws (13) securing the left and right removing/installing a switch.
3

side covers (8, 9) together.

Removal
23

7. Remove the six screws (14) securing the left and right
side covers (8, 9) to the gauge/switch cover (6). 1. Ensure that the key switch has been in the OFF position
for 2 minutes.
8. Remove the left side cover (8) from the steering column.
2. Turn the battery disconnect switch to the OFF position.
9. Disconnect the wire harness from the back of the ignition
switch (10). 3. Pull the rubber boot (11) off the bottom of the left and
right side covers (8, 9).
10. Remove the right side cover (9) from the steering
column. 4. Remove the lever (12) and spacer that locks/unlocks the
steering column tilt/telescope function.
11. Disconnect the wire harness from the bottom of the
gauge cluster (5). 5. Remove the four screws (13) securing the left and right
side covers (8, 9) together.
12. Remove the gauge cluster (5) from the gauge/switch
cover (6) by pushing in on the left and right sides of the 6. Remove the six screws (14) securing the left and right
gauge cluster (5), then pushing the gauge cluster (5) up side covers (8, 9) to the gauge/switch cover (6).
through the gauge/switch cover (6). 7. Remove the left side cover (8) from the steering column.
Installation 8. Disconnect the wire harness from the back of the ignition
switch (10).
1. Install the gauge cluster (5) in the top of the gauge/
switch cover (6) by pushing the gauge cluster (5) down 9. Remove the right side cover (9) from the steering
through the top of the gauge/switch cover (6) until the column.
gauge cluster’s retaining clips click in place.
10. Disconnect the wire harness from the bottom of the
2. Connect the wire harness to the bottom of the gauge switch (4) that must be replaced. Remove the switch by
cluster (5). squeezing the retaining clips on each side of switch and
pushing upwards until switch is free of cover.
3. Install the right side cover (9) on the steering column.

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ELECTRIC SYSTEM RT540E SERVICE MANUAL

Inspection Check
1. Visually check the switch for evidence of cracks, 1. Operate the switch per the Operator Manual. Verify each
damaged connections, or other damage. Replace of its functions works.
damaged switch as needed.
2. As needed, troubleshoot further any system or circuit
2. Check wiring for damaged insulation or damaged malfunction not corrected by repair or replacement of
connectors. Repair as needed. the switch or associated wiring.
3. Check all connectors for corrosion. Replace corroded Ignition Switch Replacement
components as needed.
Use the following procedures and refer to Figure 3-6 when
4. Perform the following check to determine switch
removing/installing the ignition switch.
serviceability.
a. Using an ohmmeter, check for continuity between Removal
the switch terminals with switch at ON or activated 1. Ensure that the key switch has been in the OFF position
position(s). Ohmmeter should register zero ohms for 2 minutes.
(continuity).
2. Turn the battery disconnect switch to the OFF position.
b. Place switch at OFF or deactivated position.
Ohmmeter should register infinity (no continuity). 3. Pull the rubber boot (11) off the bottom of the left and
right side covers (8, 9).
c. Replace switch if it fails either part of the check.
4. Remove the lever (12) and spacer that locks/unlocks the
Installation steering column tilt/telescope function.
1. Remove the rocker (3) from the old switch by holding the 5. Remove the four screws (13) securing the left and right

7
switch by its sides in one hand and then squeezing the side covers (8, 9) together.
left and right sides of the rocker with the other hand and
45
6. Remove the six screws (14) securing the left and right
pulling up.
side covers (8, 9) to the gauge/switch cover (6).
2. Orient the rocker (3) correctly relative to the new switch
7. Remove the left side cover (8) from the steering column.
(4), then install rocker in switch.
3

8. Disconnect the wire harness from the back of the ignition

3. Install the switch (4) in the gauge/switch cover (6) by
23

switch (10).
pushing the switch (4) down through the top of the
gauge/switch cover (6) until the switch’s retaining clips 9. Remove the right side cover (9) from the steering
click in place. column.
4. Connect the wire harness to the bottom of the switch (4). 10. Remove the locking nut that secures the ignition switch
(10) to the right cover (9) and remove the ignition switch
5. Install the right side cover (9) on the steering column.
(10).
6. Connect the wire harness to the ignition switch (10).
Inspection
7. Install the left side cover (8) on the steering column.
1. Visually check the ignition switch for evidence of cracks,
8. Secure the gauge/switch cover (6) to the left and right damaged connections, or other damage. Replace
side covers (8, 9) using six screws (14). damaged ignition switch as needed.
9. Secure the left and right side covers (8, 9) together using 2. Check wiring for damaged insulation or damaged
four screws (13). connectors. Repair as needed.
10. Install the lever (12) and spacer that locks/unlocks the 3. Check all connectors for corrosion. Replace corroded
steering column tilt/telescope function. components as needed.
11. Pull the rubber boot (11) up and over the bottom of the 4. Perform the following check to determine ignition switch
left and right side covers (8, 9). serviceability.
12. Turn the battery disconnect switch to the ON position. a. Using an ohmmeter, check for continuity between
the switch terminals with switch at ON or activated
position(s). Ohmmeter should register zero ohms
(continuity).

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RT540E SERVICE MANUAL ELECTRIC SYSTEM

b. Place switch at OFF or deactivated position. b. Remove the securing nut from the steering column
Ohmmeter should register infinity (no continuity). shaft and remove the steering wheel (2).
c. Replace switch if it fails either part of the check. 6. Remove the four screws (13) securing the left and right
side covers (8, 9) together.
Installation
7. Remove the six screws (14) securing the left and right
1. Install the ignition switch (10) in the right side cover (9) side covers (8, 9) to the gauge/switch cover (6).
and secure with the locking nut.
8. Remove the left side cover (8) from the steering column.
2. Install the right side cover (9) on the steering column.
9. Disconnect the wire harness from the back of the ignition
3. Connect the wire harness to the ignition switch (10). switch (10).
4. Install the left side cover (8) on the steering column. 10. Remove the right side cover (9) from the steering
column.
5. Secure the gauge/switch cover (6) to the left and right
side covers (8, 9) using six screws (14).
3
11. Disconnect the wire harness from the bottom of the
6. Secure the left and right side covers (8, 9) together using gauge cluster (5).
four screws (13). 12. Tag and disconnect the wire harness from the bottom of
7. Install the lever (12) and spacer that locks/unlocks the each switch (4).
steering column tilt/telescope function. 13. Remove the gauge/switch cover (6) from the steering
8. Pull the rubber boot (11) up and over the bottom of the column.
left and right side covers (8, 9). 14. Disconnect the wire harnesses from the bottom of the
9. Turn the battery disconnect switch to the ON position. turn signal and transmission shift levers (7).

7
15. Remove the two bolts and nuts securing the two levers
Check
45
(7) together.
1. Operate the ignition switch per the Operator Manual.
Verify each of its functions works. Installation
1. Align the location pins of the turn signal and
3
2. As needed, troubleshoot further any system or circuit
malfunction not corrected by repair or replacement of transmission shift levers (7) with the holes in the steering
23

the switch or associated wiring. column.

2. Secure the two levers (7) together using the two bolts
Turn Signal Lever and Transmission Shift and nuts.
Lever Replacement
3. Connect the wire harnesses to the levers (7).
Use the following procedures and refer to Figure 3-6 when
4. Install the gauge/switch cover (6) on the steering
removing/installing the turn signal lever or transmission shift
column.
lever.
5. Connect the wire harness to the bottom of the gauge
Removal cluster (5).
1. Ensure that the key switch has been in the OFF position 6. Install the wire harnesses on the switches (4) as tagged
for 2 minutes. during removal.
2. Turn the battery disconnect switch to the OFF position. 7. Install the right side cover (9) on the steering column.
3. Pull the rubber boot (11) off the bottom of the left and 8. Connect the wire harness to the ignition switch (10).
right side covers (8, 9).
9. Install the left side cover (8) on the steering column.
4. Remove the lever (12) and spacer that locks/unlocks the
steering column tilt/telescope function. 10. Secure the gauge/switch cover (6) to the left and right
side covers (8, 9) using six screws (14).
5. Remove the steering wheel by doing the following:
11. Secure the left and right side covers (8, 9) together using
a. Remove the steering wheel cap (1) using a twisting four screws (13).
motion by pushing on the side of the cap closest to
you with your thumbs while simultaneously pulling 12. Install the steering wheel (2); torque the securing nut to
on the side of the cap farthest from you with your 30 lb-ft ±4 (40 Nm ±5).
fingers. 13. Install the steering wheel cap (1).

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ELECTRIC SYSTEM RT540E SERVICE MANUAL

14. Install the lever (12) and spacer that locks/unlocks the Check
steering column tilt/telescope function.
1. Operate the turn signal lever or transmission shift lever
15. Pull the rubber boot (11) up and over the bottom of the per the Operator Manual. Verify each of its functions
left and right side covers (8, 9). work.
16. Turn the battery disconnect switch to the ON position. 2. As needed, troubleshoot further any system or circuit
malfunction not corrected by repair or replacement of
the switch or associated wiring.

5
1

3
6

7
4
7
45
14
3
23

8
13

14 12

9
14
13

11

14
10

7794-1

FIGURE 3-6

Windshield Wiper Assembly Replacement 3. Tag and disconnect the electrical leads from the motor.
4. Disconnect the washer hose on the wiper arm (also
Removal called the pantograph arm assembly) from the washer
1. Ensure that the key switch has been in the OFF position nozzle fitting assembly.
for 2 minutes. 5. Remove the cap nut and washer securing the wiper arm
2. Turn the battery disconnect switch to the OFF position. to the pantograph adapter kit. (The nut and washer are

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RT540E SERVICE MANUAL ELECTRIC SYSTEM

part of the pantograph adapter kit.) Remove the cap nut, 4. Install the motor bracket and attached parts in the cab
washer, and tapered sleeve securing the wiper arm to interior with attaching hardware. Ensure the pivot shaft
the pivot shaft kit. (The nut, washer, and sleeve are part sticks through the hole in the pantograph adapter kit.
of the pivot shaft kit.) NOTE: Take care not to damage any parts while moving
6. Remove the wiper arm from the pantograph adapter kit the bracket and attached parts around the steering
and the pivot shaft kit. column.

7. Remove the flanged sleeve, nut, and two flat washers 5. Secure the pivot shaft to the pantograph adapter with the
from the pivot shaft kit. (The sleeve, nut, and washers pivot shaft kit’s nut and washers. Install the flanged
are part of the pivot shaft kit.) sleeve on the pivot shaft.

8. Remove the two capscrews and lockwashers securing 6. Install the wiper arm on the shafts of the pantograph
the pantograph adapter kit’s adapter to the cab exterior. adapter kit and the pivot shaft kit. Secure the wiper arm
Remove the pantograph adapter kit’s adapter and to the pantograph adapter kit shaft with the kit’s own
gasket. washer and cap nut. Secure the wiper arm to the pivot 3
shaft with the pivot shaft kit’s own tapered sleeve,
9. Remove attaching hardware to free the windshield wiper washer, and cap nut.
motor bracket from the cab interior. Remove the bracket,
with motor and pivot shaft connected, from the cab. 7. Connect the wiper arm’s washer hose to the washer
nozzle fitting assembly.
NOTE: You may have to remove or move other parts to get
the bracket and attached parts around the steering 8. Connect the electrical leads to the wiper motor as
column. Take care not to damage any parts. marked before removal.

10. Remove the nut to free the wiper motor’s shaft from the 9. Turn the battery disconnect switch to the ON position.

7
wiper motor kit crank. Remove the three screws and
washers to free the wiper motor from its bracket. Check
45
Remove the wiper motor from its bracket. Leave the
1. Squirt some cleaning fluid onto the windshield with the
other parts attached to the bracket for now.
windshield washer.
Inspection 2. Operate the windshield wiper. Verify it works. (Replace
3

wiper blade as needed if it streaks or otherwise wipes

1. Visually check the motor housing for evidence of cracks poorly.)
23

or other damage. Check for excessive shaft end play

indicating worn or damaged bearings. Replace motor if Windshield Washer Assembly Replacement
damaged.
2. Inspect the wiper blade for serviceability. Replace wiper Removal
blade when worn.
1. Ensure that the key switch has been in the OFF position
3. Inspect the wiper arm and parts of the linking component for 2 minutes.
kits (pantograph adapter kit, pivot shaft kit, wiper motor
2. Turn the battery disconnect switch to the OFF position.
kit link and crank, wiper motor bracket) for damage.
Replace as needed. 3. Locate the windshield washer container and pump on
the left rear side of the cab.
Installation 4. Tag and disconnect the pump’s electrical lead and
1. Verify the pivot shaft and the wiper motor kit link and ground wire.
crank are in place on the motor bracket. (Washers and 5. Disconnect the hose from the windshield washer pump.
clip springs fasten the link to the pivot pins on the crank Point it so it won’t spill cleaning fluid. Catch cleaning fluid
and the pivot shaft. The pivot shaft’s pivot pin mounts in from the windshield washer container with a suitable
the hole nearest the end of the pivot shaft’s lever.) container.
2. Connect the wiper motor to the motor bracket with 6. Remove four self tapping screws securing the
screws and washers. Connect the wiper motor’s shaft to windshield washer container to the cab. Remove the
the wiper motor kit crank with the nut and washer. windshield washer container and pump.
3. Secure the adapter and the gasket of the pantograph 7. Remove pump and pump seal from container.
adapter kit to the cab exterior with capscrews and
lockwashers.

GROVE Published 2-26-2014, Control # 414-03 3-13

ELECTRIC SYSTEM RT540E SERVICE MANUAL

Inspection 8. Clean any sealing material from around holes in cab

roof.
1. Visually check the pump for evidence of cracks, leaks, or
other damage. Replace pump if damaged. Inspection
2. Inspect the container for leaking. Replace pump seal if it 1. Visually check the motor housing for evidence of cracks
is leaking. Replace container if it is damaged and or other damage. Check for excessive shaft end play
leaking. indicating worn or damaged bearings. Replace motor if
3. Inspect spray nozzle on the wiper arm. As needed, clean damaged.
the nozzle with a fine piece of wire and compressed air. 2. Inspect the wiper blade for serviceability. Replace wiper
blade when worn.
Installation
3. Inspect the wiper arm and parts for damage. Replace as
1. Install pump and pump seal on container. needed.
2. Install windshield washer container on the cab. Secure
the container with four self tapping screws. Installation
3. Attach the hose to the windshield washer pump. 1. Install sealant material around both holes in cab roof,
both inside and outside.
4. Connect the pump’s electrical lead and ground wire as
tagged during removal. 2. Install screw with nylon flat washer (from outside)
through mounting hole in cab roof.
5. Turn the battery disconnect switch to the ON position.
3. Install flat nylon washer on motor shaft and insert motor
6. Fill the container with cleaning fluid. shaft through hole in cab roof. Position small nylon

7
washer and flat washer on screw between mounting
Check bracket and cab roof. Secure with lockwasher and nut.
45
1. Squirt some cleaning fluid onto the windshield with the 4. Install nylon flat washer, leather washer, spacer, and nut
windshield washer. on motor shaft. Tighten nut.
2. Make repairs if windshield washer doesn’t work. 5. Install wiper arm and blade on motor shaft.
3

Skylight Wiper Assembly Replacement 6. Connect the electrical leads to the wiper motor as
23

marked before removal.

Removal 7. Turn the battery disconnect switch to the ON position.
1. Ensure that the key switch has been in the OFF position
for 2 minutes. Check
2. Turn the battery disconnect switch to the OFF position. 1. Operate the skylight wiper. Verify it works. (Replace
wiper blade as needed if it streaks or otherwise wipes
3. Tag and disconnect the electrical leads from the motor. poorly.)
4. Remove the wiper arm from the motor shaft.
TROUBLESHOOTING
5. Remove the nut, spacer, leather washer, and nylon flat
washer from the motor shaft outside the cab roof. NOTE: This machine incorporates a CAN-BUS Multiplex
system. In order to effectively troubleshoot the
6. Remove the nut and lockwasher securing the motor
electrical system, you need a Windows-based PC,
bracket to the cab roof and remove the motor from the
CAN-link service software (9999102587), and a
cab roof. Remove large nylon flat washer from motor
connection cable (80026376). The CAN-link
shaft and flat washer and smaller nylon flat washer from
service software and connection cable may be
mounting screw.
ordered from Crane Care. These items can only be
7. Remove mounting screw and nylon flat washer from purchased by technicians that have attended the
outside cab roof. Grove New Technology training course.

3-14 Published 2-26-2014, Control # 414-03

RT540E SERVICE MANUAL BOOM

SECTION 4
BOOM

SECTION CONTENTS
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Boom Nose Sheaves . . . . . . . . . . . . . . . . . . . . . . . 4-15
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Boom Nose Sheaves Removal . . . . . . . . . . . . . . 4-16
Boom System Components. . . . . . . . . . . . . . . . . . 4-2 Boom Nose Sheaves Installation. . . . . . . . . . . . . 4-16
Telescope Cylinder . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Boom Assembly Procedure . . . . . . . . . . . . . . . . . 4-17
Fly Section Extension Cables . . . . . . . . . . . . . . . . 4-2 Install Tele Cylinder . . . . . . . . . . . . . . . . . . . . . . . 4-17
Extend Synchronizing Cable. . . . . . . . . . . . . . . . . 4-2 Install the Outer Mid Section . . . . . . . . . . . . . . . . 4-20
Fly Retraction Cables . . . . . . . . . . . . . . . . . . . . . . 4-2 Install the Inner Mid Section . . . . . . . . . . . . . . . . 4-24
Outer Mid Retract Cables . . . . . . . . . . . . . . . . . . . 4-2 Install the Base Section . . . . . . . . . . . . . . . . . . . . 4-29
Boom Extension Sequence . . . . . . . . . . . . . . . . . . 4-2 Final Boom Assembly . . . . . . . . . . . . . . . . . . . . . . 4-31
Boom Retract Sequence . . . . . . . . . . . . . . . . . . . . 4-4 Swingaway Extension Installation . . . . . . . . . . . . 4-32
Telescope Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Tensioning the Boom Extend and Retract 4
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
Theory Of Operation . . . . . . . . . . . . . . . . . . . . . . . 4-4 Boom Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 4-36
Lift Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Functional Test Of The Boom . . . . . . . . . . . . . . . 4-36

7
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Boom Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 4-36
45
Theory Of Operation . . . . . . . . . . . . . . . . . . . . . . . 4-4 Boom Alignment And Servicing . . . . . . . . . . . . . . 4-36
General Maintenance Notes. . . . . . . . . . . . . . . . . . 4-5 Extension And Retraction Cable Maintenance . . 4-37
Swingaway Extension Removable . . . . . . . . . . . . 4-5 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37
3

Boom Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Telescope Circuit Troubleshooting . . . . . . . . . . . 4-38

Disconnect the Base Section . . . . . . . . . . . . . . . . 4-7 Lift Circuit Troubleshooting . . . . . . . . . . . . . . . . . 4-40
23

Remove the Base Section . . . . . . . . . . . . . . . . . . 4-8 Lift Cylinder Maintenance. . . . . . . . . . . . . . . . . . . 4-42

Disconnect the Inner Mid Section . . . . . . . . . . . . 4-10 Lift Cylinder Removal. . . . . . . . . . . . . . . . . . . . . . 4-42
Remove the Inner Mid Section . . . . . . . . . . . . . . 4-10 Lift Cylinder Disassembly And Assembly . . . . . . 4-42
Remove the Outer Mid Section. . . . . . . . . . . . . . 4-13 Lift Cylinder Installation . . . . . . . . . . . . . . . . . . . . 4-42
Remove the Tele Cylinder . . . . . . . . . . . . . . . . . 4-14

DESCRIPTION sheave is installed on the main boom nose and is secured by

pins that pass through the rooster sheave.
The crane is equipped with a four section 9.8 to 31.0 m (32.3
to 101.7 ft), synchronized full power, cable extended boom. The boom has a 7.92 m (26 ft) offsetable or a 7.92 to 13.7 m
(26 to 45 ft) telescoping offsetable swingaway boom
The boom is rectangular in design and utilizes one two- extension provided to obtain additional boom reach. The
stage double-acting, rod ported telescope cylinder. The boom extension mounts directly to the boom nose utilizing a
telescoping sections are supported on graphite impregnated four point attachment. The boom extensions may be offset at
nylatron wear pads. Adjustable side wear pads prevent metal 0 to 30 degrees. In addition, the swingaway can be stowed
to metal contact between the sections. on the right side of the boom base section.
Boom assembly lift is provided by a single lift cylinder. Boom
elevation range is from -3 to 76 degrees. Safety
An optional auxiliary boom nose (rooster sheave) is available Do not attempt to work on the boom without experienced
for the boom to simplify single part cable usage. The rooster supervision.

GROVE Published 2-26-2014, Control # 414-03 4-1

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
To prevent serious injury or death, always wear personal
Fly Retraction Cables
protective equipment; i.e., a hard hat, eye protection, Refer to Figure 4-1 for item location. The two retraction
gloves and metatarsal boots. cables (14) are secured at the outside front of the inner mid
section (4), are routed around sheaves (15) mounted on the
BOOM SYSTEM COMPONENTS end of the outer mid section (6) and are secured at the
opposite end (16) to the fly section (17).
Telescope Cylinder
Outer Mid Retract Cables
The telescope cylinder is attached to the boom in three
places: Refer to Figure 4-1 for item location. Refer to Figure 4-1 for item location. The four retraction
cables (18) are secured at the outside front of the base
• The outer rod end (1) of the telescope cylinder is section (2), are routed around sheaves (19) mounted on the
secured to the boom base section (2) end of the inner mid section (4) and are secured (20) at the
• The inner rod end (3) is secured to the inner mid section opposite end to the outer mid section (6).
(4)
BOOM EXTENSION SEQUENCE
• The cylinder barrel (5) is secured to the outer mid
section (6) Refer to Figure 4-1 for item location. As the telescope
cylinder extends, the cylinder barrel (5), which is attached to
Fly Section Extension Cables the outer mid section (6), and the inner cylinder rod (3) which

7
is attached to the inner mid section (4), pulls the mid sections
The fly section has five extension cables (7) attached to it.
out along with it.
45
Refer to Figure 4-1 for item location.
At the same time, the five groove sheave assembly (9) at the
The extension cables (7) are secured to the inner mid
nose end of the telescope cylinder pulls on the five fly
section (8) and are routed around a five groove sheave
extension cables around it. This causes the fly section (17)
3
assembly (9) at the barrel end (boom nose) of the telescope
and mid sections (6, 4) to deploy at the same time and rate.
cylinder (10). These cables are secured at the base end of
23

the fly section (11). The long extend synchronizing cable (12) ensures the mid
sections and the telescope cylinder remain in
Extend Synchronizing Cable synchronization.
Refer to Figure 4-1 for item location. The long extend
synchronizing cables (12) are connected to the rear of the

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RT540E SERVICE MANUAL BOOM

4
12

11

18
4

7
14
45
10

13
12
9
3

4
23

6
6838-1 5 1

12

19

8
20

15

11

7
17
16
6838-2 FIGURE 4-1

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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 the boom section to retract. All return flow from the
the inner cylinder rod) are pulled in. directional control valve goes to the reservoir.
During retraction the two fly and four outer mid retraction
cables are forced around sheaves (15, 19) at the rear of the LIFT CIRCUIT
mid section. This cable arrangement keeps the fly section,
outer mid section, and the telescope cylinder in the proper Description
sequence and timing.
The boom lift circuit consists of the lift hydraulic remote
controller, lift directional control valve, holding valve, and the
TELESCOPE CIRCUIT lift cylinder. These components enable the boom to be raised
or lowered to various degrees of elevation ranging from -3 to
Description +76 degrees from horizontal.
The boom telescope circuit consists of the telescope The lift directional control valve is the closed spool type and
hydraulic remote controller, telescope directional control is described under Valves (pg 2-28).
valve, holding valve, and the telescope cylinder.
Refer to Valves (pg 2-28) for a complete description of the
NOTE: If the crane is equipped with an auxiliary hoist, the hydraulic remote controller.
telescope function is controlled by a foot pedal
instead of a controller. The lift cylinder is the double acting type. Dirt and other
foreign material is prevented from entering the cylinder and

7
The telescope control valve is the closed spool type and is causing internal damage by a wiper seal during rod
described under Valves (pg 2-28). retraction. Oil seals on both the piston and cylinder head
45
Refer to Valves (pg 2-28) for a complete description of the prevent internal and external hydraulic oil leakage. Refer to
hydraulic remote controller. Cylinders (pg 2-56) for a complete description of the lift
cylinder.
The boom telescope cylinder is a two stage double acting,
3

rod ported cylinder. Foreign material is prevented from The holding valve is a balanced poppet type hydraulic valve.
entering the cylinder by a wiper seal during rod retraction. O- It is threaded into the port block which is an integral portion of
23

ring seals prevent internal and external leakage. Refer to the lift cylinder barrel. The holding valve functions when
Cylinders (pg 2-56) for a complete description of the booming up (cylinder rod extended), booming down (cylinder
telescope cylinder. rod retracted), or holding (cylinder rod stationary).

The holding valve is threaded into a port block on the inner A velocity fuse is installed in the RCL piston transducer port
rod end of the telescope cylinder. The holding valve of the lift cylinder port block. The velocity fuse is used to
functions during the retraction, extension, or holding prevent inadvertent retraction (lowering) of the lift cylinder
operation. When holding the boom section at a given length, should the line to the transducer develop a leak. The fuse will
oil is trapped in the cylinder by the holding valve. Refer to close when flow reaches 11.4 L/min (3 gpm).
Holding Valves (pg 2-43) for a complete description of the
holding valve. Theory Of Operation
The directional control valve bank housing the lift control
Theory Of Operation valve is supplied by flow from the hydraulic pump.
Flow from the pump travels to the telescope directional When booming up, oil unseats the poppet (check) valve in
control valve. Movement of the control lever for telescope the holding valve, letting oil flow to the piston side of the
functions from neutral sends a pilot pressure signal to the cylinder. Pressure is applied to the piston, forcing the rod to
directional control valve to shift the spool in the directional extend, raising the boom.
control valve. This aligns the appropriate passages in the
control valve to route oil to the telescope cylinder holding When booming down, oil enters the retract port of the port
valve. The holding valve, with its’ internal make-up of valves block and flows to the cylinder rod side. When pilot pressure
and springs, passes oil to and from the telescope cylinder. reaches a pre-determined value, the main poppet unseats
During extension, oil unseats the poppet (check) valve in the and oil flows from the piston side of the cylinder to the
holding valve. This oil is routed to the piston sides of the reservoir.
cylinder which forces the rods out of the cylinder, causing the All return flow from the control valve goes to the reservoir.
boom section to extend.

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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
Retract Cable threads. Before attempting to remove the boom extension; read
and strictly adhere to all danger decals installed on the
• Unless otherwise specified, torque values for all metric boom/boom nose, boom extension, and stowage
class 8.6 and/or 0.9 and grade 5 and/or grade 6 brackets.
fasteners shall be as specified under Fasteners and
Torque Values (pg 1-11). 1. Visually check to ensure all pins are installed.
• Apply multipurpose grease to all wear surfaces. 2. Crane should be set up on outriggers using normal
• Adjust bottom front adjustable wear pads such that wear setup procedures as found in the Operator Manual.
pad is within mm 1 from side plate or bottom plate of a. Fully retract boom.
next inner section. Use shims only if section needs to be
adjusted for twist. b. Lower boom to horizontal for extending over the
front of the crane for removal.
• Adjust top rear adjustable wear pads such that the wear
pad is just in contact with side plate of next outer section. 3. Remove the retainer clips from the right side attachment
pins stowed in the base of the boom extension and
• To adjust lower side wear pads use shims so that wear remove the attachment pins from the boom extension. 4
pads are just in contact with the side plate of the next Insert the right side attachment pins (Figure 4-2, 1)
outer section. through the boom attachment and boom extension
• To adjust rear bottom wear pads use shims so that wear anchor fittings (Figure 4-2, 2). Install the retainer clips in

7
pads are with in 2mm of the bottom plate of the next the attachment pins.
outer section.
45
SWINGAWAY EXTENSION REMOVABLE
3

1
23

DANGER
To prevent serious injury or death, always wear personal
protective equipment; i.e., a hard hat, eye protection,
gloves and metatarsal boots.

DANGER
Boom angles are used to control speed at which
extensions swing during erecting and stowage. Improper
boom angles will cause uncontrollable swing speeds of
extension. 6814-4

FIGURE 4-2
NOTE: Tag line used in these procedures is to control the
movement of the boom extension. 4. Remove the retaining pin from the hitch pin (Figure 4-3,
3) that secures the boom extension to the rear stowage
bracket. Remove the hitch pin, unlocking the boom
extension from the boom.

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BOOM RT540E SERVICE MANUAL

9. Place the now free swingaway extension in a safe

3 secure location.

BOOM REMOVAL
Do not attempt to work on the boom without experienced
supervision.
4

DANGER
To prevent serious injury or death, always wear personal
protective equipment; i.e., a hard hat, eye protection,
6821-1 gloves and metatarsal boots.

FIGURE 4-3 NOTE: The boom may be disassembled with the base
section left on the crane if repair of the base section
5. Attach a length of rope to the boom extension tip to aid in
is not necessary.
swinging the boom extension into place ahead of the
boom nose. NOTE: The complete boom assembly weighs
approximately 5800 kg (12.740 lb) without the
6. Raise the boom to horizontal and extend the boom
swingaway boom extension attached. Removal of
approximately 51 to 64 cm (20 to 25”). Make certain that
the swingaway boom extension will simplify boom
the boom extension stowage lugs clear the guide pins
removal.

7
(Figure 4-4, 1) and ramp (Figure 4-3, 4) on the front and
rear stowage brackets. 1. Extend and set the outriggers to level the crane and
45
ensure the boom is fully retracted and in a horizontal
position over the front of the crane.
2. Fully retract the Boom.
3
23

DANGER
Wear gloves when handling wire rope.

1 3. Remove the hook block or headache ball and wind all

the wire rope onto the hoist drum.
4. Elevate the boom slightly so that the lift cylinder is
extended approximately 30.48 cm (12 in) to allow for
6821-3 FIGURE 4-4 withdrawal of the lift cylinder rod end from the lift cylinder
lift box on the bottom of the boom.

DANGER
When removing the boom extension, ensure that all DANGER
personnel and equipment are kept clear of the swing path. Ensure the boom lift cylinder is properly supported before
disconnecting it from the boom.
7. Slightly raise and/or lower the boom to help control the Ensure all blocking and lifting devices are capable of
boom extension. Using the rope attached to the top of supporting the boom assembly.
the boom extension, manually swing the extension into
place ahead of the boom nose.
5. Shut down hydraulic power to crane.
8. Attach a lifting devise to the lifting lugs on the swingaway
6. With hydraulic power removed, move the Boom Extend
extension taking pressure off the attaching pins
control from “EXTEND” to “RETRACT” several times.
(Figure 4-2, 1). Remove the pins.
This will relieve most residual pressure in Tele Circuit
and make Tele Cylinder removal easier.

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RT540E SERVICE MANUAL BOOM

7. 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.
8. Disconnect any electrical wiring from the boom.
9. Tag and disconnect the hydraulic lines to the telescope
cylinder. Hard cap or plug the lines and openings. 1

10. Remove the bolt (Figure 4-5, 1) and washer securing the
upper lift cylinder shaft (Figure 4-5, 2) to the side of the
lift box (Figure 4-5, 3) on the boom.
2

6835 FIGURE 4-6

16. Raise the boom clear of the crane and lower to blocking
or cribbing for service. 4
Disconnect the Base Section

7
Do not attempt to work on the boom without experienced
supervision.
45
.

6818-12 2 3 1 FIGURE 4-5

DANGER
3
11. Remove the upper lift cylinder shaft (Figure 4-5, 2).
To prevent serious injury or death, always wear personal
12. Activate the hydraulic system and withdraw the lift
23

protective equipment; i.e., a hard hat, eye protection,

cylinder rod enough to clear the lift box (Figure 4-5, 3).
gloves and metatarsal boots.
13. Take up the slack on the boom lifting device.
1. Remove the boom from the crane superstructure in
accordance with “Boom Removal” procedure.
2. Remove the RCL, A2B/Cable from boom nose.
DANGER
Shut down the crane before proceeding. a. Remove cover from junction box.
b. Disconnect “SHD” wire (Figure 4-7, 1) from terminal
14. Remove the clip pin and retaining pin (Figure 4-6, 1) 1 and “CORE” wire (Figure 4-7, 2) from terminal 2.
securing the boom pivot shaft (Figure 4-6, 2) on the
boom to the superstructure assembly. c. Disconnect cable connector from side of junction
box.

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BOOM RT540E SERVICE MANUAL

1
2

FIGURE 4-9
5. 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. The telescopic cylinder will still be under
3. Disconnect cable from the Fly section (Figure 4-8, 3)
hydraulic pressure due to the holding valve.
and feed cable through cable guides (Figure 4-8, 1) and

7
attach to the Base section cable guide (Figure 4-8, 2).
45
2
3
23

1
2

6748-30

6818-14
1 FIGURE 4-10
FIGURE 4-8 6. Remove the nuts and washers securing the
4. Chain the Fly, Outer Mid and Inner Mid sections synchronizing cable (Figure 4-10, 2) ends to the base
together. This will prevent the inadvertent or unexpected section.
extension of these sections during the boom
disassembly. Figure 4-9 Remove the Base Section
Do not attempt to work on the boom without experienced
supervision

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RT540E SERVICE MANUAL BOOM

DANGER
The combined weight of the boom inner mid, outer mid,
and fly sections, including the telescope cylinder, is 2
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
protective equipment; i.e., a hard hat, eye protection,
gloves and metatarsal boots.
FIGURE 4-12
1. Remove the access cover (Figure 4-11, 1) on the top
2. Remove the bolt (Figure 4-13, 1), washer, and offset
rear of the base section. Slide the assembly out of the
base section (Figure 4-12, 1) enough to gain access to
washer securing each top rear adjustable wear pad and
remove the wear pads, keeper plates and bolts
4
the top rear adjustable wear pads on the inner mid
(Figure 4-13, 2) from the top of the inner mid. Note
(Figure 4-12, 2).
location of wear pads and shims for installation.

7
1
45
1
3
23

2 FIGURE 4-13
3. On the top front of the base section, remove the two
bolts securing the kick back plate and remove the plates.
FIGURE 4-11 4. Remove the bolts securing the outer mid retract cable
anchor plates to the lower front of the base section.
Remove the cable locknuts and the anchor plates from
the cables.
5. Remove the two screws securing each top (Figure 4-14,
1) and bottom (Figure 4-14, 2) side wear pads at the
front of the base section. Remove wear pads, shims,
and mounting angle (top left side only).

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BOOM RT540E SERVICE MANUAL

and thrust washers.If necessary, remove the grease

fitting from the shaft weldments.

2
6818-15
6748-25 1
FIGURE 4-15
FIGURE 4-14
2. Remove the two bolts and bushings securing the
6. Attach a suitable lifting device to the Fly/Outer/Inner Mid cylinder inner rod (Figure 4-16, 1) to the rear of the inner

7
assembly. Raise the front of the assembly slightly and mid (Figure 4-16, 2).
remove the wear pad mounting bolts and the wear pads
45
from the bottom of the base section.
7. Continue to pull the assembly until it is clear of the base
section.
3

NOTE: Pull the outer mid retract cables out with the
assembly to prevent them from becoming
23

damaged. 2
8. Place base section in a secure location

Disconnect the Inner Mid Section

Do not attempt to work on the boom without experienced
supervision. 1
FIGURE 4-16

3. Remove the two nuts from the extend cable anchor plate
adjusting bolts.
DANGER
4. Pull the four retract cables up through the holes in the
To prevent serious injury or death, always wear personal
protective equipment; i.e., a hard hat, eye protection, bottom of the inner mid and lay them out to the rear.
gloves and metatarsal boots.
Remove the Inner Mid Section
1. On both sides, remove the bolts (Figure 4-15, 1) Do not attempt to work on the boom without experienced
securing each retract sheave assembly shaft weldment. supervision.
Remove the shaft, spacer bushing, sheave assembly,

DANGER
To prevent serious injury or death, always wear personal
protective equipment; i.e., a hard hat, eye protection,
gloves and metatarsal boots.

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RT540E SERVICE MANUAL BOOM

1
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). Ensure that adequate
and properly tested lifting devices are used to remove
these sections

1. Slide the assembly out of the inner mid (Figure 4-17, 1)

enough to gain access to the top rear adjustable wear
pads on the outer mid (Figure 4-17, 2) through the hole
in the top of the inner mid.
2. Remove the bolt, washer, and offset washer securing
each top rear adjustable wear pad and remove the wear FIGURE 4-18
pads, keeper plates (Figure 4-17, 3) and bolts from the
top of the outer mid. 4. At the lower front of the inner mid, remove the bolts
securing the fly retract cable anchor plates (Figure 4-19,
1). Remove the cable locknuts and the anchor plates
4
from the cables.
1
5. Install thread protectors on cable ends.

7
3
45
2
3
23

FIGURE 4-17

3. At the top front of the inner mid, remove the four bolts
and washers securing the synchronizing cable sheave 1
assembly (Figure 4-18, 1). Lay the assembly with cables
on top of the outer mid.
6748-23

FIGURE 4-19
6. Remove the screws securing each top (Figure 4-20, 1)
and bottom side wear pads (Figure 4-20, 2) at the front
of the inner mid. Remove wear pads, shims. Keep the
shims with each individual wear pad for re-installation.
7. Remove the RCL cable guide mounting angle
(Figure 4-20, 3) (top left side only).

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BOOM RT540E SERVICE MANUAL

the extend cable in the proper sequence for re-

assembly.

4
1
1

2 6748-29
FIGURE 4-22
6748-25
3
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
8. Lift up on the front of the assembly and remove the wear disconnect the four retract cables (Figure 4-23, 1).
pad bolts and wear pads (Figure 4-20, 4) from the 12. Remove the cotter pins and pins (Figure 4-23, 2)

7
bottom of the inner mid. (Figure 4-20) securing the four retract cables to the rear of the outer
mid.
45
9. Remove the lock nut and adjustment nut (Figure 4-21, 1)
from the extend cable adjustment bolt. This will free the
extend cable from the inner mid weldment.
3
1
23

2
1

6748-27 FIGURE 4-23

6818-15
FIGURE 4-21 13. If necessary, remove the two bolts securing the bottom
10. Secure the extend cable keeper plate and adjustment wear pad to the inner mid. Remove wear pad.
bolt to the tele cylinder with cable ties (Figure 4-22, 1) or 14. If necessary, remove the two bolts securing each lower
tape. Failure to do so may allow the cables and keeper rear side wear pad to the inner mid. Remove wear pads
to become jammed during disassembly. and shims. Note location of shims for installation.
NOTE: It is not necessary to remove the extend cable 15. Remove the inner mid Section from outer/fly/tele
keeper plates at this time. If it is necessary to cylinder assembly.
remove the cable keeper plates, be sure to mark

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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 1 2 FIGURE 4-25
telescope cylinder, is approximately 1960 kg (3720 lb).
Ensure that adequate and properly tested lifting devices
are used to remove these sections
4. Pull the two retract cables up through the holes in the
bottom of the outer mid and lay them out to the rear.
4
1. At the rear of the outer mid, on both sides, remove the 5. Turn cylinder rod inner mounting lugs (Figure 4-26, 1) so
bolt and cable retainer bushing from above each retract they are vertical to clear mounting bracket (Figure 4-26,

7
cable sheave assembly (Figure 4-24, 1). 2) in the outer mid.
45
2. Remove the shaft, spacer bushing, sheave assembly,
and thrust washer. If necessary, remove the grease
fitting from the shaft weldments.
. 2
3
23

1 6748-38
6748-28 FIGURE 4-24
FIGURE 4-26
3. Place wood block (Figure 4-25, 1) under cylinder and
remove the four bolts and bushings securing the cylinder 6. Slide the fly assembly out of the outer mid enough to
barrel (Figure 4-25, 2) to the rear of the outer mid. gain access to the top rear adjustable wear pads on the
fly through the hole in the top of the outer mid.
7. Remove the bolt, washer, and offset washer
(Figure 4-27) securing each top rear adjustable wear
pad and remove the wear pads, keeper plates and bolts
from the top of the fly.

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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.
12. Remove the retaining plate securing the two fly retract
cables (Figure 4-30, 1) to the rear of the fly.

6748-37 FIGURE 4-27

8. At the top front of the outer mid, remove the two bolts
(Figure 4-28, 1) securing the kickback plate. Remove
the kickback plate.
1 1 FIGURE 4-30
1
13. Remove the synchronizing cable and sheave assembly
from the top of the outer mid.

7
14. Remove the two fly retract cables from the inside of the
outer mid.
45
15. Remove the two bolts securing each lower rear side
wear pad to the outer mid. Remove wear pads and
shims. Note location of shims for installation.
3
FIGURE 4-28
Remove the Tele Cylinder
23

9. Remove the two screws securing each top (Figure 4-29,

1) and bottom (Figure 4-29, 2) side wear pads at the Do not attempt to work on the boom without experienced
front of the outer mid. Remove wear pads, shims, and supervision..
mounting angle (Figure 4-29, 3) (top left side only).

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 weight of the telescope cylinder is approximately 889
1 kg (1980 lb). Ensure that adequate and properly tested
lifting devices are used to remove the telescope cylinder.
6748-22 2 3 FIGURE 4-29
1. Attach a suitable lifting device to the Tele Cylinder. Raise
cylinder and remove blocking device (Figure 4-25, 1)
from under the cylinder.
DANGER
2. Slide the Tele Cylinder out of the Fly Section until it is
Be extremely careful when remove bottom wear pads. Do
just ready to “drop out” of the section. Do not pull the
not place your hands or fingers in an area that could
Tele Cylinder completely out of the Fly Section yet.
cause injury. Use approved tools to remove wear pads.

4-14 Published 2-26-2014, Control # 414-03

RT540E SERVICE MANUAL BOOM

NOTE: Pull the extend cable along with the telescope 6. 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.
section.
Extend Cable Sheave Removal
1. Remove the bolts holding the Cable Retainer
(Figure 4-34, 1) to Sheave Mount (Figure 4-34, 2).
Remove the Retainer.
NOTE: If the extend cables are to be reused, be sure that
they are marked before removal to aid in
reassembly.
2. Remove the five extend cables.
NOTE: The boom nose sheave weighs approximately 17.3
FIGURE 4-31 kg (38 lb).

3. Remove the two bolts securing the extend cable keeper 3. Remove the sheave shaft retainer plates (Figure 4-34,
plate (Figure 4-32, 1) to the rear of the fly. Remove the 3) from left and right side of the sheave mount.
keeper plate and remove the five extend cable ends
from the slots in the fly.
4. Carefully pull the sheave shaft (Figure 4-34, 4) from the
assembly, removing the spacers, and sheave
4
(Figure 4-34, 5). Note the quantity of the spacers for
installation.

7
45
4
3
2
23

1 FIGURE 4-32

4. After supporting the weight of the tele cylinder, remove

the two bolts securing the cylinder foot weldment 5
(Figure 4-33, 1) to the telescope cylinder (Figure 4-33, 3
2). Remove the foot weldment.

2 1 3
6748-35 FIGURE 4-34

1
BOOM NOSE SHEAVES
Do not attempt to work on the boom without experienced
supervision.

DANGER
FIGURE 4-33 To prevent serious injury or death, always wear personal
5. Completely remove the Tele Cylinder from the Fly protective equipment; i.e., a hard hat, eye protection,
Section. gloves and metatarsal boots.

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BOOM RT540E SERVICE MANUAL

Boom Nose Sheaves Removal nose sheaves weigh approximately 17.4 kg (38 lb)
each.
1. Remove the clip pins from the cable retainer pins
(Figure 4-35, 7) and remove the cable retainer pins 3. Carefully pull the upper boom nose sheave shaft
(Figure 4-35, 3) from the upper and lower part of the (Figure 4-35, 6) from the boom nose, removing the
boom nose. spacers, and boom nose sheaves (Figure 4-35, 4). Note
the quantity of the spacers for installation.
2. Remove the two bolts securing the end cap
(Figure 4-35, 2) to the upper boom nose sheave shaft 4. Repeat steps 2 and 3 and remove the lower boom nose
(Figure 4-35, 6). Remove the end cap. sheave shaft.

NOTE: The boom nose sheave shafts weigh 5. Remove the shim, washer, keyed washer and locknut
approximately 12.5 kg (27.5 lb) each. The boom from both sheave shafts.

3
6

7
4
3 45
2
23

4 3

FIGURE 4-35

Boom Nose Sheaves Installation 3. Install the locknut, washer, keyed washer, and shims (if
necessary) onto the boom nose sheave shaft with the
NOTE: The boom nose sheave weighs approximately 17.4 chamfer side out. Install the end cap (Figure 4-35, 2)
kg (38 lb). onto the opposite end of the sheave shafts and secure in
1. Install the spacers and sheaves (Figure 4-35, 4) onto the place with the two bolts.
sheave shaft while installing the sheave shafts into the 4. Tighten the locknut until the play in the bearings is
lower boom nose (Figure 4-35, 5). eliminated. Bend the lockwasher tabs to secure the
NOTE: The lockwasher can be used more than once but locknut in place.
must be replaced if not in good condition. 5. Repeat steps 1 through 4 for the upper boom nose
2. Install the lockwasher onto the sheave shaft with the sheaves and sheave shaft.
tabs facing out. 6. Install the cable retainer pins (Figure 4-35, 3) into the
upper and lower part of the boom nose and secure in
place with the clip pins (Figure 4-35, 7).

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RT540E SERVICE MANUAL BOOM

BOOM ASSEMBLY PROCEDURE

Do not attempt to work on the boom without experienced
supervision.

4
2

DANGER
To prevent serious injury or death, always wear personal
protective equipment; i.e., a hard hat, eye protection,
gloves and metatarsal boots.
5

Extend Cable Sheave Installation 3

CAUTION
1 3
The extend cable sheave weighs approximately 17.3 kg
(38 lb). 6748-35 FIGURE 4-36 4
5. Install the sheave assembly (Figure 4-36, 5), shaft
NOTE: This procedure can be greatly simplified if two (Figure 4-36, 4) and spacers. Install the shaft with the
technicians are used. One technician to hold the

7
lubrication fitting to the LEFT and the notches to the
sheave in place and the other to insert the spacers Front of the boom.
and sheave shaft.
45
6. Install the sheave shaft retainer plates (Figure 4-36, 3)
1. Clean and inspect the sheave assembly shaft bushing. on the left and right side with 2 capscrews and 2
Replace the bushing if damage is found. washers in each plate.
3
2. Lubricate the shaft bushing.
Install Tele Cylinder
3. Determine the number of spacers required for the
23

sheave shaft. Do not attempt to work on the boom without experienced

supervision.
As many as six spacers (3 on each side) may be
required. If you have placed 3 spacers on the first side,
and find that only two will fit on the second side, that will
be acceptable. It will not be necessary or desirable to
remove one spacer from the first side. DANGER
To prevent serious injury or death, always wear personal
4. Apply a light coat of lubricant to the sheave shaft protective equipment; i.e., a hard hat, eye protection,
(Figure 4-36, 4). gloves and metatarsal boots.

NOTE: Apply Loctite 243 to the threads of all attaching

hardware except cable ends and cable lock nuts.
Apply multipurpose grease (MPG) to all wear
surfaces.
Use standard torque values specified in Section 1
of this Manual unless otherwise specified.
NOTE: Wear Pads. When installing upper and lower side
wear pad, use shims as necessary so wear pad is
within 1.52 mm (0.06 inch) from side plate of next
inner section. Use equal number of shims on each
If wear pad shims were previously removed, place
shims in same locations that was noted during
removal.

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BOOM RT540E SERVICE MANUAL

1. Measure and mark the center line of the Fly Section. 5. 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.
6. Position the sheave end of the Tele Cylinder at the rear
2. Install the lower rear side wear pads (Figure 4-37, 1) and of the fly section, with port block turned as shown
shims on the fly section with two screws each. (Figure 4-39).

1 FIGURE 4-39
7. Carefully insert the Tele Cylinder into the fly section until
the sheave weldment clears the retract cable weldment.
8. Install the two wear pads on the support foot weldment
with two bolts each. Torque bolts.

7
9. Install the cylinder foot weldment (Figure 4-40, 1) to the
45
6748-33 2 Tele Cylinder (Figure 4-40, 2) using two bolts.
FIGURE 4-37
10. Lower cylinder so the cylinder foot weldment rests on
3. Install the bottom rear wear pad (Figure 4-37, 2) on the support foot weldment (Figure 4-40, 3) wear pads.
3
fly section with two screws.
4. Install the Tele Cylinder Sheave Mount and sheave
23

assembly (Figure 4-38, 1) to the Tele Cylinder

(Figure 4-38, 2). 2

a. Install the sheave shaft with the grease fitting to left. 1

b. Do not install the cable retainer with hardware 3
(Figure 4-38, 3) until the Extend Cables are reeved
around the sheave
c. Lubricate the sheave

FIGURE 4-40

2 CAUTION
The five Extend Cables must be marked at both ends
1 prior to installation. If the cables are not marked, they will
3 be difficult to install in the correct order.
Do not allow the cables to become entangled or overlap.
Cable or boom failure could result.
6748-32
FIGURE 4-38
11. Mark BOTH ENDS of the five extend cables
(Figure 4-41).

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RT540E SERVICE MANUAL BOOM

. with extend cable keeper plate (Figure 4-42, 2) and two

bolts.

2 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.
4

7
45
FIGURE 4-41
3

CAUTION
23

When adjusting cables, hold the cable end and turn the
nut. do not turn cable.
Turning or twisting of the cable while adjusting will result
in damage or failure of cable. FIGURE 4-43
Install cables in their natural untwisted condition. 15. Slide the Tele Cylinder assembly completely into the Fly
Section.
12. Reeve the five extend cables around the Tele Cylinder
sheave. 16. Inspect the extend cables to ensure that they are not
crossed or out of sequence.
13. Place the five extend cable dead ends (Figure 4-42, 1) in
the slots at the top of the fly section and secure them 17. Place blocking under the rear of the Tele Cylinder to aid
in assembly (Figure 4-44).

GROVE Published 2-26-2014, Control # 414-03 4-19

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 a. Measure and note the total width of the boom
section.

7
Do not attempt to work on the boom without experienced
supervision. b. Using the measurement obtained determine the
45
center point of the boom section and clearly mark it
(Figure 4-46).
3
DANGER
To prevent serious injury or death, always wear personal
23

protective equipment; i.e., a hard hat, eye protection,

gloves and metatarsal boots.

NOTE: Before the fly section is installed the center point of Measure across section.
the fly section must be determined. Measurement
from this center point will be used to properly set
the adjustable wear pads
1. Align two straight edge tools with the outer edge of the
Fly Section at the rear of the section (not the wear pad

Make Mark At Center Line

FIGURE 4-46

2. Install the lower (brass) wear pads (Figure 4-47, 1) to the

outer mid section. Back out the adjustment set screw so
the pad seats fully into the pocket (Figure 4-47, 2). The
pad should extend no more than  of an inch into the
outer mid section for the initial installation.
NOTE: Use grease to aid in holding the wear pad in place.

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RT540E SERVICE MANUAL BOOM

CAUTION
Do not allow the cables to become entangled or overlap.
cable or boom failure could result.

6. Attach the fly retract cables to the cable anchors

(Figure 4-49, 1) on the base end of the fly section on
both sides. Install the two cable keepers with two lock
washers and two bolts on each keeper.
2
7. Feed the threaded end through outer mid and lay out
towards the front of the outer mid section.
3

1 1
6748-25

FIGURE 4-47

3. Insert the upper wear pad, backing plate and adjusting 4

plate. (Figure 4-47, 3)
a. Attach each wear pad assembly with four washers,
four lock washers and four capscrews.

7
b. Insert the hex head adjusting screws. Do not
45
tightened at this time
4. Apply lubricant to the wear pad contact areas of the Fly
Section.
3

5. To aid in the installation of the Fly Section into the Outer FIGURE 4-49
23

Mid Section, apply lubricant to the wear pad contact

8. Slide the Fly section into the Outer Mid section until the
areas of the Fly Section and secure the Extend Cables
wear pad adjustment is accessible though the access
to the Tele Cylinder. (Figure 4-48)
plate on top of the Outer Mid section.
a. Rotate the Port Block as shown in Figure 4-48.

CAUTION
Pull the two fly retract cables through the outer mid as the
fly section is being installed. Do not allow the cables to
become entangled or overlap. Cable or boom failure could
result.

9. Raise the Fly Section slightly and insert the bottom wear
pad in to place and secure with retaining bolts. Insert the
bolts (Figure 4-50, 1) from the bottom of the Outer Mid
Section.

FIGURE 4-48

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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. The correct torque will allow the
cylinder to “float” in the mount.
.

1 FIGURE 4-50

10. Insert the wear pads and pad holders (Figure 4-51, 1) on
the left and right side of the Fly section.
NOTE: The “buttons” on the wear pads may be “shaved
down” if needed. Do not cut into the wear pad.

7
11. Measure and adjust the wear pads until the Fly section is FIGURE 4-52
45
centered ± 1mm (0.04 inch) in the Outer Mid section.
14. Remove the block of wood holding the Tele Cylinder.
Apply Loctite and tighten jam nut (Figure 4-51, 2).
. 15. Route the fly retract cables down through the bottom of
the Outer Mid section. Lay the cables out toward the
3

nose end of the Outer Mid section.

23

1 16. Reeve the fly retract cable around the fly retract cable
sheave (Figure 4-53, 1) and install in the angled slots
(Figure 4-53, 2) on each side of the Outer Mid section.
2

FIGURE 4-51

2
CAUTION
Do not allow the cables to become entangled or overlap.
Cable or boom failure could result. 6748-34 FIGURE 4-53
17. Lubricate Retract Cable shaft.
12. Slide the Fly section the rest of the way into the Outer
Mid section. 18. Install kickback plate with hardware (Figure 4-54, 1) on
inside top of Outer Mid section.

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RT540E SERVICE MANUAL BOOM

FIGURE 4-54

19. Rotate cylinder mounting to facilitate mounting in to the

Inner Mid section. (Figure 4-55)

7
45
FIGURE 4-57

21. Install adjusting (Figure 4-58) bolt to the anchor

assembly.
3

.
6748-31
23

FIGURE 4-55
Permanent Anchor Bolt
20. Install Extend Cables in to the round keeper plate
(Figure 4-56 and Figure 4-57).

Assembly Bolt

FIGURE 4-58

22. Temporary secure anchor assembly to the Extend

Cylinder Rod.
23. Attach the mid retract cables to the anchor point at the
base end of the Outer Mid.

6748-29
a. Lubricate and install pin through cable ends. Secure
FIGURE 4-56
pin (Figure 4-59, 1) with cotter keys.
24. Lay out the threaded end of the mid retract cables
CAUTION through the Inner Mid section toward the base end.
Install Extend Cables in proper sequence. Do not allow
the cables to become entangled or overlap. Cable or
boom failure could result.

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BOOM RT540E SERVICE MANUAL

1
FIGURE 4-59

Install the Inner Mid Section

Do not attempt to work on the boom without experienced
supervision.

6748-26

DANGER FIGURE 4-61

To prevent serious injury or death, always wear personal 3. Assemble the mid syncro cable sheave assembly
protective equipment; i.e., a hard hat, eye protection, (Figure 4-60, 3) and lay on top of the Outer Mid section

7
gloves and metatarsal boots. about where it will go.
45
a. Reeve the mid syncro cables (Figure 4-60, 4)
1. Insert the adjustable brass wear pads (Figure 4-60, 1) around the sheaves.
and the upper wear pads (Figure 4-60, 2). Do not install
the bottom wear pads at this time. b. The cables should be reeved from the cable anchor
3
around the outside of the sheave wheels to the
inside of the sheave wheels. The threaded end of
23

the cable should be laid out down the center of the

Inner Mid section toward the base end.
4. Attach the fly retract cables button ends to the cable
anchor points(Figure 4-62, 1) in the Fly Section. Use
one keeper plate (Figure 4-62, 2), two cap screws, and
two washers on each anchor to secure the cables.

4
3

1
6748-24 FIGURE 4-60 FIGURE 4-62

2. Attach both mid syncro cable anchor ends (Figure 4-61, 5. Pass the threaded end of the fly retract cables down
1) with capscrews and bushings to the base end of the thought the bottom of the fly section. Lay the cables out
Outer Mid section. toward the nose end of the fly section.
6. Reeve the each fly retract cable around the retract
sheaves at the base of the Outer Mid section.

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RT540E SERVICE MANUAL BOOM

7. 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.
8. Lubricate both sheave assemblies

FIGURE 4-65

NOTE: Installation of the Extend Cable Anchor Assembly

will require the use of a bolt longer than the
permanent bolt. The weight of the five extend
cables and anchor assembly will make the
installation of the anchor assembly extremely
difficult with out use of a longer bolt Figure 4-66.
Use bolt Part Number 7099000555 (or equivalent) 4
for installation only (Figure 4-66).
.

7
FIGURE 4-63 45 Permanent Anchor Bolt
3
23

Assembly Bolt
FIGURE 4-66

11. Insert assembly bolt into extend cable anchor.

12. Tie the extend cable anchor assembly to the Tele
Cylinder (Figure 4-67).

FIGURE 4-64

9. Install the rear bottom and side and brass wear pads.
Install shims with the open end facing the base end of
the boom section.
FIGURE 4-67
10. Install adjustment bolts and lock nuts to the upper
adjustable wear pad weldment. Do not install wear pads 13. Assemble the Fly Retract Cable anchor weldments to
at this time (Figure 4-65). the retract cables. Thread the single nut on the cable
end until there is 1 1/2 inch of thread showing, then
install the locknut (Figure 4-68).
NOTE: There are left and right anchors. Check to make
sure the anchors are in the correct position

GROVE Published 2-26-2014, Control # 414-03 4-25

BOOM RT540E SERVICE MANUAL

FIGURE 4-68
FIGURE 4-70
14. Install the brass wear pad (Figure 4-69, 1) at the nose
end of the Inner Mid section. 18. Align the Outer Mid section with 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. Measure clearance at pads and shim as
required.

7
3 45
23

6748-24
1
FIGURE 4-69
Outer Mid Section Inner Mid Section FIGURE 4-71
15. Pull the outer mid retract cables through the Inner Mid
section with the threaded end towards the base end of NOTE: Pull the Mid Retract Cables through the Base
the section. Section as the sections are joined.
NOTE: Always lay out and inspect the cables before
installation. Laying out cables will help eliminate
twists, kinks and make inspection easier. CAUTION
Do not allow the cables to become entangled or overlap.
16. Apply grease to those parts of the inner mid and outer
Cable or boom failure could result.
mid where the wear pads will contact.
17. Attach the mid retract cables to the Outer Mid section. 19. Insert bottom wear pads on the Inner Mid section.
(Figure 4-70).

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RT540E SERVICE MANUAL BOOM

20. Attach fly retract cable anchors to the nose of the inner
mid section (Figure 4-72, 1).

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.
22. Install the adjustable wear pads (Figure 4-73, 1) to the
top of the base end of the Inner Mid section.
4
1 2 FIGURE 4-74

7
25. Check to make sure the long cable installation bolt
45
(Figure 4-75, 1) is installed in the extend cable anchor
assembly.
3
23

1 FIGURE 4-73

23. Install kickback plate on inside top Inner Mid section

(Figure 4-74, 1).
24. Install the mid syncro cable sheave assembly
(Figure 4-74, 2) to top inside of Inner Mid section.

1 FIGURE 4-75
26. Insert the installation bolt into inner mid anchor
weldment and take up as much slack as possible.
NOTE: Make certain that the extend cable anchor is
seating properly into the boom section weldment.
The “ears” on the anchor must fit into grooves
machined into the sides of the inner mid anchor
plate.

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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
a. Remove the installation bolt and replace with the
washers to the outside of the boom.
standard adjustment bolt.
NOTE: Insert ONE thrust washer to the INSIDE and TWO
b. Take up the slack on the anchor adjustment bolt and
thrust washers to the OUTSIDE of each assembly.
remove the clamps.

FIGURE 4-78

31. Reeve the mid retract cables on the left and right mid
retract cable sheave assemblies and install as shown in
Figure 4-78.

7
32. Install retainer capscrew, washer and nut to lock sheave
assembly pins in place (Figure 4-79, 1).
3 45
FIGURE 4-76
23

28. Adjust the adjustment nut until there is 2.75 inches of

thread showing. Install jam nut.
29. Attach the Tele Cylinder to the inner mid mounting
flanges. Check to ensure bushings are free to rotate
after bolts are tightened (Figure 4-77).

View looking up from the

bottom of Inner Mid Section

1 FIGURE 4-79

33. Lay out the mid retract cables toward the nose end of the
FIGURE 4-77 Inner Mid section.

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RT540E SERVICE MANUAL BOOM

34. Attach two cables to each anchor adjust each cable to 1. 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.
2. Install lower front wear pads between sections.
NOTE: Use grease to hold wear pads in place during
assembly.
3. Install brass wear pad thru base access hole in side of
the Base section and slide Inner Mid section past wear
pad and install lock plate (Figure 4-82).
FIGURE 4-80

35. Turn Tele Cylinder port block so that the test port is down
(Figure 4-81).

CAUTION
Failure to properly position the port block will cause
problems when mounting the boom on the crane. The
crane hydraulic system will not function properly if the port 4
block in installed incorrectly.

7
3 45
23

FIGURE 4-82

4. Connect the Mid Retract cables to front end of Base

section (Figure 4-83).

Test Port FIGURE 4-81

Install the Base Section

Do not attempt to work on the boom without experienced
supervision.

FIGURE 4-83
DANGER
To prevent serious injury or death, always wear personal 5. Install kickback bar between the Inner Mid section and
protective equipment; i.e., a hard hat, eye protection, the Base section (top front of base).
gloves and metatarsal boots. 6. Install top wear pad adjusting assembly inside Base
section at top rear access opening (Figure 4-84).

GROVE Published 2-26-2014, Control # 414-03 4-29

BOOM RT540E SERVICE MANUAL

FIGURE 4-84
FIGURE 4-86
9. 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. The boom will not function properly if
the Port Block is not installed as shown in Figure 4-85.

7
CAUTION
45
There is less than 3 mm of clearance between the sides of
the weldment and the port block during installation.
R e m o v e a n y p l u g s / c a ps t h a t m a y i n t e r f e r e w i t h
installation.
3
23

FIGURE 4-87

11. Plumb port block with tubing (Figure 4-88).

Test Port

Test Port
FIGURE 4-85

7. Carefully guide the port block into the anchor weldment.

8. Insert two tele rod end pins. Secure both ends of each
pin with a flat washer, lock washer, and capscrew
(Figure 4-86).
NOTE: It may be necessary to gently pry the port block to
align the pin holes. FIGURE 4-88

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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
of the boom and feed cable through the Inner and Outer Do not attempt to work on the boom without experienced
Mid section cable guides (Figure 4-89, 2) and through supervision.
the Fly section cable guide (Figure 4-89, 3).

DANGER
To prevent serious injury or death, always wear personal
protective equipment; i.e., a hard hat, eye protection,
gloves and metatarsal boots.

NOTE: The boom may be disassembled with the base

section left on the crane if repair of the base section
is not necessary.
1
NOTE: The complete boom assembly weighs
2
approximately 5800 kg (12.740 lb) without the
3 swingaway boom extension attached. Removal of
the swingaway boom extension will simplify boom
removal.
4
6818-14

FIGURE 4-89 1. Attach a lifting device to the boom to provide for equal
weight distribution.

7
13. Remove the RCL, A2B/Cable from boom nose.
2. Raise the boom off of the blocking or cribbing high
45
c. Connect cable connector to side of junction box. enough to clear the crane and lower to crane
superstructure assembly.
d. Connect “SHD” wire (Figure 4-90, 1) to terminal 1
and “CORE” wire (Figure 4-90, 2) to terminal 2. 3. Align the boom with the superstructure assembly.
3

a. Replace cover to junction box. 4. Insert the boom pivot shaft and thrust washers through
superstructure assembly and boom.
23

5. Insert the clip pin and retaining pin (Figure 4-6, 1)

securing the boom pivot shaft (Figure 4-6, 2) on the
boom to the superstructure assembly.

1
2
1

6837 6835
FIGURE 4-90 FIGURE 4-91

14. See PAT manual for proper cable reel tension. 6. Install the grease fittings on the pivot shaft and add
grease per requirements in LUBRICATION (pg 9-1).
7. Remove the hard cap or plugs in the hydraulic lines and
openings and connect the hydraulic lines to the
telescope cylinder.

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BOOM RT540E SERVICE MANUAL

8. Connect all electrical wiring to the boom.

9. Elevate the boom slightly with the lifting device so that
the lift cylinder can be extended approximately 30.48 cm
(12 in) to allow for insertion of the lift cylinder rod end to DANGER
the lift cylinder lift box on the bottom of the boom. Boom angles are used to control speed at which
extensions swing during erecting and stowage. Improper
10. Activate the hydraulic system and extend the lift cylinder boom angles will cause uncontrollable swing speeds of
rod enough to slide in the lift box (Figure 4-92, 1). extension.

NOTE: Tag line used in these procedures is to control the

movement of the boom extension.

DANGER
Before attempting to remove the boom extension; read
and strictly adhere to all danger decals installed on the
boom/boom nose, boom extension, and stowage
brackets.

1. Crane should be set up on outriggers using normal

setup procedures as found in the Operator Manual.

7
a. Fully retract boom.
45
6818-12 1 2 3 4 FIGURE 4-92 b. Lower boom to horizontal extending over the front of
the crane.
11. Insert the upper lift cylinder shaft (Figure 4-92, 2). 2. Attach a lifting devise to the lifting lugs on the swingaway
extension.
3
12. Install the upper shaft weldment (Figure 4-92, 3), bolt
(Figure 4-92, 4) and washer to the side of the lift box 3. Attach a length of rope to the boom extension tip to aid in
23

(Figure 4-92, 1), securing the upper lift cylinder shaft swinging the boom extension into place ahead of the
(Figure 4-92, 2) on the boom. boom nose.
13. Remove the boom lifting device.
14. Ensure the Boom is fully retracted.
DANGER
When removing the boom extension, ensure that all
personnel and equipment are kept clear of the swing path.
DANGER
Wear gloves when handling wire rope. 4. Raise the swingaway extension to a safe height to move
to the boom and move the extension into place ahead of
SWINGAWAY EXTENSION INSTALLATION the boom nose.
5. Using the rope attached to the top of the boom
extension, manually align the boom attachment to the
boom extension anchor fittings (Figure 4-93, 2).
DANGER 6. Move the boom slightly up or down to help align the
To prevent serious injury or death, always wear personal boom attachment and boom extension anchor fittings
protective equipment; i.e., a hard hat, eye protection, (Figure 4-93, 2).
gloves and metatarsal boots.
7. Insert the right side attachment pins (Figure 4-93, 1)
through the boom attachment and boom extension
anchor fittings (Figure 4-93, 2). Install the retainer clips
in the attachment pins.

4-32 Published 2-26-2014, Control # 414-03

RT540E SERVICE MANUAL BOOM

2
6821-1

FIGURE 4-95

6814-4
DANGER
4
FIGURE 4-93 When stowing the boom extension, ensure that all
8. Extend the boom approximately 51 to 64 cm (20 to 25”). personnel and equipment are kept clear of the swing path.

7
Make certain that the boom extension stowage lugs will
line up in front of the guide pins (Figure 4-94, 1) and
45
ramp (Figure 4-95, 2) on the stowage brackets when the
boom extension is positioned to the side of the boom. CAUTION
Do not allow the boom extension to slam into the stowage
3
bracket when swinging into the stowed position.
23

10. Using the rope attached to the tip of the boom extension,
manually swing the extension to the side of the boom.
11. Align the stowage lugs on the boom extension with the
guide pins and ramp (Figure 4-95, 2) on the stowage
brackets and fully retract the boom.
12. Install the hitch pin and clip pin (Figure 4-95, 1) securing
1 the boom extension to the rear stowage bracket.
13. Remove the attachment pins and clip pins (Figure 4-96,
1) from the anchor and attachment fittings (Figure 4-96,
2) on the right side of the boom nose and stow them in
6821-3 FIGURE 4-94 the base of the boom extension. Stow left side
attachment pins and clips in outside attachment fitting on
9. Ensure the hitch pin and clip pin (Figure 4-95, 1) are swingaway.
removed from the rear stowage bracket.

GROVE Published 2-26-2014, Control # 414-03 4-33

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
1 the boom has been rebuilt and any time the cables appear to
be loose.
Tools required:
- 15/16 in, 1-1/4 in, and 1-13/16 in crow’s feet
- torque wrench with toque capabilities of 72 in-lb to
360 in-lb
2
Do the following when tensioning the extend and retract
cables:

CAUTION
6814-4 When adjusting cables, use two wrenches. Hold the “flat”
on the cable and turn the adjusting nut.
FIGURE 4-96
Do not allow the cables to twist. Cable failure could result.
14. On the rear stowage bracket, remove the retainer pin

7
(Figure 4-97, 1) securing the sliding support in the • When tightening or loosening the cables, secure the
“OUT” position. Push in on the handle (Figure 4-97, 2) to cables using the flats at the front of the cable ends to
45
push the swingaway against the rear of the boom prevent the cables from twisting.
15. Disengage the swingaway anchor fittings from the boom • To assure cables are adequately tensioned, torque
nose attachment lugs. Install the retainer pin cables to at least the minimum torque values found in
3
(Figure 4-97, 1) securing the sliding support in the “IN” Table 4-1.
position.
23

• Ensure all tensioning nuts thread on and off of the

threaded studs by hand; weld spalls or thread damage
will adversely affect torque values.

WARNING
To prevent serious injury or death, always wear personal
p ro te c tiv e e qu i pm en t, inc l ud ing a ha rd ha t , ey e
protection, gloves and metatarsal boots.
1

6821-2 CAUTION
2
Possible Cable Damage!
FIGURE 4-97
Use of an impact wrench to tighten the cable tensioning
16. Slightly raise and/or lower the boom to help control the nuts can cause the extend and retract cables to twist,
boom extension. resulting in cable failure.

17. Rig the boom nose and hoist cable as desired per Do not use an impact wrench when tensioning the extend
Section 4 of the RT535E Operator Manual. and retract cable.

18. Align the main and auxiliary hoists to the boom per Refer to the following procedures, Figure 4-98, and Table 4-1
HOIST AND COUNTERWEIGHT (pg 5-1). when tensioning the extend and retract boom cables:
19. Install the hook block or headache ball.

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RT540E SERVICE MANUAL BOOM

1. Position the boom to horizontal before making retract simultaneously and that they do not drift out when
adjustments. the hydraulic valve is in neutral.
2. Slightly tighten all cables. a. If the 2nd stage is fully retracting late, loosen the
3/2/1 retract cables and tighten the 1/2/3 extend
3. Fully retract the boom.
cables. Extend and retract the boom a few feet. Re-
4. In the order listed here, tighten the 4/3/2 retract, the torque the 3/2/1 retract cables and the 1/2/3 extend
2/3/4 extend, the 3/2/1 retract, and the 1/2/3 extend cables to verify that the minimum torque value is
cables to remove the excess slack from the cables. achieved as specified in Table 4-1.
5. In the order listed, torque the 4/3/2 retract, the 2/3/4 b. If the 3rd stage is fully retracting late, loosen the
extend, the 3/2/1 retract, and the 1/2/3 extend cables to 4/3/2 retract cables, tighten the 2/3/4 extend cables,
the minimum torque values specified in Table 4-1. then extend and retract the boom a few feet. Re-
To provide better access to adjust the 3/2/1 retract torque the 4/3/2 retract cables and the 2/3/4 extend
cables, extend the boom approximately 300 mm (12 in), cables to verify that the minimum torque value is
then retract the boom approximately 150 mm (6 in) to achieved as specified in Table 4-1.
tension the cables correctly prior to torques being set. 8. Ensure that all extend and retract cables achieve the
Fully retract the boom before setting the torque on the minimum torque value as specified in Table 4-1.
1/2/3 extend cables. 9. Add jam nuts and tighten.
6. Fully cycle the boom. 10. Coat all stud threads with Never Seize and install cable 4
7. Tighten the extend and retract cables as follows to protectors. All threaded cable ends must be equipped
ensure that all boom sections fully extend and fully with retainer nuts and jam nuts.

7
3 45
23

4-Section Boom Cable Positioning and

Adjustment Locations
FIGURE 4-98

Table 4-1: Minimum Torque Values for Boom Cable Tensioning

Cables (Extend/Retract) Minimum Torque Values
4/3/2 retract 10.5 Nm (96 in-lb)
2/3/4 extend 40.5 Nm (360 in-lb)
3/2/1 retract 5.4 Nm (48 in-lb)
1/2/3 extend 16 Nm (144 in-lb)
Note: All above torque values shown are minimums and are calculated with the
use of a standard crow's foot attached to the torque wrench in a straight-ahead
position.

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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:

1. Activate the hydraulic system and check for proper 1. Fully extend the boom horizontally.
operation and any leaks. 2. Lubricate the boom bottom plates (sides and bottom).
2. Ensure the boom will extend and retract properly. 3. Shim the front lower side wear pads to within 1.52 mm
3. Ensure the lift cylinder will not allow the boom to drift (0.06 in) from side plate of next inner boom section, then
down until the operator lowers it. shim the front upper wear pads in the same manner. Use
equal number of shims on each side.
4. Ensure all electrical components disconnected during
removal are operating properly.
CAUTION
Boom Inspection When extending and retrac ti ng the boom during
Do not attempt to work on the boom without experienced alignment, movement should be stopped if a restriction is
supervision. encountered. re-shim wear pads as necessary to provide
free travel of the affected boom section(s).

4. Retract and extend the boom; check for the high point
where the boom has brushed the wear pads at the
DANGER widest point.
To prevent serious injury or death, always wear personal
protective equipment; i.e., a hard hat, eye protection, 5. Retract the boom sections to align the high point on the

7
gloves and metatarsal boots. boom section with the adjacent wear pads.
6. Add or subtract shims as necessary.
45
1. Visually inspect telescoping sections for adequate
lubrication of all wear surfaces. Table 4-2
2. Observe extended sections for evidence of cracks, Example
3

warping, or other damage.

If the boom deflects to the left:
23

3. Periodically check security of boom wear pads.

1 The forward left wear pad would be shimmed in.
4. Check boom nose sheaves for security and freedom of
The rear left adjustable wear pad would be
movement.
2 adjusted out, away from the internal boom
section.
Boom Alignment And Servicing
3 The forward right wear pad will be shimmed out.
Do not attempt to work on the boom without experienced
supervision. 4 The right rear adjustable pad adjusted in

7. Attach a weight and extend the boom full length. Check

for side deflection.

DANGER
To prevent serious injury or death, always wear personal
protective equipment; i.e., a hard hat, eye protection,
gloves and metatarsal boots.

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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
MAINTENANCE Consensus standard as referenced by Federal Government
Agencies.
Do not attempt to work on the boom without experienced
All wire rope will eventually deteriorate to a point where it is
supervision.
no longer usable. Wire rope shall betaken out of service
when any of the following conditions exist.
• In running ropes, six randomly distributed broken 4
DANGER wires in one lay or three broken wires in one strand
in one lay.
To prevent serious injury or death, always wear personal

7
protective equipment; i.e., a hard hat, eye protection, • Wear of one-third the original diameter of outside
gloves and metatarsal boots. individual wires. Kinking, crushing, bird caging, or
45
any other damage resulting in distortion of the rope
NOTE: For more detailed information concerning structure.
maintenance of the extension and retraction • Evidence of any heat damage from any cause.
cables, refer to Wire Rope (pg 1-15).
3

• Reductions from nominal diameter of more than:

Inspection
23

• 0.4 mm (0.016-in) for diameters up to and including

Do not attempt to work on the boom without experienced 8 mm (0.3125-in).
supervision. • 0.79 mm (0.031-in) for diameters 10 and 13 mm
(0.375 and 0.5-in) inclusive.
• 1.19 mm (0.047-in) for diameters 14 to 19 mm
(0.5625 to 0.75-in) inclusive.
DANGER
• 1.59 mm (0.063-in) for diameters 22 to 29 mm
Never handle wire rope with bare hands. Injury to hands
(0.875 to 1.125 in) inclusive.
could result.
• 2.38 mm (0.094-in) for diameters 32 to 38 mm (1.25
to 1.5 in) inclusive.
• In standing ropes, more than two broken wires in
one lay in sections beyond end connections or more
DANGER than one broken wire at an end connection.
To prevent serious injury or death, always wear personal
protective equipment; i.e., a hard hat, eye protection,
gloves and metatarsal boots.

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BOOM RT540E SERVICE MANUAL

TELESCOPE CIRCUIT TROUBLESHOOTING

Table 4-3

SYMPTOM PROBABLE CAUSE SOLUTION

1. Erratic operation of a. Low hydraulic oil level. a. Replenish hydraulic oil to proper level.
extending
b. Damaged relief valves. b. Repair or replace relief valves.
telescoping
cylinder. c. Air in telescope cylinder. c. Bleed by lowering telescope cylinder
below horizontal.
d. Low engine rpm. d. Increase engine rpm to recommended
setting.
e. Lack of lubrication on boom sections. e. Properly lubricate all boom sections.
f. Extremely tight boom extension f. Inspect and properly lubricate boom
sheaves. extension sheaves.
g. Improper boom alignment caused from g. Reduce and properly hoist load.
side loading.
h. Worn boom wear pads. h. Replace wear pads and properly
lubricate.
i. Distorted boom section. i. Replace distorted section.

7
j. Damaged telescope cylinder. j. Repair or replace cylinder.
k.
45
Clogged, broken, or loose hydraulic k. Clean, tighten, or replace lines or
lines or fittings. fittings.
l. Damaged control valve. l. Repair or replace control valve.
3
2. Erratic operation of a. Low hydraulic oil level. a. Replenish hydraulic oil to proper level.
retracting
b. Damaged relief valve. b. Repair or replace relief valve.
23

telescoping
cylinder. c. Air in cylinder. c. Bleed by lowering telescoping cylinder
below horizontal and cycle telescope
cylinder.
d. Low engine rpm. d. Increase engine rpm to recommended
setting.
e. Lack of lubrication. e. Properly lubricate all boom sections.
f. Check valve malfunctioning. f. Repair or replace check valve.
g. Improper boom alignment caused from g. Reduce and properly hoist load.
side loading.
h. Extremely tight boom retraction h. Inspect and properly lubricate.
sheave.
i. Distorted boom section. i. Replace distorted section.
j. Worn boom wear pads. j. Replace wear pads and properly
lubricate.
k. Bent cylinder rod(s). k. Replace cylinder rod(s) and all cylinder
seals.
l. Scored cylinder barrel. l. Repair or replace cylinder barrel.
m. Damaged piston seals. m. Replace all cylinder seals.
n. Loose or damaged piston(s). n. Replace all seals and re-torque or
replace piston(s).

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RT540E SERVICE MANUAL BOOM

SYMPTOM PROBABLE CAUSE SOLUTION

3. Telescope cylinder a. Low hydraulic oil level. a. Replenish oil to proper level.
will not extend.
b. Relief valve malfunctioning. b. Repair or replace relief valve.
c. Excessive load. c. Reduce load.
d. Clogged hose and fittings. d. Replace hose or fittings. (Refer to
Manitowoc Crane Care Parts Manual).
e. Broken valve spool. e. Replace valve.
f. Damaged piston seals. f. Replace all cylinder seals.
g. Damaged piston(s). g. Replace piston(s) and all cylinder
seals.
h. Bent boom section(s). h. Replace damaged boom section(s).
i. Broken hydraulic pump coupling. i. Replace broken hydraulic pump
coupling.
j. Worn or damaged hydraulic pump j. Repair or replace pump section.
section.
4. Telescope cylinder a. Low hydraulic oil level. a. Replenish oil to proper level.
4
will not retract.
b. Relief valve damaged. b. Repair or replace relief valve.
c. Excessive load. c. Reduce load. (Refer to load chart).

7
d. Inoperative check valve. d. Replace check valve.
45
e. Clogged hose and fittings. e. Replace hose or fittings. (Refer to
Manitowoc Crane Care Parts Manual).
f. Broken valve spool. f. Replace valve section.
3

g. Broken piston(s). g. Replace piston(s) and all cylinder

23

seals.
h. Damaged piston seals. h. Replace all cylinder seals.
i. Bent boom section(s). i. Replace damaged boom section(s).
j. Broken hydraulic pump coupling. j. Replace broken hydraulic pump
coupling.
k. Worn or damaged hydraulic pump. k. Repair or replace pump.
l. Broken hydraulic pump shaft. l. Replace pump shaft.

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BOOM RT540E SERVICE MANUAL

LIFT CIRCUIT TROUBLESHOOTING

Table 4-4

Symptom Probable Cause Solution

1. Boom raises a. Low hydraulic oil. a. Replenish hydraulic oil to proper level.
erratically.
b. Low engine rpm. b. Increase engine rpm to recommended
setting.
c. Main relief valve damaged. c. Replace relief valve.
d. Air in cylinder rod. d. Bleed cylinder rod.
e. Bent boom pivot shaft. e. Replace pivot shaft.
2. Boom lowers a. Low hydraulic oil. a. Replenish hydraulic oil to proper oil
erratically. level.
b. Low engine rpm. b. Increase engine rpm to recommended
level.
c. Circuit and/or relief valve inoperative. c. Repair or replace relief valve.
d. Air in hydraulic cylinder. d. Bleed air from cylinder.
e. Damaged hydraulic pump section. e. Repair or replace pump section.

7
3. Boom raises a. Low hydraulic oil level. a. Replenish hydraulic oil to proper level.
slowly.
45
b. Low engine rpm. b. Increase and maintain engine rpm.
c. Damaged relief valve. c. Repair or replace relief valve.
d. Extremely cold hydraulic oil. d. Operate unit to bring oil to operating
3
temperature.
e. Improper hose or fittings, installed. e. Replace hose or fittings. (Refer to
23

Manitowoc Crane Care Parts Manual).

f. Operating two functions with in the f. Feather controls to obtain desired
same control valve bank assembly. speed of both functions.
g. Restriction in return hose. g. Replace return hose.
h. Cylinder piston seals leaking. h. Replace all cylinder seals.
i. Scored cylinder barrel. i. Hone or replace barrel.
j. Worn hydraulic pump section. j. Repair or replace pump section.
4. Boom lowers a. Low hydraulic oil level. a. Replenish hydraulic oil to proper level.
slowly.
b. Low engine rpm. b. Increase rpm to recommended level.
c. Damaged relief valve. c. Repair or replace relief valve.
d. Operating two functions within the d. Feather controls to obtain desired
same control valve bank assembly. speed of both functions.
e. Extremely cold hydraulic oil. e. Operate unit to bring oil to operating
temperature.
f. Improper hose or fittings installed. f. Replace hose or fittings. (Refer to
Manitowoc Crane Care Parts Manual).
g. Restriction in return hose. g. Replace return hose.
h. Cylinder piston seals worn. h. Replace all cylinder seals.
i. Scored cylinder barrel. i. Hone or replace barrel.

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RT540E SERVICE MANUAL BOOM

Symptom Probable Cause Solution

Boom lowers j. Worn hydraulic pump section. j. Repair or replace pump section.
slowly. (Continued)
k. Piston rod broken (loose from piston). k. Replace piston rod and all cylinder
seals.
5. Boom will not raise. a. Low hydraulic oil. a. Replenish hydraulic oil to proper level.
b. Main relief valve or circuit relief valve b. Repair or replace relief valve.
damaged.
c. Excessive load. c. Reduce load as required.
d. Worn or damaged hydraulic pump d. Repair or replace pump section.
section.
e. Broken pump shaft. e. Replace pump shaft and seals.
f. Broken pump drive coupling. f. Replace drive coupling.
g. Broken control valve spool. g. Replace control valve.
6. Boom will not a. Low hydraulic oil. a. Replenish hydraulic oil to proper level.
lower.
b. Main relief valve or circuit relief valve
damaged.
b. Repair or replace relief valve. 4
c. Worn or damaged hydraulic pump c. Repair or replace pump section.
section.

7
d. Broken pump shaft. d. Replace pump shaft and seals.
45
e. Broken pump drive coupling. e. Replace drive coupling.
f. Broken control valve spool. f. Replace control valve.
3
23

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BOOM RT540E SERVICE MANUAL

LIFT CYLINDER MAINTENANCE 9. 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
cylinder disassembly and assembly procedures. Lift Cylinder Disassembly And Assembly
Maintenance not requiring removal of the cylinder Disassembly and assembly procedures of the lift cylinder
barrels, such as packing, may be performed holding valve, and control valve are provided under Lift
without removing the cylinders from the turntable. Cylinder (pg 2-59), Holding Valves (pg 2-43) and Directional
However, all disassembly and assembly should be Control Valves (pg 2-6).
conducted in a clean dust-free area.
1. Extend and set the outriggers and level the crane. Lift Cylinder Installation
2. Elevate the boom slightly so that the lift cylinder is 1. Attach an adequate lifting device to the lift cylinder and
extended approximately 0.3 m (1 ft). position the cylinder over the attach fitting on the
turntable.
2. Lower the lift cylinder into the attach fittings on the
turntable and align the lift cylinder bushing with the
DANGER attach fitting holes.
The weight of the Lift Cylinder is approximately 578 kg
3. Install lower pivot shaft (Detail B) with tapped hole on the
(1275 lb). Ensure that adequate and properly tested lifting
right side, side opposite the cab.
devices are used to remove the Lift Cylinder.
4. Install the lift cylinder lower pivot shaft and secure with

7
3. Ensure the boom is fully supported by placing blocking the bolt and locknut.
or cribbing under the boom. Rest the boom on the
5. Connect the extend and retract hoses to the lift cylinder.
45
blocking or cribbing.
6. Activate the crane’s hydraulic system and align the lift
4. Remove the bolt and washer securing the lift cylinder
cylinder rod end with the attach point on the boom.
upper pivot shaft to the boom (see Figure 4-100).
Install the upper pivot shaft through the cylinder and
3

5. Remove the bolt and locknut securing the lift cylinder boom attach points. Shut down the engine.
lower pivot shaft to the turntable.
23

7. Secure the upper pivot shaft with the bolt and washer.
6. Attach an adequate lifting/supporting device to the lift
8. Remove the lifting and supporting devices from the
cylinder being removed.
boom and lift cylinders. Activate the hydraulic system
7. Remove the upper pivot shaft. Activate the hydraulic and check the lift cylinders for proper operation and any
system and retract the lift cylinder enough to clear the leaks.
upper attach point.
9. Lubricate the pivot shafts using grease fittings
8. Tag and disconnect all the hydraulic lines to the cylinder.
Cap or plug all openings with high pressure fittings.

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RT540E SERVICE MANUAL BOOM

RETAINING BOLT

UPPER
PIVOT SHAFT

LOWER PIVOT SHAFT DETAIL B DETAIL A

7
B
A
45
FIGURE 4-100
3
23

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BOOM RT540E SERVICE MANUAL

7
45
THIS PAGE BLANK
3
23

4-44 Published 2-26-2014, Control # 414-03

RT540E SERVICE MANUAL HOIST AND COUNTERWEIGHT

SECTION 5
HOIST AND COUNTERWEIGHT

SECTION CONTENTS
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 BRAKE TEST PROCEDURE FOR HP15C-17G,
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . 5-1 HO30A-19G, HP35-26G HOISTS . . . . . . . . . . . . . . . 5-6
Brake Test Procedure (To be performed with no
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 load on the hoist) . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Warm-up Procedure . . . . . . . . . . . . . . . . . . . . . . . 5-1
Hoist to Boom Alignment . . . . . . . . . . . . . . . . . . . . 5-7
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Functional Check . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Piston Motor and Control Valve . . . . . . . . . . . . . . . 5-8
hoist maintenance and inspection . . . . . . . . . . . . 5-4 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Usage and Inspection . . . . . . . . . . . . . . . . . . . . . . 5-4
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Pre-Use or Daily Inspection . . . . . . . . . . . . . . . . . 5-5
Idler Drum and Cable Follower. . . . . . . . . . . . . . . . 5-9
Quarterly Inspection (every three months) . . . . . . 5-5
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Semi-Annual Inspections (every six months) . . . . 5-5
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Annual Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

7
Hoist Drum Rotation Indicator System . . . . . . . . 5-12
PREVENTIVE MAINTENANCE AND OIL Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
SAMPLING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
45
Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12 5
Gear Oil Sampling and Analysis . . . . . . . . . . . . . . 5-5 Counterweight Removal . . . . . . . . . . . . . . . . . . . . 5-14
3
23

DESCRIPTION THEORY OF OPERATION

One hoist is available; the HP15C-17G (Figure 5-1). The The hoist assembly is controlled by hydraulic remote
hoist incorporates one dual displacement piston motor which controllers located in the cab. When the control lever in the
drives a reduction unit within the hoist. The hoist utilizes cab is moved from neutral, it causes the hoist section of the
planetary reduction with a multi-disc automatic brake that is directional control valve to shift the valve spool to route
spring applied and hydraulically released. An overrunning hydraulic flow to the hoist motor control valve. The hoist
clutch allows the hoist to be raised without releasing the motor control valve is used to stop or slow the hoist when the
brake while at the same time holding the load until there is load is trying to drive the hoist down too quickly. The motor
sufficient pressure to release the brake when hoisting down. control valve is piloted open by the hoist down pressure. If
The hoist motor controls both speed and torque of the hoist. the load lowers faster than the flow of oil in the hoist down
line, the pilot pressure decreases and the motor control valve
There are two modes in which the hoist operates. One mode
partially closes to restrict the oil leaving the motor until a
is high speed. The pilot solenoid valve shifts the selector
balance occurs. This results in the load lowering at a uniform
spool on the motor to provide minimum motor displacement.
speed based on the position of the hoist control lever.
This gives high line speed and low torque.
During stopping, when the hoist down flow ceases, the pilot
The second mode is low speed. The pilot solenoid valve
pressure holding the motor control valve open decays to
shifts the selector spool on the motor to provide maximum
zero and the motor control valve spool closes, thus blocking
motor displacement. This gives low line speeds and high
all flow of oil out of the hoist motor. This same pressure
torque.
decay allows the spring applied pressure released hoist
brake to apply when the load is fully stopped. This brake acts
as a “parking brake” and holds the load in the stopped
position.

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HOIST AND COUNTERWEIGHT RT540E SERVICE MANUAL

MAINTENANCE Removal
Warm-up Procedure 1. If the CE option is provided, remove the hoist covers.
2. Remove all cable from the hoist drum.
A warm-up procedure is recommended at each start-up and
is essential at ambient temperatures below +40°F (4°C). 3. Tag and disconnect the hydraulic lines to the hoist. Cap
or plug all lines and openings.
The prime mover should be run at its lowest recommended
RPM with the hydraulic hoist control valve in neutral allowing 4. Tag and disconnect the electrical wires to the hoist
sufficient time to warm up the system. The hoist should then rotation indicator sensor box.
be operated at low speeds, forward and reverse, several
times to prime all lines with warm hydraulic oil, and to 5. Tag and disconnect the electrical wires to the hoist hi-
circulate gear lubricant through the planetary gear sets. speed solenoid valve.

6. Remove the hoist mounting nuts, capscrews, washers,

and shims (if shims are used, mark their location).
DANGER NOTE: The HP15C-17G hoist assembly, less the cable,
Failure to properly warm up the hoist, particularly under weighs approximately 300 kg (661 lb).
low ambient temperature conditions, may result in
temporary brake slippage due to high back pressures 7. Using an adequate lifting device, remove the hoist from
attempting to release the brake, which could result in the crane.
property damage, severe personal injury or death.

7
1
45
2
3
23

4, 5, 6, 7 6952
3

FIGURE 5-1

5-2 Published 2-26-2014, Control # 414-03

RT540E SERVICE MANUAL HOIST AND COUNTERWEIGHT

relation to the level positioned between the boom pivot

Item Description shaft bushings.

1 Auxiliary Hoist 6. With the hoist level, check to determine if all the hoist
mounting pads are in contact with the mounting plate by
2 Main Hoist
rocking the hoist.
3 Turntable
7. Keeping the hoist level, use a feeler gauge to determine
4 Capscrew the amount of gap existing between the pads and the
5 Washer mounting plate.
6 Hex Nut 8. Add shims to satisfy any existing gaps. Altering the shim
thickness to fit a tapering gap is acceptable. Install the
7 Counterweight
capscrews, washers and nuts and torque see Fasteners
and Torque Values (pg 1-11).
Installation
9. Remove the lifting device from the hoist.
1. Ensure the mounting plate and hoist pads are clean and
free from debris and the hoist has not been damaged 10. Connect the hydraulic lines to the hoist ensuring the
during handling. proper lines are connected to the correct ports as
marked during removal.
2. With the hoist supported by a suitable lifting device,
position the hoist on the mount. 11. Connect the electrical wires to the hoist hi speed
solenoid valve as marked during removal.
3. Check the hoist to boom alignment according to the
HOIST TO BOOM ALIGNMENT procedure in this 12. Connect the electrical wires to the hoist rotation indicator
section. sensor box as tagged during removal.

7
4. Place a level between the boom pivot shaft bushings. 13. Install the cable, following the procedures outlined under
45
5. Place a level across the top of the hoist drum and
INSTALLING CABLE ON THE HOIST, in the Operator
Manual.
5
determine if the hoist is sitting in the same plane in
3
23

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HOIST AND COUNTERWEIGHT RT540E SERVICE MANUAL

MAIN HOIST IS ALIGNED TO THE RIGHT HAND

SHEAVE

LOCATING CENTERLINE WITH

SQUARE

7
45
AUXILIARY HOIST IS ALIGNED TO THE CENTER
SHEAVE
6019
FIGURE 5-2
3
23

Functional Check 3. Ensure the hydraulic connections are secure and free
from leaks.
1. Attach a test weight to the hook and raise and lower the
load several times. Servicing
2. Check the hoist for smooth operation of the hoist motor Remove the large plug from the center of the drum support.
and brake system. Fill with AGMA EO-4 gear lubricant until level with the plug
opening. Check every 1000 hours or 12 months.

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RT540E SERVICE MANUAL HOIST AND COUNTERWEIGHT

HOIST MAINTENANCE AND INSPECTION categories based upon their usage or duty cycle, which in
turn determines appropriate intervals for inspections. The
It 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. The five crane/hoist usage
deterioration of internal critical components within the hoist
categories are as follows:
can occur. Hoists incorporate planetary gears, multi-disc
brake assemblies and sprag clutches which do not have an • Idled - The crane/hoist has not been used for three
infinite service life span. Although these components have months.
been designed to achieve long service life, reliability can be • Infrequent Usage - The crane/hoist is used less than
substantially reduced by a variety of influencing factors such ten hours per month based on a three month average
as: • Moderate Usage - Crane/hoist used 10 - 50 hours per
• High cycle operation month based on a three month average.
• Operating in high ambient temperatures • Heavy Usage - Crane/hoist used 50 - 200 hours per
month.
• High external contamination, such as dusty or sandy
conditions • Severe Duty - Crane/hoist is operated more than 200
hours per month OR where 50% of the lifts exceed 75%
• Type of lubricant used
of the rated capacity for the hoist.
• Level of maintenance
NOTE: For idled units with unknown maintenance and
The following routine servicing points must be carried out in repair history, it is highly recommended that the
accordance with manufacture’s instructions: hoist undergo a tear down inspection prior to being
placed into service.

7
Usage and Inspection
The following chart lists the inspections that are required for
Inspection procedures for hoists are divided into five general
45
each type of usage category:
5
3
23

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HOIST AND COUNTERWEIGHT RT540E SERVICE MANUAL

Pre-Use or Daily Inspection 1. Perform the pre-use/daily, quarterly and semi-annual

inspections.
Must include but is not limited to the following inspections
that will be performed prior to placing the crane into service 2. Change the lubricating oil in the hoist gear cavity after an
and then as necessary during extended operation. This oil sample has been taken as described on page 5. Refill
inspection must be performed by a qualified crane operator the hoist to the proper level with recommended
lubricant. Refer to the machine’s lubrication chart.
or qualified crane technician.
1. Check for external oil leaks and repair as necessary.
This is extremely important due to the accelerated wear
that will result from insufficient lubricating oil in the hoist. WARNING
Hoists with a sight glass; check oil level daily. Hoists
Possible equipment damage and/or
without a sight glass; check oil level monthly if no
personal injury!
external oil leaks are detected. Lubricant level must be
maintained between the minimum and maximum levels; Failure to use the proper type and viscosity of planetary
midway up sight glass or at bottom of level plug port as gear oil may contribute to intermittent brake clutch
equipped. Use ONLY the recommended type of slippage which could result in property damage, severe
lubricant. Refer to the machine’s lubrication chart. personal injury or death. Some gear lubricants contain
large amounts of EP (extreme pressure) and anti-friction
2. Check hydraulic fittings and hoses for chaffing, additives which may contribute to brake clutch slippage or
deterioration or corrosion and repair as necessary. damage to brake friction discs or seals. Oil viscosity with
3. 3. Visually inspect for corroded, loose or missing bolts, regard to ambient temperature is also critical to reliable
pins or other fasteners and replace or tighten as brake clutch operation. Our tests indicate that excessively
necessary. heavy or thick gear oil may contribute to intermittent brake

7
clutch slippage. Make certain that the gear oil viscosity
4. 4. Visually inspect rotation indicator transmitters, anti- used in your hoist is correct for your prevailing ambient
two-blocking switches and other safety equipment and
45
temperature.
repair as necessary.

Quarterly Inspection (every three months) PREVENTIVE MAINTENANCE AND OIL

SAMPLING
3

Must include but is not limited to the following inspections

23

that must be performed by a qualified crane operator or

qualified crane technician.
1. Perform the pre-use inspection. WARNING
2. Inspect for corrosion of fasteners, hoist base, drum, etc. Risk of personal injury!
and repair/replace as required to maintain the structural Hot oil may cause personal injury and/or burns to
integrity of the hoist. unprotected skin. Make certain the oil has cooled to a
safe temperature (typically less than 110°F or 43°C)
Semi-Annual Inspections (every six months) before taking an oil sample, changing oil or servicing the
1. Perform the pre-use and quarterly inspections. hoist.
2. Take a sample of the lubricant from the hoist gear cavity
as described on page 5 and analyze it for wear metals
Oil Change
content, correct viscosity, lubricant deterioration, The hoist gear oil must be changed after the first 100
moisture and other contaminants. If the oil sample operating hours then on an annual basis, at a minimum
contains a high amount of metallic particles, the hoist thereafter. In severe duty applications, the gear oil should be
must be taken out of service to undergo a tear down changed every six months. Use the recommended
inspection. lubricants. Refer to the machine’s lubrication chart.
NOTE: Oil analysis alone cannot detect nor warn against a
fatigue failure. Gear Oil Sampling and Analysis
Proper gear oil sampling and analysis is a vital part of a
Annual Inspection comprehensive preventive maintenance program.
This inspection must be carried out by a qualified crane Information obtained from the oil analysis allows the
technician. The annual inspection MUST include, but not be maintenance technician to substitute preventive
limited, to the following: maintenance for more costly unscheduled down time or a far

5-6 Published 2-26-2014, Control # 414-03

RT540E SERVICE MANUAL HOIST AND COUNTERWEIGHT

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. continue with the oil change or refill the hoist gear cavity to
Prepare the hoist by cleaning the drain plug area and drain the proper level with recommended lubricant. Iron
extension tube in order to obtain an uncontaminated contaminant levels will be on the high side of “normal”
sample. Operate the hoist in both directions for one or two during initial break-in.
minutes to thoroughly mix the gear oil then take the sample

General guidelines for iron contaminant level

PPM Condition of Oil
100-500 Normal - Acceptable level; little significant contamination
Caution - Abnormal sample. Change oil and retake sample after 50 hours of
500-800 operation. If second sample is above 500 ppm, remove hoist from service and
perform tear-down inspection to determine source of contamination.

Over 800 Unacceptable - Remove hoist from service and perform tear-down inspection to
determine the source of contamination.
Equally important as the level of contamination is the Brake Test Procedure (To be performed with
change in level of contamination. An effective oil analysis no load on the hoist)
program should provide the technician with a view of the
• Remove and cap or plug the brake release line from
progression of wear or a trend. If a sample shows a sudden

7
fitting in the hoist brake release port.
rise in contaminant level action should be taken to
• With the hydraulic power unit running, move the
45
determine what has changed.
directional control valve handle slowly to the full open, 5
NOTE: Oil analysis alone cannot detect nor warn against a lowering position.
fatigue failure.
• Increase the engine speed, if necessary, to bring system
3

BRAKE TEST PROCEDURE FOR HP15C- pressure up to the relief valve setting. The hoist drum
should remain stationary
23

17G, HO30A-19G, HP35-26G HOISTS

• If the hoist drum rotates, the hoist should be
All of the above model planetary hoists have a spring
disassembled and the brake components should be
applied, hydraulically released, multiple disc brake inside examined for wear. In addition, the brake springs should
the hoist housing. This brake holds a suspended load when be measured for the correct free length in those hoist
the directional control valve is in neutral, or when hydraulic using helical compression springs.
power is lost. An over-running brake clutch assembly
• Replace any parts showing excessive wear and any
permits the power train and drum to rotate in the direction to
spring whose length is shorter than the minimum shown
lift a load, while the brake remains fully applied. A load
in the applicable hoist Service Manual.
cannot be lowered, however, without applying hydraulic
pressure to the release port and releasing the brake. • Reassemble the brake and hoist, then repeat the above
steps.
• When testing is complete, reattach the brake release
line to the brake release port.

Contact CraneCARE with any questions

GROVE Published 2-26-2014, Control # 414-03 5-7

HOIST AND COUNTERWEIGHT RT540E SERVICE MANUAL

HOIST TO BOOM ALIGNMENT center point of adjustment to check the fleet angle of the
cable.
Preparation 2. All the cable must be removed from the hoist drum to
Boom alignment must be completed before attempting hoist check the fleet angle. Using mason cord or cat gut
alignment. If the hoist is not properly aligned, the cable can fishing line you will be able to pull the line tight to make
be damaged or fine control could be affected. an accurate measurement of the fleet angle. Find the
centerline of the hoist drum by using a square and
The crane must be set on outriggers fully extended and the drawing a line horizontal on the drum. Put a line vertical
crane must be leveled. The boom must be over the front. to the horizontal line in the absolute center of the drum
by using a tape measure. With the boom at 0 degree, tie
Tools Required the line tight to the boom nose and have it in the center
• two foot square of the right hand boom nose sheave.

• Mason cord NOTE: If this special equipment is not available, sufficient

accuracy in locating a centerline may be obtained
• chalk by using a steel square against the machine’s inner
• protractor surfaces of both flanges. It is advisable to avoid
using any cast surfaces in this procedure unless a
Procedure check from both flanges indicates that the resultant
line is straight.
The hoist mounting location will determine the alignment
procedure used. Shift one side of the hoist back or forward to 3. Tie the line around the hoist drum so that the line is very
align the hoist with the boom sheave for cranes that have the tight and the line is crossing the absolute center of the
hoist mounted either directly to the boom or on a mount drum at the centerline mark you put on the drum.

7
attached to the boom. It may be necessary to shim under 4. Using a protractor, lay it on the vertical line on the hoist
one side of the hoist to make it level.
45
drum so the string line is in the center of the protractor.
The hoist must be checked in two directions, one at 0 degree The string line will be at the 90 degree mark on the
and the other is above 45 degrees boom angle on any crane protractor if the hoist is straight with the boom nose
that the hoist is not mounted directly to the boom, stationary sheave. If it is not at the 90 degree mark, the hoist
3

mounted. mounting bolts will have to be loosened and the hoist

moved so it is.
23

Check the hoist at 0 degree to see if the hoist is aligned to

the boom nose sheave. The main hoist is aligned to the right NOTE: This test is for cable leaving gaps while spooling.
hand sheave and the auxiliary hoist is aligned to the center
sheave (Figure 5-2)
CAUTION
NOTE: The hoist cable will have gaps in it during spooling
Do not alter holes or stop blocks on the crane mounting
if the alignment is not correct.
plate, as very small adjustments result in large angular
NOTE: The hoist is not level if the cable is piling up on one changes. Extreme care should be taken to avoid over-
side of the drum. correction.
1. The boom must be extended one half of full extension on
5. Elevate the boom above 45 degrees boom angle to
all hoist alignments. This length is used because when
check if the hoist is level. Reposition the hoist drum and
the main hoist cable is positioned on the top right hand
tighten the cord so you can have the cord in the center of
boom nose sheave, the cable must leave the center of
the protractor at the 90 degree mark. If the cord is not at
the drum at a 90 degree angle. The boom has the ability
the 90 degree mark, the hoist will have to be shimmed
to extend, retract, and change the angle of departure
until the cord is at the 90 degree mark.
from the drum. Extend the boom half way to provide a
NOTE: This test is for cable piling up on one side of the
hoist drum.

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RT540E SERVICE MANUAL HOIST AND COUNTERWEIGHT

PISTON MOTOR AND CONTROL VALVE Installation

Description NOTE: Care must be taken to assure the primary thrust
plate remains properly located in its counterbore
The piston motor is a bent axis, bidirectional, variable when the motor is re-installed. If the winch is
displacement heavy-duty motor. The motor is bolted to the operated with the primary thrust plate wedged
hoist and is geared directly to the hoist planetary. between the primary gears and the planet carrier,
or with a thrust washer out of position severe
The motor control valve is bolted to the motor.
damage to internal winch components could result.
Maintenance 1. Install a new O-ring on the motor pilot then lubricate with
petroleum jelly or gear oil. Engage the motor shaft with
Removal the brake clutch inner race and lower into place.
1. Thoroughly clean the external surfaces of the drum and 2. Apply Loctite No. 243 to the mounting bolts, and install
motor with steam or clean solvent and blow dry. the bolts and lockwashers. Torque the bolts to 102 Nm
(75 lb-ft).
2. Tag and disconnect the hydraulic lines connected to the
hoist motor and the motor control valve. 3. Connect the hydraulic lines as tagged during removal.
3. Remove the capscrews and lockwashers that secures 4. Fill the drum with oil. Refer to Section 9 - LUBRICATION
the motor and motor control valve to the hoist. in this manual.
4. Place the motor and motor control valve in a clean, dry
suitable work area.

7
45
5
3
23

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HOIST AND COUNTERWEIGHT RT540E SERVICE MANUAL

IDLER DRUM AND CABLE FOLLOWER 4. Disassemble the cable follower roller as follows.
a. 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. Remove the shims and roller from the shaft.
drum on the forward side of the hoist. The main hoist idler
drum is used to keep the hoist cable from coming in contact c. If necessary, remove the bearing and bearing
with the boom. When the crane is also equipped with an housing from both ends of the roller.
auxiliary hoist, the idler drum on the auxiliary hoist is used to 5. Remove the bolt and locknut securing the arm to the
keep the hoist cable from coming in contact with the main spring attaching lever on each side of the hoist. Remove
hoist. The cable follower is mounted on the rear side of it’s arms and levers from the side plates.
respective hoist. The cable follower applies a downward
spring pressure against the cable onto the hoist drum, to NOTE: Be sure to mark each arm and lever as to what side
ensure that the cable will be uniformly wound onto the hoist (left or right) they were removed from. This will be
drum, and also prevent cable from jumping under abnormal helpful during installation.
line conditions.
Cleaning and Inspection
Maintenance 1. Clean all grease from the shaft, bearing, and roller.
2. Check the shaft, roller, and bearings for cracks, scoring,
Idler Drum or grooving. Replace if necessary.
Removal and Disassembly 3. Check the spring tension. If the springs will not provide
1. Remove the bolt, washer, and lockwasher from the right sufficient tension when adjusted, replace them.
side of the idler roller (Figure 5-3).

7
Assembly and Installation
2. Support the idler roller and withdraw the shaft from the 1. Install the left arm through the bushing on the left side
45
left side. Take care not to lose the dowel pin on the end. plate. Install left spring attaching lever on the arm and
3. Remove the roller from between the side plates. secure with a bolt and locknut. Apply Loctite 243 to the
bolt threads.
Cleaning and Inspection
3

2. Repeat step 2 on the right side.

1. Clean all rust and dirt from the shaft.
23

3. Assemble the cable follower roller as follows.

2. Inspect the shaft and roller for cracks, scoring, or
grooving. Replace if necessary. a. Apply high strength retaining compound Loctite 680
to the bearing housings and the bearings. Install
Assembly and Installation them in both ends of the roller.
1. Position the roller between the side plates b. Install the shaft into the roller with a least one shim
2. Install the shaft through the left side plate and the roller. on each end.
Ensure the flat on the shaft end aligns with the stop c. Position the angle on the right side of the shaft and
welded on the side plate, align the dowel pin. secure with two bolts and washers. Apply Loctite
3. Secure the shaft to the right side plate with a bolt, 243 to the bolt threads.
washer and lockwasher. Apply Loctite 243 to the bolt 4. Position the cable follower roller on the arms and secure
threads. with four bolts and washers. Center the roller between
the hoist drum flanges and tighten the bolts. Tack weld
Cable Follower the bolt heads.
Removal and Disassembly 5. Attach one end of the tension springs to the levers on
1. Loosen the adjusting nuts and remove the tension each side. Install the adjusting rod through the lug on
spring and adjusting rod from both sides of the hoist (see each side plate and connect to the other end of the
Figure 5-3). spring. Install the adjusting nuts on each rod and tighten
enough to take the slack out of the springs.
2. Remove the tack welds from the bolt heads securing the
arm to the cable follower roller. 6. Using a grease gun, apply grease to the fittings on each
side plate bushing.
3. Support the cable follower roller and remove the bolts
and washers securing the arms to the angles on each 7. Adjust the roller as follows.
end of the roller. Remove the cable follower roller.

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RT540E SERVICE MANUAL HOIST AND COUNTERWEIGHT

10

1 9

11
4

Item Description
1 Pivot Bracket
2 Drum

7
3 Follower Roller
4 Arm
45
6957-1
5 Spring
5
8
11 6 Spring Adjusting Rod
3

7 Lever
23

2 8 Idler Roller
9 Nut
10
10 Bracket
9
11 Hydraulic Motor

3
5

6957-2

FIGURE 5-3

GROVE Published 2-26-2014, Control # 414-03 5-11

HOIST AND COUNTERWEIGHT RT540E SERVICE MANUAL

a. With one layer of cable on the hoist drum, adjust the Remove the idler drum and cable follower assembly
bolts on the front of each side plate (that push from the hoist.
against each arm) so the roller applies pressure on
3. If necessary to completely disassemble or remove any
the layer of cable, and does not interfere with filler/
part of the assembly, refer to the applicable paragraphs
riser protrusions on the hoist drum flanges. Tighten
in this Sub-section.
jam nuts to secure setting.
Installation
b. With a full drum of cable, the adjusting spring length
from eye to eye should not exceed 25.7 cm (10.12 1. Position the idler drum and cable roller assembly on the
in). Adjust rods as necessary and tighten jam nuts to hoist and secure each side plate to the hoist with two
secure this setting. bolts and washers.

Complete Assembly 2. Adjust the tension on the cable follower. Refer to

instructions in paragraph titled CABLE FOLLOWER -
Removal Assembly and Installation in this Sub-Section.
1. Remove all tension from the springs on each side by
loosening the nuts and jam nuts.
2. Support the weight of the assembly and remove the two
bolts and washers securing each side plate to the hoist.

7
3 45
23

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RT540E SERVICE MANUAL HOIST AND COUNTERWEIGHT

HOIST DRUM ROTATION INDICATOR Proper circuit operation can be checked for each individual
SYSTEM electrical component. If a malfunction occurs within the
system, repairs should be limited to finding and replacing the
Description faulty component(s). To determine which component is at
fault, refer to the troubleshooting section of your Can-Bus
The hoist drum rotation indicator system (Figure 5-4) is an CD.
electrically operated system that provides the operator with a
touch indication of drum rotation so the operator will know if Rotation Sensor
and at what speed the hoist drum is rotating, even under the The rotation sensor is screwed into the hoist housing and
most distracting conditions. senses the rotation of the primary drive end driven gear.
The rotation indicator system consists of the rotation When installing the sensor, ensure it contacts the top land of
indicator sensor and thumb thumper solenoid. The rotation a gear tooth and not between teeth (See figure titled Hoist
sensor is located on the hoist. The pulsing thumb thumper Rotation Indicator System). Screw the sensor in until contact
solenoid is located in the applicable hoist control lever is made, then back out 1/2 turn and tighten lock nut.
handle. Actuation of the thumb thumper is controlled by the
Can-Bus system from input supplied by the rotation indicator Thumb Thumper Solenoid
sensor. The thumb thumper solenoid provides feedback proportional
to the hoist line speed by pulsing the rubber button on top of
Maintenance the hoist controller. The thumb thumper will cease operation
at high line speeds to prevent damage to the solenoid.
General
Troubleshooting
NOTE: This machine incorporates a CAN-Bus Multiplex

7
DANGER system. In order to effectively troubleshoot the
electrical system, you will need a Windows-based
45
D i s c on n e c t t h e b a t te r i es b e fo r e p e r f o r m i n g a n y
maintenance on this system. Serious burns may result PC, CAN-link service software (9999102409), and 5
from accidental shorting or grounding of live circuits. a connection cable (9999102296). The CAN-link
service software and connection cable may be
3
ordered from Manitowoc Crane Care.
23

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HOIST AND COUNTERWEIGHT RT540E SERVICE MANUAL

3 6941-5

Controller

7
Hoist 6957-3
45
FIGURE 5-4
3

Item Description Item Description

23

1 Thumb Thumper 3 Rotation Sensor Connection

2 Controller 4 Two Speed Solenoid Connection

5-14 Published 2-26-2014, Control # 414-03

RT540E SERVICE MANUAL HOIST AND COUNTERWEIGHT

COUNTERWEIGHT REMOVAL 10. Lower counterweight until attaching lugs are clear of the
turntable.
Fixed Counterweight Description 11. Back counterweight away from turntable until it is clear
The counterweight is pinned to the rear of the turntable and of crane.
weighs 4300 kg (9480 lb). For cranes without an auxiliary 12. Replace pin assembly in turntable counterweight
hoist, an additional 350.6 kg (773 lb) counterweight is bolted mounting lugs.
to the hoist mounting area in lieu of the auxiliary hoist.
13. Move counterweight far enough from crane to allow the
Fixed Counterweight Removal turntable/superstructure to clear during repositioning.
14. Rotate superstructure to the normal travel position.

Fixed Counterweight Installation

DANGER 1. Fully extend and set the outriggers.
Death or serious injury could result from being crushed by
a falling counterweight. 2. Rotate the superstructure so the counterweight will be
over the front of the carrier to gain additional clearance.
Ensure the retainer pin is properly installed to secure the
counterweight mounting pin. 3. Shut down crane.

NOTE: Use of a forklift to remove/install the fixed

counterweight is not recommended. CAUTION
Refer to (Figure 5-5) for counterweight removal. When lifting/handling the counterweight, keep the chains/
straps vertical to minimize side pull on the lifting lugs.

7
1. Fully extend and set the outriggers.
45
NOTE: Turntable lock pin can only be engaged with boom
over front.
NOTE: The counterweight weighs approximately 4300 kg
(9480 lb). 5
2. Rotate the superstructure so the counterweight is over Use of a forklift to remove/install the fixed
counterweight is not recommended.
3
the front of the carrier to gain additional clearance.
NOTE: The counterweight weighs approximately 4300 kg 4. Attach an adequate lifting device to the counterweight
23

(9480 lb). and lift the counterweight into place on the

superstructure, aligning the mounting holes on the
3. Lower and fully retract the boom counterweight to the holes in the superstructure.
4. Shut down crane. 5. Install the counterweight mounting pins and secure them
in place with hitch pin retainers.
5. Remove and cap hydraulic lines from auxiliary hoist (if
installed) 6. Remove the lifting device from the counterweight.
6. Attach an adequate lifting device to the counterweight. 7. Using the four counterweight leveling bolts, level the
counterweight and eliminate any relative movement
7. Ensure the four counterweight leveling capscrews are
between the counterweight and turntable. Maximum
set for maximum clearance with the turntable.
width of counterweight shall not exceed 6.0 mm (0.25 in)
8. Slowly raise counterweight until pin assembly can be out of level with the turntable bearing when measured
removed by pushing and turning the pin. from either counterweight outer edge.
9. Remove pin assembly from opposite side.

GROVE Published 2-26-2014, Control # 414-03 5-15

HOIST AND COUNTERWEIGHT RT540E SERVICE MANUAL

4 2
5 8, 9, 10, 11
3
1

7
45
4
5

3
3

5
4
23

6826

FIGURE 5-5

Item Description Item Description

1 Counterweight 4 Jam Nut
2 Pin Assembly 5 Hex Nut
3 Capscrew 6 Turntable

5-16 Published 2-26-2014, Control # 414-03

RT540E SERVICE MANUAL SWING SYSTEM

SECTION 6
SWING SYSTEM

SECTION CONTENTS
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . 6-1 Swing Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Swing Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Swivels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Hydraulic Swivel . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Swing Gearbox And Brake. . . . . . . . . . . . . . . . . . . 6-7 Electrical Swivel. . . . . . . . . . . . . . . . . . . . . . . . . . 6-18

INTRODUCTION Theory of Operation

7
Description Swing Drive
45
The purpose of the swing system is to allow the crane The hydraulic power for the swing drive (Figure 6-1) is
superstructure to rotate atop the carrier frame. The supplied by the engine driven hydraulic pump. Oil flows from
superstructure swing system provides full 360 degree the pump to the hydraulic Port 5 swivel. Flow from the swivel
rotation in both directions and is equipped with free swing is routed to the service brake dual accumulator charge valve.
3

capabilities. The term free swing means that, with the Bypass flow from the dual accumulator charge valve is
23

SWING BRAKE switch in the OFF position, the routed to the front steering flow divider valve in the swing
superstructure will swing freely after the SWING control lever
is released until it coasts to a stop or the glide swing brake
directional control valve. Bypass flow from the flow divider 6
valve is used to supply the swing directional control valve.
pedal is depressed.
When the hydraulic remote control is positioned to select
Swing is activated using the control lever in the cab. When right or left swing, the flow through the control valve is
the swing lever is actuated, hydraulic pressure is routed to directed to the swing motor. If the SWING BRAKE selector
the swing motor to drive the gearbox in the appropriate switch is in the OFF position, the superstructure will rotate in
direction. As the gearbox rotates, the pinion gear meshes the desired direction. Shifting the control to neutral and
with the teeth on the swing bearing and rotates the depressing the brake pedal will stop the swing.
superstructure. Swing speed can be controlled by the control
lever and a HIGH/LOW swing speed switch on the front Swing Brake
console. The maximum rotation speed is 2.0 - 2.5 rpm with
no load. Braking is accomplished by depressing a glide The hydraulic power for the swing brake is supplied by the
swing brake pedal which is a proportionate control valve that pressure reducing/sequence valve in the swing brake and
provides a controlled braking of the swing motion. armrest lockout manifold. With the SWING BRAKE selector
switch positioned to ON, the swing brake release valve
The swing system consists of a hydraulic remote controller, blocks the regulated flow to the brake release port and spring
swing speed switch, a directional control valve, the swing pressure in the swing brake applies the brake. When the
drive, the swing brake assembly, the brake pedal and power SWING BRAKE selector switch is positioned to OFF, the
brake valve, and a swing brake release solenoid valve. regulated flow is directed from the pressure reducing/
The crane is equipped with a pin type turntable lock as sequence valve to the brake release port, overcoming the
standard and a 360 degree positive swing lock. The 360 brake spring pressure and releasing the swing brake.
degree positive swing lock meshes with the swing gear teeth Regulated flow from the pressure reducing/sequence valve
at any point of rotation. The pin type turntable lock will only is also provided to the power brake valve where it is available
lock the turntable in a straight ahead position over the front of for the activation of the swing brake when the pedal is
machine. Both swing locks are operated from the cab. depressed.

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SWING SYSTEM RT540E SERVICE MANUAL

11
9

8
6

5 12

3
10
4

7
2 45
1
3
23

13

6713

FIGURE 6-1

Item Description Item Description

1 Plug 8 Dipstick
2 Plug 9 Breather
3 Plug 10 Plug
4 Elbow 11 Motor
5 Pipe 12 Gearbox and Brake
6 Breather 13 Pinion
7 Plug

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RT540E SERVICE MANUAL SWING SYSTEM

Maintenance
Troubleshooting

Symptom Probable Cause Solution

1. Boom swing a. Damaged relief valve. a. Replace relief valve.
operation erratic in
b. Swing brake dragging (not releasing b. Readjust and/or replace necessary
either direction.
properly). parts.
c. Low engine rpm. c. Increase engine rpm to obtain smooth
swing operation.
d. Low hydraulic oil. d. Replenish hydraulic oil to proper level.
e. Improper movement of control to e. Feather controls to neutral to maintain
neutral. smooth stopping action.
f. Insufficient lubricant on swing bearing. f. Lubricate bearing properly. Refer to
Section 9 - LUBRICATION.
g. Crane not level. g. Level crane using outriggers.
h. Damaged swing motor. h. Repair or replace swing motor.
i. Excessive overload. i. Reduce load. Refer to load capacity
chart.

7
j. Restricted or partly clogged hydraulic j. Replace hose or fittings.
45
hose or fittings.
k. Pump cavitation in swing section. k. Tighten suction hose or replace any
damaged fitting. Check hydraulic tank
3
level.
l. Improperly torqued turntable bolts. l. Torque turntable bolts evenly.
23

m. Excessive preload on upper and lower m. Adjust as necessary. 6

pinion shaft bearing.
n. Improperly torqued swing motor n. Torque swing motor attachment bolts.
attachment bolts.
o. Malfunction of the swing box. o. Remove swing box and make
necessary repairs.
p. Worn or damaged pump. p. Repair or replace damaged pump.
q. Damaged swing directional control q. Repair or replace swing directional
valve. control valve.
r. Damaged swing pinion. r. Replace pinion.
s. Damaged turntable bearing. s. Replace turntable bearing.
2. Boom swing a. Crane not level. a. Level crane using outriggers.
operation erratic in
b. Turntable bearing binding due to b. Rotate machine 360 degrees in both
one direction only.
continuous limited swing. (Example: directions several times and lubricate
concrete pourer.) bearing.
c. Restricted hose or fitting. c. Replace hose or fitting.
d. Damaged swing directional control d. Replace swing directional control
valve. valve.
e. Damaged swing pinion. e. Replace pinion.
f. Damaged turntable bearing. f. Replace turntable bearing.

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SWING SYSTEM RT540E SERVICE MANUAL

Symptom Probable Cause Solution

3. Boom will not swing a. Damaged relief valve. a. Remove, clean, and repair or replace
in either direction. relief valve.
b. Damaged swing motor. b. Repair or replace swing motor.
c. Swing brake not releasing properly. c. Repair as necessary.
d. Damaged hydraulic remote control d. Replace hydraulic remote control
valve. valve.
e. Internal damage to swing box. e. Remove swing box and repair.
f. Worn or damaged hydraulic pump. f. Replace pump section.
g. Damaged swing directional control g. Replace swing directional control
valve. valve.
h. Damaged swing pinion. h. Replace pinion.
i. Damaged turntable bearing. i. Replace turntable bearing.
j. Excessive overload. j. Reduce load. Refer to load capacity
chart.
4. Swing operation a. Damaged relief valve. a. Adjust, repair or replace valve.
slow in either
b. Improperly adjusted swing brake. b. Readjust.
direction.
c. Damaged hydraulic remote control c. Replace hydraulic remote control

7
valve. valve.
45
d. Improperly lubricated swing bearing. d. Lubricate bearing per
recommendations.
e. Improper size hose and/or fittings e. Refer to the Parts Manual.
3
installed.
f. Clogged or restricted hydraulic hoses f. Clean or replace damaged parts.
23

or fittings.
g. Worn or damaged output shaft g. Replace bearings.
bearings
h. Worn or damaged swing motor. h. Repair or replace motor.
i. Worn or damaged hydraulic pump. i. Repair or replace pump.
j. Crane not level. j. Level crane.
k. Damaged swing directional control k. Replace swing directional control
valve. valve.
5. Swing operation a. Crane not level. a. Level crane.
slow in one
b. Damaged hydraulic remote control b. Replace hydraulic remote control
direction only.
valve. valve.
c. Damaged swing directional control c. Replace the swing directional control
valve. valve.
d. Clogged or restricted hose. d. Replace hose or fitting.
e. Improperly torqued turntable bearing. e. Torque turntable bearing.

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RT540E SERVICE MANUAL SWING SYSTEM

Symptom Probable Cause Solution

6. Swing brake a. Improper brake adjustment. a. Adjust brake.
operation erratic.
b. Air in swing brake system. b. Bleed brake system.
c. Brake pedal not fully retracted. c. Check brake pedal return spring; repair
or replace spring.
d. Dirty or glazed brake disc. d. Clean or replace disc.
e. Malfunction of the glide swing power e. Repair or replace glide swing power
brake valve. brake valve.
f. Kinked or bent lines and/or hoses and f. Straighten or replace as required.
fittings.
7. Swing brake a. Damaged swing brake release valve. a. Replace release valve.
system will not
b. Damaged glide swing power brake b. Repair or replace glide swing power
operate.
valve. brake valve.
c. Internal damage to the swing brake c. Repair or replace affected parts.
assembly.
d. Loose or restricted brake lines or d. Tighten or replace lines and fittings.
fittings.
8. Swing brake pedal a. Damaged glide swing power brake a. Repair or replace the glide swing

7
is spongy. valve. power brake valve.
b. Loose or restricted brake lines or b. Tighten or replace brake lines and
45
fittings. fittings.
9. Swing brake drags. a. Damaged glide swing power brake a. Repair or replace the glide swing
valve. power brake valve.
3

b. Damaged swing brake release valve. b. Replace release valve.

23

c. Internal damage to the swing brake c. Repair or replace affected parts.

assembly. 6
d. Loose or restricted brake lines or d. Tighten or replace brake lines and
fittings. fittings.
10. Boom swings a. Insufficient hydraulic volume. a. Check delivery of hydraulic pump.
slowly. Ensure sufficient fluid is available to
pump. Check pump drive speed.
b. Damaged relief valve. b. Adjust, repair, or replace valve.
c. Damaged swing motor. c. Repair or replace motor.
11. Swing motor a. Hydraulic remote control valve sticking a. Repair or replace valve.
continues to or valve otherwise damaged.
operate when
b. Control valve sticking or valve b. Repair or replace valve.
swing control is in
otherwise damaged.
neutral.
12. Swing motor a. Improper port connections. a. Reverse port connection.
turning in wrong
direction.
13. Swing motor noisy. a. Air in system. a. Refer to Section 2 - HYDRAULIC
SYSTEM, for removal of air from the
system.
b. Motor binding. b. Repair or replace motor.

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SWING SYSTEM RT540E SERVICE MANUAL

SWING MOTOR
Description CAUTION
Pull straight up on the motor assembly to avoid damaging
The swing motor is mounted on the swing brake housing and the splined shaft.
drives the swing gearbox through the brake assembly. The
swing motor is a hydraulic gerotor type with low speed and
4. Remove the two screws securing the motor and lift the
high torque characteristics. It has only three moving parts,
swing motor free of the flange. Remove and discard the
the commutator valve, the drive, and the gerotor star. The
O-ring from the groove in the swing brake.
motor has two ports for connection to the hydraulic system.

Maintenance Installation

Removal
CAUTION
1. Ensure the swing brake and swing lock are engaged. Use care when engaging the swing motor drive gear, do
2. Clean the port area around the motor. Tag and not force the shaft to engage.
disconnect the hydraulic hoses from the motor
assembly. Cap or plug all openings. 1. Install a new O-ring in the groove of the swing brake.
Position the swing motor on the swing brake, engaging
the shaft with the brake input shaft.
CAUTION 2. Apply Loctite 243 to the screw threads. Install the
Oil can be hot and cause burns. screws and secure the motor to the brake housing.

7
Torque the screws 85 to 103 Nm (44 to 72 lb-ft).
3. Unscrew the drain plug to ensure that all oil has been
3. Connect the hydraulic lines to the swing motor as tagged
45
removed. Unscrew the filler and level plugs. After the oil
has been drained, replace the drain plug and any other during removal.
plugs that may have been removed.
Test
3

1. Test swing of superstructure in each direction. Stop and

start swing several times.
23

2. Inspect for hydraulic leaks and repair as necessary.

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RT540E SERVICE MANUAL SWING SYSTEM

SWING GEARBOX AND BRAKE 5. Bleed all air from the brake assembly.
Testing
Description
1. With the SWING BRAKE switch in the ON position,
The swing gearbox and brake, used in conjunction with the position the swing control lever in both directions.
swing motor, rotates and stops the superstructure. A pedal Superstructure rotation should not occur.
on the cab floor is used to activate the swing brake. The
swing gearboxes are bolted to the superstructure base plate, 2. Position the SWING BRAKE switch to OFF and swing
and its pinion gear meshes with the ring gear of the turntable the superstructure in both directions. Use the swing
bearing to rotate the turntable. brake pedal to stop rotation.

The swing gearbox utilizes double reduction planetary 3. Check for hydraulic leaks and repair as necessary.
gearing. The multi-disc swing brake assembly is an integral
part of the swing gearbox and is located between the swing Gearbox
motor and the swing gearbox. The brake mechanism is a
Removal
disc pack that is hydraulically released and spring applied.
1. Engage the turntable lock pin.
Maintenance
2. Tag and disconnect the hydraulic lines from the swing
NOTE: The swing brake can be removed and motor and swing brake. Cap and/or plug all openings
disassembled independently of the swing gearbox.
3. Unscrew the three screws securing the pinion gear
cover. Remove the cover.
Swing Brake
4. Remove the gear from the shaft.
Removal

7
NOTE: The complete gearbox assembly with motor
1. Engage the turntable lock pin.
weighs approximately 126 kg (277.7 lb).
45
2. Tag and disconnect the hydraulic lines connected to the
5. Attach a suitable lifting device to the swing gearbox.
swing motor and the brake. Cap and/or plug all
Remove the capscrews, flatwashers and bushings
openings.
securing the gearbox to the mounting plate.
3

3. Remove the swing motor from the swing brake

NOTE: Take note of the swing motor port orientation to
according to the procedures found in this Section under
23

ensure proper installation.

SWING MOTOR - REMOVAL.
6. Remove the swing gearbox. 6
7. If necessary, remove the swing motor according to the
CAUTION procedures found in this Section under SWING MOTOR
Use care when removing the capscrews securing the REMOVAL.
brake, as there is tension on the bolts due to internal
brake springs. 8. If necessary, remove the swing brake according to the
procedures found in this Section under SWING BRAKE
4. Unscrew the screws securing the brake to the gearbox. REMOVAL.
Lift the brake using the brake flange, then remove the O- 9. Cover the opening of the swing gearbox to ensure no
ring. dirt, dust, etc., gets into the gearbox.
5. Cover the opening of the swing gearbox to ensure no Installation
dirt, dust, etc., gets into the gearbox.
1. If removed, install the swing brake according to the
Installation procedures found in this Section under SWING BRAKE
1. Install a new o-ring onto the brake housing. INSTALLATION.

2. Apply Loctite 243 to the screws. Install brake onto 2. If removed, install the swing motor according to the
gearbox and secure with the screws. Torque the screws procedures found in this Section under SWING MOTOR
50 to 60 Nm (36.8 to 44.2 lb-ft). INSTALLATION.

3. Install the swing motor into the swing brake according to 3. Attach a suitable lifting device to the swing gearbox and
the procedures found in this Section under SWING lift and position the swing gearbox in place on the
MOTOR - INSTALLATION. mounting plate.

4. Connect the hydraulic lines to the motor and brake. 4. Install the capscrews, flatwashers and bushings. Torque
the capscrews 85 to 93 Nm (63 to 69 lb-ft).

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SWING SYSTEM RT540E SERVICE MANUAL

5. Apply Loctite 243 to screws. Install the pinion gear on 3. Flush the case with a light flushing oil.
the output shaft. Install the cover and secure with three
NOTE: Cleaning of the gearbox with a solvent is
screws. Torque screws 50 Nm (36.8 lb-ft).
recommended to prevent an accumulation of grit
6. Connect the hydraulic lines to the swing brake. and grime. Avoid steam cleaning where moisture
and dirt might be driven into the vent of the swing
7. Connect the hydraulic lines to the swing motor.
bearing.
8. Service the gearbox as indicated under SERVICING.
4. To refill with oil, fill through filler plug until it begins to flow
Servicing out of the level plug.
As with all highly stressed mechanisms, reasonable 5. Tighten the level and filler plugs.
operating procedures are always required. Normal
Checking The Oil Level
maintenance should only consist of proper lubrication and a
periodic check of mounting bolt torque values. Lubrication 1. Check the oil level through level plug.
consists of maintaining the gearbox oil level. Oil in a new
2. If no oil is visible on the level plug, add oil until the level
gearbox should be drained and flushed out after
is between min and max on the level plug.
approximately 250 hours of operation, and replaced with
premium quality SSGL-5 after approximately 500 hours of 3. Refer to Section 9 - LUBRICTION.
operation or each year, whichever occurs first. Operation in
high humidity or polluted air areas will require more frequent Testing
changes to minimize moisture or contaminate accumulation. 1. Test swing of superstructure in each direction. Stop and
Change the oil as follows. start swing several times.
1. Unscrew the drain plug. To ensure all oil has been 2. Inspect for hydraulic leaks and repair as necessary.

7
removed, unscrew the filler and level plugs.
2. After oil is drained, replace the drain plug and any other
45
plugs that were removed to drain the oil.
3
23

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RT540E SERVICE MANUAL SWING SYSTEM

SWING BEARING
Description
DANGER
The swing bearing is an anti-friction roller bearing that mates
the Superstructure to the Carrier. The bearing inner race is It is mandatory that bearing attaching bolts be inspected
bolted to the Superstructure and the outer race is bolted to for lack of torque and retorqued, as required, after the first
the Carrier. The inner race contains two grease fittings for 300 hours of crane operation. The bolts may loosen in
lubrication of the bearing which are hosed to two fittings at service due to vibration, shock-loads, and temperature
the front right side of the turntable center section. changes, therefore, periodic inspection should be
accomplished every 500 hours thereafter, ensuring the
Maintenance bolts are properly torqued.

General KNOW YOUR TORQUE WRENCH! Flexible beam type

wrenches, even though they might have a pre-set feature,
The swing bearing is the most critical maintenance point of must be pulled at right angle and the force must be applied at
the crane. It is here, at the centerline of rotation, that the center of the handle. Force value readings must be made
stresses of loads are concentrated. In addition, the bearing while the tool is in motion. Rigid handle type, with torque
provides the only attachment between the superstructure limiting devices that can be pre-set to required values,
and carrier. Therefore, proper care of the bearing and eliminate dial readings and provide more reliable, less
periodic maintenance of the turntable-to-bearing attach bolts variable readings.
-IS A MUST -to ensure safe and efficient operation.
NOTE: If multipliers and/or special tools are used to reach
hard to get at areas, ensure torque readings are
Torquing Turntable Bolts
accurate.

7
General
Torque wrenches are precision instruments and must be
45
handled with care. To ensure accuracy, calibrations must be
made on a scheduled basis. Whenever there is a possibility
that a torque wrench may have been either overstressed or
DANGER damaged, it should immediately be removed from service
3

Failure to maintain proper torque of the turntable bearing until recalibrated. When using a torque wrench, any erratic or
23

attaching bolts will result in damage to the crane and jerking motion can result in the application of excessive or
possible injury to personnel. improper torque. ALWAYS use a slow, even movement and
STOP when the predetermined value has been reached.
6
Maintaining proper torque value for bolts is extremely If it is reported by the crane operator or suspected that the
important for structural strength, performance, and reliability crane has been overloaded beyond the capacities specified
of the crane. Variations in torque can cause distortion, above the bold line on the cranes’ capacity chart, then all
binding, or complete separation of the superstructure from turntable bolts must be inspected for looseness and
the carrier. retorqued to specifications.
Turntable bolts should be torqued according to the
CAUTION procedures outlined in this section.
Repeated re-torquing may cause bolts to stretch. If bolts When using step wrenches, calculated wrench settings are
keep working loose, they must be replaced with new bolts valid only when the following conditions are met.
of the proper grade and size.
1. Torque wrenches must be those specified and forces
Proper identification of bolt grade is important. When marked must be applied at the handle grip. The use of handle
as a high strength bolt (grade 8 and metric grade 10.9), the extensions will change applied torque to the bolt.
serviceman must be aware of bolt classifications and that he 2. All handles must be parallel to the step wrench during
is installing a high strength heat-treated tempered final tightening. Multiplier reaction bars may be
component and the bolt must be installed according to misaligned no more than 30 degrees without causing
specifications. Special attention should be given to the serious error in torque.
existence of lubricant and plating that will cause variation
from dry torque values. When a high strength bolt is 3. Multiplier bar handles must be propped or supported
removed, or un-torqued, the bolt must be replaced with a within the outer 1/4 of the handle length, or serious
new bolt of the same classification. under or over tightening will occur.

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SWING SYSTEM RT540E SERVICE MANUAL

35 36 1 2
34 3
4
33

32 5

31 6
35 36 1 2
30 34 3 7
33 4
32 5
31 6 8
29
30 7
28 29 8
9
28 9
27 10
27 26 11 10
25 12
26 24 13 11
23 14
22
25 21 1615 12
20 19 18 17

24 13

23 14
22 15 6750-2
21

7
20 19 18
45 17 16 FIGURE 6-2

The inner race of the bearing is secured to the turntable by backlash adapter, necessary extensions, and torque
36, 1 inch, grade 8 bolts. The outer race of the bearing is wrench.
secured to the carrier frame by 36, 7/8 inch, grade 8 bolts.
3. Return to bolt 1 and torque all bolts sequentially in a
3
Torque Values clockwise direction to the final torque of 1162 to 1259
Nm (857 to 929 lb-ft). The same tools are used as in step
Torque all turntable bolts (Figure 6-2) to a final torque of 769
23

1.
to 834 Nm (567 to 615 lb-ft).
Outer Race Torquing
Tools Required
1. Extend and set the outriggers. Fully elevate the boom.
(Figure 6-3) lists the complete set of special tools required to
torque the turntable bolts. 2. Torque eight bolts 615 to 667 Nm (454 to 492 lb-ft) using
the following sequence pattern; 36, 18, 10, 28, 5, 23, 14,
Inner Race Torquing and 32. Tools used are the socket, multiplier, backlash
1. Extend and set the outriggers. Fully elevate the boom. adapter, necessary extensions, and torque wrench.

2. Torque eight bolts 930 to 1008 Nm (686 to 743 lb-ft) 3. Return to bolt 1 and torque all bolts sequentially in a
using the following sequence pattern; 36, 18, 10, 28, 5, clockwise direction to the final torque of 769 to 834 Nm
23, 14, and 32. Tools used are the socket, multiplier, (567 to 615 lb-ft). The same tools are used as in step 1.

6-10 Published 2-26-2014, Control # 414-03

RT540E SERVICE MANUAL SWING SYSTEM

7 1 3
6
5

Orders for special tools Description Grove Part Number Quantity Required
shall be referred to: 1. 1 1/2” Socket 3/4” Drive 9-999-100143 1
1

7
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 1
1565 Buchanan Trail East 4. 1/2” Drive Torque Wrench 9-999-100136 1
45
Shady Grove, PA 17256-0021 5. 10” Extension 3/4” Drive 9-999-100138 A/R
Phone: (717) 597-8121 6. 13” Extension 3/4” Drive 9-999-100137 A/R
Fax: (717) 593-5929 7. Tool Box (Optional) 9-999-100146 1
3

Special Turntable Bolt Torquing Tools

FIGURE 6-3
23

Removal 6. Remove the counterweight and auxiliary hoist following 6

procedures outlined in Section 5 - HOIST and
1. Fully extend and set the outriggers enough to take up COUNTERWEIGHT.
the slack in the pads.
7. Tag and disconnect all water and oil lines from the
NOTE: Do not raise the machine on the outriggers. bottom of the swivel. Cap or plug all lines and openings.
2. Ensure the boom is in the travel position and the 8. Locate the connectors and ground wire that joins the
turntable lock pin is engaged. swivel wiring harness to the receptacles and ground
3. Elevate the boom slightly and shut down the engine. stud on the carrier.

4. Tag and disconnect the battery cables from the 9. Disconnect the swivel wiring harness connectors from
batteries. the carrier wiring receptacles. Remove the ground wire
from the ground stud.
NOTE: The boom assembly weighs approximately 5792
kg (12,769) with stowed boom extension. Removal 10. Remove the clamp securing the swivel wiring harness to
of the swingaway boom extension will simplify the retainer plate on the bottom of the hydraulic swivel
boom removal, therefore, the above weight is for assembly.
the boom without the swingaway boom extension 11. Coil the wiring harness and secure it to the swivel to
attached. The lift cylinder weighs approximately prevent damage to the harness during turntable
578 kg (1274 lb). removal.
5. Remove the boom and lift cylinder following the 12. On the bottom of the hydraulic swivel, bend the retainer
procedures outlined in Section 4, BOOM. tabs away from the capscrew heads. Remove the
NOTE: The counterweight/auxiliary hoist and structure capscrews securing the two retainer plates to the spool.
weighs approximately 4841 kg (10,672 lb).

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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. 16. Place an adequate lifting device under the bearing and
remove the 36 bolts and washers securing the turntable
bearing to the superstructure.
17. Using the lifting device, remove the turntable bearing
DANGER from under the superstructure.
Ensure the lifting device is capable of fully supporting the
weight of the superstructure. Ensure the superstructure Inspection
will not tilt or slide during lifting and moving. Failure to do
so may result in death or injury to personnel and damage Check the bearing teeth for chipping or cracking. If any
to equipment. evidence of these is found, replace the bearing. Ensure the
bolt holes are free of dirt, oil, or foreign material.
NOTE: If a lifting device capable of lifting the entire
superstructure is not available, superstructure
Installation
weight may be reduced by removing various
components such as the hoist(s).
13. Attach a suitable lifting device to the four superstructure
lifting lugs (two near the boom pivot shaft bushings and
DANGER
two near the lower lift cylinder pivot shaft bushings). Anytime a turntable bolt has been removed, it must be
Take in cable or chain to remove slack. Do not pull up on replaced with a new bolt.

7
the superstructure.
NOTE: If the same bearing is to be used again, align the
45
marked teeth on the pinion shaft and the marked
teeth on the bearing.
DANGER NOTE: Installation is in the travel position. Ensure the
3
Ensure the superstructure is fully supported before swing lock is disengaged before attempting to mate
proceeding. the bearing to the superstructure.
23

1. Using an appropriate lifting device, position the turntable

NOTE: It will be necessary to rotate the superstructure bearing under the superstructure. If the same bearing is
while attached to the lifting device. Outer race bolts being used, position it as marked prior to removal.
can only be removed from the swing drive side of
the turntable. 2. Install 36 new bolts and washers securing the bearing to
the superstructure. Refer to Inner Race Torquing in this
14. Remove the 36 bolts and washers securing the turntable Sub-Section.
bearing outer race to the carrier.
3. Using an appropriate lifting device, align the
superstructure over the carrier in the travel position and
carefully lower the superstructure, being careful not to
DANGER damage the swivel assembly, into position on the carrier
bearing plate.
Ensure that any blocking material used is capable of fully
supporting the weight of the superstructure and will not NOTE: It will be necessary to rotate the superstructure
allow it to tilt or shift. Failure to do so may result in death or while attached to the lifting device. Outer race bolts
injury to personnel. can only be installed from the swing drive side of
the turntable.
15. Carefully lift the superstructure, using care not to
4. Install 36 new bolts and washers. Refer to Outer Race
damage the swivel assembly, and set it on blocking that
Torquing in this Sub-Section.
will not allow the superstructure to tilt or shift, or rest on
the swivel. Leave the lifting device attached. NOTE: If a new bearing is being installed, a new pinion
gear must also be used. Align the high point
NOTE: If the same bearing is to be used again, mark the
(maximum eccentricity) on the bearing with the
position of the bearing on the superstructure so it
new pinion gear high point (Figure 6-4).
can be installed in the exact position it was before
removal.

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RT540E SERVICE MANUAL SWING SYSTEM

5. Apply Loctite 271 to the capscrews. Position the two

Maximum Eccentricity Point retainer plates on the bottom of hydraulic swivel spool,
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). Bend
all the retainer tabs to make contact with the bolt heads.
6. Plug the swivel wiring harness connectors into the
carrier receptacles. Secure the ground wire to the
ground stud using a washer, lockwasher, and nut.
7. Install the clamp securing the swivel wiring harness to
the retainer plate on the bottom of the hydraulic swivel.
8. Connect all water and hydraulic lines to the ports on the
bottom of the swivel as tagged during removal.
9. Install the boom and lift cylinder following the procedures
outlined in Section 4, BOOM.
.0.20 Thick Shim
By Full Width to Tooth Bearing NOTE: The counterweight/auxiliary hoist and structure
6750-3
Engagement (.040) Backlash) weighs approximately 4841 kg (10,672 lb).
FIGURE 6-4 10. Install the counterweight and auxiliary hoist following
procedures outlined in Section 4 of the Operator
Orient ring gear such that its point of max eccentricity (“high Manual.
point”) is located between the swing drives. Position swing

7
drives so that pinion is centered within cutout in base plate 11. Reconnect the batteries.
and motor ports face towards the outboard side as shown.
45
12. Check the slew potentiometer in the electrical swivel for
proper orientation. Refer to SWIVELS in this Section

CAUTION Testing
3

Do Not Clamp Over Pinion. Activate the crane and check for proper function.
23

• Using shims, set backlash by moving the swing drive

assemblies toward the bearing in order to mesh the
NOTE: If the superstructure does not turn freely after
bearing and pinion replacement, contact your local
6
pinion with the ring gear teeth (see Figure 6-5).
distributor.
• Check tooth engagement squareness and vertical
tooth engagement.
• Remove backlash shims and recheck backlash.

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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
The swivel assembly (Figure 6-5) consists of a 14 port hydraulic swivel. The hydraulic and water swivel spools
hydraulic swivel, a 2 port water swivel, and a 20 conductor remain stationary with the carrier as the superstructure
slip ring electrical swivel. Solid connections cannot be used rotates. The water swivel case engages to hydraulic case by
to transfer oil, heater hot water and electricity between the four dowel pins.
carrier and superstructure due to the continuous 360 degree The electrical swivel center or collector ring assembly is
swing. The use of swivels efficiently accomplishes this secured by setscrews to a center post which is bolted to the
function. spool of the hydraulic swivel. This allows the collector ring
The barrel portion of the hydraulic swivel is attached to the assembly to remain stationary with the carrier. The outer
turntable base plate by four capscrews, washers and portion or brush assembly is mounted on two studs which
bushings. The spool portion of the swivel rides upon a thrust are located on the mounting plate assembly which is
ring at the top of the swivel case. The spool portion is held retained to the water swivel barrel by a bolt. This allows the
stationary with the carrier by bolts, and bolt retainer plates brush assembly to rotate with the superstructure around the
attached to the swivel retainer plate which engages the stationary collector core.
carrier frame lugs with capscrews and hex nuts. This allows

7
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23

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RT540E SERVICE MANUAL SWING SYSTEM

11 1

Item Description 12, 13, 14, 15

1 Slip Ring Assembly 2, 3

2 Capscrew
3 Washer
16, 17
4 Hydraulic Swivel
5 Retaining Plate
6 Capscrew
7 Hex Nut
4
8 Adapter
9 Hose Nipple
10 Adapter
11 Plate
12 Capscrew

7
13 Jam Nut
5
45
14 Flatwasher
6, 7
15 Capscrew
16 Hose Nipple
3

8, 9, 10
17 Adapter
23

18 Turntable Base Plate 6733-1 6

19 Carrier Top Plate
Forward 20, 21
20 Capscrew 18
21 Washer 22

22 Bushing
23 Plug
24 Retaining Plate

19

23

6825

24
FIGURE 6-5

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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)
1 250 (3625) Brake - Front
2 250 (3625) Brake - Rear
3 ----- Open
4 50 (725) Dual Return
5 245 (3553) Swing/Brake/Steer
6 245 (3553) Lift/Tele/Hoist
7 250 (3625) Front Steer - Left
8 250 (3625) Accumulator Charge Valve
9 250 (3625) Front Steer-Right

7
10 50 (725) Case Drain
45
D ----- Internal Drain
11 ----- A/C
12 ----- A/C
3

A ----- Heater Supply (Coolant)

23

B ----- Heater Return (Coolant)

Theory of Operation Maintenance

The hydraulic swivel allows oil to flow from the pumps to Removal
various crane functions on the superstructure. All oil is
1. Extend and set the outriggers. Ensure the crane is level
routed into the spool portion of the swivel where, through a
and the boom is over the front.
series of internally drilled passages, oil is transferred to
circumferential channels on the spool exterior. These 2. Elevate the boom and note at what boom angle, you
channels correspond with a mating port on the outer case of have the most clearance between the lift cylinder and
the swivel. Each channel is separated by a series of nylon the turntable side plate. Shut down the engine.
and O-ring seals that prevent transfer of oil and pressure.
Return flow from the crane superstructure is accomplished in 3. Measure the distance from the top of the lift cylinder to
the same manner through another set of ports. the base of the boom section where the lift cylinder
attaches. Cut two pieces of 10 x 10 cm (4 x 4 in) oak to
Engine coolant flows from the carrier mounted engine to the fit.
hot water heater in the operator cab through ports A and B of
the swivel. NOTE: It might be necessary to raise the boom slightly to
allow installation of the blocking.
NOTE: This blocking is to add extra support for the boom.
Any seepage or leakage in the holding valves or
internally in the cylinders will allow the boom to
settle over a period of time.
4. Use the oak blocking to block between the barrel of the
lift cylinder and the boom base section.

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RT540E SERVICE MANUAL SWING SYSTEM

5. Tag and disconnect the hydraulic lines from the case of 1. Raise the swivel into position.
the hydraulic swivel. Cap or plug all lines and openings.
2. Secure the hydraulic swivel to the turntable base plate
6. Tag and disconnect the hydraulic lines and water lines with the bushings, capscrews and washers. Torque the
from the spool of the hydraulic swivel. Cap or plug all capscrews see Fasteners and Torque Values (pg 1-
lines and openings. 11).714 to 774 Nm (526 to 571 lb-ft).
7. Tag and disconnect the water lines from the case of the 3. Apply Loctite 271 to the capscrews. Position the two
water swivel. Cap or plug all lines and openings. retainer plates on the bottom of hydraulic swivel spool,
engaging the lugs on the carrier frame, and secure them
8. Disconnect the swivel wiring harness connectors from
to the spool with four capscrew retainers and bolts.
the carrier receptacles and the yellow ground wire from
Torque the bolts 298 to 322 Nm (220 to 237 lb-ft). Bend
the connector mounting bracket on the carrier frame. If
all the retainer tabs to make contact with the bolt heads.
necessary, remove the electrical swivel. Refer to
ELECTRICAL SWIVEL in this Section. 4. If removed, install the electrical swivel. Refer to
ELECTRICAL SWIVEL in this Section. Connect the
NOTE: The hydraulic swivel weighs approximately 214 kg
swivel wiring harness connectors to the carrier
(472 lb). The hydraulic, water, and electrical swivel
receptacles and the yellow ground wire to the mounting
combined weigh approximately 243 kg (536 lb).
bracket on the carrier frame. Use the bolt and star
9. On the bottom of the swivel, bend the retainer tabs away washers taken off at removal and refer to Grove
from the capscrews. Remove the capscrews and Engineering Specification A-829-100386 for proper
capscrew retainers securing the two retainer plates to electrical termination of grounds.
the spool. Remove the retainer plates from the spool
5. Install the clamp, lockwasher, flat washer and capscrew
and the lugs on the carrier frame.
to the bottom of the swivel retainer plate securing the

7
NOTE: It may be necessary to remove some drive line wiring harness.
components to remove the swivel.
6. Connect the hydraulic lines and water lines to the spool
45
10. Position an adequate supporting device beneath the of the hydraulic swivel as tagged during removal.
swivel.
7. Connect the hydraulic lines to the hydraulic swivel case
11. Remove the capscrews, washers, and bushings as tagged during removal.
3

securing the swivel barrel to the turntable base plate and

8. Connect the water lines to the water swivel case as
lower the swivel to the ground.
23

tagged during removal.

Installation
9. Remove the blocking material from the lift cylinder.
6
NOTE: The hydraulic swivel weighs approximately 214 kg
10. Activate all systems; cycle all functions and observe for
(472 lb). The hydraulic, water, and electrical swivel
proper operation and any leakage.
combined weigh approximately 243 kg (536 lb).

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SWING SYSTEM RT540E SERVICE MANUAL

Electrical Swivel 6. Secure the connectors and wires from each of the
numbered connectors so the harness can be withdrawn
Description through the center of the hydraulic swivel.

The swivel assembly consists of a 20 conductor slip ring and 7. Tag and disconnect the connectors from the receptacles
cover assembly. on the cab bulkhead mounting plate.

Each brush set incorporates two brushes, leads, and clips 8. Remove the setscrews and remove the cover from the
which are attached to a brush holder assembly. The brush electrical swivel.
set leads are formed into harnesses which are routed 9. Loosen the capscrews securing the electrical swivel
through the mounting plate on the swivel. The collector ring mounting tube to the center post on the water swivel.
leads are formed into one harness which is routed downward
through the center of the hydraulic swivel. Extending from 10. Remove the capscrew and jam nut securing the
the base of the hydraulic swivel, the collector ring leads are electrical swivel case to the plate on the case of the
also formed into connectors which plug into receptacles from water swivel.
the chassis power supply.
The swivel cover is secured with a seal and bolts CAUTION
The electrical swivel also incorporates a slew potentiometer. When withdrawing the wiring harness through the center
The potentiometer controls functions in the load moment of the hydraulic and water swivels, ensure the wires do
indicating, working area definition, and rear axle oscillation not get caught and damaged.
lockout systems.
11. Remove the swivel and wiring harness from the crane. If
Theory of Operation necessary, remove the spacer bushing from the center

7
post.
The electrical swivel is located on top of the water swivel and
Installation
45
transfers electricity between the carrier and superstructure.
Wiring harnesses transmit the electricity between the carrier 1. If removed, install the spacer bushing on the center post.
and superstructure. Route the collector core wiring harness through the
center of the hydraulic and water swivels.
3

Maintenance
NOTE: The boom should be centered directly over the
23

Removal front of the crane before adjustment is made to the

1. Perform steps 1 through 4 of HYDRAULIC SWIVEL - slew potentiometer.
REMOVAL in this section. 2. Slide the electrical swivel mounting shaft onto the center
post.
3. Ensure the threaded hole on the bottom of the electrical
swivel base is aligned with the mounting hole in the plate
CAUTION
on the water swivel case. Install the capscrew through
D i s c on n e c t t h e b a t te r i es b e fo r e p e r f o r m i n g a n y the hole in the plate and install the jam nut. Screw the
maintenance on the electrical system. Serious burns may capscrew into the hole in the electrical swivel base until
result from accidental shorting or grounding of live the capscrew head is approximately 6.0 mm (0.23 in)
circuits. from the bracket. Tighten the nut against the electrical
swivel (Figure 6-6).
2. Disconnect the batteries. Refer to Section 3 -
ELECTRIC SYSTEM. 4. Apply medium strength Loctite to the setscrews securing
the electrical swivel to the center post and tighten them 5
3. Locate the connectors which join the collector ring to 6 Nm (44 to 53 lb-in)
harness to the receptacles for the carrier.
5. Install the swivel cover and secure with capscrews and
4. Tag the connectors and their receptacles with numbers. washers.
Disconnect the connectors from the chassis wiring
receptacles. 6. Connect the wiring harness connectors to the
receptacles on the cab bulkhead mounting plate as
5. Remove the clamp securing the wiring harness to the tagged during removal.
retainer plate on the bottom of the hydraulic swivel
assembly.

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RT540E SERVICE MANUAL SWING SYSTEM

operating hours. When this time limit is reached, perform the

4, 5, 6
following.
1. Check the collector ring and brush assembly for any
7 corrosion, pitting, arcing, and wear.
2. Check the collector ring setscrews and ensure they are
2, 3 tight.
3. Check the brush and arm assembly springs. Ensure
they are holding the brushes firmly against the collector
rings.
30° Ref 1 Slew Potentiometer Adjustment
1. Rotate the superstructure over the front and engage the
Forward house lock pin.
2. Set the RCL console to read slewing angle as follows:
TOP OF SWIVEL FIGURE 6-6 NOTE: Refer to the PAT Load Moment Indicator BCS
Operator Handbook for detailed instructions.
Item Description • Complete the RCL console setup according to the
crane’s current operating configuration.
1 Swivel
• Press limits LIM.
2 Capscrew
• Press 4 for slew angle/work area definition limits.

7
3 Hex Nut
• Press 1 for slew angle.
4 Capscrew
45
• Press 2 or 3 to display slewing angle.
5 Retaining Plate
6 Bushing 3. Remove the electrical swivel cover.
3

7 Retaining Plate
CAUTION
23

7. Plug the connector into the carrier wiring receptacle,

connect the wires as tag during removal. Install the Do not attempt to rotate the slotted shaft in the center of 6
yellow ground wire to the connector mounting bracket on the slew potentiometer.
the carrier frame using the bolt and star washers taken
of at removal and refer to Grove Engineering 4. Disengage the house lock pin and swing the
Specification A-829-100386 for proper electrical superstructure approximately 10 degrees to the right
termination of grounds. (clockwise). Slowly swing back to the left and engage
the house lock pin.
8. Install the clamp securing the harness to the retainer
plate on the bottom of the hydraulic swivel assembly. NOTE: If the superstructure swings past the house lock pin
engaged position, step 4 must be repeated.
9. Connect the batteries.
5. Loosen the three screws that secure the slew
potentiometer to the mounting plate.
CAUTION 6. Rotate the body of the slew potentiometer until the slew
It is imperative that the slew potentiometer be adjusted angle indicates 0.6 ± 0.1 degree.
anytime work is done to the electrical swivel.
NOTE: The slew angle indication in step 6 may not be
10. Activate all systems, cycle all functions, and observe for obtainable due to limited wire length on the
proper operation. Adjust the slew potentiometer in p o t e n t i o m e t e r, o r t h e e l e c t r i c a l t e r m i n a l s
accordance with SLEW POTENTIOMETER interference with one of the three mounting screws.
ADJUSTMENT procedures in this Sub-Section. If this occurs, reposition the collar set screwed to
the potentiometer shaft and repeat steps 4 thru 6.
Preventive Maintenance
7. Tighten the three screws that secure the slew
It is recommended that a normal inspection of the electrical potentiometer to the mounting plate. Install the electrical
swivel collector ring and brush assembly be established. An swivel cover.
example of this could be at approximately 100 to 150 engine

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SWING SYSTEM RT540E SERVICE MANUAL

8. Disengage the house lock pin and swing approximately 11. If the angle indicated on the console does not exceed ±
10 degrees to the left (counterclockwise). Slowly swing 1.0 degree, proceed to step 12. If the indicated angle
back to the right and engage the house lock pin. exceeds ± 1.0 degree, return to step 3.
NOTE: If the superstructure swings past the house lock pin 12. Disengage the house lock pin and swing approximately
engaged position, step 8 must be repeated. 10 degrees to the left (counterclockwise). Slowly swing
back to the right and engage the house lock pin.
9. If the angle indicated on the console does not exceed ±
1.0 degree, proceed to step 10. If the indicated angle NOTE: If the superstructure swings past the house lock pin
exceeds ± 1.0 degree, return to step 4. engaged position, step 12 must be repeated.
10. Disengage the house lock pin and swing approximately 13. Verify the angle indicated on the console does not
10 degrees to the right (clockwise). Slowly swing back to exceed ± 1.0 degree. If the indicated angle exceeds ±
the left and engage the house lock pin. 1.0 degree, return to step 3.
NOTE: If the superstructure swings past the house lock pin
engaged position, step 10 must be repeated.

7
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RT540E SERVICE MANUAL POWER TRAIN

SECTION 7
POWER TRAIN

SECTION CONTENTS
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Water Cooling System . . . . . . . . . . . . . . . . . . . . . 7-18
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
Electronic Control System. . . . . . . . . . . . . . . . . . . 7-7 Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
Engine Control System Switches and Indicator Antifreeze/Coolant . . . . . . . . . . . . . . . . . . . . . . . . 7-21
Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7 Radiator Removal and Installation. . . . . . . . . . . . 7-21
Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9 Drive Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
Air Intake and Exhaust System . . . . . . . . . . . . . . 7-11 Transmission/Torque Converter . . . . . . . . . . . . . 7-23
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
Air Intake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11 Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . 7-23
Charge-Air Cooler System . . . . . . . . . . . . . . . . . 7-15 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24
Muffler and Diesel Oxidation Catalyst - Tier 4 . . 7-16 Servicing the Crane After Transmission/Torque
Converter Overhaul . . . . . . . . . . . . . . . . . . . . . . . 7-27

7
Slip Joint Exhaust Connectors . . . . . . . . . . . . . . 7-16
45
ENGINE circulation. Access to the engine is gained through a door
3

assembly in the right side of the hood.

Description
23

The air intake filter is mounted on the rear of the left rear
The engine is a Cummins QSB6.7 (Figure 7-1) Tier 3 or Tier fender. The muffler is mounted on the left side of the hood
4i diesel engine. This Service Manual does not include behind the rear fender.
detailed information on the engine itself. A separate manual
as prepared in detail by the engine manufacturer, is supplied
with this Service Manual. However, a short description and
maintenance of certain components of the fuel system, air DANGER
intake system, and water cooling system is provided in this Do not spray starting fluid into the air inlet. The spray will
7
section. contact the heater elements and could explode causing
The engine is electronically controlled by the Electronic personal injury.
Control Module (ECM), it is the control center of the system.
It processes all of the inputs and sends commands to the fuel To aid in starting the engine in cold weather, the engine is
systems as well as vehicle and engine control devices. equipped with electric air heating elements that are located
in the engine’s intake air stream to aid in cold starting and
Engine speed is controlled by the foot throttle pedal in the reduce white smoke at start-up. In the preheat mode, the
cab. It controls engine RPM which increases or decreases engine should not be cranked until the WAIT-TO-START
proportionately with the amount of foot pressure applied to lamp turns off. The WAIT-TO-START lamp is illuminated
the pedal. The foot throttle pedal is electrically connected to during the preheat time that takes place when the ignition
the superstructure control module which sends the signal to switch is in the ON position during cold weather starting. The
the engine ECM via the J1939 data link. ECM checks intake manifold temperature to determine how
The engine and its components are enclosed in a hood long to energize the air heater before extinguishing the
assembly with a grill in the rear of the hood for adequate air WAIT-TO-START lamp. Once the engine is started, the
electric air heating element will be energized again for a time
period determined by intake air temperature.

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POWER TRAIN RT540E SERVICE MANUAL

Maintenance from the engine harness and tie up excess harness so it

is out of the way.
Engine Removal 7. Drain the engine coolant system.
1. Set the outriggers and position the boom to over the 8. Drain the engine lubrication system.
side.
9. Drain the transmission/torque converter oil system.
2. Open and remove the hood door assembly.
10. Remove the engine hood assembly and pump cover
3. Disconnect the air filter tubing at the engine and air from the machine.
cleaner. Remove and lay aside.
11. Disconnect and remove the drive shaft(s) between the
4. Disconnect the exhaust tubing at the engine and muffler. transmission/torque converter and the axle(s). Refer to
Lay to the side. DRIVE LINES in this Section.
5. Tag and disconnect the engine electrical harness 12. Tag and disconnect all lines from the radiator.
connector from the carrier harness connector and Disconnect the coolant level sensor harness from the
battery cables. engine harness and tie up excess harness so it is out of
6. Remove the start and grid heater relay panel and place the way. Remove the radiator. Refer to RADIATOR -
to the side of the frame. Lay the relay panel with the Removal in this Section.
harness on the engine. If a remote crank option is 13. Tag and disconnect all lines and tubing from the engine,
present, disconnect the remote crank harness connector transmission/torque converter, and all other
components.

7
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23

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RT540E SERVICE MANUAL POWER TRAIN

1, 2

2, 3, 4

7
3 45
23

View Of Engine
FIGURE 7-1

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POWER TRAIN RT540E SERVICE MANUAL

11

5, 6, 7

6, 9 10

8, 12

7
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23

View Of Engine FIGURE 7-1 continued

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RT540E SERVICE MANUAL POWER TRAIN

Engine Installation
Item Description
1 Capscrew
2 Washer
DANGER
3 Dockwasher The lifting device must be able to support the combined
4 Locknut weight of the engine and transmission.
5 Capscrew
NOTE: Use the same grade hardware, torque values, and
6 Washer Loctite that were used by the factory.
7 Mounting Plate NOTE: Apply medium strength sealant (Loctite 243) to
8 Washer engine attaching hardware.
9 Hex Nut 1. With all components and fittings installed on the new
10 Dockwasher engine, lift the engine into the crane.

11 Isolator 2. With the engine in position, install the mounting plate,

insulator, nuts, washers and capscrews and secure rear
12 Capscrew of engine. Torque M16 grade 10.9 capscrews see
13 Frame Fasteners and Torque Values (pg 1-11).
At the front of the engine install the capscrews, washers
and locknuts and secure the engine to the frame. Torque
the M12 grade 8.8 bolts see Fasteners and Torque

7
DANGER Values (pg 1-11).
The lifting device must be able to support the combined
45
3. Remove the lifting device.
weight of the engine and transmission.
4. Connect all lines and tubing to the engine, torque
NOTE: The engine and transmission/torque converter converter, and all other components in accordance with
3

assembly weighs approximately 1200 kg (2646 lb). the identification marks made during removal.
23

14. Attach to the engine a lifting device capable of

supporting the weight of the engine and transmission/ CAUTION
torque converter.
Do not apply sealant to the inside of the hydraulic suction
15. With the lifting device supporting the weight of the hoses.
engine, remove the capscrews, washers and locknuts
securing the front of the engine to the frame. 5. Apply a moderate coat of Permatex® Type No. 2 to the
male hose adapter and install the hydraulic hoses. Do
Remove the capscrews, washers, nuts, insulator and
mounting plate securing the rear of the engine to the
not apply sealant to the inside of the hydraulic hose, and 7
push it onto the male adapter. This can result in excess
frame.
sealant being pushed ahead of the male adapter and
16. Using the lifting device, lift the engine and transmission/ being exposed to the hydraulic oil.
torque converter as an assembly from the crane.
6. Install the radiator. Refer to RADIATOR - Installation in
17. If a new engine is to be installed, remove all this Section. Connect all hoses and electrical harnesses
components, fittings, etc., from the old engine and install to the radiator as tagged during removal.
them on the new engine in the same locations.
7. Connect the drive shafts between the transmission/
NOTE: Ensure that the same grade hardware, torque torque converter and the axles. Refer to DRIVE LINES
values, and Loctite as were installed by the factory in this Section.
are used.
8. Install the hood assembly. Install the pump cover.
9. Position the start and grid heater relay panel on the right
side on the frame and secure with the hardware. If
equipped with a remote crank option, reconnect to the
engine harness

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POWER TRAIN RT540E SERVICE MANUAL

OK
OK
OK

Missing Material Traverse Cracks Longitudinal Cracks Intersecting

with Transverse Cracks must be Replaced

FIGURE 7-2

7
10. Connect the battery cables and engine electrical Engine Drive Belts
harness connector in accordance with the identification
45
marks made during removal. The proper operation of engine belt-driven components such
as the alternator, fan, and water pump depend on the proper
11. Connect the air filter tubing at the engine and the air condition and tension of the engine drive belt.
filter. Connect the exhaust tubing to the engine and
NOTE: Belt tension is maintained with an automatic belt
3
muffler.
tension device.
12. Install the hood top door assembly.
23

The engine drive belt should be inspected visually on a daily

13. Service the transmission, engine lubrication system, and basis. The drive belt should be inspected for cracks, frayed
engine cooling system. Refer to LUBRICATION, page 9- areas, and glazed or shiny surfaces (Figure 7-2). A drive belt
1. that is glazed or shiny indicates belt slippage.
14. Start the engine. Check all hoses and fittings for leaks. Engine drive belt damage can be caused by various factors
Recheck all fluid levels. such as incorrect tension, incorrect belt size, misaligned
engine pulleys, incorrectly installed belt, or by oil, grease, or
hydraulic fluid on the belt.
Refer to the engine manufacturer’s manual for any special
tools or belt tension specifications.

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RT540E SERVICE MANUAL POWER TRAIN

ELECTRONIC CONTROL SYSTEM steering column display. If there are no engine fault codes,
zeroes will be shown in the steering column display.
The engine control system is an electronically operated fuel
control system that also provides many operator and vehicle Engine low idle function — With the engine running and the
features, as well as, reducing emissions while optimizing top of the Engine Diagnostic/Speed Control Switch pressed,
engine performance. press the top or bottom of the Increment/Decrement Switch
to increase or decrease the low engine idle.
The ECM performs diagnostic tests on most of its circuits
and will activate a fault code if a problem is detected in one of Engine rpm function — With the engine running and the
these circuits. Along with the fault code identifying the bottom of the Engine Diagnostic/Speed Control Switch
problem, a snapshot of engine operating parameters at the pressed, the Increment/Decrement Switch is used to adjust
time of fault activation is also stored in memory. Some fault engine rpm. Quickly press the top of the switch once to go to
codes will cause a diagnostic lamp to activate to signal the full engine rpm; quickly press the bottom of the switch once
driver. The fault codes can be read using the fault lamps in to return to low engine idle. If the engine speed is below the
the cab panel or with the correct service tools. The ECM maximum rpm setting, pressing and holding the top of the
communicates with service tools supplied by Cummins switch will cause the engine rpm to slowly increase; release
through a SAE data link. the switch when the desired rpm is attained. If the engine
speed is above the minimum rpm setting, pressing and
Engine Control System Switches and holding the bottom of the switch will cause the engine rpm to
Indicator Lights slowly decrease; release the switch when the desired rpm is
attained.
Engine Diagnostic/Speed Control Switch
Engine Stop Light
The Engine Diagnostic/Speed Control Switch is a two
The Engine Stop Light is located in the steering column

7
position maintained on/off rocker switch used to access the
gauge display. It is a red indicator light that illuminates to
engine fault codes or enable the control of the low engine
signify a serious engine problem that requires the vehicle
45
idle and engine rpm functions.
and the engine to be stopped as soon as safely possible.
Diagnostic function — With the Ignition Switch in the RUN The engine should remain shut down until the fault can be
position and the engine off, press the top of the Engine repaired.
3
Diagnostic/Speed Control Switch to view the engine fault
In addition to alerting the operator of system faults, the
codes on the steering column display. If there is more than
Engine Stop Light, in conjunction with the Engine Warning
23

one active engine fault code, use the Increment/Decrement

Light, is used in the diagnostic operation of the engine
Switch to toggle forward and backward through the fault
control system.
codes. If there are no engine fault codes, zeroes will be
shown in the steering column display. NOTE: When not using the diagnostic system, turn the
Engine Diagnostic Test Mode Switch to the OFF
Engine low idle function — With the engine running and the
position.
top of the Engine Diagnostic/Speed Control Switch pressed,
the engine low idle is adjusted using the Increment/
Decrement Switch.
To check for active fault codes, turn the keyswitch to the OFF
position, and move the Engine Diagnostic Test Mode Switch 7
to the ON position. Turn the vehicle keyswitch to the ON
Engine rpm function — With the engine running and the
position. If no active fault codes are recorded, both lamps
bottom of the Engine Diagnostic/Speed Control Switch
stay off. If active fault codes are recorded, both lamps will
pressed, the engine rpm is adjusted using the Increment/
come on momentarily, then begin to flash one code of the
Decrement Switch.
recorded faults.
Increment/Decrement Switch
Engine Warning Light
The Increment/Decrement Switch is a three position
The Engine Warning Light is located in the steering column
momentary rocker switch with center maintained position
gauge display. It is an amber indicator light that is a part of
being off. Use this switch to toggle backward and forward
the engine’s electronic control system and when illuminated,
through active engine fault codes or adjust engine speed.
gives the operator a signal that there is a engine problem
Diagnostic function — With the Ignition Switch in the RUN which must be corrected.
position, the engine off, and the top of the Engine Diagnostic/
In addition to alerting the operator of system faults, the
Speed Control Switch pressed, press the top or bottom of the
Engine Warning Light, in conjunction with the Engine Stop
Increment/Decrement Switch to toggle forward and
Light, is used in the diagnostic operation of the engine
backward through the engine fault codes shown on the
control system.

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NOTE: When not using the diagnostic system, turn the pause after which the number of the recorded fault code will
Engine Diagnostic/Speed Control Switch to the flash in the Engine Stop Light (red). To interpret the flash
speed control position. code, count the first sequence of red flashes for the first digit
and after a two second delay, count the second sequence of
To check for active fault codes, the keyswitch must be in the
red flashes for the second digit. When the number has
OFF position, and move the Engine Diagnostic/Speed
finished flashing in red, the Engine Warning Light (yellow)
Control Switch to the engine diagnostic position. Turn the
flashes again. The lamps flash each fault code 3 times
vehicle keyswitch to the ON position. If no active fault codes
before advancing to the next code. To skip to the next fault
are recorded, both lamps stay off. If active fault codes are
code, move the Increment/Decrement Switch in either
recorded, both lamps will come on momentarily, then begin
to flash one code of the recorded faults. position (+/-) to see other fault codes. If only one active fault
is recorded, the control system will continuously display the
Fault Code Flashing Sequence same fault code when pressing the Increment/Decrement
Switch. Reference the engine manufacturers service manual
The Engine Warning Light (amber) flashes at the beginning for explanation and correction of the fault codes.
of a fault code sequence. There will be a short 1- or 2-second

7
3 45
23

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FUEL SYSTEM Maintenance

Description NOTE: The entire fuel system must be maintained air tight
to prevent loss of prime.
The fuel system consists of the fuel tank, strainer, lift pump,
injection fuel pump, fuel-water separator filter and the fuel Fuel Tank
injectors. All components except the fuel tank are installed
on the engine or supplied with the engine for remote The fuel tank should be kept filled, especially overnight, to
mounting. reduce condensation to a minimum. Refer to the applicable
engine manual for the recommended schedule for draining
Fuel Tank any water or sediment from the tank.
Removal
The fuel tank (Figure 7-3) is a steel cylinder-type tank
located on the left side of the machine. The fuel tank has a 1. Position a suitable container under the fuel tank and
draw capacity of 220 l (58 gal). A connection on the bottom of drain all fuel from the tank.
the tank provides for fuel supply to the engine. Surplus fuel
from the engine is provided to the bottom of the fuel tank 2. Tag and disconnect the lines from the bottom of the tank.
below the fuel level. The tank is equipped with a non-vented 3. Disconnect the electrical lead from the fuel quantity
filler cap, chain-attached to the tank, and a fuel quantity sender unit.
sender unit which provides a signal to a fuel quantity gauge
on the instrument panel in the cab. 4. Support the weight of the tank, loosen and remove the
hardware securing the straps to the mounting brackets.
Injection Fuel Pump Remove the tank and steps.
5. If a new tank is to be installed, remove the fittings, the
The fuel oil is finely atomized as it is injected into the cylinder

7
fuel quantity sender, and steps from the tank and install
and ignited by the heat of the compression. It is metered
them in the new tank.
also, before injection, to meet the load requirements
45
imposed upon the engine. Surplus fuel, returning from the Installation
injectors, is bypassed back to the fuel tank or to the inlet side
of the pump. The continuous flow of fuel through the injectors 1. Position the new tank on the mounting brackets and
3
helps to cool the injectors and to purge air from the system. install the hardware on the two straps. Torque the
capscrews, see Fasteners and Torque Values (pg 1-11).
23

Fuel Filter-Water Separator 2. Connect the electrical lead to the fuel quantity sender
unit.
The fuel filter-water separator removes impurities from the
fuel and also removes water from the fuel before it reaches 3. Connect the two lines to the fittings on the bottom of the
the engine. The filter is mounted on the left side of the tank in accordance with the identification marks made
machine during removal.
The fuel mixture passes through the outer wrap of the first
stage of the filter paper, where large droplets of water are
4. Service the tank.
7
formed as it is stripped from the fuel. The water falls out into Fuel Filter-Water Separator
the void between the two paper elements and goes to a
reservoir in the bottom of the housing, where it can be Draining
drained through a drain plug at the bottom of the housing. The sump of the fuel filter-water separator should be drained
daily, 30 minutes after the engine is shut down, to remove
Electric Lift Pump any water and sediment. Adhere to the following procedure.
The ECM controls the electric lift pump located between the 1. Open the drain plug.
fuel tank and the injection pump. Whenever the keyswitch is
turned to the ON position, the lift pump will be energized for a 2. Drain until fuel appears.
few seconds to make sure the low pressure fuel lines are 3. Close the drain plug.
fully primed. The electric lift pump shuts off after the engine is
started.

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5
3

2
4

7
3 45
6
23

FIGURE 7-3

Item Description
1 Fuel Tank
2 Fuel Level Sensor
3 Fuel Supply
4 Fuel Return
5 Mounting Bracket
6 Oil Cooler

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AIR INTAKE AND EXHAUST SYSTEM 1. Inspect the air cleaner outlet tube for damage.
2. 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 3. Inspect the element gasket for damage.
amount of air available for combustion. System components
are the Air Cleaner, Turbocharger, Charge Air Cooler, 4. Check for structural failures and replace damaged parts.
Cylinder Head, and Exhaust Manifold. Inlet air is pulled 5. Inspect the restriction indicator tap for leaks.
through the Air Cleaner, compressed and heated in the
compressor side of the Turbocharger. The air is pushed Check For Filter Restriction
through the Charge Air Cooler to the Air Inlet Manifold.
As a dry cleaner element becomes loaded with dust, the
Cooling the inlet air increases combustion efficiency, lowers
vacuum on the engine side of the air cleaner (at the air
fuel consumption, and increases the horsepower. The air is
cleaner outlet) increases.
forced into the cylinder head to fill the inlet ports. Air flow
from the inlet port into the cylinder is controlled by the intake The vacuum is generally measured as restriction in
valves. kilopascals or inches of water. The engine manufacturer
places a recommended limit on the amount of restriction the
Each cylinder has two intake valves and two exhaust valves.
engine will stand without loss in performance before the
When the intake valves open, cooled compressed air from
element must be cleaned or replaced. Cummins allows a
the inlet port is pulled into the cylinder. The intake valves
vacuum of 6.2 kPa (25 inches of water) maximum with a dirty
close and the piston begins to move up on the compression
air cleaner at maximum governed RPM.
stroke. Fuel is injected into the cylinder and combustion
starts. The piston is forced down and is on the exhaust stroke A service indicator attached to the air cleaner housing will
when it moves up again. The exhaust valves open and indicate when the filter needs to be replaced. Reset the

7
exhaust is expelled through the exhaust port into the exhaust indicator each time the air cleaner is serviced. If the
manifold. indicator’s accuracy is suspect, a water manometer is the
45
most accurate and dependable method of measuring
The exhaust gas from the exhaust manifold enters the
vacuum.
turbine side of the turbocharger and causes the turbine to
turn driving the compressor. Exhaust from the turbocharger To use the manometer, hold it vertically and fill both legs
3
passes through the exhaust pipe and muffler into the approximately half full with water. One of the upper ends is
atmosphere. connected to the restriction tap on the outlet side of the air
23

cleaner by means of a flexible hose. The other end is left

The Air Cleaner is the dry-type with a replaceable element
open to the atmosphere.
and is located on the left rear fender. A service indicator,
designed to indicate red when servicing is required, is Maximum restriction in the air cleaner occurs at maximum air
attached to the Air Cleaner. flow. On this turbocharged diesel engine, the maximum air
flow occurs only at maximum engine power.
On the Cummins QSB Engine there are electric air heating
elements that are located in the engine’s intake air stream. With the manometer held vertically and the engine drawing
These elements heat the intake air when starting the engine maximum air, the difference in the height of the water 7
in cold ambient conditions. Startability and white smoke columns in the two legs, measured in inches or centimeters,
control are enhanced by the use of the intake air heater. A is the air cleaner restriction. Restriction indicators are
Wait-to-Start Lamp is located on the center front console to generally marked with the restriction at which the red signal
indicate when to crank the engine. flag locks up.
If the initial restriction on a new or clean filter reads above the
Air Intake
maximum allowed for the engine, check the following items:
Air Cleaner Checks 1. Ensure the air cleaner inlet is not plugged.
Dust passing the air cleaner can cause rapid engine wear. All 2. Inspect the air cleaner outlet to be sure it is not plugged
connections between the air cleaner and the engine must be by paper, rags, etc.
tight and sealed. If these connections are well sealed, and
3. Ensure the correct size connections are used between
there is still evidence of dust leakage, check the following
the air cleaner and the engine.
places for possible trouble.
4. Ensure all inlet accessories are the correct size and are
NOTE: Dust that gets by the air cleaner system can often
not plugged by any foreign object.
be detected by looking for dust streaks on the air
transfer tubing or just inside the intake manifold
inlet.

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1
2

3 5

1 6

7
4
45
1
3
23

8087

Air Intake Installation - Typical

FIGURE 7-4

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Figure 7-4 Item Numbers 5. Install new secondary filter (if necessary) and new
primary filter.
Item Description
1 T-bolt Clamp 6. Place the cover back on the air cleaner housing and
secure with clips (1).
2 Elbow
7. Check all connections and ducts for an air tight fit. Make
3 Air Intake Tube sure that all clamps, bolts, and connections are tight.
4 Elbow Check for holes in piping. Leaks in the air intake system
5 Service Indicator may send dust directly to the engine.

6 Air Cleaner Assembly 8. Replace decking access plate.

7 Precleaner Element Cleaning
8 Vacuator Valve It is not recommended that filter elements be cleaned.
9 Air Cleaner Mounting Bracket Cummins and most other manufacturers will not warrant a
cleaned air filter.
Filter Element Replacement Air Cleaner Body
Before installing the filter element, remove foreign material
(leaves, lint or other foreign matter) that may have collected
CAUTION inside the air cleaner body. Inspect the inside of the body for
Never service the air cleaner while the engine is running. dents or other damage that would interfere with air flow or
with the fins on the element or inside the body. Repair any
1. Lift the clips (1) (Figure 7-5) securing the cover to the air body dents, being careful not to damage the sealing

7
cleaner body and remove the cover. surfaces. Be sure to clean the sealing surface of the outlet
tube and the inside of the outlet tube, taking care not to
45
damage the sealing area on the tube.
1
Precleaner
3
The precleaner (1) (Figure 7-6) prevents large debris from
entering the air cleaner and should be cleaned periodically,
23

especially when working in severe dust conditions. Remove

the top half of the precleaner by releasing the two latches on
the sides of the precleaner. Remove all debris from inside
2 precleaner and reassemble.

8087-1
FIGURE 7-5

2. Remove primary filter (2) (Figure 7-5) from the air

cleaner and inspect for foreign material and marks of
dust.
3. Remove secondary filter (not shown) from the air
cleaner every third primary filter change. 1
7754
4. Thoroughly clean the sealing surface and inside of the
air filter housing. Inspect all parts of the intake system 2
FIGURE 7-6
and air cleaner.

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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.
automatically, thus lengthening the element service life. The
Malfunction of this valve does not reduce the air cleaner
valve lips must point straight down and be kept free from
effectiveness, but does allow the element to get dirty faster
debris to operate effectively. Mud and chaff can lodge in
and reduces serviceable life. If a valve is lost or damaged,
these lips periodically and hold them open during engine
replace it with a new valve of the same part number.
operation.
Duct Work
1. Check the intake pipe cap and screen for accumulation
of leaves, trash, and other debris that could restrict air
flow. Repair the screen or replace the cap if any large
holes are found in the screen.
2. Check all mounting hardware for security to eliminate
possible vibration of intake piping. Such vibration leads
to early failure of hoses, clamps, and mounting parts,
and can cause hoses to slip off the connecting pipes,
allowing un-filtered air into the engine air intake.
FIGURE 7-7
3. Check hoses for cracks, chafing, or deterioration, and
replace at the first sign of probable failure.

7
3 45
23

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Charge-Air Cooler System loaded T-bolt clamps is 100 lb-in (11.3 Nm). 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. The charge-air cooler provides Maintenance
better horsepower, increased fuel efficiency, and reduces
engine emissions. Check the hose clamps for proper torque.

The CAC system consists of the ducting to and from the Inspect the bellows for cracks or holes.
charge-air cooler and a hydraulically driven fan. The charge- Clean the charge-air cooler, removing any dirt or debris.
air cooler system must be air-tight in order to work efficiently.
Verify the fan is operating correctly and there are no
The ducting consists of metal tubing, hose clamps and hydraulic leaks.
bellows. The recommended installation torque of the spring

7
45
1

3
3
23

2 7
8089-1

Charge-Air Cooler

FIGURE 7-8

Item Description
1 CAC
2 Engine Coolant Radiator
3 CAC Hot Air Inlet
4 CAC Cold Air Outlet

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POWER TRAIN RT540E SERVICE MANUAL

Muffler and Diesel Oxidation Catalyst - Tier 4 1. Install the diesel oxidation catalyst into the mounting
band.
Removal 2. Connect the tube exhaust weldment/bellows assembly.
3. Install the muffler into the mounting bands.
4. Attach the elbow to the muffler using the clamp.
CAUTION 5. Install the exhaust tailpipe on the muffler. Secure the
Burn Hazard! exhaust tailpipe to the muffler with clamp. Adjust the
Do not touch muffler or exhaust parts until they are at clamp as needed.
ambient temperature. Severe burning may result. 6. Tighten all hardware and clamps.
1. Remove the sheet metal guard to gain access to the 7. Install sheet metal guard.
muffler and diesel oxidation catalyst.
Slip Joint Exhaust Connectors
2. Remove clamp to free exhaust tailpipe from muffler.
Slip joint exhaust couplers require tightening to avoid
3. Remove clamps to free elbow from muffler. exhaust leaks. Perform the following procedures at the
4. Loosen mounting bands and remove muffler. appropriate intervals.

5. Remove clamp to free exhaust tube. After 1000 Hours, or One Year
6. Remove clamp to free tube exhaust weldment/bellows Visually inspect the exhaust connector. If necessary, tighten
assembly and remove. the v-clamps by one full turn of the nuts.

7
7. Loosen mounting band to free diesel oxidation catalyst
and remove diesel oxidation catalyst. 2000 Hours or 2 Years
45
8. Inspect muffler, diesel oxidation catalyst, exhaust Tighten the v-clamps by 1 ½ turns of the nuts.
tailpipe, exhaust tubes, bellows, and attaching
hardware. Repair or replace any of these parts if 4000 Hours or 4 Years
3
damaged or missing.
Tighten the v-clamp by 1 ½ turns of the nuts.
23

Installation
5000 Hours or 5 Years
When assembling the muffler/diesel oxidation catalyst leave
Remove the v-clamps and gaskets, and replace them with
the clamps and mounting hardware loose until the assembly
new gaskets and clamps. Tighten the v-clamps to 9.6 to 11.3
is together.
Nm (85 to 100 lb-in) of torque.

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5
15

12
1 13 3
14
13 12 2

11

7
16
3
45
10
9
3

6
23

8088
Muffler and Diesel Oxidation Catalyst - Tier 4
FIGURE 7-9
7
Item Description Item Description
1 Sheet Metal Guard 9 Diesel Oxidation Catalyst
2 Tail Pipe 10 Muffler Clamp
3 Muffler Clamp 11 Tube Exhaust Weldment
4 Muffler 12 Clamp
5 Mounting Band 13 Gasket
6 Exhaust Tube 14 Bellows
7 Muffler Clamp 15 Tube Exhaust Weldment
8 Mounting Band 16 Elbow

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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.
The cooling system consists of a radiator (Figure 7-10),
surge tank, engine cooling circuit, charge air cooler circuit, Overheating
the connecting hoses and connecting tubes. Cooling system
capacity is approximately 24.6 l (26 qt). The radiator consists An engine that is overheating may lead to troubles such as
of two sections; the top section is the charge air cooler and the following:
the bottom section is the engine water cooler. The 1. Burned valves.
temperature is controlled by a 83°C (181°F) thermostat
located between the top of the engine and the top of the 2. Pinging or knocking.
radiator. At all times, the antifreeze/coolant should be 3. Excessive fuel consumption.
properly inhibited against corrosion. It is recommended that
a mixture of AFC-50/50 blended ethylene-glycol, low silicate, 4. Poor lubrication - increased engine wear.
fully formulated, engine antifreeze/coolant concentrate and 5. Sticking valves.
water which does not require a pre-charge of supplemental
coolant additives (SCA) for use in initial fill of heavy duty 6. Short injector life.
liquid cooled internal combustion engines be used at all 7. Engine hot spots.
times.
8. Need for higher grade fuel.
The crane is equipped with a cab hot water heater. Hot water
is supplied by the engine coolant system through a strainer Overcooling
and two port water swivel to the cab heater. The strainer is a
The following engine troubles result when an engine is

7
cleanable type and is located on the left side of the
transmission by the rear engine/transmission mount. Refer overcooled:
45
to Section 9 - LUBRICATION for service of the strainer. 1. Excessive fuel consumption.

Maintenance 2. Sludge formation in crankcase.

3. Corrosive acids formed in crankcase.
3

General
4. Excessive fuel deposits in the exhaust system.
23

The cooling system includes the Radiator, Surge Tank,

Thermostat, the Fan, and Water Pump. Radiator hoses are Antifreeze/Coolant
also included in this group.
Heavy duty diesel engines require a balanced mixture of
The cooling system is often neglected because the effects or water and antifreeze/coolant. For maximum rust, freeze, and
damage that result from an improperly maintained system boiling point protection, a 50/50 blended, fully formulated
usually occur gradually. The cooling system needs to be extended life antifreeze/coolant should be maintained at all
maintained with the same attention as other systems. times. Refer to LUBRICATION, page 9-1. Do not use more
than 50 percent antifreeze/coolant in the mixture unless
The circulation of water through the cooling system relies
additional freeze protection is required. Never use more than
entirely upon the water pump. The water pump draws water
68 percent antifreeze/coolant under any condition.
from the radiator and forces it through the water jacket and
Antifreeze/coolant at 68 percent provides the maximum
cylinder head. There it accumulates heat and flows to the
freeze protection; antifreeze/coolant protection decreases
radiator tank. Then the water flows across through the
above 68 percent.
radiator core and is cooled by air from the fan. This process
of removing heat from water as it circulates holds the engine
to its efficient operating temperature.
Rust Prevention
To keep engines operating at like new efficiency, all forms of
The following paragraphs point out several facts about
rust formation must be prevented. The formation of rust in
cooling system components, the effects of cooling system
the cooling system is a result of the interaction of water, iron,
neglect, and procedures to be followed for cooling system
and oxygen, and can only be prevented by maintaining full
maintenance.
strength corrosion protection at all times. Supplemental
Effects of Cooling System Neglect coolant additives (SCA) are recommended for this cooling
system. Antifreeze/coolant alone does not provide sufficient
Whenever an engine does not perform at top efficiency, a protection for heavy-duty diesel engines. Refer to Section 9
neglected cooling system may be at fault even though the for SCA specification and compatible brands.

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Engine Antifreeze/Coolant Fill Procedure Condemning limits are:

(when level is low) - Sulfate level greater than or equal to 1500 ppm.
1. Fill the system with a 50/50 blended, fully formulated - Chloride level greater than or equal to 200 ppm.
extended life antifreeze/coolant. Fill to the bottom of the
surge tank filler neck. Fill slowly. Flow exceeding 3 gpm - The pH level is less than 6.5.
(11.2 l/min) can give a false reading. - Oil or fuel contamination can be identified by odor or
NOTE: If the engine coolant is changed, the coolant filter color.
must also be changed. If condemned, flush the system using a commercially
2. Wait one minute and recheck the antifreeze/coolant available flushing agent. Refill system with fully
level. Refill as necessary repeating step 1. formulated extended life coolant. Refer to
LUBRICATION, page 9-1.
3. Run the engine for 5 minutes and recheck the
antifreeze/coolant level. Refill as necessary repeating NOTE: Remove the radiator cap when draining the system
step 1. Refer to LUBRICATION, page 9-1. to ensure proper draining.

Antifreeze/Supplemental Coolant Additives Cleaning

Maintenance Summary
Cooling System Level Check Interval
CAUTION
Daily or 10 hours
Burn Hazard!
The cooling system level should be checked every 10 hours
The cooling system contains very hot pressurized liquid

7
of operation or daily, whichever comes first. Refer to
and injury can result when removing the radiator cap at
LUBRICATION, page 9-1.
45 operating temperature. Use proper protection to remove
SCA Level Check/Coolant Filter Change the radiator cap.
Interval
1. Coolant shut-off valves to heaters and other accessories
3
6 months or 500 hours should be open to allow complete circulation during
cleaning, flushing, and draining. Run the engine with
23

• Check SCA Levels (use only Coolant Test Kit, Grove P/

radiator covered if necessary until temperature is up to
N 9414101675, to check the coolant additive
operating range 160 to 180° F (71 to 82° C). Stop the
concentration in the cooling system).
engine, remove the radiator cap, and drain the system
The Coolant Filter contains molybdate. Therefore, it is by opening the drain cocks on the radiator and engine
important to use the Grove Coolant Test Kit, which block.
checks the molybdate level, regardless of whether the
NOTE: Use a cleaning compound that is not corrosive to
SCA used to replenish the coolant system contains
molybdate or not.
aluminum to prevent damage to the radiator. 7
2. Allow the engine to cool, close the drain cocks, and pour
Only add coolant additive if levels are less than 1.2 units/
the cleaning compound into the surge tank according to
gal (see LUBRICATION, page 9-1 for specification and
the directions. Fill the system with water.
recommended additives).
3. Place a clean drain pan to catch the overflow, and use it
NOTE: An inadequate concentration of coolant additive
to maintain the level in the radiator. Do not spill the
can result in major corrosive damage to the cooling
solution on the vehicle paint.
system components. Over concentration can
cause formation of a “gel” that can cause restriction 4. Replace the radiator cap and run the engine at moderate
or plugging of coolant passages, and overheating. speed, covering the radiator if necessary, so the system
reaches a temperature of 180° F (82° C) or above, but
• Change coolant filter.
does not reach the boiling point. Allow the engine to run
Install charged filter if SCA levels are normal or below at least two hours, or according to recommendations of
normal; install non-charged filter if SCA levels are above the manufacturer of the cleaning compound, at 180° F
normal (contact Manitowoc Crane Care for filter part (82° C) so the cleaning solution may take effect. Do not
number). drive the vehicle or allow the liquid level in the radiator to
1 year or 1000 hours drop low enough to reduce circulation.

• Test antifreeze/coolant for contamination. 5. Stop the engine as often as necessary to prevent boiling.

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6. With the engine stopped, feel the radiator core with bare as to allow a loose fitting cap. Ensure the overflow tube
hands to check for cold spots, and then observe the is not plugged.
temperature gauge reading. When there is no change in
3. Radiator Cap - This is the pressure-setting type. Its
temperature for some time, drain the cleaning solution.
purpose is to hold the cooling system under a slight
7. If clogging of the core is relieved but not fully corrected, pressure, increasing the boiling point of the cooling
allow the engine to cool, pressure-flush the system (see solution and preventing loss of solution due to
Pressure Flushing) and repeat the cleaning operation. evaporation and overflow.
8. If problem persists, replace radiator. The cap has a spring-loaded valve, the seat of which is
below the overflow pipe in the filler neck. This prevents the
Pressure Flushing escape of air or liquid while the cap is in position. When the
cooling system pressure reaches a predetermined point, the
1. Disconnect both radiator hoses that connect the radiator
cap valve opens and will again close when the pressure falls
to the engine.
below the predetermined point.
2. Clamp a convenient length of hose to the radiator core
When removing the pressure type cap, perform the
outlet opening, and attach another suitable length of
operation in two steps. Loosening the cap to its first notch
hose to the radiator inlet opening to carry away the
raises the valve from the gasket and releases the pressure
flushing stream.
through the overflow pipe. In the first stage position of the
3. Connect the flushing gun to compressed air and water cap, it should be possible to depress the cap approximately
pressure, and clamp the gun nozzle to the hose 0.13 in (3 mm). The prongs on the cap can be bent to adjust
attached to the radiator outlet opening. this condition. Care must be taken that the cap is not too
loose as this would prevent proper sealing.
4. Fill the core with water. Turn on air pressure in short

7
blasts to prevent core damage.
5. Continue filling the radiator with water and applying air
45
pressure as above until the water comes out clear. CAUTION
6. Clamp the flushing gun nozzle firmly to a hose attached Burn Hazard!
securely to the engine water outlet opening. Fill the Loosen cap slowly and pause a moment to avoid possible
3

engine block with water, partly covering the water inlet burning by hot water or steam. Continue to turn the cap to
opening to permit complete filling.
23

the left until it can be removed.

7. Turn on compressed air to blow out water and loose
sediment. Continue filling with water and blowing out 4. Tubes are very small and can easily become clogged by
with air until flushing stream comes out clear. rust and scale. The general condition of the cooling
system and operating temperature are indications as to
8. When the vehicle is equipped with a water heater whether or not tubes are clean. Another good test is to
connected to the cooling system, flush the heater, feel the core for cold spots.
following the same procedure as for the radiator core.
5. Fins are thin metal sheets that dissipate heat picked up
9. After completing the flushing operation, clean out the by the tubes. They should be kept free of bugs, leaves,
surge tank overflow pipe; inspect the water pump; clean straw etc., so as to allow the free passage of air. Bent
the thermostat and the radiator cap control valves. fins should be straightened.
Check the thermostat for proper operation before
installation. Engine Water Jacket
10. Blow insects and dirt from the radiator core air The water jacket permits coolant to be circulated around the
passages, using water, if necessary, to soften cylinder walls, combustion chamber, and valve assemblies.
obstructions. Some of these coolant passages are small and can easily
become clogged, if the cooling system does not receive the
Component Inspection proper maintenance.
Radiator/Surge Tank 1. Core Plugs - These are sometimes mistakenly called
freeze plugs. They do not provide protection against
1. Side Tanks - Look for leaks, particularly where the tank is freezing expansion, but are only present because of
attached to the core. Vibration and pulsation from engine block casting methods. Remove and replace
pressure can fatigue soldered seams.
2. Filler Neck - The sealing seat must be smooth and
clean. Cams on filler neck must not be bent or worn so

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RT540E SERVICE MANUAL POWER TRAIN

core plugs that show signs of leaking or rusting through. Test Equipment
Use an installation tool for core plug replacement.
The antifreeze/coolant concentration must be checked using
2. Drain Plugs - The water jacket of each engine could a refractometer. “Floating ball” type density testers or
have one or more drain plugs. These should receive hydrometers are not accurate enough for use with heavy
seasonal care and be kept free of rust and scale. duty diesel cooling systems.
3. Gaskets - All gaskets must be in good condition to
prevent both internal and external leaks. If there are Antifreeze/Coolant
external leaks around gaskets, there may also be Heavy duty diesel engines require a balanced mixture of
internal leaks into the engine. Proper tightening of the water and antifreeze/coolant. Fill the system with a AFC-50/
head bolts with a torque wrench is essential for 50 blended, fully formulated extended life antifreeze/coolant
preventing leaks around the head gasket. at all times. Refer to Section 9 - LUBRICATION. Do not use
more than 50 percent antifreeze/coolant in the mixture
Water Pump unless additional freeze protection is required. Never use
The pump should be checked carefully for leaks and proper more than 68 percent antifreeze/coolant under any
lubrication. Replace or rebuild if leaking, cracked, or worn. condition. Antifreeze/coolant at 68 percent provides the
maximum freeze protection; antifreeze/coolant protection
Fans and Belts decreases above 68 percent.
The fan should be checked for cracked or broken blades.
Radiator Removal and Installation
Refer to Engine Drive Belts, page 7-6.
Removal
Thermostat
1. Set the outriggers and position the boom to over the

7
The thermostat is of the nonadjustable type and is side.
incorporated in the cooling system for the purpose of
45
retarding or restricting the circulation of coolant during 2. Open the drain cock at the end of the hose coming from
engine warm up. Engine overheating and loss of coolant is the water pump (under the front of engine) and drain the
sometimes due to an inoperative thermostat. To check for coolant into a suitable container. Dispose of in
accordance with local and EPA regulations.
3
t h i s c o n d i t i o n , r e m o v e t h e t h e r m o s ta t a n d t e s t b y
submerging it in hot water and noting the temperature at 3. Tag and disconnect all hoses from the top and bottom
23

which the thermostat opens and closes. Use an accurate sections of the radiator assembly.
high temperature thermometer for making this test.
4. Remove the hardware attaching the fan guard to the
Hoses and Clamps shroud. The fan guard will remain with the engine.
Hoses and their connections must be checked regularly 5. Remove the hardware securing the support plate on
because they are often the source of hidden trouble. Hoses each side of the radiator.
may often times appear in good condition on the outside
while the inside will be partially deteriorated. If there are any
NOTE: The radiator assembly weighs approximately
44.4 kg (97.9 lb).
7
doubts about a hose doing its job, replacement should be
made. The clamps should be inspected to make sure they 6. Attach an adequate lifting device to the radiator
are strong enough to hold a tight connection. assembly.
7. Remove the hardware securing the radiator to the mount
bracket and remove the radiator assembly from the
carrier.

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POWER TRAIN RT540E SERVICE MANUAL

7
3 45
23

8089-2 FIGURE 7-10

3. Attach the fan guard to the shroud using the hardware.
Item Description 4. Connect all hoses to the radiator assembly as tagged
during removal.
1 Radiator Assembly
2 Drain Cock 5. Ensure the drain cock is closed.

3 Fan Guard 6. Service the engine coolant system, transmission oil

system, and the hydraulic system as necessary. Start
4 Overflow Tank the engine, operate all systems and check for leaks.

Installation
1. Position the radiator assembly in the carrier using a
lifting device and secure the radiator to the mount
bracket with the hardware.
2. Secure the support plates to each side of the radiator
using a bolt.

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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. The main hydraulic pump is mounted on the
The transmission/torque converter is mounted on and driven
torque converter.
by the engine. The torque converter assembly provides for
mounting and driving the pumps. The transmission is a Theory of Operation
powershift with six forward speeds and six reverse speeds.
The transmission is controlled electrically by a shift lever/ The transmission and torque converter function together and
knob located on the right side of the steering column and an operate through a common hydraulic system. Therefore, it is
axle drive mode selector rocker switch located on the left necessary to consider both units in discussing operation.
side of the front console.
With the engine running, the converter charging pump draws
The transmission/torque converter oil is cooled by passing oil from the transmission sump through the removable oil
the oil through an externally mounted transmission cooler. suction screen and directs it through the pressure regulating
The cooler is part of the radiator. An oil filter is located on the valve and oil filter.
left side of the frame bottom rail.
The pressure regulating valve maintains pressure to the
Three drive lines are used. Two drive lines are connected transmission control for actuating the direction and speed
between the transmission/torque converter and the front axle clutches. This requires a small portion of the total volume of
an d t h e o th e r dr iv e li n e i s c o n ne c te d b e tw e en th e oil used in this system. The remaining volume of oil is
transmission/torque converter and the rear axle. directed through the torque converter circuit to the oil cooler

7
and returns to the transmission for positive lubrication. This
Maintenance regulator valve consists of a hardened valve spool operating
45
in a closely fitted bore. The valve spool is spring loaded to
Drive Lines hold the valve in a closed position. When a specific pressure
is achieved, the valve spool works against the spring until a
port is exposed along the side of the bore. This sequence of
3

CAUTION events provides the proper system pressure.

23

Do not disassemble drive lines when removing them from After entering the converter housing, the oil is directed
the crane. Dirt can enter the spline and cannot be purged. through the reaction member support to the converter blade
In addition, the drive lines are assembled in a specific cavity and exits in the passage between the turbine shaft and
orientation when manufactured and can easily be reaction member support. The oil then flows out of the
incorrectly reassembled. converter to the oil cooler. After leaving the cooler, the oil is
directed to a fitting on the transmission. Then, through a
Removal series of tubes and passages, lubricates the transmission
1. Support the drive line being removed so it does not fall
bearings and clutches. The oil then gravity drains to the 7
transmission sump.
when disconnected.
The torque converter consists basically of three elements
2. Remove the bolts from the bearing cap on each end of
and their related parts to multiply engine torque. The engine
the drive line.
power is transmitted from the engine flywheel to the impeller
3. Remove the drive line. element through the impeller cover. This element is the
pump portion of the hydraulic torque converter and is the
Installation
primary component which starts the oil flowing to the other
1. Position the drive line, install the bearing cap bolts and components which results in torque multiplication. This
tighten bolts securely. element can be compared to a centrifugal pump, in that it
picks up fluid at its center and discharges at its outer
2. Torque the inboard bearing cap bolts on the drive line to diameter.
95 to 108 Nm (70 to 80 lb-ft) and outboard bearing caps
to 127 to 142 Nm (94 to 105 lb-ft). The torque converter turbine is mounted opposite the
impeller and is connected to the output shaft of the torque
Lubrication converter. This element receives fluid at its outer diameter
The drive line slip joints require lubrication. Refer to Section and discharges at its center. Fluid directed by the impeller
9 - Lubrication. out into the particular design of blading in the turbine and

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POWER TRAIN RT540E SERVICE MANUAL

reaction member is the means by which the hydraulic torque Maintenance

converter multiplies torque.
The reaction member of the torque converter is located General Information
between and at the center of the inner diameters of the 1. Always check the oil level with the engine idling, and the
impeller and turbine elements. Its function is to take the fluid transmission in neutral and at normal operating
which is exhausting from the inner portion of the turbine and temperature (82 to 93 °C [180 to 200 °F]).
change its direction to allow correct entry for recirculation
into the impeller element. 2. Change the oil filter element every 500 hours. Drain and
refill the system every 1000 hours or 6 months.
The torque converter will multiply engine torque to its
designed maximum multiplication ratio when the output shaft Troubleshooting
is at zero rpm. Therefore, as the output shaft is decreasing in
speed, the torque multiplication is increasing. The following data is presented as an aid to locating the
source of difficulty in a malfunctioning unit. It is necessary to
The shift control valve assembly consists of a valve body consider the torque converter charging pump, transmission,
with selector valve spools. A detent ball and spring in the oil cooler, and connecting lines as a complete system when
selector spool provides one position for each speed range. A checking for the source of trouble, since the proper operation
detent ball and spring in the direction spool provides three of any unit therein depends greatly on the condition and
positions, one each for forward, neutral, and reverse. operation of the others. By studying the principles of
With the engine running and the directional control lever in operation together with the data in this section, it may be
the neutral position, oil pressure from the regulating valve is possible to correct any malfunction which may occur in the
blocked at the control valve, and the transmission is in system. Troubleshooting procedures basically consist of
neutral. Movement of the forward and reverse spool will hydraulic checks.

7
direct oil, under pressure, to either the forward or reverse
Hydraulic Checks
direction clutch, as desired. When either directional clutch is
45
selected, the opposite clutch is relieved of pressure and Before checking the transmission/torque converter and
vents back through the direction selector spool. The same associated hydraulic system for pressures and rate of oil
procedure is used in the speed selector. flow, it is essential that the following preliminary checks be
made.
3
The direction or speed clutch assembly consists of a drum
with internal splines and a bore to receive a hydraulically 1. Check oil level in transmission. This should be done with
23

actuated piston. The piston is oil tight by the use of sealing oil temperature at 82 to 93 °C (180 to 200 °F). Do not
rings. A steel disc with external splines is inserted into the attempt these checks with cold oil.
drum and rests against the piston. Next, a friction disc with
2. To bring the oil temperature to this level, it is necessary
splines at the inner diameter is inserted. Discs are alternated
to either work the machine or stall out the converter.
until the required total is achieved. A heavy back-up plate is
When it is impractical to work the machine, stall out the
then inserted and secured with a snap ring. A hub with OD
converter as follows.
splines is inserted into the splines of discs with teeth on the
inner diameter. The discs and hub are free to increase in a. Apply the parking brake.
speed or rotate in the opposite direction as long as no
b. Position the shift lever to forward and high speed.
pressure is present in that specific clutch.
c. Accelerate the engine to between half and three-
To engage the clutch, the control valve is placed in the
quarter throttle.
desired position. This allows oil under pressure to flow from
the control valve, through a tube, to a chosen clutch shaft.
This shaft has a drilled passageway for oil under pressure to
enter the shaft. Oil pressure sealing rings are located on the
CAUTION
clutch shaft. These rings direct oil under pressure to the Full throttle stall speeds for an excessive length of time
desired clutch. Pressure of the oil forces the piston and discs will overheat the torque converter.
against the heavy back-up plate. The discs, with teeth on the
outer diameter, clamping against discs with teeth on the d. Hold converter stalled until desired temperature is
inner diameter, enables the hub and clutch shaft to be locked reached.
together and allows them to drive as a unit. NOTE: Always make all troubleshooting checks with the
There are bleed balls in the clutch piston which allow quick converter outlet temperature at least 82.3 to 93.3
escape for oil when the pressure to the piston is released. °C (180 to 200 °F).

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RT540E SERVICE MANUAL POWER TRAIN

Troubleshooting Procedures

SYMPTOM PROBABLE CAUSE REMEDY

1. Low clutch pressure. a. Low oil level. a. Fill to proper level. Refer to
LUBRICATION (pg 9-1).
b. Clutch pressure regulating b. Clean valve spool and housing.
valve spool stuck open.
c. Faulty charging pump. c. Replace pump.
d. Broken or worn clutch shaft or d. Replace clutch shaft or sealing
piston sealing rings. rings, as applicable.
e. Clutch piston bleed valve stuck e. Clean bleed valves thoroughly.
open.
2. Low converter charging pump a. Low oil level. a. Fill to proper level.
pressure.
b. Suction screen plugged. b. Clean suction screen.
c. Defective oil pump. c. Replace pump.
3. Overheating. a. Worn oil sealing rings. a. Remove, disassemble, and
rebuild converter assembly.
b. Worn oil pump. b. Replace pump.

7
c. Low oil level. c. Fill to proper level.
4. Noisy converter. a.
45
Worn oil pump. a. Replace pump.
b. Worn or damaged bearings. b. A complete disassembly will be
necessary to determine what
bearing is faulty.
3

5. Lack of power. a. Low engine RPM at converter a. Tune engine and check
23

stall. governor.
b. See “Overheating” and make b. Make corrections as explained
same checks. in “Overheating.”

Removal 7. Remove the hardware securing the transmission/torque

converter housing to the engine flywheel housing.
1. Extend and set the outriggers just enough to take up the
slack in the outrigger pads. Chock the wheels. Installation 7
2. Position the boom over the side and stop the engine. NOTE: The transmission/torque converter assembly
3. Remove the engine and transmission/torque converter weighs approximately 374 kg (824.5 lb) dry.
from the crane as an assembly. Refer to Engine, page 7- 1. If a new transmission/torque converter is to be installed,
1 in this Section. remove all fittings and brackets from the old one and
4. Remove the hydraulic pumps from the transmission/ i n s ta l l t h e m i n t h e s a m e l o c a t i o n s o n t h e n e w
torque converter. Cover all openings. Refer to Hydraulic transmission/torque converter.
Pumps, page 2-14 for removal of the pump. 2. Install the piston and single section hydraulic pumps on
NOTE: The transmission/torque converter weighs the transmission/torque converter. Refer to Hydraulic
approximately 374 kg (824.5 lb) dry. Pumps, page 2-14 for installation of the hydraulic pump.

5. Attach an adequate lifting device to the transmission/ 3. Position the transmission/torque converter to the engine
torque converter and take up any slack. with the lifting device.

6. Remove the hardware securing the drive plate assembly 4. Remove all burrs from the flywheel mounting face and
to the flywheel. nose pilot bore. Clean the drive plate surface with
solvent (Figure 7-11).

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POWER TRAIN RT540E SERVICE MANUAL

MOUNT
DIAL
INDICATOR
HERE
FLYWHEEL
HOUSING

ENGINE

FLYWHEEL
PILOT
BORE

FLYWHEEL

CONVERTER
HOUSING

FLYWHEEL
10.2 cm

7
(4 in.) STUD
45
6.4 cm
(2-1/2 in.)
ALIGNING
STUDS
THIS PAGE BLANK
3

DRIVE
23

PLATE
FLYWHEEL
HOUSING SPECIAL STUD, WASHER AND
SELF-LOCK NUT FURNISHED
BY ENGINE MANUFACTURER

FLYWHEEL
HOUSING

IMPELLER
COVER

(3) INTERMEDIATE
DRIVE PLATES

FIGURE 7-11

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RT540E SERVICE MANUAL POWER TRAIN

5. 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
crankshaft end play. system are important links in the drive line between the
engine and the wheels. The proper operation of either the
6. Install two 63.5 mm (2.50 inch) long transmission to
unit or the system depends greatly on the condition and
flywheel housing guide studs in the engine flywheel
operation of the other; therefore, whenever repair or
housing as shown in the figure titled Transmission/
overhaul of the transmission/torque converter is performed,
Torgue Converter Installation. Rotate the engine
the balance of the system must be considered before the job
flywheel to align a drive plate mounting screw hole with
can be considered completed.
the flywheel housing front access hole.
After the overhauled or repaired transmission/torque
7. Install a 101.6 mm (4.00 inch) long drive plate locating
converter has been installed in the crane, the oil cooler and
stud 0.3750-24 fine thread in a drive plate nut.
connecting hydraulic system must be thoroughly cleaned.
8. Rotate the transmission/torque converter to align the This can be accomplished in several ways, and a degree of
locating stud in the drive plate with the flywheel drive good judgement must be exercised as to the method
plate mounting screw hole positioned in step 6. Locate employed.
the transmission on the flywheel housing, aligning the
The following are considered the minimum steps to be taken:
drive plate to the flywheel and the transmission to the
flywheel housing guide studs. Install the transmission to 1. Drain the entire system thoroughly.
flywheel housing nuts and washers. Tighten the bolts to
2. Disconnect and clean all hydraulic lines. Where feasible,
41 to 43 Nm (30 to 32 lb-ft). Remove the transmission to
hydraulic lines should be removed from the machine for
engine guide studs. Install the two remaining bolts and

7
cleaning.
washers and tighten the bolts to 41 to 43 Nm (30 to 32
lb-ft). 3. Replace oil filter elements, cleaning out the filter cases
45
thoroughly.
9. Remove the drive plate locating stud. Install one drive
plate attaching screw and lockwasher. Snug the screw 4. The oil cooler must be thoroughly cleaned. The cooler
but do not tighten. NOTE: Some engine flywheel should be back flushed with oil and compressed air until
3

housings have a hole located on the flywheel housing all foreign material has been removed. Flushing in the
circumference in line with the drive plate screw access direction of normal oil flow will not adequately clean the
23

hole. A screwdriver or pry bar used to hold the drive cooler. If necessary, the cooler assembly should be
plate against the flywheel will facilitate installation of the removed for cleaning, using oil, compressed air and a
drive plate screws. Rotate the engine flywheel and install steam cleaner for that purpose.
the remaining seven flywheel to drive plate attaching
screws and lockwashers. Snug the screws but do not
tighten. After all eight screws and lockwashers have CAUTION
been installed, torque the screws to 38 to 41 Nm (28 to
30 lb-ft). This will require torquing each screw, then
Do not use flushing compounds for cleaning purposes.
7
rotating the engine flywheel until all eight screws have 5. Remove the drain plug from the transmission/torque
been torqued. converter and inspect the interior of the unit housing,
10. Measure the engine crankshaft end play after the gears, etc. If the presence of considerable foreign
transmission/torque converter has been completely material is noted, it will be necessary for the unit to be
installed on the engine flywheel. This value must be removed, disassembled, and cleaned thoroughly. It is
within 0.025 mm (0.001 inch) of the end play recorded in realized this entails extra labor, however, such labor is a
step 5. minor cost compared to the cost of difficulties which can
result from the presence of such foreign material in the
11. Install the engine and transmission/torque converter in system.
the crane as an assembly. Refer to Engine Installation,
page 7-5. 6. Assemble all components and use only the type oil
recommended. Fill the transmission through the fill pipe
12. Service the crane as required in Servicing the Crane until fluid is at the top of the fill range on the dipstick. Run
After Transmission/Torque Converter Overhaul (pg 7- the engine for two minutes at idle (950 rpm) to prime the
27) in this section. torque converter and hydraulic lines. Recheck the level
13. Cycle all functions and observe for proper operation. of oil in the transmission with the engine running at idle
(950 rpm). Add oil as necessary to bring the level to the
LOW mark on the dipstick. After the oil temperature

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POWER TRAIN RT540E SERVICE MANUAL

reaches 82 to 93 °C (180 to 200 °F), add oil to bring the will cause accelerated deterioration and
level to the FULL mark on the dipstick. contamination. For extreme conditions, judgment
must be used to determine the required change
7. Recheck all drain plugs, lines, connections, etc., for
intervals.
leaks and tighten where necessary.
Every 500 hours, change oil filter element. Every 1000 hours
Lubrication or 6 months, drain and refill system as follows: Drain with oil
at 66 to 93 °C (150 to 200 °F).
Type Of Oil
NOTE: It is recommended that filter elements be changed
Hydraulic Oil (HYDO) or equivalent. Refer to LUBRICATION, after 50 and 100 hours of operation on new and
page 9-1. rebuilt or repaired units, then at normal intervals
Capacity thereafter.

System Capacity (includes torque converter, lines, and a. Drain transmission and remove pump screen. Clean
transmission) - Approximately 24 l (25 qt). screen thoroughly and replace, using a new gasket.
b. Remove and discard oil filters. Clean filter housing
Check Period and install new filters.
Check oil level every 10 hours or DAILY with engine running c. Refill transmission to LOW mark.
at 950 RPM and oil at 83 to 94 °C (180 to 200 °F). Maintain
oil level to FULL mark. d. Run engine at 950 RPM to prime converter and
lines.
Normal Drain Period
e. Recheck level with engine running at 950 RPM and
NOTE: Normal drain periods and filter change intervals are add oil to bring level to LOW mark. When oil

7
f o r a v e r a g e e n v i r o n m e n ta l a n d d u t y - c y c l e temperature is hot (83 to 94 °C [180 to 200 °F]),
conditions. Severe or sustained high operating make final oil level check. BRING OIL LEVEL TO
45
temperatures or very dusty atmospheric conditions FULL MARK.
3
23

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RT540E SERVICE MANUAL UNDERCARRIAGE

SECTION 8
UNDERCARRIAGE

SECTION CONTENTS
Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 Service Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18
Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . 8-7 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18
Steering Systems . . . . . . . . . . . . . . . . . . . . . . . . . 8-10 Corrosion Protection . . . . . . . . . . . . . . . . . . . . . . 8-22
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10 Parking Brake Actuator. . . . . . . . . . . . . . . . . . . . . 8-24
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . 8-10 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24
Rear Steering System. . . . . . . . . . . . . . . . . . . . . 8-12 Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-25
Hydraulic Pumps. . . . . . . . . . . . . . . . . . . . . . . . . 8-13 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-25
Front Steering Control Valve. . . . . . . . . . . . . . . . 8-13 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-25
Integrated Outrigger/Rear Steer Manifold. . . . . . 8-13 Park Brake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27
Steer Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27
Rear Axle Oscillation Lockout System . . . . . . . . 8-15 Outriggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27

7
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15 Outrigger Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . 8-27
Axle Oscillation Lockout Cylinders . . . . . . . . . . . 8-15 Outrigger Beam . . . . . . . . . . . . . . . . . . . . . . . . . . 8-31
45
Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16 Extension Cylinder. . . . . . . . . . . . . . . . . . . . . . . . 8-35
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16 Stabilizer Cylinder . . . . . . . . . . . . . . . . . . . . . . . . 8-36
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . 8-16 Outrigger Control Valves . . . . . . . . . . . . . . . . . . . 8-38
3
23

AXLES The hypoid pinion and differential assembly of the first

reduction are supported by tapered roller bearings. The
Description pinion bearing preload is adjusted and maintained by a
hardened precision spacer between the inner and outer
To provide maximum maneuverability, both the front and rear bearing. The differential tapered bearing preload is adjusted
axles are steerable. The rear axle (Figure 8-3) is mounted on and maintained by the positioning of the threaded adjusting
a pivoting cradle (fifth wheel) which allows the axle to rings in the carrier leg and cap bores.
oscillate while traversing uneven terrain. The front axle
(Figure 8-4) is bolted directly to the frame. All four wheels In the planetary wheel ends, the spur teeth of the sun gear
utilize a hydraulic braking system. The axles are equipped mesh with teeth of the planet spur gears. The planet spur
with disc type brakes. A disc-type parking brake is mounted gears rotate on planet pins which are mounted in a spider.
of the front axle input shaft. The planet spur gear teeth in turn mesh with teeth of the 8
floating ring gear.
Each axle incorporates a single reduction carrier with hypoid
gearing mounted in the axle center. The final reduction is of Power is transmitted by the hypoid gear set in the differential
planetary design spur gearing built into the wheel hubs. carrier to the axle shafts and the sun gear of the final
reduction, through the revolving planet gears, and into the
The design of these axles permits the hypoid gearing of the planetary spider which drives the wheel hub.
differential carrier and the axle shafts to carry only a nominal
torsional load while at the same time providing the highest As an option, the front axle and rear axle may be provided
practical numerical gear reduction at the wheels. with a differential lock. When in the locked mode, the axle
shafts and the differential are locked together and there is no
differential action between the wheels.

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Maintenance 6. 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
drive units. NOTE: Each tire and wheel assembly weighs
approximately 3660 lb (1660 kg).
Removal 7. Remove the wheels from the axle.
1. Using the outriggers, raise the wheels off the ground. NOTE: Each axle weighs approximately 2321 lb (1053 kg)
2. Install blocking under the frame at the outboard ends of with oil.
the four outrigger boxes. 8. Position jacks, which are capable of handling the weight
of the axle, under the axle for support.

CAUTION 9. Remove the eight nuts, washers, and capscrews

Do not disassemble drive lines when removing them from securing the axle to the frame/cradle (Figure 8-1)
the crane. Dirt can enter the spline and cannot be purged. (Figure 8-2).
In addition, the drive lines are assembled in a specific 10. Lower the axle to the ground and remove it to a clean
orientation when manufactured and can easily be working area.
incorrectly reassembled.
11. If a new axle is to be installed, remove the following from
3. Disconnect and remove the drive line from the the old axle and install them on the new one.
applicable axle. Do not disassemble the drive lines. a. The steer cylinders. Refer to Steer Cylinders in this
Refer to POWER TRAIN, page 7-1. section.

7
4. Tag, disconnect, and cap the hydraulic brake line at b. The rear wheels not centered switch actuator
each wheel. bracket (rear axle only).
45
5. Tag, disconnect, and cap the hydraulic lines to the steer
cylinders.
3
23

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2
1
4

2
4 1
3

21

3 14
19
20

18

7
13 45
5

7
6
3
15
16
23

17
11
10
9
8
12 5
FIGURE 8-1

Item Description Item Description

1 Cotter Pin 12 Capscrew
2 Pin 13 Washer
3 Pin 14 Hex Nut
8
4 Lockout Cylinder 15 Capscrew
5 Steer Cylinder 16 Lockwasher
6 Grease Fitting 17 Flatwasher
7 Pin Weld 18 Sensor Plate
8 Pin Weld 19 Capscrew
9 Capscrew 20 Lockwasher
10 Lockwasher 21 Rear Axle
11 Flatwasher

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10

7
6
7
11
8
45
5

12
3

13
23

9
2
14

FIGURE 8-2

Item Description Item Description

1 Front Axle 8 Flatwasher
2 Capscrew 9 Steer Cylinder
3 Hex Nut 10 Pin Weld
4 Washer 11 Grease Fitting
5 Pin Weld 12 Flatwasher
6 Capscrew 13 Lockwasher
7 Lockwasher 14 Capscrew

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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. Breathers, vented shift
units, and all other openings should be tightly covered or 1. Check the axle for wheel alignment. The wheels are to
closed to prevent the possibility of water entering the be straight ahead with no toe-in or toe-out. Adjust if
assembly. necessary by turning the tie rod ends in the direction
necessary.
Installation 2. Turn the wheels to the extreme left. Check the clearance
1. If a new axle is to be installed, remove the following from between the inside of the tire and the nearest object. If
the old axle and install them on the new one. the clearance is less than 1.0 in (25 mm) on the rear
axle or 0.5 in (13 mm) on the front axle, adjust the axle
a. The steer cylinders. Refer to Steer Cylinders in this stop to provide clearance. Do not adjust axle stop if
section. clearance is greater than 1.0 in (25 mm).
b. The rear wheels not centered switch actuator Check the steer cylinders to see that they are not
bracket (rear axle only). bottomed out. To check the steer cylinders, remove the
2. Position the axle under the crane on jacks which are pin at the rod end and apply pressure to move the
capable of handling the weight of the axle. cylinder rod. The cylinder rod should travel a minimum of
0.12 in (3.0 mm).
3. Raise the axle into place and secure with the eight
attaching capscrews, washers and nuts. Torque the 3. Turn the wheels to the extreme right and repeat step 2
capscrews; see Fasteners and Torque Values, page 1- for the right side.

7
11.
Rear Steer Indicator Adjustment Procedure
4. Install the wheels onto the axle. Refer to Wheels and
45
Tires, page 8-7. 1. Ensure the wheels are straight ahead.

5. Connect the hydraulic lines to the steer cylinder as NOTE: Refer to Figure 8-3 to perform the following
tagged during removal. adjustments.
3

6. Connect the hydraulic brake line to each wheel as 2. Ensure proximity sensor switch is centered in the slot of
23

marked during removal. the sensor plate bolted to the top of the axle trunnion
cap. Adjust by moving the sensor mounting bracket.
7. On the left side of the rear axle only, connect the
electrical wires to the rear wheels not centered switch. 3. Ensure a maximum gap of 0.2 in) (5 mm) exists between
Refer to Rear Steer Indicator Adjustment Procedure, the sensor switch and the sensor plate. Adjust by
page 8-5 and adjust the switch. loosening switch mounting bolts and moving switch up
or down on the mounting bracket. Tighten the mounting
8. Connect the drive line to the applicable axle. Refer to bolts.
Drive Lines, page 7-23.
4. Turn the rear wheels to verify proper operation. The
9. Refer to Brake System in this section and bleed the Rear Wheels Not Centered indicator in cab should not
hydraulic brake system. be illuminated when rear wheels are centered and the
sensor switch is centered in the slot of the sensor plate.

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2
1 5 mm

4, 5, 6

7
4, 5, 6
45
6758

3 FIGURE 8-3
3
23

Item Description
1 Sensor Plate
2 Proxy Switch
3 Angle Sensor
4 Capscrew
5 Hex Nut
6 Washer

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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 1
12 5
Possible equipment damage and/or
personal injury! 9
8
Driving the crane with a tire under inflated at 80% or less 3
of its recommended pressure can cause the wheel and/or
tire to fail. Per OSHA Standard 1910.177(f)(2), when a tire 4
has been driven under inflated at 80% or less of its 7
recommended pressure, it must first be completely
10
deflated, removed from the axle, disassembled, and
inspected before re-inflation. 6 11
2

CAUTION

7
Do not mix tires and rims of different manufacturers. FIGURE 8-4
45
Each wheel assembly (tire and rim) is mounted on the NOTE: Prior to wheel installation, remove any dirt or
planetary hub with 12 grade 8 lug nuts. grease from wheel mounting surface.
NOTE: The tire diameters, widths, and weights may vary 1. Position the wheel assembly on the mounting studs
3

slightly depending on the tire manufacturer. being careful not to damage threads. Install the lug nuts
23

and tighten them to 50 lb-ft (68 Nm) in the sequence

Off-highway tires are designed to operate with a certain
shown in (Figure 8-4)
sidewall deflection or bulge. Correct air pressure ensures
prior deflection which, in turn, ensures proper traction, 2. Ensure the wheel assembly is positioned properly on the
flotation, support of load, and prevents excessive flexing of hub.
the tire. Over inflation increases rim stresses, which results
3. Torque the lug nuts 340 to 360 lb-ft (461 to 488 Nm) in
in lowered rim life.
the sequence shown in (Figure 8-4).
Refer to and adhere to the inflation pressures in the Load
4. Retorque lug nuts after approximately one hour of travel.
Chart Book in the crane cab.

Maintenance Typical Wear Patterns

Incorrect Tire Pressure
Too high air pressure (Figure 8-5), View 1) gives rapid wear
in the middle of the tire. Too low air pressure ((Figure 8-5), 8
WARNING View 2) gives rapid shoulder wear.
Do not attempt to demount or mount tires without proper
training. The high pressures involved can cause tire and
rim parts and tools to fly with explosive force, if proper
procedures are not used, causing severe injury or death
to personnel and damage to the crane and surrounding
area.

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FIGURE 8-7
FIGURE 8-5
Item Description
Incorrect Camber 1 Incorrect Toe-In

7
Incorrect camber gives abnormal wear on one half of the tire. 2 Incorrect Toe-Out
45
3 Out-of-line Axles
4 Steering Arm Defect
3
Incorrect Caster and Wheel Imbalance
Incorrect caster or wheel imbalance shows as spot wear that
23

is either in the middle of the tire or extends to the shoulder.

This rapidly wears the mechanical parts of steering linkage,
kingpin and wheel bearing.

FIGURE 8-6
Incorrect Toe and Axle Alignment
Incorrect toe has a “scrubbing” effect on the front wheels that
shows in rapid shoulder wear or across the tire.
Incorrect axle alignment has a “scrubbing” effect on all
wheels.

FIGURE 8-8

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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
1 Cuts
2 Flaking Cuts

7
3 Rubber Flaking
FIGURE 8-11
45
Spot Wear
Sudden braking, locking brakes or out-of-round brake drums Cupping
give spot wear. Cupping is a normal occurrence that depends on the tread
3

pattern - the higher the load, the greater the wear.

23

8
FIGURE 8-12

FIGURE 8-10

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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.

To maximize maneuverability, the crane can be steered by A rear steer indicator system is provided to indicate when the
the front axle, the rear axle, or by the front and rear axles rear wheels are not centered. This system consists of an
simultaneously. The crane utilizes two separate steering indicator light located on the front console in the cab and a
systems, one to control front axle steering and one for rear switch located on the right side of the rear axle. When the
axle steering. rear wheels are turned to the left or right, the amber indicator
light will illuminate.
Front Steering System
Theory of Operation
NOTE: Pump figures in following text are theoretical.
The front steering system consists of a hydraulic pump, load Front Steering System
sense steer priority flow divider valve (part of the swing A hydraulic oil flow from pump number 2 flows through port 5
directional control valve), load sense steering control valve, of the hydraulic swivel to the steer/swing directional control
and two steer cylinders. valve. Regulated flow from the steer priority flow divider
The hydraulic pump is driven by the engine and supplies a valve is routed to the steering control valve upon turning of
hydraulic flow of 22.1 gpm (83.6 l/min) to the load sense the steering wheel and pressurizing of the load sense line.
steering priority flow divider. The load sense steer priority The steering control valve routes the oil to the appropriate
flow divider valve provides 7 gpm (26.4 l/min) to the load ends of the front steer cylinders to turn the wheels in the
sense steering control valve and the remainder to the swing desired direction.
system.
Rear Steering System

7
When the steering wheel is turned, the load sense steering
Hydraulic flow from pump number 1 is directed through the
control valve sends a load sense signal to the load sense
45
steer priority flow divider. As the load sense pressure integrated outrigger valve to the rear steer/outrigger
increases, the priority flow divider spool shifts to direct oil manifold. When the rear steer control switch in the cab is
from the hydraulic pump to the steering control valve, and to positioned to steer left (push top of switch) or steer right
3
direct oil from the L (left) port and R (right) port of the steering (push bottom of switch), a signal is sent to the directional
control valve to the steer cylinders. control valve spool, routing the supply pressure to the
23

appropriate ends of the rear steer cylinders to turn the

Rear Steering System wheels in the desired direction.

The rear steering system is controlled through a section of

the integrated outrigger/rear steer manifold and consists of

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Maintenance

Front Steering System

Troubleshooting

Table 8-1

Symptom Probable Cause Solution

1. Hard to steer left and right. a. Hydraulic oil low. a. Refill hydraulic reservoir.
Refer to Section 9 -
LUBRICATION
b. Clogged or loose hydraulic b. Clean or tighten lines or
lines or fittings. fittings. (Refer to your
Manitowoc Crane Care Parts
Manual)
c. Defective flow divider c. Repair or replace valve(s).
valve(s).
d. Defective steering control d. Repair or replace valve.
valve.
e. Defective hydraulic pump. e. Repair or replace pump.

7
2. Hard to steer either left or right. a. Clogged or loose hydraulic a. Clean or tighten lines or
lines or fittings. fittings. Refer to Section 9 -
45
LUBRICATION
b. Defective steer cylinder. b. Repair or replace cylinder.
3. Steering is erratic left and right. a. Hydraulic oil low. a. Refill hydraulic reservoir.
3
Refer to Section 9 -
LUBRICATION.
23

b. Clogged or loose hydraulic b. Clean or tighten lines or

lines or fittings. fittings.
c. Defective steering control c. Repair or replace valve.
valve.
d. Defective hydraulic pump. d. Repair or replace pump.
4. Noisy hydraulic pump caused by a. Hydraulic oil low. a. Refill hydraulic reservoir.
cavitation. Refer to Section 9 -
LUBRICATION
b. Suction line plugged or too b. Clean line and check for size.
small.
5. Hydraulic pump shaft seal
leakage.
a. Worn shaft seal. a. Replace shaft seal.
8
NOTE: If replacing the shaft seal
does not stop leakage, the
pump should be
disassembled and checked
for the following:
b. Broken diaphragm seal or b. Replace seal or gasket.
backup gasket.
c. Bearing out of position. c. Replace bearing.
d. Excessive internal wear. d. Replace pump.

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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.
loaded. If there is a great difference at low engine speed
1. Check all fittings for leakage. An accumulation of moist, and slight difference at high engine speeds this may
black dirt is a good indication of leakage. indicate a defective pump. Adequate oil pressure can
only be determined by connecting a pressure gauge
2. With the engine running at idle and at full throttle, and (3500 psi (24 MPa) full scale recommended) at the
with the machine standing still and moving, turn the accessory manifold with swing directional valve gauge
steering wheel through the full range of travel. Note any test port (GP5). With the engine running at a medium
speed irregularities and sticky sensation. This may speed, turn the steering wheel to one end of the travel
indicate dirt in the fluid. If the steering wheel continues to and hold the cylinders at the travel limit briefly, just long
rotate when started and released, a condition known as enough to read the pressure gauge. Never hold the
Motoring exists. This may also indicate dirty fluid in the system at relief pressure for more than a few seconds at
system. a time. The pressure gauge should indicate 2500 psi
3. Ensure the system has adequate power. If there is an (17.3 MPa).
indication of hard steering, this can be caused by either

Rear Steering System

Troubleshooting

7
Table 8-2

Symptom Probable Cause Solution

45
1. Rear steering inoperative. a. Hydraulic oil low. a. Refill hydraulic reservoir.
Refer to Section 9 -
LUBRICATION.
3

b. Clogged, broken, or loose b. Clean, tighten, or replace

23

hydraulic lines or fittings. lines or fittings.

c. Steer cylinder locked. c. Repair or replace cylinders.
d. Defective control valve. d. Repair or replace valve.
e. Defective steer cylinder(s). e. Repair or replace cylinder(s).
f. Lack of electrical signal f. Check electrical connections/
wiring
2. Hard to steer left and right. a. Hydraulic oil low. a. Refill hydraulic reservoir.
b. Clogged or loose hydraulic b. Clean or tighten lines or
lines or fittings. fittings.
c. Defective steering control c. Repair or replace valve.
valve.
d. Defective hydraulic pump. d. Repair or replace pump.
e. Clogged or loose hydraulic e. Clean or tighten lines or
lines or fittings. fittings.
f. Defective steer cylinder. f. Repair or replace cylinder.
g. Damaged relief. g. Replace relief valve.

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Symptom Probable Cause Solution

3. Steering is erratic left and right. a. Hydraulic oil low. a. Refill hydraulic reservoir.
b. Clogged or loose hydraulic b. Clean or tighten lines or
lines or fittings. fittings.
c. Defective steering control c. Repair or replace valve.
valve.
d. Defective hydraulic pump. d. Repair or replace pump.

Hydraulic Pumps Installation

1. Secure the valve to the steering column and secure with
Description the capscrews and washers. Torque the capscrews see
Front Steer Fasteners and Torque Values (pg 1-11).
The hydraulic pump is mounted off of drive pads of the 2. Connect the hydraulic hoses to the ports on the valve as
torque converter and driven by the engine. Pump number 2 tagged during removal.
provides the hydraulic flow necessary to power the front 3. Connect the electrical connector to the valve as tagged
steer cylinders and swing circuit. The pump is a gear type during removal.
pump that provides a flow of approximately 22.1 gpm (83.6 l/
min). 4. Verify proper operation of the valve.
Rear Steer 5. Check valve and hydraulic connections for leaks. Make
repairs as needed.

7
The hydraulic pump is mounted off of drive pads on the
torque converter and is driven by the engine. Pump number Integrated Outrigger/Rear Steer Manifold
45
1 supplies oil to the integrated outrigger/rear steer valve,
boom lift, telescope, hoist and pilot function. The pump is an The integrated outrigger/rear steer manifold controls the
axial piston pump that provides a flow of approximately outrigger and rear steer circuit. The valve is mounted on the
frame center section to the rear of the front axle.
3
65.3 gpm (247 l/min).
The manifold is made up of two sections; an inlet section and
Front Steering Control Valve
23

a working section.
Description The inlet section contains a 2500 psi (17,200 kPa) relief
valve and a solenoid valve. The solenoid valve is normally
The steering control valve is located under the dash and is open. It unloads the pump during cranking, and bypasses oil
actuated by a conventional steering wheel and steering from the inlet port to the tank port. Activation of either the
column, providing precise, full hydraulic steering. Precise outriggers or the rear steer circuit energizes the solenoid
steering is accomplished by a metering system within the valve to close and allow oil to flow to the selected circuit.
valve that is directly connected to the steering column and
wheel. The rear steer section contains a three position four way
solenoid controlled directional valve that controls left and
Maintenance right rear steer.
The outrigger section contains a three position four way
Removal solenoid controlled directional valve, two check valves and
two load sense valves, that controls outrigger extend and
8
1. Tag and disconnect the electrical connector to the valve.
retract.
2. Tag and disconnect the hydraulic hoses from the valve.
Cap or plug the lines and ports. Maintenance
3. Remove the capscrews and washers and remove the
valve from the steering column. Removal
1. Tag and disconnect the electrical connectors to the
valve.
2. Tag and disconnect the hydraulic hoses from the valve.
Cap or plug the lines and ports.

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UNDERCARRIAGE RT540E SERVICE MANUAL

3. Remove the capscrews and washers securing the valve lug on the axle end. The cylinders are controlled
to the frame bracket. Remove the valve. hydraulically by the steering control valve.

Installation Maintenance
1. Secure the valve to the frame bracket with the washers NOTE: For Disassembly and Assembly procedures, refer
and capscrews. Torque the capscrews see Fasteners to Steer Cylinders in Section 2 - HYDRAULIC and
and Torque Values, page 1-11. PRESSURE SETTINGS.
2. Connect the hydraulic hoses to the ports on the valve as Removal
tagged during removal.
1. Tag and disconnect the hydraulic lines going into the
3. Connect the electrical connectors to the valve as tagged steer cylinder. Cap or plug all openings.
during removal.
2. Remove the capscrews, flatwashers and spring
4. Verify operation as follows: lockwashers securing each pin weld in the rod end and
barrel end of the cylinder.
- Operate the rear steer left and right to verify smooth
operation. NOTE: Steer cylinder weighs approximately 19.9 lb
(9.07 kg).
- On outriggers, swing over the front outriggers to
ensure the oscillation cylinders lockout. 3. Remove both pin welds and two thrust washers (rod end
only), and remove the cylinder from the axle.
5. Check valve and hoses for leaks. Make repairs as
needed. Installation
NOTE: For further information on the Integrated Outrigger/ 1. Position the cylinder onto the attachment fittings on the

7
R e a r St e e r M a n i f o l d , r e f e r t o S e c t i o n 2 - axle and install both pin welds.
HYDRAULIC and PRESSURE SETTINGS.
2. Secure each pin weld with the capscrew, flatwashers
45
Steer Cylinders and spring lockwashers. Torque the capscrews see
Fasteners and Torque Values, page 1-11.
Description 3. Connect the hydraulic lines to the cylinder as tagged
3

during removal.
The steer cylinders are mounted on the axles, two cylinders
23

on each axle. The barrel end of each cylinder is attached to 4. Operate the steering system and check the cylinder for
the axle housing and the rod end is attached to the steering proper operation and any leakage.

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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
an area potentiometer. The lockout cylinders are mounted 1. Raise the crane up on outriggers.
between a cradle (fifth wheel) and the carrier frame. The axle 2. Rotate the turntable more than 6 degrees in either
oscillation lockout valve is located on the left inner center direction from directly over the front to lock out the
frame rail and hydraulically controls the lockout cylinders. oscillation cylinders.
The area definition potentiometer in the electrical swivel 3. Remove the wheel and tire assembly from the axle.
energizes and deenergizes the axle oscillation relay. When
the superstructure is more than 6 degrees left or right of 4. Tag and disconnect both hydraulic hoses from the ports
directly over the front, the axle oscillati on rel ay is on the cylinder. Cap or plug both hoses and the ports on
deenergized. the cylinder.
When the axle oscillation relay’s contacts are open, the 5. At the rod end of the cylinder, remove one of the cotter
normally closed solenoid valves are deenergized and isolate pins securing the retaining pin to the cradle attach fitting.
the lockout cylinders from hydraulic oil supply. This keeps the
6. Tap out the retaining pin, freeing the rod end from the
cylinders from oscillating (moving up and down to damp axle
cradle.
movement) because hydraulic oil cannot leave the cylinders.
Instead, the cylinders remain full of hydraulic oil and more 7. At the barrel end of the cylinder, remove one of the cotter
rigid. pins securing the retaining pin to the frame attach fitting.

7
When the axle oscillation relay’s contacts are closed, the 8. Tap out the retaining pin and remove the cylinder.
45
solenoid valves are energized and open. This allows
Installation
hydraulic oil in and out of the cylinders, allowing them to
oscillate. 1. Position the barrel end of the cylinder in the frame attach
3
fitting and tap in the retaining pin.
NOTE: For further information on the lockout valve, refer to
Section 2 - HYDRAULIC and PRESSURE 2. Secure the retaining pin with the cotter pin.
23

SETTINGS.
3. Align the rod end of the cylinder in the cradle attach
Axle Oscillation Lockout Cylinders fitting and tap in the retaining pin.
4. Secure the retaining pin with the cotter pin.
Description
5. Remove the caps or plugs from the two hydraulic hoses
A 12.7 cm (5 inch) diameter bore lockout cylinder is installed and the cylinder ports and connect the hoses to the
on the left and right side of the rear axle. The barrel end of appropriate cylinder ports as tagged during removal.
each cylinder is attached to each side of the carrier frame
6. Install the wheel and tire assembly on the axle. Tighten
and the rod ends are attached to each side of the cradle (fifth
the lug nuts in accordance with the procedure in Wheel
wheel).
And Tire Assemblies in this section.
The lockout cylinders are connected hydraulically so that
7. Lubricate both ends of the cylinder using the fittings
hydraulic oil flows from the rod side of the left cylinder to the
barrel side of the right cylinder and from the rod side of the
provided. 8
right cylinder to the barrel side of the left cylinder.

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UNDERCARRIAGE RT540E SERVICE MANUAL

BRAKE SYSTEM Hydraulic oil from hydraulic pump number 2 flows to swivel
port 9 to the dual accumulator charge valve. The dual
Description accumulator charge valve charges the accumulators from
the open center circuit upon demand and within its present
The brake system includes all the components necessary for operating charge rate and the high limit pressure setting.
the application of the service brakes and the parking brake. However, when the open center circuit pressure reaches the
brake relief setting, which is higher than the high
Service Brakes accumulator charge limit, then the accumulators will be
The service brakes are full power hydraulic disc brakes charged to the regulated maximum pressure setting. The
which are hydraulically controlled and are used to apply the dual accumulator charge valve regulates flow to the
brake assemblies on all four wheels. The system consists of hydraulic accumulators to provide fully powered
the tandem brake valve with treadle pedal, the dual independently separate, primary (front) and secondary
accumulator charge valve, two hydraulic accumulators, the (rear), service brake circuits. Hydraulic pressure is
brake assemblies, and all the associated hoses and tubing. c o n s ta n t l y m a i n ta i n e d i n t h e b r a k e c i r c u i ts b y t h e
The operator depresses the pedal on the tandem brake accumulators and the charging valve. The charged
valve, located on the cab floor, and the valve modulates the accumulators supply pressurized fluid to the closed tandem
brake line pressure to the brake assemblies at each wheel. brake valve.
The full powered brake system supplies a high brake system After the accumulators are fully charged, the high limit check
pressure with relatively low reactive pedal forces, while opens and all of the pump flow is directed to the excess flow
controlling the maximum brake line pressure. The service port and on to the front steer and swing circuits. When
brake dual accumulator charge valve regulates flow to the pressure to the steering or swing circuit becomes greater
hydraulic accumulators to provide fully powered than accumulator pressure, the main check valve opens and
independently separate, primary (front) and secondary charges the accumulator without the aid of the charging

7
(rear), service brake circuits. Hydraulic pressure is valve. In this condition, the maximum accumulator pressure
c o n s ta n t l y m a i n ta i n e d i n t h e b r a k e c i r c u i ts b y t h e is the brake circuit relief valve setting of 20 MPa (2900 psi).
45
accumulators and the charging valve.
Once the operator depresses the brake pedal, the tandem
Parking Brake brake valve modulates fluid out to the brakes to provide the
means of braking. The tandem brake valve will modulate the
3
The parking brake is a hydraulic release, spring apply, disc- pressure in the brake system by increasing or decreasing
type brake, located on the transmission. The system pressure as required in proportion to the input force from the
23

consists of a two-position switch, a three-way solenoid valve, operator via the brake pedal. The hydraulic force acts within
actuator, two brake assemblies, and all the associated the brake assemblies to force the brake pads against the
hardware and tubing. The selector switch, located on the brake discs, acting to slow wheel rotation. Fully powered
front console in the cab, is used to activate the solenoid separate primary (front) and secondary (rear) braking circuits
valve which controls the park brake actuator, which applies are provided with independent accumulators. A low pressure
and releases the park brake. warning switch is used to sense the accumulator pressures
and warn the operator through visual brake warning indicator
NOTE: For Description and Maintenance of the tandem
light on the cab console in the event the pressure in the
brake valve with treadle pedal, the accumulators,
accumulators drops to an unsafe operating level. In the
and the dual accumulator charge valve, refer to
event of engine failure, the accumulators are pre-charged
VA LV E S i n S e c t i o n 2 - H Y D R A U L I C a n d
with dry nitrogen gas and properly sized to provide power-off
PRESSURE SETTINGS.
stopping capacity for secondary braking.
Theory of Operation
Parking Brake
Service Brakes Hydraulic flow from the transmission charge pump is routed
to the parking brake control valve. When the PARK BRAKE
Braking begins when the operator depresses the brake
switch is in the ON position, the parking brake solenoid valve
pedal in the cab. Mechanical linkage transfers the force
shifts to route flow from the hydraulic parking brake actuator
created by the lever action of the brake pedal to the hydraulic
back to the transmission sump. The actuator spring pulls on
brake valve which modulates the brake line pressure to the
the lever on the brake assembly, applying the parking brake.
brake assemblies at each wheel.

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RT540E SERVICE MANUAL UNDERCARRIAGE

Maintenance

Troubleshooting

Symptom Probable Cause Solution

1. Brakes are poor. a. Lining thickness less than a. Replace lining.
3mm (0.125 in).
b. Brake pedal operation. b. Free mechanical linkage.
c. Restriction or leaks in lines. c. Check all lines for leaks and
restrictions.
d. Low hydraulic oil flow. d. Check the hydraulic oil level in
reservoir and check flow from
the tandem brake valve.
e. Air in brake lines. e. Bleed the brakes.
f. Brake pads/linings are f. Replace pads/linings.
grease-soaked.
g. Engine not running. g. Start engine. Due to the
operation, the engine must be
running to provide full brake
power.

7
h. Brake relief valve stuck open. h. Replace the relief valve.
45
i. Dual accumulator charge i. Check valve operation and
valve not charging repair or replace valve.
j. Accumulators not pre- j. Check accumulator pre-
3

charged. charge.
23

2. Hard brake pedal with engine a. Pedal travel being interfered a. Check all pedal linkage and
running. with. ensure it is free and adjusted
properly.
3. Brakes lock up. a. Too much hydraulic flow. a. Check the flow from the flow
divider. Too much flow will
cause the brakes to be
applied by the oil trapped in
the power boost chamber.
b. Brake pedal push rod b. Adjust the push rod linkage so
improperly adjusted, causing the brake pedal and push rod
brakes to be always applied. fully return.
4. Uneven braking or pad wear. a. Lining thickness less than 3 a. Replace the lining.
mm (0.125 in). 8
b. Grease on the pads/linings. b. Replace the pads/linings.

General Bleeding the Brake System

A schedule for the periodic adjustment, cleaning, inspection, The brake system should be bled whenever air becomes
and lubrication of brake equipment should be established by entrapped within the brake system (usually characterized by
the operator on the basis of past experience and severity of a spongy feeling during brake pedal application), whenever
operation. any brake system line has been opened, or whenever any
brake component has been replaced.
The disc brakes are not adjustable. Brakes should be
cleaned, inspected, and linkage lubricated periodically to Always start at the point in the system that is furthest from
assure maximum performance. the tandem brake valve and work back toward the tandem

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UNDERCARRIAGE RT540E SERVICE MANUAL

brake valve. Bleed every bleeder screw on every caliper/ 4. 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. When you complete a wheel, go to the SERVICE BRAKES
furthest bleeder screw on the next closest wheel.
Pressure Bleeding the Brake System. Description
NOTE: Before bleeding the brake system, ensure the The brakes utilized on the axles are hydraulic disc-type
hydraulic accumulators are fully charged. brakes. Two brake assemblies are used at each wheel end
on the front axle. One brake assembly is used at the wheel
1. Install the bleeding adapter. end on the rear axle. The action of the brake pads riding
2. Using a clean bleeding tank, fill the tank at least half full against the brake discs acts to slow the rotation of the
with hydraulic oil. Position the tank so it will not have to wheels.
be moved again until all bleeding is finished.
Maintenance
3. Connect a 35 psi (241 kPa) air source to the bleeder NOTE: To perform maintenance on the brake caliper,
tank. remove the tire and wheel assembly. Refer to
4. Open the bleeder tank valve and bleed all air out of the AXLES in this section.
hose to be connected to the adapter. Connect the
bleeder hose to the adapter and open the bleeder valve. Removal
Linings
5. Connect the end of the bleeder hose to the bleeder
screw on the caliper/actuator. Submerge the other end 1. Block the wheels.

7
in a glass jar partially filled with the proper type of clean
2. Remove the bolts securing the end plates to one side of
hydraulic oil.
45
the caliper housing. Remove the end plates.
6. Open the bleeder screw and allow fluid to flow into the 3. Loosen the bleeder screws to release hydraulic
jar until it is a solid stream free of air bubbles. Close the pressure in the caliper.
bleeder screw and torque to 100 to 120 lb-in (11.3 to
3

13.6 Nm).
23

7. Repeat steps 5 and 6 for the remaining wheel calipers/ Wood

actuators. Loosen Block
Bleeder
8. Remove the air supply from the bleeder tank. Screws
NOTE: Close the bleeder tank valve and disconnect the
hose and the bleeder adapter.

9. Remove the bleeder tank and hose.

10. Remove the bleeder adapter.

Push Wood
Manually Bleeding the Brake System Block Against
NOTE: Before bleeding the brake system, ensure the Linings to Push
Pistons Into
hydraulic accumulators are fully charged.
Bores
1. Connect the end of the bleeder hose to the bleed screw
on the caliper. Submerge the other end in a jar partially FIGURE 8-13
filled with clean hydraulic oil.
2. Open the bleed screw on the caliper/actuator and allow 4. Use a piece of wood against the linings as a pry bar to
fluid to flow into the jar, while depressing the brake push the pistons completely into the housing. Tighten
pedal. Depress the brake pedal and close the bleeder the bleeder screws (Figure 8-13).
screw, then release the brake pedal. Torque the bleeder
5. Remove the linings from the caliper housing. If
screw to 100 to 120 lb-in (11.3 to 13.6 Nm).
necessary, discard the linings.
3. Repeat step 2 until a solid stream free of air bubbles is
obtained.

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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
1. Disconnect the hydraulic brake line from the inlet fitting
out before the other piston, put a piece of wood in
on the caliper. Cap or plug all openings.
front of the piston that comes out first. Apply
2. Remove the linings as described previously. compressed air to force the other piston out of the
housing (Figure 8-15).
3. Remove the bolts securing the caliper housing to the
mounting bracket. Remove the caliper housing from the
mounting bracket. If shims are used mark the position of
the shims.
C-Clamp

Disassembly
Caliper
1. Remove the inlet fitting and o-ring from the cylinder cap.
2. Drain and discard the brake fluid.

3. Clean the outside of the housing with isopropyl alcohol. Air Gun
Dry the housing with a clean cloth. Wood
Block Piston FIGURE 8-15
4. If installed, remove the bolts that secure the end plates
to the housing. Remove the end plates and linings. c. Remove the wood block and the C-clamp from the
housing.
5. Remove the pistons from the side of the housing

7
d. Remove the pistons from the bores that are
opposite the mounting plate according to the following
opposite from the mounting plate.
procedure.
45
a. Use a C-clamp to hold a 0.5 in (12.7 mm) block of 6. Remove the two bleeder screws from the housing.
wood against two pistons on the mounting side of
7. Remove the cylinder caps from the housing using an
the housing. Ensure the C-clamp is not in the area in
3
open end wrench. Remove and discard the O-rings
front of the piston bore (Figure 8-14).
(Figure 8-16).
23

C-Clamp

Wood
Block

O-Ring
Cylinder
Cap

FIGURE 8-16
8
FIGURE 8-14
8. Remove the pistons from the mounting plate side of the
housing. Push on the ends of the pistons to force them
out of the disc side of the housing (Figure 8-17).
DANGER
Do not place hand in front of pistons when forcing them
out. Serious personal injury may occur.

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UNDERCARRIAGE RT540E SERVICE MANUAL

Shoes, Linings, and End Plates

Wood Block
Remove the shoes and linings. To help prevent abnormal
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:
• Lining Wear. Replace the linings when the thickness
of the lining is less than 0.125 in (3.2 mm) from the
back plate (Figure 8-19).
• Lining Wear Not Even. Replace the linings if the
thickness of the two linings is significantly different.
Check the pistons for correct operation. Replace the
Piston piston and/or housing if a piston is cocked in the
bore. Check that the disc surface is flat and parallel
to the linings (Figure 8-19).
FIGURE 8-17

9. Remove the dust seals from the housing. Minimum Lining Thickness
3.2 mm (0.125 in) from
10. Remove and discard the O-ring and the backup rings Backing Plate
(Figure 8-18).

7
45
O-Ring

Uneven Lining Wear

3
23

Backup Ring FIGURE 8-18

FIGURE 8-19
11. Inspect the ring grooves in the housing for scratches and
rust. Remove small scratches and rust with emery cloth. • Oil or Grease on Linings. Replace the linings.
Replace the housing if there are large scratches or large • Cracks on Linings. Replace linings that have large
amounts of rust. Refer to Inspection - Caliper Parts. or deep cracks.
12. Inspect the pistons and the bores for scratches and rust. NOTE: Small, tight cracks on the surface of the lining are
Remove small scratches and rust with emery cloth. normal when the caliper is used under high
Replace the components if they are worn or if there are temperature conditions.
large scratches or large amounts of rust. Refer to
Inspection - Caliper Parts.
Caliper for Leaks
Inspect the following areas for fluid leaks (Figure 8-20).
Inspection
Periodic On-Vehicle
Inspect the caliper, linings, and disc for any damage.

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RT540E SERVICE MANUAL UNDERCARRIAGE

Bleeder Screw Minimum Disc

Piston Fluid
Fluid Leaks Thickness
Leaks

Maximum Disc
Inlet Wear Each Side
Cylinder
Fitting Maximum
Cap
Fluid Disc Wear
Fluid Original
Leaks
Leaks Disc Thickness
15.875 mm (0.625 in)

Piston Fluid Typical Section Through Disc Showing

Leaks Recommended Maximum Wear Limits
FIGURE 8-20

• Pistons. If fluid leaks at a piston, disassemble the

caliper. Inspect the piston, the bore, the o-rings, and
Lining
back-up rings. Service as necessary. Maximum
Backing Minimum Disc
• Cylinder Cap. If fluid leaks at a cylinder cap, tighten Disc Wear
Plate Thickness
the cylinder cap, the inlet fitting, and the plug. If the Each Side
Thickness
leak continues, disassemble the caliper. Inspect the
cylinder cap threads, the housing threads, and the 7.1 mm (0.28 1.5 mm (0.06 12.7 mm (0.50
o-ring. Service as necessary. in) in) in)

7
• Bleeder Screw. If fluid leaks at the bleeder screw, 8.6 mm (0.34 2.3 mm (0.09 11.2 mm (0.44
45
tighten the bleeder screw. If the leak continued, in) in) in)
replace the bleeder screw.
FIGURE 8-21
• Inlet Fitting. If fluid leaks at the inlet fitting, tighten
3
the fitting. If the leak continues, replace the o-ring. Caliper Parts
23

Dust Seals 1. Inspect the pistons, housing bores, and o-ring grooves
Ensure the dust seals are soft and flexible. Disassemble the for scratches or corrosion. Remove small scratches or
caliper and replace dust seals that are hard or damaged. corrosion with fine emery cloth. Replace the
components if they are worn beyond wear limits or if
Disc there are large scratches or large amount of corrosion.
If the disc is worn beyond the wear limits, replace the disc 2. Measure the diameter of the piston. Replace the piston if
(Figure 8-21). the outer diameter is worn less than 2.995 in
(76.073 mm) (Figure 8-22).

8
Micrometer
Piston

Replace Piston if Outer

Diameter is Worn to Less than
76.073 mm (2.995 in)
FIGURE 8-22

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UNDERCARRIAGE RT540E SERVICE MANUAL

3. 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 3.003 in and fittings.
(76.276 mm) (Figure 8-23).
• Use soap and water to clean parts that are not made
of metal.
• Scrape away build-ups of mud and dirt on the
Replace Housing if Bore linings. Replace all linings contaminated with oil or
is Worn to More than grease.
76.276 mm (3.003 in)
• Immediately after cleaning, dry all parts with clean
paper or rags.

Corrosion Protection
Apply brake system fluid to the cleaned and dried parts that
are not damaged and are to be immediately assembled. Do
Not apply fluid to the brake linings or the disc.

Telescoping If parts are to be stored, apply a special material that

Gauge prevents corrosion to all surfaces. Do Not apply the material
FIGURE 8-23 to the brake linings or the disc. Store the parts inside special
paper or other material that prevents corrosion.
4. Inspect the linings as described previously.

5. Inspect the threads of the caliper, cylinder caps, and all

Assembly
fittings. Replace any component that has thread Caliper

7
damage that cannot be repaired.
45
6. Discard all back-up rings, o-rings, and dust seals. Use
new ones when assembling the caliper.
CAUTION
Use only specified components when assembling the
Cleaning calipers. Do not mix components from other calipers.
3

Installing the wrong components may cause the caliper

not to operate correctly and may cause damage to
23

equipment. Use of non manufacturer’s parts can cause

damage, loss of braking, and serious personal injury.
DANGER
Use of cleaning solvents, hot solution tanks, or alkaline NOTE: The o-rings, back-up rings, pistons, and bores
solutions incorrectly, can cause serious personal injury. To must be lubricated before installing the pistons.
prevent serious personal injury, follow the instructions
supplied by the manufacturer of these products. Do not 1. Lubricate all pistons, bores, o-rings, and back-up rings
use gasoline to clean parts. Gasoline can explode and with silicone grease. If silicone grease is not available,
cause serious personal injury. use the same type of fluid that is used in the brake
system.
2. Install new o-ring and a new back-up ring in the groove
CAUTION in the middle of the bore. The o-ring is installed toward
Use only solvent cleaners to clean ground or polished the outboard end of the bore. The back-up ring is
metal parts. Hot solution tanks or water and alkaline installed toward the lining side of the bore (Figure 8-16).
solutions will damage these Parts. Isopropyl alcohol,
kerosene, or diesel fuel can be used for this purpose.
CAUTION
• Use solvent cleaners to clean all metal parts that Do not use silicone grease on the dust seal.
have ground or polished surfaces. Examples of
ground or polished parts are the piston and the 3. Install a new dust seal in the top groove of the bore
piston bore in the caliper. (Figure 8-24).
• Metal parts with rough surfaces can be cleaned with
solvent cleaners or with alkaline solutions.

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RT540E SERVICE MANUAL UNDERCARRIAGE

NOTE: Apply extra grease on o-ring before installing

cylinder caps. this will keep o-ring from catching on
Backup Ring - O-Ring- threads as cylinder cap is threaded into housing.
Install Toward Lining Install Toward
Side of Bore O-Ring Outboard End of Bore 6. Install the cylinder caps in the caliper housing. Tighten
the cylinder caps to 75 lb-ft (102 Nm) minimum as
O-Ring shown in (Figure 8-26).

Cylinder Cap - -
Backup Tighten to 100 Nm 1.25 Inch
Ring (75 pounds-foot) Crow’s Foot
Minimum Wrench
Backup Ring Dust Seal
and O-Ring Groove
Dust Seal Groove
FIGURE 8-24

4. Install the pistons in the housing. Push the pistons in

from the lining side of the housing. Ensure the pistons
are straight in the bores. Push each piston into the bore
until the top of the piston is even with the top of the dust Torque
seal (Figure 8-25). Wrench
FIGURE 8-26

7
7. Install the bleeder screws in the housing. Tighten to 100
to 120 lb-in (11.3 to 13.6 Nm).
45
8. Install the o-ring and the inlet fitting in the cylinder cap.

Installation
3

Linings
23

Piston - - Use CAUTION

Equal Pressure to Always replace both linings. If only one lining is replaced,
Push Pedal into Bore
possible disc damage can occur.

1. Install the linings in the caliper housing.

2. Position the end plates on the housing and secure with
bolts. Apply Loctite 271 or equivalent to the bolt threads.
Tighten the bolts to 165 to 210 lb-ft (224 to 285 Nm).

3. Ensure the linings move freely in the housing.

4. Bleed the brake system.

8
When Correctly
Installed the End of the 5. Apply and release the brakes three times to ensure the
Piston is Even with the caliper operates correctly. Check for fluid leaks. Ensure
Top of the Dust Seal FIGURE 8-25 the linings move freely.
Caliper
5. Install a new o-ring in the groove of the cylinder cap.
Ensure the o-ring is not cut by the threads on the 1. Position the caliper housing on the mounting bracket. If
cylinder cap. shims where used, place them as marker during
removal.
2. Secure the caliper housing with the bolts and tighten
them to 500 to 600 lb-ft (678 to 813 Nm).

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UNDERCARRIAGE RT540E SERVICE MANUAL

3. Install the linings. Refer to INSTALLATION - Linings. pressure of 270 psi (1862 kPa) may be used to
pressurize the actuator.
4. Ensure the housing is installed correctly on the mounting
bracket. The disc must be within ±0.06 in (±1.5 mm) of 3. Remove the capscrews securing actuator to the brake
being centered between the lining end plates. caliper. Slide the actuator off the actuator rod.
a. To increase outboard clearance and decrease 4. Position the Park Brake switch to On (press top of
inboard clearance, install a shim either between the switch) and shut down the engine.
housing and mounting bracket or between the hub
and disc. 5. Disconnect the hydraulic line from the brake actuator,
then cap or plug all openings.
b. The shims must be steel, ground flat, and parallel
and must cover the entire mounting surface of the
hub or housing. The linings must move freely in the
Installation
housing and between the end plates (Figure 8-27). NOTE: Mount brake so that the linings are parallel with the
disc within 0.015 in (0.381 mm). Disc is to be
located the proper distance from the mounting
surface per assembly drawing.
1. Slide brake over disc and into mounting position.
2. Start hex mounting bolts into mounting surface far
enough to just support the brake.

3. Remove plug, loosen the coupling nut and then tighten

socket setscrew until linings are clamped to the disc.

7
This locates and holds the brake in the proper position to
set the hex mounting bolts and hex nuts.
45
Disc Centered
Between Linings 4. Tighten hex mounting bolts until they make contact with
the urethane springs, then tighten 4 flats approximately
0.07 in (1.778 mm) more. This puts the proper amount
3
FIGURE 8-27
of pre-load on the urethane springs.
23

5. Connect the hydraulic brake line to the inlet fitting. 5. Tighten jam nut/sleeves against mounting surface and
torque 200 lb-ft (271 Nm).
6. Bleed the brake system.

7. Apply and release the brakes three times to ensure the CAUTION
caliper operates correctly. Check for fluid leaks. Ensure
Brake linings are susceptible to contamination. When
the linings move freely.
installing or servicing brakes, keep all oil and fluids away
from linings. Poor brake performance may result if linings
PARKING BRAKE ACTUATOR are contaminated.

Description 6. Attach brake line to inlet port located on top of the

The spring-applied, hydraulically-released parking brake hydraulic cylinder.
actuator is located on the transmission and is used to apply
and release the parking brake.
CAUTION
Maintenance Do not exceed 270 psi (1861.5 kPa) hydraulic pressure to
avoid damage to the brake. 170 psi (1172.1 kPa) is
Removal required to fully release the brake.

1. Chock the wheels to prevent crane movement. 7. Apply hydraulic pressure to the brake.
2. Start the engine, ensure the transmission is in neutral, 8. With plug removed, loosen coupling nut and set running
and position the Park Brake switch to Off. This will clearance to 0.020 to 0.030 in (0.5 to 0.7 mm) total by
pressurize the brake actuator to release the tension on adjusting the socket setscrew. Torque the coupling nut
the brake linkage. Engine must remain running. Air while holding the socket setscrew in position. Torque nut
50 to 55 lb-ft (68 to 75 Nm).

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RT540E SERVICE MANUAL UNDERCARRIAGE

9. Replace plug. Torque plug 45 to 50 lb-ft (61 to 68 Nm). 270 psi (1862 kPa) may be used to pressurize the
actuator. Screw the caging nut up under the actuator
10. Even up running clearance to 0.010 to 0.015 in (0.25 to
chamber.
0.3 mm) each side by adjusting the socket head
capscrew. 3. Position the Park Brake switch to On (press top of
NOTE: Re-adjust the brake when running clearance switch) and shut down the engine.
reaches a total of 0.100 in (2.54 mm).
4. Tag and disconnect the hydraulic hose from the actuator.
11. Position the Park Brake switch to On (press top of Cap or plug all openings.
switch) and shut down the engine.
5. Unthread the two mounting bolts securing the brake
assembly to the mounting bracket, then carefully
Adjustment remove the brake assembly from the mounting bracket
1. Chock the wheels to prevent crane movement. and the brake disc.
2. Start the engine, ensure the transmission is in neutral, Installation
and position the Park Brake switch to Off (press bottom
of switch). This will pressurize the brake actuator to 1. Position the brake over the disc and align mounting
release the tension on the brake linkage. Air pressure of bracket holes.
270 psi (1862 kPa) may be used to pressurize the
2. Thread the mounting bolts into the mounting bracket
actuator. Screw the caging nut up under the actuator
until the caliper is centered over the brake disc.
chamber.
3. Torque the jam nuts to 100 to 120 lb-ft (136 to 163 Nm)
3. Install the rod ball joint until the ball joint will just connect
against the mounting bracket.
to the brake linkage with the brake lever in a horizontal

7
position. 4. Connect the hydraulic hose to the actuator.
45
4. Lock the rod ball joint with the jam nut and back off the 5. Start the engine, ensure the transmission is in neutral,
caging nut. and position the Park Brake switch to Off (press bottom
of switch). This will pressurize the brake actuator to
5. Position the Park Brake switch to On (press top of
3
release the spring tension. Air pressure of 270 psi
switch) and shut down the engine.
(1862 kPa) may be used to pressurize the actuator.
23

Unscrew the caging nut from under the actuator

PARKING BRAKE chamber.

Description 6. Position the Park Brake switch to On (press top of

switch) and shut down the engine.
The parking brake is mounted on the transmission. The
brake is a disc-type brake that is controlled by a switch on
the front console in the cab and is spring-applied and
Procedure for Manually Releasing the
hydraulically released by an actuator. Parking Brake
NOTE: Refer to (Figure 8-28) and (Figure 8-30) during
Maintenance parking brake adjustment procedure.

Removal 1. Block wheels to prevent crane from moving.

1. Chock the wheels to prevent crane movement. 2. Remove the screw-in plug (1).
8
2. Start the engine, ensure the transmission is in neutral, 3. Loosen coupling nut (3).
and position the Park Brake switch to Off (press bottom 4. Back out socket setscrew (2) until brake is released.
of switch). This will pressurize the brake actuator to
release the tension on the brake linkage. Air pressure of

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UNDERCARRIAGE RT540E SERVICE MANUAL

5. While holding the socket setscrew (2), tighten the

coupling nut (3).
6. Reinstall the screw-in plug (1).
7. Place a tag in the cab stating the following:

DANGER
Parking brake mechanically released for towing. Do not
operate until parking brake is readjusted. Refer to Service
Manual for adjustment.

6857-1
FIGURE 8-28

7
3 45
23

6857-2
Item Description
1 Screw-in Plug
2 Socket Setscrew
2
3 Coupling Nut 3
FIGURE 8-29

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RT540E SERVICE MANUAL UNDERCARRIAGE

PARK BRAKE VALVE Functional Tests

Description 1. Start and idle engine.
2. 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. The valve is NOTE: For further information on the park brake valve,
located on the center of the frame. Pressure is supplied to refer to Section 2 - HYDRAULIC and PRESSURE
the valve from the transmission charge pump. SETTINGS.
The parking brake solenoid valve is a two position three-way
valve. In its de-energized position, the inlet port is blocked OUTRIGGERS
and the parking brake actuator is drained to the reservoir.
When the solenoid is energized, the reservoir port is blocked Outrigger Circuit
and pressurized oil is directed to the actuator, engaging the The outrigger circuit consists of four extension cylinders, four
parking brake. stabilizer cylinders, an integrated outrigger/rear steer valve,
The range shift solenoid valve is a two position four-way front and rear outrigger control manifolds, pilot operated
valve. In its de-energized position, pressurized oil flows to check valves and four Outrigger Monitoring System (OMS)
the “A” port of the range shift actuator, while the “B” port is ( O p t i o n a l — St a n d a r d i n N o r t h A m e r i c a ) s t r i n g
drained to the reservoir along with the axle disconnect potentiometers. The front two extension cylinders are
actuator for two wheel drive/high range. When the solenoid mounted in the front outrigger beams and the rear two
is energized, pressurized oil is directed to the “B” port of the extension cylinders are mounted in the rear outrigger beams.
range shift actuator and the axle disconnect actuator while The front and rear outrigger beams are mounted in their
port “A” of the range shift actuator is drained to the reservoir respective outrigger boxes; in turn a stabilizer cylinder is

7
for four wheel drive/low range. mounted on the end of each outrigger beam. The integrated
outrigger/rear steer valve is mounted on the front face of the
45
Removal carrier frame front cross member. The front and rear
outrigger control manifolds are mounted on the inside center
1. Tag and disconnect the electrical connectors to the of their respective outrigger box. An OMS string
valve.
3
potentiometer (if equipped) is mounted inside each outrigger
2. Tag and disconnect the hydraulic hoses from the valve. box. The potentiometer is connected by a cable to the
23

Cap or plug the lines and ports. outrigger beam to monitor the beam’s horizontal position—
fully retracted, mid-extend, or full extended.
3. Remove the capscrews, lockwashers, flatwashers and
nuts securing the valve to the frame. Remove the valve. The outrigger selector controls are located in the cab on the
front console. Both the integrated outrigger valve and the
Installation manifold solenoid valves are electrically actuated from these
controls. The solenoid switches must be depressed and held
1. Secure the valve to the frame with the nuts, flatwashers, to actuate the solenoid valves. The integrated outrigger
lockwashers and capscrews. Torque the capscrews 18 valve switch is spring loaded to the off position. The console
to 20 lb-ft (25 to 27 Nm). is placarded with switch positions.
2. Connect the hydraulic hoses to the ports on the valve as A sight bubble level is mounted on the left side of the cab by
tagged during removal. the door latch plate. The sight bubble level provides the
operator with a visual indication of crane level attitude.
3. Connect the electrical connectors to the valve as tagged
during removal.
Theory of Operation
8
NOTE: Refer to Section 3 - OPERATING CONTROLS and
PROCEDURES in the Operator Manual for
operation of the outrigger switches.

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UNDERCARRIAGE RT540E SERVICE MANUAL

Maintenance
Troubleshooting

Symptom Probable Cause Solution

1. Slow or erratic operation of a. Damaged relief valve. a. Remove relief valve; clean or
outrigger extension cylinders. replace.
b. Low hydraulic oil. b. Replenish oil to proper level.
Refer to LUBRICATION (pg 9-
1)
c. Sticking solenoid valve spool. c. Repair or replace valve spool.
d. Improper ground to base of d. Ground properly.
solenoid.
e. Damaged O-rings and swivel e. Remove swivel and replace
O-rings.
f. Directional selector switch f. Clean or replace switch.
sticking.
g. Collector ring dirty or glazed. g. Clean and deglaze collector
ring.
h. Damaged wiring to solenoid. h. Replace wiring.

7
i. Weak brush springs on i. Replace brush springs.
45
collector ring.
j. Damaged extension cylinder j. Remove extension cylinder
(internal parts). and repair as necessary.
3

k. Bent cylinder rods. k. Replace piston rods and

seals.
23

l. Excessive material on l. Clean outrigger beams.

outrigger beams.
m. Binding outrigger beam. m. Repair or replace outrigger
beam.
n. Damaged outrigger valve. n. Repair or replace valve.
o. Damaged valve coil. o. Replace coil.
p. Main hydraulic pump p. Replace or tighten hose or
cavitation. fitting.

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RT540E SERVICE MANUAL UNDERCARRIAGE

Symptom Probable Cause Solution

Slow or erratic operation of q. Partially shifted hydraulic q. Disassemble, clean, and
outrigger extension cylinders. spool in selector valve or polish spool and valve
(continued) manifolds. housing with very fine emery
cloth (water paper).
r. Insufficient voltage for r. Solenoids require a minimum
operation of solenoid valve. of 9.5 volts to energize. Check
outrigger wiring and electrical
coupling collector rings.
s. Damaged piston seals. s. Replace all cylinder seals.
t. Worn or damaged hydraulic t. Repair or replace pump
pump section. section.
u. Scored cylinder barrel. u. Repair or replace extension
cylinder.
v. Cracked or damaged piston. v. Replace rod weld and all
cylinder seals.
w. Piston loose on piston rod. w. Replace all cylinder seals and
torque piston locknut.
2. Sticking spool. a. Dirt in the system. a. Change oil and flush system.

7
b. Distortion caused by tie bolts b. Retorque tie bolts.
being overtorqued.
45
c. Flow in excess of valve rating. c. Limit flow through valve to that
recommended. Check pump
output and cylinder ratio.
3

d. Pressure in excess of valve d. Check relief valve setting or

rating. pump compensation with that
23

recommended.
e. Electrical failure. e. Check wiring and solenoids.
3. External leakage. a. Damaged O-ring or quad a. Check for chipped packings
rings. and replace.
b. Loose tie bolts. b. Retorque tie bolts.
c. Damaged solenoid. c. Replace damaged parts.
4. Solenoid failure. a. No current. a. Check power source of at
least 85% of coil rating.
b. Damaged solenoid assembly. b. Replace solenoid.
c. Short in solenoid. c. Replace coil.
d. Loss of solenoid force. d. Decrease time of solenoid
8
energization, decrease cycle
rate.

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UNDERCARRIAGE RT540E SERVICE MANUAL

Symptom Probable Cause Solution

5. Outrigger stabilizer cylinder slow a. Low in hydraulic oil. a. Replenish oil to proper level.
or erratic.
b. Damaged main relief valve. b. Repair or replace valve.
c. Damaged holding valve seals. c. Replace holding valve seals.
d. Bent cylinder rod. d. Replace cylinder rod and
seals.
e. Bent outrigger housing. e. Repair or replace outrigger
housing.
f. Excessive material on beams. f. Clean outrigger beams.
g. Sticking solenoid valve spool. g. Repair or replace valve spool.
h. Damaged wiring to solenoid. h. Repair or replace wiring.
i. Weak brush springs on i. Replace brush springs.
collector rings.
j. Collector ring dirty or glazed. j. Clean or deglaze collector
ring.
k. Directional selector switch k. Clean or replace switch.
sticking.
l. Main hydraulic pump l. Replace or tighten hose and

7
cavitation. fittings.
45
m. Worn or damaged hydraulic m. Repair or replace pump
pump section. section.
6. Outrigger stabilizer cylinder a. Damaged piston seals. a. Replace all cylinder seals.
retracts under load.
3
b. Damaged holding valve seals. b. Replace seals.
c. Damaged holding valve. c. Replace valve assembly.
23

d. Scored cylinder barrel. d. Repair or replace cylinder.

e. Cracked or damaged piston. e. Replace piston and all
cylinder seals.
7. Outrigger stabilizer cylinder a. Damaged piston seals. a. Replace all cylinder seals.
extends while machine is
b. Scored cylinder barrel. b. Replace jack cylinder.
traveling.
c. Cracked or damaged piston. c. Replace piston and seals.
d. Piston loose on cylinder rod. d. Replace seal and retorque.
8. Outrigger system will not activate a. Hydraulic oil low. a. Replenish system.
(from stowed or extended and
b. Loose or broken wire on b. Repair or replace wiring.
down position).
switch.
c. Clogged, broken, or loose c. Clean, tighten, or replace
lines or fittings. lines or fittings.
d. Damaged relief valve or d. Repair or replace valve.
damaged control valve.

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RT540E SERVICE MANUAL UNDERCARRIAGE

Symptom Probable Cause Solution

9. Outrigger system activates, but a. Clogged, broken, or loose a. 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. Repair or replace wiring.
control switch or solenoid
valve.
c. Damaged solenoid valve. c. Repair or replace valve.
d. Damaged control switch. d. Replace switch.
e. Damaged hydraulic cylinder. e. Repair or replace cylinder.
10. Outriggers will not set. a. Improper sequence of a. Activate individual control
activation. switch; then activate system
control switch.
11. Two outriggers activate from a. Damaged solenoid valves. a. Repair or replace.
single control switch.
12. The two outriggers will not stow. a. Hydraulic lock. a. Recycle individual
outrigger(s).
13. Individual outrigger will not set or a. Damaged piston seals. a. Replace seals.
stow.
b. Damaged check valve. b. Repair or replace valve.

7
c. Loosen or broken wire on c. Repair or replace wiring.
control switch or solenoid
45
valve.
d. Damaged solenoid valve. d. Repair or replace valve.

Outrigger Beam Maintenance

3

Removal
23

Description
1. On the stabilizer cylinder end of the beam, remove the
The outrigger beam assembly (Figure 8-30) consists of an
set screw from the side adjustable wear pad and back off
outrigger beam, a stabilizer cylinder, a extension cylinder,
the wear pad from the outrigger box.
and the required hoses and mounting hardware.
2. Remove the cover from the opposite end of the outrigger
Theory of Operation box. Remove the setscrew from the side adjustable wear
pad and back off the wear pad from the beam.
When the outrigger extension is activated, it extends or
retracts the outrigger beam within the outrigger box. The 3. Remove the setscrews from the bottom adjustable wear
outrigger beam can be extended to the mid-extend position pads and back off the wear pads leaving approximately
by allowing the lock pin to ride on the top of the beam while 0.23 in (6 mm) protruding
it’s extending. The lock pin will automatically drop into the
4. Extend the outrigger slightly to facilitate attaching a
hole when the beam reaches the mid-extend position.
The stabilizer cylinder is mounted to the end of the beam and
lifting device to the outrigger beam.
8
applies force to the outrigger beam vertically. This sequence
of events provides for lifting and stabilizing the crane for
operation. DANGER
Be sure any blocking material used is capable of
supporting the weight of the outrigger beam. Do not allow
it to tilt or slide. Failure to do so could result in death or
injury to personnel.

5. Place blocking material under the outrigger beam.

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UNDERCARRIAGE RT540E SERVICE MANUAL

14, 15

18

4, 5, 6

2, 3
14, 15

6759-3

7
17
16
2, 3
45
18 8, 9, 10, 11, 12, 13
7 FIGURE 8-30
3
23

Item Description Item Description

1 Outrigger Beam Assembly 10 Capscrew
2 Hex Nut 11 Plate
3 Capscrew 12 Wear Pad
4 Pin 13 Flatwasher
5 Hex Nut 14 Cotter Pin
6 Capscrew 15 Clevis Pin
7 Adjusting Plate 16 Extension Cylinder
8 Hex Nut 17 Cover
9 Setscrew 18 Stabilizer Cylinder

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RT540E SERVICE MANUAL UNDERCARRIAGE

5 4

7
2

7
FIGURE 8-30 continued
45
Item Description Item Description
1 Stabilizer Cylinder 5 Stabilizer Cylinder Retract Port
3

2 Extension Cylinder 6 Extension Cylinder Retract Port

23

3 Outrigger Beam 7 Extension Cylinder Extend Port

4 Stabilizer Cylinder Extend Port

NOTE: Outrigger removal and

installation similar for
both front and rear
outriggers.
NOTE: Lifting belts or straps
should be used for lifting
purposes so as to avoid 8
nicking or scratching the
bottom edges of the
6120-1
outrigger beam.

FIGURE 8-31

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UNDERCARRIAGE RT540E SERVICE MANUAL

6. Tag and disconnect the hydraulic lines at the cylinder 4. 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. outrigger beam.
NOTE: Do not allow the end of the outrigger extension 5. Slide the beam into the outrigger housing and align the
cylinder to fall when the cylinder mounting shaft is cylinder bushing with the mounting hole.
removed. Use blocking to limit the drop or an
6. Apply anti-seeze compound to the clevis pin. Secure the
adequate soft support to cushion any distance the
cylinder barrel to the housing with the clevis pin and
rod will drop.
cotter pin.
7. Remove the cotter pin and clevis pin securing the
cylinder barrel end of the extension cylinder to the
outrigger housing. Carefully extend the outrigger beam CAUTION
until the extension cylinder is free of the housing and Be sure that the piston side of all outrigger cylinders are
carefully lay the end of the cylinder on the bottom of the connected to the solenoid valve bank. Reversal of port
outrigger beam or leave on blocking. connection of the rod and piston sides could result in
8. After attaching a suitable lifting device of straps or belts severe damage to the cylinders as very high pressure
(Figure 8-31) instead of chains to prevent nicking the intensification will occur.
bottom edges of the outrigger beam, pull the outrigger
beam out of the outrigger box, re-adjusting the lifting
attachment to prevent the extension cylinder from sliding
out of the outrigger beam when the beam clears the CAUTION
outrigger box. During initial start-up and checking of the outrigger
operation, each control switch must be operated before

7
operating the selector valve. If hydraulic lines are
reversed to one or more cylinders, this will prevent
45
DANGER damage to the cylinders.
Be sure any blocking material used is capable of
7. Connect the hydraulic lines as tagged prior to removal.
supporting the weight of the outrigger beam. Do not allow
3
it to tilt or slide. Failure to do so could result in death or 8. Install the side adjustable wear pad in the outrigger box.
injury to personnel.
23

9. Adjust the wear pads, refer to WEAR PAD

ADJUSTMENT in this Sub-Section.
NOTE: The outrigger beam assembly weighs
approximately 824 lb (374 kg). 10. Install the end cover.
9. Position the outrigger beam on the blocking material. NOTE: At installation, be sure that the outrigger stabilizer
cylinder hydraulic hoses are not trapped against
Inspection
the outrigger box when the beam is fully retracted.
Inspect the outrigger beams for bends, evidence of cracks,
Wear Pad Adjustment.
or other damage. Check the outrigger beam internally for
hydraulic fluid, which may indicate a leaking cylinder, loose NOTE: When adjusting wear pads, refer to Wear Pad
connection, or damaged hydraulic line. Adjustment (Figure 8-32).
Installation 1. Adjust the bottom wear pads until a gap of 0.11 in
(3 mm) is obtained between the top of the beam and the
NOTE: Apply anti-seeze compound on clevis pins and
top of the outrigger box. Install and lock setscrew against
setscrews during installation.
wear pad.
1. Apply grease (EPMPG) to the bottom of the outrigger
2. Adjust outrigger box side wear pad until a gap of 0.07 in
beam.
(2 mm) is obtained between beam and shims welded in
2. If removed, install the side adjustable wear pad in the top and bottom of box. Install and lock set screw against
outrigger beam. wear pad.
3. Install the bottom wear pads with approximately 0.23 in 3. Adjust outrigger beam side wear pad until a gap of
(6 mm) protruding. This will prevent the beam side 0.07 in (2 mm) is obtained between shim welded on
plates from riding on the bottom of the box (Figure 8-32). beam and side of box. Install and lock set screw against
wear pad.

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RT540E SERVICE MANUAL UNDERCARRIAGE

Adjust for 2 mm (0.07inch)

gap with opposing shim

7
4
1, 2
45
3

7, 8
7, 8
3
6 mm (0.23 inch) of bottom wear pad
protruding before installing outrigger beam
23

FIGURE 8-32

force for the outrigger beam’s horizontal movement. The

cylinder weighs approximately 92.5 lb (42 kg).
Item Description
1 Capscrew Maintenance
2 Washer NOTE: Refer to Cylinders in Section 2 - HYDRAULIC AND
3 Plate PRESSURE SETTINGS for Disassembly and
Assembly of the cylinder.
4 Wear Pad
5 Wear Pad
Removal 8
6 Slotted Setscrew 1. Remove the outrigger beam. Refer to OUTRIGGER
BEAM - REMOVAL in this section.
7 Setscrew
2. Remove the cotter pin and clevis pin securing the rod
8 Hex Nut end of the extension cylinder to the outrigger beam.

Extension Cylinder 3. Pull the extension cylinder from the outrigger beam until
the hydraulic hoses on the rod end of the cylinder can be
Description accessed. Tag and disconnect the hoses from the rod
end of the cylinder. Cap or plug all openings.
Two outrigger extension cylinders are utilized within each
outrigger box assembly. The extension cylinders provide the 4. Remove the cylinder.

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UNDERCARRIAGE RT540E SERVICE MANUAL

Installation the force for the outrigger beam’s vertical movement. The
cylinder weighs approximately 142.4 lb (64.6 kg).
1. Place the cylinder in the beam.
NOTE: Keep hydraulic fittings and hoses close to angles Maintenance
shown (Figure 8-33) and as low as possible to
NOTE: Refer to CYLINDERS in Section 2 - HYDRAULIC
prevent rubbing with the beam top plate and side
and PRESSURE SETTINGS for Disassembly and
plate, and for proper tracking during beam
Assembly of the cylinders.
extension and retraction.
Removal
Fittings
1. Extend the outrigger beam slightly for improved access
Outrigger Beam
to the stabilizer cylinder; shut down the engine.
Hoses 2. Tag and disconnect the hydraulic hoses from the
stabilizer cylinder. Remove the fittings from the ports.
Cap or plug all openings.
3. Remove the nut and washer and remove the cylinder
cap.
4. Place a jack capable of supporting the weight of the
stabilizer cylinder at the base of the cylinder barrel. Jack
up the cylinder just enough to relieve any pressure on
the cylinder retaining pin.
5. Remove the cotter pins securing the cylinder retaining

7
NOTE: Keep hydraulic fittings and hoses close to pin and remove the cylinder retaining pin and cylinder
angles shown and as low as possible to cap retaining bracket.
45
prevent rubbing with the beam top plate and
6. Jack the stabilizer cylinder up just enough to insert the
side plate, and for proper tracking during
retaining pin back into the cylinder. Insert the retaining
beam extension and retraction.
pin into the lugs on the cylinder and secure the pin in
3

FIGURE 8-33 place with the cotter pins.

23

2. Position the extension cylinder so the hydraulic ports on

the rod end of the cylinder can be accessed. Connect CAUTION
the hydraulic hoses to the ports as tagged during Use a nylon strap to remove the cylinder. This will ensure
removal. the retaining pin is not damaged.
3. Push the cylinder into the outrigger beam. Align the
cylinder rod with the clevis in the beam. Apply anti-seeze 7. Fasten a nylon strap onto the cylinder retaining pin and
to the clevis pin and secure in place with the clevis pin use an adequate lifting device to lift the stabilizer
and cotter pin. cylinder out of the tube on the beam assembly.

4. Install the outrigger beam. Refer to OUTRIGGER BEAM Installation

- INSTALLATION in this section. 1. Apply grease (EPMPG) to the ID of the stabilizer
Functional Check cylinder support tube.

1. Activate the hydraulic system; extend and retract the 2. If removed, install wear ring in groove in bottom of
outrigger. support tube and in groove at top on stabilizer cylinder.

2. Observe the operation of the outrigger beam. 3. Place a jack beneath the cylinder tube on the outrigger
beam. Using the same method as described under
3. Check the hydraulic connections for any evidence of REMOVAL, lower the stabilizer cylinder into the cylinder
leakage. tube on the outrigger beam until the retaining pin is just
above the tube. Position the jack so that it will support
Stabilizer Cylinder the cylinder in this position. Remove the lifting device
from the cylinder.
Description
4. Remove the retaining pin and cotter pins from the
Four stabilizer cylinders are used on the crane, one at the cylinder.
end of each outrigger beam. The stabilizer cylinders provide

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RT540E SERVICE MANUAL UNDERCARRIAGE

5. Lower the jack until the holes in the cylinder rod align b. If oil continues to flow out the rod port, the cylinder’s
with the holes in the outrigger beam. internal piston seal is leaking.
6. Apply anti-seeze compound to the retaining pin. Secure
the cylinder and cylinder cap retaining bracket to the
support tube with the retaining pin and cotter pins.
Piston Port
7. Install the cylinder cap.
8. Install the fittings in the cylinder ports and connect the Rod Port
hoses as tagged during removal.
Functional Check
1. Activate the hydraulic system.
2. Extend and retract the stabilizer cylinder.
3. Check for smooth operation of the cylinder.
4. Check all hydraulic connections and hoses for evidence
of leakage.
Outrigger Stabilizer Cylinder Internal Leak Test
Use the following procedure to troubleshoot and diagnose an
6432
internal leak, a leaking pilot operated check valve or a
thermal contraction on an outrigger stabilizer cylinder.

7
45 FIGURE 8-34

3. After determining the condition of the cylinders internal

piston seal, let the rod side hose disconnected and
DANGER continue to test the pilot operated check valve.
Perform the following procedures with the crane
3
positioned on a firm level surface with outriggers fully Testing Pilot Operated Check Valve For Leakage
extended and set, and the crane in the travel position
1. Fully extend and set the outriggers.
23

Remove hoses from one cylinder at a time.

Checking Cylinder For Internal Piston Seal Leak CAUTION

1. Fully extend and set the outriggers. When performing step number 2, remove hose to adapter
connection slowly. Trapped pressure may exit between
the outrigger cylinder and the work port pilot operated
CAUTION check valves in the outrigger selector valve.
When performing step number 2, remove hose to adapter
connection slowly. Trapped pressure may exit between 2. Remove the piston side cylinder hose from the
the outrigger cylinder and the work port pilot operated suspected leaking stabilizer cylinder (see Figure 8-27).
check valves in the outrigger selector valve. Oil will flow until the cavity in the cylinder port block
empties. Once the port block cavity empties, oil should
2. Remove the rod side cylinder hose from the suspected
stop flowing from the piston side port.
8
leaking stabilizer cylinder (Figure 8-34). Oil will flow until a. If oil stops flowing, the cylinder’s pilot operated
the cavity in the cylinder port block empties. Once the check valve is sealing properly.
port block cavity empties, oil should stop flowing from
the rod side port. b. If oil continues to flow out the piston port, the
cylinder’s pilot operated check valve is leaking.
Check for the following conditions:
If oil flow is not noticed from either port, the cylinder and pilot
a. If oil stops flowing, the cylinder’s internal piston seal operated check valve are functioning properly, and any
is sealing properly. cylinder contraction during normal operation can be
attributed to thermal contraction of the oil.

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UNDERCARRIAGE RT540E SERVICE MANUAL

Outrigger Control Valves functions; the first function is a holding valve, the second
function provides a thermal relief of the stabilizer.
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. Refer to
valve, the front and rear outrigger control manifolds, and the Section 2 - HYDRAULIC and PRESSURE SETTINGS.
pilot operated check valves.
Outrigger Control Manifold
NOTE: For a more detailed description and maintenance
of the valves, refer to Valves in Section 2 - The front and rear outrigger control manifolds are located
HYDRAULIC and PRESSURE SETTINGS. on the respective outrigger boxes. Each manifold consists of
four 2 way solenoid valves.
Pilot Operated Check Valve
The pilot operated check valves are located in the outrigger
stabilizer port blocks. The check valve provides two

7
3 45
23

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RT540E SERVICE MANUAL LUBRICATION

SECTION 9
LUBRICATION

SECTION CONTENTS
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 Drive Train (continued) . . . . . . . . . . . . . . . . . . . . 9-11
Environmental Protection . . . . . . . . . . . . . . . . . . . 9-1 Outriggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13
Turntable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15
Lubrication Intervals . . . . . . . . . . . . . . . . . . . . . . . 9-1
Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-17
Arctic Conditions Below -18°C (0°F). . . . . . . . . . . 9-1
Boom (continued) . . . . . . . . . . . . . . . . . . . . . . . . 9-19
Arctic Conditions Down To -40°F.. . . . . . . . . . . . . 9-2
Hoist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-21
Surface Protection for Cylinder Rods . . . . . . . . . . 9-2
Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-23
Wire Rope Lubrication . . . . . . . . . . . . . . . . . . . . . . 9-3
Carwell® Rust Inhibitor. . . . . . . . . . . . . . . . . . . . . 9-25
Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . 9-4 Protecting Cranes From Rusting . . . . . . . . . . . . . 9-25
CraneLUBE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4 Cleaning Procedures . . . . . . . . . . . . . . . . . . . . . . 9-25
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
Inspection and Repair . . . . . . . . . . . . . . . . . . . . . 9-26
Steering and Suspension . . . . . . . . . . . . . . . . . . . 9-5 Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-26
Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7 Areas of Application. . . . . . . . . . . . . . . . . . . . . . . 9-26
Drive Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9

7
45
GENERAL • Immediately clean up any spills.

Following the designated lubrication procedures is important

3

LUBRICATION INTERVALS
in ensuring maximum crane lifetime and utilization. The
23

procedures and lubrication charts in this section include The service intervals specified are for normal operation
information on the types of lubricants used, the location of where moderate temperature, humidity, and atmospheric
the lubrication points, the frequency of lubrication, and other conditions prevail. In areas of extreme conditions, the
information. service periods and lubrication specifications should be
altered to meet existing conditions. For information on
ENVIRONMENTAL PROTECTION extreme condition lubrication, contact your local Grove
Distributor or Manitowoc Crane Care.
Dispose of waste properly! Improperly disposing of waste
can threaten the environment.
Potentially harmful waste used in Manitowoc cranes includes CAUTION
— but is not limited to — oil, fuel, grease, coolant, air Chassis grease lubricants must not be applied with air
conditioning refrigerant, filters, batteries, and cloths which pressure devices as this lubricant is used on sealed
have come into contact with these environmentally harmful fittings.
substances.
Handle and dispose of waste according to local, state, and
federal environmental regulations.
CAUTION
When filling and draining crane components, observe the The multipurpose grease installed during manufacture is
following: of a lithium base. Use of a noncompatible grease could
• Do not pour waste fluids onto the ground, down any result in damage to equipment. 9
drain, or into any source of water.
Arctic Conditions Below -18°C (0°F).
• Always drain waste fluids into leak proof containers that
are clearly marked with what they contain. In general, petroleum based fluids developed especially for
low temperature service may be used with satisfactory
• Always fill or add fluids with a funnel or a filling pump. results. However, certain fluids, such as halogenated

GROVE Published 2-26-2014, Control # 414-03 9-1

LUBRICATION RT540E SERVICE MANUAL

hydrocarbons, nitro hydrocarbons, and phosphate ester Standard Lubricants Package

hydraulic fluids, might not be compatible with hydraulic
system seals and wear bands. If you are in doubt about the Axle and Swing Box -- Century Unigear Semi-synthetic
suitability of a specific fluid, check with your authorized SAE 80W-90; Texaco Multigear SS 80W-90; Chevron DELO
Grove distributor or Manitowoc Crane Care. 80W-90; -- Spec 6829012964

NOTE: All fluids and lubricants may be purchased by Tier 3 Engine -- CI-4 Rated 15W-40 Engine Oil Exxon XD-3;
contacting the Manitowoc Crane Care Parts Conoco Fleet Supreme; -- Spec 6829003483
Department. Tier 4 Engine -- CJ-4 Rated 15W-40 Engine Oil; Conoco
Regardless of temperature and oil viscosity, always use Fleet Supreme EC; Mobil Delvac 1300 Super; -- Spec
suitable start-up procedures to ensure adequate lubrication 6829104182
during system warm-up. Hydraulic Tank and Transmission -- To meet John Deere
Standard JDM J20C – Hyden 052-10W-20; Exxon Torque
Arctic Conditions Down To -40°F. Fluid 56- 10W-20; Esso Torque Fluid 56- 10W-20; BP-
Eldoran UTH & Trak-Tran 9 – 10W20; BP- Blend- 7367 -
ALL Weather Package & Lubricants 10W20; Exxon Mobil 424- 10W-30 -- Spec 6829006444
Engineering recommends the following lubricants for Hoist -- AGMA No. 4 EP Extreme Pressure Gear Lube-
components for ambient temperatures to -40F. Special Mobil: Mobilfluid 629; Texaco: Meropa 150; -- Spec
lubricants alone are not sufficient to operate at extreme low 6829100213
temperatures. We also recommend the use of appropriately
sized heaters for the hydraulic tank, engine oil pan, engine Grease -- EP-MPG- Multipurpose Grease – Citgo Lithoplex
jacket water and batteries. The operator needs to follow the MP # 2; Texaco Starplex Moly # 2; Phillips 66 Philube M
guide lines as stated in the operator manual. We assume Grease; Mobil Mobilgrese XHP 222 Special, # 53055-0;

7
that the customer has take steps for use of an appropriate Chemtool Inc, Lube-A-Boom-Grease; -- Spec 6829003477
engine antifreeze coolant, have taken care of the fuel, fuel Open Gear Lube -- (bearing / swingdrive teeth -- FUCHS:
45
system and starting system. And has done whatever they CEPLATTYN 300 SPRAY -- Spec 6829102971
feel necessary to add insulation for under hood temperatures
and meet the engine manufacture's intake air temperature. Antifreeze Coolant -- AFC – 50/50 Old World Industries,
Inc. Fleet Charge SCA Pre-charged Antifreeze/Coolant;
3
Other lubricants may be used if they meet the specification of
the lubricant that is requested. Please consult factory. Caterpillar DEAC Antifreeze/Coolant; Fleetguard Complete
EG Antifreeze/Coolant; -- Spec 6829101130.
23

Axles and Swing Box -- Petro- Canada Traxon E Synthetic

75W-90; CITGO, Synthetic Gear Lube 75W-90; Eaton, Surface Protection for Cylinder Rods
Roadranger EP75W-90; Mobil, Mobilube SCH 75W-90;
Shell, Spirax S 75W-90; Sunoco Duragear EP75W-90; -- Steel cylinder rods include a thin layer of chrome plating on
Spec 6829014058 their surfaces to protect them from corroding. However,
chrome plating inherently has cracks in its structure which
Engine -- Petro-Canada Duron Synthetic CI-4- 5W-40; Mobil can allow moisture to corrode the underlying steel. At typical
Delvac 1, 5W-40; -- Spec 6829101560 ambient temperatures, hydraulic oil is too thick to penetrate
Hydraulic tank and Transmission -- Petro-Canada these cracks. Normal machine operating temperatures will
Duratran Synthetic THF; Chevron All Weather THF; Texaco allow hydraulic oil to warm sufficiently to penetrate these
TDH Oil SS; -- Spec 6829101559 cracks and if machines are operated daily, protect the rods.
Machines that are stored, transported, or used in a corrosive
Hoist -- Petro-Canada ENDURATEX Synthetic EP 150; environment (high moisture, rain, snow, or coastline
Mobil SHC629; -- Spec 6829103636 conditions) need to have the exposed rods protected more
Grease -- Petro-Canada Precision Synthetic EP1; Mobil: frequently by applying a protectant. Unless the machine is
Mobilith SHC 220; -- Spec 6829104275 operated daily, exposed rod surfaces will corrode. Some
cylinders will have rods exposed even when completely
Open Gear Lube -- (bearing/swingdrive teeth) ---Vultrex.... retracted. Assume all cylinders have exposed rods, as
OGL Synthetic All Season -- No Spec corrosion on the end of the rod can ruin the cylinder.
Antifreeze Coolant -- Petro-Canada AFC 60/40; Old World It is recommended that all exposed cylinder rods be
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.

9-2 Published 2-26-2014, Control # 414-03

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
WIRE ROPE LUBRICATION is used or lost. For more detailed information concerning the
lubrication and inspection of wire rope, refer to WIRE ROPE
Wire rope is lubricated during manufacturing so that the in Section 1- INTRODUCTION in the Service Manual.
strands, and individual wires in strands, may move as the

7
3 45
23

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LUBRICATION RT540E SERVICE MANUAL

LUBRICATION POINTS lubricated with oil once a week. Motor oil, applied sparingly,
will provide the necessary lubrication and help prevent the
A regular frequency of lubrication must be established for all formation of rust. An Anti-Seize compound may be used if
lubrication points. Normally, this is based on component rust has not formed, otherwise the component must be
operating time. The most efficient method of keeping track of cleaned first.
lube requirements is to maintain a job log indicating crane
usage. The log must use the engine hourmeter to ensure Grease fittings that are worn and will not hold the grease
coverage of lube points that will receive attention based on gun, or those that have a stuck check ball, must be replaced.
their readings. Other lubrication requirements must be made Where wear pads are used, cycle the components and
on a time basis, i.e. weekly, monthly, etc. relubricate to ensure complete lubrication of the entire wear
All oil levels are to be checked with the crane parked on a area.
level surface, ensuring that the hoist is level, and in transport
position. The oil must have settled for 20 minutes, with the CraneLUBE
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
Oil should be visible in sight glass, at least 1/16” from the top performance. Contact your Manitowoc Distributor for
or bottom of the sight glass. information about the Manitowoc’s CraneLUBE lubrication
program.
On all hoists with a check plug in the drum, the fill plug shall
be directly on top of the hoist, and the check plug level. Safety
All grease fittings are SAE STANDARD unless otherwise To lubricate many of the locations the engine will need to be
indicated. Grease non-sealed fittings until grease is seen started. After positioning areas of the unit for lubrication the
extruding from the fitting. One ounce (28 grams) of EP-MPG

7
engine must be turned off and the moved areas stable before
equals one pump on a standard one pound (0.45 kg) grease approaching.
gun.
45
Over lubrication on non-sealed fittings will not harm the
fittings or components, but under lubrication will definitely
lead to a shorter lifetime. WARNING
3

On sealed U-joints, care must be exercised to prevent Movement of the superstructure and the boom may
23

rupturing seals. Fill only until expansion of the seals first create a crushing and/or pinching hazard. Failure to
becomes visible. observe this warning could result in death or serious injury
if the message is ignored.
Unless otherwise indicated, items not equipped with grease
fittings, such as linkages, pins, levers, etc., should be

9-4 Published 2-26-2014, Control # 414-03

RT540E SERVICE MANUAL LUBRICATION

Steering and Suspension

Lube Point Figure Approved Lube
Item Lube Interval Application
Description No. Lubricant Capacity
EP-MPG
Extreme
Until
Steer Cylinder Pressure
1 Figure 9-1 grease 500 hours or 3 months 8 grease fittings
Pivot Pins Multipurpose
extrudes
Grease
A6-829-003477
EP-MPG
Extreme
Until
Upper and Lower Pressure
2 Figure 9-1 grease 500 hours or 3 months 8 grease fittings
King Pins Multipurpose
extrudes
Grease
A6-829-003477
EP-MPG
Extreme
Until
Fifth Wheel Pressure
3 Figure 9-1 grease 500 hours or 3 months 2 grease fittings
Pivots Multipurpose
extrudes
Grease

7
A6-829-003477
EP-MPG
45
Extreme
Until
Lockout Cylinder Pressure
4 Figure 9-1 grease 500 hours or 3 months 4 grease fittings
Pivot Pins Multipurpose
extrudes
3
Grease
A6-829-003477
23

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LUBRICATION RT540E SERVICE MANUAL

7
3 45
23

4 6818-2
1
2 1 3 6818-1

FIGURE 9-1

9-6 Published 2-26-2014, Control # 414-03

RT540E SERVICE MANUAL LUBRICATION

Lube Point Figure Approved Lube

Item Lube Interval Application
Description No. Lubricant Capacity
Axles
• Check level every
GL-5 500 hours or 3
Extended months Fill to bottom of hole
Axle Tech 20.8 l
6 Figure 9-2 Service Interval in housing on the
Differentials 44 pt • Drain and fill every
Gear Lubricant steer cylinder side
A6-829-012964 4000 hours or 2
years
• Check level every
GL-5 500 hours or 3
Extended months Fill to bottom of hole
Kessler 18.9 l
7 Figure 9-2 Service Interval in housing on the
Differentials 40 pt • Drain and fill every
Gear Lubricant steer cylinder side
A6-829-012964 4000 hours or 2
years
NOTE: Lube level close enough to the hole to be seen or touched is not sufficient. It must be level with the hole.
When checking lube level, also check and clean housing breathers.
CAUTION: Use of non-approved lubricant may damage components and/or invalidate published lubricant intervals.
CAUTION: If the makeup amount is substantially more than 0.23 l (0.5 pt), check for leaks.

7
• Check level every
GL-5 Fill to the bottom of
45
Axle Tech 500 hours or 3
Extended months the level hole in the
Planetary Hubs 3.1 l
9 Figure 9-2 Service Interval housing with the fill
and Wheel 6.5 pt • Drain and fill every
Gear Lubricant plug and the oil level
Bearings 4000 hours or 2
3
A6-829-012964 mark horizontal.
years
23

• Check level every

GL-5 500 hours or 3 Fill to the bottom of
Kessler
Extended months the level hole in the
Planetary Hubs 1.18 l
11 Figure 9-2 Service Interval housing with the fill
and Wheel 2.5 pt • Drain and fill every
Gear Lubricant plug and the oil level
Bearings 4000 hours or 2
A6-829-012964 mark horizontal.
years
CAUTION: Use of non-approved lubricant may damage components and/or invalidate published lubricant intervals.

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LUBRICATION RT540E SERVICE MANUAL

7
3 45
23

9, 11

6, 7 6818-45

FIGURE 9-2

9-8 Published 2-26-2014, Control # 414-03

RT540E SERVICE MANUAL LUBRICATION

Lube Point Figure Approved Lube

Item Lube Interval Application
Description No. Lubricant Capacity
Drive Train
EO-15W/40 • Check level
Engine Oil • Check level every 10
through dipstick.
13a a. Engine SAE 15W-40 hours or daily
16.3 l • Fill engine oil
Crankcase Figure 9-3 Tier 3: • Drain, fill and replace
17.3 qt through fill cap on
13b b. Filter 6829003483 filter every 500 hours
Tier 4: engine valve
or 6 months
6829104182 cover.

• Check level every 10

hours or daily
• Drain and refill every
a. Transmission, 1000 hours or 6
14a HYDO Through fill pipe to
Torque 23.6 l months
Figure 9-3 Hydraulic Oil FULL mark on
Converter 25 qt • Change transmission
14b A6-829-006444 dipstick
b. Filter filter after first 50 and
100 hours of service,
then every 500 hours
thereafter

7
NOTE:
45
• Check fluid level with engine running at 1000 rpm idle and the oil at 82 to 93° C (150 to 200 ° F). Do not attempt an oil level check
with cold oil. To bring the oil temperature to this range, it is necessary to either work the crane or stall the converter. Converter
stall should be accomplished by engaging shift lever in forward high range with the brakes applied and then accelerating the
engine to half or three-quarter throttle. Hold the stall until the required converter temperature is reached and stabilized.
3

Do not operate the converter at stall condition for longer than 30 seconds at one time. Shift to neutral for 15 seconds and repeat
the procedure until the desired temperature is reached. Excessive temperature, i.e, 120° C (250° F) maximum will cause damage
23

to transmission clutches, fluid, converter and seals.

• Drain and fill with the oil at 65 to 93° C (150 to 200° F).
• Transmission filters are located on the outside left hand frame in the area of the hydraulic oil cooler.
• To add fluid:
a. Fill to FULL mark on dipstick
b. Run engine at 800 rpm to prime torque converter and lines
c. Check oil level with engine running at 800 rpm and oil at 82 to 93° C (180 to 200° F). Add oil to bring oil level to
FULL mark on dipstick.
• Fill surge tank to
AFC 50/50 center of sight
50/50 Blended • Check coolant level
glass. Run engine
Fully every 10 hours or
Engine Cooling 19.8 l through two (2)
15 Figure 9-3 Formulated daily
System 21 qt thermal cycles.
Antifreeze • Drain and fill every
Coolant • Check coolant
2000 hours or 1 year
A6-829-101130 level and refill as
required.
Change strainer screen
9
after first 100 hours and Close shutoff valves.
Coolant Strainer (Figure 9-
16 --- --- every 2000 hours or 12 Unscrew hex plug to
(Cab Heater) 3)
months intervals clean filter.
thereafter.

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LUBRICATION RT540E SERVICE MANUAL

13b 14b

Dipstick 13a 6818-36

16 6813-7

7
Other Side
3 45
23

Other Side

15

6818-40
14a 6818-29

FIGURE 9-3

9-10 Published 2-26-2014, Control # 414-03

RT540E SERVICE MANUAL LUBRICATION

Lube Point Figure Approved Lube

Item Lube Interval Application
Description No. Lubricant Capacity
Drive Train (continued)
EP-MPG
Extreme
Until
Driveline - Slip Pressure
17 Figure 9-4 grease 500 hours or 3 months 3 grease fittings
Joints Multipurpose
extrudes
Grease
A6-829-003477
• Replace/Clean filter
element when
indicator shows red
(25” H20). Remove panel
(Figure 9-
52 Air Cleaner Filter --- --- • View indicator behind ladder to
4)
through grill from rear access air filter.
of crane.
• Refer to Service
Manual
• Change filter every • Fuel filter is

7
500 hours or 6 located on the
Fuel Filter/Water (Figure 9- months. intake manifold of
53 --- ---
45
Separator 4) • Drain water trap engine.
every 10 hours or • Strainer is located
daily. near battery box.
3
23

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LUBRICATION RT540E SERVICE MANUAL

52 6818-38

Other Side

7
3 45
23

Other Side

53 6818-29
17 6818-8

17 6818-43

FIGURE 9-4

9-12 Published 2-26-2014, Control # 414-03

RT540E SERVICE MANUAL LUBRICATION

Lube Point Figure Approved Lube

Item Lube Interval Application
Description No. Lubricant Capacity
Outriggers
EP-MPG
Extreme
Brush lubricant on
Pressure
18 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
Jack Cylinder Pressure barrel and wear
19 Figure 9-5 --- 50 hours or 1 week
Support Tubes Multipurpose band before
Grease installing jack
A6-829-003477 cylinders
EP-MPG Brush lubricant on
Extreme OD of jack cylinder
Jack Cylinder Pressure support tubes (4)
51 Figure 9-5 --- 50 hours or 1 week
Barrels Multipurpose places before
Grease installing jack

7
A6-829-003477 cylinders
3 45
23

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LUBRICATION RT540E SERVICE MANUAL

7
3 45
18
23

19

51

6818-9

FIGURE 9-5

9-14 Published 2-26-2014, Control # 414-03

RT540E SERVICE MANUAL LUBRICATION

Lube Point Figure Approved Lube

Item Lube Interval Application
Description No. 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
20 Figure 9-6 Service Interval dipstick, fill to top of
Box 4.25 qt first 250 hours and
Gear Lubricant case.
A6-829-012964 every 500 hours or
12 months thereafter.
EP-OGL
Turntable Gear Open Gear Coat all
21 Figure 9-6 500 hours or 6 months Spray on
and Drive Pinion Lubricant teeth
A6-829-102971
Turntable Swivel Not shown EP-OGL
Lock Pin Open Gear
21a Coat pin 500 hours or 6 months Spray on
Lubricant
A6-829-102971
Until
EP-MPG
grease
Extreme

7
extrudes 2 grease fittings at
Turntable Pressure
22 Figure 9-6 the whole 500 hours or 6 months the front of the
Bearing Multipurpose
45
circumfer- turntable
Grease
ence of the
A6-829-003477
bearing
3
NOTE: Rotate the turntable 90° and apply grease to fittings. Continue rotating 90° and grease the fittings until the whole
bearing is greased.
23

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LUBRICATION RT540E SERVICE MANUAL

20

22 6818-11

6818-10
Dipstick

7
3 45
23

21 6818-44

FIGURE 9-6

9-16 Published 2-26-2014, Control # 414-03

RT540E SERVICE MANUAL LUBRICATION

Lube Point Figure Approved Lube

Item Lube Interval Application
Description No. Lubricant Capacity
Boom
EP-MPG
Extreme Pressure Until
Upper Lift
25 Figure 9-7 Multipurpose grease 500 hours or 3 months 2 grease fittings
Cylinder Pin Grease extrudes
A6-829-003477
EP-MPG Extreme
Pressure Until
Hook Block
29 Figure 9-7 Multipurpose grease 250 hours or 3 months 1 grease fitting
Swivel Bearing Grease extrudes
A6-829-003477
EP-MPG Extreme 4 grease fittings - 35
Pressure Until
Hook Block Tons
30 Figure 9-7 Multipurpose grease 250 hours or 3 months
Sheaves Grease
3 grease fittings - 35
extrudes
A6-829-003477 Tons
EP-MPG Extreme 2 places by brush
Telescope Pressure
Thoroughly Every boom teardown Extend boom for
31 Cylinder Wear Figure 9-7 Multipurpose
Grease coat or 125 hours/3 months access through
Pads

7
A6-829-003477 holes
Thoroughly
EP-MPG Extreme
45
Pressure coat all 12 places by brush;
32 Side Wear Pads Figure 9-7 Multipurpose areas the 250 hours or 3 months with boom in
Grease wear pad extended position
A6-829-003477
3
moves on
Thoroughly 6 places by brush;
23

EP-MPG Extreme
Boom Section Pressure coat all with boom in
33 Upper Wear Figure 9-7 Multipurpose areas the 50 hours or 1 week extended position
Pads Grease wear pad through access
A6-829-003477 moves on holes

EP-MPG Extreme Thoroughly

Boom Section Pressure coat all 3 places by brush;
34 Lower Wear Figure 9-7 Multipurpose areas the 50 hours or 1 week with boom in
Pads Grease wear pad extended position
A6-829-003477 moves on
EP-MPG Extreme 3 grease fittings
Pressure Until
Extend Cable Extend boom for
35 Figure 9-7 Multipurpose grease 250 hours or 3 months
Sheaves Grease access through
extrudes
A6-829-003477 holes
EP-MPG Extreme
Pressure Until
Retract Cable
36 Figure 9-7 Multipurpose grease 250 hours or 3 months 4 grease fittings
Sheaves Grease extrudes
A6-829-003477

NOTE: Lubricate items more frequently than interval indicated in table if environmental conditions and/or operating
9
conditions necessitate.

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LUBRICATION RT540E SERVICE MANUAL

33 33
32

32

34
34
34

34

34
35 31

36 7181-1
7181-2

7
3 45
23

30

6818-21

29

25 6818-42

6818-13

6818-26
31
FIGURE 9-7

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RT540E SERVICE MANUAL LUBRICATION

Lube Point Figure Approved Lube

Item Lube Interval Application
Description No. Lubricant Capacity
Boom (continued)
EP-MPG
Extreme
Until
Pressure
37 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
Boom Extension (Figure 9- Pressure
38 grease 250 hours or 3 months 1 grease fitting
Sheave 8) Multipurpose
extrudes
Grease
A6-829-003477
EP-MPG
Extreme
Until
Boom Extension Pressure
39 Figure 9-8 grease 250 hours or 3 months 4 grease fittings
Roller Multipurpose
extrudes
Grease

7
A6-829-003477
EP-MPG
45
Extreme
Until
Upper Boom Pressure
40 Figure 9-8 grease 250 hours or 3 months 1 grease fitting
Nose Sheave Multipurpose
extrudes
3
Grease
A6-829-003477
23

EP-MPG
Extreme
Until
Lower Boom (Figure 9- Pressure
41 grease 250 hours or 3 months 1 grease fitting
Nose Sheave 8) Multipurpose
extrudes
Grease
A6-829-003477
EP-MPG
Extreme
Until
Auxiliary Boom (Figure 9- Pressure
42 grease 250 hours or 3 months 1 grease fitting
Nose Sheave 8) Multipurpose
extrudes
Grease
A6-829-003477
EP-MPG
Extreme
Until
(Figure 9- Pressure
43 Mast Sheave grease 500 hours or 12 months 1 grease fitting
8) Multipurpose
extrudes
Grease
A6-829-003477
9

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LUBRICATION RT540E SERVICE MANUAL

40

41

42

37 6818-17 6818-41

7
3 45
23

38

39
43

6818-31

6818-30

FIGURE 9-8

9-20 Published 2-26-2014, Control # 414-03

RT540E SERVICE MANUAL LUBRICATION

Lube Point Figure Approved Lube

Item Lube Interval Application
Description No. Lubricant Capacity
Hoist
AGMA • Check and fill every
50 hours or weekly Oil level must be
Extreme
5.2 l (5.5 visible in the sight
45 Main Hoist Figure 9-9 Pressure Gear • Drain and fill every
qt) glass, within 1/16”
Lubricant 1000 hours or 12 from top or bottom
A6-829-100213 months
AGMA • Check and fill every
50 hours or weekly Oil level must be
Extreme
5.2 l (5.5 visible in the sight
46 Auxiliary Hoist Figure 9-9 Pressure Gear • Drain and fill every
qt) glass, within 1/16”
Lubricant 1000 hours or 12 from top or bottom
A6-829-100213 months
NOTE: If oil level is not visible in sight glass, the hoist may be under filled. Oil escaping from vent plug is an indication the
hoist may be overfilled.
EP-MPG
Extreme
Cable Follower Pressure Thoroughly
47 Figure 9-9 250 hours or 3 months Spray on
(Arms) Multipurpose coat

7
Grease
A6-829-003477
45
NOTE: Lubricate more frequently than interval indicated in table if environmental conditions and/or operating conditions
necessitate.
3
23

GROVE Published 2-26-2014, Control # 414-03 9-21

LUBRICATION RT540E SERVICE MANUAL

7
46 47 45 47
3 45
23

6818-17

FIGURE 9-9

9-22 Published 2-26-2014, Control # 414-03

RT540E SERVICE MANUAL LUBRICATION

Lube Point Approved Lube

Item Figure No. Lube Interval Application
Description Lubricant Capacity
Hydraulic
• Use sight gauge
on side of tank,
with boom down
HYDO and all outrigger
397.4 l Check fluid level every
48 Hydraulic Tank Figure 9-10 Hydraulic Oil cylinders
(105 gal) 10 hours or daily.
A6-829-006444 retracted.
• Drain and refill as
necessary
NOTE: Environmental and other conditions can dramatically affect the condition of hydraulic oil and filters. Therefore,
specific intervals for servicing/changing hydraulic oil, filters and hydraulic tank breathers cannot be set. However,
it is imperative for the continued satisfactory performance of Grove cranes that inspections be performed on the
basis of how and where each crane is used. Air borne and ingested contaminants can significantly reduce the life
of oil and the condition of hydraulic oil filters and tank breathers.
• Under normal operating conditions, it is recommended that hydraulic oil, filters and breathers be inspected
and oils sampled at least every 3 to 6 months and more frequently for severe operating conditions. The
inspections should be for air borne and/or ingested particles and water that deteriorate and contaminate the
oil (e.g., oil appears “milky” or no longer has a transparent clear to amber color). The return filter by-pass

7
indicator should be observed daily to determine if the contaminants content may be high. If the indicator
reaches the red zone or indicates a by-pass condition, the hydraulic oil must be sampled. The hydraulic tank
45
breather should also be inspected to assure that it is not restricting air flow into and out of the reservoir.
• To inspect hydraulic oil, fill a small glass container with a sample of reservoir oil and another glass container
with fresh oil. Let the samples stand, undisturbed, for one to two hours and then compare the samples. If the
3

reservoir oil is heavily contaminated with water the sample will appear "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
23

closely match the fresh oil. Should you have any questions, please contact your local authorized Manitowoc
distributor.
• The hydraulic oil shall meet or exceed ISO #4406 class 17/14 cleanliness level.
HYDO
Change filter when the
49 Hydraulic Filter Figure 9-10 Hydraulic Oil --- ---
indicator is red
A6-829-006444

GROVE Published 2-26-2014, Control # 414-03 9-23

LUBRICATION RT540E SERVICE MANUAL

7
45
49
3
23

48

FIGURE 9-10

9-24 Published 2-26-2014, Control # 414-03

RT540E SERVICE MANUAL LUBRICATION

CARWELL® RUST INHIBITOR

Protecting Cranes From Rusting 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.
demanded by today's industry. In partnership with our paint
supplier, we are also doing our part to help prevent Exercise special care and increase the frequency of cleaning
premature corrosion of cranes. if the crane is operated:

Grove cranes will be treated with a rust inhibitor called • on roads where large quantities of salt or calcium are
Carwell® T32-CP-90. While a rust inhibitor cannot guarantee applied to treat icy and snowy road surfaces;
that a machine will never rust, this product will help protect • in areas that use dust control chemicals;
against corrosion on Grove cranes that are treated with this
• anywhere there are increased levels of wetness -
product.
especially near salt water;
Carwell is a treatment, not a coating. It contains no silicones,
• during prolonged periods of exposure to damp
solvents, CFCs or anything that would be classified as
conditions (e.g., moisture held in mud), where certain
hazardous under OSHA Regulation 29CRF-19-10.1200. The
crane parts may become corroded even though other
product is a liquid blend of petroleum derivatives, rust
parts remain dry; or
inhibitors, water-repelling and water-displacing agents.
• in high humidity, or when temperatures are just above
Special equipment is used to spray a light film onto the entire
the freezing point.
undercarriage and various other areas of each new crane
prior to shipment. When applied the product has a red tint to

7
Cleaning Procedures
allow applicators to view coverage during application. This
red tint will turn clear on its own within approximately 24 To help protect against corrosion of Grove cranes,
45
hours after application. Manitowoc Crane Care recommends washing the crane at
least monthly to remove all foreign matter. More frequent
Once applied, treatment can appear to leave a slightly “oily”
cleaning may be needed when operating in harsh
residue on painted surfaces and until the red tinting fades
3
environmental conditions. To clean the crane, follow these
could initially be mistaken for a hydraulic oil leak. While the
guidelines:
product is not harmful to painted surfaces, glass, plastic or
23

rubber, it must be removed using standard steam-cleaning • High pressure water or steam is effective for cleaning
techniques. the crane's undercarriage and wheel housings. Keeping
these areas clean will not only help retard the effects of
This treatment works in various ways: (1) it eliminates the
corrosion, but will also improve the ability to identify
moisture containing salt, dirt and other pollutants by lifting
and removing them from the metal surface; (2) the film potential issues before they grow into larger problems.
creates a barrier to repel further moisture from coming in
contact with the metal; and (3) it penetrates crevices.
In addition to the factory-applied treatment, Grove crane CAUTION
owners must provide proper maintenance and care to help High pressure water can be forced into spaces and
ensure long-term protection of their crane against corrosion. infiltrate beyond seals. Avoid pressure washing in the
This procedure provides information and guidelines to help vicinity of electrical controls, panels, wiring, sensors,
maintain the paint finish on Grove cranes. hydraulic hoses and fittings, or anything that can be
damaged by high pressure cleaning/spraying.
The most common causes of corrosion include the following:
• Road salts, chemicals, dirt, and moisture trapped in the • Rinse the dirt and dust off before washing the crane. Dirt
hard-to-reach areas; can scratch the crane's finish during washing/cleaning.

• Chipping or wear of paint, cased by minor incidents or • Hard to clean spots caused by road tar or bugs should
moving components; be treated and cleaned after rinsing and prior to
washing. Do not use solvents or gasoline.
9
• Damage caused by personal abuse, such as using the
decks to transport rigging gear, tools, or cribbing; and • Wash using only soaps and detergents recommended
for automotive paint finishes.
• Exposure to harsh environmental hazards such as
alkaline, acids, or other chemicals that can attack the • Rinse all surfaces thoroughly to prevent streaking
crane's paint finish. caused by soap residue.

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LUBRICATION RT540E SERVICE MANUAL

• Allow the crane to dry thoroughly. You can accelerate Spots should be touched up with quality paint. Primers tend
drying by using compressed air to remove excess water. to be porous; using a single coat of primer only will allow air
and water to penetrate the repair over time.
NOTE: Polishing and waxing (using an automotive-type
wax) is recommended to maintain the original paint Application
finish.
Depending upon the environment in which a crane is used
Inspection and Repair and/or stored, the initial factory application of Carwell T32-
CP-90 should help inhibit corrosion for up to approximately
• Immediately following cleaning, Manitowoc Crane Care
12 months.
recommends an inspection to detect areas that may
have become damaged by stone chips or minor It is recommended that the treatment be periodically
mishaps. A minor scratch (one that has not penetrated reapplied by the crane owner after that time to help continue
to the substrate surface) can be buffed with an to protect against corrosion of the crane and its components.
automotive-type scratch remover. It is recommended
However, if a crane is used and/or stored in harsh
that a good coat of automotive wax be applied to this
environments (such as islands, coastal regions, industrial
area afterwards.
areas, areas where winter road salt is regularly used, etc.),
• All identified spots and/or areas that have been reapplication of treatment is recommended sooner than 12
scratched through to the metal should be touched up months, e.g., repeat treatment in 6-9 months.
and repaired as soon as possible to prevent flash
• Do not apply to recently primered and painted areas for
rusting. To repair a major scratch (down to bare metal) or
at least 48 hours after paint is properly dried and cured.
minor damage, follow these procedures:
For minor touch up areas a 24 hour period is needed for
NOTE: Manitowoc Crane Care recommends that a cure time before applying treatment.

7
qualified body repairman prepare, prime and paint
NOTE: Unit must be completely dry before applying
any major scratch(es) or minor damage. treatment.
45
• Do not allow product to puddle or build-up on weather
stripping, rubber gaskets, etc. Unit should not have
CAUTION puddles or runs evident anywhere.
3
To the extent any damage is structural in nature,
Manitowoc Crane Care must be contacted and consulted • To ensure proper coverage of treatment, the product
23

as to what repairs may be required. needs to be fogged on the unit.

• Use of pressure pots to apply the treatment to the unit
• For scratches and marks in highly visible areas: being processed is recommended.
• Sand to remove the scratch and feather outward from • Carwell treatment is available in 16 ounce spray bottles
the mark to blend the repair into the original surface. from Manitowoc Crane Care (order part number
Body putty may be applied as necessary to hide the 8898904099).
defect; then sand smooth.
• After application of the treatment is complete, wash or
• Cover all bare metal with a primer that is compatible with clean film residue from lights, windshield, grab handles,
the original paint finish ladders/steps and all access areas to crane, as
• and allow to dry thoroughly. necessary.

• Prepare the surface prior to applying the finish coat of Please contact Manitowoc Crane Care should you have any
paint. questions.

• Apply a finish coat paint using accepted blending Areas of Application

techniques. Use of original paint colors is recommended
to insure the best color match possible. Refer to Figure 9-11 and Figure 9-12.

For scratches and marks in areas of low visibility: • The underside of the unit will have full coverage of the
rust inhibitor. These are the only areas that a full coat of
• Consider touching up the spots with a brush technique the rust inhibitor is acceptable on the painted surfaces.
to cover the bare metal. This will retard the effects of Areas include; Valves, hose end and fittings, Swivel,
corrosion and enable you to do the repair at a later time pumps, axles, drive lines, transmission, slew ring
during a normal maintenance interval. fasteners and all interior surfaces of the frame.

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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. headache ball pins/ hook block pins and fasteners.
• Superstructure applications are; hose end and fittings, • All hardware, clips, pins, hose connections not painted
wire rope on hoist roller tensioning springs on hoists, all will have treatment applied.
unpainted fasteners and hardware, valves, slew ring
fasteners and all bare metal surfaces.

7
3 45
23

GROVE Published 2-26-2014, Control # 414-03 9-27

LUBRICATION RT540E SERVICE MANUAL

7
1
45
5

17
3
6
23

16 8

15 9

14 13 12 11 10

7650-7
FIGURE 9-11

9-28 Published 2-26-2014, Control # 414-03

RT540E SERVICE MANUAL LUBRICATION

18

19

20

22

9
9

7
45
8
3

12
23

21 11

FIGURE 9-12

Item Description
Item Description 9 O/R Hose Connections
1 Hoist Tension Springs 10 Hookblock Tie Down Cable
2 Boom Extension Pins, Clips 11 O/R Pins, Clips
3 Boom Nose Pins, Clips 12 O/R Beam Wear Pad Adjustment Hardware
4 Hook Block/ Headache Ball 13 Turntable Bearing Fasteners
5 Boom Extension Hanger Hardware 14 Entire underside of unit 9
6 Pivot Shaft 15 Power Train Hardware inside compartment
7 Hose Connections inside turntable 16 Valve Bank
All Hardware, Clips, Pins, Hose Connections 17 Hoist Hose Connections
8
not painted O/R Pins, Clips 18 Wire Rope

GROVE Published 2-26-2014, Control # 414-03 9-29

LUBRICATION RT540E SERVICE MANUAL

Item Description
19 Counterweight Mounting Hardware
20 Counterweight Pins
21 Hose Connections
22 Mirror Mounting Hardware

7
3 45
23

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RT540E SERVICE MANUAL

Alphabetical Index

Accessory With Swing Directional Control Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34

Air Intake And Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
Axle Oscillation Lockout Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66
Axle Oscillation Lockout Valve (Optional Ce Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54
Axle Oscillation Lockout Valve (Standard Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53
Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Boom Assembly Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Boom Extension Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Boom Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36
Boom Nose Sheaves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Boom Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Boom Retract Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Boom System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16
Brake Test Procedure For Hp15c-17g, Ho30a-19g, Hp35-26g Hoists . . . . . . . . . . . . . . 5-7
Carwell® Rust Inhibitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-25
Check Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51
Counterweight Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Cross Axle Differential Lock Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56

7
Directional Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31
Drive Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
45
Dual Accumulator Charge Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40
Dual Rod Telescope Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62
Electronic Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
3

Environmental Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

23

Extension And Retraction Cable Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37

Final Boom Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31
Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
General Maintenance Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
General Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Hoist Drum Rotation Indicator System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Hoist Maintenance And Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Hoist To Boom Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Holding Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43
Hydraulic Accumulator Service Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42
Hydraulic Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Idler Drum And Cable Follower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Integrated Outrigger/rear Steer Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Lift Circuit Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40
Lift Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Lift Cylinder Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42
Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-59
List Of Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Lubrication Intervals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
Oil Cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Outrigger Control Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46
Outrigger Extension Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-73
Outrigger Stabilizer Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-75

GROVE APL-1
SERVICE MANUAL RT540E

Outriggers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27
Park Brake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27
Parking Brake Actuator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24
Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-25
Pilot Operated Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47
Piston Motor And Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Pressure Setting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Preventive Maintenance And Oil Sampling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Range Shift/parking Brake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52
Rear Axle Oscillation Lockout System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
Service Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18
Steer Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-70
Steering Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37
Steering Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
Supply Pressure And Return Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Swing Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Swing Gearbox And Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Swing Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Swingaway Extension Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
Swingaway Extension Removable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Swivels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Tandem Brake Valve With Treadle Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38
Telescope Circuit Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38
Telescope Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

7
Tensioning The Boom Extend And Retract Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
45
Theory Of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28
Water Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
3

Wire Rope Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3

Wire Rope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
23

APL-2
23
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23
345
7