Manitowoc Grove Crane RT540E (40 TON) Spare Parts Manual SN 258110 – PDF DOWNLOAD
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Manitowoc Grove Crane RT540E (40 TON) Spare Parts Manual SN 258110 – PDF DOWNLOAD
Language : English
Pages : 773
Downloadable : Yes
File Type : PDF
TABLE OF CONTENTS:
Manitowoc Grove Crane RT540E (40 TON) Spare Parts Manual SN 258110 – PDF DOWNLOAD
1 2159910216 BOOM ASSEMBLY – 4 SECTION 11
(COMPLETE ASSEMBLY)
6372100507 CYLINDER ASSEMBLY – TELESCOPE 17
(COMPLETE ASSEMBLY)
6718100031 SHEAVE ASSEMBLY – 5/8″ ROPE 21
5 7598100094 KIT INSTALLATION – iFLEX 5 LMI BOOM 25
9333103873 CABLE REEL LWG508 – IFLEX 5 27
9333103565 BOX ASSEMBLY – JUNCTION 29
9333102633 FLAG ASSEMBLY – A2B 31
RETAINER
(COMPLETE ASSEMBLY)
9333102765 CONNECTOR ASSEMBLY 33
DUMMY PLUG, 2-PIN
5 3486000212 WEIGHT AND CHAIN ASSEMBLY 35
(COMPLETE ASSEMBLY)
7 7598100003 EXTENSION KIT INSTALLATION – 37
BOOM
9333102768 JUNCTION BOX ASSEMBLY – 39
80MM X 75MM, PG9 + 2-PIN
7 7086100148 HOOK BLOCK ASSEMBLY – 40 TON 41
3 SHEAVE
(COMPLETE ASSEMBLY)
8 6978100608 LMI BOOM INSTL KIT – iFlex 5 45
8 7053100009 BALL ASSEMBLY – OVERHAUL 47
(7.5 TON)
9 6978100037 EXTENSION INSTALLATION – JIB BOOM 49
9 7826100017 SOCKET ASSY 5/8″ 51
12 2159910130 BOOM ANGLE INDICATOR 53
INSTALLATION
2114900861 POINTER ASSEMBLY 55
13 2159910169 EXTENSION INSTALLATION – JIB BOOM 57
2159910147 EXTENSION ASSEMBLY – JIB BOOM 59
6718100031 SHEAVE ASSEMBLY – 5/8″ ROPE 63
2159910184 MAST ASSEMBLY 65
(COMPLETE ASSEMBLY)
6718100031 SHEAVE ASSEMBLY – 5/8″ ROPE 67
14 2159910193 CARRIER INSTALLATION – JIB 71
EXTENSION
I
Manitowoc Crane Group
MACHINE COMPONENT INDEX
Date: Oct 16, 2008 Rev:
Model Number
RT540E (40 TON)
Serial Number
258110
Item Part Description Page
CAB GROUP
1 6245101146 CAB INSTALLATION 75
6245101147 CAB ASSEMBLY 81
6245101145 CAB WELD 89
6245101159 DOOR INSTALLATION – CAB 91
(NOT AVAILABLE AS ASSEMBLY)
7576134398 KIT – SKYLIGHT WIPER 93
(COMPLETE ASSEMBLY)
7576134397 KIT – FRONT WIPER 95
(COMPLETE ASSEMBLY)
7498100022 SKYLIGHT ASSEMBLY – SLIDING 97
(COMPLETE ASSEMBLY)
7498000897 WINDOW ASSEMBLY – REAR 99
(COMPLETE ASSEMBLY)
7498100028 WINDOW ASSEMBLY – RIGHT HAND 101
(COMPLETE ASSEMBLY)
7425100015 FAN ASSEMBLY – 12 VOLT CAB 103
(COMPLETE ASSEMBLY)
2 80003781 SEAT INSTALLATION 105
WITHOUT AUXILIARY HOIST
80003780 SEAT ASSEMBLY 107
WITHOUT AUXILIARY HOIST
(COMPLETE ASSEMBLY)
6872100045 SWITCH ASSEMBLY – PROXIMITY 111
(NORMALLY OPEN)
(COMPLETE ASSEMBLY)
7352100097 CONTROLLER ASSEMBLY – 8-32 VOLT 113
LEFT HAND ARMREST
WITHOUT AUXILIARY HOIST
(COMPLETE ASSEMBLY)
7352100095 CONTROLLER ASSEMBLY – 8-32 VOLT 115
RIGHT HAND ARMREST
(COMPLETE ASSEMBLY)
6512100837 HARNESS ASSEMBLY – SEAT 119
(COMPLETE ASSEMBLY)
3 6001100033 ACOUSTICS INSTALLATION 123
6 6245101334 CONSOLE INSTALLATION – FRONT 125
(RT540E/RT530E2)
6245101332 CONSOLE ASSEMBLY – FRONT 129
(RT540E/RT530E2)
(COMPLETE ASSEMBLY)
II
Manitowoc Crane Group
MACHINE COMPONENT INDEX
Date: Oct 16, 2008 Rev:
Model Number
RT540E (40 TON)
Serial Number
258110
Item Part Description Page
6512101099 HARNESS ASSEMBLY – FRONT CONSOLE 141
(COMPLETE ASSEMBLY)
7486100100 GAUGE, 12 VOLT TACHOMETER 145
(WITH HOURMETER)
7 6978100900 ELECTRICAL SYSTEM INSTALLATION 149
– SUPERSTRUCTURE CAB
(DOMESTIC)
6679100195 PANEL ASSEMBLY – FUSE AND RELAY 151
(SUPERSTRUCTURE CAB)
(COMPLETE ASSEMBLY)
6512100914 HARNESS ASSEMBLY – FUSE AND RELAY PANEL 157
(SUPERSTRUCTURE CAB)
(COMPLETE ASSEMBLY)
9 6515100078 HEATER/COOLER INSTALLATION – CAB 161
80006745 KIT – CAB HEATER AND AIR CONDITIONER 163
(COMPLETE ASSEMBLY)
10 6942100004 SCREEN INSTALLATION – SUN 167
10 6258100005 BINDER INSTALLATION 169
11 7598100092 KIT, LMI S/S IFLEX 5 171
12 6978100727 KIT INSTALLATION – iFLEX 5 LMI 173
SUPERSTRUCTURE
15 7598100166 KIT – iFLEX2 LMI CAB 177
(COMPLETE ASSEMBLY)
16 6978100998 ELECTRICAL SYSTEM INSTALLATION 183
– SUPERSTRUCTURE
(RT540E/RT530E2)
6512101098 HARNESS ASSEMBLY – SUPERSTRUCTURE 193
(COMPLETE ASSEMBLY)
16 80002960 KIT – iFLEX2 LMI CAB 199
19 2159210210 HANDLE INSTALLATION 203
HOIST ACCESS
22 6245100997 COVER INSTALLATION – REAR CAB 205
22 6245100991 PEDALS INSTALLATION – 207
WITHOUT AUXILIARY HOIST
7926100912 VALVE ASSEMBLY – BRAKE TREADLE 209
(COMPLETE ASSEMBLY)
23 6245100995 CONTROLS INSTALLATION – STEER AND DRIVE 211
7926100899 VALVE ASSEMBLY – STEERING CONTROL 213
(COMPLETE ASSEMBLY)
6326100001 COLUMN ASSEMBLY – MODIFIED TILT STEERING 215
(COMPLETE ASSEMBLY)
III
Manitowoc Crane Group
MACHINE COMPONENT INDEX
Date: Oct 16, 2008 Rev:
Model Number
RT540E (40 TON)
Serial Number
258110
Item Part Description Page
7326100007 COLUMN ASSEMBLY – TILT STEERING 217
(COMPLETE ASSEMBLY)
6512100853 HARNESS ASSEMBLY – TURN SIGNAL/WASHER 219
(COMPLETE ASSEMBLY)
6512100854 HARNESS ASSEMBLY – SHIFTER 221
(COMPLETE ASSEMBLY)
39 2159110275 STEP INSTALLATION 223
HOIST ACCESS
CONTROL VALVE GROUP – UPPER
5 80001671 VALVE INSTALLATION – CONTROL 225
MAIN AND FUTURE AUXILIARY HOIST
7926100974 VALVE ASSEMBLY – DIRECTIONAL CONTROL 227
4 SECTION
(COMPLETE ASSEMBLY)
7926101042 VALVE ASSEMBLY – ACCESSORY 233
WITH SWING AND STEER DIRECTIAL CONTROL
(COMPLETE ASSEMBLY)
6 2159610259 HYDRAULIC LINES INSTALLATION – 241
MAIN AND FUTURE AUXILIARY HOIST
(SUPERSTRUCTURE)
11 2159610145 HYDRAULIC LINES INSTALLATION – CAB 249
HOIST GROUP
1 7782161382 16MM DIA HOISTING WIRE ROPE – 251
7 6974100183 HOIST INSTALLATION – MAIN 253
7974100043 HOIST ASSEMBLY – HP15C/17G 257
(COMPLETE ASSEMBLY)
8 2159210000 MIRROR INSTALLATION – HOIST 263
TURNTABLE GROUP
1 2159210215 TURNTABLE WELD AND DRIVE INSTALLATION 265
2159210219 TURNTABLE WELD 267
7576134386 MOTOR ASSEMBLY – SWING DRIVE 273
(COMPLETE ASSEMBLY)
2 2159210144 SHAFT INSTALLATION-BOOM PIVOT 277
3 2159210206 COUNTERWEIGHT INSTALLATION – 279
ITALY
(C.E. CONFORMITY)
4 6364101750 SWIVEL INSTALLATION – 281
ELECTRIC, WATER AND HYDRAULIC
6364101749 SWIVEL ASSEMBLY – 283
ELECTRIC, WATER AND HYDRAULIC
(COMPLETE ASSEMBLY)
IV
Manitowoc Crane Group
MACHINE COMPONENT INDEX
Date: Oct 16, 2008 Rev:
Model Number
RT540E (40 TON)
Serial Number
258110
Item Part Description Page
7364100165 SWIVEL ASSEMBLY – 14 PORT 285
HYDRAULIC, WATER AND AIR CONDITIONING
(COMPLETE ASSEMBLY)
7753100037 RING ASSEMBLY – SLIP 291
15 CONDUCTOR
(COMPLETE ASSEMBLY)
8 2159210143 BOLT INSTALLATION – BEARING 295
10 2159210116 CYLINDER INSTALLATION-LOWER PIVOT & LIFT 297
6372100377 CYLINDER ASSEMBLY – LIFT 299
(COMPLETE ASSEMBLY)
7926100925 VALVE ASSEMBLY – HOLDING 303
(COMPLETE ASSEMBLY)
13 6245101343 PIN INSTALLATION – TURNTABLE LOCK 305
14 6258100041 COVER INSTALLATION – VALVE 307
23 2159210124 LUBE INSTALLATION – TURNTABLE BEARING 309
MANUAL
24 2159210028 COUNTERWEIGHT INSTALLATION 311
32 2159610178 COOLER INSTALLATION – HYDRAULIC OIL 313
7726191196 COOLER ASSEMBLY – HYDRAULIC OIL 315
(COMPLETE ASSEMBLY)
ENGINE GROUP
3 2159810166 HOOD INSTALLATION – ENGINE 319
23 2159810224 ENGINE INSTALLATION 323
2159810225 ENGINE ASSEMBLY – CUMMINS QSB6.7 327
(NOT AVAILABLE AS ASSEMBLY)
7904100181 TRANSMISSION ASSEMBLY – 6 SPEED 333
12 VOLT
(COMPLETE ASSEMBLY)
9904110609 CONVERTER HOUSING GROUP 335
9904109807 CASE & REAR COVER GROUP 337
9904110611 TURBINE SHAFT GROUP 341
9904110612 DRIVE PLATE GROUP 343
9904110613 TORQUE CONVERTER GROUP 345
9904110614 GEAR GROUP 347
9904110615 AUXILIARY PUMP DRIVE GROUP 349
9904110616 PUMP DRIVE GROUP 351
9904110617 FORWARD SHAFT GROUP 353
V
Manitowoc Crane Group
MACHINE COMPONENT INDEX
Date: Oct 16, 2008 Rev:
Model Number
RT540E (40 TON)
Serial Number
258110
Item Part Description Page
9904110618 REVERSE & 2ND. SHAFT GROUP 355
9904110619 REVERSE IDLER GROUP 357
9904110620 LOW SPEED SHAFT GROUP 359
9904110621 3RD. SHAFT GROUP 361
9904110622 IDLER SHAFT GROUP 363
9904110623 OUTPUT SHAFT GROUP 365
9904110624 HI/LOW RANGE SHIFT CONT. GROUP 369
9904110625 DISC BRAKE GROUP 371
9904110626 CHARGE PUMP & FILTER GROUP 373
9904110627 CONTROL VALVE MOUNTING GROUP 375
9904110628 CONTROL VALVE ASSY. GROUP 377
80006812 BRAKE ASSEMBLY – PARKING 379
(COMPLETE ASSEMBLY)
7722100101 PUMP ASSEMBLY – GEAR 383
(COMPLETE ASSEMBLY)
7722100100 PUMP ASSEMBLY – PISTON 385
(COMPLETE ASSEMBLY)
6978100956 ELECTRICAL SYSTEM INSTALLATION 391
– ENGINE
(NOT AVAILABLE AS ASSEMBLY)
6512100819 HARNESS ASSEMBLY – ENGINE 395
(COMPLETE ASSEMBLY)
7246100345 KIT – CABLE (ENGINE) 399
(COMPLETE ASSEMBLY)
24 2159810146 RADIATOR INSTALLATION 401
2159810147 RADIATOR ASSEMBLY 405
(NOT AVAILABLE AS ASSEMBLY)
7726191194 COOLER ASSEMBLY – RADIATOR/CHARGE AIR 407
(COMPLETE ASSEMBLY)
2159810114 TANK ASSEMBLY – SURGE 409
(NOT AVAILABLE AS ASSEMBLY)
27 2159810115 SYSTEM INSTALLATION – EXHAUST 411
28 2159810116 CLEANER INSTALLATION – AIR 413
7304100005 CLEANER ASSEMBLY – AIR 415
(COMPLETE ASSEMBLY)
34 2159810143 GRILL INSTALLATION – ENGINE HOOD 417
38 80004881 FAN INSTALLATION – NON CE 419
VI
Manitowoc Crane Group
MACHINE COMPONENT INDEX
Date: Oct 16, 2008 Rev:
Model Number
RT540E (40 TON)
Serial Number
258110
Item Part Description Page
DRIVE TRAIN GROUP
22 2159810102 DRIVE LINE INSTALLATION 421
7364100114 DRIVE LINE ASSEMBLY 423
WITH CENTER BEARING
(COMPLETE ASSEMBLY)
7364100115 DRIVE LINE ASSEMBLY 425
(COMPLETE ASSEMBLY)
7364100166 DRIVE LINE ASSEMBLY 427
(COMPLETE ASSEMBLY)
AXLE GROUP
19 2159710017 AXLE INSTALLATION – REAR 429
WITHOUT DIFFERENTIAL LOCK
7049101503 AXLE ASSEMBLY – DRIVE/STEER 431
(COMPLETE ASSEMBLY)
90012611 DIFF. CARRIER GROUP 433
90012612 HOUSING & HUB GROUP 435
90012613 PLANETARY HUB GROUP 439
90012614 STEER CYLINDER GROUP 441
90012615 BRAKE GROUP 443
7372100255 CYLINDER ASSEMBLY – 5″ LOCKOUT 445
(COMPLETE ASSEMBLY)
6872100045 SWITCH ASSEMBLY – PROXIMITY 447
(NORMALLY OPEN)
(COMPLETE ASSEMBLY)
20 2159510011 AXLE INSTALLATION – FRONT 449
7049101503 AXLE ASSEMBLY – DRIVE/STEER 451
(COMPLETE ASSEMBLY)
90012611 DIFF. CARRIER GROUP 453
90012612 HOUSING & HUB GROUP 455
90012613 PLANETARY HUB GROUP 459
90012614 STEER CYLINDER GROUP 461
90012615 BRAKE GROUP 463
21 6970100369 TIRE AND WHEEL INSTALLATION – 465
20.5 X 25 GENERAL
6970100370 TIRE AND WHEEL ASSEMBLY – 467
20.5 X 25 GENERAL
(COMPLETE ASSEMBLY)
7970140719 WHEEL ASSEMBLY – 17.00″ X 25″ 469
(COMPLETE ASSEMBLY)
VII
Manitowoc Crane Group
MACHINE COMPONENT INDEX
Date: Oct 16, 2008 Rev:
Model Number
RT540E (40 TON)
Serial Number
258110
Item Part Description Page
6970100370 TIRE AND WHEEL ASSEMBLY – 471
20.5 X 25 GENERAL
(COMPLETE ASSEMBLY)
7970140719 WHEEL ASSEMBLY – 17.00″ X 25″ 473
(COMPLETE ASSEMBLY)
OUTRIGGER GROUP
4 2159110157 FLOAT INSTALLATION – OUTRIGGER 475
6458100000 FLOAT ASSEMBLY – OUTRIGGER 477
(COMPLETE ASSEMBLY)
16 2159110160 COVER INSTALLATION – OUTRIGGER BOX 479
FRAME GROUP
1 80002067 CARRIER FRAME COMPLETE 481
80002066 CARRIER FRAME 483
80002064 CARRIER FRAME ASSEMBLY 485
80002062 OUTRIGGER BEAM INSTALLATION 487
(COMPLETE ASSEMBLY)
80002077 OUTRIGGER BEAM ASSEMBLY 489
7372100238 CYLINDER ASSEMBLY – 4″ OUTRIGGER JACK 491
(COMPLETE ASSEMBLY)
6372100456 CYLINDER ASSEMBLY – OUTRIGGER EXTENSION 493
(COMPLETE ASSEMBLY)
7372100232 CYLINDER ASSEMBLY – 2 1/2″ O/R EXTENSION 495
(COMPLETE ASSEMBLY)
1 80006891 DECAL INSTALLATION RT535E/540E-STANDARD 497
80006890 DECAL INSTALLATION RT540E STANDARD-CAB 499
6376200767 DECAL INSTALLATION – RT535E 503
(STANDARD CARRIER)
6376200776 DECAL INSTALLATION – RT535E 505
(STANDARD SUPERSTRUCTURE)
6376200785 DECAL INSTALLATION – RT535E 507
(STANDARD BOOM)
2 2159110286 FENDER AND DECK INSTALLATION 509
HOIST ACCESS
2 6376206875 DECAL INSTALLATION – RT540E 513
(NOMENCLATURE)
5 2159110262 LIGHTS INSTALLATION – EXTERIOR 515
(DOMESTIC)
(FOR REFERENCE ONLY)
6 2159110098 TIE DOWN INSTALLATION – 517
HOOK BLOCK
VIII
Manitowoc Crane Group
MACHINE COMPONENT INDEX
Date: Oct 16, 2008 Rev:
Model Number
RT540E (40 TON)
Serial Number
258110
Item Part Description Page
7 2159810191 COVER INSTALLATION-BATTERY BOX 519
9 2159100686 MIRROR INSTALLATION – REAR 521
VIEW
10 2159110216 STEP INSTALLATION 523
11 6376100272 HARDWARE KIT – DECAL 525
13 6978100997 ELECTRICAL SYSTEM INSTALLATION – CARRIER 531
(RT540E/RT530E2)
6512101096 HARNESS ASSEMBLY – CARRIER 541
(COMPLETE ASSEMBLY)
6679100157 PANEL ASSEMBLY – ENGINE RELAYS 547
(COMPLETE ASSEMBLY)
6512100807 HARNESS ASSEMBLY – ENGINE RELAY PANEL 549
(COMPLETE ASSEMBLY)
14 2159110182 TANK INSTALLATION – HYDRAULIC 551
7880100112 RESERVOIR ASSEMBLY – HYDRAULIC 553
(COMPLETE ASSEMBLY)
9437100891 FILTER ASSY. HYD. RETURN 555
2159110178 LADDER ASSEMBLY 557
(COMPLETE ASSEMBLY)
15 2159610147 VALVE INSTALLATION – HYDRAULIC 559
(CARRIER)
7926100859 VALVE ASSEMBLY – OUTRIGGER CONTROL 561
4 SECTION
(COMPLETE ASSEMBLY)
7926100911 VALVE ASSEMBLY – PARK BRAKE RANGE SHIFT 563
(COMPLETE ASSEMBLY)
7926100924 VALVE ASSEMBLY – AXLE LOCKOUT 565
(COMPLETE ASSEMBLY)
7926100936 VALVE ASSEMBLY – OUTRIGGER SELECTOR 567
REAR STEER
(COMPLETE ASSEMBLY)
18 2159110152 TRAY INSTALLATION – STORAGE 571
25 2159110179 TANK INSTALLATION – FUEL 573
7880100116 TANK ASSEMBLY – 58 GALLON FUEL 577
(COMPLETE ASSEMBLY)
7576001743 MOUNTING KIT – OIL COOLER 579
2159110178 LADDER ASSEMBLY 581
(COMPLETE ASSEMBLY)
26 2159810208 BATTERY INSTALLATION 583
IX
Manitowoc Crane Group
MACHINE COMPONENT INDEX
Date: Oct 16, 2008 Rev:
Model Number
RT540E (40 TON)
Serial Number
258110
Item Part Description Page
7246100441 KIT – CABLE (BATTERIES) 587
RT535
CONTROL VALVE GROUP – LOWER
17 2159610224 HYDRAULIC LINES INSTALLATION – 591
CARRIER
SCHEMATIC
19 6829104375 SOFTWARE SPEC RT540E/RT530E-2 SCHEMATIC
X
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