Grove RT540E Crane Index:

1 2159910182 BOOM ASSEMBLY – 4 SECTION 11
6372100466 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

1 6245101146 CAB INSTALLATION 75
6245101147 CAB ASSEMBLY 81
6245101145 CAB WELDMENT
7576134398 KIT – SKYLIGHT WIPER 89
COMPLETE ASSEMBLY
7576134397 KIT – FRONT WIPER 91
COMPLETE ASSEMBLY
7498100022 SKYLIGHT ASSEMBLY – SLIDING 93
COMPLETE ASSEMBLY
7498000897 WINDOW ASSEMBLY – REAR 95
COMPLETE ASSEMBLY
7498100028 WINDOW ASSEMBLY – RIGHT HAND 97
COMPLETE ASSEMBLY
7425100015 FAN ASSEMBLY – 12 VOLT CAB 99
COMPLETE ASSEMBLY
2 6798100140 SEAT INSTALLATION – CONTROL 103
WITHOUT AUXILIARY HOIST CONTROL
6798100142 SEAT ASSEMBLY – CONTROL 107
WITHOUT AUXILIARY HOIST CONTROL
(NOT AVAILABLE AS ASSEMBLY)
6872100045 SWITCH ASSEMBLY – PROXIMITY 111
COMPLETE ASSEMBLY
7352100052 CONTROLLER ASSEMBLY – 12 VOLT LEFT HAND 115
COMPLETE ASSEMBLY
7352100050 CONTROLLER ASSEMBLY – 12 VOLT RIGHT HAND 119
COMPLETE ASSEMBLY
6512100837 HARNESS ASSEMBLY – SEAT 123
COMPLETE ASSEMBLY
3 6001100033 ACOUSTICS INSTALLATION 127
6 6245101142 CONSOLE INSTALLATION – FRONT 129
TIER 3
6245101141 CONSOLE ASSEMBLY – FRONT 133
TIER 3
COMPLETE ASSEMBLY
6512100828 HARNESS ASSEMBLY – FRONT CONSOLE 145
COMPLETE ASSEMBLY
7486100100 GAUGE, 12 VOLT TACHOMETER 149
(WITH HOURMETER)
7 6978100900 ELECTRICAL SYSTEM INSTALLATION 153
– SUPERSTRUCTURE CAB
(DOMESTIC)
II
Manitowoc Crane Group
MACHINE COMPONENT INDEX
Date: Jun 12, 2007 Rev: 001
Model Number
RT540E (40 TON)
Serial Number
226600
Item Part Description Page
6679100195 PANEL ASSEMBLY – FUSE AND RELAY 155
(SUPERSTRUCTURE CAB)
COMPLETE ASSEMBLY
6512100914 HARNESS ASSEMBLY – FUSE AND RELAY PANEL 161
(SUPERSTRUCTURE CAB)
COMPLETE ASSEMBLY
8 6593100011 LEVER INSTALLATION – 360 DEGREE 165
SWING BRAKE
9 6515100078 HEATER/COOLER INSTALLATION – CAB 167
7576134408 KIT – CAB HEATER AND AIR CONDITIONER 169
COMPLETE ASSEMBLY
10 6942100004 SCREEN INSTALLATION – SUN 173
10 6258100005 BINDER INSTALLATION 175
11 7598100092 KIT, LMI S/S IFLEX 5 177
12 6978100727 KIT INSTALLATION – iFLEX 5 LMI 179
SUPERSTRUCTURE
16 6978100896 ELECTRICAL SYSTEM INSTALLATION 181
– SUPERSTRUCTURE
TIER 3
6512100911 HARNESS ASSEMBLY – SUPERSTRUCTURE 197
TIER 3
COMPLETE ASSEMBLY
16 6978100879 LMI CAB INSTALLATION – IFLEX5 205
20 6872100082 SWITCH AND LAMP INSTALLATION – 209
CROSS AXLE
22 6245100997 COVER INSTALLATION – REAR CAB 211
22 6245100991 PEDALS INSTALLATION – 213
WITHOUT AUXILIARY HOIST
7926100912 VALVE ASSEMBLY – BRAKE TREADLE 215
COMPLETE ASSEMBLY
23 6245100995 CONTROLS INSTALLATION – STEER AND DRIVE 217
7926100899 VALVE ASSEMBLY – STEERING CONTROL 219
COMPLETE ASSEMBLY
6326100001 COLUMN ASSEMBLY – MODIFIED TILT STEERING 221
COMPLETE ASSEMBLY
7326100007 COLUMN ASSEMBLY – TILT STEERING 223
COMPLETE ASSEMBLY
6512100853 HARNESS ASSEMBLY – TURN SIGNAL/WASHER 225
COMPLETE ASSEMBLY
6512100854 HARNESS ASSEMBLY – SHIFTER 227

24 6486100037 INDICATOR INSTALLATION – 3RD WRAP 229
30 6025100012 CONTROLLER INSTALLATION – TEMPERATURE 231
CONTROL VALVE GROUP – UPPER
5 2159610213 VALVE INSTALLATION – CONTROL 233
MAIN AND FUTURE AUXILIARY HOIST
7926100974 VALVE ASSEMBLY – DIRECTIONAL CONTROL 235
4 SECTION
COMPLETE ASSEMBLY
7926100994 VALVE ASSEMBLY – ACCESSORY 241
WITH SWING AND STEER DIRECTIAL CONTROL
COMPLETE ASSEMBLY
6 2159610191 HYDRAULIC LINES INSTALLATION – 249
MAIN AND FUTURE AUXILIARY HOIST
(SUPERSTRUCTURE)
11 2159610145 HYDRAULIC LINES INSTALLATION – CAB 257
HOIST GROUP
1 7781040452 WIRE ROPE 5/8″ 6X36WS X 450 FT 259
7 6974100152 HOIST INSTALLATION – MAIN 261
(C.E. CONFORMITY)
7974100019 HOIST ASSEMBLY – HP15C/17G 265
WITH 3RD WRAP
COMPLETE ASSEMBLY
8 2159210000 MIRROR INSTALLATION – HOIST 271
TURNTABLE GROUP
1 2159210157 DRIVE INSTALLATION – TURNTABLE AND 273
(ROTEK)
2159210175 TURNTABLE SECTION 275
7576134386 MOTOR ASSEMBLY – SWING DRIVE 281
COMPLETE ASSEMBLY
2 2159210121 LOCK INSTALLATION – 360 SWING 285
2165210021 LOCK ASSEMBLY – SWING 287
COMPLETE ASSEMBLY
2 2159210144 SHAFT INSTALLATION-BOOM PIVOT 289
3 2159210149 COUNTERWEIGHT INSTALLATION 291
2150200656 PIN ASSEMBLY 293
4 6364101750 SWIVEL INSTALLATION – 295
ELECTRIC, WATER AND HYDRAULIC
6364101749 SWIVEL ASSEMBLY – 297
ELECTRIC, WATER AND HYDRAULIC
COMPLETE ASSEMBLY
IV
Manitowoc Crane Group
MACHINE COMPONENT INDEX
Date: Jun 12, 2007 Rev: 001
Model Number
RT540E (40 TON)
Serial Number
226600
Item Part Description Page
7364100165 SWIVEL ASSEMBLY – 14 PORT 299
HYDRAULIC, WATER AND AIR CONDITIONING
COMPLETE ASSEMBLY
7753100037 RING ASSEMBLY – SLIP 305
15 CONDUCTOR
COMPLETE ASSEMBLY
8 2159210143 BOLT INSTALLATION – BEARING 309
10 2159210116 CYLINDER INSTALLATION-LOWER PIVOT & LIFT 311
6372100377 CYLINDER ASSEMBLY – LIFT 313
COMPLETE ASSEMBLY
7926100925 VALVE ASSEMBLY – HOLDING 317
COMPLETE ASSEMBLY
13 6245101010 PIN INSTALLATION – TURNTABLE LOCK 319
14 6258100041 COVER INSTALLATION – VALVE 321
23 2159210124 LUBE INSTALLATION – TURNTABLE BEARING 323
MANUAL
24 2159210028 COUNTERWEIGHT INSTALLATION 325
32 2159610178 COOLER INSTALLATION – HYDRAULIC OIL 327
7726191196 COOLER ASSEMBLY – HYDRAULIC OIL 329
COMPLETE ASSEMBLY
ENGINE GROUP
3 2159810166 HOOD INSTALLATION – ENGINE 333
23 2159810202 ENGINE INSTALLATION – CUMMINS QSB6.7 337
DOMESTIC
2159810203 ENGINE ASSEMBLY – CUMMINS QSB6.7 341
DOMESTIC
(NOT AVAILABLE AS ASSEMBLY)
7904100058 TRANSMISSION ASSEMBLY – 6 SPEED 347
COMPLETE ASSEMBLY
9904110609 CONVERTER HOUSING GROUP 349
9904110610 CASE & REAR COVER GROUP 351
9904110611 TURBINE SHAFT GROUP 355
9904110612 DRIVE PLATE GROUP 357
9904110613 TORQUE CONVERTER GROUP 359
9904110614 GEAR GROUP 361
9904110615 AUXILIARY PUMP DRIVE GROUP 363
9904110616 PUMP DRIVE GROUP 365
9904110617 FORWARD SHAFT GROUP 367
V

9904110618 REVERSE & 2ND. SHAFT GROUP 369
9904110619 REVERSE IDLER GROUP 371
9904110620 LOW SPEED SHAFT GROUP 373
9904110621 3RD. SHAFT GROUP 375
9904110622 IDLER SHAFT GROUP 377
9904110623 OUTPUT SHAFT GROUP 379
9904110624 HI/LOW RANGE SHIFT CONT. GROUP 383
9904110625 DISC BRAKE GROUP 385
9904110626 CHARGE PUMP & FILTER GROUP 387
9904110627 CONTROL VALVE MOUNTING GROUP 389
9904110628 CONTROL VALVE ASSY. GROUP 391
7188100101 BRAKE ASSEMBLY – PARKING 393
COMPLETE ASSEMBLY
7722100101 PUMP ASSEMBLY – GEAR 397
COMPLETE ASSEMBLY
7722100100 PUMP ASSEMBLY – PISTON 399
COMPLETE ASSEMBLY
6978100956 ELECTRICAL SYSTEM INSTALLATION 405
– ENGINE
(NOT AVAILABLE AS ASSEMBLY)
6512100819 HARNESS ASSEMBLY – ENGINE 409
COMPLETE ASSEMBLY
7246100345 KIT – CABLE (ENGINE) 413
COMPLETE ASSEMBLY
24 2159810146 RADIATOR INSTALLATION 415
2159810147 RADIATOR ASSEMBLY 419
(NOT AVAILABLE AS ASSEMBLY)
7726191194 COOLER ASSEMBLY – RADIATOR/CHARGE AIR 421
COMPLETE ASSEMBLY
2159810114 TANK ASSEMBLY – SURGE 423
(NOT AVAILABLE AS ASSEMBLY)
27 2159810115 SYSTEM INSTALLATION – EXHAUST 425
28 2159810116 CLEANER INSTALLATION – AIR 427
7304100005 CLEANER ASSEMBLY – AIR 429
COMPLETE ASSEMBLY
34 2159810143 GRILL INSTALLATION – ENGINE HOOD 431
40 6978100967 ELECTRICAL SYSTEM INSTALLATION 435
– ENGINE
SUPPLEMENTAL
VI
Manitowoc Crane Group
MACHINE COMPONENT INDEX
Date: Jun 12, 2007 Rev: 001
Model Number
RT540E (40 TON)
Serial Number
226600
Item Part Description Page
6176100313 BOX ASSEMBLY 437
AXLE GROUP
19 2159710009 AXLE INSTALLATION – REAR 439
WITH DIFFERENTIAL LOCK
7049101488 AXLE ASSEMBLY – DRIVE/STEER 443
WITH DIFFERENTIAL LOCK
COMPLETE ASSEMBLY
9049112801 DIFF.CARRIER GROUP 445
9049112778 HOUSING GROUP 449
9049112802 HUB & SHAFT GROUP 453
9049112516 BRAKE GROUP 457
9049112523 BRAKE ASSEMBLY,GROUP 459
7372100250 CYLINDER ASSEMBLY – 2 1/2″ STEER 461
COMPLETE ASSEMBLY
7372100255 CYLINDER ASSEMBLY – 5″ LOCKOUT 463
COMPLETE ASSEMBLY
6872100045 SWITCH ASSEMBLY – PROXIMITY 465
COMPLETE ASSEMBLY
20 2159510007 AXLE INSTALLATION – FRONT 467
WITH DIFFERENTIAL LOCK
7049101488 AXLE ASSEMBLY – DRIVE/STEER 469
WITH DIFFERENTIAL LOCK
COMPLETE ASSEMBLY
9049112801 DIFF.CARRIER GROUP 471
9049112778 HOUSING GROUP 475
9049112802 HUB & SHAFT GROUP 479
9049112516 BRAKE GROUP 483
9049112523 BRAKE ASSEMBLY,GROUP 485
7372100250 CYLINDER ASSEMBLY – 2 1/2″ STEER 487
COMPLETE ASSEMBLY
21 6970003421 TIRE AND WHEEL INSTALLATION 489
20.5 X 25
6970100151 T & W ASSY – 20.5 X 25 – GENER 491
6970100153 WHEEL & DISC ASSY 493
6970100151 T & W ASSY – 20.5 X 25 – GENER 495
6970100153 WHEEL & DISC ASSY 497
22 2159810102 DRIVE LINE INSTALLATION 499

7364100114 DRIVE LINE ASSEMBLY 501
WITH CENTER BEARING
COMPLETE ASSEMBLY
7364100115 DRIVE LINE ASSEMBLY 503
COMPLETE ASSEMBLY
7364100166 DRIVE LINE ASSEMBLY 505
COMPLETE ASSEMBLY
OUTRIGGER GROUP
4 2159110157 FLOAT INSTALLATION – OUTRIGGER 507
6458100000 FLOAT ASSEMBLY – OUTRIGGER 509
COMPLETE ASSEMBLY
16 2159110160 COVER INSTALLATION – OUTRIGGER BOX 511
FRAME GROUP
1 2159110244 FRAME – CARRIER 513
(FOR REFERENCE ONLY)
2159110245 FRAME – CARRIER 515
2159110246 FRAME – CARRIER 517
COMPLETE ASSEMBLY
2159110206 BEAM INSTALL – OUTRIGGER 519
(NOT AVAILABLE AS ASSEMBLY)
2159110205 BEAM ASSEMBLY – OUTRIGGER 521
COMPLETE ASSEMBLY
7372100238 CYLINDER ASSEMBLY – 4″ OUTRIGGER JACK 523
COMPLETE ASSEMBLY
6372100456 CYLINDER ASSEMBLY – OUTRIGGER EXTENSION 525
COMPLETE ASSEMBLY
7372100232 CYLINDER ASSEMBLY – 2 1/2″ O/R EXTENSION 527
COMPLETE ASSEMBLY
1 6376207460 DECAL INSTALLATION – RT535/540E 529
(RUSSIAN)
2 2159110172 FENDER & DECKING INSTALLATION 533
2 6376206875 DECAL INSTALLATION – RT540E 537
(NOMENCLATURE)
4 6376207460 DECAL INSTALLATION – RT535/540E 539
(RUSSIAN)
5 2159110230 LIGHTS INSTALLATION – EXTERIOR 543
(DOMESTIC)
6 2159110098 TIE DOWN INSTALLATION – 545
HOOK BLOCK
7 2159810192 COVER INSTALLATION-BATTERY BOX 547
VIII
Manitowoc Crane Group
MACHINE COMPONENT INDEX
Date: Jun 12, 2007 Rev: 001
Model Number
RT540E (40 TON)
Serial Number
226600
Item Part Description Page
9 2159100686 MIRROR INSTALLATION – REAR 549
VIEW
10 2159110216 STEP INSTALLATION 551
11 6376100272 HARDWARE KIT – DECAL 553
13 6978100955 ELECTRICAL SYSTEM INSTALLATION 559
– CARRIER
6512101008 HARNESS ASSEMBLY – CARRIER 571
COMPLETE ASSEMBLY
6679100157 PANEL ASSEMBLY – ENGINE RELAYS 577
COMPLETE ASSEMBLY
6512100807 HARNESS ASSEMBLY – ENGINE RELAY PANEL 579
COMPLETE ASSEMBLY
14 2159110243 TANK INSTALLATION – HYDRAULIC 581
7880100123 RESERVOIR ASSEMBLY – HYDRAULIC 583
COMPLETE ASSEMBLY
9437100891 FILTER ASSY. HYD. RETURN 585
2159110178 LADDER ASSEMBLY 587
COMPLETE ASSEMBLY
15 2159610148 VALVE INSTALLATION – HYDRAULIC 589
CARRIER WITH DIFFERENTIAL LOCK
7926100859 VALVE ASSEMBLY – OUTRIGGER CONTROL 591
4 SECTION
COMPLETE ASSEMBLY
7926100911 VALVE ASSEMBLY – PARK BRAKE RANGE SHIFT 593
COMPLETE ASSEMBLY
7926100924 VALVE ASSEMBLY – AXLE LOCKOUT 595
COMPLETE ASSEMBLY
7926100936 VALVE ASSEMBLY – OUTRIGGER SELECTOR 597
REAR STEER
COMPLETE ASSEMBLY
7926100913 VALVE ASSEMBLY – DIFFERENTIAL LOCKOUT 601
COMPLETE ASSEMBLY
18 2159110152 TRAY INSTALLATION – STORAGE 603
25 2159110179 TANK INSTALLATION – FUEL 605
7880100116 TANK ASSEMBLY – 58 GALLON FUEL 609
COMPLETE ASSEMBLY
7576001743 MOUNTING KIT – OIL COOLER 611
2159110178 LADDER ASSEMBLY 613
COMPLETE ASSEMBLY
IX

2159810193 BATTERY INSTALLATION 615
7246100346 KIT – CABLE (BATTERY) 619
COMPLETE ASSEMBLY
CONTROL VALVE GROUP – LOWER
17 2159610184 HYDRAULIC LINES INSTALLATION – 625
CARRIER
(WITH DIFFERENTIAL LOCK