Manitowoc CD15 Operator Manual CTRL636-05 – PDF DOWNLOAD

Manitowoc CD15 Operator Manual CTRL636-05 – PDF DOWNLOAD

FILE DETAILS:

Manitowoc CD15 Operator Manual CTRL636-05 – PDF DOWNLOAD

Language : English
Pages : 158
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Manitowoc CD15 Operator Manual CTRL636-05 – PDF DOWNLOAD

Introduction..........................................................................  9
	The Manual........................................................................  9
	Directional Reference.............................................................  9
	Serial Number Plate...............................................................  9
		Serial Number.................................................................  9
	Reports...........................................................................  9
	Disclaimer........................................................................ 11
	Customer Support.................................................................. 11
		Dealer........................................................................ 11
		Safety Information............................................................ 11
		New Owners.................................................................... 11
	Nomenclature...................................................................... 11
Safety Information.................................................................... 13
	Safety Messages................................................................... 13
		General....................................................................... 13
		Safety Alert Symbol........................................................... 14
		Signal Words.................................................................. 14
	General........................................................................... 14
		Safety Decals................................................................. 14
	Accidents......................................................................... 14
	Operator Information.............................................................. 14
	Operator Qualifications........................................................... 15
	Operational Aids.................................................................. 16
		Rated Capacity Limiter (RCL) Systems (If Equipped)............................ 16
		Anti-Two-Blocking Device...................................................... 16
		Working Area Limiter (If Equipped)............................................ 17
	Crane Stability/Structural Strength............................................... 17
		Load Charts................................................................... 18
		Work Site..................................................................... 18
	Wind Forces....................................................................... 19
		Wind Speeds................................................................... 19
			Determination of 3-second wind gust speed at boom tip height:............. 22
			Size and Shape of the load:............................................... 22
			Determining Wind Drag Coefficient (Cd).................................... 23
			Maximum Permissible Wind Speed............................................ 24
				Example and Sample Calculations (metric).............................. 26
				Example 1: Crane Configuration:....................................... 26
				Load example 1.1:..................................................... 27
				Load example 1.2:..................................................... 27
				Load example 1.3a:.................................................... 27
				Load example 1.3b:.................................................... 27
			Example and Sample Calculations (Non-metric).............................. 30
				Example 2:............................................................ 30
				Load example 2.1:..................................................... 31
				Load example 2.2:..................................................... 31
				Load example 2.3a:.................................................... 31
				Load example 2.3b:.................................................... 31
		Lifting Operations............................................................ 32
		Counterweight................................................................. 33
		Outrigger Lift Off............................................................ 33
		Multiple Crane Lifts.......................................................... 33
		Tilt-Up Panel Lifting......................................................... 33
	Electrocution Hazard.............................................................. 34
		Set-Up and Operation.......................................................... 35
		Electrocution Hazard Devices.................................................. 35
		Electrical Contact............................................................ 36
		Special Operating Conditions and Equipment.................................... 36
		Grounding the Crane........................................................... 37
	Personnel Handling................................................................ 37
	Environmental Protection.......................................................... 38
	Maintenance....................................................................... 38
		Service and Repairs........................................................... 39
		Lubrication................................................................... 40
		Tires......................................................................... 40
	Hoist Rope........................................................................ 40
		Synthetic Hoist Rope.......................................................... 40
		Wire Rope..................................................................... 40
		Sheaves....................................................................... 42
		Batteries..................................................................... 42
		Super Capacitor (If Equipped)................................................. 42
		General Maintenance........................................................... 43
	Transporting the Crane............................................................ 43
	Travel Operation.................................................................. 43
	Work Practices.................................................................... 44
		Personal Considerations....................................................... 44
		Crane Access.................................................................. 44
		Job Preparation............................................................... 45
		Working....................................................................... 45
		Lifting....................................................................... 46
		Hand Signals.................................................................. 47
	Boom Extension.................................................................... 49
	Parking and Securing.............................................................. 49
	Shut-Down......................................................................... 49
	Cold Weather Operation............................................................ 49
	Temperature Effects on Hook Blocks................................................ 50
	Temperature Effects on Hydraulic Cylinders........................................ 50
	Overload Inspection............................................................... 52
		Boom Inspection............................................................... 53
		Mast Inspection............................................................... 54
		Carrier Inspection............................................................ 57
Operating Controls And Procedures..................................................... 59
	Controls, Switches, and Gauges.................................................... 60
		Crane Controls................................................................ 60
			Brake Pedal............................................................... 60
			Accelerator Pedal......................................................... 60
			Travel Direction Lever.................................................... 60
			Turn Signal/Windshield Wiper/Horn Lever................................... 60
			Swing Control............................................................. 61
			Telescope Control......................................................... 61
			Hoist Control............................................................. 61
			Drum Rotation Indicator................................................... 61
			Boom Control.............................................................. 61
			Outrigger Controls........................................................ 61
		Warning Alarms................................................................ 61
		Panel Switches, Gauges, and Indicators........................................ 62
			1 – Defroster Switch...................................................... 62
			2 – Heater Switch......................................................... 62
			3 – Auxiliary Winch Switch................................................ 62
			4 – Fuel Switch........................................................... 62
			5 – Emergency Stop Switch................................................. 62
			6 – Steering Sync Switch.................................................. 63
			7 – Emergency Flasher Switch.............................................. 63
			8 – Swing Lock Switch..................................................... 63
			9 – Swing Lock/Rear Wheels Not Centered Light............................. 63
			10 – Indicator Lights..................................................... 63
			11 – Fuel Gauge........................................................... 63
			12 – Engine Coolant Temperature Gauge..................................... 63
			13 – Hourmeter............................................................ 63
			14 – Tachometer........................................................... 63
			15 – Voltmeter............................................................ 63
			16 – 2WD/4WD Switch....................................................... 63
			17 – Steering Selection Switch............................................ 63
			18 – Parking Brake Switch................................................. 63
			19 – Work Light/Head Light Switch......................................... 63
		Ignition Switch............................................................... 64
		Operator Aids................................................................. 64
			Strobe Light.............................................................. 64
			The amber strobe light behind the cab comes on when the engine started.... 64
			Dome Light................................................................ 64
			12 volt Accessory Outlet.................................................. 64
			Crane Level Indicator..................................................... 64
			Boom Angle Indicator...................................................... 65
		Rated Capacity Limiter (RCL).................................................. 65
	Operator’s Cab.................................................................... 66
		Seat Belt..................................................................... 66
		Seat Adjustment............................................................... 66
		Cab Door (Enclosed Cab)....................................................... 66
			Opening the Cab Door From Outside (Enclosed Cab).......................... 66
			Opening the Door From Inside (Enclosed Cab)............................... 66
		Heater, A/C, and Defroster.................................................... 66
		Fire Extinguisher............................................................. 67
	Crane Operation................................................................... 68
		Starting the Engine........................................................... 68
			Normal Engine Starting.................................................... 68
			Towing or Pushing the Crane to Start the Engine........................... 69
			Jump Starting the Engine.................................................. 69
		Traveling the Crane........................................................... 69
			Shifting Gears (Travel Speed)............................................. 70
			Steering the Crane........................................................ 70
			Four-wheel Steering Indexing Procedure.................................... 71
			Changing Travel Direction................................................. 71
			Stopping Travel........................................................... 72
	Cold Climate Engine Operation..................................................... 72
		Crane Warm-up Procedures...................................................... 72
			Engine.................................................................... 72
			Transmission.............................................................. 72
			Hoist..................................................................... 73
			Swing Drive and Turntable Bearing......................................... 73
			Hydraulic Oil System...................................................... 73
	Operating Outrigger Controls...................................................... 74
		To Raise and Lower the Outriggers............................................. 74
		Outrigger Monitoring System (OMS)............................................. 74
	Operating Crane Controls.......................................................... 76
		Anti-Two Blocking System...................................................... 76
		Boom Swing Operation.......................................................... 78
			To Rotate the Boom to the Left (Counterclockwise)......................... 78
			To Stop Rotation.......................................................... 78
			To Rotate the Boom Right (Clockwise)...................................... 78
		Boom Telescope Operation...................................................... 80
			To Extend the Boom Sections............................................... 80
			To Stop Extension/Retraction.............................................. 80
			To Retract the Boom Sections.............................................. 80
		Boom Lift Operation........................................................... 82
			To Raise the Boom......................................................... 82
			To Stop Boom Movement..................................................... 82
			To Lower the Boom......................................................... 82
		Hoist Operation............................................................... 84
			To Raise the Load......................................................... 84
			To Stop the Load.......................................................... 84
			To Lower the Load......................................................... 84
	Operating Optional Controls....................................................... 86
		Auxiliary Winch Operation..................................................... 86
			To Engage/Disengage the Winch............................................. 86
			To Pay Out the Wire Rope.................................................. 86
			To Stop the Winch......................................................... 86
			To Haul In the Wire Rope.................................................. 86
	Operating Practices............................................................... 87
		Handling A Load............................................................... 87
		Attaching the Load............................................................ 87
		Holding the Load.............................................................. 87
		Moving the Load............................................................... 87
		Traveling with a Load (Pick and Carry)........................................ 87
		Turning Clearances............................................................ 87
		Crane Shutdown................................................................ 87
		Unattended Crane.............................................................. 88
		Towing A Disabled Crane....................................................... 88
Capacity Chart........................................................................ 89
	Using the Capacity Chart.......................................................... 89
		Determine Operating Status.................................................... 89
		Determining Lift Capacity..................................................... 89
		Things to Observe When Using the Capacity Chart............................... 90
		Determining Lift Capacity at the Boom Extension............................... 90
		Pick and Carry Ranges......................................................... 90
Attachments........................................................................... 93
	Hook Block........................................................................ 93
		Removing the Hook Block....................................................... 93
		Installing the Hook Block..................................................... 94
	Downhaul Weight................................................................... 94
		Installing the Downhaul Weight................................................ 94
		Removing the Downhaul Weight.................................................. 94
	Boom Extension (Jib).............................................................. 97
		Installing the Boom Extension................................................. 97
		Stowing the Boom Extension.................................................... 97
	Pivoting Boom Head................................................................ 99
		Boom Head Positions........................................................... 99
		Changing the Boom Head Position (without Boom Extension)...................... 99
		Changing the Boom Extension Offset............................................ 99
	Searcher Hook Assembly............................................................101
		Installation..................................................................101
		Removal.......................................................................101
	Installing Cable On The Hoist.....................................................102
	Wire Rope Wedge Socket............................................................102
	4 Part Wire Rope Reeving..........................................................104
Maintenance...........................................................................105
	Introduction......................................................................105
		Spark Arresting Mufflers......................................................105
		Safety List...................................................................106
	Lubricants........................................................................106
	Maintenance Records...............................................................106
	Maintenance.......................................................................106
		Preparation...................................................................106
		Hydraulic System Maintenance Precautions......................................106
		Label Parts when Disassembling................................................107
		Hydraulic Oil Recommendations.................................................107
		Draining and Flushing.........................................................107
		Removing Air From the Hydraulic System........................................107
		Parts Replacement.............................................................108
	Special Maintenance...............................................................108
		Delivery Inspection...........................................................108
		After First 50 Hours of Operation (New Cranes)................................109
		After First 100 Hours of Operation (New Cranes)...............................109
		Cranes Not In Regular Use.....................................................109
	Preventive Maintenance............................................................109
		Maintenance Schedule and Checklist............................................109
	Environmental Protection..........................................................109
		Lubrication Points............................................................112
	Scheduled Maintenance.............................................................114
		Daily (Walk-around) Inspection................................................114
			Inspections...............................................................114
				Inspect the Anti-Two Blocking System..................................114
				Inspect the Wire Rope.................................................114
				Inspect Reeving, Clamps and Connections...............................114
				Inspect the Lifting Hook..............................................114
				Inspect All Safety Devices............................................115
				Check Controls Operation..............................................115
			Component/System Checks...................................................115
				Check Fuel Level......................................................115
				Check the Engine Crankcase Oil Level..................................115
				Check the Transmission Oil Level......................................115
				Check Engine Coolant Level............................................116
				Drain Water from Engine Fuel Filter...................................116
				Check Hydraulic Oil Level.............................................117
				Service the Air Cleaner...............................................117
				Check Tire Pressure...................................................117
		50 Hours of Operation (Weekly)................................................118
			Clean the Air Cleaner Dust Cup............................................118
			Wire Rope Inspection......................................................118
				Inspection............................................................118
				General Inspection....................................................118
			Grease Fittings...........................................................119
			Lubricate Parking Brake...................................................119
			Lubricate the Boom Slides.................................................119
		100 Hours of Operation (Two Weeks)............................................120
			Inspect the Fan Belts.....................................................120
			Check Wheel Nut Torque....................................................120
		250 Hours of Operation (Monthly)..............................................120
			Inspect the Hydraulic Hoses...............................................120
			Clean Battery and Cables..................................................121
			Clean the Radiator........................................................121
			Lubricate the Wire Rope...................................................122
			Lubricate the Swing Gear and Pinion.......................................122
			Replace the Crankcase Oil and Filter......................................123
			Torque Critical Bolts.....................................................123
				Hoist Gearbox Mounting Bolts..........................................123
				Swing Gearbox Mounting Bolts..........................................123
				Mast Mounting Bolts...................................................123
				Front Axle Mounting Bolts.............................................123
				Rear Axle Mounting Bolts..............................................123
		500 Hours of Operation (3 Months).............................................124
			Replace the Transmission Filter...........................................124
			Inspect the Tires.........................................................124
			Inspect Parking Brake Pads................................................124
			Replace Fuel Filter.......................................................124
			Add SCA to Engine.........................................................124
			Lubricate the Outrigger Slides............................................124
			Add Grease to the Swing Gearbox...........................................125
			Lubricate Drivelines......................................................125
			Check Axle Housing Lubricant Level........................................126
			Check Wheel Hub Lubricant Level...........................................126
			Check Hoist Gearbox and Brake Lubricant Levels............................127
		1000 Hours of Operation (6 Months)............................................128
			Replace the Transmission Oil and Filter — 4WD.............................128
			Replace the Transmission Oil and Filter — 2WD.............................129
			Replace the Axle Housing Oil..............................................129
			Replace Axle Wheel Hub Lubricant..........................................130
			Replace the Hoist Gearbox Oil.............................................130
			Replace the Hoist Brake Oil...............................................131
			Replace the Hydraulic Oil.................................................131
			Replace the Hydraulic Oil Filter..........................................132
			Check Swing Gear/Pinion Backlash..........................................133
		2000 Hours of Operation (Yearly)..............................................133
			Replace the Engine Coolant................................................133
			Inspect the Crane Structure and Boom for Damage...........................134
			Testing the Rated Capacity Limiter (Optional).............................134
	Miscellaneous Maintenance.........................................................134
		Batteries/Charging System.....................................................134
			Checking the Charging System..............................................134
			Charging the Battery......................................................134
			Replacing the Battery.....................................................135
				Battery Electrolyte First Aid.........................................135
		Fuel System...................................................................135
			Fuel Storage..............................................................135
		Fuse Replacement..............................................................135
	Carwell® Rust Inhibitor...........................................................138
		Protecting Cranes From Rusting................................................138
		Cleaning Procedures...........................................................138
		Inspection and Repair.........................................................139
		Application...................................................................139
		Areas of Application..........................................................139
Adjustments...........................................................................143
Specification.........................................................................145
	Lubrication Schematic.............................................................146
		Lubrication Symbols...........................................................147
		Lubrication Legend............................................................147
		Lubrication Notes.............................................................148
	Engine Oil Specifications.........................................................149
	Fuel Types........................................................................149
	Environmental Protection..........................................................149
	Relief Valve Settings.............................................................150
	General Specifications............................................................150
		Boom..........................................................................150
		Electrical System.............................................................150
		Engine........................................................................150
		Fuel Tank.....................................................................150
		Hydraulic System..............................................................150
		Mast..........................................................................151
		Outriggers....................................................................151
		Tires.........................................................................151
		Travel Speeds (approximate)...................................................151
			2-Wheel Drive, Two-Wheel Steer............................................151
		Weight (GVW)..................................................................151
		Wire Rope.....................................................................151
	Dimensions (Side View)............................................................152
	Dimensions (Top View and Rear View)...............................................153