Manitowoc Grove CD15 Service Manual – PDF DOWNLOAD

Manitowoc Grove CD15 Service Manual – PDF DOWNLOAD

FILE DETAILS:

Manitowoc Grove CD15 Service Manual – PDF DOWNLOAD

Language : English
Pages :334
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Manitowoc Grove CD15 Service Manual – PDF DOWNLOAD

SECTION 1 13
Introduction 13
General 14
Supplemental Information 14
Safety Information 14
Basic Nomenclature 14
Directional Reference 14
Identification Plates 17
General Specifications 18
Boom 18
Electrical System 18
Engine 18
Fuel Tank 18
Hydraulic System 18
Mast 18
Outriggers 18
Tires 18
Travel Speeds (approximate) 19
2-Wheel Drive, Two-Wheel Steer 19
Weight (GVW) 19
Wire Rope 19
Dimensions (Side View) 20
Dimensions (Top View and Rear View) 21
General Maintenance 22
Cleanliness 22
After Cleaning 22
Removal and Installation 22
Disassembly and Assembly 22
Pressing Parts 23
Locking Devices 23
Wires and Cables 23
Shims 23
Hoses and Tubes 23
Inspection 23
Installation 24
Bearings 24
Antifriction Bearings 24
Double Row, Tapered Roller 24
Heating Bearings 24
Installation 24
Preload 24
Sleeve Bearings 24
Gaskets 24
Batteries 24
Hydraulic Systems 25
Cleanliness 25
Keep the System Clean 25
Sealing Elements 25
Hydraulic Lines 25
Visual Inspection of Hoses and Fittings 25
Electrical System 26
Harnesses, Wires, and Connectors 26
Fatigue of Welded Structures 26
Loctite® 27
Application of Medium Strength Loctite 27
Primer Application 27
Adhesive/Sealant Application 27
Fasteners and Torque Values 27
Torque Wrenches 27
Torque Values 28
Weld Studs 42
Hydraulic Fitting 42
FFFT METHOD (Flats from Finger Tight) 42
37° Flared Steel Fitting – Tube or Hose to Fitting 42
Adjustable Straight 43
Thread O-ring Fitting – Fitting to Port (Table 1-16) 43
Nonadjustable Straight Thread O-ring Fitting – Fitting to Port (Table 1-17) 43
Wire Rope 44
General 44
Environmental Conditions 44
Dynamic Shock Loads 44
Lubrication 44
Precautions and Recommendations During Inspection or Replacement 44
Wire Rope Inspection (Running Ropes and Pendant Cables) 45
Keeping Records 45
Frequent Inspection 45
Periodic Inspection 46
Wire Rope Inspection (Boom Extension and Retraction Cables) 46
Periodic Inspection 46
Wire Rope Inspection/Replacement (All Wire Rope) 46
Seizing Wire Rope 47
Method 1 47
Method 2 47
O-ring, Seal and Elastic Nut Replacement 48
Hydraulic Pressure Testing 48
SECTION 2 49
Safety Practices 49
Introduction 49
Signal Words 49
Signal Word 49
Important 49
Personal Considerations 50
Equipment Considerations 50
General Considerations 51
Operational Considerations 51
Environmental Protection 52
Final Word 52
SECTION 3 53
Electric System 53
General 53
Comparing an Electrical System to a Hydraulic System 53
Magnetism 54
Main Electrical System 54
General 54
Wire Harnesses 54
Fuses 54
Charging System 57
Alternator and Voltage Regulator 57
Batteries 57
Battery Disconnect Switch 57
Voltmeter 57
Special Precautions 57
Battery Maintenance and Charging 57
Battery 57
Charging the Battery 57
Starting Circuit 58
General Inspections 58
gauge Cluster 60
General 60
Gauges 60
Fuel 60
Engine Temperature 60
Voltmeter 60
Hourmeter 60
Hourmeter 61
Tachometer 61
Indicator Lights 61
Engine Diagnostic Connector 61
Accessory Circuits 62
Anti-Two Blocking System 62
General 62
Circuit Description 62
Electric Swivel 62
Rated Capacity Limiter (RCL) System 62
Description 62
Heater 62
Troubleshooting 63
SECTION 4 67
Hydraulic System 67
General Description 68
General 68
Hydraulic System 68
Troubleshooting 68
Troubleshooting Aids 68
Troubleshooting Procedures 69
Troubleshooting Guides 69
Hydraulic Pump 75
Description 75
Pump Output Test 75
Pump Margin (Stand-By) Pressure Check/ Adjustment 75
Dump Valve 75
Main Control Valve 77
General 77
Inlet Section 77
Working Valve Sections 77
Load Sense Relief Valve Pressure Check/ Adjustment 79
Priority Flow Load Sense and Accumulator Relief Pressure Check/Adjustment 79
Hydraulic Swivel 80
General 80
Functions 80
Troubleshooting 81
Boom Lift Circuit 81
General 81
Oil Flow 81
Raising the Boom 81
Lowering the Boom 81
Holding Valve 81
Lift Cylinder Leakage Check 81
Telescope Circuit 82
General 82
Oil Flow 82
Telescope Out 82
Telescope In 82
Holding Valve 82
System Relief Valves 82
Telescope Pressure Check/Adjustment 82
Telescope Cylinder Leakage Test 83
Hoist Circuit 85
General 85
Oil Flow 85
Hoist Up 85
Hoist Down 85
Drain Line 85
Brake Holding Valve 85
Drum Rotation/Minimum Wrap Sensor 85
Swing Circuit 86
General 86
Oil Flow 86
Neutral 86
Swing Right 86
Swing Left 87
Optional Swing Lock 87
Swing Lock Off 87
Swing Lock On 87
Swing Pressure Check/Adjustment (without Swing Lock) 87
Swing Pressure Check/Adjustment (with Swing Lock) 87
Anti-two Blocking System 89
General 89
System Operation 89
Outrigger Circuit 90
General 90
Oil Flow 90
Neutral 90
Extending an Outrigger 90
Retract an Outrigger 90
Outrigger Monitoring System (OMS) 91
Under Deck Winch Circuit 91
General 91
Oil Flow 91
Neutral 91
Pay Out 91
Haul In 91
Under Deck Winch Pressure Check/ Adjustment 91
Component Repair 92
General 92
Hydraulic Pump Repair 92
Removal 92
Disassembly and Repair 92
Installation 92
Pump Start-up 92
Swing Motor 94
Removal 94
Disassembly 94
Inspection/Cleaning 96
Assembly 96
Shaft End 96
Gerotor End 98
Timing Procedure 98
Installation 99
Hoist Motor Repair101
Removal101
Disassembly101
Installation101
Hydraulic Swivel102
Removal102
Disassembly/Assembly103
Installation103
Test103
Hydraulic Cylinders106
Removal106
Disassembly106
Inspection106
Assembly106
Test106
Installation107
SECTION 5109
Preventative Maintenance109
Introduction109
Spark Arresting Mufflers109
Safety List110
Lubricants110
Cummins Oil Registration List110
Environmental Protection110
Maintenance Records110
Maintenance110
Preparation110
Hydraulic System Maintenance Precautions111
Label Parts when Disassembling111
Hydraulic Oil Recommendations111
Draining and Flushing111
Removing Air From the Hydraulic System112
Parts Replacement112
Special Maintenance113
Delivery Inspection113
After First 50 Hours of Operation (New Cranes)113
After First 100 Hours of Operation (New Cranes)113
Cranes Not In Regular Use113
Maintenance Schedule and Checklist113
Lubrication Schematic116
Lubrication Symbols117
Lubrication Legend117
Lubrication Notes118
Lubrication Points119
Scheduled Maintenance121
Daily (Walk-around) Inspection121
Inspections121
Inspect the Anti-Double Blocking System121
Inspect the Wire Rope121
Inspect Reeving, Clamps and Connections121
Inspect the Lifting Hook121
Inspect All Safety Devices121
Check Controls Operation121
Component/System Checks121
Check Fuel Level121
Check the Engine Crankcase Oil Level122
Check the Transmission Oil Level122
Check Engine Coolant Level122
Drain Water from Engine Fuel Filter123
Check Hydraulic Oil Level123
Service the Air Cleaner124
Check Tire Pressure124
50 Hours of Operation (Weekly)125
Clean the Air Cleaner Dust Cup125
Wire Rope Inspection125
Inspection125
General Inspection125
Grease Fittings126
Lubricate Parking Brake126
Lubricate the Boom Slides126
100 Hours of Operation (Two Weeks)127
Inspect the Fan Belts127
Check Wheel Nut Torque127
250 Hours of Operation (Monthly)127
Inspect the Hydraulic Hoses127
Clean Battery and Cables128
Clean the Radiator128
Lubricate the Wire Rope129
Lubricate the Swing Gear and Pinion129
Replace the Crankcase Oil and Filter130
Torque Critical Bolts130
Hoist Gearbox Mounting Bolts130
Swing Gearbox Mounting Bolts130
Mast Mounting Bolts (Turntable)130
Front Axle Mounting Bolts130
Rear Axle Mounting Bolts130
500 Hours of Operation (3 Months)131
Replace the Transmission Filter131
Inspect the Tires131
Inspect Parking Brake Pads131
Replace Fuel Filter131
Add SCA to Engine131
Lubricate the Outrigger Slides131
Add Grease to the Swing Gearbox132
Lubricate Drivelines132
Check Axle Housing Lubricant Level133
Check Wheel Hub Lubricant Level133
Check Hoist Gearbox and Brake Lubricant Levels133
1000 Hours of Operation (6 Months)135
Replace the Transmission Oil and Filter — 4WD135
Replace the Transmission Oil and Filter — 2WD136
Replace the Axle Housing Oil136
Replace Axle Wheel Hub Lubricant137
Replace the Hoist Gearbox Oil137
Replace the Hoist Brake Oil138
Replace the Hydraulic Oil138
Replace the Hydraulic Oil Filter139
Check Swing Gear/Pinion Backlash140
2000 Hours of Operation (Yearly)140
Replace the Engine Coolant140
Inspect the Crane Structure and Boom for Damage141
Testing the Load Moment Indicator (Optional)141
Miscellaneous Maintenance141
Batteries/Charging System141
Checking the Charging System141
Charging the Battery141
Replacing the Battery142
Battery Electrolyte First Aid142
Fuel System142
Fuel Storage142
Fuse Replacement142
Carwell® Rust Inhibitor143
Protecting Cranes From Rusting143
Cleaning Procedures144
Inspection and Repair144
Application145
Areas of Application145
SECTION 6149
Engine and Engine Systems149
General149
Engine Types149
Engine Performance149
Engine RPM149
Engine Crankcase System149
Crankcase Oil Data149
Oil Performance Recommendations149
Oil Viscosity Recommendations150
Arctic Operation150
Engine Cooling System150
Coolant Requirements150
Radiator Cap and Overflow Bottle151
Thermostat151
Engine Fuel System151
Diesel Engine Fuel System Description151
Fuel Tank151
Fuel Level Sender and Gauge151
Fuel Pump151
Fuel Filter152
Fuel Injection Pump152
Fuel Injectors152
QSF Engine Electronic Controlled Fuel System Units152
Types of Fuel to Use152
Diesel152
Gasoline152
Engine Air Intake System153
Engine Air Intake System153
Engine Exhaust System153
Slip Joint Exhaust Connectors153
After 1000 Hours, or One Year153
2000 Hours or 2 Years153
4000 Hours or 4 Years153
5000 Hours or 5 Years153
Removal and Installation155
Removal155
Installation156
SECTION 7157
Transmission and Torque Converter157
Four-Wheel Drive (4WD) Transmission158
4WD General Technical Data158
4WD Clutch Solenoid Technical Data159
4WD Description of Operation160
Torque Converter160
Transmission160
Hydraulic Operation163
Clutch Operation163
4WD Clutch Identification164
4WD Solenoid Identification165
4WD General Troubleshooting166
4WD Electrical Troubleshooting168
System Operation168
Electronic Control Unit (ECU)168
Electrical Troubleshooting Chart169
Finding Electrical Problems170
Checking Solenoid Operation170
Checking for (+ V) Supply to Solenoids173
Checking the Main Frame Harness173
Checking Parking Brake Switch173
Checking Sensor Operation173
Speed Sensor Depth174
Tips On Common Problems174
ECU Mounting174
Speed Sensors174
Harnesses174
No 4th Gear174
Erratic/Sticking Gears174
Testing174
Solenoid Identification174
Test for Clutch Leakage175
Isolating A Suspect Clutch175
Individual Clutch Leakage Test175
Converter Stall Test177
Pressure and Flow Tests178
Pump Flow178
Mainline Pressure178
Converter Out Pressure/Oil Cooler Flow Rate178
Converter In Pressure178
Converter Relief (Safety) Valve Pressure179
Lubricating Pressure179
4WD Transmission Repair Tools180
Servicing Torque Converter182
Removal182
Installation182
Two-Wheel Drive (2WD) Transmission184
2WD General Technical Data184
2WD Solenoid Valve Engagement185
2WD Transmission Description of Operation186
Torque Converter186
Transmission186
2WD Transmission to Engine Installation Procedure188
Servicing Machine After Transmission Overhaul190
Cleaning and Inspection190
Cleaning190
Bearings190
Housings190
Inspection190
Bearings190
Oil Seals, Gaskets, Etc191
Gears and Shafts191
Housing, Covers, etc191
2WD Troubleshooting191
SECTION 8193
Axles/Drive Shafts/Wheels and Tires193
Description194
Front Axle194
Rear Axle194
Technical Data195
Front Drive Axle195
Rear Drive Axle195
Rear Non-Drive Axle196
Front Drive Axle Repair196
Removal196
Installation196
Special Tools196
Replacing the Pinion Oil Seal199
Axle Hub Repair201
Disassembly201
Assembly201
Drive Head Repair203
Disassembly203
Assembly207
Pinion Depth Setting Procedure207
Crownwheel and Pinion Adjustment208
Correct teeth marking Figure 8-28208
Pinion too deeply in mesh Figure 8-29208
Pinion too far out of mesh Figure 8-30208
Assembly Procedures209
Rear Axle Repair213
Removal213
Installation213
Service Tools213
Replacing the Pinion Oil Seal213
Axle Hub Repair215
Disassembly Figure 8-44215
Assembly216
Drive Head Repair (Drive Axles Only)221
Disassembly Figure 8-49221
Assembly221
Drive Shafts225
Removal225
Front Axle Drive Shaft225
Rear Axle Drive Shaft225
Disassembly225
Front Axle Drive Shaft225
Rear Drive Shaft225
Inspection225
Assembly225
Front Axle Drive Shaft225
Rear Axle Drive Shaft225
Installation226
Front Axle Drive Shaft226
Rear Axle Drive Shaft226
Lubrication Procedure226
Wheel & Tires227
Tire Inflation227
Wheel Lug Nuts227
Tire Mounting227
SECTION 9229
Brake System229
Technical Data231
Front Axle Brakes231
Rear Axle Brakes231
Accumulator231
Accumulator Charging Valve231
Priority Flow Control Valve231
Description233
Service Brake System Operation233
Hydraulic Pump233
Priority Flow Control Valve233
Accumulator Charging Valve233
Low Brake Pressure Warning Switch233
Accumulator233
Brake Modulating Valve233
Brake Light Switch233
Front Axle Brakes233
Rear Axle Brakes234
Parking Brake System Operation234
Parking Brake234
Parking Brake Solenoid Valve234
Maintenance And Adjustments235
Service Brake Bleeding235
Rear Axle235
Front Axle235
Parking Brake Bleeding236
Parking Brake Adjustment236
Accumulator Charging236
Residual Brake System Pressure237
Checking For Residual Pressure237
Tests237
Brake Piston Seal Leakage Test (Front Axle Only)237
Service Brake Repair238
Front Axle Brakes238
Disassembly238
Assembly240
Rear Axle Brakes241
Parking Brake Repair242
Lining Kit Replacement242
Repair Kit Installation243
Seal Kit Installation245
Brake Modulating Valve Repair246
Removal246
Disassembly246
Assembly247
Installation247
Troubleshooting248
Service Brakes248
SECTION 10249
Steering System249
Description249
General249
Steering Modes249
Two-Wheel Steering252
Four-Wheel Steering252
Crab Steering253
Steering Proximity Switches254
Proximity Switch Operation254
Proximity Switch Operational Check and Adjustment254
Operational Check254
Spacing Adjustment255
Steering Orbital255
Description255
General255
Steering Left255
Steering Right255
Emergency Manual Steering255
orbital Repair256
Special Tools256
Orbital Removal258
Orbital Disassembly260
Orbital Inspection262
Orbital Assembly262
Orbital Installation267
Steering Cylinder268
Special Tools268
Cylinder Repair268
Cylinder Removal268
Cylinder Disassembly268
Inspection269
Cylinder Assembly270
Cylinder Installation271
Steering System Troubleshooting272
SECTION 11275
Structurals275
Safety277
Boom Extension Assembly277
Boom Extension Removal277
Boom Extension Installation277
Boom279
Boom Removal279
Boom Installation279
Boom Assembly Drawing280
Boom Assembly Drawing Legend291
Boom Disassembly292
Boom Assembly292
Boom Cable Tensioning295
Tensioning Procedure for all Booms295
Tensioning Procedure for 4 Section Boom296
321 and 123 cable balancing296
Extension296
Retraction296
234 and 432 cable balancing297
Extension297
Retraction297
Tensioning Procedure for 3-Section Boom298
321 and 123 cable balancing298
Extension298
Retraction298
Boom Wear Pad Adjustment299
4-Section Boom299
Do not force the shims Use the same amount of shims on both sides of each boom section299
Front Side Wear Pad Adjustments299
Rear Wear Pad Adjustment299
3-Section Boom299
Do not force the shims Use the same amount of shims on both sides of each boom section299
Front Side Wear Pad Adjustment299
Rear Wear Pad Adjustment299
Top Wear Pad Adjustment299
Wire Rope, Sheaves and Hoist Blocks300
Wire Rope Description300
Wire Rope Safety300
Wire Rope Inspection301
Sheave Inspection302
Wire Rope Lubrication302
Wire Rope Installation302
Installation of Socket and Wedge302
Installation of New Wire Rope302
Hoist305
Description305
Hoist Maintenance305
Hoist Warm-up Procedure305
Hoist Lifting Equipment305
Hoist Removal305
Hoist Installation305
Drum Rotation/Minimum Wrap Indicator306
Replacing the DRI/MWI Sensor306
Tools Required306
Sensor Removal306
Sensor Installation307
Programming the Minimum Wrap Indicator307
Hoist Disassembly309
Hoist Assembly310
Servicing Hoist Motor310
Servicing Brake311
Servicing Planetary Sets311
Hoist Troubleshooting312
Turntable Bearing315
Bearing Lubrication315
Bearing Bolt Torque315
Bearing Wear315
Bearing Replacement317
Preparation317
Lifting Equipment317
Removal317
Installation318
Swing Gearbox and Pinion321
Swing Gearbox Maintenance321
Swing Gear/Pinion Maintenance321
Swing Gear and Pinion Backlash321
Checking Backlash321
Adjusting Backlash321
Swing Gearbox Repair323
Removal323
Disassembly323
Inspection323
Assembly323
Installation324
Outrigger Monitoring System325
Proximity Switch Removal325
Proximity Switch Installation325
Outriggers327
Outrigger Removal327
Disassembly328
Assembly328
Installation328
SECTION 12329
Schematics/Wiring Diagrams329

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