Manitowoc Crane CD09 Operator Manual PDF

Description

Manitowoc Crane CD09 Operator Manual – PDF DOWNLOAD

FILE DETAILS:

Manitowoc Crane CD09 Operator Manual – PDF DOWNLOAD

Language : English
Pages : 156
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Manitowoc Crane CD09 Operator Manual – PDF DOWNLOAD

SECTION 1 9
Introduction 9
The Manual 9
Directional Reference 9
Serial Number Decal 9
Serial Number 9
Reports 9
Noise Level Test Results 10
Vibration Level Test Results 10
Disclaimer 10
Customer Support 10
New Owners 10
Nomenclature 11
SECTION 2 13
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
Superstructure Inspection 55
Carrier Inspection 57
SECTION 3 61
Operating Controls and Procedures 61
Controls, Switches, and Gauges 61
Cab Controls 61
Swing Control 61
Telescope Control 61
Hoist Control 61
Boom Lift Control 61
Accelerator Pedal 62
Brake Pedal 62
Steering Wheel 62
Turn Signal/Windshield Wiper Lever 62
Left Dash Controls 63
Defroster Switch 63
Error Code Screen Toggle Switch 63
Steering Select Switch 63
Wheels Not Centered Indicator 63
Headlights/Work Lights Switch 63
Outrigger Extend/Retract Switch 63
Heat Only Fan Switch (Optional) 63
Emergency Stop Switch 63
Right Dash Controls 64
Rated Capacity Limiter (RCL) Override Switch 64
Outrigger/Jack Select Switches 64
Hazard Lights Switch 64
Crane Function Switch 64
Parking Brake Switch 65
Ignition Switch 65
Winch Switch (Optional) 65
Fuel Select Switch (Dual Fuel Engines Only) 65
360° Swing Lock Switch 65
360° Swing Lock Indicator 65
12 volt Accessory Outlet 65
Steer Synchronize Switch 65
Indicator and Gauge Display-Dual Fuel 66
Indicator and Gauge Display-Diesel 67
Fuel Gauge 68
Left Turn Signal Indicator 68
Voltmeter 68
Hourmeter 68
Diagnostic Fault Codes 68
Tachometer 68
Right Turn Signal Indicator 68
Engine Coolant Temperature Gauge 68
Crane Function Enabled Indicator 68
Outrigger Monitoring Indicator 68
Minimum Wrap Indicator 68
Headlights Indicator 68
Work Lights Indicator 68
Axle Lockout Indicator (Not Used) 68
Hydraulic Oil High Temperature Indicator 68
Engine Wait to Start Indicator 68
Engine Stop Indicator 68
Engine Warning Indicator 68
Parking Brake Engaged Indicator 68
Low Brake Pressure Indicator 69
Low Engine Oil Pressure Indicator 69
Battery Charge Indicator 69
Transmission Oil Temperature Indicator 69
Low Transmission Oil Pressure Indicator 69
Crane Level Indicator 69
Engine Warning and Stop Lights 69
Rated Capacity Limiter (RCL) 69
Air Conditioning/Heater Controls 70
Boom Angle Indicator 70
Outrigger Controls 70
Steering Controls 71
Two-Wheel Steer Mode 71
Four-Wheel Steer Mode 72
Crab Steer Mode 72
Operator’s Cab 72
Heater/Air Conditioner 72
Defroster 73
Seat Adjustment 73
Seat Belt 73
Cab Door (Enclosed Cab) 73
Opening the Cab Door from Outside 73
Opening the Door from Inside 73
Locking the Cab Door 74
Opening Side Window 74
Fire Extinguisher 74
Crane Operation 74
Starting the Engine 74
Normal Engine Starting 74
Towing or Pushing the Crane to Start the Engine 75
Jump Starting the Crane 75
Charging 75
Cold Climate Engine Operation 75
Crane Warm-up Procedures 75
Engine 76
Transmission 76
Hoist 76
Swing Drive and Turntable Bearing 76
Axles 76
Hydraulic Oil System 77
Traveling with the Crane 77
Changing Travel Direction 78
Shifting Gears 78
Stopping Travel 78
Operating the Outrigger Controls 79
Proper Leveling of the Crane 79
Bubble Level Adjustment 79
To Extend and Lower the Outriggers 79
Extending the outriggers 79
Lowering the Jacks 80
Outrigger Monitoring System (OMS) (Optional—Standard in North America) 80
Raising the Jacks 81
Retracting the Outriggers 81
Operating the Boom Controls 81
Boom Swing Operation 81
To Rotate the Mast to the Left (Counterclockwise) 81
To Stop Rotation 82
To Rotate the Mast to the Right (Clockwise) 82
Boom Telescope Operation 82
To Extend the Boom 82
To Stop Extension/Retraction 82
To Retract the Boom 82
Boom Lift Operation 83
To Raise the Boom 83
To Stop Boom Movement 84
To Lower the Boom 84
Hoist Operation 85
To Raise the Hook Block 85
To Stop Hoist Rotation 85
To Lower the Hook Block 85
Hoist Rotation Indicator 85
Optional Controls Operation 87
Under Deck Winch 87
To Extend the Wire Rope 87
To Stop the Winch 87
To Retract the Wire Rope 87
Operating Practices 88
Handling a Load 88
Attaching the Load 88
Holding the Load 88
Moving the Load 88
Travel on Slopes 88
Traveling with a Load (Pick and Carry) 89
Elevating Personnel 89
Preparation and Setup 89
Lifting Personnel 89
Capacity Limitations 90
Turning Clearances 90
Crane Shutdown 90
Battery Disconnect 90
Unattended Crane 90
Towing a Disabled Crane 90
SECTION 4 91
Capacity Chart 91
Using the Capacity Chart 91
Determine Operating Status 91
Determining Lift Capacity 91
Things to Observe When Using the Capacity Chart 91
Determining Lift Capacity at the Boom Extension 92
Pick and Carry 92
SECTION 5 95
Attachments 95
Pivoting Boom Head 95
Boom Head Positions 95
Positions When No Boom Extension is Attached 95
Positions When Boom Extension is Attached 95
Changing the Boom Head Position (No Extension) 96
Adjusting the Optional Boom Extension Offset 97
Hook Block 97
Removing the Hook Block 97
Installing the Hook Block 98
Boom Extension 98
Installing the Boom Extension 98
Stowing the Boom Extension 98
Searcher Hook Assembly 100
Installation 100
Removal 100
Installing Cable On The Hoist 100
Wire Rope Wedge Socket 101
SECTION 6 103
Maintenance 103
Introduction 103
Spark Arresting Mufflers 103
Safety List 103
Lubricants 104
Environmental Protection 104
Immediately clean up any spills 104
Maintenance Records 104
Special Maintenance 104
Delivery Inspection 104
After First 50 Hours of Operation (New Cranes) 104
Cranes Not In Regular Use 105
Preventive Maintenance 105
Maintenance Schedule and Checklist 105
Lubrication Symbol Chart 105
Scheduled Maintenance 117
Daily (Walk-around) Inspection 117
Inspections 117
Inspect the Anti-Double Blocking System 117
Inspect the Wire Rope 117
Inspect Reeving, Clamps and Connections 118
Inspect the Lifting Hook 118
Inspect All Safety Devices 118
Check Controls Operation 118
Component/System Checks 118
Check Fuel Level 118
Check the Engine Crankcase Oil Level 118
Check the Transmission Oil Level 119
Check Engine Coolant Level 119
Drain Water from Engine Fuel Filter 119
Check Hydraulic Oil Level 119
Check the Air Cleaner Restriction Indicator 120
Remove the Element 120
Inspect the Element 121
Install the Element 121
Check Tire Pressure 121
50 Hours of Operation (Weekly) 122
Clean the Air Cleaner Dust Cup 122
Wire Rope Inspection 122
Inspection 122
General Inspection 122
Grease Fittings 123
Lubricate Parking Brake 123
Lubricate the Boom Slides 123
100 Hours of Operation (Two Weeks) 125
Inspect the Fan Belts 125
Check Wheel Nut Torque 125
250 Hours of Operation (Monthly) 126
Inspect the Hydraulic Hoses 126
Clean Battery and Cables 126
Clean the Radiator 127
Lubricate the Wire Rope 127
Lubricate the Swing Gear and Pinion 127
Replace the Crankcase Oil and Filter 128
Torque Critical Bolts 128
Hoist Gearbox Mounting Bolts 128
Swing Gearbox Mounting Bolts 128
Mast Mounting Bolts 128
Front Axle Mounting Bolts 128
500 Hours of Operation (3 Months) 129
Inspect the Tires 129
Inspect Parking Brake Pads 129
Replace Fuel Filter 129
Replace Air Cleaner Element 129
Add Rust Inhibitor to Engine Cooling System 130
Lubricate the Outrigger Slides 130
Add Grease to the Swing Gearbox 130
Check Axle Housing Lubricant Level 131
Check Wheel Hub Lubricant Level 131
Check Hoist Gearbox and Brake Lubricant Levels 132
1000 Hours of Operation (6 Months) 132
Replace the Transmission Oil and Filter 132
Replace the Front Axle Housing Lubricant 133
Replace Axle Wheel Hub Lubricant 134
Replace the Hydraulic Oil 134
Replace the Hydraulic Oil Filter 135
Check Swing Gear/Pinion Backlash 136
2000 Hours of Operation (Yearly) 136
Replace the Hoist Gearbox and Brake Lubricant 136
Replacing the Engine Coolant 137
Inspect the Crane Structure and Booms for Damage 137
Testing the Rated Capacity Limiter (Optional) 137
Miscellaneous Maintenance 137
Batteries/Charging System 137
Checking the Charging System 137
Charging the Battery 137
Replacing the Battery 138
Battery Electrolyte First Aid 138
Fuel System 138
Fuel Storage 138
Fuse/Relay Replacement 138
Carwell® Rust Inhibitor 141
Protecting Cranes from Rusting 141
Cleaning Procedures 141
Inspection and Repair 142
Application 142
Areas of Application 142
SECTION 7 145
Adjustments 145
SECTION 8 147
Specifications 147
Engine Oil Specifications 147
Cummins Oil Registration List 147
Oil Performance Recommendations 147
Oil Viscosity Recommendations 147
Viscosity Grades 147
Arctic Operation 147
Diesel Fuel 148
General Specifications 149
Engine 149
Tier 4 Final Diesel 149
Tier 3 Diesel 149
Dual Fuel 149
Tires 149
Electrical System 149
Fuel Tank 150
Hydraulic System 150
Boom 150
Mast Rotation – 360° 150
Wire Rope 150
Weight 150
Torque Converter 150
Transmission 151
Travel Speeds 151
Two-Wheel Steer 151
Front Axle Drive 151
Rear Axle Non-Drive 151
Operating Dimensions 151
Two-Wheel Steer 151
Four-Wheel Steer 151
Boom Angle 151

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