Manitowoc Crane Shuttlelift CD5515-2 Grove YB5515-2 Operator Manual

Description

Manitowoc Crane Shuttlelift CD5515-2 Grove YB5515-2 Operator Manual – PDF DOWNLOAD

FILE DETAILS:

Manitowoc Crane Shuttlelift CD5515-2 Grove YB5515-2 Operator Manual – PDF DOWNLOAD

Language : English
Pages :152
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Manitowoc Crane Shuttlelift CD5515-2 Grove YB5515-2 Operator Manual – PDF DOWNLOAD

SECTION 1 13
Introduction 13
The Manual 13
Directional Reference 13
Serial Number Plate 13
Serial Number 13
Reports 13
Noise Level Test Results 14
Vibration Level Test Results 14
Disclaimer 14
Customer Support 14
New Owners 14
Nomenclature 15
SECTION 2 17
Safety Information 17
Safety Messages 17
General 17
Safety Alert Symbol 18
Signal Words 18
General 18
Warning Signs 18
Accidents 18
Operator Information 18
Operator Qualifications 19
Operational Aids 20
Rated Capacity Limiter (RCL) Systems (If Equipped) 20
Anti-Two-Blocking Device 20
Working Area Limiter (If Equipped) 21
Crane Stability/Structural Strength 22
Load Charts 22
Work Site 22
Wind Forces 23
Wind Speeds 23
Determination of 3-second wind gust speed at boom tip height: 26
Size and Shape of the load: 26
Determining Wind Drag Coefficient (Cd) 27
Maximum Permissible Wind Speed 28
Example and Sample Calculations (metric) 30
Example 1: Crane Configuration: 30
Load example 1 1: 31
Load example 1 2: 31
Load example 1 3a: 31
Load example 1 3b: 31
Example and Sample Calculations (Non-metric) 34
Example 2: 34
Load example 2 1: 35
Load example 2 2: 35
Load example 2 3a: 35
Load example 2 3b: 35
Lifting Operations 36
Counterweight 37
Outrigger Lift Off 37
Multiple Crane Lifts 37
Tilt-Up Panel Lifting 37
Pile Driving and Extracting 38
Crane Equipment 38
Crane Inspection 38
Electrocution Hazard 39
Set-Up and Operation 40
Electrocution Hazard Devices 40
Electrical Contact 41
Special Operating Conditions and Equipment 41
Earthing the Crane 41
Personnel Handling 42
Environmental Protection 43
Maintenance 43
Service and Repairs 43
Lubrication 44
Tires 45
Hoist Rope 45
Synthetic Hoist Rope 45
Wire Rope 45
Sheaves 46
Batteries 47
Super Capacitor (If Equipped) 47
General Maintenance 47
Transporting the Crane 48
Travel Operation 48
Work Practices 49
Personal Considerations 49
Crane Access 49
Job Preparation 49
Working 50
Lifting 51
Hand Signals 52
Jib 54
Parking and Securing 54
Shut-Down 54
Cold Weather Operation 54
Temperature Effects on Hook Blocks 55
Temperature Effects on Hydraulic Cylinders 55
Overload Inspection 57
Boom Inspection 58
Superstructure Inspection 60
Carrier Inspection 62
SECTION 3 65
Operating Controls and Procedures 65
Controls, Switches, and Gauges 65
Cab Controls 65
Swing Control 65
Telescope Control 65
Hoist Control 65
Boom Lift Control 65
Accelerator Pedal 66
Brake Pedal 66
Steering Wheel 66
Turn Signal/Windshield Wiper Lever 66
Left Dash Controls 67
Defroster Switch 67
Error Code Screen Toggle Switch 67
Steering Select Switch 67
Two-wheel/Four-Wheel Drive Select Switch 67
Headlights/Work Lights Switch 67
Outrigger Extend/Retract Switch 67
Hoist Speed Select Switch 67
Heat Only Fan Switch (Optional) 67
Emergency Stop Switch 67
Right Dash Controls 68
Rated Capacity Limiter (RCL) Override Switch 68
Outrigger/Stabilizer Select Switches 68
Hazard Lights Switch 68
Crane Function Switch 68
Parking Brake Switch 68
Ignition Switch 68
Winch Switch (Optional) 68
360° Swing Lock Switch 68
Indicator and Gauge Display 69
Fuel Gauge 70
Left Turn Signal Indicator 70
Voltmeter 70
Hourmeter 70
Diagnostic Fault Codes 70
Tachometer 70
Right Turn Signal Indicator 70
Engine Coolant Temperature Gauge 70
Crane Function Enabled Indicator 70
Outrigger Monitoring Indicator 70
Third Wrap Indicator 70
Headlights Indicator 70
Work Lights Indicator 70
Axle Lockout Indicator (Not Used) 70
Hydraulic Oil High Temperature Indicator 70
Engine Wait to Start Indicator 70
Engine Stop Indicator 70
Engine Warning Indicator 70
Parking Brake Engaged Indicator 70
Low Brake Pressure Indicator 71
Low Engine Oil Pressure Indicator 71
Battery Charge Indicator 71
Transmission Oil Temperature Indicator 71
Low Transmission Oil Pressure Indicator 71
Crane Level Indicator 71
Engine Warning and Stop Lights 71
Rated Capacity Limiter (RCL) 71
Air Conditioning/Heater Controls 72
Boom Angle Indicator 72
Outrigger Controls 72
Steering Controls 73
Two-Wheel Steer Mode 73
Four-Wheel Steer Mode 73
Crab Steer Mode 73
Operator’s Cab 74
Heater/Air Conditioner 74
Defroster 74
Seat Adjustment 75
Seat Belt 75
Cab Door (Enclosed Cab) 75
Opening the Cab Door from Outside 75
Opening the Door from Inside 75
Locking the Cab Door 75
Opening Side Window 75
Fire Extinguisher 75
Crane Operation 76
Starting the Engine 76
Normal Engine Starting 76
Towing or Pushing the Crane to Start the Engine 77
Jump Starting the Engine 77
Crane Warm-up Procedures 78
Engine 78
Transmission 78
Hoist 78
Swing Drive and Turntable Bearing 78
Axles 79
Hydraulic Oil System 79
Cab Heater Warm-up 79
The brake must be applied in order to engage transmission 79
Traveling with the Crane 79
Changing Travel Direction 80
Shifting Gears 80
Stopping Travel 81
Operating the Outrigger Controls 81
Proper Leveling of the Crane 81
Bubble Level Adjustment 81
To Extend and Lower the Outriggers 81
Extending the outriggers 82
Lowering the Stabilizers 82
Outrigger Monitoring System (OMS) (Optional—Standard in North America) 82
Raising the Stabilizers 83
Retracting the Outriggers 83
Operating the Boom Controls 83
Boom Swing Operation 84
To Rotate the Mast to the Left (Counterclockwise) 84
To Stop Rotation 84
To Rotate the Mast to the Right (Clockwise) 84
Boom Telescope Operation 85
To Extend the Boom 85
To Stop Extension/Retraction 85
To Retract the Boom 85
Boom Lift Operation 86
To Raise the Boom 86
To Stop Boom Movement 86
To Lower the Boom 0
Hoist Operation 87
To Raise the Hook Block 87
To Stop Hoist Rotation 87
To Lower the Hook Block 87
Hoist Rotation Indicator 88
Optional Controls Operation 89
Under Deck Winch 89
To Extend the Wire Rope 89
To Stop the Winch 89
To Retract the Wire Rope 89
Operating Practices 90
Handling a Load 90
Attaching the Load 90
Holding the Load 90
Moving the Load 90
Travel on Slopes 90
Traveling with a Load (Pick and Carry) 91
Elevating Personnel 91
Preparation and Setup 91
Lifting Personnel 91
Capacity Limitations 92
Turning Clearances 92
Crane Shutdown 92
Battery Disconnect 92
Unattended Crane 92
Towing a Disabled Crane 92
SECTION 4 93
Capacity Chart 93
Using the Capacity Chart 93
Determine Operating Status 93
Determining Lift Capacity 93
Things to Observe When Using the Capacity Chart 93
Determining Lift Capacity at the Boom Extension 94
Pick and Carry Ranges 94
SECTION 5 97
Attachments 97
Pivoting Boom Head (Optional) 97
Boom Head Positions 97
Positions When No Boom Extension is Attached 97
Positions When Boom Extension is Attached 97
Changing the Optional Boom Head Position (No Extension) 98
Adjusting the Optional Boom Extension Offset 99
Hook Block 99
Removing the Hook Block 99
Installing the Hook Block 100
Boom Extension 101
Installing the Boom Extension 101
Adjusting the Boom Extension Angle 101
Stowing the Boom Extension 101
Searcher Hook Assembly 103
Installation 103
Removal 103
Down Haul Weight 104
Installing the Down Haul Weight 104
Removing the Down Haul Weight 104
Installing Cable On The Hoist 105
Wire Rope Wedge Socket 106
4 Part Wire Rope Reeving 108
SECTION 6 109
Maintenance 109
Introduction 109
Spark Arresting Mufflers 109
Safety List 109
Lubricants 110
Environmental Protection 110
Immediately clean up any spills 110
Maintenance Records 110
Special Maintenance 110
Delivery Inspection 110
After First 50 Hours of Operation (New Cranes) 110
Cranes Not In Regular Use 110
Preventive Maintenance 111
Maintenance Schedule and Checklist 111
Lubrication Points 114
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 117
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
Clean 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 129
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 Axle Housing Lubricant 133
Replace Axle Wheel Hub Lubricant 134
Replace the Hoist Gearbox and Brake Lubricant 135
Hoist Gearbox 135
Replace the Hydraulic Oil 135
Replace the Hydraulic Oil Filter 136
Check Swing Gear/Pinion Backlash 136
2000 Hours of Operation (Yearly) 137
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 138
Replacing the Battery 138
Battery Electrolyte First Aid 138
Fuel System 138
Fuel Storage 138
Fuse/Relay Replacement 138
SECTION 7 141
Adjustments 141
SECTION 8 143
Specifications 143
Lubricants And Capacities 143
Engine Oil Specifications 144
Cummins Oil Registration List 144
Oil Performance Recommendations 144
Oil Viscosity Recommendations 144
Viscosity Grades 144
Arctic Operation 144
Diesel Fuel 145
General Specifications 145
Engine 145
Tires 145
Electrical System 145
FUEL TANK 145
HYDRAULIC SYSTEM 146
Boom 146
MAST ROTATION – 360° 146
Wire Rope 146
Hydraulic System 146
Weight 146
Travel Speeds 147
Two-Wheel Steer 147
Operating Dimensions 147
Two-Wheel Steer 147
Four-Wheel Steer 147
Boom Angle 147
CTRL516-04_Warm-up_Procedures–Supplement pdf 0
Cold Climate Engine Operation 3
Crane Warm-up Procedures 3
Engine 3
Transmission 3
Hoist 3
Swing Drive and Turntable Bearing 4
Axles 4
Hydraulic Oil System 4

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