Manitowoc Crane Shuttlelift CD5560B Grove YB5518 Operator Manual PDF

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Manitowoc Crane Shuttlelift CD5560B Grove YB5518 Operator Manual  – PDF DOWNLOAD

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Manitowoc Crane Shuttlelift CD5560B Grove YB5518 Operator Manual  – PDF DOWNLOAD

Language : English
Pages :174
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Manitowoc Crane Shuttlelift CD5560B Grove YB5518 Operator Manual  – PDF DOWNLOAD

SECTION 1 11
Introduction 11
The Manual 11
Directional Reference 11
Serial Number Plate 11
Serial Number 11
Reports 11
Disclaimer 11
Noise Level Test Results 12
Customer Support 12
New Owners 12
Nomenclature 13
Specifications 14
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 21
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
Personnel Handling 41
Environmental Protection 42
Maintenance 43
Service and Repairs 43
Lubrication 44
Tires 44
Hoist Rope 44
Wire Rope 44
Synthetic Hoist Rope 46
Sheaves 46
Batteries 46
Engine 47
Transporting the Crane 47
Travel Operation 47
Work Practices 48
Personal Considerations 48
Crane Access 48
Job Preparation 49
Working 49
Lifting 50
Hand Signals 51
Jib 53
Parking and Securing 53
Shut-Down 53
Cold Weather Operation 53
Temperature Effects on Hook Blocks 54
Temperature Effects on Hydraulic Cylinders 54
Overload Inspection 55
Boom Inspection 57
Superstructure Inspection 59
Carrier Inspection 61
SECTION 3 63
Operating Controls and Procedures 63
Controls, Switches, and Gauges 63
Cab Controls 63
Swing Control (See Figure 3-1) 63
Telescope Control (See Figure 3-1) 63
Hoist Control (See Figure 3-1) 63
Boom Control (See Figure 3-1) 63
Outrigger Controls (See Figure 3-1) 63
Accelerator Pedal (See Figure 3-1) 64
Brake Pedal (See Figure 3-1) 64
Steering Select Control (See Figure 3-1) 64
Travel Select Lever (See Figure 3-2) 65
Turn Signal and Flasher (See Figure 3-2) 65
Gauges and Indicators 65
Instrument Panel Gauge (See Figure 3-3) 65
Normal Operating Pressures 65
Normal Operating Temperature 65
Normal Voltage Ranges 65
Hourmeter (See Figure 3-4) 66
Crane Level Indicator (See Figure 3-5) 66
Engine Warning and Stop Lights (Diesel Engine Only) 66
Flashing Fault Codes 66
Engine Warning Light (Dual Fuel Engine) (See Figure 3-8) 68
Transmission Low Oil Pressure Warning Light (See Figure 3-6 and Figure 3-8) 68
Transmission Oil High Temperature Warning Light (See Figure 3-6 and Figure 3-8) 68
Low Brake Pressure Warning Light (See Figure 3-6 and Figure 3-8) 69
Optional Axle Lockout Warning Light (See Figure 3-9) 69
Boom Angle Indicator (See Figure 3-10) 69
Load Indicator Display Panel (Standard) 69
Optional Rated Capacity Limiter Display Panel (See Figure 3-12) 70
Panel Switches 70
Optional Dual Fuel Switch (See Figure 3-13) 70
Work Light/Head Light Switch (See Figure 3-13) 70
Parking Brake Switch (See Figure 3-14) 70
Ignition Switch (See Figure 3-13) 71
Auxiliary Winch Switch (Optional) (See Figure 3-13) 71
Windshield Wiper Switch (Optional) (See Figure 3-13) 71
Heater/defroster Switch (Optional) (See Figure 3-13) 71
Optional Axle Lockout Switch (See Figure 3-14) 71
Outrigger Controls 71
Outrigger Switches 72
Outrigger Select Switch 72
Standard Outriggers (Figure 3-16) 72
Optional Independent Outriggers (Figure 3-17) 72
Outrigger Extend/Retract and Lower/Raise Control (Figure 3-18) 72
Steering Controls 73
(Used on Units Prior to S/N 127904) 73
Two-Wheel Steer Mode Without Crab Steering (See Figure 3-21) 73
Two-Wheel Steer Mode With Crab Steering Option (See Figure 3-22) 73
Four-wheel Steer Mode (Figure 3-23) 74
Optional Crab Steer Mode (Figure 3-24) 74
Four-Wheel Steering Indexing Procedure 74
Units without Crab Steering 74
Units with Optional Crab Steering 74
Steering Controls (Used On Units With S/n 127904-04 And After) 75
Two-Wheel Steer Mode (see Figure 3-26) 75
Four-Wheel Steer Mode (Figure 3-27) 75
Optional Crab Steer Mode (Figure 3-28) 75
Operator’s Cab 76
Heater and Defroster 76
Seat Adjustment 76
Seat Belt 77
Cab Door (Enclosed Cab) 77
Opening the Cab Door from Outside 77
Opening the Door from Inside 77
Locking the Cab Door 77
Opening Side Window 77
Fire Extinguisher (Optional) 77
Machine Operation 78
Fuel Change Over Instructions – Dual Fuel Engines 78
Starting the Engine 78
Normal Engine Starting 78
Engine Starting Procedures 79
Applying Starting Fluid to the Diesel Engine 79
Applying Fluid Using a Metered Injection-Type Starting Aid (Optional) 79
Applying Fluid from a Spray Canister 81
Towing or Pushing the Crane to Start the Engine 81
Crane Warm-up Procedures 81
Engine 81
Transmission 81
Hoist 82
Swing Drive and Turntable Bearing 82
Axles 82
Hydraulic Oil System 82
Cab Heater Warm-up 82
Jump Starting the Engine 83
Traveling with the Crane 84
Changing Travel Direction 85
Shifting Gears (Travel Speeds) 85
Stopping Travel 86
Operating the Outrigger Controls 86
To Extend and Lower the Outriggers 86
To Raise and Retract the Outriggers 87
Independent Outrigger Operation (Optional) 88
Bubble Level Adjustment 88
Outrigger Monitoring System (OMS) (Optional—Standard in North America) 88
Operating the Boom Controls 90
Boom Swing Operation 90
To Rotate the Mast to the Left (Counterclockwise) 90
To Stop Rotation 90
To Rotate the Mast Right (Clockwise) 90
Boom Telescope Operation 91
To Extend the Booms 91
To Stop Extension/Retraction 91
To Retract the Booms 91
Boom Lift Operation 92
To Raise the Boom 92
To Stop Boom Movement 92
To Lower the Boom 92
Hoist Operation 93
To Raise the Drop Block 95
To Stop Boom Movement 95
To Lower the Boom 95
Optional Controls Operation 96
Auxiliary Winch 96
To Extend the Wire Rope 96
To Stop the Winch 96
To Retract the Wire Rope 96
Operating Practices 97
Handling a Load 97
Attaching the Load 97
Holding the Load 97
Moving the Load 97
Traveling with a Load (Pick and Carry) 97
Elevating Personnel 98
Preparation and Setup 98
Lifting Personnel 98
Capacity Limitations 98
Turning Clearances 98
Machine Shutdown 98
Unattended Crane 99
Towing a Disabled Machine 99
SECTION 4 101
Capacity Chart 101
Using the Capacity Chart 101
Operating Boom Radius 101
Locating the Lift Capacity 101
Things to Observe When Using the Capacity Chart 101
Lifting with the Jib Boom Installed 103
Pick and Carry Ranges 103
SECTION 5 105
Attachments 105
Pivoting Boom Head 105
Boom Head Positions 105
Positions When No Boom Extension Is Attached 105
Positions When Boom Extension Is Attached 105
Changing the Boom Head Position (No Boom Extension) 107
Adjusting the Boom Extension Offset 107
Hoist Block 108
Removing The Hoist Block 108
Installing the Hoist Block 109
Boom Extension 109
Attaching the Boom Extension 109
Adjusting the Boom Extension Angle 113
Stowing the Boom Extension 113
Searcher Hook Assembly 116
Installation 116
Removal 116
Down Haul Weight 117
Installing the Down Haul Weight 117
Removing the Down Haul Weight 117
Installing Cable On The Hoist 118
Wire Rope Wedge Socket 119
Downhaul Weight Sleeve Removal 120
Reeving 121
Reeving For 4-part Line 121
SECTION 6 123
Maintenance 123
Introduction 124
Spark Arresting Mufflers 124
Safety List 124
Lubricants 124
Maintenance Records 124
Special Maintenance 124
Delivery Inspection 124
After First 50 Hours Of Operation (New Cranes) 125
Cranes Not In Regular Use 125
Preventive Maintenance 125
Maintenance Schedule and Checklist 125
Lubrication Points 128
Scheduled Maintenance 131
Daily (Walk-around) Inspection 131
Inspections 131
Inspecting the Anti-Double Blocking System 131
Inspect the Wire Rope 131
Inspecting Reeving, Clamps and Connections 131
Inspecting the Lifting Hook 132
Inspecting All Safety Devices 132
Checking Controls Operation 132
Component/System Checks 132
Checking Fuel Level 132
Checking the Engine Crankcase Oil Level 132
Checking the Transmission Oil Level 133
Checking Engine Coolant Level 133
Drain Water From Engine Fuel Filter (Diesel Engine) 134
Checking Hydraulic Oil Level 134
Checking the Air Cleaner Restriction Indicator 134
Removing the Element 134
Inspecting the Element 135
Cleaning the Element 135
Installing the Element 135
Checking Tire Pressure 135
50 Hours Of Operation 135
Clean the Air Cleaner Dust Cup 135
Wire Rope Inspection 135
Inspection 135
General Inspection 136
Grease Fittings 137
Lubricating the Boom Slides 137
Lubricate Parking Brake 137
Lubricating the Boom Chains 137
100 Hours Of Operation 137
Inspecting the Fan Belts 138
Checking Wheel Nut Torque 138
250 Hours of Operation 138
Inspecting the Boom Chains 138
Inspecting Hydraulic Hoses 139
Cleaning Battery and Cables 140
Cleaning the Radiator 140
Lubricate the Wire Rope 140
Lubricating the Swing Gear and Pinion 140
Replacing the Crankcase Oil and filter 141
Torquing Critical Bolts 141
Hoist Gearbox Mounting Bolts 141
Swing Gearbox Mounting Bolts 141
Mast Mounting Bolts 142
Front Axle Mounting Bolts 142
500 Hours Of Operation 143
Inspect the Tires 143
Inspect Parking Brake Pads 143
Replacing Fuel Filter (Diesel Engine) 143
Replacing Air Cleaner Element 143
Spark Plug Gap (Gasoline Engine) 144
Adding Rust Inhibitor To Engine Cooling System 144
Lubricating the Outrigger Slides 144
Adding Grease To the Swing Gearbox 144
Checking the Axle Housing Lubricant Level 145
Checking the Wheel Hub Lubricant Level 145
Checking Hoist Gearbox and Brake Lubricant Levels 145
1000 Hours Of Operation 146
Replacing the Transmission Oil and Filter 146
Replacing the Axle Housing Lubricant 147
Replacing Axle Wheel Hub Lubricant 148
Replacing the Hoist Gearbox and Brake Lubricant 148
Hoist Gearbox 148
Replacing the Hydraulic Oil 149
Replacing the Hydraulic Oil Filter 150
Replace L P G Inline Filter 150
Checking Swing Gear/pinion Backlash 150
Cleaning the PVC Valve (Gasoline Engine) 151
Cleaning the PVC Tubing and Fittings (Gasoline Engine) 151
Replacing the Spark Plugs (Gasoline Engine) 151
Replacing the In-line Fuel Filters (Gasoline Engine) 151
Replacing the Course Fuel Filter 151
Replacing the Fine Fuel Filter 151
2000 Hours Of Operation 152
Replacing the Engine Coolant 152
Inspect the Crane Structure and Booms For Damage 152
Testing the Load Moment Indicator (Optional) 152
Miscellaneous Maintenance 152
Batteries/charging System 152
Checking the Charging System 152
Normal Operating Ranges 152
Charging the Battery 153
Replacing the Battery 153
Fuel System 153
Fuel Storage 153
Fuse Replacement 153
SECTION 7 155
Adjustments 155
Hydraulic System Adjustments 155
Testing the Relief Valve Settings 155
Pump Section No 1 Relief Valve Test (Main Hoist Circuit) 155
Pump Section No 2 Relief Valve Test (Telescope and Lift Circuits) 155
Pump Section No 3 Relief Valve Test (Swing Circuit) 156
Pump Section No 4 Relief Valve Test (Steering, Outrigger and Pilot Circuits) 156
Outrigger Circuit Relief Valve 156
Steering Circuit Relief Valve 157
Pilot Circuit Relief Valve 157
Adjusting Relief Valve Pressure 157
Pump Sections No 1 (Hoist Circuit) 157
Pump Sections No 2 (Telescope and Boom Circuits) 157
Pump Section No 3 Relief Valve Setting (Swing Circuit) 158
Pump Section No 4 Relief Valve Setting (Steering, Outrigger and Pilot Circuits) 158
Steering Circuit Relief Valve 158
Outrigger Circuit Relief Valve 158
Pilot Circuit Relief Valve 159
Boom Adjustments 159
Boom Slide Pad Adjustments 159
Swing Gear and Pinion Adjustment 161
Parking Brake Adjustment 161
SECTION 8 163
Specifications 163
Lubricants and Capacities 163
Engine Oil Specifications 165
Diesel Engine 165
Oil Performance Recommendations 165
Oil Viscosity Recommendations 165
Viscosity Grades 165
Arctic Operation 165
Gasoline Engine 166
API, SAE ASTM Classification 166
Fuel Types 166
Diesel Fuel 166
Gasoline 166
Relief Valve Settings 167
General Specifications 167
Engine 167
Diesel 167
Gasoline/L P G 167
Tires 167
Electrical System 167
Boom 168
Wire Rope 168
Hydraulic System 168
Weight 168
Travel Speeds 168
Two-Wheel Steer 168
Operating Dimensions 168
Two-Wheel Steer 168
Four-Wheel Steer 168
Boom Angle 168
Dimensions 169

Customer Support: [email protected]

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