Manitowoc CD25 Operator's Manual
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Manitowoc CD25 Operator's Manual

Manitowoc CD25 Operator's Manual

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© 2017 Manitowoc
Published 3-30-2017, Control # 516-04
OPERATOR MANUAL
Supplement
Crane Warm-up Procedures
!
An untrained operator subjects himself and others to death or
serious injury. Do not operate this crane unless:
•
You are trained in the safe operation of this crane.
responsible for qualifying personnel.
•
You read, understand, and follow the safety and operating
recommendations contained in the crane manufacturer's manuals and
load charts, your employer's work rules, and applicable government
regulations.
•
You are sure that all safety signs, guards, and other safety features are
in place and in proper condition.
•
The Operator Manual and Load Chart are in the holder provided on
crane.
DANGER
Manitowoc is not

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Summary of Contents for Manitowoc CD25

  • Page 1 An untrained operator subjects himself and others to death or serious injury. Do not operate this crane unless: • You are trained in the safe operation of this crane. Manitowoc is not responsible for qualifying personnel. • You read, understand, and follow the safety and operating recommendations contained in the crane manufacturer’s manuals and...
  • Page 2 SECTION CONTENTS Crane Warm-up Procedures......... . . 1 Engine.
  • Page 3 Lubrication section of your crane’s Operator Manual, operating temperature. by contacting your local Manitowoc distributor, or by contacting Manitowoc Crane Care directly). NOTE: Warm-up operation of 4-wheel drive transmission engaged in 2-wheel drive only could cause transmission damage.
  • Page 4 Rotate the superstructure at a speed of less than one- and engine immediately and contact a Manitowoc half RPM for at least two complete revolutions in one distributor.
  • Page 5 CD25 Operator Manual...
  • Page 7 DANGER An untrained operator subjects himself and others to death or serious injury. Do not operate this crane unless: Manitowoc is not • You are trained in the safe operation of this crane. responsible for qualifying personnel.
  • Page 8 CALIFORNIA PROPOSITION 65 WARNING Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. CALIFORNIA PROPOSITION 65 WARNING Battery posts, terminals, and related accessories contain chemical lead and lead compounds, chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.

  • Page 9: Table Of Contents

    CD25 OPERATOR MANUAL TABLE OF CONTENTS See End of this Manual for Alphabetical Index SECTION 1 ........Introduction General .
  • Page 10 TABLE OF CONTENTS CD25 OPERATOR MANUAL General Maintenance ..........2-31 Transporting the Crane.
  • Page 11 CD25 OPERATOR MANUAL TABLE OF CONTENTS Handling a Load ........... 3-27 Attaching the Load .
  • Page 12 TABLE OF CONTENTS CD25 OPERATOR MANUAL Cranes Not in Regular Use ......... . . 6-7 Preventive Maintenance .
  • Page 13 CD25 OPERATOR MANUAL TABLE OF CONTENTS Miscellaneous Maintenance ..........6-36 Batteries/Charging System .
  • Page 14 TABLE OF CONTENTS CD25 OPERATOR MANUAL THIS PAGE BLANK TOC-6...

  • Page 15: Section 1

    Crane lifting capacities are found in the Load Chart Manual located in the cab along with this Operator Manual. Serial Number When contacting Manitowoc Cranes or its distributor about this machine always refer to the machine’s serial number. The serial number is printed on the serial number decal, located behind the operator ’s seat, see Figure 1-1.

  • Page 16: Delivery Report

    CD25 Delivery Report New Owners If you are the new owner of a Manitowoc crane, please A Delivery Report must be filled out by the Manitowoc register it with Manitowoc Crane Care so we have the ability Cranes distributor, signed by the purchaser, and returned to to contact you if the need arises.
  • Page 17 CD25 INTRODUCTION Pump......................Variable displacement piston pump Main Control Valves ...................Four-way, closed center, pilot operated (hoist, lift, telescope) Four-way, open center, pilot operated (swing) Swing Motor ....................Single section, gerotor-type Hoist Motor ....................Fixed displacement, axial piston Hydraulic Filters..................One 10-micron filter in line from valves, One 100-mesh suction filter inside hydraulic tank Hydraulic Cylinders ..................Double-acting cylinders for lift, telescope,...
  • Page 18 INTRODUCTION CD25 THIS PAGE BLANK Published 1-06-2017 Control # 579-01...

  • Page 19: Safety Messages

    CD25 SAFETY INFORMATION SECTION 2 SAFETY INFORMATION SECTION CONTENTS Safety Messages......2-1 Environmental Protection....2-27 General .

  • Page 20: General

    Identifies hazards that may result in death or serious ACCIDENTS injury if the message is ignored. Following any accident or damage to equipment, the Manitowoc dealer must be immediately advised of the incident and consulted on necessary inspections and repairs. Should the dealer not be immediately available, CAUTION...

  • Page 21: Operator Qualifications

    CD25 SAFETY INFORMATION manual and Load Chart must be readily available to the American National Standard, or in any other applicable operator at all times and must remain in the cab (if equipped) federal, state or local laws. or operator’s station while the crane is in use.

  • Page 22: Operational Aids

    (HCAS), a safe load indicator (SLI), or lifting operations shall establish procedures for an EKS5; Manitowoc refers to these systems as a rated determining load weights and shall ascertain that the capacity limiter (RCL) throughout its Operator and Service weight of the load does not exceed the crane ratings at Manuals.

  • Page 23: Anti-Two-Blocking Device

    CD25 SAFETY INFORMATION Anti-Two-Blocking Device the boom is lowered. Keep load handling devices a minimum of 107 cm (42 in) below the boom nose at all times. This crane should have a functional Anti-Two-Block and Two-blocking can be prevented. Operator awareness of the Control Lock-Out System.

  • Page 24: Crane Stability/Structural Strength

    SAFETY INFORMATION CD25 CRANE STABILITY/STRUCTURAL slightly off the ground and recheck the stability before proceeding with the lift. Determine the weight of the load STRENGTH before you attempt the lift. To avoid death or serious injury, ensure that the crane is on a Unless lifting within On Rubber capacities, outrigger beams firm surface with load and crane’s configuration within...

  • Page 25: Wind Forces

    Do not allow unnecessary personnel in the vicinity of the crane while operating. Wind forces can exert extreme dynamic loads. Manitowoc recommends that a lift not be made if the wind can cause a WIND FORCES loss of control in handling the load.
  • Page 26 SAFETY INFORMATION CD25 This 3-second wind gust is assumed to act on the entire NOTE: This condition is limited to operation with the main crane and the load. The wind effect on the load can be boom on fully extended outriggers only.
  • Page 27 CD25 SAFETY INFORMATION Simplified Method to Determine Maximum Permissible Wind Speed Determine 3-Second Gust 0.14 V(z) = [(z/10) + 0.4]v [m/s] Wind Speed at boom tip, 0.14 V(z) = [(z/33) + 0.4]v [mph] V(z) 13.4 m/s < V(z) < 20.1 m/s V(z) >...
  • Page 28 Use tag lines when the wind gust speed is above 13.4 m/s (30 mph) to help control the movement of the Metric, with Z [m] and V [m/s] load. Manitowoc recommends that a lift not be made if 0.14 V(z) = [(Z/10) + 0.4] x V...
  • Page 29 CD25 SAFETY INFORMATION Calculation of Projected Wind Area (Ap) Wind Wind = 8 m = 24 m 25 ft 25 ft Wind Wind 10 ft 3 ft = 75 ft = 250 ft 10 ft 3 ft 8384-1 FIGURE 2-2...
  • Page 30 SAFETY INFORMATION CD25 Table 2-2 Wind Drag Coefficient Maximum Permissible Wind Speed If the wind resistant area of the load Awr is greater than (load) Shape the allowable wind resistant area Awr , the ratio can be (allow) used to determine a permissible wind speed V(z) for the load 1.1 to 2.0...
  • Page 31 CD25 SAFETY INFORMATION Rated Load Chart Example - Metric 8383-1 FIGURE 2-3 Published 1-06-2017 Control # 579-01 2-13...
  • Page 32 SAFETY INFORMATION CD25 Table 2-4 Example-Capacity Reduction Factors for Wind Speed V(z) Greater than 13.4 m/s - Metric (Only for lifting with main boom on fully extended outriggers, with or without stowed extension) For wind speed V(z) (3-second gust speed at boom tip height) V(z) > 13.4 m/s ≤ 20.1 m/s, the Reduced Capacity...
  • Page 33 CD25 SAFETY INFORMATION At wind speeds greater than 13.4 m/s, it is not permissible to Load example 1.3a: lift a load greater than 12,040 kg, even if the wind resistance With large wind resistance area of the load Awr (load) area of the load is less than 14.45 m...
  • Page 34 SAFETY INFORMATION CD25 • Is the load to be lifted less than allowable load? Ratio = 1.37 8,000 kg ≤ 12,040 kg • Is Awr less than Awr (load) (allow) From Table 2-5, the maximum permissible wind speed at 19.83 m ≤...
  • Page 35 CD25 SAFETY INFORMATION Rated Load Chart Example - Non-metric 8382-1 FIGURE 2-4 Published 1-06-2017 Control # 579-01 2-17...
  • Page 36 SAFETY INFORMATION CD25 Table 2-6Example-Capacity Reduction Factors for Wind Speed V(z) Greater than 30 mph - Non-metric (Only for lifting with main boom on fully extended outriggers, with or without stowed extension) For wind speed Vz (3-second gust speed at boom tip height) is greater > 30> mph ≤ 45 mph, the Reduced Capacity...
  • Page 37 CD25 SAFETY INFORMATION • Is Awr less than Awr (load) (allow) 108 ft ≤ 119 ft L i f t i n g L i m i t s a t w i n d s p e e d V ( z ) > 3 0 m p h Conclusion: This load is permissible to lift in wind speed up and ≤...

  • Page 38: Lifting Operations

    SAFETY INFORMATION CD25 Refer to the above Lifting Limits at wind speed V(z) injury could result from the crane tipping over or failing > 30 mph and ≤ 45 mph. Comparing the load and wind structurally from overload. resistant area to the allowable: The crane can tip over or fail structurally if: •...

  • Page 39: Counterweight

    The “balance point” for stability testing perform tilt-up panel lifting with two hoist lines poses new and according to SAE and Manitowoc criteria is a condition of different hazards than does normal lifting use. loading wherein the load moment acting to overturn the...

  • Page 40: Pile Driving And Extracting

    All hoist hooks shall be equipped with a positive locking driving or pile extraction is being considered. latch. It is not the intention of Manitowoc to recommend specific Crane Inspection types or makes of pile driving and pile extraction equipment, but rather to advise of the operational requirements to help •...

  • Page 41: Electrocution Hazard

    DANGER Electrocution Hazard! Thoroughly read, understand, and abide by all applicable Manitowoc cranes are not equipped with all features federal, state, and local regulations regarding operation of required to operate within OSHA 29CFR1926.1408, cranes near electric power lines or equipment.

  • Page 42: Set-Up And Operation

    SAFETY INFORMATION CD25 Most overhead power lines are not insulated. Treat all Appoint a reliable and qualified signal person, equipped with overhead power lines as being energized unless you have a loud signal whistle or horn and voice communication reliable information to the contrary from the utility company equipment, to warn the operator when any part of the crane or owner.

  • Page 43: Electrical Contact

    2.0 m (6.6 ft)) at least 1.5 m (5 ft) into the any evidence of damage and all damaged parts are repaired ground. or replaced as authorized by your Manitowoc distributor or Moisten the soil around the metal rod (3) for better Manitowoc Crane Care.

  • Page 44: Personnel Handling

    ASME B30.5, Mobile and Locomotive Cranes, ASME B30.8, Floating Cranes and Floating Derricks, and in OSHA regulations 29CFR1910.180 for General Industry and 29CFR1926.1431 for Construction. Use of a Manitowoc crane to handle personnel is acceptable provided: • The requirements of the applicable national, state and local regulations and safety codes are met.

  • Page 45: Environmental Protection

    Manitowoc reminds crane owners to ensure that all safety requirements of applicable national, state and local decals are in place and legible. Manitowoc continues to urge regulations and safety codes are met. crane owners to upgrade their cranes with rated capacity •...

  • Page 46: Lubrication

    • Consult with Manitowoc Crane Care to determine if load pressure is relieved. To relieve hydraulic pressure, stop testing is required after a structural repair is performed.

  • Page 47: Tires

    Use only the hoist rope specified by Manitowoc as indicated rope. The nominal strength of a rope should never be on the crane’s Capacity Chart. Substitution of an alternate used as its working load.

  • Page 48: Sheaves

    SAFETY INFORMATION CD25 • If an operator hoists the hook block up or down too fast Broken wires; number and location. when reeved with multiple parts of line and no hook load, Reduction in diameter. the wire rope can bird cage and damage the rope.

  • Page 49: Batteries

    CD25 SAFETY INFORMATION Inspect the boom nose and hook block sheaves for proper • Do not short across the battery posts to check charge. operation, excessive wear, and damage every 50 hours or Short circuit, spark, or flame could cause battery weekly.

  • Page 50: Transporting The Crane

    SAFETY INFORMATION CD25 required, keep hands clear of the engine fan and other on the boom, it must be secured at the tie down on the carrier moving parts while performing maintenance. to prevent swinging. Be careful of hot surfaces and hot fluids when performing When using hookblock tie downs, excessive loading can be maintenance on or around the engine.

  • Page 51: Work Practices

    Always drive the crane carefully obeying speed limits and system that have not been evaluated and approved by highway regulations. Manitowoc Crane Care. Stay alert at the wheel. Do not step on surfaces on the crane that are not approved or suitable for walking and working.

  • Page 52: Working

    SAFETY INFORMATION CD25 • Check for proper functioning of all controls and operator Never operate the crane when darkness, fog, or other aids (for example, RCL). visibility restrictions make operation unsafe. Never operate a crane in thunderstorms or high winds.

  • Page 53: Lifting

    CD25 SAFETY INFORMATION Be sure the load is well secured and attached to the hook with rigging of proper size and in good condition. Check the hoist brake by raising the load a few inches, stopping the hoist and holding the load. Be sure the hoist brake is working correctly before continuing the lift.

  • Page 54: Hand Signals

    SAFETY INFORMATION CD25 Be sure everyone is clear of the crane and work area before • Moving the crane in an area or direction in which the making any lifts. operator cannot clearly see the path of travel. Never swing over personnel, regardless of whether load is At all times use standardized hand signals - previously suspended from or attached to the boom.
  • Page 55 CD25 SAFETY INFORMATION FIGURE 2-10 8496-1 Published 1-06-2017 Control # 579-01 2-37...

  • Page 56: Jib

    Use the most stable and secure position. However, Manitowoc caution handling and operating these components in sub- recognizes that certain jobsite conditions may not permit the zero temperatures, avoiding shock loading.

  • Page 57: Temperature Effects On Hook Blocks

    CD25 SAFETY INFORMATION If applicable to your crane, frequently check all air tanks for The change in the length of a cylinder is proportional to the water in freezing weather. extended length of the cylinder and to the change in temperature of the oil in the cylinder.
  • Page 58 SAFETY INFORMATION CD25 Table 2-8: Boom Drift Chart (Cylinder length change in inches) Coeff. = 0.00043 (in / °F) STROKE Temperature Change (°F) (FT.) 0.26 0.52 0.77 1.03 1.29 1.55 1.81 2.06 2.32 2.58 0.52 1.03 1.55 2.06 2.58 3.10 3.61...

  • Page 59: Overload Inspection

    WARNING This information supplements the Rated Capacity Limiter Overload Hazard! (RCL) manual supplied with each Manitowoc crane. When the RCL system has acknowledged an overload To avoid an accident caused by overload damage to on your crane, you must carry out specified inspections your crane: on the crane.

  • Page 60: Boom Inspection

    SAFETY INFORMATION CD25 Boom Inspection 2, 3 9, 10 2-42 2-42 Published 1-06-2017 Control # 579-01...
  • Page 61 CD25 SAFETY INFORMATION Overload less than 25% Sheaves, Inspect all for damage. Rope Guides Collar-Wear Pads, Pad Inspect for damage. Retainers Overload from 25% to 49% Sheaves, Inspect all for damage. Rope Guides Collar-Wear Pads, Pad Inspect all for damage.

  • Page 62: Superstructure Inspection

    SAFETY INFORMATION CD25 Superstructure Inspection 10,11 8, 9 2-44 2-44 Published 1-06-2017 Control # 579-01...
  • Page 63 CD25 SAFETY INFORMATION Overload less than 25% Lift Cylinder Inspect for leaking. See topic in Introduction section Wire Rope Inspect all for damage. of Service Manual. Turntable See topic in Swing section of Check bolts for proper torque. Bearing Service Manual.

  • Page 64: Carrier Inspection

    SAFETY INFORMATION CD25 Carrier Inspection 5, 6 2-46 2-46 Published 1-06-2017 Control # 579-01...
  • Page 65 CD25 SAFETY INFORMATION Overload less than 25% Stabilizer Inspect for leaking. Cylinders Outrigger Inspect for deformation and cracked welds. Pads Overload from 25% to 49% jack Cylinders Inspect for leaking. Outrigger Inspect for deformation and cracked welds. Pads Outrigger Inspect for deformation and cracked welds.
  • Page 66 SAFETY INFORMATION CD25 THIS PAGE BLANK 2-48 2-48 Published 1-06-2017 Control # 579-01...

  • Page 67: Section 3

    CD25 OPERATING CONTROLS AND PROCEDURES SECTION 3 OPERATING CONTROLS AND PROCEDURES SECTION CONTENTS Controls, Switches, and Gauges....3-1 Cab Heater Warm-up..... . 3-14 Cab Controls .

  • Page 68: Foot Controls

    OPERATING CONTROLS AND PROCEDURES CD25 FIGURE 3-1 Press on the end of the lever to operate the windshield washer. Item Description Press the button on the end of the lever to sound the horn. Swing Control Lever Transmission Shift Lever...

  • Page 69: Left Dash Controls

    CD25 OPERATING CONTROLS AND PROCEDURES Item Description Swing Control Lever Telescope Control Lever Defroster Switch Error Code Screen Toggle Switch Steering Select Switch Outrigger Extend/Retract Switch Headlights/Work Lights Switch Emergency Stop Switch Hoist Speed Switch Two Wheel/Four Wheel Drive Switch...

  • Page 70: Right Dash Controls

    OPERATING CONTROLS AND PROCEDURES CD25 Hoist Speed Switch Item Description The Hoist Speed Switch (9) is used to select either high Drum Rotation Indicator (DRI) speed or low speed lifting/lowering of the hoist cable. Push the top of the switch for high speed or the bottom of the Hoist Control Lever/DRI Thumb Thumper switch for low speed.
  • Page 71 CD25 OPERATING CONTROLS AND PROCEDURES lever is in the (N) Neutral position and the parking brake engage the lock, press the top of the switch to disengage the switch is in park. The switch is spring loaded to return from lock.

  • Page 72: Indicator And Gauge Display

    OPERATING CONTROLS AND PROCEDURES CD25 Indicator and Gauge Display As a system check, the indicators will come on for two seconds when the ignition switch is turned to the RUN position. FIGURE 3-5 (Figure 3-5) Item Numbers Item Description Item...
  • Page 73 CD25 OPERATING CONTROLS AND PROCEDURES hoist down, telescope out and boom lift functions will be Fuel Gauge disabled. The Fuel Gauge (1) (Figure 3-5) indicates the quantity of fuel in the fuel tank and has a scale calibrated from 0 (empty) to Battery Charge Indicator 4/4 (full).

  • Page 74: Crane Level Indicator

    OPERATING CONTROLS AND PROCEDURES CD25 Exhaust System Cleaning Needed Indicator Transmission Oil High Temperature Indicator The Exhaust System Cleaning Needed Indicator (16) The Transmission Oil High Temperature Indicator (23) illuminates amber when the exhaust system is becoming illuminates red during high transmission oil temperature clogged and in need of cleaning.

  • Page 75: Rated Capacity Indicator (Rci)

    CD25 OPERATING CONTROLS AND PROCEDURES period of time will result in a mild derate compared to a The air filter (5) can be removed and cleaned. Refer to coolant temperature over a threshold for a longer time). Heater/Air Conditioner, page 3-11.

  • Page 76: Outrigger Controls

    OPERATING CONTROLS AND PROCEDURES CD25 Outrigger Controls selected and the steering wheel is turned, the steering mode will automatically switch when the tires are aligned in straight ahead direction. w0023 1100267 DO NOT allow any persons to stand near extending or lowering outriggers.

  • Page 77: Operator's Cab

    CD25 OPERATING CONTROLS AND PROCEDURES a0565 FIGURE 3-14 Crab Steer Mode FIGURE 3-16 NOTE: When operating the heater ensure the shut-off valve (1, Figure 3-17) in the hot water supply line on the engine is open. p0510 All wheels steer in the same direction (Figure 3-15). This mode permits the operator to move the crane sideways.

  • Page 78: Seat Adjustment

    OPERATING CONTROLS AND PROCEDURES CD25 To operate the defroster, use the defroster switch (3, Figure 3-3) located on the instrument panel. Seat Adjustment Adjust the operator’s seat correctly. Full foot pedal control must be obtained with your back firmly against the seat back.

  • Page 79: Crane Operation

    Performing a warm-up procedure is recommended at every Lubrication section of your crane’s Operator Manual, by startup and is required at ambient temperatures below 4°C contacting your local Manitowoc distributor, or by contacting (40°F). Manitowoc Crane Care directly). Warm-up Procedures:...

  • Page 80: Cab Heater Warm-Up

    If there is any unusual sound coming from the crane’s hydraulic pumps or motors, stop the operation and engine immediately and contact a Manitowoc distributor. • From 10°C to 4°C (50°F to 40°F): Crane operation with...
  • Page 81 CD25 OPERATING CONTROLS AND PROCEDURES Do not press the accelerator pedal, the engine ECM will determine the proper idle speed. If the engine fails to start on the first try, wait until the starter motor comes to a complete stop; then again crank the engine with the ignition key.
  • Page 82 OPERATING CONTROLS AND PROCEDURES CD25 NOTE: NEVER jump start the engine directly to the starter Connect the other end of the positive cable to the or starter solenoid. Serious injury could result from positive (+) post on the booster battery.

  • Page 83: Traveling With The Crane

    CD25 OPERATING CONTROLS AND PROCEDURES Traveling with the Crane CAUTION w0027 To avoid damage to the parking brake and crane, do not apply the parking brake while traveling. Select either the Forward (F) or Reverse (R) travel position transmission shift...

  • Page 84: Changing Travel Direction

    OPERATING CONTROLS AND PROCEDURES CD25 Changing Travel Direction the engine runs at high speed while the transmission is in forward or reverse and the drive wheels are not It is recommended that the crane come to a complete moving. For example, when the wheels are mired in stop before changing travel direction.
  • Page 85 CD25 OPERATING CONTROLS AND PROCEDURES Place a miracle pointer level, carpenter level, or similar Run the engine at idle speed (accelerator pedal type device on a machined surface such as the turntable released). bearing or bearing mounting surfaces. Push the top of the Extend/Retract Switch (2).

  • Page 86: Outrigger Monitoring System (Oms) (Optional-Standard In North America)

    OPERATING CONTROLS AND PROCEDURES CD25 Outrigger Monitoring System (OMS) Raising the Jacks (Optional—Standard in North America) Place Outrigger/Jack selector switches Figure 3-27) in the jack position—push the bottom of the The Outrigger Monitoring System (OMS) aids the operator switch. by using an indicator (1, Figure 3-29) on the control panel that lights when all outriggers are fully deployed.
  • Page 87 CD25 OPERATING CONTROLS AND PROCEDURES When operating each control, press the accelerator pedal to w0022 increase engine speed to maximum RPM. Slowly move the control lever. The further the control lever is moved the faster the function will operate. To stop function movement, move the control lever to the neutral position, then lower the engine speed to idle.
  • Page 88 OPERATING CONTROLS AND PROCEDURES CD25 Boom Telescope Operation WARNING Always operate the hoist control to unwind the wire rope when extending the boom. Do not let the drop block touch the boom head. An automatic cutout device is installed on this crane to inhibit the drop block from being pulled into the boom head.
  • Page 89 CD25 OPERATING CONTROLS AND PROCEDURES Boom Lift Operation w0028 w0030 1200144 NOTE: Look for overhead obstructions before raising the boom. Possible damage or electrocution could occur if the boom comes in contact with overhead power lines. To Raise the Boom...
  • Page 90 OPERATING CONTROLS AND PROCEDURES CD25 Hoist Operation CAUTION Never put side loads on the boom. Side loads can damage the swing gearbox. Move the boom so that it is directly above the load before lifting the load. Do not let the hookblock touch the boom head. An...
  • Page 91 CD25 OPERATING CONTROLS AND PROCEDURES a0584 a0583 FIGURE 3-37 Published 1-06-2017 Control # 579-01 3-25...

  • Page 92: Optional Controls Operation

    OPERATING CONTROLS AND PROCEDURES CD25 Optional Controls Operation away from the area. Injury can be caused if the wire rope breaks or the hook becomes disconnected. Under Deck Winch To Extend the Wire Rope w0031 Push and hold the top of the switch (Figure 3-38). Keep tension on the wire rope to prevent twisting of the wire rope on the winch drum.

  • Page 93: Operating Practices

    CD25 OPERATING CONTROLS AND PROCEDURES OPERATING PRACTICES That the boom when extended, is laterally straight. That the hoist rope is not kinked or damaged. Handling a Load That multiple-part lines are not twisted around each The crane must not be loaded beyond the specifications of other.

  • Page 94: Traveling With A Load (Pick And Carry)

    The owner/lessee must take appropriate measures to Lifting Personnel ensure that all persons operating or working with the affected models are in compliance with Manitowoc Crane Care’s recommendations. The operator of the crane assumes responsibility for determining the suitability of traveling on a slope.

  • Page 95: Turning Clearances

    CD25 OPERATING CONTROLS AND PROCEDURES Battery Disconnect railings, planks, ladders, etc. on the platform for the purpose of achieving additional reach or height. The battery disconnect switch is located on the right side of See ASME B30.5 (Latest Edition) for additional the cab, in front of the seat.
  • Page 96 OPERATING CONTROLS AND PROCEDURES CD25 THIS PAGE BLANK 3-30 Published 1-06-2017 Control # 579-01...

  • Page 97: Using The Capacity Chart

    CD25 CAPACITY CHART SECTION 4 CAPACITY CHART SECTION CONTENTS Using the Capacity Chart ....4-1 Things to Observe when Using the Capacity Chart4-1 Operating Boom Radius.

  • Page 98: Lifting With The Boom Extension Installed

    CAPACITY CHART CD25 • With a load both on the boom (pick and carry) and on the cranes’s deck the maximum combined load is 9072 kg (20,000 lb). The maximum load that can be placed only on the deck is 13 608 kg (30,000 lb).
  • Page 99 CD25 CAPACITY CHART a0624 FOR REFERENCE ONLY USE THE LOAD CHART IN THE OPERATOR’S CAB FIGURE 4-3 Published 1-06-2017 Control # 579-01...
  • Page 100 CAPACITY CHART CD25 THIS PAGE BLANK Published 1-06-2017 Control # 579-01...

  • Page 101: Section 5

    CD25 ATTACHMENTS SECTION 5 ATTACHMENTS SECTION CONTENTS Pivoting Boom Head......5-1 Boom Extension ......5-5 Boom Head Positions .

  • Page 102: Changing The Boom Head Position (No Extension)

    ATTACHMENTS CD25 FIGURE 5-3 a0594 Changing the Boom Head Position (No Using the hoist control, raise the block or hook ball off of the ground. Check that the wire rope is engaged in all Extension) the sheaves in the boom, hoist block and hoist drum.

  • Page 103: Adjusting The Boom Extension Offset

    CD25 ATTACHMENTS Adjusting the Boom Extension Offset Offset Boom Head +60° (Figure 5-6) Run rope above pin #1 and between pin #2 and sheave wheel. WARNING Pin #1 Wire Rope Pin #2 Crushing Hazard! The boom extension is very heavy. Use another crane or hoist to support the extension from falling when the pivot lock pin is removed and adjusting the extension angle.

  • Page 104: Hook Block

    ATTACHMENTS CD25 HOOK BLOCK Install the three pins. Removing the Hook Block Remove Pins Lower the hook block to the ground to place slack in the wire rope. CAUTION Ensure that the hook assembly’s safety latch (Figure 5-9) does not get damaged.

  • Page 105: Boom Extension

    CD25 ATTACHMENTS BOOM EXTENSION Install the pin at location No. 4 to secure the deflector sheave bracket in place. Installing the Boom Extension Swing the boom extension at the swing arm pivot point (No. 5). Align and engage the extension link with the boom head at location No.
  • Page 106 ATTACHMENTS CD25 Swing the storage arm forward. Remove pin at location Remove pin at location No. 13. Swing the boom No. 11. Engage the boom extension with the storage extension to engage it with the bracket on boom. Install arm and install pin at location No. 5.

  • Page 107: Down Haul Weight

    CD25 ATTACHMENTS DOWN HAUL WEIGHT Installing the Down Haul Weight Whenever a single part line is used on a crane to lift a load, the load indicator transmitter must be removed from the boom head and installed onto the down haul weight. Without...

  • Page 108: Installing Cable On The Hoist

    ATTACHMENTS CD25 Install the transmitter to the boom head (Figure 5-12) using the existing hardware. Install the hoist block. Install the load pin. Connect the transmitter wire (Figure 5-12) and the load pin wire to the jumper wire. INSTALLING CABLE ON THE HOIST...
  • Page 109 5/16 7.94 13.28 Of the methods shown below, Manitowoc prefers that 7/16 11.11 method A or F be used, i.e., clipping a short piece of wire rope to the dead-end or using a commercially available 12.70...
  • Page 110 ATTACHMENTS CD25 Specialty Clip Specialty Wedge Wedge Socket FIGURE 5-16 5-10 Published 1-06-2017 Control # 579-01...

  • Page 111: Section 6

    CD25 MAINTENANCE SECTION 6 MAINTENANCE SECTION CONTENTS Introduction....... 6-3 Internal Cable Sheave Lubrication... . 6-25 Spark Arresting Mufflers .

  • Page 112: Introduction

    U s e e y e p r o t e c t i o n w h e n p e r f o r m i n g s e r v i c e o r for wire ropes used on Manitowoc products (e.g. wire rope maintenance tasks.

  • Page 113: Precautions And Recommendations During Inspection Or Replacement

    This in-process treatment will provide the finished rope only pre-assembled lengths of wire rope as supplied with ample protection for a reasonable time if it is stored from Manitowoc. Do not build lengths from individual under proper conditions. But, when the rope is put into components.

  • Page 114: Wire Rope Inspection (Running Ropes And Pendant Cables)

    Periodic inspection should include all items listed NOTE: Wire rope may be purchased through Manitowoc under frequent inspection plus the following: Crane Care. •...

  • Page 115: Wire Rope Inspection/Replacement (All Wire Rope)

    CD25 MAINTENANCE It is recommended that a periodic inspection of all boom and as recommended by Manitowoc. All wire rope will extension and retraction cables be performed using the eventually deteriorate to a point where it is no longer usable.

  • Page 116: Environmental Protection

    Immediately clean up any spills. LUBRICANTS FIGURE 6-4 It is not the policy of Manitowoc Cranes, Inc. to publish lists of approved lubricants or guarantee lubricant performance. Wind a length of soft annealed wire (Figure 6-4) around the The responsibly for the quality rests completely with the wire rope at least seven times.

  • Page 117: Special Maintenance

    CD25 MAINTENANCE SPECIAL MAINTENANCE Delivery Inspection Item Action Fuel Tank Fill with correct fuel. Fill if level is low. Check oil in crankcase. Engine Remove water from fuel filters. Cooling System Check coolant level. Fill if level is low. Hydraulic Tank Check oil level.

  • Page 118: Preventive Maintenance

    MAINTENANCE CD25 PREVENTIVE MAINTENANCE Maintenance Schedule and Checklist CAUTION Hour intervals in each maintenance chart show the correct time for service. The hourmeter located in the operator’s cab indicates the total hours the crane has been running. In addition to the following scheduled maintenance, perform the scheduled maintenance suggested in the engine manual furnished with the crane.
  • Page 119 CD25 MAINTENANCE Interval 1000 2000 Daily Service/Check Hours Hours Hours Hours Hours Hours Before (Two (Three (Six Operation (Weekly) (Monthly) (Yearly) Weeks) Months) Months) Check Air Cleaner Restriction Indicator Check Hydraulic Oil Level Inspect Wire Rope and Sheaves Apply Grease to All Lubrication...

  • Page 120: Lubricant Symbols

    MAINTENANCE CD25 Interval 1000 2000 Daily Service/Check Hours Hours Hours Hours Hours Hours Before (Two (Three (Six Operation (Weekly) (Monthly) (Yearly) Weeks) Months) Months) Check Swing Gear to Pinion Backlash Replace the Transmission Oil Replace the Axle Wheel Hub Lubricant (4 places)

  • Page 121: Lubrication Points

    CD25 MAINTENANCE LUBRICATION POINTS 8534 FIGURE 6-6 Location Name Capacity Symbol Instruction Front Drive/steer Axle Differential 4.8 Gal (18.0 Liters) HYDO Planetary Hub Gears 2.1 Qts (2.0 Liters) HYDO Kingpin Bearings EP-MPG Steer Cylinder Bearing EP-MPG Universal Joints EP-MPG Brake Caliper...
  • Page 122 MAINTENANCE CD25 Location Name Capacity Symbol Instruction Hub Bearings EP-MPG Kingpin Bearings EP-MPG Steer Linkage Bearing EP-MPG Steering Cylinder EP-MPG Engine & Trans. Engine Crankcase 8.6-11.6 Qts (8.1-11.0 L) EO-15W-40 See Note 2 Engine Coolant 4.3 Gal (22.7 L) See Notes 1 & 7 Transmission 6.0 Gal (22.7 L)

  • Page 123: Booms And Main Frame

    CD25 MAINTENANCE Optional Equipment and Accessories The hydraulic oil shall be filtered through a 10-micron (absolute) filter. Both sides. Location All sides. Drop Block (See Figure 6-16) Lubricate all surfaces in contact with wear pads. Jib Boom Head Sheave (See Figure 6-17)
  • Page 124 MAINTENANCE CD25 Boom Head Sheaves and Pivot Grease Points Steering Knuckle Grease Points - Front (both sides) and Rear Axles (Both sides) FIGURE 6-11 p0489 7407-34 FIGURE 6-9 Steering Cylinder Pivot Grease Points - Front and Rear Axles (Both sides)
  • Page 125 CD25 MAINTENANCE Front Axle Drive Shaft Grease Points - Three Lube Fittings Rear Axle Drive Shaft Grease Points - Three Lube Fittings FIGURE 6-14 FIGURE 6-13 p0491 p0490 Axle Pivot Grease Points - Front and Rear Axles FIGURE 6-15 p0492...
  • Page 126 MAINTENANCE CD25 Jib Boom Deflector Sheave Drop Block Grease Point Grease Point (Both sides) p0528 FIGURE 6-16 Jib Head Sheave Grease Point FIGURE 6-18 p0316 FIGURE 6-17 p0315 6-16 Published 1-06-2017 Control # 579-01...

  • Page 127: Daily Walk-Around Inspection

    CD25 MAINTENANCE DAILY WALK-AROUND INSPECTION Inspect the Lifting Hook NOTE: You must read and understand the warnings and basic safety rules, found in Section 2, Safety Information of this manual, before performing any DANGER operation or maintenance procedures. Loads may fall if the lifting hook is damaged or loose. A For additional engine maintenance guidelines, see falling load can injure or kill.
  • Page 128 MAINTENANCE CD25 Check the Transmission Oil Level Check the oil level only when the oil is at normal operating temperature (82° to 93°C [180° to 200°F]) Level the crane, engage the parking brake and let the engine run at idle speed.
  • Page 129 CD25 MAINTENANCE of glycol antifreeze and water, do not add only water as this could cause rust to form in the radiator and engine. NOTE: For more details on proper radiator checking and maintenance procedures, see the engine manual furnished with the crane.
  • Page 130 MAINTENANCE CD25 Remove the safety element. Check the Air Cleaner Restriction Indicator Clean the inside of the housing carefully. Any dirt left The air cleaner is equipped with a filter restriction indicator inside the housing could cause damage to the engine.

  • Page 131: Hours Of Operation (Weekly)

    CD25 MAINTENANCE 50 HOURS OF OPERATION (WEEKLY) NOTE: You must read and understand the warnings and basic safety rules, found in Section 2, Safety Information, before performing any operation or maintenance procedures. For additional engine maintenance guidelines, see the engine manual furnished with this crane.

  • Page 132: Clean The Air Cleaner Vacuator Valve

    It is recommended that all exposed cylinder rods be ® protected using Boeshield T-9 Premium Metal Protectant. Manitowoc Crane Care has Boeshield T-9 Premium Metal Protectant available in 12 oz. cans that can be ordered through the Parts Department. FIGURE 6-24...

  • Page 133: Inner Boom Wear Pad Lubrication

    CD25 MAINTENANCE Item Description Boom Section Access Holes for 4 Section Wear Pad Access Holes for 3 Section Wear Pad Access Holes for 2 Section Wear Pad Section Wear Pad Access Plate FIGURE 6-25 Inner Boom Wear Pad Lubrication Extend the boom about 1/3 and retract to spread the grease.

  • Page 134: Internal Cable Sheave Lubrication

    • A 6.35 mm (0.25 in) diameter nozzle grease gun tip (P/N maximum engine performance and fuel economy. Proper 955045). Contact Manitowoc Crane Care to obtain this belt tension minimizes slippage and increases belt life. tip. Lubrication of the extend and retract sheaves is as follows:...

  • Page 135: Check The Wheel Nut Torque

    CD25 MAINTENANCE Check the Wheel Nut Torque Check the torque on each wheel nut in a crisscross pattern. Wheel nut torque is 500 Nm (368 lb-ft). 250 HOURS OF OPERATION (MONTHLY) NOTE: You must read and understand the warnings and...

  • Page 136: Lubricate The Wire Rope

    MAINTENANCE CD25 w0022 1100262 Rotating gears can cause injury. Keep hands clear of rotating pinion and gear while the mast is rotating. FIGURE 6-27 Coat the battery posts with petroleum jelly and reinstall the battery cables. Lubricate the Wire Rope Apply lubricant to the hoist wire rope to inhibit rust, corrosion and wear.

  • Page 137: Replace The Crankcase Oil

    CD25 MAINTENANCE (1, Figure 6-31). Tighten the bolts exposed in each hole, then rotate the mast until different bolts are exposed and tighten them. Rotate the mast through a complete cycle, tightening all bolts. Top View 7508-77a Bottom View FIGURE 6-31...

  • Page 138: Replace The Engine Oil Filter

    MAINTENANCE CD25 Inspect the Tires Drain the engine oil only when it is hot and the contaminants are in suspension. Inspect the tires for any signs of damage, such as cracks, Review the engine manual furnished with the crane on large gouges, deterioration, etc.

  • Page 139: Replace Air Cleaner Element

    CD25 MAINTENANCE Install the new element in the housing and slide it all the way in. Make sure the gasket is seating evenly. If the gasket isn’t seating evenly for a perfect seal, you won’t have protection. Recheck to see if the sealing surface in the housing is clean, or if the element is not the right model number.

  • Page 140: Check The Axle Housing Lubricant Level

    MAINTENANCE CD25 FIGURE 6-36 a0629 Check the Axle Housing Lubricant Level Check the Wheel Hub Lubricant Level It is necessary to climb under the crane to check the axle Position the fill/check plug so it is horizontal with the housing lubricant. Be sure engine is shut off, the ignition key ground, at the 3 o’clock position (1, Figure 6-38).

  • Page 141: Check Swing Gearbox Lubricant Level

    CD25 MAINTENANCE Check Swing Gearbox Lubricant Level NOTE: It is necessary to climb under the crane to drain the transmission oil. Be sure engine is shut off, the It is necessary to climb under the crane to check the swing ignition key is removed and chock blocks are in gearbox lubricant level.

  • Page 142: Replace The Axle Housing Lubricant

    MAINTENANCE CD25 Refill the transmission with recommended fluid to LOW mark on the dipstick. Axle Housing Check/Fill Plugs Start the engine and let it run at idle speed to prime the torque converter and fill all lines. 10. With the engine running at idle speed, check the transmission oil level and fill to the LOW mark on the dipstick.

  • Page 143: Replace The Axle Wheel Hub Lubricant

    CD25 MAINTENANCE Replace the Axle Wheel Hub Lubricant Install the plug. Repeat the above procedure for the other three wheel hubs. Replace the Hoist Gearbox and Brake Lubricant Hoist Assembly Fully lower the boom assembly, engage the parking brake, but leave the engine running.

  • Page 144: Replace Swing Gearbox Lubricant

    MAINTENANCE CD25 Replace Swing Gearbox Lubricant NOTE: The pump used on this crane requires clean hydraulic oil for proper operation. Contaminated oil Clean around the swing gear box drain, check and fill can cause damage to the pump. Before adding any plugs (Figure 6-48).

  • Page 145: Replace The Hydraulic Oil Filter

    CD25 MAINTENANCE 12. Fill the hydraulic tank with Mobil Fluid 424 hydraulic oil to b. Start the engine and check for leaks around the the bottom of fill strainer. filter. 13. After the tank is filled, start the engine and operate each Check the Swing Gear/Pinion Backlash function until all the cylinders and lines are filled.

  • Page 146: 2000 Hours Of Operation (Yearly)

    MAINTENANCE CD25 2000 HOURS OF OPERATION (YEARLY) MISCELLANEOUS MAINTENANCE NOTE: You must read and understand the warnings and Batteries/Charging System basic safety rules, found in Section 2, Safety Information of this manual, before performing any NOTE: Lead-acid batteries produce flammable operation or maintenance procedures.

  • Page 147: Fuel System

    CD25 MAINTENANCE DO NOT charge a frozen battery; it may explode and cause Fuel Storage injury. Let the battery warm up before attaching a charger. Storage of fuel for an extended period causes accumulation Charging rates between 3 to 50 amperes are satisfactory if...
  • Page 148 MAINTENANCE CD25 Battery Compartment Fuse/Relay Panels There are two fuse panels in the battery compartment, fuse block 3 (1, Figure 6-55) and fuse block 4 (2). Refer to TABLE 6-1 and TABLE 6-2 for identification of the fuses. AXLE OSC SWITCH 7.5A...

  • Page 149: Diesel Exhaust Fluid (Def) Tank

    CD25 MAINTENANCE Diesel Exhaust Fluid (DEF) Tank TABLE 6-2: Fuse Block 4 Fuse Function Size DEF Pressure Line DEF Return Line DEF Suction Line DEF Line Relay Coil DEF Supply Module Relay Coil DEF Module + Aftertreatment Sensors Aftertreatment Sensor Relay Coil...
  • Page 150 MAINTENANCE CD25 THIS PAGE BLANK 6-40 Published 1-06-2017 Control # 579-01...

  • Page 151: Section 7

    CD25 ADJUSTMENTS SECTION 7 ADJUSTMENTS All adjustments must be performed by a qualified mechanic. Refer to the Service Manual for the proper procedures. Published 1-06-2017 Control # 579-01...
  • Page 152 ADJUSTMENTS CD25 THIS PAGE BLANK Published 1-06-2017 Control # 579-01...

  • Page 153: Lubricants And Capacities

    CD25 SPECIFICATIONS SECTION 8 SPECIFICATIONS SECTION CONTENTS Lubricants and Capacities ....8-1 Oil Viscosity Recommendations ....8-2 New Engine Break-In Oils .

  • Page 154: Oil Performance Recommendations

    SPECIFICATIONS CD25 Oil Performance Recommendations Oil Viscosity Recommendations The use of quality engine lubricating oils combined with The use of multi-viscosity lubricating oil has been found to appropriate oil drain and filter change intervals are critical improve oil consumption control and improve engine factors in maintaining engine performance and durability.

  • Page 155: General Specifications

    CD25 SPECIFICATIONS GENERAL SPECIFICATIONS Engine Make and model Cummins QSB4.5-130diesel Horsepower 130 hp @ 2500 rpm Torque 525 Nm (457 lb-ft) @ 1500 rpm Low idle speed 800 rpm Intermediate Speed Control (ISC) Idle Speed 1200 rpm - Coolant Temperature is less than 71° C (160° F)
  • Page 156 SPECIFICATIONS CD25 Boom angle: Maximum 80° Minimum 0° Published 1-06-2017 Control # 579-01...
  • Page 157 CD25 OPERATORS MANUAL ALPHABETICAL INDEX ..............2-40 100 Hours of Operation (Two Weeks) .
  • Page 158 Temperature Effects on Hydraulic Cylinders ....... . 2-39 Transporting the Crane..........2-32 Travel Operation.

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