Manitowoc 18000 Service Maintenance Manual
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Manitowoc 18000 Service Maintenance Manual

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Manitowoc 18000
Service/Maintenance Manual

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  • Page 1 Manitowoc 18000 Service/Maintenance Manual...
  • Page 3 The serial number of the crane and applicable attachments (i.e. luffing jib, MAX-ER ) is the only method your Manitowoc dealer or the Manitowoc Crane Care Lattice Team has of providing you with correct parts and service information. The serial number is located on a crane identification plate attached to the operator’s cab and each attachment.
  • Page 4 THE ORIGINAL LANGUAGE OF THIS PUBLICATION IS ENGLISH...

  • Page 5: Table Of Contents

    18000 SERIVCE/MAINTENANCE MANUAL TABLE OF CONTENTS See end of this manual for Alphabetical Index SECTION 1 ..........Introduction Continuous Innovation .
  • Page 6 TABLE OF CONTENTS 18000 SERIVCE/MAINTENANCE MANUAL Boom Hoist System Operation ........... . . 1-38 Boom Hoist System Components.
  • Page 7 Hydraulic System Specifications - 18000 ........
  • Page 8 TABLE OF CONTENTS 18000 SERIVCE/MAINTENANCE MANUAL Crane Diagnostics ............. . . 3-40 General.
  • Page 9 18000 SERIVCE/MAINTENANCE MANUAL TABLE OF CONTENTS Weekly Maintenance ............5-6 Adjustment.
  • Page 10 TABLE OF CONTENTS 18000 SERIVCE/MAINTENANCE MANUAL Calibration ..............7-12 Engine Speed Calibration .
  • Page 11 Engine Faults (Tier 4) ..........1-28 Manitowoc...
  • Page 12 18000 SERIVCE/MAINTENANCE MANUAL Operating Faults and Limit Switches ........1-28 Brake and Drum Pawl Operation .

  • Page 13: Section 1

    Due to continuing product innovation, the information in this result in death or serious injury. manual is subject to change without notice. If you are in doubt about any procedure, contact your Manitowoc dealer or the Manitowoc Crane Care Lattice Team. WARNING...

  • Page 14: Safe Maintenance Practices

    Use both hands and handrails, steps and ladders provided to climb onto and off crane. To ensure safe and proper operation of Manitowoc cranes, they must be maintained according to the instructions Lift tools and other equipment which cannot be carried in...

  • Page 15: Environmental Protection

    INTRODUCTION 14. Avoid battery acid contact with skin and eyes. If contact 28. Unless authorized in writing by Manitowoc, do not alter occurs, flush area with water and immediately consult a crane in any way that affects crane’s performance (to doctor.

  • Page 16: Identification And Location Of Components

    INTRODUCTION 18000 SERIVCE/MAINTENANCE MANUAL IDENTIFICATION AND LOCATION OF COMPONENTS See Figures through 1-13 for graphic identification of crane components. Basic Crane Item Description Boom Top Load Block Boom Insert Boom Insert (with Drum 1) Boom Butt (with Drums) Operator’s Cab...

  • Page 17: Front

    18000 SERIVCE/MAINTENANCE MANUAL INTRODUCTION Typical 2 or 4 Places Front Item Description Swing Right Pressure Sender (past production) Swing Right Pressure Sender (current production) Swing Brake Swing Lock Swing Motor Swing Left Pressure Sender (past production) Swing Left Pressure Sender (current production)

  • Page 18: Top

    INTRODUCTION 18000 SERIVCE/MAINTENANCE MANUAL Item Description Item Description Item Description Charge Filter (2) Engine Air Cleaner (Tier 3) Travel 2-Speed Solenoid Valve Engine Oil Fill Tube Engine Exhaust Stack (Tier 3) Adapter Frame Accumulator Engine Whip Line Hoist Motor (Drum 3)

  • Page 19: Left Side

    18000 SERIVCE/MAINTENANCE MANUAL INTRODUCTION Left Side Item Description Item Description Item Description Mast Pins Solenoid Valves Node-3 Controller 27* Boom Hoist A Pump (Drum 4) Front Adapter Frame Pins Solenoid Val. Node-4 Controller 28* Swing Pump (Optional) Rear Adapter Frame Pins Solenoid Val.

  • Page 20: Left Side - S/N18001082 & Newer

    INTRODUCTION 18000 SERIVCE/MAINTENANCE MANUAL Left Side – S/N18001082 & Newer Item Description Item Description Current Production Luffing Jib Hoist Pump (Drum 6) Engine Node-0 Controller (S/N 18001082 & Newer) Right Travel Pump Pump Drive Accessory Pump Main Hoist Pump (Drums 2 and 5)

  • Page 21: Right Side

    18000 SERIVCE/MAINTENANCE MANUAL INTRODUCTION Right Side Item Description Mast Hoist (Drum 5) Brake Solenoid Valve Mast Hoist (Drum 5) Pawl Solenoid Valve Drum 3 Diverting Solenoid Valve Drum 5 Diverting Solenoid Valve Boom Stop Maximum Up Limit Switch Hand-Held Radio Remote Receiver...

  • Page 22: Rear

    INTRODUCTION 18000 SERIVCE/MAINTENANCE MANUAL Rear Item Description Hydraulic Fluid Cooler Fuel Cooler Node 9 Controller Fuel Level Gauge Fuel Tank Fill Cap Fuel Tank Hydraulic Tank Return Filters Hydraulic Tank Breather Access Tank Clean-Out Cover P1905 Air Bleed Valves P1991...

  • Page 23: Carbody/Crawler

    18000 SERIVCE/MAINTENANCE MANUAL INTRODUCTION Carbody/Crawler Typical 2 Places With Shaft Guard Removed Item Description Crawler Drive Universal Joint (2) Carbody Crawler Drive Shaft (2) Crawler Drive Shaft Guard Crawler Roller Lubrication Block Crawler Input Gearbox (2) Crawler Idler Roller (14 each Crawler)

  • Page 24: Operator Cab/Controls

    INTRODUCTION 18000 SERIVCE/MAINTENANCE MANUAL Operator Cab/Controls Item Description Item Description Engine Foot Throttle Test Point Receptacle Node-1 Master Controller Horn/Travel Cruise Panel Node-2 Side Console Controller Main Console Front Console (with RCL) Boom or Luffing Jib Hoist Handle Drum Handles...

  • Page 25: Cummins Engine Tier 3

    18000 SERIVCE/MAINTENANCE MANUAL INTRODUCTION Cummins Engine Tier 3 Item Description Item Description Engine Air Cleaner Engine Node-0 Controller Pump Drive Engine Water Filter Engine Exhaust Stack Engine Alternator Engine Muffler Engine Starter Motor (2) Fuel Shut Off Valve Engine Starter Solenoid (2)

  • Page 26: Cummins Engine Tier 4

    INTRODUCTION 18000 SERIVCE/MAINTENANCE MANUAL Cummins Engine Tier 4 Item Description Item Description Engine Air Cleaner Engine Oil Fill Tube Diesel Particulate Filter (DPF) Diesel Particulate Filter (DPF) Engine Exhaust Stack Engine Oil Filter PreCleaner Cooler Surge Tank Engine Node Cooler Fill Cap...
  • Page 27 18000 SERIVCE/MAINTENANCE MANUAL INTRODUCTION Cummins Engine Tier 4 (Continued) Item Description Item Description Air Intake Pre-Cleaner Circuit Breaker CB6 (Engine Start Solenoid) Air Filter Indicator Circuit Breaker CB7 (CAN System Power) Circuit Breaker CB1 (main system power) Circuit Breaker CB8 (Cab Power)

  • Page 28: Boom Butt And Insert

    INTRODUCTION 18000 SERIVCE/MAINTENANCE MANUAL Boom Butt and Insert Item Description Item Description Node-8 Controller Luffing Jib Hoist (Drum 6) Main Hoist Motor (Drum 2) Luffing Jib Hoist Motor (Drum 6) Main Hoist (Drum 2) Electrical Boom Cable Wire Rope Sheave...

  • Page 29: Mast Butt

    18000 SERIVCE/MAINTENANCE MANUAL INTRODUCTION Mast Butt Item Description Mast Butt Accumulator Boom Hoist (Drum 4) Motor Control Boom Hoist Motor (Drum 4) Boom Hoist Brake (Inside Gearbox) Motor Speed Sensor Loop Flushing Valve Pawl Electrical Junction Box Boom Hoist Pawl...

  • Page 30: Description Of Operation

    INTRODUCTION 18000 SERIVCE/MAINTENANCE MANUAL DESCRIPTION OF OPERATION Solenoid Valve Identification General Abbreviations HS-1 Swing Brake HS-2 Swing Lock In Amber Light HS-3 Swing Lock Out Air Conditioning Relay HS-4 Travel Brake Auxiliary Hoist HS-5 Travel Two-speed Auto Lube Pump HS-6...

  • Page 31: General Operation

    Disregard system pump drives a hydraulic motor. Pressure develops any equipment your crane does not have. The 18000 MAX- within the closed-loop system while resistance to movement ™ attachment is not covered in this manual.

  • Page 32: Hydraulic Components

    INTRODUCTION 18000 SERIVCE/MAINTENANCE MANUAL Hydraulic Components Return Manifolds Return fluid from closed-loop relief valves, brake valves, High-pressure piston pumps driven by a multi-pump drive motor servos, cylinders, pump case drain, and motor case transmission provide independent closed-loop hydraulic drain is routed to main return manifold or cooler return power for crane functions.

  • Page 33: Charge Pressure

    18000 SERIVCE/MAINTENANCE MANUAL INTRODUCTION Each system pump has a gerotor type gear charge pump SYSTEM FUNCTION PRESSURE (BAR) that is internally mounted on the end of each pump system Left 6,090 (420) driveshaft. System charge pump draws fluid directly from the...

  • Page 34: Main Pressure Monitoring

    INTRODUCTION 18000 SERIVCE/MAINTENANCE MANUAL Main Pressure Monitoring • Rotating bed jacking cylinders (four) • Boom hinge pin cylinders Load drums, boom hoist, luffing jib, swing, and track screens display and monitor system pressure. The system pressure • Front and rear adapter frame pin cylinders displayed on system screen is charge pressure or greater.

  • Page 35: Basic Operation

    18000 SERIVCE/MAINTENANCE MANUAL INTRODUCTION Basic Operation Hydraulic fluid from pressure limiting relief valve flows through exhaust port of displacement control valve (3). The Figure 1-17 1-18 for the following procedure. exhaust port has a restricted orifice that develops pressure for servo control cylinder (4) to pressurize and de-stroke When a control handle is moved from neutral, an input pump to limit system pressure.

  • Page 36: Engine Controls

    INTRODUCTION 18000 SERIVCE/MAINTENANCE MANUAL Each variable displacement motor, except travel, begins When PCOR valve closes, control of the motor returns to operation at maximum displacement (high torque, low servo PC valve. speed) and shifts to minimum displacement (low torque, high The travel motor servo is opposite of other system motors.

  • Page 37: Drum Identification

    The engine stop push button stops the engine in an Seven wire rope drum drives are on the Model 18000 crane. emergency only as all brakes apply and any functions stop The location and nomenclature is shown in Figure 1-19.

  • Page 38: Epic® Control System

    The Model 18000 crane’s boom, load lines, swing, crawler The system nodes controllers are listed below: t r a c k s , a n d a c c e s s o r y c o m p o n e n ts a r e c o n t r o l l e d Node-0 –...

  • Page 39: Crane Modes

    18000 SERIVCE/MAINTENANCE MANUAL INTRODUCTION Crane Modes • CAN system ground relay (CAN GND) • Air conditioning system relay (A/C CLUTCH) Standard mode is for all normal load-handling operations. • Engine starter solenoid relays (MS1/MS2) In Setup mode, the program allows limited operation of whip line hoist, boom hoist, mast hoist, swing and travel.

  • Page 40: System Faults

    INTRODUCTION 18000 SERIVCE/MAINTENANCE MANUAL System Faults Node-1 controller monitors crane systems and enables a yellow operating limit light and alert if any limit switch is open Figure 1-21 for the following procedure. or any programmed limit is reached. To identify and display operating limit, use scroll switch to access fault screen.
  • Page 41 18000 SERIVCE/MAINTENANCE MANUAL INTRODUCTION 24 VDC 18CSM1-119 BATTERY BATTERY DISCONNECT SWITCH LEFT STARTER MOTOR ENGINE RIGHT STARTER MOTOR GROUND STRAP MACHINE 6C12 6C12A LEFT STARTER SOLENOID GROUND 6C12B RIGHT STARTER SOLENOID A/C CLUTCH HIGH 6C11A 6C11 CU/ES COMPRESSOR 70C2 ENGINE...

  • Page 42: Swing System Operation

    INTRODUCTION 18000 SERIVCE/MAINTENANCE MANUAL SWING SYSTEM OPERATION pump system through a pressure reducing shuttle valve at 500 psi (34 bar). For swing brake and swing lock operation NOTE: All reference to swing lock is past production. the system pressure must be above 200-psi (14 bar) for full Current production cranes do not have a swing lock release brake and lock.

  • Page 43: Swing Holding Brake Switch

    18000 SERIVCE/MAINTENANCE MANUAL INTRODUCTION When in a swinging motion, the preferred way to stop or slow When holding brake switch is pressed in and held, an input crane is to move swing control handle beyond center in the voltage is sent to node-1 controller. Node-7 controller sends opposite direction.
  • Page 44 INTRODUCTION 18000 SERIVCE/MAINTENANCE MANUAL 18CSM1-120 ENGINE 24 VOLTS ENGINE STOP START STOP 6C8A 10 AMP P12-24 CAN POWER CRANE DISPLAY 6C13 NODE 0 50 AMP SYSTEM FAULT CAB POWER P11-09 NODE 1 6C14 LIGHT (Master) P12-37 ALARM 50 AMP OPERATING LIMIT...
  • Page 45 18000 SERIVCE/MAINTENANCE MANUAL INTRODUCTION 18CSM1-121 SWING RIGHT SWING RIGHT SWING 1 PUMP SWING 2 PUMP 350 PSI 350 PSI (24 BAR) (24 BAR) CHARGE CHARGE .060 .060 PUMP PUMP SWING LEFT SWING LEFT SUCTION SUCTION MANIFOLD MANIFOLD EQUALIZING LINE EQUALIZING LINE...

  • Page 46: Travel System Operation

    INTRODUCTION 18000 SERIVCE/MAINTENANCE MANUAL TRAVEL SYSTEM OPERATION When travel brake switch is in off - park position, an input signal is sent to node-1 controller. Travel system circuit is Travel System Components active, waiting for a travel control handle command. When...
  • Page 47 18000 SERIVCE/MAINTENANCE MANUAL INTRODUCTION 18CSM1-122 ENGINE 24 VOLTS ENGINE STOP STOP START 6C8A 10 AMP P12-24 CAN POWER CRANE DISPLAY 6C13 NODE 0 50 AMP SYSTEM FAULT P11-09 CAB POWER 6C14 LIGHT NODE 1 P12-37 ALARM (Master) 50 AMP OPERATING LIMIT...
  • Page 48 INTRODUCTION 18000 SERIVCE/MAINTENANCE MANUAL 18CSM1-123 PILOT PRESSURE TO BOOM RIGHT TRAVEL PUMP FORWARD FROM HIGH PRESSURE PUMP ACCESSORY SYSTEM SHUTTLE VALVE RIGHT PRESSURE PRESSURE SENDER 340 PSI REDUCING VALVE (23 BAR) 500 PSI (34 BAR) REVERSE SUCTION MANIFOLD PILOT SUPPLY...

  • Page 49: Two-Speed Travel Operation

    18000 SERIVCE/MAINTENANCE MANUAL INTRODUCTION As travel control handle nears neutral position, node-1 torque, low speed) position. Travel motors remain in this controller compensates for hydraulic system leakage or position until travel speed switch is placed in high speed changing engine speed. Node-3 and/or node-5 controller position and engine speed is more than 1500 RPM.

  • Page 50: Boom Hoist System Operation

    INTRODUCTION 18000 SERIVCE/MAINTENANCE MANUAL BOOM HOIST SYSTEM OPERATION node-6 controller sends a 24 volt output to brake solenoid valve HS-6 to release brake. Node-6 controller sends 24 volt Boom Hoist System Components output to enable boom hoist pawl electric motor K2 relay in the pawl out direction.
  • Page 51 18000 SERIVCE/MAINTENANCE MANUAL INTRODUCTION the load holding pressure in pressure memory. After control HS-6. Drum brake solenoid valve shifts to block pilot handle center switch opens, node-6 controller sends a zero pressure to brakes and opens a line to tank. Brakes apply output voltage to disable boom hoist brake solenoid valve before drum pump de-strokes.
  • Page 52 INTRODUCTION 18000 SERIVCE/MAINTENANCE MANUAL 18CSM1-125 MAKE-UP FLUID MAKE-UP FLUID BOOM HOIST BOOM HOIST (DRUM 4-1) PUMP (DRUM 4-2) PUMP .060 .060 340 PSI 340 PSI (23 BAR) (23 BAR) DOWN DOWN SUCTION SUCTION MANIFOLD MANIFOLD EQUALIZING LINE EQUALIZING LINE PILOT PRESSURE FROM LEFT...

  • Page 53: Boom Hoist Lower

    18000 SERIVCE/MAINTENANCE MANUAL INTRODUCTION Boom Hoist Lower PCOR valve over-rides the command from servo PC valve, increasing motor displacement and output torque and When boom hoist control handle is moved forward for reducing output speed. When PCOR valve closes, control of booming down, an input voltage of 2.6 volts or more is sent...

  • Page 54: Main Hoist 1 System

    INTRODUCTION 18000 SERIVCE/MAINTENANCE MANUAL MAIN HOIST 1 SYSTEM output to release the brake. The drum circuit is active, waiting for a control handle command. Main Hoist 1 System Components Main Hoist 1 Raising See Figures 1-28 1-29 for the following procedure.
  • Page 55 18000 SERIVCE/MAINTENANCE MANUAL INTRODUCTION displacement for slower output speed to slow the drum pressure to brakes and opens a line to tank. Brakes apply rotation. Node-1 controller stores the load holding pressure before drum pump de-strokes. in pressure memory. The diverting valve lines to main hoist 1/3 drum motor remain...
  • Page 56 INTRODUCTION 18000 SERIVCE/MAINTENANCE MANUAL 18CSM1-127 MAKE-UP CHARGE PRESSURE MAKE-UP CHARGE PRESSURE MAIN HOIST 1 MAIN HOIST 1 (DRUM 1) PUMP (DRUM 1/3) PUMP PRESSURE SENDER .060 .060 340 PSI 340 PSI (23 BAR) (23 BAR) DOWN DOWN SUCTION SUCTION MANIFOLD...

  • Page 57: Main Hoist 1 Lowering

    18000 SERIVCE/MAINTENANCE MANUAL INTRODUCTION Main Hoist 1 Lowering rides the command from servo PC valve, increasing motor displacement and output torque and reducing output speed. The following drum lowering operation is for main hoist 1 When PCOR valve closes, control of the motor returns to while operating in Standard mode.

  • Page 58: Whip Line Hoist (Drum 3) System

    INTRODUCTION 18000 SERIVCE/MAINTENANCE MANUAL WHIP LINE HOIST (DRUM 3) SYSTEM Whip Line Hoist Raising The following drum raising operation is for whip line hoist Whip Line Hoist System Components while operating in Standard mode. See Figures 1-30 1-31 for the following procedure.
  • Page 59 18000 SERIVCE/MAINTENANCE MANUAL INTRODUCTION 18CSM1-128 ENGINE 24 VOLTS ENGINE STOP STOP START 6C8A 10 AMP P12-24 CAN POWER CRANE DISPLAY 6C13 NODE 0 50 AMP SYSTEM FAULT P11-09 CAB POWER NODE 1 6C14 LIGHT P12-37 ALARM (Master) 50 AMP OPERATING LIMIT...
  • Page 60 INTRODUCTION 18000 SERIVCE/MAINTENANCE MANUAL 18CSM1-129 MAKE-UP CHARGE PRESSURE MAKE-UP CHARGE PRESSURE MAIN HOIST MAIN HOIST (DRUM 1) PUMP (DRUM 1/3) PUMP PRESSURE SENDER .060 .060 340 PSI 340 PSI (23 BAR) (23 BAR) DOWN DOWN SUCTION SUCTION LOW PRESSURE MANIFOLD...

  • Page 61: Whip Line Hoist Lowering

    18000 SERIVCE/MAINTENANCE MANUAL INTRODUCTION When drum control handle is moved to neutral position, fluid flow is from port B of pump to port A of motor. Return node-1 controller compensates for hydraulic system leakage fluid is from port B of motor to port A of pump.

  • Page 62: Main Hoist 2 System

    INTRODUCTION 18000 SERIVCE/MAINTENANCE MANUAL MAIN HOIST 2 SYSTEM When selected main hoist drum brake switch is placed in off - park position, brake solenoid valve HS-10 (Drum 2) remains Main Hoist 2 System Components applied. Brakes remain applied until node-6 controller sends a 24 volt output to release the brake.
  • Page 63 18000 SERIVCE/MAINTENANCE MANUAL INTRODUCTION When drum control handle is moved to neutral position, After control handle center switch opens, node-6 controller node-1 controller compensates for hydraulic system leakage sends a zero output voltage to disable drum brake solenoid or changing engine speed. Node-3 controller sends a zero valve HS-10.
  • Page 64 INTRODUCTION 18000 SERIVCE/MAINTENANCE MANUAL 18CSM1-131 MAKE-UP CHARGE PRESSURE MAKE-UP CHARGE PRESSURE MAIN HOIST 2 MAIN HOIST 2 PUMP 2 PUMP 2/5 PRESSURE SENDER .060 .060 340 PSI 340 PSI (23 BAR) (23 BAR) DOWN DOWN SUCTION LOW PRESSURE SUCTION MANIFOLD...

  • Page 65: Main Hoist 2 Lowering

    18000 SERIVCE/MAINTENANCE MANUAL INTRODUCTION Main Hoist 2 Lowering rides the command from servo PC valve, increasing motor displacement and output torque and reducing output speed. The following drum lowering operation is for main hoist 2 When PCOR valve closes, control of the motor returns to while operating in Standard mode.

  • Page 66: Mast Hoist Drum 5 System

    INTRODUCTION 18000 SERIVCE/MAINTENANCE MANUAL MAST HOIST DRUM 5 SYSTEM 12 is enabled to keep pawl applied to mast hoist drum flange. The pawl in solenoid is open to charge pressure from pump Mast Hoist System Components 2/5 to piston end of cylinder to extend pawl to drum flange.
  • Page 67 18000 SERIVCE/MAINTENANCE MANUAL INTRODUCTION valve to open lines to drum 5 motor and close lines to main to node-1 controller. Node-3 controller sends a variable zero hoist 2 motor. to 24 volt output that is divided by a resistor and applied to main hoist pump 2/5 EDC in the lower direction.
  • Page 68 INTRODUCTION 18000 SERIVCE/MAINTENANCE MANUAL 18CSM1-133 MAKE-UP CHARGE PRESSURE MAKE-UP CHARGE PRESSURE MAIN HOIST 2 MAIN HOIST 2 PUMP 2 PUMP 2/5 PRESSURE SENDER .060 .060 340 PSI 340 PSI (23 BAR) (23 BAR) DOWN DOWN SUCTION SUCTION LOW PRESSURE MANIFOLD...
  • Page 69 18000 SERIVCE/MAINTENANCE MANUAL INTRODUCTION Main hoist 2/5 pump EDC tilts swashplate in the up direction in rod end of the cylinders is approximately 700 psi (48 bar). to satisfy pressure memory. Node-1 controller compares Hydraulic fluid from side “B” sections of both counterbalance drum holding pressure to value in pressure memory.

  • Page 70: Mast Hoist Raising To Transport Position

    INTRODUCTION 18000 SERIVCE/MAINTENANCE MANUAL Mast Hoist Raising to Transport Position From the accessory valve, the fluid pressure enters free-flow check valve sections on side “B” of load equalizing valve. The following drum raising operation is for mast hoist (Drum From equalizing valve, fluid enters counterbalance valves 5) while lowering from 160°...
  • Page 71 18000 SERIVCE/MAINTENANCE MANUAL INTRODUCTION 18CSM1-134 MAST RAISING CYLINDERS EXTEND 3500 PSI (240 BAR) LOAD EQUALIZING VALVE 4500 PSI (310 BAR) HS-34 HS-33 From High Pressure Accessory Manifold VALVE BANK 18CSM1-135 MAST RAISING CYLINDERS RETRACT 3500 PSI (240 BAR) LOAD EQUALIZING...

  • Page 72: Luffing Jib Drum 6 (Optional) System

    INTRODUCTION 18000 SERIVCE/MAINTENANCE MANUAL LUFFING JIB DRUM 6 (OPTIONAL) SYSTEM Luffing Jib Raise Node-1 controller checks that luffing jib up limit switch is Luffing Jib System Components closed and no hydraulic system fault is present. If a block up See Figures...
  • Page 73 18000 SERIVCE/MAINTENANCE MANUAL INTRODUCTION 18CSM1-136 ENGINE 24 VOLTS ENGINE STOP STOP START 6C8A 10 AMP P12-24 CAN POWER CRANE DISPLAY 6C13 NODE 0 50 AMP SYSTEM FAULT P11-09 CAB POWER NODE 1 6C14 LIGHT P12-37 ALARM (Master) 50 AMP OPERATING LIMIT...

  • Page 74: Luffing Jib Lower

    INTRODUCTION 18000 SERIVCE/MAINTENANCE MANUAL Luffing Jib Lower c o m m a n d f r o m s e r v o P C v a l v e , i n c r e a s i n g m o t o r displacement and output torque and reducing output speed.

  • Page 75: Accessory System Components

    18000 SERIVCE/MAINTENANCE MANUAL INTRODUCTION ACCESSORY SYSTEM COMPONENTS from fixed displacement accessory pump is dumped through valve to tank. When a component of either accessory system Accessory Systems is enabled, an input signal is sent to node-1 controller. Node- 5 controller sends a variable 0 to 24 volt signal to accessory...

  • Page 76: Jacking Cylinders

    INTRODUCTION 18000 SERIVCE/MAINTENANCE MANUAL Jacking Cylinders pressure from opening counterbalance valve, holding rotating bed load in position by the counterbalance valve. See Figures 1-39 1-40 for the following procedure. Rotating bed Jacking - Raise Telescopic type jacking cylinders are mounted on each corner of rotating bed.

  • Page 77: Rotating Bed Jacking - Lower

    18000 SERIVCE/MAINTENANCE MANUAL INTRODUCTION Rotating bed Jacking - Lower controller monitors accessory system pressure sender to control jacking cylinder lowering speed rate. Move desired jacking switch to retract position and hold. An Hydraulic fluid returning to tank from piston end of the input voltage is sent to node-1 controller.
  • Page 78 INTRODUCTION 18000 SERIVCE/MAINTENANCE MANUAL 18CSM1-138 ENGINE 24 VOLTS ENGINE STOP STOP START 6C8A 10 AMP P12-24 CRANE DISPLAY CAN POWER 6C13 NODE 0 SYSTEM FAULT 50 AMP P11-09 LIGHT CAB POWER NODE 1 P12-37 ALARM 6C14 (Master) OPERATING LIMIT P12-35...
  • Page 79 18000 SERIVCE/MAINTENANCE MANUAL INTRODUCTION 18CSM1-139 LEFT FRONT JACK EXTEND RIGHT FRONT JACKS HS-24 HS-23 HS-20 HS-19 HS-18 HS-17 HS-22 HS-21 From High Pressure Accessory Manifold PROPORTIONAL ACCESSORY VALVES 18CSM1-140 LEFT FRONT JACK RETRACT RIGHT FRONT JACKS HS-24 HS-23 HS-20 HS-19...

  • Page 80: Boom Hinge Pins

    INTRODUCTION 18000 SERIVCE/MAINTENANCE MANUAL Boom Hinge Pins Hydraulic fluid pressure at approximately 3,000 psi (204 bar) flows to boom hinge pins accessory valve. Hydraulic fluid See Figures 1-39 1-41 for the following procedure. leaves the accessory valve and enters rod end of boom pin...
  • Page 81 18000 SERIVCE/MAINTENANCE MANUAL INTRODUCTION 18CSM1-152 BOOM HINGE PINS ENGAGE HS-26 HS-25 From High Pressure Accessory Manifold ACCESSORY VALVES 18CSM1-141 BOOM HINGE PINS DISENGAGE HS-26 HS-25 From High Pressure Accessory Manifold ACCESSORY VALVES FIGURE 1-41 Manitowoc 1-69 Published 12-05-17, Control # 035-23...

  • Page 82: Adapter Frame Pins

    INTRODUCTION 18000 SERIVCE/MAINTENANCE MANUAL Adapter Frame Pins Hydraulic fluid pressure at approximately 3,000 psi (204 bar) flows to adapter frame pins accessory valve. Hydraulic fluid See Figures 1-39 1-42 for the following procedure. leaves the accessory valve and enters piston end of selected...
  • Page 83 18000 SERIVCE/MAINTENANCE MANUAL INTRODUCTION 18CSM1-142 FRONT ADAPTER FRAME PINS REAR ADAPTER FRAME PINS ENGAGE ENGAGE HS-28 HS-27 HS-30 HS-29 From High Pressure Accessory Manifold ACCESSORY VALVES 18CSM1-143 REAR ADAPTER FRAME PINS FRONT ADAPTER FRAME PINS DISENGAGE DISENGAGE HS-28 HS-27 HS-30...

  • Page 84: Mast Pins

    INTRODUCTION 18000 SERIVCE/MAINTENANCE MANUAL Mast Pins Hydraulic fluid pressure at approximately 3,000 psi (204 bar) flows to mast pins accessory valve. Hydraulic fluid leaves the See Figures 1-39 1-43 for the following procedure. accessory valve and enters piston end of mast pin cylinders, extending cylinder rods to engage the mast pins.
  • Page 85 18000 SERIVCE/MAINTENANCE MANUAL INTRODUCTION 18CSM1-144 MAST PINS ENGAGE HS-32 HS-31 From High Pressure Accessory Manifold ACCESSORY VALVES 18CSM1-145 MAST PINS DISENGAGE HS-32 HS-31 From High Pressure Accessory Manifold ACCESSORY VALVES FIGURE 1-43 Manitowoc 1-73 Published 12-05-17, Control # 035-23...

  • Page 86: Rigging Winch (Drum 7)

    INTRODUCTION 18000 SERIVCE/MAINTENANCE MANUAL Rigging Winch (Drum 7) Hydraulic fluid pressure at approximately 3,000 psi (204 bar) flows to rigging winch accessory valve. Hydraulic fluid leaves See Figures 1-39 1-44 for the following procedure. the accessory valve and enters pay out side of winch motor to pay out wire rope at a fixed speed.
  • Page 87 18000 SERIVCE/MAINTENANCE MANUAL INTRODUCTION 18CSM1-146 RIGGING WINCH PAY OUT HS-35 HS-36 From High Pressure Accessory Manifold ACCESSORY VALVES 18CSM1-147 RIGGING WINCH HAUL IN HS-35 HS-36 From High Pressure Accessory Manifold ACCESSORY VALVES FIGURE 1-44 Manitowoc 1-75 Published 12-05-17, Control # 035-23...

  • Page 88: Cab Tilt

    INTRODUCTION 18000 SERIVCE/MAINTENANCE MANUAL Cab Tilt Hydraulic fluid from rod end of cylinder enters free-flow check valve before entering accessory valve and returns to See Figures 1-39 1-45 for the following procedure. tank. When cab tilt switch is released, solenoid valve HS-37 returns to center position.
  • Page 89 18000 SERIVCE/MAINTENANCE MANUAL INTRODUCTION 18CSM1-148 CAB TILT CYLINDER (RAISE CAB FRONT) HS-38 HS-37 From High Pressure Accessory Manifold ACCESSORY VALVES 18CSM1-149 CAB TILT CYLINDER (LOWER CAB FRONT) HS-38 HS-37 From High Pressure Accessory Manifold ACCESSORY VALVES FIGURE 1-45 Manitowoc 1-77...

  • Page 90: Crawler Pin Cylinders

    INTRODUCTION 18000 SERIVCE/MAINTENANCE MANUAL CRAWLER PIN CYLINDERS Pull crawler pin handle down to engage crawler pins into crawler track frame. This shifts selected crawler pins lower Crawler Pin Cylinders accessory valve to block supply through valve and opens supply port to cylinders.
  • Page 91 18000 SERIVCE/MAINTENANCE MANUAL INTRODUCTION 18CSM1-150 From High Pressure Accessory Manifold PRESSURE 500 PSI REDUCING (34 BAR) VALVE SWIVEL LOWER ACCESSORY VALVE LEFT CRAWLER PINS EXTEND RIGHT CRAWLER PINS 18CSM1-151 From High Pressure Accessory Manifold PRESSURE 500 PSI REDUCING (34 BAR)
  • Page 92 INTRODUCTION 18000 SERIVCE/MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 1-80 Published 12-05-17, Control # 035-23...
  • Page 93 Hydraulic System Specifications - 18000 ........
  • Page 94 18000 SERIVCE/MAINTENANCE MANUAL Motor Leakage Test ............2-38 Loop Flushing Valve Adjustment .

  • Page 95: Hydraulic Schematics

    This section contains hydraulic system maintenance, h. Fitting slippage on hose adjustment, calibration, and test procedures for the hydraulic system and related components on the Model 18000. Other signs of significant deterioration Experienced technicians, trained in the operation of this...

  • Page 96: Hydraulic System Maintenance

    HYDRAULIC SYSTEM 18000 SERIVCE/MAINTENANCE MANUAL Hydraulic hose assemblies operating in Zone D and E • Do not unpack parts or remove port plugs until parts are should expect a degrade of mechanical properties and needed. long term exposure to these cold temperatures will •...

  • Page 97: Hydraulic Tank Heater

    18000 SERIVCE/MAINTENANCE MANUAL HYDRAULIC SYSTEM Clean exterior of system often. Do not let dirt NOTE: A high pitched whine or scream from the pump can accumulate on or around any part of system. also indicate cavitation (pump being starved of oil).
  • Page 98 HYDRAULIC SYSTEM 18000 SERIVCE/MAINTENANCE MANUAL Hydraulic Tank Shutoff Valves Shown OPEN on Past Production, CLOSED on Current Production. Rotate DOWN to CLOSE, UP to OPEN Legend on following page P1925a Filter 1 Filter 2 Filter 8 S/N18001082 & Newer Past Production...
  • Page 99 18000 SERIVCE/MAINTENANCE MANUAL HYDRAULIC SYSTEM Legend for Figure 2-2 Item Description Vent Plug (both charge filters) (NOTE 1) Charge Filter (2 each) (NOTE 1 &2) Charge Pressure Manifold Vent Cap Thermal Bypass Valve Access Cover Return Filter (2 or 3 each)

  • Page 100: Replacing Filters

    HYDRAULIC SYSTEM 18000 SERIVCE/MAINTENANCE MANUAL Item Description Vent Plug Cover Handle (part of cover) O-Ring with Back-Up Ring O-Ring Element Tube Head Outlet Inlet Outlet Inlet 18CSM2-100 Past Production Charge Filter 18CSM2-101 NOTE: S/N18001082 and newer - Supercharge Current Production...

  • Page 101: Charge Filters

    Avoid Hydraulic System Damage! installed prior to crane s/n 18001082. Original Equipment Manufacturers’ filter elements – available from Manitowoc – must be used on this crane. NOTE: S/N18001082 and newer - Supercharge pump and Substituting with any other brand or type filter element is charge filters 1 and 2 replaced with accessory not allowed.

  • Page 102: Return Filters

    HYDRAULIC SYSTEM 18000 SERIVCE/MAINTENANCE MANUAL Past Production Current Production Return Filter Return Filter Inlet Inlet Item Description Cover O-Ring Head Element Shell 18CSM2-102 18CSM2-103 Outlet to Tank Outlet to Tank FIGURE 2-4 Return Filters Remove cover (1). Use care not to damage O-rings.

  • Page 103: Replacing Desiccant Breather

    18000 SERIVCE/MAINTENANCE MANUAL HYDRAULIC SYSTEM REPLACING DESICCANT BREATHER CHANGING OIL The following instructions apply only to current production Unless otherwise specified, see Figure 2-2 for the following cranes. procedure. D r a i n a n d r e f i l l h y d r a u l i c s y s t e m a c c o r d i n g t o t h e...

  • Page 104: Servicing Pumps

    HYDRAULIC SYSTEM 18000 SERIVCE/MAINTENANCE MANUAL If required on current production cranes, replace NOTE: S/N18001082 and newer - Supercharge pump and desiccant breather (1, Figure 2-5). charge filters 1 and 2 replaced with accessory pump and additional return filter. 10. On past production cranes, either replace breather...
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  • Page 106: Tightening Hydraulic Connections

    HYDRAULIC SYSTEM 18000 SERIVCE/MAINTENANCE MANUAL TIGHTENING HYDRAULIC CONNECTIONS SAE Straight Thread Connection • Make sure fittings and O-rings being used are proper This type connection leaks most often because the jam nut size and style. and washer are not backed up before assembly.

  • Page 107: Ors Connection

    18000 SERIVCE/MAINTENANCE MANUAL HYDRAULIC SYSTEM Table 2-3 Straight Thread Leakage Table 2-5 ORS Leakage Causes Cures Causes Cures Jam nut and washer not backed Replace O-ring and Nut Loose. Tighten to proper torque. up at assembly, causing O-ring tighten fitting properly.

  • Page 108: Split Flange Connection

    HYDRAULIC SYSTEM 18000 SERIVCE/MAINTENANCE MANUAL Split Flange Connection "A" Flange Torque Dimension Size in-lb N•m Lubricate and install O-ring in shoulder groove (see inch Figure 2-12). Align shoulder with port and assemble flanges over shoulder. NOTE: Bolts used must be grade-5 or better. Grade-5 bolt has three dashes in head.

  • Page 109: Sae Flare Connection

    18000 SERIVCE/MAINTENANCE MANUAL HYDRAULIC SYSTEM SAE Flare Connection Table 2-9 SAE 37° Flare Leakage Tighten nut finger tight until sealing surfaces touch. Causes Cures Joint loose. Tighten properly. Mark a line (use felt pen or marker) on adapter and extend it onto connector nut (Figure 2-13, View A).
  • Page 110 HYDRAULIC SYSTEM 18000 SERIVCE/MAINTENANCE MANUAL Electric Plug (typical) Gauge Coupler (typical) Right Rear P1930 Under Engine at Rear of Crane P1929b Swing Motor Cooler Fan Hydraulic Pump (Tier 4 Equipped) 18CSM2-109 Hydraulic Pressure Sender Identification Item Description Item Description Drum 4 (Boom Hoist)

  • Page 111: Pressure Sender Replacement

    18000 SERIVCE/MAINTENANCE MANUAL HYDRAULIC SYSTEM Swing Brake and Travel Solenoids Adapter Frame and Node 7 Pump Drive Cooler A13823 Pump Drive 81012957 FIGURE 2-14 continued PRESSURE SENDER REPLACEMENT Install new pressure senders and connect electric cords. Pressure senders have pipe threads. Be sure to install thread sealant.

  • Page 112: Disc Brake Operational Test

    HYDRAULIC SYSTEM 18000 SERIVCE/MAINTENANCE MANUAL DISC BRAKE OPERATIONAL TEST CAUTION There is no physical way to check the disc brakes for travel, boom hoist, lo ad dru ms, and swing. There fore, an Overheating Hazard! operational test of each brake must be performed weekly.
  • Page 113 18000 SERIVCE/MAINTENANCE MANUAL HYDRAULIC SYSTEM P2013c Drum 6 (Luffing Hoist) Shown Typical for: Drum 1 (Main Hoist) - Both Ends Drum 2 (Main Hoist) - Both Ends Drum 3 (Whip Hoist) - Left End Drum 4 (Boom Hoist) - Both Ends...

  • Page 114: Shop Procedures

    HYDRAULIC SYSTEM 18000 SERIVCE/MAINTENANCE MANUAL SHOP PROCEDURES If used, securely reinstall fill cap (8a). Apply 3-5 psi owner supplied air pressure to coupler (13a, Figure 2-2) or to air valve (13b) in side of hydraulic CAUTION tank. Equipment Damage! Breather allows 3 psi pressure to remain in tank to force Incorrectly installed filters and fittings will damage pumps oil into system.

  • Page 115: Accessory System Checks

    18000 SERIVCE/MAINTENANCE MANUAL HYDRAULIC SYSTEM • Drum 4 (Boom Hoist) Swing brake must hold without slipping. • Drum 5 (Mast Hoist) Accessory System Checks • Drum 6 (Luffing Jib Hoist) High Pressure Accessory System • Swing (left and right) The accessory pumps are the source for high pressure •...

  • Page 116: Low-Pressure Accessory Components

    HYDRAULIC SYSTEM 18000 SERIVCE/MAINTENANCE MANUAL Boom hinge pin cylinders: Crane must respond and indicate on swing screen that swing park brake and swing lock are released. NOTE: Hydraulics must be connected to boom butt to operate boom hinge pin cylinders.

  • Page 117: Travel Handle And Speed Check

    18000 SERIVCE/MAINTENANCE MANUAL HYDRAULIC SYSTEM Travel Handle and Speed Check Start engine and set speed at high idle. Push both crawler control handles fully FORWARD to Verify that travel movement responds correctly to handle travel crane at full speed. commands. Count the number of revolutions crawler roller rotates in one minute to determine travel speed.

  • Page 118: Hydraulic System Specifications - 18000

    HYDRAULIC SYSTEM 18000 SERIVCE/MAINTENANCE MANUAL HYDRAULIC SYSTEM SPECIFICATIONS - 18000 Table 2-10 Hydraulic System Specifications System System Pump-Motor Port Charge Speed Function Direction Pressure 1 Pressure 2 Connections Pressure psi (bar) psi (bar) Lower Pump A to Motor A 32 to 38...

  • Page 119: Pumps

    18000 SERIVCE/MAINTENANCE MANUAL HYDRAULIC SYSTEM Pumps Pump Identification Pump 18CSM1-105 (Prior to s/n 18001082) Drive Item Description Boom Hoist A (Drum 4) Swing (Optional) Supercharge Supercharge/Accessory Boom Hoist B (Drum 4) Main Hoist (Drums 1 and 3) Swing Engine Left Travel...
  • Page 120 HYDRAULIC SYSTEM 18000 SERIVCE/MAINTENANCE MANUAL Pump Components Item Description EDC (Electronic Displacement Control) Manual Override Control Case Drain Port (Note 1) Charge Pressure Relief Valve Multi-Function Valve (Note 2) Charge Pressure Gauge Port Charge Pump Inlet Port Pump Port B...

  • Page 121: Motors

    18000 SERIVCE/MAINTENANCE MANUAL HYDRAULIC SYSTEM Motors Boom Hoist, Load Drums, and Travel Motor 18CSM10-102 Item Port Description Item Port Description Main System Pressure Control Pressure (Maximum Displacement) Main System Pressure Control Pressure (Minimum Displacement) Case Pressure (Drain) Servo Pressure Supply...

  • Page 122: Hydraulic System Calibration Procedures

    HYDRAULIC SYSTEM 18000 SERIVCE/MAINTENANCE MANUAL HYDRAULIC SYSTEM CALIBRATION Pressure Sender Calibration PROCEDURES Percent Bank 2 Binary Bank 1 Binary Calibration Description Complete Number Number To ensure proper operation of the crane functions, the following items must be calibrated or tested at the intervals...
  • Page 123 18000 SERIVCE/MAINTENANCE MANUAL HYDRAULIC SYSTEM d. Continue to scroll up or down until calibration screen Troubleshoot the particular system to determine the appears. cause of the fault. Press bottom of CRANE MODE switch until (*) NOTE: The cause of a failed calibration or faulty display appears next to PRESSURE SENDER CAL.

  • Page 124: Control Calibration

    HYDRAULIC SYSTEM 18000 SERIVCE/MAINTENANCE MANUAL Control Calibration Press bottom of CRANE MODE switch until (*) appears next to CONTROL CAL. Percent Binary Increase engine speed to HIGH IDLE. Complete Number Engine must be running at high idle before calibration will start.

  • Page 125: Pump Pressure Test

    18000 SERIVCE/MAINTENANCE MANUAL HYDRAULIC SYSTEM Pump Pressure Test d. Continue to scroll up or down until calibration screen appears. Percent Binary Press bottom of CRANE MODE switch until (*) Complete Number appears next to PRESSURE TEST. Increase engine speed to:...

  • Page 126: Charge Pressure Check

    HYDRAULIC SYSTEM 18000 SERIVCE/MAINTENANCE MANUAL Charge Pressure Check • When a pump is replaced • When a pump control (EDC or PCP) is replaced Binary Binary • Every 6 months Number 2 Number 1 To check charge pressure, proceed as follows:...
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  • Page 128 HYDRAULIC SYSTEM 18000 SERIVCE/MAINTENANCE MANUAL Table 2-11 Binary System 2-34 Published 12-05-17, Control # 035-23...
  • Page 129 18000 SERIVCE/MAINTENANCE MANUAL HYDRAULIC SYSTEM Table 2-11 (continued) Binary System Manitowoc 2-35 Published 12-05-17, Control # 035-23...

  • Page 130: Hydraulic System Adjustment Procedures

    HYDRAULIC SYSTEM 18000 SERIVCE/MAINTENANCE MANUAL HYDRAULIC SYSTEM ADJUSTMENT If proper pressure is not indicated, adjust the corresponding multi-function valve: PROCEDURES Remove protective cap (3) from multi-function valve High Pressure Adjustment (1 or 2). See Table 2-10 Figure 2-21 for pump port identification.

  • Page 131: Charge Pressure Adjustment

    18000 SERIVCE/MAINTENANCE MANUAL HYDRAULIC SYSTEM Charge Pressure Adjustment To adjust charge pressure: Figure 2-29 for the following procedure. The following adjustment is only required when a system fails the Charge Pressure Test described in this section. Loosen lock nut (1).

  • Page 132: Motor Leakage Test

    HYDRAULIC SYSTEM 18000 SERIVCE/MAINTENANCE MANUAL Loosen lock nut (2). Typical Motor Installation Using an internal hex wrench, turn adjusting screw (3) in until pressure increases in either gauge. Note angular position of internal hex wrench. Then, turn adjusting screw out until pressure increases an equal amount in other gauge.

  • Page 133: Pump Or Motor Override

    18000 SERIVCE/MAINTENANCE MANUAL HYDRAULIC SYSTEM Start and run engine at low idle. Rotate manual override (2) in either direction to stroke pump or motor in corresponding direction. DANGER Falling or Moving Load Hazard! If pump or motor is operating properly, corresponding side of circuit will stall.

  • Page 134: Counterbalance Valves Adjustment

    HYDRAULIC SYSTEM 18000 SERIVCE/MAINTENANCE MANUAL Counterbalance Valves Adjustment P1693b P1693a 18CSM10-104 Item Description Item Description Right Mast Cylinder Mast Cylinder Extend Valve Mast Cylinder Counterbalance Extend Valve Rotating Bed Jack Mast Cylinder Counterbalance Retract Valve Rotating Bed Jack Extend Counterbalance Valve...
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  • Page 136 HYDRAULIC SYSTEM 18000 SERIVCE/MAINTENANCE MANUAL 18CSM1-103 Item Description Level Sensor Adapter Hydraulic Tank Electric Cable W2 CAL Button Sight Gauge FIGURE 2-33 2-42 Published 12-05-17, Control # 035-23...

  • Page 137: Hydraulic Tank Level Sensor Calibration

    18000 SERIVCE/MAINTENANCE MANUAL HYDRAULIC SYSTEM HYDRAULIC TANK LEVEL SENSOR In the operator cab, turn the engine stop/run/start switch to the STOP position. CALIBRATION If not already done: Figure 2-33 for the following procedures. Securely install adapter (2) and level sensor (1).
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  • Page 139 Digital Input and Output Item Tables ..........3-47 Manitowoc...
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  • Page 141: Electrical Schematics

    18000 SERIVCE/MAINTENANCE MANUAL ELECTRIC SYSTEM SECTION 3 ELECTRIC SYSTEM ELECTRICAL SCHEMATICS Damaged or missing electrical clamps or tie straps Excessive corrosion or dirt on the junction boxes Electrical schematics are located at the end of this section. Loose junction box mounting hardware...

  • Page 142: Circuit Breaker Identification

    ELECTRIC SYSTEM 18000 SERIVCE/MAINTENANCE MANUAL CIRCUIT BREAKER IDENTIFICATION Circuit breakers CB-1 through CB-8 are mounted in the engine node-0 controller box in left side enclosure. This section contains circuit breaker identification. There are Circuit breakers ABCB1 through ABCB4 are mounted in load no individual in-line fuses.

  • Page 143: Test Voltages

    CAN Bus Nodes A wireless hand-held radio remote is used for operating setup items. ® The Model 18000 operating system is an EPIC (Electrical Processed Independent Control) with Can-Bus technology. Test voltages are sorted by nodes (reference Electrical The can bus system uses multiple nodes that contain Schematic A06374).

  • Page 144: Pumps And Motors

    ELECTRIC SYSTEM 18000 SERIVCE/MAINTENANCE MANUAL Pumps and Motors The node output voltage and input voltage values at the pumps and motors are shown in Table 3-3 Table 3-4. Table 3-3. Pump Values At Node At Pump 0 to 24 Volts...

  • Page 145: Alphabetical Index Of Components

    18000 SERIVCE/MAINTENANCE MANUAL ELECTRIC SYSTEM Alphabetical Index of Components Node Heading Descriptions Find the desired component item in this index. Check the CAN ID. NO. indicates the can bus system node number, component item node location, then see indicated node to cable, receptacle number, and pin number code (43-D) is as find the test voltage for that item.

  • Page 146: Node 1 - Master Node (Front Console)

    ELECTRIC SYSTEM 18000 SERIVCE/MAINTENANCE MANUAL NODE 1 - Master Node (Front Console) Reference Electrical Schematic A06374 - Sheets 4, 5, and 17 Can ID. # Function Description Test Voltages Packet No. /Connector # Type Receptacle – Front Console 1101/P11-1 24 Volts...
  • Page 147 18000 SERIVCE/MAINTENANCE MANUAL ELECTRIC SYSTEM Can ID. # Function Description Test Voltages Packet No. /Connector # Type 1212/P12-12 Signal RCL Display Contrast Control - Wiper Between 0 to 24 Volts 1213/P12-13 DI-3 Drum 1 (Main Drum 1) Park Switch – On 0 Volts Off;...

  • Page 148: Node 2 - Handles And Cab Controls

    ELECTRIC SYSTEM 18000 SERIVCE/MAINTENANCE MANUAL NODE 2 - Handles and Cab Controls Reference Electrical Schematic A06374 - Sheets 4, 5, 6 and 18 Can ID. # Function Description Test Voltage Packet No. /Connector # Type Receptacle - Alarms 2101/P51-1 CAN-H...
  • Page 149 18000 SERIVCE/MAINTENANCE MANUAL ELECTRIC SYSTEM Can ID. # Function Description Test Voltage Packet No. /Connector # Type Receptacle - Handles 2201/P52-1 DO-7 Handle B Rotation Indicator 24 Volts Nominal CAN32-1-64 2202/P52-2 DO-3 Handle C Rotation Indicator 24 Volts Nominal CAN32-1-4...
  • Page 150 ELECTRIC SYSTEM 18000 SERIVCE/MAINTENANCE MANUAL Can ID. # Function Description Test Voltage Packet No. /Connector # Type P53-A Ground Setup Receiver Ground P53-B Ground Left Console Ground P53-C Ground Cab Ground Ground P53-E 28 Volts Setup Receiver 28 Volts Nominal...

  • Page 151: Node 3 - Drum 3 And Pressure Senders

    18000 SERIVCE/MAINTENANCE MANUAL ELECTRIC SYSTEM NODE 3 - Drum 3 and Pressure Senders Reference Electrical Schematic A06374 - Sheets 7, 19 and 20 Function Can ID. No. Description Test Voltage Packet No. Type WN10-A/WN04-A 24 Volts From Node 0 to Node 4...
  • Page 152 ELECTRIC SYSTEM 18000 SERIVCE/MAINTENANCE MANUAL Function Can ID. No. Description Test Voltage Packet No. Type 34-P DO-16 Drum 2 Pump Control – Raise Table 3-3 for Values CAN33-2-128 34-R DO-15 Drum 2 Pump Control – Lower Table 3-3 for Values...

  • Page 153: Node 4 - Connecting Pins, Jacking, And Mast

    18000 SERIVCE/MAINTENANCE MANUAL ELECTRIC SYSTEM NODE 4 - Connecting Pins, Jacking, and Mast Reference Electrical Schematic A06374 - Sheets 8, 19 and 20 Function Can ID. No. Description Test Voltage Packet No. Type WN04-A/WN30-A 24 Volts From Node 3 to Node 2...

  • Page 154: Node 5 - Alarms, Pump Controls, And Limits

    ELECTRIC SYSTEM 18000 SERIVCE/MAINTENANCE MANUAL Function Can ID. No. Description Test Voltage Packet No. Type 44-a Ground Left Rear Jack Retract Solenoid Ground 44-b DO-22 Left Rear Jack Retract Solenoid 0 Volts Off; 24 Volts On CAN35-3-32 44-g Ground Jumper to Node Select 3...
  • Page 155 18000 SERIVCE/MAINTENANCE MANUAL ELECTRIC SYSTEM Function Can ID. No. Description Test Voltage Packet No. Type Hydraulic Fluid High Temperature Switch 0 Volts Off; 24 Volts On CAN38-1-16 53-R DO-5 (Tier 2 and Tier 3) Cooler Fan Pump Control - Back-Up Coil...
  • Page 156 ELECTRIC SYSTEM 18000 SERIVCE/MAINTENANCE MANUAL Function Can ID. No. Description Test Voltage Packet No. Type 54-H DO-14 Drum 6 Pump Control – Lower Table 3-3 for Values CAN38-2-32 54-K Ground Drum 4A Pump Control – Lower Ground 54-L Ground Drum 4A Pump Control – Raise...
  • Page 157 18000 SERIVCE/MAINTENANCE MANUAL ELECTRIC SYSTEM Function Can ID. No. Description Test Voltage Packet No. Type 1.2 or 3.2 Volt Not Moving; 56-n ENC1A Drum 4 Motor Speed Sensor CAN68-2 2.2 Volts Moving 1.2 or 3.2 Volts Not Moving; 56-p ENC1B...

  • Page 158: Node 6 - Drums 2, 4, & 5, And Adapter Frame

    ELECTRIC SYSTEM 18000 SERIVCE/MAINTENANCE MANUAL NODE 6 - Drums 2, 4, & 5, and Adapter Frame Reference Electrical Schematic A06374 - Sheets 10, 19, 20 and 21. Function Can ID. No. Description Test Voltages Packet No. Type WN20-A/WNE06-A 24 Volts...
  • Page 159 18000 SERIVCE/MAINTENANCE MANUAL ELECTRIC SYSTEM Function Can ID. No. Description Test Voltages Packet No. Type 64-g Ground Jumper to Node Select 1 Ground 64-h NS-1 Node Select 1 Jumper to Ground 0 Volts (With Jumper) 64-j NS-2 Node Select 2 Jumper to Ground...

  • Page 160: Node 7 - Swing, Travel And Auto Lube

    ELECTRIC SYSTEM 18000 SERIVCE/MAINTENANCE MANUAL NODE 7 - Swing, Travel and Auto Lube Reference Electrical Schematic A06374 - Sheets 11, 19 and 21 Function Can ID. No. Description Test Voltages Packet No. Type WN12-A/WNE08-A 24 Volts From Node 6 to Node 8...
  • Page 161 18000 SERIVCE/MAINTENANCE MANUAL ELECTRIC SYSTEM Function Can ID. No. Description Test Voltages Packet No. Type 1 Volt at 0 psi; 76-b AI-10 Swing Right Pressure Sender CAN18-4 5 Volts at 7,500 psi 1 Volt at 0 psi; 76-c AI-11 Swing Brake Pressure Sender...

  • Page 162: Node 8 - Drum 1 And Drum 6

    ELECTRIC SYSTEM 18000 SERIVCE/MAINTENANCE MANUAL NODE 8 - Drum 1 and Drum 6 Reference Electrical Schematic A06374 - Sheets 12, 19 and 21 Function Can ID. No. Description Test Voltage Packet No. Type WN18-A/WN12-A 24 Volts From Node 7 to Bin Node...
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  • Page 164: Node 9 - Max-Er

    ELECTRIC SYSTEM 18000 SERIVCE/MAINTENANCE MANUAL NODE 9 - MAX-ER Reference Electrical Schematic A06374 - Sheets 13, 19 and 21 Can ID. # Function Description Test Voltage Packet No. /Connector # Type WN14-A/WN14-A 24 Volts From Node 5 to Remote Receiver...
  • Page 165 18000 SERIVCE/MAINTENANCE MANUAL ELECTRIC SYSTEM Can ID. # Function Description Test Voltage Packet No. /Connector # Type NS-2 Node Select 2 Jumper to Ground 0 Volts (With Jumper) NS-3 Node Select 3 Jumper to Ground 0 Volts (With Jumper) Ground...

  • Page 166: Node 20 - Boom Block Up, Block Sensor, & Limits

    ELECTRIC SYSTEM 18000 SERIVCE/MAINTENANCE MANUAL NODE 20 - Boom Block Up, Block Sensor, & Limits Reference Electrical Schematic A06374 - Sheets 14 and 22 Function Can ID. No. Description Test Voltage Packet No. Type Receptacle – Can In 201-A 24 Volts...

  • Page 167: Node 21 - Luffing Jib, Block Up, Block Sensor, Limits

    18000 SERIVCE/MAINTENANCE MANUAL ELECTRIC SYSTEM NODE 21 - Luffing Jib, Block Up, Block Sensor, Limits Reference Electrical Schematic A06374 - Sheets 14 and 23 Can ID. Function Description Test Voltage Packet No. Type Receptacle – Can In 211-A 24 Volts...

  • Page 168: Node 0 - Power, Engine Controls, And Diagnostics

    ELECTRIC SYSTEM 18000 SERIVCE/MAINTENANCE MANUAL NODE 0 - Power, Engine Controls, and Diagnostics Reference Electrical Schematic A06374 - Sheet 15 Receptacle/ Function Wire No. Description Test Voltage CAN/ID Type Connector – 40 Pin 24 Volts Ignition Signal 24 Volts Nominal...

  • Page 169: Abbreviations

    18000 SERIVCE/MAINTENANCE MANUAL ELECTRIC SYSTEM Abbreviations The following abbreviations are used in this section: Alternating Current Input/Output Air Conditioning L.E.D. Light Emitting Diode Analog Input Max. Maximum Analog Output Min. Minimum Controller Area Network Motor Starter CANH Controller Area Network - High...

  • Page 170: Checking Electrical Inputs/Outputs

    Remove cable from node at W1 or W7 connector. performed with in-line test boards at universal nodes or Manitowoc Unit Tester at all nodes. The in-line test boards or Connect the communication in-line test board between Manitowoc Unit Tester can be ordered from your Manitowoc cable and universal node connector.
  • Page 171 18000 SERIVCE/MAINTENANCE MANUAL ELECTRIC SYSTEM 18CSM10-101 On Boom Top On Jib Top In Boom Butt CONTROLLER UNIVERSAL NODE A00323 MCC A01411 In Right Side Cab Console 18CSM3-101 P2071 P2066 P2065 Item Description Item Description Node-0 Engine Node Node-20 At Boom Top...
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  • Page 173: Dielectric Grease

    18000 SERIVCE/MAINTENANCE MANUAL ELECTRIC SYSTEM DIELECTRIC GREASE The following figures show the proper application of dielectric grease on J - tech type connectors. Dielectric grease is need when assembling J - tech type connectors. A bead of grease needs to be applied on O-ring and face of the socket (female) connector and only on the O-ring for a pin (male) connector.

  • Page 174: Digital Display

    ELECTRIC SYSTEM 18000 SERIVCE/MAINTENANCE MANUAL DIGITAL DISPLAY • MAX WIND SPEED resets when crane power is off. Pump drive operating conditions are provided only on The digital display and scroll up/down rocker (see Special current production cranes (pump drives with a circulating oil Controls in this section) allow the operator to monitor system).

  • Page 175: System Faults

    18000 SERIVCE/MAINTENANCE MANUAL ELECTRIC SYSTEM To erase the inactive limits, scroll to the operating limit group. The system fault alert turns off when the cause of each fault Wait until the display scrolls through the name of each limit. is corrected. Each active fault that has occurred during Inactive limits will be erased automatically.
  • Page 176 ELECTRIC SYSTEM 18000 SERIVCE/MAINTENANCE MANUAL Table 3-5 Operating Conditions Listed below are the operating conditions which can be viewed on the digital display. Unit of Display Reading Operating Range Measure Normal Operating Conditions The operating conditions listed below are displayed by scrolling up or down with the digital display selector.
  • Page 177 18000 SERIVCE/MAINTENANCE MANUAL ELECTRIC SYSTEM Table 3-6 Operating Limits Listed below are limits which turn on the operating limit alert (yellow light and continuous buzzer). When the alert comes on, the OPERATING LIMIT group of the digital display indicates which limit has been reached; take corrective action.
  • Page 178 ELECTRIC SYSTEM 18000 SERIVCE/MAINTENANCE MANUAL Table 3-7 System Faults Listed below are faults which turn on the system fault alert (red light and beeper). When the alert comes on, the SYSTEM FAULT group of the digital display indicates which fault has occurred; take corrective action. The beeper sounds intermittently.
  • Page 179 18000 SERIVCE/MAINTENANCE MANUAL ELECTRIC SYSTEM Display Reading Function Response Cause of Fault LOAD PIN Load drum operation will stop. Load pin voltage not within 0.5 - 9 volts. LUFFING JIB ANGLE SENDER [1] All functions operable, but JIB ANGLE Sender output voltage 0 volts or above 9.7 and BOOM TO LUFF JIB ANG display volts.

  • Page 180: Function Speed/Torque Adjustment

    ELECTRIC SYSTEM 18000 SERIVCE/MAINTENANCE MANUAL FUNCTION SPEED/TORQUE ADJUSTMENT CRANE DIAGNOSTICS General The speed of each crane function (all drums, travel, swing) and swing torque can be adjusted to suit operator needs. To enable the diagnostic screens, turn limit bypass key Adjustment switch clockwise and scroll up at least one screen.

  • Page 181: Drum 2

    18000 SERIVCE/MAINTENANCE MANUAL ELECTRIC SYSTEM • Control HANDLE command in percent from neutral with • Park BRAKE command with 0 engaged and 1 released. + raise and - lower. • DOS (digital output status) displays a binary number (or •...

  • Page 182: Drum 5

    ELECTRIC SYSTEM 18000 SERIVCE/MAINTENANCE MANUAL • The normal operating voltage (V) outputs of the control • DOS (digital output status) displays a binary number (or handle range is 2.4 to 0.5 volts to raise a load and 2.6 to total) if digital output signal is disabled to: pump A - drum 4.5 volts to lower a load.

  • Page 183: Trk (Travel)

    18000 SERIVCE/MAINTENANCE MANUAL ELECTRIC SYSTEM • Control handle Center Switch (CS) command with 0 • DOS (digital output status) displays a binary number (or neutral and 1 active. total) if the digital output signal is disabled to: right pump (1), left pump (2), travel brake (4), or motor (8).

  • Page 184: Can (Can Bus)

    ELECTRIC SYSTEM 18000 SERIVCE/MAINTENANCE MANUAL BIN Node Node Node Number Master (Front Console) Handles and Cab Controls Drum 3 and Pressure Senders In Boom Jacking, Connecting Pins, and Mast Top or Jib Alarms, Limits and Pump Controls Drums 2, 4, 5 & Adapter Frame Pins...

  • Page 185: Hydraulic System Calibration

    18000 SERIVCE/MAINTENANCE MANUAL ELECTRIC SYSTEM Accessory System To determine a state of an individual digital input or output, find the individual crane component in Table 3-11 Table 3- 12, for example: Return Filter Alarm CAN38-1-32. HANDLE +/-0 % ACC PRES •...

  • Page 186: Wireless

    ELECTRIC SYSTEM 18000 SERIVCE/MAINTENANCE MANUAL Wireless Block Level Sensor *REMOTE TxID 0000 *BLOCK LEVEL SENSOR 01B2 SENSOR BANKS: BLOCK ANGLE + 3.43 DEG LOAD LINK TRAFFIC DRUM 1 PUMP REMOTE TRAFFIC DRUM 2 PUMP WIRELESS LEVEL The LEVEL screen displays the following information when:...

  • Page 187: Digital Input And Output Item Tables

    18000 SERIVCE/MAINTENANCE MANUAL ELECTRIC SYSTEM DIGITAL INPUT AND OUTPUT ITEM TABLES • PRESS – Fan system pressure. Increased cooling demand and increased engine speed will increase this Table 3-11 Table 3-12 identify selected component pressure. digital Inputs and digital outputs used on the crane. The •...
  • Page 188 ELECTRIC SYSTEM 18000 SERIVCE/MAINTENANCE MANUAL Table 3-12 Digital Outputs CAN Packet Item Description CAN Packet Item Description Number (Node Number) Number (Node Number) CAN32-1-1 Cab Base RCL Beacon/Alarm (2) CAN32-3-128 Handle C Lower Direction (2) CAN32-1-2 Handle A Rotation Indicator (2)
  • Page 189 18000 SERIVCE/MAINTENANCE MANUAL ELECTRIC SYSTEM CAN Packet Item Description CAN Packet Item Description Number (Node Number) Number (Node Number) CAN35-1-128 Drum 5 Diverter Solenoid (4) CAN38-3-8 Drum 4B Pump Control -Lower (5) CAN35-2-1 Mast Raise Solenoid (4) CAN38-3-16 Swing 2 (optional) Pump Control - Left (5)
  • Page 190 ELECTRIC SYSTEM 18000 SERIVCE/MAINTENANCE MANUAL Table 3-13 Bank Identifier Numbers Dark shaded boxes indicate ON; white boxes OFF. 3-50 Published 12-05-17, Control # 035-23...
  • Page 191 18000 SERIVCE/MAINTENANCE MANUAL ELECTRIC SYSTEM Table 3-13 Bank Identifier Numbers (continued) Dark shaded boxes indicate ON; white boxes OFF. Manitowoc 3-51 Published 12-05-17, Control # 035-23...
  • Page 192 ELECTRIC SYSTEM 18000 SERIVCE/MAINTENANCE MANUAL Table 3-13 Bank Identifier Numbers (continued) Dark shaded boxes indicate ON; white boxes OFF. 3-52 Published 12-05-17, Control # 035-23...
  • Page 193 18000 SERIVCE/MAINTENANCE MANUAL ELECTRIC SYSTEM Table 3-13 Bank Identifier Numbers (continued) Dark shaded boxes indicate ON; white boxes OFF. Manitowoc 3-53 Published 12-05-17, Control # 035-23...
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  • Page 195: Section 4

    Lattice Section Inspection and Lacing Replacement ........4-15 Manitowoc...
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  • Page 197: Automatic Boom Stop Adjustment

    18000 SERVICE/MAINTENANCE MANUAL BOOM SECTION 4 BOOM AUTOMATIC BOOM STOP ADJUSTMENT Maintenance At least once weekly, check that the automatic boom stop Maximum Operating Angles stops the boom at the specified maximum angle. If not, Boom stop limit switch (5,...

  • Page 198: Bypass Limit Test

    BOOM 18000 SERVICE/MAINTENANCE MANUAL Table 4-1 — Automatic Boom Stop Angles Angle A Attachment (see Figure 4-1) #55-79A, #55, or 55A Boom without Luffing Jib 83° #55-79A, #55, or 55A Boom without Luffing Jib 84° When Boom Up Limit Can be Bypassed * 85°...
  • Page 199 18000 SERVICE/MAINTENANCE MANUAL BOOM Centerline of Boom Item Description Boom Butt 2a or 2b Switch Assembly See Table 4-2 see Table 4-1 Horizontal Right Side of Crane FIGURE 4-1 Table 4-2 — Adjusting Rods Adjusting Rod Length Boom Only With Luffing Jib When Boom Up Limit Can be Bypassed 4-3/4 in (121 mm) for 83°...
  • Page 200 BOOM 18000 SERVICE/MAINTENANCE MANUAL Item Description Item Description Boom Butt Spring Washer Adjusting Rod – Boom only Spring Adjusting Rod – Boom with Luffing Jib (see Table 4-2) Spring Washer Jam Nut Dowel Pin 1/4 in (6,35 mm) Diameter Coupling...

  • Page 201: Adjustment

    18000 SERVICE/MAINTENANCE MANUAL BOOM Figure 4-2 for the remaining steps. If the boom stops before reaching the specified angle: Boom Stop Digital Level Angle Angle Loosen jam nut (3, View B). 83° 70.7° b. Turn adjusting rod (2a or 2b) all the way into 84°...

  • Page 202: Physical Boom Stop

    BOOM 18000 SERVICE/MAINTENANCE MANUAL Adjust the boom stop. • Assist in stopping the boom smoothly at any angle above 77° PHYSICAL BOOM STOP • Assist in preventing the boom rigging from pulling the boom back when traveling or setting loads with the boom at any angle above 77°...

  • Page 203: Boom And Luffing Jib Angle Indicator Calibration

    INDICATOR CALIBRATION The subject cranes do not have an angle indicator junction box mounted on the boom butt or on the luffing jib butt like other cranes manufactured by Manitowoc. The angle indicator potentiometers are located inside the Electronic node controllers mounted on the boom top and on the luffing Level jib top.
  • Page 204 BOOM 18000 SERVICE/MAINTENANCE MANUAL Connect wires from potentiometer to proper terminals on Remove existing potentiometer and terminal strip (if terminal strip. used). Make sure all parts are securely fastened to their Mount new sensor in existing holes as shown in View B.

  • Page 205: Strap Inspection And Maintenance

    Any damage found must be recorded and a procedures not covered in this Service/Maintenance Manual, determination made as to whether continued use of strap is contact your dealer or the Manitowoc Crane Care Lattice safe. Team. Before beginning inspection, thoroughly clean strap of all dirt, grease, oil, etc.

  • Page 206: Replacement Specifications

    BOOM 18000 SERVICE/MAINTENANCE MANUAL Replacement Specifications Dent Any strap not within specifications listed in Table 4-3 must be replaced. WARNING I f d a m a g e t o s t r a p e x c e e d s t h a t a l l o w e d w i t h i n...

  • Page 207: Straightness

    18000 SERVICE/MAINTENANCE MANUAL BOOM Strap Length Maximum Deviation Corrosion or Abrasion Allowed P325 20 to <30 ft (6,1 to <9,1 m) 0.250 in (6,4 mm) 30 to <40 ft (9,1 to <12,2 m) 0.375 in (9,5 mm) 40 to <50 ft (12,2 to <15,2 m) 0.50 in (12,7 mm)

  • Page 208: Storing Straps

    BOOM 18000 SERVICE/MAINTENANCE MANUAL Push pin tight against edge of hole along vertical center Length line. Measure dimension between pin and hole (View B). Link Strap If dimensions A and B are not identical, hole is elongated. Remove strap from service.
  • Page 209 18000 SERVICE/MAINTENANCE MANUAL BOOM STRAP INSPECTION CHECKLIST Inspector’s Name Signature Date Length mm (ft) Part Number Corrosion Kinks Cracks Dents Breaks Straightness Elongated Holes Abrasion Length Flatness Other Length mm (ft) Part Number Corrosion Kinks Cracks Breaks Dents Abrasion Length...
  • Page 210 NOTES SKETCHES AND PHOTOGRAPHS...

  • Page 211: Lattice Section Inspection And Lacing Replacement

    18000 SERVICE/MAINTENANCE MANUAL BOOM LATTICE SECTION INSPECTION AND LACING REPLACEMENT Refer to Folio 1316 at the end of this section for lattice section inspection and lacing replacement instructions. Manitowoc 4-15 Published 12-05-17, Control # 035-23...
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  • Page 213: Section 5

    Yearly Inspection ............. 5-24 Manitowoc...
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  • Page 215: Hoist Drawings

    18000 SERIVCE/MAINTENANCE MANUAL HOISTS SECTION 5 HOISTS HOIST DRAWINGS Applicable hoist and load block drawings are attached at the end of this section. DANGER Flying Part Hazard! BOOM HOIST PAWL ADJUSTMENT Leaf springs are preloaded. Do not proceed to step...
  • Page 216 HOISTS 18000 SERIVCE/MAINTENANCE MANUAL Set Dimension B (View B): extended and fully retracted and that pawl (1) fully engages and disengages ratchet tooth (2). Loosen jam nut (5). b. Turn adjusting screw (6) IN until Dimension B is CAUTION obtained between pawl (1) and ratchet tooth (2).

  • Page 217: Mast Hoist Pawl Maintenance

    18000 SERIVCE/MAINTENANCE MANUAL HOISTS MAST HOIST PAWL MAINTENANCE Maintenance The only maintenance required is to visually check the pawl General for proper operation. This should be done daily when the The mast hoist (Drum 5) has a drum pawl which is a positive mast hoist is in use.

  • Page 218: Speed Sensor Adjustment

    HOISTS 18000 SERIVCE/MAINTENANCE MANUAL SPEED SENSOR ADJUSTMENT Version 1 – Sensor with Flats Figure 5-3 for the following procedure. Hydraulic Motors with Speed Sensors Bring corresponding function to a complete stop, land The hydraulic motors for the hoists (boom, mast, load) have suspended load if load drum is being serviced, and a speed sensor.
  • Page 219 18000 SERIVCE/MAINTENANCE MANUAL HOISTS Version 2 – Sensor with Notch in Threads Figure 5-4 for the following procedure. Item Description Bring corresponding function to a complete stop, land Speed Sensor suspended load if load drum is being serviced, and Notch PARK function.

  • Page 220: Bail Limit Adjustment

    HOISTS 18000 SERIVCE/MAINTENANCE MANUAL BAIL LIMIT ADJUSTMENT on first layer (LED off). Adjust limit switch if necessary. NOTE: Reference to LED is past production. Check that cap screws holding rollers on lever shaft are The optional minimum bail limit assembly on Drum 1 (main tight.
  • Page 221 18000 SERIVCE/MAINTENANCE MANUAL HOISTS 3 to 4 Wraps of Wire Rope Remaining on Drum View from Left Side Drum 2 Shown Other Drums Similar 1.34 in (34,0 mm) When New 18CSM5-105 Item Description Lever Rollers Cap Screw 1.71 in Drum...

  • Page 222: Block-Up Limit Adjustment

    HOISTS 18000 SERIVCE/MAINTENANCE MANUAL BLOCK-UP LIMIT ADJUSTMENT Block-Up Limit Control Deactivated During normal operation, the weight overcomes spring force General and rotates the actuating lever away from the limit switch lever. This action allows the limit switch to close the load A block-up limit (also called anti two-block device) is a two- drum UP and boom DOWN electric circuits.
  • Page 223 18000 SERIVCE/MAINTENANCE MANUAL HOISTS Current Production adjustment procedure: d. Turn cab power on and scroll to the Level screen for the block level sensor and block level angle NOTE: The angle sensor and printed circuit board are a diagnostic display readings (see Section 3, Crane matched set.
  • Page 224 HOISTS 18000 SERIVCE/MAINTENANCE MANUAL A15729 Chain Angle Sensor Strain Relief on Cable Must 12' (3.7 m) Adjustment Direction be Connected to Hook in Boom and Jib Point With European Weight Standard Only Multiple Part Block-Up Limit at #55-79A Boom Point Shown...
  • Page 225 18000 SERIVCE/MAINTENANCE MANUAL HOISTS 18CSM5-108 Typical Boom Butt or Item Description Luffing Jib Butt Electric Cable Cable Reel Cable Fixed Jib Butt Brackets FIGURE 5-7 18CSM5-109 Dead-End Load Line or Slowest Live Line Item Description Weight Shackle Chain Connecting Pin...

  • Page 226: Disconnecting Block-Up Limit Control

    HOISTS 18000 SERIVCE/MAINTENANCE MANUAL 18CSM5-110 View A WNE14 View B Node 8 on WN18 Boom Butt WNE08 Node 7 on Adapter Frame Item Description Sealing Cap (3 each) Terminating Plug Electric Cable WNE14 Electric Cable WBM150 from Cable Reel Boom Node Controller *...

  • Page 227: Removing Upper Boom Point Or Jib Point

    18000 SERIVCE/MAINTENANCE MANUAL HOISTS Unscrew sealing cap (1, View A) from terminating plug Store excess electric cable for the boom and luffing jib by (2). winding it onto the reel mounted on the respective butt. The reel has a locking pin. Disengage the locking pin to allow the Disconnect electric cable (3, View B) from cable (4).

  • Page 228: Adjustment

    HOISTS 18000 SERIVCE/MAINTENANCE MANUAL Adjust spring tension so there is enough force to lift weight of chain and rotate actuating lever when weight is CAUTION lifted. Avoid Sheave Damage! Loosen setscrew in limit switch lever so lever is free to Use extreme care when testing block-up limits when rotate.

  • Page 229: Wire Rope Inspection And Replacement

    (see Broken Rope Wires). from Manitowoc. Do not build lengths from individual Internal wear or broken wires for ropes operating on components. synthetic sheaves. Common indicators of internal Replace an entire wire rope assembly.
  • Page 230 HOISTS 18000 SERIVCE/MAINTENANCE MANUAL End fitting wear/abrasion Minor or general corrosion Areas that deteriorate more rapidly, such as the flange points, the crossover points, and the repetitive pickup points on drums Take special care to observe the boom hoist ropes...

  • Page 231: Periodic Comprehensive Inspection

    18000 SERIVCE/MAINTENANCE MANUAL HOISTS Periodic Comprehensive Inspection • Size, nature, and frequency of lifts • Rope maintenance practices The comprehensive inspection must be done by a qualified person. The inspection must include pulling all the rope off • Severity of the environment, such as: the drum and carefully inspecting the entire length.

  • Page 232: Broken Rope Wires

    HOISTS 18000 SERIVCE/MAINTENANCE MANUAL New Wire Rope—After initial loading, measure and record • All Ropes—one outer wire broken at the point of contact the diameter of any new wire rope for comparison to future with the core and protrudes or loops out of the rope inspections.

  • Page 233: Distributing Wire Rope Wear

    NOTE: Wire rope may be purchased through the should be installed. Manitowoc Crane Care Lattice Team. For sheaves not equipped with grease fittings, be sure to pack the new bearings with grease at assembly. For steel sheaves, check the depth, width, and contour...
  • Page 234 HOISTS 18000 SERIVCE/MAINTENANCE MANUAL Inspect the nylon sheaves to verify they have not separated and “walked off” the steel inserts or the Observe the groove to see if the contour of the gauge bearings as shown in Figure 5-17. Maximum sideways matches the contour at the bottom of the sheave groove.
  • Page 235 18000 SERIVCE/MAINTENANCE MANUAL HOISTS B = tread diameter, new sheave E = tread diameter, used sheave PLASTIC SHEAVE DATA B minus E = total wear Sheav If total wear is 5 mm (3/16 in) or more, Outside Tread Rope the sheave should be replaced.

  • Page 236: Load Block And Hook-And-Weight Ball Inspection

    FIGURE 5-20 Item Description Working Load Limit (ton (US and metric) Wire Rope Diameter (in and mm) Block Weight (lb and kg) Block Serial Number Block Part Number (OEM and Manitowoc) Design Factor FIGURE 5-19 5-22 Published 12-05-17, Control # 035-23...
  • Page 237 Do not weld on any load-bearing component unless proper welding methods are used (contact the Manitowoc • The groove must be larger than the wire rope, and Crane Care Lattice Team for material and welding the groove must be free of rough edges and burrs.

  • Page 238: Yearly Inspection

    HOISTS 18000 SERIVCE/MAINTENANCE MANUAL WARNING Falling Load Hazard To prevent the load from dropping, make sure that, under slack conditions, the hook latch retains the slings or other rigging in the hook. The hook latch is not intended as an anti-fouling device.

  • Page 239: Section 6

    Manual Release Procedure ............6-1 Manitowoc...
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  • Page 241: Manual Release Of Swing Brake And Lock

    18000 SERIVCE/MAINTENANCE MANUAL SWING SECTION 6 SWING MANUAL RELEASE OF SWING BRAKE AND Pressurize brake and swing lock to 350 psi (24 bar). LOCK Remove or install swing planetary. NOTE: The swing lock is installed on past production Relieve pressure and remove hand pumps.
  • Page 242 SWING 18000 SERIVCE/MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK Published 12-05-17, Control # 035-23...
  • Page 243 Engine Belt Routing ............. . 7-16 Manitowoc...
  • Page 244 18000 SERIVCE/MAINTENANCE MANUAL Tier 3 Engine ............. . . 7-16 Tier 4 Engine .

  • Page 245: Battery Maintenance

    18000 SERIVCE/MAINTENANCE MANUAL POWER TRAIN SECTION 7 POWER TRAIN BATTERY MAINTENANCE Undercharging Undercharging can cause a type of sulfate to develop on the Safety Information plates. The sulfate causes strains in the positive plates which causes plate buckling. Buckled plates can pinch the separators and cause a short circuit.

  • Page 246: Maintenance

    POWER TRAIN 18000 SERIVCE/MAINTENANCE MANUAL Maintenance Table 7-2 Hydrometer Readings Hydrometer Reading — Weekly – Check Electrolyte Level % Charge Specific Gravity. Clean the top of the battery before removing the vent 1.260 – 1.280 = 100% caps. Keep foreign material out. Confirm that the plates in each cell are completely covered with electrolyte.

  • Page 247: High Resistance Test

    18000 SERIVCE/MAINTENANCE MANUAL POWER TRAIN amperes for a maximum of 2 hours. If the electrolyte Approximate temperature reaches 52°C (126°F) or if it gases violently, the % Charge Specific Gravity Open Circuit charging current must be reduced or halted to avoid battery Cell Voltage damage.

  • Page 248: Engine Diagnostics

    POWER TRAIN 18000 SERIVCE/MAINTENANCE MANUAL ENGINE DIAGNOSTICS On-Board Engine Diagnostics Engine Diagnostics — Cummins General Active engine faults can be viewed on the crane’s digital The Cummins QSX15 Engine has two types of fault codes: display either with the engine running or with the engine off •...
  • Page 249 18000 SERIVCE/MAINTENANCE MANUAL POWER TRAIN • OFF when DPF is full and Red Engine Stop Light is ON. The soot level is critically high and past the point of a manual stationary regeneration. The operator will notice a significant reduction in engine power. Turn off regeneration inhibit switch and shut down crane.

  • Page 250: Engine Air Cleaner Maintenance

    POWER TRAIN 18000 SERIVCE/MAINTENANCE MANUAL ENGINE AIR CLEANER MAINTENANCE Release seal carefully: Unlatch and remove service cover. Make certain latches Tier 3 and Past Production are folded back against cover so that they don’t hinder filter removal/installation. Most latches are spring loaded Figure 7-6 for the following procedure.
  • Page 251 18000 SERIVCE/MAINTENANCE MANUAL POWER TRAIN stretch slightly, adjust themselves, and distribute the Check connections for tight fit: sealing pressure evenly. To complete a tight seal, apply Make sure that all clamps, bolts, and connections in pressure by hand at outer rim of filters, not the flexible entire air intake system are tight.

  • Page 252: Tier 4 Current Production

    POWER TRAIN 18000 SERIVCE/MAINTENANCE MANUAL Tier 4 Current Production Figure 7-7 for the following procedure. CAUTION Engine Damage! The Tier 4 intake assembly has mounting brackets (4) that are fastened to the engine air cleaner assembly (3) with STOP ENGINE before servicing air cleaner or unfiltered three rubber elbow reducers (1), clamps (2), and straight air will be drawn directly into engine.
  • Page 253 18000 SERIVCE/MAINTENANCE MANUAL POWER TRAIN 81018951 81017660 Item Description Rubber Reducer Clamp (6) Air Cleaner Assembly Mounting Bracket IMG_752 Pre Cleaner Service Indicator Reset Button Filter Access Cover Air Cleaner Assembly Inlet Air Cleaner Assembly Outlet Primary Filter Secondary Filter...

  • Page 254: Engine Clutch Adjustment

    POWER TRAIN 18000 SERIVCE/MAINTENANCE MANUAL ENGINE CLUTCH ADJUSTMENT Operation Figure 7-8 for the following procedure. Grease clutch monthly. See Lubrication Guide in Section 9 of this manual. A disc-type manually operated clutch is mounted between the engine and the pump drive on this crane. The clutch...
  • Page 255 18000 SERIVCE/MAINTENANCE MANUAL POWER TRAIN 18CSM7-103 Legend is on the following page Supply Idle 22VDC Signal 5 WATT High Ground Idle Ground Signal Supply ELECTRICAL SCHEMATIC Section B–B Surface X Flat on Head of Shaft 70° RTV-162 These two holes should be aligned when initially inserting Section A–A...

  • Page 256: Engine Throttle Adjustment

    POWER TRAIN 18000 SERIVCE/MAINTENANCE MANUAL ENGINE THROTTLE ADJUSTMENT Rotate pedal approximately 40° to position "B" (low idle). At this time flat on head of shaft (3) should be parallel The engine throttle assembly consist of an electronic hand with surface X on housing. Finish turning in setscrew throttle controller in the left console and an electronic foot (14) until it contacts flat on head of shaft (Section A-A).

  • Page 257: Engine Cooling System

    18000 SERIVCE/MAINTENANCE MANUAL POWER TRAIN ENGINE COOLING SYSTEM • A small percentage of total coolant flow is circulated through a vent line to the radiator. General • Since coolant circulation is very slow in the radiator, air separates from the coolant.

  • Page 258: Maintenance

    POWER TRAIN 18000 SERIVCE/MAINTENANCE MANUAL Maintenance Clean all dirt and other debris from outside of radiator. Check that overflow line on tank is open. Figure 7-11 for the following procedure. Draining Cooling System Drain radiator system, as follows: WARNING Stop engine.
  • Page 259 18000 SERIVCE/MAINTENANCE MANUAL POWER TRAIN Tier 3 and Past Production Item Description Cooler Assembly Tier 3 and Past Production Cooler Assembly Tier 4 Coolant Level Sight Gauge Cooler Assembly Fill Cap Cooler Assembly Drain Tier 4 Current Production A14217 81017661...

  • Page 260: Engine Belt Routing

    POWER TRAIN 18000 SERIVCE/MAINTENANCE MANUAL ENGINE BELT ROUTING Tier 4 Engine Engine belt routing for the Tier 4 engine is shown in Tier 3 Engine Figure 7-13 to help service personnel with installing a new Engine belt routing for the Tier 3 engine is shown in fan belt.

  • Page 261: Diesel Particulate Filter - Tier 4

    18000 SERIVCE/MAINTENANCE MANUAL POWER TRAIN DIESEL PARTICULATE FILTER — TIER 4 NOTE: Use the INHIBIT switch in the operator’s cab only for special circumstances where it is desirable to General disable active regeneration. Prolonged engine operation with INHIBIT on will cause the DPF to fill The Diesel Particulate Filter (DPF) —...

  • Page 262: Maintenance

    POWER TRAIN 18000 SERIVCE/MAINTENANCE MANUAL Maintenance Accumulated ash must be periodically cleaned from the DPF center section. A build-up of ash can result in cold spots and WARNING compact the ash within the DPF. This reduces the life of the...

  • Page 263: Dpf Installation

    18000 SERIVCE/MAINTENANCE MANUAL POWER TRAIN 10. Mark the direction of exhaust flow, from inlet to outlet, on DPF Re-Orientation the outside of the DPF. This will help if the DPF will be Figure 7-15 for the following procedure. cleaned and re-installed.
  • Page 264 POWER TRAIN 18000 SERIVCE/MAINTENANCE MANUAL Item Description Lifting Hook Temperature Sensor 1 Temperature Sensor 2 Lifting Hook Band Inlet V-Band Clamp Pressure Sensor Outlet V-Band Clamp DPF Outlet Section DPF Center Section DPF Inlet Section View A View B Outlet End...
  • Page 265 Operation ..............8-5 Manitowoc...
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  • Page 267: Turntable Bearing Bolt Torque

    18000 SERIVCE/MAINTENANCE MANUAL UNDER CARRIAGE SECTION 8 UNDER CARRIAGE TURNTABLE BEARING BOLT TORQUE “ N e v e r - S ee z ” ( M C C N o . 3 6 1 0 10 ) o r an e q u i v a l e n t antiseizing lubricant.
  • Page 268 UNDER CARRIAGE 18000 SERIVCE/MAINTENANCE MANUAL Circled Numbers Indicate Tightening Sequence FRONT of Upperworks and Carbody Access to inner ring bolts is through hole in center of adapter frame and carbody. 18CSM8-100 Item Description Socket Head Bolt – 2 in. 4-1/2 UNRC x 15 in. Long 84 in Each Ring Flat Steel Washer –...

  • Page 269: Crawler Adjustment

    18000 SERIVCE/MAINTENANCE MANUAL UNDER CARRIAGE CRAWLER ADJUSTMENT Tread Slack Adjustment Adjustment Guideline Maintenance Check tread slack at the tumbler end of each crawler. Crawler wear cannot be eliminated, but the rate of wear can Maintain equal tread slack at both crawlers.

  • Page 270: Adjustment Procedure

    UNDER CARRIAGE 18000 SERIVCE/MAINTENANCE MANUAL Adjustment Procedure Travel crane forward or reverse to tighten shims. Check that dimension from center punch (A) in shaft to Adjust tread slack at roller end of each crawler (Figure 8-3). center punch line (B) in crawler frame is same on both Thoroughly clean crawler to be adjusted.

  • Page 271: Hydraulic Hand Pump

    Prevent Possible Death or Serious Injury For Enerpac pump: to Maintenance Personnel Place pump in vertical position with hose end Manitowoc has provided hand pump and cylinder for down. crawler adjustment only. Any other use is neither intended nor approved.
  • Page 272 UNDER CARRIAGE 18000 SERIVCE/MAINTENANCE MANUAL S135 S137 S138 Cylinder Vent/Fill Cap (Simplex Pump) Close Valve Extend Cylinder Hose Pump Open Retract Valve Notch in Dipstick Cylinder (Enerpac Pump) FIGURE 8-4 Published 12-05-17, Control # 035-23...

  • Page 273: Lubrication

    Lubrication ..............9-1 Manitowoc...
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  • Page 275 18000 SERIVCE/MAINTENANCE MANUAL LUBRICATION SECTION 9 LUBRICATION LUBRICATION See F2104 at the end of this section. Manitowoc Published 12-05-17, Control # 035-23...
  • Page 276 LUBRICATION 18000 SERIVCE/MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK Published 12-05-17, Control # 035-23...
  • Page 277 Problem 31 Mast pin cylinders will not extend or retract......10-33 Problem 32 Boom hinge pin cylinders will not extend or retract..... . . 10-34 Manitowoc 10-i...
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  • Page 279: General Troubleshooting

    Rated Capacity Indicator/Limiter display and Main operations. display for checking pump, motor, handle, brake, etc. Manitowoc cannot foresee all hazards that may occur. components. Technicians shall be familiar with the equipment, trained in • Use in-line test boards or Manitowoc Universal Tester/...

  • Page 280: Troubleshooting Charts

    If directed, consult your Manitowoc dealer or the operation. These charts contain instructions to assist in Manitowoc Crane Care Lattice Team before proceeding.
  • Page 281 18000 SERIVCE/MAINTENANCE MANUAL TROUBLESHOOTING TROUBLESHOOTING CHARTS Problem 1 Engine will not turn over to start. POSSIBLE CAUSES Dead battery; Loose connection on battery; Starter, start solenoid (MS1/ MS2) relay, or starter solenoid (SS) is damaged; Engine node is damaged. CHECKS Check for voltage at battery terminals while attempting to start engine.
  • Page 282 TROUBLESHOOTING 18000 SERIVCE/MAINTENANCE MANUAL Problem 2 Engine turns over, but will not start. POSSIBLE No fuel to or from injector pump; Water or algae in fuel; Air intake restricted or blocked; Engine load is too high; Low battery amperage to gain starting RPM; Fuel shut-off is not working correctly.
  • Page 283 18000 SERIVCE/MAINTENANCE MANUAL TROUBLESHOOTING Problem 3 Engine runs, but no hydraulic operation. POSSIBLE CAUSES Clutch not engaged; No hydraulic fluid in tank; Blocked charge inlet to pumps; Clogged tank vent; Drive train damaged from flywheel to pump mount. CHECKS Check hydraulic filter service shut-off valve.
  • Page 284 TROUBLESHOOTING 18000 SERIVCE/MAINTENANCE MANUAL Problem 4 Engine runs, but battery is not charging. POSSIBLE CAUSES Belt loose or broken; No input to alternator terminals; Damaged alternator; Corroded or loose battery connection; Battery is damaged. CHECKS Check fan drive belt and alternator belt for correct tension.
  • Page 285 18000 SERIVCE/MAINTENANCE MANUAL TROUBLESHOOTING Problem 5 An engine fault alert is enable during engine operation. (Also see See Crane Diagnostics topic in Section 3 for faults.) POSSIBLE CAUSES High engine coolant temperature or low engine oil pressure; Engine Node fault.
  • Page 286 TROUBLESHOOTING 18000 SERIVCE/MAINTENANCE MANUAL Problem 6 Crawler travels at slow speed. POSSIBLE CAUSES Partial control voltage from handle to PC; Partial control voltage from PC to pump EDC; Pump or motor is damaged. CHECKS Check travel speed switch for high-speed selection. Check that 100% travel speed is selected on speeds screen.
  • Page 287 18000 SERIVCE/MAINTENANCE MANUAL TROUBLESHOOTING Problem 7 Crawlers will not travel in either direction (one or both tracks). POSSIBLE CAUSES Brake valve is damaged; Control handle is worn; Pump EDC is damaged; No voltage from handle to controller; No voltage out of controller to pump EDC; Node fault; Low brake pressure;...
  • Page 288 TROUBLESHOOTING 18000 SERIVCE/MAINTENANCE MANUAL Problem 8 No load drum operation (drum 1, 2 or 3). POSSIBLE CAUSES Load drum brake not releasing; No voltage through control handle to controller; No voltage out of controller to pump EDC; Node fault; Wiring or switch is faulty.
  • Page 289 18000 SERIVCE/MAINTENANCE MANUAL TROUBLESHOOTING Problem 9 Load drum (1, 2 or 3) will not raise load, but will lower load. POSSIBLE CAUSES Block up limit is opened; Pump is damaged; Control handle is worn; Maximum bail limit is opened; Node fault; Speed sender is damaged.
  • Page 290 TROUBLESHOOTING 18000 SERIVCE/MAINTENANCE MANUAL Problem 10 Selected load drum will not lower load, but will raise load. POSSIBLE CAUSES Control handle is worn; Minimum bail limit opened; Pump is damaged; Node fault; Speed sender is damaged. CHECKS See Crane Diagnostics topic in Section 3 to find CAN bus packet numbers.
  • Page 291 18000 SERIVCE/MAINTENANCE MANUAL TROUBLESHOOTING Problem 11 Load drum (1, 2, or 3) will not reach maximum speed. POSSIBLE CAUSES Partial control from handle to controller; Partial control voltage from controller to pump EDC or motor PCP; Pump or motor is damaged; Node fault.
  • Page 292 TROUBLESHOOTING 18000 SERIVCE/MAINTENANCE MANUAL Problem 12 No boom hoist operation. POSSIBLE CAUSES Boom hoist brake not releasing; Boom hoist pawl not released or hung up; No voltage through control handle to controller; No voltage out of controller to pump EDC; Node fault; Wiring or switch is faulty.
  • Page 293 18000 SERIVCE/MAINTENANCE MANUAL TROUBLESHOOTING Problem 13 Boom hoist will not reach maximum speed. POSSIBLE CAUSES Partial control voltage from handle to controller; Partial control voltage from controller to pump EDC; Motor controller in low; Pump or motor is damaged; Node fault.
  • Page 294 TROUBLESHOOTING 18000 SERIVCE/MAINTENANCE MANUAL Problem 14 Boom will not boom up, but will boom down. POSSIBLE CAUSES Pump is damaged; Boom maximum up limit opened; Equalizer/ boom stop limit opened; Node fault; Control handle is worn. CHECKS See Crane Diagnostics topic in Section 3 to find CAN bus packet numbers.
  • Page 295 18000 SERIVCE/MAINTENANCE MANUAL TROUBLESHOOTING Problem 15 Boom will not boom down, but will boom up. POSSIBLE CAUSES Boom maximum down limit opened; Pawl engaged; Pump is damaged; Block-up limit open; Control handle is worn; Node fault; Speed encoder is damaged.
  • Page 296 TROUBLESHOOTING 18000 SERIVCE/MAINTENANCE MANUAL Problem 16 No luffing jib (drum 6) operation. POSSIBLE CAUSES Luffing jib drum brake is not releasing; Pawl not released or hung up; No voltage through control handle to controller; No voltage out of controller to pump EDC; Node fault; Wiring or switch is faulty.
  • Page 297 18000 SERIVCE/MAINTENANCE MANUAL TROUBLESHOOTING Problem 17 Luffing jib will not reach maximum speed. POSSIBLE CAUSES Partial control voltage from handle to controller; Partial control voltage from controller to pump EDC; Motor controller in low; Pump or motor is damaged; Node fault.
  • Page 298 TROUBLESHOOTING 18000 SERIVCE/MAINTENANCE MANUAL Problem 18 Luffing jib will not boom up, but will boom down. POSSIBLE CAUSES Maximum up limit 1 or 2 is tripped; Pawl engaged; Pump is damaged; Control handle is worn; Node fault; Speed encoder is damaged.
  • Page 299 18000 SERIVCE/MAINTENANCE MANUAL TROUBLESHOOTING Problem 19 Luffing jib will not boom down, but will boom up. POSSIBLE CAUSES Boom maximum down limit opened; Pawl engaged; Pump is damaged; Block- up limit open; Control handle is worn; Node fault; Speed encoder is damaged.
  • Page 300 TROUBLESHOOTING 18000 SERIVCE/MAINTENANCE MANUAL Problem 20 No mast hoist (drum 5) operation. POSSIBLE CAUSES Mast hoist drum brake is not releasing; Mast hoist pawl not released or hung up; No voltage through control handle to controller; No voltage out of controller to pump EDC; Node fault; Wiring or switch is faulty.
  • Page 301 18000 SERIVCE/MAINTENANCE MANUAL TROUBLESHOOTING Problem 21 No swing operation, but engine loads. POSSIBLE CAUSES Mechanical hang-up; Solenoid failure; Node fault; Wiring fault. CHECKS Check swing operation on digital display, swing screen. When applicable switch is enabled… Swing Lock - Out ....Packet #36, Bank 2 changed by 8 Swing Brake.
  • Page 302 TROUBLESHOOTING 18000 SERIVCE/MAINTENANCE MANUAL Problem 22 No swing operation, engine does not load. POSSIBLE CAUSES No voltage through control handle to controller; No voltage out of controller to pump EDC; Wiring or switch is faulty; Node is damaged; A pump or motor is damaged; Swing holding brake switch actuated.
  • Page 303 18000 SERIVCE/MAINTENANCE MANUAL TROUBLESHOOTING Problem 23 Hydraulic system (any) response is sluggish. POSSIBLE CAUSES Low hydraulic oil level in reservoir; Low hydraulic oil temperature; Water in hydraulic oil; Wrong oil viscosity for application; Reservoir shut-off valves are partially closed; Dirty charge filters; System multifunction valves are not set correctly;...
  • Page 304 TROUBLESHOOTING 18000 SERIVCE/MAINTENANCE MANUAL Problem 24 Hydraulic system is operating hot. POSSIBLE CAUSES Low hydraulic oil level in reservoir; High hydraulic oil temperature; Water or air in hydraulic oil; Wrong oil viscosity for application; Heat exchanger problem; Dirty filter; System multifunction valves are not set correctly;...
  • Page 305 18000 SERIVCE/MAINTENANCE MANUAL TROUBLESHOOTING Problem 25 System pump will not return to neutral. POSSIBLE CAUSES Control handle is worn; System pump EDC is damaged or out of adjustment; System pump is damaged; Pump is not centered. CHECKS Does problem system screen CS (center switch) indicate a voltage when system...
  • Page 306 TROUBLESHOOTING 18000 SERIVCE/MAINTENANCE MANUAL Problem 26 Pawl on boom, luffing jib, or mast hoist is not operating correctly. POSSIBLE CAUSES Mechanical hang-up; No hydraulic pressure; No voltage to pawl solenoid; Bad wiring connection; Actuator/cylinder failure. CHECKS Check for damage to pawl linkage. Check pawl or pawl actuator/cylinder for freedom of movement.
  • Page 307 18000 SERIVCE/MAINTENANCE MANUAL TROUBLESHOOTING Problem 27 Mast rasing (live mast) cylinders will not raise or lower. POSSIBLE CAUSES Not in setup remote mode; Faulty control valve section; Low pump pressure; Bad pump; Switch failure; Faulty counterbalance valve. CHECKS When applicable switch is enabled . . .
  • Page 308 TROUBLESHOOTING 18000 SERIVCE/MAINTENANCE MANUAL Problem 28 Jacking cylinder(s) will not extend or retract. POSSIBLE CAUSES Not in setup mode; Faulty control valve section; Low pump pressure; Supercharge accessory supply pump is damaged; Faulty counterbalance valve. CHECKS Check supercharge accessory supply system for 3,000 psi (207 bar) while enabling selected jacking cylinder switch on remote control.
  • Page 309 18000 SERIVCE/MAINTENANCE MANUAL TROUBLESHOOTING Problem 29 Crawler pin cylinder(s) will not extend or retract (left or right set). POSSIBLE CAUSES Not in setup mode; Faulty control valve section; Supercharge accessory supply pump is damaged; Mechanical problem. CHECKS Check supercharge accessory supply system for 3,000 psi (207 bar) while enabling selected crawler pin cylinder handle.
  • Page 310 TROUBLESHOOTING 18000 SERIVCE/MAINTENANCE MANUAL Problem 30 Rotating frame pin cylinders will not extend or retract. POSSIBLE CAUSES Not in setup remote mode; Faulty control valve section; Supercharge accessory supply pump is faulty; Mechanical problem. CHECKS Does supercharge accessory supply system pressurize to 3,000 psi (207 bar) when...
  • Page 311 18000 SERIVCE/MAINTENANCE MANUAL TROUBLESHOOTING Problem 31 Mast pin cylinders will not extend or retract. POSSIBLE CAUSES Not in setup remote mode; Faulty control valve section; Supercharge accessory supply pump is faulty; Mechanical problem. CHECKS Does supercharge accessory supply system pressurize to 3,000 psi (207 bar)
  • Page 312 TROUBLESHOOTING 18000 SERIVCE/MAINTENANCE MANUAL Problem 32 Boom hinge pin cylinders will not extend or retract. POSSIBLE CAUSES Not in setup remote mode; Faulty control valve section; Supercharge accessory supply pump is faulty; Mechanical problem. CHECKS Does supercharge accessory supply system pressurize to 3,000 psi (207 bar) when...
  • Page 313 Hydraulic System Specifications - 18000 ........
  • Page 314 18000 SERIVCE/MAINTENANCE MANUAL Introduction ..............1-1 Lattice Section Inspection and Lacing Replacement .

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