Manitowoc 18000 Boom Crawler Crane Manuals

Manuals and User Guides for Manitowoc 18000 Boom Crawler Crane. We have 4 Manitowoc 18000 Boom Crawler Crane manuals available for free PDF download: Service Maintenance Manual, Operator's Manual, Quick Start Manual

Manitowoc 18000 Operator's Manual (302 pages)

Brand: Manitowoc | Category: Construction Equipment | Size: 34 MB

Table of Contents
5
Section 1

13
- Crane Data
  13
- Crane/Attachment Identification
  13
- Change of Ownership Registration
  13
- Manitowoc Dealer
  13
- Crane Orientation
  13
- Identification and Location of Components
  14
- Outline Dimensions
  16
- Crane Weights
  18
- English and Metric Conversions
  23
  - Direct Conversion
    23
  - Inverse Conversion
    23
Section 2

25
- Continuous Innovation
  27
- Nameplates and Decals
  27
- Safety Messages
  27
  - General
    27
  - Safety Alert Symbol
    27
  - Signal Words
    27
  - Symbol Identification
    27
- Safety and Information Signs
  29
  - Maintaining Signs
    29
  - Ordering Signs
    29
- Crane Access Points
  31
  - General
    31
  - Getting on or off Crane
    31
- Personnel Fall-Protection Anchors
  34
- Operator Manual/Capacity Chart Storage
  34
  - General
    34
  - Storing Manuals
    34
- Safe Operating Practices
  35
  - General
    35
  - Read Operator Manual
    35
  - Operator Qualifications
    35
  - Operator Conduct
    35
  - Handling Load
    37
  - Size of Load
    37
  - Attaching Load
    37
  - Lifting/Moving Load
    38
  - Multiple Load Line Operation
    39
- Signals
  40
- Holding Load
  40
- Safety Devices
  41
- Operational Aids
  41
  - Category 1 Operational Aids
    41
  - Category 2 Operational Aids
    42
- Assembling, Disassembling, or Operating Crane Near Electric Power and Transmission Lines
  43
  - Electrocution Hazard
    43
  - Set-Up and Operation
    43
  - Electrocution Hazard Devices
    44
  - Electrical Contact
    44
- Refueling
  45
- Fire Extinguishers
  45
- Accidents
  45
- Safe Maintenance
  45
  - Maintenance Instructions
    45
  - Safe Maintenance Practices
    45
- Environmental Protection
  47
- Boom Disassembly Safety
  48
- General
  48
- Location
  48
- Pin Removal
  48
- Disassembly Precaution
  48
- Personnel Handling Policy
  50
- Pedestal/Barge Mounted Cranes
  52
  - Pedestal Mounted Crane
    52
  - Barge Mounted Crane
    52
  - Definition
    52
  - Examples
    52
  - Capacity Charts
    54
  - Shock Loading
    54
  - Operation on Barge
    54
  - Definition
    54
  - General
    54
  - Definitions
    54
  - Crane Inspection
    55
  - Transporting Crane on Barge
    55
Section 3

57
- Standard Hand Signals for Controlling Crane Operations
  62
- Symbol Identification
  64
- Cab Door Adjustment
  71
  - General
    71
  - Closing Cab Door
    71
  - Damper Adjustment
    71
- Front Window Operation
  72
- Crane Orientation
  72
- Operating Controls
  72
- Display Language
  72
- Controls Identification and Function
  74
  - A - Engine Controls
    74
  - A1. Engine Stop/Run/Start Switch
    74
  - A2. Engine Stop Switch
    74
  - A3. Engine Diagnostics Lights
    74
  - A4. Engine Hand Throttle
    74
  - A5. Engine Foot Throttle
    74
  - A6. Engine Clutch Handle
    74
  - A7. Battery Disconnect Switch
    74
  - A8. DPF Switch (Tier 4 Equipped)
    75
  - B - Accessory Controls
    77
  - B1. Cab Tilt Switch
    77
  - B2. Panel Lights Switch
    77
  - B3. Dome Light Switch
    77
  - B4. Climate Control
    77
  - B5. Overhead Windshield Wiper Switch
    77
  - B6. Front Windshield Wiper and Washer Switch
    77
  - B7. Crane Work Lights Switch
    79
  - B8. Accessory Control Panel
    79
  - B9. Radio/CD Player
    79
  - B10. Horn Switches
    79
  - B11. 12V Power Supply Receptacle
    79
  - B12. Machinery Heaters
    79
  - B13. Tinted Visor and Shade
    79
  - B14. Cab RCL Rotating Beacon
    79
  - B15. Cab Door Brake
    79
  - B16. Anemometer
    79
  - C - Indicators
    81
  - C1. RCL (Rated Capacity Indicator/Limiter) Controls
    81
  - C2. System Fault Alert
    81
  - C3. Operating Limit Alert
    81
  - C4. Rear View Mirrors
    81
  - C5. Boom Angle Indicator
    81
  - C6. Level
    81
  - C7. Hydraulic Level and Temperature Gauge
    81
  - C8. Drum Rotation Indicators
    81
  - C9. Fuel Level
    81
  - D - Special Controls
    82
  - D1. Drum 5 (Mast Hoist) Park Switch
    82
  - D2. Seat Switch
    82
  - D3. Dead-Man Switch (Optional)
    82
  - D4. Digital Display
    82
  - D5. Scroll Selector
    82
  - D6. Digital Display Contrast Switch
    82
  - D7. Crane Mode Confirm/Select Switch
    82
  - D8. Limit Bypass Switch
    84
  - E - Boom/Luffing Hoist Controls
    88
  - E1. Drum 4 (Boom Hoist) Park Switch
    88
  - E2. Drum 6 (Luffing Jib Hoist) Park Switch
    88
  - E3. Boom/Luffing Hoist Handle a
    88
  - E4. Boom/Luffing Hoist Handle Display Light
    88
  - F - Load Drum Controls
    89
  - F1. Drum 1 (Main Hoist 1) Park Switch
    89
  - F2. Drum 2 (Main Hoist 2) Park Switch
    89
  - F3. Drum 3 (Whip Line Hoist) Park Switch
    89
  - F4. Control Handle B
    89
  - F5. Control Handle C
    89
  - F6. Control Handle D
    89
  - F7. Control Handle Display Lights
    89
  - G - Swing Controls
    90
  - G1. Swing Park Switch
    90
  - G2. Swing Handle
    90
  - G3. Swing Holding Brake Switch
    90
  - J - Setup Controls
    91
  - K- Limit Devices
    91
  - H - Travel Controls
    91
  - H1. Travel Park Switch
    91
  - H2. Travel Speed Selector
    91
  - H3. Travel Cruise Selector
    91
  - H4. Left Crawler Handle
    91
  - H5. Right Crawler Handle
    91
  - Max up 1 (Boom)
    92
  - Block up
    92
  - Luffing Jib up Limits
    92
  - Luffing Jib down Limits
    93
  - Max Bail
    93
  - Min Bail
    93
- Seat Controls
  94
  - Load Moment (Rated Capacity Indicator/Limiter)
    94
- Preparing Crane for Operation
  95
- Calibration Procedures
  95
- Operation
  96
  - Engine Startup
    96
  - Boom Hoist Operation
    98
  - Luffing Hoist Operation
    99
  - Swing Operation
    100
  - Load Drum Operation
    101
  - Travel Operation
    102
- Stopping Engine/ Leaving Crane Unattended
  104
- Remote Controls
  105
  - General
    105
  - Controls Identification and Operation
    105
  - Setup Remote Control
    105
  - Power Controls
    105
  - Jacking Controls
    106
  - Boom Pins Control
    106
  - Rotating Frame Controls
    106
  - Mast Controls
    106
  - Replacing Batteries in Setup Remote Control
    107
  - Rigging Winch Controls
    107
  - Engine Speed Control
    107
  - Crawler Pin Controls
    107
- Digital Display Screens
  108
  - Crane Operating Conditions
    108
  - Operating Limits
    109
    
    System Faults
    109
  - Function Speed/Torque Adjustment
    115
  - Engine Diagnostics
    115
    
    General
    115
    
    Onboard Engine Diagnostics
    116
    
    DPF Diagnostics - Cummins QSX 15 (Tier 4)
    116
  - Crane Diagnostics
    117
    
    General
    117
    
    Drum 1
    117
    
    Drum 2
    118
    
    Drum 3
    118
    
    Drum 4
    118
    
    Drum 5
    119
    
    Drum 6
    119
    
    Swing (Crane)
    119
    
    Trk (Travel)
    120
    
    FCN (Front Console Node)
    120
    
    CAN (Can Bus)
    121
    
    Hydraulic System Calibration
    123
    
    Speed/Torque
    123
    
    Accessory System
    123
    
    Wireless
    123
    
    Block Level Sensor
    124
    
    Crane Mode
    124
    
    Hydraulic Fan (Tier 4 Only)
    124
    
    MAX-ER Attachment
    125
    
    Crane Mode Selector - Crane with Swing Lock
    125
    
    Crane Mode Selector - Crane Without Swing Lock
    125
  - Digital Input and Output Item Tables
    127
  - Hydraulic System Calibration Procedures
    131
    
    General
    131
    
    Pressure Sender Calibration
    131
    
    Control Calibration
    133
    
    Pump Pressure Test
    134
    
    Charge Pressure Check
    136
  - Wind Conditions
    142
  - Cold Weather Heater Package
    145
    
    General
    145
    
    Heaters
    145
    
    Turning Heaters on
    145
    
    Turning Heaters off
    145
  - Preparation for Cold Weather
    146
    
    Crane Limitations
    146
    
    Wire Rope
    146
    
    Cold Weather Starting Aid
    146
    
    Cooling System
    146
    
    Battery
    146
    
    Engine Oil
    147
    
    Fuel Oil
    147
    
    Gear Oil
    147
    
    Hydraulic Oil
    147
  - Circuit Breakers
    147
  - Rigging Drawings
    153
  - Optional Attachments
    153
  - General Safety
    153
  - Crane Orientation
    153
  - Self-Erecting Equipment
    153
Section 4

153
- Assist Crane Requirements
  154
- Assembly and Disassembly Notes
  154
- Assembly and Disassembly Area
  154
- Accessing Parts
  154
- Crane Weights
  154
- Handling Components
  154
- Retaining Connecting Pins
  157
- Cold Weather Mast Operation
  157
- Shipping Crane Components
  160
- Operating Controls
  160
- Pre-Start Checks
  161
  - Engine
    161
  - Gear Boxes
    161
  - Hydraulic System
    161
- Crane Assembly
  161
  - Rotating Bed Jack Pad Storage Location
    161
  - Remove Rotating Bed from Trailer
    162
  - Remove Wind Deflectors
    162
  - Deploy Rotating Bed Jacks
    164
  - Alignment Pendants
    166
  - Deploy Operator's Cab
    166
  - Jack Upperworks off Trailer
    166
  - Remove Carbody and Adapter Frame from Trailer
    168
  - Connect Rotating Bed to Carbody
    168
  - Lower Crane Onto Carbody Pedestals
    170
  - Install Rotating Bed Catwalks and Steps (Past Production)
    172
  - Side and Rear Catwalks
    172
  - Steps
    172
  - Cab Rear Catwalk
    172
  - Install Rotating Bed Side and Rear Catwalks and Steps (Current Production)
    174
  - Connect Hydraulic Hoses and Electric Cables
    174
  - Install Drum 3 (Whip Line Drum)
    174
  - Side and Rear Catwalks
    174
  - Steps
    174
  - Install Cab Left Platform (Current Production)
    176
  - Install Cab Rear Platform (Current Production)
    178
  - Move Platforms into Working Positions (Current Production)
    178
  - Configure Enclosure Panels
    181
  - Working Position
    181
  - Raise Live Mast to Operating Position
    183
  - Install Assembly Block
    185
  - Install Crawlers
    185
  - Install First Crawler
    187
  - Install First Crawler (Continued)
    189
  - Install Second Crawler
    189
  - Install Counterweight
    191
  - Install Carbody Counterweight
    191
  - Install Crane Counterweight
    191
  - Stow Mast Supports
    193
  - Deploy Mast Supports
    193
  - Remove Assembly Block
    195
  - Assemble Fixed Mast
    195
  - Install Mast Butt and Top
    195
  - Assemble Mast Inserts
    197
  - Connect Mast Inserts to Mast Butt
    199
  - Raise Mast Stops
    199
  - Lower Wire Rope Guide
    199
  - Attach Mast Top to Inserts
    201
  - Connect Mast Straps
    201
  - Connect Live Mast Straps to Fixed Mast Straps
    201
  - Perform Mast Pre-Raising Checks
    203
  - Raise Fixed Mast
    203
  - General
    203
  - Raise Mast
    205
  - Assemble and Install Boom and Jib
    207
  - Check Mast Stop Pressure
    207
- Pre-Raising Checks
  208
- Raising Boom and Jib
  209
- Crane Disassembly
  211
  - Lowering Boom and Jib
    211
  - Lower Fixed Mast
    211
  - General
    211
  - Store Wire Rope Guide
    215
  - Store Mast Stops
    215
  - Remove Mast Inserts
    215
  - Remove Rear Platforms and Catwalk
    217
  - Remove Rear Platforms and Catwalk (Current Production)
    217
  - Remove Crane Counterweight
    217
  - Install Assembly Block
    217
  - Remove Mast Butt and Top
    217
  - Remove Carbody Counterweight
    219
  - Deploy Rear Rotating Bed Jacks
    219
  - Remove Crawlers
    221
  - Remove First Crawler
    221
  - Remove Assembly Block
    225
- Store Live Mast
  225
  - Remove Drum 3 (Whip Line Drum)
    225
  - Deploy Front Rotating Bed Jacks
    225
  - Remove Second Crawler
    225
  - Separate Rotating Bed from Carbody
    226
  - Place Rotating Bed on Trailer
    226
  - Store Operator's Cab
    226
    
    Remove Rotating Bed Jacks
    226
    
    Install Wind Deflectors
    226
  - Boom Ladder Assembly
    228
    
    General
    228
    
    Removing Ladders from Boom Section
    228
    
    Installing Ladders on Boom Inserts
    228
    
    Storing Ladders
    228
  - Boom and Jib Rigging
    232
    
    Assist Crane Requirements
    232
    
    Blocked Crawler
    232
    
    Handling Components
    232
    
    Rigging Assembly Drawings
    232
    
    Medium Inserts
    232
    
    Identifying Boom and Jib Sections and Straps
    233
    
    Boom Installation
    235
    
    Inspect Boom Stops
    235
    
    Assemble Boom Butt and First Insert
    237
    
    Raise Drum 1 to Operating Position
    237
    
    Install Second Insert
    237
    
    Raise Drum 6 Sheaves
    237
    
    Install Boom Butt and Assembled Inserts
    239
    
    Assemble Remaining Boom Sections
    241
    
    Raise Boom Top Wire Rope Guide
    241
    
    Connect Boom Straps - #55-79A Boom
    243
    
    Install Intermediate Suspension - #55-79A Boom
    243
    
    Connect Boom Straps - #55 or #55A Boom
    245
    
    Install Standard Upper Boom Point
    247
    
    Install Extended Upper Boom Point
    247
    
    Install Rated Capacity Indicator/Limiter
    249
    
    Install Load Line
    249
    
    Install Block-Up Limit Control
    249
    
    Install Block-Level Transmitter
    250
    
    Boom Pre-Raising Checks
    251
    
    Install Wind Speed Indicator Assembly
    251
    
    Boom Removal
    254
    
    Fixed Jib Installation
    257
    
    General
    257
    
    Install Boom Backstay Straps
    257
    
    Assemble Jib
    259
    
    Install Jib Butt
    259
    
    Install Jib Strap Support Brackets
    259
    
    Install Jib Inserts and Top
    259
    
    Install Upper Jib Point
    259
    
    Connect Remaining Jib Straps
    259
    
    Connect Jib Straps to Equalizers
    259
    
    Attach Jib Stop to Boom Top
    261
    
    Install Jib Strut
    261
    
    Connect Adjustable Links
    261
    
    Raise Jib Strut
    263
    
    Raise Jib Strut (Continued)
    265
    
    Install Jib Load Line
    265
    
    Connect Electric Cords
    265
    
    Install Wind Speed Indicator Assembly
    265
    
    Jib Removal
    266
    
    Disconnect Electric Cords
    266
    
    Remove Wind Speed Indicator Assembly
    266
    
    Remove Jib Load Lines
    266
    
    Lower Jib Strut
    266
    
    Disconnect Jib Straps
    267
    
    Remove Jib Inserts and Top
    267
    
    Store Jib Strap Support Brackets
    267
    
    Remove Jib Butt
    267
  - Wire Rope Installation
    269
    
    Wire Rope Storage
    269
    
    Removing Wire Rope from Shipping Reel
    269
    
    Seizing and Cutting Wire Rope
    269
    
    Anchoring Wire Rope to Drum
    270
    
    Winding Wire Rope Onto Drum
    270
    
    Anchoring Wire Rope to Socket and Wedge
    271
    
    Anchoring Wire Rope to Button Socket
    273
    
    Breaking in Wire Rope
    273
  - Pad Eye Usage for Wire Rope Reeving
    273
    
    General
    273
    
    Safety
    273
  - Rigging Winch Operation
    275
    
    Selecting Rigging Winch Mode
    275
    
    Operating Rigging Winch (Past Production)
    275
    
    Operating Rigging Winch (Current Production)
    276
  - Load Block Reeving
    278
    
    Load Block Identification
    278
    
    Load Block Handling
    278
    
    Wire Rope Specifications
    278
    
    Wire Rope Installation and Maintenance
    278
    
    Duplex Hook
    278
    
    Guide Sheaves and Drums
    278
  - Block Level Sensor Adjustment
    288
    
    General
    288
    
    Sensor Adjustment
    288
  - Live Mast Reeving
    289
    
    General
    289
    
    Wire Rope Specification
    289

Manitowoc 18000 Service Maintenance Manual (316 pages)

Brand: Manitowoc | Category: Construction Equipment | Size: 33 MB

Table of Contents
5
Section 1
13
Continuous Innovation
13
Safety Messages
13
General
13
Safety Alert Symbol
13
Signal Words
13
Safe Maintenance Practices
14
Maintenance Instructions
14
Environmental Protection
15
Identification and Location of Components
16
Basic Crane
16
Front
17
Top
18
Left Side
19
Left Side - S/N18001082 & Newer
20
Right Side
21
Rear
22
Carbody/Crawler
23
Operator Cab/Controls
24
Cummins Engine Tier 3
25
Cummins Engine Tier 4
26
Boom Butt and Insert
28
Mast Butt
29
Description of Operation
30
General Abbreviations
30
Solenoid Valve Identification
30
General Operation
31
Hydraulic Components
32
Hydraulic Tank
32
Shutoff Valves
32
Charge Filters (Past Production)
32
Suction Manifolds
32
Return Manifolds
32
Hydraulic Fluid Cooler
32
Supercharge Pumps (Past Production)
32
Charge Pressure
33
Hydraulic Motors
33
Main Pressure Monitoring
34
Accessory Systems
34
Basic Operation
35
Engine Controls
36
Drum Identification
37
Epic® Control System
38
CAN-Bus
38
Digital Display
38
Rated Capacity Indicator/Limiter (RCL)
38
Crane Modes
39
Electrical Power to Operator's Cab
39
Pressure Senders and Speed Sensors
39
System Faults
40
Engine Faults (Tier 4)
40
Operating Faults and Limit Switches
40
Brake and Drum Pawl Operation
40
Swing System Operation
42
Swing System Components
42
Swing Brake and Swing Lock
42
Swing Right or Left
42
Swing Holding Brake Switch
43
Travel System Operation
46
Travel System Components
46
Travel Brakes
46
Travel Forward and Reverse
46
Two-Speed Travel Operation
49
Travel Cruise
49
Boom Hoist System Operation
50
Boom Hoist System Components
50
Boom Hoist Brake and Pawl
50
Boom Hoist Raise
50
Boom Hoist Lower
53
Main Hoist 1 System
54
Main Hoist 1 System Components
54
Main Hoist 1 Drum Brake
54
Main Hoist 1 Raising
54
Main Hoist 1 Lowering
57
Whip Line Hoist (Drum 3) System
58
Whip Line Hoist System Components
58
Whip Line Drum Brake
58
Whip Line Hoist Raising
58
Whip Line Hoist Lowering
61
Main Hoist 2 System
62
Main Hoist 2 System Components
62
Main Hoist 2 Drum Brake
62
Main Hoist 2 Raising
62
Main Hoist 2 Lowering
65
Mast Hoist Drum 5 System
66
Mast Hoist System Components
66
Mast Hoist Brake and Pawl
66
Mast Raising Cylinders
66
Mast Hoist Raising from Transport Position
66
Mast Hoist Raising to Transport Position
70
Luffing Jib Drum 6 (Optional) System
72
Luffing Jib System Components
72
Luffing Jib Brake and Pawl
72
Luffing Jib Raise
72
Luffing Jib Lower
74
Accessory System Components
75
Accessory Systems
75
Jacking Cylinders
76
Rotating Bed Jacking - Raise
76
Rotating Bed Jacking - Lower
77
Boom Hinge Pins
80
Adapter Frame Pins
82
Mast Pins
84
Rigging Winch (Drum 7)
86
Cab Tilt
88
Crawler Pin Cylinders
90
Hydraulic Schematics
95
Hydraulic System - General
95
Checking and Replacing Hydraulic Hoses
95
Hydraulic System Maintenance
96
Safety
96
Storing and Handling Oil
96
Storing and Handling Parts
96
Inspecting System
96
Hydraulic Tank Heater
97
Replacing Filters
100
Charge Filters
101
Return Filters
102
Replacing Desiccant Breather
103
Changing Oil
103
Servicing Pumps
104
Tightening Hydraulic Connections
106
Pipe Thread Connection
106
SAE Straight Thread Connection
106
ORS Connection
107
Split Flange Connection
108
SAE Flare Connection
109
Pressure Sender Replacement
111
Disc Brake Operational Test
112
Shop Procedures
114
Initial Oil Fill
114
Initial Engine Start-Up
114
Pressure Sender Calibration
114
Charge Pressure Check
114
Accessory System Checks
115
Control Calibration
115
Hoist Pumps Pressure Test
115
Travel Pressure Check
115
Swing Pressure Check
115
High Pressure Accessory System
115
Low-Pressure Accessory Components
116
Lower Accessory Valve
116
Travel Handle and Speed Check
117
Swing and Drum Speed Checks
117
Hydraulic System Specifications - 18000
118
Pumps
119
Motors
121
Hydraulic System Calibration Procedures
122
Calibration Description
122
Pressure Sender Calibration
122
Control Calibration
124
Pump Pressure Test
125
Charge Pressure Check
126
Hydraulic System Adjustment Procedures
130
High Pressure Adjustment
130
Charge Pressure Adjustment
131
Pump Neutral Adjustment
131
Motor Leakage Test
132
Loop Flushing Valve Adjustment
132
Manual Override Tests
132
Pump or Motor Override
133
Solenoid Valve Override
133
Counterbalance Valves Adjustment
134
Hydraulic Tank Level Sensor Calibration
137
Empty Calibration
137
Full Cold Calibration
137
Electrical Schematics
141
Checking and Replacing Electrical Components
141
Circuit Breaker Identification
142
Test Voltages
143
CAN Bus Nodes
143
Pumps and Motors
144
Alphabetical Index of Components
145
Node Heading Descriptions
145
NODE 1 - Master Node (Front Console)
146
NODE 2 - Handles and Cab Controls
148
NODE 3 - Drum 3 and Pressure Senders
151
NODE 4 - Connecting Pins, Jacking, and Mast
153
NODE 5 - Alarms, Pump Controls, and Limits
154
NODE 6 - Drums 2, 4, & 5, and Adapter Frame
158
NODE 7 - Swing, Travel and Auto Lube
160
NODE 8 - Drum 1 and Drum 6
162
Node 9 - Max-Er
164
NODE 20 - Boom Block Up, Block Sensor, & Limits
166
NODE 21 - Luffing Jib, Block Up, Block Sensor, Limits
167
NODE 0 - Power, Engine Controls, and Diagnostics
168
Abbreviations
169
Checking Electrical Inputs/Outputs
170
Control Handle Voltages
170
Dielectric Grease
173
Digital Display
174
Crane Operating Conditions
174
Operating Limits
174
System Faults
175
Function Speed/Torque Adjustment
180
Adjustment
180
Crane Diagnostics
180
General
180
Drum 1
180
Drum 2
180
Drum 3
180
Drum 4
180
Drum 2
181
Drum 3
181
Drum 4
181
Drum 5
182
Drum 6
182
Swing (Crane)
182
Trk (Travel)
183
FCN (Front Console Node)
183
CAN (Can Bus)
184
Hydraulic System Calibration
185
Speed/Torque
185
Accessory System
185
Wireless
186
Block Level Sensor
186
Crane Mode
186
Hydraulic Fan (Tier 4 Only)
186
Digital Input and Output Item Tables
187
Section 4
195
Automatic Boom Stop Adjustment
197
Maximum Operating Angles
197
Operation
197
Maintenance
197
Bypass Limit Test
198
Adjustment
201
Actuator Rod Replacement
201
Physical Boom Stop
202
Operation
202
Boom and Luffing Jib Angle Indicator Calibration
203
Mast Angle Indicator Adjustment
203
Mast Angle Indicator
203
Adjusting Angle
203
Sending Unit Assembly
203
Strap Inspection and Maintenance
205
Inspection
205
Identifying Straps
205
Frequent Inspection
205
Periodic Inspection
205
Cranes Not in Regular Use
205
Replacement Specifications
206
Corrosion or Abrasion
206
Straightness
207
Flatness
207
Elongated Hole
207
Storing Straps
208
Removing Straps from Service
208
Inspection Checklist
208
Lattice Section Inspection and Lacing Replacement
211
Section 5
213
Hoist Drawings
215
Boom Hoist Pawl Adjustment
215
General
215
Actuator Removal
215
Actuator Installation and Adjustment
215
Mast Hoist Pawl Maintenance
217
General
217
Maintenance
217
Speed Sensor Adjustment
218
Hydraulic Motors with Speed Sensors
218
Speed Sensor Replacement
218
Version 1 - Sensor with Flats
218
Bail Limit Adjustment
220
Weekly Maintenance
220
Adjustment
220
Electrical Wiring
220
Block-Up Limit Adjustment
222
General
222
Operation
222
Installation
222
Load Block Level Transmitter
222
Block-Up Limit Control Deactivated
222
Block-Up Limit Control Activated
222
Disconnecting Block-Up Limit Control
226
Removing Upper Boom Point or Jib Point
227
Storing Electric Cable
227
Maintenance
227
Adjustment
228
Wire Rope Inspection and Replacement
229
Wire Rope Lubrication
229
Maintain a Wire Rope Condition Report
229
Wire Rope Care and Replacement Guidelines
229
Daily Inspection
229
Periodic Comprehensive Inspection
231
Replacement Criteria
231
Determining the Frequency of Inspection
231
Reduction in the Rope Diameter
231
Broken Rope Wires
232
Distributing Wire Rope Wear
233
Sheave, Roller, and Drum Inspection
233
Rope that Has Been Idle a Month or more
233
Load Block and Hook-And-Weight Ball Inspection
236
Daily Inspection
236
Yearly Inspection
238
Section 6
239
Manual Release of Swing Brake and Lock
241
Manual Release Procedure
241
Section 7
241
Battery Maintenance
245
Safety Information
245
Causes of Battery Failure
245
Multiple Battery System
245
Overcharging
245
Undercharging
245
Lack of Water
245
Hold-Downs
245
Overloads
245
Maintenance
246
Open-Circuit Voltage Test
246
Weekly - Check Electrolyte Level
246

Manitowoc 18000 Operator's Manual (202 pages)

Luffing Jib Attachment

Brand: Manitowoc | Category: Construction Equipment | Size: 18 MB

Table of Contents
5
Section 1

11
- Crane Data
  11
- Crane/Attachment Identification
  11
- Change of Ownership Registration
  11
- Manitowoc Dealer
  11
- Crane Orientation
  11
- Identification and Location of Components
  12
- Outline Dimensions
  14
- Crane Weights
  16
- English and Metric Conversions
  22
  - Direct Conversion
    22
  - Inverse Conversion
    22
Section 2

25
- Continuous Innovation
  27
- Nameplates and Decals
  27
- Safety Messages
  27
  - General
    27
  - Safety Alert Symbol
    27
  - Signal Words
    27
  - Symbol Identification
    27
- Safety and Information Signs
  31
  - Maintaining Signs
    31
  - Ordering Signs
    31
- Crane Access Points
  33
  - Getting on or off Crane
    33
- Personnel Fall-Protection Anchors
  33
- Operator Manual/Capacity Chart Storage
  34
  - General
    34
  - Storing Manuals
    34
- Safe Operating Practices
  35
  - General
    35
  - Read Operator Manual
    35
  - Operator Qualifications
    35
  - Operator Conduct
    35
  - Handling Load
    37
  - Size of Load
    37
  - Attaching Load
    37
  - Lifting/Moving Load
    38
  - Multiple Load Line Operation
    39
- Signals
  40
- Holding Load
  40
- Safety Devices
  41
- Operational Aids
  41
  - Category 1 Operational Aids
    41
  - Category 2 Operational Aids
    42
- Assembling, Disassembling, or Operating Crane Near Electric Power and Transmission Lines
  43
  - Electrocution Hazard
    43
  - Set-Up and Operation
    43
  - Electrocution Hazard Devices
    44
  - Electrical Contact
    44
- Refueling
  45
- Fire Extinguishers
  45
- Accidents
  45
- Safe Maintenance Practices
  45
  - Maintenance Instructions
    45
- Environmental Protection
  47
- Boom Disassembly Safety
  49
  - General
    49
  - Location
    49
  - Pin Removal
    49
  - Disassembly Precaution
    49
- Personnel Handling Policy
  50
- Pedestal/Barge Mounted Cranes
  52
  - Pedestal Mounted Crane
    52
  - Barge Mounted Crane
    52
  - Definition
    52
  - Examples
    52
  - Capacity Charts
    54
  - Shock Loading
    54
  - Operation on Barge
    54
  - Definition
    54
  - General
    54
  - Definitions
    54
  - Crane Inspection
    55
  - Transporting Crane on Barge
    55
Section 3

57
- Standard Hand Signals for Controlling Crane Operations
  60
- General Operation
  62
- Luffing Jib Operating Controls
  63
  - Crane Mode Select/Confirm Switch
    63
  - Drum 4 (Boom Hoist) Park Switch
    63
  - Drum 6 (Luffing Hoist) Park Switch
    63
  - Boom Hoist and Whip Hoist Control
    63
  - Luffing Hoist and Swing Control
    63
  - Luffing Jib Mode
    63
  - Luffing Jib Setup Mode
    63
  - Ljib Stop Mode
    63
  - Limit Bypass Switch
    65
  - Digital Display
    65
  - Mechanical Boom Angle Indicator
    65
  - Mechanical Level
    65
- Luffing Jib Limits
  68
  - Boom up Limit
    68
  - Block up Limit
    68
  - Luffing Jib up Limits
    68
  - Luffing Jib down Limits
    68
  - Luffing Jib down Limits
    69
- Operating Precautions
  70
- Wind Conditions
  70
Section 4

71
- General Setup and Installation
  75
- Crane Orientation
  75
- Accessing Parts
  75
- Crane Weights
  76
- Operating Controls
  76
- Counterweight Requirement
  76
- Blocked Crawlers
  76
- Rigging Drawings
  76
- Luffing Jib Raising Procedure
  76
- Identifying Jib Components
  76
- Handling Components
  77
- Retaining Connecting Pins
  78
- Shipping Crane Components
  78
- Removable Lacings - #44 Jib
  79
- Luffing Jib Rigging Guide - #44
  81
  - General
    81
  - Assist Crane Requirements
    81
  - Installing #44 Luffing Jib
    81
  - Lower Boom
    81
  - Prepare Boom and Jib
    81
  - Install Jib Butt
    83
  - Install Jib Inserts and Top
    83
  - Complete Upper Jib Point Roller Installation
    85
  - Connect Jib Straps
    85
  - Install Struts
    85
  - Install Luffing Hoist Wire Rope
    87
  - Raise Main Strut
    89
  - Connect Backstay Straps
    89
  - Connect Hydraulic Hoses
    91
  - Set up Adjustable Straps
    93
  - Raise Jib Strut
    95
  - Install Load Lines
    96
  - Connect Electric Cords
    96
  - Install Wind Speed Indicator Assembly
    96
  - Adjust Electronic Devices
    96
  - Pre-Raising Checks
    97
  - Raising Boom and #44 Luffing Jib
    99
  - General
    99
  - In-Line Raising Procedure
    99
  - Jack-Knife Raising Procedure
    101
  - Lowering Boom and #44 Luffing Jib
    103
  - General
    103
  - In-Line Lowering Procedure
    103
  - Jack-Knife Lowering Procedure
    105
  - Removing #44 Luffing Jib
    106
  - Lowering Jib Strut
    106
  - Lowering Main Strut
    106
  - Removing Jib Attachment
    107
  - Remove Struts
    107
- Luffing Jib Rigging Guide - #79A
  109
  - General
    109
  - Assist Crane Requirements
    109
  - Preparing Crane, Boom, and Mast
    112
  - Install Backstay Straps on Boom
    112
  - Jib Stop Positioner Hydraulic System Operation
    115
  - Initial Setup
    115
  - Procedure for Raising Boom and Jib
    115
  - Procedure for Lowering Boom and Jib
    115
  - Periodic Check of Oil Level
    115
  - Installing #79A Luffing Jib
    117
  - Install Jib and Main Strut Butts
    117
  - Install Jib Strut Top
    117
  - Install Luffing Hoist Wire Rope
    117
  - Install Main Strut Top
    119
  - Install Backstay Straps on Main Strut
    120
  - Raise Main Strut
    121
  - Raise Main Strut (Continued)
    123
  - Raise Jib Strut
    127
  - Install Jib
    127
  - Install Jib Strap Equalizers
    129
  - Connect Jib Strut Straps to Equalizers
    129
  - Complete Jib Assembly
    129
  - Prepare Jib Dolly
    129
  - Install Jib Dolly
    129
  - Install Jib Load Line
    131
  - Connect Electric Cords/Adjust Electronic Devices
    131
  - Install Wind Speed Indicator Assembly
    131
  - Set up Jib Stop Positioners
    131
  - Pre-Raising Checks
    133
  - Raising Boom and #79A Luffing Jib
    133
  - Jack-Knife Raising Procedure
    135
  - Lowering Boom and #79A Luffing Jib
    138
  - General
    138
  - Jack-Knife Lowering Procedure
    138
  - Removing #79A Jib
    141
  - Remove Jib Load Line
    141
  - Remove Jib Dolly
    141
  - Remove Upper Jib Point
    141
  - Remove Jib
    141
  - Disassemble Jib
    141
  - Remove Jib Strap Equalizers
    143
  - Remove Butt and First Two Inserts
    143
  - Lower Jib Strut
    143
  - Lower Main Strut
    145
  - Lower Main Strut (Continued)
    147
  - Store Main Strut Top
    149
  - Store Luffing Hoist Wire Rope
    149
  - Remove Main and Jib Strut Tops
    149
  - Remove Jib and Main Strut Butts
    149
  - Changing Boom and Jib Length
    149
- Wire Rope Installation
  151
  - Wire Rope Storage
    151
  - Removing Wire Rope from Shipping Reel
    151
  - Seizing and Cutting Wire Rope
    151
  - Anchoring Wire Rope to Drum
    152
  - Winding Wire Rope Onto Drum
    153
  - Anchoring Wire Rope to Wedge Socket
    154
  - Anchoring Wire Rope to Button Socket
    154
  - Breaking in Wire Rope
    155
- Pad Eye Usage for Wire Rope Reeving
  156
  - General
    156
  - Safety
    156
- Rigging Winch Operation
  157
- Load Line Reeving - #44 Luffing Jib
  157
  - Load Blocks
    157
  - Guide Sheaves
    157
  - Duplex Hook
    157
  - Wire Rope Specifications
    157
  - Wire Rope Installation
    157
  - Reeving Diagrams
    157
- Load Line Reeving - #79A Luffing Jib
  162
  - Load Block Identification
    162
  - Load Block Handling
    162
  - Duplex Hook
    162
  - Wire Rope Specifications
    162
  - Wire Rope Installation
    162
  - Guide Sheaves and Drums
    162
  - Reeving
    162
- Block Level Sensor Adjustment
  170
  - General
    170
  - Sensor Adjustment
    170

Manitowoc 18000 Quick Start Manual (3 pages)

Brand: Manitowoc | Category: Construction Equipment | Size: 0 MB

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