Manitowoc 180001Ref Manuals

Manuals and User Guides for Manitowoc 180001Ref. We have 1 Manitowoc 180001Ref manual available for free PDF download: Operator's Manual

Manitowoc 180001Ref Operator's Manual

Manitowoc 180001Ref Operator's Manual (302 pages)

Brand: Manitowoc | Category: Construction Equipment | Size: 34.65 MB

Table of Contents

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
Section 5

291
- Lubrication
  291
Section 6

297
- Inspection and Maintenance Checklist
  297
- Fiberglass Maintenance
  297

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