Manitowoc CD25 Manuals

Manuals and User Guides for Manitowoc CD25. We have 2 Manitowoc CD25 manuals available for free PDF download: Service Manual, Operator's Manual

Manitowoc CD25 Service Manual (286 pages)

Brand: Manitowoc | Category: Construction Equipment | Size: 22.67 MB

Table of Contents
5
Directional Reference
13
Identification Decal
13
Specifications
14
General Service Information
17
Cleaning Instructions
17
Complete Assemblies
17
Parts with Machined Surfaces
17
Bearings
17
Rough Parts
17
Rubber Parts
17
After Cleaning
17
To Prevent Corrosion
17
O-Ring, Seal and Elastic Nut Replacement
17
Hoses and Tubes
18
Bearings
18
Removal
18
Cleaning
18
Installation
18
Hydraulic Fittings
19
Flats from Finger Tight (F.F.F.T.) Method
19
Hydraulic Pressure Testing
20
Fasteners
20
Loctite
20
Fasteners and Torque Values
21
Weld Studs
24
Section 2
25
Introduction
25
Signal Words
25
Signal Word
25
Personal Considerations
26
Equipment Considerations
26
General Considerations
27
Operational Considerations
27
Environmental Protection
28
Final Word
28
Section 3
29
General
29
Comparing Electrical System to a Hydraulic System
30
Magnetism
30
Main Electrical System
30
General
30
Wire Harnesses
30
Fuses and Relays
31
Charging System
33
Alternator and Voltage Regulator
33
Alternator Replacement
33
Starter Replacement
33
Batteries
34
Voltmeter
34
Special Precautions
34
Battery Maintenance and Charging
34
Battery Replacement
35
Relay Panel Component Replacement
35
Starting Circuit
35
General Inspections
36
Instrument and Light Circuits
37
General
37
Light Bulbs
37
Gauge Cluster
37
Wire Harnesses
38
Engine Wire Harness
38
Main Frame Wire Harness
38
Instrument Panel Wire Harness
38
Cab Wire Harness
38
Section 4
41
Technical Data
42
Hydraulic Pressures
42
Rated Pump Output at 2500 RPM
42
General Description
42
General
42
Hydraulic System
43
Troubleshooting
43
Troubleshooting Aids
43
Troubleshooting Procedures
43
Troubleshooting Guides
44
General Hydraulic System Troubleshooting
44
Lift Circuit Troubleshooting
46
Telescope (Crowd) Circuit Troubleshooting
46
Outrigger Circuit Troubleshooting
47
Hoist Circuit Troubleshooting
48
Swing Circuit Troubleshooting
48
Hydraulic System
48
Hydraulic System
49
General Maintenance
49
Preparation
49
Hydraulic System Maintenance Precautions
49
Label Parts When Disassembling
49
Hydraulic Oil Recommendations
49
Draining and Flushing
49
Removing Air from the Hydraulic System
50
System Description
51
Description of Operation
51
Suction, Return and Pump Pressure Circuits
54
General
54
Hydraulic Pump
56
Hydraulic Swivel
57
System Pressure Relief Valves
57
Four Section Main Control Valve
58
Checking and Adjusting Hydraulic Pressure Settings
60
Lift Circuit
64
General
64
Oil Flow
64
Counterbalance Valve
65
Lift Cylinder Leakage Test
65
Telescope Circuit
66
General
66
Oil Flow
66
Holding Valve
68
Port Relief Valve
68
Hydraulic Swivel
68
Hoist Circuit
69
General
69
Oil Flow
69
Brake Holding Valve
69
Swing Circuit
72
General
72
Oil Flow
72
Anti-Double Block System
73
General
73
System Function
73
Outrigger and Axle Lock out Circuits
74
Outrigger Circuit
74
Axle Oscillation Circuit
74
Oil Flow
74
Outrigger Control Valves
75
Load Holding Valves
77
Vertical Outrigger Cylinder Leakage Check
77
Hydraulic Pump Repair
77
Main Control Valve
78
Outrigger Control Valves
89
Swing Motor
90
Hoist Motor
95
Hydraulic Swivel
96
Hydraulic Cylinders
98
Introduction
106
Spark Arresting Mufflers
106
Wire Rope
106
General
106
Environmental Conditions
106
Dynamic Shock Loads
107
Lubrication
107
Precautions and Recommendations During Inspection or Replacement
107
Wire Rope Inspection-Running Ropes and pendant Cables
109
Wire Rope Inspection-Boom Extension and Retraction Cables
109
Wire Rope Inspection/Replacement
110
Seizing Wire Rope
110
Lubricants
111
Maintenance Records
111
Special Maintenance
112
After First 50 Hours of Operation (New Cranes)
112
After First 100 Hours of Operation (New Cranes)
112
Cranes Not in Regular Use
112
Preventive Maintenance
113
Maintenance Schedule and Checklist
113
Lubricant Symbols
115
Lubrication Points
116
Booms and Main Frame
118
Drive Train
118
Optional Equipment and Accessories
118
Daily Walk-Around Inspection
122
Inspections
122
Component/System Checks
122
Hours of Operation (Weekly)
126
Grease Fittings
126
Lubricate the Boom Slides
126
Check the Hoist Gearbox and Brake Lubricant Levels
126
Clean the Air Cleaner Vacuator Valve
127
Surface Protection for Cylinder Rods
127
Inner Boom Wear Pad Lubrication
128
Side and Bottom Boom Wear Pad Lubrication
128
Internal Cable Sheave Lubrication
129
Hours of Operation (Two Weeks)
129
Inspect the Fan Belts
129
Check the Wheel Nut Torque
130
Hours of Operation (Monthly)
130
Inspect the Hydraulic Hoses
130
Clean the Batteries and Cables
130
Lubricate the Wire Rope
131
Lubricate the Swing Gear and Pinion
131
Torque Critical Bolts
131
Replace the Crankcase Oil
132
Replace the Engine Oil Filter
133
Clean the Radiator
133
Hours of Operation (Three Months)
133
Inspect the Tires
133
Inspect the Parking Brake Pads
133
Replace Fuel Filter/Water Separator
133
Replace the Secondary Fuel Element
133
Replace Air Cleaner Element
134
Add Rust Inhibitor to Engine Cooling System
134
Lubricate the Outrigger Slides
134
Check the Axle Housing Lubricant Level
135
Check the Wheel Hub Lubricant Level
135
Check Swing Gearbox Lubricant Level
136
1000 Hours of Operation (Six Months)
136
Replacing the Transmission Oil and Filter
136
Replace the Axle Housing Lubricant
137
Replace the Axle Wheel Hub Lubricant
138
Replace the Hoist Gearbox and Brake Lubricant
139
Replace Swing Gearbox Lubricant
139
Replace the Hydraulic Oil
139
Replace the Hydraulic Oil Filter
140
Check the Swing Gear/Pinion Backlash
141
2000 Hours of Operation (Yearly)
142
Replace the Engine Coolant
142
Inspect the Crane Structure and Booms for Damage
142
Test the Rated Capacity Limiter (RCL) (Optional)
142
Miscellaneous Maintenance
142
Batteries/Charging System
142
Fuel System
143
Fuses and Relays
143
Diesel Exhaust Fluid (DEF) Tank
145
Carwell® Rust Inhibitor
146
Description
146
Cleaning Procedures
147
Inspection and Repair
147
Carwell Application
148
Areas of Application
148
General
151
Engine Performance
151
Engine RPM
151
Governor
151
Engine Crankcase System
151
Crankcase Oil Data
151
Cummins Oil Registration List
152
Engine Cooling System
152
Coolant Requirements
152
Radiator Cap
153
Thermostat
153
Engine Electrical System
153
Engine Fuel System
153
QSB Engine Electronic Controlled Fuel System Units
155
Types of Fuel to Use
155
Engine Air Intake System
155
QSB Engine Electronic Controlled Fuel System
155
Charge-Air Cooler System
156
Engine Exhaust System
157
Exhaust System Assembly
157
Removal and Installation
160
Removal
160
Installation
161
Towing or Pushing
163
4-Speed Powershift Transmission
163
Technical Specifications
164
Identification of the Unit
164
Weight, Dimensions, Oil Capacity
164
Pressure and Temperature Specifications
164
Electrical Specifications
165
Hydraulic Cooler and Filter Line Specifications
165
Maintenance
166
Oil Specification
166
Maintenance Intervals
167
Servicing Machine after Components Overhaul
167
Removal
168
Installation
168
Description
169
Front Axle and Rear Axle
169
Technical Data
170
Front and Rear Drive Axle
170
Front and Rear Drive Axle Repair
171
Removal
171
Installation
171
Special Tools
171
Drive Head - Disassembly
173
Drive Head - Assembly
175
Axle Hub and Axle Half Shaft Disassembly
181
Axle Hub and Axle Half Shaft Assembly
181
Drive Shafts
183
Removal
183
Disassembly
184
Inspection
185
Assembly
185
Installation
185
Lubrication Procedure
186
Wheels and Tires
187
Tire Inflation
187
Wheel Stud Nuts
187
Technical Data
189
Axle Brakes
189
Accumulator
189
Accumulator Charging Valve
189
Description
190
Service Brake System
190
Accumulator
190
Accumulator Charging Valve
190
Parking Brake System
191
Maintenance and Adjustments
192
Service Brake Bleeding
192
Parking Brake Bleeding
192
Parking Brake Adjustment
193
Accumulator Charging
193
Residual Brake System Pressure
193
Service Brake Repair
194
Disassembly
194
Assembly
196
Parking Brake Repair
197
Brake Modulating Valve Repair
200
Troubleshooting
202
Service Brakes
202
Section 10
203
Technical Data
203
Description
203
General
203
Steering Modes
203
Two-Wheel Steering
205
Four-Wheel Steering
206
Crab Steering
207
Relief Valve Pressure Check and Adjustment
208
Pressure Check
208
Steering Proximity Switches
208
General
208
Principle of Operation
208
Sensor Operation and Spacing Checks
210
Steering Orbitrol
213
Description
213
Orbitrol Repair
213
Steering Cylinder
220
Technical Data
220
Special Tools
220
Cylinder/Power Track Repair
220
Bleeding Steering System
225
Section 11
227
Boom
227
Theory of Operation
227
Boom Nose
228
Boom Removal
229
Lift Cylinder Removal
229
Boom Disassembly
230
Boom Assembly
232
Cable Tensioning
238
Boom Installation
240
Lift Cylinder Installation
240
Wire Rope, Sheave and Hoist Blocks
241
Inspecting Wire Rope
241
Inspection of Sheaves
241
Wire Rope Installation
241
Theory of Operation
243
Hoist Operation
243
Hoist
243
Repair
245
Troubleshooting
263
Bearing, Mast and Related Parts
265
General
265
Mast Bearing
265
Mast Bearing Bolts
265
Inspection for Bearing Wear
266
Replacing the Mast Bearing
266
Swing Gearbox and Pinion
267
Swing Gearbox Repair
270
Brake Cylinder Service
274
Planet Assembly Service
276
Outriggers
277
Removal
277
Disassembly
277
Assembly
277
Installation
277
Outrigger Monitoring System (OMS) (Optional-Standard in North America)
279
Section 12
281

Manitowoc CD25 Operator's Manual (160 pages)

Brand: Manitowoc | Category: Construction Equipment | Size: 13.07 MB

Table of Contents
9
Section 1

15
- Overview of Manuals
  15
- Serial Number
  15
- Delivery Report
  16
- Customer Support
  16
- Safety Information
  16
- General Crane Design
  16
- Specifications
  16
Section 2

19
- Safety Messages
  19
  - General
    20
  - Safety Alert Symbol
    20
  - Signal Words
    20
  - Warning Signs
    20
- Accidents
  20
- Operator Information
  20
- Operator Qualifications
  21
- Operational Aids
  22
- Crane Stability/Structural Strength
  24
  - Load Charts
    24
  - Work Site
    24
- Wind Forces
  25
  - Wind Speeds
    25
  - Lifting Operations
    38
  - Counterweight
    39
  - Outrigger Lift off
    39
  - Multiple Crane Lifts
    39
  - Tilt-Up Panel Lifting
    39
- Pile Driving and Extracting
  40
  - Crane Equipment
    40
  - Crane Inspection
    40
- Electrocution Hazard
  41
  - Set-Up and Operation
    42
  - Electrocution Hazard Devices
    42
  - Electrical Contact
    43
  - Special Operating Conditions and Equipment
    43
  - Earthing the Crane
    43
- Personnel Handling
  44
- Environmental Protection
  45
- Maintenance
  45
  - Service and Repairs
    45
  - Lubrication
    46
  - Tires
    47
- Hoist Rope
  47
  - Synthetic Hoist Rope
    47
  - Wire Rope
    47
  - Sheaves
    48
  - Batteries
    49
  - Super Capacitor (if Equipped)
    49
- General Maintenance
  49
- Transporting the Crane
  50
- Travel Operation
  50
- Work Practices
  51
  - Personal Considerations
    51
  - Crane Access
    51
  - Job Preparation
    51
  - Working
    52
  - Lifting
    53
  - Hand Signals
    54
- Jib
  56
- Parking and Securing
  56
- Shut-Down
  56
- Cold Weather Operation
  56
- Temperature Effects on Hook Blocks
  57
- Temperature Effects on Hydraulic Cylinders
  57
- Overload Inspection
  59
  - Boom Inspection
    60
  - Superstructure Inspection
    62
  - Carrier Inspection
    64
Section 3

67
- Controls, Switches, and Gauges
  67
  - Cab Controls
    67
  - Foot Controls
    68
  - Left Dash Controls
    69
  - Right Dash Controls
    70
  - Indicator and Gauge Display
    72
  - Crane Level Indicator
    74
  - Engine Warning and Stop Lights
    74
  - Rated Capacity Indicator (RCI)
    75
  - Air Conditioning/Heater Controls
    75
  - Boom Angle Indicator
    75
  - Outrigger Controls
    76
  - Steering Controls
    76
- Operator's Cab
  77
  - Heater/Air Conditioner
    77
  - Defroster
    77
  - Seat Adjustment
    78
  - Seat Belt
    78
  - Cab Door (Enclosed Cab)
    78
  - Fire Extinguisher
    78
- Crane Operation
  79
  - Crane Warm-Up Procedures
    79
  - Cab Heater Warm-Up
    80
  - Starting the Engine
    80
  - Traveling with the Crane
    83
  - Changing Travel Direction
    84
  - Shifting Gears
    84
  - Stopping Travel
    84
  - Operating the Outrigger Controls
    84
  - Outrigger Monitoring System (OMS) (Optional-Standard in North America)
    86
  - Operating the Boom Controls
    86
  - Optional Controls Operation
    92
- Operating Practices
  93
  - Handling a Load
    93
  - Attaching the Load
    93
  - Holding the Load
    93
  - Moving the Load
    93
  - Traveling with a Load (Pick and Carry)
    94
  - Elevating Personnel
    94
  - Turning Clearances
    95
  - Crane Shutdown
    95
  - Battery Disconnect
    95
  - Unattended Crane
    95
  - Towing a Disabled Crane
    95
Section 4

97
- Using the Capacity Chart
  97
Section 5

101
- Changing the Boom Head Position (no Extension)
  102
- Retaining Pin Locations
  102
- Adjusting the Boom Extension Offset
  103
- Hook Block
  104
  - Removing the Hook Block
    104
  - Installing the Hook Block
    104
- Boom Extension
  105
  - Installing the Boom Extension
    105
  - Stowing the Boom Extension
    105
- Down Haul Weight
  107
  - Installing the down Haul Weight
    107
  - Removing the down Haul Weight
    107
- Installing Cable on the Hoist
  108
- Wire Rope Wedge Socket
  108
Section 6

111
- Introduction
  112
  - Spark Arresting Mufflers
    112
- Wire Rope
  112
  - General
    112
  - Environmental Conditions
    112
- Dynamic Shock Loads
  112
- Preventive Maintenance
  118
  - Maintenance Schedule and Checklist
    118
- Lubricant Symbols
  120
- Lubrication Points
  121
  - Booms and Main Frame
    123
  - Drive Train
    123
  - Optional Equipment and Accessories
    123
- Daily Walk-Around Inspection
  127
  - Inspections
    127
  - Component/System Checks
    127
- Hours of Operation (Weekly)
  131
- Hours of Operation (Two Weeks)
  134
  - Inspect the Fan Belts
    134
  - Check the Wheel Nut Torque
    135
- Hours of Operation (Monthly)
  135
  - Inspect the Hydraulic Hoses
    135
  - Clean the Batteries and Cables
    135
  - Lubricate the Wire Rope
    136
  - Lubricate the Swing Gear and Pinion
    136
  - Torque Critical Bolts
    136
  - Replace the Crankcase Oil
    137
  - Replace the Engine Oil Filter
    138
  - Clean the Radiator
    138
- Hours of Operation (Three Months)
  138
  - Inspect the Tires
    138
  - Inspect the Parking Brake Pads
    138
  - Replace Fuel Filter/Water Separator
    138
  - Replace the Secondary Fuel Element
    138
  - Replace Air Cleaner Element
    139
  - Add Rust Inhibitor to Engine Cooling System
    139
  - Lubricate the Outrigger Slides
    139
  - Check the Axle Housing Lubricant Level
    140
  - Check the Wheel Hub Lubricant Level
    140
  - Check Swing Gearbox Lubricant Level
    141
- 1000 Hours of Operation (Six Months)
  141
- 2000 Hours of Operation (Yearly)
  146
  - Replace the Engine Coolant
    146
  - Inspect the Crane Structure and Booms for Damage
    146
  - Test the Rated Capacity Limiter (RCL) (Optional)
    146
  - Miscellaneous Maintenance
    146
    
    Batteries/Charging System
    146
    
    Fuel System
    147
    
    Fuses and Relays
    147
    
    Diesel Exhaust Fluid (DEF) Tank
    149
Section 7

151
Section 8

153
- Lubricants and Capacities
  153
- Engine Oil Specifications
  153
  - Cummins Oil Registration List
    153
  - Oil Performance Recommendations
    154
  - Oil Viscosity Recommendations
    154
  - New Engine Break-In Oils
    154
- Diesel Fuel
  154
- General Specifications
  155

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Table of Contents

Manitowoc CD25 Operator's Manual (160 pages)

Table of Contents

Section 1

Section 2

Section 3

Section 4

Section 5

Section 6

Section 7

Section 8

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