Manitowoc Grove YB5515-2 Manuals

Manuals and User Guides for Manitowoc Grove YB5515-2. We have 2 Manitowoc Grove YB5515-2 manuals available for free PDF download: Service And Maintenance Manual, Operator's Manual

Manitowoc Grove YB5515-2 Service And Maintenance Manual (293 pages)

Brand: Manitowoc | Category: Construction Equipment | Size: 28.3 MB

Table of Contents

5
Section 1 1

13
- Directional Reference
  13
- Identification Plates
  13
- Fuel Tank
  
  15
- General Specifications
  
  15
  - Engine
    15
  - Tires
    15
  - Electrical System
    15
- Hydraulic System
  
  15
  - Boom
    15
- Mast Rotation - 360
  
  16
  - Wire Rope
    16
  - Hydraulic System
    16
  - Weight
    16
  - Travel Speeds
    16
  - Operating Dimensions
    17
- General Maintenance
  
  18
  - Cleanliness
    19
  - After Cleaning
    19
  - Removal and Installation
    19
  - Disassembly and Assembly
    19
  - Pressing Parts
    19
  - Locking Devices
    19
  - Wires and Cables
    20
  - Shims
    20
  - Hoses and Tubes
    20
  - Bearings
    20
  - Gaskets
    21
  - Batteries
    21
  - Hydraulic Systems
    21
  - Electrical System
    23
  - Fatigue of Welded Structures
    23
  - Loctite
    24
  - Fasteners and Torque Values
    24
- Weld Studs (Table 1-10)
  
  28
  - Hydraulic Fitting
    28
- Wire Rope
  
  30
- O-Ring, Seal and Elastic Nut Replacement
  
  34
- Hydraulic Pressure Testing
  
  34
Section 2 Safety Practices 2

35
- Section 2
  35
  - Introduction
    35
  - Signal Words
    35
    
    Signal Word
    35
    
    Personal Considerations
    36
    
    Equipment Considerations
    36
    
    General Considerations
    37
    
    Operational Considerations
    37
  - Environmental Protection
    38
  - Final Word
    38
Section 3 Electric System

39
- Section 3
  
  39
  - General
    39
    
    Comparing Electrical System to a Hydraulic System
    40
    
    Magnetism
    40
- Main Electrical System
  
  40
- General
  
  40
  - Wire Harnesses
    40
  - Fuses
    40
- Charging System
  
  43
  - Alternator and Voltage Regulator
    43
  - Batteries
    43
  - Battery Disconnect Switch
    43
  - Voltmeter
    43
  - Pressure Switch
    43
  - Special Precautions
    43
  - Battery Maintenance and Charging
    43
- Starting Circuit
  
  44
  - General Inspections
    44
  - Starting Circuit Check
    44
- Instrument and Light Circuits
  
  45
  - General
    45
  - Light Bulbs
    45
  - Gauges and Indicators
    45
  - ECM Display Toggle Switch
    45
- Wire Harnesses
  
  46
  - Engine Wire Harness
    46
  - Main Frame Wire Harness
    46
  - Dash Wire Harness
    46
  - Cab Wire Harness
    46
  - Boom Wire Harness
    46
- Accessory Circuits
  
  58
  - Anti-Double Blocking System
    58
  - Rated Capacity Limiter (RCL) System
    58
  - Optional Engine Shutdown
    58
  - Heater
    58
- Troubleshooting
  
  59
Section 4 Hydraulic System

62
- Section 4
  
  62
  - General Description
    62
    
    General
    62
    
    Hydraulic System
    62
- Troubleshooting
  
  63
  - Troubleshooting Aids
    63
  - Troubleshooting Procedures
    63
  - Hydraulic System
    63
- Hydraulic System
  
  64
  - Hydraulic System
    65
    
    System Description
    69
    
    Description of Operation
    69
- Troubleshooting Guides
  
  64
- Hydraulic Swivel
  
  70
  - General
    70
  - Functions
    71
  - Troubleshooting
    71
- Lift Circuit
  
  71
  - Oil Flow
    72
  - Holding Valve
    72
  - Lift Cylinder Leakage Check
    72
- Telescope Circuit
  
  74
  - General
    74
  - Oil Flow
    74
  - Holding Valve
    74
  - Port Relief Valve
    74
  - Telescope Cylinder Leakage Test
    75
  - Hydraulic Swivel
    75
- Hoist Circuit
  
  75
  - General
    75
  - Oil Flow
    75
  - Brake Holding Valve
    76
  - Hydraulic Swivel
    76
- Swing Circuit
  
  76
  - General
    76
  - Oil Flow
    76
- Pilot Control System
  
  76
  - Pilot System Relief Valve
    76
- Pressure Setting Procedures
  
  76
  - Checking and Adjusting Hydraulic Pressure Settings
    76
- Outrigger and Axle Lock out Circuits
  
  80
- Anti-Double Blocking System
  
  80
  - General
    80
  - System Function
    80
- Component Repair
  
  83
  - Hydraulic Pump Repair
    83
  - Outrigger Control Valve
    84
  - Swing Motor
    84
  - Hydraulic Swivel
    91
  - Hydraulic Cylinders
    94
- Under Deck Winch
  
  101
Section 5 Preventative Maintenance

102
- Maintenance
  
  103
  - Preparation
    103
  - Hydraulic System Maintenance Precautions
    103
  - Label Parts When Disassembling
    104
  - Hydraulic Oil Recommendations
    104
  - Draining and Flushing
    104
  - Removing Air from the Hydraulic System
    105
  - Parts Replacement
    105
- Lubricants
  
  103
- Maintenance Records
  
  103
- Special Maintenance
  
  105
  - Delivery Inspection
    105
  - After First 50 Hours of Operation (New Cranes)
    106
  - Cranes Not in Regular Use
    106
- Preventive Maintenance
  
  106
  - Maintenance Schedule and Checklist
    106
  - Lubrication Points
    109
- Scheduled Maintenance
  
  113
  - Daily (Walk-Around) Inspection
    113
  - Hours of Operation (Weekly)
    118
  - Hours of Operation (Two Weeks)
    120
  - Hours of Operation (Monthly)
    121
  - Hours of Operation (3 Months)
    124
  - 1000 Hours of Operation (6 Months)
    127
  - 2000 Hours of Operation (Yearly)
    132
- Miscellaneous Maintenance
  
  133
  - Batteries/Charging System
    133
  - Fuel System
    134
- Carwell® Rust Inhibitor
  
  134
  - Protecting Cranes from Rusting
    134
  - Cleaning Procedures
    135
  - Inspection and Repair
    135
  - Application
    135
  - Areas of Application
    136
Section 6 Engine and Engine Systems

140
- Engine Cooling System
  
  141
  - Coolant Requirements
    141
  - Radiator Cap and Overflow Bottle
    142
  - Thermostat
    142
- Engine Fuel System
  
  142
- Engine Electrical System
  
  142
- Engine Exhaust System
  
  144
- Checks and Adjustments
  
  144
  - Throttle Linkage Adjustment
    144
- Engine Air Intake System
  
  144
- Removal and Installation
  
  146
  - Removal
    146
  - Installation
    147
  - Description of Operation
    150
Section 8 Axles/Drive Shafts/Wheels and Tires

176
- Axles/Drive Shafts/Wheels and Tires
  
  179
- Front Drive Axle Repair
  
  179
  - Removal
    179
  - Installation
    179
  - Special Tools
    179
  - Replacing the Pinion Oil Seal
    181
  - Axle Hub Repair
    182
  - Drive Head Repair
    186
- Rear Axles Repair
  
  194
  - Removal
    194
  - Installation
    194
  - Service Tools
    194
  - Replacing the Pinion Oil Seal
    194
  - Axle Hub Repair
    194
  - Drive Head Repair (Drive Axles Only)
    199
- Drive Shafts
  
  202
  - Disassembly
    202
  - Removal
    202
  - Assembly
    203
  - Inspection
    203
  - Installation
    204
  - Lubrication Procedure
    205
  - Tire Inflation
    205
- Wheel & Tires
  
  205
  - Wheel Stud Nuts
    205
Section 9 Brake System

206
- Accumulator
  207
- Priority Flow Control Valve
  207
- Description
  
  208
  - Service Brake System
    208
  - Parking Brake System
    211
- Maintenance and Adjustments
  
  211
  - Service Brake Bleeding
    211
  - Parking Brake Bleeding
    212
  - Parking Brake Adjustment
    212
  - Accumulator Charging
    213
  - Residual Brake System Pressure
    213
- Tests
  
  213
  - Brake Piston Seal Leakage Test (Front Axle Only)
    213
- Service Brake Repair
  
  214
  - Front Axle Brakes
    214
  - Rear Axle Brakes
    218
- Parking Brake Repair
  
  219
  - Lining Kit Replacement
    219
  - Repair Kit Installation
    220
  - Seal Kit Installation
    222
- Brake Modulating Valve Repair
  
  223
  - Removal
    223
  - Disassembly
    223
  - Assembly
    224
  - Installation
    224
- Troubleshooting
  
  225
  - Service Brakes
    225
Section 10 10

226
- Crab Steering
  229
- Steering Proximity Switches
  
  232
  - General
    232
  - Principle of Operation
    232
  - Sensor Operation and Spacing Checks
    234
- Steering System
  
  234
- Steering Orbitrol
  
  237
  - Description
    237
- Steering Cylinder
  
  249
  - Technical Data
    249
  - Special Tools
    249
  - Cylinder Repair
    249
Section 11 11

254
- Disassembly
  262
- Wire Rope, Sheaves and Hoist Blocks
  
  265
  - Wire Rope Description
    265
  - Wire Rope Safety
    265
  - Inspecting Wire Rope
    266
  - Inspection of Sheaves
    266
  - Wire Rope Lubrication
    266
  - Wire Rope Installation
    267
- Main Hoist
  
  269
  - Description
    269
  - Maintenance
    269
  - Drum Rotation Indicator
    269
  - Hoist Repair
    271
  - Hoist Service
    272
- Troubleshooting
  
  276
- Bearing, Mast and Related Parts
  
  277
  - General
    277
  - Mast Bearing
    277
  - Mast Bearing Bolts
    278
  - Inspection for Bearing Wear
    278
  - Replacing the Mast Bearing
    279
  - Swing Gearbox and Pinion
    279
  - Hydraulic Swivel
    281
  - Swing Gearbox Repair
    282
- Outriggers
  
  284
  - Outrigger Monitoring System (OMS)
    284
  - (Optional-Standard in North America)
    284
  - Removal
    285
  - Disassembly
    285
  - Assembly
    285
  - Installation
    285

Manitowoc Grove YB5515-2 Operator's Manual (152 pages)

Brand: Manitowoc | Category: Construction Equipment | Size: 7.64 MB

Table of Contents
9
Section 1

13
- The Manual
  13
- Directional Reference
  13
- Serial Number Plate
  13
- Reports
  13
  - Noise Level Test Results
    14
  - Vibration Level Test Results
    14
- Disclaimer
  14
- Customer Support
  14
  - New Owners
    14
Section 2

17
- Safety Messages
  17
  - General
    17
  - Safety Alert Symbol
    18
  - Signal Words
    18
- General
  18
  - Warning Signs
    18
- Accidents
  18
- Operator Information
  18
- Operator Qualifications
  19
- Operational Aids
  20
- Crane Stability/Structural Strength
  22
  - Load Charts
    22
  - Work Site
    22
- Wind Forces
  23
  - Wind Speeds
    23
  - Lifting Operations
    36
  - Counterweight
    37
  - Outrigger Lift off
    37
  - Multiple Crane Lifts
    37
  - Tilt-Up Panel Lifting
    37
- Pile Driving and Extracting
  38
  - Crane Equipment
    38
  - Crane Inspection
    38
- Electrocution Hazard
  39
  - Set-Up and Operation
    40
  - Electrocution Hazard Devices
    40
  - Electrical Contact
    41
  - Special Operating Conditions and Equipment
    41
  - Earthing the Crane
    41
- Personnel Handling
  42
- Environmental Protection
  43
- Maintenance
  43
  - Service and Repairs
    43
  - Lubrication
    44
  - Tires
    45
- Hoist Rope
  45
  - Synthetic Hoist Rope
    45
  - Wire Rope
    45
  - Sheaves
    46
- Batteries
  47
- Super Capacitor (if Equipped)
  47
- General Maintenance
  47
- Transporting the Crane
  48
- Travel Operation
  48
- Work Practices
  49
  - Personal Considerations
    49
  - Crane Access
    49
  - Job Preparation
    49
  - Working
    50
  - Lifting
    51
  - Hand Signals
    52
- Jib
  54
- Parking and Securing
  54
- Shut-Down
  54
- Cold Weather Operation
  54
- Temperature Effects on Hook Blocks
  55
- Temperature Effects on Hydraulic Cylinders
  55
- Overload Inspection
  57
  - Boom Inspection
    58
  - Superstructure Inspection
    60
  - Carrier Inspection
    62
Section 3

65
- Controls, Switches, and Gauges
  65
  - Cab Controls
    65
  - Left Dash Controls
    67
  - Right Dash Controls
    68
  - Rated Capacity Limiter (RCL) Override Switch
    68
  - Indicator and Gauge Display
    69
  - Crane Level Indicator
    71
  - Engine Warning and Stop Lights
    71
  - Rated Capacity Limiter (RCL)
    71
  - Air Conditioning/Heater Controls
    72
  - Boom Angle Indicator
    72
  - Outrigger Controls
    72
  - Steering Controls
    73
- Operator's Cab
  74
  - Heater/Air Conditioner
    74
  - Defroster
    74
  - Seat Adjustment
    75
  - Seat Belt
    75
  - Cab Door (Enclosed Cab)
    75
  - Fire Extinguisher
    75
- Crane Operation
  76
  - Starting the Engine
    76
  - Engine
    78
  - Transmission
    78
  - Hoist
    78
  - Swing Drive and Turntable Bearing
    78
  - Axles
    79
  - Hydraulic Oil System
    79
  - Cab Heater Warm-Up
    79
  - The Brake Must be Applied in Order to Engage Transmission
    79
  - Traveling with the Crane
    79
    
    Changing Travel Direction
    80
    
    Shifting Gears
    80
    
    Stopping Travel
    81
    
    Operating the Outrigger Controls
    81
    
    Outrigger Monitoring System (OMS) (Optional-Standard in North America)
    82
    
    Operating the Boom Controls
    83
    
    Optional Controls Operation
    89
  - Operating Practices
    90
    
    Handling a Load
    90
    
    Attaching the Load
    90
    
    Holding the Load
    90
    
    Moving the Load
    90
    
    Traveling with a Load (Pick and Carry)
    91
    
    Elevating Personnel
    91
    
    Turning Clearances
    92
    
    Crane Shutdown
    92
    
    Battery Disconnect
    92
    
    Unattended Crane
    92
    
    Towing a Disabled Crane
    92
Section 4

93
- Using the Capacity Chart
  93
Section 5

97
- Pivoting Boom Head (Optional)
  97
- Hook Block
  99
  - Removing the Hook Block
    99
  - Installing the Hook Block
    100
- Boom Extension
  101
  - Installing the Boom Extension
    101
  - Stowing the Boom Extension
    101
- Searcher Hook Assembly
  103
  - Installation
    103
  - Removal
    103
- Down Haul Weight
  104
  - Installing the down Haul Weight
    104
  - Removing the down Haul Weight
    104
- Installing Cable on the Hoist
  105
- Wire Rope Wedge Socket
  106
- Part Wire Rope Reeving
  108
Section 6

109
- Introduction
  109
  - Spark Arresting Mufflers
    109
  - Safety List
    109
- Lubricants
  110
- Environmental Protection
  110
- Immediately Clean up any Spills
  110
- Maintenance Records
  110
- Special Maintenance
  110
  - Delivery Inspection
    110
  - After First 50 Hours of Operation (New Cranes)
    110
  - Cranes Not in Regular Use
    110
- Preventive Maintenance
  111
  - Maintenance Schedule and Checklist
    111
  - Lubrication Points
    114
- Scheduled Maintenance
  117
  - Daily (Walk-Around) Inspection
    117
  - Hours of Operation (Weekly)
    122
  - Hours of Operation (Two Weeks)
    125
  - Hours of Operation (Monthly)
    126
  - Hours of Operation (3 Months)
    129
  - 1000 Hours of Operation (6 Months)
    132
  - 2000 Hours of Operation (Yearly)
    137
- Miscellaneous Maintenance
  137
  - Batteries/Charging System
    137
  - Fuel System
    138
  - Fuse/Relay Replacement
    138
Section 7

141
Section 8

143
- Lubricants and Capacities
  143
  - Engine Oil Specifications
    144
- Diesel Fuel
  145
- General Specifications
  145
  - Engine
    145
  - Tires
    145
  - Electrical System
    145
- Fuel Tank
  
  145
- Hydraulic System
  
  146
  - Boom
    146
- Mast Rotation - 360
  
  146
  - Wire Rope
    146
  - Weight
    146
  - Travel Speeds
    147
  - Operating Dimensions
    147

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Manitowoc Grove YB5515-2 Manuals

Manitowoc Grove YB5515-2 Service And Maintenance Manual (293 pages)

Table of Contents

Table of Contents

Section 1 1

Fuel Tank

General Specifications

Hydraulic System

Mast Rotation - 360

General Maintenance

Weld Studs (Table 1-10)

Wire Rope

O-Ring, Seal and Elastic Nut Replacement

Hydraulic Pressure Testing

Section 2 Safety Practices 2

Section 3 Electric System

Section 3

Main Electrical System

General

Charging System

Starting Circuit

Instrument and Light Circuits

Wire Harnesses

Accessory Circuits

Troubleshooting

Section 4 Hydraulic System

Section 4

Troubleshooting

Hydraulic System

Troubleshooting Guides

Hydraulic Swivel

Lift Circuit

Telescope Circuit

Hoist Circuit

Swing Circuit

Pilot Control System

Pressure Setting Procedures

Outrigger and Axle Lock out Circuits

Anti-Double Blocking System

Component Repair

Under Deck Winch

Section 5 Preventative Maintenance

Maintenance

Lubricants

Maintenance Records

Special Maintenance

Preventive Maintenance

Scheduled Maintenance

Miscellaneous Maintenance

Carwell® Rust Inhibitor

Section 6 Engine and Engine Systems

Engine Cooling System

Engine Fuel System

Engine Electrical System

Engine Exhaust System

Checks and Adjustments

Engine Air Intake System

Removal and Installation

Section 8 Axles/Drive Shafts/Wheels and Tires

Axles/Drive Shafts/Wheels and Tires

Front Drive Axle Repair

Rear Axles Repair

Drive Shafts

Wheel & Tires

Section 9 Brake System

Description

Maintenance and Adjustments

Tests

Service Brake Repair

Parking Brake Repair

Brake Modulating Valve Repair

Troubleshooting

Section 10 10

Steering Proximity Switches

Steering System

Steering Orbitrol

Steering Cylinder

Section 11 11

Wire Rope, Sheaves and Hoist Blocks

Main Hoist