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Shuttlelift CD5515-2
Manitowoc Shuttlelift CD5515-2 Manuals
Manuals and User Guides for Manitowoc Shuttlelift CD5515-2. We have
2
Manitowoc Shuttlelift CD5515-2 manuals available for free PDF download: Service And Maintenance Manual, Operator's Manual
Manitowoc Shuttlelift CD5515-2 Service And Maintenance Manual (293 pages)
Brand:
Manitowoc
| Category:
Construction Equipment
| Size: 28.3 MB
Table of Contents
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
General
30
Environmental Conditions
30
Dynamic Shock Loads
30
Lubrication
30
Precautions and Recommendations During Inspection or Replacement
30
Wire Rope Inspection (Running Ropes and Pendant Cables)
31
Keeping Records
31
Frequent Inspection
31
Wire Rope Inspection
31
Pendant Cables)
31
Wire Rope Inspection (Boom Extension and Retraction Cables)
32
Wire Rope Inspection/Replacement (All Wire Rope)
32
Wire Rope Inspection/Replacement
32
Seizing Wire Rope
33
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
Independently Controlled Outrigger Hydraulic System
80
Oil Flow
80
Outrigger Valves
80
Load Holding Valves
83
Vertical Outrigger Cylinder Leakage Check
83
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
Diesel Engine Fuel System Description
142
QSB Engine Electronic Controlled Fuel System Units
143
Types of Fuel to Use
143
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
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Manitowoc Shuttlelift CD5515-2 Operator's Manual (152 pages)
Brand:
Manitowoc
| Category:
Construction Equipment
| Size: 7.64 MB
Table of Contents
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
Rated Capacity Limiter (RCL) Systems (if Equipped)
20
Anti-Two-Blocking Device
20
Working Area Limiter (if Equipped)
21
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
Determine Operating Status
93
Determining Lift Capacity
93
Things to Observe When Using the Capacity Chart
93
Determining Lift Capacity at the Boom Extension
94
Pick and Carry Ranges
94
Section 5
97
Pivoting Boom Head (Optional)
97
Boom Head Positions
97
Changing the Optional Boom Head Position (no Extension)
98
Adjusting the Optional Boom Extension Offset
99
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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